WO2022186313A1 - ポリプロピレン系樹脂発泡粒子およびポリプロピレン系樹脂発泡成形体 - Google Patents
ポリプロピレン系樹脂発泡粒子およびポリプロピレン系樹脂発泡成形体 Download PDFInfo
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- WO2022186313A1 WO2022186313A1 PCT/JP2022/009019 JP2022009019W WO2022186313A1 WO 2022186313 A1 WO2022186313 A1 WO 2022186313A1 JP 2022009019 W JP2022009019 W JP 2022009019W WO 2022186313 A1 WO2022186313 A1 WO 2022186313A1
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- polypropylene
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- expanded
- resin
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- 229940105990 diglycerin Drugs 0.000 description 1
- GPLRAVKSCUXZTP-UHFFFAOYSA-N diglycerol Chemical compound OCC(O)COCC(O)CO GPLRAVKSCUXZTP-UHFFFAOYSA-N 0.000 description 1
- AFABGHUZZDYHJO-UHFFFAOYSA-N dimethyl butane Natural products CCCC(C)C AFABGHUZZDYHJO-UHFFFAOYSA-N 0.000 description 1
- 239000012153 distilled water Substances 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- HEAMQYHBJQWOSS-UHFFFAOYSA-N ethene;oct-1-ene Chemical compound C=C.CCCCCCC=C HEAMQYHBJQWOSS-UHFFFAOYSA-N 0.000 description 1
- HQQADJVZYDDRJT-UHFFFAOYSA-N ethene;prop-1-ene Chemical group C=C.CC=C HQQADJVZYDDRJT-UHFFFAOYSA-N 0.000 description 1
- 150000002170 ethers Chemical class 0.000 description 1
- 229920006242 ethylene acrylic acid copolymer Polymers 0.000 description 1
- 229920001038 ethylene copolymer Polymers 0.000 description 1
- 229920006379 extruded polypropylene Polymers 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 210000003746 feather Anatomy 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 229910052621 halloysite Inorganic materials 0.000 description 1
- 150000008282 halocarbons Chemical class 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 125000003454 indenyl group Chemical group C1(C=CC2=CC=CC=C12)* 0.000 description 1
- 239000008235 industrial water Substances 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 239000003456 ion exchange resin Substances 0.000 description 1
- 229920003303 ion-exchange polymer Polymers 0.000 description 1
- 239000001282 iso-butane Substances 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 239000004611 light stabiliser Substances 0.000 description 1
- 229920005679 linear ultra low density polyethylene Polymers 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- HCWCAKKEBCNQJP-UHFFFAOYSA-N magnesium orthosilicate Chemical compound [Mg+2].[Mg+2].[O-][Si]([O-])([O-])[O-] HCWCAKKEBCNQJP-UHFFFAOYSA-N 0.000 description 1
- GVALZJMUIHGIMD-UHFFFAOYSA-H magnesium phosphate Chemical compound [Mg+2].[Mg+2].[Mg+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O GVALZJMUIHGIMD-UHFFFAOYSA-H 0.000 description 1
- 229910000400 magnesium phosphate tribasic Inorganic materials 0.000 description 1
- 239000000391 magnesium silicate Substances 0.000 description 1
- 229910052919 magnesium silicate Inorganic materials 0.000 description 1
- 235000019792 magnesium silicate Nutrition 0.000 description 1
- 239000011976 maleic acid Substances 0.000 description 1
- 238000000691 measurement method Methods 0.000 description 1
- 229920001179 medium density polyethylene Polymers 0.000 description 1
- 239000004701 medium-density polyethylene Substances 0.000 description 1
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 1
- ZQKXQUJXLSSJCH-UHFFFAOYSA-N melamine cyanurate Chemical compound NC1=NC(N)=NC(N)=N1.O=C1NC(=O)NC(=O)N1 ZQKXQUJXLSSJCH-UHFFFAOYSA-N 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- 229920003145 methacrylic acid copolymer Polymers 0.000 description 1
- 229940117841 methacrylic acid copolymer Drugs 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000013518 molded foam Substances 0.000 description 1
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 1
- GOQYKNQRPGWPLP-UHFFFAOYSA-N n-heptadecyl alcohol Natural products CCCCCCCCCCCCCCCCCO GOQYKNQRPGWPLP-UHFFFAOYSA-N 0.000 description 1
- 229910052754 neon Inorganic materials 0.000 description 1
- GKAOGPIIYCISHV-UHFFFAOYSA-N neon atom Chemical compound [Ne] GKAOGPIIYCISHV-UHFFFAOYSA-N 0.000 description 1
- JCXJVPUVTGWSNB-UHFFFAOYSA-N nitrogen dioxide Inorganic materials O=[N]=O JCXJVPUVTGWSNB-UHFFFAOYSA-N 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- VSIIXMUUUJUKCM-UHFFFAOYSA-D pentacalcium;fluoride;triphosphate Chemical compound [F-].[Ca+2].[Ca+2].[Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O VSIIXMUUUJUKCM-UHFFFAOYSA-D 0.000 description 1
- WXZMFSXDPGVJKK-UHFFFAOYSA-N pentaerythritol Chemical compound OCC(CO)(CO)CO WXZMFSXDPGVJKK-UHFFFAOYSA-N 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 239000002685 polymerization catalyst Substances 0.000 description 1
- 229920005672 polyolefin resin Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000001294 propane Substances 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 238000001223 reverse osmosis Methods 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 229930195734 saturated hydrocarbon Natural products 0.000 description 1
- IJDNQMDRQITEOD-UHFFFAOYSA-N sec-butylidene Natural products CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 230000002194 synthesizing effect Effects 0.000 description 1
- 239000008399 tap water Substances 0.000 description 1
- 235000020679 tap water Nutrition 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 239000006234 thermal black Substances 0.000 description 1
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 1
- 229940078499 tricalcium phosphate Drugs 0.000 description 1
- 229910000391 tricalcium phosphate Inorganic materials 0.000 description 1
- 235000019731 tricalcium phosphate Nutrition 0.000 description 1
- BIKXLKXABVUSMH-UHFFFAOYSA-N trizinc;diborate Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]B([O-])[O-].[O-]B([O-])[O-] BIKXLKXABVUSMH-UHFFFAOYSA-N 0.000 description 1
- 229910021642 ultra pure water Inorganic materials 0.000 description 1
- 239000012498 ultrapure water Substances 0.000 description 1
- 229920006163 vinyl copolymer Polymers 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/16—Making expandable particles
- C08J9/18—Making expandable particles by impregnating polymer particles with the blowing agent
Definitions
- the present invention relates to expanded polypropylene resin particles and expanded polypropylene resin articles.
- Polypropylene-based resin foam moldings are used for various purposes such as automobile interior parts, core materials for automobile bumpers, heat insulating materials, cushioning packaging materials, and returnable boxes (for example, Patent Documents 1 to 3).
- an object of one embodiment of the present invention is to provide (a) expanded polypropylene resin particles capable of providing a polypropylene resin foam molded article having good fusion bondability at a low molding pressure, and (b) An object of the present invention is to provide polypropylene-based resin expanded particles capable of providing a polypropylene-based resin foam-molded article having good compressive strength and little deformation.
- the inventors of the present invention have completed the present invention as a result of intensive studies to solve the above problems.
- the expanded polypropylene resin particles according to one embodiment of the present invention comprise a polypropylene resin (A) having a melting point of 135° C. to 150° C. and a polypropylene homopolymer (B) having a melting point of 85° C. or less.
- the base resin contains 80 parts of the polypropylene resin (A) when the total amount of the polypropylene resin (A) and the polypropylene homopolymer (B) is 100 parts by weight. 0 parts by weight to 98.0 parts by weight, and 2.0 parts by weight to less than 20.0 parts by weight of the polypropylene homopolymer (B).
- the structural units include a structural unit derived from the X1 monomer, a structural unit derived from the X2 monomer, ... and an Xn monomer (where n is An integer of 2 or more) is also referred to as "X 1 /X 2 /.../X n copolymer".
- the X 1 /X 2 /.../X n copolymer is not particularly limited in its polymerization mode unless otherwise specified, and may be a random copolymer or a block copolymer. may be a graft copolymer.
- polypropylene-based resin expanded particles may be referred to as “expanded particles”
- polypropylene-based resin expanded molded articles may be referred to as “expanded molded articles”.
- polypropylene-based resin particles may be referred to as "resin particles”.
- the expanded polypropylene resin particles according to the first embodiment of the present invention comprise a polypropylene resin (A) having a melting point of 135° C. to 150° C., a polypropylene homopolymer (B) having a melting point of 85° C. or less, including a base resin containing When the total amount of the polypropylene resin (A) and the polypropylene homopolymer (B) is 100 parts by weight, the base resin has more than 80.0 parts by weight of the polypropylene resin (A) and 98 parts by weight. 0 parts by weight or less, and 2.0 parts by weight or more and less than 20.0 parts by weight of the polypropylene homopolymer (B).
- the foamed polypropylene resin particles according to the first embodiment of the present invention can be molded by a known method to provide a foamed polypropylene resin article.
- the "polypropylene-based resin expanded beads according to the first embodiment of the present invention” may be referred to as “first expanded beads”.
- the "polypropylene-based resin particles according to the first embodiment of the present invention” may be referred to as “first resin particles”.
- the first expanded beads have the above-described configuration, (a) a polypropylene-based resin foamed molded article having good fusion bondability can be provided at a low molding pressure (in other words, a low heating steam pressure), and (b) ) It has the advantage of being able to provide a polypropylene-based resin foam-molded article which has good compressive strength and hardly deforms. Since the first expanded beads have the above-described structure, they also have the advantage of being able to provide a polypropylene-based resin expanded molded article having good surface beauty.
- the base resin contains at least a polypropylene resin (A) and a polypropylene homopolymer (B) as resin components.
- the base resin may optionally contain an additive such as a foam nucleating agent in addition to the resin component. It can also be said that the base resin is a component that substantially constitutes the expanded beads. Therefore, the type and amount of each component contained in the base resin can also be said to be the type and amount of each component contained in the first expanded beads. It can also be said that the base resin is a component that constitutes the polypropylene-based resin particles.
- the polypropylene-based resin means a resin containing 50 mol% or more of structural units derived from a propylene monomer out of 100 mol% of all structural units contained in the resin.
- the "structural unit derived from a propylene monomer” may be referred to as "propylene unit”.
- the polypropylene resin (A) may be (a) a homopolymer of propylene, or (b) a block copolymer, random copolymer or graft copolymer of propylene and a monomer other than propylene. or (c) a mixture of two or more thereof.
- the polypropylene resin (A) may have one or more structural units derived from a monomer other than the propylene monomer, or may have one or more types.
- a "monomer other than a propylene monomer” used in the production of the polypropylene-based resin (A) may be referred to as a "comonomer”.
- a "structural unit derived from a monomer other than a propylene monomer” contained in the polypropylene resin (A) may be referred to as a "comonomer unit".
- Comonomers include ethylene, 1-butene, isobutene, 1-pentene, 3-methyl-1-butene, 1-hexene, 4-methyl-1-pentene, 3,4-dimethyl-1-butene, 1-heptene, Examples include ⁇ -olefins having 2 or 4 to 12 carbon atoms such as 3-methyl-1-hexene, 1-octene and 1-decene.
- polypropylene-based resin (A) examples include polypropylene homopolymer, propylene/ethylene random copolymer, propylene/1-butene random copolymer, propylene random/ethylene/1-butene copolymer, and propylene/ethylene.
- the polypropylene-based resin (A) one of these may be used alone, or two or more thereof may be used in combination.
- propylene/ethylene random copolymers and propylene/ethylene/1-butene random copolymers have good expandability in the resulting expanded beads and good moldability in the molded product. It is suitable from the point that it has.
- the 1-butene is synonymous with butene-1.
- a propylene/ethylene random copolymer or propylene/ethylene/1-butene random copolymer, which is a polypropylene resin is used as the polypropylene resin (A) (case A).
- the ethylene content in the propylene/ethylene random copolymer or the propylene/ethylene/1-butene random copolymer is 0.2% to 10.0% by weight based on 100% by weight of each copolymer. is preferred.
- the ethylene content can also be said to be the content of structural units (ethylene units) derived from ethylene.
- the 1-butene content in the propylene/ethylene/1-butene random copolymer is preferably 0.2 wt% to 10.0 wt% in 100 wt% of the copolymer.
- the 1-butene content can also be said to be the content of structural units (1-butene units) derived from 1-butene.
- the content of 1-butene units in the propylene/ethylene/1-butene random copolymer is (i) 0.2% by weight or more, the foamability of the expanded beads in the production of the first expanded beads, and (ii) When the content is 10.0% by weight or less, the mechanical properties of the foamed molded article obtained from the first expanded beads may be deteriorated. do not have.
- the total content of ethylene units and 1-butene units in the propylene/ethylene/1-butene random copolymer is 0 in 100% by weight of the propylene/ethylene/1-butene random copolymer. 0.5% to 10.0% by weight is preferred.
- the total content of ethylene units and 1-butene units in the propylene/ethylene/1-butene random copolymer is (i) 0.5% by weight or more, The foamability and/or the moldability of the obtained expanded beads tend to be good, and (ii) when the content is 10.0% by weight or less, the mechanical properties of the expanded molded product obtained from the first expanded beads are improved. There is no risk of lowering.
- the melting point of the polypropylene resin (A) according to the first embodiment of the present invention is preferably 135° C. to 150° C., more preferably 137° C. to 148° C., more preferably 139° C. to 146° C., more preferably 140° C. to 146°C is more preferred, 141°C to 145°C is even more preferred, and 142°C to 144°C is particularly preferred.
- the melting point of the polypropylene-based resin (A) is (i) 135° C. or higher, the foamed molded article obtained from the first expanded particles has excellent heat resistance, and (ii) when it is 150° C. or lower, It becomes easy to increase the expansion ratio of the expanded beads in the production of the first expanded beads.
- the melting point of the polypropylene-based resin (A) is a value obtained by measuring with a differential scanning calorimeter method (hereinafter referred to as "DSC method").
- DSC method differential scanning calorimeter method
- the specific operating procedure is as follows: (1) 5 mg to 6 mg of polypropylene resin (A) is heated from 40 ° C. to 220 ° C. at a rate of 10 ° C./min. (2) Then, the temperature of the melted polypropylene resin (A) is lowered from 220° C. to 40° C. at a rate of 10° C./min to melt the polypropylene resin (A).
- the temperature of the crystallized polypropylene-based resin (A) is further increased from 40°C to 220°C at a rate of 10°C/min.
- the temperature of the peak (melting peak) of the DSC curve of the polypropylene-based resin (A) obtained during the second heating can be obtained as the melting point of the polypropylene-based resin (A).
- the temperature of the peak (melting peak) with the maximum amount of heat of fusion is the melting point of the polypropylene resin (A).
- the differential scanning calorimeter for example, DSC6200 type manufactured by Seiko Instruments Inc. can be used.
- MFR at 230 ° C. of the polypropylene resin (A) used in the first embodiment of the present invention is not particularly limited, but is preferably 3 g / 10 minutes to 30 g / 10 minutes, 4 g / 10 minutes to 20 g / 10 more preferably 5 g/10 min to 18 g/10 min.
- the MFR of the polypropylene-based resin (A) When the MFR of the polypropylene-based resin (A) is 3 g/10 minutes or more, it tends to be easy to increase the expansion ratio of the expanded beads in the production of the first expanded beads. When the MFR of the polypropylene-based resin is 30 g/10 minutes or less, there is no possibility that the cells of the expanded beads obtained will be open, and as a result, (i) the compressive strength of the foamed molded product obtained from the first expanded beads will increase. or (ii) the surface properties of the foamed molded article tend to be improved.
- the MFR of polypropylene resin (A) is in the range of 3 g/10 minutes to 30 g/10 minutes.
- polypropylene-based resin expanded particles having a relatively large expansion ratio can be easily obtained.
- the foamed molded article obtained from the first foamed particles has excellent surface beauty and a small dimensional shrinkage.
- the MFR value of the polypropylene resin (A) is a value obtained by measuring under the following conditions using an MFR measuring instrument described in JIS K7210: 1999: an orifice diameter of 2 .0959 ⁇ 0.005 mm ⁇ , orifice length of 8.000 ⁇ 0.025 mm, load of 2.16 kgf, and temperature of 230° C. (230 ⁇ 0.2° C.).
- the polypropylene resin (A) can be obtained by a known method.
- the polymerization catalyst for synthesizing the polypropylene-based resin (A) is not particularly limited, and a Ziegler-based catalyst or the like can be used.
- the base resin contains more than 80.0 parts by weight and 98.0 parts by weight or less of the polypropylene resin (A) in 100 parts by weight of the resin component, and may contain 82.5 parts by weight to 98.0 parts by weight. Preferably, it contains 85.0 to 95.0 parts by weight, more preferably 90.0 to 95.0 parts by weight.
- the base resin contains more than 80.0 parts by weight of the polypropylene resin (A) in 100 parts by weight of the resin component, the foamed polypropylene resin has good compressive strength and almost no deformation.
- the polypropylene homopolymer (B) is a polypropylene homopolymer having a melting point of 85° C. or less.
- the present inventor independently found the following findings in the process of intensive study of the first embodiment of the present invention:
- a polypropylene-based resin foam-molded article having good fusion bondability can be provided at a low molding pressure, and (b) it has good compressive strength. and to provide a polypropylene-based resin foam-molded article which hardly deforms.
- the present inventor surprisingly found the following unique findings: By using expanded particles containing a certain polypropylene homopolymer (B), it is possible to provide a polypropylene-based resin foam-molded article having excellent surface beauty.
- the melting point of the polypropylene homopolymer (B) is 85°C or lower, preferably 80°C or lower, more preferably lower than 78°C, and even more preferably 75°C or lower.
- the obtained expanded beads can (a) provide a polypropylene-based resin foam molded article having good fusion bondability at a lower molding pressure, and (b) It has the advantage of being able to provide a foam molded article having better compressive strength, very little deformation, and excellent surface beauty. The reason for this is presumed as follows, but the present invention is not limited to this reason: when the melting point of the polypropylene homopolymer (B) is 85° C.
- the polypropylene resin (A) This is because the polypropylene homopolymer (B) can easily enter the aggregate (in the non-crystalline portion) without being crystallized.
