Substrate, method for manufacturing substrate, and method for manufacturing vehicle interior material

Abstract

To provide a base material, a base material manufacturing method, and a vehicle interior material manufacturing method, which can contribute to realization of a recycling society and carbon neutral.SOLUTION: A base material 10 has a first fiber resin layer 11, a second fiber resin layer 12 stacked on the first fiber resin layer 11, and a third fiber resin layer 13 stacked on the second fiber resin layer 12. The first fiber resin layer 11 and the third fiber resin layer 13 are constituted so as to include at least a fiber A and a thermoplastic resin. The second fiber resin layer 12 is a lamellar body consisting of a ground product 40 of a fiber resin body 32 constituted so as to include at least a fiber B and the thermoplastic resin bound to the fiber B, and includes a fiber C shorter than the fiber A due to pulverization of the fiber B.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a substrate, a method for manufacturing a substrate, and a method for manufacturing a vehicle interior material. [Background technology]

[0002] Conventionally, a known method for manufacturing vehicle interior materials (a molding method for vehicle interior materials) is the technology described in Patent Document 1. Specifically, Patent Document 1 discloses that a fiber resin member (interior base material) formed by mixing glass fiber, wood fiber, or the like (hereinafter sometimes simply referred to as fiber) with a thermoplastic resin such as PE or PP is heated at 180°C to 200°C for 30 to 40 seconds, and then inserted between a lower mold and an upper mold of a press mold for press molding. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 6-190982 Summary of the Invention [Problem to be solved by the invention]

[0004] In recent years, there has been a demand for contributions to the realization of a recycling-oriented society and carbon neutrality, but in the interior base material manufactured by the process disclosed in Patent Document 1, the thermoplastic resin is bound to the fibers, making it difficult to recover and reuse the fibers from this interior base material by, for example, scraping. On the other hand, it is conceivable to pulverize the interior base material and mold the pulverized material into, for example, a plate to reuse it as a base material, but pulverizing the interior base material shortens the length of the fibers, which raises concerns about a decrease in the strength of the base material made of the pulverized material.

[0005] The present disclosure is a technology completed based on the above circumstances, and has an object to provide a substrate, a method for manufacturing a substrate, and a method for manufacturing a vehicle interior material that can contribute to the realization of a recycling-oriented society and carbon neutrality. Another object is to provide a substrate, a method for manufacturing a substrate, and a method for manufacturing a vehicle interior material that can improve strength. [Means for solving the problem]

[0006] The present disclosure provides a substrate comprising a first fiber resin layer, a second fiber resin layer laminated on the first fiber resin layer, and a third fiber resin layer laminated on the second fiber resin layer, wherein the first fiber resin layer and the third fiber resin layer are composed of at least fiber A and a thermoplastic resin, and the second fiber resin layer is a layered body made of a pulverized fiber resin body composed of at least fiber B and a thermoplastic resin bonded to fiber B, and wherein fiber B is pulverized to include fiber C, which is shorter in length than fiber A.

[0007] This type of substrate has a configuration in which the second fiber resin layer containing fiber C is sandwiched between the first fiber resin layer and the third fiber resin layer, which are layers containing fiber A, which is longer than fiber C. As a result, when the substrate is bent upward or downward from a predetermined point, the relatively strong fiber A contained in the first fiber resin layer and the third fiber resin layer sandwiching the second fiber resin layer can resist the bending force of the substrate. Therefore, even if the second fiber resin layer is a layered body made of pulverized fiber resin material and contains fiber C, which is shorter than fiber A, the reinforcing effect of fiber A can be exhibited, resulting in a substrate that can improve strength. Furthermore, by covering the front and back sides (top and bottom sides) of the second fiber resin layer with the first fiber resin layer and the third fiber resin layer, which are layers containing fiber A, a substrate can be formed that makes use of the texture of fiber A on both sides, even if the second fiber resin layer is made of pulverized material. Furthermore, as the fiber resin body, for example, fiber waste materials such as off-cuts of vehicle interior materials, non-standard vehicle interior materials, recycled vehicle interior materials, carpet off-cuts, and ceiling off-cuts (these are sometimes called materials) can be used, and the crushed material can be used as the second fiber resin layer, making it possible to utilize materials to contribute to the realization of a circular society and carbon neutrality.

[0008] In the above configuration, the second fiber resin layer comprises a fiber C1 layer, a fiber C2 layer laminated on the fiber C1 layer, and a fiber C3 layer laminated on the fiber C2 layer, and the fiber C2 contained in the fiber C2 layer may be shorter in length than the fiber C1 contained in the fiber C1 layer and the fiber C3 contained in the fiber C3 layer.

[0009] In such a substrate, the second fiber resin layer has a fiber C2 layer containing fiber C2 sandwiched between a fiber C1 layer containing fiber C1 longer than fiber C2 and a fiber C3 layer containing fiber C3 longer than fiber C2. As a result, when the substrate is bent upward or downward from a predetermined point, the relatively strong fibers C (fibers C1 and C3) contained in the fiber C1 layer and fiber C3 layer sandwiching the fiber C2 layer can resist the force tending to bend the substrate, resulting in a substrate whose strength can be further improved.

