JPH07113017A - Foaming composition and foamed product - Google Patents

Abstract

PURPOSE:To provide the composition which comprises vegetable powder, water- soluble polymer binder, water, a foaming agent decomposable at a certain temperature, and a surfactant and car be used as a heat-insulating package material of good processability with no problem on disposition such as incineration or landfilling. CONSTITUTION:The foaming composition of excellent processability is prepared by formulating 100 pts.wt. of dried vegetable powder such as dried rice hulls crushed with a ball mill into particles passing through 40 mesh sieve, 10 to 100 pts.wt. of a water-soluble polymer binder such as alpha-form starch, 5-100 pts.wt. of a foaming agent having a decomposition point lower than 100 deg.C such as sodium hydrogen carbonate and 0.1 to 20 pts.wt. of a surfactant such as ammonium laurylsulfate. The composition is formed into particles and an inorganic powder is applied to the surface of the particles at a rate of 0.1 to 1.0g/cm<2>, then charged in a tightly closed mold, heated at the temperature over the decomposition point to give a foamed product which can be readily disposed as a waste.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foamable composition which is easily processed as a waste and has excellent processability by using a vegetable powder, and a method for producing a foam.

[0002]

2. Description of the Related Art A large amount of synthetic resin foams such as polystyrene, polyurethane and polyethylene are used in various fields. However, since these have a high combustion temperature, there is a problem that when incinerating waste, toxic substances are generated and the incinerator is damaged. For the purpose of eliminating these drawbacks, foams using a vegetable raw material have been proposed. For example, JP-A-2-298525 describes a low-density, closed-cell, biodegradable foam containing high amylose starch.

Further, Japanese Patent Laid-Open No. 4-128157 discloses that
A foam obtained by heating rice under pressure and depressurizing it at the same time as completion of cooking rice is described.

[0004]

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention
As the material described in Japanese Patent No. 525, corn, peas, barley, rice and the like having a high amylose content are used. These are useful as materials for food and industrial products, and are expensive, so it is a waste of resources to use them as disposables such as containers and cushioning materials.

Further, since the foam described in JP-A-4-128157 also uses rice as a food as a raw material, it is a waste of resources. Furthermore, the production of this foam requires a large amount of energy to obtain a high pressure.

The present invention solves the above-mentioned problems of the prior art, there is no problem even when waste is incinerated or landfilled, resources can be effectively used, and a foamable composition excellent in processability is provided. And it aims at providing the manufacturing method of a foam.

[0007]

The foamable composition of the present invention according to claim 1 is 10 to 100 parts by weight of a water-soluble polymer binder and 100 to 100 parts by weight of water based on 100 parts by weight of the dry weight of the plant powder. 1000 parts by weight, 5 to 100 parts by weight of a foaming agent having a decomposition temperature of 100 ° C. or less, and 0.1 to 20 parts by weight of a surfactant.

The foamable composition of the present invention according to claim 2 has a solid content of 20 with respect to 100 parts by weight of the dry weight of the vegetable powder.
~ 80% synthetic resin emulsion or rubber latex 5
It is composed of 0 to 200 parts by weight, 100 to 400 parts by weight of water, 5 to 100 parts by weight of a foaming agent having a decomposition temperature of 100 ° C. or less, and 0.1 to 20 parts by weight of a surfactant.

Furthermore, the method for producing a foam according to claim 3
Is a granular composition of the foamable composition according to claim 1 or 2.
0.1 to 1.0 g per unit area on the surface of the granular material
/ Cm ²Of the inorganic powder to completely remove the particulate matter.
Put in an unsealed mold and above the decomposition temperature of the blowing agent
It is characterized by heating.

The plant powder used in the present invention is a powder of the shells and skins of leaves of plants, leaves, or the pomace of plant foods. As the shells and skins of plant fruits, rice,
Grains such as barley, buckwheat, soybeans, coffee, fruit shells such as peanuts, and skins of fruits such as chestnuts, oranges, apples and pears. The leaves of the plant can be either coniferous or hardwood.
In addition, the waste that has been once used, such as a tea bowl, can also be used. As squeezed foods, extracted coffee beans,
Examples thereof include vegetable squeezed residue remaining after producing fruit juice, beer, wine, sake, shochu, miso, soy sauce and the like.

The above-mentioned plant nut shells and skins, leaves, and pomace of plant foods, etc. are used as they are or after being dried and then crushed, or crushed and finely divided to pass through a 40-mesh sieve. .

