Method of manufacturing a resin-laminated board

Patent metadata

Field	Value
Publication number	US-9757893-B1
Application number	US-201715646831-A
Country	US
Kind code	B1
Filing date	Jul 11, 2017
Priority date	Jun 29, 2011
Publication date	Sep 12, 2017
Grant date	Sep 12, 2017

Abstract

A method of manufacturing a resin-laminated board by preparing a pair of first and second split molds each of which is provided with a cavity; positioning two sheet materials made of a thermoplastic resin between the first and second split molds with the cavities of the first and second split molds opposed to each other; forming a plurality of recesses by recessing a first sheet material toward a second sheet material with use of a plurality of protrusions provided to the first split mold; and welding bottoms of the recesses to the second sheet material by clamping the pair of first and second split molds to obtain a resin-laminated board with a hollow structure. A mold includes a plurality of piece members, disposed at the cavity of the first split mold; and includes the protrusions and male screws provided to base ends of the protrusions.

First claim

The invention claimed is:

1. A method of manufacturing a resin-laminated board, comprising:
preparing a pair of first and second split molds each of which is provided with a cavity;
positioning two sheet materials made of a thermoplastic resin between the first and second split molds with the cavities of the first and second split molds opposed to each other;
forming a plurality of recesses by recessing a first sheet material toward a second sheet material with use of a plurality of protrusions provided to the first split mold; and
welding bottoms of the recesses to the second sheet material by clamping the pair of first and second split molds to obtain a resin-laminated board with a hollow structure,
wherein a mold in use is configured to include a plurality of piece members: disposed at the cavity of the first split mold; and configured to include the protrusions and male screws provided to base ends of the protrusions, wherein the male screws are screwed into female screw holes provided to the first split mold,
wherein a sealed space is formed between the first sheet material and the cavity of the first split mold, and
wherein the first sheet member is shaped to follow the protrusions by vacuum suctioning the sealed space through a gap between the cavity of the first split mold and the base ends of the protrusions and through a gap between the female screw holes and the male screws.

Assignees

• Kyoraku Co Ltd
• Kyoraku Co Ltd

Inventors

• Matsubara Yoshitaka
• Tanji Tadatoshi

Classifications

• Y10T428/24612

  Composite web or sheet · CPC title

• B29C33/306

  Exchangeable mould parts, e.g. cassette moulds, mould inserts (moulds with exchangeable mould parts for injection moulding B29C45/2673; mounting of exchangeable mould inserts for injection moulding B29C45/2675) · CPC title

• B32B3/28

  characterised by a layer comprising a deformed thin sheet {, i.e. the layer having its entire thickness deformed out of the plane}, e.g. corrugated, crumpled (B32B29/08 takes precedence) · CPC title

• B29L2024/006

  multi-channelled · CPC title

• B29C2049/2017

  outside the article · CPC title