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Fibrous formed products and methods for manufacturing such fibrous formed products

a technology fibrous materials, which is applied in the field can solve the problems of increasing the overall machine cost, and achieve the effect of reducing the machine cost for manufacturing and increasing the relative manufacturing efficiency of fibrous formed products

Inactive Publication Date: 2005-01-27
TOYOTA BOSHOKU KK +2
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0008] It is accordingly an object of the present invention to teach improved techniques that can reduce the machine cost for manufacturing fibrous formed products and that can increase the relative manufacturing efficiency of the fibrous formed products.
[0020] According to these methods, a fibrous mat having a low-density layer and a high-density layer can be formed with a single process step. Therefore, the number of machines required for manufacturing a fibrous formed product can be reduced in comparison with the known methods that require separate machines for forming a low-density layer, an upper high-density layer, and a lower high-density layer. As a result, the overall machine cost can be reduced. In addition, because the fibrous mat can be formed by a single process step, the fibrous mat manufacturing efficiency may be improved.
[0023] Therefore, the second fibrous mat may be directly placed on the first fibrous mat in order to form the fibrous formed product. Therefore, the efficiency of manufacturing the fibrous formed product can be further improved.
[0030] Because the diameter of the thick fibers is equal to or larger than 80 μm, the necessary thickness and rigidity of the fibrous formed product can be ensured. However, because the diameter of the thick fibers is less than or equal to 250 μm, the low-density layer's ability to deform may not be degraded, maintaining the formability of the fibrous formed product.
[0034] Therefore, a fibrous mat having a high-density layer and a lower density layer can be manufactured by a single process step. As a result, the number of machines required for manufacturing the fibrous mat can be reduced. The one step process allows the manufacturing costs to be reduced and the manufacturing efficiency to be improved. Therefore, the single machine can be advantageously used in manufacturing a fibrous formed product having a low-density layer interleaved between a first and second high-density layers.
[0043] Preferably, the first and second conveyors are driven in opposite directions to one another. Therefore, the first fibrous mat may be smoothly inverted when the first fibrous mat is transferred onto the second conveyor.

Problems solved by technology

This may increase the overall machine cost.

Method used

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  • Fibrous formed products and methods for manufacturing such fibrous formed products
  • Fibrous formed products and methods for manufacturing such fibrous formed products
  • Fibrous formed products and methods for manufacturing such fibrous formed products

Examples

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first representative embodiment

[0053] (First Representative Embodiment)

[0054] A first representative fibrous formed product and a first representative method of manufacturing such a fibrous formed product will now be described with reference to FIGS. 1 through 4. The first representative fibrous formed product is embodied as a panel that may be used as the base material of a ceiling member in an automobile. FIG. 1(A) shows a first representative machine 30 for manufacturing a fibrous mat. FIGS. 2(A) and 2(B) show steps of manufacturing a fibrous mat that becomes the material of a fibrous formed product. FIGS. 3(A) through 3(D) show the steps of manufacturing a ceiling member of an automobile.

[0055] Referring to FIG. 2(B), a fibrous formed product 10 is made of two sheets of fibrous mats 20. Each of the fibrous mats 20 are formed by approximately 25% by weight of natural fibers, approximately 25% by weight of inorganic fibers, and approximately 50% by weight of thermoplastic fibers. The natural fibers preferably ...

second representative embodiment

[0079] (Second Representative Embodiment)

[0080]FIG. 4(A) is a schematic view of a second representative fibrous mat manufacturing machine 1 that can continuously form two fibrous mats 20 so that they are automatically overlaid in the correct orientations with one another.

[0081] The machine 1 includes a first machine section 30a, for manufacturing one of the two fibrous mats 20 (hereinafter called “first fibrous mat 20”) and a second machine section 30b, for manufacturing the other of the two fibrous mats (hereinafter called “second fibrous mat 20”). The basic construction of the first machine section 30a and the construction of the second machine section 30b are substantially the same as with the first representative machine 30, described previously. Therefore, in FIG. 4(A), the parts of the first and second machine sections that are the same as parts of the first representative machine 30 are labeled with the same reference numerals. A repeated description of these parts will not ...

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Abstract

In a method of manufacturing a fibrous formed product, a mixture of fibers, including thick fibers and thin fibers, is prepared in order to form fibrous mats. The mixed fibers are supplied onto an outer peripheral surface of a roller. As the roller rotates, the mixed fibers are released from the roller and are thrown toward a fiber receiving surface. A fibrous mat is formed on the fiber receiving surface with a low-density layer next to the fiber receiving surface and a high-density layer on top of the low-density layer. Thick fibers mainly form the low-density layer and thin fibers mainly form the high-density layer. First and second fibrous mats are overlaid with one another such that their low-density layers oppose each other.

Description

[0001] This application claims priority to Japanese patent application serial number 2003-142008, the contents of which are incorporated herein by reference. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to fibrous formed products that include a low-density layer coarsely formed mainly by thick fibers and interleaved between high-density layers that are closely formed mainly by thin fibers. The present invention also relates to methods of manufacturing such fibrous formed products. [0004] 2. Description of the Related Art [0005] Japanese Laid-Open Patent Publication No. 6-200460 teaches a known fibrous formed product and a method for manufacturing such a product. The known fibrous formed product of this publication is shown in FIG. 5 and is labeled with reference letter “A”. The fibrous formed product “A” includes a low-density core layer 51, and upper and lower high-density surface layers, 53 and 55, disposed on the upper and lowe...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D04H1/485D04H1/559D04H1/70D04H13/00
CPCD04H1/42D04H13/007D04H13/002D04H1/70D04H1/425D04H1/4258D04H1/435D04H1/4374D04H1/498D04H1/732Y10T442/30D04H1/43838D04H1/43835
Inventor NAKAMURA, TETSUYATANABE, KAZUOSENOO, RINTAROISHIHARA, TOMOHIKOSAKAMOTO, TATSUONAKAGAWA, NORIAKI
Owner TOYOTA BOSHOKU KK
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