[0010] The present disclosure also provides a method for manufacturing a substrate, including a preparation step of preparing a first fiber resin body and a third fiber resin body each containing at least fiber A and a thermoplastic resin, and a pulverized product of a second fiber resin body containing at least fiber B and a thermoplastic resin bonded to fiber B, wherein fiber B has been pulverized to include fiber C, the fiber C being shorter than fiber A; and a lamination step of layering the first fiber resin bodies to form a first fiber resin layer, stacking the pulverized products in layers on the first fiber resin layer to form a second fiber resin layer, and stacking the third fiber resin body in layers on the second fiber resin layer to form the third fiber resin layer.

[0011] This method of manufacturing a substrate can produce a substrate in which a second fiber resin layer containing fiber C is sandwiched between first and third fiber resin layers containing fiber A, which is longer than fiber C. When such a substrate is bent upward or downward from a predetermined point, the relatively strong fiber A contained in the first and third fiber resin layers can resist the bending force of the substrate. Therefore, even if the second fiber resin layer is a layered body made of pulverized fiber resin material and contains fiber C, which is shorter than fiber A, it is possible to produce a substrate that can improve strength by utilizing the reinforcing effect of fiber A. Furthermore, by laminating the layers so that the front and back sides (top and bottom) of the second fiber resin layer are covered by the first and third fiber resin layers containing fiber A, a substrate can be produced that exhibits the texture of fiber A on both sides, even if the second fiber resin layer is made of pulverized material. Furthermore, as the second fiber resin body, for example, fiber waste materials such as off-cuts of vehicle interior materials, non-standard vehicle interior materials, recycled vehicle interior materials, carpet off-cuts, and ceiling off-cuts (these are sometimes called materials) can be used, and the ground material can be prepared and laminated as the second fiber resin layer, making it possible to utilize materials to contribute to the realization of a circular society and carbon neutrality.

[0012] In the above manufacturing method, in the laminating process, the pulverized material may be dropped onto the first fiber resin layer, and a portion of it may be sucked up and dropped again, thereby forming the second fiber resin layer on the first fiber resin layer, the second fiber resin layer comprising a fiber C1 layer containing fiber C1 of the fibers C, and a fiber C2 layer containing fiber C2 of the fibers C that is shorter in length than fiber C1 and laminated on the fiber C1 layer.

[0013] This method for manufacturing a substrate allows the pulverized material to be separated into fibrous bodies with different fiber lengths and then laminated as separate layers on the first fiber resin layer, thereby efficiently manufacturing a substrate with improved physical properties such as strength.

[0014] In the above manufacturing method, in the lamination process, the second fiber resin layer may be formed on the first fiber resin layer, the second fiber resin layer including a fiber C3 layer laminated on the fiber C2 layer, the fiber C3 being longer than the fiber C2 among the fibers C.

[0015] This method for manufacturing a substrate makes it possible to efficiently manufacture a substrate having a second fiber resin layer in which a fiber C2 layer containing fiber C2 is sandwiched between a fiber C1 layer containing fiber C1 longer than fiber C2 and a fiber C3 layer containing fiber C3 longer than fiber C2. When such a substrate is bent upward or downward from a predetermined point, the relatively strong fibers C (fibers C1 and C3) contained in the fiber C1 layer and fiber C3 layer sandwiching the fiber C2 layer can resist the force tending to bend the substrate, thereby further improving its strength.

[0016] The above manufacturing method includes a step of sieving the pulverized material to separate it into fiber C1 bodies containing fiber C1 of the fibers C and fiber C2 bodies containing fiber C2 of the fibers C that is shorter in length than fiber C1, and in the layering step, the second fiber resin layer may be formed on the first fiber resin layer, the second fiber resin layer including a fiber C1 layer formed by layering the fiber C1 bodies and a fiber C2 layer formed by layering the fiber C2 bodies on the fiber C1 layer.

[0017] According to this method for manufacturing a substrate, the pulverized material can be separated into fibrous bodies with different fiber lengths and laminated as separate layers on the first fiber resin layer, thereby producing a substrate with improved physical properties such as strength.

[0018] In the above manufacturing method, in the lamination process, the first fiber resin layer may be formed on a conveying section, the first fiber resin layer may be conveyed in a predetermined direction by the conveying section, and the first fiber resin layer being conveyed by the conveying section may be sucked from below the conveying section by a suction section, while the second fiber resin layer and the third fiber resin layer are formed.

[0019] According to this method for manufacturing a substrate, when each layer is laminated on the first fiber resin layer, fine fibers, dust, etc. generated from the first fiber resin body, the third fiber resin body, or the pulverized material are less likely to scatter.

[0020] The present disclosure also provides a method for producing a vehicle interior material, including the steps of heating a substrate produced by carrying out the steps described above, and sandwiching and pressing the heated substrate between an upper mold and a lower mold.

