Heat insulation sash and method for manufacturing same

Abstract

The purpose of the present invention is to achieve a heat insulation sash which is excellent in material recyclability, heat insulation properties, and lightweight properties. In a heat insulation sash (10), a frame body (1) and synthetic resin foam particles (2A) each include first and second polyvinyl chloride-based resins as a base material resin. The chlorine content of a first polyvinyl chloride-based resin included in the frame body (1) is lower than the chlorine content of a second polyvinyl chloride-based resin included in the synthetic resin foam particles (2A), and the expansion ratio of the synthetic resin foam particles (2A) is 10-50 times.

Description

Insulated sash and manufacturing method thereof

[0001] The present invention relates to an insulating sash and a method for manufacturing the same.

[0002] A sash frame is integrally provided in the opening of a building such as a house or office building, and a sash is disposed within the opening of the sash frame so that it can be closed or opened / closed. Traditionally, metal extrusions have been widely used as sash frames. Windows constructed with these metal sash frames have excellent airtightness, but suffer from poor thermal insulation. Furthermore, metal sash frames are heavy, placing a heavy burden on installers. To solve this problem, synthetic resin sash frames have been adopted.

[0003] Recently, as a measure to save energy and combat global warming, high levels of thermal insulation and airtightness have been required for sashes and sash frames. Accordingly, low-emissivity double-glazing has been applied, and high-insulation glass in which a low-thermal-conductivity gas is sealed in the middle layer of double-glazing has been applied. Furthermore, insulating sashes have been proposed in which insulating material is inserted into the interior (hollow portion) of a sash frame made of synthetic resin. Such insulating sashes are disclosed, for example, in Patent Documents 1 to 3.

[0004] The insulated sash of Patent Document 1 has a structure in which an insulating material made of synthetic resin foam particles is disposed inside a frame, and a pipe is disposed for supplying heated gas into the insulating material. The insulated sash of Patent Document 1 requires the frame to be filled with foam particles, which makes installation difficult and reduces workability. Patent Document 2, therefore, discloses a co-extrusion molding technique in which the frame and a core material made of synthetic resin foam are continuously disposed inside the frame by thermal fusion, which significantly improves installation. However, the insulated sash of Patent Document 2 does not clearly indicate the expansion ratio of the synthetic resin foam core material, leaving an issue of whether sufficient insulating performance can be imparted to the frame.

[0005] On the other hand, Patent Document 3 describes a technology for forming a frame made of an extrusion molded body of a resin composition containing a rigid polyvinyl chloride resin and a core material made of a foamed extrusion molded body of a polystyrene resin having an expansion ratio of 2 or more by co-extrusion molding. As a result, the insulated sash of Patent Document 3 can significantly improve the ease of installation and can impart insulating performance to the frame. However, the insulated sash of Patent Document 3 lacks material recyclability because the frame and core material are made of different resins.

[0006] Japanese Patent Laid-Open No. 3-244778 Japanese Patent Laid-Open No. 2019-100120 Japanese Patent Laid-Open No. 2021-127678

[0007] The insulating sashes disclosed in Patent Documents 1 to 3 do not yet have satisfactory performance in terms of material recyclability, insulating properties, and light weight, and further improvements have been desired.

[0008] An object of one aspect of the present invention is to realize an insulating sash that is excellent in terms of material recyclability, insulating properties, and light weight.

[0009] In order to solve the above problems, the inventors of the present application conducted extensive research into the problems and discovered that an insulated sash that satisfies performance requirements in terms of material recyclability, thermal insulation, and light weight can be realized by (1) using a polyvinyl chloride resin as the base resin for a hollow extrusion (frame) and a resin foam (core) filled or disposed within the hollow extrusion, (2) making the chlorine content of the first polyvinyl chloride resin contained in the hollow extrusion lower than the chlorine content of the second polyvinyl chloride resin contained in the resin foam, and (3) setting the expansion ratio of the resin foam (core) within a specific numerical range, thereby arriving at the present invention.

[0010] That is, one aspect of the present invention is an insulating sash comprising a hollow extrusion and a resin foam filled or disposed within the hollow extrusion, wherein both the hollow extrusion and the resin foam contain polyvinyl chloride resin as a base resin, and the polyvinyl chloride resin contained in the hollow extrusion is a first polyvinyl chloride resin and the polyvinyl chloride resin contained in the resin foam is a second polyvinyl chloride resin, wherein the chlorine content of the first polyvinyl chloride resin is lower than the chlorine content of the second polyvinyl chloride resin, and the foam expansion ratio of the resin foam is 10 to 50 times.

[0011] Another aspect of the present invention is a manufacturing method of an insulated sash, comprising a hollow extrusion and a resin foam filled or disposed within the hollow extrusion, wherein both the hollow extrusion and the resin foam contain polyvinyl chloride resin as a base resin, and the polyvinyl chloride resin contained in the hollow extrusion is a first polyvinyl chloride resin and the polyvinyl chloride resin contained in the resin foam is a second polyvinyl chloride resin, and the chlorine content of the first polyvinyl chloride resin is less than the chlorine content of the second polyvinyl chloride resin. and an extrusion-foaming step of supplying a second resin composition containing the second polyvinyl chloride resin and a foaming agent to a second extruder, melting and kneading the second resin composition, extruding the second resin composition from the second extruder into the hollow portion of the hollow extrusion, and extruding and foaming the second resin composition within the hollow extrusion.

[0012] Furthermore, one aspect of the present invention includes a method for manufacturing an insulated sash, which includes a hollow extrusion and a resin foam filled or disposed within the hollow extrusion, wherein both the hollow extrusion and the resin foam contain polyvinyl chloride resin as a base resin, wherein the polyvinyl chloride resin contained in the hollow extrusion is a first polyvinyl chloride resin and the polyvinyl chloride resin contained in the resin foam is a second polyvinyl chloride resin, and the chlorine content of the first polyvinyl chloride resin is lower than that of the second polyvinyl chloride resin, the method comprising: a resin foam manufacturing step of obtaining the resin foam consisting of one selected from the group consisting of foamed particles containing the second polyvinyl chloride resin, a bead foam molded using the foamed particles, and an extruded foam molded product containing the second polyvinyl chloride resin; and an insertion step of inserting the resin foam obtained in the resin foam manufacturing step into the hollow portion of the hollow extrusion.

[0013] According to one aspect of the present invention, an insulating sash that is excellent in material recyclability, insulating properties, and light weight can be realized.

[0014] Fig. 1 is a cross-sectional view showing the schematic configuration of a frame provided in an insulated sash according to a first embodiment of the present invention. Fig. 2 is a cross-sectional view showing the schematic configuration of an insulated sash according to a first embodiment of the present invention. Fig. 3 is a perspective view showing the schematic configuration of an insulated sash according to a second embodiment of the present invention. Fig. 4 is an overall structural diagram showing the schematic configuration of a manufacturing device for manufacturing an insulated sash according to a second embodiment of the present invention by co-extrusion. Fig. 5 is a perspective view showing the schematic configuration of an insulated sash according to a third embodiment of the present invention. Fig. 6 is an overall structural diagram showing the schematic configuration of a frame manufacturing device used in a frame manufacturing process.

[0015] An embodiment of the present invention will be described below, but the present invention is not limited thereto. The present invention is not limited to the respective configurations described below, and various modifications are possible within the scope of the claims. Furthermore, embodiments or examples obtained by combining the technical means disclosed in different embodiments or examples are also included in the technical scope of the present invention. Furthermore, new technical features can be formed by combining the technical means disclosed in each embodiment. All academic literature and patent documents described in this specification are incorporated herein by reference. Furthermore, unless otherwise specified in this specification, "A to B" representing a numerical range means "A or more (including A and greater than A) and B or less (including B and less than B)."

[0016] An insulated sash according to one embodiment of the present invention is an insulated sash comprising a hollow member and a resin foam filled or disposed within the hollow member, wherein both the hollow member and the resin foam contain a polyvinyl chloride resin as a base resin, the polyvinyl chloride resin contained in the hollow member being a first polyvinyl chloride resin and the polyvinyl chloride resin contained in the resin foam being a second polyvinyl chloride resin, the chlorine content of the first polyvinyl chloride resin being lower than the chlorine content of the second polyvinyl chloride resin, and the expansion ratio of the resin foam being 10 to 50. This allows for the realization of an insulated sash that is excellent in material recyclability, insulation, and light weight.

[0017] Furthermore, one embodiment of the present invention provides a method for manufacturing an insulated sash, the method comprising: a hollow extrusion; and a resin foam filled or disposed within the hollow extrusion; wherein the hollow extrusion and the resin foam both contain polyvinyl chloride resin as a base resin; and wherein the polyvinyl chloride resin contained in the hollow extrusion is a first polyvinyl chloride resin and the polyvinyl chloride resin contained in the resin foam is a second polyvinyl chloride resin. The chlorine content of the first polyvinyl chloride resin is lower than that of the second polyvinyl chloride resin, and the method includes the steps of: supplying a first resin composition containing the first polyvinyl chloride resin to a first extruder and melt-kneading it, and continuously extruding a long hollow extrusion molded product to become the hollow profile from a first die installed at the tip of the first extruder; and supplying a second resin composition containing the second polyvinyl chloride resin and a foaming agent to a second extruder and melt-kneading it, and extruding it from the second extruder into the hollow portion of the hollow extrusion molded product and extrusion-foaming it within the hollow portion. According to this manufacturing method, since the insulated sash is manufactured by co-extrusion as described above, it is possible to manufacture an insulated sash that is excellent in material recyclability, insulation properties, and light weight while maintaining ease of installation.

