Resin sheet and molded body

Abstract

Provided is a resin sheet comprising a chlorinated polyvinyl chloride having a chlorine content of 60 mass% or more and a dimethyltin compound, and having a load deflection temperature of 80 DEG C or more as measured according to the JIS K 7191-1A method.

Description

Technical Field

[0001] The present invention relates to a resin sheet and a molded body. Background Art

[0002] For example, as shown in Patent Document 1, a resin sheet obtained by molding a vinyl chloride resin composition is used as interior materials of vehicles such as automobiles, buses, and railways, transportation equipment such as ships and airplanes, and buildings.

[0003] The vinyl chloride resin composition is excellent in processability and the obtained resin sheet is excellent in impact resistance, chemical resistance, flame retardancy, etc., and therefore is preferably used as the interior material.

[0004] When such interior materials are used in transportation equipment such as aircraft, in particular, it is required to impart flame retardancy and suppress smoke generation to the interior materials. In order to exert such functions, it is known to add a molybdenum-based compound as a flame retardant to a vinyl chloride resin composition.

[0005] The resin sheet is produced, for example, by preparing a vinyl chloride resin composition by kneading under heating, and then molding the obtained vinyl chloride resin composition by extrusion molding.

[0006] Prior art literature

[0007] Patent Literature

[0008] Patent Document 1: Japanese Patent Application Publication No. 2006-265373. Summary of the invention

[0009] Technical issues to be solved by the invention

[0010] However, as described above, there is a problem that if a molybdenum compound is included in a vinyl chloride resin composition, the heat during extrusion by an extruder may induce thermal decomposition of the polyvinyl chloride resin. Therefore, in order to suppress the thermal decomposition of the polyvinyl chloride resin, it is conceivable to add a stabilizer to the vinyl chloride resin composition.

[0011] On the other hand, in Europe, REACH regulations for managing chemical substances are applied to protect human health and the environment. In order to comply with REACH regulations, dimethyltin compounds can be considered as stabilizers. However, if dimethyltin compounds are used, there is a problem that the heat resistance (heat deformation temperature) of the resin sheet is reduced.

[0012] The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a resin sheet having excellent flame retardancy even when containing a dimethyltin-based compound, and a molded product of the resin sheet.

[0013] Means for solving technical problems

[0014] In order to solve the above-mentioned problems, the present invention adopts the following structure.

[0015] [1]. A resin sheet, wherein:

[0016] The resin sheet includes chlorinated polyvinyl chloride and a dimethyltin compound, the chlorinated polyvinyl chloride has a chlorine content of 60% by mass or more, and the resin sheet has a deflection temperature under load measured in accordance with JIS K7191-1A method of 80° C. or more.

[0017] [2] The resin sheet according to [1], further comprising a lubricant having a softening point of 50° C. or higher.

[0018] [3] The resin sheet according to [2], wherein the lubricant is one or more selected from the group consisting of oxidized polyethylene, fatty acid esters, and hydroxy fatty acids.

[0019] [4] The resin sheet according to any one of [1] to [3], further comprising a molybdenum-based compound and magnesium hydroxide.

[0020] [5] The resin sheet according to [4], wherein the molybdenum-based compound is ammonium octamolybdate.

[0021] [6] The resin sheet according to any one of [1] to [5], wherein the content of the chlorinated polyvinyl chloride in the resin sheet is 70% by mass or more relative to the total mass of the resin sheet.

[0022] [7] The resin sheet according to [2] or [3], wherein in the resin sheet, the content of the lubricant is 40 to 65 parts by mass based on 100 parts by mass of the dimethyltin compound.

[0023] [8] The resin sheet according to [4] or [5], wherein in the resin sheet, the total content of the molybdenum-based compound and the magnesium hydroxide is 2.0 to 10.0 parts by mass relative to 100 parts by mass of the chlorinated polyvinyl chloride.

[0024] [9] The resin sheet according to any one of [1] to [8], further comprising at least one of zeolite and an antioxidant.

[0025]

[10] . A molded product, which is a molded product of the resin sheet according to any one of [1] to [9].

[0026] Effects of the Invention

[0027] According to the present invention, there are provided a resin sheet having excellent flame retardancy even when containing a dimethyltin-based compound, and a molded product of the resin sheet. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a cross-sectional view schematically showing an example of a resin sheet according to one embodiment of the present invention.

[0029] Figure 2 It is schematically indicated Figure 1 A side view of an example of an apparatus for producing a resin sheet shown. DETAILED DESCRIPTION

[0030] Hereinafter, this embodiment will be described in detail with reference to the drawings.

