TWI668257B - Foam, laminate and shaped body - Google Patents

Foam, laminate and shaped body Download PDF

Info

Publication number
TWI668257B
TWI668257B TW104129911A TW104129911A TWI668257B TW I668257 B TWI668257 B TW I668257B TW 104129911 A TW104129911 A TW 104129911A TW 104129911 A TW104129911 A TW 104129911A TW I668257 B TWI668257 B TW I668257B
Authority
TW
Taiwan
Prior art keywords
foam
elongation
jis
break
density
Prior art date
Application number
TW104129911A
Other languages
English (en)
Other versions
TW201623387A (zh
Inventor
宇野拓明
三上洋輝
Original Assignee
日商積水化學工業股份有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 日商積水化學工業股份有限公司 filed Critical 日商積水化學工業股份有限公司
Publication of TW201623387A publication Critical patent/TW201623387A/zh
Application granted granted Critical
Publication of TWI668257B publication Critical patent/TWI668257B/zh

Links

Classifications

    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/302—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/026—Knitted fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/02—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch
    • B32B9/025—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch comprising leather
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/046—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • 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
    • 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
    • C08J9/04—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
    • C08J9/06—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 chemical blowing agent
    • C08J9/10—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 chemical blowing agent developing nitrogen, the blowing agent being a compound containing a nitrogen-to-nitrogen bond
    • C08J9/102—Azo-compounds
    • C08J9/103—Azodicarbonamide
    • 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
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/16—Elastomeric ethene-propene or ethene-propene-diene copolymers, e.g. EPR and EPDM rubbers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/025—Polyolefin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2274/00—Thermoplastic elastomer material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/738—Thermoformability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/08—Dimensions, e.g. volume
    • B32B2309/10—Dimensions, e.g. volume linear, e.g. length, distance, width
    • B32B2309/105—Thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings
    • 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
    • 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
    • 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
    • C08J2205/00—Foams characterised by their properties
    • C08J2205/06—Flexible foams
    • 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
    • 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
    • C08J2323/10—Homopolymers or copolymers of propene
    • C08J2323/12—Polypropene
    • 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
    • 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
    • C08J2323/16—Ethene-propene or ethene-propene-diene copolymers
    • 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
    • C08J2423/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2423/02—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
    • C08J2423/04—Homopolymers or copolymers of ethene
    • C08J2423/06—Polyethene
    • 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
    • C08J2423/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2423/02—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
    • C08J2423/04—Homopolymers or copolymers of ethene
    • C08J2423/08—Copolymers of ethene
    • 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
    • C08J2423/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2423/02—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
    • C08J2423/10—Homopolymers or copolymers of propene
    • 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
    • C08J2423/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2423/02—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
    • C08J2423/10—Homopolymers or copolymers of propene
    • C08J2423/12—Polypropene
    • 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
    • C08J2423/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2423/02—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
    • C08J2423/16—Ethene-propene or ethene-propene-diene copolymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2203/00—Applications
    • C08L2203/14—Applications used for foams
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/03—Polymer mixtures characterised by other features containing three or more polymers in a blend

Abstract

本發明之發泡體係密度為0.036g/cc以上，未達0.133g/cc者，依據JIS K6251測得之160℃斷裂點伸長率(%)為150%以上，該斷裂點伸長率(%)乘以依據JIS K6251於160℃測得之100%模量(MPa)而得之值為7以上，交聯度為30~50%。

