JPH09314713A - Composite molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make a product be lightweight and rigid and have a bedewing preventive function by integrating a foamed thermoplastic resin between sheets (reinforcing sheets) in which a thermoplastic resin sheet and a fiber reinforced thermoplastic resin sheet (prepreg) reinforced with fibers which are continuous in one direction or prepregs are bonded together. SOLUTION: In a composite molding, a foamed thermoplastic resin 2 is integrated between a thermoplastic resin sheet molding 1' and a reinforcing sheet 3. A polystyrene sheet is used for the molding 1', and the sheet 3 is obtained by bonding thermoplastic resin sheets (prepregs) in which continuous long fibers oriented in one direction are impregnated with a thermoplastic resin. The resin 2 and the sheet 3 are fusion-bonded when the thermoplastic resins are the same or bonded with an adhesive when the resins are different. With the heat of the molding 1' which molded the thermoplastic resin sheet accumulated, the sheet 3 and the bonding member of the resin 2 are fusion-bonded and fixed to be integrated.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite molded article formed of a thermoplastic resin sheet, and more particularly to a bathroom ceiling member.

[0002]

2. Description of the Related Art As a material used for mass-produced bathroom ceiling material, a siding type ceiling material composed of a sandwich panel composed of a surface material of a polyvinyl chloride resin extruded product, urethane foam and a backing sheet, Fiber-reinforced thermosetting resin molded products (FRP molded products) in which a saturated polyester resin is reinforced with glass fibers are often used.

The siding type bathroom ceiling is constructed and assembled on site to form a flat bathroom ceiling with the same shape, while FR
P-molded products can have various shapes of ceiling materials, and for mass production, after impregnating unsaturated polyester resin compound into glass fiber mats, etc., the gelled sheet-shaped molding material is compressed with a high pressure press. A molded product that has been molded (SMC molding method) is used.

In recent years, the bathroom space has become diversified due to the improvement of the housing environment, and the design of the bathroom ceiling material has been remarkably increased. The siding type cannot follow the shape change. On the other hand, the FRP molded product by the SMC method can have various designs, but the molding pressure is 100 to 200 kg / cm.
^Since it is molded with ² , a press of about 2000 to 3000 ton class is required to mold a ceiling material having an area of about 1 to 2 m, and the mold is also very expensive, so it is not easy to change the design economically . On the other hand, in general, a thermoplastic resin sheet has a molding pressure of 1 to 1 in a vacuum molding method or the like.
Since an inexpensive mold such as a resin mold is used at about 0 kg / cm ² , bathroom ceiling materials using these molding materials and molding methods are becoming more and more easily adaptable to design changes.

[0005]

However, the width 10
To form a thermoplastic resin molded product with a length of 00 mm, a length of 2000 mm, and a height of 200 mm by a vacuum forming method, a thermoplastic resin sheet with an initial thickness of about 4 mm is used, so the molded product is assembled and the lighting equipment is installed. When doing this, there were many accidents in which the worker accidentally touched the molded product and deformed it, causing whitening or damage.Therefore, the worker tied the roof side of the molded product with a frame such as tall wood. The construction method and structure of using hands are adopted. This bathroom ceiling material has problems in that the manufacturing process of the ceiling material is complicated, takes time, and becomes heavy. Furthermore, in order to prevent dew condensation on the bathroom ceiling material, urethane foam is generally applied to the back side of the ceiling material. The problem is that they are different. Therefore, an object of the present invention is to maintain strength that does not damage the ceiling material even if an operator who installs the bathroom ceiling material accidentally touches the ceiling material without using a framework structure on the back side of the bathroom ceiling material formed of a thermoplastic resin sheet. In addition, the bathroom ceiling member has uniform dew condensation prevention performance. Another object of the present invention is to provide a high-strength composite molded product that does not break even if a person rides on the composite molded product.

[0006]

DISCLOSURE OF THE INVENTION The inventors of the present invention have completed the present invention as a result of extensive studies to achieve the above object. That is, the composite molded article according to the present invention is a thermoplastic resin sheet and a thermoplastic resin sheet reinforced with continuous fibers in one direction (hereinafter referred to as prepreg), or a sheet obtained by joining a plurality of prepregs (hereinafter referred to as prepreg and A thermoplastic resin foam body is integrated between sheets formed by joining a plurality of prepregs, which is referred to as a reinforcing sheet).

