阅读说明：本技术 树脂发泡体、树脂发泡体片、粘合带、车辆用部件和建筑部件 (Resin foam, resin foam sheet, adhesive tape, vehicle member, and building member ) 是由 高桥克典 中山和彦 增山义和 深谷重一 肥田知浩 于 2018-07-05 设计创作，主要内容包括：本发明的目的在于，提供能够发挥极高隔音性能的树脂发泡体、树脂发泡体片、粘合带、车辆用部件和建筑部件。本发明是一种树脂发泡体，其为含有热塑性树脂和增塑剂且具有多个气泡的树脂发泡体，按照JIS G0602并通过机械阻抗测定(MIM)而测得的20～60℃范围内的1次反共振频率的损失系数的最小值为0.05以上、且20～60℃范围内的2次反共振频率为300～800Hz。(The purpose of the present invention is to provide a resin foam, a resin foam sheet, an adhesive tape, a vehicle member, and a building member that can exhibit extremely high sound insulation performance. The present invention is a resin foam containing a thermoplastic resin and a plasticizer and having a plurality of cells, wherein the minimum value of the loss coefficient of 1-time antiresonance frequency in the range of 20-60 ℃ is 0.05 or more, and the 2-time antiresonance frequency in the range of 20-60 ℃ is 300-800 Hz, as measured by Mechanical Impedance Measurement (MIM) according to JIS G0602.)

1. A resin foam containing a thermoplastic resin and a plasticizer and having a plurality of cells, characterized in that,

the minimum value of the loss coefficient of 1-order antiresonance frequency in the range of 20-60 ℃ is 0.05 or more, and the 2-order antiresonance frequency in the range of 20-60 ℃ is 300-800 Hz, which are measured by mechanical impedance measurement MIM according to JIS G0602.

2. A resin foam containing a thermoplastic resin and a plasticizer and having a plurality of cells, characterized in that,

the resin foam has a minimum value of 0.005 or more of a loss coefficient of 1-order antiresonance frequency in the range of 20 to 60 ℃ and a 2-order antiresonance frequency in the range of 20 to 60 ℃ of 300 to 800Hz, which are measured by mechanical impedance measurement MIM in accordance with JIS K7391.

3. A resin foam containing a thermoplastic resin and a plasticizer and having a plurality of cells, characterized in that,

the resin foam has a maximum value of a loss coefficient of 1-order antiresonance frequency in the range of 0 to 50 ℃ of 0.20 or more and a 2-order antiresonance frequency in the range of 0 to 30 ℃ of 800Hz or less, which are measured by mechanical impedance measurement MIM according to ISO 16940.

4. The resin foam according to claim 3, wherein the maximum value of the loss coefficient of 1 st antiresonance frequency in the range of 0 ℃ to 50 ℃ is 0.24 or more as measured by mechanical impedance measurement MIM in accordance with ISO 16940.

5. The resin foam according to claim 1, 2, 3 or 4, which contains a binder.

6. A resin foam sheet comprising the resin foam according to claim 1, 2, 3, 4 or 5.

7. A pressure-sensitive adhesive tape comprising the resin foam sheet according to claim 6 and a pressure-sensitive adhesive layer formed on at least one surface of the resin foam sheet.

8. A member for a vehicle, characterized by using the resin foam according to claim 1, 2, 3, 4 or 5, the resin foam sheet according to claim 6 or the adhesive tape according to claim 7.

9. A building member using the resin foam according to claim 1, 2, 3, 4 or 5, the resin foam sheet according to claim 6 or the adhesive tape according to claim 7.

Technical Field

The present invention relates to a resin foam, a resin foam sheet, an adhesive tape, a vehicle member, and a building member, which can exhibit extremely high sound insulation performance.

Background

Sound-insulating materials that are installed in sound transmission paths to block sound transmission and thereby insulate sound are used in all applications such as vehicle parts for automobiles, airplanes, ships, and the like, building parts, living parts such as electronic components, backing materials for carpets, and household and office electrical products.

Such a sound insulating material is usually a foam, a nonwoven fabric, a gel-like material, or the like containing a resin or the like. Among them, resin foams have been used in various fields because they can exhibit excellent sound insulation performance and are also excellent in handling properties (patent document 1 and the like). It can be considered that: in the foam, air vibration caused by incident sound propagates to the air in the inner hole portion, viscous friction of the air occurs in the hole portion, and a part of sound energy is converted into heat energy, thereby giving sound insulation performance.

However, in recent years, the required performance of sound-insulating materials has become increasingly strict. The conventional sound insulating material including a resin foam has the following problems: when the sound insulator is provided in a sound propagation path, sound transmission cannot be sufficiently suppressed, and sound from a sound source is slightly perceived as noise even on the back side with the sound insulator interposed therebetween.

Disclosure of Invention

Problems to be solved by the invention

In view of the above-described situation, an object of the present invention is to provide a resin foam, a resin foam sheet, an adhesive tape, a vehicle member, and a building member, which can exhibit extremely high sound insulation performance.

Means for solving the problems

The present invention 1 is a resin foam containing a thermoplastic resin and a plasticizer and having a plurality of cells, wherein the minimum value of the loss coefficient of 1-time antiresonance frequency in the range of 20 to 60 ℃ is 0.05 or more, and the 2-time antiresonance frequency in the range of 20 to 60 ℃ is 300 to 800Hz, as measured by Mechanical Impedance Measurement (MIM) in accordance with JIS G0602.

The present invention 2 is a resin foam containing a thermoplastic resin and a plasticizer and having a plurality of cells, wherein the minimum value of the loss coefficient of 1-time antiresonance frequency in the range of 20 to 60 ℃ is 0.005 or more, and the 2-time antiresonance frequency in the range of 20 to 60 ℃ is 300 to 800Hz, as measured by Mechanical Impedance Measurement (MIM) in accordance with JIS K7391.

The present invention 3 is a resin foam containing a thermoplastic resin and a plasticizer and having a plurality of cells, wherein the maximum value of the loss coefficient of 1-order antiresonance frequency in the range of 0 to 50 ℃ is 0.20 or more and the 2-order antiresonance frequency in the range of 0 to 30 ℃ is 800Hz or less, as measured by Mechanical Impedance Measurement (MIM) in accordance with ISO 16901.

The present invention is described in detail below.

The resin foam of the present invention 1, the present invention 2, and the present invention 3 (hereinafter, the matters common to the present invention 1, the present invention 2, and the present invention 3 are also simply referred to as "the present invention") contains a thermoplastic resin and a plasticizer.

Examples of the thermoplastic resin include polyvinylidene fluoride, polytetrafluoroethylene, a vinylidene fluoride-hexafluoropropylene copolymer, polytrifluoroethylene, an acrylonitrile-butadiene-styrene copolymer, a polyester, a polyether, a polyamide, a polycarbonate, a polyacrylate, a polymethacrylate, polyvinyl chloride, polyethylene, polypropylene, polystyrene, a polyvinyl acetal, an ethylene-vinyl acetate copolymer, and the like. Among them, polyvinyl acetal or an ethylene-vinyl acetate copolymer is preferable, and polyvinyl acetal is more preferable.

