Patent Publication Number: US-2022212604-A1

Title: Luggage room board

Description:
TECHNICAL FIELD 
     The present invention relates to a luggage room board to which a cushioning material is attached and, in particular, to a technique for preventing the cushioning material from peeling off. 
     BACKGROUND ART 
     For example, resin luggage room boards are known for automobile interior components, such as cargo floor panels (cover panels or luggage boards of automobile luggage rooms) and rear parcel shelves. Among them, a hollow molded body with a skin in which a fiber sheet is attached to a surface of the hollow molded body manufactured by blow molding a thermoplastic resin is widely used as this kind of luggage room board because it is not only lightweight and strong but also has excellent appearance and texture. 
     For example, Patent Literature 1 discloses a luggage room board manufactured by attaching a strap to a luggage room board main body, and the luggage room board can be opened and closed using the strap. Further, the luggage room board main body disclosed in Patent Literature 1 consists mainly of a hollow molded body made of resin, and a skin material, such as a carpet, is attached to its surface. 
     CITATION LIST 
     Patent Literature 
     
         
         Patent Literature 1: JP-A-2018-103903 
       
    
     SUMMARY OF INVENTION 
     Technical Problem 
     While a skin material is attached to a front surface (upper surface) of the luggage room board facing a user, no skin material is attached to the opposite surface (back surface). Therefore, when the luggage room board is opened and closed, a side of the luggage room board main body made of resin to which the skin material is not attached comes into direct contact with a portion around an opening provided in a luggage room of a vehicle. This causes problems, such as damage to the luggage room board main body made of resin and the portion around the opening of the vehicle due to the impact and the generation of impact noise. 
     The present invention has been proposed in view of such circumstances and aims to provide a luggage room board that reliably produces a cushioning effect during opening and closing operations, whereby the impact is not applied during the opening and closing operations. 
     Solution to Problem 
     In order to achieve the above object, the luggage room board of the first invention of the application is a luggage room board configured to be opened and closed, comprising: a luggage room board main body made of resin, wherein a tape-shaped cushioning material is attached to the luggage room board main body, at least at one end of the cushioning material, a concave portion is provided on a surface of the luggage room board main body, the cushioning material being attached to the surface, and the end of the cushioning material is attached so as to enter the concave portion. 
     If the luggage room board main body made of resin comes into direct contact with the portion around the opening of the vehicle, it will be subjected to impact during opening and closing operations. In the luggage room board of the present invention, a tape-shaped cushioning material (for example, non-woven fabric) is attached to a back surface of the luggage room board main body, and the non-woven fabric serves as a cushioning material to reduce the impact when the luggage room board is opened and closed. 
     Further, in the luggage room board to which the tape-shaped non-woven fabric is attached, if some force is unintentionally applied to an end of the cushioning material, there is a possibility that it will be rolled up and peeled off from the end. In the luggage room board of the present invention, at the end of the cushioning material, a concave portion is provided on a surface of the luggage room board main body to which the cushioning material is attached, and the end of the cushioning material is attached so as to enter the concave portion. Consequently, the end surface of the tape-shaped cushioning member is not exposed, and the unintentional peeling of the cushioning material is reliably prevented. 
     A second invention of the present application relates to a resin panel and a manufacturing method thereof. 
     Conventionally, a resin panel with a certain strength accommodating a core material made of foamed resin inside an outer skin material made of resin have been known. For example, JP-A-2005-297220 discloses a resin panel in which a core material made of phenolic resin foam is included inside an outer skin material of the form of a fiber-reinforced phenolic panel. 
     The conventional resin panel has a structure in which the core material is uniformly arranged. In view of the above techniques, the present disclosure provides a resin panel having various structures and a manufacturing method thereof according to various embodiments. 
     According to an aspect of the second invention of the present application, provided is a resin panel comprising: a first region comprising a core material, a first front side layer, and a first back side layer, the first front side layer and the first back side layer forming a hollow portion accommodating the core material inside; a second region comprising a second front side layer and a second back side layer and having a predetermined rigidity without accommodating the core material; and a third region comprising a third front side layer and a third back side layer and connecting the first region and the second region, wherein the first region, the second region, and the third region are integrally molded with resin. 
     According to an aspect of the second invention of the present application, provided is a manufacturing method of a resin panel including a first region with a hollow portion accommodating a core material and a second region having a predetermined rigidity without accommodating the core material, comprising: an arrangement step of arranging two resin sheets in a molten state between a pair of split molds, the pair of split molds being arranged to face each other and movable between a mold clamping position and an open position, at least one of the split molds including a first cavity corresponding to the first region and a second cavity corresponding to the second region; a shaping step of shaping at least one of the resin sheets in the molten state along at least one of the split molds provided with the first cavity and the second cavity; and an integration step of integrating a peripheral edge of the at least one of the resin sheets after shaping and a peripheral edge of the other resin sheet with each other by moving the pair of split molds from the open position to the mold clamping position 
     Advantageous Effects of Invention 
     According to the first invention of the present application, it is possible to provide a luggage room board that reliably produces a cushioning effect during opening and closing operations, whereby the impact is not applied during the opening and closing operations. 
     According to the second invention of the present application, it is possible to provide a resin panel having various structures and a manufacturing method thereof. 
     The above effects are merely exemplary for convenience of explanation and are not limiting. In addition to or in place of the above effects, it is also possible to achieve any effects described in the present disclosure or effects that are obvious to those skilled in the art. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a schematic perspective view showing a luggage room board installed in a luggage room of a vehicle. 
         FIG. 2  is a schematic plan view of the luggage room board as viewed from a front surface side. 
         FIG. 3  shows opening and closing operation of the luggage room board. 
         FIG. 4  is a schematic perspective view of the vicinity of an end of a non-woven fabric attached to a luggage room board main body as viewed from a back surface side. 
         FIG. 5  is a schematic cross-sectional view showing the vicinity of the end of the non-woven fabric attached to the luggage room board main body. 
         FIG. 6  is an explanatory diagram of a molding step of the luggage room board and shows a state where molten resin sheets are suspended. 
         FIG. 7  is an explanatory diagram of the molding step of the luggage room board and shows a state where a core material is inserted. 
         FIG. 8A  and  FIG. 8B  are explanatory diagrams of the compression of the core material by forming a concave portion.  FIG. 8A  shows a state before compression, and  FIG. 8B  shows a state after compression. 
         FIG. 9  shows an example of the use of a resin panel  101  in various embodiments of a second invention of the present application. 
         FIG. 10  is an overall view showing a configuration of an upper surface of the resin panel  110  according to a first embodiment of the second invention of the present application. 
         FIG. 11  is a side view showing a configuration of a side surface of the resin panel  110  according to a first embodiment of the second invention of the present application. 
         FIG. 12  is a schematic diagram of a cross section around a third region  170  of the resin panel  110  according to the first embodiment of the second invention of the present application. 
         FIG. 13  is an enlarged perspective view of a lower surface side of an edge of a second region  140  of the resin panel  110  according to the first embodiment of the second invention of the present application. 