- the lower limit of the melting point of the polypropylene homopolymer (B) is not particularly limited, it is preferably 40°C or higher. When the melting point of the polypropylene homopolymer (B) is 40° C. or higher, the polypropylene homopolymer (B) is not sticky at room temperature, and thus has the advantage of being easy to handle.
- the melting point of the polypropylene homopolymer (B) is a value obtained by measuring by the DSC method. Specifically, except that the polypropylene homopolymer (B) is used instead of the polypropylene resin (A), the polypropylene homopolymer (B) is measured by the same method as the method for measuring the melting point of the polypropylene resin (A). A DSC curve can be obtained. The melting point of the polypropylene homopolymer (B) can be determined from the DSC curve of the polypropylene homopolymer (B) in the same manner as the melting point of the polypropylene resin (A).
- the weight average molecular weight of the polypropylene homopolymer (B) is preferably from 40,000 to 140,000, more preferably from 40,000 to 140,000, and particularly preferably from 75,000 to 140,000.
- a polypropylene homopolymer (B) having a weight average molecular weight of 40,000 or more has a sufficient viscosity. Therefore, when the weight average molecular weight of the polypropylene homopolymer (B) is 40000 or more, the polypropylene resin (A) and the polypropylene homopolymer (B) are included in the production of the polypropylene resin particles containing the base resin.
- the blend can be easily melt-kneaded.
- the resulting expanded beads can provide (a) a polypropylene resin foam molded article having good fusion bondability at a lower molding pressure.
- (b) have the advantage of being able to provide a foam molded article having better compressive strength, less deformation, and more excellent surface beauty.
- the reason for this is presumed as follows, but the present invention is not limited to this reason: when the weight average molecular weight of the polypropylene homopolymer (B) is 140000 or less, the polypropylene homopolymer (B ) becomes moderately low in melting point and becomes difficult to crystallize. Therefore, the polypropylene homopolymer (B) can easily enter into the aggregate (in the amorphous portion) of the polypropylene resin (A) without being crystallized.
- the weight average molecular weight of the polypropylene homopolymer (B) is a value obtained by converting the value obtained by gel permeation chromatography (GPC) into polystyrene.
- the polypropylene homopolymer (B) preferably has low stereoregularity, that is, it is preferably a polypropylene homopolymer having low stereoregularity.
- the polypropylene homopolymer (B) having a melting point of 85° C. or lower can be realized with a polypropylene homopolymer having low stereoregularity.
- a polypropylene homopolymer with low stereoregularity can be obtained by a polymerization reaction using a propylene monomer and a metallocene catalyst.
- the polypropylene homopolymer (B) is preferably polymerized with a metallocene catalyst.
- Polypropylene homopolymers polymerized using metallocene catalysts tend to have low stereoregularity of the polypropylene monomer in the polymer. Therefore, the melting point of the polypropylene homopolymer tends to be lower than in the case of polymerization using a Ziegler catalyst or the like.
- the resulting expanded beads can (a) provide a foamed molded article having excellent fusion bondability at a lower molding pressure, and (b) It has the advantage of being able to provide a polypropylene-based resin foam-molded article which has better compressive strength, undergoes very little deformation, and is more excellent in surface beauty.
- the reason for this is presumed as follows, but is not limited to this reason: when the mesopentad fraction is 25 mol % to 65 mol %, the melting point of the polypropylene homopolymer (B) is moderately low, Moreover, it becomes difficult to crystallize. Therefore, the polypropylene homopolymer (B) can easily enter into the aggregate (in the amorphous portion) of the polypropylene resin (A) without being crystallized.
- the mesopentad fraction of a polypropylene-based resin is a value obtained by measuring by the following methods (1) to (3): (1) sample As a polypropylene resin (eg, polypropylene homopolymer (B)) was dissolved in o-dichlorobenzene. The resulting solution is subjected to JNM-GX270 equipment manufactured by JEOL, and 13 C-NMR is measured at a resonance frequency of 67.93 MHz; (3) The ratio of the mmmm peak to the total methyl group-derived peak area is expressed as a percentage and defined as the mesopentad fraction (mol%). Detailed measurement conditions are as follows.
- Measurement solvent o-dichlorobenzene (90% by weight)/benzene-D 6 (10% by weight) Sample concentration: 15% to 20% by weight Measurement temperature: 120°C to 130°C Resonance frequency: 67.93MHz Pulse width: 10 ⁇ sec (45° pulse) Pulse repetition time: 7.091 sec Data points: 32K Cumulative count: 8168 Mode of Measurement: Noise Decoupling It should be noted that herein the assignment of the obtained spectra and the calculation of the pentad fractions are according to T.W. It is performed based on the method performed by Hayashi et al. [Polymer, 29, 138-143 (1988)].
- the base resin contains 2.0 parts by weight or more and less than 20.0 parts by weight of the polypropylene homopolymer (B) in 100 parts by weight of the resin component, and may contain 2.0 parts by weight to 17.5 parts by weight. Preferably, it contains 5.0 parts by weight to 15.0 parts by weight, and more preferably 5.0 parts by weight to 10.0 parts by weight.
- the base resin contains 2.0 parts by weight or more of the polypropylene homopolymer (B) in 100 parts by weight of the resin component, the polypropylene-based resin has excellent surface beauty and good fusion bondability.
- polypropylene-based resin expanded particles that can provide a foamed molded article at a low molding pressure, and (b) when it contains less than 20.0 parts by weight, the polypropylene-based resin has good compressive strength and hardly deforms It is possible to provide polypropylene-based resin expanded particles that can provide a resin expanded molded article.
- polypropylene homopolymer (B) in the base resin within the range described above, it is possible to provide expanded polypropylene resin particles that can provide a polypropylene resin foam molded article with more excellent surface beauty. .
- the base resin is (a) more than 80.0 parts by weight of the polypropylene resin (A), and 98.0 parts by weight.
- the base resin is more than 80.0 parts by weight and 98.0 parts by weight or less of the polypropylene resin (A) with respect to 100 parts by weight of the total amount of the polypropylene resin (A) and the polypropylene homopolymer (B).
- polypropylene homopolymer (B) (a) providing a polypropylene-based resin foam molded article having good fusion bondability at a low molding pressure. and (b) expanded polypropylene resin particles that can provide a polypropylene resin foam molded article having good compressive strength, almost no deformation, and excellent surface beauty. can do.
- the base resin is a resin component other than the polypropylene resin (A) and the polypropylene homopolymer (B) (other resins, etc.) as long as the effects of the first embodiment of the present invention are not impaired. may be called.) may be further included.
- the other resins include (a) polypropylene-based resins other than the polypropylene-based resin (A) and the polypropylene homopolymer (B), (b) high-density polyethylene, medium-density polyethylene, low-density polyethylene, linear low-density Ethylene-based resins such as density polyethylene, linear ultra-low density polyethylene, ethylene/vinyl acetate copolymer, ethylene/acrylic acid copolymer, and ethylene/methacrylic acid copolymer, (c) polystyrene, styrene/anhydride Styrenic resins such as maleic acid copolymers and styrene/ethylene copolymers, (d) polyolefin waxes such as propylene- ⁇ -olefin waxes, and (e) ethylene/propylene rubber, ethylene/butene rubber, ethylene/ Hexene rubber, olefin rubber such as ethylene/o
- the base resin may optionally contain additives in addition to the polypropylene-based resin (A) and the polypropylene homopolymer (B) described above.
- Additives include coloring agents, water-absorbing substances, foam nucleating agents, antistatic agents, flame retardants, antioxidants, light stabilizers, crystal nucleating agents, conductive agents, lubricants, and the like. Such additives may be added directly to the blend or polypropylene resin composition described later in the production of polypropylene resin particles.
- coloring agents include carbon black, ultramarine blue, cyanine pigments, azo pigments, quinacridone pigments, cadmium yellow, chromium oxide, iron oxide, perylene pigments, and anthraquinone pigments.
- carbon black is preferable as the colorant because it gives a molded product with little color unevenness and excellent colorability.
- One type of these colorants may be used alone, or two or more types may be mixed and used. Moreover, when two or more kinds of colorants are mixed and used, the mixing ratio may be appropriately adjusted depending on the purpose.
- the base resin may or may not contain carbon black.
- the content of carbon black is preferably less than 10 parts by weight when the total amount of polypropylene resin (A) and polypropylene homopolymer (B) is 100 parts by weight. .
- the water-absorbing substance is a substance used for the purpose of increasing the amount of water impregnated in the resin particles in the production of the first expanded beads.
- foaming properties can be imparted to the resin beads.
- the effect of imparting foamability to the resin particles by the water-absorbing substance is particularly remarkable when water is used as the foaming agent.
- Water-absorbing substances that can be used in the first embodiment of the present invention include, for example, glycerin, diglycerin, polyethylene glycol, C12-C18 aliphatic alcohols (eg, pentaerythritol, cetyl alcohol, stearyl alcohol), melamine , isocyanuric acid, melamine-isocyanuric acid condensate, zinc borate and the like.
- glycerin diglycerin
- polyethylene glycol eg, pentaerythritol, cetyl alcohol, stearyl alcohol
- melamine isocyanuric acid
- melamine-isocyanuric acid condensate zinc borate and the like.
- One type of these water-absorbing substances may be used alone, or two or more types may be mixed and used.
- the mixing ratio may be appropriately adjusted depending on the purpose.
- glycerin and polyethylene glycol do not promote miniaturization of the average cell diameter of expanded particles and (b) have good affinity with the polypropylene-based resin (A). Also from the point of view, it is preferable.
- the amount of the water-absorbing substance used in the production of the first foamed beads in other words, the content of the water-absorbing substance in the base resin will be explained.
- the content of the water-absorbing substance with respect to the total amount of 100 parts by weight of the polypropylene resin (A) and the polypropylene homopolymer (B) is preferably 0.01 to 1.00 parts by weight. , 0.05 to 0.70 parts by weight, more preferably 0.10 to 0.60 parts by weight.
- the content of the water-absorbing substance is (i) 0.01 parts by weight or more, the foaming effect of the water-absorbing substance can be sufficiently obtained, and (ii) when it is 1.00 parts by weight or less. , there is no risk of shrinkage of the resulting foamed beads.
- the amount of the foaming nucleating agent used in the production of the first foamed beads in other words, the content of the foaming nucleating agent in the base resin will be described.
- the content of the foam nucleating agent in the base resin is 0.005 parts by weight with respect to 100 parts by weight of the total amount of the polypropylene resin (A) and the polypropylene homopolymer (B), from the viewpoint of uniformity of the average cell diameter. parts to 2.000 parts by weight, more preferably 0.010 parts to 1.000 parts by weight, even more preferably 0.030 parts to 0.500 parts by weight.
- crystal nucleating agents examples include inorganic crystal nucleating agents such as feldspar, zeolite, talc, kaolin, mica, calcium stearate, calcium carbonate, silica, titanium oxide, bentonite, and barium sulfate. These crystal nucleating agents may be used alone or in combination of two or more. Among these crystal nucleating agents, silicate compounds such as feldspar, zeolite, talc, kaolin and mica are preferred, and talc is more preferred. When a silicate compound is used as the crystal nucleating agent, the expanded particles have a high degree of blackness and can provide a foamed molded product with no or very few intergranular spaces.
- inorganic crystal nucleating agents such as feldspar, zeolite, talc, kaolin, mica, calcium stearate, calcium carbonate, silica, titanium oxide, bentonite, and barium sulfate. These crystal nucleating agents may be used alone or in combination
- the amount of the crystal nucleating agent used in the production of the first expanded beads in other words, the content of the crystal nucleating agent in the base resin will be explained.
- the content of the crystal nucleating agent with respect to 100 parts by weight of the total amount of the polypropylene resin (A) and the polypropylene homopolymer (B) is preferably 0.01 to 0.25 parts by weight, and 0.01 part by weight to 0.25 parts by weight. 01 parts by weight to 0.20 parts by weight is more preferred.
- the content of the crystal nucleating agent (a) in the base resin is 0.01 parts by weight or more with respect to 100 parts by weight of the total amount of the polypropylene resin (A) and the polypropylene homopolymer (B)
- the expanded beads are provided.
- the foam-molded product tends to be a foam-molded product with a uniform color (black) and no color unevenness, or a foam-molded product with a substantially uniform color (black) and very little color unevenness, and (b) 0.25 parts by weight If it is below, the blackness of the foamed product provided by the expanded particles tends to be high, and the foamed product tends to have no or very few intergranular spaces.
- the first expanded beads preferably have at least two melting peaks in a DSC curve obtained by differential scanning calorimetry, which will be described later.
- the heat of fusion obtained from the melting peak on the high temperature side is referred to as the "heat of fusion on the high temperature side”
- the heat of fusion obtained from the melting peak on the low temperature side is referred to as the "heat of fusion on the low temperature side”.
- the heat of fusion obtained from the highest melting peak is defined as the "heat of fusion on the high temperature side”
- the heat of fusion obtained from the other melting peaks is defined as the heat of fusion on the low temperature side.
- the DSC ratio of the first expanded beads is not particularly limited, it is preferably 10.0% to 50.0%, more preferably 20.0% to 40.0%, and 22.0%. More preferably, it is up to 30.0%.
- the DSC ratio of the expanded beads is 10.0% or more, the expanded beads have the advantage of being able to provide a foam molded article having sufficient strength.
- the DSC ratio of the expanded beads is 50.0% or less, there is an advantage that the expanded beads can be molded at a relatively low temperature (molding temperature) to provide a foam molded product.
- the DSC ratio means the ratio of the heat of fusion on the high temperature side to the total heat of fusion calculated from the DSC curve of the first expanded beads.
- the DSC curve is obtained using a differential scanning calorimeter (eg DSC6200 manufactured by Seiko Instruments Inc.). More specifically, in the present specification, the method of measuring (calculating) the DSC ratio of expanded beads using a differential scanning calorimeter (eg DSC6200 manufactured by Seiko Instruments Inc.) is as follows (1) to (6). (1) Weigh 5 mg to 6 mg of the expanded beads; (2) Increase the temperature of the expanded beads from 40° C. to 220° C.
- the DSC ratio of the first expanded bead is also a value that serves as a measure of the amount of crystals with a high melting point contained in the expanded bead. That is, the fact that the DSC ratio is 10.0% to 50.0% indicates that the expanded beads contain a relatively large amount of crystals with a high melting point.
- the DSC ratio of the expanded beads is greatly related to the viscoelasticity of the resin beads and the expanded beads when the resin beads are expanded and when the expanded beads are expanded. That is, when the DSC ratio of the expanded beads is 10.0% to 50.0%, the resin beads and the expanded beads have excellent expandability when the resin beads are expanded and when the expanded beads are molded. and expandable. As a result, the expanded beads have the advantage that it is possible to obtain a foam molded article having excellent internal fusion bondability and excellent mechanical strength such as compressive strength at a low molding pressure.
- the conditions at the time of manufacturing the first expanded beads in particular, the expansion temperature, expansion pressure, holding time, and area for releasing the dispersion liquid ( and a method of adjusting the temperature of the space).
- the method for controlling the DSC ratio within a predetermined range the method of adjusting the foaming temperature, foaming pressure and/or holding time is preferable because of the ease of adjustment.
- the average cell diameter of the first expanded beads is not particularly limited, but is preferably 110 ⁇ m to 280 ⁇ m, more preferably 120 ⁇ m to 270 ⁇ m, more preferably 130 ⁇ m to 260 ⁇ m, and 140 ⁇ m to 250 ⁇ m. more preferably 150 ⁇ m to 240 ⁇ m, particularly preferably 160 ⁇ m to 230 ⁇ m.
- the expanded particles When the average cell diameter of the first expanded particles is (i) 110 ⁇ m or more, the expanded particles have no color unevenness, and can provide a polypropylene-based resin foam-molded article having excellent colorability and excellent compressive strength, and (ii) When the average cell diameter of the first foamed particles is 280 ⁇ m or less, there is no possibility that the molding cycle of the in-mold foamed molded product will be lengthened, and there is an advantage that the productivity is improved.
- the molding cycle refers to the process from the start of in-mold foam molding to the release of the obtained molded product from the mold when obtaining a foam molded product by performing in-mold foam molding using foamed particles. Time to finish, intend.
- the first expanded beads preferably have an expansion ratio of 15 to 50 times, more preferably 18 to 40 times, even more preferably 20 to 25 times. If the expansion ratio of the expanded particles is (i) 15 times or more, a lightweight foamed molded article can be obtained with good production efficiency, and (ii) if it is 50 times or less, the strength of the obtained foamed molded article is insufficient. there is no risk of
- the expansion ratio of the expanded beads is calculated by the following methods (1) to (4): (1) measuring the weight w (g) of the expanded beads; The foamed beads used for the measurement are submerged in ethanol contained in a graduated cylinder, and the volume v (cm 3 ) of the foamed beads is measured based on the rise in the liquid level of the graduated cylinder; (3) Weight w (g) is divided by the volume v (cm 3 ) to calculate the density ⁇ 1 of the expanded beads ; The value obtained by dividing ( ⁇ 2 / ⁇ 1 ) is multiplied by 100, and the obtained value is taken as the expansion ratio of the expanded beads.
- the first foamed particles have the advantage of being able to provide a polypropylene-based resin foamed molded article with good fusion bondability at a low molding pressure.
- the advantage can be evaluated by the minimum molding pressure during in-mold foam molding that can provide a foam molded article having an internal fusion rate of 60% or more. For the minimum molding pressure, see [1-2. This will be described in detail in the section (Minimum molding pressure) in Polypropylene-based resin foam molded article].
- the method for producing the first expanded beads is not particularly limited, and any known production method can be used as appropriate.
- One aspect of the first method for producing expanded beads will be described in detail below, and the above description (for example, the description in the ⁇ Components> section) is used as appropriate, except for the items described in detail below.
- the method for producing the first expanded beads is not limited to the following production method.
- resin particles can be produced by the following methods (1) to (5): (1) polypropylene resin (A), polypropylene homopolymer (B), and, if necessary, Accordingly, one or more selected from the group consisting of other resins and additives are blended to prepare a blend; (2) the blend is introduced into an extruder and the blend is melt-kneaded , to prepare a polypropylene resin composition; (3) extruding the polypropylene resin composition from a die provided in an extruder; (4) cooling the extruded polypropylene resin composition by passing it through water, etc.
