Method for manufacturing laminated member

Abstract

In this method for manufacturing a laminated member, a laminated member (1) that includes a printed layer (3) having a to-be-molded surface (3a) with a raised and recessed textured portion (31) and a to-be-printed surface (3b) on the reverse side from the to-be-molded surface (3a), and includes a printing layer (4) to be printed onto the to-be-printed surface (3b), is manufactured using a mold member (7) including a molding surface (7b) having a raised and recessed complementary textured portion (71) that is mold-symmetrical to the textured portion (31). This method for manufacturing a laminated member comprises a molding step for molding the to-be-molded surface (3a) by using the molding surface (7b), and a printing step for printing the printing layer (4) onto the to-be-printed surface (3b) while the to-be-molded surface (3a) is in close contact with the molding surface (7b).

Description

Laminated member manufacturing method

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

[0002] As disclosed in Patent Document 1, a decorative sheet used in vehicle interior components includes a surface layer, an intermediate layer, and a design layer. The surface of the surface layer is formed with an uneven grained portion. The intermediate layer is printed on the back surface of the surface layer. The design layer is printed on the back surface of the intermediate layer.

[0003] Japanese Patent Application Laid-Open No. 2022-157890

[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 front surface facing downwards (and the back surface facing upwards). Next, the intermediate layer is printed on the back surface (top surface) of the skin layer. Then, the design layer is printed on the back surface (top surface) of the intermediate layer. In this way, the decorative sheet is manufactured using printing.

[0005] However, during printing, only the peaks of the convex portions of the embossed portions on the surface (lower surface) of the skin layer abut against the upper surface of the printing table. In other words, the skin layer is supported from below by the print table only through the peaks 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 apexes of the convex portions of the embossed portion are supported by the printing table from below. Therefore, the portions of the back surface of the skin layer corresponding to the apexes of the convex portions are less likely to deform even when a load is applied. On the other hand, portions other than the apexes of the convex portions (for example, the concave portions of the embossed portion) are not supported by the printing table from below. Therefore, the portions of the back surface of the skin layer corresponding to the portions other than the apexes of the convex portions are more 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 laminated member manufacturing method that can suppress a decrease in printing accuracy.

[0007] (1) In order to solve the above-mentioned problems, the method for manufacturing a laminated member disclosed herein is a method for manufacturing a laminated member having a printed layer having a molded surface with an uneven embossed portion and a printed surface facing away from the molded surface, and a printing layer printed on the printed surface, using a molding die member having a molding surface with an uneven reverse embossed portion that is symmetrical to the embossed portion, and is characterized by having a molding process for molding the molded surface using the molding surface, and a printing process for printing the printing layer on the printed surface while the molded surface remains in close contact with the molding surface.

[0008] According to this configuration, in the printing process, the printing layer is printed on the printing surface while the molded surface remains in close contact with the molding surface. That is, the printing layer is printed on the printing surface while the entire surface remains supported by the molding surface (specifically, the convex portions of the embossed portion remain supported by the concave portions of the reverse embossed portion, and the concave portions of the embossed portion remain supported by the convex portions of the reverse embossed portion). Therefore, the printing surface is less likely to deform compared to when only the apexes of the convex portions of the embossed portion are supported. Furthermore, the load distribution on the printing surface is less likely to vary compared to when only the apexes of the convex portions of the embossed portion are supported. Therefore, a decrease in the printing accuracy of the printing layer on the printing surface can be suppressed.

[0009] (1-1) In the above configuration (1), the molding die member is preferably a textured separator, and the molding surface of the textured separator is preferably releasable from the molding surface. With this configuration, the textured separator can be easily peeled off from the molding surface after the printing process.

[0010] (2) In the configuration of (1) or (1-1) above, the laminated member is a decorative sheet comprising a light-transmitting surface layer, a light-transmitting intermediate layer disposed on the back side of the surface layer, and a light-transmitting design layer disposed on the back side of the intermediate layer, wherein the printable layer is the surface layer, the molded surface is the front surface of the surface layer, the printable surface is the back surface of the surface layer, the printing layer is the intermediate layer, and the printing process is an intermediate layer printing process in which the intermediate layer is printed on the back surface of the surface layer while the surface of the surface layer remains in close contact with the molded surface, and further comprises a design layer printing process in which the design layer is printed on the back surface of the intermediate layer.