[0018] Furthermore, according to another embodiment of the present invention, there is provided a method for manufacturing an insulated sash, which comprises a hollow extrusion and a resin foam filled or disposed within the hollow extrusion, wherein both the hollow extrusion and the resin foam contain polyvinyl chloride resin as a base resin, wherein the polyvinyl chloride resin contained in the hollow extrusion is a first polyvinyl chloride resin and the polyvinyl chloride resin contained in the resin foam is a second polyvinyl chloride resin, and the chlorine content of the first polyvinyl chloride resin is lower than that of the second polyvinyl chloride resin, and the method comprises: a resin foam manufacturing step of obtaining the resin foam consisting of one selected from the group consisting of foamed particles containing the second polyvinyl chloride resin, a bead foam molded using the foamed particles, and an extruded foam molded product containing the second polyvinyl chloride resin; and an insertion step of inserting the resin foam obtained in the resin foam manufacturing step into the hollow portion of the hollow extrusion. According to this manufacturing method, an insulated sash that is excellent in material recyclability, heat insulation properties, and light weight can be manufactured. The insulated sash and manufacturing method thereof according to this embodiment will be described in detail below.

[0019] [First Embodiment] Fig. 1 is a cross-sectional view showing the schematic configuration of a frame 1 provided in an insulated sash according to this embodiment. Fig. 2 is a cross-sectional view showing the schematic configuration of an insulated sash 10 according to this embodiment.

[0020] As shown in Fig. 2, the insulating sash 10 according to this embodiment is configured to allow a double-glazed window to slide, the double-glazed window including two glass panes G and a packing P interposed between the glass panes G. The insulating sash 10 according to this embodiment is not limited to the combined glass window shown in Fig. 2, but can be applied to known windows. The shape of the insulating sash 10 is not limited to the shape shown in Fig. 2, but can be appropriately set depending on the window to which the insulating sash 10 is applied.

[0021] The insulating sash 10 comprises a frame 1 (hollow extrusion) and synthetic resin foam particles 2A (resin foam). The frame 1 is a long, hollow frame that extends in the sliding direction of the window. In a cross section perpendicular to the sliding direction of the window, the hollow portion of the frame 1 is divided into five chambers. The synthetic resin foam particles 2A are filled or disposed in each of the five chambers of the hollow portion of the frame 1.

[0022] Both the frame 1 and the expanded synthetic resin particles 2A contain polyvinyl chloride resin as a base resin. In this specification, the polyvinyl chloride resin contained in the frame 1 is referred to as the "first polyvinyl chloride resin," and the polyvinyl chloride resin contained in the expanded synthetic resin particles 2A is referred to as the "second polyvinyl chloride resin."

[0023] In this way, according to the heat insulating sash 10, the base resin of the frame 1 and the base resin of the expanded synthetic resin particles 2A are made of the same material, and therefore the material is highly recyclable.

[0024] Furthermore, in order to improve the expansion ratio of the synthetic resin foamed particles 2A and maintain high thermal insulation performance for the insulating sash 10, the chlorine content of the first polyvinyl chloride resin contained in the frame 1 is low and the chlorine content of the second polyvinyl chloride resin contained in the synthetic resin foamed particles 2A is high. That is, in the insulating sash 10, the chlorine content of the first polyvinyl chloride resin contained in the frame 1 is lower than the chlorine content of the second polyvinyl chloride resin contained in the synthetic resin foamed particles 2A.

[0025] (First Polyvinyl Chloride Resin) There are no particular limitations on the first polyvinyl chloride resin contained in the frame 1, and any conventionally known polyvinyl chloride resin can be used. In consideration of cost and moldability, a general-purpose polyvinyl chloride resin (PVC) is preferably used as the first polyvinyl chloride resin.

[0026] The chlorine content of the first polyvinyl chloride resin is preferably less than 60% by weight, more preferably 57% or less. The chlorine content is the content of chlorine atoms in 100% by weight of the first polyvinyl chloride resin. If the chlorine content of the first polyvinyl chloride resin is 60% by weight or more, not only will the cost increase unnecessarily, but molding and shaping tend to become difficult. The chlorine contents of polyvinyl chloride resins and chlorinated polyvinyl chloride resins are measured in accordance with JIS K7229 Method B.

[0027] Examples of the first polyvinyl chloride resin include (a) vinyl chloride homopolymer, (b) copolymer of vinyl chloride monomer and monomer having an unsaturated bond copolymerizable with the vinyl chloride monomer, (c) graft copolymer obtained by graft copolymerizing vinyl chloride monomer onto a polymer other than vinyl chloride monomer or onto a copolymer other than vinyl chloride monomer, etc. One or more of these polymers can be used as the first polyvinyl chloride resin.

[0028] In (b), the monomer having an unsaturated bond copolymerizable with vinyl chloride monomer is not particularly limited as long as it is copolymerizable with vinyl chloride monomer, and examples thereof include α-olefins such as ethylene, propylene, and butylene; vinyl esters such as vinyl acetate and vinyl propionate; vinyl ethers such as butyl vinyl ether and cetyl vinyl ether; acrylic esters such as methyl acrylate, ethyl acrylate, and butyl acrylate; methacrylic esters such as methyl methacrylate, ethyl methacrylate, and butyl methacrylate; aromatic vinyls such as styrene and α-methylstyrene; and N-substituted maleimides such as N-phenylmaleimide and N-cyclohexylmaleimide. These may be used alone or in combination.

[0029] In (c), the polymer other than vinyl chloride monomer or copolymer other than vinyl chloride monomer is not particularly limited as long as it is graft polymerized or graft copolymerized with vinyl chloride monomer, and examples thereof include ethylene-vinyl acetate copolymer, ethylene-vinyl acetate-carbon monoxide copolymer, ethylene-ethyl acrylate copolymer, ethylene-butyl acrylate-carbon monoxide copolymer, ethylene-methyl methacrylate copolymer, ethylene-propylene copolymer, acrylonitrile-butadiene copolymer, polyurethane, chlorinated polyethylene, chlorinated polypropylene, etc. These may be used alone or in combination of two or more.

[0030] The first polyvinyl chloride resin may contain a chlorinated polyvinyl chloride resin (CPVC) obtained by chlorinating polyvinyl chloride resin (PVC). The content of the chlorinated polyvinyl chloride resin relative to the first polyvinyl chloride resin may be appropriately set within the above-mentioned range of the chlorine content.

[0031] (Second Polyvinyl Chloride Resin) Any polyvinyl chloride resin can be used as the second polyvinyl chloride resin contained in the synthetic resin foamed particles 2A, as long as it has a higher chlorine content than the first polyvinyl chloride resin contained in the frame 1 and can achieve an expansion ratio of 10 to 50. From the viewpoint of improving the expansion ratio of the synthetic resin foamed particles 2A and maintaining high thermal insulation performance for the insulating sash 10, it is particularly preferable that the second polyvinyl chloride resin contain a chlorinated polyvinyl chloride resin.

[0032] From the viewpoint of ensuring foamability, the chlorine content of the second polyvinyl chloride resin is preferably 60% by weight to 75% by weight, and more preferably 64% by weight to 70% by weight. The chlorine content is the content of chlorine atoms in 100% by weight of the second polyvinyl chloride resin. The higher the chlorine content of the second polyvinyl chloride resin, the higher the expansion ratio tends to be. However, if the chlorine content is too high, the melt viscosity increases, and the foam processability of the polyvinyl chloride resin tends to be significantly impaired. By ensuring that the chlorine content of the second polyvinyl chloride resin is within the above-mentioned numerical range, an expansion ratio of 10 to 50 times can be achieved without significantly impairing the foam processability.

[0033] The chlorinated polyvinyl chloride resins used include various polyvinyl chloride resins that have been chlorinated. Examples of the polyvinyl chloride resins to be chlorinated include homopolymers of vinyl chloride and copolymers of vinyl chloride with other copolymerizable monomers such as ethylene, propylene, vinyl acetate, allyl chloride, allyl glycidyl ether, acrylic esters, and vinyl ethers.

[0034] The average degree of polymerization of the raw material polyvinyl chloride resin before chlorination is not particularly limited, but the lower limit is preferably 300 or more, more preferably 400 or more. On the other hand, the upper limit is preferably 3,000 or less, more preferably 1,500 or less. In particular, the average degree of polymerization of the chlorinated polyvinyl chloride resin ((A) chlorinated polyvinyl chloride resin described below) serving as the base resin of the expanded synthetic resin beads 2A is preferably 400 to 1,500. If the average degree of polymerization is within this range, a high expansion ratio tends to be obtained. The average degree of polymerization of the chlorinated polyvinyl chloride resin is considered to be substantially the same as the average degree of polymerization of the polyvinyl chloride resin before chlorination. The average degree of polymerization is measured in accordance with JIS K6720-2.

[0035] The weight-average molecular weight of the chlorinated polyvinyl chloride resin is not particularly limited, but is preferably in the range of 30,000 to 400,000. A weight-average molecular weight within this range tends to provide a high expansion ratio. The weight-average molecular weight is evaluated by gel permeation chromatography in terms of polystyrene.

[0036] The expanded synthetic resin particles 2A are obtained by foam-molding expandable chlorinated polyvinyl chloride resin particles containing (A) a chlorinated polyvinyl chloride resin, (B) a copolymer having an aromatic vinyl monomer and an unsaturated nitrile as structural units, and (C) a blowing agent. The chlorinated polyvinyl chloride resin (A) can be any of the chlorinated polyvinyl chloride resins described above. The (B) copolymer having an aromatic vinyl monomer and an unsaturated nitrile as structural units and the (C) blowing agent are described in detail below.