- the solidified polypropylene-based resin composition is chopped into desired shapes such as cylindrical, elliptical, spherical, cubic, and rectangular parallelepipeds with a cutter.
- the melt-kneaded polypropylene resin composition is extruded directly into water from a die provided in an extruder, and the polypropylene resin composition is cut into particles immediately after extrusion, cooled, and solidified. Also good. By melt-kneading the blend in this manner, more uniform resin particles can be obtained.
- the weight per particle of the resin particles obtained as described above is preferably 0.2 mg/particle to 10.0 mg/particle, more preferably 0.5 mg/particle to 6.0 mg/particle.
- the weight per resin particle (A) is 0.2 mg/particle or more, the handling property of the resin particles tends to be improved, and shrinkage of the foamed molded product obtained by molding the expanded beads is possible. rate tends to decrease.
- (B) When it is 10.0 mg/grain or less, there is a tendency that the mold filling property is improved in the in-mold foam molding process.
- the melting point of the resin particles is preferably 139°C to 150°C, more preferably 140°C to 146°C.
- the melting point of the resin particles is (i) 139° C. or higher, the obtained foamed molded product obtained by molding the expanded beads has excellent heat resistance.
- the temperature is 150° C. or lower, it becomes easy to increase the expansion ratio of the obtained expanded beads in the production of the first expanded beads.
- the melting point of resin particles is a value obtained by measuring by the DSC method.
- the DSC curve of the resin particles can be obtained by the same method as for measuring the melting point of the polypropylene resin (A), except that the resin particles are used instead of the polypropylene resin (A). Similar to the melting point of the polypropylene-based resin (A), the melting point of the resin particles can be obtained from the DSC curve of the resin particles.
- the foaming step comprises: (a) a dispersing step of dispersing resin particles, an aqueous dispersion medium, a foaming agent, and, if necessary, a dispersant and/or a dispersing aid in a container; (b) a temperature increase-increase step of increasing the temperature in the container to a constant temperature and increasing the pressure in the container to a constant pressure; (c) a holding step of holding the temperature and pressure in the container at a constant temperature and a constant pressure; (d) releasing one end of the container to release the dispersion in the container into a region (space) of lower pressure than the foaming pressure (ie, pressure inside the container).
- the dispersing step can also be said to be, for example, a step of preparing a dispersion liquid in which resin particles, a foaming agent, and, if necessary, a dispersing agent and/or a dispersing aid are dispersed in an aqueous dispersion medium.
- the container is not particularly limited, it is preferably a container that can withstand the later-described foaming temperature and foaming pressure.
- the container is preferably, for example, a pressure-resistant container, more preferably an autoclave-type pressure-resistant container.
- the aqueous dispersion medium is not particularly limited as long as it can uniformly disperse the resin particles, foaming agent, and the like.
- aqueous dispersion media include (a) dispersion media obtained by adding methanol, ethanol, ethylene glycol, glycerin, etc. to water, and (b) water such as tap water and industrial water.
- water-based dispersion media include RO water (water purified by reverse osmosis membrane method), distilled water, deionized water (water purified by ion exchange resin), and the like. It is preferable to use pure water, ultrapure water, or the like.
- the amount of the aqueous dispersion medium used is not particularly limited, but is preferably 100 to 400 parts by weight with respect to 100 parts by weight of the resin particles.
- the amount of the aqueous dispersion medium used is (a) 100 parts by weight or more, there is no risk of deterioration in the stability of the dispersion (in other words, the resin particles are well dispersed), and (b) 400 parts by weight or less. In this case, there is no possibility that the productivity is lowered.
- the foaming agent includes (a) (a-1) an inorganic gas such as nitrogen, carbon dioxide, air (a mixture of oxygen, nitrogen, and carbon dioxide), and (a-2) an inorganic foaming agent such as water; (b) (b-1) saturated hydrocarbons having 3 to 5 carbon atoms such as propane, normal butane, isobutane, normal pentane, isopentane and neopentane, (b-2) ethers such as dimethyl ether, diethyl ether and methyl ethyl ether , (b-3) halogenated hydrocarbons such as monochloromethane, dichloromethane, and dichlorodifluoroethane; and the like; As the foaming agent, at least one or more selected from the group consisting of the above inorganic foaming agents and organic foaming agents can be used.
- the mixing ratio may be appropriately adjusted depending on the purpose.
- the inorganic foaming agent is preferable as the foaming agent among those mentioned above.
- carbon dioxide is preferable because it has a moderately high plasticizing effect and tends to improve the expandability of the expanded beads in the production of the first expanded beads.
- the blowing agent may be (i) composed of carbon dioxide alone, (ii) composed of water alone, or (iii) composed of carbon dioxide and water alone.
- the amount of the foaming agent to be used is not particularly limited, and may be used appropriately according to (a) the type of foaming agent and/or (b) the desired expansion ratio of the foamed particles.
- the amount of the foaming agent used is, for example, preferably 2.0 parts by weight to 60.0 parts by weight, more preferably 2.0 parts by weight to 50.0 parts by weight, with respect to 100 parts by weight of the resin particles. More preferably 2.0 to 30.0 parts by weight, still more preferably 2.0 to 20.0 parts by weight, 2.0 to 10.0 parts by weight. 0 parts by weight is particularly preferred.
- the amount of the foaming agent used is 2.0 parts by weight or more with respect to 100 parts by weight of the resin particles, expanded beads having a suitable density can be obtained.
- the amount of the foaming agent used is 60.0 parts by weight or less with respect to 100 parts by weight of the resin particles, an effect corresponding to the amount of the foaming agent used can be obtained, and no economic waste occurs.
- the water in the dispersion liquid in the container can be used as the foaming agent.
- the resin particles contain a water-absorbing substance in advance. This makes it easier for the resin particles to absorb the water in the dispersion liquid in the container, and as a result, it becomes easier to use the water as a blowing agent.
- the amount of the dispersant used in the dispersion used in the first embodiment of the present invention is preferably 0.01 to 3.00 parts by weight, preferably 0.10 parts by weight, with respect to 100 parts by weight of the resin particles. ⁇ 3.00 parts by weight is more preferred.
- the amount of the dispersant used is (a) 0.01 parts by weight or more, the greater the amount of the dispersant used, the less likely the resin particles are poorly dispersed, and (b) 3.00 parts by weight or less. In some cases, during in-mold foam molding using the obtained expanded beads, there is no fear of causing poor adhesion between the expanded beads.
- Dispersing aids include, for example, anionic surfactants.
- anionic surfactants include sodium alkylbenzenesulfonates such as sodium dodecylbenzenesulfonate, sodium alkanesulfonates, sodium alkylsulfonates, sodium alkyldiphenyletherdisulfonates, and sodium ⁇ -olefinsulfonates.
- sodium alkylbenzenesulfonates such as sodium dodecylbenzenesulfonate, sodium alkanesulfonates, sodium alkylsulfonates, sodium alkyldiphenyletherdisulfonates, and sodium ⁇ -olefinsulfonates.
- One type of these dispersing aids may be used alone, or two or more types may be mixed and used. Moreover, when two or more kinds of dispersing aids are mixed and used, the mixing ratio may be appropriately adjusted depending on the purpose.
- the amount of the dispersion aid used in the dispersion used in the first embodiment of the present invention is preferably 0.001 to 0.500 parts by weight with respect to 100 parts by weight of the resin particles. It is more preferably from 0.001 part by weight to 0.200 part by weight, and even more preferably from 0.010 part by weight to 0.200 part by weight. When the amount of the dispersing aid used is within the above range, there is no risk of poor dispersion of the resin particles.
- the temperature raising-pressurization step is preferably performed after the dispersing step, and the holding step is preferably performed after the temperature raising-pressurization step.
- the (a) constant temperature in the heating-pressurizing step and the holding step may be referred to as the foaming temperature
- the (b) constant pressure may be referred to as the foaming pressure.
- the foaming temperature cannot be defined unconditionally because it varies depending on the type of polypropylene resin (A) and polypropylene homopolymer (B), the type of foaming agent, the desired apparent density of the foamed particles, and the like.
- the foaming temperature is preferably (i) the melting point of the mixture of the polypropylene resin (A) and the polypropylene homopolymer (B) from ⁇ 20° C. to +10° C., or the melting point of the resin particles from ⁇ 20° C. to +10° C.
- the foaming pressure is preferably 1.0 MPa (gauge pressure) to 5.0 MPa (gauge pressure), more preferably 2.0 MPa (gauge pressure) to 5.0 MPa (gauge pressure), and 2.5 MPa (gauge pressure) to 3. 0.5 MPa (gauge pressure) is more preferred. If the foaming pressure is 1.0 MPa (gauge pressure) or more, expanded beads having a suitable density can be obtained.
- the time (holding time) for holding the dispersion in the container near the foaming temperature and foaming pressure is not particularly limited.
- the retention time is preferably 10 minutes to 60 minutes, more preferably 12 minutes to 55 minutes, even more preferably 15 minutes to 50 minutes.
- the holding time is 10 minutes or longer, the amount of unmelted crystals (polypropylene-based resin crystals) in the resin particles can be made sufficient in the expansion process from the resin particles to the expanded beads.
- expanded beads having a low open cell ratio can be obtained, and shrinkage of the obtained expanded beads can be reduced.
- the holding time is 60 minutes or less, the amount of unmelted crystals in the resin particles does not become excessive during the expansion process from the resin particles to the expanded particles. Therefore, the obtained expanded beads can be molded at a relatively low temperature (molding temperature) to provide a molded foam.
- the release step is preferably performed after (a) the temperature-increase-pressurization step when the holding step is not performed, or (b) after the holding step when the holding step is performed.
- the expulsion step can cause the resin particles to expand, resulting in expanded particles.
- area under pressure lower than the foaming pressure intends “area under pressure lower than the foaming pressure” or “space under pressure lower than the foaming pressure”, and “atmosphere at pressure lower than the foaming pressure”. It can also be called “lower”.
- the region of pressure lower than the foaming pressure is not particularly limited as long as the pressure is lower than the foaming pressure, and may be, for example, a region under atmospheric pressure.
- the dispersion In the ejection process, when the dispersion is ejected to a region with a pressure lower than the foaming pressure, the dispersion is passed through an orifice with a diameter of 1 mm to 5 mm for the purpose of adjusting the flow rate of the dispersion and reducing the variation in expansion ratio of the resulting expanded beads. can also be emitted.
- the low-pressure region space may be filled with saturated steam.
- Method 2 includes, for example, a method including the following (a1) to (a3) in order: (a1) producing single-stage expanded beads with an expansion ratio of 2 to 35 times in the single-stage expansion step; (a2).
- the single-stage expanded particles are placed in a pressure-resistant container and pressurized with nitrogen, air, carbon dioxide, or the like at 0.2 MPa (gauge pressure) to 0.6 MPa (gauge pressure) to reduce the pressure inside the single-stage expanded particles (hereinafter referred to as (a3) a method in which the single-stage expanded beads with increased internal pressure are then heated with steam or the like to further expand.
- the step of increasing the expansion ratio of the single-stage expanded beads as in Method 2 is called a "two-stage expanded process", and the polyolefin resin expanded beads obtained by Method 2 are called “two-stage expanded beads”.
- the pressure of the steam for heating the first-step expanded beads is 0.03 MPa (gauge pressure) to 0.20 MPa (gauge pressure) after considering the expansion ratio of the two-step expanded beads. pressure).
- the steam pressure in the two-step foaming step is 0.03 MPa (gauge pressure) or more, the expansion ratio tends to be easily improved. are less likely to coalesce.
- the obtained two-stage expanded particles may not be able to be subjected to subsequent in-mold foam molding.
- first foam molded article the "polypropylene-based resin foam molded article according to the first embodiment of the present invention” may be referred to as "first foam molded article”.
- the first foamed molded article has the above-described structure, it has the advantage of having good fusion bondability and good compressive strength, and hardly deformed.
- the first foam molded article since the first foam molded article has the above-described structure, it also has the advantage of being excellent in surface beauty.
- the first foam molded article also has the advantage of being excellent in internal fusion bondability.
- the internal fusion bondability of the first foam molded product is evaluated by the internal fusion bond ratio.
- the first foam molded article has an internal fusion rate of preferably 60% or more, more preferably 70% or more, more preferably 80% or more, and further preferably 90% or more. It is preferably 95% or more, more preferably 95% or more, and most preferably 100%.
- a foam molded product having an internal fusion rate of 60% or more has an advantage of excellent impact resistance.
- the surface beauty of the first foamed molded article is evaluated by the degree of the gaps between expanded particles (hereinafter sometimes referred to as "intergranular") on the surface of the foamed molded article. . It is intended that the smaller the size of the intergranules existing on the surface of the foam molded article and the smaller the number thereof, the more excellent the surface beauty of the foam molded article.
- the surface of the foamed molded article has no intergranules with a size exceeding 1.5 mm 2 , and grains with a size exceeding 1.0 mm 2 No gaps are particularly preferred.
- the first foam molded article also has the advantage of being excellent in compressive strength.
- the first foam molded article preferably satisfies the following formula (2), and particularly preferably satisfies the following formula (1).
- the method for producing the first foam molded article is not particularly limited, and known methods can be applied.
- the first method for producing a foamed molded product includes a method for producing a polypropylene resin foamed molded product, which includes a molding step of molding the expanded polypropylene resin beads according to one embodiment of the present invention.
- a specific embodiment of the method for producing the first foam molded article includes, for example, a production method (in-mold foam molding method) including the following (b1) to (b6) in order, but is limited to such a production method. No: (b1) A mold composed of a fixed mold that cannot be driven and a movable mold that can be driven is mounted on an in-mold foam molding machine.
- the fixed mold and the movable mold can be formed inside the fixed mold and the movable mold by driving the movable mold toward the fixed mold (this operation is sometimes referred to as "mold closing"); (b2) driving the movable mold toward the fixed mold so that a slight gap (also called cracking) is formed so that the fixed mold and the movable mold are not completely closed; (b3) filling the foamed particles into the molding space formed inside the stationary mold and the moving mold, for example through a filling machine; (b4) driving the movable mold so that the fixed mold and the movable mold are completely closed (that is, the mold is completely closed); (b5) After preheating the mold with steam to expel the air in the mold, the mold is heated in one direction and in the opposite direction with steam, and further heated on both sides with steam to perform in-mold foaming. I do; (b6) The in-mold foam-molded product is removed from the mold and dried (for example, dried at 75° C.) to obtain a foam-molded product.
- the cracking (mm) formed is not particularly limited, and may be, for example, more than 0.0 mm and 20.0 mm or less, may be 1.0 mm to 10.0 mm, or may be 1.0 mm It may be up to 5.0 mm.
- the internal pressure of the foamed particles in the method (b3-1) of the first foamed molding production method is preferably 0.10 MPa (absolute pressure) to 0.30 MPa (absolute pressure), and 0.11 MPa (absolute pressure) to 0.25 MPa (absolute pressure) is preferred.
- the temperature in the container when impregnating the foamed particles with the inorganic gas in the method (b3-1) of the first method for producing a foamed molded product is preferably 10°C to 90°C, more preferably 40°C to 90°C. more preferred.
- the recovery force of the foamed particles compressed by the gas pressure is used to fuse the foamed particles.
- water vapor pressure during one-way heating and reverse one-way heating is defined as “water vapor pressure A”
- water vapor pressure during double-sided heating is designated as “water vapor pressure B”.
- the pressure of the water vapor pressure A is not particularly limited, but is preferably 0.02 MPa (gauge pressure) to 0.22 MPa (gauge pressure), more preferably 0.04 MPa (gauge pressure) to 0.20 MPa (gauge pressure), 0.06 MPa (gauge pressure) to 0.19 MPa (gauge pressure) is more preferred, and 0.08 MPa (gauge pressure) to 0.18 MPa (gauge pressure) is particularly preferred.
- This configuration has the advantage of tending to yield a foam molded article with a high internal fusion rate.
- by setting the steam pressure A to about 1/2 of the steam pressure B at the time of in-mold foam molding excessive pressurization is not required, which is economically advantageous, and the internal fusion rate is improved. It is preferable because it can provide a high foaming molded product.
- the water vapor pressure B in the first method for producing a foamed molded product is referred to as "molding pressure".
- the first method for producing a foamed molded article by using the first foamed particles, it is possible to provide a foamed molded article with excellent internal fusion bondability at a molding pressure lower than that of the prior art.
- the first method for producing a foamed molded article can provide a foamed molded article having excellent internal fusion bondability with a lower minimum molding pressure than the conventional one.
- the "minimum molding pressure” is a value measured by the following methods (1) to (3): (1) Vapor pressure B is changed from 0.20 MPa (gauge pressure) to 0.30 MPa (gauge pressure) by 0.01 MPa, and at each steam pressure B, the expanded particles are foam-molded in the mold, and foam-molded. (2) Measure the internal fusion rate for each foamed molded article; (3) The lowest water vapor pressure B when a foamed molded article having an internal fusion rate of 60% or more is obtained. The pressure is taken as the minimum molding pressure. The method for measuring the internal fusion rate is as described above.
- Steam pressure B is preferably 0.16 MPa (gauge pressure) to 0.38 MPa (gauge pressure), more preferably 0.18 MPa (gauge pressure) to 0.34 MPa (gauge pressure), 0.19 MPa (gauge pressure) to 0 0.32 MPa (gauge pressure) is more preferred, 0.20 MPa (gauge pressure) to 0.30 MPa (gauge pressure) is particularly preferred, and 0.20 MPa (gauge pressure) to less than 0.26 MPa (gauge pressure) is most preferred.
- the molding step preferably includes a step of heating both sides of the expanded polypropylene-based resin beads at a pressure of less than 0.26 MPa (gauge pressure) using steam. The lower the water vapor pressure B, the smaller the economic burden. When the water vapor pressure B is 0.16 MPa (gauge pressure) or more, there is an advantage that a foam molded article having a high internal fusion rate and good compressive strength tends to be obtained.
- the lower the minimum molding pressure the better, for example, preferably less than 0.26 MPa, more preferably 0.25 MPa (gauge pressure) or less, more preferably 0.24 MPa (gauge pressure) or less. , 0.23 MPa (gauge pressure) or less is more preferable.
- the minimum molding pressure is within the range described above, it can be said that the foamed molded article is less economically burdensome.