         FIG. 14A  is a schematic diagram showing a manufacturing method of the resin panel  110  according to the first embodiment of the second invention of the present application. 
         FIG. 14B  is a schematic diagram showing the manufacturing method of the resin panel  110  according to the first embodiment of the second invention of the present application. 
         FIG. 14C  is a schematic diagram showing the manufacturing method of the resin panel  110  according to the first embodiment of the second invention of the present application. 
         FIG. 14D  is a schematic diagram showing the manufacturing method of the resin panel  110  according to the first embodiment of the second invention of the present application. 
         FIG. 14E  is a schematic diagram showing the manufacturing method of the resin panel  110  of according to first embodiment of the second invention of the present application. 
         FIG. 14F  is a schematic diagram showing the manufacturing method of the resin panel  110  according to the first embodiment of the second invention of the present application. 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     Hereinafter, embodiments in which the present invention is applied to a luggage room board for a vehicle will be described in detail with reference to the drawings. 
     (Embodiment of First Invention) 
     As shown in  FIG. 1 , a luggage room board  1  of the present embodiment is used as a luggage room board installed in a luggage room  11  of an automobile  10 . The luggage room  11  is provided behind a rear seat  12  of the automobile  10 , and a higher floor surface is formed by installing the luggage room board  1  so as to close an opening  11   a  of the luggage room  11 . 
     Further, a strap  13  is attached to one end edge of the luggage room board  1  of the present embodiment, and the luggage room board  1  installed on the opening  11   a  of the luggage room  11  can be easily opened and closed by pulling the strap  13 . 
     As shown in  FIG. 2 , the luggage room board  1  is a plate-shaped member having a shape corresponding to the shape of the opening  11   a  of the luggage room  11  and is opened and closed by pulling the strap  13 , as shown in  FIG. 3 . In other words, the luggage room board  1  is opened and closed using one of its edges as the center of rotation. Therefore, in the present embodiment, a rotation center line serving as the rotation center of the luggage room board  1  (x-x line in  FIG. 2 ) substantially coincides with one edge  1 A of the luggage room board  1 . 
     The luggage room board  1  is attached so as to close the opening  11   a  of the luggage room  11 , as described above. As shown in  FIG. 2 , a receiving portion  11   b , which is lower by the thickness of the luggage room board  1 , is formed along the opening  11   a  at the periphery of the opening  11   a . When the luggage room board  1  is attached, a back surface of the luggage room board  1  is supported by this receiving portion  11   b.    
     Next, the configuration of the luggage room board  1  is described. As shown in  FIG. 4  and  FIG. 5 , the luggage room board  1  includes a luggage room board main body  2  formed of a plate-shaped hollow molded body made of resin and a skin material  3  attached to a front surface. Further, a core material  4  is arranged inside the luggage room board main body  2  formed of the plate-shaped hollow molded body. 
     The luggage room board main body  2  includes, for example, a front surface wall and a back surface wall. A polyolefin resin or the like is used as a resin material forming the luggage room board main body  2 . Examples of the polyolefin resin include polypropylene resin and polyethylene resin, and it is also preferable to use a blend of propylene homopolymer having a long chain branched structure and propylene homopolymer having a linear chain structure which have different melt flow rates. 
     The resin material is not limited to the polyolefin resin. Any resin material, for example, acrylic resin, polyamide resin, polyester resins, such as polynaphthalene terephthalate (PEN) resin, polycarbonate resin, polystyrene resin, acrylonitrile-butadiene-styrene (ABS) resin, acrylonitrile-styrene (AS) resin, polyvinylidene chloride resin, polyvinyl chloride resin, polyvinyl alcohol resin, polybutylene terephthalate (PBT) resin, and a resin obtained by blending these resins may be used. 
     Further, as a thermoplastic resin forming the luggage room board main body  2 , for example, SBS resin (styrene-butadiene-styrene copolymer), SEBS resin (styrene-ethylene-butadiene-styrene copolymer) and the like may be blended with the above-mentioned polyolefin resin, whereby the impact resistance of the luggage room board  1  can be improved. Further, the luggage room board main body  2  may be formed of a foamed resin. 
     A reinforcing material may be embedded in a hollow portion of the hollow molded body forming the luggage room board main body  2 , and reinforcing ribs may be formed on the front surface wall and the back surface wall. The reinforced structure may be achieved by forming an inner rib extending from the back surface wall to the front surface wall inside the hollow portion. 
     As the skin material  3  attached to the front surface of the luggage room board main body  2 , for example, a relatively thick skin material made of a so-called napped material (for example, tufted carpet) can be used. The tufted carpet is made by inserting a loop-shaped or cut-shaped pile yarns into a base fabric and coating a back surface with adhesive to fix the pile yarns so that they do not come off. 
     Alternatively, natural fibers, such as cotton, hemp, wool, and silk, regenerated fibers, such as cuprammonium rayon, semi-synthetic fibers, such as acetate and rayon, synthetic fibers, such as nylon, polyester, acrylic, vinylon, polypropylene and polyurethane, and fiber sheets, such as knitted fabrics, woven fabrics, and non-woven fabrics obtained by processing these blended fibers can also be used. 
     The core material  4  is, for example, a foamed body formed of thermoplastic resin. The resin material forming the core material  4  is not particularly limited, and examples include polyolefins, such as polypropylene and polyethylene, any of acrylic derivatives, such as polyamide, polystyrene, and polyvinyl chloride, or a mixture of two or more of these. The foaming ratio of the foamed body used for the core material  4  is not particularly limited, but is, for example, 1.5 to 60 times. 
     Here, the skin material  3  is attached to only one surface (upper surface) of the luggage room board main body  2 . In  FIG. 4 , the luggage room board  1  is shown with the front and back reversed, and it appears that the skin material  3  is attached to a lower surface. However, the skin material  3  is actually attached to the upper surface of the luggage room board  1  in the usage mode. With such a configuration, when the luggage room board  1  is installed over the opening  11   a  of the luggage room  11 , the higher floor surface is covered with the skin material  3 . Consequently, the floor surface formed of the luggage room board  1  has a shock-absorbing effect and also has a luxurious appearance. 
     If the skin material  3  is attached only to the front surface (upper surface) of the luggage room board main body  2 , the luggage room board main body  2  made of resin exposed on the back surface of the luggage room board  1  comes into direct contact with the receiving portion  11   b  formed around the opening  11   a  when opening and closing the luggage room board  1 . Since the luggage room board main body  2  made of resin is hard and does not have cushioning properties, it will be subjected to impact when it comes into direct contact, which may cause problems, such as impact noise, or in extreme cases, damage. 
     For this reason, in the luggage room board  1  of the present embodiment, a tape-shaped non-woven fabric  20  is attached to the luggage room board main body  2  on the back surface of the luggage room board  1  and is used as a cushioning material. The tape-shaped non-woven fabric  20  is attached at a position facing the receiving portion  11   b  formed around the opening  11   a  of the luggage room  11 , as shown in  FIG. 2 . In the present embodiment, the tape-shaped non-woven fabrics are attached along two sides orthogonal to the rotation center line serving as the rotation center of the luggage room board  1  (the edge  1 A of the luggage room board  1 , x-x line in  FIG. 2 ). 
