JP2023148537A - Foamed particle and foamed particle molding - Google Patents

Abstract

To provide foamed particles which are excellent in in-mold moldability, and enable production of a polyethylene-based resin foamed particle molding in a wide density range, and a polyethylene-based resin foamed particle molding which has low apparent density and a good molding state.SOLUTION: Foamed particles contain linear low-density polyethylene as a base material resin, wherein the linear low-density polyethylene contains a butene component and a hexene component as copolymerization components, a melt flow rate of the foamed particle measured under conditions of a temperature of 190°C and a load of 2.16 kg is 0.1 g/10 min or more and 2.0 g/10 min or less, the foamed particles have such a crystal structure that a melting peak (inherent peak) inherent to the linear low-density polyethylene and one or more melting peaks (high temperature peaks) on the high-temperature side relative to the inherent peak appear, in a DSC curve obtained by heating from 23°C to 200°C at a heating rate of 10°C/min, a total melting heat quantity of the foamed particles is 70 J/g or more and 100 J/g or less, a melting heat quantity of the high temperature peaks is 30 J/g or more and 50 J/g or less, and a ratio of the melting heat quantity of the high temperature peaks to the total melting heat quantity of the foamed particles is 0.3 or more and 0.7 or less.SELECTED DRAWING: None

Description

TECHNICAL FIELD The present invention relates to expanded particles and expanded particle molded articles.

A polyethylene foamed particle molded product obtained by in-mold molding of polyethylene resin foam particles has excellent chemical resistance, cushioning properties, etc., and is also excellent in recyclability. For this reason, polyethylene resin foam particle moldings are used as shock absorbers, heat insulating materials, and various packaging materials, including packaging and cushioning materials for electrical and electronic parts, packaging and cushioning materials for automobile parts, and other precision parts as well as food products. It is widely used as a variety of packaging materials.
As mentioned above, since polyethylene-based foamed particle molded bodies are widely used, it is required to manufacture various molded bodies having shapes etc. depending on the intended use. Therefore, studies are being conducted to improve the in-mold moldability of expanded polyethylene resin particles.
For example, Patent Document 1 discloses that polyethylene resin particles having a specific density and melt flow index are foamed to make them moldable in a wide temperature range and improve surface smoothness. , melt tension, and cell diameter are disclosed.

Japanese Patent Application Publication No. 2000-017079

However, in order to obtain expanded particles with good in-mold moldability, there are a limited number of resins that can be used to form expanded particles. It would be desirable to increase the variety.
Further, Patent Document 1 describes the production of foamed particles having good in-mold moldability using linear low-density polyethylene containing a butene component and a hexene component as copolymerization components as a polyethylene resin. , nothing has been disclosed.
The present invention provides foamed particles that have excellent in-mold moldability and can produce polyethylene resin foamed particle molded bodies over a wide range of densities, and foamed particle molded bodies that have a low apparent density and a good molding state. That is the issue.

As a result of intensive studies, the present inventors have found that foamed particles that use linear low-density polyethylene having a specific comonomer component as a base resin and satisfy a specific melt flow rate and a specific heat of fusion relationship can solve the above problems. I found a solution.
That is, the present invention provides foamed particles using linear low-density polyethylene as a base resin, the linear low-density polyethylene containing a butene component and a hexene component as copolymerization components, at a temperature of 190°C, The expanded particles have a melt flow rate of 0.1 g/10 minutes or more and 2.0 g/10 minutes or less, measured under a load of 2.16 kg, and the expanded particles are heated at 23° C. at a heating rate of 10° C./minute. A crystal in which a melting peak (specific peak) specific to linear low-density polyethylene and one or more melting peaks (high-temperature peak) appear on the higher temperature side than the specific peak in the DSC curve obtained by heating from to 200 ° C. structure, the total heat of fusion of the foamed particles is 70 J/g or more and 100 J/g or less, the heat of fusion of the high temperature peak is 30 J/g or more and 50 J/g or less, and the foamed particles have a total heat of fusion of 30 J/g or more and 50 J/g or less, , the foamed particles have a ratio of heat of fusion of the high temperature peak of 0.3 or more and 0.7 or less.

According to the present invention, foamed particles having excellent in-mold moldability and capable of producing polyethylene resin foamed particle molded bodies over a wide range of densities, and foamed particle molded bodies having a low apparent density and a good molding state are provided. can be provided. In addition, according to the present invention, foamed particles with excellent in-mold moldability can be used in foamed particles whose base resin is linear low-density polyethylene containing a butene component and a hexene component as copolymerization components, which has not been considered in the past. particles can be provided.

[Foamed particles]
The foamed particles of the present invention are foamed particles using linear low-density polyethylene as a base resin, wherein the linear low-density polyethylene contains a butene component and a hexene component as copolymerization components, and has a temperature of 190°C. The foamed particles have a melt flow rate of 0.1 g/10 minutes or more and 2.0 g/10 minutes or less, measured under the conditions of temperature and load of 2.16 kg, and the foamed particles are heated at a heating rate of 10 degrees C/minute. In the DSC curve obtained by heating from 23°C to 200°C, there is a melting peak (specific peak) specific to linear low density polyethylene and one or more melting peaks (high temperature peak) on the higher temperature side than the specific peak. The foamed particles have a crystal structure that appears, the total heat of fusion of the expanded particles is 70 J/g or more and 100 J/g or less, the heat of fusion of the high temperature peak is 30 J/g or more and 50 J/g or less, and the total melting of the expanded particles is The foam particles have a ratio of heat of fusion of the high temperature peak to heat of 0.3 or more and 0.7 or less.

(Linear low density polyethylene)
The foamed particles have linear low-density polyethylene as a base resin. In this specification, "the base resin is linear low-density polyethylene" means that the expanded particles are made of a resin whose main component is linear low-density polyethylene. Note that, as described later, the expanded particles may contain polymers other than linear low-density polyethylene, as long as the effects of the present invention are not impaired.

The linear low density polyethylene has a density of 910 kg/m ³ or more and 940 kg/m ³ or less, has a linear structure, and contains a butene component and a hexene component as copolymer components (comonomers). Note that the hexene component in the linear low density polyethylene includes 1-hexene and 4-methyl-1-pentene.

From the viewpoint of being able to stably obtain expanded particles with excellent in-mold moldability, the content of a component derived from butene (butene component) in the linear low density polyethylene is 0.5 mol% or more and 6 mol% or less. It is preferably 1 mol% or more and 5 mol% or less, and even more preferably 2 mol% or more and 4 mol% or less. Further, the content of a component derived from hexene (hexene component) in the linear low density polyethylene is preferably 0.2 mol% or more and 5 mol% or less, and preferably 0.5 mol% or more and 4 mol% or less. is more preferable, and even more preferably 0.8 mol% or more and 3 mol% or less.
Furthermore, the linear low-density polyethylene does not contain a component derived from an α-olefin other than butene and hexene as a copolymerization component (comonomer) as long as the object of the present invention can be achieved and the effects of the present invention are not impaired. For example, it may contain a component derived from propylene as a copolymerization component. When the linear low density polyethylene contains a component derived from propylene, the content of the component derived from propylene in the linear low density polyethylene is preferably 0.3 mol% or more and 5 mol% or less, and 0.5 mol%. % or more and 4 mol% or less, further preferably 0.8 mol% or more and 3 mol% or less, and particularly preferably 1 mol% or more and 2 mol% or less.
The above content is the content when the total of components derived from ethylene and components derived from α-olefins (α-olefins having 3 or more carbon atoms such as butene and hexene) is 100% by mass. be. Further, the content of components derived from α-olefin in the linear low density polyethylene is preferably 10 mol% or less, more preferably 8 mol% or less. Further, the content of the component derived from α-olefin in the linear low density polyethylene is preferably 0.5 mol% or more, more preferably 1 mol% or more.
The content of components derived from each α-olefin in linear low-density polyethylene can be determined by carbon-13 nuclear magnetic resonance ( ¹³ C-NMR) measurements, etc. as described in Examples.

