Laminate, shaped article, molded article, method for manufacturing laminate, method for manufacturing shaped article, and method for manufacturing molded article

Abstract

To provide a laminate that can be pre-trimmed and can eliminate the need for a post-processing step.SOLUTION: A laminate includes a decorative layer, an adhesive layer, and a support layer which are 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.SELECTED DRAWING: Figure 1A

Description

[Technical field]

[0001] The present disclosure relates to a laminate, a shaped product, a molded product, a method for manufacturing a laminate, a method for manufacturing a shaped product, and a method for manufacturing a molded product. [Background technology]

[0002] In recent years, the need for a decoration method with a wide range of design expressions and high-quality design has been increasing due to the diversification of customer orientation in the exterior parts of home appliances and interior parts for vehicles. One of the decoration methods is the insert molding method in which the decorative material is positioned and fixed in an injection mold and integrated with the injected resin. By using this insert molding method, it is possible to obtain molded products using decorative materials made from sheets, such as veneer made by thinly slicing wood or decorative films printed on thick substrates. On the other hand, when insert molding these decorative materials made from sheets, it is common to need a mechanism for fixing the decorative material to the injection mold, such as opening a positioning hole in the 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 mold side. Note that the insert molding defined in this disclosure refers to a method of forming the entire exterior surface of a product with a decorative material, and depending on the product specifications, it also includes a shape in which the decorative material is wrapped from the exterior surface of the product to the back side of the product.

[0003] Patent Document 1 discloses a resin molded member using a composite sheet made of a resin film, a nonwoven fabric, etc. This configuration is shown in Figs.

[0004] 13 is composed of resin film 101, fabric material 102, resin film 103, and nonwoven fabric 104. Resin film 101 is formed on one side of fabric material 102 with a molten adhesive filling layer interposed therebetween, and resin film 103 and nonwoven fabric 104 are formed in this order on the other side of fabric material 102 with a molten adhesive filling layer interposed therebetween similar to that described above. Also, as shown in FIG. 14, the surface of composite sheet 200 on which nonwoven fabric 104 is formed and base resin 201 are integrated by injection molding to form resin molded member 202.

[0005] Patent Document 2 discloses a composite sheet in which a woven material and a plastic sheet are integrated. This configuration is shown in Figures 15 and 16. Composite sheet 400 is formed by integrating woven material 301 and transparent hard acrylic resin sheet 303 with adhesive 302. Woven material 301 is impregnated with a thermoplastic resin, and composite sheet 400 is transformed into three-dimensional molded object 304, which is then molded and integrated with a base resin to form composite three-dimensional molded object 305. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Patent No. 6288825 [Patent Document 2] JP 2012-218432 A Summary of the Invention [Problem to be solved by the invention]

[0007] In the conventional example of Patent Document 1, when the composite sheet 200 and the base resin 201 are integrated by injection molding, a configuration is adopted to prevent the adhesive layer (with the base resin 201) formed on the outer surface of the resin film 103 due to the heat or pressure of the base resin 201 or the resin flow from melting or flowing out. However, as described in Patent Document 1, it is not expected to increase the rigidity of the composite sheet 200 itself. In other words, since the rigidity of the composite sheet 200 is insufficient and the composite sheet 200 does not stand on its own, it is difficult to position and fix the composite sheet 200 alone to the mold without providing a fixing mechanism to the mold. As a result, when obtaining the resin molded member 202, the composite sheet 200 cut to have a margin with respect to the size of the molded product is attached to the mold fixing side with a positioning pin, and then the composite sheet 200 and the base resin 201 are integrated by injection molding. For this reason, a separate post-processing process is required to trim the margin of the composite sheet 200 that protrudes from the outer periphery of the molded product.

[0008] In the conventional example of Patent Document 2, the woven material 301 is impregnated to improve the processability of the composite sheet 400, but it is necessary to trim the unnecessary parts of the three-dimensional molded product 304 after vacuum molding into a predetermined shape. Therefore, post-processing is required in the series of processes for integrating the three-dimensional molded product with the base resin to obtain the composite three-dimensional molded product 305.

[0009] As in these conventional examples, some efforts have been made to improve the ability to follow the product shape during processing, but there are still challenges to overcome in eliminating post-processing during the entire molding process.

[0010] The present disclosure aims to provide a laminate that can be pre-trimmed and eliminates the need for post-processing steps. [Means for solving the problem]

[0011] The laminate of the present disclosure is a laminate in which a decorative layer, an adhesive layer, and a support layer are laminated in that order, and the support layer contains two or more materials with different melting points, including a material with a relatively low melting point and a material with a high melting point.

[0012] The shaped product of the present disclosure is a shaped product laminated in the order of a decorative layer, a first adhesive layer, and a support layer, wherein the support layer contains two or more materials with different melting points, including a relatively low melting point material and a high melting point material, and the low melting point material contained in the support layer fuses between the high melting point materials contained in the support layer to form a cross-linked structure and maintain the shape.

