GB2211191A - Polypropylene resin foamed sheet for thermoforming and process for producing the same - Google Patents
Polypropylene resin foamed sheet for thermoforming and process for producing the same Download PDFInfo
- Publication number
- GB2211191A GB2211191A GB8824251A GB8824251A GB2211191A GB 2211191 A GB2211191 A GB 2211191A GB 8824251 A GB8824251 A GB 8824251A GB 8824251 A GB8824251 A GB 8824251A GB 2211191 A GB2211191 A GB 2211191A
- Authority
- GB
- United Kingdom
- Prior art keywords
- sheet
- polypropylene resin
- foamed sheet
- ditto
- thermoforming
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 229920005989 resin Polymers 0.000 title claims description 86
- 239000011347 resin Substances 0.000 title claims description 86
- -1 Polypropylene Polymers 0.000 title claims description 56
- 239000004743 Polypropylene Substances 0.000 title claims description 52
- 229920001155 polypropylene Polymers 0.000 title claims description 52
- 238000003856 thermoforming Methods 0.000 title claims description 28
- 238000000034 method Methods 0.000 title claims description 14
- 230000008569 process Effects 0.000 title claims description 12
- 239000000843 powder Substances 0.000 claims description 22
- 238000001125 extrusion Methods 0.000 claims description 18
- 238000010438 heat treatment Methods 0.000 claims description 12
- 238000001816 cooling Methods 0.000 claims description 11
- 150000001875 compounds Chemical class 0.000 claims description 6
- 238000005187 foaming Methods 0.000 claims description 4
- 238000013329 compounding Methods 0.000 claims description 3
- 229920005992 thermoplastic resin Polymers 0.000 claims description 2
- 239000004604 Blowing Agent Substances 0.000 description 11
- 239000002216 antistatic agent Substances 0.000 description 10
- 239000000454 talc Substances 0.000 description 10
- 229910052623 talc Inorganic materials 0.000 description 10
- 239000000203 mixture Substances 0.000 description 9
- OFBQJSOFQDEBGM-UHFFFAOYSA-N n-pentane Natural products CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 8
- 238000007639 printing Methods 0.000 description 7
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 6
- 239000001273 butane Substances 0.000 description 6
- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 6
- 238000003851 corona treatment Methods 0.000 description 6
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical compound CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 6
- 239000002245 particle Substances 0.000 description 6
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 5
- 239000008188 pellet Substances 0.000 description 5
- UIIMBOGNXHQVGW-UHFFFAOYSA-M Sodium bicarbonate Chemical compound [Na+].OC([O-])=O UIIMBOGNXHQVGW-UHFFFAOYSA-M 0.000 description 4
- 238000009740 moulding (composite fabrication) Methods 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- 238000005452 bending Methods 0.000 description 3
- 229910000019 calcium carbonate Inorganic materials 0.000 description 3
- 229920001577 copolymer Polymers 0.000 description 3
- 208000028659 discharge Diseases 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 238000004806 packaging method and process Methods 0.000 description 3
- 229920005990 polystyrene resin Polymers 0.000 description 3
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 3
- 239000003381 stabilizer Substances 0.000 description 3
- 239000007858 starting material Substances 0.000 description 3
- 239000004094 surface-active agent Substances 0.000 description 3
- OZAIFHULBGXAKX-UHFFFAOYSA-N 2-(2-cyanopropan-2-yldiazenyl)-2-methylpropanenitrile Chemical compound N#CC(C)(C)N=NC(C)(C)C#N OZAIFHULBGXAKX-UHFFFAOYSA-N 0.000 description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 239000007864 aqueous solution Substances 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- 238000007664 blowing Methods 0.000 description 2
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
- 229910052570 clay Inorganic materials 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 238000005098 hot rolling Methods 0.000 description 2
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 2
- 239000001095 magnesium carbonate Substances 0.000 description 2
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 2
- 229920001384 propylene homopolymer Polymers 0.000 description 2
- 238000007665 sagging Methods 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 229910000030 sodium bicarbonate Inorganic materials 0.000 description 2
- 235000017557 sodium bicarbonate Nutrition 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- DDMOUSALMHHKOS-UHFFFAOYSA-N 1,2-dichloro-1,1,2,2-tetrafluoroethane Chemical compound FC(F)(Cl)C(F)(F)Cl DDMOUSALMHHKOS-UHFFFAOYSA-N 0.000 description 1
- LRSXQYQQRNVTJK-UHFFFAOYSA-N 1-amino-3-(benzenesulfonamido)urea Chemical compound NNC(=O)NNS(=O)(=O)C1=CC=CC=C1 LRSXQYQQRNVTJK-UHFFFAOYSA-N 0.000 description 1
- NBOCQTNZUPTTEI-UHFFFAOYSA-N 4-[4-(hydrazinesulfonyl)phenoxy]benzenesulfonohydrazide Chemical compound C1=CC(S(=O)(=O)NN)=CC=C1OC1=CC=C(S(=O)(=O)NN)C=C1 NBOCQTNZUPTTEI-UHFFFAOYSA-N 0.000 description 1
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 1
- 239000004156 Azodicarbonamide Substances 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- 239000005909 Kieselgur Substances 0.000 description 1
- CBENFWSGALASAD-UHFFFAOYSA-N Ozone Chemical compound [O-][O+]=O CBENFWSGALASAD-UHFFFAOYSA-N 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 150000008065 acid anhydrides Chemical class 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 235000019593 adhesiveness Nutrition 0.000 description 1
- 239000003570 air Substances 0.000 description 1
- 150000001298 alcohols Chemical class 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 239000010425 asbestos Substances 0.000 description 1
- XOZUGNYVDXMRKW-AATRIKPKSA-N azodicarbonamide Chemical compound NC(=O)\N=N\C(N)=O XOZUGNYVDXMRKW-AATRIKPKSA-N 0.000 description 1
- 235000019399 azodicarbonamide Nutrition 0.000 description 1
- 239000000440 bentonite Substances 0.000 description 1
- 229910000278 bentonite Inorganic materials 0.000 description 1
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 1
- VJRITMATACIYAF-UHFFFAOYSA-N benzenesulfonohydrazide Chemical compound NNS(=O)(=O)C1=CC=CC=C1 VJRITMATACIYAF-UHFFFAOYSA-N 0.000 description 1
- 239000000378 calcium silicate Substances 0.000 description 1
- 229910052918 calcium silicate Inorganic materials 0.000 description 1
- GBAOBIBJACZTNA-UHFFFAOYSA-L calcium sulfite Chemical compound [Ca+2].[O-]S([O-])=O GBAOBIBJACZTNA-UHFFFAOYSA-L 0.000 description 1
- 235000010261 calcium sulphite Nutrition 0.000 description 1
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 239000002666 chemical blowing agent Substances 0.000 description 1
- NEHMKBQYUWJMIP-NJFSPNSNSA-N chloro(114C)methane Chemical compound [14CH3]Cl NEHMKBQYUWJMIP-NJFSPNSNSA-N 0.000 description 1
- HRYZWHHZPQKTII-UHFFFAOYSA-N chloroethane Chemical compound CCCl HRYZWHHZPQKTII-UHFFFAOYSA-N 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 235000009508 confectionery Nutrition 0.000 description 1
- 239000007822 coupling agent Substances 0.000 description 1
- GUJOJGAPFQRJSV-UHFFFAOYSA-N dialuminum;dioxosilane;oxygen(2-);hydrate Chemical compound O.[O-2].[O-2].[O-2].[Al+3].[Al+3].O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O GUJOJGAPFQRJSV-UHFFFAOYSA-N 0.000 description 1
- PXBRQCKWGAHEHS-UHFFFAOYSA-N dichlorodifluoromethane Chemical compound FC(F)(Cl)Cl PXBRQCKWGAHEHS-UHFFFAOYSA-N 0.000 description 1
- 229910001873 dinitrogen Inorganic materials 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 239000010459 dolomite Substances 0.000 description 1
- 229910000514 dolomite Inorganic materials 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 229960003750 ethyl chloride Drugs 0.000 description 1
- 239000005038 ethylene vinyl acetate Substances 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 229920006379 extruded polypropylene Polymers 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 description 1
- 239000000347 magnesium hydroxide Substances 0.000 description 1
- 229910001862 magnesium hydroxide Inorganic materials 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 229910052901 montmorillonite Inorganic materials 0.000 description 1
- 238000007645 offset printing Methods 0.000 description 1
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 239000001294 propane Substances 0.000 description 1
- 229920005653 propylene-ethylene copolymer Polymers 0.000 description 1
- 239000008262 pumice Substances 0.000 description 1
- 238000000197 pyrolysis Methods 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- 229910000077 silane Inorganic materials 0.000 description 1
- 150000004760 silicates Chemical class 0.000 description 1
- 239000000344 soap Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000005437 stratosphere Substances 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
