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Method of producing composite material having foamed resin layer and surface layer

A technology for synthetic materials and foamed resins, which is applied in the field of manufacturing synthetic materials and can solve problems such as delamination

Inactive Publication Date: 2006-04-12
JSP CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

The synthetic material obtained by this method has a problem that the bonding between the expanded particles (internal bonding strength) and the bonding between the foamed resin layer and the surface layer (interlayer bonding strength) is not very high, so that The synthetic material is prone to intralayer and interlayer delamination

Method used

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  • Method of producing composite material having foamed resin layer and surface layer
  • Method of producing composite material having foamed resin layer and surface layer
  • Method of producing composite material having foamed resin layer and surface layer

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0064] A two-layer laminate of a skin layer of polyolefin elastomer having a thickness of 0.4 mm and a backing layer (Toraypef AP61 manufactured by Toray Inc.) of a crosslinked polypropylene expanded resin sheet having a thickness of 3 mm was molded into a predetermined shape and Place in figure 1 In the first mold 1 of the device shown. Has an apparent density of 0.176g / cm 3 The expanded resin pellets (actual expansion ratio 5.1) and containing air at 0 MPa (G) were then fed into the space 10 in an amount occupying 65% of the total capacity of the space 10 . The expanded resin pellets had a melting point of 146°C, an average particle diameter of 4 mm and were made of a propylene-ethylene random copolymer having an ethylene content of 2.4% by weight and a Vicat softening point of 132°C. The pellets in the mold cavity were degassed and then molded as follows:

[0065] (1) The first degassing step:

[0066] Valve 15: open

[0067] Valve 17: closed

[0068] Valve 19: closed...

example 2

[0107] Example 1 was repeated in the same manner as described except that the third heating step was omitted. Although gaps were found on a part of the outer surface of the foamed resin layer, the synthetic material showed very high intra-layer adhesive strength as well as very high inter-layer adhesive strength.

example 3

[0109] Example 1 was repeated in the same manner as described except that the first and second degassing steps were performed as follows.

[0110] (1) The first degassing step:

[0111] Valve 15: closed

[0112] Valve 17: closed

[0113] Valve 19: open

[0114] Valve 21: closed

[0115] Valve 23: closed

[0116] Valve 25: closed

[0117] Chamber 12a is pumped to -0.078 MPa(G) for 4 seconds.

[0118] (2) The second degassing step:

[0119] Valve 15: closed

[0120] Valve 17: closed

[0121] Valve 19: closed

[0122] Valve 21: closed

[0123] Valve 23: closed

[0124] Valve 25: open

[0125] Next, the chamber 12b is pumped to -0.078 MPa(G) for 4 seconds.

[0126] No gaps were found between the expanded grains on the surface of the foamed resin of the synthetic material. In addition, the synthetic material exhibits very high intralayer bond strengths as well as very high interlayer bond strengths.

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Abstract

A method of producing a composite material, including providing a surface layer in a first mold such that the surface layer is in contact with an interior surface thereof, disposing a second mold in position so that a space is defined between the second mold and the surface layer, the second mold having plural groups of perforations; feeding expanded resin beads to the space to fill the space therewith, deaerating the space, and then introducing a heating medium into the space successively through the plural groups of perforations of the second mold to fuse and bond the expanded resin beads.

Description

technical field [0001] The present invention relates to a method of manufacturing a synthetic material having a foamed resin layer and a surface layer superimposed on the foamed resin layer and used for cushioning, door facing, or dashboards, boxes, electrical device bodies, trays of automobiles Wait. Background technique [0002] A known method for preparing a synthetic material having a foamed resin layer and a surface layer superimposed on the foamed resin layer involves molding expanded resin pellets in a mold in which the surface layer ( EP-A-591553, EP-A-658410, EP-A-841155). During molding, the expanded resin pellets are heated with a heating medium and melted and bonded to each other to form a foamed resin layer on which the surface layer is bonded. The synthetic material obtained by this method has a problem that the bonding between the expanded particles (internal bonding strength) and the bonding between the foamed resin layer and the surface layer (interlayer b...

Claims

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Application Information

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Patent Type & Authority Patents(China)
IPC IPC(8): B29C44/34B68G7/06B29C44/00
CPCB29C44/3415B29C44/12
Inventor 手塚久男上栗基晶
Owner JSP CORP