CONTINUOUS SHEET OF ELECTRON BEAM CROSSLINKED FOAM

Abstract: A continuous sheet of electron beam-crosslinked foam comprising 100 parts by weight of a polypropylene resin mainly comprising propylene, 5 to 40 parts by weight of a copolymer of ethylene with at least one monomer selected from the group consisting of acrylic acid, ethyl acrylate, maleic anhydride and vinyl acetate, and 10 to 80 parts by weight of another copolymer of ethylene with a C₄ to C₈ α-olefin, having a melting point of 117 to 123°C and a density of 0.890 to 0.910 g/cm³ . This foam has a gel fraction of 20 to 60 % and an expansion ratio of 5 to 40.

Description: The present invention relates to a method of preparing a foam, and more particularly to a method of preparing a sheet-type foam which includes curing by an electron beam. Electron-beam cured foams have been used as cushioning materials in automobile interiors, and as heat-resisting and heat-insulating materials. JP-A-265935/1988 discloses a cured foam containing more than 10 wt% of an olefin resin comprising linear very-low-density polyethylene. The linear very-low-density polyethylene is made by copolymerizing ethylene with an α-olefin having more than 4 carbons. According to the disclosure, the olefin resin may be a polymer made from olefin monomers, such as polypropylene, or a copolymer mixture of ethylene/ethylacrylate. The linear very-low-density polyethylene may be prepared by a process in which ethylene is copolymerized with an α-olefin having more than 4 carbons, such as butene-1, hexene-1, octene-1, 4-methylpentene-1, in order to add an appropriate number of short branches to the main linear chains, whereby the density is decreased. The above document further discloses, in Example 2, an ethylene/propylene random copolymer (35 parts by weight) having a density of 0.89 g/cm 3 , Melt Index of 7.0 g/10min, and melting point of 145 °C; a high-density polyethylene (30 parts by weight) having density of 0.957 g/cm 3 and MI of 6.5 g/10min; a linear very-low-density ethylene/4-methylpentene-1 copolymer (35 parts by weight) having a density of 0.905 g/cm 3 ; azodicarbonamide, as a foaming agent, in an amount of 15 parts by weight; trimethylpropane-trimethacrylate (3.0 parts by weight); and a heat stabilizer (0.5 parts by weight) were mixed. The mixture was formed into a sheet of 1.5 mm thickness by an extruder. In order to cross-link the sheet, both surfaces were irradiated by an electron beam of 2.0 Mrad in an electron-beam irradiation apparatus. The sheet was then uniformly transported through a hot air stove at 250 °C for heat foaming, whereby a sheet-type foam of about 4 mm in thickness was obtained. The obtained cross-linked foam is of inferior tensile strength and dimensional stability, although it has good flexibility. That is, a foam produced exactly in accordance with the technology disclosed in JP-A-265935/1988 has insufficient tensile strength and too high an expansion stress, due to the inappropriateness of the selection of resins and the mixing ratio. Additionally, JP-A-155232/1981 and JP-A-157839/1983 disclose a resin made of a copolymer of ethylene and a C 4-8 α-olefin, which copolymer has a melting point of from 117°C to 123°C and a density of from 0.890 g/cm 3 to 0.910 g/cm 3 . However, this resin does not comprise 3 components, in contrast to that of the above example from JP-A-265935/1988. The present invention seeks to provide (1) an electron-beam cured sheet-type foam of improved tensile strength and dimensional stability; (2) an electron-beam cured sheet-type foam of improved tensile strength, dimensional stability and flexibility; (3) an electron-beam cured sheet-type foam of improved tensile strength at high temperatures and increased processability in molding wherein the foam is used in a composite material; (4) an electron-beam cured sheet-type foam of improved dimensional stability whereby it may be more suitably used as a cushioning material in automobile interiors; and (5) an electron-beam cured sheet-type foam of improved tensile strength at high temperatures whereby it may be more suitably used as a heat-resisting and heat-insulating foamed material. According to one aspect, the present invention provides an electron-beam cured sheet-type foam obtainable by a process comprising electron beam curing a mixture of components (a), (b) and (c) defined below, which foam comprises: (a) 100 parts by weight of a polypropylene type resin (A), which is a polypropylene homopolymer or a random, block or random/block copolymer consisting of units derived from propylene