Description

發泡體、積層體及成形體
本發明係關於一種發泡體，更詳細而言，係關於一種使發泡性組成物交聯且發泡而成之交聯聚烯烴系樹脂發泡體。
交聯聚烯烴系樹脂發泡體作為隔熱材料、緩衝材料等而通用。特別是於汽車領域中，用作車頂材料、車門、儀錶面板等車輛用內飾材料。該等車輛用內飾材料通常係將片狀之交聯聚烯烴系樹脂發泡體利用真空成形或壓縮成形等進行二次加工而成形為規定之形狀。又，交聯聚烯烴系樹脂發泡體係與聚氯乙烯樹脂、熱塑性彈性體等樹脂或彈性體片、天然或人造之布狀物等片狀素材貼合而以積層體之形式廣泛使用。
已知有各種用作車輛用內飾材料之交聯聚烯烴系樹脂發泡體，例如已知有如下發泡體，其為了提高成形加工性或耐熱性、而將DSC波峰溫度設為160℃以上，且由混合有如下3種樹脂之樹脂組成物構成：聚丙烯系樹脂(A)，其由均聚丙烯(homopolypropylene)或乙烯-丙烯無規共聚物構成；聚丙烯系樹脂(B)，其由乙烯-丙烯無規共聚物等構成；及聚乙烯系樹脂(C)(例如，參照專利文獻1)。
專利文獻1：日本專利第5217164號公報
然而，近年來，對車輛用內飾材料要求高設計性，且正在研究對貼合於發泡體之片狀素材附以複雜之花樣。例如，以往於真空成形中，陽模真空成形為主流，但為了提高設計性，而研究利用陰模真空成形進行成形。於陰模成形中，在將由發泡體與片狀素材構成之積層體成形之情形時，片狀素材配置於模具側，故而形成於模具之凹凸花樣容易準確地轉印於片狀素材。
然而，為了使模具上之凹凸花樣準確地轉印於片狀素材，必須升高成形溫度，例如，要求於160℃以上進行成形。若發泡體被加熱至160℃以上，則通常會超過成為發泡體之主成分的聚丙烯之熔點，故而存在真空成形時發泡體破裂之情況。
本發明係鑒於以上問題點而完成者，其課題在於即便於如升高將發泡體成形為成形體時的成形溫度之情形時，亦可防止發泡體之破裂等，使成形性良好。
本發明人等努力進行研究，結果發現：藉由將交聯度調整為規定範圍，並將160℃斷裂點伸長率(%)、及160℃斷裂點伸長率(%)乘以160℃之100%模量(MPa)而得之值(SS係數)均增大，可解決上述課題，從而完成以下之本發明。
即，本發明提供以下之(1)~(16)。
(1)一種發泡體，其密度為0.036g/cc以上，未達0.133g/cc，依據JIS K6251測得之160℃斷裂點伸長率(%)為150%以上，該斷裂點伸長率(%)乘以依據JIS K6251於160℃測得之100%模量(MPa)而得之值為7以上，交聯度為30~50%。
(2)如上述(1)記載之發泡體，其密度為0.036g/cc以上，未達0.044g/cc，依據JIS K6251測得之160℃斷裂點伸長率(%)為150%以上，該斷裂點伸長率(%)乘以依據JIS K6251於160℃測得之100%模量(MPa)而得之值為7以上。
(3)如上述(1)記載之發泡體，其密度為0.044g/cc以上，未達0.057g/cc，依據JIS K6251測得之160℃斷裂點伸長率(%)為170%以上，該斷裂點伸長率(%)乘以依據JIS K6251於160℃測得之100%模量(MPa)而得之值為8以上。
(4)如上述(1)記載之發泡體，其密度為0.057g/cc以上，未達0.077g/cc，依據JIS K6251測得之160℃斷裂點伸長率(%)為200%以上，該斷裂點伸長率(%)乘以依據JIS K6251於160℃測得之100%模量(MPa)而得之值為10以上。
(5)如上述(1)記載之發泡體，其密度為0.077g/cc以上，未達0.133g/cc，依據JIS K6251測得之160℃斷裂點伸長率(%)為250%以上，該斷裂點伸長率(%)乘以依據JIS K6251於160℃測得之100%模量(MPa)而得之值為15以上。
(6)如上述(1)至(5)中任一項記載之發泡體，其係使含有均聚丙烯(A)、無規聚丙烯(B)、及線性低密度聚乙烯(C)之發泡性組成物交 聯且發泡而成，上述均聚丙烯(A)相對於發泡性組成物中之樹脂成分總量為10~60質量%，並且熔體流動速率為2.5~20g/10分鐘。
(7)如上述(6)記載之發泡體，其中上述均聚丙烯(A)之熔體流動速率為6~12g/10分鐘。
(8)如上述(6)或(7)記載之發泡體，其中上述發泡性組成物相對於上述均聚丙烯(A)，以0.16~8之質量比含有上述無規聚丙烯(B)，並且以0.16~8之質量比含有上述線性低密度聚乙烯(C)。
(9)如上述(6)至(8)中任一項記載之發泡體，其中相對於組成物中之樹脂成分總量，以10質量%以上，未達20質量%含有上述均聚丙烯(A)。
(10)如上述(9)記載之發泡體，其中上述發泡性組成物相對於上述均聚丙烯(A)，以1.6~5之質量比含有上述無規聚丙烯(B)，並且以1.6~5之質量比含有上述線性低密度聚乙烯(C)。
(11)如上述(6)至(10)中任一項記載之發泡體，其中上述無規聚丙烯(B)之熔體流動速率為0.4~2.0g/10分鐘，並且上述線性低密度聚乙烯(C)之熔體流動速率為1.5~15g/10分鐘。
(12)如上述(6)至(11)中任一項記載之發泡體，其中上述無規聚丙烯(B)為乙烯-丙烯無規共聚物。
(13)如上述(1)至(12)中任一項記載之發泡體，其厚度為0.5~5.0mm，為片狀。
(14)一種積層體，其具備上述(1)至(13)中任一項記載之發泡體及積層於該發泡體之片狀素材。
(15)一種成形體，其係將上述(1)至(13)中任一項記載之發泡體或上述(14)記載之積層體成形而獲得。
