WO2017110201A1 - マイクロスフェアー、当該マイクロスフェアーを含む熱発泡性樹脂組成物、構造部材、および成形体、ならびに当該構造部材および当該成形体の製造方法 - Google Patents
マイクロスフェアー、当該マイクロスフェアーを含む熱発泡性樹脂組成物、構造部材、および成形体、ならびに当該構造部材および当該成形体の製造方法 Download PDFInfo
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- WO2017110201A1 WO2017110201A1 PCT/JP2016/079529 JP2016079529W WO2017110201A1 WO 2017110201 A1 WO2017110201 A1 WO 2017110201A1 JP 2016079529 W JP2016079529 W JP 2016079529W WO 2017110201 A1 WO2017110201 A1 WO 2017110201A1
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K3/00—Materials not provided for elsewhere
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J13/00—Colloid chemistry, e.g. the production of colloidal materials or their solutions, not otherwise provided for; Making microcapsules or microballoons
- B01J13/02—Making microcapsules or microballoons
- B01J13/06—Making microcapsules or microballoons by phase separation
- B01J13/14—Polymerisation; cross-linking
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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
- 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
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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
- C08J2203/00—Foams characterized by the expanding agent
- C08J2203/22—Expandable microspheres, e.g. Expancel®
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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
- C08J2300/00—Characterised by the use of unspecified polymers
- C08J2300/22—Thermoplastic resins
Definitions
- the present invention relates to a microsphere, a thermally foamable resin composition containing the microsphere, a structural member, and a molded body, and a method of manufacturing the structural member and the molded body.
- Microspheres also called microcapsules, are volatile foaming agents that are microencapsulated in the outer shell. When heated, the microspheres have the property of expanding rapidly with the foaming start temperature as a boundary.
- microspheres having an average particle size of less than 50 ⁇ m have been mainly developed.
- microspheres having an average particle diameter of 50 ⁇ m or more are currently being developed (see, for example, Patent Document 1).
- Microspheres may be used by being kneaded with polymer materials (base materials) such as synthetic resins and rubber. Also, instead of directly kneading the microspheres and the polymer material as the base material, a masterbatch is prepared by kneading the microspheres in advance with a low melting point thermoplastic resin, and the masterbatch is polymerized immediately before molding. Sometimes added to the material and kneaded. Therefore, if the foaming start temperature of the microsphere is low, the microsphere may foam during the kneading process with the polymer material or the thermoplastic resin. Therefore, the processing temperature must be lowered, and the types of polymer material or thermoplastic resin that can be used are limited.
- the microsphere when the microsphere is heated to a temperature higher than the foaming start temperature, the microsphere is foamed into foamed particles. However, when this microsphere is further heated, the thickness of the outer shell decreases, and the foaming agent permeates the outer shell. If it does so, the internal pressure of a foamed particle will fall and a foaming particle will shrink, and what is called a sticking phenomenon will generate
- produce when the microsphere is heated to a temperature higher than the foaming start temperature, the microsphere is foamed into foamed particles. However, when this microsphere is further heated, the thickness of the outer shell decreases, and the foaming agent permeates the outer shell. If it does so, the internal pressure of a foamed particle will fall and a foaming particle will shrink, and what is called a sticking phenomenon will generate
- microspheres that have a high foaming ratio and a high foaming start temperature and are less likely to cause a settling phenomenon.
- the foaming ratio is increased by changing the kind of the polymerizable monomer or adding a crosslinkable monomer.
- Microspheres are usually produced by suspension polymerization. At that time, the particle diameter of the microspheres can be changed by adjusting the emulsification conditions during suspension polymerization. Therefore, among the several conditions for producing microspheres having a large foaming ratio, a high foaming start temperature, and an average particle diameter of less than 50 ⁇ m that hardly cause the settling phenomenon, only suspension polymerization emulsification conditions are used. If adjusted, it is considered that a microsphere having a large foaming ratio, a high foaming start temperature, and an average particle diameter of 50 ⁇ m or more which hardly causes a settling phenomenon can be obtained.
- the present situation is that a microsphere having a high foaming ratio, a high foaming start temperature and hardly causing a settling phenomenon has not been obtained.
- the present invention has been made to solve the above problems. That is, when the average particle size is 50 ⁇ m or more and 190 ⁇ m or less, the foaming ratio is large, the foaming start temperature is high, and the settling phenomenon hardly occurs, and the thermally foamable resin composition containing such microspheres It is another object of the present invention to provide a structural member, a molded body containing foamed particles obtained by foaming such microspheres, a method for manufacturing the structural member, and a method for manufacturing the molded body.
- the present inventors have surprisingly found that the optimum content of the foaming agent in the microsphere depends on the average particle diameter of the microsphere. If the amount of the foaming agent is optimized with respect to the average particle diameter of the microsphere, even when the average particle diameter is 50 ⁇ m or more and 190 ⁇ m, the expansion ratio is large, the foaming start temperature is high, and the sag phenomenon occurs. The inventors have found that microspheres that are difficult to obtain can be obtained, and have completed the present invention.
- a microsphere comprising an outer shell and a foaming agent enclosed in the outer shell, the foaming agent comprising a compound that becomes a gas upon heating, and the microsphere
- D50 average particle diameter
- B1 mass%
- a microsphere comprising an outer shell and a foaming agent enclosed in the outer shell, wherein the outer shell is made of a monomer containing a polymerizable monomer. It is comprised from a polymer,
- the said foaming agent contains the compound which becomes gas by heating, the average particle diameter (D50) of the said microsphere is set to A (micrometer), and the quantity of the said foaming agent is set to B2 (mass part). Then, the microsphere characterized by satisfy
- B2 means the mass part of the foaming agent when the polymerizable monomer is 100 mass parts.
- the microsphere since the amount of the foaming agent is optimized with respect to the average particle diameter of the microsphere, the microsphere has an average particle diameter of 50 ⁇ m or more. Even if it is 190 ⁇ m or less, the foaming ratio is large, the foaming start temperature is high, and the settling phenomenon hardly occurs.
- microsphere according to an embodiment of the present invention, a thermally foamable resin composition including the microsphere, a structural member and a manufacturing method thereof, and a molded body and a manufacturing method thereof will be described in detail.
- the microsphere includes an outer shell and a foaming agent enclosed in the outer shell.
- an outer shell is comprised from the material which can enclose a foaming agent,
- a foaming agent contains the compound which becomes gas at the temperature below the softening point of the constituent material (for example, the said polymer) of outer shell.
- the microsphere according to the present embodiment has the following formula (1) And the relationship of (2) is satisfied.
- B1 is a value exceeding 0 mass%.
- the microsphere preferably further satisfies the relationship of the following formula (3).
- the value of B1 satisfies the relationship of the following formula (3), the amount of the foaming agent in the microsphere becomes a more optimal amount, so that the expansion ratio of the microsphere can be further increased.
- the average particle diameter A of the microsphere is a median diameter when the particle size distribution of the microsphere is measured using a particle size analyzer (product name “FPIA-3000”, manufactured by Sysmex Corporation).
