JP2002264261A - Laminated sheet, laminated and manufacturing method for laminate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance the design characteristics, resistance to light and moisture and mar resistance and eliminate the necessity to perform the conventional clear coating and buffing practice and consequently, realize a coast reduction. SOLUTION: The laminated sheet 1 comprises a transparent layer 2 formed of a thermoplastic resin composition, a first transparent adhesive layer 3 with an adhesive showing adhesive properties with the thermoplastic resin composition, a woody layer 4 composed mainly of a natural wood, a second adhesive layer 5 with an adhesive showing adhesive properties with the thermoplastic resin composition and a reinforcing layer 6 formed of the thermoplastic resin composition. The transparent layer 2, the first adhesive layer 3, the woody layer 4, the second adhesive layer 5 and the reinforcing layer 6 are laminated in that order from the face side to the back side and thus a monolithic laminate is obtained, so that the woody layer 4 is visible from the face side through the transparent layer 2 and the first adhesive layer 3, while the reinforcing layer 6 is exposed on the back side. In this laminate manufactured by a specified process using the laminated sheet 1, a molded product made of the thermoplastic resin composition is directly brought into contact with the reinforcing layer 6 of the laminated sheet 1 to obtain the monolithic body.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated sheet provided with a transparent layer on the front side of a woody layer mainly composed of natural wood, and a molded article made of a thermoplastic resin composition laminated and integrated on the back side of the laminated sheet. And a method for producing the laminate.

[0002]

2. Description of the Related Art In recent years, especially in the field of automobiles, in the case of center clusters, console uppers, ornamental door trims and the like which are interior parts of automobiles, parts (laminates) in which laminated sheets made of natural wood having excellent design properties are applied to the design surface (laminate) Is increasing.

[0003] For example, a laminate is manufactured as follows (for example, Japanese Patent Publication No. 5-58890 or
-64817). 0.1-0.2mm natural wood with excellent design such as walnut and maple
A nonwoven sheet or a thin aluminum plate for reinforcement is bonded to the sliced piece to make a single plate. Further, a laminated sheet is prepared by backing a natural wood mangashinoro material or the like to this veneer for the purpose of ensuring adhesion in the lamination and integration step with the thermoplastic resin composition. The laminated sheet is cut into a desired shape, and the laminated sheet is set along the inner surface of the mold cavity. Then, the molten thermoplastic resin composition is injected and injected into the mold cavity to obtain a laminate having the laminate sheet.

In addition, in Japanese Patent Publication No. 55555/1995, a laminate is manufactured as follows. 0.1 ~ natural wood with excellent design such as walnut and maple
A slice of 0.2 mm is impregnated with a thermoplastic resin composition or subjected to an alkali treatment, and a backing material is attached thereto for the purpose of reinforcement to prepare a laminated sheet.
Further, the laminated sheet is set along the inner surface of the mold cavity, and a molten thermoplastic resin composition is injected and injected into the mold cavity to obtain a laminate having the laminated sheet.

[0005] Although the above laminate is excellent in design, it is subjected to colored coating or clear coating of polyester resin or the like in order to further improve the design and to improve light resistance, moisture resistance and scratch resistance. ing. Especially for automotive interior parts,
The clear painted surface is mirror-finished by buffing and the like, and the design is further improved.

[0006]

However, since the above-mentioned clear coating and buff polishing are required, there has been a problem that the production cost is increased.

An object of the present invention is not only to improve the design properties, light resistance, moisture resistance and scratch resistance but also to reduce the cost by means instead of the conventional clear coating and buff polishing.

[0008]

Means for Solving the Problems and Effects of the Invention The present invention will be described with reference to the reference numerals of the drawings (FIGS. 1 to 6) of the embodiments described later. * Invention of Claim 1 The laminated sheet (1) according to the present invention is configured as follows.

The laminated sheet (1) comprises a transparent layer (2) made of a thermoplastic resin composition and a transparent first adhesive layer (3) having an adhesive having an adhesive property to the thermoplastic resin composition.
A wooden layer (4) mainly composed of natural wood, a second adhesive layer (5) having an adhesive having an adhesive property to the thermoplastic resin composition, and a reinforcing layer (6) composed of the thermoplastic resin composition. ). The transparent layer (2), the first adhesive layer (3), the wood layer (4), the second adhesive layer (5), and the reinforcing layer (6) were sequentially laminated from the front side to the back side and integrated. . This woody layer (4) was made visible from the front side through the transparent layer (2) and the first adhesive layer (3). This reinforcing layer (6) was exposed on the back side.

In the laminated sheet (1) according to the present invention,
Since the transparent layer (2) made of a thermoplastic resin composition was bonded to the woody layer (4) instead of the clear coating film provided on the front side of the conventional laminated sheet, the design, light resistance, moisture resistance, and scratch resistance were improved. In addition to the improvement of sticking property, it is not necessary to perform the conventional clear coating and buffing, and thus the cost can be reduced.

