Compositions for foam molding, foamed molded articles, and components

Abstract

The present invention provides a foaming composition that exhibits excellent foaming properties, and the resulting molded article (foamed molded article) has excellent strength, thermal expansion properties during combustion, and shape stability after combustion. [Solution] According to the present invention, a foam molding composition is provided which comprises a crosslinkable rubber component, a phosphate-based inorganic compound, a crosslinking agent, and a foaming agent, wherein, per 100 parts by mass of the crosslinkable rubber component, the content of the phosphate-based inorganic compound is 10 to 2000 parts by mass, the content of the crosslinking agent is 0.1 to 30 parts by mass, the content of the foaming agent is 1 to 30 parts by mass, and the content of the thermally expandable layered inorganic compound is less than 5 parts by mass.

Description

Technical Field

[0001] The present invention relates to a composition for foam molding, a foam molded body, and a member.

Background Art

[0002] Synthetic resins are widely used as building materials due to their good moldability and high productivity for mass production of uniform products. On the other hand, synthetic resins are inexpensive when melted or burned and generate gas and smoke. Therefore, from the viewpoint of safety in case of fire, materials with excellent low smoke generation and fire resistance are required. In particular, for door and window sashes, not only flame retardancy of the material but also a material that can prevent flames from spreading outside (back side) of the door or window by maintaining its shape even after combustion is required.

[0003] As a material that meets such requirements, Patent Document 1 describes a rubber composition that can obtain a foam molded body excellent in the balance of thermal expansion property, shape retention property, and flame retardancy and having a small specific gravity, which contains a thermosetting elastomer, a thermal expansion agent, a solid metal (meta) phosphate, an inorganic filler, and a foaming agent.

[0004] In recent years, thermally expandable refractory materials have also been used for battery members. In battery cells such as lithium ion batteries, disasters such as ignition and smoke generation may occur at high temperatures. In order to suppress damage when fire breaks out from the battery cell, a thermally expandable refractory material may be used around the battery cell. For example, Patent Document 2 describes a thermally expandable refractory sheet that contains a matrix resin and thermally expandable graphite, contains 5% by mass or more of the thermally expandable graphite, and specifies the relationship between the thickness of the thermally expandable refractory sheet and the average aspect ratio of the thermally expandable graphite.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

[0006] The thermally expandable graphite described in Patent Document 1 is obtained by treating powders of natural graphite, pyrolysis graphite, etc., with inorganic acids such as sulfuric acid and nitric acid, and strong oxidizing agents such as concentrated nitric acid and permanganate, resulting in a flattened crystalline compound that maintains a graphite layered structure. When exposed to temperatures of approximately 200°C or higher, these expand thermally, for example, more than 100 times in an accordion-like manner. There is a trade-off relationship between this thermal expandability and the dimensional stability that allows it to maintain its shape, and it has not been possible to achieve both properties simultaneously.

[0007] Similarly, the heat-expandable fire-resistant sheet described in Patent Document 2 also failed to achieve both heat expansion and shape stability, which allows it to maintain its shape.

[0008] Therefore, the present invention provides a foaming composition that exhibits excellent foaming properties, and the resulting molded article (foamed molded article) has excellent strength, thermal expansion properties during combustion, and shape stability after combustion. [Means for solving the problem]

[0009] As a result of diligent research to solve the above problems, the inventors of the present invention have found that the above problems can be solved by using a specific compound composition, and have completed the present invention.

[0010] In other words, the present invention provides the following invention. [1] A foam molding composition comprising a crosslinkable rubber component, a phosphate-based inorganic compound, a crosslinking agent, and a foaming agent, wherein, per 100 parts by mass of the crosslinkable rubber component, the content of the phosphate-based inorganic compound is 10 to 2000 parts by mass, the content of the crosslinking agent is 0.1 to 30 parts by mass, the content of the foaming agent is 1 to 30 parts by mass, and the content of the thermally expandable layered inorganic compound is less than 5 parts by mass. [2] The foam molding composition according to [1], wherein the content of the thermally expandable layered inorganic compound is less than 3 parts by mass. [3] The foam molding composition according to [1] or [2], wherein the content of the thermally expandable layered inorganic compound is 0 parts by mass. [4] The foam molding composition according to any one of [1] to [3], wherein the phosphate-based inorganic compound comprises at least one selected from aluminum hydrogen phosphite or disaluminum phosphate. [5] The foam molding composition according to any one of [1] to [4], wherein the content of the phosphoric acid-based inorganic compound is 70 to 1400 parts by mass. [6] The foam molding composition according to any one of [1] to [5], wherein the content of the phosphoric acid-based inorganic compound is 130 to 800 parts by mass. A foamed molded article of a foamed molding composition described in any one of items [7][1] to [6]. A component comprising the foamed molded body described in [8] and [7]. [9] The member described in [8] used for joinery, fireproofing of steel frames, soffit vents, or partition penetration holes.