[0031] <<Resin Sheet>>

[0032] The resin sheet 1 of the present embodiment includes chlorinated polyvinyl chloride and a dimethyltin compound, wherein the chlorine content of the chlorinated polyvinyl chloride is 60 mass % or more, and the deflection temperature under load measured in accordance with JIS K7191-1A method is 80° C. or more.

[0033] This resin sheet 1 has excellent flame retardancy even when containing a dimethyltin-based compound.

[0034] Hereinafter, as an example of the resin sheet 1 according to the present embodiment, a resin sheet containing chlorinated polyvinyl chloride, a stabilizer, a lubricant, a reinforcing agent, a processing aid, an antioxidant, a filler, and a flame retardant will be described.

[0035] Figure 1 It is a cross-sectional view schematically showing an example of a resin sheet according to one embodiment of the present invention.

[0036] <Chlorinated polyvinyl chloride>

[0037] The resin sheet 1 contains chlorinated polyvinyl chloride as its main material. Thus, the smoke and heat generation suppression effects of the resin sheet 1 can be obtained. Furthermore, when the resin sheet 1 is formed by extrusion molding, the extrudability of the resin composition can be improved, and the resin sheet 1 can be molded into a resin sheet with a uniform thickness. Therefore, the obtained resin sheet 1 is molded to have excellent appearance.

[0038] Chlorinated polyvinyl chloride is a polymer having a plurality of groups represented by -CHCl-CHCl- as repeating units.

[0039] The chlorine content, i.e., the chlorine concentration rate, of the chlorinated polyvinyl chloride is set to 60% by mass or more, preferably 61% by mass or more and 68% by mass or less, and more preferably 63% by mass or more and 67% by mass or less. By setting the chlorine content of the chlorinated polyvinyl chloride to be above the above lower limit, the effect of improving heat resistance can be obtained. By setting the chlorine content of the chlorinated polyvinyl chloride to be below the above upper limit, the effect of improving processability when producing a resin sheet can be obtained.

[0040] The number average degree of polymerization of chlorinated polyvinyl chloride is preferably 400 to 1200, more preferably 600 to 1000. By setting the number average degree of polymerization of chlorinated polyvinyl chloride to be equal to or greater than the above lower limit, the heat resistance of the resin sheet 1 can be further improved. By setting the number average degree of polymerization of chlorinated polyvinyl chloride to be equal to or less than the above upper limit, the processability of the resin sheet 1 can be further improved.

[0041] In the resin sheet 1, the content of the chlorinated polyvinyl chloride is preferably 70% by mass or more, more preferably 75% by mass or more and 90% by mass or less, and further preferably 78% by mass or more and 85% by mass or less, relative to the total mass of the resin sheet 1. Thus, the effect of including the chlorinated polyvinyl chloride in the resin sheet 1 can be further enhanced.

[0042] <Stabilizer>

[0043] The resin sheet 1 contains a dimethyltin compound as a stabilizer. This can suppress decomposition or coloration of the resin sheet 1 due to heat or light.

[0044] In the present specification, a "dimethyltin compound" refers to a compound including a structure in which two methyl groups are covalently bonded to a tin atom.

[0045] In Europe, REACH regulations for the management of chemical substances are applied to protect human health and the environment. Dimethyltin compounds are compounds that comply with REACH regulations.

[0046] In the resin sheet 1, the content of the stabilizer is preferably 0.1 parts by mass or more and 10.0 parts by mass or less, and more preferably 0.5 parts by mass or more and 8.0 parts by mass or less, relative to 100 parts by mass of the chlorinated polyvinyl chloride content. This can maintain the mechanical strength of the resin sheet 1 and further suppress decomposition or coloration of the resin sheet 1 due to heat or light.

[0047] <Lubricant>

[0048] The resin sheet 1 may contain a lubricant. This can further suppress the decrease in heat resistance (heat deformation temperature) of the resin sheet 1 caused by the inclusion of a dimethyltin compound in the resin sheet 1. In addition, when molding the resin sheet 1, the mold or roller can exhibit excellent sliding properties, thereby further improving the moldability.

[0049] The softening point of the lubricant is preferably 50° C. or higher, more preferably 60° C. or higher, further preferably 80° C. or higher, and particularly preferably 82° C. or higher. This can further suppress a decrease in the heat resistance of the resin sheet 1 .

[0050] Examples of the lubricant include polyethylene oxide, fatty acid esters, hydroxy fatty acids, metal soaps, higher aliphatic alcohols, and synthetic waxes. These may be used alone or in combination of two or more. Among them, polyethylene oxide, fatty acid esters, and hydroxy fatty acids are preferred.

