JP3588592B2 - Molding resin material and molded article molded using the molding resin material - Google Patents

Description

【００６１】
（試験評価２）
成形用樹脂材料中のウレタン樹脂組成物の含有量と、成形品を打撃した際の音の減衰特性との関係について試験評価を行った。
【００６２】
＜試験評価サンプル＞
以下の各例に係る成形用樹脂材料を準備した。なお、各構成については表２に示す。
【００６３】
−例５−
廃車された自動車のシートから抽出したウレタン樹脂組成物（発泡ウレタン樹脂）を１７０℃に調温したロール型粉砕機で粉砕し、これをふるいにかけて粒径６０μｍのもののみを分別した。また、廃車された自動車のバンパから抽出したＰＰ樹脂組成物を粉砕機によりチップ状とした。次いで、粉状乃至粒状のウレタン樹脂組成物とＰＰ樹脂組成物とを、質量比（ウレタン／ＰＰ）＝８０／２０となるようにニーダーのチャンバーに投入し、さらに両樹脂組成物の質量和に対して３％の親和性付与成分（三洋化成工業社製 ユーメックス１０１０）と１％の酸化防止剤（旭電化工業社製 アデカスタブＡＯ−６０）とを投入し、これらを混練して複合化した。そして、この複合体を粉砕機によりチップ化して形成された成形用樹脂材料を例５とした。
【００６４】
−例６−
ウレタン樹脂組成物とＰＰ樹脂組成物との質量比を、ウレタン／ＰＰ＝７０／３０としたことを除いては例５と同一構成の成形用樹脂材料を例６とした。
【００６５】
−例７−
ウレタン樹脂組成物とＰＰ樹脂組成物との質量比を、ウレタン／ＰＰ＝５０／５０としたことを除いては例５と同一構成の成形用樹脂材料を例７とした。
【００６６】
−例８−
ウレタン樹脂組成物とＰＰ樹脂組成物との質量比を、ウレタン／ＰＰ＝４０／６０としたことを除いては例５と同一構成の成形用樹脂材料を例８とした。
【００６７】
−例９−
ウレタン樹脂組成物とＰＰ樹脂組成物との質量比を、ウレタン／ＰＰ＝３０／７０としたことを除いては例５と同一構成の成形用樹脂材料を例９とした。
【００６８】
−例１０−
ウレタン樹脂組成物とＰＰ樹脂組成物との質量比を、ウレタン／ＰＰ＝２０／８０としたことを除いては例５と同一構成の成形用樹脂材料を例１０とした。
【００６９】
＜試験評価方法＞
−試験装置−
図７は試験装置の概略構成を示す。試験装置７０では、基台７１に支柱７２が立設されており、その支柱７２に上から順に筒状部材７３及び環状部材７４が設けられている。また、環状部材７４には４つのゴム紐７５，７５，…が等間隔をおくようにしてその一端が結わえられており、各ゴム紐７５の他端は正方形の板状試験片７６の四隅にそれぞれ固定されるようになっている。さらに、板状試験片７６の下方には集音マイク７７が設置されており、集音マイク７７はオシロスコープ７８に繋がっている。
【００７０】
この試験装置７０は、筒状部材７３からガラス玉７９を５５ｃｍ落下させ、そのガラス玉７９が板状試験片７６を打撃した際の音を集音マイク７７で検知し、それをオシロスコープ７８に信号として送るように構成されている。
【００７１】
−試験評価−
上記の例６〜１０に係る成形用樹脂材料により正方形の板状試験片を射出成形し、上記試験装置を用いて音圧、減衰時間及び高周波音の有無について試験した。なお、例５に係る成形用樹脂材料では試験片の成形ができなかった。
【００７２】
音圧は、検知された最大音圧をオシロスコープから読みとった。また、減衰時間は、ガラス玉の打撃時から打撃音が減衰して消えるまでに要した時間をオシロスコープから読みとった。そして、高周波音の有無は、オシロスコープで観察される減衰波のピーク部分に微少な波形があるか否かを目視観察することにより評価した。
【００７３】
＜試験評価結果＞
試験評価結果を表２に示す。ウレタン／ＰＰ＝８０／２０とした例５では試験片を作成することができなかったが、これは、ウレタン樹脂組成物の割合が高いためにＰＰ樹脂組成物のマトリックスにウレタン樹脂組成物が分散した構成の成形用樹脂材料が形成されなかったためであると考えられる。
【００７４】
図８は、ウレタン樹脂組成物とＰＰ樹脂組成物との質量和におけるウレタン樹脂組成物の含有率と、ガラス玉が成形板を打撃した際の音圧との関係を示す。同図によれば、ウレタン樹脂組成物の含有量が４０％より多くなると音圧が著しく低くなるということが分かる。
【００７５】
図９は、ウレタン樹脂組成物の含有率と、ガラス玉が成形板を打撃した際の音の減衰時間との関係を示す。同図によれば、ウレタン樹脂組成物の含有量が多くなるに従って減衰時間が短くなるということが確認できる。具体的には、ウレタン樹脂組成物の含有量が４０％より多くなると４ｍ・ｓｅｃ以下のレベルとなっている。
【００７６】
また、表２によれば、ウレタン樹脂組成物の含有量が４０％より多くなると高周波音の発生がなくなっていることが分かる。これは、比較的柔らかいウレタン樹脂組成物と硬いＰＰ樹脂組成物との界面において高周波音が減衰するため、その界面の面積が多くなるほど高周波音が効果的に減衰するためではないかと推測される。
【００７７】
【表２】

【００７８】
（試験評価３）
ウレタン樹脂組成物の粉砕条件とその嵩比重との関係及びウレタン樹脂組成物の嵩比重と成形品を打撃した際の音の減衰特性との関係について試験評価を行った。
【００７９】
＜試験評価サンプル＞
以下の各例に係る成形用樹脂材料を準備した。なお、各構成については表３に示す。
【００８０】
−例１１−
廃車された自動車のシートから抽出した塊状のウレタン樹脂組成物（発泡ウレタン樹脂）を１２０℃に調温したロール型粉砕機に投入したが、ウレタン樹脂組成物を粉砕することはできなかった。これを例１１とした。
【００８１】
−例１２−
廃車された自動車のシートから抽出した塊状のウレタン樹脂組成物（発泡ウレタン樹脂）を１５０℃に調温したロール型粉砕機で粉砕し、これをふるいにかけて粒径６０μｍのもののみを分別した。また、廃車された自動車のバンパから抽出したＰＰ樹脂組成物を粉砕機によりチップ状とした。次いで、粉状乃至粒状のウレタン樹脂組成物及びＰＰ樹脂組成物を等質量ずつニーダーのチャンバーに投入し、さらに両樹脂組成物の質量和に対して３％の親和性付与成分（三洋化成工業社製 ユーメックス１０１０）と１％の酸化防止剤（旭電化工業社製 アデカスタブＡＯ−６０）とを投入し、これらを混練して複合化した。そして、この複合体を粉砕機によりチップ化して形成された成形用樹脂材料を例１２とした。
【００８２】
−例１３−
ロール表面温度を１７０℃としたことを除いては、例１２と同一構成の成形用樹脂材料を例１３とした。
【００８３】
−例１４−
ロール表面温度を２００℃としたことを除いては、例１２と同一構成の成形用樹脂材料を例１４とした。
【００８４】
＜試験評価方法＞
上記の例１２〜１４に係る成形用樹脂材料を射出成形して板状の成形品を作成し、これを用いて、試験評価２と同様にして成形品にガラス玉が打撃した際の音圧、減衰時間及び高周波音の有無について試験評価を行った。
【００８５】
＜試験評価結果＞
試験結果を表３に示す。
【００８６】
図１０は、ロール表面温度、すなわち、ウレタン組成物の粉砕温度と粉砕されたウレタン樹脂組成物の嵩比重との関係を示す。同図によれば、粉砕温度が高くなるに従って嵩比重が大きくなることが分かる。これは、粉砕温度が高くなると熱によりウレタン樹脂組成物が収縮したためであると考えられる。
【００８７】
図１１は、ウレタン樹脂組成物の嵩比重と音圧との関係を示す。同図によれば、嵩比重が大きくなるに従って音圧が大きくなることが分かる。これは、ウレタン樹脂組成物が熱収縮して嵩比重が大きくなると、音を減衰させる機能が低下することを意味するものである。具体的には、嵩比重が０．１〜０．２では５０ｄＢ程度の音圧であるが、０．３よりも大きくなると音圧が８０ｄＢを越える水準となってしまう。
【００８８】
図１２は、ウレタン樹脂組成物の嵩比重と減衰時間との関係を示す。同図によれば、音圧の場合と同様、嵩比重が大きくなるに従って減衰時間が長くなっているのが確認でき、上記機能の低下を裏付けるものとなっている。
【００８９】
表３によれば、例１２〜１４のいずれも高周波音の発生はなかった。
【００９０】
【表３】