     The tape-shaped non-woven fabric  20  is made of, for example, natural fibers, such as cotton, hemp, wool, and silk, regenerated fibers, such as cuprammonium rayon, semi-synthetic fibers, such as acetate and rayon, synthetic fibers, such as nylon, polyester, acrylic, vinylon, polypropylene and polyurethane, or a material obtained by processing these blended fibers, and has excellent cushioning properties because it is a sheet of fibers. 
     The tape-shaped non-woven fabric  20  is attached to the luggage room board main body  2  using an adhesive or the like. However, it is in the form of a tape protruding from the luggage room board main body  2 , and thus it is easily affected by external pressure and has a problem of being easily rolled up and peeled off from its end. If some force is unintentionally applied to the end of the tape-shaped non-woven fabric  20 , the adhesive force or bonding force may be insufficient, which will trigger the peeling off, and the non-woven fabric  20  will be peeled off from the end. In particular, the tape-shaped non-woven fabrics  20  are attached along the two sides orthogonal to the rotation center line, there is a high possibility of unintentional force being applied to ends  20   a  on a side of the rotation center line, and they will be rolled up and peeled off from the edges. 
     In order to solve such inconveniences, the luggage room board  1  of the present embodiment is provided with concave portions  30  on the luggage room board main body  2  at positions corresponding to the ends  20   a  of the non-woven fabrics  20  on the side of the rotation center line, as shown in  FIG. 4  and  FIG. 5 , and the non-woven fabric  20  is attached so that the end  20   a  enters the concave portion  30 . The concave portion  30  can be easily formed by adjusting the shape of a mold when molding the luggage room board main body  2 . 
     The concave portion  30  is formed to have a width slightly larger than a width of the tape-shaped non-woven fabric  20  and is formed such that its depth gradually increases toward the end  20   a  of the non-woven fabric  20 . Therefore, a bottom  30   a  of the concave portion  30  is an inclined surface. 
     Further, as shown in  FIG. 5 , a depth d of the concave portion  30  at the end  20   a  of the non-woven fabric  20  is set to be approximately the same as a thickness t of the non-woven fabric  20 . An inner wall  30   b  of the concave portion  30  faces the end surface of the non-woven fabric  20 . This makes it difficult to be affected by external pressure and can prevent the end  20   a  of the non-woven fabric  20  from protruding and rolling up. 
     In this regard, although the concave portion  30  in the present embodiment is provided only at the position corresponding to the end  20   a  of the tape-shaped non-woven fabric  20  on the side of the rotation center line, the concave portion  30  may be provided at the position corresponding to both ends of the non-woven fabric  20 . By providing the concave portions  30  corresponding to both ends of the non-woven fabric  20 , the rolling up of the non-woven fabric  20  at both ends can be reliably prevented. On the other hand, the end  20   a  on the side of the rotation center line is easily affected by external pressure, and thus the rolling up at the position easily affected by external pressure can be reliably prevented by forming the concave portion  30  only on this side. In addition, the other end of the non-woven fabric  20  protrudes, and this has the advantage of maximizing the cushioning effect. 
     The formation of the concave portion  30  is also effective in improving the strength around the concave portion  30 . This is because the core material  4  inserted in the luggage room board main body  2  is compressed as a result of the formation of the concave portion  30 , which leads to a decrease in the foaming ratio of the core material  4  formed of a foamed body and an increase in its strength. The reason for this will be described below based on a molding method of the luggage room board  1 . 
       FIG. 6  and  FIG. 7  are explanatory diagrams of the luggage room board main body  2  of the luggage room board  1  of the present embodiment. 
     Referring to  FIG. 6 , a mold clamping device  40  includes a pair of split molds  41 A,  41 B which are moved between an open position and a closed position in a direction substantially orthogonal to molten resin sheets P, P extruded vertically downward from an extruder (not shown). The pair of split molds  41 A,  41 B are arranged with their corresponding forming surfaces  42 A,  42 B facing each other. The forming surfaces  42 A,  42 B have a shape corresponding to the front surface and the back surface of the luggage room board  1 , and a convex portion  46  is formed on the forming surface  42 A corresponding to the back surface to form the concave portion  30 . 
     In each of the pair of split molds  41 A,  41 B, pinch-off portions  44 A,  44 B are formed near an upper and lower ends of the forming surfaces  42 A,  42 B corresponding to each of the molds. These pinch-off portions  44 A,  44 B are formed in an annular shape around the forming surfaces  42 A,  42 B, respectively, and protrude toward the opposing split molds  41 B,  41 A, respectively. Consequently, when the pair of split molds  41 A,  41 B are clamped, tips of the pinch-off portions  44 A,  44 B come into contact with each other, and a parting line is formed on the periphery of the molten resin sheets P, P. 
     Sliding portions  45 A,  45 B capable of protruding from the forming surfaces  42 A,  42 B are provided around the forming surfaces  42 A,  42 B of the pair of split molds  41 A,  41 B. End surfaces of the sliding portions  45 A,  45 B in a state of protruding from the forming surfaces  42 A,  42 B are brought into contact with the molten resin sheets P, P, whereby an enclosed space is formed between the molten resin sheets P, P and the forming surfaces  42 A,  42 B of the pair of split molds  41 A,  41 B. 
     A vacuum chamber (not shown) is built into the pair of split molds  41 A,  41 B. The vacuum chamber is connected to a vacuum pump and a vacuum tank (both not shown). A communication passage (not shown) for vacuum suction is provided between the vacuum chamber and the forming surfaces  42 A,  42 B. 
     The pair of split molds  41 A,  41 B are driven by a mold driving device (not shown) to move between the open position and the closed position. In the open position, two continuous molten resin sheets P, P can be arranged at a distance from each other between the pair of split molds  41 A,  41 B. The two molten resin sheets P, P become the luggage room board main body  2  of the luggage room board  1  after molding. In the closed position, the pinch-off portions  44 A,  44 B of the pair of split molds  41 A,  41 B come into contact with each other. 
     To form the luggage room board  1 , as shown in  FIG. 6 , the molten resin sheets P, P are first extruded vertically downward from the extruder and are fed between the forming surfaces  42 A,  42 B of the pair of split molds  41 A,  41 B. At this point, the pair of split molds  41 A,  41 B are in the open position. 
     Next, the sliding portions  45 A,  45 B around the forming surfaces  42 A,  42 B protrude, and their end surfaces are brought into contact with the molten resin sheets P, P. Consequently, the enclosed space is formed between the molten resin sheets P, P and the forming surfaces  42 A,  42 B of the pair of split molds  41 A,  41 B. Then, air in the enclosed space is sucked out through the communication passage provided between the vacuum chamber and the forming surfaces  42 A,  42 B. This suction causes the two molten resin sheets P, P to be pressed respectively against the forming surfaces  42 A,  42 B of the pair of split molds  41 A,  41 B, and the sheets are shaped (formed) into a shape along the forming surfaces  42 A,  42 B, that is, the rough outline of the luggage room board main body  2 , as shown in  FIG. 7 . 