Polyvinyl acetal is widely used as a material for an interlayer film for laminated glass. When the interlayer film for laminated glass is bonded to glass in the production of laminated glass, the interlayer film for laminated glass which is excess at the end is cut off, and a large amount of the interlayer film for laminated glass is discarded. In the present invention, if waste of the interlayer film for laminated glass, which is generated in a large amount, is used as a raw material, it is also extremely significant from the viewpoint of recycling and the like.

The polyvinyl acetal is not particularly limited as long as it is a polyvinyl acetal obtained by acetalizing polyvinyl alcohol with an aldehyde, and is preferably polyvinyl butyral. Further, 2 or more kinds of polyvinyl acetals may be used in combination as necessary.

The acetalization degree of the polyvinyl acetal preferably has a lower limit of 40 mol% and an upper limit of 85 mol%, more preferably has a lower limit of 60 mol%, and even more preferably has an upper limit of 75 mol%.

The preferable lower limit of the amount of the hydroxyl group in the polyvinyl acetal is 15 mol%, and the preferable upper limit is 40 mol%. When the amount of the hydroxyl group is within this range, the compatibility with the plasticizer becomes high.

The acetalization degree and the hydroxyl group amount can be measured according to JIS K6728 "polyvinyl butyral test method", for example.

The polyvinyl acetal can be produced by acetalizing polyvinyl alcohol with an aldehyde.

The polyvinyl alcohol is usually obtained by saponifying polyvinyl acetate, and polyvinyl alcohol having a saponification degree of 70 to 99.8 mol% is usually used. The saponification degree of the polyvinyl alcohol is preferably 80 to 99.8 mol%.

The polymerization degree of the polyvinyl alcohol preferably has a lower limit of 500 and an upper limit of 4000. When the polymerization degree of the polyvinyl alcohol is 500 or more, the handling property of the obtained resin foam becomes excellent. When the polymerization degree of the polyvinyl alcohol is 4000 or less, the resin foam can be easily molded. The lower limit of the polymerization degree of the polyvinyl alcohol is more preferably 1000, and the upper limit thereof is more preferably 3600.

The aldehyde is not particularly limited, and an aldehyde having 1 to 10 carbon atoms is usually suitably used. The aldehyde having 1 to 10 carbon atoms is not particularly limited, and examples thereof include n-butyraldehyde, isobutyraldehyde, n-valeraldehyde, 2-ethylbutyraldehyde, n-hexanal, n-octanal, n-nonanal, n-decanal, formaldehyde, acetaldehyde, benzaldehyde, and the like. These aldehydes may be used alone, or 2 or more of them may be used in combination. Among them, from the viewpoint of easily designing the loss coefficient of the obtained resin foam to be high, aldehydes having 2 to 10 carbon atoms are preferable, n-butyraldehyde, n-hexanal, and n-valeraldehyde are more preferable, and n-butyraldehyde is particularly preferable.

The plasticizer is not particularly limited, and examples thereof include organic ester plasticizers such as monobasic organic acid esters and polybasic organic acid esters; phosphoric acid plasticizers such as organic phosphoric acid plasticizers and organic phosphorous acid plasticizers. The plasticizer is preferably a liquid plasticizer.

The monobasic organic acid ester is not particularly limited, and examples thereof include glycol esters obtained by reacting a glycol with a monobasic organic acid.

Examples of the diol include triethylene glycol, tetraethylene glycol, and tripropylene glycol. Examples of the monobasic organic acid include butyric acid, isobutyric acid, caproic acid, 2-ethylbutyric acid, heptanoic acid, n-octanoic acid, 2-ethylhexanoic acid, nonanoic acid (n-nonanoic acid), decanoic acid, and the like. Among them, triethylene glycol dihexanoate, triethylene glycol di-2-ethylbutyrate, triethylene glycol di-n-caprylate, triethylene glycol di-2-ethylhexanoate, and the like are preferable.

The polybasic organic acid ester is not particularly limited, and examples thereof include ester compounds formed from polybasic organic acids such as adipic acid, sebacic acid, azelaic acid, and the like, and alcohols having a linear or branched structure of 4 to 8 carbon atoms. Among them, dibutyl sebacate, dioctyl azelate, dibutyl carbitol adipate and the like are preferable.

The organic ester plasticizer is not particularly limited, and examples thereof include triethylene glycol di-2-ethylbutyrate, triethylene glycol di-2-ethylhexanoate, triethylene glycol dicaprylate, triethylene glycol di-n-caprylate, triethylene glycol di-n-heptanoate, tetraethylene glycol di-2-ethylhexanoate, dibutyl sebacate, dioctyl azelate, dibutyl carbitol adipate, ethylene glycol di-2-ethylbutyrate, 1, 3-propylene glycol di-2-ethylbutyrate, 1, 4-butylene glycol di-2-ethylbutyrate, diethylene glycol di-2-ethylhexanoate, dipropylene glycol di-2-ethylbutyrate, triethylene glycol di-2-ethylvalerate, and mixtures thereof, And 6 to 8 carbon-atom adipates such as tetraethylene glycol di-2-ethylbutyrate, diethylene glycol dicaprylate, dihexyl adipate, dioctyl adipate, hexylcyclohexyl adipate, diisononyl adipate, heptylnonyl adipate, dibutyl sebacate, oil-modified sebacic acid, a mixture of phosphate and adipate, a mixed adipate prepared from an adipate, an alkyl alcohol having 4 to 9 carbon atoms and a cyclic alcohol having 4 to 9 carbon atoms, and adipate such as hexyl adipate.

The organic phosphoric acid plasticizer is not particularly limited, and examples thereof include tributoxyethyl phosphate, isodecylphenyl phosphate, triisopropyl phosphate, and the like.

Further, the plasticizer is preferably one which hardly causes hydrolysis and contains: triethylene glycol di-2-ethylhexanoate (3GO), triethylene glycol di-2-ethylbutyrate (3GH), tetraethylene glycol di-2-ethylhexanoate (4GO), and dihexyl adipate (DHA). More preferably contains: tetraethylene glycol di-2-ethylhexanoate (4GO) and triethylene glycol di-2-ethylhexanoate (3 GO). Further preferably contains: triethylene glycol di-2-ethylhexanoate (3 GO).

The content of the plasticizer in the resin foam of the present invention is not particularly limited, and the lower limit is preferably 5 parts by weight, and the upper limit is preferably 60 parts by weight, based on 100 parts by weight of the thermoplastic resin. When the content of the plasticizer is within this range, particularly high sound-insulating properties can be exhibited, and the plasticizer does not bleed out of the resin foam. The lower limit of the content of the plasticizer is more preferably 20 parts by weight, and the upper limit is more preferably 55 parts by weight.

In many types of interlayer films for laminated glass, the content of the plasticizer is about 20 to 55 parts by weight per 100 parts by weight of polyvinyl acetal, and therefore, the waste interlayer film for laminated glass can be used as it is as a raw material for the resin foam of the present invention.

