JP7342668B2 - Method of manufacturing molded structure - Google Patents

Description

The present invention relates to a method for manufacturing a molded structure.

Conventionally, as a method for manufacturing a molded structure, the method described in Patent Document 1 is known. In the method for manufacturing a molded structure described in Patent Document 1, a preboard is created from a mat material made of a mixture of fibers and a thermoplastic resin, and the preboard is pressed by a mold, and then a molded body made of resin is attached to the preboard. It is disclosed to join.

Patent No. 5803572

Even in the molded structure manufactured by the method disclosed in Patent Document 1, although the preboard (plate-like body) and the molded body are sufficiently bonded, the preboard and the molded body bonded to the preboard (hereinafter referred to as the bonded body) It is desired to improve the adhesion with the matte material (referred to as ``1''), and from the viewpoint of cost saving, it is required to use a mat material containing a relatively inexpensive resin.

The present invention was completed based on the above-mentioned circumstances, and one of its objects is to provide a method for manufacturing a molded structure that can improve adhesiveness with a joined body. Another object of the present invention is to provide a method for manufacturing a molded structure that can realize cost savings.

The present invention provides a mat composed of at least vegetable fibers, a high viscosity resin, and a low viscosity resin whose viscosity is lower than that of the high viscosity resin, such that the low viscosity resin is disposed on at least one surface layer side. After creating a plate-like body from the mat, the plate-like body is pressed with a mold, and the molded body made of at least a resin is molded into the low-viscosity plate-like body of the plate-like body. The method for manufacturing a molded structure is characterized in that it includes a pressing step of bonding to the surface layer side on which resin is arranged to form a molded structure.

According to such a method for manufacturing a molded structure, it is possible to create a plate-like body whose surface layer contains more low-viscosity resin than high-viscosity resin. Thereby, when joining the molded body (joint body) to the surface layer of the plate-shaped body, the low-viscosity resin flows suitably and easily spreads over the surface of the molded body. This improves the anchoring effect between the molded body and the plate-like body, and increases the adhesive force. In addition, as the high viscosity resin, an inexpensive material that does not require relatively high adhesion to the molded body can be used, leading to cost reduction.

In addition, in the mat creation step, while dropping the vegetable fibers, the high-viscosity resin, and the low-viscosity resin, at least one of suctioning gas or spraying the gas is performed, so that the surface layer is The mat may be prepared using a low-viscosity resin. According to such a method of manufacturing a molded structure, the low-viscosity resin rides on the gas flow, making it easier for the low-viscosity resin to be laminated on one surface layer side.

Further, the mat is created by stacking two laminates each made by laminating the low-viscosity resin, the high-viscosity resin, and the vegetable fiber in this order so that the vegetable fibers face each other. be able to. According to such a method of manufacturing a molded structure, it is possible to create a plate-shaped body containing more low-viscosity resin than high-viscosity resin not only on one surface layer side but also on the other surface layer side. As a result, when attaching the skin (joint body) to the other surface side of the plate-shaped body, the low-viscosity resin spreads suitably to the skin, increasing the adhesive force between the plate-shaped body and the skin. .

According to the present invention, it is possible to provide a method for manufacturing a molded structure that can improve adhesiveness with a joined body. Furthermore, it is possible to provide a method for manufacturing a molded structure that can realize cost savings.

A diagram showing a cross-sectional configuration of a mat according to Embodiment 1. Diagram showing the cross-sectional configuration of a plate-shaped body A perspective view showing high viscosity resin fibers made of high viscosity resin and low viscosity resin fibers made of low viscosity resin. Explanatory diagram showing the spinning process Explanatory diagram showing the mat creation process Enlarged explanatory diagram showing how fibers are laminated in the mat creation process Cross-sectional view showing a state in which a plate-like body is placed in an opened mold during the pressing process Cross-sectional view showing the mold in a closed state Cross-sectional view showing the mold opened again A diagram showing a cross-sectional configuration of a mat according to Embodiment 2 Diagram showing the cross-sectional configuration of a plate-shaped body

<Embodiment 1>
Embodiment 1 of the present invention will be described with reference to FIGS. 1 to 9. In this embodiment, a door trim (molded structure) 1 as a vehicle interior material mounted on an automobile (vehicle) and a method for manufacturing the door trim 1 will be described. As shown in FIG. 9, the door trim (molded structure) 1 includes a plate-shaped base material 10E and a bracket (molded body) 14 joined to the base material 10E. The base material 10E is formed by creating the plate-like body 10D shown in FIG. 2 from the mat 10C shown in FIG. 1, and then pressing the plate-like body 10D with the mold 5 (details will be described later). Note that the upper surface layer 10A side of the base material 10E is the front side (design side), and the lower surface layer 10B side of the base material 10E is the back surface side. The bracket 14 is bonded to the back side of the base material 10E. As the resin constituting the bracket 14, resins such as polyolefin resins (polypropylene, polyethylene, etc.), polyester resins (aliphatic polyester resins such as polylactic acid and polycaprolactone, aromatic polyester resins such as polyethylene terephthalate) are used. be able to.

