JP7362018B2 - Composite laminate and its manufacturing method - Google Patents

Description

The present invention relates to a composite laminate and a method for manufacturing the same.

BACKGROUND ART Conventionally, as a decorative molding technique using resin, a method is known in which a member is produced by infiltrating resin into fibers (for example, Patent Documents 1 and 2). As the resin to be infiltrated at this time, for example, PVB (polyvinyl butyral) or the like is used. By integrating the resin and the fiber layer, a member having sufficient strength can be obtained. In such a member, the injection-molded base resin layer also infiltrates into the gaps between the fibers of the nonwoven fabric layer and is fixed thereto.

In the housing described in Patent Document 1, a nonwoven fabric layer is bonded to a decorative layer via an adhesive resin layer. The adhesive resin layer is made of, for example, PVB (polyvinyl butyral), which has a viscosity that allows air bubbles in the adhesive resin layer to escape when softened. Patent Document 1 also discloses that polypropylene is used as an example of the material of the base resin layer constituting the housing, and that the adhesive resin layer incorporates a conductive wire.

Patent Document 2 discloses a textile-like in-mold sheet that is integrated into a resin molded body formed by injecting molten resin by in-mold molding. In the sheet described in Patent Document 2, a polyvinyl butyral (PVB) adhesive is mentioned as an adhesive for bonding a fiber sheet layer and a textile material layer. Patent Document 2 also discloses a processing method in which a preform molded body is trimmed in advance and then injection molded so that no cut surface is formed on the end face.

Japanese Patent Application Publication No. 2020-175641 Re-table No. 2015-029453

Polypropylene is not only procurable at low cost, but also has excellent chemical resistance, and has the potential to be applied to a variety of uses. The inventors of the present invention have been working on producing an integrated laminate using only polypropylene as a resin infiltrated into the fibers of a nonwoven fabric. However, it is common knowledge in the molding field that even if multiple sheets made of polypropylene are stacked and thermocompressed together, the sheet-derived layer will peel off from the product, making it impossible to firmly integrate the whole as a polypropylene-only member. .

Patent Document 1 mentions polypropylene as an example of the material of the base resin layer, and at first glance it appears that the housing can be formed only from polypropylene and fibers. However, a resin such as PVB (polyvinyl butyral) is used to join the decorative layer and the fiber layer, and there is no idea of forming everything other than the fibers only from polypropylene.

The present invention has been made in view of the above circumstances, and by firmly bonding a film layer of a thermoplastic resin such as polypropylene to a composite layer having fibers, the present invention can be firmly integrated with the thermoplastic resin. It is an object of the present invention to provide a composite laminate using a composite laminate that can constitute a standardized plate-like member, and a method for manufacturing the same.

(1) In order to achieve the above object, the present invention takes the following measures. That is, the composite laminate of the present invention includes a film layer made of a thermoplastic resin having a uniform thickness, a composite layer made of a thermoplastic resin that is in contact with the film layer, infiltrated into a nonwoven fabric, and fixed in the network of the nonwoven fabric. The main body layer has a heater wire sandwiched between the film layer and the composite layer, and a base resin layer that is in contact with the composite layer and is made of a thermoplastic resin.

In this way, the thermoplastic resin typified by polypropylene is infiltrated into the network of the nonwoven fabric from both sides and is fixed, so that the thermoplastic resin film layer is firmly bonded to the composite layer having fibers. Thereby, a plate-like member that is firmly integrated with the thermoplastic resin can be constructed. In particular, when polypropylene is used as the thermoplastic resin, the surface of the composite laminate can be formed of polypropylene that has excellent hydrochloric acid resistance. Providing a heater wire directly below the film layer makes it easier to transfer heat to the surface, improving thermal efficiency.

(2) Furthermore, in the composite laminate described in (1) above, the main body layer has a multilayer structure in which a plurality of the film layers and the composite layer are provided alternately. Thereby, the strength of the composite laminate can be improved due to the structure in which a plurality of thermoplastic resin films are stacked.