- a foam-molded article with a low minimum molding pressure (for example, a foam-molded article with a minimum molding pressure of less than 0.26 MPa) can also be said to be a foam-molded article designed to have a low molding pressure.
- the wear rate will not change.
- the higher the steam pressure A and/or the steam pressure B, the higher the cost for pressurizing the steam. In other words, the lower the steam pressure A and/or the steam pressure B, the more economically advantageous. Therefore, the water vapor pressure A and the water vapor pressure B when producing the foamed molded article are preferably the lowest pressure within the range where the foamed molded article with the highest internal fusion rate can be obtained, and the water vapor pressure B is the lowest. Molding pressure is preferred. This makes it possible to achieve both a high internal fusion rate and economic efficiency in the resulting foamed molded product.
- the water vapor pressure A and/or the water vapor pressure B are excessively high (for example, the molding pressure is 0.26 MPa or more), only the surface of the foamed molded article is preferentially fused, and the steam I can't get through to the inside. As a result, not only is the rate of internal fusion bonding lowered, but deformation of the foamed molded product obtained after molding may be significantly increased.
- the second embodiment relates to expanded polypropylene resin particles and expanded polypropylene resin articles.
- Patent Literature 3 discloses a method for producing expanded polypropylene-based resin particles in which a predetermined amount of carbon black having a primary particle size of 0 nm or more and 50 nm or less is blended.
- Patent Document 1 discloses foamed polypropylene resin particles composed of polypropylene resin particles having a base resin of a polypropylene resin mixture composed of a polypropylene resin and a polypropylene wax. ing.
- Patent Documents 3 and 1 are not sufficient from the viewpoint of coexistence of surface beauty (for example, blackness, color unevenness, grain spacing, and wrinkles), fusion bondability, and molding cost. There was room for further improvement.
- the second embodiment of the present invention has been made in view of the above-mentioned problems, and its object is (a) to provide a polypropylene-based resin foam-molded article having good fusion bondability at a low molding pressure.
- the object of the present invention is to provide expanded polypropylene resin particles which are expanded polypropylene particles and which can provide (b) expanded polypropylene resin articles having excellent surface beauty.
- the inventors of the present invention completed the second embodiment of the present invention as a result of intensive studies to solve the above problems.
- the expanded polypropylene resin particles according to the second embodiment of the present invention are composed of a polypropylene resin (A) having a melting point of 135° C. to 150° C. and a polypropylene homopolymer (B) having a melting point of 85° C. or less. and carbon black, wherein the base resin has (i ) contains more than 80.0 parts by weight and 98.0 parts by weight or less of the polypropylene resin (A), and (ii) contains 2.0 parts by weight or more and less than 20.0 parts by weight of the polypropylene homopolymer (B) and (iii) 2 parts by weight or more and less than 10 parts by weight of the carbon black.
- the base resin has (i ) contains more than 80.0 parts by weight and 98.0 parts by weight or less of the polypropylene resin (A), and (ii) contains 2.0 parts by weight or more and less than 20.0 parts by weight of the polypropylene homopolymer (B) and (iii) 2 parts by weight or more and less than
- the expanded polypropylene resin particles are capable of providing a polypropylene resin foam molded article having good fusion bondability at a low molding pressure, and (b) the surface is beautiful. There is an effect that it is possible to provide polypropylene-based resin expanded particles that can provide a polypropylene-based resin foam-molded article having excellent properties.
- Patent Literatures 3 and 1 are not sufficient from the viewpoint of compatibility between surface beauty, fusion bondability, and molding cost, and there is room for further improvement.
- the technique of Patent Document 3 does not evaluate molding costs, for example, whether or not a foam molded article having good (desired) fusion bondability can be provided at a low molding pressure. Accordingly, the present inventor obtained an expanded molded article by molding the expanded beads obtained by the technique of Patent Document 3 at a molding pressure lower than that of the conventional art, and found that the obtained expanded molded article had an improved fusion bondability. It turns out there is room. In addition, the present inventor evaluated the grain spacing of the foamed molded product obtained by the technique of Patent Document 3 using a stricter evaluation standard than the evaluation standard described in Patent Document 3. As a result, it was found that the foamed molded article obtained by the technique of Patent Document 3 has room for improvement between grains (see Comparative Example B1). That is, it has been found that the technique of Patent Document 3 has room for further improvement in terms of surface beauty (eg, blackness, color unevenness, grain spacing, and wrinkles), fusion bondability, and molding cost.
- surface beauty eg, blackness, color unevenness, grain spacing
- the technique of Patent Document 1 does not evaluate the molding cost, for example, whether or not a foam molded article having good (desired) fusion bondability can be provided at a low molding pressure.
- a foam molded product by molding the expanded beads obtained by the technique of Patent Document 1 at a molding pressure lower than that of the conventional one, there was room for improvement in the fusion bondability of the obtained foam molded product. It turns out there is.
- the inventors of the present invention blended the foamed particles obtained by the technique of Patent Document 1 with carbon black having a small particle size as described in Patent Document 3 to produce a foamed molded product, and the obtained foamed The surface beauty of the compact was investigated.
- a relatively high melting point polypropylene resin and a relatively low melting point Polypropylene-based resin expanded particles capable of providing (a) a polypropylene-based resin foam-molded article having good fusion bondability at a low molding pressure by blending a polypropylene homopolymer and carbon black in specific amounts. and (b) to provide polypropylene resin foamed particles capable of providing a polypropylene resin foam molded article having excellent surface beauty (for example, blackness, color unevenness, grain spacing and wrinkles).
- the expanded polypropylene resin particles according to the second embodiment of the present invention comprise a polypropylene resin (A) having a melting point of 135° C. to 150° C., a polypropylene homopolymer (B) having a melting point of 85° C. or less, and a base resin containing carbon black.
- the base resin is (i) the polypropylene resin (A) from 80.0 parts by weight.
- the second embodiment of the present invention differs from the first embodiment in that it is essential to contain carbon black.
- the foamed polypropylene resin particles according to the second embodiment of the present invention can be molded by a known method to provide a foamed polypropylene resin article.
- polypropylene-based resin expanded beads according to the second embodiment of the present invention may be referred to as "second expanded beads”.
- the second foamed particles have the above-described configuration, (a) a polypropylene resin foamed molded article having good fusion bondability can be provided at a low molding pressure (in other words, a low heating steam pressure), and (b) ) It has the advantage of being able to provide a polypropylene-based resin foam molded article with excellent surface beauty.
- the "polypropylene-based resin foam molded article having excellent surface beauty” means at least (i) a high degree of blackness and (ii) a uniform color (black) without color unevenness. Or, the color (black) is substantially uniform and there is very little color unevenness, (iii) there is no or very little intergranular space, (iv) there is no or very little wrinkle, polypropylene A system resin foam molding is intended.
- the base resin contains carbon black.
- Carbon black is not particularly limited in its composition, and known carbon black can be used.
- the primary particle size of carbon black is not particularly limited, it is preferably greater than 0 nm and 100 nm or less, more preferably 20 nm to 100 nm.
- the primary particle size of the carbon black is 100 nm or less, there is an advantage that the obtained polypropylene resin-based in-mold expansion-molded product has excellent blackness.
- Examples of such carbon black include channel black, roller black, disk, gas furnace black, oil furnace black, thermal black, acetylene black and the like, and one or more of these can be used.
- the "primary particle size of carbon black” is a value obtained by the following measuring method: (1) Polypropylene-based resin foamed particles are cut in half using a microtome; (2) The obtained cross section is imaged with a transmission electron microscope at a magnification of 40,000 times to obtain a cross-sectional photograph; (3) In the obtained cross-sectional photograph, arbitrarily select 50 carbon blacks, each (4) For each primary particle of carbon black, the particle diameter in the X direction and the particle diameter in the Y direction are measured. An arithmetic mean value is calculated, and the obtained value is defined as the primary particle size of the carbon black.
- the base resin is 2 parts by weight or more and 10 parts by weight of carbon black when the total amount of the polypropylene resin (A) and the polypropylene homopolymer (B) is 100 parts by weight. parts, preferably 2 to 8 parts by weight, more preferably 2 to 6 parts by weight.
- the base resin contains 2 parts by weight or more of carbon black (a) when the total amount of the polypropylene resin (A) and the polypropylene homopolymer (B) is 100 parts by weight, the expansion provided by the expanded particles When (b) is less than 10 parts by weight, there is a tendency that the intergranular spacing of the expanded molded article provided by the expanded particles tends to decrease or disappear.
- the base resin may optionally further contain a colorant other than carbon black.
- coloring agents other than carbon black include ultramarine blue, cyanine pigments, azo pigments, quinacridone pigments, cadmium yellow, chromium oxide, iron oxide, perylene pigments, and anthraquinone pigments.
- one kind of these coloring agents other than carbon black may be used alone, or two or more kinds may be mixed and used.
- the mixing ratio may be appropriately adjusted according to the purpose.
- polypropylene resin foam molded product The polypropylene-based resin foam molded article according to the second embodiment of the present invention is described in [2-2. Polypropylene Resin Expanded Particles]. The polypropylene-based resin foam molded article according to the second embodiment of the present invention is described in [2-2. Polypropylene Resin Expanded Particles].
- polypropylene-based resin foam-molded article according to the second embodiment of the present invention may be referred to as "second foam-molded article”.
- the second foam molded article has the above-described structure, it has good fusion bondability and excellent surface beauty, specifically (i) high blackness, (ii) color (black ) is uniform with no color unevenness, or the color (black) is substantially uniform with very little color unevenness; It has the advantage of being very few, if any.
- the surface beauty of the second foam-molded product is evaluated by the degree of blackness, color unevenness, grain spacing, and wrinkles of the foam-molded product.
- the term "between grains of a foamed molded article” means the gaps between foamed particles on the surface of the foamed molded article. It is intended that the smaller the size of the intergranules between the expanded particles existing on the surface of the foamed article and the smaller the number of the intergranules between the expanded particles, the more excellent the surface beauty of the foamed article.
- An embodiment of the present invention may have the following configuration.
- the polypropylene resin (A) is more than 80.0 parts by weight and 98.0 parts by weight or less
- Expanded polypropylene resin beads containing 2.0 parts by weight or more and less than 20.0 parts by weight of the polypropylene homopolymer (B).
- the carbon black is contained in an amount of 2 parts by weight or more and less than 10 parts by weight when the total amount of the polypropylene resin (A) and the polypropylene homopolymer (B) is 100 parts by weight. polypropylene-based resin expanded particles.
- the polypropylene resin (A) is at least one of a propylene/ethylene random copolymer and a propylene/ethylene/1-butene random copolymer, and the ethylene content in the copolymer is The expanded polypropylene resin particles according to any one of [X1] to [X6], which is 0.2% by weight to 10.0% by weight in 100% by weight of the copolymer.
- [X17] a dispersing step of dispersing polypropylene resin particles, an aqueous dispersion medium, and a foaming agent in a container; one end of the container is opened; and a releasing step of releasing to a region having a pressure lower than the pressure in the container, wherein the polypropylene resin particles are composed of a polypropylene resin (A) having a melting point of 135 ° C. to 150 ° C. and a melting point of 85 ° C. or less.
- a base resin containing a certain polypropylene homopolymer (B), and the base resin is a total amount of the polypropylene resin (A) and the polypropylene homopolymer (B) of 100 parts by weight.
- polypropylene resin (A) is more than 80.0 parts by weight and 98.0 parts by weight or less
- polypropylene homopolymer (B) is 2.0 parts by weight or more and less than 20.0 parts by weight and a method for producing expanded polypropylene resin particles.
- [X20] further comprising a temperature rise-pressure step of raising the temperature in the container to the foaming temperature and raising the pressure in the container to the foaming pressure;
- the foaming temperature is a melting point of ⁇ 20° C. to +10° C. of the mixture of the polypropylene resin (A) and the polypropylene homopolymer (B), or a melting point of ⁇ 20° C. to +10° C. of the polypropylene resin particles,
- the method for producing expanded polypropylene resin particles according to any one of [X17] to [X19], wherein the foaming pressure is 1.0 MPa (gauge pressure) to 5.0 MPa (gauge pressure).
- the polypropylene resin (A) is at least one of a propylene/ethylene random copolymer and a propylene/ethylene/1-butene random copolymer, and the ethylene content in the copolymer is The method for producing expanded polypropylene resin particles according to any one of [X17] to [X25], wherein the content is 0.2% by weight to 10.0% by weight in 100% by weight of the copolymer.
- An embodiment of the present invention may have the following configuration.
- the polypropylene resin (A) is more than 80.0 parts by weight and 98.0 parts by weight or less
- Expanded polypropylene resin beads containing 2.0 parts by weight or more and less than 20.0 parts by weight of the polypropylene homopolymer (B).
- [Y4] A polypropylene resin expansion molded article obtained by molding the expanded polypropylene resin particles according to any one of [Y1] to [Y3].
- An embodiment of the present invention may have the following configuration.
- the base resin is (i) more than 80.0 parts by weight of the polypropylene resin (A) when the total amount of the polypropylene resin (A) and the polypropylene homopolymer (B) is 100 parts by weight.
- [Z5] A polypropylene-based resin foam molded article obtained by molding the expanded polypropylene-based resin particles according to any one of [Z1] to [Z4].
- Example A Hereinafter, the first embodiment of the present invention will be specifically described with reference to Example A, but the technical scope of the present invention is not limited by these Examples A.
- Polypropylene resin A-1 Propylene/ethylene random copolymer (MFR 8 g/10 min, weight average molecular weight 280,000, melting point 143° C., ethylene content 2.7% by weight)
- Polypropylene resin B-1 Propylene homopolymer (weight average molecular weight 130000, melting point 75°C, glass transition temperature -11°C, mesopentad fraction 45 mol%) [manufactured by Idemitsu Kosan Co., Ltd., L-MODU S901]
- Polypropylene resin B-2 Propylene homopolymer (weight average molecular weight 75000, melting point 75°C, glass transition temperature -11°C, mesopentad fraction 45 mol%) [manufactured by Idemitsu Kosan Co.,
- Example A ⁇ Measuring method ⁇ The evaluation methods carried out in Example A and Comparative Example A are described below.
- melting point The melting points of polypropylene resin (polypropylene resin (A), polypropylene homopolymer (B), polypropylene resin (C)), wax and polypropylene resin particles are measured by a differential scanning calorimeter (manufactured by Seiko Instruments Inc., DSC6200). A value obtained by measuring by a DSC method using a mold).
- the specific operating procedures were as follows (1) to (3): (1) The temperature of 5 mg to 6 mg of the sample (polypropylene resin, wax or polypropylene resin particles) was increased at a rate of 10 ° C./min. (2) Then, the temperature of the melted sample was lowered from 220°C to 40°C at a rate of 10°C/min.
- the temperature of the crystallized sample was further increased from 40°C to 220°C at a heating rate of 10°C/min.
- the temperature of the peak (melting peak) of the DSC curve of the sample obtained during the second heating was taken as the melting point of the sample.
- the temperature of the peak with the maximum heat of fusion is melting point.
- MFR The MFR of the polypropylene-based resin (polypropylene-based resin (A) and polypropylene-based resin (C)) was a value obtained by measuring under the following conditions using an MFR measuring instrument described in JIS K7210: 1999: The orifice diameter is 2.0959 ⁇ 0.005 mm ⁇ , the orifice length is 8.000 ⁇ 0.025 mm, the load is 2.16 kgf, and the temperature is 230° C. (230 ⁇ 0.2° C.).
- Mesopentad fraction (mmmm) of polypropylene homopolymer (B) The method for measuring the mesopentad fraction of the polypropylene homopolymer (B) was as follows (1) to (3): (1) as a sample, the polypropylene homopolymer (B) was dissolved in o-dichlorobenzene; Then, 13 C-NMR was measured at a resonance frequency of 67.93 MHz using a JNM-GX270 device manufactured by JEOL; (3) The ratio of the mmmm peak to the total methyl group-derived peak area was expressed as a percentage and defined as the mesopentad fraction (mol%). Detailed measurement conditions were as follows.
- Measurement solvent o-dichlorobenzene (90% by weight)/benzene-D 6 (10% by weight) Sample concentration: 15% to 20% by weight Measurement temperature: 120°C to 130°C Resonance frequency: 67.93MHz Pulse width: 10 ⁇ sec (45° pulse) Pulse repetition time: 7.091 sec Data points: 32K Cumulative count: 8168 Mode of measurement: noise decoupling Note that the assignment of the obtained spectra and the calculation of the pentad fraction (mmmm) are described in T.W. It was performed based on the method performed by Hayashi et al. [Polymer, 29, 138-143 (1988)].
- DSC ratio of expanded particles A differential scanning calorimeter (DSC6200 manufactured by Seiko Instruments Inc.) was used to measure (calculate) the DSC ratio of the expanded beads.
- the measurement (calculation) method of the DSC ratio of the expanded beads using a differential scanning calorimeter was as follows (1) to (6): (1) 5 mg to 6 mg of expanded beads were weighed; (2) Foaming The temperature of the particles was raised from 40° C. to 220° C.
- the method for measuring the average cell diameter of the foamed beads was as follows (1) to (5): (1) Using a razor (high stainless steel double-edged blade manufactured by Feather), so as to pass through the center of the foamed beads.
- the method of measuring the expansion ratio of the expanded beads was as follows (1) to (4): (1) the weight w (g) of the expanded beads was measured; The foamed beads used were submerged in ethanol contained in a graduated cylinder, and the volume v (cm 3 ) of the foamed beads was measured based on the rise in the liquid level of the graduated cylinder; (3) Weight w (g ) was divided by the volume v (cm 3 ) to calculate the density ⁇ 1 of the expanded beads; The value obtained by ( ⁇ 2 / ⁇ 1 ) was multiplied by 100, and the obtained value was taken as the expansion ratio of the expanded beads.
- the minimum molding pressure during in-mold foam molding was measured as follows (1) to (3): (1) Steam pressure was varied from 0.20 MPa (gauge pressure) to 0.30 MPa (gauge pressure); The pressure was changed by 0.01 MPa between the water vapor pressures, and the expanded particles were subjected to in-mold foam molding in the mold at each steam pressure to obtain a foam molded product; (3) The lowest steam pressure at which a foam molded article having an internal fusion rate of 60% or more was obtained was taken as the lowest molding pressure.
