WO2009096327A1 - 発泡性ポリスチレン系樹脂粒子とその製造方法、予備発泡粒子及び発泡成形体 - Google Patents
発泡性ポリスチレン系樹脂粒子とその製造方法、予備発泡粒子及び発泡成形体 Download PDFInfo
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- WO2009096327A1 WO2009096327A1 PCT/JP2009/051049 JP2009051049W WO2009096327A1 WO 2009096327 A1 WO2009096327 A1 WO 2009096327A1 JP 2009051049 W JP2009051049 W JP 2009051049W WO 2009096327 A1 WO2009096327 A1 WO 2009096327A1
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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
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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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F212/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring
- C08F212/02—Monomers containing only one unsaturated aliphatic radical
- C08F212/04—Monomers containing only one unsaturated aliphatic radical containing one ring
- C08F212/06—Hydrocarbons
- C08F212/08—Styrene
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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
- C08J9/22—After-treatment of expandable particles; Forming foamed products
- C08J9/228—Forming foamed products
- C08J9/232—Forming foamed products by sintering expandable particles
-
- 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
- C08J2325/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Derivatives of such polymers
- C08J2325/02—Homopolymers or copolymers of hydrocarbons
- C08J2325/04—Homopolymers or copolymers of styrene
- C08J2325/06—Polystyrene
Definitions
- the present invention relates to a method for producing expandable polystyrene resin particles used in the production of polystyrene resin foam molded articles useful as food containers, packaging, and cushioning materials.
- the present invention can provide a foamed molded article having a beautiful appearance and high strength even when the pressure of water vapor used during molding is low, and can be molded at low pressure.
- the present invention relates to a method for producing expandable polystyrene resin particles that can shorten the molding time per shot.
- a method for producing a polystyrene-based resin foam molded body that is industrially used is to heat foamable polystyrene-based resin particles containing a volatile foaming agent or the like with a heat medium such as steam to a desired bulk density.
- foaming pre-foaming
- the pre-foamed particles are filled into the cavity of a mold having a cavity having a desired molding shape, and the pre-foamed particles in the cavity are heated by a heat medium such as steam.
- In-mold foam molding is performed to obtain a foam molded body. At this time, the density of the obtained polystyrene-based resin foam molding is almost the same as the bulk density in the preliminary foaming.
- the setting of the bulk density is determined by the strength required for the polystyrene resin foam molded article and the foaming performance of the expandable polystyrene resin particles.
- polystyrene-based resin foam molded articles used for packaging materials such as home appliances and food containers such as fish boxes have a density of about 0.02 to 0.017 g / cm 3 on the market.
- the appearance and strength of the foamed molded product vary depending on the heating medium temperature such as steam (heating steam pressure in the case of steam).
- the heating medium temperature such as steam (heating steam pressure in the case of steam).
- the heating pressure is increased, the appearance and strength of the molded product tend to be improved, but the cooling time becomes longer, so the productivity is lowered, which is not preferable.
- the heating pressure is increased, the surface of the foam molded body is melted by heat, so that the appearance of the foam molded body is deteriorated.
- the molding time per shot is shortened, but the adhesion between the pre-foamed particles is weakened, and the appearance and strength of the foamed molded product are lowered.
- the steam heating vapor pressure in the molding process can be molded to some extent from low pressure to high pressure.
- the relationship between the molding time per shot and the strength of the foamed molded product in the production of polystyrene-based resin foamed molded products is that when the molding time is long, a foamed molded product having high strength is obtained. When the molding time is short, the strength of the foamed molded product tends to decrease.
- Patent Documents 1 to 5 can be cited.
- Patent Document 1 proposes a method in which the surface of expandable polystyrene resin particles is coated with a powdered aliphatic carboxylic acid and aliphatic alcohol ester that is solid at room temperature and is 60 mesh or less. This method can significantly reduce the cooling time out of the molding time and is effective in reducing the molding time, but tends to be accompanied by a decrease in strength.
- Patent Document 2 discloses a paraffin wax emulsion
- Patent Document 3 includes liquid paraffin
- Patent Document 4 includes a specific silicone compound
- Patent Document 5 includes a polyether on the surface of expandable polystyrene resin particles or expanded particles. A method of coating has been proposed. However, these methods cannot avoid a decrease in strength when formed into a foamed molded product.
- the present invention has been made in view of the above circumstances, and can obtain a foamed molded article having a beautiful appearance and high strength even when the pressure of water vapor used during molding is low, and can be molded by low pressure molding.
- An object of the present invention is to provide expandable polystyrene resin particles that can shorten the molding time per shot.
- the present invention provides: (1) In a dispersion obtained by dispersing polystyrene resin seed particles in water, 7.0 to 80.0 parts by mass of a styrene monomer and an acrylate ester system with respect to 100 parts by mass of the polystyrene resin seed particles.
- a method for producing resin particles is provided.
- the present invention is an expandable polystyrene resin particle containing a copolymer of a styrene monomer and an acrylate monomer, ATR method infrared spectroscopy of infrared absorption spectrum which is obtained by analyzing the surface of the expandable polystyrene resin particles by, obtains the absorbance D1600 at absorbance D1730 and 1600 cm -1 in 1730cm -1, D1730 / D1600 Absorbance ratio (A) calculated from Of the infrared absorption spectrum which is obtained by analyzing the central portion of the expandable polystyrene resin particles by ATR method infrared spectroscopy, it determined the absorbance D1600 at absorbance D1730 and 1600 cm -1 in 1730cm -1, D1730 /
- the absorbance ratio (B) calculated from D1600 is (A) ⁇ (B) and (A) is 0.05 or more, Expandable polystyrene resin particles satisfying the above relationship are provided.
- the absorbance ratio (A) is in the range of 0.05 to 0.50, and the absorbance ratio (B) is in the range of 0.20 to 0.60. Is preferred.
- the ratio (B / A) of the absorbance ratio (A) to (B) is preferably in the range of 1.10 to 3.00.
- the expandable polystyrene resin particles are preferably those obtained by the method for producing the expandable polystyrene resin particles.
- the present invention also provides pre-expanded particles obtained by pre-expanding the expandable polystyrene resin particles so that the bulk density is in the range of 0.01 to 0.033 g / cm 3 .
- the present invention also provides a foamed molded article obtained by filling the pre-expanded particles in a cavity of a molding die and heating and molding the preformed foam.
- the expandable polystyrene resin particles of the present invention can provide a foamed molded article having a beautiful appearance and high strength even when the pressure of water vapor used during molding is low. According to the present invention, it is possible to obtain a foamed molded article in which the appearance of the molded article hardly deteriorates due to a decrease in heat resistance even in molding at a high vapor pressure. According to the present invention, it is possible to provide a foamed molded article that has a very wide range of conditions that can be molded and that satisfies the quality required during various moldings.
- the expandable polystyrene resin particles and pre-expanded particles of the present invention have less foaming performance over time compared to conventional products, and have sufficient foaming performance even after long-term storage than conventional products. Excellent shelf life.
- the method for producing the expandable polystyrene resin particles of the present invention (1) In a dispersion obtained by dispersing polystyrene resin seed particles in water, 7.0 to 80.0 parts by mass of a styrene monomer and an acrylate ester system with respect to 100 parts by mass of the polystyrene resin seed particles.
- examples of the polystyrene resin that is a material of polystyrene resin seed particles include styrene or a homopolymer of a styrene derivative.
- examples of the styrene derivative include ⁇ -methylstyrene, paramethylstyrene, t-butylstyrene, chlorostyrene, and the like.
- the above-mentioned copolymer using a styrene copolymer such as acrylonitrile, dimethyl fumarate, and ethyl fumarate together with a copolymer of styrene and a polyfunctional monomer such as divinylbenzene or alkylene glycol methacrylate examples thereof include a resin and a resin to which an appropriate amount of a rubber-like substance is added, and a copolymer or styrene homopolymer having a styrene component of 50% by mass or more is preferable.
- This polystyrene resin preferably has a weight average molecular weight in the range of 150,000 to 400,000.
- the seed particles may be a polystyrene resin recovered product.
- the particle diameter of the seed particles can be adjusted as appropriate according to the average particle diameter of the polystyrene resin particles to be produced. For example, when producing polystyrene resin particles having an average particle diameter of 1.0 mm, the average particle diameter It is preferable to use seed particles having a diameter of about 0.4 to 0.7 mm.
- examples of the styrene monomer include styrene and styrene derivatives.
- examples of the styrene derivative include ⁇ -methylstyrene, paramethylstyrene, t-butylstyrene, chlorostyrene, and the like.
