CA2169475A1

CA2169475A1 - Laminated body and method of manufacturing the same

Info

Publication number: CA2169475A1
Application number: CA 2169475
Authority: CA
Inventors: Katsunori Ishitoya; Hiroyuki Kato; Yukio Ishihara; Kazunori Kuze; Yoshihiko Hiraiwa; Makoto Horiba
Original assignee: Individual
Current assignee: Araco Co Ltd
Priority date: 1994-06-17
Filing date: 1995-06-15
Publication date: 1995-12-28
Also published as: EP0714760A1; US5804292A; JP3820268B2; WO1995035208A1; AU2682595A; CN1073013C; CN1129920A; EP0714760A4

Abstract

The invention provides a laminated article such as door trim board capable of maintaining a bonding effect 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 an adhesive, and a manufacturing method of the laminated article by which reduction in the quantity of material to be used and simplification of manufacturing steps are achieved. A porous base member (11) molded in the shape of a door trim board and a molten resin (12melt) supplied on the surface of the porous base member are pressed between a pair of molds (31,32) so that the molten resin (12melt) is impregnated into the porous base member at least at the front surface thereof and hardened to form a skin member (12) on the porous base member (11). In the door trim board thus obtained, the resin forming the skin member (12) and the porous base member (11) are integrated by an anchor effect of resin with a reliable strength thereof retained.

Description

96 02~15 20:~4 ~152 58~ 3 E~SE P~T. i-~ G0'l~LI~G 1~004 S~ lCATlO~

LAMl NATED ARI`ICLE
ANI~ MET~TOD l~)~' MAN'JFA~rURING THE SA~E

Field o~ the l~ent~on:
The pres~nt invention relates t~ a lamlnated artlcle such as a door trim board or an in~erior mat~rial of ~n automotive vehicLe and a manu~acturLn~ m~tho~ of the lAml-nated article.

~ ackground o~ the Invention As ~ lamin~e~ article for th~ ~ore~oin~ use~ there has been pr~po~ed a laminated art~cle which ls comprised of' a base member of wc)o~ or synthetlc resin material ~ormed in a predeterm~ned ~h~pe and ~ skin layer Q~ syntheti c re~ln ~rme~ o~ the base ~ember. For exam~le~ Japanese Patent Laid-open Publ . cat.ion ~!o . 2-28~315 dis^lcises a ~loor trim board the base member of ~hich consists of a wooden hard board formed in a predetermined sh~pe and ~ully co~ere~
with a skln l~er adhered to the ~ront surf~ce th~reof, ~ urin~ manu~acturin~ process of -the door trlm board, as shown In Fig. l~a), a base ~ember 203 ~ormed ln a prede-ter~ined ~hape and a ~kin me~ber ~04 ~or~ed with ~ de~ign patter~ are ret~ined In place under ~uction alorlg with each ~olding sur~ace of lower and upper m~lds ~01 and ~0'~ o~
a vacuum ~oldlng m~chine and integrally adhered by a~ adhe-sive under pressure between the mgl~ 201 and 202. A~t~r ' 96 02~15 20: 45 ~052 5$3 t-g2-5 _ liASE PAT. ~ ,O~LI~TG 5~Loo5 adhered to the base member ~G3. the ~kin ~ember 204 is cut in such a manner thht an outer periphery o~ skin member 204 is protruded out o~ ~he ba~e member '103 as shown. in Fig.
l2(b~. The protruded portlon 204a o~ the ~kin member 204 i6 rolied lnw~rdly as ~hown in Flg. 1 ~c) a~d ~dhered to the outer peri~hery o~ the b~e member 203 for the beauty of the door trlm board.

SiIlce ~n the con~entional door trim bo~rd, nn adheslve i9 u~ed to adhere the ~ase m~mber 203 an~ skin member 204, the adhered portlon 1~ co~pr~ed of three l~yer~ such ~s the base me~ber 203, skl.n m~mber ~04 and adheslve layer.
In use o~ the door trim board ~or 8 lOIlg per~od of ti~e, there will occur straln in the ~hcred portion, particu~ar-ly ln the adhesiYe la~er due to a di~erence in physical-chemical properties such as therm~l expan~ion coefflcients o~ the three layers. This cause~ separation o~ the skin member 204 from ~he ba~e member ~03. In the door -trim board produccd by the con~ention~ manu~acturlng method.
the component layers may not be su~iclently adhered due to irregularity in coatin~ of the adhes~ve at the manufactur-inK process. In the canvent~ona~ ~anufacturing ~ethod. lt i~ required ~o pro~lde means or proce~s ~or coating the base member 2~3 and skin mernber Z04 w~th the adhe~i~e, and l$ l~ ~urther req~ired to f~rm the skin member 204 ln the shspc of a shee~ to be adhered to the base member 203. A~
~ recul~, the m~nufacluring apparatus and proces~ ~re complicated.

