CN112752790A - 交联聚烯烃系树脂发泡体及叠层体 - Google Patents
交联聚烯烃系树脂发泡体及叠层体 Download PDFInfo
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- CN112752790A CN112752790A CN201980063081.0A CN201980063081A CN112752790A CN 112752790 A CN112752790 A CN 112752790A CN 201980063081 A CN201980063081 A CN 201980063081A CN 112752790 A CN112752790 A CN 112752790A
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- foam
- polyolefin resin
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- resin
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Abstract
本发明是一种交联聚烯烃系树脂发泡体,是将至少含有聚烯烃系树脂的聚烯烃系树脂组合物交联发泡而成的交联聚烯烃系树脂发泡体,其在厚度为0.3mm以上且小于1.0mm的情况下全光线透射率为45%以上,并且在厚度为1.0mm以上且5.0mm以下的情况下全光线透射率为30%以上。根据本发明,可以提供具有优异的光透射性的交联聚烯烃系树脂发泡体。
Description
技术领域
本发明涉及将聚烯烃系树脂交联发泡而成的交联聚烯烃系树脂发泡体以及叠层体。
背景技术
使用了聚烯烃系树脂的发泡体由于柔软性、缓冲性、密封性和绝热性优异,因此在各种工业领域中被使用。可举出例如,将上述发泡体与粘着层进行了叠层的粘着带,用于便携电话、智能手机等搭载了触摸面板的设备。在这样的用途的情况下,可以利用发泡体的柔软性而对设备内部的微小凹凸容易地密合。此外,也可以利用发泡体的柔软性和密合性而保护设备内部的部件不受冲击、水等外界因素影响。
另一方面,上述发泡体由于内部具有大量气泡,因此由于气泡内的空气与构成发泡体的树脂的光的折射率之差而难以将发泡体透明化。因此,以聚烯烃系树脂发泡体作为基材的粘着带与使用了赛璐酚带等透明基材的粘着带不同,难以隔着带确认贴合位置,使电子设备等的制造效率降低了。
作为解决这样的问题的发泡体,在专利文献1中,提出了具有独立气泡结构,全光线透射率为15%以上,将长度方向(MD)、宽度方向(TD)的收缩率、长度方向(MD)的平均气泡直径、厚度、表观密度、和25%压缩硬度调整为特定范围的聚烯烃系树脂发泡体。此外,在专利文献2中提出了一种丙烯酸系树脂发泡体,其特征在于,平均气泡直径为1.2mm以上。在引用文献1和2中主要通过调整平均气泡直径从而使发泡体的光透射率提高。
进一步在专利文献3中提出了一种绝热发泡体,其特征在于,由具有80%以上的全光线透射率的热塑性树脂形成,发泡倍率为5~100倍,平均气泡直径为1~15mm。在该专利文献3中,通过使用甲基丙烯酸甲酯等全光线透射率高的树脂来使发泡体的光透射率提高。
现有技术文献
专利文献
专利文献1:日本特开2017-190375号公报
专利文献2:日本特开2013-203984号公报
专利文献3:日本特开平08-067757号公报
发明内容
发明所要解决的课题
然而,聚烯烃系树脂发泡体即使在如专利文献1那样调整了平均气泡直径的情况下,如果发泡体的厚度超过0.3mm则全光线透射率也小于20%,因此具有改善的余地。另一方面,也有时如专利文献2和3那样通过使用丙烯酸系树脂发泡体来解决光透射性的问题,但丙烯酸系树脂发泡体与如聚烯烃系树脂发泡体那样进行了电子射线交联的发泡体相比,具有在机械特性、柔软性等方面差这样的问题。
本发明是鉴于上述现有情况而提出的,其课题是提供具有优异的光透射性的交联聚烯烃系树脂发泡体。
此外,专利文献1~3所记载的发泡体例如在汽车等车辆内,作为具有使温度、时间、车速等信息通过光进行显示等功能的光显示构件而使用的情况下,从兼有高的光透射性、与柔软的触感的观点考虑,具有改善的余地。因此,本发明的其它课题是以提供作为光显示构件而适合使用,具有高的光透射性,并且具有柔软的触感的叠层体作为课题。
用于解决课题的方法
本发明人等进行了深入研究,结果发现,通过适当调整发泡倍率、树脂成分、混配于树脂的混配物,可获得光透射性高的交联聚烯烃系树脂发泡体,从而完成了本发明。
即,本发明以以下[1]~[24]作为主旨。
[1]一种交联聚烯烃系树脂发泡体,是将含有聚烯烃系树脂的聚烯烃系树脂组合物交联发泡而成的交联聚烯烃系树脂发泡体,
上述交联聚烯烃系树脂发泡体在厚度为0.3mm以上且小于1.0mm的情况下全光线透射率为45%以上,并且在厚度为1.0mm以上且5.0mm以下的情况下全光线透射率为30%以上。
[2]根据上述[1]所述的交联聚烯烃系树脂发泡体,上述聚烯烃系树脂的含量以聚烯烃系树脂组合物所包含的树脂成分总量基准计为65质量%以上。
[3]根据上述[1]或[2]所述的交联聚烯烃系树脂发泡体,1种聚烯烃系树脂的含量以聚烯烃系树脂组合物所包含的树脂成分总量基准计为65质量%以上。
[4]根据上述[1]~[3]中任一项所述的交联聚烯烃系树脂发泡体,上述聚烯烃系树脂为选自聚乙烯树脂、聚丙烯树脂、和乙烯-乙酸乙烯酯共聚物中的1种以上。
[5]根据上述[1]~[4]中任一项所述的交联聚烯烃系树脂发泡体,聚乙烯树脂、聚丙烯树脂、或乙烯-乙酸乙烯酯共聚物的任1种的含量以聚烯烃系树脂组合物所包含的树脂成分总量基准计为65质量%以上。
[6]根据上述[1]~[5]中任一项所述的交联聚烯烃系树脂发泡体,上述聚烯烃系树脂组合物含有成核剂。
[7]根据上述[1]~[6]中任一项所述的交联聚烯烃系树脂发泡体,上述聚烯烃系树脂组合物含有弹性体。
[8]根据上述[1]~[7]中任一项所述的交联聚烯烃系树脂发泡体,其发泡倍率为1.3~40倍。
[9]根据上述[1]~[8]中任一项所述的交联聚烯烃系树脂发泡体,其为汽车内装材料用。
[10]一种粘着带,其具备上述[1]~[9]中任一项所述的交联聚烯烃系树脂发泡体、和设置在上述发泡体的至少一个面上的粘着材料。
[11]一种叠层体,其具备上述[1]~[9]中任一项所述的交联聚烯烃系树脂发泡体、和设置在上述发泡体的至少一个面上的表面材料。
[12]一种光显示构件,其具备上述[1]~[9]中任一项所述的交联聚烯烃系树脂发泡体。
[13]一种叠层体,是具备表皮层、和发泡体层的叠层体,其Asker C硬度为70以下,全光线透射率超过0.01%。
[14]根据上述[13]所述的叠层体,上述表皮层的厚度为0.2~1.0mm。
[15]根据上述[13]或[14]所述的叠层体,上述表皮层的全光线透射率为0.02~30%。
[16]根据上述[13]~[15]中任一项所述的叠层体,上述发泡体层的厚度为0.5~5mm。
[17]根据上述[13]~[16]中任一项所述的叠层体,上述发泡体层的全光线透射率为10%以上。
[18]根据上述[13]~[17]中任一项所述的叠层体,上述发泡体层的发泡倍率为7~40倍。
[19]根据上述[13]~[18]中任一项所述的叠层体,上述发泡体层为聚烯烃系发泡体层或聚氨酯系发泡体层。
[20]根据上述[13]~[19]中任一项所述的叠层体,上述叠层体还具备印刷层和印刷膜层中的至少一者。
[21]根据上述[20]所述的叠层体,上述印刷层是通过对发泡体层和表皮层中的至少一者的表面进行印刷而形成的。
[22]一种光显示构件,其具备上述[13]~[21]中任一项所述的叠层体。
[23]根据上述[22]所述的光显示构件,其具有传感器元件。
[24]根据上述[22]或[23]所述的光显示构件,其具备具有传感器元件的显示器。
发明的效果
根据本发明,可以提供具有优异的光透射性的交联聚烯烃系树脂发泡体。
此外本发明的叠层体为显示高的光透射性和柔软的触感的叠层体。
附图说明
图1为本发明的叠层体的一实施方式的截面图。
图2为本发明的叠层体的其它一实施方式的截面图。
图3为本发明的叠层体的其它一实施方式的截面图。
图4为显示本发明中的印刷层的一例的俯视图。
具体实施方式
〔第1发明〕
本发明中的第1发明是以下说明的交联聚烯烃系树脂发泡体。
[交联聚烯烃系树脂发泡体]
本发明的交联聚烯烃系树脂发泡体是将含有聚烯烃系树脂的聚烯烃系树脂组合物交联发泡而成的交联聚烯烃系树脂发泡体。
本发明的交联聚烯烃系树脂发泡体在其厚度为0.3mm以上且小于1.0mm的情况下全光线透射率为45%以上,并且在厚度为1.0mm以上且5.0mm以下的情况下全光线透射率为30%以上。通过使全光线透射率为上述范围内,可以提供具有与厚度对应的优异的光透射性的交联聚烯烃系树脂发泡体。
此外,对于交联聚烯烃系树脂发泡体,优选聚烯烃系树脂为主成分。具体而言,聚烯烃系树脂的含量以聚烯烃系树脂组合物所包含的树脂成分总量基准计,优选为65质量%以上。在使用了聚烯烃系树脂作为主成分的交联聚烯烃系树脂发泡体中,一般具有光透射性降低的倾向,但在本发明中,如后述那样,通过适当调整发泡倍率、树脂成分、混配于树脂的混配物等,可以获得全光线透射率优异的交联聚烯烃系树脂发泡体。
<全光线透射率>