The blowing agent used in the present invention has a decomposition temperature of 10
It is 0 ° C. or lower, preferably 60 ° C. or higher and 100 ° C. or lower, and more preferably water-soluble. Examples thereof include sodium hydrogen carbonate (90 ° C.), ammonium carbonate (60 ° C.), a mixture of azodicarbonamide and zinc chloride (80 ° C.), a mixture of dinitrosopentamethylenetetramine and oxalic acid (60 ℃) and the like. (The inside of () shows decomposition temperature.)

The surfactant used in the present invention is water-soluble. For example, anionic surfactant such as fatty acid salt, alkylbenzene sulfonate, alkylallyl sulfate ester salt, nonionic surfactant such as polyoxyethylene alkyl ether, polyoxyethylene nonylphenyl ether, sorbitan fatty acid ester, alkyl Examples include cationic surfactants such as amine salts and quaternary ammonium salts.

The amount of the surfactant used is 0.1 to 20 parts by weight based on 100 parts by weight of the dry plant powder.
If the amount is less than 0.1 part by weight, the strength of the film formed between the plant powders is weak and a high-magnification foam cannot be obtained. Not only does the effect not increase when using more than 20 parts by weight,
In some cases, the adhesiveness of the vegetable powder due to the polymer binder or synthetic resin emulsion or rubber latex may be reduced.

Examples of the water-soluble polymer binder used in the foamable composition according to claim 1 are natural polymer substances such as starch, alginate and gum arabic, glue, gelatin,
Examples thereof include animal macromolecules such as egg white, natural macromolecule derivatives such as methylcellulose and carboxystarch, and synthetic macromolecules such as polyvinyl alcohol and polyacrylic acid.

The amount of the water-soluble polymer binder used is 10 to 100 parts by weight based on 100 parts by weight of the dry weight of the plant powder. If the amount is less than 10 parts by weight, the adhesion between the powders will be insufficient and the dried foam will be easily pulverized. 100
If it exceeds the weight part, the expansion ratio will decrease.

The synthetic resin emulsion used in the foamable composition according to claim 2 is, for example, an emulsion of polyvinyl acetate, polyethylene, polyurethane, ethylene vinyl acetate copolymer, etc., and has a solid content of 20-80.
% By weight. As rubber latex, styrene butadiene rubber, chloroprene rubber, nitrile rubber,
There are latexes such as isoprene rubber and natural rubber. Its solid content is 20-80%.

The amount of the synthetic resin emulsion or rubber latex used is 50 to 200 parts by weight based on 100 parts by weight of the dry weight of the vegetable powder. If the amount is less than 50 parts by weight, the adhesive force between the vegetable powders is insufficient and the dried foam tends to be pulverized. If it exceeds 200 parts by weight, the expansion ratio decreases.

If necessary, a filler, a coloring agent, a flame retardant, an insect repellent, a water repellent, a rodent proofing agent, a fungicide, etc. may be added to the foamable composition of the present invention.

The first feature of the foamable composition of the present invention according to claim 1 and claim 2 is that the foaming agent decomposes due to the film formed between the plant powders by water and the surfactant. It is to prevent the generated gas from escaping, to obtain a foam expanded at a high ratio, and further to obtain a foam having uniform cells by the action of a surfactant.

The second feature is that the amount of water is adjusted so that the above-mentioned foaming conditions are satisfied. The amount of water used is 100 parts by weight or more based on 100 parts by weight of the plant powder, 1000 parts by weight or less in the foamable composition according to claim 1, and 400 parts by weight in the foamable composition according to claim 2. It is less than or equal to parts by weight.

If the amount of water is less than 100 parts by weight, the plant powder and the water-soluble polymer binder, or the plant powder and the synthetic resin emulsion or the rubber latex are not sufficiently wet, so that good foaming cannot be performed. . Further, if the amount of water exceeds the above range, even if foaming occurs once, the bubbles shrink before solidification, so that a high-magnification foam cannot be obtained.

When the amount of water is adjusted within the above range, the water evaporates while foaming due to the decomposition of the foaming agent to increase the viscosity of the composition, and the generated bubbles are surrounded by the powder and fixed. To be done. Further heating reduces the water content, and the water-soluble polymer binder, synthetic resin emulsion or rubber latex continuously surrounds the vegetable powder, and the powders are firmly adhered to each other.

Next, in the method for producing a foam according to claim 3, the foamable composition according to claim 1 or 2 is made into granules, and the surface of the granules is adhered with an inorganic powder to foam. Flowability is given to the contact area between the particles that are being foamed from before, and this is supplied along the shape of the mold and heated above the decomposition temperature of the foaming agent to foam, and foamed in the mold before the completion of foaming. The foamed body is obtained by pressing and adhering the particles to each other by pressure.