and from 2 to 35%, by weight of the copolymer, of at least one comonomer selected from ethylene and butene-1; (b) 5 to 40 parts by weight of a copolymer resin (B) including units derived from ethylene and 5 to 30 weight % at least one comonomer selected from acrylic acid, ethyl acrylate, maleic anhydride and vinyl acetate; and (c) 10 to 80 parts by weight of a copolymer resin (C) consisting of units derived from ethylene and a C 4-8 α-olefin, having a melting point of from 117°C to 123°C and a density of from 0.890 g/cm 3 to 0.910 g/cm 3 ; and which foam has a gel content of from 20 to 60 and an expansion of from 5 to 40, each of which gel content and expansion is measured as hereinafter described. According to another aspect, the invention provides a method of preparing the above electron-beam cured sheet-type foam, which method comprises electron beam curing a mixture of components (a), (b) and (c) and thereafter subjecting the cured mixture to foaming. The foam thus prepared may preferably have a tensile strength at 150°C of 50 kg/cm 2 .% or more, and a size change at 120°C of 5% or less, ie size stability. The invention will now be described in more detail. We have found that a foam of improved flexibility, tensile strength, dimensional stability, and processability in molding may be obtained by mixing the resins (A), (B) and (C) in a proper ratio, and by electron-beam curing prior to foaming. Components A polypropylene type resin (A) comprising propylene for use in a foam according to the present invention is, for example, a propylene homo-polymer; or a random copolymer, block copolymer or random/block copolymer consisting of units derived from propylene and at least one monomer selected from ethylene and butene-1. The amount of ethylene and/or butene-1 in the copolymer may range from 2 to 35 weight percent, preferably from 3 to 30 weight percent. More preferably, the copolymer may be a random copolymer including units derived from ethylene in an amount of 4 to 15 weight percent. The copolymer resin (B) includes units derived from ethylene and at least one comonomer in an amount of 5 to 30 weight percent (preferably, 8 to 25 weight percent) selected from acrylic acid, ethyl acrylate, maleic acid anhydride and vinyl acetate. More preferably, the copolymer (B) may be an ethylene-ethyl acrylate (EEA) copolymer comprising 8 to 18 percent of ethyl acrylate, or a three- component copolymer of ethylene/ ethyl acrylate/maleic acid anhydride (EEA-MAH) copolymer, including 8 to 18 percent of ethyl acrylate and maleic acid anhydride in total. The copolymer resin (C) consisting of ethylene and the α-olefin having 4 to 8 carbons has a melting point of from 117 to 123°C, and a density of from 0.890 to 0.910 g/cm 3 . Preferably, the copolymer (C) may include an α-olefin having 4 to 6 carbons, and may have a melting point of from 117 to 123°C and a density of from 0.895 to 0.905 g/cm 3 . The copolymer (C) of ethylene and α-olefin may be an ethylene/α-olefin copolymer as disclosed in JP-A-157839/1983. There is a correlation between the density and the melting point of the copolymer, whereby the melting point increases as the density increases; but some physical characteristics of the resin, such as melting point, tensile strength, expansibility and flexibility, can be changed under a constant density, by using a different catalyst or a different mixing method. The copolymer (C) in the foam according to the present invention is different from the linear very-low-density polyethylenes as described in JP-A-265935/1988, viz., Ultzex (Mitsui Petrochemical Industries Ltd.) and Excelen (Sumitomo Chemical Co., Ltd.). For example, at density ranging from 0.890 to 0.910 g/cm 3 , the polyethylene used in JP-A-265935/1988 has a melting point 4 to 7°C lower than that of the present invention. The lower melting point tends to lead to a deterioration in the dimensional stability of the foam. At the same time the polyethylene used in a foam according to the present invention has a higher melting point at low density, providing good flexibility and low size-change at 120°C. According to the present invention, the mixing ratio of resin components (A), (B) and (C) is defined as follows: the amount of component (A) is 100 parts by weight, the amount of component (B) is 5 to 40 parts by weight (preferably, 5 to 25 parts by weight), and the amount of component (C) is 10 to 80 parts by weight (preferably, 20 to 50 parts by weight). If the proportion of the component (B) is more than 40 parts by weight, the size stability (size-change at 120 °C) of the