JP2012102305A - Inorganic matter-containing synthetic resin foam, and method for producing the same - Google Patents

Inorganic matter-containing synthetic resin foam, and method for producing the same Download PDF

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JP2012102305A
JP2012102305A JP2010261765A JP2010261765A JP2012102305A JP 2012102305 A JP2012102305 A JP 2012102305A JP 2010261765 A JP2010261765 A JP 2010261765A JP 2010261765 A JP2010261765 A JP 2010261765A JP 2012102305 A JP2012102305 A JP 2012102305A
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resin foam
synthetic resin
silica
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Hironori Hatano
博則 秦野
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Abstract

PROBLEM TO BE SOLVED: To provide such an inorganic matter-containing synthetic resin foam that silica-based inorganic matter is filled in the air-cellular structure of at least part of the surface of the synthetic resin foam, and to provide a method for the foam.SOLUTION: The inorganic matter-containing synthetic resin foam in which silica-based inorganic matter is filled in the air-cellular structure of at least part of the surface of the synthetic resin foam, is provided. The method for producing the foam is also provided, being characterized by including: the step (A) of putting a water-soluble silicate solution into the air-cellular structure of the surface of the synthetic resin foam; and the step (B) of putting such a coagulant as to form the silica-based inorganic matter by reacting with the water-soluble silicate into the air-cellular structure; wherein either one of the steps (A) and (B) is conducted first, followed by the other step, or both of the steps (A) and (B) are conducted simultaneously; thus forming and depositing the silica-based inorganic matter in the air-cellular structure to obtain the objective foam.

Description

本発明は、無機物含有合成樹脂発泡体とその製造方法に関する。  The present invention relates to an inorganic substance-containing synthetic resin foam and a method for producing the same.

従来より、ポリスチレン系樹脂発泡成形体などの合成樹脂発泡体は、食品トレーなどの容器類、緩衝材、断熱材、建築用資材、車両用構造部材などの各種分野で汎用されている。さらに、他の使用形態として、合成樹脂発泡体の気泡内部に各種の材料を入れ、特有の機能を持たせた発泡体が提案されている(例えば、特許文献1〜3参照。)。  Conventionally, synthetic resin foams such as polystyrene-based resin foam moldings have been widely used in various fields such as containers such as food trays, cushioning materials, heat insulating materials, building materials, and vehicle structural members. Furthermore, as other usage forms, foams in which various materials are put inside the bubbles of the synthetic resin foam to have specific functions have been proposed (for example, see Patent Documents 1 to 3).

特許文献1には、発泡体材料を含む連続気泡の微小気泡発泡体であって、70マイクロメートル以下の平均気泡径を有し、排気されており、赤外線減衰剤(カーボンブラック、グラファイト)を含み、この赤外線減衰剤の量が、この赤外線減衰剤を含まない対応する発泡体と比べて発泡体の熱伝導率を低下させるに十分な量であることを特徴とする発泡体が開示されている。
特許文献2には、平均空気通過時間が10秒以下で且つ長さ25mmの直線上にある平均気泡数が6〜50個であると共に平均破膜面積割合が20〜80%である連続気泡ポリオレフィン系樹脂発泡体の連続気泡表面に、複合金属水酸化物からなるリン吸着剤を付着一体化させてなるリン吸着フィルターにおける連続気泡ポリオレフィン系樹脂発泡体の連続気泡内に、リン成分を含有する水を流通させてリン吸着剤にリン成分を吸着させた後、このリン吸着フィルターのリン吸着剤をリン離脱剤で処理して、リン吸着剤からリン成分を分離、回収すると共にリン吸着剤を再生することを特徴とする水中からのリン成分の回収及びリン吸着フィルターの再生方法が開示されている。
特許文献3には、平均空気通過時間が10秒以下で且つ長さ25mmの直線上にある平均気泡数が6〜50個であると共に平均破膜面積割合が20〜80%である連続気泡ポリオレフィン系樹脂発泡体の連続気泡表面に、リン吸着剤をリン成分を吸着可能な状態に付着一体化させてなることを特徴とするリン吸着フィルターが開示されている。
Patent Document 1 discloses an open-celled microbubble foam containing a foam material, having an average cell diameter of 70 micrometers or less, exhausted, and containing an infrared attenuating agent (carbon black, graphite). A foam is disclosed wherein the amount of the infrared attenuating agent is sufficient to reduce the thermal conductivity of the foam compared to a corresponding foam that does not contain the infrared attenuating agent. .
Patent Document 2 discloses an open-cell polyolefin having an average air passage time of 10 seconds or less and an average number of bubbles on a straight line having a length of 25 mm of 6 to 50 and an average membrane breaking area ratio of 20 to 80%. Water containing a phosphorus component in the open cell of the open cell polyolefin resin foam in a phosphorus adsorption filter in which a phosphorus adsorbent made of a composite metal hydroxide is adhered and integrated on the open cell surface of the resin foam The phosphorus adsorbent is adsorbed to the phosphorus adsorbent, and then the phosphorus adsorbent of this phosphorus adsorption filter is treated with the phosphorus release agent to separate and recover the phosphorus component from the phosphorus adsorbent and regenerate the phosphorus adsorbent A method for recovering a phosphorus component from water and regenerating a phosphorus adsorption filter is disclosed.
Patent Document 3 discloses an open-cell polyolefin having an average air passage time of 10 seconds or less and an average number of bubbles on a straight line having a length of 25 mm of 6 to 50 and an average membrane breaking area ratio of 20 to 80%. A phosphorus adsorption filter is disclosed in which a phosphorus adsorbent is attached and integrated on a surface of an open cell of a resin foam so that a phosphorus component can be adsorbed.

特表平11−504359号公報  Japanese National Patent Publication No. 11-504359 特開2004−121895号公報  JP 2004-121895 A 特開2004−121940号公報  JP 2004-121940 A

ポリスチレン系樹脂発泡体などの合成樹脂発泡体は、連続気泡型よりも独立気泡型である方が機械的強度や断熱性に優れたものが得られることから、独立気泡型の合成樹脂発泡体の表面の気泡構造内に各種の無機物が充填された無機物含有発泡体の提供が望まれる。
また、前記無機物含有合成樹脂発泡体において、気泡構造内に充填する無機物をシリカ系無機物とすれば、表面硬度の向上、接着性能向上、吸湿・脱臭効果、上品で堅牢な色調付与などの様々な効果を得ることが期待できる。
Synthetic resin foams such as polystyrene-based resin foams are more excellent in mechanical strength and heat insulation than closed cell types. It is desired to provide an inorganic material-containing foam in which various inorganic materials are filled in the surface cell structure.
In addition, in the inorganic material-containing synthetic resin foam, if the inorganic material to be filled in the cell structure is a silica-based inorganic material, various improvements such as improved surface hardness, improved adhesion performance, moisture absorption / deodorization effect, elegant and robust color tone, etc. Expected to be effective.

しかしながら、合成樹脂発泡体の表面の気泡構造内にシリカ系無機物が充填された無機物含有合成樹脂発泡体は、これまで提供されていない。
本発明は、合成樹脂発泡体の少なくとも一部の表面の気泡構造内にシリカ系無機物が充填された無機物含有合成樹脂発泡体とその製造方法の提供を課題とする。
However, an inorganic-containing synthetic resin foam in which a silica-based inorganic substance is filled in the cell structure on the surface of the synthetic resin foam has not been provided so far.
An object of the present invention is to provide an inorganic substance-containing synthetic resin foam in which a silica-based inorganic substance is filled in a cell structure on at least a part of the surface of the synthetic resin foam, and a method for producing the same.

前記課題を達成するため、本発明は、合成樹脂発泡体の少なくとも一部の表面の気泡構造内にシリカ系無機物が充填されてなる無機物含有合成樹脂発泡体を提供する。  To achieve the above object, the present invention provides an inorganic-containing synthetic resin foam in which a silica-based inorganic substance is filled in a cell structure on at least a part of the surface of a synthetic resin foam.

本発明の無機物含有合成樹脂発泡体において、前記シリカ系無機物が、シリカ、ケイ酸カルシウム、ケイ酸マグネシウム、ケイ酸アルミニウム、アルミノケイ酸塩のうちの1種又は2種以上の混合物を含むものであることが好ましい。  In the inorganic material-containing synthetic resin foam of the present invention, the silica-based inorganic material may contain one or a mixture of two or more of silica, calcium silicate, magnesium silicate, aluminum silicate, and aluminosilicate. preferable.

本発明の無機物含有合成樹脂発泡体において、前記シリカ系無機物が遷移金属元素の中から選択される1種又は2種以上の金属元素を含み、着色した構成とすることもできる。  In the inorganic material-containing synthetic resin foam of the present invention, the silica-based inorganic material may include one or more metal elements selected from transition metal elements and may be colored.

本発明の無機物含有合成樹脂発泡体において、前記シリカ系無機物が、多孔質シリカである構成とすることもできる。  In the inorganic material-containing synthetic resin foam of the present invention, the silica-based inorganic material may be porous silica.

本発明の無機物含有合成樹脂発泡体において、前記シリカ系無機物が、二酸化チタンを含む構成とすることもできる。  In the inorganic substance-containing synthetic resin foam of the present invention, the silica-based inorganic substance may include titanium dioxide.

本発明の無機物含有合成樹脂発泡体において、前記シリカ系無機物が、含有成分の異なる2層以上のシリカ系無機物層からなる構成とすることもできる。  In the inorganic material-containing synthetic resin foam of the present invention, the silica-based inorganic material may be composed of two or more silica-based inorganic layers having different components.

本発明の無機物含有合成樹脂発泡体において、前記合成樹脂発泡体が、ポリスチレン系樹脂発泡体、ポリエチレン系樹脂発泡体、ポリプロピレン系樹脂発泡体、ポリエステル系樹脂発泡体、発泡ポリウレタンからなる群から選択されるものであることが好ましい。  In the inorganic material-containing synthetic resin foam of the present invention, the synthetic resin foam is selected from the group consisting of a polystyrene resin foam, a polyethylene resin foam, a polypropylene resin foam, a polyester resin foam, and a polyurethane foam. It is preferable that it is a thing.

本発明の無機物含有合成樹脂発泡体において、前記合成樹脂発泡体の表面に合成樹脂層が積層された構造とすることもできる。  The inorganic substance-containing synthetic resin foam of the present invention may have a structure in which a synthetic resin layer is laminated on the surface of the synthetic resin foam.

本発明の無機物含有合成樹脂発泡体において、前記合成樹脂発泡体に穴が設けられ、該穴内にシリカ系無機物が充填された構成とすることもできる。  In the inorganic material-containing synthetic resin foam of the present invention, a hole may be provided in the synthetic resin foam, and a silica-based inorganic material may be filled in the hole.