[0037] <(B) Copolymer Having Structural Units of Aromatic Vinyl Monomer and Unsaturated Nitrile Monomer> A chlorinated polyvinyl chloride resin and a copolymer having structural units of aromatic vinyl monomer and unsaturated nitrile monomer are used in combination as the material for the expanded synthetic resin beads 2A. That is, the expanded synthetic resin beads 2A contain a chlorinated polyvinyl chloride resin as the second polyvinyl chloride resin and a copolymer having structural units of aromatic vinyl monomer and unsaturated nitrile monomer (hereinafter, sometimes referred to as "copolymer (B)"). This advantageously results in a high expansion ratio and a high closed cell content for the resulting expanded synthetic resin beads 2A. This advantageously is particularly pronounced during pre-expansion or expansion molding under steam heating conditions. Copolymer (B) can also be described as a "copolymer having aromatic vinyl units derived from aromatic vinyl monomers and unsaturated nitrile units derived from unsaturated nitrile monomers."

[0038] Examples of the aromatic vinyl monomer include styrene, α-methylstyrene, ethylstyrene, halogenated styrene, and other styrene derivatives, and examples of the unsaturated nitrile monomer include acrylonitrile and methacrylonitrile.

[0039] Within the scope that does not impair the effects of this embodiment, the copolymer (B) may have a structural unit derived from a monomer other than the aromatic vinyl monomer and the unsaturated nitrile monomer (for example, a monomer (other copolymerizable monomer) that is copolymerizable with the aromatic vinyl monomer and / or the unsaturated nitrile monomer and is other than the aromatic vinyl monomer and the unsaturated nitrile monomer). Examples of the other copolymerizable monomer include (meth)acrylic acid esters such as methyl (meth)acrylate, ethyl (meth)acrylate, N-butyl (meth)acrylate, isobutyl (meth)acrylate, and 2-ethylhexyl (meth)acrylate, (meth)acrylic acid, maleic anhydride, and N-substituted maleimide.

[0040] The content of the unsaturated nitrile unit in the copolymer (B) is preferably in the range of 10 to 45% by weight, where the total weight of the copolymer (B) is 100% by weight. By being in this range, expanded synthetic resin beads 2A having a high expansion ratio and a high closed cell ratio can be easily obtained.

[0041] A preferred copolymer (B) is a styrene-acrylonitrile copolymer. The copolymer (B) may be used alone or in combination of two or more. In a preferred embodiment, a styrene-acrylonitrile copolymer is used as at least one copolymer (B).

[0042] In order to ensure a high expansion ratio and a high closed cell content, the weight-average molecular weight of the copolymer (B) is preferably higher than that of the chlorinated polyvinyl chloride resin (A). The weight-average molecular weight of the copolymer (B) is evaluated by gel permeation chromatography in terms of polystyrene. Blendex 869 manufactured by Galata, for example, can be used as the copolymer (B).

[0043] The content of copolymer (B) is not particularly limited as long as it does not impair the effects of this embodiment, but is preferably 1 to 50 parts by weight, more preferably 5 to 50 parts by weight, and even more preferably more than 5 parts by weight and not more than 30 parts by weight, per 100 parts by weight of the chlorinated polyvinyl chloride resin. When the content of copolymer (B) is 1 part by weight or more, it becomes easier to obtain expanded synthetic resin beads 2A having a high expansion ratio and a high closed cell ratio, and when the content of copolymer (B) is 50 parts by weight or less, it becomes possible to obtain expanded synthetic resin beads 2A having excellent flame retardancy.

[0044] <(C) Blowing Agent> The blowing agent used in this embodiment is not particularly limited. Examples of the blowing agent include hydrocarbons such as normal butane, isobutane, normal pentane, isopentane, neopentane, cyclopentane, normal hexane, and cyclohexane; ethers such as dimethyl ether, diethyl ether, methyl ethyl ether, isopropyl ether, n-butyl ether, diisopropyl ether, furan, furfural, 2-methylfuran, tetrahydrofuran, and tetrahydropyran; ketones such as dimethyl ketone, methyl ethyl ketone, diethyl ketone, methyl n-propyl ketone, methyl n-butyl ketone, methyl i-butyl ketone, methyl n-hexyl ketone, ethyl n-propyl ketone, and ethyl n-butyl ketone; saturated alcohols having 1 to 4 carbon atoms such as methanol, ethanol, propyl alcohol, i-propyl alcohol, butyl alcohol, i-butyl alcohol, and t-butyl alcohol; methyl formate, ethyl formate, and the like. Examples of foaming agents that can be used include carboxylic acid esters such as ter, propyl formate, butyl formate, amyl formate, methyl propionate, and ethyl propionate; alkyl halides such as methyl chloride and ethyl chloride; hydrofluoroolefins or chlorinated hydrofluoroolefins such as trans-1,3,3,3-tetrafluoropropene (trans-HFO-1234e), cis-1,3,3,3-tetrafluoropropene (cis-HFO-1234ze), 2,3,3,3-tetrafluoropropene (trans-HFO-1234yf), trans-1-chloro-3,3,3-trifluoropropene (trans-HCFO-1233zd), and cis-1-chloro-3,3,3-trifluoropropene (cis-HCFO-1233zd); physical foaming agents such as inorganic foaming agents such as water, carbon dioxide, and nitrogen; and chemical foaming agents such as azo compounds and tetrazole. These other foaming agents may be used alone or in combination of two or more.

[0045] The blowing agent is preferably a physical blowing agent, and more preferably a saturated hydrocarbon having 4 to 6 carbon atoms. The saturated hydrocarbon having 4 to 6 carbon atoms is not particularly limited, but from the viewpoint of the solubility and retention of the blowing agent in the chlorinated polyvinyl chloride resin, it is preferable that at least pentane is contained.

[0046] From the viewpoint of improving the solubility of the blowing agent, it is particularly preferable that the blowing agent contains a ketone, an alkyl halide, a hydrofluoroolefin, or a chlorinated hydrofluoroolefin. For example, by using at least one blowing agent selected from a ketone, an alkyl halide, a hydrofluoroolefin, or a chlorinated hydrofluoroolefin in combination with the saturated hydrocarbon having 4 to 6 carbon atoms, the solubility of the saturated hydrocarbon having 4 to 6 carbon atoms in the chlorinated polyvinyl chloride resin can be further improved.

[0047] The foaming agent is preferably contained in an amount of 1 to 40% by weight based on 100% by weight of the expandable chlorinated polyvinyl chloride resin particles. By controlling the content of the foaming agent within this range, it is possible to easily obtain expanded synthetic resin particles 2A having a high expansion ratio and a high closed cell content. A more preferred range of the foaming agent is 5 to 20% by weight based on 100% by weight of the expandable chlorinated polyvinyl chloride resin particles.

[0048] In a preferred embodiment used in this embodiment, the blowing agent contains at least one blowing agent selected from saturated hydrocarbons and / or ketones having 4 to 6 carbon atoms, alkyl halides, hydrofluoroolefins, and chlorinated hydrofluoroolefins, and the blowing agent is contained in an amount of 1 to 40% by weight based on 100% by weight of the expandable chlorinated polyvinyl chloride resin particles.

[0049] <Other Additives> The expanded synthetic resin beads 2A having a chlorinated polyvinyl chloride resin as a base resin may contain additives such as flame retardants, stabilizers, processing aids, lubricants, nucleating agents, foaming aids, antistatic agents, heat resistance improvers, radiant heat transfer inhibitors, antioxidants, solvents, and colorants such as pigments and dyes, as needed, within the scope that does not impair the effects of this embodiment.

[0050] Among additives, flame retardants are important from the viewpoint of imparting fire resistance. Known flame retardants can be used as the flame retardant, and examples thereof include bromine-based flame retardants, phosphorus-based flame retardants, intumescent flame retardants such as ammonium polyphosphate and melamine cyanurate, hydroxide compounds such as aluminum hydroxide and magnesium hydroxide, and flame retardant assistants such as antimony oxide and zinc oxide.

[0051] As the stabilizer, those conventionally used in polyvinyl chloride resins can be used, such as heat stabilizers, heat stabilization assistants, light stabilizers, and ultraviolet absorbers.

[0052] The heat stabilizer is not particularly limited, and examples thereof include organic tin-based stabilizers such as dibutyltin mercapto, dioctyltin mercapto, dimethyltin mercapto, dibutyltin mercapto, dibutyltin maleate, dibutyltin maleate polymer, dioctyltin maleate, dioctyltin maleate polymer, dibutylsilver laurate, and dibutyltin laurate polymer; lead stearate, dibasic lead phosphite, and tribasic lead-based stabilizers; calcium-zinc-based stabilizers; barium-zinc-based stabilizers; and barium-cadmium-based stabilizers. These may be used alone or in combination of two or more.

[0053] The stabilizing aid is not particularly limited, and examples thereof include epoxidized soybean oil, phosphate esters, etc. These may be used alone or in combination of two or more kinds.

[0054] The light stabilizer is not particularly limited, and examples thereof include hindered amine light stabilizers.

[0055] The ultraviolet absorber is not particularly limited, and examples thereof include salicylic acid ester-based, benzophenone-based, benzotriazole-based, and cyanoacrylate-based ultraviolet absorbers.

[0056] The amount of each stabilizer used is not particularly limited as long as it is within a range that does not impair the effects of the present invention, but it is preferably 10 parts by weight or less per 100 parts by weight of the chlorinated polyvinyl chloride resin.

[0057] The lubricant is not particularly limited, and examples thereof include butyl stearate, lauryl alcohol, stearyl alcohol, epoxy soybean oil, glycerin monostearate, stearic acid, bisamide, paraffin wax, polyolefin wax, ester wax, montanic acid wax, etc. These may be used alone or in combination of two or more.

[0058] The processing aid is not particularly limited, and examples thereof include acrylic processing aids such as alkyl acrylate-alkyl methacrylate copolymers having a weight average molecular weight of 100,000 to 2,000,000. The acrylic processing aid is not particularly limited, and examples thereof include n-butyl acrylate-methyl methacrylate copolymers, 2-ethylhexyl acrylate-methyl methacrylate-butyl methacrylate copolymers, and the like. These can be used alone or in combination of two or more.

