Polyolefin resin molding composite

Abstract

A foam layer can be formed at a temperature at which the surface quality of a surface layer is not deteriorated, and a molding technique that is excellent in adhesiveness of a foam layer and a surface layer or/and a base member is developed. For the purpose of obtaining a resin molding composite, the present invention is characterized by a polyolefin resin molding composite comprising a surface layer and a foam layer, or a surface layer, a foam layer, and a base member, wherein the foam layer comprises a foam layer produced by fusion bonding thermoplastic expanded resin particles one another by molding, where the thermoplastic expanded resin particles comprises a core that is made of a crystalline thermoplastic resin and is in an expanded state and a polyethylene resin coat covering the core, and the surface layer comprises a thermoplastic synthetic resin having a melting point of 5° C. or more higher than a melting point of polyethylene resin constituting the coat of the particles.

1 - 8 . (Cancelled).  
     
     
         9 . A method for producing a polyolefin resin molding composite, said molding composite comprising a surface layer and a foam layer, comprising the steps of: 
 providing thermoplastic expanded resin particles comprising a core that is made of crystalline thermoplastic resin and is in an expanded state, and a polyethylene resin coat covering the core that is in a substantially non-expanded state, wherein the polyethylene resin of the coat has a melting point of 125° C. or lower and which is 15° C. or lower than a melting point of the crystalline thermoplastic resin constituting the core,    providing the surface layer comprising a thermoplastic synthetic resin having a melting point of 5° C. or higher than the melting point of the polyethylene resin constituting the coat,    placing the surface layer in a mold,    filling the thermoplastic expanded resin particles on the surface layer,    heating the thermoplastic expanded resin particles at a heating temperature lower than the melting point of the crystalline thermoplastic resin of the core, and not lower than the melting point of the polyethylene resin of the coat, to generate the foam layer and to fusion-bond the polyethylene resin of the coat and the surface layer.    
     
     
         10 . A method for producing a polyolefin resin molding composite, said molding composite comprising a surface layer, a foam layer and a base member, comprising the steps of: 
 providing thermoplastic expanded resin particles comprising a core that is made of crystalline thermoplastic resin and is in an expanded state, and a polyethylene resin coat covering the core that is in a substantially non-expanded state, wherein the polyethylene resin of the coat has a melting point of 125° C. or lower and which is 15° C. or lower than a melting point of the crystalline thermoplastic resin constituting the core,    providing the surface layer comprising a thermoplastic synthetic resin having a melting point of 5° C. or higher than the melting point of the polyethylene resin constituting the coat,    placing the surface layer and the base member in a mold,    filling the thermoplastic expanded resin particles between the surface layer and the base member,    heating the thermoplastic expanded resin particles at a heating temperature lower than the melting point of the crystalline thermoplastic resin of the core, and not lower than the melting point of the polyethylene resin of the coat, to generate the foam layer and to fusion-bond the polyethylene resin of the coat and the base member.    
     
     
         11 . The method for producing a polyolefin resin molding composite according to  claim 9  or  10 , wherein a void fraction of the foam layer is from 1% to 40%.  
     
     
         12 . The method for producing a polyolefin resin molding composite according to  claim 9  or  10 , wherein the surface layer comprising the thermoplastic synthetic resin having a melting point of 10° C. or higher than the melting point of the polyethylene resin constituting the coat.  
     
     
         13 . The method for producing a polyolefin resin molding composite according to  claim 9  or  10 , wherein the surface layer has an uneven pattern.  
     
     
         14 . The method for producing a polyolefin resin molding composite according to  claim 9  or  10 , wherein the melting point of the coat and the melting point of the crystalline thermoplastic resin have a difference in temperature of from 20 to 60° C.  
     
     
         15 . The method for producing a polyolefin resin molding composite according to  claim 9  or  10 , wherein the melting point of the coat and the melting point of the crystalline thermoplastic resin have a difference in temperature of from 20 to 40° C.  
     
     
         16 . The method for producing a polyolefin resin molding composite according to  claim 9  or  10 , wherein the thermoplastic synthetic resin constituting the surface layer is a polyolefin resin.  
     
     
         17 . The method for producing a polyolefin resin molding composite according to  claim 9  or  10 , wherein the polyethylene resin coat comprises an ethylene polymer.  
     
     
         18 . A method for producing a polyolefin resin molding composite according to  claim 10 , wherein the surface layer is fusion-bonded to the polyethylene resin of the coat.