Laminated molded articles and processes for preparing same

• US 4,997,707 A
• Filed: 11/28/1989
• Issued: 03/05/1991
• Est. Priority Date: 11/28/1988
• Status: Expired due to Fees

• Current Assignee: Mitsui Chemicals Incorporated (Mitsui Chemicals)
• Original Assignee: Mitsui Petrochemical Industries, Ltd. (Mitsui Chemicals)
• Inventors: Takehara, Tooru, Maeda, Toshiyuki, Otawa, Yasuhiko, Sakamaki, Noboru
• Primary Examiner(s): VAN BALEN, WILLIAM
• Application Number:
  US07/442,912
• Time in Patent Office: 462 Days
• Field of Search: 428/319.3, 428/319.7, 428/319.9, 428/424.8, 428/476.9, 428/483, 156/285
• US Class Current: 428/319.3
• CPC Class Codes: B29C 31/04 Feeding of the material to be moulded, e.g. into a mould cavity B29C39/08 takes precedence; using a material distribution system to two or more fixed injection moulds B29C45/125
• CPC Class Codes: B29C 43/00 Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor by liberation of internal stresses B29C61/006
• CPC Class Codes: B29C 45/00 Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor injection blow-moulding B29C49/06
• CPC Class Codes: B29C 45/1418 the inserts being deformed or preformed, e.g. by the injection pressure
• CPC Class Codes: B29C 45/14811 Multilayered articles B29C45/14827 takes precedence
• CPC Class Codes: B29C 51/14 using multilayered preforms or sheets
• CPC Class Codes: B29C 70/78 Moulding material on one side only of the preformed part
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 37/00 Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
• CPC Class Codes: B32B 37/1018 using only vacuum
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: Y10T 428/249991 Synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/249992 Linear or thermoplastic
• CPC Class Codes: Y10T 428/31587 Hydrocarbon polymer [polyethylene, polybutadiene, etc.]
• CPC Class Codes: Y10T 428/31757 Polymer of monoethylenically unsaturated hydrocarbon
• CPC Class Codes: Y10T 428/31797 Next to addition polymer from unsaturated monomers

Abstract

In accordance with the present invention, there are provided laminated molded articles excellent in properties such as heat resistance, low-temperature resistance and the like and also excellent in soft touch and hand feel, said laminated molded articles comprising

(a) a core layer composed of a synthetic resin,

(b) an interlayer (I) composed of a polyolefin foam, polyurethane foam or thermoplastic elastomer foam, formed on said core layer,

(c) an interlayer (II) composed of a modified polyolefin elastomer graft modified with at least one graft monomer selected from the group consisting of unsaturated carboxylic acids, derivatives thereof, unsaturated epoxy monomers and unsaturated hydroxy monomers, formed on said interlayer (I), and

(d) a surface skin composed of at least one polymer selected from the group consisting of polyamides, polyurethane and polyesters, formed on said interlayer (II), said surface skin being decorated, if necessary, by gigging the surface thereof.

Claims

1. A laminated molded article comprising

(a) a core layer composed.of a synthetic resin,

(b) an interlayer (I) composed of a polyolefin foam, polyurethane foam or thermoplastic elastomer foam, formed on said core layer,

(c) an interlayer (II) composed of a modified polyolefin elastomer graft modified with at least one graft monomer selected from the group consisting of unsaturated carboxylic acids, derivatives thereof, unsaturated epoxy monomers and unsaturated hydroxy monomers, formed on said interlayer (I), and

(d) a surface skin composed of at least one polymer selected from the group consisting of polyamides, polyurethanes and polyesters, formed on said interlayer (II).

2. A process for preparing the laminated molded article as claimed in claim 1, which process comprises the steps in sequence of

obtaining a preform having a concavity by preheating a three-layer sheet comprising the interlayer (I) composed of the polyolefin foam, polyurethane foam or thermoplastic elastomer foam, the interlayer (II) composed of the modified polyolefin elastomer and the surface skin composed of the polymer, and then applying the three-layer sheet by attraction closely to an inner wall surface of cavity of a vacuum forming mold,

obtaining a molded article having a concavity by clamping said preform in a state of being applied closely to the inner wall surface of cavity of said vacuum forming mold or in a state where said preform is applied closely to an inner wall surface of cavity of a separate vacuum forming mold, and

injection molding a synthetic resin in a fluid plasticized state into the concavity of the molded article being applied closely to the inner wall surface of cavity of said mold.