- LSNNMFCWUKXFEE-UHFFFAOYSA-L sulfite Chemical class [O-]S([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-L 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 229960005196 titanium dioxide Drugs 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- CYRMSUTZVYGINF-UHFFFAOYSA-N trichlorofluoromethane Chemical compound FC(Cl)(Cl)Cl CYRMSUTZVYGINF-UHFFFAOYSA-N 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/07—Flat, e.g. panels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/07—Flat, e.g. panels
- B29C48/08—Flat, e.g. panels flexible, e.g. films
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
- B29C48/10—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels flexible, e.g. blown foils
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
- B29C48/11—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/13—Articles with a cross-section varying in the longitudinal direction, e.g. corrugated pipes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
- B29C48/911—Cooling
- B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
- B29C48/914—Cooling of flat articles, e.g. using specially adapted supporting means cooling drums
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/002—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor characterised by the choice of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B1/00—Layered products having a non-planar shape
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/0066—Use of inorganic compounding ingredients
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
- B29K2023/10—Polymers of propylene
- B29K2023/12—PP, i.e. polypropylene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/025—Polyolefin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/02—Cellular or porous
- B32B2305/022—Foam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2439/00—Containers; Receptacles
- B32B2439/70—Food packaging
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
- C08J2323/10—Homopolymers or copolymers of propene
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- Medicinal Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
- Molding Of Porous Articles (AREA)
- Laminated Bodies (AREA)
Description
221119 POLYPROPYLENE RESIN FOAMED SHEET FOR THERMOFORMING AND PROCESS FOR
PRODUCING THE SAME
FIELD OF THE INVENTION
This invention relates to a polypropylene resin foamed sheet containing a large quantity of an inorganic fine powder which is suitable for thermoforming and to a process for producing the same. More particularly, it relates to a polypropylene resin foamed sheet having thermoforming excellent deep drawing/ properties and satisfactory properties to keep the pattern printed thereon in a predetermined position upon thermoforming.
BACKGROUND OF THE INVENTION
Known thermoforming foamed sheets include a - polystyrene resin foamed sheet containing a large quantity of an inorganic fine powder as disclosed in U.S. Patent 4,426,065 and a po-lypropylene resin foamed sheet containing a large quantity of an inorganic fine powder as disclosed. in JP-A-60-141728 (the term "JP-A" as used herein means an "unexamined published Japanese patent application"). Since the polystyrene resin foamed sheet is poor in heat resistance and oil resistance, formed articles such as trays and containers obtained therefrom are incapable of use in a radar range, and the sheet is unsuitable for producing deep draws such as cups.
Further, it is poor in impact resistance and tensile 1 strength.
The above-stated polypropylene resin foamed sheet shows improved heat resistance permitting of use in a radar range and improved deep drawing properties as compared with the polystyrene resin foamed sheet. flowever, when the sheet having printed thereon a prescribed pattern is subjected to thermoforming, the pattern is liable to be shifted or deformed each time it is formed. Further, when the extruded sheet is taken off along a plug, it shows resistance against the cyclindrical plug to slow down the take-off speed or cause tearing of the sheet.
SUMMARY OF THE INVENTION
Accordingly, one object of this invention is is to provide a polypropylene resin foamed sheet having excellent thermoforming properties including deep drawing properties and formability to complicated shape.
Another object of this invention is to provide a polypropylene resin foamed sheet with a printed pattern which can be thermoformed without shift or deformation of the pattern. A still another object of this invention is to provide a polypropylene foamed sheet having heatand oil-resistance enough for use in a radar range. 25 A yet another of this invention is to provide 2 a polypropylene resin foamed sheet having excellent mechanical properties including impact resistance, hinge effect, softness, tensile strength, and bending strength.
A further object of this invention is to provide a polypropylene resin foamed sheet having satisfactory printability.
A still further object of this invention is to provide a polypropylene resin foamed sheet which can be handled with a reduced combustion calory after disposal.
A yet further object of this invention is to provide an advantageous process for producing the above-described polypropylene resin foamed sheet which can be carried out in a continuous system by reducing the resistance of an extruded sheet against a cyclindrical plug for taking off and cooling.
As a result of extensive and intensive investigations, it has now been found that the above objects of this invention can be accomplished by an extruded foamed sheet of a polypropylene resin compounded with a large quantity of an inorganic fine powder, said sheet having specific thickness, density, and a balance of shrinkage between the longitudinal direction and the crosswise direction and by an extrusion process drum wherein a cylindrical q having a twice or three times 3 larger diameter than an extrusion die is used for cooling and taking off. The present invention has been completed based on these findings.
The present invention provdies an extruded polypropylene resin foamed sheet for thermoforming having compounded therein from 10 to 50% by weight of an inorganic fine powder, said sheet having a density of from 0.2 to l.'2 alcm3and a thickness of from 0.2 to 3 mm and having a percent shrinkage of from 5 to 30% in each of the longitudinal and crosswise directions on heating at 1900C for 30 minutes, with the. ratio of a residual rate in the Iongitudirral directi- on-ta that in the crosswise direction being from 1:0.7 to 1:1A.
The present invention further provides a process for producing the above-described polypropylene resin foamed sheet for thermoforming which comprises uniformly compounding a polypropylene resin with an inorganic fine powder and- extruding and foaming the resin compound, wherein said inorganic fine powder is compounded in an amount of from 10 to 50% by weight based on the polypropylene resin, extruding and foaming the resulting compound from a ring die of an extruder, and cooling drum the extruded foamed sheet along a cylindrical whose diameter is 2.0 to.3.0 times that of said ring die, 4 followed by taking up.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Figure 1 is a plan view of the polypropylene resin foamed sheet obtained in Examplesand Comparative Examples.
Figure 2(a) is a plan view of a container obtained by thermoforming of the foamed sheet of Fig. 1, and Figure 2(b) is a coss-sectional view of said container having been trimmed.
Figure 3 is a photograph taken from the upper side of a container obtained by thermoforming the polypropylene resin foamed sheet of the invention.
Figure 4 is a photograph taken from the upper side of a container obtained by thermoforming the is comparative foamed.sheet.
and (d) Figures 3(a), (b). (c)/each shows a side view, a developed plan view, =a;a& a cross-sectional view, and a photograph, /respectively, of a doll-shaped container formed from the polypropylene foamed sheet of the invention.
Figures 4(a) and (b) each shows a perspective view and a cross-sectional view, respectively, of a lidded container formed from the polypropylene foamed sheet of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The polypropylene resin which can be used in the present invention includes a propylene homopolymer and copolymers mainly comprising propylene, e.g., a propylene-ethylene copolymer, a propylene-ethylene-diene copolymer, etc. A melting point of the propylene homopolymer is 17CC, and that of the propylene copolymer is between 135C and 16CC. The higher the melting point, the higher the heat resistance of the resulting foamed sheet. These resins may contain other resins compatible with the polypropylene resin, such as polyethylene and an ethylene-vinyl acetate copolymer, in minor proportions.