From the same viewpoint, the ratio of the content of the hexene-derived component to the content of the butene-derived component in the linear low-density polyethylene [hexene component content (mol%)/butene component content ( mol%)] is preferably 0.1 or more and 2 or less, more preferably 0.2 or more and 1 or less, and even more preferably 0.3 or more and 0.8 or less. In addition, when linear low-density polyethylene contains a component derived from propylene as a copolymerization component, the amount of the component derived from propylene relative to the total content of the component derived from butene and the content of the component derived from hexene is The content ratio [propylene component content (mol%)/{hexene component content (mol%)+butene component content (mol%)}] is preferably 0.1 or more and 2 or less, and 0.1 to 2. It is more preferably 2 or more and 1 or less, and even more preferably 0.3 or more and 0.7 or less.

The melt flow rate of the linear low density polyethylene measured at a temperature of 190° C. and a load of 2.16 kg is preferably 0.1 g/10 minutes or more and 2.0 g/10 minutes or less. When the melt flow rate of the linear low-density polyethylene is within the above range, the in-mold moldability of the expanded particles can be further improved.
The melt flow rate of the linear low density polyethylene is more preferably 0.3 g/10 minutes or more, still more preferably 0.5 g/10 minutes or more, even more preferably 0.7 g/10 minutes or more. It is. Further, the melt flow rate of the linear low density polyethylene is more preferably 1.8 g/10 minutes or less, still more preferably 1.5 g/10 minutes or less, even more preferably 1.4 g/10 minutes. minutes or less.
The melt flow rate of linear low density polyethylene is a value measured at a temperature of 190° C. and a load of 2.16 kg. More specifically, it can be measured by the method described in Examples in accordance with JIS K 7210-1:2014.

The melting point of the linear low-density polyethylene is preferably 110°C or higher, more preferably 120°C or higher, and even more preferably 122°C or higher, from the viewpoint of improving the mechanical properties of the molded product obtained. On the other hand, the melting point of the linear low-density polyethylene is preferably 135°C or lower, more preferably 130°C or lower, and Preferably it is 126°C or lower.
The melting point of linear low density polyethylene is measured based on JIS K 7121:2012 using linear low density polyethylene as a test piece. Specifically, it can be measured by the method described in Examples.

The density of the linear low-density polyethylene is 910 kg/m ³ or more and 940 kg/m ³ or less, and preferably 910 kg/m ³ or more and 935 kg/m ³ from the viewpoint of making it easier to obtain expanded particles having desired physical properties. or less, more preferably 912 kg/m ³ or more and 930 kg/m ³ or less, still more preferably 914 kg/m ³ or more and 928 kg/m ³ or less.
The density of linear low density polyethylene is measured, for example, by method A (substitution method in water) described in JIS K7112:1999.

From the viewpoint of making it easier to obtain expanded particles having desired physical properties, the heat of fusion of the linear low density polyethylene is preferably 60 J/g or more, more preferably 70 J/g or more, and even more preferably 75 J/g. /g or more. Further, from the same viewpoint, the heat of fusion of the linear low density polyethylene is preferably 120 J/g or less, more preferably 110 J/g or less, still more preferably 100 J/g or less, and particularly preferably is 90 J/g or less.
The heat of fusion of linear low-density polyethylene can be determined from the DSC curve obtained by performing differential scanning calorimetry (DSC) in accordance with JIS K 7122:2012 using linear low-density polyethylene as a test piece. . Specifically, it can be measured by the method described in Examples.

The linear low density polyethylene preferably has a biomass degree of 40% or more as measured by ASTM D 6866. When the degree of biomass is within the above range, it is possible to suppress the use of fossil resources during the production of the molded body, and also reduce the amount of carbon dioxide emitted during the life cycle of the molded body.
From the above viewpoint, the biomass degree of the linear low density polyethylene measured according to ASTM D 6866 is more preferably 50% or more, still more preferably 60% or more, and even more preferably 70% or more. Yes, and even more preferably 80% or more. Further, there is no upper limit on the upper limit, and the biomass degree measured by ASTM D 6866 of the linear low-density polyethylene may be 100% or less, but from the viewpoint of easily improving the in-mold moldability of the expanded particles, The degree of biomass measured by ASTM D 6866 of the linear low density polyethylene is preferably 95% or less, more preferably 90% or less. The biomass degree is measured according to ASTM D 6866, and means the proportion of naturally derived components contained in linear low density polyethylene. Moreover, the biomass degree is a value obtained by measuring the concentration of radioactive carbon ^C14 in linear low density polyethylene.

<Characteristics and composition of expanded particles>
As described above, the foamed particles of the present invention have linear low-density polyethylene as a base resin containing a butene component and a hexene component as copolymerization components, and preferably have the following characteristics.

The foamed particles of the present invention preferably have a bulk density of 10 kg/m ³ or more and 300 kg/m ³ or less. The bulk density of the expanded particles is preferably 10 kg/m ³ or more, more preferably 13 kg/m ³ or more, still more preferably 15 kg/m ³ or more, from the viewpoint of improving the mechanical properties of the obtained molded product. It is. On the other hand, the bulk density of the expanded particles is preferably 300 kg/m ³ or less, more preferably 240 kg/m ³ or less, still more preferably 200 kg/m ³ from the viewpoint of obtaining a molded product with a low apparent density. or less, even more preferably 100 kg/m ³ or less, even more preferably 80 kg/m ³ or less, even more preferably 60 kg/m ³ or less.
As will be described later, in the present invention, the obtained expanded particles are subjected to pressure treatment and then heated with steam etc. to further foam them, resulting in two-stage foaming, which results in foaming with a higher expansion ratio (lower bulk density). particles can be obtained. From the viewpoint of obtaining a molded article with a low apparent density, it is preferable to carry out two-stage foaming.
In the case of performing two-stage foaming, the bulk density of the foamed particles after the first-stage foaming (before the second-stage foaming) is preferably 60 kg/m ³ from the viewpoint of stably obtaining foamed particles having the desired cell structure. or more, more preferably 70 kg/m ³ or more, still more preferably 80 kg/m ³ or more. On the other hand, when performing two-stage foaming, the bulk density of the expanded particles after the first-stage foaming (before the second-stage foaming) is preferably 240 kg/m ³ from the viewpoint of stably obtaining foamed particles with a low apparent density. or less, preferably 200 kg/m ³ or less, more preferably 180 kg/m ³ or less, still more preferably 160 kg/m ³ or less.
Note that the bulk density can be measured by the method described in Examples.

The closed cell ratio of the expanded particles of the present invention is preferably 80% or more. When the closed cell ratio of the expanded beads is within the above range, the in-mold moldability of the expanded beads can be further improved. The closed cell ratio of the expanded particles of the present invention is more preferably 85% or more, still more preferably 88% or more, and even more preferably 90% or more. Further, there is no upper limit to the closed cell ratio of the expanded particles of the present invention, but it is more preferably 99% or less, still more preferably 98% or less, and even more preferably 97% or less.
Note that the closed cell ratio can be measured by the method described in Examples.

The average cell diameter of the expanded particles of the present invention is preferably 60 μm or more and 200 μm or less. When the average cell diameter of the expanded particles is within the above range, the in-mold moldability of the expanded particles can be stably improved. The average cell diameter of the expanded particles of the present invention is more preferably 70 μm or more, still more preferably 80 μm or more, even more preferably 100 μm or more. Further, the average cell diameter of the expanded particles of the present invention is more preferably 180 μm or less, still more preferably 160 μm or less, even more preferably 140 μm or less.
Further, in the case of two-stage foaming, the average cell diameter of the expanded particles after the first-stage foaming (before the second-stage foaming) is preferably 50 μm or more, more preferably 60 μm or more, and still more preferably 70 μm or more. Further, in the case of performing two-stage foaming, the average cell diameter of the expanded particles after the first-stage foaming (before the second-stage foaming) is preferably 120 μm or less, more preferably 110 μm or less, and still more preferably 100 μm or less.
The average cell diameter is calculated by drawing multiple line segments from the outermost surface of the expanded particle through the center to the opposite outermost surface on an enlarged photograph of the cross section of the expanded particle divided into two, and then calculating the number of bubbles that intersect with each line segment. can be measured by dividing by the total length of the line segments. Specifically, it can be measured by the method described in Examples.
The average cell diameter of the foamed particles can be adjusted to the desired value by adjusting the type and amount of the cell regulator added to the resin particles, and by adjusting the foaming temperature and pressure in the pressure container during foaming of the resin particles. It can be a range.

