Jsp Corporation

Toyo Seat Co., Ltd.

Hidehiro Sasaki

Hisao Tokoro

Akinobu Hira

Keiichi Hashimoto

Satoru Shioya

Masakazu Sakaguchi

Hideki Kuwabara

Masaharu Oikawa

Kazuo Tsurugai

Mitsuru Shinohara

Tomoo Tokiwa

Masato Naito

Mitsuhiro Akiyama

Seishiro Murata

Tokunobu Nohara

Hiroyuki Ito

Yasunori Nakamura

Toshio Morita

Takashi Imai

Kazuya Ogiyama

Hiroki Yanagisawa

Tomohiro Hoshino

Kazuo Turugai

Provided are composite particles in which reinforcing fibers adhere to the surface of thermoplastic resin expanded beads via a thermosetting resin being in an uncured state, a cured product of the composite particles, an in-mold molded article of the composite particles, a laminate of the composite particles and a reinforcing fiber sheet material, a composite of the composite particles, and a method for producing composite particles.

Composite particles, composite particle cured product, composite particle in-mold molded article, laminate, composite, and method for producing composite particles

The present invention provides a composite molded article in which aliphatic polyester-based resin expanded beads and a thermosetting resin cured product containing a reinforcing fiber, which is formed between the expanded beads, are integrally fixed, wherein the aliphatic polyester-based resin is a polylactic acid-based resin, and a flexural modulus E (MPa) of the composite molded article and a density &#x3c1; (kg/m) of the composite molded article satisfy Expression (1): E/&#x3c1;&#x2265;0.02 [(MPa)(kg/m)], and a composite molded article and a laminate having more improved strength.

Composite molded article, laminate, and method for producing composite molded article

The present invention provides polyolefin resin particles that are capable of producing expanded polyolefin resin beads having a favorable fine cell structure, expanded polyolefin resin beads that suffer less volume shrinkage under a high temperature environment and are excellent in recovery property on repeated compression, and a method for producing the expanded beads. The polyolefin resin particles of the present invention have a peak temperature (T) of a melting peak on first heating in a DSC curve obtained by heating the resin particles from 20&#xb0; C. to 200&#xb0; C. at a heating rate of 10&#xb0; C./min that is higher by 1.5&#xb0; C. or more than a peak temperature (T) of a melting peak on second heating in a DSC curve obtained by, subsequent to the first heating, cooling the resin particles from 200&#xb0; C. to 20&#xb0; C. at a cooling rate of 10&#xb0; C./min, and then heating the resin particles from 20&#xb0; C. to 200&#xb0; C. at a heating rate of 10&#xb0; C./min. The method for producing expanded polyolefin resin beads of the present invention includes: a step of preparing preliminary resin particles containing a polyolefin resin; a step of heat-treating the preliminary resin particles at a temperature that is higher by from 15 to 25&#xb0; C. than a melting point of the preliminary resin particles, so as to produce resin particles; and a step of expanding the resin particles.

Polyolefin resin particles, polyolefin resin foamed particles, and method for producing polyolefin resin foamed particles

A seat back for vehicles including a seat back pad having supporting bodies fixed on a periphery of an opening or a seat frame, or formed integrally with the periphery of the opening by one or multiple-point support, the supporting bodies aligned at predetermined intervals, each arranged in a direction between periphery portions opposite to each other of the opening at a front surface portion formed as a backrest surface for a seated person, the supporting bodies being independent of each other in rod or plate form, each made of a synthetic resin foam having 20 mm or larger in bending deflection amount and 2 to 100 N in load when deflected by 20 mm measured in accordance with a method defined by JIS K7221-2:2006, and having an interspace portion configured such that the supporting bodies are allowed to be deformed by bending in a rear direction.

Seat back for vehicles

A polypropylene resin foamed bead from which a foamed bead molded article excelling in appearance, heat resistance and mechanical properties can be obtained at the molding temperature lower than that for conventional polypropylene resin foamed beads; and a foamed bead molded article obtained by molding the same. The polypropylene resin foamed bead is characterized by having such a crystal structure that in the first DSC curve obtained when the temperature of the foamed bead sample is raised from ordinary temperature to 200&#xb0; C. at a temperature rising rate of 2&#xb0; C./min by a differential scanning calorimetry, there appear a main endothermic peak of 100&#xb0; to 140&#xb0; C. endothermic peak apex temperature exhibiting 70 to 95% endothermic peak calorific value based on the total endothermic peak calorific value and two or more endothermic peaks exhibited on the high temperature side with respect to the main endothermic peak.

Polypropylene resin foam particle and molding thereof

Improved polypropylene resin foamed beads that without detriment to the excellence in properties, such as compression properties and heat resistance, characterizing the polypropylene resin foamed beads, can provide a polypropylene resin foamed bead molded article with equal properties by an molding conducted at low heating temperature. There are disclosed polypropylene resin foamed beads composed of a polypropylene resin of 115 to 135&#xb0; C. melting point and 500 MPa or higher Olsen flexural modulus. The amount of ash at the surface of the foamed beads is 3000 wt. ppm or less (including 0). With respect to the foamed beads, in the first DSC curve obtained by heating 1 to 3 mg of polypropylene resin foamed beads from room temperature to 200&#xb0; C. at a temperature elevation rate of 10&#xb0; C./min by the use of a differential scanning calorimeter, there appear not only one or more endothermic peak (Pa) having the peak temperature within a temperature zone not higher than the melting point of the resin but also one or more endothermic peak (Pb) having the peak temperature within a temperature zone exceeding the melting point of the resin and not lower than 130&#xb0; C. The total calorific value of the endothermic peak (Pb) is in the range of 2 to 12 J/g. Further, there is disclosed a foamed bead molded article obtained by molding the above foamed beads.

