Integrally molded product and producing method for integrally molded product

Abstract

There is provided an integrally molded product which is produced by using at least one method of injection molding, press molding, or vacuum molding, the integrally molded product comprising: a resin molded portion; and a polyester fabric layer which is provided on the resin molded portion, wherein the polyester fabric layer is embossed.

Description

INTEGRALLY MOLDED PRODUCT AND PRODUCING METHOD FOR INTEGRALLY MOLDED PRODUCT

[0001] The contents of the following patent application(s) are incorporated herein by reference: NO. 2024-158176 filed in JP on September 12, 2024. The present invention relates to an integrally molded product and a producing method for an integrally molded product.

[0002] Patent Document 1 discloses a "leather-like non-woven fabric" which is embossed.

[0003] Patent Document 1: Japanese Patent Application Publication No. H11-241277

[0004] There is provided a leather-like fabric with a higher quality. (Solution to Problem)

[0005] (1) In a first aspect of the present invention, there is provided an integrally molded product which is produced by using at least one method of injection molding, press molding, or vacuum molding. The integrally molded product may include a resin molded portion and a polyester fabric layer which is provided on the resin molded portion. The polyester fabric layer may be embossed.

[0006] (2) In the integrally molded product according to (1), the polyester fabric layer may have a polyester fabric, and a coating layer of polyester which is provided on an upper surface of the polyester fabric.

[0007] (3) In the integrally molded product according to any of (1) or (2), a thickness of the polyester fabric may be 0.1 mm or more and 2.0 mm or less.

[0008] (4) In the integrally molded product according to any of (1) to (3), a thickness of the coating layer may be 20 μm or more and 100 μm or less.

[0009] (5) In the integrally molded product according to any of (1) to (4), the coating layer may be a polyester film.

[0010] (6) In the integrally molded product according to any of (1) to (5), the polyester may include at least one of PET (polyethylene terephthalate), PBT (polybutylene terephthalate), or PTT (polytrimethylene terephthalate).

[0011] (7) In the integrally molded product according to any of (1) to (6), the polyester fabric layer may have a suede-like polyester fabric.

[0012] (8) In the integrally molded product according to any of (1) or (7), a thickness of the suede-like polyester fabric may be 0.6 mm or more and 1.5 mm or less.

[0013] (9) In the integrally molded product according to any of (1) to (8), a material of the resin molded portion may be polyester.

[0014] (10) The integrally molded product according to any of (1) to (9) may include: a plate material of polyester which is provided between the resin molded portion and the polyester fabric layer.

[0015] (11) In a second aspect of the present invention, there is provided a producing method for producing an integrally molded product by using injection molding. The producing method may include: placing a polyester fabric layer in a mold for injection molding which has an embossed pattern; pouring a liquid material for forming a resin molded portion into the mold; and forming the resin molded portion integrally molded with the polyester fabric layer, and embossing the polyester fabric layer in the mold.

[0016] (12) In the producing method according to (11), the placing the polyester fabric layer in the mold may include placing the polyester fabric layer on a cavity side of the mold.

[0017] (13) In the producing method according to any of (11) or (12), the placing the polyester fabric layer in the mold may include placing the polyester fabric layer on a core side of the mold.

[0018] (14) In the producing method according to any of (11) to (13), a surface of the mold which has an embossed pattern, may be front surface-treated.

[0019] (15) In a third aspect of the present invention, there is provided a producing method for producing an integrally molded product by using press molding. The producing method may include: forming a polyester sheet by adhering a plate material of polyester to a lower surface of a polyester fabric layer; heating the polyester sheet; performing the press molding on the polyester sheet by using a mold which has an embossed pattern; and attaching a resin molded portion to the polyester sheet which is embossed.

[0020] (16) In a fourth aspect of the present invention, there is provided a producing method for producing an integrally molded product by using vacuum molding. The producing method may include: forming a polyester sheet by adhering a plate material of polyester to a lower surface of a polyester fabric layer; heating the polyester sheet; performing the vacuum molding on the polyester sheet by using a mold which has an embossed pattern; and attaching a resin molded portion to the polyester sheet which is embossed.

[0021] The summary clause does not necessarily describe all features of the present invention. In addition, the present invention may also be a sub-combination of the features described above.

