WO2022210957A1 - Resin foam and foam member - Google Patents
Resin foam and foam member Download PDFInfo
- Publication number
- WO2022210957A1 WO2022210957A1 PCT/JP2022/016237 JP2022016237W WO2022210957A1 WO 2022210957 A1 WO2022210957 A1 WO 2022210957A1 JP 2022016237 W JP2022016237 W JP 2022016237W WO 2022210957 A1 WO2022210957 A1 WO 2022210957A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- resin foam
- resin
- foam
- weight
- polyolefin
- Prior art date
Links
- 229920005989 resin Polymers 0.000 title claims abstract description 281
- 239000011347 resin Substances 0.000 title claims abstract description 281
- 239000006260 foam Substances 0.000 title claims abstract description 251
- 238000011084 recovery Methods 0.000 claims abstract description 25
- 229920000098 polyolefin Polymers 0.000 claims description 52
- 229920001971 elastomer Polymers 0.000 claims description 37
- 239000010410 layer Substances 0.000 claims description 28
- 239000000806 elastomer Substances 0.000 claims description 22
- 238000002844 melting Methods 0.000 claims description 16
- 229920005672 polyolefin resin Polymers 0.000 claims description 10
- 239000012790 adhesive layer Substances 0.000 claims description 9
- 230000006835 compression Effects 0.000 claims description 9
- 238000007906 compression Methods 0.000 claims description 9
- 239000000203 mixture Substances 0.000 claims description 6
- 239000011800 void material Substances 0.000 claims description 5
- 239000006261 foam material Substances 0.000 claims 1
- 210000004027 cell Anatomy 0.000 description 69
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 56
- 238000000034 method Methods 0.000 description 37
- 238000004080 punching Methods 0.000 description 37
- 239000011342 resin composition Substances 0.000 description 37
- 239000007789 gas Substances 0.000 description 36
- 229920006124 polyolefin elastomer Polymers 0.000 description 33
- 238000005187 foaming Methods 0.000 description 29
- 239000000853 adhesive Substances 0.000 description 28
- 230000001070 adhesive effect Effects 0.000 description 28
- 239000001569 carbon dioxide Substances 0.000 description 28
- 229910002092 carbon dioxide Inorganic materials 0.000 description 28
- 239000000945 filler Substances 0.000 description 27
- 229920000642 polymer Polymers 0.000 description 27
- -1 and more preferably Polymers 0.000 description 22
- 239000011261 inert gas Substances 0.000 description 19
- 239000004743 Polypropylene Substances 0.000 description 17
- 239000000463 material Substances 0.000 description 17
- 238000001035 drying Methods 0.000 description 15
- 230000000694 effects Effects 0.000 description 15
- 229920001155 polypropylene Polymers 0.000 description 15
- 238000010438 heat treatment Methods 0.000 description 14
- 230000008018 melting Effects 0.000 description 14
- 239000005060 rubber Substances 0.000 description 14
- 229910052799 carbon Inorganic materials 0.000 description 13
- 238000000465 moulding Methods 0.000 description 13
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 13
- 239000004711 α-olefin Substances 0.000 description 13
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 11
- 239000005977 Ethylene Substances 0.000 description 11
- 238000011156 evaluation Methods 0.000 description 11
- 239000000155 melt Substances 0.000 description 11
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 11
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 11
- 229910000831 Steel Inorganic materials 0.000 description 10
- 238000010521 absorption reaction Methods 0.000 description 10
- 239000000839 emulsion Substances 0.000 description 10
- 238000005470 impregnation Methods 0.000 description 10
- 238000012545 processing Methods 0.000 description 10
- 239000010959 steel Substances 0.000 description 10
- 230000000052 comparative effect Effects 0.000 description 9
- 239000000126 substance Substances 0.000 description 9
- 229920002397 thermoplastic olefin Polymers 0.000 description 9
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 8
- 229920001577 copolymer Polymers 0.000 description 8
- 239000003431 cross linking reagent Substances 0.000 description 8
- 239000003063 flame retardant Substances 0.000 description 8
- 238000002347 injection Methods 0.000 description 8
- 239000007924 injection Substances 0.000 description 8
- 239000008188 pellet Substances 0.000 description 8
- 229920001384 propylene homopolymer Polymers 0.000 description 8
- 238000012360 testing method Methods 0.000 description 8
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 7
- 239000004820 Pressure-sensitive adhesive Substances 0.000 description 7
- 210000002421 cell wall Anatomy 0.000 description 7
- 239000003795 chemical substances by application Substances 0.000 description 7
- 238000010097 foam moulding Methods 0.000 description 7
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 description 7
- 239000000347 magnesium hydroxide Substances 0.000 description 7
- 229910001862 magnesium hydroxide Inorganic materials 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 238000004132 cross linking Methods 0.000 description 6
- 238000005096 rolling process Methods 0.000 description 6
- 239000012298 atmosphere Substances 0.000 description 5
- VBICKXHEKHSIBG-UHFFFAOYSA-N beta-monoglyceryl stearate Natural products CCCCCCCCCCCCCCCCCC(=O)OCC(O)CO VBICKXHEKHSIBG-UHFFFAOYSA-N 0.000 description 5
- 238000009826 distribution Methods 0.000 description 5
- 238000004898 kneading Methods 0.000 description 5
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- 239000002245 particle Substances 0.000 description 5
- 238000009738 saturating Methods 0.000 description 5
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- 150000001336 alkenes Chemical class 0.000 description 4
- 239000004088 foaming agent Substances 0.000 description 4
- 238000002156 mixing Methods 0.000 description 4
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 4
- 229920001296 polysiloxane Polymers 0.000 description 4
- 239000002904 solvent Substances 0.000 description 4
- 239000004094 surface-active agent Substances 0.000 description 4
- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 239000003963 antioxidant agent Substances 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 238000004891 communication Methods 0.000 description 3
- 150000001875 compounds Chemical class 0.000 description 3
- 239000012943 hotmelt Substances 0.000 description 3
- 239000003999 initiator Substances 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 229910052757 nitrogen Inorganic materials 0.000 description 3
- 238000000053 physical method Methods 0.000 description 3
- 239000003505 polymerization initiator Substances 0.000 description 3
- 239000000758 substrate Substances 0.000 description 3
- 238000012719 thermal polymerization Methods 0.000 description 3
- ZGEGCLOFRBLKSE-UHFFFAOYSA-N 1-Heptene Chemical compound CCCCCC=C ZGEGCLOFRBLKSE-UHFFFAOYSA-N 0.000 description 2
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 description 2
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 2
- WSSSPWUEQFSQQG-UHFFFAOYSA-N 4-methyl-1-pentene Chemical compound CC(C)CC=C WSSSPWUEQFSQQG-UHFFFAOYSA-N 0.000 description 2
- 229920002799 BoPET Polymers 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- 229920002943 EPDM rubber Polymers 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 2
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 2
- 229920000181 Ethylene propylene rubber Polymers 0.000 description 2
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 description 2
- 239000004831 Hot glue Substances 0.000 description 2
- 241000209094 Oryza Species 0.000 description 2
- 235000007164 Oryza sativa Nutrition 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- WYURNTSHIVDZCO-UHFFFAOYSA-N Tetrahydrofuran Chemical compound C1CCOC1 WYURNTSHIVDZCO-UHFFFAOYSA-N 0.000 description 2
- 239000006096 absorbing agent Substances 0.000 description 2
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 2
- 229910052787 antimony Inorganic materials 0.000 description 2
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 239000003086 colorant Substances 0.000 description 2
- 238000007334 copolymerization reaction Methods 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
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- 230000006837 decompression Effects 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 238000000113 differential scanning calorimetry Methods 0.000 description 2
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- 239000011737 fluorine Substances 0.000 description 2
- 229910052731 fluorine Inorganic materials 0.000 description 2
- 238000010191 image analysis Methods 0.000 description 2
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- 238000010030 laminating Methods 0.000 description 2
- 239000004611 light stabiliser Substances 0.000 description 2
- 239000000395 magnesium oxide Substances 0.000 description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
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- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 2
- 229920000139 polyethylene terephthalate Polymers 0.000 description 2
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- 235000009566 rice Nutrition 0.000 description 2
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- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- 239000004925 Acrylic resin Substances 0.000 description 1
- 238000004438 BET method Methods 0.000 description 1
- 229910052582 BN Inorganic materials 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 239000004709 Chlorinated polyethylene Substances 0.000 description 1
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 1
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- IMROMDMJAWUWLK-UHFFFAOYSA-N Ethenol Chemical compound OC=C IMROMDMJAWUWLK-UHFFFAOYSA-N 0.000 description 1
- 244000043261 Hevea brasiliensis Species 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
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- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 description 1
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- 238000010168 coupling process Methods 0.000 description 1
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Images
Classifications
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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
- C08J9/0061—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof characterized by the use of several polymeric components
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- 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
- C08J9/04—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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/025—Polyolefin
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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
- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
- C08K3/013—Fillers, pigments or reinforcing additives
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/10—Homopolymers or copolymers of propene
- C08L23/12—Polypropene
Definitions
- the present invention relates to resin foams and foamed members.
- Foam is often used as a cushioning material to protect screens of electronic devices, substrates, and electronic components.
- the Related Art In recent years, there has been a demand for narrowing the clearance of a portion where a cushioning material is arranged in accordance with the trend toward thinner electronic devices. Furthermore, with the miniaturization and multi-functionalization of electronic equipment, there is a tendency for the electronic components used to be miniaturized, and a smaller cushioning material (foam) is sometimes required. Also, in order to prevent communication failures in communication devices, electrical problems in electronic devices, etc., the cushioning material (foam) is sometimes required to have a low dielectric property.
- the raw foam is punched.
- a mold is used to apply high pressure to the foam to obtain the desired shape of the foam.
- the thickness that is reduced by punching may not fully recover after the punching process, resulting in thickness variations. Such a phenomenon is particularly problematic when applied to a location with a narrow clearance, or when punched into a narrow shape (for example, 1 mm wide) such as a picture frame shape.
- Patent Document 1 discloses a resin foam with excellent shock absorption. However, this document neither discloses nor suggests workability (punching workability) at the time of punching. Further, Patent Document 2 discloses a resin foam having a thin layer and excellent shock absorption. However, this document does not disclose recoverability or crushing after punching. Furthermore, a resin foam having both low dielectric properties and punching workability has not been realized.
- An object of the present invention is to provide a resin foam that is excellent in both low dielectric properties and punchability.
- the resin foam of the present invention is a resin foam having a cell structure, the resin foam has an apparent density of less than 0.4 g/cm 3 , and a load of 1000 g/cm 2 is applied to the resin foam.
- the thickness recovery rate after maintaining the added state for 120 seconds is 80% or more.
- the resin foam has a cell number density of 30 cells/mm 2 or more.
- the resin foam has an average cell diameter of 10 ⁇ m to 200 ⁇ m.
- the resin foam has a coefficient of variation of cell diameter of 0.5 or less.
- the resin foam has a void content of 30% or more.
- the resin foam has a tensile modulus at 25° C. of 1.5 MPa or more.
- the resin foam has a 50% compression load of 20 N/cm 2 or less.
- the resin foam contains a polyolefin resin.
- the polyolefin-based resin is a mixture of a polyolefin other than a polyolefin-based elastomer and a polyolefin-based elastomer.
- the resin foam has a hot melt layer on one side or both sides.
- a foam member is provided. This foam member has a resin foam layer and an adhesive layer arranged on at least one side of the resin foam layer, and the resin foam layer is the resin foam.
- the present invention it is possible to provide a resin foam that has excellent punching workability with little change in thickness before and after punching, even after punching.
- the resin foam of the present invention is also excellent in that it has low dielectric properties.
- FIG. 1 is a schematic cross-sectional view of a foam member according to one embodiment of the invention.
- the resin foam of the present invention has a cell structure.
- the cell structure include a closed cell structure, an open cell structure, a semi-open and semi-closed cell structure (a cell structure in which a closed cell structure and an open cell structure are mixed), and the like.
- the cell structure of the resin foam is a semi-open and semi-closed cell structure.
- the resin foam of the present invention is obtained by foaming a resin composition.
- the resin composition is a composition containing at least a resin constituting a resin foam.
- the resin foam has an apparent density of less than 0.4 g/cm 3 .
- the thickness recovery rate (hereinafter also referred to as instantaneous recovery rate) after a load of 1000 g/cm 2 is applied to the resin foam and maintained for 120 seconds is 80% or more.
- a resin foam having moderate voids and excellent low dielectric properties, and having an instantaneous recovery rate within a specific range, without impeding low dielectric properties and having excellent punching workability can be obtained. Obtainable. More specifically, the resin foam shows favorable behavior such that shape change such as thickness change is small even when it is punched, and even if the thickness is temporarily reduced by punching, it recovers in a short time. , excellent punchability.
- the apparent density of the resin foam is preferably 0.4 g/cm 3 or less, more preferably 0.01 g/cm 3 to 0.3 g/cm 3 , and more preferably 0.02 g/cm 3 to 0.3 g/cm 3 . It is 0.2 g/cm 3 , more preferably 0.03 g/cm 3 to 0.1 g/cm 3 , particularly preferably 0.03 g/cm 3 to 0.05 g/cm 3 . With such a range, the above effect becomes remarkable. Moreover, when the apparent density is within the above range, a resin foam having excellent flexibility and stress dispersion can be obtained. On the other hand, a resin foam having an excessively high apparent density may cause deformation of the application site by pressing. In particular, such a problem becomes conspicuous when applied to a location with a narrow clearance. The foamability can be judged by the apparent density. A method for measuring the apparent density will be described later.
