JPH06293097A - Reinforced foam - Google Patents

Abstract

PURPOSE:To provide thin and strong lightweight reinforced foam having a high fire retardant properties using a small amt. of a surface material without lowering the characteristics of the foam. CONSTITUTION:Reinforced foam is constituted by bonding a fabric 2 formed from a composite fiber 5 and/or composite yarn mainly consisting of an adhesive component and a reinforcing component to at least one surface of foam 1 and has needle like holes 4 piercing the fabric 2 to reach the foam 1 and a surface material is directly and integrally bonded to the foam 1 through the needle like holes 3.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a strong, lightweight reinforced foam, as well as a reinforced foam having good flame retardancy.

[0002]

2. Description of the Related Art Conventionally, polystyrene foam has been used as a foam that is inexpensive, small in deformation against external force, and excellent in shape retention and dimensional stability. It has been widely used as a heat insulating building material.

[0003]

However, while the polystyrene foam has many advantages as described above, it is extremely brittle against external stress such as impact or bending, and is easily broken or broken by a slight deformation. It had the drawback of leading to total destruction of the body. Therefore, it has been considered as a material that is not suitable for a part that is subjected to a strong impact force or is subjected to a strong bending or twisting.

In order to solve this problem, a method of mixing fibers for reinforcement has been proposed (Japanese Patent Publication No. 47-2809).
No. 7, JP-A-48-100471), a substantial reinforcing effect cannot be obtained due to poor integration between the reinforcing fiber and the foam, and the inventions described in those publications are preferable methods. It was something I couldn't say.

Another disadvantage of the polystyrene foam is that it is easily burned, and its use has been severely restricted in places where fire is handled and in fields requiring flame retardancy, especially in civil engineering and construction applications. .

[0006] As such countermeasures, there is one in which a flame retardant is mixed into the foam to improve the flame retardancy, but it has not been achieved yet to impart a preferable flame retardancy. Also, there is a composite panel in which asbestos cement board, gypsum board, wood wool cement board, etc. are laminated with an adhesive on a foam board, but it has drawbacks such as heavy, thick, and brittle, and further, productivity is extremely high. There was a problem that it was bad and the price was high.

That is, even if a non-combustible / flame-retardant surface material is laminated on a foam using an adhesive, it is difficult to bond the foam and the surface material. In particular, polystyrene foam is weak against a solvent. In addition, the polymer itself is vulnerable to heat, and it is difficult to remove the solvent (drying process) such as the foaming agent remaining in the foam will undergo tertiary foaming when heat is applied. Due to problems such as long time, adhesion processing is difficult, productivity is extremely poor, and simply laminating a flame-retardant face material on foam does not have sufficient strength and is fragile. Could not be solved. Dare
If you try to solve the brittleness with non-combustible / flame-retardant face material, the thickness of the face material will be extremely thick, and as a whole, it will be thick.
Only heavy and inferior heat insulation was obtained.

The present invention has solved the above problems,
It is intended to provide a strong, lightweight reinforced foam with a thin, small amount of face material without deteriorating the properties of the foam, and further, to provide a reinforced foam having good flame retardancy. It is what

[0009]

In order to achieve the above object, the present invention has the following constitution.

That is, in the reinforced foam of the present invention, at least one surface of the foam is bonded with a cloth mainly composed of a composite fiber and / or a composite yarn mainly composed of an adhesive component and a reinforcing component, and The present invention relates to a reinforced foam having a needle-shaped hole penetrating a cloth and reaching a foam, wherein a face material is directly bonded and integrated with the foam at the needle-shaped hole through the cloth. is there.

[0011]

The present invention has been made as a result of extensive investigations to improve the drawbacks such as a foam, for example, a polystyrene foam which is light, but is brittle and weak, and moreover, it is easily burned. It has been clarified that these drawbacks can be alleviated at once by the combination of.

In the reinforced foam of the present invention, at least one surface of the foam must first be joined with a cloth composed mainly of a composite fiber and / or a composite yarn mainly composed of an adhesive component and a reinforcing component. With this cloth, the adhesive component of the composite fiber contributes to the bonding with the foam, the reinforcing component contributes to the reinforcement, and effective reinforcement is achieved. Furthermore, the foam / fabric has needle-shaped holes penetrating the cloth layer to reach the foam, and a hardening type surface material is applied to the needle-shaped holes to bite and harden and to be integrated with the cloth. It is what is converted.

