Board member and method for manufacturing a board member

Abstract

The present invention provides a board component and a method for manufacturing the board component that can reduce costs while using bamboo fibers. [Solution] A method for manufacturing a board member comprising a base material made of plant fibers other than bamboo and thermoplastic resin, on which bamboo fibers or crushed bamboo are dispersed, comprising: a fiber mat forming step of forming a fiber mat by spreading a mixed fiber, which is a mixture of plant fibers other than bamboo and thermoplastic resin fibers, into a plate shape; a bamboo scattering step of scattering the bamboo fibers or crushed bamboo on one side of the fiber mat; a pre-board forming step of forming a pre-board by heating and pressing the fiber mat on which the bamboo fibers or crushed bamboo are dispersed; and a heat press molding step of heating the pre-board and pressing it with a pair of molds to form the board member.

Description

Technical Field

[0001] The technology disclosed in this specification relates to a board member and a method for manufacturing the board member.

Background Art

[0002] Conventionally, a fiber board having a structure in which plant fibers are bonded with a thermoplastic resin has been known (for example, Patent Document 1). This type of fiber board is lightweight and has high rigidity, and is widely used as an interior material for vehicles such as a door trim of a vehicle.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, there is a desire to utilize the unique texture and feel of the natural material of the fiber board containing plant fibers as a design, and among them, bamboo fibers or pulverized bamboo having a relatively thick fiber diameter as plant fibers are attracting attention as one of various materials. However, since bamboo fibers are more expensive than other plant fibers, there is a problem that the selling cost of the product inevitably increases. In addition, since bamboo fibers are not particularly high in strength among plant fibers, it is necessary to increase the amount used to ensure strength, which not only further increases the cost but also increases the weight.

[0005] The technology disclosed in this specification has been achieved in view of the above circumstances, and an object thereof is to provide a board member and a method for manufacturing the board member capable of suppressing costs while using bamboo fibers or pulverized bamboo.

Means for Solving the Problems

[0006] The technology disclosed herein was completed in view of the above circumstances, and is a board member having bamboo fibers or crushed bamboo dispersed on one side of a base material made of plant fibers other than bamboo and a thermoplastic resin.

[0007] According to the above configuration, since bamboo fibers or crushed bamboo are dispersed on one side (the design side) of the board member, a bamboo design can be created. On the other hand, since the base material other than the one side is formed from plant fibers other than bamboo and thermoplastic resin, manufacturing costs can be reduced compared to a configuration in which expensive bamboo fibers are used throughout the entire board member.

[0008] The bamboo fibers or the crushed bamboo may be dispersed in a colored layer made of a black-colored thermoplastic resin provided on one side of the base material. With this configuration, the colored layer makes fine foreign matter in the board member less noticeable, thereby improving the aesthetic appearance.

[0009] The base material may be colored black. This configuration also makes fine foreign matter in the board material less noticeable, thus improving its aesthetic appeal.

[0010] A matte film for a matte finish, which covers the bamboo fibers or the crushed bamboo, may be laminated on one side of the base material. With such a configuration, it is possible to suppress reflection when light strikes foreign matter contained in the board member, thereby improving the design.

[0011] Furthermore, other technologies disclosed herein are methods for manufacturing a board member in which bamboo fibers or crushed bamboo are dispersed on one side of a base material made of plant fibers other than bamboo and thermoplastic resin, and the manufacturing method is to sequentially perform the following steps: a fiber mat forming step of forming a fiber mat by spreading a mixed fiber, which is a mixture of plant fibers other than bamboo and thermoplastic resin fibers, into a plate shape; a bamboo scattering step of scattering the bamboo fibers or crushed bamboo on one side of the fiber mat; a pre-board forming step of forming a pre-board by heating and pressing the fiber mat on which the bamboo fibers or crushed bamboo are dispersed; and a heat press molding step of forming the board member by heating the pre-board and pressing it with a pair of molds.

