阅读说明：本技术 聚烯烃系树脂发泡粒子、聚烯烃系树脂发泡粒子的制造方法和聚烯烃系树脂模内发泡成型体 (Expanded polyolefin resin particle, method for producing expanded polyolefin resin particle, and molded article obtained by in-mold expansion of polyolefin resin ) 是由 三浦新太郎 于 2018-06-01 设计创作，主要内容包括：本发明的课题在于提供能够提供一种长期抑制摩擦声和异响产生风险且表面光泽性优异的聚烯烃系树脂模内发泡成型体的、新型聚烯烃系树脂发泡粒子。通过制成含有聚烯烃系树脂(a)的聚烯烃系树脂发泡粒子而实现上述课题,所述聚烯烃系树脂发泡粒子含有特定量的生成物(b)、丁烯共聚聚乙烯蜡(c)、吸水性物质(d),所述生成物(b)含有作为成分1的烯烃系弹性体、除成分1以外的、由乙烯与至少1种乙烯基单体形成的作为成分2的的共聚物、作为成分3的高级脂肪酰胺而成。(The present invention addresses the problem of providing novel expanded polyolefin resin particles that can provide an in-mold expanded polyolefin resin molded article that has excellent surface gloss while suppressing the risk of frictional noise and abnormal sound generation for a long period of time. The above object is achieved by producing expanded polyolefin resin particles containing a polyolefin resin (a) containing a specific amount of a product (b) comprising an olefin elastomer as component 1, a copolymer as component 2 of ethylene and at least 1 vinyl monomer other than component 1, and a higher fatty acid amide as component 3, a butene copolymerized polyethylene wax (c), and a water-absorbing substance (d).)

1. Expanded polyolefin resin particles comprising, per 100 parts by weight of a polyolefin resin (a), 3 to 10 parts by weight of a product (b), 2 to 10 parts by weight of a butene-copolymerized polyethylene wax (c), and 0.01 to 1 part by weight of a water-absorbing substance (d)

The product (b) comprises an olefin elastomer as component 1, a copolymer as component 2 comprising ethylene and at least 1 vinyl monomer other than component 1, and a higher fatty amide as component 3.

2. The expanded polyolefin-based resin particle according to claim 1, wherein the polyolefin-based resin (a) is a polypropylene-based resin or a polyethylene-based resin.

3. The expanded polyolefin-based resin particles according to claim 1 or 2, wherein the water-absorbing substance (d) is at least 1 or more selected from the group consisting of glycerin and polyethylene glycol.

4. The expanded polyolefin resin particles according to any one of claims 1 to 3, wherein the butene-copolymerized polyethylene wax (c) has a melting point of 40 to 130 ℃.

5. The expanded polyolefin resin particle according to any one of claims 1 to 4, wherein the olefin elastomer as component 1 is at least 1 selected from the following (a) to (c): (a) ethylene-alpha-olefin copolymer rubber; (b) ethylene- α -olefin-non-conjugated diene copolymer rubber; and (c) a graft copolymer having a polymer segment comprising an ethylene/alpha-olefin copolymer rubber and/or an ethylene/alpha-olefin/nonconjugated diene copolymer rubber as a main component and a vinyl polymer segment comprising at least 1 vinyl monomer as a branch component.

6. The expanded polyolefin resin particle according to any one of claims 1 to 5, the copolymer as component 2, which is formed from ethylene and at least 1 vinyl monomer other than component 1, is at least 1 selected from the group consisting of ethylene-acrylic acid copolymer, ethylene-methyl acrylate copolymer, ethylene-methyl methacrylate copolymer, ethylene-ethyl acrylate copolymer, ethylene-isobutyl acrylate copolymer, ethylene-n-butyl acrylate copolymer, ethylene-2-ethylhexyl acrylate copolymer, ethylene-ethyl acrylate-maleic anhydride copolymer, ethylene-ethyl acrylate-glycidyl methacrylate copolymer, ethylene-vinyl acetate copolymer and saponified product thereof.

7. The expanded polyolefin resin particle according to any one of claims 1 to 6, wherein the higher fatty amide as component 3 is at least 1 selected from the group consisting of lauric acid amide, palmitic acid amide, stearic acid amide, behenic acid amide, erucic acid amide, oleic acid amide, brassidic acid amide, elaidic acid amide, methylene bis stearic acid amide, methylene bis lauric acid amide, ethylene bis stearic acid amide, ethylene bis lauric acid amide, methylene bis oleic acid amide, methylene bis erucic acid amide, ethylene bis oleic acid amide, and ethylene bis erucic acid amide.

8. A process for producing expanded polyolefin resin particles, which comprises using expanded polyolefin resin particles and a foaming agent,

the polyolefin resin foamed particles comprise, per 100 parts by weight of the polyolefin resin (a), 3 to 10 parts by weight of the product (b), 2 to 10 parts by weight of a butene-copolymerized polyethylene wax (c), and 0.01 to 1 part by weight of a water-absorbing substance (d),

the product (b) comprises an olefin elastomer as component 1, a copolymer as component 2 comprising ethylene and at least 1 vinyl monomer other than component 1, and a higher fatty amide as component 3;

the foaming agent is an inorganic foaming agent.

9. An in-mold foamed polyolefin resin molded article, wherein the expanded polyolefin resin beads according to any one of claims 1 to 7 are used.

Technical Field

The present invention relates to expanded polyolefin resin particles which are suitable for use in expanded polyolefin resin in-mold molded articles used for cushioning packaging materials, materials for logistics, heat insulating materials, civil engineering and construction parts, automobile parts, and the like, a method for producing expanded polyolefin resin particles, and an expanded polyolefin resin in-mold molded article.

Background

Polyolefin resin in-mold foam molded articles (also simply referred to as "in-mold foam molded articles") are widely used for cushioning packaging materials, returnable containers, materials for logistics such as cushioning materials for truck transportation, heat insulating materials, civil engineering and construction parts, automobile parts (for example, tool boxes, floor core materials, etc.), and the like. However, when the in-mold foamed molded articles of polyolefin resin are rubbed against each other or against other plastic products, metal products, or the like, the in-mold foamed molded articles may generate harsh rubbing noise (split noise) with high frequency.

Conventionally, as a method for suppressing the frictional noise of a polyolefin resin in-mold foam molded product, techniques described in patent documents 1 to 3 have been known. Patent document 1 describes a method of molding polypropylene resin foamed particles composed of a resin composition obtained by melt-kneading an olefin elastomer and a fatty amide in a polypropylene resin to obtain a polypropylene resin foamed molded article.

As a means having a high frictional sound suppression effect, patent documents 2 and 3 describe a method of obtaining a polypropylene resin foamed molded article by molding polypropylene resin foamed particles composed of a resin composition obtained by melt-kneading a specific polyethylene wax in a polypropylene resin.

Disclosure of Invention

However, the above-mentioned conventional techniques are insufficient from the viewpoint of providing expanded polyolefin resin particles which can provide an in-mold expanded polyolefin resin molded article having excellent surface gloss while suppressing the risk of generation of frictional sound and abnormal sound for a long period of time, and have room for further improvement.

In view of the above problems, an object of one embodiment of the present invention is to provide novel expanded polyolefin resin beads that can provide an in-mold expanded polyolefin resin molded product that is excellent in surface gloss while suppressing the risk of frictional noise and abnormal noise generation for a long period of time.

The present inventors have made extensive studies in view of the above-mentioned problems, and as a result, have found that a novel finding that polyolefin resin foamed particles can solve the above-mentioned problems can be obtained by containing a polyolefin resin (a), a product (b), a copolymer as a component 2 composed of ethylene and at least 1 vinyl monomer other than the component 1, and a higher fatty acid amide as a component 3, a butene copolymerized polyethylene wax (c), and a water-absorbing substance (d), and have completed the present invention.

Specifically, the polyolefin resin foamed particles according to one embodiment of the present invention are characterized by containing 3 to 10 parts by weight of a product (b) containing an olefin elastomer as component 1, a copolymer as component 2 composed of ethylene and at least 1 vinyl monomer other than component 1, and a higher fatty acid amide as component 3, 2 to 10 parts by weight of a butene-copolymerized polyethylene wax (c), and 0.01 to 1 part by weight of a water-absorbing substance (d), based on 100 parts by weight of a polyolefin resin (a).

