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Polyolefin resin molding composite

a polyolefin resin and composite technology, applied in the direction of synthetic resin layered products, transportation and packaging, chemistry apparatus and processes, etc., can solve the problems of deteriorating surface quality of surface layer, difficult to predominate design, and high temperature or high pressure steam heating of mold production techniques

Inactive Publication Date: 2005-02-24
YOKOYAMA MASAAKI +1
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

"The present invention is a polyolefin resin molding composite that solves the technical problem of providing a composite that has both a surface layer and a foam layer. The foam layer is made of thermoplastic expanded resin particles that have a core made of a crystalline thermoplastic resin and a polyethylene resin coat covering the core. The surface layer is made of a thermoplastic synthetic resin that has a melting point of 5° C or more higher than the melting point of polyethylene resin. The composite has good properties such as high compressive hardness, low void fraction, and good appearance."

Problems solved by technology

However, the hitherto mold producing technique needs high temperature or high pressure steam heating when expanded resin particles are fusion bonded.
This leads to a drawback that surface quality of a surface layer is deteriorated by heat when heating.
Therefore there is another drawback that when a design as an interior decoration member is formed on the surface of a surface layer, the design becomes difficult to predominate.
There is also another problem that if molding is carried out at a low temperature, fusion bonded between expanded resin particles is deteriorated and adhesion of the surface layer and the foam layer and of the foam layer and the base member are also deteriorated.
Furthermore, the above mentioned hitherto molding composite producing technique requires to heat for a long time by a high temperature steam in order to increase adhesiveness between a sheet for a surface layer and expanded resin particles.
If cooling is carried out in this condition, moisture condenses from the gas state to the liquid state, thereby causing great volume shrinkage.
On this account, pressure in the spaces between expanded resin particles or in the particles themselves reduces, thereby causing shrinkage or deformation of an expanded mold made of these particles.
This leads to a problem that shape stability becomes worse, that it is hard to obtain a mold fitted exactly in a mold, and that surface appearance of a surface layer is bad.

Method used

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  • Polyolefin resin molding composite
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Examples

Experimental program
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Effect test

an example of

production of the composite of the present invention is a cast molding. Specifically, a method that is generally used is as follows. A surface layer is placed in a mold that can be heated by hot air or steam, and if necessary, on the other side, a base member made of a comparatively hard synthetic resin plate. On the back side of the surface layer (between the surface layer and the base member), expanded resin particles are filled and heated by hot air or steam, thereby fusion bonding the expanded resin particles themselves, and expanded resin particles and the surface layer (and the base member) to be integrated. In this process, the condition that an uneven pattern such as a grain pattern and the like of the surface layer is not disappeared or blurred, or luster of the surface layer is deteriorated even if heating is carried out at a temperature at which expanded resin particles themselves are fusion bonded is the above mentioned melting point difference.

In respect of molding met...

example 1

Using a single screw extruder having an inner diameter of 40 mm, an ethylene / propylene random copolymer (melting point 153° C.) of which the ethylene content is 1.5% by weight was kneaded, and using a single screw extruder having an inner diameter of 26 mm, a linear low density polyethylene (melting point 100° C.) that is polymerized with a metallocene catalyst having a density of 0.907 was kneaded. Subsequently, ethylene / propylene random copolymer was used for a core and linear low density polyethylene was used for a coat, and a strand was extruded from a die having a die orifice of a diameter of 1.5 mm.

After cooling this strand by passing through a water tank, the strand was cut so as to be 1.2 mg. The cross section of this composite particle was observed with a phase contrast microscope, and it was found that linear low density polyethylene of thickness of 30 μm covered ethylene / propylene random copolymer.

Next, in a closed vessel, 100 parts by weight of the above mentioned c...

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Abstract

A foam layer can be formed at a temperature at which the surface quality of a surface layer is not deteriorated, and a molding technique that is excellent in adhesiveness of a foam layer and a surface layer or / and a base member is developed. For the purpose of obtaining a resin molding composite, the present invention is characterized by a polyolefin resin molding composite comprising a surface layer and a foam layer, or a surface layer, a foam layer, and a base member, wherein the foam layer comprises a foam layer produced by fusion bonding thermoplastic expanded resin particles one another by molding, where the thermoplastic expanded resin particles comprises a core that is made of a crystalline thermoplastic resin and is in an expanded state and a polyethylene resin coat covering the core, and the surface layer comprises a thermoplastic synthetic resin having a melting point of 5° C. or more higher than a melting point of polyethylene resin constituting the coat of the particles.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a polyolefin resin molding composite and, more specifically, to a polyolefin resin molding composite using thermoplastic expanded resin particles. 2. Description of the Related Art With respect to a vehicular interior decoration member, there has hitherto been a member comprising an intervening foam layer between a base member of a solid resin and a surface layer, thereby attaching soft touch to the member to make it luxurious. The process for producing such a vehicular interior decoration member is disclosed in a patent publication (Patent No. 2500645). The process for producing a vehicular interior decoration member disclosed in the above patent publication comprises placing a sheet for a surface layer made of polypropylene on one mold, and on the other mold, placing a base member made of a solid resin that is made of polypropylene and contains fillers, filling expanded resin particles made...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B32B5/20B32B5/18B32B27/32
CPCB32B27/32B32B5/20Y10T428/249972Y10T428/249992Y10T428/249989Y10T428/249988Y10T428/249991Y10T428/249993Y10T428/249976B32B3/04B32B27/20B32B2605/00B32B5/18B32B2266/0214B32B27/065B32B2323/10
Inventor YOKOYAMA, MASAAKITANAKA, MASAHIRO
Owner YOKOYAMA MASAAKI