[0013] The molded article according to the present disclosure includes the shaped article and an injection molded resin integrated with the shaped article.

[0014] The molded product according to the present disclosure includes one member selected from the group consisting of a resin member, a metal member, a glass member, a ceramic member, and a wood member, and the above-mentioned shaped product bonded to the surface of the member.

[0015] A method for manufacturing a laminate according to the present disclosure includes a step of sequentially laminating a decorative layer, a first adhesive layer, and a support layer, and a step of thermocompression bonding the laminated decorative layer, first adhesive layer, and support layer.

[0016] A method for producing a shaped product according to the present disclosure includes a step of trimming a laminate according to any one of the first to fourth aspects to a predetermined shape, and a step of aligning and fixing the trimmed laminate and subjecting it to heat press processing.

[0017] A method for producing a molded product according to the present disclosure includes the steps of aligning and fixing a shaped product according to the fifth aspect in an injection molding die and clamping the injection molding die, pouring a resin into a cavity between the injection molding die while the injection molding die is clamped, and, after the resin has hardened, opening the injection molding die and removing a molded product in which the shaped product and the hardened resin are integrated.

[0018] The method for producing a molded product according to the present disclosure obtains a molded product by bonding the shaped product according to the fifth aspect to the surface of a member selected from the group consisting of a resin member, a metal member, a glass member, a ceramic member, and a wood member. Effect of the Invention

[0019] According to the laminate of the present disclosure, the low melting point material contained in the support layer constituting the laminate melts by the thermocompression bonding during the production of the laminate, and fuses with the high melting point material contained in the support layer to form a cross-linked structure between the high melting point material. This improves the density of the support layer, improves the hardness of the support layer itself, and allows the laminate to stand on its own. Therefore, alignment can be performed in the subsequent hot pressing process and the manufacturing process of the molded product, so that pre-trimming can be performed and there is no need to perform a post-processing process. [Brief description of the drawings]

[0020] [Figure 1A] 1 is a schematic cross-sectional view showing a cross-sectional structure of a laminate according to a first embodiment. [Figure 1B] 1B is an SEM photograph (×500) showing the cross-linked structure of the support layer in the laminate of FIG. 1A. [Diagram 2] 2 is a schematic cross-sectional view showing the cross-sectional structure of a decorative film used as a decorative layer in the laminate according to the first embodiment. FIG. [Diagram 3] 3 is a schematic cross-sectional view showing a cross-sectional structure of a laminate in accordance with embodiment 1, in which a protective layer is formed on the surface of the laminate. FIG. [Figure 4] 3 is a schematic cross-sectional view showing a step of a method for producing the laminate according to the first embodiment. FIG. [Diagram 5] 1A is a plan view showing a configuration in which a laminate according to the first embodiment has been pre-trimmed to a predetermined shape, and FIG. 1B is a cross-sectional view of the laminate before trimming. [Figure 6] 2 is a schematic cross-sectional view showing a state before hot press processing in the manufacturing method of the shaped article according to the first embodiment. FIG. [Figure 7] 3 is a schematic cross-sectional view showing a hot press process in the manufacturing method of the shaped article according to the first embodiment. FIG. [Figure 8] 3 is a schematic cross-sectional view showing a state after hot press processing in the manufacturing method of the shaped article according to the first embodiment. FIG. [Figure 9] 1 is a schematic cross-sectional view showing a molded article obtained by injection molding in a manufacturing method for a molded article according to a first embodiment. [Figure 10] FIG. 11 is a schematic cross-sectional view showing a cross-sectional structure of a laminate according to a second embodiment. [Figure 11] 10 is a schematic cross-sectional view showing a cross-sectional structure of a laminate of another example according to the second embodiment. FIG. [Figure 12] FIG. 11 is a schematic cross-sectional view showing a cross-sectional structure of a molded product according to a third embodiment. [Figure 13] FIG. 1 is a schematic cross-sectional view showing the cross-sectional structure of the composite sheet of Patent Document 1. [Figure 14] 1 is a schematic cross-sectional view showing a cross-sectional structure of a resin molded member obtained by injection molding the composite sheet of Patent Document 1. FIG. [Figure 15] FIG. 1 is a schematic cross-sectional view showing the cross-sectional structure of the composite sheet of Patent Document 2. [Figure 16] FIG. 2 is a schematic cross-sectional view showing the cross-sectional structure of a three-dimensional composite molded product obtained by injection molding the composite sheet of Patent Document 2. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] The laminate according to the first aspect is a laminate in which a decorative layer, a first adhesive layer, and a support layer are laminated in that order, and the support layer contains two or more materials with different melting points, including a material with a relatively low melting point and a material with a relatively high melting point.

[0022] The laminate according to the second aspect may be the laminate of the first aspect, wherein the low melting point material contained in the support layer fuses between the high melting point materials contained in the support layer to form a cross-linked structure.

