JP2009190195A - Manufacturing method of foamed sheet or laminated foamed sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a foamed sheet and a laminated foam sheet which are excellent in compression flexibility and hardly reduce repulsive stress even when being arranged in a compression state over a long period of time. <P>SOLUTION: The manufacturing method of the foamed sheet is characterized by that a forming resin sheet is molded by melting kneading a pyrolysis type foaming agent and a resin composition comprising a rubber system resin and a synthetic resin containing a crystal composition, the forming resin sheet is crosslinked and foamed to manufacture the formed sheet and then stress for flattening air bubbles in the foamed sheet in a thickness direction is applied to the foamed sheet in a melting state. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for producing a foam sheet or a laminated foam sheet.

  Currently, foams are widely used as gaskets in various fields such as architecture, civil engineering, electricity, electronics, and vehicles. Examples of the foam used for such a gasket include a thermoplastic resin foam made of polyethylene resin, polypropylene resin, and the like, and a rubber foam made of synthetic rubber or natural rubber.

  Gaskets are used to fill gaps between various structures and prevent dust and moisture from entering the gaps between structures. This type of gasket is installed in a state in which a gasket made of a foam is compressed in a gap to be sealed, and the repulsive stress closes the gap with the interface to prevent intrusion of dust and moisture. Here, when the compression flexibility of the foam constituting the gasket is low, the structure is deformed due to the repulsive stress of the foam trying to recover its shape from the compressed state, or the gap between the structures is expanded due to the deformation of the structure. As a result, there was a problem that it was not possible to prevent the intrusion of dust and moisture.

  Therefore, a gasket excellent in compression flexibility is required, and as such a gasket, for example, Patent Document 1 proposes a urethane foam having an open cell structure. The open cell foam formed by communicating bubbles such as the urethane foam has almost no repulsive stress due to gas (air) because the gas (air) escapes to the outside of the foam through the communication part of the bubbles during compression. , Compression flexibility is good.

  However, when an open-cell foam such as the urethane foam is used as a gasket, there is a problem that dust and moisture enter through the communicating portion of the bubbles.

  On the other hand, when a closed cell foam in which the bubbles are partitioned by a partition in a three-dimensional lattice shape is used as a gasket, the repulsive stress of the closed cell foam is relieved over time, and the interface between the closed cell foam and the structure is reduced. As a result, the contact surface pressure is reduced and a gap is generated at the interface of the structure, resulting in a problem that it cannot function effectively as a gasket.

  Further, since it is difficult to reduce the thickness of the closed cell foam, it may not be used as a gasket for filling a narrow gap.

JP 2001-100216 A

  The present invention provides a foamed sheet and a method for producing a laminated foamed sheet, which are excellent in compression flexibility and are less likely to reduce the repulsion stress even when placed in a compressed state for a long period of time.

  The method for producing a foamed sheet according to the present invention comprises forming a foamable resin sheet by melting and kneading a resin composition containing a synthetic resin containing a crystal component and a rubber-based resin, and a pyrolytic foaming agent. After the resin sheet is crosslinked and foamed to produce a foamed sheet, stress is applied to the foamed sheet in a molten state to flatten the bubbles in the foamed sheet in the thickness direction.

  The rubber-based resin constituting the resin composition is not particularly limited as long as it has rubber elasticity at room temperature. Natural rubber, chloroprene rubber (CR), isoprene rubber (IR), butyl rubber (IIR), synthetic rubbers such as nitrile-butadiene rubber (NBR), butadiene rubber (BR), urethane rubber, fluorine rubber, acrylic rubber, and silicone rubber; thermoplastic elastomers such as polystyrene-based thermoplastic elastomer and polyolefin-based thermoplastic elastomer Nitrile-butadiene rubber and thermoplastic elastomer are preferable, and nitrile-butadiene rubber and polystyrene-based thermoplastic elastomer are more preferable because the foamed sheet has excellent cushioning properties and durability. Nitrile-butadiene rubber (NBR) is also referred to as nitrile rubber or acrylonitrile-butadiene copolymer rubber.

  Further, the thermoplastic elastomer is preferably a block copolymer containing a polymer block of a vinyl aromatic compound and a polymer block of a conjugated diene compound, and a polymer of a vinyl aromatic compound polymer block and a conjugated diene compound. A hydrogenated block copolymer containing a block is more preferable.

  Examples of the vinyl aromatic compound include styrene; α-alkyl substituted styrenes such as α-methylstyrene; and alkyl substitution such as o-methylstyrene, m-methylstyrene, p-methylstyrene, and pt-butylstyrene. Examples of the conjugated diene compound include 1,3-butadiene, 2-methyl-1,3-butadiene (isoprene), 2,3-dimethyl-1,3-butadiene, and the like. , 3-pentadiene, 1,3-hexadiene and the like.

  Examples of the block copolymer including a polymer block of a vinyl aromatic compound and a polymer block of a conjugated diene compound include, for example, a styrene-butadiene-styrene block copolymer and a styrene-isoprene-styrene block copolymer. Is mentioned.

