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

Abstract

A laminate in which a decorative layer, an adhesive layer, and a support layer are laminated in the stated order, wherein: the support layer includes two or more kinds of materials, having different melting points, that include a material having a relatively low melting point and a material having a relatively high melting point; and the 10% modulus value, which is evaluated as a tensile strength at a 10% elongation in a tensile test according to JIS L1913, of a 25 mm-width test piece of the laminate is 5-23N.

Description

Laminate, shaped product, molded product, manufacturing method of laminate, manufacturing method of shaped product, manufacturing method of molded product

[0001] 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.

[0002] In recent years, the diversification of customer preferences has led to a growing need for decorative techniques that offer a wide range of design expressions and high-quality design features for exterior parts of home appliances and interior parts of automobiles. One such decorative technique is the insert molding method, in which decorative materials are positioned and fixed in an injection mold and integrated with the injected resin. This insert molding method allows for the production of molded products using decorative materials produced in sheets, such as thinly sliced ​​wood veneers or decorative films printed on thick substrates. While traditional insert molding techniques have typically been used to decorate relatively shallow, plate-like shapes such as panels, there has been a growing demand for the decoration of deep-drawn shapes. Therefore, it is necessary to develop an insert molding method that offers high design freedom and can flexibly respond to customer requests. On the other hand, when insert molding these sheet-formed decorative materials, a mechanism for fixing the decorative material to the injection molding mold is generally required, such as drilling positioning holes in the margins around the product periphery in the decorative material and providing pins for installing the positioning holes in the injection molding mold. The term "insert molding" as defined in this disclosure refers to a technique in which the entire exterior surface of the product is formed with the decorative material, and depending on the product specifications, it also includes shapes in which the decorative material is wrapped around from the exterior surface to the back of the product. Furthermore, a deep-drawn shape refers to a shape in which the vertical length (depth) from the end of the product that forms the recess to the bottom surface of the product is 10 mm or more and 100 mm or less.

[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 Figures 14 and 15.

[0004] Composite sheet 200 in Fig. 14 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 the same molten adhesive filling layer interposed therebetween. Also, as shown in Fig. 15, resin molded member 202 is formed by integrating the surface of composite sheet 200 on which nonwoven fabric 104 is formed with base resin 201 by injection molding.

[0005] Furthermore, Patent Document 2 discloses a composite sheet in which a woven material and a plastic sheet are integrated. This configuration is shown in Figures 16 and 17. Composite sheet 400 is formed by integrating woven material 301 and a 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 a three-dimensional molded object 304, which is then molded and integrated with a base resin to form a composite three-dimensional molded object 305.

[0006] Japanese Patent No. 6288825 Japanese Patent Application Laid-Open No. 2012-218432

[0007] The conventional example of Patent Document 1 prevents the adhesive layer (between the base resin 201 and the resin film 103) formed on the outer surface of the resin film 103 from melting or flowing due to the heat, pressure, or resin flow of the base resin 201 when the composite sheet 200 and the base resin 201 are integrated by injection molding. However, because of the layered structure in which the fabric material 102 is sandwiched between the resin films 103, the flexibility of the composite sheet 200 itself depends on the physical properties of the resin film 103, resulting in a uniform flexibility that does not change significantly during processing. Therefore, when deep drawing, such as concave drawing, is required, the composite sheet 200 is unable to fully respond to the compressive force during deep drawing, making it difficult to suppress compression wrinkles. Even if deep drawing is performed while the margins of the composite sheet 200's product exterior are fixed with positioning pins or the like during mold fixing, the material may be pulled together due to compression at the product edges, resulting in wrinkles. However, since the composite sheet 200 has a layer structure in which the fabric material 102 is sandwiched between the resin films 103, it has a certain level of strength, and therefore the positioning accuracy relative to the injection molding die can be ensured.

[0008] In addition, in the conventional example of Patent Document 2, the woven material 301 is subjected to an impregnation process to improve the processability of the composite sheet 400. However, since the transparent hard acrylic resin sheet 303 itself has rigidity and its flexibility does not change, similar to Patent Document 1, when deep drawing such as concave drawing is required, it is unable to fully follow the compressive force during deep drawing, making it difficult to suppress compression wrinkles. On the other hand, in terms of positioning accuracy, similar to Patent Document 1, the material rigidity is ensured to a degree that prevents misalignment.

[0009] As in these conventional examples, for panels and other plate-like shapes with a relatively shallow product depth, the material has a rigidity that ensures positioning accuracy and is designed to have a material configuration that can follow the product shape during processing. On the other hand, for deep drawing, there remain challenges in finding composite sheet materials that have both flexibility to suppress wrinkles and rigidity to ensure positioning accuracy.

[0010] The present disclosure aims to provide a laminate that can achieve both improved conformability to deep-drawn shapes and high positioning ability in an injection molding die by changing the flexibility of the laminate itself before and after processing.

[0011] The laminate according to the present disclosure is a laminate in which a decorative layer, an adhesive layer, and a support layer are laminated in this order, and the support layer contains two or more types of materials with different melting points, including a material with a relatively low melting point and a material with a high melting point, and a 25 mm wide test piece of the laminate has a 10% modulus value, evaluated as the tensile strength at an elongation rate of 10% in a tensile test in accordance with JIS L1913, of 5 N or more and 23 N or less.

[0012] The shaped product according to the present disclosure is a shaped product laminated in this order with a decorative layer, a first adhesive layer, and a support layer, wherein the support layer contains two or more types of materials with different melting points, including a relatively low-melting-point material and a high-melting-point material, and a 25 mm wide test piece of the shaped product has a 10% modulus value of 30 N or more, which is evaluated as the tensile strength at an elongation rate of 10% in a tensile test in accordance with JIS L1913.

