JPH085984B2 - Polypropylene resin composition for foam, laminated sheet and laminated body - Google Patents
Polypropylene resin composition for foam, laminated sheet and laminated bodyInfo
- Publication number
- JPH085984B2 JPH085984B2 JP2369492A JP2369492A JPH085984B2 JP H085984 B2 JPH085984 B2 JP H085984B2 JP 2369492 A JP2369492 A JP 2369492A JP 2369492 A JP2369492 A JP 2369492A JP H085984 B2 JPH085984 B2 JP H085984B2
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- Prior art keywords
- weight
- resin
- sheet
- laminated sheet
- layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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Landscapes
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
- Laminated Bodies (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Description
【０００１】[0001]
【産業上の利用分野】本発明は発泡体用ポリプロピレン
系樹脂組成物、及び該組成物を用いた積層シート並びに
積層体に関する。詳しくは、本発明は、発泡倍率の高い
発泡樹脂体を容易かつ効率的に得ることができる発泡体
用ポリプロピレン系樹脂組成物、該組成物を用いて得ら
れる、自動車の内装品、具体的には自動車の内壁部、座
席、背もたれ等に張りつけて用いるに好適な、軽量で曲
げ剛性に優れたポリプロピレン積層シート及び積層体に
関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a polypropylene resin composition for foams, a laminated sheet and a laminated body using the composition. Specifically, the present invention relates to a polypropylene-based resin composition for a foam capable of easily and efficiently obtaining a foamed resin body having a high expansion ratio, an automobile interior part obtained by using the composition, specifically The present invention relates to a polypropylene laminated sheet and a laminated body, which are suitable for being attached to an inner wall portion, a seat, a backrest, etc. of an automobile and are lightweight and have excellent bending rigidity.
【０００２】[0002]
【従来の技術】ポリオレフィン系樹脂を基体とする発泡
体の製造方法として、該ポリオレフィン系樹脂に化学発
泡剤を添加した後、加熱溶融して発泡させる方法があ
る。例えば、ポリプロピレン系樹脂の発泡体を得る場合
には、該ポリプロピレン系樹脂に一般に使用される発泡
剤であるアゾジカルボンアミドを添加した後、その樹脂
組成物を加熱溶融することが行われる。2. Description of the Related Art As a method for producing a foam based on a polyolefin resin, there is a method in which a chemical foaming agent is added to the polyolefin resin and then the resin is heated and melted to foam. For example, in the case of obtaining a polypropylene-based resin foam, azodicarbonamide, which is a foaming agent generally used, is added to the polypropylene-based resin, and then the resin composition is heated and melted.
【０００３】一方、自動車の内装材として用いられるシ
ート状部品としては、外観が優れていること、軽量であ
ること、曲げ剛性が高く、しかも、生産コストが安価で
あることが要望されている。On the other hand, sheet-like parts used as interior materials for automobiles are required to have excellent appearance, light weight, high bending rigidity, and low production cost.
【０００４】従来、自動車内装用シートにおいて、良好
な外観を得るためには、その要望を満たす織布または不
織布を、ベースとなるシート状の基材に貼合わせること
が行なわれている。例えば、シート状の基材としてはポ
リオレフィン系樹脂のような熱可塑性樹脂からなるシー
トが用いられ、これに織布、不織布のようなシート状物
を表皮材として積層し、得られたシート状の積層体を熱
成形によって所望の形状に成形している。[0004] Conventionally, in order to obtain a good appearance in an automobile interior sheet, a woven or non-woven fabric satisfying the demand has been attached to a sheet-like base material as a base. For example, a sheet made of a thermoplastic resin such as a polyolefin-based resin is used as the sheet-shaped substrate, and a sheet-shaped material such as a woven fabric or a nonwoven fabric is laminated as a skin material on the sheet-shaped substrate to obtain a sheet-shaped substrate. The laminated body is formed into a desired shape by thermoforming.
【０００５】[0005]
【発明が解決しようとする課題】前述の化学発泡剤を用
いるポリオレフィン系樹脂発泡体の製造方法では、用い
る発泡剤の種類及び添加量により、得られる発泡体の発
泡倍率は若干異なるものの高々２倍未満であり、発泡倍
率が２倍以上と高倍率の所望の発泡体を容易に得ること
は困難であった。In the method for producing a polyolefin resin foam using the above-mentioned chemical foaming agent, the foaming ratio of the resulting foam is slightly different depending on the kind and the amount of the foaming agent used, but at most twice. It is difficult to easily obtain a desired foam having a high expansion ratio of 2 times or more.
【０００６】また、前記従来のシート状積層体におい
て、その軽量化をはかるために、基材となる樹脂シート
の肉厚を薄くすると、基材の曲げ強度が低下する。そこ
で、この問題を解消するために、樹脂シート材料にフィ
ラーを混和し、基材自体の剛性を上げると、比重が増大
するため、一層肉薄にする必要が生ずるなど、軽量化と
基材の曲げ剛性向上とを併せて達成しようとすることは
極めて困難であった。Further, in the conventional sheet-like laminated body, if the thickness of the resin sheet as the base material is reduced in order to reduce its weight, the bending strength of the base material is lowered. Therefore, in order to solve this problem, if a filler is mixed into the resin sheet material to increase the rigidity of the base material itself, the specific gravity increases, so that it becomes necessary to make the thickness even thinner. It has been extremely difficult to achieve the improvement in rigidity together.
【０００７】本発明は上記従来の問題点を解決し、発泡
倍率の高い発泡体を容易にかつ効率的に得ることができ
る発泡体用ポリプロピレン系樹脂組成物、並びにこれを
用いて得られる、軽量でしかも曲げ剛性に優れた積層シ
ート及び積層体を提供することを目的とする。The present invention solves the above-mentioned problems of the prior art and makes it possible to easily and efficiently obtain a foam having a high expansion ratio, and a polypropylene resin composition for foam, and a lightweight resin composition obtained by using the same. Moreover, it is an object of the present invention to provide a laminated sheet and a laminate having excellent bending rigidity.