[0059] The heat resistance improver is not particularly limited, and examples thereof include α-methylstyrene-based and N-phenylmaleimide-based heat resistance improvers.

[0060] The antioxidant is not particularly limited, and examples thereof include phenol-based antioxidants.

[0061] The nucleating agent is not particularly limited, and examples thereof include calcium carbonate, talc, etc. These may be used alone or in combination of two or more kinds.

[0062] The pigment is not particularly limited, and examples thereof include organic pigments such as azo pigments, phthalocyanine pigments, threne pigments, and dye lake pigments, and inorganic pigments such as oxide pigments, molybdenum chromate pigments, sulfide / selenide pigments, and ferrocyanide pigments. These pigments can be used alone or in combination of two or more.

[0063] Examples of the radiation heat transfer inhibitor include substances that have the property of reflecting, scattering, or absorbing light in the near-infrared or infrared region, such as graphite, graphene, carbon black, expanded graphite, and titanium oxide.

[0064] Other thermoplastic resins or thermosetting resins may be used in combination with the chlorinated polyvinyl chloride resin as long as the effects of this embodiment are not impaired. Polyvinyl chloride resins are preferred from the viewpoint of flame retardancy. Examples of polyvinyl chloride resins include homopolymers of vinyl chloride and copolymers of vinyl chloride with other copolymerizable monomers, such as ethylene, propylene, vinyl acetate, allyl chloride, allyl glycidyl ether, acrylic esters, and vinyl ethers. The average degree of polymerization of the polyvinyl chloride resin is not particularly limited, but is preferably 300 to 7,000.

[0065] When other resins are used in combination, the amount of the other resins to be blended is not particularly limited as long as it is within a range that does not impair the effects of the present invention, but it is preferably 0 to 99 parts by weight per 100 parts by weight of the chlorinated polyvinyl chloride resin.

[0066] The shape of the expandable chlorinated polyvinyl chloride resin particles used in this embodiment is not particularly limited as long as they are particles that can be used to pre-expand and foam-mold the expandable resin particles described below. The expandable chlorinated polyvinyl chloride resin particles include not only common granular objects (for example, small rounded particles such as spherical, nearly spherical, convex lens-like, and spindle-like), but also rod-shaped (cylindrical), plate-shaped, and flat particles. The particle weight of the expandable chlorinated polyvinyl chloride resin particles used in this embodiment is preferably 0.5 mg / particle to 10 mg / particle, from the viewpoint of ensuring the fillability of the expanded particles into a molding die and, ultimately, the moldability of the foamed molded article, such as the beautiful surface appearance.

[0067] <Method for Producing Expandable Chlorinated Polyvinyl Chloride Resin Particles> Expandable chlorinated polyvinyl chloride resin particles can be obtained by a known production method. The method for producing expandable chlorinated polyvinyl chloride resin particles includes, for example, the following steps I to III.

[0068] Step I: (A) a chlorinated polyvinyl chloride resin, (B) a copolymer having an aromatic vinyl monomer and an unsaturated nitrile as structural units, and optionally other additives are fed into an extruder and melt-kneaded to obtain a melt-kneaded product I.

[0069] Step II: The foaming agent (C) is dissolved and dispersed in the molten kneaded product I by the extruder or a dispersing facility subsequent to the extruder, to obtain a molten kneaded product II.

[0070] Step III: The molten kneaded material II is extruded through a die having many small holes attached after the extruder into a cutter chamber filled with pressurized circulating water, and immediately after extrusion, the molten kneaded material II is cut by a rotary cutter in contact with the die and cooled and solidified by the pressurized circulating water to obtain expandable chlorinated polyvinyl chloride resin particles.

[0071] The method including steps I to III can produce expandable chlorinated polyvinyl chloride resin particles that can give chlorinated vinyl chloride foamed particles with a higher expansion ratio and a higher closed cell content. The method for obtaining chlorinated vinyl chloride foamed particles (synthetic resin foamed particles 2A) from the expandable chlorinated polyvinyl chloride resin particles is not particularly limited, and any conventionally known method can be used.

[0072] <Expansion Ratio> In the insulating sash 10 according to this embodiment, the expansion ratio of the synthetic resin foam particles 2A is 10 to 50 times, and preferably 15 to 35 times. If the expansion ratio is less than 10 times, the expression of insulating performance and light weight tend to be poor. Furthermore, if the expansion ratio exceeds 50 times, it becomes difficult to make the cells of the foam uniform, and there is a tendency for the formation of open cells to become a greater concern.

[0073] <Closed Cell Ratio> The chlorinated polyvinyl chloride resin foamed beads (synthetic resin foamed beads 2A) used in this embodiment preferably have a closed cell ratio of 80% or more, more preferably 85% or more, and even more preferably 90% or more. The upper limit of the closed cell ratio is not particularly specified, but is substantially 99% or less. Having a closed cell ratio within the above-mentioned range facilitates secondary expansion of the foamed beads during molding, improving the moldability of the foamed beads and improving the surface properties of the resulting foamed molded article. Furthermore, having a closed cell ratio within the above-mentioned range allows low thermal conductivity to be maintained for a long period of time, resulting in superior heat insulation properties.

[0074] <Average Cell Diameter> The chlorinated polyvinyl chloride resin foam particles (synthetic resin foam particles 2A) used in this embodiment preferably have an average cell diameter of 70 μm to 1,000 μm, more preferably 90 μm to 500 μm, and even more preferably 100 μm to 400 μm. Having an average cell diameter within the above range results in a chlorinated polyvinyl chloride resin foam molded article with higher thermal insulation properties. An average cell diameter of 70 μm or more tends to facilitate a high expansion ratio, while an average cell diameter of 1,000 μm or less can avoid an increase in thermal conductivity, i.e., a deterioration in thermal insulation performance. The average cell diameter here is determined by the following measurement method. Specifically, the chlorinated polyvinyl chloride resin foam particles are cut in an arbitrary direction, and the cut cross section is photographed at 10 to 200 times magnification using a scanning electron microscope (Hitachi, Ltd., "S-3400N"). The photographed image is printed on A4 paper, 15 randomly selected cells are selected, and the average value is calculated. This value is the average bubble diameter.

[0075] (First Polyvinyl Chloride Resin and Second Polyvinyl Chloride Resin) In this embodiment, it is sufficient that the first polyvinyl chloride resin contained in the frame 1 has a low chlorine content and the second polyvinyl chloride resin contained in the synthetic resin foam particles 2A has a high chlorine content. Therefore, as described above, the first polyvinyl chloride resin may contain a chlorinated polyvinyl chloride resin. The second polyvinyl chloride resin may also contain a chlorinated polyvinyl chloride resin. That is, a preferred embodiment of the first and second polyvinyl chloride resins is one in which the first and second polyvinyl chloride resins contain a chlorinated polyvinyl chloride resin. Another preferred embodiment of the first and second polyvinyl chloride resins is one in which the first polyvinyl chloride resin does not contain a chlorinated polyvinyl chloride resin but contains a polyvinyl chloride resin, and the second polyvinyl chloride resin contains a chlorinated polyvinyl chloride resin.

[0076] [Embodiment 2] Another embodiment of the present invention will be described below. For ease of explanation, the same reference numerals will be used to designate components having the same functions as those described in the previous embodiment, and their descriptions will not be repeated. Figure 3 is a perspective view showing the schematic configuration of an insulated sash 10A according to this embodiment.

[0077] As shown in Figure 3, the insulating sash 10A according to this embodiment differs from the first embodiment in that the resin foam molded product disposed within the frame 1 is not in the form of particles such as synthetic resin foam particles 2A. In the insulating sash 10A, an extruded foam molded product 2B (resin foam) is disposed within the frame 1. In the insulating sash 10A, the frame 1 is an extruded foam molded product of a first resin composition containing a first polyvinyl chloride resin, and the extruded foam molded product 2B is an extruded foam molded product of a second resin composition containing a second polyvinyl chloride resin.

[0078] (Method for manufacturing the insulating sash 10A) In the insulating sash 10A, the frame 1 and the extruded foam molded body 2B can be formed by co-extrusion. A method for manufacturing the insulating sash 10A according to this embodiment by co-extrusion (hereinafter, sometimes referred to as the first present manufacturing method) will be described below.

[0079] The first present production method includes an extrusion step and an extrusion-foaming step. In the extrusion step, a first resin composition containing the first polyvinyl chloride resin is supplied to a first extruder and melt-kneaded, and a long hollow extrusion molding that will become the frame 1 is continuously extruded from a first die installed at the tip of the first extruder. In the extrusion-foaming step, a second resin composition containing the second polyvinyl chloride resin and a foaming agent is supplied to a second extruder and melt-kneaded, and extruded from the second extruder into the hollow portion of the hollow extrusion molding, where it is extrusion-foamed within the hollow extrusion molding. By the extrusion-foaming step, an extruded foam molding 2B is formed within the hollow portion of the long hollow extrusion molding that will become the frame 1.

[0080] As long as the first resin composition used in the extrusion step contains the above-mentioned first polyvinyl chloride resin, any resin composition used in a conventionally known molding technique for polyvinyl chloride resins can be used.

[0081] The second resin composition used in the extrusion foaming step is not particularly limited as long as it contains a second polyvinyl chloride resin and a foaming agent and is extrusion-foamable. The second resin composition is preferably the above-mentioned expandable chlorinated polyvinyl chloride resin particles. The expandable chlorinated polyvinyl chloride resin particles contain (A) a chlorinated polyvinyl chloride resin, (B) a copolymer having structural units of an aromatic vinyl monomer and an unsaturated nitrile, and (C) a foaming agent.

[0082] In this way, since the expandable chlorinated polyvinyl chloride resin particles containing a foaming agent are used as the second resin composition, there is no need to separately supply a foaming agent to the resin composition for the foam layer, which makes process control easier.

