JPH0267129A - Laminated molded body and preparation thereof - Google Patents

Abstract

PURPOSE:To prevent the generation of unevenness on the outer surface of a skin material by laminating the skin material to a specific crosslinked polyolefinic resin foamed body to form a composite material and integrally forming a resin base material layer composed of a mixture of two kinds of specific polyolefinic resins to said composite material on the foamed body side thereof to perform molding. CONSTITUTION:A composite material wherein a skin material 2 is laminated to a foamed body 1 composed of a crosslinked polyolefinic resin having a gel ratio of 20-80% and apparent density of 0.025-0.20g/cc and a resin base material layer 7 composed of a mixture prepared by mixing 2-40wt.% of a low MW polyolefinic resin having an average MW of 2,000-20,000 with a polyolefinic resin having a melt flow rate at 190 deg.C of 1-60g/10min are integrally molded in such a state that said base material layer 7 is arranged on the side of the foamed body 1. As a result, a laminated molded body 8 of high quality characterized by that the resin base material layer 7 easily flows upon the reception of pressure and the reaction force transmitted from the resin base material layer 7 to the outer surface of the skin material 2 can be reduced and the breakage of air bubbles of the foamed body or the generation of unevenness on the outer surface of the skin material 2 is prevented can be obtained.

Description

Detailed Description of the Invention [Industrial Application Field] The present invention relates to a composite material in which a skin material is bonded to one side of a polyolefin resin foam, and a polyolefin resin foam disposed on the other side of the foam. The present invention relates to a laminate molded product such as a vehicle interior molded product, which is integrally molded with a resin base material layer, and a method for manufacturing the same.

[Prior Art] The following are conventionally known as this type of laminate molded product.

■First Conventional Example As shown in Japanese Patent Application Laid-open No. 54-10367, a resin base layer previously molded into a desired shape is set in the mold of a mold, and an organic An adhesive dispersed with a solvent is applied by spraying, etc., and a composite material in a high temperature heated state made by laminating a skin material on a polyolefin resin foam is placed there, and the space between the female mold and the composite material and the composite material are The air in each space between the material and the resin base material layer is removed by vacuum suction to bring the female mold and the composite material into close contact with each other, and the composite material and the resin base material layer, respectively, and then compression is applied from the skin material side of the composite material. Air is supplied to compress and pressurize the composite material toward the resin base material layer side, thereby obtaining a vehicle interior molded product having a desired shape.

■Second Conventional Example As shown in Japanese Unexamined Patent Publication No. 54-158471, a leather sheet as a skin material is adhered to one surface of a foam sheet, and a resin base material layer (core material) is attached to the other surface. are adhered to obtain a laminate, and the laminate is heat-softened and pressure-molded using a mold to obtain a vehicle interior molded product having a desired shape.

[Problems to be Solved by the Invention] However, the first and second conventional examples described above each have the following drawbacks.

(i) Disadvantages of the first conventional example: The resin base layer must be formed into a desired shape in advance, and an adhesive must be applied to the surface of the resin base layer, resulting in a large number of steps. This had the disadvantage of decreasing productivity.

Additionally, an organic solvent is required to disperse the adhesive;
In addition to deteriorating the working environment, there was a risk of fire due to its flammability, and it also had the disadvantage of increasing costs.

(ii) Disadvantages of the second conventional example In order to heat and soften the resin base layer, the resin base layer must be heated at a high temperature, and pressure is applied to the foam sheet in the heated state, causing the foam sheet to The side that is bonded to the resin base material layer becomes hot, and at that time, rather than the resin base layer diffusing and flowing, the bubbles expand and deform and are destroyed, and this destruction causes the bubbles on the skin material side to The reaction force from the resin base material layer is transmitted to the skin material side, causing unevenness on the surface of the skin material, reducing the product value and making it easier to produce defective products.
There was a drawback of low product yield.

The present invention has been made in view of the above circumstances, and provides a laminate molded product in which a composite material in which a skin material is bonded to a foam material and a resin base material layer is integrally molded. Regardless of the
The purpose of the present invention is to provide a laminate molded product with high commercial value and a method for manufacturing the same.

