| PATENT NUMBER | This data is not available for free |
| PATENT GRANT DATE | May 27, 2003 |
| PATENT TITLE |
Extruded styrene resin foam and process for producing the same |
| PATENT ABSTRACT |
An extruded styrene resin foam obtained by extrusion-foaming of a styrene resin and excellent in environmental compatibility and excellent in flame retardant property and thermal insulating property, characterized in that it contains, as a blowing agent, 100 to 10% by weight of at least one of saturated hydrocarbons having 3 to 5 carbons and 0 to 90% by weight of other blowing agent, based on the total amount of the blowing agent, and contains (A) a halogenated flame retardant and (B) at least one compound selected from the group consisting of phosphorus type flame retardants containing nitrogen atom in a molecule, tetrazole compounds, cyanuric acid and derivatives thereof, isocyanuric acid and derivatives thereof, metal borates, and boron oxides. |
| PATENT INVENTORS | This data is not available for free |
| PATENT ASSIGNEE | This data is not available for free |
| PATENT FILE DATE | June 27, 2001 |
| PATENT CT FILE DATE | October 26, 2000 |
| PATENT CT NUMBER | This data is not available for free |
| PATENT CT PUB NUMBER | This data is not available for free |
| PATENT CT PUB DATE | May 3, 2001 |
| PATENT FOREIGN APPLICATION PRIORITY DATA | This data is not available for free |
| PATENT CLAIMS |
What is claimed is: 1. An extruded resin consisting essentially of a styrene resin foam obtained by extrusion-foaming of a styrene resin, which contains, as a blowing agent, 100 to 10% by weight of at least one of saturated hydrocarbons having 3 to 5 carbon atoms and 0 to 90% by weight of other blowing agent, based on the total amount of the blowing agent, and contains (A) a halogenated flame retardant and (B) at least one compound selected from the group consisting of phosphorus type flame retardants containing nitrogen atom in a molecule, tetrazole compounds, nitrogen-containing compounds having the following general formula 1, nitrogen-containing compounds having the following general formula 2, metal borates, and boron oxides: ##STR8## wherein R.sup.1, R.sup.2 and R.sup.3 are selected from hydrogen atom, an alkyl group having 1 to 8 carbon atoms, an organic group represented by the formula: --Y--X (wherein Y is an alkylene group having 1 to 6 carbon atoms, a phenylene group, or a cycloalkylene group, and X is an epoxy group, a carboxyl group, a hydroxyl group, an amino group, or a phenyl group), and a phenyl group, and may be different from each other. ##STR9## wherein R.sup.4, R.sup.5 and R.sup.6 are selected from hydrogen atom, an alkyl group having 1 to 8 carbon atoms, an organic group represented by the formula: --Y--X (wherein Y is an alkylene group having 1 to 6 carbon atoms, a phenylene group, or a cycloalkylene group, and X is an epoxy group, a carboxyl group, a hydroxyl group, an amino group, or a phenyl group), and a phenyl group, and may be different from each other. 2. The extruded styrene resin foam of claim 1, wherein the total content of the saturated hydrocarbon having 3 to 5 carbon atoms in the extruded styrene resin foam is 2 to 10 parts by weight based on 100 parts by weight of the foam. 3. The extruded styrene resin foam of claim 1, wherein the extruded styrene resin foam contains 0.1 to 10 parts by weight of the halogenated flame retardant (A) and 0.1 to 10 parts by weight in total of the compound (B), based on 100 parts by weight of the styrene resin. 4. The extruded styrene resin foam of claim 1, wherein the saturated hydrocarbon having 3 to 5 carbon atoms is at least one saturated hydrocarbon selected from the group consisting of propane, n-butane, and isobutane. 5. The extruded styrene resin foam of claim 1, wherein other blowing agent is at least one compound selected from the group consisting of dimethyl ether, diethyl ether, methyl ethyl ether, methyl chloride, ethyl chloride, water, and carbon dioxide. 6. The extruded styrene resin foam of claim 1, wherein the halogenated flame retardant (A) is hexabromocyclododecane. 7. The extruded styrene resin foam of claim 1, wherein the compound (B) is a phosphorus type flame retardant containing nitrogen atom in a molecule. 8. The extruded styrene resin foam of claim 7, wherein the compound (B) is a phosphorus type flame retardant containing nitrogen atom in a molecule and the thickness of the foam is 15 mm or more. 9. The extruded styrene resin foam of claim 7, wherein the phosphorus type flame retardant containing nitrogen atom in a molecule is ammonium phosphate and/or ammonium polyphosphate. 