Method for manufacturing fiber-containing board components

Abstract

To provide fiber-containing board members with high strength while reducing weight by recycling and utilizing fiber-containing resin members as waste materials.SOLUTION: A fiber-containing board member 10 comprises a board-shaped base material 13 made of nonwoven fabric and a plurality of fiber bundles 22 consisting of a plurality of fibers oriented in one direction and bound together by resin, wherein the fibers in the fiber bundles 22 are oriented in a direction along a board surface of the base material 13, the plurality of fiber bundles 22 are distributed in the base material 13 while being integrated with the base material 13.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] FIELD OF THE INVENTION The technology disclosed herein relates to fiber-containing board components and methods of making fiber-containing board components. [Background technology]

[0002] Conventionally, there are known techniques for recycling fiber-containing resin members used, for example, as trim boards in vehicles. For example, there is known a technique for crushing waste fiber-containing resin members and recycling them into building materials for housing, etc. There is also proposed a technique for crushing waste fiber-containing resin members into elongated fragments in the fiber direction, applying a binder to the surface of the fragments, stacking them in a mold, and heating them to harden the binder (see Patent Document 1 below). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2004-338227 Summary of the Invention [Problem to be solved by the invention]

[0004] As mentioned above, the method of crushing waste fiber-containing resin components has the problem that the fibers in the resin components are shortened by crushing, resulting in a decrease in the strength and rigidity of the recycled product. In addition, the method of crushing the fiber-containing resin into long, thin fragments in the fiber direction, adding a binder to the resulting fiber-containing resin, laminating and heating the resulting resin, or extrusion molding it together with a thermoplastic resin has the problem that the density of the recycled product is high, making it difficult to achieve light weight.

[0005] The technology disclosed in this specification was developed based on the above circumstances, and aims to provide a fiber-containing board component that is lightweight yet strong by recycling waste fiber-containing resin components. [Means for solving the problem]

[0006] The technology disclosed in this specification is a fiber-containing board member that includes a plate-shaped substrate made of nonwoven fabric and a plurality of fiber bundles in which a plurality of fibers oriented in one direction are bonded with resin, and the plurality of fiber bundles are dispersed in and integrated with the substrate, with the fibers in the fiber bundles oriented in a direction along the plate surface of the substrate.

[0007] According to the above configuration, a lightweight fiber-containing board member can be obtained by forming the substrate from a nonwoven fabric, while the multiple fiber bundles integrally formed on the substrate provide high strength. Furthermore, the fiber bundles can be recycled as waste resin components containing multiple fibers oriented in one direction. Specifically, the waste fiber-containing resin component can be shredded along the fiber orientation direction to cut out multiple fiber-containing resin pieces, which can then be dispersed in the substrate and integrated with the substrate by hot pressing, thereby enabling the waste fiber-containing resin component to be recycled.

[0008] The plurality of fiber bundles may be dispersed relative to the substrate such that the fibers in the fiber bundles are oriented in the same direction as the fibers in adjacent fiber bundles.

[0009] According to the above configuration, by orienting the fibers in the plurality of fiber bundles in the same direction, the strength of the fiber-containing board member in the direction in which the fibers are oriented can be increased.

[0010] The substrate may include substrate-side fibers in its nonwoven fabric that are oriented in one direction along the plate surface of the substrate, and the fibers in the fiber bundle and the substrate-side fibers may be oriented in intersecting directions.

[0011] According to the above-mentioned configuration, the strength of the substrate in a direction in which the strength is relatively weak (a direction intersecting the direction in which the substrate-side fibers are oriented) can be increased by the fiber bundles, thereby increasing the strength of the entire fiber-containing board member.

[0012] The plurality of fiber bundles may be covered by the substrate.

[0013] The fiber-containing board member may have a flat portion and a vertical wall portion rising from the flat portion, and the plurality of fiber bundles may be provided at a boundary portion between the flat portion and the vertical wall portion. According to the above configuration, the strength of the boundary portion can be increased by the fiber bundles.

[0014] The technology disclosed in this specification is a method for manufacturing a fiber-containing board member, which includes a shredding process in which a resin member containing a plurality of fibers oriented in one direction is shredded along the orientation direction of the fibers to cut out a plurality of fiber-containing resin pieces; a nonwoven fabric mat formation process in which the plurality of resin fibers are stacked in a mat shape to form a nonwoven fabric mat; a dispersion process in which the plurality of fiber-containing resin pieces cut out by the shredding process are dispersed on the nonwoven fabric mat; a pre-board formation process in which the nonwoven fabric mat in which the plurality of fiber-containing resin pieces are dispersed is heat-pressed to form a pre-board in which the plurality of fiber-containing resin pieces and the nonwoven fabric mat are integrated; and a press molding process in which the pre-board is press-molded using a molding die.