- the lower limit of the average particle diameter A of the microspheres is preferably 55 ⁇ m or more, and more preferably 60 ⁇ m or more.
- the upper limit of the average particle diameter A of the microspheres is preferably 120 ⁇ m or less, and more preferably 100 ⁇ m or less.
- the amount B1 of the foaming agent in the outer shell of the microsphere can be measured using a gas chromatograph (product name “GC-14B”, manufactured by Shimadzu Corporation). Specifically, the amount of blowing agent in the microsphere can be determined by swelling the microsphere with N, N-dimethylformamide (DMF) and performing gas chromatography analysis on the supernatant of the liquid. .
- a gas chromatograph product name “GC-14B”, manufactured by Shimadzu Corporation.
- the amount of the foaming agent contained in the microsphere is grasped by directly measuring, but it is also possible to grasp from the amount of foaming agent charged.
- the microsphere has the following formulas (4) and (5). Meet the relationship.
- B2 is a value exceeding 0 mass part.
- B2 means the mass part of a foaming agent when a polymerizable monomer is 100 mass parts.
- the optimum content of the blowing agent depends on the average particle size of the microspheres.
- the relationship is expressed by the above formula (5) in terms of the amount of foaming agent charged.
- the above formula (5) is a formula derived by experiments.
- the value of B1 satisfies the above formula (5), the amount of the foaming agent in the microsphere is optimized. Therefore, it is possible to avoid the possibility that the foaming start temperature of the microspheres is lowered for the reasons described later, the settling phenomenon is likely to occur, and the foaming ratio is also reduced.
- the measuring method and preferable range of the average particle diameter A in the said Formula (4) are the same as that of the case of the average particle diameter A in the said Formula (1), description shall be abbreviate
- the microsphere preferably further satisfies the relationship of the following formula (6).
- the value of B2 satisfies the relationship of the following formula (6)
- the amount of the foaming agent in the microsphere becomes a more optimal amount, so that the expansion ratio of the microsphere can be further increased.
- Microspheres are foamed (expanded) above the foaming start temperature.
- the foaming agent vaporizes and expands, acting on the outer shell.
- the elastic modulus of the polymer that forms the outer shell decreases sharply. Rapid expansion of the fair occurs.
- the temperature at which this rapid expansion occurs is referred to as “foaming start temperature”.
- the foaming start temperature was 0.25 mg of microsphere, the temperature was increased at a rate of temperature increase of 5 ° C./min, and the displacement of the height was continuously measured. The temperature at which the displacement began.
- the “foaming start temperature of the microsphere” means the foaming start temperature of the untreated microsphere.
- the foaming start temperature of the microsphere is preferably 200 ° C. or higher. Since the foaming start temperature of the microsphere is 200 ° C. or higher, the processing temperature at the time of kneading with the polymer material or thermoplastic resin described later can be increased, so the choice of the type of polymer material or thermoplastic resin can be selected. Can be spread.
- the foaming start temperature of the microsphere is more preferably 210 ° C. or higher, and most preferably 220 ° C. or higher.
- the density of the expanded particles when the microspheres are expanded is preferably 0.024 g / ml or less, and more preferably 0.022 g / ml or less.
- the “density of the expanded particles” herein means the true density of the expanded particles when the microspheres are heat-treated at 150 ° C. for 5 minutes and then heated at 200 ° C. for 5 minutes for foaming. It can be said that the expansion ratio of the microsphere is large when the density of the expanded particles measured at least under these conditions is 0.024 g / ml or less.
- the “foamed particles” in the present specification means microspheres during foaming or after foaming.
- the density of the expanded particles obtained by heating the microsphere at 150 ° C. for 5 minutes and then heating at 200 ° C. for 5 minutes is R1, and the microsphere is heated at 150 ° C. for 5 minutes and then heated at 190 ° C. for 5 minutes.
- R2 the density of the obtained expanded particles
- the outer shell can be composed of a monomer polymer containing a polymerizable monomer as described above.
- the monomer is a monomer for forming the outer shell, and preferably contains a crosslinkable monomer in addition to the polymerizable monomer.
- foaming characteristics, heat resistance, and the like can be improved.
- the outer shell is preferably a polymer mainly composed of (meth) acrylonitrile from the viewpoint of increasing the foaming start temperature of the microsphere.
- the polymerizable monomer is a compound having one carbon-carbon double bond (—C ⁇ C—).
- Examples of the carbon-carbon double bond include a vinyl group, a (meth) acryloyl group, and an allyl group.
- the polymerizable monomer is not particularly limited, but the outer shell of the polymer has gas barrier properties, solvent resistance and heat resistance, and also has good foaming properties and, if desired, foaming at a high temperature.
- At least one monomer selected from the group consisting of acrylonitrile and methacrylonitrile (collectively referred to as “(meth) acrylonitrile”) And / or vinylidene chloride is preferably used.
- polymerizable monomers other than these monomers may be added to the polymerizable monomer.
- the polymerizable monomer other than (meth) acrylonitrile and / or vinylidene chloride is not particularly limited.
- the polymerizable monomer can be (meth) acrylonitrile alone or (meth) acrylonitrile and vinylidene chloride, (meth) acrylic acid ester, styrene, and vinyl acetate. It preferably contains at least one monomer selected from the group consisting of (hereinafter, sometimes referred to as “specific monomer other than (meth) acrylonitrile”), and (meth) acrylonitrile and the above ( More preferred are those consisting only of specific monomers other than (meth) acrylonitrile.
- the foaming start temperature and the maximum foaming ratio of the microspheres to be formed can be adjusted depending on the type and composition of a specific monomer other than (meth) acrylonitrile. Therefore, desired microspheres can be formed by adjusting the ratio of (meth) acrylonitrile to specific monomers other than (meth) acrylonitrile and the type and composition of specific monomers other than (meth) acrylonitrile. can do.
- the content of (meth) acrylonitrile is preferably 25% by mass or more and less than 100% by mass. 25 mass% or more and 99.5 mass% or less is more preferable, and 30 mass% or more and 99 mass% or less are still more preferable.
- the content of the specific monomer other than (meth) acrylonitrile is preferably more than 0% by mass and 75% by mass or less, and preferably 0.5% by mass or more and 75% by mass or less. 1 mass% or more and 70 mass% or less are more preferable.
- the total amount of specific monomers other than (meth) acrylonitrile and (meth) acrylonitrile is 100% by mass.
- methyl methacrylate is particularly preferable.
- the content ratio of (meth) acrylonitrile is too low, the foaming start temperature of the formed microspheres is lowered, and the gas barrier property may be insufficient.
- the polymerizable monomer contains vinylidene chloride
- the polymerizable monomer is at least one selected from the group consisting of vinylidene chloride, (meth) acrylonitrile, (meth) acrylic acid ester, styrene, and vinyl acetate.
- a monomer hereinafter sometimes referred to as “a specific monomer other than vinylidene chloride”.