[0051] Examples of the types of oxidized polyethylene include a highly oxidized type, a slightly oxidized type, and an acid-modified type.

[0052] The weight average molecular weight of the oxidized polyethylene is preferably 1000 to 3000, more preferably 1500 to 2500, and still more preferably 1800 to 2300. This can further enhance the effect of including the lubricant in the resin sheet 1 .

[0053] Examples of the fatty acid ester include butyl stearate and triglyceride.

[0054] Examples of the hydroxy fatty acid include hydroxystearic acid and the like.

[0055] In the resin sheet 1 , the lubricant content is preferably 0.05 to 5.00 parts by mass, more preferably 0.30 to 4.00 parts by mass, relative to 100 parts by mass of chlorinated polyvinyl chloride.

[0056] In the resin sheet 1, the lubricant content is preferably 40 to 65 parts by mass, more preferably 41 to 55 parts by mass, and even more preferably 43 to 52 parts by mass relative to 100 parts by mass of the dimethyltin compound. Thus, the effect of including the lubricant in the resin sheet 1 can be further enhanced.

[0057] In addition, depending on the combination of constituent materials contained in the resin sheet 1 and the like, the addition of a lubricant to the resin sheet 1 may be omitted.

[0058] <Enhancer>

[0059] The resin sheet 1 may contain a reinforcing agent. Thereby, the impact resistance of the resin sheet 1 can be mainly further improved, and the moldability of the resin sheet 1 during molding can be further improved.

[0060] Examples of the reinforcing agent include chlorinated polyethylene, ethylene-vinyl acetate copolymers, and multi-component acrylic rubber resins, and among these, multi-component acrylic rubber resins are preferably used. This can further improve the durability of the resin sheet 1 .

[0061] The multi-component acrylic rubber resin (acrylic polymer) mainly comprises acrylic esters such as methyl acrylate, ethyl acrylate, butyl acrylate, and octyl acrylate, and is a copolymer of these monomers with 2-chloroethyl vinyl ether, methyl vinyl ketone, acrylic acid, styrene, acrylonitrile, butadiene, and the like. Examples thereof include "Kane Ace FM" manufactured by Kaneka Corporation and "KUREHA KM-334" manufactured by KUREHA Corporation.

[0062] The weight average molecular weight of the multi-component acrylic rubber resin is preferably 1.0×10 5 Above and 1.0×10 7 Below, more preferably 1.0×10 6 Above and 7.0×10 6 the following.

[0063] In the resin sheet 1 , the content of the multi-component acrylic rubber resin is preferably 5.0 parts by mass or more and 20.0 parts by mass or less, and more preferably 6.0 parts by mass or more and 14.0 parts by mass or less, relative to 100 parts by mass of the chlorinated polyvinyl chloride.

[0064] Furthermore, depending on the impact resistance required of the interior material to which the resin sheet 1 is applied, it is also possible to omit the addition of a reinforcing agent to the resin sheet 1 .

[0065] <Processing aids>

[0066] The resin sheet 1 may contain a processing aid. Thereby, the moldability of the resin sheet 1 during molding can be further improved.

[0067] As the processing aid, for example, an acrylic processing aid is used, and specific examples thereof include acrylic acid ester copolymers (for example, high molecular weight acrylic acid ester copolymers) such as 2-ethylhexyl acrylate / butyl acrylate copolymers, and copolymers of methyl methacrylate and acrylic acid ester.

[0068] The weight average molecular weight of the processing aid is preferably 1.0×10 5 Above and 5.0×106 Below, more preferably 7.0×10 5 Above and 4.0×10 6 Below, more preferably 1.3×10 6 Above and 3.0×10 6 the following.

[0069] In the resin sheet 1 , the content of the processing aid is preferably 1.0 to 15.0 parts by mass, more preferably 2.0 to 10.0 parts by mass, relative to 100 parts by mass of the chlorinated polyvinyl chloride.

[0070] In addition, depending on the combination of constituent materials contained in the resin sheet 1 and the like, it is also possible to omit the addition of a processing aid to the resin sheet 1 .

[0071] <Antioxidants>

[0072] The resin sheet 1 may contain an antioxidant. This can further prevent oxidation of the constituent materials contained in the resin sheet 1.

[0073] Furthermore, if the resin composition contains a molybdenum-based compound, the heat during extrusion by the extruder may induce thermal decomposition of the chlorinated polyvinyl chloride. On the other hand, by including an antioxidant in the resin sheet 1, the induction of thermal decomposition of the chlorinated polyvinyl chloride can be further suppressed.

