Composite resin particles, foamable particles, pre-foamed particles, and foam molded body

Patent metadata

Field	Value
Publication number	US-9988511-B2
Application number	US-201515113227-A
Country	US
Kind code	B2
Filing date	Mar 10, 2015
Priority date	Mar 12, 2014
Publication date	Jun 5, 2018
Grant date	Jun 5, 2018

Abstract

Composite resin particles including: a polyethylene-based resin and a polystyrene-based resin, wherein the polyethylene-based resin and the polystyrene-based resin are included in the ranges of 50 to 20% by mass and 50 to 80% by mass respectively, with respect to the total of these resins, the polyethylene-based resin is composed of: a first polyethylene-based resin having a medium density to a high density in the range of 925 to 965 kg/m 3 ; and a second polyethylene-based resin which is linear and which has a lower density than the first polyethylene-based resin, and the first polyethylene-based resin and the second polyethylene-based resin are included in the ranges of 90 to 30% by mass and 10 to 70% by mass respectively, with respect to the total of these resins.

First claim

What is claimed is:

1. Composite resin particles comprising: a polyethylene-based resin and a polystyrene-based resin, wherein
said polyethylene-based resin and said polystyrene-based resin are included in ranges of 50 to 20% by mass and 50 to 80% by mass respectively, with respect to the total of these resins,
said polyethylene-based resin is composed of: a first polyethylene-based resin having a medium density to a high density in a range of 925 to 965 kg/m 3 ; and a second polyethylene-based resin which is linear and which has a lower density than said first polyethylene-based resin,
said first polyethylene-based resin and said second polyethylene-based resin are included in ranges of 90 to 30% by mass and 10 to 70% by mass respectively, with respect to the total of these resins, and
said composite resin particles are particles in which a gel fraction is less than 5% by weight.

2. The composite resin particles according to claim 1 , wherein said second polyethylene-based resin has a density of 15 kg/m 3 or more lower than the density of said first polyethylene-based resin.

3. The composite resin particles according to claim 1 , wherein said first polyethylene-based resin has a crystallization calorific value of 140 mJ/mg or more and said second polyethylene-based resin has a crystallization calorific value of 120 mJ/mg or less.

4. The composite resin particles according to claim 1 , wherein said composite resin particles have an average particle diameter of 1.0 to 2.0 mm.

5. The composite resin particles according to claim 1 , wherein said first polyethylene-based resin is provided with two or more peaks in an elution temperature-elution amount curve by continuous temperature rising elution fractionation (TREF).

6. Composite resin particles comprising: a polyethylene-based resin and a polystyrene-based resin, wherein
said polyethylene-based resin and said polystyrene-based resin are included in ranges of 50 to 20% by mass and 50 to 80% by mass respectively, with respect to the total of these resins,
said polyethylene-based resin is composed of: a first polyethylene-based resin having a medium density to a high density in a range of 925 to 965 kg/m 3 , and a second polyethylene-based resin which is linear and which has a lower density than said first polyethylene-based resin,
said first polyethylene-based resin and said second polyethylene-based resin are included in ranges of 90 to 30% by mass and 10 to 70% by mass respectively, with respect to the total of these resins, and
said composite resin particles further include carbon black in a range of 0.5 to 2.5% by mass.

7. The composite resin particles according to claim 6 , wherein said composite resin particles are particles in which a gel fraction is less than 5% by weight.

8. The composite resin particles according to claim 1 , wherein said composite resin particles are obtained by impregnating a styrene-based monomer into seed particles formed from a polyethylene-based resin and polymerizing.

9. Composite resin particles comprising:
a polyethylene-based resin and a polystyrene-based resin, wherein said polyethylene-based resin and said polystyrene-based resin are included in ranges of 50 to 20% by mass and 50 to 80% by mass respectively, with respect to the total of these resins,
said polyethylene-based resin is composed of: a first polyethylene-based resin having a medium density to a high density in a range of 930 to 950 kg/m 3 ; and a second polyethylene-based resin which is linear and which has a lower density than said first polyethylene-based resin,
said first polyethylene-based resin and said second polyethylene-based resin are included in ranges of 90 to 30% by mass and 10 to 70% by mass respectively, with respect to the total of these resins, and
said first polyethylene-based resin, in terms of polystyrene, has a number-average molecular weight Mn in a range of 25,000 to 50,000, a Z-average molecular weight Mz in a range of 700,000 to 1,300,000, and Mz/Mn in a range of 20 to 50.

10. The composite resin particles according to claim 9 , wherein said first polyethylene-based resin, in terms of polystyrene, has a weight-average molecular weight Mw in the range of 150,000 to 250,000 and Mw/Mn in a range of 4.5 to 9.0.

11. The composite resin particles according to claim 9 , wherein said polystyrene-based resin has a Z-average molecular weight Mz in a range of 600,000 to 1,000,000.

12. The composite resin particles according to claim 9 , wherein said polystyrene-based resin has a weight-average molecular weight Mw in a range of 250,000 to 450,000.

13. Expandable particles comprising the composite resin particles according to claim 1 and a physical blowing agent.

14. Pre-expanded particles obtained by pre-expanding the expandable particles according to claim 13 .

15. The pre-expanded particles according to claim 13 , wherein said polystyrene-based resin has a Z-average molecular weight Mz in a range of 600,000 to 1,000,000.

16. The pre-expanded particles according to claim 15 , wherein said polystyrene-based resin has a weight-average molecular weight Mw in a range of 250,000 to 450,000.

17. An expanded molded article obtained by in-die expansion molding the pre-expanded particles according to claim 14 .

18. The composite resin particles according to claim 2 , wherein said first polyethylene-based resin, in terms of polystyrene, has a weight-average molecular weight Mw in the range of 150,000 to 250,000 and Mw/Mn in a range of 4.5 to 9.0.

Assignees

• Sekisui Plastics

Inventors

• Terasaki Shingo
• Sakakibara Yushi

Classifications

• C08J9/22

  After-treatment of expandable particles; Forming foamed products · CPC title

• C08L23/06

  Polyethylene · CPC title

• C08J9/0028

  containing nitrogen · CPC title

• C08J2423/08

  Copolymers of ethene (C08J2423/16 takes precedence) · CPC title

• C08J2423/06

  Polyethene · CPC title