[0013] A molded article according to the present disclosure includes the above-described 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] The method for manufacturing a laminate according to the present disclosure includes the steps of sequentially laminating a decorative layer, a first adhesive layer, and a support layer 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, and thermocompressing the laminated decorative layer, first adhesive layer, and support layer together so that the surface temperature of the support layer is equal to or lower than the melting point of the low melting point material.

[0016] The method for producing a shaped product according to the present disclosure includes the steps of trimming the laminate to a predetermined shape, and aligning and fixing the trimmed laminate, and then subjecting it to heat pressing.

[0017] The method for manufacturing a molded product according to the present disclosure includes the steps of aligning and fixing the shaped product in an injection mold and clamping the injection mold, pouring resin into a cavity between the injection molds while the injection molds are clamped, and, after the resin has hardened, opening the injection mold and removing a molded product in which the shaped product and the hardened resin are integrated.

[0018] The method for manufacturing a molded product according to the present disclosure provides a molded product by bonding the above-described shaped product 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 wooden member.

[0019] According to the laminate of the present disclosure, the highly flexible laminate can follow the compressive force that occurs during deep drawing in the hot press process to form the shaped body, thereby suppressing the occurrence of compression wrinkles.

[0020] Furthermore, in the shaped product, the low-melting-point material of the support layer constituting the laminate melts due to the heat generated during the deep drawing process and heat press process, and fuses with the high-melting-point material of the support layer to form a crosslinked structure. As a result, the hardness of the laminate in the shaped product after the heat press process is improved, and shape retention and high positioning accuracy in the injection molding die can be ensured.

[0021] 1A is a schematic cross-sectional view showing the cross-sectional structure of a laminate according to embodiment 1. FIG. 1B is an SEM photograph (500x magnification) showing the cross-linked structure of a support layer in the laminate of FIG. 1A. FIG. 1C is a schematic cross-sectional view showing the cross-sectional structure of a decorative film used as a decorative layer for use in a laminate according to embodiment 1. FIG. 1D is a schematic cross-sectional view showing the cross-sectional structure of a laminate having a protective layer formed on the surface of the laminate according to embodiment 1. FIG. 1E is a schematic cross-sectional view showing one step of a method for manufacturing a laminate according to embodiment 1. FIG. 1F is a plan view (1) showing a configuration in which a laminate according to embodiment 1 has been pre-trimmed to a predetermined shape, and a cross-sectional view (2) of the laminate before trimming. FIG. 1G is a plan view (1) showing a configuration in which a laminate according to embodiment 1 has been pre-trimmed to a predetermined shape, and a cross-sectional view (2) of the laminate before trimming. FIG. 1H is a schematic cross-sectional view showing a state before heat-pressing in a method for manufacturing a shaped product according to embodiment 1. FIG. 1I is a schematic cross-sectional view showing a state before heat-pressing in a method for manufacturing a shaped product according to embodiment 1. FIG. 1J is a schematic cross-sectional view showing a state during heat-pressing in a method for manufacturing a shaped product according to embodiment 1. FIG. 1J is a schematic cross-sectional view showing a state during heat-pressing in a method for manufacturing a shaped product according to embodiment 1. FIG. 1J is a schematic cross-sectional view showing a state after heat-pressing in a method for manufacturing a shaped product according to embodiment 1. FIG. 1 is a schematic cross-sectional view showing a state after hot press processing in the method for producing a shaped article according to embodiment 1. FIG. 2 is a diagram showing 10% modulus values ​​evaluated as tensile strength at an elongation rate of 10% in a tensile test according to JIS L1913 for the laminate according to example 1 and the shaped article according to example 2 in embodiment 1. FIG. 3 is a schematic cross-sectional view showing a molded article obtained by injection molding in the method for producing a molded article according to embodiment 1. FIG. 4 is a schematic cross-sectional view showing a molded article obtained by injection molding in the method for producing a molded article according to embodiment 1. FIG. 5 is a schematic cross-sectional view showing the cross-sectional structure of a laminate according to embodiment 2. FIG. 6 is a schematic cross-sectional view showing the cross-sectional structure of a laminate of another example according to embodiment 2. FIG. 7 is a schematic cross-sectional view showing the cross-sectional structure of a molded article according to embodiment 3. FIG. 8 is a schematic cross-sectional view showing the cross-sectional structure of a composite sheet according to Patent Document 1. FIG. 9 is a schematic cross-sectional view showing the cross-sectional structure of a resin-molded member obtained by injection molding the composite sheet according to Patent Document 1. FIG. 10 is a schematic cross-sectional view showing the cross-sectional structure of a composite sheet according to Patent Document 2. FIG. 11 is a schematic cross-sectional view showing the cross-sectional structure of a composite three-dimensional molded product obtained by injection molding the composite sheet according to Patent Document 2.

[0022] The laminate of the first aspect is a laminate formed by laminating a decorative layer, a first adhesive layer, and a support layer in this order, wherein the support layer contains two or more types of materials with different melting points, including a material with a relatively low melting point and a material with a high melting point, and wherein a 25 mm wide test piece of the laminate has a 10% modulus value, evaluated as the tensile strength at an elongation rate of 10% in a tensile test in accordance with JIS L1913, of 5 N or more and 23 N or less.

[0023] The laminate according to the second aspect may be the same as that of the first aspect, in which the low-melting-point material contained in the support layer fuses between the high-melting-point material contained in the support layer to form a cross-linked structure.

