JP6301760B2 - 架橋ポリエチレン系樹脂発泡粒子の製造方法及び架橋ポリエチレン系樹脂粒子の製造方法 - Google Patents
架橋ポリエチレン系樹脂発泡粒子の製造方法及び架橋ポリエチレン系樹脂粒子の製造方法 Download PDFInfo
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- JP6301760B2 JP6301760B2 JP2014141302A JP2014141302A JP6301760B2 JP 6301760 B2 JP6301760 B2 JP 6301760B2 JP 2014141302 A JP2014141302 A JP 2014141302A JP 2014141302 A JP2014141302 A JP 2014141302A JP 6301760 B2 JP6301760 B2 JP 6301760B2
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- 125000000816 ethylene group Chemical group [H]C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
- 239000005038 ethylene vinyl acetate Substances 0.000 description 1
- 229920006244 ethylene-ethyl acrylate Polymers 0.000 description 1
- 229920005680 ethylene-methyl methacrylate copolymer Polymers 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 235000011187 glycerol Nutrition 0.000 description 1
- 229910052602 gypsum Inorganic materials 0.000 description 1
- 239000010440 gypsum Substances 0.000 description 1
- DMEGYFMYUHOHGS-UHFFFAOYSA-N heptamethylene Chemical class C1CCCCCC1 DMEGYFMYUHOHGS-UHFFFAOYSA-N 0.000 description 1
- CAYGQBVSOZLICD-UHFFFAOYSA-N hexabromobenzene Chemical compound BrC1=C(Br)C(Br)=C(Br)C(Br)=C1Br CAYGQBVSOZLICD-UHFFFAOYSA-N 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- 230000036571 hydration Effects 0.000 description 1
- 238000006703 hydration reaction Methods 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 150000003949 imides Chemical class 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000001282 iso-butane Chemical class 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 239000004611 light stabiliser Substances 0.000 description 1
- 229920000092 linear low density polyethylene Polymers 0.000 description 1
- 239000004707 linear low-density polyethylene Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 description 1
- 239000000347 magnesium hydroxide Substances 0.000 description 1
- 229910001862 magnesium hydroxide Inorganic materials 0.000 description 1
- 238000000691 measurement method Methods 0.000 description 1
- 229920001179 medium density polyethylene Polymers 0.000 description 1
- 239000004701 medium-density polyethylene Substances 0.000 description 1
- 229910000000 metal hydroxide Inorganic materials 0.000 description 1
- 150000004692 metal hydroxides Chemical class 0.000 description 1
- 239000011259 mixed solution Substances 0.000 description 1
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical class CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 1
