Reinforced foamed resin structural material and process for manufacturing the same

Claim 1

A process for preparing a foamed resin structural material which comprises placing a core material having a honeycomb structure between two or more layers of fiber materials, supplying a foamable thermosetting resinous liquid to the voids of the honeycomb structure, introducing the resulting laminate into a passage for molding and heating said previously supplied foamable thermosetting resinous liquid in said passage to cause said resinous liquid to foam and thereby fill the voids of said honeycomb structure and at the same time permeate and cover said fiber materials, wherein said method comprises feeding said core material to said passage for molding from an elevated position wherein said core material is fed to said passage for molding in a descending manner and so that the angle of descent is decreased as said core material advances toward said passage for molding, and applying said thermosetting resinous liquid from a resinous liquid-injecting apparatus situated above to the voids of the honeycomb structure such that said resinous liquid flows down the honeycomb structure toward the passage for molding, while the honeycomb structure is elevated from the passage for molding and does not come entirely into contact with the passage for molding.