【０００８】[0008]
【課題を解決するための手段】請求項１の発泡体用ポリ
プロピレン系樹脂組成物は、ポリプロピレン系樹脂１０
０重量部に、予め水分を２重量％以上含浸させた多孔質
フィラー０．５〜１０重量部と、化学発泡剤０．１〜１
重量部とを配合してなることを特徴とする。A polypropylene-based resin composition for foam according to claim 1 is a polypropylene-based resin 10
0.5 to 10 parts by weight of a porous filler, which is previously impregnated with 0% by weight of water in an amount of 2% by weight or more, and a chemical foaming agent of 0.1 to 1
It is characterized by being mixed with parts by weight.
【０００９】請求項２の積層シートは、上層と下層とが
中間層を介して積層されてなる積層シートにおいて、該
上層及び下層はポリプロピレン系樹脂からなるソリッド
樹脂層であり、かつ、該中間層は、請求項１に記載のポ
リプロピレン系樹脂組成物を発泡倍率２倍以上に発泡成
形して得られた発泡樹脂層であることを特徴とする。The laminated sheet of claim 2 is a laminated sheet in which an upper layer and a lower layer are laminated with an intermediate layer interposed therebetween, wherein the upper layer and the lower layer are solid resin layers made of polypropylene resin, and the intermediate layer. Is a foamed resin layer obtained by foaming the polypropylene resin composition according to claim 1 at a foaming ratio of 2 times or more.
【００１０】請求項３の積層体は、請求項２に記載の積
層シートの片面に、伸縮性を有する表皮材を積層してな
ることを特徴とする。According to a third aspect of the present invention, a laminated sheet according to the second aspect is formed by laminating a stretchable skin material on one surface.
【００１１】即ち、本発明者等は上記従来の問題に鑑
み、ポリプロピレン系樹脂と化学発泡剤よりなる組成物
を添加溶融して発泡倍率の高い発泡体を容易かつ効率的
に得る方法について鋭意検討を重ねた結果、ポリプロピ
レン系樹脂と化学発泡剤よりなる組成物に更に予め特定
量の水分を含浸させた多孔質フィラーを配合することに
より、該多孔質フィラーと化合発泡剤との相乗効果で発
泡性が改良され、発泡倍率が２倍以上という高発泡性樹
脂発泡体が得られることを見出した。That is, in view of the above conventional problems, the present inventors have earnestly studied a method for easily and efficiently obtaining a foam having a high expansion ratio by adding and melting a composition comprising a polypropylene resin and a chemical foaming agent. As a result, by adding a porous filler impregnated with a specific amount of water in advance to a composition consisting of a polypropylene resin and a chemical foaming agent, foaming is achieved by the synergistic effect of the porous filler and the compounding foaming agent. It was found that a highly expandable resin foam having improved foamability and a foaming ratio of 2 or more can be obtained.
【００１２】併せて、本発明者等は樹脂シートの軽量化
と基材の曲げ剛性の向上について鋭意検討を重ねた結
果、外層と内層をポリプロピレン系樹脂からなるソリッ
ド層とし、中間層をポリプロピレン系樹脂からなる発泡
倍率２倍以上の発泡層からなる三層積層シートとするこ
とにより、上記目的が達成できることを見出した。本発
明は上記このような知見に基き完成されたものである。
以下に本発明を詳細に説明する。In addition, the inventors of the present invention have made extensive studies as to the weight reduction of the resin sheet and the improvement of the bending rigidity of the base material. As a result, the outer layer and the inner layer are solid layers made of polypropylene resin, and the intermediate layer is polypropylene type. It has been found that the above object can be achieved by using a three-layer laminated sheet made of a resin and having a foaming ratio of 2 times or more. The present invention has been completed based on the above findings.
The present invention will be described in detail below.
【００１３】請求項１の発泡体用ポリプロピレン系樹脂
組成物において、原料として用いられるポリプロピレン
系樹脂としては、例えば、結晶性を有するアイソタクチ
ックプロピレン単独重合体や、エチレン単位の含有量が
少ないエチレンプロピレンランダム共重合体から成る共
重合部又はプロピレン単独重合体からなるホモ重合部と
エチレン単位の含有量が比較的多いエチレンプロピレン
ランダム共重合体から成る共重合部とから構成された、
いわゆるプロピレンブロック共重合体として市販されて
いる実質上結晶性のプロピレンとエチレンとのブロック
共重合体、或いは、このブロック共重合体における各ホ
モ重合部又は共重合部が、更にブテン−１などのα−オ
レフィンを共重合してなる実質上結晶性のプロピレン−
エチレン−α−オレフィン共重合体などが挙げられる。In the polypropylene resin composition for foams according to claim 1, as the polypropylene resin used as a raw material, for example, crystalline isotactic propylene homopolymer or ethylene having a low ethylene unit content is used. A copolymer part composed of a propylene random copolymer or a homopolymer part composed of a propylene homopolymer and a copolymer part composed of an ethylene propylene random copolymer having a relatively large content of ethylene units,
A substantially crystalline block copolymer of propylene and ethylene, which is commercially available as a so-called propylene block copolymer, or each homopolymerization part or copolymerization part in this block copolymer further includes butene-1 and the like. Substantially crystalline propylene obtained by copolymerizing α-olefin
Examples thereof include ethylene-α-olefin copolymers.
【００１４】このようなポリプロピレン系樹脂には、必
要に応じて熱安定剤、紫外線吸収剤、酸化防止剤、着色
剤等の各種添加剤を配合することができる。なお、ポリ
プロピレン系樹脂としては、メルトインデックス（ＭＦ
Ｒ）が０．５〜２０ｇ／１０分の範囲のものが好適に用
いられる。If desired, various additives such as a heat stabilizer, a UV absorber, an antioxidant and a colorant may be added to the polypropylene resin. As a polypropylene resin, the melt index (MF
Those in which R) is in the range of 0.5 to 20 g / 10 minutes are preferably used.