本发明的交联聚烯烃系树脂发泡体(以下,也称为“发泡体”。)在厚度为0.3mm以上且小于1.0mm的情况下全光线透射率为45%以上。通过在发泡体的厚度为0.3mm以上且小于1.0mm的情况下全光线透射率为45%以上,则发泡体具有充分的光透射性,因此可以适合用于汽车内装用的光显示构件、智能手机等电子设备。从该观点考虑,在发泡体的厚度为0.3mm以上且小于1.0mm的情况下全光线透射率优选为50%以上,更优选为55%以上,进一步优选为60%以上,特别优选为70%以上。在厚度为0.3mm以上且小于1.0mm的情况下全光线透射率越高越好,但例如为95%以下。
在厚度为0.3mm以上且小于1.0mm的情况下可以通过适当调整发泡倍率、树脂成分、混配于树脂的混配物等而使全光线透射率为上述范围。另外,全光线透射率可以通过实施例所记载的方法来测定。
本发明的发泡体在厚度为1.0mm以上且5.0mm以下的情况下全光线透射率为30%以上。如果在发泡体的厚度为1.0mm以上且5.0mm以下的情况下全光线透射率为30%以上,则兼具充分的光透射性和冲击吸收性,因此可以适合用于汽车内装用的光透射性构件、智能手机等电子设备。从该观点考虑,在发泡体的厚度为1.0mm以上且5.0mm以下的情况下全光线透射率优选为35%以上,更优选为40%以上,进一步优选为45%以上。在发泡体的厚度为1.0mm以上且5.0mm以下的情况下全光线透射率越高越好,但例如为90%以下。在上述厚度为1.0mm以上且5.0mm以下的情况下可以通过适当调整发泡倍率、树脂成分、混配于树脂的混配物等而使全光线透射率为上述范围。
<交联度(凝胶分率)>
本发明的发泡体的交联度(凝胶分率)优选为15~60质量%。如果凝胶分率为上述下限值以上,则在发泡体中形成充分的交联因此机械强度易于变高。此外,如果交联度为这些上限值以下,则易于确保发泡体的柔软性等。从这样的观点考虑,交联度更优选为20~55质量%,进一步优选为25~50质量%。另外,交联度可以通过后述的测定方法来测定。
<发泡倍率>
发泡体的发泡倍率优选为1.3~40倍,更优选为1.5~12倍,进一步优选为1.8~9倍,更进一步优选为2.0~7倍。如果发泡倍率为上述下限值以上则使光透射性提高,同时发泡体被适度发泡从而柔软性、冲击吸收性变得良好。此外,如果发泡倍率变高则有光透射性也提高的倾向,但为了确保机械强度,也优选为上述上限值以下。在本发明中通过调整发泡倍率,同时适当选择后述树脂的种类、成核剂等从而可以使全光线透射率提高。
<表观密度>
在本发明中,发泡体的表观密度优选为0.05~0.60g/cm3。如果发泡体的表观密度为上述范围内,则使光透射性提高,同时赋予一定的柔软性和机械强度,冲击吸收性等也变得良好。从这些观点考虑,表观密度更优选为0.10~0.50g/cm3,进一步优选为0.15~0.40g/cm3。
<厚度>
本发明的发泡体的厚度为0.3~5.0mm,优选为0.3~2.0mm,更优选为0.3~1.5mm。如果发泡体的厚度为上述下限值以上则可以维持机械强度同时使光透射性提高。另一方面,如果为上述上限值以下,则维持光透射性同时能够使用于智能手机等小型电子设备。
<25%压缩强度>
发泡体的25%压缩强度优选为30~200kPa。如果25%压缩强度为上述上限值以下,则发泡体的柔软性提高,例如在制成粘着带时对被粘物的追随性变得良好。另一方面,如果25%压缩强度为上述下限值以上,则机械强度、冲击吸收性等变得良好。从这些观点考虑,发泡体的25%压缩强度更优选为30~150kPa。
另外,25%压缩强度为通过按照JIS K6767的测定方法测定的值。
<聚烯烃系树脂>
作为聚烯烃系树脂,优选为选自聚乙烯树脂、聚丙烯树脂、乙烯-乙酸乙烯酯共聚物中的1种以上。这些树脂可以单独使用任1种,也可以并用2种以上。
本发明的发泡体优选为以聚烯烃系树脂作为主成分,具体而言,聚烯烃系树脂的含量以聚烯烃系树脂组合物所包含的树脂成分总量基准计,优选为65质量%以上。通过聚烯烃系树脂的含量为65质量%以上,从而易于确保发泡体的机械强度、柔软性等。此外,如后述那样,易于使1种聚烯烃系树脂为主成分树脂。从这些观点考虑,聚烯烃系树脂的含量以发泡体树脂组合物所包含的树脂成分总量基准计,优选为70~100质量%,更优选为75~100质量%。另外,以下,将聚烯烃系树脂组合物所包含的树脂成分总量基准简称为“树脂成分总量基准”。
《聚乙烯树脂》
作为聚乙烯树脂,可举出低密度聚乙烯树脂(0.93g/cm3以下,LDPE)、中密度聚乙烯树脂(大于0.930g/cm3且小于0.942g/cm3,MDPE)、高密度聚乙烯树脂(0.942g/cm3以上,HDPE)。此外,作为低密度聚乙烯树脂的适合的具体例,可举出直链状低密度聚乙烯树脂(LLDPE)。
它们之中,优选为直链状低密度聚乙烯树脂、高密度聚乙烯树脂,更优选为直链状低密度聚乙烯树脂。通过使用这些树脂,从而易于使发泡体的压缩强度变化率低。
另外,直链状低密度聚乙烯树脂的密度优选为0.90g/cm3以上,更优选为0.91g/cm3以上且0.93g/cm3以下。此外,高密度聚乙烯树脂的密度优选为0.98g/cm3以下,更优选为0.95g/cm3以上且0.97g/cm3以下。通过使高密度聚乙烯树脂、直链状低密度聚乙烯树脂的密度为这些范围内,从而不损害发泡体的柔软性,易于使压缩强度等低。
聚乙烯树脂可以为乙烯的均聚物,但也可以为以乙烯作为主成分(全部单体的优选75质量%以上,更优选90质量%以上)的、乙烯与少量的α-烯烃的共聚物等。作为α-烯烃,优选列举出碳原子数3~12、更优选碳原子数4~10的α-烯烃,具体而言,可举出1-丁烯、1-戊烯、1-己烯、4-甲基-1-戊烯、1-庚烯、1-辛烯等。另外,在共聚物中,可以将这些α-烯烃单独使用或组合使用2种以上。
此外,聚乙烯树脂可以单独使用1种,也可以并用2种以上。
《聚丙烯树脂》
作为聚丙烯树脂,可以为作为丙烯的均聚物的均聚丙烯,可举出以丙烯作为主成分(全部单体的优选75质量%以上,更优选90质量%以上)的、丙烯与少量的乙烯和丙烯以外的α-烯烃的共聚物等。
作为丙烯、与乙烯和丙烯以外的α-烯烃的共聚物,可举出嵌段共聚物(嵌段聚丙烯)、无规共聚物(无规聚丙烯)、无规嵌段共聚物等。
作为丙烯以外的α-烯烃,可举出1-丁烯、1-戊烯、1-己烯、4-甲基-1-戊烯、1-庚烯、1-辛烯等碳原子数4~10左右的α-烯烃等,但它们之中,从成型性和耐热性的观点考虑,优选为乙烯。另外,在共聚物中,这些α-烯烃可以单独使用或组合使用2种以上。
此外,聚丙烯树脂可以单独使用,也可以并用2种以上。
在本发明中,可以使用通过齐格勒/纳塔化合物、金属茂化合物、氧化铬化合物等聚合催化剂而被聚合了的聚乙烯树脂、聚丙烯树脂、或它们的混合物的任一者。通过使用通过金属茂化合物的聚合催化剂而获得的、聚乙烯树脂特别是直链状低密度聚乙烯,易于获得柔软性高,具有高的冲击吸收性的发泡体。
《乙烯-乙酸乙烯酯共聚物》
作为聚烯烃系树脂而使用的乙烯-乙酸乙烯酯共聚物可举出例如,含有来源于乙烯的结构单元50质量%以上的乙烯-乙酸乙烯酯共聚物。乙烯-乙酸乙烯酯共聚物由于与聚乙烯树脂、聚丙烯树脂的相容性高,因此通过将乙烯-乙酸乙烯酯共聚物、与选自聚乙烯树脂和聚丙烯树脂中的1种以上并用从而发泡体的光透射性提高。
乙烯-乙酸乙烯酯共聚物的密度优选为0.92g/cm3以上,更优选为0.93g/cm3以上,进一步优选为0.94g/cm3以上,而且,优选为0.97g/cm3以下,更优选为0.96g/cm3以下。通过使乙烯-乙酸乙烯酯共聚物的密度为这些范围内,从而不损害发泡体的柔软性,易于使压缩强度等低。
在本发明中,聚烯烃系树脂组合物优选使用上述聚烯烃树脂之中的任1种作为主成分树脂。这里,所谓主成分树脂,是指聚烯烃树脂之中的任1种树脂以树脂成分总量基准计含有65质量%以上,因此,优选含有聚丙烯树脂、聚乙烯树脂、或乙烯-乙酸乙烯酯共聚物的任1种65质量%以上。
一般而言,树脂如果掺混2种以上,则该树脂彼此不完全混合,起因于混合而产生浑浊,但在本发明中,通过使用特定的1种树脂(即,单一树脂成分)作为主成分树脂,从而起因于掺混的浑浊不易产生,发泡体的光透射性提高。
成为主成分树脂的树脂在上述树脂中,优选为聚丙烯树脂和聚乙烯树脂的任一者,更优选为聚丙烯树脂。发泡体通过使主成分树脂为聚丙烯树脂,从而耐热性优异,可以适合用于汽车内装材料用。
如果更具体地说明,则在使用聚丙烯树脂作为主成分树脂的情况下,使该聚丙烯树脂以树脂成分总量基准计含有65质量%以上为好,优选含有75质量%以上,更优选含有85质量%以上,最优选含有100质量%。
此外,优选使聚丙烯树脂之中的特定的1种树脂以树脂成分总量基准计含有65质量%以上。例如,使嵌段聚丙烯为65质量%以上、或使无规聚丙烯为65质量%以上为好,在该情况下,这些特定的1种树脂也优选含有75质量%以上,更优选含有85质量%以上,最优选含有100质量%。
同样地,在使用聚乙烯树脂作为主成分树脂的情况下,使该聚乙烯树脂以树脂成分总量基准计含有65质量%以上为好,优选含有75质量%以上,更优选含有85质量%以上。
此外,优选使聚乙烯树脂之中的特定的1种树脂以树脂成分总量基准计含有65质量%以上。例如,使LDPE为65质量%以上为好,在该情况下,这些特定的1种树脂也优选为75质量%以上,更优选为85质量%以上。