- the higher the content ratio of vinylidene chloride the higher the gas barrier property of the formed microsphere, and the lower the content ratio, the lower the gas barrier property of the formed microsphere. is there.
- the foaming start temperature and the maximum foaming ratio of the formed microsphere can be adjusted by the kind and composition of specific monomers other than vinylidene chloride. Therefore, a desired microsphere can be formed by adjusting the ratio of vinylidene chloride and a specific monomer other than vinylidene chloride, and the type and composition of the specific monomer other than vinylidene chloride. .
- the content of the base vinylidene is preferably 30% by mass to 95% by mass, and more preferably 35% by mass to 90%. More preferably, it is at most 40 mass%, more preferably at least 40 mass% but at most 80 mass%.
- the content of the specific monomer other than vinylidene chloride is preferably 5% by mass or more and 70% by mass or less, preferably 10% by mass or more and 65% by mass or less, and 20% by mass. More preferably, it is 60 mass% or less. In this case, the total amount of vinylidene chloride and a specific monomer other than vinylidene chloride is 100% by mass.
- Specific monomers other than vinylidene chloride are preferably (meth) acrylonitrile and methyl methacrylate.
- the polymerizable monomer contains vinylidene chloride, (meth) acrylonitrile 20 to 50% by mass, and methyl methacrylate, 45 to 75% by mass of vinylidene chloride, 20 to 50% by mass of (meth) acrylonitrile, and methacrylic acid Methyl acid is preferably 3 to 10% by mass (the total amount is 100% by mass). It is preferable that the content ratio of vinylidene chloride is in the above range in that the gas barrier property of the formed microsphere is sufficient and a desired maximum expansion ratio is obtained.
- the polymerizable monomer preferably does not contain a monomer having a carboxyl group.
- the monomer having a carboxyl group include acrylic acid, methacrylic acid, maleic acid, maleic anhydride, and itaconic acid.
- a monomer having a carboxyl group, particularly methacrylic acid is used as the polymerizable monomer, the heat resistance of the outer shell can be improved.
- the polymerizable monomer does not contain a monomer having a carboxyl group, the effect of the present invention is sufficiently exhibited and the dispersion of the polymerizable mixture (oil phase) during polymerization becomes stable.
- abnormal polymerization may occur in the aqueous dispersion medium other than oil droplets, and furthermore, a lot of settling may be observed during the production of a molded product including a foaming process of the obtained microspheres.
- the production conditions of the molded body are not limited, and the thermal stability is good.
- the polymerizable monomer does not contain a monomer having a carboxyl group
- the foamability does not decrease even under high humidity conditions. Therefore, in that case, there is no possibility that the use of the microsphere is limited.
- the polymerizable monomer contains a monomer having a carboxyl group
- the foamability may be reduced under high humidity conditions. This is because the barrier property of the outer shell is due to hydrogen bonding. This is because, in a situation where moisture is present, the carboxyl group may cause a decrease in barrier properties.
- the crosslinkable monomer is a compound having two or more carbon-carbon double bonds.
- Examples of the crosslinkable monomer include divinylbenzene, ethylene glycol di (meth) acrylate [ethylene glycol di (meth) acrylate], diethylene glycol di (meth) acrylate [diethylene glycol di (meth) acrylate], di (meth) acrylate.
- the content of the crosslinkable monomer is preferably 0.01% by mass or more and 5% by mass or less, and more preferably 0.02% by mass or more and 3% by mass or less of the total amount of the polymerizable monomers. Preferably, it is 0.03 mass% or more and 2 mass% or less.
- a foaming agent is a substance that becomes a gas upon heating.
- hydrocarbons having a boiling point corresponding to the foaming start temperature can be used.
- blowing agents include ethane, ethylene, propane, propene, n-butane, isobutane, butene, isobutene, n-pentane, isopentane, neopentane, n-hexane, heptane, n-octane, isooctane, isododecane, petroleum ether, isoparaffin hydrocarbons such as mixtures, and isomeric mixtures thereof; CCl 3 F, CCl 2 F 2, CClF 3, chlorofluorocarbons such as CClF 2 -CClF 2; tetramethylsilane, trimethylethyl silane, trimethyl isopropyl silane, trimethyl -n- And tetraal
- isobutane, n-butane, n-pentane, isopentane, n-hexane, isooctane, isododecane, and isomer mixtures thereof, petroleum ether, and a mixture of two or more of these are preferable.
- microspheres are produced, for example, by suspension polymerization of a polymerizable mixture containing at least a foaming agent and a monomer containing a polymerizable monomer in an aqueous dispersion medium containing a dispersion stabilizer. can do.
- Aqueous dispersion medium water can be used. Specifically, deionized water or distilled water can be used.
- the amount of the aqueous dispersion medium used with respect to the total amount of the polymerizable monomers is not particularly limited, but is usually 0.5 to 30 times, and in many cases 1 to 10 times (mass ratio).
- Dispersion stabilizer examples include silica such as colloidal silica, calcium phosphate, magnesium hydroxide, aluminum hydroxide, ferric hydroxide, barium sulfate, calcium sulfate, sodium sulfate, calcium oxalate, calcium carbonate, barium carbonate, A magnesium carbonate etc. can be mentioned.
- a dispersion stabilizer is normally used in the ratio of 0.1 to 20 parts by mass with respect to 100 parts by mass of the total amount of polymerizable monomers.
- an auxiliary stabilizer such as a condensation product of diethanolamine and aliphatic dicarboxylic acid may be added in addition to the dispersion stabilizer.
- colloidal silica it is preferable to use a condensation product of diethanolamine and an aliphatic dicarboxylic acid as an auxiliary stabilizer.
- aqueous dispersion medium in addition to the dispersion stabilizer, at least one selected from the group consisting of alkali metal nitrites, stannous chloride, stannic chloride, water-soluble ascorbic acids, and boric acid as a polymerization aid.
- the compound may be added.
- aggregation of polymer particles does not occur during polymerization. Further, the polymer does not adhere to the polymerization can wall. Therefore, it is possible to stably produce microspheres while efficiently removing heat generated by polymerization.
- alkali metal nitrites sodium nitrite or potassium nitrite is preferable in terms of availability and price.
- These compounds are usually used at a ratio of 0.001 to 1 part by mass, preferably 0.01 to 0.1 part by mass, with respect to 100 parts by mass of the total amount of polymerizable monomers. Is done.
- a polymerization initiator such as dialkyl peroxide, diacyl peroxide, peroxydicarbonate or azo compound may be added.
- the polymerization initiator is usually used in a proportion of 0.0001% by mass or more and 3% by mass or less based on the aqueous dispersion medium.
- dispersion stabilizer In carrying out suspension polymerization, it is preferable to select optimum pH conditions depending on the type of dispersion stabilizer or auxiliary stabilizer used.
- silica such as colloidal silica
- the polymerization is preferably performed in an acidic environment.For example, an acid is added to an aqueous dispersion medium containing the dispersion stabilizer to reduce the pH of the system. You may adjust to 3-4.
