Resin sheet and molded article

Abstract

To provide a resin sheet that can satisfy both impact resistance and flame resistance, and a molded article of the resin sheet.SOLUTION: A resin sheet contains chlorinated polyvinylchloride, dimethyl tin-based compound, acrylic reinforcement material, and flame retarder, and chlorine content of the chlorinated polyvinylchloride is 60 mass% or more. In the resin sheet, the content of the acrylic reinforcement material for the content 100 pts.mass of the chlorinated polyvinylchloride is 6.0 pts.mass or more and less than 8.0 pts.mass, the content of the flame retarder for the content 100 pts.mass of the chlorinated polyvinylchloride is 4.0 pts.mass or more, and the content of the acrylic reinforcement material for the content 1 pt.mass of the flame retarder is 0.8 pt.mass or more and less than 1.5 pts.mass.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a resin sheet and a molded article. [Background technology]

[0002] For example, as shown in Patent Document 1, resin sheets obtained by molding vinyl chloride resin compositions are used as interior materials for vehicles such as automobiles, buses, and trains, transportation equipment such as ships and aircraft, and buildings.

[0003] Such vinyl chloride resin compositions are excellent in processability, and the resin sheets obtained from them are excellent in impact resistance, chemical resistance, flame retardancy, etc., and therefore are preferably used as the interior materials.

[0004] When such interior materials are applied to transportation equipment such as aircraft, in particular, it is required to impart impact resistance to the interior materials, and it is known to add an acrylic reinforcing material to the vinyl chloride resin composition as a reinforcing material to achieve this function. It is also known to impart flame retardancy to the interior materials and suppress smoke generation, and it is known to add a molybdenum compound as a flame retardant to the vinyl chloride resin composition to achieve this function.

[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. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-265373 Summary of the Invention [Problem to be solved by the invention]

[0007] However, when an acrylic reinforcing material is added to a vinyl chloride resin composition, there is a problem that the composition is resistant to impact but flammable, whereas when a molybdenum compound is added as a flame retardant to a vinyl chloride resin composition, there is a problem that the composition is resistant to flame but vulnerable to impact.

[0008] 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 that can achieve both impact resistance and flame retardancy, and a molded article of the resin sheet. [Means for solving the problem]

[0009] In order to solve the above problems, the present invention employs the following configuration. [1] A resin sheet comprising chlorinated polyvinyl chloride, a dimethyltin compound, an acrylic reinforcing material, and a flame retardant, wherein the chlorine content of the chlorinated polyvinyl chloride is 60% by mass or more, the content of the acrylic reinforcing material per 100 parts by mass of the chlorinated polyvinyl chloride in the resin sheet is 6.0 parts by mass or more and less than 8.0 parts by mass, the content of the flame retardant in the resin sheet is 4.0 parts by mass or more and the content of the acrylic reinforcing material per 1 part by mass of the flame retardant in the resin sheet is 0.8 parts by mass or more and less than 1.5 parts by mass. [2] The acrylic reinforcing material has a weight average molecular weight of 1.0 × 10 5 Over 1.0 x 10 7 The resin sheet according to [1], which is the following multi-component acrylic rubber-based resin: [3] The resin sheet according to [1] or [2], wherein the flame retardant is one or more selected from the group consisting of molybdenum compounds and metal hydroxides. [4] The resin sheet according to [3], wherein the molybdenum compound is ammonium octamolybdate. [5] The resin sheet according to any one of [1] to [4], further comprising an acrylic processing aid. [6] The acrylic processing aid has a weight average molecular weight of 1.0 × 10 5 Over 5.0 x 10 6 The resin sheet according to [5], which is the following multi-component acrylic resin: [7]. A resin sheet according to [5] or [6], wherein the total content of the acrylic reinforcing material and the acrylic processing aid per 1 part by mass of the flame retardant is 1.3 parts by mass or more and less than 2.0 parts by mass. [8] The resin sheet according to any one of [1] to [7], wherein the content of the chlorinated polyvinyl chloride in the resin sheet is 70 mass % or more relative to the total mass of the resin sheet. [9] The resin sheet according to any one of [1] to [8], further comprising an antioxidant.

[10] A molded article of the resin sheet according to any one of [1] to [9]. [Effects of the Invention]

[0010] According to the present invention, there are provided a resin sheet that can achieve both impact resistance and flame retardancy, and a molded article of the resin sheet. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a cross-sectional view schematically illustrating an example of a resin sheet according to an embodiment of the present invention. [Figure 2] FIG. 2 is a side view schematically showing an example of a manufacturing apparatus for the resin sheet shown in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, the present embodiment will be described in detail with reference to the drawings.