In the DSC curve obtained by heating from 23°C to 200°C at a heating rate of 10°C/min, the expanded particles of the present invention have a melting peak (unique peak) specific to linear low-density polyethylene and a unique peak. also has a crystal structure in which one or more melting peaks (high temperature peaks) appear on the high temperature side, the total heat of fusion of the expanded particles is 70 J/g or more and 100 J/g or less, and the heat of fusion of the high temperature peak is 30 J/g. g or more and 50 J/g or less, and the ratio of the heat of fusion of the high temperature peak to the total heat of fusion of the expanded particles is 0.3 or more and 0.7 or less.

The DSC curve is a DSC curve obtained by differential scanning calorimetry (DSC) based on JIS K7122:2012. Specifically, the DSC curve can be obtained by heating 1 to 3 mg of the expanded particles of the present invention from 23° C. to 200° C. at a heating rate of 10° C./min using a differential scanning calorimeter.
As described above, the expanded particles of the present invention have a melting peak (unique peak) specific to linear low-density polyethylene, and a melting peak (unique peak) on the higher temperature side than the intrinsic peak in the DSC curve measured for the expanded beads. The above melting peak (high temperature peak) appears.

This will be explained in more detail below.
The DSC curve means a DSC curve obtained by heating expanded particles by the measurement method (DSC curve in the first heating). Further, the melting peak (unique peak) specific to linear low-density polyethylene is a melting peak that appears due to melting of crystals that linear low-density polyethylene that constitutes expanded particles usually has.
On the other hand, the melting peak on the higher temperature side than the characteristic peak (high temperature peak) is the melting peak that appears on the higher temperature side than the characteristic peak in the DSC curve in the first heating. When this high temperature peak appears, it is presumed that secondary crystals exist in the resin. Note that after heating the expanded particles from 23°C to 200°C at a heating rate of 10°C/min (first heating), they were cooled from 200°C to 23°C at a cooling rate of 10°C/min, and then heated again at 10°C. In the DSC curve obtained when heating from 23 °C to 200 °C (second heating) at a heating rate of °C/min (second heating DSC curve), the linear low Only the melting peak due to melting of crystals, which density polyethylene usually has, appears. This characteristic peak appears in both the DSC curve of the first heating and the DSC curve of the second heating, and the temperature at the peak apex may differ somewhat between the first and second heating, but usually, The difference is less than 5°C. This makes it possible to confirm which peak is the unique peak.
The expanded particles of the present invention are heated from 23°C to 200°C at a heating rate of 10°C/min, then cooled from 200°C to 23°C at a cooling rate of 10°C/min, and then cooled at a cooling rate of 10°C/min. Preferably, the foamed particles exhibit only a melting peak (unique peak) specific to linear low-density polyethylene in the DSC curve obtained during the second heating when heated from 23° C. to 200° C. at a heating rate. .

The total heat of fusion of the expanded particles of the present invention is the sum of the heat of fusion of all melting peaks (endothermic peaks) appearing on the DSC curve. The total heat of fusion of the expanded particles of the present invention is 70 J/g or more and 100 J/g or less. When the total heat of fusion of the expanded particles is within the above range, expanded particles with excellent two-stage foamability and in-mold moldability can be obtained, and molded articles with excellent strength can be obtained.
The total heat of fusion of the expanded particles of the present invention is preferably 72 J/g or more, more preferably 75 J/g or more, still more preferably 78 J/g or more, from the viewpoint of improving the strength of the obtained molded product. be. In addition, the total heat of fusion of the expanded particles of the present invention is preferably 95 J/g or less, more preferably 90 J/g or less, from the viewpoint of improving the two-stage foamability and in-mold moldability of the expanded particles, More preferably, it is 85 J/g or less.
The total heat of fusion of the expanded particles can be determined from a DSC curve obtained by performing differential scanning calorimetry (DSC) in accordance with JIS K 7122:2012 using the expanded particles as a test piece. Specifically, "(2) When measuring the melting temperature after a certain heat treatment" was adopted as the conditioning of the test piece, and the test piece was heated at a heating rate of 10°C/min for 23 hours. Heating from ℃ to 200℃, after reaching 200℃, cooling from 200℃ to 23℃ at a rate of 10℃/min, and then heating again from 23℃ to 200℃ at a rate of 10℃/min. By doing this, a DSC curve (DSC curve at the time of second heating) is obtained. The point on the obtained DSC curve during the second heating at a temperature of 80° C. is designated as α, and the point on the DSC curve corresponding to the melting end temperature is designated as β. The area of the portion surrounded by the DSC curve and the line segment (α-β) in the section between points α and β is measured, and the heat of fusion of the expanded particles can be calculated from this area.

The heat of fusion of the expanded particles of the present invention at a high temperature peak is 30 J/g or more and 50 J/g or less. When the heat of fusion at the high temperature peak of the expanded particles is within the above range, even if the expanded particles have a low bulk density, the in-mold moldability of the expanded particles can be improved, and the molding pressure at which in-mold molding is possible can be improved. A wide range of expanded particles can be obtained. Thereby, good molded bodies can be obtained over a wide density range.
The heat of fusion at the high temperature peak of the foamed particles of the present invention can suppress sink marks in the molded product immediately after molding and improve the in-mold moldability of the foamed particles even when the foamed particles have a lower bulk density. From the viewpoint of stability and suppression of shrinkage of the two-stage foamed particles when the foamed particles are expanded in two stages, it is 30 J/g or more, preferably 32 J/g or more, and more preferably 34 J/g. /g or more. In addition, the heat of fusion at the high temperature peak of the foamed particles of the present invention improves the fusion properties of the foamed particles under low molding pressure conditions, improves the in-mold moldability of the foamed particles, and allows the foamed particles to be expanded in two stages. In this case, from the viewpoint of making it easier to obtain expanded particles with a lower bulk density, it is 50 J/g or less, preferably 45 J/g or less, and more preferably 40 J/g or less.
The heat of fusion at the high temperature peak can be determined by heat flux differential scanning calorimetry in accordance with JIS K7122:2012 using expanded particles as a test piece. Specifically, it can be determined from the DSC curve (DSC curve in the first heating) obtained by heating the expanded particles from 23 ° C to 200 ° C at a heating rate of 10 ° C / min. can be measured by the method described in Examples.

The ratio of the heat of fusion of the high temperature peak to the total heat of fusion of the expanded particles of the present invention [heat of fusion of the high temperature peak/total heat of fusion] is 0.3 or more and 0.7 or less. When each of the heats of fusion described above is within the above range and the ratio is within the above range, it is possible to obtain expanded particles that have excellent in-mold formability and can be formed over a wide density range and over a wide molding pressure range. can. Moreover, expanded particles with good two-stage foamability can be obtained.
The ratio of the heat of fusion of the high-temperature peak to the total heat of fusion of the foamed particles of the present invention is such that even when the foamed particles have a lower bulk density, it suppresses sink marks in the molded product immediately after molding, and It is preferably 0.35 or more, more preferably 0.35 or more, from the viewpoint of improving moldability and stably suppressing the shrinkage of the two-stage expanded particles when the expanded beads are expanded in two stages. It is 38 or more, more preferably 0.40 or more. In addition, the ratio of the heat of fusion of the high temperature peak to the total heat of fusion of the expanded particles of the present invention is determined from the viewpoint of improving the fusion properties of the expanded particles under low molding pressure conditions and increasing the in-mold moldability of the expanded particles. It is preferably 0.6 or less, more preferably 0.55 or less, from the viewpoint of making it easier to obtain foamed particles with a lower bulk density when foamed in two stages.
Note that the ratio of the heat of fusion of the high temperature peak to the total heat of fusion can be calculated from the total heat of fusion and the heat of fusion of the high temperature peak.

