JP4168418B2 - ポリマー複合発泡体 - Google Patents
ポリマー複合発泡体 Download PDFInfo
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- JP4168418B2 JP4168418B2 JP2002564997A JP2002564997A JP4168418B2 JP 4168418 B2 JP4168418 B2 JP 4168418B2 JP 2002564997 A JP2002564997 A JP 2002564997A JP 2002564997 A JP2002564997 A JP 2002564997A JP 4168418 B2 JP4168418 B2 JP 4168418B2
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- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/022—Foaming unrestricted by cavity walls, e.g. without using moulds or using only internal cores
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- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
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- C08G65/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
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- C08J9/14—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
- C08J9/141—Hydrocarbons
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- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/22—After-treatment of expandable particles; Forming foamed products
- C08J9/228—Forming foamed products
- C08J9/236—Forming foamed products using binding agents
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- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
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- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/33—Agglomerating foam fragments, e.g. waste foam
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- C08L25/02—Homopolymers or copolymers of hydrocarbons
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- C08L61/04—Condensation polymers of aldehydes or ketones with phenols only
- C08L61/06—Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/292—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and sheet metal
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
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- B29K2105/048—Expandable particles, beads or granules
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- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
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- Y10T428/24999—Inorganic
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Description
本発明は、ポリマー複合発泡体(polymeric composite foams)に関する。本発明はまた、ポリマー複合発泡体を製造するための液体組成物、およびこれらの発泡体から形成された絶縁パネルに関する。
ポリマー発泡体(polymeric foams)は、ビル建築における断熱および防音のために広く使用されている。ポリスチレン発泡体のようなポリマー発泡体は、それらの優れた機械的特性、高断熱値(insulation value)および低コストのために、冷却室および工場用の断熱パネル(insulation panels)を形成するために、スチールのシート内に封入されるコアとして広く使用される。これらの断熱パネルの主要な負の特徴は、炎において燃焼および/または溶解して構造的強度の損失へ至るそれらの高い傾向である。他方、フェノールおよびフラン発泡体は優れた耐熱性を有するが、それらの乏しい機械的特性のために、スチールクラッドパネル(steel clad panels)中のコアとして使用され得ない。それらは、非常に硬くそして切断時に脆い表面を形成する。
本発明は、一形態において、発泡されたフェノールまたはフラン(フェノール/フラン)ポリマーの連続相および発泡されたポリスチレンポリマーの分散相を含むポリマー複合発泡体であって、ここで、該複合発泡体は、5〜50% w/wの発泡性の膨張されていないポリスチレンビーズおよび50〜95%のフェノール/フラン樹脂を含む液体発泡性組成物を触媒することによって製造され、ここで、該触媒された発泡性組成物は、外部の熱またはエネルギー源の適用を必要とせずに、該フェノール/フラン樹脂を重合しそして該ポリスチレンポリマーを膨張させるに十分な温度を達成する、ポリマー複合発泡体を提供する。
本発明に好適な樹脂は、合成熱硬化性樹脂である。それらは、例えば、フェノール、置換フェノールまたはフルフリルアルコールとアルデヒド(例えば、ホルムアルデヒド、アセトアルデヒド(acetal dehyde)およびフルフラール)との縮合によって得られ得る。しかし、当業者によって理解されるように、フェノールは、フェノール様化学を有する他の物質(例えば、置換フェノール、クレゾールまたは天然フェノール化合物(例えば、リグニンまたはタンニン))によって、全体的にまたは部分的に、置換され得る。特にタンニンは、本発明において低コスト樹脂増量剤(extender)として相当な量で使用され得る反応性物質である。フルフリルアルコールは、フラン分子構造(即ち、4つの炭素および1つの酸素原子によって形成される環)を含む他の反応性化合物によって置換され得る。該環は、0、1または2つの二重結合を有し得る(好ましくは2つ。これは、該化合物を、より反応性にしそして高温に曝される場合によりチャー(char)形成しやすくするためである)。ホルムアルデヒドは、他のアルデヒドによって置換され得るが、これらは、一般的に、より高価でありそしてより反応性が低く、従って好ましくない。フェノール−ホルムアルデヒド樹脂は、本発明に好適なフェノール樹脂の主なクラス(main class)を構成する。それらは、通常、塩基性触媒の存在下50〜100℃で、フェノールと37〜50%水性ホルムアルデヒドとを反応させることによって製造される。
