JP2006231761A - Plastic corrugated board - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a plastic corrugated board which is excellent in fire retardancy. <P>SOLUTION: The plastic corrugated board 1 comprises: a core material 2; and a covering material 3 covering one side or both sides of the core material 2, wherein at least the core material is made of a thermoplastic resin containing a flame retarder. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a plastic cardboard containing a flame retardant.

  Conventionally, paper corrugated cardboard has been used for various purposes such as packaging materials used for packaging, shock-absorbing materials for cushioning shocks, and sound-absorbing materials for absorbing noise. Corrugated cardboard is provided. Plastic cardboard made of thermoplastic resin such as polypropylene and polyvinyl chloride is also provided. The plastic cardboard is excellent in moldability and can be molded into a predetermined shape (for example, see Patent Documents 1 and 2).

JP 2002-52635 A JP 2001-9891 A

  As described above, the plastic corrugated cardboard is used for a shock absorbing material and a sound absorbing material. However, the shock absorbing material and the sound absorbing material are often used in, for example, a building material and an automobile. Has been.

As a means for solving the above-mentioned problems, the present invention is a corrugated cardboard comprising a core material 2 and a covering material 3 applied to one or both surfaces of the core material 2, wherein at least the core material 2 is a flame retardant. The plastic corrugated cardboard 1 which uses the thermoplastic resin containing this as a material is provided.
The thermoplastic resin is preferably an engineering plastic or a polymer alloy of an engineering plastic and a thermoplastic resin, or a polymer alloy of an engineering plastic, a thermoplastic resin, and a rubber-like substance. The engineering plastic may be polyamide (PA), polyester (PE), polyacetal (POM), polycarbonate (PC), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polysulfone (PSF), polyethersulfone (PES), polyphenylene ether (PPE), modified polyphenylene ether ( Modified PPE), polyphenylene sulfide (PPS), polyarylate (PAR), polyetheretherketone (PEEK), polyamidoimi (PAI), polyimide (PI), polyetherimide (PEI), polyaminobismaleimide, methylpentene copolymer (TPX), one or more plastics selected from the group consisting of crystalline polyester and stereoregular polystyrene It consists of 1 type or 2 types or more chosen from the group which consists of.
Moreover, the said thermoplastic resin consists of 1 type, or 2 or more types chosen from the group which consists of polystyrene, polyamide, and polypropylene.
The rubbery material used in the present invention is preferably a styrene elastomer.
A compatibilizing agent may be further added to the polymer alloy of the present invention.
The core material 2 of the plastic corrugated cardboard 1 of the present invention is made of a corrugated plate, in the case of a honeycomb structure, in the case of a grid-like honeycomb structure, in the case of a molded thin plate in which a large number of convex portions 4 are formed on the thin plate, etc. Various aspects can be taken.
The covering material 3 of the plastic corrugated cardboard 1 may be made of a heat resistant material, for example, when made of a porous material, and the heat resistant material is preferably a sheet of carbon fiber and / or aramid fiber.

  The plastic cardboard of the present invention is excellent in moldability and flame retardancy.

Hereinafter, the contents of the present invention will be described in detail.
The plastic corrugated cardboard 1 (hereinafter referred to as corrugated cardboard 1) of the present invention comprises a core material 2 and a covering material 3 applied to the core material 2 (see FIGS. 1 to 4).

The core material 2 of the corrugated cardboard 1 according to the present invention is composed of, for example, a core material 2A in which a large number of cylindrical portions 6 are formed on a thin plate as shown in FIGS. The core material 2 of the corrugated cardboard 1 of the present invention is not limited to the case of the core material 2A. For example, in the case of the corrugated plate 2B as shown in FIG. 5, a honeycomb structure as shown in FIG. Various shapes such as a case of 2C may be used.
In the present invention, the honeycomb structure 2C includes a grid-like structure 2D as shown in FIG.

  The core material 2A is obtained by cutting out the upper end portion 5 of the convex portion 4 of the precursor member 2E shown in FIGS. 8 and 9, and this precursor member 2E itself is used as the corrugated cardboard 1 of the present invention. It may be used as the core material 2. In this case, the convex portion 4 is not limited to the one having a planar upper end surface as shown in FIGS. 8 and 9. For example, the convex portion 4A (see FIG. 10) whose upper end portion is V-shaped 5A, U-shaped 5B. The convex portion 4B (see FIG. 11) and the convex portion 4 having various shapes such as a convex portion 4C having a circular opening 5C on the upper end surface (see FIG. 12) may be used. Further, the protrusions 4 formed on the precursor member 2E need not all have the same shape on the precursor member 2E. For example, as shown in FIG. 13, a cylindrical protrusion 4 (tubular portion 6) is formed. It may be a precursor member 2E which is arranged around and has a convex portion 4 having a planar shape at the upper end at the center, or a precursor member 2E in which convex portions 4 of various shapes are arranged as shown in FIG. In the present invention, the cylindrical convex portion 4 is particularly referred to as a cylindrical portion 6.