The degree of biomass of the expanded particles of the present invention as measured by ASTM D 6866 is preferably 40% or more. When the degree of biomass is within the above range, it is possible to suppress the use of fossil resources during the production of the molded body, and also reduce the amount of carbon dioxide emitted during the life cycle of the molded body.
From the above point of view, the degree of biomass of the expanded particles of the present invention as measured by ASTM D 6866 is preferably 50% or more, more preferably 60% or more, still more preferably 70% or more, and particularly preferably is 80% or more. Further, there is no upper limit to the upper limit, and the degree of biomass measured by ASTM D 6866 of the expanded particles of the present invention may be 100% or less, but from the viewpoint of easily improving the in-mold moldability of the expanded particles, The degree of biomass of the expanded particles of the present invention as measured by ASTM D 6866 is preferably 95% or less, more preferably 90% or less. The biomass degree is measured according to ASTM D 6866, and means the proportion of naturally derived components contained in the expanded particles of the present invention. In addition, the biomass degree can be determined by measuring the concentration of radioactive carbon C ¹⁴ in the expanded particles, or by determining the biomass degree of the biomass-derived resin used to manufacture the expanded particles, and the biomass degree of the biomass-derived resin in the expanded particles. It can be calculated from the content ratio.

The melt flow rate of the expanded particles measured at a temperature of 190° C. and a load of 2.16 kg is 0.1 g/10 minutes or more and 2.0 g/10 minutes or less. When the melt flow rate of the expanded particles is within the above range, the in-mold moldability of the expanded particles can be further improved.
The melt flow rate of the expanded particles is preferably 0.3 g/10 minutes or more, more preferably 0.5 g/10 minutes or more, still more preferably 0.7 g/10 minutes or more. Further, the melt flow rate of the expanded particles is preferably 1.8 g/10 minutes or less, more preferably 1.5 g/10 minutes or less, still more preferably 1.4 g/10 minutes or less.
The melt flow rate of the expanded particles is a value measured at a temperature of 190° C. and a load of 2.16 kg. More specifically, it can be measured by the method described in Examples in accordance with JIS K 7210-1:2014. In addition, in the measurement, foamed particles that have been subjected to defoaming treatment by heat press or the like may be used as the measurement sample, as long as the physical properties of the resin are not significantly impaired.

Further, it is preferable that the expanded particles are non-crosslinked. Non-crosslinking makes it easier to recycle the foamed particles, making it easier to reduce environmental impact.
The term "non-crosslinked" as used herein means that the proportion of insoluble matter in the expanded particles as determined by the hot xylene extraction method of the expanded particles is 5% by mass or less. From the viewpoint of easier recycling of the foamed particles, the proportion of insoluble matter extracted from the foamed particles by hot xylene extraction is preferably 3% by mass or less, and most preferably 0.
The xylene-insoluble content of expanded particles obtained by hot xylene extraction can be measured as follows. First, approximately 1 g of precisely weighed expanded particles (the exact mass is M (g)) is placed in a 150 mL round bottom flask, 100 mL of xylene is added, and the mixture is heated with a mantle heater and refluxed for 6 hours. Thereafter, the undissolved residue (insoluble matter) is separated by filtration through a 100-mesh wire mesh, and dried in a vacuum dryer at 80° C. for 8 hours or more. By measuring the mass m (g) of the dried product obtained by drying the residue and expressing the ratio of m to M as a percentage, the ratio of the xylene-insoluble content in the expanded particles can be determined.

The average mass per foamed particle of the present invention (the arithmetic average value per one obtained by measuring the mass of 100 randomly selected particles) is preferably 0.1 to 20 mg, more preferably 0.1 to 20 mg. The amount is 2 to 10 mg, more preferably 0.3 to 5 mg, even more preferably 0.4 to 2 mg. The average mass per foamed particle can be calculated by measuring the mass of 100 randomly selected foamed particles and taking the arithmetic average of these masses.

Moreover, additives may be appropriately added to the expanded particles of the present invention within a range that does not impede the effects of the present invention. Examples of additives include antioxidants, ultraviolet absorbers, antistatic agents, flame retardants, pigments, dyes, and bubble control agents. These additives can be contained in the expanded particles by, for example, being added during the process of manufacturing the resin particles.

As the bubble control agent, for example, inorganic powder or organic powder can be used. Examples of the inorganic powder include boric acid metal salts such as zinc borate and magnesium borate, and examples of the organic powder include fluororesin powder such as polytetrafluoroethylene (PTFE).
From the viewpoint of stably obtaining expanded particles having the desired bulk density and with little variation in cell diameter, the amount of the cell regulator in the resin particles should be 50 mass ppm or more and 5000 mass ppm or less. is preferable, more preferably 100 mass ppm or more and 2000 mass ppm or less, and even more preferably 150 mass ppm or more and 1500 mass ppm or less.
Further, from the viewpoint of easily adjusting the average cell diameter of the expanded particles to a desired range, it is preferable to use a boric acid metal salt as the cell regulator, and it is more preferable to use zinc borate. Further, when zinc borate is used, the arithmetic mean particle size based on the number of particles is preferably 0.5 μm or more and 10 μm or less, more preferably 1 μm or more and 8 μm or less.
The number-based arithmetic mean particle diameter of zinc borate is calculated by converting it into a number-based particle size distribution assuming that the shape of the particles is spherical, based on the volume-based particle size distribution measured by laser diffraction scattering method. It can be determined by obtaining a number-based particle size distribution and arithmetic averaging the particle diameters based on this number-based particle size distribution. In addition, the said particle diameter means the diameter of the virtual sphere which has the same volume as a particle.

The foamed particles of the present invention may contain polymers such as resins and elastomers other than the linear low-density polyethylene, within a range that does not impede the effects of the present invention. In this case, the content of the polymer other than the linear low-density polyethylene in the expanded particles is preferably 40 parts by mass or less, more preferably 30 parts by mass or less, based on 100 parts by mass of the linear low-density polyethylene. It is preferably 20 parts by mass or less, more preferably 10 parts by mass or less, even more preferably 5 parts by mass or less.

The foamed particles of the present invention can have a fusion layer on the surface thereof to enhance the fusion properties of the foamed particles during in-mold molding. The adhesive layer may be present on the entire surface of the foamed particles, or may be present on a part of the surface. The resin constituting the adhesive layer includes a crystalline polyolefin resin having a melting point lower than that of the linear low-density polyethylene constituting the foamed particles, and a crystalline polyolefin resin having a melting point lower than the melting point of the linear low-density polyethylene constituting the foamed particles. Examples include amorphous polyolefin resins having a low softening point.
The method of forming the fusion layer on the surface of the foamed particles is not particularly limited, and examples include a method of foaming resin particles having a fusion layer on the surface, or a method of forming the fusion layer on the surface of the foamed particles after obtaining the foamed particles. An example of how to do this can be given. When foamed particles are obtained by foaming resin particles having a fused layer on the surface, an extrusion device capable of co-extrusion is used to melt the resin to form the resin particle body. It is preferable to adopt a method of laminating a fusion layer on the surface of the resin particles by co-extruding the material and a resin melt for forming the fusion layer.

As described above, the expanded particles of the present invention can be suitably used as expanded particles for in-mold molding. In addition, the foamed particles of the present invention satisfy a specific heat of fusion relationship, making them foamed particles with excellent foaming properties during two-stage foaming, and are therefore suitable as foamed particles for two-stage foaming. They are foam particles.
On the other hand, the foamed particles of the present invention have appropriate flexibility and restorability by satisfying a specific heat of fusion relationship. Therefore, the expanded particles of the present invention can also be suitably used, for example, as stuffing beads for cushioning materials. Stuffing beads are particulate stuffing that is used to fill a bag to form a cushioning material, and the foamed particles of the present invention can be particularly suitably used as stuffing beads for beaded cushions.