- magnesium hydroxide or calcium phosphate it is preferable to polymerize in an alkaline environment.
- a foaming agent and an outer shell-forming monomer are added to an aqueous dispersion medium containing a dispersion stabilizer, and the mixture is stirred and mixed. Since the foaming agent and the outer shell-forming monomer form droplets that are an oil phase in an aqueous dispersion medium, they can be granulated into fine droplets of a desired size by stirring and mixing. .
- the foaming agent is added in such an amount as to satisfy the above formula (5) assuming the average particle diameter of the microspheres to be produced.
- stirrer When stirring and mixing, conditions such as the type of stirrer and the number of rotations are set according to the desired particle size of the microsphere. At this time, the conditions are selected in consideration of the size and shape of the reaction vessel, the presence or absence of baffles, and the like. As the stirrer, a homogenizer having a high shearing force is preferable.
- the obtained dispersion is poured into the reaction tank, and then suspension polymerization is performed in the reaction tank.
- the reaction is carried out at a temperature of 40 to 80 ° C. for 5 to 50 hours with stirring. Since the microspheres produced by the polymerization form an oil phase (solid phase), the aqueous phase containing the aqueous dispersion medium is separated and removed from the microspheres by a separation method such as filtration. Finally, the obtained microsphere is dried at a relatively low temperature so that the blowing agent is not gasified, if necessary.
- the microsphere since the microsphere satisfies the above formulas (1) and (2) or the above formulas (4) and (5), the microsphere has a large expansion ratio and a foaming start temperature. Is high, and it is difficult for the settling phenomenon to occur.
- the foaming ratio is small, the foaming start temperature is low, or the settling phenomenon is likely to occur. If the amount of the foaming agent in the microsphere is too large relative to the average particle size of the microsphere, the thickness of the outer shell will be reduced by that amount. Further, the outer shell that has become thinner is transmitted, which causes the microsphere to sag and causes the foaming ratio of the microsphere to decrease. Also, if the amount of foaming agent in the microsphere is too large relative to the average particle size of the microsphere, depending on how much foaming agent is present, the internal pressure of the microsphere increases during heating. It may become too much, and this may reduce the foaming start temperature.
- the average particle diameter of the microspheres since the microsphere satisfies the above formulas (1) and (2) or the above formulas (4) and (5), the average particle diameter of the microspheres
- the amount of blowing agent in the microsphere is optimized.
- the amount of foaming agent in the microsphere with respect to the average particle size of the microsphere, the thickness of the outer shell is not too thin, and the foaming agent can penetrate the outer shell during foaming. Since it can suppress, it can suppress the generation
- the microsphere according to the present embodiment has a high foaming ratio, a high foaming start temperature, and is unlikely to cause a settling phenomenon.
- the microsphere according to the present embodiment uses, for example, a filler for paints for automobiles, wallpaper, a foaming agent for foamed ink (relief patterning for T-shirts), and an anti-shrinkage agent. Although it can be used, it is also possible to use the microsphere as a composition or structural member in which the microsphere is combined with other materials depending on the application.
- the microsphere according to this embodiment can be used in a state of a thermally foamable resin composition obtained by melt-kneading the microsphere with a thermoplastic resin.
- This thermally foamable resin composition can be used as a master batch for pelletizing and adding to the following materials.
- thermoplastic resin is not particularly limited, and examples thereof include general thermoplastic resins such as polyvinyl chloride, polystyrene, polypropylene, polypropylene oxide, and polyethylene.
- thermoplastic resin thermoplastic elastomers such as ethylene, vinyl chloride, olefin, urethane, and ester may be used, or these resins may be used in combination.
- the microsphere according to the present embodiment can be used in a state of a structural member provided with a microsphere in a material containing at least one of a polymer and a fiber.
- polystyrene examples include polyethylene (PE), polypropylene (PP), polystyrene (PS), polyamide (PA), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyphenylene sulfide (PPS), ABS (acrylic. Butadiene / styrene) resin, styrene / butadiene / styrene block copolymer (SBS), styrene / isoprene block copolymer (SIS), hydrogenated SIS, natural rubber, various synthetic rubbers, and thermoplastic polyurethane. However, it is not limited to these.
- the fiber examples include glass fiber, kenaf, and carbon fiber. Since such a fiber does not have a function of holding air by itself, it is preferable to use it with microspheres that are closed cells.
- the microsphere When manufacturing this structural member, it is preferable to heat-treat the microsphere at a temperature lower than the foaming start temperature of the microsphere (for example, 150 ° C.) with the microsphere provided in the material. Until the microspheres are included in the material, the foaming start temperature of the microspheres can be maintained at a high level, and therefore various materials can be used as the material.
- the heat treatment includes a drying process and a molding process (for example, master batch processing, hot press processing, roll processing, and the like) at the time of manufacturing the structural member.
- the microspheres are heat-treated at a temperature lower than the foaming start temperature of the microspheres, so that compared to the foaming start temperature of the unheated microspheres.
- the foaming start temperature of the microsphere after the heat treatment is lowered.
- various materials can be used as the material, and the microspheres can be foamed with a smaller amount of heat when the molded body is produced.
- the microsphere according to the present embodiment is blended with a structural member, paint, ink, and the like to form a molded body (for example, a foamed molded product, a foamed coating film, and a foamed ink) containing foamed particles obtained by foaming the microsphere.
- a molded body for example, a foamed molded product, a foamed coating film, and a foamed ink
- foamed particles obtained by foaming the microsphere.
- you can also.
- the molded product can be cushioned and reduced in weight, and the molded product can be provided with various functionalities such as slip properties, heat insulating properties, and sound insulation properties.
- the structural member is heat-treated at a temperature lower than the foaming start temperature of the microsphere, and the structural member is heated at a temperature equal to or higher than the foaming start temperature of the microsphere after the heat treatment. It is preferable. Thereby, the microsphere can be foamed with a small amount of heat.
- a microsphere comprising an outer shell and a foaming agent enclosed in the outer shell, wherein the foaming agent becomes a gas upon heating.
- D50 average particle diameter
- B1 mass%
- a microsphere comprising an outer shell and a foaming agent enclosed in the outer shell, wherein the outer shell is made of a monomer containing a polymerizable monomer. It is comprised from a polymer,
- the said foaming agent contains the compound which becomes a gas by heating, the average particle diameter (D50) of the said microsphere is set to A (micrometer), and the quantity of the said foaming agent is set to B2 (mass part). Then, the microsphere characterized by satisfy
- thermoplastic resin composition comprising the above microsphere and a thermoplastic resin.
- a structural member comprising the above microsphere in a material containing at least one of a polymer and a fiber.
- a molded body including expanded particles obtained by expanding the above microspheres.
- a method for manufacturing a structural member having a microsphere in the material including a step of performing a heat treatment at a temperature lower than a foaming start temperature of the sphere.
