JP4900778B2 - Polystyrene resin laminate sheet - Google Patents

Description

  The present invention relates to a polystyrene-based resin laminated sheet, and more specifically, a laminated sheet produced by coextrusion, which is thin and lightweight, has excellent rigidity and has the same thermoformability as a solid sheet. The present invention relates to a resin laminated sheet.

  In recent food logistics, the use of take-out lunch boxes and prepared foods, which are called the “meal” market, wrapped in packaging containers has increased, and a large amount of food packaging materials have been used. The characteristics required for these packaging containers are that the food can be cooked in a microwave oven while being wrapped in the packaging container, and has a good appearance even if it is arranged on the table as it is. In order to satisfy these requirements, a packaging container with increased rigidity by filling a polypropylene resin with a filler has been used.

However, the enforcement of the Container Recycling Law has led to a need for containers with as little resin as possible.
Therefore, the present inventors have proposed a polystyrene-based resin laminated foam sheet described in Japanese Patent Application Laid-Open No. 2000-103016 (Patent Document 1). This foam sheet is a multilayer body in which a polyolefin resin layer is laminated on at least one surface of a polystyrene resin foam layer via a resin layer, and the resin layer is made of a mixed resin of a polystyrene resin and a polyolefin resin. It will be.

  The laminated foam sheet described in Patent Document 1 satisfies microwave oven compatibility and light weight, but cannot be easily thermoformed like a solid sheet, requires a curing period, and has a large inventory space. There was a drawback. In addition, the mold cost is twice that of the conventional solid sheet, resulting in a high molding cost.

  That is, when the laminated foamed sheet is thermoformed, secondary foaming occurs due to the influence of the foaming agent remaining on the sheet, and the secondary thickness of the sheet cannot be prevented from increasing. As a result, there is a merit that rigidity is further increased, but in order to flatten the surface of the obtained container, it is necessary to press from both sides using a pair of molding dies consisting of a male mold and a female mold. The cost of molding equipment was forced to increase. On the other hand, since the thickness of the conventional solid sheet does not change when heated, vacuum forming (hereinafter referred to as “single-sided mold forming”) using a male or female (usually female) mold. The cost of the molding apparatus is low.

  In addition, containers with increased thickness due to secondary foaming have a higher height when stacked, requiring a larger inventory space and lower cost competitiveness than conventional solid sheet containers. It was.

  On the other hand, a method for obtaining a polystyrene-based resin foam sheet with little secondary foaming using carbon dioxide as a foaming agent has been proposed. Since carbon dioxide gas dissipates from the foamed sheet at an early stage, the foamed sheet made of carbon dioxide gas only slightly increases in thickness due to secondary foaming at the time of thermoforming, so it is possible to mold on one side and obtain a good product It has sex. However, in reality, when polystyrene resin is foamed using carbon dioxide gas as a foaming agent, the plasticizing effect of carbon dioxide gas on the resin is low, and the resin temperature rises, so that only a very brittle foam sheet can be obtained. As a result, the sheet after the extrusion foaming was cracked before it was put on an annular cooling device called a mandrel, or the sheet was cracked when the cylindrical foamed sheet was cut in the extrusion direction, and the sheet was cracked. It was virtually impossible to roll the sheet into a roll. Furthermore, the polystyrene-based resin foam sheet obtained by carbon dioxide gas has the property of increasing the strain in the extrusion direction, the shrinkage balance after heating is poor, and a sheet having good thermoformability cannot be obtained. Therefore, in the prior art, a polystyrene-based resin foam sheet produced using carbon dioxide as a foaming agent, which is thin and lightweight but has excellent rigidity and good thermoformability has been put to practical use. There is no reality.

JP 2000-103016 A

  The present invention is a polystyrene-based resin laminate having a foamed layer that has improved brittleness, is lightweight, has a high rigidity, and can be molded on one side even though it is a sheet with a low secondary foaming ratio. It is an object to provide a sheet. Furthermore, the present invention provides a polystyrene-based resin laminated sheet that can be easily heat-bonded with a printed film that is compatible with a microwave oven, has excellent heat resistance and oil resistance, is rich in design, and has a high degree of freedom in design selection. The purpose is to do.

According to this invention, the polystyrene-type resin foam sheet shown below is provided.
[1] Non-main component mainly composed of a mixed resin composed of 40 to 70% by weight of polystyrene resin, 15 to 50% by weight of polypropylene resin, and 5 to 25% by weight of styrene elastomer (however, the total is 100% by weight). the foamed synthetic resin layer possess on both sides, the annular foaming agent tubular polystyrene type resin foamed layer formed using a co-extrusion extrusion City, the tubular polystyrene resin foamed layer mainly composed of carbon dioxide A polystyrene-based resin laminated sheet obtained by slitting in the extrusion direction while being taken through a cooling device , having a thickness of 0.3 to 1.7 mm, a density of 0.26 to 0.39 g / cm ³ , and a closed cell ratio There 75% or more, the secondary expansion ratio of 1.7 times or less, a polystyrene-based resin laminate sheet of heat shrinkage rate and satisfies the following relationship (1) and (2) below.
1.3 <Heating Shrinkage Ratio in the Extrusion Direction / Heating Shrinkage Ratio in the Width Direction orthogonal to the Extrusion Direction <3.0 (1)
20% <Heat shrinkage rate in extrusion direction (%) <55% (2)
[2] basis weight 460 g / m ² or less, a polystyrene-based resin laminate sheet according to the above [1] to the front and rear total basis weight of the non-foamed synthetic resin layer is characterized in that it is 160 g / m ² or less.
[3] The polystyrene resin laminated sheet according to [1] or [2], wherein the polypropylene resin contained in the non-foamed synthetic resin layer has a melting point of 150 ° C or higher.
[4] The non-foamed synthetic resin layer has a phase structure index PI value obtained from the following formula (5) of 0.7 to 1.3, and the polystyrene-based resin foam layer has a polystyrene-based resin as a main component and polypropylene. The polystyrene resin laminated sheet according to any one of claims 1 to 3, which does not contain a resin.
PI value = η _A · φ _B / η _B · φ _A (5)
Where φ _A is the volume fraction of the polystyrene resin phase in the resin layer, η _A is the melt viscosity of the polystyrene resin at 200 ° C. and a shear rate of 100 sec ⁻¹ , and φ _B is the volume of the polypropylene resin phase in the resin layer. The fraction, η _B, is the melt viscosity of the polypropylene resin at 200 ° C. and a shear rate of 100 sec ⁻¹ .
[5] The polystyrene according to [4], wherein a polystyrene resin film or a polypropylene resin film is laminated on the non-foamed synthetic resin layer surface on at least one side of the polystyrene resin foam sheet by a thermal laminating method. -Based resin laminate sheet.

The polystyrene-based resin laminated sheet according to claim 1 of the present invention (hereinafter sometimes referred to as the first laminated sheet of the present invention) contains a specific amount of a polystyrene-based resin, a polypropylene-based resin, and a styrene-based elastomer. having a non-foamed synthetic resin layer which is on both sides, a cylindrical formed using a blowing agent consisting mainly of carbon dioxide polystyrene resin foam layer coextruded City, the tubular polystyrene resin foamed layer It is obtained by slitting in the extrusion direction while being taken through an annular cooling device , and the density of the entire laminated sheet is 0.26 to 0.39 g / cm ³ (assuming that the entire laminated sheet is made of polystyrene resin. as the expansion ratio is high lamination sheet closed cell content which is foamed to approximately 2.7 to 4-fold), below 1.7 times the secondary expansion ratio, especially Since it has a thermal shrinkage rate, while having lightweight to meet the demands of the market, it has an improved brittleness, rich in rigidity, excellent in low stackability, but also satisfactory thermoformability. Furthermore, it is a material that can be used for single-sided die molding such as plug-assist vacuum molding as well as a solid sheet, and can contribute to cost reduction.

  Since the first laminated sheet of the present invention has a low secondary foaming rate, the obtained molded body has almost no increase in wall thickness, so that the inventory space is small and cost reduction is achieved. Moreover, since the 1st lamination sheet of this invention has a favorable heat shrink balance, its thermoformability is also good.