Bonding in the present invention means foam / fabric,
This means that the two components of the fabric / face material or the foam / face material can be chemically or physically integrated at the interface, and includes bonding, fusion, bonding by an anchor effect, and the like.

As the surface material, any curable material having a film-forming ability such as solvent-free curable material, room temperature curable material, and thermosetting material can be used. Preferably there is.

With such a structure, the brittleness of the foam can be improved, and the fracture resistance and splattering resistance against various external stresses can be remarkably improved, and a non-combustible / flame-retardant material can be used as the face material. By using it, it is possible to provide a reinforced foam having preferable flame retardancy at the same time.

Here, the reinforced foam of the present invention will be described with reference to the schematic sectional view of FIG. In FIG. 1, a fabric 2 made of a composite fiber or a composite yarn is heat-fused and adhered to both sides of a foam 1, and a large number of needle-shaped holes 4 that penetrate the fabric layer and reach the foam are arranged. That is, the face material 3 digs into needle-like holes and forms a film, and is firmly fixed and integrated in the form of being held in the foam / fabric.

The cloth referred to in the present invention means a non-woven fabric or a structure mainly composed of a composite fiber and / or a composite yarn composed of at least two components of an adhesive component which adheres well to a foam and a reinforcing component having high strength. It is also possible to use a structure or a composite fabric in which the nonwoven fabric and the tissue structure are combined.

Examples of the foam used in the present invention include polystyrene, styrene / ethylene copolymer, polyurethane, acrylonitrile / styrene copolymer, and AB.
Bead molding made of polystyrene resin such as S resin,
A foamed molded product obtained by extrusion molding or a raw material thereof can be preferably applied. In addition, it can be applied to foams made of polyethylene, polypropylene, polyester, and phenol resin. In particular, a high-rigidity resin having a small deformation with respect to external stress has a high reinforcing efficiency according to the present invention and can obtain a higher effect.

The preferred form of the composite fiber constituting the cloth is a form of core / sheath type fiber, bimetal type fiber, multilayer bonded type fiber, radial multilayer type fiber, and the like.
A multi-core / sheath type composite fiber, which is a fiber having a structure having many core components in the sheath component, is preferable. For example, it is represented by polymer array fibers, mixed spun fibers and the like.

FIG. 2 to FIG. 8 are schematic cross-sectional model views showing model embodiments of the conjugate fiber used in the present invention.

In such a composite fiber, the adhesive component is preferably arranged on the outer periphery or outer shell of the composite fiber. For example, in the core / sheath type composite fibers as shown in FIGS. 2, 3 and 4, it is preferable to arrange them in the sheath component. Further, in the bimetal type or multi-layer bonding type composite fiber as shown in FIGS. 5, 6, 7 and 8, it may be arranged in any component, but it is arranged in a portion having a large exposed area to the outside. It is more effective and preferable. In these figures, 5 is a composite fiber, 6 and 6'are core components, and 7 is a sheath component.

The thickness of the composite fiber is not particularly limited as long as it is suitable as a reinforcing material for its specific use, but generally 0.1 to 1,000 composite fibers are used.
The range of denier is suitable, and in the multi-core / sheath type composite fiber, the thickness of the core fiber is usually 1/3 to 1 of the composite fiber.
/ 1000 is preferable, and the number of cores in the composite fiber is preferably in the range of 3 to 10,000.
10 to 1000 are particularly preferable.

As an adhesive component in the composite fiber, it is important that it is thermally deformed or melted by heating to bring about high bondability, and further, the following A or B is used.
It is preferable that the above is satisfied. That is, A: a polymer containing the same monomer units as the foam, B: a polymer having good adhesiveness and compatibility with the foam, and especially A is preferable, but the foam is Even if it does not contain the same monomer unit as above, the present invention can be sufficiently achieved as long as the anchor effect or the like acts on the foam by heat deformation or melting to achieve preferable bonding. Such preferable representative examples include polystyrene, a polystyrene copolymer obtained by copolymerizing styrene with a higher alcohol ester of acrylic acid or methacrylic acid, a polyester copolymer having an acid component of terephthalic acid / isophthalic acid, and a glycol component of ethylene glycol. Is mentioned.

On the other hand, as the reinforcing component, polyesters typified by polyethylene terephthalate, polyamides typified by nylon 6, nylon 66, aramids, other polyarylate, polyacrylonitrile, polyethylene, polypropylene, polyvinyl alcohol,
It is possible to apply polymers having various spinnability such as polyurethanes and modified copolymers thereof or mixtures of other components. Depending on the foam type from these polymer groups, One kind or two or more kinds of polymers are used depending on the purpose and application of the foam.