<Method for manufacturing expanded particles>
As described above, the foamed particles of the present invention have linear low density polyethylene as a base resin, and the linear low density polyethylene contains a butene component and a hexene component as copolymerization components. In the DSC curve obtained by heating the expanded particles from 23°C to 200°C at a heating rate of 10°C/min, the foamed particles have a melting peak (unique peak) unique to linear low-density polyethylene and a unique peak. It has a crystal structure in which one or more melting peaks (high temperature peaks) appear on the higher temperature side than the peak, the total heat of fusion of the expanded particles is 70 J/g or more and 100 J/g or less, and the heat of fusion of the high temperature peak is The manufacturing method is not particularly limited as long as it is 30 J/g or more and 50 J/g or less and the ratio of the heat of fusion of the high temperature peak to the total heat of fusion of the expanded particles is 0.3 or more and 0.7 or less. The foamed particles can be produced, for example, by impregnating resin particles having the linear low-density polyethylene as a base resin with a foaming agent and foaming the resin particles containing the foaming agent. An example of a suitable manufacturing method is shown below.

A preferred method for producing expanded particles of the present invention includes a dispersion step of dispersing resin particles having linear low-density polyethylene as a base resin in an aqueous medium in a container, and a step of impregnating the resin particles with a foaming agent in the container. and a foaming step in which the resin particles containing the foaming agent are discharged from the container together with an aqueous medium into a pressure atmosphere lower than the pressure inside the container to foam the resin particles.

(Manufacture of resin particles using linear low-density polyethylene as the base resin)
The resin particles used in the production of the expanded particles of the present invention are produced by feeding the linear low-density polyethylene, a cell regulator, etc. blended as necessary into an extruder, and heating and kneading the resin particles to form a resin melt. After that, the resin melt is extruded from an extruder and pelletized by a strand cut method, a hot cut method, an underwater cut method, etc. to obtain the resin melt.

The average mass per resin particle is preferably adjusted to 0.1 to 20 mg, more preferably 0.2 to 10 mg, still more preferably 0.3 to 5 mg, and more preferably More preferably, it is 0.4 to 2 mg. Further, the external shape of the particles is not particularly limited as long as it can achieve the intended purpose of the present invention, but is preferably cylindrical.
When the external shape of the resin particles is cylindrical, the particle diameter (length in the extrusion direction) of the resin particles is preferably 0.1 to 3.0 mm, more preferably 0.3 to 1.5 mm. be. Further, the ratio (length/diameter ratio) between the length of the resin particles in the extrusion direction and the length of the resin particles in the direction perpendicular to the extrusion direction (diameter of the resin particles) is preferably 0.5 to 5. .0, more preferably 1.0 to 3.0.

In addition, when pelletizing by the strand cutting method, the particle diameter, length/diameter ratio, and average mass of the resin particles depend on the extrusion speed when extruding the resin melt, the strand take-up speed, and the speed when cutting the strand. It can be adjusted by pelletizing by changing the cutter speed etc. as appropriate.

(Manufacture of expanded particles)
A preferred method for producing expanded particles of the present invention includes a dispersion step of dispersing the resin particles in an aqueous medium in a container, a blowing agent impregnation step of impregnating the resin particles with a blowing agent in the container, and a blowing agent. It includes a foaming step of foaming the resin particles by releasing the resin particles together with an aqueous medium from the container into a pressure atmosphere lower than the pressure inside the container, but it is preferable that these steps are performed in this order. It is more preferable that the steps are performed as a series of steps. Note that the method of foaming through this series of steps is also referred to as a dispersion medium release foaming method.

In the dispersion step, an aqueous dispersion medium is preferably used as a dispersion medium for dispersing the resin particles obtained as described above in a closed container. The aqueous dispersion medium is a dispersion medium containing water as a main component. The proportion of water in the aqueous dispersion medium is preferably 70% by mass or more, more preferably 80% by mass or more, still more preferably 90% by mass or more, and may be 100% by mass. Examples of the dispersion medium other than water in the aqueous dispersion medium include ethylene glycol, glycerin, methanol, and ethanol.

In the dispersion medium release foaming method suitably used in the present invention, it is preferable to add a dispersant to the dispersion medium so that the resin particles heated in the container do not fuse together in the container. Any dispersant may be used as long as it prevents the resin particles from fusing together in the container, but inorganic dispersants are preferably used. Examples of inorganic dispersants include natural or synthetic clay minerals such as amsonite, kaolin, mica, and clay, aluminum oxide, titanium oxide, basic magnesium carbonate, basic zinc carbonate, calcium carbonate, iron oxide, and the like. , one type of these may be used, or two or more types may be used in combination. Among these, natural or synthetic clay minerals are preferred. The amount of the dispersant added is preferably 0.001 to 5 parts by weight per 100 parts by weight of the resin particles.

In addition, when using a dispersing agent, it is preferable to use an anionic surfactant such as sodium dodecylbenzenesulfonate, sodium alkylsulfonate, and sodium oleate as a dispersing aid. The dispersion aid is preferably added in an amount of about 0.001 to 1 part by mass per 100 parts by mass of the resin particles.

In the foaming agent impregnation step, it is preferable to use a physical foaming agent as the foaming agent for foaming the resin particles. Examples of the physical blowing agent include inorganic physical blowing agents and organic physical blowing agents. Examples of the inorganic physical blowing agent include carbon dioxide, air, nitrogen, helium, and argon. Examples of organic physical blowing agents include aliphatic hydrocarbons such as propane, n-butane, isobutane, n-pentane, isopentane, and hexane; cycloaliphatic hydrocarbons such as cyclopentane and cyclohexane; ethyl chloride; , 3,3-tetrafluoropropene, trans-1,3,3,3-tetrafluoropropene, trans-1-chloro-3,3,3-trifluoropropene, and other halogenated hydrocarbons. In addition, the said physical foaming agent may be used individually, and 2 or more types may be used. Further, an inorganic physical foaming agent and an organic physical foaming agent may be used together. The blowing agent used in this production method is preferably an inorganic physical blowing agent, more preferably carbon dioxide, from the viewpoint of ease of producing desired expanded particles.

The amount of the blowing agent added is determined by considering the bulk density of the desired foamed particles, the type of blowing agent, etc.; The amount is preferably 0.1 to 30 parts by weight, more preferably 0.5 to 15 parts by weight.

In the foamed particle manufacturing process, a method for impregnating resin particles with a blowing agent includes, for example, dispersing the resin particles in an aqueous dispersion medium in a closed container, pressurizing the blowing agent into the closed container, and heating the closed container. Preferably, a method is used in which the resin particles are impregnated with a foaming agent by pressurizing and holding the resin particles.

In the foaming step, the pressure (internal pressure) inside the closed container during foaming is preferably 0.5 MPa (G) or higher, more preferably 0.8 MPa (G) or higher. Further, the upper limit is preferably 4 MPa (G) or less, more preferably 3 MPa (G) or less. Within the above range, desired expanded particles can be safely produced without fear of damage to the closed container or explosion. Further, the temperature is preferably raised to 100 to 200°C, more preferably 130 to 160°C, and after being maintained at that temperature for about 5 to 30 minutes, the resin particles containing the foaming agent are removed from the airtight container under pressure inside the airtight container. It is preferable to discharge the foam into an atmosphere at a lower pressure (for example, atmospheric pressure).

Further, the expanded particles of the present invention having a crystal structure in which a unique peak and a high temperature peak appear in the first DSC curve can be produced, for example, as follows.
First, resin particles dispersed in a dispersion medium in a closed container are mixed from (melting point of linear low-density polyethylene constituting the resin particles -15°C) to (melting point of linear low-density polyethylene constituting the resin particles). +10° C.) and held at this temperature for a sufficient time, preferably about 10 to 60 minutes (holding step). Next, by foaming the resin particles that have undergone this holding step, expanded particles exhibiting the above-mentioned melting peak can be obtained. The holding step can be performed, for example, as part of the dispersion step or the blowing agent impregnation step.
From the perspective of increasing the productivity of foamed particles, the resin particles dispersed in a dispersion medium in a sealed container are heated in the presence of a foaming agent to perform the above holding step, and then the contents of the sealed container are sealed. It is preferable to obtain expanded particles exhibiting the above-mentioned melting peak by foaming the resin particles by discharging the resin particles from the inside of the container into a pressure atmosphere lower than the pressure inside the closed container.