[0011] This configuration can reduce variations in the thickness of the intermediate layer compared to when the intermediate layer is applied by painting, for example. It also prevents the intermediate layer from becoming excessively thick. The same applies to the decorative layer. It also reduces misalignment in the layer direction (layer expansion direction, a direction intersecting the stacking direction) between the three layers (skin layer, intermediate layer, and decorative layer).

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

[0013] FIG. 1 is a partial perspective view of a door trim on which a decorative sheet manufactured by a laminated member manufacturing method according to one embodiment of the present disclosure is disposed. FIG. 2 is a perspective view of the interior of frame II in FIG. 1. FIG. 3 is an exploded perspective view of the interior of frame II in FIG. 1. FIG. 4 is a cross-sectional view taken along the line IV-IV in FIG. 2. FIG. 5(A) is a schematic diagram of the molding step of the laminated member manufacturing method. FIG. 5(B) is a schematic diagram of the intermediate layer printing step of the laminated member manufacturing method. FIG. 6(A) is a schematic diagram of the design layer printing step of the laminated member manufacturing method. FIG. 6(B) is a schematic diagram of the demolding step of the laminated member manufacturing method.

[0014] Hereinafter, an embodiment 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 on which a decorative sheet manufactured by a laminated member manufacturing method according to one embodiment of the present disclosure (hereinafter referred to as "decorative sheet of this embodiment") is arranged. FIG. 2 shows a perspective view of the area within frame II in FIG. 1. FIG. 3 shows an exploded perspective view of the area within frame II in FIG. 1. FIG. 4 shows a cross-sectional view (cross-sectional view from the front to the back) taken along the line IV-IV in FIG. 2. Note that in FIGS. 2 to 4, the grained portion 31 is shown schematically.

[0016] [Arrangement and configuration of decorative sheet] First, the arrangement and configuration of the decorative sheet of this embodiment will be described. As shown in Fig. 1, a decorative sheet (laminate member) 1 is arranged on a door trim 9 of a vehicle interior. 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 layered in this order from the front side (upper side, inside the vehicle interior) to the back side (lower side, outside the vehicle interior).

[0017] As shown in Figures 3 and 4, the decorative sheet 1 comprises, from the front side to the back side, a skin layer (printable layer) 3, an intermediate layer (printable layer) 4, and a design layer 5. The skin layer 3 is made of synthetic resin and has a layered structure. The skin layer 3 is light-transmitting and flexible. The skin layer 3 comprises a front surface (the surface to be molded; upper surface) 3a and a back surface (the surface to be printed; lower surface) 3b. The front surface 3a and the back surface 3b are back-to-back in the front-to-back direction. The front surface 3a has a plurality of unevenly textured portions 31. That is, the textured portions 31 have downward recesses 31a and upward protrusions 31b. The back surface 3b is a flat surface (smooth surface) without the textured portions 31. As shown in Figure 1, the front surface 3a is exposed to the interior of the vehicle. Light is irradiated onto the design layer 5, which will be described later, from a light source unit 90 on the back side. The light causes the wood grain pattern of the design layer 5 to appear on the surface 3 a of the skin layer 3 .

[0018] The intermediate layer 4 is printed on the back surface 3b of the surface layer 3. The intermediate layer 4 is made of light-transmitting ink and has a layered shape. The intermediate layer 4 is light-transmitting and flexible. The intermediate layer 4 has lower light transmittance than the surface layer 3. The intermediate layer 4 is semi-transparent with a smoky color. 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-transmitting ink and has a layered structure. The design layer 5 is light-transmitting and flexible. The design layer 5 has higher light transmittance than the intermediate layer 4. The design layer 5 displays a wood grain pattern when viewed from the front side.

[0020] The light source unit 90 is disposed on the back side of the design layer 5. The light source unit 90 includes a plurality of light sources (LEDs) 900. The plurality of light sources 900 are distributed throughout the layer-wise direction (layer expansion direction; direction intersecting the stacking direction; surface direction) of the light source unit 90. The entire surface of the light source unit 90 is capable of emitting light. Light from the light sources 900 passes through the design layer 5, intermediate layer 4, and skin layer 3 and reaches the surface of the door trim 9 (i.e., surface 3a of the skin layer 3).