此外,在使用聚丙烯树脂作为主成分树脂的情况下,作为聚烯烃系树脂,可以单独使用聚丙烯树脂,但除了聚丙烯树脂以外,也可以并用选自聚乙烯树脂和乙烯-乙酸乙烯酯共聚物中的至少1种。如果单独使用聚丙烯树脂,则不需要与其它聚烯烃树脂相容,因此能够防止树脂彼此的混合所造成的透明性的降低。此外,通过将聚丙烯树脂、与选自乙烯-乙酸乙烯酯共聚物和聚乙烯树脂中的至少1种并用从而相容性变得良好,透明性良好地维持。进一步,由于易于调整交联度、发泡倍率,因此易于调整发泡体的全光线透射率。
在该情况下,优选以树脂成分总量基准计,聚丙烯树脂的含量为65~95质量%,选自聚乙烯树脂和乙烯-乙酸乙烯酯共聚物中的至少1种为5~35质量%。此外,更优选前者为75~95质量%,后者为5~25质量%,进一步优选前者为85~95质量%,后者为5~15质量%。
此外,并用的树脂优选为聚乙烯树脂或乙烯-乙酸乙烯酯共聚物的任一者,但更优选为乙烯-乙酸乙烯酯共聚物。
此外,在使用聚丙烯树脂作为主成分树脂的情况下,如后述那样可以进一步使用弹性体。该情况下的弹性体的含量如后述那样。
另一方面,在使用聚乙烯树脂作为主成分树脂的情况下,作为聚烯烃系树脂,除了聚乙烯树脂以外,还可以并用选自聚丙烯树脂和乙烯-乙酸乙烯酯共聚物中的至少1种,但优选单独使用聚乙烯树脂。然而,在单独使用聚乙烯树脂的情况下,优选进一步使用后述弹性体,此时的弹性体的含量如后述那样。
构成发泡体的树脂可以仅由聚烯烃系树脂构成,但也可以为聚烯烃系树脂与弹性体混合而得的树脂。通过聚烯烃系树脂组合物包含弹性体,可以降低聚烯烃系树脂的结晶度,发泡体的全光线透射率提高。即,在本发明中,弹性体使用发挥作为所谓透明化剂的功能的物质为好。
此外,通过使用弹性体,可以使发泡体的柔软性、冲击吸收性提高。
作为弹性体,使用与聚烯烃系树脂相容性良好的弹性体,具体而言,可举出乙烯-丙烯-二烯橡胶(EPDM)、乙烯-丙烯橡胶(EPM)、苯乙烯橡胶等。
此外,作为弹性体,也可举出热塑性弹性体。作为热塑性弹性体,可举出烯烃系热塑性弹性体、苯乙烯系热塑性弹性体等。
弹性体可以单独使用1种上述成分,也可以并用2种以上。从易于将发泡体的全光线透射率调整到上述范围内的观点考虑,优选为苯乙烯橡胶、烯烃系热塑性弹性体、苯乙烯系热塑性弹性体,其中更优选为苯乙烯橡胶、苯乙烯系热塑性弹性体。
作为苯乙烯橡胶,可举出苯乙烯与共轭二烯化合物的无规共聚物等各种聚合物,可以为其加氢物。具体而言,可举出苯乙烯丁二烯共聚物(SBR)、或其加氢物(HSBR)等。
作为烯烃系热塑性弹性体,可举出掺混型、动态交联型,更具体而言,可举出硬链段使用了聚丙烯、聚乙烯等热塑性结晶性聚烯烃,软链段使用了完全硫化或部分硫化了的橡胶的热塑性弹性体。软链段成分可举出丁基橡胶、卤代丁基橡胶、EPDM、EPM、丙烯腈/丁二烯橡胶、NBR、天然橡胶等,优选使用EPDM。
此外,作为烯烃系热塑性弹性体,也可举出嵌段共聚物型。作为嵌段共聚物型,可举出具有结晶性嵌段、和软链段嵌段的物质,更具体而言,可例示结晶性烯烃嵌段-乙烯/丁烯共聚物-结晶性烯烃嵌段共聚物(CEBC)。在CEBC中,结晶性烯烃嵌段优选为结晶性乙烯嵌段,作为那样的CEBC的市售品,可举出JSR株式会社制的“DYNARON 6200P”等。
作为苯乙烯系热塑性弹性体,可举出具有苯乙烯的聚合物或共聚物嵌段、和共轭二烯化合物的聚合物或共聚物嵌段的嵌段共聚物等。作为共轭二烯化合物,可举出异戊二烯、丁二烯等。
本发明所使用的苯乙烯系热塑性弹性体可以进行加氢,也可以不进行加氢。在进行加氢的情况下,加氢可以通过公知的方法进行。
作为苯乙烯系热塑性弹性体,通常为嵌段共聚物,可举出苯乙烯-异戊二烯嵌段共聚物、苯乙烯-异戊二烯-苯乙烯嵌段共聚物、苯乙烯-丁二烯嵌段共聚物、苯乙烯-丁二烯-苯乙烯嵌段共聚物、苯乙烯-乙烯/丁烯-苯乙烯嵌段共聚物(SEBS)、苯乙烯-乙烯/丙烯-苯乙烯嵌段共聚物(SEPS)、苯乙烯-乙烯/丁烯嵌段共聚物(SEB)、苯乙烯-乙烯/丙烯嵌段共聚物(SEP)、苯乙烯-乙烯/丁烯-结晶性烯烃嵌段共聚物(SEBC)等。
作为上述苯乙烯系热塑性弹性体,优选为嵌段共聚物,其中更优选为SEBC。通过将这样的弹性体与聚烯烃系树脂并用,进一步调整发泡倍率,从而能够使发泡体的光透射性提高。
另外,作为苯乙烯系热塑性弹性体的市售品,可举出商品名“DYNARON 1320P”(苯乙烯含量10质量%)、株式会社JSR制商品名“DYNARON 8600P”(苯乙烯含量15质量%)、商品名“DYNARON 4600P”(苯乙烯含量20质量%)等。
在本发明中,在作为树脂成分聚烯烃系树脂与弹性体并用的情况下,弹性体的含量以树脂成分量基准计优选为5~30质量%,更优选为8~22质量%。如果弹性体的含量为这些范围内,则维持发泡体的机械强度,同时可以更加提高发泡体的光透射性。
<成核剂>
本发明的聚烯烃系树脂组合物优选含有成核剂。作为本发明所使用的成核剂,只要是具有使结晶核生成过程的进行速度提高的效果的物质,就没有特别限制。通过在聚乙烯树脂、聚丙烯树脂等聚烯烃系树脂中添加成核剂,从而可以使产生的结晶的尺寸小,因此发泡体的透明性提高。
作为在本发明中使用的成核剂,作为具有使结晶核生成过程的进行速度提高的效果的物质,可举出具有经过聚合物的分子链的吸附过程而促进分子链取向的效果的物质。
更具体而言,可举出高熔点聚合物、有机羧酸或其金属盐、脂肪族醇族、二亚苄基山梨糖醇或其衍生物、松香酸部分金属盐、酰胺化合物、无机微粒、有机磷酸化合物或其金属盐、酰亚胺类、喹吖啶酮类、醌类、芳香族磺酸盐或其金属盐、糖类、和它们的混合物。它们可以单独使用1种,也可以并用2种以上。
作为高熔点聚合物,可举出聚3-甲基戊烯-1、聚3-甲基丁烯-1等聚烯烃、聚乙烯基环己烷、聚乙烯基环戊烷等聚乙烯基环链烷、间规聚苯乙烯、和聚烯基硅烷等。
作为有机羧酸及其金属盐,可举出苯甲酸、对叔丁基苯甲酸、己二酸、噻吩羧酸、吡咯羧酸、苯甲酸铝盐、对叔丁基苯甲酸铝盐、己二酸钠、噻吩羧酸钠、和吡咯羧酸钠等。
作为二亚苄基山梨糖醇及其衍生物,可举出二亚苄基山梨糖醇、1,3:2,4-双(邻3,4-二甲基亚苄基)山梨糖醇、1,3:2,4-双(邻2,4-二甲基亚苄基)山梨糖醇、1,3:2,4-双(邻4-乙基亚苄基)山梨糖醇、1,3:2,4-双(邻4-氯亚苄基)山梨糖醇、1,3:2,4-二亚苄基山梨糖醇等。作为二亚苄基山梨糖醇及其衍生物的市售品,可举出新日本理化株式会社制的ゲルオールMD、ゲルオールMD-R(商品名)等。
作为松香酸部分金属盐,可举出荒川化学工业株式会社制的パインクリスタルKM1600、パインクリスタルKM1500、パインクリスタルKM1300(商品名)等。
作为酰胺化合物,可举出己二酰苯胺、和辛二酰苯胺等。
作为无机微粒,可举出滑石、粘土、云母、石棉、玻璃纤维、玻璃薄片、玻璃珠、硅酸钙、蒙脱石、膨润土、石墨、铝粉末、氧化铝、二氧化硅、硅藻土、氧化钛、氧化镁、浮石粉末、浮石球、氢氧化铝、氢氧化镁、碱性碳酸镁、白云石、硫酸钙、钛酸钾、硫酸钡、亚硫酸钙、硫化钼等。
作为有机磷酸金属盐,下述通式(1)所示的有机磷酸金属盐气味的发生少,是优选的。
(式中,R1表示氢原子或碳原子数1~4的烷基,R2和R3分别表示氢原子、碳原子数1~12的烷基、环烷基、芳基或芳烷基。M表示选自碱金属、碱土金属、铝和锌中的1种。在M为碱金属时m表示0,n表示1,在M为碱土金属或锌时n表示1或2,在n为1时m表示1,在n为2时m表示0,M为铝时m表示1,n表示2。)
作为有机磷酸金属盐的市售品,可举出アデカスタブNA-11、アデカスタブNA-21(株式会社ADEKA)。
在成核剂中,从对烯烃系的相容性和透明性的观点考虑,优选为糖类系。作为糖类系,可举出山梨糖醇系、诺尼醇(Nonitol)系、木糖醇系等,更优选使用选自它们中的1种以上作为成核剂。
在本发明中使用成核剂的情况下,聚烯烃系树脂组合物中的成核剂的含量相对于聚烯烃系树脂100质量份优选为0.5~10质量份,更优选为1.5~8质量份,更进一步优选为2~7质量份。如果成核剂的含量为上述下限值以上则发泡体的透明性提高。另一方面,如果成核剂的含量为上述上限值以下则可以抑制制造成本同时使发泡体的透明性提高。
本发明的聚烯烃系树脂组合物可以具有成核剂和弹性体两者,但优选具有任一者。通过具有任一者,从而可以有效地使光透射性提高。
<发泡剂>
本发明的发泡体通过将包含含有聚烯烃系树脂的树脂、和发泡剂等的聚烯烃系树脂组合物进行发泡来获得。作为发泡剂,优选为热分解型发泡剂。
作为热分解型发泡剂,能够使用有机发泡剂、无机发泡剂。作为有机发泡剂,可举出偶氮二甲酰胺、偶氮二羧酸金属盐(偶氮二羧酸钡等)、偶氮二异丁腈等偶氮化合物、N,N’-二亚硝基五亚甲基四胺等亚硝基化合物、联二脲、4,4’-氧基双(苯磺酰肼)、甲苯磺酰肼等肼衍生物、甲苯磺酰氨基脲等氨基脲化合物等。
作为无机发泡剂,可举出碳酸铵、碳酸钠、碳酸氢铵、碳酸氢钠、亚硝酸铵、氢化硼钠、无水柠檬酸单钠等。
它们之中,从获得微细的气泡的观点、和经济性、安全方面的观点考虑,优选为偶氮化合物,更优选为偶氮二甲酰胺。
热分解型发泡剂可以单独使用1种,也可以并用2种以上。
聚烯烃系树脂组合物中的发泡剂的含量相对于聚烯烃系树脂100质量份,优选为1~30质量份,更优选为2~25质量份,进一步优选为2~20质量份。通过使发泡剂的混配量为1质量份以上,从而发泡性片被适度地发泡,能够向发泡体赋予适度的柔软性和冲击吸收性。此外,通过使发泡剂的混配量为30质量份以下,从而可以防止发泡体过度发泡,使发泡体的机械强度等良好。