  The shape of the core material 2 is determined by the intended use of the cardboard 1 and the like. For example, when the cardboard 1 of the present invention is used as a sound absorbing material for the purpose of sound absorption and sound insulation, an excellent shape such as sound absorption efficiency is selected.

  The core material 2 of the cardboard 1 of the present invention is made of a thermoplastic resin. Examples of the thermoplastic resin include polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-propylene terpolymer, ethylene-vinyl acetate copolymer, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyvinyl acetate, fluororesin, Thermoplastic synthetic resins such as thermoplastic acrylic resin, thermoplastic polyester, thermoplastic polyamide, thermoplastic urethane resin, acrylonitrile-butadiene copolymer, styrene-butadiene copolymer, acrylonitrile-butadiene-styrene copolymer can be used. However, it is desirable to use engineering plastic as a material when heat resistance is required.

  Examples of the engineering plastic include polyamide (PA), polyester (PE), polyacetal (POM), polycarbonate (PC), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polysulfone (PSF), polyethersulfone ( PES), polyphenylene ether (PPE), modified polyphenylene ether (modified PPE), polyphenylene sulfide (PPS), polyarylate (PAR), polyether ether ketone (PEEK), polyamideimide (PAI), polyimide (PI), polyether Thermoplastic engineering plastics such as imide (PEI), polyamino bismaleimide, and methylpentene copolymer (TPX), and liquid crystalline resins such as polyallyl ether Near-ring plastic, compression-molding engineering plastics such as polytetrafluoroethylene (PTFE), etc., amorphous polymer, polyaminobismaleimide, bismaleimide-triazine-based thermosetting aromatic polyimide, crystalline polyethylene terephthalate and crystalline polybutylene Desirably, engineering plastics having a melting point of 200 ° C. or higher, such as crystalline polyester such as terephthalate, stereoregular polystyrene such as syndiotactic polystyrene and isotactic polystyrene, and the like. These engineering plastics are used alone or in combination of two or more.

  The modified PPE is PPE with styrene, α-methylstyrene, α-ethylstyrene, α-methylvinyltoluene, α-methyldialkylstyrene, o, m or p-vinyltoluene, o-ethylstyrene, p-ethyl. Styrene, 2,4-dimethylstyrene, o-chlorostyrene, p-chlorostyrene, o-bromostyrene, 2,4-dichlorostyrene, 2-chloro-4-methylstyrene, 2,6-dichlorostyrene, vinylnaphthalene, A polymer alloy formed by graft polymerization of styrene monomers such as vinylanthracene or by mixing styrene resins such as polystyrene, styrene-acrylonitrile resin, acrylonitrile-butadiene-styrene resin (ABS), high impact polystyrene (HIPS), etc. It is.

  When the core material 2 of the present invention is made of a polymer alloy of the engineering plastic and a thermoplastic resin, examples of the thermoplastic resin used in the polymer alloy include polyethylene, polypropylene, ethylene-propylene copolymer, and ethylene-acetic acid. Polyolefin resins such as vinyl copolymers, polystyrene resins such as polystyrene, styrene-acrylonitrile resins, acrylonitrile-butadiene-styrene resins, polycaprolactam (nylon 6), polyhexamethylene adipamide (nylon 66), polyhexamethylene There are polyamide resins such as sebacamide (nylon 610), polyundeca 1 lactam (nylon 11), and polydodeca 1 lactam (nylon 12). These thermoplastic resins may be used alone or in combination of two or more. It is use.