[0013] <<Resin sheet>> The resin sheet 1 of this embodiment contains chlorinated polyvinyl chloride, a dimethyltin-based compound, an acrylic reinforcing material, and a flame retardant, and is characterized in that the chlorine content of the chlorinated polyvinyl chloride is 60 mass% or more, the content of the acrylic reinforcing material in the resin sheet is 6.0 parts by mass or more and less than 8.0 parts by mass per 100 parts by mass of the chlorinated polyvinyl chloride, the content of the flame retardant in the resin sheet is 4.0 parts by mass or more per 100 parts by mass of the chlorinated polyvinyl chloride, and the content of the acrylic reinforcing material in the resin sheet is 0.8 parts by mass or more and less than 1.5 parts by mass per part by mass of the flame retardant. This resin sheet 1 is both impact resistant and flame retardant.

[0014] Hereinafter, as an example of the resin sheet 1 of this embodiment, a resin sheet containing chlorinated polyvinyl chloride, a dimethyltin-based compound, an acrylic reinforcing material, an acrylic processing aid, a flame retardant, a lubricant, and an antioxidant will be described.

[0015] FIG. 1 is a cross-sectional view schematically illustrating an example of a resin sheet according to one embodiment of the present invention.

[0016] <Chlorinated polyvinyl chloride> The resin sheet 1 contains chlorinated polyvinyl chloride as its main material. This can suppress the smoke generation and heat generation of the resin sheet 1. Furthermore, when the resin sheet 1 is molded by extrusion molding, the extrudability of the resin composition is improved, and the resin sheet 1 can be molded to have a uniform thickness. Therefore, the resulting resin sheet 1 is molded to have excellent appearance.

[0017] Chlorinated polyvinyl chloride is a polymer having a plurality of repeating units represented by -CHCl-CHCl-.

[0018] The chlorine content, i.e., chlorine concentration, of chlorinated polyvinyl chloride is set to 60% by mass or more, preferably 61% by mass to 68% by mass, and more preferably 63% by mass to 67% by mass. By setting the chlorine content of chlorinated polyvinyl chloride to the above lower limit or more, the effect of improving heat resistance can be obtained. By setting the chlorine content of chlorinated polyvinyl chloride to the above upper limit or less, the effect of improving processability when producing a resin sheet can be obtained.

[0019] The number-average degree of polymerization of chlorinated polyvinyl chloride is preferably 400 or more and 1200 or less, and more preferably 600 or more and 1000 or less. By setting the number-average degree of polymerization of chlorinated polyvinyl chloride to the above-mentioned lower limit or more, 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 the above-mentioned upper limit or less, the processability of the resin sheet 1 can be further improved.

[0020] In the resin sheet 1, the content of chlorinated polyvinyl chloride relative to the total mass of the resin sheet 1 is preferably 70 mass% or more, more preferably 75 mass% to 90 mass% or less, and even more preferably 78 mass% to 85 mass% or less, thereby further improving the effect of including chlorinated polyvinyl chloride in the resin sheet 1.

[0021] <Dimethyltin compounds> The resin sheet 1 contains a dimethyltin compound as a stabilizer, which can prevent the resin sheet 1 from being decomposed or discolored by heat or light.

[0022] As used herein, the term "dimethyltin compound" refers to a compound containing a structure in which two methyl groups are covalently bonded to a tin atom. In Europe, the REACH regulation, which controls chemical substances to protect human health and the environment, is in effect. Dimethyltin compounds are compounds that comply with the REACH regulation.

[0023] In the resin sheet 1, the content of the dimethyltin compound 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, thereby making it possible to further suppress decomposition and discoloration of the resin sheet 1 due to heat or light while maintaining the mechanical strength of the resin sheet 1.

[0024] <Acrylic reinforcement> The resin sheet 1 contains an acrylic reinforcing material, which mainly improves the impact resistance of the resin sheet 1 and further improves the moldability of the resin sheet 1 during molding.

[0025] Examples of acrylic reinforcing materials include chlorinated polyethylene, ethylene-vinyl acetate copolymer, and multi-component acrylic rubber resins, among which multi-component acrylic rubber resins are preferably used, which can further improve the durability of the resin sheet 1.

[0026] Multi-component acrylic rubber resins (acrylic polymers) are copolymers of acrylic acid esters such as methyl acrylate, ethyl acrylate, butyl acrylate, and octyl acrylate as the main component, with these monomers mixed with 2-chloroethyl vinyl ether, methyl vinyl ketone, acrylic acid, styrene, acrylonitrile, butadiene, etc., and examples thereof include "Kane Ace FM" manufactured by Kaneka Corporation and "Kureha KM-334" manufactured by Kureha Chemical Industry Co., Ltd.

[0027] The weight average molecular weight of the acrylic reinforcing material is 1.0 × 10 5 Over 1.0 x 10 7 Preferably, it is 1.0 x 10 or less. 6 Over 7.0 x 10 6 More preferably, it is:

[0028] The acrylic reinforcing material has a weight average molecular weight of 1.0 x 10 5 Over 1.0 x 10 7The following multi-component acrylic rubber-based resins are particularly preferred.