In addition, the polystyrene-based resin laminated sheet according to claim 5 of the present invention (hereinafter sometimes referred to as a second laminated sheet of the present invention. In addition, when referred to as a laminated sheet without particular distinction, the present invention Is a generic term for the first laminated sheet and the second laminated sheet of the present invention.) Is a non-foamed synthetic resin layer in which a specific amount of polystyrene resin, polypropylene resin, and styrene elastomer is blended. Ru laminated sheet der synthetic resin film on one side or both sides of those obtained are laminated by co-extruding the polystyrene resin foam layer having on both sides. The 2nd lamination sheet of this invention has a synthetic resin film on the surface, and can give functions, such as design nature and oil resistance, by a synthetic resin film.

  Since the second laminated sheet of the present invention has a low secondary foaming rate, it can be easily molded by single-sided mold molding, and the resulting container has almost no increase in wall thickness, so the inventory space is small and the cost is reduced. Achieved. Moreover, since the 2nd lamination sheet of this invention has a favorable heat shrink balance, its thermoformability is also good.

Hereinafter, the polystyrene resin laminated sheet of the present invention will be described in detail.
As described above, the polystyrene-based resin laminated sheet of the present invention has two aspects of the first laminated sheet of the present invention and the second laminated sheet of the present invention. The second laminated sheet of the present invention is formed by adhering a synthetic resin film to the surface of the first laminated sheet of the present invention (in this case, it is slightly lighter by the amount of the synthetic resin film to be bonded). Each of the laminated sheets has a non-foamed synthetic resin layer (hereinafter also simply referred to as a resin layer) on both surfaces of a polystyrene resin foam layer (hereinafter also simply referred to as a foam layer). A sheet having a sandwich structure is obtained by coextrusion of each of these layers. Since the laminated foam sheet has a sandwich structure, it has excellent strength even though the center layer is a foam.

In the present invention, the foam layer has a polystyrene resin as a main component, and the resin layer has a mixed resin composed of a polystyrene resin, a polypropylene resin, and a styrene elastomer as a main component. However, the resin layer may be a single layer or a plurality of layers.
In the present specification, the main component means that the foamed layer contains 70% by weight or more (preferably 85% by weight or more, more preferably 90% by weight or more) of the polystyrene-based resin. , 70% by weight or more (preferably 85% by weight or more, more preferably 90% by weight or more) of the specific mixed resin.

  The polystyrene resin constituting the foamed layer of the present invention and also added to the resin layer includes a styrene homopolymer and a copolymer, and is a structural unit derived from a styrene monomer contained in the polymer. Is at least 60% by weight or more, preferably 80% by weight or more. A preferred polystyrene resin used in the present invention is a resin containing at least 60% by weight of a structural unit represented by the following general formula (1) in the resin.

  In the general formula (1), R represents a hydrogen atom or a methyl group, Z represents a halogen atom or a methyl group, and p is 0 or an integer of 1 to 3.

  Examples of the polystyrene resin include polystyrene, rubber-modified polystyrene, styrene-acrylonitrile copolymer, styrene-butadiene-acrylonitrile copolymer, styrene-acrylic acid copolymer, styrene-methacrylic acid copolymer, and styrene-methyl methacrylate. Copolymer, styrene-ethyl methacrylate copolymer, styrene-methyl acrylate copolymer, styrene-ethyl acrylate copolymer, styrene-maleic anhydride copolymer, polystyrene-polyphenylene ether copolymer, polystyrene and Examples thereof include a mixture with polyphenylene ether.

In addition, the heat resistance of this invention laminated sheet can be improved by using the polystyrene-type resin whose Vicat softening point is 110 degreeC or more.
However, in this specification, the Vicat softening point of the resin indicates a value obtained by JIS K7206 (the test load is the method A, and the heating rate of the heat transfer medium is 50 ± 5 ° C./hour).

  In the case of the foamed layer of the present invention, a polystyrene-based elastomer may be added to these resins. However, the addition amount of the polystyrene-based elastomer in the foamed layer is preferably 10% or less. Since the present invention aims to develop a thin and rigid laminated sheet, adding too much elastomer to the foamed layer is not preferable because the impact resistance increases but the rigidity decreases. More preferably, it is 7% or less, More preferably, it is 3% or less. In other words, the rubber content is preferably 6% or less, more preferably 4% or less, and particularly preferably 2% or less.

The melt viscosity of the polystyrene-based resin is preferably 20 Pa · s or more and less than 10000 Pa · s, more preferably 100 to 5000 Pa · s, under the conditions of 200 ° C. and a shear rate of 100 sec ⁻¹ . If the melt viscosity is within the above range, foam molding is facilitated, and it becomes easy to form a high-quality foam layer. The melt viscosity of the polystyrene resin can be measured by a flow tester CFT-500, which is a melt viscosity measuring device manufactured by Shimadzu Corporation.

  The polypropylene resin used in the resin layer of the present invention includes propylene homopolymers, copolymers and blends. In the propylene copolymer, the copolymer component includes other α-olefins other than ethylene and propylene, and the α-olefin has 12 or less carbon atoms, preferably 8 or less. The content of the structural unit derived from ethylene or / and other α-olefin as the copolymer component is 20% by weight or less for a block copolymer, and 8% by weight or less for a random copolymer. It is preferable. In the blend of polypropylene resin, the blending resin includes an ethylene homopolymer, a copolymer of ethylene and an α-olefin having 3 to 12 carbon atoms, and an α having 4 to 6 carbon atoms. -The homopolymer of an olefin etc. are mentioned. In these blends, the content of the structural unit derived from propylene is 50% by weight or more, preferably 75% by weight or more.

  The propylene resin referred to in the present specification is obtained by graft polymerization of a compound having at least one double bond (for example, unsaturated carboxylic acid, vinylsilane compound, etc.) to the propylene resin. Modified propylene-based resins are also included.

  Among these polypropylene resins, preferred as the polypropylene resin used in the present invention is a polypropylene homopolymer having a melting point of 150 ° C. or higher, an ethylene-propylene block copolymer having a melting point of 150 ° C. or higher, and a melting point of 150 ° C. or lower. This is an ethylene-propylene random copolymer. However, those having a melting point of 150 ° C. or higher are more preferred because of excellent heat resistance and rigidity.

  That is, the polypropylene resin used in the present invention is more preferably a polypropylene homopolymer or an ethylene-propylene block copolymer. Furthermore, since it is excellent in coextrusion moldability, an ethylene-propylene block copolymer is more preferable. When a sheet is manufactured by coextrusion, a scale pattern due to unevenness of elongation may occur depending on the manufacturing conditions. However, if an ethylene-propylene block copolymer is used, there is no possibility of the scale pattern being generated.

When the inventors previously developed a polystyrene-based resin foam laminated sheet described in Patent Document 1, in order to obtain a foam laminated sheet excellent in deep drawing formability without stretch unevenness, an ethylene-propylene random copolymer We have found that coalescence is preferred. On the other hand, in the present invention, as described above, a polypropylene homopolymer or an ethylene-propylene block copolymer is preferable. The difference is that the first laminated sheet of the present invention is thin and has a high foamed layer density, and it is preferable to laminate a synthetic resin film on the first laminated sheet as described later. Since the basis weight of the resin layer is preferably 160 g / m ² or less, this is because there is little deviation in the thermoforming temperature range between the foam layer and the resin layer.

  In the laminated sheet of the present invention, as described above, since it is not necessary to use an ethylene-propylene random copolymer excellent in low temperature thermoformability, it is excellent in heat resistance and can be preferably used for microwave oven use, It is preferable to use a polypropylene resin having excellent rigidity even when the amount of the resin is small and having a melting point of 150 ° C. or higher.