While the foamable composition foams due to the decomposition of the foaming agent, water evaporates to increase the viscosity of the composition and the generated bubbles are fixed between the fibers. Upon further heating, the water content is reduced, and the animal and vegetable paste, synthetic resin emulsion or rubber latex surrounds the intersections of the fibers and the fibers are firmly bonded together.

The inorganic powder used in the method for producing a foam according to claim 3 is for preventing sticking in order to impart fluidity to the contact part between the particles during foaming of the foamable composition before foaming. Therefore, examples thereof include talc, calcium carbonate, aluminum hydroxide, zeolite, and the like, and the average particle size thereof is preferably 100 μm or less.

The amount of the inorganic powder used varies depending on the adhesiveness, size, and shape of the surface of the granules of the foamable composition, but is 0.1 to 1.0 g / cm ² per unit surface area of the granules. To use. If the amount is less than 0.1 g / cm ² , the particles cannot be foamed while adhering to each other before foaming and maintaining the shape of the particles. If it exceeds 1.0 g / cm ² , it is difficult to bond the granular materials after foaming.

Since the above-mentioned granules are put in a mold which is not completely sealed and foamed, the air in the mold is removed as the granules expand and the foam of the granules fills the mold. It is molded according to the shape of the mold. The foam after molding is dried when the water content is high. Drying may be complete and moisture may remain depending on the application. As the heating for foaming, an electric heater, hot air, a method using a liquid as a heat medium, a method using a microwave, or the like can be adopted.

[0029]

In the foamable composition of the present invention as set forth in claim 1, the foaming agent is decomposed by the film of water, the water-soluble polymer binder and the surfactant, which is formed by continuously surrounding the vegetable powder. Since the generated gas is prevented from escaping, a foam having a high expansion ratio and having uniform bubbles can be obtained by the action of the surfactant. Further, since the amount of water is 100 to 1000 parts by weight with respect to 100 parts by weight of the plant powder, the above foaming conditions can be obtained.

In the foamable composition of the present invention according to claim 2,
A film made of water, synthetic resin emulsion or rubber latex, and a surfactant, which is formed by continuously surrounding the vegetable powder, prevents the gas generated by the decomposition of the foaming agent from being dissipated. By foaming, and further by the action of the surfactant, a foam having uniform cells can be obtained. Further, since the amount of water is 100 to 400 parts by weight with respect to 100 parts by weight of the plant powder, the above foaming conditions can be obtained.

In the method for producing a foam according to a third aspect of the present invention, by adhering the inorganic powder to the surface of the granules, the adhesive force between the granules is suppressed, and the particles flow to the contact portion between the granules before and during foaming. Since the moldability is imparted, the mold is easily filled along the shape of the mold, and the moldability is improved.

[0032]

EXAMPLES Examples of the present invention will be described below. (Examples 1 to 7) The dried rice husks were made 40 by a ball mill.
Finely crushed powder that passes through a mesh sieve, pregelatinized starch as a vegetable binder (trade name: Sizarin P manufactured by Matsutani Chemical Co., Ltd.), water, ammonium lauryl sulfate as a surfactant, and sodium hydrogencarbonate as a foaming agent. The formulations shown in No. 1 were used, and each of the formulations was kneaded with a frying machine to obtain a foamable composition. 5 of these foamable compositions
What was press-molded to a size of cm × 5 cm × 1 cm was placed on a fluororesin-coated glass fiber sheet, and heated in hot air at 180 ° C. for 40 minutes to foam and dry. Table 1 shows the density, average cell diameter, and cell uniformity of the obtained foam.

(Comparative Examples 1 to 8) Foamable compositions were prepared in the same manner as in Examples 1 to 7 except that the same materials as those used in Examples 1 to 7 were used and the formulations shown in Table 1 were used. To obtain a foam. Table 1 shows the density, average cell diameter, and cell uniformity of the obtained foam.

[0034]

[Table 1]

However, * 1 is in parts by weight. * 2 ○: uniform ×: non-uniform * 3 ○: good ×: insufficient adhesion and easy to collapse

(Examples 8 to 14) Examples 1 to 7 except that the dry tea leaves were crushed by a ball mill into fine particles that passed through a 40-mesh sieve instead of the rice husks and the composition shown in Table 2 was used. A foam was obtained in the same manner as. Table 2 shows the density, average cell diameter and cell uniformity of the obtained foam.