[0021] When the light source unit 90 is off, the light source 900 is turned off. In other words, the backlight for the decorative sheet 1 is turned off. The light transmittance of each layer is set in descending order of the surface layer 3 (most transparent), the design layer 5, and the intermediate layer 4 (least transparent). For this reason, it is difficult for a user to see the wood grain pattern of the design layer 5 from the front side of the decorative sheet 1 (inside the vehicle cabin). Furthermore, it is easy for a user to see the three-dimensional shape of the grain portion 31 of the surface layer 3 and the color of the intermediate layer 4 together from the front side of the decorative sheet 1 (inside the vehicle cabin).

[0022] When the light source unit 90 is on, the light source 900 is lit. In other words, the backlight for the decorative sheet 1 is lit. As mentioned above, the light transmittance of each layer is set in descending order of the surface layer 3, the design layer 5, and the intermediate layer 4. This makes it easy for the user to see 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 depending on whether the light source unit 90 is on or off.

[0023] [Laminated Member Manufacturing Method] Next, a laminated member manufacturing method of this embodiment will be described. The laminated member manufacturing method includes a molding process, an intermediate layer printing process, a design layer printing process, and a demolding process. The laminated member manufacturing method is performed with the decorative sheet 1 shown in Figures 1 to 4 turned upside down.

[0024] Fig. 5(A) shows a schematic diagram of the molding process of the laminated member manufacturing method of this embodiment. Fig. 5(B) shows a schematic diagram of the intermediate layer printing process of the laminated member manufacturing method. Fig. 6(A) shows a schematic diagram of the design layer printing process of the laminated member manufacturing method. Fig. 6(B) shows a schematic diagram of the demolding process of the laminated member manufacturing method.

[0025] (Molding Process) In this process, the skin layer 3 is produced, and the grain portion 31 is molded on the surface 3a of the skin layer 3. As shown in FIG. 5(A), the molding 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 hopper 80 stores raw material (synthetic resin raw material) A for the skin layer 3. The screw feeder 81 includes a pipe 810 and a screw shaft 811. The hopper 80 is connected to the rear end (upstream end) of the side wall of the pipe 810. The screw shaft 811 is rotatable around its own axis and is inserted through the pipe 810. The heater 82 is annularly mounted on the side 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 disposed in front of the die 83. The pair of rollers 84 and 85 are disposed apart from and facing each other.

[0026] In this process, raw material A is supplied from a hopper 80 to a screw feeder 81 by gravity. The pellet-like (solid) raw material A is transported from the rear to the front by the screw of the screw shaft 811. During transport, raw material A softens and melts due to heat transferred from a heater 82, becoming a fluid (gel-like, starch syrup-like). The gel-like raw material A is formed into a strip by a die 83. The formed raw material A merges with a texture transfer separator 7 supplied from below and passes between a pair of rollers 84 and 85. Note that a textured back texture portion 71 (see FIG. 5B ) is previously arranged on the back surface (molding surface, peeling surface, upper surface) 7b of the texture transfer separator 7. The texture transfer separator 7 is included in the concept of a "molding mold member" in this disclosure. The back surface 7b is included in the concept of a "molding surface" in this disclosure.

[0027] As they pass between the pair of rollers 84, 85, the upper raw material A and the lower embossed separator 7 are laminated to produce a strip-shaped laminated sheet B. The surface (the surface to be molded; the lower surface) 3a of the raw material A and the back surface 7b of the embossed separator 7 are pressed together. By this pressing, 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 downwardly recessed portions 71a and upwardly protruding portions 71b. The recessed portions 71a form protrusions 31b on the front surface 3a. The protrusions 71b form recesses 31a on the front surface 3a. Therefore, the embossed portion 31 (recesses 31a, protrusions 31b) has an uneven shape symmetrical to the back embossed portion 71 (recesses 71a, protrusions 71b). As shown in FIG. 5(A), the surface of the upper roller 84 is flat. Therefore, the back surface (printed surface; upper surface) 3b of the raw material A is formed flat by pressure contact with the roller 84. After passing between the pair of rollers 84 and 85, the raw material A is cooled (allowed to cool) and solidified. In this manner, the skin layer 3 with the embossed portion 31 is produced.