[10] Components used in batteries, as described in [8]. [Effects of the Invention]

[0011] According to the present invention, it is possible to provide a foam molding composition that exhibits excellent foaming properties, and the resulting molded article (foamed molded article) has excellent strength, thermal expansion properties during combustion, and dimensional stability after combustion. Foamed molded articles made from such a foam molding composition can be used, for example, in building fixtures, fireproofing for steel frames, soffit vents, partition penetration holes, or components used in batteries. Furthermore, since such a foam molding composition also exhibits excellent adhesion to the substrate after thermal expansion, the residue after thermal expansion adheres to the metal or resin substrate of door and window frames, batteries, etc., preventing it from falling off due to the heat, wind, or deformation of the adherend during a fire. [Brief explanation of the drawing]

[0012] [Figure 1]FIG. 1A is a schematic view showing a state of attaching a paste-like refractory composition to the surface of a cylindrical battery cell. FIG. 1B is a schematic view showing a state where the paste-like refractory composition is attached to the surface of the cylindrical battery cell. [Figure 2] It is a figure explaining the test method of adhesiveness after thermal expansion.

Embodiments for Carrying Out the Invention

[0013] Hereinafter, embodiments for carrying out the present invention (hereinafter referred to as "the present embodiment") will be described in detail.

[0014] The composition for foam molding of the present embodiment contains a crosslinkable rubber component, a phosphoric acid-based inorganic compound, a crosslinking agent, and a foaming agent. Hereinafter, each component will be described.

[0015] <Crosslinkable Rubber> The crosslinkable rubber used in the present invention is not particularly limited as long as it can be crosslinked or vulcanized by a crosslinking agent or a vulcanizing agent and the strength is improved. For example, chloroprene rubber (CR), ethylene-propylene-diene rubber (EPDM), styrene-butadiene rubber (SBR), natural rubber (NR), acrylonitrile-butadiene rubber (NBR), silicone rubber, chlorosulfonated polyethylene (CSM), chlorinated polyethylene (CPE), hydrogenated nitrile rubber (HNBR), acrylic rubber (ACM), urethane rubber, butyl rubber, etc. can be mentioned. These crosslinkable rubbers may be used alone or in combination of two or more.

[0016] Among these, chloroprene rubber is preferable from the viewpoint of flame retardancy.

[0017] <Phosphoric Acid-Based Inorganic Compound> The phosphoric acid-based inorganic compound is used as a thermally expandable compound for imparting shape stability that greatly thermally expands and maintains the expanded form when the foam molded body is exposed to a high temperature such as 600°C.

[0018] The phosphoric acid-based inorganic compound preferably contains at least one of phosphoric acid-based compounds, phosphorous acid-based compounds, hypophosphorous acid-based compounds, metaphosphoric acid-based compounds, pyrophosphoric acid-based compounds, and polyphosphoric acid-based compounds.

[0019] Examples of phosphoric acid-based compounds include aluminum monophosphate, sodium monophosphate, potassium monophosphate, calcium monophosphate, zinc monophosphate, aluminum diphosphate, sodium diphosphate, potassium diphosphate, calcium diphosphate, zinc diphosphate, aluminum triphosphate, sodium triphosphate, potassium triphosphate, calcium triphosphate, zinc triphosphate, magnesium triphosphate, ammonium monophosphate, diammonium phosphate, tricalcium phosphate, aluminum phosphate, etc.

[0020] Examples of phosphorous acid-based compounds include aluminum phosphite, aluminum hydrogen phosphite, sodium phosphite, potassium phosphite, calcium phosphite, zinc phosphite, etc.

[0021] Examples of hypophosphorous acid-based compounds include aluminum hypophosphite, sodium hypophosphite, potassium hypophosphite, calcium hypophosphite, zinc hypophosphite, etc.