[0023] The laminate according to the third aspect may be the laminate of the first aspect above, wherein the first adhesive layer penetrates into the inside of the support layer and is adhered and integrated with the support layer, and the first adhesive layer covers the surface of the support layer.

[0024] The laminate according to a fourth aspect may be the laminate of the first aspect, further comprising a base layer formed between the decorative layer and the first adhesive layer.

[0025] The shaped product of the fifth aspect is a shaped product having a decorative layer, a first adhesive layer, and a support layer laminated in that order, the support layer containing two or more materials with different melting points including a relatively low melting point material and a high melting point material, and the low melting point material contained in the support layer fuses between the high melting point materials contained in the support layer to form a cross-linked structure and maintain the shape.

[0026] A molded article according to a sixth aspect includes the shaped article according to the fifth aspect, and an injection-molded resin integrated with the shaped article.

[0027] The molded product of the seventh aspect includes a member selected from the group consisting of a resin member, a metal member, a glass member, a ceramic member, and a wood member, and the shaped product of the fifth aspect bonded to a surface of the member.

[0028] A method for manufacturing a laminate according to the eighth aspect includes a step of sequentially laminating a decorative layer, a first adhesive layer, and a support layer, and a step of thermocompression bonding the laminated decorative layer, first adhesive layer, and support layer.

[0029] A method for producing a shaped product according to a ninth aspect includes a step of trimming a laminate according to any one of the first to fourth aspects to a predetermined shape, and a step of aligning and fixing the trimmed laminate, and performing a heat press process.

[0030] A method for producing a molded product according to the tenth aspect includes the steps of aligning and fixing the shaped product according to the fifth aspect in an injection molding die and clamping the injection molding die, pouring resin into a cavity between the injection molding die while the injection molding die is clamped, and, after the resin has hardened, opening the injection molding die and removing a molded product in which the shaped product and the hardened resin are integrated.

[0031] A method for producing a molded product according to an eleventh aspect of the present invention provides a molded product by bonding the shaped product according to the fifth aspect to the surface of a member selected from the group consisting of a resin member, a metal member, a glass member, a ceramic member, and a wood member.

[0032] Hereinafter, a laminate, a shaped product, a molded product, and a manufacturing method thereof according to each embodiment of the present disclosure will be described with reference to the accompanying drawings.

[0033] (Embodiment 1) FIG. 1A is a schematic cross-sectional view showing the cross-sectional structure of the laminate 31 according to the first embodiment. FIG. 1B is an SEM photograph (500x) showing the cross-linked structure of the support layer in the laminate of FIG. 1A. As shown in FIG. 1A, the laminate 31 has a decorative layer 1, a first adhesive layer 2, and a support layer 3 laminated in this order. As shown in FIG. 1B, the support layer 3 includes two or more materials with different melting points, including a relatively low melting point material and a high melting point material. According to the laminate according to the first embodiment, the low melting point material in the support layer is melted by thermocompression bonding, and the high melting point material in the support layer is fused to form a cross-linked structure. This improves the density of the support layer, improves the hardness of the support layer, and allows the laminate to stand on its own. Therefore, since alignment can be performed in the subsequent hot press processing and manufacturing process of the molded product, pre-trimming can be performed and there is no need to perform a post-processing step.

[0034] In addition, the adhesive layer penetrates into the support layer and is bonded and integrated by the anchor effect, so that the adhesive layer covers the surface of the support layer, and the adhesive layer itself easily follows the shape of the support layer after the subsequent heat press processing. Furthermore, the decorative layer also follows the shape through the adhesive layer. As a result, the shape followability of the laminate itself is improved, and the shape retention of the shaped product after the heat press processing is improved due to the effect of improving the hardness of the support layer itself described above.

[0035] In addition, this laminate is pre-trimmed to a shape in anticipation of the product shape before being input into the manufacturing method for the molded product, and the trimmed laminate is subjected to the above-mentioned heat press processing to obtain a shaped product of a predetermined shape, and the shaped product can also retain its shape. Furthermore, as described below, the shaped product that has retained its shape can be directly fixed to an injection molding die and molded and integrated with the base resin, thereby realizing a manufacturing method for a molded product that does not require post-processing.

[0036] The members constituting this laminate will be described below.

[0037] <Decorative layer> The decorative layer 1 is not limited as long as it is a commonly used decorative material such as fabric, natural wood, leather, decorative film, etc. The thickness of the decorative layer 1 is not particularly limited depending on the characteristics of the decorative material, but is, for example, in the range of 0.1 mm or more and 3.0 mm or less. When the thickness of the decorative layer 1 is in the above range, the handleability is good and defects such as wrinkles and tears during processing are unlikely to occur. In addition, when the thickness of the decorative layer 1 is in the above range, the hardness of the entire laminate is kept low, flexibility is maintained, and conformability to the product shape is obtained.