また本発明は、合成樹脂発泡体の表面の気泡構造内に水溶性ケイ酸塩の溶液を入れる工程(A)と、前記気泡構造内に前記水溶性ケイ酸塩と反応してシリカ系無機物を生成する凝固剤を入れる工程(B)とを有し、前記工程(A)と工程(B)のいずれか一方を先に、いずれか他方を後に行うか又は両方を同時に行って、前記気泡構造内にシリカ系無機物を形成し、それを気泡構造内に沈着させて無機物含有合成樹脂発泡体を得ることを特徴とする無機物含有合成樹脂発泡体の製造方法を提供する。  The present invention also includes a step (A) of placing a water-soluble silicate solution in the cell structure on the surface of the synthetic resin foam, and reacting with the water-soluble silicate in the cell structure to form a silica-based inorganic substance. A step (B) of adding a coagulant to be produced, and performing either one of the step (A) and the step (B) first, performing the other later or both at the same time, There is provided a method for producing an inorganic material-containing synthetic resin foam, wherein a silica-based inorganic material is formed therein and deposited in a cell structure to obtain an inorganic material-containing synthetic resin foam.

本発明の無機物含有合成樹脂発泡体の製造方法において、前記凝固剤が、酸又は酸性化合物、Ca含有化合物、Mg含有化合物、Al含有化合物からなる群から選択される1種又は2種以上の混合物を含むものであることが好ましい。  In the method for producing an inorganic-containing synthetic resin foam according to the present invention, the coagulant is one or a mixture of two or more selected from the group consisting of an acid or an acidic compound, a Ca-containing compound, a Mg-containing compound, and an Al-containing compound. It is preferable that it contains.

本発明の無機物含有合成樹脂発泡体の製造方法において、前記水溶性ケイ酸塩が、ケイ酸ナトリウム、ケイ酸二ナトリウム、ケイ酸二ナトリウム五水和物、ケイ酸カリウムからなる群から選択される1種又は2種以上の混合物を含むものであることが好ましい。  In the method for producing an inorganic substance-containing synthetic resin foam of the present invention, the water-soluble silicate is selected from the group consisting of sodium silicate, disodium silicate, disodium silicate pentahydrate, and potassium silicate. It is preferable to include one or a mixture of two or more.

本発明の無機物含有合成樹脂発泡体の製造方法において、前記シリカ系無機物が、シリカ、ケイ酸カルシウム、ケイ酸マグネシウム、ケイ酸アルミニウム、アルミノケイ酸塩のうちの1種又は2種以上の混合物を含むものであることが好ましい。  In the method for producing an inorganic material-containing synthetic resin foam according to the present invention, the silica-based inorganic material contains one or a mixture of two or more of silica, calcium silicate, magnesium silicate, aluminum silicate, and aluminosilicate. It is preferable.

本発明の無機物含有合成樹脂発泡体の製造方法において、前記シリカ系無機物が遷移金属元素の中から選択される1種又は2種以上の金属元素を含み、着色した構成とすることもできる。  In the method for producing an inorganic substance-containing synthetic resin foam according to the present invention, the silica-based inorganic substance may include one or two or more metal elements selected from transition metal elements and may be colored.

本発明の無機物含有合成樹脂発泡体の製造方法において、前記シリカ系無機物が、多孔質シリカである構成とすることもできる。  In the method for producing an inorganic substance-containing synthetic resin foam of the present invention, the silica-based inorganic substance may be porous silica.

本発明の無機物含有合成樹脂発泡体の製造方法において、前記シリカ系無機物が、二酸化チタンを含むものである構成とすることもできる。  In the method for producing an inorganic substance-containing synthetic resin foam according to the present invention, the silica-based inorganic substance may contain titanium dioxide.

本発明の無機物含有合成樹脂発泡体の製造方法において、前記工程(A)及び工程(B)を複数回行い、前記気泡構造内に同一成分の又は含有成分の異なる2層以上のシリカ系無機物層を形成する構成とすることもできる。  In the method for producing an inorganic material-containing synthetic resin foam of the present invention, the step (A) and the step (B) are performed a plurality of times, and two or more silica-based inorganic layers having the same component or different contained components in the cell structure. It can also be set as the structure which forms.

本発明の無機物含有合成樹脂発泡体の製造方法において、前記合成樹脂発泡体が、ポリスチレン系樹脂発泡体、ポリエチレン系樹脂発泡体、ポリプロピレン系樹脂発泡体、ポリエステル系樹脂発泡体、発泡ポリウレタンからなる群から選択されるものであることが好ましい。  In the method for producing an inorganic substance-containing synthetic resin foam according to the present invention, the synthetic resin foam comprises a polystyrene resin foam, a polyethylene resin foam, a polypropylene resin foam, a polyester resin foam, and a polyurethane foam. It is preferable that it is selected from.

本発明の無機物含有合成樹脂発泡体の製造方法では、前記工程(A)において、前記水溶性ケイ酸塩の溶液がケイ酸ゲルを含むものである構成とすることもできる。  In the manufacturing method of the inorganic substance containing synthetic resin foam of this invention, it can also be set as the structure which the solution of the said water-soluble silicate contains a silicate gel in the said process (A).

本発明の無機物含有合成樹脂発泡体の製造方法では、前記工程(A)と工程(B)の一方又は両方において、前記合成樹脂発泡体を減圧雰囲気に置き、溶液を接触させ、該雰囲気を大気圧に戻すことで前記気泡構造内に溶液を入れる構成とすることもできる。  In the method for producing an inorganic material-containing synthetic resin foam according to the present invention, in one or both of the step (A) and the step (B), the synthetic resin foam is placed in a reduced-pressure atmosphere, and the solution is brought into contact therewith. It can also be set as the structure which puts a solution in the said bubble structure by returning to atmospheric | air pressure.

本発明の無機物含有合成樹脂発泡体の製造方法において、前記工程(A)又は(B)の前に予め合成樹脂発泡体を切断し、気泡が開口した状態の気泡構造を形成する工程を行うこともできる。  In the method for producing an inorganic substance-containing synthetic resin foam of the present invention, the step of cutting the synthetic resin foam in advance before the step (A) or (B) to form a cell structure in which bubbles are opened is performed. You can also.

本発明の無機物含有合成樹脂発泡体の製造方法において、前記工程(A)又は(B)の前に予め合成樹脂発泡体の表面に研磨処理又は穿刺処理を施し、気泡が開口した状態の気泡構造を形成する工程を行うこともできる。  In the method for producing an inorganic substance-containing synthetic resin foam according to the present invention, a cell structure in which bubbles are opened by subjecting the surface of the synthetic resin foam to polishing or puncture before the step (A) or (B). The process of forming can also be performed.

本発明の無機物含有合成樹脂発泡体の製造方法において、前記無機物含有合成樹脂発泡体の表面に合成樹脂層を積層する工程をさらに有する構成とすることもできる。  In the manufacturing method of the inorganic substance containing synthetic resin foam of this invention, it can also be set as the structure which further has the process of laminating | stacking a synthetic resin layer on the surface of the said inorganic substance containing synthetic resin foam.

本発明の無機物含有合成樹脂発泡体の製造方法において、前記合成樹脂発泡体に穴が設けられ、該穴内に前記水溶性ケイ酸塩の溶液及び前記凝固剤の溶液を入れてもよい。  In the method for producing an inorganic-containing synthetic resin foam of the present invention, a hole may be provided in the synthetic resin foam, and the water-soluble silicate solution and the coagulant solution may be placed in the hole.

本発明の無機物含有合成樹脂発泡体は、合成樹脂発泡体の少なくとも一部の表面の気泡構造内にシリカ系無機物が充填されてなるものなので、その表面硬度を大幅に向上させることができる。
また、この無機物含有合成樹脂発泡体の表面は、接着剤、特にモルタルなどの無機系接着剤に対する接着強度が高くなり、コンクリートなどの建築物の表面に対して強固に接着させることができる。
また、この無機物含有合成樹脂発泡体の表面は、耐火性・難燃性に優れており、合成樹脂発泡体の耐火・難燃性能を高めることができる。
また、シリカ系無機物を多孔質シリカとした場合には、吸湿及び吸臭効果が得られる。
また、シリカ系無機物に二酸化チタンを含ませることで光触媒効果が得られる。
また、シリカ系無機物に1種又は2種以上の遷移金属元素を含有させることで容易に着色できる。これにより得られる着色表面は、美麗で且つ耐候性に優れ、長期間にわたり優れた意匠面を維持できる。
Since the inorganic substance-containing synthetic resin foam of the present invention is formed by filling a silica-based inorganic substance in the cell structure of at least a part of the surface of the synthetic resin foam, the surface hardness can be greatly improved.
Further, the surface of the inorganic material-containing synthetic resin foam has high adhesive strength to an adhesive, particularly an inorganic adhesive such as mortar, and can be firmly adhered to the surface of a building such as concrete.
Moreover, the surface of this inorganic substance containing synthetic resin foam is excellent in fire resistance and flame retardance, and can improve the fire resistance and flame retardancy performance of the synthetic resin foam.
Further, when the silica-based inorganic material is porous silica, moisture absorption and odor absorption effects can be obtained.
Moreover, the photocatalytic effect is acquired by including titanium dioxide in a silica type inorganic substance.
Moreover, it can color easily by making a silica type inorganic substance contain 1 type, or 2 or more types of transition metal elements. The colored surface thus obtained is beautiful and excellent in weather resistance, and can maintain an excellent design surface over a long period of time.

本発明の無機物含有合成樹脂発泡体の製造方法によれば、合成樹脂発泡体の表面の気泡構造内に水溶性ケイ酸塩の溶液を入れる工程(A)と、前記気泡構造内に前記水溶性ケイ酸塩と反応してシリカ系無機物を生成する凝固剤を入れる工程(B)とを有し、前記工程(A)と工程(B)のいずれか一方を先に、いずれか他方を後に行うか又は両方を同時に行って、前記気泡構造内にシリカ系無機物を形成し、それを気泡構造内に沈着させて無機物含有合成樹脂発泡体を得る構成としたことによって、前述した通り、優れた効果を有する前記無機物含有合成樹脂発泡体を容易に且つ低コストで製造することができる。  According to the method for producing an inorganic material-containing synthetic resin foam of the present invention, the step (A) of placing a water-soluble silicate solution in the cell structure on the surface of the synthetic resin foam, and the water-soluble in the cell structure A step (B) of adding a coagulant that reacts with a silicate to produce a silica-based inorganic substance, and one of the step (A) and the step (B) is performed first, and the other is performed after the other. As described above, it is possible to obtain a mineral-containing synthetic resin foam by forming a silica-based inorganic substance in the cell structure and depositing it in the cell structure. The said inorganic substance containing synthetic resin foam which has can be manufactured easily and at low cost.