Further, in the step of heating the thermoplastic resin sheet and then shaping it with a vacuum or pressure molding machine, after molding the thermoplastic resin sheet with a mold, the thermoplastic resin foam is pressure-bonded to the molded product. The present invention relates to a composite molded article, characterized in that the surface of a thermoplastic resin foam is melted by heat held by the molded article, and the thermoplastic resin sheet and the thermoplastic resin foam are integrated. Further, it has been possible to solve the problem by providing a bathroom ceiling member in which a reinforcing sheet is joined to the thermoplastic resin foam.

[0008]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described in detail below with reference to an example of a bathroom ceiling member. Polystyrene, polypropylene, polyvinyl chloride, acrylic and the like are used as the thermoplastic resin sheet used in the present invention, but the present invention is not limited to these. In general, it is desirable to use an impact-resistant polystyrene sheet (hereinafter referred to as HIPS sheet) from the viewpoint of strength and processability of a molded product, and from the viewpoint of joining with a thermoplastic resin foam used in the present invention.
HIPS sheet, width 1000mm, length 2000mm,
A sheet having a thickness of about 1.5 to 5 mm is used for a concave ceiling having a height of 150 to 200 mm when viewed from the inside of the bathroom. The sheet thickness is the size of the ceiling material and the thermoplastic resin foam that is formed. It depends on the foaming density and thickness of the body and the presence or absence of a reinforcing sheet to be combined therewith, but generally 2 to 3 mm is used.

The thermoplastic resin foam used in the present invention is polystyrene, polypropylene, polyethylene, or acrylic foam which is obtained by molding such as mold foaming or extrusion foam molding. Usually, a foaming ratio of 5 to 40 is used, but the expansion ratio is not limited to this. From the standpoint of strength and integral processability of the thermoplastic resin at the time of manufacturing, it is preferably a foam of 15 to 30 times. Similar to the thermoplastic resin sheet, the thickness is determined by the size of the molded product and the relationship with other constituent materials. Generally 5 mm to 5
Although about 0 mm is used, about 7 mm to 15 mm is preferable for the ceiling member in terms of moldability. If it is thick, the stacking property during transportation is poor, and if it is too thin, there are few parts that remain as a foam during heat welding, which does not contribute to strength improvement.

Further, a reinforced sheet (made by Mitsui Toatsu Kagaku Co., Ltd .: trade name Pregron), which is a thermoplastic resin sheet reinforced with continuous filaments arranged in one direction and joined to a foam, is disclosed. These are presented as a prepreg or a laminated sheet in which prepregs are laminated. Specifically, fibers obtained by aligning continuous fibers in one direction are used as aggregates, and these are impregnated with a thermoplastic resin. These prepregs are laminated alone or in combination so as to have a desired fiber orientation and thickness, and by heating and compressing these laminated bodies in advance prior to the molding step, deaeration of air existing between the prepregs can be prevented. It is possible to improve the physical properties of the obtained molded product.

As the fibers serving as the above-mentioned aggregate, glass fiber, carbon fiber, synthetic resin fiber such as aramid fiber (trademark: Kevlar), inorganic fiber such as silicon carbide fiber, titanium fiber, boron fiber, metal fiber such as stainless steel, etc. However, the present invention is not limited to these.

On the other hand, examples of the thermoplastic resin impregnated between the aggregate fibers include polystyrene, polyvinyl chloride, high density polyethylene, polypropylene, polycarbonate, polybutylene terephthalate, polyethylene terephthalate, polyether sulfone, polysulfone, and polyether. Examples thereof include, but are not necessarily limited to, imide (trademark “ULTEM”), polyether ether ketone, polyphenylene sulfide, and the like.

The prepreg is reinforced with unidirectional continuous filaments, and a sheet having a volume content of 30% or more and 85% or less is used, preferably about 45 to 55% in terms of moldability and strength. The thickness of the sheet can be used up to 50 to 1000 μm, but generally 80 to 200 μm is preferable.
When only one prepreg is used, it is advisable to match the fiber direction with the longitudinal direction of the composite molded product. In general, it is better to use a plurality of sheets joined together, and it is more desirable to use a reinforced sheet joined by overlapping so that the fiber directions are orthogonal to each other. In the case of a prepreg having a sheet thickness of 80 to 200 μm, it is preferable to use about 2 to 4 reinforcing sheets, but the prepreg is not limited to this.

