WO2014092086A1 - フェノール樹脂発泡体とその製造方法 - Google Patents
フェノール樹脂発泡体とその製造方法 Download PDFInfo
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- WO2014092086A1 WO2014092086A1 PCT/JP2013/083104 JP2013083104W WO2014092086A1 WO 2014092086 A1 WO2014092086 A1 WO 2014092086A1 JP 2013083104 W JP2013083104 W JP 2013083104W WO 2014092086 A1 WO2014092086 A1 WO 2014092086A1
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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
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
- C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
- C08J9/141—Hydrocarbons
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G8/00—Condensation polymers of aldehydes or ketones with phenols only
- C08G8/04—Condensation polymers of aldehydes or ketones with phenols only of aldehydes
- C08G8/08—Condensation polymers of aldehydes or ketones with phenols only of aldehydes of formaldehyde, e.g. of formaldehyde formed in situ
- C08G8/10—Condensation polymers of aldehydes or ketones with phenols only of aldehydes of formaldehyde, e.g. of formaldehyde formed in situ with phenol
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/0061—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof characterized by the use of several polymeric components
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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
- C08J2203/00—Foams characterized by the expanding agent
- C08J2203/14—Saturated hydrocarbons, e.g. butane; Unspecified hydrocarbons
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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
- C08J2203/00—Foams characterized by the expanding agent
- C08J2203/18—Binary blends of expanding agents
- C08J2203/182—Binary blends of expanding agents of physical blowing agents, e.g. acetone and butane
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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
- C08J2205/00—Foams characterised by their properties
- C08J2205/04—Foams characterised by their properties characterised by the foam pores
- C08J2205/052—Closed cells, i.e. more than 50% of the pores are closed
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- 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
- C08J2361/00—Characterised by the use of condensation polymers of aldehydes or ketones; Derivatives of such polymers
- C08J2361/04—Condensation polymers of aldehydes or ketones with phenols only
- C08J2361/06—Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols
- C08J2361/08—Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols with monohydric phenols
- C08J2361/10—Phenol-formaldehyde condensates
Definitions
- the present invention relates to a phenol resin foam excellent in thermal conductivity, which is used as a heat insulating material for buildings, a heat insulating material for vehicles, a heat insulating material for equipment, and the like, and a method for producing the same.
- Phenol resin foam used as a heat insulating material can obtain the heat insulating performance required with a thin thickness as it has low thermal conductivity, so the amount of heat insulating material used can be reduced and the space required for construction is small. For example, in a house, an effective living space can be widened with respect to the building area of the house. Moreover, since it will be used for a long time once it is constructed, it is necessary to maintain high heat insulation performance for a long time. In recent years, the need for long-term excellent houses has been increasing for energy and resource savings, and it has been required to maintain high heat insulation performance and low initial thermal conductivity for a longer period than before. .
- Patent Document 1 discloses a phenol resin foam characterized in that the void area ratio in the cross-sectional area of the foam is 5% or less, and the pores are substantially absent in the cell walls. The initial thermal conductivity and the rate of change in thermal conductivity over time are insufficient.
- Patent Document 2 discloses a foamable phenolic resole resin composition
- a foaming agent mainly composed of cyclopentane and a partial hydrolysis condensate of an organosilicon compound having a hydrolyzable group.
- the foamed phenol resin foam has a high initial thermal conductivity and a large increase in thermal conductivity over time.
- Patent Document 3 discloses a phenol resin, which is a filler selected from metal hydroxide, metal oxide, metal carbonate and metal powder, and the phenol resin foam has a pH of 5 or more. Although a foam is disclosed, the initial thermal conductivity is high, and the increase in thermal conductivity over time is also large.
- Patent Document 4 the standard deviation of the bubble diameter distribution is 7% or less of the average bubble diameter, the void area ratio in the cross-sectional area of the foam is 0.5% or less, and pores are formed in the bubble wall.
- a phenolic resin foam characterized by having a uniform fine cell structure in which no water is present is disclosed, but the initial thermal conductivity and the rate of change in thermal conductivity over time are insufficient.
- An object of the present invention is to obtain a phenol resin foam having a low initial thermal conductivity and maintaining a low thermal conductivity over a long period of time, and a method for producing the same.
- the present inventor has made the foaming agent present in the phenolic resin foam into a specific composition range and the amount of the foaming agent present in the foam.
- the inventors have found that the initial thermal conductivity is low and the low thermal conductivity can be maintained over a long period of time by setting the value in a specific range, and the present invention has been made. That is, the present invention is as follows.
- a phenol resin foam containing a hydrocarbon having 6 or less carbon atoms and having a density of 10 kg / m 3 or more and 150 kg / m 3 or less,
- the hydrocarbon having 6 or less carbon atoms contains cyclopentane in an amount of 40 to 90 mol% and 60 to 10 mol% of one or more selected from hydrocarbons having a boiling point of ⁇ 50 ° C. to 5 ° C.
- the average boiling point X of hydrocarbons having 6 or less carbon atoms is 5 to 44 ° C.
- the content Y of hydrocarbons having 6 or less carbon atoms in the phenolic resin foam has a volume volume 22 in the phenolic resin foam.
- a phenolic resin foam of 0.25 to 0.9 mol per 4 ⁇ 10 ⁇ 3 m 3 .
- the total amount of cyclopentane and hydrocarbon having a boiling point of ⁇ 50 ° C. to 5 ° C. contained in the substance having a boiling point of ⁇ 100 to 81 ° C. contained in the phenol resin foam is 70 to 100 mol%.
- (Viii) a production method for producing the phenolic resin foam according to any one of (i) to (vii),
- a foaming phenol resin composition containing at least a phenol resin, a surfactant, cyclopentane and a hydrocarbon having a boiling point of ⁇ 50 ° C. to 5 ° C., and an acid curing catalyst is mixed using a mixer.
- the foamable phenolic resin composition is discharged from the distributor of the mixer and then heated, and in the process of foaming and curing the foamable phenolic resin composition, pressure is applied from the top and bottom sides of the foamable phenolic resin composition.
- the manufacturing method of a phenol resin foam which manufactures the phenol resin foam shape
- the amount of water contained in the foamable phenolic resin composition charged into the mixer is 2 to 20 wt%, and the temperature in the double conveyor in the process of foaming and curing is 60 to 100 ° C. (viii ) Or (ix).
- the present invention it is possible to provide a phenol resin foam having a low initial thermal conductivity and maintaining a low thermal conductivity over a long period of time, and a method for producing the same. Therefore, the phenol resin foam of the present invention is preferably used as a building heat insulating material, a vehicle heat insulating material, a device heat insulating material, or the like.
- the phenol resin foam in the present embodiment is a phenol resin foam having a density of 10 kg / m 3 or more and 150 kg / m 3 or less, preferably 15 kg / m 3 or more and 70 kg / m 3 or less.
- the density is too low, the strength is weak and difficult to handle as a foam, and because the foam film is thin, there is a concern that the foaming agent in the foam tends to be easily replaced with air, and the long-term heat insulation performance tends to decrease, Further, if the density is too high, there is a concern that the heat conduction of the resin portion forming the bubble film increases and the heat insulation performance tends to be lowered.
- the phenol resin foam of this embodiment contains a hydrocarbon having 6 or less carbon atoms.
- Hydrocarbon is mainly used as a blowing agent to produce a phenolic resin foam having the above-mentioned density.
- the hydrocarbon in the present embodiment is a compound composed only of a hydrogen atom and a carbon atom, and the hydrocarbon having 6 or less carbon atoms is, for example, methane, ethane, ethylene, propane, propylene, butane, butene, Examples include aliphatic hydrocarbons such as alkanes such as butadiene, pentane, pentene, hexane and hexene, alkenes and dienes, and cycloalkanes such as cyclobutane, cyclopentane and cyclohexene, and cyclic aliphatic hydrocarbons such as cycloalkene.
- the phenol resin foam of this embodiment is characterized in that the hydrocarbon composition having 6 or less carbon atoms contained in the foam satisfies the following conditions.
- (1) Contains cyclopentane.
- (2) In addition to the above (1), one or more selected from hydrocarbons having a boiling point in the range of ⁇ 50 ° C. to 5 ° C. are contained.
- (3) The ratio of each of the above (1) and (2) with respect to the total of hydrocarbons having 6 or less carbon atoms is selected from hydrocarbons having cyclopentane of 40 to 90 mol% and boiling point of ⁇ 50 ° C. to 5 ° C.