Further, in the above description, the case of the composite fiber obtained by the composite spinning has been described, but the present invention is not limited to the case of using such a composite fiber, and the core component or A composite yarn such as a sheath component, or a mixed yarn (including a twisted yarn) made of polymer fibers described as an adhesive component and a reinforcing component may be used. That is, in the present invention, a fiber or yarn made of an adhesive component,
It is also possible to use a composite yarn using a combination of fibers or yarns composed of strong components.

As the non-woven fabric, a short fiber (staple) or long fiber (filament) non-woven fabric produced by a method such as a card / cross wrapper method, a papermaking method, a random webber method, or a direct spinning method can be applied.

The tissue structure is a material such as a woven fabric, a knitted fabric, a braid, and a net sheet material, and has a tissue that retains a sheet form, and any of them can be applied.

As the woven fabric in the tissue structure, plain weave,
Twill weave, satin weave, and various materials based on these structures are applied. As a special thing, even at low density,
Ro-ori, gauze, etc. that do not cause misalignment are preferably applied.
As the knitted fabric, various kinds of weft melias and warp melias can be applied. The net sheet-like material may be a net-like sheet in which the intersections of fibers are bonded or fused to form a net-shaped sheet.

Of course, the constituent fibers of the tissue structure, even if the above-mentioned composite fibers and / or composite yarns are all used,
Alternatively, it may be used in combination with other fibers.

The cloth (composite cloth) in which the non-woven fabric and the tissue structure are composite is a laminate of the above-mentioned non-woven fabric and the tissue structure, or a form in which the both are entangled.

As described above, it is a requirement of the present invention that any of the fabrics should contain the above-mentioned composite fibers in a sufficient amount to bond to the foam, but the range in which the bondability is not significantly deteriorated. It may be used in combination with other fibers. In particular, as a preferable example of the non-woven fabric / tissue structure, by using the non-woven fabric made of the composite fiber and the high-strength tissue structure together, the bonding and integration with the foam is good due to the action of the adhesive component, and The reinforcing component in the non-woven fiber and the high tenacity of the tissue structure are sufficiently exhibited, and a reinforced foam having good mechanical performance can be obtained.
Compared to those reinforced with only a non-woven fabric or a tissue structure, this has better bondability, and not only general mechanical performance is improved, but also extremely high impact resistance is obtained.
In particular, the reinforced foam in which the nonwoven fabric / tissue structure is joined has an advantage that even if a defect occurs, the propagation of the fracture is stopped at the tissue portion of the tissue structure, so that the entire fracture does not occur. In this case, the components that make up the tissue structure are:
Those having as high strength as possible are preferable, but they may be the same as the reinforcing component in the above-mentioned composite fiber.
For example, aramid fiber, polyarylate, high-molecular-weight polyethylene, high-molecular-weight polyvinyl alcohol and the like are preferable, and particularly high strength fiber having a fiber strength of 3 g / d or more, particularly 5 g / d or more is preferable.

Another structural structure, which is commonly called a geogrid, is a sheet made by extruding a molten polymer from a die and forming a circular hole in the sheet, and then stretching the sheet in one or two directions. Which is called a geogrid because it is often used for
A so-called geonet, which has a lattice-shaped net, is also preferably used. Specific examples of these include “Nisseki Conwed Net” manufactured by Nisseki Goju Products Co., Ltd. and “Netron Sheet” manufactured by Mitsui Kasei Co., Ltd. They can be appropriately selected depending on the purpose and application such as the unit weight, the basis weight, and the thickness, and are not particularly limited.

On the other hand, the needle-shaped holes are needle-shaped or rod-shaped holes that penetrate the fabric layer of the fabric-reinforced foam to reach the foam, and in a more preferred embodiment, are commonly called "ant mortise holes". A typical example is one in which the deep portion is wider than the inlet portion (external opening portion) in the cross-sectional area. Of course, not only the "ant mortise" but also various other mortise shapes can be applied. The cross-sectional area of the entrance of the needle-like hole is
0.5~300mm preferably this is a ^2, and particularly preferably 5~100mm ^2. If it is narrower than this range, the curable surface material is less likely to permeate and the anchor effect becomes smaller, and if it is too large, the ratio of the curable surface material present in the needle-shaped holes becomes too high, which is characteristic of a foam. Some heat insulation,
It is not preferable because the lightness and the low cost are impaired. Further, the depth of the needle-like holes varies depending on the thickness of the foam, but is preferably 1 mm or more at the shallowest and 80% or less of the thickness of the foam at the deepest. Further, the depth cross section (D) and the entrance cross section (E) have D / E values of 1. It is preferably O5 or more, and particularly preferably 1.2 or more. The larger this value, the stronger the integrity of the fabric-reinforced foam and the curable surface material, which is preferable. The density of the needle-shaped holes is
Although it depends on the cross-sectional area of the needle-like holes, the total area of the inlet is preferably 60% or less of the surface area of the foam, and particularly preferably 50% or less. The needle-like hole space is filled with a curable surface material and bites into the space, and the bite portion is firmly integrated, and a sheet layer is formed on the surface. That is, with such a structure, the foam / fabric / face material is firmly joined and integrated to achieve effective reinforcement. Further, by using a non-combustible / flame-retardant material for the curable surface material, preferable flame-retardant properties are simultaneously achieved.