[Means for Solving the Problems] The laminate molded product according to the present invention is a crosslinked polyolefin resin foam having a gel fraction of 20 to 80% and an apparent density of 0.025 to 0.20 g/cc. A composite material with a skin material attached to it, a polyolefin resin placed on the foam side of this composite material and having a melt flow rate of 1 to 60 g/10 minutes at 190°C, and an average molecular weight of 2,000 to 20,0
00 low molecular weight polyolefin resin.
% mixed with a resin base material layer.

As the material for the polyolefin resin foam used in the present invention, it is preferable to use a polypropylene resin copolymerized with 0.5 to 35% ethylene in a random, block, or random-block form, but with a density of 0.5% to 35%. Polyethylene resins with a melt flow rate of 897 to 0.955 g/cc and 1 to 60 g/lo min, polypropylene resins in which butene and propylene are copolymerized in random or block or random-block form, and ethylene and α-olefins. Foams made of linear polyethylene resins copolymerized with , polyethylene resins copolymerized with ethylene and monomers such as vinyl acetate, acrylic acid, acrylic acid esters, and mixtures of copolymerized polyethylene resins. Applicable to the body etc.

Furthermore, other resins may be mixed with the above-mentioned resins as long as they do not adversely affect the foam. For example, low-density, medium-density or high-density polyethylene, a polyethylene copolymer copolymerized with α-olefin, or a copolymer containing ethylene as a main component with vinyl acetate or acrylic ester may be mixed. .

The gel fraction of the crosslinked polyolefin resin foam used in the present invention is 20 to 80%, preferably 40 to 60%.

If the gel fraction is less than 20%, bubbles will burst due to the heat and pressure during molding, resulting in unevenness on the skin material side, while if the gel fraction exceeds 80%, molding will become extremely difficult.

Note that the gel fraction of the crosslinked polyolefin resin foam mentioned above refers to a value measured as follows.

First, the foam is cut into approximately 1 m square pieces, about 0.1 g is collected, and this is accurately weighed as a sample, and its weight is defined as A (g).

This sample is heated in tetralin at a temperature of 130° C. for 3 hours, then cooled, washed with acetone and then water to remove the eluted portion, and then dried.

The dried sample is accurately weighed and its weight is defined as B (g).

The gel fraction (%) is calculated using the following formula.

Gel fraction (%) = B/AX 100 The apparent density of the crosslinked polyolefin resin foam used in the present invention is 0.025 to 0.20 g/cc, preferably 0.
050-0.10 g/cc. 0.025
If it is less than g/cc, the strength of the molded product decreases, making it difficult to mold it into a complex shape. Moreover, if it exceeds 0.20 g/cc, the cushioning properties of the foam will decrease, for example,
It becomes impossible to satisfy the characteristics required for vehicle interior molded products.

The polyolefin resin foam used in the present invention includes:
It may be one using a pyrolytic foaming agent, or it may be produced by a method called extrusion foaming, which is obtained by kneading a liquid and a polyolefin resin in an extruder and gasifying the liquid. Any method may be used as long as it produces a polyolefin resin foam.

A particularly preferred method is to crosslink a mixture consisting of a polyolefin resin, a blowing agent, and a crosslinking accelerator with ionizing radiation;
Thereafter, a method of foaming by heating above the decomposition temperature of the foaming agent, or a method of foaming a mixture consisting of a polyolefin resin, a foaming agent, an organic peroxide, a crosslinking accelerator, and in some cases a crosslinking regulator, is combined with an organic peroxide and a foaming agent. Examples include a method of heating above the decomposition temperature of the agent to cause crosslinking and foaming.

These methods are suitable for producing endless continuous sheet foams.

As the blowing agent, any compound that is liquid or solid at room temperature and that decomposes or vaporizes when heated above the melting point of the polyolefin resin can be used as long as it does not substantially interfere with sheet formation or crosslinking reactions. , the decomposition temperature is 1
The temperature range is preferably from 80 to 240°C, and specific examples thereof include abdicarbonamide, azodicarboxylic acid metal salts, dinitrosopentamethylenetetramine, and the like.

