Molding method of resin molded product and resin molded product

• US 10,668,652 B2
• Filed: 07/28/2016
• Issued: 06/02/2020
• Est. Priority Date: 07/14/2011
• Status: Active Grant

• Current Assignee: Kyoraku Co.,Ltd.
• Original Assignee: Kyoraku Co.,Ltd.
• Inventors: Sumi, Takehiko
• Primary Examiner(s): Rolland, Alex A
• Application Number:
  US15/221,667
• Publication Number:
  US 20160332343A1
• Time in Patent Office: 1,405 Days
• CPC Class Codes: B29C 2049/2013 for connecting opposite walls, e.g. baffles in a fuel tank
• CPC Class Codes: B29C 2948/92561 Time, e.g. start, termination, duration or interruption
• CPC Class Codes: B29C 44/1233 the preformed parts being supported during expanding
• CPC Class Codes: B29C 48/0017 combined with blow-moulding or thermoforming
• CPC Class Codes: B29C 48/0021 combined with joining, lining or laminating
• CPC Class Codes: B29C 48/08 flexible, e.g. films
• CPC Class Codes: B29C 48/305 having a wide opening, e.g. for forming sheets
• CPC Class Codes: B29C 51/12 of articles having inserts or reinforcements
• CPC Class Codes: B29C 51/262 Clamping means for the sheets, e.g. clamping frames
• CPC Class Codes: B29C 51/267 Two sheets being thermoformed in separate mould parts and joined together while still in the mould B29C49/0691 takes precedence
• CPC Class Codes: B29C 65/028 making use of inherent heat, i.e. the heat for the joining comes from the moulding process of one of the parts to be joined
• CPC Class Codes: B29C 65/7441 for making welds and cuts of other than simple rectilinear form
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/1142 Single butt to butt joints
• CPC Class Codes: B29C 66/433 Casing-in, i.e. enclosing an element between two sheets by an outlined seam for bookbinding B42C11/06; for packaging B65B; by laminating B32B37/00; enclosing tubular articles between substantially flat elements B29C66/53261
• CPC Class Codes: B29C 66/721 Fibre-reinforced materials B29C66/729 takes precedence
• CPC Class Codes: B29C 66/727 being porous, e.g. foam
• CPC Class Codes: B29C 66/81427 comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
• CPC Class Codes: B29C 66/81431 comprising a single cavity, e.g. a groove
• CPC Class Codes: B29K 2025/04 Polymers of styrene
• CPC Class Codes: B29L 2009/00 : Layered products
• CPC Class Codes: B32B 2250/03 : 3 layers
• CPC Class Codes: B32B 2250/246 : All polymers belonging to those covered by groups B32B27/32 and B32B27/30
• CPC Class Codes: B32B 2451/00 : Decorative or ornamental articles wall paper B32B2607/02
• CPC Class Codes: B32B 5/20 : foamed in situ
• CPC Class Codes: Y10T 428/249953 : Composite having voids in a component [e.g., porous, cellular, etc.]

Abstract

A molding method of a resin molded product in which it is possible to increase the welding strength between the core member and the resin sheets. In a molding method of a resin molded product in which a core member including a foaming element is interposed between at least two resin sheets in a melted state into a laminated product, wherein the resin sheets include fibrous filler, and while melting surfaces of the core member by heat of the resin sheets, the core member and the resin sheets are welded onto each other, and the core member and the resin sheets are clamped by a metallic mold, to mold the resin molded product.

Claims

1. A molding method of a resin molded product having a core with a foaming element interposed between at least two resin sheets in a melted state to form a laminated product, the resin sheets including fibrous filler, the method comprising:

suspending the resin sheets downward in a melted state by extruding the resin sheets from an extruding slit,

an extruding speed of the resin sheet from the extruding slit being 700 kg/h or more, a extruding quantity per unitary area and unitary time of the thermoplastic resin from the extruding slit is 150 kg/h cm2 or more and the extrusion being completed in a range from 10 seconds to 20 seconds,

and a slit gap being gradually enlarged beginning at the extrusion start point to be maximum at the extrusion end point,

and the temperature of the resin sheets being extruded being 250°

C. or more, and thinning each of the extruded resin sheets by pinching the extruded resin sheets between a pair of rollers, the pair of the rollers each having wrinkles in the contour of depressions and projections on outer surfaces to be brought into contact with the resin sheet, and a gear mechanism being disposed at one end of the rollers, and having an adjustable surface temperature means which flows coolant through the inside of the roller and circulating the coolant, the temperature of the coolant being to be kept constant during the molding of the resin sheet P,

while melting surfaces of the core by heat of the resin sheets, welding the core and the resin sheets onto each other; and

clamping the core and the resin sheets by metallic molds such that, when clamped, a sealed space is formed having a width smaller than a total of a thickness of the core and a thickness of the resin sheets, and the resin sheets are compressed in a range from 0.5 mm to 1.0 mm, to mold the resin molded product, wherein a melting point of a resin used for the resin sheets is higher than that of a resin used for the core wherein

the resin sheet includes fibrous filler in a range from 20 wt % to 40 wt %, the core and the resin sheet include styrene-based resin at least 30 wt % or more, styrene-based resin has MFR equal to or less than 3.5 g/10 min at 230°

C., the core has a foaming rate of 15 times or more and a dimensional change ratio within ±

0.5% in 168 hours at 80°

C.,

the fibrous filler is glass fiber, the value of aspect ratio of the filler ranges from 500 to 1200, the fiber length is from 10 mm to 12 mm, and the fiber diameter is from 14 μ

m to about 17 μ

m,

the core includes resin beads, which contain a fire-retardant agent, the resin beads include α

-methyl styrene at 10 wt % or more and 50 wt % or less, acrylonitrile at 5 wt % or more and 35 wt % or less, and styrene-based monomer at 80 wt % or less,

a dose of the fire-retardant agent ranges from 3 wt % to 10 wt % in the resin beads, the fire-retardant agent is selected from the group consisting of hexabrom cyclododecan, tetrabrom bisphenol A, diallyl ether, and monochlor penthabrom cyclohexane, and

the fire-retardant assistant agent has a half-life temperature per hour of 150°

C. or more and 250°

C. or less.