<添加剂>
聚烯烃系树脂组合物可以包含交联助剂、分解温度调节剂、和抗氧化剂等成分。
作为交联助剂,可以使用多官能单体。通过将交联助剂添加于聚烯烃系树脂,从而减少在后述工序(2)中照射的电离性放射剂量,防止伴随电离性放射线的照射的树脂分子的切断、劣化。
作为交联助剂,具体而言,可举出三羟甲基丙烷三甲基丙烯酸酯、三羟甲基丙烷三丙烯酸酯、偏苯三甲酸三烯丙酯、1,2,4-苯三甲酸三烯丙酯、异氰脲酸三烯丙酯等1分子中具有3个官能团的化合物、1,6-己二醇二甲基丙烯酸酯、1,9-壬二醇二甲基丙烯酸酯、1,10-癸二醇二甲基丙烯酸酯、二乙烯基苯等1分子中具有2个官能团的化合物、邻苯二甲酸二烯丙酯、对苯二甲酸二烯丙酯、间苯二甲酸二烯丙酯、乙基乙烯基苯、新戊二醇二甲基丙烯酸酯、甲基丙烯酸月桂基酯、甲基丙烯酸硬脂基酯等。
这些交联助剂可以单独使用或组合使用2种以上。
交联助剂的添加量相对于聚烯烃系树脂100质量份优选为0.5~10质量份,更优选为1.0~8质量份,进一步优选为1.5~5质量份。通过使该添加量为0.5质量份以上从而发泡体能够稳定地获得所希望的交联度,通过为10质量份以下从而发泡体的交联度的控制变得容易。
在聚烯烃系树脂组合物中,可以混配分解温度调节剂。分解温度调节剂是作为使热分解型发泡剂的分解温度低,或加快分解速度进行调节的物质而混配的,作为具体的化合物,可举出氧化锌、硬脂酸锌、脲等。为了调整发泡体的表面状态等,分解温度调节剂例如相对于聚烯烃系树脂100质量份混配0.01~5质量份。
在聚烯烃系树脂组合物中,可以混配抗氧化剂。作为抗氧化剂,可举出2,6-二-叔丁基-对甲酚、季戊四醇四[3-(3,5-二-叔丁基-4-羟基苯基)丙酸酯]等酚系抗氧化剂、硫代二丙酸二月桂基酯等硫系抗氧化剂、磷系抗氧化剂、胺系抗氧化剂等。抗氧化剂例如相对于聚烯烃系树脂100质量份混配0.01~5质量份。
在聚烯烃系树脂组合物中,除它们以外,还可以混配热稳定剂、着色剂、阻燃剂、抗静电剂、填充材等一般使用于发泡体的添加剂。
[发泡体的制造方法]
对本发明的发泡体的制造方法没有特别限制,可以通过将由至少包含树脂和热分解型发泡剂的聚烯烃系树脂组合物形成的发泡性片进行加热而使热分解型发泡剂发泡来制造。该制造方法更具体而言优选包含以下工序(1)~(3)。
工序(1):成型由至少包含树脂和热分解型发泡剂的聚烯烃系树脂组合物形成的发泡性片的工序
工序(2):向发泡性片照射电离性放射线而使发泡性片交联的工序
工序(3):将进行了交联的发泡性片加热,使热分解型发泡剂发泡,获得发泡体的工序
在工序(1)中,成型发泡性片的方法没有特别限定,例如,只要通过将树脂和添加剂供给到挤出机进行熔融混炼,从挤出机片状地挤出聚烯烃系树脂组合物来进行成型即可。此外,发泡体可以通过将聚烯烃系树脂组合物进行压制等来成型。
发泡性片的成型温度(即,挤出时的温度、或压制时的温度)优选为50℃以上且250℃以下,更优选为80℃以上且180℃以下。
在工序(2)中作为将聚烯烃系树脂组合物交联的方法,使用向发泡性片照射电子射线、α射线、β射线、γ射线等电离性放射线的方法。上述电离放射线的照射量只要以所得的发泡体的交联度成为上述所希望的范围的方式调整即可,优选为1~12Mrad,更优选为1.5~8Mrad。
在工序(3)中,将聚烯烃系树脂组合物加热使热分解型发泡剂发泡时的加热温度只要为热分解型发泡剂的发泡温度以上即可,优选为200~300℃,更优选为220~280℃。
此外,在本制造方法中,发泡体可以沿MD或TD的任一者或两者拉伸。发泡体的拉伸可以在使发泡性片发泡而获得了发泡体后进行,也可以在使发泡性片发泡的同时进行。另外,在使发泡性片发泡而获得了发泡体后,将发泡体拉伸的情况下,可以不将发泡体冷却而在维持了发泡时的熔融状态下直接继续将发泡体拉伸,也可以在将发泡体冷却后,再次将发泡体加热而形成熔融或软化状态后将发泡体拉伸。发泡体通过拉伸从而易于为薄厚度。此外,在拉伸时发泡体例如只要加热到100~280℃,优选为150~260℃即可。在本发明中,通过将发泡体拉伸,从而发泡体的气泡直径沿着MD或TD的一者或两者而变大,光透射性易于变高。
然而,本制造方法不限定于上述,也可以通过上述以外的方法获得发泡体。例如,可以代替照射电离性放射线,通过在聚烯烃系树脂组合物中预先混配有机过氧化物,将发泡性片加热而使有机过氧化物分解的方法等进行交联。
此外,在本发明的发泡体的制造中,可以通过将所得的发泡体进行切片来制成具有所希望的厚度的发泡体。
[发泡体的使用方法]
本发明的发泡体可以适合用于各种电子设备、汽车内装材料等,更优选使用于汽车内装材料。作为电子设备,可举出智能手机等便携电话、游戏设备、电子手册、平板终端、笔记本型个人计算机等。
发泡体可以在各种电子设备的内部作为例如密封材料、冲击吸收材料而使用。本发明的发泡体由于光透射性优异,因此可以隔着发泡体片确认贴合位置等,因此能够以高的位置精度贴合于各种电子部件等。
此外,本发明的发泡体可以作为光显示构件而适合使用。光显示构件是使发光二极管(LED)等光源配置在发泡体的一个面(即,背面)侧,并且通过从光源朝向发泡体照射光从而光透过发泡体,在发泡体的另一个面(即,前面)侧通过来自该光源的光而使各种信息显示的构件。
此外,发泡体可以叠层其它构件而制成叠层体。具体而言,优选制成具有本发明的发泡体、和设置在发泡体的至少一个面的表面材料的叠层体。这样的叠层体能够使用于电子设备、汽车内装的任一者,但优选使用于汽车内装用。
此外,叠层体优选作为光显示构件而使用。在光显示构件中,通过从发泡体的背面侧使用发光二极管(LED)等光源而照射光从而光透过发泡体和表面材料,能够使各种信息(车速等)显示在表面材料上。此外,如果对表面材料施与几何学花样的凹凸等,则透过了的光几何学花样状地浮起,因此能够使汽车内装的设计性提高。
表面材料在汽车内装材料中也称为表皮材。具体而言,表面材料可举出聚氯乙烯片、聚氯乙烯与ABS树脂的混合树脂、在热塑性弹性体片等中例示的树脂片、使用了天然纤维、人造纤维的机织物、针织物、无纺织物、人工皮革、合成皮革等皮革等。可以对表面材料如上述那样适当施与几何学花样的凹凸等。它们中,优选为树脂片,更优选树脂片具有光透射性。通过使用具有光透射性的树脂片,从而可以通过来自上述光源的光而使各种信息显示在表面材料上。此外,能够对叠层体整体赋予光透射性。
表面材料的厚度没有特别限定,例如为0.1~5mm,优选为0.2~2mm,更优选为0.2~1mm。通过使表面材料的厚度为这些范围内,从而使表面材料的机械强度等良好,同时也可以确保高的光透射性等。此外,通过使表面材料的厚度为0.2mm以上,从而可以防止发泡体等内部能够透过看到。
表面材料的全光线透射率没有特别限定,优选为0.02~30%。如果表面材料的全光线透射率为0.02%以上,则易于将叠层体整体的全光线透射率调整到一定以上。如果表面材料的全光线透射率为30%以下,则易于防止从表面材料侧,发泡体等的内部能够透过看到。表面材料的全光线透射率优选为0.05~25%,更优选为0.1~22%。
作为使表面材料贴合的方法,可举出例如,挤出层压法、涂布了粘接剂后贴合的粘接层压法、热层压法(热熔合法)、热熔法、高频焊接法等,只要两者被粘接哪种方法都可以。
此外,在使用于汽车内装材料的情况下,发泡体、和具有发泡体的上述叠层体可以适当成型为所希望的形状。作为成型方法,可举出真空成型、压缩成型、冲压成型等。
[粘着带]
本发明的粘着带使用本发明涉及的发泡体作为基材,在发泡体的一个面或两面设置了粘着材料。粘着带的厚度通常为0.5~2.0mm左右。
构成粘着带的粘着材料的厚度优选为50~200μm,更优选为80~150μm。如果构成粘着带的粘着材料的厚度为50~200μm,则可以使粘着带的厚度薄,光透射性提高。
粘着材料只要至少具备粘着剂层即可,可以为叠层在发泡体的至少一个面的单独粘着剂层,也可以为粘贴在发泡体的至少一个面的双面粘着片,但从光透射性等观点考虑,优选为单独粘着剂层。另外,双面粘着片具备基材、和设置在基材的两面的粘着剂层。双面粘着片为了使一个粘着剂层与树脂发泡体片粘接,并且使另一个粘着剂层与其它构件粘接而使用。
作为构成粘着剂层的粘着剂,没有特别限制,可以使用例如,丙烯酸系粘着剂、氨基甲酸酯系粘着剂、橡胶系粘着剂、有机硅系粘着剂等。此外,可以在粘着材料上,进一步贴合脱模纸等剥离片。
使用了本发明的发泡体的粘着带可以作为内装于电子设备主体内的冲击吸收材料、密封材料等而使用。此外,可以通过粘着带的粘着剂层而使发泡体与上述表面材料贴合。
〔第2发明〕
本发明中的第2发明为以下说明的叠层体。
[叠层体]
本发明中的第2发明为下述叠层体,是具备表皮层、和发泡体层的叠层体,上述叠层体的Asker C硬度为70以下,全光线透射率超过0.01%。
将本发明的叠层体的一实施方式的截面图示于图1中。本发明的叠层体为具备表皮层11和发泡体层12的叠层体10,在发泡体层12的一个表面上叠层有表皮层11。在将该叠层体10使用于例如汽车的内装材料等的情况下,表皮层11例如为树脂片等,通过将其叠层于发泡体层12,可以对使用者(驾驶员等)带来高级感。
此外,在发泡体层12的另一个表面侧设置有LED13,该LED13可以在汽车等车辆内,将温度、时间、车速等必要信息通过发光而显示。由LED13发出的光透过发泡体层12、和表皮层11,由此,人可以从表皮层11侧感知必要信息。另外,在附图中,LED13被层状图示,但可以不一定为层状。此外,LED13以与发泡体层等接触地设置的方式被图示,但LED13可以从发泡体层等隔开一定距离而配置。