96 02~15 2û . 45 ~052 583 1925 HASE PAT. ~ LI.~-G ~ ~lo~

~lsclosure of ~he Inventiuli The present lnvention ls dlrected to ~o~ve t:he proble~s described abo~e. Thus, ~n obJeet o~ l,he present in~ention is to provide a la~inated ~rticle such as a door tri~ board capable o~ maintalnlng ~ bondin~ ef~ect of the componeD.ts ror ~ long period of time by integrally formirlg ~ base member and a skin member without forming the skir.. member ~n the shape o~ a sheet ~rld without u~in~ a~ adhesi~e and to provide ~ ~anufa~turing method 0~ the lami~ated article by ~h~c~h reduction in the qu~rltlty Or materi~ls to be used and slmpli~ication 0~ the manufaeturing Stf,pS are ~c~eYed.

According to the present inventlon, the object is accomplished by proYidin~ a laminated ~rtlcle com~rised oi a porous base ~e~ber formed ln a predeter~ined s~ape and co~ered ~lth a skirL member of resin material whirh is hardened in ~ con~ltlon where it was impre~aLed into the porous base member at least at the front surrac~ thereof.

Accordlng to an a~pect, there is proYlded a manufaetur-in~ ~ethod of the lamina~ed art~ele wherein a porous ba~e member ~ormed in a predetermine~ s~ape and an a~ount o~
resin melt supplied onto the ~ron+ surface o~ the porous base member are pressed between a palr o~ mol~s sv that the resin melt is impregnated into the pcrous bASe me~ber at least at the front sur~nce th~re~ ~nd harde~ed to lnte-grally form a skir~ ~ember on the porous base me~er.

The manu~acturing method o~ the lamlnate~ ar~lele 96 02.fl5 20:4~ ~05~ 583 1925 E~SE PAT. ~ OWL~J~G i~Oo7 cumpr1ses steps of ~ettl~g a pcrou~ base member ~ormed in a predetermired shape between a paLr o~ mold~ ecting an amo~lt o~ resln melt onto the ~ront surfac~ o~ the porous ~ase member ~etween the molds ~o impre~nate Lhe resln ~elt into the ~orous ba~e memb~r at :least ~t the ~rnnt surface thereof, and hardenln~ the InJected resln melt to lntegr~lLy form a ski.n member o~ the porous base member.

To enhance w~tne~s o~ the porous ~ase member to the resin melt ln the manuf~cturing method, thc frQIIt sur~ace o~P the porous ba~e member ~a~ be treated by a surface reformlng agent prior to i~pregnation o~ the resln melt.
The porous base ~ember u~,d ln the present inventlon may be in the ~orm oY a molded member of re~ln or ~03d material.
Preferably, the l~mlnated article is used as a door trim board or an interior ~teriaL of an auto~otive vehicle.

Since in the laminate~ artiele comprised as described above, the re~ln me~t ~vr the skin member is hardened after directl~ imprcgn~ted lnto at least the front sur~a~e o~ the porous ~ase member, the integrate~ portion of the skin me~ber and the porou6 base me~er ls compri~ed of o~y two materIals integrated b~ an anchor ef~ect oY res.in. As a result, any strRin d~es not occur in ~he iIltegr~ted portlon a~ in the laminated layers adhered ~y A conventlonal ~an-ner. Accordingl~ even if th~ l~minated articl~ wa~ u~ed for a long perlod of tlme, the ~kln member woul~ not sepa-rate irom ~.,he porous bas~ ~emb~r. Since the l~minated '86 02~15 20.~ ~052 583 1~25 ~ SF.PAT. 7 ~ G~ OQ~

artl~le ls manu~actured ~ithout u~lng any a~e~lve, ~n incompletely bonded portion cau~ed by irrc~ularlty in coating of the adhe~ive does not occ~r.

The laml~ated arti~sle can bç m~nufAct~red ln a simpl~
manner b~ presslng the por~us base me~ber and the thermo-plastic resin melt ~or the ski Il ~e~ber ~etween the pair of molds and hardenin~ the ~hermopl.astis resln ~elt impr~gnat-ed lnto the ~ront surface of the p~rous base member. The lamina~ed article can be also manufactured ~n a s~mple m~nner by ln~ectlng a thermop~stic resln melt 01tO the ~ront sur~ace c~ the porous base member placed b~tween $he pair of molds ~nd hard~ning the thermoplA~tic re&in melt impregnated into ~he front sur~ace o~ the porous ha~e member. ~ith such a ~anufacturlng ~t~d o4 the laminated ar~lcle sccQrdin~ to the present inventi~n, the mamif~tur-lng proces~ c~n ~e si~plified without c~atlng proce~s of an adhe~ive and ~ormlng process of th~ skln me~ber in the conventLonal manufacturiIlg ~ethod.

Lr the case that wetness o~` the ther~opla~ic resin melt to the porous base me~ber ls poor ~n the manuf~cturlng process, wetne~s o~ the ther~oplastlc resin melt can be enhanced by treating the ~rQnt sur~'ace o~ the porous base me~ber ~ith ~ sur~ace refor~1n~ a~ent prior t~ lmpregn~tlon Or the thermopla~tic re~ln melt.