(3) Furthermore, in the composite laminate described in (1) or (2) above, the circuit member is a composite wire consisting of an insulated wire and one or more conductive wires wound around the insulated wire. It is characterized by When the conductive wire is wound around the insulated wire in this way, the conductive wire becomes loose. As a result, the composite laminate has excellent shape stability and can prevent disconnection of conductive wires while streamlining the manufacturing process.

(4) Furthermore, in the composite laminate described in (3) above, the composite wire is a covering wire formed by providing the conductive wire around the insulated wire, and the insulated wire shrinks when heated. It is characterized by As a result, the conductive wire becomes loose as the insulated wire contracts, and the function of preventing disconnection of the conductive wire can be strengthened.

(5) Furthermore, in the composite laminate described in (3) or (4) above, the insulated wire is a polyester woolly yarn or a highly shrinkable yarn. Thereby, the slack of the conductive wire can be increased, and the function of preventing disconnection of the conductive wire can be strengthened.

(6) Furthermore, in the composite laminate described in (1) or (2) above, the edge is formed by covering the main body layer with the base resin layer. This allows the edges to be sealed and ensures reliable circuit insulation.

(7) Furthermore, in the composite laminate described in (6) above, the circuit member is characterized in that the terminals are not exposed and are entirely buried. This makes it possible to prevent electrical leakage due to water penetration, etc., in a non-contact current-carrying structure without a lead-out electrode.

(8) A step of arranging a film made of thermoplastic resin and a nonwoven fabric based on a predetermined design, arranging a circuit member between the film and the nonwoven fabric, and forming the film with the film and the nonwoven fabric. further comprising the steps of: forming a laminated sheet by thermocompression bonding at a temperature below the melting point or above the softening point of the thermoplastic resin; and injection molding the thermoplastic resin onto the main surface of the laminated sheet formed of the nonwoven fabric. It is a feature.

In this manner, by thermocompression bonding at a temperature higher than the softening point and lower than the melting point, the thermoplastic resin forming the film infiltrates into the network of the nonwoven fabric and is firmly fixed to the network due to the anchor effect. The obtained composite laminate can be used to form various housings using thermoplastic resin as the surface layer material.

(9) The circuit member is characterized in that it is a composite wire consisting of an insulated wire and one or more conductive wires wound around the insulated wire. Thereby, disconnection of the conductive wire can be prevented while increasing the efficiency of the process, and a composite laminate having excellent shape stability can be manufactured.

It is a sectional view showing a composite laminate. It is a perspective view showing the process of thermocompression bonding a PP film and a nonwoven fabric. (a) to (d) are cross-sectional views showing the steps of preform molding and trimming. (a), (b) It is sectional drawing which shows the process of injection molding. (a) and (b) are cross-sectional views showing a composite laminate in which conductive wires and elements are embedded, respectively. (a) to (c) are plan views showing a covering wire (two conductive wires), a covering wire (one conductive wire), and a stranded wire, respectively. It is a perspective view showing a heated toilet seat provided with a composite laminate.

Through repeated trial and error, the inventors of the present invention discovered that by sandwiching a nonwoven fabric between thermoplastic resin films, they can be firmly integrated, and have arrived at the present invention. Multiple layers can be integrated by infiltrating and fixing polypropylene into the mesh of the nonwoven fabric. In particular, even if only polypropylene films (hereinafter referred to as PP films) are simply laminated and thermocompressed, the resulting laminate will peel off in layers, but by sandwiching a nonwoven fabric between the films, they will be firmly integrated. Embodiments of the present invention will be described in detail below with reference to the drawings.

[First embodiment]
[Composition of composite laminate]
First, the structure and manufacturing method of the composite laminate will be explained. FIG. 1 is a cross-sectional view showing a composite laminate 100. The composite laminate 100 includes a main body layer 110 and a base resin layer 120. The main body layer 110 is composed of film layers 111 and 113 and composite layers 112 and 114. The film layers 111, 113 and the composite layers 112, 114 are stacked alternately.

