Multilayer molded article

Details Multilayer molded article Multilayer molded article

1994-07-05

2001-08-28

Copenheaver, Blaine (Department: 1771)

Stock material or miscellaneous articles

Web or sheet containing structurally defined element or...

Composite having voids in a component

C428S319700, C428S319900

Reexamination Certificate

active

06280836

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to a method for producing a multilayer molded article comprising laminating a composite skin layer which has been beforehand formed from a skin material and a foam sheet and a core layer of a thermoplastic resin, and a multilayer molded article produced by this method.
PRIOR ART
A large amount of plastic molded articles are used in various fields including automobiles and domestic electric equipments in view of its economy, free moldability and light weight. With the increase of diversification of the applications, varieties of appearance of the products are required. In particular, in these years, it has been strongly desired to impart a decorative effect and soft feeling to the product. Hitherto, many studies have been made to provide a compound which has functions satisfying such desires. However, it is difficult for a single material to have the above surface properties while maintaining free moldability and strength. At present, a large number of multilayer molded articles in which several materials having different functions are combined are usually used.
Among the multilayer molded articles, a multilayer molded article having a foam layer between the core layer and the skin material is excellent in soft feeling, and various types of such articles are proposed.
Hitherto, as a method for producing such multi-layer molded article, there is proposed as method comprising placing a composite skin layer which comprises a skin material and a foam sheet between molds, supplying a molten resin when the molds are not closed and then closing the molds to obtain the multilayer molded article (see Japanese Patent Kokai Publication No. 235613/1989).
Though the above method is an industrially advantageous method, when it is used to produce an article having a complicated shape such as an instrument panel of an automobile, the skin layer tends to suffer from breakages, wrinkles and debossing.
SUMMARY OF THE INVENTION
An object of the present invention is to solve the above problems of the prior arts and provide a method for producing a multilayer molded article which has a good appearance without breakages, wrinkles or debossing in its skin layer.
As the result of the extensive study to achieve the above object, it has been found that, by the use of a composite skin layer comprising a skin material which has the specific properties before lamination, a multilayer molded article having fairly good appearance is obtained even if the article is a large size one having a complicated shape, and the present invention has been completed. Accordingly, the present invention provides a method for producing a multilayer molded article comprising laminating a composite skin layer which is preformed from a skin material and a foam sheet on a core layer of a thermoplastic resin, characterized in that a tensile modulus E of said skin material of the composite skin layer is not larger than 950 kg/cm
2
, and a tensile modulus E (kg/cm
2
), a heat shrinkage factor F (%) and a thickness t (cm) of said skin material satisfy the following relationship (1):
20/(E×t)+F≧2.5  (1)


REFERENCES:
patent: 3954537 (1976-05-01), Alfter et al.
patent: 4543289 (1985-09-01), Park
patent: 4769278 (1988-09-01), Kamimura et al.
patent: 5053179 (1991-10-01), Masui et al.
patent: 5154872 (1992-10-01), Masui et al.
patent: 4030964 (1992-04-01), None
patent: 0466179 (1992-01-01), None
patent: 0480153 (1992-04-01), None
patent: 59-150740 (1984-08-01), None
patent: 62-297123 (1987-12-01), None
patent: 63-159022 (1988-07-01), None
patent: 63-251206 (1988-10-01), None
patent: 64-26414 (1989-01-01), None
patent: 64-22545 (1989-01-01), None
patent: 1-141011 (1989-06-01), None
patent: 1-235613 (1989-09-01), None
Abstract from EPX 333 193, which corresponds to JPX 01-235613; 9/1989.*
English language Abstract for JPX 64-22545; 1/1989.

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