[0021] According to this process, it is possible to manufacture a vehicle interior material that can improve strength, and also to manufacture a vehicle interior material that utilizes raw materials. [Effects of the Invention]

[0022] According to the present disclosure, it is possible to provide a substrate, a method for manufacturing a substrate, and a method for manufacturing a vehicle interior material that can contribute to the realization of a recycling-oriented society and carbon neutrality. It is also possible to provide a substrate, a method for manufacturing a substrate, and a method for manufacturing a vehicle interior material that can improve strength. [Brief explanation of the drawings]

[0023] [Figure 1] 1 is a diagram showing a cross-sectional configuration of a substrate according to embodiment 1. [Figure 2] An explanatory diagram showing a fiber resin body and its pulverized material. [Figure 3] Diagram showing the lamination process [Figure 4] Diagram showing the first pressing process [Figure 5] Diagram showing the second pressing process [Figure 6] FIG. 10 is a diagram showing a process for separating pulverized material according to embodiment 2. [Figure 7] Diagram showing the lamination process DETAILED DESCRIPTION OF THE INVENTION

[0024] <Embodiment 1> A first embodiment of the present disclosure will be described with reference to Figures 1 to 5. In this embodiment, a substrate 10 that is a precursor of a door trim (vehicle interior material) 100 that is attached to an automobile (vehicle) door, a method for manufacturing the substrate 10, and a method for manufacturing the door trim 100 will be described.

[0025] As shown in Figure 1, the substrate 10 includes a first fiber / resin layer 11, a second fiber / resin layer 12 laminated on the first fiber / resin layer 11, and a third fiber / resin layer 13 laminated on the second fiber / resin layer 12. The first fiber / resin layer 11 and the third fiber / resin layer 13 contain at least fiber A and a thermoplastic resin. The first fiber / resin layer 11 and the third fiber / resin layer 13 have a lower elastic modulus than the second fiber / resin layer 12 and are mat-shaped.

[0026] Fiber A is not particularly limited, and may be, for example, one or more of plant fibers, resin fibers, glass fibers, metal fibers, etc. Plant fibers include, for example, one or more of fibers from plants such as kenaf, flax, hemp, jute, Manila hemp, sisal, gampi, mitsumata, kozo, banana, pineapple, coconut, corn, sugarcane, bagasse, palm, papyrus, reed, esparto, saba grass, wheat, rice, bamboo, conifers (such as cedar and cypress), broadleaf trees, and cotton. Fiber A's length is not particularly limited, and may be, for example, 10 mm or more, 50 mm or more, or 100 mm or more in average fiber length calculated in accordance with JIS L1015. The thermoplastic resin contained in the first fiber resin layer 11 and the third fiber resin layer 13 is not particularly limited, but may be one or more of polyolefin resins (polypropylene, polyethylene, etc.), polyester resins (aliphatic polyester resins such as polylactic acid and polycaprolactone, aromatic polyester resins such as polyethylene terephthalate), etc. The first fiber resin layer 11 and the third fiber resin layer 13 may contain the same fiber A and thermoplastic resin, or different fiber A or thermoplastic resins.

[0027] The second fiber resin layer 12 is a layered body made of a pulverized fiber resin body 40 (see FIG. 2) of a fiber resin body (second fiber resin body) 32 that contains at least fiber B and a thermoplastic resin bonded to fiber B. As a result of pulverizing fiber B, fiber C, which is shorter than fiber A, is also included. Fibers B and C are not particularly limited, but may be one or more of vegetable fibers, resin fibers, glass fibers, metal fibers, etc. Vegetable fibers may be one or more of fibers from plants such as kenaf, flax, hemp, jute, Manila hemp, sisal, gampi, mitsumata, kozo, banana, pineapple, coconut, corn, sugarcane, bagasse, palm, papyrus, reed, esparto, saba grass, wheat, rice, bamboo, conifers (such as cedar and cypress), broad-leaved trees, and cotton. The thermoplastic resin contained in the second fiber resin layer 12 is not particularly limited, but may be one or more of polyolefin resins (polypropylene, polyethylene, etc.), polyester resins (aliphatic polyester resins such as polylactic acid and polycaprolactone, aromatic polyester resins such as polyethylene terephthalate), etc.

[0028] The length of fiber B is not particularly limited, but for example, the average fiber length calculated in accordance with JIS L1015 may be 10 mm or more, 50 mm or more, or 100 mm or more. The length of fiber C is not particularly limited as long as it is shorter than the length of fiber A and the length of fiber B, but for example, the average fiber length calculated in accordance with JIS L1015 may be 0.5 mm or more, 1 mm or more, or 2 mm or more. It may be less than 10 mm, 7 mm or less, or 5 mm or less.

[0029] The second fiber resin layer 12 includes a fiber C1 layer 21 laminated on the first fiber resin layer 11, a fiber C2 layer 22 laminated on the fiber C1 layer 21, and a fiber C3 layer 23 laminated on the fiber C2 layer 22. The third fiber resin layer 13 is laminated on the fiber C3 layer 23. The fiber C1 layer contains fiber C1 of a predetermined length among fibers C and a thermoplastic resin bonded to the fiber C1. Similarly, the fiber C3 layer contains fiber C3 of a predetermined length among fibers C and a thermoplastic resin bonded to the fiber C3. Meanwhile, the fiber C2 layer contains fiber C2, which is a fiber C that is shorter than fibers C1 and C3, and a thermoplastic resin bonded to the fiber C2. The lengths of Fiber C1 and Fiber C3 are not particularly limited as long as they are shorter than the lengths of Fiber A and Fiber B and longer than the length of Fiber C2, but for example, the average fiber length calculated in accordance with JIS L1015 may be 3 mm or more, 5 mm or more, less than 10 mm, or 7 mm or less. The length of Fiber C2 is not particularly limited as long as it is shorter than the lengths of Fiber A, Fiber B, Fiber C1, and Fiber C3, but for example, the average fiber length calculated in accordance with JIS L1015 may be 0.5 mm or more, 1 mm or more, less than 3 mm, or 2 mm or less.