本发明的叠层体10由于全光线透射率为一定以上,因此人易于感知必要信息。此外,该叠层体通过Asker C硬度为一定值以下,从而具有柔软的触感。另外,在图1中,显示表皮层11与发泡体层12被直接叠层的形态,但也可以在表皮层11与发泡体层12之间设置未图示的粘接层。
将本发明的叠层体的其它一实施方式示于图2中。图2所示的叠层体10进一步具备印刷层14。更详细而言,该叠层体10依次叠层有表皮层11、发泡体层12、印刷层14,在印刷层14的与发泡体层12存在的表面相反的表面侧设置有LED13。印刷层14具有将从LED13发出的光进行遮光的遮光部分、和使光透过的光透过部分,通过使光透过部分为一定的文字的形状等,从而通过LED13的光而从表皮层侧确认必要信息。将印刷层14的俯视图的一例示于图4中,黑色的部分为遮光部分,白底的部分为光透过部分,在该情况下白底的部分(S字)从表皮层侧被感知。
另外,在图2中,印刷层14为在发泡体层12的表面通过公知的方法而形成的层,但设置印刷层14的形态不限定于该形态,印刷层14可以通过对发泡体层12和表皮层11中的至少一者的表面进行印刷而形成。
此外,可以代替印刷层14而使用膜的至少一者的表面被印刷的印刷膜层。该印刷膜层也同样地具有将光进行遮光的遮光部分、和使光透过的光透过部分。换言之,叠层体10可以具备印刷层和印刷膜层中的至少一者,这样的叠层体10可以显示与印刷层或印刷膜层的光透过部分的形状对应的信息。
此外,这样的印刷层14如图3所示那样,可以设置在表皮层11与发泡体层12之间。此外在图2或图3的叠层体10中,可以在各层之间设置未图示的粘接层。
(叠层体的全光线透射率)
本发明中的、具备表皮层和发泡层的叠层体的全光线透射率超过0.01%。如果叠层体的全光线透射率为0.01%以下,则光透射性差,从表皮层侧难以辨认必要信息。叠层体的全光线透射率优选为0.02%以上,更优选为0.5%以上,进一步优选为1%以上。此外叠层体如上述那样在从LED等照射了光时,优选能够从表皮层侧感知必要信息,但在不照射光的情况下,优选从表皮层侧不能透过看到发泡层、印刷层、印刷膜层等内部。从这样的观点考虑,叠层体的全光线透射率优选为5%以下,更优选为4%以下,进一步优选为3%以下。
另外,叠层体的全光线透射率在叠层体具备印刷层和印刷膜层中的至少一者的情况下,是指叠层体的最大的全光线透射率。即,印刷层和印刷膜层如上述那样具备不通过光的遮光部分、和使光透过的光透过部分,所谓叠层体的最大的全光线透射率,是以该光透过部分作为测定对象的情况下的全光线透射率。
叠层体的全光线透射率可以通过后述表皮层和发泡体层的厚度、组成等来调节。
(叠层体的Asker C硬度)
本发明中的叠层体的Asker C硬度为70以下。如果叠层体的Asker C硬度超过70,则难以保持柔软的触感。叠层体的Asker C硬度优选为60以下,更优选为50以下,进一步优选为40以下。此外,Asker C硬度的下限没有特别限定,但从保持一定的机械强度的观点等考虑,叠层体的Asker C硬度优选为5以上,更优选为10以上。叠层体的Asker C硬度可以通过发泡体层的厚度、发泡倍率等来调节。
(表皮层)
关于表皮层的厚度,只要叠层体的全光线透射率和Asker C硬度为上述范围,就没有特别限定,优选为0.2~1.0mm。通过使表皮层的厚度为1.0mm以下,从而易于将叠层体的全光线透射率和Asker C硬度调整为上述范围。此外,通过使表皮层的厚度为0.2mm以上,从而易于防止从表皮层侧能够透过看到发泡层、和根据需要设置的印刷层以及印刷膜层等的内部。表皮层的厚度更优选为0.2~0.8mm,进一步优选为0.2~0.7mm。
表皮层的全光线透射率优选为0.02~30%。如果表皮层的全光线透射率为0.02%以上,则易于将叠层体的全光线透射率如上述那样调整到一定以上。如果表皮层的全光线透射率为30%以下,则易于防止从表皮层侧能够透过看到发泡层、和根据需要设置的印刷层以及印刷膜层等的内部。表皮层的全光线透射率优选为0.05~25%,更优选为0.1~22%。
从将全光线透射率调整为所希望的值的观点考虑,表皮层可以包含炭黑、二氧化钛、珠光粒子、铝粉等金属粉等颜料。表皮层优选包含后述树脂片和颜料,表皮层中的颜料的含量以表皮层总量基准计,优选为0.01~3质量%,更优选为0.02~1质量%。
构成表皮层的材料没有特别限定,可举出聚丙烯片、聚乙烯片、烯烃系热塑性弹性体(TPO)片、聚氯乙烯片、在聚氯乙烯与ABS树脂的混合树脂片等中例示的树脂片、使用了天然纤维、人造纤维的机织物、针织物、无纺织物、人工皮革、合成皮革等皮革等。
它们之中,从易于将全光线透射率调整为所希望的范围的观点考虑,优选为树脂片,其中优选为聚丙烯片、烯烃系热塑性弹性体片,更优选为烯烃系热塑性弹性体片。
从提高设计性的观点考虑,可以在表皮层的表面形成皱缩花样。此外,可以使用带有从真皮、石、木等转印了的凹凸的有机硅印模等,对表皮层的表面施与皮纹、木纹花样等。
此外,从防止损伤的观点考虑,可以对表皮层表面施与各种涂层。
(发泡体层)
以下对构成本发明中的叠层体的发泡体层进行说明。
<厚度>
关于发泡体层的厚度,只要叠层体的全光线透射率和Asker C硬度成为上述范围,就没有特别限定,但优选为0.5~5mm。通过使发泡体层的厚度为0.5mm以上,从而叠层体的触感易于变得柔软。此外,通过使发泡体层的厚度为5mm以下,从而易于将叠层体的全光线透射率调整为上述范围。发泡体层的厚度优选为0.5~4mm,更优选为0.6~3.5mm。
<全光线透射率>
发泡体层的全光线透射率优选为10%以上。通过发泡体层的全光线透射率为10%以上,从而易于将叠层体的全光线透射率调整为上述范围。发泡体层的全光线透射率更优选为20%以上,进一步优选为30%以上。发泡体层的全光线透射率越高越好,但通常为95%以下。
<发泡倍率>
发泡体层的发泡倍率没有特别限制,优选为7~40倍。如果发泡倍率为7倍以上,则叠层体的Asker C硬度变低,触感易于变得柔软,叠层体的全光线透射率也易于调整为上述范围。通过使发泡体层的发泡倍率为40倍以下,从而可以使叠层体的机械强度为一定以上。发泡体层的发泡倍率更优选为10~35倍,进一步优选为12~33倍。
<交联度(凝胶分率)>
聚烯烃系发泡体层的交联度(凝胶分率)优选为5~60质量%。如果凝胶分率为上述下限值以上,则在发泡体层中形成充分的交联,因此机械强度易于变高。此外,如果交联度为这些上限值以下,则易于确保柔软的触感。从这样的观点考虑,交联度更优选为10~50质量%,进一步优选为10~40质量%。另外,交联度可以通过后述测定方法来测定。
<材料>
发泡体层优选通过树脂来形成,具体而言,优选为聚烯烃系发泡体层或聚氨酯系发泡体层,更优选为聚烯烃系发泡体层。聚烯烃系发泡体层通过使包含聚烯烃树脂的发泡性树脂组合物发泡来形成,作为聚烯烃树脂,可举出例如,聚丙烯树脂、聚乙烯树脂、乙烯-乙酸乙烯酯共聚物等,可以将它们单独使用,或混合使用2种以上。
形成发泡体层的树脂优选为仅1种。通过使用仅1种,从而起因于掺混的浑浊难以产生,能够提高发泡体层的光透射性。
发泡体层可以为单层的发泡体层,也可以为将2个以上发泡体进行了叠层的多层的发泡体层。构成多层的发泡体层的各个发泡体的组成、厚度、全光线透射率、发泡倍率、交联度等各物性可以不同,作为多层的发泡体层整体,优选满足上述各物性。
《聚乙烯树脂》
作为聚乙烯树脂,可举出低密度聚乙烯树脂(0.93g/cm3以下,LDPE)、中密度聚乙烯树脂(大于0.930g/cm3且小于0.942g/cm3,MDPE)、高密度聚乙烯树脂(0.942g/cm3以上,HDPE)。此外,作为低密度聚乙烯树脂的适合的具体例,可举出直链状低密度聚乙烯树脂(LLDPE)。
聚乙烯树脂可以为乙烯的均聚物,但也可以为以乙烯作为主成分(全部单体的优选75质量%以上,更优选90质量%以上)的、乙烯与少量的α-烯烃的共聚物等。作为α-烯烃,可举出优选为碳原子数3~12,更优选为碳原子数4~10的α-烯烃,具体而言,可举出1-丁烯、1-戊烯、1-己烯、4-甲基-1-戊烯、1-庚烯、1-辛烯等。另外,在共聚物中,这些α-烯烃可以单独使用或组合使用2种以上。
此外,聚乙烯树脂可以单独使用1种,也可以并用2种以上。
《聚丙烯树脂》
作为聚丙烯树脂,可以为作为丙烯的均聚物的均聚丙烯,可举出以丙烯作为主成分(全部单体的优选75质量%以上,更优选90质量%以上)的、丙烯与少量的乙烯和丙烯以外的α-烯烃的共聚物等。
作为丙烯、与乙烯和丙烯以外的α-烯烃的共聚物,可举出嵌段共聚物(嵌段聚丙烯)、无规共聚物(无规聚丙烯)、无规嵌段共聚物等。
作为丙烯以外的α-烯烃,可举出1-丁烯、1-戊烯、1-己烯、4-甲基-1-戊烯、1-庚烯、1-辛烯等碳原子数4~10左右的α-烯烃等,但它们之中,从成型性和耐热性的观点考虑,优选为乙烯。另外,在共聚物中,这些α-烯烃可以单独使用或组合使用2种以上。
此外,聚丙烯树脂可以单独使用,也可以并用2种以上。
在本发明中,可以使用通过齐格勒/纳塔化合物、金属茂化合物、氧化铬化合物等聚合催化剂而被聚合了的聚乙烯树脂、聚丙烯树脂、或它们的混合物的任一者。
《乙烯-乙酸乙烯酯共聚物》
