FOAM BODY, LAYERED FOAM BODY, RESIN SHEET, AND HOUSING BUILDING MATERIAL

Abstract

The present invention aims to provide a foam, a laminated foam, and a resin sheet having good foaming properties, capable of exhibiting particularly excellent vibration-damping properties while being lightweight, and useful for recycling interlayer films for a laminated glass. The present invention also aims to provide a building material for housing including any of the foam, the laminated foam, and the resin sheet. Provide is a foam having a plurality of cells, the foam containing a polyvinyl acetal, a plasticizer, and a hydrogenated petroleum resin, the hydrogenated petroleum resin containing a compound having a softening point of 130° C. or higher.

Claims

1. A foam having a plurality of cells, the foam comprising: a polyvinyl acetal; a plasticizer; and a hydrogenated petroleum resin, wherein the hydrogenated petroleum resin contains a compound having a softening point of 130° C. or higher.

2. The foam according to claim 1, wherein the hydrogenated petroleum resin is contained in an amount of 1 part by weight or greater and 30 parts by weight or less relative to 100 parts by weight of the polyvinyl acetal.

3. The foam according to claim 1, wherein the plasticizer is contained in an amount of 10 parts by weight or greater and 80 parts by weight or less relative to 100 parts by weight of the polyvinyl acetal.

4. The foam according to claim 1, further comprising a filler.

5. The foam according to claim 4, wherein the filler is barium sulfate.

6. The foam according to claim 1, having a loss factor of 0.01 or greater at an anti-resonance frequency at 20° C. and 100 to 10,000 Hz as measured by mechanical impedance measurement (MIM) in conformity with JIS K7391 (2008).

7. A laminated foam comprising: the foam according to claim 1; and a non-woven fabric on at least one main surface of the foam.

8. A resin sheet comprising: a polyvinyl acetal; a plasticizer; and a hydrogenated petroleum resin, wherein the hydrogenated petroleum resin contains a compound having a softening point of 130° C. or higher.

9. The resin sheet according to claim 8, further comprising a foaming agent.

10. A building material for housing, the building material comprising the foam according to claim 1, a laminated foam comprising the foam according to claim 1, and a non-woven fabric on at least one main surface of the foam; or a resin sheet comprising a polyvinyl acetal, a plasticizer, a hydrogenated petroleum resin, wherein the hydrogenated petroleum resin contains a compound having a softening point of 130° C. or higher.

Description

DESCRIPTION OF EMBODIMENTS

[0113] The embodiments of the present invention are more specifically described in the following with reference to, but not limited to, examples.

[0114] The following compounds were used as compounding components for resin compositions in examples and comparative examples.

(1) Polyvinyl Acetal

[0115] Polyvinyl butyral 1 (PVB1): hydroxy group content 31 mol %, degree of acetylation 0.7 mol %, degree of butyralization 68.3 mol %, average degree of polymerization 1,800

[0116] Polyvinyl butyral 2 (PVB2): hydroxy group content 22.0 mol %, degree of acetylation 4.0 mol %, degree of butyralization 74.0 mol %, average degree of polymerization 550

(2) Plasticizer: triethylene glycol di-2-ethylhexanoate (3GO)

(3) Hydrogenated Petroleum Resin

[0117] M-135: ARKON M-135, produced by Arakawa Chemical Industries Ltd., softening point 135° C. [0118] M-100: ARKON M-100, Arakawa Chemical Industries Ltd., softening point 100° C. [0119] P-140: ARKON P-140, Arakawa Chemical Industries Ltd., softening point 140° C. [0120] P-125: ARKON P-125, Arakawa Chemical Industries Ltd., softening point 125° C.

(4) Filler: Barium Sulfate (Barytes Powder FBA, Produced by Nippon Talc Co., Ltd.)

[0121] (5) Foaming Agent: VINYFOR AC #R, Produced by Eiwa Chemical Ind. Co., Ltd.

Example 1

(1) Production of Foam

[0122] To 100 parts by weight of polyvinyl butyral 1 (PVB1) were added 40 parts by weight of the plasticizer, 20 parts by weight of the hydrogenated petroleum resin shown in Table 1, and 6 parts by weight of the foaming agent, whereby a resin composition was obtained. The obtained resin composition was sufficiently kneaded at 110° C. with a mixing roll and then extruded with an extruder into a sheet. This sheet is also referred to as a resin sheet.