  The styrenic elastomer added to the resin layer of the present invention has a function of compatibilizing a polystyrene resin and a polypropylene resin, and includes SEBS type, SEPS type, SBS type, SIS type, etc. Is done. The SBS-based or SIS-based one has a polystyrene crystal phase as a hard segment, and has a structure in which polybutadiene or polyisoprene is block-copolymerized as a soft segment. On the other hand, in the SEBS and SEPS series, polybutadiene and polyisoprene contained in the SBS and SIS series are highly hydrogenated to saturate double bonds in the main chain. These SEBS type, SEPS type, SBS type, SIS type and other styrenic thermoplastic elastomers are described in detail in “Plastic Age”, pages 101 to 106 (June 1985). In addition, the structural unit derived from styrene in the styrene-based elastomer is usually 10 to 65% by weight, preferably 30 to 55% by weight.

  The mixed resin constituting the resin layer in the present invention is composed of the polystyrene-based resin, the polypropylene-based resin, and the styrene-based elastomer, and the blending amount thereof is 40 to 70% by weight for the polystyrene-based resin and 15 to 15% for the polypropylene-based resin. 50% by weight and 5 to 25% by weight of styrene elastomer (however, the total is 100% by weight). When the resin layer is configured in this manner, the adhesive strength between the resin layer and the foam layer is sufficient, and as will be described later, the adhesive strength with the synthetic resin film laminated on the resin layer is also sufficient. .

The adhesive strength between the foam layer and the resin layer is preferably 40 gf / cm or more, more preferably 100 gf / cm or more, and still more preferably 150 gf / cm or more. The upper limit of the adhesive strength is usually about 500 gf / cm.
However, the adhesive strength between the foamed layer and the resin layer was obtained by cutting a test piece having a width of 25 mm from the laminated sheet and measuring it in a 90 ° peel test under a peel speed condition of 300 mm / min in accordance with JIS Z0237 ( gf / 25 mm) is divided by 2.5, and obtained as adhesive strength (gf / cm).

  When the content of the polystyrene-based resin in the resin layer exceeds 70% by weight, the adhesive strength between the resin layer and the foamed layer is improved, but as described later, when a polypropylene-based resin film is laminated on the resin layer, There is a possibility that the adhesive strength between the resin layer and the film is insufficient. On the other hand, when the content of the polystyrene resin in the resin layer is less than 40% by weight, conversely, the adhesive strength in the case of laminating the resin layer and the polypropylene resin film is improved, but the resin layer and the foamed layer There is a possibility that the adhesive strength is insufficient, and there is a possibility that the adhesive strength is insufficient when a polystyrene resin film is laminated on the resin layer of the laminated sheet. From this viewpoint, the content of the polystyrene resin in the resin layer is preferably 40 to 70% by weight, and more preferably 45 to 65% by weight.

  If the content of the polypropylene resin in the resin layer exceeds 50% by weight, the adhesive strength between the resin layer and the polypropylene resin film is improved, but the adhesive strength between the resin layer and the foamed layer may be insufficient. There is. On the other hand, when the content of the polypropylene resin in the resin layer is less than 15% by weight, on the contrary, the adhesive strength between the resin layer and the foamed layer is improved, and adhesion when a polystyrene resin film is laminated on the resin layer. Although the strength is improved, the adhesive strength between the resin layer and the polypropylene resin film may be insufficient. From this viewpoint, the content of the polypropylene resin in the resin layer is preferably 15 to 50% by weight, and more preferably 20 to 45% by weight.

  If content in the resin layer of a styrene-type elastomer is in the said range, the adhesiveness of a foam layer and a resin layer, the impact strength of a laminated sheet, and brittleness will be improved. On the other hand, when the content of the styrene elastomer exceeds 25% by weight, the rigidity is lost and the cost is increased. On the other hand, when the content of the styrene elastomer is less than 5% by weight, the entire laminated sheet becomes brittle and cannot be used as a thermoforming material.

Moreover, when the polystyrene-type elastomer is added to the resin layer, there exists an advantage that the laminated sheet of this invention can be manufactured easily. That is, the laminated sheet of the present invention is a sheet having a low expansion ratio of 0.26 to 0.39 g / cm ³ and thermoforming in the same manner as a solid sheet having a secondary expansion ratio of 1.7 times or less. It is a laminated sheet that can be made. Since such a laminated sheet cannot use a plastic foaming agent such as butane or pentane as a main component, the extruded foam layer is very fragile and tends to be cut easily when pulled strongly. However, when a styrene elastomer is added to the resin layer, the entire laminated sheet becomes rich in elasticity, and the sheet extruded from the die can be easily taken up.
In addition, since the elastomer content differs depending on the type of polystyrene elastomer, the addition amount is affected. In other words, the rubber content added to the resin layer is preferably 3 to 15% by weight, more preferably 6 to 12% by weight.

  As described above, the laminated sheet of the present invention can be suitably used as it is (the laminated sheet of the first present invention) for thermoforming applications. Moreover, the resin layer has a polystyrene resin film depending on the purpose. Even if it is a polypropylene-based resin film, it can be thermally bonded satisfactorily, and even those in which such a synthetic resin film is thermally bonded (the laminated sheet of the second invention) are suitable for thermoforming applications. It can be used.

  In order to make the adhesive strength between the foamed layer and the resin layer more excellent, in addition to the above formulation, the phase structure index PI value in the resin layer is 0.7 to 1.3, preferably 0.8 to It is preferable to select a polystyrene resin and a polypropylene resin so as to be within the range of 1.2. The phase structure index PI value indicates a mixed state of the polystyrene resin and the polypropylene resin of the resin layer, and is obtained by the following formula (5).

In the formula (5), φ _A is a volume fraction of polystyrene resin phase in the resin layer, eta _A is 200 ° C., a melt viscosity of the polystyrene resin at a shear rate of 100 sec ^-1, phi _B is polypropylene resin layer The volume fraction of the resin phase, η _B, is the melt viscosity of the polypropylene resin at 200 ° C. and a shear rate of 100 sec ⁻¹ . These melt viscosities can be measured by a flow tester CFT-500, which is a melt viscosity measuring apparatus manufactured by Shimadzu Corporation.

If the PI value of the resin layer is not less than the above range, it is possible to prevent the polypropylene resin in the resin layer from being covered with the polystyrene resin and not exposed to the adhesive surface. When both appear on the surface of the resin layer, the adhesive strength between the foam layer and the resin layer is sufficient, and the adhesive strength between the resin layer and the polypropylene resin film or polystyrene resin film is also sufficient, and the laminated sheet No delamination occurs when the is thermoformed into a container. On the other hand, if the PI value is 1.3 or less, it is possible to prevent the polystyrene resin in the resin layer from being covered with the polyolefin resin and not being exposed to the adhesive surface. By appearing on the surface of the resin layer, the adhesive strength between the polypropylene resin film or polystyrene resin film and the resin layer is sufficient, and the adhesive strength between the resin layer and the foam layer is sufficient, and the laminated sheet is thermoformed. And delamination does not occur in the container.
Eventually, when the PI value is in the range of 0.7 to 1.3, the adhesive strength between the foam layer and the resin layer is excellent.

  In addition, the volume fraction of the polystyrene resin phase and the volume fraction of the polypropylene resin phase in the formula (5) are 100 as the total volume of the polystyrene resin and the polypropylene resin used for the non-foamed synthetic resin layer. It means that the volume fraction of each of the obtained elastomers is added, and the above-mentioned PI value is set in the range of 0.7 to 1.3, and the polystyrene-based elastomer may be additionally added so as to have the above-mentioned blending ratio.

  The polystyrene-based resin laminate sheet of the present invention is produced by a conventionally known multilayer coextrusion method. That is, it is manufactured by providing a resin layer on both sides of the foamed layer and extruding it by a multilayer coextrusion method. Since the laminated sheet of the present invention is produced by a multilayer coextrusion method, the cost can be reduced by the simple process, and the adhesive strength between the foamed layer and the resin layer is high. The polystyrene-based resin, polyolefin-based resin, styrene-based elastomer and the like used for the resin layer may be dry blended in the form of pellets and then directly put into the inlet of the extruder, or may be previously melt-kneaded.

The density of the whole laminated sheet of the present invention is 0.26 to 0.39 g / cm ³ . If the density is less than 0.26 g / cm ³ , the required rigidity cannot be obtained. On the other hand, if the density is too high, the required lightness cannot be obtained. From this viewpoint, the density is preferably 0.31 to 0.39 g / cm ³ , more preferably 0.35 to 0.39 g / cm ³ .