- the thickness recovery rate (hereinafter, also referred to as instantaneous recovery rate) after a load of 1000 g/cm 2 is applied to the resin foam and maintained for 120 seconds is preferably 80% or more, more preferably 85% or more. , more preferably 87% or more, and particularly preferably 90% or more. With such a range, the above effect becomes remarkable.
- the thickness recovery rate is preferably as high as possible, its upper limit is, for example, 99% (preferably 100%). A method for measuring the thickness recovery rate will be described later.
- the resin foam as described above uses a resin having a die swell ratio of 1.4 or less at +20°C (the melting point of the resin that constitutes the resin foam) as the resin that constitutes the resin foam.
- a resin having a die swell ratio of 1.4 or less at +20°C the melting point of the resin that constitutes the resin foam
- the die swell ratio at +20°C of the melting point of the resin forming the resin foam before foaming is 1.4 or less. If a resin having a die swell ratio within the above range is used, shrinkage during formation of the resin foam can be prevented, and a thick resin foam can be formed, and the resin foam can contain cells with a small cell size.
- the die swell ratio at +20°C of the melting point of the resin forming the resin foam before foaming is preferably 1.2 or less, more preferably 1.1 or less.
- the lower limit of the die swell ratio of the resin (before foaming) is, for example, 1.05 (preferably 1.02, more preferably 1.01).
- the die swell ratio at the melting point +20°C of the resin constituting the resin foam is preferably 1.4 or less, more preferably 1.2 or less, and still more preferably 1. .1 or less.
- the lower limit of the die swell ratio of the resin (after foaming) is, for example, 1.05 (preferably 1.02, more preferably 1.01).
- the die swell ratio means a value obtained by dividing the diameter of the extruded resin by the diameter of the die when extruding molten resin from a die.
- the die swell ratio is obtained by extruding a resin melted at a melting point of +20°C using a die having a length of 10 mm and a diameter of 1 mm ⁇ at a shear rate of 20 mm/s, and measuring the diameter of the resulting string-like molding. It is calculated by the formula of diameter (mm) of molding/diameter of die (mm).
- the melting point of the resin is measured by the peak top temperature of the endothermic peak obtained by differential scanning calorimetry (DSC).
- DSC Differential scanning calorimetry
- the resin foam as described above can be formed by using a resin having a shear viscosity of 3000 Pa ⁇ s or less at the melting point (the melting point of the resin constituting the resin foam) +20°C. can. That is, in one embodiment, the shear viscosity at +20°C of the melting point of the resin forming the resin foam before foaming is 3000 Pa ⁇ s or less. If a resin having a shear viscosity within the above range is used, the gas used for forming the cell structure can be preferably dispersed when forming the resin foam, and as a result, a resin foam with small cell sizes can be obtained.
- the shear viscosity at +20°C of the melting point of the resin forming the resin foam before foaming is preferably 2500 Pa s or less, more preferably 2100 Pa s or less, still more preferably 2000 Pa s or less, and particularly preferably. is 1900 Pa ⁇ s or less.
- the lower limit of the shear viscosity of the resin (before foaming) is, for example, 500 Pa ⁇ s (preferably 700 Pa ⁇ s, more preferably 1000 Pa ⁇ s).
- the shear viscosity at the melting point +20°C of the resin constituting the resin foam is preferably 3000 Pa s or less, more preferably 2500 Pa s or less, and still more preferably 2100 Pa s.
- the lower limit of the shear viscosity of the resin (after foaming) is, for example, 500 Pa ⁇ s (preferably 700 Pa ⁇ s, more preferably 1000 Pa ⁇ s).
- the shear viscosity can be measured by extruding a resin melted at a melting point of +20° C. using a die having a length of 10 mm and a diameter of 1 mm ⁇ at a shear rate of 20 mm/s.
- the thickness of the resin foam is preferably 100 ⁇ m to 8000 ⁇ m, more preferably 200 ⁇ m to 5000 ⁇ m, still more preferably 300 ⁇ m to 4000 ⁇ m, still more preferably 400 ⁇ m to 3000 ⁇ m, still more preferably 500 ⁇ m to 2000 ⁇ m. be.
- Such a range is advantageous in that a fine and uniform cell structure can be formed, and excellent punching workability and impact absorption can be exhibited.
- the average cell diameter (average cell diameter) of the resin foam is preferably 10 ⁇ m to 200 ⁇ m, more preferably 20 ⁇ m to 180 ⁇ m, still more preferably 40 ⁇ m to 150 ⁇ m, and particularly preferably 40 ⁇ m to 80 ⁇ m. Within such a range, it is possible to obtain a resin foam that is more excellent in flexibility and stress dispersibility. In addition, it is possible to obtain a resin foam that is excellent in compression recovery, stamping workability, and resistance to repeated impact. In one embodiment, the resin foam has an average cell diameter (average cell diameter) of 90 ⁇ m or less (preferably 80 ⁇ m or less). Within such a range, a resin foam having a low dielectric constant and excellent stamping workability can be obtained. A method for measuring the average bubble diameter will be described later.
- the coefficient of variation of the bubble diameter (cell diameter) of the resin foam is preferably 0.5 or less, more preferably 0.4 or less, still more preferably 0.3 or less, still more preferably 0.3. It is 25 or less, and particularly preferably 0.2 or less. Within such a range, when compressive force is applied by punching or the like, variation in bubble deformation is reduced. With such a resin foam, for example, a processed product (cut product) having excellent thickness accuracy can be obtained when punched. Further, when the coefficient of variation of cell diameter is within the above range, deformation due to impact becomes uniform, local stress load is prevented, and a resin foam having excellent stress dispersibility and particularly excellent impact resistance is obtained. be able to. Although the coefficient of variation is preferably as small as possible, its lower limit is, for example, 0.15 (preferably 0.1, more preferably 0.01). A method for measuring the coefficient of variation of bubble diameter will be described later.
- the foam rate (cell rate) of the resin foam is preferably 30% or more, more preferably 50% or more, and still more preferably 80% or more. Within such a range, a resin foam having moderate flexibility can be obtained. Such a resin foam has excellent punching workability, and prevents the occurrence of uncut parts when punched.
- the upper limit of the void content is, for example, 99% or less. A method for measuring the void content will be described later.
- the thickness of the cell wall (cell wall) of the resin foam is preferably 0.1 ⁇ m to 10 ⁇ m, more preferably 0.3 ⁇ m to 8 ⁇ m, still more preferably 0.5 ⁇ m to 5 ⁇ m, and particularly preferably 0.7 ⁇ m to 4 ⁇ m, most preferably 1 ⁇ m to 3 ⁇ m.
- a resin foam having appropriate strength can be obtained.
- Such a resin foam has excellent punching workability, and is prevented from tearing, dusting, and uncut parts during punching.
- the thickness of the cell wall (cell wall) of the resin foam is 5 ⁇ m or less. With such a range, the above effect becomes remarkable.
- the thickness of the cell wall can be measured by capturing an enlarged image of the cell portion of the resin foam and analyzing the image using the analysis software of the measuring instrument.
- the proportion of the closed cell structure therein is preferably 40% or less, more preferably 30% or less.
- the ratio of the closed-cell structure of the resin foam is determined, for example, by submerging the object to be measured in water in an environment with a temperature of 23 ° C. and a humidity of 50%, measuring the mass after that, and then measuring the temperature at 80 ° C. It is obtained by measuring the mass again after drying it sufficiently in an oven.
- the mass of open cells is measured as open cells.
- the proportion of open cells in the resin foam is preferably higher than 60%, more preferably higher than 70%.
- a resin foam having a low dielectric constant can be obtained.
- the ratio of open cells was also determined by immersing the measurement object in water in an environment of 23 ° C. and 50% humidity, measuring the mass after that, then drying it sufficiently in an oven at 80 ° C., and measuring the mass again. is obtained by measuring
- the cell number density of the resin foam is preferably 30 cells/mm 2 or more, more preferably 50 cells/mm 2 or more, still more preferably 65 cells/mm 2 or more, and still more preferably 80 cells/mm 2 or more. /mm 2 or more, more preferably 90/mm 2 or more, still more preferably 100/mm 2 or more, and particularly preferably 110/mm 2 or more.
- a resin foam that preferably has flexibility, a low dielectric constant, and excellent punching workability.
- the higher the bubble number density the easier it is to store energy when compressed, and a resin foam having excellent compression recovery can be obtained.
- the upper limit of the cell number density of the resin foam is preferably 400 cells/mm 2 , more preferably 200 cells/mm 2 , still more preferably 150 cells/mm 2 .
- the cell number density of the resin foam is the number density in the cross section of cells observed in a randomly selected cross section of the resin foam, and can be obtained by image analysis of the cross section of the resin foam.
- the 50% compressive load of the resin foam is preferably 20 N/cm 2 or less, more preferably 10 N/cm 2 or less, still more preferably 8 N/cm 2 or less, still more preferably 5 N/cm 2 . or less, and particularly preferably 3 N/cm 2 or less. Within such a range, it is possible to obtain a resin foam that preferably has flexibility and is excellent in stamping workability.
- the lower limit of the 50% compressive load of the resin foam is, for example, 0.5 N/cm 2 .
- the 50% compressive load of the resin foam is the stress (N) when the resin foam is compressed to a compressibility of 50%, converted per unit area (1 cm 2 ).
- the tensile modulus of the resin foam at 25°C is preferably 1.5 MPa or more, more preferably 1.6 MPa to 2.5 MPa, and more preferably 1.8 MPa to 2.0 MPa. Within such a range, the shape can be maintained even after punching by having a predetermined strength.
- the tensile elastic modulus is obtained by fixing a sample (size: 10 mm ⁇ 80 mm) at a distance between chucks of 40 mm and performing a tensile test at a tensile speed of 500 mm / min to obtain a tensile strain-tensile strength curve. It is obtained from the slope of the straight line connecting the tensile strengths at a tensile strain of 10%.
- the dielectric constant of the resin foam is preferably 3 or less, more preferably 2 or less, still more preferably 1.5 or less, and particularly preferably 1.2 or less. According to the present invention, it is possible to obtain a resin foam having a low dielectric constant and suitable for communication equipment, electronic equipment, and the like.
- the lower limit of the dielectric constant of the resin foam is, for example, 1.01. A method for measuring the dielectric constant will be described later.
- the impact absorption of the resin foam is preferably 20% or more, more preferably 27% or more, still more preferably 30% or more, particularly preferably 35% or more, and most preferably 40%. That's it.
- Impact absorption is measured as follows. A test sample was formed by placing a resin foam, double-sided tape (product number: No. 5603W, manufactured by Nitto Denko), and PET film (product number: Diafoil MRF75, manufactured by Mitsubishi Plastics) in this order on the impact force sensor. A 66-g iron ball is dropped onto the specimen from a height of 50 cm above the PET film, and the impact force F1 is measured. ⁇ Furthermore, the impact force F0 of the blank is measured by dropping the iron ball directly onto the impact force sensor as described above. ⁇ From F1 and F0, calculate the impact absorption (%) by the formula (F0-F1)/F0 ⁇ 100.
- any appropriate shape can be adopted as the shape of the resin foam according to the purpose.
- Such a shape is typically sheet-like.
- the resin foam may have a heat-melting layer on one side or both sides.
- a resin foam having a hot-melt layer is produced by, for example, using a pair of heating rolls heated to a melting temperature of the resin composition constituting the resin foam (or a precursor of the resin foam ( It can be obtained by rolling the foamed structure)).
- the resin foam can be formed by any suitable method as long as the effects of the present invention are not impaired.
- a method typically includes a method of foaming a resin composition containing a resin material (polymer).
- the resin foam of the present invention can typically be obtained by foaming a resin composition.
- the resin composition includes any suitable resin material (polymer).
- a non-crosslinkable resin composition is used.
- a non-crosslinkable resin composition is suitably used in the method for forming a resin foam, which will be described later.
- polymer examples include acrylic resins, silicone resins, urethane resins, polyolefin resins, ester resins, and rubber resins.
- acrylic resins silicone resins
- urethane resins examples include acrylic resins, silicone resins, urethane resins, polyolefin resins, ester resins, and rubber resins.
- the above polymers may be used singly or in combination of two or more.
- the polymer content is preferably 30 parts by weight to 95 parts by weight, more preferably 35 parts by weight to 90 parts by weight, and still more preferably 40 parts by weight to 80 parts by weight with respect to 100 parts by weight of the resin composition. parts, particularly preferably 40 to 60 parts by weight. Within such a range, it is possible to obtain a resin foam that is more excellent in flexibility and stress dispersibility.
- a polyolefin resin is used as the polymer.
- a resin foam whose dielectric constant is preferably adjusted.
- the content of the polyolefin resin is preferably 50 parts by weight to 100 parts by weight, more preferably 70 parts by weight to 100 parts by weight, and still more preferably 90 parts by weight to 100 parts by weight, with respect to 100 parts by weight of the polymer. parts by weight, particularly preferably 95 to 100 parts by weight, most preferably 100 parts by weight.
- the polyolefin-based resin preferably includes at least one selected from the group consisting of polyolefin and polyolefin-based elastomer, and more preferably, polyolefin and polyolefin-based elastomer are used in combination.
- Each of polyolefin and polyolefin elastomer may be used alone or in combination of two or more.
- the term "polyolefin” does not include “polyolefin elastomer”.