Note that the foamed particles obtained as described above can be foamed in multiple stages to obtain foamed particles with a higher expansion ratio (lower bulk density). For example, foamed particles are pressurized with air or the like to increase the pressure (internal pressure) inside the cells of the foamed particles, and then heated with steam or the like to further foam (two-stage foaming), resulting in a higher expansion ratio (bulk). (low density) foamed particles. From the viewpoint of obtaining a molded article with a low apparent density, it is preferable to carry out two-stage foaming.

[Foamed particle molded product]
The expanded particle molded article of the present invention is formed by molding the expanded particles in a mold.
Specifically, linear low-density polyethylene is used as a base resin, the linear low-density polyethylene contains a butene component and a hexene component as copolymerization components, and the expanded particles are heated at 10° C./min. In the DSC curve obtained by heating from 23°C to 200°C at a high speed, there is a melting peak (specific peak) specific to linear low-density polyethylene, and one or more melting peaks (high temperature peak) on the higher temperature side than the specific peak. have a crystal structure in which Expanded particles having a ratio of the heat of fusion of the high temperature peak to the total heat of fusion of 0.3 or more and 0.7 or less are molded in a mold.

The foamed particle molded article of the present invention can be produced by filling a mold with foamed particles and heat-molding using a heating medium such as steam. Specifically, after filling the foamed particles into a mold, a heating medium such as steam is introduced into the mold to heat and expand the foamed particles (secondary foaming), and at the same time fuse them together. In this way, it is possible to obtain a foamed particle molded article in which the shape of the molding space is shaped. Furthermore, in-mold molding in the present invention is performed by pressurizing the foamed particles in advance with a pressurized gas such as air to increase the pressure inside the cells of the foamed particles, so that the pressure inside the foamed particles is 0.01 higher than atmospheric pressure. After adjusting the pressure to ~0.3 MPa, the foamed particles are filled into a mold under atmospheric pressure or reduced pressure, and then a heating medium such as steam is supplied into the mold to heat and fuse the foamed particles. Molding can also be performed by a pressure molding method (for example, Japanese Patent Publication No. 51-22951). In addition, after filling a mold pressurized to above atmospheric pressure with compressed gas, foamed particles pressurized above the pressure, a heating medium such as steam is supplied into the cavity to heat the foamed particles. Molding can also be performed by a compression filling molding method (Japanese Patent Publication No. 4-46217) in which heat-fusion is performed. In addition, foamed particles with high secondary foaming power obtained under special conditions are filled into the cavity of a mold under atmospheric pressure or reduced pressure, and then heated by supplying a heating medium such as steam. Molding can also be carried out by a normal pressure filling molding method (Japanese Patent Publication No. 6-49795) in which foamed particles are heated and fused, or a method combining the above methods (Japanese Patent Publication No. 6-22919).

From the viewpoint of improving mechanical properties, the density of the expanded particle molded article of the present invention is preferably 10 kg/m ³ or more, more preferably 13 kg/m ³ or more, and still more preferably 15 kg/m ³ or more. be. In addition, from the viewpoint of obtaining a lightweight molded product, the density of the expanded particle molded product is preferably 240 kg/m ³ or less, more preferably 200 kg/m ³ or less, and still more preferably 100 kg/m ³ or less. It is more preferably 80 kg/m ³ or less, particularly preferably 60 kg/m ³ or less.
The density of the expanded bead molded body is calculated by dividing the mass of the expanded bead molded body by the volume calculated based on the dimensions of the expanded bead formed body, and can be measured by the method described in Examples. can.

The foamed particle molded product of the present invention is lightweight and has excellent mechanical properties, so it can be used as a shock absorber, a heat insulator, and various packaging materials, etc. It can be used for vehicle parts such as automobile bumpers, architectural parts such as residential insulation materials, and miscellaneous goods.

Next, the present invention will be explained in more detail with reference to Examples, but the present invention is not limited by these Examples.

[Measurement and evaluation]
The following measurements and evaluations were performed on the resins, expanded particles, and expanded particle molded bodies used in Examples and Comparative Examples. In addition, the evaluation of the foamed particles or the foamed particle moldings was performed after conditioning them by allowing them to stand for 2 days at a relative humidity of 50%, 23° C., and 1 atm.

<Biomass degree of polyethylene, biomass degree of foamed particles>
The biomass degree of polyethylene (linear low-density polyethylene or high-density polyethylene) used in Examples and Comparative Examples is a value determined by measuring the concentration of radioactive carbon C ¹⁴ in accordance with ASTM D 6866. . Furthermore, the biomass degree of the expanded particles was calculated from the biomass degree of the biomass-derived resin used to produce the expanded particles and the content ratio of the biomass-derived resin in the expanded particles.
In Table 1, LL1, LL3, LL4, and HD1 are polyethylenes listed in the positive list of biomass plastics by the Japan Biomass Plastics Association. In addition, in the positive list, LL1 and LL4 contain a butene component as a copolymerization component, represented by the chemical structural formula [(C ₂ H ₄ ) _n (C ₄ H ₈ ) _m (C ₆ H ₁₂ ) _o ]. LL3 is described as a linear low-density polyethylene containing a hexene component and a copolymer component represented by the chemical structural formula [(C ₂ H ₄ ) _n (C ₄ H ₈ ) _m ]. It is described as a linear low density polyethylene containing a butene component.

<Density of polyethylene>
The density of the polyethylene (linear low-density polyethylene or high-density polyethylene) used in Examples and Comparative Examples was measured based on method A (underwater displacement method) of JIS K 7112:1999.

<Content of components derived from α-olefin in linear low density polyethylene>
The content of components derived from each α-olefin in linear low density polyethylene was determined by carbon-13 nuclear magnetic resonance ( ¹³ C-NMR) as described below.
First, linear low-density polyethylene was dissolved in a mixed solvent (130°C) of o-dichlorobenzene-d ₄ (ODCB):benzene-d ₆ (C ₆ D ₆ ) = 4:1, and the concentration was 10 wt/vol. A solution for measuring % was prepared. NMR ( ¹³ C-NMR) spectrum measurement of the measurement solution using ¹³ C as the measurement nucleus was performed using a nuclear magnetic resonance apparatus "ECZ-400S model manufactured by JEOL Ltd.". Based on the chemical shift information in the obtained NMR spectrum, the component derived from the α-olefin contained in the linear low density polyethylene was identified, and its content (mol%) was calculated.

<Melt flow rate (MFR) of polyethylene and expanded particles>
The melt flow rate (MFR) of the polyethylene (linear low-density polyethylene or high-density polyethylene) used in the Examples and Comparative Examples and the melt flow rate (MFR) of the expanded particles of the Examples and Comparative Examples were determined according to JIS K7210-1. :2014, the temperature was 190°C and the load was 2.16 kg. In the measurement of the melt flow rate of the foamed particles, the measurement was carried out using foamed particles that had been defoamed to the extent that the physical properties of the resin were not significantly impaired as a measurement sample.

<Melting point of polyethylene>
The melting point of the polyethylene (linear low density polyethylene or high density polyethylene) used in the Examples and Comparative Examples was measured by heat flux differential scanning calorimetry based on JIS K7121:2012. As a measuring device, a highly sensitive differential scanning calorimeter "EXSTAR DSC7020" (manufactured by SII Nanotechnology) was used. The condition of the test piece was adjusted according to "(2) When measuring the melting temperature after a certain heat treatment", and the test piece was heated at 10°C/min under a nitrogen flow rate of 30 mL/min. Heating from 23°C to 200°C at a heating rate, then holding at that temperature for 10 minutes, then cooling at a cooling rate of 10°C/min to 23°C, and again at a heating rate of 10°C/min to 200°C. It was heated to obtain a DSC curve (DSC curve during second heating). The apex temperature of the melting peak in the DSC curve was determined, and this value was taken as the melting point.
In addition, when a plurality of melting peaks appear in the DSC curve, the apex temperature of the melting peak having the largest area is adopted as the melting point. At this time, by distinguishing each melting peak based on the temperature in the valley of the DSC curve located between the peak temperatures of each melting peak and comparing the area (heat of fusion) of each melting peak, it is possible to find the largest area. Melting peaks can be determined. Note that the temperature in the valley of the DSC curve corresponds to the temperature at which the value on the vertical axis of the differential curve of the DSC curve (DDSC) becomes 0, so it can also be determined from the differential curve of the DSC curve.

