JP2010260631A - Decomposition cushioning material and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a decomposable cushioning material and a manufacturing method thereof having an excellent cushioning properties against products and commodities of a wide range of weights and shapes, while being capable of being decomposed to be lost promptly after use. <P>SOLUTION: The decomposable cushioning material and its manufacturing method include a process of blending 25-45 units of a mutual-fusion-bonding material made of polyethylene or polypropylene resin with 100 units of decomposable material having rice or 20-40 wt.% of grain crop mixed with rice, while, against the whole quantity of the foregoing, a decomposition accelerator of 0.1-5.0 wt.% is blended, whereas furthermore, water of 3.0-6.0 wt.% is added thereto so as to be subjected to extrusion forming for a resultant achievement of a prescribed width and thickness while foaming with an expansion ratio of 20-100 times. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a degradable cushioning material and a method for producing the same, and more particularly, it is possible to safely transport multiple and diverse products and products with high cushioning properties, and to quickly decompose and destroy them after use. The present invention relates to a degradable cushioning material and a manufacturing method thereof.

  In Japan, mass transportation and mass sales in the high growth period have been supported, and accordingly, a large amount of cushioning materials that are lightweight and inexpensive and that protect the transported products and products, that is, the so-called cushioning properties, are required. It came. For this reason, buffer sheet materials, block-shaped rose cushioning materials, etc., which are formed by foaming polyethylene, polypropylene, or polystyrene resin materials having excellent processability, have been developed and used in large quantities.

By the way, since the cushioning material is intended to protect the product or commodity to be packed and transported within a short period during which the product or commodity is produced and consumed, it is discarded along with the consumption.
These buffer materials are not decomposable or disintegratable and cannot be disposed of in landfills. Also, incineration is not only damaging to the incinerators, but also is very bulky. Due to its light weight, used cushioning materials are scattered and scattered everywhere, causing environmental pollution such as significantly hindering the landscape, and countermeasures against this are strongly demanded.

  Therefore, a degradable buffer material can be obtained by foaming by heat evaporation using water, using a so-called biodegradable material that retains hydrolyzability and microbial degradability such as aliphatic polyester and starch / PVA instead of synthetic resin material. However, the biodegradable material has high rigidity and hardness and is convenient for film materials and plate materials, etc., but can exhibit high compression elastic force, that is, shock absorbing property due to foaming and softness like a cushioning material. Therefore, if the foamed partition structure is thin and rough and has a foaming ratio of at least 30 to 70 times or more, the foamed partition structure does not retain flexibility, while the foamed partition structure does not exhibit compression elastic force, Buffering for multiple products and products is not created. For this reason, even if a degradable material such as an aliphatic polyester type or starch / PVA type is used, at present, a rose cushioning material that is foam-molded and cut to about 10 to 30 mm in diameter and about 30 to 60 mm in length, The product is used only in a relatively light-weight product or product packing space, and has not yet solved various problems caused by the cushioning material.

  Inventors and others have made extensive studies in view of such circumstances, and as a result, in order to form a cushioning material that retains degradability and retains flexibility and high compressive elasticity, high adhesiveness and plasticity can be obtained by heating and pressurizing and adding water. 100 parts of rice or a degradable material mixed with cereals in a proportion of 20 to 40% by weight with respect to the rice as a material that retains degradability can be mixed and kneaded with the degradable material and is flexible even if relatively thick 25 to 45 parts of a phase melt adhesive material made of polyethylene or polypropylene resin can be used to form a dense foamed compartment structure and maintain a fusion property that allows the foamed cushioning material to be fused and laminated together. The present invention has been conceived to solve the above-mentioned problems by foaming into a flat shape by extrusion while adding 0.1 to 5.0% by weight of a decomposition accelerator with respect to the total amount. It came.

  The present invention provides a degradable cushioning material that can be safely held and transported by excellent buffering properties even in products and products having a wide range of weights and shapes, and that can be quickly destroyed after use, and a method for producing the same. It is to provide.