【００９１】
（試験評価４）
親和性付与成分の添加の有無及びその添加量が成形品の物理特性に及ぼす影響について試験評価を行った。
【００９２】
＜試験評価サンプル＞
以下の各例に係る成形用樹脂材料を準備した。なお、各構成については表２に示す。
【００９３】
−例１５−
廃車された自動車のシートから抽出した塊状のウレタン樹脂組成物（発泡ウレタン樹脂）を１５０℃に調温したロール型粉砕機で粉砕し、これをふるいにかけて粒径６０μｍのもののみを分別した。また、廃車された自動車のバンパから抽出したＰＰ樹脂組成物を粉砕機によりチップ状とした。次いで、粉状乃至粒状のウレタン樹脂組成物及びＰＰ樹脂組成物を等質量ずつニーダーのチャンバーに投入し、これらを混練して複合化した。そして、この複合体を粉砕機によりチップ化して形成された成形用樹脂材料を例１５とした。
【００９４】
−例１６−
ウレタン樹脂組成物とＰＰ樹脂組成物との質量和に対して、カルボキシル基含有オレフィン系樹脂である親和性付与成分Ａ（三洋化成工業社製 ユーメックス１０１０）を０．５％、及び水酸基及びカルボキシル基含有ロジン（荒川化学工業社製 パインクリスタルＫＲ−８５）を０．５％添加したことを除いて例１５と同一構成の成形用樹脂材料を例１６とした。
【００９５】
−例１７−
ウレタン樹脂組成物とＰＰ樹脂組成物との質量和に対して、カルボキシル基含有オレフィン系樹脂である親和性付与成分Ａ（三洋化成工業社製 ユーメックス１０１０）を２％添加したことを除いて例１５と同一構成の成形用樹脂材料を例１７とした。
【００９６】
−例１８−
ウレタン樹脂組成物とＰＰ樹脂組成物との質量和に対して、カルボキシル基含有オレフィン系樹脂である親和性付与成分Ａ（三洋化成工業社製 ユーメックス１０１０）を２％、及び水酸基及びカルボキシル基含有ロジン（荒川化学工業社製 パインクリスタルＫＲ−８５）を２％添加したことを除いて例１５と同一構成の成形用樹脂材料を例１８とした。
【００９７】
＜試験評価方法＞
各例に係る成形用樹脂材料について、試験評価１と同様にして曲げ弾性率、曲げ強度、アイゾット衝撃値、引張強度及び切断時伸びについて試験評価を行った。
【００９８】
＜試験評価結果＞
試験結果を表４に示す。
【００９９】
図１３は、各例に係る成形用樹脂材料を射出成形した成形品の曲げ弾性率及び曲げ強度を示す。同図によれば、親和性付与成分を添加していない例１５に比べて、親和性付与剤を添加した例１６〜１８は、曲げ弾性率及び曲げ強度が高くなっているのが分かる。これは、親和性付与材の添加によってウレタン樹脂組成物の分散性が向上し、そのために成形用樹脂材料としての均一性が高められたためであると考えられる。また、例１６〜１８を比較すると、親和性付与成分の添加量が多いものほどその効果が大きいことが分かる。
【０１００】
図１４は、各例に係る成形用樹脂材料を射出成形した成形品のアイゾット衝撃値を、図１５は引張強度を、図１６は切断時伸びをそれぞれ示す。これらの図より明らかなように、アイゾット衝撃値、引張強度及び切断時伸びのいずれもが、親和性付与成分を添加していない例１５に比べて、親和性付与成分を添加した例１６〜１８の方が高くなっている。その理由については曲げ弾性率及び曲げ強度の場合と同様であると考えられる。また、親和性付与成分の添加量が多いものほどその効果が大きい点も上記と同様である。
【０１０１】
【表４】

【０１０２】
（試験評価５）
酸化防止剤の添加の有無及びその添加量が成形用樹脂材料の成形加工性に及ぼす影響について試験評価を行った。
【０１０３】
＜試験評価サンプル＞
以下の各例に係る成形用樹脂材料を準備した。なお、各構成については表５に示す。
【０１０４】
−例１９−
廃車された自動車のシートから抽出した塊状のウレタン樹脂組成物（発泡ウレタン樹脂）を１５０℃に調温したロール型粉砕機で粉砕し、これをふるいにかけて粒径６０μｍのもののみを分別した。また、廃車された自動車のバンパから抽出したＰＰ樹脂組成物を粉砕機によりチップ状とした。次いで、粉状乃至粒状のウレタン樹脂組成物及びＰＰ樹脂組成物を等質量ずつニーダーのチャンバーに投入し、これらを混練して複合化した。そして、この複合体を粉砕機によりチップ化して形成された成形用樹脂材料を例１９とした。
【０１０５】
−例２０−
ウレタン樹脂組成物とＰＰ樹脂組成物との質量和に対して、高分子量のヒンダードフェノール系酸化防止剤Ａ（旭電化工業社製 アデカスタブＡＯ−６０ 化学名：テトラキス［メチレン-3-(4'-ヒドロキシ-3',5'-ジ-t-ブチルフェニル）プロピオネート］）を３％、及びポスファイト系酸化防止剤Ｂ（旭電化工業社製 アデカスタブ２１１２ 化学名：トリス(2,4-ジ-t-ブチルフェニル)ホスファイト））を３％添加したことを除いて例１９と同一構成の成形用樹脂材料を例２０とした。
【０１０６】
−例２１−
ウレタン樹脂組成物とＰＰ樹脂組成物との質量和に対して、ヒンダードフェノール系酸化防止剤Ａを１％、及び芳香族を有するポスファイト系酸化防止剤Ｂを１％添加したことを除いて例１９と同一構成の成形用樹脂材料を例２１とした。
【０１０７】
−例２２−
ウレタン樹脂組成物とＰＰ樹脂組成物との質量和に対して、酸化防止剤Ａを０．５％、及び高分子量チオエーテル系酸化防止剤Ｃ（旭電化工業社製 アデカスタブＡＯ−２３ 化学名：2,2'-チオジエチルビス［3-(3,5-ジ-t-ブチル-4-ヒドロキシフェニル）プロピオネート]）を１％添加したことを除いて例１９と同一構成の成形用樹脂材料を例２２とした。
【０１０８】
−例２３−
ウレタン樹脂組成物とＰＰ樹脂組成物との質量和に対して、ヒンダードフェノール系酸化防止剤Ａを０．５％、及びヒンダードフェノール系酸化防止剤Ｄ（武田薬品社製 ＢＨＴ 化学名：2,6-ジ-t-ブチル-4-メチルフェノール）を１％添加したことを除いて例１９と同一構成の成形用樹脂材料を例２３とした。
【０１０９】
＜試験評価方法＞
上記の各例に係る成形用樹脂材料を１８０℃で溶融させて射出成形し、次いで１９５℃で溶融させて射出成形するというように、１８０℃から５℃間隔で溶融温度を昇温しつつ射出成形を行った。そして、樹脂材料の欠損の有無、やけ等の観点から成形品を観察し、良好な成形品が得られた上限温度と下限温度との差を成形温度幅とした。
【０１１０】
また、各例に係る成形用樹脂材料のスパイラルフローを測定した。
【０１１１】
＜試験評価結果＞
試験結果を表５に示す。
【０１１２】
図１７は、各例に係る成形用樹脂材料の成形温度幅を示す。同図によれば、酸化防止剤を添加していない例１９に比べて、酸化防止剤を添加した例２０〜２３では、成形温度幅が広くなっているのが分かる。これは、高温下に晒されたウレタン樹脂の分子鎖上に発生したラジカルが酸化防止剤によって捕捉されるためであると考えられる。また、例２０〜２３を比較すると、酸化防止剤の添加量が多いものほどその効果が大きいことが分かる。
【０１１３】
図１８は、各例に係る成形用樹脂材料のスパイラルフローを示す。同図によれば、酸化防止剤を添加していない例１９に比べて、酸化防止剤を添加した例２０〜２３では、スパイラルフローが長くなっているのが分かる。これは、酸化防止剤の存在によって成形用樹脂材料の成形加工性が上記のように向上したことに起因するものであると考えられる。また、酸化防止剤を添加した例２０〜２３を比較すると、例２３を除いては、酸化防止剤の添加量が多いものほどその効果が大きい結果となっている。
【０１１４】
【表５】

【０１１５】
（試験評価６）
粉状乃至粒状のウレタン樹脂組成物とＰＰ樹脂組成物との複合化方法についてニーダーと二軸押出機とで比較検討した。
【０１１６】
＜試験評価サンプル＞
以下の各例に係る樹脂混合物を準備した。なお、各構成については表６に示す。
【０１１７】
−例２４−
廃車された自動車のシートから抽出したウレタン樹脂組成物（発泡ウレタン樹脂）を１５０℃に調温したロール型粉砕機で粉砕し、これをふるいにかけて粒径６０μｍのもののみを分別した。また、廃車された自動車のバンパから抽出したＰＰ樹脂組成物を粉砕機によりチップ状とした。そして、粉状乃至粒状のウレタン樹脂組成物とＰＰ樹脂組成物とを、質量比（ウレタン／ＰＰ）＝８０／２０となるように混合し、これに両樹脂組成物の質量和に対して３％の親和性付与成分（三洋化成工業社製 ユーメックス１０１０）と１％の酸化防止剤（旭電化工業社製 アデカスタブＡＯ−６０）とを添加してなる樹脂混合物を例２４とした。
【０１１８】
−例２５−
ウレタン樹脂組成物とＰＰ樹脂組成物との質量比を、ウレタン／ＰＰ＝５０／５０としたことを除いては例２４と同一構成の樹脂混合物を例２５とした。
【０１１９】
−例２６−
ウレタン樹脂組成物とＰＰ樹脂組成物との質量比を、ウレタン／ＰＰ＝４５／５５としたことを除いては例２４と同一構成の樹脂混合物を例２６とした。
【０１２０】
−例２７−
ウレタン樹脂組成物とＰＰ樹脂組成物との質量比を、ウレタン／ＰＰ＝４０／６０としたことを除いては例２４と同一構成の樹脂混合物を例２７とした。
【０１２１】
−例２８−
ウレタン樹脂組成物とＰＰ樹脂組成物との質量比を、ウレタン／ＰＰ＝３０／７０としたことを除いては例２４と同一構成の樹脂混合物を例２８とした。
【０１２２】
＜試験評価方法＞
上記の各例に係る樹脂混合物をニーダー及び二軸押出機でそれぞれ混練した。そして、樹脂混合物の複合化できたものについてはアイゾット衝撃試験用の試験片を射出成形し、試験評価１と同一の方法によりアイゾット衝撃試験を実施し、アイゾット衝撃値を算出した。
【０１２３】
＜試験評価結果＞
試験結果を表６に示す。同表によれば、ニーダーにより密閉されてバッチ方式で混練した場合には、ウレタン樹脂組成物とＰＰ樹脂組成物との質量比（ウレタン／ＰＰ）が５０／５０以下で混練可能であるが、二軸押出機により密閉されて連続方式で混練した場合には、質量比（ウレタン／ＰＰ）が４０／６０以下でなければ混練することができないということが分かる。しかも、混練して形成された成形用樹脂材料を射出成形してなる成形品のアイゾット衝撃値は、ニーダーにより混練したものが二軸押出機により混練したものの約５倍の値となっている。すなわち、ニーダーのような密閉式混練機を用いてバッチ方式で混練することによりウレタン樹脂組成物の分散性を良好なものとすることができるということが確認された。
【０１２４】
【表６】