- the method for measuring and evaluating the compressive strength of the foam molded product was as follows (1) to (3): (1) Foam molding obtained in the step [Preparation of foam molded product (A)] described later A test piece with a length of 50 mm, a width of 50 mm, and a thickness of 25 mm was cut out from approximately the center of the body (foamed molded body (A)); [Minebea, TG series] was used to measure the compressive stress (MPa) at 50% compression when compressed at a speed of 10 mm / min; (3) Measurement result of compressive strength at 50% strain (MPa) Based on, the compressive strength of the foam molded product was evaluated according to the following criteria: ⁇ (Good): The following formula (1) is satisfied ⁇ (Pass): The following formula (1) is not satisfied, but the following formula (2) is satisfied ⁇ (Bad): The following formula (1) and the following Expression (2) is not satisfied (Compressive strength at 50% strain of foamed molded article (MPa))
- Example A the method for evaluating the surface beauty of the foamed molded article was as follows: The foamed molded article (foamed molded article (B) ) was visually observed and evaluated on a scale of 1 to 5 based on the following criteria. 5: There are no intergranules with a size exceeding 1.0 mm 2 on the surface of the foamed molded product. 4: On the surface of the foam molded product, there are intergranules with a size exceeding 1.0 mm 2 , but there are no intergranules with a size exceeding 1.5 mm 2 .
- the evaluation method for the presence or absence of deformation of the foam-molded article was as follows: The foam-molded article (foam-molded article (B)) obtained in the step [Preparation of foam-molded article (B)] described later was visually observed. and evaluated according to the following criteria.
- Example A1 [Production of resin particles] 97.5 parts by weight of polypropylene resin A-1 as polypropylene resin (A), 2.5 parts by weight of polypropylene resin B-1 as propylene homopolymer (B), and 0.1 talc as an additive. parts by weight and 0.2 parts by weight of glycerin were blended.
- the blend was then melt-kneaded with an extruder (resin temperature: 225°C) to obtain a resin composition.
- an extruder resin temperature: 225°C
- the resin composition was extruded in a strand from the tip of the extruder, it was granulated by cutting to produce resin particles (1.2 mg/particle).
- a twin-screw extruder [TEM26-SX, manufactured by Toshiba Machine Co., Ltd.] having two shafts (screws) with a shaft diameter ( ⁇ ) of 26 mm was used.
- the foaming pressure (internal pressure of the vessel) was set to 2.8 MPa (heating-pressurizing step). After the temperature and pressure in the pressure vessel reached the predetermined foaming temperature and pressure, the temperature and pressure in the pressure vessel were maintained at the predetermined foaming temperature and pressure for another 30 minutes (holding step). After that, while maintaining the foaming pressure in the pressure vessel at a predetermined level by supplying carbon dioxide, the dispersion is brought to 95° C. under atmospheric pressure through an orifice with a diameter of 3.2 mm provided at the bottom of the pressure vessel. It was released to obtain foamed particles of polypropylene resin (release step). After that, the expanded polypropylene resin particles were dried at 75° C. for 24 hours. The DSC ratio, average cell diameter, and expansion ratio of the obtained expanded beads were measured. Table 1 shows the results.
- the obtained expanded beads showed two peaks in the DSC curve obtained by the DSC method.
- a foamed molded product was produced by methods (1) to (6) in the following order: (1) The expanded beads obtained in the above [production of expanded beads] step were put into a pressure vessel, and air was introduced into the pressure vessel. By pressurizing and pressurizing the inside of the pressure vessel, the foamed beads are impregnated with pressurized air to set the internal pressure of the foamed beads to 0.20 MPa (absolute pressure); It was filled into a mold set in a molding machine.
- a polyolefin foam molding machine [manufactured by Daisen Kogyo Co., Ltd., EP-900] is used as the molding machine, and a mold capable of forming a molding space of 370 mm long ⁇ 320 mm wide ⁇ 50 mm thick is used as the mold.
- a foamed molded product was produced by methods (1) to (6) in the following order: (1) The expanded beads obtained in the above [production of expanded beads] step were put into a pressure vessel, and air was introduced into the pressure vessel. By pressurizing and pressurizing the inside of the pressure vessel, the foamed beads are impregnated with pressurized air to set the internal pressure of the foamed beads to 0.20 MPa (absolute pressure); A mold set in a molding machine was filled without compression in the thickness direction.
- a polyolefin foam molding machine [manufactured by Daisen Kogyo Co., Ltd., EP-900] is used as the molding machine, and a mold capable of forming a molding space of 370 mm long ⁇ 320 mm wide ⁇ 20 mm thick is used as the mold.
- the foamed particles were steamed at 0.1 MPa (gauge pressure) (steam pressure A).
- the air in the mold was expelled by heating for 10 seconds (one side heating and one side heating); (gauge pressure) (both sides heated) with steam of (steam pressure B);
- the expanded molded article (B) was removed from the mold, left at room temperature for 2 hours, and then cured and dried at 75° C. for 16 hours.
- the obtained foam molded article (B) was evaluated for surface beauty and deformation. Table 1 shows the results.
- Example A2 95.0 parts by weight of polypropylene resin A-1 is used as the polypropylene resin (A), 5.0 parts by weight of the polypropylene resin B-1 is used as the propylene homopolymer (B), and a foaming agent is used.
- An expanded bead and an expanded molded product were produced in the same manner as in Example A1 except that the amount was changed to 5.4 parts by weight and the expansion pressure was changed to 2.7 MPa, and each physical property was measured and evaluated. Table 1 shows the results.
- Example A3 90.0 parts by weight of polypropylene resin A-1 is used as the polypropylene resin (A), 10.0 parts by weight of the polypropylene resin B-1 is used as the propylene homopolymer (B), and a blowing agent is used.
- An expanded bead and an expanded molded product were produced in the same manner as in Example A1 except that the amount was changed to 5.4 parts by weight and the expansion pressure was changed to 2.7 MPa, and each physical property was measured and evaluated. Table 1 shows the results.
- Example A4 85.0 parts by weight of polypropylene resin A-1 is used as the polypropylene resin (A), 15.0 parts by weight of the polypropylene resin B-1 is used as the propylene homopolymer (B), and a blowing agent is used.
- An expanded bead and an expanded molded product were produced in the same manner as in Example A1 except that the amount was changed to 5.4 parts by weight and the expansion pressure was changed to 2.7 MPa, and each physical property was measured and evaluated. Table 1 shows the results.
- Example A5 95.0 parts by weight of polypropylene resin A-1 is used as the polypropylene resin (A), 5.0 parts by weight of the polypropylene resin B-2 is used as the propylene homopolymer (B), and a foaming agent is used.
- An expanded bead and an expanded molded product were produced in the same manner as in Example A1 except that the amount was changed to 5.4 parts by weight and the expansion pressure was changed to 2.7 MPa, and each physical property was measured and evaluated. Table 1 shows the results.
- Example A6 95.0 parts by weight of polypropylene resin A-1 is used as polypropylene resin (A), 5.0 parts by weight of polypropylene resin B-3 is used as propylene homopolymer (B), and a foaming agent is used.
- An expanded bead and an expanded molded product were produced in the same manner as in Example A1 except that the amount was changed to 5.4 parts by weight and the expansion pressure was changed to 2.7 MPa, and each physical property was measured and evaluated. Table 1 shows the results.
- Example A1 Expanded particles and foam molding were performed in the same manner as in Example A1 except that 100.0 parts by weight of polypropylene resin A-1 was used as the polypropylene resin (A) and the propylene homopolymer (B) was not used. A body was produced, and each physical property was measured and evaluated. Table 2 shows the results.
- Example A2 Example except that 98.5 parts by weight of the polypropylene resin A-1 was used as the polypropylene resin (A), and 1.5 parts by weight of the polypropylene resin B-1 was used as the propylene homopolymer (B).
- An expanded bead and an expanded molded article were produced by the same method as A1, and each physical property was measured and evaluated. Table 2 shows the results.
- Example A3 80.0 parts by weight of polypropylene resin A-1 is used as the polypropylene resin (A), 20.0 parts by weight of the polypropylene resin B-1 is used as the propylene homopolymer (B), and a foaming agent is used.
- An expanded bead and an expanded molded product were produced in the same manner as in Example A1 except that the amount was changed to 5.4 parts by weight and the expansion pressure was changed to 2.7 MPa, and each physical property was measured and evaluated. Table 2 shows the results.
- Example A6 As the polypropylene resin (A), 92.0 parts by weight of polypropylene resin A-1 is used, 8.0 parts by weight of wax is used instead of propylene homopolymer (B), and the amount of foaming agent used is An expanded bead and an expanded molded article were produced in the same manner as in Example A1 except that the amount was 5.4 parts by weight, the expansion temperature was 150° C., and the expansion pressure was 2.7 MPa, and each physical property was measured and evaluated. Table 2 shows the results.
- Example A7 As the polypropylene resin (A), 50.0 parts by weight of polypropylene resin A-1 is used, and 50.0 parts by weight of polypropylene resin (C) is used instead of propylene homopolymer (B), and foaming is performed.
- An expanded bead and an expanded molded article were produced in the same manner as in Example A1 except that the temperature was 150° C. and the expansion pressure was 2.9 MPa, and each physical property was measured and evaluated. Table 2 shows the results.
- the expanded beads of Examples A1 to A6 can be molded at a low molding pressure, and the expanded molded article obtained by molding the expanded beads has a compression strength above a certain level, is excellent in surface beauty, and is resistant to deformation. suppressed.
- Example B The second embodiment of the present invention will be specifically described below with reference to Example B, but the technical scope of the present invention is not limited by these Examples B.
- Example B ⁇ material ⁇ Substances (materials) used in Example B and Comparative Example B are shown below.
- Tables 3 and 4 also show the average particle size of carbon black in the expanded particles obtained.
- Example B ⁇ Other resins and additives>
- the other resins and additives used in Example B are the same as those described in the sections ⁇ Other resins> and ⁇ Additives> in Example A, respectively. We omit the explanation here.
- Example B ⁇ Measuring method ⁇ Evaluation methods performed in Example B and Comparative Example B are described below.
- the following (1) to (4) were carried out to measure the primary particle size of carbon black: (1) Polypropylene-based resin foamed particles were cut in half using a microtome; (2) About the obtained cross section , A cross-section magnified 40,000 times with a transmission electron microscope was imaged to obtain a cross-sectional photograph; (3) In the obtained cross-sectional photograph, arbitrarily selected 50 carbon blacks, and For the primary particles, the particle diameters in the X direction and the Y direction (Feret diameter) were measured; (4) For each primary particle of carbon black, the arithmetic mean value of the particle diameter in the X direction and the particle diameter in the Y direction. was calculated, and the obtained value was taken as the primary particle size of the carbon black.
- the fusion bondability of the foam molded body was evaluated by the internal fusion rate of the foam molded body.
- the method for measuring the internal fusion bonding rate is the same as that described in the section (Measurement of internal fusion bonding rate and minimum molding pressure of foamed molded article) in Example A, so this description is used here. Description is omitted.
- the fusion property of the foam molded product was evaluated according to the following evaluation criteria.
- Example B the appearance of the surface of the foam molded product was evaluated by evaluating the degree of blackness, color unevenness, grain spacing and wrinkles of the foam molded product.
- Each evaluation method and evaluation criteria were as follows.
- the evaluation method of the blackness of the foamed molded article was as follows (1) to (3): (1) the surface of the obtained foamed molded article (formed from the mold surface in which the steam holes described later are drilled holes) 320 mm ⁇ 370 mm surface) is scanned by a printer multifunction machine (iR-ADVC5035, manufactured by Canon Inc.) to obtain a surface image of the foam molded body; (2) The surface of the foam molded body in the obtained image (320 mm ⁇ 370 mm), the blackness was evaluated by RGB analysis performed using image processing software (DIBAS32); The mode value (measured value) was quantified by the following formula with 0 (100%) for black and 255 (0%) for white as the standard, and the degree of blackness was determined according to the following standard.
- Blackness of foam molded product (%) (255 - measured value) / 255 x 100 ⁇ (Good): Blackness is 88% or more. x (defective): Blackness is less than 88%.
- the method for evaluating the color unevenness of the foam-molded product was as follows: For the foam-molded product for which the above (blackness of the foam-molded product) was evaluated as ⁇ (good), the foam-molded product was visually observed. , was evaluated according to the following criteria.
- ⁇ (Good) The black color of the foamed molded product is uniform or substantially uniform, and there is no or very little color unevenness within the expanded beads and between the expanded beads.
- ⁇ (acceptable) The black color of the foam molded product is uneven, and grayish portions are slightly found here and there.
- x (defective) The black color of the foam molded product is uneven, and many grayish portions are present.
- the method for evaluating the intergranular spacing of the foamed molded article was as follows: The surface of the obtained foamed molded article was visually observed and evaluated according to the following criteria. ⁇ (Good): On the surface of the foamed molded product, there are no intergranules (gaps between foamed particles), or even if there are, there are very few intergranules with a size of 1.0 mm 2 or less, and 1.0 mm 2 There is no intergranular space exceeding the size.
- ⁇ Acceptable: There are a few (not many) intergranules with a size exceeding 1.0 mm 2 on the surface of the foamed molded product, but there are no intergranules with a size exceeding 1.5 mm 2 .
- x defective: on the surface of the foam molded product, there are many intergranular spaces with a size exceeding 1.0 mm 2 and/or there are intergranular spaces with a size exceeding 1.5 mm 2 .
- the method for evaluating the wrinkles of the foam-molded article was as follows: The surface of the obtained foam-molded article was visually observed and evaluated according to the following criteria. ⁇ (Good): There are no or very few wrinkles on the surface of the foamed molded product. Very few ⁇ (defective): A large number of small wrinkles are present, and some or a large number of large wrinkles are also present.
- Example B the description of (Melting point) in Example A is used for the melting points of the polypropylene resin, wax, and polypropylene resin particles.
- the MFR of the polypropylene resin (A) and the mesopentad fraction of the polypropylene homopolymer (B) are, respectively, (MFR) in Example A, (polypropylene homopolymer The description of the mesopentad fraction (mmmm) in (B) is used.
- the DSC ratio of the expanded beads, the average cell diameter of the expanded beads, and the expansion ratio of the expanded beads are the same as (DSC ratio of expanded beads), (average cell diameter of expanded beads), and ( The description of the expansion ratio of the expanded beads) is used.
- Example B1 [Production of resin particles]
- the polypropylene resin (A) 97.5 parts by weight of the polypropylene resin A-1, and as the propylene homopolymer (B), 2.5 parts by weight of the polypropylene resin B-1 and 4 parts by weight of carbon black. and 0.1 part by weight of talc and 0.2 part by weight of glycerin as additives.
- the blend was then melt-kneaded with an extruder (resin temperature: 225°C) to obtain a resin composition.
- an extruder resin temperature: 225°C
- the resin composition was extruded in a strand from the tip of the extruder, it was granulated by cutting to produce resin particles (1.2 mg/particle).
- a twin-screw extruder [TEM26-SX, manufactured by Toshiba Machine Co., Ltd.] having two shafts (screws) with a shaft diameter ( ⁇ ) of 26 mm was used.
- the foaming pressure (internal pressure of the vessel) was set to 2.9 MPa (heating-pressurizing step). After the temperature and pressure in the pressure vessel reached the predetermined foaming temperature and pressure, the temperature and pressure in the pressure vessel were maintained at the predetermined foaming temperature and pressure for another 30 minutes (holding step). After that, while maintaining the foaming pressure in the pressure vessel at a predetermined level by supplying carbon dioxide, the dispersion is brought to 95° C. under atmospheric pressure through an orifice with a diameter of 3.2 mm provided at the bottom of the pressure vessel. It was released to obtain foamed particles of polypropylene resin (release step). After that, the expanded polypropylene resin particles were dried at 75° C. for 24 hours. The DSC ratio, average cell diameter, and expansion ratio of the obtained expanded beads were measured. Table 3 shows the results.
- a foamed molded product was produced by methods (1) to (6) in the following order: (1) The expanded beads obtained in the above [production of expanded beads] step were put into a pressure vessel, and air was introduced into the pressure vessel. By pressurizing and pressurizing the inside of the pressure vessel, the foamed beads are impregnated with pressurized air to set the internal pressure of the foamed beads to 0.20 MPa (absolute pressure); It was filled into a mold set in a molding machine.
- the molding machine a polyolefin foam molding machine [manufactured by Daisen Kogyo Co., Ltd., EP-900] is used, and as the mold, the steam holes are perforated holes, and the molding space is 370 mm long ⁇ 320 mm wide ⁇ 50 mm thick.
- Example B2 95.0 parts by weight of polypropylene resin A-1 was used as the polypropylene resin (A), and 5.0 parts by weight of the polypropylene resin B-1 was used as the propylene homopolymer (B), and foaming pressure
- An expanded bead and an expanded molded article were produced in the same manner as in Example B1 except that the (gauge pressure) was changed to 2.8 MPa, and each physical property was measured and evaluated. Table 3 shows the results.
- Example B3 85.0 parts by weight of polypropylene resin A-1 was used as the polypropylene resin (A), and 15.0 parts by weight of the polypropylene resin B-1 was used as the propylene homopolymer (B), and foaming pressure An expanded bead and an expanded molded article were produced in the same manner as in Example B1 except that the (gauge pressure) was changed to 2.8 MPa, and each physical property was measured and evaluated. Table 3 shows the results.
- Example B4 As the polypropylene resin (A), 95.0 parts by weight of the polypropylene resin A-1 is used, and as the propylene homopolymer (B), 5.0 parts by weight of the polypropylene resin B-1 is used, and as the carbon black, Except for using 6 parts by weight of carbon black B and changing the foaming pressure (gauge pressure) to 2.8 MPa, expanded beads and a foamed molded product were produced in the same manner as in Example B1, and each physical property was measured and measured. evaluated. Table 3 shows the results.
- Example B5 95.0 parts by weight of polypropylene resin A-1 was used as the polypropylene resin (A), and 5.0 parts by weight of the polypropylene resin B-2 was used as the propylene homopolymer (B), and foaming Expanded beads and an expanded molded product were produced in the same manner as in Example B1 except that the pressure (gauge pressure) was changed to 2.8 MPa, and each physical property was measured and evaluated. Table 3 shows the results.