[0022] Examples of metaphosphoric acid-based compounds include aluminum metaphosphate, sodium metaphosphate, potassium metaphosphate, calcium metaphosphate, zinc metaphosphate, sodium hexametaphosphate, etc.

[0023] Examples of pyrophosphoric acid-based compounds include sodium pyrophosphate, etc.

[0024] Examples of polyphosphoric acid-based compounds include ammonium polyphosphate, melamine-modified ammonium polyphosphate, sodium tripolyphosphate, sodium pentapolyphosphate, sodium tetrapolyphosphate, potassium tripolyphosphate, etc.

[0025] The content of the phosphoric acid-based inorganic compound is 10 to 2000 parts by mass per 100 parts by mass of crosslinkable rubber, preferably 70 to 1400 parts by mass, and more preferably 130 to 800 parts by mass. If the content of the phosphoric acid-based inorganic compound is less than 10 parts by mass, the thermal expansion properties will be poor. If the content of the phosphoric acid-based inorganic compound exceeds 2000 parts by mass, the foaming properties during foam molding will be poor (the hardness of the foamed molded article will be too high). The content of the phosphoric acid-based inorganic compound may be, for example, 10, 50, 70, 100, 130, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, or 2000 parts by mass per 100 parts by mass of crosslinkable rubber, and may be within the range of any two of the values ​​exemplified here.

[0026] The phosphate-based inorganic compound preferably contains a phosphite compound and a phosphate compound, and more preferably contains aluminum hydrogen phosphite or disaluminum phosphate. The inclusion of aluminum hydrogen phosphite or disaluminum phosphate tends to improve the shape stability after thermal expansion.

[0027] These phosphate-based inorganic compounds can be used individually or in combination of two or more.

[0028] <Thermally expandable layered inorganic compound> Thermally expandable layered inorganic compounds may be used to assist the thermal expansion of phosphate-based inorganic compounds, in addition to non-layered phosphate-based inorganic compounds. While there are no particular limitations on thermally expandable compounds other than phosphate-based inorganic compounds, as long as they expand upon heating, examples include thermally expandable layered inorganic compounds and other thermally expandable layered compounds.

[0029] As thermally expandable layered inorganic compounds, any known inorganic compound having a layered structure that expands when heated can be used, such as vermiculite, kaolin, mica, and thermally expandable graphite. Thermally expandable graphite is a crystalline compound that maintains a graphite layered structure, obtained by treating powders of natural graphite, pyrolysis graphite, etc., with inorganic acids such as sulfuric acid and nitric acid, and strong oxidizing agents such as concentrated nitric acid and permanganate. When exposed to temperatures of around 200°C or higher, these expand by more than 100 times, for example. In addition to deacidification treatment, various types of powders of natural graphite, pyrolysis graphite, etc., are available, including those that have undergone neutralization treatment, and all types can be used.

[0030] The thermally expandable graphite used in this invention preferably has an average aspect ratio of 20 or more. An average aspect ratio of 20 or more allows for sufficient filling of the frame structure constituting the opening frame of building components such as fire-resistant resin sashes, and it can also be suitably used for steel frame covering.

[0031] The average aspect ratio is the ratio of the average horizontal diameter to the vertical thickness. Since the thermally expandable graphite used in this invention is generally flat, the vertical direction can be considered to coincide with the thickness direction and the horizontal direction with the diameter direction. Therefore, the aspect ratio is defined as the maximum horizontal dimension divided by the vertical thickness. Then, the aspect ratio is measured for a sufficiently large number of graphite pieces, i.e., 10 or more, and the average value is taken as the average aspect ratio. The average particle size of thermally expandable graphite can also be determined as the average value of the maximum horizontal dimensions. The maximum horizontal dimensions and thickness of thermally expandable graphite can be measured, for example, using a field emission scanning electron microscope (FE-SEM).

[0032] The content of the thermally expandable layered inorganic compound is less than 5 parts by mass, preferably less than 3 parts by mass, and more preferably 0 parts by mass, per 100 parts by mass of the crosslinkable rubber component. If the content of the thermally expandable layered inorganic compound is 5 parts by mass or more, the shape stability after thermal expansion deteriorates. Specifically, the content of the thermally expandable layered inorganic compound is, for example, 0, 0.01, 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, or 4 parts by mass per 100 parts by mass of the crosslinkable rubber component, and may be within the range between any two of the values ​​exemplified here, or less than either of them.