10. The extruded styrene resin foam of claim 1, wherein the compound (B) is a tetrazole compound. 11. The extruded styrene resin foam of claim 10, wherein the tetrazole compound is a tetrazole compound having a thermal decomposition temperature of 250.degree. C. or higher. 12. The extruded styrene resin foam of claim 1, wherein the compound (B) is at least one compound selected from the group consisting of nitrogen-containing compounds having the foregoing general formula 1 and nitrogen-containing compounds having the foregoing general formula 2. 13. The extruded styrene resin foam of claim 1, wherein the compound (B) is a nitrogen-containing compound having the foregoing general formula 2. 14. The extruded styrene resin foam of claim 13, wherein the nitrogen-containing compound having the forgoing general formula 2 is isocyanuric acid and/or bis(2-carboxyethyl)isocyanurate. 15. The extruded styrene resin foam of claim 1, wherein the compound (B) is a metal borate. 16. The extruded styrene resin foam of claim 15, wherein the compound (B) is a metal borate and a fatty acid metal salt is further contained. 17. The extruded styrene resin foam of claim 15, wherein the metal borate is zinc borate. 18. The extruded styrene resin foam of claim 1, wherein the compound (B) is a boron oxide. 19. The extruded styrene resin foam of claim 18, wherein the boron oxide is a boron oxide surface-treated with a surface treating agent. 20. The extruded styrene resin foam of claim 18, wherein the boron oxide is diboron trioxide. 21. The extruded styrene resin foam of claim 19, wherein the surface treating agent comprises a thermosetting resin as a main component. 22. The extruded styrene resin foam of claim 1, which further contains 0.1 to 10 parts by weight of a phosphoric acid ester compound based on 100 parts by weight of the styrene resin. 23. The extruded styrene resin foam of claim 1, wherein the compound (B) is at least one compound selected from the group consisting of tetrazole compounds, nitrogen-containing compounds having the foregoing formula 1, nitrogen-containing compounds having the foregoing formula 2 and boron oxides surface-treated with a surface treating agent, and a montmorillonite type mineral is further contained. 24. The extruded styrene resin foam of claim 1, wherein the compound (B) is at least one compound selected from the group consisting of tetrazole compounds, nitrogen-containing compounds having the foregoing formula 1, nitrogen-containing compounds having the foregoing formula 2 and boron oxides surface-treated with a surface treating agent, and a montmorillonite type mineral and a phosphoric acid ester compound are further contained. 25. The extruded styrene resin foam of claim 23, wherein the montmorillonite type mineral is bentonite. 26. The extruded styrene resin foam of claim 23 wherein the compound (B) is isocyanuric acid and/or bis(2-carboxyethyl)isocyanurate. 27. A method for producing an extruded styrene resin foam comprising the steps of heating and melting a resin consisting essentially of a styrene resin, adding a blowing agent to the styrene resin, and extrusion-foaming the resultant through a die, wherein the extrusion-foaming is carried out in a condition where (A) a halogenated flame retardant and (B) at least one compound selected from the group consisting of phosphorus type flame retardants containing nitrogen atom in a molecule, tetrazole compounds, nitrogen-containing compounds having the following general formula 1, nitrogen-containing compounds having the following general formula 2, metal borates, and boron oxides, and further a blowing agent comprising 100 to 10% by weight of at least one of saturated hydrocarbons having 3 to 5 carbon atoms and 0 to 90% by weight of other blowing agent, based on the total amount of the blowing agent, are made coexist in the styrene resin: ##STR10## wherein R.sup.1, R.sup.2 and R.sup.3 are selected from hydrogen atom, an alkyl group having 1 to 8 carbon atoms, an organic group represented by the formula: --Y--X (wherein Y is an alkylene group having 1 to 6 carbon atoms, a phenylene group, or a cycloalkylene group, and X is an epoxy group, a carboxyl group, a hydroxyl group, an amino group, or a phenyl group), and a phenyl group, and may be different from each other, ##STR11## wherein R.sup.4, R.sup.5 and R.sup.6 are selected from hydrogen atom, an alkyl group having 1 to 8 carbon atoms, an organic group represented by the formula: --Y--X (wherein Y is an alkylene group having 1 to 6 carbon atoms, a phenylene group, or a cycloalkylene group, and X is an epoxy group, a carboxyl group, a hydroxyl group, an amino group, or a phenyl group), and a phenyl group, and may be different from each other. 