     At this time, on a side of the split mold  41 B, the skin material  3  is inserted between the molten resin sheet P and the forming surface  42 B of the split mold  41 B and is attached to one side (front surface) of the luggage room board main body  2 . 
     Next, a manipulator (not shown) is used to position the core material  4  between the pair of split molds  41 A,  41 B and insert it by pressing it against one of the split molds (the split mold  41 B in  FIG. 7 ) from a side, as shown in  FIG. 7 . Consequently, the core material  4  is welded to one of the molten resin sheets P, and the core material  4  is arranged between the pair of molten resin sheets P pressed against the forming surfaces  42 A,  42 B. 
     The pair of split molds  41 A,  41 B are then moved from the open position to the closed position and are clamped. Consequently, the core material  4  that has been welded to one of the molten resin sheets P (on a right side of  FIG. 7 ) is welded to the other molten resin sheet P (on a left side of  FIG. 7 ). Further, the peripheral edges of the pair of molten resin sheets P, P are welded on the pinch-off portions  44 A,  44 B of the pair of split molds  41 A,  41 B to form the parting line PL. 
     Finally, the pair of split molds  41 A,  41 B are moved to the open position again. The formed luggage room board  1  is separated from the forming surfaces  42 A,  42 B, and burrs formed around the parting line PL are cut and removed using a cutter or the like. The luggage room board  1  is then completed. In this regard, although the molten resin sheets P are pressed by suction against the forming surfaces  42 A,  42 B of the pair of split molds  41 A,  41 B in the above-described molding method of the luggage room board  1 , the method is not limited thereto. The molten resin sheet P may be pressed against the forming surfaces  42 A,  42 B of the pair of split molds  41 A,  41 B by blowing fluid, such as air, onto the molten resin sheet P (blow molding). 
     In the luggage room board  1  formed by the molding method described above, the convex portion  46  for forming the concave portion  30  is formed on the forming surface  42  of the split mold  41 AA, and the core material  4  is compressed by this convex portion  46  (by the molten resin sheet P molded by this convex portion  46 ).  FIG. 8A  shows a state before molding, and  FIG. 8B  shows a state after molding. As shown in  FIG. 8B , after molding, the core material  4  is compressed by the convex portion  46  (by the molten resin sheet P molded by this convex portion  46 ). Therefore, the foaming ratio of the core material  4  formed of a foamed body decreases in this portion, resulting in increased strength of the core material  4  and improved strength around the concave portion  30 . Further, by improving the strength around the concave portion  30 , the non-woven fabric  20  can be easily attached to the concave portion  30  and is less likely to be peeled off after the attachment. 
     As described above, since the tape-shaped non-woven fabric  20  is attached to the back surface of the luggage room board main body  2  in the luggage room board  1  of the present embodiment, the non-woven fabric  20  serves as a cushioning material to reduce the impact when opening and closing the luggage room board  1 . Further, at the end  20   a  of the non-woven fabric  20 , the concave portion  30  is provided on the surface of the luggage room board main body  2  to which the non-woven fabric  20  is attached, and the end  20   a  of the non-woven fabric  20  is attached so as to enter the concave portion  30 , so that the tape-shaped non-woven fabric  20  is prevented from being rolled up and peeled off. Further, the formation of the concave portion  30  is also effective in improving the strength of the luggage room board  1 . 
     (Embodiment of Second Invention) 
     &lt;Resin Panel of Second Invention&gt; 
     The present disclosure relates to a resin panel. One example is a resin panel including at least a first region in which a core material is accommodated, a second region having a predetermined rigidity without accommodating the core material, and a third region connecting the first region and the second region. 
       FIG. 9  shows one example of a use of a resin panel  101  according to various embodiments of the present disclosure. Specifically,  FIG. 9  shows the resin panel  101  including a first region  102  in which a core material is accommodated, a second region  104  in which the core material is not accommodated, and a third region  107  connecting the first region  102  and the second region  104 . 
     The resin panel  101  is used, for example, as a luggage room board for a vehicle. As shown in  FIG. 9 , the resin panel  101  is arranged to cover a luggage room located at the rear of a vehicle  108 . Here, for example, the first region  102  in which the core material is accommodated is arranged in a position to cover an accommodation space  103  formed in the luggage room. Since the first region  102  accommodates the core material inside, it can easily support the load in the direction of gravity. Further, the second region  104  is arranged in a position to cover a region other than the accommodation space  103 , that is, a region where the floor of the luggage room is formed. Since the second region  104  has a predetermined rigidity without including the core material, it is thinner and can serve as a decorative panel. Further, the third region  107  serves as a hinge, so that the first region  102  serves as a lid that can be opened upward. 
     In this regard,  FIG. 9  shows an example of using the resin panel  101  as the luggage room board of the vehicle, and the applications of the resin panel are not limited thereto. For example, the resin panel  101  can be used for a variety of applications including interior materials, exterior materials, reinforcement materials, decorative materials, and heat insulation materials for transportation equipment, such as passenger cars, trucks, trains, aircraft, and ships, building structures, such as houses, buildings, and other structures, and mass-produced products, such as toys for personal use, amusement machines for stores, sporting goods, and leisure goods. 
     &lt;First Embodiment of Second Invention&gt; 
     [Configuration of Resin Panel  110 ] 
     1. Overview of Configuration of Resin Panel  110   
       FIG. 10  is an overall view showing a configuration of an upper surface of the resin panel  110  according to a first embodiment of the present disclosure. Further,  FIG. 11  is a side view showing a configuration of a side surface of the resin panel  110  according to the first embodiment of the present disclosure. According to  FIG. 10  and  FIG. 11 , the resin panel  110  includes a first region  120 , a second region  140 , a third region  170  connecting the first region  120  and the second region  140 , and a skin material  180  laminated to cover these regions. The first region  120  accommodates a core material  122  over the substantially entire region of an accommodation space  123  formed therein. Further, the second region  140  has a reinforced structure (the concave portion  142 ) of a predetermined shape over its entire area, instead of accommodating the core material inside. The third region  170  is connected to the first region  120  at one end and to the second region  140  at the other end and connects the first region  120  and the second region  140 . In the present embodiment, the third region  170  is formed thinner than the other regions to enable the resin panel  110  to be bent in the region. 
     In the present embodiment, the first region  120 , the second region  140  and the third region  170  are integrally molded with resin. That is, for example, the first region  120 , the second region  140 , and the third region  170  are continuously formed by injection molding or other methods using a molten resin material. Thermoplastic resin, such as polyolefin, is used as the resin for integrally molding the regions. As the thermoplastic resin, low density polyethylene, linear low density polyethylene, high density polyethylene, polypropylene, ethylene-propylene copolymer, vinyl acetate copolymer, polyvinyl chloride, ABS, polyamide, polystyrene, polyester, polycarbonate, modified polyphenylene ether can be used alone or in a mixture of two or more resins. In addition to these main components, additives, such as glass fiber, carbon fiber, calcium carbonate, talc, mica, stabilizers, colorants, antistatic agents, and flame retardants can be added as appropriate. 