[0015] According to the above manufacturing method, the length of the fibers contained in the fiber-containing resin pieces can be maintained longer than in conventional methods in which the resin component is finely crushed, and therefore the strength and rigidity of the fiber-containing board component can be improved compared to when the resin component is finely crushed.

[0016] In the dispersing step, the plurality of fiber-containing resin pieces may be dispersed so that the fibers in the plurality of fiber-containing resin pieces are oriented in the same direction.

[0017] In addition, the nonwoven fabric mat may contain nonwoven fabric mat side fibers oriented in one direction along the plate surface of the nonwoven fabric mat, and in the dispersion process, the plurality of fiber-containing resin pieces may be dispersed so that the fibers in the plurality of fiber-containing resin pieces are oriented in a direction intersecting the nonwoven fabric mat side fibers. [Effects of the Invention]

[0018] According to the technology disclosed in this specification, a fiber-containing board member that is lightweight yet has high strength can be obtained by recycling waste fiber-containing resin members. [Brief explanation of the drawings]

[0019] [Figure 1] FIG. 1 is a perspective view showing a trim board according to a first embodiment; [Figure 2] Schematic diagram showing the process of shredding discarded door trim [Figure 3] Schematic diagram showing the nonwoven fabric mat manufacturing process and dispersion process [Figure 4] Schematic plan view showing a part of a nonwoven fabric mat [Figure 5] FIG. 1 is a schematic plan view showing a portion of a nonwoven fabric mat in which fiber-containing resin pieces are dispersed. [Figure 6] A side view showing the nonwoven fabric mat placed in the heating and pressurizing device. [Figure 7] A side view showing the process of forming a pre-board [Figure 8] Side view showing the pre-board placed in the mold [Figure 9] Side view showing the press forming process [Figure 10] FIG. 10 is a perspective view showing a trim board according to a second embodiment; [Figure 11] FIG. 1 is a schematic plan view showing a part of a substrate in which fiber bundles are dispersed. [Figure 12] FIG. 10 is a cross-sectional view showing a trim board according to another embodiment; DETAILED DESCRIPTION OF THE INVENTION

[0020] <Embodiment 1> A first embodiment will be described with reference to Figures 1 to 9. In this embodiment, the configuration and manufacturing method of a trim board 10 as a fiber-containing board member will be illustrated.

[0021] First, we will explain the trim board 10. This trim board 10 constitutes part of the door trim that is placed inside the door of a vehicle such as an automobile, and as shown in Fig. 1, is configured with a substantially flat, plate-like flat portion 11 and an upright wall portion 12 that rises from the edge of the flat portion 11.

[0022] The trim board 10 is mainly composed of a base material 13 made of nonwoven fabric containing fiber and thermoplastic resin, and multiple fiber bundles 22 are distributed in the boundary portion between the flat portion 11 and the vertical wall portion 12 of this base material 13 and in the surrounding area, and are configured to be integrated with the base material 13.

[0023] Each fiber bundle 22 is a mass of multiple fibers oriented in one direction that are partially bound together by a thermoplastic resin. The orientation direction of each fiber is considered to be generally oriented in one direction even when some of the fibers are not oriented in the same direction. In this embodiment, the multiple fiber bundles 22 are distributed in the boundary between the flat portion 11 and the upright wall portion 12 and its surrounding area such that the fibers in each fiber bundle 22 are oriented in a direction along the plate surface of the substrate 13 and are randomly oriented such that the orientation directions of the fibers in adjacent fiber bundles 22 do not match.

[0024] Hereinafter, the fibers and thermoplastic resin contained in the substrate 13 will be referred to as substrate-side fibers 14 and substrate-side thermoplastic resin, and the fibers and thermoplastic resin contained in the fiber bundles 22 will be referred to as fiber bundle-side fibers (not shown) and fiber bundle-side thermoplastic resin, and when no distinction is made, they will be referred to as fibers and thermoplastic resin.