The process for producing expanded polyolefin resin particles according to one embodiment of the present invention is a process for producing expanded polyolefin resin particles using expanded polyolefin resin particles and a foaming agent, wherein the expanded polyolefin resin particles contain, based on 100 parts by weight of a polyolefin resin (a), 3 to 10 parts by weight of a product (b) containing an olefin elastomer as component 1, a copolymer as component 2 of ethylene and at least 1 vinyl monomer other than component 1, and a higher fatty acid amide as component 3, 2 to 10 parts by weight of a butene-copolymerized polyethylene wax (c), and 0.01 to 1 part by weight of a water-absorbing substance (d), and the foaming agent is an inorganic foaming agent.

According to one embodiment of the present invention, there is provided expanded polyolefin resin particles which can provide an in-mold expanded polyolefin resin molded article having excellent surface gloss while suppressing the risk of frictional noise and abnormal noise generation for a long period of time.

Drawings

FIG. 1 shows an example of a DSC curve (DSC curve of example 1) obtained by Differential Scanning Calorimetry (DSC) in which the temperature of expanded polypropylene resin particles according to one embodiment of the present invention is raised from 40 ℃ to 220 ℃ at a temperature rise rate of 10 ℃/min. The horizontal axis represents temperature, and the vertical axis represents heat absorption.

Detailed Description

An embodiment of the present invention will be described below, but the present invention is not limited to this. The present invention is not limited to the configurations described below, and various modifications are possible within the scope of the claims. In addition, embodiments and examples obtained by appropriately combining the technical means disclosed in the different embodiments and examples are also included in the technical scope of the present invention. Further, by combining the technical means disclosed in each embodiment, new technical features can be formed. All academic and patent documents described in the present specification are incorporated herein by reference. In the present specification, "a to B" indicating a numerical range means "a to (including a and larger than a) and" B (including B and smaller than B) "unless otherwise specified.

[ 1] technical idea of an embodiment of the present invention ]

The present inventors have conducted extensive studies and, as a result, have found that the techniques described in the above-mentioned prior art documents 1 to 3 have room for improvement or problems as described below.

The technique described in patent document 1 is known as a method for suppressing the noise of friction of a polyolefin resin foam molded product. However, the present inventors have studied and found that the polyolefin resin foam molded article actually generates a frictional sound and is insufficient in practical characteristics.

However, when two objects slide in contact with each other, a stick-slip phenomenon is known as a vibration phenomenon in which sliding-stopping is repeated. As a method for evaluating the risk of abnormal noise due to the stick-slip phenomenon, a stick-slip test according to German automobile industry Association standards 'VDA 230-206' is given. The abnormal noise occurrence risk index (RPN) obtained by this evaluation method is determined based on the values of the elements (frictional force and acceleration) of the vibration detected by sliding two objects in a state where a constant load is applied to the two objects in contact. It is known that an object having a higher RPN value has a higher possibility of generating abnormal noise, and that when the object is used as a component of an automobile, the correlation between the object and the abnormal noise actually generated in the automobile is high. The present inventors have studied and found that the polypropylene resin foamed molded articles described in patent documents 2 and 3 have a high frictional sound suppression effect, but have room for improvement in the risk index of abnormal sound generation.

In recent years, the appearance of polyolefin resin in-mold foam molded articles is expected to have a high-grade appearance. When the polyolefin resin in-mold foam molded product is used as an automobile interior part, a high-grade feel is particularly desired. The present inventors have studied and found that the polyolefin resin foam molded article described in patent document 1 and the polypropylene resin foam molded articles described in patent documents 2 and 3 have poor high-grade feeling because they do not have surface gloss of the in-mold foam molded article, and are expected to be improved.

An embodiment of the present invention has been made in view of the above problems, and an object of the present invention is to obtain expanded polyolefin resin particles which can provide an in-mold expanded polyolefin resin molded article satisfying the following (a) which can suppress generation of harsh friction sound (split noise) and generation of abnormal noise (abnormal noise generation risk) having a high frequency for a long period of time when friction is generated between the in-mold expanded polyolefin resin molded articles or between the in-mold expanded polyolefin resin molded article and another plastic or metal article; (b) has excellent surface gloss and high quality feeling.

[ 2. polyolefin resin expanded particles ]

The polyolefin resin foamed particles according to one embodiment of the present invention are characterized by containing a polyolefin resin (a), a product (b) that contains an olefin elastomer as component 1, a copolymer as component 2 composed of ethylene and at least 1 vinyl monomer other than component 1, and a higher fatty acid amide as component 3, a butene copolymerized polyethylene wax (c), and a water absorbing material (d).

[ 2-1 ] polyolefin resin (a) ]

The polyolefin-based resin (a) (hereinafter also simply referred to as "polyolefin-based resin") used in one embodiment of the present invention is not particularly limited as long as it is a polymer compound synthesized from an olefin as a monomer, and examples thereof include a polyethylene-based resin and a polypropylene-based resin. These may be used alone, or 2 or more of them may be used in combination.

Examples of the polyethylene resin used in one embodiment of the present invention include high-density polyethylene, medium-density polyethylene, low-density polyethylene, linear low-density polyethylene, and styrene-modified polyethylene resins. These may be used alone or in combination of 2 or more.

The polyethylene resin used in one embodiment of the present invention is a comonomer copolymerizable with ethylene, and may contain a comonomer other than ethylene. As the comonomer copolymerizable with ethylene, an α -olefin having 4 to 18 carbon atoms can be used, and examples thereof include 1-butene, 1-pentene, 1-hexene, 3-dimethyl-1-butene, 4-methyl-1-pentene, 4-dimethyl-1-pentene, 1-octene, and the like, and these may be used alone or 2 or more of them may be used in combination. In order to set the density of the copolymer within the above range, the copolymerization amount of the comonomer is preferably 1 to 12% by weight in general.

The melting point of the polyethylene resin used in one embodiment of the present invention is not particularly limited, and is, for example, preferably 110 to 135 ℃, and more preferably 115 to 130 ℃. The melting point of the polyethylene resin (a) tends to decrease the heat resistance of the foamed molded article when the temperature is less than 110 ℃, and (b) tends to be difficult to increase the expansion ratio of the expanded beads in the production of the expanded beads when the temperature exceeds 135 ℃.

Incidentally, in [ 2. expanded polyolefin resin particles ] and [ 3. expanded polyolefin resin particles and a method for producing an in-mold expanded molded article ], unless otherwise mentioned, (a) the "expanded polyolefin resin particles according to an embodiment of the present invention" may be simply referred to as "expanded particles", and (b) the "expanded polyolefin resin in-mold molded article obtained by in-mold expansion molding of the expanded polyolefin resin particles according to an embodiment of the present invention" may be simply referred to as "in-mold expanded molded article". In addition, in the polyolefin-based resin foamed particles, the polyolefin-based resin in-mold foamed molded article, or the like, the term "polyolefin" depends on the polyolefin-based resin used. For example, when polyethylene is used as the polyolefin resin, the obtained expanded particles are polyethylene resin expanded particles, and the obtained in-mold expanded molded article is a polyethylene resin in-mold expanded molded article.

Here, the melting point of the polyethylene resin can be measured by differential scanning calorimetry (hereinafter referred to as "DSC method"). The specific operation sequence is as follows: (1) heating the polyethylene resin from 40 ℃ to 220 ℃ at a heating rate of 10 ℃/min to melt 5 to 6mg of the polyethylene resin; (2) cooling from 220 deg.C to 40 deg.C at a cooling rate of 10 deg.C/min to crystallize; (3) further, the temperature was raised from 40 ℃ to 220 ℃ at a temperature raising rate of 10 ℃/min. The melting point can be determined as the temperature of the peak (melting peak) of the DSC curve obtained at the second temperature rise (i.e., (3)).

The melt index (hereinafter referred to as "MI") of the polyethylene resin used in one embodiment of the present invention is not particularly limited, but is preferably 0.1g/10 min to 10g/10 min, more preferably 0.3g/10 min to 8g/10 min, and still more preferably 0.5g/10 min to 5g/10 min.