- the method includes a step of heating the structural member obtained by the method for manufacturing the structural member at a temperature equal to or higher than a foaming start temperature of the microsphere after the heat treatment.
- a method for producing a molded body is provided.
- the microsphere of one aspect and the other aspect of the present invention since the amount of the foaming agent is optimized with respect to the average particle diameter of the microsphere, the microsphere has an average particle diameter of 50 ⁇ m. Even when the thickness is 190 ⁇ m or less, the foaming ratio is large, the foaming start temperature is high, and the settling phenomenon hardly occurs.
- the foaming ratio is large, the foaming start temperature is high, and the settling phenomenon hardly occurs, and the average particle size is 50 ⁇ m or more and 190 ⁇ m or less.
- the thermally foamable resin composition containing the microspheres can be provided.
- the foaming ratio is large, the foaming start temperature is high, and the settling phenomenon hardly occurs, and the average particle diameter is 50 ⁇ m to 190 ⁇ m.
- the structural member containing the microsphere can be provided.
- a molded article excellent in cushioning and weight reduction can be provided by including foamed particles obtained by foaming the microspheres. .
- Example 2 In Example 2, 259 g of the isododecane isomer mixture, 49 g of the isooctane isomer mixture, and 14 g of the isopentane isomer mixture were used as the foaming agent, and the suspension was suspended at 3500 rpm using a homogenizer. Microspheres were obtained in the same manner as above. The total amount of foaming agent (charge amount) was 23 parts by mass with respect to 100 parts by mass of the total amount of polymerizable monomers.
- Example 3 280 g of the isododecane isomer mixture, 56 g of the isooctane isomer mixture, and 14 g of the isopentane isomer mixture were used as the blowing agent, and the suspension was suspended at 5000 rpm using a homogenizer. Microspheres were obtained in the same manner as above.
- the total amount of foaming agent (charge amount) was 25 parts by mass with respect to 100 parts by mass of the total amount of polymerizable monomers.
- Example 5 224 g of the isododecane isomer mixture, 42 g of the isooctane isomer mixture, and 14 g of the isopentane isomer mixture were used as the blowing agent, and the suspension was suspended at 2000 rpm using a homogenizer. Microspheres were obtained in the same manner as above.
- the total amount of foaming agent (charge amount) was 20 parts by mass with respect to 100 parts by mass of the total amount of polymerizable monomers.
- Comparative Example 1 In Comparative Example 1, microspheres were obtained in the same manner as in Example 2 except that 392 g of isododecane isomer mixture, 84 g of isooctane isomer mixture, and 14 g of isopentane isomer mixture were used as the blowing agent. .
- the total amount of foaming agent (charge amount) was 35 parts by mass with respect to 100 parts by mass of the total amount of polymerizable monomers.
- Comparative Example 2 In Comparative Example 2, microspheres were obtained in the same manner as in Example 2 except that 336 g of isododecane isomer mixture, 70 g of isooctane isomer mixture, and 14 g of isopentane isomer mixture were used as the blowing agent. .
- the total amount of foaming agent (charge amount) was 30 parts by mass with respect to 100 parts by mass of the total amount of polymerizable monomers.
- Comparative Example 3 In Comparative Example 3, microspheres were obtained in the same manner as in Example 5 except that 280 g of isododecane isomer mixture, 56 g of isooctane isomer mixture, and 14 g of isopentane isomer mixture were used as the blowing agent. .
- the total amount of foaming agent (charge amount) was 25 parts by mass with respect to 100 parts by mass of the total amount of polymerizable monomers.
- a flow type particle size analyzer product name “FPIA-3000”, manufactured by Sysmex Corporation
- thermomechanical analyzer model number “TMA / SDTA840”, manufactured by METTLER TRADE CO., LTD.
- the temperature was raised and the displacement at the height was continuously measured.
- the temperature at which the displacement of the height of the microspheres in the container began was taken as the unheated foaming start temperature.
- the foaming start temperature of the microsphere heat-processed for 5 minutes at 150 degreeC was also measured by the same method.
- ⁇ Foamed particle density measurement> The microspheres according to Examples and Comparative Examples were foamed and the expanded particle density was measured. Specifically, 0.5 g of microspheres and 2.5 g of silicon oil were weighed in an aluminum cup, mixed well, then heated and foamed in an oven at 200 ° C. for 5 minutes, taken out, put into a 50 ml volumetric flask, and isopropanol The true density of the expanded foam was determined from the sample weight and the weight after the measurement. Separately, 0.5 g of microspheres according to Examples and Comparative Examples and 2.5 g of silicon oil were weighed into an aluminum cup, mixed well, and then heated and foamed in an oven at 190 ° C. for 5 minutes and taken out.
- the true density of the expanded foamed foam was determined from the sample weight and the weight after the volume-up by placing in a 50 ml volumetric flask and making up with isopropanol.
- the microsphere used for the foamed particle density measurement was heat-treated at 150 ° C. for 5 minutes before foaming.
- the amount of the foaming agent (measured amount and charged amount) satisfied the above formulas (1) and (2) (see FIG. 1), and the above (4) And (5) is satisfied (see FIG. 2) and is optimized for the average particle size of the microsphere, so that the average particle size according to the reference example is less than 50 ⁇ m, The foaming ratio was large, the foaming start temperature was high, and almost no settling phenomenon occurred. Accordingly, when the amount of the foaming agent satisfies the above formulas (1) and (2), or when the above (4) and (5) are satisfied, the foaming ratio is large and the foaming start temperature is It was confirmed that a microsphere which is high and hardly causes a settling phenomenon can be obtained.
- microsphere according to Example 2 and the microsphere according to Example 3 have substantially the same average particle diameter, but the microsphere according to Example 3 is more microsphere according to Example 2. Since the amount of the foaming agent was larger than that, the expansion ratio was large.