As shown in FIG. 1, the mat 10C has a mat shape in which fibers are intertwined, and has a vegetable fiber layer 11 mainly composed of vegetable fibers and a high viscosity resin fiber mainly composed of high viscosity resin. a high-viscosity resin fiber layer 12, and a low-viscosity resin fiber layer 13 mainly composed of low-viscosity resin fibers made of a low-viscosity resin that has a lower viscosity than the high-viscosity resin contained in the high-viscosity resin fiber layer 12; Consisted of. On the upper surface layer 10A side of the mat 10C, relatively more vegetable fibers than other high-viscosity resin fibers and low-viscosity resin fibers are laminated, and on the lower surface layer 10B side, low-viscosity resin fibers are laminated. It is laminated relatively more than other vegetable fibers or high viscosity resin fibers.

FIG. 3 is a perspective view showing high viscosity resin fibers 12F forming the high viscosity resin fiber layer 12 and low viscosity resin fibers 13F forming the low viscosity resin fiber layer 13. The high viscosity resin fiber 12F has a cylindrical shape. On the other hand, the low-viscosity resin fiber 13F has a cylindrical shape with a hollow portion 13F1 inside. The low-viscosity resin fibers 13F are fibers that are more susceptible to the influence of air (gas) flow than the high-viscosity resin fibers 12F, and are easier to move along the air (gas) flow. Note that the high viscosity resin fiber 12F and the low viscosity resin fiber 13F may be simply referred to as resin fiber.

As the vegetable fibers constituting the vegetable fiber layer 11, bast vegetable fibers such as kenaf, wood fibers obtained by defibrating fibrous wood, etc. can be used. The resins constituting the high viscosity resin fibers 12F and the low viscosity resin fibers 13F include polyolefin resins (polypropylene, polyethylene, etc.), polyester resins (aliphatic polyester resins such as polylactic acid and polycaprolactone, and aromatic resins such as polyethylene terephthalate). Resin such as polyester resin) can be used.

Next, a manufacturing apparatus (molded structure manufacturing apparatus) 2 for manufacturing the door trim 1 will be described using FIGS. 4 to 8. As shown in FIGS. 4 to 7, the manufacturing device 2 includes a spinning device 3 that spins high-viscosity resin fibers 12F and low-viscosity resin fibers 13F from high-viscosity resin and low-viscosity resin using a melt-spinning method; It consists of a mat making device 4 that makes a mat 10C from resin fibers spun by and separately made vegetable fibers, and a mold 5 that presses a plate-like body 10D made of the mat 10C.

As shown in FIG. 4, the spinning device 3 includes an extruder 30 that extrudes molten high-viscosity resin and low-viscosity resin (hereinafter referred to as molten resin raw materials), and a molten resin raw material extruded from the extruder 30 into a fibrous form. The fibrous resin discharged from the cap 31 is provided with a cap 31, and a plurality of rollers 32 that wind up and stretch the fibrous resin discharged from the cap 31. The cap 31 is provided with a plurality of pores, and any molten resin raw material is discharged from the pores, thereby creating resin fibers that follow the shape of the pores. The shape of the pores of the cap 31 is hollow or annular. When high viscosity resin is discharged from the cap 31 having circular hollow pores, cylindrical resin fibers (ie, high viscosity resin fibers 12F shown in FIG. 3) can be created. On the other hand, when the low viscosity resin is discharged from the mouthpiece 31 having annular pores, an annular resin fiber (that is, the low viscosity resin fiber 13F shown in FIG. 3) can be created. Note that the spinning device 3 is a device that spins resin fibers using a melt spinning method, but is not limited thereto, and may be a device that spins resin fibers using a dry spinning method, a wet spinning method, or the like.