[0074] As the antioxidant, there can be mentioned phosphite antioxidants (phosphorus antioxidants) such as trisnonylphenyl phosphite, tridecyl phosphite, and diphenyldecyl phosphite; hindered phenol antioxidants; phenol antioxidants such as alkylated monophenols and alkylated hydroquinone; amine antioxidants such as alkylated tert-butylphenylenediamine and hydroxylamine, etc., and one of them can be used or two or more of them can be used in combination, among which phosphite antioxidants and phenol antioxidants are preferred. Thus, the effect produced by including the antioxidant in the resin sheet 1 can be further improved.

[0075] Examples of hindered phenol-based antioxidants include 2,2′-methylenebis(4-methyl-6-tert-butylphenol) and pentaerythritol=tetrakis[3-(3′,5′-di-tert-butyl-4′-hydroxyphenyl)propionate].

[0076] In the resin sheet 1, the content of the antioxidant is preferably 0.01 parts by mass or more and 5.0 parts by mass or less, more preferably 0.1 parts by mass or more and 2.0 parts by mass or less, and even more preferably 0.3 parts by mass or more and 1.5 parts by mass or less relative to 100 parts by mass of the chlorinated polyvinyl chloride. This can further suppress the induction of thermal decomposition of the chlorinated polyvinyl chloride.

[0077] In addition, depending on the combination of constituent materials contained in the resin sheet 1 and the like, it is also possible to omit the addition of an antioxidant to the resin sheet 1 .

[0078] <Zeolite>

[0079] The resin sheet 1 may contain zeolite. If the resin composition contains a molybdenum-based compound, the heat during extrusion by the extruder may induce thermal decomposition of the chlorinated polyvinyl chloride. On the other hand, by containing zeolite in the resin sheet 1, the induction of thermal decomposition of the chlorinated polyvinyl chloride can be further suppressed.

[0080] The zeolite is not particularly limited, and examples thereof include natural zeolites such as chabazite, mordenite, erionite, and clinoptilolite, and synthetic zeolites such as A-type zeolite, X-type zeolite, and Y-type zeolite. These may be used alone or in combination of two or more.

[0081] Zeolite is contained in the resin sheet 1 as particles. The average particle size of the particles is not particularly limited, but is preferably set to about 1.0 μm to 50.0 μm, and more preferably about 5.0 μm to 30.0 μm. Thus, the zeolite can be dispersed more uniformly in the resin sheet 1 without agglomerating.

[0082] In this specification, the "average particle size" refers to the particle size when the accumulation of particles is 50%, and may be referred to as "D50".

[0083] In this specification, the particle size of particles having shapes other than spherical shapes is determined by a laser diffraction / scattering particle size distribution measurement method.

[0084] The shape of the particles containing zeolite is not particularly limited, and may be any of spherical, elliptical, flat, and needle-shaped.

[0085] In the resin sheet 1, the content of zeolite is preferably 0.1 to 5.0 parts by mass, more preferably 0.2 to 1.0 parts by mass, relative to 100 parts by mass of chlorinated polyvinyl chloride. This can further suppress the induction of thermal decomposition of chlorinated polyvinyl chloride.

[0086] In addition, depending on the combination of constituent materials contained in the resin sheet 1 and the like, the addition of zeolite to the resin sheet 1 may be omitted.

[0087] The resin sheet 1 preferably contains at least one of zeolite and an antioxidant. In addition, by adopting a structure in which both zeolite and an antioxidant are added to the resin sheet 1 as in the present embodiment, the induction of thermal decomposition of chlorinated polyvinyl chloride can be further suppressed.

[0088] <Flame retardant>

[0089] The resin sheet 1 may contain a flame retardant. This can further improve the flame retardancy of the resin sheet 1, further suppress the combustion of the resin sheet 1, and further improve the safety thereof.

[0090] As flame retardants, there can be mentioned antimony compounds such as antimony trioxide; metal hydroxides such as aluminum hydroxide and magnesium hydroxide; phosphorus compounds such as toluene diphenyl phosphate, trichloroethyl phosphate, trichloropropyl phosphate, and tridichloropropyl phosphate; nitrogen-containing compounds such as melamine compounds and guanidine compounds; halogen compounds such as chlorinated paraffin, etc., and one of them can be used or two or more of them can be used in combination.

[0091] Furthermore, the resin sheet 1 may contain a molybdenum compound in addition to the flame retardant, thereby further improving the flame retardancy of the resin sheet 1 and further suppressing the smoke generation of the resin sheet 1 to achieve low toxicity of the resin sheet 1, thereby further improving its safety.