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Abstract
Description
B1≦-0.14×A+33 …式(2)
本発明の他の態様によれば、外殻と、当該外殻内に封入された発泡剤とを含むマイクロスフェアーであって、当該外殻が、重合性単量体を含む単量体の重合体から構成され、当該発泡剤が、加熱により気体となる化合物を含み、当該マイクロスフェアーの平均粒子径(D50)をA(μm)とし、前記発泡剤の量をB2(質量部)としたとき、下記式(4)および(5)の関係を満たすことを特徴とする、マイクロスフェアーが提供される。
B2≦-0.22×A+43 …式(5)
(上記式(5)中、B2は前記重合性単量体を100質量部としたときの前記発泡剤の質量部を意味する。)
マイクロスフェアーは、外殻と、外殻内に封入された発泡剤とを含んでいる。外殻は、発泡剤を封入できる材料から構成されていれば、特に限定されないが、例えば、重合性単量体を含む単量体の重合体から構成されていることが好ましい。発泡剤は、外殻の構成材料(例えば、上記重合体)の軟化点以下の温度で気体となる化合物を含むものである。
B1≦-0.14×A+33 …式(2)
上記したように発泡剤の最適含有量はマイクロスフェアーの平均粒子径に依存する。その関係を表したのが上記式(2)である。上記式(2)は実験により導き出した式である。B1の値が上記式(2)を満足することによって、マイクロスフェアー内の発泡剤の量が最適となる。そのため、後述する理由によってマイクロスフェアーの発泡開始温度が低くなり、ヘタリ現象が発生し易くなり、また発泡倍率も小さくなるおそれを回避することができる。
マイクロスフェアーの平均粒子径Aは、粒子径分析装置(製品名「FPIA-3000」、シスメックス株式会社製)を用いて、マイクロスフェアーの粒度分布を測定したときのメジアン径である。マイクロスフェアーの平均粒子径Aの下限は55μm以上であることが好ましく、60μm以上であることがより好ましい。また、マイクロスフェアーの平均粒子径Aの上限は120μm以下であることが好ましく、100μm以下であることがより好ましい。
B2≦-0.22×A+43 …式(5)
上記式(5)中、B2は重合性単量体を100質量部としたときの発泡剤の質量部を意味する。
マイクロスフェアーは、発泡開始温度以上で発泡(膨張)するものである。マイクロスフェアーを加熱すると、発泡剤が気化して膨張する力が外殻に働くが、同時に、外殻を形成する重合体の弾性率が急激に減少するため、ある温度を境にしてマイクロスフェアーの急激な膨張が起きる。本明細書においては、この急激な膨張が起きる温度を「発泡開始温度」と言う。具体的には、発泡開始温度は、マイクロスフェアー0.25mgを使用し、昇温速度5℃/分で昇温して、その高さの変位を連続的に測定し、マイクロスフェアーの高さの変位が始まった温度とする。ここで、本明細書において、特に言及しない場合には「マイクロスフェアーの発泡開始温度」は、未熱処理のマイクロスフェアーの発泡開始温度を意味するものとする。
ここで、R1/R2は、マイクロスフェアーのヘタリ度合いの指標として用いることができる。具体的には、R1/R2<1であれば、200℃で加熱して発泡させた発泡粒子の方が190℃で加熱して発泡させた発泡粒子よりも発泡倍率が大きくなる。また、R1/R2=1であれば、200℃で加熱して発泡させた発泡粒子と190℃で加熱して発泡させた発泡粒子との発泡倍率が同じとなる。これらは、いずれもマイクロスフェアーのヘタリ現象が発生していないことを意味している。一方で、R1/R2>1であれば、200℃で加熱して発泡させた発泡粒子の方が190℃で加熱して発泡させた発泡粒子よりも発泡倍率が小さくなり、これは、マイクロスフェアーのヘタリ現象が生じていることを意味している。したがって、マイクロスフェアーが、上記式(7)の関係を満たすことにより、200℃では、マイクロスフェアーのヘタリ現象が発生していないか、またはマイクロスフェアーのヘタリ現象がほぼ発生していないと言える。
外殻は、上記したように重合性単量体を含む単量体の重合体から構成することが可能である。単量体は、外殻を形成するための単量体であり、重合性単量体の他、架橋性単量体を含んでいることが好ましい。単量体が、重合性単量体の他、架橋性単量体を含むことにより、発泡特性及び耐熱性等を改良することができる。外殻における(メタ)アクリロニトリルの含有比率が高いほど、形成されるマイクロスフェアーの発泡開始温度が高くなる傾向がある。したがって、外殻は、マイクロスフェアーの発泡開始温度を高める観点から、(メタ)アクリロニトリルを主成分とする重合体であることが好ましい。
重合性単量体は、1つの炭素-炭素二重結合(-C=C-)を有する化合物である。炭素-炭素二重結合としては、例えば、ビニル基、(メタ)アクリロイル基、およびアリル基等が挙げられる。重合性単量体としては、特に限定されるものではないが、重合体の外殻がガスバリア性、耐溶剤性および耐熱性を有し、また、良好な発泡性、所望によっては高温での発泡性を有する重合体を生成することができる観点から、アクリロニトリル及びメタクリロニトリルからなる群より選ばれる少なくとも一種の単量体(この単量体を総称して、「(メタ)アクリロニトリル」ということがある。)および/または塩化ビニリデンを用いることが好ましい。
架橋性単量体は、2以上の炭素-炭素二重結合を有する化合物である。架橋性単量体としては、例えば、ジビニルベンゼン、ジ(メタ)アクリル酸エチレングリコール〔エチレングリコールジ(メタ)アクリレート〕、ジ(メタ)アクリル酸ジエチレングリコール〔ジエチレングリコールジ(メタ)アクリレート〕、ジ(メタ)アクリル酸トリエチレングリコール、(メタ)アクリル酸アリル、イソシアン酸トリアリル、トリアクリルホルマール、トリ(メタ)アクリル酸トリメチロールプロパン、ジ(メタ)アクリル酸1,3-ブチルグリコール、ペンタエリスリトールトリ(メタ)アクリレート、ペンタエリスリトールテトラ(メタ)アクリレート等が挙げられる。架橋性単量体の含有量は、重合性単量体の合計量の0.01質量%以上5質量%以下であることが好ましく、0.02質量%以上3質量%以下であることがより好ましく、0.03質量%以上2質量%以下であることがさらに好ましい。
発泡剤は、加熱により気体となる物質である。発泡剤として、発泡開始温度に応じた沸点を有する炭化水素等を用いることができる。発泡剤として、例えば、エタン、エチレン、プロパン、プロペン、n-ブタン、イソブタン、ブテン、イソブテン、n-ペンタン、イソペンタン、ネオペンタン、n-ヘキサン、ヘプタン、n-オクタン、イソオクタン、イソドデカン、石油エーテル、イソパラフィン混合物などの炭化水素、およびその異性体混合物;CCl3F、CCl2F2、CClF3、CClF2-CClF2等のクロロフルオロカーボン;テトラメチルシラン、トリメチルエチルシラン、トリメチルイソプロピルシラン、トリメチル-n-プロピルシランなどのテトラアルキルシランなどが挙げられる。これらは、それぞれ単独で、あるいは2種以上を組み合わせて使用することができる。これらの中でも、イソブタン、n-ブタン、n-ペンタン、イソペンタン、n-ヘキサン、イソオクタン、イソドデカン、およびそれらの異性体混合物、石油エーテル、ならびにこれらの2種以上の混合物が好ましい。また、所望により、発泡剤として、加熱により熱分解して気体となる化合物を使用してもよい。