[0029] (Intermediate Layer Printing Step) In this step, the intermediate layer 4 is printed on the back surface 3b of the skin layer 3 while the back surface 7b of the embossed separator 7 remains in intimate contact with the front surface 3a of the skin layer 3. Specifically, as shown in Fig. 5(B) , a laminate (a laminate of the skin layer 3 and the embossed separator 7) B1, obtained by cutting the laminate sheet (a laminate sheet of the skin layer 3 and the embossed 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 using a silk screen printer (not shown). Note that if 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] 6(A), in the same manner as in the intermediate layer printing process, a silk screen printer (not shown) is used to print the design layer 5 on the back surface (top surface) of the intermediate layer 4 of the laminate C (a laminate of the intermediate layer 4, the skin layer 3, and the grain transfer separator 7) while the back surface 7b of the grain transfer separator 7 remains in close contact with the surface 3a of the skin layer 3. If the design layer 5 has a multi-layer structure (for example, a structure in which multiple layers are stacked to form a wood grain pattern when viewed from the front), each layer is printed in order.

[0031] (Mold-releasing process) In this process, as shown in Fig. 6(B) , the embossed separator 7 is peeled off from the laminate D (a laminate of the design layer 5, intermediate layer 4, skin layer 3, and embossed separator 7) after printing the design layer 5. The back surface 7b of the embossed separator 7 has releasability relative to the front surface 3a of the skin layer 3. This allows the embossed separator 7 to be easily peeled off. In this manner, the decorative sheet 1 of this embodiment is produced.

[0032] [Effects] Next, the effects of the laminated member manufacturing method of this embodiment will be described. As shown in FIG. 5(B), in the intermediate layer printing step, the intermediate layer 4 is printed on the back surface 3b of the skin layer 3 while the back surface 7b of the embossed separator 7 remains in close contact with the front surface 3a of the skin layer 3. That is, the intermediate layer 4 is printed on the back surface 3b while the front surface 3a remains entirely supported by the back surface 7b (specifically, the convex portions 31b of the embossed portion 31 remain supported by the concave portions 71a of the back surface 71, and the concave portions 31a of the embossed portion 31 remain supported by the convex portions 71b of the back surface 71). Therefore, the back surface 3b is less likely to deform than when only the apexes of the convex portions 31b of the embossed portion 31 are supported (when the embossed separator 7 is not disposed). Furthermore, when the intermediate layer 4 is printed, the load distribution on the back surface 3b is less likely to vary than when only the apexes of the convex portions 31b of the embossed portion 31 are supported. Therefore, it is possible to suppress a decrease in the printing accuracy of the intermediate layer 4 on the rear surface 3b.

[0033] 6(B), the back surface 7b of the embossed separator 7 has releasability relative to the surface 3a of the skin layer 3. Therefore, in the demolding step, the back surface 7b of the embossed separator 7 can be easily peeled off from the surface 3a of the skin layer 3.

[0034] As shown in Figure 5(B), in the intermediate layer printing process, the intermediate layer 4 is placed on the back surface 3b of the skin layer 3 by printing (silk screen printing machine). Therefore, compared to when the intermediate layer 4 is placed by painting, for example, it is possible to suppress variations in the thickness (thickness in the front-to-back direction) of the intermediate layer 4. It is also possible to suppress excessive thickness of the intermediate layer 4. The same is true for the design layer 5 shown in Figure 6(A). It is also possible to suppress misalignment in the layer direction between the three layers (skin layer 3, intermediate layer 4, and design layer 5).

[0035] Let us assume that the design layer 5 has lower light transmittance than the intermediate layer 4. In this case, the intermediate layer 4 becomes more transparent than the design layer 5. Therefore, when the backlight is turned off, the design layer 5 (i.e., the wood grain pattern) is likely to be visible through the intermediate layer 4 on the surface of the skin layer 3.

[0036] In this regard, in the decorative sheet 1 of this embodiment, the design layer 5 has higher light transmittance than the intermediate layer 4. Therefore, the intermediate layer 4 is less transparent than the design layer 5. Therefore, when the backlight is turned off, it is possible to prevent light from passing through the intermediate layer 4 and showing the design layer 5 on the surface of the skin layer 3.

