JP2008246936A - Foamed molding and manufacturing method of the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a foamed molding capable of inexpensively and efficiently making the foamed molding more environment-friendly than conventional ones and the foamed molding obtained by the manufacturing method. <P>SOLUTION: The manufacturing method of the foamed molding characterized by including the step of obtaining a cylindrical thermoplastic resin by extruding a thermoplastic resin constituted by dispersing at least a thermo-swellable microcapsule from an extruder having a circular die and the step of developing the cylindrical thermoplastic resin in a planar plate shape and at the same time foaming the same by foaming magnification of 1.5 times or more and 10.0 times or less and cooling and the solidifying the same. The manufacturing method of the foamed molding is characterized by that the thermoplastic resin contains 20 to 60 wt.% filler. Further the manufacturing method of the foamed molding depicted in a claim 2 is characterized by that the filler contains a fibrous organic filler of 30 to 100 wt.% based on the total filler quantity. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a resin foam that has excellent dimensional stability, high rigidity, and is friendly to the environment. The resin foam is mainly used as a base material of a decorative material used for building interior materials such as floor materials, wall materials, and ceiling materials, joinery, furniture, and home appliance surface materials. In addition, it may be used for structural purposes such as wood deck materials and benches.

  Conventionally, as a decorative material for the above-mentioned various uses, a natural veneer, a decorative paper or a decorative sheet that has been printed on a paper or a synthetic resin sheet, and the like are bonded to a wooden base material such as plywood or fiberboard. Many things are used. However, these decorative materials have problems such as warpage due to moisture absorption and release of wood base materials, worm-eatenness and corrosion, and are difficult to recycle. However, it is disposed of by landfill or incineration. In addition, so-called sick house syndrome due to formalin derived from the thermosetting resin as a raw material and environmental hormone substances eluted after landfill have become problems.

  In addition, as a base material other than wood, a synthetic resin base material such as a cushion floor base material in which a polyvinyl chloride resin is formed in a different shape, a fabricated member, or a foamed sheet is conventionally used. Polyvinyl chloride, however, is a dioxin that is unavoidable in the generation of toxic hydrochloric acid gas in the event of a fire, etc. There is a problem that the environment is polluted by hydrochloric acid gas or corrosion of molds and incineration facilities, etc., and it is gradually replaced by polyolefin-based materials.

Furthermore, an attempt to use a base material by reducing thermal expansion by filling a filler has been made and put into practical use. However, although the thermal expansion coefficient of the resin is lowered, the problem of pushing up has not been solved, and it has been necessary to absorb the expansion and contraction of the base material by providing play in the shape of the base material and the joint portion. On the other hand, when the filler content is too much, the strength derived from the resin is lost, and there is a problem such as a remarkable decrease in impact resistance and an inconvenience due to an increase in specific gravity.
Moreover, in order to prevent push-up due to a decrease in the coefficient of thermal expansion due to filler filling, in a generally used base material having an initial flexural modulus of 2000 MPa or more, it is extremely low such as 1 × 10 ⁻⁵ / ° C. or less. Since it is necessary to keep the coefficient of thermal expansion small and it is very difficult, in fact, it was necessary to suppress the push-up by means such as the shape and arrangement of the base material.

On the other hand, with respect to the base material made of polyolefin-based material, the load on the human body, the environment, and facilities, as seen in polyvinyl chloride, is greatly reduced. Since it is a petroleum-derived synthetic polymer material, incineration causes an increase in carbon dioxide in the atmosphere, which causes a problem of global warming. In response to the problem of global warming, efforts are being made to reduce carbon dioxide emissions by using plant-derived resources. This is because when fossil resources in the ground are burned, the carbon contained in the fossil resources is released into the atmosphere as carbon dioxide. Since it is returned to the atmosphere, it is promoted based on the consideration that it has little effect on global warming.