obtained foam becomes more than 5 percent. If the proportion of component (B) is lower than 5 parts by weight, the obtained foam cannot satisfy the required levels of flexibility, heat resistance, tensile strength and molding processability. In particular, the obtained foam lacks sufficient tensile strength at high temperatures. Moreover, if the proportion of the component (B) is lower than 5 parts by weight, the obtained foam has the same characteristics as those of a foam made from a mixture of the components (A) and (C). If a foam contains an excess of the component (A), the obtained foam lacks sufficiently high flexibility, although it has high shock resistance and dimensional stability. If a foam contains an excess of the component (C), the obtained foam has inferior heat resistance, although it has high flexibility. If the proportion of the component (C) is less than 10 parts by weight, the flexibility of the obtained foam deteriorates. Moreover, if the proportion of the component (C) is more than 80 parts by weight, the size stability deteriorates, although good flexibility may be obtained. Gel Content and Expansion According to the present invention, the gel content of the foam ranges from 20 to 60 percent and the expansion from 5 to 40. If the gel content is lower than 20 percent, the dimensional stability of the obtained foam deteriorates due to gel shortage. Furthermore, the predetermined density cannot be obtained and the formed surfaces of the foam are rough, due to the fact that a gas is generated inside the foam during production which disrupts the surfaces. Moreover, sufficient tensile strength at high temperatures cannot be obtained. If the gel content is more than 60 percent, the obtained foam tends too strongly to retain its shape resulting in greater than 5 percent size-change at 120°C, ie lower dimensional stability. The flexibility also deteriorates. The expansion must range from 5 to 40. If the expansion is lower than 5, the flexibility deteriorates inasmuch as the foam becomes too hard, although the tensile strength and the molding processability remain sufficient. If the expansion is more than 40, the shock-absorbing ability deteriorates inasmuch as the obtained foam becomes too soft, although the flexibility remains sufficient. Tensile Strength According to the present invention, the foam may have a tensile strength at 150°C of 50 kg/cm 2 .% or more. If the tensile strength is lower than 50 kg/cm 2 .%, the obtained foam becomes ruptured, because the tensile strength of the foam is not sufficient at high temperatures to correspond with the expansion and the expansion stress of the facing material (such as a sheet of vinyl chloride), when the foam is heat-processed after being laminated with the facing material. Cured foams made of conventional resin proportions have a problem in that only few kinds of facing material may be used in a heat molding process due to the low expansion stress of the foams. However, a foam according to the present invention has a tensile strength of 50 kg/cm 2 .% or more, so that it is superior to conventional foams. Foam according to the present invention is of improved tensile strength at high temperatures, whereby less disuniformity in thickness of the product occurs, and heat-molding processability is improved. The molding processability (L/D) can be expanded to 1.2. Dimensional Stability The dimensional stability (size-change at 120 °C) of a foam according to the present invention is preferably 5 percent or less. If the dimensional stability is more than 5 percent, foam shrinkage is so great that products in which the inclusion of a heat-process method is essential cannot be obtained. Compressive Hardness and Stress The 25%-compressive hardness of the foam according to the present invention preferably ranges from 0.1 to 1.0 kg/cm 2 at ordinary temperatures, i.e. 20±2°C. If the compressive hardness is more than 1.0 kg/cm 2 , the tensile strength of foam becomes so great that its tactility deteriorates. If the compressive hardness is lower than 0.1 kg/cm 2 , the foam becomes so soft that a "reaching-the-bottom feeling" results (i.e., a feeling of reaching the opposite surface when the foam is pressed by a finger). Furthermore, foam of weak tensile strength deteriorates handling characteristics in manufacturing and transforming processes. The 5%-tensile stress of the foam according to the present invention may range from 10 to 100 kg/cm 2 at ordinary temperature. If the stress is more than 100 kg/cm 2 , the shock absorbing ability deteriorates and the tensile