JP2018080227A - Manufacturing method of foamed particles - Google Patents
Manufacturing method of foamed particles Download PDFInfo
- Publication number
- JP2018080227A JP2018080227A JP2016221948A JP2016221948A JP2018080227A JP 2018080227 A JP2018080227 A JP 2018080227A JP 2016221948 A JP2016221948 A JP 2016221948A JP 2016221948 A JP2016221948 A JP 2016221948A JP 2018080227 A JP2018080227 A JP 2018080227A
- Authority
- JP
- Japan
- Prior art keywords
- particles
- block
- polymer particles
- foamed
- block copolymer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000002245 particle Substances 0.000 title claims abstract description 344
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 32
- 229920000642 polymer Polymers 0.000 claims abstract description 110
- 229920001400 block copolymer Polymers 0.000 claims abstract description 65
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims abstract description 38
- 239000005977 Ethylene Substances 0.000 claims abstract description 38
- 239000004711 α-olefin Substances 0.000 claims abstract description 38
- 238000000034 method Methods 0.000 claims abstract description 34
- 229920000089 Cyclic olefin copolymer Polymers 0.000 claims abstract description 33
- 150000001451 organic peroxides Chemical class 0.000 claims abstract description 33
- -1 polyethylene Polymers 0.000 claims abstract description 32
- 239000004698 Polyethylene Substances 0.000 claims abstract description 30
- 229920000573 polyethylene Polymers 0.000 claims abstract description 30
- 238000002844 melting Methods 0.000 claims abstract description 27
- 230000008018 melting Effects 0.000 claims abstract description 27
- 239000004088 foaming agent Substances 0.000 claims abstract description 25
- 238000005187 foaming Methods 0.000 claims abstract description 17
- 238000004132 cross linking Methods 0.000 claims abstract description 13
- 239000002612 dispersion medium Substances 0.000 claims description 17
- 150000003839 salts Chemical class 0.000 claims description 10
- 229910052751 metal Inorganic materials 0.000 claims description 9
- 239000002184 metal Substances 0.000 claims description 9
- DIZPMCHEQGEION-UHFFFAOYSA-H aluminium sulfate (anhydrous) Chemical group [Al+3].[Al+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O DIZPMCHEQGEION-UHFFFAOYSA-H 0.000 claims description 6
- 239000002270 dispersing agent Substances 0.000 abstract description 5
- 238000000465 moulding Methods 0.000 description 29
- 238000007906 compression Methods 0.000 description 17
- 230000006835 compression Effects 0.000 description 17
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 12
- 239000006260 foam Substances 0.000 description 12
- 239000000463 material Substances 0.000 description 12
- 230000000704 physical effect Effects 0.000 description 11
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 10
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 9
- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 9
- 239000008096 xylene Substances 0.000 description 9
- 238000010438 heat treatment Methods 0.000 description 8
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 6
- 239000000654 additive Substances 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 6
- 239000003431 cross linking reagent Substances 0.000 description 6
- 238000011049 filling Methods 0.000 description 6
- 239000002609 medium Substances 0.000 description 5
- 239000000155 melt Substances 0.000 description 5
- 229920005989 resin Polymers 0.000 description 5
- 239000011347 resin Substances 0.000 description 5
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 4
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 description 4
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- 238000010521 absorption reaction Methods 0.000 description 4
- 239000002585 base Substances 0.000 description 4
- 238000005452 bending Methods 0.000 description 4
- 239000001569 carbon dioxide Substances 0.000 description 4
- 229910002092 carbon dioxide Inorganic materials 0.000 description 4
- 229920006037 cross link polymer Polymers 0.000 description 4
- 238000005520 cutting process Methods 0.000 description 4
- 230000006378 damage Effects 0.000 description 4
- 238000011156 evaluation Methods 0.000 description 4
- 238000005470 impregnation Methods 0.000 description 4
- 238000005259 measurement Methods 0.000 description 4
- 229920006030 multiblock copolymer Polymers 0.000 description 4
- 239000002667 nucleating agent Substances 0.000 description 4
- 239000004604 Blowing Agent Substances 0.000 description 3
- YMWUJEATGCHHMB-UHFFFAOYSA-N Dichloromethane Chemical compound ClCCl YMWUJEATGCHHMB-UHFFFAOYSA-N 0.000 description 3
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 3
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 3
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 229920001577 copolymer Polymers 0.000 description 3
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- 239000011800 void material Substances 0.000 description 3
- VBQCFYPTKHCPGI-UHFFFAOYSA-N 1,1-bis(2-methylpentan-2-ylperoxy)cyclohexane Chemical compound CCCC(C)(C)OOC1(OOC(C)(C)CCC)CCCCC1 VBQCFYPTKHCPGI-UHFFFAOYSA-N 0.000 description 2
- ZGEGCLOFRBLKSE-UHFFFAOYSA-N 1-Heptene Chemical compound CCCCCC=C ZGEGCLOFRBLKSE-UHFFFAOYSA-N 0.000 description 2
- AFFLGGQVNFXPEV-UHFFFAOYSA-N 1-decene Chemical compound CCCCCCCCC=C AFFLGGQVNFXPEV-UHFFFAOYSA-N 0.000 description 2
- JRZJOMJEPLMPRA-UHFFFAOYSA-N 1-nonene Chemical compound CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 2
- WSSSPWUEQFSQQG-UHFFFAOYSA-N 4-methyl-1-pentene Chemical compound CC(C)CC=C WSSSPWUEQFSQQG-UHFFFAOYSA-N 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 2
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- RGSFGYAAUTVSQA-UHFFFAOYSA-N Cyclopentane Chemical compound C1CCCC1 RGSFGYAAUTVSQA-UHFFFAOYSA-N 0.000 description 2
- LCGLNKUTAGEVQW-UHFFFAOYSA-N Dimethyl ether Chemical compound COC LCGLNKUTAGEVQW-UHFFFAOYSA-N 0.000 description 2
- XPDWGBQVDMORPB-UHFFFAOYSA-N Fluoroform Chemical compound FC(F)F XPDWGBQVDMORPB-UHFFFAOYSA-N 0.000 description 2
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 description 2
- TWRXJAOTZQYOKJ-UHFFFAOYSA-L Magnesium chloride Chemical compound [Mg+2].[Cl-].[Cl-] TWRXJAOTZQYOKJ-UHFFFAOYSA-L 0.000 description 2
- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical compound [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 description 2
- 238000005481 NMR spectroscopy Methods 0.000 description 2
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- 239000003570 air Substances 0.000 description 2
- 235000012211 aluminium silicate Nutrition 0.000 description 2
- VSCWAEJMTAWNJL-UHFFFAOYSA-K aluminium trichloride Chemical compound Cl[Al](Cl)Cl VSCWAEJMTAWNJL-UHFFFAOYSA-K 0.000 description 2
- 239000000470 constituent Substances 0.000 description 2
- 238000000354 decomposition reaction Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000002349 favourable effect Effects 0.000 description 2
- 239000003063 flame retardant Substances 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- NNPPMTNAJDCUHE-UHFFFAOYSA-N isobutane Chemical compound CC(C)C NNPPMTNAJDCUHE-UHFFFAOYSA-N 0.000 description 2
- QWTDNUCVQCZILF-UHFFFAOYSA-N isopentane Chemical compound CCC(C)C QWTDNUCVQCZILF-UHFFFAOYSA-N 0.000 description 2
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 2
- YIXJRHPUWRPCBB-UHFFFAOYSA-N magnesium nitrate Chemical compound [Mg+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O YIXJRHPUWRPCBB-UHFFFAOYSA-N 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000013518 molded foam Substances 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- YWAKXRMUMFPDSH-UHFFFAOYSA-N pentene Chemical compound CCCC=C YWAKXRMUMFPDSH-UHFFFAOYSA-N 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 2
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 2
- 239000004094 surface-active agent Substances 0.000 description 2
- JXCAHDJDIAQCJO-UHFFFAOYSA-N (1-tert-butylperoxy-2-ethylhexyl) hydrogen carbonate Chemical compound CCCCC(CC)C(OC(O)=O)OOC(C)(C)C JXCAHDJDIAQCJO-UHFFFAOYSA-N 0.000 description 1
- FVQMJJQUGGVLEP-UHFFFAOYSA-N (2-methylpropan-2-yl)oxy 2-ethylhexaneperoxoate Chemical compound CCCCC(CC)C(=O)OOOC(C)(C)C FVQMJJQUGGVLEP-UHFFFAOYSA-N 0.000 description 1
- MYOQALXKVOJACM-UHFFFAOYSA-N (2-methylpropan-2-yl)oxy pentaneperoxoate Chemical compound CCCCC(=O)OOOC(C)(C)C MYOQALXKVOJACM-UHFFFAOYSA-N 0.000 description 1
- BNGXYYYYKUGPPF-UHFFFAOYSA-M (3-methylphenyl)methyl-triphenylphosphanium;chloride Chemical compound [Cl-].CC1=CC=CC(C[P+](C=2C=CC=CC=2)(C=2C=CC=CC=2)C=2C=CC=CC=2)=C1 BNGXYYYYKUGPPF-UHFFFAOYSA-M 0.000 description 1
- LVGUZGTVOIAKKC-UHFFFAOYSA-N 1,1,1,2-tetrafluoroethane Chemical compound FCC(F)(F)F LVGUZGTVOIAKKC-UHFFFAOYSA-N 0.000 description 1
- NPNPZTNLOVBDOC-UHFFFAOYSA-N 1,1-difluoroethane Chemical compound CC(F)F NPNPZTNLOVBDOC-UHFFFAOYSA-N 0.000 description 1
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- XMNIXWIUMCBBBL-UHFFFAOYSA-N 2-(2-phenylpropan-2-ylperoxy)propan-2-ylbenzene Chemical compound C=1C=CC=CC=1C(C)(C)OOC(C)(C)C1=CC=CC=C1 XMNIXWIUMCBBBL-UHFFFAOYSA-N 0.000 description 1
- BRQMAAFGEXNUOL-UHFFFAOYSA-N 2-ethylhexyl (2-methylpropan-2-yl)oxy carbonate Chemical compound CCCCC(CC)COC(=O)OOC(C)(C)C BRQMAAFGEXNUOL-UHFFFAOYSA-N 0.000 description 1
- YHQXBTXEYZIYOV-UHFFFAOYSA-N 3-methylbut-1-ene Chemical compound CC(C)C=C YHQXBTXEYZIYOV-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- XWCDCDSDNJVCLO-UHFFFAOYSA-N Chlorofluoromethane Chemical compound FCCl XWCDCDSDNJVCLO-UHFFFAOYSA-N 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- XOBKSJJDNFUZPF-UHFFFAOYSA-N Methoxyethane Chemical compound CCOC XOBKSJJDNFUZPF-UHFFFAOYSA-N 0.000 description 1
- CBENFWSGALASAD-UHFFFAOYSA-N Ozone Chemical compound [O-][O+]=O CBENFWSGALASAD-UHFFFAOYSA-N 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- OFBQJSOFQDEBGM-UHFFFAOYSA-N Pentane Chemical compound CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- BCKXLBQYZLBQEK-KVVVOXFISA-M Sodium oleate Chemical compound [Na+].CCCCCCCC\C=C/CCCCCCCC([O-])=O BCKXLBQYZLBQEK-KVVVOXFISA-M 0.000 description 1
- 229910021536 Zeolite Inorganic materials 0.000 description 1
- 239000006096 absorbing agent Substances 0.000 description 1
- 239000011358 absorbing material Substances 0.000 description 1
- 150000001338 aliphatic hydrocarbons Chemical class 0.000 description 1
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical class [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 150000001412 amines Chemical class 0.000 description 1
- 239000003945 anionic surfactant Substances 0.000 description 1
- 239000003242 anti bacterial agent Substances 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 239000002216 antistatic agent Substances 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000004323 axial length Effects 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 229910021538 borax Inorganic materials 0.000 description 1
- BXIQXYOPGBXIEM-UHFFFAOYSA-N butyl 4,4-bis(tert-butylperoxy)pentanoate Chemical compound CCCCOC(=O)CCC(C)(OOC(C)(C)C)OOC(C)(C)C BXIQXYOPGBXIEM-UHFFFAOYSA-N 0.000 description 1
- 125000000484 butyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 239000001506 calcium phosphate Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 235000011089 carbon dioxide Nutrition 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- NEHMKBQYUWJMIP-NJFSPNSNSA-N chloro(114C)methane Chemical compound [14CH3]Cl NEHMKBQYUWJMIP-NJFSPNSNSA-N 0.000 description 1
- HRYZWHHZPQKTII-UHFFFAOYSA-N chloroethane Chemical compound CCCl HRYZWHHZPQKTII-UHFFFAOYSA-N 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 238000012669 compression test Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 150000001983 dialkylethers Chemical class 0.000 description 1
- 238000000113 differential scanning calorimetry Methods 0.000 description 1
- 238000001938 differential scanning calorimetry curve Methods 0.000 description 1
- AFABGHUZZDYHJO-UHFFFAOYSA-N dimethyl butane Natural products CCCC(C)C AFABGHUZZDYHJO-UHFFFAOYSA-N 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- GVGUFUZHNYFZLC-UHFFFAOYSA-N dodecyl benzenesulfonate;sodium Chemical compound [Na].CCCCCCCCCCCCOS(=O)(=O)C1=CC=CC=C1 GVGUFUZHNYFZLC-UHFFFAOYSA-N 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 229960003750 ethyl chloride Drugs 0.000 description 1
- 125000000816 ethylene group Chemical group [H]C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 238000010097 foam moulding Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 235000011187 glycerol Nutrition 0.000 description 1
- 238000005469 granulation Methods 0.000 description 1
- 230000003179 granulation Effects 0.000 description 1
- 238000001864 heat-flux differential scanning calorimetry Methods 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- DMEGYFMYUHOHGS-UHFFFAOYSA-N heptamethylene Natural products C1CCCCCC1 DMEGYFMYUHOHGS-UHFFFAOYSA-N 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 125000004435 hydrogen atom Chemical class [H]* 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 239000001282 iso-butane Substances 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 239000004611 light stabiliser Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 229910001629 magnesium chloride Inorganic materials 0.000 description 1
- GVALZJMUIHGIMD-UHFFFAOYSA-H magnesium phosphate Chemical compound [Mg+2].[Mg+2].[Mg+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O GVALZJMUIHGIMD-UHFFFAOYSA-H 0.000 description 1
- 239000004137 magnesium phosphate Substances 0.000 description 1
- 229960002261 magnesium phosphate Drugs 0.000 description 1
- 229910000157 magnesium phosphate Inorganic materials 0.000 description 1
- 235000010994 magnesium phosphates Nutrition 0.000 description 1
- 159000000003 magnesium salts Chemical class 0.000 description 1
- 229910052943 magnesium sulfate Inorganic materials 0.000 description 1
- 235000019341 magnesium sulphate Nutrition 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 239000006078 metal deactivator Substances 0.000 description 1
- 229920000609 methyl cellulose Polymers 0.000 description 1
- 239000001923 methylcellulose Substances 0.000 description 1
- 235000010981 methylcellulose Nutrition 0.000 description 1
- 229940073584 methylene chloride Drugs 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical compound CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 1
- 125000004108 n-butyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 229910052754 neon Inorganic materials 0.000 description 1
- GKAOGPIIYCISHV-UHFFFAOYSA-N neon atom Chemical compound [Ne] GKAOGPIIYCISHV-UHFFFAOYSA-N 0.000 description 1
- 239000002736 nonionic surfactant Substances 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 150000002978 peroxides Chemical class 0.000 description 1
- 239000010452 phosphate Substances 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 238000013001 point bending Methods 0.000 description 1
- 229920005672 polyolefin resin Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 235000019422 polyvinyl alcohol Nutrition 0.000 description 1
- 229920000036 polyvinylpyrrolidone Polymers 0.000 description 1
- 239000001267 polyvinylpyrrolidone Substances 0.000 description 1
- 235000013855 polyvinylpyrrolidone Nutrition 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 239000001294 propane Substances 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- IJDNQMDRQITEOD-UHFFFAOYSA-N sec-butylidene Natural products CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 229940080264 sodium dodecylbenzenesulfonate Drugs 0.000 description 1
- 239000004328 sodium tetraborate Substances 0.000 description 1
- 235000010339 sodium tetraborate Nutrition 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 238000010557 suspension polymerization reaction Methods 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- QORWJWZARLRLPR-UHFFFAOYSA-H tricalcium bis(phosphate) Chemical compound [Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O QORWJWZARLRLPR-UHFFFAOYSA-H 0.000 description 1
- 229940078499 tricalcium phosphate Drugs 0.000 description 1
- 229910000391 tricalcium phosphate Inorganic materials 0.000 description 1
- 235000019731 tricalcium phosphate Nutrition 0.000 description 1
- BIKXLKXABVUSMH-UHFFFAOYSA-N trizinc;diborate Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]B([O-])[O-].[O-]B([O-])[O-] BIKXLKXABVUSMH-UHFFFAOYSA-N 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
Abstract
Description
本発明は、発泡粒子の製造方法に関する。 The present invention relates to a method for producing expanded particles.