The bathroom ceiling member of the present invention will be described below with reference to the drawings. FIG. 1 is a sectional view showing a thermoplastic resin foam 2 having a reinforcing sheet 3 joined to one side thereof. FIG. 2 is a perspective view including a cross-sectional view of the composite molded product of the present invention in which the thermoplastic resin foam 2 is integrated between the thermoplastic resin sheet molded product 1 ′ and the reinforcing sheet 3 and which has a three-layer structure. FIG. 3 is a perspective view including a cross-sectional view showing a conventional bathroom ceiling member composed of the thermoplastic resin sheet 1 ′ and the frame body 8. FIG. 4 is a diagram showing a process for producing the composite molded article of the present invention. As shown in FIG. 1, it is desirable that the reinforcing sheet and the foamed body are previously integrated into a panel (hereinafter referred to as a laminated panel).

When the thermoplastic resin of the reinforcing sheet and the thermoplastic resin forming the foam are the same, the joining of the reinforcing sheet and the foam can be carried out by heat welding by a usual heat laminating method. If they are different, a method of joining with an adhesive or the like is used. In general, resin foam is strong against compression force,
Polystyrene foam is often used as a highly rigid foam. On the other hand, polypropylene, polyethylene or the like is often used as the thermoplastic resin of the reinforcing sheet. When the thermoplastic resin of the reinforced sheet and the thermoplastic resin of the foam are different, the resin foam and the reinforced sheet cannot be joined by heat welding, and a method of joining with an adhesive can be used. Is a material that dissolves polystyrene foam well, and even if it does not dissolve the foam, it is difficult to volatilize the solvent. In addition, it takes a long time to cure a two-component reaction-curable adhesive, and thus it is generally difficult to obtain good adhesion with a reinforced sheet using polypropylene or polyethylene. The present inventors impregnated a polyester-based non-woven fabric into a tank in which polystyrene was dissolved in a solvent, and then volatilized the solvent content to adhere a polystyrene resin to the surface of the fibers in the non-woven fabric or the non-woven fabric (hereinafter, referred to as polystyrene-adhered non-woven fabric). Say), and completed a structure that can be joined to the reinforced sheet by thermal bonding. It is advisable to bond the reinforcing sheet and the polystyrene-bonded nonwoven fabric in advance, and then bond them to the foam. The heat-welding conditions for the reinforcing sheet and the polystyrene-adhered non-woven fabric must be the softening temperature or higher of the thermoplastic resin of the reinforcing sheet, and preferably the melting temperature or higher. Crimping force is 0.1-2kg / cm
² is preferable, and more preferably 0.2 to 0.5 kg / cm ^2.
Is good.

Under such conditions, the reinforcing sheet and the polystyrene-adhered non-woven fabric are joined, and a part of the non-woven fabric adheres in a form embedded in the thermoplastic resin part of the reinforcing sheet (anchor effect), and part of the non-woven fabric is reinforced. It remains on the surface of the sheet.
Generally, the rate of non-woven fabric remaining on the surface of the reinforcing sheet is 20 to 8
0%, preferably 40 to 60%, further 45 to 55
% Is preferable.

The reinforced sheet to which the polystyrene foam and the polystyrene-adhered nonwoven fabric are joined can be integrated by thermal joining at a softening temperature of polystyrene or higher. Further, it is possible to bond them by using a polystyrene resin solvent, but in general, many adhesives contain a solvent, and since these need to be volatilized, heat welding is preferable.

The joint strength between the reinforced sheet of the thermoplastic resin other than polystyrene / polystyrene-bonded nonwoven fabric / polystyrene foam thus obtained and the foam is determined by the destructive force of the external force applied to the composite molded article of the present invention. It is necessary to have a resistance force, and it is necessary to obtain strength at which the foam breaks the material or more. In general, polystyrene foam has a T-peel of 4 g if the interlayer strength of 200 g / cm or more is maintained.
Material failure occurs within a 0x expanded polystyrene foam.

The non-woven fabric constituting the polystyrene-adhered non-woven fabric is preferably a non-woven fabric which is resistant to a solvent that dissolves polystyrene, such as toluene, xylene, benzene and acetone, and which does not melt at the melting temperature of the thermoplastic resin of the reinforcing sheet. Specifically, there are polyester non-woven fabric, nylon non-woven fabric and the like, and the fiber form may be either long fiber or short fiber non-woven fabric, but long fiber non-woven fabric is preferable from the viewpoint of strength.