  When the core material 2 of the present invention is made of a polymer alloy of the engineering plastic, thermoplastic resin, and rubber-like substance, examples of the rubber-like substance used for the polymer alloy include acrylic rubber, butyl rubber, silicon rubber, Urethane rubber, fluoride rubber, polysulfide rubber, graft rubber, butadiene rubber, isoprene rubber, chloroprene rubber, polyisobutylene rubber, polybutene rubber, isobutene rubber-isoprene rubber, acrylate-butadiene rubber, styrene-butadiene rubber, acrylonitrile -Synthetic rubber such as butadiene rubber, pyridine-butadiene rubber, styrene-isoprene rubber, acrylonitrile-chloroprene rubber, styrene-chloroprene rubber, natural rubber, styrene-butadiene-styrene block copolymer (SBS) Styrene-isoprene-styrene block copolymer (SIS), α-methylstyrene-butadiene-α-methylstyrene block copolymer (α-MeS-Bd-MeS), α-methylstyrene-isoprene-α-methylstyrene Examples include block copolymers, styrene elastomers such as styrene-hydrogenated polyolefin-styrene block copolymers (SEBS, SEPS), polyolefin elastomers, polyurethane elastomers, polyester elastomers, polyamide elastomers, and the like. These rubber-like substances are used alone or in combination of two or more.

Furthermore, a compatibilizing agent may be added to the polymer alloy for the purpose of improving the compatibility of each component.
Since the compatibilizing agent is composed of a compound having affinity for each component of the polymer alloy, the mixing state of each component in the polymer alloy is made uniform through each component. Accordingly, the characteristics of each component are effectively exhibited, and the material has extremely good heat resistance and moldability, and a core material having a complicated shape can be easily manufactured by vacuum forming or the like.

  For example, as a compatibilizing agent for an aromatic engineering plastic such as PPE, modified PPE, or PPS, and a polymer alloy (including a polymer alloy including a rubbery substance) made of polyolefin such as polypropylene, for example, PPE and polypropylene may be used. Block or graft copolymer bonded by chemical bond, block or graft copolymer of polypropylene and polystyrene, block or graft copolymer of PPE and ethylene-butene copolymer, alkenyl aromatic compound (for example, styrene) A polymer obtained by hydrogenating a diblock copolymer or a triblock copolymer of a conjugated diene (for example, butadiene or isoprene) is used.

Examples of the compatibilizer of (a) (i) an ethylenic carbon-carbon double bond or carbon include a polymer alloy containing a polymer alloy rubber-like substance composed of the above aromatic engineering plastic and a polyamide resin. A compound containing both a carbon triple bond and; (ii) a carboxylic acid, an acid anhydride, an acid amide, an imide, a carboxylic ester, an amine or a hydroxyl group; (b) a liquid diene polymer; (c) an epoxy compound; (d) a polycarboxylic acid or a derivative thereof; (e) an oxidized polyolefin wax; (f) an acyl functional group-containing compound; (g) a chloroepoxytriazine compound; and (h) a trialkylamine salt of maleic acid or fumaric acid. Illustrated.
Details of the compatibilizers (a) to (h) are disclosed in JP-A-9-12497, and the compatibilizers (a) to (h) are disclosed in US Pat. No. 4,315,086. (References to (a), (b) and (c)), US Pat. No. 4,873,286 (references to (d)), US Pat. No. 4,659,760 ((e) Literature), U.S. Pat. No. 4,642,358 and U.S. Pat. No. 4,600,741 (literature relating to (f)), U.S. Pat. No. 4,895,945, U.S. Pat. No. 5,096,979, US Pat. Nos. 5,089,566 and 5,041,504 (references to (g)), US Pat. No. 4,755,566 (( References on h)).

  The compatibilizer is usually added in an amount of 0.1 to 60% by mass relative to the polymer alloy.

  A flame retardant is added to the thermoplastic resin. The flame retardant is at least one selected from halogen flame retardant, phosphorus flame retardant, nitrogen flame retardant, inorganic flame retardant, silicon flame retardant, metal salt flame retardant, fluorine flame retardant, expanded graphite and the like. These flame retardants are exemplified.

  Examples of the halogen flame retardant include halogenated bisphenol, aromatic halogen compound, halogenated polycarbonate, halogenated aromatic vinyl polymer, halogenated cyanurate resin, halogenated polyphenylene ether, and the like. Decabromodiphenyl ether, tetrabromobisphenol A, oligomer of tetrabromobisphenol A, brominated bisphenol phenoxy resin, brominated bisphenol polycarbonate, brominated polystyrene, brominated crosslinked polystyrene, brominated polyphenylene ether, polydibromophenylene ether, Examples thereof include decabromodiphenyl ether bisphenol condensate, halogen-containing phosphate ester and fluorine-based resin.

  Examples of the phosphorus flame retardant include organic phosphorus compounds, red phosphorus, inorganic phosphates, and the like.

