Method of making a multi-level, expanded resinous product

Details Method of making a multi-level, expanded resinous product Method of making a multi-level, expanded resinous product

1995-11-20

1998-03-17

Kuhns, Allan R.

Plastic and nonmetallic article shaping or treating: processes

Pore forming in situ

Composite article making

156 79, 264 451, 264 52, 264 54, 264DIG82, B29C 4406

Patent

active

057283320

ABSTRACT:
A process for preparing multi-level, selectively expanded, resinous sheeting comprising:
(A) providing a composite comprising a backing material and adhered thereto a layer of a foamable resin which contains a blowing agent;
(B) forming a partially printed composite by applying to a portion of the surface of the layer a composition containing an accelerator which functions to lower the temperature at which the blowing agent decomposes and by applying to some, but not all, of the other portions of the surface of the layer a composition containing an inhibitor which functions to decrease the activity of the blowing agent; and
(C) forming the multi-level, selectively expanded, resinous sheeting by raising the temperature of the printed composite to a level such that the blowing agent decomposes and the resin fuses, the decomposition of the blowing agent evolving gas which causes expansion of the foamable resin in the portion where the surface is not printed and expansion of the foamable resin in the portion where the surface is printed with said accelerator-containing composition, the latter portion being expanded to a greater extent than the former, and wherein the portion of the surface printed with said inhibitor-containing composition is unexpanded or expanded to a limited degree; and
a resinous product having a printed base portion, an unprinted expanded portion elevated above the base portion and a printed expanded portion elevated above the unprinted expanded portion, the resin portion of the product being substantially uniform throughout the product.

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