Foamable vinyl chloride-base resin compositions

• US 6,723,762 B1
• Filed: 03/07/2002
• Issued: 04/20/2004
• Est. Priority Date: 09/22/1999
• Status: Expired due to Fees

• Current Assignee: Kaneka Corporation
• Original Assignee: Kaneka Corporation
• Inventors: Sato, Mitsutaka, Sakashita, Noriko, Kadokura, Mamoru, Sunagawa, Takenobu
• Primary Examiner(s): Foelak, Morton
• Application Number:
  US10/069,953
• Time in Patent Office: 775 Days
• Field of Search: 521/82, 521/92, 521/93, 521/94, 521/134, 521/145
• US Class Current: 521/82
• CPC Class Codes: C08F 220/14 Methyl esters , e.g. methyl (meth)acrylate
• CPC Class Codes: C08F 259/04 on to polymers of vinyl chloride
• CPC Class Codes: C08J 2327/06 Homopolymers or copolymers of vinyl chloride
• CPC Class Codes: C08J 2433/00 Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers
• CPC Class Codes: C08J 9/0061 characterized by the use of several polymeric components
• CPC Class Codes: C08J 9/04 using blowing gases generated by a previously added blowing agent
• CPC Class Codes: C08J 9/06 by a chemical blowing agent
• CPC Class Codes: C08L 2666/24 Graft or block copolymers according to groups C08L51/00, C08L53/00 or C08L55/02; Derivatives thereof
• CPC Class Codes: C08L 27/06 Homopolymers or copolymers of vinyl chloride
• CPC Class Codes: C08L 51/003 grafted on to macromolecular compounds obtained by reactions only involving unsaturated carbon-to-carbon bonds C08L51/04, C08L51/06 take precedence

Abstract

There is provided a foamable poly(vinyl chloride) resin composition which can remarkably improve an expansion ratio. There is used a foamable poly(vinyl chloride) resin composition comprising 100 parts by weight of (A) a poly(vinyl chloride) resin, 0.5 to 30 parts by weight of (B) a processing aid, and 0.5 to 15 parts by weight of water and 0 to 20 parts by weight of a thermal decomposition foaming agent as a foaming agent (C), wherein the processing aid is obtained by adding and polymerizing 0 to 50 parts of a monomer mixture (b) comprising 0 to 50% by weight of methyl methacrylate, 50 to 100% by weight of at least one monomer selected from the group consisting of methacrylate excluding methyl methacrylate and acrylate, and 0 to 20% by weight of a vinyl monomer copolymerizable therewith, in the presence of a latex of a (co)polymer obtained by emulsion polymerizing 50 to 100 parts by weight of a monomer mixture (a) comprising 50 to 100% by weight of methyl methacrylate, 0 to 50% by weight of a monomer selected from the group consisting of methacrylate excluding methyl methacrylate and acrylate, and 0 to 20% of a vinyl monomer copolymerizable therewith in an amount that a total amount of (a) and (b) is 100 parts by weight.

Claims

1. A foamable poly(vinyl chloride) resin composition comprising 100 parts by weight of (A) a poly(vinyl chloride) resin, 0.5 to 30 parts by weight of (B) a processing aid, and 0.5 to 15 parts by weight of water and 0 to 20 parts by weight of a thermal decomposition foaming agent as a foaming agent (C),

wherein the processing aid is obtained by adding and polymerizing 5 to 40 parts by weight of a monomer mixture (b) comprising 0 to 50% by weight of methyl methacrylate, 50 to 100% by weight of at least one monomer selected from the group consisting of methacrylate excluding methyl methacrylate and acrylate, and 0 to 20% by weight of a vinyl monomer copolymerizable therewith, in the presence of a latex of a (co)polymer obtained by emulsion polymerizing 60 to 95 parts by weight of a monomer mixture (a) comprising 50 to 100% by weight of methyl methacrylate, 0 to 50% by weight of a monomer selected from the group consisting of methacrylate excluding methyl methacrylate and acrylate, and 0 to 20% by weight of a vinyl monomer copolymerizable therewith in an amount that a total amount of (a) and (b) is 100 parts by weight.

2. The foamable poly(vinyl chloride) resin composition of claim 1, wherein the water is steam generated by heating 0.5 to 30 parts by weight of a substance.

3. The foamable poly(vinyl chloride) resin composition of claim 1, wherein the processing aid (B) is a (meth)acrylate copolymer which is obtained by adding and polymerizing 0 to 50 parts by weight of a monomer mixture (b) comprising 0 to 50% by weight of methyl methacrylate, 50 to 100% by weight of at least one monomer selected from the group consisting of methacrylate excluding methyl methacrylate and acrylate, and 0 to 20% by weight of a vinyl monomer copolymerizable therewith and wherein specific viscosity at 30°

C. of the solution containing 0.1 g of the polymer mixture in 100 mL of chloroform is at least 0.5, in the presence of a latex of a (co)polymer which is obtained by emulsion polymerizing 50 to 100 parts by weight of a monomer mixture (a) comprising 50to 100% by weight of methyl methacrylate, 0 to 50% by weight of a monomer selected from a group consisting of methacrylate excluding methyl methacrylate, and acrylate, and 0 to 20% of a vinyl monomer copolymerizable therewith in an amount that a total amount of (a) and (b) is 100 parts by weight, and wherein specific viscosity at 30°

C. of the solution containing 0.1 g of the polymer mixture in 100 mL of chloroform is at least 0.7.