When the MI of the polyethylene resin is less than 0.1g/10 minutes, it is difficult to increase the expansion ratio of the expanded beads in the production of the expanded beads, and the surface properties of the expanded molded article tend to decrease. When the MI of the polyethylene resin exceeds 10g/10 min, the cells of the obtained expanded beads are connected. As a result, (a) the compressive strength of the foamed molded article tends to decrease, or (b) the surface property of the foamed molded article tends to decrease.

Here, the MI value is measured using JIS K7210: the MI measuring instrument described in 1999 had a diameter of 2.0959. + -. 0.005mm, a length of 8.000. + -. 0.025mm, a load of 2160g and a temperature of 190. + -. 0.2 ℃.

The polypropylene resin used in one embodiment of the present invention is not particularly limited, and examples thereof include a polypropylene homopolymer, an ethylene/propylene random copolymer, a butene-1/propylene random copolymer, an ethylene/propylene block copolymer, a butene-1/propylene block copolymer, a propylene-chlorinated vinyl copolymer, a propylene/maleic anhydride copolymer, and a styrene-modified polypropylene resin. Among them, ethylene/propylene random copolymers and ethylene/butene-1/propylene random copolymers are preferable from the viewpoint of good foamability of the obtained expanded beads and from the viewpoint of good moldability of the foamed molded article. Incidentally, the above butene-1 and 1-butene have the same meaning.

In the present production method, it is conceivable to use an ethylene/propylene random copolymer or an ethylene/butene-1/propylene random copolymer as the polyolefin resin (a) (as the case a) as the polypropylene resin. In the case A, the ethylene content in the ethylene/propylene random copolymer or the ethylene/butene-1/propylene random copolymer is preferably from 0.2 to 10% by weight based on 100% by weight of each copolymer.

In the case a, the butene content in the ethylene/butene-1/propylene random copolymer is preferably 0.2 to 10% by weight based on 100% by weight of the copolymer. In the case a, the total content of ethylene and butene-1 in the ethylene/propylene random copolymer or the ethylene/butene-1/propylene random copolymer is preferably 0.5 to 10% by weight based on 100% by weight of each copolymer. In the case a, the content of ethylene or butene-1 in the ethylene/propylene random copolymer or the ethylene/butene-1/propylene random copolymer tends to decrease in (a) the foamability of the foamed particles in the production of the foamed particles and/or the moldability of the foamed particles obtained in the case of less than 0.2% by weight, and (b) the mechanical properties of the in-mold foamed molded article tend to decrease in the case of more than 10% by weight.

The polymerization catalyst used in the synthesis of the polypropylene resin used in one embodiment of the present invention is not particularly limited, and ziegler-based catalysts, metallocene-based catalysts, and the like can be used.

The melting point of the polypropylene resin used in one embodiment of the present invention is not particularly limited, and is, for example, preferably 125 to 160 ℃ and more preferably 130 to 155 ℃. The melting point of the polypropylene resin (a) tends to decrease the heat resistance of the in-mold expanded molded article when the temperature is less than 125 ℃, and (b) tends to make it difficult to increase the expansion ratio of the expanded beads in the production of the expanded beads when the temperature exceeds 160 ℃.

Here, the melting point of the polypropylene resin can be measured by DSC method. The specific operation sequence is as follows: (1) heating the polypropylene resin from 40 ℃ to 220 ℃ at a heating rate of 10 ℃/min to melt 5 to 6mg of the polypropylene resin; (2) cooling from 220 ℃ to 40 ℃ at a cooling rate of 10 ℃/min to crystallize; (3) further, the temperature was raised from 40 ℃ to 220 ℃ at a temperature raising rate of 10 ℃/min. The melting point can be determined as the temperature of the peak (melting peak) of the DSC curve obtained at the second temperature rise (i.e., (3)).

The heat of crystal fusion of the polypropylene resin used in one embodiment of the present invention is not particularly limited, but is preferably 50 to 110J/g, and more preferably 75 to 100J/g. With respect to the heat of crystal fusion of the polypropylene-based resin, (a) when the heat of crystal fusion is less than 50J/g, it is difficult to maintain the shape of the expanded beads in the in-mold expansion molding using the obtained expanded beads, and (b) when the heat of crystal fusion exceeds 110J/g, it is difficult to increase the expansion ratio of the expanded beads in the production of the expanded beads.

Here, the heat of crystal melting of the polypropylene resin can be measured by the DSC method similar to the melting point measurement. Specifically, the above-mentioned operations (1) to (3) can be performed, and the peak (melting peak) of the DSC curve obtained at the second temperature rise (that is, at (3)) can be obtained by the following method. When a tangent is drawn from a differential curve from the intersection of a line extending from the melting peak to the high temperature side and a base line extending from the high temperature side to the low temperature side, the amount of heat enclosed by the tangent and the melting peak can be determined as the heat of crystal melting.

The MI of the polypropylene resin used in one embodiment of the present invention is not particularly limited, and is preferably 3g/10 min to 30g/10 min, more preferably 4g/10 min to 20g/10 min, and still more preferably 5g/10 min to 18g/10 min.

When the MI of the polypropylene resin is less than 3g/10 min, it is difficult to increase the expansion ratio of the expanded beads in the production of the expanded beads. When the MI of the polypropylene resin exceeds 30g/10 minutes, the cells of the obtained expanded beads are communicated with each other. As a result, (a) the compressive strength of the foamed molded article tends to decrease, or (b) the surface property of the foamed molded article tends to decrease.

Consider the case where the MI of the polypropylene resin is in the range of 3g/10 min to 30g/10 min. In this case, expanded polypropylene resin beads having a large expansion ratio can be easily obtained. In this case, the foamed molded article has advantages of excellent surface appearance and small dimensional shrinkage.

Here, the MI value is measured using JIS K7210: the MI measuring instrument described in 1999 measured the diameter of the hole of 2.0959. + -. 0.005mm, the length of the hole of 8.000. + -. 0.025mm, the load of 2160g, and the temperature of 230. + -. 0.2 ℃.

[ 2-2. product (b) ]

The polyolefin resin particles according to one embodiment of the present invention contain a product (b) (hereinafter, may be simply referred to as "product (b)") containing an olefin elastomer as a component 1, a copolymer of ethylene and at least 1 vinyl monomer as a component 2 other than the component 1, and a higher fatty acid amide as a component 3. In the present specification, the "olefin-based elastomer as component 1" may be abbreviated as "component 1", the "copolymer of ethylene and at least 1 vinyl monomer as component 2 other than component 1" may be abbreviated as "component 2", and the "higher fatty amide as component 3" may be abbreviated as "component 3".

The olefin elastomer used as the component 1 in the product (b) is a component showing affinity for the higher fatty amide as the component 3. The component 1 includes the following (a) to (c): (a) ethylene-alpha-olefin copolymer rubber; (b) ethylene- α -olefin-non-conjugated diene copolymer rubber; and (c) a graft copolymer having a polymer segment comprising an ethylene/alpha-olefin copolymer rubber and/or an ethylene/alpha-olefin/non-conjugated diene copolymer rubber as a main component and a vinyl polymer segment comprising at least 1 vinyl monomer as a branch component.

Examples of the α -olefin used for forming the copolymer rubber include propylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene, 2-methyl-1-propene, 3-methyl-1-pentene, 4-methyl-1-pentene, and 5-methyl-1-hexene. These alpha-olefins may be used alone or in combination of 2 or more. Examples of the non-conjugated diene (non-conjugated diene compound) include dicyclopentadiene, 1, 4-hexadiene, cyclooctadiene, methylene norbornene, ethylidene norbornene, vinyl norbornene, and the like.

Specific examples of the ethylene/α -olefin copolymer rubber include ethylene/propylene copolymer rubber, ethylene/1-butene copolymer rubber, ethylene/1-hexene copolymer rubber, ethylene/1-octene copolymer rubber, and the like. Among these, ethylene-propylene copolymer rubber and ethylene-1-octene copolymer rubber are particularly preferable because they have excellent affinity with the higher fatty acid amide of component 3 and can give a foamed molded article having high elastic recovery.

