JP7756823B1 - foam resin composite - Google Patents

Abstract

The objective of the present invention is to provide a lightweight and robust foamed resin composite. The foamed resin composite (1) has a thickness direction and is formed by laminating foamed foamed resin (2) and unfoamed resin (3) in the thickness direction, the foamed resin (2) having an expansion ratio of 30 times or more, and the unfoamed resin (3) being an engineering plastic. [Selected Figure] Figure 1

Description

The present invention relates to a foamed resin composite.

Resin foams, formed by foaming resin, are lightweight and have insulating and shock-absorbing properties, making them suitable for a variety of applications. Furthermore, in applications requiring mechanical strength, it is known that resin foams are used as composites by laminating metal materials onto the foam (see, for example, Patent Document 1).

Japanese Patent Application Laid-Open No. 2003-27656

However, laminating metal material onto foam resin posed problems such as corrosion of the metal material and an increase in overall weight.

The present invention has been made in consideration of the above-mentioned problems, and an object of the present invention is to provide a foamed resin composite having a thickness direction and in which a foamed resin and an unfoamed resin that has not been foamed are laminated in the thickness direction, wherein the foamed resin has an expansion ratio of 30 times or more and the unfoamed resin is an engineering plastic , thereby providing a lightweight and robust foamed resin composite.

In order to achieve the above-mentioned object, the present invention provides a foamed resin composite having a thickness direction and in which foamed foamed resin and unfoamed resin that has not been foamed are laminated in the thickness direction, wherein the foamed resin has an expansion ratio of 30 times or more, the unfoamed resin is an engineering plastic, and further, the foamed resin and the unfoamed resin have abutment portions where they abut against each other, a protective resin is provided at the abutment portion, and the foamed resin and the unfoamed resin are joined by an adhesive via the protective resin .
The present invention also provides a foamed resin composite having a thickness direction and in which foamed foamed resin and unfoamed resin that has not been foamed are laminated in the thickness direction, wherein the foamed resin has an expansion ratio of 30 times or more, the unfoamed resin is an engineering plastic, and the unfoamed resin is provided as a form for the foamed resin, the foamed resin is foamed inside the form for the unfoamed resin, the foamed resin is formed into a shape that conforms to the shape of the form for the unfoamed resin, and the foamed resin and the unfoamed resin are bonded together when the foamed resin is foamed.
Furthermore, the present invention provides a foamed resin composite having a thickness direction and formed by laminating foamed foamed resin and unfoamed resin in the thickness direction, wherein the foamed resin has an expansion ratio of 30 times or more and the unfoamed resin is an engineering plastic, and at least a portion of the foamed resin composite has an outer portion that is used in an outdoor exposed state, and a weather-resistant resin is provided on the outer portion, and the weather-resistant resin is composed of a weather-resistant paint such as a fluororesin paint, a silicone paint, a urethane paint, an acrylic paint, a two-component polyurethane enamel paint, an acrylic silicone resin enamel paint, or a room temperature drying fluororesin enamel paint, and the foamed resin composite is used as at least a part of the roof and wall portions of a box-shaped body having a space inside, and at least a part of the roof and the wall portions are molded as a single unit.

Other features of the present invention will become apparent from the description of this specification and the accompanying drawings.

According to the present invention, there is provided a foamed resin composite having a thickness direction and in which a foamed foamed resin and an unfoamed resin that has not been foamed are laminated in the thickness direction, wherein the foamed resin has an expansion ratio of 30 times or more and the unfoamed resin is an engineering plastic , thereby making it possible to provide a lightweight and robust foamed resin composite.

The drawings illustrate particular embodiments of the present invention, including essential features of the invention as well as alternative and preferred embodiments.
1 is a schematic diagram showing the appearance of a foamed resin composite body according to a first embodiment. FIG. 1 is a diagram showing a cross section of a foamed resin composite body according to a first embodiment. FIG. FIG. 10 is a schematic diagram showing the appearance of a foamed resin composite body according to a second embodiment. 4 is a cross-sectional view taken along the line AA in FIG. 3, showing a cross section of a foamed resin composite body according to a second embodiment. 10( a ) to 10 ( c ) are diagrams illustrating a manufacturing process of a foamed resin composite body according to a third embodiment. 1 is a schematic diagram showing the appearance of a box, which is an application example 1 of a foamed resin composite. FIG. FIG. 7 is an enlarged view of B in FIG. 6, illustrating the structure of the box. 8 is a cross-sectional view taken along the line CC in FIG. 7, illustrating the structure of the box. 1 is a schematic diagram showing the appearance of a dome-shaped tent, which is an application example 2 of a foam resin composite.