本発明の無機物含有合成樹脂発泡体は、合成樹脂発泡体の少なくとも一部の表面の気泡構造内にシリカ系無機物が充填されてなるものである。
ここで「少なくとも一部の表面」とは、合成樹脂発泡体の表面に存在する気泡構造のうちの少なくとも一部を意味し、表面に存在する気泡構造の一部又は全部及び合成樹脂発泡体の表面より内部にある気泡構造も含まれる。
また「気泡構造」とは、合成樹脂発泡体において、薄い合成樹脂からなる気泡壁で囲まれた空間である気泡(セル)及び開口を有する気泡並びに該気泡の気泡壁の一部が残った状態にある気泡残部を意味する。なお、以下の明細書の記載において「気泡構造」の語句は、前記気泡のうち合成樹脂発泡体の外部に通じる開口を有する気泡のことを意味する場合がある。例えば、独立気泡型の合成樹脂発泡体については、合成樹脂発泡体の表面に存在する気泡のうち、内部のガス流通が容易な開口を有する気泡(以下、開口気泡と記す)又は気泡壁の一部が残った状態にある気泡残部のことを指し、連続気泡型の合成樹脂発泡体については、合成樹脂発泡体表面に開口した連続気泡のことを指す場合がある。
また「充填」とは、前記気泡構造内に前記シリカ系無機物の粒子が入っている状態を指し、前記気泡構造内がシリカ系無機物の粒子で埋め尽くされた状態であってもよいし、前記気泡構造内の一部にシリカ系無機物の粒子が付着している状態であってもよい。
The inorganic material-containing synthetic resin foam of the present invention is one in which a silica-based inorganic material is filled in the cell structure on the surface of at least a part of the synthetic resin foam.
Here, “at least a part of the surface” means at least part of the cell structure existing on the surface of the synthetic resin foam, and part or all of the cell structure existing on the surface and the synthetic resin foam. It also includes bubble structures that are internal to the surface.
“Bubble structure” refers to a state in which bubbles (cells), which are spaces surrounded by bubble walls made of a thin synthetic resin, bubbles having openings, and a part of the bubble walls of the bubbles remain in the synthetic resin foam. Means the remaining bubble. In the description of the following specification, the phrase “bubble structure” may mean a bubble having an opening communicating with the outside of the synthetic resin foam among the bubbles. For example, in the case of a closed cell type synthetic resin foam, among the bubbles existing on the surface of the synthetic resin foam, there are bubbles having an opening through which gas can easily flow (hereinafter referred to as an open cell) or a bubble wall. The open cell synthetic resin foam is sometimes referred to as an open cell on the surface of the synthetic resin foam.
Further, “filling” refers to a state in which the silica-based inorganic particles are contained in the cell structure, and the cell structure may be filled with silica-based inorganic particles, It may be in a state where silica-based inorganic particles are attached to a part of the cell structure.

本発明の無機物含有合成樹脂発泡体において、前記合成樹脂発泡体としては、従来より周知の各種合成樹脂発泡体を用いることができ、その材質、密度、気泡径、形状などは特に限定されない。前記合成樹脂発泡体の中でも、軽量で且つ機械的強度に優れ、種々の形状のものを容易に製造でき、しかも低コストで提供できるなどの点から、ポリスチレン系樹脂発泡体、ポリエチレン系樹脂発泡体、ポリプロピレン系樹脂発泡体、ポリエステル系樹脂発泡体、発泡ポリウレタンからなる群から選択されるものであることが好ましい。
なお、製品コストや製造容易性などの制約が無ければ、他の合成樹脂、例えば、ポリアミド系樹脂、ポリイミド系樹脂、ポリフェニレンエーテルなどの所謂エンジニアリングプラスチックなどを樹脂材料とした合成樹脂発泡体を使用することも可能である。
また、合成樹脂発泡体の形状は、シート状、ボード状、ブロック状、トレー状、カップ状、丼状、球状、粒子状、箱形、棒状、柱状、管状などの種々の形状であってよく、また所定形状の合成樹脂発泡体を切断、打ち抜きなどして所望の形状に二次加工した合成樹脂発泡体や合成樹脂発泡体のシートを熱成形した成形品を使用することもできる。
In the inorganic substance-containing synthetic resin foam of the present invention, as the synthetic resin foam, conventionally known various synthetic resin foams can be used, and the material, density, bubble diameter, shape, etc. are not particularly limited. Among the synthetic resin foams, polystyrene resin foams and polyethylene resin foams are lightweight and excellent in mechanical strength, can be easily manufactured in various shapes, and can be provided at low cost. It is preferably selected from the group consisting of a polypropylene resin foam, a polyester resin foam, and a polyurethane foam.
If there are no restrictions such as product cost or manufacturability, a synthetic resin foam made of another synthetic resin, for example, a so-called engineering plastic such as polyamide resin, polyimide resin, or polyphenylene ether is used. It is also possible.
The shape of the synthetic resin foam may be various shapes such as a sheet shape, a board shape, a block shape, a tray shape, a cup shape, a bowl shape, a spherical shape, a particle shape, a box shape, a rod shape, a column shape, and a tubular shape. Also, a synthetic resin foam obtained by cutting or punching a synthetic resin foam having a predetermined shape and secondary processing into a desired shape, or a molded product obtained by thermoforming a sheet of the synthetic resin foam can be used.

前記ポリスチレン系樹脂発泡体は、使用用途などに応じて適宜選択して各種市販品の中から適宜選択して使用することができ、或いは、ポリスチレン系樹脂粒子にブタンやペンタンなどの発泡剤を含有させた発泡性樹脂粒子(発泡ビーズ)を加熱して発泡させた粒子(予備発泡粒子)を用い、該予備発泡粒子を所望形状のキャビティを有する成形型の該キャビティ内に充填し加熱して型内発泡成形を行って発泡成形体を製造することもできる。  The polystyrene-based resin foam can be appropriately selected and used from various commercially available products according to the intended use, or contains a foaming agent such as butane or pentane in the polystyrene-based resin particles. The expanded foamed resin particles (expanded beads) are heated and expanded (pre-expanded particles), the pre-expanded particles are filled into the cavity of a mold having a cavity of a desired shape, and heated to form a mold. It is also possible to produce a foamed molded article by performing internal foam molding.

前記ポリスチレン系樹脂発泡体の原料のポリスチレン系樹脂としては、ポリスチレン、スチレンと他の共重合可能なモノマーとの共重合体、ポリスチレン系樹脂と他の合成樹脂とのブレンドポリマーなどが挙げられる。
前記ポリスチレン系樹脂発泡体には、物性を損なわない範囲内において、気泡調整剤、架橋剤、充填剤、難燃剤、難燃助剤、滑剤、着色剤等の添加剤を添加してもよい。ここで、着色剤としては有機染料でもよいし、無機顔料でもよい。また、後述するようにシリカ系無機物を着色する場合、ポリスチレン系樹脂発泡体をシリカ系無機物と同色に着色してもよいし、異なる色に着色してもよい。
Examples of the polystyrene resin used as a raw material for the polystyrene resin foam include polystyrene, a copolymer of styrene and another copolymerizable monomer, and a blend polymer of a polystyrene resin and another synthetic resin.
To the polystyrene resin foam, additives such as a bubble adjusting agent, a crosslinking agent, a filler, a flame retardant, a flame retardant aid, a lubricant, and a colorant may be added within a range that does not impair the physical properties. Here, the colorant may be an organic dye or an inorganic pigment. Moreover, when coloring a silica type inorganic substance so that it may mention later, a polystyrene type resin foam may be colored in the same color as a silica type inorganic substance, and may be colored in a different color.

前記ポリエチレン系樹脂発泡体は、使用用途などに応じて適宜選択して各種市販品の中から適宜選択して使用することができ、或いは、前述したポリスチレン系樹脂発泡体の場合と同様に製造して得られた発泡成形体を用いることができる。原料のポリエチレン系樹脂としては、各種密度のポリエチレン(低密度ポリエチレン、中密度ポリエチレン、高密度ポリエチレン、低密度直鎖状ポリエチレンなど)、エチレン−酢酸ビニル共重合体やエチレン−ビニルアルコール共重合体などのエチレン含有共重合体、ポリエチレンと他の樹脂とのブレンドポリマーなどが挙げられる。  The polyethylene-based resin foam can be appropriately selected and used from various commercially available products according to the intended use, or can be produced in the same manner as the polystyrene-based resin foam described above. The foamed molded product obtained in this way can be used. The raw material polyethylene resin includes various density polyethylene (low density polyethylene, medium density polyethylene, high density polyethylene, low density linear polyethylene, etc.), ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, etc. And ethylene-containing copolymers, blend polymers of polyethylene and other resins, and the like.

前記ポリプロピレン系樹脂発泡体は、使用用途などに応じて適宜選択して各種市販品の中から適宜選択して使用することができ、或いは、前述したポリスチレン系樹脂発泡体の場合と同様に製造して得られた発泡成形体を用いることができる。原料のポリプロピレン系樹脂としては、ポリプロピレン、プロピレンと他のモノマーとの共重合体、ポリプロピレンと他の樹脂とのブレンドポリマーなどが挙げられる。  The polypropylene resin foam can be appropriately selected according to the intended use and used from various commercially available products, or can be produced in the same manner as the polystyrene resin foam described above. The foamed molded product obtained in this way can be used. Examples of the raw material polypropylene resin include polypropylene, copolymers of propylene and other monomers, blend polymers of polypropylene and other resins, and the like.

前記ポリエステル系樹脂発泡体としては、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリエチレンナフタレート、ポリブチレンテレフタレートなどの樹脂発泡体が挙げられ、それらの中でも特にポリエチレンテレフタレート発泡体が好ましい。このポリエチレンテレフタレート発泡体としては、使用用途などに応じて適宜選択して各種市販品の中から適宜選択して使用することができる。  Examples of the polyester resin foam include resin foams such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, and polybutylene terephthalate. Among these, polyethylene terephthalate foam is particularly preferable. As this polyethylene terephthalate foam, it can select suitably according to a use application etc., and it can select from various commercial items suitably, and can be used.

前記発泡ポリウレタンは、使用用途などに応じて適宜選択して各種市販品の中から適宜選択して使用することができ、或いは、ポリオール、イソシアネート、水、触媒及び整泡剤等を含む原料から所望形状の発泡ウレタンを製造することもできる。  The foamed polyurethane can be appropriately selected and used from various commercially available products according to the intended use, or desired from raw materials including polyol, isocyanate, water, catalyst, foam stabilizer and the like. Shaped urethane foam can also be produced.