The method of adhering polystyrene to the non-woven fabric is as follows. Polystyrene is dissolved in a solvent such as toluene, xylene, benzene, and acetone, or a mixed solution of these to impregnate the non-woven fabric, or after coating the non-woven fabric with the solvent, Should be volatilized. As a manufacturing device, a dipping device, a coating device, or a gravure printing device can be used. When the laminate panel manufactured by the above method is used, a reinforced sheet made of polypropylene or a reinforced sheet made of polyethylene can be used in the same manner as the polystyrene resin reinforced sheet.

Further, the reinforced sheet / foam laminated panel thus formed is a thermoplastic resin sheet molded product 1 '.
If it is processed in advance so as to match the shape of the molded product 1 ′ as shown in FIG. It can be bonded to the surface of foam.

Next, FIG. 4 shows a process for integrating the reinforced panel / foamed laminate sheet and the heated thermoplastic resin sheet. FIG. 4 (a) is a diagram showing the relationship between the members constituting the present invention and the molding apparatus. The thermoplastic sheet 1 is fixed between the lower mold 4 and the upper mold 5 by the clamps 6 and 6 '. The resin sheet 1 is sufficiently heated and softened by a far infrared heater or the like. On the other hand, immediately after the thermoplastic resin sheet 1 is molded on the upper mold 5, the upper mold 5 is reinforced in advance so that the thermoplastic resin sheet 1 can be pressure-bonded to the molded product 1'formed as shown in FIG. 4 (b). Sheet /
Install the foam laminate panel members.

Next, as shown in FIG. 4B, the thermoplastic resin sheet 1 is molded by the mold 4 of the vacuum molding machine. Next, FIG.
As shown in Fig. 1, the molded product 1'molded with the lower mold 4 has the heat accumulated by the heating by the far infrared heater before molding, and the upper mold 5 holding the members of Fig. 1 descends to mold. Item 1
1 is pressure-bonded onto the surface of the molded product 1'and the surface of the thermoplastic resin foam 2 is melted by the heat of the molded product 1 ', fused and solidified to be integrated, whereby the composite molded product of the present invention is obtained.

The obtained molded product has a thickness of 7 to 70 mm. Generally, the ceiling member is preferably about 7 to 20 mm. In this case, the reinforcing sheet is 0.4 mm, the thermoplastic resin sheet is 2 mm, and the foam is 4.6 to 17.6 mm. For example, since the thickness of the thermoplastic resin sheet and the number of laminated prepregs of the reinforcing sheet are changed by forming a deep drawing, these relationships differ depending on the desired molded product. Therefore, the unit m ^{2 of the} molded product
The weight per unit is 1 to 12 kg / m ² , preferably 1.5
10 kg / m ² is desirable. 1.5 to 6 kg / m ² is desirable as a bathroom ceiling member, and projected area is 1 m x 2 m
About ² to 4 kg / m ² is good for the product. The conventional product shown in FIG.
The m × 2 m product is about 18 kg, and the bathroom ceiling member, which is the composite molded product of the present invention, is about 7 kg, which achieves a significant weight reduction. This makes it easier to assemble the bathroom,
This has the advantage of significantly reducing the load on the walls that make up the bathroom, as well as improving transport efficiency and reducing damage during transport.

The composite molded article thus completed is
Since the thermoplastic resin sheet can play the role of designability and functionality, and the foam and the reinforcing sheet are combined to form a layer structure, a composite molded article having strength and surface designability and functionality is obtained. Other examples of the composite molded article of the present invention include a bathtub and a wash basin. The bathtub and washbasin are made of wood, cold wood,
In addition to metals, unsaturated polyester moldings are used,
In recent years, bathtubs obtained by thermoforming acrylic sheets have been proposed. Since these baths are formed by deep-drawing an acrylic sheet, which is a thermoplastic resin, there is a problem that the bottom part becomes thin and the acrylic sheet molded product is damaged by the repeated load of the bather. The lower part of the bathtub is strengthened and there is no damage. A bath having excellent heat retention as a heat insulating material is formed from the composite molded article of the present invention.