[0037] The surface of the skin layer 3 has a textured portion 31. Therefore, when the backlight is off, external light can be diffused between the unevenness of the textured portion 31. This makes it possible to blur the boundaries of the design layer 5 (for example, when the design layer 5 has a wood grain pattern, the areas where the wood grain has a distinct shade). This prevents the boundaries of the design layer 5 from being visible through the surface of the skin layer 3. Furthermore, when the backlight is 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 textured portion 31 is mainly visible when the backlight is off.

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

[0039] [Others] The embodiments of the laminated member manufacturing method of the present disclosure have been described above. However, the embodiments are not particularly limited to the above embodiments. Various modified and improved embodiments that can be achieved by those skilled in the art are also possible.

[0040] (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 have a single-layer structure or a multi-layer structure. Another layer may be interposed between two adjacent layers in the front-to-back direction. Furthermore, another layer may be disposed on the back side of the design layer 5 or on the front side of the skin layer 3.

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

[0042] The design of the design layer 5 is not particularly limited. Preferably, the design is different from the design of the skin layer 3 (such as the grained portion 31) and the design of the intermediate layer 4 (such as color). This allows the design displayed on the surface 3a of the skin layer 3 to have a dual nature depending on whether the backlight is on or off. Examples of the design of the design layer 5 include designs including one or more types selected from patterns (such as wood grain, marble, stone wall, polka dots, stripes, and checkerboard patterns), characters (such as alphabets, hiragana, katakana, kanji, numbers, and braille), figures (such as polygons and circles), and symbols (such as buttons for operating devices and icons indicating the status of devices).

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

[0044] There is no particular limitation on the brightness of the light source 900. There is no particular limitation on the type, number, or location of the light source 900. The light source 900 may be an organic EL sheet, an inorganic EL sheet, a phosphorescent sheet, or the like. Furthermore, the light source unit 90 may include the light source 900 and a light guide plate (e.g., an acrylic plate).

[0045] The type of interior component on which the decorative sheet 1 is disposed is not particularly limited. Examples include door trim 9, seats, armrests, floors, ceilings, instrument panels, glove compartments, steering wheels, center consoles, and cash registers. The surface of the interior component (the surface 3a of the skin layer 3) may be flat or curved. The orientation of the interior component (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 vertical, horizontal, or a direction intersecting the vertical and horizontal directions. The decorative sheet 1 may be disposed in interior components of transportation equipment other than vehicles (such as motorcycles, ships, and aircraft) and buildings (such as buildings and houses). The decorative sheet 1 may also be disposed in exterior components (such as the exterior walls of transportation equipment and buildings). The type of laminated component is not particularly limited. The laminated component may be a sheet other than the decorative sheet 1 (a sheet that does not require a light source unit 90). For example, it may be an anti-slip sheet or building material.

[0046] (Regarding Materials) The material of the skin layer 3 is not particularly limited. Examples include synthetic leather, resin, and elastomer. Specific examples include acrylic, polyethylene terephthalate, polycarbonate, polyvinyl chloride, silicone, epoxy, polyurethane, styrene-based thermoplastic elastomer, olefin-based thermoplastic elastomer, and dynamically crosslinked thermoplastic elastomer. The skin layer 3 may contain a colorant (such as colored polyethylene), a light diffusing agent (such as silicone, acrylic, or titanium oxide), or a light absorbing agent (such as titanium black or carbon black).

[0047] There are no particular limitations on the material of the intermediate layer 4. Examples include resins and elastomers such as acrylic, polyethylene terephthalate, polycarbonate, polyvinyl chloride, silicone, polyester, epoxy, polyurethane, styrene-based thermoplastic elastomer, olefin-based thermoplastic elastomer, and dynamically crosslinked thermoplastic elastomer. The intermediate layer 4 may contain the aforementioned colorant, light diffusing agent, and light absorbing agent.

[0048] There are no particular limitations on the material of the design layer 5. Examples include resins and elastomers such as acrylic, polyethylene terephthalate, polycarbonate, polyvinyl chloride, silicone, polyester, epoxy, polyurethane, styrene-based thermoplastic elastomer, olefin-based thermoplastic elastomer, and dynamically crosslinked thermoplastic elastomer. The design layer 5 may contain the aforementioned colorants, light diffusing agents, and light absorbing agents.