In the present invention, the haze of the transparent layer (2) according to the first aspect of the present invention is set to 5% or less, so that in addition to the effect of the first aspect, the woody layer (4) Can be reliably seen through the transparent layer (2), and the design is further improved.

According to the present invention, in the transparent layer (2) according to the first or second aspect of the present invention, the surface roughness (R) of the surface (2a) on the surface side is defined as R.
Since a is set to 0.3 μm or less, in addition to the effect of the invention of claim 1 or claim 2, the woody layer (4) can be reliably seen through this transparent layer (2), and the design is further improved. improves.

* Invention of Claim 4 According to the present invention, Claim 1 or Claim 2 or Claim 3
The first adhesive layer (3) and the second adhesive layer (5) according to the invention of (1).
Since the flow start temperature of the sheet is set to 100 ° C. or more and 150 ° C. or less, in addition to the effects of the invention of claim 1, claim 2, or claim 3, the laminated sheet (1) is securely adhered to prevent peeling thereof. Can be.

According to the present invention, the embrittlement temperature of the first adhesive layer (3) and the second adhesive layer (5) according to any one of the first to fourth aspects of the present invention. Is set to -40 ° C. or lower.
In addition to the effects of the invention of any one of claims 4 to 4, the laminated sheet (1) can be securely adhered to prevent its peeling.

* The invention according to claim 6 The laminate (8) according to the present invention comprises a laminate sheet (1) according to any one of claims 1 to 5, and a laminate sheet (1) according to any one of claims 1 to 5. A) a molded article made of a thermoplastic resin composition (9) which is brought into direct contact with and integrated with the reinforcing layer (6) on the back side. In this invention, since the laminated sheet (1) having the effect of any one of the first to fifth aspects of the present invention is used, cost reduction can be achieved even in the case of manufacturing the laminated body (8). It becomes possible.

The invention according to claim 7 The laminate (8) according to the present invention is manufactured through the following steps. A part of the laminated sheet (1) according to any one of claims 1 to 5 is cut out to form a laminated sheet (1a) for molding.

As shown in FIG. 5A, a transparent layer (in the following embodiment, only the transparent layer 2 or a hard coat layer in addition to the transparent layer 2) on the surface side of the lamination sheet (1a) 7) is applied along the inner surface of the cavity (11a) of the mold (11) to position the laminated sheet (1a) for molding in the mold (11).

As shown in FIGS. 5 (b) and 5 (c), the molding laminated sheet (1a) is formed in the cavity (11a).
The thermoplastic resin composition in a molten state is supplied to the molding space facing the reinforcing layer (6) on the back surface side of the above to directly contact the reinforcing layer (6). Then, FIG.
As shown in (1), a laminate (8) in which a molded body (9) made of the thermoplastic resin composition and the molded laminated sheet (1a) are integrated is manufactured.

Therefore, the above manufacturing method is suitable for manufacturing a laminated body (8) using the laminated sheet (1) exhibiting the effects of any one of the first to fifth aspects of the present invention.
Manufacturing costs can be reduced.

* Invention of Claim 8 The laminate (8) according to the present invention is manufactured through the following steps. -As shown in Figs. 3 (a), (b) and (c), after preliminarily shaping the laminated sheet (1) according to any one of claims 1 to 5, A part of the laminated sheet (1) is cut out to form a laminated sheet for molding (1a), or as shown in FIGS. 4 (a) and (b), any one of claims 1 to 5 A part of the laminated sheet (1) according to the present invention is cut out to form a molded laminated sheet (1a), and then the molded laminated sheet (1a) is subjected to preliminary shaping.

As shown in FIG. 5A, a transparent layer (in the embodiment described later, only the transparent layer 2 or a hard coat layer in addition to the transparent layer 2) on the surface side of the lamination sheet (1a) 7) is applied along the inner surface of the cavity (11a) of the mold (11) to position the laminated sheet (1a) for molding in the mold (11).

As shown in FIGS. 5 (b) and 5 (c), the molding laminated sheet (1a) is formed in the cavity (11a).
The thermoplastic resin composition in a molten state is supplied to the molding space facing the reinforcing layer (6) on the back surface side of the above to directly contact the reinforcing layer (6). Then, FIG.
As shown in (1), a laminate (8) in which a molded body (9) made of the thermoplastic resin composition and the molded laminated sheet (1a) are integrated is manufactured.

Therefore, the above-mentioned manufacturing method is suitable for manufacturing a laminated body (8) using the laminated sheet (1) exhibiting the effects of any one of the first to fifth aspects of the present invention.
Manufacturing costs can be reduced.

* The invention of claim 9 The laminate (8) according to the present invention is manufactured through the following steps. -As shown in Fig. 6 (a), a molded article (9) is molded in advance with a thermoplastic resin composition.

