JP2007191518A - Foam-molded article of thermoplastic resin particle - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a foam-molded article of thermoplastic resin particles exhibiting dimensional stability and a high compression strength under a high temperature. <P>SOLUTION: This foam-molded article of the thermoplastic resin particles is provided by being obtained from the foaming thermoplastic resin particles, having ≥50 to ≤250 kg/m<SP>3</SP>density, heat resistance and ≥5 kgf/cm<SP>2</SP>compression strength at 80°C, and a supporting body consisting of the same is also provided. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a foamed thermoplastic resin particle article having excellent dimensional stability and compressive strength at high temperatures.

  Supports for structures such as containers, tanks and pipes where the contents can become hot, sleepers that can be exposed to high temperatures outdoors, ceiling materials such as cars and buildings, flooring, wall materials, etc. For the so-called support, a material that exhibits high compressive strength at a high temperature is used. Generally, concrete, metal, and the like are widely used from the viewpoint of ease of forming and cost.

  However, in recent years, even in such fields, energy saving and weight reduction have been demanded. From these viewpoints, lightweight materials having heat insulating properties and heat retaining properties have been desired.

  Typical heat insulation materials include glass wool, rock wool, calcium silicate, etc., but because of its high water absorption, heat insulation performance can be achieved by absorbing rainwater, etc. for applications that are intended for outdoor use. However, there was a drawback that it was significantly reduced. Furthermore, since fiber-based heat insulating materials such as glass wool and rock wool are not self-supporting and cannot provide strength as a structure, a support device having a special structure as in Patent Document 1 is required. .

As a material to compensate for these drawbacks, there is a urethane foam molded body made of a thermosetting resin. The molded product made of urethane foam has higher molded product strength than glass wool and rock wool, and is used in a wide range of fields. However, in order to use the urethane foam molded article for the above-mentioned use, it is necessary to use it at a high density of 300 kg / m ³ or more, and sufficient heat insulation performance cannot be obtained. There was a drawback that the corners were missing. In addition, there are cases where corroded stainless steel and other metals are corroded by free chlorine and amine-based catalysts, and as a member in such fields that are often used in contact with metal over a long period of use. Was insufficient. In order to prevent such corrosion, Patent Document 2 discloses a method of attaching a buyer film to a contact surface with metal, and Patent Document 3 discloses a phenol urethane foam heat insulating material modified with a novolac resin. Yes. Furthermore, although the heat insulation support apparatus by the blow molding goods which use a thermoplastic resin as a material is disclosed by patent document 4, all will become a more expensive thing.

  On the other hand, the thermoplastic resin particle foam molded article is widely recognized as a material having excellent buffer performance and heat insulation performance and high utility value. Since these molded products are made of thermoplastic resin, they can be easily foamed by a heat source such as water vapor, and can be molded into special shapes by in-mold foam molding. A wide range of food containers, heat insulating materials, cushioning materials, etc. Used in the field.

For example, a styrene-based foam molded body, which is one of thermoplastic resin particle foam molded bodies, can be easily molded by a heat source such as water vapor, and can be molded into a shape suitable for the application by in-mold foam molding. Therefore, it is used for a wide range of purposes. However, due to the characteristics of the thermoplastic resin foam, the dimensional stability at high temperatures is poor, and there is a drawback in that it may be difficult to obtain a sufficient compressive strength against the loaded load. At most, it is set to 80 ° C. or lower. In Patent Document 5, monomers constituting the polymer are 10 to 80% by weight of α-methylstyrene, 5 to 50% by weight of acrylonitrile, styrene, chlorostyrene, paramethylstyrene, t-butylstyrene, acrylic ester, An expanded molded article obtained from expandable thermoplastic copolymer particles in which at least one compound selected from methacrylic acid esters is 0 to 70% by weight has excellent dimensional stability when left at 168 hours at 100 ° C. However, the foamable thermoplastic particles constituting the foamed molded article specifically shown in the literature, for example, in Example 1, contains 10 parts by weight of a volatile foaming agent. In addition, since the polymerization conversion rate is 99.4%, the amount of residual monomer is large, and since 1.0 part by weight of toluene is contained, it does not show good compressive strength at high temperatures.
Japanese Patent Laid-Open No. 9-14511 JP 7-293786 A Utility Model Registration No. 3083734 Japanese Patent Laid-Open No. 11-63302 JP-A-60-206850 JISA9511: 2003