  Examples of the organic phosphorus compound include phosphine, phosphine oxide, biphosphine, phosphonium salt, phosphinic acid salt, phosphate ester, phosphite ester, and the like. Specific examples thereof include triphenyl phosphate, methylneo Pentyl phosphite, pentaerythritol diethyl diphosphite, methyl neopentyl phosphate, phenyl neopentyl phosphate, pentaerythritol diphenyl diphosphate, dicyclopentyl high positive phosphate, dineopentyl hypophosphite, phenyl pyrocatechol phosphite, Ethyl pyrocatechol phosphite, dipyrro catechol high positive phosphate, phenoxypropoxyphosphazene, diphenoxyphosphazene, pheno Shi amino phosphazene, although phenoxy fluoroalkyl phosphazene, and the like, aromatic phosphoric acid ester monomer and condensate is preferable.

  As the above-mentioned red phosphorus, in addition to general red phosphorus, the surface thereof is previously coated with a metal hydroxide film selected from aluminum hydroxide, magnesium hydroxide, zinc hydroxide, titanium hydroxide, Coated with a metal hydroxide selected from aluminum hydroxide, magnesium hydroxide, zinc hydroxide and titanium hydroxide and a thermosetting resin, aluminum hydroxide, magnesium hydroxide, zinc hydroxide, water Examples thereof include a film formed by double coating with a thermosetting resin film on a metal hydroxide film selected from titanium oxide.

  Examples of the inorganic phosphate include ammonium phosphate and ammonium polyphosphate.

  Examples of the nitrogen-based flame retardant include at least one kind composed of a triazine compound, a triazole compound, a tetrazole compound, a phosphazene compound, and a diazo compound. Specific examples include melamine, melam, melem, melon, melamine cyanurate, melamine phosphate, succinoguanamine, adipoguanamine, methylglutalogamine, melamine resin, BT resin and the like, and in particular, melamine cyanurate. Is preferred.

  Examples of the inorganic flame retardant include silica, sodium sulfate, calcium sulfate, potassium sulfate, aluminum hydroxide, magnesium hydroxide, zirconium hydroxide, barium hydroxide, calcium hydroxide, dolomite, hydrotalcite, basic carbonate Magnesium, tin oxide hydrate, aluminum oxide, iron oxide, titanium oxide, manganese oxide, magnesium oxide, zirconium oxide, zinc oxide, molybdenum oxide, cobalt oxide, bismuth oxide, chromium oxide, tin oxide, antimony oxide, nickel oxide , Copper oxide, tungsten oxide, aluminum, iron, titanium, manganese, zinc, molybdenum, cobalt, bismuth, chromium, nickel, copper, tungsten, tin, antimony, SUS, zinc borate, zinc metaborate, barium metaborate, carbonic acid Asia , Magnesium carbonate, calcium carbonate, barium carbonate, hydrated glass are exemplified, can be used in combination singly, or two or more kinds. Among these, aluminum hydroxide, magnesium hydroxide, basic magnesium carbonate, hydrotalcide, and hydrated glass are preferable.

  Examples of the silicon-based flame retardant include a silicone compound and a silane compound.

Examples of the silicone compound include silicone oil which is polydiorganosiloxane, or a silicone resin formed by combining structural units such as SiO ₂ , RSiO _3/2 , R ₂ SiO, R ₃ SiO _1/2. . In the structural unit, R represents a methyl group, an ethyl group, a propyl group, a phenyl group, a benzyl group, or a vinyl group. Specific examples include polydimethylsiloxane resin, polymethylphenylsiloxane resin, polydiphenylsiloxane resin, polymethylethylsiloxane resin, polycarbosiloxane, and mixtures thereof. The number average molecular weight of these silicone resins is preferably in the range of 200 to 5000000, and the shape may be any of oil, varnish, gum, powder, and pellet.

  Examples of the silane compounds include polyalkylsilane compounds, polycarbosilane compounds, and the like. Among these, polymethylphenylsilane, polydiphenylsilane, and polyphenylsilin are representative. These compounds may be terminated with either an OH group or an alkyl group, and may have a cyclic structure.

  Examples of the metal salt flame retardant include organic sulfonic acid metal salts such as trichlorobenzene sulfonic acid metal salt, perfluorobutane sulfonate, diphenyl sulfone-3-sulfonic acid metal salt, aromatic sulfonimide metal salt, styrene ( Polystyrene sulfonic acid alkali metal salts and polyphenylene sulfones in which sulfonic acid metal salts, sulfate metal salts, phosphate metal salts, and borate metal salts are bonded to the aromatic rings of aromatic group-containing polymers such as co) polymers and polyphenylene ethers. Examples thereof include metal salt flame retardants such as acid metal salts. In addition, as a metal seed | species used for a metal salt, an alkali metal, alkaline-earth metal, Zn, Sn, Al, and Sb are suitable.