[0026]

The present invention will be described below with reference to examples. (1) Production of reinforced sheet used [Joining polystyrene resin reinforced sheet and polystyrene foam] Production of polystyrene resin reinforced sheet Glass fiber containing 50% by volume content, thickness 200μ
Two reinforced sheets of m polystyrene resin prepreg are laminated so that the directions of the fibers are orthogonal to each other. Bonding of polystyrene resin reinforced sheet and polystyrene foam Overlaid on the reinforced sheet and polystyrene foam (JSP: Miraboard) having a foaming ratio of 15 times and a thickness of 10 mm,
From the side of the reinforced sheet, a pressure of 0.2 kg / m ² was applied with a heat press controlled at 180 ° C., and the product was heated and pressed for 10 seconds with a hot plate and taken out and cooled. The thickness of the molded product was 8 mm.

[Joining of Polypropylene Resin Reinforcement Sheet and Polystyrene Foam] Production of Polypropylene Resin Reinforcement Sheet Two reinforced sheets of polypropylene resin prepreg are stacked under the same conditions as above. Manufacturing polystyrene-bonded non-woven fabric Polyester non-woven fabric (Spunbond 3 manufactured by Toyobo Co., Ltd.)
0 g / m ² ) of polystyrene resin (Mitsui Toatsu Chemicals, Inc .:
GP550-51) was impregnated with a solution of toluene dissolved in toluene, and then the nonwoven fabric was taken out and dried to volatilize toluene.
A non-woven fabric having 20 g / m ² of polystyrene attached per m ² was prepared. Bonding of Polypropylene Resin Reinforced Sheet and Polystyrene Foam Body The reinforced sheet is overlaid with the non-woven fabric, and the non-woven fabric surface is overlaid with a polystyrene foam body (JSP: Miraboard) having a foaming ratio of 15 times and a thickness of 10 mm. 0.2 in a heat press controlled at 180 ° C
It was pressurized at a pressure of kg / m ² , heated and pressed for 10 seconds on a hot plate, taken out, and cooled. The thickness of the molded product was 8 mm.

(2) Method of Dew Condensation Test in Bathroom In a bathroom with a site area of 3.3 m ² and a temperature of 27 ° C. and a humidity of 98%, a ceiling material was actually attached and evaluated.

Example 1 A vacuum forming machine was used to install a member having a thickness of 8 mm in which a polystyrene foam and a polystyrene resin reinforced sheet were previously joined to an upper mold, and a HIPS sheet having a thickness of 2 mm (manufactured by Sekisui Plastics Co., Ltd.) was installed. 2kg / cm within 5 seconds after forming HIPS sheet with lower mold by heating to 140 ℃ with far infrared heater
^The mold was closed under a pressure of about ² and pressure-bonded, and after cooling for 60 seconds, a polystyrene resin-reinforced sheet, a polystyrene foam, and a HIPS sheet were firmly bonded to each other to obtain a ceiling material. The thickness of the ceiling material was 12 mm. Width 900mm, length 1600mm,
When a bathroom ceiling material having a height of 150 mm was manufactured, the weight was 5 kg. Width 500m from the flat part of the ceiling material
When the bending rigidity was measured using a test piece of m and a length of 1000 mm, it was found to be 1.6 × 10 ⁷ kg · mm ² . Even if a person with a weight of 60 kg placed in the center on the reinforced sheet side of this composite molded article, there was no destruction. Further, when the bathroom dew condensation test was conducted for 2 hours, no dew condensation occurred on the entire surface.

Example 2 Using the same processing method as in Example 1, using only the foam and the thermoplastic resin sheet molded product 1'without using a reinforcing sheet, the ceiling material has a thickness of 11 mm. Weight is 4
kg. When the bending rigidity is measured, it is 6.0 × 10 ⁶ k
It was g · mm ² . Further, when the bathroom dew condensation test was conducted for 2 hours, no dew condensation occurred on the entire surface.

Example 3 In the same manner as in Example 1, a vacuum molding machine was used to install a member having a thickness of 8 mm in which a polystyrene foam and a polypropylene resin reinforced sheet were bonded in advance on the upper mold, and molding was performed to obtain a polypropylene resin reinforced sheet. And polystyrene foam and HI
A ceiling material was obtained in which the PS sheets were firmly joined and integrated. The thickness of the ceiling material was 12 mm. When the flexural rigidity was measured, it was 1.6 × 10 ⁷ kg · mm ² .
Even if a person with a weight of 60 kg placed in the center on the reinforced sheet side of this composite molded article, there was no destruction. Further, when the bathroom dew condensation test was conducted for 2 hours, no dew condensation occurred on the entire surface.

