WO2012111443A1 - 樹脂発泡体及びその製造方法 - Google Patents
樹脂発泡体及びその製造方法 Download PDFInfo
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- WO2012111443A1 WO2012111443A1 PCT/JP2012/052355 JP2012052355W WO2012111443A1 WO 2012111443 A1 WO2012111443 A1 WO 2012111443A1 JP 2012052355 W JP2012052355 W JP 2012052355W WO 2012111443 A1 WO2012111443 A1 WO 2012111443A1
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- Prior art keywords
- foam
- resin
- resin composition
- weight
- resin foam
- Prior art date
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Images
Classifications
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- 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
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- B32B3/04—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 features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
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- C—CHEMISTRY; METALLURGY
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
- C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
- C08F220/42—Nitriles
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- C08F220/46—Acrylonitrile with carboxylic acids, sulfonic acids or salts thereof
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- 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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
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Abstract
Description
また、本発明の他の目的は、歪回復性、特に高温での歪回復性に優れるとともに、強度、柔軟性、クッション性に優れる樹脂発泡体を提供することにある。
硬化条件:樹脂組成物を厚さ0.3mmのシート状に成形してから、電子線(加速電圧:250kV)を線量が200kGyとなるように照射し、さらに170℃雰囲気下で1時間放置する。
また、本発明の樹脂発泡体の製造方法は、歪回復性に優れ、特に、高温で樹脂の復元力による気泡構造の収縮が少なく、高温での歪回復性に優れる樹脂発泡体を効率よく製造できる点で有用である。
発泡倍率(倍)=(発泡前の密度)/(発砲後の密度)
発泡前の密度は、例えば、原料となる樹脂組成物の密度である。また、発泡後の密度は、得られた樹脂発泡体の密度である。
硬化条件(硬化条件A):樹脂組成物を厚さ0.3mmのシート状に成形してから、電子線(加速電圧:250kV)を線量が200kGyとなるように照射し、さらに170℃雰囲気下で一時間放置する。