前記合成樹脂発泡体の気泡は、多数の小気泡が気泡壁を隔てて密集した独立気泡型でもよいし、長い気泡孔が形成された通気性のある連続気泡型でもよい。一般に、独立気泡型の合成樹脂発泡体の方が、連続気泡型の同種の合成発泡体よりも機械的強度や断熱性に優れているが、従来技術では、通気性の無い独立気泡型の気泡構造内に無機物を充填するのは困難であった。本発明では、前記独立気泡型の合成樹脂発泡体であっても、その表面の気泡構造にシリカ系無機物を充填することが可能となったことから、機械的強度や断熱性に優れた独立気泡型の合成樹脂発泡体を用いることが好ましい。  The bubbles of the synthetic resin foam may be a closed cell type in which a large number of small bubbles are densely spaced across the cell wall, or may be an open cell type with air permeability in which long cell holes are formed. In general, closed cell type synthetic resin foam has better mechanical strength and heat insulation than open cell type same type synthetic foam, but in the prior art, closed cell type bubble without air permeability It was difficult to fill the structure with inorganic substances. In the present invention, even if it is the closed cell type synthetic resin foam, it is possible to fill the cell structure of the surface with a silica-based inorganic substance, so that closed cells excellent in mechanical strength and heat insulating properties can be obtained. It is preferable to use a synthetic resin foam of the mold.

本発明の無機物含有合成樹脂発泡体において、前記シリカ系無機物は、シリカ(SiO)を主成分とする無機物であればよく、特に限定されない。本発明において好ましいシリカ系無機物としては、シリカ、ケイ酸カルシウム、ケイ酸マグネシウム、ケイ酸アルミニウム、アルミノケイ酸塩のうちの1種又は2種以上の混合物が挙げられる。前記シリカは、無水ケイ酸、含水ケイ酸などを含み得る。前記ケイ酸カルシウム、ケイ酸マグネシウム、ケイ酸アルミニウム、アルミノケイ酸塩について、ケイ酸と各金属元素(Ca,Mg,Al)との組成モル比は特に限定されず、種々の組成モル比とすることができる。
また、前記シリカ系無機物がシリカ、ケイ酸カルシウム、ケイ酸マグネシウム、ケイ酸アルミニウム、アルミノケイ酸塩の各無機物のうちの2種以上の混合物である場合、各無機物の組成比は特に限定されない。
In the inorganic material-containing synthetic resin foam of the present invention, the silica-based inorganic material is not particularly limited as long as it is an inorganic material mainly composed of silica (SiO 2 ). In the present invention, preferred silica-based inorganic materials include one or a mixture of two or more of silica, calcium silicate, magnesium silicate, aluminum silicate, and aluminosilicate. The silica may include anhydrous silicic acid, hydrous silicic acid and the like. About the said calcium silicate, magnesium silicate, aluminum silicate, and aluminosilicate, the composition molar ratio of silicic acid and each metal element (Ca, Mg, Al) is not specifically limited, It shall be various composition molar ratios Can do.
Moreover, when the said silica type inorganic substance is a mixture of 2 or more types of each inorganic substance of a silica, calcium silicate, magnesium silicate, aluminum silicate, and aluminosilicate, the composition ratio of each inorganic substance is not specifically limited.

本発明の無機物含有合成樹脂発泡体において、前記シリカ系無機物は、遷移金属元素の中から選択される1種又は2種以上の金属元素を含み、着色している構成とすることができる。前記遷移金属元素としては、例えば、Co、Cr、Cu、Ti、Fe、Ni、Mn、V、Mo、Au、白金族元素、希土類元素、U等が挙げられる。前記遷移金属元素は、イオンの状態でシリカ系無機物中に存在し、それぞれの金属イオンの電荷数に応じて様々な色に着色する。一例を挙げれば、Co2+は青色〜ピンク、Cr3+は緑色、Cr5+は淡黄色、Cu2+は青色、Ti3+は青色、Fe2+は青緑色、Fe3+は褐色、Ni2+は黄褐色〜暗紫色、Mn2+は淡赤紫色、Mn3+は紫褐色、V3+及びV4+は緑色、Mo3+は橙色、Mo4+は緑色などである。In the inorganic material-containing synthetic resin foam of the present invention, the silica-based inorganic material may include one or more metal elements selected from transition metal elements and may be colored. Examples of the transition metal element include Co, Cr, Cu, Ti, Fe, Ni, Mn, V, Mo, Au, a platinum group element, a rare earth element, U, and the like. The transition metal element exists in the silica-based inorganic substance in an ionic state, and is colored in various colors according to the number of charges of each metal ion. For example, Co 2+ is blue to pink, Cr 3+ is green, Cr 5+ is light yellow, Cu 2+ is blue, Ti 3+ is blue, Fe 2+ is blue-green, Fe 3+ is brown, Ni 2+ is tan Dark purple, Mn 2+ is light reddish purple, Mn 3+ is purple brown, V 3+ and V 4+ are green, Mo 3+ is orange, Mo 4+ is green, etc.

本発明の無機物含有合成樹脂発泡体において、前記シリカ系無機物が多孔質シリカ(所謂シリカゲル)である構成とすることができる。
多孔質シリカは、周知の通り吸湿・吸臭性に優れており、この多孔質シリカが気泡構造内に充填された無機物含有合成樹脂発泡体は、吸湿・吸臭機能を発揮し得る。
In the inorganic substance-containing synthetic resin foam of the present invention, the silica-based inorganic substance may be porous silica (so-called silica gel).
As is well known, porous silica is excellent in moisture absorption and odor absorption, and the inorganic-containing synthetic resin foam in which the porous silica is filled in the cell structure can exhibit moisture absorption and odor absorption functions.

本発明の無機物含有合成樹脂発泡体において、前記シリカ系無機物が二酸化チタンを含む構成とすることができる。二酸化チタンは、光触媒機能を有しており、これを含むシリカ系無機物が気泡構造内に充填された無機物含有合成樹脂発泡体に光を照射することで、脱臭効果を発揮する。なお、二酸化チタンの光触媒機能を求める場合、二酸化チタンの微粒子は、シリカ系無機物の表面近くに存在することが望ましい。  In the inorganic material-containing synthetic resin foam of the present invention, the silica-based inorganic material may include titanium dioxide. Titanium dioxide has a photocatalytic function, and exhibits a deodorizing effect by irradiating light to an inorganic-containing synthetic resin foam in which a silica-based inorganic material containing the photocatalyst is filled in a cell structure. When obtaining the photocatalytic function of titanium dioxide, it is desirable that the fine particles of titanium dioxide exist near the surface of the silica-based inorganic substance.

本発明の無機物含有合成樹脂発泡体において、前記シリカ系無機物は、含有成分の異なる2層以上のシリカ系無機物層からなる構成とすることができる。含有成分の異なるシリカ系無機物層の組み合わせとしては、例えば、着色していないシリカ系無機物層の上に着色したシリカ系無機物層を乗せる場合や、二酸化チタンを含まないシリカ系無機物層の上に二酸化チタンを含むシリカ系無機物層を乗せる場合など多数の組み合わせが考えられる。なお、二酸化チタンが樹脂に接しているとその光触媒機能によって樹脂が劣化しやすいなるため、二酸化チタンを含まないシリカ系無機物層の上に二酸化チタンを含むシリカ系無機物層を乗せる組み合わせは、合成樹脂発泡体の劣化を防ぐ上でも好ましい。  In the inorganic material-containing synthetic resin foam of the present invention, the silica-based inorganic material may be composed of two or more silica-based inorganic layers having different components. Examples of combinations of silica-based inorganic layers having different components include, for example, a case where a colored silica-based inorganic layer is placed on an uncolored silica-based inorganic layer, or a case where a silica-based inorganic layer not containing titanium dioxide is oxidized. Many combinations are conceivable, such as when a silica-based inorganic layer containing titanium is placed. If titanium dioxide is in contact with the resin, the resin is likely to deteriorate due to its photocatalytic function, so the combination of placing the silica-based inorganic layer containing titanium dioxide on the silica-based inorganic layer not containing titanium dioxide is a synthetic resin. It is also preferable for preventing deterioration of the foam.

本発明の無機物含有合成樹脂発泡体において、前記シリカ系無機物が気泡構造内に充填されている合成樹脂発泡体の表面に、合成樹脂層が積層された構造とすることもできる。前記合成樹脂層は、合成樹脂発泡体の樹脂と同種の樹脂であってもよいし、異なる樹脂であってもよい。また、透明な非発泡の合成樹脂層でもよいし、発泡した合成樹脂層でもよい。合成樹脂発泡体の表面に合成樹脂層を積層することで、気泡構造内に充填されたシリカ系無機物の脱落を防止することができる。  The inorganic substance-containing synthetic resin foam of the present invention may have a structure in which a synthetic resin layer is laminated on the surface of the synthetic resin foam in which the silica-based inorganic substance is filled in a cell structure. The synthetic resin layer may be the same type of resin as the resin of the synthetic resin foam, or may be a different resin. Further, it may be a transparent non-foamed synthetic resin layer or a foamed synthetic resin layer. By laminating the synthetic resin layer on the surface of the synthetic resin foam, it is possible to prevent the silica-based inorganic material filled in the cell structure from falling off.

本発明の無機物含有合成樹脂発泡体において、前記合成樹脂発泡体に穴が設けられており、該穴内にシリカ系無機物が充填された構成とすることもできる。前記穴は、前記気泡構造とは別に形成されたものであって、該穴の大きさ、形成個数、穴形状及び形成ピッチ等は特に限定されない。例えば、合成樹脂成形体に円形、角形、楕円形などの多数の小穴を格子状、千鳥格子状、或いはランダムに形成しておく構成が挙げられる。また、該穴の径は、穴深さ方向に一定でもよいし、表面の開口に向けて先細りとなる形状としてもよい。このように開口に向けて先細りの形状の穴を形成すれば、シリカ系無機物の脱落が防止できることから好ましい。
このように、合成樹脂発泡体が穴を有しており、該穴内にシリカ系無機物を充填した構成とすることで、合成樹脂発泡体に充填されるシリカ系無機物の量を格段に増加させることができるので、シリカ系無機物による機械的強度の向上効果、吸湿・吸臭効果、着色による意匠性向上効果などをさらに向上させることができる。また難燃性を高めることができる。さらに、シリカ系無機物と合成樹脂発泡体との接着強度を高めることができるので、無機物含有合成樹脂発泡体を無機系接着剤を介して接合対象物に接着固定する場合の接着強度を高めることができる。
In the inorganic material-containing synthetic resin foam of the present invention, a hole may be provided in the synthetic resin foam, and the hole may be filled with a silica-based inorganic material. The holes are formed separately from the bubble structure, and the size, number of formed holes, hole shape, formation pitch, and the like are not particularly limited. For example, a configuration in which a large number of small holes such as a circle, a square, and an ellipse are formed in a lattice shape, a staggered lattice shape, or at random in a synthetic resin molded body can be given. In addition, the diameter of the hole may be constant in the hole depth direction, or may be tapered toward the opening on the surface. It is preferable to form a tapered hole toward the opening in this manner because the silica-based inorganic material can be prevented from falling off.
Thus, the synthetic resin foam has holes, and the amount of the silica-based inorganic material filled in the synthetic resin foam is remarkably increased by adopting a configuration in which the holes are filled with the silica-based inorganic material. Therefore, it is possible to further improve the mechanical strength improvement effect by the silica-based inorganic material, the moisture absorption / odor absorption effect, the designability improvement effect by coloring, and the like. Moreover, a flame retardance can be improved. Furthermore, since the adhesive strength between the silica-based inorganic substance and the synthetic resin foam can be increased, it is possible to increase the adhesive strength when the inorganic-containing synthetic resin foam is bonded and fixed to the object to be joined via the inorganic adhesive. it can.