[0024] The laminate according to the third aspect may be the laminate according to the first or second aspect, wherein the first adhesive layer penetrates into the support layer, adheres and integrates with the support layer, and the first adhesive layer covers the surface of the support layer.

[0025] The laminate according to a fourth aspect is the laminate of any one of the first to third aspects, wherein a base layer is formed between the decorative layer and the first adhesive layer.

[0026] The shaped product of the fifth aspect 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 types of materials with different melting points, including a relatively low-melting-point material and a high-melting-point material, and a 25 mm wide test piece of the shaped product has a 10% modulus value of 30 N or more, which is evaluated as the tensile strength at an elongation rate of 10% in a tensile test in accordance with JIS L1913.

[0027] The shaped product of the sixth aspect may be the same as that of the fifth aspect, in which the low-melting point material contained in the support layer fuses with the high-melting point material contained in the support layer to form a cross-linked structure, thereby maintaining the shape.

[0028] The shaped product of the seventh aspect may be the product of the fifth or sixth aspect, wherein the product depth, expressed as the length from the opening surface of the recess of the laminate constituting the shaped product to the bottom of the recess, is 10 mm or more and 100 mm or less.

[0029] A molded article according to an eighth aspect includes the shaped article according to any one of the fifth to seventh aspects, and an injection-molded resin integrated with the shaped article.

[0030] The molded product of the ninth aspect 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 a shaped product of any one of the fifth to seventh aspects bonded to the surface of the member.

[0031] The method for manufacturing a laminate according to the tenth aspect includes the steps of sequentially laminating a decorative layer, a first adhesive layer, and a 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 thermocompressing the laminated decorative layer, first adhesive layer, and support layer together so that the surface temperature of the support layer is equal to or lower than the melting point of the low-melting-point material.

[0032] The method for producing a laminate according to an eleventh aspect may be the method for producing a laminate according to the tenth aspect, wherein a 25 mm wide test piece of the laminate obtained by the thermocompression bonding step has a 10% modulus value evaluated as tensile strength at an elongation of 10% in a tensile test in accordance with JIS L1913 of 5 N or more and 23 N or less.

[0033] The method for manufacturing a shaped product according to the twelfth aspect includes the steps of trimming a laminate according to any one of the first to fourth aspects to a predetermined shape, and aligning and fixing the trimmed laminate and subjecting it to heat pressing.

[0034] The method for producing a shaped product according to the thirteenth aspect may be the same as the twelfth aspect, wherein a 25 mm wide test piece of the shaped product obtained by the hot press processing step has a 10% modulus value of 30 N or more, evaluated as the tensile strength at an elongation rate of 10% in a tensile test in accordance with JIS L1913.

[0035] The method for manufacturing a molded product according to the fourteenth aspect includes the steps of aligning and fixing a shaped product according to any one of the fifth to seventh aspects 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.

[0036] The method for manufacturing a molded product according to the fifteenth aspect obtains a molded product by bonding a shaped product according to any one of the fifth to seventh aspects 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 wooden member.

[0037] Hereinafter, laminates, shaped articles, molded articles, and methods for manufacturing these according to embodiments of the present disclosure will be described with reference to the accompanying drawings. Note that substantially identical components in the drawings are designated by the same reference numerals.

[0038] (Embodiment 1) Fig. 1A is a schematic cross-sectional view showing the cross-sectional structure of a laminate 31 according to embodiment 1. Fig. 1B is an SEM photograph (500x magnification) 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 material with a relatively low melting point and a material with a high melting point.

[0039] According to the laminate of embodiment 1, the hardness of the support layer changes before and after heat treatment such as heat pressing to obtain a shaped product. That is, during heat pressing, the occurrence of wrinkles is suppressed by deep drawing the flexible laminate, and after heat pressing, the low-melting-point material contained in the support layer melts, and the high-melting-point material contained in the support layer fuses to form a crosslinked structure, which improves the hardness of the support layer and allows for the production of a shaped product that maintains a predetermined shape.

[0040] The adhesive layer penetrates into the support layer and adheres and integrates with it through the anchor effect, so that the adhesive layer covers the surface of the support layer, making it easier for the adhesive layer itself to conform to the shape of the support layer in the shaped product after heat pressing. Furthermore, the decorative layer also conforms to the shape via the adhesive layer. As a result, the shape conformability of the laminate itself is improved, and the aforementioned effect of improving the hardness of the support layer itself improves the shape retention of the shaped product after heat pressing.

[0041] Furthermore, by directly fixing the shaped product that has retained its shape to the injection molding die, the shaped product can be accurately aligned with the injection molding die, and can be molded integrally with the base resin.

[0042] The members that make up this laminate will be described below.

[0043] <Decorative Layer> The decorative layer 1 is not limited to any commonly used decorative material, such as fabric, natural wood, leather, or decorative film. 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 less likely to occur. Furthermore, 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.

[0044] <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 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. This decorative film 4 is produced using known printing and coating techniques, such as inkjet printing, gravure printing, screen printing, and roll coating, 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 common film material, such as polyethylene terephthalate resin, acrylic resin, or polycarbonate resin, without any particular limitation. 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 thermal drying or other processes in the process of forming the decorative pattern layer 5, making it easy to handle. Furthermore, the decorative film itself has good conformability to the shape of the product. 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 is good for carrying, etc., and manufacturing costs can be kept low. In addition to the design layer, the decorative design layer 5 may also be formed with functional layers such as electronic wiring and a video display layer produced using known printing and coating techniques. In this way, any color, design, and function can be formed in the decorative layer 1 according to customer requests.