[0033] <Foaming agent> A foaming agent is a substance that generates gas when heated. The foaming agent is a component excluding thermally expandable layered inorganic compounds and phosphoric acid-based inorganic compounds. The foaming agent is used to obtain a foamed molded article from the foaming molding composition (rubber composition) of this embodiment. When the foaming agent is heated to about 200°C (for example, 180-240°C or 200-220°C), gas is generated, and the foaming molding composition is transformed into a foamed molded article. Foaming agents are broadly classified into chemical foaming agents and physical foaming agents, and chemical foaming agents can be classified into organic foaming agents and inorganic foaming agents. The foaming agent used in the foaming molding composition of this embodiment is preferably an organic foaming agent or an inorganic foaming agent.

[0034] Examples of organic blowing agents include azo-based blowing agents such as azodicarbonamide (ADCA), azobisisobutyronitrile, azodiaminobenzene, and azocyclohexylnitrile; nitroso-based blowing agents such as N,N'-dinitrosopentamethylenetetramine and N,N'-dimethylN,N'-dinitrosotelephthalamide; sulfonyl hydrazide-based blowing agents such as p,p'-oxybisbenzenesulfonyl hydrazide (OBSH), benzenesulfonyl hydrazide, toluenesulfonyl hydrazide, and diphenylsulfone-3,3'-disulfonyl hydrazide; and microspheres, melamine, and the like.

[0035] Examples of inorganic foaming agents include ammonium bicarbonate, ammonium carbonate, sodium bicarbonate, ammonium nitrite, and calcium azide.

[0036] Among these, organic blowing agents are more preferred, and azodicarbonamide (ADCA) is even more preferred. These blowing agents may be used alone or in combination of two or more.

[0037] The foaming agent content is 1 to 30 parts by mass, preferably 5 to 25 parts by mass, and more preferably 10 to 20 parts by mass, per 100 parts by mass of the crosslinkable rubber component. If the foaming agent content is less than 1 part by mass, the foaming properties are poor and the material becomes hard. If the foaming agent content exceeds 30 parts by mass, the durability, such as tensile strength, deteriorates. Specifically, the foaming agent content may be, for example, 1, 5, 8, 10, 15, 17, 20, 25, or 30 parts by mass per 100 parts by mass of the crosslinkable rubber component, and may also be within the range of any two of the values ​​exemplified here.

[0038] <Crosslinking agent> The crosslinking agent is not particularly limited as long as it can crosslink or vulcanize rubber, but examples include sulfur, sulfur compounds such as polysulfides, oxime compounds such as p-quinone dioxime and p,p'-dibenzoylquinone oxime; organic peroxide compounds such as t-butyl hydroperoxide, acetylacetone peroxide, and cumene hydroperoxide; magnesium oxide, zinc oxide (1 type), zinc oxide (2 types), and zinc oxide (3 types). These crosslinking agents may be used alone or in combination of two or more types.

[0039] The crosslinking agent preferably contains at least one of zinc oxide and sulfur. For example, zinc oxide is preferred for materials containing chlorine moieties, such as chloroprene rubber (CR) and chlorosulfonated polyethylene rubber (CSM), while sulfur is preferred for EPDM and butyl rubber.

[0040] The crosslinking agent content is 0.1 to 30 parts by mass, preferably 1 to 22 parts by mass, and more preferably 3 to 13 parts by mass, per 100 parts by mass of the crosslinkable rubber component. If the crosslinking agent content is less than 0.1 parts by mass, durability such as tensile strength will be poor. If the crosslinking agent content exceeds 30 parts by mass, foaming properties will be poor and the material will become hard. Specifically, the crosslinking agent content may be, for example, 0.1, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 13, 15, 20, 22, 25, or 30 parts by mass per 100 parts by mass of the crosslinkable rubber component, and may also be within the range of any two of the values ​​exemplified here.

[0041] <Other ingredients> In this embodiment, plasticizers (softeners), antioxidants, processing aids, lubricants, tackifiers, fibrous organic compounds, inorganic compounds (excluding phosphate-based inorganic compounds, thermally expandable layered inorganic compounds, and foaming agents), crosslinking accelerators, carbonizing agents, flame retardants, etc., commonly used in rubber compositions for foam molding, may be used in combination, to the extent that they do not impair the effect.