【０１２５】
（試験評価７）
ウレタン樹脂組成物と架橋済みゴム組成物とからなる架橋済みエラストマーを分散材としてＰＰ樹脂組成物のマトリックスに分散させた成形用樹脂材料について、物理特性及び音特性を試験評価した。
【０１２６】
＜試験評価サンプル＞
以下の各例に係る樹脂混合物を準備した。なお、各構成については表７に示す。
【０１２７】
−例２９−
廃車された自動車のシートから抽出した塊状のウレタン樹脂組成物（発泡ウレタン樹脂）を１５０℃に調温したロール型粉砕機で粉砕し、これをふるいにかけて粒径２０μｍ以下のもののみを分別した。また、廃車された自動車から取り外したウェザーストリップ（架橋済みゴム組成物）を微粉砕し、これをふるいにかけて粒径２０μｍ以下のもののみを分別した。さらに、廃車された自動車のバンパから抽出したＰＰ樹脂組成物を粉砕機によりチップ状とした。そして、粉状乃至粒状のウレタン樹脂組成物と、粉状乃至粒状の架橋済みゴム組成物と（以上、架橋済みエラストマー）、ＰＰ樹脂組成物とを、質量比（ウレタン／ゴム／ＰＰ）＝４５／５／５０となるようにニーダーのチャンバーに投入し、さらにこれらの混合物の質量和に対して３％の親和性付与成分（三洋化成工業社製 ユーメックス１０１０）と１％の酸化防止剤（旭電化工業社製 アデカスタブＡＯ−６０）とを投入し、これらを混練して複合化した。そして、得られた複合体を粉砕機によりチップ化して形成された成形用樹脂材料を例２９とした。例２９に係る成形用樹脂材料では、分散材である架橋済みエラストマーのゴム質量分率が１０％（ウレタン質量分率９０％）である。
【０１２８】
−例３０−
ウレタン樹脂組成物と架橋済みゴム組成物とＰＰ樹脂組成物との質量比を、ウレタン／ゴム／ＰＰ＝４０／１０／５０としたことを除いては例２９と同一構成の成形用樹脂材料を例３０とした。例３０に係る成形用樹脂材料では、分散材である架橋済みエラストマーのゴム質量分率が２０％（ウレタン質量分率８０％）である。
【０１２９】
−例３１−
ウレタン樹脂組成物と架橋済みゴム組成物とＰＰ樹脂組成物との質量比を、ウレタン／ゴム／ＰＰ＝２５／２５／５０としたことを除いては例２９と同一構成の成形用樹脂材料を例３１とした。例３１に係る成形用樹脂材料では、分散材である架橋済みエラストマーのゴム質量分率が５０％（ウレタン質量分率５０％）である。
【０１３０】
−例３２−
ウレタン樹脂組成物と架橋済みゴム組成物とＰＰ樹脂組成物との質量比を、ウレタン／ゴム／ＰＰ＝１５／３５／５０としたことを除いては例２９と同一構成の成形用樹脂材料を例３２とした。例３２に係る成形用樹脂材料では、分散材である架橋済みエラストマーのゴム質量分率が７０％（ウレタン質量分率３０％）である。
【０１３１】
＜試験評価方法＞
上記の例２９〜３２に係る各成形用樹脂材料を射出成形して板状の成形品をそれぞれ成形し、これを用いて試験評価１及び２と同一の方法で、曲げ弾性率、曲げ強度、アイゾット衝撃値、引張強度及び切断時伸び、並びに成形品をガラス玉で打撃した際の音圧、減衰時間及び高周波音の有無について計測又は観測を行った。
【０１３２】
＜試験評価結果＞
試験結果を表７に示す。
【０１３３】
図１９は、架橋済みエラストマーのゴム質量分率と曲げ弾性率及び曲げ強度との関係を示す。同図によれば、いずれの曲げ特性もゴム質量分率に関わりなくほぼ同水準であるものの、ゴム質量分率が高くなることにより若干上昇する傾向が伺われる。図２０は、架橋済みエラストマーのゴム質量分率とアイゾット衝撃値との関係を示す。同図によれば、ゴム質量分率に関わりなくアイゾット衝撃値がほぼ同水準であることが分かる。図２１は、架橋済みエラストマーのゴム質量分率と引張強度との関係を示す。同図によれば、引張強度もまたゴム質量分率に関わりなくほぼ同水準であることが分かる。図２２は、架橋済みエラストマーのゴム質量分率と切断時伸びとの関係を示す。同図によれば、ゴム質量分率が２０％以上になると急激に切断時伸びが大きくなるのが分かる。以上より、例２９〜３２の成形用樹脂材料の成形品の曲げ弾性率等の物理特性は、ゴム質量分率が１０〜７０％の範囲において、切断時伸びが大幅に大きくなるという特性はあるものの、概ねゴム成分を有しない例１と同等の性能を有するものと判断できる。すなわち、これは、ゴム質量分率が０〜７０％の範囲（ウレタン質量分率が３０〜１００％）の成形用樹脂材料では、物理特性の優れる成形品を得ることができるということを意味するものである。
【０１３４】
図２３は、架橋済みエラストマーのゴム質量分率と音圧との関係を示す。同図によれば、ゴム質量分率が５０％までは音圧が７０ｄＢ以下であるのに対し、ゴム質量分率が７０％では８０ｄＢを越えるレベルとなっているのが分かる。図２４は、架橋済みエラストマーのゴム質量分率と減衰時間との関係を示す。同図によれば、ゴム質量分率が５０％までは減衰時間が３．２〜３．６ｍ・ｓｅｃのレベルであるのに対し、ゴム質量分率が７０％では４．５ｍ・ｓｅｃのレベルとなっているのが分かる。すなわち、これは、ゴム質量分率が０〜５０％の範囲（ウレタン質量分率が５０〜１００％）の成形用樹脂材料では、音特性の優れる成形品を得ることができるということを意味するものである。
【０１３５】
以上より、架橋済みエラストマーのゴム質量分率が０〜５０％の範囲（ウレタン質量分率が５０〜１００％）の成形用樹脂材料では、物理特性及び音特性共に優れる成形品を得ることができることとなる。
【０１３６】
【表７】