[0029] In the resin sheet 1, the content of the acrylic reinforcing material relative to 100 parts by mass of the chlorinated polyvinyl chloride is 6.0 parts by mass or more and less than 8.0 parts by mass, preferably 6.0 parts by mass or more and 7.5 parts by mass or less, and more preferably 6.0 parts by mass or more and 7.0 parts by mass or less, thereby further improving the impact resistance of the resin sheet 1.

[0030] <Acrylic processing aids> The resin sheet 1 may contain an acrylic processing aid such as a multi-component acrylic resin, which can further improve the moldability of the resin sheet 1 during molding.

[0031] Examples of acrylic processing aids include acrylic ester copolymers (e.g., high molecular weight copolymers of acrylic esters) such as 2-ethylhexyl acrylate-butyl acrylate copolymer, and copolymers of methyl methacrylate and acrylic esters.

[0032] The weight average molecular weight of the acrylic processing aid is 1.0 x 10 5 Over 5.0 x 10 6 Preferably, it is 7.0 x 10 or less. 5 Over 4.0 x 10 6 More preferably, it is 1.3×10 or less. 6 Over 3.0 x 10 6 It is even more preferable that:

[0033] The acrylic processing aid has a weight-average molecular weight of 1.0 x 10 5 Over 5.0 x 10 6 The following multi-component acrylic resins are particularly preferred.

[0034] In the resin sheet 1, the content of the acrylic processing aid relative to 100 parts by mass of the chlorinated polyvinyl chloride is preferably 1.0 part by mass or more and 15.0 parts by mass or less, more preferably 2.0 parts by mass or more and 10.0 parts by mass or less, and even more preferably 2.0 parts by mass or more and 5.0 parts by mass or less, thereby further improving the formability of the resin sheet 1 during molding.

[0035] The addition of the acrylic processing aid to the resin sheet 1 may be omitted depending on the combination of constituent materials contained in the resin sheet 1, etc.

[0036] In the resin sheet 1, the total content of the acrylic reinforcing material and the acrylic processing aid relative to 100 parts by mass of the chlorinated polyvinyl chloride is preferably from 0.1 to 20 parts by mass, more preferably from 1 to 15 parts by mass, and even more preferably from 5 to 13 parts by mass, relative to 100 parts by mass of the chlorinated polyvinyl chloride content. This can further improve the impact resistance of the resin sheet 1, and can further improve the formability of the resin sheet 1 during molding.

[0037] <Flame retardant> The resin sheet 1 contains a flame retardant, which improves the flame retardancy of the resin sheet 1 and suppresses combustion of the resin sheet 1, thereby improving its safety.

[0038] Examples of flame retardants include antimony compounds such as antimony trioxide; metal hydroxides such as aluminum hydroxide and magnesium hydroxide; phosphorus compounds such as cresyl diphenyl phosphate, trischloroethyl phosphate, trischloropropyl phosphate and trisdichloropropyl phosphate; nitrogen-containing compounds such as melamine compounds and guanidine compounds; and halogen compounds such as chlorinated paraffins, and these can be used alone or in combination of two or more.

[0039] Furthermore, the resin sheet 1 may contain a molybdenum-based compound as a flame retardant, which further improves the flame retardancy of the resin sheet 1 and further reduces the smoke generation of the resin sheet 1, thereby realizing low toxic gas properties of the resin sheet 1 and further improving its safety.

[0040] In this specification, the term "molybdenum-based compound" refers to a compound containing molybdenum as a constituent element. Similarly, "antimony-based compounds" refer to compounds containing antimony as a constituent atom, "phosphorus-based compounds" refer to compounds containing phosphorus as a constituent element, and "halogen-based compounds" refer to compounds containing halogen as a constituent element.

[0041] The molybdenum-based compound is contained in the resin sheet 1 as particles, more specifically, as secondary particles including primary particles of the molybdenum-based compound and primary particles of a flame retardant other than the molybdenum-based compound. The average particle size of these particles is not particularly limited, but is preferably set to, for example, about 1.0 μm or more and 50.0 μm or less, more preferably about 3.0 μm or more and 15.0 μm or less. This allows the molybdenum-based compound to be dispersed more uniformly in the resin sheet 1 without agglomeration.

[0042] The shape of the particles containing a molybdenum-based compound is not particularly limited, and may be any of spherical, elliptical, flat, acicular, etc. In this specification, the particle diameter of the particles refers to the maximum diameter of particles having each shape, and for example, in the case of a spherical particle, it refers to the diameter.

[0043] The molybdenum compound is not particularly limited, but 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 molybdenum dialkyldithiophosphate. These compounds may be used alone or in combination of two or more. Among these, ammonium molybdate, zinc molybdate, and molybdenum trioxide are preferred, and ammonium molybdate is more preferred.

