JPH06298979A - Resin foam and manufacturing method thereof - Google Patents

Abstract

PURPOSE:To efficiently obtain a resin foam, excellent in adhesion and useful as a resin film, a coating material, etc., by mixing a keratinous substance together with a surfactant in water, expanding the resultant mixture and mixing the expanded bubbles in a synthetic-resin latex. CONSTITUTION:The resin foam is obtained by mixing 70-30wt.% keratinous substance prepared from feather, etc., together with a surfactant such as polyoxyethylene lauryl ether in water, expanding the resultant mixture and mixing the obtained expanded bubbles in 30-70wt.% synthetic resin latex such as an acrylic or a urethane emulsion.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin foam and a method for producing the same, more specifically, a resin film, a resin sheet, an adhesive or an adhesive resin layer, a coating material or a coating resin film, or a paint or a coating resin film. And a method for producing a resin foam that can be used as

[0002]

2. Description of the Related Art As a conventional resin foam of this type, for example, a thermoplastic resin is mixed with an inorganic salt to form a film, and the inorganic salt is immersed in a meltable solution and eluted. Also, acetic acid fiber-based films and the like are provided.

[0003]

According to the above-mentioned means, the above-mentioned resin foam and its manufacturing method are limited in use because only minute inorganic salts are eluted and only extremely fine pores are formed. Moreover, other acetic acid fiber-based films have a drawback that the mechanical strength of the film-like material is weak.

The present invention was developed to solve the above-mentioned problems, and a raw material and a keratin-containing substance such as feather which can be obtained at a low cost with respect to urethane foam and polyisocyanurate foam, which are relatively expensive to produce, are used as a raw material. And a resin foam and a resin foam that can be manufactured at a relatively simple process at low cost and can be used in a wide range of applications as a resin film, a resin sheet, an adhesive or an adhesive resin layer, a coating material or a coating resin film, or a paint or a coating resin film. It is intended to provide a manufacturing method.

[0005]

DISCLOSURE OF THE INVENTION The present invention relates to a resin foam comprising a synthetic resin latex of 30 to 70% and a keratin foam of 70 to 30% by weight, and a method for producing the same. The keratin obtained from the above is mixed with water together with a surfactant, and the foam obtained by extruding from a minute void by pressurizing and foaming is mixed with a synthetic resin latex such as an acrylic or urethane emulsion and stirred to mix bubbles. Characterize.

The present invention will be described in more detail below. As described above, the resin foam of the present invention contains, as a main component, keratin obtained from a feather or the like, and foams it.
It is obtained by mixing it with a latex such as acrylic or urethane.

The above-mentioned keratin is also contained in feathers, animal hair, nails and the like, and these can be used alone or in combination of several kinds. However, it is desirable that the keratin is subjected to a crushing step as a pretreatment. It is preferable to use feathers as a raw material that can omit this step.

In order to make the feathers into a slurry, the feathers are sufficiently boiled at 70 ° C. to 120 ° C. for 3 to 5 hours under normal pressure or pressure by adding water with an indirect heating type heat exchanger. The amount of water to be added is not particularly limited as long as it is the amount necessary to make the feathers into a slurry state, but the feathers 100
Water can be 50 to 80 parts (weight ratio) with respect to parts.

The feathers thus boiled and ripe are filtered together with water.

For example, the boiled liquor together with the slurry-like feathers is put into a filter having a cloth of 100 μm mesh as a filter, and 60 parts of the β-keratin aqueous solution is recovered with respect to 100 parts of the feathers. The remaining 40 parts are discarded.

Next, this keratin aqueous solution is mixed and stirred by a blending machine together with water and a surfactant.
This mixing and stirring is performed in order to mix air bubbles in the keratin aqueous solution and form a liquid foam having a predetermined particle shape in the next step. The blending amount of water and the surfactant is 1 to 10 parts of the keratin aqueous solution and 0.1 to 10 parts of the surfactant with respect to 1000 parts of water.
It can be 0.7 part. It has been found that when the ratio of the surfactant and / or water to the keratin aqueous solution is too large, it becomes difficult to maintain the foam in the next step.

