JPH0885122A - Laminate and production thereof - Google Patents

Abstract

PURPOSE: To obtain a laminate, such as a door trim, by a simplified production process and the production method thereof by providing a skin material and fittings on a substrate by integral molding. CONSTITUTION: On a substrate 21, a skin material 22 covering the top surface of the substrate overall and fittings 23, 24 mounted on the rear side of the substrate in position are provided by integral molding. The skin material and the fittings are made of a weldable thermoplastic resin material. A plurality of small through holes 21a, 21b are provided in fitting mounting parts of the substrate. At the time of molding the skin material, a part of the resin material for the skin material is supplied to the fitting mounting parts on the rear surface of the substrate through the small through holes to form welding bases 22a, 22b. The fittings are welded to the welding bases simultaneously with molding.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated body used for vehicle door trims, vehicle interior materials, indoor interior materials and the like, and a method for producing the same.

[0002]

2. Description of the Related Art As a laminate used for the above-mentioned applications, there is known a laminate in which a resin material is coated on a base material made of a wood-based material or a resin-based material molded into a predetermined shape. An example of such a laminated body is, for example, Japanese Patent Application Laid-Open No. Hei 2
As disclosed in JP-A-286315, a door trim including a base material made of a wooden hardboard formed in the shape of a door trim, and a skin material adhered to the surface of the base material to cover the entire surface thereof. There is.

In the process of manufacturing the door trim having such a structure, as shown in FIGS. 14 and 15, first, the base material 1 is formed into a predetermined shape before the skin material is bonded to the base material.
A long base 12 which is a metal component having a substantially L-shaped cross section is attached to the upper edge of the base 1, and a plurality of brackets 13 which are metal components are attached to predetermined positions of the base material 11. To attach the base 12 and the bracket 13 to the base material 11, as shown in FIGS. 16 and 17, the claw portion 12a or 13a provided on the back surface of the base 12 or the bracket 13 is cut into the base material 11 by pressing. The method of attaching it is generally adopted.

The base 12 is inserted into a slit-like opening at the lower edge of the window formed by the outer panel and inner panel of the door, and functions as a hooking portion for both door panels of the door trim 10 and a weather. It functions as a support for the strip. The plurality of brackets 13 have a function of fixing the base material 11 to the inner panel of the door through a push-in type resin clip locked in the notches 24b.

Next, as shown in FIG. 18 (a), a base material 11 having a base 12 and a bracket 13 attached thereto and formed into a predetermined shape, and a skin material 14 having a surface provided with a predetermined design pattern are formed. Are respectively suction-held along the mold surfaces of the lower mold 15 and the upper mold 16 of the vacuum forming mold, and then both molds 15 and 16 are held.
The base material 11 and the skin material 14 are bonded and integrated with the adhesive 17 by pressing both members 11 and 14 between them. After the two members 11 and 14 have been integrated in this manner, the skin material 14 is cut so that its ends are slightly protruded from the base material 11, as shown in FIG. 18B. This skin material 1
The protruding portion 14a of No. 4 is subsequently subjected to an adhesive treatment so as to wrap the end portion of the base material 11 as shown in FIG. 18C, and is formed so as not to protrude from the skin material 14 and spoil the appearance.

[0006]

In the above-mentioned conventional door trim, the base material 11 and the skin material 14 are bonded by the adhesive 17.
Since it is adhered by using, the apparatus and process for applying the adhesive 17 to the surface of the base material 11 are required, and the base material 1
The skin material 14 to be bonded to No. 1 must be formed into a sheet shape in advance, and therefore, a separate device and process for molding the skin material 14 are also required, and a series of manufacturing devices and the number of manufacturing steps are increased. There was a problem that it was complicated.

Therefore, the inventors of the present application have simplified the manufacturing process of the laminated body by integrally forming the base material and the skin material without forming the skin material in a sheet shape in advance and without using an adhesive. A method for producing a laminate by doing so has already been proposed (Japanese Patent Application No. 6-136072).

By the way, even in the above-mentioned method already proposed, a metal base 12 and a metal bracket 13 which are formed by sheet metal beforehand are required, and an operation of striking the base 12 and the bracket 13 on a base material is required. Therefore, there is a problem that the number of steps is large and the cost is increased.

