A molding method for a resin molded article includes: a step of sandwiching a sheet-shaped resin in a molten state extruded downward by a pair of rollers, and sending out downward the sheet-shaped resin in the molten state by a rotational driving of the rollers so as to allow a first stretching; a step of drawing downward the sheet-shaped resin in the molten state sent out downward so as to allow a second stretching; a step of disposing the sheet-shaped resin in the molten state that is drawn in a side portion of a mold disposed below the pair of rollers; and a step of molding the sheet-shaped resin into a shape conforming to a mold shape by depressurizing a sealed space formed between the sheet-shaped resin in the molten state and the mold and/or pressurizing the sheet-shaped resin toward the mold.

A molding method for a resin molded article includes: a step of sandwiching a sheet-shaped resin in a molten state extruded downward by a pair of rollers, and sending out downward the sheet-shaped resin in the molten state by a rotational driving of the rollers so as to allow a first stretching; a step of drawing downward the sheet-shaped resin in the molten state sent out downward so as to allow a second stretching; a step of disposing the sheet-shaped resin in the molten state that is drawn in a side portion of a mold disposed below the pair of rollers; and a step of molding the sheet-shaped resin into a shape conforming to a mold shape by depressurizing a sealed space formed between the sheet-shaped resin in the molten state and the mold and/or pressurizing the sheet-shaped resin toward the mold.

A load floor for a vehicle includes a carpet having a tuft attached to a backing, a plurality of inserts attached to a second side of the backing, a top surface fused to the carpet and encapsulating the inserts, and a bottom surface fused to the encapsulated inserts. The inserts may be varied in material, shape, thickness, and spacing to provide a tunable stiffness. A related method includes forming a parison feeding the parison between mold halves shaped like a load floor, hanging a carpet and a plurality of inserts in the first mold half, clamping the parison by moving the mold halves together to form a mold, and pushing the parison outward, using blown air, such that the parison is adjacent the backing in the first mold forming a top surface and encapsulating the inserts, and adjacent the second mold half forming a bottom surface fused to the parison encapsulating the inserts.