Method for manufacturing laminated member

Abstract

To provide a method for manufacturing a laminated member that can suppress the reduction of printing accuracy.SOLUTION: In a method for manufacturing a laminated member, a laminated member 1, which has a printed layer 3 having a molded surface 3a with an uneven embossed portion 31 and a printed surface 3b facing away from the molded surface 3a, and a printing layer 4 printed on the printed surface 3b, is manufactured using a molding die member 7 having a molding surface 7b with an uneven reverse embossed portion 71 that is die symmetrical to the embossed portion 31. The method for manufacturing a laminated member includes a molding step of molding the molded surface 3a with the molding surface 7b, and a printing step of printing the printing layer 4 on the printed surface 3b while the molded surface 3a is in close contact with the molding surface 7b.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a laminated member by laminating each layer using printing.

Background Art

[0002] As shown in Patent Document 1, a decorative sheet used for an interior member of a vehicle includes a skin layer, an intermediate layer, and a design layer. Concavo-convex embossed portions are formed on the surface of the skin layer. The intermediate layer is printed on the back surface of the skin layer. The design layer is printed on the back surface of the intermediate layer.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The decorative sheet is manufactured, for example, by the following manufacturing method. First, the skin layer is set on the printing table of a printing machine with the surface facing down (the back surface facing up). Next, the intermediate layer is printed on the back surface (upper surface) of the skin layer. Then, the design layer is printed on the back surface (upper surface) of the intermediate layer. In this way, the decorative sheet is manufactured using printing.

[0005] However, during printing, only the apexes of the convex portions of the embossed portions on the surface (lower surface) of the skin layer are in contact with the upper surface of the printing table. In other words, the skin layer is supported by the printing table from below only by the apexes of the convex portions of the embossed portions.

[0006] During printing, a load (such as printing pressure) is applied to the skin layer from above. The apex of the convex portion of the embossed portion is supported by the printing table from below. Therefore, among the back surfaces of the skin layer, the portion corresponding to the apex of the convex portion is difficult to deform even when a load is applied. On the other hand, portions other than the apex of the convex portion (for example, the concave portion of the embossed portion) are not supported by the printing table from below. Therefore, among the back surfaces of the skin layer, the portion corresponding to the portion other than the apex of the convex portion is likely to deform when a load is applied. Therefore, the printing accuracy of the intermediate layer and the design layer is likely to decrease. Therefore, an object of the present disclosure is to provide a method for manufacturing a laminated member capable of suppressing a decrease in printing accuracy.

Means for Solving the Problems

[0007] (1) To solve the above problems, a method for manufacturing a laminated member according to the present disclosure includes a printed layer having a surface to be formed with an uneven embossed portion and a printing surface facing away from the surface to be formed, and a printing layer printed on the printing surface. A method for manufacturing a laminated member, which manufactures a laminated member using a molding die member having a molding surface with an uneven back embossed portion that is die-symmetric with the embossed portion, the method comprising: a molding step of molding the surface to be formed with the molding surface; and a printing step of printing the printing layer on the printing surface while the surface to be formed is in close contact with the molding surface.

[0008] According to this configuration, in the printing step, the printing layer is printed on the printing surface while the surface to be formed is in close contact with the molding surface. That is, while the surface to be formed is entirely supported by the molding surface (specifically, the convex portion of the embossed portion is supported by the concave portion of the back embossed portion, and the concave portion of the embossed portion is supported by the convex portion of the back embossed portion), the printing layer is printed on the printing surface. Therefore, compared with the case where only the apex of the convex portion of the embossed portion is supported, the printing surface is less likely to deform. Also, compared with the case where only the apex of the convex portion of the embossed portion is supported, variations in the load distribution on the printing surface are less likely to occur. Therefore, a decrease in the printing accuracy of the printing layer with respect to the printing surface can be suppressed.

[0009] (1-1) In the configuration of (1) above, the molding die member is a texture transfer separator, and the molding surface of the texture transfer separator preferably has a releasability with respect to the surface to be molded. According to this configuration, after the printing process, the texture transfer separator can be easily peeled off from the surface to be molded.