- 229920003986 novolac Polymers 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- VTRUBDSFZJNXHI-UHFFFAOYSA-N oxoantimony Chemical compound [Sb]=O VTRUBDSFZJNXHI-UHFFFAOYSA-N 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 150000003018 phosphorus compounds Chemical class 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000001294 propane Chemical class 0.000 description 1
- 230000035484 reaction time Effects 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 238000010992 reflux Methods 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 229930195734 saturated hydrocarbon Chemical class 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000004328 sodium tetraborate Substances 0.000 description 1
- 235000010339 sodium tetraborate Nutrition 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000010025 steaming Methods 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 125000001424 substituent group Chemical group 0.000 description 1
- BDHFUVZGWQCTTF-UHFFFAOYSA-M sulfonate Chemical compound [O-]S(=O)=O BDHFUVZGWQCTTF-UHFFFAOYSA-M 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 125000000999 tert-butyl group Chemical group [H]C([H])([H])C(*)(C([H])([H])[H])C([H])([H])[H] 0.000 description 1
- YLQBMQCUIZJEEH-UHFFFAOYSA-N tetrahydrofuran Natural products C=1C=COC=1 YLQBMQCUIZJEEH-UHFFFAOYSA-N 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- STCOOQWBFONSKY-UHFFFAOYSA-N tributyl phosphate Chemical compound CCCCOP(=O)(OCCCC)OCCCC STCOOQWBFONSKY-UHFFFAOYSA-N 0.000 description 1
- DQWPFSLDHJDLRL-UHFFFAOYSA-N triethyl phosphate Chemical compound CCOP(=O)(OCC)OCC DQWPFSLDHJDLRL-UHFFFAOYSA-N 0.000 description 1
- WVLBCYQITXONBZ-UHFFFAOYSA-N trimethyl phosphate Chemical compound COP(=O)(OC)OC WVLBCYQITXONBZ-UHFFFAOYSA-N 0.000 description 1
- XZZNDPSIHUTMOC-UHFFFAOYSA-N triphenyl phosphate Chemical compound C=1C=CC=CC=1OP(OC=1C=CC=CC=1)(=O)OC1=CC=CC=C1 XZZNDPSIHUTMOC-UHFFFAOYSA-N 0.000 description 1
- IVJLIUKQYNWCEZ-UHFFFAOYSA-N tris(2-bromophenyl) phosphate Chemical compound BrC1=CC=CC=C1OP(=O)(OC=1C(=CC=CC=1)Br)OC1=CC=CC=C1Br IVJLIUKQYNWCEZ-UHFFFAOYSA-N 0.000 description 1
- WTLBZVNBAKMVDP-UHFFFAOYSA-N tris(2-butoxyethyl) phosphate Chemical compound CCCCOCCOP(=O)(OCCOCCCC)OCCOCCCC WTLBZVNBAKMVDP-UHFFFAOYSA-N 0.000 description 1
- BHYQWBKCXBXPKM-UHFFFAOYSA-N tris[3-bromo-2,2-bis(bromomethyl)propyl] phosphate Chemical compound BrCC(CBr)(CBr)COP(=O)(OCC(CBr)(CBr)CBr)OCC(CBr)(CBr)CBr BHYQWBKCXBXPKM-UHFFFAOYSA-N 0.000 description 1
- 229920001862 ultra low molecular weight polyethylene Polymers 0.000 description 1
- 239000006097 ultraviolet radiation absorber Substances 0.000 description 1
- 239000008096 xylene Substances 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