[0042] <Other inorganic compounds> Other inorganic compounds can take the following shapes: spherical, ellipsoidal, cuboidal, rectangular, random, or fibrous, and may be hollow or solid. The average particle size of particulate inorganic compounds is, for example, 10 to 1000 μm, preferably 20 to 800 μm, more preferably 30 to 500 μm, and even more preferably 40 to 200 μm. "Average particle size" refers to the particle size at 50% of the cumulative value of the particle size distribution determined by laser diffraction / scattering. These may be used individually or in combination of two or more.

[0043] Other inorganic compounds include, for example, metal oxides such as alumina, silica, aluminosilicate, zinc oxide, titanium oxide, calcium oxide, magnesium oxide, iron oxide, tin oxide, antimony oxide, and ferrites; hydrated inorganic substances such as calcium hydroxide, magnesium hydroxide, aluminum hydroxide, and hydrotalcite; metal carbonates such as basic magnesium carbonate, calcium carbonate, magnesium carbonate, zinc carbonate, strontium carbonate, and barium carbonate; calcium salts such as calcium sulfate and calcium silicate; glass beads, silica-based balloons, aluminum nitride, boron nitride, silicon nitride, carbon black, graphite, carbon balloons, charcoal powder, various metal powders, potassium titanate, magnesium sulfate, lead zirconate titanate, aluminum borate, molybdenum sulfide, silicon carbide, zinc borate, various magnetic powders, fly ash, inorganic hollow fillers, perlite, obsidian, perlite, pitchstone, diatomaceous earth, dewatered sludge, boron, sodium tetraborate hydrate (borax), and the like. These may be used individually or in combination of two or more. Of these, it is preferable to include aluminum hydroxide from the viewpoint of flame retardancy.

[0044] <Plasticizer (softener)> Examples of softening agents include, but are not limited to, rapeseed oil, cottonseed oil, palm oil, coconut oil, peanut oil, sub(factis), tall oil, pine tar, process oils (paraffinic oils, naphthenic oils, and aromatic process oils), carboxylic acid ester plasticizers (phthalates, adipicates, sebacates, maleates, fumarates, trimelliticates, citrates, oleates, ricinoleates, stearates, glycolates, etc.), phosphate ester plasticizers (tritolyl phosphate, triisopropylphenyl phosphate, etc.), sulfur factis, and others. Softening agents may be used individually or in combination of two or more.

[0045] Crosslinking accelerators are used to promote the crosslinking of rubber and are not particularly limited, but examples include thiuram compounds such as tetramethylthiuram disulfide, tetrabutylthiuram disulfide, tetramethylthiuram monosulfide, and dipentamethylenethiuram tetrasulfide; thiazole compounds such as 2-mercaptobenzothiazole and dibenzothiazole disulfide; carbamate compounds such as zinc dimethyldithiocarbamate and zinc dibutyldithiocarbamate; aldehyde amine compounds such as n-butyraldehyde aniline; sulfenamide compounds such as N-cyclohexyl-2-benzothiadylsulfenamide; guanidine compounds such as diorthotrylguanidine and diorthonitrileguanidine; thiourea compounds such as thiocarbanilide, diethylthiourea, and trimethylthiourea; and metal compounds such as zinc oxide. Crosslinking accelerators may be used individually or in combination of two or more of these. The amount of crosslinking accelerator used is preferably 0.1 to 15 parts by mass, and more preferably 0.2 to 10 parts by mass, per 100 parts by mass of crosslinkable rubber component.

[0046] The carbonizing agent generally has the effect of forming a thick foamed layer with superior heat insulation properties by dehydrating and carbonizing itself along with the carbonization of the binder due to fire. The carbonizing agent is not particularly limited as long as it has this effect, and the same carbonizing agents as those used in known foamed refractory materials can be used. Examples include polyhydric alcohols such as pentaerythritol, dipentaerythritol, and trimethylolpropane, as well as starch and casein. These can be used one or more at a time. Among these, dipentaerythritol is particularly preferred because it has excellent dehydration cooling effect and foamed layer formation effect.