[0010] (2) In the configuration of (1) or (1-1) above, the laminated member is a decorative sheet including a light-transmissive skin layer, an intermediate layer having light transmissivity and disposed on the back side of the skin layer, and a design layer having light transmissivity and disposed on the back side of the intermediate layer. The layer to be printed is the skin layer, the surface to be molded is the surface of the skin layer, the surface to be printed is the back surface of the skin layer, the printing layer is the intermediate layer, and the printing process is an intermediate layer printing process of printing the intermediate layer on the back surface of the skin layer while the surface of the skin layer is in close contact with the molding surface, and further preferably has a design layer printing process of printing the design layer on the back surface of the intermediate layer.

[0011] According to this configuration, for example, compared with the case where the intermediate layer is disposed by coating, variations in the layer thickness of the intermediate layer can be suppressed. In addition, it is possible to suppress the intermediate layer from becoming excessively thick. The same applies to the design layer. Also, misalignment in the layer direction (layer expansion direction, a direction intersecting the lamination direction) between the three layers (skin layer, intermediate layer, design layer) can be suppressed.

Effect of the Invention

[0012] According to the method for manufacturing a laminated member of the present disclosure, a decrease in printing accuracy can be suppressed.

Brief Description of the Drawings

[0013]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Embodiments for Carrying Out the Invention

[0014] Hereinafter, embodiments of the laminated member manufacturing method of the present disclosure will be described.

[0015] FIG. 1 shows a partial perspective view of a door trim in which a decorative sheet (hereinafter, appropriately referred to as "the decorative sheet of the present embodiment") manufactured by the laminated member manufacturing method according to an embodiment of the laminated member manufacturing method of the present disclosure is arranged. FIG. 2 shows a perspective view within frame II of FIG. 1. FIG. 3 shows an exploded perspective view within frame II of FIG. 1. FIG. 4 shows a sectional view taken along the line IV-IV of FIG. 2 (a sectional view in the front-back direction). In FIGS. 2 to 4, the embossed portion 31 is schematically shown.

[0016] [Arrangement and Configuration of Decorative Sheet] First, the arrangement and configuration of the decorative sheet of the present embodiment will be described. As shown in FIG. 1, the decorative sheet (laminated member) 1 is arranged on the door trim 9 of the passenger compartment. As shown in FIGS. 1 to 4, the door trim 9 includes the decorative sheet 1 and a light source unit 90. The decorative sheet 1 and the light source unit 90 are laminated in this order from the front side (upper side, inside the passenger compartment) to the back side (lower side, outside the passenger compartment).

[0017] As shown in FIGS. 3 to 4, the decorative sheet 1 includes an outer skin layer (printing target layer) 3, an intermediate layer (printing layer) 4, and a design layer 5 from the front side to the back side. The outer skin layer 3 is made of synthetic resin and has a layered structure. The outer skin layer 3 has light transmissivity and flexibility. The outer skin layer 3 includes a front surface (molding target surface. upper surface) 3a and a back surface (printing target surface. lower surface) 3b. The front surface 3a and the back surface 3b face away from each other in the front-back direction. The front surface 3a has a plurality of uneven embossed portions 31. That is, the embossed portion 31 has a concave portion 31a that indents downward and a convex portion 31b that protrudes upward. The back surface 3b is a flat surface (smooth surface) without the embossed portion 31. As shown in FIG. 1, the front surface 3a is exposed inside the vehicle compartment. The design layer 5 described later is irradiated with light from the light source portion 90 on the back side. Due to the light, the wood grain pattern of the design layer 5 is displayed on the front surface 3a of the outer skin layer 3.

[0018] The intermediate layer 4 is printed on the back surface 3b of the outer skin layer 3. The intermediate layer 4 is made of light-transmissive ink and has a layered structure. The intermediate layer 4 has light transmissivity and flexibility. The intermediate layer 4 has lower light transmissivity than the outer skin layer 3. The intermediate layer 4 is smoky translucent. The intermediate layer 4 is colored and transparent.

[0019] The design layer 5 is printed on the back surface of the intermediate layer 4. The design layer 5 is made of light-transmissive ink and has a layered structure. The design layer 5 has light transmissivity and flexibility. The design layer 5 has higher light transmissivity than the intermediate layer 4. A wood grain pattern is displayed on the design layer 5 when viewed from the front side.