The inorganic fine powder to be compounded with the polypropylene resin includes oxides, e.g., silica, diatomaceous earth, alumina, titanium -oxide, iron oxide, zinc oxide, magnesium oxide, pumice powder, etc.; hydroxies, e.g., aluminum hydroxide, magnesium hydroxide, basic magnesium carbonate, etc.; carbonates, e.g., calcium carbonate, magnesium carbonate, dolomite, etc.; sulfates or sulfites, e.g., calcium sulfate, barium sulfate, calcium sulfite, etc.; silicates, e.g., talc, clay, mica, asbestos, calcium silicate, montmorillonite, bentonite, etc.; and metallic powders, e.g., powders of aluminum, iron, zinc, etc. These inorganic substances may be used either individually or in combinations of two or more thereof. Particularly preferred of them are talc, calcium carbonate, clay, silica, and alumina each having an 6 0 average particle size of from 1 to 30 pm.
The amount of the inorganic fine powder to be compounded ranges from 10 to 50% by weight, preferably from 20 to 35% by weight, based on the polypropylene resin. If it is less than 10% by weight, the sheet cannot be sufficiently formed to shape, particularly to complicated shape and, moreover, the calory required for thermal disposal would be increased. On the other hand, if it exceeds 50% by weight, not only drawing tolerance of the foamed sheet is reduced, resulting in the failure of deep draw, but the sheet would have reduced mechanical properties, such as impact resistance and hinge strength, poor appearance, and deteriorated printability- The inorganic fine powder should be uniformly mixed and dispersed in the polypropylene resin. For the purpose of improving compatibility between the resin and- the inorganic powder, it is preferable to add a small amount of a silane or titanium coupling agent commonly employed in the art, a surface active agent for dispersion aid, a metallic soap, a polyhydric alcohol, an acid anhydride or the like additive.
Since the foamed sheet of the present invention contains the inorganic powder in such a high proportion as recited, not only the calory required for combusting 7 the waste can be so decreased to facilitate thermal disposal of the waste but also the unit cost of the sheet would be decreased.
A blowing agent which can be used in the present invention includes --blowing agents which are gaseous --at ambient temperature, e.g., nitrogen gas, carbon dioxide, and air; volatile blowing agents, e.g., water, alcohols, propane, butane, pentane, Freon 11, 12 and 114 (tradenames of E.I. Du Pont), methyl chloride, and ethyl chloride; and chemical blowing agents decomposable on heating, e.g., azodicarbonamide, N,W-dinitrosopenta methylenetetramine, p,p'-oxybis(benzenesulfonylhydrazide)I PIP f-oxybis(benzenesulfonylcarbazide), azobisisobutyro nitrile, benzenesulfonyl hydrazide, and a mixture of sodium hydrogencarbonate and citric acid. In the production of the foamed sheet of the present invention, a relatively small amount of these blowing agents would be enough. That is, the blowing agent is usually used in an amount of from 0.5 to 10% by weight, preferably from 0.5 to 2.0%, based on the resin.
The foamed sheet according to the present invention can generally be produced in a continuous system by the use of an extruder. The polypropylene resin and the inoganic powder are fed to an extruder and heat-melted together with a blowing agent, or the Further, it is easy to choose hydrocarbon type blowing agents or pyrolysis type blowing agnets which do not - 8 - destroy the ozone layer in stratosphere.
e blowing agent is fed to the midway of an extruder and kneaded well with the resin. The resin compound is set at a temperature suited for foaming and forwarded to an extrusion die. The resin temperature at the die is adjusted to 180C to 240C, and the temperature of the die is adjusted at a temperature lower than the resin temperature by 10 to 60C. The die to be used includes a coathanger die or a T die having a slit whose width is greater than the thickness of the tip and a ring die having a cylindrical form and a ring orifice at the tip thereof. When the former type. of die is used, the extruded sheet is cooled by a chill roll while controlling the degree of stretching in the extrusion direction by adjusting the pulling speed and stress. If desired, the stretching in the cross direction can be controlled by clamping. In cases where the latter type of die (ring die) is used, the tubular foamed sheet extruded from the ring orifice is chilled by air blast and also by drum pulling the sheet around and along a cylindrical =ia while controlling the extrusion direction stretch by utilizing the pulling speed and stress and the cross drum direction stretch by adjusting the diameter of the The orifice of the ring die usually has a width of from 0.2 to 1.4 mm. A ratio of the diameter of the drum p"wg to the diameter of the ring die, i.e., a blow-up 9 1 ratio, is set in the range of from 2.0 to 3.0. If the blow-up ratio is less than 2.0, it would be difficult to balance the residual dimensions in the extrusion direction (or longitudinal direction) and the crosswise direction after heat shrinkage. Achievement of a blow-up ratio exceeding 3.0 is virtually difficult because of such a large proportion of the compounded inorganic fine powder.
drum It is preferable that the cylindrical @Q=" be composed of a firstor front cylinder and a second or rear cylinder having a slightly smaller diameter than 1 the front cylinder. In this case, the resistance of drum the tubular foamed sheet to the due to shrinkage upon chilling can be lessened whereby the tubular sheet can be pulled more smoothly and taken up more easily around a take-off roll. The thus increased take-off speed would lead to improvement of productivity.
It is also possible to facilitate introduction drum of the extruded tubular sheet to the =PAa4 by raising drum the temperature of the frontgslttg.
By controlling the extrusion conditions, such as resin feed, amount of a blowing agent, size of the die orifice, die temperature, blow-up ratio, chilling temperature, pulling speed, and the like, as described above, there can be produced a polypropylene resin foamed 1 sheet having a density of from 0.2 to 1.2 g/cm 3 and a thickness of from 0.2 to 3 mm, preferably from 0.2 to 2.0 mm, and having a percent shrinkage of from 5 to 30%, preferably from 10 to 25%, in the longitudinal or crosswise direction on heating at 190C for 30 minutes, with the ratio of a residual rate in the longitudinal direction to that in the crosswise direction being from 1:07 to 1:1.1.
If the density of the sheet is less than 3 0.2 g/cm ' sufficient bending strength cannot be obtained even with the thickness increased, and surface smoothness of the sheet is deteriorated, making clear printing 3 difficult. If the density exceeds 1.2 g/cm the sheet undergoes sagging by gravity on thermoforming.
If the thickness of the sheet is less than 0.2 mm, such a thin sheet finds difficulty in smoothly drum introducing itself to the cylindrical and is unapplicable as thermoforming material due to its insufficient bending strength. Besides, holes would be formed at the time of preheating before thermoforming.
On the other hand, if the thickness exceeds 3.0 mm, the drum cylindrical..p meets with resistance while the extruded tubular sheet passes on, thus making take-up of the sheet difficult. Further, the sheet fails to have a smooth surface suitable for printing. From the standpoint of 0 ease of take-up, a preferred thickness of the sheet is 2.0 mm or less. oil resistance The thermoforming properties/and other physical properties of the foamed sheet according to the present invention can further be improved by laminating with a thermoplastic resin film having adhesiven ess.
The phrase "on heating at 190C for 30 minutes" as used in the present invention means that the resin foamed sheet is heated for 30 minutes at a temperature higher than the melting point of a crystalline polypropylene resin by at least 2CC. Such heating provides a condition that -the crystalline structure of the polypropylene resin foamed sheet may entirely disappear and the residual stress may be removed completely. When the foamed sheet is heated under such a condition, if the heat percent shrinkage of the foamed sheet is less than 5%, the sheet undergoes sagging by gravity on preheating in an oven before thermoforming td cause a-shift of position for forming. If it is more than 30%, the sheet is incapable of deep drawing. Further, the sheet shrinks on removal from a preheating plate, resulting in removal from a forming tool or the position of the printed pattern may be shifted from the predetermined position.