[0038] <Decorative film> FIG. 2 is a schematic cross-sectional view showing the cross-sectional structure of the decorative film 4 used as the decorative layer 1 used in the laminate according to the first embodiment. The decorative film 4 is configured by forming a decorative pattern layer 5 on the surface of a base substrate 51. The decorative film 4 is produced using a known printing and coating method such as inkjet printing, gravure printing, screen printing, roll coater, etc., and is formed as a decorative pattern layer 5 having any color or pattern according to customer requests. The base substrate 51 of the decorative film 4 may be formed from a general film material such as polyethylene terephthalate resin, acrylic resin, polycarbonate resin, etc., and is not particularly limited. The average thickness of the base substrate 51 is, for example, 20 μm or more and 300 μm or less. When the average thickness of the base substrate 51 is within the above range, the base substrate 51 is less likely to wrinkle, tear, or warp even during heat drying in the process of forming the decorative pattern layer 5, and is easy to handle. In addition, the decorative film itself has good conformability to the product shape. Furthermore, when produced as a film roll, since the thickness of the base substrate 51 is within the above range, the overall weight is not heavy, handling during transportation is good, and manufacturing costs are kept low. In addition to the pattern layer, the decorative pattern layer 5 may also have functional layers such as electronic wiring and a video display layer produced using known printing and coating techniques. In this way, any color, pattern, and function can be formed in the decorative layer 1 according to customer requests.

[0039] <Protective layer> In addition, in consideration of durability, as shown in FIG. 3, a protective layer 6 may be formed on the outermost surface of the decorative layer 1. When the protective layer 6 is formed, the thickness of the protective layer 6 is, for example, in the range of 3 μm or more and 100 μm or less. When the thickness is in the above range, the protective layer 6 can easily follow the uneven shape of the material surface, pinholes are unlikely to occur, and the protective layer 6 can fully function. In addition, the appearance derived from the protective layer 6 is not apparent, and the texture of the decorative layer 1 is unlikely to be damaged. However, as long as the desired effect is obtained, a thickness outside the above range is also acceptable. Furthermore, it is also possible to add fillers, colorants, etc. to the protective layer 6 itself.

[0040] <First adhesive layer> The first adhesive layer 2 has a role of bonding the decorative layer 1 and the support layer 3. The first adhesive layer 2 is composed of, for example, a vinyl chloride-vinyl acetate copolymer, an olefin-based, a polyolefin-based, a urethane-based, an acrylic-based, or other resin, and is formed in such a manner as to completely cover the surface of the support layer 3. As long as it is possible to bond the decorative layer 1 and the support layer 3, respectively, the material is not limited. In addition, the average thickness of the first adhesive layer 2 is, for example, 2 μm or more and 200 μm or less. When the average thickness of the first adhesive layer 2 is in the above range, the film strength of the first adhesive layer 2 itself is sufficient, and the occurrence of peeling failure such as cohesive failure can be suppressed. Furthermore, the adhesive thickness is sufficient, and sufficient adhesive strength to the decorative layer 1 and the support layer 3 can be obtained. In addition, when the average thickness of the first adhesive layer 2 is in the above range, the manufacturing cost can be kept low. Considering the balance between the film strength, adhesive strength, and manufacturing cost, a film thickness of 3 μm or more and 100 μm or less is more preferable. In addition, the penetration thickness (due to the anchor effect) of the first adhesive layer 2 with respect to the support layer 3 is preferably 5 μm or more. If it is less than 5 μm, the adhesive strength with respect to the support layer 3 is insufficient, and there is a risk of interface peeling failure occurring. The process for forming the first adhesive layer 2 is not limited depending on the handling form. When the first adhesive layer 2 is handled in a liquid state, it may be formed in advance on the decorative layer 1 side or on the support layer 3 side using a known printing / coating process such as spraying, roll coating, inkjet coating, etc. Alternatively, when the first adhesive layer 2 is handled in a solid state such as a sheet, it may be bonded to the decorative layer 1 in advance and then bonded to the support layer 3, or conversely, it may be bonded to the support layer 3 in advance and then bonded to the decorative layer 1. Furthermore, the decorative layer 1, the first adhesive layer 2, and the support layer 3 may be bonded simultaneously. By forming the first adhesive layer 2 in a form that completely covers the surface of the support layer 3, it is possible to improve the conformability to the support layer 3, and since the coating portion is less permeable to air, the laminate 31 can be directly positioned and fixed to the surface of the injection molding die using a vacuum suction mechanism. Furthermore, the coating portion acts as a barrier layer, reducing the seepage of the injection molding resin onto the surface of the laminate 31.

[0041] <Support layer> The support layer 3 improves the strength of the laminate 31 itself by thermocompression bonding, and plays a role in maintaining the laminate 31 in a predetermined processed shape. In addition, the first adhesive layer 2 is formed in a form that completely covers the support layer 3, and the decorative layer 1 is formed through the first adhesive layer 2, so that the improvement in the strength of the support layer 3 itself effectively improves the strength and shape retention of the laminate 31 itself. In other words, the laminate 31 can be made to be self-supporting, and can be aligned to a mold when manufacturing a shaped product and when manufacturing a molded product, making a post-processing step unnecessary.

