JP5216353B2 - 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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- JP5216353B2 JP5216353B2 JP2008029886A JP2008029886A JP5216353B2 JP 5216353 B2 JP5216353 B2 JP 5216353B2 JP 2008029886 A JP2008029886 A JP 2008029886A JP 2008029886 A JP2008029886 A JP 2008029886A JP 5216353 B2 JP5216353 B2 JP 5216353B2
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- polypropylene resin
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Description
平均気泡径(μm)≧230−8×発泡倍率 (1)
[2][1]に記載の製造方法によって得られる、ポリプロピレン系樹脂発泡粒子。
[3][2]に記載のポリプロピレン系樹脂発泡粒子を型内成形して得られる、型内発泡成形体。
測定機器:
Waters社製Alliance GPC 2000型 ゲルパーミエーションクロマトグラフィー(GPC)
カラム:
TSKgel GMH6−HT 2本、
TSKgel GMH6−HTL 2本(それぞれ、内径7.5mm×長さ300mm、東ソー社製)
移動相:o−ジクロロベンゼン(0.025%BHT含有)
カラム温度:140℃
流速:1.0mL/min
試料濃度:0.15%(W/V)−o−ジクロロベンゼン
注入量:500μL
分子量較正:ポリスチレン換算(標準ポリスチレンによる較正)
平均気泡径(μm)≧230−8×発泡倍率 (1)
一段発泡粒子が式(1)の範囲外の平均気泡径を有する場合、最終的に得られる成形体の収縮率が大きくなったり、表面性が低下したりする。
平均気泡径(μm)≧240−8×発泡倍率 (2)
本発明において平均気泡径とは後記するように見かけの平均気泡径である。図1に本発明の製造方法に用いる一段発泡粒子の発泡倍率と平均気泡径の範囲を図示する。
1)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)得られた発泡粒子を2つの金型からなる、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0.2〜0.4MPa程度のスチーム圧で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)金型を水冷する
5)金型を開いて、型内発泡成形体を取り出す。
発泡粒子3〜10g程度を取り、60℃で6時間乾燥したのち重量W(g)および水没体積V(cm3)を測定する。発泡倍率はポリプロピレン系樹脂の樹脂密度0.9(g/cm3)から次式によって計算される。
発泡倍率=V/(W/0.9)
発泡粒子から任意に10個を取り出し、気泡膜が破壊されないように充分注意して発泡粒子を切断する。切断面の拡大顕微鏡写真(×100倍)において、表層部を除く部分に長さ2mmに相当する線分を引き、該線分が通る気泡数を数える。他の9個の発泡粒子についても同様に、気泡数を数え、発泡粒子10個の気泡数の平均を平均気泡数とし、発泡粒子の平均気泡径は、2mmを発泡粒子10個の平均気泡数で除して計算される。
型内発泡成形体の乾燥重量W(g)、水没体積V(cm3)およびポリプロピレン系樹脂の樹脂密度0.9(g/cm3)から次式によって計算される。
型内発泡成形体の発泡倍率=V/(W/0.9)
収縮率は外形寸法が400mm×300mm×20mmの平板成形用金型から得られた型内発泡成形体を用いて評価した。成形後、室温で1時間静置して、つぎに75℃で3時間養生した。さらに室温で1時間静置して、型内発泡成形体の長手方向の長さを測定した。収縮率は金型の長さに対する収縮率を計算した。収縮性は次の基準により評価した。
◎:収縮率4%以下
〇:収縮率4%超で5%以下
△:収縮率5%超で6%以下
×:収縮率6%超
成形体の収縮率を評価した型内発泡成形体の表面を観察した。表面性は次の基準により評価した。
〇:しわ、粒間少なく、美麗
△:僅かなしわ、粒間あるが良好
×:しわ、ヒケがあり外観不良
ポリプロピレン樹脂(エチレン含量:4.0重量%、MFR:5.2g/10分、Mn:10万、融点:137℃)を用い、表1に示す発泡倍率、平均気泡径およびDSC比を有する一段発泡粒子を製造した。なお、得られた一段発泡粒子は示差走査熱量計測定において、ほぼ131℃と151℃に2つの融点を示した。
Claims (3)
- 共重合成分としてエチレンを3.0〜6.0重量%含み、メルトフローレート5g/10分以上15g/10分以下、融点132℃以上145℃以下であるポリプロピレン系樹脂を原料とし、発泡剤として二酸化炭素を使用して製造され、発泡倍率が7倍以上15倍以下であり、平均気泡径が500μm以下で且つ下記式(1)を満たすポリプロピレン系樹脂発泡粒子を、さらに発泡させることを特徴とする、もとの発泡粒子より高発泡倍率を有するポリプロピレン系樹脂発泡粒子の製造方法。
平均気泡径(μm)≧230−8×発泡倍率 (1) - 請求項1に記載の製造方法によって得られる、ポリプロピレン系樹脂発泡粒子。
- 請求項2に記載のポリプロピレン系樹脂発泡粒子を型内成形して得られる、型内発泡成形体。
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