  Examples of the hydrogenated block copolymer containing a polymer block of a vinyl aromatic compound and a polymer block of a conjugated diene compound include, for example, styrene-ethylene / butylene-styrene block copolymer, styrene-ethylene. A propylene-styrene block copolymer etc. are mentioned.

  When the rubber-based resin is a mixture of a nitrile-butadiene rubber and a thermoplastic elastomer, if the content of the nitrile-butadiene rubber in the rubber-based resin is small, the compression recovery property of the resulting foamed sheet may be lowered. On the other hand, if the amount is too large, the foaming property of the foamable resin sheet may be lowered when the synthetic resin containing the crystal component in the resin composition is 20% by weight or more, so 80 to 95% by weight is preferable.

  When the rubber-based resin is a mixture of a nitrile-butadiene rubber and a thermoplastic elastomer, the content of the thermoplastic elastomer in the rubber-based resin is preferably 5 to 20% by weight for the same reason.

  And as synthetic resin containing the crystal component which comprises the resin composition, polyolefin resin, such as polyethylene resin and a polypropylene resin, is preferable.

  When the content of the synthetic resin containing the crystal component in the resin composition is small, the dimensional stability of the obtained foamed sheet may be reduced, whereas when it is large, the foamability of the foamable resin sheet is reduced. A beautiful foamed sheet cannot be obtained, or the compression recoverability of the obtained foamed sheet may be lowered, so 5 to 50% by weight is preferable, and 10 to 30% by weight is more preferable.

  For the same reason, the content of the rubber-based resin in the resin composition is preferably 50 to 95% by weight, and more preferably 70 to 90% by weight.

  Further, when the rubber-based resin is a mixture of a nitrile-butadiene rubber and a hydrogenated block copolymer including a polymer block of a vinyl aromatic compound and a polymer block of a conjugated diene compound, the block copolymer If the combined hydrogenated product is large, the compression recovery property of the resulting foamed sheet may be lowered. Therefore, the content in the resin composition is preferably 10% by weight or less, and more preferably 3 to 7% by weight.

  Examples of the thermally decomposable foaming agent include azodicarbonamide, benzenesulfonylhydrazide, dinitrosopentamethylenetetramine, toluenesulfonylhydrazide, 4,4-oxybis (benzenesulfonylhydrazide), and the like. In addition, a thermal decomposition type foaming agent may be used independently, or 2 or more types may be used together.

  If the amount of the thermal decomposable foaming agent is small, the foamable resin sheet may not foam. On the other hand, if the amount is large, the foamable resin sheet may be broken. The amount is preferably 1 to 30 parts by weight.

  Furthermore, a general-purpose additive may be added to the foamable resin sheet for the purpose of adjusting the viscosity and crosslinkability during foaming of the foamable resin sheet, or for the purpose of adjusting the strength of the foamed sheet, etc. .

  The additives include conventionally known additives such as foaming aids, crosslinking aids, antioxidants, fillers, stabilizers, ultraviolet absorbers, pigments, flame retardants, antistatic agents, plasticizers and the like. Also good. Specifically, for example, vulcanization accelerators and vulcanization accelerators such as aldehyde ammonias, aldehyde amines, guanidines, thiazoles, sulfenamides, turums, dithiocarbamic acids, xanthogenic acids, thioureas; Vulcanization retarders such as organic acids such as phthalic anhydride, benzoic acid, salicylic acid, amines such as N-nitroso-diphenylamine, N-nitroso-phenyl-β-naphthylamine; acrylics such as poly (meth) acrylic acid alkyl esters Resins: paraffins such as chlorinated paraffin, waxes, drying oils such as linseed oil, animal and vegetable oils, petroleum oils and various low molecular weight resins; phthalates, phosphates, stearic acid And softeners such as esters thereof, alkylsulfonic acid esters, and tackifiers Or plasticizer); talc, calcium carbonate, bentonite, carbon black, fumed silica, aluminum silicate, acetylene black, and the like fillers such as aluminum powder.

  After knead | mixing the foamable resin composition by which an additive etc. are added to the said resin composition and thermal decomposition type foaming agent as needed with kneading machines, such as a Banbury mixer and a pressure kneader, A foamable resin sheet is formed by melting and kneading continuously below the decomposition temperature of the pyrolytic foaming agent using a calendar, an extruder, a conveyor belt casting, or the like.

  Next, the foamable resin sheet is crosslinked. The crosslinking method of the foamable resin sheet is not particularly limited, and examples thereof include a method of irradiating the foamable resin sheet with ionizing radiation, a method of crosslinking the foamable resin sheet with a crosslinking agent, and the like. A method of irradiating ionizing radiation is preferable.

  The ionizing radiation is not particularly limited, and examples thereof include electron beams, α rays, β rays, γ rays, and electron beams are preferable. If the irradiation amount of ionizing radiation to the foamable resin sheet is small, the foamable resin sheet may be insufficiently crosslinked, and foam breakage may occur. Since it becomes too much and foamability may fall, 0.1-3Mrad is preferable.