As shown in FIGS. 6 (b) and 6 (c), the reinforcing layer (6) on the back side of the laminated sheet (1) according to any one of claims 1 to 5 is provided. The molded sheet (9) is brought into direct contact with the laminated sheet (1).
This molded article (9) and this laminated sheet (1)
To produce a laminated body (8).

Therefore, the above manufacturing method is suitable for manufacturing a laminated body (8) using the laminated sheet (1) exhibiting the effects of any one of the first to fifth aspects of the present invention.
Manufacturing costs can be reduced.

[0027]

DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to the drawings. <Laminated sheet 1 shown in FIG. 2 (a)> As the cross-sectional structure of the laminated sheet 1, there are four types shown in FIGS. 1 (a), (b), (c) and (d). In the laminated sheet 1 shown in FIG. 1A and the laminated sheet 1 shown in FIG. 1B, the transparent layer 2, the first adhesive layer 3, the woody layer 4, the second adhesive layer 5, and the reinforcing layer are all provided. 6 are sequentially laminated and integrated in a five-layer structure in direct contact with each other from the front side to the back side. This woody layer 4 is visible from the front side through the transparent layer 2 and the first adhesive layer 3. This reinforcing layer 6 is exposed on the back side. The surface 2a on the front side of the transparent layer 2 is exposed. Further, in the laminated sheet 1 shown in FIG. 1C and the laminated sheet 1 shown in FIG.
In each case, the front surface 2a of the transparent layer 2 is covered with a transparent hard coat layer 7. This hard coat layer 7
, The transparent layer 2, the first adhesive layer 3, the wood layer 4, the second adhesive layer 5, and the reinforcing layer 6 are sequentially laminated and integrated in a six-layer structure in direct contact with each other from the front side to the back side. ing. This woody layer 4 comprises a hard coat layer 7, a transparent layer 2, and a first adhesive layer 3.
And the reinforcing layer 6 is exposed on the back side while being visible from the front side.

* Regarding each transparent layer 2 The transparent layer 2 is mainly composed of a thermoplastic resin composition. This thermoplastic resin composition may be of any type as long as it is transparent, and is appropriately selected and used. Preferably, polyethylene, polypropylene, polystyrene, vinyl chloride, AB
S, polycarbonate, polyethylene terephthalate,
It is preferable that at least one of polymethyl methacrylate is included. In terms of transparency, flexibility and scratch resistance, polycarbonate and polymethyl methacrylate are more preferable.

Further, in order to improve the light resistance of the transparent layer 2, a light stabilizer or an ultraviolet absorber may be appropriately selected and added in an appropriate amount. Further, in order to improve the scratch resistance and the light resistance, the hard coat layer 7 may be formed on the surface side of the transparent layer 2 as described above. The hard coat layer 7 is mainly composed of a thermosetting resin or a thermoplastic resin composition. As the thermosetting resin, polyester, polyurethane and the like are preferable. As the thermoplastic resin, polyethylene terephthalate, polymethyl methacrylate and the like are preferable. Also in this hard coat layer 7, a light stabilizer and an ultraviolet absorber may be appropriately selected and added in an appropriate amount in order to improve the light resistance.

The thickness of the transparent layer 2 is preferably from 0.2 mm to 0.5 mm, more preferably from 0.3 mm to 0.4 mm. If it is less than 0.2 mm, the appearance (depth) of the woody layer 4 seen through the transparent layer 2 is poor.
When the thickness exceeds 0.5 mm, sufficient flexibility cannot be obtained, so that the difficulty in integrating the laminated sheet 1 and the molded body 9 as a laminated body 8 described later increases.

As for the transparency of the transparent layer 2, haze, which is an index of transparency, is preferably set to 5% or less. Preferably, it is 2% or less. If it exceeds 5%, the transparent layer 2
Is cloudy, so that the woody layer 4 seen through the transparent layer 2 becomes difficult to see. This haze (cloudiness value) is determined according to JIS K 710
It is a value measured by the test method specified in 5. The thickness and transparency of the hard coat layer 7 are also set so as to improve the appearance (depth) of the wooden layer 4.

The surface roughness of the front surface 2a of the transparent layer 2 is preferably Ra = 0.3 μm or less. Preferably R
a = 0.05 μm or less is good. If Ra exceeds 0.3 μm, the surface 2a of the transparent layer 2 is rough like ground glass, so that the woody layer 4 becomes invisible or difficult to see. This surface roughness is measured according to JIS B 0601-1994.
Is the value specified in.

* Regarding Each First Adhesive Layer 3 The first adhesive layer 3 is a layer made of a transparent adhesive. This adhesive may be any adhesive as long as it has an adhesive property to the thermoplastic composition constituting the transparent layer 2 and the woody layer 4, and is appropriately selected and used. Preferably, a hot melt adhesive is used.