strength becomes too great. If the stress is lower than 10 kg/cm 2 , the tensile strength becomes too weak, although the flexibility is adequate. The 25%-compressive hardness and the 5%-tensile stress at ordinary temperature may be used as a measure of suppleness flexibility. Foams of which characteristics are within the above ranges will have suppleness noticeably different from those of conventional foams, when such foams are evaluated after they are laminated with various kinds of facing material and processed to form products. Sheet The foam according to the present invention is a sheet. The foam may be more than 10 m long, and may be rolled in forming a material product. The long sheet may be processed in several continuous manufacturing steps in order to decrease losses during these steps. Manufacturing Steps A method for manufacturing a foam according to the present invention will now be described. The resin components (A), (B) and (C), powdered into 32-mesh-passing size, are provided, of which the proportions are within the ranges of the present invention. The components are fed into a high-speed mixing apparatus (such as a Henschel mixer or a super mixer). Furthermore, an ordinary chemical foaming agent of the decomposable type (for example, azodicarbonamide, dinitrosopentamethylene-tetramine, etc.) in an amount of 2 to 20 parts by weight is added to the resin components in an amount of 100 parts by weight. At the same time, other additives may also be included. Thereby, initial mixing is carried out. The obtained material is fed into an extruder heated at 130 to 190 °C, and melt-diffusion mixing is effected, producing a long sheet which is 0.5 to 6 mm in thickness. In the mixing steps, it is important that the foaming agent be decomposed as little as possible. The obtained sheet must be cured in order not to allow interior gas generated by the decomposition of the fbaming agent to escape during the foaming process. In order to cure the sheet, a conventional ionizing radiation method may be used. A conventional peroxide compound can be added prior to irradiation; furthermore, if desired, a multi-functional monomer such as divinylbenzene, trimethylolpropane triacrylate or pentaerythritol triacrylate; a multi functional dimer of these; or a multi functional trimer of these may be added as a crosslinking promoting agent. Added within the scope of the present invention may be an inorganic filler such as calcium carbonate, talc, glass balloon, glass fiber, etc.; an antistatic agent; a flame retarder; and a colorant. The obtained cured sheet is introduced into a heated-air atmosphere or onto a chemical liquid such as a silicone oil, the temperature of which is 10 to 100 °C higher than the decomposing temperature of the foaming agent, whereby the foaming agent is rapidly decomposed to make the sheet-type cured foam. If a corona discharging process is applied to at least one surface of the obtained foam, whereby the surface-wetting tension is more than 37 dyne/cm, the foam will be sufficiently adhesive to coating materials. A foam having an adhesive layer, or a cohesive layer formed of a coating material, can be laminated with a sheet of facing material, a film, another kind of foam, a metallic foil, a sheet of paper, a piece of nonwoven fabric made of natural fiber or synthetic fiber, or a piece of synthetic leather. The obtained laminated product can be molded by various methods. Parameters The parameters will be explained as follows: (a) Melting Point (°C) The melting point is a temperature at the highest peak of endothermic peaks in measurement with a differential spectrum calorimeter (DSC). (b) Density (g/cm 3 ) The density is measured in accordance with JISK6767. (c) Gel Content (%) The foam to be measured is broken into small pieces, and 0.2 g pieces of the foam are selected by accurate weighing. The weighed pieces are soaked in tetralin at 135 °C for 2 hours, to elute soluble substances. Then, the insoluble part is taken out from the tetralin, and the tetralin remaining in the insoluble part is removed by acetone. The acetone is removed by hot water at 40 °C. The insoluble part is then dried in a vacuum drier at 100 °C for 1 hour, and the weight wl(g) of the insoluble part is measured. The gel content (%) is calculated by the following formula, wherein 10 pieces of the foam should be used. Gel Content (%) = (w1 / 0.2) x 100 (d) Expansion A 10x10-cm piece is taken from a sheet-type foam. The piece is measured with respect to its thickness t (cm) and its weight w2 (g). The expansion is calculated by the following formula, wherein 10 sample pieces are used. Expansion = 1 / (w2 / [10 x 10 x t]) (e) Tensile Strength at 150 °C (kg/cm 2 ·%) A 1x10-cm piece is taken from a sheet-type foam, and measured with respect to its thickness t(cm). The piece of foam is set between chucks in a tensilon-type tensile tester within a heat box at 150 °C. The distance between the chucks is 5 cm. The piece of foam is protected by paper or the like at the chucked portions, so that it will not be fractured at those portions. 