Sumitomo Chemical Company, Limited

Kawasaki Steel Corporation

K-Plasheet Corporation

Kawasaki Steel Corporation Sumitomo Chemical Co., Ltd.

Satoru Funakoshi

Masahito Matsumoto

Syohei Masui

Katsuhiro Nagayama

Hiroyuki Yoshitake

Masami Fujimaki

Yoshihiro Nakatsuji

Toshio Igarashi

Hiroyuki Sugimoto

Yuji Kobayashi

Takeo Kitayama

Shigeyoshi Matsubara

Masayuki Tatsumi

Taiji Matsumoto

Kenzou Chikanari

Nobuhiro Usui

Akihiro Furuta

Shigeyoshi Matubara

Shigeru Takano

Kohsuke Ohtani

Tomoshige Ono

Harunori Fujita

Hitoshi Murotani

Mituaki Sunada

Yukio Nagashima

Mitsuaki Sunada

The present invention provides a speaker grille-integrated foamed thermoplastic resin molding for automotive interior comprising a base portion and a speaker grille wherein at least the base portion has a foamed layer and the foamed layer in the base portion has a density &#x3c1; of not greater than 0.7 g/cmand an average expansion ratio of the speaker grille is 1 to 1.3 times, said molding being lightweight and being strong even in its speaker grille part so that it can be used as a speaker grille-integrated foamed thermoplastic resin molding for automotive interior such as a door trim and an instrument panel.

Foamed thermoplastic resin molding for automotive interior and production method thereof

The present invention intends to provide a thermoplastic resin foam molding comprising a substrate having a foam layer and a projection formed in one piece together with the substrate wherein the projection hardly separates from the substrate and they are firmly jointed together. The invention provides a thermoplastic resin foam molding comprising a substrate and a projection formed in one piece together with the substrate wherein the substrate has a foam layer and a skin layer containing no voids wherein the ratio (R/L) of the curvature R of a joint between the projection and the substrate to the thickness L of the skin layer is from 3 to 50.

Thermoplastic resin foam molding

The present invention provides a method for producing an expanded fiber-reinforced thermoplastic resin molding, the method using a mold comprising a female and male dies and comprising processes for supplying a molten thermoplastic resin containing reinforcing fibers whose average fiber length is maintained at 1 mm or more to between the female and male dies to charge a mold cavity with the molten thermoplastic resin, opening a part or the whole of the mold in the thickness direction of a molding after the charging, and cooling a molding while maintaining a cavity clearance at the thickness of a final molding, the method wherein the mold cavity of the mold is interconnectable to the atmosphere, the method further comprising steps for (a) forming a solidified layer in the surface of the molten thermoplastic resin charged in the mold cavity, followed by (b) breaking at least a part of the solidified surface layer, introducing the air through the broken part concurrently with or after the breakage, and opening a part or the whole of the mold concurrently with the introduction of the air so that a cavity clearance defined there reaches the thickness of the final molding.

Method for the production of an expanded fiber-reinforced thermoplastic resin molding

There is provided a process for producing a multi-layer molded product having a plurality of thermoplastic resin layers. This process provides for (i) a step of supplying first and second molten thermoplastic resins each through first and second resin supplying gates which are temperature-controllable independently of each other, to between female and male molds kept in an open state with a time difference being provided between supply starts of the first and second resins, and (ii) a step of closing the female and male molds after completion of supply of the first and second resins. The process enables production of high-quality multi-layer molded products having a plurality of resin layers with good repeatability under relatively low resin supply pressure and by single mold closing. Further, high-quality multi-layer molded products can readily be produced without restrictions on materials used.

Process for producing multi-layer molded product

A hollow molded article having no sink marks on its surface and having an excellent appearance is produced by filling a mold cavity with a resin being in a molten state and then ejecting at least a part of the resin by sucking through a resin-ejection opening and introducing gas through a gas-introduction opening into the resin inside of which being in a negative pressure. According to this process, the use of a high-pressure gas is not required.

Process for producing thermoplastic resin hollow molded article

A multi-layer molded article having a skin material layer made of a vinyl chloride resin, a propylene resin core, and an adhesive layer present between the skin material layer and the core, in which the adhesive layer includes (A) a layer having (a) a sublayer containing a polyester resin and an epoxy group-containing ethylene copolymer, which is bonded to the skin material of the vinyl chloride resin, and (b) a sublayer containing at least one copolymer selected from an ethylene copolymer and an epoxy group-containing copolymer, which is bonded to said propylene resin core, or (B) a layer obtained from an ethylene resin composition containing a polybasic carboxylic acid and an epoxy-group containing copolymer (c) which contains ethylene units, unsaturated carboxylic acid glycidyl ester units or unsaturated glycidyl ether units and an ethylenically unsaturated ester units other than the unsaturated carboxylic acid glycidyl ester units.

Method for producing a multi-layer molded article

Sound absorbing component

An acoustic absorbing component comprising a fiber-reinforced thermoplastic resin expanded body having a percentage of void not less than 50 vol %, and a resin molded body. The fiber-reinforced thermoplastic resin expanded body is fused under a pressure to at least a part of a surface of said resin molded body.

