WO2024247567A1 - マスターバッチ、及び発泡成形体 - Google Patents

マスターバッチ、及び発泡成形体 Download PDF

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Publication number
WO2024247567A1
WO2024247567A1 PCT/JP2024/016087 JP2024016087W WO2024247567A1 WO 2024247567 A1 WO2024247567 A1 WO 2024247567A1 JP 2024016087 W JP2024016087 W JP 2024016087W WO 2024247567 A1 WO2024247567 A1 WO 2024247567A1
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master batch
mass
masterbatch
antioxidant
parts
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French (fr)
Japanese (ja)
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奈緒子 栗生
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Kureha Corp
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Kureha Corp
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J3/00—Processes of treating or compounding macromolecular substances
    • C08J3/20—Compounding polymers with additives, e.g. colouring
    • C08J3/22—Compounding polymers with additives, e.g. colouring using masterbatch techniques
    • 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
    • C08J9/32—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof from compositions containing microballoons, e.g. syntactic foams

Definitions

  • the present invention relates to a masterbatch and a foam molded product made from the masterbatch.
  • plastic foam molded products have been used in a variety of applications because they can exhibit heat insulation, thermal insulation, sound insulation, sound absorption, vibration damping, weight reduction, etc., depending on the material of the molded product and the state of the bubbles formed.
  • One method for producing such plastic foam molded products is to heat a master batch containing thermally foamable microspheres and a resin to foam and mold them.
  • thermally foamable microspheres also known as thermally foamable microcapsules
  • thermally foamable microspheres are microencapsulated volatile foaming agents with a resin shell.
  • Thermally foamable microspheres have the property of expanding rapidly when heated, once the foaming starts.
  • Patent Document 1 a masterbatch containing thermally expandable microspheres and using a polyethylene resin in combination with a polyethylene wax has been proposed.
  • the thermally foamable microspheres When the thermally foamable microspheres are heated above the foaming initiation temperature, they expand by themselves to form foam particles (closed cells). However, when they are heated further, the thickness of the outer shell becomes thinner and the volatile foaming agent permeates through the outer shell, causing the internal pressure to decrease and the thermally foamable microspheres to shrink. When the thermally foamable microspheres shrink, the foamed molded article becomes unstable in appearance and gas flow marks become a problem. When the foamed molded article becomes unstable, the smoothness of the surface of the foamed molded article is lost and roughness occurs.
  • the master batch disclosed in Patent Document 1 also has the problem that the foamed molded article is prone to shrinkage. For this reason, there is a demand for foamed molded articles with excellent shrinkage resistance.
  • the present invention was made in consideration of the above problems, and aims to provide a masterbatch that can produce a foamed molded article with excellent shrinkage resistance, and a foamed molded article made from the masterbatch.
  • additives such as antioxidants are added to commercially available synthetic resins such as polyethylene and polypropylene, but the amount added is generally 0.1 wt%.
  • the inventors discovered that the amount of antioxidants contained in commercially available synthetic resins alone is not effective in suppressing shrinkage resistance during foaming, and that shrinkage resistance can be imparted by adding an additional antioxidant, which led to the completion of the present invention.
  • aspects of the present invention relate to the following master batches and foam molded articles.
  • a master batch comprising thermally expandable microspheres (A), a base resin (B), and an antioxidant (C),
  • the content of the antioxidant (C) is 0.2 parts by mass or more and 4 parts by mass or less per 100 parts by mass of the total of the thermally foamable microspheres (A) and the base resin (B).
  • the masterbatch according to [1] having a shrinkage resistance (250°C) of 4.0 minutes or more as measured by the following measurement method.
  • Shrinkage resistance (250°C) 1/2Tb - 1/2Ta
  • a container containing the master batch is used as a measurement sample and placed in the heating furnace of a thermomechanical analyzer (TMA), the temperature inside the heating furnace is raised from 30°C to 190°C over a period of 2 min, and then raised from 190°C to 250°C over a period of 0 min.
  • the master batch is heated at 250°C for a total heating time of 20 minutes from the point of 30°C.
  • the master batch is heated at 230°C for a total heating time of 30 minutes from the point of 30°C.
  • the minimum height of the master batch is 0% and the maximum foaming height is 100%, the time on the short-term side at which the height displacement is 50% is 1/2Ta and the time on the long-term side is 1/2Tb.
  • the base resin (B) is a polyethylene-based resin.
  • the antioxidant (C) contains a phenolic compound including a hindered phenolic compound or a phosphite compound.