次に、本発明の無機物含有合成樹脂発泡体の製造方法を説明する。
本発明の無機物含有合成樹脂発泡体の製造方法は、合成樹脂発泡体の表面の気泡構造内に水溶性ケイ酸塩の溶液を入れる工程(A)と、前記気泡構造内に前記水溶性ケイ酸塩と反応してシリカ系無機物を生成する凝固剤を入れる工程(B)とを有し、前記工程(A)と工程(B)のいずれか一方を先に、いずれか他方を後に行うか又は両方を同時に行って、前記気泡構造内にシリカ系無機物を形成し、それを気泡構造内に沈着させて無機物含有合成樹脂発泡体を得ることを特徴とする。
Next, the manufacturing method of the inorganic substance containing synthetic resin foam of this invention is demonstrated.
The method for producing an inorganic substance-containing synthetic resin foam according to the present invention comprises a step (A) of placing a water-soluble silicate solution in the cell structure on the surface of the synthetic resin foam, and the water-soluble silicic acid in the cell structure. A step (B) of adding a coagulant that reacts with a salt to form a silica-based inorganic substance, and either one of the step (A) and the step (B) is performed first, and the other is performed after the other. Both are performed simultaneously to form a silica-based inorganic substance in the cell structure and deposit it in the cell structure to obtain an inorganic-containing synthetic resin foam.

前記工程(A)で用いる水溶性ケイ酸塩は、各種ケイ酸塩のうち、水溶性があり、後述する凝固剤と反応してシリカ系無機物を析出するものであればよく、特に限定されない。本発明の製造方法において好適な水溶性ケイ酸塩を挙げれば、例えば、ケイ酸ナトリウム、ケイ酸二ナトリウム、ケイ酸二ナトリウム五水和物、ケイ酸カリウムからなる群から選択される1種又は2種以上の混合物を含むものである。
ケイ酸ナトリウムは、その濃厚水溶液が水ガラスと呼称される化合物であり、JIS規格表・K1408に記されたような各種規格品が市販されている。
The water-soluble silicate used in the step (A) is not particularly limited as long as it is water-soluble among various silicates and can react with a coagulant described later to precipitate a silica-based inorganic substance. If water-soluble silicate suitable in the manufacturing method of this invention is mentioned, for example, 1 type selected from the group which consists of sodium silicate, disodium silicate, disodium silicate pentahydrate, potassium silicate, or It contains a mixture of two or more.
Sodium silicate is a compound whose concentrated aqueous solution is called water glass, and various standard products as described in JIS standard table K1408 are commercially available.

前記水溶性ケイ酸塩溶液の濃度は、著しく粘度が高くて合成樹脂発泡体の気泡構造内に入れることが困難となる場合を除き、特に限定されない(以下、適度に希釈した水溶性ケイ酸塩の水溶液を水溶性ケイ酸塩溶液と記す)。
前記水溶性ケイ酸塩溶液は、ケイ酸ゲルを含むものであってもよい。ただし、ケイ酸ゲルを含む水溶性ケイ酸塩溶液の粘度が、合成樹脂発泡体の気泡構造内に入れることが困難となるような粘度となる場合を除く。
The concentration of the water-soluble silicate solution is not particularly limited unless the viscosity is so high that it is difficult to enter the cell structure of the synthetic resin foam (hereinafter referred to as a moderately diluted water-soluble silicate solution). Is referred to as a water-soluble silicate solution).
The water-soluble silicate solution may contain a silicate gel. However, the case where the viscosity of the water-soluble silicate solution containing the silicate gel becomes a viscosity that makes it difficult to enter the cell structure of the synthetic resin foam is excluded.

前記工程(B)で用いる凝固剤としては、前記水溶性ケイ酸塩と反応してシリカ系無機物を生成するものであればよく、前記水溶性ケイ酸塩の種類に応じて適宜選択可能である。前記水溶性ケイ酸塩がケイ酸ナトリウムやケイ酸カリウムである場合、好ましい凝固剤としては、酸又は酸性化合物、Ca含有化合物、Mg含有化合物、Al含有化合物からなる群から選択される1種又は2種以上の混合物を含むものが挙げられる。これらの凝固剤は、粉末状のまま使用することもできるが、水溶液として使用することが好ましい(以下、凝固剤溶液と記す)。
酸としては、塩酸、硫酸、硝酸、リン酸、酢酸、クエン酸などの周知の酸を用いることができる。
酸性化合物としては、硫酸水素ナトリウム、リン酸二水素ナトリウムなどの酸性塩、二酸化硫黄、酸化リンなどの酸性無機化合物、フェノール、有機スルホン酸化合物などの酸性有機化合物などが挙げられる。
Ca含有化合物としては、酸化カルシウム、水酸化カルシウム、塩化カルシウム、硝酸カルシウム、酢酸カルシウム、クエン酸カルシウム、水溶性リン酸カルシウムなどが挙げられる。
Mg含有化合物としては、酸化マグネシウム、水酸化マグネシウム、塩化マグネシウム、硝酸マグネシウム、酢酸マグネシウム、クエン酸マグネシウムなどが挙げられる。
Al含有化合物としては、塩化アルミニウム、第1リン酸アルミニウム、重リン酸アルミニウム、乳酸アルミニウム、アルミン酸ナトリウム、アルミン酸カリウムなどが挙げられる。
The coagulant used in the step (B) is not particularly limited as long as it reacts with the water-soluble silicate to produce a silica-based inorganic substance, and can be appropriately selected according to the type of the water-soluble silicate. . When the water-soluble silicate is sodium silicate or potassium silicate, a preferable coagulant is selected from the group consisting of acids or acidic compounds, Ca-containing compounds, Mg-containing compounds, and Al-containing compounds, or What contains 2 or more types of mixtures is mentioned. These coagulants can be used in powder form, but are preferably used as aqueous solutions (hereinafter referred to as coagulant solutions).
As the acid, known acids such as hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, acetic acid and citric acid can be used.
Examples of the acidic compound include acidic salts such as sodium hydrogen sulfate and sodium dihydrogen phosphate, acidic inorganic compounds such as sulfur dioxide and phosphorus oxide, and acidic organic compounds such as phenol and organic sulfonic acid compounds.
Examples of the Ca-containing compound include calcium oxide, calcium hydroxide, calcium chloride, calcium nitrate, calcium acetate, calcium citrate, and water-soluble calcium phosphate.
Examples of the Mg-containing compound include magnesium oxide, magnesium hydroxide, magnesium chloride, magnesium nitrate, magnesium acetate, and magnesium citrate.
Examples of the Al-containing compound include aluminum chloride, primary aluminum phosphate, aluminum biphosphate, aluminum lactate, sodium aluminate, and potassium aluminate.

本発明の製造方法において、合成樹脂発泡体は、表面の気泡が開口気泡であることが望ましい。型内発泡成形法や押出発泡法などによって製造された合成樹脂発泡体、特に、独立気泡型の合成樹脂発泡体にあっては、最表層の気泡が、気泡壁によって囲まれて密閉された状態であり、その内部にスムーズに水溶性ケイ酸塩溶液や凝固剤溶液を入れることが難しい。そこで、このような合成樹脂発泡体につては、予め表面の気泡を開口させて開口気泡を形成することが望ましい。表面の気泡を開口させるための方法は、特に限定されず、例えば、切断や研磨、穿刺などの機械加工を施す方法や、表面を局部加熱して破泡させる方法、或いは、有機溶媒によって破泡させる方法などが挙げられる。これらの開口形成方法の中でも、操作の簡便性、処理速度が速い等の点から(ア)合成樹脂発泡体を切断する方法、(イ)合成樹脂発泡体の表面に研磨処理又は穿刺処理を施す方法が好ましい。
前記(ア)の切断処理において、使用する切断装置は特に限定されず、従来から合成樹脂発泡体の切断等に用いられているカッター等を使用することができる。
前記(イ)の研磨処理に用いられる研磨装置は特に限定されず、従来から合成樹脂や発泡成形体の表面研磨などに用いられている各種の研磨装置を使用することができる。
前記(イ)の穿刺処理に用いられる穿刺装置としては、例えば、多数の針を表面から突出させたローラに合成樹脂発泡体を通して表面に穿刺処理を施す装置などが挙げられる。なお、この種の穿刺装置によって処理する場合には、使用する針の長さによって穿刺されて開口する気泡構造の深さ(すなわち、水溶性ケイ酸塩溶液や凝固剤溶液を浸透させてシリカ系無機物を形成可能な深さ)を調節することができる。
In the production method of the present invention, it is desirable that the surface bubbles of the synthetic resin foam are open cells. In the case of a synthetic resin foam produced by an in-mold foam molding method or an extrusion foaming method, in particular, in a closed cell type synthetic resin foam, the outermost bubbles are enclosed and enclosed by a cell wall. It is difficult to smoothly put a water-soluble silicate solution or a coagulant solution into the inside. Therefore, it is desirable for such synthetic resin foam to form open bubbles by opening bubbles on the surface in advance. The method for opening the bubbles on the surface is not particularly limited, for example, a method of performing machining such as cutting, polishing, and puncturing, a method of locally heating the surface to break bubbles, or a bubble breakage with an organic solvent The method of making it, etc. are mentioned. Among these opening forming methods, (a) a method of cutting the synthetic resin foam from the viewpoint of easy operation and high processing speed, and (b) a polishing process or a puncture process is performed on the surface of the synthetic resin foam. The method is preferred.
In the cutting process (a), a cutting device to be used is not particularly limited, and a cutter or the like conventionally used for cutting a synthetic resin foam can be used.
The polishing apparatus used for the polishing treatment (a) is not particularly limited, and various polishing apparatuses conventionally used for surface polishing of synthetic resins and foamed molded articles can be used.
Examples of the puncture device used in the puncture process (A) include a device that performs a puncture process on a surface through a synthetic resin foam on a roller in which a large number of needles protrude from the surface. When processing with this type of puncture device, the depth of the bubble structure that is punctured and opened depending on the length of the needle to be used (that is, impregnated with a water-soluble silicate solution or a coagulant solution to make silica-based The depth at which the inorganic substance can be formed can be adjusted.