[0044] Examples of ammonium molybdate include ammonium octamolybdate and ammonium heptamolybdate, and these can be used alone or in combination of two or more, with ammonium octamolybdate being preferred, which can further enhance the effect of including a molybdenum-based compound in the resin sheet 1.

[0045] The particles containing the molybdenum compound may have a coupling agent having a hydrocarbon group bonded to the surface thereof.

[0046] As the coupling agent, for example, a silane-based coupling agent, a titanium-based coupling agent, an aluminum-based coupling agent, or the like can be used.

[0047] As described above, examples of flame retardants include molybdenum compounds and metal hydroxides, and one or more of these can be used in combination, thereby further improving the flame retardancy of the resin sheet 1.

[0048] In the resin sheet 1, the content of the flame retardant per 100 parts by mass of the chlorinated polyvinyl chloride is 4 parts by mass or more, preferably 0.1 to 20.0 parts by mass, more preferably 0.5 to 18.0 parts by mass, and even more preferably 3.0 to 14.0 parts by mass, thereby further improving the flame retardancy of the resin sheet 1.

[0049] In the resin sheet 1, the content of the acrylic reinforcing material per part by mass of the flame retardant is preferably 0.8 parts by mass to 1.5 parts by mass, more preferably 0.8 parts by mass to 1.3 parts by mass, and even more preferably 0.8 parts by mass to 1.1 parts by mass, which allows the resin sheet 1 to have both impact resistance and flame retardancy.

[0050] In the resin sheet 1, the total content of the acrylic reinforcing material and the acrylic processing aid per part by mass of the flame retardant is preferably 1.3 parts by mass or more and less than 2.0 parts by mass, more preferably 1.3 parts by mass or more and 1.7 parts by mass or less, and even more preferably 1.4 parts by mass or more and 1.6 parts by mass or less, thereby enabling the resin sheet 1 to achieve both impact resistance and flame retardancy.

[0051] <Lubricant> The resin sheet 1 may contain a lubricant. This can further suppress a decrease in the heat resistance (heat distortion temperature) of the resin sheet 1, which is caused by the inclusion of a dimethyltin-based compound in the resin sheet 1. In addition, when the resin sheet 1 is molded, it can exhibit excellent slip properties against molds, rollers, and the like, thereby further improving moldability.

[0052] The softening point of the lubricant is preferably 50° C. or higher, more preferably 60° C. or higher, even more preferably 80° C. or higher, and particularly preferably 82° C. or higher. This makes it possible to further suppress a decrease in the heat resistance of the resin sheet 1.

[0053] Examples of lubricants include polyethylene oxide, high-density polyethylene oxide, polymeric composite esters, fatty acid esters, hydroxy fatty acids, metal soaps, higher aliphatic alcohols, and synthetic waxes. Among these, one or a combination of two or more can be used, with polyethylene oxide, high-density polyethylene oxide, and polymeric composite esters being preferred.

[0054] Examples of the type of oxidized polyethylene include a highly oxidized type, a slightly oxidized type, and an acid-modified type.

[0055] The weight average molecular weight of the polyethylene oxide is preferably 1000 or more and 3000 or less, more preferably 1500 or more and 2500 or less, and even more preferably 1800 or more and 2300 or less. This can further improve the effect of the lubricant contained in the resin sheet 1.

[0056] Examples of fatty acid esters include butyl stearate and triglycerides.

[0057] Examples of hydroxy fatty acids include hydroxystearic acid.

[0058] In the resin sheet 1, the content of the lubricant relative to 100 parts by mass of the chlorinated polyvinyl chloride is preferably 0.05 parts by mass or more and 5.00 parts by mass or less, and more preferably 0.30 parts by mass or more and 4.00 parts by mass or less, thereby further improving the effect of the lubricant contained in the resin sheet 1.

[0059] In the resin sheet 1, the content of the lubricant relative to 100 parts by mass of the dimethyltin-based compound is preferably 40 parts by mass to 65 parts by mass, more preferably 41 parts by mass to 55 parts by mass, and even more preferably 43 parts by mass to 52 parts by mass, thereby further improving the effect of the lubricant contained in the resin sheet 1.

[0060] The addition of a lubricant to the resin sheet 1 may be omitted depending on the combination of constituent materials contained in the resin sheet 1, etc.

[0061] <Antioxidants> The resin sheet 1 may contain an antioxidant, which can further prevent oxidation of the constituent materials contained in the resin sheet 1. Furthermore, if the resin composition contains a molybdenum compound, there is a risk that thermal decomposition of the chlorinated polyvinyl chloride may be induced by heating during extrusion using an extruder. On the other hand, if the resin sheet 1 contains an antioxidant, the thermal decomposition of the chlorinated polyvinyl chloride can be further suppressed.