[0047] Examples of flame retardants include organophosphorus compounds such as tricresyl phosphate and diphenylcresyl phosphate; chlorine compounds such as chlorinated polyphenyls, chlorinated polyethylenes, diphenyl chloride, triphenyl chloride, pentachloride fatty acid esters, perchloropentacyclodecane, chlorinated naphthalene, and tetrachlorophthalic anhydride; antimony compounds such as antimony trioxide and antimony pentachloride; phosphorus compounds such as phosphorus trichloride and phosphorus pentachloride; and other inorganic compounds such as zinc borate and sodium borate.

[0048] When both a carbonizing agent and a flame retardant are included, the weight ratio is preferably 2:8 to 8:2, and more preferably 3:7 to 7:3. Furthermore, the total amount of the carbonizing agent and flame retardant is preferably 10 to 500 parts by mass per 100 parts by mass of the matrix polymer component.

[0049] The foam molding composition may contain a low molecular weight polyhydric alcohol compound. The content of the low molecular weight polyhydric alcohol compound is less than 30 parts by mass, preferably less than 10 parts by mass, and more preferably 0 parts by mass, per 100 parts by mass of the crosslinkable rubber component. Specifically, the content of the low molecular weight polyhydric alcohol compound may be, for example, 0, 5, 10, 15, 20, 25, or 29 parts by mass per 100 parts by mass of the crosslinkable rubber component, and may be within the range between any two of the values ​​exemplified herein, or less than either of them.

[0050] Low molecular weight polyhydric alcohol compounds are compounds that have two or more hydroxyl groups in their molecule and have a molecular weight of 500 or less. Examples of low molecular weight polyhydric alcohols include ethylene glycol, diethylene glycol, propylene glycol, glycerin, butylene glycol, 1,4-butanediol, 1,6-hexanediol, trimethylolpropane, pentaerythritol, dipentaerythritol, tripentaerythritol, sorbitol, inositol, mannitol, glucose, and fructose. The molecular weight of low molecular weight polyhydric alcohols is, for example, 50 to 500, such as 50, 100, 150, 200, 250, 300, 350, 400, 450, and 500, and may also be within the range of any two of the values ​​exemplified here.

[0051] The foam molding composition of the present invention can be obtained, for example, by blending and kneading each component in a predetermined proportion. The method for producing a foam molded article according to another embodiment is not particularly limited, but includes a blending step to obtain the foam molding composition, a molding step to mold the foam molding composition into a desired shape, a foaming step to heat the foaming agent above its foaming start temperature to cause foaming, and a crosslinking step to heat the foaming agent above its crosslinking start temperature to cause crosslinking. The foaming step and the crosslinking step may be performed as separate steps or simultaneously.

[0052] In another embodiment, the component comprises a foamed molded body. The component may consist solely of the foamed molded body, or it may be composed of other components as appropriate. The foamed molded body or component may be used for component fittings, fireproofing of steel frames, soffit vents, or partition penetration holes. The foamed molded body or component may also be used to cover batteries.

[0053] For example, the component may have components other than the foam molded body laminated onto it, or a base material may be provided on at least one surface of the foam molded body. The base material may be a combustible material layer, a semi-noncombustible material layer, or a noncombustible material layer. The thickness of the base material is not particularly limited, but is for example 5 μm to 1 mm. Examples of materials used for the combustible material layer include one or more types of materials such as cloth, paper, wood, and resin film. When the base material is a semi-noncombustible material layer or a noncombustible material layer, examples of materials used include metals and inorganic materials, and more specifically, woven or nonwoven fabrics made of glass fibers, ceramic fibers, carbon fibers, and graphite fibers. Alternatively, composite materials of these fibers and metals may be used, for example, aluminum glass cloth is preferred. Furthermore, an adhesive layer may be laminated onto the foam molded body. The use of an adhesive layer makes it possible to easily adhere the foam molded body to other components. The adhesive layer may be provided on top of the base material or may be formed directly on the surface of the foam molded body. Alternatively, a double-sided adhesive tape having adhesive layers on both sides of the base material may be used. In this case, one adhesive layer is attached to the foamed molded body, and the other adhesive layer is used to attach it to another component.

[0054] Conventional mixing equipment for kneading the compound includes known mixers, Banbury mixers, kneader mixers, and double-roll mixers. Conventional molding equipment for molding the kneaded compound includes known press molding, extrusion molding, and calendering. Generally, the compound is extruded into the product shape using a rubber extruder, then introduced into a crosslinking tank, and crosslinking and foaming can be performed by heating with hot air, a fluidized bed, microwaves, or other means. The shape of the foamed molded product can be designed as appropriate for the application, such as in the form of a sheet or tape.