(16)一種成形體，其係將上述(14)記載之積層體成形而獲得者，於上述片狀素材表面附有凹凸。
根據本發明，即便於如升高將發泡體成形為成形體時的成形溫度之情形時，亦可防止成形時發泡體之破裂等，使成形性良好。
以下，使用以下實施形態對本發明更詳細地進行說明。
<發泡體>
本發明中之發泡體係密度為0.036g/cc以上，未達0.133g/cc者，依據JIS K6251測得之160℃斷裂點伸長率(%)為150%以上，且該斷裂點伸長率(%)乘以依據JIS K6251於160℃測得之100%模量(MPa)而得之值(以下，亦稱為「SS係數」)為7以上。
本發泡體藉由將密度設為規定範圍，並如上所述升高斷裂伸長率及SS係數，即便於高溫(例如，160℃以上)下成形，亦不易於發泡體產生破裂等，而適於成形為車輛用內飾材料等各種成形體。
另一方面，若160℃斷裂點伸長率(%)未達150%，或SS係數未達7， 則將發泡體於高溫下成形為成形體時，於發泡體產生破裂等，而難以使成形性良好。又，若密度未達0.036g/cc，或高於0.133g/cc，則難以獲得柔軟性、機械強度等車輛用內飾材料等成形體所要求之物性。
又，就製造容易性等觀點而言，160℃斷裂點伸長率較佳為400%以下，SS係數較佳為30以下，但並無特別限定。
於本發明中，發泡體之交聯度為30~50%。若發泡體之交聯度未達30%，則發泡體之機械強度降低，SS係數變低，故而於成形時產生破裂，而發泡體之成形性不會良好。又，存在無法賦予下述發泡性組成物之發泡所需的剪切黏度之情況。
另一方面，若交聯度超過50%，則發泡體之伸縮性、拉伸強度降低，容易產生無法將成形體按照模具正確地成形，或產生破裂之不良狀況。又，亦存在發泡性組成物之剪切黏度過高，而發泡性降低，不易獲得發泡倍率高之發泡體，並且發泡體之外觀性降低的情況。
再者，交聯度係利用實施例中記載之方法，採集溶劑不溶解成分，求出試片之重量A與不溶解成分之重量B，根據下述式算出。
交聯度(重量%)=(B/A)×100
就使發泡體之成形性或機械特性更為良好之觀點而言，發泡體之交聯度較佳為32~48%，更佳為35~45%。
又，發泡體較佳為片狀。發泡體之具體之厚度較佳為0.5~5.0mm，更佳為1~4mm左右。若厚度為該等範圍，則容易利用真空成形等將發泡體成形為車輛用內飾材料。
於使發泡體成形時，根據發泡體之密度不同，斷裂伸長率、 模量等機械物性之最佳值不同。例如，於密度為0.036g/cc以上，未達0.044g/cc的低密度之發泡體中，較佳依據JIS K6251測得之160℃斷裂點伸長率(%)為150%以上，並且SS係數為7以上。
如上所述之低密度之發泡體可以相對較弱之力成形，故而無需使斷裂點伸長率、SS係數高如上述程度，若斷裂點伸長率、SS係數為上述值以上，則可獲得充分之成形性。又，藉由使用例如下述發泡體組成物，而即便為低密度之發泡體，亦可容易地製造具有該等斷裂點伸長率及SS係數之發泡體。
就同時實現製造容易性與成形性之觀點而言，於上述低密度之發泡體中，更佳斷裂點伸長率為160~240%，並且SS係數為7.5~15左右。
於密度為0.044g/cc以上，未達0.057g/cc之中低密度的發泡體中，較佳依據JIS K6251測得之160℃斷裂點伸長率(%)為170%以上，並且上述SS係數為8以上。於中低密度之發泡體中，藉由使斷裂點伸長率、SS係數為該等下限值以上，可獲得充分之成形性。又，藉由使用例如下述發泡性組成物，而容易於中低密度之發泡體中，使斷裂點伸長率及SS係數為該等下限值以上。又，就同時實現成形性及製造容易性之觀點而言，於上述中低密度之發泡體中，更佳斷裂點伸長率為180~300%，並且SS係數為8.5~20左右。
於密度為0.057g/cc以上，未達0.077g/cc之中高密度的發泡體中，較佳依據JIS K6251測得之160℃斷裂點伸長率(%)為200%以上，並且SS係數為10以上。於中高密度之發泡體中，藉由使斷裂點伸長率、SS係數為該等下限值以上，可獲得充分之成形性，並且藉由使用例如 下述發泡性組成物，而容易使斷裂點伸長率及SS係數為該等下限值以上。又，就同時實現成形性及製造容易性之觀點而言，於該中高密度之發泡體中，更佳斷裂點伸長率為220~360%，並且SS係數為12~25左右。
又，於密度為0.077g/cc以上，未達0.133g/cc之高密度之發泡體中，較佳依據JIS K6251測得之160℃斷裂點伸長率(%)為250%以上，並且SS係數為15以上。於高密度之發泡體中，為了使成形性良好，需要使斷裂點伸長率及SS係數相對較大，藉由設為該等下限值以上，可獲得充分之成形性。又，藉由使用例如下述發泡性組成物，可於高密度之發泡體中，使斷裂點伸長率及SS係數容易地為該等下限值以上。又，就同時實現成形性及製造容易性之觀點而言，於上述高密度之發泡體中，更佳斷裂點伸長率為300~400%，並且SS係數為15~30左右。
<發泡性組成物>
本發明之發泡體係使發泡性組成物交聯且發泡而成者。發泡體例如為交聯聚烯烴系樹脂發泡體。用以獲得交聯聚烯烴系樹脂發泡體之發泡性組成物例如含有均聚丙烯(A)、無規聚丙烯(B)、及線性低密度聚乙烯(C)。發泡性組成物藉由含有該等(A)~(C)成分，且使(A)成分之量為下述規定量，而容易使發泡體之160℃斷裂點伸長率(%)及SS係數為上述規定值以上。
以下，對發泡性組成物所使用之(A)~(C)成分進行說明。
