JP2001131319A - Foamed composite molded product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reuse a sheet state plastic molded product in a state capable of utilizing a high mechanical strength that the molded material as a raw material originally has. SOLUTION: This foamed composite molded product is obtained by mixing plate state filling materials having 5-50 mm mean maximum diameter with a foaming resin, foaming to arrange at least 75% of the upper surface or the lower surface of the above plate like filling materials so as to have within ±30 deg. range of their inclining angles to a prescribed plane.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foam composite molded article mixed with a plate-like filler.

[0002]

2. Description of the Related Art In recent years, the amount of sheet-shaped oriented plastic moldings such as magnetic cards as prepaid cards and clear cases used for packaging materials for cosmetics and the like has increased dramatically. Along with this, the amount of used sheet-shaped oriented plastic moldings such as used magnetic cards and clear cases, long-lasting products, defective products, in-process waste materials, and the like are increasing.

[0003] Ideally, these should be reused.
In reality, they are incinerated or landfilled.

[0004] In general, the recycling of a plastic molded product is performed by separating and pulverizing a different material from the plastic molded product, or by separating the different material after the pulverization and granulating the remaining plastic material by melt extrusion or the like. It is performed by performing melt molding and re-forming into another molded body.

[0005]

However, when a used plastic molded article, a long-lasting product, a defective product, or a waste material in a process is reused, there is a problem that a considerable cost is required for separating the plastic material from a different material. Further, in the reuse of used plastic molded articles, there are also problems regarding the recovery efficiency and the quality of the recovered products.

[0006] Further, the remolded body obtained by reuse has a problem that it is inevitable that the properties deteriorate due to heat history, and it becomes difficult to produce a reshaped body having high characteristics. Furthermore, in such a method, the high mechanical strength inherently possessed by the sheet-like plastic molded product used as a raw material is not utilized at all in the remolded product.

Accordingly, an object of the present invention is to reuse a sheet-like plastic molded product as a raw material while taking advantage of its inherently high mechanical strength.

[0008]

According to the present invention, a plate-like filler having an average maximum diameter of 5 to 50 mm is mixed with a foamable resin and foamed, and at least 75% of the upper surface of the plate-like filler or The above problem was solved by arranging the lower surface with respect to a predetermined surface so that the inclination angle was within a range of ± 30 °.

Specifically, fragments obtained by cutting or crushing an oriented plastic sheet molded product can be used as the plate-like filler, and a room temperature foam-curable polyurethane resin can be used as the foam resin.

[0010]

Embodiments of the present invention will be described below.

The expanded composite molded article according to the present invention is shown in FIG.
As shown in (1), it is obtained by mixing a plate-shaped filler 1 with a foamable resin 2 and foaming.

The above-mentioned plate-like filler is a used product of a sheet-shaped oriented plastic molded article such as a magnetic card as a prepaid card, a clear case used for a packaging material for cosmetics, and the like. A piece obtained by cutting or crushing a long-lasting product, defective product, in-process waste material, or the like, and has various shapes as shown in FIGS. 2 (a) to 2 (c). However, since the fragments are made of a sheet-shaped oriented plastic molded body, the fragments shown in FIG. 2A have a smaller difference in vertical and horizontal lengths of the fragment upper surface (or lower surface) as shown in FIG. As shown in (b), more fragments longer in the alignment direction are obtained.

[0013] The strength of the plate-like filler is JIS
The tensile yield measured by the method specified in K 7113 is preferably 250 kg / cm ² or more. If it is smaller than this, when mixed with the foamable resin, sufficient strength may not be exhibited.

[0014] The material of the sheet-shaped oriented plastic molded material as a raw material of the plate-like filler is polystyrene, polypropylene, polyethylene terephthalate (hereinafter, referred to as "polyethylene terephthalate").
Called "PET". ) And the like. In particular, cards having excellent physical property balance include cards represented by prepaid cards using a biaxially stretched sheet made of PET.