【００１５】また、化学発泡剤としては、加熱によって
ガスを発生する分解型発泡剤、例えば、アゾジカルボン
アミド、ジニトロペンタメチレンテトラミン、アゾジイ
ソブチロニトリル等が挙げられる。上記化学発泡剤の配
合量は、ポリプロピレン系樹脂１００重量部に対して
０．１〜１重量部、好ましくは０．２〜０．８重量部の
範囲である。この化学発泡剤の配合量が０．１重量部未
満では発泡効果が十分でなく、また１重量部より多いと
発泡により形成されるセル（気泡）が大きくなりすぎて
気泡のふき破れが起こり、発泡倍率が逆に低下する等、
発泡成形性が悪化する。As the chemical foaming agent, decomposition type foaming agents which generate gas by heating, for example, azodicarbonamide, dinitropentamethylenetetramine, azodiisobutyronitrile and the like can be mentioned. The compounding amount of the chemical foaming agent is 0.1 to 1 part by weight, preferably 0.2 to 0.8 part by weight, based on 100 parts by weight of the polypropylene resin. If the compounding amount of this chemical foaming agent is less than 0.1 parts by weight, the foaming effect is not sufficient, and if it is more than 1 part by weight, the cells (bubbles) formed by foaming become too large and the bubbles burst. On the contrary, the expansion ratio decreases, etc.
Foam moldability deteriorates.
【００１６】多孔質フィラーとしては、多孔性の無機物
であれば良く特に制限はないが、例えば、珪藻土、活性
炭、炭酸カルシウム、塩化カルシウム、モレキュラシー
ブ等が用いられる。このような多孔質フィラーに含浸さ
せる水分量は、該多孔質フィラーに対して２重量％以
上、好ましくは２〜２０重量％、より好ましくは５〜１
５重量％の範囲である。該水分の含浸量が２重量％未満
では、上記化学発泡剤との併用配合による相乗効果が十
分に得られない。また、含浸量は多過ぎると成形時の発
泡現象が著しく多くなり、成形性が悪化するので、該水
分の含浸量としては２０重量％以下が望ましい。The porous filler is not particularly limited as long as it is a porous inorganic substance, and for example, diatomaceous earth, activated carbon, calcium carbonate, calcium chloride, molecular sieve and the like are used. The amount of water impregnated into such a porous filler is 2% by weight or more, preferably 2 to 20% by weight, and more preferably 5 to 1% with respect to the porous filler.
It is in the range of 5% by weight. When the impregnated amount of the water is less than 2% by weight, the synergistic effect due to the combined use with the chemical foaming agent cannot be sufficiently obtained. Further, if the amount of impregnation is too large, the foaming phenomenon at the time of molding remarkably increases and the moldability deteriorates. Therefore, the amount of impregnation of the water is preferably 20% by weight or less.
【００１７】上記水分を特定量含浸させた多孔質フィラ
ーの配合量は、該ポリプロピレン系樹脂１００重量部に
対し、０．５〜１０重量部、好ましくは２〜１０重量部
の範囲である。該多孔質フィラーの配合量が０．５重量
部未満では成形時の発泡性が不十分となり、また、１０
重量部より多いとポリプロピレン系樹脂の機械的強度、
特に衝撃強度等の性質が低下する。The amount of the porous filler impregnated with the above-mentioned water in a specified amount is 0.5 to 10 parts by weight, preferably 2 to 10 parts by weight, based on 100 parts by weight of the polypropylene resin. If the compounding amount of the porous filler is less than 0.5 part by weight, the foaming property at the time of molding becomes insufficient.
If it is more than weight part, the mechanical strength of polypropylene resin,
In particular, properties such as impact strength decrease.
【００１８】本発明のポリプロピレン系樹脂組成物は、
常法により適宜加熱溶融して発泡成形させることができ
る。この発泡方法としては、例えば押出成形機や射出成
形機を用いて加圧下で加熱溶融したものを常圧下に押出
し、若しくはフォーミング型中に押出すか、或いは、成
形金型中に射出して発泡させる方法がある。その他、密
閉容器中で加圧下、加熱溶融した後、加圧状態を取り去
ることにより発泡させても良く、また、常圧下で加圧溶
融発泡させても良い。The polypropylene resin composition of the present invention comprises
It can be appropriately heat-melted and foam-molded by a conventional method. As the foaming method, for example, an extruding machine or an injection molding machine is used to heat and melt under pressure, extrude under normal pressure, or extrude into a forming mold, or inject into a molding die to foam. There is a way. In addition, after heating and melting under pressure in an airtight container, foaming may be performed by removing the pressurized state, or pressure-melting and foaming may be performed under normal pressure.
【００１９】なお、発泡成形に際し、発泡剤の気泡調整
剤として、少量のタルク、シリカ等の無機質粉末、亜鉛
華（酸化亜鉛）、リサージ（酸化鉛）等の金属酸化物、
ステアリン酸、ラウリン酸等の脂肪酸又はそれら脂肪酸
の金属塩（例えば、亜鉛、カルシウム、鉛、バリウム等
の塩）を添加しても良い。In foam molding, a small amount of talc, inorganic powder such as silica, metal oxides such as zinc white (zinc oxide) and litharge (lead oxide) are used as a foam control agent for the foaming agent.
Fatty acids such as stearic acid and lauric acid or metal salts of these fatty acids (for example, salts of zinc, calcium, lead, barium, etc.) may be added.
【００２０】次に、このような本発明の発泡体用ポリプ
ロピレン系樹脂組成物を発泡倍率２倍以上に発泡成形し
てなる、実質的に独立気泡よりなる発泡樹脂層を中間層
とする本発明の積層シートの製造方法について説明す
る。Next, the present invention having a foamed resin layer consisting of substantially closed cells, which is formed by foaming such a polypropylene resin composition for foams of the present invention at a foaming ratio of 2 times or more, as an intermediate layer. The manufacturing method of the laminated sheet of is described.
【００２１】なお、本発明の積層シートにおいて、上層
及び下層のソリッド樹脂層を構成するポリプロピレン系
樹脂としては、前掲のポリプロピレン系樹脂組成物に用
いられるポリプロピレン系樹脂を用いることができる。In the laminated sheet of the present invention, the polypropylene resin used in the above-mentioned polypropylene resin composition can be used as the polypropylene resin constituting the upper and lower solid resin layers.