BRIEF DESCRIPTICN OF '~EE ~RAWIN~6 Flg. l is a perspectl~Ye ~lew of a d(~or trlm board ln '9~ 02~15 20:~7 ~U52 583 1~25 HASE PAT. ~ G0~ oo~

accordance wlth the present inYen~ion, Fig. 2 is ~ vcrtlcal sectLonal vieu ~a~en alon~ linc 2-in Fl~. l;
Fig. ~ illustrRtes a ~irst embo~im~nt of the manu~ac-turln~ method o~ th~ door trlm bo~rd;
Fig. 4 illustrate~ ~ secon~ embodiment vf the m~nu~c-turing m~thod of the door trlm board;
F.g. 5 illustrate~ ~ third Pmbodiment of the m~nufac-turing method o~ the door trim board;
Fig. ~ lllu~trates a ~ourth embodiment of t~e manufac-tur~ng method o~ the door trim boar~, Fig. 7 lllustrates ~ th embodl~ent ~f the mnnu~'ac-turing ~et~od o~ the door Lr1~ board;
F1g. B illustra~es a si~th embodlment o~ the manw~ac-turlng method o~ the door trl~ ~o~rd;
~ ig. ~ illustra~es a seventh embod7m~nt o~ the ~anufac-turing method o~ the door trlm bcard;
Fig. IQ lllu~trates a elgkth embodiment of the ~anufa~-turlng method of the door tlim bo~rd;
F~g. 11 ls ~ Yertlcal sectional ~lew of a door trim broad produced by m~nufacturlrlg met~d~ A and B in açcord-ance wlth the preBent i.nvention; and Fig. 1~ illustrates manu~acturing process ~f ~ conven-tlonal door trl~ board.

De6crlptlon o~ tha Preferred embodiment:~s Hereinafter, a door trim bo~rd o~ ~n au~omotive ~ehicle in accorddnce ffith presen~ in~entlon ~nd ~ ~anu~acturi~
method of ~he door trlm board ~ill be described w~th re~er-' ~ 02,'15 20; 47 ~052 583 19L5 ~SE PAT. ~-~ ' Gl~LI~ 010 ~, ence to the d~awings. As shown in F.L~s. 1 and 2, the door trim board 10 i9 comprised oY a porous ba~e member 11 formed in the shap~ o~ a door trim and a ~kin member 12 formed on the por~us base member 11. The sk~n member 12 i~
provided with a design pattern ~ ~or decor~tlon, in neces-~lty. The base member 11 is in the form Qf a p~rous member ~hich i~ formed by a ~ix~ure of wood r~ber and a bonding agent 6uch as phenol resin m~xed at a ratlo of 93 7. The skin me~ber 1~ is made of a thermoplastlc resin such as polypropylene. The porou~ bhse ~ember 11 and skln member 12 are integrated ~ an ~hor e~fect o~ resl~ at a por~ion where the thermoplastic re~in melt of the skln member 12 ls hardened ln a condition where the resin melt was impregnat-ed into lnternal pores ~n the porous base member 11.

Sin~e in the door trim bonrd 10, the bonded portion of the porous base member and skin ~ember 12 is comprised of only two materlals inte~rated by an anchor e~ect o~ res~n, sny stress doe~ not occur at ~he lntegrated portion.
Aecordlngly, ~ven if the laminated article in the ~orm o~
the door tr ~m board wa.s u~ed ~or ~ long period of time.
separation of the skin member 1~ from the porous b~s~
member would not occur. Slnce the la~inated ~rticle is manufactured without u~ing any adhesive, there will not occur an lncompletely bQn~ed portlo~ caused by irregularity in coatln~ Or the sdhes~ve d~ring the ma~uf~cturing proc-ess.

Herelna~ter, a ~anu~acturing method of the door trim '96 02~15 20:48 ~05~ 583 la25 ~SE PAT. ~ GO~LI~ ~011 board will be descrihed with re~erence to the ~a~ngs. ln Fig. 3, th~re i~ il1ustrated a ~irs~ embo~iment of' the manuracturlng method o~ the door tri~ board 10 shown in Fig.s 1 and ~. In the ~anuf~cturing method o~ thi~ embodl-ment, a 1Ower ~c1d 31 for~ed with ~ mo1dtng surface 31a forming the back sur~aee o~ ~he trim b~ard, an upper mold formed w1th a moldlng ~ur~ac~ 32a hav1ng embo~sed orn~ments ~orm1~;g ~ de61gn pattern on the ~ront surfac~ of the skin member and an in~ection de~ice 33 for in~e~tln~ o~ a ther-mop1astie resin me1t ar~ used ~ uring the ma~ufacturin~ process, t-he lower and upper mo1ds 31 and 32 are prebeated at 20'C-30 C. and a porous basa member 11 formed ln Lhe do~r trim is set on the mo1d-ln~ surf~ce 31a of lower mold 31a at a tempcrature of 20-G-~O C. Therea~ter, polypropylere .~esln 1~melt i~ a molten st~te (at lBO C-220 C) i8 suppli~ by the 1nJect~on device 33 onto the ~ront surface o~ the p~rous base member li at a d~scharge amount o~ about 1~Q gJmin. w1thln about 12 minutes ~er one s~,ee~. In th~s instanee, the pol~propylene re~in 12m~1t is supplied onto the ~ront .surlace o~ the porous b~se member 11 1n sueh a ~anner t~t the th1ckness of po1ypropy~en~ re~in m~lt becomes larger ln O~lmm th~n that of the teim bo~rd and th~t the supply ~idth c~ poly-propylene resin melt becomes U.95 times the width of the trim board. Subsequently~ ~n a coTlditi~n ~here the temper-ature o~ po1ypropy1ene re~in 1~melt is maint~ined at 140-C-160-, the poly~ropylenc re~in 12melt is ~pread vut under pressure ~ore than 3~ kgfJcm2b between the upper ar~d 1Ower ' ~6 02~15 ~0: 48 ~052 ~83 192.~ E P.~T. ~ C;QW~ G ~1012 - _ 21 69475 molds 3~ and 31. with1n 2-3 seconds and im~regnates into internal poreæ in the porou~ ba~e mem~er ll at its front surface 81 de. When the ~olyprop~ylene resin 12melt ls cooled ~or about 30 seccr.ds under pressure more th~n 30 kg~/cm2 and hardened, the ~ront ~urfa~e n~ the poroufi base member ll is fully covered with a fikin member 12 formed by the polypropylene resln t~ pro~iuce the door trim bo~rd iO.