- styrene is preferable.
- examples of the acrylate monomer include methyl acrylate, ethyl acrylate, propyl acrylate, butyl acrylate, pentyl acrylate, hexyl acrylate, and the like. Preference is given to propyl acid and butyl acrylate.
- the styrene monomer used in the first polymerization step of the present invention is 7.0 to 80.0 parts by mass with respect to 100 parts by mass of the polystyrene resin seed particles. When the amount is less than 7.0 parts by mass, the heat resistance during molding decreases, and when the amount exceeds 80.0 parts by mass, the low-pressure formability is inferior. The amount is preferably 8.0 to 72.0 parts by mass.
- the acrylate monomer used in the first polymerization step of the present invention is 2.0 to 12.0 parts by mass with respect to 100 parts by mass of the polystyrene resin seed particles. If it is less than 2.0 mass parts, it is inferior to low-pressure moldability, and if it exceeds 12.0 mass parts, heat resistance will fall. Preferably, it is 2.0 to 11.2 parts by mass.
- a gaseous or liquid organic compound having a boiling point below the softening point of the polystyrene resin and normal pressure is suitable.
- hydrocarbons such as propane, n-butane, isobutane, n-pentane, isopentane, neopentane, cyclopentane, cyclopentadiene, n-hexane, petroleum ether, ketones such as acetone and methyl ethyl ketone, methanol, ethanol, isopropyl alcohol, etc.
- foaming agents may use only 1 type and may use 2 or more types together.
- preferred blowing agents are hydrocarbons having a boiling point of ⁇ 45 to 40 ° C., and propane, n-butane, isobutane, n-pentane, isopentane and the like are preferred.
- the amount of the foaming agent added is preferably in the range of 5 to 15 parts by mass with respect to 100 parts by mass of the polystyrene resin particles.
- an aqueous medium is placed in a reaction vessel such as an autoclave, and the seed particles are dispersed in the aqueous medium.
- a reaction vessel such as an autoclave
- the seed particles are dispersed in the aqueous medium.
- a styrene monomer and an acrylate monomer and then in (2) the second polymerization step, only the styrene monomer is supplied continuously or intermittently to polymerize.
- an initiator a styrene-acrylic acid ester copolymer and a polystyrene resin are grown on the seed particle surface and / or inside the seed particles to produce polystyrene resin particles having a predetermined particle diameter.
- the proper use amount of seed particles is preferably in the range of 10 to 60% by mass and more preferably in the range of 15 to 50% by mass with respect to the total amount of polystyrene resin.
- the polymerization initiator that can be used in the (1) first polymerization step and (2) second polymerization step is not particularly limited as long as it is conventionally used for the polymerization of styrene monomers.
- polymerization initiators those having a decomposition temperature of 80 to 120 ° C. for obtaining a half-life of 10 hours are particularly preferable.
- One kind of this polymerization initiator can be used alone, or two or more different kinds of polymerization initiators can be used in combination.
- any suspension stabilizer conventionally used for suspension polymerization of polystyrene resins can be used. It can be used without being particularly limited, and examples thereof include water-soluble polymers such as polyvinyl alcohol, methyl cellulose, polyacrylamide, and polyvinyl pyrrolidone, and poorly soluble inorganic compounds such as tricalcium phosphate and magnesium pyrophosphate.
- One type of suspension stabilizer can be used alone, or two or more types of suspension stabilizers can be used in combination.
- anionic surfactant When using a poorly soluble inorganic compound as the suspension stabilizer, it is preferable to use an anionic surfactant in combination.
- anionic surfactants include fatty acid soaps, N-acyl amino acids or salts thereof, carboxylates such as alkyl ether carboxylates, alkylbenzene sulfonates, alkyl naphthalene sulfonates, and dialkyl sulfosuccinates.
- Sulfonates such as alkyl sulfoacetates and ⁇ -olefin sulfonates; sulfates such as higher alcohol sulfates, secondary higher alcohol sulfates, alkyl ether sulfates, polyoxyethylene alkylphenyl ether sulfates, etc.
- Salt Phosphate ester salts such as alkyl ether phosphate ester salts and alkyl phosphate ester salts.
- the amount of the styrene monomer and the acrylate monomer to be supplied to the aqueous medium is 7.0 to 70% of the styrene monomer with respect to 100 parts by mass of the seed particles.
- the range is 80.0 parts by mass, and the acrylate monomer is in the range of 2.0 to 12.0 parts by mass.
- the (2) second polymerization step after the completion of the (1) first polymerization step, only a styrene monomer is added to an aqueous medium in a reaction vessel such as an autoclave, and the (1) first polymerization step A polystyrene resin is grown on the grown seed particles to form polystyrene resin particles.
- the amount of the styrene monomer used in the (2) second polymerization step is not particularly limited, but is 30.0 to 80.80 with respect to 100 parts by mass of the resin content of the polystyrene resin particles obtained after the second polymerization step. A range of 0 parts by mass is desirable.
- polystyrene resin particles are impregnated with a foaming agent.
- A a method of impregnating a foaming agent after producing polystyrene-based resin particles;
- B or a method of impregnating a foaming agent during the growth of polystyrene resin particles, Either of these can be used.
- the produced resin particles are taken out, washed and dried to obtain expandable polystyrene resin particles.
- the expandable polystyrene resin particles of the present invention if necessary, in the polystyrene resin, other additives commonly used in the production of expandable polystyrene resin particles, for example, Bubble regulators, plasticizers, solvents, flame retardants, colorants such as dyes, and the like can be added.
- the surface of the expandable polystyrene resin particles of the present invention is coated with a surface treatment agent such as a fatty acid metal salt, a fatty acid ester, or an antistatic agent, as is usually done for conventional expandable polystyrene resin particles. It is also possible to improve the fluidity and pre-foaming characteristics of the resin particles (beads) by coating the surface treatment agent.
- a surface treatment agent such as a fatty acid metal salt, a fatty acid ester, or an antistatic agent
- the expandable polystyrene resin particles of the present invention contain a copolymer of a styrene monomer and an acrylate monomer, Of the infrared absorption spectrum which is obtained by analyzing the surface of the expandable polystyrene resin particles by ATR method infrared spectroscopy, determined the absorbance D1600 at absorbance D1730 and 1600 cm -1 in 1730 cm -1, from D1730 / D1600 The calculated absorbance ratio (A), ATR method infrared spectroscopy of infrared absorption spectrum which is obtained by analyzing the heart of expandable polystyrene resin particles by, obtains the absorbance D1600 at absorbance D1730 and 1600 cm -1 in 1730cm -1, D1730 / D1600 The absorbance ratio (B) calculated from (A) ⁇ (B) and (A) is 0.05 or more, It is characterized by satisfying the
- the ATR method infrared spectroscopic analysis is an analysis method for measuring an infrared absorption spectrum by a single reflection type ATR method using total reflection absorption.
- This analysis method is a method in which an ATR prism having a high refractive index is brought into close contact with a sample, infrared light is irradiated to the sample through the ATR prism, and light emitted from the ATR prism is spectrally analyzed.
- ATR infrared spectroscopic analysis includes organic substances such as polymer materials because of the simplicity of being able to measure the spectrum simply by bringing the sample and the ATR prism into close contact, and the ability to perform surface analysis up to a depth of several ⁇ m. It is widely used for surface analysis of various substances.
- the absorbance D1730 and 1600 cm -1 in 1730 cm -1 absorbance D1730 and 1600 cm -1 in 1730 cm -1
- the absorbance D1600 is determined.
- the absorbance ratio (A) on the surface of the resin particle and the absorbance ratio (B) at the center of the particle are calculated from the absorbance values.
- the absorbance D1600 at 1600 cm ⁇ 1 obtained from the infrared absorption spectrum refers to the height of a peak appearing in the vicinity of 1600 cm ⁇ 1 derived from the in-plane vibration of the benzene ring contained in the polystyrene resin.
- the surface absorbance is a value obtained by measuring the surface A of the expandable polystyrene resin particle 1 by ATR infrared spectroscopy as shown in FIG. 1, and the absorbance at the center is shown in FIG. As shown, it is a value obtained by measuring the central part B of the cross section obtained by cutting the expandable polystyrene resin particles 1 through the center thereof by ATR infrared spectroscopy.
- the expandable polystyrene resin particles of the present invention have an absorbance ratio (A) of the surface of the resin particles calculated as described above and an absorbance ratio (B) of the center part of the particle particles.