The curable surface material referred to in the present invention is solvent curable, room temperature curable or thermosetting, and a curable material having film forming ability is used. Of these, those made of non-combustible / flame-retardant materials are preferable. Such hardening type surface materials include cement, mortar, coal tar, concrete, asphalt, gypsum, asbestos cement, calcium silicate board, cement calcium silicate board, calcium asbestos silicate board, pulp cement, asbestos calcium silicate board, etc. 1 type or 2 or more types can be applied. Further, as a matter of course, other materials may be mixed with these flame-retardant surface material raw materials as long as flame retardancy and strength are not significantly reduced.

The curable face material is infiltrated as a liquid into the space of the needle-like holes to be filled therein, and is cured to form a sheet layer on the outer surface. Due to the anchor effect of the needle-like holes, the cloth and the curable surface material can form a strongly integrated structure. With such a structure, for example, even if the combination of foam / fabric / curable surface material has a low bonding property, strong integration can be achieved. This is possible only by the presence of the cloth made of the composite fiber adhered to the surface of the foam, and the great feature of the present invention is that the curable face material is extremely unlikely to be peeled off or dropped from the foam / fabric. . For example, even if only the foam is used to form the dovetail-like structure needle-like holes described above and the face material is eroded, the foam itself is fragile, so the integration of the foam / face material is not strong. It cannot be removed and easily peels off.

As a method for producing the reinforced foam of the present invention, one is to arrange a cloth on the inner surface of a mold having a desired shape, and in the mold, various latent foam forming materials such as expandable polymer beads. The material is filled and heated by supplying steam or hot air to heat and foam and simultaneously deform and / or melt the adhesive component of the fabric constituent fibers to join and integrate the fabric on a part or the entire surface of the foam. Done by that. In addition, a method of forming a foam in advance, pressing the cloth under pressure to the surface of the foam, thermally deforming and / or melting the bonding component, and adhering and integrating it with a part or the whole of the foam surface, Further, a fabric is placed on the surface of the foam, and a heating body such as an iron, a trowel, a roll, and a heat press is pressed against the fabric to heat it, and the adhesive component of the constituent fibers of the nonwoven fabric is thermally deformed and / or melted, It is carried out by a method in which the cloth is joined and integrated with a part or the whole of the surface of the foam.

As a preferable means for forming needle-like holes in such a fabric-reinforced foam, a cylindrical roller is provided with a large number of metal needles or rod-shaped rollers (hereinafter referred to as needles) arranged radially, and foaming is performed. The melting point or softening point of the body, or a method of heating above the melting point of the reinforcing component of the cloth and pressing while rotating so that the metal needle sticks, or using a plate with many needles planted, A punching method in which a heated needle portion penetrates into the foam may be used. By such a method, since the foam has a lower melting point or softening point and a lower density than the fabric portion, it is more susceptible to heat, and the deep portion where the foam is present is cut off more than the entrance where the fabric is present. Form pores with a large area. This "ant mortise structure" is preferably formed by heating the tip of the needle to a higher temperature for processing.

Next, as a method of integrating the face material with the fabric foam having needle-like holes, a curable face material-containing liquid material is applied by means such as coating, spraying or impregnation, and at least the needle-like holes are provided. It is carried out by penetrating to form an anchor portion and further forming a coating or a sheet layer to form a film on the surface of the fabric. Needless to say, acrylic resin, styrene
It may be a compounding mixture of adhesives such as butadiene rubber type, epoxy type, vinyl acetate type, ethylene / vinyl acetate type and other various synthetic rubbers.

