Manufacturing method of decorative molded article and decorative molded article

1. A manufacturing method of a decorative molded article having a layer which includes a thermoplastic resin (P2) on a surface of a fiber-reinforced resin shaped product including carbon fibers and a thermoplastic resin (P1), wherein the thermoplastic resin (P1) is the same kind as the thermoplastic resin (P2), the method comprising:

(i) using a shaped product in which at least some carbon fibers are contained in a form of fiber bundle as the fiber-reinforced resin shaped product, a ratio of the carbon fibers being contained in the form of fiber bundle is 20% to 99% by volume with respect to a total amount of the carbon fibers, and placing the fiber-reinforced resin shaped product containing the fiber bundle in a mold heated;

(ii) introducing the thermoplastic resin (P2) into the mold;

(iii) molding the thermoplastic resin (P2) in the mold by pressurization; and

(iv) cooling an inside of the mold, while maintaining the inside of the mold to a pressure within a range from 2 MPa to 50 MPa:

to a temperature range from 10° C. to a glass transition point when the thermoplastic resin (P1) is an amorphous resin and the glass transition point is 10° C. or more;

to a temperature range from 10° C. to a crystallization temperature when the thermoplastic resin (P1) is a crystalline resin and the crystallization temperature is 10° C. or more; or

to a temperature range from 10° C. to 80° C. when the thermoplastic resin (P1) is an amorphous resin and the glass transition point is less than 10° C. or the thermoplastic resin (P1) is an crystalline resin and the crystallization temperature is less than 10° C.,

wherein a thickness of the layer including the thermoplastic resin (P2) is within a range from 30 μm to 500 μm.

2. The manufacturing method of a decorative molded article according to claim 1 , further comprising, before the step (i), (i′) placing a precursor of the fiber-reinforced resin shaped product, containing at least some carbon fibers are contained in a form of fiber bundle in a heated mold and molding the precursor by heating and pressurization to manufacture the fiber-reinforced resin shaped product.

3. The manufacturing method of a decorative molded article according to claim 1 ,

wherein the inside of the mold is maintained to a constant pressure within a range from 2 MPa to 50 MPa in the step (iv).

4. The manufacturing method of a decorative molded article according to claim 1 ,

wherein the pressurization is performed within a range from 2 MPa to 50 MPa in the step (iii).

5. The manufacturing method of a decorative molded article according to claim 1 ,

wherein the carbon fibers are discontinuous.

6. The manufacturing method of a decorative molded article according to claim 1 ,

wherein an average thickness of the fiber bundle is within a range from 10 μm to 300 μm.

7. The manufacturing method of a decorative molded article according to claim 1 ,

wherein a weight-average fiber width of the fiber bundle is within a range from 0.03 mm to 4 mm.

8. The manufacturing method of a decorative molded article according to claim 1 ,

wherein the thermoplastic resin (P1) is a crystalline resin.

9. A decorative molded article obtained by using the manufacturing method of a decorative molded article according to claim 1 .

10. A decorative molded article comprising a layer which includes a thermoplastic resin (P2) on a surface of a fiber-reinforced resin shaped product including carbon fibers and a thermoplastic resin (P1),

wherein at least some carbon fibers are contained in a form of fiber bundle in the fiber-reinforced resin shaped product, and

a ratio of the carbon fibers being contained in the form of fiber bundle is 20% to 99% by volume with respect to a total amount of the carbon fibers,

wherein the thermoplastic resin (P1) is the same kind as the thermoplastic resin (P2), and

wherein a thickness of the layer including the thermoplastic resin (P2) is within a range from 30 μm to 500 μm.

11. The decorative molded article according to claim 10 ,

wherein the carbon fibers are discontinuous.

12. The decorative molded article according to claim 10 ,

wherein an average thickness of the fiber bundle is within a range from 10 μm to 300 μm, and

a weight-average fiber width of the fiber bundle is within a range from 0.03 mm to 4 mm.

13. The decorative molded article according to claim 10 ,

wherein irregularity on a surface of the layer is generally within a range from 1 μm to 5 μm by Ra.