  The fluorine-based flame retardant is a resin containing a fluorine atom in a resin, such as polymonofluoroethylene, polydifluoroethylene, polytrifluoroethylene, polytetrafluoroethylene, tetrafluoro / hexafluoropropylene copolymer, etc. Is exemplified. Moreover, you may use together the monomer copolymerizable with the said fluorine monomer as needed. These fluorine resins preferably have an average molecular weight of 100,000 to 10,000,000.

  As the expanded graphite, natural graphite is immersed in an inorganic acid such as concentrated sulfuric acid, nitric acid or selenic acid, and an oxidizing agent such as perchloric acid, perchlorate, permanganate, dichromate or hydrogen peroxide. It is obtained by adding and processing, and expansion start temperature is about 250 to 300 degreeC. The expanded graphite has an expansion volume of about 30 to 300 ml / g and a particle size of about 300 to 30 mesh.

  The flame retardant is usually added in an amount of about 0.1 to 60.0% by mass relative to the thermoplastic resin.

  To the thermoplastic resin, calcium carbonate, magnesium carbonate, barium sulfate, calcium sulfate, calcium sulfite, calcium phosphate, calcium hydroxide, magnesium hydroxide, aluminum hydroxide, magnesium oxide, to the extent that the object of the present invention is not impaired. Titanium oxide, iron oxide, zinc oxide, alumina, silica, diatomaceous earth, dolomite, gypsum, talc, clay, asbestos, mica, calcium silicate, bentonite, white carbon, carbon black, iron powder, aluminum powder, glass powder, stone powder, Synthetic resin powder, blast furnace slag, fly ash, cement, zirconia powder, linter, linen, sisal, wood powder, palm powder, walnut powder, den flour, flour, cotton, hemp, wool, asbestos, kenaf fiber and other natural fibers, Polyamide fiber, polyester fiber, polyolefin Filling with synthetic fibers such as vinyl fibers, acrylic fibers, vinyl chloride fibers and vinylidene chloride fibers, semi-synthetic fibers such as acetate fibers, asbestos fibers, glass fibers, carbon fibers, ceramic fibers, metal fibers, inorganic fibers such as whiskers One or more of materials, pigments and dyes, antioxidants, antistatic agents, crystallization accelerators, flameproofing agents, lubricants, antiaging agents, ultraviolet absorbers and the like may be added.

  The core material 2 of the corrugated cardboard 1 of the present invention may be manufactured from the thermoplastic resin foam.

  The core material 2 of the cardboard 1 of the present invention may be coated with a porous layer 7 as shown in FIG. Examples of the porous material used as the material of the porous layer 7 include organic synthesis such as polyester fiber, polyethylene fiber, polyamide fiber, acrylic fiber, urethane fiber, polyvinyl chloride fiber, polyvinylidene chloride fiber, and acetate fiber. Natural fiber such as fiber, pulp, cotton, palm fiber, hemp fiber, bamboo fiber, kenaf fiber, etc., inorganic fiber such as glass fiber, carbon fiber, ceramic fiber, asbestos fiber, stainless steel fiber, or fiber products using these fibers Fiber aggregates such as knitted fabrics, nonwoven fabrics, felts, and laminates thereof composed of one or two or more kinds of recycled fibers obtained by defibrating scraps of polyurethane, polyurethane foam having open cells (soft Polyurethane foams, including rigid polyurethane foams), polyolefins such as polyethylene and polypropylene Foam, polyvinyl chloride foam, polystyrene foam, amino resin foam such as melamine resin and urea resin, epoxy resin foam, phenolic resin foam composed of phenolic compounds such as monohydric phenol and polyhydric phenol Well-known foams such as a plastic having an open cell structure such as a sintered body of plastic beads.

  The porous layer 7 may be impregnated or coated with the above-described flame retardant, or may be impregnated or coated with a synthetic resin. Examples of the synthetic resin include initial condensates of thermosetting resins such as melamine resins, urea resins, and phenol resins, emulsions and aqueous solutions of thermoplastic resins, and other pigments, dyes, antioxidants, antistatic agents, Crystallization accelerators, flameproofing agents, lubricants, antiaging agents, ultraviolet absorbers, and the like may be added.

  The covering material 3 used for the corrugated cardboard 1 of the present invention is applied to one or both sides of the core material 2, and the covering material 3 is exemplified as the porous material of the porous layer 7. The above-mentioned fiber aggregate, the above-mentioned thermoplastic resin sheet or film, the above-mentioned thermoplastic resin foam sheet or film, and metal foil such as aluminum foil are used.