The film layers 111 and 113 are layers formed by thermocompression bonding PP films (thermoplastic resin films). The thickness is uniform because a certain proportion of the PP film is infiltrated into the fibers of the nonwoven fabric by thermocompression bonding.

The composite layers 112, 114 are formed of a nonwoven fabric and polypropylene (thermoplastic resin) infiltrated and fixed into the mesh of the nonwoven fabric. The material of the nonwoven fabric is not particularly limited. The nonwoven fabric is preferably a spunbond nonwoven fabric. The nonwoven fabric is preferably a spunbond nonwoven fabric containing polyester, but may also be a papermaking nonwoven fabric containing polyester or felt.

The composite layers 112, 114 are in contact with the film layers 111, 113, and polypropylene continuous from the film layers 111, 113 infiltrates into the network of the nonwoven fabric. Due to the anchor effect, the composite layers 112, 114 and the film layers 111, 113 are firmly bonded. Thereby, a plate-like member strongly integrated with polypropylene can be constructed.

The base resin layer 120 is formed of polypropylene (thermoplastic resin) by injection molding, and is in contact with the composite layer 114. In each of the composite layers 112 and 114, polypropylene infiltrates into the mesh of the nonwoven fabric from both sides and is fixed thereto.

In the composite laminate 100, the main body layer 110 preferably has a four-layer structure composed of film layers 111 and 113 and composite layers 112 and 114. By having a four-layer structure or more, the strength of the composite laminate can be improved and the shape can be stabilized. On the other hand, if it has a four-layer structure or less, molding becomes easier. The thermoplastic resin constituting the composite laminate 100 is preferably polypropylene, but may also be ABS resin (acrylonitrile butadiene styrene resin).

However, the main body layer may have a two-layer structure consisting of only a film layer and a composite layer, or may have a six-layer structure or more. In any case, the layer closest to the surface is the film layer, and the layer closest to the base resin layer is the composite layer.

[Method for manufacturing composite laminate]
A method for manufacturing the composite laminate 100 configured as described above will be described. Composite laminate 100 is manufactured using thermocompression, preform molding, trimming, and injection molding processes. FIG. 2 is a perspective view showing a process of thermocompression bonding a PP film (thermoplastic resin film) and a nonwoven fabric.

First, a PP film and a nonwoven fabric are placed one on top of the other according to a predetermined design and bonded together by thermocompression. In the example shown in FIG. 2, PP film A1, nonwoven fabric A2, PP film A3, and nonwoven fabric A4 are layered in this order from above and thermocompression bonded from above and below to form a sheet-like laminate. The thermocompression bonding is performed by pressing the material using a hydraulic heat press machine or a multistage press machine while heating the material to a temperature below the melting point of polypropylene and above the softening point. Specifically, the temperature is preferably 140°C or higher and 160°C or lower.

In this way, by thermocompression bonding at a temperature higher than the softening point and lower than the melting point, the polypropylene forming the film is softened, infiltrates into the network of the nonwoven fabric, and is firmly fixed to the network due to the anchor effect. The result is a laminate sheet in which a polypropylene film layer is firmly bonded to a composite layer with fibers.

The PP film preferably has a thickness of 100 μm or more and 1500 μm or less, and more preferably has a thickness of 100 μm or more and 500 μm or less. Moreover, it is preferable to use a nonwoven fabric having a thickness of 50 μm or more and 500 μm or less. As a result of the above thermocompression bonding, a laminate sheet corresponding to the main body layer 110 of the composite laminate 100 is obtained.

FIGS. 3(a) to 3(d) are cross-sectional views showing the steps of preform molding and trimming. First, the laminated sheet B1 is softened by heating. Then, as shown in FIG. 3A, the laminated sheet B1 is placed between the male mold D1 and the female mold D2, with the PP film side facing the female mold D2.