アクリル酸ブチル:85重量部、アクリロニトリル:15重量部、アクリル酸:6重量部から構成されるアクリル系エラストマー(アクリル酸:5.67重量%、重量平均分子量(ポリスチレン換算分子量):217万、ガラス転移温度:-20℃):100重量部、活性エネルギー線硬化型化合物としてのポリプロピレングリコールジアクリレート(2官能アクリレート、商品名「アロニックスM270」、東亞合成株式会社製、ガラス転移温度:-32℃):45重量部、活性エネルギー線硬化型化合物としてのトリメチロールプロパントリメタクリレート(3官能アクリレート、商品名「NKエステルTMPT」、新中村化学工業株式会社製、ホモポリマーとした場合のガラス転移温度:250℃以上):30重量部、無機粒子としての水酸化マグネシウム(商品名「EP1-A」、神島化学工業株式会社製):50重量部、エラストマー架橋剤(熱架橋剤)としてのヘキサメチレンジアミン(商品名「diak No.1」、デュポン株式会社製):2重量部、エラストマー架橋助剤としての1,3-ジ-o-トリルグアニジン(商品名「ノクセラーDT」、大内新興化学工業株式会社製):2重量部、フェノール系老化防止剤(商品名「スミライザーGM」、住友化学株式会社製):8重量部を、2枚羽根を設けた小型加圧式ニーダー(装置名「TD-10-20MDX」、株式会社トーシン製、混合容量:10L)に投入し、羽根の回転速度:30rpm、温度:80℃の条件で、40分間混練して、樹脂組成物を得た。
電子線照射後、さらに、170℃の雰囲気下で1時間放置して加熱処理を行った。この加熱処理により、エラストマー架橋剤が反応して、架橋構造が形成される。
そして、発泡体(シート状、厚さ:約5mm)を得た。
アクリル酸ブチル:85重量部、アクリロニトリル:15重量部、アクリル酸:6重量部から構成されるアクリル系エラストマー(アクリル酸:5.67重量%、重量平均分子量(ポリスチレン換算分子量):217万、ガラス転移温度:-20℃):100重量部、活性エネルギー線硬化型化合物としてのポリプロピレンジグリコールアクリレート(2官能アクリレート、商品名「アロニックスM270」、東亞合成株式会社製、ガラス転移温度:-32℃):30重量部、活性エネルギー線硬化型化合物としてのトリメチロールプロパントリメタクリレート(3官能アクリレート、商品名「NKエステルTMPT」、新中村化学工業株式会社製、ホモポリマーとした場合のガラス転移温度:250℃以上):45重量部、無機粒子としての水酸化マグネシウム(商品名「EP1-A」、神島化学工業株式会社製):50重量部、エラストマー架橋剤(熱架橋剤)としてのヘキサメチレンジアミン(商品名「diak No.1」、デュポン株式会社製):2重量部、エラストマー架橋助剤としての1,3-ジ-o-トリルグアニジン(商品名「ノクセラーDT」、大内新興化学工業株式会社製):2重量部、着色剤としてのカーボンブラック(商品名「旭カーボン♯35」、旭カーボン株式会社製):10重量部、フェノール系老化防止剤(商品名「スミライザーGM」、住友化学株式会社製):8重量部を、2枚羽根を設けた小型加圧式ニーダー(装置名「TD-10-20-MDX」、株式会社トーシン製、混合容量:10L)に投入し、羽根の回転速度:30rpm、温度:80℃の条件で、40分間混練して、樹脂組成物を得た。
電子線照射後、さらに、170℃の雰囲気下で1時間放置して加熱処理を行った。この加熱処理により、エラストマー架橋剤が反応して、架橋構造が形成される。
そして、発泡体(シート状、厚さ:約5mm)を得た。
アクリル酸ブチル:85重量部、アクリロニトリル:15重量部、アクリル酸:6重量部から構成されるアクリル系エラストマー(アクリル酸:5.67重量%、重量平均分子量(ポリスチレン換算分子量):217万、ガラス転移温度:-20℃):100重量部、活性エネルギー線硬化型化合物としてのエトキシ化ビスフェノールAジアクリレート(2官能アクリレート、商品名「A-BPE30」、新中村化学工業株式会社製、ホモポリマーとした場合のガラス転移温度:250℃以上):30重量部、活性エネルギー線硬化型化合物としてのトリメチロールプロパントリメタクリレート(3官能アクリレート、商品名「NKエステルTMPT」、新中村化学工業株式会社製、ホモポリマーとした場合のガラス転移温度:250℃以上):45重量部、無機粒子としての水酸化マグネシウム(商品名「EP1-A」、神島化学工業株式会社製):50重量部、エラストマー架橋剤(熱架橋剤)としてのヘキサメチレンジアミン(商品名「diak No.1」、デュポン株式会社製):2重量部、フェノール系老化防止剤(商品名「スミライザーGM」、住友化学株式会社製):8重量部を、2枚羽根を設けた小型加圧式ニーダー(装置名「TD-10-20MDX」、株式会社トーシン製、混合容量:10L)に投入し、羽根の回転速度:30rpm、温度:80℃の条件で、40分間混練して、樹脂組成物を得た。
そして、この樹脂発泡組成物を用いて、実施例1と同様にして、発泡体を得た。