【００２２】ここで、上層を構成するポリプロピレン系
樹脂と下層を構成するポリプロピレン系樹脂とは同一で
あっても異なるものであっても良く、また、上層及び／
又は下層を構成するポリプロピレン系樹脂と中間層に用
いられるポリプロピレン系樹脂とは同一であっても異な
っていても良い。Here, the polypropylene resin constituting the upper layer and the polypropylene resin constituting the lower layer may be the same or different, and the upper layer and / or
Alternatively, the polypropylene resin forming the lower layer and the polypropylene resin used for the intermediate layer may be the same or different.
【００２３】本発明の積層シートは、熱接着法、押出又
はドライラミネーション法、共押出法等の積層法によっ
て製造することができ、特に共押出法が好適である。The laminated sheet of the present invention can be produced by a lamination method such as a heat bonding method, an extrusion or dry lamination method, and a coextrusion method, and the coextrusion method is particularly preferable.
【００２４】共押出法の場合、インフレーション成形又
はＴダイ成形のいずれも採用可能である。例えば、Ｔダ
イ成形を採用する場合には、マルチマニホールドＴダイ
又は押出機とＴダイとの間にフィードブロックを設けた
装置（フィードブロック付Ｔダイ）等の多層ダイを用い
て、１６０〜２００℃の成形温度で、二種三層、又は三
種三層等の共押出法により、本発明の積層シートを製造
することができる。即ち、各層の構成樹脂を、それぞれ
押出機内で加熱溶融してＴダイより押出す。中間層の発
泡樹脂層は、この押出機内で、加圧下、樹脂と発泡剤等
が溶融混練され、ダイスの出口直後において、低圧雰囲
気下、押出発泡され、これを挟んで両外側のソリッド層
が共押出しされ、積層シートが得られる。In the case of the coextrusion method, either inflation molding or T-die molding can be adopted. For example, when T die molding is adopted, a multi-manifold T die or a multi-layer die such as a device having a feed block between the extruder and the T die (T die with a feed block) is used to obtain 160 to 200. The laminated sheet of the present invention can be produced by a coextrusion method such as a two-kind three-layer or a three-kind three-layer at a molding temperature of ° C. That is, the constituent resin of each layer is melted by heating in an extruder and extruded from a T-die. In this extruder, the foamed resin layer of the intermediate layer is melt-kneaded with the resin and the foaming agent under pressure, and immediately after the die exit, is extruded and foamed under a low pressure atmosphere. It is coextruded to obtain a laminated sheet.
【００２５】本発明の積層シートにおいて、中間層の発
泡樹脂層の発泡倍率は、２倍以上、好ましくは２〜５
倍、より好ましくは２〜４倍の範囲である。発泡樹脂層
の発泡倍率はポリプロピレン系樹脂組成物の化学発泡剤
の種類及びその添加量、多孔質フィラーの添加量及びそ
の含水量又は成形温度等を適宜組合わせることにより容
易に所望の倍率に調節することができる。In the laminated sheet of the present invention, the foaming ratio of the foamed resin layer as the intermediate layer is 2 times or more, preferably 2 to 5
It is twice, more preferably 2 to 4 times. The foaming ratio of the foamed resin layer can be easily adjusted to a desired ratio by appropriately combining the type of the chemical foaming agent of the polypropylene resin composition and its addition amount, the addition amount of the porous filler and its water content, molding temperature, etc. can do.
【００２６】このような本発明の積層シートの厚みは５
ｍｍ以下、好ましくは１．１〜５ｍｍが良く、中間層を
挟む上層及び下層の厚みはそれぞれ０．０５〜２ｍｍの
範囲、中間層の厚みは１〜４．９ｍｍの範囲とするのが
好ましい。即ち、本発明の積層シートによれば、厚さ５
ｍｍ以下で自動車用内装材等として十分な強度が得ら
れ、５ｍｍを超えて厚くなるとコストアップになり好ま
しくない。The laminated sheet of the present invention has a thickness of 5
The thickness of the upper and lower layers sandwiching the intermediate layer is preferably 0.05 to 2 mm, and the thickness of the intermediate layer is preferably 1 to 4.9 mm. That is, according to the laminated sheet of the present invention, the thickness of 5
If the thickness is 5 mm or less, sufficient strength is obtained as an interior material for automobiles, and if the thickness exceeds 5 mm, the cost increases, which is not preferable.
【００２７】なお、本発明の積層シートは、単位面積当
り同一重量で、かつ同一組成からなり、しかも発泡部分
を含まないソリッド層のみのシートの曲げ剛性に比べ
て、曲げ剛性が大であるように、例えば１．１倍以上、
好ましくは２〜５倍、より好ましくは２〜４倍の範囲の
物性を有するように構成することが望ましい。これらの
物性を有する積層シートを得るには、中間層の発泡条
件、例えば化学発泡剤の種類及びその添加量等による発
泡倍率の調整、成形温度又は、中間層の厚さ等の適宜組
合わせ、軽量化と曲げ剛性向上とのバランスを図れば良
い。It should be noted that the laminated sheet of the present invention has a higher flexural rigidity than that of a sheet having the same weight per unit area and the same composition and having only a solid layer containing no foamed portion. For example, 1.1 times or more,
It is desirable to have a physical property in the range of preferably 2 to 5 times, more preferably 2 to 4 times. In order to obtain a laminated sheet having these physical properties, the foaming conditions of the intermediate layer, for example, the adjustment of the expansion ratio by the type of the chemical foaming agent and its addition amount, the molding temperature, or an appropriate combination of the thickness of the intermediate layer, It suffices to balance the reduction in weight and the improvement in bending rigidity.
【００２８】本発明の積層シートは、基本的には、上
層、中間層及び下層よりなる三層積層シートであるが、
必要に応じて接着層、その他第２の中間層等を介在させ
ても良い。The laminated sheet of the present invention is basically a three-layer laminated sheet consisting of an upper layer, an intermediate layer and a lower layer,
An adhesive layer, a second intermediate layer, or the like may be interposed if necessary.