  In view of the above situation, the present invention is to provide a thermoplastic resin particle foamed molded article having heat insulation and workability, and exhibiting dimensional stability and high compressive strength at high temperatures.

  As a result of intensive studies to solve the above problems, the foamable thermoplastic resin particles contain 2% by weight or more and 5% by weight or less of the readily volatile foaming agent, and the content of the organic softening agent is 0.7% by weight or less. As a result, it was found that the molded article can be excellent in heat insulation, dimensional stability at high temperature and compressive strength, and has led to the present invention.

That is, the present invention is a foam-molded article obtained from expandable thermoplastic resin particles, having a density of 50 kg / m ³ or more and 250 kg / m ³ or less, heat resistance, and compression at 80 ° C. The present invention relates to a thermoplastic resin particle foam molded article having a strength of 5 kgf / cm ² or more.

As a preferred embodiment,
(1) The foamable thermoplastic resin particles contain 2% by weight or more and 5% by weight or less of the easily volatile foaming agent, and the content of the organic softening agent capable of plasticizing the foamable thermoplastic resin particles is 0.7% by weight. Is
(2) The expandable thermoplastic resin particles are composed of a styrene-based monomer composition of 10% to 80% by weight of alphamethylstyrene, 5% to 50% by weight of acrylonitrile, and further 85% by weight or less.
(3) has self-extinguishing properties,
The present invention relates to the thermoplastic resin particle foam molded article described above.

  2nd of this invention is related with the support body which consists of a thermoplastic resin particle foaming molding of the said description.

The foamed molded product of the present invention has heat resistance and a compressive strength at 80 ° C. of 5 kgf / cm ² or more. Therefore, support bases for structures such as containers, tanks, pipes, etc., conventionally used with concrete, metal, etc., various members near the hot air outlet, air conditioner mounts, sleepers exposed to high temperatures outdoors, It can be suitably used as a support for heavy objects such as ceiling materials, floor materials, and wall materials such as automobiles and buildings, particularly for a support that can be installed in a place exposed to an environment with a large temperature difference.

The thermoplastic resin particle foam molded article of the present invention (hereinafter sometimes simply referred to as a foam molded article) is a foam molded article obtained from expandable thermoplastic resin particles, and has a density of 50 kg / m ³ or more and 250 kg / m ³ or less, heat resistance, and compressive strength at 80 ° C. is 5 kgf / cm ² or more.

  The heat resistance in the present invention refers to dimensional stability at a high temperature, and specifically means that the dimensional change rate at 168 hours at 80 ° C. is within ± 0.5%. If the dimensional change rate is within ± 0.5%, it can be suitably used for a support having a high shape retention capability.

The density of the foamed molded product in the present invention is represented by the weight per apparent volume of the thermoplastic resin particle foamed molded product, and is 50 kg / m ³ or more and 250 kg / m ³ or less. Preferably, 80 kg / ^{m 3} or more 200 kg / ^{m 3} or less, still more preferably not more than 80 kg / ^{m 3} or more 100 kg / ^{m 3.} Within this range, the density can be appropriately selected depending on the load to be processed. If it is 50 kg / m ³ or more, strength for supporting heavy objects can be obtained, and if it is 250 kg / m ³ or less, excellent heat insulation performance is exhibited, so that sufficient heat insulation and heat retention effects can be obtained.