The resin foam of the present invention preferably further contains a binder. The resin foam of the present invention can exhibit adhesiveness and improve handling properties by containing a binder.

The adhesive is not particularly limited, and examples thereof include known adhesives such as acrylic adhesives, urethane adhesives, and rubber adhesives.

The resin foam of the present invention may contain additives such as an adhesive strength adjuster, a heat ray absorber, an ultraviolet shielding agent, an antioxidant, a light stabilizer, and an antistatic agent, in addition to the thermoplastic resin and the plasticizer. In addition, pigments such as carbon black, dyes, and the like may be contained to adjust the appearance of the obtained resin foam.

The resin foam of the present invention 1 has a minimum value of 0.05 or more of a loss coefficient of 1-time antiresonance frequency in a range of 20 to 60 ℃ as measured by Mechanical Impedance Measurement (MIM) in accordance with JIS G0602, and a 2-time antiresonance frequency in a range of 20 to 60 ℃ of 300 to 800 Hz.

JIS G0602 is a standard for obtaining a loss coefficient of 1-order antiresonance frequency and a loss coefficient of 2-order antiresonance frequencies by performing Mechanical Impedance Measurement (MIM) with a test object sandwiched between 2 steel plates. Since the measurement is performed in a state of being sandwiched between the steel sheets, it is considered that the resin foam is used in applications such as vibration dampers and sound insulators, in which the resin foam is used in a gap between an interior and an exterior of an automobile or the like, a gap between a floor base material and a surface material of a house, a gap between an exterior wall and an interior of a house, and a gap between panels of a soundproof material including a plurality of panels.

The resin foam of the present invention 1 can exhibit high vibration absorbability by setting the minimum value of the loss coefficient of the 1 st order antiresonance frequency (hereinafter also simply referred to as "loss coefficient") to 0.05 or more, and can exhibit high sound insulation performance by causing acoustic energy to be lost. The loss coefficient of the 1 st antiresonance frequency is preferably 0.06 or more, and more preferably 0.11 or more.

In the resin foam of the present invention 1, the 2-fold antiresonance frequency is set to 300 to 800Hz, so that even when resonance occurs with a material to be combined, the resonance frequency is low, and thus the resin foam is less likely to be perceived by human ears as noise. The lower limit of the 2-time antiresonance frequency is preferably 320Hz, the upper limit thereof is preferably 720Hz, the lower limit thereof is more preferably 330Hz, and the upper limit thereof is more preferably 630 Hz.

The 2-order antiresonance frequency of 300 to 800Hz means that the minimum value of the 2-order antiresonance frequency is 300Hz or more and the maximum value is 800Hz or less.

In the present invention 1, the loss coefficient of the 1 st antiresonance frequency and the 2 nd antiresonance frequency in the range of 20 to 60 ℃ are measured because: among the resonance phenomena, the amplitude of 1 st order resonance is the largest, and is most problematic as a vibration element, and the reason is that: in many practical applications, vibration in the medium frequency range of 300 to 800Hz is problematic, and therefore it is preferable to have an antiresonant point in this range.

The resin foam of the present invention 2 has a minimum value of 0.005 or more of a loss coefficient of 1-time antiresonance frequency in the range of 20 to 60 ℃ and 300 to 800Hz of 2-time antiresonance frequency in the range of 20 to 60 ℃ as measured by Mechanical Impedance Measurement (MIM) in accordance with JIS K7391.

JIS K7391 is a standard for obtaining a loss coefficient of 1-order antiresonance frequency and a loss coefficient of 2-order antiresonance frequency by performing Mechanical Impedance Measurement (MIM) in a state where one surface of a test object is attached to 1 steel plate and the other surface is open. Since the measurement is performed in a state where one surface is attached to 1 steel sheet and the other surface is open, it is considered that the resin foam is suitable for applications such as sound-insulating materials and vibration-damping materials in which sound-insulating properties and sound-damping properties are obtained by using the resin foam for adhesion to interior and exterior parts of automobiles, exterior walls of houses, interior walls, walls for which sound-insulating properties and sound-damping properties are desired, and the like.

The resin foam of the present invention 2 can exhibit high vibration absorbability by setting the minimum value of the loss coefficient of the 1 st-order anti-resonance frequency to 0.005 or more, and can exhibit high sound insulation performance by causing acoustic energy to be lost. The loss coefficient of the 1 st antiresonance frequency is preferably 0.006 or more, and more preferably 0.007 or more.

In the resin foam of the present invention 2, the 2-fold antiresonance frequency is set to 300 to 800Hz, so that even when resonance occurs with a material to be combined, the resonance frequency is low, and thus the resin foam is less likely to be perceived by human ears as noise. The lower limit of the 2-time antiresonance frequency is preferably 440Hz, the upper limit is preferably 740Hz, the lower limit is more preferably 470Hz, and the upper limit is more preferably 720 Hz.

It should be noted that the 2-time antiresonance frequency of 300-800 Hz means: the minimum value of the 2-order antiresonance frequency is more than 300Hz, and the maximum value is less than 800 Hz.

In the present invention 2, the loss coefficient of the 1 st order antiresonance frequency and the 2 nd order antiresonance frequency in the range of 20 to 60 ℃ are measured because: among the resonance phenomena, the amplitude of 1 st order resonance is the largest, and is most problematic as a vibration element, and the reason is that: in many practical applications, vibration in the medium frequency range of 300 to 800Hz is problematic, and therefore it is preferable to have an antiresonant point in this range.

The resin foam of the present invention 3 has a maximum value of a loss coefficient of 1-order antiresonance frequency in the range of 0 to 50 ℃ of 0.20 or more and a 2-order antiresonance frequency in the range of 0 to 30 ℃ of 800Hz or less, as measured by Mechanical Impedance Measurement (MIM) in accordance with ISO 16901.

ISO 16901 is a standard for obtaining a loss coefficient of 1-order antiresonance frequency and 2-order antiresonance frequency by performing Mechanical Impedance Measurement (MIM) with a test object sandwiched between 2 glass plates. Since the measurement is performed in a state of being sandwiched between glass plates, it is considered that the resin foam is used in applications such as a vibration damper for suppressing vibration by being sandwiched between a mirror glass and a wall surface in a wall mirror, and an impact absorber and a vibration damper for being sandwiched between a front panel and a housing of a television, a smart phone, a tablet personal computer, a personal computer, and the like.

In the present invention 3, the maximum value of the loss coefficient of the 1 st order antiresonance frequency is 0.20 or more, so that high vibration absorbability can be exhibited, and acoustic energy can be lost to exhibit high sound insulation performance. The loss coefficient of the 1 st antiresonance frequency is preferably 0.24 or more, and more preferably 0.33 or more.

In the present invention 3, the 2-order antiresonance frequency is set to 800Hz or less, so that even when resonance occurs with a material to be combined, the resonance frequency is low, and thus the material is less likely to be perceived as noise by human ears. The 2-order antiresonance frequency is preferably 780Hz or less. The lower limit of the 2-fold antiresonance frequency is not particularly limited, and is preferably 300Hz or higher.

