JP7647504B2 - Board member and method for manufacturing the board member - Google Patents

Description

The present invention relates to a board member having a fiber layer using natural fibers, and to a method for manufacturing the board member.

Conventionally, molded bodies have been known in which intertwined plant fibers such as kenaf are bonded together by a thermoplastic resin. The plant fibers are contained in the molded body mainly for the purpose of reducing weight, and members manufactured using the molded body are often used in a state where they cannot be seen, with the surface covered with a skin material or a resin surface material, as in the vehicle interior material described in the following Patent Document 1. On the other hand, as in the following Patent Document 2, it is being considered to use the above-mentioned plant fiber-containing molded body in the design surface of, for example, vehicle interior materials and furniture, and to realize articles with a fiber pattern design. The vehicle interior material described in Patent Document 1 is configured such that a film decorated by printing is adhered to a translucent base material, and a lighting means is arranged on the back side of the film, and by irradiating light from the back side, it is possible to highlight designs such as patterns that are not expressed when not illuminated.

JP 2015-003662 A JP 2021-160118 A

As in Patent Documents 1 and 2, the expression of a natural fiber feel has been considered in the design surfaces of various articles, etc., by a configuration in which the natural fibers can be directly seen, or a configuration in which the natural fibers are highlighted by irradiating them from the back side. The inventors of the present application have considered a board material in which a design material consisting of a fiber layer formed into a mat shape using natural fibers and a film material adhered to the front side of the fiber layer is attached to a plate-shaped substrate. However, a problem has arisen in that the design surface consisting of the film material has unevenness due to the natural fibers, which impairs the natural fiber feel. In addition, in order to express the natural fiber feel, it is desirable for the surface of the fiber layer to be uneven in the natural fibers, and a problem has arisen in that adhesion unevenness (variation in adhesive strength on the adhesion surface) occurs when the fiber layer is adhered to the substrate or film material.

The present invention was made in consideration of such circumstances, and aims to suppress unevenness on the film caused by natural fibers in board components, and to reliably adhere the fiber layer to the film material and base material.

In order to solve the above problems, the board material of the present invention is
A plate-shaped substrate;
A fiber layer mainly made of natural fibers and bonded to a surface side of the substrate;
A film material that is adhered to the front surface side of the fiber layer and forms a design surface,
The fiber layer is characterized in that the first fibers, which are the natural fibers, and the second fibers, which are fibers having a smaller fiber diameter than the natural fibers, are entangled and formed into a mat shape.

In a board member of this configuration, the second fibers, which have a smaller fiber diameter, are entangled around the natural fibers, which have a relatively large fiber diameter, and the second fibers are interposed between the natural fibers and the film material or between the natural fibers and the base material, thereby preventing the natural fibers from causing unevenness in the film material. In addition, the presence of the second fibers in a board member of this configuration increases the surface area, i.e., increases the bonding area, and the second fibers are distributed even in areas where there are few natural fibers, so that it is possible to reduce variations in adhesive strength on the bonding surface and ensure that the fiber layer is bonded to the film material and base material.

For example, when natural fibers are used as the base material for the purpose of reducing the weight of vehicle interior materials, the natural fibers are bonded with thermoplastic resin to form a plate-like molded body. In contrast, the "fiber layer" in this type of board material is not bonded with thermoplastic resin, and its shape can be changed relatively freely. In other words, the fiber layer can be adhered to base materials of various shapes. The "fiber layer" in this type of board material may be formed from one or more types of natural fibers, or may be a mixture of synthetic fibers.

The "substrate" in this configuration is not limited to a flat one, but can also be curved or have an uneven shape. For example, when attaching a decorative material composed of a film material and a fiber layer to a substrate, even when the decorative material is attached to a portion of the substrate that extends in the vertical direction, the presence of the second fiber layer prevents the applied adhesive from dripping downward, making it possible to firmly adhere the decorative material to the substrate.

In the above configuration, the first fibers may have a fiber diameter of 80 μm or more and 100 μm or less, and the second fibers may have a fiber diameter of 10 μm or more and 30 μm or less.

In a board member of this configuration, the second fibers are easily entangled with the first fibers, making it suitable for increasing the adhesion of the fiber layer.