【００２９】本発明の積層体は、上述の本発明の積層シ
ートの片面に伸縮性を有する表皮材を積層してなるもの
である。The laminated body of the present invention is obtained by laminating a stretchable skin material on one surface of the laminated sheet of the present invention.
【００３０】本発明の積層体に使用される表皮材として
は、ポリエチレン繊維、ポリプロピレン繊維、ポリエス
テル繊維、ポリアミド繊維、ポリスチレン繊維、ポリア
クリル繊維等の熱可塑性樹脂繊維の１種又は２種以上か
らなる不織布、織布、又は人造皮革、その他、軟質プラ
スチックフィルム或いはシート等のような伸縮性を有す
るシート又はマット状物が用いられる。ここで伸縮性を
有するとは、５０ｋｇ／ｃｍ2 の力で引張るとき、伸び
率５％以上を示すものをいう。The skin material used in the laminate of the present invention comprises one or more thermoplastic resin fibers such as polyethylene fibers, polypropylene fibers, polyester fibers, polyamide fibers, polystyrene fibers and polyacrylic fibers. Non-woven fabric, woven fabric, artificial leather, or a stretchable sheet or mat-like material such as a soft plastic film or sheet is used. Here, having elasticity means that when it is pulled by a force of 50 kg / cm 2 , the elongation rate is 5% or more.
【００３１】このような表皮材を積層して一体化するに
は、本発明の積層シートの片面に、必要に応じてエチレ
ン−酢酸ビニル共重合体、エチレン−プロピレンラバ
ー、不飽和カルボン酸変性ポリオレフィン樹脂等のよう
な接着性樹脂を介して表皮材を積層し、熱接着又は押出
ラミネート法等により接着する。In order to laminate and integrate such a skin material, an ethylene-vinyl acetate copolymer, ethylene-propylene rubber, unsaturated carboxylic acid-modified polyolefin may be provided on one surface of the laminated sheet of the present invention, if necessary. A skin material is laminated via an adhesive resin such as a resin and bonded by heat bonding or extrusion laminating.
【００３２】この際、積層シートは、これを構成する素
材樹脂の融点±３０℃の範囲内の温度、特に融点±２０
℃の範囲内の温度に保持した状態で表皮材と積層するの
が好ましい。この積層時の接着温度が上記温度より高い
と、積層シートの中間層の気泡が破壊され、積層体の強
度が低下する。また、表皮材の接着時には、１．５〜５
ｋｇ／ｃｍ2 の範囲内の圧力でロール圧着を行なうのが
良い。At this time, the laminated sheet has a melting point of the material resin constituting the laminated sheet of ± 30 ° C., particularly a melting point of ± 20.
It is preferable to laminate with the skin material while maintaining the temperature within the range of ° C. If the bonding temperature at the time of lamination is higher than the above temperature, the air bubbles in the intermediate layer of the laminated sheet are destroyed, and the strength of the laminated body is reduced. Also, when adhering the skin material, 1.5 to 5
Roll pressure bonding is preferably performed at a pressure within the range of kg / cm 2 .
【００３３】上記のようにして得られた積層体は、これ
を例えば自動車内装材にするときには、所望の形状に熱
成形する。熱成形は、通常、積層体の構成樹脂の融点±
３０℃の範囲、好ましくは構成樹脂の融点±２０℃の範
囲の温度において行う。The laminate obtained as described above is thermoformed into a desired shape when it is used as an automobile interior material, for example. Thermoforming is usually performed with the melting point of the resin constituting the laminate ±
It is carried out at a temperature in the range of 30 ° C., preferably in the range of the melting point of the constituent resin ± 20 ° C.
【００３４】この熱成形における加熱方法としては任意
の方法を採用することができ、例えば、熱風加熱方式、
赤外線ヒーター、遠赤外線ヒーターなどによる輻射熱加
熱方法が挙げられる。また、熱成形法としては広く一般
に行なわれている真空成形法、圧空成形法、真空圧空成
形法又はスタンピング成形法等が用いられる。As a heating method in this thermoforming, any method can be adopted, for example, hot air heating method,
A radiant heat heating method using an infrared heater, a far infrared heater or the like can be used. As the thermoforming method, a vacuum forming method, a pressure forming method, a vacuum pressure forming method, a stamping forming method, or the like, which is widely used in general, is used.
【００３５】本発明における積層シート、積層シートと
表皮材との積層による積層体の製造及びこの積層体から
成形品の製造は、次のような工程を連続的に行うことに
よって、極めて効率的に、かつコストを低減して遂行す
ることができる。The production of a laminated sheet, a laminated body by laminating a laminated sheet and a skin material, and a molded article from the laminated body in the present invention are extremely efficient by carrying out the following steps continuously. In addition, the cost can be reduced.
【００３６】 基材としての積層シートを押出機（Ｔ
ダイ）より押出し、中間層となる樹脂組成物はダイスの
出口直後において発泡させ、これを挟んで両外側のソリ
ッド層を共押出しする。The laminated sheet as the base material is extruded (T
The resin composition as an intermediate layer is extruded from a die, and is foamed immediately after the exit of the die, and the solid layers on both outer sides are co-extruded with the resin composition sandwiched therebetween.
【００３７】 上記によって共押出しされて得られ
た積層シートを、その素材樹脂の融点±３０℃の範囲内
の温度に保持しながら、表皮材をロール圧着にて貼合わ
せるか、又は両者を接着剤を介してロール圧着する。While maintaining the laminated sheet obtained by coextrusion as described above at a temperature within the range of the melting point of the material resin ± 30 ° C., the skin material is laminated by roll pressure bonding, or both are bonded by an adhesive. Roll crimp through.
【００３８】 上記で得られた積層体を、その構成
樹脂の融点±３０℃の範囲内の温度に保ち、この温度を
下げることなく直ちに熱成形機に投入して熱成形する。The laminated body obtained above is maintained at a temperature within the range of the melting point of the constituent resin ± 30 ° C., and immediately put into a thermoforming machine without lowering the temperature to perform thermoforming.