[0083] An example of the first present manufacturing method will be described with reference to Fig. 4. Fig. 4 is an overall configuration diagram showing the schematic configuration of a manufacturing apparatus 20 for manufacturing the thermally insulated sash 10A by co-extrusion.

[0084] As shown in FIG. 4 , the manufacturing apparatus 20 mainly comprises a foaming extruder 21 (second extruder) for producing the extruded foam molding 2B, a non-foaming extruder 22 (first extruder) for producing the frame 1, a two-kind two-layer feed block 23 (first mold), a molding mold 24, a cooling water tank 25, a take-up machine 26, and a cutting machine 27.

[0085] The foaming extruder 21 melts and kneads the expandable chlorinated polyvinyl chloride resin particles (second resin composition) for forming the extruded foam molded product 2B to produce a molten kneaded product X2, and extrudes the molten kneaded product X2 into the molding die 24. The foaming extruder 21 may be connected to a foaming agent cylinder and a metering pump so that a foaming agent can be injected through a vent hole, as necessary, to adjust the expansion ratio of the extruded foam molded product 2B.

[0086] The non-foaming extruder 22 melts and kneads the first resin composition for forming the frame 1 to produce a molten kneaded product X1, and extrudes the molten kneaded product X1 into the molding die 24.

[0087] The two-kind two-layer feed block 23 functions as a mold installed at the tip of the foaming extruder 21 and the non-foaming extruder 22. The melt-kneaded material X2 extruded from the foaming extruder 21 and the melt-kneaded material X1 extruded from the non-foaming extruder 22 flow into the two-kind two-layer feed block 23. The two-kind two-layer feed block 23 continuously extrudes a long hollow extrusion molded product that will become the frame 1 from the melt-kneaded material X1, while extruding the melt-kneaded material X2 into the hollow portion of the hollow extrusion molded product. The two-kind two-layer feed block 23 molds a hollow extrusion molded product made of the melt-kneaded material X1 from the melt-kneaded material X1 and the melt-kneaded material X2, with the melt-kneaded material X2 filled inside. Hereinafter, the extrusion molded product output from the two-kind two-layer feed block 23 will be referred to as the extrusion molded product X3. The extrusion molded product X3 is uncured.

[0088] The molding die 24 is a die for molding the extrusion molded product X3 to a predetermined size. In the extrusion molded product X3, the hollow extrusion molded product made of the molten kneaded product X1 corresponds to the frame 1, and the foam of the molten kneaded product X2 foam-filled inside the hollow extrusion molded product corresponds to the extruded foam molded product 2B.

[0089] The cooling water tank 25 cools the uncured extrusion X3 that has been discharged from the molding die 24. The take-up machine 26 takes up the extrusion X3 that has been cooled in the cooling water tank 25. The cutter 27 cuts the extrusion X3 that has been discharged from the take-up machine 26 into pieces of a predetermined size.

[0090] The foaming extruder 21 and the non-foaming extruder 22 are arranged in parallel and are both connected to a two-kind two-layer feed block 23. The two-kind two-layer feed block 23 is connected to a molding die 24, and a cooling water tank 25 is connected to the molding die 24. Furthermore, a take-up machine 26 is connected to the cooling water tank 25, and a cutting machine 27 is connected to the take-up machine 26.

[0091] In the first present production method, first, a first resin composition containing a non-expandable polyvinyl chloride resin is supplied to a non-foaming extruder 22 and melt-kneaded. Separately, expandable chlorinated polyvinyl chloride resin particles (second resin composition) are supplied to a foaming extruder 21 and melt-kneaded.

[0092] 4, the molten mixture X1 for forming the frame 1, which is melt-kneaded by the non-foaming extruder 22, and the molten mixture X2 for forming the extruded foam 2B, which is melt-kneaded by the foaming extruder 21, are merged inside the two-kind two-layer feed block 23 to form the uncured extrudate X3 having a two-kind two-layer structure. More specifically, inside the two-kind two-layer feed block 23, a long, uncured hollow extrudate made from the molten mixture X1 is first continuously extruded, while the molten mixture X2 is extruded into the hollow portion of the extruded long, hollow extrudate, to form the uncured extrudate X3. The uncured extrudate X3 is configured such that the molten mixture X2 is formed in the hollow portion of a hollow extrudate made from the molten mixture X1 (corresponding to the frame 1).

[0093] The uncured extrusion product X3 is then discharged from the two-kind two-layer feed block 23, thereby foaming the molten mixture X2 of expandable chlorinated polyvinyl chloride resin particles. The extrusion product X3 is then formed into a predetermined rectangular shape in a molding die 24, and cooled in a cooling water tank 25 to form a frame 1 filled with the extruded foam 2B. The frame 1 is then taken up by a take-up machine 26, sent to a cutter 27, and cut to predetermined dimensions by the cutter 27 to obtain the insulating sash 10A shown in FIG.

[0094] [Embodiment 3] Yet another embodiment of the present invention will be described below. For ease of explanation, components having the same functions as those described in the previous embodiment will be designated by the same reference numerals, and their description will not be repeated. Figure 5 is a perspective view showing the schematic configuration of an insulated sash 10B according to this embodiment.

[0095] As shown in Figure 5, the insulating sash 10B according to this embodiment differs from the first and second embodiments in the resin foam molded body disposed within the frame 1. In the insulating sash 10B, a bead foam molded body 2C (resin foam) is inserted into the frame 1. In the insulating sash 10B, the frame 1 is an extrusion molded body of a first resin composition containing a first polyvinyl chloride resin, and the bead foam molded body 2C is a bead foam molded body of the synthetic resin foam particles 2A described in the first embodiment. The bead foam molded body 2C is inserted into the frame 1 through an opening 1a formed in the frame 1.

[0096] (Method for manufacturing the insulating sash 10B) In the insulating sash 10B, the frame 1 is manufactured by extrusion molding, while the bead foam molding 2C can be manufactured by bead foam molding of the synthetic resin foam particles 2A described in embodiment 1. The insulating sash 10B is obtained by inserting the bead foam molding 2C into the frame 1, which is manufactured by separate methods. The method for manufacturing the insulating sash 10B according to this embodiment (hereinafter sometimes referred to as the second manufacturing method) will be described below. Note that embodiment 1 may be referred to as appropriate for the synthetic resin foam particles 2A below.

[0097] The second present manufacturing method includes a resin foam manufacturing step and an insertion step. In the resin foam manufacturing step, a bead foam molded body 2C is obtained by molding synthetic resin foam particles 2A. In the insertion step, the bead foam molded body 2C obtained in the resin foam manufacturing step is inserted into the hollow portion of a frame 1. Furthermore, the second present manufacturing method preferably includes a frame manufacturing step (hollow extrusion manufacturing step). In the frame manufacturing step, a first resin composition containing the first polyvinyl chloride resin is extrusion molded to obtain the frame 1.

[0098] 6 is an overall configuration diagram showing the schematic configuration of a manufacturing apparatus 30 for the frame 1 used in the frame manufacturing process. As shown in Fig. 6, the manufacturing apparatus 30 mainly comprises a non-foaming extruder 32 for manufacturing the frame 1, a molding die 34, a cooling water tank 35, a take-up machine 36, and a cutting machine 37.

[0099] The non-foaming extruder 32 melts and kneads the first resin composition for forming the frame 1 to produce a molten kneaded product X1, and extrudes the molten kneaded product X1 into the molding die 34. The molding die 34 is a die for molding the molten kneaded product X1 into the shape of the frame 1. The cooling water tank 35 cools the uncured extrusion molded product X4 that has been discharged from the molding die 34. The take-up machine 36 takes up the extrusion molded product X4 that has been cooled in the cooling water tank 35. The cutter 37 cuts the extrusion molded product X4 discharged from the take-up machine 36 to a predetermined size.

[0100] In the frame manufacturing process, a first resin composition containing a non-foamable polyvinyl chloride resin is first supplied to a non-foaming extruder 32 and melt-kneaded. The melt-kneaded product X1 produced by the non-foaming extruder 32 is then fed to a molding die 34, where it is shaped into a predetermined shape to obtain an uncured extrusion X4 having the shape of the frame 1. The extrusion X4 is then cooled in a cooling water tank 35. After cooling, the extrusion X4 is taken up by a take-up machine 36, sent to a cutter 37, and cut to predetermined dimensions by the cutter 37 to obtain the frame 1 shown in FIG. 5 . Note that in the second manufacturing method, the frame manufacturing process is a process that can be performed as needed and does not necessarily have to be performed. If the frame manufacturing process is not performed, a frame procured from elsewhere can be used as the frame 1.

[0101] The resin foam production step can employ a conventionally known bead expansion method. For example, a bead expansion molded product 2C may be produced from the synthetic resin foam particles 2A containing the second polyvinyl chloride resin by applying a molding technique for a styrene-based resin foam using a conventional bead expansion method.

[0102] The frame 1 manufactured in the frame manufacturing process is long and has a hollow portion inside. An opening 1a is provided at one end of the frame 1 in the extension direction. Here, in the extension direction of the frame 1, the side of the opening 1a is the front side, and the side opposite the opening 1a is the rear side. In the insertion process, the bead foam molded body 2C manufactured in the resin foam manufacturing process is cut to a predetermined shape to fit the dimensions of the opening 1a, and then inserted into the hollow portion of the frame 1 through the opening 1a (see Figure 5).

[0103] In the above description, the resin foam production process produces a bead foam molded body 2C from synthetic resin foam beads 2A. However, the resin foam production process may be any process for producing a resin foam using a second polyvinyl chloride resin as a base resin, and is not limited to a molding process using a bead expansion method. That is, the resin foam production process may produce, as the resin foam, synthetic resin foam beads 2A containing the second polyvinyl chloride resin, a bead foam molded body 2C molded using the synthetic resin foam beads 2A, or an extruded foam molded body containing the second polyvinyl chloride resin.

