Polypropylene resin foamed particles, in-mold foam molded body of polypropylene resin, and method for manufacturing same

Patent metadata

Field	Value
Publication number	US-10221292-B2
Application number	US-201815910652-A
Country	US
Kind code	B2
Filing date	Mar 2, 2018
Priority date	Oct 15, 2014
Publication date	Mar 5, 2019
Grant date	Mar 5, 2019

Abstract

A method of producing a polypropylene resin in-mold expanded product, includes: placing polypropylene resin particles obtained from a base material resin having a melting point of 140° C. to 150° C., the base material resin comprising: a polypropylene resin A comprising 3 weight % to 15 weight % of 1-butene and having a melting point of 130° C. to 140° C.; and a polypropylene resin B having a melting point of 145° C. to 165° C., water, and an inorganic gas foaming agent in a pressure-resistant container, forming a mixture, dispersing the polypropylene resin particles while stirring the mixture, obtaining a dispersion liquid, increasing a temperature and a pressure in the pressure-resistant container, releasing the dispersion liquid from the pressure-resistant container into a region having a pressure lower than the pressure in the pressure-resistant container, producing expanded polypropylene resin particles; and filling a mold with the expanded polypropylene resin particles, and then heating the expanded polypropylene resin particles.

First claim

What is claimed is:

1. A method of producing a polypropylene resin in-mold expanded molded product, comprising:
placing polypropylene resin particles, water, and an inorganic gas foaming agent in a pressure-resistant container, forming a mixture,
wherein the polypropylene resin particles comprise a core layer and a covering layer,
wherein the core layer is obtained from a base material resin having a melting point of 140° C. to 150° C., the base material resin comprising:
a polypropylene resin A comprising 3 weight % to 15 weight % of 1-butene and having a melting point of 130° C. to 140° C.; and
a polypropylene resin B having a melting point of 145° C. to 165° C., and

wherein the covering layer consists of the polypropylene resin A,
dispersing the polypropylene resin particles while stirring the mixture, obtaining a dispersion liquid,
increasing a temperature and a pressure in the pressure-resistant container,
releasing the dispersion liquid from the pressure-resistant container into a region having a pressure lower than the pressure in the pressure-resistant container, producing expanded polypropylene resin particles each having an average cell diameter of 100 μm to 340 μm
wherein the expanded polypropylene resin particles are each an expanded composite particle comprising the core layer and the covering layer, the core layer being covered with the covering layer; and
obtaining the polypropylene resin in-mold expanded molded product by filling a mold with the expanded polypropylene resin particles, and then heating the expanded polypropylene resin particles,
wherein the polypropylene resin in-mold expanded molded product has a density and a 50%-strained compressive strength satisfying the following:
[50%-strained compressive strength (MPa)]≥0.0069×[Molded product density (g/L)]+0.018.

2. The method according to claim 1 , wherein the polypropylene resin A comprises 2 weight % to 10 weight % of ethylene.

3. The method according to claim 1 , wherein the inorganic gas foaming agent contains carbon dioxide.

4. The method according to claim 1 , further comprising:
melting and kneading the polypropylene resin A and the polypropylene resin B in an extruder and obtaining the polypropylene resin particles.

5. The method according to claim 1 , further comprising:
obtaining the polypropylene resin A by polymerization using a Ziegler catalyst.

6. The method according to claim 1 , wherein the expanded polypropylene resin particles are heated with steam having a pressure of 0.22 MPa (gauge pressure) or less.

Assignees

• Kaneka Corp

Inventors

• Yoshida Toru
• Miura Shintaro

Classifications

• C08J2423/16

  Ethene-propene or ethene-propene-diene copolymers · CPC title

• C08J9/18 Primary

  by impregnating polymer particles with the blowing agent · CPC title

• C08J2423/14

  Copolymers of propene (C08J2423/16 takes precedence) · CPC title

• C08J2201/03

  Extrusion of the foamable blend · CPC title

• B29C44/02

  for articles of definite length, i.e. discrete articles · CPC title