  The measurement of the density of the laminated sheet in the present specification is obtained by randomly cutting the thickness from the laminated sheet, cutting into a square of 30 cm width and 30 cm length, and dividing the weight of the sample by the volume of the sample. .

The closed cell ratio of the laminated sheet of the present invention is 75 % or more. If the closed cell ratio is low, the rigidity of the container obtained by thermoforming may be lowered, and when used for a microwave oven, the container may be deformed and may not function as a container .

  The closed cell ratio in this specification is measured using an air comparison type hydrometer 930 type manufactured by Toshiba Beckman Co., Ltd. according to the procedure C of ASTM-D2856-70 (cut cut from a laminated sheet to 25 mm × 25 mm × sheet thickness) The sample is stacked and stored in a sample cup so as to have a thickness of 20 mm.) Using the true volume Vx of the laminated sheet (cut sample), the closed cell ratio S (% ) And obtain an average value of N = 3.

      S (%) = (Vx−W / ρ) × 100 / (Va−W / ρ) (6)

Vx: the true volume (cm ³ ) of the cut sample measured by the above method, which corresponds to the sum of the volume of the resin constituting the laminated sheet and the total cell volume of the closed cell portion in the cut sample.
Va: Apparent volume (cm ³ ) of the cut sample calculated from the outer dimensions of the cut sample used for measurement.
W: Total weight (g) of cut sample used for measurement.
ρ: Density of resin constituting the laminated sheet (g / cm ³ ) (Since the laminated sheet is substantially made of polystyrene resin, 1.05 g / cm ³ which is the density of polystyrene resin is adopted for convenience. )

The secondary foaming ratio of the laminated sheet of the present invention is 1.7 times or less. If the secondary foaming ratio is 1.7 times or less, a container can be obtained by plug assist molding as in the case of the solid sheet. That is, if the secondary thickness is increased to such an extent, a container having a flat surface can be obtained by single-sided mold forming without using male and female molds and pressing from both sides.
On the other hand, when a laminated sheet having a secondary foaming ratio of more than 1.7 times is thermoformed, the rigidity of the double foaming increases, but the sharpness of the surface that does not come into contact with the mold is inferior in single-sided mold forming, and the resulting container has an appearance. It becomes inferior to. In addition, the low stackability is lost, it is difficult to handle, and a large inventory space is required. From this viewpoint, the secondary expansion ratio is preferably 1.6 times or less, more preferably 1.5 times or less.

  Those with a secondary foaming ratio of 1 or less are those that do not undergo secondary foaming at all, and it is expected that the closed cell ratio is low or the replacement of the foaming agent and the inflow of air are not completed. Since the strength of the obtained container is insufficient, it is not preferable. Therefore, the lower limit of the secondary foaming ratio is preferably 1.1 times or more, more preferably 1.2 times or more.

The secondary foaming ratio in this specification is a numerical value obtained by dividing the thickness of the laminated sheet after heating by the thickness of the laminated sheet before heating, and is measured as follows.
The thickness of the laminated sheet before heating is determined as follows. A square with a side of 260 mm that is randomly cut from the laminated sheet so that the vertical and horizontal sides coincide with the extrusion direction (hereinafter also referred to as MD) and the width direction (hereinafter also referred to as TD) of the laminated sheet. For the sample, starting points are arbitrarily determined within ± 80 mm from the center of the sample in the extruding direction, and 7 points are determined at 10 mm intervals from the starting point to both sides in the width direction. For a total of 15 points including the starting point, the thickness of the laminated sheet is measured using a thickness gauge that can be measured to the second decimal place (for example, DIAL THICKNESS GAUGE made by PEACOCK), and the average value is taken as the laminated sheet thickness before heating. In addition, the lamination sheet thickness as described in an Example was measured by this method, and in the Example, the decimal place was rounded off to the first decimal place.

  The thickness of the laminated sheet after heating is determined as follows. Prepare a plurality of samples for calculating the laminated sheet thickness before heating, each sample for which the measurement of the sheet thickness before heating is completed is a square wooden frame material having a size of 300 mm in length, 300 mm in width, and 10 mm in thickness, Using two wooden frame materials with a square through-hole of 200 mm length and 200 mm width at the center, two laminated sheets were placed so that the center of the sample and the center of the through-hole of the wooden frame coincided with each other. The wooden frame is sandwiched from both sides, and the wooden frame is firmly fixed with a clip or a vise so that the sample and the wooden frame are not displaced without covering the through hole. A plurality of samples fixed with such a wooden frame material are prepared. Subsequently, the laminated sheet sample (No. 1) fixed in the wooden frame in such a state is placed in an air circulation oven (product number PERFECT OVEN PH-200 manufactured by Tabai Espec Co., Ltd.) adjusted to 160 ° C. After heating for 2 seconds, take it out of the oven into a room with a temperature of 25 ° C. and let it cool. Next, the laminated sheet sample (No. 2) fixed in the wooden frame is put into the same oven whose temperature is adjusted to 160 ° C. and heated for 8 seconds, then taken out from the oven into a room at a temperature of 25 ° C., and left to cool. To do. Next, the laminated sheet sample (No. 3) fixed in the wooden frame is put in the same oven whose temperature is adjusted to 160 ° C. and heated for 12 seconds, then taken out from the oven into a room with an air temperature of 25 ° C., and left to cool. To do. Further, the fourth, fifth, sixth,..., Each n-th (n is a natural number) laminated sheet sample are sequentially placed in the same oven for 16 seconds, 20 seconds, 24 seconds,... After heating for n × 4 seconds (n is a natural number), it is taken out from the oven into a room with an air temperature of 25 ° C. and left to cool. The reason why the heating time is extended by 4 seconds for a plurality of laminated sheet samples in this way is to confirm the maximum value (maximum value) of the secondary foaming ratio of the laminated sheet to be described later. If the maximum value can be confirmed, no further measurement is necessary. In addition, if the laminated sheet immediately after heating is out of the wooden frame or there is a deviation, it may not show the correct secondary foaming ratio, so use another laminated sheet sample of the same lot. Measure again.

Next, for each of the laminated sheet samples after cooling, the laminated sheet thickness is measured at 15 points in the width direction in the same manner as described above, and each average value is defined as the laminated sheet thickness after heating in each specified number of seconds.
By calculating (thickness of laminated sheet after heating) / (thickness of laminated sheet before heating) in each sample heated for a specified number of seconds, the secondary expansion ratio in each specified number of seconds of heating is calculated.

In general, when a foamed sheet or a laminated sheet including a thermoplastic resin foam layer has a constant heating temperature (assuming that it is within a temperature range suitable for thermoforming), the secondary foaming ratio increases as the heating time increases. growing. And when fully heated, the increase in the secondary foaming ratio stops and shows a maximum value (maximum value). After that, the overexposure of the foamed layer proceeds due to overheating and the secondary foaming ratio decreases. To go. FIG. 1 is a graph showing an example of the relationship between the secondary expansion ratio and heating time of a laminated sheet sample prepared from the above measurement results, and the “maximum value of secondary expansion ratio” in FIG. 1 is the present invention. This means “secondary expansion ratio”.
The reason for setting the heating temperature to 160 ° C. is that the ambient temperature when the laminated sheet is heated in the heating furnace in continuous production is about 160 ° C.

In the first laminated sheet of the present invention, the heat shrinkage rate satisfies the relationship of the following formulas (1) and (2).
1.3 <Heating Shrinkage Ratio in the Extrusion Direction / Heating Shrinkage Ratio in the Width Direction orthogonal to the Extrusion Direction <3.0 (1)
20% <Heat shrinkage rate in extrusion direction (%) <55% (2)
Moreover, the 2nd lamination sheet of this invention satisfies the relationship of the following (3) Formula and (4) Formula in the heat shrinkage rate.
1.3 <Heating Shrinkage Ratio in the Extrusion Direction / Heating Shrinkage Ratio in the Width Direction perpendicular to the Extrusion Direction <3.0 (3)
20% <Heat shrinkage rate in extrusion direction (%) <55% (4)

That is, the heat shrinkage rate in the extrusion direction of the laminated sheet / the heat shrinkage rate in the width direction orthogonal to the extrusion direction is less than 3.0. Ideally, the heat shrinkage rate in the extrusion direction and the heat shrinkage rate in the width direction perpendicular to the extrusion direction are the same. However, the laminated sheet of the present invention, because they are manufactured using a blowing agent consisting mainly of carbon dioxide gas as the secondary expansion ratio by coextrusion becomes 1.7 times or less, shrinkage of the MD It is not easy to make the MD and TD heat shrinkage the same. However, the range satisfying the above formula (1) or equation (3) control - if Le even, it is possible to obtain a container (molded article) which is not deformed after thermoforming.