[0012] The process may include a spunbond lamination step between the fiber mat formation step and the pre-board formation step, in which a black spunbond made of thermoplastic resin is laminated onto one side of the fiber mat. With this configuration, bamboo fibers or crushed bamboo dispersed on one side of the fiber mat can be stably integrated into the base material by the spunbond. Furthermore, by using a black spunbond, fine foreign matter in the board member becomes less noticeable, improving the aesthetic appearance.

[0013] The spunbond lamination process may be carried out between the bamboo scattering process and the pre-board formation process. With this configuration, compared to the configuration in which the spunbond lamination process is carried out between the fiber mat formation process and the bamboo scattering process, bamboo fibers or crushed bamboo can be integrated with the substrate more stably.

[0014] The process may include a matte film placement step between the pre-board forming step and the heat press molding step, in which a matte film for matting is placed on one side of the pre-board where the bamboo fibers or crushed bamboo are dispersed. [Effects of the Invention]

[0015] According to the technology disclosed in this specification, it is possible to provide a board member and a method for manufacturing the board member that can suppress costs while using bamboo fiber or pulverized bamboo.

Brief Description of the Drawings

[0016] [Figure 1] Front view of a door trim in one embodiment [Figure 2] Partial enlarged cross-sectional view of an ornament board [Figure 3] Explanatory drawing showing the fiber mat forming step of Example 1 [Figure 4] Explanatory drawing showing the bamboo spraying step, spunbond lamination step, and pre-board forming step [Figure 5] Explanatory drawing showing the matte film placement step [Figure 6] Explanatory drawing showing the heat press forming step [Figure 7] Explanatory drawing showing the spunbond lamination step and bamboo spraying step of Example 2 [Figure 8] Explanatory drawing showing the bamboo spraying step and spunbond lamination step of Example 4 [Figure 9] Explanatory drawing showing the spunbond lamination step and bamboo spraying step of Example 5 [Figure 10] Partial enlarged cross-sectional view of an ornament board manufactured according to Examples 4 to 6 [Figure 11] Table showing photographs of each ornament board manufactured by different manufacturing methods

Modes for Carrying Out the Invention

[0017] One embodiment will be described with reference to FIGS. 1 to 11. In this embodiment, as a board member, an ornament board 20 provided in a door trim 10 used as an interior material for a vehicle and a manufacturing method thereof will be exemplified.

[0018] The door trim 10 constitutes the interior portion of the vehicle's side door and is attached to the door inner panel from the interior side. The door trim 10 is mainly composed of a rectangular trim board 11, and in addition to the trim board 11, it includes various functional components such as an inside handle 12, an armrest 13, a door pocket 14, and a speaker grille 15, which are provided on the trim board 11 (see Figure 1).

[0019] The trim board 11 is made up of multiple board members assembled together, and mainly consists of an upper board 17, a lower board 18, an ornament board 20, and an armrest board 19. Of these, the ornament board 20 is the board member of this embodiment, and the ornament board 20 is positioned above the armrest 13 provided on the trim board 11. The interior surface of the ornament board 20 is not covered with surface material such as synthetic leather, genuine leather, or fabric, and the design utilizes the texture and feel of the ornament board 20 itself. The board members other than the ornament board 20 are constructed with the surface of a plate-shaped base material covered with a surface material.

[0020] The ornament board 20 is a plate-shaped member having a predetermined thickness. The ornament board 20 mainly consists of a base material 21 containing plant fibers other than bamboo and thermoplastic resin, and bamboo fibers 24 or crushed bamboo are dispersed on one side of this base material 21 (the side facing the interior of the vehicle), and it is covered with a matte film 26 (see Figure 2).

[0021] As described above, the base material 21 includes plant fibers other than bamboo and a thermoplastic resin. Examples of plant fibers included in the base material 21 include bast plant fibers such as kenaf and plant fibers obtained by unraveling fibrous wood. The base material 21 is obtained by heating and pressing a fiber mat 21M, which is a mixture of plant fibers and thermoplastic resin fibers, as described later, and the thermoplastic resin functions as a binder that binds the plant fibers together. Examples of thermoplastic resins included in the base material 21 include polyolefin resins (polypropylene, polyethylene, etc.), polyester resins (aliphatic polyester resins such as polylactic acid and polycaprolactone, aromatic polyester resins such as polyethylene terephthalate), etc. Furthermore, the thermoplastic resin included in the base material 21 may be uncolored or colored, for example, black.