At least the following points become clear from the description in this specification and the accompanying drawings.

A foamed resin composite having a thickness direction and formed by laminating foamed resin and unfoamed resin in the thickness direction, wherein the foamed resin has an expansion ratio of 30 times or more and the unfoamed resin is an engineering plastic.

With this type of foamed resin composite, by setting the foaming ratio of the foamed resin to 30 times or more and using engineering plastic for the unfoamed resin, it is possible to provide a lightweight and robust foamed resin composite.

<Regarding the First Embodiment>
A foamed resin composite 1 according to a first embodiment will be described with reference to the drawings. Fig. 1 is a schematic diagram showing the appearance of the foamed resin composite 1 according to the first embodiment, and Fig. 2 is a diagram showing a cross section of the foamed resin composite 1 according to the first embodiment.

As shown in Figure 1, the foamed resin composite 1 is a substantially rectangular sheet (panel) and is constructed by laminating foamed resin 2 and unfoamed resin 3 in the thickness direction. In the first embodiment, the foamed resin 2 has an expansion ratio of 30 times or more, and the unfoamed resin 3 is made of engineering plastic.

In other words, the foamed resin composite 1 according to the first embodiment has a thickness direction and is a foamed resin composite 1 in which foamed foamed resin 2 and unfoamed unfoamed resin 3 are laminated in the thickness direction, with the foamed resin 2 having an expansion ratio of 30 times or more and the unfoamed resin 3 being an engineering plastic.

By setting the expansion ratio of the foamed resin 2 to 30 times or more and using an engineering plastic for the unfoamed resin 3, it is possible to provide a lightweight and robust foamed resin composite 1. The expansion ratio can be calculated as follows: Expansion ratio = (thickness (mm) x width (m) x length (m)) / weight (kg).

Furthermore, the shape of the foamed resin composite 1 is not limited to a substantially rectangular shape, and can be any shape that is easy to use, depending on processing, etc.

Foamed resin 2 is resin that has been foamed using some method. Examples of the resin that is the base of foamed resin 2 include polystyrene, polyethylene, polypropylene, polyurethane, phenolic resin, polyvinyl chloride, urea resin, silicone, polyimide, and melamine resin. In the first embodiment, foamed polystyrene (recycled foamed polystyrene, expanded polystyrene) is used as foamed resin 2.

Unfoamed resin 3 (engineering plastic) is a plastic that has heat resistance, mechanical strength, etc., and examples include polycarbonate, polyamide, polyacetal, modified polyphenylene ether, polyester, polyphenylene sulfide, polysulfone, polyethersulfone, polyarylate, polyamideimide, polyetheretherketone, fluororesin, and liquid crystal polymer. In the first embodiment, polycarbonate (recycled polycarbonate) is used as the unfoamed resin 3.

In other words, in the foamed resin composite 1 according to the first embodiment, the foamed resin 2 is polystyrene foam (recycled polystyrene foam), and the unfoamed resin 3 is polycarbonate (recycled polycarbonate). Since polycarbonate (recycled polycarbonate) and polystyrene foam (recycled polystyrene foam) are widely available commercially, it is possible to provide an inexpensive, lightweight, and environmentally friendly (recyclable) foamed resin composite.

Furthermore, as shown in Figure 2, in the cross section of the foamed resin composite 1, the layers are layered in the following order from one side to the other in the thickness direction: unfoamed resin 3, protective resin 4, adhesive 5, protective resin 4, and foamed resin 2. For ease of explanation, hereinafter, the layers of protective resin 4 and adhesive 5 are collectively referred to as the contact portion X (between the foamed resin 2 and the unfoamed resin 3).