- (A) ⁇ (B) and (A) is 0.05 or more, It is characterized by satisfying the relationship. That is, in the expandable polystyrene resin particles of the present invention, in the diameter direction of the particles, the ratio of the styrene-acrylic acid ester copolymer component contained is high in the central portion and low in the surface layer side. There is a tendency. Further, a certain amount of styrene-acrylate copolymer component is also present in the surface layer portion of the particles.
- the expandable polystyrene resin particles of the present invention have the distribution structure of the styrene-acrylic ester copolymer component as described above, the appearance is good even when the pressure of water vapor used during molding is low.
- a foamed molded article having a beautiful and high strength can be obtained, and a foamed molded article in which the appearance of the molded article hardly deteriorates due to a decrease in heat resistance even in molding at a high vapor pressure can be obtained.
- the relationship of (A) ⁇ (B) and (A) being 0.05 or more it is difficult to obtain the above effect.
- the absorbance ratio (A) is preferably in the range of 0.05 to 0.50, and more preferably in the range of 0.08 to 0.47.
- the absorbance ratio (B) is preferably in the range of 0.20 to 0.60, and more preferably in the range of 0.23 to 0.55. Further, the ratio (B / A) of the absorbance ratio (A) to (B) is preferably in the range of 1.10 to 3.00, and more preferably in the range of 1.17 to 2.88.
- the expandable polystyrene resin particles of the present invention can be efficiently produced by the production method according to the present invention described above, but the production method is not limited thereto.
- the expandable polystyrene resin particles of the present invention are pre-expanded into pre-expanded particles so that the bulk density is in the range of 0.01 to 0.033 g / cm 3 . It is used to produce a foamed molded article by filling in, heating and molding in-mold.
- Example 1 Manufacture of seed particles 40000 g of water, 100 g of tricalcium phosphate as a suspension stabilizer and 2.0 g of calcium dodecylbenzenesulfonate as an anionic surfactant are fed into a polymerization vessel equipped with a stirrer with an internal volume of 100 liters, and 40000 g of styrene and a polymerization initiator are stirred. After adding 96.0 g of benzoyl peroxide and 28.0 g of t-butylperoxybenzoate, the mixture was heated to 90 ° C. and polymerized. And it hold
- the polystyrene resin particles (a) were sieved to obtain polystyrene resin particles (b) having a particle diameter of 0.5 to 0.71 mm as seed particles.
- the absorbance ratio (D1730 / D1600) is measured as follows. That is, the ATR method red is used for the surface of each of 10 resin particles selected at random (reference A in FIG. 1) and the central portion (reference B in FIG. 2) of the cross section cut through the particle. Infrared absorption spectrum is obtained by particle surface analysis by external spectroscopic analysis. The absorbance ratio (D1730 / D1600) was calculated from each infrared absorption spectrum, the arithmetic average of the absorbance ratio calculated for surface A was defined as the absorbance ratio (A), and the arithmetic average of the absorbance ratio calculated for center B was the absorbance. The ratio (B).
- the absorbances D1730 and D1600 are measured using, for example, a measurement apparatus sold by Nicolet under the trade name “Fourier transform infrared spectrophotometer MAGMA 560”.
- the absorbance D1600 at 1600 cm ⁇ 1 obtained from the infrared absorption spectrum refers to the height of a peak appearing in the vicinity of 1600 cm ⁇ 1 derived from the in-plane vibration of the benzene ring contained in the polystyrene resin.
- n-butane as a foaming agent was press-fitted into the polymerization vessel containing the polystyrene resin particles (c), held for 3 hours, cooled to 30 ° C. or lower, taken out from the polymerization vessel and dried. Above, it was left in a thermostatic chamber at 13 ° C. for 5 days to obtain expandable polystyrene resin particles.
- Example 2 In the first polymerization step, 6.8 g of benzoyl peroxide and 1.5 g of t-butylperoxybenzoate as polymerization initiators, 200 g of styrene (40 parts by mass with respect to 100 parts by mass of seed particles), and 10 g of butyl acrylate (seed Expandable polystyrene resin particles were obtained in the same manner as in Example 1 except that it was dissolved in a mixed solution of 2 parts by mass with respect to 100 parts by mass of the particles.
- Example 3 In the first polymerization step, 6.8 g of benzoyl peroxide and 1.5 g of t-butylperoxybenzoate as polymerization initiators, 154 g of styrene (30.8 parts by mass with respect to 100 parts by mass of seed particles), and 56 g of butyl acrylate Expandable polystyrene resin particles were obtained in the same manner as in Example 1 except that it was dissolved in a mixed liquid (11.2 parts by mass with respect to 100 parts by mass of seed particles).
- Example 4 In the first polymerization step, 6.8 g of benzoyl peroxide and 1.5 g of t-butylperoxybenzoate as polymerization initiators, 40 g of styrene (8 parts by mass with respect to 100 parts by mass of seed particles), 30 g of butyl acrylate (seed 1430 g of styrene that is dissolved in a mixed solution of 6 parts by mass with respect to 100 parts by mass of particles and that is supplied in a certain amount by a pump into the polymerization vessel while raising the temperature in 150 minutes in the second polymerization step. Except that, expandable polystyrene resin particles were obtained in the same manner as in Example 1.
- Example 5 In the first polymerization step, 6.8 g of benzoyl peroxide and 1.5 g of t-butylperoxybenzoate as polymerization initiators, 360 g of styrene (72 parts by mass with respect to 100 parts by mass of seed particles), 30 g of butyl acrylate (seed 1110 g of styrene that was dissolved in a mixed solution of 6 parts by mass with respect to 100 parts by mass of the particles and that was supplied in a certain amount by a pump into the polymerization vessel while raising the temperature in 150 minutes in the second polymerization step. Except that, expandable polystyrene resin particles were obtained in the same manner as in Example 1.
- Example 6 In the first polymerization step, the acrylic ester used is ethyl acrylate, 6.8 g benzoyl peroxide and 1.5 g t-butylperoxybenzoate are used as a polymerization initiator, and 170 g of styrene (based on 100 parts by mass of seed particles). 34 parts by mass) and 40 g of ethyl acrylate (8 parts by mass with respect to 100 parts by mass of seed particles), and the temperature is raised in 150 minutes while supplying a constant amount by pump into the polymerization vessel. Expandable polystyrene resin particles were obtained in the same manner as in Example 1 except that 1290 g of the styrene monomer was used.
- Example 7 As a polymerization initiator, 6.8 g of benzoyl peroxide and 1.5 g of t-butylperoxybenzoate were dissolved in a mixed solution of 180 g of a styrene monomer and 30 g of butyl acrylate, and the temperature was increased in 150 minutes. Expandable polystyrene resin particles were obtained in the same manner as in Example 1 except that the amount of the styrene monomer to be supplied in a constant amount by a pump was changed to 750 g.
- Example 8 As a polymerization initiator, 6.8 g of benzoyl peroxide and 1.5 g of t-butylperoxybenzoate were dissolved in a mixed solution of 180 g of a styrene monomer and 30 g of butyl acrylate, and the temperature was increased in 150 minutes. Expandable polystyrene resin particles were obtained in the same manner as in Example 1 except that 2000 g of the styrene monomer to be supplied in a constant amount by a pump was used.
- Example 9 As a polymerization initiator, 6.8 g of benzoyl peroxide and 1.5 g of t-butylperoxybenzoate were dissolved in a mixed solution of 180 g of a styrene monomer and 30 g of butyl acrylate, and the temperature was increased in 150 minutes. Expandable polystyrene resin particles were obtained in the same manner as in Example 1 except that the amount of the styrene monomer to be supplied in a fixed amount by a pump was changed to 500 g.
- Example 10 As a polymerization initiator, 6.8 g of benzoyl peroxide and 1.5 g of t-butylperoxybenzoate were dissolved in a mixed solution of 180 g of a styrene monomer and 30 g of butyl acrylate, and the temperature was increased in 150 minutes. Expandable polystyrene resin particles were obtained in the same manner as in Example 1 except that the amount of the styrene monomer to be supplied in a fixed amount by a pump was changed to 2750 g.
- Example 1 Comparative Example 1 In Example 1, 6.8 g of benzoyl peroxide and 1.5 g of t-butylperoxybenzoate were used in the first polymerization step without using an acrylate ester, and 210 g of styrene (42 parts by mass with respect to 100 parts by mass of seed particles). Except for the above, expandable polystyrene resin particles were obtained in the same manner as in the Examples. In the same manner as in Example 1, for the polystyrene resin particles (c) before impregnation with the foaming agent, the surface absorbance ratio (A) and the central absorbance ratio (B) were measured, and these ratios ((B) / (A)) was calculated. The results are shown in Table 1.