     2. Configuration of First Region  20   
       FIG. 12  is a schematic diagram of a cross section around the third region  170  of the resin panel  110  according to the first embodiment of the present disclosure. Specifically,  FIG. 12  schematically shows the cross-sectional structure of the portion enclosed by a broken line A in  FIG. 11 . According to  FIG. 12 , in the first region  120 , a first front side layer  121   a  and a first back side layer  121   b  are arranged to face each other. The first front side layer  121   a  and the first back side layer  121   b  are both formed of resin and are integrally formed by welding their peripheral edges. By welding the peripheral edges, the accommodation space  123  is formed between the first front side layer  121   a  and the first back side layer  121   b . The core material  122  is accommodated in the accommodation space  123  to provide rigidity to the first region. 
     Here, in one example, a thickness t 1  connecting the outer surface of the first front side layer  121   a  and the outer surface of the first back side layer  121   b  of the first region  120  is larger than a thickness t 2  connecting an outer surface of a second front side layer  141   a  and the outer surface of the second back side layer  141   b  of the second region  140 , and a thickness t 3  connecting a front surface  171   a  and a back surface  171   b  of the third region  170 . Specifically, the thickness t 1  is formed to be 1.1 to 5 times larger, preferably 1.2 to 3 times larger, and more preferably 1.3 to 2 times larger than the thickness t 2 . In this regard, although the thickness t 1  can be formed at the thickness described above when used as the luggage room board of  FIG. 9 , it can be adjusted as needed depending on the application of the resin panel, the degree of rigidity to be provided, resin raw material, raw material of the core material  122  and the like. 
     A foamed body is mainly used for the core material  122 . In the present embodiment, a foamed body that is molded into a shape including an upper surface, a lower surface facing the upper surface, and side surfaces connecting the upper surface and the lower surface is used as the core material  122 , and the foamed body is evenly accommodated in the entire area of the accommodation space  123  formed by the first front side layer  121   a  and the first back side layer  121   b . Although not specifically shown in the drawings, in order to provide a higher support function for loads in a thickness direction or gravity direction, it is also possible to use the core material  122  that has been processed into a desired shape, such as one with a recess (concave portion) in the thickness direction or gravity direction and one employing a honeycomb structure with holes. Further, in addition to the core material  122 , various reinforcing materials or reinforcing structures can be arranged in the accommodation space  123 . 
     In this regard, as the materials used for the core material  122 , thermoplastic resin, such as polyolefins which are homopolymers or copolymers of ethylene, propylene, isoprenepentene, methylpenten and the like, polyamide, polystyrene, polyvinyl chloride, polyacrylonitrile, acrylic derivatives, polycarbonate, vinyl acetate copolymer, ionomer, ethylene-propylene copolymer, acrylonitrile-styrene copolymer, ABS, polyphenylene oxide, polyacetal, thermoplastic polyimide, and thermosetting resin, such as phenol resin, melamine resin, epoxy resin, polyurethane, and thermosetting polyimide can be used alone or in a mixture of two or more resins. Further, in addition to these resin materials, additives, such as glass fiber, carbon fiber, calcium carbonate, talc, mica, stabilizers, coloring agents, antistatic agents, flame retardants, and the like can be added to the core material  122 . Further, the core material  122  is formed of the above resin materials, and a foaming agent can be added to form it as a foamed body. 
     3. Configuration of Second Region  140   
     According to  FIG. 12 , in the second region  140 , the second front side layer  141   a  and a second back side layer  141   b  are arranged to face each other. The second front side layer  141   a  and the second back side layer  141   b  are both formed of resin and are integrally formed by welding at least their peripheral edges. Here, the second back side layer  141   b  has a plurality of openings  143  at predetermined intervals. In each of the openings  143 , a concave portion  142  is formed from each opening  143  toward the second front side layer  141   a . The concave portions  142  includes a top  142   b  formed at a predetermined distance from the opening  143  of the second back side layer  141   b  and a wall portion  142   a  connecting the opening  143  and the top  142   b . Therefore, the concave portion  142  having the wall portion  142   a  makes it possible to provide a predetermined rigidity against a load in the thickness direction connecting the second front side layer  141   a  and the second back side layer  141   b.    
     In the present embodiment, the opening  143  and the top  142   b  are formed in a substantially circular shape, and the area of the opening  143  is larger than the area of the top  142   b . Therefore, the wall portion  142   a  connecting the opening  143  and the top  142   b  forms an inclined surface, and a cross section of the concave portion  142  has an inverted mortar shape (trapezoidal shape). Here, an inclination angle θ 1  of the wall portion  142   a  (here, the angle between the top  142   b  and the wall portion  142   a ) is 90 to 135 degrees, preferably 90 to 125 degrees, and more preferably 90 to 110 degrees. However, the shape is not limited thereto, and the area of the top  142   b  may be larger than that of the opening  143  so that the cross section of the concave portion  142  has a mortar shape. Further, it is also possible to make the area of the opening  143  and the top  142   b  approximately the same so that the concave portion  142  has a rectangular cross section. 
     In addition to the peripheral edges of the second front side layer  141   a  and the second back side layer  141   b , the top  142   b  of the concave portion  142  is also welded to the second front side layer  141   a . Therefore, the region where the top  142   b  is welded is formed to be thicker than the other regions of the second front side layer  141   a . Further, the second region  140  has a hollow portion  144  which is formed by the region other than the region where the top  142   b  of the second front side layer  141   a  is welded, the second back side layer  141   b , and the wall portion  142   a . In the present embodiment, as described above, the concave portion  142  having the wall portion  142   a  is formed in the second region  140 . Therefore, although the hollow portion  144  does not accommodate any core material or other contents, it is possible to provide the second region  140  with a predetermined rigidity against loads in the thickness direction connecting the second front side layer  141   a  and the second back side layer  141   b.    
     Further, the thickness t 2  connecting an outer surface of the second front side layer  141   a  and an outer surface of the second back side layer  141   b  of the second region  140  is smaller than the thickness t 1  connecting the outer surface of the first front side layer  121   a  and the outer surface of the first back side layer  121   b  of the first region  120  and is larger than the thickness t 3  connecting the front surface  171   a  and the back surface  171   b  of the third region  170 . Specifically, the thickness t 2  is formed such that the thickness t 1  is 1.1 to 5 times larger, preferably 1.2 to 3 times larger, and more preferably 1.3 to 2 times larger than the thickness t 2 . In this regard, although the thickness t 2  can be formed at the thickness described above when used as the luggage room board of  FIG. 9 , it can be adjusted as needed depending on the application of the resin panel, the degree of rigidity to be provided, and resin raw material and the like. 