In the above configuration, the fiber layer may have a mass per unit area of 8 g/m ² or more and 20 g/m ² or less.

For example, when natural fibers are used as a substrate for the purpose of reducing the weight of vehicle interior materials, the fibers of the natural fibers are bonded with a thermoplastic resin to form a molded body in a plate shape, and the mass per unit area (basis weight) of the molded body is about 400 to 600 g/m ^2. The fiber layer used in the board member of this configuration has a very small basis weight compared to when used as such a substrate, and is suitable for conforming to articles of various shapes. In addition, the board member of this configuration is suitable for a configuration in which the substrate and film substrate are formed from a material having optical transparency, and light is irradiated from the back side to make the natural fibers of the fiber layer stand out on the surface of the film material. In addition, in such a configuration, the basis weight of the fiber layer is preferably as small as possible, but from the viewpoint of adhesion to the film substrate and formability into a mat shape, it is preferable that it is 8 g/m ² to 12 g/m ² .

In the above configuration, the content of the second fibers in the fiber layer can be set to 20% or more and 50% or less.

In order to express a natural fiber texture on the surface when light is irradiated from the back side, the more natural fibers there are, the more desirable it is. With this light-transmitting design material, the adhesive strength of the second fibers is sufficiently ensured, while the first fibers can adequately express a natural fiber texture. It is more desirable for the content of the second fibers to be 25-35%.

In the above configuration, the film material is made of a light-transmitting material and has a fiber pattern printed on its surface, and the base material can be made of a light-transmitting material.

When light is not irradiated from the back side of the board member with this configuration, the fiber pattern on the surface of the film material creates a natural fiber feel. On the other hand, when light is irradiated from the back side, the fiber pattern on the film material will be partially blurred or erased by the light, but the natural fibers in the fiber layer will stand out on the surface of the film material, creating a natural fiber feel. From the perspective of creating a natural fiber feel, it is preferable for this fiber layer to be a so-called nonwoven fabric, and it is preferable for it to not be needle punched.

In the above configuration, the second fiber can be a resin fiber having optical transparency.

In a board member having this configuration, since the second fibers are optically transparent, when light is irradiated from the back side to make the natural fibers of the fiber layer stand out on the surface of the film material, the second fibers do not stand out on the surface of the film material, and the natural fiber feel of the first fibers is accentuated while increasing the adhesive strength to the film material and base material.

In the above configuration, the fiber layer is formed so that the first fibers extend in a uniform manner in a specific direction, and the fiber pattern of the film material can be configured to extend in a uniform manner in the specific direction.

As described above, when light is applied from the back side to make the natural fibers of the fiber layer stand out on the surface of the film material, a visible portion of the fiber pattern printed on the film material and the natural fibers of the fiber layer that stand out due to the light are visible and overlap each other. With a board member of this configuration, the printed fiber pattern and the natural fibers that stand out are aligned, so that the image seen when light is applied from the back side does not look out of place and a high level of design is ensured.

In order to solve the above problems, the method for manufacturing a board member of the present invention comprises the steps of:
a fiber web forming step of forming a fiber web from the first fibers and the second fibers in an amount at least twice the mass per unit area of the fiber layer;
a film material bonding step of bonding two sheets of the film material to both sides of the fiber web;
A decorative material forming process includes a separation process of peeling one of the two film materials from the other, and forms two decorative materials in which the fiber layer is laminated on the film material;
A board member forming process in which the decorative material is adhered to the surface of the base material to form the board member;
The present invention is characterized by having the following.

While the first fibers, which are natural fibers, are relatively straight, the second fibers, which have a smaller fiber diameter, are often curled compared to the first fibers. In the separation step of the manufacturing method for a board component of this configuration, when the two sheets of film material are peeled away from each other, the second fibers tend to stand up against the film material. As a result, the fiber layer tends to have the second fibers extending from the first fibers to the opposite side to the film material, ensuring an adhesive surface to the substrate and increasing adhesive strength to the substrate.

In the manufacturing method configured as above, the decorative material forming process includes a bonding process in which the two separated decorative materials are pressed together to bond them together, and the bonding process and the separation process can be repeated.

