JP2001301041A - Multilayered molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a multilayered molded article wherein two kinds of skin materials are integrally bonded to the surfaces of thermoplastic resin base materials certainly, and the base materials formed on the rear surfaces of two kinds of the skin materials are strongly bonded mutually. SOLUTION: In the multilayered molded article wherein two kinds of the skin materials are integrally bonded to the surfaces of the base materials comprising a thermoplastic resin without using an adhesive, the thermoplastic resin base material formed on the rear surface of one skin material and the thermoplastic resin base material formed on the rear surface of the other skin material are integrally bonded through ribs at the mating edges of the skin materials.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a multilayer molded product in which two kinds of skin materials are bonded adjacent to a surface of a base material made of a thermoplastic resin.

[0002]

2. Description of the Related Art A multilayer molded product in which two kinds of skin materials are bonded to a surface of a base material made of a thermoplastic resin is used for an automobile interior part (for example, a door trim, It is widely used in instrument panels, interior and exterior parts of home appliances, and other wide fields.

[0003] Such multi-layer molded products, particularly those in which two kinds of skin materials are bonded to the surface of a thermoplastic resin substrate, have heretofore been applied to the surface of the thermoplastic resin substrate by injection molding or compression molding. Two types of parts to which a single skin material was bonded were separately formed, and these were joined in a later step by heat fusion or the like (FIG. 1).
2).

In another method, a single surface material is bonded to the surface of a thermoplastic resin by injection molding or compression molding, and another surface material is bonded to the surface of the thermoplastic resin using an adhesive or the like in a later step ( (FIG. 13).

[0005] However, in the case of the former, such a multilayer molded product is a partial fusion bonding between two types of base materials, and the bonding strength may be insufficient. In the latter case, there is a problem such as peeling of the skin material.

[0006]

SUMMARY OF THE INVENTION
The present inventors are a multilayer molded product in which two kinds of skin materials are bonded and integrated on the surface of a thermoplastic resin base material, and the skin material is securely adhered to the base material, and the two kinds of skin materials are attached to the back surface. As a result of studying a multilayer molded product in which the formed base materials are firmly joined, the present invention has been achieved.

[0007]

The present invention provides a multilayer molded article in which two kinds of skin materials are bonded and integrated without using an adhesive, on the surface of a base material made of a thermoplastic resin. The thermoplastic resin base material formed on the back surface of the skin material and the thermoplastic resin base material formed on the back surface of the other skin material are connected via ribs at the edge of each skin material. It is intended to provide a multilayer molded product characterized by the following.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail with reference to the drawings. This description is an example of the present invention, and the present invention is not limited to this. FIG. 1 is a plan view of a multilayer molded product (1) of the present invention as viewed from the surface side on which a skin material is bonded. A first skin material (2) and a second skin material are provided on the surface of a thermoplastic resin base material. The skin material (3) is bonded and integrated without using an adhesive.

FIG. 2 is a plan view of the multi-layer molded product as viewed from the back, in which a thermoplastic resin base material (4) formed on the back surface of the first skin material (2) and a second skin material (3) are shown. The base materials of the thermoplastic resin base materials (5) formed on the back surface are not connected continuously at the joining portions of the respective skin materials, but are connected discontinuously via the ribs (6). ing.

FIG. 3 is a cross-sectional view taken along the line AA in FIG. 2, showing a thermoplastic resin base material (4) formed on the back surface of the first skin material (2) and a second skin material. The base material of the thermoplastic resin base material (5) formed on the back surface of the material (3) is not connected to each other, and in this portion, the first skin material (2) is provided between the respective thermoplastic resin base materials. ) And the second skin material (3) are present, and the base materials are completely separated from each other.

FIG. 4 is a cross-sectional view taken along the line BB in FIG. 2, showing a thermoplastic resin base material (4) formed on the back surface of a first skin material (2) and a second skin material. The thermoplastic resin substrate (5) formed on the back surface of the material (3) and the rib (6)
, And each base material is integrated via a rib.

FIG. 5 shows a connecting portion formed by ribs formed on the back surface of the second skin material (3) and viewed from the side of the thermoplastic resin substrate (5) when the line CC in FIG. 2 is cut. FIG. 3 is a cross-sectional view, in which ribs are arranged at appropriate intervals and connect the substrates to each other to maintain the product strength of the multilayer molded product (1).