【００３９】[0039]
【作用】本発明において、ポリプロピレン系樹脂と化学
発泡剤の配合物に特定量の水分を含浸させた多孔質フィ
ラーを配合することにより、発泡倍率を高めることがで
きる理由の詳細は明らかではないが、価額発泡剤と水分
を含浸させた多孔質フィラーとの相乗効果により、発泡
性が著しく改良され、得られる発泡体の発泡倍率が高め
られるものと推定される。因みに、本発明の発泡体用ポ
リプロピレン系樹脂組成物によれば、従来、発泡倍率
１．３〜１．５倍であったものを、２〜５倍まで高発泡
することが可能とされる。In the present invention, the reason why the expansion ratio can be increased by adding a porous filler impregnated with a specific amount of water to a mixture of a polypropylene resin and a chemical foaming agent is not clear. It is presumed that the synergistic effect of the foaming agent and the porous filler impregnated with water significantly improves the foamability and increases the expansion ratio of the resulting foam. By the way, according to the polypropylene-based resin composition for foams of the present invention, it is possible to highly expand the foaming ratio of 1.3 to 1.5 times from the conventional one to 2 to 5 times.
【００４０】しかして、このような高発泡性ポリプロピ
レン系樹脂組成物を発泡倍率２倍以上に発泡成形してな
る発泡樹脂層を中間層として有する本発明の積層シート
によれば、その中間層の高発泡樹脂層により軽量化及び
曲げ剛性の大幅な改善が達成される。Therefore, according to the laminated sheet of the present invention having as the intermediate layer a foamed resin layer formed by foam-molding such a highly expandable polypropylene resin composition with an expansion ratio of 2 or more, the intermediate layer The highly foamed resin layer achieves weight reduction and a great improvement in bending rigidity.
【００４１】また、この積層シートに表皮材を積層して
得られる積層体によれば、各種自動車用内装材として好
適な積層材が提供される。Further, according to the laminated body obtained by laminating the skin material on the laminated sheet, a laminated material suitable as an interior material for various automobiles is provided.
【００４２】[0042]
【実施例】以下に実施例及び比較例を挙げて本発明をよ
り具体的に説明するが、本発明はその要旨を超えない限
り、以下の実施例に限定されるものではない。EXAMPLES The present invention will be described in more detail with reference to Examples and Comparative Examples, but the present invention is not limited to the following Examples unless it exceeds the gist.
【００４３】実施例１ 耐衝撃ポリプロピレン（プロピレン−エチレンブロック
共重合体）（ＭＦＲ：２３０℃において１．１８／１０
分）１００重量部に対し、化学発泡剤（アゾジカルボン
アミド）０．３重量部と、９重量％の水分を含浸させた
珪藻土５重量部とをヘンシェルミキサーにて均一混合
し、７１１ｍｍ幅のＴダイを取り付けた単軸押出機（ス
クリュー径６５ｍｍφ）にて、成形温度２００℃でシー
ト状に押出成形した。得られたシートの発泡倍率は３．
０倍であった。Example 1 Impact polypropylene (propylene-ethylene block copolymer) (MFR: 1.18 / 10 at 230 ° C.)
Min) 100 parts by weight, 0.3 parts by weight of a chemical foaming agent (azodicarbonamide) and 5 parts by weight of diatomaceous earth impregnated with 9% by weight of water are uniformly mixed with a Henschel mixer, and a 711 mm wide T A single screw extruder (screw diameter: 65 mmφ) equipped with a die was used to perform extrusion molding into a sheet at a molding temperature of 200 ° C. The expansion ratio of the obtained sheet is 3.
It was 0 times.
【００４４】実施例２ 実施例１において、珪藻土として、６重量％の水分を含
浸させたものを使用したこと以外は同様な方法で、シー
ト状に押出成形した。得られたシートの発泡倍率は２．
０倍であった。Example 2 A sheet was extruded in the same manner as in Example 1 except that the diatomaceous earth impregnated with 6% by weight of water was used. The expansion ratio of the obtained sheet is 2.
It was 0 times.
【００４５】比較例１ 実施例１において、珪藻土を全く添加しなかったこと以
外は同様な方法で、シート状に押出成形した。得られた
シートの発泡倍率は１．５倍であった。Comparative Example 1 Extrusion molding was carried out in the form of a sheet by the same method as in Example 1 except that diatomaceous earth was not added at all. The expansion ratio of the obtained sheet was 1.5 times.
【００４６】実施例３ フィードブロック付Ｔダイ共押出多層シート製造装置を
用い、発泡樹脂層を中間層とし、両外面にソリッド樹脂
層を積層した三層積層シートを製造した。装置の第１押
出機（５０ｍｍφ）からは、三層積層シートの上層及び
下層となるそれぞれのソリッド樹脂層となる耐衝撃ポリ
プロピレン（プロピレン−エチレンブロック共重合体）
（ＭＦＲ，２３０℃において１．１ｇ／１０分）を押出
し、第２押出機（６３．５ｍｍφ）からは、中間層の発
泡樹脂層となる、上記ソリッド樹脂層の素材と同じ耐衝
撃ポリプロピレン１００重量部に対し、化学発泡剤（ア
ゾジカルボンアミド）０．６重量部と、予め水分を９重
量％含浸させた珪藻土２．５重量部と加えたものを押出
した。Example 3 Using a T-die coextrusion multi-layer sheet manufacturing apparatus with a feed block, a three-layer laminated sheet having a foam resin layer as an intermediate layer and solid resin layers laminated on both outer surfaces was produced. From the first extruder (50 mmφ) of the apparatus, impact-resistant polypropylene (propylene-ethylene block copolymer) which becomes the respective upper and lower solid resin layers of the three-layer laminated sheet
(MFR, 1.1 g / 10 minutes at 230 ° C.) was extruded, and from the second extruder (63.5 mmφ), 100 weight of the same impact-resistant polypropylene as the material of the solid resin layer, which becomes the foamed resin layer of the intermediate layer 0.6 parts by weight of a chemical foaming agent (azodicarbonamide) and 2.5 parts by weight of diatomaceous earth preliminarily impregnated with water of 9% by weight were extruded.