Comparative Example 1 After molding using a HIPS sheet having a thickness of 4 mm, the ceiling material has a thickness of 2.5 mm and a cross section of 30 mm × 30 mm.
A frame structure was made using the above-mentioned tar wood, and was incorporated into a HIPS molded product for a total length of 13 m. Weight is 14 kg
Then, when the bending rigidity is measured, 1.2 × 10 ⁶ kg ・ m
m ² . Further, when a bathroom dew condensation test was conducted for 15 minutes, the occurrence of dew condensation was recognized. Table 1 summarizes the above results.

[0033]

[Table 1]

[0034]

In the work of mounting the lighting equipment on the bathroom ceiling material, the ceiling material of the present invention strengthens the entire surface instead of partially reinforcing it as in the conventional type shown in FIG. Since the local load due to holding hands and the load of the parts when mounting the parts are added to the entire molded product 1 ', it is possible to prevent the damage from being damaged by the ceiling member and the rigidity that allows the worker to ride on the ceiling material and work. Since the bathroom ceiling member that can be held is completed and the foam is evenly attached, it is possible to provide a ceiling member having the same dew and waterproof property in any part of the ceiling member. Moreover, in the manufacturing process, the productivity was greatly improved because the reinforcing foam and the composite panel in which the reinforcing sheet was laminated are joined together at the same time as the molding. Moreover, since the ceiling material and the like are 50% lighter in weight than conventional products, it is easy to perform construction, the load burden on the walls and columns is reduced, and resource saving can be achieved. A thermoplastic resin foam is pressure-melted, solidified, and integrated into a thermoplastic resin sheet in a state where a molded article formed by molding a thermoplastic resin sheet is molded with a mold to make it lightweight and rigid, and also a composite molded article. A composite molded product with uniform dew condensation prevention performance and heat insulation on the molding surface was completed.

[Brief description of drawings]

FIG. 1 is a perspective view including a cross section of a member of a composite molded article used in the present invention, in which a thermoplastic resin foam 2 and a reinforcing sheet 3 are joined.

FIG. 2 is a perspective view including a cross section of a composite molded article according to the present invention, in which a thermoplastic resin sheet molded article 1 ′ and a thermoplastic resin foam 2 are shown.
The figure which showed the structure of the reinforcement sheet 3.

FIG. 3 is a perspective view including a cross section showing a conventional bathroom ceiling material constituted by a thermoplastic resin sheet molded product 1 ′ and a frame body 8.

FIG. 4 is a schematic cross-sectional view showing a method for forming a ceiling material according to the present invention by a vacuum forming method.

[Explanation of symbols]

 1 thermoplastic resin sheet 1'thermoplastic resin sheet molded product 2 thermoplastic resin foam 3 reinforced sheet 4 lower mold 5 upper mold 6,6 'clamp 7,7', 8 frame

Claims (7)

[Claims] 1. A thermoplastic resin sheet and a fiber-reinforced thermoplastic resin sheet (hereinafter referred to as prepreg) reinforced with fibers continuous in one direction, or a sheet in which a plurality of prepregs are joined (hereinafter referred to as a prepreg and a plurality of prepregs). A composite molded product in which a thermoplastic resin foam is integrated between two sheets that are joined together is called a reinforced sheet). 2. A thermoplastic resin sheet is molded by a mold in a step of heating the thermoplastic resin sheet and then shaping with a vacuum or pressure molding machine, and then the thermoplastic resin foam is pressure-bonded to the molded product. Then, the surface of the thermoplastic foam is melted by the heat possessed by the molded product, and a composite molded product in which the thermoplastic resin sheet and the thermoplastic resin foam are integrated. 3. The composite molded article according to claim 2, wherein a reinforcing sheet is bonded to one surface of the thermoplastic resin foam. 4. The composite molded article according to claim 1, wherein the thermoplastic resin sheet and the thermoplastic resin foam are made of polystyrene. 5. The reinforced sheet and the thermoplastic resin foam, wherein the thermoplastic resin of the reinforced sheet is a thermoplastic resin other than polystyrene, the fibers are glass fibers, and the thermoplastic resin foam is a polystyrene foam. The composite molded article according to claim 1 or 3, wherein a non-woven fabric having polystyrene adhered to the body is used as a bonding material. 6. The composite molded article according to claim 1, wherein the volume content of the reinforcing fiber of the prepreg reinforced with the unidirectionally continuous fiber is 30% or more and 85% or less. . 7. The composite molded article according to claim 1, wherein the composite molded article is a bathroom ceiling member.