- BNEMLSQAJOPTGK-UHFFFAOYSA-N zinc;dioxido(oxo)tin Chemical compound [Zn+2].[O-][Sn]([O-])=O BNEMLSQAJOPTGK-UHFFFAOYSA-N 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/16—Making expandable particles
- C08J9/18—Making expandable particles by impregnating polymer particles with the blowing agent
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/0014—Use of organic additives
- C08J9/0019—Use of organic additives halogenated
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/0061—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof characterized by the use of several polymeric components
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/0066—Use of inorganic compounding ingredients
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/122—Hydrogen, oxygen, CO2, nitrogen or noble gases
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/22—After-treatment of expandable particles; Forming foamed products
- C08J9/228—Forming foamed products
- C08J9/232—Forming foamed products by sintering expandable particles
-
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2201/00—Foams characterised by the foaming process
- C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
- C08J2201/026—Crosslinking before of after foaming
-
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2201/00—Foams characterised by the foaming process
- C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
- C08J2201/034—Post-expanding of foam beads or sheets
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- C08J2203/00—Foams characterized by the expanding agent
- C08J2203/06—CO2, N2 or noble gases
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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- C08J2205/00—Foams characterised by their properties
- C08J2205/04—Foams characterised by their properties characterised by the foam pores
- C08J2205/052—Closed cells, i.e. more than 50% of the pores are closed
-
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- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
- C08J2323/04—Homopolymers or copolymers of ethene
- C08J2323/06—Polyethene
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- C08J2463/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins
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- C08J2471/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
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- C08J2481/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen, or carbon only; Polysulfones; Derivatives of such polymers
- C08J2481/06—Polysulfones; Polyethersulfones