- the total amount of the species or two or more species is 60 to 10 mol%.
- it is a composition in which the total amount of one or more selected from cyclopentane 50 to 85 mol% and hydrocarbons having a boiling point of ⁇ 50 ° C. to 5 ° C. is 50 to 15 mol%, particularly preferably The total amount of one or more selected from cyclopentane 65 to 80 mol% and hydrocarbons having a boiling point of ⁇ 50 ° C. to 5 ° C. is 35 to 20 mol%.
- cyclopentane In the phenol resin foam of this embodiment, it is necessary for cyclopentane to be contained in order to improve the heat insulation performance. If the content of cyclopentane is too small, the initial heat insulation performance and long-term heat insulation performance at 23 ° C. are reduced. Tend. When the content of cyclopentane was too large, the initial heat insulation performance at 10 ° C. tended to decrease, but the present inventors contained a specific amount of hydrocarbon having a boiling point of ⁇ 50 ° C. to 5 ° C. From the above, it was found that the initial heat insulation performance and long-term heat insulation performance at 10 ° C. can be improved.
- hydrocarbon having a boiling point of ⁇ 50 ° C. to 5 ° C. examples include propane, propylene, isobutane, normal butane, 1-butene, cis-2-butene, trans-2-butene, 2-methylpropene, and butadiene. From the viewpoint of thermal conductivity and stability, propane, normal butane and isobutane are preferable, and isobutane is particularly preferable.
- the phenol resin foam in the present embodiment is characterized in that the hydrocarbon having 6 or less carbon atoms has an average boiling point calculated by the following formula (3) of 5 to 44 ° C.
- the temperature is preferably 10 to 40 ° C, more preferably 15 to 37 ° C. If the average boiling point is too low, the thermal conductivity of the mixed gas tends to increase, so the initial heat insulation performance at 23 ° C. tends to decrease, and the content of cyclopentane that is difficult to escape from within the bubbles decreases. For this reason, there is a concern that the long-term heat insulation performance tends to be lowered, and if the boiling point average value is too high, the hydrocarbon tends to be liquefied at low temperatures, so that the initial heat insulation performance at 10 ° C.
- X a ⁇ Ta + b ⁇ Tb + c ⁇ Tc + (3)
- the types of hydrocarbons contained are A, B, C,..., Each content is a, b, c,... (Molar fraction), and the boiling point is Ta, Tb, Tc,. is there.
- the content Y of hydrocarbons having 6 or less carbon atoms is 0.25 to about 22.4 ⁇ 10 ⁇ 3 m 3 (22.4 L) in the space volume in the foam. 0.9 mol, preferably 0.3 to 0.8 mol, more preferably 0.35 to 0.7 mol. If the content of hydrocarbons having 6 or less carbon atoms is small, there is a concern that long-term heat insulation performance is likely to deteriorate, and if it is too large, there is a concern that initial heat insulation performance at 10 ° C and 23 ° C tends to decrease. .
- the phenol resin foam in the present embodiment is calculated by the following formula (4) from the boiling point average value X of the hydrocarbon having 6 or less carbon atoms and the content Y of the hydrocarbon having 6 or less carbon atoms.
- the value of the coefficient Z is preferably 0.40 or more and 1.10 or less, more preferably 0.55 or more and 0.95 or less, and particularly preferably 0.6 or more and 0.85 or less. is there.
- Z 0.0063 ⁇ X + Y (4) If the value of the coefficient Z is too small, there is a concern that the long-term heat insulation performance is likely to deteriorate because there are few hydrocarbons with good heat insulation performance, and if it is too large, the contained hydrocarbon is liable to liquefy. There is a concern that the initial thermal insulation performance tends to decrease.
- the phenol resin foam in the present embodiment includes carbon dioxide, nitrogen, oxygen, helium, argon and other inorganic gases, dimethyl ether, diethyl ether, methyl ethyl ether, furan and other ethers, acetone, methyl ethyl ketone and other ketones, and methyl chloride.
- the total amount of cyclopentane and hydrocarbon having a boiling point of ⁇ 50 ° C. to 5 ° C. contained in a substance having a boiling point of ⁇ 100 to 81 ° C. is preferably 70 to 100 mol%, more preferably 90 to 100 mol%, 95 to 100 mol% is particularly preferable.
- the phenol resin foam in this embodiment preferably has a thermal conductivity of less than 0.0205 W / m ⁇ k, more preferably 10 ° C.
- the thermal conductivity in a 23 ° C. environment is less than 0.0195 W / m ⁇ k, more preferably less than 0.0189 W / m ⁇ k, and particularly preferably less than 0.0185 W / m ⁇ k. is there.
- the thermal conductivity of a heat insulating material tends to be better as the temperature is lower, and the thermal conductivity measured in an environment of 10 ° C. described later is preferably less than 0.0190, more preferably.
- both the thermal conductivity measured under the environment of 10 ° C. and 23 ° C. is a deterioration (increase) of the thermal conductivity after the acceleration test described later from the initial thermal conductivity before the acceleration test (thermal conductivity after the acceleration test).
- Rate ⁇ initial thermal conductivity is preferably 0.0020 W / m ⁇ k or less, more preferably 0.0010 W / m ⁇ k or less, and still more preferably 0.0005 W / m ⁇ k or less.
- a phenol resin foam having such a thermal conductivity is preferable because it exhibits excellent heat insulation performance at both normal temperature and low temperature and maintains excellent heat insulation performance for a long period of time.
- the closed cell ratio of the phenol resin foam in the present embodiment tends to cause a decrease in the heat insulation performance with time if it is small, it is preferably 90% or more, more preferably 95% or more, and 98% or more and 100% or less. Particularly preferred.
- the average cell diameter of the phenol resin foam in the present embodiment is too small, the strength tends to decrease or the heat insulation performance tends to deteriorate with time, and if it is too large, the initial heat insulation performance tends to deteriorate.
- 40 micrometers or more and 300 micrometers or less are preferable, 50 micrometers or more and 200 micrometers or less are more preferable, and 60 micrometers or more and 150 micrometers or less are especially preferable.
- the average cell diameter of the phenol resin foam in this embodiment is 40 ⁇ m or more and 300 ⁇ m or less, but there may be a large-diameter hole partially called a void.
- a large-diameter hole having an area of 2 mm 2 or more is defined as a void, and an area of 2 mm 2 or more in a cut surface obtained by cutting substantially the center in the thickness direction of the phenol resin foam in parallel with the front and back surfaces.
- the ratio of the area occupied by large-diameter holes (voids) is defined as the void area ratio.
- the phenol resin foam in the present embodiment may contain inorganic fine powder and / or organic fine powder. These fine powders preferably have no reactivity with the acid curing catalyst described later. If inorganic fine powders that are not reactive with the acid curing catalyst such as aluminum hydroxide, talc, silicon oxide, glass powder, and titanium oxide are contained, the initial heat insulating performance tends to be improved. When the amount of the inorganic fine powder to be contained is too large, the initial thermal conductivity tends to deteriorate, and the thermal insulation performance tends to decrease with time.
- the inorganic fine powder that does not react with the acid curing catalyst is preferably contained in an amount of 0.1 to 35 wt%, more preferably 1 to 20 wt%, particularly preferably 2 to 15 wt% with respect to the phenol resin foam. It is.
- the particle size of the inorganic fine powder that is not reactive with the acid curing catalyst is preferably 0.5 to 500 ⁇ m, more preferably 2 to 100 ⁇ m, and particularly preferably 5 to 50 ⁇ m.
- aluminum hydroxide is particularly preferable.
- an inorganic fine powder such as a powder tends to cause a decrease in heat insulation performance over time, and it is preferable not to contain an inorganic fine powder having reactivity with an acid curing catalyst.
- the initial heat insulation performance tends to be improved. If the amount of the fine powder contained is too large, the heat insulation performance tends to be lowered with time.
- the content of the organic fine powder having no reactivity with the acid curing catalyst is preferably 0.1 to 35 wt% or less, more preferably 0.5 to 20 wt%, particularly with respect to the phenol resin foam. Preferably, it is 1 to 10 wt%.
- the average particle size of the organic fine powder having no reactivity with the acid curing catalyst is preferably 0.5 to 2000 ⁇ m, more preferably 5 to 500 ⁇ m, and particularly preferably 10 to 200 ⁇ m.
