JP2011069012A - Expandable sheet for molding, bulky molded product using the same and method for producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a thermoformable expandable sheet for molding, which produces a bulky deep drawing molded product having characteristics such as heat insulating properties, heat-retaining properties, and cushioning properties. <P>SOLUTION: The thermoformable expandable sheet for molding comprises wood pulp, polyolefin-based synthetic pulp, a thermoplastic synthetic fiber and expandable microcapsule particles as main components and is a multilayer sheet composed of a surface layer, a middle layer and a back layer. The content of wood pulp in the whole sheet for molding is not more than 20 mass%, the middle layer contains 10-50 mass% of expandable microcapsule particles based on 100 mass% of the fiber constituting the middle layer, the surface and the back layers do not contain the expandable microcapsule particles or contain the particles in an amount of 10 mass% or less which is smaller than that of the middle layer. The expandable microcapsule particles are dried in an unexpanded state in a drying step of paper machine and wound. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention has a foamability for deep-drawing molding capable of thermoforming that is excellent in processability and is composed mainly of wood pulp, polyolefin-based synthetic pulp, thermoplastic synthetic fiber, and microcapsule particles having the property of foaming by heat. The present invention relates to a molding sheet. This molding sheet becomes a bulky molded article after foaming. More specifically, the present invention relates to a bulky molded article which is used for applications such as a heat insulating material and an automobile interior material after deep drawing and has characteristics such as heat insulation, heat retention and cushioning.

  Conventionally, high density polymer sheets such as foamed polystyrene and foamed polyethylene are used for applications such as heat insulating materials and automotive interior materials, which have low density, and have excellent heat insulation and heat retention, moldability, workability, and cushioning. Because it is good and inexpensive, it is used in large quantities. On the other hand, due to recent demands for preventing environmental pollution, conversion to paper that does not generate pollutants even if it is naturally decomposed or burned is being promoted. However, with paperboard, it is not possible to perform deep drawing because the paperboard breaks or wrinkles appear on the paperboard when performing deep drawing, which requires large elongation during molding.

Softwood bleached kraft pulp, which is a composition mainly of thermoplastic synthetic fibers and filler, and the surface layer, middle layer, the basis weight of 250 g / m ² or more multilayer paper making consists of backing layer, excellent thermoforming processability A technique for possible molding paper has been proposed (see, for example, Patent Document 1). The purpose of the technique of Patent Document 1 is deep drawing suitability and molding holding property, excellent workability at the time of hot press molding, opacity, oil resistance, water resistance, and flatness of the flange part. Excellent top-sealability, and for heat-resistant applications, even if a film is applied, the wood pulp content is 51% by weight or more, so it is treated as paper by the Containers and Packaging Recycling Law, and provides molded products with high production efficiency. It is.

A method for producing a mixed paper having a density of 0.1 to 0.3 g / cm ³ by adding 3 to 20 parts by weight of expandable particles to 100 parts by weight of natural pulp, mixing and foaming during heat drying. It has been proposed (see, for example, Patent Document 2). The object of the technology of Patent Document 2 is to provide a foam particle mixed paper that is a low-density body and excellent in heat insulation, heat retention, impact resistance, cushioning properties, and the like.

Similar to Patent Document 2, the purpose is to provide a foam particle mixed paper having a low density and excellent heat insulation, heat retention, impact resistance, cushioning and the like. A method has been proposed in which 3 to 20 parts by weight of expandable particles are added to a fiber layer containing pulp and mixed to produce a mixed paper having a density of 0.1 to 0.3 g / cm ³ (for example, , See Patent Document 3).

JP 2006-022439 A JP-A-10-88495 JP 2000-34695 A

However, the technology of Patent Document 1 has a high density of about 0.5 g / cm ³ after deep drawing, and does not have properties such as heat insulation, heat retention and cushioning.

  Further, in the case of the technology of Patent Document 2, the formability is not sufficient, the mixed paper breaks when performing deep drawing molding that requires a large elongation at the time of molding, or the mixed paper is wrinkled, Deep drawing cannot be performed.

  Furthermore, even in the case of the mixed paper of the technique of Patent Document 3, when performing deep drawing that requires a large elongation, the mixed paper breaks or wrinkles on the mixed paper, and deep drawing is performed. I can't do it.

  An object of the present invention is to provide a thermoformable foamable molding sheet that makes it possible to produce a bulky deep-drawn molded product having properties such as heat insulating properties, heat retaining properties, cushioning properties, Further, this foamable molding sheet is produced by using a normal paper machine, and when the molding sheet is further foamed and deep drawing is performed at the same time to obtain a deep drawing bulky molded body or the molding sheet It is intended to provide a sheet for deep drawing which does not cause breakage when foamed is made into a bulky molded body and a deep drawn bulky molded body is obtained in a subsequent process.