[0020] The light source portion 90 is disposed on the back side of the design layer 5. The light source portion 90 includes a plurality of light sources (LEDs) 900. The plurality of light sources 900 are distributed throughout the layer direction (layer unfolding direction. direction intersecting the stacking direction. plane direction) of the light source portion 90. The entire surface of the light source portion 90 can emit light. The light from the light source 900 reaches the surface of the door trim 9 (that is, the front surface 3a of the outer skin layer 3) via the design layer 5, the intermediate layer 4, and the outer skin layer 3.

[0021] When the light source unit 90 is off, the light source 900 is turned off. That is, the backlight for the decorative sheet 1 is in the off state. Here, the light transmittance of each layer is set so that, in descending order, it is the skin layer 3 (the most permeable), the design layer 5, and the intermediate layer 4 (the least permeable). For this reason, it is difficult for the user to visually recognize the wood grain pattern of the design layer 5 from the front side (inside the vehicle) of the decorative sheet 1. Also, it is easy for the user to visually recognize the three-dimensional shape of the uneven portion 31 of the skin layer 3 and the color of the intermediate layer 4 integrally from the front side (inside the vehicle) of the decorative sheet 1.

[0022] When the light source unit 90 is on, the light source 900 is turned on. That is, the backlight for the decorative sheet 1 is in the on state. As described above, the light transmittance of each layer is set so that, in descending order, it is the skin layer 3, the design layer 5, and the intermediate layer 4. For this reason, it is easy for the user to visually recognize the wood grain pattern of the design layer 5 from the front side of the decorative sheet 1. In this way, the decorative sheet 1 can display two types of designs on the surface 3a of the skin layer 3 according to whether the light source unit 90 is on or off.

[0023] [Method for manufacturing a laminated member] Next, the method for manufacturing a laminated member according to the present embodiment will be described. The method for manufacturing a laminated member includes a molding step, an intermediate layer printing step, a design layer printing step, and a release step. Note that the method for manufacturing a laminated member is executed with the decorative sheet 1 shown in FIGS. 1 to 4 turned upside down.

[0024] FIG. 5(A) shows a schematic diagram of the molding step of the method for manufacturing a laminated member according to the present embodiment. FIG. 5(B) shows a schematic diagram of the intermediate layer printing step of the same method for manufacturing a laminated member. FIG. 6(A) shows a schematic diagram of the design layer printing step of the same method for manufacturing a laminated member. FIG. 6(B) shows a schematic diagram of the release step of the same method for manufacturing a laminated member.

[0025] (Molding step) In this process, the skin layer 3 is produced, and the embossed portion 31 is formed on the surface 3a of the skin layer 3. As shown in Fig. 5(A), the forming device 8 includes a hopper 80, a screw feeder 81, a heater 82, a die 83, and a pair of rollers 84 and 85. The raw material (synthetic resin raw material) A of the skin layer 3 is stored in the hopper 80. The screw feeder 81 includes a pipe 810 and a screw shaft 811. The hopper 80 is connected near the rear end (upstream end) of the side peripheral wall of the pipe 810. The screw shaft 811 is rotatable around its own axis and is inserted into the pipe 810. The heater 82 is annularly mounted on the side peripheral wall of the pipe 810. The die 83 is connected to the opening at the front end (downstream end) of the pipe. The pair of rollers 84 and 85 are arranged on the front side of the die 83. The pair of rollers 84 and 85 are arranged so as to be separated from and opposed to each other.

[0026] In this process, the raw material A is supplied from the hopper 80 to the screw feeder 81 by its own weight. The pellet-shaped (solid) raw material A is conveyed from the rear side to the front side by the screw of the screw shaft 811. During the conveyance, the raw material A is softened and melted by the heat transfer from the heater 82 and becomes a fluid state (gel state, syrup state). The gel-like raw material A is formed into a strip shape by the die 83. The formed raw material A merges with the embossing transfer separator 7 supplied from below and passes between the pair of rollers 84 and 85. Note that an uneven back embossed portion 71 (see Fig. 5(B)) is arranged in advance on the back surface (forming surface, peeling surface, upper surface) 7b of the embossing transfer separator 7. The embossing transfer separator 7 is included in the concept of the "molding die member" of the present disclosure. The back surface 7b is included in the concept of the "forming surface" of the present disclosure.