     Here,  FIG. 13  is an enlarged perspective view of a lower surface side of an edge of the second region  140  of the resin panel  110  according to the first embodiment of the present disclosure. Specifically,  FIG. 13  is an enlarged perspective view of the portion enclosed by a broken line B in  FIG. 11  when viewed from below. According to  FIG. 13 , the openings  143  are formed in the substantially entire area of the second back side layer  141   b  of the second region  140  at predetermined intervals (s 1  and s 2 ) with respect to other adjacent openings  143 . The concave portion  142  is formed from each of the openings  143  toward the second front side layer  141   a . The opening  143  and the top  142   b  of the concave portion  142  in the present embodiment are formed in a circular shape. However, the shape is not limited thereto, and it is also possible to form them in a polygonal shape, such as a hexagon or octagon. Further, the shapes of the opening  143  and the top  142   b  do not necessarily correspond to each other, and the opening  143  and the top  142   b  may have different shapes. 
     Further, in the present embodiment, the plurality of concave portions  142  are spaced equally apart by s 1  in the left-right direction and by s 2  in the depth direction. However, the interval can be adjusted as desired, for example, by decreasing the intervals of the plurality of concave portions  142  toward the center of the second region  140  of the resin panel, or conversely, decreasing the intervals of the plurality of concave portions  142  toward the outer edge. 
     4. Configuration of Third Region  170   
     According to  FIG. 12 , the third region  170  is formed of a resin having the front surface  171   a  and the back surface  171   b . One end of the third region  170  is connected to the vicinity of the peripheral edge where the first front side layer  121   a  and the first back side layer  121   b  of the first region  120  are welded. Further, the other end of the third region  170  is connected to the vicinity of the peripheral edge where the second front side layer  141   a  and the second back side layer  141   b  of the second region  140  are welded. Therefore, the third region  170  connects the first region  120  and the second region  140  at one end and the other end. 
     The first back side layer  121   b  of the first region  120  is connected to form a predetermined slope toward the back surface  171   b  of the third region  170 . Further, the second back side layer  141   b  of the second region  140  is connected to form a predetermined slope toward the back surface  171   b  of the third region  170 . The angle θ 2  between the first back side layer  121   b  of the first region  120  and the back surface  171   b  of the third region  170  and the angle θ 3  between the second back side layer  141   b  of the second region  140  and the back surface  171   b  of the third region  170  are each 90 to 160 degrees, preferably 90 to 135 degrees, and more preferably 90 to 120 degrees. 
     Here, the third region  170  can serve as a hinge to allow the first region  120  and the second region  140  to be bent with respect to each other. In such a case, the thickness t 3  connecting the front surface  171   a  and the back surface  171   b  of the third region  170  is smaller than the thickness t 1  connecting the outer surface of the first front side layer  121   a  and the outer surface of the first back side layer  121   b  of the first region  120  and the thickness t 2  connecting the outer surface of the second front side layer  141   a  and the outer surface of the second back side layer  141   b  of the second region  140 . Further, the thickness t 3  is formed to be smaller than a thickness of the first front side layer  121   a  of the first region  120  and a thickness of the second front side layer  141   a  of the second region  140 . Consequently, the third region  170  can serve as a hinge to allow the first region  120  and the second region  140  to be bent with respect to each other. 
     In this regard, the thickness t 3  of the third region  170  is formed to be 0.9 times or less, preferably 0.5 times or less, and more preferably 0.2 times or less with respect to a thickness t 4  of the first front side layer  121   a  of the first region  120 . In this regard, the thickness t 3  can be adjusted as needed depending on resin raw material, the presence or absence of the skin material and its material, the degree of bendability and the like. 
     5. Configuration of Skin Material  180   
     The skin material  180  is a member laminated on the regions to cover the first region  120 , the second region  140 , and the third region  170  and is formed on an outermost surface of the resin panel  110 . Generally, the skin material  180  is used for the purpose of improving appearance and decorative properties, imparting desired surface characteristics (such as fire resistance) to the resin panel  110 , and protecting articles in contact with the resin panel  110 . Therefore, the skin material  180  does not have to be formed over the entire surface of the resin panel  110  and may be formed to cover only a part of the resin panel. Further, it is not always necessary to provide the skin material  180 . In addition, the resin panel  110  may include another layer between the skin material  180  and the regions for the purpose of imparting desired properties. 
     For the skin material  180 , it is possible to use a skin material having a desired shape, such as a fiber skin material, a sheet skin material, or a film skin material. Further, its material can be selected from synthetic fibers, such as polyester, polypropylene, polyamide, polyurethane, acrylic, vinylon, semi-synthetic fibers, such as acetate and rayon, regenerated fibers, such as viscose rayon and copper ammonia rayon, natural fibers, such as cotton, hemp, wool, and silk, or composite fibers of these. In addition, the form of the material may be non-woven fabric, woven fabric, knitted fabric, or their napped fabric. 
     [Manufacturing Method of Resin Panel  110 ] 
     1. Outline of Manufacturing Method 
     In the present embodiment, as described above, the resin panel  110  has a shape in which the first region  120  accommodating the core material  122  inside, the second region  140  having a predetermined rigidity without accommodating the core material, and the third region  170  connecting the first region  120  and the second region  140  are integrally molded with resin. The resin panel  110  is manufactured in one example by a method including the following steps. 
     [Step  1 ] an arrangement step of arranging two resin sheets in a molten state between a pair of split molds, which are arranged to face each other and movable between a mold clamping position and an open position, and at least one of which includes a first cavity corresponding to the first region  120  and a second cavity corresponding to the second region  140 
 
[Step  2 ] a shaping step of shaping at least one of the resin sheets in the molten state along at least one of the split molds provided with the first cavity and the second cavity
 
[Step  3 ] an integration step of integrating a peripheral edge of at least one of the resin sheets after shaping and a peripheral edge of the other resin sheet with each other by moving the pair of split molds from the open position to the mold clamping position
 
     In this regard, the step  2  can include a step of forming an enclosed space between the first cavity and the second cavity and at least one of the resin sheets and sucking from the enclosed space. Further, a step of blowing air into the second region  140  can be included after the step  3 . 
     2. Configuration of Molding Machine  200   
       FIG. 14A  is a schematic diagram showing a manufacturing method of the resin panel  110  of the first embodiment of the present disclosure. Specifically, it shows a state in which two resin sheets P 1  and P 2  in a molten state are arranged in the Step  1  between a first mold  210  including a first cavity  301  corresponding to the first region  120  and a second cavity  501  corresponding to the second region  140  and a second mold  220  that is arranged to face the first mold  210  and is movable relative to the first mold  210  between the mold clamping position and the open position. 
     According to  FIG. 14A , a molding machine  200  has an extruder  113  including a hopper for feeding resin as raw material of the resin panel  110 , a heater for heating and melting the fed raw material, a screw for kneading the molten resin, and a cylinder for extruding the kneaded molten resin in a direction toward the first mold  210  and the second mold  220 . 
