Stock material or miscellaneous articles – Web or sheet containing structurally defined element or... – Composite having voids in a component
Patent
1996-06-17
1998-09-08
Smith, Lynette F.
Stock material or miscellaneous articles
Web or sheet containing structurally defined element or...
Composite having voids in a component
428109, 428234, 428247, 428248, 156148, 156196, 156221, 156242, B32B 512, B32B 506, B31F 122, B29B 1165
Patent
active
058042920
DESCRIPTION:
BRIEF SUMMARY
FIELD OF THE INVENTION
The present invention relates to a laminated article such as a door trim board or an interior material of an automotive vehicle and a manufacturing method of the laminated article.
BACKGROUND OF THE INVENTION
As a laminated article for the foregoing use, there has been proposed a laminated article which is comprised of a base member of wood or synthetic resin material formed in a predetermined shape and a skin layer of synthetic resin formed on the base member. For example, Japanese Patent Laid-open Publication No. 2-286315 discloses a door trim board the base member of which consists of a wooden hard board formed in a predetermined shape and fully covered with a skin layer adhered to the front surface thereof.
During manufacturing process of the door trim board, as shown in FIG. 12(a), a base member 203 formed in a predetermined shape and a skin member 204 formed with a design pattern are retained in place under suction along with each molding surface of lower and upper molds 201 and 202 of a vacuum molding machine and integrally adhered by an adhesive under pressure between the molds 201 and 202. After adhered to the base member 203, the skin member 204 is cut in such a manner that an outer periphery of skin member 204 is protruded out of the base member 203 as shown in FIG. 12(b). The protruded portion 204a of the skin member 204 is rolled inwardly as shown in FIG. 12(c) and adhered to the outer periphery of the base member 203 for the beauty of the door trim board.
Since in the conventional door trim board, an adhesive is used to adhere the base member 203 and skin member 204, the adhered portion is comprised of three layers such as the base member 203, skin member 204 and adhesive layer. In use of the door trim board for a long period of time, there will occur strain in the adhered portion, particularly in the adhesive layer due to a difference in physical-chemical properties such as thermal expansion coefficients of the three layers. This causes separation of the skin member 204 from the base member 203. In the door trim board produced by the conventional manufacturing method, the component layers may not be sufficiently adhered due to irregularity in coating of the adhesive at the manufacturing process. In the conventional manufacturing method, it is required to provide means or process for coating the base member 203 and skin member 204 with the adhesive, and it is further required to form the skin member 204 in the shape of a sheet to be adhered to the base member 203. As a result, the manufacturing apparatus and process are complicated.
DISCLOSURE OF THE INVENTION
The present invention is directed to solve the problems described above. Thus, an object of the present invention is to provide a laminated article such as a door trim board capable of maintaining a bonding effect of the components for a long period of time by integrally forming a base member and a skin member without forming the skin member in the shape of a sheet and without using any adhesive and to provide a manufacturing method of the laminated article by which reduction in the quantity of materials to be used and simplification of the manufacturing steps are achieved.
According to the present invention, the object is accomplished by providing a laminated article comprised of a porous base member formed in a predetermined shape and covered with a skin member of resin material which is hardened in a condition where it was impregnated into the porous base member at least at the front surface thereof.
According to an aspect, there is provided a manufacturing method of the laminated article wherein a porous base member formed in a predetermined shape and an amount of resin melt supplied onto the front surface of the porous base member are pressed between a pair of molds so that the resin melt is impregnated into the porous base member at least at the front surface thereof and hardened to integrally form a skin member on the porous base member.
The manufacturing method of the laminated article comprises ste
REFERENCES:
patent: 4986865 (1991-01-01), Fuji
patent: 5297842 (1994-03-01), Hayashi
patent: 5308570 (1994-05-01), Hara et al.
patent: 5401556 (1995-03-01), Ishitoya et al.
Patent Abstracts of Japan, vol. 018, No. 453 (M-1662), 24 Aug. 1994 & JP 06 144123 (Kasai Kogyo Co. Ltd.), 24 May 1994.
Hiraiwa Yoshihiko
Horiba Makoto
Ishihara Yukio
Ishitoya Katsunori
Kato Hiroyuki
Araco Kabushiki Kaisha
Smith Lynette F.
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