近年、圧縮永久ひずみ回復性、反発弾性、収縮、硬度、摩耗などの発泡体特性をバランス良く有する発泡体を得るために、特定の物性を有するエチレン／α−オレフィン・マルチブロック共重合体を含む発泡体が開示されている（例えば、特許文献１参照）。
また、圧縮強度と透水係数が大きく、融着性に優れ、収縮等もない良好な発泡成形体を得るために、特定の形状であって、連通した空隙を有するポリオレフィン系樹脂発泡成形体が開示されている（例えば、特許文献２参照）。
In recent years, ethylene / α-olefin multiblock copolymers having specific physical properties have been included in order to obtain a foam having a good balance of foam properties such as compression set recovery, rebound resilience, shrinkage, hardness, and wear. A foam is disclosed (for example, refer to Patent Document 1).
Also disclosed is a polyolefin-based resin foam molded article having a specific shape and having continuous voids in order to obtain a good foam molded article having a large compressive strength and water permeability coefficient, excellent fusibility, and no shrinkage. (For example, refer to Patent Document 2).
しかしながら、特許文献１には、プレス発泡して成形する手法が検証されているのみで、型内成形用の発泡粒子や、型内成形してなる発泡粒子成形体については十分な検討がされていなかった。
一方、特許文献２には、発泡粒子の基材樹脂の例として種々の形態が示されているものの、ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体発泡粒子については検討がなされておらず、貫通孔がつぶれてしまい、目的の形状の発泡粒子を得ることができなかった。
However, Patent Document 1 only examines the technique of press foaming and molding, and sufficient studies have been made on foam particles for in-mold molding and foamed-particle molded articles formed by in-mold molding. There wasn't.
On the other hand, although various forms are shown in Patent Document 2 as examples of the base resin of the expanded particles, the block copolymer expanded particles of a polyethylene block and an ethylene / α-olefin copolymer block are studied. However, the through-holes were crushed, and it was not possible to obtain expanded particles having the desired shape.
本発明は、貫通孔を有する、ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体の発泡粒子の製造方法を提供することを目的とする。 An object of this invention is to provide the manufacturing method of the foamed particle of the block copolymer of a polyethylene block and an ethylene / alpha-olefin copolymer block which has a through-hole.
本発明者らは、鋭意研究を重ねた結果、以下に示す構成を採用することにより、上記課題を解決し得ることを見出し、本発明を完成するに至った。
すなわち、本発明は、以下のとおりである。
〔１〕
ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体の、貫通孔を有する発泡粒子の製造方法であって、
工程（ａ）：密閉容器内で、分散媒に、前記ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体の、貫通孔を有する重合体粒子を分散させる工程、
工程（ｂ）：前記重合体粒子に下式（１）の関係を満足する有機過酸化物を含浸させ、前記重合体粒子を構成する前記ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体の融点以上、前記融点＋８０℃以下の温度で、前記重合体粒子を架橋させる工程、
工程（ｃ）：前記重合体粒子に発泡剤を含浸させる工程、及び
工程（ｄ）：前記発泡剤を含む発泡性重合体粒子を発泡させる工程、
を有する、発泡粒子の製造方法。
５≦Ｔｍ−Ｔｈ≦４５・・・（１）
〔Ｔｍ：前記重合体粒子を構成する前記ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体の融点（℃）、Ｔｈ：前記有機過酸化物の１０時間半減期温度（℃）〕
〔２〕
少なくとも前記工程（ｂ）において、更に、分散媒に、前記重合体粒子１００重量部に対して、２価または３価の金属塩が０．０１〜５重量部添加されている、前記〔１〕に記載の発泡粒子の製造方法。
〔３〕
前記工程（ｂ）において、前記重合体粒子を架橋させる温度が、下式の（２）の関係を満足する、前記〔１〕または〔２〕に記載の発泡粒子の製造方法。
１０≦Ｔｍ−Ｔｈ≦４０・・・（２）
〔４〕
前記有機過酸化物の１０時間半減期温度Ｔｈが、８０〜１１０℃である前記〔１〕〜〔３〕のいずれか１つに記載の発泡粒子の製造方法。
〔５〕
前記金属塩が、硫酸アルミニウムである、前記〔２〕〜〔４〕のいずれか１つに記載の発泡粒子の製造方法。
〔６〕
前記重合体粒子を構成する前記ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体が、ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのマルチブロック共重合体である前記〔１〕〜〔５〕のいずれか１つに記載の発泡粒子の製造方法。
As a result of intensive studies, the present inventors have found that the above-described problems can be solved by adopting the configuration shown below, and have completed the present invention.
That is, the present invention is as follows.
[1]
A block copolymer of a polyethylene block and an ethylene / α-olefin copolymer block, which is a method for producing expanded particles having through holes,
Step (a): Dispersing polymer particles having through-holes of the block copolymer of the polyethylene block and the ethylene / α-olefin copolymer block in a dispersion medium in a closed container,
Step (b): impregnating the polymer particles with an organic peroxide satisfying the relationship of the following formula (1), and the polyethylene block and the ethylene / α-olefin copolymer block constituting the polymer particle: A step of crosslinking the polymer particles at a temperature not lower than the melting point of the block copolymer and not higher than the melting point + 80 ° C.,
Step (c): a step of impregnating the polymer particles with a foaming agent, and step (d): a step of foaming expandable polymer particles containing the foaming agent,
A process for producing expanded particles, comprising:
5 ≦ Tm−Th ≦ 45 (1)
[Tm: melting point (° C.) of block copolymer of polyethylene block and ethylene / α-olefin copolymer block constituting the polymer particles, Th: 10 hour half-life temperature (° C. of organic peroxide) )]
[2]
At least in the step (b), 0.01 to 5 parts by weight of a divalent or trivalent metal salt is further added to the dispersion medium with respect to 100 parts by weight of the polymer particles, [1] The manufacturing method of the expanded particle as described in 2.
[3]
The method for producing expanded particles according to [1] or [2], wherein in the step (b), the temperature at which the polymer particles are crosslinked satisfies the relationship of the following formula (2).
10 ≦ Tm−Th ≦ 40 (2)
[4]
The method for producing expanded particles according to any one of [1] to [3], wherein the organic peroxide has a 10-hour half-life temperature Th of 80 to 110 ° C.
[5]
The method for producing expanded particles according to any one of [2] to [4], wherein the metal salt is aluminum sulfate.
[6]
The block copolymer of the polyethylene block and the ethylene / α-olefin copolymer block constituting the polymer particle is a multi-block copolymer of a polyethylene block and an ethylene / α-olefin copolymer block. [1] The method for producing expanded particles according to any one of [5].
本発明によれば、貫通孔を有する、ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体の発泡粒子の製造方法を提供することができる。 ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the foamed particle of the block copolymer of the polyethylene block and ethylene / alpha-olefin copolymer block which has a through-hole can be provided.
１．発泡粒子の製造方法
本発明の発泡粒子の製造方法は、ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体の発泡粒子の製造方法であって、
工程（ａ）：密閉容器内で、分散媒に、前記ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体の、貫通孔を有する重合体粒子を分散させる工程、
工程（ｂ）：前記重合体粒子に下式（１）の関係を満足する有機過酸化物を含浸させ、前記重合体粒子を構成する前記ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体の融点以上、前記融点＋５０℃以下の温度で、前記重合体粒子を架橋させる工程、
工程（ｃ）：前記重合体粒子に発泡剤を含浸させる工程、及び
工程（ｄ）：前記発泡剤を含む発泡性重合体粒子を発泡させる工程、
を有する。
５≦Ｔｍ−Ｔｈ≦４５・・・（１）
〔Ｔｍ：前記重合体粒子を構成する前記ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体の融点（℃）、Ｔｈ：前記有機過酸化物の１０時間半減期温度（℃）〕
本発明の発泡粒子の製造方法は、工程（ａ）〜（ｄ）以外の工程を有していてもよいし、工程（ａ）〜（ｄ）の各工程において、更に他の成分を添加したり、他の工程を有してもよい。また、工程（ａ）〜工程（ｃ）は同時に行ってもよい。
上記製造方法により発泡粒子を製造することで、貫通孔を有する発泡粒子が得られ、かかる発泡粒子を型内発泡成形することで、従来よりも密度が小さく軽量で、５〜４０％程度の空隙率を有し、回復性に優れる発泡粒子成形体を製造することができる。
工程（ａ）〜（ｄ）の説明の前に、まず、発泡粒子の製造に用いるポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体について説明する。
1. Method for producing foamed particles The method for producing foamed particles of the present invention is a method for producing foamed particles of a block copolymer of a polyethylene block and an ethylene / α-olefin copolymer block,
Step (a): Dispersing polymer particles having through-holes of the block copolymer of the polyethylene block and the ethylene / α-olefin copolymer block in a dispersion medium in a closed container,
Step (b): impregnating the polymer particles with an organic peroxide satisfying the relationship of the following formula (1), and the polyethylene block and the ethylene / α-olefin copolymer block constituting the polymer particle: A step of crosslinking the polymer particles at a temperature not lower than the melting point of the block copolymer and not higher than the melting point + 50 ° C.,
Step (c): a step of impregnating the polymer particles with a foaming agent, and step (d): a step of foaming expandable polymer particles containing the foaming agent,
Have
5 ≦ Tm−Th ≦ 45 (1)
[Tm: melting point (° C.) of block copolymer of polyethylene block and ethylene / α-olefin copolymer block constituting the polymer particles, Th: 10 hour half-life temperature (° C. of organic peroxide) )]
The manufacturing method of the expanded particle of this invention may have processes other than process (a)-(d), and also adds another component in each process of process (a)-(d). Or may have other processes. Moreover, you may perform process (a)-process (c) simultaneously.
By producing foamed particles by the above production method, foamed particles having through-holes can be obtained. By foam-molding the foamed particles in the mold, the density is smaller and lighter than before, and the gap is about 5 to 40%. It is possible to produce a foamed particle molded body having a high rate and excellent recoverability.
Prior to the description of the steps (a) to (d), first, a block copolymer of a polyethylene block and an ethylene / α-olefin copolymer block used for producing foamed particles will be described.
（ブロック共重合体）
上記ブロック共重合体は、ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとを有する。前記ブロック共重合体は、たとえば、下記の式（Ｍ）によって表すことができる。
（ＡＢ）ｎ （Ｍ）
（式中、ｎは１以上の整数であり、Ａはハードブロックを表し、Ｂはソフトブロックを表す。）
(Block copolymer)
The block copolymer has a polyethylene block and an ethylene / α-olefin copolymer block. The block copolymer can be represented by, for example, the following formula (M).
(AB) n (M)
(In the formula, n is an integer of 1 or more, A represents a hard block, and B represents a soft block.)
ここで、Ａのハードブロック（以下、Ａブロックともいう）はポリエチレンブロックに該当し、Ｂのソフトブロック（以下、Ｂブロックともいう）はエチレン／α−オレフィン共重合体ブロックに該当する。Ａブロック及びＢブロックは、直鎖状に配列していることが好ましい。さらに、ブロック共重合体は、Ａブロック及びＢブロック以外の第３のブロックを含まないことが好ましい。 Here, the hard block of A (hereinafter also referred to as A block) corresponds to a polyethylene block, and the soft block of B (hereinafter also referred to as B block) corresponds to an ethylene / α-olefin copolymer block. The A block and B block are preferably arranged in a straight chain. Furthermore, it is preferable that a block copolymer does not contain 3rd blocks other than A block and B block.
