JP2010173258A - Method for manufacturing resin foamed sheet, and container made from foamed resin - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a resin foamed sheet excellent in peel strength between a solid layer and a foamed layer, and a container made from a foamed resin easily separating a surface coating sheet bonded onto the surface. <P>SOLUTION: This method for manufacturing the resin foamed sheet comprises coextrusion of a thermally fused foamable resin composition and a thermally fused nonfoaming resin composition in a sheet form, in order to manufacture the resin foamed sheet having the solid layer on a surface, and forms thereby the solid layer of the nonfoaming resin composition, while forming a foamed layer of the foamable resin composition, and performs the coextrusion while cooled from a solid layer side. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for producing a resin foam sheet having a solid layer on the surface, and a foamed resin container formed by molding a resin foam sheet and having a surface sheet adhered to the surface.

  Conventionally, foods such as instant noodles in which dry noodles and powdered soup are contained in cup-shaped containers have been widely used, and this instant noodle container has a relatively high strength while being lightweight, A foamed resin container formed of a resin foam sheet is widely used because of its excellent heat insulation.

The resin foam sheet used to form such a foamed resin container includes a sheet composed only of a foam layer obtained by foaming a foamable resin composition into a sheet, a plurality of foam layers, and a foam layer and a non-foamed state. A laminated sheet obtained by laminating a solid layer is used.
Among them, the resin foam sheet having a solid layer on the surface can be expected to improve smoothness and strength due to the solid layer. For example, in Patent Document 1 below, the cup inner surface is formed by the solid layer. Describes the construction of a foamed resin container.

The foamed resin container described in Patent Document 1 is formed with a flange extending outward in an opening provided in the upper portion thereof, and the upper surface side of the flange contacting the lid for closing the opening is the above-mentioned It is formed to be a solid layer.
This prevents a gap from being formed between the lid and the collar.
That is, the solid layer improves the smoothness of the upper surface of the collar portion and improves the adhesion with the lid portion.

By the way, with the recent improvement of environmental awareness, more environmentally friendly materials have been actively incorporated into such food containers, which are disclosed in Patent Document 1 or Patent Document 2 below. As shown, a paper cover sheet is adhered to the surface of a foamed resin container.
In addition, since it is difficult to perform fine printing on the surface of the foam layer, when the outer side is formed as a foam layer as in the foamed resin container described in Patent Document 1, the aesthetics thereof are obtained. For the purpose of improving the above, it has been practiced to bond the cover sheet to the surface of the foamed resin container.
However, if the outer surface is formed by a foam layer as in the foamed resin container described in Patent Document 1, the outer surface is formed by a thin cell membrane, and when the cover sheet is adhered, for example, the container is used When the surface layer sheet is peeled off for the purpose of separating paper and resin later, the peeling force causes cohesive failure of the foamed resin container and a part of the surface of the foamed resin container is attached to the cover sheet side May be separated.

  On the other hand, it is conceivable to provide a solid layer on the outside where the cover sheet is bonded, but it is difficult to sufficiently improve the surface strength simply by providing a solid layer. There is a risk of peeling between the layers.

Such an improvement in the peel strength between the solid layer and the foamed layer is not only used in the formation of the foamed resin container as described above, but is generally required for the resin foamed sheet. Until then, sufficient measures have not been established.
And since it is difficult to sufficiently improve the peel strength between the solid layer and the foamed layer in the conventional resin foam sheet having a solid layer, the foamed resin container is used with the cover sheet adhered to the surface. However, it is difficult to separate it from the cover sheet after use.

JP 2005-247354 A JP 2003-40277 A

  The present invention provides a method for producing a resin foam sheet having excellent peel strength between a solid layer and a foam layer, and thus provides a foamed resin container suitable for use in which a surface sheet is bonded to the surface. Is an issue.

  As a result of studies to solve the above problems, the present inventor can produce a resin foam sheet having excellent adhesion between these layers by forming a solid layer and a foam layer by coextrusion, Moreover, simply co-extrusion of the solid layer and the foam layer makes it difficult to sufficiently improve the peel strength between the layers because the bubbles in the foam layer are coarsened on the side close to the solid layer. It was found that by implementing this cooling, it was possible to suppress the coarsening of the bubbles, and it was possible to produce a resin foam sheet having excellent peel strength between the solid layer and the foam layer, and the present invention was completed.

