Molded product having coating film

Abstract

A process for forming a coating layer on the surface of a molded product by boiling a coating solution in a closed metal mold. The molding process includes depressurizing the cavity of the metal mold, boiling a coating solution in the cavity and injecting a urethane material into the cavity under reduced pressure.

What is claimed is:  
     
         1 . A process for manufacturing a molded product having a coating layer on the surface, comprising: 
 forming a coating layer on the wall surface of a cavity while a metal mold is closed; and    filling a filler material in the cavity.    
     
     
         2 . The process according to  claim 1 , wherein the forming step includes forming a coating layer on the wall surface of the cavity by increasing the volume of a coating solution in the cavity.  
     
     
         3 . The process according to  claim 1  further comprising reducing the pressure in the cavity.  
     
     
         4 . The process according to  claim 1 , wherein the foaming step includes supplying a coating solution into the cavity and depressurizing the cavity.  
     
     
         5 . The process according to  claim 1 , wherein the forming step includes depressurizing the cavity and supplying a coating solution into the cavity.  
     
     
         6 . The production process according to  claim 1 , wherein the filler material contains a urethane material that reacts and cures in the cavity.  
     
     
         7 . The process according to  claim 2 , wherein the coating solution contains methyl ethyl ketone and isopropyl alcohol as solvents and a urethane resin.  
     
     
         8 . The process according to  claim 1 , wherein the forming step further includes the step of heating the metal mold.  
     
     
         9 . A molded product formed by injecting a filler material into the cavity of a metal mold, wherein the filler material is coated with a film having a substantially uniform thickness.  
     
     
         10 . The molded product according to  claim 9 , wherein the filler material includes a urethane material that reacts and cures in the cavity.  
     
     
         11 . A steering wheel having a first side facing a driver and a second side, which is opposite to the first side, the steering wheel being coated with a film, the film being thicker on the first side than on the second side.  
     
     
         12 . The steering wheel according to  claim 11 , wherein the thickness of the film gradually increases from the second side toward the first side.  
     
     
         13 . The steering wheel according to  claim 11  including a foamed urethane molded portion, wherein the coating film covers the foamed urethane portion.  
     
     
         14 . A process for molding a steering wheel providing a metal mold having a mold cavity, wherein the cavity is formed such that a grip portion of the steering wheel faced downward; comprising: 
 boiling a coating solution, during which a coating layer is formed on the wall surface of the cavity from the coating solution; and    supplying a predetermined filler material into the cavity.    
     
     
         15 . The process according to  claim 14 , wherein the boiling step includes depressurizing the cavity.  
     
     
         16 . The process according to  claim 15 , wherein the depressurizing step includes exhausting gas in the cavity through a passage connected to the upper position of the cavity.  
     
     
         17 . A process for manufacturing an insert molded product, comprising: 
 setting an insert member in a metal mold;    forming a coating layer on the wall surface of a cavity in the metal mold while the metal mold is closed; and    depositing a filler material into the cavity.    
     
     
         18 . The process according to  claim 17 , wherein the forming step includes boiling a coating solution, wherein a coating layer is formed on the wall surface of the cavity in the metal mold from the coating solution during the boiling step.  
     
     
         19 . The process according to  claim 17  further comprising depressurizing the cavity.  
     
     
         20 . An insert molded product formed by molding a filler material comprising: 
 an insert member;    an intermediate layer formed from the same material as the coating film and located between the insert member and the filler material; and    a coating film formed on the surface of the filler material, the coating film having a substantially uniform thickness.    
     
     
         21 . The insert molded product according to  claim 20 , wherein the filler material contains a urethane material.  
     
     
         22 . A method of coating a coating on the wall surface of a cavity in a metal mold comprising: 
 closing the metal mold;    supplying a solution of the coating into the cavity; and    depressurizing the cavity.    
     
     
         23 . The method according to  claim 22 , wherein depressurization is carried out until the coating solution boils in the depressurizing step.  
     
     
         24 . A method of coating a coating on the wall surface of a cavity in a metal mold comprising: 
 closing the metal mold;    depressurizing the cavity; and    supplying a coating solution into the cavity during the depressurizing step.    
     
     
         25 . The method according to  claim 24 , wherein the step of depressurizing the cavity is continued until the coating solution dries.  
     
     
         26 . A molded product of a urethane resin formed by foam molding using water comprising: 
 a core portion molded by foaming a urethane material; and    a coating film having a substantially uniform thickness, the film being formed on the surface of the core portion, wherein the surface characteristics of the metal mold is transferred to the coating.    
     
     
         27 . The molded product according to  claim 26 , wherein the coating film has a thickness of 4 μm or more.  
     
     
         28 . A process for manufacturing a urethane resin molded product formed by foam molding using water comprising: 
 boiling a coating solution in a cavity in a metal mold while the metal mold is closed, during which time a coating film is formed on the wall surface of the cavity from the coating solution; and    supplying a urethane material into the cavity at normal pressure.    
     
     
         29 . A product molded with urethane material in a mold cavity comprising: 
 a core portion made of a highly foamed urethane material;    a skin layer formed on the outside of the core portion, the skin layer being made of a urethane material that has less foaming than the core portion; and    a coating film formed with a substantially uniform thickness on the surface of the skin layer, wherein the surface characteristics of the cavity are transferred to the film.    
     
     
         30 . A process for manufacturing a foamed urethane molded product having a surface skin layer comprising: 
 depressurizing a cavity in a metal mold;    boiling a coating solution in the cavity;    forming a coating layer on the wall surface of the cavity during the boiling step; and    injecting a urethane material into the cavity under reduced pressure.    
     
     
         31 . The process according to  claim 30  further comprising supplying a coating solution into the cavity before the depressurizing step.  
     
     
         32 . The production process according to  claim 30  further comprising supplying a coating solution into the cavity after the depressurizing step.  
     
     
         33 . A process for manufacturing a resin molded product, wherein molding and coating are performed simultaneously, the process comprising: 
 applying a coating solution to the wall surface of a cavity in a metal mold;    boiling the coating solution in the cavity under reduced pressure to form a coating layer on the wall surface of the cavity;    heating a resin material to reduce flow resistance;    supplying the heated resin material into the cavity; and    curing the resin material in the cavity.    
     
     
         34 . A product molded with resin material, wherein the flow resistance of the resin material can be reduced by heating, wherein the resin material is coated with a film having a substantially uniform thickness.  
     
     
         35 . A process for manufacturing a urethane molded product comprising: 
 forming a coating layer on the surface of a cavity of a closed metal mold;    first injecting a first urethane material containing a pigment into the cavity; and    second injecting a second urethane material that includes a larger amount of a pigment than the first urethane material.    
     
     
         36 . The process according to  claim 35 , wherein the forming step is carried out under reduced pressure.  
     
     
         37 . The process according to  claim 35 , wherein the first injecting step is carried out under reduced pressure.  
     
     
         38 . The process according to  claim 35  further comprising a third injection step of injecting a third urethane material containing a smaller amount of a pigment than the first urethane material after the injection of the first urethane material and before the injection of the second urethane material.