Ａブロックを構成するポリエチレンブロックにおけるエチレンに由来する構成単位の成分の割合は、ポリエチレンブロックの質量に対して、好ましくは９５重量％よりも大きく、より好ましくは９８重量％よりも大きい。一方、Ｂブロックを構成するエチレン／α−オレフィン共重合体ブロックでは、α−オレフィンに由来する構成単位の成分の割合は、エチレン／α−オレフィン共重合体ブロックの質量に対して、好ましくは５重量％よりも大きく、より好ましくは１０重量％よりも大きく、さらに好ましくは１５重量％よりも大きい。 The proportion of constituent units derived from ethylene in the polyethylene block constituting the A block is preferably greater than 95% by weight, more preferably greater than 98% by weight, based on the mass of the polyethylene block. On the other hand, in the ethylene / α-olefin copolymer block constituting the B block, the proportion of the constituent unit component derived from the α-olefin is preferably 5 with respect to the mass of the ethylene / α-olefin copolymer block. It is greater than wt%, more preferably greater than 10 wt%, and even more preferably greater than 15 wt%.
ブロック共重合体におけるＢブロックを構成するエチレン／α−オレフィン共重合体ブロックの割合は、ブロック共重合体の質量に対して、好ましくは１〜９９重量％であり、より好ましくは５〜９５重量％である。ポリエチレンブロックの割合及びエチレン／α−オレフィン共重合体ブロックの割合は、示差走査熱量測定（ＤＳＣ）又は核磁気共鳴（ＮＭＲ）から得られるデータに基づいて計算することができる。 The ratio of the ethylene / α-olefin copolymer block constituting the B block in the block copolymer is preferably 1 to 99% by weight, more preferably 5 to 95% by weight, based on the mass of the block copolymer. %. The proportion of polyethylene blocks and the proportion of ethylene / α-olefin copolymer blocks can be calculated based on data obtained from differential scanning calorimetry (DSC) or nuclear magnetic resonance (NMR).
ブロック共重合体におけるＢブロックを構成するエチレン／α−オレフィン共重合体ブロックは、好ましくは、Ｃ３〜Ｃ２０のα−オレフィンとエチレンとの共重合体のブロックである。エチレン／α−オレフィン共重合体ブロックにおいて、エチレンと共重合するα−オレフィンには、例えば、プロピレン、１−ブテン、１−ペンテン、１−へキセン、１−へプテン、１−オクテン、１−ノネン、１−デセン、３−メチル−１−ブテン、４−メチル−１−ペンテン等が挙げられ、それらを組み合わせて使用することもできる。工業的な入手のしやすさや諸特性、経済性等の観点からは、エチレンと共重合するα−オレフィンとしては、プロピレン、１−ブテン、１−へキセン、１−オクテンが挙げられ、特に１−オクテンが好ましい。 The ethylene / α-olefin copolymer block constituting the B block in the block copolymer is preferably a block of a copolymer of C 3 to C 20 α-olefin and ethylene. Examples of the α-olefin copolymerized with ethylene in the ethylene / α-olefin copolymer block include propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-octene, Nonene, 1-decene, 3-methyl-1-butene, 4-methyl-1-pentene and the like can be mentioned, and these can be used in combination. From the viewpoint of industrial availability, various characteristics, economy, etc., examples of the α-olefin copolymerized with ethylene include propylene, 1-butene, 1-hexene and 1-octene. -Octene is preferred.
（マルチブロック共重合体）
なお、上記ブロック共重合体としては、ジブロック構造、トリブロック構造、およびマルチブロック構造であってもよいが、特に、マルチブロック構造であることが好ましい。
(Multi-block copolymer)
The block copolymer may be a diblock structure, a triblock structure, or a multiblock structure, but a multiblock structure is particularly preferable.
上記ブロック共重合体には、例えば、特許文献１に記載されているエチレン／α−オレフィンの共重合体が挙げられる。また、上記マルチブロック共重合体において市販されているものには、例えば、ダウ・ケミカル（株）製の商品名「インフューズ（Ｉｎｆｕｓｅ）」等が挙げられる。 Examples of the block copolymer include ethylene / α-olefin copolymers described in Patent Document 1. Moreover, what is marketed in the said multiblock copolymer includes the brand name "Infuse" by Dow Chemical Co., Ltd. etc., for example.
前記ブロック共重合体は、曲げ弾性率が１０〜１００ＭＰａのものであることが好ましい。上記範囲内である場合には、発泡時に生成する気泡が破泡することなく、良好な気泡構造を有する発泡粒子が得られる。上記観点から、前記曲げ弾性率は１１〜９０ＭＰａが好ましく、１２〜５０ＭＰａが更に好ましい。 The block copolymer preferably has a flexural modulus of 10 to 100 MPa. When it is within the above range, the foamed particles having a good cell structure can be obtained without bubbles generated during foaming. From the above viewpoint, the flexural modulus is preferably 11 to 90 MPa, and more preferably 12 to 50 MPa.
前記ブロック共重合体の１９０℃、荷重２．１６ｋｇにおけるメルトフローレイト（ＭＦＲ）は、好ましくは２〜１０ｇ／１０分であり、より好ましくは３〜８ｇ／１０分であり、さらに好ましくは４〜７ｇ／１０分である。メルトフローレイトが上記範囲内であれば、前記ブロック共重合体の発泡粒子の融着性を損ねにくく、発泡粒子を型内成形して発泡粒子成形体を作製し易く、良好な物性を有する発泡粒子成形体となる。なお、このメルトフローレイトは、ＪＩＳ Ｋ７２１０−1（２０１４年）に準拠して、温度１９０℃、荷重２．１６ｋｇの条件で測定される値である。 The melt flow rate (MFR) at 190 ° C. and a load of 2.16 kg of the block copolymer is preferably 2 to 10 g / 10 minutes, more preferably 3 to 8 g / 10 minutes, and still more preferably 4 to 7 g / 10 min. If the melt flow rate is within the above range, it is difficult to impair the fusing property of the foamed particles of the block copolymer, the foamed particles are molded in-mold to easily produce a foamed particle compact, and the foam has good physical properties. It becomes a particle compact. The melt flow rate is a value measured under conditions of a temperature of 190 ° C. and a load of 2.16 kg in accordance with JIS K7210-1 (2014).
前記ブロック共重合体の見掛け密度は、８００〜１０００ｇ／Ｌであることが好ましく、８５０〜９００ｇ／Ｌであることがより好ましく、８６０〜８９０であることが最も好ましい。 The apparent density of the block copolymer is preferably 800 to 1000 g / L, more preferably 850 to 900 g / L, and most preferably 860 to 890.
また、前記ブロック共重合体の融点は１００〜１３０℃であることが好ましく、１１５〜１２５℃であることがより好ましい。前記ブロック共重合体の融点が上記範囲であると、工程（ｂ）において、架橋剤が均一に含浸され、良好な発泡粒子を得ることが可能となる 次に、工程（ａ）〜（ｄ）について詳細に説明する。 Moreover, it is preferable that melting | fusing point of the said block copolymer is 100-130 degreeC, and it is more preferable that it is 115-125 degreeC. When the melting point of the block copolymer is in the above range, in step (b), the crosslinking agent is uniformly impregnated, and it becomes possible to obtain good expanded particles. Next, steps (a) to (d) Will be described in detail.
（１）工程（ａ）
工程（ａ）は、密閉容器内で、分散媒に、貫通孔を有する、ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体の重合体粒子を分散させる工程である。
(1) Step (a)
Step (a) is a step of dispersing polymer particles of a block copolymer of a polyethylene block and an ethylene / α-olefin copolymer block having a through hole in a dispersion medium in a sealed container.
〔重合体粒子〕
工程（ａ）で用いる重合体粒子は既述のポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体からなり、貫通孔を有する。
(Polymer particles)
The polymer particles used in the step (a) are composed of a block copolymer of the aforementioned polyethylene block and an ethylene / α-olefin copolymer block, and have through holes.
重合体粒子が有する貫通孔の形状は特に制限されず、通常、孔の軸方向と直交する面の輪郭（以下「孔の断面形状」と称する）が円形であるが、楕円形、矩形、台形、三角形、五角以上の多角形、不定形等のいずれであってもよい。また、重合体粒子の形状も特に制限されず、球形または多面体形であってもよいし、断面形状が円形、矩形、台形、三角形、五角以上の多角形、または不定形の柱状であってもよい。
以上の中でも、貫通孔を有する重合体粒子は、重合体粒子の断面形状が円形であって、孔の断面形状が円形である円筒状であることが更に好ましい。なお、円形には略円形を含むものとする。
The shape of the through hole of the polymer particle is not particularly limited, and the outline of the surface perpendicular to the axial direction of the hole (hereinafter referred to as “hole cross-sectional shape”) is generally circular, but is oval, rectangular, trapezoidal. , A triangle, a pentagon or more polygon, and an indefinite shape. In addition, the shape of the polymer particles is not particularly limited, and may be spherical or polyhedral, and the cross-sectional shape may be a circle, rectangle, trapezoid, triangle, pentagon or more polygon, or an irregular column shape. Good.
Among the above, the polymer particles having through-holes are more preferably cylindrical in which the cross-sectional shape of the polymer particles is circular and the cross-sectional shape of the holes is circular. The circular shape includes a substantially circular shape.
重合体粒子の内径（孔の断面形状の長径）は、貫通孔の形状を維持する観点から、０．２〜５ｍｍであることが好ましく、０．５〜３ｍｍであることがより好ましい。発泡粒子の内径は、一定でなくてもよく、例えば、貫通孔の端部の一方の内径が小さく、他方の内径が大きくてもよいし、重合体粒子の表面側となる貫通孔の両端部の内径よりも、重合体粒子の中心部付近の内径が大きいか、小さくなる異径孔であってもよい。
また、貫通孔の軸方向の長さは、０．５〜１０ｍｍであることが好ましく、１〜７ｍｍであることがより好ましい。
From the viewpoint of maintaining the shape of the through-hole, the inner diameter of the polymer particle (the major axis of the cross-sectional shape of the hole) is preferably 0.2 to 5 mm, and more preferably 0.5 to 3 mm. The inner diameter of the expanded particles may not be constant. For example, one inner diameter of the end portion of the through hole may be small and the other inner diameter may be large, or both end portions of the through hole on the surface side of the polymer particle Different diameter holes may be used in which the inner diameter in the vicinity of the center of the polymer particles is larger or smaller than the inner diameter.
Moreover, it is preferable that the length of the through-hole of the axial direction is 0.5-10 mm, and it is more preferable that it is 1-7 mm.
重合体粒子の外径は、成形性や、金型への充填性の観点から、０．５〜５ｍｍが好ましく、０．８〜３ｍｍがより好ましい。また、前記重合体粒子の外径に対する前記重合体粒子の内径の比は、０．１〜０．８であることが好ましく、０．２〜０．７であることが更に好ましい。上記範囲内であれば、貫通孔を有する発泡粒子を得ることも可能である。 The outer diameter of the polymer particles is preferably 0.5 to 5 mm, more preferably 0.8 to 3 mm, from the viewpoints of moldability and moldability. Further, the ratio of the inner diameter of the polymer particles to the outer diameter of the polymer particles is preferably 0.1 to 0.8, and more preferably 0.2 to 0.7. If it is in the said range, it is also possible to obtain the expanded particle which has a through-hole.
（重合体粒子の製造方法）
重合体粒子は、ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体を押出機に供給し、混練して溶融混練物とし、該溶融混練物を押出機からストランド状に押出し、該ストランドを発泡粒子とするのに適した大きさに切断する方法等、公知の造粒方法より製造される。例えば、ストランド状に押出された溶融混練物を水冷により冷却した後、所定の長さに切断することにより重合体粒子を得ることができる。所定の長さに切断する際には、例えば、ストランドカット法を採用することができる。その他に、該溶融混練物を押出した直後に切断するホットカット法や水中で切断するアンダーウォーターカット法等により重合体粒子を得ることができる。
(Method for producing polymer particles)
For polymer particles, a block copolymer of a polyethylene block and an ethylene / α-olefin copolymer block is supplied to an extruder, kneaded to form a melt-kneaded product, and the melt-kneaded product is extruded into a strand form from the extruder. The strand is produced by a known granulation method such as a method of cutting the strand into a size suitable for forming expanded particles. For example, polymer particles can be obtained by cooling a melt-kneaded product extruded in a strand shape by water cooling and then cutting it into a predetermined length. When cutting into a predetermined length, for example, a strand cutting method can be employed. In addition, polymer particles can be obtained by a hot cut method in which the melt-kneaded product is cut immediately after being extruded or an underwater cut method in which the melt-kneaded product is cut in water.
重合体粒子に貫通孔を形成する手法は特に制限されない。
例えば、貫通孔を有する重合体粒子を得るには、押出機ダイス出口に所望の孔の断面形状と同様のスリットを有するものを選択すればよい。
The method for forming the through-holes in the polymer particles is not particularly limited.
For example, in order to obtain polymer particles having through-holes, it is only necessary to select those having a slit similar to the cross-sectional shape of the desired hole at the exit of the extruder die.
重合体粒子の１個当たりの平均重量は、通常０．０１〜１０ｍｇが好ましく、０．１〜５ｍｇがより好ましい。なお、重合体粒子の平均重量は、無作為に選んだ１００個の重合体粒子の重量（ｍｇ）を１００で除した値である。 The average weight per polymer particle is usually preferably 0.01 to 10 mg, more preferably 0.1 to 5 mg. The average weight of the polymer particles is a value obtained by dividing the weight (mg) of 100 randomly selected polymer particles by 100.
〔分散媒〕
工程（ａ）で使用する分散媒は、前記ブロック共重合体粒子を溶解しない分散媒であれば、特に限定されない。分散媒には、例えば、水、エチレングリコール、グリセリン、メタノール、エタノール等が挙げられる。好ましい分散媒は水である。
[Dispersion medium]
The dispersion medium used in the step (a) is not particularly limited as long as the dispersion medium does not dissolve the block copolymer particles. Examples of the dispersion medium include water, ethylene glycol, glycerin, methanol, ethanol, and the like. A preferred dispersion medium is water.
工程（ａ）において、分散剤を分散媒にさらに添加してもよい。分散剤には、例えば、ポリビニルアルコール、ポリビニルピロリドン、メチルセルロース等の有機系分散剤；酸化アルミニウム、酸化亜鉛、カオリン、マイカ、リン酸マグネシウム、リン酸三カルシウム等の難溶性無機塩等が挙げられる。 In the step (a), a dispersant may be further added to the dispersion medium. Examples of the dispersant include organic dispersants such as polyvinyl alcohol, polyvinyl pyrrolidone, and methyl cellulose; hardly soluble inorganic salts such as aluminum oxide, zinc oxide, kaolin, mica, magnesium phosphate, and tricalcium phosphate.