- fine powders that are reactive with acid curing catalysts such as basic ion-exchange resin fine powders tends to cause a decrease in the heat insulation performance over time, so organic compounds that are reactive with acid curing catalysts. It is preferable not to contain fine powder.
- the phenol resin foam in the present embodiment may contain a plasticizer or the like as long as it does not affect the foaming property, but a compound that is reactive with an acid curing catalyst or a compound that is altered by an acid curing catalyst. It is preferable not to contain, for example, when containing a partial hydrolysis condensate of an organosilicon compound having a hydrolyzable group such as a partial hydrolysis condensate of organomethoxysilane, there is a tendency that the thermal insulation performance is likely to deteriorate over time, It is preferable not to contain an organosilicon compound having a hydrolyzable group.
- the content of the compound having reactivity with the acid curing catalyst or the compound altered by the acid curing catalyst is preferably such that the total amount of these compounds is 0.5 wt% or less with respect to the phenol resin foam, more preferably It is 0.1 or less, particularly preferably 0.01 wt% or less.
- the phenol resin in this embodiment can be synthesized by polymerization of phenols and aldehydes.
- the starting molar ratio of phenols to aldehydes is preferably from 1: 1 to 1: 4.5, more preferably from 1: 1.5 to 1: 2.5.
- Examples of the phenols preferably used in the synthesis of the phenol resin in the present embodiment include phenol, resorcinol, catechol, o-, m- and p-cresol, xylenols, ethylphenols, p-tertbutylphenol and the like. . Dinuclear phenols can also be used.
- Aldehydes preferably used in the present embodiment include formaldehyde, glyoxal, acetaldehyde, chloral, furfural, benzaldehyde, paraformaldehyde and the like. Urea, dicyandiamide, melamine, etc. may be added as additives. In this embodiment, when adding these additives, a phenol resin refers to the thing after adding an additive.
- the viscosity of the phenol resin at 40 ° C. is preferably 200 mPa ⁇ s or more and 100,000 mPa ⁇ s or less, more preferably 500 mPa ⁇ s or more and 50,000 mPa ⁇ s or less.
- the water content is preferably 1% by weight to 30% by weight.
- the mixing method of the powder and the phenol resin when the inorganic and / or organic fine powder is added is not particularly limited, and may be mixed using a mixer having a pin mixer, or may be biaxial extrusion. A machine, a kneader or the like may be used.
- the stage of mixing the powder with the phenol resin is not particularly limited, and when the phenol resin is synthesized, it may be added together with the raw materials, or may be added before or after each additive is added after the synthesis is completed.
- the viscosity may be adjusted, or may be mixed with a surfactant or / and a foaming agent. However, adding the powder to the phenolic resin increases the overall viscosity.
- the viscosity adjustment of the phenolic resin is estimated based on the amount of water. Preferably it is done. Moreover, you may mix with the foamable phenol resin composition containing the phenol resin, surfactant, the foaming agent containing a hydrocarbon, and an acid curing catalyst. Furthermore, the powder may be mixed with a phenol resin in a required amount, or a high concentration powdered phenol resin may be prepared as a master batch, and the required amount added to the phenol resin.
- the viscosity at 40 ° C. of the phenol resin containing the powder is preferably 200 mPa ⁇ s or more and 300,000 mPa ⁇ s or less in consideration of the load on the apparatus due to an increase in pressure in the flow-through piping of the foamable phenol resin composition. More preferably, it is 100,000 mPa * s or less, More preferably, it is 50,000 mPa * s or less.
- the water content is preferably 1% by weight to 30% by weight.
- the phenol resin foam of this embodiment is obtained from a phenol resin composition containing at least a phenol resin, a surfactant, cyclopentane, a foaming agent containing a hydrocarbon having a boiling point of ⁇ 50 ° C. to 5 ° C., and an acid curing catalyst. It is done.
- the surfactant and the foaming agent may be added in advance to the phenol resin, or may be added simultaneously with the acid curing catalyst.
- nonionic surfactants are effective, for example, ethylene oxide and propylene oxide.
- Fatty acid esters, silicone compounds such as ethylene oxide grafted polydimethylsiloxane, and polyalcohols are preferred.
- One type of surfactant may be used, or two or more types may be used in combination.
- the amount used is not particularly limited, but it is preferably used in the range of 0.3 to 10 parts by weight per 100 parts by weight of the phenol resin composition.
- the acid curing catalyst used in the present embodiment is not particularly limited, but if an acid curing catalyst containing a large amount of water is used, the foam cell wall may be destroyed. Therefore, phosphoric anhydride and anhydrous aryl sulfonic acid are preferable.
- aryl sulfonic anhydride examples include toluene sulfonic acid, xylene sulfonic acid, phenol sulfonic acid, substituted phenol sulfonic acid, xylenol sulfonic acid, substituted xylenol sulfonic acid, dodecyl benzene sulfonic acid, benzene sulfonic acid, and naphthalene sulfonic acid. May be used alone or in combination of two or more. Further, resorcinol, cresol, saligenin (o-methylolphenol), p-methylolphenol and the like may be added as a curing aid. Moreover, you may dilute with solvents, such as ethylene glycol and diethylene glycol.
- the acid curing catalyst is added to the phenol resin, the acid curing catalyst is uniformly dispersed as quickly as possible using a pin mixer or the like.
- the amount of the foaming agent described above varies depending on the viscosity, water content, and foaming curing temperature of the phenol resin, but is preferably 1 part by weight or more and 25 parts by weight or less, more preferably 3 parts by weight with respect to 100 parts by weight of the phenol resin. More than 15 parts by weight is used.
- the amount of the acid curing catalyst used varies depending on the type, and when phosphoric anhydride is used, it is preferably 5 to 30 parts by weight, more preferably 8 to 25 parts by weight, with respect to 100 parts by weight of the phenol resin. Used in: When a mixture of 60% by weight of paratoluenesulfonic acid monohydrate and 40% by weight of diethylene glycol is used, it is preferably 3 parts by weight or more and 30 parts by weight or less, more preferably 5 parts by weight or more with respect to 100 parts by weight of the phenol resin. Used at 20 parts by weight or less.
- the foamable phenolic resin composition of the present embodiment is mixed using a mixer, and is discharged from the distribution unit and molded.
- the pressure of the mixing section of the mixer is too low, there is a concern that voids increase, heat insulation performance decreases and long-term heat insulation performance tends to decrease.
- the pressure in the distribution section of the mixer is 0.3 MPa or more and 10 MPa or less. Preferably, it is 0.5 MPa or more and 3 MPa or less.
- the pressure in the distributor of such a mixer can be adjusted by controlling the temperature of the mixer and / or distributor, the diameter of the tip of the distributor, the pipe before the distributor, and controlling the pipe diameter and length. Is possible.
- the moisture is contained in the foamable phenolic resin composition, and the moisture contributes to foaming. If the amount is too large, the closed cell ratio tends to be lowered, and there is a concern that long-term heat insulation performance may be lowered. Therefore, it is preferable to control moisture at the time of ejection.
- the water content contained in the foamable phenolic resin composition it is preferable to adjust the water content contained in the foamable phenolic resin composition to be added to the mixer to 2 wt% or more and 20 wt% or less, more preferably 2.5 wt%. % To 13 wt%, particularly preferably 3 wt% to 10 wt%. This moisture content can be calculated from the measured moisture value of each material constituting the composition when it is put into the mixer.
- the foamable phenolic resin composition discharged from the mixer distributor is formed by, for example, a method using a double conveyor, a method using a metal roll or a steel plate, and a method using a combination of these in a vertical direction (upper surface) Direction and lower surface direction), pressure can be applied to form a plate, and among them, the method using a double conveyor is preferred because the smoothness of the obtained plate-like foam is good.
- the temperature in the double conveyor in the process of foaming and curing is too low, there is a concern that the foaming ratio will not increase and the initial heat insulation performance will be reduced, and if it is too high, the closed cell ratio will be liable to decrease and long-term heat insulation performance will be reduced. Therefore, it is preferably 60 ° C. or higher and 100 ° C. or lower, more preferably 65 ° C. or higher and 98 ° C. or lower, and further preferably 70 ° C. or higher and 95 ° C. or lower.
- the amount of water P (wt%) contained in the foamable phenolic resin composition charged into the mixer described above, and the temperature Q (° C) in the double conveyor in the process of foaming and curing described above If the coefficient R calculated from the following formula is too large, the content Y of hydrocarbons having 6 or less carbon atoms in the space volume of 22.4 ⁇ 10 ⁇ 3 m 3 (22.4 L) in the phenol resin foam decreases.