[0030] Next, a method for manufacturing the substrate 10 will be described. As shown in FIGS. 2 and 3, the method for manufacturing the substrate 10 includes a preparation step for preparing the fiber-resin bodies 31, 32, and 33 and the pulverized material 40, and a lamination step for laminating the fiber-resin layers 11, 12, and 13. As shown in FIG. 2, the preparation step includes a pulverization step for pulverizing the second fiber-resin body 32 to obtain the pulverized material 40. The second fiber-resin body 32 is not particularly limited as long as it contains fiber B and a thermoplastic resin bonded to the fiber B. For example, one or more of non-standard substrates 32X, substrate scraps 32Y, and recycled vehicle interior materials 32Z (materials) can be used. The pulverization method for the second fiber-resin body 32 is not particularly limited, and methods such as cutting, tearing, and smashing can be used. The pulverized material 40 contains fiber A and fiber C (see FIG. 1) that is shorter than fiber B due to the pulverization of fiber B. It is also possible to reuse the base material 10 and the door trim 100 manufactured by the present technology as the second fiber resin body 32.

[0031] The preparation process includes a process for producing the first fiber resin body 31 and the third fiber resin body 33. This production process is not particularly limited, but for example, the first fiber resin body 31 and the third fiber resin body 33 may be produced by defibrating and laminating the fiber A and the fibrous thermoplastic resin using a carding machine, and then entangling them into a mat shape using needle punching.

[0032] As shown in FIG. 3 , in the laminating process, first fiber-resin bodies 31 are arranged in layers on a mesh-like first conveyor (transport section) 51 to form a first fiber-resin layer 11, pulverized material 40 is layered on the first fiber-resin layer 11 to form a second fiber-resin layer 12, and third fiber-resin bodies 33 are layered on the second fiber-resin layer 12 to form a third fiber-resin layer 13. In the laminating process, after (or while) the first fiber-resin layer 11 is formed on the first conveyor 51, the first fiber-resin layer 11 is transported downstream (in a predetermined direction) R by the first conveyor 51, and the first fiber-resin layer 11 being transported by the first conveyor 51 is sucked from below the first conveyor 51 by a first suction section 60, whereby the second fiber-resin layer 12 and the third fiber-resin layer 13 are laminated together to form the third fiber-resin layer 13. The first conveyor 51 is configured to transport an object placed on its upper surface downstream R. The first suction section 60 includes, for example, a fan, and is configured to suck gas downward through the first conveyor 51 by driving the fan.

[0033] The method for arranging the first fiber-resin bodies 31 in layers on the first conveyor 51 to form the first fiber-resin layer 11 is not particularly limited, and for example, the first fiber-resin body 31 may be transferred from another conveyor (not shown) onto the first conveyor 51 to form the first fiber-resin layer 11, or an operator may place the first fiber-resin body 31 on the first conveyor 51 to form the first fiber-resin layer 11. The same method applies to the method for laminating the third fiber-resin body 33 in layers on the second fiber-resin layer 12 to form the third fiber-resin layer 13.

[0034] In the layering process, the pulverized material 40 is dropped onto the first fiber resin layer 11, and a portion 40Y of the pulverized material 40 is sucked up and dropped again from the discharge port 57. This forms a second fiber resin layer 12 on the first fiber resin layer 11. The second fiber resin layer 12 includes a fiber C1 layer 21 containing fiber C1, a fiber C2 layer 22 containing fiber C2 and layered on the fiber C1 layer 21, and a fiber C3 layer 23 containing fiber C3 and layered on the fiber C2 layer 22. The pulverized material 40 is separated into a first pulverized material 40X containing fiber C1 and fiber C3 and a second pulverized material 40Y containing fiber C2 by the separation and layering device 50. The first pulverized material 40X, the second pulverized material 40Y, and the first pulverized material 40X are then layered on the first fiber resin layer 11 in this order. In this embodiment, the fiber C1 is the same fiber as the fiber C3.

[0035] The separating / stacking device 50 is capable of separating the pulverized material 40 by weight. The second pulverized material 40Y is lighter than the first pulverized material 40X. The separating / stacking device 50 includes a second conveyor 52 and a third conveyor 53 for transporting the pulverized material 40 placed on its upper surface, a second suction section 54 and a third suction section 55 disposed at the downstream ends of the conveyors 52 and 53, a junction section 56 where two ducts 58A and 58B extending from the two suction sections 54 and 55 join, and a discharge section 57 connected to the junction section 56 via a duct 58C. The separating / stacking device 50 also includes a fan (not shown), which, when driven, sucks the second pulverized material 40Y together with gas from the two suction sections 54 and 55 and sends the gas and the second pulverized material 40Y to the discharge section 57 via the junction section 56. The discharge port 57A of the discharge unit 57 is disposed in the direction of the downstream R of the first conveyor 51 relative to the second suction unit 54. The third suction unit 55 is disposed in the direction of the downstream R of the first conveyor 51 relative to the discharge port 57A. The second suction unit 54, the discharge port 57A of the discharge unit 57, and the third suction unit 55 are disposed above the first conveyor 51 (above the first fiber resin layer 11) so as to face in this order in the direction of the downstream R of the first conveyor 51.