Further, in order to simplify the manufacturing process, a base 12 made of a thermoplastic resin is provided at a predetermined position on the back surface of the base material 11.
In the case of adopting the method of integrating the brackets 13 and the brackets 13 by injection molding, the base 12 and the brackets 13 are only joined to the surface layer of the base material 11 by the anchor effect, so that the mounting strength is low. There was a point. Then, this invention aims at solving the said subject.

[0010]

In order to achieve the above object, the present invention comprises a base material, a skin material covering substantially the entire surface of the base material, and a mounting part mounted on the back side of the base material. In the laminated body constituted by the above, the skin material and the attachment part are made of a thermoplastic resin material that can be welded to each other, and at least one through hole is provided in a portion of the base material which is the attachment part of the attachment part, Forming a welding base with the same thermoplastic resin material as the skin material at least at a part between the back surface of the base material and the mounting component, and filling the through hole with the same thermoplastic resin material as the skin material. The skin material and the welding base are connected to each other, and the attachment part is welded to the welding base to be integrally connected to the base material.

Further, the method for producing such a laminated body uses a base material in which at least one through hole is provided in advance in a portion to be a mounting portion of a mounting component, and the base material and this base material are combined. Corresponding to the surface of the skin material and the base material side molding die that supports the base material by abutting the molten thermoplastic resin material serving as the skin material supplied on the surface to almost the entire back surface of the base material A skin material is formed by pressing the molten thermoplastic resin material over substantially the entire surface of the base material by pressing to a predetermined thickness with a skin material molding die having a skin-side molding die having a molding surface of a shape In addition, at least a part of the mounting part mounting part on the back surface of the base material through the through hole provided in the part that becomes the mounting part of the mounting part of the base material, and the melted thermoplastic resin having a predetermined thickness. Material And a step of forming a welding base by rolling over, and a base material integrally formed with the skin material and the welding base is brought into contact with substantially the entire back surface of the base material integrally formed with the skin material to support the base material. At the same time, it corresponds to the front surface of the skin material and a base material side molding die in which a concave portion for forming a void in the shape of the attachment part between the back surface of the base material integrally molded with the skin material is provided. A step of setting in a mounting part molding die comprising a skin side molding die having a shaped molding surface,
From the step of injecting in a molten state a thermoplastic resin material that can be welded with the thermoplastic resin material that constitutes the skin material into a void in the shape of the attachment part, and integrally forming the attachment part by welding with the welding base. It is characterized by

Further, in the same method for producing a laminated body, a base material in which at least one through hole is provided in advance in a portion to be a mounting portion of a mounting component is used, and the base material is A base material that abuts almost the entire back surface to support the same base material, and that has a concave portion formed in part to form a thin plate-like void between the back surface of the base material that will be the mounting portion of the mounting component. A skin material molding comprising a side molding die and a skin molding die having a molding surface having a shape corresponding to the surface of the skin material and forming a thin gap between the surface of the base material and the mold surface when the mold is clamped. A step of setting in a mold, and by injecting a molten thermoplastic resin material serving as the skin material into a thin gap between the surface of the base material and the mold surface, the molten heat is applied to almost the entire surface of the base material. In front of the base material while spreading the plastic resin material The molten thermoplastic resin material is spread over the thin plate-like voids on the back surface of the base material through the through-holes provided in the mounting portion of the mounting component and cured to form the skin material and the welding base. And a base material integrally formed with the skin material, and abutting substantially the entire back surface of the base material integrally formed with the skin material and the welding base to support the base material, and the shape of the mounting part. A base material side molding die partly provided with a recess forming a void between the back surface of the base material integrally molded with the skin material, and a skin side having a molding surface having a shape corresponding to the surface of the skin material. A step of setting in a mounting part molding die including a molding die, and injecting a thermoplastic resin material that can be welded with a thermoplastic resin material forming the skin material into a void in the shape of the mounting part in a molten state, and performing the welding. Fused to the base Characterized in that comprising the step of integrally forming the serial fitting.

