Method for producing crosslinked foam

Claim 1

A method of producing a crosslinked foamed article, said method comprising: (a) uniformly mixing a crosslinkable thermoplastic resin, a crosslinking agent which has a decomposition temperature higher than the melting point of said resin and a foaming agent which has a decomposition or volatization temperature higher than that of said crosslinking agent and generates a gas upon decomposition or volatization; (b) extruding said mixture through a long-land die provided with a heating means and having a front or upstream portion and a rear or downstream portion, the temperature of said rear portion being higher than the temperature of said front or upstream portion, and said long-land die being further provided with a choking orifice at an intermediate portion between said front or upstream portion and said rear or downstream portion and/or at an end portion thereof, said choking orifice creating back pressure in said long-land die and having a choking ratio A/B of from 4/3-10/2, wherein A is the vertical cross-sectional area of said long-land die in front of said orifice and B is the vertical cross-sectional area of the narrowest section of said orifice, and simultaneously supplying a lubricant into an interface between the inner surface of said long-land die and said mixture; (c) heating said conveyed mixture in said front or upstream portion of said long-land die to a temperature sufficient to cause decomposition of said crosslinking agent and crosslinking of said crosslinkable thermoplastic resin, the degree of crosslinking as defined by gel ratio being at least 5%; (d) heating the conveyed mixture from step (c) in said rear or downstream portion of said long-land die to a temperature higher than the temperature in said front or upstream portion of the die to cause decomposition or volatization of said foaming agent; and (e) releasing the mixture from step (d) from said long-land die into an atmospheric or controlled pressure zone to allow said mixture to expand and form said foamed article.

Claim 2

A method of producing a crosslinked foamed article, said method comprising: (a) uniformly mixing a crosslinkable thermoplastic resin, a crosslinking agent which has a decomposition temperature higher than the melting point of said resin and a foaming agent which has a decomposition or volatization temperature higher than that of said crosslinking agent and generates a gas upon decomposition or volatization; (b) extruding said mixture through a long-land die provided with a heating means and having a front or upstream portion and a rear or downstream portion, the temperature of said rear portion being higher than the temperature of said front or upstream portion, and said long-land die being further provided with a choking orifice at an intermediate portion between said front or upstream portion and said rear or downstream portion and/or at an end portion thereof, said choking orifice creating back pressure in said long-land die and having a choking ratio A/B of from 4/3-10/2, wherein A is the vertical cross-sectional area of said long-land die in front of said orifice and B is the vertical cross-sectional area of the narrowest section of said orifice, and simultaneously supplying a lubricant into an interface between the inner surface of said long-land die and said mixture; (c) heating said conveyed mixture in said front or upstream portion of said long-land die to a temperature sufficient to cause decomposition of said crosslinking agent and crosslinking of said crosslinkable thermoplastic resin, the degree of crosslinking as defined by gel ratio being at least 5%; (d) heating the conveyed mixture from step (c) in said rear or downstream portion of said long-land die to a temperature higher than the temperature in said front or upstream portion of the die to cause decomposition or volatization of said foaming agent; and (e) releasing the mixture from step (d) from said long-land die into an atmospheric or controlled pressure zone to allow said mixture to expand and form said foamed article.

Claim 12

The method according to any one of claims 2-6 wherein said rear or downstream portion of the long-land die is gradually increased in cross-sectional area along the direction of resin flow.

Claim 13

A method for producing a crosslinked foamed article, said method comprising: (a) uniformly mixing a crosslinkable thermoplastic resin, a crosslinking agent which has a decomposition temperature higher than the melting point of said resin and a foaming agent which has a decomposition temperature higher than that of said crosslinking agent and generates a gas upon decomposition; (b) extruding said mixture through a long-land die provided with a heating means and having a front or upstream portion having a length of more than 200 cm and a rear or downstream portion having a length of 1/5-2 times the length of said front or upstream portion, the temperature of said rear or downstream portion being higher than the temperature of said front or upstream portion, and said long-land die being further provided with a choking orifice at an intermediate portion between said front or upstream portion and said rear or downstream portion, said choking orifice creating back pressure in said long-land die and having a choking ratio A/B of from 10/7-10/2, wherein A is the vertical cross-sectional area of said long-land die in front of said orifice and B is the vertical cross-sectional area of the narrowest section of said orifice, and simultaneously supplying a lubricant into an interface between the inner surface of said long-land die and said mixture; (c) heating said conveyed mixture in said front or upstream portion of said long-land die to a temperature sufficient to cause decomposition of said crosslinking agent and crosslinking of said crosslinkable thermoplastic resin, the degree of crosslinking as defined by gel ratio being 10-70%; (d) heating the mixture from step (c) in said rear or downstream portion of said long-land die to a temperature higher then the temperature in said front or upstream part of the die to cause decomposition of said foaming agent; and (e) releasing the mixture from step (d) from said long-land die into an atmospheric or controlled pressure zone to allow said mixture to expand and form said foamed article.

Claim 14

A method for producing a crosslinked foamed article, said method comprising: (a) uniformly mixing a crosslinkable thermoplastic resin, a crosslinking agent which has a decomposition temperature higher than the melting point of said resin and a foaming agent which has a decomposition temperature higher than that of said crosslinking agent and generates a gas upon decomposition; (b) extruding said mixture through a long-land die provided with a heating means and having a front or upstream portion having a length of more than 200 cm and a rear or downstream portion having a length of 1/5-2 times the length of said front or upstream portion, the temperature of said rear or downstream portion being higher than the temperature of said front or upstream portion, and said long-land die being further provided with a choking orifice at an intermediate portion between said front or upstream portion and said rear or downstream portion, said choking orifice creating back pressure in said long-land die and having a choking ratio A/B of from 10/7-10/2, wherein A is the vertical cross-sectional area of said long-land die in front of said orifice and B is the vertical cross-sectional area of the narrowest section of said orifice, and simultaneously supplying a lubricant into an interface between the inner surface of said long-land die and said mixture; (c) heating said conveyed mixture in said front or upstream portion of said long-land die to a temperature sufficient to cause decomposition of said crosslinking agent and crosslinking of said crosslinkable thermoplastic resin, the degree of crosslinking as defined by gel ratio being 10-70%; (d) heating the mixture from step (c) in said rear or downstream portion of said long-land die to a temperature higher then the temperature in said front or upstream part of the die to cause decomposition of said foaming agent; and (e) releasing the mixture from step (d) from said long-land die into an atmospheric or controlled pressure zone to allow said mixture to expand and form said foamed article.

Claim 18

The method according to any one of claims 12-15, wherein said rear or downstream portion of the long-land die is gradually increased in cross-sectional area along the direction of resin flow.