[0027] When passing between the pair of rollers 84 and 85, the upper raw material A and the lower embossing transfer separator 7 are laminated to produce a strip-shaped laminated sheet B. The surface (formed surface, lower surface) 3a of the raw material A and the back surface 7b of the embossing transfer separator 7 are pressure-bonded. By the pressure bonding, the shape of the back embossed portion 71 is transferred to the surface 3a, and the embossed portion 31 (see Fig. 5(B)) is formed on the surface 3a.

[0028] Specifically, as shown in FIG. 5(B), the back embossed portion 71 has a recessed portion 71a that indents downward and a convex portion 71b that protrudes upward. Due to the recessed portion 71a, a convex portion 31b is formed on the surface 3a. Due to the convex portion 71b, a recessed portion 31a is formed on the surface 3a. Therefore, the embossed portion 31 (recessed portion 31a, convex portion 31b) exhibits an uneven shape that is mirror-symmetrical to the back embossed portion 71 (recessed portion 71a, convex portion 71b). As shown in FIG. 5(A), the surface of the upper roller 84 is flat. For this reason, the back surface (the surface to be printed, the upper surface) 3b of the raw material A is formed into a flat surface when the roller 84 is in pressure contact therewith. After the raw material A passes between the pair of rollers 84 and 85, it solidifies by cooling (natural cooling). In this way, the skin layer 3 with the embossed portion 31 is produced.

[0029] (Intermediate layer printing process) In this process, with the back surface 7b of the embossing transfer separator 7 in close contact with the surface 3a of the skin layer 3, the intermediate layer 4 is printed on the back surface 3b of the skin layer 3. Specifically, as shown in FIG. 5(B), a laminate (a laminate of the skin layer 3 and the embossing transfer separator 7) B1 obtained by cutting a laminate sheet (a laminate sheet of the skin layer 3 and the embossing transfer separator 7) B shown in FIG. 5(A) into a predetermined shape is placed on a printing table (not shown), and the intermediate layer 4 is printed on the back surface 3b of the skin layer 3 by a silk screen printing machine (not shown). When the intermediate layer 4 has a multi-layer structure (for example, a structure having a surface layer (transparent layer) on the skin layer 3 side and a back layer (colored layer) on the design layer 5 side), each layer is printed in order.

[0030] (Design layer printing process) In this process, as shown in FIG. 6(A), in the same manner as in the intermediate layer printing process, with the back surface 7b of the embossing transfer separator 7 in close contact with the surface 3a of the skin layer 3, the design layer 5 is printed on the back surface (upper surface) of the intermediate layer 4 of the laminate (a laminate of the intermediate layer 4, the skin layer 3, and the embossing transfer separator 7) C by a silk screen printing machine (not shown). When the design layer 5 has a multi-layer structure (for example, a structure in which a plurality of layers are laminated to form a wood grain pattern when viewed from the front side), each layer is printed in order.

[0031] (Release process) In this process, as shown in Fig. 6(B), the embossing transfer separator 7 is peeled off from the laminate (the laminate of the design layer 5, the intermediate layer 4, the skin layer 3, and the embossing transfer separator 7) D after printing the design layer 5. Note that the back surface 7b of the embossing transfer separator 7 has releasability with respect to the front surface 3a of the skin layer 3. Therefore, the embossing transfer separator 7 can be easily peeled off. In this way, the decorative sheet 1 of the present embodiment is produced.

[0032] [Function and effect] Next, the function and effect of the laminate member manufacturing method of the present embodiment will be described. As shown in Fig. 5(B), in the intermediate layer printing process, the intermediate layer 4 is printed on the back surface 3b of the skin layer 3 while the back surface 7b of the embossing transfer separator 7 is in close contact with the front surface 3a of the skin layer 3. That is, while the front surface 3a is entirely supported by the back surface 7b (specifically, the convex portion 31b of the embossed portion 31 is supported by the concave portion 71a of the back embossed portion 71, and the concave portion 31a of the embossed portion 31 is supported by the convex portion 71b of the back embossed portion 71, respectively), the intermediate layer 4 is printed on the back surface 3b. Therefore, compared with the case where only the apex of the convex portion 31b of the embossed portion 31 is supported (when the embossing transfer separator 7 is not arranged), the back surface 3b is less likely to be deformed. Also, compared with the case where only the apex of the convex portion 31b of the embossed portion 31 is supported, when printing the intermediate layer 4, the load distribution on the back surface 3b is less likely to vary. Thus, a decrease in the printing accuracy of the intermediate layer 4 with respect to the back surface 3b can be suppressed.