[0022] Fig. 1 is a photograph of a front surface of an integrally molded product 100 which is embossed.Fig. 2A is a schematic view of a cross section of the integrally molded product 100 which is embossed.Fig. 2B shows a modified example of the cross section of the integrally molded product 100 which is embossed.Fig. 3A shows an example of a flowchart of producing the integrally molded product 100.Fig. 3B shows an example of a producing method for the integrally molded product 100.Fig. 3C shows an example of the producing method for the integrally molded product 100.Fig. 3D shows a modified example of the producing method for the integrally molded product 100.Fig. 4A shows an example of the flowchart of producing the integrally molded product 100.Fig. 4B shows an example of the producing method for the integrally molded product 100.Fig. 5A shows an example of the flowchart of producing the integrally molded product 100.Fig. 5B shows an example of the producing method for the integrally molded product 100.Description Of Exemplary Embodiments

[0023] The present invention will be described below through embodiments of the invention, but the following embodiments do not limit the invention according to the claims. Also, not all of the combinations of features described in the embodiments are essential to the solving means of the invention.

[0024] Fig. 1 is a photograph of a front surface of an integrally molded product 100 which is embossed in the present example. The integrally molded product 100 includes a fabric of a woven fabric or a knitted fabric to which a pattern expressed by embossing is applied. The integrally molded product 100 in the present example has a leather-like design realized by being embossed.

[0025] The integrally molded product 100 is formed by attaching polyester resin to a polyester fabric with a polyester coating, or a suede-like fabric of polyester. The polyester fabric and the suede-like fabric of polyester are examples of a polyester fabric 120 which will be described below, and the polyester coating is an example of a coating layer 130 which will be described below. The polyester fabric with the polyester coating, or the suede-like fabric is an example of a polyester fabric layer 110 which will be described below. The integrally molded product 100 may have an embossed pattern and may be given a shape.

[0026] The integrally molded product 100 in the present example is produced by using at least one method of injection molding, press molding, or vacuum molding. A producing method for the integrally molded product 100 in the present example will be described below.

[0027] Fig. 2A is a schematic view of a cross section of the integrally molded product 100 which is embossed. The integrally molded product 100 includes the polyester fabric layer 110 and a resin molded portion 180. The polyester fabric layer 110 is an example of the polyester fabric with the polyester coating, or the suede-like fabric of polyester, which is used for the integrally molded product 100.

[0028] The polyester fabric layer 110 has the polyester fabric 120 and the coating layer 130 of polyester. The polyester fabric layer 110 in the present example is provided on the resin molded portion 180. The polyester fabric layer 110 being provided on the resin molded portion 180 is not limited to the polyester fabric layer 110 being directly adhered to the resin molded portion 180. A case where a different component is arranged between the resin molded portion 180 and the polyester fabric layer 110, is also included in the state in which the polyester fabric layer 110 is provided on the resin molded portion 180.

[0029] The polyester fabric layer 110 is a fabric for which polyester is used. The polyester fabric layer 110 may contain a material other than polyester. The polyester fabric layer 110 may contain at least one of nylon, acrylic, linen, cotton, silk, rayon, or wool. The polyester fabric layer 110 may have protrusions and recesses, and gloss as in genuine leather or synthetic leather. The polyester fabric layer 110 in the present example can realize a leather-like texture without providing a backing fabric of a non-woven fabric or the like on a back side. Note that a lining of polyurethane, a non-woven fabric, or the like may be provided on a back surface of the polyester fabric layer 110.

[0030] The polyester fabric layer 110 for which polyester is used can reduce mass by 50% or more in comparison with a fabric for which genuine leather or polyvinyl chloride (PVC) is used. In addition, unlike a fabric for which genuine leather or PVC is used, the polyester fabric layer 110 does not easily become hot in the summer, and does not easily become cold in the winter. When the polyester fabric layer 110 is constituted by polyester alone, it is possible to enhance recyclability.

[0031] The polyester fabric layer 110 may be used for a vehicle seat cover which requires high strength, wrinkle resistance, flame retardancy, and the like. The polyester fabric layer 110 may have water repellency or may have flame retardancy. The polyester fabric layer 110 may meet at least one of evaluation criteria of JIS L1091, JIS L1092, JIS L1093, JIS L1096, JIS L1076, JIS L0860, JIS L0849, JIS L0844, or JIS L0842. Note that the use of the polyester fabric layer 110 is not particularly limited.

