Manufacturing method for molded multilayer article

A manufacturing method of a multilayer article composed of a soft skin material, a foamed intermediate layer and a base member, said method comprising the steps of:

• extruding a melted resin layer for the skin material, a melted resin layer for the intermediate layer containing a foaming agent and a melted resin layer for the base member in the form of a multilayer resin sheet from a die-head of an extruding machine on a lower molding die of a molding machine in such a manner that the melted resin layer for the base member is placed on the lower molding die of the molding machine while the die-head is being moved in a horizontal direction;
• and
• moving down a pre-heated upper molding die of the molding machine and clamping the upper molding die with the lower molding die to foam the resin layer for the intermediate layer and to mold the extruded resin layers under pressure in a multilayer article,
• wherein the melted resin layers for the intermediate layer and base member are extruded in the form of a multilayer resin sheet from the die-head of said extruding machine, and wherein the melted resin layer for the skin material is layered on the extruded resin layer for the intermediate layer after being extruded in the form of a single layer sheet from the die-head of said molding machine.

A manufacturing method of a multilayer article composed of a soft skin material, a foamed intermediate layer and a rigid base member, said method comprising the steps of:

• setting a preliminarily molded rigid base member on a lower molding die of a molding machine;
• extruding a melted resin layer for the skin material and a melted resin layer for the intermediate layer containing a foaming agent in the form of a multilayer resin sheet from a die-head of an extruding machine having extrusion slits on the lower molding die in such a manner that the resin layer for intermediate layer is layered on the rigid base member while the die-head is being moved in a horizontal direction perpendicular;
• clamping a heated upper molding die with the lower molding die of said molding machine to foam the resin layer for the intermediate layer and to mold the resin layers for the skin material and intermediate layer integrally with the rigid base member;
• and
• cooling the molding dies of said molding machine.

A manufacturing method of a multilayer article composed of a rigid base member, a foamed soft intermediate layer layered on the base member and a soft skin material layered on the intermediate layer, said method comprising the steps of:

• extruding a melted resin layer for the base member, a melted resin layer for the intermediate layer including a foaming agent and a melted resin layer for the skin material in the form of a multilayer resin sheet from a die-head of an extruding machine having extrusion slits on a lower molding die of a molding machine in such a manner that the resin layer for the base member is placed on a first molding surface formed on the lower molding die of said molding machine while the die-head of said extruding machine is being moved in a horizontal direction perpendicular to the extrusion slits;
• moving down an upper molding die formed with a second molding surface corresponding with the surface of the skin material and clamping the upper molding die with the lower molding die in a manner such that the upper molding die is positioned to form a clearance between the first and second molding surfaces larger than the thickness of the multilayer resin sheet;
• heating the upper molding die to foam the resin layer for the intermediate layer including the foaming agent until the surface of the resin layer for the skin material is pressed into contact with the second molding surface;
• and
• cooling the melted resin layers for the base member, intermediate layer and skin material.

A manufacturing method of a multilayer article composed of a rigid base member, a foamed soft intermediate layer layered on the base member and a soft skin material layered on the intermediate layer, said method comprising the steps of:

• extruding a melted resin layer for the base member, a melted resin layer for the intermediate layer including a foaming agent and a melted resin layer for the skin material in the form of a multilayer resin sheet from a die-head of an extruding machine on a lower molding die of a molding machine in such a manner that the resin layer for the base member is placed on a first molding surface formed on the lower molding die of said molding machine while the die-head of said extruding machine is being moved in a horizontal direction;
• moving down an upper molding die formed with a second molding surface corresponding with the surface of the skin material and clamping the upper molding die with the lower molding die in a manner such that the upper molding die is positioned to form a clearance between the first and second molding surfaces larger than the thickness of the multilayer resin sheet;
• heating the upper molding die to foam the resin layer for the intermediate layer including the foaming agent until the surface of the resin layer for the skin material is pressed into contact with the second molding surface;
• and
• cooling the melted resin layers for the base member, intermediate layer and skin material,
• wherein a first stepped portion formed on the lower molding die at an outer periphery of the first molding surface and a second stepped portion formed on the upper molding die at an outer periphery of the second molding surface are coupled with each other during the clamping process of the molding dies to cut out a useless remainder portion of the multilayer resin sheet.