Comparative Examples 9 to 16 Foamable compositions were prepared in the same manner as in Examples 8 to 14 except that the same materials as those used in Examples 8 to 14 were used and the formulations shown in Table 2 were used. To obtain a foam. Table 2 shows the density, average cell diameter and cell uniformity of the obtained foam.

[0038]

[Table 2]

However, * 1 is in parts by weight. * 2 ○: uniform ×: non-uniform * 3 ○: good ×: insufficient adhesion and easy to collapse

(Examples 15 to 21) Dry cedar leaves were used in place of rice husks, and styrene-butadiene rubber latex was used as a binder in place of pregelatinized starch (trade name: FR-S2000 manufactured by Firestone, solid content 40). %) Was used, and the formulation shown in Table 3 was used.
A foamed product was obtained in the same manner as described above. Table 3 shows the density, average cell diameter, and cell uniformity of the obtained foam.

(Comparative Examples 17 to 24) Foamable compositions were prepared in the same manner as in Examples 15 to 21 except that the same materials as those used in Examples 15 to 21 were used and the formulations shown in Table 3 were used. To obtain a foam. Table 3 shows the density, average cell diameter, and cell uniformity of the obtained foam.

[0042]

[Table 3]

However, * 1 is in parts by weight. * 2 ○: uniform ×: non-uniform * 3 ○: good ×: insufficient adhesion and easy to collapse

(Examples 22 to 28) Dried and extracted coffee beans instead of rice husks were crushed with a ball mill into a fine powder that passed through a 60-mesh sieve. Foams were obtained in the same manner as in Examples 1 to 7. Table 4 shows the density, average cell diameter, and cell uniformity of the obtained foam.

(Comparative Examples 25 to 32) Foamable compositions were prepared in the same manner as in Examples 22 to 28 except that the same materials as those used in Examples 22 to 28 were used and the formulations shown in Table 4 were used. To obtain a foam. Table 4 shows the density, average cell diameter, and cell uniformity of the obtained foam.

[0046]

[Table 4]

However, * 1 is in parts by weight. * 2 ○: uniform ×: non-uniform * 3 ○: good ×: insufficient adhesion and easy to collapse

(Examples 29 to 35) Dried beer pomace instead of rice husks was ground into a fine powder that passed through a 40-mesh sieve with a ball mill, and styrene-butadiene rubber latex was used as a binder instead of pregelatinized starch. (Product name of Firestone: F
A foam was obtained in the same manner as in Examples 1 to 7 except that the formulation shown in Table 5 was used using R-S2000, solid content 40%).
Table 5 shows the density, average cell diameter, and cell uniformity of the obtained foam.

(Comparative Examples 33 to 40) Foamable compositions were prepared in the same manner as in Examples 29 to 35 except that the same materials as those used in Examples 29 to 35 were used and the formulations shown in Table 5 were used. To obtain a foam. Table 5 shows the density, average cell diameter, and cell uniformity of the obtained foam.

[0050]

[Table 5]

However, * 1 is in parts by weight. * 2 ○: uniform ×: non-uniform * 3 ○: good ×: insufficient adhesion and easy to collapse

Next, an embodiment of the invention of claim 3 will be described. (Examples 36 to 44) 100 parts by weight of dried orange peel pulverized with a ball mill into a fine powder that can pass through a 60 mesh sieve, 50 parts by weight of sodium alginate as a binder, 300 parts by weight of water, and lauryl as a surfactant. 1 part by weight of ammonium sulfate and 30 parts by weight of sodium hydrogen carbonate as a foaming agent were compounded as shown in Table 6, and each compound was kneaded with a muller to obtain a foamable composition.
These foamable compositions were press-molded into particles having a diameter of 4 mm, and talc powder having an average particle size of 50 μm was formed on the surface of the particles.
Calcium carbonate with an average particle size of 20 μm, average particle size of 60 μm
Alumina was deposited in the amounts shown in Table 6, respectively.

20 g of the granular material is 5 cm × 5 cm, depth 1
Put it in a 0 cm polypropylene container, cover it with a polypropylene lid with many holes with a diameter of 1 mm, and output 1 k.
After heating in the microwave oven for cooking for 5 minutes to foam,
It was taken out of the container and heated for another 5 minutes to be dried. Table 6 shows the shape of the obtained foam, the adhesion between particles, and the apparent density.
It was as shown in.

(Comparative Examples 41 to 44) The same materials as those used in Examples 36 to 44 were used, and the same procedures as in Examples 36 to 44 were performed except that the amount of the inorganic powder deposited was changed to the amount shown in Table 6. A foamable composition was prepared to obtain a foam. Table 6 shows the shape of the obtained foam, the adhesion between particles, and the apparent density.