This manufacturing method for board components can equalize the mass of the two decorative materials by repeating the bonding and separation processes.

In the manufacturing method configured as above, the decorative material forming process is performed after the separation process, and can include a brushing process in which brushing is performed so that the extension directions of the first fibers and the second fibers are aligned in a specific direction.

In this manufacturing method for board components, when the decorative material is bonded to the base material in the subsequent board component molding process, the fibers are aligned in the same direction, making it easy to apply adhesive and ensuring a sufficient adhesive area. In addition, when the natural fibers of the fiber layer are made to stand out on the surface of the film material by irradiating light from the back side as described above, it is possible to align the direction with the fiber pattern of the film material, ensuring high designability when irradiated with light.

In the manufacturing method configured as above, the decorative material forming process is performed after the brushing process, and can include a pressing process for setting the thickness of the fiber layer to a predetermined thickness.

This method of manufacturing a board member allows the raised second fibers to lie flat, ensuring a larger adhesive area.

According to the present invention, in a board member, it is possible to suppress unevenness on the film caused by natural fibers and to reliably adhere the fiber layer to the film material and the base material.

FIG. 1 is a view showing a vehicle using a board member according to the present invention, as seen from inside the vehicle interior. FIG. 2 is a cross-sectional view showing the ornament shown in FIG. 1 as viewed from the rear side of the vehicle. FIG. 1 is an enlarged cross-sectional view showing a schematic diagram of a board member according to the present invention. FIG. 2 is a plan view showing a schematic diagram of a fiber layer constituting the board member of the present invention. Schematic diagram showing the separation process Schematic diagram showing the brushing process Schematic diagram showing the pressing process A schematic cross-sectional view of the completed design material FIG. 1 is a schematic diagram showing an image when not irradiated. FIG. 1 is a schematic diagram showing an image upon irradiation.

Figure 1 shows an embodiment of a vehicle interior material using the board member of the present invention. The vehicle interior material of this embodiment is used for the door trim 12 that constitutes the interior surface of the vehicle interior of a side door 10 of a vehicle (automobile). The side doors 10 are provided on the driver's side (right side in the vehicle width direction) and the passenger side (left side in the vehicle width direction), and are configured to be able to be opened and closed by rotating around a rotation axis that extends generally vertically on the front side of the vehicle. The vehicle interior material of this embodiment is used for both the driver's side side door 10 and the door trim 12 of the driver's side side door 10. In the following explanation, the door trim 12 of the driver's side side door 10 will be explained as a representative example.

The door trim 12 constitutes the interior portion of the side door 10 and is attached to the door inner panel from the interior side of the vehicle. As shown in FIG. 1, the door trim 12 includes a lower board 14, an upper board 15, and an ornament 16. An armrest 17 is formed at the upper end of the lower board 14, and the ornament 16 is disposed above the armrest 17.

The ornament 16 is the vehicle interior material of this embodiment. The ornament 16 is mainly composed of a housing 20 with a space formed inside. As shown in FIG. 1, the housing 20 is elongated and extends in the fore-aft direction of the vehicle, and is fixed between the lower board 14 and upper board 15 that constitute the door trim 12, with one surface of the housing 20 forming part of the interior surface of the vehicle.

2, the housing 20 is generally box-shaped and is made up of a first housing member 21 that constitutes the portion inside the vehicle cabin and a second housing member 22 that constitutes the portion outside the vehicle cabin. More specifically, the second housing member 22 has a bottom surface portion 23 (the portion outside the vehicle cabin) and a wall portion 24 that stands upright from the periphery of the bottom surface portion 23, and is generally a dish-shaped member. Meanwhile, the first housing member 21 is a lid-shaped member that closes the opening of the second housing member 22, which is formed into a dish shape. Specifically, the first housing member 21 has the same external shape as the second housing member 22 when viewed from the perspective in the vehicle cabin interior and exterior direction, and is joined at its periphery to the tip of the wall portion 24 of the second housing member 22.

