Kasai Kogyo Co., Ltd.

Kasai Koyco Co., Ltd

Tetsuyuki Ota

Masahiko Hara

Hiroyuki Aizawa

Tatsushi Ohno

Kiyohiko Obara

The laminated structure includes a lightweight and shape-retaining foamed resin base member, an outer circumference frame integrally laminated on the reverse side of the foamed resin base member along the outer circumference of an article, and bridging ribs connecting between respective points on the outer circumference frame. Accordingly, the present invention provides a lightweight laminated structure with low cost by reducing the amount of the resin used, since the molded synthetic resin outer circumference frame and bridging ribs have small projection areas.

Laminated structure and method for manufacturing the same

In a method for molding a laminated assembly comprising a resin core member, and a surface skin member either partly or entirely placed over the surface of the resin core member, the dimensional precision of a part of the surface skin member involving a high rate of extension is improved, and the cushioning property and the surface quality of this part are avoided from being impaired. An approximately molded portion is defined in a part of the surface skin member involving a relatively high rate of extension during the vacuum molding process using a vacuum molding die assembly, and the thus molded surface skin member is mounted on the upper die for mold press forming with a gap defined between the approximately molded portion or an unmolded portion and the associated die surface. During the mold press forming process, the pressure of the semi-molten resin material molds the surface skin member into its final shape so that the molding precision of the part of the surface skin member involving a high rate of extension can be improved. In particular, when the surface skin member is lined with a foamed lining layer, damage to the foamed lining layer of the surface skin member during the process of mold press forming is minimized.

Method for molding a laminated assembly

In a method and die assembly device for molding a laminated assembly comprising a resin core member and a surface skin member covering a part of the surface of the resin core member, the shifting and creasing of the surface skin member is avoided, the molding precision is increased during the mold press forming process, and the external appearance of the assembly is improved. By providing an outer peripheral groove in the die surface of the upper die for mold press forming along the outer periphery of the cavity of the upper die, and relatively large vacuum suction holes in this outer peripheral groove while providing relatively small vacuum suction holes inside the cavity, in particular in recessed parts thereof corresponding to the corners of the product, the surface skin member can be retained to the upper die when mounting the surface skin member on the upper die in both secure and well sealed manner so that the surface skin member would not shift or crease during the mold press forming process, and, therefore, the molding precision can be improved.

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Kanagawa-ken, Japan

Tetsuyuki Ota