US 7,067,082 B2Granted

Method for producing a molded resin laminate

AssigneeHonda Giken Kogyo Kabushiki Kaisha

InventorsKenichi Chujo, Kazushiro Wakabayashi, Hiroe Hashimoto

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Abstract

A molded resin laminate in which the dimensional accuracy and the strength are excellent at a bent portion and a method for producing the same are provided. One, in which an average diameter of small cells existing in a region on a side of a resin cover to be formed into a surface layer is smaller than an average diameter of large cells existing in a region on a side of a base resin component to be formed into a base layer, is used as a foamed resin component to be formed into an intermediate layer of the molded resin laminate. After the base resin component is molded with a molding machine, the base resin component is held on a male mold of a forming machine different from the molding machine described above. A sheet-shaped laminate, which is obtained by joining the foamed resin component and the resin cover, is arranged between the base resin component and a female mold. Subsequently, the forming machine is subjected to mold clamping. The sheet-shaped laminate and the base resin component are joined to one another in a cavity, and the gas in the cavity is vacuum-evacuated to thereby form the sheet-shaped laminate.

Claims18

Dependent claims

A method for producing a molded resin laminate comprising:

a first step of molding a base resin component composed of a molded resin piece by using a first forming machine, the base resin component being formed with multiple holes piercing through the base resin component;
a second step of arranging a resin cover between the base resin component held on a first mold of a second forming machine and a second mold with a foamed resin component intervening therebetween;
a third step of performing mold clamping for said second forming machine;
a fourth step of forming said resin cover by evacuating gas from a cavity of said second forming machine by the aid of said second mold of said second forming machine;
and
a fifth step of forming said foamed resin component and joining said base resin component and said resin cover to one another with said foamed resin component intervening therebetween by evacuating the gas from said cavity by the aid of said mold of said second forming machine on which said base resin component is held,
thereby forming said molded resin laminate, which comprises a base layer composed of said base resin component, an intermediate layer composed of said foamed resin component, and a surface layer composed of said resin cover in this order,
wherein an average diameter of cells existing in a region of said foamed resin component on a side of said resin cover is smaller than an average diameter of cells existing in a region of said foamed resin component on a side of said base resin component.

5 more elements

A method for producing a molded resin laminate comprising:

a first step of molding a base resin component composed of a molded resin piece by using a first forming machine;
a second step of arranging a resin cover between the base resin component held on a first mold of a second forming machine and a second mold with a foamed resin component intervening therebetween;
a third step of performing mold clamping for said second forming machine;
a fourth step of forming said resin cover by evacuating gas from a cavity of said second forming machine by the aid of said second mold of said second forming machine;
and
a fifth step of forming said foamed resin component and joining said base resin component and said resin cover to one another with said foamed resin component intervening therebetween by evacuating the gas from said cavity by the aid of said mold of said second forming machine on which said base resin component is held, at least a portion of the gas being evacuated through holes in the first mold that are aligned with holes in the base resin component,
thereby forming said molded resin laminate, which comprises a base layer composed of said base resin component, an intermediate layer composed of said foamed resin component, and a surface layer composed of said resin cover in this order, wherein an average diameter of cells existing in a region of said foamed resin component on a side of said resin cover is smaller than an average diameter of cells existing in a region of said foamed resin component on a side of said base resin component.

4 more elements

Dependencies are inferred from the claim text.

Facts

Application: 10/793,898Filed 8 Mar 2004 · division
Priority: JP 2000-1036665 Apr 2000
Published: US 2004/0169301 A12 Sep 2004
Granted: 27 Jun 2006
Term ends: Not estimatedThe source records don’t support an estimate.

Classification15 codes

B32B 27/065
As the main or only constituent of a layer, which is next to another layer of the same or of a different material: of foam
B29C 44/1233
Joining preformed parts by the expanding material: the preformed parts being supported during expanding
B32B 3/02
Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products…:…
B32B 5/14
Layered products characterised by the non- homogeneity or physical structure , i.e. comprising a fibrous, filamentary, particulate or foam…