[0032] A thickness of the polyester fabric 120 is 0.1 mm or more and 2.0 mm or less. The polyester fabric 120 may be a woven fabric constituted by a warp yarn and a weft yarn. The polyester fabric 120 may also be a knitted fabric. A material of the polyester fabric 120 in the present example is polyester; however, a material other than polyester may be contained. The polyester fabric 120 in the present example does not have a lining, but may have a lining.

[0033] The polyester fabric 120 may be a suede-like polyester fabric. That is, the polyester fabric layer 110 may have the suede-like polyester fabric 120. To the integrally molded product 100 in the present example, it is possible to apply pressure by integral molding, and thus even in a case where the polyester fabric 120 is a suede-like polyester fabric, it is possible to apply an embossed pattern.

[0034] The thickness of the polyester fabric 120 is greater in the case where the polyester fabric 120 is a suede-like polyester fabric in comparison with a case where it is not a suede-like polyester fabric. The thickness of the suede-like polyester fabric 120 may be 0.7 mm or more and 1.2 mm or less. The thickness of a single yarn of the polyester fabric 120 may be thinner in the case where the polyester fabric 120 is a suede-like polyester fabric in comparison with a case where it is not a suede-like polyester fabric. By reducing the thickness of a single yarn of the polyester fabric 120, it becomes easy to perform embossing during molding.

[0035] The coating layer 130 is a coating layer of polyester which is provided on an upper surface of the polyester fabric 120. In the present specification, the upper surface of the polyester fabric 120 refers to a surface of a side on which the embossing is performed. The coating layer 130 may be adhered to the polyester fabric 120. The coating layer 130 may be attached to the polyester fabric 120, or may be applied thereto.

[0036] The coating layer 130 contains polyester. The coating layer 130 may be entirely polyester, or may contain a material other than polyester. The coating layer 130 may be a film which is mainly made of copolyester, or may be a layer formed by applying a liquid agent of copolyester to the polyester fabric 120. The coating layer 130 in the present example is a polyester film.

[0037] The polyester fabric 120 and the coating layer 130 may be constituted by the same material. By constituting each layer of the polyester fabric layer 110 by the same material, recyclability is enhanced. The polyester fabric 120 and the coating layer 130 may have different compositions from each other, even when they are made of the same material. For example, the polyester fabric 120 is made of polyester which has a composition different from that of the coating layer 130. The polyester fabric 120 may have a melting point different from that of the coating layer 130 due to the different compositions. The polyester may include at least one of PET (polyethylene terephthalate), PBT (polybutylene terephthalate), or PTT (polytrimethylene terephthalate).

[0038] The melting point of the coating layer 130 may be lower than the melting point of the polyester fabric 120. By heating the polyester fabric layer 110 to melt the coating layer 130, it is possible to adhere the coating layer 130 to the polyester fabric 120.

[0039] The thickness of the coating layer 130 may be thinner than the thickness of the polyester fabric 120. The thickness of the coating layer 130 may be 1.5% or more, may be 100% or less, or may be 200% or less of the thickness of the polyester fabric 120. The thickness of the coating layer 130 may be 2% or more, or may be 30% or less of the thickness of the polyester fabric 120. The thickness of the coating layer 130 in the present example is 30 μm or more and 200 μm or less.

[0040] The coating layer 130 may be transparent, or may be colored. A color of the coating layer 130 may be the same as a color of the polyester fabric 120, or the color of the coating layer 130 may be different from the color of the polyester fabric 120. By coloring the coating layer 130, it is possible to adjust the color of the polyester fabric layer 110. As an example, by laminating the polyester fabric 120 of a black color, with the coating layer 130 of the same black color, it is possible to increase a depth of the black color of the polyester fabric layer 110. The coating layer 130 may have water repellency, or may have flame retardancy.

[0041] By providing the coating layer 130, it is possible to give glossiness to the polyester fabric layer 110, and to realize a genuine leather-like design. The coating layer 130 can coat dense fibers of the polyester fabric 120, and thus it is possible to enhance scratch resistance. The coating layer 130 fills gaps between the fibers of the polyester fabric 120, thereby making it possible to enhance an embossed texture in comparison with the polyester fabric 120 alone.