In the case where the sheet-shaped oriented plastic molded body as a raw material of the above-mentioned plate-like filler is a recovered product, it is preferable to perform cutting, pulverization, etc. after washing and drying. This is because the surface is likely to have dirt and moisture, etc., unless it is removed, the adhesiveness with the foamed resin deteriorates,
This is because the function as a reinforcing material is weakened, and the strength is reduced. Further, when mixed with the foamable resin and foamed, in the later-described foaming step, the water becomes voids and foaming is likely to be uneven. Further, when the foaming material is polyurethane, moisture works as the foaming material, and the foaming ratio is likely to be uncertain.

The average maximum diameter of the plate-like filler is 5 to 50.
mm is better. Here, the maximum diameter refers to the length in the length direction of the plate-like filler, and refers to L shown in FIGS. 2 (a) to 2 (c). When the average maximum diameter is 5 mm or less, the strength of the sheet-shaped oriented plastic molded body before cutting or crushing is not utilized, and the reinforcing effect is reduced. On the other hand, if the average maximum diameter exceeds 50 mm, it may be difficult to form the foamed composite molded article according to the present invention. The average maximum diameter is obtained by sampling 10 g of the plate-like filler, measuring the total number of the samples, and setting the average value of all the numbers as the average maximum diameter.

The method for cutting or crushing the sheet-shaped oriented plastic molded body is not particularly limited.
A method of cutting with a blade having a certain shape, a method of crushing into an irregular shape with a crusher, and the like can be used.

The foamable resin is used as a binder for the plate-like filler. Examples of the resin include polyvinyl chloride, polyethylene, polypropylene, acrylonitrile-butadiene-styrene resin (ABS resin), and acrylic resin. A resin obtained by foaming a resin such as a resin or a polyurethane using a foaming agent can be used. Among them, a polyurethane resin is preferable in view of the bonding property between the above-mentioned plate-like filler and the foamable resin.

As the polyurethane resin, a mixture of an isocyanate component such as tolylene diisocyanate and diphenylmethane diisocyanate and a component comprising a polyester polyol or polyether polyol chain-extended with polypropylene oxide, ethylene oxide or the like is foamed and cured at room temperature. Items. A catalyst such as a tertiary amine such as polyethylamine or tetramethylhexadiamine or an organotin compound, or a foam stabilizer such as polyether siloxane may be added to the above-mentioned components composed of the polyester polyol or the polyether polyol.

The foaming agent is not particularly limited as long as it does not deteriorate the foamable resin. Examples of the foaming agent include pyrolysis, such as azodicarbonamide and azobisisobutyronitrile, which generates gas by thermal decomposition. Organic gas having a boiling point equal to or lower than the melting point of the foamable resin, such as a type chemical blowing agent, butane, pentane, dichlorodifluoromethane, monochlorodifluoroethane, etc., and carbon dioxide, nitrogen, air, argon, neon, etc. Inorganic gas, volatile liquid, water, and the like. This foaming agent can be used alone, or two or more kinds may be used in combination.

Among the above foaming agents, inorganic gas and water are preferable from the viewpoint of safety and environmental friendliness. Among them, when it is desired to obtain a high foaming ratio, a solvent having a high solubility in a foamable resin such as carbon dioxide gas is preferred. Gas is preferred. Also, when accompanied by a urethane reaction such as a room temperature foaming-curable urethane resin,
Water is preferred.

The amount of the foaming agent to be added can be set arbitrarily according to the specific gravity required for the obtained foamed composite molded article.