     Further, the molding machine  200  has the first mold  210  and the second mold  220 , which are a pair of split molds that can be moved relative to each other between the mold clamping position and the open position. The first mold  210  includes the first cavity  301  surrounded by a standing wall  302   a  and a ridge  802  for shaping the first back side layer  121   b  of the first region  120  of the resin panel  110 , the second cavity  501  surrounded by a standing wall  502   a  and the ridge  802  for shaping the second back side layer  141   b  of the second region  140  of the resin panel  110 , and the ridge  802  formed between the first cavity  301  and the second cavity  501  to separate the cavities. Here, the first cavity  301  has no protrusions formed therein so that the hollow accommodation space  123  of the first region  120  of the resin panel  110  can be formed. On the other hand, the second cavity  501  has a plurality of convex portions  503  corresponding to positions of the plurality of concave portions  142  of the second region  140 . 
     The second mold  220  has a third cavity  901  surrounded by a standing wall  302   b  and a standing wall  502   b  in order to shape the first front side layer  121   a  of the first region  120  of the resin panel  110 , the second front side layer  141   a  of the second region  140 , and the front surface  171   a  of the third region  170 . 
     Here, the thickness t 1  connecting the outer surface of the first front side layer  121   a  and the outer surface of the first back side layer  121   b  of the first region  120  of the resin panel  110  is formed to be larger than the thickness t 2  connecting the outer surface of the second front side layer  141   a  and the outer surface of the second back side layer  141   b  of the second region  140  ( FIG. 12 ). Therefore, the depth of the first cavity  301  corresponding to the first region  120  is formed to be larger than the depth of the second cavity  501  corresponding to the second region  140 . 
     3. Step  1   
     In the Step  1 , as shown in  FIG. 14A , the first mold  210  and the second mold  220  are arranged to face each other and interpose, between the molds, the resin sheet P 1  and the resin sheet P 2  in the molten state that are suspended from an extruder  113 . Here, the amount of molten resin to be suspended can be adjusted as appropriate according to the thickness of the resin panel after molding. Further, when the regions are covered with the skin material  180 , the skin material  180  is arranged between the resin sheet P 2  on a side of the second mold  220  and the second mold  220 . 
     As raw materials for the resin sheet P 1  and the resin sheet P 2 , thermoplastic resin, such as polyolefin, is used. As the thermoplastic resin, low density polyethylene, linear low density polyethylene, high density polyethylene, polypropylene, ethylene-propylene copolymer, vinyl acetate copolymer, polyvinyl chloride, ABS, polyamide, polystyrene, polyester, polycarbonate, modified polyphenylene ether can be used alone or in a mixture of two or more resins. In addition to these main components, additives, such as glass fiber, carbon fiber, calcium carbonate, talc, mica, stabilizers, colorants, antistatic agents, and flame retardants can be added as appropriate. 
     4. Step  2   
       FIG. 14B  and  FIG. 14C  are schematic diagrams showing the manufacturing method of the resin panel  110  according to the first embodiment of the present disclosure. Specifically,  FIG. 14B  shows the formation of the enclosed space in the Step  2  between the first mold  210  with the first cavity  301  and the second cavity  501  and the resin sheet P 1 , and between the second mold  220  with the third cavity  901  and the resin sheet P 2 . Further,  FIG. 14C  shows a state where the resin sheet P 1  and the resin sheet P 2  in the molten state are shaped in the Step  2  along the first mold  210  with the first cavity  301  and the second cavity  501  and the second mold  220  with the third cavity  901 , respectively. 
     In the Step  2 , as shown in  FIG. 14B , the first mold  210  is first moved to bring the standing wall  302   a  and the standing wall  502   a  into contact with the resin sheet P 1 . At this time, a lower end of the resin sheet P 1  is pressed against a side of the standing wall  502   a  of the first mold  210  using, for example, a clip-shaped member, and an enclosed space  710  is formed by the standing wall  302   a , the first cavity  301 , the ridge  802 , the second cavity  501 , the standing wall  502   a , and the resin sheet P 1 . Similarly, the second mold  220  is moved to bring the standing wall  302   b  and the standing wall  302   b  into contact with the resin sheet P 2 , and an enclosed space  902  is formed by the standing wall  302   b , the third cavity  901 , the standing wall  502   b , and the resin sheet P 2 . Since the skin material  180  is used in the present embodiment, the enclosed space  902  is formed with the skin material  180  interposed between the resin sheet P 2  and the second mold  220 . 
     Here, according to  FIG. 14B , the first mold  210  further includes a vacuum suction chamber  700  for depressurizing and sucking air from the enclosed space  710 , a plurality of suction holes  701   a , and a plurality of suction holes  701   b . Further, although not specifically shown in the drawings, the second mold  220  also has a vacuum suction chamber and a plurality of suction holes as well. 
     Next, as shown in  FIG. 14C , the air filled in the formed enclosed space  710  is sucked under reduced pressure from the suction hole  701   a  and the suction hole  701   b  of the first mold  210  to shape the sheet along the first cavity  301 , the ridge  802 , and the second cavity  501 . Specifically, the first back side layer  121   b  forming the accommodation space  123  of the first region  120  of the resin panel  110  is formed along the first cavity  301 . Further, the second back side layer  141   b  forming the second region  140  of the resin panel  110  is formed along the second cavity  501 . In this regard, the second cavity  501  has a plurality of convex portions  303 . As a result of shaping along the plurality of convex portions  303 , the concave portion  142  including the wall portion  142   a  and the top  142   b  is formed at a position corresponding to each of the convex portions  303 . 
     Similarly, the air filled in the enclosed space  902  is sucked under reduced pressure from the suction holes of the second mold  220  to shape the sheet along the third cavity  901 . The skin material  180  is pressed against the second mold  220  by the resin sheet P 2  and is integrally formed on the resin sheet P 2 . Specifically, the skin material  180  and the resin sheet P 2  are integrated with each other by welding the skin material  180  to the resin sheet P 2  or by allowing the resin of the resin sheet P 2  to soak into the skin material  180 . 
     5. Step  3   
       FIG. 14D  to  FIG. 14F  are schematic diagrams showing the manufacturing method of the resin panel  110  according to the first embodiment of the present disclosure. Specifically,  FIG. 14D  shows a state in the Step  3  where the core material  122  is arranged between the first mold  210  and the second mold  220  in the open position.  FIG. 14E  shows a state in the Step  3  where the peripheral edge of the shaped resin sheet P 1  and the peripheral edge of the resin sheet P 2  are integrated with each other by relatively moving the pair of the first mold  210  and the second mold  220  from the open position to the mold clamping position.  FIG. 14F  shows a state in the Step  3  where the resin panel  110  is obtained by taking out a molded body from the first mold  210  and the second mold  220  in the mold clamping position and removing burrs from the welded peripheral edge portion. 
     In the Step  3 , as shown in  FIG. 14D , the core material  122  is first arranged by a holding tool (not shown) between the first mold  210  and the second mold  220  in the open position. Then, the core material  122  is moved by the holding tool in the direction toward the second mold  220  to be welded to the resin sheet P 2 . Since the core material  122  is arranged in the accommodation space  123  formed in the first region  120  of the resin panel  110 , it is welded in the position corresponding to the accommodation space  123 . 