  When the covering material 3 and the porous layer 7 are made of fibers, examples of the fibers include glass fibers, carbon fibers, ceramic fibers, asbestos fibers, stainless fibers, and other inorganic fibers, polymetaphenylene isophthalamide fibers, and poly-p-. When heat-resistant synthetic fibers having a melting point of 250 ° C. or higher, such as aramid fibers such as phenylene terephthalamide fibers, polyarylate fibers, polyether ether ketone fibers, and polyphenylene sulfide fibers, are used, cardboard with extremely high heat resistance can be obtained. . Among them, carbon fiber is a useful inorganic fiber because it can be incinerated and is difficult to disperse fine pieces, and aramid fiber is a useful synthetic fiber because it is relatively inexpensive and easily available.

  When the covering material 3 is a fiber assembly, the covering material 3 may be impregnated with a synthetic resin. The synthetic resin is the same as the synthetic resin impregnated in the porous layer 7.

A method for manufacturing the cardboard 1 of the present invention will be described below. First, a method for manufacturing the core material 2 of the cardboard 1 will be described.
The core material 2 of the cardboard 1 of the present invention is molded into a predetermined shape. For example, the core material 2B of the cardboard 1A shown in FIG. 14 is a core material 2B made of a corrugated plate shown in FIG. is there.
The corrugated plate is manufactured by a known molding method such as injection molding.

  For example, as shown in FIG. 15, the core material 2D shown in FIG. 7 has a notch 8A cut from the upper side of the strip-shaped substrate 8 made of engineering plastic or the like and a notch 9A from the lower side of the strip-shaped substrate 9. Are manufactured by assembling them with each other by engaging the notches with each other.

A method for manufacturing the core material 2 of the cardboard 1 shown in FIGS. 1 to 4 will be described. As shown in FIGS. 8 and 9, the core material 2 is manufactured by first vacuum forming a sheet made of engineering plastic or the like to produce a precursor member 2E in which a large number of convex portions 4 are arranged vertically and horizontally. It is manufactured by cutting off the upper end portion of the convex portion 4 of the precursor member 2E. According to the above manufacturing method, the core material 2A in which a large number of cylindrical convex portions (tubular portions 6) shown in FIGS. 3 and 4 are arranged vertically and horizontally can be manufactured.
In the manufacturing method of the core material 2 of this type of corrugated cardboard 1, the above manufacturing method is most suitable for mass production of the core material 2, but in addition to vacuum molding, pressure molding, vacuum / pressure molding, press molding, injection molding, etc. It can manufacture by the well-known method of these.

  The covering material 3 that covers the core material 2 is bonded to the core material 2 by a known technique in consideration of the material, shape, and the like of each core material 2.

  Hereinafter, the present invention will be described by way of examples. However, this invention is not limited only to the Example shown below.

  Cardboard 1A shown in FIG. 14 is used as a heat insulating material. The core 2 and the covering 3 made of corrugated corrugated board are made of polyethylene terephthalate (flame retardancy: UL94 standard HB) mixed with 40.0 mass% ammonium polyphosphate.

(Sound absorption test)
As shown in FIG. 1 to FIG. 4, it is composed of a polymer alloy of polyphenylene ether / styrene / SEBS mixed with 20.0% by mass of ammonium polyphosphate and 10.0% by mass of expanded graphite. 4. The core material 2A (flame retardancy: UL94 standard V-0), the covering material 3 composed of a polyester fiber nonwoven fabric (weight per unit area: 40 g / m ² ) impregnated with 5.0% by mass of ammonium polyphosphate, and ammonium polyphosphate 5. The sound absorption efficiency of the sound absorbing material was measured using plastic corrugated cardboard 1 made of a porous layer 7 (thickness 10 mm, basis weight 60 g / m ² ) made of polyester fiber impregnated with 0% by mass as a sound absorbing material.
The height h of the sound absorbing material is 15 mm, and the upper end surface L × L of the cylinder portion is 10 mm × 10 mm.
Waveforms having frequencies of 800 Hz, 1500 Hz, and 2000 Hz were irradiated from the upper surface of the sound absorbing material, and the sound absorption efficiency was measured on the lower surface of the sound absorbing material.
The sound absorption efficiency (%) at each frequency was 85% (800 Hz), 98% (1500 Hz) and 95% (2000 Hz), respectively, and it was confirmed that the sound absorption efficiency of the sound absorbing material was good.
(Heat resistance test)
The operation of leaving the sound absorbing material 1A at 150 ° C. for 30 minutes and then leaving it at room temperature (20 ° C.) for 30 minutes was repeated 10 times, and then the state of the sound absorbing material was observed. As a result of observation, no abnormalities in appearance such as deformation and warping were found in the sound absorbing material.
The sound absorbing material was examined for sound absorption efficiency under the same conditions as in the sound absorption test, but no change was found in the sound absorption efficiency.