Description
(1)(a)密閉容器内で、ハロゲン系難燃剤を含むポリエチレン系樹脂粒子を分散媒に分散させる工程、
(b)前記樹脂粒子に有機過酸化物を含浸させ、前記樹脂粒子を構成するポリエチレン系樹脂の融点以上、該融点+80℃以下の温度:T1でポリエチレン系樹脂を架橋する工程、
(c)前記樹脂粒子に発泡剤を含浸させる工程、
(d)発泡剤を含む発泡性架橋ポリエチレン系樹脂粒子を密閉容器内から低圧下に放出して発泡させる工程、
とを含み、前記架橋工程における温度:T1と、ハロゲン系難燃剤の融点およびガラス転移温度のうちいずれか低い方の温度:T2とが、下記(1)式を満足する架橋ポリエチレン系樹脂発泡粒子の製造方法、
(数1)
T1<T2+30・・・・(1)
(2)前記温度:T2が、130〜350℃である上記(1)のポリエチレン系樹脂発泡粒子の製造方法、
(3)ポリエチレン系樹脂粒子中のハロゲン系難燃剤の割合が、ポリエチレン系樹脂100重量部に対し、3〜25重量部である上記(1)又は(2)の架橋ポリエチレン系樹脂発泡粒子の製造方法、
(4)ハロゲン系難燃剤が、臭素化ポリフェニレンエーテル、臭素化エポキシ樹脂、臭素化トリアジン化合物から選択される少なくとも1つである上記(1)〜(3)のいずれかの架橋ポリエチレン系樹脂発泡粒子の製造方法、
(5)ポリエチレン系樹脂粒子が、ポリエチレン系樹脂100重量部に対し、三酸化アンチモンを1〜10重量部含有する上記(1)〜(4)のいずれかの架橋ポリエチレン系樹脂発泡粒子の製造方法、
(6)(a)密閉容器内で、ハロゲン系難燃剤を含むポリエチレン系樹脂粒子を分散媒に分散させる工程、
(b)前記樹脂粒子に有機過酸化物を含浸させ、前記樹脂粒子を構成するポリエチレン系樹脂の融点以上該融点+80℃以下の温度:T1でポリエチレン系樹脂を架橋する工程、
とを含み、前記架橋工程における温度:T1と、ハロゲン系難燃剤の融点およびガラス転移温度のうちいずれか低い方の温度:T2とが、下記(1)式を満足する架橋ポリエチレン系樹脂粒子の製造方法、
(数2)
T1<T2+30・・・・(1)
を要旨とするものである。
さらに、本発明の製造方法によれば、難燃性と成形性に優れる発泡粒子が得られる架橋ポリエチレン系樹脂粒子を製造することができ、前記樹脂粒子の生産性が向上する。
(a)密閉容器内で、ハロゲン系難燃剤を含むポリエチレン系樹脂粒子を分散媒に分散させる工程、
(b)前記樹脂粒子に有機過酸化物を含浸させ、前記樹脂粒子を構成するポリエチレン系樹脂の融点以上で融点+80℃以下の温度:T1でポリエチレン系樹脂を架橋する工程、
(c)樹脂粒子に発泡剤を含浸させる工程、
(d)発泡剤を含む発泡性架橋ポリエチレン系樹脂粒子を密閉容器内から低圧下に放出して発泡させる工程、
とを含み、密閉容器内で分散媒に分散させた発泡性の架橋ポリエチレン系樹脂を、密閉容器内から低圧下に放出して発泡させて発泡粒子を得る方法である。
樹脂1:低密度ポリエチレン系樹脂(日本ポリエチレン株式会社製、融点112℃、全融解熱量106J/g、メルトフローレイト5.2g/10分(190℃、荷重2.16kg)、曲げ弾性率180MPa)。
実施例、比較例で使用した難燃剤を表1に示す。
難燃助剤1:三酸化アンチモン:鈴裕化学株式会社製 製品名ヒロマスターC−380
(有機過酸化物)
過酸化物1:ジクミルパーオキサイド(日油株式会社製、商品名パークミルD、分子量270、融点38℃、1時間半減期温度136℃)
直径40mmの押出機内でポリエチレン系樹脂を溶融し、ストランド状に押出した後、ペレタイザーで重量が5mgとなるように切断、乾燥して樹脂粒子を得た。この際に、難燃剤、難燃助剤、気泡調整剤としてホウ酸亜鉛(株式会社富田製薬製、ポリエチレン系樹脂100重量部に対して1重量部)が表2,3に示す割合で樹脂粒子中に含有されるように調整した。次いで攪拌機を備えた5Lの耐圧容器中に、分散媒としての水3L、分散剤としてカオリン3g、界面活性剤(商品名:ネオゲンS−20F、第一工業製薬株式会社製、アルキルベンゼンスルホン酸ナトリウム)0.04gを仕込むと共に、前記樹脂粒子1kgを分散させた。その後、架橋剤としての有機過酸化物ジクミルパーオキサイドを表2,3に示す量、添加し、撹拌下で表2,3に示す有機過酸化物含浸温度まで昇温し、その温度で30分間、樹脂粒子中に有機過酸化物を含浸させた。次いで、表2,3に示す架橋温度まで昇温しその温度で30分保持して、ポリエチレン系樹脂を架橋させた。保持終了後、表2,3に示す発泡温度まで昇温し、耐圧容器内に発泡剤として二酸化炭素を同表に示す耐圧容器内圧力になるまで圧入し、発泡温度で30分間保持した。なお、架橋温度と発泡温度が同じ場合は、架橋工程と発泡剤の含浸工程を併せて行うこともできる。その後、容器内圧力が一定になるように二酸化炭素で容器内に背圧を加えながら、容器内容物を大気圧下に放出して発泡粒子を得た。得られた発泡粒子の性状を表2,3に示す。また、別途、実施例1において、発泡剤の含浸工程を経ずに、架橋工程後、容器内を冷却し、樹脂粒子を取り出した場合には、架橋樹脂粒子を得ることができた。
発泡粒子外観は発泡粒子を肉眼で観察し、以下の基準で評価した。
○:発泡粒子表面に凹凸が殆ど認められず、表面状態良好である
△:発泡粒子表面に激しくはないが凹凸が認められる
×:発泡粒子表面に著しい凹凸がある
発泡粒子の独立気泡率は、次のようにして測定される。発泡粒子を大気圧下、相対湿度50%、23℃の条件の恒温室内にて10日間放置し養生し、同恒温室内にて、嵩体積約20cm3の養生後の発泡粒子を測定用サンプルとし水没法により正確に見かけの体積Vaを測定する。見かけの体積Vaを測定した測定用サンプルを十分に乾燥させた後、ASTM−D2856−70に記載されている手順Cに準じ、東芝・ベックマン株式会社製空気比較式比重計930により測定される測定用サンプルの真の体積Vxを測定する。そして、これらの体積Va及びVxを基に、下記式により独立気泡率を計算し、N=5の平均値を発泡粒子の独立気泡率とする。