Conventional woody substrates are excellent in this respect, and although there are soil contamination and problems with the human body, the impact on global warming is lower than that of polyolefin-based materials. Under these circumstances, in order to suppress carbon dioxide emissions, it is required to reduce the amount of petroleum-derived resin used, and research is being conducted on techniques for increasing the expansion ratio and converting the resin to biomass. Under these circumstances, various aliphatic polyesters including polylactic acid have been synthesized from plant-derived raw materials.
The polylactic acid resin is a homopolymer of either L-lactic acid or D-lactic acid, a random copolymer of L-lactic acid and D-lactic acid, a block copolymer of L-lactic acid and D-lactic acid, or a mixture of two or more thereof. . The enantiomeric ratio of lactic acid greatly affects the crystallization ability of polylactic acid resin. Therefore, it is used while appropriately adjusting in light of the required quality such as heat resistance and impact resistance of the target molded product.
As for aliphatic polyesters other than polylactic acid, many resins are currently synthesized from petroleum-derived raw materials, but attempts to synthesize these from plant-derived resources continue, and plant-derived resources are used. Development is also in progress from this point of view.
Aliphatic polyesters are aliphatic polyesters that can be produced by various combinations of aliphatic hydroxycarboxylic acids, aliphatic dihydric alcohols, and aliphatic dibasic acids. In addition to polylactic acid, polyglycolic acid, polyethylene oxalate, polybutylene Examples thereof include oxalate, polycaprolactone, polyneopentyl glycol oxalate, polyethylene succinate, polybutylene succinate, polyhydroxybutyric acid and the like.

However, aliphatic polyester has a lower melt viscosity than polyolefin and causes foam breakage during extrusion foam molding, forcing the use of materials with a cross-linked structure and severe restrictions on molding conditions. It had various drawbacks such as receiving.

The problems of reducing the environmental load and preventing the push-up as described above can be reduced or solved by foaming the base material. Attempts to foam a resin that is difficult to be foamed by using heat-swellable microcapsules have been widely studied.
However, in order to use heat-swellable microcapsules in extrusion molding, heat-swellable microcapsules have low heat resistance with respect to the molding temperature, and there is a problem that the expansion ratio differs between the part with a long residence time and the part with a short residence time. Therefore, it was difficult to produce a molded body that required uniform foaming as a whole. In particular, when a T-die is used to make a wide sheet-like foamed molded article, since the structure has a manifold, the residence time in the die becomes very long as it goes to the end, so the foaming ratio is large. Distribution occurred and it was difficult to make a homogeneous foamed molded product.
The inventors have made a sheet-like base material thermoplastic when sliding the thermoplastic resin melt through a sizing die in a foamed molded article containing a thermoplastic resin, a heat-swellable microcapsule and a filler and having a skin layer. We have invented a method for manufacturing foamed molded products that are passed between a resin melt and a sliding sizing die. Here, a uniform foaming ratio is maintained by using a sliding sizing die. (See Patent Document 1). However, in this method, it is necessary to match the entire foaming ratio when the residence time is long and the foaming ratio is lowered, and there is much waste in a mold having a large residence distribution such as a wide T-die.
JP 2006-292356 A

  The present invention has been made to solve the above-described problems in the prior art, and the problem is that the resin extruded from the single-screw extruder prevents the residence time distribution from occurring. In order to obtain a wide sheet-like foam molded article having a uniform foaming ratio, a method for producing a foam molded article using an extruder having a circular die is provided, which is more environmentally friendly than conventional foam molded articles. An object of the present invention is to provide a method for producing a foamed molded product that can be produced at low cost and efficiently, and a foamed molded product obtained by the production method.

  The invention according to claim 1 is a method for producing a foamed molded article, wherein at least a thermoplastic resin in which heat-swellable microcapsules are dispersed is extruded from an extruder having a circular die to obtain a cylindrical thermoplastic resin, A method for producing a foamed molded article comprising the steps of expanding the tubular thermoplastic resin into a flat plate shape and foaming at a foaming ratio of 1.5 to 10.0 times and cooling and solidifying.

  Invention of Claim 2 is a manufacturing method of the foaming molding of Claim 1 in which the said thermoplastic resin contains 20 to 60 weight% of fillers.

  Invention of Claim 3 is a manufacturing method of the foaming molding of Claim 2 in which the said filler contains 30 to 100 weight% of fibrous organic fillers with respect to the filler whole quantity. is there.

  Invention of Claim 4 is a manufacturing method of the foaming molding in any one of Claim 1 to 3 whose biomass ratio of the said thermoplastic resin is 50% or more.

  The invention according to claim 5 is a foam molded article obtained by the method for producing a foam molded article according to any one of claims 1 to 4.

  The invention according to claim 6 is the foam molded article according to claim 5, wherein a non-foamed layer having a foaming ratio of 1.0 is provided on one side or both sides of the foam molded article.