A sound absorbing material made of corrugated cardboard 1B (see FIG. 17) was manufactured using the coated core material 2F shown in FIG. 16 instead of the core material 2A of the sound absorbing material of Example 2 above. The coated core material 2F is obtained by coating the upper and lower sides of the core material 2A with a porous layer 7.
The core material 2A of the coated core material 2F is a sheet made of a polymer alloy mainly composed of PPE, PA and styrene-based elastomer mixed with 10.0% by mass of ammonium polyphosphate and 5.0% by mass of expanded graphite. Flame retardancy: UL94 standard V-0) was produced by vacuum forming. The porous layer is made of a polyurethane foam impregnated with 30.0% by mass of ammonium polyphosphate. In addition, the polyester fiber nonwoven fabric similar to the said Example 2 was used for the coating | covering material 3 which coat | covers this core material 2. FIG.
The sound-absorbing material of this example also had good sound-absorbing efficiency, heat resistance, and flame retardance, similar to the sound-absorbing material of Example 2 above.

As another sound absorbing material, a sound absorbing material made of corrugated cardboard 1C shown in FIG. 18 was manufactured.
As the covering core material 2G of the sound absorbing material, a structure in which a core material 2E having a convex portion 4 having a flat upper end surface is coated with a porous layer 7 as shown in FIGS. It is.
The core 2E was manufactured by vacuum forming using PP (flame retardancy: UL94 standard V-0) containing 0.8% by mass of melamine cyanurate as a material.
Further, as the covering material 3 for covering the core material 2E, a polyester fiber nonwoven fabric impregnated with 0.5% by mass of melamine cyanurate was used.
The sound absorption efficiency, heat resistance, and flame retardancy of the sound absorbing material of this example were good as in Example 2 and Example 3.

The comparative example of the sound-absorbing material consisting of the cardboard 1 of the present invention is shown below. The comparative example is a conventional sound absorbing material.
[Comparative Example 1]
A sound absorbing material 11 shown in FIG. 19 is obtained by coating a core material 12 made of a porous body such as a fiber layer with a covering material 13.
Although this type of sound absorbing material 11 has good sound absorption efficiency, it has been considered to be inferior in flame retardancy and large in weight.

[Comparative Example 2]
The sound absorbing material 11A shown in FIG. 20 uses a core material (12A) made of polypropylene, which is a general-purpose plastic.
Although this sound absorbing material 11A is lightweight, it is inferior in heat resistance and flame retardancy.

A honeycomb structure shown in FIG. 6 was used as a core material 2C, and the core material 2C was coated with a coating material 3 to manufacture a cardboard 1D (see FIG. 21). The core material 2C is made of a 1: 1 mass ratio mixture of polymer alloy mainly composed of PPE and SEBS and polytetrafluoroethylene (flame retardant: UL94 standard HB), and covers the core material 2C. The covering material 3 is made of a polyester fiber nonwoven fabric impregnated with 1% by mass of sodium sulfonate.
The corrugated cardboard 1D of this example was used as a cushioning material excellent in flame retardancy for reducing the impact during transportation of the article.

The core material 2D shown in FIG. 7 is composed of a polymer alloy (flame retardancy: UL94 standard HB) in which some compatibilizer is added to polyphenylene ether / polypropylene / SEBS containing 15.0% by mass of antimony oxide. The core material 2D was coated with a carbon fiber nonwoven fabric 3 as shown in FIG.
The corrugated cardboard 1E is excellent in heat resistance and flame retardancy for both the core material and the covering material. For example, an insulator hood stuck inside the engine hood of an automobile, a dash set between an engine room of an automobile and a cabin. It is useful as a sound-absorbing material or a buffer material for parts exposed to high temperatures such as an outer silencer and a dash silencer.

In the corrugated cardboard 1D shown in FIG. 21, the material of the core material 2C is crystalline polyethylene terephthalate mixed with 30.0% by mass of ammonium polyphosphate, and the material of the coating material 3 is polymetaphenylene containing 15.0% by mass of ammonium polyphosphate. Use non-woven fabric of isophthalamide fiber.
The corrugated cardboard 1D is also excellent in heat resistance and flame retardancy, and is useful as a buffer material or a sound absorbing material in a portion exposed to a high temperature.