[0042] The material, structure, thickness, etc. of the support layer 3 can be selected according to the application. The support layer 3 includes two or more materials with different melting points, including a material with a relatively low melting point and a material with a high melting point. For example, when the material is polyethylene terephthalate-based, the weight ratio of polyethylene terephthalate staple fibers with an average fineness of 0.6 to 3.3 dtex (decitex) and heat-fusible polyester staple fibers with a core-sheath structure containing a low melting point component can be 10 / 90 to 90 / 10 (Example 1).

[0043] In the manufacturing process of the support layer, fibers spun from a card spinning machine are folded crosswise obliquely to form a web, and after fiber entanglement by a needle punch machine, the heat-fusible polyester staple fibers are melted by a heat treatment device to form a nonwoven fabric sheet as the support layer. The heat-fusible polyester staple fibers having a core-sheath structure are composite fibers having a core-sheath structure in which the core is made of polyethylene terephthalate, which is a material having a high melting point, and the sheath is made of copolymerized polyester, which is a material having a low melting point. The melting point of the low-melting material of the sheath in the heat-fusible polyester staple fibers is preferably in the range of 100°C to 160°C so that molding can be performed even at a relatively low mold temperature.

[0044] In addition, when a nonwoven fabric is used for the support layer 3, a multilayer structure is formed in which each layer can deform in the shear direction. As a result, the layers of the support layer 3 deform in the shear direction against the tensile deformation and compression deformation that occur during hot press processing, and act as a buffer material, thereby suppressing wrinkles and tears in the laminate 31. The number of layers in the multilayer structure is preferably 5 to 30 layers. If the number of layers is less than 5 layers, the range in which the laminate can deform in the shear direction is narrowed, and the effect of the laminate 31 against wrinkles and tears is reduced. On the other hand, if the number of layers is more than 30 layers, the laminate 31 itself becomes too thick, so that the difference in circumferential length during bending processing becomes large, making it difficult to sufficiently follow the product shape. Considering the effect against wrinkles and tears and bending processability, the number of layers in the multilayer structure is more preferably 10 to 20 layers. However, the number of layers in the multilayer structure is not limited as long as the above-mentioned effect is obtained.

[0045] 1B, the copolymer polyester, which is a low melting point material in the sheath of the heat-fusible polyester staple fibers 21 having a core-sheath structure, is thermally melted by heat compression and is fused to other heat-fusible polyester staple fibers 21 or polyethylene terephthalate staple fibers 22 to form a crosslinked structure. Note that, as shown in FIG. 1B, in the entire support layer, all of the copolymer polyester, which is a low melting point material, does not have to be thermally melted, and fused portions 23 and non-fused portions 24 may exist.

[0046] Furthermore, the weight ratio of the fibers used in the support layer 3 described above in Example 1 is, for example, polyethylene terephthalate staple fiber / core-sheath-bondable polyester staple fiber = 10 / 90 to 90 / 10, and more preferably 30 / 70 to 70 / 30. When the weight ratio of the core-sheath-bondable polyester staple fiber is within the above range, the texture maintains a moderate hardness, the mold followability is good, and sufficient molding accuracy is obtained. Furthermore, since the processing temperature in the heat treatment device also affects the texture of the nonwoven fabric, processing at 100°C to 160°C is preferable, but if the mold followability is good and sufficient molding accuracy is obtained, the processing temperature is not necessarily limited to this processing temperature range.

[0047] In Example 1, a hybrid combination of polyethylene terephthalate staple fibers, which are a high melting point material, and heat-fusible polyester staple fibers having a sheath-core structure including a core portion made of a high melting point material and a sheath portion made of a low melting point material is given as a polyethylene terephthalate-based material, but is not limited thereto. The heat-fusible polyester staple fibers having a sheath-core structure are so-called composite fibers including a high melting point material and a low melting point material in one fiber. The fibers contained in the support layer may be a combination of a basic low melting point material and a high melting point material without using composite fibers having a sheath-core structure. In addition, as described above, the material and structure can be selected according to the application. For example, fibers such as nylon, polypropylene, and polyethylene may be used as raw materials, or different raw materials may be used in combination. Furthermore, the fiber structure of the composite fiber may be formed not in a sheath-core structure but in an island-sea structure or a side-by-side structure. Furthermore, a combination of multiple types of composite fibers may be used. Furthermore, the method of thermocompression bonding is not limited as long as it can improve the strength of the laminate 31 itself and fulfill the role of the support layer 3 of maintaining the laminate 31 in a predetermined processed shape.

[0048] <Method of manufacturing laminate> Next, the molding process (manufacturing method) of the laminate 31 will be described.