- Comparative Example 2 In the first polymerization step, 6.8 g of benzoyl peroxide and 1.5 g of t-butylperoxybenzoate as a polymerization initiator, 202 g of styrene (40.4 parts by mass with respect to 100 parts by mass of seed particles), and 8 g of butyl acrylate Styrene that is dissolved in a mixed solution (1.6 parts by mass with respect to 100 parts by mass of seed particles) and that is supplied in a certain amount by a pump into the polymerization vessel while raising the temperature in 150 minutes in the second polymerization step. Expandable polystyrene resin particles were obtained in the same manner as in Example 1 except that 1290 parts by mass was used.
- Comparative Example 3 In the first polymerization step, 6.8 g of benzoyl peroxide and 1.5 g of t-butylperoxybenzoate as polymerization initiators, 140 g of styrene (28 parts by mass with respect to 100 parts by mass of seed particles), 70 g of butyl acrylate (seed 1290 g of styrene that is dissolved in a mixed solution of 14 parts by mass with respect to 100 parts by mass of particles and that is supplied in a certain amount by a pump into the polymerization vessel while raising the temperature in 150 minutes in the second polymerization step. Except that, expandable polystyrene resin particles were obtained in the same manner as in Example 1.
- Comparative Example 4 In the first polymerization step, 6.8 g of benzoyl peroxide and 1.5 g of t-butylperoxybenzoate as polymerization initiators, 30 g of styrene (6 parts by mass with respect to 100 parts by mass of seed particles), 30 g of butyl acrylate (seed 1440 parts by mass of styrene that is dissolved in a mixed solution of 6 parts by mass with respect to 100 parts by mass of particles) and that is supplied in a certain amount by a pump into the polymerization vessel while raising the temperature in 150 minutes in the second polymerization step. Except that, expandable polystyrene resin particles were obtained in the same manner as in Example 1.
- Comparative Example 5 In the first polymerization step, 6.8 g of benzoyl peroxide and 1.5 g of t-butylperoxybenzoate as polymerization initiators, 460 g of styrene (92 parts by mass with respect to 100 parts by mass of seed particles), and 30 g of butyl acrylate (seed 1010 g of styrene that is dissolved in a mixed solution of 6 parts by mass with respect to 100 parts by mass of particles and that is supplied in a certain amount by a pump into the polymerization vessel while raising the temperature in 150 minutes in the second polymerization step. Except that, expandable polystyrene resin particles were obtained in the same manner as in Example 1.
- Comparative Example 6 In a polymerization vessel equipped with a stirrer having an internal volume of 5 liters, 2000 parts by mass of water, 500 parts by mass of the styrene resin particles (B), 6.0 parts by mass of magnesium pyrophosphate as a suspension stabilizer, and dodecyl as an anionic surfactant The mixture was heated to 75 ° C. while supplying 0.3 parts by mass of calcium benzenesulfonate and stirring.
- a mixed liquid of 1470 parts by mass of styrene and 30 parts by mass of butyl acrylate was prepared in advance, and 210 parts by mass of the mixed liquid (41.2 parts by mass of styrene and 0.84 of butyl acrylate with respect to 100 parts by mass of seed particles). 6.8 parts by mass of benzoyl peroxide and 1.5 parts by mass of t-butylperoxybenzoate were dissolved and fed to the 5 liter polymerization vessel and held at 75 ° C. for 60 minutes.
- the absorbance ratio (A) of the surface of the polystyrene-based resin particles and the absorbance ratio (B) of the central portion are (A) ⁇ (B). And (A) was 0.05 or more.
- the absorbance ratio (A) was in the range of 0.05 to 0.50
- the absorbance ratio (B) was in the range of 0.20 to 0.60.
- the ratio (B / A) of the absorbance ratio (A) to (B) was in the range of 1.10 to 3.00.
- Comparative Example 1 since no acrylic acid ester was added, the absorbance D1730 at 1730 cm ⁇ 1 derived from absorption of the ester group was not measured.
- Comparative Example 2 since the amount of butyl acrylate used in the first polymerization step was small, the surface absorbance ratio (A) was 0.02, and the lower limit (0) of the surface absorbance ratio (A) defined in the present invention. .05).
- Comparative Example 3 since the amount of butyl acrylate used in the first polymerization step was large, the absorbance ratio (A) on the surface was larger than the absorbance ratio (B) at the center.
- Comparative Example 4 since the amount of styrene used in the first polymerization step was small, the surface absorbance ratio (A) was larger than the central absorbance ratio (B). In Comparative Example 5, since the amount of styrene used in the first polymerization step was large, the surface absorbance ratio (A) was 0.04, which was the lower limit (0) of the surface absorbance ratio (A) defined in the present invention. .05). Further, in Comparative Example 6, the use of butyl acrylate together with styrene in the second polymerization step resulted in a surface absorbance ratio (A) that was greater than the central absorbance ratio (B).
- the pre-expanded particles are filled into the cavities of an automatic foaming bead molding machine equipped with a mold having a rectangular parallelepiped cavity with an internal dimension of 300 mm ⁇ 400 mm ⁇ 30 mm, and the following two conditions (molding vapor pressure) are used.
- a polystyrene resin foam molded article having a density of 0.0167 g / cm 3 was molded.
- Molding conditions Molding Machine ACE-3SP manufactured by Sekisui Koki Co., Ltd.
- Molding vapor pressure 2 conditions (cage pressure: 0.04 MPa, 0.09 MPa) Mold heating 5 seconds
- One side heating set pressure 0.03MPa
- Reverse one side heating 3 seconds
- Double-sided heating 15 seconds
- Water cooling 5 seconds
- Cooling vacuum cooling QS molding mode
- the foamed molded product in the case of 09 MPa the bending strength, the foamed molded product appearance, and the cooling time were examined and evaluated under the following conditions. The results are shown in Table 2.
- Bending strength (MPa) 3FL / 2bh 2 (Here, F represents the maximum bending load (N), L represents the distance between supporting points (mm), b represents the width (mm) of the test piece, and h represents the thickness (mm) of the test piece. )
- the cooling time of the present invention is the cooling time when the foaming pressure of the molded body in the cavity reaches the take-out set surface pressure of 0.02 MPa after the water cooling process is performed under the molding conditions described above. did.
- the cooling time three sheets were molded for each condition (molding vapor pressure), and the average value was taken.
- Comparative Example 1 in which the monomer used in the first polymerization step is only styrene and no acrylate ester is added, the appearance of the foamed molded article obtained by molding at a low water vapor pressure (0.04 MPa) is It was bad and the bending strength was low.
- Comparative Example 2 in which an acrylic ester was added in an amount less than the range of the present invention in the first polymerization step, the appearance of the foamed molded article obtained by molding at a low water vapor pressure (0.04 MPa) was poor and the bending strength was low. It became low.
- Comparative Example 3 in which the amount of the acrylate ester in the first polymerization step exceeds the range of the present invention, the appearance of the foamed molded article obtained by molding at a high water vapor pressure (0.09 MPa) is poor, and the bending strength. Became lower.
- Comparative Example 4 in which the amount of styrene in the first polymerization step is less than the range of the present invention, both foamed molded products obtained by molding with both a low water vapor pressure (0.04 MPa) and a high water vapor pressure (0.09 MPa) The appearance was poor and the bending strength was low.
- Comparative Example 4 in which the amount of styrene in the first polymerization step exceeds the range of the present invention, the appearance of the foamed molded article obtained by molding at a low water vapor pressure (0.04 MPa) is poor, and the bending strength is low. became.
- Comparative Example 6 using a mixture of styrene and an acrylate ester has a poor appearance of a foam molded article obtained by molding at a high water vapor pressure (0.09 MPa). And the bending strength was low.
- the pre-expanded particles are filled into the cavities of an automatic foaming bead molding machine provided with a mold having a rectangular parallelepiped-shaped cavity with an inner size of 300 mm ⁇ 400 mm ⁇ 30 mm, and the density is 0.0167 g / A polystyrene resin foam molded article of cm 3 was molded.
- Molding conditions (Molding Machine ACE-3SP manufactured by Sekisui Koki Co., Ltd.) Molded vapor pressure Cage pressure: 0.04 MPa Mold heating 5 seconds One side heating (set pressure 0.03MPa) Reverse one side heating 3 seconds Double-sided heating 15 seconds Water cooling 5 seconds Cooling (vacuum cooling QS molding mode) Extraction set surface pressure 0.02 MPa
- Comparative Examples 1 to 6 it was not possible to obtain foam molded articles having a beautiful appearance under the same conditions as in the Examples.