  The present invention intends to solve the above-mentioned problems by repeatedly studying from the viewpoint of moldability and foamability. That is, the foamable molding sheet according to the present invention is a thermoformable foamable molding sheet composed mainly of wood pulp, polyolefin-based synthetic pulp, thermoplastic synthetic fiber, and expandable microcapsule particles. The molding sheet is a multilayer paper sheet composed of a surface layer, at least one middle layer and a back layer, the wood pulp content in the whole molding sheet is 20% by mass or less, and the middle layer is The foamable microcapsule particles are contained in an amount of 10 to 50% by mass with respect to 100% by mass of the fibers constituting the middle layer, and the surface layer and the back layer do not contain the foamable microcapsule particles or are smaller than the middle layer. And, containing up to 10% by mass, the foamable microcapsule particles are dried in an unfoamed state in a paper machine drying step, and wound up That.

  In the foamable molding sheet according to the present invention, the wood pulp is preferably a softwood bleached kraft pulp or a pulp mainly composed of softwood bleached kraft pulp. By using softwood bleached kraft pulp, there is an advantage that strength is obtained in the molded body.

  In the foamable molding sheet according to the present invention, it is preferable that the foamable microcapsule particles are expanded by heating to a diameter of 4 to 5 times and a volume of 60 times or more. A bulky molded product is easily obtained.

  In the foamable molding sheet according to the present invention, the surface layer and the back layer contain 1 to 10% by mass of the foamable microcapsule particles with respect to 100% by mass of the fibers constituting the surface layer and the back layer. And it is preferable that the sheet | seat for shaping | molding contains 5-40 mass% of said foamable microcapsule particles with respect to 100 mass% of fibers which comprise the whole sheet | seat for shaping | molding.

  The foamable molding sheet according to the present invention is preferably a multi-branched polyethylene synthetic pulp in which the polyolefin synthetic pulp has a melting point of 100 to 180 ° C. Excellent wet papermaking and excellent adhesion to wood pulp.

  The foamable molding sheet according to the present invention is a heat-fused polyester fiber in which the thermoplastic synthetic fiber has a melting point of 80 ° C. or higher, and may be contained in any of the surface layer, the middle layer, and the back layer. preferable. By containing the heat-fused polyester fiber, the elongation at the time of high-temperature molding increases, and the deep-drawn molded product does not break.

The bulky molded product according to the present invention is characterized in that the foamable molding sheet according to the present invention is heated and foamed to have a density of 0.1 g / cm ³ or less.

  The bulky molded product according to the present invention includes a form that is deep-drawn.

  The method for producing a bulky molded article according to the present invention is characterized in that the foamable molding sheet according to the present invention is heated and foamed by hot pressing at 100 to 220 ° C. to obtain a molded article.

The molding sheet of the present invention can be deep-drawn without breakage when deep drawing is performed by combining wood pulp, polyolefin synthetic pulp, thermoplastic synthetic fiber and expandable microcapsule particles. For example, since the thickness is 1 mm or less, wrinkles and folds do not occur during winding with a reel, and foaming unevenness does not occur. After foaming or after deep drawing, it becomes a bulky molded article with high functionality having properties such as heat insulation, heat retention and cushioning. Further, a low-density molded body having a density of 0.1 g / cm ³ or less that can be thermoformed, which could not be obtained conventionally, is also obtained.

  Next, the present invention will be described in detail with reference to embodiments, but the present invention is not construed as being limited to these descriptions. As long as the effect of the present invention is exhibited, the embodiment may be variously modified.

  The foamable molding sheet according to this embodiment is a thermoformable multi-layer sheet for molding which is mainly composed of wood pulp, polyolefin synthetic pulp, thermoplastic synthetic fiber, and foamable microcapsule particles. The multilayer paper sheet is composed of a surface layer, at least one middle layer and a back layer.

  The polyolefin synthetic pulp is preferably a polyolefin synthetic pulp made of polyethylene or polypropylene having multi-branched fiber properties suitable for a wet papermaking process using a general-purpose paper machine. Moreover, what is excellent in the adhesiveness by heat fusion with a wood pulp by the heating at the time of shaping | molding is preferable, and the polyolefin-type synthetic pulp whose melting | fusing point is 100-180 degreeC is cheap, and is used suitably. For example, what is marketed under the trade name SWP from Mitsui Chemicals, Inc. can be used, but the present invention is not limited to this SWP.