- Example B6 As the polypropylene resin (A), 95.0 parts by weight of the polypropylene resin A-1 is used, and as the propylene homopolymer (B), 5.0 parts by weight of the polypropylene resin B-3 is used, and carbon black is used. Expanded beads and a foamed molded product were produced in the same manner as in Example B1 except that 4 parts by weight of carbon black A was used and the foaming pressure (gauge pressure) was changed to 2.7 MPa, and each physical property was measured and measured. evaluated. Table 3 shows the results.
- Example B1 Expanded particles and foam molding were prepared in the same manner as in Example B1 except that 100.0 parts by weight of polypropylene resin A-1 was used as the polypropylene resin (A) and the propylene homopolymer (B) was not used. A body was produced, and each physical property was measured and evaluated. Table 4 shows the results.
- Example B2 As the polypropylene resin (A), 100.0 parts by weight of polypropylene resin A-1 is used, and 6 parts by weight of carbon black B is used instead of carbon black A without using propylene homopolymer (B). An expanded bead and an expanded molded article were produced in the same manner as in Example B1, except for the above, and each physical property was measured and evaluated. Table 4 shows the results.
- Comparative example B5 80.0 parts by weight of polypropylene resin A-1 was used as the polypropylene resin (A), and 20.0 parts by weight of the polypropylene resin B-1 was used as the propylene homopolymer (B).
- An expanded bead and an expanded molded article were produced by the same method as in Example B1, and each physical property was measured and evaluated. Table 4 shows the results.
- Comparative example B7 As the polypropylene resin (A), 95.0 parts by weight of the polypropylene resin A-1 is used, and as the propylene homopolymer (B), 5.0 parts by weight of the polypropylene resin B-1 is used, and carbon black B and the expansion pressure (gauge pressure) was changed to 3.0 MPa. Table 4 shows the results.
- the foamed particles of Examples B1 to B6 were able to provide foamed molded articles with excellent fusion bondability even when molded at a low molding pressure (0.24 MPa (gauge pressure)).
- the foamed molded articles obtained by molding the expanded beads of Examples B1 to B6 have excellent surface beauty, that is, (i) high degree of blackness, (ii) uniform color (black) and no color unevenness. There is no or the color (black) is almost uniform and there is very little color unevenness, (iii) there is no or very little intergranular space, (iv) there is no wrinkle or very little wrinkle, A polypropylene-based resin foam molded product is intended.
- a polypropylene-based resin foam molded article having good fusion bondability can be provided at a low molding pressure, and (b-1) it has good compressive strength and is resistant to deformation. It is possible to provide polypropylene-based resin expanded particles that can provide almost no expanded polypropylene-based resin molded articles.
- a polypropylene resin foam molded article having good fusion bondability can be provided at a low heating steam pressure, and (b) it has a good blackness and a color It is possible to provide polypropylene-based resin expanded particles that can provide a polypropylene-based resin foam-molded article that is uniform, has no color unevenness, and hardly deforms. Therefore, one embodiment of the present invention can be used for various purposes such as automobile interior parts, core materials for automobile bumpers, heat insulating materials, cushioning packaging materials, returnable boxes, and the like.
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Abstract
Description
〔1-1.ポリプロピレン系樹脂発泡粒子〕
本発明の第1の実施形態に係るポリプロピレン系樹脂発泡粒子は、融点が135℃~150℃であるポリプロピレン系樹脂(A)と、融点が85℃以下であるポリプロピレン単独重合体(B)と、を含有する基材樹脂を含む。前記基材樹脂は、前記ポリプロピレン系樹脂(A)および前記ポリプロピレン単独重合体(B)の合計量を100重量部としたとき、前記ポリプロピレン系樹脂(A)を80.0重量部より多く、98.0重量部以下含み、かつ前記ポリプロピレン単独重合体(B)を2.0重量部以上、20.0重量部未満含む。
(基材樹脂)
基材樹脂は、樹脂成分として、少なくともポリプロピレン系樹脂(A)とポリプロピレン単独重合体(B)と、を含む。基材樹脂は、樹脂成分以外に、任意で発泡核剤等の添加剤を含み得る。基材樹脂は、発泡粒子を実質的に構成している成分であるともいえる。それ故、基材樹脂に含まれる各成分の種類および量は、第1の発泡粒子が含む各成分の種類および量ともいえる。基材樹脂は、ポリプロピレン系樹脂粒子を構成している成分であるともいえる。
ポリプロピレン系樹脂(A)は、(a)プロピレンの単独重合体であってもよく、(b)プロピレンとプロピレン以外の単量体とのブロック共重合体、ランダム共重合体もしくはグラフト共重合体であってもよく、または(c)これらの2種以上の混合物であってもよい。
本発明の第1の実施形態に係るポリプロピレン単独重合体(B)は、85℃以下の融点を有するポリプロピレン単独重合体である。本発明者は、本発明の第1の実施形態の鋭意検討過程において、驚くべきことに、以下の知見を独自に見出した:上述したポリプロピレン系樹脂(A)と融点が85℃以下であるポリプロピレン単独重合体(B)とを含む発泡粒子を用いることにより、(a)良好な融着性を有するポリプロピレン系樹脂発泡成形体を低い成形圧力で提供でき、また(b)良好な圧縮強度を有し、かつ変形がほとんどないポリプロピレン系樹脂発泡成形体を提供できること。
測定溶媒:o-ジクロロベンゼン(90重量%)/ベンゼン-D6(10重量%)
試料濃度:15重量%~20重量%
測定温度:120℃~130℃
共鳴周波数:67.93MHz
パルス幅:10μsec(45゜パルス)
パルス繰り返し時間:7.091sec
データポイント:32K
積算回数:8168
測定モード:ノイズデカップリング
なお、本明細書において、得られたスペクトルの帰属およびペンタッド分率の計算は、T.Hayashiらが行った方法[Polymer,29,138~143(1988)]に基づき行う。
基材樹脂は、本発明の第1の実施形態に係る効果を損なわない範囲で、樹脂成分として、ポリプロピレン系樹脂(A)およびポリプロピレン単独重合体(B)以外の樹脂(その他の樹脂等、と称する場合がある。)をさらに含んでいてもよい。前記その他の樹脂等としては、(a)ポリプロピレン系樹脂(A)およびポリプロピレン単独重合体(B)以外のポリプロピレン系樹脂、(b)高密度ポリエチレン、中密度ポリエチレン、低密度ポリエチレン、直鎖状低密度ポリエチレン、直鎖状超低密度ポリエチレン、エチレン/酢酸ビニル共重合体、エチレン/アクリル酸共重合体、およびエチレン/メタアクリル酸共重合体などのエチレン系樹脂、(c)ポリスチレン、スチレン/無水マレイン酸共重合体、およびスチレン/エチレン共重合体などのスチレン系樹脂、(d)プロピレン-α-オレフィン系ワックスなどのポリオレフィン系ワックス、並びに(e)エチレン/プロピレンゴム、エチレン/ブテンゴム、エチレン/ヘキセンゴム、エチレン/オクテンゴムなどのオレフィン系ゴム、などが挙げられる。
基材樹脂は、上述したポリプロピレン系樹脂(A)およびポリプロピレン単独重合体(B)の他に、さらに任意で添加剤を含んでいてもよい。添加剤としては、着色剤、吸水性物質、発泡核剤、帯電防止剤、難燃剤、酸化防止剤、光安定剤、結晶核剤、導電剤、滑剤等が挙げられる。このような添加剤は、ポリプロピレン系樹脂粒子の製造において、後述するブレンド物もしくはポリプロピレン系樹脂組成物へ直接添加してもよい。
以下、第1の発泡粒子の物性について説明する。
第1の発泡粒子は、後述の示差走査熱量測定で得られるDSC曲線において融解ピークを少なくとも2つ有することが好ましい。当該融解ピークのうち、高温側の融解ピークから求められる融解熱量を「高温側融解熱量」とし、低温側の融解ピークから求められる融解熱量を「低温側融解熱量」とする。また、融解ピークが3つ以上である場合には、最も高温の融解ピークから求められる融解熱量を「高温側融解熱量」し、それ以外の融解ピークから求められる融解熱量を「低温側融解熱量」とする。
第1の発泡粒子の平均気泡径は、特に制限されないが、110μm~280μmであることが好ましく、120μm~270μmであることがより好ましく、130μm~260μmであることがより好ましく、140μm~250μmであることがさらに好ましく、150μm~240μmであることがさらに好ましく、160μm~230μmであることが特に好ましい。第1の発泡粒子の平均気泡径が(i)110μm以上である場合、当該発泡粒子は色ムラが無く、着色性に優れるとともに圧縮強度に優れるポリプロピレン系樹脂発泡成形体を提供でき、(ii)第1の発泡粒子の平均気泡径が280μm以下である場合、型内発泡成形体の成形サイクルが長くなる虞がなく、生産性が良好となる利点を有する。ここで、成形サイクルとは、発泡粒子を用いて型内発泡成形することにより、発泡成形体を得るときの、型内発泡成形の開始から、得られた成形体を金型から離型する成形終了までの時間、を意図する。
平均気泡径(μm)=L/n。
第1の発泡粒子は、発泡倍率が15倍~50倍であることが好ましく、18倍~40倍であることがより好ましく、20倍~25倍であることがさらに好ましい。発泡粒子の発泡倍率が(i)15倍以上であれば、軽量な発泡成形体を、生産効率よく得ることができ、(ii)50倍以下であれば、得られる発泡成形体の強度が不足する虞がない。
第1の発泡粒子の製造方法としては、特に限定されず、公知の製造方法を適宜使用することができる。以下に、第1の発泡粒子の製造方法の一態様について詳説するが、以下に詳説した事項以外は、適宜、上述の記載(例えば<成分>の項の記載)を援用する。なお、第1の発泡粒子の製造方法は以下の製造方法に限定されるものではない。
第1の発泡粒子を製造するに際しては、まず、基材樹脂を含むポリプロピレン系樹脂粒子を製造する工程(造粒工程)が行われ得る。
発泡粒子の製造方法における発泡工程の態様としては、樹脂粒子を発泡させることができる限り、特に限定されない。本発明の第1の実施形態において、発泡工程は、
(a)樹脂粒子と、水系分散媒と、発泡剤と、必要に応じて分散剤および/または分散助剤とを容器中に分散させる分散工程と、
(b)容器内温度を一定温度まで昇温し、かつ容器内圧力を一定圧力まで昇圧する昇温-昇圧工程と、
(c)容器内温度および圧力を一定温度かつ一定圧力で保持する保持工程と、
(d)容器の一端を解放し、容器内の分散液を、発泡圧力(すなわち、容器内圧力)よりも低圧の領域(空間)に放出する放出工程と、を含むことが好ましい。
分散工程は、例えば、水系分散媒中に樹脂粒子と発泡剤と、必要に応じて分散剤および/または分散助剤とが分散している分散液を調製する工程ともいえる。
昇温-昇圧工程は、分散工程後に実施されることが好ましく、保持工程は、昇温-昇圧工程後に実施されることが好ましい。本明細書において、昇温-昇圧工程および保持工程における(a)一定温度を発泡温度と称する場合があり、(b)一定圧力を発泡圧力と称する場合がある。
放出工程は、(a)保持工程を実施しない場合には昇温-昇圧工程後、(b)保持工程後を実施する場合には保持工程後、に実施されることが好ましい。放出工程により、樹脂粒子を発泡させることができ、結果として発泡粒子が得られる。
ところで、発泡倍率の高い発泡粒子を得る為には、一段発泡工程において無機系発泡剤の使用量を多量にするという方法(以下、方法1とする)がある。さらに、方法1以外の方法として、一段発泡工程で比較的低倍率(発泡倍率2倍~35倍程度)の発泡粒子(一段発泡粒子)を得た後、得られた一段発泡粒子を再度発泡させることで発泡倍率を高くする方法(以下、方法2とする)、も採用可能である。
本発明の第1の実施形態に係るポリプロピレン系樹脂発泡成形体は、〔1-1.ポリプロピレン系樹脂発泡粒子〕の項に記載のポリプロピレン系樹脂発泡粒子を成形してなる発泡成形体である。本発明の第1の実施形態に係るポリプロピレン系樹脂発泡成形体は、〔1-1.ポリプロピレン系樹脂発泡粒子〕の項に記載のポリプロピレン系樹脂発泡粒子を含む、ともいえる。
第1の発泡成形体は、内部融着性に優れるという利点も有する。本明細書において、第1の発泡成形体の内部融着性は、内部融着率によって評価される。第1の発泡成形体は、内部融着率が60%以上であることが好ましく、70%以上であることがより好ましく、80%以上であることがより好ましく、90%以上であることがさらに好ましく、95%以上であることがよりさらに好ましく、100%であることが最も好ましい。内部融着率が60%以上である発泡成形体は、耐衝撃性に優れるという利点を有する。
内部融着率(%)=(領域において粒子界面以外で破断している発泡粒子数/領域に存在する全発泡粒子数)×100。
本明細書において、第1の発泡成形体の表面美麗性は、発泡成形体表面の発泡成形体表面における発泡粒子間の隙間(以下「粒間」と称する場合がある。)の程度によって評価する。発泡成形体表面に存在する粒間の大きさが小さいほど、また、その数が少ないほど、発泡成形体が表面美麗性に優れることを意図する。
本明細書において、第1の発泡成形体の変形は、発泡成形体表面のしわによって評価する。発泡成形体表面にしわが少ないほど、発泡成形体は変形が少ない発泡成形体であることを意図する。
第1の発泡成形体は、圧縮強度に優れるという利点も有する。例えば、第1の発泡成形体は、以下の式(2)を充足することが好ましく、以下の式(1)を充足することが特に好ましい。
(発泡成形体の50%歪時圧縮強度(MPa))≧0.0069×(発泡成形体の密度(g/L))・・・式(2)
なお、発泡成形体の50%歪時圧縮強度(MPa)および密度(g/L)の測定方法については、後の実施例にて詳説する。
第1の発泡成形体の製造方法は特に限定されず、公知の方法を適用することができる。第1の発泡成形体の製造方法としては、本発明の一実施形態に係るポリプロピレン系樹脂発泡粒子を成形する成形工程を有する、ポリプロピレン系樹脂発泡成形体の製造方法が挙げられる。第1の発泡成形体の製造方法の具体的態様としては、例えば以下(b1)~(b6)を順に含む製造方法(型内発泡成形法)が挙げられるが、かかる製造方法に限定されるものではない:(b1)駆動し得ない固定型と駆動可能な移動型とから構成される金型を型内発泡成形機に搭載する。ここで、固定型および移動型は、固定型に向かって移動型を駆動させる(当該操作を「型閉じ」と称する場合がある)ことにより、固定型および移動型の内部に形成可能である;
(b2)固定型と移動型とが完全に型閉じされないように、わずかな隙間(クラッキングとも称する)が形成されるように、固定型に向かって移動型を駆動させる;
(b3)固定型および移動型の内部に形成された成形空間内に、例えば充填機を通して、発泡粒子を充填する;
(b4)固定型と移動型とが完全に型閉じするように移動型を駆動させる(すなわち、完全に型閉じする);
(b5)金型を水蒸気で予熱し、金型内の空気を追い出した後、金型を水蒸気で一方加熱および逆一方加熱し、さらに金型を水蒸気で両面加熱することにより、型内発泡成形を行う;
(b6)型内発泡成形物を金型から取り出し、乾燥(例えば、75℃で乾燥)することで、発泡成形体を得る。
(b3-1)発泡粒子(上述の二段発泡粒子を含む、以下同じ)を容器内で無機ガスで加圧処理して、当該発泡粒子内に無機ガスを含浸させ、所定の発泡粒子内圧を付与した後、該発泡粒子を成形空間に充填する方法;
(b3-2)発泡粒子を成形空間に充填した後、該金型内の体積を10%~75%減ずるように圧縮する方法;
(b3-3)発泡粒子をガス圧力で圧縮して成形空間に充填する方法;
(b3-4)特に前処理することなく、発泡粒子を成形空間に充填する方法。
本明細書において、「最低成形圧力」とは、以下の(1)~(3)の方法によって測定した値である:
(1)水蒸気圧力Bを0.20MPa(ゲージ圧)から0.30MPa(ゲージ圧)の間で0.01MPaずつ変化させ、それぞれの水蒸気圧力Bにおいて、発泡粒子を型内発泡成形し、発泡成形体を得る;(2)それぞれの発泡成形体について、内部融着率を測定する;(3)内部融着率が60%以上の発泡成形体が得られたときの水蒸気圧力Bのうち最も低い圧力を最低成形圧力とする。内部融着率の測定方法は、上述した通りである。