Accordingly, the heat shrinkage ratio of MD / heat shrinkage ratio of TD is preferably 2.5 or less, and more preferably 2.2 or less.
On the other hand, in order to produce a laminated sheet so that the MD thermal shrinkage ratio / TD thermal shrinkage ratio is less than 1.3, the blow-up of the laminated sheet in the cooling process immediately after extrusion is extremely increased or taken over. The speed must be extremely slow, and in any case, the extruded laminated sheet must be forcibly deformed. As a result, the resin layer on the surface is ruptured and the closed cell ratio is reduced, so the MD heat shrinkage ratio / TD heat shrinkage ratio is required to be 1.3 or more, preferably 1.35 or more, Preferably it is 1.4 or more.

  The MD heat shrinkage ratio / TD heat shrinkage ratio of the present invention (hereinafter sometimes simply referred to as MD / TD shrinkage ratio ratio) was measured under specific conditions described later, If the formula (1) and the above formula (2) are satisfied, or if the above formula (3) and the above formula (4) are satisfied, the heating of the MD at the time of heating the laminated sheet at the time of actual thermoforming. The shrinkage rate and the heat shrinkage rate of TD can be made not so different. That is, the heat shrinkage rate of the laminated sheet of the present invention behaves as shown in FIG. 2 as the heating time elapses. Here, the heat shrinkage rate in this specification is a value when the shrinkage rate after 36 seconds from the start of heating is almost stable, but the heating during thermoforming is performed in 17 to 20 seconds from the start of heating. In the middle of the shrinkage, when the heat shrinkage rate becomes about 20% for both MD and TD, it is transferred from the heating zone to the molding zone and molded. Therefore, the MD / TD shrinkage ratio at the time of thermoforming is a value close to 1. On the other hand, the heat shrinkage ratio of MD in this specification / heat shrinkage ratio of TD is measured where the shrinkage ratio is almost stable in order to obtain a stable measurement value (see FIG. 2). The value of the shrinkage ratio is large.

Also, when the MD heat shrinkage exceeds 55%, the shrinkage force of the laminated sheet becomes too strong or the shrinking speed becomes too fast during thermoforming, and the laminated sheet comes off the clamp, and the followability to the mold is good. It becomes worse, and it becomes easy to cause trouble in molding.
On the other hand, when the MD heat shrinkage rate is less than 20%, the take-up speed of the laminated sheet in the cooling process immediately after extrusion must be extremely slowed down. At that time, when the laminated sheet is heated, uneven heating occurs, which hinders molding.

  The heat shrinkage rate in the extrusion direction of the laminated sheet in this specification (MD heat shrinkage rate) is the difference between the dimension before heating in the extrusion direction of the laminated sheet and the dimension after heating in the extrusion direction of the laminated sheet. The heating shrinkage in the width direction (TD heat shrinkage) perpendicular to the extrusion direction of the laminated sheet is the value obtained by dividing by 100 before heating and multiplying by 100. The difference between the dimension before heating and the dimension after heating in the width direction of the laminated sheet is divided by the dimension before heating in the width direction of the laminated sheet and multiplied by 100 (%). Specifically, it is measured as follows.

  First, a square sample having a side of 200 mm is cut out from the laminated sheet so that the vertical and horizontal sides coincide with the extrusion direction and the width direction of the foamed layer. Next, a straight line (A) is drawn on one side of the square sample parallel to MD and passing through the center of the surface, and crosses the sample parallel to TD and passing through the center of the same surface. Draw a straight line (B). The straight line (A) and the straight line (B) are straight lines each having a length of 200 mm. The length (200 mm) of the straight line (A) is the dimension before heating in the extrusion direction of the laminated sheet, and the length (200 mm) of the straight line (B) is the dimension before heating in the width direction of the laminated sheet. Become.

  Next, prepare two wooden frame members that are 300 mm long, 300 mm wide, and 10 mm thick square wooden frame materials, each having a central 250 mm long and 250 mm wide horizontal through hole. . A wire having a circular cross section with a diameter of 0.1 mm is used on one surface of each wooden frame member, and the wire is fixed with a nail so as to form a net-like shape with an interval of 20 mm vertically and horizontally on the through hole. In addition, when the through-hole of the wooden frame member is viewed from the side opposite to the side on which the wire is fixed, the wire has a coarse mesh shape in which 12 wires are arranged vertically and horizontally at intervals of 20 mm. Next, wooden spacers having a length of 20 mm, a width of 10 mm, and a thickness of 5 mm are fixed to the four corners on the wire fixing side frame of one of the wooden frame members.

  Next, the square sample is fixed by the frame or the spacer in the space formed by the spacer and the wire formed when the two wooden molds are brought into contact with the side to which the wire is fixed. In this state, the two wooden molds are firmly fixed with clips or a vise. On the other hand, the temperature in the apparatus of the air circulation type oven (product number PERFECT OVEN PH-200 manufactured by Tabai Espec Co., Ltd.) is set to 160 ° C., and the square sample is placed in the two wooden molds therein. After heating for 36 seconds, take it out from the oven into a room at 25 ° C. and let it cool. Thereafter, the length of the straight line or curve (a) corresponding to the straight line (A) before heating and the length of the straight line or curve (b) corresponding to the straight line (B) before heating are measured. In this case, the length of the straight line or the curve (a) is a dimension after heating in the extrusion direction of the laminated sheet, and the length of the straight line or the curve (b) is a dimension after heating in the width direction of the laminated sheet. Based on these measurement results, the heat shrinkage rate of MD and the heat shrinkage rate of TD are calculated.

The reason for setting the heating temperature to 160 ° C. is that the ambient temperature when the laminated sheet is heated in the heating furnace in continuous production is about 160 ° C. In addition, the reason for heating in the oven with the square sample placed in the above-mentioned wooden frame material is that the heating of the sample is not hindered (arrangement of a coarse mesh wire), and the sample shrinks during heating. (Arrangement of wooden spacers), making it difficult to bend the sample during contraction (arrangement of coarse mesh wire and wooden spacer), and measuring the dimensions after heat shrinkage is easy.

The thickness of the laminated sheet of the present invention is 0.3 to 1.7 mm. If the thickness is 0.3 mm or more, the resulting container has sufficient strength to withstand practical use. On the other hand, if it is 1.7 mm or less, the container obtained by single-sided mold forming will be excellent in sharpness, and low stacking will be possible. From this viewpoint, the thickness of the laminated sheet is more preferably 0.6 to 1.3 mm.

The basis weight of the laminated sheet is preferably 460 g / ^{m 2} or less, more preferably 420 g / ^{m 2} or less, more preferably 380 g / ^{m 2} or less. If該坪weight of 460 g / ^{m 2} or less, compared to the basis weight of conventional solid sheet (approximately 500 g / ^{m 2),} weight reduction can be achieved. Although the minimum of basic weight is based also on the shape of a container, it is about 130 g / m < ² > in general, More preferably, it is 160 g / m < ² > or more, More preferably, it is 180 g / m < ² > or more. If it is 130 g / m ² or less, the rigidity of the container may not be satisfied.

  In the laminated sheet of the present invention, a plurality of layers or a single layer resin layer is provided on both surfaces of a foamed layer made of a polystyrene resin, and the basis weight ratio of the front and back of the resin layer is basically preferably 1: 1. It is not limited to that. However, the limit is generally 1: 4, preferably 1: 3, and more preferably 1: 2. By arranging the resin layers on both sides in a well-balanced manner, sufficient strength is ensured even with a thin sheet. If there is too much bias between the front and back, it deviates from the design philosophy aiming at giving strength by the sandwich structure, and it becomes a laminated sheet having substantially weak strength.