  In addition, as a method of crosslinking the foamable resin sheet using a crosslinking agent, an uncrosslinked foamable resin sheet is formed by adding a crosslinking agent to the resin composition and the thermally decomposable foaming agent and then melt-kneading. And a method of heating the foamable resin sheet and crosslinking with a crosslinking agent.

  The crosslinking agent is not particularly limited, and examples thereof include organic peroxides, sulfur, sulfur compounds, and the like, and organic peroxides are preferable. Examples of the organic peroxide include diisopropylbenzene hydroperoxide, 2,4-dichlorobenzoyl peroxide, benzoyl peroxide, t-butyl perbenzoate, cumyl hydroperoxide, t-butyl hydroperoxide, 1, 1-bis (t-butylperoxy) -3,3,5-trimethylhexane, n-butyl-4,4-bis (t-butylperoxy) valerate, α, α′-bis (t-butylperoxy) Isopropyl) benzene, 2,5-dimethyl-2,5-bis (t-butylperoxy) hexyne-3, t-butylperoxycumene and the like. Examples of the sulfur compound include tetramethylthiuram disulfide, Tetramethylthiuram monosulfide, zinc dimethyldithiocarbamate, 2-methyl Examples include lucaptobenzothiazole, dibenzothiazyl disulfide, N-cyclohexyl-2-benzothiazole sulfenamide, Nt-butyl-2-benzothiazole sulfenamide, sulfur monochloride, sulfur dichloride and the like.

  Moreover, if the addition amount of the crosslinking agent is small, the foamable resin sheet may be insufficiently crosslinked and may not be suitable for foaming. Since the degree increases too much, the foamable resin sheet may not foam, so 0.05 to 10 parts by weight is preferable and 0.1 to 7 parts by weight is more preferable with respect to 100 parts by weight of the resin composition.

  Next, when the foamable resin sheet is cross-linked using ionizing radiation, the foamable resin sheet is heated above the decomposition temperature of the pyrolyzable foaming agent to decompose and foam the pyrolyzable foaming agent, A foam sheet having flat bubbles is produced.

  On the other hand, when a crosslinking agent is added to the foamable resin sheet, the foamable sheet is produced by heating the foamable resin sheet and then crosslinking with the crosslinking agent or by decomposing and foaming the thermally decomposable foaming agent while crosslinking. .

  Thereafter, the foamed sheet is once cooled and then heated to a molten state, or the foamed sheet is continuously maintained in a molten state from the foaming step, and the bubbles in the foamed sheet become flat in the thickness direction. Thus, a stress is applied to obtain a foam sheet.

  As a method for applying stress to the foam sheet, for example, a pair of gripping tools are detachably attached to both ends in the width direction of the foam sheet, and the foam sheets are displaced in the width direction by displacing the grip tools in directions away from each other. In addition to the method of flattening the foam sheet in the thickness direction, the foam sheet is pressed in the direction of compressing the foam sheet in the thickness direction from both sides, and the foam sheet is flattened in the thickness direction. Is mentioned.

  At this time, since the closed foam sheet of the present invention contains a synthetic resin containing a crystal component, a stress is applied to the foam sheet to compress the bubbles in the thickness direction so that the flattened state contains the crystal component. Can be fixed by the synthetic resin, and the flattening of the bubbles can be reliably maintained.

  When a foamable resin sheet is produced using an extruder, if the stretch ratio in the extrusion direction (MD) of the foamed sheet obtained by foaming the foamable resin sheet is small, the bubbles are not sufficiently flattened. In some cases, the effect of flattening the bubbles may not be obtained. On the other hand, if it is large, cracks may occur in the foamed sheet, so 1.2 to 3.8 times is preferable. In addition, the draw ratio of a foam sheet means what remove | divided the dimension of the foam sheet after extending | stretching in the extending direction by the dimension of the foam sheet before extending | stretching in an extending direction.

  Similarly, when a foamable resin sheet is produced using an extruder, if the stretch ratio in the width direction (CD) of the foamed sheet obtained by foaming the foamable resin sheet is small, the bubbles are sufficiently flat. In some cases, the effect of flattening the bubbles may not be obtained. On the other hand, if it is large, the foamed sheet may be cracked, so 1.2 to 3.8 times is preferable.

  When the foamable resin sheet is manufactured using an extruder, the effect of flattening the bubbles is small when the aspect ratio of the bubbles in the foamed sheet (average bubble diameter of MD / average bubble diameter of VD) is small. On the other hand, if it is large, cracks may occur in the foamed sheet in the process of flattening the bubbles, so 1.5 to 15 is preferable.

  In the case where the foamable resin sheet is produced using an extruder, the effect of flattening the bubbles when the foam aspect ratio of the foamed sheets (average bubble diameter of CD / average bubble diameter of VD) is small. On the other hand, if it is large, cracks may occur in the foamed sheet in the process of flattening the bubbles, so 1.5 to 15 is preferable.

  Here, as shown in FIG. 1, the MD [machine direction] of the foam sheet 1 refers to the extrusion direction, and the CD [crossing direction] of the foam sheet 1 is orthogonal to the MD (machine direction) and the foam sheet. The VD (vertical (thickness) direction) of the foam sheet 1 is a direction perpendicular to the surface of the foam sheet 1.