The 2-order antiresonance frequency of 800Hz or less means that the maximum value of the 2-order antiresonance frequency is 800Hz or less.

In the present invention 3, the loss coefficient of the 1 st order antiresonance frequency in the range of 0 to 50 ℃ and the 2 nd order antiresonance frequency in the range of 0 to 30 ℃ are measured because: among the resonance phenomena, the amplitude of 1 st order resonance is the largest, and is most problematic as a vibration element, and the reason is that: in many practical applications, vibration in the medium frequency range of 300 to 800Hz is problematic, and therefore it is preferable to have an antiresonant point in this range.

The loss factor and the 2-fold antiresonance frequency can be achieved by adjusting the foaming state of the resin foam. Specifically, for example, the open cell ratio of the resin foam is preferably 20% or more. By setting the open cell ratio to 20% or more, the loss coefficient of the 1 st order antiresonance frequency and the 2 nd order antiresonance frequency of the obtained resin foam can be adjusted to desired ranges, and extremely high sound insulation can be exhibited. The open cell ratio is more preferably 30% or more, still more preferably 40% or more, and particularly preferably 50% or more. The upper limit of the above-mentioned continuous bubble rate is not particularly limited, and the upper limit is substantially about 98%.

In the present specification, the term "interconnected bubbles" means: the cells forming the resin foam are connected to each other.

The above-mentioned open cell ratio is defined by the ratio of the volume of cells connected to the outside of the resin foam obtained by the size measurement to the apparent volume of the resin foam, and can be measured by the densitometry method described in JIS K7138 or the like.

The lower limit of the average cell diameter of the resin foam of the present invention is preferably 100 μm, and the upper limit is preferably 1000. mu.m. When the average cell diameter is within this range, higher sound insulation can be achieved. The average cell diameter is more preferably 120 μm at the lower limit, more preferably 500 μm at the upper limit, and still more preferably 200 μm at the lower limit.

The average cell diameter can be measured by observing the cell wall and the void by using a cross-sectional observation photograph of the cell, and measuring the size of the void.

The average aspect ratio of cells in the resin foam of the present invention is preferably 2 or less. By setting the average aspect ratio of the bubbles to 2 or less, higher sound insulation can be exhibited. The average aspect ratio of the bubbles is more preferably 1.5 or less.

The average aspect ratio of the bubbles can be measured by measuring the major axis and the minor axis of the voids by using a cross-sectional observation photograph of the bubbles and calculating the ratio of the major axis and the minor axis.

The apparent density of the resin foam of the present invention is preferably 300kg/m³The following. By setting the apparent density to 300kg/m³Hereinafter, more excellent impact absorbability, vibration damping property and low fluidity can be exhibited. The apparent density is more preferably 200kg/m³The following. The lower limit of the apparent density is not particularly limited, but is substantially 50kg/m³Left and right.

The upper limit of the thickness of the resin foam of the present invention is preferably 10mm or less. If the upper limit of the thickness of the resin foam is within the above-mentioned preferable range, the resulting resin foam can be made less likely to be broken by shearing. The lower limit of the thickness of the resin foam of the present invention is preferably 50 μm or more. If the lower limit of the thickness of the resin foam is within the above-described preferred range, the sound-insulating property of the resulting resin foam can be further improved.

The method for producing the resin foam of the present invention is not particularly limited, and for example, a method of preparing a resin composition by adding a thermal decomposition type foaming agent to the thermoplastic resin, the plasticizer and, if necessary, an additive, and heating the resin composition to a foaming temperature to decompose the thermal decomposition type foaming agent is preferable.

Here, in order to achieve a very high sound insulation performance by adjusting the loss coefficient of the 1 st order antiresonance frequency and the 2 nd order antiresonance frequency to desired ranges while setting the open cell ratio to 20% or more, it is very important to set the kind and the blending amount of the thermal decomposition type foaming agent and the foaming temperature at the time of production in addition to the selection of the thermoplastic resin and the plasticizer. Among them, the setting of the foaming temperature is necessary for achieving a high open cell ratio.

The foaming temperature is preferably 180 ℃ or higher. It can be considered that: when the temperature is 180 ℃ or higher, the resin composition is sufficiently softened during foaming and cells are easily connected to each other, so that open cells are easily generated.

The thermal decomposition type foaming agent is not particularly limited as long as it has a decomposition temperature of about 120 to 240 ℃, and conventionally known thermal decomposition type foaming agents can be used. In addition, from the viewpoint of further improving the above-mentioned open cell ratio, it is preferable to use a thermal decomposition type foaming agent having a decomposition temperature higher by 20 ℃ or more than the molding temperature of the resin composition as a raw material before foaming, and it is more preferable to use a thermal decomposition type foaming agent having a decomposition temperature higher by 50 ℃ or more.

Specific examples of the thermal decomposition type foaming agent include azodicarbonamide, N '-dinitrosopentamethylenetetramine, 4' -oxybis (benzenesulfonylhydrazide), urea, sodium hydrogen carbonate, and a mixture thereof.

Examples of commercially available products among the above thermal decomposition type foaming agents include CELLMIC series (manufactured by sanko chemical industries, Ltd.), VINIFOL series, cellulan series, and neocellbond series (manufactured by henceforth chemical industries, Ltd.).

The amount of the thermal decomposition type foaming agent to be blended in the resin composition is not particularly limited, and is preferably 4 parts by weight at the lower limit and 20 parts by weight at the upper limit to 100 parts by weight of the thermoplastic resin. When the amount of the thermal decomposition type foaming agent is within this range, a foam having an open cell content of 10% or more can be produced. The lower limit of the amount of the thermal decomposition type foaming agent is more preferably 5 parts by weight, and the upper limit is more preferably 15 parts by weight.

The resin foam of the present invention, having the above-described structure, can exhibit extremely high sound insulation performance which cannot be achieved by a conventional sound insulation material comprising a resin foam. Therefore, the resin foam of the present invention is extremely suitable as a sound insulating material or a sound insulating material.

Specifically, the resin composition can be used for various applications such as vehicle parts for automobiles, airplanes, ships, and the like, building parts, electronic parts, living parts such as backing materials for carpets, and electric products for home and office use. In particular, a resin foam sheet obtained by molding the resin foam of the present invention into a sheet shape is excellent in handling properties and can be suitably used for various applications.

A resin foam sheet comprising the resin foam of the present invention is also one of the present invention.

The pressure-sensitive adhesive tape having the pressure-sensitive adhesive layer formed on at least one surface of the resin foam sheet of the present invention is extremely excellent in handling properties.

An adhesive tape comprising the resin foam sheet of the present invention and an adhesive layer formed on at least one surface of the resin foam sheet is also one aspect of the present invention.

The pressure-sensitive adhesive constituting the pressure-sensitive adhesive layer is not particularly limited, and examples thereof include known pressure-sensitive adhesives such as acrylic pressure-sensitive adhesives, urethane pressure-sensitive adhesives, and rubber pressure-sensitive adhesives.