  The invention described in claim 7 is characterized in that a fine foam layer having a foaming ratio larger than 1.0 times and 1.3 times or smaller is provided on one side or both sides of the foamed molded product. It is a foam molded article.

The invention according to claim 1 is a method for producing a foamed molded article, wherein at least a thermoplastic resin in which heat-swellable microcapsules are dispersed is extruded from an extruder having a circular die to obtain a cylindrical thermoplastic resin, A method for producing a foamed molded article comprising the steps of expanding the tubular thermoplastic resin into a flat plate shape and foaming at a foaming ratio of 1.5 to 10.0 times and cooling and solidifying. By using a circular die, the thermoplastic resin spreads symmetrically around the entire circumference of the circular die, so that the residence time distribution can be prevented, the resin residence time can be made uniform, and the thermal swellability When forming a sheet-like foam molded article using microcapsules, it becomes possible to produce a foam molded article having a homogeneous foam structure in a direction perpendicular to the molding direction. In addition, since the resin residence time in the mold can be designed to be short with respect to the molding by the T-die, it is easy to cope with the problem of heat resistance and is advantageous in terms of widening.

Invention of Claim 2 is a manufacturing method of the foaming molding of Claim 1 in which the said thermoplastic resin contains 20 to 60 weight% of fillers. By containing 20 to 60% by weight of filler in the heat-sparing resin, it becomes possible to reduce thermal expansion and improve the scratch resistance of the surface.

Invention of Claim 3 is a manufacturing method of the foaming molding of Claim 2 in which the said filler contains 30 to 100 weight% of fibrous organic fillers with respect to the filler whole quantity. is there. By including 30 to 100% by weight of the fibrous organic filler with respect to the total amount of the filler, it becomes possible to improve workability such as machinability and nailing.

Invention of Claim 4 is a manufacturing method of a foaming molding in any one of Claim 1 to 3 whose biomass ratio of the said thermoplastic resin is 50% or more. When the biomass ratio of the thermoplastic resin is 50% or more, it is possible to reduce the environmental load.

The invention according to claim 5 is a foam molded article obtained by the method for producing a foam molded article according to any one of claims 1 to 4.

The invention according to claim 6 is the foam molded article according to claim 5, wherein a non-foamed layer having a foaming ratio of 1.0 is provided on one side or both sides of the foam molded article. By providing the non-foamed layer, it is possible to improve the surface scratch resistance and smoothness.

The invention described in claim 7 is characterized in that a fine foam layer having a foaming ratio larger than 1.0 times and 1.3 times or smaller is provided on one side or both sides of the foamed molded product. It is a foam molded article. By providing the fine foam layer, it becomes possible to improve the surface scratch resistance and smoothness.

  The present invention is described in detail below.

  FIG. 1 is a view showing an example of an extruder having a circular die of the present invention. The extruder has an extruder 1, a circular die 2, a torpedo 3, and a notch 4. Since the heat-expandable microcapsules to be described later have a problem in heat resistance, when an excessive amount of heat is applied, the shell deteriorates and gas escape occurs and the expansion ratio decreases. For this reason, in order to form a sheet having a uniform expansion ratio by extrusion, the residence time from when the thermoplastic resin in which at least heat-swellable microcapsules are dispersed from the extruder to the exit from the mold is uniform. It is very important to make it. For this reason, it is important to use a circular die. The circular die is preferably provided with one or more notches so that the cylindrical thermoplastic resin coming out of the mold can be easily opened.

  The manufacturing method of the foaming molding of this invention has the process of obtaining a cylindrical thermoplastic resin by extruding the thermoplastic resin which disperse | distributed the heat-swellable microcapsule at least from the extruder which has the circular die mentioned above. Here, when the circular die described above has a notch, the cylindrical shape is a cylindrical shape having a notch necessary for opening the cylindrical thermoplastic resin into a flat plate shape, and the circular die described above has a notch. When it does not have, it is a cylindrical shape without a break.

The method for producing a foamed molded product according to the present invention is as follows. Immediately after obtaining the cylindrical foamed molded product, the tubular foamed molded product is expanded into a flat plate shape and foamed at a foaming ratio of 1.5 to 10.0 times. And cooling and solidifying. The cooling method is not particularly specified, and can be appropriately selected from a single method such as roll cooling, sliding sizing die cooling, steel belt cooling, water cooling, or a combination of a plurality of methods.

