Polyester-based resin foam and method for producing resin composite
A resin composite having excellent strength is easily produced by using a resin foam having a specific surface roughness (Ra) as the core material of the resin composite.
1. A method for producing a resin composite, comprising:
performing a laminating step of using a fiber-reinforced resin sheet and a core material including a resin foam, and integrally laminating said core material and said fiber-reinforced resin sheet to form the resin composite, wherein
said fiber-reinforced resin sheet comprises a substrate sheet including a fiber woven fabric and a resin impregnated in said substrate sheet,
said core material is a polyester-based resin foam having a surface roughness (Ra) of 2.41 μm or less, and
in the laminating step, said fiber-reinforced resin sheet is laminated on a surface of said polyester-based resin foam, the surface having said surface roughness (Ra),
wherein said polyester-based resin foam is crosslinked by a crosslinking agent, wherein the crosslinking is performed using a ratio of 0.01 parts by mass or more and 5 parts by mass or less of the crosslinking agent based on 100 parts by mass of the polyester-based resin foam
performing a sheet preparing step of extrusion foaming a polyester-based resin composition to prepare a polyester-based resin expanded sheet to be used as said core material, and
performing a sheet smoothing step of smoothing a surface of said polyester-based resin expanded sheet obtained in the sheet preparing step,
in the sheet preparing step, said polyester-based resin expanded sheet having a surface roughness (Ra) exceeding 2.5 μm is prepared,
in the sheet smoothing step, a surface of said polyester-based resin expanded sheet is smoothed so that said surface roughness (Ra) becomes 2.41 μm or less, and
in the laminating step, said fiber-reinforced resin sheet is laminated on a surface of said polyester-based resin expanded sheet, said surface having been smoothed in the sheet smoothing step.