[0022] In this embodiment, the base material 21 is made of plant fibers obtained from kenaf (kenaf fibers 23) and polypropylene, but the material of the base material 21 is not limited to these and can be changed as appropriate. Also in this embodiment, the base material 21 (thermoplastic resin) is colored black.

[0023] The bamboo fibers 24 or bamboo pulverized material dispersed on one side of the base material 21 are bamboo-derived fibers or pulverized material and have a larger diameter than the kenaf fibers 23 contained in the base material 21. The bamboo fibers 24 or bamboo pulverized material are dispersed in a black colored layer 25 laminated on one side of the base material 21. The colored layer 25 is made of a thermoplastic resin. The thermoplastic resin constituting the colored layer 25 may be the same material as the thermoplastic resin contained in the base material 21, or it may be a different material.

[0024] The interior side (design side) of the colored layer 25 containing bamboo fibers 24 or crushed bamboo is covered with a translucent matte film 26. The matte film 26 is waterproof and odor-resistant, protects the surface of the colored layer 25, and provides a matte effect, thereby enhancing the design of the ornament board 20. The matte film 26 is constructed by applying a matting agent to a nylon film.

[0025] Next, the effects of the ornament board 20 described above will be explained. The ornament board 20 of this embodiment has bamboo fibers 24 or crushed bamboo dispersed on one side of a base material 21 made of plant fibers other than bamboo (kenaf fibers 23) and thermoplastic resin.

[0026] According to the above configuration, since bamboo fibers 24 or crushed bamboo are dispersed on one side (the design side) of the ornament board 20, a bamboo design can be created. On the other hand, since the parts of the base material 21 other than the one side are formed from plant fibers other than bamboo (kenaf fibers 23) and thermoplastic resin, the manufacturing cost can be reduced compared to a configuration in which expensive bamboo fibers or crushed bamboo are used for the entire ornament board.

[0027] Furthermore, the bamboo fibers 24 or crushed bamboo are dispersed in a colored layer 25 made of black-colored thermoplastic resin provided on one side of the base material 21. With this configuration, the colored layer 25 makes fine foreign matter in the ornament board 20 less noticeable, thereby improving its aesthetic appeal.

[0028] Furthermore, the base material 21 is colored black. This configuration also helps to make fine foreign matter in the ornament board 20 less noticeable. In other words, it improves the aesthetic appeal.

[0029] Furthermore, a matte film 26, which covers bamboo fibers 24 or crushed bamboo, is laminated to one side of the base material 21. With this configuration, it is possible to suppress reflection when light hits foreign matter contained in the ornament board 20, thereby improving the design.

[0030] Next, the method for manufacturing the ornament board 20 will be described. However, the method for manufacturing the ornament board 20 is not limited in any way to the following examples.

[0031] (Example 1) The manufacturing method for the ornament board 20 of Example 1 involves sequentially performing the following steps: a fiber mat formation step, a bamboo scattering step, a spunbond lamination step, a pre-board formation step, a matte film placement step, and a heat press molding step. Each step will be described in detail below.

[0032] <Fiber mat formation process> First, plant fibers (kenaf fibers 23) and thermoplastic resin fibers (polypropylene fibers) to constitute the base material 21 are laminated in a mat-like manner to form a fiber mat 21M that will serve as the base material 21 of the ornament board 20. The fiber mat 21M is manufactured using a fiber mat manufacturing apparatus 30. In this embodiment, black-colored polypropylene fibers are used as the thermoplastic resin fibers to constitute the base material 21.

[0033] As shown in Figure 3, the fiber mat manufacturing apparatus 30 is configured to include a fiber supply unit 31, a feed conveyor 32, a fiber opening cylinder 33, a conveyor 34, a suction device 35, an entanglement device 36, and a cutter 37.

