Foam molded article

Patent metadata

Field	Value
Publication number	US-12209169-B2
Application number	US-202318207972-A
Country	US
Kind code	B2
Filing date	Jun 9, 2023
Priority date	Feb 8, 2019
Publication date	Jan 28, 2025
Grant date	Jan 28, 2025

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 mixture composition comprising:
a main agent resin;
a mixture of fibrous fillers of celluloses with different fibrous filler aspect ratios; 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,
the fibrous fillers include a first fiber having a first aspect ratio (length (L)/diameter (d)) and a second fiber having a second aspect ratio (L/d),
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, and
the proportion of the first fiber is greater than or equal to 50% and less than or equal to 70% of the fibrous fillers, and the proportion of the second fiber is greater than or equal to 1% and less than or equal to 10% of the fibrous fillers, and
wherein the foam molded article includes a core inner layer that includes the main agent resin, the fibrous fillers, 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,
a second core surface layer that is positioned on the second surface of the core inner layer,
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,

a total amount of the fibrous filler in the first skin layer and the second skin layer relative to an amount of fibrous filler in the core inner layer is 1.05 or more and 1.6 or less, and
a total amount of the fibrous filler in the first core surface layer and the second core surface layer relative to the amount of fibrous filler in the core inner layer is 1.02 or more and 1.5 or less.

2. The foam molded article of claim 1 , wherein the main agent resin is olefins.

3. 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.

4. The foam molded article of claim 1 , wherein
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.

5. The foam molded article of claim 4 , wherein the first and the second skin layers do not include foam cells.

6. The foam molded article of claim 1 , further comprising a dispersant
wherein a content of the dispersant is greater than or equal to 0.01% by mass and less than or equal to 20% by mass, and
the dispersant is maleic anhydride.

7. The foam molded article of claim 1 , wherein
the foam molded article is a foam molded article with both high strength and weight reduction obtained.

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

• C08J2205/10

  Rigid foams · CPC title

• C08J2323/12

  Polypropene · 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