また、分散媒には、界面活性剤をさらに添加することもできる。界面活性剤には、例えば、オレイン酸ナトリウム、ドデシルベンゼンスルホン酸ナトリウム、その他懸濁重合で一般的に使用されるアニオン系界面活性剤、ノニオン系界面活性剤等が挙げられる。 Further, a surfactant can be further added to the dispersion medium. Examples of the surfactant include sodium oleate, sodium dodecylbenzenesulfonate, and other anionic surfactants and nonionic surfactants commonly used in suspension polymerization.
なお、工程（ｂ）において、分散媒に、２価または３価の金属塩（Ａ）が添加されていることが好ましい。工程（ｂ）の際に、前記金属塩（Ａ）の存在下で架橋剤の含浸、架橋反応が行われると、理由は定かではないが、工程（ｄ）により得られる発泡粒子の貫通孔が閉塞し難くなり、より大きな貫通孔を有する発泡粒子が得られ易くなる。なお、前記金属塩（Ａ）は、水溶性であることが好ましい。具体的には、硫酸アルミニウム、硝酸アルミニウム、塩化アルミニウムなどのアルミニウム塩、塩化マグネシウム、硝酸マグネシウム、硫酸マグネシウムなどのマグネシウム塩が挙げられる。これらの中でも、硫酸アルミニウムが特に好ましい。前記金属塩（Ａ）の添加量は、前記ブロック共重合体粒子１００重量部に対し、０．００１〜０．１重量部であることが好ましく、０．００５〜０．０８重量部であることがより好ましい。
具体的には、工程（ａ）の際に、分散媒に、前記金属塩（Ａ）を添加して、重合体粒子を分散させればよい。
In step (b), it is preferable that a divalent or trivalent metal salt (A) is added to the dispersion medium. In the step (b), if the impregnation of the crosslinking agent and the crosslinking reaction are performed in the presence of the metal salt (A), the reason is not clear, but the through-holes of the expanded particles obtained by the step (d) It becomes difficult to block, and it becomes easy to obtain expanded particles having larger through holes. The metal salt (A) is preferably water-soluble. Specific examples include aluminum salts such as aluminum sulfate, aluminum nitrate, and aluminum chloride, and magnesium salts such as magnesium chloride, magnesium nitrate, and magnesium sulfate. Among these, aluminum sulfate is particularly preferable. The addition amount of the metal salt (A) is preferably 0.001 to 0.1 parts by weight, and 0.005 to 0.08 parts by weight with respect to 100 parts by weight of the block copolymer particles. Is more preferable.
Specifically, in the step (a), the metal salt (A) may be added to the dispersion medium to disperse the polymer particles.
〔密閉容器〕
工程（ａ）で使用する密閉容器は、密閉することができる容器であれば、特に限定されない。後述する工程（ｂ）で密閉容器内の圧力が上昇し易いため、密閉容器は、工程（ｂ）における圧力の上昇に耐えられることが必要である。密閉容器は、例えば、オートクレーブが用いられる。
[Closed container]
The sealed container used in step (a) is not particularly limited as long as it can be sealed. Since the pressure in the sealed container is likely to increase in the step (b) described later, the sealed container needs to be able to withstand the increase in pressure in the step (b). For example, an autoclave is used as the sealed container.
（２）工程（ｂ）
工程（ｂ）は、重合体粒子に下式（１）の関係を満足する有機過酸化物を含浸させ、前記重合体粒子を構成する前記ブロック共重合体の融点以上、前記融点＋８０℃以下の温度で、重合体粒子を架橋させて、重合体粒子を得る工程である。工程（ｂ）を経ることにより、重合体粒子は架橋重合体粒子となる。
５≦Ｔｍ−Ｔｈ≦４５・・・（１）
式（１）において、Ｔｍは、前記ブロック共重合体の融点（℃）を表し、Ｔｈは、有機過酸化物の１０時間半減期温度（℃）を表す。以下、「Ｔｍ−Ｔｈ」を「ΔＴ」と表すことがある。
有機過酸化物として、ΔＴが５℃未満の有機過酸化物を用いると、貫通孔を有する重合体粒子が閉塞してしまい、貫通孔を有する発泡粒子を得ることができない。一方、ΔＴが４５℃超の有機過酸化物を用いると、重合体粒子に十分に有機過酸化物が含浸されず重合体粒子が発泡し難くなり、発泡粒子を得ることが困難となる。
上記観点から、有機過酸化物は、下式（２）を満足することがより好ましく、下式（３）を満足することがさらに好ましく、下式（４）を満足することが最も好ましい。
１０≦Ｔｍ−Ｔｈ≦４０・・・（２）
１５≦Ｔｍ−Ｔｈ≦３５・・・（３）
２０≦Ｔｍ−Ｔｈ≦３０・・・（４）
なお、工程（ｂ）を経ることにより、重合体粒子は架橋重合体粒子となる。
(2) Step (b)
In the step (b), the polymer particles are impregnated with an organic peroxide that satisfies the relationship of the following formula (1), and the melting point is not less than the melting point of the block copolymer constituting the polymer particles and the melting point is not more than 80 ° C. This is a step of obtaining polymer particles by crosslinking the polymer particles at a temperature. By passing through the step (b), the polymer particles become cross-linked polymer particles.
5 ≦ Tm−Th ≦ 45 (1)
In the formula (1), Tm represents the melting point (° C.) of the block copolymer, and Th represents the 10-hour half-life temperature (° C.) of the organic peroxide. Hereinafter, “Tm−Th” may be expressed as “ΔT”.
When an organic peroxide having a ΔT of less than 5 ° C. is used as the organic peroxide, the polymer particles having through holes are blocked, and foamed particles having through holes cannot be obtained. On the other hand, when an organic peroxide having a ΔT of more than 45 ° C. is used, the polymer particles are not sufficiently impregnated with the organic peroxide, making the polymer particles difficult to foam and making it difficult to obtain expanded particles.
From the above viewpoint, the organic peroxide preferably satisfies the following formula (2), more preferably satisfies the following formula (3), and most preferably satisfies the following formula (4).
10 ≦ Tm−Th ≦ 40 (2)
15 ≦ Tm−Th ≦ 35 (3)
20 ≦ Tm−Th ≦ 30 (4)
In addition, a polymer particle turns into a crosslinked polymer particle by passing through a process (b).
〔式（１）の関係を満足する有機過酸化物〕
有機過酸化物は、式（１）の関係を満足する有機化酸化物であれば、特に限定されない。
具体的には、例えば、１，１−ジ（ｔ−ヘキシルパーオキシ）シクロヘキサン（１０時間半減期温度：８７℃）、ｔ−ブチルパーオキシ−２−エチルヘキシルモノカルボネート（１０時間半減期温度：９９℃）、ｎ−ブチル４，４−ビス（ｔ−ブチルパーオキシ）バレレート（１０時間半減期温度：１０５℃）等の過酸化物が挙げられる。これらは、単独又は２種類以上組み合わせて使用することができる。
かかる１０時間半減期温度を有する有機過酸化物を用いることで、工程（ａ〜ｄ）において、貫通孔が潰れにくくなり、貫通孔を有する発泡粒子を得ることができる。以上の中でも、１０時間半減期温度が８０〜１１０℃であることが好ましく、９０〜１０５℃がさらに好ましい。
[Organic peroxide satisfying the relationship of formula (1)]
The organic peroxide is not particularly limited as long as it is an organic oxide that satisfies the relationship of the formula (1).
Specifically, for example, 1,1-di (t-hexylperoxy) cyclohexane (10-hour half-life temperature: 87 ° C.), t-butylperoxy-2-ethylhexyl monocarbonate (10-hour half-life temperature: 99.degree. C.) and peroxides such as n-butyl 4,4-bis (t-butylperoxy) valerate (10 hour half-life temperature: 105.degree. C.). These can be used alone or in combination of two or more.
By using the organic peroxide having such a 10-hour half-life temperature, in the steps (a to d), the through holes are hardly crushed, and foamed particles having the through holes can be obtained. Among these, the 10-hour half-life temperature is preferably 80 to 110 ° C, more preferably 90 to 105 ° C.
有機過酸化物の配合量は、重合体粒子１００重量部に対して、好ましくは０．１〜５重量部であり、より好ましくは０．２〜３重量部である。有機過酸化物の配合量が上記範囲であると、適度なキシレン不溶分を有する架橋重合体粒子が得られ、架橋重合体粒子が十分に発泡することができるとともに、発泡に十分耐えることができる強度を重合体に付与することができる。 The compounding amount of the organic peroxide is preferably 0.1 to 5 parts by weight, more preferably 0.2 to 3 parts by weight with respect to 100 parts by weight of the polymer particles. When the blending amount of the organic peroxide is within the above range, crosslinked polymer particles having an appropriate xylene-insoluble content can be obtained, and the crosslinked polymer particles can be sufficiently foamed and sufficiently resistant to foaming. Strength can be imparted to the polymer.
工程（ｂ）では、貫通孔を有する重合体粒子の架橋が始まる温度よりも低い温度（含浸温度と称することがある）で重合体粒子に有機過酸化物を含浸させることが好ましい。含浸温度は、工程（ｂ）で用いる有機過酸化物の分解温度よりも低い温度（有機過酸化物を複数種用いる場合は、最も低い分解温度を基準とする）であれば特に限定されず、用いる有機過酸化物の種類によって異なるが、通常、９０〜１３０℃である。
次いで、貫通孔を有する重合体粒子が軟化し、有機過酸化物が実質的に分解する温度以上の温度（架橋温度と称することがある）に加熱して、貫通孔を有する架橋重合体粒子を得ることが好ましい。具体的には、密閉容器内で、有機過酸化物が実質的に分解する温度以上の温度に加熱することが好ましい。
架橋のための加熱温度（架橋温度）は、前記重合体粒子を構成する前記ブロック共重合体の融点以上、前記融点＋８０℃以下の温度であり、具体的には、１００〜１７０℃の範囲である。これにより、前記ブロック共重合体の架橋が生じる。また、得られる発泡粒子のキシレン不溶分は３０〜７０重量％であることが好ましい。上記キシレン不溶分を有する発泡粒子を得る際には、概ね、前記ブロック共重合体を架橋させるための保持時間を、１〜１００分とすることが好ましく、２０〜６０分とすることがより好ましい。
In the step (b), it is preferable that the polymer particles are impregnated with the organic peroxide at a temperature lower than the temperature at which the crosslinking of the polymer particles having through holes starts (sometimes referred to as an impregnation temperature). The impregnation temperature is not particularly limited as long as the temperature is lower than the decomposition temperature of the organic peroxide used in the step (b) (when using a plurality of organic peroxides, the lowest decomposition temperature is used as a reference). Although it varies depending on the type of organic peroxide used, it is usually 90 to 130 ° C.
Next, the polymer particles having through-holes are softened and heated to a temperature equal to or higher than the temperature at which the organic peroxide is substantially decomposed (sometimes referred to as a crosslinking temperature). It is preferable to obtain. Specifically, it is preferable to heat to a temperature equal to or higher than the temperature at which the organic peroxide is substantially decomposed in the sealed container.
The heating temperature for crosslinking (crosslinking temperature) is a temperature not lower than the melting point of the block copolymer constituting the polymer particles and not lower than the melting point + 80 ° C., specifically, in the range of 100 to 170 ° C. is there. Thereby, the block copolymer is crosslinked. Moreover, it is preferable that the xylene insoluble content of the foamed particle obtained is 30 to 70% by weight. When obtaining the expanded particles having xylene-insoluble components, the retention time for crosslinking the block copolymer is preferably 1 to 100 minutes, more preferably 20 to 60 minutes. .
（３）工程（ｃ）
工程（ｃ）は、重合体粒子に発泡剤を含浸させる工程である。
工程（ｃ）は、工程（ｂ）より前に行ってもよいし、工程（ｂ）と同時に行ってもよい。
具体的には、架橋剤を含浸させた重合体粒子を、前記ブロック共重合体の融点以上、融点＋８０℃以下の温度で架橋させる、前記工程（ｂ）の前であっても、前記工程（ｂ）中であっても、前記工程（ｂ）終了後であっても良い。なお、合体粒子に発泡剤を含浸させる温度は、重合体粒子が軟化状態となる温度以上の温度であれば、特に限定されないが、例えば、１００〜１７０℃の範囲である。また、上記の工程（ｂ）と同じ温度であっても良い。
(3) Step (c)
Step (c) is a step of impregnating polymer particles with a foaming agent.
The step (c) may be performed before the step (b) or may be performed simultaneously with the step (b).
Specifically, even before the step (b), the polymer particles impregnated with the crosslinking agent are crosslinked at a temperature not lower than the melting point of the block copolymer and not lower than the melting point + 80 ° C. It may be during b) or after the end of the step (b). The temperature at which the coalesced particles are impregnated with the foaming agent is not particularly limited as long as the temperature is equal to or higher than the temperature at which the polymer particles are in a softened state, but is, for example, in the range of 100 to 170 ° C. Moreover, the same temperature as said process (b) may be sufficient.