- the curing temperature in the present embodiment is preferably 40 ° C. or higher and 130 ° C. or lower, more preferably 60 ° C. or higher and 110 ° C. or lower. Curing may be performed in one stage, or may be cured in several stages by changing the curing temperature according to the degree of curing.For example, the temperature of the latter half of the double conveyor can be changed, or a double conveyor can be provided. It can be led to a temperature control area that does not change and the temperature of that area can be changed and cured.
- the density of the solid phenol resin is 1.3 g / ml
- the foam sample under the same production conditions was measured 6 times, and the average value was taken as the representative value of the production condition sample.
- Thermal conductivity JIS A 1412-2 1999, the thermal conductivity at 10 ° C. and 23 ° C. was measured by the following method.
- a phenol resin foam sample is cut into approximately 600 mm squares, and a specimen is placed in an atmosphere of 23 ⁇ 1 ° C. and humidity 50 ⁇ 2%, and the weight change over time is measured every 24 hours.
- Condition adjustment was carried out until it became 0.2 wt% or less.
- Conditioned specimens were introduced into a thermal conductivity device placed in the same environment. If the thermal conductivity measurement device is not placed in a room controlled at 23 ⁇ 1 ° C and humidity 50 ⁇ 2% where the specimen was placed, immediately put it in a polyethylene bag and close the bag. It was taken out of the bag within the time and immediately subjected to measurement of thermal conductivity.
- the face material is peeled off so as not to damage the foamed portion
- the thermal conductivity at 10 ° C. is the condition of the low temperature plate 0 ° C. and the high temperature plate 20 ° C.
- a symmetrical configuration type measuring device (Eihiro Seiki Co., Ltd., trade name “HC-074 / 600”) were used.
- (C) Water content in liquid The water content of the liquid was measured with a Karl Fischer moisture meter. When the viscosity of the liquid is high, dissolve the liquid in dehydrated methanol (manufactured by Kanto Chemical Co., Inc.) whose moisture content has been measured, and subtract the moisture content in the dehydrated methanol from the moisture content of the solution. The moisture content of the product was determined. A Karl Fischer moisture meter (manufactured by Kyoto Electronics Industry Co., Ltd., MKC-510) was used for the measurement.
- Amount of substance with a boiling point of ⁇ 100 to 81 ° C. contained in the foam 10 g of the foam sample with the face material peeled off and a metal file in a 10 L container (product name Tedlar bag) are sealed and nitrogen 5 L Injected.
- the sample was shaved from the top of the Tedlar pack using a file and finely crushed. Subsequently, it was placed in an oven adjusted to 81 ° C. for 10 minutes.
- 100 ⁇ L of gas generated in the Tedlar bag was sampled and measured by GC / MS, and the types and composition ratios of the generated gas components were analyzed. Separately, the detection sensitivity of the generated gas component was measured, and the composition ratio was calculated from the detection area area and detection sensitivity of each gas component obtained by the GC / MS.
- the sample-filled zippered bag with some openings left is placed in a circulating oven controlled at 81 ° C. for 30 ⁇ 5 minutes.
- the gas in the bag is discharged while preventing it from coming out, the bag is sealed, and cooled to room temperature.
- the weight of the bag with the specimen containing the specimen not subjected to moisture content measurement was measured with a precision balance, the weight of the bag with the chuck was subtracted, and the weight (W2) from which the volatile components were removed was measured. .
- W2 weight
- the content weight of hydrocarbons having 6 or less carbon atoms in the foam is obtained by subtracting the difference in water content from the difference between W1 and W2 and the solid phenol resin density from the volume (V) of the specimen. .3 g / cm 3, and the volatile component weight (by adding the air buoyancy weight calculated by the volume obtained by subtracting the resin volume calculated from W2 (space volume in the foam) and the density of air (0.00119 g / mL) ( W3) was measured, and the content weight (W4) was calculated by multiplying W3 by the ratio in the gas component of the hydrocarbon having 6 or less carbon atoms measured by the present measurement method (8).
- the content of the hydrocarbon having 6 or less carbon atoms in the foam (mol / 22.4 ⁇ 10 ⁇ 3 m 3 ) is the same as the above W4 in the space volume of 22.4 ⁇ 10 ⁇ 3 m 3 in the foam. And the measured amount and molecular weight of the hydrocarbons measured by the present measurement method (8).
- Viscosity of phenol resin Measured values after stabilizing for 3 minutes at 40 ° C. using a rotational viscometer (R-100, manufactured by Toki Sangyo Co., Ltd., rotor part is 3 ° ⁇ R-14) did.
- the viscosity of the foamable phenolic resin composition at the time of forming into a plate is evaluated by eliminating the influence of the increase in viscosity due to curing of the resin as much as possible. The measured value was used.
- Example 1 The reactor was charged with 3500 kg of 52 wt% formaldehyde and 2510 kg of 99 wt% phenol, stirred with a propeller rotary stirrer, and the temperature inside the reactor was adjusted to 40 ° C. with a temperature controller. Next, the reaction was carried out by increasing the temperature while adding a 50 wt% aqueous sodium hydroxide solution. When the Ostwald viscosity reached 60 centistokes (measured value at 25 ° C.), the reaction solution was cooled, and 570 kg of urea (corresponding to 15 mol% of the charged amount of formaldehyde) was added. Thereafter, the reaction solution was cooled to 30 ° C., and the pH was neutralized to 6.4 with a 50 wt% aqueous solution of paratoluenesulfonic acid monohydrate.
- the composition consists of 4.7 parts by weight of a mixture of 87 mol% of cyclopentane and 13 mol% of isobutane as a blowing agent, and 11 parts by weight of a mixture of 80% by weight of xylene sulfonic acid and 20% by weight of diethylene glycol, as 100 parts by weight of phenol resin A.
- the composition was supplied to a mixing head whose temperature was adjusted to 25 ° C., and supplied to the moving lower surface material through a multiport distribution pipe.
- the mixer (mixer) to be used is shown in FIG. This mixer is obtained by enlarging the mixer disclosed in JP-A-10-225993 and increasing the number of nozzles.
- the resin composition 1 in which a surfactant is added to a phenolic resin and a foaming agent 2 on the upper side surface, and an inlet for the curing catalyst 3 on the side surface near the center of the stirring portion where the rotor d stirs. It has.
- the part after the stirring part is connected to a nozzle for discharging the foam. That is, the part up to the catalyst inlet is the mixing part (A), the part from the catalyst inlet to the stirring end is the mixing part (B), and the part from the stirring end to the discharge nozzle is the distribution part (C).
- the distribution part (C) has a plurality of nozzles at the tip, and is designed so that the mixed foamable phenolic resin composition is uniformly distributed.
- a temperature sensor (D) and a pressure sensor (E) are set in the distributor (C) so that the temperature and pressure in the system can be measured (not shown). Furthermore, each mixing part and the distribution part are each provided with the jacket for temperature control for enabling temperature adjustment.
- the temperature measured by this temperature sensor (D) was 41.5 ° C.
- the pressure measured by this pressure sensor (E) was 1.0 MPa.
- a polyester nonwoven fabric (“Spunbond E05030” manufactured by Asahi Kasei Fibers Co., Ltd., weighing 30 g / m 2 , thickness 0.15 mm) was used.
- the foamable phenolic resin composition supplied onto the lower surface material was coated with the upper surface material, and at the same time, sandwiched between the upper and lower surface materials, sent to a slat type double conveyor, and cured with a residence time of 15 minutes.
- a slat type double conveyor to be used is shown in FIG. This conveyor is a slat type double conveyor disclosed in Japanese Patent Application Laid-Open No.
- a temperature sensor (F) is set (not shown) so that the double conveyor temperature in the process of foaming and curing can be measured.
- the temperature measured by this temperature sensor (F) was 87 ° C.
- the foamable phenolic resin composition coated with the upper and lower surface materials was formed into a plate shape by applying moderate pressure through the surface material from above and below with a slat type double conveyor.
- Example 2 A 48.5 mm phenol resin foam was obtained in the same manner as in Example 1 except that 100 parts by weight of the phenol resin was changed to 4.8 parts by weight of a mixture of 82 mol% of cyclopentane and 18 mol% of isobutane as a foaming agent. It was. The temperature measured by the temperature sensor (D) was 40.7 ° C., and the pressure measured by the pressure sensor (E) was 1.0 MPa.