5 minutes after the piece is set in the heat box, the piece is stretched at a tensile speed of 200 mm/min. The rupture stress s1(kg) and the rupture extension s2(cm) are recorded on a sheet of record paper. The tensile strength at 150 °C (kg/cm 2 ·%) can be calculated by the following formula, wherein 5 pieces of foam are used. Rupture Strength (kg/cm 2 ) = s1 / (1 x t) Rupture Elongation (%) = s2 / 5 x 100 Tensile Strength at 150 °C (kg/cm 2 .%) = (1) x (2) where s1 is 0.3 kg/cm 2 or more and s2 is 100 % or more. (f) Size-Change at 120 °C (Dimensional Stability) (%) A 10x10-cm piece is taken from a sheet-type foam, and measured in thickness t(mm) at the center. The piece is heated for 1 hour in a hot air drier at 120 °C. Subsequently, the piece is left for 2 hours at room temperature, and then its size is measured. The 120°C-Size-Change (%) can be calculated by the following formula. 120°C-Size-Change (%) MD = (10 - X MD )/10 x 100 ditto (%) TD = (10 - X TD )/10 x 100 where TD signifies the lengthwise direction, MD signifies the widthwise direction. (g) 25% Compressive Hardness at Ordinary Temperature (kg/cm 2 ) The Compressive Hardness is measured in accordance with JIS K-6767. (h) 5% Expansion Stress at Ordinary Temperature (kg/cm 2 ) A 1x10-cm piece is taken from a sheet-type foam, and its thickness t(cm) is measured. The piece is set between chucks separated by a distance of 5 cm in a tensilon-type tensile tester, and stretched at 20 mm/min. The changes of stress and elongation are recorded on a sheet of paper, and then the stress s1 (kg) of the piece is measured when it has been stretched five percent. The 5%-expansion stress at ordinary temperature is calculated by the following formula. 5%-expansion Stress (kg/cm 2 ) at ordinary temperature = s1 / (1 x t) (i) Molding Processability (L/D) Cylindrical metal molds of which the depth(L)/diameter(D) ratio varies at intervals of 0.05 are used. A foam or laminated sheet is vacuum-molded at 160 to 180 °C by a vacuum molding machine. The maximum ratio at which the foam forms a molding without any breaks is determined as the value of molding processability. Molding Processability (L/D) = L / D EXAMPLES Tables 1A and 1B show the resin composition, the mixing ratio, the curing methods and the characteristics of the foams according to the present invention. In the tables, "random" means random copolymer, "block" means block copolymer, and "homo" means homo polymer. "EPC" means propylene/ethylene copolymer, "BPC" means propylene/butene copolymer, "EEA" means ethylene/ethylacrylate, "EVA" means ethylene/vinylacetate copolymer, and "EEA·MAH" means (ethylene/ethyl acrylate/maleic acid anhydride) terpolymer. "Et-Bt" of ethylene/α-olefin copolymer means a copolymer formed by the polymerization of ethylene with butene as an α-olefin. The low-density polyethylene is made by the high pressure method, and the high-density polyethylene is made by the low pressure method. The linear very-low-density polyethylene is a polyethylene of which density is 0.910 g/cm 3 or lower, and which is made by the highpressure ion polymerization method and the intermediate-low-pressure solution polymerization method. Examples according to the present invention and comparative examples will now be described. One hundred and fifty·kg mixtures of the resin components, a foaming agent, and other additives were each fed into a 500-litre Henschel mill. Each portion of the obtained mixed material was fed into an extruder the cylinder temperature of which was 170 to 180°C to carry out melt-mixing, whereby a long sheet of 1.5 mm thickness and 500 mm width was formed. The long sheet was set in an electron-beam irradiating device, and then it was cured with 2 to 10 Mrad electron-beam radiation. The obtained foamable cured sheet was introduced uniformly onto a silicone oil the temperature of which ranges from 210 to 240 °C, thereby foaming the sheet. The foamed sheet was dried by hot air, whereby a sheet-type cured foam was obtained. The obtained foams ranged from 2.5 to 3.5 mm in thickness and from 950 to 1100 mm in