In particular, since the resin foam sheet of the present invention contains a plasticizer, there is a possibility that the adhesive force is reduced by the plasticizer transferring to the pressure-sensitive adhesive layer. Therefore, as the pressure-sensitive adhesive layer, a pressure-sensitive adhesive layer having high plasticizer resistance is preferably used.

Examples of the pressure-sensitive adhesive layer having high plasticizer resistance include a pressure-sensitive adhesive layer formed from a pressure-sensitive adhesive composition containing an acrylic polymer (X), a tackifier resin (Y) having a softening point of 140 to 160 ℃, and a crosslinking agent (Z). By using such an adhesive composition, the adhesive force is less likely to be reduced with time due to the transfer of the plasticizer.

Hereinafter, each component constituting the adhesive composition will be described in detail.

The acrylic polymer (X) is a polymer obtained by polymerizing a monomer mixture containing 5 to 18 parts by weight of a carboxyl group-containing monomer (B) per 100 parts by weight of an alkyl (meth) acrylate monomer (A) containing 60% by weight or more of an alkyl (meth) acrylate monomer (a) having 4 or less carbon atoms.

In the present specification, (meth) acrylic acid means acrylic acid or methacrylic acid, and (meth) acrylate means acrylate or methacrylate.

The alkyl (meth) acrylate monomer (a) preferably contains 60% by weight or more of an alkyl (meth) acrylate monomer (a) having an alkyl group and 4 or less carbon atoms. When the content of the alkyl (meth) acrylate monomer (a) having an alkyl group of 4 or less carbon atoms is 60% by weight or more, the plasticizer resistance of the obtained pressure-sensitive adhesive layer is increased. The content of the alkyl (meth) acrylate monomer (a) is more preferably 80% by weight or more, still more preferably 90% by weight or more, and particularly preferably 100% by weight, from the viewpoint of suppressing a decrease in adhesive force to the flexible polyvinyl chloride.

Specific examples of the alkyl (meth) acrylate monomer (a) include methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, isopropyl (meth) acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, and t-butyl (meth) acrylate. These alkyl (meth) acrylate monomers (a) may be used alone or in combination of 2 or more. Among them, n-butyl (meth) acrylate is preferably contained, and more preferably, only n-butyl (meth) acrylate alone is contained.

The alkyl (meth) acrylate monomer (a) may contain an alkyl (meth) acrylate monomer (b) in which the number of carbon atoms in the alkyl group is 5 or more.

Specific examples of the alkyl (meth) acrylate monomer (b) include 2-ethylhexyl (meth) acrylate, isooctyl (meth) acrylate, isononyl (meth) acrylate, and lauryl (meth) acrylate.

The content of the alkyl (meth) acrylate monomer (a) when it contains the alkyl (meth) acrylate monomer (b) is preferably 20% by weight or less, and more preferably 10% by weight or less.

The carboxyl group-containing monomer (B) is a polymerizable monomer having a carboxyl group in the molecule, and is preferably a carboxyl group-containing vinyl monomer.

Specific examples of the carboxyl group-containing monomer (B) include (meth) acrylic acid, itaconic acid, maleic acid, fumaric acid, and crotonic acid. These carboxyl group-containing monomers (B) may be used alone or in combination of 2 or more. Among them, (meth) acrylic acid is preferable, and acrylic acid is more preferable.

The monomer mixture to be the raw material of the acrylic polymer (X) may further contain other monomers in addition to the alkyl (meth) acrylate monomer (a) and the carboxyl group-containing monomer (B).

Examples of the other monomers include monomers containing a polar group other than a carboxyl group, styrene monomers such as styrene, α -methylstyrene, o-methylstyrene and p-methylstyrene, and the like.

The content of the carboxyl group-containing monomer (B) in the monomer mixture to be a raw material of the acrylic polymer (X) is preferably 5 parts by weight at the lower limit and 18 parts by weight at the upper limit with respect to 100 parts by weight of the alkyl (meth) acrylate monomer (a). By using 5 parts by weight or more of the carboxyl group-containing monomer (B), the plasticizer resistance of the resulting pressure-sensitive adhesive layer is increased. The content of the carboxyl group-containing monomer (B) is more preferably 6 parts by weight at the lower limit, more preferably 17 parts by weight at the upper limit, still more preferably 10 parts by weight at the lower limit, and still more preferably 15 parts by weight at the upper limit.

The lower limit of the weight average molecular weight of the acrylic polymer (X) is preferably 55 ten thousand, and the upper limit is preferably 100 ten thousand. If the weight average molecular weight is 55 ten thousand or more, the plasticizer resistance of the resulting adhesive layer becomes high. If the weight average molecular weight is 100 ten thousand or less, the pressure-sensitive adhesive layer can be inhibited from becoming excessively hard, and adhesive force can be exerted on an adherend having a complicated shape. The weight average molecular weight is more preferably 60 ten thousand at the lower limit, more preferably 80 ten thousand at the upper limit, still more preferably 65 ten thousand at the lower limit, and still more preferably 75 ten thousand at the upper limit.

The acrylic polymer (X) can be obtained by polymerizing the monomer mixture.

The polymerization method is not particularly limited, and examples thereof include a method of subjecting the monomer mixture to radical polymerization in the presence of a polymerization initiator. More specifically, a conventionally known polymerization method such as solution polymerization, emulsion polymerization, suspension polymerization, bulk polymerization, or the like can be used.

The polymerization initiator is not particularly limited, and examples thereof include an organic peroxide-based polymerization initiator, an azo-based polymerization initiator, and the like.

Examples of the organic peroxide-based polymerization initiator include cumene hydroperoxide, benzoyl peroxide, lauroyl peroxide, octanoyl peroxide, stearoyl peroxide, o-chlorobenzoyl peroxide, acetyl peroxide, t-butyl hydroperoxide, t-butyl peroxyacetate, t-butyl peroxyisobutyrate, 3, 5, 5-trimethylhexanoyl peroxide, t-butyl peroxy-2-ethylhexanoate, and di-t-butyl peroxide.

Examples of the azo polymerization initiator include 2, 2 '-azobisisobutyronitrile, 2' -azobis (2, 4-dimethylvaleronitrile), 4 '-azobis (4-cyanovaleric acid), and 2, 2' -azobis (2-methylbutyronitrile).

These polymerization initiators may be used alone, or 2 or more kinds thereof may be used in combination. Among them, lauroyl peroxide, octanoyl peroxide, stearoyl peroxide, and 3, 5, 5-trimethylhexanoyl peroxide are preferable from the viewpoint of reducing the odor of the resulting acrylic polymer (X).

The amount of the polymerization initiator is not particularly limited, and is preferably about 0.01 to 10 parts by weight, more preferably about 0.05 to 2 parts by weight, based on 100 parts by weight of the monomer mixture.

The softening point of the tackifier resin (Y) is preferably 140 ℃ at the lower limit and 160 ℃ at the upper limit. When the softening point is within the above range, deterioration of the adhesive strength of the resulting pressure-sensitive adhesive layer with time can be suppressed. From the viewpoint of further suppressing the decrease in the adhesive force with time, a more preferable upper limit of the softening point is 150 ℃.

The softening point of the tackifier resin (Y) may be measured according to JIS K2207.