Next, as shown in FIG. 3(b), the male mold D1 and the female mold D2 are clamped. As a result, the laminated sheet B1 is shaped. After clamping, as shown in FIG. 3(c), the male mold D1 and the female mold D2 are opened, and the obtained preform B2 is released.

Then, as shown in FIG. 3(d), unnecessary portions are removed by trimming to obtain a preform molded body B3. By trimming the preform molded body B3, the cut surface resulting from the trimming can be covered with injected polypropylene by subsequent injection molding.

FIGS. 4(a) and 4(b) are cross-sectional views showing the injection molding process. As shown in FIG. 4(a), the preform molded body B3 is placed in the female mold M12 for injection molding with the PP film side facing up, and then the female mold M12 is inserted into the male mold for injection molding. While moving toward M13, the injection hole M15 of the injection machine is pressed against the injection molding hole M16 of the male mold M13, and the injection screw M11 is rotated clockwise to release the raw material for the base resin layer in the tank T1. P1 is injected into a space defined by the preform molded body B3 and the male mold M13 for injection molding. That is, polypropylene is injection molded onto the other main surface formed of the nonwoven fabric, which is opposite to one main surface forming the surface of the laminated sheet.

A polypropylene melt (thermoplastic resin melt), which is the raw material P1 for the base resin layer, is heated and melted in an injection molding machine M10, and injected into a female mold M12 equipped with a preform molded body B3 to form a nonwoven fabric. It infiltrates into the gaps between each fiber of the layer and is fixed. At this time, the polypropylene infiltrates into the gaps between each fiber of the nonwoven fabric, and the shrinkage of the raw material P1 during cooling and solidification further strengthens the adhesion between the preform molded body B3 and the base resin layer 120. Then, as shown in FIG. 4B, after the injection molded base resin layer 120 is cooled and solidified, the injection machine and the injection molding male mold M13 are separated from the female mold M12, and the composite laminate 100 is is taken out. The obtained composite laminate 100 is suitably cut according to the intended use. The obtained composite laminate 100 can be applied to various products using polypropylene as a surface layer material.

[Second embodiment]
[Structure of composite laminate with embedded circuit components]
A circuit member can be embedded in the main body layer of the composite laminate 100 described above. FIGS. 5A and 5B are cross-sectional views showing composite laminates 200 and 300, respectively, in which conductive wires and elements are embedded in the main body layer.

Composite laminate 200 has basically the same structure as composite laminate 100, but has circuit member 231 embedded in main body layer 210 and features related thereto.

The main body layer 210 is provided with a circuit member 231 sandwiched between the film layer 211 and the composite layer 212. In this way, it is possible to construct a composite laminate 200 that is strongly integrated with polypropylene and has additional functions with the circuit member 231 provided inside.

In the example shown in FIG. 5A, a conductive wire with a circular cross section is provided as a circuit member 231 between the film layer 211 and the composite layer 212. The conducting wire used in the circuit member 231 is, for example, a heater wire. Since the composite laminate 200 is formed by thermocompression bonding with the circuit member 231 sandwiched therebetween, the composite layer 212 pressed against the circuit member 231 has a semicircular depression corresponding to the cross-sectional shape of the conducting wire. . Since the composite layer 212 is flexibly deformed in this way, the surface on the film layer 211 can be made smooth.

The edges of the composite laminate 200 are preferably formed by the base resin layer 120 covering the main body layer 210. Thereby, the edge 210a of the main body layer 210 can be covered with the base resin layer 120, allowing reliable circuit insulation. The circuit member 231 is entirely buried without exposed terminals. This makes it possible to prevent electrical leakage due to water penetration, etc., in a non-contact current-carrying structure without a lead-out electrode.

Note that in the above example, the circuit member 231 is provided between the film layer 211 and the composite layer 212, but it is provided between the composite layer 212 and the film layer 113 or between the film layer 113 and the composite layer 114. may be provided. That is, the circuit member 231 only needs to be buried inside the plurality of layered structures that constitute the main body layer, and in that case, it may be buried between any of the layers. However, the circuit member 231 cannot be embedded between the main body layer 210 and the base resin layer 120.