The mat creation device 4 includes a fiber supply section 40, a feed conveyor 41, a fiber opening cylinder 42, a web conveyor 43, a blowing device 44, a suction device 45, an entangling device 46, and a cutting device 47. . The resin fibers and vegetable fibers spun by the spinning device 3 are fed into the fiber supply section 40 . These fibers are discharged as mixed fibers 15 from the fiber supply section 40 and conveyed to the opening cylinder 42 by the feed conveyor 41.

The opening cylinder 42 includes a cylinder body 42A having a cylindrical shape and a plurality of protrusions 42B formed on the surface (outer peripheral surface) of the cylinder body 42A. The plurality of protrusions 42B are composed of, for example, garnet wire wound around the surface of the cylinder body 42A. The opening cylinder 42 can rotate about the central axis G in the direction of an arrow H (clockwise when viewed from the front side of the page). The rotating opening cylinder 42 is capable of opening the mixed fibers 15 sent from the feed conveyor 41 by scratching them with the projections 42B. Further, as the opening cylinder 42 rotates, the mixed fibers 15 are caught on the surface (protrusions 42B) of the opening cylinder 42 and transported upward. Thereafter, the mixed fibers 15 are released into the air by the centrifugal force caused by the rotation of the opening cylinder 42.

The mat creating device 4 also includes a stripper roller 48 and a walker roller 49 provided along the outer periphery of the opening cylinder 42 . A protrusion (not shown) made of garnet wire or the like is formed on each surface of the stripper roller 48 and the walker roller 49, similarly to the opening cylinder 42. By passing the mixed fibers 15 between the walker roller 49 and the opening cylinder 42, the mixed fibers 15 can be subjected to a fiber opening process. The stripper roller 48 can strip the mixed fibers 15 attached to the surface of the walker roller 49.

The web conveyor 43 is a mesh conveyor, which deposits the mixed fibers 15 that are released into the air from the opening cylinder 42 and falls, and conveys the mixed fibers 15 to the right (in the direction of the entangling device 46). , shall form a web 16. The blowing device 44 is disposed to the right of the opening cylinder 42 and above the web conveyor 43, and blows air (gas) onto the mixed fibers 15 that are released into the air from the opening cylinder 42 and fall. be able to. The suction device 45 is disposed below the web conveyor 43 and can suction the mixed fibers 15 onto the web conveyor 43 by suctioning air (gas). The entangling device 46 is, for example, a needle punch device, and can create the mat 10C from the web 16 by intertwining the fibers included in the web 16.

As shown in FIG. 7, the mold 5 includes an upper mold 51 disposed above and having a molding surface 51A that presses and molds the plate-shaped body 10D from the upper surface layer 10A side, and a mold 51 facing the upper mold 51. and a lower mold 52 having a molding surface 52B that presses and molds the plate-like body 10D from the lower surface layer 10B side. The lower die 52 includes a concave portion 53 on the side of the molding surface 52B that is concave enough to allow the bracket 14 to be inserted therein.

The upper mold 51 is a movable mold that can be moved vertically relative to the lower mold 52 by a drive device (for example, an electric motor, an air cylinder, a hydraulic cylinder, etc.) not shown. FIG. 7 shows a state in which the upper mold 51 has moved away from the lower mold 52 (a state in which the mold 5 is open). FIG. 8 shows a state in which the upper mold 51 moves toward the lower mold 52 (a state in which the mold 5 is closed).

Next, a method for manufacturing the door trim (molded structure) 1 will be described. The method for manufacturing the door trim 1 can be roughly divided into: a mat 10C composed of a vegetable fiber layer 11, a high viscosity resin fiber layer 12, and a low viscosity resin fiber layer 13; A mat creation process in which a plate-shaped body 10D is created from the mat 10C, and a bracket made of resin is pressed while pressing the plate-shaped body 10D with a mold 5. It includes a pressing step of joining the molded body 14 to the surface layer 10B side (back side) on which the low-viscosity resin fiber layer 13 is arranged of the plate-like body 10D to form the door trim 1.

As shown in FIG. 4, in the mat creation step, the spinning device 3 creates high viscosity resin fibers 12F and low viscosity resin fibers 13F. Specifically, the molten resin raw material extruded from the extruder 30 is discharged from the die 31 in the form of fibers. The fibrous molten resin raw material discharged from the nozzle 31 is cooled with gas, and is wound up and stretched by a plurality of rollers 32 to create resin fibers. Different resin fibers are produced by appropriately changing the type of molten resin raw material fed into the extruder 30 and the nozzles 31 having different pore shapes. A cylindrical high-viscosity resin fiber 12F (see FIG. 3) is created by charging a high-viscosity resin into an extruder 30 and discharging it from a nozzle 31 having hollow circular pores. Further, a low viscosity resin is put into the extruder 30 and discharged from the mouthpiece 31 having circular pores, thereby creating a circular low viscosity resin fiber 13F.