The foamed composite molded article according to the present invention is obtained by mixing the above-mentioned plate-like filler with the above-mentioned foamable resin and then foaming. The amount of the plate-shaped filler to be mixed into the foamed composite molded article is determined by the strength required for the obtained foamed composite molded article, but is usually determined by a mixing ratio of the plate-shaped filler and the foamable resin. Plate-shaped filler / foamable resin = 5 /
1 to 1/1 (weight ratio) is preferred. If it is larger than 5/1, uniform dispersion and uniform foaming become difficult depending on the combination of the plate-like filler and the foamable resin, and a problem may occur in molding. On the other hand, when the ratio is less than 1/1, it is not preferable in that the waste is reused, the effect of improving the mechanical strength is small, and the orientation of the plate-like filler becomes insufficient as described later. There is.

The method for mixing the plate-like filler with the foamable resin is not particularly limited, and various methods can be adopted. For example, when using a thermoplastic resin as a foamable resin, a method of mixing a plate-like filler and a pyrolytic foaming agent with the thermoplastic resin and extruding the mixture with a single-screw or twin-screw extruder, Mix a plate-shaped filler and an organic gas, inorganic gas, volatile liquid, physical blowing agent such as hydrogen, and install a vent type screw,
A method of extruding with a single-screw or twin-screw extruder having an injection port capable of being press-fitted from a vent portion in the middle of a cylinder is exemplified.

When polyurethane is used as the foaming resin, the isocyanate component and the component composed of polyester polyol or polyether polyol, and the foaming agent are previously mixed uniformly and evenly wetted on the surface of the plate-like filler. Alternatively, after the isocyanate component and the component composed of polyester polyol or polyether polyol are discharged at a high speed with separate spray guns, the mixture obtained at the outlet may be evenly sprayed on the plate-like filler in the form of a mist. .

The mixture of the foamable resin and the plate-like filler thus mixed is placed in a mold having a predetermined shape and foamed under predetermined conditions such as heating to form a foamed composite molded article having a predetermined shape. You can get the body. As the above-mentioned mold, a continuous mold such as a batch mold or a caterpillar former can be used.

The mixture of the foaming resin and the plate-like filler has a predetermined shape, and after being placed in a mold having one open side, the open side is closed and heated. Before foaming, external pressure is applied to the mixture from the open surface of the mold. Thereby, the upper surface or the lower surface of at least 75% of the plate-like filler in the mixture has an inclination angle of ± 30 ° with respect to the surface of the mixture disposed on the open surface of the mold. Orientation. Then, by foaming, a foam composite oriented so that at least 75% of the upper or lower surface of the plate-like filler has an inclination angle (θ in FIG. 3) formed with respect to a predetermined surface within a range of ± 30 °. A molded article can be obtained. The predetermined surface serving as the reference is one surface of the foamed composite molded article disposed on the open surface of the mold used for molding.

The ratio at which the plate-like filler is oriented in a predetermined direction is as follows:
If it is less than 75%, the resulting foamed composite molded article may have insufficient strength.

The method for applying the external pressure is not particularly limited, and various methods can be employed. For example, there are a method of applying an ultrasonic vibration plate and a method of applying a pressure contact roll.

[0030]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in more detail with reference to embodiments. In addition, the evaluation in each Example and the comparative example was performed by the following method. (1) Flexural strength Two fulcrums were placed at an interval of 200 mm, and the samples manufactured in the examples and comparative examples were placed thereon. Then, a strength was applied to the center of the two fulcrums, the breaking load was measured, and the bending strength (MPa or kgf / cm ² ) was calculated. It measured using 20 samples and made the average value the bending strength. The bending strength was 9.80 MPa (1
00 kgf / cm ² ) or more, “○”, 7.84M
Pa (80 kgf / cm ² ) or more and 9.80 MPa (10
Those with less than 0 kgf / cm ² ) are rated “を”, 7.84 MP
a (less than 80 kgf / cm ² ) was evaluated as “×”. (2) Degree of plane orientation Cross section of the sample for measuring bending strength (45 mm x 15 mm)
Were cut out at five points, and the angle and the number of the plate-shaped fillers with respect to the plane parallel to the sample upper surface were determined by image processing. The image processing is performed by the image processing software “LU
ZEX ".