  That is, the present invention relating to a method for producing a resin foam sheet is a method in which a thermally meltable foamable resin composition and a non-foamable resin composition are combined in a sheet form in order to produce a resin foam sheet having a solid layer on the surface. Extruding to form a foam layer with the foamable resin composition, forming a solid layer with the non-foamable resin composition, and carrying out the co-extrusion while cooling from the solid layer side. It is a feature.

  Further, the present invention related to a foamed resin container is a foamed resin container formed by molding a resin foam sheet having a solid layer, and having a surface sheet adhered to the surface, wherein the resin foam The sheet is solidified with the non-foamable resin composition while the foamed resin composition and the non-foamable resin composition that are melted by heat are coextruded into a sheet shape to form a foamed layer with the foamable resin composition. A layer is formed, and the co-extrusion is performed while cooling from the solid layer side, and a molding process is performed so that the surface to which the cover sheet is bonded is formed by the solid layer. It is characterized by being.

According to the production method of the present invention, a resin foam sheet excellent in peel strength between the solid layer and the foam layer can be produced.
Therefore, the cover sheet once bonded in the foamed resin container molded so that the solid layer of the resin foam sheet is on the side to be bonded to the cover sheet can be easily separated.
That is, according to the present invention, a resin foam sheet excellent in the peel strength between the solid layer and the foam layer can be provided, and a foam resin container suitable for applications in which a cover sheet is adhered to the surface can be provided.

Sectional drawing which shows the structure of the resin foam sheet which concerns on this embodiment. Sectional drawing which shows the usage example (food container) of the container made from a foamed resin which concerns on this embodiment. Schematic which shows the apparatus structure used for the manufacturing method of a resin foam sheet. Sectional drawing which shows the structure of a confluence | merging metal mold | die. Sectional drawing which showed a mode that co-extrusion was implemented cooling from the solid layer side. The top view (a) and side view (b) which show other embodiment using a flat die. Sectional drawing which shows the structure of the resin foam sheet which concerns on other embodiment. Sectional drawing which shows the structure of the resin foam sheet which concerns on other embodiment. Schematic which shows the apparatus structure used for manufacture of the resin foam sheet in an Example. Sectional drawing which shows the structure of the confluence | merging die used for manufacture of the resin foam sheet in an Example.

Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
First, a resin foam sheet and a container using the resin foam sheet will be described.
FIG. 1 is a cross-sectional view of a resin foam sheet according to the present embodiment. As shown in FIG. 1, the resin foam sheet 1 according to the present embodiment is in a non-foamed state in which no bubbles are contained. It has a two-layer structure of the solid layer 10 formed in the above and the foamed layer 20 formed in a foamed state.

  About each thickness of the solid layer 10 and the foam layer 20 in the said resin foam sheet 1, although depending on the use of a resin foam sheet etc., in the case where it is normally used for formation of a foam resin container, the above-mentioned The solid layer 10 has a thickness of 10 to 300 μm, and the foam layer 20 has a thickness of 0.3 to 5 mm.

For the formation of the solid layer 10, the material used is not particularly limited as long as it is a resin composition that can be extruded in a non-foamed state (hereinafter also referred to as “non-foamable resin composition”). A resin composition containing a polyolefin resin such as a polyethylene resin or a polypropylene resin or a thermoplastic resin such as a polystyrene resin as a base polymer can be suitably used.
Among these, polystyrene resins are excellent in strength and heat resistance while being relatively inexpensive, and can be suitably used as the base polymer when the resin foam sheet is used as a member constituting a container.

Examples of the base polymer include one or more polymers selected from styrenic monomers, and vinyls copolymerizable with styrenic monomers and styrenic monomers as long as they are polystyrene resins. And a copolymer with a monomer.
Examples of the styrene monomer include styrene, α-methyl styrene, vinyl toluene, chlorostyrene, ethyl styrene, i-propyl styrene, t-butyl styrene, and dimethyl styrene.
Examples of the vinyl monomer include alkyl (meth) acrylates such as methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, and cetyl (meth) acrylate, (meth) acrylonitrile, and dimethyl. Examples include maleate, dimethyl fumarate, diethyl fumarate, and ethyl fumarate.

