Process for the production of composite molded articles.

摘要

Disclosed is a process for the production of an integral composite molded item comprising (i) a surface portion (c) comprising a synthetic resin phase containing a fibrous reinforcing material, (ii) a core portion (a) comprising the synthetic resin phase containing bubble-containing particles, and (iii) a separation layer (b) positioned between the surface portion and the core portion, the process comprising the steps of: (a) providing in a substantially sealed mold (1) a separation layer which does not substantially pass therethrough expandable particles or compressed lightweight particles of an elastic material but which is capable of passing a synthetic resin or its precursor that is liquidized at the time of molding; (b) providing the synthetic resin or its precursor in the mold; (c) arranging a fibrous reinforcing material (3) between the separation layer and the mold, integrated with the separation layer or separately but associated therewith; (d) providing an aggregate of the expandable particles (4) and/or compressed particles of the lightweight elastic material on a side of the separation layer opposite to the side of an inner surface of the mold; (e) causing volume expansion of the aggregate by elevation of temperature to thereby expand the expandable particles or relieving compression urged on the compressed lightweight particles to thereby expand the lightweight particles; (f) flowing the liquidized synthetic resin or its precursor through the separation layer to spread it over between the separation layer and the mold, and among the expanded particles, or among the particles of the lightweight elastic material, while pressing the separation layer onto the inner surface of the mold as the result of volume expansion in the step (e) above; (g) completing formation-solidification or solidification of the synthetic resin to form a surface portion and a core portion; and (h) taking out the resulting composite molded item. The type of the resin and the type of bubble-containing particles may be selected and combined differently.