[0033] As shown in Fig. 6(B), the back surface 7b of the embossing transfer separator 7 has releasability with respect to the front surface 3a of the skin layer 3. Therefore, in the release process, the back surface 7b of the embossing transfer separator 7 can be easily peeled off from the front surface 3a of the skin layer 3.

[0034] As shown in FIG. 5(B), in the intermediate layer printing step, the intermediate layer 4 is disposed on the back surface 3b of the skin layer 3 by printing (silk screen printing machine). Therefore, the variation in the layer thickness (front-back direction thickness) of the intermediate layer 4 can be suppressed as compared with the case where the intermediate layer 4 is disposed by, for example, painting. Further, it is possible to suppress the layer thickness of the intermediate layer 4 from becoming excessively large. The same applies to the design layer 5 shown in FIG. 6(A). Further, the displacement in the layer direction between the three layers (skin layer 3, intermediate layer 4, design layer 5) can be suppressed.

[0035] Assume that the design layer 5 has lower light transmittance than the intermediate layer 4. In this case, the intermediate layer 4 is more easily seen through than the design layer 5. Therefore, when the backlight is turned off, the design layer 5 (that is, the wood grain pattern) is easily seen through the intermediate layer 4 and displayed on the surface of the skin layer 3.

[0036] In this regard, according to the decorative sheet 1 of the present embodiment, the design layer 5 has higher light transmittance than the intermediate layer 4. Therefore, the intermediate layer 4 is less easily seen through than the design layer 5. Therefore, when the backlight is turned off, it is possible to suppress the design layer 5 from being seen through the intermediate layer 4 and displayed on the surface of the skin layer 3.

[0037] The skin layer 3 has a concavo-convex portion 31 on the surface. Therefore, when the backlight is turned off, external light can be diffusely reflected between the unevenness of the concavo-convex portion 31. Therefore, the boundary portion of the design layer 5 (for example, when the design layer 5 has a wood grain pattern, the portion where the shade of the wood grain is prominent) can be blurred. Therefore, it is possible to suppress the boundary portion of the design layer 5 from being seen through and displayed on the surface of the skin layer 3. Further, when the backlight is turned on, a three-dimensional design can be displayed on the surface of the skin layer 3. The skin layer 3 is colorless and transparent and has higher light transmittance than the design layer 5 and the intermediate layer 4. Therefore, the concavo-convex portion 31 becomes prominent mainly when the light is turned off.

[0038] The decorative sheet 1 is disposed on the door trim 9. Therefore, by switching on and off the backlight, the design and texture of the door trim 9 can be given a two-sided property. Specifically, when the light source unit 90 is turned off, a leather-like design can be displayed on the door trim 9, and when the light source unit 90 is turned on, a wood-grain-like design can be displayed on the door trim 9.

[0039] [Others] As described above, embodiments of the method for manufacturing a laminated member of the present disclosure have been described. However, the embodiments are not particularly limited to the above forms. It is also possible to implement in various modified forms and improved forms that those skilled in the art can perform.

[0040] (Regarding the configuration) The layer structure of each layer (skin layer 3, intermediate layer 4, design layer 5) of the decorative sheet 1 is not particularly limited. It may be a single-layer structure or a multi-layer structure. Among the layers, another layer may be interposed between two adjacent layers in the front-back direction. Also, another layer may be disposed on the back side of the design layer 5 or the front side of the skin layer 3.

[0041] The shape etc. (shape (shape along the layer direction, shape in the lamination direction), size, number of arrangements, position, etc.) of the concave portion 31a of the embossed portion 31 of the skin layer 3 is not particularly limited. The same applies to the convex portion 31b of the embossed portion 31. The concave portion 31a and the convex portion 31b may be arranged regularly or irregularly. The pattern of the embossed portion 31 is not particularly limited. Examples of the pattern of the embossed portion 31 include patterns including one or more selected from leather patterns, wood-grain patterns, rock-grain patterns, sandy patterns, satin patterns, fabric patterns, geometric patterns, etc.