width. The foams according to the present invention, as shown in Table 1B, had high degrees of flexibility, tensile strength, dimensional stability and molding processability, since the resin components, the mixing ratio, the curing method and the crosslinking density were chosen appropriately. In particular, 25%-compressive hardness and 5%-expansion stress as parameters of flexibility were superior, so that the obtained flexible foams had a good tactility. Furthermore, the obtained foams had a tensile strength at high temperature which had not been achieved by conventional foams. Tables 2A and 2B show the resin component, the mixing ratio, the curing method and the characteristics of the obtained foams with regard to comparative examples. The comparative examples were cured by the electron-beam curing method in the same manner as in the examples according to the present invention, or in the curing method with peroxide compounds, and foamed in the same way as in the examples according to the present invention. Comparative examples 1 to 3 were made of ethylene/α-olefin copolymer. As shown in Table 2B, the comparative examples were inferior, at least in terms of flexibility, tensile strength and dimensional stability, since the resin components, the mixing ratio and the curing method were outside the scope of the present invention. In particular, the comparative examples were much inferior in terms of tensile strength at high temperature and 120°C size-change. Comparative examples 4 to 7 were made of linear very-low-density polyethylene (EXCELEN). As shown in Table 2B, the comparative examples were inferior, at least in terms of flexibility, tensile strength and dimensional stability, since the resin components, the mixing ratio and the curing method were outside the scope of the present invention. Comparative examples 4 to 7, as well as Comparative examples 1 to 3, were noticeably inferior to the examples according to the present invention in terms of tensile strength at high temperature and 120°C size-change. In the tables, the parts marked by an asterisk are outside the scope of the present invention. As has been described above, the foams according to the present invention are superior in terms of flexibility, or tactility in particular. A high degree of molding processability can be obtained in accordance with the present invention, because the foams have a high degree of tensile strength, particularly at high temperatures. Furthermore, the foams according to the present invention also have sufficient dimensional stability, whereby they may be suitable as a damping material, for application to the doors, ceilings, instrument panels, etc. of automobiles interiors. The foams according to the present invention can also be applied to the base material of heat-resist adhesive tape, the base material of packagings, and heat-resisting and heat-insulate molding products, including various kinds of valves and pipes, etc., by virtue of the above characteristics.

Claims: An electron-beam cured sheet-type foam obtainable by a process comprising electron beam curing a mixture of component (a), (b) and (c) defined below prior to foaming and which foam comprises: (a) 100 parts by weight of a polypropylene type resin (A), which is a polypropylene homopolymer or a random, block or random/block copolymer consisting of units derived from propylene and from 2 to 35%, by weight of the copolymer, of at least one comonomer selected from ethylene and butene-1; (b) 5 to 40 parts by weight of a copolymer resin (B) including units derived from ethylene and 5 to 30 weight % of at least one comonomer selected from acrylic acid, ethyl acrylate, maleic anhydride and vinyl acetate; and (c) 10 to 80 parts by weight of a copolymer resin (C) consisting of units derived from ethylene and a C 4-8 α-olefin, having a melting point of from 117°C to 123°C and a density of from 0.890 g/cm 3 to 0.910 g/cm 3 ; and which foam has a gel content of from 20 to 60 and an expansion of from 5 to 40, each of which gel content and expansion is measured as indicated in the description. A foam according to claim 1, wherein the tensile strength of the foam at 150°C is 50 kg/cm 2 .