[0042] In the polyester fabric layer 110 in the present example, the polyester fabric 120 and the coating layer 130 are embossed. The polyester fabric 120 and the coating layer 130 have the protrusions and the recesses formed by the embossing. In the present example, the polyester fabric 120 and the coating layer 130 are bonded to each other, and both of the polyester fabric 120 and the coating layer 130 are embossed, thereby making it possible to realize a deep texture. An embossing depth De of the polyester fabric layer 110 may be 160 μm or more and 300 μm or less. The embossing depth De may be a maximum value of a difference between a protrusion portion and a recess portion in the coating layer 130 which is embossed. By embossing the polyester fabric layer 110, it is possible to enhance friction on the front surface, and when the polyester fabric layer 110 is used for a vehicle seat or the like, it is possible to make it easy to hold items placed on the seat.

[0043] In the polyester fabric layer 110 in the present example, by laminating the polyester fabric 120, which is constituted by a woven fabric or a knitted fabric, with the coating layer 130, and then performing the embossing, it is possible to obtain a more stable physical property in comparison with the non-woven fabric or the like which has a variation in density. In this manner, the polyester fabric layer 110 with uniform tensile strength and elasticity is obtained. By realizing the uniform embossing, the leather-like polyester fabric layer 110 with a higher quality is obtained.

[0044] The resin molded portion 180 is provided on a lower surface side of the polyester fabric layer 110. The lower surface side of the polyester fabric layer 110 refers to a side of the polyester fabric layer 110 opposite to a side on which an embossed pattern is applied.

[0045] The resin molded portion 180 is formed of thermoplastic resin. The resin molded portion 180 may be formed of thermoplastic resin that is able to be used for injection molding. The resin molded portion 180 may be formed of the same material as that of the polyester fabric layer 110. By using the same material for the resin molded portion 180 as the material of the polyester fabric layer 110, the polyester fabric layer 110 and the resin molded portion 180 can be joined to each other without using an adhesive.

[0046] The resin molded portion 180 may be formed of polyester, or may be formed of thermoplastic resin such as ABS resin. A material of the resin molded portion 180 in the present example is polyester.

[0047] Fig. 2B shows a modified example of the cross section of the integrally molded product 100 which is embossed. An example of Fig. 2B includes a plate material 140 of polyester provided between the resin molded portion 180 and the polyester fabric layer 110, which is a difference from the example of Fig. 2A. The integrally molded product 100 in the present example includes a polyester sheet 150 formed by adhering the plate material 140 to a lower surface of the polyester fabric layer 110.

[0048] The plate material 140 is provided on the lower surface of the polyester fabric layer 110. A material of the plate material 140 may be the same as, or may be different from the material of the polyester fabric layer 110. The material of the plate material 140 in the present example is polyethylene terephthalate. The plate material 140 may be adhered to the polyester fabric layer 110 by using an adhesive such as a polyester hot melt adhesive.

[0049] The thickness of the plate material 140 may be thicker than the thickness of the polyester fabric layer 110. As an example, the thickness of the plate material 140 is 0. 5 mm or more and 2. 0 mm or less. By providing the plate material 140 to set the polyester sheet 150, it becomes easy to give a shape to the polyester sheet 150 in comparison with a case where the polyester fabric layer 110 is used alone.

[0050] Fig. 3A shows an example of a flowchart of producing the integrally molded product 100 by using the injection molding. The flowchart in the present example is an example of a producing method for the integrally molded product 100, and the present invention is not limited to this.

[0051] In step S100, the polyester fabric layer 110 is placed in a mold 200 for injection molding. The mold 200 for injection molding has an embossed pattern that is transferred to be applied to the polyester fabric layer 110. That is, the mold 200 has an embossed pattern. A structure of the mold 200 will be described in detail below.

[0052] In step S110, a liquid material for forming the resin molded portion 180 is poured into the mold 200. The liquid material may be molten polyester resin.