[(A)成分]
均聚丙烯(A)為丙烯均聚物，其熔體流動速率(以下，亦稱為「MFR」) 較佳為2.5~20g/10分鐘。藉由使均聚丙烯(A)之MFR為2.5g/10分鐘以上，20g/10分鐘以下，樹脂之流動性變良好，另一方面，可防止樹脂之流動性變得過高，將發泡性組成物加工成發泡體時之加工性變良好。因此，例如可防止於發泡體之表面產生粗糙、或難以將發泡性組成物加工成片狀之發泡體。
就使上述加工性變良好之觀點而言，均聚丙烯(A)之MFR較佳為4~16g/10分鐘，更佳為6~12g/10分鐘。
發泡性組成物中之均聚丙烯(A)相對於發泡性組成物所含有之樹脂成分總量，較佳含有10~60質量%。藉由使均聚丙烯(A)為10質量%以上，發泡體之機械強度、及上述SS係數變高，成形時不易於成形體產生破裂等。又，藉由使含量為60質量%以下，發泡體之拉伸強度及伸縮性等變高，成形體容易按照模具正確地成形，且不易發生產生破裂之不良狀況。
均聚丙烯(A)相對於樹脂成分總量，較佳為10~40質量%，更佳為10質量%以上，未達20質量%。於本發明中，藉由使(A)成分之含量相對較少，而使發泡性組成物加工成發泡體之加工性良好，並且發泡體之拉伸強度及SS係數均變得更為良好，容易成為成形性優異者。
[(B)、(C)成分]
無規聚丙烯(B)為使丙烯與丙烯以外之α-烯烴進行無規共聚而獲得之共聚物。作為丙烯以外之α-烯烴，可列舉碳數為2之乙烯、或1-丁烯、1-戊烯、1-己烯、4-甲基-1-戊烯、1-庚烯、1-辛烯等碳數4~10左右之α-烯烴，於該等之中，就成形性及耐熱性之觀點而言，較佳為 乙烯。即，無規聚丙烯(B)較佳為乙烯-丙烯無規共聚物。
又，於共聚物中，α-烯烴可單獨使用，或將2種以上組合使用。又，作為(B)成分，亦可使用2種以上之無規聚丙烯之混合物。
無規聚丙烯(B)較佳為使丙烯50重量%以上，未達100重量%與丙烯以外之α-烯烴50重量%以下進行共聚而獲得。此處，更佳相對於構成共聚物之所有單體成分，丙烯為80~99.9重量%，丙烯以外之α-烯烴為0.1~20質量%，進而較佳丙烯為90~99.5重量%，丙烯以外之α-烯烴為0.5~10質量%，進一步更佳丙烯為95~99重量%，丙烯以外之α-烯烴為1~5質量%。
線性低密度聚乙烯(C)係密度為0.910g/cm3以上，未達0.950g/cm3之聚乙烯，較佳密度為0.910~0.930g/cm3者。發泡體藉由除了上述(A)(B)成分以外，亦含有密度低之線性低密度聚乙烯(C)，將發泡性組成物加工成發泡體時之加工性變良好。又，上述斷裂點伸長率及SS係數成為適當之值，將發泡體成形為成形體時之成形性等容易變良好。
線性低密度聚乙烯(C)通常係以乙烯為主成分(所有單體之50質量%以上，較佳為70質量%以上)之乙烯與少量的α-烯烴之共聚物。此處，作為α-烯烴，可列舉碳數為3~12，較佳碳數為4~10者，具體而言，可列舉1-丁烯、1-戊烯、1-己烯、4-甲基-1-戊烯、1-庚烯、1-辛烯等。
發泡性組成物較佳相對於上述(A)成分，以0.16~8之質量比含有無規聚丙烯(B)，以0.16~8之質量比含有線性低密度聚乙烯(C)，更佳以1.6~5之質量比含有無規聚丙烯(B)，以1.6~5之質量比含有線性 低密度聚乙烯(C)。進而，發泡性組成物進而較佳相對於上述(A)成分，以2.5~4.5之質量比含有無規聚丙烯(B)，以1.5~4.0之質量比含有線性低密度聚乙烯(C)，又，(B)成分之含量(質量)較佳高於(C)成分。於本發明中，藉由將(B)(C)成分設為以上之範圍，上述加工成發泡體之加工性變良好。又，斷裂點伸長率及SS係數容易變高，而容易使發泡體之成形性等變良好。
又，無規聚丙烯(B)相對於樹脂成分總量，較佳為5~80質量%，更佳為15~60質量%，進而較佳為40~60質量%。線性低密度聚乙烯(C)相對於樹脂成分總量，較佳為5~80質量%，更佳為15~60質量%，進而較佳為20~40質量%。
又，較佳無規聚丙烯(B)之MFR為0.4~2.0g/10分鐘，並且線性低密度聚乙烯(C)之MFR為1.5~15g/10分鐘。又，更佳(B)成分之MFR為0.5~1.5g/10分鐘，並且(C)成分之MFR為2~12g/10分鐘。於本發明中，藉由如以上所述，除了(A)成分以外，亦調整(B)、(C)成分之MFR，而容易使上述將發泡性組成物加工成發泡體之加工性及發泡體之成形性等更為優異。
[其他成分]
發泡性組成物可僅含有(A)、(B)、及(C)成分作為樹脂成分，但只要為不阻礙本發明之目的之範圍，則亦可含有(A)、(B)、(C)成分以外之樹脂成分。作為(A)、(B)、(C)成分以外之樹脂成分，可列舉：高密度聚乙烯等上述(C)成分以外之聚乙烯、乙烯-丙烯嵌段共聚物、改質聚丙烯樹脂等上述(A)、(B)成分以外之聚丙烯、乙烯-丙烯橡膠(EPM)、 乙烯-丙烯橡膠-二烯橡膠(EPDM)、乙烯-乙酸乙烯酯共聚物、乙烯-丙烯酸共聚物、乙烯-(甲基)丙烯酸烷基酯共聚物、或使馬來酸酐與該等進行共聚而成之改質共聚物等。作為(A)、(B)、(C)成分以外之樹脂成分，相對於樹脂成分總量，通常含有30質量%以下，較佳含有10質量%以下。
<添加劑>
發泡性組成物通常含有發泡劑作為添加劑，又，較佳含有交聯助劑及抗氧化劑中之一者或兩者。
(發泡劑)
作為發泡劑，使用熱分解型發泡劑，例如可使用分解溫度為160~270℃左右之有機系或無機系之化學發泡劑。