[0034] The mixed fibers 22 of plant fibers (kenaf fibers 23) and thermoplastic resin fibers (polypropylene fibers), which are fed into the fiber supply unit 31 and mixed, are supplied to the fiber opening cylinder 33 by the feed conveyor 32. The fiber opening cylinder 33 has a cylindrical cylinder body 33A with multiple protrusions 33B on its surface (outer surface) and rotates clockwise in Figure 3 around the central axis L1. The rotating fiber opening cylinder 33 is capable of opening the mixed fibers 22 sent from the feed conveyor 32 by scratching them with the protrusions 33B. As the fiber opening cylinder 33 rotates, the mixed fibers 22 are caught on the surface (protrusions 33B) of the fiber opening cylinder 33 and transported upward, and then released into the air by the centrifugal force caused by the rotation of the fiber opening cylinder 33. In Figure 3, the direction of rotation of the fiber opening cylinder 33 is indicated by the arrow A1.

[0035] The outer circumference of the fiber-opening cylinder 33 is provided with a walker roller 38 and a stripper roller 39, each of which has multiple protrusions formed on its surface. The walker roller 38 has the function of opening the mixed fibers 22 by passing them between itself and the fiber-opening cylinder 33, while the stripper roller 39 has the function of peeling off the mixed fibers 22 that have adhered to the surface of the walker roller 38.

[0036] The conveyor 34 is a mesh conveyor with a mesh-like structure, and it is possible to deposit the mixed fibers 22 on its upper surface 34A. A suction device 35 is located below the conveyor 34, and by sucking air, the mixed fibers 22 can be drawn onto the upper surface 34A of the conveyor 34. The conveyor 34 forms a fiber web 21W by transporting the layer of mixed fibers 22 to the right side of Figure 3 while depositing the mixed fibers 22 on its upper surface 34A. The direction of transport of the mixed fibers 22 by the conveyor 34 is indicated by arrow A2.

[0037] The entanglement device 36 is, for example, a needle punching device, and is configured to entangle the fibers contained in the fiber web 21W, thereby forming a fiber mat 21M from the fiber web 21W. The entangled fiber web 21W (fiber mat 21M) is cut to a predetermined size by a cutter 37. The fiber mat 21M thus formed is black in color.

[0038] <Bamboo spraying process> In the fiber mat formation process, the fiber mat 21M, which has been shredded to a predetermined size, is transported to a dispersion device 40 (see Figure 4). The dispersion device 40 disperses bamboo fibers 24 or bamboo pulverized material onto the fiber mat 21M. The dispersion device 40 disperses the bamboo fibers 24 or bamboo pulverized material randomly (without directionality) onto the fiber mat 21M. In this embodiment, the amount of bamboo fibers 24 or bamboo pulverized material dispersed is approximately 1% of the weight of the kenaf fibers 23 used.

[0039] <Spunbond lamination process> Next, a nonwoven spunbond 25F is laminated onto a fiber mat 21M in which bamboo fibers 24 or crushed bamboo are dispersed. In this embodiment, the spunbond 25F is made of polypropylene and is colored black.

[0040] In this manner, the fiber mat 21M, in which bamboo fibers 24 or crushed bamboo are dispersed and spunbond 25F is laminated, is transported to the heating and pressurizing device 45.

[0041] <Pre-board formation process> The heating and pressurizing device 45 consists of, for example, a hot plate press or a hot belt press, and is equipped with a heating means such as a heater that generates heat when electricity is applied. The fiber mat 21M, on which bamboo fibers 24 or crushed bamboo are dispersed on one side (top surface) and spunbond 25F is laminated, is heated or pressurized after heating. The heating temperature at this time is set to be above the temperature at which the thermoplastic resin fibers contained in the fiber mat 21M and the thermoplastic resin constituting the spunbond 25F melt.

[0042] As a result, the thermoplastic resin fibers contained in the fiber mat 21M melt, and the kenaf fibers 23 are bound together by the thermoplastic resin. This layer, to which the kenaf fibers 23 are bound by the thermoplastic resin, is shown as 21P, which forms the base layer of the substrate 21.