Examples of the hot melt adhesive include ethylene vinyl acetate copolymer, ethylene ethyl acrylate copolymer, ethylene acrylic acid, polyester, atactic polypropylene, propylene ethylene copolymer, propylene ethylene butene-1 copolymer, At least one of polycarbonate, polyvinyl ether, polyurethane, styrene isoprene styrene copolymer, styrene butadiene styrene copolymer, styrene ethylene butylene styrene copolymer, styrene ethylene propylene styrene copolymer, butyl rubber, ethylene propylene rubber, and polyamide It is better to include one.

The thickness of the first adhesive layer 3 is 0.0
5 mm or more and 0.2 mm or less, preferably 0.05
mm or more and 0.1 mm or less is good. If the thickness is less than 0.05 mm, a desired adhesion strength may not be obtained. on the other hand,
When the thickness exceeds 0.2 mm, cohesive failure occurs in the first adhesive layer 3 and a desired adhesion strength may not be obtained.

The flow start temperature of the first adhesive layer 3 is 10
The temperature is preferably from 0 ° C to 150 ° C. If the temperature is lower than 100 ° C., the laminated sheet 1 may be peeled off when the surface temperature rises due to direct sunlight in an automobile room such as in summer.
On the other hand, when the temperature exceeds 150 ° C., it becomes difficult to develop an adhesive force in the production of the laminated sheet 1. Here, the flow start temperature is defined as the process from the time when the test piece heated at a fixed rate reaches the fluidized area through the rubber elastic area using a Koka type flow tester CFT-500 (manufactured by Shimadzu Corporation). Is continuously measured to determine the temperature at which it flows out of the nozzle (with a load of 10K
gf, nozzle; 1 mmΦ × 1 mmL).

The embrittlement temperature of the first adhesive layer 3 is -40.degree.
The following temperatures are good. When the temperature is higher than −40 ° C., the first adhesive layer 3 loses flexibility and becomes hard in a vehicle compartment in winter or the like, cracks may occur, and the laminated sheet 1 may peel. This embrittlement temperature is determined according to JIS K6261.
It is a value measured by the test method specified in.

The first adhesive layer 3 may be appropriately selected from a light stabilizer and an ultraviolet absorber and added in an appropriate amount in order to improve the light resistance. * Regarding each woody layer 4 The woody layer 4 is mainly made of natural wood. This natural tree is
It is a log cut from a primeval forest or plantation. Any kind of raw wood may be used, but a tree of a kind called precious wood is preferable in terms of design. For example, Karamatsu, Yakusugi, Nara, Yu, Keyaki, Cherry, Tochi, Kusunoki, Katsura, Yellow tiller, Maple, Sophora, Sycamore, Rosewood, Teak, Mahogany, African mahogany, Meranti, Kokutan, Rosewood, American black walnut, Karin, Zebrawood, Brazilian Rose, Versimon, Silver Rose, Palma, Silky Oak, Silver Heart,
Thai Wanks, Cherry, Miltre, Black Leo, White Leo,
Sapele, Bubinga, Makole, Madrona, Maple, Claro Walnut, Ash and the like are preferred.

The woody layer 4 mainly composed of natural wood is obtained by slicing natural wood to a predetermined thickness or impregnating the sliced natural wood with a thermosetting resin or a thermoplastic resin composition. Etc. Any thermoplastic resin composition may be impregnated, but preferably, a urea resin, a phenol resin, an epoxy resin, an acrylic resin, polyvinyl chloride, vinyl acetate,
Ethylene-vinyl acetate copolymer and polyurethane are preferred.

The thickness of the woody layer 4 is 0.1 mm
The thickness is preferably not less than 0.1 mm and not more than 0.3 mm, more preferably not less than 0.1 mm and not more than 0.4 mm.
2 mm or less is good. If the thickness is less than 0.1 mm, the woody layer 4 becomes brittle and the handleability of the laminated sheet 1 deteriorates, and the difficulty of slicing natural wood increases. on the other hand,
If the thickness exceeds 0.4 mm, the rigidity of the laminated sheet 1 becomes too high and lacks its flexibility. When the wood layer 4 is formed, cracks occur in the wooden layer 4.

In order to improve the design, the wood layer 4 may be colored. Pigments or dyes are used for coloring. With respect to this pigment or dye, a light stabilizer or an ultraviolet absorber may be appropriately selected and added in an appropriate amount in order to improve light resistance.

* Regarding each of the second adhesive layers 5 The second adhesive layer 5 of the laminated sheet 1 shown in FIGS.
Is a layer 5a made of an adhesive described later. FIG.
(B) The second adhesive layer 5 of the laminated sheet 1 shown in (d) is a layer 5b in which this adhesive is impregnated in a nonwoven fabric.

As the adhesive, any adhesive may be used as long as it has adhesiveness to the woody layer 4 and a thermoplastic resin composition constituting the reinforcing layer 6 described later. use. Preferably, a hot melt adhesive is used.

