Foam particles, and moulded article thereof

Patent metadata

Field	Value
Publication number	US-11466137-B2
Application number	US-201716348108-A
Country	US
Kind code	B2
Filing date	Nov 7, 2017
Priority date	Nov 11, 2016
Publication date	Oct 11, 2022
Grant date	Oct 11, 2022

Abstract

The present invention is concerned with expanded beads that are olefin-based thermoplastic elastomer expanded beads containing a coloring agent, wherein an apparent density of the expanded beads is 40 to 300 g/L, and an average surface layer membrane thickness (a) is 3 to 25 μm, and a molded article thereof, and is able to provide expanded beads capable of producing an expanded beads molded article which is excellent in in-mold moldability and excellent in tensile characteristics and an expanded beads molded article using the expanded beads.

First claim

The invention claimed is:

1. Expanded beads, which are olefin-based thermoplastic elastomer expanded beads containing a coloring agent and a cell controlling agent, and have an apparent density of 40 to 300 g/L, the expanded beads having a surface layer membrane having an average surface layer membrane thickness (a) of 5 to 20 μm,
wherein the olefin-based thermoplastic elastomer constituting the expanded beads is a multi-block copolymer of a polyethylene block and an ethylene/α-olefin copolymer block,
wherein the expanded beads are crosslinked expanded beads, provided that a proportion of a xylene insoluble fraction of the crosslinked expanded beads by a hot xylene extraction method is from 30 to 70% by mass,
wherein the expanded beads have an average cell diameter (b) of 70 to 220 μm, provided that a ratio (b/a) of the average cell diameter (b) to the average surface layer membrane thickness (a) is from 8 to 12,
wherein the multi-block copolymer has a flexural modulus of from 10 to 50 MPa,
wherein the cell controlling agent in the expanded beads is from 0.01 to 1 parts by mass based on 100 parts by mass of the multi block copolymer,
wherein an average cell membrane thickness of the expanded beads Tm is defined as (c), and a ratio (c/a) of the average cell membrane thickness Tm (c) to the average surface layer membrane thickness (a) is 0.36 or more and less than 1, and
wherein the expanded beads are formed from resin particles comprising the multi-block copolymer, the coloring agent, and the cell controlling agent extruded in a strand form from an extruder and cut, the resin particles being expanded to form the expanded beads.

2. The expanded beads according to claim 1 , wherein the coloring agent is an inorganic pigment and/or an organic pigment, and a blending amount of the coloring agent in the expanded beads is from 0.1 to 3.0 parts by mass based on 100 parts by mass of the olefin-based thermoplastic elastomer constituting the expanded beads.

3. The expanded beads according to claim 1 , wherein the average cell membrane thickness Tm is defined as (c), the ratio (c/a) of (c) to the average surface layer membrane thickness (a) is 0.36 or more and less than 0.8.

4. The expanded beads according to claim 1 , wherein the multi-block copolymer has a melt flow rate of 2 to 10 g/10 min at 190° C. and a load of 2.16 kg.

5. The expanded beads according to claim 1 , wherein the multi-block copolymer is a multi-block copolymer containing a polyethylene block and an ethylene/1-octene copolymer block.

6. The expanded beads according to claim 1 , wherein the cell controlling agent has a 50% volume average particle diameter (d50) of 0.01 to 50 μm as measured by a centrifugal sedimentation particle size measurement method.

7. An expanded beads molded article obtained by molding expanded beads to in-mold molding, the expanded beads molded article having a tensile elongation of 140% or more, wherein prior to in-mold molding, the expanded beads have the following characteristics:
the expanded beads being olefin-based thermoplastic elastomer expanded beads containing a coloring agent and a cell controlling agent, and having an apparent density of 40 to 300 g/L, the expanded beads having a surface layer membrane having an average surface layer membrane thickness (a) of 5 to 20 μm,
wherein the olefin-based thermoplastic elastomer constituting the expanded beads is a multi-block copolymer of a polyethylene block and an ethylene/β-olefin copolymer block,
wherein the expanded beads are crosslinked expanded beads, provided that a proportion of a xylene insoluble fraction of the crosslinked expanded beads by a hot xylene extraction method is from 30 to 70% by mass,
wherein the expanded beads have an average cell diameter (b) of 70 to 220 μm, provided that a ratio (b/a) of the average cell diameter (b) to the average surface layer membrane thickness (a) is from 8 to 12,
wherein the multi-block copolymer has a flexural modulus of from 10 to 50 MPa,
wherein the cell controlling agent in the expanded beads is from 0.01 to 1 parts by mass based on 100 parts by mass of the multi block copolymer,
wherein an average cell membrane thickness Tm is defined as (c), and a ratio (c/a) of the average cell membrane thickness Tm (c) to the average surface layer membrane thickness (a) is 0.36 or more and less than 1, and
wherein the expanded beads are formed from resin particles comprising the multi-block copolymer, the coloring agent, and the cell controlling agent extruded in a strand form from an extruder and cut, the resin particles being expanded to form the expanded beads.

8. The expanded beads molded article according to claim 7 , wherein the average cell membrane thickness Tm is defined as (c), and the ratio (c/a) of the average cell membrane thickness Tm (c) to the average surface layer membrane thickness (a) is 0.36 or more and less than 0.8.

9. The expanded beads molded article according to claim 7 , wherein the coloring agent is an inorganic pigment and/or an organic pigment, and a blending amount of the coloring agent in the expanded beads is from 0.1 to 3.0 parts by mass based on 100 parts by mass of the olefin-based thermoplastic elastomer constituting the expanded beads.

Assignees

• Jsp Corp

Inventors

• Takagi Shota
• Oikawa Masaharu

Classifications

• C08J9/0066

  Use of inorganic compounding ingredients · CPC title

• C08J2353/00

  Characterised by the use of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers · CPC title

• C08J9/16 Primary

  Making expandable particles · CPC title

• C08J9/228 Primary

  Forming foamed products · CPC title

• C08K3/04

  Carbon · CPC title