[0092] In this specification, a "molybdenum-based compound" refers to a compound containing molybdenum as a constituent element.

[0093] Similarly, an “antimony compound” refers to a compound containing antimony as a constituent atom, a “phosphorus compound” refers to a compound containing phosphorus as a constituent element, and a “halogen compound” refers to a compound containing halogen as a constituent element.

[0094] The resin sheet 1 preferably contains a molybdenum-based compound and magnesium hydroxide as a flame retardant. This can further improve the flame retardancy of the resin sheet 1.

[0095] In the resin sheet 1 , the content of the flame retardant is preferably 0.1 to 20.0 parts by mass, more preferably 0.5 to 8.0 parts by mass, relative to 100 parts by mass of the chlorinated polyvinyl chloride.

[0096] The molybdenum compound is included in the resin sheet 1 as particles, more specifically, as primary particles of the molybdenum compound or secondary particles of primary particles of other flame retardants other than the molybdenum compound. The average particle size of the particles is not particularly limited, and is preferably set to about 1.0 μm or more and about 50.0 μm or less, and more preferably set to about 3.0 μm or more and about 15.0 μm or less. Thus, in the resin sheet 1, the molybdenum compound can be dispersed more uniformly without agglomerating.

[0097] The shape of the particles containing the molybdenum compound is not particularly limited, and may be any of spherical, elliptical, flat, and needle-shaped. In addition, in this specification, the particle size of the particle refers to the maximum diameter of particles having various shapes, for example, in the case of a spherical particle, it refers to the diameter.

[0098] There are no particular limitations on the molybdenum compound, and examples thereof include inorganic molybdenum compounds such as molybdenum trioxide, zinc molybdate, ammonium molybdate, magnesium molybdate, calcium molybdate, barium molybdate, sodium molybdate, potassium molybdate, molybdenum disulfide, and molybdenum nitride; and organic molybdenum compounds such as dialkyl dithiophosphate molybdenum. One or more of these compounds can be used, and among them, ammonium molybdate, zinc molybdate, and molybdenum trioxide are preferred, and ammonium molybdate is more preferred.

[0099] Examples of ammonium molybdate include ammonium octamolybdate and ammonium heptamolybdate, and one or more of these can be used alone or in combination. Among them, ammonium octamolybdate is preferred. Thus, the effect of including a molybdenum-based compound in the resin sheet 1 can be further enhanced.

[0100] The particles containing the molybdenum-based compound may have a coupling agent having a hydrocarbon group bonded to the surface thereof.

[0101] As the coupling agent, for example, a silane coupling agent, a titanium coupling agent, an aluminum coupling agent, or the like can be used.

[0102] In the resin sheet 1, the total content of the molybdenum-based compound and the magnesium hydroxide is preferably 2.0 parts by mass or more and 10.0 parts by mass or less, more preferably 2.5 parts by mass or more and 8.0 parts by mass or less, and even more preferably 3.0 parts by mass or more and 5.0 parts by mass or less, relative to 100 parts by mass of the chlorinated polyvinyl chloride content. This can further suppress the smoke generation of the resin sheet 1.

[0103] Furthermore, depending on the application of the interior material to which the resin sheet 1 is applied, that is, depending on the flame retardant properties required of the resin sheet 1 , it is also possible to omit the addition of a flame retardant to the resin sheet 1 .

[0104] <Pigment>

[0105] The resin sheet 1 may contain a pigment as a coloring material.

[0106] The pigment is selected according to the desired coloring (hue), and for example, in addition to titanium oxide and carbon black, there can be mentioned organic pigments such as azo, benzimidazolone, diarylide, quinacridone, isoindolinone, vat, phthalocyanine, and dioxane, or inorganic pigments such as titanium yellow and chrome yellow. One of them can be used alone or in combination of two or more thereof.

[0107] The content of the pigment in the resin sheet 1 relative to 100 parts by mass of the chlorinated polyvinyl chloride is set according to the desired coloring (color tone), but is preferably 0.01 parts by mass or more and 8.00 parts by mass or less, and more preferably 0.05 parts by mass or more and 6.00 parts by mass or less. This can further enhance the effect of including the pigment in the resin sheet 1.

[0108] In the resin sheet 1, the primary particles of the molybdenum compound and the secondary particles containing the molybdenum compound have a white color. Therefore, when the resin sheet 1 contains a colored pigment, the speckled pattern caused by the particles containing the molybdenum compound is more prominently visually recognized, so in this case, the resin sheet 1 of the present invention is more suitably applied.