Examples of the tackifier resin (Y) include rosin resins such as petroleum resin-based tackifier resin, hydrogenated petroleum resin-based tackifier resin, rosin glycol-based tackifier resin, and rosin ester-based tackifier resin, terpene resins, phenol resins, xylene resins, coumarone resins, ketone resins, and modified resins thereof. These tackifying resins may be used alone or in combination of 2 or more. Among these, rosin-based tackifying resins are preferable, and rosin ester-based tackifying resins are more preferable, from the viewpoint of suppressing the adhesive force with time.

Examples of the rosin ester-based tackifying resin include disproportionated rosin ester, polymerized rosin ester, hydrogenated rosin ester, rosin phenol-based resin, and the like.

The content of the component having a molecular weight of 600 or less in the tackifier resin (Y) is preferably 13% by weight or less. When such a tackifier resin is used, the volatile components generated from the tackifier resin can be suppressed to a low level while maintaining the tackiness. Further, since the low-molecular weight component is small, the viscosity of the pressure-sensitive adhesive layer can be relatively increased, and the movement of the plasticizer to the pressure-sensitive adhesive layer is easily inhibited, so that the deterioration of the adhesive strength with time is less likely to occur.

Examples of the method for removing the component having a molecular weight of 600 or less from the tackifier resin include a method of heating and melting the tackifier resin to a softening point or higher, and a method of blowing steam.

The molecular weight and the content of the tackifier resin can be measured by Gel Permeation Chromatography (GPC), and calculated from polystyrene conversion values and area ratios.

The amount of the tackifier resin (Y) blended in the pressure-sensitive adhesive composition is preferably 3 parts by weight at the lower limit and 9 parts by weight at the upper limit with respect to 100 parts by weight of the acrylic polymer (X). When the amount of the tackifier resin blended is 3 parts by weight or more, the adhesive strength to a hardly adhered object is improved. When the blending amount of the tackifier resin is 9 parts by weight or less, the plasticizer can be easily prevented from moving to the pressure-sensitive adhesive layer, and the deterioration of the adhesive strength with time can be prevented. From the viewpoint of improving the adhesive force to the difficult-to-adhere object and maintaining the adhesive force, the blending amount of the tackifier resin (Y) is more preferably 4 parts by weight at the lower limit, more preferably 8 parts by weight at the upper limit, and still more preferably 7 parts by weight at the upper limit.

The crosslinking agent (Z) has an effect of improving the cohesive force of the obtained pressure-sensitive adhesive layer and improving the physical properties of the pressure-sensitive adhesive tape.

The crosslinking agent (Z) is not particularly limited, and examples thereof include an isocyanate-based crosslinking agent, an epoxy-based crosslinking agent, an aziridine-based crosslinking agent, and a metal chelate-based crosslinking agent. Among them, an isocyanate-based crosslinking agent or a metal chelate-based crosslinking agent is preferable.

Specific examples of the isocyanate crosslinking agent include toluene diisocyanate, naphthalene-1, 5-diisocyanate, and diphenylmethane diisocyanate. Examples of commercially available products include CORONATE L manufactured by polyurethane corporation, japan.

Specific examples of the metal chelate-based crosslinking agent include chelate compounds in which a metal atom is aluminum, zirconium, titanium, zinc, iron, tin, or the like. Among them, an aluminum chelate compound in which the central metal is aluminum is preferable. Commercially available products include aluminum chelate compound A and aluminum chelate compound M manufactured by Kagawa Fine chemical Co.

The content of the crosslinking agent (Z) in the pressure-sensitive adhesive composition is not particularly limited, and the lower limit is preferably 0.005 parts by weight, the upper limit is preferably 5 parts by weight, the lower limit is more preferably 0.01 parts by weight, the upper limit is more preferably 1 part by weight, the lower limit is more preferably 0.02 parts by weight, and the upper limit is more preferably 0.1 parts by weight, based on 100 parts by weight of the acrylic polymer (X).

The pressure-sensitive adhesive composition may contain a solvent such as ethyl acetate, dimethyl sulfoxide, ethanol, acetone, or diethyl ether in addition to the acrylic polymer (X), the tackifier resin (Y), and the crosslinking agent (Z). Among them, ethyl acetate is preferable from the viewpoint of suppressing the volatile component to a low level.

The pressure-sensitive adhesive composition may further contain additives such as fillers, pigments, dyes, and antioxidants, if necessary.

The lower limit of the thickness of the pressure-sensitive adhesive layer is preferably 5 μm, and the upper limit is preferably 200 μm. When the thickness of the pressure-sensitive adhesive layer is within this range, sufficient pressure-sensitive adhesive properties can be exhibited. The lower limit of the thickness of the pressure-sensitive adhesive layer is more preferably 7 μm, the upper limit is more preferably 150 μm, the lower limit is more preferably 10 μm, and the upper limit is more preferably 100 μm.

The method for producing the adhesive tape of the present invention by forming an adhesive layer on at least one surface of the resin foam sheet of the present invention is not particularly limited, and examples thereof include a method of applying an adhesive to at least one surface of a resin foam sheet using an applicator such as a coater; a method of spraying and applying the adhesive using a sprayer; a method of coating an adhesive using bristles, and the like. The pressure-sensitive adhesive layer may be formed by a method of bonding a double-sided pressure-sensitive adhesive tape to at least one side of the resin foam sheet.

The resin foam, the resin foam sheet, and the adhesive tape of the present invention can exhibit extremely high sound insulation performance, and therefore can exhibit excellent performance as a sound insulation material or a soundproof material. Therefore, the resin composition can be used for all purposes such as vehicle parts for automobiles, airplanes, ships and the like, building parts, electronic parts, living parts such as backing materials of carpets and the like, and electric products for home and office use.

Examples of the living parts include carpet backing materials, curtain materials, wall papers, and the like for the purpose of damping vibration, impact, sound, and the like.

Examples of the electric parts include electronic components such as a mobile phone, a tablet computer, and a personal computer; parts used for the purpose of reducing vibration, impact, sound, and the like in home electric appliances such as audio equipment, headphones, televisions, refrigerators, washing machines, and vacuum cleaners, and in office electric appliances.

Examples of the members for other uses include members used for the purpose of mitigating impact at the time of collision, such as floors, mats, and walls in indoor and outdoor sports facilities.

The resin foam, the resin foam sheet, and the adhesive tape of the present invention are particularly suitable as a vehicle member and a building member.

A vehicle member using the resin foam, the resin foam sheet, or the adhesive tape of the present invention is also one aspect of the present invention.

A building member using the resin foam, the resin foam sheet, or the adhesive tape of the present invention is also one aspect of the present invention.

Examples of the vehicle member include members for the purpose of damping vibration, impact, sound, and the like, such as a ceiling material, an interior material, and an interior lining material of a vehicle such as an automobile, an airplane, and a ship.

More specifically, examples of the damping material include a damping material used by being directly attached to a steel sheet member such as a ceiling, a door panel, or a floor of a vehicle such as an automobile; a shock absorbing material, a cushion material, or the like used by being sandwiched between a steel plate member constituting the exterior trim or the frame and a resin member constituting the interior trim.