独立気泡率(%)=(Vx−W/ρ)×100/(Va−W/ρ)
ただし、
Vx:上記方法で測定される発泡粒子の真の体積、即ち、発泡粒子を構成する樹脂の容積と、発泡粒子内の独立気泡部分の気泡全容積との和(cm3)
Va:発泡粒子を、水の入ったメスシリンダーに沈めて、水位上昇分から測定される発泡粒子の見かけの体積(cm3)
W:発泡粒子測定用サンプルの重量(g)
ρ:発泡粒子を構成する樹脂の密度(g/cm3)
発泡粒子のゲル分率は、発泡粒子0.7gを150mlの丸底フラスコに入れ、100mlのキシレンを加え、マントルヒーターで加熱して6時間還流させた後、とけ残った残査を100メッシュの金網でろ過して分離し、80℃の減圧乾燥器で8時間以上乾燥する。この際に得られた乾燥物重量W2を測定する。この重量W2の試料重量W1に対する重量百分率[(W2/W1)×100](%)をゲル分率とする。
○:成形体の表面において発泡粒子相互に隙間がなく、角の形状が金型の形状と同じ。
×:成形体の表面において発泡粒子相互に隙間が多く、角の形状が金型の形状より丸い。
融着性評価は、発泡粒子成形体を破断した際の破断面に露出した発泡粒子のうち、材料破壊した発泡粒子の数の割合(融着率)に基づいて行った。具体的には、発泡粒子成形体を、カッターナイフで発泡粒子成形体の厚み方向に約10mmの切り込みを入れた後、切り込み部から発泡粒子成形体を破断させた。次に、破断面に存在する発泡粒子の個数(n)と、材料破壊した発泡粒子の個数(b)を測定し、(b)と(n)の比(b/n)を百分率で表して融着率(%)とした。
回復性の評価は、発泡粒子成形体の厚み方向の寸法を測定して行った。
具体的には、まず、縦約200mm、横約250mmの発泡粒子成形体における端部(端より10mm内側)と中心部(縦方向、横方向とも2等分する部分)の厚みを計測した。次いで、発泡粒子成形体の厚み比(成形体中心部の厚み/成形体端部の厚み×100(%))を算出した。そして、回復性の評価は、厚み比が95%以上の場合を「○」として評価し、95%未満の場合を「×」として評価することにより行った。
成形体の独立気泡率は、発泡粒子成形体中央部より25×25×30mmのサンプルを切出し(スキンはすべて切り落とす)、測定用サンプルとする他は、前記発泡粒子の独立気泡率の測定と同様にして求めた。
圧縮強度は、成形体中央部より、表面のスキン層を除いて縦50mm×横50mm×厚み25mmの試験片を切り出し、この試験片の50%ひずみ時の荷重を、JIS K6767(1999年)に準拠して圧縮速度10mm/分で測定し、この値を試験片の受圧面積で除して求められる50%圧縮応力(kPa)を圧縮強度とした。
酸素指数はJIS K7201に従い測定した。成形体から切り出した10mm×10mm×150mmの試験片を資料ホルダーに垂直に取り付け、酸素・窒素混合ガスを流しながら試験片の上端に点火装置で点火した。着火後、添加装置を取り去り、直ちに燃焼時間と燃焼長さの測定を開始した。酸素濃度変化させて、燃焼時間が3分以下か、燃焼長さが50mmに達するのに必要な最低酸素濃度を求め、下記式により酸素指数(OI)を求めた。
酸素指数(OI)=最低酸素濃度×100÷(最低酸素濃度+窒素濃度)
燃焼性試験は、JIS A9511(燃焼性:測定方法A)に従って行った。成形体から10mm×25mm×200mmの試験片を5個切り出し、着火限界指示線及び燃焼限界指示線を付け、試験片を水平から45°傾けた状態で先端より約5秒間かけてろうそくの炎を等速で着火限界指示線まで移動させ、着火限界指示線に達したところで炎素早く後退させ、その瞬間から炎が消えるまでの時間を測定し、残じんの有無、燃焼の停止位置を確認した。5個の消炎時間の平均を平均消火時間とした。燃焼限界支持線に炎が達しない、かつ消炎時間の平均が3.0s以内であるものを自己消火と評価した。
Claims (6)
- (a)密閉容器内で、ハロゲン系難燃剤を含むポリエチレン系樹脂粒子を分散媒に分散させる工程、
(b)前記樹脂粒子に有機過酸化物を含浸させ、前記樹脂粒子を構成するポリエチレン系樹脂の融点以上、該融点+80℃以下の温度:T1でポリエチレン系樹脂を架橋する工程、
(c)前記樹脂粒子に発泡剤を含浸させる工程、
(d)発泡剤を含む発泡性架橋ポリエチレン系樹脂粒子を密閉容器内から低圧下に放出して発泡させる工程、
とを含み、前記架橋工程における温度:T1と、ハロゲン系難燃剤の融点およびガラス転移温度のうちいずれか低い方の温度:T2とが、下記(1)式を満足する架橋ポリエチレン系樹脂発泡粒子の製造方法。
(数1)
T1<T2+30・・・・(1) - 前記温度:T2が、130〜350℃である請求項1記載の架橋ポリエチレン系樹脂発泡粒子の製造方法。
- ポリエチレン系樹脂粒子中のハロゲン系難燃剤の割合が、ポリエチレン系樹脂100重量部に対し、3〜25重量部である請求項1又は2記載の架橋ポリエチレン系樹脂発泡粒子の製造方法。
- ハロゲン系難燃剤が、臭素化ポリフェニレンエーテル、臭素化エポキシ樹脂、臭素化トリアジン化合物から選択される少なくとも1つである請求項1〜3のいずれかに記載の架橋ポリエチレン系樹脂発泡粒子の製造方法。
- ポリエチレン系樹脂粒子が、ポリエチレン系樹脂100重量部に対し、三酸化アンチモンを1〜10重量部含有する請求項1〜4のいずれかに記載の架橋ポリエチレン系樹脂発泡粒子の製造方法。
- (a)密閉容器内で、ハロゲン系難燃剤を含むポリエチレン系樹脂粒子を分散媒に分散させる工程、
(b)前記樹脂粒子に有機過酸化物を含浸させ、前記樹脂粒子を構成するポリエチレン系樹脂の融点以上、該融点+80℃以下の温度:T1でポリエチレン系樹脂を架橋する工程、
とを含み、前記架橋工程における温度:T1と、ハロゲン系難燃剤の融点およびガラス転移温度のうちいずれか低い方の温度:T2とが、下記(1)式を満足する架橋ポリエチレン系樹脂粒子の製造方法。
(数2)
T1<T2+30・・・・(1)
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