12 - If the ratio of a residual rate in the longitudinal direction to that in the crosswise direction is less 1:0.7, the positional shift of the printed pattern would be serious to cause unpredictable distortion of the pattern on thermoforming. On the other hand, if the ratio of a residual rate in the longitudinal direction to that in the crosswise direction exceeds 1:1. 1, in introducing a tubular polypropylene resin foamed sheet into the drum, the drum meets with resistance, thus making pass along the drum and take-up of the sheet difficult. Furthermore, the clamps at the both ends are left on thermoforming, thus making it difficult to obtain good molded artciles.
- 33 For the purpose of increasing a printing speed and avoiding' dust collection, an antistatic agent may be incorporated into the resin compound or coated thinly on the surface of the sheet to control the surface resistivity within a range of from 10 8 to 10 12 2.
The terminology "surface resistivity" as used herein means a value obtained by measurement 2 weeks after extrusion at 23C and 60% RH according to JIS-K 6911.
When the resin foamed sheet for thermoforming is printed with a printing ink to form a pattern, adhesion of the printing ink to the sheet can be ensured by increasing the surface tension of the sheet. To this effect, an index of wettability, indicative of surface 15. tension, of the sheet is preferably increased to 40 dyne/cm or more. Such can be done by incorporating a surface active agent into the resin compund or thinly applying a surface active agent on the surface of the sheet, or by solvent treatment, or desirably by corona - 1k - discharge treatment or plasma discharge treatment.
The terminology "index of wettability" as used herein means a value obtained by measurement 2 weeks after extrusion at 23C and 50% RH in accordance with JIS-K 6768.
The extruded foamed sheet taken off and rolled up can be subjected to thermoforming as such. If desired, the rolled-up sheet may be unrolled, contacted with a hot roll under tension to be flattened, cut to size, and printed. The cut-to-size foamed sheets can be printed by unexpensive offset printing. The foamed sheet exhibits satisfactory receptivity and adhesion to a printing ink and, because of its light weight, does not cause ink offset even when piled up one on another. Further, owing to the antistatic treatment, the sheets are prevented from turning -up during high-speed printing so that a pattern can be formed in position and the resulting formings have the printed pattern in position.
The present invention is now illustrated in greater detail with reference to Examples and Comparative Examples, but it should be understood that the present invention is not deemed to be limited thereto. In these examples, all the parts are by weight.
EXAMPLE 1
A mixture of 70 parts of a polypropylene resin (a base resin of "Noblen D501" produced by Sumitomo Chemical Co., Ltd.), 0.1 part of a stabilizer ('SHV produced by Sumitomo Chemical), and 30 parts of talc having an average particle size of 8 lim was extruded to obtain pellets.
A hundred parts of the pellets were mixed with 1 part of an antistatic agent ("ElectrostriiDper TS-2" Corporation produced by Kao and the mixture was supplied to an extruder having a cylinder diameter of 65 mm fitted with a ring die having a diameter of 105 mm and an orifice width of 0.45 mm. The cylinder temperature was set at 200 to 230C, and about 0.5 part of butane was fed to the midway of -the cylinder under pressure.
The compounded resin was extruded from the orifice and is foamed at a resin temperature of 200C and a die temperature lower than the resin temperature by about 100C. The extrusion output was 25 kg/hr. The outer side of the extruded and foamed tubular sheet was cooled 2 with a light wind (1.0 kg/cm or less) blown from an air ring provided concentrically with the ring die and at a distance within 20 mm from the die.
The tubular sheet was taken off while cooling drum along a cylindrical which comprised a first (front) cylinder having a front diameter of 240 mm, a rear diameter of 239 mm, and a length of 50 mm and a second 1 (rear) cylinder having a front diameter of 235 mm, a rear diameter of 234 mm, and a length of 300 mm which were placed side by s ide in the extrusion direction with a small gap therebetween. The blow-up ratio was 2.29. The cooling:-temperature of the first cyclinder was set higher than that of the second cyclinder by.about 300C so as to lessen the resistance of the sheet. The thus cooled tubular sheet was cut open along the extrusion direction with a cutter fitted to the rear end of the second cyclinder and then taken up in the form of roll. The resulting web of resin foamed sheet had a thickness of 0.74 mm, a width of 750 mm, and a densiy of 0.73 g/cm 3.
A 100-by-100 mm square was cut out of the web and heated in an oven set at 190C for 30 minutes. After th6 heating, the residual dimentions were 74 mm in the longitudinal direction (percent shrinkage: 26%) and 81 mm in the crosswise direction (percent shrinkage: 19%). Therefore, the ratio of a residual rate in the longitudinal direction to that in the (hereinafter referred to as RD ratio) was 0.91. The sheet had a surface resistivity of 10 11 51 and an index of wettability of 32 dyne/cm.
crosswise direction 17 The rolled up sheet as above obtained was unrolled and sent to a pair of adjacent hot rolls at 1500C in the S-shape with respect to the surfaces of the hot rolls. Thereafter, the both surfaces of the sheet were successiv61y contacted and heated, followed by sending to a pair of adjacent chill rolls in the S-shape with respect to the surfaces of the chill rolls. Then, the both surfaces of the sheet were contacted and chilled and simultaneously taken up 10 while applying a tension. By this hot-rolling, Is - 1 deformation of the sheet, such as curling, was corrected and the foamed sheet was leveled to have a uniform thickness of 0.72 mm. After the hot-rolling, both sides of the sheet were subjected to corona discharge treatment to improve printability, and the sheet was then cut to' "650 mm in width and 950 mm in length. The density of the resulting sheet was 0.72 g/cm 3 and a flatness of not more than 2 mm per m. The flatness could be determined by placing the sheet on a flat plate and measuring a maximum height of the wave per m (hereinafter the same).
A 100 mm square was cut out of the above-obtained cut-to-size sheet and heated in an oven at 190C for minutes. After the heating, the residual dimention in the longitudinal direction was 71 mm (percent shrinkage: 29%) and that in the crosswise direction was 83 mm (percent shrinkage: 17%), with the RD ratio being 0.86. The index of wettability was 46 dyne/cm.
EXAMPLE 2
A polypropylene foamed sheet was produced in the same manner as in Example 1, except for using no antistatic agent.
The web of the foamed sheet taken up in the form of roll had a thickness of 0.73 mm, a width of 750 3 mm, a density of 0.72 g/cm and a surface resistivity 1 of 10 17 2.
When a 100 mm square cut out ofthe web was heated in the same manner as in Example 1, the residual dimention in the longitudinal direction was 79 mm (percent shrinkage: 21%) and that in the crosswise direction was t4 mm (percent shrinkage: 16%), with the RD ratio being 0.94.
The sheet was hot-rolled for flattening, subjected to corona discharge treatment, and cut to size (width: 640 mm; length: 950 mm) in the same manner as in Example 1 to obtain a sheet having a thickness of 0.72 mm, a density of 0.74 g/cm 3, an index of wettability of 44 dyne/cm, and a flatness of 2 mm/m or less When a 100 mm square cut out of the cut-to-size sheet was heated in the same manner as in Example 1, the residual dimention in the longitudinal direction was 74 mm (percent shrinkage: 26%) and that in the crosswise direction was 85 mm (percent shrinkage: 15%), with the RD ratio being 0.87.
EXAMPLE 3
A mixture of 50 parts of a polypropylene resin ("Noblen AD 571" produced by Sumitomo Chemical), 20 parts of a high-density polyethylene resin ("Yukalon HD JX-1011 produced by Mitsubishi Petrochemical Co., Ltd.), and L parts of calcium carbonate having an average particle size of 4.5 pm U'Sunlight #70011 produced by Takehara Kagaku Co., Ltd.) was kneaded and pelletized in an extruder. The pellets were processed in the same manner as in Example 1 to -obtain a web of resin foamed sheet the form of roll.