<Heat of fusion of polyethylene and total heat of fusion of expanded particles>
The heat of fusion of polyethylene (linear low density polyethylene or high density polyethylene) used in the Examples and Comparative Examples and the total heat of fusion of the expanded particles were measured in accordance with JIS K7121:2012.
First, using polyethylene or foamed particles as a test piece, a DSC curve during the second heating was obtained using the same method as in the measurement of the melting point of polyethylene described above. The point on the obtained DSC curve during the second heating at a temperature of 80° C. was designated as α, and the point on the DSC curve corresponding to the melting end temperature was designated as β. The area of the portion surrounded by the DSC curve and the line segment (α-β) in the section between points α and β was measured, and from this area, the heat of fusion of polyethylene or the total heat of fusion of the expanded particles was calculated.

<Heat of fusion of expanded particles at high temperature peak>
The heat of fusion at the high temperature peak of the expanded particles was measured by heat flux differential scanning calorimetry in accordance with JIS K7122:2012. Specifically, about 2 mg of expanded particles were collected and heated from 23°C to 200°C at a heating rate of 10°C/min using a differential scanning calorimeter (EXSTAR DSC7020) to obtain a DSC curve with two or more melting peaks. (DSC curve in the first heating) was obtained. In the following explanation, the characteristic peak of polyethylene (linear low density polyethylene or high density polyethylene) is referred to as A, and the high temperature peak that appears on the higher temperature side is referred to as B.
A straight line (α-β) was drawn connecting the point α corresponding to 80° C. on the DSC curve and the point β on the DSC curve corresponding to the melting end temperature T of the expanded particles. Note that the melting end temperature T is the end point on the high temperature side of the high temperature peak B, and refers to the intersection of the high temperature peak and the high temperature side baseline. Next, draw a straight line parallel to the vertical axis of the graph from point γ on the DSC curve, which corresponds to the valley between the characteristic peak A and the high temperature peak B, and set the point where it intersects with the straight line (α-β) as δ. .
The area of the portion surrounded by the high-temperature peak B portion of the DSC curve, the line segment (δ-β), and the line segment (γ-δ) was determined, and the heat of fusion of the high-temperature peak was calculated from this area.

<Bulk density of expanded particles>
About 500 cm ³ of foamed particles were filled into a measuring cylinder, and the filling height of the foamed particles in the measuring cylinder was stabilized by lightly tapping the floor several times with the bottom of the measuring cylinder. The bulk volume of the expanded particle group indicated by the graduated cylinder scale was read, and this was defined as V1 (L). Next, the mass of the expanded particle group was measured, and this was defined as W1 [g].
The bulk density of the foamed particles was determined by dividing the mass W1 [g] of the foamed particles by the volume V1 (W1/V1) and converting the unit to [kg/m ³ ].

<Closed cell ratio of expanded particles>
The closed cell ratio of the expanded particles was measured as follows. The apparent volume Va of the foamed particles was measured by immersing the foamed particles having a bulk volume of about 20 cm ³ in ethanol. Next, after sufficiently drying the foamed particle group whose apparent volume Va was measured, the true volume of the expanded particle group (constituting the foamed particle The value Vx (the sum of the volume of the resin and the total volume of the closed cells in the expanded particles) was measured. To measure the true volume Vx, an air comparison hydrometer "930" manufactured by Toshiba Beckman Corporation was used. Next, the closed cell ratio was calculated using the following formula (1), and the arithmetic mean value of the results of five measurements using different expanded particle groups was determined.
Closed cell ratio (%) = (Vx-W/ρ) x 100/(Va-W/ρ)...(1)
Vx: True volume of expanded particle group measured by the above method (cm ³ )
Va: Apparent volume of foamed particles (cm ³ ) measured from the rise in water level when the foamed particles are submerged in ethanol in a measuring cylinder
W: Mass of expanded particle group (g)
ρ: Density of resin constituting expanded particles (g/cm ³ )

<Average cell diameter of expanded particles>
The average cell diameter of the expanded particles was measured as follows.
Thirty foam particles were randomly selected from the foam particle group. The foamed particles were cut into two parts by cutting through the center thereof, and an enlarged photograph of one cross section was taken. In each cross-sectional photograph, four line segments were drawn from the outermost surface of the expanded particle through the center to the opposite outermost surface so that the angles formed by two adjacent line segments were equal. Measure the number of bubbles that intersect with each line segment, divide the total length of the four line segments by the total number of bubbles that intersect with the line segment, calculate the average bubble diameter of each foam particle, and calculate these values. The average cell diameter of the foamed particles was determined by taking the arithmetic mean of the values.

<Ratio of bulk density of single-stage expanded particles to bulk density of second-stage expanded particles>
The bulk density of the single-stage expanded particles and the bulk density of the second-stage expanded particles were measured using the bulk density measurement method described above. By dividing the bulk density of the first-stage foamed particles by the bulk density of the second-stage foamed particles, the ratio of the bulk density of the first-stage foamed particles to the bulk density of the second-stage foamed particles (bulk density _one-stage foaming/bulk density _{two-stage foaming} ) was calculated. Incidentally, the larger the value of the ratio, the more excellent the two-stage foamability is because it is possible to obtain two-stage expanded particles with a lower bulk density.

<State of two-stage expanded particles>
The surface condition of the two-stage expanded particles was visually observed. If there are no clear wrinkles on the foamed particles and almost no shrinkage of the foamed particles is confirmed, it is evaluated as "〇", and if there are clear wrinkles on the foamed particles and a lot of shrinkage of the foamed particles is confirmed. was evaluated as "x".
In addition, when the above evaluation is "〇", there is little variation in the density between the obtained two-stage expanded particles, it is easy to control the density of the expanded particles when producing the desired molded object, and it is possible to obtain a good mold. The resulting foamed particles exhibit stable internal moldability.

<Molding pressure range that allows good products to be molded>
Using the method described below in <Manufacture of expanded particle molded object>, molding the expanded particle molded object by changing the molding pressure (molding steam pressure) in steps of 0.01 MPa between 0.10 and 0.20 MPa (G), The in-mold moldability of the obtained molded product was evaluated in terms of fusion properties, surface appearance (gap = degree of voids), and recovery properties (recovery of expansion or contraction after in-mold molding). Those that met the criteria shown below were deemed to have passed, and the steam pressure that passed all items was defined as the steam pressure that allowed molding. Note that the pressure marked with (G) is a gauge pressure, that is, a pressure value based on atmospheric pressure.
The wider the moldable steam pressure range from the lower limit to the upper limit, the wider the moldable range, which is preferable.
(Fusability)
The expanded particle molded product was bent and fractured, and the number of expanded particles present on the fracture surface (C1) and the number of broken expanded particles (C2) were determined. The ratio of the number of broken foam particles to the number of foam particles (C2/C1×100) was calculated as the material destruction rate. The above measurement was carried out five times using different test pieces, and the material destruction rate for each was determined. When the material destruction rate obtained by calculating the arithmetic average of these was 80% or more, it was considered a pass, and when it was less than 80%, it was judged as a failure. did.
(Surface appearance)
A 100 mm x 100 mm square was drawn in the center of the expanded particle molded product, a line was drawn diagonally from one corner of the square, and the number of voids (gaps) larger than 1 mm x 1 mm on that line was counted. . When the number of voids was less than 5 and there was no unevenness on the surface, it was judged as a pass; otherwise, it was judged as a fail.
(Recoverability)
The thickness near the four corners (10 mm inward from the corner toward the center) and the center (with the molded body in the longitudinal direction The thickness at the intersection of the line dividing the sample into two equal parts and the line dividing the sample into two equal parts in the lateral direction was measured. Next, the ratio (%) of the thickness of the center to the thickness of the thickest part near the four corners was calculated. When the ratio was 95% or more, it was judged as a pass, and when the ratio was less than 95%, it was judged as a failure.