  The form of these polyolefin-based synthetic pulps may be short fibers or long fibers as long as they can be made by a paper machine, but the average fiber length is preferably in the range of 0.1 to 10 mm. If it is less than 0.1 mm, it is difficult to form a sheet substantially with little entanglement between fibers, and if it exceeds 10 mm, it may be difficult to make a uniform sheet by papermaking. A Canadian standard freeness (CSF) of 300 to 400 ml is preferred.

  As the wood pulp used in the present invention, wood bleached chemical pulp typified by N-BKP (conifer bleach bleached kraft pulp) is mainly used. If necessary, mechanical pulp such as L-BKP (hardwood bleached kraft pulp), GP (crushed wood pulp), TMP (thermomechanical pulp), BCTMP (bleached chemithermomechanical pulp), and used paper pulp can be appropriately blended. By using softwood bleached kraft pulp, there is an advantage that strength is obtained in the molded body.

  As thermoplastic synthetic fibers, polyolefins such as polyethylene and polypropylene, polyesters such as polyethylene terephthalate, synthetic fibers such as polyvinyl chloride, polyvinylidene chloride, polystyrene, polyacrylic acid ester, polyacrylonitrile, and mixtures thereof can be used. is there.

  As these thermoplastic synthetic fibers, when molding the obtained molding paper with a hot press, the melting point is too high to exhibit sufficient thermoplasticity at a general mold temperature, or the melting point is too low. It is preferable that the shape is difficult to maintain after mold forming, rapid cooling is required and molding processability is not deteriorated, and the melting point is preferably 80 to 200 ° C. More preferably, it is 100-140 degreeC.

  The content of the polyolefin-based synthetic pulp, thermoplastic synthetic fiber, and wood pulp may be different in the surface layer, the back layer, and the middle layer. The appropriate content is determined in consideration of the deep drawing suitability during thermoforming, the shape stability of the molded body, workability, and the like.

  The content of the polyolefin-based synthetic pulp is 60 to 90% by mass, preferably 80 to 90% by mass in the surface layer and the back layer. If it is less than 60% by mass, the deep drawability during thermoforming may be inferior. If it exceeds 90% by mass, paper-making properties may be inferior. In the middle layer, the content is 50 to 70% by mass, preferably 50 to 60% by mass. If it is less than 50% by mass, the deep drawability during thermoforming may be inferior. If it exceeds 70% by mass, the paper-making property may be inferior.

  The content of the thermoplastic synthetic fiber is 5 to 20% by mass, preferably 10 to 15% by mass in the surface layer and the back layer. When it exceeds 20 mass%, it becomes easy to heat-seal to a metal mold at the time of molding. If it is less than 5% by mass, the deep drawability during thermoforming may be inferior. In the middle layer, the content is 10 to 40% by mass, preferably 20 to 30% by mass. If it exceeds 40% by mass, the paper-making property may be inferior. If it is less than 10% by mass, the deep drawability during thermoforming may be inferior. The thermoplastic synthetic fiber is preferably blended with any of the surface layer, the middle layer, and the back layer, and the molded body has high strength.

  The wood pulp content in the entire molding sheet is 20% by mass or less, preferably 5 to 20% by mass. If it exceeds 20 mass%, the deep drawability during thermoforming may be inferior. The wood pulp content is 20% by mass or less, preferably 15% by mass or less in the surface layer and the back layer. If it exceeds 20 mass%, the deep drawability during thermoforming may be inferior. In the middle layer, it is 30% by mass or less, preferably 20% by mass or less. If it exceeds 30% by mass, the deep drawability during thermoforming may be inferior.

  The expandable microcapsule particles are heat-expandable microcapsules in which a low-boiling solvent is enclosed in the microcapsule particles, and preferably have a diameter of 4 to 5 times and a volume by heating for a short time at a temperature of 80 to 220 ° C. Are particles having an average diameter of 5 to 40 μm that expand 60 times or more. The upper limit of volume expansion is approximately 60 times or more. A bulky molded product is easily obtained. Low boiling solvents include volatile organic solvents such as isobutane, pentane, petroleum ether, hexane, low boiling halogenated hydrocarbons, and methylsilane, and heat composed of copolymers such as vinylidene chloride, acrylonitrile, acrylic esters, and methacrylic esters. Wrapped with plastic resin. As these expandable microcapsule particles, for example, Expandel DU and Expandel WUF (made in Sweden, distributor: Nihon Philite Co., Ltd.) can be used, but the present invention relates to these Expandel DU and Expandel WUF. It is not limited to.