  The technical means used by the degradable cushioning material of the present invention to solve the above-mentioned problems is easily decomposed and lost in a natural environment, so that the material used is 20% to 40% by weight based on rice or rice. 100 parts of the decomposable material mixed with the above, and the meltable kneading with the decomposable material can form a relatively thick foamed compartment structure densely and maintain the fusion property capable of fusing and laminating the foamed products. 25 to 45 parts of a phase melting adhesive material made of polyethylene or polypropylene resin, and a decomposition accelerator made of a photodecomposing agent and a biodegrading agent or a chemical decomposing agent for decomposing them in a short time, 0.1 to 5 with respect to the total amount. In addition to being blended at a ratio of 0.0% by weight, water is further added at a ratio of 3.0 to 6.0% by weight, and the extrusion is performed to obtain the required width and thickness and the expansion ratio is 20 to 100 times. Slightly cured on the front and back The layers are formed, Thus also located beyond the layers of formed a number of vertical wrinkles in the degradable buffer material.

  In addition, several decomposable cushioning materials in which foam-molded degradable cushioning materials are appropriately fused and laminated, and several decomposable cushioning materials in which a mounting gap for mounting a product or a product is formed are suitably fused and laminated. It exists in the degradable shock absorbing material made.

  Furthermore, using an extruder, the decomposable material, the phase melt adhesive and the decomposition accelerator are blended and supplied from the hopper at the required ratio, and the temperature gradient in the cylinder is 30 to 40 ° C. 3 to 6% by weight with respect to the total amount of distributable material, phase melt adhesive and decomposition accelerator supplied from the front part of the hopper. In addition to hydration and melt kneading, the tip is provided with a T-shaped die with slits of the required thickness and width, and melted and kneaded with sufficient heat and melting at the cylinder metering section. In order to prevent die swell and melt fracture due to discharge molding of objects, the temperature of the T-shaped die is reduced to 160 to 190 ° C., and the foam is blown and discharged in a flat shape with a foaming ratio of 20 to 100 times. Those existing in a method of manufacturing the degradable buffer material of a required thickness and width drives out take-off speed by the upper cooling roll.

  In addition, each of the foam-formed degradable cushioning materials is supplied from a supply roll, the opposing surfaces are heated in the heating unit, and the opposing heating surfaces are pressurized with a pressure roll, thereby The present invention resides in a method for manufacturing a degradable cushioning material to be fused and laminated, and further, a mounting portion on which a product or a product to be packed is mounted in a foamable degradable cushioning material supplied by a supply roll is formed in advance. It exists in the structure which becomes.

  The present invention has the structure as described above, and the main use material of the degradable cushioning material is 100 parts of rice or a degradable material in which cereals are mixed in a proportion of 20 to 40% by weight with respect to the rice, 25 to 45 parts of a phase melt adhesive material made of polyethylene or polypropylene resin which can be melt-kneaded and retains the meltability, and 0.1 to 5.0% by weight based on the total amount of the photodecomposition agent and biodegradation A decomposability accelerator consisting of an agent or a chemical decomposing agent is blended, and water is added in an amount of 3.0 to 6.0% by weight, melted and kneaded by an extruder, and is flat and has a required thickness and width. It is formed by discharge molding at an expansion ratio of 20 to 100 times.