<Density of expanded particle molded body>
The expanded particle molded product was left for 2 days under the conditions of 50% relative humidity, 23° C., and 1 atm. Next, its mass was measured, and this was defined as W [g].
Next, the volume V [cm ³ ] of the expanded bead molded body was measured based on the dimensions of the expanded bead molded body.
The density of the expanded bead molded body was determined by dividing the mass W [g] of the expanded bead molded body by the volume V (W/V) and converting the unit to [kg/m ³ ].

<Compressive stress at 50% strain of expanded particle molded body>
A test piece measuring 5 cm long x 5 cm wide x 2.5 cm high was taken from the molded bodies obtained in the Examples and Comparative Examples, and the test piece was compressed at a compression rate of 10 mm/min to determine the stress at 50% strain. was measured. The higher the stress, the better the strength of the expanded particle molded product.

[polyethylene]
Table 1 shows the polyethylene (linear low density polyethylene or high density polyethylene) used in the Examples and Comparative Examples.

[Manufacture of expanded particles and expanded particle molded bodies]
(Example 1)
<Manufacture of expanded particles>
An extruder with an inner diameter of 26 mm and equipped with a strand-forming die on the exit side was prepared.
LL1 and zinc borate (number-based arithmetic mean particle diameter: 7 μm) were supplied to the extruder as a cell regulator, and melted and kneaded to form a resin melt. Note that the expanded particles were supplied so that the content of zinc borate in the expanded particles was 500 ppm by mass.
The obtained resin melt was extruded as a strand from a strand forming die, and the extruded strand was cooled with water and then cut with a pelletizer, and the average mass per piece was 1.5 mg and the particle size was 1.9 mm. Resin particles having a length/diameter ratio of 1.9 and having a linear low density polyethylene as a base resin were obtained.

In a 5L sealed container, 500g of the resin particles, 3.5L of water as a dispersion medium, 3g of kaolin as a dispersant, and sodium dodecylbenzenesulfonate (trade name: Neogen, manufactured by Daiichi Kogyo Seiyaku Co., Ltd.) as a surfactant. 0.2g was charged.
Next, carbon dioxide was pressurized as a blowing agent into the closed container, and the pressure was increased until the equilibrium vapor pressure shown in Table 2 was reached. Next, the contents of the sealed container were heated to the foaming temperature (124°C) at a rate of 2°C/min while stirring. Furthermore, it was held at the same temperature for 15 minutes (holding step). Through this holding step, the heat of fusion of the high temperature peak (obtained from the endothermic curve determined by DSC measurement) was adjusted. Thereafter, the contents of the sealed container were released under atmospheric pressure to obtain expanded particles (single-stage expanded particles).
The foamed particles obtained as described above were left for 24 hours in an environment of 23° C. temperature, 50% relative humidity, and 1 atm for curing. Next, the foamed particles after curing were filled into a pressurizable airtight container, and the pressure inside the airtight container was increased from normal pressure to pressurize the foamed particles. The foamed particles were kept under pressure for 24 hours to allow air to be impregnated into the cells of the foamed particles. Thereafter, the foamed particles were taken out from the closed container to obtain foamed particles in which the internal pressure of the bubbles in the foamed particles was 0.5 MPa (G). Thereafter, the foamed particles were fed to a two-stage foaming device. Steam was supplied into the apparatus to cause two-stage foaming of the foamed particles to obtain foamed particles (two-stage foamed particles) having a bulk density of 22 kg/m ³ . The foamed particles after two-stage foaming were used for the above-mentioned measurements and production of foamed particle molded bodies.

<Manufacture of expanded particle molded body>
After applying an internal pressure of 0.25 MPa (G) to the foamed particles with air, the foamed particles are filled into a mold that can form a flat plate of 250 mm long x 200 mm wide x 50 mm thick, and heated using the following heating method. Heating was performed with
First, preheating (exhaust process) was performed by supplying steam to the mold with drain valves provided on both sides of the mold open. Thereafter, steam was supplied from one side of the mold for heating, and further steam was supplied from the other side of the mold for heating. Subsequently, the mold was heated by supplying steam from both sides of the mold at a predetermined molding heating steam pressure (main heating). After the main heating was completed, the pressure was released and the mold was cooled with water until the pressure generated on the molding surface of the mold became 0.04 MPa (G), and then the mold was opened and the expanded particle molded product was taken out.
The obtained molded product was cured in an oven at 80° C. for 12 hours to obtain a foamed particle molded product (polyethylene resin foamed particle molded product). In addition, in the evaluation of the above-mentioned <molding pressure range capable of molding non-defective products>, molding was performed while changing the molding pressure.
Table 2 shows the measurement results of the physical properties of the obtained expanded particles and the evaluation results of the molded product. Note that the biomass degree of the expanded particles was the same as that of polyethylene constituting each expanded particle. Moreover, each foamed particle is a non-crosslinked foamed particle.

(Examples 2 to 5)
Expanded particles and polyethylene resin expanded particle molded articles were obtained in the same manner as in Example 1, except that the polyethylene, foaming temperature, and equilibrium vapor pressure were changed to the conditions shown in Table 2. Table 2 shows the measurement results of the physical properties of the obtained expanded particles and the evaluation results of the molded product.

(Example 6)
In Example 1, the foaming temperature and equilibrium vapor pressure were changed to the conditions shown in Table 2, and in-mold molding was performed using the obtained single-stage expanded particles, but in the same manner as in Example 1, Expanded particles and polyethylene resin expanded particle molded articles were obtained. Table 2 shows the measurement results of the physical properties of the obtained expanded particles and the evaluation results of the molded product.

(Comparative Examples 1 to 7)
In Example 1, expanded particles and polyethylene resin foamed particle molded bodies were obtained in the same manner as in Example 1, except that the polyethylene and foaming temperature were changed to the conditions shown in Table 3. Table 3 shows the measurement results of the physical properties of the obtained expanded particles and the evaluation results of the molded product.

From the results shown in Table 2, it can be seen that the foamed particles of Examples can be used to produce foamed particle molded objects over a wide range of densities, and have excellent moldability. It is also seen that a foamed particle molded article with a low apparent density can be obtained satisfactorily. Furthermore, it can be seen that the polyethylene resin expanded particle molded article produced using the expanded particles of Examples has a high degree of biomass, high compressive stress, and excellent strength despite having a low apparent density.

Claims (6)

Expanded particles using linear low-density polyethylene as a base resin,
The linear low density polyethylene contains a butene component and a hexene component as copolymer components,
The melt flow rate of the expanded particles measured at a temperature of 190° C. and a load of 2.16 kg is 0.1 g/10 minutes or more and 2.0 g/10 minutes or less,
In the DSC curve obtained by heating the expanded particles from 23°C to 200°C at a heating rate of 10°C/min, the foam particles have a melting peak (specific peak) specific to linear low-density polyethylene and a temperature higher than the specific peak. It has a crystal structure in which one or more melting peaks (high temperature peaks) appear on the side,
The total heat of fusion of the expanded particles is 70 J/g or more and 100 J/g or less,
The heat of fusion of the high temperature peak is 30 J/g or more and 50 J/g or less,
The foamed particles have a ratio of the heat of fusion of the high temperature peak to the total heat of fusion of the foamed particles of 0.3 or more and 0.7 or less. The foamed foam according to claim 1, wherein the content of the butene component in the linear low density polyethylene is 0.5 mol% or more and 6 mol% or less, and the content of the hexene component is 0.2 mol% or more and 5 mol% or less. particle. The expanded particles according to claim 1 or 2, wherein the expanded particles have a bulk density of 10 kg/m ³ or more and 300 kg/m ³ or less. The expanded particle according to any one of claims 1 to 3, wherein the expanded particle has a closed cell ratio of 80% or more. The expanded particles according to any one of claims 1 to 4, wherein the expanded particles have an average cell diameter of 60 μm or more and 200 μm or less. A foamed particle molded article obtained by molding the foamed particles according to any one of claims 1 to 5 in a mold.