作为聚烯烃树脂而使用的乙烯-乙酸乙烯酯共聚物可举出例如,含有来源于乙烯的结构单元50质量%以上的乙烯-乙酸乙烯酯共聚物。乙烯-乙酸乙烯酯共聚物由于与聚乙烯树脂、聚丙烯树脂的相容性高,因此也可以将乙烯-乙酸乙烯酯共聚物、与选自聚乙烯树脂和聚丙烯树脂中的1种以上并用。
乙烯-乙酸乙烯酯共聚物的密度优选为0.92g/cm3以上,更优选为0.93g/cm3以上,进一步优选为0.94g/cm3以上,而且,优选为0.97g/cm3以下,更优选为0.96g/cm3以下。
聚烯烃系发泡体层可以仅由上述聚烯烃树脂构成,但也可以为由聚烯烃系树脂和弹性体混合而得的物质。作为弹性体,可举出乙烯-丙烯-二烯橡胶(EPDM)、乙烯-丙烯橡胶(EPM)、苯乙烯橡胶等。此外,作为弹性体,也可举出热塑性弹性体。作为热塑性弹性体,可举出烯烃系热塑性弹性体、苯乙烯系热塑性弹性体等。
聚烯烃系发泡体层中的聚烯烃树脂的含量以发泡体层总量基准计,优选为50质量%以上,更优选为70质量%以上,进一步优选为90质量%以上。
聚氨酯系发泡体层通过聚氨基甲酸酯树脂而形成,如后述那样,通过使含有多元醇化合物、多异氰酸酯化合物的发泡性树脂组合物发泡而形成。
聚烯烃系发泡体层中的聚氨基甲酸酯树脂的含量以发泡体层总量基准计,优选为50质量%以上,更优选为70质量%以上,进一步优选为90质量%以上。
[发泡体层的制造]
本发明中的发泡体层通过使发泡性树脂组合物发泡而形成。作为发泡方法,可举出如后述那样使用热分解型发泡剂、水等发泡剂使其发泡的方法、使用二氧化碳、丁烷气体等非活性气体使其发泡的方法等。
(聚烯烃系发泡体层的制造)
聚烯烃系发泡体层例如通过将包含上述聚烯烃树脂、和发泡剂等的发泡性树脂组合物进行发泡来制造。作为发泡剂,可举出化学发泡剂、物理发泡剂等。
<发泡剂>
作为化学发泡剂,优选为热分解型发泡剂。作为热分解型发泡剂,能够使用有机发泡剂、无机发泡剂。作为有机发泡剂,可举出偶氮二甲酰胺、偶氮二羧酸金属盐(偶氮二羧酸钡等)、偶氮二异丁腈等偶氮化合物、N,N’-二亚硝基五亚甲基四胺等亚硝基化合物、联二脲、4,4’-氧基双(苯磺酰肼)、甲苯磺酰肼等肼衍生物、甲苯磺酰氨基脲等氨基脲化合物等。
作为无机发泡剂,可举出碳酸铵、碳酸钠、碳酸氢铵、碳酸氢钠、亚硝酸铵、氢化硼钠、无水柠檬酸单钠等。
它们之中,从获得微细的气泡的观点、和经济性、安全方面的观点考虑,优选为偶氮化合物,更优选为偶氮二甲酰胺。
热分解型发泡剂可以单独使用1种,也可以并用2种以上。
作为物理发泡剂,可举出后述非活性气体等。
发泡性树脂组合物中的发泡剂的含量相对于聚烯烃树脂100质量份,优选为1~30质量份,更优选为2~25质量份,进一步优选为2~20质量份。通过使发泡剂的混配量为1质量份以上,从而发泡体层被适度发泡,能够赋予一定的柔软性。此外,通过使发泡剂的混配量为30质量份以下,从而可以防止发泡体层过度发泡,使发泡体层的机械强度等良好。
<成核剂>
发泡性树脂组合物可以含有成核剂。作为成核剂,只要是具有使结晶核生成过程的进行速度提高的效果的物质,就没有特别限制。通过在聚乙烯树脂、聚丙烯树脂等聚烯烃树脂中添加成核剂,从而可以使产生的结晶的尺寸小,因此发泡体层的透明性提高。
作为成核剂,作为具有使结晶核生成过程的进行速度提高的效果的物质,可举出具有经过聚合物的分子链的吸附过程而促进分子链取向的效果的物质。
更具体而言,可举出高熔点聚合物、有机羧酸或其金属盐、脂肪族醇族、二亚苄基山梨糖醇或其衍生物、松香酸部分金属盐、酰胺化合物、无机微粒、有机磷酸化合物或其金属盐、酰亚胺类、喹吖啶酮类、醌类、芳香族磺酸盐或其金属盐、糖类、和它们的混合物。它们可以单独使用1种,也可以并用2种以上。
<添加剂>
发泡性树脂组合物可以包含交联助剂、分解温度调节剂、和抗氧化剂等成分。关于这些交联助剂、分解温度调节剂、和抗氧化剂的种类和量,也与上述内容同样。
在发泡性树脂组合物中,除它们以外,还可以混配热稳定剂、着色剂、阻燃剂、抗静电剂、填充材等一般使用于发泡体的添加剂。
(聚烯烃系发泡体层的制造工序)
聚烯烃系发泡体层的制造方法没有特别限制,可以通过将由至少包含聚烯烃树脂和热分解型发泡剂的发泡性树脂组合物形成的发泡性片加热而使热分解型发泡剂发泡来制造。其制造方法更具体而言优选包含以下工序(1)~(3)。
工序(1):成型由至少包含聚烯烃树脂和热分解型发泡剂的发泡性树脂组合物形成的发泡性片的工序
工序(2):向发泡性片照射电离性放射线而使发泡性片交联的工序
工序(3):将进行了交联的发泡性片加热,使热分解型发泡剂发泡,获得发泡体层的工序
在工序(1)中,成型发泡性片的方法没有特别限定,例如,只要将聚烯烃树脂、热分解型发泡剂、根据需要混配的成核剂、和添加剂供给到挤出机进行熔融混炼,从挤出机片状地挤出发泡性树脂组合物来进行成型即可。此外,发泡体层可以通过将发泡性树脂组合物进行压制等来成型。
发泡性树脂组合物的成型温度(即,挤出时的温度、或压制时的温度)优选为50℃以上且250℃以下,更优选为80℃以上且180℃以下。
作为在工序(2)中将发泡性片交联的方法,使用向发泡性片照射电子射线、α射线、β射线、γ射线等电离性放射线的方法。上述电离放射线的照射量只要以所得的发泡体层的交联度成为上述所希望的范围的方式调整即可,但优选为1~9Mrad,更优选为1.9~5Mrad。
在工序(3)中,将发泡性片加热而使热分解型发泡剂发泡时的加热温度只要为热分解型发泡剂的发泡温度以上即可,但优选为200~300℃,更优选为220~280℃。
此外,在本制造方法中,发泡性片可以沿MD或TD的任一者或两者拉伸。发泡性片的拉伸可以在使发泡性片发泡而获得了发泡体层后进行,也可以在使发泡性片发泡的同时进行。另外,在使发泡性片发泡而获得了发泡体层后,将发泡体层拉伸的情况下,可以不将发泡体层冷却而在维持发泡时的熔融状态下直接继续将发泡体层拉伸,也可以在将发泡体层冷却后,再次将发泡体层加热而形成熔融或软化状态后将发泡体拉伸。发泡体层通过进行拉伸从而易于为薄厚度。此外,在拉伸时发泡体层例如只要加热到100~280℃,优选为150~260℃即可。在本发明中,通过进行拉伸,从而发泡体的气泡直径沿着MD或TD的一者或两者而变大,光透射性易于变高。
然而,在上述工序(1)~(3)中,可以代替照射电离性放射线,通过在聚烯烃系树脂组合物中预先混配有机过氧化物,将发泡性片加热而使有机过氧化物分解的方法等来进行交联。
聚烯烃系发泡体层的制造方法不限定于进行上述工序(1)~(3)的方法,可以通过进行物理发泡使其发泡。
在通过物理发泡使其发泡的情况下,优选在含有聚烯烃树脂、根据需要混配的成核剂、和添加剂的树脂组合物中使物理发泡剂含浸。物理发泡剂的含浸优选在将树脂组合物成型为片状后进行。另外,可以将树脂组合物成型为片状,进行了电子射线照射后,使物理发泡剂含浸。电子射线照射可以使用与上述工序(2)同样的方法。
作为物理发泡剂,优选使用高压的非活性气体。作为非活性气体,只要是相对于树脂组合物为非活性,并且能够含浸的物质,就没有特别限制,可举出例如,二氧化碳、丁烷气体、氮气、空气等。这些气体可以混合使用。它们之中,从易于提高发泡体层的发泡倍率的观点考虑,优选为二氧化碳、丁烷气体。含浸时的非活性气体优选为超临界状态或亚临界状态。
(聚氨酯系发泡体层的制造)
聚氨酯系发泡体层通过使包含多元醇化合物、异氰酸酯化合物、和发泡剂的发泡性树脂组合物发泡和固化来获得。
<多元醇化合物>
作为多元醇化合物,可举出聚内酯多元醇、聚碳酸酯多元醇、芳香族多元醇、脂环族多元醇、脂肪族多元醇、聚酯多元醇、和聚醚多元醇等。上述多元醇化合物可以为聚合物多元醇。上述多元醇化合物可以仅使用1种,也可以并用2种以上。
作为上述聚内酯多元醇,可举出聚丙内酯二醇、聚己内酯二醇、和聚戊内酯二醇等。
作为上述聚碳酸酯多元醇,可举出含羟基化合物与碳酸酯化合物的脱醇反应物等。作为上述含羟基化合物,可举出乙二醇、丙二醇、丁二醇、戊二醇、己二醇、辛二醇、和壬二醇等。作为上述碳酸酯化合物,可举出碳酸二乙酯、和碳酸二丙酯等。
作为上述芳香族多元醇,可举出双酚A、双酚F、苯酚酚醛清漆、和甲酚酚醛清漆等。
作为上述脂环族多元醇,可举出环己二醇、甲基环己二醇、异佛尔酮二醇、二环己基甲烷二醇、和二甲基二环己基甲烷二醇等。
作为上述脂肪族多元醇,可举出乙二醇、丙二醇、丁二醇、戊二醇、和己二醇等。
作为上述聚酯多元醇,可举出多元酸与多元醇的脱水缩合物、内酯的开环聚合物、和羟基羧酸与多元醇的缩合物等。作为上述多元酸,可举出己二酸、壬二酸、癸二酸、对苯二甲酸、间苯二甲酸、和琥珀酸等。作为上述多元醇,可举出双酚A、乙二醇、丙二醇、丁二醇、二甘醇、己二醇、和新戊二醇等。作为上述内酯,可举出ε-己内酯、和α-甲基-ε-己内酯等。作为上述羟基羧酸,可举出蓖麻油、和蓖麻油与乙二醇的反应生成物等。
作为上述聚醚多元醇,可举出具有2个以上活性氢原子的活性氢化合物与环氧烷(alkylene oxide)的开环聚合物等。作为上述环氧烷,可举出环氧乙烷(ethylene oxide)、环氧丙烷(propylene oxide)和四氢呋喃等。上述活性氢化合物的分子量优选低。作为上述活性氢化合物,可举出双酚A、乙二醇、丙二醇、丁二醇、和1,6-己二醇等二醇化合物、甘油、和三羟甲基丙烷等三醇化合物、乙二胺、和丁二胺等胺化合物等。
作为上述聚合物多元醇,可举出不饱和有机化合物与多元醇化合物接枝聚合了的接枝聚合物、聚丁二烯多元醇、多元醇的改性多元醇、和它们的加氢物等。
