Decorative sheet, shaped product, automobile, and method for producing shaped product

• US 20050221063A1
• Filed: 12/25/2003
• Published: 10/06/2005
• Est. Priority Date: 01/08/2003
• Status: Active Grant

• Current Assignee: Yamaha Hatsudoki Kabushiki Kaisha (Yamaha Corporation), Yamaha Motor Company Limited (Yamaha Corporation)
• Original Assignee: Yamaha Hatsudoki Kabushiki Kaisha (Yamaha Corporation)
• Inventors: Morozumi, Naohiro, Suzuki, Yasuo
• Granted Patent: US 7,371,453 B2
• Time in Patent Office: Days
• US Class Current: 428/195.100
• CPC Class Codes: B44C 1/105 comprising an adhesive layer decalcomania B44C1/16; adhesive tapes C09J7/20
• CPC Class Codes: B60R 13/02 Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners B60R13/01 takes precedence ; padded linings for the vehicle interior B60R21/04; arrangements or adaptations of floor mats or carpets in vehicles B60N3/04; internal lining for trains B61D17/18
• CPC Class Codes: B60R 13/04 External Ornamental or guard strips; Ornamental inscriptive devices thereon fastening strips or bars to sheets or plates by means of clips F16B5/12
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24876 Intermediate layer contains particulate material [e.g., pigment, etc.]
• CPC Class Codes: Y10T 428/24917 including metal layer

Abstract

A decorative sheet includes a base member made of a resin material and having a first and a second principal surfaces opposite to each other, a decoration layer provided on the first principal surface of the base member and having a pattern area representing a predetermined pattern, and a spread suppressing member provided in a position corresponding to the pattern area on the side of the first principal surface or on the side of the second principal surface of the base member, for suppressing the spread of the pattern area of the decoration layer.

Claims

1-41. -41. (canceled)

42. A decorative sheet comprising:

a base member having first and second principal surfaces opposed to each other;

a decoration layer provided on the first principal surface of the base member and having a pattern area representing a predetermined pattern; and

a spread suppressing member provided at a location corresponding to the pattern area on the side of the first principal surface or on the side of the second principal surface of the base member, for suppressing the spreading of the pattern area of the decoration layer.

43. The decorative sheet of claim 42, wherein the base member is made of a resin material.

44. The decorative sheet of claim 43, wherein the resin material is a thermoplastic resin material.

45. The decorative sheet of claim 42, wherein the spread suppressing member has a higher coefficient of thermal conductivity than a coefficient of thermal conductivity of the base member.

46. The decorative sheet of claim 42, wherein the spread suppressing member is made of a material including one of a metal and a metal compound.

47. The decorative sheet of claim 42, wherein the spread suppressing member is made of metal.

48. The decorative sheet of claim 42, wherein the base member is made of a resin material, and the spread suppressing member is made of a material including one of a metal and a metal compound.

49. The decorative sheet of claim 42, wherein the base member is made of a resin material, and the spread suppressing member is made of metal.

50. The decorative sheet of claim 42, wherein a coefficient of thermal conductivity of the spread suppressing member is at least about 10 W/m·

K.

51. The decorative sheet of claim 42, wherein a thickness of the spread suppressing member is in a range of about 5 μ

m to about 100 μ

m.

52. The decorative sheet of claim 42, wherein the spread suppressing member includes a first portion that overlaps the pattern area.

53. The decorative sheet of claim 52, wherein the spread suppressing member includes a second portion arranged along an outer circumference of the first portion.

54. The decorative sheet of claim 53, wherein a width of the second portion of the spread suppressing member is in a range of about 1 mm to about 10 mm.

55. The decorative sheet of claim 53, wherein a width of the second portion of the spread suppressing member is in a range of about 2 mm to about 8 mm.

56. A molded article comprising a molded article body and the decorative sheet of claim 42 which is joined to a surface of the molded article body.

59. A motor vehicle comprising the molded article of claim 56.

57. A molded article comprising:

a molded article body; and

a sheet joined to a surface of the molded article body;

wherein

the sheet includes a base member and a decoration layer provided on a surface of the base member on the side of the molded article body;

the decoration layer includes a pattern area representing a predetermined pattern; and

a portion of the sheet corresponding to the pattern area has a thickness which is in a range of about 1.1 times to about 1.8 times a thickness of remaining portions of the sheet.

58. The molded article of claim 57, wherein the portion of the sheet corresponding to the pattern area has a thickness which is in a range of about 1.2 times to about 1.6 times the thickness of the remaining portions of the sheet.

60. A production method of a molded article comprising the steps of:

preparing a decorative sheet including a base member having first and second principal surfaces opposite to each other, a decoration layer provided on the first principal surface of the base member and having a pattern area representing a predetermined pattern, and a spread suppressing member provided in a location corresponding to the pattern area on the side of the first principal surface or on the side of the second principal surface of the base member, for suppressing the spreading of the pattern area of the decoration layer;

preparing a molded article body; and

joining the decorative sheet to a surface of the molded article body.