Examples of the hot melt adhesive include ethylene vinyl acetate copolymer, ethylene ethyl acrylate copolymer, ethylene acrylic acid, polyester, atactic polypropylene, propylene ethylene copolymer, propylene ethylene butene-1 copolymer, At least one of polycarbonate, polyvinyl ether, polyurethane, styrene isoprene styrene copolymer, styrene butadiene styrene copolymer, styrene ethylene butylene styrene copolymer, styrene ethylene propylene styrene copolymer, butyl rubber, ethylene propylene rubber, and polyamide It is better to include one.

The non-woven fabric is preferably made of various fibers such as rayon, nylon, polyester, acrylic, polyethylene, vinylon, polypropylene and cupra. With this nonwoven fabric, the strength and flexibility of the laminated sheet 1 can be improved.

The thickness of the second adhesive layer 5 is 0.0
5 mm or more and 0.2 mm or less, preferably 0.05
mm or more and 0.1 mm or less is good. If the thickness is less than 0.05 mm, a desired adhesion strength may not be obtained. on the other hand,
If it exceeds 0.2 mm, cohesive failure in the second adhesive layer 5 may occur and a desired adhesion strength may not be obtained.

The flow start temperature of the second adhesive layer 5 is 10
The temperature is preferably from 0 ° C to 150 ° C. If the temperature is lower than 100 ° C., the laminated sheet 1 may be peeled off when the surface temperature rises due to direct sunlight in an automobile room such as in summer.
On the other hand, when the temperature exceeds 150 ° C., it becomes difficult to develop an adhesive force in the production of the laminated sheet 1. Here, the flow start temperature is defined as the process from the time when the test piece heated at a fixed rate reaches the fluidized area through the rubber elastic area using a Koka type flow tester CFT-500 (manufactured by Shimadzu Corporation). Is continuously measured to determine the temperature at which it flows out of the nozzle (with a load of 10K
gf, nozzle; 1 mmφ × 1 mmL).

The embrittlement temperature of the second adhesive layer 5 is -40 ° C.
The following temperatures are good. If the temperature is higher than −40 ° C., the second adhesive layer 5 loses flexibility and becomes hard in a vehicle compartment in winter or the like, cracks may occur, and the laminated sheet 1 may be peeled. This embrittlement temperature is determined according to JIS K6261.
It is a value measured by the test method specified in.

* Regarding each reinforcing layer 6 The reinforcing layer 6 is used when the thermoplastic resin composition is laminated and integrated with the laminated sheet 1 in a later-described manufacturing process of the laminated body 8. Any thermoplastic resin composition having at least one thermoplastic resin composition heat-fusible with the thermoplastic resin composition constituting the above may be used, and may be appropriately selected and used.

The thickness of the reinforcing layer 6 is 0.1 mm
The thickness is preferably not less than 0.4 mm and preferably not less than 0.1 mm and not more than 0.2 mm. If it is less than 0.1 mm, desired strength cannot be obtained. On the other hand, if it exceeds 0.4 mm,
Since the rigidity of the laminated sheet 1 becomes too high and lacks its flexibility, the difficulty in laminating and integrating the thermoplastic resin composition with the laminated sheet 1 in the manufacturing process of the laminated body 8 described later increases. .

<Lamination Method of Laminated Sheet 1> * Lamination Method of Laminated Sheet 1 shown in FIGS. 1 (a) and 1 (c) A liquid adhesive is applied to the woody layer 4 or the transparent layer 2 in the form of mist. Adhesive to the first adhesive layer 3, or
An adhesive is applied to the wooden layer 4 or the transparent layer 2 by a roller, and the adhesive is used as the first adhesive layer 3. In the case of a hot-melt adhesive, the hot-melt adhesive is extrusion-laminated to the wood layer 4 or the transparent layer 2 to form the first adhesive layer 3, or a hot-melt adhesive previously processed into a sheet is used for the wood material. The first adhesive layer 3 is formed by thermally laminating the layer 4 or the transparent layer 2. In addition, the hot melt adhesive processed into a sheet is applied to the wooden layer 4 and the transparent layer 2.
Between the two.

Subsequently, a liquid adhesive is applied to the wooden layer 4 or the reinforcing layer 6 in the form of a mist, and the adhesive is used as the second adhesive layer 5, or the wooden layer 4 or the reinforcing layer 6 is The adhesive is applied by a roller to make the adhesive into the second adhesive layer 5. In the case of a hot-melt adhesive, the hot-melt adhesive is extrusion-laminated to the wood layer 4 or the reinforcing layer 6 to form the second adhesive layer 5, or the hot-melt adhesive is processed into a sheet shape in advance. Later, the hot melt adhesive is heat-laminated to the wood layer 4 or the reinforcing layer 6 to form the second adhesive layer 5. In addition, the hot melt adhesive processed into a sheet is sandwiched between the woody layer 4 and the reinforcing layer 6.

Each layer 2, 3, 4, thus prepared
5 and 6 are overlapped in the order shown in FIG. 1 and hot-pressed.
However, all the layers 2, 3, 4, 5, and 6 may be laminated at once, or may be divided into several layers.