[0049] FIG. 4 is a schematic cross-sectional view showing one step of a method for producing the laminate 31 according to the first embodiment. FIG. 5(a) is a plan view showing a configuration in which the laminate 31 according to the first embodiment has been pre-trimmed to a predetermined shape, and (b) is a cross-sectional view of the laminate before trimming.

[0050] FIG. 4 shows a laminate state in which the decorative layer 1 and the support layer 3 are integrated by thermocompression through the first adhesive layer 2. The laminate 31 is formed using a thermocompression device P that can apply heat and pressure. Examples of the thermocompression device P include known devices such as a general-purpose press device that applies pressure with upper and lower heated plates, a multi-stage press device, a vacuum laminator device, and a roll-to-roll press device. The laminate 31 manufactured by these devices is in a stiff sheet state, that is, the laminate 31 can stand on its own, so that the handling during processing can be improved compared to when the decorative layer 1 is used alone.

[0051] 5 shows a laminate 31 that has been pre-trimmed to a shape that takes into account the unevenness and bending of the product shape. Trimming techniques include, for example, shape punching using a Thompson die, laser cutting, hand cutting, etc., but are not limited as long as they can be trimmed to the desired product shape. In this way, since trimming is performed to the desired product shape at the early stage of the molding process, there is no need to provide a positioning part in the margin other than the product shape, and post-processing after heat pressing is not required.

[0052] <Manufacturing method of excipients> Fig. 6 is a schematic cross-sectional view showing a state before the heat press processing in the manufacturing method of the shaped product according to the embodiment 1. Fig. 7 is a schematic cross-sectional view showing a state during the heat press processing in the manufacturing method of the shaped product according to the embodiment 1. Fig. 8 is a schematic cross-sectional view showing a state after the heat press processing in the manufacturing method of the shaped product according to the embodiment 1. 6 shows a state in which the pre-trimmed laminate 31 is placed on the processing surface of the heat press machine N before the heat press processing. Since this laminate 31 can stand on its own, the laminate 31 can be placed on the processing surface of the heat press machine N using a positioning mechanism such as an L-shaped metal fitting that fits the shape of the laminate 31 after trimming.

[0053] FIG. 7 shows a shaped product 34 in which the laminate 31 is heat-pressed by the heat press machine N and shaped into a predetermined product shape. At this time, the laminate 31 is heated by heat conduction from the processing surface of the heat press machine N. The first adhesive layer 2 is easily deformed because its flexibility is improved by the heat. Accordingly, the decorative layer 1 and the support layer 3, which are bonded to the first adhesive layer 2 at the interface, are also easily deformed. In addition, among the materials constituting the support layer 3, the material with a low melting point is thermally melted by heating, and penetrates and fuses between the materials with a high melting point to form a cross-linked structure. The formation of the cross-linked structure improves the hardness of the support layer 3. Since the process of forming the cross-linked structure and the process of heat pressing into the product shape proceed simultaneously in parallel, the support layer 3's ability to conform to the product shape and its shape retention due to the improved hardness are improved. As a result, the laminate 31 changes into a shaped product 34 having a predetermined product shape, and the shape conformability and shape retention for the product shape are improved. The processing temperature during the hot press processing is not limited as long as it is in a temperature range that promotes the flexibility of the first adhesive layer 2 and the support layer 3 and the formation of a crosslinked structure, but a temperature range of 80° C. or higher is preferable.

[0054] After the heat press processing of Figure 8, the cross-linked structure formed in the support layer 3 in Figure 7 is maintained, and a shaped product 34 is obtained that retains the product shape even after being removed from the processing surface of the heat press machine N.

[0055] <Method of manufacturing molded products> FIG. 9 is a schematic cross-sectional view showing a molded product 8 obtained by injection molding in the manufacturing method of a molded product according to the first embodiment. Next, during the injection molding of FIG. 9, the shaped product 34 is placed so as to be fitted into the product shape portion of the injection molding die, and is molded and integrated with the base resin 7 to obtain a molded product 8 having the shaped product 34 on the product exterior surface. Examples of the base resin 7 include general-purpose molding resins such as PMMA resin, ABS resin, PS resin, and PC resin. In addition, it is also possible to handle resins that require molding at high temperatures, such as resins for optical applications and super engineering resins. The shaped product 34 is self-supporting, has high shape retention, and can be positioned in the die. As shown in FIG. 5, the shaped product 34 is pre-trimmed in advance to correspond to the molded product at the stage of the laminate 31 before the heat press processing of FIG. 6, so that the obtained molded product 8 does not require post-processing.