In the laminated body and the manufacturing method thereof, the thermoplastic resin forming the skin material is a relatively soft thermoplastic resin material, and the thermoplastic resin material forming the mounting part constitutes the skin material. It is desirable to use a thermoplastic resin material that is harder than the thermoplastic resin material.

[0014]

In the laminated body of the present invention having the above-mentioned structure, the skin material on the front surface side of the base material is passed through at least one through hole provided in the portion to be the mounting portion of the mounting component to the base material. Since the welding base on the back side is integrally connected and the mounting component is welded to this welding base, the mounting component will not come off unless the thermoplastic resin for skin material in the through hole is broken. It can be firmly fixed to the base material.

In such a method for producing a laminate of the present invention, it is not necessary to form the skin material in a sheet shape in advance, and since an adhesive is not used, it is not necessary to provide an adhesive application step. The manufacturing process of the laminated body can be simplified. Further, the manufacturing process of the laminated body can be further simplified by integrating the mounting component with the base material simultaneously with molding.

In such a laminate, in particular, the thermoplastic resin material forming the skin material is a relatively soft thermoplastic resin material, and the thermoplastic resin material forming the mounting part is the thermoplastic resin forming the skin material. When the thermoplastic resin material harder than the resin material is used, the surface feeling of the laminate can be improved and the strength of the mounting component can be sufficiently maintained.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A vehicle door trim is adopted as an example of the laminated body of the present invention, and its structure and manufacturing method will be described below with reference to the drawings. The door trim of this embodiment is an automobile door trim 20 as shown in FIGS. 1 and 2, and includes a base material 21 formed in the shape of a door trim and provided with small through holes 21a and 21b at predetermined positions, and a base material 21 thereof. A skin material 22 that covers the entire surface of the material 21, welding bases 22a and 22b that cover predetermined locations on the back surface, a base 23 that is a resin component attached to the back side of the base material 21, and a bracket 24. To be done. If necessary, this skin material 22
A part of is decorated with ornament 25.

The base material 21 is made of a wood-based molded product formed by maintaining the porosity of an aggregate obtained by mixing a main raw material such as wood fiber or powder with a phenol resin as a binder.
Its dimensions are 90 cm in the front-rear direction, 50 cm in the up-down direction, and a wall thickness of about 3 mm. As shown in FIG.
The base material 21 is provided at a portion having a width of about 20 mm over the entire length in the front-rear direction of the upper edge portion and a portion having a width of about 20 mm and a length of about 50 mm at a predetermined plurality of portions on the inner side of the front edge and the lower edge. Are provided with small through holes 21a, 21b in the thickness direction. The diameter of these small through holes 21a, 21b is 1
It is about mm, and it is opened at a density of about 4 per 1 cm 2.

The skin material 22 is made of polypropylene resin which is a thermoplastic resin material having a JIS-A Shore hardness of about 60. The thermoplastic resin material for the skin material 22 covers the entire front surface of the base material 21 with a thickness of about 0.5 mm to form the skin material 22, and at the same time, the upper edge of the base material 21 and small penetrations. With the thermoplastic resin material that has passed through the holes 21a, the back surface is coated with a thickness of about 0.5 mm on a portion of a width of about 20 mm over the entire length of the upper edge of the base material 21 in the front-rear direction,
The welding base 22a is formed. Further, the thermoplastic resin material for the skin material 22 passes through the small through-holes 21b of the base material 21, and on the back surface, a plurality of predetermined 20 mm portions of the front and rear edge ends and the lower edge end of the base material 21 at a plurality of predetermined positions. A region having a width of about 50 mm and a length of about 0.5 mm is covered to form a welding base 22b. The joined portion of the porous wood-based base material 21 with the skin material 22 and the welding bases 22a and 22b is a base material 21 in which the thermoplastic resin material for the skin material 22 is porous.
Is hardened in a state where it is impregnated and filled in the innumerable gaps on the surface of the two members 21 and 22, 22a, 22b.
Are joined by the anchor effect. Further, the insides of the plurality of small through holes 21a, 21b are also filled with the same thermoplastic resin material as the skin material 22, so that the skin material 22 and the both welding bases 22
a and 22b are connected.