On the other hand, the composite laminate 300 is basically configured similarly to the composite laminate 200, but differs in the circuit member 331 embedded in the main body layer 310 and the features related thereto. In the example shown in FIG. 5B, an element having a flat cross section is provided as a circuit member 331 between the film layer 311 and the composite layer 312. The composite layer 312 pressed against the circuit member 331 during the manufacturing process has a plate-shaped depression corresponding to the cross-sectional shape of the element.

The manufacturing process for composite laminates 200 and 300 is similar to that for composite laminate 100. However, the difference is that circuit members 231 and 331 are placed between the PP film and the nonwoven fabric when they are placed.

[Third embodiment]
[Form of line]
As the circuit member 231 in the above embodiment, a composite wire consisting of an insulated wire and one or more conductive wires wound around the insulated wire may be used. Specifically, various forms of joining lines can be used. FIGS. 6A to 6C are plan views showing the covering wire 231a (two conductive wires), the covering wire 231b (one conductive wire), and the stranded wire 231c, respectively.

The covering wire 231a shown in FIG. 6(a) consists of an insulated wire 232a and two conductive wires 233a. The two conductive wires 233a are wound around the insulated wire 232a in a crossed manner. Since the conductive wire 233a is wound around the insulated wire 232a in this way, the conductive wire 233a becomes loose. As a result, disconnection of the conductive wire can be prevented during manufacturing. Particularly in the structure of the covering wire, the conductive wire 233a becomes loose because the insulated wire, which is the core wire, contracts during the manufacturing process.

It is preferable that the insulated wire 232a is made of polyester. Thereby, the conductive wire 233a can be kept loose without melting even at temperatures below 250° C. during the manufacturing process. Moreover, it is preferable that the insulated wire 232a is a polyester woolly yarn or a highly shrinkable yarn. Thereby, the slack of the conductive wire can be increased, and the disconnection prevention function of the conductive wire 233a can be strengthened.

Polyester woolly yarn is a long-staple yarn that has the bulge and elasticity of wool. Since the polyester wooly yarn is bulky, the conductive wire 233a wound around the polyester wooly yarn can be integrated into the polyester wooly yarn as a combined wire. Polyester woolly yarn is particularly advantageous in that it can sufficiently impregnate and retain hot melt polypropylene. Note that the woolly yarn is preferably made of polyester, but is not limited thereto.

High shrinkage yarns are yarns that shrink due to heat. High shrinkage polyester fibers can be used for the high shrinkage yarn. When heated, the high-shrinkage yarn that is the core wire contracts, which increases the loosening of the conductive wire. The insulated wire 232a may be a heat-sealable thread. In this case, by using a material that fuses at the temperature of thermocompression bonding, the composite wire can be integrated into the composite layer.

For example, a copper wire is used as the conductive wire 233a if it is used for signal transmission or power supply. If it is for a heater, nickel chromium may be used. It is preferable that the number of conductive wires 233a used for covering is three or less. Thereby, the diameter of the joining wire can be made small, so that the smoothness of the surface of the composite laminate can be maintained. The covering wire 231b shown in FIG. 2(b) consists of an insulated wire 232b and one conductive wire 233b. When giving priority to smoothness, it is effective to use one conductive wire 233b.

The twisted wire 231c shown in FIG. 6(c) consists of an insulated wire 232c and a conductive wire 233c. The insulated wire 232c and the conductive wire 233c are twisted and intertwined. This causes the conductive wire 233c to become loose. Further, in the case of the twisted wire 231c, the conductive wire 233c can be easily loosened by twisting two wires.

Note that a conductive wire coated with polyvinyl chloride is not used. Polyvinyl chloride has a too low melting point, softens at 60°C, and melts or foams during heat processing, so composite laminates manufactured using polyvinyl chloride contain air bubbles and are difficult to commercialize. .