- Table 2 Comparative Example 3 and Comparative Example 6 in which a foamed molded article having a good appearance was obtained with a low water vapor pressure (0.04 MPa)
- a foamed molded article having a good appearance was obtained with a low water vapor pressure (0.04 MPa)
- the pre-expanded particles that were allowed to stand for 7 days after the pre-expansion were used, it was not possible to obtain a foamed molded article having a beautiful appearance. From this test result, it can be seen that the pre-expanded particles obtained in Examples 1 to 10 according to the present invention are excellent in retention of foaming force and excellent in storage stability.
- the expandable polystyrene resin particles of the present invention are suitable for the production of polystyrene resin foam molded articles useful as food containers, packaging, and cushioning materials.
- the expandable polystyrene resin particles of the present invention can provide a foamed molded article having a beautiful appearance and high strength even when the pressure of water vapor used during molding is low, so that the manufacturing cost of the foamed molded article is reduced. Energy saving in manufacturing and manufacturing.
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Abstract
Description
本願は、2008年1月30日に日本に出願された特願2008-19000号に基づき優先権を主張し、その内容をここに援用する。
更に、加熱圧力が高くなると、発泡成形体の表面が熱で融けることで、発泡成形体の外観が低下する。
逆に加熱圧力を低くして成形すると、1ショット当たりの成形時間は短かくなるが、予備発泡粒子同士の接着が弱くなり、発泡成形体の外観、強度が低下する。
このように、成形工程におけるスチームの加熱蒸気圧が低圧から高圧まで、ある程度自由に成形できることは、発泡性ポリスチレン系樹脂粒子の重要な特性の一つである。
特許文献1には、発泡性ポリスチレン系樹脂粒子の表面に、常温で固体で60メッシュ以下の粉末状の脂肪族カルボン酸と脂肪族アルコールのエステルを被覆する方法が提案されている。この方法は、成形時間のうち、冷却時間が大幅に短縮でき、成形時間の短縮には有効であるが、強度の低下を伴なう傾向がある。
また特許文献2にはパラフィンワックスのエマルジョンを、特許文献3には流動パラフィンを、特許文献4には特定のシリコーン化合物を、特許文献5ではポリエーテルを発泡性ポリスチレン系樹脂粒子または発泡粒子表面に被覆する方法が提案されている。しかし、これらの方法も、発泡成形体としたときの強度の低下は避けられない。
(1)ポリスチレン系樹脂種粒子を水中に分散させてなる分散液中に、ポリスチレン系樹脂種粒子100質量部に対し、スチレン系単量体7.0~80.0質量部とアクリル酸エステル系単量体2.0~12.0質量部とを供給し、これらの単量体を種粒子に吸収、重合させてポリスチレン系樹脂種粒子を成長させる第1重合工程と、
(2)次いで、該分散液中にスチレン系単量体のみを供給し、これを種粒子に吸収、重合させてポリスチレン系樹脂粒子を成長させる第2重合工程と、
(3)第2重合工程を行ってポリスチレン系樹脂粒子を製造した後、又はポリスチレン系樹脂粒子の成長途上で発泡剤を含浸させる工程とを行って発泡性ポリスチレン系樹脂粒子を得る発泡性ポリスチレン系樹脂粒子の製造方法を提供する。
ATR法赤外分光分析により前記発泡性ポリスチレン系樹脂粒子の表面を分析し得られた赤外線吸収スペクトルのうち、1730cm-1での吸光度D1730と1600cm-1での吸光度D1600とを求め、D1730/D1600から算出される吸光度比(A)と、
ATR法赤外分光分析により前記発泡性ポリスチレン系樹脂粒子の中心部を分析し得られた赤外線吸収スペクトルのうち、1730cm-1での吸光度D1730と1600cm-1での吸光度D1600とを求め、D1730/D1600から算出される吸光度比(B)とが、
(A)<(B)であり、且つ
(A)が0.05以上であること、
の関係を満たす発泡性ポリスチレン系樹脂粒子を提供する。
前記発泡性ポリスチレン系樹脂粒子において、前記吸光度比(A)が0.05~0.50の範囲内であり、且つ前記吸光度比(B)が0.20~0.60の範囲内であることが好ましい。
前記発泡性ポリスチレン系樹脂粒子において、前記吸光度比(A)と(B)との比(B/A)が、1.10~3.00の範囲内であることが好ましい。
前記発泡性ポリスチレン系樹脂粒子は、前記発泡性ポリスチレン系樹脂粒子の製造方法により得られたものであることが好ましい。
本発明によれば、高い蒸気圧力での成形においても耐熱性低下による成形体外観の劣化が起こりにくい発泡成形体を得ることができる。
本発明によれば、成形可能な条件範囲が非常に広く、様々な成形時に要望される品質を満足する発泡成形体を提供することができる。
本発明の発泡性ポリスチレン系樹脂粒子及び予備発泡粒子は、従来品と比べて、発泡性能の経時変化が少なくなり、従来品よりも長期保存した後でも、十分な発泡性能を有しており、保存性に優れている。
(1)ポリスチレン系樹脂種粒子を水中に分散させてなる分散液中に、ポリスチレン系樹脂種粒子100質量部に対し、スチレン系単量体7.0~80.0質量部とアクリル酸エステル系単量体2.0~12.0質量部とを供給し、これらの単量体を種粒子に吸収、重合させてポリスチレン系樹脂種粒子を成長させる第1重合工程と、
(2)次いで、該分散液中にスチレン系単量体のみを供給し、これを種粒子に吸収、重合させてポリスチレン系樹脂粒子を成長させる第2重合工程と、
(3)第2重合工程を行ってポリスチレン系樹脂粒子を製造した後、又はポリスチレン系樹脂粒子の成長途上で発泡剤を含浸させる工程とを行って発泡性ポリスチレン系樹脂粒子を得ることを特徴としている。
さらに、種粒子の粒径は、作製するポリスチレン系樹脂粒子の平均粒子径等に応じて適宜調整でき、例えば、平均粒子径が1.0mmのポリスチレン系樹脂粒子を作製する場合には、平均粒子径が0.4~0.7mm程度の種粒子を用いることが好ましい。
本発明の第1重合工程に用いられるスチレン系単量体としては、ポリスチレン系樹脂種粒子100質量部に対して7.0~80.0質量部とする。7.0質量部未満の場合、成形時の耐熱性が低下し、80.0質量部を超えると低圧成形性に劣る。好ましくは、8.0~72.0質量部である。
また、本発明の第1重合工程に用いられるアクリル酸エステル単量体としては、ポリスチレン系樹脂種粒子100質量部に対して2.0~12.0質量部とする。2.0質量部未満では、低圧成形性に劣り、12.0質量部を超えると耐熱性が低下する。好ましくは、2.0~11.2質量部である。
(a)ポリスチレン系樹脂粒子を製造した後に、発泡剤を含浸させる方法、
(b)又はポリスチレン系樹脂粒子の成長途上で発泡剤を含浸させる方法、
のいずれかを用いることができる。
本発明の発泡性ポリスチレン系樹脂粒子は、スチレン系単量体とアクリル酸エステル系単量体との共重合体を含有し、