Illustr~ted in Flg. 4 is a ~eco~d embodi~ent Or the manufacturing method of the ~oor trl~ board lO shGwn ~n Fi~s. l and 2. In the manu~acturln~ method o~ this embodi~
ment, an upper mold 4~ formed with a molding surface 42a -formin~ the front surface o~ the trim board and a lo~er mold 41 formed with a ~oldi~g sur~ace 4ia ~or~ing the back surface o~ the trlm hoard ~re used. The ~ow~r m~ld 4t ts formed wi~h resin suppl~ passages 44 openi~g toward the molding ~urrace 41a at appropriately d~stributed posl~lon~
and prov~ ded wl .,h a hea~er 45 tv prevent fall of the tem-perature O-r polypropylene resin 12melt belng sup~1.ied into the passa~es 44. During the manuf~cturing process, mo]ten polypropy]ene re~in 12melt is inJeGted by an inf ection device 43 lnto the resin supply pa~s~geæ 44 and supplled onto the ~ront surfa~e o~ the porous ba~e ~ember 11 .

Illustrated in ~ig. 5 ls a th~rd e~bodiment o~ the manufacturing method o~ the door 5rim board lO shown ~ n Figs. 1 and 2. ln the ~anu~acturin~ method of thls embodi-ment, an upper mold 52 ~ormed with a ~ol~in~ sur~ace 52a '96 02,~1a ~0:~9 ~0~i? 5~.~ 19~5 HASE PAT. `~ ~UWLI~'G ~1013 - ~ 2 1 69475 ~ormlng the front ~urf~ce o-f ~he tzi~ boarcl and n lvwer mold 51 ~or~ed wlth a moldlng sur~ce 5L~ t~orming the back ~urface ~f the rr1m board are use~. Th~ upper mold 5~ ls forme~ ~ith resin supply passages ~A which ~re opened toward the moldlng surface 52a at appropriately distributed positions a~d ~r~vlded wlth ~ hea7:;er 55 to prevent fall of the te~perature of polypropylene resin 12melt belng sup-plled lnto the pa~sages ~4. Duri~,g the manuf~turlng process , ~ mol~en polypropylene resln 12mel~ i~ irl~ected by an injection de~lce .53 into the resirl supply pMs~ages 54 and suppl~ed O~ltO the fr~nt surface ~f the porous base member 11.

I1.lustrat~d in ~g. ~ ls a ~ourth embodiment of the manufacturing meth~d of' the do~r tr-im b~ard lG shown in Fig~. 1 and 2. In a pair o~ molds 61 and ~2 used in thls embodlment, the lower mold 61 ls ~or~ed wlth a moldlng surf~ce 61a ~orming the front sur~ace of the trim ~oard, whlle the upper mold B~ ~s ~crmed w~th a moiding sur~ace 62a forming the back surf'ace o~ tlie trim boa~d. In addi-~lon, the moldlng ~urface ~la o~ low~r mold 61 is ~ormed ~ith embossed orna~ents forminK a de~ign patt~rn on t.he front surface o~ the skin me~ber.

During the manufacturing process o~' the door trim ~oard 1~, the upper and lower ~olds 61 and ~ are pr~heated at ~O'C-~ C, and polypropylene resin 12~slt in a molten ~tate (at l~O'C-~ZO~Cj ls suppl1ec by an inJeetl~n device 63 on the mo~ding sur~ace 61a of lower ~ol~ ~1 a~ ~ discharge '9B 0~15 20 4~ 2S052 59~ 1925 ~ASE PAT. ~ ` G~)WL~G ~014 amount o~ 150Qg/miI~ . wi th-in 12 ~ec~?nds Per one shee~ Yvhile a porous b~se memb~r 11 o. wood ~aterial formed In the shape o~ the ~oor tr~m bo~rd 1 s set on ~he molding ~urface 62a of upper mold 62 at 20 C-~0 C . Thereaf tcr, the upper mold ~2 is lowered to pre~s the porou~ hase member 11 and polypropylene re~in 12~elt under ~res~ure more than 30 kg~c~2 ~or 2-3 seconds thereby to impregnate the resi~
12m~1t lnto internal pores ir. the front surface o~ the ~orous base member 11. When the res1n 12meit is cQoled under pre6sure of 3~ kg~/c~2 ~cr 30 seconds and hardened, the rront surface of the porous base me~ber 11 is ~ully covered wlth a ~kin member IZ ~ormed b~ the resln l~melt to produce the door trim bo~rd 10.