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

[0050] (Regarding the laminated member manufacturing method) The printing method in the intermediate layer printing step shown in Figure 5 (B) and the design layer printing step shown in Figure 6 (A) is not particularly limited. Screen printing (such as silk screen printing), gravure printing, inkjet printing, flexographic printing, etc. may be used. There is no particular limitation on the difference between the printing methods used in the intermediate layer printing step and the design layer printing step.

[0051] The design layer printing step shown in Figure 6(A) does not have to be performed. That is, the design layer 5 may be laminated on the intermediate layer 4 by adhesion, crimping, pasting, vapor deposition, welding, painting, or the like. For example, the design layer 5 may be adhered to the back surface of the intermediate layer 4. Alternatively, the design layer 5 may be painted on the back surface of the intermediate layer 4.

[0052] The laminated sheet B (strip-shaped continuous body) of Fig. 5(A) may be subjected to the subsequent steps (the intermediate layer printing step shown in Fig. 5(B), the design layer printing step shown in Fig. 6(A), and the demolding step shown in Fig. 6(B)) without being cut. In other words, it is sufficient if the decorative sheet 1 having a predetermined shape is completed before being placed on the door trim 9 shown in Fig. 1.

[0053] The laminated member manufacturing method may include processes other than the intermediate layer printing process shown in Fig. 5(B) and the design layer printing process shown in Fig. 6(A). For example, a light-diffusing diffusion layer may be disposed on the back side of the design layer 5 to diffuse light from the multiple light sources (point light sources) 900 of the light source unit 90. In this case, after the design layer printing process, a diffusion layer printing process may be performed in which a diffusion layer is printed on the back side of the design layer 5.

[0054] In the molding process shown in Fig. 5(A), the state of the raw material A before forming the surface (molded surface) 3a is not particularly limited. It may be in a liquid, fluid, solid, or other state. As shown in Fig. 5(B), it is sufficient that the surface 3a has a grained portion 31 after the molding process.

[0055] In the molding process, the method for molding the front surface 3a (i.e., the embossed portion 31) using the back surface (molding surface) 7b is not particularly limited. Examples include injection molding, extrusion molding, and press molding. As an example, when molding the front surface 3a by injection molding, the back embossed portion 71 may be placed on the molding surface (molding surface) of a mold (molding mold member), and the liquid raw material A may be injected into the cavity of the mold, and the raw material A may be cooled and hardened to form the front surface 3a. Note that the printing process after the molding process may be carried out while the front surface 3a remains in close contact with the mold surface of the mold.

[0056] 1: Decorative sheet, 3: Skin layer, 3a: Surface, 3b: Back surface, 31: Textured portion, 31a: Concave portion, 31b: Convex portion, 4: Intermediate layer, 5: Design layer, 7: Texture transfer separator (molding mold member), 7b: Back surface (molding surface), 71: Back textured portion, 71a: Concave portion, 71b: Convex portion, 8: Molding 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 portion, 900: Light source, A: Raw material, B: Laminated sheet, B1 to D: Laminated body

Claims

1. A method for manufacturing a laminated member, using a molding mold member having a molding surface with an uneven textured portion and a printing surface facing away from the molding surface, and a printing layer to be printed on the printing surface, the method comprising: a molding process for molding the molded surface with the molding surface, and a printing process for printing the printing layer on the printed surface while the molded surface is in close contact with the molding surface.

2. The laminated member manufacturing method described in claim 1, wherein the laminated member is a decorative sheet comprising a surface layer having light transparency, an intermediate layer having light transparency and disposed on the back side of the surface layer, and a design layer having light transparency and disposed on the back side of the intermediate layer, wherein the printable layer is the surface layer, the molded surface is the front surface of the surface layer, the printable surface is the back surface of the surface layer, the printing layer is the intermediate layer, the printing process is an intermediate layer printing process in which the intermediate layer is printed on the back surface of the skin layer while the front surface of the skin layer is in close contact with the molded surface, and further comprises a design layer printing process in which the design layer is printed on the back surface of the intermediate layer.

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