【図面の簡単な説明】
【図１】ニーダーの概略構成を示す図である。
【図２】曲げ試験、アイゾット衝撃試験及び引張試験の各試験片形状を示す図である。
【図３】ウレタン樹脂組成物の粒径と曲げ弾性率及び曲げ強度との関係を示すグラフ図である。
【図４】ウレタン樹脂組成物の粒径とアイゾット衝撃値との関係を示すグラフ図である。
【図５】ウレタン樹脂組成物の粒径と引張強度との関係を示すグラフ図である。
【図６】ウレタン樹脂組成物の粒径と切断時伸びとの関係を示すグラフ図である。
【図７】音圧及び減衰時間を計測する試験装置の概略構成を示す図である。
【図８】ウレタン樹脂組成物の含有量と音圧との関係を示すグラフ図である。
【図９】ウレタン樹脂組成物の含有量と減衰時間との関係を示すグラフ図である。
【図１０】ウレタン樹脂組成物の粉砕温度とその嵩比重との関係を示すグラフ図である。
【図１１】ウレタン樹脂組成物の嵩比重と音圧との関係を示すグラフ図である。
【図１２】ウレタン樹脂組成物の嵩比重と減衰時間との関係を示すグラフ図である。
【図１３】例１５〜１８の曲げ弾性率及び曲げ強度を示すグラフ図である。
【図１４】例１５〜１８のアイゾット衝撃値を示すグラフ図である。
【図１５】例１５〜１８の引張強度を示すグラフ図である。
【図１６】例１５〜１８の切断時伸びを示すグラフ図である。
【図１７】例１９〜２３の成形温度幅を示すグラフ図である。
【図１８】例１９〜２３のスパイラルフロー成形温度幅を示すグラフ図である。
【図１９】架橋済みエラストマーのゴム質量分率と曲げ弾性率及び曲げ強度との関係を示すグラフ図である。
【図２０】架橋済みエラストマーのゴム質量分率とアイゾット衝撃値との関係を示すグラフ図である。
【図２１】架橋済みエラストマーのゴム質量分率と引張強度との関係を示すグラフ図である。
【図２２】架橋済みエラストマーのゴム質量分率と切断時伸びとの関係を示すグラフ図である。
【図２３】架橋済みエラストマーのゴム質量分率と音圧との関係を示すグラフ図である。
【図２４】架橋済みエラストマーのゴム質量分率と減衰時間との関係を示すグラフ図である。
【符号の説明】
１０ ニーダー
１１ チャンバー
１２ 蓋
１３ ブレード
７０ 試験装置
７１ 基台
７２ 支柱
７３ 筒状部材
７４ 環状部材
７５ ゴム紐
７６ 板状試験片
７７ 集音マイク
７８ オシロスコープ
７９ ガラス玉[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a molding resin material and a molded article molded using the molding resin material.
[0002]
[Prior art]
Composite resin materials comprising a urethane resin composition and a thermoplastic resin composition are widely used as molding materials, paints, adhesives and the like.
[0003]
JP-A-5-97958 discloses a composite comprising a polypropylene and a polyurethane obtained by reacting an active hydrogen-containing compound with a polyisocyanate in a molten polypropylene in the presence of a dispersant such as maleic anhydride-modified polypropylene. A resin composition is described, and it is disclosed that a molded article having excellent mechanical properties such as impact strength and tensile strength is obtained by such a configuration.
[0004]
JP-A-7-82472 describes a thermoplastic mixture of a thermoplastic polyurethane, a polypropylene grafted with maleic anhydride or the like, and a polyamide resin. It is disclosed to improve compatibility with polypropylene and to obtain molded articles having improved mechanical properties.
[0005]
[Problems to be solved by the invention]
By the way, the resin material most used in automobiles is a polypropylene resin composition (hereinafter referred to as “PP resin composition”). Further, a foamed urethane resin composition, which is a heat-cured urethane resin composition (hereinafter abbreviated as "urethane resin composition"), is also used in a large amount for a sheet or the like. Until now, these resin materials have been made into chips after the scrapping of automobiles and used for landfills. However, in recent years, demand for recycling of various materials including these resin materials has increased due to the increasing awareness of environmental conservation. ing.
[0006]
However, for example, to purify only a polypropylene resin from a bumper to which paint or the like has adhered, a special device for that purpose is required, and a great deal of time and cost are required. There is a problem that it becomes expensive. Therefore, in order to effectively recycle these resin materials, it is required that added value exceeding the cost required for recycling is provided.
[0007]
The present invention has been made in view of such a point, and the purpose thereof is to use a urethane resin composition and a thermoplastic resin composition extracted from a used product, and have excellent characteristics as a molded article. It is an object of the present invention to provide a molding resin material capable of exhibiting the following.
[0008]
[Means for Solving the Problems]
In the present invention, a molding resin material is constituted by dispersing a powdery or granular urethane resin composition in a thermoplastic resin composition as a matrix.
[0009]
In particular,The present invention is a molding resin material in which a powdery or granular thermosetting urethane resin composition is dispersed in a matrix of a thermoplastic resin composition,
The heat-cured urethane resin composition is extracted from a used urethane foam molded article, and the content thereof is the mass of the heat-cured urethane resin composition and the thermoplastic resin composition. 40-70% of the sum,
The thermoplastic resin composition is extracted from a used thermoplastic resin molded article coated with a thermosetting urethane resin coating, and contains the thermosetting urethane resin coating.
It is characterized by the following.
[0010]
According to the above configuration, a sea / island structure in which the powdery or granular urethane resin composition is dispersed in the thermoplastic resin composition serving as the matrix is formed, and the urethane resin composition and the thermoplastic resin composition Since the urethane resin composition occupies 40 to 70% of the mass sum of the above, the sound generated by the external impact is effectively attenuated in the urethane resin composition which is an island, and the sound generated even when the impact is received. However, it is possible to obtain a molded article having a small size. Here, when the content of the urethane resin composition is less than 40%, the above effect becomes extremely dilute. On the other hand, when the content is more than 70%, it becomes difficult to form a composite of the urethane resin composition and the thermoplastic resin composition. Would. Further, as will be clarified later in the examples, according to the molding material of the present invention, it is possible to obtain a molded article in which high-frequency sound which is particularly annoying to human ears is effectively attenuated. Although the reason for this is not clear, it is presumed that high-frequency sound is attenuated at the interface between the relatively soft urethane resin composition and the hard thermoplastic composition. This effect is ensured by constituting the urethane resin composition with a powdery or granular foamed urethane resin composition having a bulk specific gravity of 0.1 to 0.3, preferably 0.15 to 0.20. Can be obtained. From the above, for example, when an automobile pocket integrally molded door trim is molded from the molding resin material of the present invention, even if a coin or the like put in the pocket hits the inner wall of the pocket, loud noise or harshness may occur. In addition to producing no sound, the door trim itself has excellent sound absorption. In addition, when an undercover formed of the molding resin material of the present invention is attached to the lower surface of a tire house of an automobile, even if the undercover is hit by a stone or the like, a similarly loud or unpleasant sound is generated. Does not occur.
[0011]
That is, it can be said that the molding resin material of the present invention is suitable for molding a blow itself given from the outside and a molded product that absorbs a sound caused by the blow.
[0012]
Further, the urethane resin composition was constituted by one extracted from a used urethane foam molded article such as an automobile seat, and the thermoplastic resin composition was extracted from a used thermoplastic resin molded article such as an automobile bumper. It is possible to obtain a molded resin material with added value from used urethane foam molded products and used thermoplastic resin molded products, and effective recycling of these used materials can be achieved. Will be provided. In addition, since the used thermoplastic resin molded product coated with the thermosetting urethane resin paint is crushed and applied to the molding resin material as it is, the thermoplastic resin composition is purified for recycling. The effect of dispersing the urethane resin composition in the matrix of the thermoplastic resin composition can be obtained.
[0013]
In the present invention, the thermosetting urethane resin composition may have a particle size of 60 μm or less.
[0014]
According to the above configuration, a sea-island structure in which the powdery or granular urethane resin composition is dispersed in the thermoplastic resin composition serving as the matrix is formed, and the particle size is 60 μm or less. Thus, the impact applied from the resin is effectively absorbed by the urethane resin composition which is an island, and a molded article having high impact strength can be obtained. In addition, since the particle size is 60 μm or less, the tensile strength and elongation at break of the molded product are at high levels, as will be described later in Examples. As described above, for example, when a floor material is molded using the molding resin material of the present invention, a floor having sufficient strength and extremely excellent cushioning properties can be obtained.
[0015]
Further, the operation and effect as described above can be obtained not only when the powdery or granular urethane resin composition is used alone as the dispersing agent, but also when the urethane resin composition accounts for 50% by mass or more. A powdery or granular crosslinked elastomer having a diameter of 60 μm or less is used as a dispersant.The content is 40 to 70% of the mass sum of the crosslinked elastomer and the thermoplastic resin composition.Can also be obtained. Examples of the components other than the urethane resin composition constituting the crosslinked elastomer include an epoxy resin composition, a phenol resin composition, and a crosslinked rubber.
[0016]
Here, the thermoplastic resin composition is not particularly limited, and examples thereof include a PP resin composition, a styrene-based resin composition such as ABS, and the like. It is necessary that the molded article is hard under the temperature conditions at which it is used.
[0017]
Further, it is preferable that an antioxidant and an affinity-imparting component that imparts an affinity between the urethane resin composition and the thermoplastic resin composition are added to the molding resin material of the present invention. That is, by adding an antioxidant to the molding resin material as in this configuration, even when the urethane resin composition having poor heat resistance is heated to around 200 ° C., it is oxidized and formed on urethane molecules. Since the radicals are trapped by the antioxidant, a wide moldable temperature range can be secured, and the degree of freedom in molding can be increased. In addition, by adding the affinity-imparting component to the molding resin material, the dispersibility of the urethane resin composition in the matrix of the thermoplastic resin composition is improved, and a molded article having uniform and stable physical properties is obtained. Obtainable.
[0018]
The amount of the antioxidant to be added is preferably 0.5 to 6.0% based on the total weight of the urethane resin composition or the crosslinked elastomer and the thermoplastic resin composition. If the amount is less than 0.5%, the above-mentioned effects and effects by adding an antioxidant will be dilute, and if it is more than 6.0%, the above-mentioned effects and effects will be saturated. It is because. However, since the antioxidant is expensive, the content is preferably 2.0% or less from the economical viewpoint.
[0019]
Further, it is preferable that the affinity imparting component has a structure having a polymer hydrocarbon component that diffuses into the matrix of the thermoplastic resin composition. According to such a configuration, since the affinity imparting component is diffused into the matrix of the thermoplastic resin composition, the powdery or granular urethane resin composition is surely dispersed in the matrix with it. It is.
[0020]
In the case where the above-mentioned powdery or granular crosslinked elastomer is used as a dispersant, the urethane resin composition is extracted from a used urethane foam molded article such as an automobile sheet, and, for example, used tires and the like are used. What is necessary is just to extract the crosslinked rubber from the rubber product and combine them to constitute a crosslinked elastomer which is a dispersant.
[0021]
The powdery or granular urethane resin composition or the crosslinked elastomer used for the molding resin material of the present invention may be used as a lump-shaped urethane resin composition or a crosslinked elastomer in a roll-type pulverizer having a roll surface temperature of 150 to 200 ° C. And applying a shearing force to the urethane foam resin composition or the crosslinked elastomer to form a powder or granule. Here, when the roll surface temperature is lower than 150 ° C, the foamed urethane resin composition or the crosslinked elastomer cannot be pulverized. On the other hand, when the roll surface temperature is higher than 200 ° C, the urethane resin composition or the crosslinked elastomer shrinks due to thermal deterioration. Will be done.
[0022]
Further, as a method for producing a molding resin material of the present invention, a powdery or granular urethane resin composition or a crosslinked elastomer and a thermoplastic resin composition are charged into a chamber of a closed kneader, and a batch method is used. And a method of kneading. It is very difficult to melt-knead the thermoplastic resin composition with the urethane powder having a bulk specific gravity of 0.1 to 0.3 in an amount of 50% by mass or more based on the whole mass, and a cylinder such as a twin screw extruder is used. In the method of continuously kneading by applying a shear with a screw in the inside, it is not possible to knead the both uniformly to form a composite. However, by using a closed kneader and kneading in a batch manner, the urethane resin composition or the crosslinked elastomer and the thermoplastic resin composition are forcibly compounded, and the molding of the present invention A resin material can be obtained.
[0023]
【The invention's effect】
As described above, according to the present invention, the impact applied from the outside is effectively absorbed by the urethane resin composition which is an island, and a molded article having high impact strength can be obtained.
[0024]
BEST MODE FOR CARRYING OUT THE INVENTION
(Configuration of molding resin material)
The molding resin material according to the embodiment of the present invention includes a PP resin composition as a matrix, a powdery or granular urethane resin composition dispersed in the matrix, and an oxidation such as a hindered phenol compound added thereto. It comprises an inhibitor and an affinity-imparting component such as a carboxyl-containing olefin-based resin having a high-molecular hydrocarbon component, and is in the form of pellets.
[0025]
The PP resin composition is extracted from a bumper of a scrapped automobile and contains a powdery or granular material of a thermosetting urethane resin paint that has coated the bumper surface.
[0026]
The powdery or granular urethane resin composition is made of a foamed urethane resin composition extracted from a sheet of a scrapped automobile and is crushed to a particle size of 60 μm or less. Further, the content of the urethane resin composition accounts for 40 to 70% of the total mass of the urethane resin composition and the PP resin composition. And bulk specific gravity is 0.1-0.3.
[0027]
The antioxidant is added in an amount of 0.5 to 6.0% based on the total weight of the urethane resin composition and the PP resin composition. Note that, even when a plurality of types of antioxidants are added, the sum of them is within the above range.
[0028]
The affinity-imparting component improves the affinity between the PP resin composition as a matrix and the powdery or granular urethane resin composition. For example, the carboxyl group of the affinity-imparting component forms a chemical bond with the hydroxyl group of the urethane resin composition, and the hydrocarbon chain diffuses through the matrix of the PP resin composition, thereby imparting an affinity between the two. It will be. The affinity-imparting component is added in an amount of 1.0 to 4.0% based on the total weight of the urethane resin composition and the PP resin composition. Note that, even when a plurality of types of affinity imparting components are added, their sum is within the above range.
[0029]
According to the molding resin material having the above structure, a sea / island structure in which a powdery or granular urethane resin composition is dispersed in a PP resin composition as a matrix is formed, and the particle size is 60 μm or less. Therefore, the impact applied from the outside is effectively absorbed by the urethane resin composition as an island, and a molded article having high impact strength can be obtained. Further, since the particle size is 60 μm or less, the tensile strength and the elongation at break of the molded product are at a high level. Therefore, for example, when a floor material is molded from the molding resin material, a floor having sufficient strength and extremely excellent soundproofing can be obtained.
[0030]
The urethane resin composition occupies 40 to 70% of the total mass of the urethane resin composition and the PP resin composition, and the urethane resin composition has a bulk specific gravity of 0.1 to 0.3. Since it is composed of the composition, the sound generated by the impact from the outside is effectively attenuated in the urethane resin composition which is an island, and it is possible to obtain a molded product in which the sound generated by the impact is extremely small. Further, in particular, it is possible to obtain a molded product in which high-frequency sounds that are annoying to human ears are effectively attenuated. Therefore, for example, when a door trim integrally molded with an automobile is molded from this molding resin material, even if a coin or the like inserted in the pocket hits the inner wall of the pocket, loud noise or harsh sound is generated. In addition to this, the sound absorption of the door trim itself is also excellent. In addition, when an undercover formed of the resin material for molding is attached to the lower surface of a tire house of an automobile, even if the undercover is hit by a stone or the like, a loud sound or annoying sound is similarly generated. Nothing.
[0031]
Further, since an antioxidant is added to this molding resin material, even when the urethane resin composition having poor heat resistance is heated to around 200 ° C., radicals generated on the urethane molecules by oxidation are generated. Is trapped by the antioxidant, a wide moldable temperature range can be secured, and the degree of freedom in molding is high. And since the addition amount of an antioxidant is 0.5-6.0% with respect to the mass sum of a urethane resin composition and a PP resin composition, the effective effect by an antioxidant can be acquired. .
[0032]
Further, since an affinity-imparting component for imparting an affinity between the urethane resin composition and the PP resin composition is added, the urethane resin composition is dispersed in a matrix of the PP resin composition, and therefore, the uniformity is obtained. Thus, a molded product having stable physical properties can be obtained. And, since the affinity-imparting component is a carboxyl group-containing olefin resin or the like having a high-molecular hydrocarbon component, the affinity-imparting component is diffused into the matrix of the PP resin composition, and the dispersibility thereof is extremely excellent. It has become something.
[0033]
In addition, since the urethane resin composition is constituted by the one extracted from the sheet of the scrapped car, and the PP resin composition is constituted by the one extracted from the bumper of the scrapped car, the used urethane foam is used. A molded resin material with added value is obtained from the molded article and the used PP resin molded article, and an effective recycling application of these used materials is provided.
[0034]
And, since the bumper coated with the thermosetting urethane resin paint is applied to the molding resin material as it is, there is no need to purify the PP resin composition for recycling, and the urethane resin composition is used. The effect of dispersing in the matrix of the PP resin composition can be obtained.
[0035]
(Production method of resin material for molding)
Next, a method for producing the molding resin material will be described.
[0036]
<Pulverization of urethane resin composition and PP resin composition>
First, a lump-shaped urethane foam resin composition extracted from a scrapped automobile sheet is put into a roll-type pulverizer having a roll surface temperature of 150 to 200 ° C., and is made into a powdery or granular form.
[0037]
In parallel with this, the PP resin composition extracted from the bumper of the scrapped car is put into a grinder, and this is used as a chip. At this time, the heat-cured urethane resin coating on the bumper surface is ground together without peeling.
[0038]
<Composite of urethane resin composition and PP resin composition>
A powdery or granular urethane resin composition and a chip-shaped PP resin composition are charged into a chamber 11 of a kneader 10 as shown in FIG. 1, and further, predetermined amounts of an antioxidant and an affinity imparting component are charged. Then, this is sealed with a lid 12, a shear is given by rotating a pair of blades 13, 13, and these composites are formed by kneading for a predetermined time. This kneading is a batch method in which the input and the discharge of the material are not performed continuously, but the input and the discharge of the material are performed each time.
[0039]
<Complex pelletization>
A composite of the urethane resin composition, the PP resin composition, and the like formed by kneading is charged into a pulverizer, and is used as a chip to form a molding resin material.
[0040]
According to the method of manufacturing a molding resin material having the above-described configuration, since the lump-shaped foamed urethane resin composition is put into the roll-type pulverizer with the roll surface temperature being 150 to 200 ° C., the urethane resin composition powdery to Granulation will be performed properly.
[0041]
Further, since the urethane resin composition and the PP resin composition are charged into a kneader chamber, which is a closed kneader, and kneaded in a batch mode, the urethane resin composition and the PP resin composition are forcibly mixed. Thus, a desired molding resin material can be obtained.
[0042]
(Other embodiments)
In the above embodiment, the PP resin composition was used as the thermoplastic resin composition. However, the present invention is not particularly limited to this, and a styrene-based material such as ABS which is hard under the temperature conditions at which the molded product is used is used. It may be a resin composition or the like.
[0043]
In the above embodiment, a hindered phenol-based antioxidant is mentioned. However, the present invention is not particularly limited thereto, and a phosphite-based or thioether-based one may be used.
[0044]
In the above embodiment, an olefin-based resin having a carboxyl group is given as an affinity-imparting component. However, the present invention is not particularly limited to this, and a rosin having a hydroxyl group and / or a carboxyl group may be used. .
[0045]
In the above embodiment, the lump-shaped urethane foam resin composition is pulverized by a roll-type pulverizer.However, the present invention is not particularly limited thereto. Is also good.
[0046]
In the above embodiment, the resin material for molding is formed by dispersing the powdery or granular urethane resin composition in the matrix of the PP resin composition. However, the present invention is not limited to this. A powdery or granular crosslinked elastomer composed of a resin composition and having a particle size of 60 μm or less may be dispersed in a matrix.
[0047]
【Example】
(Test evaluation 1)
Test evaluation was performed on the relationship between the urethane particle size of the urethane resin composition and the physical properties of the injection molded product.
[0048]
<Test evaluation sample>
A molding resin material according to each of the following examples was prepared. Table 1 shows each configuration.
[0049]
-Example 1-
The massive urethane resin composition (urethane foam resin) extracted from the scrapped automobile sheet was pulverized by a roll-type pulverizer controlled at 150 ° C., and sieved to separate only those having a particle size of 20 μm. Further, a PP resin composition extracted from a bumper of a scrapped car was formed into chips by a crusher. Next, the powdery or granular urethane resin composition and the PP resin composition are put into a kneader chamber in equal amounts by mass, and an affinity imparting component (Sanyo Chemical Industry Co., Ltd.) of 3% with respect to the mass sum of both resin compositions. (Umex 1010) and 1% of an antioxidant (ADK STAB AO-60, manufactured by Asahi Denka Kogyo KK), and kneaded to form a composite. A molding resin material formed by chipping the composite with a crusher was used as Example 1.
[0050]
-Example 2
A molding resin material having the same configuration as that of Example 1 except that the particle size of the urethane resin composition was 30 μm was used as Example 2.
[0051]
-Example 3
A molding resin material having the same configuration as that of Example 1 except that the particle size of the urethane resin composition was 60 μm was used as Example 3.
[0052]
-Example 4-
A molding resin material having the same configuration as that of Example 1 except that the particle size of the urethane resin composition was 100 μm was used as Example 4.
[0053]
<Test evaluation method>
−Bending characteristics−
The molding resin material according to each of the above examples was put into an injection molding machine, and a plate-like test piece having a length of 127 mm, a width of 12.7 mm, and a thickness of 3 mm as shown in FIG. 2A was formed. Next, a bending test was performed using the test piece according to JIS K3114. And the bending elastic modulus and bending strength were calculated | required from the result.
[0054]
−Izod impact value−
The molding resin material according to each of the above examples was put into an injection molding machine, and a test having a notch in a plate shape having a length of 60 mm, a width of 12.7 mm, and a thickness of 3 mm as shown in FIG. A piece was molded. Next, an Izod impact test was performed on the test piece according to JIS K3114. Then, an Izod impact value was calculated from the result.
[0055]
−Tensile properties−
The molding resin material according to each of the above examples was charged into an injection molding machine, and a test piece of a No. 3 dumbbell as shown in FIG. 2C was molded. Next, a tensile test was performed using the test piece according to JIS K3114. Then, tensile strength and elongation at break were determined from the results.
[0056]
<Test evaluation results>
Table 1 shows the test results.
[0057]
FIG. 3 shows the relationship between the particle size of the urethane resin composition, the flexural modulus, and the flexural modulus. According to the figure, it can be seen that the flexural modulus and flexural strength are almost the same level regardless of the particle size of the urethane resin composition.
[0058]
FIG. 4 shows the relationship between the particle size of the urethane resin composition and the Izod impact value. According to the figure, it can be seen that the Izod impact value decreases as the particle size of the urethane resin composition increases. This is because the impact absorption occurs at the interface in the sea-island structure between the PP resin composition as the matrix and the urethane resin composition, and the area constituting the interface decreases as the particle size increases. It is presumed. Specifically, when the particle size is 60 μm or less, 10 J / m^TwoThe above Izod impact value is obtained.
[0059]
FIG. 5 shows the relationship between the particle size of the urethane resin composition and the tensile strength, and FIG. 6 shows the relationship between the particle size of the urethane resin composition and the elongation at break, respectively. According to FIGS. 5 and 6,
It can be seen that as the particle size of the urethane resin composition increases, the tensile strength and the elongation at break decrease. In particular, the elongation at break significantly decreases.
[0060]
[Table 1]