The protective resin 4 is provided to increase the bonding strength between the foamed resin 2 and the unfoamed resin 3 by the adhesive 5. Any protective resin 4 can be used as long as it has the function and effect of increasing the bonding strength between the foamed resin 2 and the unfoamed resin 3; for example, a primer (a water-soluble resin paint used for surface preparation) can be used.

Furthermore, when the foam resin 2 is polystyrene foam, as in the first embodiment, and the adhesive 5 contains a solvent that dissolves polystyrene foam, applying the adhesive 5 directly to the polystyrene foam will dissolve the polystyrene foam, making it difficult to bond the parts.

In such cases, as shown in the contact portion X of the first embodiment, by joining the foamed resin 2 and the unfoamed resin 3 with adhesive 5 via protective resin 4, the polystyrene foam is protected from the solvent of the adhesive 5, making it easier to join the foamed resin 2 and the unfoamed resin 3.

In other words, in the foamed resin composite 1 according to the first embodiment, the foamed resin 2 and the unfoamed resin 3 have abutment portions X where they abut against each other, and protective resin 4 is provided at the abutment portions X, with the foamed resin 2 and the unfoamed resin 3 being bonded together by adhesive 5 via the protective resin 4. This makes it possible to increase the bonding strength between the foamed resin 2 and the unfoamed resin 3 by adhesive 5, regardless of the type of foamed resin 2.

In addition, in the first embodiment, the value of T2/T3, obtained by dividing the value of the thickness T2 of the foamed resin 2 shown in Figure 2 by the value of the thickness T3 of the unfoamed resin 3, is 20 or less. Specifically, T2 is 30 mm, T3 is 1.6 mm, and T2/T3 is 18.75.

In other words, in the foamed resin composite 1 according to the first embodiment, the value obtained by dividing the thickness T2 of the foamed resin 2 by the thickness T3 of the unfoamed resin 3 is 20 or less. This increases the proportion of unfoamed resin 3 in the foamed resin composite 1, thereby providing an even more robust foamed resin composite 1.

In addition, the foamed resin composite 1 according to the first embodiment uses one foamed resin 2 and one unfoamed resin 3, but this is not limited to this and multiple foamed resins may be used. In other words, the foamed resin composite may have multiple layers of at least one of the foamed resin 2 and the unfoamed resin 3.

By laminating multiple layers, it is possible to provide a foamed resin composite with even higher thermal insulation performance and greater durability.

As shown in Figures 1 and 2, the unfoamed resin 3 has a typical plate shape, but this is not limited to this. For example, a thin, hollow plate-shaped resin can also be used.

<Regarding the Second Embodiment>
Next, a foamed resin composite 10 according to a second embodiment will be described with reference to the drawings. Fig. 3 is a schematic diagram showing the appearance of the foamed resin composite 10 according to the second embodiment, and Fig. 4 is a cross-sectional view taken along line A-A in Fig. 3, showing a cross section of the foamed resin composite 10 according to the second embodiment. In Fig. 4, to make the drawing easier to see, the contact portion X corresponding to the contact portion between the foamed resin 2 and the unfoamed resin 3 shown in Fig. 2 is omitted.

In the following explanation, only the differences from the first embodiment will be described. In other words, the features that differ from the first embodiment will be described in detail, and explanations of parts that are similar in configuration to the first embodiment will be omitted.

In the second embodiment, as shown in FIG. 3, in addition to the unfoamed resin 13, there is a first unfoamed resin 13a, a second unfoamed resin 13b, and a third unfoamed resin 13c stretched in the thickness direction. As shown in FIGS. 3 and 4, the first unfoamed resin 13a, the second unfoamed resin 13b, and the third unfoamed resin 13c are arranged to support the foamed resin 12 and the unfoamed resin 13 in the thickness direction.

More specifically, the first unfoamed resin 13a is arranged to surround the four outer surfaces of the foamed resin 12, and extends in the thickness direction and the length or width direction. The unfoamed resin 13 and the first unfoamed resin 13a then surround and cover the entire outer surface (six sides) of the foamed resin 12, thereby supporting the foamed resin 12.

The second unfoamed resin 13b is provided inside the foamed resin 12, running continuously from left to right in the longitudinal direction at approximately the center in the width direction. The second unfoamed resin 13b supports the foamed resin 12 in the thickness direction at approximately the center in the width direction of the foamed resin 12.