[0045] <Protective Layer> In consideration of durability, a protective layer 6 may be formed on the outermost surface of the decorative layer 1, as shown in FIG. 3 . When the protective layer 6 is formed, its thickness is, for example, in the range of 3 μm or more and 100 μm or less. When the thickness is within the above range, it easily conforms to the uneven shape of the material surface, pinholes are less likely to occur, and the function of the protective layer 6 can be fully exerted. In addition, the appearance derived from the protective layer 6 is not revealed, and the texture of the decorative layer 1 is less likely to be impaired. However, as long as the desired effect is obtained, a thickness outside the above range is not a problem. Furthermore, it is also possible to add fillers, colorants, etc. to the protective layer 6 itself.

[0046] <First Adhesive Layer> The first adhesive layer 2 serves to bond 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 resin, a polyolefin-based resin, a urethane-based resin, an acrylic-based resin, or the like, and is formed in a manner that completely covers the surface of the support layer 3. The material is not limited as long as it is capable of bonding the decorative layer 1 and the support layer 3 to each other. Furthermore, the average film thickness of the first adhesive layer 2 is, for example, 2 μm or more and 200 μm or less. When the average film thickness of the first adhesive layer 2 is within the above range, the first adhesive layer 2 itself has sufficient film strength, and peeling defects such as cohesive failure can be suppressed. Furthermore, the adhesive thickness is sufficient, and sufficient adhesive strength between the decorative layer 1 and the support layer 3 can be obtained. Furthermore, when the average film thickness of the first adhesive layer 2 is within the above range, manufacturing costs can be kept low. Considering the balance between film strength, adhesive strength, and manufacturing costs, a film thickness of 3 μm or more and 100 μm or less is more preferable. Furthermore, the penetration thickness (due to the anchoring effect) of the first adhesive layer 2 relative to the support layer 3 is preferably 5 μm or more. If it is less than 5 μm, the adhesive strength to the support layer 3 may be insufficient, which may result in poor interfacial peeling. 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 pre-formed on the decorative layer 1 side or on the support layer 3 side using a known printing or coating process, such as spraying, roll coating, or inkjet coating. Alternatively, when the first adhesive layer 2 is handled in a solid state, such as a sheet, it may be pre-adhered to the decorative layer 1 and then adhered to the support layer 3, or conversely, it may be pre-adhered to the support layer 3 and then adhered to the decorative layer 1. Furthermore, the decorative layer 1, the first adhesive layer 2, and the support layer 3 may be adhered 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 conformability to the support layer 3, and because the coating portion is less permeable to air, it is possible to position and fix the laminate 31 directly to the surface of the injection molding die using a vacuum suction mechanism. Furthermore, the coating portion acts as a barrier layer, reducing seepage of the injection molding resin onto the surface of the laminate 31.

[0047] <Support Layer> The support layer 3 improves the strength of the laminate 31 itself through thermocompression bonding and plays a role in maintaining the laminate 31 in a predetermined processed shape. Furthermore, the first adhesive layer 2 is formed in a form that completely covers the support layer 3, and the decorative layer 1 is formed via the first adhesive layer 2. Therefore, 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 self-supporting and can be aligned to a mold when producing a shaped product or a molded product, eliminating the need for post-processing steps.

[0048] 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, the weight ratio of polyethylene terephthalate staple fibers with an average fineness of 0.6 to 3.3 dtex (decitex) to 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).

[0049] In the manufacturing process for the support layer, fibers spun from a carding machine are folded obliquely crosswise to form a web, and after entangling the fibers using a needle punch machine, the heat-fusible polyester staple fibers are melted using 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, a material with a high melting point, and the sheath is made of a copolymer polyester, a material with a low melting point. The melting point of the low-melting-point 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.

[0050] Furthermore, when a nonwoven fabric is used for the support layer 3, a multilayer structure is formed in which each layer is deformable in the shear direction. This allows the layers of the support layer 3 to deform in the shear direction against tensile and compressive deformations that occur during hot press processing, acting as a buffer and suppressing wrinkling and tearing of the laminate 31. The number of layers in the multilayer structure is preferably 5 to 30. With fewer than five layers, the range of shear deformation is narrowed, reducing the effectiveness of the laminate 31 in preventing wrinkling and tearing. On the other hand, with more than 30 layers, the laminate 31 itself becomes too thick, resulting in large circumferential differences during bending, making it difficult to adequately conform to the product shape. Considering the effectiveness against wrinkling and tearing and bending processability, the number of layers in the multilayer structure is more preferably 10 to 20. However, the number of layers in the multilayer structure is not limited as long as the aforementioned effects are obtained.

[0051] 1B, by being thermocompressed, the copolymer polyester, which is a low-melting material in the sheath portion of the heat-fusible polyester staple fibers 21 having a core-sheath structure, is thermally melted and 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, it is not necessary for all of the copolymer polyester, which is a low-melting material, to be thermally melted in the entire support layer, and fused portions 23 and non-fused portions 24 may exist.

[0052] 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, good mold conformability, and sufficient molding precision can be 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 this processing temperature range is not necessarily limited as long as good mold conformability and sufficient molding precision can be obtained.

[0053] 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 made of a high-melting-point material and a sheath made of a low-melting-point material, was cited as a polyethylene terephthalate-based material. However, the present invention is not limited to this. The heat-fusible polyester staple fibers having a sheath-core structure are so-called composite fibers that include a high-melting-point material and a low-melting-point material in a single 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, rather than a composite fiber having a sheath-core structure. As described above, the material and structure may be selected according to the application. For example, nylon, polypropylene, polyethylene-based fibers, etc. 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 into an island-sea structure or a side-by-side structure, rather than a sheath-core 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.