[0053] In step S120, the resin molded portion 180 integrally molded with the polyester fabric layer 110, is formed. In step S120, the resin molded portion 180 is formed by the liquid material being solidified, and thus the polyester fabric layer 110 and the resin molded portion 180 are adhered to each other without using an adhesive. The polyester fabric layer 110 is pressed against a mold having an embossed pattern by the resin molded portion 180, and thus the polyester fabric layer 110 is embossed in the mold 200 in step S120.

[0054] Fig. 3B shows an example of a producing method for the integrally molded product 100. The present example describes steps S102, S110, and S120 for producing the integrally molded product 100 by using the injection molding. Step S102 in the present example is an example of step S100 in Fig. 3A.

[0055] The mold 200 for injection molding has a core 210 and a cavity 220. The core 210 has a region E to which an embossed pattern is transferred.

[0056] The region E of the mold 200 to which the embossed pattern is transferred, may be front surface-treated. The front surface treatment may be at least one of blasting treatment or plating treatment. The blasting treatment may be dry blasting treatment, or may be wet blasting treatment. The plating treatment may be plating with a plurality of pieces of metal. As an example, the plating treatment may be plating with chrome or the like. By performing the front surface treatment on the mold 200, it is possible to adjust glossiness of an upper surface of the polyester fabric layer 110 which is embossed.

[0057] In step S102, the polyester fabric layer 110 is placed on a core 210 side of the mold 200. That is, step S100 of placing the polyester fabric layer 110 in the mold 200 includes a step of placing the polyester fabric layer 110 on the core 210 side of the mold 200.

[0058] In the subsequent step S110, the mold 200 is closed, and the liquid material is poured through a hole portion provided, in the cavity 220, for pouring a material. Then, in step S120, the liquid material is solidified, thereby molding the resin molded portion 180 integrally with the polyester fabric layer 110. In step S120, the polyester fabric layer 110 is pressed against the region E of the cavity 220 having an embossed pattern, thereby transferring the embossed pattern to the polyester fabric layer 110.

[0059] The mold 200 may be heated to a temperature at which the liquid material is solidified. As an example, the temperature of the liquid material at a time of pouring is 260°C, and the temperature of the mold 200 is 50°C.

[0060] Fig. 3C shows an example of the producing method for the integrally molded product 100. Fig. 3C is a continuation of step S120 described in Fig. 3B. Among the steps of producing the integrally molded product 100 by using the injection molding, the present example describes step S125 of taking out the integrally molded product 100 from the mold 200.

[0061] In step S125, the mold 200 is opened and the integrally molded product 100 is taken out from the mold 200. In the integrally molded product 100, the upper surface of the polyester fabric layer 110 is embossed. As shown in Fig. 3C, the integrally molded product 100 may have a burr immediately after being taken out from the mold 200. The burr may be removed in a subsequent step.

[0062] Fig. 3D shows a modified example of the producing method for the integrally molded product 100. Step S104 for producing the integrally molded product 100 will be described with reference to Fig. 3D. Step S104 in the present example is an example of step S100 in Fig. 3A.

[0063] In step S104, unlike step S102, the polyester fabric layer 110 is placed on a cavity 220 side of the mold 200. That is, step S100 of placing the polyester fabric layer 110 in the mold 200 includes step S104 of placing the polyester fabric layer 110 on the cavity 220 side of the mold 200. In this case, the region E having the embossed pattern may be provided on the cavity 220 side of the mold 200. In addition, the hole portion for pouring the liquid material for forming the resin molded portion 180 may be provided on the core 210 side. Even in this case, it is possible to use the injection molding and produce the integrally molded product 100 including the polyester fabric layer 110 having the embossed pattern.

[0064] Fig. 4A shows an example of the flowchart of producing the integrally molded product 100 by using the press molding. The flowchart in the present example is an example of a producing method for the integrally molded product 100, and the present invention is not limited to this.

[0065] In step S200, the polyester sheet 150 is formed. The polyester sheet 150 is formed by adhering the plate material 140 of polyester to the lower surface of the polyester fabric layer 110.

[0066] In step S210, the polyester sheet 150 is heated. A heating temperature in step S210 may be higher than or equal to the melting point of the coating layer 130. In an example, the heating temperature in step S210 is higher than or equal to the melting point of the coating layer 130, and lower than or equal to the melting point of the coating layer 130 + 40°C.