Next, as shown in FIG. 5, the high-viscosity resin fibers 12F and low-viscosity resin fibers 13F created by the spinning device 3 and the separately created vegetable fibers are fed into the fiber supply section 40. The fiber supply unit 40 mixes these fibers and discharges the mixed fibers 15 onto the feed conveyor 41 . The feed conveyor 41 conveys the mixed fibers 15 to the opening cylinder 42 .

Subsequently, the mixed fibers 15 are opened by a rotating opening cylinder 42 and conveyed upward. The opening cylinder 42 conveys the mixed fibers 15 (opened fibers) to the right side (toward the spraying device 44 side), and then releases them into the air and causes them to fall onto the web conveyor 43. At this time, the blowing device 44 blows air onto the falling mixed fibers 15, and the suction device 45 sucks the mixed fibers 15 onto the web conveyor 43. Further, the suction device 45 suctions the mixed fibers 15 through the ventilation holes of the web conveyor 43 having a mesh shape. Then, as shown in FIG. 6, the low-viscosity resin fibers 13F ride the air flow with priority over the high-viscosity resin fibers 12F and vegetable fibers, and are deposited on the bottom layer (on the surface layer 10B side), resulting in low Laminated as a viscosity resin fiber layer 13. The high viscosity resin fibers 12F are deposited on the upper side of the low viscosity resin fiber layer 13 to form the high viscosity resin fiber layer 12, and the vegetable fibers are deposited on the upper side of the high viscosity resin fiber layer 12. Laminated as a vegetable fiber layer 11. Note that the high viscosity resin fibers 12F may enter the low viscosity resin fiber layer 13 and the vegetable fiber layer 11.

The mixed fibers 15 stacked in layers on the web conveyor 43 are conveyed to the right side by the web conveyor 43. By continuously stacking the mixed fibers 15 on the web conveyor 43 and conveying the stacked mixed fibers 15, a web 16 made of the spread mixed fibers 15 is formed.

Next, as shown in FIG. 5, the fibers included in the web 16 are interlaced using an interlacing device 46 to create a mat 10C. Then, the mat 10C is cut into a predetermined length by the cutting device 47. In addition, since the fiber diameter of the vegetable fiber is larger than that of the high-viscosity resin fiber 12F and the low-viscosity resin fiber 13F, which are resin fibers, it is difficult to get caught in the barb of the needle punch in the interlacing device 46, and the influence of the interlacing process by the needle punch is reduced. It's hard to accept. Further, the fibers of the web 16 may be entangled using an interlacing device other than the needle punch type interlacing device 46 (for example, a water jet type entangling device, etc.).

The mat 10C thus created is pressed from above and below with a heated metal mold to create a plate-like plate 10D (see FIG. 2). The temperature at which the metal mold is heated is higher than the temperature at which the resin fibers contained in the mat 10C melt. The resin fibers contained in the mat 10C function as a binder that binds the vegetable fibers together when melted. In the plate-like body 10D, each layer is bound together, and one (lower) surface layer 10B side becomes a low-viscosity resin fiber layer 13 containing a relatively large amount of low-viscosity resin, and the other (upper) surface layer 10A side is made of vegetable fiber. This results in a vegetable fiber layer 11 that contains a lot of fibers.

Next, as shown in FIG. 7, the mold 5 is opened and the plate-like body 10D is placed between the upper mold 51 and the lower mold 52. Further, the bracket 14 is inserted into the recess 53 of the lower mold 52. From this state, the mold 5 is heated and the upper mold 51 is gradually brought closer to the lower mold 52, thereby closing the mold 5.

Then, as shown in FIG. 8, the upper surface layer 10A of the plate-like body 10D is pressed against the molding surface 51A of the upper die 51, and is molded to follow the shape of the molding surface 51A. The lower surface layer 10B is pressed against the molding surface 52B of the lower mold 52, so that it is molded to follow the shape of the molding surface 52B. At this time, the low-viscosity resin contained in a large amount on the lower surface layer 10B side of the plate-shaped body 10D flows while closely contacting the surface of the bracket 14.