[0062] Examples of antioxidants include phosphite-based antioxidants (phosphorus-based antioxidants) such as trisnonylphenyl phosphite, tridecyl phosphite, and diphenyldecyl phosphite; hindered phenol-based antioxidants; phenol-based antioxidants such as alkylated monophenols and alkylated hydroquinones; and amine-based antioxidants such as alkylated tert-butylphenylenediamine and hydroxylamine. These antioxidants can be used alone or in combination of two or more, with phenol-based antioxidants being preferred. This can further enhance the effects of the antioxidant contained in the resin sheet 1.

[0063] Examples of hindered phenol antioxidants include 2,2'-methylenebis(4-methyl-6-tert-butylphenol), pentaerythritol tetrakis[3-(3',5'-di-tert-butyl-4'-hydroxyphenyl)propionate], and tetrakis[methylene-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate]methane.

[0064] In the resin sheet 1, the content of the antioxidant relative to 100 parts by mass of the chlorinated polyvinyl chloride is preferably 0.01 to 5.0 parts by mass, more preferably 0.1 to 3.0 parts by mass, and even more preferably 0.3 to 2.0 parts by mass, which can further suppress the induction of thermal decomposition of the chlorinated polyvinyl chloride.

[0065] The addition of an antioxidant to the resin sheet 1 may be omitted depending on the combination of constituent materials contained in the resin sheet 1, etc.

[0066] <Zeolite> The resin sheet 1 may contain zeolite. If the resin composition contains a molybdenum-based compound, there is a risk that thermal decomposition of the chlorinated polyvinyl chloride may be induced by heating during extrusion using an extruder. On the other hand, by containing zeolite in the resin sheet 1, thermal decomposition of the chlorinated polyvinyl chloride can be further suppressed.

[0067] The zeolite is not particularly limited, but 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, and these can be used alone or in combination of two or more.

[0068] The zeolite is contained as particles in the resin sheet 1. The average particle size of the particles is not particularly limited, but is preferably set to, for example, about 1.0 μm or more and 50.0 μm or less, and more preferably about 5.0 μm or more and 30.0 μm or less. This allows the zeolite to be dispersed more uniformly in the resin sheet 1 without agglomeration.

[0069] In this specification, the term "average particle size" refers to the particle size at 50% cumulative accumulation of particles, and may be referred to as "D50." In this specification, the particle size of particles having a shape other than spherical is determined by a laser diffraction / scattering particle size distribution measurement method.

[0070] The shape of the zeolite-containing particles is not particularly limited, and may be any of spherical, elliptical, flat, and needle-like shapes.

[0071] In the resin sheet 1, the content of zeolite relative to 100 parts by mass of chlorinated polyvinyl chloride is preferably 0.1 part by mass or more and 5.0 parts by mass or less, and more preferably 0.2 part by mass or more and 1.0 part by mass or less, thereby making it possible to further suppress the induction of thermal decomposition of chlorinated polyvinyl chloride.

[0072] The addition of zeolite to the resin sheet 1 may be omitted depending on the combination of constituent materials contained in the resin sheet 1, etc.

[0073] The resin sheet 1 preferably contains at least one of an antioxidant and a zeolite. By adding both an antioxidant and a zeolite to the resin sheet 1 as in the present embodiment, the thermal decomposition of chlorinated polyvinyl chloride can be further suppressed.

[0074] <Pigments> The resin sheet 1 may contain a pigment as a coloring material.

[0075] The pigment is selected depending on the required coloring (color tone), and examples thereof include organic pigments such as azo pigments, benzimidazolone pigments, diarylide pigments, quinacridone pigments, isoindolinone pigments, vat pigments, phthalocyanine pigments, and dioxane pigments, as well as inorganic pigments such as titanium yellow and yellow lead, and these pigments may be used alone or in combination of two or more.

[0076] 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 required coloring (tone), but is preferably 0.01 to 8.00 parts by mass, and more preferably 0.05 to 6.00 parts by mass, which can further improve the effect of including the pigment in the resin sheet 1.

[0077] In the resin sheet 1, the primary particles of the molybdenum-based compound and the secondary particles containing the molybdenum-based compound have a whitish color. Therefore, when the resin sheet 1 contains a colored pigment, the spotted pattern caused by the particles containing the molybdenum-based compound is more clearly visible, and in such cases, the resin sheet 1 of the present invention is more preferably used.

[0078] Addition of a pigment to the resin sheet 1 can be omitted if there is no need to color the resin sheet 1.

[0079] The resin sheet 1 contains the above-mentioned chlorinated polyvinyl chloride, dimethyltin-based compound, acrylic reinforcing material, and flame retardant.

[0080] In addition to the above-mentioned chlorinated polyvinyl chloride, dimethyltin-based compound, acrylic reinforcing material, and flame retardant, the resin sheet 1 may also contain the above-mentioned acrylic processing aid, lubricant, antioxidant, zeolite, and pigment.

