Molded resin laminate and method for producing the same

Abstract

A molded resin laminate in which the dimensional accuracy and the strength are excellent at a bent portion and a method for producing the same are provided. One, in which an average diameter of small cells existing in a region on a side of a resin cover to be formed into a surface layer is smaller than an average diameter of large cells existing in a region on a side of a base resin component to be formed into a base layer, is used as a foamed resin component to be formed into an intermediate layer of the molded resin laminate. After the base resin component is molded with a molding machine, the base resin component is held on a male mold of a forming machine different from the molding machine described above. A sheet-shaped laminate, which is obtained by joining the foamed resin component and the resin cover, is arranged between the base resin component and a female mold. Subsequently, the forming machine is subjected to mold clamping. The sheet-shaped laminate and the base resin component are joined to one another in a cavity, and the gas in the cavity is vacuum-evacuated to thereby form the sheet-shaped laminate.

What is claimed is:  
     
         1 . A molded resin laminate produced by joining a resin cover and a base resin component held on a mold of a forming machine to one another with a foamed resin component intervening therebetween in a cavity of said forming machine, and forming said resin cover and said foamed resin component by evacuating gas from said cavity, wherein: 
 said molded resin laminate comprises a base layer composed of said base resin component, an intermediate layer composed of said foamed resin component, and a surface layer composed of said resin cover in this order, and an average diameter of cells existing in a region of said intermediate layer on a side of said surface layer is smaller than an average diameter of cells existing in a region on a side of said base layer.    
     
     
         2 . The molded resin laminate according to    claim 1   , wherein said average diameter of said cells existing in said region of said intermediate layer on said side of said surface layer is {fraction (1/20)} to ¾ of said average diameter of said cells existing in said region of said intermediate layer on said side of said base layer.  
     
     
         3 . A method for producing a molded resin laminate comprising: 
 a first step of molding a base resin component composed of a molded resin piece by using a first forming machine;    a second step of arranging a resin cover between the base resin component held on a first mold of a second forming machine and a second mold with a foamed resin component intervening therebetween;    a third step of performing mold clamping for said second forming machine;    a fourth step of forming said resin cover by evacuating gas from a cavity of said second forming machine by the aid of said second mold of said second forming machine; and    a fifth step of forming said foamed resin component and joining said base resin component and said resin cover to one another with said foamed resin component intervening therebetween by evacuating gas from said cavity by the aid of said mold of said second forming machine on which said base resin component is held and said base resin component, wherein: 
 said molded resin laminate, which comprises a base layer composed of said base resin component, an intermediate layer composed of said foamed resin component, and a surface layer composed of said resin cover in this order, is produced; and  
 one, in which an average diameter of cells existing in a region on a side of said resin cover is smaller than an average diameter of cells existing in a region on a side of said base resin component, is used as said foamed resin component.  
   
     
     
         4 . The method for producing said molded resin laminate according to    claim 3   , wherein one, in which said average diameter of said cells existing in said region on said side of said resin cover is {fraction (1/20)} to ¾ of said average diameter of said cells existing in said region on said side of said base resin component, is used as said foamed resin component.