  Next, the average cell diameter of MD of a foam sheet means what was measured in the following way. That is, the foamed sheet is cut over the entire length along a plane parallel to VD at a substantially central portion of the CD.

  Thereafter, the cut surface of the foam sheet is magnified 60 times using a scanning electron microscope (SEM), and a photograph is taken so that the full length of the VD of the foam sheet is accommodated.

  In the obtained photograph, a straight line having a length of 15 cm (actual length of 2500 μm before enlargement) on the photograph is parallel to the surface of the foam sheet in a portion corresponding to the center portion of the VD of the foam sheet. Draw.

Next, the number of bubbles located on the straight line is visually counted, and the average bubble diameter of bubbles MD is calculated based on the following formula.
Average bubble diameter of MD (μm) = 2500 (μm) / number of bubbles (pieces)

  Moreover, the average cell diameter of VD of a foam sheet means what was measured in the following way. That is, the photograph is taken in the same manner as the procedure for calculating the average bubble diameter of the MD of the foam sheet.

  In the obtained photograph, three straight lines that divide the cut surface of the photographed foam sheet into four parts are drawn over the entire length of the foam sheet in a direction (VD) perpendicular to the surface of the foam sheet.

Thereafter, the length of each straight line is measured and the number of bubbles located on each straight line is visually counted, and the average bubble diameter of the bubble VD is calculated for each straight line based on the following formula, and the arithmetic mean of these is calculated. Is the average bubble diameter of the VD of the bubbles.
Average bubble diameter of VD (μm) = length of straight line on photo (μm)
/ (60 x number of bubbles (pieces))

  Next, the average cell diameter of the CD of the foam sheet is measured in the following manner. That is, the foamed sheet is cut over the entire length in the thickness direction on a plane parallel to the CD and parallel to the direction (VD) perpendicular to the surface of the foamed sheet.

  Thereafter, the cut surface of the foam sheet is magnified 60 times using a scanning electron microscope (SEM), and a photograph is taken so that the total length in the thickness direction of the foam sheet is accommodated.

  And based on the obtained photograph, the average bubble diameter of CD is calculated in the same manner as when the average bubble diameter of MD of the foam sheet is measured.

  In the above-described procedure for measuring the average bubble diameter, when counting the number of bubbles located on a straight line, the bubble diameter is determined based only on the bubble cross section appearing on the photograph.

  That is, even if the bubbles seem to be completely separated from each other by the bubble wall on the cut surface of the foam sheet, they may communicate with each other at a portion other than the cut surface of the foam sheet. In the present invention, without considering whether or not the portions other than the cut surface of the foam sheet communicate with each other, the bubble form is determined based on only the bubble wall cross section appearing on the photograph, and the bubbles appearing on the photograph One void portion completely surrounded by the wall cross section is judged as one bubble.

  Positioning on a straight line means that the straight line completely penetrates the bubble at any part of the bubble, and the straight line does not completely penetrate the bubble at both ends of the straight line. In the case where the end portion of the bubble is located in the bubble, the bubble was counted as 0.5.

  When taking a photograph of the cut surface of the foam sheet, coloring the cut surface of the foam sheet facilitates the discrimination of the bubbles, and when the photograph is taken with the 2500 μm scale magnified together, It becomes easy to specify the length.

  The foam sheet of the present invention does not need to be all closed cells, and may include open cells in a part of the bubbles. Specifically, if the closed cell rate of the foam sheet is low, The bubbles in the foamed sheet communicate with each other, and dust and moisture can easily pass through, and the dustproofness and moistureproofness of the foamed sheet may be lowered. Therefore, 80 to 100% is preferable, and 85 to 100% is more preferable.

As a method for measuring the closed cell ratio of the foam sheet, first, a test piece having a flat square shape with a side of 5 cm and a constant thickness is cut out from the foam sheet. Subsequently, the weight W ₁ of the test piece is measured, and the thickness of the test piece is further measured to calculate the apparent volume V ₁ of the test piece.

Next, the value obtained as described above is substituted into the following equation (1) to calculate the apparent volume V ₂ occupied by the bubbles. The density of the resin constituting the test piece is ρg / cm ³ .
Apparent volume occupied by bubbles V ₂ = V ₁ −W ₁ / ρ Formula (1)

Subsequently, the test piece is submerged in distilled water at 23 ° C. so that the distance from the upper surface of the test piece to the water surface is 100 mm, and a pressure of 15 kPa is applied to the test piece for 3 minutes. After that, the test piece is taken out from the distilled water, the water adhering to the surface of the test piece is removed, the weight W _{2 of the} test piece is measured, and the open cell ratio F ₁ is calculated based on the following formula (2). Thus, the closed cell rate F ₂ is obtained from the open cell rate F ₁ .
Open cell ratio F ₁ (%) = 100 × (W ₂ −W ₁ ) / V ₂ Formula (2)
Closed cell ratio F ₂ (%) = 100−F ₁ Formula (3)

And when the apparent density of the foam sheet is small, the foam sheet is brittle and the strength cannot be maintained, and when used as a gasket, the long-term sealability may be lowered, whereas when high, the foam sheet is hard, Compression flexibility is reduced, the repulsive force at the time of compression is increased, workability is deteriorated, and when used as a sealing material, a sealed member such as a structure is deformed, or the sealing member 30-200 kg / m ³ is preferable because the gap in the sealed portion may be enlarged due to deformation. In addition, the apparent density of a foam sheet means what was measured based on JISK7222.