Because of this, the main material used is rice or a degradable material in which 20 to 40% by weight of cereal is mixed with rice, so it can be used as grain, so it can be used without requiring milling and adjustment processes such as starch. In addition to being extremely inexpensive because it can be used, foam molding by an extrusion molding machine is used, so that small chip-like forms such as rice and cereals can be expected to have very good supply and high productivity.
In the present invention, although rice and grains are used, there is a risk that the molded product will swell and become brittle due to moisture absorption and moisture absorption unless the gelatinization by heating such as starch is suppressed. 25 to 45 parts of the dressing material is blended and melt-kneaded with the decomposable material and homogeneously dispersed throughout, so that sufficient moisture and water resistance is exhibited, and flexibility when used under low temperature conditions after foam molding In combination with the strong viscosity of the degradable material, foaming is formed densely with a relatively thick foaming compartment structure, so lightweight products and products as well as multiple products and products have high buffering properties. It is retained and can be handled and transported. And, since the decomposition accelerator composed of a photodecomposition agent and a biodegradation agent or a chemical decomposition material is dispersed and kneaded at a ratio of 0.1 to 5.0% by weight with respect to the total amount of the decomposable material and the phase melt adhesive, After use, it can be decomposed and lost in a short time under natural conditions.

  In addition, since the decomposable buffer material is formed by dispersing and kneading the phase melt adhering material over the whole at a blending ratio of 25 to 45 parts, the mutual side surfaces can be heated and pressurized only by pressing each other. Since fusion lamination is performed, a degradable cushioning material that requires a sufficient thickness can be easily formed.

Further, in the production method of the present invention, foam discharge molding is performed from a T-shaped die using an extrusion molding machine, and the decomposable material, the phase melt adhesive material, and the decomposition material with the required blending ratio from the hopper. Extruder using screw, because the accelerator is supplied, the degradable material is in the shape of grains in which rice and grains are mixed, and the polyethylene and polypropylene resin of the phase melting material is also in the form of pellets Then, supply efficiency is very good and high productivity can be expected.
At the front part of the hopper, water is added in a proportion of 3.0 to 6.0% by weight with respect to the total amount of the decomposable material and phase melting material to be supplied, and the temperature in the cylinder is 30 to 40 ° C. in the supply part. A T-shaped die having a required slit and width at the tip thereof, which is heated and pressurized by melt pressure kneading with a temperature gradient of 220 to 250 ° C. in the compression section and 250 to 290 ° C. in the weighing section and contains pressurized steam. And the T-shaped die is set at a low temperature of 160 to 190 ° C., so that the foaming discharge pressure is remarkably reduced, and die swell, ie, blistering, and melt fracture, ie, fluctuation in thickness during discharge, are prevented. The

In the manufacturing method of the present invention, the foaming rate is substantially 20 to 100 times from the T-shaped die, and the foam is discharged in a flat shape. Buffer material can be produced easily and efficiently.
In addition, the opposite surfaces of the decomposable cushioning material, which are flat and discharged and formed with the required thickness and width, are heated by the feeding rolls while the opposing faces are heated. By applying the bonding pressure, it is possible to fuse and laminate very easily and efficiently and to easily form a decomposable buffer material having a desired thickness.

  100 parts of a degradable material made of rice, 40 parts of a phase melt adhesive made of polypropylene resin, a photodecomposing agent made of an aliphatic ketone, a biodegrading agent made of chitin, a metal carboxylate and an aliphatic polyhydroxycarboxylic acid The chemical decomposing agent consisting of acid is blended at 4.5% by weight with respect to the total amount of the decomposable material and the phase melt adhering material, and the cylinder supply unit is 30 ° C. and the measuring unit is 280 ° C. in the extruder. Under conditions of a gradient and a T-shaped die of 180 ° C., water is further added at a ratio of 4.5% by weight based on the total amount, and foam discharge is formed at a foaming ratio of 30 times.

  In the following, the embodiment of the present invention will be described in detail based on the production method of the present invention. FIG. 1 is an explanatory view of a material 1 used in the present invention. It is a sketch of the rice used mainly, and the reason why the rice is used as the degradable material 1A is that the use of the extrusion molding machine 2 makes the grain shape excellent in the ability to feed into the screw and water absorption. Heat-pressure kneading creates strong viscosity and plasticity due to starch gelatinization, creation of foamability due to water absorption, and low cost in the future and stable production and supply. Is to maintain the decomposability in the buffer material to be formed.