[0061]
(Test evaluation 2)
Test evaluation was performed on the relationship between the content of the urethane resin composition in the resin material for molding and the attenuation characteristics of sound when the molded article was hit.
[0062]
<Test evaluation sample>
A molding resin material according to each of the following examples was prepared. Table 2 shows each configuration.
[0063]
-Example 5-
The urethane resin composition (urethane foam resin) extracted from the sheet of the scrapped automobile was pulverized by a roll-type pulverizer controlled at 170 ° C., and sieved to separate only those having a particle size of 60 μm. Further, a PP resin composition extracted from a bumper of a scrapped car was formed into chips by a crusher. Next, the powdery or granular urethane resin composition and the PP resin composition are charged into a kneader chamber such that the mass ratio (urethane / PP) becomes 80/20. On the other hand, 3% of an affinity-imparting component (Umex 1010 manufactured by Sanyo Kasei Kogyo Co., Ltd.) and 1% of an antioxidant (Adeka Stab AO-60 manufactured by Asahi Denka Kogyo Co., Ltd.) were charged, and kneaded to form a composite. A molding resin material formed by chipping the composite with a pulverizer was used as Example 5.
[0064]
-Example 6-
A molding resin material having the same structure as that of Example 5 was used as Example 6 except that the mass ratio of the urethane resin composition to the PP resin composition was set to be urethane / PP = 70/30.
[0065]
-Example 7-
Example 7 was a molding resin material having the same configuration as that of Example 5 except that the mass ratio between the urethane resin composition and the PP resin composition was set to be urethane / PP = 50/50.
[0066]
-Example 8-
A molding resin material having the same configuration as that of Example 5 was used as Example 8 except that the mass ratio between the urethane resin composition and the PP resin composition was set to be urethane / PP = 40/60.
[0067]
-Example 9-
Example 9 was a molding resin material having the same configuration as that of Example 5 except that the mass ratio between the urethane resin composition and the PP resin composition was set to be urethane / PP = 30/70.
[0068]
-Example 10-
A molding resin material having the same configuration as that of Example 5 was used as Example 10 except that the mass ratio between the urethane resin composition and the PP resin composition was set to be urethane / PP = 20/80.
[0069]
<Test evaluation method>
-Test equipment-
FIG. 7 shows a schematic configuration of the test apparatus. In the test apparatus 70, a column 72 is erected on a base 71, and a cylindrical member 73 and an annular member 74 are provided on the column 72 in order from the top. Also, one end of four rubber cords 75, 75,... Are connected to the annular member 74 at equal intervals, and the other end of each rubber cord 75 is connected to the four corners of a square plate-shaped test piece 76. Each is fixed. Further, a sound collecting microphone 77 is provided below the plate-shaped test piece 76, and the sound collecting microphone 77 is connected to an oscilloscope 78.
[0070]
The test apparatus 70 drops a glass ball 79 from the cylindrical member 73 by 55 cm, detects a sound when the glass ball 79 hits the plate-shaped test piece 76 with a sound collecting microphone 77, and sends a signal to an oscilloscope 78. Is configured to send as.
[0071]
-Test evaluation-
Square plate-like test pieces were injection molded from the molding resin materials according to Examples 6 to 10 described above, and the sound pressure, the decay time, and the presence or absence of high-frequency sound were tested using the test apparatus. The test piece could not be molded with the molding resin material according to Example 5.
[0072]
For the sound pressure, the maximum sound pressure detected was read from an oscilloscope. As the decay time, the time required from when the glass ball was hit to when the hitting sound attenuated and disappeared was read from an oscilloscope. The presence or absence of the high-frequency sound was evaluated by visually observing whether or not there was a minute waveform at the peak portion of the attenuation wave observed by the oscilloscope.
[0073]
<Test evaluation results>
Table 2 shows the results of the test evaluation. In Example 5 where urethane / PP = 80/20, a test piece could not be prepared, but this was because the urethane resin composition was dispersed in the matrix of the PP resin composition because of the high ratio of the urethane resin composition. It is considered that this is because the molding resin material having the above configuration was not formed.
[0074]
FIG. 8 shows the relationship between the content of the urethane resin composition in the sum of the masses of the urethane resin composition and the PP resin composition, and the sound pressure when the glass ball hits the molded plate. According to the figure, it can be seen that when the content of the urethane resin composition is more than 40%, the sound pressure is significantly reduced.
[0075]
FIG. 9 shows the relationship between the urethane resin composition content and the sound decay time when the glass ball hits the molded plate. According to the figure, it can be confirmed that the decay time decreases as the content of the urethane resin composition increases. Specifically, when the content of the urethane resin composition is more than 40%, the level is 4 m · sec or less.
[0076]
According to Table 2, it is found that when the content of the urethane resin composition is more than 40%, generation of high-frequency noise is eliminated. This is presumed to be because the high-frequency sound is attenuated at the interface between the relatively soft urethane resin composition and the hard PP resin composition, and the higher the interface area, the more effectively the high-frequency sound is attenuated.
[0077]
[Table 2]