  The content of the expandable microcapsule particles is 10 to 50% by mass, preferably 10 to 40% by mass, and more preferably 10 to 35% by mass with respect to 100% by mass of the fibers constituting the middle layer of the molding sheet. It is. If it is less than 10% by mass, the density becomes high, and the heat insulating property, the heat retaining property and the cushioning property are lowered. If it exceeds 50% by mass, it is not very suitable in terms of economy. Moreover, when mix | blending with a surface layer and a back layer, 1-10 mass% is mix | blended with respect to 100 mass% of fibers which comprise a surface layer and a back layer, The quantity is from content of the foamable microcapsule particle of a middle layer. Less. If the particle content of the surface layer and the back layer exceeds 10% by mass, wrinkles may occur in the molded body during deep drawing. It is preferable to use 5 to 40% by mass of expandable microcapsule particles with respect to 100% by mass of fibers constituting the entire molding sheet. When the content of the foamable microcapsule with respect to the entire fibers of the molding sheet is less than 5% by mass, the foaming amount is too small and sufficient heat insulation, heat retention and cushioning properties may not be achieved. If it exceeds 40% by mass, a sheet having sufficient strength may not be obtained.

  Here, the surface layer and the back layer contain 1 to 10% by mass of expandable microcapsule particles with respect to 100% by mass of the fibers constituting the surface layer and the back layer, and the molding sheet constitutes the entire molding sheet. When the foamable microcapsule particles are contained in an amount of 5 to 40% by mass with respect to 100% by mass of the fibers to be produced, it is preferable in that the amount of pulp is insufficient and the deep drawability at the time of thermoforming is not inferior.

  In the molding sheet, in addition to the pulp and foamable microcapsule particles, various yield improvers, paper strength improvers, Chemicals such as additive sizing agents, pitch control agents, and antifoaming agents can be used as appropriate.

  The forming sheet according to this embodiment is manufactured by a general multi-layer paper machine such as a long paper machine, a circular paper machine, or a combination machine of a long net and a circular net.

  In addition, starch, polyvinyl alcohol, a surface sizing agent, a fluorescent brightening agent, and the like can be applied to the surface of the sheet by a coating method such as a size press or a gate roll on the molding sheet of this embodiment.

The basis weight of the molding sheet of the present embodiment is not particularly limited, but is usually in the range of about 200 to 600 g / m ² .

  The drying method before the foaming treatment is not particularly limited, and it is necessary to dry at 70 ° C. or less where foamable microcapsule particles do not foam in a normal cylinder dryer or the like.

  The calendering of the molding sheet according to the present embodiment is performed for the purpose of processing the sheet to a thickness that can be taken up by a paper machine while making the sheet thickness uniform. The thickness is desirably 1 mm or less. For the calendar process, a machine calendar arranged on-machine, a super calendar, a gloss calendar, a brush calendar, a mat calendar, a soft calendar, and the like can be used, and the type of calendar is not particularly limited. In this way, the foamable microcapsule particles are dried in an unfoamed state in the paper machine drying step, and wound to obtain a wound product.

  As one of the foaming methods of the molding sheet of the present invention, there is a flat hot plate foaming post molding method. A forming sheet is set and foamed in a heated flat plate. After foaming, the mold is moved to a mold and molded. It is preferable that the temperature of a hot press shall be 100-220 degreeC.

  Another method of foaming is an in-mold foam molding method. This is a method in which a molding sheet is set in a heated mold and hot compression molding is performed. It is preferable that the temperature of a hot press shall be 100-220 degreeC.

  When deep drawing is performed, the deep-drawn formable paper is directly put into a deep-drawing machine and heated to form a bulky formed body and at the same time a deep-drawn formed body. Alternatively, the deep-drawn formable paper may be heated to form a bulky formed body, and then formed into a deep-drawn formed body in a later step.

  The present invention will be described in more detail with reference to examples, but the present invention is not limited thereto. In addition, unless otherwise indicated, the part in an example and addition% are the mass part and mass% in conversion of solid content.