[0109] When it is not necessary to color the resin sheet 1 , it is also possible to omit the addition of a pigment to the resin sheet 1 .

[0110] The resin sheet 1 may contain, for example, an ultraviolet absorber, a plasticizer, an antistatic agent, etc. in addition to the above-mentioned chlorinated polyvinyl chloride, stabilizer, lubricant, reinforcing agent, processing aid, antioxidant, zeolite, flame retardant, and pigment.

[0111] The thickness of the resin sheet 1 is preferably set to 0.5 mm or more and 8.0 mm or less, and more preferably set to 1.0 mm or more and 5.0 mm or less. Thereby, the resin sheet 1 can be made lighter and its strength can be further improved.

[0112] The resin sheet 1 exhibits the following heat resistance.

[0113] That is, the deflection temperature under load of the resin sheet 1 measured in accordance with JIS K 7191-1A method is 80° C. or higher. Therefore, the resin sheet 1 has excellent heat resistance even if it contains a dimethyltin-based compound.

[0114] The deflection temperature under load of the resin sheet 1 is preferably 75° C. or higher and 100° C. or lower, more preferably 76° C. or higher and 95° C. or lower, and further preferably 78° C. or higher and 90° C. or lower.

[0115] Furthermore, the resin sheet 1 preferably exhibits flame retardancy as shown below.

[0116] That is, when the resin sheet 1 is burned according to the heat release test specified in ASTM E906, the maximum heat release rate measured within 5 minutes from the ignition of the resin sheet 1 is preferably 65 kW / m 2 Below, more preferably 55kW / m 2 As a result, the flame retardancy of the resin sheet 1 can be further improved.

[0117] Furthermore, the total heat generation within 2 minutes from the ignition of the resin sheet 1 is preferably 65 kW·min / m 2 Below, more preferably 55kW·min / m 2 As a result, the flame retardancy of the resin sheet 1 can be further improved.

[0118] In the smoke density test during combustion using an NBS smoke chamber, which is a smoke test specified in ASTM E662, the smoke density (Ds) during combustion for 4.0 minutes is preferably 200 or less, more preferably 150 or less. This can further suppress the generation of smoke from the resin sheet 1 .

[0119] The resin sheet 1 can be produced, for example, as follows.

[0120] <<Method for producing resin sheet>>

[0121] First, before describing the method for producing the resin sheet 1 , a production apparatus 10 for producing the resin sheet 1 will be described.

[0122] Figure 2 It is schematically indicated Figure 1 A side view of an example of a manufacturing apparatus for a resin sheet shown in FIG. Figure 2 In the drawings, some parts are shown exaggeratedly and are greatly different from the actual size.

[0123] Figure 1 The flat plate-shaped resin sheet 1 shown is produced by using a production apparatus 10 and molding a resin composition containing chlorinated polyvinyl chloride and a dimethyltin-based compound.

[0124] like Figure 2 As shown, the manufacturing device 10 includes a supply unit 100 , an extruder 200 , a molding unit 300 , a cooling unit 400 , and a cutting unit 500 .

[0125] The supply unit 100 stores a resin composition, and supplies the stored resin composition to the extruder 200. In the supply unit 100, the resin composition is stored in a mixed (kneaded) state.

[0126] The extruder 200 extrude the resin composition supplied from the supply unit 100 into a sheet by extrusion. The extruder 200 has a flow path through which the resin composition passes and a screw disposed in the flow path. The resin composition is extruded into a sheet by the rotation of the screw.

[0127] Here, when the resin composition is extruded by the extruder 200, the resin composition is heated by the temperature setting of the extruder barrel (cylinder) and the rotation of the screw of the extruder 200. Thus, the resin composition supplied from the supply unit 100 to the extruder 200 is continuously heated. The resin composition is usually heated to a heating temperature of about 120° C. to about 200° C., and when set to a higher temperature, it is heated to a heating temperature of about 170° C. to about 200° C.

[0128] In this embodiment, the molding unit 300 has three rollers 301, 302, and 303. The rollers 301 to 303 are arranged in a vertical direction and rotate independently of each other. The extruded sheet is wound around the rollers 301 to 303, and the sheet is sandwiched between the rollers 301 to 303 to be molded into a uniform thickness.

[0129] The cooling unit 400 includes a plurality of cooling rollers 401. Each cooling roller 401 comes into contact with one surface of a formed sheet, thereby cooling the sheet.

[0130] The cutting unit 500 has a blade portion 501 , and cuts the sheet into a predetermined length by the blade portion 501 .