[0036] The second conveyor 52 transports the pulverized material 40 downstream (rightward) R relative to the second conveyor 52, where it drops onto the first fiber resin layer 11. Here, a second suction unit 54 is provided at the downstream end of the second conveyor 52. The pulverized material 40 dropping from the second conveyor 52 is separated into second pulverized material 40Y, which is sucked up together with the gas by the second suction unit 54, and first pulverized material 40X, which is not sucked up by the second suction unit 54 and drops as it is. The first pulverized material 40X that drops as it is is layered on the first fiber resin layer 11 to form the fiber C1 layer 21. The second pulverized material 40Y sucked up by the second suction unit 54 is sent together with the gas via a junction 56 to a discharge unit 57. The discharge section 57 drops the second pulverized material 40Y again from the discharge port 57A in the direction downstream R of the first conveyor 51 from the position where the first pulverized material 40X dropped from the second conveyor 52, and layers the second pulverized material 40Y on the fiber C1 layer 21 to form the fiber C2 layer 22. Note that the discharge section 57 separates the gas from the second pulverized material 40Y by dropping the second pulverized material 40Y from the discharge port 57A while discharging the gas to the outside through a fourth duct (not shown).

[0037] Similarly, the third conveyor 53 conveys the pulverized material 40 downstream (leftward) L relative to the third conveyor 53, where it drops onto the fiber C2 layer 22. Here, a third suction unit 55 is provided at the downstream end of the third conveyor 53. Therefore, the pulverized material 40 dropping from the third conveyor 53 is separated into a second pulverized material 40Y that is sucked up together with the gas by the third suction unit 55, and a first pulverized material 40X that is not sucked up by the third suction unit 55 and drops as it is. The first pulverized material 40X that drops as it is is layered on the fiber C2 layer 22 to form the fiber C3 layer 23. The second pulverized material 40Y sucked up by the third suction unit 55 is sent together with the gas via a confluence unit 56 to a discharge unit 57. The discharge section 57 drops the second pulverized material 40Y again from the discharge outlet 57A in the direction upstream L of the first conveyor 51 from the position where the first pulverized material 40X fell from the third conveyor 53, and stacks the second pulverized material 40Y in layers on the fiber C1 layer 21 to form the fiber C2 layer 22.

[0038] As described above, the fiber C1 layer 21, the fiber C2 layer 22, and the fiber C3 layer 23 are laminated in this order on the first fiber resin layer 11 to form the second fiber resin layer 12. The third fiber resin body 33 is laminated on the second fiber resin layer 12 in a layered manner in the downstream R direction of the first conveyor 51 from the position where the first pulverized material 40X falls from the third conveyor 53 to form the third fiber resin layer 13. The laminate 10A formed by laminating the fiber resin layers 11, 12, and 13 is then cut to a predetermined length using a cutting machine (not shown) to obtain a mat body (substrate 10) as shown in FIG. 1 . For convenience, in this embodiment, the mat body will be described below as the substrate 10 of the present technology. However, in other embodiments, the substrate of the present technology may be a plate-like body 10B, as described below. That is, the substrate of the present technology includes a mat body and a plate-like body.

[0039] Next, the manufacturing method for vehicle interior material includes a first pressing process in which the base material 10 is heated and then pressed with a first molding die 70 to form a plate-like body 10B, as shown in Figure 4, and a second pressing process in which the plate-like body 10B is heated again and pressed with a second molding die 80 to form a door trim 100, as shown in Figure 5.

[0040] In the first pressing step, the substrate 10 is heated to a temperature equal to or higher than the melting point of the thermoplastic resin contained in the first fiber resin layer 11, the second fiber resin layer 12, and the third fiber resin layer 13. Next, the heated substrate 10 is sandwiched between the upper mold 71 and the lower mold 72 of the first molding die 70 and pressed to reduce its thickness into a plate, thereby forming a plate-like body 10B. Because this plate-like body 10B is flat, it is suitable for storing or transporting a plurality of such bodies together, for example.

[0041] In the second pressing step, the plate-like body 10B is heated to a temperature at which it can be softened or higher. Next, the heated plate-like body 10B is sandwiched between an upper mold 81 and a lower mold 82 of a second molding die 80 and pressed to form the door trim 100. The front and back surfaces of the door trim 100 are pressed against a recess 81A formed on the molding surface of the upper mold 81 and a protrusion 82A formed on the molding surface of the lower mold 82, thereby forming corners 100A in the door trim 100. Note that the first pressing step may be omitted. In this case, the door trim 100 may be formed directly from the substrate 10 by heating the substrate 10 and then pressing it with the second molding die 80.

[0042] Next, the effects of this embodiment will be described. In this embodiment, a substrate 10 is shown, which includes a first fiber-resin layer 11, a second fiber-resin layer 12 laminated on the first fiber-resin layer 11, and a third fiber-resin layer 13 laminated on the second fiber-resin layer 12, where the first fiber-resin layer 11 and the third fiber-resin layer 13 are composed of at least fiber A and a thermoplastic resin, and the second fiber-resin layer 12 is a layered body made of pulverized fiber-resin body 40 composed of at least fiber B and a thermoplastic resin bonded to fiber B, and where fiber C, which is shorter than fiber A, is included due to the pulverization of fiber B.