Example 1
<Manufacture of sheet for molding>
As a surface layer and a back layer, N-BKP (CSF; 700 ml) / SWP (manufactured by Mitsui Chemicals, E620, multi-branched polyethylene-based synthetic pulp having a melting point of 135 ° C.) / Polyester fiber (manufactured by Unitika: Melty 4080) = 10 / 80/10% blended pulp was mixed, and rosin emulsion (manufactured by Seiko PMC, AL-120) as an internal sizing agent was 0.3% with respect to 100% by mass of fibers, and a sulfuric acid band was made into 100% by mass of fibers. On the other hand, 1% of cationized starch (manufactured by Nippon Shokuhin Kako Co., Ltd., Neotac 40T) was added at 1% with respect to 100% by mass of the fiber to obtain a raw material slurry. This raw material slurry was paper-made with a circular net paper machine with a target basis weight of the surface layer and the back layer of 80 g / m ² . As the middle layer, N-BKP (CSF; 700 ml) / SWP (Mitsui Chemicals, E620) / Polyester fiber (Melty 4080, melting point 110 ° C.) = 10/60/30% is blended to constitute this middle layer 20% by mass of EXPANSEL 009DU80 (made by Sweden, distributor: Nihon Philite Co., Ltd.) as expandable microcapsule particles is added to 100% by mass of the fibers to be processed, and rosin emulsion (Hoshimitsu PMC Co., Ltd.) is used as an internal sizing agent. Manufactured by AL-120) with respect to 100% by mass of fiber, sulfuric acid band with 1% with respect to 100% by mass of fiber, and cationized starch (manufactured by Nippon Shokuhin Kako Co., Ltd., Neotac 40T) with 100% by mass of fiber. 1% was added to make a raw material slurry. This raw material slurry is paper-made on a circular net paper machine with a target basis weight of three middle layers of 80 (medium layer total 240) g / m ² , and a target basis weight is obtained by combining five layers with the surface layer and the back layer. A sheet was made at 400 g / m ² , dried at 70 ° C. with a dryer, and wound up with a reel at a thickness of 1 mm to produce a molding sheet in which the foamable microcapsule particles were not foamed.

<Adjustment of foamed bulky molded product>
The molding sheet before foaming is cut into a size of 20 cm long × 20 cm wide, and the molding sheet is heated and foamed at a flat plate temperature of 160 ° C., a flat plate heating plate clearance of 7 mm, and a flat plate heating time of 3 minutes, A bulky molded product was obtained.

The basis weight, thickness, and density in the examples of the present invention were evaluated visually for the presence or absence of foaming unevenness and mold formability according to the following JIS.
a. Basis weight: JIS P 8124: 1998
b. Thickness and density: JIS P 8118: 1998
c. Foaming unevenness: Evaluated visually. The evaluation criteria are as follows.
○: No foaming unevenness and practical level.
Δ: Some foaming unevenness is not practical.
X: There is foaming unevenness and it cannot endure practical use.
d. Deep drawability: After heating and foaming the raw material at a flat plate temperature of 160 ° C., flat plate plate clearance of 7 mm, and flat plate heating time of 3 minutes, it is immediately transferred to a 150 ° C. mold (clearance 5 mm) and free forming (20 Second), and evaluated the comprehensiveness of deep drawing suitability such as material destruction and the presence or absence of wrinkles and the shape stability of the bulky molded product. The evaluation criteria are as follows.
○: Good and practical level.
Δ: Slightly inferior and not practical.
X: Inferior and not practical.

(Example 2)
As a middle layer of Example 1, N-BKP (CSF; 700 ml) / SWP (manufactured by Mitsui Chemicals, E620, multi-branched polyethylene-based synthetic pulp having a melting point of 135 ° C.) / Polyester fiber (manufactured by Unitika: Melty 4080) = 20 Except for blending at 60/20%, in the same manner as in Example 1, a sheet is made at a basis weight of 400 g / m ² by 5 layers, dried at 70 ° C. with a dryer, and wound up with a reel. A molding sheet in which the foamable microcapsule particles were not foamed was obtained. Further, a bulky molded body obtained by foaming expandable microcapsule particles was obtained by hot pressing in the same manner as in Example 1.

(Example 3)
As a middle layer of Example 1, N-BKP (CSF; 700 ml) / SWP (manufactured by Mitsui Chemicals, E620, polybranched polyethylene-based synthetic pulp having a melting point of 135 ° C.) / Polyester fiber (manufactured by Unitika: Melty 4080) = 30 Except for blending at 60/60%, a sheet was made at a basis weight of 400 g / m ² by 5 layers as in Example 1 and dried at 70 ° C. with a dryer and wound up with a reel. A molding sheet in which the foamable microcapsule particles were not foamed was obtained. Further, a bulky molded body obtained by foaming expandable microcapsule particles was obtained by hot pressing in the same manner as in Example 1.

Example 4
As a surface layer and a back layer of Example 1, N-BKP (CSF; 700 ml) / SWP (manufactured by Mitsui Chemicals, E620, multi-branched polyethylene synthetic pulp having a melting point of 135 ° C.) / Polyester fiber (manufactured by Unitika: Melty 4080) ) = 15/80/5% Except for blending, a sheet was made at a basis weight of 400 g / m ² by 5 layers as in Example 1, and dried at 70 ° C. with a dryer. To obtain a molding sheet in which the foamable microcapsule particles were not foamed. Further, a bulky molded body obtained by foaming expandable microcapsule particles was obtained by hot pressing in the same manner as in Example 1.

