US4506037A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Production of resin foam by aqueous medium
Assignee: Chuo Kagaku Co Ltd
•
Filing: 1984-03-15
•
Granted: 1985-03-19
•
Expires: 2004-03-15
Abstract
Abstract A process for producing a resin foam by using an aqueous medium, which comprises (a) treating a resin compound with said aqueous medium to cause the aqueous medium to adhere to and be held by the resin compound, said resin compound being composed of porous agglomerated particles resulting from partial melt-adhesion of thermoplastic resin particles coated with a fine hydrophilic solid powder which does not substantially melt at the melting temperature of the resin particles, said solid powder being embedded in the resin particles but partly exposed at their surfaces, (b) melt-kneading the resin compound treated with the aqueous medium under such an elevated pressure that evaporation of the aqueous medium is substantially inhibited, and (c) thereafter releasing the kneaded resin composition from the pressurized state to foam it; and a thermoplastic resin compound used for the aforesaid process.
Inventors
- 👤 Shigemasa Suzuki
- 👤 Toshiyuki Takai
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 13:07
CPC Classifications
C; C08; C08J; C08J3/00; C08J3/20; C08J3/203; C08J9/00; C08J9/04; C08J9/12; C08J9/125
Claims Analysis
Total Claims: 35
Claim 1
Independent Claim
129 words
A process for producing a resin foam by using an aqueous medium, which comprises (a) treating a resin compound with said aqueous medium to cause the aqueous medium to adhere to and be held by the resin compound, said resin compound being composed of porous agglomerated particles resulting from partial melt-adhesion of thermoplastic resin particles coated with a fine hydrophilic solid powder which does not substantially melt at the melting temperature of the resin particles, said solid powder being embedded in the resin particles but partly exposed at their surfaces, (b) melt-kneading the resin compound treated with the aqueous medium under such an elevated pressure that evaporation of the aqueous medium is substantially inhibited, and (c) thereafter releasing the kneaded resin composition from the pressurized state to foam it.
Claim 2
Dependent Claim
129 words
A process for producing a resin foam by using an aqueous medium, which comprises (a) treating a resin compound with said aqueous medium to cause the aqueous medium to adhere to and be held by the resin compound, said resin compound being composed of porous agglomerated particles resulting from partial melt-adhesion of thermoplastic resin particles coated with a fine hydrophilic solid powder which does not substantially melt at the melting temperature of the resin particles, said solid powder being embedded in the resin particles but partly exposed at their surfaces, (b) melt-kneading the resin compound treated with the aqueous medium under such an elevated pressure that evaporation of the aqueous medium is substantially inhibited, and (c) thereafter releasing the kneaded resin composition from the pressurized state to foam it.
Claim 3
Dependent Claim
38 words
The process of claim 1 wherein the thermoplastic resin particles are composed of at least one resin selected from the group consisting of olefinic resin, diene resins, vinyl resins, acrylic resins, styrene resins, polyamide resins, and polyester resins.
Claim 4
Dependent Claim
20 words
The process of claim 2 wherein the thermoplastic resin particles are composed of an olefinic resin or a styrene resin.
Claim 5
Dependent Claim
25 words
The process of claim 1 wherein the fine hydrophilic solid powder has a solubility in water of not more than 10 g/liter at 25° C.
Claim 6
Dependent Claim
22 words
The process of claim 1 wherein the fine hydrophilic solid powder has an average particle diameter of not more than 100 microns.
Claim 7
Dependent Claim
40 words
The process of claim 1 wherein the fine hydrophilic solid powder is selected from the group consisting of a powder of a plant, a powder of a resin, a powder of a metal and a powder of an inorganic material.
Claim 8
Dependent Claim
25 words
The process of claim 1 wherein the fine hydrophilic solid powder is selected from the group consisting of talc, calcium carbonate, clay, silica and alumina.
Claim 9
Dependent Claim
21 words
The process of claim 7 wherein the fine hydrophilic solid powder has an average particle diameter of 1 to 15 microns.
Claim 10
Dependent Claim
17 words
The process of claim 1 wherein the fine hydrophilic solid powder is surface-treated with a surface-active agent.
Claim 11
Dependent Claim
28 words
The process of claim 1 wherein the fine hydrophilic solid powder contains up to 20% by weight, based on its total weight, of organic or inorganic short fibers.
Claim 12
Dependent Claim
20 words
The process of claim 1 wherein the porous agglomerated particles have a water vapor adsorption ratio of at least 0.05%.
Claim 13
Dependent Claim
34 words
The process of claim 1 wherein the porous agglomerated particles consist of 100 parts by weight of the thermoplastic resin particles and 30 to 250 parts by weight of the fine hydrophilic solid powder.
Claim 14
Dependent Claim
21 words
The process of claim 12 wherein the proportion of the fine hydrophilic solid powder is 60 to 150 parts by weight.