Further, specific examples of the ethylene α -olefin/non-conjugated diene copolymer rubber are preferably an ethylene 1-butene/non-conjugated diene copolymer rubber and an ethylene propylene/non-conjugated diene copolymer rubber, and particularly preferably an ethylene propylene ethylidene norbornene copolymer rubber and an ethylene propylene dicyclopentadiene copolymer rubber. These copolymer rubbers are excellent in affinity with the higher fatty acid amide of component 3 and can give a foamed molded article having high elastic recovery. These ethylene/α -olefin copolymer rubbers may be used alone, or 2 or more kinds thereof may be used in combination. These ethylene/α -olefin/non-conjugated diene copolymer rubbers may be used alone, or 2 or more kinds thereof may be used in combination. Further, 1 or more kinds of these ethylene/α -olefin copolymer rubbers and 1 or more kinds of these ethylene/α -olefin/non-conjugated diene copolymer rubbers may be used in combination.

The olefin-based elastomer of component 1 may be an elastomer composed of a graft copolymer having, as a main component, a polymer segment composed of the above-mentioned ethylene/α -olefin copolymer rubber, the above-mentioned ethylene/α -olefin/nonconjugated diene copolymer rubber, or the like, and, as a branch component, a vinyl polymer segment composed of at least 1 vinyl-based monomer.

As mentioned above, the vinyl monomer forming the vinyl polymer segment is formed from at least 1 vinyl monomer. The vinyl monomer is at least 1 monomer selected from alkyl (meth) acrylate having an alkyl chain length and having 1 to 20 carbon atoms, a vinyl monomer having an acid group, a vinyl monomer having a hydroxyl group, a vinyl monomer having an epoxy group, a vinyl monomer having a cyano group, and styrene.

In the present specification, acrylic acid and methacrylic acid are collectively referred to as (meth) acrylic acid.

Specific examples of the vinyl monomer include methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, hexyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, lauryl (meth) acrylate, stearyl (meth) acrylate, meth) acrylic acid, maleic anhydride, 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, glycidyl (meth) acrylate, (meth) acrylonitrile, and styrene.

Among them, methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, meth) acrylic acid, 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, glycidyl (meth) acrylate, (meth) acrylonitrile, styrene, and the like are particularly preferable because of a large interaction with the higher fatty acid amide of component 3 and easy adjustment of the surface migration property of component 3. The surface migration property of the component 3 indicates the degree of migration of the component 3 to the surface of the finally obtained in-mold foamed molded article. The surface mobility of the component 3 may have an influence on suppression of the frictional sound and the risk of generation of abnormal noise.

The copolymer as component 2, which is composed of ethylene and at least 1 vinyl monomer other than component 1, used in the product (b) is a component having a low affinity for the higher fatty amide as component 3. Specific examples of the component 2 include an ethylene-acrylic acid copolymer, an ethylene-methyl acrylate copolymer, an ethylene-methyl methacrylate copolymer, an ethylene-ethyl acrylate copolymer, an ethylene-isobutyl acrylate copolymer, an ethylene-n-butyl acrylate copolymer, an ethylene-2-ethylhexyl acrylate copolymer, an ethylene-ethyl acrylate-maleic anhydride copolymer, an ethylene-ethyl acrylate-glycidyl methacrylate copolymer, an ethylene-vinyl acetate copolymer, and saponified products thereof. These components 2 may be used alone, or 2 or more of them may be used in combination.

The component 2 is preferably a copolymer of ethylene and at least 1 vinyl monomer, which has a (meth) acrylate or vinyl acetate in which the vinyl monomer is a lower alkyl group having 1 to 4 carbon atoms, because the polarity can be greatly changed and the higher aliphatic amide component 3 has excellent affinity for the higher aliphatic amide. Specific examples of such component 2 include an ethylene/methyl acrylate copolymer, an ethylene/methyl methacrylate copolymer, an ethylene/ethyl acrylate copolymer, an ethylene/n-butyl acrylate copolymer, an ethylene/vinyl acetate copolymer, and a saponified product thereof.

The higher fatty acid amide as component 3 used in the product (b) is preferably formed from a higher fatty acid having 10 to 25 carbon atoms as a raw material. Examples of the higher fatty amide include saturated fatty amides, unsaturated fatty amides, and di-fatty amides. The higher fatty acid amide as component 3 formed from a higher fatty acid having less than 10 carbon atoms as a raw material has insufficient compatibility with component 1, and the effect of component 3 cannot be sufficiently exhibited. On the other hand, higher fatty acids having more than 25 carbon atoms are difficult to obtain and are not practical.

Specifically, examples of the saturated fatty amide which can be suitably used as the higher fatty amide of the component 3 include lauric acid amide, palmitic acid amide, stearic acid amide, behenic acid amide, and the like. Examples of unsaturated fatty acid amides that can be preferably used as the higher fatty acid amide of component 3 include erucamide, oleamide, brassidic acid amide, elaidic acid amide, and the like. Examples of the di-fatty amide which can be preferably used as the higher fatty amide of component 3 include methylenebisstearamide, methylenebislauramide, ethylenebisstearamide, ethylenebislauramide, methylenebisoleamide, methylenebiserucamide, ethylenebisoleamide, and ethylenebiserucamide. These higher fatty acid amides may be used in combination of 1 or 2 or more.

Among these lubricants, stearic acid amide, behenic acid amide, oleic acid amide, erucic acid amide, ethylene bis oleic acid amide, ethylene bis erucic acid amide oleic acid amide, and erucic acid amide are mentioned, particularly from the viewpoint of improving the squeal suppression effect.

The product (b) is produced by heating, melting and mixing the component 1, the component 2 and the component 3. The heating temperature in this case is appropriately selected depending on the melting temperature of the component 1 and the component 2 and the heat-resistant temperature of the lubricant, but is preferably 70 to 300 ℃. In the case where the temperature is less than 70 ℃, the melting of the rubber and/or copolymer may be incomplete and the melt viscosity may become high. As a result, the mixture of the components 1, 2 and 3 becomes insufficient, and phase separation and/or delamination occur, which is not preferable. On the other hand, when the temperature exceeds 300 ℃, the decomposition of the rubber, copolymer or lubricant becomes severe, and therefore, it is preferable. As the method of melting and mixing, a known method such as a kneading method using a single-screw extruder, a twin-screw extruder, a banbury mixer, a kneader, or a roll is used.

The amount of the product (b) added to the polyolefin resin (a) is 3 to 10 parts by weight, preferably 3 to 9 parts by weight. When the amount of the product (b) added is less than 3 parts by weight, the effect of suppressing the risk of generation of abnormal noise by the product (b) is not exhibited in the foam molded article. When the amount of the product (b) added exceeds 10 parts by weight, wrinkles due to shrinkage occur in the expanded beads, and wrinkles also occur on the surface of the in-mold expanded molded article finally obtained. As a result, the test pieces of the foamed molded article used for evaluation of the abnormal noise occurrence risk index vibrate when they rub against each other due to the influence of wrinkles, and the possibility of abnormal noise occurrence (i.e., the abnormal noise occurrence risk) increases.

The ratio of the components 1, 2 and 3 in the product (b) is preferably 0.15 to 9.5 parts by weight for the component 1, 0.15 to 9.5 parts by weight for the component 2 and 0.15 to 6.0 parts by weight for the component 3, based on 100 parts by weight of the polyolefin resin (a). Further, it is more preferable that the amount of the component 1 is 0.3 to 9.0 parts by weight, the amount of the component 2 is 0.3 to 9.0 parts by weight, and the amount of the component 3 is 0.3 to 5.0 parts by weight.

The amount of component 1 added is (a) less than 0.15 parts by weight, because the affinity between component 1 and the component 3 higher fatty amide is reduced, the component 3 higher fatty amide tends to bleed out excessively from the foam molded article, and (b) more than 9.5 parts by weight, the surface migration of the higher fatty amide as component 3 is deteriorated, and the effect of component 3 on suppressing the squeak noise is reduced. The amount of component 2 is not preferable because (a) when it is less than 0.15 parts by weight, the surface migration of the higher fatty amide of component 3 is poor, and therefore the effect of component 3 in suppressing the frictional noise is reduced, and (b) when it is more than 9.5 parts by weight, the affinity between component 2 and the higher fatty amide of component 3 is reduced, and the higher fatty amide of component 3 is likely to excessively bleed out in the foam molded article. The amount of the higher fatty amide as the component 3 is not preferable because (a) the effect of suppressing the frictional noise by the component 3 is reduced when the amount is less than 0.15 parts by weight, and (b) the bleeding out in the foamed molded article of the higher fatty amide as the component 3 is too large when the amount is more than 6.0 parts by weight.