[0081] In addition to the above-mentioned chlorinated polyvinyl chloride, dimethyltin-based compounds, acrylic reinforcing materials, acrylic processing aids, flame retardants, lubricants, antioxidants, zeolites, and pigments, the resin sheet 1 may also contain, for example, ultraviolet absorbers, plasticizers, antistatic agents, etc.

[0082] <Characteristics of resin sheets> 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 0.8 mm or more and 5.0 mm or less, thereby making it possible to further reduce the weight of the resin sheet 1 and further improve its strength.

[0083] The resin sheet 1 exhibits the following impact resistance: In other words, when a weight with a load of 5 kg is dropped from a height of 30 cm onto the resin sheet 1 in a DuPont impact test, the resin sheet 1 does not deform upon impact.

[0084] Furthermore, the resin sheet 1 exhibits the following flame retardancy: when the resin sheet 1 is burned in accordance with the heat release test specified in ASTM E906, the maximum heat release rate measured within 5 minutes after the ignition of the resin sheet 1 is 65 kW / m 2 The total heat generated in the two minutes after the ignition of the resin sheet 1 is 65 kW·min / m or less. 2 The following is the result.

[0085] Furthermore, in the smoke generation test specified in ASTM E662, i.e., the smoke density test during combustion using an NBS smoke chamber, the resin sheet 1 preferably has a smoke density (Ds) of 200 or less, more preferably 150 or less, after burning for 4.0 minutes. This allows the resin sheet 1 to further suppress smoke generation.

[0086] <<Manufacturing method for resin sheets>> The resin sheet 1 can be produced, for example, as follows. First, before describing the method for manufacturing the resin sheet 1, a manufacturing apparatus 10 used for manufacturing the resin sheet 1 will be described.

[0087] Fig. 2 is a side view schematically showing an example of the resin sheet manufacturing apparatus shown in Fig. 1. Note that Fig. 2 shows some parts in an exaggerated manner and is significantly different from the actual dimensions.

[0088] The flat resin sheet 1 shown in FIG. 1 is produced by molding a resin composition containing chlorinated polyvinyl chloride, a dimethyltin-based compound, an acrylic reinforcing material, and a flame retardant using a production apparatus 10.

[0089] As shown in FIG. 2, the manufacturing apparatus 10 includes a supply section 100, an extruder 200, a molding section 300, a cooling section 400, and a cutting section 500.

[0090] The supply unit 100 stores the 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.

[0091] The extruder 200 extrudes the resin composition supplied from the supply unit 100 into a sheet by an extrusion method. The extruder 200 has a flow path through which the resin composition passes and a screw provided in the flow path. The resin composition is extruded into a sheet by the rotation of the screw.

[0092] 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) provided in the extruder 200 and the rotation of the screw. As a result, the resin composition supplied from the supply section 100 to the extruder 200 is continuously heated. The resin composition is usually heated to a heating temperature of about 120°C or higher and 200°C or lower, or if the temperature is higher, about 170°C or higher and 200°C or lower.

[0093] In this embodiment, the forming unit 300 has three rollers 301, 302, and 303. The rollers 301 to 303 are arranged side by side in the vertical direction and are configured to rotate independently of each other. The extruded sheet material is wrapped around these rollers 301 to 303, and the sheet material is sandwiched between the rollers 301 to 303 and formed to a uniform thickness.

[0094] The cooling section 400 has a plurality of cooling rollers 401. Each cooling roller 401 comes into contact with one side of the formed sheet, thereby cooling the sheet.

[0095] The cutting section 500 has a blade section 501, and cuts the sheet to a predetermined length using the blade section 501.

[0096] Using such a manufacturing apparatus 10, the resin sheet 1 can be manufactured, for example, as follows.

[0097] [1] First, a dimethyltin compound, an acrylic reinforcing material, and a flame retardant are added to a powder containing chlorinated polyvinyl chloride, and, if necessary, one or more selected from the group consisting of an acrylic processing aid, a lubricant, and an antioxidant are further added. Thereafter, the mixture is kneaded using a super mixer, a Henschel mixer, a blender, or the like to prepare a resin composition.

[0098] [2] Next, the prepared resin composition is molded using a manufacturing apparatus 10 to obtain a resin sheet 1.

[0099] In the manufacturing method using the manufacturing apparatus 10 described above, the resin composition supplied from the supply unit 100 is continuously extruded into a sheet material by the extruder 200, and the surface is flattened and molded to a predetermined thickness by the molding unit 300. The resin sheet 1 is then cooled in contact with the cooling unit 400 and cut to a predetermined length by the cutting unit 500, thereby obtaining the resin sheet 1.

[0100] In this embodiment, the resin sheet 1 is described as being a cut sheet, but the cutting of the sheet may be omitted and the resin sheet 1 may be a sheet wound into a roll.

[0101] In addition, in the manufacturing apparatus 10, the rollers 301, 302, and 303 may be provided with a cooling function, and the molding section 300 may function as a cooling section.