  In addition to the base polymer as described above, the non-foamable resin composition used for forming the solid layer 10 can contain an additive used as a general polymer film material, for example, Various stabilizers such as weathering agents and anti-aging agents, processing aids such as lubricants, antistatic agents, slip agents, pigments, fillers and the like can be further added as additives.

For the formation of the foam layer 20, a resin composition (hereinafter also referred to as “foamable resin composition”) that can cause foaming by performing extrusion in a heated and melted state can be used. As the composition, for example, a resin composition used for forming the solid layer 10 and further containing a foaming component can be adopted.
The non-foamable resin composition used for forming the solid layer 10 and the foamable resin composition used for forming the foamed layer 20 are made of the same base polymer from the viewpoint of the adhesive strength between the solid layer 10 and the foamed layer 20. For example, when a polystyrene resin is used for forming the solid layer 10, a polystyrene resin that is the same as or different from the solid layer 10 is used for the base polymer of the foamable resin composition. It is preferred that
That is, the adhesive strength can be improved by adopting a polystyrene-based resin as a base polymer for forming the solid layer 10 and the foamed layer 20, respectively.

  Examples of the foaming component contained in the non-foamable resin composition include, for example, a gas component that is in a gaseous state at least at the melting point of the base polymer, and a nucleating agent that serves as a nucleus when bubbles are formed by the gas component. In addition, there may be mentioned a thermal decomposition type foaming agent that generates a gas by generating thermal decomposition at least at the melting point of the base polymer.

Examples of the gas component include aliphatic hydrocarbons such as propane, butane, and pentane; 1,1-dichloro-1-fluoroethane (HCFC-141b), 1-chloro-1,1-difluoroethane (HCFC-142b), Such as 2-chloro-1,1,1,2-tetrafluoroethane (HCFC-124), 1,1,1,2-tetrafluoroethane (HFC-134a), 1,1-difluoroethane (HFC-152a), etc. Freon-based gas components; nitrogen, carbon dioxide, argon, water and the like can be mentioned.
Of these, aliphatic hydrocarbons are preferred.
These gas components may be used alone or in combination.

  Examples of the nucleating agent include talc, mica, silica, diatomaceous earth, aluminum oxide, titanium oxide, zinc oxide, magnesium oxide, magnesium hydroxide, aluminum hydroxide, calcium hydroxide, potassium carbonate, calcium carbonate, magnesium carbonate, and sulfuric acid. Examples thereof include inorganic compound particles such as potassium, barium sulfate and glass beads, and organic compound particles such as polytetrafluoroethylene.

  Furthermore, examples of the thermal decomposition type foaming agent include azodicarbonamide, sodium hydrogen carbonate, a mixture of sodium hydrogen carbonate and citric acid, and the like.

As the expansion ratio of the foam layer 20, but are not particularly limited, the apparent density may be any of a range of 0.07~0.45g / cm ^3.
And it is preferable that this foaming layer 20 is formed so that it may be in the state which reduced the foaming ratio from the thickness direction center part to the interface side with the said solid layer 10. FIG.
The strength of the foam layer 20 can usually be improved by lowering the expansion ratio.
However, on the other hand, when the expansion ratio is lowered, there is a risk that the light weight and heat insulation of the resin foam sheet 1 may be impaired.
Therefore, the strength at the interface with the solid layer 10 can be improved while imparting excellent heat insulating properties and light weight to the resin foam sheet 1 by decreasing the expansion ratio in an inclined manner toward the solid layer 10 as described above. . In addition, when a stress in the peeling direction is applied to the solid layer 10, it is possible to suppress the stress from being concentrated on the interface between the solid layer 10 and the foam layer 20. A resin foam sheet having excellent peel strength can be formed.

Next, a container, which is an example of an application of the resin foam sheet 1, will be described with reference to FIG.
FIG. 2 shows a cross-sectional view of the food container 100. As shown in this figure, the food container 100 according to the present embodiment is mounted on the foamed resin container 50 formed by the resin foam sheet 1. The sheet 60 is formed by bonding.
More specifically, the foamed resin container 50 is formed into a bucket shape by sheet molding using the resin foam sheet 1, and the outer surface side to which the cover sheet 60 is bonded is It is formed by deep drawing so as to become the solid layer 10.

