Toyoda Gosei Co., Ltd.

Keizou Ito

Takashi Kato

Hikaru Ando

Syoji Sakaida

Yuji Kuriyama

A resin laminate of the invention includes sheet laminate including a skin, which is securely joined with a foamed bead base by heating. The resin laminate is manufactured according to the following steps. The foamed bead base and the sheet laminate consisting of the skin, a foam layer, and a thermoplastic resin film are prepared separately. The thermoplastic resin film is made of a resin material which thermally adheres to both the foam layer and the foamed bead base and has a softening temperature lower than those of the foam layer and the foamed bead base. The thermoplastic resin film is softened by heating the sheet laminate, which is then softened by heating the sheet laminate, which is then pressed against and bonded to the foamed bead base by vacuum molding or press forming. The thermoplastic resin film thermally adheres to both the foam layer of the sheet laminate and the foamed bead base, thus joining the sheet laminate with the foamed bead base.

Resin laminate

A resin laminate of the invention includes a sheet laminate including a skin, which is securely joined with a foamed bead base by heating. The resin laminate is manufactured according to the following steps. The foamed bead base and the sheet laminate consisting of the skin, a foam layer, and a thermoplastic resin film are prepared separately. The thermoplastic resin film is made of a resin material which thermally adheres to both the foam layer and the foamed bead base and has a softening temperature lower than those of the foam layer and the foamed bead base. The thermoplastic resin film is softened by heating the sheet laminate, which is then softened by heating the sheet laminate, which is then pressed against and bonded to the foamed bead base by vacuum molding or press forming. The thermoplastic resin film thermally adheres to both the foam .layer of the sheet laminate and the foamed bead base, thus joining the sheet laminate with the foamed bead base.

Method of forming a resin laminate containing foam beads

An air bag apparatus in which the appearance of the interface between the portion covering the air bag and portions surrounding it can be improved, the number of components can be reduced, and the assembly process can be shortened. A cover unit covers an air bag, which inflates on a predetermined occasion, consists of a cover which-opens with the inflation of the air bag, and a body for holding the cover. The cover unit is an integrally molded product in which a skin is formed on a substrate, and includes, at the location connecting the periphery of the cover with the body, a breakaway portion along which the cover is separable from the body when the air bag inflates, and a hinge portion for maintaining the connection of the body and the cover. In the breakaway portion, the substrate has a fragile portion, and the skin is separated into two parts at the position of the fragile portion. In the hinge portion, the substrate and skin are continuously formed and extend from the body to the cover.

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Inazawa, Japan

Keizou Ito