Illustr~ted in l~ig. 7 ~s a f~f~h ~mbodi~en~ ~f the manu~acturing method o~ the door trlm board according to the present lnvention, whereir. a l~wer mold 71 ~ormed with a molding sur~a~e 71a rormin~ the front surface oI` the trim board and an upper mold 72 formed ~ith a molding ~ur~ce 72a for~lng thc back ~urface o~ the trim ~oard are used.
Thi~ ~bodiment is d~ferent from the fourth embodiment only ln the facts that tne lower mold 71 is ~ormed ~lth resln supply p~s~Age~ 74 Op811irlg iIltO ~he molding surface 71a at appropriately dlstributed po~itions ~nd provide~
with a heater 75 to prevent faLl of the te~perature of resln 12melt ~upplied int~ the Pa~sage~ 74 and that the resin lZmelt i.6 injected by an inJection devlce 73 lnto the pa~s~Kes ~4 and suppl~ed onto thn frorl~ ~ur~ace OI the porous base member 11 through the passages 74.

~6 0 2~'15 20: 50 23~052 56i3 1~ 25 lIiSE PAT . ~ O~ G l~j Ol S

Illu~tr~ted in liig 8 i5 a sixth embodlmer~t of the ~anufacturing method of the do~r trim bo~r~ ceordin~ to the present inv4ntlon, wherein a lower mol~ 81 formed with a moldlng surrace 81a ~orming the ~ront surYace of the trim board and an upper ~ol d 82 ~ormed ~ th a ~oldln~ surfane 8Za formln~ the back surrace of the t;rim ~oard ~re used.
This embodl~nent ls diff'erellt -~roD7 t;he ~ourth embo~iment only ln the ~acts that the upper m~ld 8? 19 ~ormed wlth resin supply p~ssage~ 84 opening lnto the mo~ding surfa~e &2~i at appropriately distributed pc~.tic~ns and pro~i-id~d with A heater to prevent ~all o~ the temperature of molten poly~ropylene re~in l?melt ~upp~ ied intv the pass~ges 84 and that th~ molten polypro~lene resir. l~melt ls inJ~ted by an in~, ection device 83 into the rssi~ supply passage~ 84 and supp~ i ed onto the f'ron~ ~urface of the porous bas~
member 11 through the resin supply pa~s~Lges ~4~

I I lu~trated ln Flg. ~ ls a seversth e~odlmer.t oiF the manufacturlng method of the door trim board shown in Ylg. 1 and ~. In the manufacturing method of this embod~ment.
a porous base member 11 i6 ~irst set between a ~air ~
molds ~1 and 2. Subsequentl~~, polypropylene resin 12~elt in a molten st~te ~t 180 C-22~-C~ is inject~d by an inje~-~lon dev~ce ~3 into a reslr, suppl~ pA~sage 94 under high pressure of lOG-300 kgJomZ and supplied be'cween the front sur~ace of the porous b~Lse member 11 and a ~lding surf~ce 91a o~ lo~er mold ~1 so that the resln l:~melt :Ls impre~Fnat-ed into por~s 1ll the front æurfaee o~ th~a pOrOUB base member 11 Whe~l the resin 12~elt læ h~rdened, the front 96 02~15 20:50 2~052 S83 1925 ~SE PAT. -~ G~ 'LI~ b~1016 -surface of the poro~s ba~e member 11 ls fu~ly covered ~ith a skln laye~ 12 formed by the resln l~melt to ~roduce the door trim board 10. The lower m~ld ~1 is provided therein with a heater ~5 to pr~vent ~all Or the temperature o~
resin l~melt supplled into the resin ~upply pa~sage g4. In the case that the openirl~ pos1tion Or resin suyply pasæage 94 ls loeat~d at a portlon where P. dl~t~] end o~ the trlm board is ~vrmed or an ornament is attached thereto, thc de~lgn of the door trlm boRrll wo~ld not be ~poil.ed even i~
burrs were for~ed at the openlng pos~tlon of the resin sup~ly pass~e.

Tllu5~;r~ed in Fi~. ~0 is an eighth elnbodlm~nt of the manuf~cturing me~hod of the door tri~ b~ard 10 shown in Flgs. 1 and ~, whereln a lower mold l03 ~or~ed with a molding ~ur~ace 101~ ~ormlng the front surf~ce of the trim `board and an upper ~ol~ 102 formed with a mclding surface 1~2a forming the back surraee of the tr~m board are used. This em~odiment ~s different from the seventh embod-iment onl~ in the facts tha~ the upper mold 102 i~ rormed w1th resin 6upply pN~a~efi 104 opening to~ard the m~lding surface 102a at appropr~tely distributed posltlons and provided with a heater 1~ to prevellt fall o~ the tempera-t~re of re~in 12melt being supplied lnto the passa~es 104 and that the resin 12melt ls ln~ected by an in~ection devlce 103 L~to the re~in su~ply passage~ 104 ~nd supplied onto the ~r~nt sur~ace ~f the porous base member 11.