The attachment parts attached to the back side of the base material 21 include a base 23 attached to the back side of the upper edge of the base material 21 over the entire length in the front-rear direction, and front and rear edges and a lower edge of the base material 21. There are a plurality of brackets 24 attached to a plurality of predetermined positions on the back surface side of the inner part of several tens of mm from the end.
These attachment parts 23 and 24 are made of polypropylene resin which is a thermoplastic resin material having a JIS-A Shore hardness of about 90. The base 23 is a long component having a substantially L-shaped cross section, and one outer surface of the L-shape is welded to the above-mentioned welding base 22a provided at the upper edge portion of the back surface of the base material 21 as described later. ing. As shown in FIG. 3, each of the plurality of brackets 24 has an opening 24a on one surface,
Further, on the other surface perpendicular to the opening 24a, a notch 24b for locking a push-in type resin clip for fixing to the door inner panel and a notch 24b opening toward the opening 24a are formed. Resin clip introduction opening 24c
It has a hollow rectangular parallelepiped shape. Then, it is welded to the above-mentioned welding bases 22b provided at a plurality of predetermined positions on the back surface of the base material 21 on the opposite outer surface 24d, which is the surface provided with the notches 24b for locking the resin clip.

As shown in FIG. 2, the ornament 25, which is attached as required, is made by processing a thin steel plate into a predetermined shape into a predetermined shape, and a substrate 25a provided with claws 25b for attaching to the base material 21 is made of urethane foam or the like. It has a structure in which a decorative skin material 25c such as a fabric is stuck through a cushion material.

In the door trim 20 thus constructed, a plurality of small through holes 21a provided in the base 23 of the base material 21 and the mounting portion of the bracket 24,
21b through the skin material 22 and the welding bases 22a, 22
Since b is integrally connected, the through holes 21a, 21
Unless the thermoplastic material for the skin material 22 in b is broken, the welding bases 22a and 22b do not come off from the base material 21, and the base 23 and the base material 21 of the bracket 24 welded to the welding bases 22a and 22b. The mounting strength for the is extremely high. Furthermore, since no adhesive is used, there is no possibility of forming a part that is not securely adhered due to uneven application of the adhesive at the time of manufacturing, and it is possible to reduce the amount of material used. Further, the thermoplastic resin material forming the skin material 22 is a relatively soft thermoplastic resin material, and the thermoplastic resin material forming the mounting parts 23 and 24 is harder than the thermoplastic resin material forming the skin material 22. Since it is made of a thermoplastic resin material, the surface feeling of the door trim 20 can be made good, and the strength of the attachment parts 23, 24 can be sufficiently maintained.

Next, a method of manufacturing the door trim having the above-described structure, which is one embodiment of the method of manufacturing the laminated body of the present invention, will be described with reference to the drawings. FIGS. 4 to 12 are views showing the case where the manufacturing method according to the present invention is applied to the manufacture of the door trim 20 shown in FIGS. 1 and 2. Here, FIGS. 4 to 6 are views for explaining a method of integrally forming the skin material 22 on the base material 21, and FIGS. 7 to 12 are parts attached to the base material 21 on which the skin material 22 is formed. It is a figure for demonstrating the construction method of integrally forming the base 23 and the bracket 24.

First, a method of integrally forming the skin material 22 on the base material 21 will be described. In order to integrally form the skin material 22 on the base material 21, the back surface of the base material 21 is brought into contact with almost the entire back surface of the base material 21.
A lower mold 30 having a back side molding surface 30a for supporting
A pair of upper and lower molding dies 30, 31 including an upper mold 31 having a front molding surface 31a in which a grain pattern is formed for forming a design pattern on the surface of the skin material is used. As shown in FIG. 5, the back side molding surface 30a of the lower mold 30 has a back side molding surface 30a.
When the base material 21 is set on a, the back surface 21 having a width of about 20 mm over the entire length of the upper edge of the base material 21 in the front-rear direction.
A concave portion 30a1 is provided between c and the back side molding surface 30a of the lower mold 30 so as to form a void 30b with an interval of about 0.5 mm. Further, as shown in FIG. 6, on the back side molding surface 30a of the lower mold 30, the base material 21 is provided on the back side molding surface 30a.
When set, between the back side 21d and the back side molding surface 30a of the lower die 30 in a range of about 20 mm width and 50 mm length at a plurality of predetermined positions of several tens of mm from the front and rear edges and the bottom edge of the base material 21. Are provided with recesses 30a2 so as to form voids 30c with an interval of about 0.5 mm.