- the weight ratio of polyolefin and polyolefin elastomer is preferably 1/99 to 99/1, more preferably 10/90 to 10/90. 90/10, more preferably 20/80 to 80/20, particularly preferably 30/70 to 70/30.
- the weight ratio of polyolefin to polyolefin elastomer is preferably 25/75 to 75/25, more preferably 35/65 to 65/35.
- any appropriate polyolefin can be adopted as the polyolefin as long as it does not impair the effects of the present invention.
- examples of such polyolefins include linear polyolefins and branched (having branched chains) polyolefins.
- a branched polyolefin is used as the polyolefin resin.
- the polyolefin only branched polyolefin may be used, or branched polyolefin and linear polyolefin may be used in combination.
- the content of the branched polyolefin is preferably 30 to 100 parts by weight, more preferably 50 to 80 parts by weight, per 100 parts by weight of the polyolefin.
- polystyrene resins examples include polymers containing structural units derived from ⁇ -olefins.
- the polyolefin may be composed only of structural units derived from ⁇ -olefins, or may be composed of structural units derived from ⁇ -olefins and structural units derived from monomers other than ⁇ -olefins.
- any appropriate copolymerization form can be adopted as its copolymerization form. Examples include random copolymers and block copolymers.
- ⁇ -olefins that can constitute polyolefins include ⁇ -olefins having 2 to 8 (preferably 2 to 6, more preferably 2 to 4) carbon atoms (e.g., ethylene, propylene, 1-butene, 1-pentene, , 1-hexene, 4-methyl-1-pentene, 1-heptene, 1-octene, etc.) are preferred.
- the ⁇ -olefin may be of only one type, or may be of two or more types.
- Examples of monomers other than ⁇ -olefins that constitute polyolefins include ethylenically unsaturated monomers such as vinyl acetate, acrylic acid, acrylic acid esters, methacrylic acid, methacrylic acid esters, and vinyl alcohol.
- Monomers other than the ⁇ -olefin may be of only one type, or may be of two or more types.
- polyolefins include low-density polyethylene, medium-density polyethylene, high-density polyethylene, linear low-density polyethylene, polypropylene (propylene homopolymer), copolymers of ethylene and propylene, and ethylene and other than ethylene.
- copolymers with ⁇ -olefins copolymers of propylene and ⁇ -olefins other than propylene, copolymers of ethylene and propylene with ⁇ -olefins other than ethylene and propylene, propylene and ethylenically unsaturated monomers and a copolymer with a polymer.
- a polypropylene-based polymer having structural units derived from propylene is used as the polyolefin.
- polypropylene-based polymers include polypropylene (propylene homopolymer), copolymers of ethylene and propylene, copolymers of propylene and ⁇ -olefins other than propylene, and the like, and preferably polypropylene (propylene homopolymer ).
- the polypropylene-based polymer may be used alone or in combination of two or more.
- the melt flow rate (MFR) of the polyolefin at a temperature of 230° C. is preferably 0.25 g/10 minutes to 10 g/10 minutes, more preferably 0.3 g/10 minutes, in terms of being able to further express the effects of the present invention. min to 6 g/10 min, more preferably 0.35 g/10 min to 5 g/10 min, particularly preferably 0.35 g/10 min to 1 g/10 min, most preferably 0.35 g/10 min. 10 minutes to 0.6 g/10 minutes.
- the melt flow rate (MFR) refers to the MFR measured at a temperature of 230° C. and a load of 2.16 kgf (21.2 N) based on ISO1133 (JIS-K-7210). .
- the melt flow rate of the polyolefin that makes up the resin foam controls the die swell ratio and shear viscosity of the resin.
- the weight average molecular weight of the polyolefin is preferably 50,000 to 120,000, more preferably 55,000 to 110,000, still more preferably 60,000 to 100,000. Within such a range, the die swell ratio and shear viscosity of the resin can be preferably adjusted. Further, the molecular weight distribution (weight average molecular weight/number average molecular weight) of the polyolefin is preferably 7-10, more preferably 6-9. Within such a range, the die swell ratio and shear viscosity of the resin can be preferably adjusted.
- the weight average molecular weight and number average molecular weight can be determined by gel permeation chromatography (solvent: tetrahydrofuran, polystyrene conversion).
- polyolefins may be used, for example, "E110G” (manufactured by Prime Polymer Co., Ltd.), “EA9” (manufactured by Japan Polypropylene Corporation), “EA9FT” (manufactured by Japan Polypropylene Corporation), “E- 185G” (manufactured by Prime Polymer Co., Ltd.), “WB140HMS” (manufactured by Borealis), and “WB135HMS” (manufactured by Borealis).
- “E110G” manufactured by Prime Polymer Co., Ltd.
- EA9 manufactured by Japan Polypropylene Corporation
- EA9FT manufactured by Japan Polypropylene Corporation
- E- 185G manufactured by Prime Polymer Co., Ltd.
- WB140HMS manufactured by Borealis
- WB135HMS manufactured by Borealis
- any appropriate polyolefin elastomer can be adopted as the polyolefin elastomer as long as it does not impair the effects of the present invention.
- examples of such polyolefin-based elastomers include ethylene-propylene copolymers, ethylene-propylene-diene copolymers, ethylene-vinyl acetate copolymers, polybutene, polyisobutylene, chlorinated polyethylene, polyolefin components and rubber components.
- thermoplastic olefin elastomers such as elastomers in which polyolefin components and rubber components are physically dispersed, elastomers having a structure in which a polyolefin component and a rubber component are microphase-separated; resin component A (olefin A mixture containing system resin component A) and domain-forming rubber component B is dynamically heat-treated in the presence of a cross-linking agent.
- TPV dynamically crosslinked thermoplastic olefin elastomer
- TPV dynamically crosslinked thermoplastic olefin elastomer
- the polyolefin elastomer preferably contains a rubber component.
- rubber components include JP-A-08-302111, JP-A-2010-241934, JP-A-2008-024882, JP-A-2000-007858, JP-A-2006-052277, and JP-A-2006-052277. 2012-072306, JP-A-2012-057068, JP-A-2010-241897, JP-A-2009-067969, Table No. 03/002654, and the like.
- elastomers having a structure in which a polyolefin component and an olefin-based rubber component are microphase-separated include elastomers composed of polypropylene resin (PP) and ethylene-propylene rubber (EPM), and polypropylene resin (PP). Examples thereof include elastomers made of ethylene-propylene-diene rubber (EPDM).
- the weight ratio of the polyolefin component to the olefin rubber component is preferably 90/10 to 10/90, more preferably 80/20 to 20/80.
- a dynamically crosslinked thermoplastic olefin elastomer generally has a higher elastic modulus and a smaller compression set than a non-crosslinked thermoplastic olefin elastomer (TPO). Thereby, the recoverability is good, and excellent recoverability can be exhibited when a resin foam is formed.
- thermoplastic olefin elastomer is, as described above, a mixture containing a matrix-forming resin component A (olefin-based resin component A) and a domain-forming rubber component B, and a cross-linking agent. It is a multiphase polymer having a sea-island structure in which crosslinked rubber particles are finely dispersed as domains (island phases) in resin component A, which is a matrix (sea phase), obtained by dynamic heat treatment in the presence of .
- thermoplastic olefin-based elastomers examples include, for example, JP-A-2000-007858, JP-A-2006-052277, JP-A-2012-072306, JP-A-2012-057068, Examples thereof include those described in JP-A-2010-241897, JP-A-2009-067969, Table No. 03/002654, and the like.
- thermoplastic olefin elastomer (TPV)
- TSV thermoplastic olefin elastomer
- the melt flow rate (MFR) of the polyolefin elastomer at a temperature of 230° C. is preferably 1.5 g/10 minutes to 25 g/10 minutes, more preferably 2 g/10 minutes to 20 g/10 minutes, and still more preferably 2 g/10 minutes to 15 g/10 minutes.
- the die swell ratio and shear viscosity of the resin are controlled by the melt flow rate of the polyolefin elastomer that constitutes the resin foam.
- two or more polyolefin-based elastomers having different melt flow rates (MFR) at a temperature of 230°C within the above range are used in combination.
- a polyolefin elastomer (low MFR polyolefin elastomer) and a melt flow rate (MFR) at a temperature of 230° C. is preferably 8 g/10 min to 25 g/10 min (more preferably 9 g/10 min to 20 g/10 min, still more preferably 10 g/10 min to 20 g/10 min) polyolefin-based elastomer (high MFR polyolefin-based elastomer).
- the compounding ratio of the low MFR polyolefin elastomer to the high MFR polyolefin elastomer is preferably 1.5 to 5, more preferably 1.8. ⁇ 3.5, particularly preferably 2-3. Within such a range, the melt tension of the polyolefin elastomer is preferably adjusted, and as a result, the effect of the present invention becomes remarkable.
- the melt tension (190°C, at break) of the polyolefin elastomer is preferably less than 10 cN, more preferably 5 cN to 9.5 cN.
- the die swell ratio and shear viscosity of the resin are controlled by the melt tension of the polyolefin elastomer forming the resin foam.
- the JIS A hardness of the polyolefin elastomer is preferably 30° to 95°, more preferably 35° to 90°, still more preferably 40° to 88°, and particularly preferably 45° to 85°. Yes, most preferably between 50° and 83°. JIS A hardness is measured based on ISO7619 (JIS K6253).
- the resin foam (that is, the resin composition) may further contain a filler.
- a filler By containing a filler, it is possible to form a resin foam that requires a large amount of energy to deform the cell walls, and the resin foam exhibits excellent impact absorption.
- a filler By including a filler, it is possible to form a fine and uniform cell structure, which is advantageous in that excellent impact absorption can be exhibited. Only one filler may be used alone, or two or more fillers may be used in combination.
- the content of the filler is preferably 10 parts by weight to 150 parts by weight, more preferably 30 parts by weight to 130 parts by weight, and still more preferably 100 parts by weight of the polymer constituting the resin foam. 50 to 100 parts by weight. With such a range, the above effect becomes remarkable.
- the filler is inorganic.
- Materials constituting inorganic fillers include, for example, aluminum hydroxide, magnesium hydroxide, calcium carbonate, magnesium carbonate, calcium silicate, magnesium silicate, calcium oxide, magnesium oxide, aluminum oxide, aluminum nitride, and boric acid.
- the filler is organic.
- materials constituting the organic filler include polymethyl methacrylate (PMMA), polyimide, polyamideimide, polyetheretherketone, polyetherimide, and polyesterimide.
- a flame retardant may be used as the filler.
- flame retardants include brominated flame retardants, chlorine flame retardants, phosphorus flame retardants, and antimony flame retardants. From the viewpoint of safety, non-halogen-nonantimony flame retardants are preferably used.
- non-halogen-non-antimony flame retardants include compounds containing aluminum, magnesium, calcium, nickel, cobalt, tin, zinc, copper, iron, titanium, boron, and the like.
- examples of such compounds (inorganic compounds) include hydrated metal compounds such as aluminum hydroxide, magnesium hydroxide, magnesium oxide/nickel oxide hydrate, and magnesium oxide/zinc oxide hydrate. .
- Any appropriate surface treatment may be applied to the filler.
- Examples of surface treatment include silane coupling treatment and stearic acid treatment.
- the bulk density of the filler is preferably 0.8 g/cm 3 or less, more preferably 0.6 g/cm 3 or less, still more preferably 0.4 g/cm 3 or less, particularly It is preferably 0.3 g/cm 3 or less.
- the filler can be contained with good dispersibility, and the effect of adding the filler can be sufficiently exhibited while reducing the content of the filler.
- a resin foam with a low filler content is advantageous in that it is highly foamed, flexible, stress-dispersible, and has excellent appearance.
- the lower limit of bulk density of the filler is, for example, 0.01 g/cm 3 , preferably 0.05 g/cm 3 , more preferably 0.1 g/cm 3 .
- the number average particle size (primary particle size) of the filler is preferably 5 ⁇ m or less, more preferably 3 ⁇ m or less, and even more preferably 1 ⁇ m or less. Within such a range, the filler can be contained with good dispersibility and a uniform cell structure can be formed. As a result, a resin foam having excellent stress dispersibility and appearance can be obtained.
- the lower limit of the number average particle size of the filler is, for example, 0.1 ⁇ m.
- the number average particle diameter of the filler is measured using a particle size distribution analyzer (Micrtrac II, Microtrac Bell Co., Ltd.) using a suspension prepared by mixing 1 g of the filler with 100 g of water at 25° C. as a sample. can do.
- the specific surface area of the filler is preferably 2 m 2 /g or more, more preferably 4 m 2 /g or more, still more preferably 6 m 2 /g or more. Within such a range, the filler can be contained with good dispersibility and a uniform cell structure can be formed. As a result, a resin foam having excellent stress dispersibility and appearance can be obtained.
- the upper limit of the specific surface area of the filler is, for example, 20 m 2 /g.
- the specific surface area of the filler can be measured by the BET method, that is, molecules having a known adsorption area are adsorbed on the surface of the filler at a low temperature using liquid nitrogen, and the adsorption amount is measured.
- the resin composition may contain any appropriate other component within a range that does not impair the effects of the present invention. Only one such component may be used, or two or more components may be used.
- Such other components include, for example, rubber, resins other than polymers blended as resin materials, softeners, aliphatic compounds, anti-aging agents, antioxidants, light stabilizers, weathering agents, and UV absorbers.
- a resin composition is used that does not contain a crosslinker.
- the resin foam of the present invention is typically obtained by foaming a resin composition.