[0054] <Flexibility (Modulus Value) of Laminate> Figure 9 is a diagram showing the 10% modulus value evaluated as the tensile strength at an elongation rate of 10% in a tensile test according to JIS L1913 for the laminate according to Example 1 in Embodiment 1 and the shaped article according to Example 2. The horizontal axis of Figure 9 is the elongation rate (%), and the vertical axis is the load (N). As shown in Figure 9, when a load is applied to the test piece, the test piece elongates. The load at the point where the elongation rate is 10% is the 10% modulus value.

[0055] As described above, the laminate 31 includes the decorative layer 1, the first adhesive layer 2, and the support layer 3, which are formed in this order. The flexibility of the laminate 31 before and after hot pressing is significantly affected by the flexibility of the support layer 3. The flexibility of the laminate 31 is evaluated using the 10% modulus value, which is the tensile strength at an elongation of 10% in a tensile test in accordance with JIS L1913. The modulus value evaluates the load required for a given elongation (10% in this case). In the case of the laminate 31, the degree of hardening of the support layer 3 can be evaluated. For example, if the fusion between the low-melting-point material and the high-melting-point material constituting the support layer 3 is not sufficiently advanced, the fibers of the support layer 3 are easily deformed, reducing the load required for a given elongation. As a result, the modulus value of the laminate 31 becomes relatively small. On the other hand, if the heat of the hot press processing sufficiently fuses the low-melting-point material and the high-melting-point material that make up the support layer 3, the fibers of the support layer 3 fuse together to form a crosslinked structure. Therefore, deformation is less likely to occur, and the load required for a given elongation increases, resulting in a relatively large modulus value of the laminate 31. In this way, evaluating the modulus value makes it possible to confirm the degree of hardening of the support layer 3 and can be used as an index for confirming the flexibility of the laminate 31.

[0056] When processing into the deep-drawn shape described above, the 10% modulus value of the laminate 31 before hot pressing is preferably 5N or more and 23N or less (tensile test in accordance with JIS L1913, modulus value at 10% elongation, test piece width 25 mm). Furthermore, a modulus of 8N or more and 20N or less is preferable, and particularly a modulus of 8N or more and 17N or less improves conformability to shape deformation during deep drawing, and a significant effect of suppressing compression wrinkles during processing can be expected. If the modulus is less than 5N, the flexibility is too high, making it difficult to set up the device during shaping processing. On the other hand, if the modulus is greater than 23N, the flexibility of the laminate 31 is impaired, and shape conformability is reduced.

[0057] Furthermore, when the relative degree of hardening based on the 10% modulus value of the laminate 31 in the shaped body after heat pressing is taken as 100%, the relative degree of hardening of the 10% modulus value of the laminate 31 before heat pressing (10% modulus value of the laminate before heat pressing / 10% modulus value of the laminate in the shaped body after heat pressing) is preferably 15% or more and 80% or less. More specifically, 20% or more and 70% or less is preferable, and in particular, if the relative degree of hardening is 20% or more and 60% or less, it becomes easier to follow shape deformation during processing. If the relative degree of hardening is less than 15%, as mentioned above, it becomes difficult to set up the device during shaping processing. On the other hand, if the degree of hardening is greater than 80%, the flexibility of the laminate 31 is impaired, and shape followability is reduced.

[0058] When the laminate 31 is flexible and highly compliant, the fibers constituting the support layer 3 can deform independently. In other words, when deformation occurs during deep drawing, the fibers can deform and move freely, allowing the support layer 3 alone to absorb the stress of the deformation. This suppresses the occurrence of compression wrinkles. On the other hand, if the fibers constituting the support layer 3 are fused together and fixed by a cross-linked structure, the fibers cannot move freely, and the support layer 3 deforms as if it were a single, uniform object. If deep drawing is performed in this state, the compression deformation occurring in the support layer 3 is transmitted directly to the decorative layer 1 via the first adhesive layer 2, resulting in wrinkles and a poor appearance on the surface of the decorative layer 1. While the above modulus value and relative hardness ranges are shown as indicators of the flexibility of the laminate 31, the modulus value and relative hardness outside the above ranges are not limited as long as the desired effect is achieved.

[0059] <Manufacturing Method of Laminate> Next, a molding process (manufacturing method) of the laminate 31 will be described.

[0060] FIG. 4 is a schematic cross-sectional view showing one step of a method for manufacturing the laminate 31 according to the first embodiment.

[0061] 4 shows a laminate state in which the decorative layer 1 and the support layer 3 are integrated by thermocompression bonding via the first adhesive layer 2. The laminate 31 is formed using a thermocompression bonding device P that can apply heat and pressure. Examples of the thermocompression bonding device P include well-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.

[0062] When manufacturing the laminate 31 using a thermocompression bonding device P, it is preferable to keep the modulus value and relative hardness of the laminate 31 within the aforementioned range. Therefore, it is necessary to adjust the amount of heat applied to the support layer 3. As an indicator of this, it is preferable that the surface temperature of the support layer 3 immediately after thermocompression bonding is a temperature below the melting point of the low-melting-point material constituting the support layer 3. The temperature immediately after thermocompression bonding refers to the temperature when the processing section of the thermocompression bonding device P is completely separated from the surface of the laminate 31. If the temperature is finished at a temperature above the melting point, fusion between the low-melting-point material and the high-melting-point material constituting the support layer 3 will progress, increasing the hardness of the support layer 3. Adjustment parameters for the amount of heat applied to the support layer 3 include, for example, the surface temperature, pressure, and time of the processing section when a general-purpose press device is used; and the surface temperature of the heating roll, the contact pressure between the rolls, the conveying speed, and the tension of the material when a roll-to-roll press device is used. The specific heat adjustment parameters and set values ​​vary depending on the selected thermocompression bonding device P, but the combination is not limited as long as the surface temperature of the support layer 3 immediately after thermocompression bonding is equal to or lower than the melting point of the low-melting-point material that makes up the support layer 3. The laminate 31 manufactured in this manner has flexibility before the hot-pressing process and can follow the deep-drawn shape during the hot-pressing process.