[0078]
(Test evaluation 3)
Test evaluation was performed on the relationship between the grinding conditions of the urethane resin composition and the bulk specific gravity thereof, and the relationship between the bulk specific gravity of the urethane resin composition and the sound attenuation characteristics when the molded product was hit.
[0079]
<Test evaluation sample>
A molding resin material according to each of the following examples was prepared. Table 3 shows each configuration.
[0080]
-Example 11-
A lump-shaped urethane resin composition (urethane foam resin) extracted from a scrapped automobile sheet was put into a roll-type pulverizer controlled at 120 ° C., but the urethane resin composition could not be pulverized. This was designated as Example 11.
[0081]
-Example 12-
A lump-shaped urethane resin composition (urethane foam resin) extracted from a scrapped automobile sheet was pulverized by a roll-type pulverizer controlled at 150 ° C., and sieved to separate only those having a particle size of 60 μm. Further, a PP resin composition extracted from a bumper of a scrapped car was formed into chips by a crusher. Next, the powdery or granular urethane resin composition and the PP resin composition are put into a kneader chamber in equal amounts by mass, and an affinity imparting component (Sanyo Chemical Industry Co., Ltd.) of 3% with respect to the mass sum of both resin compositions. (Umex 1010) and 1% of an antioxidant (ADK STAB AO-60, manufactured by Asahi Denka Kogyo KK), and kneaded to form a composite. A molding resin material formed by chipping this composite with a crusher was used as Example 12.
[0082]
-Example 13-
A molding resin material having the same configuration as that of Example 12 except that the roll surface temperature was 170 ° C. was used as Example 13.
[0083]
-Example 14-
A molding resin material having the same configuration as that of Example 12 except that the roll surface temperature was 200 ° C. was used as Example 14.
[0084]
<Test evaluation method>
A sheet-like molded product was prepared by injection molding the molding resin material according to Examples 12 to 14 described above, and using this, the sound pressure when a glass ball was hit on the molded product in the same manner as in Test Evaluation 2. The test evaluation was performed on the decay time and the presence or absence of high-frequency sound.
[0085]
<Test evaluation results>
Table 3 shows the test results.
[0086]
FIG. 10 shows the relationship between the roll surface temperature, that is, the pulverization temperature of the urethane composition and the bulk specific gravity of the pulverized urethane resin composition. According to the figure, it can be seen that the bulk specific gravity increases as the grinding temperature increases. This is considered to be because the urethane resin composition shrunk by heat when the pulverization temperature was increased.
[0087]
FIG. 11 shows the relationship between the bulk specific gravity of the urethane resin composition and the sound pressure. According to the figure, it can be seen that the sound pressure increases as the bulk specific gravity increases. This means that when the urethane resin composition thermally shrinks to increase the bulk specific gravity, the function of attenuating sound decreases. Specifically, when the bulk specific gravity is 0.1 to 0.2, the sound pressure is about 50 dB. However, when the bulk specific gravity is more than 0.3, the sound pressure becomes a level exceeding 80 dB.
[0088]
FIG. 12 shows the relationship between the bulk specific gravity of the urethane resin composition and the decay time. According to the figure, similarly to the case of the sound pressure, it can be confirmed that the decay time becomes longer as the bulk specific gravity becomes larger, which confirms the deterioration of the above function.
[0089]
According to Table 3, no high-frequency sound was generated in any of Examples 12 to 14.
[0090]
[Table 3]