The foamed sheet had a thickness of 0.80 mm, 3 a web width of 750.mm, a density of 0.70 g/cm ' a surface resistivity of 10 11 2 and an index of wettability of 32 dyne/cm.
When a 100 mm square cut out of the web was heated in the same manner as in Example 1, the residual dimention in the longitudinal direction was 76 mm (percent .shrinkage: 24%) and that in the crosswise direction was is 88 mm (percent shrinkage: 12%), with the RD ratio being 0.86.
EXAMPLE 4
A polypropylene resin foamed sheet was produced in the same.manner as in Example 1, except that the resin to talc weight ratio was changed to 80:20, the butane used as a blowing agent was replaced with 1 part of a mixture of sodium hydrogencarbonate and citric acid U'Dai Blow #2" produced by Dainichiseka Colour & Chemical Mfg. Co., Ltd.), and the antistatic agent was not fed to the extruder.
1 The resulting web of foamed sheet taken up in the form of roll had a thickness of 1.10 mm, a width 3 of 750 mm, a density of 0.50 g/cm and a surface resistivity of 10 16 2.
After the heat shrinkage in the same manner as in Example 1, the residual dimension in the longitudinal direction was 75 mm (percent shrinkage:
25%) and that in the corsswise direction was 90 mm (percent shrinkage: 10%), with the RD ratio being 0.83.
The rolled web was unrolled, and an aqueous solution of an antistatic agent ("Hostastat HS-1" produced by Hoechst) was coated thinly on both sides of the web.
Then, the sheet was hot-rolled, subjected to corona discharge treatment to impart printa bility, and cut to size (width: 650 mm; length: 950 mm) in the same manner as in Example 1 The cut-to-size sheet had a thickness of 1.0 mm, a density of 0.52 g/cm 3, a flatness of 2 mm/m or less, a suface resistivity of 10 12 S2, and an index of wettability of 44 dyne/cm.
When a 100 mm square cut out of the cut-to-size sheet was heated in the same manner as in Example 1, the residual dimension in the longitudinal direction was 73 mm (percent shrinkage: 27%) and that in the crosswise direction was 91 mm (percent shrinkage: 9%), with the RD ratio being 0.80.
4 EXAMPLE 5
A propylene resin foamed sheet was produced in the same manner as in Example 4, except for changing the polypropylene resin to talc weight ratio to 60:40.
The resulting web of foamed sheet had a thickness 3 of 1.10 mm, a width of 750 mm, a density of 0.61 g/cm and a surface resistivity of 10 16 2.
When a 100 mm square cut out of the web was heated in the same manner as in Example 1, the residual dimension in the longitudinal direction was 74 mm (percent shrinkage: 26%) and that in the crosswise direction was 78 mm (percent shrinkage 22%), with the RD ratio being 0.95.
The web was coated with an. antistatic agent, subjected to corona discharge treatment, and cut to size (width: 650 mm; length: 950 mm) in the same manner as in Example 4 to prepare sheets having a thickness of 3 1.0 mm, a density of 0.65 g/cm ' a flatness of 2 mm/m or 'less, a' surface resistivity of 10 10 S2, and an index of wettability of 44 dyne/cm.
When a 100 mm square cut out of the sheet was heated in the same manner as in example 1, the residual dimention in the longitudinal direction was 70 mm (percent shrinkage: 30) and that in the crosswise direction was 80 mm (percent shrinkage: 20%), with the RD ratio being 23 - 0 0.87.
EXAMPLE 6
A mixture of 70 parts of a polypropylene resin (base resin of "Noblen D501"), 0.1 part of a stabilizer ("BHT"), and 30 parts of talc having an average particle Size of 8 lim was pelletized in an extruder.
A hundred parts of the pellets were fed to an extruder having a cylinder diameter of 90 mn, fitted with a ring die having a diameter of 180 mm and an orif ice width of 0.50 mm, and extruded and foamed in the vertical direction. The cylinder temperature was set at 200 to 240C, and about 0.5 part of butane was introduced to the midway of the cylinder"under pressure. The compounded resin was extruded from the ring orifice and foamed at a resin temperature of 220C and a die temperature controlled lower than the resin temperature by about 100C. The extrusion output was 80 kg/hr. The outer side of the extruded and foamed tubular sheet was cooled with a light wind (1.0 kg/cm 2 or less) blown from an air ring provided concentrically with the ring die and at a distance within 20 mm from the die. The tubular sheet was takenoff while cooling along a cylindrical plug
which comprised a first (front) cylinder having a front diameter of 455 mm, a rear diameter of 454 mm, and a length of 70 mm and a second 1 (rear) cylLnder having a front diameter of 450 mm, a rear diameter of 448 mm, and a length of 430 mm which were connected vertically with a small gap therebetween. The blow-up ratio was 2.53. The cooling temperature of the first cyclinder was set higher than that of the second cyclinder by about 3CC so as to lessen the resistance of the tubular sheet to the plug. The tubular sheet was cut in two halves along the extrusion direction with two cutters f itted to the rear end of the second cyclinder to obtain two webs, each of which was separately taken up in the form of roll. When a compounding ratio of an inorganic fine powder, e. g., talc, is high as in this example, it is very difficult to introduce the extruded tubular sheet io the cooled cyclinderical plug.
Such being the case, the resin compound can be extruded to the downward direction as in the case of this example to relatively facilitate the introduction to the plug.
The resulting web of foamed sheet had a thickness 3 of 0.73 mm, a width of 700 mm, a densiy of 0.81 g/cm a surface resistivity of 10 16 Q, and an index of wettability of 32 dyne/cm. When a 100 mm square cut out of the web was heated in the same manner as in Example 1, the residual dimension in the longitudinal direction was 85 mm (percent shrinkage: 15%) and that in the crosswise direction was 87 mm (percent shirnkage: 13%), with the RD ratio being 0.98.
The web was unrolled and passed through a pair of hot rolls at 150C, cooled under tension, and taken up to obtain a flattened sheet. In the course of take-up, the both sides of -the web were subjected to corona discharge treatment, and an aqueous solution of an anti static agent ("SAT-5" produced by Nippon Junyaku Co., Ltd.) was atomized and sprayed onto the sheet to form a thin antistatic layer, followed by drying at about 80C. The thus processed web was cut to 650 mm in width and 950 mm in length to obtain sheets having a thickness of 0.72 mm, a density of 0.83 g/cm 3, a flatness of 2 mm/m, a surface resistivity of 10 10 n -and an index of wettability of 48 dyne/cm.
When a 100 mm square cut out of the sheet was heated in the same manner as in Example 1, the residual dimention in the longitudinal direction was 84 mm (percent shrinkage: 16%) and that in the crosswise direction was 87 mm (percent shrinkage: 13%), with the RD ratio being 0.97.
EXAMPLE 7
A polypropylene foamed sheet was produced in the same manner as in Example 6, except for using an extruder fitted with a ring die having a diameter of 180 mm and an orifice width of 0.35 mm.
The resulting web of foamed sheet in the form of roll had a thickness of 0.48 mm, a width of 700 mm, 3 16 a density of 0.43 g/cm ' a surface resistivity of 10 92 2 and an index of wettability of 32 dyne/cm When a 100 -mm square cut out of the web was eated in the same manner as in Example 1, the residual dimention in the longitudinal direction was 80 mm (percent shrinkage: 20%) and that in the crosswise direction was 88 mm (percent shrinkage: 12%), with the RD ratio_ being 0.91.