The cover sheet 60 may be paper or resin film decorated by printing or the like.
In particular, in the case where a paper cover sheet is employed for the food container 100, the material of the foamed resin container and the cover sheet are greatly different, so the demand for separation is strong, and the effects of the present invention can be exhibited more remarkably. .

  That is, the foamed resin container 50 of the food container 100 uses the resin foam sheet 1 whose surface is constituted by the solid layer 10 having improved peel strength from the foamed layer 20, and is formed by the solid layer 10. Since the cover sheet 60 is used by being adhered to the outer surface, when the cover sheet 60 is peeled off after the food container 100 is used, cohesive failure occurs in the foamed resin container 50 and the side of the cover sheet It can be suppressed that a part of the foamed resin container 50 adheres.

  The food container as described above and the resin foam sheet used therefor can be produced as follows.

FIG. 3 is a configuration diagram showing an example of a manufacturing apparatus used in the method for manufacturing a resin foam sheet according to the present invention. As shown in FIG. 3, in the method for manufacturing a resin foam sheet, tandem is used. A merge mold XH having a first extruder 70 as an extruder and a second extruder 80 as a single extruder, into which a resin composition melt-kneaded in these extruders is merged, and the merge Equipment having a circular die CD for discharging the resin composition merged in the mold XH into a cylindrical shape is used.
In addition, this manufacturing apparatus includes a cooling device CL that air-cools the resin foam sheet discharged from the circular die CD in a cylindrical shape from the solid layer side (the outside in FIG. 3), and the cylindrical resin foam sheet is expanded in diameter. And a slitting device for slitting the resin foam sheet after passing through the mandrel MD into two sheets (not shown: up and down in FIG. 3) And only a winding roller 92 for winding the slit resin foam sheet 1 after passing the plurality of rollers 91 is shown.

The first extruder 70 is for forming the foamed layer 20, and a material such as a base resin is charged into the upstream extruder (hereinafter also referred to as “upstream extruder 70a”). A hopper 71 and a gas introduction part 72 for supplying gas components such as hydrocarbons into the cylinder are provided.
Further, on the downstream side of the upstream side extruder 70a, an extruder (hereinafter referred to as "downstream side") that melts and kneads the foamable resin composition containing the base resin and the gaseous component and discharges it to the joining mold XH. Extruder 70b ").

  The second extruder 80 is for forming the solid layer 10. A material such as a base resin is introduced from the hopper 81, and the non-foamable resin composition is melted and kneaded inside the cylinder. It is configured to be discharged into the mold XH.

  As shown in the schematic cross-sectional view of FIG. 4, the merging mold XH is a non-foaming resin composition discharged from an annular slit provided in the middle of a flow path through which the foaming resin composition passes. The foamable resin composition is configured to be supplied to the circular die CD in a state where the outer foam of the non-foamable resin composition is coated.

  Therefore, as shown in a cross-sectional view of FIG. 5 in which the foamable resin composition and the non-foamable resin composition are co-extruded from the discharge hole CDa of the circular die CD, A solid layer 10 is disposed on the outside, and the cooling device CL can perform cooling by airflow AF by blowing a gas to the cylindrical resin foam sheet 1 from the outside where the solid layer 10 is disposed. Is arranged.

In order to produce a resin foam sheet using such an apparatus, first, a resin material used for forming the foam layer 20 is introduced from the hopper 71 of the first extruder 70, and a solid layer is produced from the hopper 81 of the second extruder 80. Ten resin materials are charged and heated to a temperature equal to or higher than the melting temperature of the resin in each extruder to carry out melt kneading.
In addition, in the case where additives such as the resin material used as the base polymer are included in the foamable resin composition or the non-foamable resin composition, these are also added from the hopper and melt kneaded with each extruder. do it.

Among these extruders, in the first extruder 70, a gas component is press-fitted from the gas introduction part 72 provided in the upstream extruder 70a and mixed with the molten resin.
The foamable resin composition melt-kneaded by the upstream extruder 70a in the first extruder 70 is adjusted to a temperature suitable for extrusion foaming by the downstream extruder 70b and sent to the confluence mold XH. In the two-extruder 80, the non-foamable resin composition is adjusted to a temperature suitable for forming the solid layer 10 and sent to the confluence mold XH.