The shape of the ribs (6) for joining the base materials may be wide, for example, as shown in FIG. 6, or may be irregular, as shown in FIG. There is no particular limitation as long as the bases are connected discontinuously, and a form in which ribs having different shapes are combined may be used. Further, the interval between the ribs (6) may be any distance as long as the base materials are discontinuously connected to each other and arranged so as not to reduce the strength of the product. do it. For this reason, the interval between the ribs (6) may be constant or may be different, but the thickness of the rib is 2 mm from the viewpoint of the product appearance and structure.
The following is preferred. The width of the rib is appropriately selected depending on the shape and size of the product, but is generally about 2 to 20 mm. It is more preferable that such ribs are arranged so finely that the product strength does not decrease.

FIG. 8 shows a thermoplastic resin substrate (4) formed on the back surface of the first skin material (2) and the back surface of the second skin material (3) of the multilayer molded product (1) shown in FIG. This is an example in which the thermoplastic resin substrate (5) formed in the above is connected by another method.

In the embodiment shown in FIG. 8, a thermoplastic resin base material (4) formed on the back surface of the first skin material (2) and a heat-sensitive resin formed on the back surface of the second skin material (3). Since the plastic resin base material (5) is discontinuously connected via the rib (6) and the ribs are connected by the resin pool (7) at the rib tip portion and are continuously connected, The strength of the entire product is stronger than in the case of connection using only the rib (6), which is a preferable form.

FIG. 9 is a cross-sectional view taken along the line DD in FIG. 8, showing a thermoplastic resin base material (4) formed on the back surface of the first skin material (2) of the multilayer molded product. The thermoplastic resin base material (5) formed on the back surface of the second skin material (3) is not connected via the rib (6), and in this portion, the base materials are completely separated from each other. The resin pool (7) is present near the edge of the two kinds of skin materials in an independent state. FIG. 10 is a cross-sectional view taken along line EE in FIG. 8. The thermoplastic resin base material (4) and the second skin material (3) formed on the back surface of the first skin material (2) of the multilayer molded product. ) Is connected via a rib (6) to a thermoplastic resin substrate (5) formed on the back surface, and the respective substrates are integrated via the rib, and the rib (6) is further connected to a resin reservoir ( 7).

FIG. 11 is a cross-sectional view taken along line FF in FIG. 8, and shows a second skin material (3) of a multilayer molded product.
It is sectional drawing which shows the connection part by the rib (6) seen from the thermoplastic-resin base material (5) side formed in the back surface of the rib, the rib is arrange | positioned at an appropriate space | interval, and while connecting base materials, The ribs are continuously connected by the resin reservoir, and the product strength is further strengthened.

At this time, the resin reservoir (7) is too large in thickness and width, and leads to an increase in product weight and cost. Therefore, it is preferable that the resin reservoir (7) be large enough to maintain the product strength and as small as possible. Further, the resin reservoir may be completely separated from the two types of skin material edges, or a part of the skin material edge may be buried in the resin reservoir.

In the multilayer molded article of the present invention described above, the thermoplastic resin substrate (4), the thermoplastic resin substrate (5), the rib (6) and the resin reservoir (7) are clearly shown in the drawings for convenience of explanation. Although they are shown separately, they are actually provided continuously and integrally, and all the thermoplastic resins constituting them may be the same.

Examples of the skin material applicable to the present invention include woven or knitted fabrics such as moquettes and tricots, nonwoven fabrics such as needle punched carpets, metal foils, and sheets or films of thermoplastic resins and thermoplastic elastomers.

These skin materials may be two or three or more laminated skin materials in which a foam layer and a backing layer are appropriately laminated as necessary, but those which can be thermally fused with a thermoplastic resin. Alternatively, it is necessary that the back surface of the skin material is impregnated with a thermoplastic resin in a molten state and can be bonded to the base resin portion.

As the foam layer used for the laminated skin material,
Examples include foams of polyolefins such as polypropylene and polyethylene, polyvinyl chloride foams, and soft or semi-rigid polyurethane foams.

As the backing layer, a nonwoven fabric, a synthetic resin sheet or a film is generally used. As the fibers constituting the nonwoven fabric, natural fibers such as cotton, wool, silk, hemp and various synthetic fibers such as polyamide, polyester, nylon and the like can be used. Is used. For example, non-woven fabrics such as a needle punch type, a thermal bond type, a spun bond type, a melt blow type, a spun lace type and the like can be mentioned. As a sheet or film made of synthetic resin,
Examples include sheets and films of thermoplastic resins such as polypropylene and polyethylene, and polyolefin-based thermoplastic elastomers, and those having a fusibility with the thermoplastic resin used as the base resin are used.