The web was unrolled, hot-rolled, subjected to corona discharge treatment, coated with an antistatic agent, and cut to size (width: 650 mm; length: 950 mm) to obtain sheets having a thickness of 0.46 mm, a density of 0.46 g/cm 3, a flatness of 1'mm/m or less, a surface resistivity of 10 10 n, and anindex of wettability of 49 dyne/cm.
When a 100 mm square cut out of the sheet was heated in the same manner as in Example 1, the residual dimention in the longitudinal direction was 78 mm (percent shrinkage: 22%), and that in the crosswise direction was 84 mm (percent shrinkage: 16%), with the RD ratio being 0.93.
COMPARATIVE EXAMPLE 1 A polypropylene resin foamed sheet was produced in the same manner as in Example 1, except for using a single cylindrical plug having a diameter of 200 mm and a length of 300 mm for cooling and taking off. The blow-up ratio was 1.90.
The resulting web had a thickness of 0.73 mm, 3 a width of 620 mm, a density of 0.71 g/cm ' a surface resistivity of 10 11 R, and an index of wettability of 32 dyne/cm.
When a 100 mm square cut out of the web was heated n the same manner as in Example 1, the residual dimention in the longitudinal direction was 52 mm (percent shrinkage: 48%) and that in the crosswise direction was 82 mm (percent shrinkag: 18%), with the RD ratio being 0.63.
COMPARATIVE EXAMPLE 2 A polypropylene resin foamed sheet was produced in the same manner as in Example 6, except that a first cylinder having a front diameter of 340 mm, a rear diameter of 339 mm, and a length of 70 mm and a second cylinder having a front diameter of 335 mm, a rear diameter of 333 mm, and a length of 430 mm connected with a small gap therebetween were used for taking off and cooling and that the tubular sheet was cut open along the extrusion direction by means of a single cutter fitted to the rear end of the second cylinder. The blow-up 29 ratio was 1.89.
The resulting web of foamed resin sheet had a thickness of 0.70 mm, a width of 1050 mm, a density 3 16 of 0.77 g/cm ' a surface resistivity of 10 2, and an index of wettability of 32 dyne/cm. When a'100 mm square dut out of the web was heated in the same manner as in Example 1, the residual dimention in the longitudinal direction was 52 mm (percent shrinkage: 48%) and that in the crosswise direction was 86 mm (percent shrinkage:
14%), with the RD ratio being 0.60.
The composition of each of the resin foamed sheets produced in the foregoing examples and the apparatus and conditions for extrusion are summarized in Table 1 below. The dimensions and various properties of each of the extruded foamed sheets in the form of roll and the cut-to- size sheets produced in the foregoing examples are shown in Table 2 below.
In order to evaluate formability of the polypropylene resin foamed sheet of the present invention, each of the cut-to-size sheets prepared in the foregoing Examples and Comaprative Examples was tested as follows.
A 200 mm square sheet (Fig. 1) was cut out of the sheet by means of a rotary sheeting machine, and a pattern comprising two straight 150 mm long lines cross- ing with each other at right angles was printed on the surface of the sheet, the intersection of the two lines being at the center of the sheet and each line being parallel to the side of the square.
The patterned sheet was thermoformed by contact with a hot plate (area to contact with sheet: 170 mm x i70 mm) set at a temperature of 170C, 180C, or 190C for 6 seconds to obtain a container having a width of mm, a length of 150 mm, and a deoth of 20 mm as illustrated in Figs. 2(a) and 2(b).
The distortion of the pattern caused by thermoforming was examined by measuring a deviation (mm) of each end of each line on the bottom -or side wall of the formed container from the respective imaginary straight line, and the greatest measured value as to the bottom or side wall was assigned to the following rating system:
Good... Within 0.5 mm Medium... Within 1.0 mm Poor... More than 1.0 mm Further, the formed container was checkedfor appearance by visually examining cracks, forming defects due to breakage, extreme local variation of thickness, and wrinkles or overlaps, and the container passing all these checks was rated "good", the one failing to pass any one of these checks was rated "medium", and the one failing to pass all of the checks was rated "bad".
The reuslts of these evaluations are shown in Table 3 below.
TABLE 1 le 1 EK. 2 Example 3 Example 4 a. 5 Example 6 Ex. 7. Ex. 1 Cemp. Ex. 2 Composition (part):
Polypropylene Noblen D501 ditto Noblen Noblene D501 ditto ditto ditto ditto (70) ditto (70) Resin base resin (70) AD571 (50) base resin (80) (60) (70) (70) High-Density Poly- Yukalon HD - - - ethylnee Resin JX-10 (20) Inorganic Fine talc (average ditto Sunlight talc (8 pm)(20) ditto ditto ditto ditto (30) ditto (30) Powder particle size: #700 (4.5 W) (40) (30) (30) 8 pm) (30) (30) Stabi.lizer BHT (0.11) ditto - BHT (0.1) ditto ditto ditto ditto (0.1) ditto (0.1) (0.1) (0.1) (0.1) Blowing Agent butane ditto ditto Dai Blow #2 ditto butane ditto ditto (ca. ditto (ca. 0.5) (1.0) (1.0) (ca. 0.5) (ca. 0.5) (ca. 0.5) 0.5) Antistatic Agent Electrostripper - Electrostripper - Electrostr- - TS-2 (1) TS-2 (1) ipper TS-2 (1) Extrusion Condition:
Direction horizonzal ditto ditto ditto ditto downward ditto horizonzal downward Cylinder Diameter 65 ditto ditto ditto ditto 90 ditto 65 90 (ffm) Ring Die Diameter 105 ditto ditto ditto ditto 180 ditto 105 180 Orifice Width WM) 0.45 ditto ditto ditto ditto 0.50 0.35 0.45 0.50 First Plug:
Front Diameter 240 ditto ditto ditto ditto 455 ditto 200 340 (m-n) /To be contId.
ly TABLE 1 (cont'd.) Example 1 Ex. 2 Example 3 Example 4 Ex.5 Eicample 6 Ex. 7 Comp. Ex. 1 Comp. Ex. 2 Re ' ar Diameter 239 ditto ditto ditto ditto 454 ditto 200 339 (m-n) Length (ffm) 50 ditto ditto ditto ditto 70 ditto 300 70 Second Plug:
Front Diameter (mm) 235 ditto ditto ditto ditto 450 ditto - 335 Rear Diameter (mm) 234 ditto ditto ditto ditto 448 ditto 333 Length,(=) 300 ditto ditto ditto ditto 430 ditto - 430 Blow-up Ratio 2.29 ditto ditto ditto ditto 2.53 ditto 1.90 1.89 Cylinder Temp. (C) 200-230 ditto ditto ditto ditto 200-240 ditto 200-230 200-240 W Resin Tenp. (T) 200 ditto ditto ditto ditto 220 ditto 200 220 Output (kg/hr) 25 ditto ditto ditto ditto 80 ditto 25 80 Note: Unit: Parts per 100 parts of the resin TABLE 2
Exarnple 1 Ele 2 Example 3 Example 4 Example 5 Example 6 ltainple 7 Comp. Ebc. 1 Comp. Ex. 2 Extruded Sheet (roll) Dimetnion:
Thickness (m-n) 0.34 03 3 0.80 L_.-10 1.10 0.73 0.48 0.73 0.70 Width (ffm) 750 750' 750 750 750 700. 700 620 1050 Density (g/an 3 0.73 0.72 0.70 0.50 0.61 0.81 0.43 0.71 0.77 Dimensional Change on Heating:
W RD Dimension L: 74 L: 79 L:'.76 L:'.75 L: 74 L: 85 L: 80 L: 52 L: 52 C: 81 C: 84 C: 88 C: 90 C: 78 C% 87 C: 88 C: 82 C: 86 Percent Shrinkage L: 26 L: 21 L: 24 L: 25 L: 26 L: 15 L: 20 L: 48 L: 48 (%) C: 19 C: 16 C: 12 C:10 C: 22 C: 13 C: 12 C: 18 C: 14 RD Ratio 0.91 0.94 0.86 0.83 0.95 0.98 0.91 0.63 0.60 Surface Resistivity 10 11 10 17 10 11 10 16 10 16 - 10 16 10 11 10 16 (n) Index of Wett- 32 - 32 - - 32 32 32 ability (dyne/cm) Post-Processed Sheet (cut-to-size) Antistatic Agent - Hostastat ditto SAT-5 ditto HS-1 Hot Roll Temp. (C) 150 ditto 150 ditto ditto ditto Corona Discharge done done done done done done Treatment /To be cont'd.