  In addition, if the 50% compressive stress measured by a method in accordance with JIS K6767 in a foamed sheet is high, the foamed sheet has insufficient flexibility, and when used as a gasket, it sufficiently follows the shape of the member to be sealed. This is not possible, and a gap is generated between the part to be sealed and causes a sealing failure. Therefore, 100 kPa or less is preferable, and 20 to 100 kPa is more preferable.

  Furthermore, if the compression set of the foamed sheet is high, the foamed sheet is inferior in shape recoverability, and when used as a gasket, the long-term water-stopping property may be lowered. -40% is more preferable. The compression set of the foamed sheet was measured 24 hours after removing the compressive force after compressing under the conditions of a temperature of 70 ° C., a compression ratio of 50% and a compression time of 22 hours according to JIS K6262. Value.

  The thickness of the foam sheet is often used to fill a narrow space when used as a gasket in the fields of electricity, electronics, vehicles, etc. Therefore, the gasket is required to be thin. 1-2 mm is preferable and 0.1-1 mm is more preferable.

  Furthermore, since the foamed sheet contains a rubber-based resin, it has adhesiveness, and when the foamed sheet is wound into a roll, the foamed sheets adjacent to each other in the inner and outer directions are blocked. Therefore, a synthetic resin layer having no adhesiveness may be laminated and integrated on at least one surface of the foamed sheet to form a laminated foamed sheet.

  As a method for producing the above laminated foam sheet, in the above foam sheet producing method, a synthetic resin layer is laminated and integrated on one surface of the foamable resin sheet to produce a foamable laminate sheet. In the same way, it is sufficient to produce a laminated foamed sheet in which a synthetic resin layer is laminated and integrated on one surface of a foamed sheet obtained by crosslinking and foaming and foaming a foamable resin sheet of a foamable laminated sheet. A foamable laminated sheet may be used instead of the conductive resin sheet.

  The synthetic resin layer can be laminated and integrated on one side of the foamable resin sheet. The synthetic resin sheet separately prepared on one side of the foamable resin sheet can be heat-sealed and integrated. The synthetic resin layer can be integrated on one side of the foamable resin sheet. Examples thereof include a method of laminating and integrating a resin sheet by extrusion lamination, and a method of laminating and integrating a synthetic resin layer on one surface of a foamable resin sheet by coextrusion. The synthetic resin sheet can be manufactured by a general-purpose method such as a T-die method, an inflation method, a calendering method, or a solution casting method.

  The synthetic resin constituting the synthetic resin layer (synthetic resin sheet) includes a low density polyethylene resin, a medium density polyethylene resin, a high density polyethylene resin, a linear low density polyethylene resin, and a linear medium density polyethylene. Polyolefin resins such as polyethylene resins, linear high density polyethylene resins, polyethylene resins such as ethylene-vinyl acetate copolymers, and polypropylene resins such as homopolypropylene and propylene-α-olefin copolymers. More preferred is a polyethylene resin, and particularly preferred is a polyethylene resin having a melting point of 130 ° C. or lower. In addition, a synthetic resin may be used independently or 2 or more types may be used together. The melting point of the synthetic resin refers to that measured according to JIS K7172.

  Examples of the α-olefin copolymerized with propylene include ethylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-nonene, 1-decene and the like. Is mentioned.

  In addition, if the thickness of the synthetic resin layer in the foamable laminated sheet is thin, the thickness of the synthetic resin layer in the laminated foam sheet becomes too thin, and the anti-blocking effect may be lowered. Since the flexibility of the sheet may be lowered, 5 to 50 μm is preferable.

  In the above description, the case where either ionizing radiation or a crosslinking agent is used in crosslinking the foamable resin sheet or the foamable laminated sheet has been described, but ionizing radiation and a crosslinking agent may be used in combination. In this case, first, a foamable resin sheet or a foamable laminate sheet containing a crosslinking agent is prepared, and this foamable resin sheet or foamable laminate sheet is crosslinked by irradiation with ionizing radiation. A resin sheet or a foamable laminated sheet is heated to a temperature at which the crosslinking agent does not decompose and foamed to produce a foamed sheet or a laminated foamed sheet.

  Therefore, it is necessary to select a crosslinking agent that does not decompose at the decomposition temperature of the pyrolytic foaming agent, and it is preferable to select a crosslinking agent having a one-minute half-life temperature higher than the decomposition temperature of the pyrolytic foaming agent. The decomposition temperature of the thermal decomposition type foaming agent is the decomposition temperature of the thermal decomposition type foaming agent described in pages 98 to 99 of “Various polymer foam molding technology” issued by the Technical Information Association.