The housing 20 is provided with a lighting device 30. As shown in FIG. 2, the lighting device 30 is configured to include a plurality of LED tapes 33 each consisting of a longitudinal substrate 31 and a plurality of LEDs 32 arranged on the substrate 31 along the longitudinal direction. The LED tapes 33 are attached to the bottom surface 23 of the second housing member 22 in a state in which they extend in the longitudinal direction of the vehicle at intervals in the vertical direction. The second housing member 22 is made of synthetic resin and does not transmit or reflect light. The lighting device 30 is capable of controlling the lighting state of the LEDs 32, specifically, of switching the LEDs 32 on and off, and of changing the illuminance within a certain range, and when the LEDs 32 are on, the illuminance can be changed in stages from a relatively bright high illuminance to a relatively dark low illuminance.

The first housing member 21 is the board member of the present invention, and is made of a skin material 40 and a base material 42. The base material 42 is made of a highly light-transmitting synthetic resin (e.g., acrylic, polyethylene terephthalate, polycarbonate). In this embodiment, the base material 42 is made of acrylic. As shown in FIG. 2, the base material 42 has a central portion in the vertical direction that bulges toward the interior of the room, giving it a mountain-shaped cross section. The skin material 40, which is a light-transmitting design material, is adhered to the interior side of the base material 42.

As shown in FIG. 3, the skin material 40 is composed of a surface layer 44 constituting the design surface and a fiber layer 46 bonded to the back surface of the surface layer 44. The surface layer 44 is a film material mainly composed of a film substrate 50 made of a material having optical transparency. The film substrate 50 is not particularly limited, but in this embodiment, it is made of polyvinyl chloride. The surface layer 44 is made of a printed layer 52 on the surface side (inside the vehicle interior) of the film substrate 50, in which a fiber pattern imitating the fiber layer 46 is printed by inkjet paint, and a three-dimensional shape layer 54 on the surface side of the printed layer 52, in which an uneven shape is formed of a resin material having optical transparency (e.g., UV cured resin) to match the fiber pattern of the printed layer 52. In this embodiment, the thickness of the surface layer 44 is about 130 μm to 230 μm. More specifically, the thickness of the film substrate 50 is approximately 70 μm to 90 μm, the thickness of the printed layer 52 is approximately 15 μm to 40 μm, and the thickness of the three-dimensional shape layer 54 is approximately 45 μm to 100 μm.

The fiber layer 46 is formed into a mat shape by intertwining plant fibers 60, which are natural fibers as the first fibers, and resin fibers 62, which are second fibers. Examples of the plant fibers 60 include bast plant fibers such as kenaf, and wood fibers obtained by defibrating wood. Although the plant fibers 60 are exemplified as natural fibers, they may also be animal fibers or mineral fibers. In the fiber layer 46 of this embodiment, the plant fibers 60, which are natural fibers, are kenaf fibers. The resin fibers 62 are made of a transparent or semi-transparent resin material that is light-transmitting, and examples of the thermoplastic resin include polyolefin resins (polypropylene, polyethylene, etc.), polyester resins (aliphatic polyester resins such as polylactic acid and polycaprolactone, and aromatic polyester resins such as polyethylene terephthalate), etc. In this embodiment, the resin fibers 62 are made of polypropylene (PP).

In this embodiment, the plant fibers 60, which are kenaf fibers, have an average fiber diameter of 80 μm or more and 100 μm or less, while the resin fibers 62 are smaller than the fiber diameter of the plant fibers 60. The fiber diameter of the resin fibers 62 is 10 μm or more and 30 μm or less. Also, as shown in FIG. 4, the plant fibers 60 are fibers with a relatively straight shape, while the resin fibers 62 are fibers with a curled shape.

The fiber layer 46 is formed by mixing the vegetable fibers 60 and the resin fibers 62 in a predetermined ratio, and opening and laminating the mixture by a carding machine. The fiber layer 46 is not needle-punched, and no holes or the like are formed by the needle punching. In this embodiment, when the total mass of the mixed fibers is 100 wt%, the mixed fibers may contain, for example, 70 wt% vegetable fibers 60 and 30 wt% resin fibers 62. In this embodiment, the fiber layer 46 is formed so that the mass per unit area is about 10 g/m ^2. The fiber layer 46 is to express an image of natural fibers on the design surface of the first housing member 21, as will be described in detail later, so that the mass per unit area of the fiber layer 46 is relatively small, and is preferably 8 g/m ² or more and 20 g/m ² or less. More preferably, it is 8 g/m ² or more and 12 g/m ² or less.