  • the content of the antioxidant (C) is 0.4 parts by mass or more and 3 parts by mass or less per 100 parts by mass of the total of the thermally foamable microspheres (A) and the base resin (B).
  • the master batch according to any one of [1] to [5].
  • [7] A foam molded product of the masterbatch according to any one of [1] to [6].
  • the present invention provides a masterbatch that can produce a foamed molded article with excellent shrinkage resistance, and a foamed molded article made from the masterbatch.
  • FIG. 1 is a schematic diagram showing the relationship between the displacement of the master batch at each time and time when the master batch of the present embodiment is heated at a predetermined temperature (foaming temperature) for a predetermined time using a thermomechanical analysis (TMA) device and the foaming temperature is maintained for a predetermined time.
  • a predetermined temperature Foaming temperature
  • TMA thermomechanical analysis
  • the master batch of the present embodiment contains thermally expandable microspheres (A), a base resin (B), and an antioxidant (C).
  • the content of the antioxidant (C) is 0.2 parts by mass or more and 4 parts by mass or less per 100 parts by mass of the total of the thermally expandable microspheres (A) and the base resin (B). According to the masterbatch of the present embodiment, since the antioxidant (C) is contained in a specific amount, a foamed molded article having excellent shrinkage resistance can be obtained.
  • the thermally expandable microsphere (A) has a structure in which a foaming agent is enclosed within an outer shell formed from a polymer.
  • the polymer forming the outer shell is preferably, for example, a homopolymer or copolymer having a structural unit derived from one or more monomers selected from the group consisting of (meth)acrylonitrile, (meth)acrylic acid esters, (meth)acrylic acid, vinyl chloride, vinylidene chloride, and styrene.
  • copolymers having structural units derived from (meth)acrylonitrile, (meth)acrylic acid, and (meth)acrylic acid esters are preferred.
  • “(meth)acrylonitrile” means both “acrylonitrile” and “methacrylonitrile”
  • “(meth)acrylic” means both "acrylic” and "methacrylic”.
  • crosslinkable monomers include bifunctional crosslinkable monomers such as aromatic divinyl compounds such as divinylbenzene, divinylnaphthalene, and derivatives thereof; diethylenically unsaturated carboxylic acid esters such as ethylene glycol diacrylate, diethylene glycol diacrylate, ethylene glycol dimethacrylate, and diethylene glycol dimethacrylate; polyethylenically unsaturated carboxylic acid esters such as triethylene glycol diacrylate and triethylene glycol dimethacrylate; acrylates or methacrylates derived from aliphatic alcohols at both ends such as 1,4-butanediol and 1,9-nonanediol; and divinyl compounds such as N,N-divinylaniline and divinyl ether.
  • bifunctional crosslinkable monomers such as aromatic divinyl compounds such as divinylbenzene, divinylnaphthalene, and derivatives thereof
  • the foaming agent is a substance that becomes a gas when heated.
  • a hydrocarbon having a boiling point according to the foaming initiation temperature can be used, and examples thereof include hydrocarbons such as ethane, ethylene, propane, propene, n-butane, isobutane, butene, isobutene, n-pentane, isopentane, neopentane, n-hexane, heptane, n-octane, isooctane, isododecane, petroleum ether, and isoparaffin mixtures, and isomeric mixtures thereof; chlorofluorocarbons such as CCl 3 F, CCl 2 F 2 , CClF 3 , and CClF 2 -CClF 2 ; and tetraalkylsilanes such as tetramethylsilane, trimethylethylsilane, tri
  • isobutane, n-butane, n-pentane, isopentane, n-hexane, isohexane, heptane, 2,2,4-trimethylpentane, isooctane, isododecane, and mixtures of their isomers, petroleum ether, and mixtures of two or more of these are preferred.
  • compounds that decompose when heated to form a gas may also be used.
  • the amount of the foaming agent is preferably 5 parts by mass or more and 70 parts by mass or less, more preferably 10 parts by mass or more and 60 parts by mass or less, and even more preferably 15 parts by mass or more and 50 parts by mass or less, relative to 100 parts by mass of the polymer.
  • the average particle size of the thermally expandable microspheres (A) is preferably 5 ⁇ m or more and 100 ⁇ m or less.
  • the thermally expandable microspheres (A) preferably have an expansion start temperature of 140°C or more and 250°C or less, and a maximum expansion temperature of 180°C or more and 300°C or less.
  • thermally expandable microspheres (A) can be produced by suspension polymerization of the above monomer and, if necessary, the above crosslinkable monomer together with the above foaming agent in an aqueous dispersion medium containing a dispersion stabilizer.