  In this way, by combining crosslinking with ionizing radiation and crosslinking with a crosslinking agent, the foamable resin sheet or foamable laminated sheet is crosslinked with ionizing radiation to obtain a melt viscosity suitable for foaming, and the foamable resin sheet. Alternatively, the foamability of the foamable laminated sheet can be expanded and foamed to produce a foamed sheet or laminated foamed sheet, and the foamed sheet or laminated foamed sheet can be further cross-linked by a crosslinking agent. Alternatively, the foamable laminated sheet can be easily adjusted to have a melt viscosity suitable for foaming, and the foamed sheet or laminated foamed sheet is further cross-linked by a cross-linking agent, so that the amount of components that undergo plastic deformation can be reduced. The compression set can be excellent.

  Furthermore, an adhesive layer may be laminated and integrated on one surface of the foamed sheet and the laminated foamed sheet. The pressure-sensitive adhesive is not particularly limited, and examples thereof include a urethane-based pressure-sensitive adhesive and a rubber-based pressure-sensitive adhesive, and a urethane-based pressure-sensitive adhesive is preferable because it has excellent adhesion and removability.

And, when the apparent density of the foam sheet constituting the laminated foam sheet is small, the foam sheet is brittle, the strength cannot be maintained, and when used as a gasket, the long-term sealability may be reduced, If it is high, the foam sheet is hard, the compression flexibility is lowered, the repulsive force during compression is increased, the workability is deteriorated, and the sealed member such as a structure is deformed when used as a sealing material. Or the deformation of the member to be sealed may cause the gap in the sealed portion to expand, so 30 to 200 kg / m ³ is preferable. The apparent density of the foamed sheet refers to that measured based on JIS K7222 after removing the synthetic resin layer from the laminated foamed sheet.

  In addition, if the 50% compressive stress measured by the method according to JIS K6767 in the laminated foam sheet is high, the foam sheet has insufficient flexibility, and when used as a gasket, the shape of the member to be sealed is sufficient. Since it cannot follow and a space | gap arises between the to-be-sealed site | parts and causes a sealing defect, 100 kPa or less is preferable and 20-100 kPa is more preferable.

  Furthermore, when the compression set of the laminated foamed sheet is high, the foamed sheet is inferior in shape recoverability, and when used as a gasket, the long-term water stoppage may be lowered, so 40% or less is preferable, 0 to 30% is more preferable. The compression set of the foamed sheet was measured 24 hours after removing the compressive force after compressing under the conditions of a temperature of 70 ° C., a compression ratio of 50% and a compression time of 22 hours according to JIS K6262. Value.

  The thickness of the laminated foam sheet is often filled in a narrow space especially when used as a gasket in the fields of electricity, electronics, vehicles, etc. Therefore, the gasket is required to be thin, .1 to 2 mm is preferable, and 0.1 to 1 mm is more preferable.

  The method for producing a foamed sheet of the present invention uses a resin composition containing a synthetic resin containing a crystalline component and a rubber-based resin as a resin constituting the foamable resin sheet. The foam shape flattened in the thickness direction can be securely fixed by a synthetic resin having a crystal component, and as a result, the foam sheet obtained is excellent in compression flexibility because the bubbles are flattened in the thickness direction. At the same time, it maintains an excellent repulsive force for a long time, and can be widely used as a high-performance gasket in the fields of architecture, civil engineering, electricity, electronics, vehicles and the like.

  Hereinafter, embodiments of the present invention will be described in more detail with reference to examples. However, the present invention is not limited to these examples.

Example 1
90 parts by weight of nitrile-butadiene rubber (NBR: density 0.96 g / cm ³ ) and linear low-density polyethylene (LLDPE, product name “Moretech 0278G” manufactured by Prime Polymer Co., Ltd.), MFR: 2.1 g / 10 min, density: 939 kg / m ³ ) 10 parts by weight of resin composition, and 8 parts by weight of azodicarbonamide (ADCA, trade name “SO-L” manufactured by Otsuka Chemical Co., Ltd.) are supplied to an extruder and melt kneaded at 130 ° C. Then, a foamable resin sheet having a long and constant width was extruded.

Next, 0.8 Mrad was irradiated with an electron beam at an acceleration voltage of 500 keV on both surfaces of the foamable resin sheet to crosslink the foamable resin sheet. Then, by supplying the foamable resin sheet to a foaming furnace and heating to 240 ° C., the azodicarbonamide is decomposed to foam the foamable resin sheet and then cooled, so that the apparent density is 100 kg / m ³ , the thickness. A foam sheet having a long constant width of 1.0 mm was obtained.

And after heating the said elongate foam sheet to 130 degreeC and making it a molten state, a holding tool is fixed to each of the both ends of the width direction of a foam sheet, and these gripping tools are spaced apart from each other. By displacing the foamed sheet, the foamed sheet is stretched twice in the width direction, and the bubbles in the foamed sheet are flattened in the thickness direction and then cooled to obtain an apparent density of 100 kg / m ³ and a thickness of 0.5 mm. A scale-shaped foam sheet was obtained.