[0055]

[Table 6]

However, * 1 ○: almost foamed inside the container ×: not foamed according to the shape inside the container * 2 ○: completely adhered ×: partially insufficient * 3 density due to uneven foaming Not measurable

(Examples 45 to 53) Examples 36 to 4 except that dried beech tree leaves were used instead of dried orange peel and the amount of the inorganic powder adhered was set to the amount shown in Table 7.
A foamable composition was prepared in the same manner as in 4 to obtain a foam.
Table 7 shows the shape of the obtained foam, the adhesion between particles, and the apparent density.

(Comparative Examples 45 to 48) The same materials as those used in Examples 45 to 53 were used, and the same procedures as in Examples 36 to 44 were performed except that the amount of the inorganic powder deposited was changed to the amount shown in Table 7. A foamable composition was prepared to obtain a foam. Table 7 shows the shape of the obtained foam, the adhesion between particles, and the apparent density.

[0059]

[Table 7]

However, * 1 ○: almost foamed inside the container ×: not foamed according to the shape inside the container * 2 ○: completely adhered ×: partially insufficient * 3 density due to uneven foaming Not measurable

(Examples 54 to 62) Example 36 was repeated, except that dried apple pomace was used instead of dried orange peel and the amount of the inorganic powder adhered was set to the amount shown in Table 8.
A foamable composition was prepared in the same manner as in ~ 44 to obtain a foam. Table 8 shows the shape of the obtained foam, the adhesion between particles, and the apparent density.

(Comparative Examples 49 to 52) The same materials as those used in Examples 54 to 62 were used, and the same procedures as in Examples 54 to 62 were carried out except that the amount of the inorganic powder deposited was changed to the amount shown in Table 8. A foamable composition was prepared to obtain a foam. Table 8 shows the shape of the obtained foam, the adhesion between particles, and the apparent density.

[0063]

[Table 8]

However, * 1 ○: almost foamed inside the container ×: not foamed according to the shape inside the container * 2 ○: completely adhered ×: partially insufficient * 3 Density due to uneven foaming Not measurable

[0065]

The present invention has the above-mentioned constitution. According to the foamable composition of claim 1, a water-soluble polymer binder is used, and according to the foamable composition of claim 2, a synthetic resin emulsion or rubber is used. The latex firmly adheres the vegetable powders to each other and prevents the gas generated by decomposing the foaming agent, so the foaming ratio is high, and the foaming with uniform bubbles due to the action of the surfactant. The body is obtained.

Further, since the foamable composition of the present invention contains vegetable powder as a main component, it is possible to use discarded materials and effectively use resources. Therefore, the amount of waste is reduced, the incineration process is easy, and when buried in the soil, it is decomposed by the action of bacteria, so there is no risk of pollution.

Furthermore, the foamable composition of the present invention can be foamed in any shape by foaming it in a mold. It can be coated on the surface, adhered to paper or wood, or cut with a knife. Since it can be easily cut, it can be used as a heat insulating material, a packaging material, a cushioning material, a core material, and the like in the fields of construction, vehicles, electric devices, and the like.

According to the method for producing a foam according to claim 3, by adhering the inorganic powder to the surface of the granules of the foamable composition, the adhesive force between the granules is suppressed and the expansion of the individual granules is suppressed. Since the foam is sufficiently foamed while maintaining the space, a foam having high-magnification and uniform-sized cells can be obtained.

Claims (3)

[Claims] 1. A water-soluble polymer binder of 10 to 100 parts by weight, water of 100 to 1000 parts by weight, and a foaming agent of 100 to 1000 parts by weight, and a foaming agent of 5 to 100, which has a decomposition temperature of 100 ° C. or less, based on 100 parts by weight of the dry weight of the vegetable powder. A foamable composition comprising 1 part by weight and 0.1 to 20 parts by weight of a surfactant. 2. 50 to 200 parts by weight of a synthetic resin emulsion or rubber latex having a solid content of 20 to 80% and 100 to 400 parts of water based on 100 parts by weight of the dry weight of the plant powder.
5 to 10 parts by weight, a blowing agent having a decomposition temperature of 100 ° C. or less
A foamable composition comprising 0 part by weight and 0.1 to 20 parts by weight of a surfactant. 3. The expandable composition according to claim 1 or 2 is formed into particles, and the surface of the particles is 0.1 per unit area.
The production of a foam, characterized in that an inorganic powder in an amount of ˜1.0 g / cm ² is deposited, the granules are placed in a not completely sealed mold and heated above the decomposition temperature of the foaming agent. Method.