Then, the respective resin compositions joined in the joining mold XH are co-extruded in a cylindrical shape from the annular discharge hole CDa of the circular die CD, and foamed in the foamable resin composition so as to be foamed layer 20. The solid layer 10 is formed in the non-foamable resin composition.
At this time, for forming the solid layer 10 and the foamed layer 20, for example, the compatibility of the interface can be improved by using the same kind of resin material by adopting, for example, polystyrene resin. The peel strength from the foam layer 20 can be improved.

At this time, co-extrusion while cooling from the solid layer 10 side by the cooling device CL is important for further improving the peel strength between the solid layer 10 and the foamed layer 20.
This will be described in more detail. Since the strength of the foamed layer decreases as the foaming ratio of the foamed layer 20 directly below (inner side) of the solid layer 10 decreases, the resulting foamed resin sheet has sufficient peel strength. It may be difficult to apply.
On the other hand, by cooling from the solid layer 10 side, the growth of bubbles immediately below the solid layer 10 can be suppressed, and the peel strength between the solid layer 10 and the foamed layer 20 can be improved.

The cooling from the solid layer 10 is preferably performed under conditions that allow a predetermined amount of heat to be removed before the bubbles formed in the foam layer 20 are sufficiently grown.
For example, when extruding a resin foam sheet using a polystyrene resin so that the extrusion speed is about 3 to 6 m / min, the distance from the discharge hole CDa of the circular die CD (L in FIG. 5) is 25 mm. And within a distance of 25 mm from the surface of the solid layer 10 (D in FIG. 5), cooling is performed by blowing a gas having a temperature of less than 80 ° C. to 0.1 m ³ or more per 1 m ² of the resin foam sheet. Is preferred.

If the cooling air is too strong, the extruded resin foam sheet may flutter due to the air current, or low molecular components discharged from the discharge holes CDa together with the resin foam sheet may accumulate at the gas outlet, There is a risk that objects adhere to the resin foam sheet.
Therefore, the distance (L) from the circular die is preferably 3 mm or more, more preferably 4 to 15 mm, and most preferably 5 to 10 mm.
The distance (D) from the surface of the solid layer 10 is preferably 3 mm or more, more preferably 4 to 15 mm, and most preferably 5 to 10 mm.
Furthermore, if the temperature of the gas is extremely low, deposits may be generated, and wrinkles may be generated in the resin foam sheet.
Therefore, the gas temperature is preferably any one of 10 to 70 ° C, more preferably 20 to 60 ° C, and particularly preferably 35 to 50 ° C.
The air volume is more preferably 0.2 m ³ or more per 1 m ² of the outer peripheral surface of the cylindrical resin foam sheet, and particularly preferably 0.25 m ³ or more.

  The cylindrical resin foam sheet in which the peel strength between the solid layer 10 and the foam layer 20 is improved in this way is maintained in a state where the diameter has been expanded by the mandrel MD and is easily cut by the mandrel MD. The temperature is cooled down to a certain temperature, two places are cut by a slitting device, and the winding roller 22 is wound up through a plurality of rollers 21 above and below.

It should be noted that the case where a flat die is used instead of the method using the circular die is within the range intended by the present invention when co-extrusion is performed while cooling from the solid layer side.
For example, as shown in FIG. 6, a method of performing co-extrusion while cooling from the solid layer 10 side by using the roller R arranged in parallel with the opening direction of the flat die FD is also employed. Is possible.

That is, while rotating the roller R having a length equal to or greater than the sheet width of the co-extruded resin foam sheet in the front direction of the discharge hole FDa of the flat die FD in the direction away from the discharge hole FDa, A laminate (resin foam sheet 1) of the non-foamable resin composition and the foamable resin composition in a state of being melted by heating on the outer peripheral surface is coextruded, and the non-foamable resin composition side, that is, By co-extrusion so that the solid layer side is in contact with the outer peripheral surface of the roller R, a resin foam sheet having excellent peel strength between the solid layer 10 and the foam layer 20 can be obtained.
At this time, by circulating an appropriate heat medium such as water, steam or oil through the roller R, the surface temperature can be maintained at a temperature suitable for cooling the solid layer.

  In the case of adopting this method, the surface state of the roller R can be reflected in the surface state of the solid layer 10. For example, surface gloss is imparted to the resin foam sheet using a roller having a mirror-finished surface. Alternatively, a frosted resin foam sheet can be produced using a roller having a roughened surface.