[0067] In step S220, the press molding is performed on the polyester sheet 150. The press molding is performed by using the mold 200 having the embossed pattern. This makes it possible to give a shape to the polyester sheet 150, and to emboss the polyester sheet 150 at the same time.

[0068] In step S230, the resin molded portion 180 is attached to the polyester sheet 150 which is embossed. In this manner, the integrally molded product 100 is produced. In step S230, the polyester sheet 150 may be fitted into the resin molded portion 180, or may be adhered to the resin molded portion 180. In step S230, by performing the injection molding on the polyester sheet 150 which is given a shape, the resin molded portion 180 may be attached.

[0069] Fig. 4B shows an example of the producing method for the integrally molded product 100. The present example describes steps S210, S222, S224, and S230 for producing the integrally molded product 100 by using the press molding. Steps S222 and S224 in the present example are examples of step S220 in Fig. 4A.

[0070] In step S210, the polyester sheet 150 is heated by a heater 230. An aspect of the heater 230 is not specifically limited as long as it is able to heat the polyester sheet 150 to a temperature higher than or equal to the melting point of the coating layer 130.

[0071] In step S222, the core 210 is pressed into the cavity 220 to perform the press molding on the polyester sheet 150. The core 210 may be referred to as a lower mold, and the cavity 220 may be referred to as an upper mold. The cavity 220 in the present example has the region E to which the embossed pattern is transferred. This makes it possible to emboss an upper surface of the polyester sheet 150 during the press molding. In step S222, the polyester sheet 150 is cooled down to a temperature lower than or equal to the melting point of the coating layer 130.

[0072] In step S224, the mold 200 is released, and the polyester sheet 150 which is given a shape is taken out. The upper surface of the polyester sheet 150 is embossed. It should be noted that the embossed pattern may be transferred to the core 210 side of the mold 200. In this case, it is possible to emboss a recess portion side of the polyester sheet 150 which is given a shape.

[0073] In the subsequent step S230, the resin molded portion 180 is attached to a lower surface of the polyester sheet 150. The polyester sheet 150 is embossed and is given a shape, and thus it is possible to produce the integrally molded product 100 with a more complex shape than is produced by the injection molding.

[0074] Fig. 5A shows an example of the flowchart of producing the integrally molded product 100 by using the vacuum molding. The flowchart in the present example is an example of a producing method for the integrally molded product 100, and the present invention is not limited to this. Similar to the case of using the press molding shown in Fig. 4A, the flowchart of producing the integrally molded product 100 by using the vacuum molding includes: step S300 of forming the polyester sheet 150 by adhering the plate material 140 of polyester to the lower surface of the polyester fabric layer 110; step S310 of heating the polyester sheet 150; and step S330 of attaching the resin molded portion 180 to the polyester sheet 150 which is embossed. The descriptions of these common steps will be omitted.

[0075] In step S320, the vacuum molding is performed on the polyester sheet 150. The vacuum molding is performed by using the mold 200 having the embossed pattern. This makes it possible to give a shape to the polyester sheet 150, and to emboss the polyester sheet 150 at the same time.

[0076] Fig. 5B shows an example of the producing method for the integrally molded product 100. The present example describes steps S310, S322, S324, and S330 for producing the integrally molded product 100 by using the vacuum molding. Steps S322 and S324 in the present example are examples of step S320 in Fig. 5A.

[0077] In step S310, the polyester sheet 150 is heated by the heater 230. Step S310 is common to step S210 described with reference to Fig. 4B, and thus the description will be omitted.

[0078] In step S322, the polyester sheet 150 is pressed into the mold 200. The core 210 may be referred to as a plug, and the cavity 220 may be referred to as a vacuum molding mold. The cavity 220 in the present example has the region E to which the embossed pattern is transferred. This makes it possible to emboss the upper surface of the polyester sheet 150 during the vacuum molding.

[0079] In step S324, the vacuum molding is performed on the polyester sheet 150, by vacuum-suctioning the polyester sheet 150 by using a vacuum hole 240 provided in the cavity 220 of the mold 200. By using the vacuum molding, it is possible to give, to the polyester sheet 150, even a shape that is difficult to give by the press molding.