[0055] <Other Embodiments> Furthermore, a battery according to another embodiment of the present invention comprises a component made of the above composition. The battery typically has at least one battery cell 3, and the foamed molded body is attached to the battery as a component 1 such as a protective material or fire-resistant material (Figure 1). The foamed molded body is typically attached to the surface of the battery cell. The battery may have one battery cell or two or more battery cells.

[0056] Battery cells include, but are not limited to, lithium-ion batteries, lithium-ion polymer batteries, nickel-metal hydride batteries, lithium-sulfur batteries, nickel-cadmium batteries, nickel-iron batteries, nickel-zinc batteries, sodium-sulfur batteries, lead-acid batteries, and air batteries.

[0057] Batteries are used in, for example, small electronic devices such as mobile phones and smartphones, laptop computers, automobiles, power tools, and the like, but are not limited to these. [Examples]

[0058] The present invention will be described in more detail below with reference to examples, but these examples are not intended to limit the present invention. The unit of measurement for the amount of each substance used below is parts by mass. The raw materials used in the examples and comparative examples are as follows.

[0059] [Examples and Comparative Examples] The mixture, prepared according to the proportions shown in the table, was kneaded uniformly using a 3L pressure kneader (temperature: 100°C, time: 10 minutes) and then a roller machine (temperature: 40°C, time: 10 minutes) to form a sheet. Next, the resulting sheet was foamed and crosslinked at 200°C for 4 minutes to obtain a foamed molded body. Its physical properties were evaluated, and the results are shown in the table.

[0060] 1.Material [Cross-linkable rubber] • Chloroprene rubber (CR): Denka Co., Ltd. "S-40V" • EPDM rubber (EPDM): Mitsui Chemicals, Inc. "EPT3092M" • Butyl rubber: "BUTYL268" manufactured by JSR Corporation [Phosphate-based inorganic compounds] • Aluminum hydrogen phosphite (Hydrogen Hydrogen Phosphite AL): Manufactured by Taihei Chemical Industry Co., Ltd. "NSF" • Dicatrix aluminum phosphate (Dicatrix AL): Manufactured by Taihei Chemical Industry Co., Ltd. Sodium phosphite (Na Phosphite): Manufactured by Taihei Chemical Industry Co., Ltd. • Ammonium polyphosphate (NH4 polyphosphate): "HP-APP II" manufactured by SCM Industrial Chemical Co., Ltd. [Thermally expandable layered inorganic compound] • Thermally expandable graphite: ADT501 (aspect ratio 25.2): ADT Corporation's "ADT501" with an aspect ratio of 25.2 [Foaming agent] • Azodicarbonamide (ADCA): "Cell Microphone C-1" manufactured by Sankyo Chemical Co., Ltd. • Sodium bicarbonate: "Cellmicron 417" manufactured by Sankyo Chemical Co., Ltd. [Crosslinking agent] • Sulfur: Manufactured by Hosoi Chemical Industry Co., Ltd.

[0061] 2. Various evaluations The following measurements and evaluations were performed on the foamed molded articles of each example and comparative example. The results are shown in the table.

[0062] The details of the evaluation method are as follows:

[0063] <Foaming (E hardness)> The foamed molded bodies of the examples and comparative examples were prepared as test specimens measuring 30 mm (length) x 30 mm (width) x 10 mm (thickness), and their Shore E hardness was measured at a load of 1 kg in an environment of 21°C according to JIS K6253. Based on the measured values, the hardness was determined according to the following evaluation criteria. [Evaluation Criteria] ◎: Shore E hardness is less than 25. ○: Shore E hardness is 25 or higher and less than 30. △: Shore E hardness is 30 or higher, but less than 35. ×: The Shore E hardness is 35 or higher.