[0056] In addition, the molded product 8 in FIG. 9 shows a state in which only the exterior surface is covered with the decorative layer 1, but after a crease is made on the end surface of the shaped product 34 during the heat press processing shown in FIG. 8, the shaped product 34 and the base resin 7 are molded and integrated from the crease at the injection molding to obtain a molded product in which the shaped product 34 is wrapped not only on the exterior surface but also on the exterior back side. The length and angle of the crease can be changed according to the target product shape. In this way, by designing the mold structure according to the product shape and using the process of the present disclosure, the finishing method of the product shape can be arbitrarily handled. In particular, in the process of wrapping the shaped product 34 up to the exterior back side described above, it is difficult to realize a post-processing-free process in the conventional process in which a positioning mechanism is provided in the margin other than the product shape, and the strength of the manufacturing method of the molded product according to the embodiment 1 of the present disclosure can be maximized. With these configurations, a manufacturing method of a molded product that does not require post-processing can be realized.

[0057] (Embodiment 2) 10 and 11 are schematic cross-sectional views showing the cross-sectional structure of a laminate 32 according to embodiment 2. The same reference numerals are used to describe components that perform the same functions as those in embodiment 1. The laminate 32 shown in FIG. 10 is configured as a laminate 32 in which the decorative layer 1, the second adhesive layer 10, the primer layer 11, the base layer 12, the first adhesive layer 2, and the support layer 3 are formed in this order. In addition, in another example of a laminate 32a shown in FIG. 11, the decorative layer 1, the second adhesive layer 10, the primer layer 11, the base layer 12, the primer layer 11, the first adhesive layer 2, and the support layer 3 are formed in this order.

[0058] <Second adhesive layer> The second adhesive layer 10 is formed for the purpose of bonding the decorative layer 1 and the base layer 11. The components of the second adhesive layer 10 are, for example, vinyl chloride-vinyl acetate copolymers, olefins, polyolefins, urethanes, acrylics, etc., but are not limited to the above-mentioned materials as long as the bonding purpose can be achieved. In order to improve the adhesive strength, the layer may be composed of components that form a cross-linked structure such as a urethane bond. The average film thickness is 3 μm or more and 200 μm or less. When the average film thickness is in the above range, the adhesive thickness is sufficient and sufficient adhesive strength is obtained. In addition, when the average film thickness is in the above range, the manufacturing cost is kept low. More preferably, the layer is 5 μm or more and 100 μm or less.

[0059] <Primer layer> The primer layer 11 has a role of firmly adhering the base layer 12 to the first adhesive layer 2 or the second adhesive layer 10, and is provided on one side or both sides of the base layer 12. For example, if the component of the first adhesive layer 2 or the second adhesive layer 10 is an acrylic adhesive, the primer layer 11 of the same acrylic component can be provided, and the compatibility can be selected in consideration of the nature of the adhesive. In addition, by forming a crosslinked structure such as a urethane bond in the primer layer 11, the film strength of the primer layer 11 itself can be improved, or if the first adhesive layer 2 or the second adhesive layer 10 has a similar component, a crosslinked structure can be formed with each of them, greatly improving the interlayer adhesive force itself. Note that if the first adhesive layer 2 or the second adhesive layer 10 can be directly and firmly adhered to the base layer 12, it is not necessarily necessary to provide the primer layer 11.

[0060] <Base material layer> The base layer 12 plays a role in improving the shape conformability of the laminate 32, 32a and in improving durability against poor appearance caused by resin heat and pressure during injection molding. The material is, for example, a general-purpose polymer film that is generally used as an industrial product, such as polyethylene terephthalate, polycarbonate, acrylic, polyolefin, etc. The base layer 12 does not need to be composed of only one type of component, and one or both sides of the base layer 12 may be treated in combination with other substances, such as an easy-adhesion coat. In addition, a surface modification treatment such as a corona treatment or a plasma treatment may be performed. Furthermore, the base layer 12 may be treated to enhance design and functionality. For example, design may be achieved by printing a pattern or coloring the material of the base layer 12 itself. In addition, functionality may be achieved by having an IR / UV cut function or forming an electronic circuit on the base layer 12 using a conductive material. In this way, as long as the base layer 12 achieves its original purpose of improving the shape conformability of the laminate 32 and improving durability during injection molding, other design and functionality can be imparted without any restrictions. The laminate 32 is manufactured by a manufacturing method using thermocompression bonding similar to that shown in Figure 4 of embodiment 1, the shaped product is further manufactured by hot pressing processing similar to that shown in Figures 5 to 8 of embodiment 1, and the molded product can be processed by the molded product manufacturing method described above in Figure 9.

[0061] With the configuration of this embodiment 2, the base material layer 12 is provided between the decorative layer 1 and the support layer 3, thereby improving the strength of the laminate 32 itself, and realizing laminates 32, 32a with improved shape conformability during subsequent hot press processing and improved durability against the heat and pressure of the resin during injection molding.

[0062] (Embodiment 3) <Molded products> 12 is a schematic cross-sectional view showing the cross-sectional structure of a molded article 13 according to embodiment 3. Note that the same reference numerals are used to denote components that perform the same functions as those in embodiments 1 and 2. The molded article 13 according to embodiment 3 has a structure in which a laminate 31, a third adhesive layer 14, and a reinforcing layer 15 formed in a separate process are laminated in this order and integrated.