[0131] Using such a manufacturing apparatus 10 , the resin sheet 1 can be manufactured, for example, as follows.

[0132] [1] First, a dimethyltin compound is added to a powder containing chlorinated polyvinyl chloride, and if necessary, one or more selected from the group consisting of a stabilizer, a lubricant, a reinforcing agent, a processing aid, an antioxidant, a zeolite and a flame retardant are further added, and then kneaded using a super mixer, a Henschel mixer, a stirrer, etc., to prepare a resin composition.

[0133] [2] Next, the prepared resin composition is molded using the production apparatus 10 to obtain a resin sheet 1 .

[0134] In the manufacturing method using the manufacturing apparatus 10, the resin composition supplied from the supply unit 100 is continuously extruded into a sheet by the extruder 200, and the surface is flattened and formed into a predetermined thickness by the molding unit 300. Then, the sheet is cooled by contact with the cooling unit 400, and cut into a predetermined length by the cutting unit 500 to obtain the resin sheet 1.

[0135] In addition, in the present embodiment, the cut sheet is described as the resin sheet 1 , but the cut sheet may be omitted, and the resin sheet 1 may be a sheet wound in a roll shape.

[0136] Furthermore, in the manufacturing apparatus 10 , a cooling function may be imparted to the rollers 301 , 302 , and 303 , so that the molding unit 300 can function as a cooling unit.

[0137] By molding the resin composition using the above-described production apparatus 10 , the resin sheet 1 can be stably obtained.

[0138] <<Molding body>>

[0139] The molded product of the present embodiment is a molded product of the resin sheet 1. The molded product is obtained by thermoforming (vacuum forming) the resin sheet 1 and forming it into an arbitrary shape.

[0140] The resin sheet 1 and its molded article can be used as interior materials for vehicles such as automobiles, buses, and railways, transportation equipment such as ships, airplanes, and spacecrafts, and buildings. In particular, since smoke generation is suppressed, they are preferably used as interior materials for transportation equipment requiring higher safety.

[0141] As mentioned above, the resin sheet, the method for producing the resin sheet, and the molded article of the resin sheet of the present invention have been described, but the present invention is not limited thereto, and an arbitrary constituent may be added to the resin composition.

[0142] Example

[0143] Hereinafter, this embodiment will be described in more detail based on examples.

[0144] 1. Preparation of raw materials

[0145] As raw materials for preparing the resin composition, the raw materials shown below were respectively prepared.

[0146] (Chlorinated Polyvinyl Chloride (CPVC))

[0147] Chlorinated polyvinyl chloride (manufactured by Kaneka Co., Ltd., "H-516A"; chlorine concentration 65%, degree of polymerization 800)

[0148] (Stabilizer)

[0149] ·Dimethyltin compounds (manufactured by NITTO KASEI CO., LTD., "AT-1500", dimethyltin mercaptan)

[0150] (Lubricant)

[0151] Hydroxy fatty acids (Emery Oleochemicals, “Loxiol G32”)

[0152] Hydroxy fatty acid (manufactured by Emery Oleochemical Company, "Loxiol G21")

[0153] ·High molecular weight complex ester (manufactured by Emery Oleochemical Company, "VPN963")

[0154] Oxidized polyethylene (manufactured by Honeywell, "A-C629A")

[0155] Oxidized polyethylene (manufactured by Mitsui Chemicals, Inc., "HW220MP"; slightly oxidized, molecular weight 2000)

[0156] (Enhancer)

[0157] ·Acryloyl (MMA / BA / EA) polymer (manufactured by Kaneka Co., Ltd., "FM-50")

[0158] (Processing Aids)

[0159] ·Acryloyl (MMA / BA) polymer (manufactured by Kaneka Co., Ltd., "PA-20"; low molecular weight)

[0160] ·Acryloyl (MMA / BA) polymer (manufactured by Kaneka Co., Ltd., "PA-40"; medium molecular weight)

[0161] (Antioxidant)

[0162] Phenolic antioxidant (manufactured by BASF Japan Ltd., hindered phenolic antioxidant, "Irganox 1010")

[0163] (Zeolite)

[0164] Zeolite (manufactured by TOSOH CORPORATION, "GLS-1000")

[0165] (Flame Retardant)

[0166] Magnesium hydroxide (manufactured by Kyowa Chemical Industry Co., Ltd., "KISUMA5J")

[0167] · Molybdenum compounds (manufactured by Climax, "AMO-W", ammonium octamolybdate)

[0168] 2. Manufacture of resin sheets

[0169] [Example 1]

[0170] [1] First, the raw materials shown in Table 1 among the raw materials described above were stirred and mixed in a super mixer at a temperature of 100° C., and then cooled to 30° C. to prepare a resin composition.