This rice can be used not only in domestic rice but also in foreign rice, and more preferably it is crushed 10A to about 1/2 to 1/4 as shown in FIG. And the rice of this degradable material 1A may use only rice or may mix cereals such as wheat, whey, fins and sorghum with a weight of 20 to 40%.
However, the use of starch such as rice or cereal as the raw material 1 results in the formation of a buffer material while the starch is pre-gelatinized by heating and pressurization and hydration. Not only for practical use but also extremely hard and inferior in buffering performance depending on the water conditions. On the other hand, if the water is sufficient, the foamed foam structure is thin and the compression elasticity of multiple products and products is insufficient. As a result, the result cannot be put to practical use.

In order to supplement the deficiency of the degradable material 1A, in the present invention, as shown in FIG. 2A, a phase melt adhesive 1B made of polyethylene or polypropylene resin is blended, and the blending ratio of the phase melt adhesive 1B is as follows. 25 to 45 parts are desired for 100 parts of the degradable material 1A.
This phase melt adhering material 1B is to be kneaded with the decomposable material 1A sufficiently while being heated and pressurized and kneaded using the extrusion molding machine 2 so as to be uniformly dispersed and containing heated steam.
The fact that polyethylene or polypropylene resin is selected as the phase melt adhesive 1B means that these resin materials are compatible with the heat and pressure conditions of the decomposable material 1A and are compatible with the decomposable material 1A, even at room temperature. In addition to creating flexibility, it is easy to form dense foam with a relatively thick foamed compartment structure when heated and foamed, and on the other hand, it is extremely inexpensive as a synthetic resin material and has the object of degradability due to inferior light resistance and weather resistance And, because of the compatibility, it is dispersed throughout, so that after the formation of foam, mutual fusion lamination can be easily performed by heating.

And since it aims at provision of the degradable buffer material 7 in this invention, it is necessary to aim at decomposition | disassembly loss after a practical use actively. For this purpose, as shown in FIG. 2B, the decomposition accelerator 1C is 0 with respect to the total amount of the decomposable material 1A and the phase melt adhesive 1B in order to decompose and lose the decomposable material 1A and the phase melt adhesive 1B. .1 to 5.0 by weight.
This decomposition accelerator 1C is decomposed and lost by hydrolysis, biodegradation action of microorganisms, etc., photolysis action by ultraviolet rays, infrared rays, etc., or by chemical action such as temperature change, external impact or acid alkali. Therefore, the decomposition accelerator 1C is preferably a mixture of one or more of the photodegradation agent 10C, the biodegradation agent 11C, and the chemical decomposition agent 12C.

  Specific examples of the photodegradation agent 10C include aliphatic or aromatic ketones as well as quinones, peroxides, hydroperoxides, azo compounds and the like, and biodegradation agents 11C include chitin, starch, Cellulose, glucose derivatives, poly-β-hydroxybutyrate, carbodiimides and the like, and further as a chemical decomposition agent 12C, a combination of a metal carboxylate and an aliphatic polyhydroxycarboxylic acid, a combination of a metal carboxylate and a filler, a transition metal complex Etc.

The decomposable material 1A, the phase melt adhesive 1B and the decomposition accelerator 1C thus selected are subjected to foam molding using an extruder 2 as shown in FIG.
That is, as shown in FIG. 3, the extrusion molding machine 2 has a decomposable material 1A, a phase melt adhering material 1B and a decomposing accelerator 1C supplied from the hopper 2A in the cylinder 3 equipped with heating means. A screw 4 that is kneaded and transferred while being heated and pressurized forward is formed to be rotatable by a drive motor 4A.
The extruder 2 kneads the aforementioned degradable material 1A, the phase melt adhesive 1B, and the decomposition accelerator 1C, and foams them with heated water vapor from the water. An injection hole 2B for injecting water 10D is provided. The cylinder 3 is provided with appropriate heating means, and once the cylinder 3 is brought into a molten state containing sufficient heating and pressurization and heated steam, the cylinder supply section 3A has a temperature of about 30 to 40 ° C. Further, the temperature is set at a temperature gradient of about 230 to 250 ° C. in the cylinder compression unit 3B and 260 to 290 ° C. in the cylinder metering unit 3C.