In the multilayer molded article of the present invention, the thermoplastic resin as the base resin is a resin usually used in compression molding, injection molding, extrusion molding and the like, and for example, polypropylene, polyethylene, acrylonitrile-styrene-
General thermoplastic resins such as butadiene block copolymers, polyamides such as polystyrene and nylon, polyvinyl chloride, polycarbonate, acrylic resins, and styrene butadiene block copolymers; thermoplastic elastomers such as EPM and EPDM; and mixtures thereof Or polymer alloys using these, and these may be non-foamable or foamable. In addition, these thermoplastic resins may contain fillers such as commonly used glass fibers and various inorganic or organic fillers, if necessary.Of course, various pigments and lubricants that are commonly used, Various additives such as an antistatic agent and a stabilizer may be blended.

As a molding method for producing the multilayer molded article of the present invention, injection molding or compression molding is applied. In the case of injection molding, the temperature and pressure of the molten resin are directly applied to the skin material during resin supply. Since the damage to the skin material is increased, compression molding that can reduce the damage to the skin material by performing mold clamping after supplying the molten resin can be more preferably applied.

The multilayer molded article according to the present invention, in the molding method as described above, is provided with a groove-shaped recess in which the edges of both skin materials can be overlapped and folded at the edge of the skin material. In addition, by using a mold in which a concave portion corresponding to a rib portion is provided discontinuously in the groove concave portion, it can be easily manufactured.

[0027]

The multilayer molded article of the present invention is a multilayer molded article obtained by laminating and integrating two kinds of skin materials on the surface of a thermoplastic resin base material, and the skin material is securely bonded to the base material, Moreover, since the base materials formed on the two types of back surfaces of the skin materials are joined via the ribs, the skin material does not come off from the base materials, and the bonding between the base materials is also strong.

[Brief description of the drawings]

FIG. 1 is a plan view of an example of a multilayer molded product of the present invention as viewed from a skin material side.

FIG. 2 is a plan view of the multilayer molded product shown in FIG. 1 as viewed from the back surface side.

FIG. 3 is a cross-sectional view of the multilayer molded article taken along line AA of FIG. 2;

FIG. 4 is a sectional view taken along line BB of the multilayer molded article shown in FIG.

FIG. 5 is a cross-sectional view of the multilayer molded product shown in FIG. 2, taken along the line CC.

FIG. 6 is a plan view of another example of the multilayer molded product of the present invention viewed from the back surface side.

FIG. 7 is a plan view of another example of the multilayer molded product of the present invention viewed from the back surface side.

FIG. 8 is a plan view of another example of the multilayer molded product shown in FIG. 1 as viewed from the back side.

9 is a cross-sectional view of the multilayer molded product shown in FIG. 8, taken along the line DD.

FIG. 10 is a sectional view taken along line E-E of the multilayer molded product shown in FIG.

FIG. 11 is a sectional view taken along line FF of the multilayer molded product shown in FIG.

FIG. 12 shows an example of a partial cross section of a conventional multilayer molded product.

FIG. 13 shows an example of a partial cross section of a multilayer molded product according to the prior art.

[Explanation of symbols]

 1: Multi-layer molded product 2: First skin material 3: Second skin material 4: Thermoplastic resin 5: Thermoplastic resin 6: Rib 7: Resin pool

Continued on front page (72) Inventor Takeo Kitayama 2-1-1 Tsukahara, Takatsuki-shi, Osaka Sumitomo Chemical Co., Ltd. F-term (reference) 4F211 AG03 AH26 TA08 TC13 TD07 TJ30 TN81

Claims (2)

[Claims] 1. A multi-layer molded product in which two kinds of skin materials are adjacently bonded to and integrated with a base material made of a thermoplastic resin without interposing an adhesive on the surface thereof. That the thermoplastic resin base material formed on the back surface of the material and the thermoplastic resin base material formed on the back surface of the other skin material are integrally joined via ribs at the edge of each skin material. Characterized multilayer molded product. 2. The multilayer molded article according to claim 1, wherein the thickness of the rib is 2 mm or less.