(Example 5)
As a surface layer and a back layer of Example 1, N-BKP (CSF; 700 ml) / SWP (manufactured by Mitsui Chemicals, E620, multi-branched polyethylene synthetic pulp having a melting point of 135 ° C.) / Polyester fiber (manufactured by Unitika: Melty 4080) ) = 0/80/20% Except having been blended, a sheet was made at a basis weight of 400 g / m ² by 5 layers as in Example 1 and dried at 70 ° C. with a dryer. To obtain a molding sheet in which the foamable microcapsule particles were not foamed. Further, a bulky molded body obtained by foaming expandable microcapsule particles was obtained by hot pressing in the same manner as in Example 1.

(Example 6)
As a surface layer and a back layer of Example 1, N-BKP (CSF; 700 ml) / SWP (manufactured by Mitsui Chemicals, E620, multi-branched polyethylene synthetic pulp having a melting point of 135 ° C.) / Polyester fiber (manufactured by Unitika: Melty 4080) ) = 20/70/10% Except for blending, a sheet was made at a basis weight of 400 g / m ² by 5 layers as in Example 1, and dried at 70 ° C. with a dryer. To obtain a molding sheet in which the foamable microcapsule particles were not foamed. Further, a bulky molded body obtained by foaming expandable microcapsule particles was obtained by hot pressing in the same manner as in Example 1.

(Example 7)
As a surface layer and a back layer of Example 1, N-BKP (CSF; 700 ml) / SWP (manufactured by Mitsui Chemicals, E620, multi-branched polyethylene synthetic pulp having a melting point of 135 ° C.) / Polyester fiber (manufactured by Unitika: Melty 4080) ) = 0/90/10%, except that it was blended in the same manner as in Example 1, a sheet was made at a basis weight of 400 g / m ² by 5 layers, and dried at 70 ° C. with a dryer. To obtain a molding sheet in which the foamable microcapsule particles were not foamed. Further, a bulky molded body having foamable micro properties was obtained by hot pressing in the same manner as in Example 1.

(Example 8)
8% by mass of EXPANSEL 009DU80 (made in Sweden, distributor: Nihon Philite Co., Ltd.) is added as expandable microcapsule particles to 100% by mass of the fibers constituting the surface layer and the back layer of Example 1, and the middle layer is the middle layer 5 in the same manner as in Example 1 except that 20% by mass of EXPANSEL 009DU80 (manufactured by Sweden, trader: Nihon Philite Co., Ltd.) was added as expandable microcapsule particles to 100% by mass of the fibers constituting Sheets were made by layering together at a basis weight of 400 g / m ² , dried at 70 ° C. with a dryer, and wound up with a reel to obtain a molding sheet in which foamable microcapsule particles were not foamed. Further, a bulky molded body obtained by foaming expandable microcapsule particles was obtained by hot pressing in the same manner as in Example 1.

Example 9
The target basis weight of the surface layer and the back layer is 30 g / m ² , the target basis weight of the middle layer is 340 g / m ² (the target basis weight of the three middle layers is 113.3 g / m ² ), and the fibers 100 constituting the middle layer A bulky molded body was obtained in the same manner as in Example 1 except that the microcapsules were 50% based on mass%.

(Example 10)
The target basis weight of the surface layer and the back layer is 80 g / m ² , the target basis weight of the middle layer is 240 g / m ² (the target basis weight of each of the three middle layers is 80 g / m ² ), and 100% by mass of fibers constituting the middle layer A bulky molded body was obtained in the same manner as in Example 1, except that the example was 10% of microcapsules.

(Example 11)
When the total amount (100%) of the wood pulp used in the surface layer, the back layer and the middle layer was N-BKP (CSF; 700 ml), N-BKP (CSF; 700 ml) / L-BKP (CSF; 700 ml) = 70 A bulky molded body was obtained in the same manner as in Example 1 except that it was replaced with wood pulp at a ratio of% / 30% and the microcapsule was 27% with respect to 100% by mass of the fibers constituting the middle layer.

