Abstract: The present invention provides a method for producing a thermosetting resin molded article, in which emboss or decorative pattern can be formed at the same time of molding a thermosetting resin composition. In the present invention, a decorative film having abase film and a decorative layer is disposed on at least a design forming area in a surface of a shaping mold so that the decorative layer is faced inwardly, and a thermosetting resin composition is injected into a cavity of the shaping mold and the thermosetting resin composition is thermally cured. The base film is (1) a film which has a tensile elongation at break of more than 500% and a tensile stress at 100% of 0.1 MPa to 2.5 MPa, at the thermal curing temperature for the thermosetting resin composition; or (2) a film which is formed of a non-crosslinked olefin thermoplastic resin and which has a tensile elongation at break of 500% or more and a tensile stress at 100% of 0.

Abstract: Embodiments of the present invention provide a thermosetting resin molded article having a surface on which a plated membrane or a painted membrane may be formed without application of a mold release agent, defatting, sanding and primer processing. The thermosetting resin molded article is produced by a method of applying a thermoplastic resin solution obtained by dissolving at least a styrene resin in a solvent to at least a design forming area in a surface of a shaping mold; drying the shaping mold to form a thermoplastic resin membrane; and injecting a thermosetting resin composition into a cavity of the shaping mold and thermally curing the thermosetting resin composition, to obtain a thermosetting resin molded article having a surface on which the thermoplastic resin membrane. The thermoplastic resin solution may be obtained by dissolving the styrene resin and a carbon material in the solvent.

Abstract: Disclosed is a resin molded article characterized by comprising a resin base as a hard foamed body composed of a thermosetting resin, a resin film composed of a thermoplastic resin, and a skin layer formed therebetween, wherein the skin layer is composed of the same thermosetting resin as that of the resin base and has a density larger than that of the resin base. Consequently, the strength of the surface of a resin base acting as an interface with a superficial layer of the resin molded article or the strength of a portion including the surface is increased, thereby suppressing deformation of the surface of the molded article and improving moldability as a resin molded article.

Abstract: A resin mold has a surface layer formed on the molding surface of a main body from a thermosetting resin and containing fine particles of silicon carbide. The surface layer can be formed simply by thermosetting the resin without calling for any plating, so that the mold can be made in a short time. The high hardness of silicon carbide gives a high wear resistance to the surface layer. The main body is formed from a thermosetting resin and contains metal particles.

Abstract: A process produces a resin intake member by injection moling. The intake member has a hollow generally cylindrical main section and a subsidiary section integrally connected to an outer periphery of the hollow main section. The process includes a primary molding step which forms the hollow main section in a primary molding die and a secondary molding step which subsequently inserts the formed hollow main section into a secondary molding die to integrally form the subsidiary section with the hollow main section in the secondary molding die.

Abstract: A laminated plate comprising a glass layer located in front and formed from a glass sheet and a resin layer located at the back of the glass layer and molded from a molten thermoplastic material spread at a low pressure over the glass layer, the glass layer and the resin layer being arranged in a laminated fashion. A method for producing the laminated plate wherein the glass sheet is first provided so as to be in close contact with the inner side of at least either one of dies used in a compression molding machine and then the dies are clamped for compression molding, with the molten resinous material to be supplied to a mold cavity being spread at a low pressure over the glass sheet, whereby the laminated plate comprising, in a laminated fashion, the glass layer composed of the glass sheet and the resin layer molded by spreading the molten resinous material at a low pressure can be formed.

Abstract: A vacuum covering method for covering a profiled surface of a base member with a sheet by effecting bonding between the sheet and the base member under vacuum, wherein the base member has a multiplicity of spaced vacuum grooves extending across the profiled surface. When air is evacuated from the vacuum grooves, the sheet is drawn by vacuum or suction down onto the profiled surface. The base member is injection-molded of synthetic resin and undergoes thermal shrinkage when it becomes cool after molding. With the vacuum grooves provided in the profiled surface, thermal shrinkage is distributed uniformly over the entire area of the profiled surface and does not generate shrink mark which may form a depression on a front surface of the sheet bonded to the base member.

Abstract: To provide a polypropylene-based resin exterior panel which has the same appearance qualities as a coated product though it is not coated and which is excellent in rigidity and impact resistance, a polypropylene-based resin exterior panel comprising a surface layer made from a highly transparent resin composition comprising a propylene-.alpha.-olefin random copolymer having a melting point lower than 155.degree. C. and a melt flow rate (MFR) of 0.5 to 30 g/10 min and a clarifying nucleating agent, an intermediate layer made from a colored resin composition comprising a propylene-.alpha.-olefin random copolymer having a melting point lower than 155.degree. C. and an MFR of 0.5 to 30 g/10 min and a coloring pigment, and a base layer made from a base composition comprising a propylene-.alpha.-olefin block copolymer having a melting point of 155.degree. C.