By keeping the plate-shaped body 10D pressed by the mold 5 for a predetermined period of time and cooling the mold 5, the plate-shaped body 10D is molded as the base material 10E, and the bracket 14 is molded as the plate-shaped body 10D (base material 10E) is bonded to the lower surface layer 10B side. As shown in FIG. 9, the upper mold 51 is separated from the lower mold 52 and the mold is opened again, thereby obtaining the door trim 1 in which the bracket 14 is joined to the back surface 10B of the base material 10E.

Next, the effects of this embodiment will be explained. The manufacturing method of this embodiment includes a vegetable fiber layer 11 mainly composed of vegetable fibers, a high viscosity resin fiber layer 12 mainly composed of high viscosity resin fibers 12F made of high viscosity resin, and high viscosity resin fibers. The mat 10C is composed of a low viscosity resin fiber layer 13 mainly composed of low viscosity resin fibers 13F made of a low viscosity resin having a lower viscosity than the high viscosity resin contained in the layer 12. A mat creation process in which the mat is created so that it is placed on the lower surface layer 10B side, and after creating a plate-like plate 10D from the mat 10C, while pressing the plate-like body 10D with the mold 5, it is made of resin. The door trim 1 is formed by bonding the bracket 14 to the surface layer 10B side of the plate-like body 10D on which the low-viscosity resin fiber layer 13 is disposed.

According to such a method of manufacturing the door trim 1, it is possible to create a plate-like body 10D containing more low-viscosity resin than high-viscosity resin on the surface layer 10B side. Thereby, when the bracket 14 (joint body) is joined to the surface layer 10B of the plate-like body 10D, the low-viscosity resin flows suitably and easily spreads on the surface of the bracket 14. Then, the anchoring effect between the bracket 14 and the plate-like body 10D is improved, and the adhesive force can be increased. In addition, an inexpensive material that does not require relatively high adhesiveness to the bracket 14 can be used as the high-viscosity resin, leading to cost reduction.

In the mat 10C creation step, while dropping the vegetable fibers, high viscosity resin fibers 12F, and low viscosity resin fibers 13F, a low viscosity resin fiber layer is added to the surface layer 10B by sucking air and blowing air. A mat 10C on which No. 13 is arranged is created. According to this method of manufacturing a molded structure, the low-viscosity resin fibers 13F ride the gas flow, making it easier to stack the low-viscosity resin fibers 13F on the surface layer 10B side.

<Embodiment 2>
Next, a second embodiment of the present invention will be described with reference to FIGS. 10 and 11. This embodiment exemplifies a method for manufacturing a molded structure that differs from the above embodiment in the procedure of the mat creation step. In addition, in this embodiment, the same reference numerals are used for the same parts as in the above embodiment, and overlapping explanations regarding the structure, process, action, and effect will be omitted.

As shown in FIG. 10, the mat 100C has a mat shape formed by overlapping two laminates 10C1 and 10C2. The two laminates 10C1 and 10C2 include a vegetable fiber layer 11 mainly composed of vegetable fibers, a high viscosity resin fiber layer 12 mainly composed of high viscosity resin fibers, and a high viscosity resin fiber layer 12 mainly composed of high viscosity resin fibers. It is formed by laminating a low-viscosity resin fiber layer 13 mainly composed of low-viscosity resin fibers made of a low-viscosity resin having a lower viscosity than the high-viscosity resin contained in the resin fiber layer 12. In the laminate 10C1, a low-viscosity resin fiber layer 13, a high-viscosity resin fiber layer 12, and a vegetable fiber layer 11 are laminated in this order from the lower surface layer 100B side. In the laminate 10C2, a vegetable fiber layer 11, a high-viscosity resin fiber layer 12, and a low-viscosity resin fiber layer 13 are laminated in this order from the lower surface layer 100B side. The vegetable fiber layer 11 of the laminate 10C2 is laminated on the vegetable fiber layer 11 of the laminate 10C1. The upper surface layer 100A side and the lower surface layer 100B side of the mat 100C are laminated so that low viscosity resin fibers are contained in a relatively larger amount than other vegetable fibers and high viscosity resin fibers.

The mat 100C is created by stacking two laminates 10C1 and 10C2 so that the respective vegetable fiber layers 11 and 11 face each other. Specifically, in the mat creation process, the low-viscosity resin fiber layer 13, the high-viscosity resin fiber layer 12, and the vegetable fiber layer 11 are laminated in this order from the lower surface layer 100B side to form a laminate (web) 10C1. Create. The obtained laminate 10C1 is turned upside down to form a laminate 10C2, and is stacked on the upper surface (on the vegetable fiber layer 11) of another laminate 10C1 to obtain a mat 100C.