[Comparative Example 1]
As a surface layer and a back layer of Example 1, N-BKP (CSF; 700 ml) / SWP (manufactured by Mitsui Chemicals, E620 melting point 135 ° C. multi-branched polyethylene-based synthetic pulp) = 80/20% blended, N-BKP (CSF; 700 ml) / SWP (Mitsui Chemicals, E620, multi-branched polyethylene-based synthetic pulp with a melting point of 135 ° C.) = 50/50% blended, except that 0% thermoplastic synthetic fiber was blended In the same manner as in Example 1, a sheet was made at a basis weight of 400 g / m ² by 5-layer making, dried at 70 ° C. with a dryer, wound with a reel, and expanded microcapsule particles were expanded. An unmolded molding sheet was obtained. Further, a bulky molded body obtained by foaming expandable microcapsule particles was obtained by hot pressing in the same manner as in Example 1.

[Comparative Example 2]
As a surface layer and a back layer of Example 1, N-BKP (CSF; 700 ml) / SWP (manufactured by Mitsui Chemicals, E620, multi-branched polyethylene-based synthetic pulp having a melting point of 135 ° C.) = 20/80% is blended, and as a middle layer N-BKP (CSF; 700 ml) / SWP (manufactured by Mitsui Chemicals, E620, multi-branched polyethylene-based synthetic pulp having a melting point of 135 ° C.) = 50/50%, and 0% thermoplastic synthetic fiber Except for the above, in the same manner as in Example 1, a sheet was made with a basis weight of 400 g / m ² by five-layer making, dried at 70 ° C. with a dryer, wound on a reel, and expanded microcapsule particles were obtained. An unfoamed molding sheet was obtained. Further, a bulky molded body obtained by foaming expandable microcapsule particles was obtained by hot pressing in the same manner as in Example 1.

[Comparative Example 3]
As the middle layer of Comparative Example 1, N-BKP (CSF; 700 ml) / SWP (Mitsui Chemicals, E620, multi-branched polyethylene-based synthetic pulp having a melting point of 135 ° C.) = 40/60% is blended, and thermoplastic synthetic fiber is blended. In the same manner as in Comparative Example 1, except that 0% was added, a sheet was made at a basis weight of 400 g / m ² by 5 layers, dried at 70 ° C. with a dryer, and wound up with a reel. A molding sheet in which the foamable microcapsule particles were not foamed was obtained. Further, a bulky molded body obtained by foaming expandable microcapsule particles was obtained by hot pressing in the same manner as in Example 1.

[Comparative Example 4]
As a surface layer and a back layer of Comparative Example 2, N-BKP (CSF; 700 ml) / SWP (manufactured by Mitsui Chemicals, multi-branched polyethylene synthetic pulp having an E620 melting point of 135 ° C.) / Polyester fiber (manufactured by Unitika: Melty 4080) = Same as Comparative Example 2 except that 10/80/10% was blended, a sheet was made at a basis weight of 400 g / m ² by 5 layers, and dried at 70 ° C. with a dryer and reeled. The sheet | seat for shaping | molding which did not wind up and foamable microcapsule particle | grains was obtained. Further, a bulky molded body obtained by foaming expandable microcapsule particles was obtained by hot pressing in the same manner as in Example 1.

[Comparative Example 5]
As a middle layer of Comparative Example 1, N-BKP (CSF; 700 ml) / SWP (manufactured by Mitsui Chemicals, E620, multi-branched polyethylene-based synthetic pulp having a melting point of 135 ° C.) / Polyester fiber (manufactured by Unitika: Melty 4080) = 50 A sheet was made at a basis weight of 400 g / m ² by 5 layers as in Comparative Example 1 except that / 40/10% was blended, dried at 70 ° C. with a dryer, and wound up with a reel. A molding sheet in which the foamable microcapsule particles were not foamed was obtained. Further, a bulky molded body obtained by foaming expandable microcapsule particles was obtained by hot pressing in the same manner as in Example 1.

[Comparative Example 6]
As the middle layer of Comparative Example 2, N-BKP (CSF; 700 ml) / SWP (Mitsui Chemicals, E620, multi-branched polyethylene synthetic pulp having a melting point of 135 ° C.) = 40/60% was blended, and thermoplastic synthetic fiber was blended. In the same manner as in Comparative Example 2, except that 0% was added, a sheet was made at a basis weight of 400 g / m ² by 5 layers, dried at 70 ° C. with a dryer, and wound up with a reel. A molding sheet in which the foamable microcapsule particles were not foamed was obtained. Further, a bulky molded body obtained by foaming expandable microcapsule particles was obtained by hot pressing in the same manner as in Example 1.

[Comparative Example 7]
A bulky molded body was obtained in the same manner as in Comparative Example 1 except that the foaming microcapsule particle-containing mass% relative to 100 mass% of the fibers constituting the middle layer was 55%.

[Comparative Example 8]
A bulky molded body was obtained in the same manner as in Comparative Example 1 except that the foaming microcapsule particle content mass% with respect to 100 mass% of the fibers constituting the middle layer was changed to 5%.