In this way, when foamed and discharged from the discharge slit 5A of the T-shaped die 5 provided at the tip in the molten state formed by heating and pressurizing, die swell (blowing phenomenon due to pressure drop due to discharge) occurs and melt fracture occurs. Occurrence of (fluctuation in wall thickness due to high-speed discharge) is caused.
Therefore, the T-type die 5 is set at a low temperature of about 170 to 190 ° C. to prevent die swell and melt fracture and to increase the viscosity to achieve stable foam discharge molding. It is formed.

  However, since the decomposable cushioning material 7 formed by foaming and discharging is at a high temperature and may not necessarily be formed with a predetermined thickness or width, the decomposable buffering material 7 formed by foaming and discharging is The cooling roll 6 having a variable take-up speed is cooled by adjusting the thickness and width of the decomposable buffer material 7 according to the discharge speed from the T-type die 5 and the take-up speed of the cooling roll 6, and is cooled. Is formed.

  FIG. 4 is a schematic view of the formed degradable cushioning material 7. On the front and back surfaces of the degradable cushioning material 7, a phase melt adhesive 1 B having excellent fluidity is formed in the cylinder 3 and T By flowing along the inner surface of the die 5, a slightly hardened outer coat layer 7 A is formed, and the outer cover layer 7 A is rapidly cooled and cooled after being discharged by heating and foaming along the discharge direction. A number of downspouts 7B are created along with the contraction in the width direction by the drawing. An enormous number of foamed compartments 7C are formed inside the envelope layer 7A.

  By the way, the decomposable cushioning material 7 of the present invention has a thickness and width cross-sectional area of the discharge slit 5A formed in the T-shaped die 5 of the extruder 2 and a discharge speed of the extruder 2 used for heat and pressure kneading. The discharge amount is also determined, but generally a screw diameter of about 65 m / m or 90 m / m is used, and the T-type die 5 in the case of the twin screw extruder 2 of 65 m / m is used. The discharge slit 5A has a thickness and width of 0.4 to 0.5 mm, about 200 to 250 mm, and a discharge speed of 100 to 150 mm / min. The substantial thickness of the cushioning material 7 is formed to be about 5 to 6 mm, and the production of the degradable cushioning material 7 having a thickness larger than this becomes difficult in terms of foam management.

  Thus, in the case of multiple products and products that require strong compressive elasticity during transportation and packaging, or precision equipment that requires high shock-absorbing properties, a buffer material with a thickness of about 30 to 100 mm may be used. Many.

Therefore, in the present invention, the decomposable buffer material 7 is fused and laminated to cope with such a demand, and FIG. 5 shows a fusion lamination method 8.
That is, the decomposable cushioning materials 7 and 7 that have been foamed and discharged in advance with a required thickness and width are delivered from the delivery rolls 8A and 8A, respectively, and the delivered degradable cushioning materials 7 and 7 face each other. The side surfaces are heated by an appropriate heating tool 8B, and the heated side surfaces are bonded and pressurized by a pressure roll 8C, so that the fusion-bonding decomposable buffer material 70 is laminated.
On the other hand, in addition to the fusion laminating method 8, the decomposable buffer material 7 is cut to a required length in advance, the two identical side surfaces of the degradable buffer material 7 are heated, and the heated side surfaces are joined to each other. It is formed even under pressure. In such a case, the heating temperature for fusing and laminating is generally about 120 to 180 ° C., although it depends on the material of the phase fusing material.

  Further, as shown in FIG. 6, the mounting portion 70 </ b> A is notched by a punching process or the like in a size and shape so that a product or a product to be transported or packed can be mounted on the degradable cushioning material 7 formed in advance. The same side surface of the cutout decomposable cushioning material 7 is heated, and the heated side surfaces are bonded and pressurized to each other, thereby forming a product or a product and forming a highly buffered fusion laminated degradable cushioning material 70. Is done.