In the corrugated cardboard 1E shown in FIG. 22, the core material 2D is added with 10.0% by mass of barium metaborate to form syndiotactic polystyrene, and the coating material 3 is impregnated with 5.0% by mass of barium metaborate. A non-woven fabric of fibers.
The cardboard 1E is also excellent in heat resistance and flame retardancy, and is useful as a cushioning material or a sound absorbing material in a portion exposed to a high temperature.

  The plastic corrugated cardboard of the present invention has flame retardancy and is useful as a cushioning material and sound absorbing material for buildings and automobiles.

Perspective view of sound-absorbing material made of plastic cardboard AA sectional view of the sound absorbing material shown in FIG. Perspective view of the cylindrical member BB sectional view of the cylindrical member shown in FIG. Perspective view of core material made of corrugated plate Perspective view of core material made of honeycomb structure Perspective view of core material made of grid-like honeycomb structure Perspective view of precursor member CC sectional view of the precursor member shown in FIG. Partial sectional view of another precursor member Further, a partial cross-sectional view of another precursor member Perspective view of other precursor members Perspective view of other precursor members Partial sectional view of corrugated cardboard having a core made of corrugated plate Explanation of other core manufacturing methods Partial cross-sectional view of a core material covered with a porous layer on the top and bottom 14 is a partial cross-sectional view of a cardboard (sound absorbing material) having the core material of FIG. Partial cross-sectional view of a cardboard (sound absorbing material) having a core having a convex portion whose upper end surface is planar. Notched perspective view of conventional sound absorbing material Notched perspective view of another conventional sound absorbing material A partially cutaway perspective view of a cardboard having a honeycomb structure core. FIG. 7 is a partially cutaway perspective view of a cardboard having the core material of FIG.

Explanation of symbols

1, 1A, 1B, 1C, 1D Plastic corrugated cardboard 2 Core material 2A Core material in which a large number of cylindrical portions are arranged vertically and horizontally 2B Corrugated plate core material 2C Honeycomb structure core material 2D Grid-like core material 2E Precursor member (core Material)
DESCRIPTION OF SYMBOLS 3 Covering material 4 Convex part 5 Upper end part 6 Cylindrical part 7 Porous layer 8,9 Substrate 8A, 9A Cutting 11,11A Sound-absorbing material 12,12A Core material 13,13A Covering material

Claims (13)

  A plastic corrugated cardboard comprising a core material and a covering material applied to one or both surfaces of the core material, wherein at least the core material is made of a thermoplastic resin containing a flame retardant.   2. The plastic cardboard according to claim 1, wherein the thermoplastic resin is a polymer alloy of engineering plastic, engineering plastic and thermoplastic resin, or a polymer alloy of engineering plastic, thermoplastic resin and rubber-like substance.   The engineering plastics are polyamide (PA), polyester (PE), polyacetal (POM), polycarbonate (PC), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polysulfone (PSF), polyethersulfone (PES). , Polyphenylene ether (PPE), modified polyphenylene ether (modified PPE), polyphenylene sulfide (PPS), polyarylate (PAR), polyetheretherketone (PEEK), polyamideimide (PAI), polyimide (PI), polyetherimide ( One or more selected from the group consisting of PEI), polyaminobismaleimide, methylpentene copolymer (TPX), crystalline polyester and stereoregular polystyrene Plastic cardboard according to claim 2 consisting of plastic.   The plastic cardboard according to claim 2 or 3, wherein the thermoplastic resin is one or two or more thermoplastic resins selected from the group consisting of polystyrene, polyamide, and polypropylene.   The plastic corrugated cardboard according to claim 2, wherein the rubber-like substance is a styrene elastomer.   The plastic cardboard according to claim 2, wherein a compatibilizer is further added to the polymer alloy.   The plastic corrugated cardboard according to any one of claims 1 to 6, wherein the core material comprises a corrugated plate.   The plastic corrugated cardboard according to any one of claims 1 to 6, wherein the core material has a honeycomb structure.   The plastic corrugated cardboard according to any one of claims 1 to 6, wherein the core material is a molded thin plate in which a plurality of convex portions are formed on a thin plate.   The plastic corrugated cardboard according to any one of claims 1 to 6, wherein the core material is a grid-like honeycomb structure.   The plastic corrugated cardboard according to any one of claims 1 to 10, wherein the covering material is made of a porous material.   The plastic corrugated cardboard according to any one of claims 1 to 11, wherein the covering material is made of a heat resistant material.   The plastic cardboard according to claim 12, wherein the heat-resistant material is a sheet of carbon fiber and / or aramid fiber.

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