- Example 3 A 49.5 mm phenol resin foam was obtained in the same manner as in Example 1 except that the foam weight was changed to 4.8 parts by weight of a mixture of 75 mol% of cyclopentane and 25 mol% of isobutane with respect to 100 parts by weight of the phenol resin. It was.
- the temperature measured by the temperature sensor (D) was 40.5 ° C.
- the pressure measured by the pressure sensor (E) was 1.1 MPa.
- Example 4 4.8 parts by weight of a mixture of 68 mol% of cyclopentane and 32 mol% of isobutane as a blowing agent with respect to 100 parts by weight of phenol resin, the temperature of the double conveyor measured by the temperature sensor (F) is 83 ° C, and the slat type double conveyor stays A 48.2 mm phenol resin foam was obtained in the same manner as in Example 1 except that the time was changed to 20 minutes.
- the temperature measured by the temperature sensor (D) was 40.1 ° C.
- the pressure measured by the pressure sensor (E) was 1.1 MPa.
- Example 5 Except for the dehydration conditions, except that the water content was 9.5% by weight, the addition amount of the blowing agent was 3.6 parts by weight with respect to 100 parts by weight of the phenolic resin as in Example 1, and the temperature sensor (F ), A 49.1 mm phenolic resin foam was obtained in the same manner as in Example 4 except that the double conveyor temperature was 93 ° C. and the residence time of the slat type double conveyor was 15 minutes. .
- the temperature measured by the temperature sensor (D) was 40.1 ° C.
- the pressure measured by the pressure sensor (E) was 0.8 MPa.
- Example 6 Example 5 except that the amount of foaming agent added was 3.8 parts by weight with respect to 100 parts by weight of the phenol resin, and the double conveyor temperature measured by the temperature sensor (F) was changed to 90 ° C. Thus, a 48.8 mm phenolic resin foam was obtained.
- the temperature measured by the temperature sensor (D) was 40.2 ° C.
- the pressure measured by the pressure sensor (E) was 0.8 MPa.
- Example 7 Except for the dehydration conditions, except that the water content was 4.6% by weight, the amount of the blowing agent added was 6.1 parts by weight and the temperature sensor (F ), A 47.3 mm phenolic resin foam was obtained in the same manner as in Example 4 except that the temperature of the double conveyor was changed to 80 ° C. The temperature measured by the temperature sensor (D) was 40.1 ° C., and the pressure measured by the pressure sensor (E) was 1.3 MPa.
- Example 8 With respect to 100 parts by weight of phenol resin, the amount of foaming agent added is 7.8 parts by weight, the double conveyor temperature measured by the temperature sensor (F) is 75 ° C., and the residence time of the slat type double conveyor is 25 minutes. A 48.3 mm phenolic resin foam was obtained in the same manner as in Example 7 except that the above was changed. The temperature measured by the temperature sensor (D) was 40.1 ° C., and the pressure measured by the pressure sensor (E) was 1.4 MPa.
- Example 9 The amount of foaming agent added is 6.5 parts by weight with respect to 100 parts by weight of the phenol resin, the double conveyor temperature measured by the temperature sensor (F) is 83 ° C., and the residence time of the slat type double conveyor is 20 minutes.
- a 48.6 mm phenol resin foam was obtained in the same manner as in Example 7 except that the above was changed.
- the temperature measured by the temperature sensor (D) was 40.2 ° C.
- the pressure measured by the pressure sensor (E) was 1.3 MPa.
- Example 10 For 100 parts by weight of phenolic resin, 6.7 parts by weight of a mixture of 68 mol% cyclopentane and 32 mol% normal butane as a blowing agent, the temperature of the double conveyor measured by the temperature sensor (F) is 75 ° C., and the slat type double conveyor A 49.8 mm phenol resin foam was obtained in the same manner as in Example 7 except that the residence time was changed to 25 minutes.
- the temperature measured by the temperature sensor (D) was 40.4 ° C.
- the pressure measured by the pressure sensor (E) was 1.3 MPa.
- Example 11 Example 7 except that the amount of foaming agent added was 6.5 parts by weight with respect to 100 parts by weight of the phenol resin, and the double conveyor temperature measured by the temperature sensor (F) was 83 ° C. Thus, a 49.2 mm phenolic resin foam was obtained.
- the temperature measured by the temperature sensor (D) was 40.1 ° C.
- the pressure measured by the pressure sensor (E) was 1.4 MPa.
- Example 12 A 49.8 mm phenol resin foam was obtained in the same manner as in Example 5 except that 100 parts by weight of the phenol resin was changed to 3.6 parts by weight of a mixture of 68 mol% of cyclopentane and 32 mol% of propane as a foaming agent. It was. The temperature measured by the temperature sensor (D) was 39.8 ° C., and the pressure measured by the pressure sensor (E) was 1.5 MPa.
- Example 13 The amount of foaming agent added is 3.9 parts by weight with respect to 100 parts by weight of the phenol resin, the double conveyor temperature measured by the temperature sensor (F) is 90 ° C., and the residence time of the slat type double conveyor is 15 minutes.
- a 48.9 mm phenol resin foam was obtained in the same manner as in Example 4 except that the above was changed.
- the temperature measured by the temperature sensor (D) was 40.1 ° C.
- the pressure measured by the pressure sensor (E) was 1.2 MPa.
- Example 14 With respect to 100 parts by weight of phenol resin, 3.6 parts by weight of the amount of foaming agent changed to 3.6 parts by weight of a mixture of 45 mol% of cyclopentane and 55 mol% of isopentane as a blowing agent was measured by a temperature sensor (F). A 47.3 mm phenol resin foam was obtained in the same manner as in Example 4 except that the double conveyor temperature was changed to 80 ° C. The temperature measured by the temperature sensor (D) was 39.7 ° C., and the pressure measured by the pressure sensor (E) was 1.2 MPa.
- Example 1 A 48.7 mm phenol resin foam was obtained in the same manner as in Example 1 except that 100 parts by weight of the phenol resin was changed to 4.4 parts by weight of a mixture of 50 mol% of isopentane and 50 mol% of isobutane as a foaming agent. .
- the temperature measured by the temperature sensor (D) was 37.5 ° C.
- the pressure measured by the pressure sensor (E) was 1.4 MPa.
- Example 2 A 49.7 mm phenol resin foam was obtained in the same manner as in Example 1 except that 100 parts by weight of the phenol resin was changed to 4.9 parts by weight of a mixture of 80 mol% of normal pentane and 20 mol% of isobutane as a foaming agent. It was. The temperature measured by the temperature sensor (D) was 39.5 ° C., and the pressure measured by the pressure sensor (E) was 1.2 MPa.
- Example 3 A phenol resin foam of 50.3 mm was obtained in the same manner as in Example 1 except that the foaming agent was changed to 5.9 parts by weight of cyclopentane with respect to 100 parts by weight of the phenol resin.
- the temperature measured by the temperature sensor (D) was 41.5 ° C.
- the pressure measured by the pressure sensor (E) was 0.8 MPa.
- Example 4 A 47.9 mm phenol resin foam was obtained in the same manner as in Example 1 except that the foaming agent was changed to 5.4 parts by weight of a mixture of 68 mol% cyclopentane and 32 mol% isopentane with respect to 100 parts by weight of the phenol resin. It was. The temperature measured by the temperature sensor (D) was 40.4 ° C., and the pressure measured by the pressure sensor (E) was 1.2 MPa.
- Example 6 (Comparative Example 6) In the synthesis, Example 1 except that the reaction liquid was cooled when the Ostwald viscosity reached 70 centistokes (measured value at 25 ° C.), the dehydration conditions were different, and the water content was 14.5% by weight. And 100 parts by weight of the phenol resin, 2.4 parts by weight of a mixture of 68 mol% cyclopentane and 32 mol% isobutane as a blowing agent, and the double conveyor temperature measured by the temperature sensor (F) was changed to 96 ° C. Except for the above, a 49.2 mm phenol resin foam was obtained in the same manner as in Example 1. The temperature measured by the temperature sensor (D) was 38.6 ° C., and the pressure measured by the pressure sensor (E) was 0.8 MPa.
- Example 7 A 47.7 mm phenol resin foam was obtained in the same manner as in Example 1 except that 100 parts by weight of the phenol resin was changed to 4.5 parts by weight of a mixture of 25 mol% of cyclopentane and 75 mol% of isobutane as a foaming agent. It was. The temperature measured by the temperature sensor (D) was 39.7 ° C., and the pressure measured by the pressure sensor (E) was 1.5 MPa.