[0063] <Third adhesive layer> The third adhesive layer 14 has an average thickness of 1 μm or more and 100 μm or less, and may be in the form of a liquid or sheet, a thermoplastic adhesive, a thermosetting adhesive, or the like. In addition, the components may be, for example, a vinyl chloride-vinyl acetate copolymer, an olefin, a polyolefin, a urethane, an acrylic, or the like, and are not limited to these, as long as the purpose of bonding the support layer 3 and the reinforcing layer 15 can be achieved. In addition, the third adhesive layer 14 may be formed in advance on the back surface of the support layer 3 of the laminate 31, or may be formed in advance on the surface of the reinforcing layer 15.

[0064] <Reinforcing layer> The material of the reinforcing layer 15 can be selected according to the application. For example, general-purpose molding resins such as PMMA resin, ABS resin, PS resin, and PC resin, resins for optical applications, super engineering resins, metal members, glass members, ceramic members, and wood materials can be selected according to the required application, and the process for manufacturing them is not limited. The components of the third adhesive layer 14 may be selected according to the material of the reinforcing layer 15. Examples of the process for integrating the laminate 31 and the reinforcing layer 15 include hand attachment and vacuum / pressure molding, and are not limited as long as the laminate 31 and the reinforcing layer 15 can be bonded via the third adhesive layer 14. As in the first embodiment, a fold is formed in the laminate 31 during heat press processing, and the laminate 31 is integrated with the reinforcing layer 15 to obtain a molded product in which the laminate 31 is wrapped around the back side of the exterior.

[0065] Incidentally, in embodiment 3, a molded product using the laminate 31 according to embodiment 1 is taken as an example, but the laminates 32, 32a described above in embodiment 2 can also be integrated with the reinforcing layer 15 in a similar process to form a molded product. [Industrial Applicability]

[0066] The laminates, shaped articles, and molded articles according to the present disclosure contribute to high functionality and design in fields requiring decoration, such as the exteriors of various home appliances and the interiors of vehicles. [Explanation of symbols]

[0067] 1 Decorative layer 2 First adhesive layer 3 Support layer 4. Decorative Film 5 Decorative pattern layer 6 Protective layer 7 Base resin 8 Molded products 9 Molded products 10 Second adhesive layer 11 Primer layer 12 Base material layer 13 Molded products 14 Third adhesive layer 15 Reinforcement layer 21 Heat-bondable polyester staple fiber (core-sheath structure) 22 Polyethylene terephthalate staple fiber 23 Fusion part 24 Non-fused part 31 Laminate 32, 32a Laminate 34 Shaped products 51 Base Material

Claims

1. A laminate comprising a decorative layer, a first adhesive layer, and a support layer, in that order. The support layer is a laminate containing two or more materials with different melting points, including a material with a relatively low melting point and a material with a high melting point.

2. The laminate according to claim 1, wherein the low-melting-point material contained in the support layer fuses with the high-melting-point material contained in the support layer, forming a cross-linked structure.

3. The laminate according to claim 1, wherein the first adhesive layer penetrates into the interior of the support layer and adheres to and integrates with the support layer, and the first adhesive layer covers the surface of the support layer.

4. The laminate according to claim 1, wherein a base material layer is formed between the decorative layer and the first adhesive layer.

5. A shaped product comprising a decorative layer, a first adhesive layer, and a support layer laminated in that order, wherein the support layer includes two or more materials with different melting points, including a material with a relatively low melting point and a material with a high melting point. A shaped product in which the low-melting-point material contained in the support layer fuses with the high-melting-point material contained in the support layer, forming a cross-linked structure and maintaining its shape.

6. The shaped product described in claim 5, A molded article comprising an injection-molded resin integrated with the aforementioned excipient.

7. One component selected from the group consisting of resin components, metal components, glass components, ceramic components, and wood components, A molded article comprising the shaped article described in claim 5, which is bonded to the surface of the member.

8. A process of sequentially laminating a decorative layer, a first adhesive layer, and a support layer, A method for manufacturing a laminate, comprising the step of heat-pressing the laminated decorative layer, the first adhesive layer, and the support layer together.

9. A step of trimming the laminate according to any one of claims 1 to 4 into a predetermined shape, The process involves aligning and fixing the trimmed laminate and then heat-pressing it, A method for manufacturing excipients, including those mentioned above.

10. A step of aligning and fixing the molded product described in claim 5 to an injection molding die, and clamping the injection molding die, With the injection molding die clamped, the process involves pouring resin into the cavity between the injection molding dies, After the resin has hardened, the injection molding die is opened to remove the molded product in which the shaped part and the hardened resin have been integrated. A method for manufacturing molded articles, including the method described above.

11. A method for manufacturing a molded article, comprising bonding the shaped part described in claim 5 to the surface of one member selected from the group consisting of a resin member, a metal member, a glass member, a ceramic member, and a wood member.

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