[0104] When the resin foam is synthetic resin foam beads 2A containing a second polyvinyl chloride resin, the resin foam production step produces the synthetic resin foam beads 2A from the expandable chlorinated polyvinyl chloride resin particles described above. The method for obtaining the synthetic resin foam beads 2A containing a second polyvinyl chloride resin from the expandable chlorinated polyvinyl chloride resin particles is not particularly limited, and any conventionally known method can be used.

[0105] When the resin foam is an extruded foam containing a second polyvinyl chloride resin, the resin foam production step involves, for example, melt-kneading the above-described expandable chlorinated polyvinyl chloride resin particles (second resin composition) to obtain a molten kneaded product (corresponding to molten kneaded product X2 shown in FIG. 4 ), followed by conventional extrusion molding to produce the extruded foam.

[0106] [Summary] The embodiments of the present invention are as follows.

[0107] [1] An insulating sash comprising a hollow extrusion and a resin foam filled or disposed within the hollow extrusion, wherein both the hollow extrusion and the resin foam contain polyvinyl chloride resin as a base resin, and the polyvinyl chloride resin contained in the hollow extrusion is a first polyvinyl chloride resin, and the polyvinyl chloride resin contained in the resin foam is a second polyvinyl chloride resin, wherein the chlorine content of the first polyvinyl chloride resin is lower than the chlorine content of the second polyvinyl chloride resin, and the foam expansion ratio of the resin foam is 10 to 50 times.

[0108] [2] The insulating sash of [1], wherein the chlorine content of the first polyvinyl chloride resin is less than 60% by weight, and the chlorine content of the second polyvinyl chloride resin is 60% to 75% by weight.

[0109] [3] The heat-insulating sash according to [1] or [2], wherein the first and second polyvinyl chloride resins contain chlorinated polyvinyl chloride resins.

[0110] [4] The insulating sash of [1] or [2], wherein the first polyvinyl chloride resin does not contain a chlorinated polyvinyl chloride resin but contains a polyvinyl chloride resin, and the second polyvinyl chloride resin contains a chlorinated polyvinyl chloride resin.

[0111] [5] The insulating sash of [1] or [2], wherein the first polyvinyl chloride resin contains a chlorinated polyvinyl chloride resin and a polyvinyl chloride resin, and the second polyvinyl chloride resin contains a chlorinated polyvinyl chloride resin.

[0112] [6] The heat-insulating sash according to any one of [1] to [4], wherein the resin foam is synthetic resin foam particles.

[0113] [7] The heat-insulating sash according to any one of [1] to [4], wherein the resin foam is a foamed bead molded body of synthetic resin foam particles.

[0114] [8] The heat insulating sash according to any one of [1] to [4], wherein the resin foam is an extruded foam molding.

[0115] [9] The insulating sash of any one of [1] to [4], wherein the resin foam contains a chlorinated polyvinyl chloride resin as the second polyvinyl chloride resin and a copolymer having an aromatic vinyl monomer and an unsaturated nitrile monomer as structural units.

[0116]

[10] A method for manufacturing an insulated sash, comprising a hollow extrusion and a resin foam filled or disposed within the hollow extrusion, wherein the hollow extrusion and the resin foam both contain polyvinyl chloride resin as a base resin, wherein the polyvinyl chloride resin contained in the hollow extrusion is a first polyvinyl chloride resin and the polyvinyl chloride resin contained in the resin foam is a second polyvinyl chloride resin, and the chlorine content of the first polyvinyl chloride resin is higher than the chlorine content of the second polyvinyl chloride resin. and an extrusion-foaming step of supplying a second resin composition containing the second polyvinyl chloride resin and a foaming agent to a second extruder, melting and kneading the second resin composition, extruding the second resin composition from the second extruder into the hollow portion of the hollow extrusion, and extruding and foaming the second resin composition within the hollow extrusion.

[0117]

[11] A method for manufacturing an insulated sash, comprising a hollow extrusion and a resin foam filled or disposed within the hollow extrusion, wherein both the hollow extrusion and the resin foam contain polyvinyl chloride resin as a base resin, wherein the polyvinyl chloride resin contained in the hollow extrusion is a first polyvinyl chloride resin and the polyvinyl chloride resin contained in the resin foam is a second polyvinyl chloride resin, the chlorine content of the first polyvinyl chloride resin being lower than the chlorine content of the second polyvinyl chloride resin, the method comprising: a resin foam manufacturing step of obtaining the resin foam consisting of one selected from the group consisting of foamed particles containing the second polyvinyl chloride resin, a bead foam molded using the foamed particles, and an extruded foam molded product containing the second polyvinyl chloride resin; and an insertion step of inserting the resin foam obtained in the resin foam manufacturing step into the hollow portion of the hollow extrusion.

[0118]

[12] The method for manufacturing an insulating sash according to

[11] , further comprising a hollow extrusion manufacturing step of extruding a first resin composition containing the first polyvinyl chloride resin to obtain the hollow extrusion.

[0119] The following examples are provided to specifically describe the present invention. The insulated sashes obtained in the examples and comparative examples were tested and evaluated for particle weight, expansion ratio, closed cell ratio, thermal insulation properties, light weight, shape expression, and recyclability, using the following procedures.

[0120] <Measurement of particle weight> The weight of 100 randomly sampled expandable chlorinated polyvinyl chloride resin particles was measured using an electronic balance capable of measuring to 0.01 mg, and the particle weight was calculated using the following formula: Particle weight (mg) = [Weight of 100 particles (mg)] / 100.

[0121] <True density measurement> Polyvinyl chloride resin was blended with auxiliary materials such as processing aids, stabilizers, and lubricants to obtain a uniform mixture, which was then melt-kneaded in an extruder. The weight of the resulting polyvinyl chloride resin pellets, W1 (kg), was submerged in a measuring cylinder containing ethanol, and the volume, V1 (m), was determined from the rise in the liquid level in the measuring cylinder (submersion method). ３ ) was obtained and calculated using the following formula: ３ )=(W1 / V1).

[0122] Based on the above method, the true density of the chlorinated polyvinyl chloride resin used in the examples and comparative examples was 1,430 kg / m ３ The true density of polyvinyl chloride resin is 1,400 kg / m ３ This value was used as the density of the base resin used in the examples and comparative examples.

[0123] <Expansion ratio measurement> A polyvinyl chloride resin foam particle with a weight of W2 (kg) is submerged in a measuring cylinder containing ethanol, and the volume V2 (m ３ ) was obtained and calculated using the following formula: From the above-mentioned <True Density Measurement>, the density of the base resin was 1,430 kg / m ３ The following was used: Expansion ratio (times) of chlorinated polyvinyl chloride resin expanded particles = 1,430 / (W2 / V2) Expansion ratio (times) of polyvinyl chloride resin expanded particles = 1,400 / (W2 / V2).

[0124] <Expansion Evaluation of Expandable Polyvinyl Chloride Resin Particles> The expandable polyvinyl chloride resin particles obtained in Examples and Comparative Examples were measured for maximum expansion ratio of the expanded polyvinyl chloride resin particles according to the following measurement method. Note that, in order to properly evaluate the expansion of the expandable polyvinyl chloride resin particles, the following measurements were carried out on the same day.

[0125] (Evaluation of Maximum Expansion Ratio of Expanded Polyvinyl Chloride Resin Beads) A portion of the obtained expandable polyvinyl chloride resin beads was placed in an oven (forced convection constant temperature dryer SOFW-600, manufactured by AS ONE Corporation) heated to 130°C, and expanded under a heated air atmosphere at a temperature of 130°C for varying heating times to obtain expanded beads for each heating time. The heating time was varied in 30-second intervals, such as 30, 60, and 90 seconds after placing in the oven, and heating was continued until shrinkage of the expanded beads due to overheating (a decrease in the expansion ratio of the expanded beads) was confirmed. The expansion ratio of the expanded beads obtained for each heating time was measured (based on the expansion ratio measurement described above), and the highest expansion ratio among these was taken as the maximum expansion ratio of the expanded polyvinyl chloride resin beads.

[0126] <Insulating Property: Measurement of Thermal Conductivity of Polyvinyl Chloride Resin Foam> Test pieces were cut from flat areas of the insulating sash samples produced in the Examples and Comparative Examples, and the cut test pieces were arranged to measure 300 mm in length, 300 mm in width, and 25 mm in thickness to prepare samples for thermal conductivity measurement. After leaving the samples at 23°C for 24 hours, the thermal conductivity (λ) was measured using a thermal conductivity measuring device (manufactured by Eiko Seiki Co., Ltd., HC-074) according to JIS A1412-2:1999 using a heat flow meter method with plate temperatures set to 10°C and 30°C (average temperature 20°C, temperature difference 20°C). The insulating properties of the insulating sash samples used in the Examples and Comparative Examples were evaluated based on the measured thermal conductivity. The designation criteria are as follows:

[0127] (Insulation evaluation criteria) 1: Thermal conductivity (λ)≦0.070 (W / m·K) 2: 0.070<thermal conductivity (λ)≦0.100 (W / m·K) 3: 0.100<thermal conductivity (λ) (W / m·K).

[0128] <Closed Cell Ratio> Using the test piece collected for the evaluation of expansion ratio, the volume was measured with an air comparison type hydrometer at 23°C ± 2°C in accordance with JIS K 7138:2006, and the volume was also measured with a water displacement type hydrometer at 23°C ± 2°C in accordance with JIS K 7112:1999, and the closed cell ratio was calculated using the following formula (1).

[0129] Cc = (Va / Vaq) × 100 (1) [In formula (2), Cc is the closed cell rate (%), Va is the air comparative volume (cm ３ ) and Vaq is the water displacement volume (cm ３ ) ].