61. The production method of a molded article of claim 60, further comprising, before the step of joining the decorative sheet to the surface of the molded article body, the step of heating the decorative sheet.

62. The production method of a molded article of claim 60, wherein the base member is made of a resin material.

63. The production method of a molded article of claim 62, wherein the resin material is a thermoplastic resin material.

64. The production method of a molded article of claim 60, wherein the spread suppressing member has a higher coefficient of thermal conductivity than a coefficient of thermal conductivity of the base member.

65. The production method of a molded article of claim 60, wherein the spread suppressing member is formed from a material including one of a metal and a metal compound.

66. The production method of a molded article of claim 60, wherein the spread suppressing member is formed of metal.

67. The production method of a molded article of claim 60, wherein the base member is made of a resin material, and the spread suppressing member is made of a material including one of a metal and a metal compound.

68. The production method of a molded article of claim 60, wherein the base member is made of a resin material, and the spread suppressing member is made of metal.

69. The production method of a molded article of claim 60, wherein the coefficient of thermal conductivity of the spread suppressing member is at least about 10 W/m·

K.

70. The production method of a molded article of claim 60, wherein a thickness of the spread suppressing member is in a range of about 5 μ

m to about 100 μ

m.

71. The production method of a molded article of claim 60, wherein the spread suppressing member includes a first portion which overlaps the pattern area.

72. The production method of a molded article of claim 71, wherein the spread suppressing member includes a second portion arranged along an outer circumference of the first portion.

73. The production method of a molded article of claim 72, wherein a width of the second portion of the spread suppressing member is in a range of about 1 mm to about 10 mm.

74. The production method of a molded article of claim 72, wherein a width of the second portion of the spread suppressing member is in a range of about 2 mm to about 8 mm.

75. The production method of a molded article of claim 61, wherein the step of joining the decorative sheet to the surface of the molded article body includes the step of moving the heated decorative sheet closer to the molded article body, and the step of reducing a pressure of a first space formed between the decorative sheet moving closer to the molded article body and the molded article body as compared with a pressure of a second space expanded oppositely to the first space with respect to the decorative sheet.

76. The production method of a molded article of claim 75, wherein the step of moving the decorative sheet closer to the molded article body is performed such that the spread suppressing member faces the second space.

77. The production method of a molded article of claim 75, further comprising, after the step of moving the decorative sheet closer to the molded body, the step of cooling the spread suppressing member by introducing a gas into the second space.

78. The production method of a molded article of claim 60, further comprising, after the step of joining the decorative sheet to the surface of the molded body, the step of removing the spread suppressing member.

79. The production method of a molded article of claim 60, wherein the spread suppressing member is provided on the side of the second principal surface of the base member.

80. The production method of a molded article of claim 60, wherein, after the step of joining the decorative sheet to the surface of the molded article body, the decoration layer is located between the base member and the molded article body.

81. The production method of a molded article of claim 60, wherein the molded article body includes a first member and a second member disposed on a surface of the first member, and in the step of joining the decorative sheet to the surface of the molded article body, the decorative sheet is joined to the surface of the molded article body so as to cover both of the first member and the second member, thereby joining the first member and the second member.

82. A production method of a molded article comprising the steps of:

preparing a decorative sheet including a base member having first and second principal surfaces opposite to each other, and a decoration layer provided on the first principal surface of the base member and having a pattern area representing a predetermined pattern;

preparing a molded article body;

heating the decorative sheet; and

joining the decorative sheet which is heated to a surface of the molded article body in a condition in which a temperature of a portion of the decorative sheet corresponding to the pattern area is less than a temperature of another portion of the decorative sheet.

83. The production method of a molded article of claim 82, wherein the step of joining the decorative sheet to the surface of the molded article body includes the step of cooling the decorative sheet such that the temperature of the portion corresponding to the pattern area is rapidly reduced as compared to the temperature of the other portion.

84. The production method of a molded article of claim 82, wherein the decorative sheet further includes a member provided in a location corresponding to the pattern area on the side of the first principal surface or on the side of the second principal surface of the base member and having a higher coefficient of thermal conductivity than a coefficient of thermal conductivity of the base member.

85. The production method of a molded article of claim 84, wherein the member is formed from a material including one of a metal and a metal compound.

86. The production method of a molded article of claim 84, wherein the member is formed of metal.

87. The production method of a molded article of claim 84, wherein the base member is made of a resin material, and the spread suppressing member is made of a material including one of a metal and a metal compound.

88. The production method of a molded article of claim 84, wherein the base member is made of a resin material, and the spread suppressing member is made of metal.

89. The production method of a molded article of claim 84, wherein a coefficient of thermal conductivity of the member is at least about 10 W/m·

K.