- a method commonly used for foam molding such as a physical method or a chemical method, can be employed. That is, the resin foam may typically be a foam formed by a physical method (physical foam) or a foam formed by a chemical method (chemical foam). foam). Physical methods generally involve dispersing a gaseous component such as air or nitrogen in a polymer solution and mechanically mixing to form cells (mechanical foam).
- the chemical method is generally a method in which cells are formed by gas generated by thermal decomposition of a foaming agent added to a polymer base to obtain a foam.
- the resin composition to be subjected to foam molding is, for example, the constituent components are mixed with any suitable melt-kneading device, such as an open mixing roll, a non-open Banbury mixer, a single-screw extruder, a twin-screw extruder, a continuous type It may be prepared by mixing using any appropriate means such as a kneader, a pressure kneader, and the like.
- any suitable melt-kneading device such as an open mixing roll, a non-open Banbury mixer, a single-screw extruder, a twin-screw extruder, a continuous type It may be prepared by mixing using any appropriate means such as a kneader, a pressure kneader, and the like.
- ⁇ Embodiment 1 for forming a resin foam for example, an emulsion resin composition (emulsion containing a resin material (polymer), etc.) is mechanically foamed to foam the resin (step A).
- the foaming device includes, for example, a high-speed shearing device, a vibrating device, and a pressurized gas discharging device.
- a high-speed shearing apparatus is preferable from the viewpoint of miniaturization of the bubble diameter and production of a large volume.
- This one embodiment of forming a resin foam is applicable to forming from any resin composition.
- the solid content concentration of the emulsion is preferably higher from the viewpoint of film-forming properties.
- the solid content concentration of the emulsion is preferably 30% by weight or more, more preferably 40% by weight or more, and still more preferably 50% by weight or more.
- Bubbles generated by mechanical stirring are gas trapped in the emulsion.
- any appropriate gas can be adopted as long as it is inert to the emulsion, as long as it does not impair the effects of the present invention.
- gases include, for example, air, nitrogen, carbon dioxide, and the like.
- the resin foam of the present invention can be obtained by applying the emulsion resin composition foamed by the above method (cell-containing emulsion resin composition) onto a substrate and drying it (step B).
- the substrate include a release-treated plastic film (release-treated polyethylene terephthalate film, etc.), a plastic film (polyethylene terephthalate film, etc.), and the like.
- Step B any appropriate method can be adopted as the coating method and drying method as long as the effects of the present invention are not impaired.
- Step B comprises a preliminary drying step B1 of drying the bubble-containing emulsion resin composition applied on the base material at 50° C. or more and less than 125° C., and a main drying step B2 of further drying at 125° C. or more and 200° C. or less. preferably.
- the temperature in the preliminary drying step B1 is preferably 50°C to 100°C.
- the duration of the preliminary drying step B1 is preferably 0.5 to 30 minutes, more preferably 1 to 15 minutes.
- the temperature in the main drying step B2 is preferably 130°C to 180°C or less, more preferably 130°C to 160°C.
- the time of the main drying step B2 is preferably 0.5 to 30 minutes, more preferably 1 to 15 minutes.
- ⁇ Embodiment 2 for forming a resin foam there is a form in which a foam is formed by foaming a resin composition with a foaming agent.
- a foaming agent those commonly used in foam molding can be used, and from the viewpoint of environmental protection and low contamination of the object to be foamed, it is preferable to use a high-pressure inert gas.
- any appropriate inert gas can be adopted as the inert gas as long as it is inert to the resin composition and can be impregnated.
- examples of such inert gas include carbon dioxide, nitrogen gas, and air. These gases may be mixed and used. Among these, carbon dioxide is preferable from the viewpoint of a large impregnation amount to the resin material (polymer) and a high impregnation speed.
- the inert gas is preferably in a supercritical state. That is, it is particularly preferable to use carbon dioxide in a supercritical state. In the supercritical state, the solubility of the inert gas in the resin composition increases, and it is possible to mix the inert gas at a high concentration. More nuclei are generated, and the density of the bubbles formed by the growth of the bubble nuclei becomes higher than in other states even if the porosity is the same, so fine bubbles can be obtained.
- Carbon dioxide has a critical temperature of 31° C. and a critical pressure of 7.4 MPa.
- Methods for forming a foam by impregnating a resin composition with an inert gas at high pressure include, for example, a gas impregnation step of impregnating a resin composition containing a resin material (polymer) with an inert gas under high pressure; Examples include a method of forming through a depressurization step in which the pressure is lowered after the step to foam the resin material (polymer) and, if necessary, a heating step in which bubbles are grown by heating.
- a preformed unfoamed molded article may be impregnated with an inert gas, or the molten resin composition may be impregnated with an inert gas under pressure and then subjected to molding when the pressure is reduced.
- steps may be carried out by either a batch system or a continuous system. That is, a resin composition is preliminarily molded into an appropriate shape such as a sheet to form an unfoamed resin molded body, and then the unfoamed resin molded body is impregnated with high-pressure gas and expanded by releasing the pressure. It may be a batch system, or a continuous system in which the resin composition is kneaded under pressure with a high-pressure gas, molded and at the same time the pressure is released, and molding and foaming are performed simultaneously.
- a resin sheet for foam molding is produced by extruding the resin composition using an extruder such as a single-screw extruder or a twin-screw extruder.
- the resin composition may be uniformly kneaded using a kneader equipped with blades such as a roller, a cam, a kneader, or a Banbury type, and then pressed to a predetermined thickness using a hot plate press or the like.
- a non-foamed resin molding is produced by the above.
- the unfoamed resin molded article thus obtained is placed in a high-pressure vessel, and a high-pressure inert gas (such as carbon dioxide in a supercritical state) is injected to impregnate the unfoamed resin molded article with the inert gas.
- a high-pressure inert gas such as carbon dioxide in a supercritical state
- the inert gas is sufficiently impregnated, the pressure is released (usually to atmospheric pressure) to generate bubble nuclei in the resin.
- the bubble nuclei may be grown at room temperature as they are, or may be grown by heating in some cases.
- a heating method a known or commonly used method such as a water bath, an oil bath, a hot roll, a hot air oven, far infrared rays, near infrared rays, or microwaves can be used.
- the foam is rapidly cooled with cold water or the like to fix the shape, thereby obtaining a foam.
- the unfoamed resin molding to be foamed is not limited to a sheet-like article, and various shapes can be used depending on the application.
- the unfoamed resin molded article to be foamed can be produced by extrusion molding, press molding, or other molding methods such as injection molding.
- a heating step may be provided, if necessary, to grow air bubbles by heating. After the bubbles are grown in this way, if necessary, they may be rapidly cooled with cold water or the like to fix the shape. Also, the high-pressure gas may be introduced continuously or discontinuously.
- an extruder or an injection molding machine can be used in the kneading impregnation step and the molding depressurization step. Any suitable heating method such as water bath, oil bath, hot roll, hot air oven, far-infrared rays, near-infrared rays, and microwaves can be used as a heating method for growing bubble nuclei.
- Any appropriate shape can be adopted as the shape of the foam. Such shapes include, for example, a sheet shape, prismatic shape, cylindrical shape, irregular shape, and the like.
- the amount of gas to be mixed when foam-molding the resin composition is preferably 2% to 10% by weight with respect to the total amount of the resin composition, in that a highly foamed resin foam can be obtained. Yes, more preferably 2.5 wt % to 8 wt %, still more preferably 3 wt % to 6 wt %.
- the pressure when the resin composition is impregnated with the inert gas can be appropriately selected in consideration of operability and the like.
- Such pressure is, for example, preferably 6 MPa or higher (eg, 6 MPa to 100 MPa), more preferably 8 MPa or higher (eg, 8 MPa to 50 MPa).
- the pressure is preferably 7.4 MPa or more from the viewpoint of maintaining the supercritical state of carbon dioxide. If the pressure is lower than 6 MPa, the cell growth during foaming will be significant, and the cell diameter will become too large, and a preferable average cell diameter (average cell diameter) may not be obtained.
- the temperature in the gas impregnation process varies depending on the inert gas used and the type of components in the resin composition, and can be selected within a wide range. When operability and the like are considered, the temperature is preferably 10°C to 350°C.
- the impregnation temperature for impregnating an unfoamed molded article with an inert gas is preferably 10° C. to 250° C., more preferably 40° C. to 230° C. in a batch system. Further, the impregnation temperature when foaming and molding are simultaneously performed by extruding a molten polymer impregnated with a gas is preferably 60° C. to 350° C. in a continuous system.
- carbon dioxide is used as the inert gas
- the temperature during impregnation is preferably 32° C. or higher, more preferably 40° C. or higher, in order to maintain a supercritical state.
- the decompression speed is preferably 5 MPa/sec to 300 MPa/sec in order to obtain uniform microbubbles.
- the heating temperature in the heating step is preferably 40°C to 250°C, more preferably 60°C to 250°C.
- the foamed structure after obtaining a foamed structure through a predetermined process (for example, after obtaining a resin foam by the method of ⁇ Embodiment 1> or ⁇ Embodiment 2>), the foamed structure is formed into a thin film. Then, it is roll-rolled to obtain a resin foam. Through such steps, a resin foam having an appropriately adjusted aspect ratio can be obtained. Moreover, a resin foam having a small thickness (for example, 0.2 mm or less) can be obtained.
- the hot melt layer may be formed by the roll rolling.
- Thinning of the foam structure can be performed using any appropriate slicer.
- the thickness of the foam structure after thinning is preferably 0.01 mm to 3 mm, more preferably 0.05 mm to 2 mm, even more preferably 0.1 mm to 1 mm, and particularly preferably 0.1 mm to 0.5 mm.
- the rolls used for the roll rolling are heating rolls.
- the temperature of the roll is preferably 150°C to 250°C, more preferably 160°C to 230°C.
- the rolling rate of the foamed structure is preferably 80% or less, more preferably 10% to 80%, still more preferably 20% to 75%. , particularly preferably 30% to 75%. Within such a range, a resin foam with an appropriately adjusted aspect ratio can be obtained.
- FIG. 1 is a schematic cross-sectional view of a foam member according to one embodiment.
- the foam member 100 has a resin foam layer 10 and an adhesive layer 20 arranged on at least one side of the resin foam layer 10 .
- the resin foam layer 10 is composed of the above resin foam.
- the thickness of the adhesive layer is preferably 5 ⁇ m to 300 ⁇ m, more preferably 6 ⁇ m to 200 ⁇ m, more preferably 7 ⁇ m to 100 ⁇ m, and particularly preferably 8 ⁇ m to 50 ⁇ m.
- a layer made of any suitable adhesive can be adopted as the adhesive layer.
- adhesives constituting the adhesive layer include rubber-based adhesives (synthetic rubber-based adhesives, natural rubber-based adhesives, etc.), urethane-based adhesives, acrylic urethane-based adhesives, acrylic-based adhesives, and silicone-based adhesives.
- Adhesives, polyester-based adhesives, polyamide-based adhesives, epoxy-based adhesives, vinyl alkyl ether-based adhesives, fluorine-based adhesives, rubber-based adhesives, and the like can be mentioned.
- the adhesive constituting the adhesive layer is preferably at least one selected from acrylic adhesives, silicone adhesives, and rubber adhesives. Only one type of such adhesive may be used, or two or more types may be used.
- the pressure-sensitive adhesive layer may be one layer, or two or more layers.
- the adhesive when classified by adhesive form, for example, emulsion type adhesive, solvent type adhesive, ultraviolet cross-linking (UV cross-linking) adhesive, electron beam cross-linking (EB cross-linking) adhesive, hot melt adhesive agents (hot-melt adhesives) and the like. Only one type of such adhesive may be used, or two or more types may be used.
- UV cross-linking ultraviolet cross-linking
- EB cross-linking electron beam cross-linking
- hot melt adhesive agents hot-melt adhesives
- the water vapor permeability of the pressure-sensitive adhesive layer is preferably 50 (g/(m 2 ⁇ 24 hours)) or less, more preferably 30 (g/(m 2 ⁇ 24 hours)) or less, still more preferably 20 (g/(m 2 ⁇ 24 hours)) or less, particularly preferably 10 (g/(m 2 ⁇ 24 hours)) or less. If the water vapor permeability of the pressure-sensitive adhesive layer is within the above range, the foam sheet can stabilize impact absorption without being affected by moisture.
- the water vapor transmission rate can be measured, for example, by a method according to JIS Z 0208 under test conditions of 40° C. and relative humidity of 92%.
- the adhesive that constitutes the adhesive layer may contain any appropriate other component within a range that does not impair the effects of the present invention.
- Other components include, for example, other polymer components, softeners, antioxidants, curing agents, plasticizers, fillers, antioxidants, thermal polymerization initiators, photopolymerization initiators, ultraviolet absorbers, and light stabilizers.
- coloring agents pigments, dyes, etc.
- solvents organic solvents
- surfactants e.g., ionic surfactants, silicone-based surfactants, fluorine-based surfactants, etc.
- cross-linking agents e.g., polyisocyanate-based cross-linking agents, silicone-based cross-linking agents, epoxy-based cross-linking agents, alkyl-etherified melamine-based cross-linking agents, etc.
- a thermal polymerization initiator and a photopolymerization initiator can be included in the material for forming the polymer component.
- the foam member can be manufactured by any appropriate method.
- the foamed member is produced, for example, by laminating a foamed resin layer and a pressure-sensitive adhesive layer, or by laminating a material for forming the pressure-sensitive adhesive layer and a foamed resin layer, and then forming a pressure-sensitive adhesive layer by a curing reaction or the like. methods and the like.
- Bubble rate (cell rate) The measurement was performed in an environment with a temperature of 23°C and a humidity of 50%.