〔発泡剤〕
工程（ｃ）で使用する発泡剤は、重合体粒子を発泡させるものであれば特に限定されない。発泡剤には、例えば、空気、窒素、二酸化炭素、アルゴン、ヘリウム、酸素、ネオン等の無機物理発泡剤、プロパン、ノルマルブタン、イソブタン、ノルマルペンタン、イソペンタン、ノルマルヘキサン等の脂肪族炭化水素、シクロヘキサン、シクロペンタン等の脂環式炭化水素、クロロフロロメタン、トリフロロメタン、１，１−ジフロロエタン、１，１，１，２−テトラフロロエタン、メチルクロライド、エチルクロライド、メチレンクロライド等のハロゲン化炭化水素、ジメチルエーテル、ジエチルエーテル、メチルエチルエーテル等のジアルキルエーテル等の有機物理発泡剤等が挙げられる。これらの中でもオゾン層の破壊がなく、かつ安価な無機物理発泡剤が好ましく、窒素、空気、二酸化炭素がより好ましく、特に二酸化炭素が好ましい。これらは、単独又は２種類以上組み合わせて使用することができる。
発泡剤の配合量は、目的とする発泡粒子の見掛け密度、前記ブロック共重合体の種類、発泡剤の種類等を考慮して決定されるが、通常、重合体粒子１００重量部に対して、有機物理発泡剤で２〜２０重量部を用いることが好ましく、無機物理発泡剤で０．５〜２０重量部を用いることが好ましい。
なお、上記の分散、架橋、及び発泡剤含浸の工程は、それぞれの工程を独立して行ってもよく、また同時に行うこともできる。好ましくは、工程（ａ）〜工程（ｃ）は単一の密閉容器における一連の工程として行うことが好ましい。
[Foaming agent]
The foaming agent used in the step (c) is not particularly limited as long as it causes the polymer particles to foam. Examples of blowing agents include inorganic physical blowing agents such as air, nitrogen, carbon dioxide, argon, helium, oxygen and neon, aliphatic hydrocarbons such as propane, normal butane, isobutane, normal pentane, isopentane and normal hexane, cyclohexane Halocarbons such as cycloaliphatic hydrocarbons such as cyclopentane, chlorofluoromethane, trifluoromethane, 1,1-difluoroethane, 1,1,1,2-tetrafluoroethane, methyl chloride, ethyl chloride, methylene chloride Examples thereof include organic physical foaming agents such as hydrogen, dimethyl ether, diethyl ether, and dialkyl ethers such as methyl ethyl ether. Among these, an inexpensive inorganic physical foaming agent that does not destroy the ozone layer is preferable, nitrogen, air, and carbon dioxide are more preferable, and carbon dioxide is particularly preferable. These can be used alone or in combination of two or more.
The blending amount of the foaming agent is determined in consideration of the apparent density of the intended foamed particles, the type of the block copolymer, the type of the foaming agent, etc., but usually with respect to 100 parts by weight of the polymer particles, It is preferable to use 2 to 20 parts by weight with the organic physical foaming agent, and it is preferable to use 0.5 to 20 parts by weight with the inorganic physical foaming agent.
In addition, each process of said dispersion | distribution, bridge | crosslinking, and a foaming agent impregnation may be performed independently, and can also be performed simultaneously. Preferably, steps (a) to (c) are preferably performed as a series of steps in a single sealed container.
（４）工程（ｄ）
工程（ｄ）は、発泡剤を含む発泡性重合体粒子発泡させる工程である。
具体的には、工程（ｃ）により発泡剤が含浸している重合体粒子（発泡性重合体粒子）を、密閉容器内の圧力よりも低い圧力の雰囲気下に放出して発泡させて発泡粒子を作製する方法、工程（ｃ）により得られた発泡性重合体粒子を取り出した後、別途発泡性重合体粒子を加熱して発泡させる方法などが挙げられる。
なお、工程（ｃ）の密閉容器内の圧力よりも低い圧力の雰囲気下に貫通孔を有する発泡性重合体粒子を放出することにより、貫通孔を有する発泡粒子を作製することがより好ましい。具体的には、密閉容器内の圧力を発泡剤の蒸気圧以上の圧力に保持しながら、密閉容器内の水面下の一端を開放し、発泡剤を含有する発泡性重合体粒子を分散媒とともに密閉容器内から密閉容器内の圧力よりも低圧の雰囲気下、通常は大気圧下に放出して発泡性重合体粒子を発泡させることによって、発泡粒子を作製する。
工程（ｄ）は、工程（ｂ）を経た後に行われるため、工程（ｄ）を経て得られる発泡粒子は架橋発泡粒子である。
(4) Step (d)
Step (d) is a step of foaming expandable polymer particles containing a foaming agent.
Specifically, the polymer particles impregnated with the foaming agent in step (c) (expandable polymer particles) are released into an atmosphere having a pressure lower than the pressure in the sealed container, and are expanded to form expanded particles. And a method of taking out the foamable polymer particles obtained by the step (c) and then separately heating and foaming the foamable polymer particles.
In addition, it is more preferable to produce expanded particles having through-holes by releasing expandable polymer particles having through-holes in an atmosphere having a pressure lower than the pressure in the sealed container in the step (c). Specifically, while maintaining the pressure in the airtight container at a pressure equal to or higher than the vapor pressure of the foaming agent, one end under the water surface in the airtight container is opened, and the foamable polymer particles containing the foaming agent are combined with the dispersion medium. The foamed particles are produced by releasing the foamed polymer particles from the sealed container under an atmosphere lower than the pressure in the sealed container, usually under atmospheric pressure.
Since the step (d) is performed after the step (b), the expanded particles obtained through the step (d) are crosslinked expanded particles.
（その他の添加剤）
重合体粒子には、本発明の目的効果を阻害しない範囲においてその他の添加剤を添加することができる。その他の添加剤としては、例えば、酸化防止剤、紫外線吸収剤、帯電防止剤、難燃剤、難燃助剤、気泡核剤、可塑剤、光安定剤、抗菌剤、金属不活性剤、導電性フィラー、気泡調整剤等を挙げることができる。気泡調整剤としては、たとえばホウ酸亜鉛、タルク、炭酸カルシウム、ホウ砂、水酸化アルミニウム、シリカ、ゼオライト、カーボン等の無機粉体やリン酸系核剤、フェノール系核剤、アミン系核剤、ポリフッ化エチレン系樹脂粉末等の有機系粉体が例示される。これらの添加剤は、合計で前記ブロック共重合体１００重量部に対して２０重量部以下が好ましく、１０重量部以下がより好ましく、５重量部以下がさらに好ましい。特に、気泡調整剤の割合は、前記ブロック共重合体１００重量部あたり、０．０１〜１重量部が好ましい。なお、これらの添加剤は、通常、必要最小限の量で使用される。また、これらの添加剤は、例えば、重合体粒子を製造する際、前記ブロック共重合体と共に押出機内に添加、混練することによって重合体粒子中に含有させることができる。
(Other additives)
Other additives can be added to the polymer particles as long as the objective effects of the present invention are not impaired. Other additives include, for example, antioxidants, ultraviolet absorbers, antistatic agents, flame retardants, flame retardant aids, cell nucleating agents, plasticizers, light stabilizers, antibacterial agents, metal deactivators, and conductivity. A filler, a bubble regulator, etc. can be mentioned. Examples of the air conditioner include zinc borate, talc, calcium carbonate, borax, aluminum hydroxide, silica, zeolite, carbon and other inorganic powders, phosphate nucleating agents, phenol nucleating agents, amine nucleating agents, Organic powders such as polyfluorinated ethylene resin powder are exemplified. These additives in total are preferably 20 parts by weight or less, more preferably 10 parts by weight or less, and still more preferably 5 parts by weight or less with respect to 100 parts by weight of the block copolymer. In particular, the ratio of the cell regulator is preferably 0.01 to 1 part by weight per 100 parts by weight of the block copolymer. These additives are usually used in the minimum necessary amount. These additives can be contained in the polymer particles by, for example, adding and kneading them together with the block copolymer in an extruder when producing the polymer particles.
２．発泡粒子
本発明の発泡粒子の製造方法を経て製造される発泡粒子は、貫通孔を有する重合体粒子由来の貫通孔が潰れずに存在し、両端とも開孔した貫通孔であることが好ましい。このような発泡粒子は、発泡粒子自体が従来の発泡粒子とは異なる特異な物性を有するため、クッションビーズなどとしても有用であると考えられる。
また、発泡粒子が貫通孔を有していると、発泡粒子の孔の部分には、空隙が存在することとなる。この発泡粒子が成形によって発泡粒子成形体を形成することで、発泡粒子成形体内には比較的均等に空隙を形成させることができる。
そして、このような発泡粒子を型内成形して得られる発泡粒子成形体は、荷重がかかった場合には、発泡粒子の孔の部分が優先的に潰されることから、発泡粒子の気泡部分は相対的に潰されにくくなる。一方、圧縮から開放されると、前記空隙の部分が優先的に、早く体積を回復するので、発泡粒子成形体として優れた回復性（圧縮解放後の回復性）を発揮することができる。
2. Foamed particles The foamed particles produced by the method for producing foamed particles of the present invention are preferably through-holes in which through-holes derived from polymer particles having through-holes are present without being crushed and both ends are opened. Such expanded particles are considered useful as cushion beads because the expanded particles themselves have unique physical properties different from those of conventional expanded particles.
Moreover, when the foamed particle has a through hole, a void exists in the hole portion of the foamed particle. By forming the foamed particle molded body by molding the foamed particles, voids can be formed relatively evenly in the foamed particle molded body.
The foamed particle molded body obtained by in-mold molding of such foamed particles is preferentially crushed in the pores of the foamed particles when a load is applied. It becomes relatively difficult to be crushed. On the other hand, when released from the compression, the void portion preferentially recovers the volume, so that excellent recoverability (recoverability after compression release) as a foamed particle molded body can be exhibited.
発泡粒子が有する貫通孔の形状は特に制限されず、通常、孔の軸方向と直交する面の輪郭（孔の断面形状）が円形であるが、楕円形、矩形、台形、三角形、五角以上の多角形、不定形等のいずれであってもよい。また、発泡粒子の形状も特に制限されず、球形または多面体形であってもよいし、断面形状が円形、矩形、台形、三角形、五角以上の多角形、または不定形の柱状であってもよい。
以上の中でも、貫通孔を有する発泡粒子は、発泡粒子の断面形状が円形であって、孔の断面形状が円形である円筒状であることが更に好ましい。なお、円形には略円形を含むものとする。
The shape of the through-hole of the foamed particle is not particularly limited, and the outline of the surface perpendicular to the axial direction of the hole (the cross-sectional shape of the hole) is usually circular, but it is oval, rectangular, trapezoidal, triangular, pentagonal or more Any of a polygon, an indefinite form, etc. may be sufficient. Further, the shape of the expanded particles is not particularly limited, and may be spherical or polyhedral, and the cross-sectional shape may be circular, rectangular, trapezoidal, triangular, pentagonal or more polygonal, or irregular columnar shape. .
Among the above, the foamed particles having through-holes are more preferably cylindrical in which the cross-sectional shape of the foamed particles is circular and the cross-sectional shape of the holes is circular. The circular shape includes a substantially circular shape.
発泡粒子の内径（孔の断面形状の長径）は、発泡粒子成形体の短時間での回復性の観点から、１〜７ｍｍであることが好ましく、１．５〜５ｍｍであることがより好ましい。発泡粒子の内径は、一定でなくてもよく、例えば、貫通孔の端部の一方の内径が小さく、他方の内径が大きくてもよいし、発泡粒子の表面側となる貫通孔の両端部の内径よりも、発泡粒子の中心部付近の内径が大きいか、小さくなる異径孔であってもよい。
また、貫通孔の軸方向の長さは、発泡粒子を型内成形するときに、発泡粒子の金型への投入のし易さの観点から、１〜１０ｍｍであることが好ましく、１〜７ｍｍであることがより好ましい。
From the viewpoint of recoverability of the foamed particle molded body in a short time, the inner diameter of the expanded particles (the major axis of the cross-sectional shape of the holes) is preferably 1 to 7 mm, and more preferably 1.5 to 5 mm. The inner diameter of the expanded particle may not be constant. For example, one inner diameter of the end portion of the through hole may be small, the other inner diameter may be large, or both end portions of the through hole on the surface side of the expanded particle. Different diameter holes may be used in which the inner diameter in the vicinity of the center of the expanded particles is larger or smaller than the inner diameter.
In addition, the axial length of the through hole is preferably 1 to 10 mm from the viewpoint of easy introduction of the foamed particles into the mold when the foamed particles are molded in the mold, and is preferably 1 to 7 mm. It is more preferable that
発泡粒子の見掛け密度は、好ましくは４０〜２００ｇ／Ｌであり、より好ましくは６０〜１９５ｇ／Ｌである。発泡粒子の見掛け密度が上記範囲であれば、発泡粒子や成型体が収縮しにくく、良好な発泡粒子成形体を得られ易くなる。 The apparent density of the expanded particles is preferably 40 to 200 g / L, more preferably 60 to 195 g / L. When the apparent density of the expanded particles is within the above range, the expanded particles and the molded body are less likely to shrink, and a favorable expanded particle molded body can be easily obtained.
発泡粒子の平均粒子径（外径）は、好ましくは１．５〜１０ｍｍであり、より好ましくは１．８〜８ｍｍであり、さらに好ましくは２〜５ｍｍである。発泡粒子の平均粒子径が上記範囲であると、発泡粒子の製造が容易であるとともに、発泡粒子を型内成形するとき、発泡粒子を金型内に充填させることが容易になる。なお、発泡粒子の平均粒子径は、例えば、発泡剤量、発泡条件、重合体粒子の粒径等を調整することにより制御することができる。
また、発泡粒子の外径に対する発泡粒子の内径の比は、０．０１〜０．８であることが好ましく、０．１〜０．８であることが更に好ましい。
The average particle diameter (outer diameter) of the expanded particles is preferably 1.5 to 10 mm, more preferably 1.8 to 8 mm, and further preferably 2 to 5 mm. When the average particle diameter of the expanded particles is within the above range, the expanded particles can be easily produced, and when the expanded particles are molded in the mold, the expanded particles can be easily filled in the mold. The average particle diameter of the expanded particles can be controlled, for example, by adjusting the amount of the foaming agent, the expansion conditions, the particle diameter of the polymer particles, and the like.
Further, the ratio of the inner diameter of the expanded particle to the outer diameter of the expanded particle is preferably 0.01 to 0.8, and more preferably 0.1 to 0.8.
（キシレン不溶分）
発泡粒子の熱キシレン抽出法によるキシレン不溶分は３０〜７０重量％であることが好ましい。
上記範囲内であれば、発泡時に貫通孔形状を維持することができるとともに、良好な成形性を有する発泡粒子となる。上記観点から、発泡粒子成形体のキシレン不溶分は、３５〜６０重量％が好ましく、４０〜５５重量％が更に好ましい。なお、発泡粒子を型内成形して得られる発泡粒子成形体においても、成形時にキシレン不溶分が変化することは通常、考えられないことから、同様のキシレン不溶分を有する成形体が得られる。
(Xylene insoluble matter)
It is preferable that the xylene insoluble content of the expanded particles by the hot xylene extraction method is 30 to 70% by weight.
If it is in the said range, while being able to maintain a through-hole shape at the time of foaming, it becomes a foamed particle which has favorable moldability. From the above viewpoint, the xylene-insoluble content of the foamed particle molded body is preferably 35 to 60% by weight, and more preferably 40 to 55% by weight. In addition, even in the foamed particle molded body obtained by molding the foamed particles in the mold, since it is not usually considered that the xylene-insoluble content changes during molding, a molded body having the same xylene-insoluble content can be obtained.