作為有機系發泡劑，可列舉：偶氮雙甲醯胺(azodicarbonamide)、偶氮二羧酸金屬鹽(偶氮二羧酸鋇等)、偶氮二異丁腈等偶氮化合物、N,N'-二亞硝基五亞甲基四胺等亞硝基化合物、二縮酸醯胺基聯氨(hydrazodicarbonamide)、4,4'-氧基雙(苯磺醯肼)、甲苯磺醯肼等肼衍生物、甲苯磺醯胺基脲等胺基脲化合物等。
作為無機系發泡劑，可列舉：酸銨、碳酸鈉、碳酸氫銨、碳酸氫鈉、亞硝酸銨、硼氫化鈉、無水檸檬酸單鈉等。
於該等之中，就獲得微細之氣泡的觀點，及就經濟性、安全方面之觀點而言，較佳為偶氮化合物、亞硝基化合物，更佳為偶氮雙甲醯胺、偶氮二異丁腈、N,N'-二亞硝基五亞甲基四胺，尤佳為偶氮雙甲醯胺。該等熱分解型發泡劑可單獨使用，或將2種以上組合使用。
為了可使發泡體之氣泡不破裂而適當地發泡，熱分解型發泡劑之添加 量相對於樹脂成分100質量份，較佳為1~30質量份，更佳為2~15質量份。
(交聯助劑)
作為交聯助劑，可使用多官能單體。例如可列舉：三羥甲基丙烷三甲基丙烯酸酯、三羥甲基丙烷三丙烯酸酯等三官能(甲基)丙烯酸酯系化合物；偏苯三羧酸三烯丙酯、1,2,4-苯三羧酸三烯丙酯、異氰尿酸三烯丙酯等1分子中具有3個官能基之化合物；1,6-己二醇二甲基丙烯酸酯、1,9-壬二醇二甲基丙烯酸酯、1,10-癸二醇二甲基丙烯酸酯、新戊二醇二甲基丙烯酸酯等二官能(甲基)丙烯酸酯系化合物；二乙烯苯等1分子中具有2個官能基之化合物；鄰苯二甲酸二烯丙酯、對苯二甲酸二烯丙酯、間苯二甲酸二烯丙酯、乙基乙烯基苯、甲基丙烯酸月桂酯、甲基丙烯酸硬脂酯等。交聯助劑可單獨使用，或將2種以上組合使用。於該等之中，更佳為三官能(甲基)丙烯酸酯系化合物。
藉由將交聯助劑添加至發泡性組成物中，可以鮮少之游離輻射量使發泡性組成物交聯。因此，可防止伴隨游離輻射之照射之各樹脂分子的切斷、劣化。
交聯助劑之含量相對於樹脂成分100質量份，較佳為0.2~20質量份，更佳為0.5~15質量份。若該含量為0.2質量份以上，則於使發泡性組成物發泡時，容易調整為所欲之交聯度。又，若為20質量份以下，則容易控制對發泡性組成物賦予之交聯度。
(抗氧化劑)
作為抗氧化劑，可列舉酚系抗氧化劑、硫系抗氧化劑、磷系抗氧化劑、胺系抗氧化劑等，於該等之中，較佳為酚系抗氧化劑、硫系抗氧化劑，更 佳將酚系抗氧化劑與硫系抗氧化劑組合使用。
例如，作為酚系抗氧化劑，可列舉：2,6-二第三丁基對甲酚、3-(3,5-二第三丁基-4-羥基苯基)丙酸正十八烷基酯、丙烯酸2-第三丁基-6-(3-第三丁基-2-羥基-5-甲基苄基)-4-甲基苯酯、四[亞甲基-3-(3,5-二第三丁基-4-羥基苯基)丙酸酯]甲烷等。該等酚系抗氧化劑可單獨使用，亦可並用2種以上。
又，作為硫系抗氧化劑，例如可列舉：硫代二丙酸二月桂酯、硫代二丙酸二肉豆蔻酯、硫代二丙酸二硬脂酯、新戊四醇四(3-月桂基硫代丙酸酯)等。該等硫系抗氧化劑可單獨使用，亦可並用2種以上。
抗氧化劑之含量相對於樹脂成分100質量份，較佳為0.1~10質量份，更佳為0.2~5質量份。
又，發泡體組成物亦可以根據需要含有氧化鋅、硬脂酸鋅、脲等分解溫度調節劑、阻燃劑、抗金屬危害劑、抗靜電劑、穩定劑、填充劑、顏料等上述以外之添加劑。
<發泡體之製造方法>
發泡體例如可藉由使含有(A)、(B)、(C)成分、根據需要調配之其他樹脂成分、及熱分解型發泡劑等添加劑之發泡性組成物，以交聯度成為30~50%之方式進行交聯之後進行加熱發泡而製造。具體而言，利用具有以下步驟(1)~(3)之方法進行製造於工業上有利。
步驟(1)：將含有熱分解型發泡劑之發泡性組成物之各成分供給至混練裝置中，於未達熱分解型發泡劑之分解溫度之溫度下進行熔融、混練之後，製成片狀等所需形狀之發泡性組成物的步驟
步驟(2)：對步驟(1)中獲得之發泡性組成物照射游離輻射，以交聯度成為30~50%之方式進行交聯的步驟
步驟(3)：將步驟(2)中已交聯之發泡性組成物加熱至發泡劑之分解溫度以上，使其發泡，獲得發泡體的步驟
作為上述步驟(1)中之混練裝置，例如可列舉單軸擠出機、雙軸擠出機等擠出機、班布里混合機、滾筒等通用混練裝置等，較佳為擠出機。
又，作為步驟(2)中所使用之游離輻射，可列舉α射線、β射線、γ射線、電子束等，較佳為電子束。游離輻射之照射量只要可獲得所欲之交聯度即可，較佳為0.1~10Mrad，更佳為0.2~5Mrad，進而較佳為0.5~3Mrad。游離輻射之照射量受(A)、(B)、(C)成分之比率或添加劑等之影響，故而通常一面測量交聯度一面調整照射量。
於步驟(3)中，使發泡性組成物加熱發泡之溫度取決於用作發泡劑之熱分解型發泡劑的分解溫度，通常為140~300℃，較佳為150~260℃。又，於步驟(3)中，發泡體亦可於發泡後，或一面發泡一面向MD方向或CD方向中之任一方向或兩個方向延伸。
[積層體]
本發明之積層體為具備發泡體及積層於該發泡體之片狀素材之積層體。於積層體中，發泡體為片狀，並且片狀素材通常接著於發泡體。作為片狀素材，可列舉樹脂片、熱塑性彈性體片、布帛等，於將積層體用於車輛用內飾材料之情形時，較佳使用聚氯乙烯片、由聚氯乙烯與ABS樹脂之混合樹脂構成之樹脂片、熱塑性彈性體片、梭織物、針織物、不織布、皮 革、人工皮革、合成皮革等各種布帛。該等片狀素材於將積層體成形為成形體時，較佳於成形體中配置於表面。
又，於積層體中，上述片狀素材可僅設置於發泡體之一面，亦可設置於兩面。例如，於將積層體用於車輛用內飾材料之情形時，亦可於發泡體之一面積層上述樹脂片、熱塑性彈性體片、布帛，並且於另一面配置由聚乙烯、聚戊二烯等構成之樹脂片。