In the manufacturing process, first of all, a base material made of a wood-based molded body in the shape of a door trim is first formed on the molding surface 30a of the lower mold 30 of the molding dies 30, 31 whose temperature is adjusted to 50 ° C. to 80 ° C. After setting 21, the top surface of the base material 21 is made of polypropylene resin 22me serving as a skin material.
lt in a molten state (180 ° C to 200 ° C) supply device 32
To supply. Then, by lowering the upper mold 31 and pressing it between the lower mold 30 and the lower mold 30, the molten resin 22melt is spread, covering the entire surface of the base material 21 and passing outside the upper edge of the base material 21. This is filled through a plurality of small through holes 21a, and the back surface of the base material 21 and the molding surface 30 of the lower die are filled.
The void 30b formed between the concave portions 30a1 of a is filled. At the same time, the molten resin 22melt passes through the plurality of small through holes 21b and fills it, and fills the voids 30c formed between the back surface of the base material 21 and the recesses 30a2 of the molding surface 30a of the lower mold. The molten resin 22melt is impregnated so as to fill the innumerable gaps on at least the front surface inside the base material 21 at the portion in contact with the base material 21, and is immediately hardened, so that the entire surface and the back surface of the base material 21 are predetermined. Part 21c, 2
1d is covered with the thermoplastic resin material for the skin material 22, the skin material 22 and the welding bases 22a, 22b are formed, and a plurality of small through holes 21a, 21b are filled with the thermoplastic resin material for the skin material 22. An integrally molded body of the base material 21 and the skin material 22 is formed.

Next, a method for integrally molding the base 23 and the bracket 24, which are mounting parts, on the base material 21 on which the skin material 22 is formed will be described. As shown in FIG. 7, in order to integrally mold the base 23 and the bracket 24, which are attachment parts, to the base material 21 having the skin material 22 formed thereon, the base material 21 having the skin material 22 formed thereon is contacted with almost the entire back surface of the base material 21. A lower mold 40 having a molding surface 40a for supporting the base material 21 having the skin material 22 formed thereon and an upper mold having a molding surface 41a corresponding to the surface shape of the base material 21 having the skin material 22 formed thereon. A pair of upper and lower molds 40 and 41 composed of 41 are used. As will be described later, when the base material 21 having the skin material 22 formed on the molding surface 40a is set on the molding surface 40a of the lower mold 40, the welding base 22a on the back surface of the upper edge of the base material 21 and the lower mold 40. Shape of the base 23 and the bracket 24 between the molding surfaces 40a of the lower mold 40 and the welding bases 22b at a plurality of predetermined positions on the inner side of the front and rear edges and the lower edge of the base material 21 by several tens mm. Recesses are provided to form the voids 40b and 40c. Further, in the lower mold 40, a base portion slide 43 which is slidable in the vertical direction of the mold by an air cylinder 42 is formed on the molded portion of the base 23 above the base material 21, and an air is formed on the molded portion of the bracket 24 below the base material 21. Bracket part slide 45 that can be slid to the left and right of the mold by the cylinder 44
And the space 40b and the bracket 24 for molding the base 23
A resin supply passage 46 opening to the molding gap 40c (note that a heater 47 is provided in the resin supply passage 46 to prevent the temperature of the molten resin from dropping during the supply). . Further, a molten resin injection device 48 is attached to the other end of the resin supply passage 46.

As shown in FIG. 8, the mold structure of the base 23 molding part has the upper surface 43a which forms a part of the lower mold molding surface 40a in a state where the base slide 43 is lowered to the lowermost limit, and is formed on the molding surface 40a. When the base material 21 on which the skin material 22 is formed is set, the base material 21 on which the skin material 22 is formed is closely adhered and supported, and a part 43b of the side surface and the lower die molding surface 40a
40d for forming the base 23, which is surrounded by the part 40d and the surface of the welding base 22a formed on a part of the back surface of the base material 21. Void 40 for molding the base 23
A resin supply passage 46 is opened in a portion 40d of the lower die molding surface 40a forming b.