[0043] In this substrate 10, the second fiber resin layer 12 containing fiber C is sandwiched between the first fiber resin layer 11 and the third fiber resin layer 13, which are layers containing fiber A longer than fiber C. As a result, for example, when the substrate 10 (plate-like body 10B) that has undergone the first pressing step is bent upward or downward from a predetermined base point, the relatively strong fiber A contained in the first fiber resin layer 11 and the third fiber resin layer 13 that sandwich the second fiber resin layer 12 can resist the bending force of the substrate 10. Therefore, even if the second fiber resin layer 12 is a layered body made of pulverized fiber resin material 40 and contains fiber C that is shorter than fiber A, the reinforcing effect of fiber A can be exhibited, resulting in a substrate 10 that can be strengthened. Furthermore, by covering the front and back sides (upper and lower sides) of the second fiber resin layer 12 with the first fiber resin layer 11 and the third fiber resin layer 13, which are layers containing fiber A, the substrate 10 can retain the texture of fiber A on both sides, even if the second fiber resin layer 12 is made of pulverized material 40. Furthermore, non-standard substrates 32X, substrate scraps 32Y, and recycled vehicle interior materials 32Z (materials) can be used as the fiber resin body 32, and the pulverized material 40 obtained by pulverizing these materials can be used as the second fiber resin layer 12, thereby making it possible to utilize materials to contribute to the realization of a recycling-oriented society and carbon neutrality.

[0044] The second fiber resin layer 12 comprises a fiber C1 layer 21, a fiber C2 layer 22 laminated on the fiber C1 layer 21, and a fiber C3 layer 23 laminated on the fiber C2 layer 22, and the fiber C2 contained in the fiber C2 layer 22 is shorter in length than the fiber C1 contained in the fiber C1 layer 21 and the fiber C3 contained in the fiber C3 layer 23.

[0045] In this substrate 10, the second fiber resin layer 12 has a configuration in which a fiber C2 layer 22 containing fiber C2 is sandwiched between a fiber C1 layer 21 containing fiber C1 longer than fiber C2 and a fiber C3 layer 23 containing fiber C3 longer than fiber C2. As a result, when the substrate 10 is bent upward or downward from a predetermined portion as a base point, the relatively strong fibers C (fibers C1 and C3) contained in the fiber C1 layer 21 and fiber C3 layer 23 that sandwich the fiber C2 layer 22 can resist the force that tries to bend the substrate 10, making it possible to obtain a substrate 10 whose strength can be further improved.

[0046] In addition, in this embodiment, a method for manufacturing a substrate 10 has been described, which includes a preparation step of preparing a pulverized material 40 of a first fiber resin body 31 and a third fiber resin body 33 each containing at least fiber A and a thermoplastic resin, and a pulverized material 40 of a second fiber resin body 32 containing at least fiber B and a thermoplastic resin bonded to fiber B, where fiber B has been pulverized to include fiber C that is shorter in length than fiber A; and a lamination step of layering the first fiber resin body 31 to form a first fiber resin layer 11, stacking the pulverized material 40 in layers on the first fiber resin layer 11 to form a second fiber resin layer 12, and stacking the third fiber resin body 33 in layers on the second fiber resin layer 12 to form a third fiber resin layer 13.

[0047] This manufacturing method for the substrate 10 can produce a substrate 10 in which the second fiber resin layer 12 containing fiber C is sandwiched between the first fiber resin layer 11 and the third fiber resin layer 13 containing fiber A longer than fiber C. When this substrate 10 is bent upward or downward from a predetermined point, the relatively strong fiber A contained in the first fiber resin layer 11 and the third fiber resin layer 13 can resist the bending force of the substrate 10. Therefore, even if the second fiber resin layer 12 is a layered body made of pulverized fiber resin material 40 and contains fiber C shorter than fiber A, it is possible to produce a substrate 10 that can improve strength by utilizing the reinforcing effect of fiber A. Furthermore, by laminating the layers so that the front and back sides (top and bottom sides) of the second fiber resin layer 12 are covered by the first fiber resin layer 11 and the third fiber resin layer 13 containing fiber A, it is possible to produce a substrate 10 that retains the texture of fiber A on both the front and back sides, even if the second fiber resin layer 12 is made of pulverized fiber resin material 40. Furthermore, materials can be used as the second fiber resin body 32, and the pulverized material 40 can be prepared and laminated as the second fiber resin layer 12, making it possible to utilize materials and contribute to the realization of a circular society and carbon neutrality.

[0048] In the lamination process, the pulverized material 40 is dropped onto the first fiber resin layer 11, and some of it is sucked up and dropped again, thereby forming a second fiber resin layer 12 on the first fiber resin layer 11, the second fiber resin layer 12 comprising a fiber C1 layer 21 containing fiber C1 of the fibers C, and a fiber C2 layer 22 containing fiber C2 of the fibers C that is shorter in length than fiber C1 and laminated on the fiber C1 layer 21.

[0049] According to this method for manufacturing the substrate 10, the pulverized material 40 can be separated into fibrous bodies with different fiber lengths, and these can be laminated as separate layers on the first fiber resin layer 11. This allows for efficient manufacturing of the substrate 10, which can have improved physical properties such as strength.