These blowing agents are 0.1
It is used in the range of ~40% by weight, and the mixing amount can be changed arbitrarily depending on the type and apparent density of each.

When a peroxide is used in the crosslinking reaction, the decomposition temperature is about 120% when the decomposition point is higher than the flow start temperature of the polyolefin resin used in the present invention and the decomposition half-life is 1 minute.
The temperature is preferably 150°C or higher, particularly preferably 150°C or higher. Specific examples thereof include methyl ethyl ketone peroxide (182'C), t-butylperoxyisopropyl carbonate (153°C), and dicumyl peroxide (171'C). These organic peroxides are 0.01 to 1% of the polyolefin resin.
0% by weight is used, preferably 0.05-5% by weight.

Typical examples of crosslinking accelerators include divinylbenzene,
Diallylbenzene, divinylnaphthalene, etc. are included, and the preferable amount of addition thereof is 0.00% relative to the polyolefin resin.
It is 1 to 30% by weight, more preferably 0.3 to 20% by weight.

The polyolefin resin, the blowing agent, the crosslinking accelerator, and the organic peroxide can be mixed by a conventionally known mixing method. For example, there are mixing methods using a Henschel mixer, a Panbury mixer, a mixing roll, a kneading extruder, and the like. Particularly when the resin is in powder form, powder mixing using a Henschel mixer is convenient. Powder mixing is usually carried out between room temperature and the softening temperature of the resin, and melt mixing is usually carried out between the melting temperature of the resin and 195°C.

When producing a continuous sheet-like foam, it is desirable to form the foam into a sheet by extrusion at a temperature below the decomposition temperature of the blowing agent.

Crosslinking and foaming of the uniformly mixed or kneaded foam composition using an organic peroxide can be carried out by heating at a temperature range of 130 to 300°C, preferably 150 to 260'C, under normal pressure or pressure. can. If crosslinking and decomposition of the foaming agent occur almost simultaneously during heating, a method is used in which the mold is heated for the time necessary for crosslinking and foaming in a pressure-sealable mold, and the pressure is removed and foaming is simultaneously performed. This method is extremely effective when foaming a powder mixture as it is. If the foaming agent does not decompose under heat crosslinking conditions, a method is used in which after crosslinking, the foaming agent is heated at normal pressure or under increased pressure at a temperature equal to or higher than the decomposition temperature of the foaming agent.

In particular, in order to obtain a foam with fine cells, a method of foaming under pressure is preferred. The heating time required for crosslinking and foaming varies depending on the composition, heating temperature, thickness of the material to be foamed, etc.
Usually it takes 1 to 30 minutes.

When crosslinking the foamable composition by irradiating it with ionizing radiation, the ionizing radiation includes electron beams from an electron beam accelerator, α and β from other radioactive isotopes.
, gamma rays are preferred, but X-rays and ultraviolet rays may also be used. The radiation dose varies depending on the type of crosslinking accelerator and the desired crosslinking ratio;
d, preferably 0.5 to 20 Mrad.

Foaming of the radiation-crosslinked resin in this manner may be carried out under normal pressure or pressurized conditions as long as it is heated to the melting temperature of the polyolefin resin, preferably 190°C or higher; As in the case described above, any heating medium can be used depending on the shape of the unfoamed molded product and the pressure state during foaming.

The skin materials to be bonded to the polyolefin resin foam of the present invention include fabrics made of natural or artificial fibers, sheets made of polyvinyl chloride resin, thermoplastic elastomer sheets, leather, polyvinyl chloride resin and ABS resin. Known materials such as a mixed sheet can be used.

The base layer resin used in the present invention is a polyolefin resin similar to the foam described above. If a resin with a considerably high melting point, such as polyamide or polybutylene terephthalate resin, is used as a base layer resin for a crosslinked polyolefin resin foam, the melting temperature of the resin base layer will be high. This temperature causes the disadvantage that the cells of the crosslinked polyolefin resin foam are destroyed during pressure molding.