(Example 1) In-process waste materials (such as punching scraps) discharged in manufacturing a PET prepaid card are cut to collect a 30 mm diameter mesh under product, and a plate-like filling having an average maximum diameter of 30 mm is obtained. Wood was obtained. This is a room temperature foam-curing type hard polyurethane resin (manufactured by Mitsubishi Chemical Corporation; RM50
2) In the weight ratio, plate-like filler / polyurethane = 3/1
And mixed. Put this mixture in a batch mold,
Before solidification, it was squeezed with a pressure roll. And foaming
The sample is solidified (90 mm width x 250 mm
(Length × 10 mm thick). The specific gravity of this sample is 0.6
Met. Using this sample, the bending strength and the degree of plane orientation were measured. Table 1 shows the results.

(Example 2) In-process waste materials (such as punched chips) discharged in manufacturing a PVC clear case were cut to obtain a 30 mm-diameter mesh-under product, and the average maximum diameter was 5 mm.
mm plate-like filler was obtained. This was added to a room-temperature foam-curable hard polyurethane resin (RM502, manufactured by Mitsubishi Chemical Corporation).
The mixing was carried out at a weight ratio of plate-like filler / polyurethane = 3/1. The mixture was placed in a batch mold and squeezed with a pressure roll before foaming and solidifying. Then, by foaming and solidifying, the sample (90 mm width × 250 mm length × 10
mm thickness). The specific gravity of this sample was 0.6. Using this sample, the bending strength and the degree of plane orientation were measured. Table 1 shows the results.

(Example 3) In-process waste materials (such as punched chips) discharged in manufacturing a PVC clear case were cut to obtain a 30 mm-diameter mesh-under product, and the average maximum diameter was 5 mm.
A plate-like filler of 0 mm was obtained. This is a room-temperature foam-curing hard polyurethane resin (RM502, manufactured by Mitsubishi Chemical Corporation).
Were mixed in a weight ratio of plate-like filler / polyurethane = 3/1. The mixture was placed in a batch mold and squeezed with a pressure roll before foaming and solidifying. The sample (90mm width x 250mm length x
10 mm thick). The specific gravity of this sample was 0.6. Using this sample, the bending strength and the degree of plane orientation were measured. Table 1 shows the results.

(Example 4) In-process waste materials (cutting wastes, etc.) discharged in manufacturing a PET prepaid card are cut to obtain a 30 mm-diameter mesh-under product, and a plate-like filling having an average maximum diameter of 30 mm is obtained. Wood was obtained. This is a room temperature foam-curing type hard polyurethane resin (manufactured by Mitsubishi Chemical Corporation; RM50
2) In the weight ratio, plate-like filler / polyurethane = 3/1
And mixed. Put this mixture in a batch mold,
Ultrasonic vibration was applied before solidification. Then, a sample (90 mm width × 250 mm length × 10 mm thickness) was obtained by foaming and solidification. The specific gravity of this sample was 0.6. Using this sample, the bending strength and the degree of plane orientation were measured. Table 1 shows the results.

(Comparative Example 1) In-process waste materials (such as punched scraps) discharged in manufacturing a PET prepaid card are cut to obtain a 30 mm-diameter mesh-under product, and a plate-like filling having an average maximum diameter of 30 mm is obtained. Wood was obtained. This is a room temperature foam-curing type hard polyurethane resin (manufactured by Mitsubishi Chemical Corporation; RM50
2) In the weight ratio, plate-like filler / polyurethane = 3/1
And mixed. Put this mixture in a batch mold,
Before solidification, nothing was done. Then, a sample (90 mm width × 250 mm length × 10 mm thickness) was obtained by foaming and solidification. The specific gravity of this sample was 0.6. Using this sample, the bending strength and the degree of plane orientation were measured. Table 1 shows the results.

