Resin composite and method for producing resin composite

Patent metadata

Field	Value
Publication number	US-2018237607-A1
Application number	US-201815959713-A
Country	US
Kind code	A1
Filing date	Apr 23, 2018
Priority date	Mar 27, 2014
Publication date	Aug 23, 2018
Grant date	—

Abstract

A resin composite in which a fiber-reinforced resin material comprising fibers and a resin, and a resin expanded body are integrally laminated, wherein the resin expanded body has a hole opened at the interface with the fiber-reinforced resin material and resin of the fiber-reinforced resin material is caused to flow into the hole.

First claim

What is claimed is:

1 . A method for producing a resin composite, the method comprising:
providing at least one fiber-reinforced resin material comprising fibers and a resin, providing a resin expanded body, providing at least one hole in a surface of the resin expanded body, arranging the at least one hole at an interface between the resin expanded body and the at least one fiber-reinforced resin material, and integrally laminating the at least one fiber-reinforced resin material and the resin expanded body together by causing the resin of the at least one fiber-reinforced resin material to flow into the at least one hole of the resin expanded body.

2 . The method according to claim 1 , further comprising:
thermally fusing a plurality a resin expanded particles to each other to form the resin expanded body, wherein the resin expanded particles are provided at the interface between the resin expanded body and the at least one fiberreinforced resin material, the resin expanded particles being provided with the at least one hole therein, and causing the resin of the at least one fiberreinforced resin material to flow into an inner area of the resin expanded particles.

3 . The method according to claim 1 , further comprising:
forming the resin expanded body by direct thermal fusion integrating a plurality of resin expanded particles being integrated, the resin expanded body being formed such that a void section is provided between the resin expanded particles, and wherein the at least one hole comprises a void section opening at the interface between the resin expanded body and the at least one fiberreinforced resin material.

4 . The method according to claim 3 , further comprising:
providing the void section to penetrate from a first surface of the resin expanded body to a second surface of the resin expanded body that is opposite the first surface, the void section opening at both the first surface and the second surface, providing the at least one fiberreinforced resin material as a first fiber-reinforced resin material and a second fiberreinforced resin material, providing the first fiberreinforced resin material on the first surface of the resin expanded body and providing the second fiberreinforced resin material on the second surface of the resin expanded body, and integrally laminating the first fiberreinforced resin material on the first surface of the resin expanded body and the second fiberreinforced resin material on the second surface of the resin expanded body by causing the resin of at least one of the first fiber-reinforced resin material and the second fiber-reinforced resin material to flow into the void section that opens at both the first surface and the second surface.

5 . The method according to claim 3 , further comprising providing a proportion of the void section occupying the resin expanded body to be 0.1 to 50% by volume.

Assignees

• Sekisui Plastics

Inventors

• Fukunaga Yoichiro
• KUWABARA Yusuke
• Hitomi Kazutoshi

Classifications

• C08J9/232 Primary

  by sintering expandable particles · CPC title

• C08J2201/03

  Extrusion of the foamable blend · CPC title

• B32B27/08

  of synthetic resin · CPC title

• C08J2203/146

  Saturated hydrocarbons containing oxygen and halogen atoms, e.g. F3C-O-CH2-CH3 · CPC title

• C08J2325/14

  with unsaturated esters · CPC title