In the present invention, the polyolefin resin used as the resin for the base material layer is a polypropylene resin, or a mixture of propylene and α-olefin in a random, random/random/
Blocks, polypropylene resins copolymerized into block shapes, polyethylene resins, copolymer resins of ethylene and α-olefins, vinyl acetate or acrylic esters, and resins obtained by arbitrarily mixing these resins can be used. Furthermore, an inorganic compound such as talc, silicic acid, calcium carbonate, or the like may be mixed as a filler in the resin base layer to the extent that the properties of the resin base layer are not impaired.

Further, a known heat stabilizer, antioxidant, nucleating agent, coloring agent, etc. may be added to the resin base layer as necessary. Further, resins other than polyolefin resins such as ABS resin, polystyrene resin, petroleum resin, etc. may be added within a range that does not impair the quality of the laminate molded product of the present invention.

Further, as a combination of a polyolefin resin foam and a polyolefin resin base layer, a combination of a polypropylene resin foam and a polypropylene resin base layer is preferred, but a polyethylene resin foam and a polyethylene resin base layer may also be used. Alternatively, different materials may be combined, such as a polypropylene resin foam and a polyethylene resin base layer, or a polyethylene resin foam and a polypropylene resin base layer.

The polyolefin resin for the resin base layer used in the present invention has a melt flow rate of 1 to 6 at 190"C.
0 g/10 minutes. If it is less than 1 g/10 minutes, the fluidity will be poor, and as pressure is applied during molding, the crosslinked polyolefin resin foam will be prone to cell collapse and sag, resulting in a decrease in quality. If it exceeds this, the fluidity becomes too high and the impact resistance of the base resin deteriorates.

Here, the melt flow rate is calculated by measuring the weight of the sample discharged from the nozzle in 1 minute when a 4 to 5 g sample is pressurized with a load of 2.16 kg under heating at 190'C. It is expressed as a value obtained by multiplying the measured value by 10 (8710 minutes).

Furthermore, the low molecular weight polyolefin resin used in the present invention has an average molecular weight of 2.000 to 20°000.
Polypropylene resins and polyethylene resins, as well as propylene-ethylene copolymer resins obtained by copolymerizing them, can be used alone or in combination. If the average molecular weight is less than 2.000, the strength of the resin will be low and the elongation rate will be low, making molding difficult.
If it exceeds 0, the fluidity deteriorates, and as pressure is applied during molding, the crosslinked polyolefin resin foam tends to collapse or sag, creating unevenness on the outer surface of the skin material and reducing quality. do.

Regardless of whether the resin is used alone or in a mixed state, the mixing ratio of the low molecular weight polyolefin resin to the polyolefin resin for the resin base layer is 2 to 40% by weight. If it is less than 2% by weight, the fluidity will be poor, and as pressure is applied during molding, the crosslinked polyolefin resin foam will easily break and sag, causing unevenness on the outer surface of the skin material, resulting in poor quality. decreases,
On the other hand, if the content exceeds 1%, the strength of the entire laminate will decrease.

Methods for measuring molecular weight include vapor pressure osmosis method or c
, p, c method is used.

The laminate molded product of the present invention is produced by hot stamping a composite material in which a skin material is laminated to the above-mentioned crosslinked polyolefin resin foam, and the above-mentioned polyolefin resin base material layer placed on the foam side of this composite material. It was obtained by integral molding.

The true stamping mold method is to distribute and supply a molten polyolefin resin for the resin base layer onto one press surface of a mold in the form of dots or sheets. Then, a predetermined amount of a composite material made by bonding a skin material to a polyolefin resin foam is supplied at a desired temperature, and the polyolefin resin base material layer is integrally formed on the foam side of the composite material by applying pressure in that state. This is a method of heat-sealing.

The laminated molded product according to the present invention is typically used as a vehicle interior molded product, but it can also be used as an interior product for an aircraft or a ship, or an interior product for a room.