[Comparative Example 9]
A bulky molded body was obtained in the same manner as in Comparative Example 1 except that the foaming microcapsule particle-containing mass% relative to 100 mass% of the fibers constituting the front and back layers was 11%.

  These results are shown in Table 1.

As is clear from the results in Table 1, the molding sheet of this example is formed by deep drawing by a configuration in which wood pulp, polyolefin synthetic pulp, thermoplastic synthetic fiber, and expandable microcapsule particles are combined. Can be deep-drawn without breakage and has a thickness of 1 mm or less, so there is no wrinkle or crease in winding with the reel, no foaming unevenness, and heat insulation after foaming or after deep-drawing In addition, it has become possible to provide a bulky molded article having a low density of 0.1 g / cm ³ or less, which has high functionality, such as heat retaining properties and cushioning properties, and which has not been able to be thermoformed.

Specifically, when the content of the polyester fiber in the surface layer, the back layer, and the middle layer in Comparative Example 1 is 0%, the deep drawability after foaming is insufficient. Moreover, in the comparative example 2, even if it raises the SWP content rate of the surface layer and the back layer of the comparative example 1 from 20% to 80%, the deep drawability after foaming is insufficient. Further, in Comparative Example 3, even if the SWP content in the middle layer of Comparative Example 2 is increased from 50% to 60%, the deep drawability after foaming is insufficient. In Comparative Example 4, even when 10% of polyester fiber is blended in the surface layer and back layer of Comparative Example 2 instead of NBKP, the deep drawability after foaming is insufficient. In Comparative Example 5, even if 10% of polyester fiber is blended in the middle layer of Comparative Example 1 instead of SWP, the deep drawability after foaming is insufficient. In Comparative Example 6, even if the SWP content in the middle layer of Comparative Example 2 is increased from 50% to 60%, the deep drawability after foaming is insufficient. In Comparative Example 7, even if the foaming agent content in the middle layer of Comparative Example 1 is increased from 20% to 55%, the deep drawability after foaming is insufficient. In Comparative Example 8, even if the foaming agent content in the middle layer of Comparative Example 1 is lowered from 20% to 5%, the deep drawability after foaming is insufficient. In Comparative Example 9, even if the foaming agent content in the front and back layers of Comparative Example 1 is increased from 0% to 11%, the deep drawability after foaming is insufficient.

Claims (9)

A thermoforming foamable molding sheet composed mainly of wood pulp, polyolefin-based synthetic pulp, thermoplastic synthetic fiber and expandable microcapsule particles,
The molding sheet is a multilayer paper sheet composed of a surface layer, at least one middle layer and a back layer,
The content of wood pulp in the entire molding sheet is 20% by mass or less,
The middle layer contains 10 to 50% by mass of the expandable microcapsule particles with respect to 100% by mass of the fibers constituting the middle layer,
The surface layer and the back layer do not contain the foamable microcapsule particles or less than the middle layer, and contain up to 10% by mass,
A foamable molding sheet, wherein the foamable microcapsule particles are dried and wound in an unfoamed state in a paper machine drying process.   2. The foamable molding sheet according to claim 1, wherein the wood pulp is a softwood bleached kraft pulp or a pulp mainly composed of a softwood bleached kraft pulp.   The foamable molding sheet according to claim 1 or 2, wherein the foamable microcapsule particles are expanded by heating to a diameter of 4 to 5 times and a volume of 60 times or more.   The surface layer and the back layer contain 1 to 10% by mass of the foamable microcapsule particles with respect to 100% by mass of the fibers constituting the surface layer and the back layer, and the molding sheet is the entire molding sheet. The foamable molding sheet according to claim 1, wherein the foamable microcapsule particles are contained in an amount of 5 to 40% by mass with respect to 100% by mass of the fibers constituting the glass.   The foamable molding sheet according to claim 1, 2, 3, or 4, wherein the polyolefin-based synthetic pulp is a multi-branched polyethylene-based synthetic pulp having a melting point of 100 to 180 ° C.   The thermoplastic synthetic fiber is a heat-fused polyester fiber having a melting point of 80 ° C or higher, and is contained in any of the surface layer, the middle layer, and the back layer. Or 5. The foamable molding sheet according to 5. A bulky molded article, wherein the foamable molding sheet according to any one of claims 1 to 6 is heated and foamed to have a density of 0.1 g / cm ³ or less.   The bulky molded article according to claim 7, which is deep drawn. A foamable molding sheet according to any one of claims 1 to 6 is heated by a hot press at 100 to 220 ° C and foamed to obtain a molded body. Method.