本発明の製造方法では、前述したように表面に開口気泡を形成した合成樹脂発泡体の該気泡構造内に、水溶性ケイ酸塩溶液と凝固剤溶液とを同時に又は別々に入れ、気泡構造内にシリカ系無機物を生成させる。水溶性ケイ酸塩溶液と凝固剤溶液とを混ぜると、殆どの場合瞬時に固化が生じるので、両者を同時に入れるよりも、両者を別々に入れる方が好ましいが、その順序はどちらを先にしてもかまわない。以下の記載においては、一例として、気泡構造内に水溶性ケイ酸塩溶液の入れる工程(A)を先に行い、凝固剤溶液を入れる(b)工程を後で行う手順を記載する。  In the production method of the present invention, as described above, a water-soluble silicate solution and a coagulant solution are placed simultaneously or separately in the cell structure of the synthetic resin foam having open cells formed on the surface, and the cell structure To produce a silica-based inorganic substance. When mixing a water-soluble silicate solution and a coagulant solution, in most cases, solidification occurs instantaneously. Therefore, it is preferable to put both of them separately, rather than putting them together at the same time. It doesn't matter. In the following description, as an example, a procedure is described in which the step (A) of putting the water-soluble silicate solution into the bubble structure is performed first, and the step (b) of putting the coagulant solution is performed later.

前記合成樹脂発泡体の表面の気泡構造内に水溶性ケイ酸塩溶液を入れる工程(A)を行う場合、合成樹脂発泡体と水溶性ケイ酸塩溶液とを接触させる方法は、特に限定されない。例えば、槽内に入れた水溶性ケイ酸塩溶液中に合成樹脂発泡体の一部又は全部を浸漬する方法、合成樹脂発泡体の表面に水溶性ケイ酸塩溶液を塗布又は噴霧する方法、水溶性ケイ酸溶液を高圧で吹き付ける方法、水溶性ケイ酸溶液を含浸させたローラで押圧する方法などが挙げられる。  When performing the step (A) of putting the water-soluble silicate solution in the cell structure on the surface of the synthetic resin foam, the method of bringing the synthetic resin foam into contact with the water-soluble silicate solution is not particularly limited. For example, a method of immersing part or all of a synthetic resin foam in a water-soluble silicate solution placed in a tank, a method of applying or spraying a water-soluble silicate solution on the surface of a synthetic resin foam, Examples thereof include a method of spraying an aqueous silicate solution at a high pressure and a method of pressing with a roller impregnated with a water-soluble silicate solution.

本発明の製造方法において、工程(A)を実施する場合、前記合成樹脂発泡体を減圧雰囲気に置き、水溶性ケイ酸塩溶液を接触させ、該雰囲気を大気圧に戻すことで気泡構造内に水溶性ケイ酸塩溶液を入れる方法を行ってもよい。具体的には、減圧可能なチャンバー内に水溶性ケイ酸塩溶液を入れ、該チャンバー内に処理すべき合成樹脂発泡体を投入する。合成樹脂発泡体の表面の一部のみに水溶性ケイ酸塩溶液を入れる場合には、その部分を水溶性ケイ酸塩溶液に浸漬させた状態で浮かべればよいし、合成樹脂発泡体の表面全域に水溶性ケイ酸塩溶液を入れる場合には、合成樹脂発泡体に荷重を加えて水溶性ケイ酸塩溶液中に全体を浸漬させればよい。
次に、該チャンバー内を減圧状態とする。減圧状態とすれば、気泡構造内のガスが脱気され、次にチャンバー内を大気圧に戻すことで、気泡構造内に水溶性ケイ酸塩溶液がスムーズに。なお、この減圧〜大気圧への圧力変動は、1回でもよいし複数回繰り返してもよい。
In the production method of the present invention, when the step (A) is carried out, the synthetic resin foam is placed in a reduced-pressure atmosphere, brought into contact with a water-soluble silicate solution, and the atmosphere is returned to the atmospheric pressure to bring it into the bubble structure. A method of adding a water-soluble silicate solution may be performed. Specifically, a water-soluble silicate solution is placed in a chamber that can be decompressed, and a synthetic resin foam to be treated is placed in the chamber. When the water-soluble silicate solution is put in only a part of the surface of the synthetic resin foam, it may be floated while the part is immersed in the water-soluble silicate solution, or the surface of the synthetic resin foam When the water-soluble silicate solution is put in the entire area, a load is applied to the synthetic resin foam and the whole is immersed in the water-soluble silicate solution.
Next, the inside of the chamber is evacuated. When the pressure is reduced, the gas in the bubble structure is degassed, and then the chamber is returned to atmospheric pressure, so that the water-soluble silicate solution is smoothly formed in the bubble structure. The pressure fluctuation from the reduced pressure to the atmospheric pressure may be performed once or repeated a plurality of times.

気泡構造内に水溶性ケイ酸塩溶液を入れた合成樹脂発泡体は、必要に応じて表面の余分な水溶性ケイ酸塩溶液を除去し、乾燥させた後、凝固剤溶液と接触させる工程(B)を行う。この場合、気泡構造内には水溶性ケイ酸塩溶液又はその乾燥物が入っているので、凝固剤溶液は気泡構造内に浸透しやすくなっているため、合成樹脂発泡体を凝固剤溶液に浸漬させたり、凝固剤溶液を塗布又は噴霧することで、凝固剤溶液を気泡構造内に入れることができる。或いは、この工程(B)においても、前述した工程(A)の場合と同様にして、減圧可能なチャンバーを用いて減圧雰囲気〜大気圧の圧力変動を用いて凝固剤溶液を気泡構造内に入れる処理を行ってもよい。  In the synthetic resin foam in which the water-soluble silicate solution is put in the cell structure, the excess water-soluble silicate solution on the surface is removed as necessary, and after drying, the step of contacting with the coagulant solution ( B). In this case, since the water-soluble silicate solution or its dried product is contained in the cell structure, the coagulant solution easily penetrates into the cell structure, so the synthetic resin foam is immersed in the coagulant solution. Or by applying or spraying the coagulant solution, the coagulant solution can be placed in the cell structure. Alternatively, also in this step (B), the coagulant solution is put into the bubble structure using a pressure-reduced atmosphere to atmospheric pressure using a chamber capable of being depressurized in the same manner as in the above-described step (A). Processing may be performed.

気泡構造内に水溶性ケイ酸塩溶液、次いで凝固剤溶液を入れると、水溶性ケイ酸塩と凝固剤の反応によってシリカ系無機物が析出し、気泡構造内で沈積し固化する。次いで、合成樹脂発泡体の表面を乾燥させることによって、表面の気泡構造内にシリカ系無機物が充填された無機物含有合成樹脂発泡体が得られる。  When a water-soluble silicate solution and then a coagulant solution are placed in the cell structure, a silica-based inorganic substance is precipitated by the reaction of the water-soluble silicate and the coagulant, and is deposited and solidified in the cell structure. Next, by drying the surface of the synthetic resin foam, an inorganic-containing synthetic resin foam in which a silica-based inorganic substance is filled in the cell bubble structure on the surface is obtained.

本発明の製造方法では、使用する凝固剤の種類などによって各種の成分組成のシリカ系無機物を生成させることができ、例えば、塩酸などの酸を用いればシリカが生成し、Ca含有化合物を用いればケイ酸カルシウムが生成し、Mg含有化合物を用いればケイ酸マグネシウムが生成し、Al含有化合物を用いればケイ酸アルミニウムやアルミノケイ酸塩が生成する。また、複数種の凝固剤を混合して用いれば、各種の無機物の混合物を生成させることもできる。  In the production method of the present invention, silica-based inorganic substances having various component compositions can be generated depending on the type of coagulant used. For example, if an acid such as hydrochloric acid is used, silica is generated, and if a Ca-containing compound is used. Calcium silicate is produced, magnesium silicate is produced when an Mg-containing compound is used, and aluminum silicate and aluminosilicate are produced when an Al-containing compound is used. Further, if a plurality of types of coagulants are mixed and used, a mixture of various inorganic substances can be generated.

遷移金属元素の中から選択される1種又は2種以上の金属元素を含み、着色しているシリカ系無機物を形成する場合には、前記遷移金属元素の化合物(酸化物、水酸化物、塩など)の溶液を、前記無機物含有合成樹脂発泡体の表面に塗布、噴霧又は溶液中浸漬することによってシリカ系無機物に該溶液を浸透させる方法、工程(A)又は(B)のいずれか一方又は両方の溶液中に前記遷移金属元素の化合物を混ぜておく方法、などにより行うことができる。  When forming a colored silica-based inorganic material containing one or more metal elements selected from transition metal elements, the transition metal element compound (oxide, hydroxide, salt) Or the like, by applying the solution to the surface of the inorganic-containing synthetic resin foam, spraying or immersing the solution in the solution, and infiltrating the solution into the silica-based inorganic material, either of the steps (A) or (B) or It can be carried out by a method of mixing the transition metal element compound in both solutions.

多孔質シリカを形成する場合には、凝固剤として塩酸などの酸を用い、水溶性ケイ酸塩からケイ酸ゲルを生成させ、次いでこれを十分に乾燥させることで形成可能である。
また二酸化チタンを含むシリカ系無機物を形成する場合には、顔料や光触媒用として市販されている二酸化チタン微粒子を工程(A)又は(B)で用いる溶液中に懸濁させておき、この二酸化チタンを懸濁させた溶液を用いて前記と同様に工程(A)及び(B)を実施することによって形成可能である。
In the case of forming porous silica, it can be formed by using an acid such as hydrochloric acid as a coagulant, generating a silicate gel from a water-soluble silicate, and then sufficiently drying it.
When a silica-based inorganic substance containing titanium dioxide is formed, titanium dioxide fine particles that are commercially available for pigments and photocatalysts are suspended in the solution used in step (A) or (B), and this titanium dioxide is used. It can be formed by carrying out steps (A) and (B) in the same manner as described above using a solution in which

気泡構造内に、同一成分の又は含有成分の異なる2層以上のシリカ系無機物層を形成する場合には、前記工程(A)及び工程(B)を一度行ってシリカ系無機物からなる第1層を形成した後、好ましくは該発泡体表面を十分に洗浄し、乾燥した後、前記工程(A)及び(B)を行ってシリカ系無機物からなる第2層を形成する。この工程を必要な層数だけ繰り返し行うことによって、同一成分の又は含有成分の異なる2層以上のシリカ系無機物層を形成することができる。  When two or more layers of the silica-based inorganic material having the same component or different contained components are formed in the cell structure, the first layer made of the silica-based inorganic material is performed once by performing the steps (A) and (B). After forming, preferably, the surface of the foam is sufficiently washed and dried, and then the steps (A) and (B) are performed to form a second layer made of a silica-based inorganic substance. By repeating this step as many times as necessary, two or more silica-based inorganic layers having the same component or different components can be formed.