３．発泡粒子成形体
本発明の発泡粒子の製造方法を経て製造した発泡粒子を、型内成形することで、軽量性と短時間での回復性を両立する発泡粒子成形体を製造することができる。
発泡粒子成形体は、従来公知の方法により、発泡粒子を成形型内に充填し、スチーム等の加熱媒体を用いて加熱成形することにより得ることができる。具体的には、発泡粒子を成形型内に充填した後、成形型内にスチーム等の加熱媒体を導入することにより、発泡粒子を加熱して発泡させ、相互に融着させて成形空間の形状が賦形された発泡粒子成形体を得ることができる。
また、型内成形は、発泡粒子を空気等の加圧気体により予め加圧処理して発泡粒子内の圧力を高めて、発泡粒子内の圧力を０．０１〜０．２ＭＰａ（Ｇ）（Ｇはゲージ圧を意味する）に調整し、大気圧下又は減圧下で発泡粒子を成形型キャビティ内に充填して型閉めを行った後、次いで、型内にスチーム等の加熱媒体を供給して発泡粒子を加熱融着させる加圧成形法（例えば、特公昭５１−２２９５１号公報に記載の方法）により成形することが好ましい。また、圧縮ガスにより大気圧以上に加圧したキャビティー内に、当該圧力以上に加圧した発泡粒子を充填した後、キャビティー内にスチーム等の熱媒を供給して加熱を行い、発泡粒子を加熱融着させる圧縮充填成形法（特公平４−４６２１７号公報）により成形することもできる。その他に、特殊な条件にて得られる二次発泡力の高い発泡粒子を、大気圧下又は減圧下で雌雄一対の成形型のキャビティー内に充填した後、次いでスチーム等の熱媒を供給して加熱を行い、発泡粒子を融着させる常圧充填成形法（特公平６−４９７９５号公報）又は上記の方法を組み合わせた方法（特公平６−２２９１９号公報）などによっても成形することができる。
3. Foamed particle molded body A foamed particle molded body that achieves both light weight and recoverability in a short time can be manufactured by in-mold molding of the foamed particles produced through the method for producing foamed particles of the present invention.
The foamed particle molded body can be obtained by filling the foamed particles in a mold and heat-molding using a heating medium such as steam by a conventionally known method. Specifically, after the foam particles are filled into the mold, a foam or the like is heated and foamed by introducing a heating medium such as steam into the mold, and the foamed particles are fused together to form the shape of the molding space. Can be obtained.
Further, in-mold molding is performed by pressurizing the foamed particles with a pressurized gas such as air in advance to increase the pressure in the foamed particles, so that the pressure in the foamed particles is 0.01 to 0.2 MPa (G) (G Means a gauge pressure), and after filling the mold cavity into the mold cavity under atmospheric pressure or reduced pressure, the mold is closed, and then a heating medium such as steam is supplied into the mold. It is preferable to mold by a pressure molding method (for example, a method described in Japanese Patent Publication No. 51-22951) in which the expanded particles are heat-fused. In addition, after filling the cavities pressurized above the atmospheric pressure with compressed gas with foamed particles pressurized above the pressure, a heating medium such as steam is supplied into the cavities and heated to produce the foamed particles. It is also possible to mold by a compression filling molding method (Japanese Patent Publication No. 4-46217). In addition, after filling foam particles with high secondary foaming power obtained under special conditions into a cavity of a pair of male and female molds under atmospheric pressure or reduced pressure, a heating medium such as steam is then supplied. It can also be molded by a normal pressure filling molding method (Japanese Patent Publication No. 6-49795) or a method combining the above methods (Japanese Patent Publication No. 6-22919) or the like in which heating is performed and the expanded particles are fused. .
（空隙率）
以上のようにして得られる発泡粒子成形体は、成形体の空隙率が５〜４０％であることが好ましい。発泡粒子成形体の空隙率が５％未満であると、成形体に荷重がかかったときに、空隙と共に、発泡粒子の気泡部分が潰れ易くなるので、荷重が取り除かれたときに、成形体の回復性が低下するおそれがある。発泡粒子成形体の空隙率が４０％を超えると、空隙が過多となり、発泡粒子同士の接着が弱くなり、成形体に荷重がかかったときに強度を保てなくなるおそれがある。成形体に負荷がかかったときに強度を保てず、反発弾性に優れない。
上記観点から、発泡粒子成形体の空隙率は、８〜３５％であることがより好ましく、１０〜３０％であることが更に好ましい。
発泡粒子成形体に空隙が形成され、その空隙率が上記範囲であれば、回復性を向上する効果を奏し易くなる。本発明の発泡粒子は貫通孔を有するため、発泡粒子成形体に均等で方向性のない空隙を安定して形成させることができる。
(Porosity)
The foamed particle molded body obtained as described above preferably has a molded body porosity of 5 to 40%. If the porosity of the foamed particle molded body is less than 5%, when a load is applied to the molded body, the air bubble part of the foamed particles is easily crushed together with the voids. Restorability may be reduced. When the porosity of the foamed particle molded body exceeds 40%, the voids become excessive, the adhesion between the foamed particles becomes weak, and the strength may not be maintained when a load is applied to the molded body. When a load is applied to the molded body, the strength cannot be maintained and the resilience is not excellent.
From the above viewpoint, the porosity of the foamed particle molded body is more preferably 8 to 35%, and further preferably 10 to 30%.
If voids are formed in the foamed particle molded body and the void ratio is in the above range, the effect of improving recoverability is easily achieved. Since the foamed particles of the present invention have through holes, uniform and non-directional voids can be stably formed in the foamed particle molded body.
（成形体密度）
発泡粒子成形体は、その成形体密度が３０〜３００ｇ／Ｌであることが好ましい。上記範囲内であれば、気泡膜の強度が保たれ、圧縮に対抗し易くなり、圧縮後に成形体が回復し易くなる。
上記観点から、発泡粒子成形体の密度は、より好ましくは４０〜２００ｇ／Ｌであり、さらに好ましくは４５〜１５０ｇ／Ｌである。
(Molded body density)
The foamed particle molded body preferably has a molded body density of 30 to 300 g / L. If it is in the above-mentioned range, the strength of the bubble film is maintained, it becomes easy to resist compression, and the molded body is easy to recover after compression.
From the above viewpoint, the density of the foamed particle molded body is more preferably 40 to 200 g / L, and further preferably 45 to 150 g / L.
（融着性）
発泡粒子成形体の融着性は、発泡粒子成形体を折り曲げて破断し、破断面に露出した発泡粒子のうち材料破壊した発泡粒子の比率を材料破壊率とし、その材料破壊率（融着率）から評価することができる。材料破壊率は８０％以上が好ましく、９０％以上がより好ましい。発泡粒子成形体の融着性が上記範囲であると最大引張応力、引張破壊伸び等の物性に優れ、シートクッション材、スポーツパッド材、靴底材等の用途に好適な成形体となる。
(Fusability)
The meltability of the foamed particle compact is determined by bending the foamed particle compact and breaking it. The ratio of the foamed particles exposed to the fracture surface is the material fracture rate. ) Can be evaluated. The material destruction rate is preferably 80% or more, and more preferably 90% or more. When the fusion property of the foamed particle molded body is within the above range, the molded article is excellent in physical properties such as maximum tensile stress and tensile elongation at break, and is suitable for applications such as seat cushion materials, sports pad materials, and shoe sole materials.
（発泡粒子成形体の用途）
本発明の発泡粒子の製造方法で製造された発泡粒子を用いて型内成形された発泡粒子成形体は、回復性に優れるので、靴底材、クッション材、エネルギー吸収材として好適である。
(Applications of foamed particle compact)
The foamed particle molded body molded in-mold using the foamed particles produced by the method for producing foamed particles of the present invention is excellent in recoverability, and is therefore suitable as a shoe sole material, a cushion material, and an energy absorbing material.
次に、本発明を実施例により、さらに詳細に説明するが、本発明は、これらの例によってなんら限定されるものではない。 EXAMPLES Next, although an Example demonstrates this invention further in detail, this invention is not limited at all by these examples.
＜マルチブロック共重合体の物性＞
実施例及び比較例の発泡粒子の作製に用いたマルチブロック共重合体（重合体１）の融点（Ｔｍ）、メルトフローレイト、デュロメータ硬さタイプＡ、曲げ弾性率、基材樹脂であるマルチブロック共重合体の粒子（重合体粒子）の貫通孔内径、及び、重合体粒子の外径は、次のようにして測定した。
<Physical properties of multi-block copolymer>
Melting point (Tm), melt flow rate, durometer hardness type A, multi-block which is a base resin for the multi-block copolymer (Polymer 1) used for the production of the expanded particles of Examples and Comparative Examples The through-hole inner diameter of the copolymer particles (polymer particles) and the outer diameter of the polymer particles were measured as follows.
（融点）
前記ブロック共重合体の融点は、ＪＩＳ Ｋ７１２１（１９８７年）に準拠して求めた。具体的には、ペレット状の基材樹脂２ｍｇを試験片としてＪＩＳ Ｋ７１２１：１９８７に記載されている熱流束示差走査熱量測定法に基づいて、１０℃／分の昇温速度で３０℃から２００℃まで昇温した後に、１０℃／分の冷却速度で３０℃まで降温し、再度１０℃／分の昇温速度で３０℃から２００℃まで昇温した際に得られるＤＳＣ曲線により定まる吸熱ピークの頂点温度を基材樹脂の融点とした。なお、測定装置は、熱流束示差走査熱量測定装置（エスアイアイ・ナノテクノロジー（株）社製、型番：ＤＳＣ７０２０）を用いた。
(Melting point)
The melting point of the block copolymer was determined according to JIS K7121 (1987). Specifically, based on the heat flux differential scanning calorimetry described in JIS K7121: 1987 using 2 mg of the pellet-shaped base resin as a test piece, the temperature is increased from 30 ° C. to 200 ° C. at a rate of temperature increase of 10 ° C./min. Of the endothermic peak determined by the DSC curve obtained when the temperature was lowered to 30 ° C. at a cooling rate of 10 ° C./min, and again raised from 30 ° C. to 200 ° C. at a rate of 10 ° C./min. The vertex temperature was defined as the melting point of the base resin. In addition, the heat flux differential scanning calorimeter (SII nanotechnology Co., Ltd. make, model number: DSC7020) was used for the measuring apparatus.
（メルトフローレイト）
前記ブロック共重合体のメルトフローレイトは、温度１９０℃、荷重２．１６ｋｇの条件でＪＩＳ Ｋ７２１０−１（２０１４年）に準拠して測定した。
(Melt flow rate)
The melt flow rate of the block copolymer was measured according to JIS K7210-1 (2014) under the conditions of a temperature of 190 ° C. and a load of 2.16 kg.
（デュロメータ硬さタイプＡ）
前記ブロック共重合体のデュロメータ硬さタイプＡは、ＡＳＴＭ Ｄ２２４０に準拠して測定した。
(Durometer hardness type A)
The durometer hardness type A of the block copolymer was measured in accordance with ASTM D2240.
（曲げ弾性率）
前記ブロック共重合体の曲げ弾性率は、押出機で溶融押し出しして、板状の小片を得た後、ＪＩＳ Ｋ ７１７１（２０１６年）に記載の測定法に準拠して測定した。測定は、８０×１０×４ｍｍの試験片を作製し、１０ｋｇのロードセルを使用して、支点間距離６４ｍｍ、曲げ速度２ｍｍ／ｍｉｎの条件下で３点曲げを行った。曲げ弾性率は、変位０．５〜１．０ｍｍ間の勾配より算出した。
(Flexural modulus)
The bending elastic modulus of the block copolymer was melt extruded with an extruder to obtain a plate-like piece, and then measured according to the measuring method described in JIS K 7171 (2016). For the measurement, a test piece of 80 × 10 × 4 mm was prepared, and a three-point bending was performed using a 10 kg load cell under the conditions of a distance between supporting points of 64 mm and a bending speed of 2 mm / min. The flexural modulus was calculated from the gradient between displacements of 0.5 to 1.0 mm.
（重合体粒子の貫通孔内径及び重合体粒子の外径）
重合体粒子の貫通孔内径及び重合体粒子の外径は、重合体粒子の断面写真を撮影し、その断面写真における貫通孔の内径（直径）及び重合体粒子の外径を測定した。得られた結果から、（重合体粒子の貫通孔内径）／（重合体粒子の外径）となる内外比を算出した。
(Inner diameter of through hole of polymer particle and outer diameter of polymer particle)
The through-hole inner diameter of the polymer particle and the outer diameter of the polymer particle were obtained by taking a cross-sectional photograph of the polymer particle and measuring the inner diameter (diameter) of the through-hole and the outer diameter of the polymer particle in the cross-sectional photograph. From the obtained results, an inner / outer ratio of (the inner diameter of the through hole of the polymer particles) / (the outer diameter of the polymer particles) was calculated.
＜発泡粒子の物性＞
発泡粒子の見掛け密度、嵩密度、空隙率、貫通孔内径及びキシレン不溶分は、次のようにして測定し、結果を表１及び２の「発泡粒子」欄に示した。
<Physical properties of expanded particles>
The apparent density, bulk density, porosity, through-hole inner diameter and xylene insoluble content of the expanded particles were measured as follows, and the results are shown in the “Expanded Particles” column of Tables 1 and 2.
（発泡粒子の見掛け密度）
２００ｍｌのメスシリンダーに１００ｍｌのエタノールを入れ、予め重量Ｗａ（ｇ）を秤量した嵩体積約５０ｍｌの発泡粒子を、金網等を使用してエタノール中に沈め、水位が上昇した分の体積Ｖａ（Ｌ）を読み取った。Ｗａ／Ｖａを求めることにより発泡粒子の見掛け密度（ｇ／Ｌ）とした。
測定は、気温２３℃、相対湿度５０％の大気圧下において行った。
(Apparent density of expanded particles)
A volume Va (L) corresponding to a rise in the water level is obtained by placing 100 ml of ethanol in a 200 ml graduated cylinder, preliminarily weighing the weight Wa (g), and submerging the foamed particles having a bulk volume of about 50 ml in ethanol using a wire mesh or the like. ) Was read. The apparent density (g / L) of the expanded particles was determined by calculating Wa / Va.