(Example 2)
A foamable resin sheet was produced in the same manner as in Example 1, and this foamed resin sheet was crosslinked in the same manner as in Example 1. Next, the foamable resin sheet and the foamable resin sheet are expanded while the azodicarbonamide is decomposed by supplying the foamable resin sheet to a foaming furnace and heated to 240 ° C. to foam the foamable resin sheet. After the foamed sheet in a molten state obtained by stretching is stretched 3.2 times in the extrusion direction (MD) and 3.2 times in the width direction (CD), the foamed cells are flattened in the thickness direction. After cooling, a long foam sheet having an apparent density of 100 kg / m ³ and a thickness of 0.5 mm was obtained.

  In addition, the expansion | extension of the extrusion direction of a foaming resin sheet and the foamed sheet of a molten state obtained by foaming this foaming resin sheet is the discharge rate from a foaming furnace rather than the supply speed to the foaming furnace of a foaming resin sheet. On the other hand, the expansion in the width direction of the foamed resin sheet and the foamed sheet in a molten state obtained by foaming the foamable resin sheet is performed by doubling the foamed resin sheet and the foamable resin sheet. A gripping tool was fixed to each of both ends in the width direction of the foamed foam sheet obtained by foaming, and these gripping tools were displaced in directions away from each other.

(Example 3)
Similar to Example 1, except that the nitrile-butadiene rubber was changed to 70 parts by weight instead of 90 parts by weight, and the linear low density polyethylene was changed to 30 parts by weight instead of 10 parts by weight, the apparent density of 105 kg / A foamed sheet having a thickness of m ³ and a thickness of 0.5 mm was obtained.

Example 4
The apparent density of 115 kg / kg was the same as in Example 1 except that the nitrile-butadiene rubber was changed to 50 parts by weight instead of 90 parts by weight and the linear low density polyethylene was changed to 50 parts by weight instead of 10 parts by weight. A foamed sheet having a thickness of m ³ and a thickness of 0.5 mm was obtained.

(Example 5)
As a resin composition, 62 parts by weight of nitrile-butadiene rubber (NBR: density 0.96 g / cm ³ ), linear low-density polyethylene (LLDPE, product name “Moretech 0278G” manufactured by Prime Polymer Co., Ltd.), MFR: 2.1 g / 10 minutes, density: 939 kg / m ³ ) 30 parts by weight, and styrene-ethylene / propylene-styrene block copolymer (SEPS, hydrogenated product of styrene-isoprene-styrene block copolymer, “Septon S2063” manufactured by Kuraray Density: 939 kg / m ³ ) A foamed sheet having an apparent density of 95 kg / m ³ and a thickness of 0.5 mm was obtained in the same manner as in Example 1 except that 8 parts by weight were used.

(Example 6)
90 parts by weight of nitrile-butadiene rubber (NBR: density 0.96 g / cm ³ ) and linear low-density polyethylene (LLDPE, product name “Moretech 0278G” manufactured by Prime Polymer Co., Ltd.), MFR: 2.1 g / 10 min, density: 939 kg / m ³ ) 10 parts by weight of a resin composition and 8 parts by weight of azodicarbonamide (“SO-L” manufactured by Otsuka Chemical Co., Ltd.) are fed into an extruder and melt-kneaded at 0 ° C. At the same time as extruding the foamable resin sheet, a high-density polyethylene sheet having a thickness of 40 μm (trade name “HD” manufactured by Tamapoly Co., Ltd., softening point: 125 ° C.) was extruded and laminated on one surface of the foamable resin sheet. A foamable laminated sheet having a certain width was produced.

Next, 0.8 Mrad was irradiated with an electron beam at an acceleration voltage of 500 keV on both surfaces of the foamable laminated sheet to crosslink the foamable resin sheet. Then, the foamable resin sheet is foamed by supplying the foamable resin sheet to a foaming furnace and heating it to 240 ° C. to decompose the azodicarbonamide to foam the foamable resin sheet and then cooling. A laminated foam sheet having a long and constant width formed by laminating and integrating a high-density polyethylene layer on one surface of the foam sheet was obtained. The laminated foam sheet had an apparent density of 100 kg / m ³ and a thickness of 1.0 mm.

And after heating the said elongate laminated foam sheet to 130 degreeC and making it a molten state, a holding tool is fixed to each of the both ends of the width direction in a laminated foam sheet, and these holding tools are spaced apart from each other. By displacing in the direction, the laminated foamed sheet was stretched twice in its width direction, the bubbles in the foamed sheet were flattened in the thickness direction, and then cooled to obtain a long laminated foamed sheet. The laminated foam sheet had an apparent density of 100 kg / m ³ , a foam sheet thickness of 0.496 mm, a high density polyethylene layer thickness of 0.004 mm, and an overall thickness of 0.5 mm.

  When the laminated foamed sheet was wound in a spiral shape with the high-density polyethylene layer on the outside, blocking was not generated when it was left for 30 days.

