Resin laminate manufacturing method

A resin laminate manufacturing method, comprising:

• providing a pair of split mold blocks including a first mold block and a second mold block, the first mold block having a cavity with a plurality of protrusions extending toward the second mold block,
• preparing first and second molten thermoplastic resin sheets each having a flat shape;
• feeding the first and second molten thermoplastic resin sheets between the pair of split mold blocks with a predetermined gap left therebetween such that each thermoplastic resin sheet protrudes around annular pinch-off parts of the pair of the split mold blocks;
• forming a hermetic space between the first thermoplastic resin sheet and the cavity of the first mold block opposed to an outer surface of the first thermoplastic resin sheet;
• sucking air in the hermetic space from a side of the first mold block, pressing the outer surface of the first thermoplastic resin sheet against the cavity of the first mold block to shape the first thermoplastic resin sheet, and elongating the first thermoplastic resin sheet so as to fit the first thermoplastic resin sheet to the protrusions;
• and
• clamping the pair of mold blocks, welding peripheral edges of the first and second molten thermoplastic resin sheets to each other, and welding top ends of the first thermoplastic resin sheet corresponding to tip ends of the protrusions to an inner surface of the second thermoplastic resin sheet, wherein,
• either prior to or at said feeding of the first and second molten thermoplastic resin sheets between the pair of split mold blocks, the thickness of each of the first and second thermoplastic resin sheets is adjusted independently of the other to have the thickness of the first molten thermoplastic resin sheet thicker than the thickness of the second molten thermoplastic resin sheet.