[0171] [2] Next, the prepared resin composition is placed in Figure 2 The molten sheet is obtained by extruding the molten sheet in the extruder 200 of the manufacturing device 10 shown in the figure. Then, the molten sheet is wound around the rollers 301 to 303 and clamped to be flattened, and then cooled in the cooling unit 400. Then, the resin sheet 1 with a thickness of 2.0 mm is obtained by cutting it into a predetermined length in the cutting unit 500.

[0172] [Example 2, Comparative Example 1]

[0173] In the step [1], except that the raw materials used to prepare the resin composition and the mass parts of each raw material contained in the resin composition were as shown in Table 1, the resin sheets 1 of Example 2 and Comparative Example 1 were obtained in the same manner as in Example 1.

[0174] 3. Evaluation of heat resistance of resin sheet

[0175] The heat resistance of the resin sheets of the respective Examples and Comparative Examples was evaluated by the following method.

[0176] <Load deflection temperature>

[0177] About the resin sheet of each Example and Comparative Example, the load deflection temperature was measured by the following method.

[0178] The load deflection temperature (unit: °C) was measured using a HDT tester under a load of 1.80 MPa (A method) in accordance with ISO75-1.

[0179] As a HDT (load deflection temperature) test apparatus, “6M-2” (trade name) manufactured by Toyo Seiki Seisaku-sho, Ltd. was used.

[0180] The evaluation results of the resin sheets of the respective Examples and Comparative Examples obtained as described above are shown in Table 1 below.

[0181] [Table 1]

[0182]

[0183] The resin sheets of Examples 1 and 2 and Comparative Example 1 contain a dimethyltin-based compound and therefore satisfy the REACH regulation.

[0184] Furthermore, it was confirmed that the deflection temperature under load of the resin sheets of Examples 1 and 2 was 80° C. or higher, and that they had excellent heat resistance.

[0185] On the other hand, it was confirmed that the deflection temperature under load of the resin sheet in Comparative Example 1 was lower than 80° C., and that it did not have sufficient heat resistance.

[0186] Industrial Applicability

[0187] The present invention can provide a resin sheet having excellent flame retardancy even when containing a dimethyltin-based compound, and a molded product of the resin sheet.

[0188] Description of Reference Numerals

[0189] 1-Resin sheet

[0190] 10- Manufacturing device,

[0191] 100-Supply Department,

[0192] 200-Extruder,

[0193] 300-forming department,

[0194] 301-Roller,

[0195] 302-Roller,

[0196] 303-Roller,

[0197] 400-Cooling Department,

[0198] 401-Roller,

[0199] 500-cutting part,

[0200] 501-Blade.

Claims

1. A resin sheet, wherein: The resin sheet comprises chlorinated polyvinyl chloride and a dimethyltin compound. The chlorine content of the chlorinated polyvinyl chloride is 60% by mass or more, The deflection temperature under load of the resin sheet measured in accordance with JIS K7191-1A method is 80° C. or higher.

2. The resin sheet according to claim 1, wherein The resin sheet further includes a lubricant having a softening point of 50° C. or higher.

3. The resin sheet according to claim 2, wherein The lubricant is one or more selected from the group consisting of oxidized polyethylene, fatty acid esters, and hydroxy fatty acids.

4. The resin sheet according to claim 1 or 2, wherein The resin sheet further includes a molybdenum-based compound and magnesium hydroxide.

5. The resin sheet according to claim 4, wherein The molybdenum compound is ammonium octamolybdate.

6. The resin sheet according to claim 1 or 2, wherein In the resin sheet, a content of the chlorinated polyvinyl chloride is 70% by mass or more based on the total mass of the resin sheet.

7. The resin sheet according to claim 2 or 3, wherein In the resin sheet, the lubricant content is 40 parts by mass to 65 parts by mass based on 100 parts by mass of the dimethyltin compound.

8. The resin sheet according to claim 4, wherein In the resin sheet, a ratio of a total content of the molybdenum-based compound and the magnesium hydroxide to 100 parts by mass of the chlorinated polyvinyl chloride is 2.0 parts by mass to 10.0 parts by mass.

9. The resin sheet according to claim 1 or 2, wherein The resin sheet further includes at least one of zeolite and an antioxidant.

10. A molded body, wherein This is a molded body of the resin sheet according to claim 1 or 2.

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