[Heated toilet seat]
It is possible to construct a heated toilet seat including a laminated composite body using a heater wire as the circuit member 231 as described above. FIG. 7 is a perspective view showing a heated toilet seat 400 including a composite laminate 200. The heated toilet seat 400 can maintain the surface temperature at about 40° C. by passing an electric current through the heater wire. The material of the heater wire is not particularly limited.

By applying the composite laminate 200 to the heated toilet seat 400, the surface can be formed of polypropylene with excellent hydrochloric acid resistance. Note that if the heater wire 231 is provided directly below the film layer 211, heat can be easily conducted to the surface and thermal efficiency can be improved.

[Wire Harness]
The composite laminate can be used in a wire harness in which wires for supplying power to equipment and conducting wires for transmitting electrical signals to control equipment are embedded. Since the conductor wires are buried between the composite layers, it is possible to create a wire harness that is less prone to problems such as short circuits. It is also possible to incorporate a touch panel and an antenna into the composite laminate.

[Experiment 1]
A total of four sheets of PP film and spunbond nonwoven fabric were alternately stacked and laminated without embedding a non-circuit member, and thermocompression bonding was performed. It was pressed for 1 minute using a hydraulic heat press at a pressure of 3.9 MPa. After pressing, the total thickness decreased by 10-20% in all cases. The thickness of the PP film, the thickness of the nonwoven fabric, and the temperature at that time are as shown in Table 1.

The obtained laminated sheet was cut and the cut surface was observed under a microscope. In addition, a peel test of the laminated sheet was conducted. The peel test was conducted at 3 kN/m in accordance with JIS K6854. Table 1 shows the presence or absence of fiber breakage and peeling that can be seen from observation of the cut surface.

(1) Thickness and temperature of PP film Pressing was performed while changing the thickness and temperature conditions of the PP film. In each case, a nonwoven fabric with a thickness of 100 μm was used. When a PP film with a thickness of 200 μm was pressed at 155° C., no peeling occurred. Even when a PP film with a thickness of 300 μm was used under similar conditions, no peeling occurred. On the other hand, when a 500 μm thick PP film was pressed at 155° C., peeling occurred.

When a PP film with a thickness of 500 μm was pressed at 158° C., no peeling occurred. The same result was obtained even when a PP film with a thickness of 1500 μm was used. When a PP film with a thickness of 2000 μm was pressed at 158° C., peeling occurred.

(2) Thickness of nonwoven fabric Pressing was performed while changing the thickness of the nonwoven fabric. Pressing was performed at 158° C. using a nonwoven fabric with a thickness of 40 μm, and when the cut surface of the obtained laminated sheet was observed, it was found that fibers of the nonwoven fabric were broken. A nonwoven fabric with a thickness of 50 μm was pressed in the same manner, and the cut surface was observed, and no fiber breaks were found in the nonwoven fabric.

A nonwoven fabric with a thickness of 500 μm was pressed at 158° C., and a peel test was performed, and no peeling occurred. On the other hand, when a nonwoven fabric with a thickness of 600 μm was pressed at 158° C., peeling occurred. Furthermore, when two sheets of PP films were laminated and thermocompression bonded under the same conditions, peeling occurred.

[Experiment 2]
When a total of two sheets of 500 μm thick PP film and 100 μm thick nonwoven fabric were stacked alternately and pressed at 158°C to produce a two-layer laminated sheet, no peeling occurred, but the laminated sheet did warp. .

[Experiment 3]
A heater wire with a diameter of 0.1 mm was buried between the first layer and the second layer of a four-layer structure to produce a laminated sheet. When the surface of the obtained laminated sheet was observed, it was found to be smooth and free of irregularities caused by the heater wires. When a current of 3 V and 4.5 A was applied to the heater wire through the obtained laminated sheet, the surface temperature rose to 40° C. in about 5 seconds.