[0025] The fibers that make up the trim board 10 can be selected from wood fibers obtained by unraveling wood or the like, bast plant fibers such as kenaf, inorganic fibers such as glass fiber and carbon fiber, synthetic resin fibers, etc. Among these, bast plant fibers such as kenaf are preferred in terms of weight reduction because the fibers themselves have voids.

[0026] The thermoplastic resin may be polyethylene, polypropylene, polyethylene terephthalate, polylactic acid, or the like. The substrate-side fibers and the fiber bundle-side fibers may be the same type of fiber or different types of fibers. The substrate-side thermoplastic resin and the fiber bundle-side thermoplastic resin may be the same type of thermoplastic resin or different types of thermoplastic resin.

[0027] In this embodiment, the substrate side fibers 14 and the fiber bundle side fibers are both kenaf fibers, and the substrate side thermoplastic resin and the fiber bundle side thermoplastic resin are both polypropylene.

[0028] Next, a description will be given of a manufacturing method of the trim board 10. The trim board 10 of this embodiment is formed in part using discarded door trim 20 as a recycled material.

[0029] <Shredding process> First, discarded door trim (an example of a resin member) 20 made of thermoplastic resin containing a plurality of kenaf fibers oriented in one direction (the left-right direction in FIG. 2) as a recycled material is shredded into matchstick shapes along the orientation direction of the kenaf fibers (see FIG. 2). In FIG. 2, the straight lines drawn on the inside edge of the discarded door trim 20 indicate an example of a cutting line. This cuts out a plurality of fiber-containing resin pieces 21 containing a plurality of kenaf fibers oriented in one direction.

[0030] <Nonwoven fabric mat forming process> Next, thermoplastic resin fibers (polypropylene fibers) and plant fibers (kenaf fibers) for constituting the base material 13 are laminated in a mat shape to form a nonwoven fabric mat 13M that serves as the base of the base material 13 of the trim board 10. The nonwoven fabric mat 13M is manufactured using a nonwoven fabric mat manufacturing apparatus 30.

[0031] As shown in FIG. 3, the nonwoven fabric mat manufacturing apparatus 30 is configured to include a fiber supply section 31, a feed conveyor 32, a fiber opening cylinder 33, a conveyor 34, a suction device 35, an entangling device 36, and a cutter 37.

[0032] Mixed fibers 15 of thermoplastic resin fibers (polypropylene fibers) and plant fibers (kenaf fibers) are fed into the fiber supply section 31 and mixed together. The mixed fibers 15 are then supplied to the spreading cylinder 33 by the feed conveyor 32. The spreading cylinder 33 has a cylindrical cylinder body 33A with multiple protrusions 33B on the surface (outer circumferential surface) thereof, and rotates clockwise in FIG. 3 around the central axis L1. The rotating spreading cylinder 33 is capable of spreading the mixed fibers 15 fed from the feed conveyor 32 by scratching them with the protrusions 33B. As the spreading cylinder 33 rotates, the mixed fibers 15 are caught on the surface (protrusions 33B) of the spreading cylinder 33 and transported upward. They are then released into the air by the centrifugal force generated by the rotation of the spreading cylinder 33. The rotation direction of the spreading cylinder 33 is indicated by arrow A1 in FIG. 3.

[0033] A stripper roller 38 and a walker roller 39 are provided on the outer periphery of the spreading cylinder 33, and a plurality of protrusions are also formed on the surface of each of them. The walker roller 39 has a function of subjecting the mixed fibers 15 to a spreading process by passing the mixed fibers 15 between itself and the spreading cylinder 33, and the stripper roller 38 has a function of peeling off the mixed fibers 15 adhering to the surface of the walker roller 39.

[0034] The conveyor 34 is a mesh conveyor having a mesh-like structure, and the mixed fibers 15 can be deposited on its upper surface 34A. A suction device 35 is disposed below the conveyor 34, and by sucking air, the mixed fibers 15 can be sucked onto the upper surface 34A of the conveyor 34. The conveyor 34 deposits the mixed fibers 15 on the upper surface 34A while transporting the layer of mixed fibers 15 to the right in Figure 3, thereby forming a fiber web 13W. The direction in which the mixed fibers 15 are transported by the conveyor 34 is indicated by arrow A2.

[0035] At this time, the orientation direction of each fiber (mixed fiber 15) in the fiber web 13W is aligned in a generally predetermined direction. Specifically, the orientation direction of the mixed fiber 15 in the fiber web 13W is aligned with the conveyance direction of the fiber web 13W in the nonwoven fabric mat manufacturing apparatus 30 (the left-right direction in FIG. 3).