[0063] <Laminate Molding Process> Fig. 5A(a) is a plan view showing a configuration in which the laminate 31 according to embodiment 1 has been pre-trimmed to a predetermined shape without using positioning tabs, Fig. 5A(b) is a cross-sectional view of the laminate before trimming, Fig. 5B(a) is a plan view showing a configuration in which the laminate 31 according to embodiment 1 has been pre-trimmed to a predetermined shape using positioning tabs 33, and Fig. 5B(b) is a cross-sectional view of the laminate before trimming.

[0064] 5A(a) and 5B(a) show a laminate 31 that has been pre-trimmed to a shape that takes into account the unevenness and bending of the product shape. Trimming methods include, for example, shape punching using a Thomson die, laser cutting, and hand cutting, but are not limited as long as they can be trimmed to the desired product shape. If trimming to the desired product shape is performed in the early stages of the molding process, there is no need to provide positioning sections in the margins outside the product shape, eliminating the need for post-processing after the heat press process. Alternatively, as shown in FIG. 5B(a), it is possible to provide a minimum number of positioning tabs 33, etc., provided that the laminate 31 after heat press has a hardness that ensures positioning accuracy in the injection molding die.

[0065] Example 1 In the laminate according to Example 1, for example, a polyester woven fabric was used as a decorative layer, and a polyester nonwoven fabric (basis weight 90 g / m ２ ) are integrated by thermocompression bonding via an olefin-based hot melt as a first adhesive layer.

[0066] The laminate was processed under the following conditions: the above materials were laminated together, and the laminate was obtained in a roll-to-roll processing device at a temperature of 160° C., a speed of 5.2 m / min, and a pressure of 0.7 MPa.

[0067] The laminate obtained in Example 1 had a 10% modulus value, which is evaluated as the tensile strength at an elongation rate of 10% in a tensile test in accordance with JIS L1913, of 17.0 N, as shown in FIG.

[0068] <Method for manufacturing shaped product> Figures 6A and 6B are schematic cross-sectional views showing the state before the heat press processing in the method for manufacturing a shaped product according to embodiment 1. Figures 7A and 7B are schematic cross-sectional views showing the state during the heat press processing in the method for manufacturing a shaped product according to embodiment 1. Figures 8A and 8B are schematic cross-sectional views showing the state after the heat press processing in the method for manufacturing a shaped product according to embodiment 1.

[0069] 6A and 6B show a state in which a pre-trimmed laminate 31 is placed on the processing surface of a heat press machine N before heat pressing. The laminate 31 in Fig. 6A 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 conforms to the shape of the laminate 31 after trimming. Alternatively, as shown in Fig. 6B, the laminate 31 can be placed by inserting a positioning pin 35 of the heat press machine N into a positioning tab 33 provided on the laminate 31.

[0070] 7A and 7B show a shaped product 34 in which a laminate 31 is heat-pressed in a heat press machine N and shaped into a predetermined product shape. FIG. 7B shows the state in which a positioning tab 33 provided on the laminate 31 and a positioning pin 35 of the heat press machine N are used. 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 becomes more flexible due to the heat, making it more susceptible to deformation. Accordingly, the decorative layer 1 and the support layer 3, which are bonded to the first adhesive layer 2 at their interfaces, also become more susceptible to deformation. Furthermore, among the materials constituting the support layer 3, the materials with lower melting points melt when heated, penetrating and fusing between the materials with higher melting points, forming a crosslinked structure. The formation of the crosslinked structure improves the hardness of the support layer 3. Because the process of forming the crosslinked structure and the process of heat pressing into the product shape proceed simultaneously, the support layer 3's ability to conform to the product shape and its shape retention are improved due to its improved hardness. As a result, the laminate 31 is transformed into a shaped article 34 having a predetermined product shape, and the shape-following ability and shape-retention ability to the product shape are improved. The processing temperature during the hot press processing is not limited as long as it is within 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 preferred.

[0071] After the heat press processing of Figures 8A and 8B, the cross-linked structure formed in the support layer 3 in Figures 7A and 7B is maintained, and a shaped product 34 is obtained that retains its product shape even after being removed from the processing surface of the heat press processing machine N.

[0072] <Shaped Item> The shaped item 34 is constructed by laminating a decorative layer, a first adhesive layer, and a support layer in this order. Of these, 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. Furthermore, the modulus value of the shaped item 34 is preferably 30N or more and 100N or less (tensile test in accordance with JIS L1913, modulus value at 10% elongation, test piece width 25mm). Furthermore, a modulus value of 30N or more and 80N or less is preferable, and particularly, a modulus value of 30N or more and 60N or less can accommodate positioning and fixing to the injection molding die and material deformation associated with resin flow during injection molding. If the modulus value is less than 30N, the accuracy of positioning and fixing to the injection molding die is impaired. If the modulus value is greater than 100N, the shaped item 34 cannot accommodate material deformation associated with resin flow during injection molding, and cracks or other damage may occur.