In one embodiment of the present invention, when the polyolefin resin particles contain the product (b) and do not contain the butene-copolymerized polyethylene wax (c), a polyolefin resin in-mold foamed article in which generation of frictional sound and abnormal noise is sufficiently suppressed cannot be obtained in the end. When the polyolefin resin particles contain the product (b) and the butene-copolymerized polyethylene wax (c), finally, a polyolefin resin in-mold foamed molded article in which generation of frictional sound and abnormal noise is sufficiently suppressed can be obtained.

In one embodiment of the present invention, a preferable combination of specific compounds of component 1, component 2 and component 3 in the product (b) [ component 1/component 2/component 3] is as follows: [ ethylene-propylene copolymer rubber/ethylene-ethyl acrylate copolymer/erucamide ], [ ethylene-propylene copolymer rubber/ethylene-ethyl acrylate copolymer/oleamide ], [ ethylene-propylene copolymer rubber/ethylene-methyl methacrylate copolymer/erucamide ], [ ethylene-propylene copolymer rubber/ethylene-methyl methacrylate copolymer/oleamide ], [ ethylene-octene copolymer rubber/ethylene-ethyl acrylate copolymer/erucamide ], [ ethylene-octene copolymer rubber/ethylene-ethyl acrylate copolymer/oleamide ], [ ethylene-octene copolymer rubber/ethylene-methyl methacrylate copolymer/erucamide ], [ ethylene-octene copolymer rubber/ethylene-methyl methacrylate copolymer/oleamide ], [ ethylene-octene copolymer rubber/ethylene-methyl, [ graft copolymer A/ethylene/ethyl acrylate copolymer/erucamide ], [ graft copolymer A/ethylene/ethyl acrylate copolymer/oleamide ], [ graft copolymer A/ethylene/methyl methacrylate copolymer/erucamide ], [ graft copolymer A/ethylene/methyl methacrylate copolymer/oleamide ], [ graft copolymer B/ethylene/ethyl acrylate copolymer/erucamide ], [ graft copolymer B/ethylene/ethyl acrylate copolymer/oleamide ], [ graft copolymer B/ethylene/methyl methacrylate copolymer/erucamide ], [ graft copolymer B/ethylene/methyl methacrylate copolymer/oleamide ]. The graft copolymer a is a graft copolymer having a polymer segment composed of an ethylene-octene copolymer rubber as a main component and a vinyl polymer segment composed of methyl methacrylate, methacrylic acid, and butyl acrylate as a branch component. The graft copolymer B is a graft copolymer having a polymer segment composed of an ethylene-propylene copolymer rubber as a main component and a vinyl polymer segment composed of styrene, butyl acrylate and 2-hydroxypropyl methacrylate as a branch component.

[ 2-3. butene copolymerized polyethylene wax (c) ]

The polyolefin-based resin particles in one embodiment of the present invention contain a butene copolymerized polyethylene wax (c). The butene-copolymerized polyethylene wax (c) used in one embodiment of the present invention is a wax containing ethylene and butene as monomer components. The butene content in the butene-copolymerized polyethylene wax is preferably 2 to 12% by weight, more preferably 5 to 10% by weight, and still more preferably 7 to 9% by weight. In the case where the content of butene is less than 2% by weight, the frictional sound suppressing effect based on the butene-copolymerized polyethylene wax (c) is not easily obtained. When the content of butene is more than 12% by weight, the mechanical strength of the polyolefin resin composition prepared by adding butene-copolymerized polyethylene wax to the polyolefin resin tends to be reduced.

The melting point of the butene-copolymerized polyethylene wax (c) used in one embodiment of the present invention is preferably 40 to 130 ℃, more preferably 80 to 110 ℃, and particularly preferably 85 to 110 ℃. When the melting point of the butene-copolymerized polyethylene wax (c) is less than 40 ℃, there is a tendency that the dispersion of the polyolefin resin particles in the pressure-resistant container becomes unstable when the polyolefin resin pre-expanded particles are produced. In addition, the mechanical strength of the polyolefin resin composition produced tends to be lowered. In addition, when the melting point is more than 130 ℃, the frictional sound suppression effect by the butene copolymerized polyethylene wax (c) may not be obtained.

Here, the melting point of the butene-copolymerized polyethylene wax (c) can be measured by the DSC method. The specific operation sequence is as follows: (1) heating from 40 ℃ to 220 ℃ at a heating rate of 10 ℃/min to melt 5-6 mg of the butene copolymerized polyethylene wax; (2) cooling from 220 ℃ to 40 ℃ at a cooling rate of 10 ℃/min to crystallize; (3) further, the temperature was raised from 40 ℃ to 220 ℃ at a temperature raising rate of 10 ℃/min. The melting point can be determined as the temperature of the peak (melting peak) of the DSC curve obtained at the second temperature rise (i.e., (3)).

The viscosity-average molecular weight of the butene-copolymerized polyethylene wax (c) used in one embodiment of the present invention is preferably 1000 to 5000. When the viscosity average molecular weight is less than 1000, the butene-copolymerized polyethylene wax (c) tends to be sticky, and thus, when the butene-copolymerized polyethylene wax (c) and the polyolefin-based resin are melt-kneaded, processing may be difficult. When the viscosity average molecular weight exceeds 5000, the butene-copolymerized polyethylene wax (c) is less likely to appear on the surface of the polyolefin resin particles when the butene-copolymerized polyethylene wax (c) and the polyolefin resin are melt-kneaded, and the effect of suppressing the frictional sound by the butene-copolymerized polyethylene wax (c) may not be obtained.

Examples of the polymerization method for producing the butene-copolymerized polyethylene wax (c) include a ziegler catalyst method and a metallocene catalyst method, and among them, the butene-copolymerized polyethylene wax (c) polymerized by the metallocene catalyst method is particularly preferable because the molecular weight distribution is narrow and the frictional sound suppression effect is easily obtained.

The amount of the butene-copolymerized polyethylene wax (c) added to the polyolefin resin is 2 to 10 parts by weight, preferably 3 to 9 parts by weight, based on 100 parts by weight of the polyolefin resin. When the amount of the butene-copolymerized polyethylene wax (c) added is less than 2 parts by weight, the effect of suppressing frictional noise tends to be deteriorated in the foamed molded article, and the effect of suppressing the risk of generation of abnormal noise due to the butene-copolymerized polyethylene wax (c) is not exhibited. When the amount of the butene copolymerized polyethylene wax (c) added exceeds 10 parts by weight, wrinkles due to shrinkage occur in the expanded beads, and wrinkles also occur on the surface of the in-mold expanded molded article finally obtained. As a result, the test pieces of the foamed molded article used for evaluation of the abnormal noise occurrence risk index vibrate when they rub against each other due to the influence of wrinkles, and thus the possibility of abnormal noise occurrence increases.

[ 2-4 ] Water-absorbing Material (d) ]

The water-absorbent material (d) used in one embodiment of the present invention is a material for increasing the amount of impregnation water in polyolefin resin particles when producing polyolefin resin foamed particles, and can impart foamability to the polyolefin resin particles when using water as a foaming agent. The reason is not clear, but the addition of the water-absorbent material (d) results in excellent surface gloss of the finally obtained in-mold foamed molding.

Examples of the water-absorbing substance (d) used in one embodiment of the present invention include water-absorbing organic substances such as glycerin, diglycerin, polyethylene glycol, fatty alcohols having from C12 to C18 (e.g., pentaerythritol, cetyl alcohol, stearyl alcohol), melamine, isocyanuric acid, and melamine/isocyanuric acid condensates. These water-absorbent substances may be used in combination of 2 or more.

Among them, glycerin and polyethylene glycol are preferable because of a large effect of improving the surface gloss in the foamed molded article.

The amount of the water-absorbent substance (d) added to the polyolefin resin particles according to one embodiment of the present invention is 0.01 to 1 part by weight, preferably 0.05 to 0.7 part by weight, and more preferably 0.1 to 0.6 part by weight, based on 100 parts by weight of the polyolefin resin (a). When the amount is less than 0.01 part by weight, the effect of improving the surface gloss by the water-absorbent material (d) is not obtained, and when the amount exceeds 1 part by weight, the expanded particles tend to shrink.

[ 2-5. other Components ]

The polyolefin resin particles are preferably added with a foam nucleating agent which can serve as a foam nucleus during foaming.