[0036] The entangling device 36 is, for example, a needle punch device, and is configured to entangle the fibers contained in the fibrous web 13W, thereby turning the fibrous web 13W into a nonwoven fabric mat 13M. The entangled fibrous web 13W (nonwoven fabric mat 13M) is cut into a predetermined size by a cutter 37.

[0037] 4 is a plan view schematically illustrating a portion of nonwoven fabric mat 13M, and the numerous lines extending left and right in the figure represent kenaf fibers (substrate-side fibers 14) in nonwoven fabric mat 13M. Note that although some of the kenaf fibers are entangled in the thickness direction of nonwoven fabric mat 13M, they are considered to be oriented generally in one direction (the left-right direction in FIG. 4).

[0038] <Dispersion process> The nonwoven fabric mat 13M that has been shredded to a predetermined size in the nonwoven fabric mat forming process is transported to a dispersing device 40 (see FIG. 3). The dispersing device 40 disperses the above-mentioned fiber-containing resin pieces 21 onto the nonwoven fabric mat 13M. The dispersing device 40 can randomly disperse the fiber-containing resin pieces 21 onto the nonwoven fabric mat 13M, or can disperse the fiber-containing resin pieces 21 while imparting directionality to the fiber-containing resin pieces 21. The dispersing device 40 can also disperse the fiber-containing resin pieces 21 throughout the nonwoven fabric mat 13M, or can disperse them in a predetermined region of the nonwoven fabric mat 13M.

[0039] In this embodiment, the fiber-containing resin pieces 21 are dispersed randomly (without directionality) in a specific region of the nonwoven fabric mat 13M, which will be described later. Fig. 5 is a plan view schematically showing a portion of the nonwoven fabric mat 13M in which the fiber-containing resin pieces 21 are dispersed, and the numerous pieces scattered in random directions in the figure represent the dispersed fiber-containing resin pieces 21.

[0040] The nonwoven fabric mat 13M in which the fiber-containing resin pieces 21 have been dispersed by the dispersion device 40 is transported to the heating and pressurizing device 45.

[0041] <Pre-board forming process> The heating and pressurizing device 45 is, for example, a hot plate press or a hot belt press, and is equipped with a heater or other heat generating means that generates heat when electricity is applied. The nonwoven fabric mat 13M, in which the fiber-containing resin pieces 21 are dispersed, is pressurized while being heated or after being heated (see FIGS. 6 and 7). The heating temperature is set to a temperature above the melting point of the thermoplastic resin fibers (substrate-side thermoplastic resin) contained in the nonwoven fabric mat 13M and the thermoplastic resin (fiber bundle-side thermoplastic resin) contained in the fiber-containing resin pieces 21. This causes the thermoplastic resin fibers contained in the nonwoven fabric mat 13M and the thermoplastic resin contained in the fiber-containing resin pieces 21 to melt and function as a binder that binds the substrate-side fibers 14 together and the substrate-side fibers 14 and the fiber bundles 22 together. In other words, a flat pre-board 10P is formed in which the substrate-side fibers 14 and the fiber bundle-side fibers are bound by the thermoplastic resin. The pre-board 10P is in a state before being molded into the finished shape (trim board 10) of a vehicle interior material.

[0042] <Press molding process> Next, the pre-board 10P is press-molded. In the press-molding process, first, the pre-board 10P produced in the pre-board forming process is set between the upper mold 51 and the lower mold 52 of the molding die 50, which are in the open state (see FIG. 8), and then the upper mold 51 and the lower mold 52 are closed (see FIG. 9).

[0043] The upper mold 51 is a movable mold that can be moved relative to the lower mold 52 (fixed mold) by a driving device (not shown, for example, an electric motor, an air cylinder, a hydraulic cylinder, etc.). The upper mold 51 and the lower mold 52 can be closed and opened by moving the upper mold 51 toward and away from the lower mold 52.

[0044] The lower mold 52 has a shape in which a molding surface 52A, which is the surface facing the upper mold 51, protrudes toward the upper mold 51. In addition, the upper mold 51 has a molding surface 51A, which is the surface facing the lower mold 52, which is recessed in shape to correspond to the shape of the lower mold 52.