% or more, and the size-change at 120°C is 5 percent or less each of which tensile strength and size change is measured as indicated in the description. A foam according to claim 2, wherein the 25%-compressive hardness measured according to JIS K-6767 at a temperature of 20±2°C ranges from 0.1 to 1.0 kg/cm 2 , and the 5%-expansion stress, measured as indicated in the description, at that temperature ranges from 10 to 100 kg/cm 2 . A foam according to claim 3, wherein the number of parts by weight of the polypropylene type resin (A) is 100, the number of parts by weight of the copolymer (B) ranges from 5 to 25, and the number of parts by weight of the copolymer (C) ranges from 20 to 50. A foam according to claim 4, wherein the copolymer (C) includes a C 4-6 α-olefin, has a melting point of from 117 to 123°C, and a density of from 0.895 to 0.905 g/cm 3 . A foam according to claim 5, wherein the copolymer (B) includes a comonomer in an amount of 5 to 30 weight percent. A foam according to claim 6, wherein the copolymer (B) includes a comonomer in an amount of 8 to 25 weight percent. A foam according to claim 7, wherein the copolymer (B) is selected from an ethylene/ethyl acrylate copolymer, containing from 8 to 18 weight percent of ethyl acrylate; and a three-component copolymer of ethylene/ethyl acrylate/maleic acid anhydride, containing 8 to 18 weight percent of ethyl acrylate and maleic acid anhydride in total. A foam according to any preceding claim, wherein the polypropylene type resin (A) contains 3 to 30 weight percent of the comonomer. A foam according to claim 9, wherein the polypropylene type resin (A) is a random copolymer containing 4 to 15 weight percent of ethylene. A method of preparing an electron-beam cured sheet-type foam, which foam comprises: (a) 100 parts by weight of a polypropylene type resin (A), which is a polypropylene homopolymer or a random, block or random/block copolymer consisting of units derived from propylene and from 2 to 35%, by weight of the copolymer, of at least one comonomer selected from ethylene and butene-1; (b) 5 to 40 parts by weight of a copolymer resin (B) including units derived from ethylene and 5 to 30 weight % of at least one comonomer selected from acrylic acid, ethyl acrylate, maleic anhydride and vinyl acetate; and (c) 10 to 80 parts by weight of a copolymer resin (C) consisting of units derived from ethylene and a C 4-8 α-olefin, having a melting point of from 117°C to 123°C and a density of from 0.890 g/cm 3 to 0.910 g/cm 3 ; and which foam has a gel content of from 20 to 60 and an expansion of from 5 to 40, each of which gel content and expansion is measured as indicated in the description; and which method comprises electron beam curing a mixture of components (a), (b) and (c) and thereafter subjecting the cured mixture to foaming. A method according to claim 11, wherein the tensile strength of the foam at 150°C is 50 kg/cm 2 .% or more, and the size-change at 120°C is 5 percent or less, each of which tensile strength and size change is measured as indicated in the description A method according to claim 12, wherein the 25%-compressive hardness measured according to JIS K-6767 at a temperature of 20±2°C ranges from 0.1 to 1.0 kg/cm 2 , and the 5%-expansion stress, measured as indicated in the description, at that temperature ranges from 10 to 100 kg/cm 2 . A method according to claim 13, wherein, in the foam, the number of parts by weight of the polypropylene type resin (A) is 100, the number of parts by weight of the copolymer (B) ranges from 5 to 25, and the number of parts by weight of the copolymer (C) ranges from 20 to 50. A method according to claim 14, wherein the copolymer (C) includes a C 4-6 α-olefin, has a melting point of from 117 to 123°C, and a density of from 0.895 to 0.905 g/cm 3 . A method according to claim 15, wherein the copolymer (B) includes a comonomer in an amount of 5 to 30 weight percent. A method according to claim 16, wherein the copolymer (B) includes a comonomer in an amount of 8 to 25 weight percent. A method according to claim 17, wherein the copolymer (B) is selected from an ethylene/ethyl acrylate copolymer, containing from 8 to 18 weight percent of ethyl acrylate; and a three-component copolymer of ethylene/ethyl acrylate/maleic acid anhydride, containing 8 to 18 weight percent of ethyl acrylate and maleic acid anhydride in total. A method according to any one of claims 11 to 18, wherein the polypropylene type resin (A) contains 3 to 30 weight percent of the comonomer. A method according to claim 19, wherein the polypropylene type resin (A) is a random copolymer containing 4 to 15 weight percent of ethylene.

Inventors: TAKEDA MASASHI, UEJIKKOKU NARIO, TAKEDA, MASASHI, UEJIKKOKU, NARIO, TAKEDA, MASASHI 1567, OHARA-UEDA KOUGA-CHO, UEJIKKOKU, NARIO 35-216, OAZA-YAMAZURA RYUOU-CHO
Applicants: TORAY INDUSTRIES, TORAY INDUSTRIES, INC.
Application year: 1990
Main classification: C08J9
IPC codes: C08J9, C08L23, C08L51