Method of making a composite foamed and shaped article

Abstract: A method of making a composite foamed and shaped article includes a first step in which a thermoplastic resin powder is filled in a slush molding die to form a first resin layer, a second step in which a mixed powder consisting of a heat decomposable foaming agent and the thermoplastic resin powder is filled in the die in which the first resin layer was already formed, to form a second resin layer on the surface of the first resin layer, and a third step in which the heat decomposable foaming agent is made to foam by heat treatment to form a final product of a composite foamed and shaped article. In this method the slush molding die is pre-heated by an infrared heating method.

Description: The present invention relates to a method for making a composite foamed and shaped article suitable for use for the interior of cars or surface fitting of furniture. A method for making a composite foamed and shaped article suitable for use for the interior of cars or surface fitting of furniture utilizing the powder slushing method is already known. For example, a method of making a composite foamed and shaped article, is disclosed in JP-B-42-11510, including a first step in which a thermoplastic resin powder is introduced into an unheated slush moulding die which is then heated so as to form a first resin layer and then the surplus thermoplastic resin powder is discharged; a second step in which a mixed powder consisting of heat decomposable foaming agent and the thermoplastic resin powder is introduced into the slush moulding die where the first resin layer is formed and then reheated to form a sintered second resin layer on the first resin layer and then the surplus mixed resin powder is discharged; and a third step in which the slush moulding die in which the first and the second resin layers are formed is further heated to foam the second resin layer and then the die is cooled and the foamed and shaped article is taken out from the die. In this method, however, the slush moulding die is heated to form the sintered resin layer in the first and second steps, so it takes a relatively long time to obtain a shaped article, which is disadvantageous in productivity. To overcome this problem in the prior art, as another proposal, JP-B-63-27167 discloses a first step in which a thermoplastic resin powder is filled in a slush moulding die preheated in a gas oven to form a first resin layer and a second step in which a mixed powder is filled in the slush moulding die and heated to be adhered to the first resin layer, utilizing the remaining heat of the die to form a second resin layer. Even utilizing this method, however, the time required to produce a single shaped article, i.e., the moulding time, cannot sufficiently be shortened. That is, in a conventional moulding die heating method utilizing heated air or the like, a problem arises in that it is difficult to rapidly and uniformly heat a moulding die with heated air. Therefore, even if the heating of the moulding die in the second step is eliminated, the time required to produce a shaped article cannot be sufficiently shortened. That is, a heating method has never been obtained which can fully meet with these conditions. The hot air heating method is the most typical heating method. However, in this method, air is heated and the die is heated by the thus heated air. Air has an extremely low coefficient of thermal conductivity. Accordingly, a lot of heat sources are required to heat the heating medium per se, and the heating time is naturally extended. Further, it is difficult for the die to be heated uniformly. On the other hand, there is a method in which use is made of oil as a heating medium. Oil is heated by a suitable heating source and supplied to conduits arranged on the outer peripheral surface of the die to heat it. This method has an advantage over the air heating method in view of the heating medium (the coefficient of thermal conductivity of oil is higher than that of air), but the heating temperature of the die can be easily be affected by the degree of contact between the die and the conduits, the position on the outer surface of the die on which the conduits are installed, and the number of conduits installed per unit area of the surface of the die, etc. Thus, a lot of time and expense is required for manufacturing the die and for heating tests. Further, the die cannot be heated sufficiently uniformly and rapidly in spite of taking a lot of time and expense. Moreover, a cooling oil should be prepared to cool the die. In the induction heating method, induction coils are arranged on the outer peripheral surface of the die and actuated through an oscillator. Since the induction coils are installed on the outer surface of the die, however, this method has the same drawbacks as the oil heating method. To overcome this problem, many countermeasures have been considered. Finally it was found that heating the moulding die by infrared ray is the best. Therefore, according to the present invention, there is provided a method for making a composite foamed and shaped article, which method comprises the steps of (a) preheating a slush moulding die, (b) introducing into the slush moulding die powder of thermoplastics resin and allowing the heat of the slush moulding die to cause adhesion of at least a portion of the powder to the said die to form a first resin layer, (c) optionally discharging surplus unadhered powder if present, (d) contacting the said first resin layer in the slush moulding die with a mixed powder comprising a heat decomposable foaming agent and powder of thermoplastics resin, (e) utilizing at least a residual heat in the slush moulding die to allow adhesion of at least a portion of the mixed powder to the first layer of thermoplastics resin and thereby form a second resin layer, (f) optionally discharging surplus unadhered mixed powder if present, and (g) subjecting the second resin layer in the slush moulding die to heat treatment to cause foaming and thereby cause foaming and shaping of the article in the slush molding die, the said step (a) of preheating the slush moulding die being carried out by an infrared heating method utilizing an infrared gas burner in an atmosphere which is agitated by an agitating device. Thus, the method may include the following steps, namely a first step in which a heated slush moulding die is filled with a thermoplastic resin powder to form a first resin layer and then the surplus thermoplastic resin powder is discharged, a second step in which the die with the first resin layer formed therein is filled with a mixed powder consisting of a heat decomposable foaming agent and the thermoplastic resin powder, the remaining heat of the die is utilized and the mixed powder brought into contact with the first resin layer to form a second resin layer, and the surplus mixed resin powder is discharged, and a third step in which the second resin layer is subjected to heat treatment to cause foaming, and the die is cooled