Resin composite and method for producing resin composite

Patent metadata

Field	Value
Publication number	US-10052845-B2
Application number	US-201514771664-A
Country	US
Kind code	B2
Filing date	Mar 10, 2015
Priority date	Sep 27, 2013
Publication date	Aug 21, 2018
Grant date	Aug 21, 2018

Abstract

A resin composite in which the flatness ratio of cells in a corner section of a core material is 20% or more is provided.

First claim

What is claimed is:

1. A resin composite comprising: a core material comprising a resin expanded body; and a fiber-reinforced resin material comprising a resin and fibers, a surface of said core material being covered by said fiber-reinforced resin material, wherein said core material is provided with a corner section, one site and another site in said surface adjoin each other at an inner angle of less than 180 degrees via said corner section, and said core material has a flatness ratio of cells of 20% or more from a surface of said corner section to a depth of 2.5 mm.

2. The resin composite according to claim 1 , wherein said core material is a thermoformed expanded sheet and is provided with said corner section formed by said thermoforming, and a thickness of said corner section is greater than a thickness of the sites adjoining each other via said corner section.

3. The resin composite according to claim 2 , wherein said expanded sheet is provided with a unexpanded layer on a surface layer.

4. The resin composite according to claim 1 , wherein said core material is a bead expanded molded article.

5. A method for producing a resin composite, said method being for producing a resin composite comprising: a core material comprising a resin expanded body; and a fiber-reinforced resin material comprising a resin and fibers, a surface of said core material being covered by said fiber-reinforced resin material, wherein said core material of said produced resin composite is provided with a corner section, via which one site and another site adjoin each other in the surface at an inner angle of less than 180 degrees in a surface covered by said fiber-reinforced resin material, a first step of producing a pre-molded article by laminating said fiber-reinforced resin material on the surface of said core material and a second step of thermobonding said core material and said fiber-reinforced resin material by pressurizing with a molding die said pre-molded article in a heated state are carried out, a core material including a blowing agent in at least said sites becoming said corner section is used in the second step, and a size of cells in said sites of said core material is increased by said second step, and said core material has a flatness ratio of cells of 20% or more from a surface of said corner section to a depth of 2.5 mm.

Assignees

• Sekisui Plastics

Inventors

• Hitomi Kazutoshi
• KUWABARA Yusuke
• Fukunaga Yoichiro

Classifications

• B32B2605/00

  Vehicles · CPC title

• B29K2105/089

  fabric · CPC title

• B29C48/15

  incorporating preformed parts or layers, e.g. extrusion moulding around inserts · CPC title

• B29K2995/004

  Semi-crystalline · CPC title

• B32B2262/106

  Carbon fibres, e.g. graphite fibres · CPC title