[0073] The low-melting-point material contained in the support layer may fuse between the high-melting-point material contained in the support layer to form a crosslinked structure, thereby maintaining the shape.

[0074] Furthermore, as shown in Fig. 8A, the product depth d, which is expressed as the length from the opening surface 38 of the recess 36 of the laminate constituting the shaped product 34 to the bottom of the recess, may be 10 mm or more and 100 mm or less. While the recess 36 is defined by three surfaces in Fig. 8A, this is not limited to this. For example, the recess may be formed by two adjacent surfaces at an angle. Furthermore, each surface constituting the recess may not be flat but may be curved.

[0075] Example 2 The shaped product according to Example 2 was obtained by, for example, hot pressing the laminate according to Example 1 at a temperature of 90°C and waiting for 30 seconds at the bottom dead center.

[0076] The shaped product of Example 2 obtained had a 10% modulus value, which is evaluated as the tensile strength at an elongation rate of 10% in a tensile test in accordance with JIS L1913, of 40.9 N, as shown in FIG.

[0077] <Method of Manufacturing Molded Product> FIGS. 10A and 10B are schematic cross-sectional views showing a molded product 8 obtained by injection molding in the method of manufacturing a molded product according to the first embodiment. Next, during the injection molding process shown in FIG. 10A , a shaped product 34 is fitted into the product shape portion of the injection mold and integrated with the base resin 7 to obtain a molded product 8 having the shaped product 34 on its exterior surface. As shown in FIG. 9B , the positioning tab 33 of the shaped product 34 may be fitted into the positioning pin 35 of the injection mold. Examples of the base resin 7 include general-purpose molding resins such as PMMA resin, ABS resin, PS resin, and PC resin. Other resins that require high-temperature molding, such as resins for optical applications and super engineering resins, can also be used. The shaped product 34 is self-supporting, has high shape retention, and can be aligned within the mold. As shown in FIG. 5 , the shaped product 34 is pre-trimmed to correspond to the molded product at the laminate 31 stage before the hot press processing shown in FIG. 6 , eliminating the need for post-processing for the resulting molded product 8.

[0078] While the molded product 8 in FIG. 10A or 10B shows only the exterior surface covered with the decorative layer 1, a crease can be made in the end surface of the shaped product 34 during the hot press processing shown in FIG. 8A and 8B , and then the shaped product 34 and the base resin 7 can be integrated using the crease as a starting point during 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 surface. The length and angle of the crease can be changed depending on 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 freely adapted. 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 freely adapted. In particular, if the product is trimmed to a predetermined shape in the early stages of the molding process, there is no need to provide a positioning portion in the margin outside the product shape, so even in the process of wrapping the laminate 31 to the exterior back surface as described above, no post-processing is required.

[0079] 11 and 12 are schematic cross-sectional views showing the cross-sectional structure of a laminate 32 according to embodiment 2. Components that perform the same functions as those in embodiment 1 will be described using the same reference numerals. The laminate 32 shown in FIG. 11 is configured as a laminate 32 in which a decorative layer 1, a second adhesive layer 10, a primer layer 11, a base layer 12, a first adhesive layer 2, and a support layer 3 are formed in this order. Also, in another example laminate 32a shown in FIG. 12, 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.

[0080] <Second Adhesive Layer> The second adhesive layer 10 is formed for the purpose of adhering 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 aforementioned materials as long as the adhesive purpose is achieved. For the purpose of improving adhesive strength, the second adhesive layer 10 may be composed of a component that forms 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 within the above range, the adhesive thickness is sufficient and sufficient adhesive strength is obtained. Furthermore, when the average film thickness is within the above range, manufacturing costs can be kept low. More preferably, the average film thickness is 5 μm or more and 100 μm or less.

[0081] <Primer Layer> The primer layer 11 serves to firmly bond the substrate layer 12 to the first adhesive layer 2 and the second adhesive layer 10, and is provided on one or both sides of the substrate layer 12. For example, if the first adhesive layer 2 or the second adhesive layer 10 is an acrylic adhesive, a primer layer 11 containing the same acrylic component can be provided, and the primer layer 11 can be selected taking compatibility into consideration. Furthermore, 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 contains similar components, a crosslinked structure can be formed with each of them, significantly improving the interlayer adhesion strength itself. Note that if the first adhesive layer 2 or the second adhesive layer 10 can be directly and firmly bonded to the substrate layer 12, the primer layer 11 does not necessarily need to be provided.

[0082] <Substrate Layer> The substrate layer 12 serves to improve the shape conformability of the laminate 32, 32a and to improve durability against appearance defects caused by resin heat and pressure during injection molding. It is made of a general-purpose polymer film commonly used in industrial products, such as polyethylene terephthalate, polycarbonate, acrylic, or polyolefin. The substrate layer 12 does not need to be made of only one type of component; one or both sides may be treated with a coating that is easily adhered to other substances. Surface modification treatments such as corona treatment and plasma treatment may also be performed. Furthermore, the substrate layer 12 may be treated to enhance its design or functionality. Examples of design enhancements include printing a pattern or coloring the substrate layer 12 itself. Examples of functionality enhancements include IR / UV blocking or the formation of electronic circuits on the substrate layer 12 using a conductive material. In this way, other design features and functionality can be imparted without any limitations as long as the base layer 12 achieves its original purposes of improving the shape conformability of the laminate 32 and improving durability during injection molding. The laminate 32 is manufactured by a manufacturing method using thermocompression bonding similar to that shown in Figure 4 of the first embodiment, the shaped product is further manufactured by hot pressing similar to that shown in Figures 5A to 8B of the first embodiment, and the molded product can be processed by the molded product manufacturing method described above in Figures 10A and 10B.