In the present invention, the compressive strength at 80 ° C. refers to the compressive strength at 5% strain measured after curing the molded body at a temperature of 80 ° C. for 1 hour or more. The thermoplastic resin particle foam molded body of the present invention has 5 kgf. / Cm ² or more, preferably 5 kgf / cm ² or more and 50 kgf / cm ² or less. If it is 5 kgf / cm ² or more, it can be said that the strength is sufficient to support heavy objects.

  The thermoplastic resin constituting the expandable thermoplastic resin particles of the present invention is not particularly limited. For example, a resin mainly composed of polystyrene, a resin mainly composed of polypropylene, and a resin mainly composed of polymethacrylate. And a resin mainly composed of polyvinyl chloride. Among them, the monomer composition constituting the thermoplastic resin is 10% by weight to 80% by weight of alphamethylstyrene, 5% by weight to 50% by weight of acrylonitrile. Further, it is preferably composed of 85% by weight or less of a styrene monomer, more preferably 10% by weight to 50% by weight of alphamethylstyrene, 5% by weight to 35% by weight of acrylonitrile, and 80% by weight or less. It is preferably composed of a styrene monomer. If it is a composition within the said range, it exists in the tendency for the foaming molding which has heat resistance to be obtained.

  The foamable thermoplastic resin particles of the present invention contain an easily volatile foaming agent in the foamable thermoplastic resin particles in an amount of 2% by weight to 5% by weight, and can be used to plasticize the foamable thermoplastic resin particles. Is preferably 0.7% by weight or less in the foamable thermoplastic resin particles. If the easily volatile foaming agent is 2% by weight or more, the foaming force necessary for foaming is obtained, and if it is 5% by weight or less, the excess foaming force does not remain and tends to exhibit good compressive strength at high temperatures. .

  Examples of the organic softening agent that can be plasticized in the present invention include solvents such as toluene, xylene, and ethylbenzene used for the purpose of supplementing foaming power, or plasticizers such as phthalic acid esters and adipic acid esters, Alternatively, it refers to an unreacted polymer such as alpha methyl styrene, acrylonitrile, styrene monomer used to obtain thermoplastic resin particles. If the content of the organic softening agent is 0.7% by weight or less, it tends to exhibit good compressive strength at high temperatures.

  Methods for reducing the organic softener to 0.7% by weight or less include a method for reducing the amount of monomer remaining in the foamable thermoplastic particles by increasing the polymerization conversion rate, and the amount of solvent or plasticizer added. The method of reducing this etc. is mentioned.

  The organic softening agent can be obtained by a generally known analysis method. For example, it can be obtained by dissolving resin particles and using gas chromatography (GC) with reference to an internal standard substance.

  Examples of the readily volatile foaming agent in the present invention include aliphatic hydrocarbons such as propane, butane and pentane, cyclic aliphatic hydrocarbons such as cyclobutane, cyclopentane and cyclohexane, and trichlorofluoromethane, dichlorofluoromethane, Halogenated hydrocarbons such as chlorodifluoromethane, methyl chloride, dichlorotetrafluoroethane, ethyl chloride and the like can be mentioned, and these can be used alone or in admixture of two or more.

  The support of the present invention has a structure that is laid under the heavy object and supports the whole weight or a part of the heavy object. Specifically, a hot water tank, a hot water tank, a fermentation tank, etc. Insulation supports and floors for structures such as containers and tanks where the contents can become hot, and insulation supports that support piping for hot water, hot water, steam, etc. can be mentioned, but the place to use is located at the bottom of the structure The present invention is not limited to this, and it can be suitably used for a side wall surface and a top surface on which a load is applied due to tightening of a mounting bracket or the like and a roll in an earthquake. In addition, since it is a foamed molded article with excellent heat insulation properties, not only when the contents are hot, but also in heat storage tanks, tanks, pipes, etc. that are also used for heating and cooling by appropriately switching the contents to cooling water or brine It is suitable and can effectively prevent condensation as well as loss of thermal energy. The shape used may be a flat plate, but in particular, in the present invention, a molded body having a shape matched to the situation and irregularities can be obtained inexpensively and easily on an in-mold molding machine usually used with expanded polystyrene, In the case of a shape having a curved surface, irregularities or grooves, the utility value is high.