[成形體]
於本發明中，將上述發泡體或積層體利用公知之方法進行成形，而成為成形體。作為成形方法，可列舉真空成形、壓縮成形、沖壓成形等，於該等之中，較佳為真空成形。又，真空成形有陽模真空成形、陰模真空成形，較佳為陰模真空成形。
又，於成形體為將具有片狀素材之積層體成形而得者之情形時，較佳對片狀素材之表面附以凹凸。凹凸通常係於成形時將模具表面之凹凸轉印而得者，此時，較佳成形體係利用陰模真空成形而成形。
成形體係用作隔熱材料、緩衝材料等，較佳於汽車領域中，用作車頂材料、車門、儀錶面板等車輛用內飾材料。
實施例
以下，利用實施例對本發明更詳細地進行說明，但本發明並不受該等例任何限定。
各物性之測量方法、及發泡體之評價方法如下所述。
(1)交聯度
自發泡體採集約100mg之試片，準確稱量試片之重量A(mg)。接著， 將該試片浸漬於120℃之二甲苯30cm3中，放置24小時後，用200目之金屬線網進行過濾，採集金屬線網上之不溶解成分，進行真空乾燥，準確稱量不溶解成分之重量B(mg)。根據所得之值，利用下述式算出交聯度(重量%)。
交聯度(重量%)=100×(B/A)
(2)MFR
MFR係基於JIS K7210，聚丙烯係於溫度為230℃、荷重為2.16kgf之條件下、聚乙烯係於溫度為190℃、荷重為2.16kgf之條件下測得之值。
(3)密度
發泡體之密度係依據JISK 7222進行測量。又，各樹脂成分之密度係依據JISK7112進行測量。
(4)斷裂點伸長率、100%模量
斷裂點伸長率及100%模量係於160℃，依據JIS K6251中記載之方法測得之值。
(5)片加工性
對各實施例、比較例中獲得之發泡片，利用以下之評價基準進行評價，確認將發泡性組成物加工成發泡片時之加工性。
A：表面不粗糙，表面狀態良好。
B：雖然表面稍微粗糙，但實用上無問題。
C：表面粗糙，實用上無法使用。
D：無法成形為片狀。
(6)成形性
將各實施例、比較例之發泡片於表面溫度160℃，利用陰模真空成形罩進行真空成形，評價成形性。將罩之直徑設為D，將深度設為H，增大深度H與直徑D之比H/D，分別進行真空成形，根據於發泡片產生破裂、或於發泡片之一部分產生薄且透明的部分時之比H/D，對成形性進行評價。
再者，實用上，根據發泡體之密度不同，成形體之大小亦不同，故而將評價基準如以下般設為針對每一密度而不同者。
(評價基準)
‧密度：0.036g/cc以上，未達0.044g/cc
A：0.8<H/D B：0.75<H/D≦0.8
C：0.7<H/D≦0.75 D：H/D≦0.7
‧密度：0.044g/cc以上，未達0.057g/cc
A：0.82<H/D B：0.77<H/D≦0.82
C：0.72<H/D≦0.77 D：H/D≦0.72
‧密度：0.057g/cc以上，未達0.077g/cc
A：0.84<H/D B：0.79<H/D≦0.84
C：0.74<H/D≦0.79 D：H/D≦0.74
‧密度：0.077g/cc以上，未達0.133g/cc
A：0.86<H/D B：0.81<H/D≦0.86
C：0.76<H/D≦0.81 D：H/D≦0.76
實施例1~10、比較例1~9
於各實施例、比較例中，將表1所示之各樹脂成分及添加劑以表1所示之份數投入至單軸擠出機中，於樹脂溫度190℃進行熔融混練並擠出，而 獲得厚度1.3mm之片狀之發泡組成物。對該片狀之發泡組成物的兩面，用加速電壓800kV，以成為規定的交聯度之方式，以表1之照射量照射電子束，藉此使發泡性組成物交聯。然後，利用250℃之氣相烘箱使已交聯之發泡性組成物發泡，而製成發泡片(發泡體)。將各實施例、比較例之發泡體之評價結果示於表1中。
各實施例、比較例所使用之樹脂成分及添加劑分別如下所述。
均聚PP1：均聚丙烯，製品名：J105G，普萊姆高分子(Prime Polymer)公司製造，MFR=9g/10分鐘
均聚PP2：均聚丙烯，製品名：J106G，普萊姆高分子公司製造，MFR=15g/10分鐘
均聚PP3：均聚丙烯，製品名：EA7AD，日本波利普洛(Japan Polypropylene)公司製造，MFR=1.3g/10分鐘
均聚PP4：均聚丙烯，製品名：J3000GP，普萊姆高分子公司製造，MFR=30g/10分鐘
均聚PP5：均聚丙烯，製品名：Y400-GP，普萊姆高分子公司製造，MFR=4g/10分鐘
無規PP：乙烯-丙烯無規共聚物，製品名：EG8，日本波利普洛公司製造，MFR=0.8g/10分鐘，乙烯量：3質量%
LLDPE：線性低密度聚乙烯，製品名：2047G，Dow Chemical Japan公司製造，MFR=2.3g/10分鐘
交聯助劑：三羥甲基丙烷三甲基丙烯酸酯
發泡劑：偶氮雙甲醯胺
抗氧化劑1：2,6-二第三丁基對甲酚
抗氧化劑2；硫代二丙酸二月桂酯
如上所述，於實施例1~10中，藉由使發泡體之交聯度為30~50%，並使160℃斷裂伸長率高為150%以上，使SS係數高為7以上， 而使高溫下之伸縮性、機械強度等變良好，發泡體之高溫下之成形性變良好。
另一方面，根據比較例2~8可知：若160℃斷裂伸長率、SS係數、及交聯度中之任一者超出上述範圍，則高溫下之發泡體之伸縮性、機械強度等降低，發泡體之成形性不充分。再者，於比較例1、9中，因均聚丙烯(A)之MFR過低、或過高，故而片加工性變差，無法將發泡性組成物加工成發泡體。