(Comparative Example 2) In-process waste materials (such as punched chips) discharged in the production of a PET prepaid card are cut to collect a 30 mm-diameter mesh-under product, and are filled into a plate having an average maximum diameter of 30 mm. Wood was obtained. This is a room temperature foam-curing type hard polyurethane resin (manufactured by Mitsubishi Chemical Corporation; RM50
2) In the weight ratio, plate-like filler / polyurethane = 3/1
And mixed. Put this mixture in a batch mold,
Before solidification, it was conditioned by hand. Then, by foaming and solidifying, the sample (90 mm width × 250 mm length × 10
mm thickness). The specific gravity of this sample was 0.6. Using this sample, the bending strength and the degree of plane orientation were measured. Table 1 shows the results.

(Comparative Example 3) In-process waste materials (such as punched chips) discharged in manufacturing a PVC clear case were cut to obtain a 30 mm-diameter mesh-under product, and the average maximum diameter was 5 mm.
A 5 mm plate-like filler was obtained. This is a room-temperature foam-curing hard polyurethane resin (RM502, manufactured by Mitsubishi Chemical Corporation).
Were mixed in a weight ratio of plate-like filler / polyurethane = 3/1. The mixture was placed in a batch mold and squeezed with a pressure roll before foaming and solidifying. The sample (90mm width x 250mm length x
10 mm thick). The specific gravity of this sample was 0.6. Using this sample, the bending strength and the degree of plane orientation were measured. Table 1 shows the results.

(Comparative Example 4) In-process waste materials (such as punching waste) discharged in manufacturing a PVC clear case were cut to obtain a 30 mm-diameter mesh-under product, and the average maximum diameter was 3 mm.
mm plate-like filler was obtained. This was added to a room-temperature foam-curable hard polyurethane resin (RM502, manufactured by Mitsubishi Chemical Corporation).
The mixing was carried out at a weight ratio of plate-like filler / polyurethane = 3/1. The mixture was placed in a batch mold and squeezed with a pressure roll before foaming and solidifying. Then, by foaming and solidifying, the sample (90 mm width × 250 mm length × 10
mm thickness). The specific gravity of this sample was 0.6. Using this sample, the bending strength and the degree of plane orientation were measured. Table 1 shows the results.

[0039]

[Table 1]

[0040]

The foamed composite molded article according to the present invention has the mechanical strength possessed by the shards and also has a higher strength in the direction perpendicular to the length direction of the shards.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an example of a foam composite molded article according to the present invention.

FIGS. 2A, 2B, and 2C are perspective views showing examples of a plate-like filler.

FIG. 3 is a sectional view taken along line AA of FIG. 1;

[Explanation of symbols]

 1 Plate-like filler 2 Foamable resin

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme court ゛ (Reference) C08G 101: 00) C08G 101: 00) B29K 75:00 B29K 75:00 105: 04 105: 04 105: 20 105: 20 F-term (reference) 4F074 AA12 AA17 AA24 AA35 AA48 AA78 BA13 BA14 BA32 BA33 BA37 BA39 BA53 CA22 4F204 AA42 AB02 AB11 AC03 AG20 EA01 EB01 EE02 EF01 EF27 EF51 EK13 EK24 EL03 EL1 4J002 BB03 BB03 BB03 FA012 FA016 FD012 FD016 FD320 GR02 4J034 DA01 DB03 DF01 DG01 HA01 HA07 HC12 HC46 HC52 HC61 HC64 HC71 QC01

Claims (3)

[Claims] 1. A plate-like filler having an average maximum diameter of 5 to 50 mm is mixed with a foamable resin and foamed, and at least 75% of the upper or lower surface of the plate-like filler is above a predetermined surface. A foam composite molded article having an inclination angle within a range of ± 30 °. 2. The foam composite molded article according to claim 1, wherein the plate-like filler is a fragment obtained by cutting or crushing an oriented plastic sheet molded article. 3. The foamed composite molded article according to claim 1, wherein the foamed resin is a cold-setting polyurethane resin.