第2の実施形態はポリプロピレン系樹脂発泡粒子およびポリプロピレン系樹脂発泡成形体に関する。
上述したように、特許文献3および1に記載の技術は、表面美麗性、融着性および成形コストの両立という観点からは、十分なものでなく、さらなる改善の余地があった。
本発明の第2の実施形態に係るポリプロピレン系樹脂発泡粒子は、融点が135℃~150℃であるポリプロピレン系樹脂(A)と、融点が85℃以下であるポリプロピレン単独重合体(B)と、カーボンブラックと、を含有する基材樹脂を含む。前記基材樹脂は、前記ポリプロピレン系樹脂(A)および前記ポリプロピレン単独重合体(B)の合計量を100重量部としたとき、(i)前記ポリプロピレン系樹脂(A)を80.0重量部より多く、98.0重量部以下含み、(ii)前記ポリプロピレン単独重合体(B)を2.0重量部以上、20.0重量部未満含み、かつ(iii)前記カーボンブラックを、2重量部以上10重量部未満含む。すなわち、本発明の第2の実施形態は、カーボンブラックを含むことを必須の構成とする点で、第1の実施形態と相違する。
本発明の第2の実施形態において、基材樹脂は、カーボンブラックを含む。カーボンブラックは、その構成が特に限定されることはなく、公知のカーボンブラックを使用できる。カーボンブラックの一次粒径は、特に限定されるものではないが、0nmより大きく100nm以下が好ましく、20nm~100nmであることがより好ましい。カーボンブラックの一次粒径が100nm以下である場合、得られるポリプロピレン系樹脂型内発泡成形体の黒色度が優れるという利点を有する。このようなカーボンブラックの例としては、チャンネルブラック、ローラーブラック、ディスク、ガスファーネスブラック、オイルファーネスブラック、サーマルブラック、アセチレンブラック等が挙げられ、これらの一種またはニ種以上を使用することができる。
本発明の第2の実施形態に係るポリプロピレン系樹脂発泡成形体は、〔2-2.ポリプロピレン系樹脂発泡粒子〕の項に記載のポリプロピレン系樹脂発泡粒子を成形してなる発泡成形体である。本発明の第2の実施形態に係るポリプロピレン系樹脂発泡成形体は、〔2-2.ポリプロピレン系樹脂発泡粒子〕の項に記載のポリプロピレン系樹脂発泡粒子を含む、ともいえる。
第2実施形態における内部融着率については、第1実施形態における(内部融着性)の項で説明したものと同じであるため、当該記載を援用し、ここでは説明を省略する。
本明細書において、第2の発泡成形体の表面美麗性は、発泡成形体の黒色度、色ムラ、粒間およびシワの程度によって評価する。本明細書において、「発泡成形体の粒間」とは、発泡成形体表面における発泡粒子間の隙間を意図する。発泡成形体表面に存在する発泡粒子間の粒間の大きさが小さいほど、また、発泡粒子間の粒間の数が少ないほど、発泡成形体が表面美麗性に優れることを意図する。発泡成形体の黒色度、色ムラおよびシワの評価方法については、下記〔実施例B〕にて詳述する。
本発明の第2の実施形態における発泡成形体の製造方法の各態様については、第1の実施形態における<発泡成形体の製造方法>の項で説明したものと同じであるため、当該記載を援用し、ここでは説明を省略する。
前記発泡温度が、ポリプロピレン系樹脂(A)およびポリプロピレン単独重合体(B)の混合物の融点-20℃~融点+10℃、またはポリプロピレン系樹脂粒子の融点-20℃~融点+10℃であり、
前記発泡圧力が、1.0MPa(ゲージ圧)~5.0MPa(ゲージ圧)である、〔X17〕~〔X19〕のいずれか1つに記載のポリプロピレン系樹脂発泡粒子の製造方法。
以下、実施例Aにより本発明の第1の実施形態を具体的に説明するが、本発明は、これらの実施例Aによりその技術的範囲を限定されるものではない。
実施例Aおよび比較例Aで使用した物質(材料)を以下に示す。
<ポリプロピレン系樹脂>
(ポリプロピレン系樹脂(A))
ポリプロピレン系樹脂A-1:プロピレン/エチレンランダム共重合体(MFR8g/10分、重量平均分子量280000、融点143℃、エチレン含有率2.7重量%)
(ポリプロピレン単独重合体(B))
ポリプロピレン系樹脂B-1:プロピレン単独重合体(重量平均分子量130000、融点75℃、ガラス転移温度-11℃、メソペンタッド分率45mol%)[出光興産株式会社製、L-MODU(エルモーデュ)S901]
ポリプロピレン系樹脂B-2:プロピレン単独重合体(重量平均分子量75000、融点75℃、ガラス転移温度-11℃、メソペンタッド分率45mol%)[出光興産株式会社製、L-MODU(エルモーデュ)S600]
ポリプロピレン系樹脂B-3:プロピレン単独重合体(重量平均分子量45000、融点75℃、ガラス転移温度-11℃、メソペンタッド分率45mol%)[出光興産株式会社製、L-MODU(エルモーデュ)S400]
<その他の樹脂>
ポリプロピレン系樹脂(C):プロピレン/エチレン/1-ブテンランダム共重合体(MFR7g/10分、融点134℃)
ワックス:プロピレン/エチレンランダム共重合体(重量平均分子量6400、融点78℃、ガラス転移温度-27℃)
<添加剤>
吸水性物質:グリセリン[ライオン(株)製、精製グリセリンD]
発泡核剤:タルク[林化成(株)製、タルカンパウダーPK-S]。
実施例Aおよび比較例Aにおいて実施した評価方法に関して、以下に説明する。
ポリプロピレン系樹脂(ポリプロピレン系樹脂(A)、ポリプロピレン単独重合体(B)、ポリプロピレン系樹脂(C))、ワックスおよびポリプロピレン系樹脂粒子の融点は、示差走査熱量計(セイコーインスツルメンツ(株)製、DSC6200型)を用いたDSC法により測定して求められる値とした。具体的な操作手順は以下(1)~(3)の通りであった:(1)試料(ポリプロピレン系樹脂、ワックスまたはポリプロピレン系樹脂粒子)5mg~6mgの温度を10℃/分の昇温速度で40℃から220℃まで昇温することにより、当該試料を融解させた;(2)その後、融解された試料の温度を10℃/分の降温速度で220℃から40℃まで降温することにより当該試料を結晶化させた;(3)その後、さらに、結晶化された試料の温度を10℃/分の昇温速度で40℃から220℃まで昇温した。2回目の昇温時(すなわち(3)のとき)に得られる当該試料のDSC曲線のピーク(融解ピーク)の温度を当該試料の融点とした。なお、上述の方法により、2回目の昇温時に得られる、試料のDSC曲線において、ピーク(融解ピーク)が複数存在する場合、融解熱量が最大のピーク(融解ピーク)の温度を、当該試料の融点とした。
ポリプロピレン系樹脂(ポリプロピレン系樹脂(A)およびポリプロピレン系樹脂(C))のMFRは、JIS K7210:1999に記載のMFR測定器を用い、以下の条件下で測定して得られた値とした:オリフィスの直径が2.0959±0.005mmφ、オリフィスの長さが8.000±0.025mm、荷重が2.16kgf、かつ温度が230℃(230±0.2℃)。
ポリプロピレン単独重合体(B)のメソペンタッド分率の測定方法は、以下の(1)~(3)の通りであった:(1)試料としてポリプロピレン単独重合体(B)をo-ジクロロベンゼンに溶解し、JEOL製JNM-GX270装置を用い、共鳴周波数67.93MHzで13C-NMRを測定した;(2)メチル基由来のスペクトルについてmmmmピークを21.855ppmとして各ピークの帰属を行い、ピーク面積を求めた;(3)メチル基由来全ピーク面積に対するmmmmピークの比率を百分率で表示し、メソペンタッド分率(mol%)とした。詳細な測定条件は以下のとおりであった。
測定溶媒:o-ジクロロベンゼン(90重量%)/ベンゼン-D6(10重量%)
試料濃度:15重量%~20重量%
測定温度:120℃~130℃
共鳴周波数:67.93MHz
パルス幅:10μsec(45゜パルス)
パルス繰り返し時間:7.091sec
データポイント:32K
積算回数:8168
測定モード:ノイズデカップリング
なお、得られたスペクトルの帰属およびペンタッド分率(mmmm)の計算は、T.Hayashiらが行った方法[Polymer,29,138~143(1988)]に基づき行った。
発泡粒子のDSC比の測定(算出)では、示差走査熱量計(セイコーインスツルメンツ社製DSC6200型)を使用した。示差走査熱量計を用いる発泡粒子のDSC比の測定(算出)方法は次の(1)~(6)の通りであった:(1)発泡粒子5mg~6mgを量り取った;(2)発泡粒子の温度を10℃/分の昇温速度にて40℃から220℃まで昇温して、発泡粒子を融解した;(3)前記(2)の過程で得られた発泡粒子のDSC曲線において、融解開始前の温度を表す点と融解終了後の温度を表す点とを直線で結びベースラインを作成した;(4)高温側の融解ピークまたは最も高温の融解ピークと隣の融解ピークとの間の極大点を通る直線を、X軸に対して垂直方向に引いた;(5)ベースラインと極大点を通る直線とDSC曲線とに囲まれる高温側の領域から算出される熱量を高温側融解熱量とし、ベースラインと極大点を通る直線とDSC曲線とに囲まれる低温側の領域から算出される熱量を低温側融解熱量とし、ベースラインとDSC曲線とに囲まれる領域から算出される熱量を全融解熱量(=高温側融解熱量+低温側融解熱量)とした;(6)以下の式からDSC比を算出した:
DSC比(%)=(高温側融解熱量/全融解熱量)×100。
発泡粒子の平均気泡径の測定方法は、以下の(1)~(5)の通りであった:(1)カミソリ(フェザー社製ハイステンレス両刃)を用いて、発泡粒子の中心を通るように当該発泡粒子を切断した;(2)得られた発泡粒子の切断面を、光学顕微鏡(キーエンス社製VHX-100)を用いて、倍率50倍にて観察した;(3)観察によって得られた画像において、当該発泡粒子の切断面の中心または略中心を通る直線を引いた;(4)(4-1)当該直線上に存在する気泡数nを測定し、(4-2)当該直線と当該発泡粒子表面との交点によって当該直線から切り取られた線分の長さを測定し、発泡粒子径Lとした;(5)以下の式により発泡粒子の平均気泡径を算出した:
平均気泡径(μm)=L/n。
発泡粒子の発泡倍率の測定方法は、以下の(1)~(4)の通りであった:(1)発泡粒子の重量w(g)を測定した;(2)次に、重量の測定に用いた発泡粒子を、メスシリンダー中に入っているエタノール中に沈め、メスシリンダーの液面位置の上昇分に基づき当該発泡粒子の体積v(cm3)を測定した;(3)重量w(g)を体積v(cm3)で除し、発泡粒子の密度ρ1を算出した;(4)発泡粒子の製造に用いたポリプロピレン系樹脂粒子の密度ρ2を発泡粒子の密度ρ1で除し(ρ2/ρ1)て得られた値に100を乗じ、得られた値を発泡粒子の発泡倍率とした。
内部融着率の測定は、以下の(1)~(4)の通りであった:(1)発泡成形体の任意の一面に対して、カッターで垂直方向に、当該面を有する部位の垂直方向に5mmの切り込みを入れた;(2)その後、発泡成形体を切り込みに沿って手で破断した;(3)得られた破断面のうち、前記切り込み部分を除いた領域を目視で観察し、当該領域に存在する全発泡粒子、および当該領域において粒子界面以外で破断している発泡粒子(すなわち発泡粒子自体が破断している発泡粒子)の数を計測した;(4)以下の式に基づき内部融着率を算出した;
内部融着率(%)=(領域において粒子界面以外で破断している発泡粒子数/領域に存在する全発泡粒子数)×100。
〇(低成形圧力化が十分に達成されている):最低成形圧力が0.26MPa(ゲージ圧)未満
×(低成形圧力化が不十分(未達成)である):最低成形圧力が0.26MPa(ゲージ圧)以上。
発泡成形体の密度の測定方法および評価方法は、以下の(1)~(3)の通りであった:(1)後述する[発泡成形体(A)の作製]工程で得られた発泡成形体(発泡成形体(A))の縦の長さ、横の長さ、および厚さを、ノギスで測定し、発泡成形体の体積V(cm3)を算出した;(2)その後、当該発泡成形体の重量W(g)を測定した;(3)以下の式に基づき、発泡成形体の密度を算出した:
発泡成形体の密度(g/cm3)=発泡成形体の重量W(g)/発泡成形体の体積V(cm3)。
発泡成形体の圧縮強度の測定方法および評価方法は以下の(1)~(3)の通りであった:(1)後述する[発泡成形体(A)の作製]工程で得られた発泡成形体(発泡成形体(A))のほぼ中央から、縦50mm×横50mm×厚み25mmの試験片を切り出した;(2)前記試験片に対して、NDZ-Z0504に準拠し、引張圧縮試験機[ミネベア製、TGシリーズ]を用いて、10mm/分の速度で圧縮したときの50%圧縮時の圧縮応力(MPa)を測定した;(3)50%歪時圧縮強度(MPa)の測定結果に基づき、以下の基準により発泡成形体の圧縮強度を評価した:
◎(良好):下記式(1)が充足される
〇(合格):下記式(1)が充足されず、下記式(2)が充足される
×(不良):下記式(1)および下記式(2)が充足されない
(発泡成形体の50%歪時圧縮強度(MPa))≧0.0069×(発泡成形体の密度(g/L))+0.018・・・式(1)
(発泡成形体の50%歪時圧縮強度(MPa))≧0.0069×(発泡成形体の密度(g/L))・・・式(2)
ここで、発泡成形体の密度の測定方法は上述の(発泡成形体の密度)項に記載の通りである。
実施例Aにおいて、発泡成形体の表面美麗性の評価方法は以下の通りであった:後述する[発泡成形体(B)の作製]工程で得られた発泡成形体(発泡成形体(B))の表面を目視で観察し、下記の基準に基づき、1~5の5段階で評価した。
5:発泡成形体の表面に、1.0mm2を超える大きさの粒間が無い。
4:発泡成形体の表面に、1.0mm2を超える大きさの粒間はあるが、1.5mm2を超える大きさの粒間は無い。
3:発泡成形体の表面に、1.5mm2を超える大きさの粒間はあるが、2.0mm2を超える大きさの粒間は無い。
2:発泡成形体の表面に、2.0mm2を超える大きさの粒間がある。
1:発泡粒子がほとんど膨張せず、粒子同士の隙間がほぼ埋まっていない。
なお、評価の値が大きいほど、表面美麗性に優れることを示している。
発泡成形体の変形の有無の評価方法は以下の通りであった:後述する[発泡成形体(B)の作製]工程で得られた発泡成形体(発泡成形体(B))を目視で観察し、下記の基準で評価した。
〇(良好):発泡成形体の変形がほとんどなく、発泡成形体の表面に皺が無い。
△(合格):発泡成形体が少し変形しており、発泡成形体の表面に小さな皺が存在する。×(不良):発泡成形体が大きく変形しており、発泡成形体の表面に皺が多く存在する。
[樹脂粒子の作製]
ポリプロピレン系樹脂(A)としてポリプロピレン系樹脂A-1を97.5重量部と、プロピレン単独重合体(B)としてポリプロピレン系樹脂B-1を2.5重量部と、添加剤としてタルク0.1重量部およびグリセリン0.2重量部と、をブレンドした。
10L耐圧容器に、得られた樹脂粒子100重量部と、水系分散媒として水200重量部、分散剤としてカオリンを0.3重量部、分散助剤としてドデシルベンゼンスルホン酸ナトリウム(DBS)を0.06重量部、ならびに発泡剤として炭酸ガスを5.6重量部仕込み、発泡剤を含む分散液を作製した(分散工程)。当該分散液を撹拌しながら、発泡温度(耐圧容器内の温度)を151℃、および発泡圧力(容器内圧)を2.8MPaとした(昇温-昇圧工程)。耐圧容器内の温度および圧力が所定の発泡温度および発泡圧力に達した後、さらに30分間、耐圧容器内の温度および圧力を所定の発泡温度および発泡圧力で保持した(保持工程)。その後、二酸化炭素を供給することにより、耐圧容器内の発泡圧力を所定の発泡圧力に保持しながら、耐圧容器の下部に設けられた直径3.2mmφオリフィスを通して分散液を95℃の大気圧下に放出し、ポリプロピレン系樹脂の発泡粒子を得た(放出工程)。その後、ポリプロピレン系樹脂の発泡粒子を75℃で24時間乾燥した。得られた発泡粒子について、DSC比、平均気泡径、発泡倍率を測定した。結果を表1に示す。
以下順に(1)~(6)の方法によって、発泡成形体を作製した:(1)前記[発泡粒子の作製]工程で得られた発泡粒子を耐圧容器に投入し、耐圧容器内に空気を圧入して耐圧容器内を昇圧することにより、発泡粒子内に加圧空気を含浸させて、発泡粒子の内圧を0.20MPa(絶対圧)にした;(2)内圧を付与した発泡粒子を、成形機に設置された金型に充填した。ここで、成形機としては、ポリオレフィン発泡成形機[株式会社ダイセン工業製、EP-900]を使用し、金型としては縦370mm×横320mm×厚み50mmの成形空間を形成し得る金型を使用し、クラッキングは5mmとした;(3)発泡粒子の充填後、成形機の排水ラインの排水弁を開けた状態で、0.1MPa(ゲージ圧)(水蒸気圧力A)の水蒸気にて発泡粒子を10秒間加熱(一方加熱および逆一方加熱)することにより、金型内の空気を追い出した;(4)その後、成形機の排水ラインの排水弁を閉めた状態で、さらに10秒間、上述した方法にて得られた最低成形圧力(水蒸気圧力B)の水蒸気で加熱(両面加熱)した;(5)当該加熱により、発泡粒子同士を融着させて、発泡成形体(A)を得た;(6)得られた発泡成形体(A)を金型から取り出し、室温で2時間放置した後、75℃で16時間養生乾燥した。得られた発泡成形体(A)について、発泡成形体の密度、および、圧縮強度を測定した。結果を表1に示す。
以下順に(1)~(6)の方法によって、発泡成形体を作製した:(1)前記[発泡粒子の作製]工程で得られた発泡粒子を耐圧容器に投入し、耐圧容器内に空気を圧入して耐圧容器内を昇圧することにより、発泡粒子内に加圧空気を含浸させて、発泡粒子の内圧を0.20MPa(絶対圧)にした;(2)内圧を付与した発泡粒子を、成形機に設置された金型に、厚み方向に圧縮せずに充填した。ここで、成形機としては、ポリオレフィン発泡成形機[株式会社ダイセン工業製、EP-900]を使用し、金型としては縦370mm×横320mm×厚み20mmの成形空間を形成し得る金型を使用し、クラッキングは0mmとした;(3)発泡粒子の充填後、成形機の排水ラインの排水弁を開けた状態で、0.1MPa(ゲージ圧)(水蒸気圧力A)の水蒸気にて発泡粒子を10秒間加熱(一方加熱および逆一方加熱)することにより、金型内の空気を追い出した;(4)その後、成形機の排水ラインの排水弁を閉めた状態で、さらに10秒間、0.27MPa(ゲージ圧)(水蒸気圧力B)の水蒸気で加熱(両面加熱)した;(5)当該加熱により、発泡粒子同士を融着させて、発泡成形体(B)を得た;(6)得られた発泡成形体(B)を金型から取り出し、室温で2時間放置した後、75℃で16時間養生乾燥した。得られた発泡成形体(B)について、表面美麗性、および変形を評価した。