  Also, heavy objects such as solar panels, solar water heaters, and outdoor units of air conditioning equipment when used as roof insulation base materials and roof insulation base materials for buildings that become hot when exposed to direct sunlight. Can be installed without extensive reinforcement work. It can also be suitably used for the ceiling of vehicles such as trucks and freight cars, and for the foundation of ship decks.

  Other examples include various members used at high temperatures such as in the vicinity of a hot air outlet, sleepers that may be exposed to high temperatures in the outdoors, air conditioner mounts and drain pans, and wall materials such as buildings. However, the present invention is not limited to this. In addition, the embodiment may be covered with a metal plate, foil, resin or the like in order to protect the surface.

  Since the foamed molded article of the present invention may be used in an environment where there is a possibility of contact with fire during assembly or use, it is preferable to have self-extinguishing properties. The self-extinguishing property in the present invention means that the extinguishing time is within 3 seconds in the JISA9511: 2003 flammability test.

  In order for the support in the present invention to have self-extinguishing properties, for example, a method using a flame retardant can be mentioned. A flame retardant having a melting point of 80 ° C. or higher is preferable. Examples of such flame retardants include halogen-based flame retardants, and specific examples include hexabromocyclododecane, tetrabromobisphenol A and diallyl ether, and monochloropentabromocyclohexane. A good self-extinguishing property can be imparted to the foamed molded article by a method such as adding such a flame retardant when producing foamable thermoplastic particles.

  As an example of a method for obtaining expandable thermoplastic resin particles as a thermoplastic resin particle foam molded article in the present invention, a polymer obtained by a polymerization method such as an emulsion polymerization method or a bulk polymerization method is formed into a pellet shape. An example is a method of further impregnating with a foaming agent after granulation. Moreover, the method etc. which impregnate the granulated polymer particle obtained by the suspension polymerization method with a foaming agent are mention | raise | lifted. There are no particular restrictions on the production method and impregnation method of the foaming agent, but the suspension polymerization method is preferred because of the simplicity of the process.

The foamable thermoplastic resin particles obtained in this way are expanded into pre-expanded particles having a desired density as required, filled into a mold having a desired shape, and heat-fused to obtain thermoplasticity. Let it be a resin particle foam molding. The obtained foamed molded product is a foamed molded product having a density of 50 kg / m ³ or more and 250 kg / m ³ or less, has heat resistance, and has a compressive strength at 80 ° C. of 5 kgf / cm ² or more. is there.

Examples and Comparative Examples are given below, but the present invention is not limited thereby. In the measurement evaluation method, items other than those described above were carried out as follows.
<Heat resistance>
A sample piece obtained by cutting the foamed molded product into 150 × 150 × 20 (t) mm was measured in accordance with JIS K 6767 (dimensional stability at high temperature: method B), and the heating dimensional change rate after 168 hours at 80 ° C. It was measured. Moreover, the state of the molded body shape after the measurement was observed and evaluated visually.
<Compressive strength at 80 ° C>
A sample piece obtained by cutting the foamed molded product into 50 × 50 × 20 (t) mm was held at 80 ° C. for 1 hour, and then the compressive strength at 5% strain was measured using an autograph.
<Self-extinguishing>
A sample piece obtained by cutting the foamed molded product into 25 × 200 × 10 (t) mm was measured in accordance with JIS A 9511 (combustibility) until the flame disappeared. Flames that disappeared within 3 seconds, had no residue, and did not burn beyond the combustion limit indicating line were accepted.
<Shape retention at high temperatures>
A sample piece obtained by cutting the foam molded body into 50 × 50 × 20 (t) mm was applied with a load of 1 kg / cm ² at 80 ° C., and the appearance of the foam molded body after 168 hours was observed.