* Laminated sheet 1 shown in FIGS. 1 (b) and 1 (d)
A liquid adhesive is applied to the wooden layer 4 or the transparent layer 2 in the form of a mist, and the adhesive is used as the first adhesive layer 3, or
An adhesive is applied to the wooden layer 4 or the transparent layer 2 by a roller, and the adhesive is used as the first adhesive layer 3. In the case of a hot-melt adhesive, the hot-melt adhesive is extrusion-laminated to the wood layer 4 or the transparent layer 2 to form the first adhesive layer 3, or a hot-melt adhesive previously processed into a sheet is used for the wood material. The first adhesive layer 3 is formed by thermally laminating the layer 4 or the transparent layer 2. In addition, the hot melt adhesive processed into a sheet is applied to the wooden layer 4 and the transparent layer 2.
Between the two.

Subsequently, a liquid adhesive is applied to the nonwoven fabric in a mist state, or the adhesive is applied by a roller, and the nonwoven fabric is adhered to the wooden layer 4 or the reinforcing layer 6 by hot pressing or the like. The second adhesive layer 5 is formed. In the case of a hot-melt adhesive, after extruding a hot-melt adhesive to the nonwoven fabric, the nonwoven fabric is adhered to the wood layer 4 or the reinforcing layer 6 by hot pressing or the like, and the second adhesive layer 5 is formed.
To Alternatively, after the hot melt adhesive is processed into a sheet shape in advance, the sheet hot melt adhesive and the nonwoven fabric are sequentially laminated on the woody layer 4 or the reinforcing layer 6 and thermally laminated, and then the sheet hot melt adhesive is formed. And the nonwoven fabric to form the second adhesive layer 5. In addition, a sheet-like hot-melt adhesive and a non-woven fabric are laminated and subjected to thermal lamination, and are sandwiched between the wood layer 4 and the reinforcing layer 6.

Each layer 2, 3, 4, thus prepared
5 and 6 are overlapped in the order shown in FIG. 1 and hot-pressed.
However, all the layers 2, 3, 4, 5, and 6 may be laminated at once, or may be divided into several layers.

<Laminate 8 shown in FIG. 2B> This laminate 8 is manufactured by various methods described below, and directly contacts the above-described various laminated sheets 1 and the reinforcing layer 6 on the back side thereof. Molded article 9 made of thermoplastic resin composition and integrated
Consists of

The thermoplastic resin composition constituting the molded article 9 may be any one as long as it can be heat-fused to the reinforcing layer 6 of the above-mentioned various laminated sheets 1, and is appropriately selected and used. .

Examples of the thermoplastic resin composition include acrylonitrile butadiene styrene resin, acrylonitrile styrene acrylate, polyamide, polycarbonate, polyethylene, polyethylene terephthalate,
Polybutyl terephthalate, polymethyl methacrylate,
Polyacetal, polypropylene, polystyrene, polyvinyl acetate, polyvinyl alcohol, polyvinyl chloride,
It is preferable that at least one of polyvinylidene chlorides is contained. Preferably, acrylonitrile butadiene styrene resin, acrylonitrile styrene acrylate, polyamide, polycarbonate, polyethylene, polyethylene terephthalate, polybutyl terephthalate, polymethyl methacrylate, polyacetal, polypropylene, polystyrene,
It is preferable to include at least one of them.

<Method of Manufacturing the Laminated Body 8> * Method of Manufacturing the Laminated Body 8 shown in FIGS. 3 and 5 First, as shown in FIGS. After pre-shaping by 10
As shown in FIG. 3C, a part of the laminated sheet 1 is cut out to form a laminated sheet for molding 1a. Next, FIG.
(A) As shown in (b), the transparent layer 2 on the surface side of the lamination sheet 1a is formed into a cavity 11a of a molding die 11.
This molding laminated sheet 1 is applied along the inner surface of
a is positioned in the mold 11. Then, FIG.
As shown in (c), the thermoplastic resin composition in a molten state is supplied to the molding space facing the reinforcing layer 6 on the back surface side of the lamination sheet 1a in the cavity 11a. Make direct contact. As the molding means, a conventionally known means such as injection molding is employed. Then, as shown in FIG. 5D, a part of the molded product taken out of the molding die 11 is cut to obtain a laminate 8.

* Method for Manufacturing Laminate 8 shown in FIGS. 4 and 5 First, as shown in FIG. 4A, a part of each of the various laminated sheets 1 is cut out to form a material for a molded laminated sheet 1a. Next, as shown in FIG. 4B, this material is subjected to preliminary shaping by a thermoforming mold 10 to form a laminated sheet 1 for forming.
a. Thereafter, as shown in FIGS. 5 (a), (b), (c) and (d), molding is performed in the same manner.