アクリル酸ブチル:85重量部、アクリロニトリル:15重量部、アクリル酸:6重量部から構成されるアクリル系エラストマー(アクリル酸:5.67重量%、重量平均分子量(ポリスチレン換算分子量):217万、ガラス転移温度:-20℃):100重量部、活性エネルギー線硬化型化合物としての多官能アクリレート混合物(商品名「アロニックスM8530」、東亞合成株式会社製):75重量部、無機粒子としての水酸化マグネシウム(商品名「EP1-A」、神島化学工業株式会社製):50重量部、エラストマー架橋剤(熱架橋剤)としてのヘキサメチレンジアミン(商品名「diak No.1」、デュポン株式会社製):2重量部、エラストマー架橋助剤としての1,3-ジ-o-トリルグアニジン(商品名「ノクセラーDT」、大内新興化学工業株式会社製):2重量部、フェノール系老化防止剤(商品名「スミライザーGM」、住友化学株式会社製):8重量部を、2枚羽根を設けた小型加圧式ニーダー(装置名「TD-10-20-MDX」、株式会社トーシン製、混合容量:10L)に投入し、羽根の回転速度:30rpm、温度:80℃の条件で、40分間混練して、樹脂組成物を得た。
電子線照射後、さらに、170℃の雰囲気下で1時間放置して加熱処理を行った。この加熱処理により、エラストマー架橋剤が反応して、架橋構造が形成される。
そして、発泡体(シート状、厚さ:約5mm)を得た。
アクリル酸ブチル:85重量部、アクリロニトリル:15重量部、アクリル酸:6重量部から構成されるアクリル系エラストマー(アクリル酸:5.67重量%、重量平均分子量(ポリスチレン換算分子量):217万、ガラス転移温度:-20℃):100重量部、活性エネルギー線硬化型化合物としての多官能アクリレート混合物(商品名「アロニックスM8530」、東亞合成株式会社製):75重量部、無機粒子としての水酸化マグネシウム(商品名「EP1-A」、神島化学工業株式会社製):50重量部、エラストマー架橋剤(熱架橋剤)としてのヘキサメチレンジアミン(商品名「diak No.1」、デュポン株式会社製):2重量部、エラストマー架橋助剤としての1,3-ジ-o-トリルグアニジン(商品名「ノクセラーDT」、大内新興化学工業株式会社製):2重量部、着色剤としてのカーボンブラック(商品名「旭カーボン♯35」、旭カーボン株式会社製):10重量部、フェノール系老化防止剤(商品名「スミライザーGM」、住友化学株式会社製):8重量部を、2枚羽根を設けた小型加圧式ニーダー(装置名「TD-10-20-MDX」、株式会社トーシン製、混合容量:10L)に投入し、羽根の回転速度:30rpm、温度:80℃の条件で、40分間混練して、樹脂組成物を得た。
電子線照射後、さらに、170℃の雰囲気下で1時間放置して加熱処理を行った。この加熱処理により、エラストマー架橋剤が反応して、架橋構造が形成される。
そして、発泡体(シート状、厚さ:約5mm)を得た。
アクリル酸ブチル:85重量部、アクリロニトリル:15重量部、アクリル酸:6重量部から構成されるアクリル系エラストマー(アクリル酸:5.67重量%、重量平均分子量(ポリスチレン換算分子量):217万、ガラス転移温度:-20℃):100重量部、活性エネルギー線硬化型化合物としてのポリプロピレングリコールジアクリレート(2官能アクリレート、商品名「アロニックスM270」、東亞合成株式会社製、ガラス転移温度:-32℃):75重量部、無機粒子としての水酸化マグネシウム(商品名「EP1-A」、神島化学工業株式会社製):50重量部、エラストマー架橋剤(熱架橋剤)としてのヘキサメチレンジアミン(商品名「diak No.1」、デュポン株式会社製):2重量部、エラストマー架橋助剤としての1,3-ジ-o-トリルグアニジン(商品名「ノクセラーDT」、大内新興化学工業株式会社製):2重量部、フェノール系老化防止剤(商品名「スミライザーGM」、住友化学株式会社製):8重量部を、2枚羽根を設けた小型加圧式ニーダー(装置名「TD-10-20MDX」、株式会社トーシン製、混合容量:10L)に投入し、羽根の回転速度:30rpm、温度:80℃の条件で、40分間混練して、樹脂組成物を得た。
しかし、発泡直後の初期の形状から大きく収縮してしまった。
実施例及び比較例について、ガラス転移温度、20℃における貯蔵弾性率、発泡倍率、歪回復率(80℃、50%圧縮永久歪)を求めた。その結果を表1に示した。
樹脂発泡体の形成に用いた樹脂組成物を厚さ0.3mmのシート状に成形し樹脂成形体を得て、該樹脂成形体に電子線(加速電圧:250kV)を線量が200kGyとなるように両側から一回ずつ照射して、さらに170℃の雰囲気下で1時間放置し、未発泡状態の測定用サンプルとした。
動的粘弾性測定装置(ARES、ティー・エイ・インスツルメント社製)を用いて、5mmの引っ張り治具により、試験モードを引張、周波数1Hz、温度範囲-50~200℃、昇温速度5℃/分で、動的粘弾性測定を行った。