     In this regard, although the core material  122  is moved to a side of the second mold  220  and welded to the resin sheet P 2 , it may be moved to a side of the first mold  210  and welded to the resin sheet P 1 . Further, preferably, the surface of the core material  122  is melted by the heat of the resin sheet P 2  in the molten state, so that the core material  122  is welded to the resin sheet P 2 . Therefore, for the raw material of the core material  122 , it is more preferable to select a material that can be melted by the heat of the resin sheet P 2 . 
     Next, as shown in  FIG. 14E , the first mold  210  and the second mold  220  in the open position are moved relative to each other to the mold clamping position, and the first mold  210  and the second mold  220  are clamped. Specifically, the first mold  210  and the second mold  220  are moved until the standing wall  302   a  and the standing wall  302   b , and the standing wall  502   a  and the standing wall  502   b  are respectively brought into contact with each other. At this time, since the standing wall  302   a  and the standing wall  302   b , and the standing wall  502   a  and the standing wall  502   b  are brought into contact with each other, the peripheral edges of the resin sheet P 1  and the resin sheet P 2  are welded and fixed to each other and integrated. After the integration, although not specifically shown in the drawings, air is blown into the inside of the molded body formed by the integration of the resin sheet P 1  and the resin sheet P 2 , in particular into the region where the second region  140  of the resin panel  110  is formed, to shape the molded body by this blowing pressure. Consequently, the resin can be formed into a shape that more accurately follows the second cavity  501 , which has a complex shape due to the plurality of convex portions  503 . Preferably, air is not blown into the first region  102  where the core material  122  is laminated, by inserting an air release needle and is blown only into the second region  104  where the core material  122  is not present and the hollow portion  144  is formed. While the first region  102  is a laminated body, which may cause the contraction of the core material  122  accommodated in the accommodation space  103  and fusion defect with the skin material  180 , the second region  104  is a hollow portion, which improves transferability to the molds and cooling efficiency. In this regard, when air is not blown in, it is necessary to prolong cooling time because the cooling efficiency of the resin sheet decreases. 
     Here, the ridge  802  separating the first cavity  301  and the second cavity  501  is formed to have a height lower than the height of the standing wall  302   a  and the standing wall  502   a  and higher than the height of the convex portion  503 . Therefore, when the first mold  210  and the second mold  220  are clamped, the portion corresponding to the third region  170  is not completely divided though the resin is compressed by the ridge  802  and the thickness of the portion (t 3  in  FIG. 12 ) is smaller than the thickness of the resin (t 4  in  FIG. 12 ) forming the first region  120  and the second region  140 . This makes it possible for the third region  170  corresponding to the ridge  802  to serve as a hinge. 
     Further, as described above, the convex portion  503  is formed to have a height lower than the height of the standing wall  302   a  and the standing wall  502   a  and lower than the height of the ridge  802 , as shown in  FIG. 14B . Therefore, when the molds are clamped, the thickness of the portion corresponding to the top  142   b  of the second region  140  (t 5  in  FIG. 12 ) is formed to be larger than the thickness of one resin sheet (t 4  in  FIG. 12 ) by the difference in height with the convex portion  503 . 
     Next, as shown in  FIG. 14F , the first mold  210  and the second mold  220  are opened to take out the formed molded body. Then, the desired resin panel  110  is obtained by removing burrs formed on an outer side of the peripheral edges of the resin sheet P 1  and the resin sheet P 2 . In the resin panel  110 , as described in  FIG. 10  to  FIG. 13 , the first region  120  accommodating the core material  122  inside, the second region  140  having a predetermined rigidity without accommodating the core material, and the third region  170  connecting the first region  120  and the second region  140  are integrally molded with resin. 
     The resin panel in which the regions are integrated can be manufactured by the manufacturing method shown in  FIG. 14A  to  FIG. 14E  Although each of the steps has been described with specific examples in the present embodiment, steps other than the above-described steps may be included. Further, in some cases, some of the steps may be omitted. Further, the above-described manufacturing method is one example of the manufacturing method of the resin panel  110  in which the regions are integrally formed. Therefore, the resin panel  110  may be manufactured by any manufacturing method as long as it has the structure described in  FIG. 10  to  FIG. 13 . 
     As described above, in the present embodiment, the resin panel  110  has a shape in which the first region  120 , the second region  140 , and the third region  170  are integrally molded. Therefore, a plurality of regions having different characteristics (the first region  120  with the core material  122  and the second region  140  without the core material) can be integrally formed in a single molding. Further, by forming the concave portion  142  in the second region, the predetermined rigidity against loads in the thickness direction can be provided. Further, by forming the third region  170  to have the thickness smaller than the thickness of the resin in the other regions, it can serve as a hinge allowing the first region  120  and the second region  140  to be bent with respect to each other. 
     Further, in the manufacturing method of the resin panel  110  in the present embodiment, the mold including the first cavity  301  corresponding to the first region  120  of the resin panel  110 , the second cavity  501  corresponding to the second region  140 , and the ridge  802  separating them is used. Therefore, the first region  120 , the second region  140 , and the third region  170  can be integrally molded. 
     &lt;Other Embodiments of Second Invention&gt; 
     In the first embodiment, a case where two regions (the first region  120  and the second region  140 ) are connected by the third region  170  has been described. However, the present invention is not limited thereto. It is also possible to make a resin panel in which regions are combined in multiple steps, for example, by forming the first region  120 , the third region  170 , the second region  140 , the third region  170 , the first region  120 , the third region  170 , and the second region  140  in this order. 
     Further, the resin panel  110  in which the regions and the skin material  180  are laminated has been described in the first embodiment. However, the present invention is not limited thereto, and the resin panel may not include the skin material  180 , or another functional material may be laminated in the resin panel. 
     Further, the resin panel  110  having a substantially plate-shaped has been described in the first embodiment. However, the present invention is not limited thereto, and a resin panel may have a desired three-dimensional shape. 
     Further, the resin panel  110  having the first region  120  in which the core material  122  is accommodated inside has been described in the first embodiment. However, the first region  120  may have a structure including, in addition to the core material  122 , another structure (for example, a concave portion) for providing rigidity or may be formed with only the above-described structure instead of the core material  122 . 
     Further, in the manufacturing method of the resin panel  110  ( FIG. 14A  to  FIG. 14F ) in the first embodiment, the first region  102  is formed on a side of the extruder  113 , and the second region  104  is formed below the first region  102 . However, the present invention is not limited thereto. The second region  104  may be formed on the side of the extruder  113 , and the first region  102  may be formed below the second region  104 . 
     In this regard, it is also possible to combine the components described in the embodiments as appropriate or replace them to form a system. 
     While the embodiments to which the present invention is applied have been described, the scope of the present invention is not limited by the above embodiments, and various changes can be made without departing from the scope of the invention.