[0050] In the lamination process, a second fiber resin layer 12 is formed on the first fiber resin layer 11, the second fiber resin layer 12 including a fiber C3 layer 23 laminated on a fiber C2 layer 22, the fiber C3 being longer than the fiber C2 among the fibers C.

[0051] This method for manufacturing the substrate 10 makes it possible to efficiently manufacture a substrate 10 having a configuration in which a fiber C2 layer 22 containing fiber C2 is sandwiched between a fiber C1 layer 21 containing fiber C1 longer than fiber C2 and a fiber C3 layer 23 containing fiber C3 longer than fiber C2 in the second fiber resin layer 12. When this type of substrate 10 is bent upward or downward from a predetermined point, the relatively strong fibers C (fibers C1 and C3) contained in the fiber C1 layer 21 and fiber C3 layer 23 sandwiching the fiber C2 layer 22 can resist the force tending to bend the substrate 10, thereby further improving its strength.

[0052] In the lamination process, a first fiber resin layer 11 is formed on a first conveyor 51, the first fiber resin layer 11 is transported in a predetermined direction by the first conveyor 51, and the first fiber resin layer 11 transported by the first conveyor 51 is sucked from below the first conveyor 51 by a first suction section 60, thereby forming a second fiber resin layer 12 and a third fiber resin layer 13.

[0053] According to this manufacturing method of the substrate 10, when each layer is laminated on the first fiber resin layer 11, fine fibers, dust, etc. generated from the first fiber resin body 31, the third fiber resin body 33, or the pulverized material 40 are less likely to scatter.

[0054] In addition, in this embodiment, a method for manufacturing the door trim 100 is shown, which includes a step of heating the substrate 10 manufactured by performing the steps described above, and pressing the heated substrate 10 between an upper mold 81 and a lower mold 82.

[0055] According to this process, it is possible to manufacture the door trim 100 with improved strength. Also, it is possible to manufacture the door trim 100 using the available materials.

[0056] <Embodiment 2> Next, a second embodiment of the present disclosure will be described. In this embodiment, the same components as those in the above embodiment are designated by the same reference numerals, and redundant descriptions of the structure, manufacturing process, actions, and effects will be omitted.

[0057] As shown in FIG. 6, the method for manufacturing a substrate in this embodiment includes a step of passing the pulverized material 40 through a sieve 90 to separate the pulverized material 40 into a first pulverized material 40X (fiber C1 body) containing fiber C1 and fiber C3, and a second pulverized material 40Y (fiber C2 body) containing fiber C2. The sieve 90 is capable of separating the pulverized material 40 by size. The second pulverized material 40Y has a smaller average particle diameter than the first pulverized material 40X. In this disclosure, the term "average particle diameter" refers to the particle diameter at 50% of the cumulative value in the particle size distribution determined by laser diffraction / scattering.

[0058] 7, in the layering process, the first pulverized material 40X, the second pulverized material 40Y, and the first pulverized material 40X are layered in this order on the first fiber resin layer 11, which is being transported downstream (in the predetermined direction) R by a conveyor 251, to form a second fiber resin layer 12 on the first fiber resin layer 11. Above the first fiber resin layer 11, there are arranged a first discharge section 91 that discharges the first pulverized material 40X, a second discharge section 92 that is located downstream of the first discharge section 91 and discharges the second pulverized material 40Y, and a third discharge section 93 that is located downstream of the second discharge section 92 and discharges the first pulverized material 40X.

[0059] The first pulverized material 40X is discharged from the first discharge section 91 onto the first fiber resin layer 11 to form a fiber C1 layer 21 made of a layer of the first pulverized material 40X. The second pulverized material 40Y is discharged from the second discharge section 92 onto the fiber C1 layer 21 to form a fiber C2 layer 22 made of a layer of the second pulverized material 40Y. The first pulverized material 40X is discharged from the third discharge section 93 onto the fiber C2 layer 22 to form a fiber C3 layer 23 made of a layer of the first pulverized material 40X.

[0060] As described above, the fiber C1 layer 21, fiber C2 layer 22, and fiber C3 layer 23 are laminated in this order on the first fiber resin layer 11 to form the second fiber resin layer 12. The third fiber resin body 33 is laminated in layers on the second fiber resin layer 12 in a direction downstream of the position where the first pulverized material 40X is discharged from the third discharge section 93 to form the third fiber resin layer 13 (see FIG. 3). The laminate formed by laminating the fiber resin layers 11, 12, and 13 is then cut to a predetermined length by a cutting machine (not shown) to obtain the substrate 10.

[0061] According to this method for manufacturing the substrate 10, the pulverized material 40 can be divided into fibrous bodies with different fiber lengths, and these can be laminated as separate layers on the first fiber resin layer 11. This makes it possible to manufacture a substrate with improved physical properties such as strength.

[0062] <Other embodiments> The present disclosure is not limited to the embodiments described above and in the drawings, and for example, the following embodiments are also included within the technical scope of the present disclosure. Furthermore, various modifications other than those described below can be made without departing from the spirit of the present disclosure.

[0063] (1) The configuration of the substrate may be modified as appropriate, in addition to the above-described embodiments. In the substrate, the first and third fiber resin layers sandwiching the second fiber resin layer may be plate-like bodies having a higher elastic modulus than the mat-like first and third fiber resin layers in the above-described embodiments. For example, the plate-like bodies may be formed by heating the mat-like first fiber resin layer or the mat-like third fiber resin layer in the above-described embodiments and then press-molding the mat-like first fiber resin layer or the mat-like third fiber resin layer in the above-described embodiments using a mold similar to the first mold.