160 g / m ² or less is preferable, the total basis weight of the resin layers on the front and back of the laminated sheet is preferably 120 g / m ² or less, and more preferably 100 g / m ² or less. If the total basis weight of the resin layer is 160 g / m ² or less, as will be described later, when the synthetic resin film is pressure-bonded and laminated on the resin layer with a hot roll, the amount of heat required to soften the resin layer is set. Since it can supply easily, the adhesive strength of a printing film and a resin layer will become enough. On the other hand, the lower limit of the total basis weight of the resin layer is preferably 40 g / m ² or more, more preferably 60 g / m ² , and still more preferably 80 g / m ² or more in order to ensure sufficient rigidity.

The first laminated sheet of the present invention has a non-foamed synthetic resin layer on both surfaces thereof, and a second laminated sheet can be obtained by laminating a synthetic resin film on at least one of the resin layers. it can. In that case, the basis weight of the resin layer on which the synthetic resin film is laminated is preferably 80 g / m ² or less, more preferably 65 g / m ² or less, and still more preferably 50 g / m ² or less. A printed film can be easily adhered to the resin layer having a basis weight of 80 g / m ² or less by thermal lamination. For example, when the resin layers of the front and back are 160 g / m ^{2 in} total, and the basis weight of one resin layer is 120 g / m ² and the other basis weight is 40 g / m ² , the basis weight is 40 g / m ^2. Although the resin layer of the m ² can be bonded easily printed film, it is difficult to basis weight adhering the printed film on the resin layer of 120 g / m ^2.
In addition, although it can laminate | stack if a synthetic resin film is laminated at a low speed on the resin layer side with a basis weight of 120 g / m < ² >, it is not preferable from a viewpoint of industrial profitability.

  As a synthetic resin film laminated | stacked on the 2nd lamination sheet of this invention, a polypropylene resin film or a polystyrene resin film is preferable. However, the present invention is not limited to these films, and may be a high-density polyethylene resin film or a linear polyethylene resin film.

In particular, in order to obtain a container that can be cooked in a microwave oven, it is preferable to laminate a polypropylene resin film having excellent heat resistance and oil resistance. The film may be either a plain film for imparting heat resistance and oil resistance, or a printed film for imparting design properties.
The polypropylene resin constituting the film may be a polypropylene homopolymer, an ethylene-propylene block copolymer, or an ethylene-propylene random copolymer, but because of its excellent rigidity, a polypropylene homopolymer resin film. Is most preferred.

  However, even when a container for microwave ovens is obtained, a polystyrene resin film can be used as the film laminated on the outside of the container.

  Although the thickness of a synthetic resin film is selected suitably, 15-60 micrometers is preferable. If the thickness of the film is 15 μm or more, it contributes to improvement of heat resistance and oil resistance and can be easily laminated. On the other hand, when the thickness is 60 μm or less, the cost is not increased excessively and the layers can be easily stacked.

  When producing a laminated sheet having a resin layer on both sides of a foam layer by coextrusion of the present invention, an annular die is attached to the foam layer forming extruder, and an unfoamed layer forming extruder is connected to the annular die. It is preferable to perform coextrusion by forming resin layers on both sides of the foam layer by joining them in an annular die attached to the foam layer forming extruder.

  Furthermore, in order to obtain the 2nd lamination sheet by which the synthetic resin film was laminated | stacked, synthetic resin films, such as a polypropylene resin film or a polystyrene resin film, are heated to the obtained 1st lamination sheet as needed. It is preferable to laminate by pressure bonding with (thermal laminating method). In addition, when a synthetic resin film is pressure-bonded with a heat roll and laminated by a thermal laminating method, the thermal shrinkage rate of the second laminated sheet on which the synthetic resin film is laminated depends on the heat at the time of film lamination, and the synthetic resin film Since the heat shrinkage rate of the first laminated sheet before lamination is slightly relaxed, it is desirable not to increase the heating at the time of laminating the synthetic resin film.

The thermal laminating method is a preferable method because various containers having excellent appearance can be obtained by selecting and laminating a film having excellent design properties for each container.
However, if a synthetic resin film may be laminated on one or both sides of the resin layer of the laminated sheet using a T-die, a resin layer is laminated on both sides of the foamed layer by coextrusion and further synthesized on one or both sides. A resin film may be laminated and extruded. However, in the case of coextrusion, if the basis weight of both the resin layer and the synthetic resin film is not 160 g / m ² or less, the ratio of open cells in the foam layer may increase.

The foaming agent used in forming the foamed layer, composed mainly of carbon dioxide (ratio of carbon dioxide in the blowing agent total amount more than 50 mol%) Ru with what you. If carbon dioxide gas is the main component, a desired laminated foam sheet having a low secondary foaming rate can be easily obtained. However, there is no problem in using other foaming agents mixed with carbon dioxide.

Examples of the blowing agent to be mixed with carbon dioxide include propane, n-butane, i-butane, a mixture of n-butane and i-butane, pentane, hexane aliphatic hydrocarbon, cyclobutane, cyclopentane, cyclohexane Aliphatic hydrocarbons are mentioned.
Ethanol or the like can also be used favorably. As will be described later, the thermal contraction rate of the laminated sheet can be controlled to be small by using the above foaming agent other than carbon dioxide as the foaming agent. However, in order to achieve a secondary foaming ratio of 1.7 times or less, it is necessary to select a foaming agent that hardly remains.

  The above-mentioned thing can be used as a polystyrene-type resin which forms a foamed layer, The above-mentioned thing can be used by the said mixing | blending as a polystyrene-type resin, a polypropylene-type resin, and a styrene-type elastomer which form a resin layer.

  Shrinkage in the extrusion direction (MD) can be adjusted by swell control with a die lip. In particular, the laminated sheet of the present invention obtained by coextrusion is likely to be strained in the extrusion direction (MD), and the thermal shrinkage value tends to increase. Furthermore, when forming a foamed layer with carbon dioxide gas as the main component, the tendency becomes stronger, so it is important to control the heat shrinkage value of the resulting laminated sheet. In order to control the heat shrinkage rate to a small value, as shown in FIGS. 3A and 3B, the molten resin passage 3 immediately before the die outlet (slit) 4 constituted by the outer lip 1 and the inner lip 2 is used. It is effective to increase the resin speed at the lip outlet. Furthermore, in order to make the thermal contraction rate of MD of the laminated sheet of the present invention within the range of the present invention, the drawing angle θ of the molten resin passage 3 immediately before the die outlet (slit) 4 (θ shown in FIG. 3B) ) Is preferably about 3 to 7 degrees. The interval between the outer lip 1 and the inner lip 2 in the slit 4 is suitably 0.1 to 1.0 mm.

  The blow-up ratio affects the heat shrinkage in the width direction (TD) perpendicular to the extrusion direction. The appropriate blow-up ratio varies somewhat depending on the target sheet structure, but 2.8 to 3.2 is generally good for obtaining the heat shrinkage within the range of the present invention.

  In order to control the heat shrinkage rate to be small, it is preferable to blend a secondary component such as n-butane, pentane and ethanol other than carbon dioxide with the foaming agent, and in particular, the effect of reducing the heat shrinkage rate in the extrusion direction (MD). There is. However, if it is added too much, it remains as a residual gas, and it becomes impossible to achieve a target laminated sheet having a secondary foaming rate of 1.7 times or less. The amount of addition is generally up to 35% by weight of the total foaming agent.

  In addition, a polystyrene foam sheet using carbon dioxide gas as a foaming agent has a small expansion ratio, but does not exhibit a plasticizing effect due to the foaming agent, so that the foam layer is brittle and easily cut. Therefore, it is not easy to take out the sheet extruded from the die, and the range of extrusion conditions for obtaining a sheet having a particularly small thickness is narrow, and the conventional technology cannot be industrially manufactured. On the other hand, in the present invention, by providing resin layers on both sides of the sheet and adding 5 to 25% by weight of a polystyrene-based elastomer, the entire laminated sheet is excellent in elasticity, so that it is extruded from a die. The laminated sheet can be easily taken up.