28. The method for producing an extruded styrene resin foam of claim 27, wherein the extrusion foaming is carried out further in the presence of a montmorillonite type mineral and/or a phosphoric acid ester compound. 29. The method for producing an extruded styrene resin foam of claim 27, wherein the compound (B) is a phosphorus type flame retardant containing nitrogen atom in a molecule and the blowing agent comprises 70 to 30% by weight of at least one of saturated hydrocarbons having 3 to 5 carbon atoms and 30 to 70% by weight of at least one ether selected from the group consisting of dimethyl ether, diethyl ether, and methyl ethyl ether, based on the total amount of the blowing agent. 30. The method for producing an extruded styrene resin foam of claim 27, wherein the compound (B) is a metal borate and the extrusion foaming is carried out further in the presence of a fatty acid metal salt. 31. The method for producing an extruded styrene resin foam of claim 30, wherein the blowing agent comprises 90 to 10% by weight of at least one of saturated hydrocarbons having 3 to 5 carbon atoms and 10 to 90% by weight of at least one ether selected from dimethyl ether, diethyl ether, and methyl ethyl ether, based on the total amount of the blowing agent. 32. The method for producing an extruded styrene resin foam of claim 27, wherein the compound (B) is a tetrazole compound and the blowing agent comprises 90 to 10% by weight of at least one of saturated hydrocarbons having 3 to 5 carbon atoms and 10 to 90% by weight of at least one ether selected from the group consisting of dimethyl ether, diethyl ether, and methyl ethyl ether, based on the total amount of the blowing agent. 33. The method for producing an extruded styrene resin foam of claim 37, where in the compound (B) is a nitrogen-containing compound having the foregoing general formula 1 and/or a nitrogen-containing compound having the foregoing general formula 2. 34. The method for producing an extruded styrene resin foam of claim 27, wherein the compound (B) is a nitrogen-containing compound having the foregoing general formula 1 and/or a nitrogen-containing compound having the foregoing general formula 2 and further a montmorillonite type mineral is made to coexist and the blowing agent comprises 99 to 20% by weight of at least one of saturated hydrocarbons having 3 to 5 carbon atoms, 1 to 80% by weight of water, and 0 to 79% by weight of other blowing agent other than water, based on the total amount of the blowing agent. 35. The method for producing an extruded styrene resin foam of claim 27, wherein the compound (B) is a boron oxide. 36. The method for producing an extruded styrene resin foam of claim 35, wherein the blowing agent comprises 70 to 30% by weight of at least one of saturated hydrocarbons having 3 to 5 carbon atoms and 30 to 70% by weight of at least one of methyl chloride and ethyl chloride. 37. The method for producing an extruded styrene resin foam of claim 27, wherein the compound (B) is a boron oxide treated with a surface treating agent and the blowing agent comprises at least one of saturated hydrocarbons having 3 to 5 carbon atoms and water and the extrusion foaming is carried out further in the presence of a montmorillonite type mineral. 38. The method for producing an extruded styrene resin foam of claim 28, wherein the montmorillonite type mineral is bentonite. 39. An extruded styrene resin foam according to claim 1, containing no flon type blowing agent and having both thermal insulating property and flame retardant property meeting thermal insulating board No. 3 of extruded polystyrene foam prescribed in JIS A 9511. 40. The extruded styrene resin foam of claim 39, wherein the thermal insulating property is 0.028 W/mK or lower in terms of thermal conductivity. 41. The extruded styrene resin foam of claim 39, wherein the flame retardant property meets the requirements that the flame is extinguished within 3 seconds and neither remaining ember nor spreading flame beyond the indicating line of combustion limit exists in the combustion test prescribed in JIS A 9511. |
| PATENT DESCRIPTION | available on request |
| PATENT EXAMPLES | available on request |
| PATENT PHOTOCOPY | available on request |
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