[0091]
(Test evaluation 4)
Test evaluation was performed to determine whether or not the affinity-imparting component was added and the effect of the addition amount on the physical properties of the molded article.
[0092]
<Test evaluation sample>
A molding resin material according to each of the following examples was prepared. Table 2 shows each configuration.
[0093]
-Example 15-
A lump-shaped urethane resin composition (urethane foam resin) extracted from a scrapped automobile sheet was pulverized by a roll-type pulverizer controlled at 150 ° C., and sieved to separate only those having a particle size of 60 μm. Further, a PP resin composition extracted from a bumper of a scrapped car was formed into chips by a crusher. Next, the powdery or granular urethane resin composition and the PP resin composition were put into a kneader chamber in equal amounts by mass and kneaded to form a composite. Then, a molding resin material formed by chipping the composite with a crusher was used as Example 15.
[0094]
-Example 16-
0.5% of an affinity imparting component A (Umex 1010 manufactured by Sanyo Chemical Industries, Ltd.), which is a carboxyl group-containing olefin resin, based on the weight sum of the urethane resin composition and the PP resin composition, and a hydroxyl group and a carboxyl group A molding resin material having the same configuration as that of Example 15 was used as Example 16 except that 0.5% of a contained rosin (Pine Crystal KR-85 manufactured by Arakawa Chemical Industries, Ltd.) was added.
[0095]
-Example 17-
Example 15 except that 2% of an affinity-imparting component A (Umex 1010 manufactured by Sanyo Kasei Kogyo Co., Ltd.), which is a carboxyl group-containing olefin resin, was added to the mass sum of the urethane resin composition and the PP resin composition. A molding resin material having the same configuration as that of Example 17 was used.
[0096]
-Example 18-
Affinity-imparting component A (Umex 1010 manufactured by Sanyo Kasei Kogyo Co., Ltd.), which is a carboxyl group-containing olefin resin, is 2% with respect to the mass sum of the urethane resin composition and the PP resin composition, and a hydroxyl group and a carboxyl group-containing rosin A molding resin material having the same configuration as that of Example 15 except that 2% (Pine Crystal KR-85 manufactured by Arakawa Chemical Industries, Ltd.) was added was used as Example 18.
[0097]
<Test evaluation method>
With respect to the molding resin material according to each example, the test evaluation was performed in the same manner as in Test Evaluation 1 for the flexural modulus, bending strength, Izod impact value, tensile strength, and elongation at break.
[0098]
<Test evaluation results>
Table 4 shows the test results.
[0099]
FIG. 13 shows the bending elastic modulus and the bending strength of a molded product obtained by injection-molding the molding resin material according to each example. According to the figure, it can be seen that Examples 16 to 18 in which the affinity-imparting agent was added had higher flexural modulus and flexural strength than Example 15 in which the affinity-imparting component was not added. This is considered to be because the addition of the affinity-imparting material improved the dispersibility of the urethane resin composition and, as a result, increased the uniformity of the resin material for molding. Further, comparing Examples 16 to 18, it can be seen that the effect increases as the amount of the affinity-imparting component added increases.
[0100]
14 shows the Izod impact value of a molded product obtained by injection-molding the molding resin material according to each example, FIG. 15 shows the tensile strength, and FIG. 16 shows the elongation at break. As is clear from these figures, all of the Izod impact value, the tensile strength and the elongation at break were smaller in Examples 16 to 18 in which the affinity-imparting component was added than in Example 15 in which the affinity-imparting component was not added. Is higher. The reason is considered to be the same as in the case of the bending elastic modulus and the bending strength. In addition, the effect is larger as the amount of the affinity-imparting component is larger, as in the above case.
[0101]
[Table 4]

[0102]
(Test evaluation 5)
Test evaluation was performed on the effect of the presence or absence of the antioxidant and the amount of the addition on the moldability of the resin material for molding.
[0103]
<Test evaluation sample>
A molding resin material according to each of the following examples was prepared. Table 5 shows each configuration.
[0104]
-Example 19-
A lump-shaped urethane resin composition (urethane foam resin) extracted from a scrapped automobile sheet was pulverized by a roll-type pulverizer controlled at 150 ° C., and sieved to separate only those having a particle size of 60 μm. Further, a PP resin composition extracted from a bumper of a scrapped car was formed into chips by a crusher. Next, the powdery or granular urethane resin composition and the PP resin composition were put into a kneader chamber in equal amounts by mass and kneaded to form a composite. A molding resin material formed by chipping the composite with a crusher was used as Example 19.
[0105]
-Example 20-
High molecular weight hindered phenolic antioxidant A (Adeka Stab AO-60 manufactured by Asahi Denka Kogyo Co., Ltd., chemical name: tetrakis [methylene-3- (4 ′)), based on the weight sum of the urethane resin composition and the PP resin composition. -Hydroxy-3 ', 5'-di-t-butylphenyl) propionate]) and 3% of phosphite-based antioxidant B (Adeka Stab 2112 manufactured by Asahi Denka Kogyo Co., Ltd. Chemical name: Tris (2,4-di- A molding resin material having the same constitution as that of Example 19 except that 3% of t-butylphenyl) phosphite)) was added was used as Example 20.
[0106]
-Example 21-
Except that 1% of a hindered phenolic antioxidant A and 1% of an aromatic phosphite-based antioxidant B are added to the total weight of the urethane resin composition and the PP resin composition. A molding resin material having the same configuration as that of Example 19 was used as Example 21.
[0107]
-Example 22-
Antioxidant A is 0.5% and high molecular weight thioether-based antioxidant C (Adeka Stab AO-23 manufactured by Asahi Denka Kogyo Co., Ltd., based on the total weight of the urethane resin composition and the PP resin composition, chemical name: 2 A molding resin material having the same composition as in Example 19 except that 1% of 2,2'-thiodiethylbis [3- (3,5-di-t-butyl-4-hydroxyphenyl) propionate]) was added. 22.
[0108]
-Example 23-
The hindered phenolic antioxidant A is 0.5% and the hindered phenolic antioxidant D (BHT manufactured by Takeda Pharmaceutical Co., Ltd., chemical name: 2) is based on the total weight of the urethane resin composition and the PP resin composition. , 6-di-t-butyl-4-methylphenol) was added to 1% of the molding resin material of Example 19 except that 1% was added.
[0109]
<Test evaluation method>
The molding resin material according to each of the above examples is melted at 180 ° C., injection-molded, and then melted at 195 ° C. and injection-molded. Molding was performed. Then, the molded product was observed from the viewpoints of the presence or absence of resin material defects and burns, and the difference between the upper limit temperature and the lower limit temperature at which a good molded product was obtained was defined as the molding temperature width.
[0110]
Further, the spiral flow of the molding resin material according to each example was measured.
[0111]
<Test evaluation results>
Table 5 shows the test results.
[0112]
FIG. 17 shows the molding temperature range of the molding resin material according to each example. According to the figure, it can be seen that the molding temperature range is wider in Examples 20 to 23 in which the antioxidant is added than in Example 19 in which the antioxidant is not added. This is considered to be because radicals generated on the molecular chains of the urethane resin exposed to high temperatures are trapped by the antioxidant. In addition, comparing Examples 20 to 23, it can be seen that the effect increases as the amount of the added antioxidant increases.
[0113]
FIG. 18 shows a spiral flow of the molding resin material according to each example. According to the figure, it can be seen that the spiral flow is longer in Examples 20 to 23 in which the antioxidant was added than in Example 19 in which the antioxidant was not added. This is thought to be due to the fact that the moldability of the molding resin material was improved as described above due to the presence of the antioxidant. In addition, comparing Examples 20 to 23 in which an antioxidant was added, except that in Example 23, the larger the amount of the antioxidant added, the greater the effect.
[0114]
[Table 5]

[0115]
(Test evaluation 6)
The method of compounding the powdery or granular urethane resin composition with the PP resin composition was compared and examined between a kneader and a twin-screw extruder.
[0116]
<Test evaluation sample>
Resin mixtures according to the following examples were prepared. Table 6 shows each configuration.
[0117]
-Example 24-
The urethane resin composition (urethane foam resin) extracted from the sheet of the scrapped automobile was pulverized by a roll-type pulverizer adjusted to 150 ° C., and sieved to separate only those having a particle size of 60 μm. Further, a PP resin composition extracted from a bumper of a scrapped car was formed into chips by a crusher. Then, the powdery or granular urethane resin composition and the PP resin composition are mixed so that the mass ratio (urethane / PP) = 80/20, and 3 to the mass sum of both resin compositions is added thereto. % Of an affinity imparting component (Umex 1010 manufactured by Sanyo Kasei Kogyo KK) and 1% of an antioxidant (Adeka Stab AO-60 manufactured by Asahi Denka Kogyo KK) were used as a resin mixture.
[0118]
-Example 25-
Example 25 was a resin mixture having the same constitution as that of Example 24 except that the mass ratio between the urethane resin composition and the PP resin composition was urethane / PP = 50/50.
[0119]
-Example 26-
Example 26 was a resin mixture having the same constitution as that of Example 24 except that the mass ratio between the urethane resin composition and the PP resin composition was urethane / PP = 45/55.
[0120]
-Example 27-
Example 27 was a resin mixture having the same constitution as that of Example 24 except that the mass ratio between the urethane resin composition and the PP resin composition was set to be urethane / PP = 40/60.
[0121]
-Example 28-
Example 28 was a resin mixture having the same constitution as that of Example 24 except that the mass ratio between the urethane resin composition and the PP resin composition was set to be urethane / PP = 30/70.
[0122]
<Test evaluation method>
The resin mixture according to each of the above examples was kneaded with a kneader and a twin-screw extruder, respectively. Then, for the composite of the resin mixture, a test piece for an Izod impact test was injection-molded, and an Izod impact test was carried out in the same manner as in Test Evaluation 1 to calculate an Izod impact value.
[0123]
<Test evaluation results>
Table 6 shows the test results. According to the table, when the mixture is kneaded by a batch method while being sealed by a kneader, the mixture can be kneaded at a mass ratio (urethane / PP) of the urethane resin composition to the PP resin composition of 50/50 or less. It can be seen that when the mixture is kneaded in a continuous manner while being sealed by a twin-screw extruder, kneading cannot be performed unless the mass ratio (urethane / PP) is 40/60 or less. Moreover, the Izod impact value of a molded product obtained by injection-molding a molding resin material formed by kneading is about five times that obtained by kneading with a kneader than that obtained by kneading with a twin-screw extruder. That is, it was confirmed that the dispersibility of the urethane resin composition can be improved by kneading in a batch system using a closed kneader such as a kneader.
[0124]
[Table 6]