However, if the basis weight of both sides of the resin layer is increased too much, the foam layer tends to be heated too much in the coextrusion die, and the closed cell ratio tends to decrease. Is preferably 160 g / m ² or less.

  Addition of a polystyrene-based elastomer to the foamed layer improves elasticity (impact resistance) but decreases rigidity and tends to reduce the closed cell ratio of the foamed layer. Cannot be achieved. From this viewpoint, the amount of the polystyrene-based elastomer added to the foamed layer is preferably 10% or less.

  Hereinafter, the laminated sheet of the present invention will be described in detail with reference to examples. However, the present invention is not limited to the examples.

  In both Examples and Comparative Examples, a single-axis first extruder having an inner diameter of 90 mm and a single-axis second extruder having an inner diameter of 120 mm were connected in series. A co-extrusion die is attached to the tip, and a co-extrusion die is connected to a resin layer surface forming third extruder (inner diameter 50 mm) and a resin layer rear surface forming fourth extruder (inner diameter 50 mm). An extrusion apparatus was used. However, in Examples 1 to 8 and Comparative Examples 3 and 4, a co-extrusion die having an inner lip diameter of 115 mm, a drawing angle (θ) of 5 degrees, and a gap of 0.3 mm between the outer lip 1 and the inner lip 2 in the slit 4 is used. Used (mandrel diameter 335 mm, blow-up ratio 2.9), and in Comparative Example 1, a die for coextrusion in which only the drawing angle (θ) was changed to 9 degrees was used. In Comparative Example 2, the inner lip diameter was 80 mm, A co-extrusion die with an angle of 5 degrees was used (mandrel diameter 335 mm, blow-up ratio 4.2).

  Table 1 shows the types and physical properties of the resins used to form the foamed layer in Examples and Comparative Examples. In the table, the general-purpose polystyrene resin is expressed as GPPS, the styrene-methacrylic acid copolymer resin is expressed as heat-resistant PS, and the styrene-based elastomer is expressed as SBS. MFR in Table 1 means a melt flow rate at 200 ° C. and a load of 5 kgf.

Table 2 shows the configuration, type, and physical properties of the resin used to form the resin layer. In Table 2, polystyrene resin is referred to as PS resin, polypropylene resin as PP resin, and styrene elastomer as PS elastomer. The melt viscosity in Table 2 is the melt viscosity shown in paragraph 0040. Moreover, the phase structure index PI value in Table 2 is the phase structure index PI value shown in paragraph numbers 0038 and 0039.
Table 3 shows the types of synthetic resin films laminated on the resin layer.

Example 1
General polystyrene resin (GPPS) as a polystyrene resin for the foam layer is supplied to the first extruder and heated, melted and kneaded, and the types and amounts shown in Table 4 (weight ratio with respect to the total amount of resin and foaming agent) The foaming agent was injected, adjusted to the resin temperature shown in Table 4 in the second extruder, and introduced into the coextrusion die.
At the same time, the respective resins (SP1) for the front and back resin layers having the composition shown in Table 4 are supplied to the third extruder and the fourth extruder, and heated, melted and kneaded to obtain the resin temperatures shown in Table 4. After adjustment, it was introduced into a coextrusion die.
In the co-extrusion die, the resin for the resin layer on the front side, the resin for the foam layer and the resin for the resin layer on the back are merged and laminated, then extruded through a die lip into a cylindrical shape, and then taken through a mandrel and cut to form a laminated sheet. Obtained (FIG. 3A).

  The discharge rate was 80 kg / hr for the foamed layer, and the resin layer was adjusted according to the discharge rate so as to match the target basis weight. The overall basis weight was adjusted by controlling the take-up speed to 6.3 m / min.

(Example 2)
The same as in Example 1 except that a polystyrene-based resin for the foam layer was blended with 50 wt% GPPS and 50 wt% heat-resistant PS, and the resin temperature of the foam layer and the resin temperature of the resin layer were adjusted as shown in Table 4. A laminated sheet was obtained.

Example 3
A laminated sheet was obtained in the same manner as in Example 1, and F1 which is a polypropylene resin film printed on the laminated sheet was pressure-bonded with a hot roll under the conditions shown in Table 4 to obtain a film laminated sheet.

Example 4
A laminated sheet was obtained in the same manner as in Example 1 except that the blended SP2 was used as the resin for the resin layer, the take-up speed was controlled to 5.0 m / min, and the basis weight of the laminated sheet was 350 g / m ² . A polypropylene-based resin film F2 was pressure-bonded to the obtained laminated sheet with a hot roll under the conditions shown in Table 4 to obtain a film-laminated sheet.

( Reference Example 1 )
Two types of SP1 and SP2 shown in Table 2 are laminated separately as the resin layer, and the take-up speed is set at 8.
Example 2 except that the sheet basis weight was increased to 0 m / min and the sheet basis weight was 220 g / m 2.
A laminated sheet was obtained in the same manner as above.
Next, F1 which is a polypropylene resin film was pressure-bonded and laminated on the surface side (SP1 side) under the conditions shown in Table 4 using a heat roll.

(Example 5 )
A laminated sheet was obtained in the same manner as in Example 3 except that a foaming agent in which carbon dioxide gas and n-butane were mixed at a ratio of 75% to 25% by weight was used as the foaming agent.

(Example 6 )
Implemented except changing the discharge amount of the third extruder and the fourth extruder for forming the resin layer and changing the basis weight of the resin layer on the front side to 60 g / m ² and the basis weight of the resin layer on the back side to 20 g / m ^2. A laminated sheet was obtained in the same manner as in Example 2.
Next, F1 which is a polypropylene resin film was pressure-bonded and laminated on the surface layer side under the conditions shown in Table 4 using a heat roll.

(Example 7 )
A laminated sheet in which F1 which is a polypropylene resin film is pressure-bonded in the same manner as in Example 3 is obtained except that the resin constituting the resin layer is SP3 having the structure shown in Table 2 (using propylene ethylene random copolymer as the PP resin). It was.

(Example 8 )
A laminated sheet was obtained in the same manner as in Example 1 except that a polystyrene-based resin for the foam layer was blended with 48 wt% GPPS, 47 wt% heat resistant PS and 5 wt% SBS.

(Comparative Example 1)
A laminated sheet was obtained in the same manner as in Example 1 except that the die slip aperture angle θ was 9 degrees.
The laminated sheet obtained in Comparative Example 1 frequently suffered from a problem that it was detached from the forming frame that was tightly contracted during thermoforming. Therefore, it was judged that the moldability was poor and the subsequent evaluation was not performed.

(Comparative Example 2)
A laminated sheet was obtained in the same manner as in Example 1 except that a die having an inner lip diameter of 80 mm was used and the blow-up ratio was 4.2. In Comparative Example 2, the resin layer was torn during the blow-up process during the production of the laminated sheet. In addition, the closed cell ratio slightly decreased. Since a good laminated sheet could not be obtained, proper evaluation was not performed on thermoformability, stacking height, and electron len.

(Comparative Example 3)
A laminated sheet was obtained in the same manner as in Example 1 except that a laminated sheet was obtained using the blended SP4 to which no polystyrene elastomer was added to the resin layer. The obtained laminated sheet was very brittle and very brittle, and it was judged that the physical properties were insufficient, and evaluation after thermoformability was not performed.

(Comparative Example 4)
A laminated sheet was obtained in the same manner as in Example 1 except that the resin temperature of the resin layer was increased. The laminated sheet had a reduced closed cell ratio and became a sheet subjected to rigidity. In addition, due to a large decrease in the closed cell ratio, wrinkles occurred at the bottom of the molded body in the microwave oven suitability test.

(Comparative Example 5)
A laminated sheet was obtained in the same manner as in Example 1 except that n-butane was used as the foaming agent. The obtained sheet has no problem in rigidity and impact, but when single-sided mold molding is performed, the sharpness of the molded product is poor, and the height when the molded product is stacked is high and close to the target solid sheet did not become. Therefore, the microwave oven suitability test was not evaluated.