9~ 02J15 2û:51 ~052 583 1925 H4.SE PAT. )~ GO~LI~;G Ij~jo1? __ With the manu~acturlng metho~s of the ~ore~oin~ embodi-ment~, the manufacturin~ process can be 6i~plifled without coating proce66 of an adhesive and ~orminK proçes~ of a skin ~e~ber requlred ln a conventional manu~acturlng method. In addition, the mater~als u~ed for production of the dovr trlm board can ~e reduced ~ln~e an~ adhesive i9 not used.

As shown ln th~ drawlngs, each molding ~u~face 3~a, 42a, ~2a, 61a. 71a, Bla, ~ln, lOla ~ in~ the ~ro~t sur-face o~ the trim board is embo~d ~or ~or~lng a desien pattern on the ~kin member 12 ~t the tlme ~hen the porous base member 11 wa~ covered ~lth the ~kin member 1~. In each p~ir o~ the m~lds 31., 32; 41 r 42; 51~ 52; ~1~ 62; 71~
72; 81, ~2; ~ 2; 101, 102; the mold~ng sur~a~es 3'a, 32a;
41a, 4Za; 51~, 52a; 6~a, ~a: 71a. 72a; 81a, ~a; 91a, 92~;
lOla, 102a each are formed to suppl~ the re~in l~melt into a ca~rity clearance ~or~ed betwecn ~-he ~uter Peripheral edge lla and the ~orresponding molding surf~ce. It i6, there-~ore, Hble to ~ully cover the outer peripheral ed~e lla of t~e porous base member 11 with the resln melt. As a re-sult, the outer periFheral ed~e of the door tr~m board 10 can be treated without cutting prccess of the ski~ me~ber ~see Flg. 12(b~) ~nd roll~ng ~rocess of the protruded portlon of the ~kln member (see Fig. 12(c~ re~uired in the conventlonal. manu~acturing method and can be completed ~lthout any ~poll o~ thç beauty.

~se 02~15 20:51 ~052 ~83 1~"5 11.4SE PAT. 7'~ GO~LI~-G 1~1018 A'thollgh T r. the em~odiments de~cribed above, a mixture of wood fiber and phenvl resln mixed at a ratio ~ g3:
wa6 used as ~ raw mater~al of t~e porous base member, a ~i~ture oP ~0% ~ood flber, 10~ phe~ol resin and lU%
olefinic ~lber may be used a~s ~ raw mater~a~ of the porvus base member. Alternati~ely, a porous mcmber made o~ hard foamable pGlyurethane resin m~ be used as thc porous base member. ~'urthermore, a molded poro~s member made of A thermoplastle resin such as ~henol re~ln, epoxy resln, polyester resln, etc. or polvpropylene resin, A~S resin, etc. added wlth a rei~lfolcing agent and an antist~tic agent, a molded porous mem~er made o~ pre~sed metal fibers, a molded member of carbon mater~al, or a yor~u~ member comprised of porous resln laminated on an unwoven ~abrtc may be used as the porous ~a~e member. ~or example~
a mlxture o~ polypropylene resin ~r polyethylene resin mixed with 10-30% msgnesium sllicate, glass ~iber or calci-um cnrbonate may be used as a raw ~ateri~l c~ t~e porous base member. In the case that wetness o~ the base member made of the ~oregolng matcrialæ to th~ ~kin me~ber i~ poor, a surface re~orming agent such as olefl.ne m~y be eoatcd on or impregnnted into the ~ront surface o~ the p~rous base member to enh~nce permea~ility of the resln me]t lnto pores in the porous base member. For ex~mple, .i~ the case that the ~ase member is made o~ polypropylene resin ~hile ~he ækin member ls made of vinyl chloride re~in, a ~olYQlefine chloride based primer is used as the surface reforming agent.

~6 02~15 ~0:52 ~052 583 1925 ~4SE P.~T. ~ o~LING ~019 Although in the abuv~ e~bodiment~ polypr~py~ne restn wa~ u~ed to Yorm the skin member~ etnylene propylene elas-~omer~ may be m2xed wlth th~ pc~yprvp~ ne resln ~t a ratlo o~ 10-5~%, pre~er~bly 49% to a~u~t ~uldity and hardne~s of th~ resln ~elt. In th~ folJo~ln~ tab~Y, the rluid~ty and har~ness of the re~i.n melt ~re evalllated ln relatvioIl to the mlxing r~io of polypr~p~leDe resin anu ~thy~ene prvpylene ela~tGmers .
Table No ~ 2 3 4 Property Fluidity x ~ 0 O
MFR i 8~ lS9 155 Hardness x ,~ x O
Shore A ~2 8~ 8~ 73 MFR(Melt ~l~w Ratio): Flu~dity by JIS ~ 676C
Unit: gtmln Shore A: Hardness measured by ~ hard~ess te.~ter Unit ~9 No. l: polypropylene : ethylene propyiene ela~tomers _ 90 : 10 No. 2; po~Yprc~pylene ; ~hylerle propylene el~tomer~
- 8~ : ~0 Nv. 3: polyprepyl~ne e.hyl~ne prop~lefLe elastQmers = 50 ; ~