In addition, in the above, the resin foam sheet in which the solid layer and the foam layer are formed one by one is illustrated. For example, as shown in the cross-sectional view of FIG. A resin foam sheet in which the solid layers 10, 10 'are formed on both surfaces can also be manufactured by the manufacturing method of the present invention.
In this case, it is only necessary to co-extrusion while cooling on the side where an improvement in peel strength between the solid layer and the foamed layer is required. When an improvement in peel strength is required on both sides, for example, a circular die is used. In this case, gas can be blown from both inside and outside of the cylindrical body. When a flat die is used, two cooling rollers are prepared, and cooling is performed from both sides with a resin foam sheet sandwiched between them. do it.

Further, for the foamed layer, for example, a plurality of foamed layers having different foaming ratios are formed as shown in the cross-sectional view of FIG.
The obtained resin foam sheet can be molded into a foam resin container by a general sheet molding method such as vacuum molding or vacuum / pressure forming.

  And although not explained in detail here, it is possible to employ conventionally known technical matters regarding the resin foam sheet and the foamed resin container within a range where the effects of the present invention are not significantly impaired.

  EXAMPLES Next, although an Example is given and this invention is demonstrated in more detail, this invention is not limited to these.

Example 1
For the production of the resin foam sheet, equipment having an apparatus configuration as shown in FIG. 9 was used.
Moreover, the confluence | merging metal mold | die used the structure shown in FIG.
As the first extruder 70, a single-screw extruder having a diameter of 115 mm (upstream extruder 70a) and a single-screw extruder having a diameter of 150 mm connected to the single-screw extruder (downstream extruder 70b) are used. A tandem extruder was prepared.
A single-screw extruder having a diameter of 115 mm was prepared as the second extruder 80, while a single-screw extruder having a diameter of 90 mm was prepared as the third extruder 85.
Then, a highly foamable foamable resin composition is introduced from the first extruder 70 into the merging mold XH ′, and a low foamable foamable resin composition is coated on the outside from the third extruder 85. Further, the respective extruders were connected to the merging die XH ′ so that the non-foamable resin composition was coated from the second extruder 80 on the outside thereof.

  In the first extruder 70, talc particles having a particle size of 5 to 15 μm and dispersed as a nucleating agent in the polystyrene resin with respect to 100 parts by weight of the polystyrene resin (manufactured by PS Japan, trade name “G0002”). The resin material is supplied at a ratio of 0.6 parts by weight of the master batch (Kihara Kasei Co., Ltd., trade name “SMA-01”, talc particles: about 40% by weight) to which the additive is added, and the resin temperature is 220 ° C. Then, 2.8 parts by weight of butane (normal butane: 65% by weight, isobutane: 35% by weight) as a gas component is press-fitted into the upstream side extruder 70a and melt-kneaded to obtain a highly foaming foam. Next, the resin temperature was lowered to 154 ° C. by the downstream side extruder 70b and supplied to the confluence mold XH ′.

  In the second extruder 80, impact-resistant polystyrene (manufactured by Toyo Styrene Co., Ltd., trade name “HIPS, E641N”, melt flow rate: 3.6 g / 10 min) is supplied at a resin temperature of 220 ° C. After melt-kneading, the mixture was cooled to a resin temperature of 180 ° C. and supplied to the confluence mold XH ′.

  Furthermore, in the third extruder 85, talc particles having a particle diameter of 5 to 15 μm as a nucleating agent and a dispersing agent for polystyrene with respect to 100 parts by weight of polystyrene (trade name “GPPS, HRM18” manufactured by Toyo Styrene Co., Ltd.) Is added to the master batch (Kihara Kasei Co., Ltd., trade name “SMA-01”, talc: about 40% by weight) in a ratio of 1.4 parts by weight, and the resin temperature is 220 ° C. After melt-kneading, 2.1 parts by weight of butane (normal butane: 65% by weight, isobutane: 35 parts by weight) is press-fitted and then melt-kneaded to prepare a low-foaming foamable resin composition, and the resin temperature is 161 ° C. The product was cooled to a combined mold XH ′.

