Complex structure material, resin component, method of producing resin component

Abstract

A complex structure material includes a foam made of thermosetting resin and coverings made of thermoplastic resin. The foam includes a matrix and pores. At least some of the pores communicate with each other. The foam has a continuous porous structure formed by the matrix and the pores. The coverings cover inner walls of the pores in the foam.

1 . A complex structure material comprising:
 a foam made of thermosetting resin and including a matrix and pores, at least some of the pores communicating with each other, the foam having a continuous porous structure formed by the matrix and the pores; and   coverings made of thermoplastic resin and covering inner walls of the pores in the foam.   
     
     
         2 . The complex structure material according to  claim 1 , wherein
 the complex structure material has a restoration ratio of 30% or less, and   the restoration ratio is expressed by equation (1):
   Restoration ratio (%)=( B−A/ 4)/( A−A/ 4)×100   (1)
 
   where A is a thickness of the complex structure material in a natural state, B is a thickness of the complex structure material in a state after the complex structure material is heated to a temperature at which the thermoplastic resin is softened or greater, compressed until the thickness A becomes one fourth, and released after the thermoplastic resin is solidified.   
     
     
         3 . The complex structure material according to  claim 1 , wherein the foam includes a soft polyurethane foam. 
     
     
         4 . A resin component comprising the complex structure material according to  claim 1 . 
     
     
         5 . A method of producing a resin component, the method comprising:
 preparing a foam made of thermosetting resin and including a matrix and pores, at least some of the pores communicating with each other, the foam having a continuous porous structure formed by the matrix and the pores;   covering inner walls of the pores with a thermoplastic resin to form a complex structure material;   heating the complex structure material to a temperature at which the thermoplastic resin is softened or greater; and   cold-pressing the complex structure material into a shape of the resin component.   
     
     
         6 . The method according to  claim 5 , further comprising:
 emulsifying and dispersing the thermoplastic resin to prepare an emulsified dispersion;   soaking the foam in the emulsified dispersion until the foam is impregnated with the emulsified dispersion; and   drying the foam impregnated with the emulsified dispersion.