* Manufacturing method of laminated body 8 shown in FIG. 6 First, a molded body 9 which is a part of the laminated body 8 is molded in advance by molding means such as injection molding. Then, the molded body 9 is set on the mounting table 12 as shown in FIG. Next, as shown in FIG. 6 (b), the various heat-softened laminated sheets 1 are thermoformed, and the reinforcing layer 6 on the back side is directly brought into contact with the molded body 9 and adhered. . afterwards,
As shown in FIG. 6C, a part of the laminated sheet 1 is cut out to form a laminated body 8.

* Although not shown, the laminate 8 having the hard coat layer 7 shown in FIG.
(A) Using the laminated sheet 1 shown in (b), FIG.
After the production of the laminate 8, the hard coat layer 7 may be formed on the surface side of the transparent layer 2 of the laminated sheet 1.

[Brief description of the drawings]

FIG. 1 is an enlarged schematic view showing a laminated sectional structure of various laminated sheets.

FIG. 2A is a perspective view showing the entire laminated sheet according to the embodiment, and FIG. 2B is a perspective view showing the entire laminated body according to the embodiment.

FIG. 3 is a process chart showing a preliminary shaping method of the laminated sheet.

FIG. 4 is a process chart showing a preliminary shaping method of the laminated sheet.

FIG. 5 is a process chart showing a method for manufacturing the laminate.

FIG. 6 is a process chart showing a method for manufacturing the laminate.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Laminated sheet, 1a ... Laminated sheet for molding, 2 ... Transparent layer, 2a ... Surface, 3 ... First adhesive layer, 4 ... Woody layer, 5 ... Second adhesive layer, 6 ... Reinforcement layer, 8 ... Laminate, 9: molded article made of thermoplastic resin composition, 10: thermoformed mold, 11: molded mold, 11a
…cavity.

[Procedure amendment]

[Submission date] March 8, 2002 (2002.3.8)

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] Claims

[Correction method] Change

[Correction contents]

[Claims]

[Procedure amendment 2]

[Document name to be amended] Statement

[Correction target item name] 0014

[Correction method] Change

[Correction contents]

According to the present invention, the embrittlement temperature of the first adhesive layer (3) and the second adhesive layer (5) according to any one of the first to fourth aspects of the present invention. Is set to -40 ° C. or lower.
In addition to the effects of the invention of any one of claims 4 to 4, the laminated sheet (1) can be securely adhered to prevent its peeling. * The invention of claim 6 According to the present invention, any one of claims 1 to 5 is provided.
In the claimed invention, the colored wooden layers are laminated and integrated.
It has become.

[Procedure amendment 3]

[Document name to be amended] Statement

[Correction target item name] 0015

[Correction method] Change

[Correction contents]

[0015] * The invention of claim 7 laminate according to the present invention (8), according to claim claim 1
6. A thermoplastic resin composition integrated with a laminated sheet (1) according to any one of claims 6 to 6 and a reinforcing layer (6) on the back side of the laminated sheet (1). And a molded product (9). In this invention, since the laminated sheet (1) having the effect of any one of the first to sixth aspects of the present invention is used, cost reduction can be achieved even when the laminated body (8) is manufactured. It becomes possible.

[Procedure amendment 4]

[Document name to be amended] Statement

[Correction target item name] 0016

[Correction method] Change

[Correction contents]

* Invention of Claim 8 The laminate (8) according to the present invention is manufactured through the following steps. A part of the laminated sheet (1) according to any one of claims 1 to 6 is cut out to form a molded laminated sheet (1a).

[Procedure amendment 5]

[Document name to be amended] Statement

[Correction target item name] 0019

[Correction method] Change

[Correction contents]

[0019] Therefore, the manufacturing method described above, 請 claim 1
It is suitable for manufacturing a laminated body (8) using the laminated sheet (1) exhibiting the effect of the invention of any one of claims 6 to 9,
Manufacturing costs can be reduced.

[Procedure amendment 6]

[Document name to be amended] Statement

[Correction target item name] 0020

[Correction method] Change

[Correction contents]

* The invention of claim 9 The laminate (8) according to the present invention is manufactured through the following steps. As shown in FIGS. 3 (a), 3 (b) and 3 (c), after preliminarily shaping the laminated sheet (1) according to any one of the first to sixth aspects of the present invention. A part of the laminated sheet (1) is cut out to form a laminated sheet for molding (1a), or as shown in FIGS. 4 (a) and 4 (b), any one of claims 1 to 6 A part of the laminated sheet (1) according to the present invention is cut out to form a molded laminated sheet (1a), and then the molded laminated sheet (1a) is subjected to preliminary shaping.

[Procedure amendment 7]

[Document name to be amended] Statement

[Correction target item name] 0023

[Correction method] Change

[Correction contents]

[0023] Therefore, the manufacturing method described above, 請 claim 1
It is suitable for manufacturing a laminated body (8) using the laminated sheet (1) exhibiting the effect of the invention of any one of claims 6 to 9,
Manufacturing costs can be reduced.