then the foamed and shaped article is taken out therefrom. The characterising feature of this method is that the slush moulding die in which the thermoplastic resin powder is later contained is heated, before the first step is carried out, by an infrared heating method utilizing an infrared gas burner in an atmosphere in which air is agitated by an air agitating device. The preferred embodiments of the present invention will be explained hereunder. The preferred method for making the composite foamed and shaped article includes the following main steps: (1) Preheating a slush moulding die; (2) The first step as mentioned above; (3) The second step as mentioned above, and (4) The third step as mentioned above. In the step of preheating the slush moulding die, infrared heating is used. To this end, a gas burner utilizing infrared rays is used, and at the same time as this heating operation is carried out, an air agitating device for agitating the atmosphere (air) is used. By this, the slush moulding die can be heated more rapidly and more uniformly. The heating temperature of the slush moulding die is selected as desired depending upon conditions such as the kind of thermoplastic resin powder used, although it is generally 250°C to 270°C. In the first step, the slush moulding die, preheated by infrared rays, is filled with the thermoplastic resin powder. The thermoplastic resin powder is melted by the heat of the slush moulding die to form a first resin layer inside the die. (The term "melted" means that at least a surface of particles of the resin powder is sufficiently molten to allow adhesion of the particles to one another and/or to the mould). Vinyl chloride resin is most preferably used as the thermoplastic resin powder. After the first resin layer is formed in the slush moulding die, the die is turned upside down to discharge the surplus thermoplastic resin powder. In the second step, the slush moulding die, in which the first resin layer is formed, is filled with a mixed powder consisting of a heat decomposable foaming agent and the thermoplastic resin powder. This may be done when the slush moulding die, pre-heated, for example, to 270°C, is gradually cooled and the temperature reaches around 210°C. The decomposable foaming agent is not decomposed and remains in the slush moulding die. After the second resin layer is formed on the surface of the first resin layer, the slush moulding die is overturned again to discharge the surplus thermoplastic resin powder. Up to this point, the slush moulding die was gradually cooled to a temperature of around 190°C. In the third step, the second resin layer in the slush moulding die is heated at 210 °C. With this, the decomposable foaming agent contained in the second resin layer is decomposed to convert the second resin layer into foam. After the foamed and shaped article is formed, the slush moulding die is cooled and the article taken out. The second resin layer is heated either by first heating the slush moulding die from which heat is transmitted to the second resin layer or directly heating the second resin layer. The latter is preferable. Further, heating with hot air is generally preferable. The slush moulding die is preferably cooled by spraying water on the die. According to the present invention, a composite foamed and shaped article can be obtained which is suitable for the interior of cars or surface fittings of furniture. In this production process, the time required to obtain a composite foamed and shaped article is shortened since the slush moulding die is heated rapidly and uniformly by infrared rays. Therefore, the method defined in the present invention is suitable for a mass production of the composite foamed and shaped articles. In a moulding process utilizing the powder-slush method, the die must be heated uniformly. Further, in a continuous moulding operation, rapid heating for the die is required. In the present invention, the infrared heating method is adopted. Accordingly, the pre-heated dies can be transferred to the first step successively in a short time and can be transferred from the first step to the second step in a short time. Thus, the second resin layer can be formed without reheating the die in the second step, and the time required to produce one shaped article, i.e., the moulding time, can further be shortened. As one example of the infrared heating method, mention may be made of use of an infrared gas burned in which infrared radiation is emitted by burning gases in a gas burner made of ceramic fibers. The heat efficiency is about two times that of the heated air method, i.e., about 60%. To achieve more uniform heating of the die and to improve the coefficient of irradiation of the infrared radiation to the die, a device for agitating the atmosphere (air) is provided in the room in which the die is irradiated. Moreover, a coating, for example, alkali silicate, may be provided on the surface of the die for accelerating the thermal absorption. The coating may be provided on the whole surface of the die or on local portions of the die in order to achieve a uniform die temperature. Example Giving a specific example of the steps of the present invention, in the die pre-heating step, a slush moulding die made of a Ni-Cu alloy was prepared for making a composite foamed and shaped article suitable for a console box used inside a car. This was placed in a furnace heated at 500°C and heated for 90 seconds with infrared radiation from an infrared gas burner in which liquefied petroleum gas was burned. In the first step, the die, preheated to 250°C, was filled with a thermoplastic resin powder and a skin-forming operation carried out for 10 seconds to form a sintered first resin layer. The moulding die was then overturned to discharge the surplus thermoplastic resin powder. This step required 30 seconds. In the second step, the die was filled with a mixed powder consisting of a heat decomposable foaming agent and the thermoplastic resin powder and a skin-forming operation carried out for 10 seconds to form a second resin layer on the surface of the first resin layer. At this stage, the temperature of the die was 210°C. Thereafter, the die was overturned to discharge the surplus thermoplastic resin powder. This step required 30 seconds. In the third step, the die was inserted into a hot air circulating furnace maintained at a temperature of 250°C and was heat treated for about 20 seconds to cause the second resin layer to foam. The die was then inserted into a cooling chamber and sprayed with cooling water for 20 seconds. The foamed and shaped article was manually released from the die. The total time for moulding the resin in this embodiment (moulded time) was 4 minutes. As explained above, in accordance with the method for making a composite foamed and shaped article of the present invention, the total time required to produce one shaped article, i.e., the moulding time, can be further shortened and a method suitable for mass production of composite foamed and shaped articles can be obtained.