  • thermally expandable microspheres (A) for example, products under the trade name "S2640" (manufactured by Kureha Corporation) and the trade name "S2340” (manufactured by Kureha Corporation) are preferably used.
  • the base resin (B) may be any known thermoplastic resin or thermoplastic elastomer, and is not particularly limited.
  • the thermoplastic resin used in the base resin (B) include polyvinyl chloride, polystyrene, polypropylene-based resin, polypropylene oxide, polyethylene-based resin, and acrylic-based resin.
  • the thermoplastic elastomer used in the base resin (B) include ethylene-based, vinyl chloride-based, olefin-based, urethane-based, and ester-based elastomers. Among these, polyethylene resins are preferred from the viewpoint of kneadability with thermally expandable microspheres.
  • polyethylene resins include low-density polyethylene, linear low-density polyethylene, and high-density polyethylene.
  • linear low-density polyethylene examples include products under the trade names “Novatec” (manufactured by Mitsubishi Chemical Corporation), “Nipolon” (manufactured by Tosoh Corporation), “Ultrazex” (manufactured by Prime Polymer Co., Ltd.), and “Excellen” (manufactured by Sumitomo Chemical Co., Ltd.).
  • thermoplastic resins or thermoplastic elastomers may be used alone or in combination of two or more.
  • antioxidant (C) examples include tocopherol-based compounds, phenol-based compounds, hindered amine-based compounds, phosphite-based compounds, sulfur-based compounds, benzotriazole-based compounds, benzophenone-based compounds, hydroxylamine-based compounds, salicylic acid ester-based compounds, triazine-based compounds, etc. These can be used alone or in combination of two or more. Among these, phenol-based compounds and phosphite-based compounds are preferred from the viewpoint of obtaining a foamed molded article having excellent shrinkage resistance.
  • Phenol compounds include hindered phenol compounds and phenol compounds other than hindered phenol compounds (hereinafter also referred to as “other phenol compounds”).
  • hindered phenol compounds refers to compounds that are used as antioxidants and contain a structure in which tert-butyl groups are bonded to the two ortho positions of a phenolic hydroxyl group.
  • other phenol compounds refers to compounds that are used as antioxidants and contain phenolic hydroxyl groups but do not fall under the above-mentioned hindered phenol compounds.
  • Hindered phenol compounds include, for example, pentaerythritol-tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate]: trade name "Irganox 1010" (manufactured by BASF Corporation), 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)benzene: trade name "Irganox 1330" (manufactured by BASF Corporation), tris(3,5-di-tert-butyl-4-hydroxybenzyl)isocyanurate: trade name "Irganox 3114" (manufactured by BASF Corporation), BASF Corporation), 3-(3,5-di-tert-butyl-4-hydroxyphenyl)stearyl propionate: trade name "Irganox 1076" (BASF Corporation), 2,2'-thiodiethylbis[3-(3,5-di-
  • the product names "Irganox 1076" (manufactured by BASF), "Irganox 245" (manufactured by BASF), “Irganox 1010” (manufactured by BASF), and "Adekastab AO-330" (manufactured by ADEKA) are preferably used.
  • phenolic compounds include, for example, bis[3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionic acid][ethylene bis(oxyethylene)]: trade name "Irganox 245" (manufactured by BASF Corporation), 4,4',4''-(1-methylpropanylidene)tris[6-tert-butyl-m-cresol]: trade name "ADEKA STAB AO-30" (manufactured by ADEKA Corporation), 6,6 '-Di-tert-butyl-4,4'-butylidenedi-m-cresol: Trade name "Adeka STAB AO-40" (manufactured by ADEKA Corporation), 3,9-bis[2-[3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionyloxy]-1,1-dimethylethyl]-2,4,8,10-tetraoxaspiro[5,5]undecane: Trade name "A
  • phosphite compounds include 3,9-bis(2,6-di-tert-butyl-4-methylphenoxy)-2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane: trade name "ADEKA STAB PEP-36" (manufactured by ADEKA Corporation), 3,9-bis(octadecyloxy)-2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane: trade name "ADEKA STAB PEP-8" (manufactured by ADEKA Corporation), 2,2'-methylenebis(4,6-di-tert-butylphenyl)2-ethylhexylphosphite: trade name "ADEKA STAB HP-10" (manufactured by ADEKA Corporation), tris(2,4-di-tert-butylphenyl)phosphite: trade name " Examples of suitable phosphite include Ad
  • the trade name "Adeka STAB PEP-36" (manufactured by ADEKA CORPORATION) is preferably used. Of these, the product name “Adeka STAB PEP-36” (manufactured by ADEKA Corporation) is preferably used. Of these, the product name “Adeka STAB PEP-36” (manufactured by ADEKA Corporation) is preferably used.