[0042] The design of the design layer 5 is not particularly limited. Preferably, it is better for the design of the skin layer 3 (such as the textured part 31) and the design of the intermediate layer 4 (such as color) to be different. In this way, according to the lighting and extinguishing of the backlight, the design displayed on the surface 3a of the skin layer 3 can be given a two-sided property. Examples of the design of the design layer 5 include designs containing one or more selected from patterns (such as wood grain patterns, marble patterns, stone wall patterns, polka dot patterns, stripe patterns, lattice patterns, etc.), characters (such as alphabets, hiragana, katakana, Chinese characters, numbers, braille, etc.), figures (such as polygons, circles, etc.), symbols (such as buttons for operating the device, icons indicating the state of the device, etc.).

[0043] The color of the design displayed on the skin layer 3 may be a single color or multiple colors. The color may be expressed on the skin layer 3 by one or more selected from each layer and the light source unit 90. The light transmittance of each layer is not particularly limited. It may be colorless transparent, colored transparent, translucent, etc. The degree of light transmittance between the design layer 5 and the intermediate layer 4 is not particularly limited. The design layer 5 may have higher light transmittance or lower light transmittance than the intermediate layer 4. The light transmittance of the design layer 5 and the intermediate layer 4 may be the same. The color (hue, chroma, lightness) of each layer and the light source 900 is not particularly limited.

[0044] The luminance of the light source 900 is not particularly limited. The type, number of arrangements, and position of the light source 900 are not particularly limited. The light source 900 may be an organic EL sheet, an inorganic EL sheet, a phosphorescent sheet, etc. Also, the light source unit 90 may include the light source 900 and a light guide plate (such as an acrylic plate).

[0045] The type of interior member on which the decorative sheet 1 is disposed is not particularly limited. For example, door trim 9, seat, armrest, floor, ceiling, instrument panel, glove box, steering wheel, center console, register, etc. may be mentioned. The surface of the interior member (the surface 3a of the skin layer 3) may be flat or curved. The orientation of the interior member (the orientation of the front and back of the decorative sheet 1) is not particularly limited. That is, the front and back direction may be the vertical direction, the horizontal direction, or a direction intersecting the vertical and horizontal directions. The decorative sheet 1 may be disposed on interior members of transportation equipment other than vehicles (motorcycles, ships, aircraft, etc.), buildings (buildings, houses, etc.). Further, the decorative sheet 1 may be disposed on exterior members (such as the outer wall of transportation equipment or building). The type of the laminated member is not particularly limited. The laminated member may be a sheet other than the decorative sheet 1 (a sheet not requiring the light source unit 90). For example, an anti-slip sheet or building materials may be used.

[0046] (Regarding the material) The material of the skin layer 3 is not particularly limited. For example, synthetic leather, resin, elastomer, etc. may be mentioned. Specifically, acrylic, polyethylene terephthalate, polycarbonate, polyvinyl chloride, silicone, epoxy, polyurethane, styrene-based thermoplastic elastomer, olefin-based thermoplastic elastomer, dynamically crosslinked thermoplastic elastomer, etc. may be mentioned. The skin layer 3 may contain a colorant (such as colored polyethylene), a light diffusing agent (such as silicone, acrylic, titanium oxide), and a light absorber (such as titanium black, carbon black).

[0047] The material of the intermediate layer 4 is not particularly limited. For example, resins and elastomers such as acrylic, polyethylene terephthalate, polycarbonate, polyvinyl chloride, silicone, polyester, epoxy, polyurethane, styrene-based thermoplastic elastomer, olefin-based thermoplastic elastomer, dynamically crosslinked thermoplastic elastomer, etc. may be mentioned. The intermediate layer 4 may contain the aforementioned colorant, light diffusing agent, and light absorber.

[0048] The material of the design layer 5 is not particularly limited. For example, resins and elastomers such as acrylic, polyethylene terephthalate, polycarbonate, polyvinyl chloride, silicone, polyester, epoxy, polyurethane, styrene-based thermoplastic elastomer, olefin-based thermoplastic elastomer, dynamically crosslinked thermoplastic elastomer, etc. may be mentioned. The design layer 5 may contain the aforementioned colorant, light diffusing agent, and light absorbing agent.

[0049] When each layer has light diffusing properties, the method for imparting such light diffusing properties is not particularly limited. For example, a light diffusing agent (such as silicone, acrylic, titanium oxide, etc.) having a refractive index different from that of the base material may be dispersed in a transparent base material.