[0083] 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.

[0084] (Embodiment 3) <Molded Product> Fig. 13 is a schematic cross-sectional view showing the cross-sectional structure of a molded product 13 according to embodiment 3. Components that perform the same functions as those in embodiments 1 and 2 will be described using the same reference numerals. The molded product 13 according to embodiment 3 has a configuration 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.

[0085] <Third Adhesive Layer> The third adhesive layer 14 has an average film 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. Furthermore, 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 adhering the support layer 3 and the reinforcing layer 15 can be achieved. The third adhesive layer 14 may be formed in advance on the back surface of the support layer 3 of the laminate 31, or on the surface of the reinforcing layer 15.

[0086] <Reinforcing Layer> The material of the reinforcing layer 15 can be selected depending on the application. For example, general-purpose molding resins such as PMMA resin, ABS resin, PS resin, and PC resin, optical resins, super engineering resins, metal members, glass members, ceramic members, and wood materials can be selected depending on the required application, and the manufacturing process thereof is not limited. The components of the third adhesive layer 14 may be selected according to the material of the reinforcing layer 15. Processes for integrating the laminate 31 and the reinforcing layer 15 include hand lamination 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. Note that, as in the first embodiment, a molded product in which the laminate 31 is folded over to the outer back surface can be obtained by forming a fold in the laminate 31 during hot pressing and integrating it with the reinforcing layer 15.

[0087] Incidentally, in embodiment 3, a molded product using the laminate 31 according to embodiment 1 is taken as an example, but the laminates 32 and 32a described above in embodiment 2 can also be integrated with the reinforcing layer 15 to form a molded product using a similar process.

[0088] 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 household electrical appliances and the interiors of automobiles.

[0089] DESCRIPTION OF SYMBOLS 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 article 9 Molded article 10 Second adhesive layer 11 Primer layer 12 Base layer 13 Molded article 14 Third adhesive layer 15 Reinforcing layer 21 Heat-fusible polyester staple fiber (core-sheath structure) 22 Polyethylene terephthalate staple fiber 23 Fused portion 24 Non-fused portion 31, 31a Laminate 32, 32a Laminate 33 Positioning tab 34 Shaped article 35 Positioning pin 36 Recess 38 Opening surface 51 Base substrate

Claims

1. A laminate in which a decorative layer, a first adhesive layer, and a support layer are laminated in this order, wherein the support layer contains two or more types of materials having different melting points, including a relatively low-melting-point material and a high-melting-point material, and for a 25-mm-wide test piece of the laminate, the 10% modulus value evaluated as the tensile strength at an elongation rate of 10% in a tensile test according to JIS L1913 is 5 N or more and 23 N or less.

2. The laminate according to claim 1, 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 crosslinked structure.

3. The laminate according to claim 1, wherein the first adhesive layer penetrates into the support layer and is adhesively integrated 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 article in which a decorative layer, a first adhesive layer, and a support layer are laminated in this order, wherein the support layer contains two or more types of materials having different melting points, including a relatively low-melting-point material and a high-melting-point material, and for a 25-mm-wide test piece of the shaped article, the 10% modulus value evaluated as the tensile strength at an elongation rate of 10% in a tensile test according to JIS L1913 is 30 N or more.

6. The shaped article according to claim 5, 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 crosslinked structure and the shape is maintained.

7. The shaped article according to claim 5, wherein the product depth represented as the length from the opening surface of the recess of the laminate constituting the shaped article to the bottom of the recess is 10 mm or more and 100 mm or less.

8. A molded article comprising the shaped article according to claim 5 and an injection-molded resin integrated with the shaped article.

9. A molded article comprising one member selected from the group consisting of a resin member, a metal member, a glass member, a ceramic member, and a wooden member, and the shaped article according to claim 5 bonded to the surface of the member.

10. A step of sequentially laminating a decorative layer, a first adhesive layer, and a support layer including two or more types of materials having different melting points including a relatively low melting point material and a high melting point material; and a step of thermocompression bonding the laminated decorative layer, the first adhesive layer, and the support layer such that the surface temperature of the support layer is equal to or lower than the melting point of the low melting point material. A method for manufacturing a laminate, comprising:

11. The method for manufacturing a laminate according to claim 10, wherein, for a 25 mm wide test piece of the laminate obtained by the thermocompression bonding step, the 10% modulus value evaluated as the tensile strength at an elongation rate of 10% in a tensile test according to JIS L1913 is 5 N or more and 23 N or less.

12. A method for manufacturing a shaped article, comprising: a step of trimming the laminate according to any one of claims 1 to 4 into a predetermined shape; and a step of aligning and fixing the trimmed laminate and performing hot press working.

13. The method for manufacturing a shaped article according to claim 12, wherein, for a 25 mm wide test piece of the shaped article obtained by the hot press working step, the 10% modulus value evaluated as the tensile strength at an elongation rate of 10% in a tensile test according to JIS L1913 is 30 N or more.

14. A method for manufacturing a molded article, comprising: a step of aligning and fixing the shaped article according to claim 5 to an injection molding die and clamping the injection molding die; a step of pouring resin into a cavity between the injection molding dies with the injection molding die clamped; and a step of opening the injection molding die after the resin has cured and taking out a molded article in which the shaped article and the cured resin are integrated.

15. A method for manufacturing a molded article, comprising obtaining a molded article in which the shaped article according to claim 5 is bonded 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 wooden member.

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