[0080] In the subsequent step S330, the resin molded portion 180 is attached to the lower surface of the polyester sheet 150. The polyester sheet 150 is embossed and is given a shape, and thus it is possible to produce the integrally molded product 100 with a more complex shape than is produced by the injection molding.

[0081] While the present invention has been described above by way of the embodiments, the technical scope of the present invention is not limited to the scope described in the above-described embodiments. It is apparent to persons skilled in the art that various changes or improvements can be made to the above-described embodiments. It is also apparent from the description of the claims that the embodiments to which such alterations or improvements are made can fall within the technical scope of the present invention.

[0082] Each process of the operations, procedures, steps, stages, and the like performed by a device, system, program, and method shown in the claims, the specification, and the drawings can be performed in any order as long as the order is not indicated by "prior to," "before," and the like and as long as the output from a previous process is not used in a later process. Even if the operational flow is described using phrases such as "first" or "next" for convenience in the claims, the specification, and the drawings, it does not necessarily mean that the process must be performed in this order.

[0083] 100: integrally molded product; 110: polyester fabric layer; 120: polyester fabric; 130: coating layer; 140: plate material; 150: polyester sheet; 180: resin molded portion; 200: mold; 210: core; 220: cavity; 230: heater; 240: vacuum hole.

Claims

1. An integrally molded product which is produced by using at least one method of injection molding, press molding, or vacuum molding, the integrally molded product comprising: 　　a resin molded portion; and 　　a polyester fabric layer which is provided on the resin molded portion, wherein 　　the polyester fabric layer is embossed.

2. The integrally molded product according to claim 1, wherein 　　the polyester fabric layer has 　　a polyester fabric, and 　　a coating layer of polyester which is provided on an upper surface of the polyester fabric.

3. The integrally molded product according to claim 2, wherein a thickness of the polyester fabric is 0.1 mm or more and 2.0 mm or less.

4. The integrally molded product according to claim 2, wherein a thickness of the coating layer is 20 μm or more and 100 μm or less.

5. The integrally molded product according to claim 2, wherein the coating layer is a polyester film.

6. The integrally molded product according to any one of claims 2 to 5, wherein the polyester includes at least one of PET (polyethylene terephthalate), PBT (polybutylene terephthalate), or PTT (polytrimethylene terephthalate).

7. The integrally molded product according to claim 1, wherein the polyester fabric layer has a suede-like polyester fabric.

8. The integrally molded product according to claim 7, wherein a thickness of the suede-like polyester fabric is 0.6 mm or more and 1.5 mm or less.

9. The integrally molded product according to any one of claims 1 to 5, wherein a material of the resin molded portion is polyester.

10. The integrally molded product according to any one of claims 1 to 5, comprising: a plate material of polyester which is provided between the resin molded portion and the polyester fabric layer.

11. A producing method for producing an integrally molded product by using injection molding, the producing method comprising: 　　placing a polyester fabric layer in a mold for injection molding which has an embossed pattern; 　　pouring a liquid material for forming a resin molded portion into the mold; and 　　forming the resin molded portion integrally molded with the polyester fabric layer, and embossing the polyester fabric layer in the mold.

12. The producing method according to claim 11, wherein the placing the polyester fabric layer in the mold includes placing the polyester fabric layer on a cavity side of the mold.

13. The producing method according to claim 11, wherein the placing the polyester fabric layer in the mold includes placing the polyester fabric layer on a core side of the mold.

14. The producing method according to claim 11, wherein a surface of the mold which has an embossed pattern, is front surface-treated.

15. A producing method for producing an integrally molded product by using press molding, the producing method comprising: 　　forming a polyester sheet by adhering a plate material of polyester to a lower surface of a polyester fabric layer; 　　heating the polyester sheet; 　　performing the press molding on the polyester sheet by using a mold which has an embossed pattern; and 　　attaching a resin molded portion to the polyester sheet which is embossed.

16. A producing method for producing an integrally molded product by using vacuum molding, the producing method comprising: 　　forming a polyester sheet by adhering a plate material of polyester to a lower surface of a polyester fabric layer; 　　heating the polyester sheet; 　　performing the vacuum molding on the polyester sheet by using a mold which has an embossed pattern; and 　　attaching a resin molded portion to the polyester sheet which is embossed.

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