SKIN MATERIAL-COATED FOAMED PARTICLE MOLDED BODY

• US 20200130239A1
• Filed: 03/19/2018
• Published: 04/30/2020
• Est. Priority Date: 03/31/2017
• Status: Active Grant

• Current Assignee: JSP Corporation (Mitsubishi Electric Corporation)
• Original Assignee: JSP Corporation (Mitsubishi Electric Corporation)
• Inventors: TOKIWA, Tomoo, KAWAKAMI, Hiroki
• Granted Patent: US 11,529,754 B2
• Time in Patent Office: Days
• CPC Class Codes: B29C 44/14 the preformed part being a lining B29C44/1209 takes precedence
• CPC Class Codes: B29C 44/44 in solid form
• CPC Class Codes: B29C 44/445 in the form of expandable granules, particles or beads
• CPC Class Codes: B32B 1/00 Layered products having a non-planar shape
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2266/025 Polyolefin vinyl or acrylic copolymers B32B2266/0221, B32B2266/0242
• CPC Class Codes: B32B 2307/51 Elastic
• CPC Class Codes: B32B 2307/538 Roughness
• CPC Class Codes: B32B 2307/5825 Tear resistant
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2307/732 Dimensional properties
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/18 characterised by the use of special additives
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 5/245 another layer next to it being a foam layer
• CPC Class Codes: B32B 5/28 impregnated with or embedded in a plastic substance not used
• CPC Class Codes: B32B 7/022 : Mechanical properties
• CPC Class Codes: C08J 9/228 : Forming foamed products
• CPC Class Codes: C08J 9/365 : Coating

Abstract

A skin material-coated foamed particle molded body includes a skin material made of a polypropylene-based resin molded body and a polypropylene-based resin foamed particle molded body coated with the skin material. The skin material has a multilayer structure including an inner layer adhered to the foamed particle molded body and an outer layer outside the inner layer. The outer layer contains a polypropylene-based resin and a reinforcement fiber. The inner layer contains the polypropylene-based resin and a reinforcement fiber in a lower content ratio than a content ratio of the reinforcement fiber contained in the outer layer or contains the polypropylene-based resin and substantially no reinforcement fiber. An average value of the outer layer thickness ratio to a sum of of the outer and inner layer thicknesses is 0.20 or more and 0.65 or less, and a coefficient of variation Cv of the ratio is 30% or less.

Claims

1. A skin material-coated foamed particle molded body comprising:

a skin material made of a polypropylene-based resin molded body and a polypropylene-based resin foamed particle molded body coated with the skin material, wherein

the skin material has a multilayer structure including an inner layer adhered to the polypropylene-based resin foamed particle molded body and an outer layer disposed outside the inner layer,

the outer layer contains a polypropylene-based resin and a reinforcement fiber,

the inner layer contains the polypropylene-based resin and a reinforcement fiber in a lower content ratio than a content ratio of the reinforcement fiber contained in the outer layer or contains the polypropylene-based resin and no reinforcement fiber, and

an average value of a ratio of a thickness of the outer layer to a sum of a thickness of the outer layer and a thickness of the inner layer is 0.20 or more and 0.65 or less, and a coefficient of variation Cv of the ratio is 30% or less.

2. The skin material-coated foamed particle molded body according to claim 1, wherein an average thickness of the skin material is 1 mm or more and 5 mm or less.

3. The skin material-coated foamed particle molded body according to claim 1, wherein a weight average fiber length of the reinforcement fiber contained in the outer layer is 0.5 mm or more and 2.0 mm or less.

4. The skin material-coated foamed particle molded body according to claim 1, wherein a fusion ratio of the polypropylene-based resin foamed particle molded body is 40% or more.

5. The skin material-coated foamed particle molded body according to claim 1, wherein

the content ratio of the reinforcement fiber in the outer layer is 5% by mass or more and 30% by mass or less, and

a content ratio of the reinforcement fiber in the inner layer is 0% by mass or more and less than 5% by mass.

6. The skin material-coated foamed particle molded body according to claim 1, wherein a peel strength between the skin material and the polypropylene-based resin foamed particle molded body is 0.3 MPa or more.

7. The skin material-coated foamed particle molded body according to claim 1, wherein the reinforcement fiber is a carbon fiber.

8. The skin material-coated foamed particle molded body according to claim 1, wherein the polypropylene-based resin molded body is a hollow blow molded body formed by blow-molding a parison having a multilayer structure including an inner layer and an outer layer disposed outside the inner layer which were formed by coextrusion.

9. The skin material-coated foamed particle molded body according to claim 1, wherein an apparent density of the skin material-coated foamed particle molded body is 180 g/L or more and 500 g/L or less.