発泡性混合物を以下の処方を使用して製造した。ここで、パーライトは、フェノール樹脂の発泡の助けとなる核形成剤(nucleating agent)として含まれた:
この実施例は、より高いポリスチレン含有量の効果を例示する。発泡性混合物を、以下の処方を使用して調製した:
この実施例は、より多い膨張および従ってより低い発泡体密度を生じさせる、より高いレベルのフルフリルアルコールの効果を示す。この実施例はまた、フラン樹脂の使用を例示する。
この実施例は、界面活性剤の存在無しに、フェノール樹脂を発泡させることが可能であることを示す。
この実施例は、本発明の方法が非常に低い密度、すなわち30kg/m3未満の複合発泡体を製造するために使用され得ることを示す。
この実施例は、本発明の発泡体の、そのプレライズ(pre-rise)形状の“記憶(memory)”を有する能力を例示する。
Claims (19)
- フランポリマー、又はフェノールポリマー及びフランポリマーの連続相並びに発泡ポリスチレンポリマーの分散相を含むポリマー複合発泡体であって、ここで、該複合発泡体は、5〜50% w/wの発泡性の膨張されていないポリスチレンビーズと、50〜95% w/wのフラン樹脂、フェノール樹脂及びフラン樹脂、並びに、フェノール樹脂及びフルフリルアルコールからなる群より選択される樹脂又は樹脂混合物と、有効量の酸触媒とを含む液体発泡性組成物を反応させることによって製造され、ここで、反応させた発泡性組成物は、外部の熱またはエネルギー源の適用を必要とせずに、該樹脂又は樹脂混合物を重合しそして該ポリスチレンポリマーを膨張させるに十分な温度を達成する、ポリマー複合発泡体。
- 前記フラン樹脂が、フルフリルアルコールを含有する、請求項1に記載のポリマー複合発泡体。
- 前記複合発泡体中のポリスチレンポリマーの重量パーセントが5〜50の範囲内である、請求項1又は2に記載のポリマー複合発泡体。
- 前記複合発泡体中のポリスチレンポリマーの重量パーセントが10〜40である、請求項1又は2に記載のポリマー複合発泡体。
- 前記複合発泡体が25〜200kg/m3の範囲の密度を有する、請求項1又は2に記載のポリマー複合発泡体。
- 前記複合発泡体が25〜50kg/m3の範囲の密度を有する、請求項1又は2に記載のポリマー複合発泡体。
- 前記複合発泡体が50〜200kg/m3の範囲の密度を有する、請求項1又は2に記載のポリマー複合発泡体。
- 前記連続相中のフランポリマー、又はフェノールポリマー及びフランポリマーが発泡されている、請求項1に記載のポリマー複合発泡体。
- フランポリマー、又はフェノールポリマー及びフランポリマーの連続相並びに発泡ポリスチレンポリマーの分散相を含むポリマー複合発泡体であって、ポリスチレンに対するフェノールポリマー及び/又はフランポリマーの重量比が少なくとも1であるポリマー複合発泡体のコアを有するスチールクラッド絶縁パネル。
- 前記フランポリマー、又はフェノールポリマー及びフランポリマーが発泡されている、請求項9に記載のスチールクラッド絶縁パネル。
- 5〜50% w/wの発泡性ポリスチレンビーズ、50〜95% w/wのフェノール樹脂及び/又はフラン樹脂ならびに有効量の酸触媒を含む液体発泡性組成物を、塊形状において臨時型に添加すること、ならびに該液体発泡性組成物が膨張し始めた後に該臨時型を除去することを包含する、ポリマー複合発泡体の塊の形成方法であって、ここで、該発泡性組成物は、外部の熱またはエネルギー源の適用を必要とせずに、該フェノール樹脂及び/又はフラン樹脂を重合しそして該ポリスチレンポリマーを膨張させるに十分な温度を達成する、方法。
- 前記フェノール樹脂又はフラン樹脂がフルフリルアルコールと混合されている、請求項11に記載の方法。
- 前記臨時型を外側型(outer mould)上に配置し、該外側型は膨張後の前記複合発泡体の形状を規定する、請求項11に記載の方法。
- 前記フェノール樹脂及び/又はフラン樹脂が発泡される、請求項11または12に記載の方法。
- 前記反応させた発泡性組成物が少なくとも80℃に達する、請求項1に記載のポリマー複合発泡体。
- 前記反応させた発泡性組成物が少なくとも90℃に達する、請求項1に記載のポリマー複合発泡体。
- 前記反応させた発泡性組成物が少なくとも100℃に達する、請求項1に記載のポリマー複合発泡体。
- 難燃剤、膨張性グラファイト、発泡剤(intumescent agents)および充填剤からなる群から選択される添加剤を含む、請求項1に記載のポリマー複合発泡体。
- 前記難燃剤が炎に曝されるとアンモニアガスを放出する、請求項18に記載のポリマー複合発泡体。
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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AUPR3091A AUPR309101A0 (en) | 2001-02-14 | 2001-02-14 | Polymeric composite foam |
PCT/AU2002/000152 WO2002064672A1 (en) | 2001-02-14 | 2002-02-14 | Polymeric composite foam |
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JP2004521975A JP2004521975A (ja) | 2004-07-22 |
JP2004521975A5 JP2004521975A5 (ja) | 2005-12-22 |
JP4168418B2 true JP4168418B2 (ja) | 2008-10-22 |
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EP (1) | EP1368421B1 (ja) |
JP (1) | JP4168418B2 (ja) |
KR (1) | KR100714373B1 (ja) |
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AU (2) | AUPR309101A0 (ja) |
BR (1) | BR0207250B1 (ja) |
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DE (1) | DE60223228T2 (ja) |
DK (1) | DK1368421T3 (ja) |
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JP2011219621A (ja) * | 2010-04-09 | 2011-11-04 | Sekisui Chem Co Ltd | 発泡性樹脂組成物および樹脂発泡体 |
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