Incidentally, from the viewpoint of expressing a fibrous texture on the design surface of the first housing member 21, the fiber layer 46 needs only the plant fibers 60 and does not require the resin fibers 62. On the other hand, if the fiber layer 46 is composed only of the plant fibers 60, the film substrate 50 is the main component and is relatively thin, so that the natural fibers create unnatural irregularities on the design surface (indoor side) of the surface layer 44, which impairs the natural fiber texture. In addition, the surface of the fiber layer 46 is made of uneven natural fibers in order to express the natural fiber texture, so that the adhesion of the fiber layer 46 to the substrate 42 or surface layer 44 causes uneven adhesion (variation in adhesive strength on the adhesion surface).

In this embodiment, as described above, the fiber layer 46 is mainly composed of plant fibers 60 and is intertwined with resin fibers 62 having a smaller fiber diameter than the plant fibers 60. Therefore, the presence of the plant fibers 62 between the plant fibers 60 and the surface layer 44 or between the plant fibers 60 and the base material 42 can suppress the occurrence of unevenness in the surface layer 44 due to the plant fibers 60. In addition, the presence of the resin fibers 62 increases the surface area of the fiber layer 46, that is, increases the bonding area. In addition, the resin fibers 62 are dispersed even in areas where there are few plant fibers 60, so that the variation in adhesive force on the bonding surface can be suppressed. Therefore, in this embodiment, the fiber layer 46 can be reliably bonded to the surface layer 44 and the base material 42. In order to enhance adhesive strength while expressing a fibrous texture, it is desirable to set the plant fiber 60 content to 50 wt% or more and 80 wt% or less, and to contain resin fiber 62 at a ratio of 50 wt% or less and 20 wt% or more, so that the total mass of the plant fiber 60 is 100 wt%. Even more desirable is to set the plant fiber 60 content to 65 wt% or more and 75 wt% or less, and to contain resin fiber 62 at a ratio of 35 wt% or less and 25 wt% or more.

Here, we will explain the manufacturing method of the first housing member 21, which is the board member of this embodiment. First, the vegetable fibers 60 and the resin fibers 62 are mixed in the predetermined ratio described above. This mixed fiber is opened and stacked using a carding machine to form a flat fiber web 70 as shown in Figure 5 (fiber web forming process). However, this fiber web 70 is formed to have a basis weight that is more than twice the target basis weight of the fiber layer 46.

Next, two sheets of film material 72 corresponding to the above-mentioned surface layer 44 are prepared. These two sheets of film material 72A, 72B are attached to each of the two sides of the fiber web 70 (film material adhesion process). Incidentally, the back surface of the film material 72, more specifically, the back surface of the film substrate 50, is laminated with an adhesive, which enables the film material 72 to be adhered to the fiber web 70. In this case, the fiber web 70 is configured such that the plant fibers 60 are surrounded by resin fibers 62 with small fiber diameters, so that the film materials 72A, 72B can be firmly adhered.

Next, as shown in FIG. 5, the upper film material 72A is peeled off from the lower film material 72B to separate it into two (separation process). In addition, in the fiber web 70, the resin fibers 62 with small fiber diameters are easily entangled with the plant fibers 60, and the resin fibers 62 tend to extend outward from the plant fibers 60. In other words, the resin fibers 62 tend to be attached to the film materials 72A and 72B. When the fiber web 70 is separated from this state, the fiber webs 70A and 70B bonded to the respective film materials 72A and 72B tend to be in a state in which the resin fibers 62 with small fiber diameters are pulled to the other side, and tend to stand up against the film material 72 and become fluffy. As a result, a part of the resin fibers 62 extends outward from the plant fibers 60 to the opposite side of the film material 72. In other words, when the decorative material 74 consisting of the film materials 72A, 72B and the fiber webs 70A, 70B is bonded to the substrate 42, the raised resin fibers 62 ensure a sufficient bonding area.

