Resin composite and method for producing resin composite

Patent metadata

Field	Value
Publication number	US-9976007-B2
Application number	US-201514771682-A
Country	US
Kind code	B2
Filing date	Mar 10, 2015
Priority date	Mar 27, 2014
Publication date	May 22, 2018
Grant date	May 22, 2018

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 resin composite, comprising:
a fiber-reinforced resin material comprising fibers and a resin; and
a resin expanded body integrally laminated with said fiber-reinforced resin material, wherein
said resin expanded body comprises a plurality of resin expanded particles integrated by direct thermal fusion,
at least one of said plurality of resin expanded particles is arranged at said interface between said resin expanded body and said fiber-reinforced resin material, said at least one resin expanded particle includes a first hole provided through the surface skin of said at least one resin expanded particle, a lump of the resin penetrates through the first hole and into an inner area of said at least one resin expanded particle,
said resin expanded body has a second hole opened at an interface between said resin expanded body and said fiber-reinforced resin material,
said fiber-reinforced resin material and said resin expanded body are integrally laminated via a portion of said resin of said fiber-reinforced resin material that flowed into the second hole,
a void section is provided between said resin expanded particles,
the second hole comprising an opening in said void section provided at a surface of said resin expanded body that is disposed at said interface of said resin expanded body and said fiber-reinforced resin material,
wherein a core material of said resin expanded body comprises polyester, and the apparent density of said core material is 0.9 to 1.2 g/cm 3 .

2. The resin composite according to claim 1 , wherein said portion of said resin flowed into an inner area of said resin expanded particles.

3. The resin composite according to claim 1 , wherein
said void section penetrates from a first surface having said opening to a second surface, which is a surface opposite to said first surface, and said void section is also open in said second surface,
said fiber-reinforced resin material is laminated on both said first surface and said second surface, and
said fiber-reinforced resin material is continuously integrated by said portion of said resin that flowed into said void section.

4. The resin composite according to claim 1 , wherein a proportion of said void section occupying said resin expanded body is 0.1 to 50% by volume.

5. The resin composite according to claim 1 , wherein
said void section is arranged between adjacent surface skins of said plurality of resin expanded particles.

Assignees

• Sekisui Plastics

Inventors

• Fukunaga Yoichiro
• KUWABARA Yusuke
• Hitomi Kazutoshi

Classifications

• C08J2367/02

  Polyesters derived from dicarboxylic acids and dihydroxy compounds; (C08J2367/06 takes precedence) · CPC title

• C08J5/042

  with carbon fibres · CPC title

• B32B2264/0257

  Polyolefin particles, e.g. polyethylene or polypropylene homopolymers or ethylene-propylene copolymers · CPC title

• C08J2201/03

  Extrusion of the foamable blend · CPC title

• B32B2272/00

  Resin or rubber layer comprising scrap, waste or recycling material · CPC title