The surfactant is not limited to this, but it is a nonionic polyoxyethylene lauryl ether, polyoxyethylene oleyl ether, polyethylene glycol nonyl phenyl ether or the like having a degreasing effect, or an amino type. Anionic compounds such as ether type, ether ester type, resin acid salt, lignin sulfonic acid, ABS, and lauryl alcohol sulfate ester salt are used.

The liquid containing the mixed and stirred foam is then put into a foaming machine. Foamer has a gauge pressure of 6-8kg / c
0.2 to 0.5 mm in diameter at the discharge port of the tank regulated to m ²
3 to 10 are provided with a foaming part in which beads of plastic or ceramic of
Generates a foam containing μ keratin.

When the particle diameter of the beads in the foaming portion and the particle diameter of the foam exceed the above-mentioned ranges, the foam disappears when the foam is mixed into the synthetic resin latex. In addition, a foam having a uniform particle size cannot be obtained.

A mixer is connected to the discharge port of the foaming machine, and 70 to 10% of foam is mixed with 30 to 70% (weight ratio, the same applies hereinafter) of synthetic resin latex, such as urethane or acrylic emulsion. And stir.

Besides urethane or acrylic, an emulsion of rubber latex, polyvinyl chloride, vinyl acetate, etc. is used.

Examples will be described below.

[0018]

[Examples] 60 water was added to 100 parts of chicken feathers in a volume ratio, and the mixture was boiled at 90 ° C. for 4 hours in an indirect heating type boiler at normal pressure to form a slurry boiled boiled liquid. Got

Next, the boiled and matured liquid is filtered with a filter having a cloth filter to recover a 60% (weight ratio) keratin aqueous solution based on the weight of the feathers.

Furthermore, 3 parts by weight of this aqueous solution of keratin is used.
1000 parts of water, 1000 parts of lauryl alcohol sulfate ester salt 0.3 parts (parts by weight) as a surfactant
Mix and stir on blender for 3 minutes at rpm. For 10 liters of water, 30 cc of keratin aqueous solution and 3 cc of surfactant.

Then, the mixed and stirred aqueous solution containing the foam layer scum is immediately put into a foaming machine composed of a pressure vessel having a gauge pressure of 8 kg / cm ³ . The foaming machine is regulated to a gauge pressure of 8 kg / cm ^2, and the discharge port of the tank is equipped with a foaming part that contains ceramic beads with a diameter of 0.5 mm in a compacted state. Particle size of almost uniform viscosity 9
Generates a foam containing μ keratin.

Further, the foam was introduced into a mixer communicating with the discharge port, and a urethane emulsion 30% was prepared.
(Volume ratio, the same applies below) At a blending ratio of 70% foam, both are mixed and agitated for about 3 minutes, and when the foam is mixed, a foamed urethane resin with an extremely stable adsorption film is formed. An emulsion can be obtained.

50% of this foamy urethane emulsion
In addition, 40% of WA351 urethane emulsion, trade name of Dainichiseika Kogyo Co., Ltd., a known crosslinking aid such as melamine resin or curing agent such as isocyanate (C96), and other additives for stabilizing mechanical strength are added. A total of 10% can be added and used as an adhesive. 1 and 2
Are cross-sectional photomicrographs of 200 times and 500 times, respectively, obtained by applying the above foamy urethane emulsion to a urethane film with a knife coater from the same figure and laminating the fibers. The particle size of the resin foam of the adhesive layer after drying is shown in FIG. It can be seen that independent bubbles of 5 to 10 μm are maintained.