[0123] A non-woven fabric SPC (N) (produced by Nippon Paper Papylia Co., Ltd., type: pulp, mass per unit area: 15 g/m.sup.2) was placed on both surfaces of the resin sheet and thermally compression-bonded at 120° C. with a press machine, whereby a laminate was obtained. The obtained laminate was placed in an oven, and the heat-decomposable foaming agent was decomposed at 210° C. for five minutes in the oven, whereby a sheet-shaped foam was obtained.

[0124] The laminate was placed in the oven without being cooled.

(2) Calculation of Expansion Ratio

[0125] The apparent density of the obtained foam was measured in conformity with JIS K7222 (2005). The density of the resin sheet before foaming was divided by the density (apparent density) of the foam after foaming to calculate the expansion ratio.

(3) Measurement of Thickness

[0126] The thickness of the obtained foam was measured.

Example 2

[0127] A resin sheet was obtained as in Example 1 except that the filler was added in the amount shown in Table 1. Thereafter, a sheet-shaped foam was prepared as in Example 1 and subjected to evaluations of physical properties and the like.

Example 3

[0128] A resin sheet was obtained as in Example 1 except that PVB2 was used instead of PVB1, and that the amount of the hydrogenated petroleum resin was as shown in Table 1, and the filler was added in the amount shown in Table 1. Thereafter, a sheet-shaped foam was prepared as in Example 1 and subjected to evaluations of physical properties and the like.

Example 4

[0129] To 100 parts by weight of polyvinyl butyral 2 (PVB2) were added 20 parts by weight of the plasticizer, 10 parts by weight of M-100 and 20 parts by weight of M-135 as hydrogenated petroleum resins, 30 parts by weight of the filler, and 6 parts by weight of the foaming agent, whereby a resin composition was obtained. The obtained resin composition was sufficiently kneaded at 110° C. with a mixing roll and then extruded with an extruder into a sheet (resin sheet). Thereafter, a sheet-shaped foam was prepared as in Example 1 and subjected to evaluations of physical properties and the like.

Example 5

[0130] A resin sheet was obtained as in Example 4 except that only P-140 was used as the hydrogenated petroleum resin in the amount shown in Table 1. Thereafter, a sheet-shaped foam was prepared as in Example 1 and subjected to evaluations of physical properties and the like.

Examples 6 and 7

[0131] A resin sheet was obtained as in Example 2 except that the amount of the hydrogenated petroleum resin was changed to the amount shown in Table 1. Thereafter, a sheet-shaped foam was prepared as in Example 1 and subjected to evaluations of physical properties and the like.

Examples 8 and 9

[0132] A resin sheet was obtained as in Example 4 except that the amounts of the respective hydrogenated petroleum resins were changed to the amounts shown in Table 1. Thereafter, a sheet-shaped foam was prepared as in Example 1 and subjected to evaluations of physical properties and the like.

Comparative Example 1

[0133] A resin sheet was obtained as in Example 1 except that M-100 was used instead of M-135. Thereafter, a sheet-shaped foam was prepared as in Example 1 and subjected to evaluations of physical properties and the like.

Comparative Example 2

[0134] A resin sheet was obtained as in Example 2 except that M-100 was used instead of M-135. Thereafter, a sheet-shaped foam was prepared as in Example 1 and subjected to evaluations of physical properties and the like.

Comparative Example 3

[0135] A resin sheet was obtained as in Example 2 except that P-125 was used instead of M-135. Thereafter, a sheet-shaped foam was prepared as in Example 1 and subjected to evaluations of physical properties and the like.

Comparative Example 4

[0136] A resin sheet was obtained as in Example 2 except that no hydrogenated petroleum resin was compounded. Thereafter, a sheet-shaped foam was prepared as in Example 1 and subjected to evaluations of physical properties and the like.

Evaluation

[0137] The following evaluations were performed on the foams and the raw laminates before foaming (laminates after the thermal compression bonding in the foam production step) obtained in the examples and the comparative examples. Table 1 and Table 2 show the results.

(1) Vibration-Damping Properties

[0138] The loss factor and the anti-resonance frequencies at ° C. were measured by mechanical impedance measurement (MIM) in conformity with JIS K7391 (2008).