Examples of the building material include floor base materials, materials for sound-insulating walls, ceiling materials, lining materials for resin and metal tiles, and the like for the purpose of damping vibration, impact, sound, and the like.

More specifically, examples of the sound insulation mat include an attenuation material directly adhered to a metal tile including a GALVALUME steel sheet (registered trademark) as a measure against rain, and a sound insulation mat used by being sandwiched between a floor material and a base material of a house floor.

ADVANTAGEOUS EFFECTS OF INVENTION

According to the present invention, a resin foam sheet, an adhesive tape, a vehicle member, and a building member, which can exhibit extremely high sound insulation performance, can be provided.

Detailed Description

The present invention will be described in more detail with reference to examples, but the present invention is not limited to these examples.

(example 1)

(1) Production of resin foam

A resin composition was obtained by adding 40 parts by weight of triethylene glycol di-2-ethylhexanoate (3GO) as a plasticizer and 9 parts by weight of CELLMIC CE (208 ℃ C. as a thermal decomposition type foaming agent) to 100 parts by weight of polyvinyl butyral 1(PVB 1). The obtained resin composition was sufficiently kneaded at 110 ℃ using an open roll, and then extruded using an extruder to obtain a sheet-like body. The content of hydroxyl groups in PVB1 was 34 mol%, the degree of acetylation was 1.0 mol%, the degree of butyralization was 65 mol%, and the average degree of polymerization was 1650.

The obtained sheet-like body was decomposed by a thermal decomposition type foaming agent in an oven at a foaming temperature of 220 ℃ to obtain a sheet-like resin foam (resin foam sheet). The thickness of the obtained resin foam sheet was 4 mm.

(2) Measurement of continuous bubble Rate and apparent Density

The open cell ratio of the obtained resin foam was measured by a densitometry method in accordance with JIS K7138. The apparent density was measured by a method of calculating from the measured weight and the apparent volume obtained by the dimension measurement.

(3) Measurement of loss coefficient of 1 st order antiresonance frequency and 2 nd order antiresonance frequency

(3-1) measurement based on JIS G0602

The loss coefficient of 1-order antiresonance frequency in the range of 20-60 ℃ and 2-order antiresonance frequency in the range of 20-60 ℃ were measured by Mechanical Impedance Measurement (MIM) according to JIS G0602.

Specifically, a resin foam was fixed between 2 steel plates having a width of 12mm, a length of 240mm and a thickness of 1.6mm by a double-sided tape (product #5782 of hydrops chemical industries) to obtain a laminated sample, and the loss coefficient of 1-fold antiresonance frequency and the 2-fold antiresonance frequency were measured by a center-vibration method using the laminated sample.

(3-2) measurement based on JIS K7391

The loss coefficient of 1-order antiresonance frequency in the range of 20 to 60 ℃ and 2-order antiresonance frequency in the range of 20 to 60 ℃ were measured by Mechanical Impedance Measurement (MIM) according to JIS K7391.

Specifically, a laminated sample was obtained by fixing a resin foam to a steel plate having a width of 12mm, a length of 240mm and a thickness of 1.6mm with a double-sided tape (# 5782, manufactured by hydroprocess chemical industries, Ltd.), and the loss coefficient of 1-order antiresonance frequency and 2-order antiresonance frequency were measured by a center-vibration method using the laminated sample.

(3-3) ISO 16901-based measurement

The loss coefficient of 1-fold antiresonance frequency in the range of 0 to 50 ℃ and 2-fold antiresonance frequency in the range of 0 to 30 ℃ were measured by Mechanical Impedance Measurement (MIM) according to ISO 16901.

Specifically, a laminated sample was obtained by fixing a resin foam between 2 glass plates having a width of 25mm, a length of 305mm and a thickness of 2mm with a double-sided tape (# 5782 manufactured by hydroprocess chemical industries, Ltd.), and the loss coefficient of 1-order antiresonance frequency and 2-order antiresonance frequency were measured by a center-shaking method using the laminated sample.

(examples 2 to 4, comparative example 4)

A resin foam was produced in the same manner as in example 1 except that the blending amounts of the thermal decomposition type foaming agent and the plasticizer were set as shown in Table 1, and the loss coefficient of 1-fold antiresonance frequency and 2-fold antiresonance frequency were measured.

(example 5)

Resin foams were produced in the same manner as in example 1 except that polyvinyl butyral 2(PVB2) was used in place of polyvinyl butyral 1 and the amount of the thermal decomposition type foaming agent was changed as shown in table 1, and the loss coefficient of 1-fold antiresonance frequency and 2-fold antiresonance frequency were measured. The content of hydroxyl groups in PVB2 was 23 mol%, the degree of acetylation was 13 mol%, the degree of butyralization was 64 mol%, and the average degree of polymerization was 2400.

Comparative example 1

As a comparative example, a commercially available polyethylene foam (SoFTLON S, 30-fold expansion ratio, manufactured by WATERPOWDER CHEMICAL CO., Ltd.) was prepared. The polyethylene foam was subjected to the measurement of the loss coefficient of 1-fold antiresonance frequency and 2-fold antiresonance frequency in the same manner as in example 1.

Comparative example 2

As a comparative example, a commercially available ethylene-vinyl acetate copolymer (EVA) FOAM (MITSUKUKU FOAM V10, manufactured by Sanfu industries Co., Ltd.) was prepared. The EVA foam was measured for the loss coefficient of 1 antiresonant frequency and 2 antiresonant frequencies in the same manner as in example 1.

Comparative example 3

As a comparative example, a commercially available urethane gel (Exseal co., ltd., Exseal) was prepared. The loss coefficient of 1-time antiresonance frequency and 2-time antiresonance frequency of this urethane gel were measured in the same manner as in example 1.

Comparative example 5

A resin foam was produced in the same manner as in example 1 except that CELLMIC CAP (made by Sansynergists Co., Ltd., decomposition temperature: 125 ℃) was used as the thermal decomposition type foaming agent and the foaming temperature was 150 ℃, and the loss coefficient of 1-fold antiresonance frequency and 2-fold antiresonance frequency were measured.

(evaluation)

The resin foams obtained in examples and comparative examples were evaluated by the following methods.

The results are shown in tables 1 and 2.

(evaluation of Sound insulating Properties 1)

The acoustic transmission loss was measured by the acoustic intensity method according to JIS a 1441. For the measurement, the measurement temperature is set to 20 ℃, and the frequency range is set to 100 to 10000Hz per 1/3 octaves. The sample was fixed by a double-sided tape (# 5782, manufactured by waterlogging chemical industries, Ltd.) with a resin foam sample (thickness of about 4mm) sandwiched between 2mm thick glass, and the size (open face) was 500mm × 500 mm. The incident power is calculated from the average sound pressure level at 5 points in the reverberant room, and the transmission power is calculated from the acoustic intensity at 25 points at 5 × 5 in the measurement region (500mm × 500 mm).

The sound insulation performance was evaluated by the following criteria.