And from these extruders, two types of foamable resin compositions and one type of non-foamable resin composition are extruded into a confluence mold, and a highly foamable foamable resin composition layer having a circular cross section is formed. Laminating a low-foaming foamable resin composition layer on the outer peripheral surface, and further supplying continuously to a circular die CD for coextrusion with a non-foamable resin composition layer laminated on the outside, A cylindrical resin foam sheet was manufactured by extrusion foaming from the circular discharge hole of the circular die CD.
The amount of extrusion from the first extruder 70 was 152 kg / hour, the amount of extrusion from the second extruder 80 was 73 kg / hour, and the amount of extrusion from the third extruder 85 was 25 kg / hour.
The circular die CD used for coextrusion had an inner tip surface diameter of 215 mm and an opening clearance of 0.74 mm.

In the co-extrusion, the outer peripheral surface of the extruded cylindrical resin foam sheet is 7 mm from the discharge hole of the circular die CD (corresponding to L in FIG. 5) by the air cooling device CL, and the solid layer at a distance (corresponding to D in FIG. 5) the position of 7mm from the surface was carried out cooling by blowing in an amount of 0.32 m ³ in area 1 m ² per resin foam sheet obtained the temperature of the air of 40 ° C. .
In addition, at the temperature of 40 ° C. in an amount of 0.18 m ³ per 1 m ² area of the resin foam sheet obtained from the inner foam layer (high foam layer) with cooling from the solid layer side. Cooling was performed by blowing air.

In this co-extrusion, the diameter of the resin foam sheet is gradually expanded while being cooled with air in this way, and further, the resin foam sheet is continuously supplied to a cylindrical cooling mandrel MD having a constant diameter (diameter: 670 mm) and cooled. Thereafter, the cylindrical resin foam sheet was continuously cut along the extrusion direction, opened, and developed into a sheet shape.
Note that the "area 1 m ² per the resulting resin foam sheet" in cooling, which means "resin foam sheet 1 m ² per became sheet is expanded after being cooled by a cooling mandrel" this.

The obtained resin foam sheet had a basis weight of 480 g / m ² , a foam layer (total of two layers) 341 g / m ² , a solid layer 139 g / m ² , a width of 1052 mm, and a thickness of 2.35 mm.

(Example 2)
The cooling air blowing position from the solid layer side is changed to L (distance from the discharge hole) = 7 mm and D (distance from the surface of the resin foam sheet) = 7 mm, L = 20 mm, D = 20 mm and then, a 0.25 m ³ / m ² instead of the air volume to 0.32 m ³ / m ^2, except that the 60 ° C. instead of air temperature 40 ° C. was prepared a resin foam sheet in the same manner as in example 1 .

(Example 3)
The cooling air blowing position from the solid layer side is changed to L = 7 mm and D = 7 mm, L = 5 mm and D = 5 mm, and the air volume is changed to 0.32 m ³ / m ² and 0.46 m. ^A resin foam sheet was produced in the same manner as in Example 1 except that ³ / m ² and the air temperature was changed to 20 ° C. instead of 40 ° C.

Example 4
A resin foam sheet was produced in the same manner as in Example 1 except that the cooling air blowing position from the solid layer side was changed to D = 27 mm instead of D = 7 mm.

(Example 5)
A resin foam sheet was produced in the same manner as in Example 1 except that the cooling air blowing position from the solid layer side was changed to D = 2 mm instead of D = 7 mm.

(Example 6)
A resin foam sheet was produced in the same manner as in Example 1 except that the cooling air blowing position from the solid layer side was changed to L = 27 mm instead of L = 7 mm.

(Example 7)
A resin foam sheet was produced in the same manner as in Example 1 except that the cooling air blowing position from the solid layer side was changed to L = 2 mm instead of L = 7 mm.

(Example 8)
A resin foam sheet was produced in the same manner as in Example 1 except that the temperature of the air used for cooling from the solid layer side was changed to 80 ° C. instead of 40 ° C.

Example 9
A resin foam sheet was produced in the same manner as in Example 1 except that the temperature of the air used for cooling from the solid layer side was changed to 5 ° C. instead of 40 ° C.

(Example 10)
A resin foam sheet was produced in the same manner as in Example 1 except that the amount of air used for cooling from the solid layer side was changed to 0.09 m ³ / m ² instead of 0.32 m ³ / m ² .