- the present invention it is possible to provide a phenol resin foam having a low initial thermal conductivity and maintaining a low thermal conductivity over a long period of time, and a method for producing the same. Therefore, the phenol resin foam of the present invention is preferably used as a building heat insulating material, a vehicle heat insulating material, a device heat insulating material, or the like.
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Abstract
Description
また、一旦施工されると長期間にわたって使用される為、長期間にわたり高い断熱性能を保持する必要がある。
近年、省エネルギーと省資源化の為、長期優良住宅の必要性が増しており、従来にも増して、高い断熱性能とより長期間にわたり初期の低い熱伝導率を保持することが求められている。
すなわち、本発明は以下の通りである。
炭素数が6以下の炭化水素が、シクロペンタンを40~90mol%、及び沸点が-50℃~5℃の炭化水素より選ばれた1種又は2種以上を60~10mol%含み、
炭素数が6以下の炭化水素の沸点平均値Xが5~44℃であり、且つ、フェノール樹脂発泡体内の炭素数が6以下の炭化水素の含有量Yが、フェノール樹脂発泡体内の空間体積22.4×10-3m3あたり0.25~0.9molである、フェノール樹脂発泡体。
Z=0.0063X+Y (1)
少なくとも、フェノール樹脂、界面活性剤、シクロペンタン及び沸点が-50℃~5℃の炭化水素を含有する発泡剤、及び酸硬化触媒を含む発泡性フェノール樹脂組成物を、混合機を用いて混合し、混合機の分配部から発泡性フェノール樹脂組成物を吐出させた後、加熱し、発泡性フェノール樹脂組成物が発泡及び硬化する過程において、発泡性フェノール樹脂組成物の上下方向側から圧力を加え、板状に成形されたフェノール樹脂発泡体を製造する、フェノール樹脂発泡体の製造方法。
R=P+0.2286Q (2)
本実施形態におけるフェノール樹脂発泡体は、密度が10kg/m3以上150kg/m3以下であり、好ましくは、15kg/m3以上70kg/m3以下のフェノール樹脂発泡体である。密度があまり低くすぎると強度が弱く発泡体として取り扱いにくいと共に、気泡膜が薄い為、発泡体中の発泡剤が空気と置換し易く長期の断熱性能が低下し易い傾向が生じるという懸念があり、また、密度があまり高すぎると気泡膜を形成する樹脂部分の熱伝導が大きくなり断熱性能が低下する傾向が生じるという懸念がある。
(1)シクロペンタンを含有する。
(2)上記(1)以外に、沸点が-50℃~5℃の範囲にある炭化水素から選ばれた1種または2種以上を含有する。
(3)炭素数が6以下の炭化水素の合計に対する上記(1)(2)各々の比率が、シクロペンタン40~90mol%、及び沸点が-50℃~5℃の炭化水素より選ばれた1種又は2種以上の合計量が60~10mol%である。
X=a×Ta+b×Tb+c×Tc+… (3)
上式において、含有する炭化水素の種類がA,B,C,… 、各々の含有率がa,b,c,…(モル分率)、沸点がTa,Tb,Tc,…(℃)である。
Z=0.0063×X+Y (4)
係数Zの値が小さすぎると含有する断熱性能の良い炭化水素が少ない為長期の断熱性能が低下し易くなるという懸念があり、大きすぎると含有する炭化水素が液化し易く10℃及び23℃の初期断熱性能が低下する傾向が生じるという懸念がある。
R=P+0.2286Q (5)
実施例及び比較例中のフェノール樹脂、フェノール樹脂発泡体の組成、構造、特性は以下のようにして測定し、評価した。
(1)発泡体密度
20cm角のフェノール樹脂発泡体を試料とし、この試料の面材、サイディング材を取り除いて重量と見かけ容積を測定して求めた値であり、JIS-K-7222に従い測定した。
JIS-K-6402記載の方法を参考に、以下の方法で測定した。
フェノール樹脂発泡体の厚み方向ほぼ中央を表裏面に平行に切削して得られた切断面を50倍に拡大した写真を撮影し、得られた写真上に9cmの長さ(実際の発泡体断面における1,800μmに相当する)の直線を4本引き、各直線が横切った気泡の数の平均値を求めた。平均気泡径は横切った気泡の数の平均値で1,800μmを除した値である。
ASTM-D-2856-94(1998)A法を参考に以下の方法で測定した。
発泡体の厚み方向中央部から、約25mm角の立方体試片を切り出した。厚みが薄く25mmの均質な厚みの試片が得られない場合は、切り出した約25mm角の立方体試片表面を約1mmずつスライスし均質な厚みを有する試片を用いる。各辺の長さをノギスにより測定し、見かけ体積(V1:cm3)を計測すると共に試片の重量(W:有効数字4桁,g)を測定した、引き続き、エアーピクノメーター(東京サイエンス社、商品名「MODEL1000」)を使用し、ASTM-D-2856のA法に記載の方法に従い、試片の閉鎖空間体積(V2:cm3)を測定した。また、本願記載(2)平均気泡径の測定法に従い気泡径(t:cm)を計測すると共に、既測定の各辺の長さより、試片の表面積(A:cm3)を計測した。t及びAより、式VS=(A×t)/1.14により、試片表面の切断された気泡の開孔体積(VS:cm3)を算出した。また、固形フェノール樹脂の密度は1.3g/mlとし、試片に含まれる気泡壁を構成する固体部分の体積(VS:cm3)を式VS=試片重量(W)/1.3により、算出した。
下記式により独立気泡率を算出した。
独立気泡率(%)=〔(V2-VS)/(V1-VA-VS)〕×100 (6)
同一製造条件の発泡体サンプルについて6回測定し、その平均値をその製造条件サンプルの代表値とした。
フェノール樹脂発泡体サンプルの厚み方向のほぼ中央を表裏面に平行に切削して得られた切削断面の100mm×150mmの範囲を200%拡大した写真またはカラーコピーを撮影した。撮影された写真またはコピー図面において、縦横それぞれの長さが実寸の2倍に、面積は実面積の4倍になる。該写真または図面に透明方眼紙を上から重ね、大径の気泡を選び、該気泡の断面積を方眼紙のマス目を使って計測した。1mm×1mmマスが8マス以上にわたり連続して存在する孔をボイドとし、観察されるボイド面積を積算し面積分率を計算した。即ち、拡大コピーをとっているため、この8マスが実際の発泡体断面では2mm2の面積に相当する。同一製造条件の試料について12回測定し、その平均値をその製造条件サンプルの代表値とした。
JIS A
1412-2:1999に準拠し、以下の方法で10℃と23℃における熱伝導率を測定した。
フェノール樹脂発泡体サンプルを約600mm角に切断し、試片を23±1℃・湿度50±2%の雰囲気に入れ、24時間ごとに重量の経時変化を測定し、24時間経過の重量変化が0.2wt%以下になるまで、状態調節をした。状態調節された試片は、同環境下に置かれた熱伝導率装置に導入した。熱伝導率測定装置が、試片が置かれていた23±1℃・湿度50±2%にコントロールされた室内に置かれていない場合は、速やかにポリエチレン製の袋に入れ袋を閉じ、1時間以内に袋から出し、速やかに熱伝導率の測定に供した。
EN13166を参考に、25年経過後を想定した下記条件放置後の熱伝導率を測定した。
フェノール樹脂発泡体サンプルを約600mm角に切断し、気体の透過性面材を有する発泡体は、面材を有したまま、気体不透過性面材を有する場合は、発泡体自体の特性を評価する為、発泡部を傷つけないように面材を剥がし、試片とし加速試験に供した。
600mm角の試片は、110±2℃に温調された循環式オーブン内に14±0.05日間入れ加速試験を行った。
引き続き「(5)熱伝導率」の測定方法に従い、10℃及び23℃の熱伝導率の測定を行った。
組成物自体の水分量を測定することは困難であるため、以下の方法で組成物を構成する各々の材料の水分率を測定し、混合比率に応じて加重平均した水分率を算出した。
水分量を測定した脱水メタノール(関東化学(株)製)に、フェノール樹脂を3重量%から7重量%の範囲で溶解して、その溶液の水分量から脱水メタノール中の水分を除して、フェノール樹脂の水分量を求めた。測定にはカールフィッシャー水分計(京都電子工業(株)製、MKC-510)を用いた。
ボートタイプ水分気化装置を有するカールフィッシャー水分計で、下記条件で加熱して気化させた水分を測定した。
なお、加熱温度は、フェノール樹脂微粉末、及び分解性の低い個固体については、水分気化装置で110℃に加熱して測定し、水和物等の高温加熱により分解し水分を発生する固形物については、分解温度以下の低温で加熱し、含有水分を気化させた。
液体の水分量はカールフィッシャー水分計で測定した。液体物の粘度が高いときは、水分量を測定した脱水メタノール(関東化学(株)製)に液体物を溶解して、その溶液の水分量から脱水メタノール中の水分率を除して、液体物の水分量を求めた。測定にはカールフィッシャー水分計(京都電子工業(株)製、MKC-510)を用いた。
