Polyolefin resin foam sheet and laminate

Patent metadata

Field	Value
Publication number	US-2023151171-A1
Application number	US-202117919802-A
Country	US
Kind code	A1
Filing date	Apr 23, 2021
Priority date	May 1, 2020
Publication date	May 18, 2023
Grant date	—

Abstract

A polyolefin resin foam sheet includes a resin mixture as a base resin, the resin mixture including 0% by mass or more and 30% by mass or less of polyethylene resin, 30% by mass or more and 80% by mass or less of polypropylene resin, and 20% by mass or more and 40% by mass or less of a polyolefin elastomer, the polyolefin resin foam sheet fulfilling a range of −35% or more and 0% or less for dimensional changes in machine and transverse directions under heating for 10 minutes at a temperature 20° C. higher than a maximum melting point that is a highest melting peak in a differential scanning calorimetry.

First claim

1 - 12 . (canceled)

13 . A polyolefin resin foam sheet comprising:
a resin mixture as a base resin, the resin mixture comprising 0% by mass or more and 30% by mass or less of polyethylene resin, 30% by mass or more and 80% by mass or less of polypropylene resin, and 20% by mass or more and 40% by mass or less of a polyolefin elastomer, the polyolefin resin foam sheet having −35% or more and 0% or less for dimensional changes in machine and transverse directions under heating for 10 minutes at a temperature 20° C. higher than a maximum melting point that is a highest melting peak in a differential scanning calorimetry.

14 . A polyolefin resin foam sheet satisfying: 2.5 or less for a value obtained by dividing a 25% compressive strength (kPa) by a density (kg/m 3 ); and −35% or more and 0% or less for dimensional changes in machine and transverse directions obtained under heating for 10 minutes at a temperature 20° C. higher than a maximum melting point that is a highest melting peak in a differential scanning calorimetry.

15 . The polyolefin resin foam sheet according to claim 13 , wherein the polyolefin resin foam sheet has a thickness of 1 mm or more and 5 mm or less, a density of 40 kg/m 3 or more and 100 kg/m 3 or less, and a gel fraction of 30% or more and 60% or less.

16 . The polyolefin resin foam sheet according to claim 15 , wherein the polyolefin resin foam sheet satisfies 0.5 or more and 1.5 or less for a ratio of the dimensional change in the machine direction to the dimensional change in the transverse direction under the heating for 10 minutes at the temperature 20° C. higher than the maximum melting point that is the highest melting peak in the differential scanning calorimetry.

17 . The polyolefin resin foam sheet according to claim 15 , wherein the polyolefin resin foam sheet satisfies −5% or more and 0% or less for dimensional changes in the machine and transverse directions obtained under the heating for 10 minutes at a temperature 20° C. lower than the maximum melting point that is the highest melting peak in the differential scanning calorimetry.

18 . The polyolefin resin foam sheet according to claim 15 , wherein the polyolefin resin foam sheet satisfies 0.7 or more and 1.3 or less for an average cell size ratio BD MD /BD TD that is obtained by dividing an average cell size BD MD in the machine direction by an average cell size BD TD in the transverse direction.

19 . The polyolefin resin foam sheet according to claim 15 , wherein the polyolefin resin foam sheet satisfies 0.7 or more and 1.3 or less for a ratio of a tensile strength in the machine direction to a tensile strength in the transverse direction at 23° C.

20 . The polyolefin resin foam sheet according to claim 15 , wherein the polyolefin resin foam sheet has a foam sheet thickness or more and 15 mm or less for a curl height obtained under the heating for 10 minutes at the temperature 20° C. higher than the maximum melting point that is the highest melting peak in the differential scanning calorimetry.

21 . The polyolefin resin foam sheet according to claim 15 , wherein the polyolefin resin foam sheet has 1.0 or more and 1.2 or less for a surface layer gel fraction ratio calculated by dividing GF A by GF B , where GF A and GF B respectively represent larger and smaller ones of gel fractions of first and fifth layers obtained by dividing the polyolefin resin foam sheet equally into five layers, which are labeled as the first to fifth layers in this order, in a thickness direction.

22 . The polyolefin resin foam sheet according to claim 15 , wherein the polyolefin resin foam sheet has 1.0 or more and 1.2 or less for a surface layer average cell size ratio calculated by dividing BD A by BD B , where BD A and BD B respectively represent larger and smaller ones of average cell sizes BD of first and fifth layers obtained by dividing the polyolefin resin foam sheet equally into five layers, which are labeled as the first to fifth layers in this order, in a thickness direction.

23 . The polyolefin resin foam sheet according to claim 15 , wherein the polyolefin resin foam sheet has 1.0 or more and 1.5 or less for an average cell size ratio before and after heating calculated by dividing BD BF by BD AF , where BD BF and BD AF respectively represent average cell sizes of the polyolefin resin foam sheet obtained before and after the heating for 10 minutes at the temperature 20° C. higher than the maximum melting point that is the highest melting peak in the differential scanning calorimetry for both machine and transverse directions.

24 . A laminate formed by laminating one or more type(s) of a surface material selected from the group consisting of sheet, film, cloth, non-woven fabric and skin, on the polyolefin resin foam sheet according to claim 15 .

Assignees

• Toray Industries

Inventors

• Kondo Hirotaka
• Oka Yoshiyuki

Classifications

• C08J2323/12

  Polypropene · CPC title

• B32B2266/025

  Polyolefin · CPC title

• C08J2323/06

  Polyethene · CPC title

• B32B2307/50

  having particular mechanical properties · CPC title

• C08J9/103

  Azodicarbonamide · CPC title