[0064] <Durability (Tensile Strength)> The foamed molded bodies of the examples and comparative examples were prepared as 2 mm thick test specimens, punched out using a dumbbell-shaped die (Type 3) in accordance with JIS K6251, and the tensile strength of the test specimens was measured at a tensile speed of 500 mm / min. The results were judged according to the following criteria. ◎: Tensile strength of 2 MPa or more ○: Tensile strength of 1 MPa or more, but less than 2 MPa. △: Tensile strength of 0.5 MPa or more, but less than 1 MPa. ×: Tensile strength is less than 0.5 [MPa]

[0065] <Thermal expansion properties> The foamed molded articles of the examples and comparative examples were prepared as test specimens with a thickness of 2 mm, a length of 30 mm, and a width of 30 mm. These specimens were heat-treated at 600°C for 0.5 hours, and their expansion ratio was measured. Specifically, the volume expansion ratio was calculated by dividing the volume after heat treatment by the volume before heat treatment, and the thermal expansion properties were determined according to the following criteria. The volume was calculated by measuring the pressure, width, and length. ◎: Volume expansion ratio of 10 times or more ○: Volume expansion ratio is 5 times or more, but less than 10 times. △: Volume expansion ratio is 2 times or more, but less than 5 times. ×: Volume expansion ratio is less than 2 times

[0066] <Shape stability after thermal expansion> After evaluating the thermal expansion properties described above, a three-point bending test fixture (upper pressing tip R1mm and width 80mm, lower two-point support R1mm, width 80mm, support distance 20mm) was used to measure the strength (three-point bending fracture strength) of the specimen after thermal expansion when it was fractured at a compression rate of 50mm / min. The shape stability after thermal expansion was then determined according to the following criteria. ◎: Three-point bending fracture strength of 30[N] or higher ○: Three-point bending fracture strength of 20[N] or more, but less than 30[N]. △: Three-point bending fracture strength of 5[N] or more and less than 20[N] ×: Three-point bending fracture strength is less than 5 [N]

[0067] <Adhesion after thermal expansion> Using the specimens from the examples and comparative examples, a specimen measuring 30 mm (length) x 30 mm (width) x 2 mm (thickness) was prepared and placed on a calcium silicate board. This was then left in an atmosphere maintained at 600°C for 0.5 hours to allow thermal expansion. As shown in Figure 2, the surface of the calcium silicate board to which the sample was attached was fixed parallel to the vertical direction. The thermally expanded specimen was then pressed against the boundary between the calcium silicate board and the expanded specimen using the upper pressing jig (tip radius 1 mm and width 80 mm) of a three-point bending test jig at a speed of 50 mm / min, and the adhesion strength was measured when the thermally expanded specimen was peeled off. Based on the adhesion strength, the adhesion after thermal expansion was determined according to the following criteria. If the thermally expanded specimen fell before the upper pressing jig was pressed against it, the adhesion strength was set to 0.0 [N]. ◎:1.5[N] or more ○: 1.0[N] or greater, less than 1.5[N] △: 0.5[N] or greater, less than 1.0[N] ×: Less than 0.5 [N]

[0068] [Table 1]

[0069] [Table 2]

[0070] [Table 3]

[0071] [Table 4] [Explanation of symbols]

[0072] 1: Components 3: Battery cell

Claims

1. It contains a crosslinkable rubber component, a phosphate-based inorganic compound, a crosslinking agent, and a foaming agent. With respect to 100 parts by mass of the crosslinkable rubber component, The content of the aforementioned phosphoric acid-based inorganic compound is 10 to 2000 parts by mass. The content of the crosslinking agent is 0.1 to 30 parts by mass. The foaming agent content is 1 to 30 parts by mass. The content of the thermally expandable layered inorganic compound is less than 5 parts by mass. Composition for foam molding.

2. The foam molding composition according to claim 1, wherein the content of the thermally expandable layered inorganic compound is less than 3 parts by mass.

3. The foam molding composition according to claim 1, wherein the content of the thermally expandable layered inorganic compound is 0 parts by mass.

4. The foam molding composition according to claim 1, wherein the phosphate-based inorganic compound comprises at least one selected from aluminum hydrogen phosphite or disaluminum phosphate.

5. The foam molding composition according to claim 1, wherein the content of the phosphate-based inorganic compound is 70 to 1400 parts by mass.

6. The foam molding composition according to claim 1, wherein the content of the phosphate-based inorganic compound is 130 to 800 parts by mass.

7. A foamed molded article of a foaming molding composition according to any one of claims 1 to 6.

8. A member comprising the foamed molded body described in claim 7.

9. The member according to claim 8, used for joinery, fireproofing of steel frames, soffit ventilation openings, or partition penetration holes.

10. A component according to claim 8, used in a battery.

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