- a 100 mm ⁇ 100 mm punching blade (processing blade (trade name “NCA07”, thickness 0.7 mm, cutting edge angle 43°, manufactured by Nakayama Co., Ltd.)) is used to punch out the resin foams obtained in Examples and Comparative Examples, The dimensions of the punched samples were measured. Also, the thickness was measured with a 1/100 dial gauge having a measuring terminal diameter ( ⁇ ) of 20 mm. From these values, the volumes of the resin foams obtained in Examples and Comparative Examples were calculated. Next, the weights of the resin foams obtained in Examples and Comparative Examples were measured with a balance with a minimum scale of 0.01 g or more. From these values, the void ratio (cell ratio) of the resin foams obtained in Examples and Comparative Examples was calculated.
- the resin foam was cut with a razor blade in the TD (direction orthogonal to the flow direction) and in the direction (thickness direction) perpendicular to the main surface of the resin foam.
- TD direction orthogonal to the flow direction
- Thickness direction direction perpendicular to the main surface of the resin foam.
- Thickness recovery rate instantaneous recovery rate
- the thickness recovery rate is obtained by the following formula from the "thickness 0.5 seconds after releasing the compressed state” and the thickness (initial thickness) of the resin foam before the load is applied. rice field.
- Thickness recovery rate (%) ⁇ (thickness 0.5 seconds after releasing the compressed state) / (initial thickness) ⁇ x 100
- Relative permittivity was measured using an E4980A precision LCR meter (Agilent Technologies) under an environment of 23°C temperature and 50% humidity. The compression rate was measured as 0% by the parallel plate capacitor method (based on JIS C 2138).
- Tensile modulus was measured using a tensile tester (RTG-1201, manufactured by Tansui Co., Ltd.) at an ambient temperature of 25°C, and a sample (size: 10 mm x 80 mm) was fixed at a chuck distance of 40 mm. Then, a tensile test was performed at a tensile speed of 500 mm/min to obtain a curve consisting of tensile strain and tensile strength. The tensile modulus was obtained from the slope of the straight line connecting the origin of this curve and the tensile strength at a tensile strain of 10%.
- Shear viscosity A sample (resin A resin (size: 5 mm square) that constitutes the foam is added and melted over 7 minutes. Thereafter, the melt was extruded through a die having a length of 10 mm and a diameter of 1 mm ⁇ at a shear rate of 20 mm/s, and the shear viscosity was measured. The shear viscosity of the resin was measured before and after foaming. In Comparative Example 2, the shear viscosity of the foam made of the crosslinked material could not be measured.
- Example 1 Polypropylene (propylene homopolymer, MFR: 0.4 g/10 min (230°C, load 21.2 N), density: 0.90 g/cm 3 , ethylene content: 0 wt%, propylene content: 100 wt%, weight average Molecular weight: 64500, molecular weight distribution: 8.43) 30 parts by weight, polyolefin elastomer (melt flow rate (MFR): 15 g/10 min, JIS A hardness: 79°) 46 parts by weight, polyolefin elastomer (melt flow rate (MFR ): 2.2 g / 10 min, JIS A hardness: 69 °) 19 parts by weight, magnesium hydroxide (trade name “KISUMA 5P” manufactured by Kyowa Chemical Industry) 10 parts by weight, carbon (trade name “Asahi # 35” Asahi Carbon Co., Ltd.
- MFR polyolefin elastomer
- Example 2 Polypropylene (propylene homopolymer, MFR: 0.4 g/10 min (230°C, load 21.2 N), density: 0.90 g/cm 3 , ethylene content: 0 wt%, propylene content: 100 wt%) 35 weight part, polyolefin elastomer (melt flow rate (MFR): 15 g/10 min, JIS A hardness: 79°) 42 parts by weight, polyolefin elastomer (melt flow rate (MFR): 2.2 g/10 min, JIS A hardness: 69 °) 18 parts by weight, 10 parts by weight of magnesium hydroxide (trade name "KISUMA 5P" manufactured by Kyowa Chemical Industry Co., Ltd.), 10 parts by weight of carbon (trade name "Asahi #35" manufactured by Asahi Carbon Co., Ltd.), and 1 weight part of stearic acid monoglyceride The parts were kneaded at a temperature of 200° C.
- MFR poly
- Example 3 A resin foam c was obtained in the same manner as in Example 2, except that the injection amount of carbon dioxide gas was 4.5 parts by weight with respect to 100 parts by weight of the resin. Furthermore, it was thinned using a slicer to obtain a resin foam C having a thickness of 1.0 mm. The obtained resin foam C was subjected to the above evaluation. Table 1 shows the results.
- Example 4 A resin foam d was obtained in the same manner as in Example 2, except that the injection amount of carbon dioxide gas was 4.2 parts by weight with respect to 100 parts by weight of the resin. Furthermore, it was thinned using a slicer to obtain a resin foam D having a thickness of 1.0 mm. The obtained resin foam D was subjected to the above evaluation. Table 1 shows the results.
- Example 5 Polypropylene (propylene homopolymer, MFR: 0.4 g/10 min (230° C., load 21.2 N), density: 0.90 g/cm 3 , ethylene content: 0% by weight, propylene content: 100% by weight) 40 weight part, polyolefin elastomer (melt flow rate (MFR): 15 g/10 min, JIS A hardness: 79°) 39 parts by weight, polyolefin elastomer (melt flow rate (MFR): 2.2 g/10 min, JIS A hardness: 69 °) 16 parts by weight, magnesium hydroxide (trade name “KISUMA 5P” manufactured by Kyowa Chemical Industry Co., Ltd.) 10 parts by weight, carbon (trade name “Asahi #35” manufactured by Asahi Carbon Co., Ltd.) 10 parts by weight, and stearic acid monoglyceride 1 weight The parts were kneaded at a temperature of 200° C.
- Example 6 Polypropylene (propylene homopolymer, MFR: 0.5 g/10 min (230°C, load 21.2 N), density: 0.90 g/cm 3 , ethylene content: 0 wt%, propylene content: 100 wt%, weight average Molecular weight: 54500, molecular weight distribution: 9.83) 40 parts by weight, polyolefin elastomer (melt flow rate (MFR): 15 g/10 min, JIS A hardness: 79°) 39 parts by weight, polyolefin elastomer (melt flow rate (MFR ): 2.2 g / 10 min, JIS A hardness: 69 °) 16 parts by weight, magnesium hydroxide (trade name “KISUMA 5P” manufactured by Kyowa Chemical Industry) 10 parts by weight, carbon (trade name “Asahi #35” Asahi Carbon Co., Ltd.
- MFR polyolefin elastomer
- Example 7 A resin foam e was obtained in the same manner as in Example 2, except that the injection amount of carbon dioxide gas was 4.2 parts by weight with respect to 100 parts by weight of the resin. Furthermore, it was thinned using a slicer to obtain a resin foam having a thickness of 0.3 mm. Furthermore, the resin foam is passed through a pair of rolls, one of which is heated to 230 ° C. (the gap between the rolls) to obtain a resin foam E having a thickness of 0.20 mm. rice field. The gap (clearance) between the rolls was set so that a resin foam E having a thickness of 0.20 mm was obtained. The obtained resin foam E was subjected to the above evaluation. Table 1 shows the results.
- the resin foam of the present invention has low dielectric properties and excellent punching workability by setting the apparent density and instantaneous recovery rate within specific ranges.
- the resin foam of the present invention can be suitably used, for example, as a cushioning material for electronic devices.
Abstract
Description
1つの実施形態においては、上記樹脂発泡体は、気泡数密度が、30個/mm2以上である。
1つの実施形態においては、上記樹脂発泡体は、平均気泡径が、10μm~200μmである。
1つの実施形態においては、上記樹脂発泡体は、気泡径の変動係数が、0.5以下である。
1つの実施形態においては、上記樹脂発泡体は、気泡率が、30%以上である。
1つの実施形態においては、上記樹脂発泡体は、25℃における引張弾性率が、1.5MPa以上である。
1つの実施形態においては、上記樹脂発泡体は、50%圧縮荷重が、20N/cm2以下である。
1つの実施形態においては、上記樹脂発泡体は、ポリオレフィン系樹脂を含む。
1つの実施形態においては、上記ポリオレフィン系樹脂が、ポリオレフィン系エラストマー以外のポリオレフィンとポリオレフィン系エラストマーの混合物である。
1つの実施形態においては、上記樹脂発泡体は、片面または両面に、熱溶融層を有する。
本発明の別の局面によれば、発泡部材が提供される。この発泡部材は、樹脂発泡層と、該樹脂発泡層の少なくとも一方の側に配置された粘着剤層を有し、該樹脂発泡層が、上記樹脂発泡体である。 The resin foam of the present invention is a resin foam having a cell structure, the resin foam has an apparent density of less than 0.4 g/cm 3 , and a load of 1000 g/cm 2 is applied to the resin foam. The thickness recovery rate after maintaining the added state for 120 seconds is 80% or more.
In one embodiment, the resin foam has a cell number density of 30 cells/mm 2 or more.
In one embodiment, the resin foam has an average cell diameter of 10 μm to 200 μm.
In one embodiment, the resin foam has a coefficient of variation of cell diameter of 0.5 or less.
In one embodiment, the resin foam has a void content of 30% or more.
In one embodiment, the resin foam has a tensile modulus at 25° C. of 1.5 MPa or more.
In one embodiment, the resin foam has a 50% compression load of 20 N/cm 2 or less.
In one embodiment, the resin foam contains a polyolefin resin.
In one embodiment, the polyolefin-based resin is a mixture of a polyolefin other than a polyolefin-based elastomer and a polyolefin-based elastomer.
In one embodiment, the resin foam has a hot melt layer on one side or both sides.
According to another aspect of the invention, a foam member is provided. This foam member has a resin foam layer and an adhesive layer arranged on at least one side of the resin foam layer, and the resin foam layer is the resin foam.
本発明の樹脂発泡体は、気泡構造(セル構造)を有する。気泡構造(セル構造)としては、独立気泡構造、連続気泡構造、半連続半独立気泡構造(独立気泡構造と連続気泡構造が混在している気泡構造)などが挙げられる。好ましくは、樹脂発泡体の気泡構造は、半連続半独立気泡構造である。代表的には、本発明の樹脂発泡体は、樹脂組成物を発泡させることにより得られる。上記樹脂組成物は、樹脂発泡体を構成する樹脂を少なくとも含有する組成物である。 A. Resin Foam The resin foam of the present invention has a cell structure. Examples of the cell structure include a closed cell structure, an open cell structure, a semi-open and semi-closed cell structure (a cell structure in which a closed cell structure and an open cell structure are mixed), and the like. Preferably, the cell structure of the resin foam is a semi-open and semi-closed cell structure. Typically, the resin foam of the present invention is obtained by foaming a resin composition. The resin composition is a composition containing at least a resin constituting a resin foam.
・衝撃力センサー上に、樹脂発泡体、両面テープ(品番:No.5603W、日東電工製)、PETフィルム(品番:ダイヤホイルMRF75、三菱樹脂製)をこの順に配置して試験体を形成した。PETフィルム上方50cmの高さから、66gの鉄球を試験体に落下させて、衝撃力F1を測定する。
・また、衝撃力センサーに直接、上記のように鉄球を落下させて、ブランクの衝撃力F0を測定する。
・F1、F0から、(F0-F1)/F0×100の式により、衝撃吸収性(%)を算出する。 The impact absorption of the resin foam is preferably 20% or more, more preferably 27% or more, still more preferably 30% or more, particularly preferably 35% or more, and most preferably 40%. That's it. Impact absorption is measured as follows.
A test sample was formed by placing a resin foam, double-sided tape (product number: No. 5603W, manufactured by Nitto Denko), and PET film (product number: Diafoil MRF75, manufactured by Mitsubishi Plastics) in this order on the impact force sensor. A 66-g iron ball is dropped onto the specimen from a height of 50 cm above the PET film, and the impact force F1 is measured.
・Furthermore, the impact force F0 of the blank is measured by dropping the iron ball directly onto the impact force sensor as described above.
・From F1 and F0, calculate the impact absorption (%) by the formula (F0-F1)/F0×100.
本発明の樹脂発泡体は、代表的には、樹脂組成物を発泡させて得られ得る。樹脂組成物は、任意の適切な樹脂材料(ポリマー)を含む。1つの実施形態においては、非架橋性の樹脂組成物が用いられる。非架橋性の樹脂組成物は、後述の樹脂発泡体の形成方法に好適に用いられる。 A-1. Resin Composition The resin foam of the present invention can typically be obtained by foaming a resin composition. The resin composition includes any suitable resin material (polymer). In one embodiment, a non-crosslinkable resin composition is used. A non-crosslinkable resin composition is suitably used in the method for forming a resin foam, which will be described later.
重量平均分子量および数平均分子量は、ゲルパーミエーションクロマトグラフィ測定(溶媒:テトラヒドロフラン、ポリスチレン換算)により求めることができる。 The weight average molecular weight of the polyolefin is preferably 50,000 to 120,000, more preferably 55,000 to 110,000, still more preferably 60,000 to 100,000. Within such a range, the die swell ratio and shear viscosity of the resin can be preferably adjusted. Further, the molecular weight distribution (weight average molecular weight/number average molecular weight) of the polyolefin is preferably 7-10, more preferably 6-9. Within such a range, the die swell ratio and shear viscosity of the resin can be preferably adjusted.
The weight average molecular weight and number average molecular weight can be determined by gel permeation chromatography (solvent: tetrahydrofuran, polystyrene conversion).