The thermoplastic resin used in the present invention is not particularly limited, but polyolefin resins such as polyethylene and polypropylene, polystyrene resins, polyvinyl chloride resins, polymethyl methacrylate resins, aliphatic polyester resins, polyethylene terephthalate. It is possible to appropriately select from resin, polyamide resin, and the like. These may be used alone, or may be used as a blend or a copolymer.

In addition, a high melt tension is usually desirable for improving foamability, but in the molding method of the present invention, heat-swellable microcapsules are used as a foaming agent, so that even a low melt tension resin can be foamed well. is there. When high foaming exceeding 3 times is used, conventionally, a resin suitable for foaming such as polystyrene or polyvinyl chloride, or use of a grade resin in which long chain branching by electron beam crosslinking is introduced, It was desired to adjust the melt tension as necessary by a known method such as control of the molecular weight distribution and blending of a fluorine-based additive for increasing the melt tension. However, in the present invention, it is possible to use a resin having a low melt tension without any particular problem.

Therefore, in the present invention, a high-magnification foamed molded product of a mixture of homopolypropylene and filler having a relatively high melt flow rate, which has low environmental burden and excellent physical properties as a base material but has been difficult to form by conventional methods, Although the load is low, the melt viscosity is low, and it is possible to produce a foamed molded product of an aliphatic polyester resin from a plant-derived raw material such as polylactic acid, which requires a secondary treatment such as crosslinking for foam molding. Become.

If necessary, heat stabilizers, acid neutralizers, UV absorbers, light stabilizers, bubble regulators, carboxyl end-capping agents, colorants such as pigments and dyes, antistatic agents, lubricants, nucleating agents A flame retardant, an antiblocking agent, a gloss adjusting agent, and the like can also be added. Among these additives, hindered phenols, sulfurs, phosphoruss, etc. as heat stabilizers, stearic acid metal salts, hydrotalcite, etc. as acid neutralizers, benzotriazoles, benzoates as ultraviolet absorbers, etc. , Benzophenone, triazine, etc., hindered amines as light stabilizers, polytetrafluoroethylene modified with acrylic resin as bubble regulators, carbodiimide, glycidyl ester, etc. as flame retardants, carboxyl group terminal blockers As halogen-based flame retardants, phosphorus-based flame retardants, chlorine-based flame retardants, etc., lubricants as hydrocarbon-based lubricants, fatty acids, higher alcohols, fatty acid amides, metal soaps, esters, fluorines, etc. As pigments such as carboxylic acid metal salt, sorbitol, phosphate ester metal salt, etc. There are pearl pigments such as condensed azo, insoluble azo, quinacridone, isoindoline, anthraquinone, imidazolone, cobalt, phthalocyanine, carbon, titanium oxide, iron oxide, mica, etc., and these additives are generally used in any combination Is.

The filler used in the present invention can be appropriately selected from known inorganic fillers and organic fillers.
Specific examples of the inorganic filler include talc, non-swellable mica, swellable mica, swollen mica subjected to ion exchange, calcium carbonate, bentonite, organically modified montmorillonite, magnesium hydroxide, wollastonite, silica, alumina, oxidation Magnesium, calcium oxide, calcium silicate, sodium aluminate, calcium aluminate, sodium aluminosilicate, magnesium silicate, glass balloon, carbon black, zinc oxide, antimony trioxide, zeolite, hydrotalcite, potassium titanate, boron nitride, Examples thereof include graphite, glass fiber, and carbon fiber.
Specific examples of organic fillers include cotton fiber, hemp fiber, kenaf fiber, hemp fiber, jute fiber, banana fiber, coconut fiber, cellulose fiber, paper powder, wood powder, bamboo powder, cellulose powder, rice husk powder, fruit shell powder. , Protein, starch and the like.
These fillers may be coated with a thermoplastic resin such as an ethylene / vinyl acetate copolymer or a thermosetting resin such as an epoxy resin to improve adhesion with the resin, such as aminosilane or epoxysilane. You may process by a well-known method with a coupling agent etc. Moreover, according to a use and the objective, you may use single and may mix multiple types.