このようにして得られた無機物含有合成樹脂発泡体の表面には、同種の樹脂又は異なる樹脂からなる合成樹脂層を積層してもよい。前記無機物含有合成樹脂発泡体の表面に合成樹脂層を積層する場合、接着剤層又は粘着剤層を介して接着してもよい。一方、合成樹脂発泡体の樹脂と同じ材料の樹脂フィルムを積層する場合、シリカ系無機物が充填された気泡構造の最表面部分には、気泡壁が残っており、合成樹脂発泡体の表面にTダイ押出法等によって溶融押出したフィルム状の樹脂を乗せることで、合成樹脂発泡体の表面に合成樹脂層を強固に積層することができる。  A synthetic resin layer made of the same kind of resin or a different resin may be laminated on the surface of the thus obtained inorganic substance-containing synthetic resin foam. When a synthetic resin layer is laminated on the surface of the inorganic substance-containing synthetic resin foam, it may be bonded via an adhesive layer or an adhesive layer. On the other hand, when a resin film made of the same material as the resin of the synthetic resin foam is laminated, a cell wall remains on the outermost surface portion of the cell structure filled with the silica-based inorganic substance, and T on the surface of the synthetic resin foam. By placing a film-like resin melt-extruded by a die extrusion method or the like, the synthetic resin layer can be firmly laminated on the surface of the synthetic resin foam.

本発明の無機物含有合成樹脂発泡体の製造方法において、合成樹脂発泡体に予め穴を設けておき、この合成樹脂発泡体に前記工程(A)及び工程(B)を施して、前記穴内にシリカ系無機物を充填して無機物含有合成樹脂発泡体を製造することもできる。この穴の大きさ、形成個数、穴形状及び形成ピッチ等は特に限定されない。
合成樹脂発泡体に穴を形成するには、合成樹脂発泡体を型内発泡成形する際に用いる成形型に前記穴に対応する突起を設けておき、該成形型を用いて合成樹脂発泡成形体を成形する方法、ドリルによる穴開け加工を施す方法、プレス加工により凹部を形成する方法、局部加熱や溶媒によって穴を設ける方法などによって容易に形成できる。
前記工程(A)及び工程(B)を行うことで、前記穴内に水溶性ケイ酸塩溶液や凝固剤溶液を入れることが可能であり、これらの工程を経て、穴内にシリカ系無機物が充填された無機物含有合成樹脂発泡体を簡単に製造することができる。
In the method for producing an inorganic material-containing synthetic resin foam of the present invention, a hole is provided in advance in the synthetic resin foam, the step (A) and the step (B) are performed on the synthetic resin foam, and silica is formed in the hole. An inorganic substance-containing synthetic resin foam can also be produced by filling a system inorganic substance. The size, number of holes formed, hole shape, formation pitch, etc. are not particularly limited.
In order to form a hole in the synthetic resin foam, a projection corresponding to the hole is provided in a mold used when the synthetic resin foam is subjected to in-mold foam molding, and the synthetic resin foam molded body is formed using the mold. Can be easily formed by a method of forming a hole, a method of drilling with a drill, a method of forming a recess by pressing, a method of forming a hole by local heating or a solvent, and the like.
By performing the step (A) and the step (B), it is possible to put a water-soluble silicate solution or a coagulant solution into the hole. After these steps, the hole is filled with a silica-based inorganic substance. In addition, an inorganic substance-containing synthetic resin foam can be easily produced.

以下、実施例により本発明をさらに具体的に説明するが、以下の実施例は本発明の単なる例示であって、本発明は以下の実施例の記載に限定されない。  Hereinafter, the present invention will be described more specifically by way of examples. However, the following examples are merely illustrative of the present invention, and the present invention is not limited to the description of the following examples.

合成樹脂発泡体として、ポリスチレン系樹脂発泡成形体(商品名「ピオセラン」、積水化成品工業社製)のブロックをカッターで切断したものを用いた。
水溶性ケイ酸塩溶液として、ケイ酸ナトリウム濃厚溶液(和光純薬工業社製)を2〜10倍に希釈した溶液を用いた。
凝固剤溶液として、酸性クエン酸カルシウム溶液を用いた。
シャーレに前記水溶性ケイ酸塩溶液を入れ、前記合成樹脂発泡体の切断面を該溶液に浸し、これらを真空チャンバー内に置いた。次に、真空チャンバー内を減圧し、しばらく置いた後、大気圧に戻した。この圧力変動によって合成樹脂発泡体の表面の気泡構造内に水溶性ケイ酸塩溶液を入れることができた。真空チャンバーから取り出した合成樹脂発泡体の表面(切断面)にろ紙を置き、余分な水溶性ケイ酸塩溶液を吸着除去した後、表面をドライヤーで乾燥させた。
次に、合成樹脂発泡体の該表面を上向きに置き、該表面に前記凝固剤溶液を静かに注ぎ、該表面上に溶液が載った状態のまま放置(数分〜数十分)した。
その後、余分な凝固剤溶液を除去し、ドライヤーで乾燥させ、表面の気泡構造内にシリカ系無機物が充填された無機物含有合成樹脂発泡体を得た。
As the synthetic resin foam, a block obtained by cutting a block of a polystyrene-based resin foam molded product (trade name “Piocelan”, manufactured by Sekisui Plastics Co., Ltd.) with a cutter was used.
As a water-soluble silicate solution, a solution obtained by diluting a sodium silicate concentrated solution (manufactured by Wako Pure Chemical Industries, Ltd.) 2 to 10 times was used.
An acidic calcium citrate solution was used as the coagulant solution.
The water-soluble silicate solution was placed in a petri dish, the cut surface of the synthetic resin foam was immersed in the solution, and these were placed in a vacuum chamber. Next, the inside of the vacuum chamber was decompressed and left for a while, and then returned to atmospheric pressure. Due to this pressure fluctuation, the water-soluble silicate solution could be put into the cell structure on the surface of the synthetic resin foam. A filter paper was placed on the surface (cut surface) of the synthetic resin foam taken out from the vacuum chamber, and after removing the excess water-soluble silicate solution by adsorption, the surface was dried with a drier.
Next, the surface of the synthetic resin foam was placed upward, the coagulant solution was gently poured onto the surface, and the solution was left on the surface (several minutes to several tens of minutes).
Thereafter, excess coagulant solution was removed and dried with a drier to obtain an inorganic substance-containing synthetic resin foam in which a silica-based inorganic substance was filled in a cell structure on the surface.

実施例1で作製した無機物含有合成樹脂発泡体の表面に、1%塩化コバルト水溶液を塗布した。しばらく放置した後、余分な溶液をろ紙で吸着除去し、ドライヤーで乾燥した。これによってシリカ系無機物を美しい青色に着色することができた。  A 1% aqueous solution of cobalt chloride was applied to the surface of the inorganic material-containing synthetic resin foam produced in Example 1. After standing for a while, the excess solution was removed by adsorption with filter paper and dried with a dryer. As a result, the silica-based inorganic substance could be colored in a beautiful blue color.

合成樹脂発泡体としてポリスチレン系樹脂発泡成形体に代えて、ポリエチレン系樹脂発泡シート(商品名「ライトロン」、積水化成品工業社製)を用いた。それ以外は実施例1と同様にして無機物含有合成樹脂発泡体を製造した。  As the synthetic resin foam, a polyethylene resin foam sheet (trade name “Lightlon”, manufactured by Sekisui Plastics Co., Ltd.) was used in place of the polystyrene resin foam molding. Other than that was carried out similarly to Example 1, and manufactured the inorganic substance containing synthetic resin foam.

合成樹脂発泡体としてポリスチレン系樹脂発泡成形体に代えて、ポリプロピレン系樹脂発泡ボード(商品名「ネオフラットボード」、積水化成品工業社製)を用いた。それ以外は実施例1と同様にして無機物含有合成樹脂発泡体を製造した。  A polypropylene resin foam board (trade name “Neoflat Board”, manufactured by Sekisui Plastics Co., Ltd.) was used as the synthetic resin foam instead of the polystyrene resin foam molded article. Other than that was carried out similarly to Example 1, and manufactured the inorganic substance containing synthetic resin foam.

合成樹脂発泡体としてポリスチレン系樹脂発泡成形体に代えて、ポリエチレンテレフタレート(PET)系樹脂発泡シート(商品名「セルペット」、積水化成品工業社製)を用いた。それ以外は実施例1と同様にして無機物含有合成樹脂発泡体を製造した。  As the synthetic resin foam, a polyethylene terephthalate (PET) resin foam sheet (trade name “Selpet”, manufactured by Sekisui Plastics Co., Ltd.) was used in place of the polystyrene resin foam molding. Other than that was carried out similarly to Example 1, and manufactured the inorganic substance containing synthetic resin foam.