在上述接枝聚合物中,作为上述多元醇化合物,可举出芳香族多元醇、脂环族多元醇、脂肪族多元醇、聚酯多元醇、和聚醚多元醇等。作为上述不饱和有机化合物,可举出丙烯腈、苯乙烯、和(甲基)丙烯酸甲酯等。
作为上述多元醇的改性多元醇,可举出多元醇与环氧烷的反应改性物等。作为上述多元醇,可举出甘油和三羟甲基丙烷等3元醇、季戊四醇、山梨糖醇、甘露糖醇、失水山梨糖醇、双甘油、二季戊四醇、蔗糖、葡萄糖、甘露糖、果糖、甲基葡糖苷和它们的衍生物等4元以上且9元以下的醇、苯酚、均苯三酚、甲酚、连苯三酚、儿茶酚、氢醌、双酚A、双酚F、双酚S、1-羟基萘、1,3,6,8-四羟基萘、蒽酚、1,4,5,8-四羟基蒽、和1-羟基芘等酚化合物、聚丁二烯多元醇、蓖麻油多元醇、(甲基)丙烯酸羟基烷基酯的(共)聚合物、聚乙烯醇等多官能(例如官能团数2以上且100以下)多元醇、酚与甲醛的缩合物(酚醛清漆)等。作为上述环氧烷,可举出碳原子数为2以上且6以下的环氧烷。作为上述环氧烷的具体例,可举出环氧乙烷、1,2-环氧丙烷(1,2-propylene oxide)、1,3-环氧丙烷(1,3-propylene oxide)、1,2-环氧丁烷(1,2-butylene oxide)、和1,4-环氧丁烷(1,4-butylene oxide)等。从使性状、反应性良好的观点考虑,上述环氧烷优选为1,2-环氧丙烷、环氧乙烷或1,2-环氧丁烷,更优选为1,2-环氧丙烷或环氧乙烷。上述环氧烷可以仅使用1种,也可以并用2种以上。
<多异氰酸酯化合物>
作为多异氰酸酯化合物,可举出芳香族多异氰酸酯、脂环族多异氰酸酯、和脂肪族多异氰酸酯等。
作为上述芳香族多异氰酸酯,可举出苯撑二异氰酸酯、甲苯二异氰酸酯、苯二亚甲基二异氰酸酯、二苯基甲烷二异氰酸酯、二甲基二苯基甲烷二异氰酸酯、三苯基甲烷三异氰酸酯、萘二异氰酸酯、和多亚甲基多苯基多异氰酸酯(Polymethylene polyphenylpolyisocyanate)等。
作为上述脂环族多异氰酸酯,可举出环己二异氰酸酯、甲基环己二异氰酸酯、异佛尔酮二异氰酸酯、二环己基甲烷二异氰酸酯、和二甲基二环己基甲烷二异氰酸酯等。
作为上述脂肪族多异氰酸酯,可举出亚甲基二异氰酸酯、乙二异氰酸酯、丙二异氰酸酯、1,4-丁二异氰酸酯、和1,6-己二异氰酸酯等。
相对于上述多元醇化合物100质量份,上述异氰酸酯化合物的含量优选为10质量份以上,更优选为15质量份以上,优选为35质量份以下,更优选为30质量份以下。
<发泡剂>
作为用于制造聚氨酯系发泡体层的发泡剂,可举出水、有机卤素化合物等。
作为有机卤素化合物,可举出有机氯化合物、有机氟化合物等。
作为有机氯化合物,可举出例如,二氯乙烷、丙基氯、异丙基氯、丁基氯、异丁基氯、戊基氯、和异戊基氯等。
作为有机氟化合物,可举出例如,二氟甲烷(HFC32)、1,1,1,2,2-五氟乙烷(HFC125)、1,1,1-三氟乙烷(HFC143a)、1,1,2,2-四氟乙烷(HFC134)、1,1,1,2-四氟乙烷(HFC134a)、1,1-二氟乙烷(HFC152a)、1,1,1,2,3,3,3-七氟丙烷(HFC227ea)、1,1,1,3,3-五氟丙烷(HFC245fa)、1,1,1,3,3-五氟丁烷(HFC365mfc)和1,1,1,2,2,3,4,5,5,5-十氟戊烷(HFC4310mee)等。
发泡剂的含量只要根据发泡剂的种类来适当调整即可。在使用水作为发泡剂的情况下,只要相对于多元醇化合物和多异氰酸酯化合物的合计100质量份,使发泡剂优选为1~10质量份,更优选为1~5质量份即可。在使用有机卤素化合物作为发泡剂的情况下,只要相对于多元醇化合物和多异氰酸酯化合物的合计100质量份,使发泡剂优选为1~10质量份,更优选为1~5质量份即可。在使用水和有机卤素化合物作为发泡剂的情况下,优选以分别成为上述范围的方式调整混配量。
<催化剂>
发泡性树脂组合物可以含有催化剂。作为催化剂,可举出氨基甲酸酯化催化剂、三聚化催化剂等。作为氨基甲酸酯化催化剂,可举出胺催化剂等。作为三聚化催化剂,可举出芳香族化合物、羧酸的碱金属盐、羧酸的季铵盐、和季铵盐/乙二醇混合物等。
催化剂的含量(合计量)相对于多元醇化合物和多异氰酸酯化合物的合计100质量份,优选为0.05~1质量份。
在用于制造聚氨酯系发泡体层的发泡性树脂组合物中,除了上述以外,还可以含有分解温度调节剂、抗氧化剂、热稳定剂、着色剂、阻燃剂、抗静电剂、填充剂等。
聚氨酯系发泡体层可以通过使上述发泡性树脂组合物发泡和固化来获得。例如,可以将发泡性树脂组合物注入到模具中,进行加热,使其发泡和固化。可以在使发泡性树脂组合物发泡和固化后,将所得的固化体切片成所希望的厚度等,调整发泡体层的厚度。
(印刷层、印刷膜层)
本发明的叠层体如上述那样可以具备印刷层和印刷膜层中的至少一者。由此,可以通过光,从表皮层侧感知与印刷的图案对应的形状。印刷层例如可以通过在发泡体层的一个面进行印刷来形成。印刷膜层是使印刷层形成于聚烯烃膜、PET膜等聚酯膜等基材膜而得的。作为使印刷层形成的方法,可以适当使用喷墨法等公知的方法。印刷层的厚度优选为1~25μm,更优选为2~10μm。印刷膜层的厚度优选为4~50μm,更优选为12~25μm。
另外,即使在叠层体不设置印刷层和印刷膜层的情况下,也能够通过将从发泡体层侧照射的光以使一定的文字信息显示的方式照射,从而从表皮层侧辨认文字信息。
(叠层体的制造)
本发明的叠层体例如可以通过将发泡体层与表皮层、和根据需要设置的印刷膜层进行叠层来制造。关于具体的层构成,如上述那样。发泡体层可以使用形成了印刷层的发泡体层。叠层可以使用热层压法,也可以通过粘接剂使层彼此粘接。
(光显示构件)
本发明的叠层体可以作为光显示构件而适合地使用。即,优选为具备叠层体的光显示构件。该光显示构件的构成没有特别限定,但优选具备叠层体、和信息显示部件,可以为例如,依次叠层了表皮层、发泡体层、信息显示部件的光显示构件。作为该信息显示部件,可举出例如,显示器、被排列了的LED等。所谓被排列了的LED,是为了显示特定的信息而以特定形状地配置了多个LED的物质。
光显示构件可以具有传感器元件,例如,上述信息显示部件可以为具有触摸面板等传感器元件的显示器。
该光显示构件作为汽车等车辆用而适合使用,优选作为使温度、时间、车速、危险、安全、预告等必要信息显示、或用于设计性、照明的构件而使用。
实施例
通过实施例进一步详细地说明本发明,但本发明不受这些例子任何限定。
〔第1发明:交联聚烯烃系树脂发泡体〕
[测定方法]
本说明书中的各物性的测定方法如下所述。
<表观密度>
发泡体的表观密度按照JIS K7222:2005测定。
<发泡倍率>
发泡倍率通过将发泡前的发泡性片的密度除以发泡后的发泡体的密度(表观密度)来算出。
<交联度(凝胶分率)>
从发泡体片采取约100mg的试验片,精密称量试验片的重量A(mg)。接下来,将该试验片在120℃的二甲苯30cm3中浸渍而放置24小时后,用200目的金属网过滤而采取金属网上的不溶解成分,进行真空干燥,精密称量不溶解成分的重量B(mg)。从所得的值,通过下述式算出交联度(质量%)。
交联度(质量%)=(B/A)×100
<全光线透射率>
发泡体的全光线透射率对调整为表1所记载的厚度的发泡体按照ASTM D1003,使用雾度计测定。
<辨认性评价>
关于辨认性评价,如下所述进行。
首先,作为表皮材,准备加有ABS树脂的聚氯乙烯片(厚度0.6mm)。在该聚氯乙烯片的表面以1文字的大小成为12磅(font)的方式记载文字“abc”。
接着,将在实施例和比较例中制造的交联聚烯烃系树脂发泡体与上述表皮材的2层叠层物加入到保持为160℃的压制成型模具(深度10mm,模具8mm,凹部的曲率半径5mm)中,以0.2kg/cm2的压力压制25秒而获得了成型品。
从该成型品的交联聚烯烃系树脂发泡体侧朝向表皮材侧进行LED点亮,判定是否可以从距离1m的场所辨认文字。将可以辨认文字的情况设为“A”,将不能辨认的情况设为“B”。将结果示于表1中。
<使用原料>
在实施例和比较例中使用的材料如下所述。
〔聚烯烃系树脂〕
PP:住友化学株式会社制“ノーブレンAD571”(密度:0.900g/cm3)
LLDPE:東ソー株式会社“ニポロン-Z ZF231B”(密度:0.917g/cm3)
LDPE:宇部丸善ポリエチレン株式会社“UBEポリエチレンF522N”(密度:0.922g/cm3)
EVA(1):東ソー株式会社“ウルトラセン636”(密度:0.941g/cm3)
EVA(2):東ソー株式会社“ウルトラセン710”(密度:0.949g/cm3)
〔弹性体〕
HSBR:JSR株式会社“DYNARON 1320P”
SEBC:JSR株式会社“DYNARON 4600P”
成核剂:糖类系,東京インキ株式会社“NAT-95”
发泡剂:荣和化成株式会社“AC#R”(偶氮二甲酰胺)
交联助剂:共荣社化学“ライトエステル1.9-ND”(1,9-壬二醇二甲基丙烯酸酯)
抗氧化剂:BASFジャパン“イルガノックス1010”
分解温度调节剂(1):堺化学工业氧化锌
分解温度调节剂(2):堺化学工业“SZ-2000”硬脂酸锌
实施例1
通过将聚丙烯树脂(PP)80质量份、聚乙烯树脂(LLDPE)19质量份、成核剂2质量份、发泡剂8质量份、交联助剂3质量份、和抗氧化剂0.8质量份进行熔融混炼后,进行压制,从而获得了厚度0.3mm的发泡性片。向所得的发泡性片的两面以加速电压500keV照射电子射线3Mrad,使发泡性片交联了。接下来将交联了的发泡性片加热到250℃从而使其发泡,获得了表观密度0.09g/cm3、厚度1.0mm的发泡体片。