The third unfoamed resin 13c is arranged like a diagonal brace and is provided in two locations inside the foamed resin 12. Specifically, one location is provided such that one side is approximately in the center of the width direction and extends from the left side in the lengthwise direction at an angle to the right, and the other side is provided so as to continue to the rear side in the widthwise direction at a position on the right side in the lengthwise direction. The other location is provided such that one side is approximately in the center of the width direction and extends from the right side in the lengthwise direction at an angle to the left, and the other side is provided so as to continue to the front side in the widthwise direction at a position on the left side in the lengthwise direction.

In other words, in the foamed resin composite 10 according to the second embodiment, the unfoamed resins (first unfoamed resin 13a, second unfoamed resin 13b, and third unfoamed resin 13c) are arranged so as to extend from one side to the other in the thickness direction of the foamed resin 12 (so as to support the thickness direction). Furthermore, by arranging the unfoamed resins (first unfoamed resin 13a, second unfoamed resin 13b, and third unfoamed resin 13c) in a shape that extends in the thickness direction of the foamed resin 12, an even more robust foamed resin composite can be provided.

<Regarding the Third Embodiment>
Next, a foamed resin composite 100 according to a third embodiment will be described with reference to the drawings. Fig. 5 is a diagram showing the manufacturing process of the foamed resin composite 100 according to the third embodiment, in which Fig. 5(a) shows unfoamed resin 103 set as a formwork, Fig. 5(b) shows pre-foamed resin 102a before foaming being poured into the unfoamed resin 103 set as a formwork, and Fig. 5(c) shows the pre-foamed resin 102a foamed and foam-molded into a shape conforming to the formwork as foamed resin 102b (the foamed resin composite 100 is completed).

As shown in Figure 5, in the manufacturing process of the foamed resin composite 100 according to the third embodiment, during the manufacturing process in which the pre-foamed resin 102a is foamed and molded, the foamed resin 102b is molded integrally with the unfoamed resin 103 in accordance with the shape of the unfoamed resin 103, thereby significantly reducing the manufacturing process of the foamed resin composite 100.

Specifically, there is no need to prepare a separate mold for foaming the foamed resin 102b, and the process of applying a mold release agent to the inner surface of the mold to remove the foamed resin 102b from the mold can be omitted. Furthermore, because the pre-foamed resin 102a foams along the side of the unfoamed resin 103 (the inner surface of the mold), the foamed resin 102b and the unfoamed resin 103 naturally bond together. This eliminates the need for materials and adhesives at the contact area X (see Figure 2) between the foamed resin 102b and the unfoamed resin 103, and also makes it possible to prevent gaps from forming between the foamed resin 102b and the unfoamed resin 103.

In addition, the size and shape of the unfoamed resin 103 can be freely set to form a mold. Therefore, if a mold is set up in a shape that matches the desired shape (finished product shape) of the foamed resin composite 100, a roughly finished shape can be obtained after foaming, thereby eliminating many of the processing and joining steps required to obtain the desired foamed resin composite 100.

In other words, in the foamed resin composite 100 according to the third embodiment, the unfoamed resin 103 is provided as a mold for the foamed resin 102b, and the foamed resin 102b is foamed inside the mold for the unfoamed resin 103. The foamed resin 102b is formed into a shape that matches the shape of the mold for the unfoamed resin 103, and when the foamed resin 102b is foamed, the foamed resin 102b and the unfoamed resin 103 are bonded together.

By using the unfoamed resin 103 as a formwork, the process of removing the foamed resin 102b from the formwork can be omitted, and the process of joining the foamed resin 102b and the unfoamed resin 103 with an adhesive or the like can also be omitted, thereby reducing manufacturing costs.

Furthermore, because the foamed resin 102b foams along the shape of the formwork of the unfoamed resin 103, it is possible to prevent gaps from forming between the unfoamed resin 103 and the foamed resin 102b. Additionally, by installing a formwork that conforms to the desired shape (finished product shape) of the foamed resin composite 100, many of the processing and joining steps required to obtain the desired foamed resin composite 100 can be omitted, thereby reducing manufacturing costs.

In addition, the foamed resin 102b in the third embodiment can be, for example, a spray-type or two-component foamed urethane or epoxy. These are widely available commercially, making it easy to manufacture the foamed resin composite 100 using the unfoamed resin 103 as a mold.

