Abstract: A skin layer is formed on sides of a resin panel along the direction of the panel thickness and both surfaces of the resin panel substantially orthogonal to the sides. An expanded layer is formed in an inner part of the panel surrounded by the skin layer to have a multiplicity of voids. Inner ribs are formed of solid layers in the expanded layer to extend along the surfaces and the direction of the panel thickness so that both the longitudinal ends of each inner rib continue out to the skin layer at the opposed sides. Reinforcing members are inserted into the inner ribs respectively, to expose both the longitudinal end surfaces thereof from the opposed sides. Both the longitudinal end surfaces of each reinforcing member are formed with engaging holes releasably engageable with a support member for supporting the reinforcing member in the cavity of the mold assembly.

Abstract: A resin panel for an automobile includes a skin layer formed on sides of a package tray along the direction of the thickness of the package tray and both surfaces of the package tray substantially orthogonal to the sides. An expanded layer is formed in an inner part of the package tray surrounded by the skin layer having voids by enlarging the volume of the cavity of a mold assembly during molding of the package tray to expand a thermoplastic resin in the cavity. Hollow ribs are formed of solid layers in the expanded layer to extend along the surfaces, each have a hollow formed inside over the entire length so that ends of the hollow rib continue out to the skin layer at the opposed sides of the panel. Openings in communication with the hollow rib are formed through the skin layer at the opposed sides, respectively.

Abstract: An annular mount base 11 continuously protruded from one face of a panel main body 3 and surrounding a through hole 9 has a dual structure of an inner mount base portion 17 and an outer mount base portion 19 which are joined to each other by four parts of a joint mount base portion 21. A skin layer 23 is formed at the surface of a door inner panel 1. An expanded layer 25 with a large number of pores is formed inside the panel main body 3. The mount base 11 and a part of the panel main body 3 between the inner mount base portion 17 and the outer mount base portion 19 are formed of a solid layer 27 having no expanded layer 25. Whereby, a lightweight resin molded article including a high-rigidity mount base is provided.

Abstract: An annular mount base 11 continuously protruded from one face of a panel main body 3 and surrounding a through hole 9 has a dual structure of an inner mount base portion 17 and an outer mount base portion 19 which are joined to each other by four parts of a joint mount base portion 21. A skin layer 23 is formed at the surface of a door inner panel 1. An expanded layer 25 with a large number of pores is formed inside the panel main body 3. The mount base 11 and a part of the panel main body 3 between the inner mount base portion 17 and the outer mount base portion 19 are formed of a solid layer 27 having no expanded layer 25. Whereby, a lightweight resin molded article including a high-rigidity mount base is provided.

Abstract: In a molding method for producing a molded foamed resin product in which an expandable resin containing a resin material containing a foaming agent is charged into a cavity between a stationary mold half and a movable mold half and core-backing is then performed by setting the movable mold half back from the stationary mold half to extend the cavity to a volume corresponding to the size of the molded foamed resin product, the core-backing speed is controlled to be higher in a latter core-backing term than in a previous core-backing term, thereby providing a good-appearance molded foamed resin product having a skin layer over the entire surrounding surface and a homogeneous foam structure under the skin layer.

Abstract: A skin layer (19) is formed of a solid layer on sides (15) of a package tray along the direction of the thickness of the package tray and both surfaces (17) of the package tray substantially orthogonal to the sides (15). An expanded layer (21) is formed in an inner part of the package tray surrounded by the skin layer (19) to have a multiplicity of voids by enlarging the volume of the cavity of a mold assembly during molding of the package tray to expand a thermoplastic resin in the cavity. Hollow ribs (23) are formed of solid layers in the expanded layer (21) to extend along the surfaces (17) and each have a hollow (23a) formed inside over the entire length so that both ends of each hollow rib continue out to the skin layer (19) at the opposed sides (15) adjacent thereto. Openings (19a) in communication with the hollow (23a) of the hollow rib (23) are formed through the skin layer (19) at the opposed sides (15), respectively.

