Foamed molding of expanded polypropylene resin beads

Abstract

A process for the production of expanded beads, including kneading a base resin containing a polypropylene resin and having a tensile modulus of at least 1,200 MPa together with a mixture of a coloring agent and a thermoplastic polymer having a tensile modulus lower than that of the base resin to form a kneaded mixture including a matrix of the base resin and a multiplicity of domains dispersed in the matrix and each containing the thermoplastic polymer and the coloring agent. The kneaded mixture is formed into resin particles, then treated with an organic peroxide to modify surfaces of the resin particles therewith. Foaming and expanding of the surface-modified resin particles gives expanded beads having an inside region surrounded by a surface region. The heat of fusion of a high temperature peak of the surface region is lower than that of the inside region.

1 . A foamed molding comprising fuse-bonded expanded beads, each of said expanded beads comprising cell walls defining a plurality of closed cells, each of said cell walls comprising a matrix of a base resin including a polypropylene resin and having a tensile modulus of at least 1,200 MPa and a multiplicity of domains dispersed in said matrix and each containing a coloring agent and a thermoplastic polymer having a tensile modulus lower than that of said base resin, said expanded bead comprising an inside region surrounded by a surface region, each of said inside and surface regions showing a high temperature peak in a DSC curve thereof, the heat of fusion of the high temperature peak of the surface region being lower than that of the inside region, said expanded bead having a sea-islands structure wherein said matrix is the sea and said domains are the islands.  
   
   
       2 . The foamed molding as claimed in  claim 1 , wherein said polypropylene resin has a tensile modulus of at least 1,200 MPa.  
   
   
       3 . The foamed molding as claimed in  claim 2 , wherein said polypropylene resin is a propylene homopolymer.  
   
   
       4 . The foamed molding as claimed in  claim 1 , wherein said coloring agent is carbon black.  
   
   
       5 . The foamed molding as claimed in  claim 4 , wherein said carbon black has an average particle diameter of 5 nm to 100 nm.  
   
   
       6 . The foamed molding as claimed in  claim 4 , wherein said carbon black is used in an amount of 0.1% by weight or more but less than 5% by weight based on a total weight of said base resin and said thermoplastic polymer.  
   
   
       7 . The foamed molding as claimed in  claim 1 , wherein the mixture of the coloring agent and the thermoplastic polymer has a viscosity greater than that of the base resin.  
   
   
       8 . The foamed molding as claimed in  claim 7 , wherein the mixture of the coloring agent and the thermoplastic polymer has a melt flow rate of 0.1-50 g/10 min.  
   
   
       9 . The foamed molding as claimed in  claim 7 , wherein the mixture of the coloring agent and the thermoplastic polymer has a melt flow rate of 0.2-30 g/10 min.  
   
   
       10 . The foamed molding as claimed in  claim 7 , wherein the mixture of the coloring agent and the thermoplastic polymer has a melt flow rate of 0.3-10 g/10 min.  
   
   
       11 . The foamed molding as claimed in  claim 10 , wherein said polypropylene resin has a melt flow rate of 10-70 g/10 min.  
   
   
       12 . The foamed molding as claimed in  claim 1 , wherein said polypropylene resin has a tensile yield strength of at least 31 Mpa and a tensile breaking elongation of 200-1000%.  
   
   
       13 . The foamed molding as claimed in  claim 1 , wherein said base resin has a tensile modulus of at least 1250 MPa.  
   
   
       14 . The foamed molding as claimed in  claim 1 , wherein said base resin has a tensile modulus of at least 1300 MPa.  
   
   
       15 . The foamed molding as claimed in  claim 1 , wherein said base resin has a tensile modulus of 1360-2500 Mpa.  
   
   
       16 . The foamed molding as claimed in  claim 1  further comprising a surface layer integrally molded with said expanded beads.  
   
   
       17 . The foamed molding as claimed in  claim 16  wherein said surface layer is a reinforcement layer.  
   
   
       18 . The foamed molding as claimed in  claim 1  further comprising at least one reinforcing insert embedded within the fuse-bonded expanded beads.  
   
   
       19 . A foamed molding produced by a process comprising: 
 (a) kneading a coloring agent and a thermoplastic polymer having a tensile modulus lower than that of a base resin to form a master batch;    (b) then kneading the master batch with the base resin to form a kneaded mixture comprising a matrix of the base resin and a multiplicity of domains dispersed in said matrix, each domain being composed of the thermoplastic polymer and the coloring agent;    (c) forming the kneaded mixture into resin particles;    (d) treating the resin particles with an organic peroxide to modify surfaces of the resin particles;    (e) foaming and expanding the surface-modified resin particles to obtain expanded beads having a sea-island structure wherein the matrix is the sea and the domains are the islands;    (f) placing the expanded beads within a mold; and    (g) heating the expanded beads within the mold to fuse-bond the expanded beads together, thereby forming the foamed molding.