On the other hand, in the method for producing a laminate molded product according to the present invention, the gel fraction is 20 to 80% and the apparent density is 0.025 to 0.20 g/
A composite material in which a skin material is bonded to a crosslinked polyolefin resin foam (CC) is placed in a predetermined amount 1 of a pair of upper and lower molds, and the melt flow rate at 190°C is 1 to 60 g.
/10 minutes, a melt of a resin obtained by mixing 2 to 40% by weight of a low molecular weight polyolefin resin with an average molecular weight of 2.000 to 20,000 to a polyolefin resin having an average molecular weight of 2.000 to 20,000 is placed on the foam side of the composite material. After a predetermined amount is distributed and supplied to a predetermined position of a mold, the mold is clamped and compression molded.

The composite material is placed on the upper molding surface or the lower molding surface of a pair of upper and lower molding molds, or at an intermediate position between the upper mold and the lower mold. The temperature of the mold is arbitrarily selected as appropriate.

The polyolefin resin for the resin base layer is measured in an appropriate amount depending on the size of the molded product, and is supplied to the molding surface using, for example, a nozzle. The amount of polyolefin resin for the resin base layer to be supplied to the molding surface is adjusted so that the amount of polyolefin resin supplied to the molding surface is large in areas where the expansion rate is high, and conversely, it is supplied in a small amount in areas where the expansion rate is low. It is desirable to adjust the amount.

Figures 1 to 4 show an example of the manufacturing method according to the present invention. Figure 1 shows a composite material 3 in which a skin material 2 is bonded to a crosslinked polyolefin resin foam 1 into a convex upper part. 4 and a lower concave mold 5 are shown arranged at a predetermined position between a pair of upper and lower molding molds 4.5. FIG. 2 shows a state in which molten polyolefin resin 7 for the resin base layer is being supplied by a nozzle 6 to the molding surface of one example of foam (in this example, the molding surface of the lower mold). . FIG. 3 shows a pressure molded layer, and FIG. 4 shows a laminate molded body 8 obtained by pressure molding.

[Example] To 100 parts by weight of a polypropylene resin copolymerized with 10% by weight of ethylene and having a melt flow rate of 18 g/10 minutes at 190°C, 20 parts by weight of talc and a low polymer with an average molecular weight of 6000 were added. A resin composition for a resin base layer was prepared by uniformly mixing 5 parts by weight of a molecular weight polypropylene resin and 0.1 part by weight of a phenolic stabilizer (antioxidant). Approximately 25 g of this resin composition was discharged at a temperature of 17
Extrude with an extruder under conditions of 0 to 1.75°C, set the mold temperature to 60°C, place on the lower concave mold forming the mold, and place between the upper convex mold and the lower concave mold. A 20 cm square piece made of a cross-linked polypropylene resin foam with an apparent density of 0.067 g/cc and a gel fraction of 49.9%, and a soft vinyl chloride sheet with a thickness of 0.411111 laminated with a polyester adhesive. The composite material was set and compression molded using a hydraulic press at a pressure of 58 kg/cm" to obtain a laminate molded product.

A laminate molded product was obtained by compression molding under the same conditions as in Example 1, except that the amount of low molecular weight polypropylene resin mixed was 10 parts by weight.

1 Cliff 1 The mixing amount of low molecular weight polypropylene resin is 10 parts by weight, and as a crosslinked polypropylene resin foam,
Apparent density is 0.050g/cc and gel fraction is 50.8%
A laminate molded product was obtained by compression molding under the same conditions as in Example 1 above, except that the same material was used.

A laminate was obtained by compression molding under the same conditions as in Example 1, except that the amount of low molecular weight polypropylene resin mixed was 20 parts by weight.

The mixing amount of the low molecular weight polypropylene resin was 20 parts by weight, and as a crosslinked polypropylene resin foam,
Apparent density is 0.050g/cc and gel fraction is 50.8%
A laminate molded product was obtained by compression molding under the same conditions as in Example 1 above, except that the same material was used.

A laminate molded product was obtained by compression molding under the same conditions as in Example 1, except that the mixed amount of the low molecular weight polypropylene resin was 30 parts by weight.