本発明の樹脂発泡体は、代表的には、樹脂組成物を発泡させて得られる。発泡の方法(気泡の形成方法)としては、物理的方法や化学的方法など、発泡成形に通常用いられる方法が採用できる。すなわち、樹脂発泡体は、代表的には、物理的方法により発泡して形成された発泡体(物理発泡体)であってもよいし、化学的方法により発泡して形成された発泡体(化学発泡体)であってもよい。物理的方法は、一般的に、空気や窒素等のガス成分をポリマー溶液に分散させて、機械的混合により気泡を形成させるもの(機械発泡体)である。化学的方法は、一般的に、ポリマーベースに添加された発泡剤の熱分解により生じたガスによりセルを形成し、発泡体を得る方法である。 A-2. Formation of Resin Foam The resin foam of the present invention is typically obtained by foaming a resin composition. As the method of foaming (method of forming cells), a method commonly used for foam molding, such as a physical method or a chemical method, can be employed. That is, the resin foam may typically be a foam formed by a physical method (physical foam) or a foam formed by a chemical method (chemical foam). foam). Physical methods generally involve dispersing a gaseous component such as air or nitrogen in a polymer solution and mechanically mixing to form cells (mechanical foam). The chemical method is generally a method in which cells are formed by gas generated by thermal decomposition of a foaming agent added to a polymer base to obtain a foam.
樹脂発泡体を形成させる一つの実施形態1としては、例えば、エマルション樹脂組成物(樹脂材料(ポリマー)などを含むエマルション)を機械的に発泡させて起泡化させる工程(工程A)を経て樹脂発泡体を形成する形態が挙げられる。起泡装置としては、例えば、高速せん断方式の装置、振動方式の装置、加圧ガスの吐出方式の装置などが挙げられる。これらの起泡装置の中でも、気泡径の微細化、大容量作製の観点から、高速せん断方式の装置が好ましい。樹脂発泡体を形成させるこの一つの実施形態1は、どのような樹脂組成物からの形成にも適用可能である。 <Embodiment 1 for forming a resin foam>
As one embodiment 1 for forming a resin foam, for example, an emulsion resin composition (emulsion containing a resin material (polymer), etc.) is mechanically foamed to foam the resin (step A). Forms that form foams are included. The foaming device includes, for example, a high-speed shearing device, a vibrating device, and a pressurized gas discharging device. Among these foaming apparatuses, a high-speed shearing apparatus is preferable from the viewpoint of miniaturization of the bubble diameter and production of a large volume. This one embodiment of forming a resin foam is applicable to forming from any resin composition.
樹脂発泡体を形成させる一つの実施形態2としては、樹脂組成物を発泡剤により発泡させて発泡体を形成する形態が挙げられる。発泡剤としては、発泡成形に通常用いられるものを使用でき、環境保護及び被発泡体に対する低汚染性の観点から、高圧の不活性ガスを用いることが好ましい。 <Embodiment 2 for forming a resin foam>
As one embodiment 2 of forming a resin foam, there is a form in which a foam is formed by foaming a resin composition with a foaming agent. As the foaming agent, those commonly used in foam molding can be used, and from the viewpoint of environmental protection and low contamination of the object to be foamed, it is preferable to use a high-pressure inert gas.
図1は、1つの実施形態による発泡部材の概略断面図である。発泡部材100は、樹脂発泡層10と、樹脂発泡層10の少なくとも一方の側に配置された粘着剤層20とを有する。樹脂発泡層10は、上記樹脂発泡体により構成される。 B. Foam Member FIG. 1 is a schematic cross-sectional view of a foam member according to one embodiment. The
(1)見かけ密度
樹脂発泡体の密度(見かけ密度)は、以下のように算出した。実施例・比較例で得られた樹脂発泡体を20mm×20mmサイズに打ち抜いて試験片とし、試験片の寸法をノギスで測定した。次に、試験片の重量を電子天秤にて測定した。そして、次式により算出した。
見かけ密度(g/cm3)=試験片の重量/試験片の体積 <Evaluation method>
(1) Apparent Density The density (apparent density) of the resin foam was calculated as follows. The resin foams obtained in Examples and Comparative Examples were punched out into 20 mm×20 mm size test pieces, and the dimensions of the test pieces were measured with vernier calipers. Next, the weight of the test piece was measured with an electronic balance. Then, it was calculated by the following formula.
Apparent density (g/cm 3 ) = weight of test piece/volume of test piece
JIS K 6767に記載されている樹脂発泡体の圧縮硬さ測定方法に準じて測定した。具体的には、実施例・比較例で得られた樹脂発泡体を30mm×30mmサイズに切り出して試験片とし、圧縮速度10mm/minで圧縮率が50%となるまで圧縮したときの応力(N)を単位面積(1cm2)当たりに換算して、50%圧縮荷重(N/cm2)とした。 (2) 50% Compressive Load Measured according to the method for measuring compression hardness of resin foam described in JIS K 6767. Specifically, the stress (N ) was converted to a unit area (1 cm 2 ) to obtain a 50% compressive load (N/cm 2 ).
樹脂発泡体を、カミソリ刃を用いて、TD(流れ方向に直交する方向)、かつ、樹脂発泡体の主面に対して垂直方向(厚み方向)に切断し、計測器としてデジタルマイクロスコープ(商品名「VHX-500」、キーエンス株式会社製)を用い、樹脂発泡体の切断面画像を取り込み、同計測器の解析ソフトを用いて、画像解析することにより、数平均気泡径(平均セル径)(μm)を求めた。なお、取り込んだ拡大画像の気泡数は400個程度であった。また、セル径の全データから標準偏差を計算し、以下の式を用いて変動係数を算出した。
変動係数=標準偏差/平均気泡径(平均セル径) (3) Average cell diameter (average cell diameter), coefficient of variation of cell diameter (cell diameter) The resin foam is treated with a razor blade in the TD (direction perpendicular to the flow direction), and the main surface of the resin foam Cut in the vertical direction (thickness direction), use a digital microscope (trade name "VHX-500", manufactured by Keyence Corporation) as a measuring instrument, capture the cut surface image of the resin foam, and use the measuring instrument The number average bubble diameter (average cell diameter) (μm) was determined by image analysis using analysis software. The number of bubbles in the captured enlarged image was about 400. In addition, the standard deviation was calculated from all the cell diameter data, and the coefficient of variation was calculated using the following formula.
Variation coefficient = standard deviation / average bubble diameter (average cell diameter)
温度23℃、湿度50%の環境下で測定を行った。100mm×100mmの打抜き刃型(加工刃(商品名「NCA07」、厚さ0.7mm、刃先角度43°、ナカヤマ社製))にて実施例・比較例で得られた樹脂発泡体を打抜き、打抜いた試料の寸法を測定した。また、測定端子の直径(φ)20mmである1/100ダイヤルゲージにて厚みを測定した。これらの値から実施例・比較例で得られた樹脂発泡体の体積を算出した。次に、実施例・比較例で得られた樹脂発泡体の重量を最小目盛り0.01g以上の上皿天秤にて測定した。これらの値より、実施例・比較例で得られた樹脂発泡体の気泡率(セル率)を算出した。 (4) Bubble rate (cell rate)
The measurement was performed in an environment with a temperature of 23°C and a humidity of 50%. A 100 mm × 100 mm punching blade (processing blade (trade name “NCA07”, thickness 0.7 mm, cutting edge angle 43°, manufactured by Nakayama Co., Ltd.)) is used to punch out the resin foams obtained in Examples and Comparative Examples, The dimensions of the punched samples were measured. Also, the thickness was measured with a 1/100 dial gauge having a measuring terminal diameter (φ) of 20 mm. From these values, the volumes of the resin foams obtained in Examples and Comparative Examples were calculated. Next, the weights of the resin foams obtained in Examples and Comparative Examples were measured with a balance with a minimum scale of 0.01 g or more. From these values, the void ratio (cell ratio) of the resin foams obtained in Examples and Comparative Examples was calculated.
樹脂発泡体を、カミソリ刃を用いて、TD(流れ方向に直交する方向)、かつ、樹脂発泡体の主面に対して垂直方向(厚み方向)に切断した。
計測器としてデジタルマイクロスコープ(商品名「VHX-500」、キーエンス株式会社製)を用い、樹脂発泡体の切断面画像を取り込み、同計測器の解析ソフトを用いて、画像解析することにより、単位面積[mm2]当たりの気泡数を測定した。 (5) Cell Number Density The resin foam was cut with a razor blade in the TD (direction orthogonal to the flow direction) and in the direction (thickness direction) perpendicular to the main surface of the resin foam.
Using a digital microscope (trade name "VHX-500", manufactured by Keyence Corporation) as a measuring instrument, capturing an image of the cut surface of the resin foam and analyzing the image using the analysis software of the measuring instrument, the unit The number of air bubbles per area [mm 2 ] was measured.
樹脂発泡体に、樹脂発泡体に1000g/cm2の荷重を加えた状態で120秒間維持し、圧縮を解除し、解除してから0.5秒後の樹脂発泡体の厚み(圧縮状態を解除してから0.5秒後の厚み)を測定した。「圧縮状態を解除してから0.5秒後の厚み」と、荷重を加える前の樹脂発泡体の厚み(初期厚み)とから、下記の式により、厚み回復率(瞬間回復率)を求めた。
厚み回復率(%)={(圧縮状態を解除してから0.5秒後の厚み)/(初期厚み)}×100 (6) Thickness recovery rate (instantaneous recovery rate)
A load of 1000 g/cm 2 was applied to the resin foam and maintained for 120 seconds, and the compression was released. After 0.5 seconds, the thickness) was measured. The thickness recovery rate (instantaneous recovery rate) is obtained by the following formula from the "thickness 0.5 seconds after releasing the compressed state" and the thickness (initial thickness) of the resin foam before the load is applied. rice field.
Thickness recovery rate (%) = {(thickness 0.5 seconds after releasing the compressed state) / (initial thickness)} x 100
温度23℃、湿度50%の環境下で、E4980A プレシジョンLCRメーター(Agilent Technologies)を用い、比誘電率を測定した。平行平板コンデンサ法(JIS C 2138に基づく)により、圧縮率を0%として測定した。 (7) Relative permittivity The relative permittivity was measured using an E4980A precision LCR meter (Agilent Technologies) under an environment of 23°C temperature and 50% humidity. The compression rate was measured as 0% by the parallel plate capacitor method (based on JIS C 2138).
引張弾性率は、25℃の環境温度下、引張試験機(RTG-1201、株式会社タンスイ製)を用いて、チャック間距離40mmでサンプル(サイズ:10mm×80mm)を固定し、引張速度500mm/minで引張試験を行い、引張歪と引張強度からなる曲線を得た。この曲線の原点と引張歪10%の時の引張強度を結んだ直線の傾きより引張弾性率を求めた。 (8) Tensile modulus Tensile modulus was measured using a tensile tester (RTG-1201, manufactured by Tansui Co., Ltd.) at an ambient temperature of 25°C, and a sample (size: 10 mm x 80 mm) was fixed at a chuck distance of 40 mm. Then, a tensile test was performed at a tensile speed of 500 mm/min to obtain a curve consisting of tensile strain and tensile strength. The tensile modulus was obtained from the slope of the straight line connecting the origin of this curve and the tensile strength at a tensile strain of 10%.
樹脂発泡体を金型(2枚の加工刃(商品名「NCA07」、厚さ0.7mm、刃先角度43°、2枚の加工刃の間隔10mm、(株)ナカヤマ製))を用いて、10mm×10mmサイズになるようにMD方向(流れ方向)、TD方向(流れ方向に直交する方向)にそれぞれ打ち抜き加工を行い、MD方向とTD方向の断面において厚み変化が大きい方の断面をマイクロスコープ(商品名「VHX-2000」キーエンス株式会社製)で観察した。画像から測定した端部の厚みと、打ち抜き加工前の厚みを用いて、下記式で加工後の厚み回復率を測定した。当該厚み回復率が大きいほど、打ち抜きにより形状変化が小さく、打ち抜き加工性に優れるということになる。
加工後の厚み回復率(%)=100×(1-(打ち抜き加工前の厚み-端部の厚み)/打ち抜き加工前の厚み) (9) Punching workability (10 mm × 10 mm)
Using a mold (two processing blades (trade name “NCA07”, thickness 0.7 mm, blade edge angle 43°, distance between two processing
Thickness recovery rate after processing (%) = 100 × (1 - (thickness before punching - thickness of edge) / thickness before punching)
樹脂発泡体を金型(2枚の加工刃(商品名「NCA07」、厚さ0.7mm、刃先角度43°、2枚の加工刃の間隔1mm(株)ナカヤマ製))を用いて、MD方向(流れ方向)に2枚の加工刃の間隔1mmにかつ長さ50mmに、かつ樹脂発泡体の主面に対して垂直方向(厚み方向)に打ち抜き加工を行い、断面をマイクロスコープ(商品名「VHX-2000」キーエンス株式会社製)で観察した。画像から測定した端部の厚みと、打ち抜き加工前の厚みを用いて、下記式で加工後の厚み回復率を測定した。当該厚み回復率が大きいほど、打ち抜きにより形状変化が小さく、打ち抜き加工性に優れるということになる。
加工後の厚み回復率(%)=100×(1-(打ち抜き加工前の厚み-端部の厚み)/打ち抜き加工前の厚み) (10) Punching workability (1 mm width)
The resin foam is molded using a mold (two processing blades (trade name “NCA07”, thickness 0.7 mm, blade angle 43 °, interval between two processing blades 1 mm, manufactured by Nakayama Co., Ltd.)). Punching is performed in the direction (flow direction) with a distance of 1 mm between the two processing blades and a length of 50 mm, and in the direction (thickness direction) perpendicular to the main surface of the resin foam. "VHX-2000" (manufactured by Keyence Corporation) was used for observation. Using the edge thickness measured from the image and the thickness before punching, the thickness recovery rate after processing was measured by the following formula. The larger the thickness recovery rate, the smaller the change in shape due to punching, and the better the punching workability.
