Method for manufacturing foam molded body and foam molded body

Patent metadata

Field	Value
Publication number	US-11945140-B2
Application number	US-202318170266-A
Country	US
Kind code	B2
Filing date	Feb 16, 2023
Priority date	Jun 26, 2017
Publication date	Apr 2, 2024
Grant date	Apr 2, 2024

Abstract

A method for producing a foam-molded product by using a plasticizing cylinder, includes: plasticizing and melting the thermoplastic resin to provide the molten resin in a plasticization zone of the plasticizing cylinder; introducing a pressurized fluid containing the physical foaming agent at a fixed pressure into a starvation zone of the plasticizing cylinder to retain the starvation zone at the fixed pressure; allowing the molten resin to be in the starved state in the starvation zone; bringing the molten resin in contact with the pressurized fluid containing the physical foaming agent at the fixed pressure, in the starvation zone in a state in which the starvation zone is retained at the fixed pressure; and molding the molten resin having been brought in contact with the pressurized fluid containing the physical foaming agent into the foam-molded product.

First claim

What is claimed is:

1. A method for producing a foam-molded product by using a plasticizing cylinder which has a plasticization zone for plasticizing and melting a thermoplastic resin into a molten resin and a starvation zone for allowing the molten resin to be in a starved state, and which has an introducing port for introducing a physical foaming agent into the starvation zone,
the method comprising:
plasticizing and melting the thermoplastic resin to provide the molten resin in the plasticization zone;
introducing a pressurized fluid containing the physical foaming agent at a fixed pressure into the starvation zone, thereby retaining the starvation zone at the fixed pressure;
allowing the molten resin to be in the starved state in the starvation zone;
bringing the molten resin in the starved state in contact with the pressurized fluid containing the physical foaming agent at the fixed pressure, in the starvation zone in a state in which the starvation zone is retained at the fixed pressure; and
molding the molten resin having been brought in contact with the pressurized fluid containing the physical foaming agent into the foam-molded product,

wherein the thermoplastic resin contains 60% by weight or more of a super engineering plastic, and the fixed pressure is from 0.5 MPa to 6 MPa, and
wherein the thermoplastic resin does not contain a chemical forming agent.

2. The method according to claim 1 , wherein the super engineering plastic contains a polyphenylene sulfide or a liquid crystal polymer.

3. The method according to claim 1 , wherein the super engineering plastic contains a liquid crystal polymer, and the fixed pressure is from 1 MPa to 6 MPa.

4. The method according to claim 1 , wherein the physical foaming agent is nitrogen.

5. The method according to claim 1 , wherein in the starvation zone, the molten resin is pressurized by the pressurized fluid containing the physical foaming agent.

6. The method according to claim 1 , wherein the starvation zone is retained at the fixed pressure constantly during the production of the foam-molded product.

7. The method according to claim 1 , wherein the plasticizing cylinder has an introducing speed adjusting container which is connected to the introducing port,
the method further comprising:
supplying the pressurized fluid containing the physical foaming agent into the introducing speed adjusting container, wherein the pressurized fluid containing the physical foaming agent at the fixed pressure is introduced from the introducing speed adjusting container into the starvation zone.

8. The method according to claim 7 , wherein the introducing port is constantly open and the introducing speed adjusting container and the starvation zone are retained at the fixed pressure during the production of the foam-molded product.

9. The method according to claim 1 , wherein an average cell diameter of foam cells contained in the foam-molded product is not larger than 100 μm.

10. A foam-molded product comprising a thermoplastic resin containing 60% by weight or more of a super engineering plastic,
wherein under a condition that the foam-molded product is heated to keep a surface temperature of the foam-molded product at 240° C. to 260° C. for 5 minutes, a change ratio of a thickness of the foam-molded product due to the heating is −2% to 2%, and
wherein the thermoplastic resin does not contain a chemical forming agent.

11. The foam-molded product according to claim 10 , wherein the foam-molded product is heated by a reflow furnace.

12. The foam-molded product according to claim 10 , wherein the super engineering plastic contains a polyphenylene sulfide or a liquid crystal polymer.

13. The foam-molded product according to claim 10 , wherein an average cell diameter of foam cells contained in the foam-molded product is not larger than 100 μm.

14. A method for producing a foam-molded product by using a plasticizing cylinder which has a plasticization zone for plasticizing and melting a thermoplastic resin into a molten resin and a starvation zone for allowing the molten resin to be in a starved state, and which has an introducing port for introducing a physical foaming agent into the starvation zone,
the method comprising:
plasticizing and melting the thermoplastic resin to provide the molten resin in the plasticization zone;
introducing a pressurized fluid containing the physical foaming agent at a fixed pressure into the starvation zone, thereby retaining the starvation zone at the fixed pressure;
allowing the molten resin to be in the starved state in the starvation zone;
bringing the molten resin in the starved state in contact with the pressurized fluid containing the physical foaming agent at the fixed pressure, in the starvation zone in a state in which the starvation zone is retained at the fixed pressure; and
molding the molten resin having been brought in contact with the pressurized fluid containing the physical foaming agent into the foam-molded product,

wherein the thermoplastic resin is a super engineering plastic, and
either the super engineering plastic contains a polyphenylene sulfide and the fixed pressure is from 2 MPa to 10 MPa, or
the super engineering plastic contains a liquid crystal polymer and the fixed pressure is from 1 MPa to 6 MPa, and

wherein the thermoplastic resin does not contain a chemical forming agent.

15. The method according to claim 14 , wherein an average cell diameter of foam cells contained in the foam-molded product is not larger than 100 μm.

Assignees

• Maxell Ltd

Inventors

• Yusa Atsushi
• Goto Hideto
• Yamamoto Satoshi

Classifications

• B29C44/105 Primary

  the counterpressure being exerted by a fluid · CPC title

• B29C44/0415

  by regulating the pressure of the material during or after filling of the mould, e.g. by local venting · CPC title

• B29C44/3415

  Heating or cooling · CPC title

• B29C44/3442

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

• B29K2081/04

  Polysulfides, e.g. PPS, i.e. polyphenylene sulfide or derivatives thereof · CPC title