The mixing amount of the low molecular weight polypropylene resin for backing was 30 parts by weight, and as a crosslinked polypropylene resin foam,
Apparent density is 0.050g/cc and gel fraction is 50.8%
A laminate molded product was obtained by compression molding under the same conditions as in Example 1 above, except that the same material was used.

Comparison (1) A laminate molded product was obtained by compression molding under the same conditions as in Example 1 without mixing a low molecular weight polypropylene resin.

As a crosslinked polypropylene resin foam without mixing low molecular weight polypropylene resin, the apparent density is 0.
A laminate molded product was obtained by compression molding under the same conditions as in Example 1, except that a product having a gel content of 0.050 g/cc and a gel fraction of 50.8% was used.

As a result of evaluating the surface unevenness and foam breakage of the molded products for the laminate molded products of Examples 1 to 7 and Comparative Example 1 and Comparative Example 2 obtained as described above, The results shown in Table 1 were obtained.

Table 1 In Table 1 above and Table 2 described below, the meanings of the symbols representing the evaluation of the unevenness on the outer surface of the skin material of the molded product are as follows.

◎: Good condition with no unevenness observed.

O: There are some uneven parts, and it is slightly inferior to the product judged as ◎, but from a practical point of view, there is no problem at all.

Δ: Slight unevenness was observed and the sample could not be put to practical use.

×: The level of unevenness on the foam side was large and could not be used for practical use at all.

As a result of the above, in the molded product according to the example of the laminate molded product of the present invention, the destruction of the foam during molding and the accompanying unevenness on the outer surface of the skin material were hardly observed, and the molded product was good. It was confirmed that the drawability was also practically sufficient.

Further, the drawability is defined as H/D, where the diameter of the molded product is H1 and the depth is D.

Actual ■-100 parts by weight of a polypropylene resin copolymerized with 10% by weight of ethylene and having a melt flow rate of 4 g/10 minutes at 190°C, 20 parts by weight of talc, and a low molecular weight polypropylene resin with an average molecular weight of 9000. 10 parts by weight, and 0.1 part of phenolic stabilizer (antioxidant)
Parts by weight were uniformly mixed to prepare a resin composition for a resin base layer. Approximately 30 g of this resin composition was discharged at a temperature of 1
Extrude with an extruder under conditions of 80 to 183°C, set the mold temperature to 60°C, place on the lower concave mold that makes up the mold, and place an apparent mold between the upper convex mold and the lower concave mold. A 20 cam square piece made by laminating a 0.4 meaW-thick soft vinyl chloride sheet to a cross-linked polypropylene resin foam with a density of 0.045 g/cc and a gel fraction of 48.9% using a polyester adhesive. The composite material was centrifuged and compression molded using a hydraulic press at a pressure of 30 kg/cm" to obtain a laminate.

A laminate molded product was obtained by compression molding under the same conditions as in Example 8 above, except that a polypropylene resin with a melt flow rate of 10 g/10 min at 190'C was used as the "Yayayaki Somame" polypropylene resin.

Implementation 2 A laminate molded product was obtained by compression molding under the same conditions as in Example 8, except that a monopropylene resin having a melt flow rate of 20 g/10 min at 190° C. was used.

A laminate molded product was obtained by compression molding under the same conditions as in Example 8, except that a polypropylene resin having a melt flow rate of 35 g/10 min at 190° C. was used.

Ken Kotan IL A laminate molded product was obtained by compression molding under the same conditions as in Example 8, except that a polypropylene resin having a melt flow rate of 45 g/10 min at 190° C. was used.

Comparison (1) A laminate molded product was obtained by compression molding under the same conditions as in the above example without mixing a low molecular weight polypropylene resin.

The mixture was compression molded under the same conditions as in Example 9 without mixing a low molecular weight polypropylene resin to obtain a laminate molded product.

A laminate molded product was obtained by compression molding under the same conditions as in Example 10 without mixing the low molecular weight polypropylene resin.

1. A laminate molded product was obtained by compression molding under the same conditions as in Example 11 without mixing a low molecular weight polypropylene resin.

