Patent ID: 8562898

Claim:
A method of forming a resin molded article, the method comprising: melting and kneading a thermoplastic resin; storing a predetermined amount of the melted and kneaded thermoplastic resin; extruding the stored thermoplastic resin intermittently in a predetermined extrusion amount per unit time from an extrusion slit provided in a T-die and having a predetermined gap, such that the resin droops downward in a shape of a molten sheet as a sheet-shaped resin; feeding the sheet-shaped resin downward by rotary driving of a pair of rollers having a nip between the rollers larger than a predetermined thickness of the sheet-shaped resin by sandwiching the sheet-shaped resin between the rollers and by causing the rollers to move relatively toward each other after a lowermost part of the sheet-shaped resin extruded downward passes through between the rollers; disposing the sheet-shaped resin, fed by the rollers, near a side of a mold arranged below the rollers; forming the sheet-shaped resin in a shape conforming to a shape of the mold by at least one of depressurizing a sealed space formed between the sheet-shaped resin and the mold or pressurizing the sheet-shaped resin toward the mold; and the feeding includes setting a surface temperature of each of the rollers lower than a temperature of the extruded sheet-shaped resin and within a predetermined temperature range, and sandwiching the sheet-shaped resin between the rollers and feeding the resin downward with rotation speeds of the rollers set equal to each other by meshing of gear mechanisms, the rollers including a driving roller and a driven roller to which a rotary driving force of the driving roller is transmitted through the meshed gear mechanisms in a synchronized manner, and adjusting at least one of the rotation speed of the rollers or an extrusion speed of the thermoplastic resin such that a difference between the rotation speed of the rollers and the extrusion speed of the thermoplastic resin is decreased.