96 02~15 20:52 ~052 583 1~25 ~E PAT. 7~i GO~LI~G li~lO~0 No. 4: polypropylene : ethylene propylene elastomers = 60 : 4~

As the material of the s~in we~ber, another oleflnlc thermopla~tic resin such as vinyl chloride, polyethylene, ethylene-propylene polymer, eth~lene-vinyl acetate PolYmer, ethylene-~crylic acid polymer. acrylonltrile-b~ltadiene-styrene ~olymer ~ABS resln), poly~mlde reiln. ~SA re~in~
etc. or a mlxtur~ o~ two kinds of the thernopl~ic resln~
may be used. The materi~l o~ the skin member may he al60 ~dded with a brightener and B non~lammable ~gent t~king into account appearance ~nd prr)perty o~ the product.

Although the foregoin~ ~olds 31, ~: 41, 42; 51, 62:
~1, 62: 71, 72: 81, 82~ 2: 101. 102 were made of aluminum, the mol.de may be m~de o~ ~ron, ZAS ~Trade name of ~inc alloy manufa~tured by SumlLomo Kinzo~u Ko~yo K K~ or re~in, Although ln the ~bo~re embo~iments, the door trlm board shoun in ~igs. 1 and ~ ~as manufa~tur~d by harden7n~ t~le pol~propylene resin melt ~pread out orl the front surface of the porsus b~e memher placed between the palr of mold , a portlon of ihe 6kln member may be roam~d -to produce a door ~rim board 110 the skin :layer o~ which is soften as ~hown Ln Flg. 11. The door trlm ~oa~d 110 i S compri~ed Q~
~ porous base mem~er 111 m~de o~ wood or resin material and a skln ~e~ber integrally ~ormed on the porous base ~e~ber 111. The ~kin member 112 ls decor~ted ~y a de~gn pattern ' ~6 Q2~15 Z0: 53 ~Po52 5~3 1~25 H~SE PAT. ~ i GOY~ YG ~ 0:~1 ~13 partly ~ormed thereon as ln the dvor t~im board show~ in Flg. 2. The skin member 112 consists of a ~amed la~er 112a ~ormed by foaming a thermoplastic re~i~ such as po~y-propylene and hardening the same and ~ skin layer 112b ~ormed by hardening the thermo~laslic re~in wlthou-~ foa~ing the same. The intcgrated portlon of the porous base member 111 and the sk.in member 112 is in ~ condit1or where ~he thermoplastic re~in of the skin member 12 ls hardened aft.er impregn~ted into the lnternal pore~ in the porou~ base member 11~. Tha~ is to say, the porous base member .lll and skin ~ember 112 are integrated to each other by an anchor effect of resin.

The manuf~cturlng method o~ the door tri~ ~oard described above ~s di~rerent from the manuYacturin~ method~
o~ the first to ei~hth embod:iments o~ly ill the facts that the fosmable thermoplaetle resin is u~ed as the material ~or the ~kin member 112 and that the foamed layer 112a and skin layer 112b are ~or~ed by proce~s for separating the molds in a predetermined c].earance ~fter the ~o~mable thermoplasti.c resin melt is spread ou~ on the ~ront surface o~ the porous base ~em~er 111 between the mold~. As an example o~ the manufacturin~ method of the door trim board shown in Fig. 11~ ~ manufaeturing ~ethod A corres~ondlng with the first embodiment shown in Fig. 3 ar~d a manuf~c-tur-ing method ~ corresponding with the seventh embodlment sho~n in Pig. g wlll be descr~be~ below.

' g~ aZ~15 20: 53 ~052 58~ 1925 ~SE P.~T. ~ GtiM.I~ 022 In the manu~acturirl~ method A. the molds 31 ~2 and in~ection deYlce ~3 sho~n ~In Flg. 3 can be used. In the following descriptlo~, the ~ame m~lds and injectlon device as those ~;h~wn in ~ . 3 are de~l gnated by the B~me re~er-ence n-~nerals. Durin~ the m~nufactl;ring process o~ the door trim bo~rd 111, the mol~ 31, 32 are ~rehe~ted ~
50' C-~' C, and a ~orous base member 111 o~ wood materiAl formed in $he shape oY the trlm board is placed o~ the mold1ng sur~ace 31a o~ 1 ~wer mol~ 31. In such a eondltlon, a molten polypropylene re~in ll~melt mlxed ~ith lnert ~as ~ror in~trLr,ce, nitrogen gAS) at 180- c-220 C ~s ~upplled on the sur:face of the porous ba~e member 111 by means of the injectlon ~e~ice 33. ~The re8in 112melt in the manufactur-ing ~rocess eorre~po~ds q~ith the resin 1 2~elt sho~n ln Fig.