Examples of the foam nucleating agent used in one embodiment of the present invention include silica (silica), silicate, alumina, diatomaceous earth, calcium carbonate, magnesium carbonate, calcium phosphate, feldspar apatite (long stone 1245097 タイ ト), barium sulfate, and the like. Examples of the silicate include talc, magnesium silicate, kaolin, halloysite, dickite, aluminum silicate, and zeolite. These foam nucleating agents may be used alone or in combination of two or more.

From the viewpoint of uniformity of the cell diameter, the content of the foam nucleating agent in the polyolefin resin particles according to one embodiment of the present invention is preferably 0.005 to 2 parts by weight, more preferably 0.01 to 1 part by weight, and most preferably 0.03 to 0.5 parts by weight or less, based on 100 parts by weight of the polyolefin resin (a).

In one embodiment of the present invention, a colorant may be used within a range that does not inhibit the effects of one embodiment of the present invention. More specifically, the polyolefin resin particles according to one embodiment of the present invention may contain a coloring agent. Examples of the colorant used in one embodiment of the present invention include carbon black, ultramarine blue, cyanine pigments, azo pigments, quinacridone pigments cadmium yellow, chromium oxide, iron oxide, perylene pigments, anthraquinone pigments, and the like.

The content of the colorant in the polyolefin resin particles according to one embodiment of the present invention is preferably 0.001 to 10 parts by weight, and more preferably 0.01 to 8 parts by weight, based on 100 parts by weight of the polyolefin resin (a). In particular, when the blackening is achieved by carbon black, the colorant is preferably 1 to 10 parts by weight based on 100 parts by weight of the polyolefin resin (a).

The polyolefin resin particles may contain additives such as antistatic agents, flame retardants, antioxidants, light stabilizers, nucleating agents, conductive agents, and lubricants, in addition to the foam nucleating agents and colorants. Such an additive may be added directly to the blend or the polyolefin resin composition in the production of the polyolefin resin particles, or the additive may be previously incorporated in another resin in a high concentration to prepare a master batch, and the master batch resin may be added to the blend or the polyolefin resin composition. The resin used in the production of the masterbatch resin is preferably a polyolefin resin.

[ 3] method for producing expanded polyolefin resin particles and in-mold foamed molded article

In order to produce the expanded polyolefin resin particles according to one embodiment of the present invention, first, a step (granulation step) of producing polyolefin resin particles composed of a polyolefin resin as a base resin may be performed.

Examples of the method for producing the polyolefin resin particles include a method using an extruder. Specifically, for example, the polyolefin resin particles can be produced by the following methods (1) to (5): (1) the polyolefin-based resin composition is produced by (1) blending a polyolefin-based resin (a), a product (b), a butene-copolymerized polyethylene wax (c), a water-absorbing substance (d), and, if necessary, additives (for example, other resins, a foam nucleating agent, a coloring agent, etc.) to produce a blend, (2) feeding the blend into an extruder and melt-kneading the blend to produce a polyolefin-based resin composition, (3) extruding the polyolefin-based resin composition from a die, (4) solidifying the extruded polyolefin-based resin composition by passing the composition through water or the like, and (5) cutting the solidified polyolefin-based resin composition into a desired shape such as a cylindrical shape, an oval shape, a spherical shape, a cubic shape, a rectangular parallelepiped shape, etc. with a cutter. Alternatively, in (3), the polyolefin resin composition that has been melt-kneaded may be directly extruded from a die into water, and then cut into a pellet shape, cooled, and solidified. In this way, more uniform polyolefin resin particles can be obtained by melt-kneading the blend.

The weight of one polyolefin resin particle obtained in the above manner is preferably 0.2 mg/particle to 10 mg/particle, and more preferably 0.5 mg/particle to 5 mg/particle. When the weight of one polyolefin resin particle is less than 0.2mg per particle, the handling properties of the polyolefin resin particle tend to be lowered, and when the weight of one polyolefin resin particle exceeds 10mg per particle, the mold filling properties tend to be lowered in the in-mold foam molding step.

The polyolefin resin foamed particles according to one embodiment of the present invention can be produced by using the polyolefin resin particles obtained as described above.

The process for producing expanded polyolefin resin particles according to one embodiment of the present invention is a process for producing expanded polyolefin resin particles using expanded polyolefin resin particles and a foaming agent, wherein the expanded polyolefin resin particles contain, based on 100 parts by weight of a polyolefin resin (a), 3 to 10 parts by weight of a product (b) containing an olefin elastomer as component 1, a copolymer as component 2 composed of ethylene and at least 1 vinyl monomer other than component 1, and a higher fatty acid amide as component 3, 2 to 10 parts by weight of a butene-copolymerized polyethylene wax (c), and 0.01 to 1 part by weight of a water-absorbing substance (d), and the foaming agent is an inorganic foaming agent. In the present specification, the "method for producing polypropylene resin expanded beads according to one embodiment of the present invention" is simply referred to as "the present production method".

The present production method will be specifically described below. The polypropylene resin foamed particles are produced by the following steps: (i) the method for producing the polyolefin resin foam of the present invention comprises the steps of (i) containing a dispersion liquid containing the polyolefin resin particles, an aqueous dispersion medium, a dispersant and a dispersion aid at a predetermined ratio and an inorganic foaming agent in a pressure-resistant container, (ii) dispersing the polyolefin resin particles in the dispersion liquid in the pressure-resistant container by stirring the dispersion liquid, and raising the temperature in the pressure-resistant container to a predetermined temperature (at least the softening point temperature of the polyolefin resin particles) and a predetermined pressure, (iii) if necessary, maintaining the temperature in the pressure-resistant container after the temperature is raised for more than 0 minute and 120 minutes or less, and (iv) then releasing the dispersion liquid in the pressure-resistant container in a pressure region lower than the internal pressure of the pressure-resistant container to foam the polyolefin resin particles.

In this way, the process of producing expanded polyolefin resin particles from expanded polyolefin resin particles is referred to as "primary expansion process", and the resulting expanded polyolefin resin particles are referred to as "primary expanded particles". The dispersion liquid in the subsequent step (ii) is a mixed liquid containing the polyolefin resin particles, the aqueous dispersion medium, the dispersant, the dispersion aid, the foaming agent, and the like, and being contained in a pressure-resistant container, and the polyolefin resin particles, the aqueous dispersion medium, the dispersant, the dispersion aid, the foaming agent, and the like are dispersed under stirring.

Here, in view of ensuring the foamability of the expanded beads in the production of the expanded beads, when the temperature in the pressure vessel is raised to a temperature equal to or higher than the softening point temperature, the temperature is preferably raised at a temperature ranging from-20 ℃ to +10 ℃ inclusive of the melting point of the polyolefin resin, or from-20 ℃ to +10 ℃ inclusive of the melting point of the polyolefin resin beads, as the temperature raising rate. The temperature rise temperature is appropriately determined depending on the type of the polyolefin resin as a raw material and/or the desired expansion ratio of the expanded polyolefin resin particles, further, the DSC ratio described later, and the like, and also needs to be appropriately changed depending on the foaming agent used.

The melting point of the polyolefin resin particles was measured by the same method as that for the polyolefin resin.

The pressure region lower than the internal pressure of the pressure-resistant vessel is preferably atmospheric pressure.

The aqueous dispersion medium used in one embodiment of the present invention is preferably water alone, and a dispersion medium obtained by adding methanol, ethanol, ethylene glycol, glycerin, or the like to water may be used.

The amount of the aqueous dispersion medium used in the dispersion liquid used in one embodiment of the present invention is preferably 100 to 400 parts by weight based on 100 parts by weight of the polyolefin resin. When the amount of the aqueous dispersion medium used exceeds 400 parts by weight, the productivity tends to be lowered, and when the amount is less than 100 parts by weight, the stability of the dispersion tends to be lowered (in other words, the polyolefin resin expanded particles tend to be poorly dispersed).

Examples of the dispersant used in one embodiment of the present invention include inorganic dispersants such as tricalcium phosphate, trimagnesium phosphate, basic magnesium carbonate, calcium carbonate, barium sulfate, kaolin, talc, and clay. These may be used alone, or 2 or more of them may be used in combination.

