Vehicle interior article of skin-integrated laminate, method for manufacturing non-foaming polyurethane resin and method for manufacturing skin-integrated laminate using the same

A method of producing a skin-integrated laminate comprising a design surface of a non-foaming polyurethane resin, a semi-rigid polyurethane foam and a core material, which comprises the steps of:

• (1) applying a mold release agent on a core part and a cavity part of an article mold for the surface skin which forms the design surface;
• (2) optionally, applying a paint film on the cavity surface of an article mold;
• (3) closing the core part and the cavity part of the article mold;
• (4) reaction injection molding a mixture comprising (I) a polyol mixture, and (II) a polyisocyanate compound, wherein (I) said polyol mixture comprises:
• (1) a polyol, (2) from 2.0 to 7.0 parts by weight, based on 100 parts by weight of (I) the polyol mixture, of a chain extender, the chain extender being selected from the group consisting of 1-methyl-3,5-diethyl-2,4-diaminobenzene, 1-methyl-3,5-diethyl-2,6-diaminobenzene and mixtures thereof (3) a catalysts, and (4) optionally, an auxiliary agent;
• (5) removing the molded article of a non-foaming polyurethane resin which forms the design surface skin;
• (6) placing the molded article of a non-foaming polyurethane resin from step (5) into a cavity part of a foaming mold,
• (7) installing the core material to a core part of the foaming mold,
• (8) pouring a semi-rigid polyurethane foam mixture onto the non-foaming polyurethane resin which was placed onto the cavity part of the foaming mold in the step (6), with an opened or closed system, and
• (9) removing the resultant integral molded article having a design surface skin.