結果を表1に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を95.0重量部使用し、プロピレン単独重合体(B)として、ポリプロピレン系樹脂B-1を5.0重量使用し、発泡剤の使用量を5.4重量部とし、発泡圧力を2.7MPaとしたこと以外は実施例A1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表1に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を90.0重量部使用し、プロピレン単独重合体(B)として、ポリプロピレン系樹脂B-1を10.0重量使用し、発泡剤の使用量を5.4重量部とし、発泡圧力を2.7MPaとしたこと以外は実施例A1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表1に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を85.0重量部使用し、プロピレン単独重合体(B)として、ポリプロピレン系樹脂B-1を15.0重量使用し、発泡剤の使用量を5.4重量部とし、発泡圧力を2.7MPaとしたこと以外は実施例A1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表1に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を95.0重量部使用し、プロピレン単独重合体(B)として、ポリプロピレン系樹脂B-2を5.0重量使用し、発泡剤の使用量を5.4重量部とし、発泡圧力を2.7MPaとしたこと以外は実施例A1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表1に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を95.0重量部使用し、プロピレン単独重合体(B)として、ポリプロピレン系樹脂B-3を5.0重量使用し、発泡剤の使用量を5.4重量部とし、発泡圧力を2.7MPaとしたこと以外は実施例A1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表1に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を100.0重量部使用し、プロピレン単独重合体(B)を使用しなかったこと以外は実施例A1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表2に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を98.5重量部使用し、プロピレン単独重合体(B)として、ポリプロピレン系樹脂B-1を1.5重量使用したこと以外は実施例A1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表2に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を80.0重量部使用し、プロピレン単独重合体(B)として、ポリプロピレン系樹脂B-1を20.0重量使用し、発泡剤の使用量を5.4重量部とし、発泡圧力を2.7MPaとしたこと以外は実施例A1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表2に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を98.5重量部使用し、プロピレン単独重合体(B)に変えて、ワックスを1.5重量部使用し、発泡圧力を2.9MPaとしたこと以外は実施例A1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表2に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を95.0重量部使用し、プロピレン単独重合体(B)に変えて、ワックスを5.0重量部使用し、発泡圧力を2.8MPaとしたこと以外は実施例A1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表2に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を92.0重量部使用し、プロピレン単独重合体(B)に変えて、ワックスを8.0重量部使用し、発泡剤の使用量を5.4重量部とし、発泡温度を150℃とし、発泡圧力を2.7MPaとしたこと以外は実施例A1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表2に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を50.0重量部使用し、プロピレン単独重合体(B)に変えて、ポリプロピレン系樹脂(C)を50.0重量部使用し、発泡温度を150℃とし、発泡圧力を2.9MPaとしたこと以外は実施例A1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表2に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を40.0重量部使用し、プロピレン単独重合体(B)に変えて、ポリプロピレン系樹脂(C)を60.0重量部使用し、発泡温度を150℃とし、発泡圧力を2.9MPaとしたこと以外は実施例A1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表2に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を30.0重量部使用し、プロピレン単独重合体(B)に変えて、ポリプロピレン系樹脂(C)を70.0重量部使用し、発泡温度を150℃としたこと以外は実施例A1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表2に示す。
表1および表2より、以下のことが明らかにわかる:
(1)実施例A1~6の発泡粒子は低い成形圧力で成形でき、当該発泡粒子を成形してなる発泡成形体は、一定水準以上の圧縮強度を有し、表面美麗性に優れ、変形が抑制されている。
以下、実施例Bにより本発明の第2の実施形態を具体的に説明するが、本発明は、これらの実施例Bによりその技術的範囲を限定されるものではない。
実施例Bおよび比較例Bで使用した物質(材料)を以下に示す。
実施例Bで使用したポリプロピレン系樹脂については、実施例Aにおける<ポリプロピレン系樹脂>の項で説明したものと同じであるため、当該記載を援用し、ここでは説明を省略する。
カーボンブラックAまたはB40重量部とポリプロピレン系樹脂(MFR=7.5g/10分)60重量部とを混合し、カーボンブラックAまたはBのマスターバッチを作製した。すなわちいずれのマスターバッチにおいても、マスターバッチ100重量%中のカーボンブラックの濃度は40重量%であった。以下の実施例Bおよび比較例Bでは、これらカーボンブラックマスターバッチを使用した。なお、表3および4には、得られた発泡粒子中でのカーボンブラックの平均粒子径を併記した。
実施例Bで使用したその他の樹脂および添加剤については、それぞれ、実施例Aにおける<その他の樹脂>および<添加剤>の項で説明したものと同じであるため、当該記載を援用し、ここでは説明を省略する。
実施例Bおよび比較例Bにおいて実施した評価方法に関して、以下に説明する。
以下(1)~(4)を実施し、カーボンブラックの一次粒径を測定した:(1)ポリプロピレン系樹脂発泡粒子をミクロトームを用いて、略半分に切断した;(2)得られた断面について、透過型電子顕微鏡にて4万倍に拡大した断面を撮像し、断面写真を得た;(3)得られた断面写真において、任意に50個のカーボンブラックを選択し、各々のカーボンブラックの一次粒子について、X方向とY方向の粒子径(フェレ径)をそれぞれ測定した;(4)各々のカーボンブラックの一次粒子について、X方向の粒子径とY方向の粒子径との相加平均値を算出し、得られた値をカーボンブラックの一次粒径とした。
発泡成形体の融着性は、発泡成形体の内部融着率により評価した。内部融着率の測定方法については、実施例Aにおける(発泡成形体の内部融着率および最低成形圧力の測定)の項で説明したものと同じであるため、当該記載を援用し、ここでは説明を省略する。
〇(良好):内部融着率が60%以上である。
×(不良):内部融着率が60%未満である。
実施例Bにおいて、発泡成形体の表面美麗性は、発泡成形体の黒色度、色ムラ、粒間およびシワの程度を評価して行った。各々の評価方法および評価基準は以下の通りであった。
発泡成形体の黒色度の評価方法は以下(1)~(3)の通りであった:(1)得られた発泡成形体の表面(後述する水蒸気孔がキリ穴である金型面から形成される、320mm×370mmの表面)をプリンター複合機(iR-ADVC5035、キヤノン社製)によってスキャンして、発泡成形体の表面画像を得る;(2)得られた画像における、発泡成形体の表面(320mm×370mm)の全範囲について、画像処理ソフト(DIBAS32)を用いて行ったRGB分析によって黒色度を評価した;(3)具体的には、発泡成形体の表面の全範囲のRGB合計の最頻値(測定値)について、黒0(100%)、白255(0%)を基準として、以下の式で数値化して黒色度とし、下記の基準で判断した。なお、黒色度(%)の数値が大きいほど、黒色度が高いことを意図する。
発泡成形体の黒色度(%)=(255-測定値)/255×100
〇(良好):黒色度が88%以上である。
×(不良):黒色度が88%未満である。
発泡成形体の色ムラの評価方法は以下の通りであった:前記(発泡成形体の黒色度)の評価が〇(良好)であった発泡成形体に関して、当該発泡成形体を目視で観察し、下記の基準で評価した。
〇(良好):発泡成形体の黒色が均一または略均一であり、発泡粒子内および発泡粒子間の色にムラが無いか、あっても非常に少ない。
△(合格):発泡成形体の黒色にムラがあり、灰色っぽい部分がわずかに散見される。
×(不良):発泡成形体の黒色にムラがあり、灰色っぽい部分が多数存在する。
発泡成形体の粒間の評価方法は以下の通りであった:得られた発泡成形体の表面を目視で観察し、下記の基準で評価した。
〇(良好):発泡成形体の表面に、粒間(発泡粒子間の隙間)が無いか、あっても1.0mm2以下の大きさの粒間が非常に少し有り、1.0mm2を超える大きさの粒間は無い。
△(合格):発泡成形体の表面に、1.0mm2を超える大きさの粒間が少し(多数ではない)あるが、1.5mm2を超える大きさの粒間は無い。
×(不良):発泡成形体の表面に、1.0mm2を超える大きさの粒間が多数ある、および/または、1.5mm2を超える大きさの粒間がある。
発泡成形体のシワの評価方法は以下の通りであった:得られた発泡成形体の表面を目視で観察し、下記の基準で評価した。
〇(良好):発泡成形体の表面に、シワが無いか、あっても非常に少ない
△(合格):小さなシワがある程度(但し多数でなく)存在し、大きなシワは無いか、あっても非常に少ない
×(不良):小さなシワが多数存在し、大きなシワもある程度または多数存在する。
[樹脂粒子の作製]
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を97.5重量部と、プロピレン単独重合体(B)として、ポリプロピレン系樹脂B-1を2.5重量部と、カーボンブラック4重量部と、添加剤として、タルク0.1重量部およびグリセリン0.2重量部と、をブレンドした。
10L耐圧容器に、得られた樹脂粒子100重量部と、水系分散媒として水200重量部、分散剤としてカオリンを0.3重量部、分散助剤としてドデシルベンゼンスルホン酸ナトリウム(DBS)を0.06重量部、ならびに発泡剤として炭酸ガスを5.6重量部仕込み、発泡剤を含む分散液を作製した(分散工程)。当該分散液を撹拌しながら、発泡温度(耐圧容器内の温度)を151℃、および発泡圧力(容器内圧)を2.9MPaとした(昇温-昇圧工程)。耐圧容器内の温度および圧力が所定の発泡温度および発泡圧力に達した後、さらに30分間、耐圧容器内の温度および圧力を所定の発泡温度および発泡圧力で保持した(保持工程)。その後、二酸化炭素を供給することにより、耐圧容器内の発泡圧力を所定の発泡圧力に保持しながら、耐圧容器の下部に設けられた直径3.2mmφオリフィスを通して分散液を95℃の大気圧下に放出し、ポリプロピレン系樹脂の発泡粒子を得た(放出工程)。その後、ポリプロピレン系樹脂の発泡粒子を75℃で24時間乾燥した。得られた発泡粒子について、DSC比、平均気泡径、発泡倍率を測定した。結果を表3に示す。
以下順に(1)~(6)の方法によって、発泡成形体を作製した:(1)前記[発泡粒子の作製]工程で得られた発泡粒子を耐圧容器に投入し、耐圧容器内に空気を圧入して耐圧容器内を昇圧することにより、発泡粒子内に加圧空気を含浸させて、発泡粒子の内圧を0.20MPa(絶対圧)にした;(2)内圧を付与した発泡粒子を、成形機に設置された金型に充填した。ここで、成形機としては、ポリオレフィン発泡成形機[株式会社ダイセン工業製、EP-900]を使用し、金型としては水蒸気孔がキリ穴であり、縦370mm×横320mm×厚み50mmの成形空間を形成し得る金型を使用し、クラッキングは5mmとした;(3)発泡粒子の充填後、成形機の排水ラインの排水弁を開けた状態で、0.1MPa(ゲージ圧)(水蒸気圧力A)の水蒸気にて発泡粒子を10秒間加熱(一方加熱および逆一方加熱)することにより、金型内の空気を追い出した;(4)その後、成形機の排水ラインの排水弁を閉めた状態で、さらに10秒間、0.24MPa(ゲージ圧)(水蒸気圧力B)の水蒸気で加熱(両面加熱)した;(5)当該加熱により、発泡粒子同士を融着させて、発泡成形体を得た;(6)得られた発泡成形体を金型から取り出し、室温で2時間放置した後、75℃で16時間養生乾燥した。得られた発泡成形体について、発泡成形体の融着性、および表面美麗性(黒色度、色ムラ、粒間およびシワ)を測定および評価した。結果を表3に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を95.0重量部使用し、プロピレン単独重合体(B)として、ポリプロピレン系樹脂B-1を5.0重量使用したこと、および発泡圧力(ゲージ圧)を2.8MPaに変更したこと以外は実施例B1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表3に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を85.0重量部使用し、プロピレン単独重合体(B)として、ポリプロピレン系樹脂B-1を15.0重量使用したこと、および発泡圧力(ゲージ圧)を2.8MPaに変更したこと以外は実施例B1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表3に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を95.0重量部使用し、プロピレン単独重合体(B)として、ポリプロピレン系樹脂B-1を5.0重量使用し、カーボンブラックとして、カーボンブラックBを6重量部使用したこと、および発泡圧力(ゲージ圧)を2.8MPaに変更したこと以外は実施例B1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表3に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を95.0重量部使用し、プロピレン単独重合体(B)として、ポリプロピレン系樹脂B-2を5.0重量部使用したこと、および発泡圧力(ゲージ圧)を2.8MPaに変更したこと以外は実施例B1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表3に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を95.0重量部使用し、プロピレン単独重合体(B)として、ポリプロピレン系樹脂B-3を5.0重量部使用し、カーボンブラックとしてカーボンブラックAを4重量部使用したこと、および発泡圧力(ゲージ圧)を2.7MPaに変更したこと以外は実施例B1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表3に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を100.0重量部使用し、プロピレン単独重合体(B)を使用しなかったこと以外は実施例B1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表4に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を100.0重量部使用し、プロピレン単独重合体(B)を使用せず、カーボンブラックAに変えて、カーボンブラックBを6重量部使用したこと以外は実施例B1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表4に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を95.0重量部使用し、プロピレン単独重合体(B)に変えて、プロピレン-αオレフィン系ワックスを5.0重量部使用したこと、および発泡圧力(ゲージ圧)を2.8MPaに変更したこと以外は実施例B1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表4に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を98.5重量部使用し、プロピレン単独重合体(B)として、ポリプロピレン系樹脂B-1を1.5重量部使用したこと以外は実施例B1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表4に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を80.0重量部使用し、プロピレン単独重合体(B)として、ポリプロピレン系樹脂B-1を20.0重量部使用したこと以外は実施例B1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表4に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を95.0重量部使用し、プロピレン単独重合体(B)として、ポリプロピレン系樹脂B-1を5.0重量部使用し、カーボンブラックAを10重量部使用したこと、および発泡圧力(ゲージ圧)を3.0MPaに変更したこと以外は実施例B1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表4に示す。
ポリプロピレン系樹脂(A)として、ポリプロピレン系樹脂A-1を95.0重量部使用し、プロピレン単独重合体(B)として、ポリプロピレン系樹脂B-1を5.0重量部使用し、カーボンブラックBを10重量部使用したこと、および発泡圧力(ゲージ圧)を3.0MPaに変更したこと以外は実施例B1と同じ方法により発泡粒子および発泡成形体を作製し、各物性を測定および評価した。結果を表4に示す。
Claims (15)
- 融点が135℃~150℃であるポリプロピレン系樹脂(A)と、
融点が85℃以下であるポリプロピレン単独重合体(B)と、を含有する基材樹脂を含み、
前記基材樹脂は、前記ポリプロピレン系樹脂(A)および前記ポリプロピレン単独重合体(B)の合計量を100重量部としたとき、
前記ポリプロピレン系樹脂(A)を80.0重量部より多く、98.0重量部以下含み、かつ
前記ポリプロピレン単独重合体(B)を2.0重量部以上、20.0重量部未満含む、ポリプロピレン系樹脂発泡粒子。 - 前記基材樹脂が、カーボンブラックを含む、請求項1に記載のポリプロピレン系樹脂発泡粒子。
- 前記ポリプロピレン系樹脂(A)および前記ポリプロピレン単独重合体(B)の合計量を100重量部としたとき、前記カーボンブラックを、2重量部以上10重量部未満含む、請求項2に記載のポリプロピレン系樹脂発泡粒子。
- 前記ポリプロピレン単独重合体(B)の重量平均分子量が40000~140000である、請求項1~3のいずれか1項に記載のポリプロピレン系樹脂発泡粒子。
- 前記ポリプロピレン単独重合体(B)のメソペンタッド分率(mmmm)が25mol%~65mol%である、請求項1~4のいずれか1項に記載のポリプロピレン系樹脂発泡粒子。
- 前記カーボンブラックの一次粒径が100nm以下である、請求項2~5のいずれか1項に記載のポリプロピレン系樹脂発泡粒子。
- 前記ポリプロピレン系樹脂(A)が、プロピレン/エチレンランダム共重合体およびプロピレン/エチレン/1-ブテンランダム共重合体の少なくとも一方であって、
前記共重合体中のエチレン含有率が、各共重合体100重量%中、0.2重量%~10.0重量%である、請求項1~6のいずれか1項に記載のポリプロピレン系樹脂発泡粒子。 - 前記ポリプロピレン系樹脂(A)の230℃におけるMFRが、3g/10分~30g/10分である、請求項1~7のいずれか1項に記載のポリプロピレン系樹脂発泡粒子。
- 前記ポリプロピレン系樹脂発泡粒子のDSC比((高温側融解熱量/全融解熱量)×100)が、10.0%~50.0%である、請求項1~8のいずれか1項に記載のポリプロピレン系樹脂発泡粒子。
- 前記ポリプロピレン系樹脂発泡粒子の平均気泡径が、110μm~280μmである、請求項1~9のいずれか1項に記載のポリプロピレン系樹脂発泡粒子。
- 前記ポリプロピレン系樹脂発泡粒子の発泡倍率が、15倍~50倍である、請求項1~10のいずれか1項に記載のポリプロピレン系樹脂発泡粒子。
- 請求項1~11のいずれか1項に記載のポリプロピレン系樹脂発泡粒子を成形して得られるポリプロピレン系樹脂発泡成形体。
- ポリプロピレン系樹脂粒子と、水系分散媒と、発泡剤とを容器中に分散させる分散工程と、
前記容器の一端を解放し、前記分散工程で得られた前記容器内の分散液を、当該容器内の圧力よりも低圧の領域に放出する放出工程と、を含み、
前記ポリプロピレン系樹脂粒子は、融点が135℃~150℃であるポリプロピレン系樹脂(A)と、融点が85℃以下であるポリプロピレン単独重合体(B)と、を含有する基材樹脂を含み、前記基材樹脂は、前記ポリプロピレン系樹脂(A)および前記ポリプロピレン単独重合体(B)の合計量を100重量部としたとき、
前記ポリプロピレン系樹脂(A)を80.0重量部より多く、98.0重量部以下含み、かつ
前記ポリプロピレン単独重合体(B)を2.0重量部以上、20.0重量部未満含む、ポリプロピレン系樹脂発泡粒子の製造方法。 - 前記発泡剤が、二酸化炭素および水の少なくとも一方からなる、請求項13に記載のポリプロピレン系樹脂発泡粒子の製造方法。
- 前記発泡剤の使用量が、樹脂粒子100重量部に対して、2.0重量部~60.0重量部である、請求項13または14に記載のポリプロピレン系樹脂発泡粒子の製造方法。
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