【００４７】成形温度は１７０℃で、同時押出しし、溶
融樹脂合流部において三層に合流後、シート状に押出
し、これに表皮材（ポリエステル繊維不織布、厚さは目
付重量で表わして１５０ｇ／ｍ2 ）をロール圧着にて貼
合せて積層体とし、引き続き、真空圧空成形により成形
を行い、高級感を有する外観の成形品を得た。The molding temperature was 170 ° C., the mixture was coextruded, and the melted resin was joined into three layers, and then extruded into a sheet, which was then covered with a surface material (polyester fiber non-woven fabric, thickness: 150 g / m 2 by weight per unit area). 2 ) was laminated by roll pressure bonding to form a laminate, which was subsequently molded by vacuum pressure forming to obtain a molded product with a high-class appearance.
【００４８】本実施例で製造した積層シートにおける上
層及び下層のソリッド樹脂層及び中間層の発泡樹脂層の
樹脂の種類（上記耐衝撃ポリプロピレン、以下、「Ｐ
Ｐ」と略記する。）、厚み、重量、これらを積層した積
層シートの厚み、重量、下記（１）の方法で測定した曲
げ剛性、下記（２）の方法で測定した軽量化率等を表１
に示す。なお、得られた積層シートの曲げ剛性は、単位
面積当り同一重量であって、同一組成からなり、かつ発
泡部分を有しないソリッド樹脂シートの曲げ剛性と対比
したところ、約３倍であった。The resin types of the upper and lower solid resin layers and the foamed resin layer of the intermediate layer in the laminated sheet manufactured in this example (the above impact polypropylene, hereinafter referred to as "P").
It is abbreviated as "P". ), Thickness, weight, thickness and weight of a laminated sheet obtained by laminating these, flexural rigidity measured by the following method (1), and weight reduction ratio measured by the following method (2).
Shown in The bending rigidity of the obtained laminated sheet was about 3 times that of the solid resin sheet having the same weight per unit area and the same composition and having no foamed portion.
【００４９】（１） 曲げ剛性 試験片：５０ｍｍ（幅）×１５０ｍｍ（長） 方 法：ＪＩＳ Ｋ７２０３に準ずる。 条件：支点間距離＝１００ｍｍ 加圧スピード＝５０ｍｍ／分 試験片を１０ｍｍたわませるのに必要な力（ｇ）を求
め、これを曲げ剛性値とする。(1) Bending rigidity Test piece: 50 mm (width) × 150 mm (length) Method: According to JIS K7203. Condition: Distance between fulcrums = 100 mm Pressing speed = 50 mm / min The force (g) required to bend the test piece by 10 mm is determined and used as the bending rigidity value.
【００５０】（２） 軽量化率 従来、使用された形式の自動車内装品用積層シートの基
材（後述する比較例１のもの、厚さ１．８ｍｍのソリッ
ド樹脂シートであって単位面積当りの重量１６２０ｇ／
ｍ2 ）を基準品とし、次式に示すようにして被測定試料
との重量の差から計算する。 軽量化率（％）＝｛１６２０（ｇ／ｍ2 ）−試料重量
（ｇ／ｍ2 ）｝ ／１６２０（ｇ／ｍ2 ）×１００ 実施例４、比較例２及び比較例３ 本発明の積層シートにおいて、中間層を発泡樹脂層とす
ることにより、かかる発泡樹脂層を有しない基材シート
に比べ曲げ剛性の向上及び軽量化がはかれることを明ら
かにするため、実施例４、比較例２及び比較例３を示
す。(2) Weight reduction ratio Conventionally, a base material of a laminated sheet for automobile interior parts of the type used (of Comparative Example 1 described later, a solid resin sheet having a thickness of 1.8 mm, per unit area) Weight 1620g /
m 2 ) as a standard product, and is calculated from the difference in weight with the sample to be measured as shown in the following formula. Weight reduction rate (%) = {1620 (g / m 2 ) −Sample weight (g / m 2 )} / 1620 (g / m 2 ) × 100 Example 4, Comparative Example 2 and Comparative Example 3 Lamination of the present invention In the sheet, in order to clarify that the use of the foamed resin layer as the intermediate layer improves the bending rigidity and reduces the weight as compared with the base sheet having no such foamed resin layer, Example 4, Comparative Example 2 and Comparative Example 3 is shown.
【００５１】実施例４で得た積層シートは、表１に示す
如く、中間層の厚み及び単位面積当りの重量のみが異な
り、その他の構成は実施例３で得られた積層シートと同
様であり、押出成形も同様にして行なった。As shown in Table 1, the laminated sheet obtained in Example 4 was different only in the thickness of the intermediate layer and the weight per unit area, and the other constitutions were the same as those of the laminated sheet obtained in Example 3. The extrusion molding was performed in the same manner.
【００５２】また、比較例２，３は表１に示す如く、中
間層を有さずＰＰのソリッド樹脂層のみからなるもので
ある。この比較例２，３では、成形温度２３０℃で押出
成形した。Further, as shown in Table 1, Comparative Examples 2 and 3 do not have an intermediate layer and are composed only of a solid resin layer of PP. In Comparative Examples 2 and 3, extrusion molding was performed at a molding temperature of 230 ° C.
【００５３】各々のシートについて、曲げ剛性を調べ、
また実施例４の積層シートについて軽量化率を調べ、結
果を表１に示した。The flexural rigidity of each sheet was examined,
The weight reduction rate of the laminated sheet of Example 4 was examined, and the results are shown in Table 1.
【００５４】[0054]
【表１】 [Table 1]
【００５５】表１中、実施例４と比較例２との対比か
ら、次のことが明らかである。即ち、基材シートの曲げ
剛性として同じ１５００ｇを得ようとするとき、本発明
の積層シートでは９００ｇ／ｍ2 の樹脂量で足りるが、
比較例２では１６２０ｇ／ｍ2の樹脂量を必要とする。In Table 1, the following is clear from the comparison between Example 4 and Comparative Example 2. That is, when the same flexural rigidity of the base material sheet is to be obtained as 1500 g, a resin amount of 900 g / m 2 is sufficient for the laminated sheet of the present invention,
Comparative Example 2 requires a resin amount of 1620 g / m 2 .
