Method for producing foam-molded article, and foam-molded article

Patent metadata

Field	Value
Publication number	US-9527228-B2
Application number	US-201314374595-A
Country	US
Kind code	B2
Filing date	Jan 21, 2013
Priority date	Jan 26, 2012
Publication date	Dec 27, 2016
Grant date	Dec 27, 2016

Abstract

Even when a mixture resin of virgin resin and recovered resin material is used as a resin material for molding, a stable, high-quality foam-molded article with excellent impact resistance is produced at low cost. For this, the resin material that is used includes a mixture resin of recovered resin material obtained by pulverizing a resin material solidified after melting, and virgin resin without thermal history of melting, and a foaming agent added to the mixture resin. The resin material is a mixture of a polypropylene-based resin and a polyethylene-based elastomer.

First claim

The invention claimed is:

1. A method for producing a foam-molded article comprising:
preparing a resin material that is a mixture of:
a virgin resin of a polypropylene-based resin; and
a virgin resin of a reforming material including a polyethylene-based elastomer;

obtaining a recovered resin material by pulverizing the resin material that has solidified after melting;
obtaining a mixture resin by mixing the recovered resin material and the resin material that is a virgin resin without thermal history of melting;
adding a foaming agent to the mixture resin; and
clamping the mixture resin in molten state with split mold blocks,
wherein the polyethylene-based elastomer has a compounding ratio of 3% to 15% by weight of the mixture resin.

2. The method for producing a foam-molded article according to claim 1 , wherein
the polyethylene-based elastomer has a melt flow rate (MFR) of 3 g/10 min or more at 190° C.

3. The method for producing a foam-molded article according to claim 1 , wherein
the polyethylene-based elastomer has a density of less than 0.87 g/cm 3 .

4. A foam-molded article comprising a mixture resin including:
a recovered resin that is made of a resin material prepared by mixing:
a virgin resin of a polypropylene-based resin; and
a virgin resin of a reforming material including a polyethylene-based elastomer, wherein the recovered resin being obtained by pulverizing the resin material that has solidified after melting; and

a virgin resin that is the resin material without thermal history of melting,
wherein the polyethylene-based elastomer has a compounding ratio of 3% to 15% by weight of the mixture resin.

5. The method for producing a foam-molded article according to claim 2 , wherein the polyethylene-based elastomer has a density of less than 0.87 g/cm 3 .

6. The foam-molded article according to claim 4 , wherein the polyethylene-based elastomer has a density of less than 0.87 g/cm 3 .

Assignees

• Kyoraku Co Ltd

Inventors

• Sano Takeru
• Igarashi Yu
• ARITA Yuki
• Nomura Takashi

Classifications

• B29C44/02 Primary

  for articles of definite length, i.e. discrete articles · CPC title

• B29K2105/04

  cellular or porous · CPC title

• C08J2300/22

  Thermoplastic resins · CPC title

• C08J9/122

  Hydrogen, oxygen, CO2, nitrogen or noble gases · CPC title

• C08J9/228

  Forming foamed products · CPC title