Claims (16)

  1. 一種發泡體，其密度為0.036g/cc以上，未達0.133g/cc，依據JIS K6251測得之160℃斷裂點伸長率(%)為150%以上，該斷裂點伸長率(%)乘以依據JIS K6251於160℃測得之100%模量(MPa)而得之值為7以上，交聯度為30~46%。
  2. 如申請專利範圍第1項之發泡體，其密度為0.036g/cc以上，未達0.044g/cc，依據JIS K6251測得之160℃斷裂點伸長率(%)為150%以上，該斷裂點伸長率(%)乘以依據JIS K6251於160℃測得之100%模量(MPa)而得之值為7以上。
  3. 如申請專利範圍第1項之發泡體，其密度為0.044g/cc以上，未達0.057g/cc，依據JIS K6251測得之160℃斷裂點伸長率(%)為170%以上，該斷裂點伸長率(%)乘以依據JIS K6251於160℃測得之100%模量(MPa)而得之值為8以上。
  4. 如申請專利範圍第1項之發泡體，其密度為0.057g/cc以上，未達0.077g/cc，依據JIS K6251測得之160℃斷裂點伸長率(%)為200%以上，該斷裂點伸長率(%)乘以依據JIS K6251於160℃測得之100%模量(MPa)而得之值為10以上。
  5. 如申請專利範圍第1項之發泡體，其密度為0.077g/cc以上，未達0.133g/cc，依據JIS K6251測得之160℃斷裂點伸長率(%)為250%以上，該斷裂點伸長率(%)乘以依據JIS K6251於160℃測得之100%模量(MPa)而得之值為15以上。
  6. 如申請專利範圍第1至5項中任一項之發泡體，其係使含有均聚丙烯 (homopolypropylene)(A)、無規聚丙烯(B)、及線性低密度聚乙烯(C)之發泡性組成物交聯且發泡而成，該均聚丙烯(A)相對於發泡性組成物中之樹脂成分總量為10~60質量%，並且熔體流動速率為2.5~20g/10分鐘。
  7. 如申請專利範圍第6項之發泡體，其中，該均聚丙烯(A)之熔體流動速率為6~12g/10分鐘。
  8. 如申請專利範圍第6項之發泡體，其中，該發泡性組成物相對於該均聚丙烯(A)，以0.16~8之質量比含有該無規聚丙烯(B)，並且以0.16~8之質量比含有該線性低密度聚乙烯(C)。
  9. 如申請專利範圍第6項之發泡體，其中，相對於組成物中之樹脂成分總量，以10質量%以上，未達20質量%含有該均聚丙烯(A)。
  10. 如申請專利範圍第9項之發泡體，其中，該發泡性組成物相對於該均聚丙烯(A)，以1.6~5之質量比含有該無規聚丙烯(B)，並且以1.6~5之質量比含有該線性低密度聚乙烯(C)。
  11. 如申請專利範圍第6項之發泡體，其中，該無規聚丙烯(B)之熔體流動速率為0.4~2.0g/10分鐘，並且該線性低密度聚乙烯(C)之熔體流動速率為1.5~15g/10分鐘。
  12. 如申請專利範圍第6項之發泡體，其中，該無規聚丙烯(B)為乙烯-丙烯無規共聚物。
  13. 如申請專利範圍第1至5項中任一項之發泡體，其厚度為0.5~5.0mm，為片狀。
  14. 一種積層體，其具備申請專利範圍第1至13項中任一項之發泡體及積 層於該發泡體之片狀素材。
  15. 一種成形體，其係將申請專利範圍第1至13項中任一項之發泡體或申請專利範圍第14項之積層體成形而獲得。
  16. 一種成形體，其係將申請專利範圍第14項之積層體成形而獲得者，於該片狀素材表面附有凹凸。
TW104129911A 2014-09-10 2015-09-10 Foam, laminate and shaped body TWI668257B (zh)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2014184305 2014-09-10
JPJP2014-184305 2014-09-10