  • the content of the antioxidant (C) is preferably 0.4 parts by mass or more and 3 parts by mass or less, and more preferably 0.5 parts by mass or more and 2 parts by mass or less, per 100 parts by mass of the total of the thermally foamable microspheres (A) and the base resin (B).
  • the antioxidant hereinafter also referred to as "pre-added antioxidant"
  • the content of the antioxidant (C) is the total amount of the pre-added antioxidant and the antioxidant blended when preparing the master batch.
  • the master batch may contain components other than the above-mentioned thermally foamable microspheres (A), base resin (B), and antioxidant (C) (hereinafter, also referred to as "other components") as long as the effects of the present invention are not impaired.
  • other components include lubricants, plasticizers, stabilizers, fillers, and dispersibility improvers.
  • the master batch can be obtained by melt-kneading the above-mentioned thermally expandable microspheres (A), the base resin (B), the antioxidant (C), and, if necessary, other components.
  • the masterbatch may be in the form of, for example, powder, flakes, pellets, or the like.
  • the foaming density of the master batch is preferably 0.005 g/ml or more and 1 g/ml or less, and more preferably 0.01 g/ml or more and 0.8 g/ml or less.
  • the volumetric foaming ratio of the master batch is preferably 2.5 times or more and 150 times or less, and more preferably 2.5 times or more and 120 times or less.
  • the shrinkage resistance of the masterbatch is evaluated by a thermomechanical analyzer (TMA). Specifically, a container containing the masterbatch is placed as a measurement sample in a heating furnace of the thermomechanical analyzer (TMA), the temperature inside the heating furnace is raised to a foaming temperature, and the foaming temperature is maintained for a predetermined time, and the height displacement of the masterbatch at each time from the start of heating is measured, thereby evaluating the shrinkage resistance of the masterbatch. Specifically, as shown in FIG.
  • the amount of master batch used is preferably about 2.0 to 3.0 mg.
  • the foaming temperature is preferably 230°C, 240°C, or 250°C, and the total heating time from the start of heating is preferably 20 minutes or 30 minutes.
  • the foaming temperature of the master batch is 230°C
  • 1/2Tb-1/2Ta is preferably 22 minutes or more, more preferably 25 minutes or more, and even more preferably 27 minutes or more.
  • the foaming temperature of the master batch is 250°C
  • 1/2Tb-1/2Ta is preferably 4.0 minutes or more, more preferably 6 minutes or more, and even more preferably 7 minutes or more.
  • the foamed molded article is obtained by adding the master batch of the present embodiment described above to a thermoplastic resin and foaming it.
  • the thermoplastic resin include polyethylene, polypropylene, polystyrene, ethylene vinyl acetate copolymer, ethylene vinyl alcohol copolymer, polyvinyl chloride, acrylonitrile styrene copolymer, acrylonitrile butadiene styrene copolymer, polyacetal, polyethylene terephthalate, polybutylene terephthalate, methacrylic, polycarbonate, polyamide, polyurethane, ionomer, and various thermoplastic elastomers (TPE, TPO, TPS, TPU, TPV, etc.).
  • the content of the master batch varies depending on the expansion ratio of the final product, but is generally 0.1 parts by mass or more and 20 parts by mass or less with respect to 100 parts by mass of the thermoplastic resin.
  • the molding method may be a conventionally known method such as injection molding.
  • Foamed products are useful as injection molded products, blow molded products, calendar molded products, and extrusion molded products, as films, sheets, building materials (flooring, wall materials, embedded panel materials, etc.), automotive molded products (sealing materials, door trim, instrument panels, and other interior molded products, bumpers and other body materials), shoe soles, etc.
  • A1 S2640 (manufactured by Kureha Corporation, average particle size: 20.5 ⁇ m, foaming start temperature: 194° C., maximum foaming temperature: 265° C.)
  • A2 S2340 (manufactured by Kureha Corporation, average particle size: 21.7 ⁇ m, foaming start temperature: 182° C., maximum foaming temperature: 242° C.)
  • B1 was used as the base resin (B).
  • B1 Excellen FX551 (linear low-density polyethylene, manufactured by Sumitomo Chemical Co., Ltd.) Incidentally, no antioxidant is blended in the base resin B1.
  • C1 to C5 were used as the antioxidant (C).