ATR法赤外分光分析により発泡性ポリスチレン系樹脂粒子の表面を分析し得られた赤外線吸収スペクトルのうち、1730cm-1での吸光度D1730と1600cm-1での吸光度D1600とを求め、D1730/D1600から算出される吸光度比(A)と、
ATR法赤外分光分析により発泡性ポリスチレン系樹脂粒子の中心部を分析し得られた赤外線吸収スペクトルのうち、1730cm-1での吸光度D1730と1600cm-1での吸光度D1600とを求め、D1730/D1600から算出される吸光度比(B)とが、
(A)<(B)であり、且つ
(A)が0.05以上であること、
の関係を満たすことを特徴とする。
この分析方法は、高い屈折率を持つATRプリズムを試料に密着させ、ATRプリズムを通して赤外線を試料に照射し、ATRプリズムからの出射光を分光分析する方法である。ATR法赤外分光分析は、試料とATRプリズムとを密着させるだけでスペクトルを測定できるという簡便さ、深さ数μmまでの表面分析が可能である等の理由で高分子材料等の有機物をはじめ、種々の物質の表面分析に広く利用されている。
なお、赤外吸収スペクトルから得られる1600cm-1での吸光度D1600 は、ポリスチレン系樹脂に含まれるベンゼン環の面内振動に由来する1600cm-1付近に現われるピークの高さをいう。
また、赤外吸収スペクトルから得られる1730cm-1での吸光度D1730は、アクリル酸エステルに含まれるエステル基のC=0間の伸縮振動に由来する1730cm-1付近に現われるピークの高さをいう。
また、表面の吸光度は、図1に示すように発泡性ポリスチレン系樹脂粒子1の表面AについてATR法赤外分光分析により測定して求めた値であり、また中心部の吸光度は、図2に示すように、発泡性ポリスチレン系樹脂粒子1をその中心を通って切断した断面の中心部BについてATR法赤外分光分析により測定して求めた値である。
(A)<(B)であり、且つ
(A)が0.05以上であること、
の関係を満たすことを特徴とする。
すなわち、本発明の発泡性ポリスチレン系樹脂粒子は、粒子の直径方向において、含有されているスチレン-アクリル酸エステル共重合体成分の割合が、中心部で濃度が高く、表層側で低濃度となる傾向にある。また、粒子の表層部においても、ある程度のスチレン-アクリル酸エステル共重合体成分が存在している。
また前記吸光度比(B)は、0.20~0.60の範囲内が好ましく、0.23~0.55の範囲がさらに好ましい。
さらに、前記吸光度比(A)と(B)との比(B/A)は、1.10~3.00の範囲内が好ましく、1.17~2.88の範囲内がさらに好ましい。
(種粒子の製造)
内容量100リットルの撹拌機付き重合容器に、水40000g、懸濁安定剤として第三リン酸カルシウム100g及びアニオン界面活性剤としてドデシルベンゼンスルフォン酸カルシウム2.0gを供給し撹拌しながらスチレン40000g並びに重合開始剤としてベンゾイルパーオキサイド96.0g及びt-ブチルパーオキシベンゾエート28.0gを添加した上で90℃に昇温して重合した。そして、この温度で6時間保持し、更に、125℃に昇温してから2時間保持し、その後冷却してポリスチレン系樹脂粒子(a)を得た。
次に、重合開始剤としてベンゾイルパーオキサイド6.8g及びt-ブチルパーオキシベンゾエート1.5gをスチレン180g(種粒子100質量部に対して36質量部)、アクリル酸ブチル30g(種粒子100質量部に対して6質量部)の混合液に溶解させたものを前記5リットルの重合容器に供給し、75℃で60分間保持した。
60分経過後に反応液を110℃まで150分で昇温しつつ、且つスチレン1290gを150分で重合容器内にポンプで一定量づつ供給した上で、120℃に昇温して2時間経過後に冷却しポリスチレン系樹脂粒子(c)を得た。
得られたポリスチレン系樹脂粒子(c)について、下記<吸光度比の測定>によって樹脂粒子の表面の吸光度比(A)と中心部の吸光度比(B)とを測定した。その結果を表1に記す。
また、吸光度比(A)と(B)との比((B)/(A))を算出し、これも表1に記す。
また、得られた発泡性ポリスチレン系樹脂についても、下記の「吸光度比の測定」により吸光度比を測定することができる。
吸光度比(D1730/D1600)は下記の要領で測定される。
即ち、無作為に選択した10個の各樹脂粒子の表面(図1中の符号A)、及び粒子を中心を通って切断した断面の中心部(図2中の符号B)について、ATR法赤外分光分析により粒子表面分析を行なって赤外線吸収スペクトルを得る。各赤外線吸収スペクトルから吸光度比(D1730/D1600)をそれぞれ算出し、表面Aについて算出した吸光度比の相加平均を吸光度比(A)とし、中心部Bについて算出した吸光度比の相加平均を吸光度比(B)とする。
吸光度D1730及びD1600は、例えば、Nicolet社から商品名「フーリエ変換赤外分光光度計 MAGMA560」で販売されている測定装置を用いて測定する。
なお、赤外吸収スペクトルから得られる1600cm-1での吸光度D1600は、ポリスチレン系樹脂に含まれるベンゼン環の面内振動に由来する1600cm-1付近に現われるピークの高さをいう。
また、赤外吸収スペクトルから得られる1730cm-1での吸光度D1730は、アクリル酸エステルに含まれるエステル基のC=0間の伸縮振動に由来する1730cm-1付近に現われるピークの高さをいう。
続いて、別の内容量5リットルの撹拌機付き重合容器に、水2200g、ポリスチレン系樹脂粒子(c)1800g、懸濁安定剤としてピロリン酸マグネシウム6.0g及びドデシルベンゼンスルフォン酸カルシウム1.0gを供給して撹拌しながら70℃に昇温した。次に、発泡助剤としてシクロヘキサン27.0g及び可塑剤としてジイソブチルアジペート12.6gを重合容器内に入れて密閉し100℃に昇温した。次に、発泡剤としてn-ブタン90gをポリスチレン系樹脂粒子(c)が入った重合容器内に圧入して3時間保持した後、30℃以下まで冷却した上で重合容器内から取り出し乾燥させた上で13℃の恒温室内に5日間放置して発泡性ポリスチレン系樹脂粒子を得た。
第1重合工程において、重合開始剤としてベンゾイルパーオキサイド6.8g及びt-ブチルパーオキシベンゾエート1.5gを、スチレン200g(種粒子100質量部に対して40質量部)、アクリル酸ブチル10g(種粒子100質量部に対して2質量部)の混合液に溶解したこと以外は、実施例1と同様にして発泡性ポリスチレン系樹脂粒子を得た。
実施例1と同様に、発泡剤含浸前のポリスチレン系樹脂粒子(c)について、表面の吸光度比(A)と中心部の吸光度比(B)とを測定し、またこれらの比((B)/(A))を算出した。結果を表1に記す。
第1重合工程において、重合開始剤としてベンゾイルパーオキサイド6.8g及びt-ブチルパーオキシベンゾエート1.5gを、スチレン154g(種粒子100質量部に対して30.8質量部)、アクリル酸ブチル56g(種粒子100質量部に対して11.2質量部)の混合液に溶解したこと以外は、実施例1と同様にして発泡性ポリスチレン系樹脂粒子を得た。
実施例1と同様に、発泡剤含浸前のポリスチレン系樹脂粒子(c)について、表面の吸光度比(A)と中心部の吸光度比(B)とを測定し、またこれらの比((B)/(A))を算出した。結果を表1に記す。
第1重合工程において、重合開始剤としてベンゾイルパーオキサイド6.8g及びt-ブチルパーオキシベンゾエート1.5gを、スチレン40g(種粒子100質量部に対して8質量部)、アクリル酸ブチル30g(種粒子100質量部に対して6質量部)の混合液に溶解したこと、及び第2重合工程において、150分で昇温しつつ、重合容器内にポンプで一定量づつ供給するスチレンを1430gとしたこと以外は、実施例1と同様にして発泡性ポリスチレン系樹脂粒子を得た。
実施例1と同様に、発泡剤含浸前のポリスチレン系樹脂粒子(c)について、表面の吸光度比(A)と中心部の吸光度比(B)とを測定し、またこれらの比((B)/(A))を算出した。結果を表1に記す。
第1重合工程において、重合開始剤としてベンゾイルパーオキサイド6.8g及びt-ブチルパーオキシベンゾエート1.5gを、スチレン360g(種粒子100質量部に対して72質量部)、アクリル酸ブチル30g(種粒子100質量部に対して6質量部)の混合液に溶解したこと、及び第2重合工程において、150分で昇温しつつ、重合容器内にポンプで一定量づつ供給するスチレンを1110gとしたこと以外は、実施例1と同様にして発泡性ポリスチレン系樹脂粒子を得た。
実施例1と同様に、発泡剤含浸前のポリスチレン系樹脂粒子(c)について、表面の吸光度比(A)と中心部の吸光度比(B)とを測定し、またこれらの比((B)/(A))を算出した。結果を表1に記す。