In addition, in this embodiment, after the above-mentioned separation process, the two separated decorative materials 74 are bonded to each other by pressing the surfaces of the respective fiber webs 70A and 70B together (adhesion process). This adhesion process and the above-mentioned separation process are then repeated to equalize the mass of the two decorative materials 74.

Next, as shown in FIG. 6, the fiber webs 70A, 70B are brushed in a specific direction against each decorative material 74. This brushing process aligns the fiber extension direction of the fiber webs 70A, 70B in a specific direction. Furthermore, in this brushing process, the basis weight of the fiber webs 70A, 70B is set to a target basis weight. As described above, the fiber webs 70A, 70B in the decorative material 74 tend to have the resin fibers 62 adhered to the film material 72, and the plant fibers 60 tend to be held by the resin fibers 62. Therefore, in the brushing process, the presence of the resin fibers 62 makes it easy to brush the plant fibers 60 in a specific direction.

The brush 80 used in this brushing process has elastic fibers and a spherical tip. This makes it possible to effectively align the fiber direction while preventing damage to the film material 72. It is also desirable for the brush 80 to be a mixture of long and short fibers in order to brush the plant fibers 60 with a large fiber diameter as well as the resin fibers 62 extending out on the opposite side of the film material 72.

After the brushing process, as shown in FIG. 7, a pressing process is performed using a roller 82, and the thickness of the fiber webs 70A and 70B is adjusted to a predetermined thickness. As a result, the standing resin fibers 62 are aligned in a specific direction and laid down. As a result, as shown in FIG. 8, the skin material 40, which is a light-transmitting decorative material, is completed. Since the resin fibers 62 of the skin material 40 are aligned in a specific direction and laid down through the brushing and pressing processes, it is easy to apply adhesive to the fiber webs 70A and 70B, and the adhesive area to the base material 42 can be reliably secured. In addition, in the film material 72 described above, the fiber pattern of the printing layer 52 imitates the plant fiber 60 that has been brushed as described above, and is a fiber pattern that extends in a specific direction. As described above, the decorative material forming process for forming the decorative material 74 is composed of the above-mentioned separation process, adhesion process, brushing process, and pressing process.

Then, the fiber webs 70A and 70B of the skin material 40 are coated with adhesive and attached to the base material 42, completing the first housing member 21, which is the board member of the present invention (board member molding process). The fiber webs 70A and 70B of the skin material 40 are not bonded by thermoplastic resin and can be relatively freely changed in shape, so the base material 42 has a mountain-shaped cross section, but the material can be attached along that shape. This configuration also makes it possible to attach the skin material 40 to various shapes, and board members of various shapes can be realized. In addition, the fiber webs 70A and 70B can hold the liquid adhesive firmly when the fiber web is formed only from the plant fibers 60 due to the presence of the resin fibers 62, so that the fiber webs can be reliably attached to the base material 42. Furthermore, even when the skin material 40 is attached to a vertical wall-shaped portion, the adhesive is less likely to drip downwards and can be firmly attached.

When the lighting device 30 is turned off and light is not irradiated from the back side, the first housing member 21, which is a board member configured as described above, expresses a natural fiber feel by the fiber pattern provided on the surface layer 44, as shown in FIG. 9. On the other hand, when the lighting device 30 is turned on and light is irradiated from the back side, the fiber pattern provided on the surface layer 44 is partially blurred or disappeared by the light, but as shown in FIG. 10, the plant fiber 60 in the fiber layer 46 stands out on the surface of the surface layer 44, and a natural fiber feel can be expressed. Note that when the lighting device 30 is turned on, the extension direction of the fiber pattern on the surface layer 44 and the extension direction of the plant fiber 60 of the fiber layer 46 that stands out on the surface layer 44 are the same, so that the image does not feel unnatural and high designability is ensured.

<Other embodiments>
The present invention is not limited to the above-described embodiment, and can be embodied in various forms with various modifications and improvements based on the knowledge of those skilled in the art. For example, the following embodiments are also included within the technical scope of the present invention.