A manufacturing method of a multilayer article composed of a rigid base member, a foamed soft intermediate layer layered on the base member and a soft skin material layered on the intermediate layer, said method comprising the steps of:

• extruding a melted resin layer for the base member, a melted resin layer for the intermediate layer including a foaming agent and a melted resin layer for the skin material in the form of a multilayer resin sheet from a die-head of an extruding machine on a lower molding die of a molding machine in such a manner that the resin layer for the base member is placed on a first molding surface formed on the lower molding die of said molding machine;
• moving down an upper molding die formed with a second molding surface corresponding with the surface of the skin material and clamping the upper molding die with the lower molding die in a manner such that the upper molding die is positioned to form a clearance between the first and second molding surfaces larger than the thickness of the multilayer resin sheet;
• heating the upper molding die to foam the resin layer for the intermediate layer including the foaming agent until the surface of the resin layer for the skin material is pressed into contact with the second molding surface;
• and
• cooling the melted resin layers for the base member, intermediate layer and skin material,
• wherein the melted resin layers for the base member, intermediate layer and skin material are simultaneously extruded from extrusion slits of the die-head of said extruding machine while the die-head is being moved in a horizontal direction perpendicular to the extrusion slits.

A manufacturing method of a multilayer article composed of a rigid base member, a foamed soft intermediate layer formed on the base member and a soft skin material formed on the intermediate layer, said method comprising the steps of:

• setting a preliminarily molded rigid base member on a first molding surface formed on a lower molding die of a molding a machine;
• extruding a melted resin layer for the intermediate layer including a foaming agent and a melted resin layer for the skin material in the form of a multilayer resin sheet from a die-head of an extruding machine having extrusion slits on the lower molding die of said molding machine in such a manner that the base member and an upper outer peripheral portion of the lower molding die are fully covered with the resin layer for the intermediate layer placed thereon while the die-head of said extruding machine is being moved in a horizontal direction perpendicular to the extrusion slits;
• moving down an upper molding die formed with a second molding surface corresponding with the surface of the skin material and clamping the upper molding die with the lower molding die in a manner such that the upper molding die is positioned to provide a clearance between the first and second molding surfaces larger than the thickness of the base member and the multilayer resin sheet;
• heating the upper molding die of said molding machine to foam the resin layer for the intermediate layer including the foaming agent until the surface of the resin layer for the skin material is pressed into contact with the second molding surface;
• and
• cooling the resin layers for the intermediate layer and skin material.

A manufacturing method of a multilayer article composed of a rigid base member, a foamed soft intermediate layer formed on the base member and a soft skin material formed on the intermediate layer, said method comprising the steps of:

• setting a preliminarily molded rigid base member on a first molding surface on a lower molding die of a molding machine;
• extruding a melted resin layer for the intermediate layer including a foaming agent and a melted resin layer for the skin material in the form of a multilayer resin sheet from a die-head of an extruding machine on the lower molding die of said molding machine in such a manner that the base member and an upper outer peripheral portion of the lower molding die are fully covered with the resin layer for the intermediate layer placed thereon while the die-head of said extruding machine is being moved in a horizontal direction;
• moving down an upper molding die formed with a second molding surface corresponding with the surface of the skin material and clamping the upper molding die with the lower molding die in a manner such that the upper molding die is positioned to provide a clearance between the first and second molding surfaces larger than the thickness of the base member and the multilayer resin sheet;
• heating the upper molding die of said molding machine to foam the resin layer for the intermediate layer including the foaming agent until the surface of the resin layer for the skin material is pressed into contact with the second molding surface;
• and
• cooling the resin layers for the intermediate layer and skin material,
• wherein the resin layer for the skin material comprises a thermoplastic elastomer, the resin layer for the intermediate layer comprises an ethylenic copolymer of ethylene and at least one radical copolymerizable acid anhydride, and the base member is made of a porous material in the form of a wooden material consisting of wood fibers bonded by thermosetting resin.

A manufacturing method of a multilayer article composed of a rigid base member, a foamed soft intermediate layer formed on the base member and a soft skin material formed on the intermediate layer, said method comprising the steps of:

• setting a preliminarily molded rigid base member on a first molding surface on a lower molding die of a molding machine;
• extruding a melted resin layer for the intermediate layer including a foaming agent and a melted resin layer for the skin material in the form of a multilayer resin sheet from a die-head of an extruding machine on the lower molding die of said molding machine in such a manner that the base member and an upper outer peripheral portion of the lower molding die are fully covered with the resin layer for the intermediate layer placed thereon while the die-head of said extruding machine is being moved in a horizontal direction;
• moving down an upper molding die formed with a second molding surface corresponding with the surface of the skin material and clamping the upper molding die with the lower molding die in a manner such that the upper molding die is positioned to provide a clearance between the first and second molding surfaces larger than the thickness of the base member and the multilayer resin sheet;
• heating the upper molding die of said molding machine to foam the resin layer for the intermediate layer including the foaming agent until the surface of the resin layer for the skin material is pressed into contact with the second molding surface;
• and
• cooling the resin layers for the intermediate layer and skin material,
• wherein a first stepped portion formed on the lower molding die at an outer periphery of the first molding surface and a second stepped portion formed on the upper molding die at an outer periphery of the second molding surface are coupled with each other during the clamping process of the molding dies to cut out a useless remainder portion of the multilayer resin sheet protruding outwardly from the first molding surface of the lower molding die.