In one embodiment of the present invention, a dispersion aid is preferably used to improve the stability of the dispersion in the pressure-resistant vessel. Examples of the dispersing aid include sodium dodecylbenzenesulfonate, sodium alkane sulfonate, sodium alkyl diphenyl ether disulfonate, sodium α -olefin sulfonate, and the like. These may be used alone, or 2 or more of them may be used in combination.

The amount of the dispersant used in the dispersion liquid used in one embodiment of the present invention is preferably 0.01 to 3.0 parts by weight based on 100 parts by weight of the polyolefin resin. When the amount of the dispersant is less than 0.01 part by weight, dispersion failure tends to occur, and when the amount is 3.0 parts by weight or more, fusion failure between expanded polyolefin resin particles tends to occur during in-mold expansion molding.

The amount of the dispersion aid used in the dispersion liquid used in one embodiment of the present invention is preferably 0.001 to 0.2 parts by weight based on 100 parts by weight of the polyolefin resin. When the amount of the dispersion aid used is less than 0.001 parts by weight or more than 0.2 parts by weight, dispersion failure may occur.

If the stability of the dispersion is lowered, a plurality of polyolefin resin particles may adhere to each other or may agglomerate in the pressure resistant container. As a result, (a) the adhered expanded polyolefin resin particles are obtained, (b) blocks of the expanded polyolefin resin particles remain in the pressure-resistant container, and the expanded polyolefin resin particles cannot be produced, or (c) the productivity of the expanded polyolefin resin particles may be lowered.

The foaming agent used in one embodiment of the present invention is an inorganic foaming agent. Examples of the inorganic foaming agent include water, carbon dioxide, nitrogen, and air (a mixture of oxygen, nitrogen, and carbon dioxide). These may be used alone or in combination. Among these blowing agents, carbon dioxide is preferable from the viewpoint of having an appropriately high plasticizing effect and easily improving the foamability of the foamed particles in the production of the foamed particles.

In one embodiment of the present invention, the amount of the foaming agent used is not limited, and may be appropriately used depending on the desired expansion ratio of the polyolefin resin foamed particles, and is usually preferably 1 to 10 parts by weight based on 100 parts by weight of the polyolefin resin.

In the case of using water as the blowing agent, water in the dispersion in the pressure-resistant container may be used as the blowing agent. Specifically, when water in the dispersion is used as the foaming agent, it is preferable to previously contain a water-absorbing substance in the polyolefin resin particles. As a result, the polyolefin resin particles easily absorb water in the dispersion liquid in the pressure-resistant container, and as a result, water can be easily used as the foaming agent.

The pressure vessel used in the production of the expanded polyolefin resin particles is not particularly limited, and a vessel capable of withstanding the pressure in the pressure vessel and the temperature in the pressure vessel set in the production of the expanded polyolefin resin particles may be used, and examples thereof include autoclave-type pressure vessels.

However, in order to obtain expanded polyolefin resin particles having a high expansion ratio, there is a method of increasing the amount of the foaming agent used in the primary foaming step (hereinafter referred to as method 1). As a method other than method 1, a method may be employed in which expanded polyolefin resin particles (primary expanded particles) having a relatively low expansion ratio (from about 2 to 35 expansion ratios) are obtained in a primary expansion step, and then expanded again to increase the expansion ratio (hereinafter referred to as method 2). In the present specification, the expansion ratio is a true expansion ratio that can be calculated from the density of the polyolefin resin composition before expansion, the weight of the polyolefin resin expanded beads, and the volume of the polyolefin resin expanded beads immersed in water (or immersed in ethanol).

The method 2 includes, for example, the following methods (i) to (iii). (i) A method of producing primary expanded beads having an expansion ratio of 2 to 35 times in the primary expansion step, (ii) placing the primary expanded beads in a pressure-resistant container in advance, and subjecting the primary expanded beads to a pressure treatment at 0.1 to 0.6MPa (gauge pressure) using nitrogen, air, carbon dioxide, or the like to make the pressure (hereinafter, sometimes referred to as "internal pressure") within the primary expanded beads higher than normal pressure, and (iii) heating the primary expanded beads with steam or the like to further expand the primary expanded beads. As in method 2, the step of increasing the expansion ratio of the primary foamed particles is referred to as "secondary foaming step", and the foamed polyolefin resin particles obtained by the method of method 2 are referred to as "secondary foamed particles".

In one embodiment of the present invention, the pressure of the steam in the secondary foaming step is preferably adjusted to 0.03 to 0.20MPa (gauge pressure) in consideration of the expansion ratio of the secondary foamed particles.

When the pressure of the steam in the secondary expansion step is less than 0.03MPa (gauge pressure), there is a tendency that it is difficult to increase the expansion ratio, and when it exceeds 0.20MPa (gauge pressure), the obtained secondary expanded beads are bonded to each other, and as a result, the obtained secondary expanded beads tend not to be supplied to the subsequent in-mold expansion molding.

The internal pressure of nitrogen, air, carbon dioxide, or the like impregnated in the primary expanded beads is preferably changed as appropriate in consideration of the expansion ratio of the secondary expanded beads and the steam pressure in the secondary expansion step, and is preferably 0.2MPa (absolute pressure) to 0.6MPa (absolute pressure).

When the internal pressure of nitrogen, air, carbon dioxide, or the like impregnated in the primary expanded beads is less than 0.2MPa (absolute pressure), high-pressure steam is required to increase the expansion ratio, and as a result, the secondary expanded beads tend to adhere to each other. When the internal pressure of nitrogen, air, carbon dioxide, or the like impregnated in the primary foamed particles exceeds 0.6MPa (absolute pressure), the secondary foamed particles tend to be foamed continuously. As a result, the rigidity such as the compressive strength of the in-mold foamed molded article finally obtained tends to be lowered. The "continuous bubbling" is also referred to as "communicating bubbles".

The shape of the expanded polyolefin resin particles according to an embodiment of the present invention is preferably spherical or substantially spherical in view of filling properties in a mold when the expanded polyolefin resin particles are used for in-mold expansion molding, and is not limited to these. For example, a polyolefin resin in-mold foam molded product having voids may be produced because sound absorption and/or water permeability are imparted to the polyolefin resin in-mold foam molded product. In such a case, expanded polyolefin resin beads having a cylindrical shape, an oval shape, a rectangular parallelepiped shape, or a tubular shape (suction pipe shape) can be used.

In one embodiment of the present invention, the average diameter (also referred to as an average particle diameter) of the expanded polyolefin resin particles in the case where the expanded polyolefin resin particles are spherical or substantially spherical is not particularly limited. The average diameter of the expanded polyolefin resin particles according to one embodiment of the present invention varies depending on the size, expansion ratio, and the like of the polyolefin resin particles before expansion, and is preferably 0.5mm to 10mm, more preferably 1mm to 7mm, and still more preferably 2mm to 5 mm. Here, the average diameter of the expanded polyolefin resin particles is an arithmetic average of the diameters measured for arbitrary 20 expanded polyolefin resin particles.

The average diameter of the expanded polyolefin resin particles according to one embodiment of the present invention tends to be limited by (a) the workability in the in-mold expansion molding using the expanded polyolefin resin particles when the average diameter is less than 0.5mm, and (b) the shape of the molded article of the expanded polyolefin resin in-mold expansion molded when the average diameter exceeds 10 mm. The case where the shape of the molded article is limited refers to, for example, a case where a polyolefin resin in-mold foam molded article having a thin portion cannot be produced.

The average weight of the expanded polyolefin resin particles according to one embodiment of the present invention is substantially the same as that of the polyolefin resin particles used for production of the expanded polyolefin resin particles, and is preferably 0.1 mg/particle to 100 mg/particle, and more preferably 0.3 mg/particle to 10 mg/particle. Here, the average weight of the expanded polyolefin resin particles is an arithmetic average of the weights measured for any 10 expanded polyolefin resin particles.

The expanded polyolefin resin particle according to an embodiment of the present invention preferably has an expansion ratio of 2 to 60 times, more preferably 3 to 40 times.

The expanded polyolefin resin particles according to one embodiment of the present invention preferably have 2 or more melting peaks as shown in fig. 1 on a DSC curve obtained by measuring the heat of the expanded polyolefin resin particles by a DSC method. Such expanded polyolefin resin particles having 2 or more melting peaks can be produced by a known method.