  Table 4 summarizes the production conditions such as the foamed layer, the raw material composition of the resin layer, the resin temperature, and the die structure in each example and comparative example.

  With respect to the laminated sheets obtained in each Example and Comparative Example, various physical properties such as density and thickness were measured, and evaluations such as rigidity and suitability for microwave oven were performed. The results are shown in Table 5.

  Evaluation of rigidity, brittleness, thermoformability, stacking height, and microwave oven suitability in Table 5 was performed as follows.

(rigidity)
The bending elastic modulus of the laminated sheet was measured, and the rigidity was evaluated according to the following criteria.
◎ ・ ・ ・ Elastic modulus is 700 MPa or more ○ ・ ・ ・ Elastic modulus is 630 MPa or more and less than 700 MPa × ・ ・ ・ Elastic modulus is less than 630 MPa

The thermoformed product obtained from the laminated sheet having the evaluation ◎ is excellent in rigidity.
The thermoformed product obtained from the laminated sheet having the evaluation of ○ is sufficiently rigid and suitable for food containers.
The thermoformed product obtained from the laminated sheet having the evaluation of “x” has insufficient rigidity, and there is a risk of difficulty in holding the contents when used as a food container.

The bending elastic modulus of the laminated sheet is calculated from the value obtained by measuring the width direction (TD) of the laminated sheet and arithmetically averaging the obtained values in accordance with JIS K 7203 (1982). The measurement according to JIS K 7203 (1982) was performed using a test piece having a length of 100 mm × width of 25 mm × laminated sheet as a test piece, a fulcrum tip R = 5 (mm), a pressure tip R = 5 (mm ), The distance between fulcrums is 50 mm, and the bending speed is 10 mm / min. In addition, the measurement value about the width direction (TD) was obtained for each test piece using 10 or more test pieces collected evenly in the width direction of the laminated sheet so that the positions to be pressurized do not overlap. Five arithmetic average values were calculated from the small measured values and adopted as the flexural modulus. The reason for selecting a small measured value is that the case where the evaluation of the rigidity of the laminated sheet varies in the width direction due to non-uniformity in the width direction of the laminated sheet is taken into consideration.

(Brittle)
The impact drilling strength (F) was measured, and the brittleness was evaluated according to the following criteria.
○ ・ ・ ・ F ≧ 10kgf ・ cm
× ・ ・ ・ F <10kgf · cm

The thermoformed product obtained from the laminated sheet having the evaluation of ○ is not brittle and is suitable for food containers.
The thermoformed product obtained from the laminated sheet having the evaluation of “x” tends to crack at the end of the molded product when deformed, and in the worst case, there is a possibility of causing cracking.

The impact piercing strength is measured according to JIS P 8134 (1976). For the measurement, a test piece having a total thickness of 150 mm long × 150 mm wide × laminated sheet was used. In this test, 10 or more test pieces collected evenly in the width direction of the laminated sheet so that the striking positions do not overlap are obtained, and measurement values for each test piece are obtained. The arithmetic average value of each piece is calculated, and the value indicates the impact drilling strength (kgf · cm). The reason for selecting a small measured value is that the case where the evaluation of the rigidity of the laminated sheet varies in the width direction due to non-uniformity in the width direction of the laminated sheet is taken into consideration.

(Thermoformability)
Asano Lab. Product No. FKS-0631-10 using plug assist molding, so that the surface on which the resin layer is laminated is located on the inner side under the conditions of heater temperature 400 ° C. and heating time 7 seconds ± 1 second. The pasta tray was formed into a circular shape with a diameter of 206 mm at the opening, a circular shape with a diameter of 134 mm inside the bottom, and a depth of 24 mm, and the appearance of the molded product was observed. Evaluation was performed according to the following criteria.
○ ... Good formability (no molding defects)
X: There is a defect Note that the reason for the defect is described below in Table 5.

(Stacking height)
The sheet thickness of the bottom part of the thermoformed product of the pasta tray obtained above was measured and evaluated.
◎ ・ ・ ・ 0.5mm or more and less than 1.2mm Excellent in low stackability ○ ・ ・ ・ 1.2mm or more and less than 1.8mm Low effect but small effect × ・ ・ ・ 1.8mm or more Low stackability Absent

(Suitability for microwave oven)
The pasta tray obtained above was filled with 120 g of edible blended oil (salad oil), heated for 45 seconds in a 1600 W commercial microwave oven, and the degree of deformation and appearance of the container were observed. The average temperature of the salad oil in this test was about 100 ° C., and the partial maximum temperature was 112 ° C.
◎ ... Container external dimension change within ± 0.5mm ○ ・ ・ ・ Container external dimension change within ± 1mm,
× ・ ・ ・ Change in outer dimensions of container ± 2 mm or more, or poor appearance

  In the case of defects in appearance, the situation is listed below in Table 5.

FIG. 1 is an explanatory diagram showing an example of the relationship between the secondary foaming ratio and the heating time of a laminated sheet sample. FIG. 2 is an explanatory diagram showing an example of the relationship between the heat shrinkage rate and the heating time of the laminated sheet of the present invention. FIG. 3A is a cross-sectional view showing an outline of a main part including a die of a manufacturing apparatus in the production of a laminated sheet by an extrusion foaming method, and FIG. 3B illustrates a drawing angle θ at the tip of the die lip. It is an expanded sectional view near a die lip.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Outer lip 2 Inner lip 3 Molten resin flow path 4 Slit which is an exit of foamable molten resin 5 Cylindrical cooling drum (mandrel)
6 Cylindrical laminated sheet

Claims (5)

Non-foamed synthetic resin whose main component is a mixed resin comprising 40 to 70% by weight of a polystyrene resin, 15 to 50% by weight of a polypropylene resin, and 5 to 25% by weight of a styrene elastomer (however, the total is 100% by weight). have a layer on both sides, pull blowing agent tubular polystyrene resin foam layer coextruded city formed using a cylindrical polystyrene resin foamed layer through an annular cooling device mainly comprising carbon dioxide A polystyrene-based resin laminated sheet obtained by cutting in the extrusion direction while taking , having a thickness of 0.3 to 1.7 mm, a density of 0.26 to 0.39 g / cm ³ , and a closed cell ratio of 75 % or more. A polystyrene-based resin laminate sheet, characterized in that the secondary foaming ratio is 1.7 times or less and the heat shrinkage rate satisfies the relationship of the following formulas (1) and (2).
1.3 <Heating Shrinkage Ratio in the Extrusion Direction / Heating Shrinkage Ratio in the Width Direction orthogonal to the Extrusion Direction <3.0 (1)
20% <Heat shrinkage rate in extrusion direction (%) <55% (2) ^2. The polystyrene-based resin laminate sheet according to claim 1, wherein the basis weight is 460 g / m ² or less, and the total front and back basis weight of the non-foamed synthetic resin layer is 160 g / m ² or less.   The melting point of the polypropylene resin contained in the non-foamed synthetic resin layer is 150 ° C or higher, and the polystyrene resin laminated sheet according to claim 1 or 2. The non-foamed synthetic resin layer has a phase structure index PI value (however, the phase structure index PI value is obtained from the following formula (5)) of 0.7 to 1.3, and the polystyrene resin foam layer is a polystyrene resin. The polystyrene-based resin laminated sheet according to any one of claims 1 to 3, wherein the polystyrene-based resin does not contain a polypropylene-based resin.
PI value = η _A ・ Φ _B / Η _B ・ Φ _A     ... (5)
However, φ _A Is the volume fraction of the polystyrene resin phase in the resin layer, η _A Is 200 ° C, shear rate 100 sec ^-1 Melt viscosity of polystyrene resin at _B Is the volume fraction of the polypropylene resin phase in the resin layer, η _B Is 200 ° C, shear rate 100 sec ^-1 Is the melt viscosity of the polypropylene resin. 5. The polystyrene resin laminated sheet according to claim 4, wherein a polystyrene resin film or a polypropylene resin film is laminated on a non-foamed synthetic resin layer surface on at least one side of the polystyrene resin foam sheet by a heat laminating method. .