上記(C)の方法で測定が困難な低沸点液体や液化ガスについては、液化ガス気化装置を有するカールフィッシャー水分計で測定し、含有する水分量を求めた。
添加物(界面活性剤、酸硬化触媒、発泡剤、粉体等)は、メーカー分析値水分量を用いればよく、メーカー分析値が無い時等不十分な場合は、上記記載の方法にて測定を行った。
面材を剥がした発泡体試料を10gと金属製やすりを10L容器(製品名テドラーバック)に入れて密封し、窒素5Lを注入した。テドラーパックの上からヤスリを使い試料を削り、細かく粉砕した。続いて、81℃に温調されたオーブン内に10分間入れた。テドラーバック中で発生したガスを100μL採取し、GC/MSで測定し、発生したガス成分の種類と組成比を分析した。
なお、別途、発生したガス成分の検出感度を測定し、上記GC/MSで得られた各ガス成分の検出エリア面積と検出感度より、組成比は、算出した。
フェノール樹脂発泡体サンプルを約100mm角に切断し、試片6個を準備すると共に、密封可能な耐熱性を有するチャック付袋(以下チャック付袋と略す)を6袋準備し、各々の袋の重量を精密天秤で、測定した。試片を70℃に温調された循環式オーブン内に24±0.5hr入れ含有する水分を飛散させた後、速やかに、チャック付袋に入れ、封をして、室温まで冷やす。室温まで冷却後、チャック付袋より試片を取り出し、速やかに試片の面材を剥離すると共に、各試片の重量(W1)を精密天秤より測定すると共に、各辺の長さをノギスにより測定し、試片の体積(V)を算出した。その後、各試片をチャック付袋に戻し、一部の開口部を残し再度封をし、室温の油圧プレスの盤面間に入れ、油圧プレスで約200N/cm2の圧力まで徐々に圧縮し、試片の気泡を破壊した。3試片については、試片の一部試料を採取し、上記固形物中の水分量の測定法により、含有する水分量を測定した。残りの試片は引き続き、一部の開口部を残した試片入りチャック付袋を、81℃に温調された循環式オーブン内に30±5分入れた後、直ちに、粉体が袋から出ないようにしつつ袋内気体を排出し、袋を密封し、室温まで冷やす。室温まで冷却後、上記で水分率測定に供していない試片入りチャック付袋の重量を精密天秤で測定し、チャック付袋の重量を差し引き、揮発成分が除かれた重量(W2)を測定した。同時に、上記で水分率を測定した3試片の袋より、一部試料を採取し、同様に水分量を測定した。
発泡体中の炭素数が6以下の炭化水素の含有量(mol/22.4×10-3m3)は、上述の発泡体内の空間体積22.4×10-3m3における、上記W4と本願測定法(8)で測定された該炭化水素の測定量と分子量により算出した。
回転粘度計(東機産業(株)製、R-100型、ローター部は3°×R-14)を用い、40℃で3分間安定させた後の測定値とした。また、板状成形する際の発泡性フェノール樹脂組成物の粘度は、樹脂の硬化による粘度上昇の影響をできるだけ排除した評価とするため、該粘度計を用いて、40℃で2分間経過後の測定値とした。
レーザー回析光散乱方式粒径分布測定装置(日機装(株)製、マイクロトラックHRA;9320-X100)を使用し、粉体を水中に一様に分散させるため超音波で1分間処理した後測定した。
反応器に52重量%ホルムアルデヒド3500kgと99重量%フェノール2510kgを仕込み、プロペラ回転式の攪拌機により攪拌し、温調機により反応器内部液温度を40℃に調整した。次いで50重量%水酸化ナトリウム水溶液を加えながら昇温して、反応を行わせた。オストワルド粘度が60センチストークス(25℃における測定値)に到達した段階で、反応液を冷却し、尿素を570kg(ホルムアルデヒド仕込み量の15モル%に相当)添加した。その後、反応液を30℃まで冷却し、パラトルエンスルホン酸一水和物の50重量%水溶液でpHを6.4に中和した。
脱水後の反応液100重量部に対して、界面活性剤としてエチレンオキサイド-プロピレンオキサイドのブロック共重合体(BASF製、プルロニックF-127)を2.5重量部の割合で混合した。これをフェノール樹脂Aとした。
下面材上に供給した発泡性フェノール樹脂組成物は、上面材で被覆されると同時に、上下面材で挟み込むようにして、スラット型ダブルコンベアへ送り、15分の滞留時間で硬化させた。使用するスラット型ダブルコンベアを図2に示す。本コンベアは、特開2000-218635号公報に開示されているスラット型ダブルコンベアであり、フェノール樹脂組成物が吐出されてから3分後に通過する位置の上部スラットコンベアの上下プレート間の中央に、発泡・硬化する過程のダブルコンベア温度が測定できるように、温度センサー(F)がセットされている(図示せず)。この温度センサー(F)で計測された温度は、87℃であった。
フェノール樹脂100重量部に対して、発泡剤としてシクロペンタン82mol%とイソブタン18mol%の混合物4.8重量部に変更した以外は、実施例1と同様にして48.5mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が40.7℃、圧力センサー(E)で計測された圧力は1.0MPaであった。
フェノール樹脂100重量部に対して、発泡剤としてシクロペンタン75mol%とイソブタン25mol%の混合物重量4.8部に変更した以外は、実施例1と同様にして49.5mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が40.5℃、圧力センサー(E)で計測された圧力は1.1MPaであった。
フェノール樹脂100重量部に対して、発泡剤としてシクロペンタン68mol%とイソブタン32mol%の混合物4.8重量部、温度センサー(F)で計測されたダブルコンベア温度が83℃、スラット型ダブルコンベアの滞留時間が、20分になるように変更した以外は、実施例1と同様にして48.2mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が40.1℃、圧力センサー(E)で計測された圧力は1.1MPaであった。
脱水条件のみ異なり、水分量を9.5重量%とした以外は、実施例1と同様にしたフェノール樹脂100重量部に対して、発泡剤の添加量を3.6重量部、温度センサー(F)で計測されたダブルコンベア温度が93℃、スラット型ダブルコンベアの滞留時間が、15分になるように変更した以外は、実施例4と同様にして49.1mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が40.1℃、圧力センサー(E)で計測された圧力は0.8MPaであった。
フェノール樹脂100重量部に対して、発泡剤の添加量を3.8重量部、温度センサー(F)で計測されたダブルコンベア温度が90℃になるように変更した以外は、実施例5と同様にして48.8mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が40.2℃、圧力センサー(E)で計測された圧力は0.8MPaであった。
脱水条件のみ異なり、水分量を4.6重量%とした以外は、実施例1と同様にしたフェノール樹脂100重量部に対して、発泡剤の添加量を6.1重量部、温度センサー(F)で計測されたダブルコンベア温度が80℃になるように変更した以外は、実施例4と同様にして47.3mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が40.1℃、圧力センサー(E)で計測された圧力は1.3MPaであった。
フェノール樹脂100重量部に対して、発泡剤の添加量を7.8重量部、温度センサー(F)で計測されたダブルコンベア温度が75℃、スラット型ダブルコンベアの滞留時間が、25分になるように変更した以外は、実施例7と同様にして48.3mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が40.1℃、圧力センサー(E)で計測された圧力は1.4MPaであった。
フェノール樹脂100重量部に対して、発泡剤の添加量を6.5重量部、温度センサー(F)で計測されたダブルコンベア温度が83℃、スラット型ダブルコンベアの滞留時間が、20分になるように変更した以外は、実施例7と同様にして48.6mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が40.2℃、圧力センサー(E)で計測された圧力は1.3MPaであった。
フェノール樹脂100重量部に対して、発泡剤としてシクロペンタン68mol%とノルマルブタン32mol%の混合物6.7重量部、温度センサー(F)で計測されたダブルコンベア温度が75℃、スラット型ダブルコンベアの滞留時間が、25分になるように変更した以外は、実施例7と同様にして49.8mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が40.4℃、圧力センサー(E)で計測された圧力は1.3MPaであった。
フェノール樹脂100重量部に対して、発泡剤の添加量を6.5重量部、温度センサー(F)で計測されたダブルコンベア温度が83℃になるように変更した以外は、実施例7と同様にして49.2mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が40.1℃、圧力センサー(E)で計測された圧力は1.4MPaであった。