[0102] By molding the resin composition using the manufacturing apparatus 10 as described above, the resin sheet 1 can be obtained stably.

[0103] <<Molded body>> The molded article of this embodiment is a molded article of a resin sheet 1. The molded article is obtained by thermoforming (vacuum forming) the resin sheet 1 into a desired shape.

[0104] The resin sheet 1 and its molded body can be applied to interior materials for vehicles such as automobiles, buses, and trains, transportation equipment such as ships, aircraft, and spacecraft, buildings, etc., and is particularly preferred as an interior material for transportation equipment that requires higher safety because of its suppressed smoke generation.

[0105] The resin sheet, the method for producing the resin sheet, and the molded body of the resin sheet of the present invention have been described above, but the present invention is not limited thereto, and any component may be added to the resin composition. [Example]

[0106] The present embodiment will be described in more detail below based on examples. <Preparing raw materials> The following raw materials were prepared for preparing the resin compositions.

[0107] (chlorinated polyvinyl chloride) Chlorinated polyvinyl chloride (Kaneka Corporation, "H-516A"; chlorine concentration 65%, degree of polymerization 800)

[0108] (Dimethyltin compounds) Dimethyltin compounds (manufactured by Nitto Kasei Co., Ltd., "AT-1500", dimethyltin mercapto)

[0109] (acrylic reinforcement) Acrylic (MMA / BA / EA) polymer (Kaneka Corporation, "FM-50")

[0110] (Acrylic processing aid) Acrylic (MMA / BA) polymer (Kaneka Corporation, "PA-20"; low molecular weight) Acrylic (MMA / BA) polymer (Kaneka Corporation, "PA-40"; medium molecular weight)

[0111] (Flame retardant) Magnesium hydroxide (Kyowa Chemical Industry Co., Ltd., "KISUMA 5J") Molybdenum compounds (Climax Corporation, "AMO-W", ammonium octamolybdate)

[0112] (lubricant) Oxidized polyethylene (Honeywell, "A-C629A") High-density polyethylene oxide (Honeywell, "A-C316A") Polymer complex ester (Emery Oleochemicals, "VPN963")

[0113] (antioxidant) Phenolic antioxidant (BASF Japan, hindered phenolic antioxidant, "Irganox 1010") Zeolite (Tosoh Corporation, "GLS-1000") <Manufacturing of resin sheets> [Example 1] [1] First, the raw materials shown above, as shown in Table 1, were mixed in the amounts shown in Table 1 in a super mixer while stirring, while heating to 100°C, and then cooled to 30°C to prepare a resin composition.

[0114] [2] Next, the prepared resin composition was placed in the extruder 200 provided in the manufacturing apparatus 10 shown in Fig. 2 and extruded to obtain a molten sheet. The molten sheet was then wrapped around and clamped between rollers 301 to 303 to be flattened, and then cooled in the cooling section 400. The resin sheet 1 was then cut to a predetermined length in the cutting section 500 to obtain a resin sheet 1 having a thickness of 2.0 mm.

[0115] [Examples 2 to 4, Comparative Examples 1 to 7] Resin sheets 1 of Examples 2 to 4 and Comparative Examples 1 to 7 were obtained in the same manner as in Example 1, except that in step [1], the raw materials used in preparing the resin composition, and the mass parts of each raw material contained in the resin composition, were as shown in Table 1.

[0116] <Evaluation of resin sheets> <Impact resistance: Evaluation by DuPont impact test> The resin sheets produced in Examples 1 to 4 and Comparative Examples 1 to 7 were cut into 50 mm squares, and impacts were applied from a height of 30 cm with a load of 5 kg in a DuPont impact test. The occurrence of cracks in the samples was confirmed, and the impact resistance was evaluated according to the following criteria. [Evaluation criteria] A: No cracks or fractures have occurred that would cause the sample to break into two or more pieces. B: The sample was cracked into two or more pieces.

[0117] <Flame retardancy: OSU heat release test> The flame retardancy of the resin sheets produced in Examples 1 to 4 and Comparative Examples 1 to 7 was evaluated in accordance with the heat release test specified in ASTM E906. Specifically, the resin sheets produced in Examples 1 to 4 and Comparative Examples 1 to 6 were cut into 75 mm (length) × 75 mm (width) × 3.0 mm (thickness) to prepare test specimens. The surfaces of the test specimens were ignited and burned. Inside the device, air was flowed from the bottom to the top of the test specimen heating section at a constant flow rate, and thermopiles were installed on the upstream and downstream sides of the air flow, and the thermoelectromotive force difference between the upstream and downstream thermopiles was measured. The heat generation amount (kW) per 1 mV of thermoelectromotive force was calculated in advance by calibration, and the heat generation rate per unit area of ​​the test specimen (kW / m 2 ) was calculated and the flame retardancy was evaluated according to the following criteria. [Evaluation criteria] A: The maximum heat release rate measured within 5 minutes of ignition of the test specimen is 65 kW / m 2 or less, and the total heat generation rate within 2 minutes after ignition of the test specimen is 65kW·min / m 2 It was as follows. B: The maximum heat release rate measured within 5 minutes of ignition of the test specimen is 65 kW / m 2 and / or the total heat release rate within 2 minutes after ignition of the test specimen is 65 kW·min / m 2 It was super.