Polypropylene resin foamed bead and molded article therefrom

Expanded beads including cell walls which define a plurality of cells and which comprise a base resin containing a polypropylene resin, each of the beads having a through hole extending therein from one end to the other end. The expanded beads have a maximum diameter D(mm), an average cell diameter Lin a radial direction, an average cell diameter Lin a circumferential direction and a maximum through hole diameter H(mm) satisfying the following conditions: L/Lis at least 1.05, H/Dis 0.08 to 0.4 and the ratio H/Lis 0.1 to 10, where D, Land Lare as defined in the specification. The expanded beads may give a foam molding by an in-mold molding method.

Expanded polypropylene resin beads, method of producing foam molding of expanded polypropylene resin beads and foam molding obtained by the method

A process of producing a foamed molding, wherein expanded, substantially non-crosslinked polypropylene-based resin beads are heated in a mold to fuse-bond the beads together into a unitary body. Each of the expanded beads has been surface-modified with an organic peroxide.

Process of producing foamed molding from expanded polypropylene resin beads and process of producing expanded polypropylene resin beads

Process of producing foamed molding from expanded polypropylene resin beads

A process for the production of expanded beads, including kneading a base resin containing a polypropylene resin and having a tensile modulus of at least 1,200 MPa together with a mixture of a coloring agent and a thermoplastic polymer having a tensile modulus lower than that of the base resin to form a kneaded mixture including a matrix of the base resin and a multiplicity of domains dispersed in the matrix and each containing the thermoplastic polymer and the coloring agent. The kneaded mixture is formed into resin particles, then treated with an organic peroxide to modify surfaces of the resin particles therewith. Foaming and expanding of the surface-modified resin particles gives expanded beads having an inside region surrounded by a surface region. The heat of fusion of a high temperature peak of the surface region is lower than that of the inside region.

Expanded polypropylene resin beads and process for the production thereof

A composite foamed polypropylene resin molding including a plurality of sections which are fuse-bonded to each other, at least two of which differ from each other in color, apparent density, composition and/or mechanical strengths, each of which is formed from expanded polypropylene resin beads, and each of which shows a high temperature endothermic peak in a DSC curve thereof. At least one of the sections satisfies conditions (d) to (f) at the same time: (d) to be formed from specific expanded polypropylene resin beads of a base resin having a tensile modulus of at least 1,200 MPa, (e) to have an apparent density Dof 10&#x2013;500 g/L, and (f) to have such a high temperature endothermic peak with a calorific of EJ/g, wherein Dand Ehave the relationship 20&#x2212;0.020&#xd7;D&#x2266;E&#x2266;65&#x2212;0.100&#xd7;DThe composite molding may be prepared by filling expanded polypropylene resin beads in each of a plurality of contiguous spaces defined in a mold cavity and heating the expanded beads to fuse-bond respective expanded beads together into a unitary body. At least one of the spaces is filled with the specific expanded polypropylene resin beads.

Composite foamed polypropylene resin molding and method of producing same

Expanded, substantially non-crosslinked polypropylene resin beads capable of producing a high rigidity foamed molding at a relatively low temperature. The beads are produced by a process including a step of dispersing substantially non-crosslinked polypropylene resin particles in a dispersing medium containing an organic peroxide to obtain a dispersion, a step of heating the dispersion to decompose the organic peroxide and to modify the surface of the surface-modified polypropylene resin particles, and a step of expanding the non-crosslinked, surface-modified polypropylene resin particles using a blowing agent.

Expanded polypropylene resin bead and process of producing same

A method for producing expanded polypropylene resin particles wherein polypropylene resin particles impregnated with a physical blowing agent are heated along with an aqueous medium and a dispersant and are released and expanded at reduced pressure from the interior of a pressure-tight vessel, wherein the aforementioned aqueous medium has an electrical conductivity of from not less than 0.00 ms/m to not more than 20.00 mS/m. The resulting particles obtained are without inconsistencies caused by differences in the amount of dispersant adhering to the particles or the amount of dispersant added to prevent the particles from fusing together during the heat treatment step of the method.

Production method of foamed polypropylene resin beads

Foamed and expanded beads including a polyester-based resin containing at least 35 mole % of an aliphatic ester component. The foamed beads have a gel fraction of at least 5 % by weight and comprises at least one gel accelerating agent selected from fatty acids having 12-25 carbon atoms, metal salts of the fatty acids, esters of the fatty acids and amides of the fatty acids in an amount of 0.15-3 % by weight. A foam molding is obtained by heating the foamed and expanded beads in a mold.

Foamed and expanded beads of polyester-based resin and foam molding obtained therefrom

Propylene resin beads for molding expansion molded articles having improved high temperature resistance include as base resin metallocene-catalyzed copolymers of propylene with at least one or more of ethylene and &prop;-olefins of 4 to 20 carbon atoms. The metallocene-catalyzed propylene copolymers are isotactic random copolymers characterized by a melting point higher than 140&deg; C. to 160&deg; C. and a melt flow rate (MFR) of not higher than 12 g/10 minutes, especially, 0.5 to 12 g/10 minutes. Expansion molded articles produced by expansion molding the expanded beads have a high temperature degree of deflection which is lower than that of metallocene-catalyzed propylene homopolymers and lower than that of Ziegler-Natta-catalyzed random propylene copolymers having the same comonomers and melting point.

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Tochigi-ken, Japan

Hidehiro Sasaki