動的粘弾性測定により、20℃における貯蔵弾性率(E’)を求めた。また、ガラス転移温度は、動的粘弾性測定により、損失弾性率E’’を求めて、該E’’のピーク温度をガラス転移温度とすることにより求めた。
樹脂組成物を成形して未発泡樹脂成形体を得た。電子比重計(商品名「MD-200S」、アルファーミラージュ社製)を用いて、比重測定を行うことにより、該未発泡樹脂成形体の密度を求めて、「発泡前密度」とした。なお、測定は、未発泡樹脂成形体製造後室温で24時間保存してから行った。
次に、電子比重計(商品名「MD-200S」、アルファーミラージュ社製)を用いて、比重測定を行うことにより、発泡体の密度を求めて、「発泡後密度」とした。なお、測定は、発泡体製造後室温で24時間保存してから行った。
そして、下記式より、発泡倍率を求めた。
発泡倍率(倍)=発泡前密度/発砲後密度
発泡体を、1辺の長さが25mmの正方形に切断し、試験片とし、その厚さを正確に測りとった。このときの試験片の厚さをaとした。試験片の厚さの半分の厚さbを有するスペーサーを用いて、試験片を50%の厚さ(厚さb)になるように圧縮し、その状態で、80℃で24時間保存した。24時間後、圧縮状態を維持しつつ常温に戻し、圧縮状態を解放した。解放してから24時間後試験片の厚さを正確に測りとった。
このときの試験片の厚さをcとした。圧縮した距離に対する回復した距離の比率を歪回復率(80℃、50%圧縮永久歪)とした。
歪回復率(80℃、50%圧縮永久歪)[%] =(c-b)/(a-b)×100
2 表面層
Claims (10)
- エラストマー及び活性エネルギー線硬化型化合物を含む樹脂組成物から得られ、未発泡状態の測定サンプルについての動的粘弾性測定により求められるガラス転移温度が30℃以下であり、未発泡状態の測定サンプルについての動的粘弾性測定により求められる20℃における貯蔵弾性率(E’)が1.0×107Pa以上であることを特徴とする樹脂発泡体。
- 前記エラストマーのガラス転移温度が30℃以下であり、下記硬化条件で硬化した後の樹脂組成物のガラス転移温度が30℃以下である請求項1記載の樹脂発泡体。
硬化条件:樹脂組成物を厚さ0.3mmのシート状に成形してから、電子線(加速電圧:250kV)を線量が200kGyとなるように照射し、さらに170℃雰囲気下で一時間放置する。 - 前記樹脂組成物を発泡成形して発泡構造体を得た後、さらに活性エネルギー線を照射することから得られる請求項1又は2記載の樹脂発泡体。
- 前記樹脂組成物の発泡成形が、樹脂組成物に発泡剤を含浸させて減圧することにより発泡させることである請求項3記載の樹脂発泡体。
- 樹脂組成物の発泡成形の際に用いられる発泡剤が、二酸化炭素又は窒素である請求項3又は4記載の樹脂発泡体。
- 樹脂組成物の発泡成形の際に用いられる発泡剤が、液化二酸化炭素である請求項3~5の何れかの項に記載の樹脂発泡体。
- 樹脂組成物の発泡成形の際に用いられる発泡剤が、超臨界状態の二酸化炭素である請求項3~6の何れかの項に記載の樹脂発泡体。
- 歪回復率(80℃、50%圧縮永久歪)が、40%以上である請求項1~7の何れかの項に記載の樹脂発泡体。
- 発泡倍率が5倍以上である請求項1~8の何れかの項に記載の樹脂発泡体。
- エラストマー及び活性エネルギー線硬化型化合物を含む樹脂組成物を発泡成形して発泡構造体を形成する工程(1)、該発泡構造体に活性エネルギー線を照射する工程(2)を含み、未発泡状態の測定サンプルについての動的粘弾性測定により求められるガラス転移温度が30℃以下であり、未発泡状態の測定サンプルについての動的粘弾性測定により求められる20℃における貯蔵弾性率(E’)が1.0×107Pa以上である樹脂発泡体を形成することを特徴とする樹脂発泡体の製造方法。
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WO2013179945A1 (ja) * | 2012-05-28 | 2013-12-05 | 日東電工株式会社 | 樹脂発泡体及び発泡部材 |
WO2013179947A1 (ja) * | 2012-05-28 | 2013-12-05 | 日東電工株式会社 | 樹脂発泡体、発泡部材、発泡部材積層体及び電気又は電子機器類 |
WO2013179946A1 (ja) * | 2012-05-28 | 2013-12-05 | 日東電工株式会社 | 樹脂発泡体及び発泡部材 |
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JP5676798B1 (ja) * | 2013-08-26 | 2015-02-25 | 日東電工株式会社 | 発泡シート |
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