1 TABLE 2 (cont'd.) Example 1 Example 2 &le 3 Example 4 Ex"le 5 Example 6 &ahlple 7 Ccmp. Ex. 1 Cemp. Ex. 2 Dimension:
Thickness (rrm) 0.72 0.72 1.00 1.00 0.72 0.46 Width (ffm) 650 650 650 650 650 650 Length (rrm) 950 950 950 950 950 950 Density (glan 3 0.72 0.74 0.52 0.65 0.83 0.46 Flatness (ffm/m) 2 or less 2 or less 2 or less 1 or less 2 or less 1 or less Dimensional Change on Heating:
RD Dimension (nm) L: 71 L: 74 L: 73 L: 70 L: 84 L: 78 C: 83 C: 85 C: 91 C: 80 C: 87 C: 84 Percent Shrinkage L: 29 L: 26 L: 27 L: 30 L: 16 L: 22 (%) C: 17 C: 15 C: 9 C: 20 C: 13 C: 16 RD Ratio 0.86 0.87 0.80 0.87 0.97 0.93 Surface Resistivity - - 10 12 10 10 10 10 10 16 (S2) Index of Wett- 46 44 44 44 48 49 ability (dyne/cm) Note: RD Dimension: Residual dimension L: Longitudinal direction C: Crosswise direction RD Ratio = ratio of residual rate in the longitudinal direction to that in the crosswise direction TABLE 3
Example 1 Example 2 Bie 4 b)caple 5 Ex5ngle 6 Example 7 C Ex. 1 cmp. Ex. 2 Pattern Distortion Bottan:
170C: L good good medium good good good medium medium medium C good good good medium good good good medium poor 180C: L good good good good good good good medium medium C good good good good good good good poor poor 190C: L medium good good medium good good medium medium poor C good good good good good good good poor poor Side Wall:
170C: L good good good good good good good poor medium C good good good good good good good poor poor 180C: L good good good good good good good medium medium C good good good good good good good poor poor 19WC: L medium good medium medium good good medium poor poor C good good good good good good medium poor poor Appearance good good good good good good good bad bad Note: L: Longitudinal direction C: Crosswise direction 1 It can be seen f rom Table 3 that positional deviation of the printed pattern on thermoforming can be controlled within 0.5 mm in almost all of the formed containers obtained from the foamed sheet of the present invention whereas the comparative formed containers suffer 'from a positional deviation of the printed pattern of more than 1.0 mm.
Additional examples of formed articles which were obtained from the polypropylene resin foamed sheet according to the present invention are illustrated in and (d) Figs. 3(a), (b (c)/and Figs. 4(a) and (b).
The article of Figs. 3 is. composed of two symmetrical parts connected via a hinge and is bent double at the hinge to make a doll-shaped packaging container suitable for candies, etc. As can be seen from these figures, the unevenness of the formed sheet is in good agreement with the pattern of a doll printed on the foamed sheet, as shown in a phorograph of Fig. 3(d).
The article of Figs. 4 is a lidded packaging container having a turned side wall. It can be seen that the resin foamed sheet of the present invention is capable of deep draw at a high draw ratio.
EXAMPLE 8
A mixture of 70 parts of a polypropylene resin (base resin of 11Noblen D501"), 0.1 part of a stabilizer (11BHV'), and 30 parts of talc having an average particle size of 8 pm was pelletized in an extruder. A hundred parts of the pellets were used as a starting material of foamed product and fed to an extruder having a cylinder diameter of 90 mm.
Separately, a polypropylene resin ("Noblen PS2011W' produced by Sumitomo Chemical Co., Ltd.) was used as a starting material of film. This starting material of film was fed to two extruders having a cylinder diameter of 50 mm and 45 mm, respectively, and the extrudates were combined with the extrudate from the former extruder having a cylinder diameter of 90 mm, followed by coextrusion to produce a laminated foamed sheet-in which the film layers were laminated on the both surfaces of the foamed product. At this time, the extruder used was fitted with a ring die having a diameter of 180 mm and an orifice width of 0.50 mm at the tip thereof, and the coextrusion and blowing were performed downwardly.
Thereafter, the same procedures as in Example 6 were followed. The physical properties and moldability of the laminated foamed sheet are shown in Table 4.
- 38 0 TABLE 4
Extruded Sheet (roll) Dimension (Thickness):
Film Layer (mm) 0.046 Foamed Layer (mm) 0.72 Film Layer (mm) 0.044 Total (mm) 0.81 Dimensional Change on Heating:
RD Dimension (mm) L: 73 C: 85 Percent Shrinkage (%) L: 27 C: 15 RD Ratio 0.86 Surface Resistivity (52) 10 16 Index of Wettability (dyne/cm) 32 Pattern Distortion Bottom:
170C: L good C good 180C: L good C good 190C: L medium C good Side Wall:
170C: L good C good TABLE 4 (contld.) 180OC: L good c good 190OC: L medium c good Appearance good (Note) & Same as in Table 2.
As described above, the polypropylene resin foamed sheet according to the present invention exhibits excellent thermoforming properties, and the process for 1 production of the present invention makes it possible to increase a take- up speed and productivity by using a specifically designed cyclindrical plug.
Thus, the resin foamed sheet of the invention, with a pattern formed thereon, can be formed to an article having a beautiful appearance free from pattern deviation and other defects and having a precisely formed complicated steric shape. Therefore, the sheet is suitable for producing containers for foodstuff, packaging containers, display panels having a three-dimensional pattern, and the like.
While the invention has been describedin detail and with reference to specific embodiments thereof, it will be. apparent to one skilled in the art that various changes and modifi.cation can be made therein without departing from the spirit and scope thereof.
p
Claims (9)
- CLAIMS.A polypropylene resin foamed sheet for thermoforming having compounded therein from 10 to 50% by weight of an inorganic fine powder, said sheet having a density of from O_.2 to 1.2 g/cn and a thickness of rom 0. 2 to 3 mm and having a percent shrinkage of f rom 5 to 30% in each of the longitudinal and crosswise directions on -heating at 190C for 30 minutes, with the ratio of a residual rate in the longitudinal direction to that in the crosswise direction being from 1:07 to 1:1A.
- 2. A polypropylene resin foamed sheet as claimed 1 in claim 1, wherein said sheet has a surface resistivity 8 12 of 10 to 10
- 3. A polypropylene resin foamed sheet as claimed in claim 1, wherein said sheet has an index of wettability of at least 40 dyne/cm.
- 4.' A polypropylene resin foamed sheet as claimed in claim 1, wherein said sheet has laminated thereon a thermoplastic resin film.
- 5. A container for foodstuff obtained by thermoforming a polypropylene resin foamed sheet as claimed in claim 1.
- 6. A process for producing a polypropylene resin foamed sheet for thermoforming having compounded therein from 10 to 50% by weight of an inorganic fine powder, said sheet having a density of from 0.2 to 1.2 g/cm and a thickness of from 0.2 to.3 mm and having a percent shrinkage of from 5 to 30% in each of the longitudinal and crosswise directions on heating at 1900C for 30 minutes, with the ratio of a residual rate in the longitudinal direction to that in the crosswise direction being from 1:0.7 to 1:1.1P the proce ss comprising uniformly compounding a polypropylene resin with the inorganic fine powder, extruding and foaming the resin compound from a ring die of an extruder, and taking off the extruded tubular drum foamed sheet along a cylindrical whose diameter is 2.0 to 3.0 times that of said ring die.