[0045] 9, in a closed state in which the upper mold 51 and the lower mold 52 are closed, the upper mold 51 is disposed opposite the lower mold 52 at a distance equal to the thickness of the trim board 10. That is, in the closed state, a substrate molding space S1 for molding the trim board 10 is formed between the upper mold 51 and the lower mold 52. As a result, when the pre-board 10P is pressed by the upper mold 51 and the lower mold 52, the pre-board 10P is compressed into a shape corresponding to the shape of the substrate molding space S1, thereby molding the trim board 10. Note that the thickness of the trim board 10, i.e., the distance between the upper mold 51 and the lower mold 52 in the closed state, is smaller than the thickness of the pre-board 10P.

[0046] The above-mentioned dispersion device 40 is controlled so as to disperse the fiber-containing resin pieces 21 in the peripheral area of ​​the nonwoven fabric mat 13M, including the boundary between the flat portion 11 and the vertical wall portion 12 of the trim board 10.

[0047] Thereafter, the upper mold 51 and the lower mold 52 are opened to remove the trim board 10. This completes the manufacturing of the trim board 10.

[0048] Next, the effects of this embodiment will be described. The trim board 10 of this embodiment includes a plate-shaped base material 13 made of nonwoven fabric and a plurality of fiber bundles 22 formed by bonding a plurality of fibers oriented in one direction with resin. The plurality of fiber bundles 22 are dispersed in and integrated with the base material 13, with the fibers in the fiber bundles 22 oriented in a direction along the plate surface of the base material 13.

[0049] According to the above configuration, the base material 13 is made of nonwoven fabric, thereby achieving a lightweight design, while the plurality of fiber bundles 22 integrally formed with the base material 13 makes it possible to obtain a trim board 10 with high strength. Furthermore, the fiber bundles 22 can be recycled from discarded door trim 20, which is a waste material containing a plurality of fibers oriented in one direction. That is, the discarded door trim 20 is shredded along the fiber orientation direction to cut out a plurality of fiber-containing resin pieces 21, and the cut-out fiber-containing resin pieces 21 can be dispersed in the base material 13 (nonwoven fabric mat 13M) and integrated with the base material 13 by heat pressing, thereby making it possible to recycle the discarded door trim 20.

[0050] The trim board 10 has a flat portion 11 and a standing wall portion 12 rising from the flat portion 11, and the plurality of fiber bundles 22 are provided at the boundary portion between the flat portion 11 and the standing wall portion 12 and in the surrounding area. According to the above configuration, the fiber bundles 22 can partially increase the strength of the boundary portion and the surrounding area.

[0051] In addition, the manufacturing method of the trim board 10 of this embodiment includes a shredding process in which discarded door trim 20 containing multiple fibers oriented in one direction is shredded along the fiber orientation direction to cut out multiple fiber-containing resin pieces 21; a nonwoven fabric mat formation process in which multiple mixed fibers 15 are stacked in a mat shape to form a nonwoven fabric mat 13M; a dispersion process in which the multiple fiber-containing resin pieces 21 cut out in the shredding process are dispersed on the nonwoven fabric mat 13M; a pre-board formation process in which the nonwoven fabric mat 13M in which the multiple fiber-containing resin pieces 21 are dispersed is heat-pressed to form a pre-board 10P in which the multiple fiber-containing resin pieces 21 and the nonwoven fabric mat 13M are integrated; and a press-molding process in which the pre-board 10P is press-molded using a molding die 50.

[0052] According to this manufacturing method, the length of the fibers contained in the fiber-containing resin pieces 21 can be kept long compared to the conventional method of finely crushing discarded door trim 20, thereby improving the strength and rigidity of the trim board 10.

[0053] As described above, according to this embodiment, discarded door trim 20 can be recycled, and a trim board 10 having high strength can be obtained while achieving a reduction in weight.

[0054] <Embodiment 2> In the first embodiment, the fiber bundles 22 are dispersed in random orientations in the boundary portion and the surrounding area of ​​the base material 13, but in this embodiment, as shown in Fig. 10, the fiber bundles 122 are dispersed with their orientation direction aligned with respect to the base material 113 of the trim board 110. The orientation direction of the fiber bundles 122 is perpendicular to the orientation direction of the base material side fibers 114 (see Fig. 11).

[0055] In other words, in the trim board 110 of this embodiment, the multiple fiber bundles 122 are distributed relative to the base material 113 so that the fiber bundle side fibers in the fiber bundles 122 are oriented in the same direction as the fiber bundle side fibers in the fiber bundles 122 that are arranged adjacent to each other.