[0050] (Regarding the method for manufacturing the laminated member) The printing methods in the intermediate layer printing process shown in FIG. 5(B) and the design layer printing process shown in FIG. 6(A) are not particularly limited. Screen printing (such as silk screen printing), gravure printing, inkjet printing, flexographic printing, etc. may be used. The similarities and differences in the printing methods used in the intermediate layer printing process and the design layer printing process are not particularly limited.

[0051] The design layer printing process shown in FIG. 6(A) may not be executed. That is, the design layer 5 may be laminated on the intermediate layer 4 by adhesion, pressure bonding, sticking, vapor deposition, welding, coating, etc. For example, the design layer 5 may be adhered to the back surface of the intermediate layer 4. Also, the design layer 5 may be coated on the back surface of the intermediate layer 4.

[0052] The subsequent processes (the intermediate layer printing process shown in FIG. 5(B), the design layer printing process shown in FIG. 6(A), and the release process shown in FIG. 6(B)) may be performed without cutting the laminated sheet B (strip-shaped long continuous body) in FIG. 5(A). That is, it is sufficient that the decorative sheet 1 of a predetermined shape is completed at the stage before being arranged on the door trim 9 shown in FIG. 1.

[0053] The method for manufacturing the laminated member may have steps other than the intermediate layer printing step shown in Fig. 5(B) and the design layer printing step shown in Fig. 6(A). For example, on the back side of the design layer 5, a diffusion layer having light diffusibility may be disposed to diffuse light from a plurality of light sources (point light sources) 900 of the light source unit 90. In this case, after the design layer printing step, a diffusion layer printing step of printing the diffusion layer on the back surface of the design layer 5 may be performed.

[0054] In the forming step shown in Fig. 5(A), the state of the raw material A before forming the surface (the surface to be formed) 3a is not particularly limited. It may be in a liquid state, a fluid state, a solid state, or the like. As shown in Fig. 5(B), after the forming step, as long as the dimpled portion 31 is disposed on the surface 3a.

[0055] In the forming step, the method of forming the surface 3a (that is, the dimpled portion 31) by the back surface (the forming surface) 7b is not particularly limited. For example, injection molding, extrusion molding, press molding, and the like can be mentioned. As an example, when forming the surface 3a by injection molding, a back dimpled portion 71 is disposed on the mold surface (the forming surface) of the mold (the forming die member), and the liquid raw material A is injected into the cavity of the mold, and the raw material A is cooled and cured, whereby the surface 3a may be formed. Note that the printing step after the forming step may be performed while the surface 3a is in close contact with the mold surface of the mold.

Description of reference numerals

[0056] 1: Decorative sheet, 3: Skin layer, 3a: Surface, 3b: Back surface, 31: Dimpled portion, 31a: Concave portion, 31b: Convex portion, 4: Intermediate layer, 5: Design layer, 7: Dimpled transfer separator (forming die member), 7b: Back surface (forming surface), 71: Back dimpled portion, 71a: Concave portion, 71b: Convex portion, 8: Forming device, 80: Hopper, 81: Screw feeder, 810: Pipe, 811: Screw shaft, 82: Heater, 83: Die, 84: Roller, 85: Roller, 9: Door trim, 90: Light source unit, 900: Light source, A: Raw material, B: Laminated sheet, B1 to D: Laminated body

Claims

1. A printed layer having a formed surface with concavo-convex indentations and a printed surface facing away from the formed surface, and A printing layer printed on the printed surface, A method for manufacturing a laminated member, comprising using a molding die member having a molding surface with reverse concavo-convex indentations that are die-symmetric to the indentations, the method including: A molding step of molding the formed surface with the molding surface; and A printing step of printing the printing layer on the printed surface while the formed surface remains in close contact with the molding surface. A method for manufacturing a laminated member.

2. The laminated member is a decorative sheet including a light-transmissive skin layer, an intermediate layer having light transmissivity and disposed on the back side of the skin layer, and a design layer having light transmissivity and disposed on the back side of the intermediate layer, The printed layer is the skin layer, the formed surface is the surface of the skin layer, the printed surface is the back surface of the skin layer, The printing layer is the intermediate layer, The printing step is an intermediate layer printing step of printing the intermediate layer on the back surface of the skin layer while the surface of the skin layer remains in close contact with the molding surface, and The method for manufacturing a laminated member according to claim 1, further including a design layer printing step of printing the design layer on the back surface of the intermediate layer.

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