By the above method, the foam / fabric / face material can be joined firmly and with good durability to effectively strengthen the foam. It is possible to impart destructiveness and anti-scattering property. Furthermore, preferable flame retardant properties can be imparted.
Further, depending on the selection of the face material, it is possible to obtain the waterproofing effect.

The reinforced foam of the present invention is a material for preventing mud on roads subjected to severe impacts and mechanical effects, various civil engineering materials, various fences, concrete formwork, waterproof layer protective materials, waterproof sheets, and tatami core materials. It can be preferably applied to the construction and civil engineering fields such as. In addition, the present invention can also be applied to the field of heat insulation, insulation materials in the field of vehicles such as automobiles, the field of packaging and packing, and the field of sports and sundries.

[0041]

The present invention will be described in more detail with reference to the following examples.

In the examples, all "percentages" are by weight.

Example 1 As a cloth, a polymer array fiber having a sheath component of 80 parts by weight of styrene / 20 parts by weight of 2-ethylhexyl acrylate copolymer and a core component of nylon 6 (fiber length: 51 mm,
The number of islands: 16 and the denier of the composite fiber: 3d) were used to produce a nonwoven web through the steps of card and cross wrapper, and then needle punching was performed to produce two nonwoven fabrics.

An extruded expanded polystyrene plate (30 times expanded product, 25 mm product) was used as the foam. After disposing the above cloth on the foam plate using a heat press machine, heat press (temperature: 120 ° C., pressure: 2 kg / cm ₂ , time: 45 se
Then, the both were adhered to obtain a fabric-reinforced foam.

Then, using a needle cloth roller in which stainless needles having a diameter of 1.5 mm and a length of 10 mm were planted at a needle density of about 200 needles / 100 cm ² , the needle portion was heated to about 300 ° C. and then the cloth was reinforced. The foam was perforated to form needle-like holes having a tenon structure. The needle-like hole had a dovetail structure having a diameter of about 2 mm at the entrance and a diameter of about 3.5 mm at the deep part.

Next, an asphalt / styrene / butadiene rubber adhesive mixture is applied to the fabric-reinforced foam to fill the needle-like holes and about 0.5
mm flame-retardant face material layer was formed.

Using this foam, a falling ball test was conducted using 540 g of stainless steel balls, and the height was 300 cm.
No destruction was observed in the falling ball test from. However, the conventional foam (without cloth / flame-retardant surface material) caused a total destruction at a height of only 30 cm, and the debris was scattered around.

Further, the reinforced foam of the present invention did not burn in a burning test in which a lighter flame was indirect for 20 seconds, and did not cause any deformation. The non-combustible / flame-retardant surface material used as a comparative product (the one to which only the cloth was adhered) burned in a portion in contact with the flame within 10 seconds, and subsequently burned in its entirety.

Example 2 As a fabric, a polymer array fiber having a sheath component of polystyrene and a core component of polyethylene terephthalate (fiber length: 51 mm, number of islands: 16, denier of composite fiber: 3d)
A non-woven fabric web was prepared by using the above method and a card and a cross wrapper, and then needle punched to prepare two non-woven fabrics.

Two non-woven fabric webs and the same foam plate as in Example 1 were used, and a plain woven fabric (weight per unit area: 100 g / m ² ) made of 1000d-666f aramid fiber was inserted between them to form a three-layer sheet. Furthermore, needle punching was performed to produce a composite fabric in which the non-woven fabric and the woven fabric were entangled. Further, heat pressing was performed in the same manner as in Example 1 to obtain a fabric-reinforced foam in which the composite fabric was bonded and integrated on the front and back of the foam.

Thereafter, the same needle cloth roller as in Example 1 was used to heat the needle portion to about 330 ° C., and then the cloth was reinforced and treated to form needle-like holes having a dovetail mortise structure. A cement / acrylic adhesive mixture was applied to the fabric-reinforced foam to fill the needle-like holes, and a flame-retardant face material layer having a thickness of about 1 mm was formed on both front and back surfaces.

No breakage was observed in the reinforced foam in a drop ball test from 700 cm with 700 g of stainless steel balls.

Further, the reinforced foam of the present invention did not burn in the flame test of the lighter for 60 seconds, and did not deform at all.

Example 3 The same non-woven web as in Example 1 was used, and the tissue structure was manufactured by Nisseki Goju Products Co., Ltd., “Nisseki Conwed Net, ON”.
3010 ", using an extruded foam sheet (30 times foamed product) as a foam, arranged in a non-woven fabric / tissue structure / foam / tissue structure / non-woven fabric, and 120
A fabric reinforced foam was produced by heat pressing at ² ° C. for 30 seconds at 2 kg / cm ² . The resulting foam was one in which the nonwoven fabric passed through the interstices of the tissue structure and strongly adhered to the foam to be firmly adhered and integrated as a whole.