Claims (24)

合成樹脂発泡体の少なくとも一部の表面の気泡構造内にシリカ系無機物が充填されてなる無機物含有合成樹脂発泡体。  An inorganic-containing synthetic resin foam obtained by filling a silica-based inorganic substance in a cell structure on at least a part of the surface of a synthetic resin foam. 前記シリカ系無機物が、シリカ、ケイ酸カルシウム、ケイ酸マグネシウム、ケイ酸アルミニウム、アルミノケイ酸塩のうちの1種又は2種以上の混合物である請求項1に記載の無機物含有合成樹脂発泡体。  The inorganic substance-containing synthetic resin foam according to claim 1, wherein the silica-based inorganic substance is one or a mixture of two or more of silica, calcium silicate, magnesium silicate, aluminum silicate, and aluminosilicate. 前記シリカ系無機物が、遷移金属元素の中から選択される1種又は2種以上の金属元素を含み、着色している請求項1又は2に記載の無機物含有合成樹脂発泡体。  The inorganic-containing synthetic resin foam according to claim 1 or 2, wherein the silica-based inorganic substance contains one or more metal elements selected from transition metal elements and is colored. 前記シリカ系無機物が、多孔質シリカである請求項1〜3のいずれか1項に記載の無機物含有合成樹脂発泡体。  The inorganic material-containing synthetic resin foam according to any one of claims 1 to 3, wherein the silica-based inorganic material is porous silica. 前記シリカ系無機物が、二酸化チタンを含むものである請求項1〜4のいずれか1項に記載の無機物含有合成樹脂発泡体。  The inorganic material-containing synthetic resin foam according to any one of claims 1 to 4, wherein the silica-based inorganic material contains titanium dioxide. 前記シリカ系無機物が、含有成分の異なる2層以上の無機物層からなる請求項1〜5のいずれか1項に記載の無機物含有合成樹脂発泡体。  The inorganic material-containing synthetic resin foam according to any one of claims 1 to 5, wherein the silica-based inorganic material is composed of two or more inorganic layers having different components. 前記合成樹脂発泡体が、ポリスチレン系樹脂発泡体、ポリエチレン系樹脂発泡体、ポリプロピレン系樹脂発泡体、ポリエステル系樹脂発泡体、発泡ポリウレタンからなる群から選択される請求項1〜6のいずれか1項に記載の無機物含有合成樹脂発泡体。  The synthetic resin foam is selected from the group consisting of a polystyrene resin foam, a polyethylene resin foam, a polypropylene resin foam, a polyester resin foam, and a foamed polyurethane. An inorganic substance-containing synthetic resin foam described in 1. 前記合成樹脂発泡体の表面に合成樹脂層が積層された構造である請求項1〜7のいずれか1項に記載の無機物含有合成樹脂発泡体。  The inorganic material-containing synthetic resin foam according to any one of claims 1 to 7, which has a structure in which a synthetic resin layer is laminated on a surface of the synthetic resin foam. 前記合成樹脂発泡体に穴が設けられ、該穴内にシリカ系無機物が充填された請求項1〜8のいずれか1項に記載の無機物含有合成樹脂発泡体。  The inorganic resin-containing synthetic resin foam according to any one of claims 1 to 8, wherein a hole is provided in the synthetic resin foam, and a silica-based inorganic material is filled in the hole. 合成樹脂発泡体の表面の気泡構造内に水溶性ケイ酸塩の溶液を入れる工程(A)と、
前記気泡構造内に前記水溶性ケイ酸塩と反応してシリカ系無機物を生成する凝固剤を入れる工程(B)とを有し、前記工程(A)と工程(B)のいずれか一方を先に、いずれか他方を後に行うか又は両方を同時に行って、前記気泡構造内にシリカ系無機物を形成し、それを気泡構造内に沈着させて無機物含有合成樹脂発泡体を得ることを特徴とする無機物含有合成樹脂発泡体の製造方法。
Placing the water-soluble silicate solution in the cellular structure of the surface of the synthetic resin foam (A);
And (B) adding a coagulant that reacts with the water-soluble silicate to produce a silica-based inorganic substance in the cell structure, and either one of the step (A) and the step (B) is performed first. In addition, either one is performed later, or both are performed at the same time to form a silica-based inorganic substance in the cellular structure, and deposit it in the cellular structure to obtain an inorganic substance-containing synthetic resin foam. A method for producing an inorganic-containing synthetic resin foam.
前記凝固剤が、酸又は酸性化合物、Ca含有化合物、Mg含有化合物、Al含有化合物からなる群から選択される1種又は2種以上の混合物を含むものである請求項10に記載の無機物含有合成樹脂発泡体の製造方法。  The inorganic substance-containing synthetic resin foam according to claim 10, wherein the coagulant contains one or a mixture of two or more selected from the group consisting of an acid or acidic compound, a Ca-containing compound, a Mg-containing compound, and an Al-containing compound. Body manufacturing method. 前記水溶性ケイ酸塩が、ケイ酸ナトリウム、ケイ酸二ナトリウム、ケイ酸二ナトリウム五水和物、ケイ酸カリウムからなる群から選択される1種又は2種以上の混合物を含むものである請求項10又は11に記載の無機物含有合成樹脂発泡体の製造方法。  The water-soluble silicate contains one or a mixture of two or more selected from the group consisting of sodium silicate, disodium silicate, disodium silicate pentahydrate, and potassium silicate. Or the manufacturing method of the inorganic substance containing synthetic resin foam of 11. 前記シリカ系無機物が、シリカ、ケイ酸カルシウム、ケイ酸マグネシウム、ケイ酸アルミニウム、アルミノケイ酸塩のうちの1種又は2種以上の混合物を含むものである請求項10〜12のいずれか1項に記載の無機物含有合成樹脂発泡体の製造方法。  The silica-based inorganic substance includes one or a mixture of two or more of silica, calcium silicate, magnesium silicate, aluminum silicate, and aluminosilicate. A method for producing an inorganic-containing synthetic resin foam. 前記シリカ系無機物が、遷移金属元素の中から選択される1種又は2種以上の金属元素を含み、着色している請求項10〜13のいずれか1項に記載の無機物含有合成樹脂発泡体の製造方法。  The inorganic substance-containing synthetic resin foam according to any one of claims 10 to 13, wherein the silica-based inorganic substance contains one or more metal elements selected from transition metal elements and is colored. Manufacturing method. 前記シリカ系無機物が、多孔質シリカである請求項10〜14のいずれか1項に記載の無機物含有合成樹脂発泡体の製造方法。  The method for producing an inorganic substance-containing synthetic resin foam according to any one of claims 10 to 14, wherein the silica-based inorganic substance is porous silica. 前記シリカ系無機物が、二酸化チタンを含むものである請求項10〜15のいずれか1項に記載の無機物含有合成樹脂発泡体の製造方法。  The method for producing an inorganic substance-containing synthetic resin foam according to any one of claims 10 to 15, wherein the silica-based inorganic substance contains titanium dioxide. 前記工程(A)及び工程(B)を複数回行い、前記気泡構造内に同一成分の又は含有成分の異なる2層以上のシリカ系無機物層を形成する請求項10〜16のいずれか1項に記載の無機物含有合成樹脂発泡体の製造方法。  The process (A) and the process (B) are performed a plurality of times to form two or more silica-based inorganic layers of the same component or different contained components in the cell structure. The manufacturing method of the inorganic substance containing synthetic resin foam of description. 前記合成樹脂発泡体が、ポリスチレン系樹脂発泡体、ポリエチレン系樹脂発泡体、ポリプロピレン系樹脂発泡体、ポリエステル系樹脂発泡体、発泡ポリウレタンからなる群から選択される請求項10〜17のいずれか1項に記載の無機物含有合成樹脂発泡体の製造方法。  The synthetic resin foam is selected from the group consisting of a polystyrene resin foam, a polyethylene resin foam, a polypropylene resin foam, a polyester resin foam, and a foamed polyurethane. The manufacturing method of the inorganic substance containing synthetic resin foam as described in any one of. 前記工程(A)において、前記水溶性ケイ酸塩の溶液がケイ酸ゲルを含むものである請求項10〜18に記載の無機物含有合成樹脂発泡体の製造方法。  In the said process (A), the solution of the said water-soluble silicate contains a silicate gel, The manufacturing method of the inorganic substance containing synthetic resin foam of Claims 10-18. 前記工程(A)と工程(B)の一方又は両方において、前記合成樹脂発泡体を減圧雰囲気に置き、前記水溶性ケイ酸塩の溶液を接触させ、該雰囲気を大気圧に戻すことで前記気泡構造内に前記水溶性ケイ酸塩の溶液を入れる請求項10〜19のいずれか1項に記載の無機物含有合成樹脂発泡体の製造方法。  In one or both of the step (A) and the step (B), the synthetic resin foam is placed in a reduced-pressure atmosphere, the solution of the water-soluble silicate is brought into contact, and the atmosphere is returned to atmospheric pressure to thereby introduce the bubbles. The method for producing an inorganic substance-containing synthetic resin foam according to any one of claims 10 to 19, wherein a solution of the water-soluble silicate is put in a structure. 前記工程(A)又は(B)の前に予め合成樹脂発泡体を切断し、気泡が開口した状態の気泡構造を形成する工程を行う請求項10〜20のいずれか1項に記載の無機物含有合成樹脂発泡体の製造方法。  The inorganic substance-containing material according to any one of claims 10 to 20, wherein a step of cutting a synthetic resin foam in advance and forming a bubble structure in which bubbles are opened is performed before the step (A) or (B). A method for producing a synthetic resin foam. 前記工程(A)又は(B)の前に予め合成樹脂発泡体の表面に研磨処理又は穿刺処理を施し、気泡が開口した状態の気泡構造を形成する工程を行う請求項10〜21のいずれか1項に記載の無機物含有合成樹脂発泡体の製造方法。  The process according to any one of claims 10 to 21, wherein a step of polishing or puncturing the surface of the synthetic resin foam in advance before the step (A) or (B) to form a bubble structure in which bubbles are opened is performed. The manufacturing method of the inorganic substance containing synthetic resin foam of 1 item | term. 前記無機物含有合成樹脂発泡体の表面に合成樹脂層を積層する工程をさらに有する請求項10〜22のいずれか1項に記載の無機物含有合成樹脂発泡体の製造方法。  The manufacturing method of the inorganic substance containing synthetic resin foam of any one of Claims 10-22 which further has the process of laminating | stacking a synthetic resin layer on the surface of the said inorganic substance containing synthetic resin foam. 前記合成樹脂発泡体に穴が設けられ、該穴内に前記水溶性ケイ酸塩の溶液及び前記凝固剤の溶液を入れる請求項10〜23のいずれか1項に記載の無機物含有合成樹脂発泡体の製造方法。  The synthetic resin foam according to any one of claims 10 to 23, wherein a hole is provided in the synthetic resin foam, and the water-soluble silicate solution and the coagulant solution are placed in the hole. Production method.
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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020137987A1 (en) 2018-12-28 2020-07-02 デンカ株式会社 Fire-resistant heat-insulation composition, fire-resistant heat-insulation composition slurry, fire-resistant heat-insulation board, and fire-resistant heat-insulation structure
WO2021177378A1 (en) 2020-03-04 2021-09-10 株式会社ジェイエスピー Fireproof heat insulating board and fireproof heat insulating structural body

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020137987A1 (en) 2018-12-28 2020-07-02 デンカ株式会社 Fire-resistant heat-insulation composition, fire-resistant heat-insulation composition slurry, fire-resistant heat-insulation board, and fire-resistant heat-insulation structure
WO2021177378A1 (en) 2020-03-04 2021-09-10 株式会社ジェイエスピー Fireproof heat insulating board and fireproof heat insulating structural body

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