JPH1044112A - Fiber-based forming base material and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide fiber-based forming base material which is used as lining material for the interior of an automobile or the like and is low in density and lightweight and to provide a method for manufacturing it. SOLUTION: Foamed synthetic resin bead bodies 2 are included in fiber material 1 being main material. The body of forming base material is fused on the surfaces of the respective foamed synthetic resin bead bodies 2 to manufacture fiber-based forming base material consisting of a platelike forming body. Both the fiber-based forming base material and the forming material, in which numberless foamed synthetic resin bead bodies 2 are included between fiber materials being the main material, are sandwiched between air-permeable members and hot air is passed. The surfaces of the foamed synthetic resin bead bodies 2 are melted by this hot air. Thereafter, the fiber-based forming base material and the forming material are pressurized between the air- permeable members.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a low-density and lightweight fibrous base material used as a lining material for interior parts of automobiles and the like, and a method for producing the same.

[0002]

2. Description of the Related Art For example, lining materials for interiors of automobiles and the like include:
For the purpose of weight reduction and good texture, etc., fiber-based molded base materials for interior materials mainly using fiber materials are often used,
Conventionally, this type of fibrous molding base material is generally formed by fusing a fibrous material as a main material with a thermoplastic resin mixed with the fibrous material.

However, since the non-foamed solid resin having a small volume ratio such as powder or pellets is used as the thermoplastic resin mixed with the main fiber material, the main fiber material is not sufficiently used. In order to bond the fibers, it was necessary to add and mix at least 50% by weight with respect to the fiber material. As a result, there is a problem in that the density is high, the weight cannot be sufficiently reduced, and the texture of the fiber material is impaired. In addition, since there is almost no air permeability, there is a problem that it is difficult to apply the vacuum forming method to the laminating process with the skin material and the processability is poor.

[0004]

DISCLOSURE OF THE INVENTION The present invention solves the above-mentioned conventional problems, and can exhibit a sufficient lightness at a low density and also provide a texture of a fiber material as a main material. The present invention provides a fibrous base material and a method for producing the same, which have air permeability, can apply a vacuum forming method to a laminating process with a skin material, and can exhibit excellent workability. It was completed for the purpose of doing.

[0005]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention is directed to a molding base material in which a surface of a foamed synthetic resin bead body in which a main fiber material is mixed is melted. A fibrous molding base material characterized by being a plate-shaped molded body integrated as a landing point, and a molding material in which countless foamed synthetic resin beads are mixed between a fibrous material as a main material and a breathable member. Hot air is passed between the foamed synthetic resin beads, and the surface of the foamed synthetic resin bead body is melted by the hot air and pressurized between the air-permeable members. A method for producing a fibrous molded base material, characterized in that the surface of the body is formed into an integrated plate-like molded body with a fusion point.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below with reference to the drawings. In the figure, 1 is a fiber material as a main material, 2 is a foamed synthetic resin bead body fused and integrated between the fiber materials, and the foamed synthetic resin bead body 2 has its surface acting as a fusion point. By maintaining a constant shape in this way, a molded base material body mainly composed of the fiber material 1 is formed.

The above-mentioned fiber material has a diameter of 0.5
Wood fibers defibrated to about 1.0 mm and a length of about 20 to 30 mm are used. On the other hand, as the foamed synthetic resin bead body 2, a polypropylene resin having a diameter of about 3 to 5 mm expanded 40 to 60 times is used. Thermoplastic foam synthetic resin is used. And such a foamed synthetic resin bead body 2
By using as a binder, the molded base material body exhibits excellent lightness at a low density of 0.1 g / cm ³ or less.

Next, a method for manufacturing the fibrous base material will be described with reference to FIG. First, a foamed synthetic resin bead body 2 is mixed with a fiber material 1 such as a wood fiber as a main material at a predetermined ratio to form a fiber mass 3. The means for forming the fiber mass 3 is not different from the case where a non-foamed solid resin is mixed with a fiber material as a main material to form a fiber mass, and therefore the description is omitted. At this time, the addition amount of the foamed synthetic resin bead body 2 is 20
It is preferable to mix at a ratio of ４０40% by weight. The reason is that if the content is less than 20% by weight, there is a possibility that a sufficient bonding of the fibrous materials 1 may not be obtained, and it is impossible to achieve a sufficient weight reduction. This is because there is a possibility that sufficient strength as a material may not be obtained.

Next, the obtained fiber mass 3 is permeable to a permeable member 10 such as a punched metal or a mesh belt.
0 and subjected to a temporary compression treatment to a thickness not reaching the final product thickness. In this state, hot air of about 200 to 250 ° C. is supplied through the air holes of the air-permeable members 10 and 10 so that the inside of the fiber mass 3 is To melt the surface of the foamed synthetic resin bead body 2. Finally, the heated fiber mass 3 is formed into a pair of upper and lower press molds 11,
A cold press is performed in a temperature range of 50 to 60 ° C. according to 11 to obtain a fibrous molding base material having a predetermined thickness in which the foamed synthetic resin bead 2 is fused and integrated between the fibrous materials 1. At this time, since the heated fiber mass 3 has been subjected to a temporary compression treatment to a thickness not reaching the final product thickness in the above-described process and only the surface of the foamed synthetic resin bead body 2 is in a molten state, it is cooled. Pressing is performed accurately in a short time.
The reason why only the surface of the foamed synthetic resin bead body 2 is melted is that if the inside of the foamed synthetic resin bead body 2 is melted, bubbles disappear and the density does not become low and light. It is important that only the surface of the foamed synthetic resin bead body 2 be a fusion point by melting only the foamed synthetic resin bead body 2.

[0010]

As is clear from the above description, the first
The invention of the present invention can exhibit sufficient lightness at low density and can also bring out the texture of the fiber material, and since it has air permeability, the vacuum forming method is applied to the bonding process with the skin material It is also possible to exhibit excellent workability. The second invention is capable of efficiently producing the fibrous molding base material as described above. Therefore, the present invention greatly contributes to industrial development as a fibrous base material and a method for producing the fibrous base material that have eliminated the conventional problems.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an embodiment of the first invention.

FIG. 2 is an explanatory view showing a molding step according to a second invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Fiber material 2 Foamed synthetic resin beads 3 Fiber lump 10 Breathable member

Claims (4)

[Claims] 1. A molding base body is a plate-like molding integrally formed by using a surface of a foamed synthetic resin bead in which a fibrous material as a main material is mixed therein as a fusion point. Fiber-based molding substrate. 2. The expansion ratio of the expanded synthetic resin bead body is 4
The fibrous base material according to claim 1, wherein the ratio is from 0 to 60 times. 3. The fibrous molding base material according to claim 1, wherein a foamed synthetic resin bead is mixed in a proportion of 20 to 40% by weight with respect to a fibrous material as a main material. 4. A molding material in which a myriad of foamed synthetic resin beads are mixed between fibrous materials as a main material is sandwiched between air-permeable members, and hot air is allowed to pass therethrough. Melting the surface and pressurizing between air-permeable members to form an integrated plate-shaped molded body with the surface of the foamed synthetic resin bead body in which the main fiber material is mixed in as a fusion point A method for producing a fibrous molding base material, characterized by the following.