将所得的发泡体的评价结果示于表1中。
实施例2~17、比较例1~6
将聚烯烃系树脂组合物的混配如表1所示那样进行变更,并且以成为表1的交联度的方式调整了电子射线照射量,除此以外,与实施例1同样地实施。将所得的发泡体的评价结果示于表1中。
[表1]
由上述结果明确可知,本发明的聚烯烃系树脂发泡体在厚度为0.3mm~5.0mm的情况下具有优异的光透射性。
〔第2发明:叠层体〕
评价方法如下所述。
<Asker C硬度>
使用Asker橡胶硬度计C型(高分子计器株式会社制),使硬度计的压针与叠层体的表皮层抵接而测定。测定在25℃下进行。
<发泡倍率>
发泡倍率是求出发泡体层的密度(表观密度),计算密度的倒数而算出。表观密度按照JIS K7222:2005测定。
<凝胶分率(交联度)>
从发泡体层采取约100mg的试验片,精密称量试验片的重量A(mg)。接下来,将该试验片在120℃的二甲苯30cm3中浸渍而放置24小时后,用200目的金属网过滤而采取金属网上的不溶解成分,进行真空干燥,精密称量不溶解成分的重量B(mg)。从所得的值,通过下述式算出交联度(质量%)。
交联度(质量%)=(B/A)×100
<全光线透射率>
全光线透射率按照ASTM D1003,使用雾度计测定。
<透过感的评价>
从表皮层侧目视内部,通过发泡体层的辨认的程度来评价。
A··发泡体层完全不能看到
B··发泡体层能够看到一部分
C··发泡体层的整体能够看到
<发泡体层的使用原料>
在实施例和比较例中使用的材料如下所述。
〔聚烯烃树脂〕
聚丙烯树脂(PP):住友化学株式会社制“ノーブレンAD571”(密度:0.900g/cm3)
聚乙烯树脂(LLDPE,直链状低密度聚乙烯):東ソー株式会社“ニポロン-ZZF231B”(密度:0.917g/cm3)
聚乙烯树脂(LDPE(1),低密度聚乙烯):宇部丸善ポリエチレン株式会社“UBEポリエチレンF522N”(密度:0.922g/cm3)
聚乙烯树脂(LDPE(2),低密度聚乙烯):sdabic“1905UO”(密度:0.920g/cm3)
EVA:東ソー株式会社“ウルトラセン636”(密度:0.941g/cm3)
〔聚氨基甲酸酯树脂〕
多元醇化合物(1):三洋化成GP3000
多元醇化合物(2):乙二醇
多异氰酸酯化合物:日本ポリウレタンコロネートT-80
〔发泡剂〕
偶氮二甲酰胺(1):荣和化成株式会社“AC#R”(偶氮二甲酰胺)
偶氮二甲酰胺(2):大塚化学株式会社“SO-L”(偶氮二甲酰胺)
水
交联助剂:共荣社化学“ライトエステル1.9-ND”(1,9-壬二醇二甲基丙烯酸酯)
抗氧化剂:BASFジャパン“イルガノックス1010”
分解温度调节剂:堺化学“酸化亜鉛II種”
催化剂:日东化成“U-28”
稳泡剂:モメンティブ“L-626”
<表皮层>
在实施例和比较例中使用的表皮层包含含有颜料(炭黑)40wt%的颜料母料(東京インキ制PEX99901)、和烯烃系热塑性弹性体(TPO)。颜料母料的混配量、和颜料的含量如表2所示那样调整。表2所示的颜料的含量为表皮层总量基准的值。
(实施例18)
将聚丙烯树脂(PP)85质量份、聚乙烯树脂(LLDPE)15质量份、发泡剂6质量份、交联助剂3质量份、和抗氧化剂0.5质量份进行熔融混炼后,进行压制从而获得了发泡性片。向所得的发泡性片的两面以加速电压800keV照射电子射线2Mrad,使发泡性片交联了。接下来将交联了的发泡性片加热到250℃从而使其发泡,获得了发泡倍率13倍、厚度0.6mm的发泡体层。
使所得的发泡体层与表皮层通过厚度0.03mm的粘接片(积水化学制,“3803H”)进行叠层而获得了叠层体。
对所得的叠层体进行各种评价,在表2中显示结果。
(实施例19~24、28、29、比较例8~10)
将发泡性树脂组合物的组成、表皮层的种类如表2那样变更,并且以交联度成为如表2那样的方式将电子射线的照射条件适当变更,除此以外,与实施例18同样地操作而获得了叠层体。
对所得的叠层体进行各评价,在表2中显示结果。
(实施例25)
将聚乙烯树脂(LDPE(2))100质量份、和抗氧化剂0.5质量份投入到单螺杆挤出机中,以7MPa注入超临界二氧化碳进行了混合。然后,随着向单螺杆挤出机的前端方向前进,温度降低,并且将模头出口的温度以成为110℃的方式进行温度设定,进行挤出成型,从而获得了片状的发泡体。
向所得的片状的发泡体的两面以加速电压500keV照射电子射线1.9Mrad使其交联,获得了发泡体层。
使所得的发泡体层与表皮层通过厚度0.03mm的粘接片(积水化学制,“3803H”)进行叠层而获得了叠层体。
(比较例7、11)
以发泡体层的交联度成为如表2那样的方式将电子射线的照射条件变更,并且将表皮层的种类如表2那样变更,除此以外,与实施例25同样地操作而获得了叠层体。
对所得的叠层体进行各种评价,在表2中显示结果。
(实施例26)
将由多元醇化合物(1)100质量份、多元醇化合物(2)5质量份构成的多元醇化合物、多异氰酸酯化合物20质量份、作为催化剂的0.1质量份的U-28、作为稳泡剂的2质量份的L626、作为发泡剂的水2质量份进行混合而制作出发泡性树脂组合物。将该发泡性组合物注入到模具(150mm×150mm×50mm)后,用80℃的烘箱加热60分钟,使其发泡和固化,从而获得了固化体。通过将该固化体切片,从而获得了厚度3mm的发泡体层。
使所得的发泡体层与表皮层通过0.03mm的粘接片(积水化学制,“3803H”)进行叠层而获得了叠层体。
对所得的叠层体进行各种评价,在表2中显示结果。
(实施例27)
将发泡性树脂组合物的组成、和表皮层的种类等如表2那样变更,除此以外,与实施例26同样地操作而获得了叠层体。
对所得的叠层体进行各种评价,在表2中显示结果。
[表2]
本发明的叠层体由于Asker C硬度为一定值以下,因此可知具有柔软的触感,并且全光线透射率高,光透射性优异,易于从表皮层侧辨认必要信息。
符号的说明
10 叠层体
11 表皮层
12 发泡体层
13 LED
14 印刷层。
Claims (24)
1.一种交联聚烯烃系树脂发泡体,是将含有聚烯烃系树脂的聚烯烃系树脂组合物交联发泡而成的交联聚烯烃系树脂发泡体,
所述交联聚烯烃系树脂发泡体在厚度为0.3mm以上且小于1.0mm的情况下全光线透射率为45%以上,并且在厚度为1.0mm以上且5.0mm以下的情况下全光线透射率为30%以上。
2.根据权利要求1所述的交联聚烯烃系树脂发泡体,所述聚烯烃系树脂的含量以聚烯烃系树脂组合物所包含的树脂成分总量基准计为65质量%以上。
3.根据权利要求1或2所述的交联聚烯烃系树脂发泡体,1种聚烯烃系树脂的含量以聚烯烃系树脂组合物所包含的树脂成分总量基准计为65质量%以上。
4.根据权利要求1~3中任一项所述的交联聚烯烃系树脂发泡体,所述聚烯烃系树脂为选自聚乙烯树脂、聚丙烯树脂、和乙烯-乙酸乙烯酯共聚物中的1种以上。
5.根据权利要求1~4中任一项所述的交联聚烯烃系树脂发泡体,聚乙烯树脂、聚丙烯树脂、或乙烯-乙酸乙烯酯共聚物的任1种的含量以聚烯烃系树脂组合物所包含的树脂成分总量基准计为65质量%以上。
6.根据权利要求1~5中任一项所述的交联聚烯烃系树脂发泡体,所述聚烯烃系树脂组合物含有成核剂。
7.根据权利要求1~6中任一项所述的交联聚烯烃系树脂发泡体,所述聚烯烃系树脂组合物含有弹性体。
8.根据权利要求1~7中任一项所述的交联聚烯烃系树脂发泡体,其发泡倍率为1.3~40倍。
9.根据权利要求1~8中任一项所述的交联聚烯烃系树脂发泡体,其为汽车内装材料用。
10.一种粘着带,其具备权利要求1~9中任一项所述的交联聚烯烃系树脂发泡体、和设置在所述发泡体的至少一个面上的粘着材料。
11.一种叠层体,其具备权利要求1~9中任一项所述的交联聚烯烃系树脂发泡体、和设置在所述发泡体的至少一个面上的表面材料。
12.一种光显示构件,其具备权利要求1~9中任一项所述的交联聚烯烃系树脂发泡体。
13.一种叠层体,是具备表皮层、和发泡体层的叠层体,其Asker C硬度为70以下,全光线透射率超过0.01%。
14.根据权利要求13所述的叠层体,所述表皮层的厚度为0.2~1.0mm。
15.根据权利要求13或14所述的叠层体,所述表皮层的全光线透射率为0.02~30%。
16.根据权利要求13~15中任一项所述的叠层体,所述发泡体层的厚度为0.5~5mm。
17.根据权利要求13~16中任一项所述的叠层体,所述发泡体层的全光线透射率为10%以上。
18.根据权利要求13~17中任一项所述的叠层体,所述发泡体层的发泡倍率为7~40倍。
19.根据权利要求13~18中任一项所述的叠层体,所述发泡体层为聚烯烃系发泡体层或聚氨酯系发泡体层。
20.根据权利要求13~19中任一项所述的叠层体,所述叠层体还具备印刷层和印刷膜层中的至少一者。
21.根据权利要求20所述的叠层体,所述印刷层是通过对发泡体层和表皮层中的至少一者的表面进行印刷而形成的。
22.一种光显示构件,其具备权利要求13~21中任一项所述的叠层体。
23.根据权利要求22所述的光显示构件,其具有传感器元件。
24.根据权利要求22或23所述的光显示构件,其具备具有传感器元件的显示器。
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