Methods of producing polyolefin foam sheets and articles made thereof
AssigneeToray Plastics (America), Inc.
InventorsJesse J. Baldwin, Gary H. Clark, Donald A. Foltz, Paul F. Geibler, Pawel Sieradzki
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Abstract
A method of manufacturing a polyolefin foam sheet composition includes extruding a polyolefin sheet, irradiating the extruded sheet to obtain a physically crosslinked sheet, foaming the physically crosslinked sheet with heat to obtain a foamed layer, and skiving the foamed layer to obtain a foam sheet with at least one skived surface. The surface roughness of the skived surface of the foam sheet is different from the surface roughness of an unskived surface.
Claims32
A physically crosslinked polyolefin foam sheet comprising at least one polyolefin resin selected from the group consisting of a polypropylene and a polyethylene,
- wherein a surface of the physically crosslinked foam sheet is skived to obtain a skived primary surface and the skived primary surface of the foam sheet has a Sa of about 20 to about 150 μm and an Sz of about 250 to about 1000 μm,
- the foam sheet has an unskived surface and a surface roughness of the skived primary surface of the foam sheet is greater than the surface roughness of the unskived surface,
- the unskived surface has an Sa of about 5 to about 30 μm and an Sz of about 90 to about 350 μm, and
- Sa is defined by the following expression:
- Sa
- =
- 1
- A
-
- ∫
- ∫
- A
- ❘
- "\[LeftBracketingBar]"
- z
-
- (
- x
- ,
- y
- )
- ❘
- "\[RightBracketingBar]"
-
- dxdy
- .
Dependencies are inferred from the claim text.