<Application examples of foam resin composites>
Next, a box 200 will be described with reference to the drawings as an example of application of the foamed resin composite 202. Fig. 6 is a schematic diagram showing the appearance of the box 200, which is an application example 1 of the foamed resin composite 202, Fig. 7 is an enlarged view of B in Fig. 6 and is a diagram for explaining the structure of the box 200, and Fig. 8 is a cross-sectional view taken along the line CC in Fig. 7 and is a diagram for explaining the structure of the box 200.

As shown in Figure 6, Application Example 1 is an example of application as a box 200 placed on the bed of a vehicle. The box 200 is intended to prevent damage to luggage loaded on the vehicle due to wind and rain, etc., and is what is commonly known as a luggage compartment or canopy provided on the bed of a vehicle.

The box 200 according to Application Example 1 has a support portion 201 and a foam resin composite 202. The support portion 201 can be, for example, a metal rod or pipe made of aluminum, stainless steel, or the like, or a plastic rod or pipe made of PVC, or the like. The foam resin composite 202 can be, for example, the foam resin composite 10 according to the second embodiment.

The box 200 has support columns 201 arranged in a grid pattern on the ceiling and sides, and a foamed resin composite 202 that fits into the grid pattern, with the support columns 201 and the foamed resin composite 202 fixed to each other. In Application Example 1, the outside of the foamed resin composite 202 is directly exposed to the natural environment (e.g., exposed to sunlight, wind, rain, etc.), so as shown in Figure 8, weather-resistant resin 202b is provided on the outer portion.

For example, weather-resistant paint can be used as the weather-resistant resin 202b, and examples include fluororesin paint, silicone paint, urethane paint, acrylic paint, two-component polyurethane enamel paint, acrylic silicone resin enamel paint, and room temperature drying fluororesin enamel paint.

Figures 7 and 8 show the state in which the support portion 201 and the foamed resin composite 202 are joined. As shown in Figures 7 and 8, the support portion 201 has holding portions 201a spaced apart by the thickness of the foamed resin composite 202, and the foamed resin composite 202 is fixed to the support portion 201 by sandwiching it between the holding portions 201a.

Then, to prevent wind and rain from entering through the gaps between the foamed resin composite 202 and the support portion 201 and the holding portion 201a, the gaps where the foamed resin composite 202 comes into contact with the outer surfaces of the support portion 201 and the holding portion 201a are filled with caulking material 202a. For example, a silicone-based sealant can be used as the caulking material 202a.

In addition, if the size and thickness of the foamed resin composite 202 are made larger than the size of the lattice of the support portion 201 and the spacing of the holding portion 201a, the foamed resin composite 202 will be inserted and fixed while shrinking, thereby making it possible to reduce the gap between the support portion 201 and the holding portion 201a and the foamed resin composite 202 (strengthening the fixation).

Furthermore, as in Application Example 1, by using the foamed resin composite 202 as a box 200 to be placed on the bed of a vehicle, it is possible to reduce the weight compared to, for example, conventional metal boxes, making it possible to transport a large amount of cargo at one time.

Furthermore, box 200 has higher insulation performance than metal boxes or canopies, so if, for example, ice packs or dry ice are placed inside box 200, it can be used as a simple refrigerated or frozen vehicle. In addition, it has higher cushioning performance than metal boxes, so even if the vehicle shakes and cargo collides with the side of box 200, damage to the cargo can be reduced.

In Application Example 1, the box 200 was constructed from the support posts 201 and the foamed resin composite 202, but for example, a general-purpose container can be used in place of the support posts 201. In other words, by installing the foamed resin composite 202 inside the container, it is possible to create a container with high insulation and cushioning performance equivalent to that of the box 200.

Furthermore, as a configuration different from Application Example 1, for example, there is a box configuration made by the manufacturing method of the third embodiment shown in Figure 5 above. According to the manufacturing method of the third embodiment, foamed resin 102b is foam-molded in a mold for unfoamed resin 103, making it possible to manufacture a box equivalent to box 200 without using the support members 201 of box 200. A box made by this manufacturing method can be made with almost no gaps, which can further prevent the intrusion of rain, wind, etc., and the absence of support members 201 makes it possible to achieve even greater weight reduction.