第1重合工程において、使用するアクリル酸エステル種をアクリル酸エチルとし、重合開始剤としてベンゾイルパーオキサイド6.8g及びt-ブチルパーオキシベンゾエート1.5gを、スチレン170g(種粒子100質量部に対して34質量部)、アクリル酸エチル40g(種粒子100質量部に対して8質量部)の混合液に溶解し、且つ150分で昇温しつつ、重合容器内にポンプで一定量づつ供給するスチレン系単量体を1290gとした以外は、実施例1と同様にして発泡性ポリスチレン系樹脂粒子を得た。
実施例1と同様に、発泡剤含浸前のポリスチレン系樹脂粒子(c)について、表面の吸光度比(A)と中心部の吸光度比(B)とを測定し、またこれらの比((B)/(A))を算出した。結果を表1に記す。
重合開始剤としてベンゾイルパーオキサイド6.8g及びt-ブチルパーオキシベンゾエート1.5gをスチレン系単量体180g、アクリル酸ブチル30gの混合液に溶解し、150分で昇温しつつ、重合容器内にポンプで一定量づつ供給するスチレン系単量体を750gとした以外は実施例1と同様にして発泡性ポリスチレン系樹脂粒子を得た。
実施例1と同様に、発泡剤含浸前のポリスチレン系樹脂粒子(c)について、表面の吸光度比(A)と中心部の吸光度比(B)とを測定し、またこれらの比((B)/(A))を算出した。結果を表1に記す。
重合開始剤としてベンゾイルパーオキサイド6.8g及びt-ブチルパーオキシベンゾエート1.5gをスチレン系単量体180g、アクリル酸ブチル30gの混合液に溶解し、150分で昇温しつつ、重合容器内にポンプで一定量づつ供給するスチレン系単量体を2000gとした以外は実施例1と同様にして発泡性ポリスチレン系樹脂粒子を得た。
実施例1と同様に、発泡剤含浸前のポリスチレン系樹脂粒子(c)について、表面の吸光度比(A)と中心部の吸光度比(B)とを測定し、またこれらの比((B)/(A))を算出した。結果を表1に記す。
重合開始剤としてベンゾイルパーオキサイド6.8g及びt-ブチルパーオキシベンゾエート1.5gをスチレン系単量体180g、アクリル酸ブチル30gの混合液に溶解し、150分で昇温しつつ、重合容器内にポンプで一定量づつ供給するスチレン系単量体を500gとした以外は実施例1と同様にして発泡性ポリスチレン系樹脂粒子を得た。
実施例1と同様に、発泡剤含浸前のポリスチレン系樹脂粒子(c)について、表面の吸光度比(A)と中心部の吸光度比(B)とを測定し、またこれらの比((B)/(A))を算出した。結果を表1に記す。
重合開始剤としてベンゾイルパーオキサイド6.8g及びt-ブチルパーオキシベンゾエート1.5gをスチレン系単量体180g、アクリル酸ブチル30gの混合液に溶解し、150分で昇温しつつ、重合容器内にポンプで一定量づつ供給するスチレン系単量体を2750gとした以外は実施例1と同様にして発泡性ポリスチレン系樹脂粒子を得た。
実施例1と同様に、発泡剤含浸前のポリスチレン系樹脂粒子(c)について、表面の吸光度比(A)と中心部の吸光度比(B)とを測定し、またこれらの比((B)/(A))を算出した。結果を表1に記す。
実施例1において、第1重合工程でアクリル酸エステルは使用せずに、ベンゾイルパーオキサイド6.8g及びt-ブチルパーオキシベンゾエート1.5gを、スチレン210g(種粒子100質量部に対して42質量部)とした以外は、実施例と同様にして発泡性ポリスチレン系樹脂粒子を得た。
実施例1と同様に、発泡剤含浸前のポリスチレン系樹脂粒子(c)について、表面の吸光度比(A)と中心部の吸光度比(B)とを測定し、またこれらの比((B)/(A))を算出した。結果を表1に記す。
第1重合工程において、重合開始剤としてベンゾイルパーオキサイド6.8g及びt-ブチルパーオキシベンゾエート1.5gを、スチレン202g(種粒子100質量部に対して40.4質量部)、アクリル酸ブチル8g(種粒子100質量部に対して1.6質量部)の混合液に溶解したこと、及び第2重合工程において、150分で昇温しつつ、重合容器内にポンプで一定量づつ供給するスチレンを1290質量部としたこと以外は、実施例1と同様にして発泡性ポリスチレン系樹脂粒子を得た。
実施例1と同様に、発泡剤含浸前のポリスチレン系樹脂粒子(c)について、表面の吸光度比(A)と中心部の吸光度比(B)とを測定し、またこれらの比((B)/(A))を算出した。結果を表1に記す。
第1重合工程において、重合開始剤としてベンゾイルパーオキサイド6.8g及びt-ブチルパーオキシベンゾエート1.5gを、スチレン140g(種粒子100質量部に対して28質量部)、アクリル酸ブチル70g(種粒子100質量部に対して14質量部)の混合液に溶解したこと、及び第2重合工程において、150分で昇温しつつ、重合容器内にポンプで一定量づつ供給するスチレンを1290gとしたこと以外は、実施例1と同様にして発泡性ポリスチレン系樹脂粒子を得た。
実施例1と同様に、発泡剤含浸前のポリスチレン系樹脂粒子(c)について、表面の吸光度比(A)と中心部の吸光度比(B)とを測定し、またこれらの比((B)/(A))を算出した。結果を表1に記す。
第1重合工程において、重合開始剤としてベンゾイルパーオキサイド6.8g及びt-ブチルパーオキシベンゾエート1.5gを、スチレン30g(種粒子100質量部に対して6質量部)、アクリル酸ブチル30g(種粒子100質量部に対して6質量部)の混合液に溶解したこと、及び第2重合工程において、150分で昇温しつつ、重合容器内にポンプで一定量づつ供給するスチレンを1440質量部としたこと以外は、実施例1と同様にして発泡性ポリスチレン系樹脂粒子を得た。
実施例1と同様に、発泡剤含浸前のポリスチレン系樹脂粒子(c)について、表面の吸光度比(A)と中心部の吸光度比(B)とを測定し、またこれらの比((B)/(A))を算出した。結果を表1に記す。
第1重合工程において、重合開始剤としてベンゾイルパーオキサイド6.8g及びt-ブチルパーオキシベンゾエート1.5gを、スチレン460g(種粒子100質量部に対して92質量部)、アクリル酸ブチル30g(種粒子100質量部に対して6質量部)の混合液に溶解したこと、及び第2重合工程において、150分で昇温しつつ、重合容器内にポンプで一定量づつ供給するスチレンを1010gとしたこと以外は、実施例1と同様にして発泡性ポリスチレン系樹脂粒子を得た。
実施例1と同様に、発泡剤含浸前のポリスチレン系樹脂粒子(c)について、表面の吸光度比(A)と中心部の吸光度比(B)とを測定し、またこれらの比((B)/(A))を算出した。結果を表1に記す。
内容量5リットルの撹拌機付き重合容器内に、水2000質量部、前記スチレン系樹脂粒子(B)500質量部、懸濁安定剤としてピロリン酸マグネシウム6.0質量部及びアニオン界面活性剤としてドデシルベンゼンスルフォン酸カルシウム0.3質量部を供給して撹拌しながら75℃に昇温した。
実施例1と同様に、発泡剤含浸前のポリスチレン系樹脂粒子(c)について、表面の吸光度比(A)と中心部の吸光度比(B)とを測定し、またこれらの比((B)/(A))を算出した。結果を表1に記す。
また、実施例1~10では、吸光度比(A)が0.05~0.50の範囲内であり、且つ前記吸光度比(B)が0.20~0.60の範囲内であった。
さらに、実施例1~10では、吸光度比(A)と(B)との比(B/A)が、1.10~3.00の範囲内であった。
また比較例2では、第1重合工程で使用したアクリル酸ブチルが少なかったために、表面の吸光度比(A)が0.02と、本発明で規定した表面の吸光度比(A)の下限(0.05)未満となった。
また比較例3では、第1重合工程で使用したアクリル酸ブチルの量が多かったために、表面の吸光度比(A)が中心部の吸光度比(B)よりも大きくなった。
また比較例4では、第1重合工程で使用したスチレンの量が少なかったために、表面の吸光度比(A)が中心部の吸光度比(B)よりも大きくなった。
また比較例5では、第1重合工程で使用したスチレンの量が多かったために、表面の吸光度比(A)が0.04と、本発明で規定した表面の吸光度比(A)の下限(0.05)未満となった。
また比較例6では、第2重合工程においてスチレンと共にアクリル酸ブチルを使用したことによって、表面の吸光度比(A)が中心部の吸光度比(B)よりも大きくなった。
前述したように製造し、5日間13℃以下で保管した実施例1~10、及び比較例1~6のそれぞれの発泡性ポリスチレン系樹脂粒子は、粒子の表面に表面処理剤としてジンクステアレート及びヒドロキシステアリン酸トリグリセリドを被覆処理した上で予備発泡装置にて嵩密度0.0167g/cm3に予備発泡した後に20℃で24時間熟成して予備発泡粒子を得た。