Thereafter, using the same needle cloth roller as in Example 1, the needle portion was heated to about 350 ° C. and then treated through a cloth-reinforced foam to form needle-like holes having a dovetail structure.

Next, a plaster / acrylic adhesive mixture was applied to the fabric-reinforced foam to fill the needle-like holes and to form a flame-retardant face material layer on both front and back surfaces of about 1.5 mm. .

The reinforced foam of the present invention has a lighter flame resistance of 3
In the indirect combustion test for 0 seconds, no combustion occurred and no deformation occurred. Furthermore, in a ball drop test from 300 cm with 1200 g of stainless steel balls, it did not break and no peeling of the non-combustible / flame retardant surface material layer was observed.

[0058]

As described above, the reinforced foam of the present invention is
A cloth composed mainly of a composite fiber and / or a composite yarn mainly composed of an adhesive component and a reinforcing component is bonded to at least one surface of the foam, and a needle-like hole penetrating the cloth to reach the foam. And the face material is directly bonded and integrated with the foamed body through the needle through the cloth. With such a structure, it is possible to improve the brittleness of the foam and to significantly improve the fracture resistance and the splash resistance against various external stresses, and at the same time provide a reinforced foam having a preferable flame retardant performance. be able to.

[Brief description of drawings]

FIG. 1 is a schematic perspective view showing a model example of one embodiment of a reinforced foam of the present invention.

FIG. 2 is a schematic perspective view showing a model of one embodiment of a core / sheath type composite fiber that can be used in the present invention.

FIG. 3 is a schematic perspective view schematically showing another embodiment of the core / sheath type conjugate fiber that can be used in the present invention.

FIG. 4 is a schematic perspective view showing a model of another embodiment of the core / sheath type conjugate fiber that can be used in the present invention.

FIG. 5 is a schematic perspective view showing one model example of the bimetal type composite fiber that can be used in the present invention.

FIG. 6 is a schematic perspective view showing a model of one embodiment of the multi-layered conjugate fiber that can be used in the present invention.

FIG. 7 is a schematic perspective view showing another model example of the multi-layered conjugate fiber that can be used in the present invention.

FIG. 8 is a schematic perspective view showing a model of another embodiment of the multi-layered conjugate fiber that can be used in the present invention.

[Explanation of symbols]

 1: Foam 2: Fabric 3: Face material 4: Needle-like holes 5: Composite fiber 6, 6 ': Core component 7: Sheath component

Claims (13)

[Claims] 1. A fabric composed mainly of a composite fiber and / or a composite yarn mainly composed of an adhesive component and a reinforcing component is bonded to at least one surface of the foam, and the foam penetrates the fabric to form a foam. A reinforced foam, which has needle-shaped holes reaching it, and a face material is directly bonded and integrated with the foam at the needle-shaped holes through the cloth. 2. The reinforced foam according to claim 1, wherein the needle-shaped hole is formed in the foam, and the cross-sectional area of the needle-shaped hole is wider than the entrance portion. 3. The reinforced foam according to claim 1, wherein the face material is filled in the needle-like holes and integrated with the foam. 4. The reinforced foam according to claim 1, wherein the cloth is a non-woven fabric, a tissue structure or a non-woven / tissue structure. 5. The reinforced foam according to claim 1, wherein the foam is a polystyrene resin foam. 6. The reinforced foam according to claim 1, wherein the joining is fusion bonding. 7. The reinforced foam according to claim 1, wherein the fusion is caused by a low melting point fiber or a low melting point component. 8. The composite fiber or composite yarn is a core / sheath composite composite fiber or composite yarn.
The reinforced foam described. 9. The reinforced foam according to claim 8, wherein the core / sheath type composite structure is a multi-core / sheath type composite fiber. 10. The reinforced foam of claim 4, wherein the tissue structure is a geogrid. 11. The reinforced foam according to claim 4, wherein the tissue structure is Geonet. 12. The reinforced foam according to claim 1, wherein the face material is a non-combustible or flame-retardant material. 13. The surface material is cement, asphalt, coal tar, gypsum, asbestos cement, calcium silicate board,
The reinforced foam according to claim 1, which is composed of one or more of cement calcium silicate board, asbestos calcium silicate board, pulp cement, and asbestos calcium silicate board.