In addition, while Application Example 1 uses a box 200 for transporting luggage, it can also be used, for example, as a living space in a camper van or a workshop in a kitchen van. In cases where people live or work inside such spaces, the interior of the foamed resin composite 202 shown in Figure 8 can be decorated (so-called interior decoration) to create a more comfortable interior space.

For example, wallpaper, paint, sheets, etc. can be installed to improve the aesthetics, flame retardancy, sound absorption, moisture absorption, etc. of the inside of the box, ensuring safety and reducing discomfort for people living or working inside.

Furthermore, while Application Example 1 shows an application example in which the tent is placed on the bed of a vehicle, this is not limited to this. Figure 9 is a schematic diagram showing the appearance of dome-shaped tent 300, which is Application Example 2, in which support portion 301, first foam resin composite 302, and second foam resin composite 303 are used.

Application example 2 is not intended to be placed on the bed of a vehicle, but is simply an example of an outdoor installation. Therefore, it is not limited to the dome-shaped tent 300, and can be applied to tents with floors, vertical walls, a sloped roof, etc., as well as storage sheds to be installed in home gardens and simple houses (buildings such as container houses).

Furthermore, as shown in Figure 9, the first foamed resin composite 302 and the second foamed resin composite 303 are easy to process, so their shapes can be easily changed. It is also easy to create shapes that follow a triangular or trapezoidal shape, as in the first foamed resin composite 302, or to provide windows or doors, as in the second foamed resin composite 303.

Therefore, in the box 200 according to this embodiment, at least a portion of the foamed resin composite 202 has an outer portion that is used in an exposed outdoor environment, and the outer portion is provided with weather-resistant resin 202b. By providing weather-resistant resin 202b, deterioration of the foamed resin composite 202 over time in the natural environment can be suppressed.

Furthermore, from the above description, in the foamed resin composite 100 produced using the manufacturing method according to the third embodiment, the foamed resin composite is used as at least part of the roof and wall portions of a box-shaped structure having an internal space, and at least part of the roof and wall portions are molded as a single unit. Furthermore, by molding the roof and wall portions as a single unit, it is possible to further reduce weight and prevent the intrusion of wind and rain, etc.

<Other embodiments>
The above-described embodiments are intended to facilitate understanding of the present invention and are not intended to limit the present invention. The present invention may be modified or improved without departing from the spirit thereof, and the present invention naturally includes equivalents thereof.

In addition, in the above embodiment, the value of T2/T3, obtained by dividing the thickness T2 of the foamed resin 2 by the thickness T3 of the unfoamed resin 3, was 20 or less, but this is not limited to this and may be greater than 20.

In other words, in the foamed resin composite 1 according to the first embodiment, the value obtained by dividing the thickness T2 of the foamed resin 2 by the thickness T3 of the unfoamed resin 3 exceeds 20. This increases the proportion of foamed resin 2 in the foamed resin composite 1, making it possible to provide an even lighter foamed resin composite.

Furthermore, the present invention may include at least the following embodiments, which may be adopted separately or in combination with each other.

(1) A foamed resin composite, characterized in that the value obtained by dividing the thickness of the foamed resin by the thickness of the unfoamed resin is 20 or less. This increases the proportion of unfoamed resin in the foamed resin composite, thereby providing an even more robust foamed resin composite.

(2) A foamed resin composite, wherein the value obtained by dividing the thickness of the foamed resin by the thickness of the unfoamed resin exceeds 20. This increases the proportion of foamed resin in the foamed resin composite, making it possible to provide an even lighter foamed resin composite.

(3) A foamed resin composite, characterized in that the foamed resin is polystyrene foam and the unfoamed resin is polycarbonate. Since polycarbonate (recycled polycarbonate) and polystyrene foam (recycled polystyrene foam) are widely available commercially, using polycarbonate as the unfoamed resin and polystyrene foam as the foamed resin makes it possible to provide an inexpensive, lightweight, and environmentally friendly (recyclable) foamed resin composite.

