US-20260124817-A1 - LAMINATE, SHAPED ARTICLE, MOLDED ARTICLE, METHOD FOR MANUFACTURING LAMINATE, METHOD FOR MANUFACTURING SHAPED ARTICLE, AND METHOD FOR MANUFACTURING MOLDED ARTICLE

US20260124817A1US 20260124817 A1US20260124817 A1US 20260124817A1US-20260124817-A1

Abstract

Provided is a laminate that can be pre-trimmed and can eliminate the need for a post-processing step. A laminate includes a decorative layer, an adhesive layer, and a support layer laminated in this order. The support layer includes two or more kinds of materials having different melting points including a material having a relatively low melting point and a material having a relatively high melting point.

Inventors

Tomonori Sugiyama
Kazuhiko KANEUCHI
Takashi Morimoto
Hiroshi Morioka
Hideki Chiba
Makoto Utsumi
Kazuya Kusu

Assignees

PANASONIC HOLDINGS CORPORATION

Dates

Publication Date: 20260507
Application Date: 20251230
Priority Date: 20220628

Claims (8)

1 . A method for manufacturing a molded article, the method comprising: preparing a laminate having a decorative layer, a first adhesive layer, and a support layer laminated in this order, wherein the support layer includes two or more kinds of materials having different melting points including a material having a low melting point and a material having a high melting point which is higher than the melting point of the material having the low melting point; trimming the laminate into a predetermined shape; aligning and fixing the trimmed laminate, and performing hot press working to obtain a shaped article; aligning and fixing the shaped article to an injection molding mold, and mold-clamping the injection molding mold; pouring a resin into a cavity between the injection molding molds in a state where the injection molding mold is mold-clamped; and after the resin is cured, mold-opening the injection molding mold to take out a molded article in which the shaped article and the cured resin are integrated.
2 . The method for manufacturing a molded article according to claim 1 , wherein the material having the low melting point included in the support layer is fused between portions of the material having the high melting point included in the support layer to form a cross-linked structure.
3 . The method for manufacturing a molded article according to claim 1 , wherein the first adhesive layer penetrates into the support layer and is bonded and integrated with the support layer, and the first adhesive layer covers a front surface of the support layer.
4 . The method for manufacturing a molded article according to claim 1 , wherein a base material layer is formed between the decorative layer and the first adhesive layer.
5 . The method for manufacturing a molded article according to claim 1 , wherein the shaped article has a decorative layer, a first adhesive layer, and a support layer laminated in this order, wherein the support layer includes two or more kinds of materials having different melting points including a material having a low melting point and a material having a high melting point which is higher than the melting point of the material having the low melting point, and the material having a the low melting point included in the support layer is fused between portions of the materials material having a the high melting point included in the support layer to form a cross-linked structure, and a shape is retained.
6 . The method for manufacturing a molded article according to claim 1 , wherein the step of preparing a laminate comprising: laminating the decorative layer, the first adhesive layer, and the support layer in this order; and thermocompression-bonding the decorative layer, the first adhesive layer, and the support layer which are laminated.
7 . The method for manufacturing a molded article according to claim 1 , wherein the material having the low melting point is copolymerized polyester, and the material having the high melting point is polyethylene terephthalate.
8 . The method for manufacturing a molded article according to claim 1 , wherein the material having the low melting point and the material having the high melting point form a core-sheath structure in which a core portion is made of the material having the high melting point and a sheath portion is made of the material having the low melting point.

Description

This application is a divisional of U.S. application Ser. No. 18/213,939 filed on Jun. 26, 2023, the entire contents of which are hereby incorporated by reference. BACKGROUND 1. Technical Field The present disclosure relates to a laminate, a shaped article, a molded article, a method for manufacturing a laminate, a method for manufacturing a shaped article, and a method for manufacturing a molded article. 2. Description of the Related Art In recent years, in exterior parts of home appliances, in-vehicle interior parts, and the like, there is an increasing need for a decoration method having a wide range of design expression and high grade designability due to diversification of customer orientation. As one of the decoration methods, there is an insert molding method in which a decorative material is positioned and fixed in an injection molding mold and integrated with an injected resin. By using this insert molding method, for example, it is possible to obtain a molded article using a decorative material produced in sheets, such as a sliced veneer obtained by thinly slicing wood or a decorative film printed on a thick base material. On the other hand, when the decorative material produced in these sheets is insert-molded, a mechanism for fixing the decorative material to the injection molding mold is generally required, such as making a positioning hole in a margin of the outer periphery of the product on the decorative material side and providing a pin for setting the positioning hole on the injection molding mold side. It should be noted that the insert molding defined in the present disclosure refers to a method of forming the entire external appearance surface of a product with a decorative material, and includes a shape of involving the decorative material from the external appearance surface to the back side of the product depending on product specifications. Japanese Patent No. 6288825 discloses a resin molded member using a composite sheet made of a resin film, a nonwoven fabric, or the like. This configuration is shown in FIGS. 13 and 14. A composite sheet 200 in FIG. 13 includes a resin film 101, a fabric material 102, a resin film 103, and a nonwoven fabric 104. The resin film 101 is formed on one surface side of the fabric material 102 with interposition of a molten adhesive filling layer, and the resin film 103 and the nonwoven fabric 104 are sequentially formed on another surface side of the fabric material 102 with interposition of the same molten adhesive filling layer. In addition, as shown in FIG. 14, the resin molded member 202 is formed by integrating the surface on which the nonwoven fabric 104 is formed of the composite sheet 200 and the base material resin 201 by injection molding. JP 2012-218432 A discloses a composite sheet in which a woven fabric and a plastic sheet are integrated. This configuration is shown in FIGS. 15 and 16. The composite sheet 400 is obtained by integrating the woven fabric 301 and the transparent hard acrylic resin sheet 303 with interposition of the adhesive 302. The woven fabric 301 is impregnated with a thermoplastic resin, and the composite sheet 400 is deformed into the three-dimensional molded product 304 and then molded and integrated with the base material resin, thereby forming the composite three-dimensional molded product 305. In the conventional example of Japanese Patent No. 6288825, when the composite sheet 200 and the base material resin 201 are integrated by injection molding, the adhesive layer (with the base material resin 201) formed on the outer surface of the resin film 103 due to heat, pressure, or resin flow of the base material resin 201 is prevented from melting and flowing out. However, as described in Japanese Patent No. 6288825, it cannot be expected to increase the rigidity of the composite sheet 200 itself. That is, the rigidity of the composite sheet 200 is not sufficient, and the composite sheet 200 alone does not stand by itself. Therefore, it is difficult to position and fix the composite sheet 200 alone to a mold without providing a fixing mechanism to the mold. As a result, when the resin molded member 202 is obtained, the composite sheet 200 cut with a margin with respect to the size of the molded article is attached to the mold fixing side with a positioning pin, and then the composite sheet 200 and the base material resin 201 are integrated by injection molding. Therefore, post-processing processing of trimming a loose portion of the composite sheet 200 protruding to the outer periphery of the molded body is separately required. In addition, in the conventional example of JP 2012-218432 A, the processing followability as the composite sheet 400 is improved by applying impregnation processing to the woven fabric 301, but it is necessary to trim, into a predetermined shape, an unnecessary portion of the three-dimensional molded product 304 after vacuum molding. Therefore, post-processing processing occurs in a series of pr