Thickness recovery rate after processing (%) = 100 × (1 - (thickness before punching - thickness of edge) / thickness before punching)
計測器として伸長粘度計(商品名「RH-7」、マルバーン社)を用いて、樹脂発泡体を構成する樹脂の融点よりも20℃高い温度にて、シリンダーにサンプル(樹脂発泡体を構成する樹脂(サイズ:5mm角))を投入し、7minかけて溶融状態にする。その後、せん断速度20mm/sの速度で溶融物を長さ10mm、口径1mmφのダイに押出し、得られた紐状の成型物の直径をデジタルノギス(商品名「CD67-s PM」、株式会社ミツトヨ社)を用いて測定し、下記の式からダイスウェル比を算出した。なお、発泡の前後それぞれについて、樹脂のダイスウェル比を測定した。なお、比較例2については、架橋系の材料で構成された発泡体につき、ダイスウェル比を測定することがでない。
ダイスウェル比=成型物の直径(mm)/ダイ口径(mm) (11) Die swell ratio A sample ( A resin (size: 5 mm square) that constitutes the resin foam is put in and melted over 7 minutes. After that, the molten product was extruded into a die having a length of 10 mm and a diameter of 1 mmφ at a shear rate of 20 mm / s, and the diameter of the obtained string-shaped molded product was measured with a digital caliper (trade name “CD67-s PM”, Mitutoyo Co., Ltd. (Company), and the die swell ratio was calculated from the following formula. The die swell ratio of the resin was measured before and after foaming. In Comparative Example 2, the die swell ratio could not be measured for the foam made of the crosslinked material.
Die swell ratio = diameter of molding (mm) / diameter of die (mm)
計測器として伸長粘度計(商品名「RH-7」、マルバーン社)を用いて、樹脂発泡体を構成する樹脂の融点よりも20℃高い温度にて、シリンダーにサンプル(樹脂発泡体を構成する樹脂(サイズ:5mm角))を投入し、7minかけて溶融状態にする。その後、せん断速度20mm/sの速度で溶融物を長さ10mm、口径1mmφのダイに押出し、せん断粘度を測定した。なお、発泡の前後それぞれについて、樹脂のせん断粘度を測定した。なお、比較例2については、架橋系の材料で構成された発泡体につき、せん断粘度を測定することがでない。 (12) Shear viscosity A sample (resin A resin (size: 5 mm square) that constitutes the foam is added and melted over 7 minutes. Thereafter, the melt was extruded through a die having a length of 10 mm and a diameter of 1 mmφ at a shear rate of 20 mm/s, and the shear viscosity was measured. The shear viscosity of the resin was measured before and after foaming. In Comparative Example 2, the shear viscosity of the foam made of the crosslinked material could not be measured.
ポリプロピレン(プロピレン単独重合体、MFR:0.4g/10分(230℃、荷重21.2N)、密度:0.90g/cm3、エチレン含量:0重量%、プロピレン含量:100重量%、重量平均分子量:64500、分子量分布:8.43)30重量部、ポリオレフィン系エラストマー(メルトフローレート(MFR):15g/10min、JIS A硬度:79°)46重量部、ポリオレフィン系エラストマー(メルトフローレート(MFR):2.2g/10min、JIS A硬度:69°)19重量部、水酸化マグネシウム(商品名「KISUMA 5P」協和化学工業製)10重量部、カーボン(商品名「旭♯35」旭カーボン株式会社製)10重量部、およびステアリン酸モノグリセリド1重量部を、日本製鋼所(JSW)社製の二軸混練機にて、200℃の温度で混練した後、ストランド状に押出し、水冷後ペレット状に成形した。このペレットを、日本製鋼所社製の単軸押出機に投入し、220℃の雰囲気下、13MPa(注入後12MPa)の圧力で、二酸化炭素ガスを注入した。二酸化炭素ガスは、樹脂100重量部に対して4.8重量部の割合で注入した。二酸化炭素ガスを十分飽和させた後、発泡に適した温度まで冷却後、ダイから押出して、シート状の樹脂発泡体aを得た。
さらに、スライサーを用いて薄膜化し、厚みが1.0mmの樹脂発泡体Aを得た。
得られた樹脂発泡体Aを、上記評価に供した。結果を表1に示す。 [Example 1]
Polypropylene (propylene homopolymer, MFR: 0.4 g/10 min (230°C, load 21.2 N), density: 0.90 g/cm 3 , ethylene content: 0 wt%, propylene content: 100 wt%, weight average Molecular weight: 64500, molecular weight distribution: 8.43) 30 parts by weight, polyolefin elastomer (melt flow rate (MFR): 15 g/10 min, JIS A hardness: 79°) 46 parts by weight, polyolefin elastomer (melt flow rate (MFR ): 2.2 g / 10 min, JIS A hardness: 69 °) 19 parts by weight, magnesium hydroxide (trade name “KISUMA 5P” manufactured by Kyowa Chemical Industry) 10 parts by weight, carbon (trade name “Asahi # 35” Asahi Carbon Co., Ltd. Company) 10 parts by weight and 1 part by weight of stearic acid monoglyceride are kneaded at a temperature of 200 ° C. in a twin-screw kneader manufactured by Japan Steel Works (JSW), extruded into strands, water-cooled and pelletized. molded into The pellets were put into a single-screw extruder manufactured by Japan Steel Works, Ltd., and carbon dioxide gas was injected under an atmosphere of 220° C. and a pressure of 13 MPa (12 MPa after injection). Carbon dioxide gas was injected at a rate of 4.8 parts by weight with respect to 100 parts by weight of the resin. After sufficiently saturating the carbon dioxide gas, it was cooled to a temperature suitable for foaming, and then extruded from a die to obtain a sheet-like resin foam a.
Furthermore, it was thinned using a slicer to obtain a resin foam A having a thickness of 1.0 mm.
The obtained resin foam A was subjected to the above evaluation. Table 1 shows the results.
ポリプロピレン(プロピレン単独重合体、MFR:0.4g/10分(230℃、荷重21.2N)、密度:0.90g/cm3、エチレン含量:0重量%、プロピレン含量:100重量%)35重量部、ポリオレフィン系エラストマー(メルトフローレート(MFR):15g/10min、JIS A硬度:79°)42重量部、ポリオレフィン系エラストマー(メルトフローレート(MFR):2.2g/10min、JIS A硬度:69°)18重量部、水酸化マグネシウム(商品名「KISUMA 5P」協和化学工業製)10重量部、カーボン(商品名「旭♯35」旭カーボン株式会社製)10重量部、およびステアリン酸モノグリセリド1重量部を、日本製鋼所(JSW)社製の二軸混練機にて、200℃の温度で混練した後、ストランド状に押出し、水冷後ペレット状に成形した。このペレットを、日本製鋼所社製の単軸押出機に投入し、220℃の雰囲気下、13MPa(注入後12MPa)の圧力で、二酸化炭素ガスを注入した。二酸化炭素ガスは、樹脂100重量部に対して4.8重量部の割合で注入した。二酸化炭素ガスを十分飽和させた後、発泡に適した温度まで冷却後、ダイから押出して、シート状の樹脂発泡体bを得た。
さらに、スライサーを用いて薄膜化し、厚みが1.0mmの樹脂発泡体Bを得た。
得られた樹脂発泡体Bを、上記評価に供した。結果を表1に示す。 [Example 2]
Polypropylene (propylene homopolymer, MFR: 0.4 g/10 min (230°C, load 21.2 N), density: 0.90 g/cm 3 , ethylene content: 0 wt%, propylene content: 100 wt%) 35 weight part, polyolefin elastomer (melt flow rate (MFR): 15 g/10 min, JIS A hardness: 79°) 42 parts by weight, polyolefin elastomer (melt flow rate (MFR): 2.2 g/10 min, JIS A hardness: 69 °) 18 parts by weight, 10 parts by weight of magnesium hydroxide (trade name "KISUMA 5P" manufactured by Kyowa Chemical Industry Co., Ltd.), 10 parts by weight of carbon (trade name "Asahi #35" manufactured by Asahi Carbon Co., Ltd.), and 1 weight part of stearic acid monoglyceride The parts were kneaded at a temperature of 200° C. using a twin-screw kneader manufactured by Japan Steel Works (JSW), extruded into strands, cooled with water, and formed into pellets. The pellets were put into a single-screw extruder manufactured by Japan Steel Works, Ltd., and carbon dioxide gas was injected under an atmosphere of 220° C. and a pressure of 13 MPa (12 MPa after injection). Carbon dioxide gas was injected at a rate of 4.8 parts by weight with respect to 100 parts by weight of the resin. After sufficiently saturating the carbon dioxide gas, it was cooled to a temperature suitable for foaming, and then extruded through a die to obtain a sheet-like resin foam b.
Furthermore, it was thinned using a slicer to obtain a resin foam B having a thickness of 1.0 mm.
The obtained resin foam B was subjected to the above evaluation. Table 1 shows the results.
二酸化炭素ガスの注入量を、樹脂100重量部に対して4.5重量部の割合としたこと以外は、実施例2と同様にして、樹脂発泡体cを得た。
さらに、スライサーを用いて薄膜化し、厚みが1.0mmの樹脂発泡体Cを得た。
得られた樹脂発泡体Cを、上記評価に供した。結果を表1に示す。 [Example 3]
A resin foam c was obtained in the same manner as in Example 2, except that the injection amount of carbon dioxide gas was 4.5 parts by weight with respect to 100 parts by weight of the resin.
Furthermore, it was thinned using a slicer to obtain a resin foam C having a thickness of 1.0 mm.
The obtained resin foam C was subjected to the above evaluation. Table 1 shows the results.
二酸化炭素ガスの注入量を、樹脂100重量部に対して4.2重量部の割合としたこと以外は、実施例2と同様にして、樹脂発泡体dを得た。
さらに、スライサーを用いて薄膜化し、厚みが1.0mmの樹脂発泡体Dを得た。
得られた樹脂発泡体Dを、上記評価に供した。結果を表1に示す。 [Example 4]
A resin foam d was obtained in the same manner as in Example 2, except that the injection amount of carbon dioxide gas was 4.2 parts by weight with respect to 100 parts by weight of the resin.
Furthermore, it was thinned using a slicer to obtain a resin foam D having a thickness of 1.0 mm.
The obtained resin foam D was subjected to the above evaluation. Table 1 shows the results.
ポリプロピレン(プロピレン単独重合体、MFR:0.4g/10分(230℃、荷重21.2N)、密度:0.90g/cm3、エチレン含量:0重量%、プロピレン含量:100重量%)40重量部、ポリオレフィン系エラストマー(メルトフローレート(MFR):15g/10min、JIS A硬度:79°)39重量部、ポリオレフィン系エラストマー(メルトフローレート(MFR):2.2g/10min、JIS A硬度:69°)16重量部、水酸化マグネシウム(商品名「KISUMA 5P」協和化学工業製)10重量部、カーボン(商品名「旭♯35」旭カーボン株式会社製)10重量部、およびステアリン酸モノグリセリド1重量部を、日本製鋼所(JSW)社製の二軸混練機にて、200℃の温度で混練した後、ストランド状に押出し、水冷後ペレット状に成形した。このペレットを、日本製鋼所社製の単軸押出機に投入し、220℃の雰囲気下、13MPa(注入後12MPa)の圧力で、二酸化炭素ガスを注入した。二酸化炭素ガスは、樹脂100重量部に対して4.5重量部の割合で注入した。二酸化炭素ガスを十分飽和させた後、発泡に適した温度まで冷却後、ダイから押出して、シート状の樹脂発泡体eを得た。
さらに、スライサーを用いて薄膜化し、厚みが1.0mmの樹脂発泡体Eを得た。
得られた樹脂発泡体Eを、上記評価に供した。結果を表1に示す。 [Example 5]
Polypropylene (propylene homopolymer, MFR: 0.4 g/10 min (230° C., load 21.2 N), density: 0.90 g/cm 3 , ethylene content: 0% by weight, propylene content: 100% by weight) 40 weight part, polyolefin elastomer (melt flow rate (MFR): 15 g/10 min, JIS A hardness: 79°) 39 parts by weight, polyolefin elastomer (melt flow rate (MFR): 2.2 g/10 min, JIS A hardness: 69 °) 16 parts by weight, magnesium hydroxide (trade name “KISUMA 5P” manufactured by Kyowa Chemical Industry Co., Ltd.) 10 parts by weight, carbon (trade name “Asahi #35” manufactured by Asahi Carbon Co., Ltd.) 10 parts by weight, and stearic acid monoglyceride 1 weight The parts were kneaded at a temperature of 200° C. using a twin-screw kneader manufactured by Japan Steel Works (JSW), extruded into strands, cooled with water, and formed into pellets. The pellets were put into a single-screw extruder manufactured by Japan Steel Works, Ltd., and carbon dioxide gas was injected under an atmosphere of 220° C. and a pressure of 13 MPa (12 MPa after injection). Carbon dioxide gas was injected at a rate of 4.5 parts by weight with respect to 100 parts by weight of the resin. After sufficiently saturating the carbon dioxide gas, it was cooled to a temperature suitable for foaming, and then extruded through a die to obtain a sheet-like resin foam e.