[0125]
(Test evaluation 7)
Physical properties and sound properties of a molding resin material obtained by dispersing a crosslinked elastomer comprising a urethane resin composition and a crosslinked rubber composition as a dispersant in a matrix of a PP resin composition were evaluated.
[0126]
<Test evaluation sample>
Resin mixtures according to the following examples were prepared. Table 7 shows each configuration.
[0127]
-Example 29-
A lump-shaped urethane resin composition (urethane foam resin) extracted from a scrapped automobile sheet was pulverized by a roll-type pulverizer adjusted to 150 ° C., and sieved to separate only those having a particle size of 20 μm or less. Further, the weather strip (crosslinked rubber composition) removed from the scrapped automobile was finely pulverized and sieved to separate only those having a particle diameter of 20 μm or less. Further, the PP resin composition extracted from the bumper of the scrapped automobile was made into a chip shape by a crusher. The mass ratio (urethane / rubber / PP) = 45 of the powdery or granular urethane resin composition, the powdery or granular crosslinked rubber composition (the above, crosslinked elastomer), and the PP resin composition. / 5/50 into a kneader chamber, and 3% of an affinity-imparting component (Umex 1010 manufactured by Sanyo Kasei Kogyo Co., Ltd.) and 1% of an antioxidant (Asahi ADK STAB AO-60 manufactured by Denka Kogyo Co., Ltd. was charged, and kneaded to form a composite. A molding resin material formed by chipping the obtained composite with a crusher was used as Example 29. In the molding resin material according to Example 29, the rubber mass fraction of the crosslinked elastomer as the dispersant was 10% (urethane mass fraction of 90%).
[0128]
-Example 30-
A molding resin material having the same configuration as that of Example 29 except that the mass ratio of the urethane resin composition, the crosslinked rubber composition, and the PP resin composition was set to be urethane / rubber / PP = 40/10/50. Example 30 was used. In the resin material for molding according to Example 30, the rubber mass fraction of the crosslinked elastomer as the dispersant was 20% (urethane mass fraction of 80%).
[0129]
-Example 31-
A molding resin material having the same configuration as that of Example 29 except that the mass ratio of the urethane resin composition, the crosslinked rubber composition, and the PP resin composition was set to be urethane / rubber / PP = 25/25/50. Example 31 was used. In the molding resin material according to Example 31, the rubber mass fraction of the crosslinked elastomer that is the dispersant is 50% (urethane mass fraction 50%).
[0130]
-Example 32-
A molding resin material having the same configuration as that of Example 29 except that the mass ratio of the urethane resin composition, the crosslinked rubber composition, and the PP resin composition was set to be urethane / rubber / PP = 15/35/50. Example 32 was used. In the molding resin material according to Example 32, the rubber mass fraction of the crosslinked elastomer which is the dispersant is 70% (the urethane mass fraction is 30%).
[0131]
<Test evaluation method>
Each of the molding resin materials according to Examples 29 to 32 is injection-molded to form a plate-like molded product, and the flexural modulus, flexural strength, The Izod impact value, tensile strength and elongation at break, as well as sound pressure, decay time and the presence or absence of high frequency sound when a molded product was hit with a glass ball were measured or observed.
[0132]
<Test evaluation results>
Table 7 shows the test results.
[0133]
FIG. 19 shows the relationship between the rubber mass fraction of the crosslinked elastomer, the flexural modulus and the flexural strength. According to the figure, although all of the bending characteristics are almost the same level regardless of the rubber mass fraction, it can be seen that there is a tendency for the bending properties to increase slightly as the rubber mass fraction increases. FIG. 20 shows the relationship between the rubber mass fraction of the crosslinked elastomer and the Izod impact value. According to the figure, it can be seen that the Izod impact value is almost the same level regardless of the rubber mass fraction. FIG. 21 shows the relationship between the rubber mass fraction of the crosslinked elastomer and the tensile strength. According to the figure, it is understood that the tensile strength is also substantially the same level regardless of the rubber mass fraction. FIG. 22 shows the relationship between the rubber mass fraction of the crosslinked elastomer and the elongation at break. According to the figure, it can be seen that when the rubber mass fraction becomes 20% or more, the elongation at break sharply increases. As described above, the physical properties such as the flexural modulus of the molded articles of the molding resin materials of Examples 29 to 32 are such that when the rubber mass fraction is in the range of 10 to 70%, the elongation at break is greatly increased. However, it can be determined that it has substantially the same performance as Example 1 having no rubber component. That is, this means that a molded resin material having excellent physical properties can be obtained with a molding resin material having a rubber mass fraction of 0 to 70% (urethane mass fraction of 30 to 100%). Things.
[0134]
FIG. 23 shows the relationship between the rubber mass fraction of the crosslinked elastomer and the sound pressure. According to the figure, it can be seen that the sound pressure is 70 dB or less up to a rubber mass fraction of 50%, whereas the sound pressure exceeds 80 dB at a rubber mass fraction of 70%. FIG. 24 shows the relationship between the rubber mass fraction of the crosslinked elastomer and the decay time. According to the figure, the damping time is at a level of 3.2 to 3.6 msec until the rubber mass fraction is 50%, whereas the damping time is at a level of 4.5 msec at a rubber mass fraction of 70%. You can see that In other words, this means that a molded resin material having a rubber mass fraction of 0 to 50% (a urethane mass fraction of 50 to 100%) can provide a molded article having excellent sound characteristics. Things.
[0135]
As described above, in the molding resin material in which the rubber mass fraction of the crosslinked elastomer is in the range of 0 to 50% (the urethane mass fraction is 50 to 100%), it is possible to obtain a molded product excellent in both physical properties and sound properties. It becomes.
[0136]
[Table 7]

[Brief description of the drawings]
FIG. 1 is a diagram showing a schematic configuration of a kneader.
FIG. 2 is a diagram showing the shape of each test piece in a bending test, an Izod impact test, and a tensile test.
FIG. 3 is a graph showing the relationship between the particle size of the urethane resin composition, the flexural modulus and the flexural strength.
FIG. 4 is a graph showing the relationship between the particle size of the urethane resin composition and the Izod impact value.
FIG. 5 is a graph showing the relationship between the particle size of the urethane resin composition and the tensile strength.
FIG. 6 is a graph showing the relationship between the particle size of the urethane resin composition and the elongation at break.
FIG. 7 is a diagram showing a schematic configuration of a test device that measures a sound pressure and a decay time.
FIG. 8 is a graph showing the relationship between the content of the urethane resin composition and the sound pressure.
FIG. 9 is a graph showing the relationship between the urethane resin composition content and the decay time.
FIG. 10 is a graph showing the relationship between the grinding temperature of a urethane resin composition and its bulk specific gravity.
FIG. 11 is a graph showing the relationship between the bulk specific gravity of a urethane resin composition and sound pressure.
FIG. 12 is a graph showing the relationship between the bulk specific gravity of the urethane resin composition and the decay time.
FIG. 13 is a graph showing flexural modulus and flexural strength of Examples 15 to 18.
FIG. 14 is a graph showing Izod impact values of Examples 15 to 18.
FIG. 15 is a graph showing the tensile strength of Examples 15 to 18.
FIG. 16 is a graph showing the elongation at break of Examples 15 to 18.
FIG. 17 is a graph showing the molding temperature range of Examples 19 to 23.
FIG. 18 is a graph showing spiral flow molding temperature ranges of Examples 19 to 23.
FIG. 19 is a graph showing the relationship between the rubber mass fraction of the crosslinked elastomer, the flexural modulus and the flexural strength.
FIG. 20 is a graph showing a relationship between a rubber mass fraction of a crosslinked elastomer and an Izod impact value.
FIG. 21 is a graph showing the relationship between the rubber mass fraction of the crosslinked elastomer and the tensile strength.
FIG. 22 is a graph showing the relationship between the rubber mass fraction of the crosslinked elastomer and the elongation at break.
FIG. 23 is a graph showing the relationship between the rubber mass fraction of the crosslinked elastomer and the sound pressure.
FIG. 24 is a graph showing the relationship between the rubber mass fraction of the crosslinked elastomer and the decay time.
[Explanation of symbols]
10 Kneader
11 chambers
12 Lid
13 blade
70 Test equipment
71 base
72 prop
73 tubular member
74 annular member
75 Rubber String
76 Plate specimen
77 Sound collection microphone
78 oscilloscope
79 Glass Ball

Claims (4)

A molding resin material in which a powdery or granular heat-cured urethane resin composition is dispersed in a matrix of a thermoplastic resin composition,
The thermosetting urethane resin composition is extracted from a used urethane foam molded article, and the content thereof is the mass of the thermosetting urethane resin composition and the thermoplastic resin composition. 40-70% of the sum,
The thermoplastic resin composition is extracted from a used thermoplastic resin molded article coated with a thermosetting urethane resin coating, and contains the thermosetting urethane resin coating. Molding resin material. The molding resin material according to claim 1,
The heat-cured urethane resin composition has a particle size of 60 μm or less,
A resin material for molding, characterized in that: A molding resin material in which a powdery or granular crosslinked elastomer is dispersed in a matrix of a thermoplastic resin composition,
The crosslinked elastomer has a particle size of 60 μm or less, and 50% by mass or more of the crosslinked elastomer is composed of a thermosetting urethane resin composition extracted from a used urethane foam molded article, and has a content of Is 40 to 70% of the mass sum of the crosslinked elastomer and the thermoplastic resin composition,
The thermoplastic resin composition is extracted from a used thermoplastic resin molded article coated with a thermosetting urethane resin coating, and contains the thermosetting urethane resin coating. Molding resin material. A molded product obtained by molding the resin material for molding according to claim 1 into a predetermined shape.

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