As shown in FIG. 9, the mold structure of the molding portion of the bracket 24 has a surface 45a and a part 4 of the lower molding surface 40a with the bracket slide 45 positioned at the rightmost position.
0e and the welding base 2 formed on a part of the back surface of the base material 21.
2b, a space 40c for molding the bracket 24 is formed. A resin supply passage 46 is opened in a part 40e of the lower mold molding surface 40a that forms a space 40c for molding the bracket 24.

In the manufacture, the skin material 22 is formed between the molding surfaces 40a, 41a of the pair of upper and lower molding dies 40, 41 which are adjusted to a temperature of about room temperature in the previous step.
And the base material 21 on which the welding bases 22a and 22b are formed is set. At this time, the base slide 43 is set to the lowermost position by the air cylinder 42, and the bracket slide 45 is set to the rightmost position by the air cylinder 44. In this state, the space 4 for molding the base 23
0b and the thermoplastic resin material 23melt for the mounting parts 23 and 24 in a molten state (180 ° C. to 200 ° C.) in the void 40c for molding the bracket 24 from the resin supply passage 46 under high pressure (100 to 100 cm 2 per square cm). (300 kg), the molten resin material 23melt becomes the base material 2
Welding bases 22a and 22b formed on a part of the back surface of the No. 1
Then, the base 23 and the bracket 24 are molded by welding and hardening.

Next, as shown in FIGS. 10 to 12, a notch 24 for locking the resin clip of the bracket 24 on the bracket slide 45 by the air cylinder 44.
The base material 21 with the skin material 22 formed by integrally molding the resin parts 23 and 24 by moving the base slide 43 to the uppermost position by the air cylinder 42 while moving to the position where the face material 24e provided with b can be removed from the mold. Demold diagonally upward.
After removing the mold, the runners 23a and 24f attached to the base 23 and the bracket 24 are cut off to obtain the door trim 20 shown in FIGS.

FIG. 13 is a process for integrally forming the skin material 22 and the welding bases 22a and 22b on the base material 21 in the door trim manufacturing method which is the second embodiment of the manufacturing method according to the present invention. The figure for demonstrating is shown. The base material 21 has a skin material 22 and welding bases 22a, 22.
In order to integrally mold b, the upper die 51 having a molding surface 51a that abuts almost the entire back surface of the base material 21 and the front molding surface having a grain for forming a design pattern on the surface of the skin material are formed. A pair of upper and lower molding dies 50 and 51 including a lower mold 50 on which 50a is formed is used. Similar to the first embodiment, the upper mold 51 has a space 51b between the back surface of the base material 21 and
A recess is provided to form 51c. The lower mold 50 has a resin supply passage 52 that opens in a part of the molding surface 50a.
(Note that the resin supply passage 52 is provided with a heater 53 to prevent the temperature of the molten resin from dropping during the supply.). Further, a molten resin injection device 54 is attached to the other end of the resin supply passage 52.

In manufacturing, first, a pair of molding dies 5 is used.
The base material 21 is set between the molding surfaces 50a and 51a of 0 and 51. Then, a molten state (180) that constitutes a skin material is formed between the surface of the base material 21 and the molding surface 50a of the lower mold 50.
C. to 200.degree. C.) by injecting the thermoplastic resin material 22melt from the resin supply passage 52 at a high pressure (100 to 300 kg per 1 cm.sup.2) by the injection device 54, thereby covering the entire surface of the base material 21 and the base material. 21 a plurality of small through-holes 21a, 21b provided at a plurality of predetermined positions on the upper edge portion and the upper edge portion and the front and rear edge edges and the lower edge edge by several tens of mm
Through which the voids 51b and 51c are provided at predetermined positions between the back surface of the base material 21 and the molding surface 30a of the lower mold. The molten resin 22melt is impregnated so as to fill the innumerable gaps on at least the front surface inside the base material 21 at the portion in contact with the base material 21, and is immediately hardened, so that the entire surface and the back surface of the base material 21 are predetermined. The portions 21c and 21d are covered with the thermoplastic resin material for the skin material 22, and the skin material 22 and the welding base 2 are covered.
2a and 22b are formed, and a plurality of small through holes 2 are formed.
1a, 21b through the skin material 22 and the welding base 22a,
22b are connected. The next step, that is, the step of integrally molding the base 23 and the bracket 24, which are the mounting parts, on the base material 21 having the skin material 22 formed thereon is the same as that of the first embodiment.