Furthermore, it was thinned using a slicer to obtain a resin foam E having a thickness of 1.0 mm.
The obtained resin foam E was subjected to the above evaluation. Table 1 shows the results.
ポリプロピレン(プロピレン単独重合体、MFR:0.5g/10分(230℃、荷重21.2N)、密度:0.90g/cm3、エチレン含量:0重量%、プロピレン含量:100重量%、重量平均分子量:54500、分子量分布:9.83)40重量部、ポリオレフィン系エラストマー(メルトフローレート(MFR):15g/10min、JIS A硬度:79°)39重量部、ポリオレフィン系エラストマー(メルトフローレート(MFR):2.2g/10min、JIS A硬度:69°)16重量部、水酸化マグネシウム(商品名「KISUMA 5P」協和化学工業製)10重量部、カーボン(商品名「旭♯35」旭カーボン株式会社製)10重量部、およびステアリン酸モノグリセリド1重量部を、日本製鋼所(JSW)社製の二軸混練機にて、200℃の温度で混練した後、ストランド状に押出し、水冷後ペレット状に成形した。このペレットを、日本製鋼所社製の単軸押出機に投入し、220℃の雰囲気下、13MPa(注入後12MPa)の圧力で、二酸化炭素ガスを注入した。二酸化炭素ガスは、樹脂100重量部に対して4.5重量部の割合で注入した。二酸化炭素ガスを十分飽和させた後、発泡に適した温度まで冷却後、ダイから押出して、シート状の樹脂発泡体fを得た。
さらに、スライサーを用いて薄膜化し、厚みが1.0mmの樹脂発泡体Fを得た。
得られた樹脂発泡体Fを、上記評価に供した。結果を表1に示す。 [Example 6]
Polypropylene (propylene homopolymer, MFR: 0.5 g/10 min (230°C, load 21.2 N), density: 0.90 g/cm 3 , ethylene content: 0 wt%, propylene content: 100 wt%, weight average Molecular weight: 54500, molecular weight distribution: 9.83) 40 parts by weight, polyolefin elastomer (melt flow rate (MFR): 15 g/10 min, JIS A hardness: 79°) 39 parts by weight, polyolefin elastomer (melt flow rate (MFR ): 2.2 g / 10 min, JIS A hardness: 69 °) 16 parts by weight, magnesium hydroxide (trade name “KISUMA 5P” manufactured by Kyowa Chemical Industry) 10 parts by weight, carbon (trade name “Asahi #35” Asahi Carbon Co., Ltd. Company) 10 parts by weight and 1 part by weight of stearic acid monoglyceride are kneaded at a temperature of 200 ° C. in a twin-screw kneader manufactured by Japan Steel Works (JSW), extruded into strands, water-cooled and pelletized. molded into The pellets were put into a single-screw extruder manufactured by Japan Steel Works, Ltd., and carbon dioxide gas was injected under an atmosphere of 220° C. and a pressure of 13 MPa (12 MPa after injection). Carbon dioxide gas was injected at a rate of 4.5 parts by weight with respect to 100 parts by weight of the resin. After sufficiently saturating the carbon dioxide gas, it was cooled to a temperature suitable for foaming, and then extruded through a die to obtain a sheet-like resin foam f.
Furthermore, it was thinned using a slicer to obtain a resin foam F having a thickness of 1.0 mm.
The obtained resin foam F was subjected to the above evaluation. Table 1 shows the results.
二酸化炭素ガスの注入量を、樹脂100重量部に対して4.2重量部の割合としたこと以外は、実施例2と同様にして、樹脂発泡体eを得た。
さらに、スライサーを用いて薄膜化し、厚みが0.3mmの樹脂発泡体を得た。さらに、一方のロールが230℃に加熱された一対のロールにおけるロール間(ロールとロールの間の隙間)に、上記樹脂発泡体を通過させて、厚みが0.20mmの樹脂発泡体Eを得た。なお、ロール間のギャップ(隙間)は、厚みが0.20mmの樹脂発泡体Eが得られるように設定した。
得られた樹脂発泡体Eを、上記評価に供した。結果を表1に示す。 [Example 7]
A resin foam e was obtained in the same manner as in Example 2, except that the injection amount of carbon dioxide gas was 4.2 parts by weight with respect to 100 parts by weight of the resin.
Furthermore, it was thinned using a slicer to obtain a resin foam having a thickness of 0.3 mm. Furthermore, the resin foam is passed through a pair of rolls, one of which is heated to 230 ° C. (the gap between the rolls) to obtain a resin foam E having a thickness of 0.20 mm. rice field. The gap (clearance) between the rolls was set so that a resin foam E having a thickness of 0.20 mm was obtained.
The obtained resin foam E was subjected to the above evaluation. Table 1 shows the results.
ポリプロピレン(プロピレン単独重合体、MFR:0.4g/10分(230℃、荷重21.2N)、密度:0.90g/cm3、エチレン含量:0重量%、プロピレン含量:100重量%、重量平均分子量:108000、分子量分布:4.93)65重量部、ポリオレフィン系エラストマー(メルトフローレート(MFR):15g/10min、JIS A硬度:79°)35重量部、水酸化マグネシウム(商品名「KISUMA 5P」協和化学工業製)5重量部、カーボン(商品名「旭♯35」旭カーボン株式会社製)10重量部、およびステアリン酸モノグリセリド1重量部を、日本製鋼所(JSW)社製の二軸混練機にて、200℃の温度で混練した後、ストランド状に押出し、水冷後ペレット状に成形した。このペレットを、日本製鋼所社製の単軸押出機に投入し、220℃の雰囲気下、13MPa(注入後12MPa)の圧力で、二酸化炭素ガスを注入した。二酸化炭素ガスは、樹脂100重量部に対して4.5重量部の割合で注入した。二酸化炭素ガスを十分飽和させた後、発泡に適した温度まで冷却後、ダイから押出して、シート状の樹脂発泡体fを得た。
さらに、スライサーを用いて薄膜化し、厚みが1.0mmの樹脂発泡体Fを得た。
得られた樹脂発泡体Fを、上記評価に供した。結果を表1に示す。 [Comparative Example 1]
Polypropylene (propylene homopolymer, MFR: 0.4 g/10 min (230°C, load 21.2 N), density: 0.90 g/cm 3 , ethylene content: 0 wt%, propylene content: 100 wt%, weight average Molecular weight: 108,000, molecular weight distribution: 4.93) 65 parts by weight, polyolefin elastomer (melt flow rate (MFR): 15 g/10 min, JIS A hardness: 79°) 35 parts by weight, magnesium hydroxide (trade name "KISUMA 5P ” manufactured by Kyowa Chemical Industry Co., Ltd.) 5 parts by weight, carbon (trade name “Asahi #35” manufactured by Asahi Carbon Co., Ltd.) 10 parts by weight, and 1 part by weight of stearic acid monoglyceride are biaxially kneaded by Japan Steel Works (JSW). After kneading at a temperature of 200° C. in a machine, the mixture was extruded into strands, cooled with water, and formed into pellets. The pellets were put into a single-screw extruder manufactured by Japan Steel Works, Ltd., and carbon dioxide gas was injected under an atmosphere of 220° C. and a pressure of 13 MPa (12 MPa after injection). Carbon dioxide gas was injected at a rate of 4.5 parts by weight with respect to 100 parts by weight of the resin. After sufficiently saturating the carbon dioxide gas, it was cooled to a temperature suitable for foaming, and then extruded through a die to obtain a sheet-like resin foam f.
Furthermore, it was thinned using a slicer to obtain a resin foam F having a thickness of 1.0 mm.
The obtained resin foam F was subjected to the above evaluation. Table 1 shows the results.
ポリウレタンを主成分とする樹脂発泡体(見かけ密度:0.7g/cm3)を準備した。当該樹脂発泡体を上記評価に供した。結果を表1に示す。 [Comparative Example 2]
A resin foam (apparent density: 0.7 g/cm 3 ) containing polyurethane as a main component was prepared. The resin foam was subjected to the above evaluation. Table 1 shows the results.
10 樹脂発泡層(樹脂発泡体)
20 粘着剤層 100
20 adhesive layer
Claims (11)
- 気泡構造を有する樹脂発泡体であって、
該樹脂発泡体の見かけ密度は、0.4g/cm3未満であり、
該樹脂発泡体に1000g/cm2の荷重を加えた状態で120秒間維持した後の厚み回復率が、80%以上である、
樹脂発泡体。 A resin foam having a cell structure,
The resin foam has an apparent density of less than 0.4 g/cm 3 ,
The thickness recovery rate after maintaining a load of 1000 g/cm 2 on the resin foam for 120 seconds is 80% or more.
Resin foam. - 気泡数密度が、30個/mm2以上である、請求項1に記載の樹脂発泡体。 The resin foam according to claim 1, which has a cell number density of 30 cells/ mm2 or more.
- 平均気泡径が、10μm~200μmである、請求項1に記載の樹脂発泡体。 The resin foam according to claim 1, which has an average cell diameter of 10 μm to 200 μm.
- 気泡径の変動係数が、0.5以下である、請求項1に記載の樹脂発泡体。 The resin foam according to claim 1, wherein the coefficient of variation of cell diameter is 0.5 or less.
- 気泡率が、30%以上である、請求項1に記載の樹脂発泡体。 The resin foam according to claim 1, which has a void content of 30% or more.
- 25℃における引張弾性率が、1.5MPa以上である、請求項1に記載の樹脂発泡体。 The resin foam according to claim 1, which has a tensile modulus at 25°C of 1.5 MPa or more.
- 50%圧縮荷重が、20N/cm2以下である、請求項1に記載の樹脂発泡体。 The resin foam according to claim 1, having a 50% compression load of 20 N/cm 2 or less.
- ポリオレフィン系樹脂を含む、請求項1に記載の樹脂発泡体。 The resin foam according to claim 1, which contains a polyolefin resin.
- 前記ポリオレフィン系樹脂が、ポリオレフィン系エラストマー以外のポリオレフィンとポリオレフィン系エラストマーの混合物である、請求項8に記載の樹脂発泡体。 The resin foam according to claim 8, wherein the polyolefin-based resin is a mixture of a polyolefin other than a polyolefin-based elastomer and a polyolefin-based elastomer.
- 片面または両面に、熱溶融層を有する、請求項1に記載の樹脂発泡体。 The resin foam according to claim 1, which has a heat-melting layer on one side or both sides.
- 樹脂発泡層と、該樹脂発泡層の少なくとも一方の側に配置された粘着剤層を有し、
該樹脂発泡層が、請求項1に記載の樹脂発泡体である、
発泡部材。
Having a resin foam layer and an adhesive layer disposed on at least one side of the resin foam layer,
The resin foam layer is the resin foam according to claim 1,
foam material.
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PCT/JP2022/016237 WO2022210957A1 (en) | 2021-03-31 | 2022-03-30 | Resin foam and foam member |
PCT/JP2022/016236 WO2022210956A1 (en) | 2021-03-31 | 2022-03-30 | Resin foamed body and foamed member |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/JP2022/016236 WO2022210956A1 (en) | 2021-03-31 | 2022-03-30 | Resin foamed body and foamed member |
Country Status (4)
Country | Link |
---|---|
JP (2) | JPWO2022210957A1 (en) |
KR (2) | KR20230164049A (en) |
CN (2) | CN116981723A (en) |
WO (2) | WO2022210957A1 (en) |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2020209353A1 (en) * | 2019-04-10 | 2020-10-15 | 日東電工株式会社 | Resin foam body and foam member |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP5836463B1 (en) | 2014-09-29 | 2015-12-24 | 積水化学工業株式会社 | Double-sided adhesive tape |
JP5833213B2 (en) | 2014-10-31 | 2015-12-16 | 日東電工株式会社 | Shock absorber |
JP6534645B2 (en) | 2016-03-30 | 2019-06-26 | 積水化成品工業株式会社 | Shock absorbing foam and shock absorbing material |
-
2022
- 2022-03-30 CN CN202280020186.XA patent/CN116981723A/en active Pending
- 2022-03-30 KR KR1020237032932A patent/KR20230164049A/en unknown
- 2022-03-30 JP JP2023511517A patent/JPWO2022210957A1/ja active Pending
- 2022-03-30 CN CN202280020188.9A patent/CN117062861A/en active Pending
- 2022-03-30 JP JP2023511516A patent/JPWO2022210956A1/ja active Pending
- 2022-03-30 KR KR1020237032934A patent/KR20230164050A/en unknown
- 2022-03-30 WO PCT/JP2022/016237 patent/WO2022210957A1/en active Application Filing
- 2022-03-30 WO PCT/JP2022/016236 patent/WO2022210956A1/en active Application Filing
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2020209353A1 (en) * | 2019-04-10 | 2020-10-15 | 日東電工株式会社 | Resin foam body and foam member |
JP2020172641A (en) * | 2019-04-10 | 2020-10-22 | 日東電工株式会社 | Heat resistant foam body and foam member |
Also Published As
Publication number | Publication date |
---|---|
JPWO2022210957A1 (en) | 2022-10-06 |
CN116981723A (en) | 2023-10-31 |
KR20230164049A (en) | 2023-12-01 |
CN117062861A (en) | 2023-11-14 |
KR20230164050A (en) | 2023-12-01 |
JPWO2022210956A1 (en) | 2022-10-06 |
WO2022210956A1 (en) | 2022-10-06 |
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