上記のマイクロスフェアーは、例えば、分散安定剤を含有する水系分散媒体中で、少なくとも発泡剤と重合性単量体を含む単量体とを含有する重合性混合物を懸濁重合することにより製造することができる。
水系分散媒体としては、水を使用することができ、具体的には脱イオン水または蒸留水を使用することができる。重合性単量体の合計量に対する水系分散媒体の使用量は、特に限定されないが、通常0.5~30倍、多くの場合1~10倍(質量比)である。
分散安定剤としては、例えば、コロダイルシリカ等のシリカ、リン酸カルシウム、水酸化マグネシウム、水酸化アルミニウム、水酸化第二鉄、硫酸バリウム、硫酸カルシウム、硫酸ナトリウム、シュウ酸カルシウム、炭酸カルシウム、炭酸バリウム、炭酸マグネシウムなどを挙げることができる。分散安定剤は、重合性単量体の合計量100質量部に対して、通常、0.1質量部以上20質量部以下の割合で使用される。
水系分散媒体中には、分散安定剤の他、ジエタノールアミンと脂肪族ジカルボン酸との縮合生成物等の補助安定剤が添加されていてもよい。分散安定剤としてコロイダルシリカを用いた場合には、補助安定剤としてジエタノールアミンと脂肪族ジカルボン酸との縮合生成物を用いることが好ましい。
本実施形態に係るマイクロスフェアーは、その膨張性を利用して、例えば、自動車等の塗料の充填剤、壁紙、発泡インク(T-シャツ等のレリーフ模様付け)の発泡剤、収縮防止剤として用いることができるが、用途に応じて、当該マイクロスフェアーを他の材料と組み合わせた組成物または構造部材として用いることも可能である。
以上、本発明のマイクロスフェアーの具体的な態様として、外殻と、当該外殻内に封入された発泡剤とを含むマイクロスフェアーであって、当該発泡剤が、加熱により気体となる化合物を含み、当該マイクロスフェアーの平均粒子径(D50)をA(μm)とし、当該マイクロスフェアーに対する当該発泡剤の量をB1(質量%)としたとき、下記式(1)および(2)の関係を満たすことを特徴とする、マイクロスフェアーが提供される。
B1≦-0.14×A+33 …式(2)
本発明の他の態様によれば、外殻と、当該外殻内に封入された発泡剤とを含むマイクロスフェアーであって、当該外殻が、重合性単量体を含む単量体の重合体から構成され、当該発泡剤が、加熱により気体となる化合物を含み、当該マイクロスフェアーの平均粒子径(D50)をA(μm)とし、当該発泡剤の量をB2(質量部)としたとき、下記式(4)および(5)の関係を満たすことを特徴とする、マイクロスフェアーが提供される。
B2≦-0.22×A+43 …式(5)
(上記式(5)中、B2は前記重合性単量体を100質量部としたときの前記発泡剤の質量部を意味する。)
本発明の他の態様によれば、上記のマイクロスフェアーと、熱可塑性樹脂とを含む、熱発泡性樹脂組成物が提供される。
(1)水系分散媒体の調製
20質量%のコロイダルシリカ210g、50質量%のジエタノールアミン-アジピン酸縮合生成物(酸価=78mgKOH/g)9.8g、亜硝酸ナトリウム0.84g、塩化ナトリウム1246gおよび水3982gを混合して、水系分散媒体を調製した。この水系分散媒体に塩酸を加えて、pHを3.5に調整した。
重合性単量体であるアクリロニトリル938g、メタクリロニトリル434g、メタクリル酸メチル28gと、発泡剤であるイソドデカン異性体混合物315g、イソオクタン異性体混合物63g、イソペンタン異性体混合物14gと、架橋性単量体であるジエチレングリコールジメタクリレート15.4gと、重合開始剤である2、2´-アゾビスイソブチロニトリル16.8gとを混合して、重合性混合物を調製した。総発泡剤量(仕込量)は、重合性単量体の合計量100質量部に対して28質量部であった。
上記で調製した水系分散媒体と重合性混合物とを、ホモジナイザーを用いて回転数6000rpmで30秒間攪拌混合して、水系分散媒体中に重合性混合物の微小な液滴を形成した。この重合性混合物の微小な液滴を含有する水系分散媒体を、攪拌機付きの重合缶(10L)に仕込み、温水バスを用いて回転数360rpmで60℃13.5時間、さらに70℃で10時間加熱して反応させた。重合後、生成したマイクロスフェアーを含有するスラリーを濾過・水洗し、乾燥して、実施例1に係るマイクロスフェアーを得た。
実施例2においては、発泡剤として、イソドデカン異性体混合物259g、イソオクタン異性体混合物49g、およびイソペンタン異性体混合物14gを用い、ホモジナイザーを用いて回転数3500rpmで懸濁した以外は、実施例1の方法と同様な方法でマイクロスフェアーを得た。総発泡剤量(仕込量)は、重合性単量体の合計量100質量部に対して23質量部であった。
実施例3においては、発泡剤として、イソドデカン異性体混合物280g、イソオクタン異性体混合物56g、およびイソペンタン異性体混合物14gを用い、ホモジナイザーを用いて回転数5000rpmで懸濁した以外は、実施例1の方法と同様な方法でマイクロスフェアーを得た。総発泡剤量(仕込量)は、重合性単量体の合計量100質量部に対して25質量部であった。
実施例4においては、20質量%のコロイダルシリカを189g、50質量%のジエタノールアミン-アジピン酸縮合生成物(酸価=78mgKOH/g)を8.7g、水を4002g、発泡剤として、イソドデカン異性体混合物259g、イソオクタン異性体混合物49g、およびイソペンタン異性体混合物14gを用い、ホモジナイザーを用いて回転数3500rpmで懸濁した以外は、実施例1の方法と同様な方法でマイクロスフェアーを得た。総発泡剤量(仕込量)は、重合性単量体の合計量100質量部に対して23質量部であった。
実施例5においては、発泡剤として、イソドデカン異性体混合物224g、イソオクタン異性体混合物42g、およびイソペンタン異性体混合物14gを用い、ホモジナイザーを用いて回転数2000rpmで懸濁した以外は、実施例1の方法と同様な方法でマイクロスフェアーを得た。総発泡剤量(仕込量)は、重合性単量体の合計量100質量部に対して20質量部であった。
参考例においては、発泡剤として、イソドデカン異性体混合物224gおよびイソオクタン異性体混合物196gを用い、ホモジナイザーを用いて回転数7000rpmで48秒間懸濁した以外は、実施例1の方法と同様な方法でマイクロスフェアーを得た。総発泡剤量(仕込量)は、重合性単量体の合計量100質量部に対して30質量部であった。
比較例1においては、発泡剤として、イソドデカン異性体混合物392g、イソオクタン異性体混合物84g、およびイソペンタン異性体混合物14gを用いた以外は、実施例2の方法と同様な方法でマイクロスフェアーを得た。総発泡剤量(仕込量)は、重合性単量体の合計量100質量部に対して35質量部であった。