  • TMA measurements were performed using a Mettler Toledo TMA/SDTA840 model. Using 2.0 to 3.0 mg of sample, the temperature was raised at a rate of 5° C./min to observe the foaming behavior. More specifically, the sample (master batch precursor) was placed in a container, a load of 0.1 N was applied, the temperature was raised at a rate of 5° C./min, and the height displacement was continuously measured. The temperature at which the height of the sample in the container was maximum was taken as the maximum foaming temperature (T max ).
  • the foaming density was measured for those that had been heat-treated at 230° C. for 3 minutes and those that had been heat-treated at 240° C. for 3 minutes.
  • the masterbatches of the examples and comparative examples were foamed, and the shrinkage resistance was measured. Specifically, about 2.0 to 3.0 mg of the masterbatch was placed in a measurement container (a SUS container with a diameter of 7 mm and a height of 2 mm), an aluminum lid was placed on the top, and a force of 0.1 N was applied to the top with a pressure bar. The container was then placed in a heating furnace of a thermomechanical analysis (TMA) device, and the temperature in the heating furnace was heated for a predetermined time to foam the masterbatch. The temperature in the heating furnace (foaming temperature) was then maintained for a predetermined time, and the height displacement of the masterbatch at each time from the start of heating was measured.
  • TMA thermomechanical analysis
  • the heat treatment elapsed times at which the displacement was 50% during expansion and contraction were determined as 1/2Ta (short-time side) and 1/2Tb (long-time side), respectively, and 1/2Tb-1/2Ta was used as an index of shrinkage resistance.
  • 1/2Ta and 1/2Tb were measured for the following: the temperature inside the heating furnace was raised from 30° C. to 180° C. in a time setting of 2 min, then the temperature was raised from 180° C. to 240° C. in a time setting of 0 min, and a heat treatment was performed at 240° C. for a total heating time of 20 minutes from the 30° C.
  • the temperature inside the heating furnace was raised from 30° C. to 190° C. in a time setting of 2 min, then the temperature was raised from 190° C. to 250° C. in a time setting of 0 min, and a heat treatment was performed at 250° C. for a total heating time of 20 minutes from the 30° C. point.
  • the temperature inside the heating furnace was raised from 30° C. to 170° C. over a time setting of 2 min, then the temperature was raised from 170° C. to 230° C. over a time setting of 0 min, and heat-treated at 230° C. for a total heating time of 30 minutes from the 30° C.
  • the 1 ⁇ 2Ta and 1 ⁇ 2Tb were measured for the following masterbatches.

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PCT/JP2024/016087 2023-06-02 2024-04-24 マスターバッチ、及び発泡成形体 Ceased WO2024247567A1 (ja)

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2012140608A (ja) * 2010-12-15 2012-07-26 Matsumoto Yushi Seiyaku Co Ltd 発泡性樹脂組成物およびその用途
JP2016160414A (ja) * 2015-03-05 2016-09-05 ダイヤプラスフィルム株式会社 発泡樹脂シート用樹脂組成物、および、発泡樹脂シート
JP2019108507A (ja) * 2017-12-20 2019-07-04 株式会社カネカ 熱膨張性マイクロカプセルのマスターバッチ
JP2019529625A (ja) * 2016-09-13 2019-10-17 ダウ グローバル テクノロジーズ エルエルシー 発泡性ケーブル絶縁体用核形成剤
WO2023017822A1 (ja) * 2021-08-11 2023-02-16 積水化学工業株式会社 発泡成形用マスターバッチ及び発泡成形体
JP2023066410A (ja) * 2021-10-28 2023-05-15 三菱エンジニアリングプラスチックス株式会社 熱可塑性樹脂組成物ペレットの製造方法

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2012140608A (ja) * 2010-12-15 2012-07-26 Matsumoto Yushi Seiyaku Co Ltd 発泡性樹脂組成物およびその用途
JP2016160414A (ja) * 2015-03-05 2016-09-05 ダイヤプラスフィルム株式会社 発泡樹脂シート用樹脂組成物、および、発泡樹脂シート
JP2019529625A (ja) * 2016-09-13 2019-10-17 ダウ グローバル テクノロジーズ エルエルシー 発泡性ケーブル絶縁体用核形成剤
JP2019108507A (ja) * 2017-12-20 2019-07-04 株式会社カネカ 熱膨張性マイクロカプセルのマスターバッチ
WO2023017822A1 (ja) * 2021-08-11 2023-02-16 積水化学工業株式会社 発泡成形用マスターバッチ及び発泡成形体
JP2023066410A (ja) * 2021-10-28 2023-05-15 三菱エンジニアリングプラスチックス株式会社 熱可塑性樹脂組成物ペレットの製造方法

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