[0130] <Lightweightness> The insulating sash samples produced in each of the examples and comparative examples were held by hand and subjected to a sensory evaluation based on the following evaluation criteria.

[0131] (Evaluation criteria) 1: Very light 2: Light 3: Slightly heavy 4: Heavy.

[0132] <Shape development> The cross section of the heat-insulating sashes produced in each of the examples and comparative examples was visually observed, and the state of cross-sectional shape development was evaluated using the following indices.

[0133] (Evaluation Criteria) 1: The predetermined shape of the frame is realized, and no significant deformation is observed. No significant gaps are observed in the resin foam in the hollow portion of the frame.

[0134] 2: Partial deformation of the frame shape is observed. Voids are observed in the resin foam in the hollow part of the frame (air bubbles in the resin foam are observed to be open). 3: Significant deformation of the frame shape is observed. Broken bubbles are observed in the resin foam in the hollow part of the frame.

[0135] <Recyclability> The insulating sashes manufactured in each of the examples and comparative examples were evaluated according to the following indices.

[0136] 1: The resins that make up the insulated sashes are the same material, so material recycling is possible. 2: The resins that make up the insulated sashes are different materials, so material recycling is not possible because it requires labor to separate and recover the frame and core material.

[0137] <Overall Evaluation> The insulating sashes manufactured in each of the examples and comparative examples were comprehensively evaluated according to the following criteria.

[0138] (Evaluation criteria) 1: Thermal insulation rating of "1", light weight rating of "1", and recyclability rating of "1" 2: Thermal insulation rating of "2", light weight rating of "1" or "2", and recyclability rating of "1" 3: Thermal insulation rating of "2", and meeting one of the following conditions: 1) light weight rating of "3" or "4", and 2) recyclability rating of "2" 4: Thermal insulation rating of "3", light weight rating of "4", and recyclability rating of "2".

[0139] In the above overall evaluation, insulating sashes that met the criteria of "1" or "2" were deemed to pass (satisfactory in terms of material recyclability, insulating properties, and light weight).

[0140] The raw materials used in the examples and comparative examples are listed below.

[0141] (Polyvinyl chloride resins) (A-1) Chlorinated polyvinyl chloride resin [manufactured by Kaneka Corporation, H716S, average degree of polymerization 600, chlorine content 67.6% by weight] (A-2) Polyvinyl chloride resin [manufactured by Kaneka Corporation, average degree of polymerization 600, chlorine content 56.8% by weight] (Processing aids) (B-1) Styrene-acrylonitrile copolymer (manufactured by Galata, Blendex 869, weight average molecular weight 2,860,000, proportion of acrylonitrile-derived components in the copolymer; 20% by weight) (B-2) Acrylic resin [manufactured by Kaneka Corporation, Kane Ace PA-40] (Blowing agents) (C-1) Normal pentane [manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.] (C-2) Acetone [manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.].

[0142] Example 1 [Preparation of Expandable Polyvinyl Chloride Resin Particles] To 100 parts by weight of chlorinated polyvinyl chloride resin (A-1), 13 parts by weight of processing aid (B-1), 5 parts by weight of butyltin mercapto stabilizer, 3 parts by weight of lubricant (ester wax, polyethylene wax), and 5 parts by weight of chlorinated polyethylene with a chlorine content of 35% by weight were added and blended to obtain a uniform composition. The composition was then melt-kneaded in a co-rotating intermeshing twin-screw extruder to obtain pellets (chlorinated polyvinyl chloride resin composition) of the above composition ratio.

[0143] The obtained pellets were melt-kneaded in a φ40 mm co-rotating intermeshing twin-screw extruder at a feed rate of 40 kg / hr. From the middle of the φ40 mm co-rotating intermeshing twin-screw extruder, 8.6 parts by weight of normal pentane (C-1) and 0.9 parts by weight of acetone (C-2) were injected per 100 parts by weight of the pellets.

[0144] Then, through a continuation pipe attached to the tip of the twin-screw extruder, a single-screw extruder, a gear pump, and a diverter valve, the resin was cooled to a temperature of 165 ° C., and extruded at a discharge rate of 45 kg / hr into pressurized circulating water at a temperature of 70 ° C. and 1.3 MPa from a die attached downstream of the diverter valve and set at 230 ° C. with 30 small holes of 1.0 mm diameter and 3.5 mm land length. The extruder tip pressure at this time was 12 MPa, and the resin temperature of the melt (i.e., the resin temperature of the resin melt at the tip of the extruder) was 167 ° C. The extruded molten resin was cut and granulated using a rotary cutter in contact with the die, and transferred to a centrifugal dehydrator, where it was cut into small particles with a particle weight of 6.0 mg and a true density of 1,330 kg / m ３ As a result, expandable chlorinated polyvinyl chloride resin particles of the above formula were obtained.

[0145] [Expansion Evaluation of Expandable Polyvinyl Chloride Resin Particles] The obtained expandable polyvinyl chloride resin particles were cured at 10°C for 3 days, and then subjected to expansion evaluation by evaluating the maximum expansion ratio of expanded polyvinyl chloride resin particles. As a result, the maximum expansion ratio of the expanded particles was 25.9 times.

[0146] [Preparation of Polyvinyl Chloride Resin Particles] To 100 parts by weight of polyvinyl chloride resin (A-2), 6 parts by weight of a methyl methacrylate-butadiene-styrene copolymer (B22 manufactured by Kaneka) as an impact absorber, 3 parts by weight of chlorinated polyethylene having a chlorine content of 35% by weight, 2 parts by weight of butyltin mercapto as a stabilizer, 1 part by weight of synthetic zeolite (CS-100 manufactured by Kosei Co., Ltd.) as a heat stabilizer, 3 parts by weight of polyethylene wax as a lubricant, and 5 parts by weight of titanium dioxide as a filler were added, and these were blended to obtain a uniform composition. The resulting composition was then melt-kneaded in a co-rotating intermeshing twin-screw extruder to obtain polyvinyl chloride resin particles consisting of a non-foamable polyvinyl chloride resin composition.

[0147] [Extrusion Molding Process] The polyvinyl chloride resin particles were used as a resin composition for a frame, and the expandable polyvinyl chloride resin particles were used as a resin composition to fill the frame.

[0148] These resin compositions were extrusion molded using a manufacturing apparatus 20 shown in FIG. 4. Specifically, the polyvinyl chloride resin particles were kneaded in a non-foaming extruder 22 at 190°C and injected into a two-kind two-layer feed block 23 at an extrusion rate of 50 kg / hr. Meanwhile, the expandable polyvinyl chloride resin particles were kneaded in a foaming extruder 21 at 190°C and injected into a two-kind two-layer feed block 23 at 75 kg / hr. The composition discharged from the two-kind two-layer feed block 23 was inserted into a molding die 24, cooled in a cooling water tank 25, taken up by a take-up machine 26, and cut to a predetermined length by a cutter 27 to obtain an insulated sash. The evaluation results of the obtained insulated sash are shown in Table 1.

[0149] (Example 2) Expandable polyvinyl chloride resin particles were obtained in the same manner as in Example 1, except that the amount of acetone (C-2) added was changed to 0.3 parts by weight. The obtained expandable polyvinyl chloride resin particles had a particle weight of 6.5 mg and a true density of 1,380 kg / m ３ The pressure at the tip of the extruder was 14 MPa, and the resin temperature of the molten material was 168°C.

[0150] The resulting expandable polyvinyl chloride resin particles were subjected to an expansion evaluation in the same manner as in Example 1, and the maximum expansion ratio of the expanded particles was found to be 15.4 times.

[0151] A heat insulating sash was obtained in the same manner as in [Preparation of polyvinyl chloride resin particles] and [Extrusion molding] in Example 1. The evaluation results of the obtained heat insulating sash are shown in Table 1.

[0152] (Example 3) Expandable polyvinyl chloride resin particles were obtained in the same manner as in Example 1, except that the amount of acetone (C-2) added was changed to 3.9 parts by weight. The obtained expandable polyvinyl chloride resin particles had a particle weight of 5.5 mg and a true density of 1,280 kg / m ３ The pressure at the tip of the extruder was 11 MPa, and the resin temperature of the molten material was 165°C.

[0153] The resulting expandable polyvinyl chloride resin particles were subjected to an expansion evaluation in the same manner as in Example 1, and the maximum expansion ratio of the expanded particles was found to be 32.6 times.

[0154] A heat insulating sash was obtained in the same manner as in [Preparation of polyvinyl chloride resin particles] and [Extrusion molding] in Example 1. The evaluation results of the obtained heat insulating sash are shown in Table 1.

[0155] (Example 4) Expandable polyvinyl chloride resin particles were obtained in the same manner as in Example 1, except that 13 parts by weight of the processing aid (B-2) was used instead of 13 parts by weight of the processing aid (B-1) in Example 1. The obtained expandable polyvinyl chloride resin particles had a particle weight of 6.0 mg and a true density of 1,330 kg / m ３ The pressure at the tip of the extruder was 12 MPa, and the resin temperature of the molten material was 165°C.

[0156] The resulting expandable polyvinyl chloride resin particles were subjected to an expansion evaluation in the same manner as in Example 1, and the maximum expansion ratio of the expanded particles was found to be 24.8 times.

[0157] The resulting expandable polyvinyl chloride resin particles were used in an in-mold molding machine using steam to obtain a block-shaped polyvinyl chloride resin foam molded article, which was then cut to dimensions that matched the cross-sectional shape of a frame to obtain a foam molded article in a shape that could be enclosed within the frame.

[0158] On the other hand, in the [Extrusion Molding Process] of Example 1, expandable polyvinyl chloride resin particles were not supplied to the foaming extruder 21, and only polyvinyl chloride resin particles were kneaded in the foaming extruder 21 and discharged at an extrusion rate of 50 kg / hr. The composition was inserted into a molding die 24 without passing through a two-kind two-layer feed block 23, cooled in a cooling water tank 25, taken up by a take-up machine 26, and then cut to a predetermined length by a cutter 27 to obtain a frame. That is, in this example, a manufacturing apparatus 30 shown in Fig. 6 was used to manufacture the frame.