[0043] Furthermore, the thermoplastic resin constituting the spunbond 25F melts and flows between the bamboo fibers 24 or bamboo pulverized material, resulting in a state where the bamboo fibers 24 or bamboo pulverized material are bound together by the thermoplastic resin. It can also be said that the bamboo fibers 24 or bamboo pulverized material are dispersed in the black layer 25P, which is the base of the colored layer 25, formed from the molten spunbond 25F. The pre-board 20P formed in this manner is in a state before being molded into the product shape (ornament board 20) of the interior material for vehicles.

[0044] Furthermore, by heating and pressing the fiber mat 21M and spunbond 25F together in this manner, the boundary between the fiber mat 21M and spunbond 25F is mixed and blended together (see Figure 2).

[0045] <Matte film placement process and heat press molding process> Next, the pre-board 20P is heat-press molded into the desired shape. First, the pre-board 20P formed in the pre-board forming process described above is heated and set between the upper mold 51 and the lower mold 52 of the molding die 50, which are in the open state (see Figure 5). At this time, the matte film 26 is placed between the upper surface of the pre-board 20P (the surface on which the bamboo fibers 24 or crushed bamboo are dispersed, and the surface on which the black layer 25P is placed) and the molding surface 51A of the upper mold 51. Once the matte film 26 is in the predetermined position, the upper mold 51 and the lower mold 52 are closed, and the pre-board 20P and the matte film 26 are cooled and compressed (see Figure 6).

[0046] The upper mold 51 is a movable mold that can be moved relative to the lower mold 52 (fixed mold) by a drive device (e.g., electric motor, air cylinder, hydraulic cylinder, etc.) not shown. The upper mold 51 and lower mold 52 can be closed and opened by moving the upper mold 51 closer to and further away from the lower mold 52.

[0047] The lower mold 52 has a molding surface 52A that protrudes toward the upper mold 51, which is the surface facing the upper mold 51. The upper mold 51 has a molding surface 51A that is recessed, corresponding to the shape of the lower mold 52, which is the surface facing the lower mold 52.

[0048] As shown in Figure 6, when the upper mold 51 and lower mold 52 are closed, the upper mold 51 is positioned opposite the lower mold 52 at a distance equal to the thickness of the ornament board 20. In other words, in the closed state, a molding space S1 for molding the ornament board 20 is formed between the upper mold 51 and the lower mold 52.

[0049] As a result, when the pre-board 20P and the matte film 26 are pressed by the upper die 51 and the lower die 52, the pre-board 20P and the matte film 26 are compressed into a shape corresponding to the shape of the molding space S1, and the ornament board 20 is formed. The thickness of the ornament board 20, that is, the distance between the upper die 51 and the lower die 52 in the closed state, is set to be smaller than the sum of the thickness of the pre-board 20P and the thickness of the matte film 26.

[0050] When the thermoplastic resin contained in the pre-board 20P cools and solidifies, the matte film 26 adheres to the upper surface of the pre-board 20P by the thermoplastic resin seeping out from the pre-board 20P, thereby obtaining an ornament board 20 with a matte film 26.

[0051] Subsequently, the upper mold 51 and the lower mold 52 are opened, and the ornament board 20 is demolded. This completes the manufacturing of the ornament board 20.

[0052] Next, the effects of the manufacturing method for the ornament board 20 of Example 1 will be described. The manufacturing method for the ornament board 20 of this example involves sequentially performing the following steps: a fiber mat forming step in which a mixed fiber 22, which is a mixture of plant fibers other than bamboo (kenaf fiber 23) and thermoplastic resin fibers, is spread into a plate-like shape to form a fiber mat 21M; a bamboo scattering step in which bamboo fibers 24 or crushed bamboo are scattered on one side of the fiber mat 21M; a pre-board forming step in which the fiber mat 21M with the bamboo fibers 24 or crushed bamboo dispersed in it is heated and pressed to form a pre-board 20P; and a heated press molding step in which the pre-board 20P is heated and pressed with a pair of molds 50 to form the ornament board 20. This manufacturing method makes it possible to create a design using bamboo while keeping manufacturing costs down.