[0139] Specifically, the foam was fixed between a steel plate having a width of 12 mm, a length of 240 mm, and a thickness of 1.2 mm and an aluminum plate (0.3 mm) having the same size using a double-sided tape (produced by Sekisui Chemical Co., Ltd., #5782). The resulting laminate sample was used to measure the loss factor and the anti-resonance frequencies by the central exciting method. The vibration-damping properties were evaluated in accordance with the following criteria. The tables show the third anti-resonance point and the loss factor.

(Rating)

[0140] A: The loss factor was 0.1 or greater at the third anti-resonance point. [0141] B: The loss factor was less than 0.1 at the third anti-resonance point.

(2) Foaming Properties

[0142] The raw laminate before foaming was cut into a specimen having a thickness of 2 mm and a size of 10 cm×10 cm. The specimen was heated at 210° C. for five minutes. The apparent density of this specimen after heating was measured in conformity with JIS K7222 (2005). The obtained apparent density was divided by the density (apparent density) of the specimen before heating to calculate the expansion ratio. The foaming properties were evaluated in accordance with the following criteria.

(Foaming Rate)

[0143] A: The expansion ratio was 3 times or greater; in other words, the specimen after heating had a thickness of 6 mm or greater. [0144] B: The expansion ratio was less than 3 times; in other words, the specimen after heating had a thickness of less than 6 mm.

(Cell Stability)

[0145] A: No broken cell was observed in the specimen after heating (visual observation). [0146] B: A broken cell was observed in the specimen after heating (visual observation).

(Rating)

[0147] A: The foaming rate was evaluated as “A” and the cell stability was evaluated as “A”. [0148] B: One of the foaming rate and the cell stability was evaluated as “A” and the other was evaluated as “B”. [0149] C: The foaming rate was evaluated as “B” and the cell stability was evaluated as “B”.

TABLE-US-00001 TABLE 1 Ex- Ex- Ex- Ex- Ex- Ex- Ex- Ex- Ex- ample ample ample ample ample ample ample ample ample 1 2 3 4 5 6 7 8 9 Foam Composition Polyvinyl PVB1 100 100 — — — 100 100 — — (parts by acetal PVB2 — — 100 100 100 — — 100 100 weight) Plasticizer 40 40 40 20 20 40 40 20 20 Hydrogenated M-135 20 20 10 20 — 1 30 25 10 petroleum M-100 — — — 10 — — — 5 20 resin P-140 — — — — 20 — — — — P-125 — — — — — — — — — Filler — 30 30 30 30 30 30 30 30 Shape Foaming ratio [times] 3.2 3.1 3.2 3.5 3.1 3.1 3.5 3.4 3 Thickness [mm] 6.4 6.2 6.4 7 6.2 6.2 7 6.8 6 Eval- Foaming Foaming rate A A A A A A A A A uation properties Cell stability B A A A A B B A B Rating B A A A A B B A B Vibration- Third anti- Hz 1623 1673 1569 1560 1647 1560 1688 1589 1555 damping resonance point properties Loss factor 0.1 0.12 0.14 0.15 0.12 0.12 0.15 0.15 0.11 Rating B A A A A A A A B

TABLE-US-00002 TABLE 2 Comparative Comparative Comparative Comparative Example 1 Example 2 Example 3 Example 4 Foam Composition Polyvinyl PVB1 100 100 100 100 (parts by acetal PVB2 — — — — weight) Plasticizer 40 40 40 40 Hydrogenated M-135 — — — — petroleum M-100 20 20 — — resin P-140 — — — — P-125 — — 20 — Filler — 30 30 30 Shape Foaming ratio [times] 2.7 2.5 2.8 2.7 Thickness [mm] 5.4 5 5.6 5.4 Eval- Foaming Foaming rate B B B B uation properties Cell stability B B B B Rating C C C C Vibration- Third anti- Hz 1694 1573 1573 1645 damping resonance point properties Loss factor 0.1 0.11 0.11 0.08 Rating B B B C

INDUSTRIAL APPLICABILITY

[0150] The present invention can provide a foam, a laminated foam, a resin sheet, and a building material for housing having good foaming properties, capable of exhibiting particularly excellent vibration-damping properties while being lightweight, and useful for recycling interlayer films for a laminated glass.