Acoustic absorbing component and production process thereof

A process for producing a hollow article in an assembly comprising first and second mold members movable relative to each other between a closed position in which an inner surface of the assembly defines a cavity and an open position. The cavity is shaped to define a corresponding configuration to the article. According to this process, a charge containing at least one molten thermoplastic resin is supplied at the first and/or second mold member while the mold members are not in the closed position. The first mold member is moved relative to the second mold member into the closed position so as to define the cavity, and a first clamping force F1 is applied to the first and second mold members. The charge is then compressed within the mold cavity under the first clamping force F1. Thereafter, the clamping force is reduced from the first clamping force F1 to a second clamping force F2 before the molten thermoplastic resin in the mold cavity has completely solidified. A compressed gas is supplied into at least one unsolidified portion of the molten thermoplastic resin subsequent to the step of closing the mold members and before the molten thermoplastic resin in the mold cavity has completely solidified. The molten thermoplastic resin can then be cooled in the mold cavity and solidified while supplying the compressed gas.

Process for producing molded article having a hollow portion from a

A method for producing a fiber-reinforced thermoplastic resin molded article laminated with a skin material comprises the steps of: providing a mold assembly including a first mold and a second mold; preheating a fiber-reinforced thermoplastic resin sheet; preheating a skin material; supplying the preheated sheet and skin material to between the molds; drawing the preheated skin material under reduced pressure so as to bring the skin material into close contact with a cavity face of the second mold; and moving the molds so as to attain a closed state thereby laminating the sheet and skin material together.

Method for producing fiber-reinforced thermoplastic resin molded article

Paper-made stampable sheet, light-weight stampable sheet shaped body and

A process for producing a fiber-reinforced thermoplastic resin molded article including: (a) projecting a sheet-holding member from a cavity face of a lower mold towards a cavity face of an upper mold, (b) placing a heated fiber-reinforced thermoplastic resin sheet on the sheet-holding member, (c) closing the upper and lower molds, (d) in the step of closing the upper and lower molds, putting the sheet-holding member into the lower mold before the cavity face of the upper mold contacts with the resin sheet, (e) maintaining the upper and lower molds in a closed state, and (f) opening the upper and lower molds and removing the molded article. A fiber-reinforced thermoplastic resin molded article which has a good surface appearance and, if any, whose protrusions such as ribs and bosses are sufficiently filled with thermoplastic resin and reinforcing fibers, can be produced, without using an additional thermoplastic resin sheet and without repeating the molding process.

Process for producing a fiber-reinforced thermoplastic resin molded

A mold assembly for producing a fiber-reinforced thermoplastic resin molded article laminated with a skin material comprises: a first mold having a first cavity face; a second mold having an indentation whose bottom surface forms a second cavity face; a driving unit for reciprocating the mold connected thereto; and a cutting blade, attached to the first mold, having a cutting edge opposed to the second cavity face of the second mold, the cutting edge being relatively moved, at closing operation, along an inner peripheral side surface of the second mold with a predetermined clearance with respect to the inner peripheral side surface.

Mold assembly for producing fiber-reinforced thermoplastic resin molded

The present invention provides a polyethylenic foaming composition comprising (a) 100 parts by weight of an ethylenic copolymer having glycidyl groups consisting of 20 to 99.9% by weight of ethylene units, 0.1 to 30% by weight of a unit of a glycidyl ester of an unsaturated carboxylic acid or an unsaturated glycidyl ether, and 0 to 50% by weight of ethylenically unsaturated ester units other than a glycidyl ester, (b) 0.1 to 30 parts by weight of a carboxylic acid having 2 or more carboxyl groups and a molecular weight of 1500 or less, and (c) 0.1 to 20 parts by weight of a foaming agent of a thermal decomposition type. The present invention also provides a polyethylenic foam molded from said foaming composition. In addition, the present invention provides a molded composite foam having a foam layer molded from a powder of said foaming composition and a non-foam layer molded from a composition powder containing a certain thermoplastic elastomer, as well as a multilayer molded article containing said molded composite foam.

Polyethylenic foaming compositions and molded foams

The present invention provides a polyethylenic foaming composition comprising (a) 100 parts by weight of an ethylenic copolymer having glycidyl groups consisting of 20 to 99.9% by weight of ethylene units, 0.1 to 30% by weight of a unit of a glycidyl ester of an unsaturated carboxylic acid or an unsaturated glycidyl ether, and 0 to 50% by weight of ethylenically unsaturated ester units other than a glycidyl ester, (b) 0.1 to 30 parts by weight of a carboxylic acid having 2 or more carboxyl groups and a molecular weight of 1500 or less, and (c) 0.1 to 20 parts by weight of a foaming agent of a thermal decomposition type. The present invention also provides a polyethylenic foam molded from said foaming composition. In addition, the present invention provides a molded composite foam having a foam layer molded from a powder of said foaming composition and a non-foam layer molded from a composition powder containing a certain thermoplastic elastomer, as well as a multilayer molded article containing said molded composite foam. According to the present inventive polyethylenic foaming composition, a foam having excellent lightness in weight, excellent cleanness, uniformly foamed cells, high expansion ratio, and excellent impact resilience can be obtained.

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Osaka, Japan

Satoru Funakoshi