[0053] Furthermore, between the bamboo scattering process and the pre-board formation process, a spunbond lamination process is included in which a black spunbond 25F made of thermoplastic resin is laminated to one side of the fiber mat 21M. With this configuration, the bamboo fibers 24 or crushed bamboo dispersed on one side of the fiber mat 21M can be stably integrated with the base material 21 by the spunbond 25F. In addition, because the spunbond 25F is black, fine foreign matter in the ornament board 20 becomes less noticeable, improving the aesthetic appeal.

[0054] Furthermore, between the pre-board formation process and the heat press molding process, a matte film placement process is included in which a matte film 26 is placed on one side of the pre-board 20P where bamboo fibers 24 or crushed bamboo are dispersed. With this configuration, it is possible to suppress reflection when light strikes foreign matter contained in the board material, thereby improving the aesthetic appearance.

[0055] (Example 2) The manufacturing method for the ornament board 20 in Example 2 differs from that of Example 1 in that the order of the bamboo scattering step and the spunbond lamination step is reversed, while the other steps and their order are the same as in Example 1. That is, the manufacturing method for the ornament board 20 in Example 2 involves sequentially performing the fiber mat formation step, the spunbond lamination step, the bamboo scattering step, the pre-board formation step, the matte film placement step, and the heat press molding step. In the following, only the parts that differ from Example 1 will be described, and the parts that are the same as in Example 1 will be omitted to avoid repetition.

[0056] <Spunbond lamination process> As shown in Figure 3, once the fiber mat 21M is formed by the fiber mat formation process, the spunbond 25F is then laminated onto the fiber mat 21M, as shown in Figure 7. The spunbond 25F in this embodiment is also made of polypropylene and is colored black.

[0057] <Bamboo spraying process> Next, bamboo fibers 24 or crushed bamboo are dispersed on the upper surface of the spunbond 25F, which is laminated on the fiber mat 21M, by the dispersion device 40. After that, the fiber mat 21M, which has the spunbond 25F laminated on it and the bamboo fibers 24 or crushed bamboo dispersed on it, is transported to the heating and pressurizing device 45.

[0058] <Pre-board formation process> The fiber mat 21M, on which spunbond 25F is laminated and bamboo fibers 24 or bamboo pulverized material is dispersed, is heated in a heating and pressurizing device 45, or pressurized after heating. As a result, the thermoplastic resin fibers contained in the fiber mat 21M and the thermoplastic resin constituting the spunbond 25F melt, and the bamboo fibers 24 or bamboo pulverized material dispersed on the spunbond 25F sink into the molten thermoplastic resin (spunbond), forming a pre-board 20P on which kenaf fibers 23 and bamboo fibers 24 or bamboo pulverized material are bound together by the thermoplastic resin. In other words, the bamboo fibers 24 or bamboo pulverized material are dispersed in the black, colored layer 25P, which is the base layer of the colored layer 25, formed from the molten spunbond 25F.

[0059] Subsequently, the ornament board 20 can be formed by heat-press molding the pre-board 20P together with the matte film 26 in the mold 50 (matte film placement step and heat-press molding step).

[0060] Even when spunbond 25F and bamboo fiber 24 or crushed bamboo are laminated onto the fiber mat 21M in this order, an inexpensive ornament board 20 that takes advantage of the design of the bamboo fiber 24 or crushed bamboo can be manufactured.

[0061] (Example 3) The manufacturing method for the ornament board 20 in Example 3 differs from that of Examples 1 and 2 in that the spunbond lamination step is omitted, while the other steps and their order are the same as in Examples 1 and 2. Specifically, the manufacturing method for the ornament board 20 in Example 3 involves sequentially performing the fiber mat formation step, the bamboo scattering step, the pre-board formation step, the matte film placement step, and the heat press molding step. In the following, only the parts that differ from Example 1 will be described, and the parts that are the same as in Example 1 will be omitted to avoid repetition.

