Method for producing fiber-reinforced resin foam

The pultrusion molding method for producing fiber-reinforced resin foam addresses the limitations of existing technologies by uniformly distributing reinforcing fibers throughout the foam structure, thereby enhancing both mechanical strength and thermal insulation performance.

JP7650790B2Active Publication Date: 2025-03-25FUKUBI KAGAKU IND
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Patent Information

Application Number
JP2021206938
Authority / Receiving Office
JP · JP
Patent Type
Patents
Current Assignee / Owner
Filing Date
2021-12-21
Publication Date
2025-03-25
Estimated Expiration
2041-12-21

AI Technical Summary

Technical Problem

Existing fiber-reinforced resin foams have limited mechanical strength due to the restricted distribution of reinforcing fibers to the skin layer only, which hampers the improvement of thermal insulation and mechanical properties simultaneously.

Method used

A pultrusion molding method is employed to produce fiber-reinforced resin foam by introducing a mixture of a matrix resin containing a foaming agent and reinforced fibers into a mold. The foaming agent is heated to expand the matrix resin, creating a foam structure with reinforcing fibers distributed throughout, thereby enhancing mechanical strength and thermal insulation.

Benefits of technology

The method effectively increases the mechanical strength of the fiber-reinforced resin foam while maintaining good thermal insulation performance by ensuring the uniform distribution of reinforcing fibers within the foam structure.

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Abstract

To ensure the thermal insulation performance of a fiber-reinforced resin foam while sufficiently increasing mechanical strength thereof.SOLUTION: A method for producing a fiber-reinforced resin foam includes: a first step of preparing a prepreg material (10), which is a mixture of a matrix resin (2) containing a foaming agent and reinforcing fibers (3); and a second step of introducing the prepreg material (10) into a mold (32) having a cavity C penetrating in the drawing direction and expanding the matrix resin (2) by foaming the foaming agent in the mold (32), thereby forming a fiber-reinforced resin foam (20) having a cross-sectional shape corresponding to the cavity C. In the second step, the prepreg material (10) is introduced into a mold (53) with a gap between the prepreg material (10) and the wall surface of the cavity C at an inlet C1 of the cavity C, and the prepreg material (10) is heated so that the foaming agent foams from the middle of the cavity C and the matrix resin (2) expands.SELECTED DRAWING: Figure 4
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