JP5161593B2 - ポリプロピレン系樹脂発泡粒子の製造方法 - Google Patents
ポリプロピレン系樹脂発泡粒子の製造方法 Download PDFInfo
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- JP5161593B2 JP5161593B2 JP2008004834A JP2008004834A JP5161593B2 JP 5161593 B2 JP5161593 B2 JP 5161593B2 JP 2008004834 A JP2008004834 A JP 2008004834A JP 2008004834 A JP2008004834 A JP 2008004834A JP 5161593 B2 JP5161593 B2 JP 5161593B2
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Description
すなわち、本発明は、
耐圧容器内でポリプロピレン系樹脂粒子を分散剤と共に分散媒に分散させ、発泡剤を含ませた分散物を、加圧下で所定の発泡温度まで加熱した後、該分散物を低圧域に放出して得られたポリプロピレン系樹脂発泡粒子を加熱処理することを特徴とするポリプロピレン系樹脂発泡粒子の製造方法であって、
ポリプロピレン系樹脂発泡粒子の加熱処理温度が、ポリプロピレン系樹脂の融点より10℃〜30℃高い温度であり、かつ、加熱処理時間が50秒以上105秒以下であり、
加熱処理後のポリプロピレン系樹脂発泡粒子が示差走査熱量分析において2つの吸熱ピークを有し、かつ、示差走査熱量分析によって得られる特性値Qf、Qtが次の式(1)及び(2)を満たすポリプロピレン系樹脂発泡粒子の製造方法。
Qf<20% (1)
Qf/Qt<90% (2)
ここで、Qtは得られたポリプロピレン系樹脂発泡粒子の示差走査熱量測定により求められるDSC曲線における、低温側吸熱ピーク吸熱量と高温側吸熱ピーク吸熱量の合計に対する高温側吸熱ピークの吸熱量の比(%)を表す。
また、Qfは得られたポリプロピレン系樹脂発泡粒子表面部の示差走査熱量測定により求められるDSC曲線における、低温側吸熱ピーク吸熱量と高温側吸熱ピーク吸熱量の合計に対する高温側吸熱ピーク吸熱量の比(%)を表す。なお、発泡粒子表面部とは、発泡粒子が球状の場合、球の中心線上で表面から直径の4分の1の距離にある2点において中心線に垂直な面によってポリプロピレン系樹脂発泡粒子を切断して得られる3つの切断片のうち、中心を含まない2つの切断片であり、他方、発泡粒子が球状でない場合、粒子の重心を通る最も長い線分(長径)において最外表面から長径の4分の1の距離にある2点における長径に垂直な面において粒子を切断して得られる3つの切断片のうち、重心を含まない2つの切断片(当該表面を含む2つの切断片)である。
Qf<20% (1)
Qfが20%以上であると、型内発泡成形を行った際に、ポリプロピレン系樹脂発泡粒子間の融着が不十分になる。
Qf/Qt<90% (2)
Qf/Qtが90%以上になると、型内発泡成形を行った際、ポリプロピレン系樹脂発泡粒子間の融着が不十分になる。
1)あらかじめポリプロピレン系樹脂発泡粒子を耐圧容器内で空気加圧し、ポリプロピレン系樹脂発泡粒子中に空気を圧入することにより発泡能を付与する
2)これを2つの金型からなり、閉鎖しうるが密閉し得ない成形空間内に充填する
3)水蒸気などを加熱媒体として0.20〜0.4MPa程度の加熱水蒸気圧で3〜30秒程度の加熱時間で成形し、ポリプロピレン系樹脂発泡粒子同士を融着させる
4)このあと成形金型を水冷により、型内発泡成形体取り出し後の型内発泡成形体の変形を抑制できる程度まで冷却する
5)この後、金型を開いて型内発泡成形体を取り出す。
ポリプロピレン系樹脂(MFR=6.0g/10分、融点=145℃)100重量部に対し、造核剤として0.3重量部のタルクを添加・混合し、50mmφ単軸押出機で混練したのち造粒し、ポリプロピレン系樹脂粒子(1.8mg/粒)を製造した。
成形後の型内発泡成形体を25℃で2時間静置し、次いで65℃に温調した恒温室内に8時間静置した後、取り出し、25℃で放冷した。該型内発泡成形体を割った際に破断面に全粒子数に対しポリプロピレン系樹脂発泡粒子内で破断している粒子の割合を融着率とした。表1における評価基準は次のとおりである。
○:融着率 90%以上
△:融着率 80%以上90%未満
×:融着率 80%未満
Claims (1)
- 耐圧容器内でポリプロピレン系樹脂粒子を分散剤と共に分散媒に分散させ、発泡剤を含ませた分散物を、加圧下で所定の発泡温度まで加熱した後、該分散物を低圧域に放出して得られたポリプロピレン系樹脂発泡粒子を加熱処理することを特徴とするポリプロピレン系樹脂発泡粒子の製造方法であって、
ポリプロピレン系樹脂発泡粒子の加熱処理温度が、ポリプロピレン系樹脂の融点より10℃〜30℃高い温度であり、かつ、加熱処理時間が50秒以上105秒以下であり、
加熱処理後のポリプロピレン系樹脂発泡粒子が示差走査熱量分析において2つの吸熱ピークを有し、かつ、示差走査熱量分析によって得られる特性値Qf、Qtが次の式(1)及び(2)を満たすポリプロピレン系樹脂発泡粒子の製造方法。
Qf<20% (1)
Qf/Qt<90% (2)
ここで、Qtは得られたポリプロピレン系樹脂発泡粒子の示差走査熱量測定により求められるDSC曲線における、低温側吸熱ピーク吸熱量と高温側吸熱ピーク吸熱量の合計に対する高温側吸熱ピークの吸熱量の比(%)を表す。
また、Qfは得られたポリプロピレン系樹脂発泡粒子表面部の示差走査熱量測定により求められるDSC曲線における、低温側吸熱ピーク吸熱量と高温側吸熱ピーク吸熱量の合計に対する高温側吸熱ピーク吸熱量の比(%)を表す。なお、発泡粒子表面部とは、発泡粒子が球状の場合、球の中心線上で表面から直径の4分の1の距離にある2点において中心線に垂直な面によってポリプロピレン系樹脂発泡粒子を切断して得られる3つの切断片のうち、中心を含まない2つの切断片であり、他方、発泡粒子が球状でない場合、粒子の重心を通る最も長い線分(長径)において最外表面から長径の4分の1の距離にある2点における長径に垂直な面において粒子を切断して得られる3つの切断片のうち、重心を含まない2つの切断片(当該表面を含む2つの切断片)である。
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