The foamed urethane emulsion is polymerized with various other monomers and dispersed with pigments and other additives to be used as a paint for various plastic molded articles by air spraying or other methods. The surface can be formed to have a satin finish, and it has a good feel of friction. Furthermore, it can be laminated with various plastic films. In addition, the above foamy urethane emulsion may be other various emulsions, for example, solid content 5
Polymerized with 0 ± 2%, clay 100-1500, ph 6.5-8 average particle size 0.5μ uretane marsion and produced as a resin film or resin sheet by a known film-forming process, or laminated on a fiber. It can be used as a garment material (in the state where there is no urethane film or fiber in FIGS. 1 and 2) or as a coating material by various coating methods.

That is, what is formed by blending the resin foam obtained in this example is a resin molded product (injection molding, blow molding, rotational molding, vacuum molding, press molding produced by various molding methods. Molding, slush molding and other molding methods) or resin tubes, resin sheets (extrusion molding, calendar roll molding and other molding methods) or resin films (inflation molding and other methods) Coatings, coatings, laminate films, adhesives and the like, which are formed by the method of painting and coating.

The coating material containing the resin foam obtained in this example can be applied to the surface of various products by various coating methods such as brush coating, roll coating and gun spraying. Also, coating the base fabric surface with a coating liquid containing the resin foam obtained in this example,
The base cloth can be used by being dipped and immersed in this coating solution. Further, after applying the coating liquid containing the resin foam obtained in this example to the release paper by the doctor knife coating method or the like, the film formed on the surface of the release paper is reversely transferred to the base cloth surface or the like. Can be used.

The coating film or other formed article containing the resin foam obtained in this example can be used as it is, and in particular, the coating film, the coating, and the adhesive layer. , Coating layers, laminated films or thin films, etc., these coatings, films,
Adhesive material layer, coating layer, laminate film or thin film, etc. are projected, and the surface of these coating films etc. is not roughened, and cracks are not generated in these coating films etc. Can be applied to the coating film and the like.

From this point of view, it is used in various electric appliances, furniture, fittings, building materials, personal belongings, automobile parts, paints applied to the surface of interiors, or in various resin coating liquids or resin lining liquids. It can be used to form a surface coating layer. Further, the resin foam obtained in this example may be included in the laminate film and used by transferring it to the film base cloth surface or the like, or the film itself may be used independently.

The resin to be blended is selected and used according to the characteristics required for the molded product.

[0030]

[Effect] The present invention uses a keratin-containing substance such as feathers that can be obtained at low cost as a raw material, and can be manufactured at a relatively low cost with a resin film, a resin sheet, an adhesive or an adhesive resin layer, a coating material or a coating resin film,
Alternatively, it was possible to provide a resin foam which can be used in a wide range of applications as a paint or a coated resin film and a method for producing the resin foam.

[Brief description of drawings]

FIG. 1 is a schematic view of a 200 × cross-sectional photomicrograph of a plastic film laminated with fibers showing an example of the present invention.

FIG. 2 is a schematic view of a cross-sectional micrograph taken at a magnification of 500 in FIG.

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[Procedure amendment]

[Submission date] April 5, 1993

[Procedure Amendment 1]

[Document name to be corrected] Drawing

[Correction target item name] All drawings

[Correction method] Change

[Correction content]

[Figure 1]

[Fig. 2]

[Procedure amendment]

[Submission date] June 13, 1994

[Procedure Amendment 2]

[Document name to be amended] Statement

[Name of item to be corrected] Brief description of the drawing

[Correction method] Change

[Correction content]

[Brief description of drawings]

FIG. 1 is a 200 × cross-sectional photomicrograph of a plastic film laminated with fibers according to an example of the present invention.

FIG. 2 is a 500 × cross-sectional micrograph of FIG.

Claims (3)

[Claims] 1. A resin foam prepared by mixing 30 to 70% of synthetic resin latex with 70 to 30% by weight of keratin foam. 2. A method for producing a resin foam, which comprises mixing keratin obtained from feathers and the like with water together with a surfactant and mixing the foamed foam into a synthetic resin latex. 3. A keratin material obtained from feathers and the like is mixed with water together with a surfactant, and is extruded from a minute void by pressurization to foam, and the foam is mixed and stirred into an acrylic or urethane emulsion. A method for producing a resin foam characterized by the above.