(4) A foamed resin composite, characterized in that the foamed resin and the unfoamed resin have abutting portions where they abut, a protective resin is provided at the abutting portion, and the foamed resin and the unfoamed resin are bonded together with an adhesive via the protective resin. This increases the bonding strength between the foamed resin and the unfoamed resin by the adhesive, regardless of the type of foamed resin.

(5) A foamed resin composite, characterized in that the unfoamed resin is provided so as to extend from one side to the other in the thickness direction of the foamed resin. By providing the unfoamed resin in a shape that extends in the thickness direction of the foamed resin, an even more robust foamed resin composite can be provided.

(6) A foamed resin composite characterized in that at least one of the foamed resin and the unfoamed resin is laminated in multiple layers. By laminating multiple layers, it is possible to provide a foamed resin composite with even higher thermal insulation performance and greater robustness.

(7) A foamed resin composite, characterized in that the unfoamed resin is provided as a mold for the foamed resin, the foamed resin is foamed inside the mold for the unfoamed resin, the foamed resin is formed to a shape that conforms to the shape of the mold for the unfoamed resin, and the foamed resin and the unfoamed resin are bonded together when the foamed resin is foamed. By using the unfoamed resin as a mold, the process of removing the foamed resin from the mold can be eliminated, and the process of bonding the foamed resin and the unfoamed resin with an adhesive or the like is not required, thereby reducing manufacturing costs. Furthermore, because the foamed resin foams along the shape of the mold for the unfoamed resin, the occurrence of gaps between the unfoamed resin and the foamed resin can be suppressed. Additionally, by installing a mold in a shape that conforms to the desired shape (finished product shape) of the foamed resin composite, many of the processing and bonding steps required to obtain the desired foamed resin composite can be omitted, thereby reducing manufacturing costs.

(8) At least a portion of the foamed resin composite has an outer portion that is used in an outdoor exposed state, and the outer portion is provided with a weather-resistant resin. In this way, by providing the weather-resistant resin, it is possible to suppress deterioration of the foamed resin composite over time in the natural environment.

(9) The foamed resin composite is used as at least part of the roof and wall of a box-shaped structure having an internal space, and at least part of the roof and wall are molded as a single unit. In this way, the roof and wall are molded as a single unit, further reducing weight and preventing the intrusion of wind and rain.

1 Foamed resin composite 2 Foamed resin 3 Unfoamed resin 4 Protective resin 5 Adhesive

Claims (3)

having a thickness direction,
A foamed resin composite in which a foamed resin and an unfoamed resin that has not been foamed are laminated in the thickness direction,
The foamed resin has an expansion ratio of 30 times or more,
the unfoamed resin is an engineering plastic,
moreover,
the foamed resin and the unfoamed resin have contact portions where they come into contact with each other,
The contact portion is provided with a protective resin,
the foamed resin and the unfoamed resin are bonded to each other by an adhesive via the protective resin .
A foamed resin composite. having a thickness direction,
A foamed resin composite in which a foamed resin and an unfoamed resin that has not been foamed are laminated in the thickness direction,
The foamed resin has an expansion ratio of 30 times or more,
the unfoamed resin is an engineering plastic,
moreover,
the unfoamed resin is provided as a mold for the foamed resin,
The foamed resin is foamed inside the mold of the unfoamed resin,
The foamed resin is formed into a shape that conforms to the shape of the formwork for the unfoamed resin,
When the foamed resin is foamed, the foamed resin and the unfoamed resin are bonded together .
A foamed resin composite. having a thickness direction,
A foamed resin composite in which a foamed resin and an unfoamed resin that has not been foamed are laminated in the thickness direction,
The foamed resin has an expansion ratio of 30 times or more,
the unfoamed resin is an engineering plastic,
moreover,
At least a part of the foamed resin composite has an outer part that is used in an outdoor exposed state,
A weather-resistant resin is provided on the outer portion,
The weather-resistant resin is a weather-resistant paint, such as a fluorine paint, a silicone paint, a urethane paint, an acrylic paint, a two-component polyurethane enamel paint, an acrylic silicone resin enamel paint, or a room-temperature drying fluorine resin enamel paint,
moreover,
the foamed resin composite is used as at least a part of a roof and a part of a wall of a box-shaped structure having an internal space,
At least a portion of the roof portion and the wall portion are integrally formed.
A foamed resin composite.