The measurement was performed under atmospheric pressure with an air temperature of 23 ° C. and a relative humidity of 50%.
（発泡粒子の嵩密度）
発泡粒子群から発泡粒子を無作為に取り出し、容積１Ｌのメスシリンダーの中に入れ、静電気を除去しつつ、自然堆積状態となるように多数の発泡粒子を１Ｌの目盛まで収容した。次に、収容された発泡粒子の重量を測定し、発泡粒子の重量と、収容体積（１Ｌ）とから、発泡粒子の嵩密度（ｇ／Ｌ）を算出した。
なお、測定は、気温２３℃、相対湿度５０％の大気圧下において行った。
また、得られた嵩密度と見掛け密度とから「見掛け密度／嵩密度」を算出した。
(Bulk density of expanded particles)
The foamed particles were randomly taken out from the foamed particle group, placed in a 1 L graduated cylinder, and a large number of foamed particles were accommodated up to a 1 L scale so as to be naturally deposited while removing static electricity. Next, the weight of the accommodated expanded particles was measured, and the bulk density (g / L) of the expanded particles was calculated from the weight of the expanded particles and the accommodated volume (1 L).
The measurement was performed under atmospheric pressure with an air temperature of 23 ° C. and a relative humidity of 50%.
Further, “apparent density / bulk density” was calculated from the obtained bulk density and apparent density.
（発泡粒子の空隙率）
発泡粒子の空隙率ｘ（％）は、発泡粒子をメスシリンダーに入れた時のメスシリンダーの目盛りが示す見かけの体積Ａ（ｃｍ3 ）、この量の発泡粒子をアルコールの入ったメスシリンダーに沈めて増量した分のメスシリンダーの目盛りが示す真の体積Ｂ（ｃｍ3 ）を求め、ｘ（％）＝〔（Ａ−Ｂ）／Ａ〕×１００の関係より求めた。
(Porosity of expanded particles)
The porosity x (%) of the expanded particle is the apparent volume A (cm 3 ) indicated by the scale of the graduated cylinder when the expanded particle is placed in the graduated cylinder. This amount of expanded particle is submerged in the graduated cylinder containing alcohol. The true volume B (cm 3 ) indicated by the scale of the graduated cylinder was calculated from the relationship of x (%) = [(A−B) / A] × 100.
（発泡粒子の貫通孔内径及び発泡粒子外径）
上記発泡粒子の貫通孔の内径は、成形体の断面写真を撮影し、その断面写真における貫通孔の内径（直径）を測定して算出した。発泡粒子外径は発泡粒子にノギスを当てて測定した。得られた結果から、（発泡粒子の貫通孔内径）／（発泡粒子の外径）となる内外比を算出した。
(Inner diameter of through-hole and outer diameter of expanded particle)
The inner diameter of the through hole of the foamed particle was calculated by taking a cross-sectional photograph of the molded body and measuring the inner diameter (diameter) of the through hole in the cross-sectional photograph. The outer diameter of the expanded particles was measured by applying calipers to the expanded particles. From the obtained results, an inside / outside ratio of (through-hole inner diameter of foamed particles) / (outer diameter of foamed particles) was calculated.
（発泡粒子のキシレン不溶分）
発泡粒子のキシレン不溶分は、発泡粒子約１．０ｇの試料を切り取り、試料を秤量し、試料重量Ｗ１ｂとした。秤量した発泡粒子成形体を１５０ｍｌの丸底フラスコに入れ、１００ｍｌのキシレンを加え、マントルヒーターで加熱して６時間還流させた後、溶け残った残査を１００メッシュの金網でろ過して分離し、８０℃の減圧乾燥器で８時間以上乾燥した。この際に得られた乾燥物重量Ｗ２ｂを測定した。この重量Ｗ２ｂの試料重量Ｗ１ｂに対する重量百分率［（Ｗ２ｂ／Ｗ１ｂ）×１００］（重量％）を、発泡粒子成形体のキシレン不溶分とした。得られた値を表中の「発泡粒子」欄の「キシレン不溶分」欄に示した。
(Xylene insoluble matter in foamed particles)
For the xylene-insoluble matter in the expanded particles, a sample of approximately 1.0 g of expanded particles was cut out and the sample was weighed to obtain a sample weight W1b. The weighed foamed particle compact is put into a 150 ml round bottom flask, 100 ml of xylene is added, heated with a mantle heater and refluxed for 6 hours, and then the undissolved residue is filtered and separated with a 100 mesh wire mesh. , And dried in a vacuum dryer at 80 ° C. for 8 hours or more. The dry matter weight W2b obtained at this time was measured. The weight percentage [(W2b / W1b) × 100] (wt%) of the weight W2b with respect to the sample weight W1b was used as the xylene-insoluble matter of the foamed particle molded body. The obtained value was shown in the “xylene insoluble matter” column in the “foamed particle” column in the table.
＜発泡粒子成形体の物性＞
実施例及び比較例により作製した発泡粒子成形体の密度及び空隙率は次のようにして測定した。
<Physical properties of molded foam particles>
The density and porosity of the foamed particle molded bodies produced according to Examples and Comparative Examples were measured as follows.
（発泡粒子成形体の密度）
発泡粒子成形体から無作為に、縦５０ｍｍ×横５０ｍｍ×厚み２５ｍｍに、成形時のスキン層を除いて直方体状となるように試験片を３つ切り出し、それぞれの試験片の重量及び体積（圧縮していないときの体積）を測定して、３つの試験片の見掛け密度を算出して、その算術平均値を発泡粒子成形体の密度とし、表中の「成形体」欄の「成形体密度」欄に示した。
(Density of foamed particle compact)
Three test pieces were cut out from the foamed particle compact at 50 mm length × 50 mm width × thickness 25 mm so as to form a rectangular parallelepiped shape excluding the skin layer during molding, and the weight and volume of each test piece (compression) The volume when not) is calculated, the apparent density of the three test pieces is calculated, and the arithmetic average value thereof is defined as the density of the foamed particle molded body. "Column.
（発泡粒子成形体の空隙率）
発泡粒子成形体から切り出した立方体形状の試験片を、エタノールを入れた容積中に沈めてエタノールの液面の上昇分から試験片の真の体積Ｖｃ（Ｌ）を求めた。また、該試験片の外形寸法から（縦×横×高さ）見かけの体積Ｖｄ（Ｌ）を求めた。求められた真の体積Ｖｃと見かけの体積Ｖｄから次式に基づいて発泡粒子成形体の空隙率を求めた。得られた値を表中の「成形体」欄の「空隙率」欄に示した。
空隙率（％）＝〔（Ｖｄ−Ｖｃ）／Ｖｄ〕×１００
(Porosity of foamed particle compact)
A cube-shaped test piece cut out from the foamed particle molded body was submerged in a volume containing ethanol, and the true volume Vc (L) of the test piece was determined from the increase in the liquid level of ethanol. Moreover, the apparent volume Vd (L) was calculated | required from the external dimension of this test piece (length x width x height). From the obtained true volume Vc and apparent volume Vd, the porosity of the foamed particle molded body was obtained based on the following formula. The obtained values are shown in the “Porosity” column of the “Molded product” column in the table.
Porosity (%) = [(Vd−Vc) / Vd] × 100
＜発泡粒子成形体の評価＞
（融着性）
架橋発泡粒子成形体の融着性は、以下の方法により評価した。
架橋発泡粒子成形体を折り曲げて破断し、破断面に存在する発泡粒子の数（Ｃ１）と破壊した架橋発泡粒子の数（Ｃ２）とを求め、上記架橋発泡粒子に対する破壊した架橋発泡粒子の比率（Ｃ２／Ｃ１×１００）を材料破壊率として算出した。異なる試験片を用いて前記測定を５回行い、それぞれの材料破壊率を求め、それらを算術平均して、下記評価基準に基づき、融着性を評価した。評価結果を表中の「成形体」欄の「融着性」欄に示した。
［評価基準］
○：材料破壊率８０％
△：材料破壊率２０％以上８０％未満
×：材料破壊率２０％未満
<Evaluation of foamed particle compact>
(Fusability)
The fusing property of the crosslinked foamed particle molded body was evaluated by the following method.
The number of foamed particles (C1) and the number of broken crosslinked foamed particles (C2) present on the fractured surface were determined by bending and breaking the crosslinked foamed particle molded body, and the ratio of the broken crosslinked foamed particles to the crosslinked foamed particles was determined. (C2 / C1 × 100) was calculated as the material fracture rate. The measurement was performed five times using different test pieces, the respective material fracture rates were determined, and they were arithmetically averaged to evaluate the fusing property based on the following evaluation criteria. The evaluation results are shown in the “Fusability” column of the “Molded product” column in the table.
[Evaluation criteria]
○: Material destruction rate 80%
Δ: Material destruction rate 20% or more and less than 80% ×: Material destruction rate 20% or less
（発泡粒子成形体の圧縮永久ひずみ）
発泡粒子成形体から縦５０ｍｍ、横５０ｍｍ、厚み２５ｍｍに、成形時のスキン層を除いて直方体状となるように３つの試験片を切り出し、ＪＩＳ Ｋ６７６７：１９９９に基づき、温度２３℃、５０℃それぞれについて、相対湿度５０％の環境下で厚み方向に２５％圧縮した状態で２２時間放置し、圧縮開放３０分後と２４時間後に厚みを測定し、それぞれの試験片の圧縮永久ひずみ（％）を求め、その算術平均値を圧縮永久ひずみ（％）とした。得られた値を表中の「物性」欄の「圧縮永久ひずみ」欄に、条件別に示した。
(Compression set of foamed particle compact)
Three test pieces were cut out from the foamed particle molded body to a length of 50 mm, a width of 50 mm, and a thickness of 25 mm so as to form a rectangular parallelepiped shape excluding the skin layer at the time of molding. In the environment of 50% relative humidity, the sample is left for 22 hours in a state of being compressed 25% in the thickness direction, measured for thickness after 30 minutes and 24 hours after compression release, and the compression set (%) of each test piece is measured. The arithmetic average value was determined as compression set (%). The obtained values are shown according to conditions in the “compression set” column of the “physical properties” column of the table.
＜発泡粒子成形体の圧縮物性＞
実施例及び比較例により作製した架橋発泡粒子成形体について、所定の体積に圧縮したときの圧縮応力を測定した。具体的には、発泡粒子成形体の中央部より、縦５０ｍｍ×横５０ｍｍ×厚み２５ｍｍに、成形時のスキン層を除いて直方体状となるように試験片を切り出し、この試験片に対し、ＡＵＴＯＧＲＡＰＨ ＡＧＳ−Ｘ（株式会社島津製作所製）を用いて、圧縮速度を１０ｍｍ／分とし、ＪＩＳ Ｋ ６７６７（１９９９年）に準拠して、各体積％圧縮させた時（ひずみ時）の荷重を求め、これを試験片の受圧面積で除して算出することにより圧縮応力［ｋＰａ］を求めた。
なお、５０％ひずみ時のエネルギー吸収量（５０％ Ｅ／Ａ）は、ＪＩＳ Ｋ７２２０（１９９９年）に準拠して、試験片温度２３℃，圧縮速度１０ｍｍ／分の条件にて圧縮試験を行って、応力−ひずみ線図を得、そして、下記式により単位体積当たりのエネルギー吸収量を求め，これをＪ（ジュール）／Ｌ（リッター）単位に換算することによって成形体のエネルギー吸収量を求めた。
単位体積当たりのエネルギー吸収量（ｋｇｆ／ｃｍ／ｃｍ３）＝５０％ひずみ時の応力（ｋｇｆ／ｃｍ２）×５０％歪時までのエネルギー吸収効率×０．５（ｃｍ／ｃｍ）
<Compressed physical properties of molded foam particles>
About the crosslinked foamed-particle molded object produced by the Example and the comparative example, the compression stress when compressed to a predetermined | prescribed volume was measured. Specifically, a test piece was cut out from the center part of the foamed particle molded body into a rectangular parallelepiped shape, excluding the skin layer at the time of molding, 50 mm long × 50 mm wide × 25 mm thick. Using AGS-X (manufactured by Shimadzu Corporation), the compression rate was 10 mm / min, and the load when each volume was compressed (during strain) was determined in accordance with JIS K 6767 (1999). The compressive stress [kPa] was calculated by dividing this by the pressure receiving area of the test piece.
The amount of energy absorbed at 50% strain (50% E / A) was determined by performing a compression test in accordance with JIS K7220 (1999) under conditions of a test piece temperature of 23 ° C. and a compression speed of 10 mm / min. The stress-strain diagram was obtained, and the energy absorption amount per unit volume was determined by the following formula, and the energy absorption amount of the molded body was determined by converting this to J (joule) / L (liter) units. .
Energy absorption amount per unit volume (kgf / cm / cm 3 ) = stress at 50% strain (kgf / cm 2 ) × energy absorption efficiency up to 50% strain × 0.5 (cm / cm)
〔実施例１〕
（ブロック共重合体の粒子の作製）
ブロック共重合体として、融点１２０℃、メルトフローレイト５．４ｇ／１０分（１９０℃、荷重２．１６ｋｇ）、デュロメータ硬さタイプＡ８６、曲げ弾性率２８ＭＰａのポリエチレンブロックとエチレン／１−オクテン共重合体ブロックとを有するマルチブロック共重合体（重合体１）を用意した。
重合体１を押出機に投入し、溶融混練して、円形状のスリットを有する筒状のダイからストランド状に押し出し、水中で冷却してからペレタイザーにて粒子重量約５ｍｇとなるようにカットして造粒し、貫通孔を有するマルチブロック共重合体の筒状の重合体粒子１を得た。
[Example 1]
(Preparation of block copolymer particles)
As a block copolymer, a polyethylene block having a melting point of 120 ° C., a melt flow rate of 5.4 g / 10 minutes (190 ° C., a load of 2.16 kg), a durometer hardness type A86, a flexural modulus of 28 MPa, and ethylene / 1-octene copolymer A multi-block copolymer (polymer 1) having a combined block was prepared.
Polymer 1 is put into an extruder, melted and kneaded, extruded into a strand from a cylindrical die having a circular slit, cooled in water, and then cut with a pelletizer to a particle weight of about 5 mg. To obtain cylindrical polymer particles 1 of a multi-block copolymer having through-holes.