Claim 15
Dependent Claim
37 words
The process of claim 1 wherein the aqueous medium is water or a mixture of water with at least one material selected from the group consisting of surface-active agents, water-soluble polymers, polyhydric alcohols and water-miscible organic solvents.
Claim 16
Dependent Claim
11 words
The process of claim 1 wherein the aqueous medium is water.
Claim 17
Dependent Claim
28 words
The process of claim 1 wherein 1 to 15 parts by weight of the aqueous medium is adhered per 100 parts by weight of the porous agglomerated particles.
Claim 18
Dependent Claim
19 words
The process of claim 1 wherein the proportion of the aqueous medium is 1.5 to 10 parts by weight.
Claim 19
Dependent Claim
15 words
The process of claim 1 wherein the melt-kneading is carried out in a nonvent-type extruder.
Claim 20
Dependent Claim
21 words
The process of claim 1 wherein the melt-kneaded resin composition is extruded from a die lip or injected into a mold.
Claim 21
Dependent Claim
64 words
A thermoplastic resin compound having a water vapor adsorption ratio of at least 0.05% and being composed of porous agglomerated particles resulting from partial melt-adhesion of thermoplastic resin particles coated with a fine hydrophilic solid powder which does not substantially melt at the melting temperature of the resin particles, said solid powder being embedded in the resin particles but partly exposed at their surfaces.
Claim 22
Dependent Claim
64 words
A thermoplastic resin compound having a water vapor adsorption ratio of at least 0.05% and being composed of porous agglomerated particles resulting from partial melt-adhesion of thermoplastic resin particles coated with a fine hydrophilic solid powder which does not substantially melt at the melting temperature of the resin particles, said solid powder being embedded in the resin particles but partly exposed at their surfaces.
Claim 23
Dependent Claim
39 words
The resin compound of claim 20 wherein the thermoplastic resin particles are composed of at least one resin selected from the group consisting of olefinic resins, diene resins, vinyl resins, acrylic resins, styrene resins, polyamide resins, and polyester resins.
Claim 24
Dependent Claim
21 words
The resin compound of claim 20 wherein the thermoplastic resin particles are composed of an olefinic resin or a styrene resin.
Claim 25
Dependent Claim
32 words
The resin compound of claim 20 wherein the fine hydrophilic solid powder has a solubility in water of not more than 10 g/liter, preferably not more than 5 g/liter, at 25° C.
Claim 26
Dependent Claim
23 words
The resin compound of claim 20 wherein the fine hydrophilic solid powder has an average particle diameter of not more than 100 microns.
Claim 27
Dependent Claim
41 words
The resin compound of claim 20 wherein the fine hydrophilic solid powder is selected from the group consisting of a powder of a plant, a powder of a resin, a powder of a metal and a powder of an inorganic material.
Claim 28
Dependent Claim
26 words
The resin compound of claim 20 wherein the fine hydrophilic solid powder is selected from the group consisting of talc, calcium carbonate, clay, silica and alumina.
Claim 29
Dependent Claim
22 words
The resin compound of claim 20 wherein the fine hydrophilic solid powder has an average particle diameter of 1 to 15 microns.
Claim 30
Dependent Claim
18 words
The resin compound of claim 20 wherein the fine hydrophilic solid powder is surface-treated with a surface-active agent.
Claim 31
Dependent Claim
29 words
The resin compound of claim 20 wherein the fine hydrophilic solid powder contains up to 20% by weight, based on its total weight, of organic or inorganic short fibers.
Claim 32
Dependent Claim
21 words
The resin compound of claim 20 wherein the porous agglomerated particles have a water vapor adsorption ratio of at least 0.3%.
Claim 33
Dependent Claim
35 words
The resin compound of claim 20 wherein the porous agglomerated particles consist of 100 parts by weight of the thermoplastic resin particles and 30 to 250 parts by weight of the fine hydrophilic solid powder.
Claim 34
Dependent Claim
22 words
The resin compound of claim 31 wherein the proportion of the fine hydrophilic solid powder is 60 to 150 parts by weight.
Claim 35
Dependent Claim
81 words
A process for producing the thermoplastic resin compound of claim 20, which comprises mixing thermoplastic resin particles and a fine hydrophilic solid powder which does not substantially melt at the melting temperature of the resin, in a high-speed rotating mixer at a high speed and a temperature above the melting temperature of the resin, and immediately cooling and solidifying the mixture when porous agglomerated particles result from partial melt-adhesion of the thermoplastic resin particles coated with the fine hydrophilic solid powder.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1988-03-18 | 1988-09-17 | 1989-03-19 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-03-18 | 1992-09-17 | 1993-03-19 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-03-18 | 1996-09-17 | 1997-03-19 | $7700.00 | Window Closed / Lapsed |