次に、内寸300mm×400mm×30mmの直方体形状のキャビティを有する成形型を備えた発泡ビーズ自動成形機のキャビティ内に前記予備発泡粒子を充填し、下記の2条件(成形蒸気圧)にて、密度0.0167g/cm3のポリスチレン系樹脂発泡成形体の成形を行った。
成形条件 (成形機 株式会社積水工機製作所製 ACE―3SP)
成形蒸気圧 2条件(ケージ圧:0.04MPa、0.09MPa)
金型加熱 5秒
一方加熱 (設定圧力0.03MPa)
逆一方加熱 3秒
両面加熱 15秒
水冷 5秒
放冷 (真空放冷 QS成形モード)
取出設定面圧 0.02MPa
実施例(及び比較例)で得られた発泡成形体について、JIS A9511:2006「発泡プラスチック保温材」記載の方法に準じて曲げ強度を測定した。
すなわち、テンシロン万能試験機UCT-10T(オリエンテック社製)を用い、試験体サイズは75mm×300mm×50mmとし、圧縮速度を10mm/min、先端治具は加圧くさび10R、支持台10Rで、支点間距離200mmの条件として測定し、次式にて曲げ強度を算出した。試験片の数は3個とし、その平均値を求めた。
曲げ強度(MPa)=3FL/2bh2
(ここで、Fは曲げ最大荷重(N)を表し、Lは支点間距離(mm)を表し、bは試験片の幅(mm)を表し、hは試験片の厚み(mm)を表す。)
発泡成形体の表面を目視にて確認し、以下の評価基準に基づき評価した。
○:外観が美麗で発泡粒子間に隙間がないもの。
×:発泡粒子間に隙間が多い、または融けが発生したもの。
本発明の冷却時間は前記記載の成形条件にて成形した際の、水冷工程終了後からキャビティ内の成形体の発泡圧が取出設定面圧0.02MPaになるまでの放冷時間を冷却時間とした。冷却時間は、1条件(成形蒸気圧)につき各3枚成形し、その平均値とした。
次の評価基準に基づき総合評価した。
◎:成形時の水蒸気圧0.04MPaの場合、0.09MPaの場合の両方ともに、得られた発泡成形体の外観が美麗なもの。
×:成形時の水蒸気圧0.04MPaの場合、0.09MPaの場合の少なくとも一方で発泡成形体の外観が劣るもの。
第1重合工程でアクリル酸エステルを本発明の範囲未満の量で添加した比較例2は、低い水蒸気圧(0.04MPa)での成形により得られる発泡成形体の外観が悪く、且つ曲げ強度が低くなった。
第1重合工程でのアクリル酸エステルの量が本発明の範囲を超えている比較例3は、高い水蒸気圧(0.09MPa)での成形により得られる発泡成形体の外観が悪く、且つ曲げ強度が低くなった。
第1重合工程でのスチレンの量が本発明の範囲未満である比較例4は、低い水蒸気圧(0.04MPa)及び高い水蒸気圧(0.09MPa)の両方の成形で得られる発泡成形体ともに、外観が悪く、且つ曲げ強度が低くなった。
第1重合工程でのスチレンの量が本発明の範囲を超えている比較例4は、低い水蒸気圧(0.04MPa)での成形により得られる発泡成形体の外観が悪く、且つ曲げ強度が低くなった。
第1重合工程及び第2重合工程の両方で、スチレンとアクリル酸エステルとの混合物を用いた比較例6は、高い水蒸気圧(0.09MPa)での成形により得られる発泡成形体の外観が悪く、且つ曲げ強度が低くなった。
前記(予備発泡・発泡成形)の場合と同様に、実施例1~10、及び比較例1~6のそれぞれの発泡性ポリスチレン系樹脂粒子の表面に表面処理剤としてジンクステアレート及びヒドロキシステアリン酸トリグリセリドを被覆処理した上で予備発泡装置にて嵩密度0.0167g/cm3に予備発泡した。
予備発泡後、得られた各予備発泡粒子を30℃、湿度50%の雰囲気下で7日間放置した。
成形条件 (成形機 株式会社積水工機製作所製 ACE―3SP)
成形蒸気圧 ケージ圧:0.04MPa
金型加熱 5秒
一方加熱 (設定圧力0.03MPa)
逆一方加熱 3秒
両面加熱 15秒
水冷 5秒
放冷 (真空放冷 QS成形モード)
取出設定面圧 0.02MPa
◎:得られた発泡成形体の外観が美麗なもの。
×:発泡成形体の外観が悪いもの。
この試験結果から、本発明に係る実施例1~10で得られた予備発泡粒子は、発泡力の保持性に優れ、保存性が良好であることが分かる。
Claims (8)
- (1)ポリスチレン系樹脂種粒子を水中に分散させてなる分散液中に、ポリスチレン系樹脂種粒子100質量部に対し、スチレン系単量体7.0~80.0質量部とアクリル酸エステル系単量体2.0~12.0質量部とを供給し、これらの単量体を種粒子に吸収、重合させてポリスチレン系樹脂種粒子を成長させる第1重合工程と、
(2)次いで、該分散液中にスチレン系単量体のみを供給し、これを種粒子に吸収、重合させてポリスチレン系樹脂粒子を成長させる第2重合工程と、
(3)第2重合工程を行ってポリスチレン系樹脂粒子を製造した後、又はポリスチレン系樹脂粒子の成長途上で発泡剤を含浸させる工程とを行って発泡性ポリスチレン系樹脂粒子を得る発泡性ポリスチレン系樹脂粒子の製造方法。 - スチレン系単量体とアクリル酸エステル系単量体との共重合体を含有する発泡性ポリスチレン系樹脂粒子であって、
ATR法赤外分光分析により前記発泡性ポリスチレン系樹脂粒子の表面を分析し得られた赤外線吸収スペクトルのうち、1730cm-1での吸光度D1730と1600cm-1での吸光度D1600とを求め、D1730/D1600から算出される吸光度比(A)と、
ATR法赤外分光分析により前記発泡性ポリスチレン系樹脂粒子の中心部を分析し得られた赤外線吸収スペクトルのうち、1730cm-1での吸光度D1730と1600cm-1での吸光度D1600とを求め、D1730/D1600から算出される吸光度比(B)とが、
(A)<(B)であり、且つ
(A)が0.05以上であること、
の関係を満たす発泡性ポリスチレン系樹脂粒子。 - 前記吸光度比(A)が0.05~0.50の範囲内であり、且つ前記吸光度比(B)が0.20~0.60の範囲内である請求項2に記載の発泡性ポリスチレン系樹脂粒子。
- 前記吸光度比(A)と(B)との比(B/A)が、1.10~3.00の範囲内である請求項2に記載の発泡性ポリスチレン系樹脂粒子。
- 前記吸光度比(A)と(B)との比(B/A)が、1.10~3.00の範囲内である請求項3に記載の発泡性ポリスチレン系樹脂粒子。
- 請求項1に記載の発泡性ポリスチレン系樹脂粒子の製造方法により得られた発泡性ポリスチレン系樹脂粒子。
- 請求項2~6のいずれか1項に記載の発泡性ポリスチレン系樹脂粒子を嵩密度が0.01~0.033g/cm3の範囲となるように予備発泡して得られた予備発泡粒子。
- 請求項7に記載の予備発泡粒子を成形型のキャビティ内に充填し、加熱して型内発泡成形することにより得られた発泡成形体。
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JP7121279B2 (ja) | 2018-10-26 | 2022-08-18 | 株式会社ジェイエスピー | 発泡性スチレン系樹脂粒子 |
WO2020184007A1 (ja) * | 2019-03-12 | 2020-09-17 | 株式会社カネカ | 発泡性樹脂粒子及び予備発泡粒子並びに発泡成形体 |
CN112079610A (zh) * | 2019-06-14 | 2020-12-15 | 上海圣奎塑业有限公司 | 一种发泡保温板的制作工艺 |
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CN102675680A (zh) | 2012-09-19 |
CN101925647A (zh) | 2010-12-22 |
CN102675680B (zh) | 2014-09-24 |
TWI490256B (zh) | 2015-07-01 |
JPWO2009096327A1 (ja) | 2011-05-26 |
CN101925647B (zh) | 2013-01-23 |
KR20100099255A (ko) | 2010-09-10 |
TWI396707B (zh) | 2013-05-21 |
JP5284987B2 (ja) | 2013-09-11 |
KR20120083519A (ko) | 2012-07-25 |
TW200938572A (en) | 2009-09-16 |
TW201329140A (zh) | 2013-07-16 |
KR101218422B1 (ko) | 2013-01-03 |
KR101297878B1 (ko) | 2013-08-19 |
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