Process for producing a multilayer molded article

Details Process for producing a multilayer molded article Process for producing a multilayer molded article

1988-11-29

1991-10-01

Tentoni, Leo B.

Plastic and nonmetallic article shaping or treating: processes

Mechanical shaping or molding to form or reform shaped article

To produce composite, plural part or multilayered article

264275, 264278, 264279, B29C 3314, B29C 4318, B32B 2706

Patent

active

050531794

DESCRIPTION:

BRIEF SUMMARY
FIELD OF THE INVENTION

The present invention relates to a process for producing a multilayer molded article comprising a thermoplastic resin and a skin material. More particularly, it relates to a process for producing a multilayer molded article comprising a thermoplastic resin and a skin material which covers a desired part of the article


DESCRIPTION OF THE RELATED ART

The above described multilayer molded article comprising the thermoplastic resin and the skin material which covers only a desired part of the article is used as a door trim or a rear trim of an automobile and the like. As a process for producing such multilayer molded article comprising the thermoplastic resin and the skin material which covers only the desired part of the article (hereinafter referred to as "skin material partially laminated article"), practically used are a process which comprises molding the thermoplastic resin by, for example, injection molding and laminating the skin material having a desired shape on the molded article with an adhesive and the like, and a process which comprises making a part by laminating the skin material on a hard board and attaching said part to the molded article with small screws and the like. These processes require post-processing of the article, which is troublesome and increases the production cost of the article.
As processes for integrally molding the skin material partially laminated article, Japanese Patent Publication No. 28704/1981 and Japanese Patent Kokai Publication No. 177332/1983 disclose processes for integrally producing a skin material partially laminated article by injection molding which comprise fixing the skin material at a desired position on an inner wall of a mold with a fastener or a magic band, closing the mold and then injecting the thermoplastic resin. These processes require special means for fixing the skin material to the mold. Further, since the resin melt is supplied after closing the mold, it flows at a very high flow rate in a very narrow clearance which corresponds to a difference between a thickness of the article and the thickness of the skin material, a rear face of the skin material receives a large shear rate so that the skin material tends to be easily displaced even though the fastener or the magic band is used. In addition, the skin material is largely influenced by heat, and after the supply of the resin melt, a large pressure is applied to the skin material in a dwell time so that grain pattern, texture, hand and feeling (hereinafter referred to as "feeling") of the skin material tend to be impaired.


DESCRIPTION OF THE INVENTION

As a result of the extensive study on a process for producing a skin material partially laminated article having good feeling without displacement of the skin material, it has been found that conditions for supplying the resin melt are important and the present invention has been completed.
Accordingly, the present invention provides a process for producing a multilayer molded article which comprises supplying at least one piece of a skin material having a desired shape and a resin melt between upper and lower molds and closing the molds to form a multilayer molded article, wherein the resin melt is supplied at or near a center area of a rear face of the skin material, or wherein after the skin material is lifted to a position at which the skin material contacts a cavity surface of the upper mold by a vertically movable rod or bar which is positioned at a part of the lower mold on which the skin material is placed, the resin melt is supplied between the upper and lower molds and the rod or bar is returned to a determined position at least before the molding is completed.
That is, the present invention provides a method for economically producing the skin material partially laminated article wherein the skin material is not moved and the article has good feeling by supplying the resin melt at or near the center area of rear face of the skin material through a passage for the resin melt provided in the upper or lower

REFERENCES:
patent: 2797179 (1957-06-01), Reynolds et al.

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