[0159] The foamed molded article was inserted into the hollow portion of the obtained frame to obtain a heat insulating sash. The evaluation results of the obtained heat insulating sash are shown in Table 1.

[0160] Example 5 Polyvinyl chloride resin particles made of a non-foamable polyvinyl chloride resin composition were obtained in the same manner as in Example 1, except that in [Preparation of polyvinyl chloride resin particles] of Example 1, 100 parts by weight of the polyvinyl chloride resin (A-2) was changed to 100 parts by weight of a mixture consisting of 90% by weight of the polyvinyl chloride resin (A-2) and 10% by weight of a chlorinated polyvinyl chloride resin (A-1).

[0161] Further, in the [Preparation of Expandable Polyvinyl Chloride Resin Particles], 100 parts by weight of the chlorinated polyvinyl chloride resin (A-1) was replaced with 100 parts by weight of a mixture consisting of 90% by weight of the chlorinated polyvinyl chloride resin (A-1) and 10% by weight of the polyvinyl chloride resin (A-2), and 13 parts by weight of the processing aid (B-1) was replaced with 13 parts by weight of the processing aid (B-2). Except for this, expandable polyvinyl chloride resin particles were obtained in the same manner as in Example 1. The resulting expandable polyvinyl chloride resin particles had a particle weight of 6.0 mg and a true density of 1,380 kg / m ３ The pressure at the tip of the extruder was 13 MPa, and the resin temperature of the molten material was 167°C.

[0162] The resulting expandable polyvinyl chloride resin particles were subjected to an expansion evaluation in the same manner as in Example 1, and the maximum expansion ratio of the expanded particles was found to be 25.9 times.

[0163] A heat insulating sash was obtained in the same manner as in [Preparation of polyvinyl chloride resin particles] and [Extrusion molding] in Example 1. The evaluation results of the obtained heat insulating sash are shown in Table 1.

[0164] Comparative Example 1 In the [Extrusion Molding Process] of Example 1, expandable polyvinyl chloride resin particles were not supplied to the foaming extruder 21, and only polyvinyl chloride resin particles were kneaded in the foaming extruder 21 and injected into a two-kind two-layer feed block 23 at an extrusion rate of 50 kg / hr. The composition discharged from the two-kind two-layer feed block 23 was inserted into a molding die 24, cooled in a cooling water tank 25, taken up by a take-up machine 26, and then cut to a predetermined length by a cutter 27 to obtain a frame. The evaluation results of the obtained frame are shown in Table 1.

[0165] (Comparative Example 2) A heat-insulating sash was obtained in the same manner as in Example 4, except that a rigid urethane foam (Achilles Board 45 times manufactured by Achilles Corporation) was used as the resin foam filled in the frame. The evaluation results of the obtained heat-insulating sash are shown in Table 1.

[0166] (Comparative Example 3) Expandable polyvinyl chloride resin particles were obtained in the same manner as in Example 3, except that 100 parts by weight of the chlorinated polyvinyl chloride resin (A-1) was replaced with 100 parts by weight of the polyvinyl chloride resin (A-2). The obtained expandable polyvinyl chloride resin particles had a particle weight of 7.8 mg and a true density of 1,400 kg / m ３ The pressure at the tip of the extruder was 17 MPa, and the resin temperature of the molten material was 168°C.

[0167] The resulting expandable polyvinyl chloride resin particles were subjected to an expansion evaluation in the same manner as in Example 1, and the maximum expansion ratio of the expanded particles was found to be 3.1 times.

[0168] A heat insulating sash was obtained in the same manner as in [Preparation of polyvinyl chloride resin particles] and [Extrusion molding] in Example 1. The evaluation results of the obtained heat insulating sash are shown in Table 1.

[0169] Comparative Example 4 Expandable polyvinyl chloride resin particles were obtained in the same manner as in Example 1, except that 13 parts by weight of the processing aid (B-2) and 12.5 parts by weight of normal pentane (C-1) were used as the only blowing agent, relative to 100 parts by weight of the chlorinated polyvinyl chloride resin (A-1). The resulting expandable polyvinyl chloride resin particles had a particle weight of 5.6 mg and a true density of 1,320 kg / m ３ In addition, the pressure at the tip of the extruder was unstable at 4 to 11 MPa.

[0170] The resulting expandable polyvinyl chloride resin particles were subjected to an expansion evaluation in the same manner as in Example 3, and the maximum expansion ratio of the expanded particles was found to be 6.8 times.

[0171] A heat insulating sash was obtained in the same manner as in [Preparation of polyvinyl chloride resin particles] and [Extrusion molding] in Example 1. The evaluation results of the obtained heat insulating sash are shown in Table 1.

[0172] From the results in Table 1, it was found that the insulating sashes of Examples 1 to 5 have excellent light weight because the frame is made of synthetic resin, and excellent insulating properties because a resin foam with an expansion ratio of 10 to 50 is disposed inside the frame. Furthermore, it was found that an insulating sash with excellent material recyclability can be obtained because the frame and the resin foam are made of the same type of resin material.

[0173] The present invention can be used, for example, in window frames with high thermal insulation performance.

[0174] DESCRIPTION OF SYMBOLS 1 Frame (hollow profile) 1a Opening 2A Synthetic resin foam particles (resin foam) 2B Extruded foam molded body (resin foam) 2C Bead foam molded body (resin foam) 10, 10A, 10B Heat-insulating sash 20 Manufacturing apparatus 21 Foaming extruder 22 Non-foaming extruder 23 Type 2 two-layer feed block 24 Molding mold 25 Cooling water tank 26 Take-off machine 27 Cutting machine 30 Manufacturing apparatus 32 Non-foaming extruder 34 Molding mold 35 Cooling water tank 36 Take-off machine 37 Cutting machine X1, X2 Melt-kneaded product X3, X4 Extrusion molded product

Claims

1. An insulating sash comprising: a hollow material; and a resin foam filled or disposed within the hollow material, wherein both the hollow material and the resin foam contain polyvinyl chloride resin as a base resin, and the polyvinyl chloride resin contained in the hollow material is a first polyvinyl chloride resin, and the polyvinyl chloride resin contained in the resin foam is a second polyvinyl chloride resin, wherein the chlorine content of the first polyvinyl chloride resin is lower than the chlorine content of the second polyvinyl chloride resin, and the foaming ratio of the resin foam is 10 to 50 times.

2. An insulating sash as described in claim 1, wherein the chlorine content of the first polyvinyl chloride resin is less than 60% by weight, and the chlorine content of the second polyvinyl chloride resin is 60% to 75% by weight.

3. An insulating sash as described in claim 1 or 2, wherein the first and second polyvinyl chloride resins contain chlorinated polyvinyl chloride resins.

4. An insulated sash as described in claim 1 or 2, wherein the first polyvinyl chloride resin does not contain chlorinated polyvinyl chloride resin but contains polyvinyl chloride resin, and the second polyvinyl chloride resin contains chlorinated polyvinyl chloride resin.

5. An insulating sash as described in claim 1 or 2, wherein the first polyvinyl chloride resin contains a chlorinated polyvinyl chloride resin and a polyvinyl chloride resin, and the second polyvinyl chloride resin contains a chlorinated polyvinyl chloride resin.

6. The insulating sash according to claim 1 or 2, wherein the resin foam is synthetic resin foam particles.

7. The insulated sash according to claim 1 or 2, wherein the resin foam is a bead foam molded body made of synthetic resin foam particles.

8. The insulating sash according to claim 1 or 2, wherein the resin foam is an extruded foam.

9. An insulated sash as described in claim 1 or 2, wherein the resin foam contains a chlorinated polyvinyl chloride resin as the second polyvinyl chloride resin and a copolymer having an aromatic vinyl monomer and an unsaturated nitrile monomer as structural units.

10. A method for manufacturing an insulated sash, comprising: a hollow profile; and a resin foam filled or disposed within the hollow profile, wherein both the hollow profile and the resin foam contain polyvinyl chloride resin as a base resin, the method comprising the steps of: supplying a first resin composition containing the first polyvinyl chloride resin to a first extruder and melt-kneading the first resin composition, and continuously extruding a long hollow extrusion molded product, which becomes the hollow profile, from a first die installed at the tip of the first extruder; and and an extrusion-foaming step of supplying a second resin composition containing the second polyvinyl chloride resin and a foaming agent to a second extruder, melt-kneading the second resin composition, and extruding the second resin composition from the second extruder into a hollow portion of the hollow extrusion molding, thereby causing extrusion foaming within the hollow extrusion molding.

11. A method for manufacturing an insulating sash comprising a hollow profile and a resin foam filled or disposed within the hollow profile, wherein both the hollow profile and the resin foam contain polyvinyl chloride resin as a base resin, the method comprising: a resin foam manufacturing step of obtaining the resin foam consisting of any one selected from the group consisting of foamed particles containing the second polyvinyl chloride resin, a bead foam molded using the foamed particles, and an extruded foam molded product containing the second polyvinyl chloride resin, wherein the polyvinyl chloride resin contained in the hollow profile is a first polyvinyl chloride resin and the polyvinyl chloride resin contained in the resin foam is a second polyvinyl chloride resin, the chlorine content of the first polyvinyl chloride resin being lower than the chlorine content of the second polyvinyl chloride resin; and an insertion step of inserting the resin foam obtained in the resin foam manufacturing step into the hollow portion of the hollow profile.

12. A method for manufacturing an insulating sash as described in claim 11, further comprising a hollow profile manufacturing step of extruding a first resin composition containing the first polyvinyl chloride resin to obtain the hollow profile.

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