In the above embodiment, the fiber layer 46 is a mixture of resin fiber 62 as the second fiber, but it is not limited thereto, and may be a natural fiber (e.g., cotton) having a smaller fiber diameter than the plant fiber 60 as the first fiber. According to this aspect, when the lighting device 30 is turned on, a sense of depth can be expressed by two types of natural fibers with different fiber diameters. Furthermore, when the mixed fibers are spread and stacked, a mat shape is formed in which the first fiber (kenaf fiber) 60 with a larger fiber diameter is more abundant compared to the second fiber (cotton) toward the surface layer 44, thereby creating a greater sense of depth. In addition, three or more types of fibers, for example fibers with different fiber diameters, may be mixed to form the fiber layer.

The fiber layer can also be made by mixing two or more types of natural fibers of similar colors but different shades. According to this embodiment, a sense of depth can be expressed by using two types of natural fibers with different shades. Furthermore, when the mixed fibers are spread and layered, a greater sense of depth can be created by forming them into a mat shape such that the darker natural fibers are more abundant on the outer layer 44 side compared to the lighter natural fibers.

In the above embodiment, the board member is used in the door trim 12 for a vehicle, but it is not limited to this and can be used in other vehicle interior materials such as the ceiling material and instrument panel of the vehicle. It is also not limited to vehicles and can be used in interior materials for other vehicles. Furthermore, it is not limited to vehicle interior materials and can be used in the interior of buildings, furniture, etc.

16...Ornament (vehicle interior material), 21...First housing member (board member), 30...Lighting device, 40...Skin material (design material), 42...Base material, 44...Surface layer, 46...Fiber layer, 50...Film base material, 52...Printed layer, 54...Three-dimensional shape layer, 60...Plant fiber (natural fiber, first fiber), 62...Resin fiber (second fiber), 70, 70A, 70B...Fiber web, 72A, 72B...Film material, 74...Design material

Claims (11)

A plate-shaped substrate;
A fiber layer mainly made of natural fibers and bonded to a surface side of the substrate;
A film material that is adhered to the surface side of the fiber layer and forms a design surface,
The board member is characterized in that the fiber layer is formed into a mat shape by intertwining first fibers, which are natural fibers, and second fibers, which are fibers having a smaller fiber diameter than the natural fibers. The board member according to claim 1, wherein the first fibers have a fiber diameter of 80 μm or more and 100 μm or less, and the second fibers have a fiber diameter of 10 μm or more and 30 μm or less. The board member according to claim 1 or 2, wherein the fiber layer has a mass per unit area of 8 g/ ^m2 or more and 20 g/ ^m2 or less. The board member according to any one of claims 1 to 3, wherein the content of the second fibers in the fiber layer is 20% or more and 50% or less. The film material is made of a light-transmitting material and has a fiber pattern printed on its surface.
The board member according to claim 1 , wherein the base material is made of a light-transmitting material. The board member according to claim 5, wherein the second fibers are optically transparent resin fibers. The fiber layer is formed so that the first fibers extend uniformly in a specific direction,
7. The board member according to claim 5 or 6, wherein the fiber pattern of the film material is a pattern extending uniformly in the specific direction. A manufacturing method for manufacturing the board member according to any one of claims 1 to 7, comprising:
a fiber web forming step of forming a fiber web from the first fibers and the second fibers in an amount at least twice the mass per unit area of the fiber layer;
a film material bonding step of bonding two sheets of the film material to both sides of the fiber web;
A decorative material forming process includes a separation process of peeling one of the two film materials from the other, and forms two decorative materials in which the fiber layer is laminated on the film material;
A board member forming process in which the decorative material is adhered to the surface of the base material to form the board member;
A method for manufacturing a board member having the above structure. The manufacturing method for board components described in claim 8, characterized in that the decorative material forming process includes a bonding process in which two separated pieces of the decorative material are pressed together to bond them together, and the bonding process and the separation process are repeated. The method for manufacturing a board member according to claim 8 or 9, wherein the decorative material forming process is carried out after the separation process and includes a brushing process in which the first fibers and the second fibers are brushed so that their extension directions are aligned in a specific direction. The method for manufacturing a board member according to claim 10, wherein the decorative material forming process is carried out after the brushing process and includes a pressing process for setting the thickness of the fiber layer to a predetermined thickness.

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