[0062] <Bamboo spraying process> Once the fiber mat 21M is formed by the fiber mat formation process, bamboo fibers 24 or crushed bamboo are then dispersed on the upper surface of the fiber mat 21M using the dispersion device 40. After that, the fiber mat 21M with the dispersed bamboo fibers 24 or crushed bamboo is transported to the heating and pressurizing device 45.

[0063] <Pre-board formation process> The fiber mat 21M, in which bamboo fibers 24 or bamboo pulverized material is dispersed, is heated in the heating and pressurizing device 45, or pressurized after heating. As a result, the thermoplastic resin fibers contained in the fiber mat 21M melt, and the bamboo fibers 24 or bamboo pulverized material dispersed on the fiber mat 21M sink into the molten thermoplastic resin, forming a pre-board 20P in which the kenaf fibers 23 and bamboo fibers 24 or bamboo pulverized material are bound together by the thermoplastic resin. The bamboo fibers 24 or bamboo pulverized material are dispersed together with the kenaf fibers 23 on the surface layer of the base material 21.

[0064] Subsequently, the ornament board 20 can be formed by heat-press molding the pre-board 20P together with the matte film 26 in the mold 50 (matte film placement step and heat-press molding step).

[0065] Thus, even when the spunbond 25F (colored layer 25) is omitted, an inexpensive ornament board 20 that utilizes the design of bamboo fibers 24 or crushed bamboo can be formed.

[0066] (Example 4) The manufacturing method for the ornament board 20 in Example 4 differs in that, following the fiber mat formation step, the fiber mat 21M is heated and pressed to form a base material pre-board 21P in which plant fibers are pre-bonded with thermoplastic resin, and then the formed base material pre-board 21P is subjected to a bamboo scattering step and a spunbond lamination step in sequence (see Figure 8), and then heated and pressed again (corresponding to the pre-board formation step in Examples 1 to 3).

[0067] Furthermore, when the fiber mat 21M is pre-boarded in this manner, and then the spunbond 25F and bamboo fibers 24 or crushed bamboo are laminated, the boundary between the base material 21 and the colored layer 25 of the finished ornament board 20 is relatively clearly separated compared to Examples 1 to 3 (see Figure 10).

[0068] Even when the ornament board 20 is manufactured in this order, it is possible to manufacture an inexpensive ornament board 20 that makes use of the design of the bamboo fiber 24 or crushed bamboo.

[0069] (Example 5) The manufacturing method of the ornament board 20 in Example 5 differs from that of Example 4 in that the order of the bamboo scattering step and the spunbond lamination step is reversed. In other words, the manufacturing method of the ornament board 20 in Example 5 involves, following the fiber mat formation step, heating and pressing the fiber mat 21M to form a base material pre-board 21P in which plant fibers are pre-bonded with thermoplastic resin, and then sequentially performing the spunbond lamination step and the bamboo scattering step on the formed base material pre-board 21P (see Figure 9), followed by heating and pressing again (corresponding to the pre-board formation step in Examples 1 to 3).

[0070] Even when the ornament board 20 is manufactured in this order, an inexpensive ornament board 20 that makes use of the design of bamboo fibers 24 or crushed bamboo can be manufactured, similar to Example 4 above.

[0071] (Example 6) The manufacturing method of the ornament board 20 in Example 6 differs from that of Examples 4 and 5 in that the spunbond lamination process is omitted. In other words, the manufacturing method of the ornament board 20 in Example 6 involves, following the fiber mat formation process, heating and pressing the fiber mat 21M to form a base material pre-board 21P in which plant fibers are pre-bonded with thermoplastic resin, and then performing a bamboo scattering process on the formed base material pre-board 21P and heating and pressing it again (corresponding to the pre-board formation process in Examples 1 to 3).

[0072] Thus, even when the spunbond 25F is omitted, an inexpensive ornament board 20 can be formed that utilizes the design of bamboo fibers 24 or crushed bamboo.

[0073] Figure 11 is a table summarizing photographs of each ornament board 20 obtained by the manufacturing methods of Examples 1, 2, 4, and 5 described above. The photographs in the left column of the table are of ornament boards 20 with bamboo fibers 24 scattered on them, and the photographs in the right column are of ornament boards 20 with crushed bamboo scattered on them. In addition, the left half of the photograph in each column is a photograph without the matte film 26, and the right half is a photograph with the matte film 26 laminated on it.