[0056] With this configuration, by orienting the fibers in the multiple fiber bundles 122 in the same direction, the strength of the trim board 110 can be increased in the direction in which the fibers in the fiber bundles 122 are oriented (the vertical direction in Figure 11).

[0057] In addition, the substrate 113 contains substrate-side fibers 114 in its nonwoven fabric that are oriented in one direction along the plate surface of the substrate 113, and the fibers in the fiber bundles 122 and the substrate-side fibers 114 are oriented in a direction that intersects the vertical direction.

[0058] According to the above configuration, the strength of the base material 113 in a direction in which the strength is relatively weak (a direction intersecting the direction in which the base material side fibers 114 are oriented) can be increased by the fiber bundles 122. In other words, the strength of the entire trim board 110 can be increased.

[0059] <Other embodiments> The technology disclosed in this specification is not limited to the embodiments described above and illustrated in the drawings, and the following embodiments, for example, are also included in the technical scope.

[0060] (1) In the above embodiment, the fiber bundles 22, 122 are dispersed in the boundary portions of the substrates 13, 113 and in the surrounding areas thereof. However, the fiber bundles may be dispersed over the entire substrate.

[0061] (2) In the above embodiment, the substrates 13, 113 include substrate-side fibers 14, 114, but the techniques described in this specification can also be applied to cases where the substrates do not include substrate-side fibers.

[0062] (3) In the above embodiment, a configuration in which fiber bundles 22, 122 are integrally provided on the surface of base material 13, 113 is shown. However, for example, as shown in FIG. 12, a so-called sandwich structure can also be used in which fiber bundles 222 are provided inside base material 213.

[0063] (4) In the above embodiment, the fiber bundles 22, 122 are formed by bonding multiple fibers together with a thermoplastic resin. However, the fiber bundles may also be formed by bonding multiple fibers together with a thermosetting resin.

[0064] (5) The technology disclosed in this specification is applicable to various fiber-containing board members, not limited to the trim boards 10 and 110 of vehicle door trim. In addition, the discarded door trim 20 (recycled material) that is the basis for the fiber-containing resin piece 21 is not limited to the discarded door trim 20, but may be a non-standard door trim product, a post-press molding scrap material, or another fiber-containing resin member, all of which can lead to a reduction in waste. [Explanation of symbols]

[0065] 10, 110: trim board, 10P: pre-board, 11: flat portion, 12: standing wall portion, 13, 113, 213: base material, 13M: nonwoven fabric mat, 14, 114: base material side fiber (nonwoven fabric mat side fiber), 20: discarded door trim (resin component), 21: fiber-containing resin piece, 22, 122, 222: fiber bundle, 30: nonwoven fabric mat manufacturing device, 40: dispersion device, 45: heating and pressurizing device, 50: molding device

Claims

1. a shredding step of shredding a resin member containing a plurality of fibers oriented in one direction along the orientation direction of the fibers to cut out a plurality of fiber-containing resin pieces; a nonwoven fabric mat forming step of laminating a plurality of resin fibers into a mat shape to form a nonwoven fabric mat; a dispersing step of dispersing the plurality of fiber-containing resin pieces cut out by the shredding step, each of which has the plurality of fibers oriented in one direction, on the nonwoven fabric mat; a pre-board forming step of heat-pressing the nonwoven fabric mat in which the plurality of fiber-containing resin pieces are dispersed to form a pre-board in which the plurality of fiber-containing resin pieces and the nonwoven fabric mat are integrated; and a press molding step of press-molding the pre-board using a mold.

2. The method for manufacturing a fiber-containing board member according to claim 1 , wherein in the dispersing step, the plurality of fiber-containing resin pieces are dispersed so that the fibers in the plurality of fiber-containing resin pieces are oriented in the same direction.

3. The nonwoven fabric mat includes nonwoven fabric mat side fibers oriented in one direction along the plate surface of the nonwoven fabric mat, 3. The method for manufacturing a fiber-containing board member according to claim 2, wherein in the dispersion step, the plurality of fiber-containing resin pieces are dispersed so that the fibers in the plurality of fiber-containing resin pieces are oriented in a direction intersecting the fibers of the nonwoven fabric mat.

4. A method for manufacturing a fiber-containing board member as described in claim 1, wherein in the dispersion process, the plurality of fiber-containing resin pieces are dispersed so that the fibers in the plurality of fiber-containing resin pieces are randomly oriented so that their orientation direction does not match that of the fibers in adjacent fiber-containing resin pieces.

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