Abstract: A vacuum forming apparatus has a first mold and a second mold, the first mold including a forming surface. The first mold has a hollow space defined therein and communicating with the forming surface through holes defined in the first mold. The hollow space is connected to a vacuum pump for developing a vacuum in the hollow space to attract a sheet against the forming surface through the holes. The second mold has a presser including a cylinder which displaces a cutter having a serrated trimming blade of the second mold. The presser has an upper groove which accommodates teeth of the serrated trimming blade. The first mold has a lower groove for receiving the teeth of the serrated trimming blade when it is displaced downwardly by the cylinder.

Abstract: A trim member for use as an interior furnishing in a motor vehicle includes a covering sheet including one surface having an embossed pattern, a first foamed body disposed on the other surface of the covering sheet, with a first component embedded partly in the first foamed body, and a second foamed body disposed on the other surface and/or the first foamed body, with a second component partly embedded in the second foamed body. The covering sheet, the first foamed body, and the second foamed body are integrally formed as a unitary construction. Since the trim member is constructed as an integral unitary assembly, it does not squeak while the motor vehicle is running, and does not have visible steps and joints on its outer surface.

Abstract: A surface layer of an interior article, comprising a surface layer body formed of a synthetic resin and endowed with high extensibility, and a surface skin formed on the surface layer body and having a softening temperature lower than that of the surface layer body, with an uneven pattern being formed on the surface skin. Because of its lower softening temperature, the surface skin is held in a softer condition during a forming operation, so it is possible to form a clear uneven pattern positively on the surface skin.

Abstract: A process and apparatus for manufacturing an embossed article of synthetic resin including heating a synthetic resin sheet to a softening temperature; pressing the heated synthetic resin sheet on an embossing die by a press die. The embossing die being made by an electro-chemical molding process and having an embossing surface with an embossing pattern thereon and a multitude of fine vacuum pores distributed uniformly over the entire embossing surface. Forcing the synthetic resin sheet against the embossing surface by applying suction through the fine vacuum pores to imprint the embossing pattern onto the synthetic resin sheet. The press die having an undercut shaping portion. Applying blowing pressure through the embossing dies and applying a vacuum through the undercut shaping portion. Thus, releasing the synthetic resin sheet from the embossing surface and forming an undercut in the synthetic resin sheet.

Abstract: A process and apparatus for manufacturing an embossed article of synthetic resin by heating a synthetic resin sheet to a softening temperature; overlaying the heated synthetic resin sheet on an embossing die made by an electro-chemical molding process and having an embossing surface with an embossing pattern thereon and a multitude of fine vacuum pores distributed uniformly over the entire embossing surface; and forcing the synthetic resin sheet against the embossing surface by applying suction through the fine vacuum pores to imprint the embossing pattern onto the synthetic resin sheet.

Abstract: A method of manufacturing an air permeable electrocast shell comprising forming a conductive layer on the surface of a model, placing a layer of elutable particles into close contact with the surface of the conductive layer and effecting an electrocasting treatment to deposit metal between the conductive layer and the particles, except for the points of contact between the conductive layer and the particles, and between adjoining particles. The deposit of the metal is controlled so that the thickness of the electrocast shell is less than that of the particle layer. Thereafter, the particles are eluted from the electrocast shell to form innumberable fine vent holes which open at both surfaces of the electrocast shell.

Abstract: An apparatus for manufacturing an embossed article of synthetic resin comprising heating a synthetic resin sheet to a softening temperature; overlaying the heated synthetic resin sheet on an embossing die made by an electro-chemical molding process and having an embossing surface with an embossing pattern thereon and a multitude of fine vacuum pores distributed uniformly over the entire embossing surface; and forcing the synthetic resin sheet against the embossing surface by applying suction through the fine vacuum pores to imprint the embossing pattern onto the synthetic resin sheet.

Abstract: A vacuum mold for vacuum-forming a plastic sheet heated to a high temperature to transfer grain patterns onto the surface of the plastic sheet, the mold comprising an electrocast shell formed, by an electroforming step, with a casting surface having the grain patterns thereon and a multitude of fine vacuum holes uniformly distributed at the casting surface. A back-up body is mounted at the rear surface of the electrocast shell and is provided with vent holes communicating with the vacuum holes in the shell.

Abstract: A method of pressing a blank comprises the steps of pressing the blank between a die assembly having a cavity with a highly viscous substance contained therein and a punch, inserting the punch into the cavity to increase a pressure of the highly viscous substance in the cavity, and pressing the blank against a surface of the punch under the pressure of the highly viscous substance. The pressing method can form pressed product of complex shape highly accurately and free from cracks, wrinkles, or other damages. There is also disclosed a punch and die press suitable for effecting the abovesaid pressing method.