By pressing the mat 100C from above and below using, for example, a heated metal mold, a plate-like plate 100D (see FIG. 11) is created. Although each layer of the plate-shaped body 100D is bonded together, one (lower) surface layer 100B side and the other (upper) surface layer 100A side are layers containing a relatively large amount of low-viscosity resin.

According to the manufacturing method of such a molded structure, it is possible to create a plate-shaped body 100D containing more low-viscosity resin than high-viscosity resin not only on the lower surface layer 100B side but also on the upper surface layer 100A. As a result, when attaching the skin (joint body) to the surface layer 100A above the plate-like body 100D, the low-viscosity resin spreads suitably to the skin, increasing the adhesive force between the plate-like body 100D and the skin. be able to.

<Other embodiments>
The present invention is not limited to the embodiments described above and illustrated in the drawings; for example, the following embodiments are also included within the technical scope of the present invention; It can be implemented with various modifications.

(1) In addition to the embodiments described above, the joining procedure of the molded bodies can be changed as appropriate. In the above embodiment, the molded body and the plate-like body are joined by inserting the molded body into the recess of the lower mold in advance and closing the plate-like body with the mold, but the present invention is not limited thereto. For example, assume that a space is provided in the lower mold in which a molded object is formed, and the plate-shaped object is closed in the mold, and molten resin is injected into the space to form the molded object. It is also possible to join the body and the plate-shaped body.

(2) In addition to the embodiments described above, the shapes of the high-viscosity resin fibers and the low-viscosity resin fibers can be changed as appropriate. In the above embodiment, the high viscosity resin fibers are cylindrical and the low viscosity resin fibers are circular, but the present invention is not limited to this. For example, the low-viscosity resin fibers may be different in length and weight (density) than the high-viscosity resin fibers. Moreover, the low-viscosity resin fiber may be bent or spirally shaped. Furthermore, the cross-sectional shape of the low-viscosity resin fiber may be elliptical, polygonal, or the like. The low-viscosity resin fibers may have a structure that is more easily affected by gas flow than the high-viscosity resin fibers.

(3) In addition to the embodiments described above, the configuration of the mat creation device can be modified as appropriate. In the above embodiment, the mat creation device includes both a spray device and a suction device, but the mat creation device is not limited to this. For example, the mat creation device may include only a suction device or may include only a spray device.

(4) In the above embodiment, the molded body is a bracket, but it is not limited to this. For example, the molded body may be a boss or other structure made of resin. Further, in the above embodiment, the molded structure is a door trim, but the molded structure is not limited thereto. For example, the molded structure may be a side trim forming a side wall of a luggage compartment of an automobile, a pillar garnish attached to a pillar panel, or other vehicle interior materials.

(5) The method of manufacturing a molded structure exemplified in the above embodiments is not limited to a method provided to an automobile, but may be provided to a variety of vehicles. For example, the above method for manufacturing a molded structure can also be applied to vehicles such as trains and recreational vehicles as ground vehicles, airplanes and helicopters as flying vehicles, and ships and submarines as vehicles on the sea and under the sea. can.

DESCRIPTION OF SYMBOLS 1... Door trim (molding structure), 5... Molding mold, 10C... Mat, 10D... Plate-shaped body, 11... Vegetable fiber layer (vegetable fiber), 12... High viscosity resin layer (high viscosity resin), 13... Low viscosity resin layer (low viscosity resin), 14...bracket (molded body)

Claims (2)

A mat creation step of creating a mat composed of at least vegetable fibers, a high viscosity resin, and a low viscosity resin whose viscosity is lower than the high viscosity resin, such that the low viscosity resin is disposed on at least one surface layer side. and,
After creating a plate-shaped body from the mat, while pressing the plate-shaped body with a mold, the molded body made of at least a resin is molded into the surface layer of the plate-shaped body on which the low-viscosity resin is arranged. a pressing step of joining the sides to form a molded structure ;
The mat is created by stacking two laminates in which the low-viscosity resin, the high-viscosity resin, and the vegetable fibers are laminated in this order so that the vegetable fibers face each other. A method for producing a characterized molded structure. In the mat creation step, while dropping the vegetable fibers, the high-viscosity resin, and the low-viscosity resin, the low-viscosity resin is applied to the surface layer by at least one of sucking gas or spraying the gas. 2. The method of manufacturing a molded structure according to claim 1, further comprising creating the mat on which resin is arranged.

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