According to the door trim manufacturing method of the first and second embodiments as described above, it is not necessary to provide the adhesive applying step and the skin material forming step which are indispensable in the conventional manufacturing method. , While simplifying the manufacturing process,
By simultaneously forming the base and the bracket and integrating them with the base material, the manufacturing process of the laminate can be further simplified.

In the above embodiments, the wood-based molded product was used as the base material, but a porous resin-based molded product made of hard urethane foam or the like may be used. In addition, a porous resin system mainly composed of a thermosetting resin material such as a phenol resin, an epoxy resin, a polyester resin or a thermoplastic resin material such as a polypropylene resin or an ABS resin, to which a reinforcing material and an antistatic agent are appropriately added. A molded body or the like can be used. Then, when the wettability between the base material made of these materials and the resin constituting the skin material is poor, a surface modifier such as a modified olefin may be applied to the surface of the base material.

Although polypropylene resin is used as the skin material in the above embodiments, other olefin resin, for example, thermoplastic resin material such as polyethylene or ethylene-propylene copolymer may be used. It is also possible to appropriately add a gloss-imparting agent for imparting gloss to the skin material, a flame retardant, or the like in consideration of the appearance and performance of the product.

[Brief description of drawings]

FIG. 1 is a perspective view of a door trim that is an embodiment of a laminated body according to the present invention.

FIG. 2 is a cross-sectional view taken along the line YY in FIG.

FIG. 3 is a perspective view of a bracket which is one of attachment parts.

FIG. 4 is a diagram for explaining a step of integrally molding a skin material and a welding base on a base material in the method for manufacturing a door trim, which is the first embodiment of the method for manufacturing a laminate according to the present invention.

5 is an enlarged view of portion C in FIG.

6 is an enlarged view of part D in FIG.

FIG. 7 illustrates a step of integrally forming a mounting component on a base material integrally formed with a skin material and a welding base in the door trim manufacturing method that is the first embodiment of the laminated body manufacturing method according to the present invention. FIG.

FIG. 8 is an enlarged view of part E in FIG.

9 is an enlarged view of an F portion of FIG.

FIG. 10 illustrates a step of integrally forming a mounting component on a base material integrally formed with a skin material and a welding base in the method for manufacturing a door trim, which is the first embodiment of the method for manufacturing a laminate according to the present invention. FIG.

11 is an enlarged view of part G in FIG.

FIG. 12 is an enlarged view of part H in FIG.

FIG. 13 is a diagram for explaining a step of integrally molding a skin material and a welding base on a base material in the method for manufacturing a door trim which is the second embodiment of the method for manufacturing a laminate according to the present invention.

FIG. 14 is a rear perspective view of a conventional door trim.

15 is a sectional view taken along line XX in FIG.

16 is an enlarged view of part A in FIG.

FIG. 17 is an enlarged view of part B in FIG.

FIG. 18 is a process diagram for explaining a conventional door trim manufacturing method.

