JP2986253B2 - Method for producing fiber composite - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention mainly relates to interior materials for automobiles,
For example, the present invention relates to a method for producing a fiber composite suitably used as a ceiling material, a door core material, or an interior material for a building.

[0002]

2. Description of the Related Art Generally, ceiling materials for automobiles are lightweight,
Materials with excellent properties such as rigidity, heat resistance, sound absorption, and moldability are required.

Conventionally, as a method for producing this kind of material, for example, a method described in Japanese Patent Application Laid-Open No. 64-77664 is known. That is, in this method, first, a thermoplastic resin film is laminated on both surfaces of a mat-like material mainly composed of inorganic fibers, the laminate is heated, and then compressed,
The molten thermoplastic resin is impregnated inside the mat-like material.
After that, the thermoplastic resin is expanded in a molten state, and the thickness of the laminated sheet is increased to be cooled.

[0004] In the mat-like material used in this manufacturing method, a large number of fibers are oriented in the thickness direction by needle punching in order to develop strength in the thickness direction of the product.

[0005]

However, in the above-mentioned conventional method for producing a fiber composite, the strength of the product is reduced because the orientation state of the fiber in the plane direction is not taken into account. That is, by performing a needle punching process on the mat-like material and orienting a large number of fibers in a thickness direction, the strength of the product in the thickness direction is developed. In this case, the strength is caused by the needle punching process. A large number of holes are formed, and a large number of fibers are oriented only in the thickness direction.

As a result, the bending properties of the resulting fiber composite are reduced. Alternatively, it is conceivable to manufacture a fiber composite by laminating mat-like materials in consideration of the fiber orientation state in the plane direction, but the work process becomes complicated, and the resulting product becomes costly. I will.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a method for producing a fiber composite which can easily produce a fiber composite having excellent bending properties.

[0008]

According to the present invention, there is provided a method for producing a fiber composite, comprising an orienting step of orienting inorganic fibers in a nonwoven mat comprising mainly inorganic fibers; A laminating step of laminating a film made of a thermoplastic resin to form a laminate, a heating step of heating the laminate to a temperature equal to or higher than the melting temperature of the resin component to melt the resin component, A method for producing a fiber composite, comprising: a compression step of compressing a laminate, and an expansion step of sequentially expanding the laminate in a state where the resin component is melted and increasing the thickness of the laminate, In the orientation step,
The surface of the non-woven mat is rubbed with a polychaete to orient the inorganic fibers in the plane direction.

The mat-like material used in the present invention is mainly composed of inorganic fibers and has a thickness of about 5 to 10 mm. As the inorganic fibers used in this mat-like material,
For example, glass fiber, rock wool and the like can be mentioned, and the length is preferably 5 to 200 mm, more preferably 50 mm or more, and more preferably 70% by weight or more in view of the formability of the mat-like material.

The thickness is preferably from 5 to 30 μm, more preferably from 7 to 20 μm, because the mechanical strength decreases as the thickness decreases and the weight increases as the thickness increases.
μm. An arbitrary method may be adopted as a method for producing the mat-like material, for example, a method of supplying an inorganic fiber to a card machine, defibrating and mixing and producing a mat-like material. Thermoplastic organic fibers such as polyethylene, polypropylene, saturated polyester, polyamide, and polyacrylonitrile may be added for bonding inorganic fibers or reducing the bulk density of the mat-like material.

In the orientation step, a mat-like material is usually subjected to needle punching. At this time, the punch density is 1c
It is preferably performed at 10 to 70 places per m ² . This needle punching treatment is performed not only to facilitate the handling of the mat-like material by entanglement of the inorganic fibers, but also to increase the compressive strength of the product by orienting a large number of the inorganic fibers in the thickness direction of the mat-like material.

After performing the needle punching treatment, the surface of the mat-like material 2 is rubbed with a poly-hair roll 1 as shown in FIG. As a method of rubbing, a polychamber roll 1
Is transported by the mat-like material 2 (in the direction of the arrow in FIG. 1A).
The rotation is performed in the same direction or in the opposite direction, and furthermore, as shown in FIG. Roll 1 is a roll 1 arranged on the top side in the same direction.
May be rotated in the opposite direction (preferably when the mat-like material 2 is soft and easily stretched because tension is hardly applied to the mat-like material 2).

Further, the polychaete roll 1 itself is matted with a mat-like material 2.
By moving in an appropriate direction (for example, the width direction) on the surface of the substrate. This allows
One end of the inorganic fiber on the surface of the mat-like material 2 is oriented along the surface in a manner to be pulled out. And
The bending strength is improved by the inorganic fibers oriented in the plane direction.

It is preferable that the amount of the inorganic fibers oriented in the plane direction is oriented to be 0.5 to 10% by weight of the whole mat-like material 2. If the amount of orientation is less than 0.5% by weight, the effect is weak, and if it exceeds 10% by weight, the inside of the mat-like material 2 becomes weak and the overall strength is reduced.

Note that the polychamber roll 1 has a roll body 10
A large number of hairs 11 are planted on the outer peripheral surface of. The amount of hair transplanted, the material, and the like of the hair body 11 may be any as long as the inorganic fibers on the surface of the mat-like material 2 can be oriented along the surface.

Further, the present invention is not particularly limited to the polypillary roll 1, but for example, as shown in FIG.
May be rubbed, or as shown in FIG. 3, the mat-like material 2 may be passed between a plurality of brushes 13 and rubbed.