Publications (2)

Publication Number Publication Date
TW201623387A TW201623387A (zh) 2016-07-01
TWI668257B true TWI668257B (zh) 2019-08-11

Family

ID=55459144

Family Applications (1)

Application Number Title Priority Date Filing Date
TW104129911A TWI668257B (zh) 2014-09-10 2015-09-10 Foam, laminate and shaped body

Country Status (8)

Country Link
US (1) US10442908B2 (zh)
EP (1) EP3192828A4 (zh)
JP (1) JP6859103B2 (zh)
KR (1) KR102517797B1 (zh)
CN (1) CN106795311B (zh)
CA (1) CA2960463A1 (zh)
TW (1) TWI668257B (zh)
WO (1) WO2016039400A1 (zh)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3604412B1 (en) * 2017-03-31 2022-06-29 Sekisui Chemical Co., Ltd. Foam and molded article
JP7446822B2 (ja) 2019-05-31 2024-03-11 住友化学株式会社 熱可塑性エラストマー組成物およびその製造方法

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2004149665A (ja) * 2002-10-30 2004-05-27 Sekisui Chem Co Ltd 架橋オレフィン系樹脂発泡体

Family Cites Families (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5134314A (en) 1974-09-17 1976-03-24 Toyota Motor Co Ltd Rootaripisuton no haujinguichigimenotsukupinsochi
US3981545A (en) 1975-07-30 1976-09-21 Aspro, Incorporated Traction control apparatus
JPH0480237A (ja) * 1990-07-20 1992-03-13 Tonen Chem Corp 架橋発泡体用ポリオレフィン樹脂組成物
JPH05295149A (ja) 1992-04-14 1993-11-09 Tonen Chem Corp ポリオレフィン架橋発泡体用樹脂組成物
JPH06192461A (ja) 1992-12-25 1994-07-12 Tonen Chem Corp ポリプロピレン架橋発泡体の製造方法
IT1264681B1 (it) 1993-07-07 1996-10-04 Himont Inc Composizione poliolefiniche parzialmente reticolate
JP2004075976A (ja) * 2002-06-21 2004-03-11 Sekisui Chem Co Ltd 架橋ポリオレフィン系樹脂発泡体及びその製造方法
JP2004339362A (ja) * 2003-05-15 2004-12-02 Sekisui Chem Co Ltd 架橋ポリオレフィン系樹脂発泡体及び成形品
JP2004339361A (ja) 2003-05-15 2004-12-02 Sekisui Chem Co Ltd 架橋ポリオレフィン系樹脂発泡体
ATE408489T1 (de) * 2004-10-18 2008-10-15 Alveo Ag Kombiniertes kompressions- und scherverfahren für die produktion eines gequetschten polyolefinschaumstoffs und dabei erhaltenes produkt
US20090023826A1 (en) 2005-05-18 2009-01-22 Toray Industries, Inc. Crosslinked polyolefin resin foam
JP5208865B2 (ja) * 2008-06-25 2013-06-12 トヨタ紡織株式会社 自動車用内装材

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2004149665A (ja) * 2002-10-30 2004-05-27 Sekisui Chem Co Ltd 架橋オレフィン系樹脂発泡体

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
J *

Also Published As

Publication number Publication date
JP6859103B2 (ja) 2021-04-14
CA2960463A1 (en) 2016-03-17
KR102517797B1 (ko) 2023-04-05
US20170260349A1 (en) 2017-09-14
KR20170049517A (ko) 2017-05-10
TW201623387A (zh) 2016-07-01
EP3192828A4 (en) 2018-01-24
WO2016039400A1 (ja) 2016-03-17
CN106795311A (zh) 2017-05-31
CN106795311B (zh) 2020-07-07
JPWO2016039400A1 (ja) 2017-06-22
US10442908B2 (en) 2019-10-15
EP3192828A1 (en) 2017-07-19

Similar Documents

Publication Publication Date Title
JP5475991B2 (ja) 高耐熱性を有する軟質ポリオレフィン
CN106715551B (zh) 交联聚烯烃系发泡体
JP7240448B2 (ja) 架橋ポリオレフィン発泡体、及びそれを用いた成形体
JP6846342B2 (ja) 架橋ポリオレフィン系樹脂発泡体、及びそれを用いた成形体
TWI668257B (zh) Foam, laminate and shaped body
JP6974312B2 (ja) 架橋ポリオレフィン発泡体、及びそれを用いた成形体
JP6696807B2 (ja) 積層発泡シート、及びそれを用いた成形体
JP5905660B2 (ja) 架橋ポリオレフィン系樹脂発泡体の製造方法及び該樹脂発泡体を用いた積層品
JP7377047B2 (ja) ポリオレフィン系樹脂発泡体シート、及びその製造方法
JP2003082144A (ja) ポリオレフィン系樹脂架橋発泡体
JP6323036B2 (ja) 発泡体
JP2021046506A (ja) 発泡体シート
JP2003183435A (ja) 架橋樹脂発泡体
JP2022057092A (ja) 発泡体及び車両用内装材
JP2022019933A (ja) 架橋ポリオレフィン系樹脂発泡体、架橋ポリオレフィン系樹脂発泡体の製造方法、及び凹状成形体
JP2020163756A (ja) 複合発泡シート及び成形体
JP2001098099A (ja) ポリエチレン系架橋発泡体
JP2004291372A (ja) 積層体
JP2004027119A (ja) ポリオレフィン系樹脂架橋発泡体
JPH06287341A (ja) ポリオレフィン系樹脂発泡体