比較例2においては、発泡剤として、イソドデカン異性体混合物336g、イソオクタン異性体混合物70g、およびイソペンタン異性体混合物14gを用いた以外は、実施例2の方法と同様な方法でマイクロスフェアーを得た。総発泡剤量(仕込量)は、重合性単量体の合計量100質量部に対して30質量部であった。
比較例3においては、発泡剤として、イソドデカン異性体混合物280g、イソオクタン異性体混合物56g、およびイソペンタン異性体混合物14gを用いた以外は、実施例5の方法と同様な方法でマイクロスフェアーを得た。総発泡剤量(仕込量)は、重合性単量体の合計量100質量部に対して25質量部であった。
実施例および比較例に係るマイクロスフェアーの平均粒子径(D50)をそれぞれ測定した。具体的には、まず、マイクロスフェアーのスラリーを篩分網#100(目開き150μm)で篩分した。篩分したスラリー0.5gを純イオン交換水20mlに分散し、超音波を15分以上かけて分散して、これを試料とした。そして、この試料に含まれるスラリーの平均粒子径(D50)を、フロー式粒子径分析装置(製品名「FPIA-3000」、シスメックス株式会社製)を用いて、測定条件トータルカウント10000(撮影粒子数は10000個)で測定した。
実施例および比較例に係るマイクロスフェアーの発泡剤量をそれぞれ測定した。具体的には、マイクロスフェアー0.1gをN,N-ジメチルホルムアミド(DMF)に浸漬後、超音波にて15分間分散させ、一晩静置させで膨潤液を調製した。該膨潤液の上澄みについてガスクロマトグラフィー分析を行なうことより、マイクロスフェアーの発泡剤量を求めた。
ガスクロマトグラフィー分析の条件は以下の通りとした。
ガスクロマトグラフ:島津製作所社製 GC-14B
検出器:FID、温度200℃
パックドカラム:島津GLC社製 UCON LB-550X 10%
Shimalite 80-100 AW-DMCS
昇温プログラム:120℃(11分)→15℃/分→180℃(保持)
注入口温度:200℃
注入量:3μL
定量:検量線法(既知量の試料をDMFに溶解させた溶液)
<発泡開始温度測定>
実施例および比較例に係るマイクロスフェアーの発泡開始温度をそれぞれ測定した。具体的には、容器に未熱処理のマイクロスフェアー0.25mgを入れて、熱機械分析装置(型番「TMA/SDTA840」、メトラー・トレイド株式会社製)を用いて、昇温速度5℃/分で昇温し、その高さの変位を連続的に測定した。そして、容器内におけるマイクロスフェアーの高さの変位が始まった温度を未熱処理の発泡開始温度とした。また、同様の方法によって、150℃5分間熱処理したマイクロスフェアーの発泡開始温度も測定した。
実施例および比較例に係るマイクロスフェアーを発泡させて、発泡粒子密度をそれぞれ測定した。具体的には、マイクロスフェアー0.5gおよびシリコンオイル2.5gをアルミカップに秤取り、良く混ぜた後、200℃で5分間オーブンで加熱発泡させて取り出し、50mlのメスフラスコに入れ、イソプロパノールでメスアップしてサンプル重量、メスアップ後の重量から発泡した発泡粒子の真密度を求めた。また、これとは別に、実施例および比較例に係るマイクロスフェアー0.5gおよびシリコンオイル2.5gをアルミカップに秤取り、良く混ぜた後、190℃で5分間オーブンで加熱発泡させて取り出し、50mlのメスフラスコに入れ、イソプロパノールでメスアップしてサンプル重量、メスアップ後の重量から発泡した発泡粒子の真密度を求めた。なお、発泡粒子密度測定に用いたマイクロスフェアーは、発泡させる前に予め150℃で5分間の熱処理を行ったものであった。
Claims (14)
- 外殻と、当該外殻内に封入された発泡剤とを含むマイクロスフェアーであって、
前記発泡剤が、加熱により気体となる化合物を含み、
前記マイクロスフェアーの平均粒子径(D50)をA(μm)とし、前記マイクロスフェアーに対する前記発泡剤の量をB1(質量%)としたとき、下記式(1)および(2)の関係を満たすことを特徴とする、マイクロスフェアー。
50≦A≦190 …式(1)
B1≦-0.14×A+33 …式(2) - 下記式(3)の関係を満たす、請求項1に記載のマイクロスフェアー。
-0.14×A+27≦B1 …式(3) - 外殻と、当該外殻内に封入された発泡剤とを含むマイクロスフェアーであって、
前記外殻が、重合性単量体を含む単量体の重合体から構成され、
前記発泡剤が、加熱により気体となる化合物を含み、
前記マイクロスフェアーの平均粒子径(D50)をA(μm)とし、前記発泡剤の量をB2(質量部)としたとき、下記式(4)および(5)の関係を満たすことを特徴とする、マイクロスフェアー。
50≦A≦190 …式(4)
B2≦-0.22×A+43 …式(5)
(上記式(5)中、B2は前記重合性単量体を100質量部としたときの前記発泡剤の質量部を意味する。) - 下記式(6)の関係を満たす、請求項3に記載のマイクロスフェアー。
-0.22×A+39≦B2 …式(6) - 前記マイクロスフェアーの発泡開始温度が、200℃以上である、請求項1~4のいずれか一項に記載のマイクロスフェアー。
- 前記マイクロスフェアーを発泡させたときの発泡粒子の密度が、0.024g/ml以下である、請求項1~5のいずれか一項に記載のマイクロスフェアー。
- 下記式(7)の関係を満たす、請求項1~6のいずれか一項に記載のマイクロスフェアー。
R1/R2≦1.3 …式(7)
(上記式(7)中、R1は、前記マイクロスフェアーを150℃で5分間熱処理した後に200℃で5分間加熱して発泡させたときの発泡粒子の密度であり、R2は、前記マイクロスフェアーを150℃で5分間熱処理した後に190℃で5分間加熱して発泡させたときの発泡粒子の密度である。) - 前記外殻が、(メタ)アクリロニトリルを主成分とする重合体である、請求項1~7のいずれか一項に記載のマイクロスフェアー。
- 前記外殻が、(メタ)アクリロニトリルと、塩化ビニリデン、(メタ)アクリル酸エステル、スチレン、および酢酸ビニルからなる群から選択される1以上の単量体とのみからなる重合性単量体を含む単量体の重合体である、請求項1~8のいずれか一項に記載のマイクロスフェアー。
- 請求項1~9のいずれか一項に記載のマイクロスフェアーと、熱可塑性樹脂とを含む、熱発泡性樹脂組成物。
- 請求項1~9のいずれか一項に記載のマイクロスフェアーを、ポリマーおよび繊維の少なくともいずれかを含む素材中に備える、構造部材。
- 請求項1~9のいずれか一項に記載のマイクロスフェアーを発泡させた発泡粒子を含む、成形体。
- マイクロスフェアーを素材中に備える構造部材の製造方法であって、
請求項1~9のいずれか一項に記載のマイクロスフェアーを素材中に備えた状態で、当該マイクロスフェアーに対して、当該マイクロスフェアーの発泡開始温度未満の温度で熱処理する工程を含む、構造部材の製造方法。 - 請求項13に記載の構造部材の製造方法により得られた前記構造部材に対して、前記熱処理後の前記マイクロスフェアーの発泡開始温度以上の温度で加熱する工程を含む、成形体の製造方法。
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