As the selection of the filler in the present invention, the thermal expansion coefficient reducing effect is high, and there is also a nucleating effect. Plates such as talc, mica, organically modified montmorillonite, scale-like filler, relatively low specific gravity, and cutting of foam molded products More preferably, it is selected from fibrous organic fillers such as kenaf fiber and wood flour, which have a great effect on the properties and nailing properties.
The blending ratio of the filler depends on the use of the foamed molded product and the type of the filler, but it is important that the thermoplastic resin is 100 to 20 wt% to 60 wt%, and 30 wt% to 50 wt%. Further preferred. When the blending ratio of the filler is 20% by weight or more and 60% by weight or less, it is possible to reduce thermal expansion and improve the scratch resistance of the surface. When the blending ratio of the filler is less than 20% by weight, the coefficient of thermal expansion is high, which causes a gap or push-up when used as a flooring material, lacks rigidity, and spreads the ground surface, resulting in poor design. Moreover, even if it exceeds 60 weight%, it will become a foaming molded object which is brittle and easy to crack.

Moreover, it is preferable that the filler used for this invention contains 30 to 100 weight% of fibrous organic fillers with respect to the filler whole quantity. By including 30 to 100% by weight of the fibrous organic filler with respect to the total amount of the filler, it becomes possible to improve workability such as machinability and nailing. If it is less than 30% by weight, flash tends to occur during cutting.

The thermoplastic resin of the present invention preferably has a biomass ratio of 50% or more. When the biomass ratio of the thermoplastic resin is 50% or more, it is possible to reduce the environmental load. If the biomass ratio is low, it will contribute to global warming due to the generation of CO ₂ by incineration when discarded. In order to set the biomass ratio to 50% or more, a plant-derived resin such as polylactic acid may be selected as the thermoplastic resin. Here, the biomass ratio is defined as (fibrous organic filler weight + plant-derived resin weight) / (total thermoplastic resin weight including filler−inorganic filler weight) × 100 (%).

The heat-swellable microcapsules in the present invention include those obtained by wrapping a hydrocarbon foaming agent such as isobutane, isopentane, isohexane, or isooctane with a polymer having a high gas barrier property such as a vinylidene chloride / acrylonitrile copolymer. In particular, since heat resistance is required for heat-swellable microcapsules to be used in extrusion molding, heat-swellable microcapsules having a polymer composed of a nitrile monomer and a monomer having a carboxyl group as an outer shell polymer, Furthermore, a heat-swellable microcapsule having a polymer composed of a nitrile monomer, a monomer having a carboxyl group, a monomer having an amide group, a monomer having a cyclic structure in the side chain as an outer shell polymer in JP WO2004 / 058910, It is desirable to use heat-swellable microcapsules with high heat resistance.
By using heat-swellable microcapsules under appropriate conditions, it is possible to produce foamed molded products with high mechanical strength of closed cells even when using resins with low melt viscosity or resins that are generally not suitable for foaming with strain rate softening properties. It becomes possible to make.

The method of kneading the filler and the thermoplastic resin is not particularly limited, but a method of kneading with a gelation mixer and pelletizing with a pelletizer or a method of mixing and pelletizing with a twin screw extruder kneader are common.
In addition, a known foaming technique and equipment can be used as they are for the extrusion technique and equipment. As the extruder, both a single screw extruder and a twin screw extruder can be used. In the twin screw extruder, any of the same direction, different direction, conical, and parallel can be used. Similar to the known foaming technique, it is not desirable in terms of quality and stability that the heat-swellable microcapsules swell in the extruder while maintaining a sufficient resin pressure near the exit of the extruder.

Moreover, the foaming molding of this invention may provide the non-foaming layer whose foaming ratio is 1.0 time in the foaming molding obtained by the manufacturing method of this invention mentioned above. Moreover, the foaming molding of this invention may provide the foaming molding obtained by the manufacturing method of this invention mentioned above with the fine foaming layer whose foaming ratio is larger than 1.0 time and 1.3 times or less. By providing a non-foamed layer or a fine foamed layer, it is possible to improve surface hardness, scratch resistance, and ensure rigidity as a foamed molded product. The non-foamed layer or the microfoamed layer can be provided on the foamed molded article by coextrusion.

  The resin for forming the non-foamed layer or the microfoamed layer is not particularly limited, and a known thermoplastic resin or a thermoplastic resin similar to the foamed molded article obtained by the production method of the present invention described above is used. be able to. Moreover, it is possible to use a well-known filler suitably. In order to increase rigidity, it is preferable to add a large amount of filler. However, in order to prevent warping due to temperature change, the foamed molding obtained by the above-described production method of the present invention and the flow direction (MD), vertical It is desirable to have the same thermal expansion coefficient in both directions (TD).

