Foam molded article

Patent metadata

Field	Value
Publication number	US-11725092-B2
Application number	US-202016750035-A
Country	US
Kind code	B2
Filing date	Jan 23, 2020
Priority date	Feb 8, 2019
Publication date	Aug 15, 2023
Grant date	Aug 15, 2023

Abstract

A foam molded article includes a main agent resin, a filler of greater than or equal to 15% by mass and less than or equal to 80% by mass, and a foaming agent of greater than or equal to 0.01% by mass and less than or equal to 10% by mass, and a foaming ratio caused by the foaming agent is greater than or equal to 1.1 times.

First claim

What is claimed is:

1. A foam molded article produced from a composition comprising:
a main agent resin;
greater than or equal to 15% by mass and less than or equal to 80% by mass, based on the composition, of a filler; and
a plurality of foam cells formed by a foaming agent,
wherein a foaming ratio caused by the foaming agent is 1.1 times or more wherein,
the filler is a mixed fiber including a first fiber having a first aspect ratio (length (L)/diameter (d)) and a second fiber having a second aspect ratio (L/d), wherein the first aspect ratio is lower than the second aspect ratio, and
the first aspect ratio of the first fiber is less than or equal to 2 and the second aspect ratio of the second fiber is greater than or equal to 10.

2. The foam molded article of claim 1 ,
wherein in the filler, a proportion of the first fiber is greater than a proportion of the second fiber.

3. The foam molded article of claim 2 ,
wherein the proportion of the first fiber in the filler is greater than or equal to 50% and less than or equal to 70%, and the proportion of the second fiber in the filler is greater than or equal to 1% and less than or equal to 10%.

4. The foam molded article of claim 1 , wherein a cell diameter of each of the plurality of foam cells is greater than or equal to 90 μm and smaller than or equal to 500 μm.

5. The foam molded article of claim 4 , wherein
the foam molded article includes a core inner layer that includes the main agent resin, the filler, and the plurality of foam cells, the core inner layer including a first surface and a second surface that are opposite to each other,
the foam molded article further comprises:
a first core surface layer that is positioned on the first surface of the core inner layer, and
a second core surface layer that is positioned on the second surface of the core inner layer,

the first and the second core surface layers include a plurality of foam cells, and
a cell diameter of each of the plurality of foam cells of the first and the second core surface layers is greater than or equal to 40 μm and smaller than or equal to 80 μm.

6. The foam molded article of claim 5 , further comprising:
a first skin layer that is positioned on the first core surface layer, and
a second skin layer that is positioned on the second core surface layer, wherein the first and the second skin layers do not include foam cells.

Assignees

• Panasonic Ip Man Co Ltd

Inventors

• Takahashi Yoshie
• Hamabe Masashi
• Imanishi Masayoshi
• Nagino Toshifumi

Classifications

• C08J2497/02

  Lignocellulosic material, e.g. wood, straw or bagasse · CPC title

• C08J9/34 Primary

  Chemical features in the manufacture of articles consisting of a foamed macromolecular core and a macromolecular surface layer having a higher density than the core · CPC title

• B29C44/3442

  Mixing, kneading or conveying the foamable material (mixing plastics B29B7/00; mixing in general B01F) · CPC title

• C08J9/00

  Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof (mechanical aspects of shaping of plastics or substances in a plastic state for the production of porous or cellular articles B29C) · CPC title

• C08J9/0085 Primary

  Use of fibrous compounding ingredients (C08J9/0076 takes precedence) · CPC title