In the laminating step, a thermoplastic resin film is laminated on both sides of the mat-like material to form a laminate. At this time,
As the thermoplastic resin film to be used, polyethylene, polypropylene, polyamide, polyester and the like are considered suitable.

In the heating step, the laminate is heated to a temperature higher than the melting temperature of the resin component to melt the resin component. At this time, an arbitrary heating method may be adopted,
For example, a hot air heating method, a radiant heating method using an infrared heater or the like can be used.

In the compression step, the laminate is compressed in a molten state. At this time, any method may be adopted,
For example, a method of pressing, a method of compressing with a roll, and the like can be used. The pressing pressure may be 0.1 to 20 kg / cm ² and the compression time may be 1 to 10 seconds. When compressing with a roll, it is preferable to set the distance between the rolls to 80% to 5% of the material thickness.

When both the press and the roll are compressed, they are preferably heated to a temperature higher than the melting temperature of the thermoplastic resin. At this time, when compressed, the molten thermoplastic resin is impregnated into the inorganic fibers.

Next, when the pressure is released, the material tries to recover to the original thickness, but does not recover sufficiently because the inorganic fibers have been crushed once. Therefore, it is preferable to go through a spreading step such as vacuum suction from above and below.

In the expanding step, the pressure applied in the compressing step is released, and the thermoplastic resin is expanded in a molten state to increase the thickness of the material.

In order to shape the fiber composite thus obtained, the fiber composite is reheated to a temperature higher than the melting temperature of the resin component,
Compression molding such as pressing may be performed. For example, for use as a ceiling material for automobiles, a cosmetic skin material such as vinyl chloride leather or non-woven fabric may be laminated and formed during compression molding.

[0024]

According to the method for producing a fiber composite of the present invention, in the orientation step, the inorganic fibers in the mat-like material can be oriented in the plane direction by rubbing the surface of the non-woven mat-like material with the polychaete. .

[0025]

An embodiment of the present invention will be described below.

[0026]

EXAMPLE 1 length 50mm, glass fiber and the length 50mm in diameter 13 .mu.m, the weight ratio of polypropylene fibers having a diameter of 10 [mu] m 3: supplying a card machine at the rate of 1, after defibration, 1 cm ² per 60 places Needle punching was performed to obtain a mat-like material having a thickness of 6 mm and an average weight of 400 g / m ² .

Then, as shown in FIG. 1 (a), both surfaces of the mat-like material 2 were rubbed with a polypillary roll 1 to orient the surface of the mat-like material 2 in the plane direction. In addition, polychamber roll 1
Was rotated so that the surface speed was 10 times as high as the conveying speed of the mat-like material 2.

Next, on both sides of the mat-like material, a thickness of about 120 μm
After laminating a high-density polyethylene film of MI5 at m, the whole was sandwiched between Teflon sheets, heated at 200 ° C. for 3 minutes, and compressed with a press heated to 200 ° C. at a pressure of 3 kg / cm ² , After maintaining the temperature at 200 ° C., the Teflon sheet was vacuum-suctioned from both sides and expanded to 5 mm, and then the whole was cooled.

Various parts having different weights were taken from the obtained sample, and the flexural strength and flexural modulus were measured. Table 1 shows the results.

[0030]

Example 2 In the orientation step of Example 1, as shown in FIG. 3, the mat-like material 2 was passed between a plurality of poly-hair brushes 13 to rub the surface of the mat-like material 2. Otherwise, a sample was prepared in the same manner as in Example 1.

Various parts having different weights were taken from the obtained sample, and the flexural strength and flexural modulus were measured. Table 1 shows the results.

[0032]

Comparative Example 1 A sample was prepared in the same manner as in Example 1 except that the surface of the mat-like material was not rubbed.

Various parts having different weights were taken from the obtained sample, and the flexural strength and flexural modulus were measured. Table 1 shows the results.

[0034]

[Table 1]

[0035]

As described above, according to the present invention, in the orientation step, the surface of the nonwoven mat-like material is rubbed with the polychassis to orient the inorganic fibers in the mat-like material in the plane direction. Therefore, a fiber composite having excellent bending properties can be easily produced.

[Brief description of the drawings]

FIG. 1 is a view for explaining a main part of a manufacturing method according to the present invention, and is a schematic view showing an alignment step.

FIG. 2 is a view for explaining a main part of a manufacturing method according to the present invention, and is a schematic view showing another embodiment of an alignment step.

FIG. 3 is a view for explaining a main part of a manufacturing method according to the present invention, and is a schematic view showing still another embodiment of an alignment step.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Poly-hair roll (poly-hair) 13 Poly-hair brush (poly-hair) 2 Matte

Claims (1)

(57) [Claims] 1. An orientation step for orienting inorganic fibers in a non-woven mat material mainly composed of inorganic fibers, and laminating a film made of a thermoplastic resin on both surfaces of the non-woven mat material to form a laminate. A laminating step, a heating step of heating the laminate to a temperature equal to or higher than the melting temperature of the resin component to melt the resin component, a compression step of compressing the laminate in this molten state, and a melting of the resin component. And a spreading step of sequentially expanding the laminate in a state to increase the thickness of the laminate, wherein in the orientation step, the surface of the nonwoven mat-like material is a polychaete. A method for producing a fiber composite, comprising: rubbing the inorganic fibers in a plane direction by rubbing with a substrate.