Examples of the present invention and comparative examples are shown below.
The following equipment was used. The blending ratio is expressed in weight% where the total amount is 100. However, the foaming agent is externally added. For example, when 3% by weight of the foaming agent is added, the total amount is 103% by weight.

<Device used>
Co-directional twin-screw extruder (Nippon Steel Works TEX65)
Single screw extruder (Ikegai Iron Works FS-65)

<Device conditions>
Same direction twin screw extruder 180 ° C setting 150rpm 100kg / h
Single screw extruder conditions 150 ° C setting mold temperature 170 ° C setting sizing temperature 30 ° C setting

(1) Preparation of Compound 1 Compound 1 was prepared by kneading maleic acid-modified polypropylene: 10% by weight, homopolypropylene: 30% by weight, and wood flour: 60% by weight in the same direction twin screw extruder.
(2) Preparation of Foam Molded Body Compound 1: 50% by weight, polylactic acid: 50% by weight, heat-swellable microcapsules (capsule foaming agent master batch MBF-230): 10% by weight, additive 1% by weight Extrusion was performed using a circular die with a single screw extruder to obtain a foamed molded article 1 having a thickness of 5 mm. The biomass ratio of the obtained foamed molded body 1 is 70%.

  On one side of the foamed molded product 1 obtained in Example 1, a non-foamed layer having a thickness of 1 mm composed of compound 1: 50% by weight and polylactic acid 50% by weight was provided, whereby a foamed molded product 2 was obtained.

  On one side of the foamed molded product 1 obtained in Example 1, compound 1: 50% by weight, polylactic acid: 50% by weight, heat-swellable microcapsules (capsule foaming agent master batch MBF-230): 1% by weight A foamed article 3 was obtained by providing a fine foam layer having a thickness of 1 mm.

<Comparative example>
A T-die was used instead of the circular die of Example 1, and a foamed molded product of Comparative Example was obtained in the same manner as in Example 1 except that.

Table 1 shows the results of evaluating the thicknesses of the foamed molded products 1 to 3 obtained in Examples 1 to 3 and the foamed molded products obtained in Comparative Examples, and the variation in the expansion ratio, and the evaluation results of the surface hardness. . The surface hardness was compared with a pencil hardness at a load of 200 g.
As is clear from Table 1, each of the foamed molded products 1 to 3 obtained in Examples 1 to 3 had a uniform thickness and a uniform foaming ratio. In addition, it can be seen from Examples 2 and 3 that the foam molded body provided with the non-foamed layer and the fine foam layer has improved surface scratch resistance as compared with the foam molded body 1 of Example 1. Moreover, in the comparative example using T-die, it became a foaming molding with non-uniform thickness and foaming ratio.

It is a schematic diagram of the extruder of an example of the manufacturing method of this invention.

Explanation of symbols

1 Extruder 2 Circular Die 3 Torpedo 4 Notch

Claims (7)

  A method for producing a foam-molded product, comprising: a step of extruding a thermoplastic resin in which at least a heat-swellable microcapsule is dispersed from an extruder having a circular die to obtain a cylindrical thermoplastic resin; And a step of foaming at a foaming ratio of 1.5 times or more and 10.0 times or less and simultaneously solidifying by cooling.   The method for producing a foamed molded article according to claim 1, wherein the thermoplastic resin contains a filler of 20 to 60% by weight.   The said filler contains the fibrous organic filler of 30-100 weight% with respect to the filler whole quantity, The manufacturing method of the foaming molding of Claim 2 characterized by the above-mentioned.   The method for producing a foamed molded product according to any one of claims 1 to 3, wherein a biomass ratio of the thermoplastic resin is 50% or more.   A foam molded article obtained by the method for producing a foam molded article according to any one of claims 1 to 4.   6. The foamed molded product according to claim 5, wherein a non-foamed layer having a foaming ratio of 1.0 is provided on one or both surfaces of the foamed molded product.   6. The foamed molded product according to claim 5, wherein a fine foamed layer having a foaming ratio larger than 1.0 times and 1.3 times or smaller is provided on one side or both sides of the foamed molded product.

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