Kaneka Corporation

Kanegafuchi Kagaku Kogyo Kabushiki Kaisha

Kiyoshi Matsuki

Yoriki Kakimoto

Izumi Ibata

Yoshiaki Yawata

Kaoru Yaguchi

A cellular molded article in a mold pattern having a surface skin, which has an excellent releasing property from a metal mold as well as an excellent printing property of a design formed on a surface of the metal mold, and a producing method thereof are provided. The cellular molded article in a mold pattern having the surface skin and a producing method thereof, in which, at least a face of the surface skin material, which contacts the metal mold, is an olefin thermoplastic elastomer sheet which is composed of an olefin resin without containing a polyethylene resin as its matrix, and pre-expanded beads, which are employed for an expansion molding in a mold pattern, are pre-expanded beads of an olefin resin.

Cellular molded article in mold pattern having surface skin and producing method thereof

In a simultaneous molding to one piece, at a time of heat molding of a surface skin material , after an edge part of the surface skin material is folded back to an inside direction of the mold pattern and is formed up a folded back part along a mold pattern for folding back which is placed as in a manner of projecting from an opening edge of a cavity face toward the inside direction of the mold pattern, the mold pattern for folding back is removed, and then at a time of the expansion molding, one face of the folded back part is melt united to one piece with a back face of the cellular molded article in a mold pattern , and at the same time, a folded returning part , which is in a state that an outer edge part of the surface skin material is folded returning toward an outside direction of the mold pattern from a tip of this folded back part , is pressed so as to pile on the other face of the above-mentioned folded back part

Skin-carrying in-mold expanded molded body manufacturing method, the molded body, and mold used for manufacturing the same

This invention relates to a method for producing cellular molded article in mold pattern of synthetic resin having surface skin which is used, for example, as an automobile interior trim material or the like and a mold pattern for producing thereof. This invention aims to provide a method for producing cellular molded article of synthetic resin having surface skin which has good production efficiency and which comprises that cellular molded article of synthetic resin obtained by cellular molding of expanded beads in which poor melt bonding does not occur and thermoplastic resin skin material united with this cellular molded article of synthetic resin which has excellent appearance without residing beads pattern on its surface, and a mold used for producing thereof. In so-called simultaneous united molding, at least the part of one mold part (,) on which thermoplastic resin skin material (,) is set is made of gas permeable metal mold, gas permeable ceramic mold or gas permeable electron casted mold (,) having fine gas permeable holes of not more than,&mgr;m of diameter on the whole surface (,) and at least during steam heating and before expanding expanded beads (,), one mold part (,) on which thermoplastic resin skin material (,) is set is made to be the upper part, and the other mold part (,) is made to be the lower part.

Method of manufacturing skin-carrying internal-mold expansion molded body of synthetic resin and metal mold used for the same method

A cellular molded article (11) of a polypropylene resin having a skin (8) was produced by placing a skin material (8) on the interior surface of a die A (13), clamping the die A (13) with a die B (14) to form a mold (7), then charging the mold (7) with pre-expanded particles of a polyethylene resin, pre-heating the pre-expanded particles using steam supplied through the vapor holes (4) of the die B (14) at a temperature lower than the temperature at which the pre-expanded particles are melt bonded together, then holding to the pre-expanded particles in said steam, and next performing the main heating of the pre-expanded particles through the die B (14) at a temperature not less than the temperature at which the pre-expanded particles are melt bonded together. At the time of the main heating of the pre-expanded particles through the die B (14), the die A (13) may also be heated up as needed.

Polypropylene resin cellular molded article having a skin and production

A large-sized in-mold expansion-molded article of an olefin synthetic resin having 150 mm or more in thickness, 50% or more in fusion ratio and 10% or less in density distribution is disclosed. The expansion-molded article is obtainable by adoption of a process in which pre-expanded beads are charged into a mold, preheated and steamed before molding. Large-sized expansion-molded article of an olefin synthetic resin 500 mm or even more in thickness is obtainable by the present invention.

Growing community of inventors

Nishinomiya, Japan

Kiyoshi Matsuki