Comparison Group 1 A laminate molded product was obtained by compression molding under the same conditions as in Example 12 without mixing a low molecular weight polypropylene resin.

Table 2 shows the results of evaluating the surface unevenness and foam breakage of the molded products of Examples 8 to 12 and Comparative Examples 3 to 7 obtained as described above. The results shown are obtained.

(Hereinafter, blank space) Table 2 MFR in the above table indicates the melt flow rate.

As a result of the above, in the molded product according to the example of the laminate molded product of the present invention, the destruction of the foam during molding and the accompanying unevenness on the outer surface of the skin material were hardly observed, and the molded product was good. It was confirmed that the drawability was also practically sufficient.

In Comparative Example 7, a practically usable molded product was obtained without mixing low molecular weight polypropylene resin, but since the melt flow rate had to be considerably high, precision was required in the management of the melt flow rate. The disadvantage is that it is difficult to manufacture.

[Effects of the Invention] As is clear from the above description, according to the present invention, the gel fraction is 20 to 80% and the apparent density is 0.025 to 0.20.
g/cc, and the same polyolefin resin as the foam is used for the resin base layer, and the polyolefin resin for the resin base layer has a The melt flow rate is 1 to 60 g/10 minutes, and the polyolefin resin has an average molecular weight of 2,000 to 20,00.
Since 2 to 40% by weight of a low molecular weight polyolefin resin of 0.0% is mixed and integrally molded with the resin base layer, the resin base layer easily flows as pressure is applied during stamping molding. The reaction force transmitted from the resin base layer to the outer surface of the skin material can be reduced, and air bubbles in the foam can be reduced due to heat transmitted from the molten resin on the resin base layer side or due to poor flowability of the molten resin. A high-quality laminate molded product can be obtained without breakage or unevenness on the outer surface of the skin material.

Further, according to the present invention, since the composite material and the resin base material layer are integrally molded by the Honto Sumping Molding method, there is no need to mold the composite material or the resin base material layer in advance, and the process can be simplified. Productivity can be improved.

Furthermore, since no adhesive is used when integrally molding the composite material and the resin base layer, the cost is reduced, and the laminate molded product can be safely manufactured without the risk of environmental deterioration or fire.

[Brief explanation of the drawing]

Figures 1 to 4 are explanatory views of the method for manufacturing a laminate molded product according to the present invention, in which Figure 1 shows the state in which the composite material is set in a mold, and Figure 2 shows the state in which the composite material is melted for the resin base layer. FIG. 3 shows a state in which resin is being supplied, a state in which pressure molding is performed, and FIG. 4 shows a state in which molding is completed. 1...Crosslinked polyolefin resin foam 2...Skin material 3...Composite material 4...Top convex type
5... Lower concave mold 6... Nozzle 7... Molten resin for resin base layer (polyolefin resin) 8... Laminated molded product

Claims (3)

[Claims] (1) Gel fraction is 20-80% and apparent density is 0.025
~0.20 g/cc of a composite material in which a skin material is attached to a crosslinked polyolefin resin foam, and a composite material with a melt flow rate of 1
A laminate formed by integrally molding a resin base layer formed by mixing 2 to 40% by weight of a low molecular weight polyolefin resin with an average molecular weight of 2,000 to 20,000 to a polyolefin resin with an average molecular weight of 2,000 to 20,000. Molded object. (2) A laminate molded product according to claim (1), wherein the laminate molded product is a vehicle interior molded product. (3) Gel fraction is 20-80% and apparent density is 0.025
A composite material in which a skin material is bonded to a cross-linked polyolefin resin foam with a density of ~0.20 g/cc is placed in a predetermined position in a pair of upper and lower molds, and the melt flow rate at 190°C is 1 to 60 g/10. A melt of a resin obtained by mixing 2 to 40% by weight of a polyolefin resin with an average molecular weight of 2,000 to 20,000 is molded onto the foam side of the composite material. A method for producing a laminate molded article, in which a predetermined amount is distributed and supplied to a predetermined position of a mold, and then the mold is clamped and compression molded.