Claims: A method for making a composite foamed and shaped article, which method comprises the steps of (a) preheating a slush moulding die, (b) introducing into the slush moulding die powder of thermoplastics resin and allowing the heat of the slush moulding die to cause adhesion of at least a portion of the powder to the said die to form a first resin layer, (c) optionally discharging surplus unadhered powder if present, (d) contacting the said first resin layer in the slush moulding die with a mixed powder comprising a heat decomposable foaming agent and powder of thermoplastics resin, (e) utilizing at least a residual heat in the slush moulding die to allow adhesion of at least a portion of the mixed powder to the first layer of thermoplastics resin and thereby form a second resin layer, (f) optionally discharging surplus unadhered mixed powder if present, and (g) subjecting the second resin layer in the slush moulding die to heat treatment to cause foaming and thereby cause foaming and shaping of the article in the slush molding die, characterized in that the preheating step (a) is carried out by an infrared heating method utilizing an infrared gas burner in an atmosphere which is agitated by an agitating device. A method according to claim 1, wherein (i) in step (b), only a portion of the said powder is adhered to the said die and the said optional step (c) is thereafter carried out, and (ii) in step (e), only a portion of the said mixed powder is adhered to the first layer of thermoplastics resin and the said optional step (f) is carried out. A method according to Claim 1 or 2, wherein the temperature of the heated slush moulding die in step (b) ranges from about 250°C to about 270°C. A method according to Claim 1, 2 or 3, wherein, in step (b), at least a portion of the thermoplastics resin powder is melted to form the said first resin layer. A method according to any preceding claim, wherein the thermoplastics resin powder comprises vinyl chloride. A method according to any preceding claim, wherein the said second resin layer absorbs heat from the said first resin layer until the slush moulding die reaches a temperature of about 190°C. A method according to any preceding claim, wherein, in step (g), the said second resin layer is heated at a temperature of abut 210°C. A method according to any preceding claim, wherein, in step (g), the said second resin layer is heated indirectly by heating the slush moulding die which then heats the said second rein layer via the said first resin layer. A method according to any one of Claims 1 to 7, wherein, in step (g), the said second resin layer is heated directly. A method according to Claims 9, wherein, in step (g), the said second resin layer is heated with hot air. A method according to any preceding claim, which includes the additional step of cooling the slush moulding die. A method according to Claim 11, wherein the slush moulding die is cooled by spraying water on it. A method according to any preceding claim, wherein, in step (g), the air surrounding the slush moulding die is agitated simultaneously with the said heat treatment. A method according to Claim 13, wherein the said agitation is carried out in a hot air circulating furnace. A method according to any preceding claim, wherein the slush moulding die is coated with a composition effective in accelerating thermal absorption of the slush moulding die. A method according to Claim 15, wherein the said coating on the slush moulding die comprises an alkali silicate. A method according to Claims 15 or 16, wherein the said coating of the slush moulding die covers less than the entire surface thereof, the location of the said coating being selected so as to effect a uniform heating of the slush moulding die. A method according to any preceding claim, wherein the slush moulding die comprises a Ni-Cu alloy. A method according to any preceding claim, wherein the combination of steps (a) to (c) is completed in about 30 seconds. A method according to any preceding claim wherein the combination of steps (d) to (f) is completed in about 30 seconds. A method according to any preceding claim, wherein the entire moulding cycle is completed in about 4 minutes.

Inventors: TSUCHIHASHI HIROSHI, TSUCHIHASHI, HIROSHI
Applicants: TORAY ENG CO LTD, TORAY ENGINEERING CO., LTD.
Application year: 1989
Main classification: B29C41
IPC codes: B29C41, B29C35, B29K105, B29L31, B29C33, B29C44