The DSC curve of the expanded polyolefin resin beads is obtained by heating 5 to 6mg of the expanded polyolefin resin beads from 40 ℃ to 220 ℃ at a heating rate of 10 ℃/min by the DSC method. As an example of such a DSC curve, a DSC curve of example 1 described later is shown in fig. 1. As shown in fig. 1, according to the amount of the product (b) and the amount of the butene copolymerized polyethylene wax (c) added in the invention of the present application, endothermic peaks derived from the higher fatty amide and the butene copolymerized polyethylene wax (c) constituting the product (b) may appear. In FIG. 1, small endothermic peaks derived from the higher fatty amide and the butene copolymerized polyethylene wax appear in the vicinity of 79 ℃ and 102 ℃ respectively.

The polyolefin resin foamed particles in one embodiment of the present invention preferably have an average cell diameter of 80 to 500. mu.m, more preferably 90 to 400. mu.m, and still more preferably 100 to 350. mu.m. When the average cell diameter of the expanded polyolefin resin particles is less than 80 μm, the compression strength of the in-mold expanded polyolefin resin molded article tends to decrease. When the average cell diameter of the expanded polyolefin resin particles exceeds 500 μm, the cycle time of the in-mold expanded polyolefin resin molded product tends to be long, and productivity tends to be low. Here, the molding cycle is a time from the start of in-mold expansion molding to the end of molding in which the obtained molded article is released from the mold when the polyolefin resin in-mold molded article is obtained by in-mold expansion molding using the expanded polyolefin resin particles.

The polyolefin resin in-mold foam molded article according to an embodiment of the present invention can be obtained by in-mold foam molding of polyolefin resin foamed particles by a general method.

When the expanded polyolefin resin particles are used for in-mold expansion molding, examples of a method for filling a mold such as a mold with the expanded polyolefin resin particles include the following in-mold filling methods (a) to (C):

(A) a method of previously injecting (applying an internal pressure) an inorganic gas such as nitrogen, air or carbon dioxide into expanded polyolefin resin particles to thereby fill the expanded polyolefin resin particles with an expansion ability,

(B) a method for filling expanded polyolefin resin particles without applying an internal pressure (i.e., maintaining the internal pressure at the same level as the atmospheric pressure),

(C) a method of filling expanded polyolefin resin particles while increasing the internal pressure of the expanded polyolefin resin particles by compressing the expanded polyolefin resin particles with conveying air (which may be nitrogen or carbon dioxide) during in-mold filling. These methods may be used in combination, or a conventionally known in-mold filling method other than these methods may be used.

In one embodiment of the present invention, examples of the method for producing a polyolefin resin in-mold foamed molded article from polyolefin resin foamed particles include the following methods (i) to (iv). (i) A method of filling the polyolefin resin foamed particles in a closable and non-sealable molding die in a slightly opened state, (ii) heating the polyolefin resin foamed particles with a heating medium such as steam at a heating water vapor pressure of about 0.05MPa (gauge pressure) to about 0.5MPa (gauge pressure) to fuse the polyolefin resin foamed particles to each other, (iii) cooling the molding die with water cooling to a degree that can suppress deformation of the in-mold foamed molded article after the in-mold foamed molded article is taken out from the molding die, (iv) opening the molding die, and taking out the in-mold foamed molded article from the molding die to obtain the polyolefin resin in-mold foamed molded article. In (i), the opening width of the mold before filling the polyolefin resin foamed particles is defined as the opening amount.

The polyolefin resin in-mold foamed molded article thus obtained can be suitably used for various applications such as cushioning packaging materials, materials for logistics, heat insulating materials, civil engineering and construction parts, automobile parts, and the like.

An embodiment of the present invention may be configured as follows.

[ 1] expanded polyolefin resin particles comprising 100 parts by weight of a polyolefin resin (a) and, based on the resin (a), 3 to 10 parts by weight of a product (b) comprising an olefin elastomer as component 1, a copolymer of ethylene and at least 1 vinyl monomer as component 2 other than component 1, and a higher fatty acid amide as component 3, 2 to 10 parts by weight of a butene-copolymerized polyethylene wax (c), and 0.01 to 1 part by weight of a water-absorbing substance (d).

[ 2] the expanded polyolefin resin particle according to [ 1], wherein the polyolefin resin (a) is a polypropylene resin or a polyethylene resin.

[ 3] the expanded polyolefin resin particles according to [ 1] or [ 2], wherein the water-absorbent substance (d) is at least 1 or more selected from the group consisting of glycerol and polyethylene glycol.

[ 4 ] the expanded polyolefin resin beads according to any one of [ 1] to [ 3], wherein the butene copolymerized polyethylene wax (c) has a melting point of 40 to 130 ℃.

[ 5] the expanded polyolefin resin particle according to any one of [ 1] to [ 4 ], wherein the olefin elastomer as the component 1 is at least 1 selected from the group consisting of (a) ethylene/α -olefin copolymer rubbers; (b) ethylene- α -olefin-non-conjugated diene copolymer rubber; and (c) a graft copolymer having a polymer segment composed of an ethylene/α -olefin copolymer rubber and/or an ethylene/α -olefin/nonconjugated diene copolymer rubber as a main component and a vinyl polymer segment composed of at least 1 vinyl monomer as a branch component.

[ 6 ] the expanded polyolefin resin particle according to any one of [ 1] to [ 5], wherein, the copolymer as component 2, which is composed of ethylene and at least 1 vinyl monomer other than component 1, is at least 1 selected from the group consisting of ethylene-acrylic acid copolymer, ethylene-methyl acrylate copolymer, ethylene-methyl methacrylate copolymer, ethylene-ethyl acrylate copolymer, ethylene-isobutyl acrylate copolymer, ethylene-n-butyl acrylate copolymer, ethylene-2-ethylhexyl acrylate copolymer, ethylene-ethyl acrylate-maleic anhydride copolymer, ethylene-ethyl acrylate-glycidyl methacrylate copolymer, ethylene-vinyl acetate copolymer, and saponified products thereof.

[ 7] the polyolefin resin foamed particles according to any one of [ 1] to [ 6 ], wherein the higher fatty amide as component 3 is at least 1 selected from the group consisting of lauric acid amide, palmitic acid amide, stearic acid amide, behenic acid amide, erucic acid amide, oleic acid amide, brassidic acid amide, elaidic acid amide, methylenebisstearic acid amide, methylenebislauric acid amide, ethylenebisstearic acid amide, ethylenebislauric acid amide, methylenebisoleic acid amide, methylenebiserucic acid amide, ethylenebisoleic acid amide, and ethylenebiserucic acid amide.

[ 8] A method for producing expanded polyolefin resin particles, which comprises using 100 parts by weight of a polyolefin resin (a) 3 to 10 parts by weight of a product (b) comprising an olefin elastomer as component 1, a copolymer as component 2 of ethylene and at least 1 vinyl monomer other than component 1, and a higher fatty acid amide as component 3, 2 to 10 parts by weight of a butene copolymerized polyethylene wax (c), and 0.01 to 1 part by weight of a water-absorbing substance (d), and a foaming agent which is an inorganic foaming agent.

[ 9] an in-mold foamed polyolefin resin molded article obtained by using the expanded polyolefin resin beads according to any one of [ 1] to [ 7 ].

The method for producing expanded polyolefin resin particles according to an embodiment of the present invention may have the following configuration.

[ 10] A process for producing expanded polyolefin resin particles, which comprises dispersing polyolefin resin particles in an aqueous dispersion medium together with a foaming agent in a pressure-resistant vessel, heating and pressurizing the pressure-resistant vessel to a temperature not lower than the softening temperature of the polyolefin resin particles, and then discharging the aqueous dispersion medium in which the polyolefin resin particles and the foaming agent are dispersed into a pressure region lower than the internal pressure of the pressure-resistant vessel, wherein the expanded polyolefin resin particles comprise, per 100 parts by weight of a polyolefin resin (a), 3 to 10 parts by weight of a product (b), 2 to 10 parts by weight of a butene-copolymerized polyethylene wax (c), and 0.01 to 1 part by weight of a water-absorbing substance (d), the product (b) comprises an olefin elastomer as a component 1, a copolymer as a component 2 comprising ethylene and at least 1 vinyl monomer other than the component 1, and a higher fatty acid amide as a component 3, and the foaming agent is an inorganic foaming agent.