Abstract: A skin layer (19) is formed on sides (15) of a resin panel along the direction of the panel thickness and both surfaces (17) of the resin panel substantially orthogonal to the sides (15). An expanded layer (21) is formed in an inner part of the panel surrounded by the skin layer (19) to have a multiplicity of voids by enlarging the volume of the cavity of a mold assembly during molding of the resin panel to expand a thermoplastic resin in the cavity. Inner ribs (23) are formed of solid layers in the expanded layer (21) to extend along the surfaces (17) and the direction of the panel thickness so that both the longitudinal ends of each inner rib continue out to the skin layer (19) at the opposed sides (15). Reinforcing members (24) are inserted into the inner ribs (23), respectively, in the course of molding of the resin panel to expose both the longitudinal end surfaces thereof from the opposed sides (15).

Abstract: A first half part includes a second raised portion and a third raised portion respectively on the inner side of the hollow body and on the outer side of the hollow body with respect to a first raised portion, the second raised portion and the third raised portion being separated from the first raised portion with a spacing and being lower than the first raised portion. A second half part includes a third raised portion on the outer side of the hollow body with respect to a first raised portion, the third raised portion being separated from the first raised portion with a spacing and being lower than the first raised portion. An internal member includes a second raised portion on the inner side of the hollow body with respect to a first raised portion, the second raised portion being separated from the first raised portion with a spacing and being lower than the first raised portion. As a result, there is provided a high quality hollow body that can be provided at low cost and is cosmetically appealing.

Abstract: A first half part includes a second raised portion and a third raised portion respectively on the inner side of the hollow body and on the outer side of the hollow body with respect to a first raised portion, the second raised portion and the third raised portion being separated from the first raised portion with a spacing and being lower than the first raised portion. A second half part includes a third raised portion on the outer side of the hollow body with respect to a first raised portion, the third raised portion being separated from the first raised portion with a spacing and being lower than the first raised portion. An internal member includes a second raised portion on the inner side of the hollow body with respect to a first raised portion, the second raised portion being separated from the first raised portion with a spacing and being lower than the first raised portion. As a result, there is provided a high quality hollow body that can be provided at low cost and is cosmetically appealing.

Abstract: An inertia charge intake manifold is associated with an internal combustion engine having a plurality of cylinders. The intake manifold includes a plurality of elongated separate branch pipes each corresponding to a respective one of the cylinders. The intake manifold also includes a common flange for connecting a first end of each branch pipe to the internal combustion engine. The common flange has a first surface attached to the internal combustion engine. Further, the intake manifold includes a surge tank to which a second end of each branch pipe is connected. The common flange, the surge tank and each branch pipe are made of a hard thermoplastic synthetic resin. The common flange is integrally connected to the surge tank.

Abstract: A method for joining thermoplastic resin molded products by pressing together joining surfaces of two molded products with electric resistance wire therebetween is provided, wherein the method comprising: a first step in which electric resistance wire 20 is sandwiched between the joining surfaces of two molded products which are to be joined, pressure is applied at a first predetermined pressure, and current of a predetermined value is applied for a predetermined time to the electric resistance wire, so that the resin around the electric resistance wire is melted by the thermal energy produced in the electric resistance wire while the surfaces of the two molded products that are to be joined are held at a predetermined interval; and a second step in which, following the conclusion of the first step, the current being applied to the electric resistance wire is stopped, and a second predetermined pressure is applied to attach the molten resin under pressure.

Abstract: An inertia charge intake manifold is associated with an internal combustion engine having a plurality of cylinders. The intake manifold includes a plurality of elongated separate branch pipes each corresponding to a respective one of the cylinders. The intake manifold also includes a common flange for connecting a first end of each branch pipe to the internal combustion engine. The common flange has a first surface attached to the internal combustion engine. Further, the intake manifold includes a surge tank to which a second end of each branch pipe is connected. The common flange, the surge tank and each branch pipe are made of a hard thermoplastic synthetic resin. The common flange is integrally connected to the surge tank.

Abstract: An inertia charge intake manifold is associated with an internal combustion engine having a plurality of cylinders. The intake manifold includes a plurality of elongated separate branch pipes each corresponding to a respective one of the cylinders. The intake manifold also includes a common flange for connecting a first end of each branch pipe to the internal combustion engine. The common flange has a first surface attached to the internal combustion engine. Further, the intake manifold includes a surge tank to which a second end of each branch pipe is connected. The common flange, the surge tank and each branch pipe are made of a hard thermoplastic synthetic resin. The common flange is integrally connected to the surge tank.