[0074] These photographs confirm that bamboo fibers 24 or crushed bamboo can be used as a design element in any of the ornament boards 20 manufactured by the manufacturing methods of Example 1, Example 2, Example 4, and Example 5. Furthermore, it was confirmed that the ornament boards 20 of Example 4 and Example 5 have comparable design quality to the ornament boards 20 of Example 1 and Example 2, but Examples 1 and Example 2 are preferable because they have fewer manufacturing steps (there is no step to form the base material side pre-board 21P).

[0075] Furthermore, the photograph on the right, in which the matte film 26 is laminated, makes it more difficult to see fine foreign matter, and the bamboo fibers 24 or crushed bamboo are more clearly visible, thus giving it superior aesthetic appeal.

[0076] <Other Embodiments> The technologies disclosed herein are not limited to the embodiments described above in the description and drawings, but also include, for example, the following embodiments.

[0077] (1) In the above embodiment, the base material 21 (fiber mat 21M) is shown to be colored black, but the technical scope also includes a form in which the base material (fiber mat) is not colored.

[0078] (2) The matte film 26 can be omitted.

[0079] (3) In the above embodiment, an ornament board 20 constituting a door trim 10 for a vehicle was given as an example of a board member. However, the technology disclosed herein is not limited to the ornament board 20, and can be applied in various ways to other vehicle interior materials such as pillar garnishes, ceiling materials, console boxes, dashboards, various instrument panels, deck trims, as well as to vehicle interior materials for railways, airplanes, ships, etc., and to applications other than vehicle interior materials. [Explanation of Symbols]

[0080] 10: Door trim 20: Ornament board (board component) 20P: Pre-board 21: Base material 21M: Fiber mat 23: Kenaf fiber 24: Bamboo fiber 25: Coloring layer 25F: Spunbond 26: Matte film 30: Fiber mat manufacturing equipment 40: Dispersion equipment 45: Heating and pressurizing equipment 50: Molding mold

Claims

1. A board member comprising a base material made of plant fibers other than bamboo and thermoplastic resin, with bamboo fibers or crushed bamboo dispersed on one side.

2. The board member according to claim 1, wherein the bamboo fibers or the crushed bamboo are dispersed in a colored layer made of a black-colored thermoplastic resin provided on one side of the base material.

3. The board member according to claim 1 or claim 2, wherein the base material is colored black.

4. The board member according to claim 1 or claim 2, wherein a matte film for matting, which covers the bamboo fibers or the crushed bamboo, is laminated on one side of the base material.

5. A method for manufacturing a board member comprising a base material made of plant fibers other than bamboo and a thermoplastic resin, in which bamboo fibers or crushed bamboo are dispersed on one side, A fiber mat forming step involves forming a fiber mat by spreading a mixed fiber, which is a mixture of plant fibers other than bamboo and thermoplastic resin fibers, into a plate-like shape. A bamboo scattering step in which the bamboo fibers or the crushed bamboo are scattered on one side of the fiber mat, A pre-board forming step involves heating and pressing the fiber mat in which the bamboo fibers or the crushed bamboo are dispersed to form a pre-board, A method for manufacturing a board member, comprising: a heating press molding step of heating the pre-board and pressing it with a pair of molds to form the board member; and a step of sequentially performing these steps.

6. A method for manufacturing a board member according to claim 5, comprising a spunbond lamination step between the fiber mat forming step and the pre-board forming step, in which a black spunbond made of thermoplastic resin is laminated on one side of the fiber mat.

7. The method for manufacturing a board member according to claim 6, wherein the spunbond lamination step is performed between the bamboo scattering step and the pre-board formation step.

8. A method for manufacturing a board member according to any one of claims 5 to 7, further comprising a matte film placement step between the pre-board forming step and the heat press molding step, in which a matte film for matting is placed on one side of the pre-board where the bamboo fibers or crushed bamboo are dispersed.

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