【００５６】また、実施例４と比較例３との対比から、
次のことが明らかである。即ち、比較例２のソリッド樹
脂基材シートの重量１６２０ｇ／ｍ2 を基準とし、実施
例４は４４％の軽量化率を示す。これと同じ４４％の軽
量化率をソリッド樹脂基材シトで達成しようとすると、
実施例４の積層シートでは１５００ｇの曲げ剛性を示す
のに対し、比較例３のシートでは２５０ｇの曲げ剛性し
か得られない。即ち、実施例４と比較例３とは単位面積
当り同一重量で、かつ同一組成からなるが、曲げ剛性
は、前者が後者の６倍の値を有する。From the comparison between Example 4 and Comparative Example 3,
The following is clear. That is, based on the weight of the solid resin base material sheet of Comparative Example 2 of 1620 g / m 2 , Example 4 shows a weight reduction rate of 44%. Attempting to achieve the same weight reduction of 44% with a solid resin base sheet,
The laminated sheet of Example 4 exhibits a bending rigidity of 1500 g, whereas the sheet of Comparative Example 3 can obtain a bending rigidity of only 250 g. That is, Example 4 and Comparative Example 3 have the same weight per unit area and the same composition, but the flexural rigidity of the former is 6 times that of the latter.
【００５７】[0057]
【発明の効果】以上詳述した通り、本発明の発泡体用ポ
リプロピレン系樹脂組成物によれば、２倍以上という高
い発泡倍率で容易かつ効率的に発泡成形可能な高発泡性
樹脂組成物が提供される。As described in detail above, according to the polypropylene resin composition for foams of the present invention, a highly expandable resin composition which can be easily and efficiently foam-molded with a high expansion ratio of 2 times or more. Provided.
【００５８】しかして、このような本発明の発泡体用ポ
リプロピレン系樹脂組成物よりなる発泡樹脂層を中間層
として有する本発明の積層シート及び積層体によれば、
軽量かつ曲げ剛性に優れ、自動車用内装材等として好適
な材料が提供される。Therefore, according to the laminated sheet and the laminated body of the present invention having the foamed resin layer made of the polypropylene resin composition for a foamed body of the present invention as an intermediate layer,
A material which is lightweight and excellent in bending rigidity and which is suitable as an interior material for automobiles is provided.
───────────────────────────────────────────────────── フロントページの続き (72)発明者 足立 浩一 岡山県倉敷市潮通３丁目10番地 三菱化成 株式会社水島工場内 (72)発明者 大畑 智生 埼玉県志木市上宗岡三丁目12番20号 クミ 化成株式会社内 (72)発明者 中井 秀 埼玉県志木市上宗岡三丁目12番20号 クミ 化成株式会社内 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Koichi Adachi 3-10 Shiodori, Kurashiki-shi, Okayama Prefecture Mizushima Plant, Mitsubishi Kasei Co., Ltd. (72) Inventor Tomohio Ohata 3-12-20 Kamisooka, Shiki City, Saitama Prefecture Kumi Kasei Co., Ltd. (72) Inventor Hide Nakai, 3-12-20 Kamisooka, Shiki City, Saitama Prefecture Kumi Kasei Co., Ltd.
Claims (3)
予め水分を２重量％以上含浸させた多孔質フィラー０．
５〜１０重量部と、化学発泡剤０．１〜１重量部とを配
合してなる発泡体用ポリプロピレン系樹脂組成物。1. To 100 parts by weight of polypropylene resin,
Porous filler impregnated with water in an amount of 2% by weight or more in advance.
A polypropylene resin composition for a foam, which comprises 5 to 10 parts by weight and 0.1 to 1 part by weight of a chemical foaming agent.
てなる積層シートにおいて、該上層及び下層はポリプロ
ピレン系樹脂からなるソリッド樹脂層であり、かつ、該
中間層は、請求項１に記載のポリプロピレン系樹脂組成
物を発泡倍率２倍以上に発泡成形して得られた発泡樹脂
層であることを特徴とする積層シート。2. A laminated sheet in which an upper layer and a lower layer are laminated with an intermediate layer interposed therebetween, wherein the upper layer and the lower layer are solid resin layers made of polypropylene resin, and the intermediate layer is the same as in claim 1. A laminated sheet, which is a foamed resin layer obtained by foaming the polypropylene-based resin composition as described above at a foaming ratio of 2 or more.
伸縮性を有する表皮材を積層してなる積層体。3. On one surface of the laminated sheet according to claim 2,
A laminate formed by laminating elastic skin materials.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2369492A JPH085984B2 (en) | 1992-02-10 | 1992-02-10 | Polypropylene resin composition for foam, laminated sheet and laminated body |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2369492A JPH085984B2 (en) | 1992-02-10 | 1992-02-10 | Polypropylene resin composition for foam, laminated sheet and laminated body |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH05222233A JPH05222233A (en) | 1993-08-31 |
| JPH085984B2 true JPH085984B2 (en) | 1996-01-24 |
Family
ID=12117526
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2369492A Expired - Lifetime JPH085984B2 (en) | 1992-02-10 | 1992-02-10 | Polypropylene resin composition for foam, laminated sheet and laminated body |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH085984B2 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2005023918A1 (en) * | 2003-08-27 | 2005-03-17 | Idemitsu Kosan Co., Ltd. | Thermoplastic resin composition for foamed product and foamed product therefrom |
| JP4540101B2 (en) * | 2004-07-30 | 2010-09-08 | 積水化成品工業株式会社 | Antistatic polypropylene-based resin laminated foam sheet |
| CN111621092B (en) * | 2020-06-09 | 2023-05-26 | 浙江新恒泰新材料有限公司 | Preparation method of high-efficiency mould pressing foaming polypropylene |
-
1992
- 1992-02-10 JP JP2369492A patent/JPH085984B2/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| JPH05222233A (en) | 1993-08-31 |
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