(Examples 1-3)
A reactor equipped with a stirrer was charged with 100 parts by weight of pure water, 0.1 part by weight of tribasic calcium phosphate, and 0.004 part by weight of sodium α-olefin sulfonate, and 30 parts by weight of alphamethylstyrene and acrylonitrile 20 with stirring. 6 parts by weight of hexastyrene cyclododecane, 0.5 parts by weight of 2,3-dimethyl-2,3-diphenylbutane, 0.5 parts by weight of dicumyl peroxide and polymerization initiation The agent was mixed and added to the autoclave, and polymerization was carried out at 100 ° C. for 8 hours. Next, 5 parts by weight of butane was added and impregnated with a blowing agent at 100 ° C. for 8 hours (the total amount of unreacted polymerization products of alphamethylstyrene, acrylonitrile and styrene monomer was 0.4% by weight, No softener was detected). The obtained thermoplastic foamed resin particles were washed and dehydrated, and then pre-foamed to the density shown in Table 1 by heating with water vapor, and allowed to stand at room temperature for 1 day for curing and drying. Next, the obtained thermoplastic resin pre-expanded particles were obtained by using a KR-57 molding machine manufactured by Daisen to obtain a foam-molded product with a 300 × 450 × 20 (t) mm size mold. Evaluation was performed using the obtained thermoplastic resin particle foamed molded article, and the results shown in Table 1 were obtained.

(Comparative Example 1)
After obtaining the thermoplastic resin expanded particles in the same manner as in Example 1, a molded product having the density shown in Table 1 was obtained by the same operation, and evaluation was performed to obtain the results shown in Table 1.

(Comparative Example 2)
A reactor equipped with a stirrer is charged with 100 parts by weight of pure water, 0.2 part by weight of tribasic calcium phosphate, and 0.004 part by weight of sodium α-olefin sulfonate, and with stirring, 100 parts by weight of styrene and a polymerization initiator are mixed. Then, it was added to the autoclave and polymerized at 100 ° C. for 4 hours. Next, 5 parts by weight of butane was added and impregnated with a foaming agent at 115 ° C. for 3 hours (the total amount of unreacted styrene monomer polymerization was 0.4% by weight, and no other organic softening agents were detected. ) Thereafter, the obtained foamed thermoplastic resin particles were treated in the same manner as in Example 1 to obtain a molded product having the density shown in Table 1, evaluated, and the results shown in Table 1 were obtained.

(Comparative Example 3)
Using the foamable thermoplastic polymer particles obtained in the same manner as described in Example 2 of JP-A-60-206850, a molded product having the expansion ratio shown in Table 1 was obtained and evaluated. The results shown in Table 1 were obtained.

Claims (5)

A foam molded article obtained from expandable thermoplastic resin particles, having a density of 50 kg / m ³ or more and 250 kg / m ³ or less, heat resistance, and a compressive strength at 80 ° C. of 5 kgf / cm ² The thermoplastic resin particle foam molded body as described above.   The foamable thermoplastic resin particles contain 2% by weight or more and 5% by weight or less of a readily volatile foaming agent, and the content of the organic softening agent capable of plasticizing the foamable thermoplastic resin particles is 0.7% by weight or less. The thermoplastic resin particle foam molded article according to claim 1.   The foamable thermoplastic resin particles are composed of a styrenic monomer composition of 10% to 80% by weight of alphamethylstyrene, 5% to 50% by weight of acrylonitrile, and further 85% by weight or less. 2. The thermoplastic resin particle foam molded article according to 2.   The thermoplastic resin particle foam molded article according to any one of claims 1 to 3, which has self-extinguishing properties.   The support body which consists of a thermoplastic resin particle foaming molding in any one of Claims 1-4.