# US 11,111,349 B2 · Molded foam

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- Number: US 11,111,349 B2
- Document ID: US11111349B2
- Status: Granted
- Kind: B2
- Application number: 15/107,968
- Filed: 2014-12-08
- Published: 2016-11-17
- Granted: 2021-09-07
- Earliest claimed: 2013-12-27
- Assignees: Kyoraku Co., Ltd.
- Applicants: Kyoraku Co., Ltd.
- Inventors: Masaaki Onodera; Takeru Sano
- Web page: https://patentgrep.com/patent/US11111349B2

## CPC

- C08J 9/0061: {characterized by the use of several polymeric components}
- B29C 49/0005: {characterised by the material}
- C08J 9/122: {Hydrogen, oxygen, CO2, nitrogen or noble gases}
- B29K 2023/0633: {LDPE, i.e. low density polyethylene}
- B29K 2023/065: {HDPE, i.e. high density polyethylene}
- B29K 2105/04: cellular or porous
- B29L 2031/30: Vehicles, e.g. ships or aircraft, or body parts thereof {(vanes or blades B29L2031/08, air bags B29L2022/027)}
- C08J 2201/03: Extrusion of the foamable blend
- C08J 2203/06: CO2, N2 or noble gases
- C08J 2203/08: Supercritical fluid
- C08J 2205/052: Closed cells, i.e. more than 50% of the pores are closed
- C08J 2207/00: Foams characterised by their intended use
- C08J 2323/06: Polyethene
- C08J 2423/06: Polyethene
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

A molded foam that can be easily taken out of split mold blocks is provided. According to an aspect of the present disclosure, a molded foam is obtained by clamping, with split mold blocks, foamed resin obtained by melting and kneading a polyethylene-based resin, wherein the molded foam has a MFR (190° C., g/10 min) of less than 0.8, or the polyethylene-based resin has a MFR (190° C., g/10 min) of not more than 1.0.

## Claims

### Claim 1

A blow molded foam molded from a foamed resin made of a polyethylene-based resin, the blow molded foam being an automobile duct configured to circulate cool or warm aft supplied from an air conditioning unit,
wherein the blow molded foam has a MFR (190° C., g/10 min) of not less than 0.17 and not more than 0.40, and wherein a surface roughness Rmax of the blow molded foam is 200 μm or less,
wherein the polyethylene-based resin has a MFR (190° C., g/10 min) of not less than 0.34 and not more than 1.0,
wherein the polyethylene-based resin consists of:
a high-density polyethylene-based resin of between 50 parts by mass and 90 parts by mass, wherein the high-density polyethylene-based resin has a density 0.949 g/cm3, a MFR of 0.3 g/10 min, and
a low-density polyethylene-based resin of between 10 parts by mass and 50 parts by mass, wherein the low-density polyethylene-based resin has a density 0.919 g/cm3, a a MFR of 1.7 g/10 min.

### Claim 2 (depends on 1)

The blow molded foam molded according to claim 1, wherein the low-density polyethylene-based resin is manufactured by an autoclave process.

### Claim 3 (depends on 1)

The blow molded foam according to claim 1, wherein the polyethylene-based resin consists of the high-density polyethylene-based resin of 50 parts by mass and the low-density polyethylene-based resin of 50 parts by mass.

### Claim 4 (depends on 1)

The blow molded foam according to claim 1, comprising
a tube body having a supply portion to be connected to an air conditioner unit; and tube portions with one end connected to the supply portion and other end provided with fitting portions, and
flange portions connected to the tube body, wherein
the automobile duct is configured to circulate cool or warm air supplied from the supply portion into the tube body.

### Claim 5 (depends on 1)

The blow molded foam molded according to claim 1, wherein the polyethylene-based resin has a MFR (190° C., g/10 min) of 0.34 to 0.9.

### Claim 6 (depends on 1)

The blow molded foam molded according to claim 1, wherein the polyethylene-based resin has a MFR (190° C., g/10 min) of not less than 0.44 and not more than 1.0.