[0118] The evaluation results of the resin sheets of the Examples and Comparative Examples obtained as described above are shown in Table 1 below.

[0119] [Table 1]

[0120] [Table 2]

[0121] In the resin sheets of Examples 1 to 4, the content of acrylic reinforcing material per 100 parts by mass of chlorinated polyvinyl chloride was 6 parts by mass or more and less than 8 parts by mass, the content of flame retardant per 100 parts by mass of chlorinated polyvinyl chloride was 4 parts by mass or more, and the content of acrylic reinforcing material per 1 part by mass of flame retardant was 0.8 parts by mass or more and less than 1.5 parts by mass, and therefore it was confirmed that impact resistance and flame retardancy were compatible.

[0122] On the other hand, it was confirmed that the resin sheet of Comparative Example 1 did not have sufficient impact resistance because the content of acrylic reinforcing material was less than 6 parts by mass per 100 parts by mass of chlorinated polyvinyl chloride. Furthermore, it was confirmed that the resin sheets of Comparative Examples 2 to 4 did not have sufficient impact resistance because the content of the acrylic reinforcing material per 1 part by mass of the flame retardant was less than 0.8 parts by mass. Furthermore, the resin sheet of Comparative Example 5 was found to have insufficient flame retardancy because the content of the acrylic reinforcing material was 8 parts by mass or more per 100 parts by mass of chlorinated polyvinyl chloride and the content of the acrylic reinforcing material was 1.5 parts by mass or more per 1 part by mass of flame retardant. Furthermore, it was confirmed that the resin sheet of Comparative Example 6 did not have sufficient impact resistance because the content of the acrylic reinforcing material was less than 6 parts by mass relative to 100 parts by mass of the chlorinated polyvinyl chloride content. Furthermore, the resin sheet of Comparative Example 7 was found to have insufficient flame retardancy because the flame retardant content was less than 4 parts by mass per 100 parts by mass of chlorinated polyvinyl chloride and the acrylic reinforcing material content was 1.5 parts by mass or more per 1 part by mass of flame retardant. [Industrial Applicability]

[0123] The present invention can provide a resin sheet that can achieve both impact resistance and flame retardancy, and a molded article of the resin sheet. [Explanation of symbols]

[0124] 1. Resin sheet 10...Manufacturing equipment 100...supply section 200···Extruder 300...Molding section 301 Roller 302 Roller 303 Roller 400...Cooling section 401 Roller 500...cutting section 501...Blade part

Claims

1. A resin sheet, the resin sheet contains chlorinated polyvinyl chloride, a dimethyltin-based compound, an acrylic reinforcing material, and a flame retardant; The chlorine content of the chlorinated polyvinyl chloride is 60% by mass or more, In the resin sheet, the content of the acrylic reinforcing material is 6.0 parts by mass or more and less than 8.0 parts by mass relative to 100 parts by mass of the chlorinated polyvinyl chloride, In the resin sheet, the content of the flame retardant is 4.0 parts by mass or more relative to 100 parts by mass of the chlorinated polyvinyl chloride, In the resin sheet, the content of the acrylic reinforcing material relative to 1 part by mass of the flame retardant is 0.8 parts by mass or more and less than 1.5 parts by mass.

2. The acrylic reinforcing material has a weight average molecular weight of 1.0×10 ５ Above 1.0 x 10 ７ The resin sheet according to claim 1, which is a multi-component acrylic rubber-based resin:

3. The resin sheet according to claim 1 , wherein the flame retardant is one or more selected from the group consisting of molybdenum compounds and metal hydroxides.

4. The resin sheet according to claim 3 , wherein the molybdenum compound is ammonium octamolybdate.

5. The resin sheet according to claim 1 , further comprising an acrylic processing aid.

6. The acrylic processing aid has a weight average molecular weight of 1.0 × 10 ５ Above 5.0 x 10 ６ The resin sheet according to claim 5, which is a multi-component acrylic resin:

7. 6. The resin sheet according to claim 5, wherein the total content of the acrylic reinforcing material and the acrylic processing aid relative to 1 part by mass of the flame retardant is 1.3 parts by mass or more and less than 2.0 parts by mass. The resin sheet.

8. The resin sheet according to claim 1 , wherein the content of the chlorinated polyvinyl chloride in the resin sheet is 70% by mass or more with respect to the total mass of the resin sheet.

9. The resin sheet according to claim 1 , further comprising an antioxidant.

10. A molded article of the resin sheet according to any one of claims 1 to 9.

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