- 7. A process as claimed in claim 6, wherein drum said cylindrical comprises a front cylinderand a rear cylinder having a diameter smaller than that of the front cyclinder connected with a small gap therebetween, and the cooling temperature of the front tylinder is set higher than that of the rear cylinder.
- 8. A process as claimed in claim 6, wherein said processs further includes cutting the tubular foamed drum sheet having been cooled along the cylindrical along the extrusion direction, contacting the sheet with a hot roll under tension, and cutting the sheet to size.
- 9. A process as claimed in claim 8, wherein -the foamed.sheet is sent to a pair of adjecanet hot rolls in the S-shape with respect to the surfaces of the hot rolls, the both surfaces of.the sheet are successively contacted and heated, and the sheet is taken up while cooling under tension.Published 1989 atThe PatentMee. State House, 66171 High Holbom London WC1R 4TP. Further copies maybe obtainedfrom The Patent=ce. Sales Branch, St Maxy Cray, Orpington, Kent BR5 3B.D. Printed by Multip3ex techniques 1t41, St Maxy Cray, Kent. Con. 1187
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP25945887 | 1987-10-16 |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB8824251D0 GB8824251D0 (en) | 1988-11-23 |
| GB2211191A true GB2211191A (en) | 1989-06-28 |
| GB2211191B GB2211191B (en) | 1991-11-06 |
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ID=17334346
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB8824251A Expired - Fee Related GB2211191B (en) | 1987-10-16 | 1988-10-17 | Polypropylene resin foamed sheet for thermoforming and process for producing the same |
Country Status (8)
| Country | Link |
|---|---|
| JP (1) | JPH01200931A (en) |
| KR (1) | KR970002312B1 (en) |
| AU (1) | AU616435B2 (en) |
| CA (1) | CA1295448C (en) |
| DE (1) | DE3835083A1 (en) |
| FR (1) | FR2621853A1 (en) |
| GB (1) | GB2211191B (en) |
| ZA (1) | ZA887693B (en) |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0428897A2 (en) * | 1989-11-24 | 1991-05-29 | Tetra Laval Holdings & Finance SA | Process for producing a fluid material package, device for producing such a package and usage of a particular plastic |
| GB2263435A (en) * | 1992-01-14 | 1993-07-28 | Shell Int Research | Plastics laminate containing foamed polypropylene |
| FR2696975A1 (en) * | 1992-10-15 | 1994-04-22 | Bridgestone Corp | Method for molding polyurethane seat cushions. |
| GB2268496B (en) * | 1992-07-08 | 1996-03-20 | Intersurgical Ltd | Improved thermal capacity reticulated polymer foams |
| EP3511369A4 (en) * | 2016-09-09 | 2020-03-25 | TBM Co., Ltd. | Process for producing sheet |
Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2843474B2 (en) * | 1993-01-06 | 1999-01-06 | 積水化成品工業株式会社 | Forming method of expanded polypropylene sheet |
| DE4420991A1 (en) * | 1994-06-16 | 1995-12-21 | Danubia Petrochem Deutschland | Polypropylene for thermo-forming |
| US7083849B1 (en) * | 1999-06-04 | 2006-08-01 | 3M Innovative Properties Company | Breathable polymer foams |
| JP2007002026A (en) * | 2005-06-21 | 2007-01-11 | Kaneka Corp | Expanded polypropylene resin extruded sheet |
| EP2802449A4 (en) * | 2012-01-12 | 2015-09-16 | Microgreen Polymers Inc | Thermoplastic material having a surface texture that promotes adherence of inks and other materials, and related systems and methods |
| KR101250772B1 (en) * | 2012-10-30 | 2013-04-05 | 주식회사 폼테크 | Method for preparing of form film with excellent impact absorption power and heat resistance |
Family Cites Families (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3560600A (en) * | 1963-11-07 | 1971-02-02 | Dow Chemical Co | Surface treatment on extruded plastic foam |
| US3985931A (en) * | 1973-06-04 | 1976-10-12 | Owens-Illinois, Inc. | Method for the cooling of a tubular extrudate of expanded polystyrene |
| US4049768A (en) * | 1976-04-09 | 1977-09-20 | Mobil Oil Corporation | Method for extending thermoplastic foams having smooth external skins |
| US4407768A (en) * | 1982-01-08 | 1983-10-04 | Phillips Petroleum Company | Foamable polymeric composition comprising propylene polymer and hydrated alumina |
| JPH0236141B2 (en) * | 1983-12-28 | 1990-08-15 | Sekisui Plastics | NETSUSEIKEISEINOSUGURETAHORIPUROPIRENKEIHATSUHOSHIITO |
| JPS61130025A (en) * | 1984-11-29 | 1986-06-17 | Asahi Chem Ind Co Ltd | Manufacture of foamed film |
| JPS62265332A (en) * | 1986-05-14 | 1987-11-18 | Mitsui Toatsu Chem Inc | Container for use in microwave oven |
-
1988
- 1988-10-13 CA CA000580054A patent/CA1295448C/en not_active Expired - Fee Related
- 1988-10-13 AU AU23708/88A patent/AU616435B2/en not_active Ceased
- 1988-10-14 ZA ZA887693A patent/ZA887693B/en unknown
- 1988-10-14 JP JP63258889A patent/JPH01200931A/en active Granted
- 1988-10-14 DE DE3835083A patent/DE3835083A1/en not_active Withdrawn
- 1988-10-14 FR FR8813592A patent/FR2621853A1/en not_active Withdrawn
- 1988-10-15 KR KR1019880013491A patent/KR970002312B1/en active IP Right Grant
- 1988-10-17 GB GB8824251A patent/GB2211191B/en not_active Expired - Fee Related
Non-Patent Citations (1)
| Title |
|---|
| JP60141728 A * |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0428897A2 (en) * | 1989-11-24 | 1991-05-29 | Tetra Laval Holdings & Finance SA | Process for producing a fluid material package, device for producing such a package and usage of a particular plastic |
| EP0428897A3 (en) * | 1989-11-24 | 1992-05-27 | Tetra Pak Holdings & Finance S.A. | Method for active reduction of parasitic magnetic fields in an apparatus for measuring biomagnetic signals |
| GB2263435A (en) * | 1992-01-14 | 1993-07-28 | Shell Int Research | Plastics laminate containing foamed polypropylene |
| GB2268496B (en) * | 1992-07-08 | 1996-03-20 | Intersurgical Ltd | Improved thermal capacity reticulated polymer foams |
| FR2696975A1 (en) * | 1992-10-15 | 1994-04-22 | Bridgestone Corp | Method for molding polyurethane seat cushions. |
| EP3511369A4 (en) * | 2016-09-09 | 2020-03-25 | TBM Co., Ltd. | Process for producing sheet |
Also Published As
| Publication number | Publication date |
|---|---|
| FR2621853A1 (en) | 1989-04-21 |
| GB2211191B (en) | 1991-11-06 |
| JPH01200931A (en) | 1989-08-14 |
| JPH0577490B2 (en) | 1993-10-26 |
| DE3835083A1 (en) | 1989-05-24 |
| AU616435B2 (en) | 1991-10-31 |
| ZA887693B (en) | 1989-06-28 |
| KR890006370A (en) | 1989-06-13 |
| GB8824251D0 (en) | 1988-11-23 |
| CA1295448C (en) | 1992-02-11 |
| KR970002312B1 (en) | 1997-02-27 |
| AU2370888A (en) | 1989-04-20 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PCNP | Patent ceased through non-payment of renewal fee |
Effective date: 19941017 |