A graph of frequency versus transmission loss was prepared, and a case where the difference in transmission loss between the first maximum value on the low frequency side and the adjacent minimum value was 7dB or less was evaluated as "○", and a case where the difference in transmission loss exceeded 7dB was evaluated as "x".

(evaluation of Sound insulating Properties 2)

Evaluation method of soundproofing performance of buildings and building parts by JIS A1417-1: the air sound insulation performance was evaluated with respect to the air sound insulation performance.

For the measurement, the measurement temperature is set to 25 ℃, and the frequency range is set to be 31.5 to 4000Hz per 1/1 octaves. As to the sample, a resin foam sample (thickness: about 4mm) was fixed to a gypsum board with a double-sided tape (product #5782 of Water chemical industries, Ltd.) so that the size (open surface) was 990mm × 990 mm. The sound was emitted from the reverberation chamber side at a sound pressure of 100dB, and the differential pressure was measured at the soundless chamber side.

The sound insulation performance was evaluated by the following criteria.

A1/1 octave frequency-sound pressure level graph was prepared, and a case where the DM value was +1.0dB or more on average and a case where the DM value was less than +1.0dB was designated as "○" and "x" with respect to a state where the resin foam was not mounted.

(evaluation of Sound insulating Properties 3)

Evaluation method of soundproofing performance of buildings and building parts by JIS A1417-1: the air sound insulation performance was evaluated with respect to the air sound insulation performance.

For the measurement, the measurement temperature is set to 25 ℃, and the frequency range is set to be 31.5 to 4000Hz per 1/1 octaves. For the sample, a resin foam (thickness of about 4mm) obtained by fixing aluminum (0.3mm) with a double-sided tape (manufactured by waterlogging chemical industries, #5782) was used, and one side of the non-laminated aluminum was fixed to a gypsum board with a double-sided tape (manufactured by waterlogging chemical industries, #5782), and the size (open side) was 990mm × 990 mm. The sound was emitted from the reverberation chamber side at a sound pressure of 100dB, and the differential pressure was measured at the soundless chamber side.

The sound insulation performance was evaluated by the following criteria.

A1/1 octave frequency-sound pressure level graph was prepared, and a case where the DM value was +2.0dB or more on average and a case where the DM value was less than +2.0dB was designated as "○" and "x" with respect to a state where the resin foam was not mounted.

[ Table 1]

[ Table 2]

(example 6)

A double-sided adhesive tape for fastening an interior material (product of water-collecting chemical industries, inc. #5782) as an adhesive layer was attached to one surface of the resin foam sheet obtained in example 1 to obtain a single-sided adhesive tape.

The obtained single-sided pressure-sensitive adhesive tape can exhibit adhesiveness while maintaining the flexibility and sound insulation properties of the resin foam sheet described in example 1.

In the measurement of the sound insulation property, one side of the obtained single-sided pressure-sensitive adhesive tape to which the interior member-fixing double-sided tape (product #5782 of water chemical industries) was bonded was used as it was without re-bonding the double-sided tape, and the double-sided tape (product #5782 of water chemical industries) was re-bonded for the measurement only on the side to which the interior member-fixing double-sided tape was not bonded.

(example 7)

(1) Production of acrylic Polymer

A monomer component was obtained by introducing 100 parts by weight of n-butyl acrylate and 11 parts by weight of acrylic acid into a reaction vessel. This monomer component was dissolved in ethyl acetate, 0.1 part by weight of lauroyl peroxide as a polymerization initiator was added at the reflux point, and the mixture was refluxed at 70 ℃ for 5 hours to obtain a solution of an acrylic polymer having a weight average molecular weight of 72 ten thousand.

(2) Adhesive composition and production of adhesive tape

To the obtained acrylic polymer solution, a polymerized rosin ester based tackifying resin (softening point 140 ℃) having a content of 13% of components having a molecular weight of 600 or less was added in an amount of 6.3 parts by weight and an aluminum chelate compound as a crosslinking agent and being a metal chelate crosslinking agent was added in an amount of 0.054 part by weight based on 100 parts by weight of the acrylic polymer, which is a nonvolatile component of the acrylic polymer solution. Thereafter, the mixture was uniformly mixed to obtain an adhesive composition.

Next, the obtained pressure-sensitive adhesive composition was applied to one surface of the resin foam sheet obtained in example 1, and then dried at 120 ℃ for 5 minutes to obtain a one-sided pressure-sensitive adhesive tape in which a pressure-sensitive adhesive layer having a thickness of 60 μm was laminated on one surface of the resin foam sheet.

The obtained single-sided pressure-sensitive adhesive tape can exhibit adhesiveness while maintaining the flexibility and sound insulation properties of the resin foam sheet described in example 1. Further, the adhesiveness was not reduced even after 1 month passed after the adhesion.

In the measurement of the sound-insulating property, the pressure-sensitive adhesive layer-laminated surface of the obtained single-sided pressure-sensitive adhesive tape was used as it is without re-laminating a double-sided tape, and a double-sided tape (product #5782 of water chemical industries, Ltd.) was re-laminated for the measurement only on the surface on which the pressure-sensitive adhesive layer was not laminated.

(evaluation)

The single-sided pressure-sensitive adhesive tapes obtained in examples 6 and 7 were evaluated by the following methods.

(evaluation of plasticizer resistance)

(1) Preparation of test body

The one-sided pressure-sensitive adhesive tapes obtained in examples 6 and 7 were cut into a width of 25mm × a length of 150mm, and a 2kg rubber roller was reciprocated 1 time at a speed of 10 mm/sec in accordance with JIS Z0237 so as to be pressure-bonded to SUS304 (surface BA finish) specified in JIS G4305.

(2) Determination of initial adhesion

The single-sided pressure-sensitive adhesive tape obtained by the preparation of the test piece was pressure-bonded at 23 ℃ and 50% RH, left to stand for 20 minutes, and then subjected to a 90-degree peel test in accordance with JIS Z0237 with the number of tests being 3, and the average value was defined as the initial adhesive force (N/25 mm). The peeling speed was 300 mm/min.

(3) Measurement of adhesion force with time

The test piece obtained by the preparation of the test piece was left at 60 ℃ for 72 hours in an atmosphere, then left at 23 ℃ and 50% RH for 30 minutes, and then subjected to 90-degree peel test with 3 test times according to JIS Z0237, and the average value was defined as the time-dependent adhesive force (N/25 mm).

(4) Evaluation of adhesive force maintenance ratio

The initial adhesive force and the adhesive force with time obtained above were used to calculate the adhesive force maintenance rate (%) using the following formula.

Adhesion force maintenance ratio (%) ═ 100 × (adhesion force with time/initial adhesion force)

According to the results of the above evaluation, the adhesive force maintenance ratio of the one-sided pressure-sensitive adhesive tape obtained in example 7 was greatly improved as compared with the adhesive force maintenance ratio of the one-sided pressure-sensitive adhesive tape obtained in example 6.

Industrial applicability

According to the present invention, a resin foam sheet, an adhesive tape, a vehicle member, and a building member, which can exhibit extremely high sound insulation performance, can be provided.