（架橋発泡粒子の作製）
得られた重合体粒子１ｋｇを分散媒である水３リットル、分散剤としてカオリンを３ｇ、アルキルベンゼンスルホン酸ナトリウムを０．０４ｇ、硫酸アルミニウム：０．１ｇ、有機過酸化物（架橋剤）としてｔ−ブチルパーオキシ−２−エチルヘキシルモノカーボネート（化薬アクゾ株式会社製トリゴノックス１１７（Ｔｒｉ１１７）；１０時間半減期温度：９９℃）をマルチブロック共重合体１００重量部に対して０．８重量部（８ｇ）配合し発泡剤として二酸化炭素（ドライアイス）をマルチブロック共重合体１００重量部に対して２．５重量部（２５ｇ）を容積５Ｌの密閉容器内に仕込み、撹拌下で架橋温度である１６０℃まで昇温し、３０分保持した後、１６０℃の発泡温度で内容物を大気圧下に放出して架橋発泡粒子を得た。この時の蒸気圧は１．５ＭＰａ（Ｇ）であった。なお、工程（ｄ）において、発泡剤が含浸した発泡性重合体粒子を、密閉容器内より低圧下に放出した時の温度を発泡温度とした。
(Production of crosslinked foamed particles)
1 kg of the obtained polymer particles is 3 liters of water as a dispersion medium, 3 g of kaolin as a dispersing agent, 0.04 g of sodium alkylbenzenesulfonate, 0.1 g of aluminum sulfate, t- as an organic peroxide (crosslinking agent) 0.8 parts by weight (8 g) of butyl peroxy-2-ethylhexyl monocarbonate (Trigonox 117 (Tri117) manufactured by Kayaku Akzo Co., Ltd .; 10 hour half-life temperature: 99 ° C.) with respect to 100 parts by weight of the multiblock copolymer ) Carbon dioxide (dry ice) as a blowing agent was added in an amount of 2.5 L (25 g) in a closed container having a volume of 5 L with respect to 100 parts by weight of the multiblock copolymer, and the crosslinking temperature was 160 under stirring. The temperature was raised to 0 ° C. and held for 30 minutes, and then the contents were released under atmospheric pressure at a foaming temperature of 160 ° C. to obtain crosslinked foamed particles. The vapor pressure at this time was 1.5 MPa (G). In step (d), the foaming temperature was defined as the temperature at which the expandable polymer particles impregnated with the foaming agent were released from the inside of the sealed container under a low pressure.
（架橋発泡粒子成形体の作製）
得られた架橋発泡粒子を密閉容器に投入し、０．２ＭＰａ（Ｇ）の圧縮空気で１２時間加圧して架橋発泡粒子内に０．１０ＭＰａの内圧を付与し、取り出した後、縦２５０ｍｍ、横２００ｍｍ、厚み５０ｍｍの平板形状の金型に該架橋発泡粒子をクラッキング５ｍｍ（すなわち、１０％）で金型に充填した。金型内を、成形圧が０．１４ＭＰａ（Ｇ）となる水蒸気で加熱後、空冷して金型より成形体を取り出し、さらに該架橋発泡粒子成形体を６０℃に調整されたオーブン内で１２時間加熱して乾燥し、養生した後に取り出し、架橋発泡粒子成形体を得た。
得られた架橋発泡粒子成形体の密度、空隙率、及びキシレン不溶分を測定し、２３℃及び５０℃における圧縮永久ひずみ並びに融着性を評価した。また、架橋発泡粒子成形体を所定の体積に圧縮したときの圧縮物性を評価した。
(Preparation of crosslinked foamed particle molded body)
The obtained crosslinked foamed particles were put into a sealed container, pressurized with 0.2 MPa (G) compressed air for 12 hours to give an internal pressure of 0.10 MPa in the crosslinked foamed particles, and taken out. The cross-linked foamed particles were filled in a mold having a thickness of 200 mm and a thickness of 50 mm with cracking 5 mm (that is, 10%). The mold is heated with water vapor having a molding pressure of 0.14 MPa (G), then air-cooled, the molded product is taken out from the mold, and the crosslinked foamed particle molded product is further removed in an oven adjusted to 60 ° C. in an oven. Heated for a period of time, dried, cured, and then taken out to obtain a crosslinked foamed particle molded body.
The density, porosity, and xylene insoluble content of the obtained crosslinked foamed particle molded body were measured, and the compression set at 23 ° C. and 50 ° C. and the fusing property were evaluated. Moreover, the compression physical property when the crosslinked foamed particle molded body was compressed to a predetermined volume was evaluated.
〔実施例２〕
実施例１の架橋発泡粒子の作製において、発泡条件を表１の「発泡条件」欄に示す条件で発泡した以外は実施例１と同様の操作で架橋発泡粒子を得た。次いで、得られた架橋発泡粒子を用い、成形条件を表１の「成形条件」欄に示す条件とした他は実施例１と同様の方法で成形を行い、架橋発泡粒子成形体を得た。
〔実施例３〕
実施例１の筒状の重合体粒子１の作製において、押出機のスリット径を小さくすることにより、貫通孔内径を小さくした以外は実施例１と同様の操作で筒状の重合体粒子（重合体粒子２）を得た。次いで、実施例２の架橋発泡粒子の作製において、重合体粒子１に代えて、重合体粒子２を用いた以外は実施例２と同様の操作で架橋発泡粒子を得、表１の「成形条件」欄に示す条件で成形を行い、架橋発泡粒子成形体を得た。
[Example 2]
In the production of the crosslinked foamed particles of Example 1, crosslinked foamed particles were obtained in the same manner as in Example 1 except that foaming was performed under the conditions shown in the “foaming conditions” column of Table 1. Next, molding was performed in the same manner as in Example 1 except that the obtained crosslinked foamed particles were used and the molding conditions were changed to those shown in the “molding conditions” column of Table 1, to obtain a crosslinked foamed particle molded body.
Example 3
In the production of the cylindrical polymer particles 1 of Example 1, the cylindrical polymer particles (heavy weight) were obtained in the same manner as in Example 1 except that the through-hole inner diameter was reduced by reducing the slit diameter of the extruder. Combined particles 2) were obtained. Next, in the production of the crosslinked foamed particles of Example 2, crosslinked foamed particles were obtained in the same manner as in Example 2 except that the polymer particles 2 were used instead of the polymer particles 1, and the “molding conditions” in Table 1 were obtained. Molding was performed under the conditions indicated in the column "" to obtain a crosslinked foamed particle molded body.
〔実施例４〕
実施例１の架橋発泡粒子の作製において、有機過酸化物種を１，１−ジ（ｔ−ヘキシルパーオキシ）シクロヘキサン（日油株式会社製パーヘキサＨＣ；１０時間半減期温度：８７℃）」に変更し、発泡条件を表１の「発泡条件」欄に示す条件で発泡した以外は、実施例１と同様の操作で架橋発泡粒子を得た。次いで、得られた架橋発泡粒子を用い、成形条件を表１の「成形条件」欄に示す条件とした他は、実施例１と同様の方法で成形を行い、架橋発泡粒子成形体を得た。
Example 4
In the production of the crosslinked foamed particles of Example 1, the organic peroxide species was changed to 1,1-di (t-hexylperoxy) cyclohexane (Perhexa HC manufactured by NOF Corporation; 10-hour half-life temperature: 87 ° C.) Then, crosslinked foamed particles were obtained by the same operation as in Example 1 except that foaming was performed under the conditions shown in the “foaming conditions” column of Table 1. Subsequently, molding was performed in the same manner as in Example 1 except that the obtained crosslinked foamed particles were used and the molding conditions were changed to the conditions shown in the “molding conditions” column of Table 1, to obtain a crosslinked foamed particle molded body. .
〔実施例５〕
硫酸アルミニウムを添加しない以外は実施例３と同様の操作で架橋発泡粒子を得、表２の「成形条件」欄に示す条件で成形を行い、架橋発泡粒子成形体を得た。
Example 5
A crosslinked foamed particle was obtained in the same manner as in Example 3 except that aluminum sulfate was not added, and molded under the conditions shown in the “Molding Conditions” column of Table 2 to obtain a crosslinked foamed particle molded body.
〔実施例６〕
有機過酸化物をｎ−ブチル４，４−ジ（ｔ−ブチルパーオキシ）バレレート（パーヘキサＶ；１０時間半減期温度：１０５℃）に変更した以外は実施例２と同様の操作で架橋発泡粒子を得、表２の「成形条件」欄に示す条件で成形を行い、架橋発泡粒子成形体を得た。なお、得られた発泡粒子は、貫通孔が形成されているものの、その内径は小さくなっていた。
Example 6
Crosslinked foamed particles were prepared in the same manner as in Example 2 except that the organic peroxide was changed to n-butyl 4,4-di (t-butylperoxy) valerate (Perhexa V; 10 hour half-life temperature: 105 ° C.). And molded under the conditions shown in the “Molding Conditions” column of Table 2 to obtain crosslinked foamed particle molded bodies. In addition, although the obtained expanded particle had the through-hole, the internal diameter was small.
〔比較例１〕
有機過酸化物をジクミルパーオキサイド（パークミルＤ；１０時間半減期温度：１１６℃）に変更した以外は実施例３と同様の操作で架橋発泡粒子を得、表２の「成形条件」欄に示す条件で成形を行い、架橋発泡粒子成形体を得た。なお、得られた架橋発泡粒子は、重合体粒子由来の中空部分が無くなり、貫通孔を有しない架橋発泡粒子であった。
[Comparative Example 1]
Cross-linked foamed particles were obtained in the same manner as in Example 3 except that the organic peroxide was changed to dicumyl peroxide (Park Mill D; 10-hour half-life temperature: 116 ° C.). Molding was performed under the conditions shown to obtain a crosslinked foamed particle molded body. In addition, the obtained crosslinked foamed particle was a crosslinked foamed particle having no hollow portion derived from polymer particles and having no through-holes.
〔比較例２〕
有機過酸化物をｔ−ブチルパーオキシ−２−エチルヘキサノエート（パーブチルＯ；１０時間半減期温度：７２℃）に変更した以外は比較例１と同様の操作で架橋発泡粒子を得た。
得られた架橋発泡粒子は、貫通孔を有しない架橋発泡粒子であった。
また、発泡粒子の見かけ密度が高いため、良好な成形体を作製することができなかったため、物性測定を行うことができなかった。
[Comparative Example 2]
Crosslinked foamed particles were obtained in the same manner as in Comparative Example 1 except that the organic peroxide was changed to t-butylperoxy-2-ethylhexanoate (perbutyl O; 10 hour half-life temperature: 72 ° C.).
The obtained crosslinked foamed particles were crosslinked foamed particles having no through-holes.
Further, since the apparent density of the expanded particles was high, a good molded product could not be produced, and physical properties could not be measured.
表１〜２の「発泡粒子」欄の「貫通孔内径」からわかるように、実施例１〜６の架橋発泡粒子は、いずれも貫通孔を有する架橋発泡粒子として形成された。また、良好な発泡粒子成形体が得られた。しかし、架橋剤として式（１）を満たさない架橋剤を用いて製造された架橋発泡粒子は貫通孔を有さないものしか得られなかった。 As can be seen from the “through-hole inner diameter” in the “foamed particle” column of Tables 1 and 2, all of the crosslinked foamed particles of Examples 1 to 6 were formed as crosslinked foamed particles having through-holes. In addition, a good foamed particle molded body was obtained. However, only crosslinked foamed particles produced using a crosslinking agent that does not satisfy Formula (1) as a crosslinking agent were obtained without through-holes.
Claims (6)
工程（ａ）：密閉容器内で、分散媒に、前記ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体の、貫通孔を有する重合体粒子を分散させる工程、
工程（ｂ）：前記重合体粒子に下式（１）の関係を満足する有機過酸化物を含浸させ、前記重合体粒子を構成する前記ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体の融点以上、前記融点＋８０℃以下の温度で、前記重合体粒子を架橋させる工程、
工程（ｃ）：前記重合体粒子に発泡剤を含浸させる工程、及び
工程（ｄ）：前記発泡剤を含む発泡性重合体粒子を発泡させる工程、
を有する、発泡粒子の製造方法。
５≦Ｔｍ−Ｔｈ≦４５・・・（１）
〔Ｔｍ：前記重合体粒子を構成する前記ポリエチレンブロックとエチレン／α−オレフィン共重合体ブロックとのブロック共重合体の融点（℃）、Ｔｈ：前記有機過酸化物の１０時間半減期温度（℃）〕 A block copolymer of a polyethylene block and an ethylene / α-olefin copolymer block, which is a method for producing expanded particles having through holes,
Step (a): Dispersing polymer particles having through-holes of the block copolymer of the polyethylene block and the ethylene / α-olefin copolymer block in a dispersion medium in a closed container,
Step (b): impregnating the polymer particles with an organic peroxide satisfying the relationship of the following formula (1), and the polyethylene block and the ethylene / α-olefin copolymer block constituting the polymer particle: A step of crosslinking the polymer particles at a temperature not lower than the melting point of the block copolymer and not higher than the melting point + 80 ° C.,
Step (c): a step of impregnating the polymer particles with a foaming agent, and step (d): a step of foaming expandable polymer particles containing the foaming agent,
A process for producing expanded particles, comprising:
5 ≦ Tm−Th ≦ 45 (1)
[Tm: melting point (° C.) of block copolymer of polyethylene block and ethylene / α-olefin copolymer block constituting the polymer particles, Th: 10 hour half-life temperature (° C. of organic peroxide) )]
１０≦Ｔｍ−Ｔｈ≦４０・・・（２） The method for producing expanded particles according to claim 1 or 2, wherein the temperature at which the polymer particles are crosslinked at least in the step (b) satisfies the relationship of the following formula (2).
10 ≦ Tm−Th ≦ 40 (2)
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| EP17870372.4A EP3540005B1 (en) | 2016-11-14 | 2017-11-13 | Foam particle moulded article, sole cushion, and method for producing foam particles |
| PCT/JP2017/040720 WO2018088551A1 (en) | 2016-11-14 | 2017-11-13 | Foam particle moulded article, sole cushion, and method for producing foam particles |
| CN201780069533.7A CN109937232B (en) | 2016-11-14 | 2017-11-13 | Foamed particle molded body, cushioning body for shoe sole, and method for producing foamed particles |
| KR1020197013476A KR102443719B1 (en) | 2016-11-14 | 2017-11-13 | Method for manufacturing expanded particle molded article, cushion for soles and expanded particles |
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