Industrial applicability

  The cushioning material can be replaced by conventional cushioning materials according to the shape, thickness and degree of foaming according to the weight and shape of the products and goods to be transported and packed.

  It is a sketch of a degradable material.   It is a sketch of a phase melt adhesion material and a decomposition accelerator.   It is explanatory drawing of this invention manufacturing method.   It is explanatory drawing of this invention degradable shock absorbing material.   It is explanatory drawing of the fusion | melting lamination method.   It is explanatory drawing of a fusion | melting lamination | stacking decomposable buffer material.

DESCRIPTION OF SYMBOLS 1 Material used 1A Degradable material 10A Crushed degradable material 1B Phase melt-adhesive material 1C Decomposition accelerator 1D Hydrolysis 10C Photodegradation agent 11C Biodegradation agent 12C Chemical decomposition agent 2 Extruder 2A Hopper 2B Injection hole 3 Cylinder 3A Cylinder supply Part 3B Cylinder compression part 3C Cylinder metering part 4 Screw 4A Drive motor 5 T-type die 5A Discharge slit 6 Cooling roll 7 This invention decomposable buffer material 7A Outer layer 7B Vertical gutter 7C Foaming section 70 Fusion lamination decomposable buffer material 70A Mounting part 8 Fusing and laminating method 8A Supply roll 8B Heating tool 8C Pressure roll

Claims (6)

  100 parts of degradable material in which cereals are mixed at a rate of 20 to 40% by weight with respect to rice or rice, 25 to 45 parts of phase melt adhesive made of polyethylene or polypropylene resin, and photodegradation agent, biodegradation agent and chemistry A decomposition accelerator composed of a decomposing agent is blended in an amount of 0.1 to 5.0% by weight with respect to the entire decomposable material and the phase melt adhesive, and water is added in an amount of 3.0 to 6.0% by weight and extruded. After heating and pressure kneading, the foam width is 20 to 100 times with the required width and thickness, and the outer cover layer is formed on the front and back surfaces, and many vertical lines are created in the discharge direction. A degradable cushioning material characterized by comprising:   The degradable cushioning material according to claim 1, wherein the degradable material rice or cereal is crushed to about 1/2 to 1/4.   The photodegradation agent is selected from aliphatic or aromatic ketones, quinones, peroxides, hydroperoxides, and azo compounds, and the biodegradation agent is chitin, starch, cellulose, glucose derivatives, poly-β-hydroxybutyrate The decomposable buffer material according to claim 1, wherein the chemical decomposing agent is selected from metal carboxylates and aliphatic polyhydroxycarboxylic acids, combinations of metal carboxylates and fillers, and transition metal complexes.   A fusion-decomposable cushioning material characterized in that one side surface of a degradable buffer material is heated, and the heated side surface is subjected to opposing bonding and pressurization to be fused and laminated.   An extrusion machine provided with a required slit and a T-shaped die at its tip, and its cylinder temperature is 30 to 40 ° C. at the supply unit, 220 to 250 ° C. at the compression unit, 250 to 290 ° C. at the weighing unit, and The T-type die was maintained at 160 to 190 ° C., the decomposable material was 100 parts, the phase melt was 25 to 45 parts, and the decomposition accelerator was 0.1 to 5.0% by weight based on the total amount. The water is supplied from the hopper, and water is added in an amount of 3.0 to 6.0% by weight with respect to the total amount supplied from the front part of the hopper. A method for producing a degradable cushioning material, wherein foamable discharge molding is performed 20 to 100 times and a degradable cushioning material having a desired thickness and width is formed with a take-up speed of a cooling roll.   Two degradable cushioning materials formed in the required thickness and width are fused by fusing each supply side with a pressure roll while heating the opposing side surfaces while supplying them with the respective supply rolls. A method for producing a fusion-decomposable buffer material that is laminated.

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