[Explanation of symbols]

21 Base Material 21a, 21b Through Hole 22 Skin Material 22a, 22b Welding Base 23 Mounting Parts (Base) 24 Mounting Parts (Bracket) 30, 31, 50, 51 Skin Material Mold 40, 41 Mounting Parts Mold 30a, 31a, 40a, 41a, 50a, 51a Molding surface 30a1, 30a2 Recessed portion 30b, 30c, 40b, 40c, 51b, 51c Void

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Claims (5)

[Claims] 1. A laminate comprising a base material, a skin material covering substantially the entire surface of the base material, and a mounting component attached to the back side of the base material, wherein the skin material and the mounting component are It is made of thermoplastic resin materials that can be welded to each other, and at least one through hole is provided in a portion of the base material that serves as a mounting portion of the mounting component, and at least a part between the back surface of the base material and the mounting component. The welding base is formed of the same thermoplastic resin material as the skin material, and the skin material and the welding base are connected by filling the through holes with the same thermoplastic resin material as the skin material, and the mounting part is attached. A laminated body, which is welded to the welding base and integrally bonded to the base material. 2. The thermoplastic resin material forming the skin material is a relatively soft thermoplastic resin material, and the thermoplastic resin material forming the mounting part is harder than the thermoplastic resin material forming the skin material. The laminated body according to claim 1, which is the thermoplastic resin material. 3. A method for manufacturing a laminate, comprising: a base material; a skin material that covers the entire surface of the base material; and a mounting part mounted on the back side of the base material. A base material in which at least one through hole is provided in advance in a portion to be formed, and the base material and the melted thermoplastic resin material serving as the skin material supplied to the surface of the base material A skin material molding die comprising a base material molding die that abuts almost the entire back surface of the material to support the same material and a skin material molding die having a molding surface having a shape corresponding to the surface of the skin material. By pressing to spread the molten thermoplastic resin material on almost the entire surface of the base material to form a skin material,
Spread the molten thermoplastic resin material to a predetermined thickness on at least a part of the attachment part attachment portion on the back surface of the base material through the through hole provided in the portion of the base material to be the attachment part attachment portion. A step of forming a welding base with the base material integrally formed with the skin material and the welding base, and supporting the base material by abutting substantially the entire back surface of the base material integrally formed with the skin material, A base material side molding die partially provided with a recess for forming a void in the shape of the mounting part between the back surface of the base material integrally molded with the skin material, and molding of a shape corresponding to the surface of the skin material A step of setting in a mounting part molding die comprising a skin side molding die having a surface, and a thermoplastic resin material which can be welded with a thermoplastic resin material constituting the skin material in a void of the shape of the mounting part in a molten state. Inject the above Method for producing a laminate characterized by comprising a step of integrally molding the fitting by wearing the base and welded. 4. A method of manufacturing a laminated body, comprising: a base material; a skin material that covers the entire surface of the base material; and a mounting part mounted on the back side of the base material. A base material in which at least one through hole is provided in advance is used for supporting the base material by contacting the base material with almost the entire back surface of the base material, It has a base material side molding die partly provided with a recess forming a void between the back surface of the base material which becomes the mounting portion of the mounting part, and a molding surface having a shape corresponding to the surface of the skin material. A step of setting in a skin material molding die comprising a skin side molding die which forms a thin space between the surface of the base material and a mold surface when clamped, and a thin space between the surface of the base material and the mold surface. , By injecting a molten thermoplastic resin material that becomes the skin material ,
The molten thermoplastic resin material is spread over almost the entire surface of the base material, and the thin plate-like shape of the back surface of the base material is passed through the through hole provided in a portion of the base material that serves as a mounting portion of the mounting component. The step of forming the skin material and the welding base by making the molten thermoplastic resin material spread in the voids and curing the same, and the base material integrally formed with the skin material and the welding base, and integrally molding the skin material. The back surface of the base material is supported by contacting almost the entire back surface of the base material, and a recess is formed in part to form a void in the shape of the mounting part between the back surface of the base material integrally formed with the skin material. And a base material side molding die, a step of setting in a mounting part molding die comprising a skin side molding die having a molding surface having a shape corresponding to the surface of the skin material, and the skin in the void of the shape of the mounting part. Make up the material Method for producing a laminate that a thermoplastic resin material and weldable thermoplastic resin material is injected in a molten state, characterized by comprising the step of integrally molding the fitting by the welding base and the welding. 5. The thermoplastic resin material forming the skin material is a relatively soft thermoplastic resin material, and the thermoplastic resin material forming the mounting part is harder than the thermoplastic resin material forming the skin material. The thermoplastic resin material according to claim 3, wherein the method for producing a laminated body according to claim 3 or claim 4.