3. ) Su~equen$1~. the resin l~melt i~ pressed be$ween the ~ol d~ 31 and 37 and spread ou~ :in a cavlty cl~ar~nce of ~bout lmm ~ormed between the p~rou~ ~a~e me~ber 111 arld th~
mo:ldin~ ~ur~ace o~ the upper mo.Ld 32. When ~he c~vity cle~r~nce between the molds 31 and 3~ .ls widened by about lmm aftc~ mantalned ln ~he abov-3 condlti.on fvr abou~ one second, ~he resin 112melt in contact wlth the molding s~rface 32a of up~er mold 32 i~ ~or~ed wtth the deslgn patiern and hard~ned at a high coolin~ spee~ to form the skin ~ayer ~12b. wh~le '.he resln ll2melt a~acen~ to th~
porous ba~e member l11 Ls f~m~d and h~rdc~ed at a low coollng speed to furm the ~o~med laYer 112~ ee Fl~
The resin 112mel~ impregrlated in+Jo the ln~ernal pores ln the porou~ ba~e member l}l Is h~rdened as it ls, ~nd the front sur~ce o~ the po~ous ba~e member 11~ ls fully cov-ls ~ 02,15 20:54 ~o~. ~h3 1925 ~ASE P.4T. ~t Go~Ll~G ~023 21 6~475 ered with the skin l~-er 11~ to produce the door trlm board llU.

In the manufacturing method B, the mold~ 51, ~2 and lnJection device 93 shown in Flg. 9 can be used. In the ~ollowing description~ the sa~e molds and inJection devlce as those sho~n in Fig. 9 are de~gnated by the sAme refer-ence numerals. Durin~ the manufacturing proces~ of the door trim board 111, a porous base ~e~ber 111 o~ wood ~aterlal ~ormed in the shape G~ the trim ~oard ls placed between the molding surfaces ~la, 9~a of molds ~1, 92 in a condition where a ca~ity c~learanee of about lmm i~ belng ~ormed between the ~ront ~urface of the porou~ base member 111 and the mol~ing sur~ace ~la o~ lower mold ~1. Subse-quently, a molten polypropyleile resi~ 112melt mlxed with nitrogen gas at 1~0 ~-~2~ C is injected under high pressure ~100-300 kg/cm2 by the inJection device 93 into the re~in supply pa~sa~e 84 ~nd ~upplled into the cavity cle~rance between t~e ~ront æurface o~ the porous base member 111 And the molding surface 91a of lower mold 91. (The resln 112melt ln the ma~u~acturing process eorresponds with the resin 12melt shown in Flg. 7~ 1'hus, the resln 112melt ls spread out on the ~ro~t ~ur~ace of the porous b~se member 111. When the ca~ity clearante bet~een the molds ~l and g2 is widened by about l~m in ~u~h a condition a~ described above, the r~in 112melt in contact with the moldin~ ~ur-~ace gla oi lower ~old 91 is formed wirh the design pattern and hardened at a high coo1in~ speed to form the ~kin layer 112b, while the reslc 11.2~elt ~acent to the base member 96 02~15 20:54 ~p052 583 1925 ~ASE P.~T. ~ Go~LI~G ~024 ~11 ls ~oamed and hardened at a low cool~ng ~peed to ~orm the ~oamed l~yer 112~. ~see Fig. 11) The resin 112melt impregnated into the internal pores in the porou~ ~&se mem~er 111 ls hardened as it is, and the ~ront sur~ace o~
the porous base member 111 is ~ully covered wlth the skin layer 112 to produce the door trim ~oard llU, In ~he manu~acturing methods A ~nd B deseribed a~ove, the manufacturlng proccss of the door -trim boQrd can be ~impli~ied without proee~s for forming a ~kln sheet ~nd a foamed sheet required in the conventional manuf~cturl~g method. Since the foamed layer llZa and skln l~rer ll~b are integrally forMed w~ thout adhesion therecI to form the skin member 112, seyaration o~E the layer6 ll~a ~nd :L12b does not occur. ~n addltlon, the thlckne~s and porosity o~
the foa~ed laYer 112a can be uni~ormed, an~ th~ ~urface of the skin layer ll~b can be unlforml~ forme~ ~lon~ with the molding surfa~. Thi~ is use~ul to provide ~ minated article excellent in uniform elasticlty ar,d ~eel ~nd appearance.

Claims

Claims:

1. A laminated article comprised of a porous base member formed in a predetermined shape and a skin member of resin material formed on the porous base member, wherein the resin material of the skin member is hardened in a condition where it was impregnated into the porous base member at least at the front surface thereof.

2. A laminated article as set forth in Claim 1, where-in the porous base member is made of wood or resin materi-al.

3. A laminated article as set forth in Claim 1 or 2, wherein the laminated article is in the form of a door trim board or an interior material of an automotive vehicle.

4. A manufacturing method of a 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 there-of and hardened to integrally form a skin member on the porous base member.

5. A manufacturing method of a laminated article, comprising the steps of setting a porous base member formed in a predetermined shape between a pair of molds, injecting an amount of resin melt onto the front surface of the porous base member between the molds to impregnate the resin melt into the porous base member at least at the front surface thereof, and hardening the injected resin melt to integrally form a skin member on the porous base member.

6. A manufacturing method as set forth in Claim 4 or 5, wherein the front surface of the porous base member is treated by a surface reforming agent prior to impregnation of the resin melt.

7. A manufacturing method as set forth in any one of Claims 4 to 6, wherein the porous base member is made of wood or resin material.

8. A manufacturing method as set forth in any one of Claims 4 to 7, wherein the laminated article is in the form of a door trim board or an interior material of an automo-tive vehicle.