(Comparative Example 1)
A resin foam sheet was produced in the same manner as in the previous examples except that the cooling from the solid layer side was not performed.

(Evaluation)
The obtained resin foam sheet was evaluated as follows.
[Peel strength 1]
The resin foam sheet was cut with a width of 30 mm from end to end in the sheet width direction, the film peel strength was measured with a tensile tester (Tensilon), and the average value of n = 3 was taken as the film peel strength measurement value. The results are shown in Table 1.

[Peel strength 2]
It has a circular bottom surface with a diameter of 90 mm, a peripheral wall with a height of 105 mm that stands upright from the outer periphery of the bottom surface, and a flange that extends outward from its upper end is formed on the peripheral wall. Four buckets (144 pieces) were produced by a sheet molding method of 36 pieces / shot, in which the tip (contour in top view) of the flange portion was formed into a circle having a diameter of 140 mm.
The 144 bucket-type containers are stacked for each shot (36), and four container stacks are produced, which are stored in cardboard boxes that can be stored in two rows and two rows. Let this cardboard box drop naturally 50 cm high, and repeat the operation 10 times. Does the rubbing between the buttocks and the rubbing between the buttock and the inner wall of the cardboard box cause separation between the foam layer and the solid layer? I confirmed.
As a result, out of 144 bucket-shaped containers, even if 1 to 5 were peeled off between the solid layer and the foamed layer, it was determined as “Δ”, and those where 6 or more peeled off were “x”, Those that did not peel all were judged as “◯”.
The determination results are shown in Table 1.

[Sheet appearance]
The appearance of the resin foam sheet is visually inspected, the beautiful one is marked with `` ○ '', and the one that the appearance of the solid layer is damaged even a little due to the adherence of polystyrene derived from polystyrene resin `` × ”. The results are shown in Table 1.

  Also from this table, it can be seen that by performing coextrusion while cooling from the solid layer side, a resin foam sheet having excellent peel strength between the solid layer and the foam layer can be obtained.

DESCRIPTION OF SYMBOLS 1 Resin foam sheet 10 Solid layer 20 Foam layer 50 Foamed resin container 60 Surface sheet 100 Food container AF Airflow CD Circular die CDa Discharge hole CL Cooling device FD Flat die FDa Discharge hole MD Mandrel R Roller XH Merge mold

Claims (7)

  In order to produce a resin foam sheet having a solid layer on the surface, the foamed resin composition and the non-foamable resin composition that are melted by heat are coextruded into a sheet shape to form a foam layer with the foamable resin composition. A solid foam is formed from the non-foamable resin composition while the co-extrusion is carried out while cooling from the solid layer side.   The method for producing a resin foam sheet according to claim 1, wherein both of the base polymer of the foamable resin composition and the non-foamable resin composition are polystyrene resins.   The manufacturing method of the resin foam sheet of Claim 1 or 2 which implements the said co-extrusion using a circular die | dye, sprays gas from the solid layer side, and implements the said cooling. The extrusion rate of the resin foam sheet is 3 to 6 m / min, and the area of the resin foam sheet from which the gas having a temperature of less than 80 ° C. is produced from a distance within 25 mm from the circular die and within 25 mm from the surface of the solid layer is 1 m. ^The method for producing a resin foam sheet according to claim 3, wherein the cooling is performed by spraying an amount of 0.1 m ³ or more per ² .   While rotating a roller having a length equal to or larger than the width of the resin foam sheet, the roller is coextruded on the outer peripheral surface of the roller using a flat die, and the side in contact with the outer peripheral surface of the roller is a solid layer. The manufacturing method of the resin foam sheet of Claim 1 or 2 which implements the said cooling by implementing coextrusion. A resin foam sheet having a solid layer is formed by molding, and is a foam resin container used with a surface sheet adhered to the surface,
The non-foamable resin composition is formed by forming a foamed layer with the foamable resin composition by coextrusion of the heat-meltable foamable resin composition and the non-foamable resin composition into a sheet shape. A solid layer is formed by the object, and the co-extrusion is performed while cooling from the solid layer side, and the surface to which the cover sheet is bonded is formed by the solid layer. A foamed resin container characterized by being molded.   The foamed resin container according to claim 6, wherein a paper cover sheet is adhered to the container.

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