[Procedure amendment 8]

[Document name to be amended] Statement

[Correction target item name] 0024

[Correction method] Change

[Correction contents]

* Invention of Claim 10 The laminate (8) according to the present invention is manufactured through the following steps. -As shown in Fig. 6 (a), a molded article (9) is molded in advance with a thermoplastic resin composition.

[Procedure amendment 9]

[Document name to be amended] Statement

[Correction target item name] 0025

[Correction method] Change

[Correction contents]

[0025] - As shown in FIG. 6 (b) (c), a reinforcing layer on the back side of the laminated sheet according to any one of claims of claims 1 to 6 (1) to (6) The molded sheet (9) is brought into direct contact with the laminated sheet (1).
This molded article (9) and this laminated sheet (1)
To produce a laminated body (8).

[Procedure amendment 10]

[Document name to be amended] Statement

[Correction target item name] 0026

[Correction method] Change

[Correction contents]

[0026] Therefore, the manufacturing method described above, 請 claim 1
Suitable for the manufacture of the laminate (8) using a laminated sheet (1) the effects of the invention of any of claims of Motomeko 6,
Manufacturing costs can be reduced.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification code FI Theme coat ゛ (Reference) B29L 9:00 B29L 9:00 F term (Reference) 4F100 AK01A AK01E AP00C AR00B AR00D BA05 BA07 BA10A BA10E DD07A EH362 EJ182 EJ301 GB33 JA01A JA08B JA08D JA20B JA20D JB16A JB16E JD04 JK12 JL09 JL11B JL11D JN01B JN01D JN08A YY00A YY00B YY00D 4F206 AD05 AD06 AD08 AD20 AG03 JA07 JB13 JF05 JL02 JM04 AD05 AD08 MG08 AD08 AD08 AD208 WA43 WA53 WA58 WB01 WB13

Claims (9)

[Claims] 1. A transparent layer comprising a thermoplastic resin composition,
A transparent first adhesive layer having an adhesive having an adhesive property to the thermoplastic resin composition, a woody layer mainly composed of natural wood, and a second having an adhesive having an adhesive property to the thermoplastic resin composition. An adhesive layer and a reinforcing layer made of a thermoplastic resin composition are provided, and the transparent layer, the first adhesive layer, the wood layer, the second adhesive layer, and the reinforcing layer are sequentially laminated from the front side to the back side to be integrated. A laminated sheet wherein the wood layer is made visible from the front side through the transparent layer and the first adhesive layer, and the reinforcing layer is exposed on the back side. 2. The laminated sheet according to claim 1, wherein the haze of the transparent layer is 5% or less. 3. The laminated sheet according to claim 1, wherein the surface roughness Ra of the front surface side of the transparent layer is set to 0.3 μm or less. 4. The laminated sheet according to claim 1, wherein a flow start temperature of the first adhesive layer and the second adhesive layer is set to 100 ° C. or more and 150 ° C. or less. 5. The laminated sheet according to claim 1, wherein the first adhesive layer and the second adhesive layer have an embrittlement temperature of −40 ° C. or less. . 6. A laminated sheet according to any one of claims 1 to 5, and a thermoplastic resin which is brought into direct contact with and integrated with a reinforcing layer on the back side of the laminated sheet. A laminate comprising a composition formed article. 7. A laminated sheet for molding by cutting out a part of the laminated sheet according to any one of claims 1 to 5, and forming a transparent layer on the surface side of the laminated sheet for molding. The molding laminated sheet is positioned along the inner surface of the cavity of the molding die and positioned in the molding die, and the cavity is melted in the molding space facing the reinforcing layer on the back side of the molding laminated sheet in the cavity. Supply the thermoplastic resin composition in a state and directly contact the reinforcing layer,
A method for producing a laminate, comprising producing a laminate in which a molded article made of the thermoplastic resin composition and the laminated sheet for molding are integrated. 8. A laminated sheet according to any one of claims 1 to 5, wherein the laminated sheet according to any one of claims 1 to 5 is preliminarily shaped, and a part of the laminated sheet is cut out to form a laminated sheet for molding. Or, after cutting a part of the laminated sheet according to any one of claims 1 to 5 to form a laminated sheet for molding, the laminated sheet for molding is subjected to preliminary shaping, The transparent layer on the front side of the laminated sheet for molding is applied along the inner surface of the cavity of the mold to position the laminated sheet for molding in the mold, and the back side of the laminated sheet for molding in the cavity To supply the thermoplastic resin composition in a molten state to the molding space facing the reinforcing layer, and directly contact the reinforcing layer,
A method for producing a laminate, comprising producing a laminate in which a molded article made of the thermoplastic resin composition and the laminated sheet for molding are integrated. 9. A molded article is preliminarily molded from a thermoplastic resin composition, and a reinforcing layer on the back side of the laminated sheet according to claim 1 is attached to the molded article. A method for producing a laminated body, comprising: directly forming a laminated sheet by directly contacting the laminated sheet; and producing a laminated body obtained by integrating the molded article and the laminated sheet.