フェノール樹脂100重量部に対して、発泡剤としてシクロペンタン68mol%とプロパン32mol%の混合物3.6重量部に変更した以外は、実施例5と同様にして49.8mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が39.8℃、圧力センサー(E)で計測された圧力は1.5MPaであった。
フェノール樹脂100重量部に対して、発泡剤の添加量を3.9重量部、温度センサー(F)で計測されたダブルコンベア温度が90℃、スラット型ダブルコンベアの滞留時間が、15分になるように変更した以外は、実施例4と同様にして48.9mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が40.1℃、圧力センサー(E)で計測された圧力は1.2MPaであった。
フェノール樹脂100重量部に対して、発泡剤としてシクロペンタン45mol%とイソペンタン55mol%の混合物3.6重量部に変更した発泡剤の添加量を3.6重量部、温度センサー(F)で計測されたダブルコンベア温度が80℃になるように変更した以外は、実施例4と同様にして47.3mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が39.7℃、圧力センサー(E)で計測された圧力は1.2MPaであった。
フェノール樹脂100重量部に対して、発泡剤としてイソペンタン50mol%とイソブタン50mol%の混合物4.4重量部に変更した以外は、実施例1と同様にして48.7mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が37.5℃、圧力センサー(E)で計測された圧力は1.4MPaであった。
フェノール樹脂100重量部に対して、発泡剤としてノルマルペンタン80mol%とイソブタン20mol%の混合物4.9重量部に変更した以外は、実施例1と同様にして49.7mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が39.5℃、圧力センサー(E)で計測された圧力は1.2MPaであった。
フェノール樹脂100重量部に対して、発泡剤としてシクロペンタン100mol%5.9重量部に変更した以外は、実施例1と同様にして50.3mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が41.5℃、圧力センサー(E)で計測された圧力は0.8MPaであった。
フェノール樹脂100重量部に対して、発泡剤としてシクロペンタン68mol%とイソペンタン32mol%の混合物5.4重量部に変更した以外は、実施例1と同様にして47.9mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が40.4℃、圧力センサー(E)で計測された圧力は1.2MPaであった。
フェノール樹脂100重量部に対して、発泡剤としてシクロペンタン68mol%とイソブタン32mol%の混合物10重量部、温度センサー(F)で計測されたダブルコンベア温度が58℃、スラット型ダブルコンベアの滞留時間が、30分に変更した以外は、実施例1と同様にして47.3mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が39.8℃、圧力センサー(E)で計測された圧力は1.1MPaであった。
合成において、オストワルド粘度が70センチストークス(25℃における測定値)に到達した段階で、反応液を冷却すると共に、脱水条件が異なり、水分量を14.5重量%とした以外は、実施例1と同様にしたフェノール樹脂100重量部に対して、発泡剤としてシクロペンタン68mol%とイソブタン32mol%の混合物2.4重量部、温度センサー(F)で計測されたダブルコンベア温度が96℃に変更した以外は、実施例1と同様にして49.2mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が38.6℃、圧力センサー(E)で計測された圧力は0.8MPaであった。
フェノール樹脂100重量部に対して、発泡剤としてシクロペンタン25mol%とイソブタン75mol%の混合物4.5重量部に変更した以外は、実施例1と同様にして47.7mmのフェノール樹脂発泡体を得た。温度センサー(D)で計測された温度が39.7℃、圧力センサー(E)で計測された圧力は1.5MPaであった。
Claims (11)
- 炭素数が6以下の炭化水素を含有し、密度が10kg/m3以上150kg/m3以下のフェノール樹脂発泡体であって、
前記炭素数が6以下の炭化水素が、シクロペンタンを40~90mol%、及び沸点が-50℃~5℃の炭化水素より選ばれた1種又は2種以上を60~10mol%含み、
前記炭素数が6以下の炭化水素の沸点平均値Xが5~44℃であり、且つ、前記フェノール樹脂発泡体内の前記炭素数が6以下の炭化水素の含有量Yが、前記フェノール樹脂発泡体内の空間体積22.4×10-3m3あたり0.25~0.9molである、フェノール樹脂発泡体。 - 前記XとYから下記式(1)で算出される係数Zが0.40以上1.10以下である、請求項1記載のフェノール樹脂発泡体。
Z=0.0063X+Y (1) - 10℃及び23℃環境下における熱伝導率がいずれも0.0205W/m・k未満である、請求項1または2に記載のフェノール樹脂発泡体。
- 独立気泡率が90%以上、平均気泡径が40μm以上300μm以下であり、かつボイド面積率が0.2%以下である、請求項1~3のいずれか一項に記載のフェノール樹脂発泡体。
- 前記沸点が-50℃~5℃の炭化水素がイソブタンを含有する、請求項1~4のいずれか一項に記載のフェノール樹脂発泡体。
- フェノール樹脂発泡体中に含有される沸点が-100~81℃の物質中にしめる、前記シクロペンタン及び前記沸点が-50℃~5℃の炭化水素の合計量が、70~100mol%である、請求項1~5のいずれか一項に記載のフェノール樹脂発泡体。
- 酸硬化触媒と反応性を有する化合物、又は、酸硬化触媒により変質する化合物の合計含有量が、前記フェノール樹脂発泡体に対して0.5wt%以下である、請求項1~6のいずれか一項に記載のフェノール樹脂発泡体。
- 請求項1~7のいずれか一項に記載のフェノール樹脂発泡体を製造する製造方法であって、
少なくとも、フェノール樹脂、界面活性剤、シクロペンタン及び沸点が-50℃~5℃の炭化水素を含有する発泡剤、及び酸硬化触媒を含む発泡性フェノール樹脂組成物を、混合機を用いて混合し、混合機の分配部から前記発泡性フェノール樹脂組成物を吐出させた後、加熱し、前記発泡性フェノール樹脂組成物が発泡及び硬化する過程において、前記発泡性フェノール樹脂組成物の上下方向側から圧力を加え、板状に成形されたフェノール樹脂発泡体を製造する、フェノール樹脂発泡体の製造方法。 - 前記分配部の圧力が0.3MPa以上10MPa以下である、請求項8に記載の製造方法。
- 前記混合機に投入される前記発泡性フェノール樹脂組成物中に含まれる水分量が2~20wt%であり、前記発泡及び硬化する過程のダブルコンベア中の温度が60~100℃である、請求項8または9に記載の製造方法。
- 前記水分量P(wt%)と前記ダブルコンベア中の温度Q(℃)とから下記式(2)で算出される係数Rが、20以上36以下である、請求項8~10のいずれか一項に記載の製造方法。
R=P+0.2286Q (2)
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PCT/JP2013/083104 WO2014092086A1 (ja) | 2012-12-11 | 2013-12-10 | フェノール樹脂発泡体とその製造方法 |
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EP (1) | EP2933286B1 (ja) |
JP (2) | JP6204376B2 (ja) |
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CN108841134A (zh) * | 2018-04-16 | 2018-11-20 | 安徽昊森新材料科技有限公司 | 一种阻燃高强度轻质酚醛树脂 |
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US10253151B2 (en) | 2019-04-09 |
JP6204376B2 (ja) | 2017-09-27 |
EP2933286B1 (en) | 2018-07-11 |
KR101766988B1 (ko) | 2017-08-09 |
EP2933286A1 (en) | 2015-10-21 |
JP2017206714A (ja) | 2017-11-24 |
CN104854174A (zh) | 2015-08-19 |
EP2933286A4 (en) | 2015-11-25 |
JPWO2014092086A1 (ja) | 2017-01-12 |
US20150329690A1 (en) | 2015-11-19 |
KR20150081449A (ko) | 2015-07-14 |
CN104854174B (zh) | 2018-02-27 |
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