(Example 7)
A foamable laminated sheet was produced in the same manner as in Example 6, and this foamable laminated sheet was crosslinked in the same manner as in Example 1. Next, the foamable laminated sheet and the foamed laminated sheet are obtained by supplying the foamable laminated sheet to a foaming furnace and heating it to 240 ° C. to decompose the azodicarbonamide to foam the foamable laminated sheet. The laminated foam sheet is stretched 3.2 times in the extrusion direction (MD) and 3.2 times in the width direction (CD), and the foamed foam is flattened in the thickness direction and then cooled to be elongated. A laminated foam sheet was obtained. The laminated foam sheet has an apparent density of 100 kg / m ³ , the thickness of the foam sheet is 0.496 mm, the thickness of each high-density polyethylene layer laminated and integrated on both surfaces of the foam sheet is 0.004 mm, The overall thickness was 0.5 mm.

  In addition, extending | stretching of the foaming laminated sheet and the extrusion direction of the laminated foam sheet obtained by foaming this makes 3.2 times the discharge speed from a foaming furnace rather than the supply speed to the foaming furnace of a foaming laminated sheet. On the other hand, stretching in the width direction of the foamable laminated sheet and the laminated foamed sheet obtained by foaming the foamed laminated sheet is performed at each of both ends in the width direction of the foamable laminated sheet and the laminated foamed sheet obtained by foaming the foamed laminated sheet. The gripping tools were fixed to each other, and these gripping tools were displaced in directions away from each other.

  When the laminated foamed sheet was wound in a spiral shape with the high-density polyethylene layer on the outside, blocking was not generated when it was left for 30 days.

(Comparative Example 1)
An attempt was made to produce a foam sheet in the same manner as in Example 1 except that the nitrile-butadiene rubber was changed to 100 parts by weight instead of 90 parts by weight and the linear low-density polyethylene was not used. A bad and beautiful foam sheet could not be obtained.

  The compression set in the obtained foamed sheet and laminated foamed sheet was measured in the above-described manner, and 50% compressive stress was measured according to JIS K6767. The results are shown in Table 1.

  In addition, the foam aspect ratio (average bubble diameter of MD / average bubble diameter of VD) and aspect ratio (average bubble diameter of CD / VD) of the obtained foam sheet and the foam sheet constituting the laminated foam sheet. (Average bubble diameter) was measured as described above.

  In Table 1, the aspect ratio (MD / VD average bubble diameter) and aspect ratio (CD average bubble diameter / VD average bubble diameter) and aspect ratio (MD / VD) of the foamed sheet are shown. ) And aspect ratio (CD / VD).

  Furthermore, the closed cell rate of the obtained foamed sheet and the foamed sheet constituting the laminated foamed sheet was measured as described above. The closed cell ratio of the foam sheet constituting the laminated foam sheet was measured after removing the synthetic resin layer laminated and integrated on one surface of the foam sheet.

It is the schematic diagram which showed MD, CD, and VD of the foam sheet.

Explanation of symbols

1 Foam sheet

Claims (8)

A resin composition containing a synthetic resin containing a crystalline component and a rubber-based resin, and a foamable resin sheet is formed by melting and kneading a pyrolytic foaming agent, and the foamable resin sheet is crosslinked and foamed to obtain a foamed sheet After manufacturing this, the stress for flattening the bubble of the said foam sheet in the thickness direction is added to this foam sheet in a molten state, The foam sheet manufacturing method characterized by the above-mentioned. The foamed sheet is flattened in the thickness direction by stretching the foamed sheet in the width direction or the extrusion direction or compressing the foamed sheet in the thickness direction. A method for producing a foam sheet. The method for producing a foamed sheet according to claim 1, wherein the resin composition contains 50 to 95% by weight of a rubber-based resin and 5 to 50% by weight of a synthetic resin containing a crystal component. The method for producing a foamed sheet according to claim 1, wherein the synthetic resin containing a crystal component is a polyolefin resin. The method for producing a foam sheet according to claim 1, wherein the rubber-based resin is a nitrile-butadiene rubber. The rubber-based resin includes a nitrile-butadiene rubber and a hydrogenated block copolymer including a polymer block of a vinyl aromatic compound and a polymer block of a conjugated diene compound, and the block copolymer is contained in the resin composition. The method for producing a foamed sheet according to claim 1, further comprising 10% by weight or less of a combined hydrogenated product. A resin composition containing a crystalline resin-containing synthetic resin and a rubber-based resin, and a thermally decomposable foaming agent are melt-kneaded to form a foamable resin sheet, and a synthetic resin layer is laminated on one surface of the foamable resin sheet After producing a foamed laminated sheet by integrating the foamed laminated sheet, the foamed laminated sheet is crosslinked and foamed to produce a laminated foamed sheet, and then the cells of the laminated foamed sheet are flattened in the thickness direction in a molten state in the laminated foamed sheet. A method for producing a laminated foamed sheet, characterized by applying a stress for making the resin foam. The method for producing a laminated foam sheet according to claim 7, wherein the synthetic resin layer is a polyolefin resin layer.

Images