3. A process for preparing the laminated molded article as claimed in claim 1, which process comprises the steps in sequence of

obtaining a preform having a concavity by preheating a three-layer sheet comprising the interlayer (I) composed of the polyolefin foam, polyurethane foam or thermoplastic elastomer foam, the interlayer (II) composed of the modified polyolefin elastomer and the surface skin composed of the polymer, and then applying the three-layer sheet by attraction closely to an inner wall surface of cavity of a vacuum forming mold, and

stamp molding after casting a synthetic resin into the concavity of the preform in a state of being applied closely to the inner wall surface of cavity of the vacuum molding mold or in a state where said preform is applied closely to an inner wall surface of cavity of a separate vacuum molding mold.

4. A process for preparing the laminated molded article as claimed in claim 1, which process comprises preheating a four-layer sheet comprising the core layer composed of the synthetic resin, the interlayer (I) composed of the polyolefin foam, polyurethane foam or thermoplastic elastomer foam, the interlayer (II) composed of the modified polyolefin elastomer and the surface skin composed of the polymer, followed by vacuum forming said four-layer sheet.

9. A laminated molded article claimed in claim 1, wherein the thermoplastic elastomer forming said thermoplastic elastomer foam comprises as essential components a polyolefin resin and an ethylene/α

-olefin copolymer rubber.

5. A laminated molded article comprising

(a) a core layer composed of a synthetic resin,

(b) an interlayer (II) composed of a modified polyolefin elastomer graft modified with at least one graft monomer selected from the group consisting of unsaturated carboxylic acids derivatives thereof, unsaturated epoxy monomers and unsaturated hydroxy monomers, formed on said core layer, and

(c) a surface skin composed of at least one polymer selected from the group consisting of polyamides, polyurethanes and polyesters, formed on said interlayer (II).

6. A process for preparing the laminated molded article as claimed in claim 5, which process comprises the steps in sequence of

obtaining a preform having a concavity by preheating a two-layer sheet qomprising the interlayer (II) composed of the modified polyolefin elastomer and the surface skin composed of the polymer, and then applying the two-layer sheet by attraction closely to an inner wall surface of cavity of a vacuum molding mold,

obtaining a molded article having a concavity by clamping said preform in a state of being applied closely to an inner wall surface of cavity of the vacuum molding mold or in a state where said preform is applied closely to an inner wall surface of cavity of a separate vacuum forming mold, and

of molding after injecting a synthetic resin in a fluid plasticized state into the concavity of said molded article applied closely to the inner wall surface of cavity of said mold.

7. A process for preparing the laminated molded article as claimed in claim 5, which process comprises the steps in sequence of

obtaining a preform having a concavity by preheating a two-layer sheet comprising the interlayer (II) composed of the modified polyolefin elastomer and the surface skin composed of the polymer, and then applying said two layer-sheet by attraction closely to an inner wall surface of cavity of a vacuum forming mold, and

stamp molding after casing a synthetic resin in a fluid plasticized state into the concavity of said preform being applied closely to the inner wall surface of cavity of the vacuum forming mold or into the concavity of said preform being applied closely to an inner wall surface of cavity of a separate vacuum forming mold.

8. A process for preparing the laminated molded article as claimed in claim 5, which process comprises preheating a three-layer sheet comprising the core layer composed of the synthetic resin, the interlayer (II) composed of the modified polyolefin elastomer and the surface skin composed of the polymer, followed by vacuum forming said three-layer sheet.

10. A laminated molded article comprising

(a) a core layer composed of a synthetic resin,

(b) an interlayer (II) composed of a modified polyolefin elastomer graft modified with at least one graft monomer selected from the group consisting of unsaturated carboxylic acids, derivatives thereof, unsaturated epoxy monomers and unsaturated hydroxy monomers, formed on said core layer, and

(c) a surface skin decorated on the surface thereof by gigging and composed of at least one polymer selected from the group consisting of polyamides, polyurethanes and polyesters, formed on said interlayer (II).

11. A laminated molded article comprising

(a) a core layer composed of a synthetic resin,

(b) an interlayer (I) composed of a polyolefin foam, polyurethane foam or thermoplastic elastomer foam, formed on said core layer,

(c) an interlayer (II) composed of a modified polyolefin elastomer graft modified with at least one graft monomer selected from the group consisting of unsaturated carboxylic acids, derivatives thereof, unsaturated epoxy monomers and unsaturated hydroxy monomers, formed on said interlayer (I), and

(d) a surface skin decorated on the surface thereof by gigging and composed of at least one polymer selected from the group consisting of polyamides, polyurethanes and polyesters, formed on said interlayer (II).