[0064] (2) In addition to the above embodiment, the configuration of the second fiber resin layer can be modified as appropriate. In the above embodiment, the second fiber resin layer is three layers, but it may be one layer, two layers, or four or more layers. When manufacturing a substrate with one second fiber resin layer, the pulverized material can be directly stacked on the first fiber resin layer without separation using a separation and stacking device or the like. When manufacturing a substrate with two second fiber resin layers, the third conveyor and third suction unit need not be provided. When manufacturing a substrate with four or more second fiber resin layers, the number of conveyors and suction units can be increased according to the number of layers.

[0065] (3) In addition to the above-described embodiments, the second fiber resin body, which is a precursor of the pulverized material, can be appropriately modified. In the above-described embodiments, the second fiber resin body is a non-standard substrate, a substrate scrap, or a vehicle interior material recovered through recycling. However, the second fiber resin body is not limited to this. For example, the second fiber resin body may be a fiber-containing resin component such as a carpet or its scrap, or a housing construction material.

[0066] (4) The vehicle interior material is not limited to vehicles and may be provided for various vehicles. For example, the vehicle interior material of the present disclosure can be applied to ground vehicles such as trains and recreational vehicles, air vehicles such as airplanes and helicopters, and marine and underwater vehicles such as ships and submarines. [Explanation of symbols]

[0067] 10...Base material, 11...First fiber resin layer, 12...Second fiber resin layer, 13...Third fiber resin layer, 21...Fiber C1 layer, 22...Fiber C2 layer, 23...Fiber C3 layer, 31...First fiber resin body, 32...Second fiber resin body, 33...Third fiber resin body, 40...Ground material, 51...First conveyor (transport section), 60...First suction section (suction section), 81...Upper mold, 82...Lower mold, 100...Door trim (vehicle interior material)

Claims

1. a first fiber resin layer; a second fiber resin layer laminated on the first fiber resin layer; a third fiber / resin layer laminated on the second fiber / resin layer, the first fiber resin layer and the third fiber resin layer are configured to contain at least fiber A and a thermoplastic resin, The second fiber resin layer is a layered body made of a pulverized fiber resin body that contains at least fiber B and a thermoplastic resin bonded to fiber B, and the base material contains fiber C that is shorter in length than fiber A due to the pulverization of fiber B.

2. The second fiber resin layer is A fiber C1 layer; a fiber C2 layer laminated on the fiber C1 layer; A fiber C3 layer laminated on the fiber C2 layer, The substrate according to claim 1 , wherein the fibers C2 contained in the fiber C2 layer are shorter in length than the fibers C1 contained in the fiber C1 layer and the fibers C3 contained in the fiber C3 layer.

3. a first fiber-resin body and a third fiber-resin body each containing at least a fiber A and a thermoplastic resin; a preparation step of preparing a pulverized product of a second fiber resin body including at least fiber B and a thermoplastic resin bonded to the fiber B, the pulverized product including fiber C having a length shorter than that of the fiber A due to the pulverization of the fiber B; The first fiber resin body is layered to form a first fiber resin layer; The pulverized material is layered on the first fiber resin layer to form a second fiber resin layer; a laminating step of laminating the third fiber resin body in layers on the second fiber resin layer to form a third fiber resin layer.

4. In the layering step, the pulverized material is dropped onto the first fiber resin layer, and a part of the pulverized material is sucked up and dropped again. a fiber C1 layer containing fiber C1 among the fibers C; 4. A method for manufacturing a substrate as described in claim 3, wherein the second fiber resin layer is formed on the first fiber resin layer, the second fiber resin layer including a fiber C2 layer laminated on the fiber C1 layer, the fiber C2 layer including fibers C2 of the fibers C that are shorter in length than the fibers C1.

5. 5. The method for manufacturing a substrate according to claim 4, wherein in the laminating process, the second fiber resin layer including a fiber C3 layer laminated on the fiber C2 layer, the fiber C3 being longer than the fiber C2 among the fibers C, is formed on the first fiber resin layer.

6. The method includes a step of sieving the pulverized material to separate the pulverized material into a fiber C1 body containing fiber C1 of the fibers C and a fiber C2 body containing fiber C2 of the fibers C that is shorter in length than fiber C1, In the lamination step, A fiber C1 layer formed by layering the fiber C1 body; The method for manufacturing a substrate according to claim 3, wherein the second fiber resin layer is formed on the first fiber resin layer, the second fiber resin layer including a fiber C2 layer formed by stacking the fiber C2 bodies in layers on the fiber C1 layer.

7. In the lamination step, forming the first fiber resin layer on a conveying section, and conveying the first fiber resin layer in a predetermined direction by the conveying section; 5. The method for manufacturing a substrate according to claim 3, wherein the second fiber resin layer and the third fiber resin layer are formed while the first fiber resin layer being transported by the transport unit is sucked by a suction unit from below the transport unit.

8. 5. A method for producing an interior material for a vehicle, comprising the steps of heating a substrate produced by carrying out the steps according to claim 3 or 4, and pressing the heated substrate by sandwiching it between an upper mold and a lower mold.

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