[Experiment 4]
Using a PP film and a nonwoven fabric, a covering wire with a diameter of 0.3 mm was embedded between the first and second layers of a four-layer structure to produce a laminated sheet. The covering wire used was one in which two conductive wires (copper wires) were arranged around an insulated wire (polyester woolly thread). Then, using a male mold D1 and a female mold D2 as shown in FIG. 3(b), the molds were clamped at 150° C. to obtain a molded body. When the surface of the obtained molded article was observed, it was found to be smooth and free of irregularities due to covering lines. Further, when a current of 3V and 4.5A was passed through the conductive wire of the covering wire, conduction was achieved without any problem.

100 Composite laminate 110 Main body layer 111, 113 Film layer 112, 114 Composite layer 120 Base resin layer 200, 300 Composite laminate 210 Main body layer 210a Edge 211 Film layer 212 Composite layer 231 Circuit member (conductor wire such as heater wire)
231a Covering wire 231b Covering wire 231c Twisted wires 232a-c Insulated wires 233a-c Conductive wire 331 Circuit member (element)
300 Composite laminate 310 Main body layer 311 Film layer 312 Composite layer 331 Circuit member 400 Heated toilet seat A1, A2 PP film A3, A4 Nonwoven fabric B1 Laminated sheet B2 Preform body B3 Preform mold body D1 Male mold D2 Female mold M10 Injection Molding machine M11 Injection screw M12 Female mold for injection molding M13 Male mold for injection molding M15 Injection hole M16 Injection molding hole P1 Raw material (thermoplastic resin melt)
T1 tank

Claims (12)

A main body layer comprising a film layer made of polypropylene and having a uniform thickness, and a composite layer that is in contact with the film layer and is made of a nonwoven fabric and polypropylene infiltrated and fixed into the mesh of the nonwoven fabric;
a base resin layer made of polypropylene and in contact with the composite layer ,
The composite laminate, wherein the main body layer has a multilayer structure in which a plurality of the film layers and the composite layer are provided alternately . A main body layer comprising a film layer made of polypropylene and having a uniform thickness, and a composite layer that is in contact with the film layer and is made of a nonwoven fabric and polypropylene infiltrated and fixed into the mesh of the nonwoven fabric;
a base resin layer made of polypropylene and in contact with the composite layer ,
The composite laminate, wherein the main body layer further includes a circuit member sandwiched between the film layer and the composite layer . 3. The composite laminate according to claim 2 , wherein the circuit member is a composite wire consisting of an insulated wire and one or more conductive wires wound around the insulated wire. The combined wire is a covering wire formed by providing the conductive wire around the insulated wire,
4. The composite laminate according to claim 3 , wherein the insulated wire shrinks when heated. 4. The composite laminate according to claim 3 , wherein the insulating wire is a polyester woolly yarn or a high shrinkage yarn. 2. The composite laminate according to claim 1, wherein the edge is formed by the base resin layer covering the main body layer. 3. The composite laminate according to claim 2 , wherein the circuit member is entirely buried without exposed terminals. The thickness of the film layer is 1500 μm or less,
The composite laminate according to any one of claims 1 to 7 , wherein the composite layer has a thickness of 500 μm or less. a step of arranging a film made of polypropylene and a nonwoven fabric based on a predetermined design;
forming a laminated sheet by thermocompression bonding the film and the nonwoven fabric at a temperature below the melting point or above the softening point of the polypropylene forming the film;
A method for manufacturing a composite laminate, further comprising the step of injection molding polypropylene onto the main surface formed of the nonwoven fabric in the laminate sheet. The thickness of the film is 200 μm or more and 1500 μm or less, the thickness of the nonwoven fabric is 50 μm or more and 500 μm or less, and the thermocompression bonding is performed at 155° C. or more and 170° C. or less. Method for manufacturing composite laminate. 11. The method for manufacturing a composite laminate according to claim 10 , further comprising arranging a circuit member between the film and the nonwoven fabric according to the predetermined design. 12. The method for manufacturing a composite laminate according to claim 11 , wherein the circuit member is a combined wire consisting of an insulated wire and one or more conductive wires wound around the insulated wire.