CA1337233C - Multilayered structure utilizing an ethylene-vinyl alcohol copolymer composition - Google Patents
Multilayered structure utilizing an ethylene-vinyl alcohol copolymer compositionInfo
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- CA1337233C CA1337233C CA000616944A CA616944A CA1337233C CA 1337233 C CA1337233 C CA 1337233C CA 000616944 A CA000616944 A CA 000616944A CA 616944 A CA616944 A CA 616944A CA 1337233 C CA1337233 C CA 1337233C
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Abstract
This invention provides a multilayered structure comprising an ethylene-vinyl alcohol copolymer composition having specific flow characteristics in the relationship between the heating time and the extrusion rate measured with a capillary rheometer. The multilayered structure can be used to obtain a molded article having excellent appearance. In particular, when a continuous melt molding operation is conducted over a long period of time the mold article still has an excellent appearance. Its desirable appearance does not deteriorate with running time.
Description
t 337233 Multilayered Structure Utilizinq an Ethylene-VinYl Alcohol CopolYmer Com~osition The present invention has been divided out of Canadian Patent Application Serial No. 576,561.
This invention relates to a multilayered structure utilizing an ethylene-vinyl alcohol copolymer (hereinafter referred to as EVOH) composition.
EVOH is a useful polymeric material having high gas barrier properties and transparency, as well as oil resistance and odour keeping property, and is widely used for films, sheets, containers and the like.
EVOH is obtained by saponifying ethylene-vinyl acetate copolymer with caustic alkali. However, the saponified product cannot be subjected to melt-molding as is because it readily undergoes thermal decomposition causing a large decrease in viscosity and severe colouring. A variety of means have been employed to improve the above. For example, Examined Published Japanese Patent Application Nos. 37664/1971 and 19242/1980 and Unexamined Japanese Patent Laid-Open Nos. 25048/1973, 88544/1976, 88545/1976 disclose the improvements by fully washing EVOH, adding an acid to EVOH, and by dipping EVOH in an acid solution. Further, unexamined Japanese Patent Laid-Open Nos. 854/1977, 955/1977 and 41204/1981 disclose a method which comprises improve the melt-moldability by adding a metal salt on the basis that some types of metal salts have marked effects on thermal stabilization.
.
1 }37233 The above-mentioned processes all principally attempt to decrease the time-dependent viscosity change in the melting operation, and can certainly give molded articles having good appearances when a short-period melt-molding is conducted.
However, at a continuous melt molding over 24 hours or longer, gelled matter or streaky irregularities appear on the molded article, causing the obtained articles to have an unacceptable appearance and finally to be unusable.
The above-described phenomena take place also when co-extruding or co-injecting an EVOH with a hydrophobic thermoplastic resin. Examined Published Japanese Patent Application Nos. 2984/1985, 35125/1983 and 39548/1985 disclose a method which comprises co-extruding an EVOH with a hydrophobic thermoplastic resin and, interposed between the two, another thermoplastic resin modified with an ethylenically unsaturated carboxylic acid or its anhydride. The process however has a drawback in that the appearance of the obtained multilayered structure gradually gets poorer.
An object of the present invention is to provide a molded article comprising no fish eyes or streaky irregularities even when a long-period melt-molding process is utilized.
To achieve the object stated above, the present invention provides a molded article prepared using an EVOH composition having such flow characteristics that: in the relationship between the heating time and the extrusion rate at at least one point in temperatures 10 to 80C higher than the melting point of the ethylene-vinyl alcohol copolymer, between the heating time and the extrusion rate measured with a capillary rheometer t 337233 (Koka* Flow Tester, available from Shimadzu Corp.), the extrusion rate does not substantially increase for the initial 15 minutes, thereafter the extrusion rate at any heating time after 15 minutes until 2 hours is in a range of from 1/10 to 50 times that after the initial 15 minutes, and the extrusion rate at any time after 2 hours until 10 hours is at least once in a range of from 2 to 50 times that after the initial 15 minutes.
In the present invention, the EVOH suited for obtaining a molded article having an excellent appearance is a saponified product of an ethylene-vinyl acetate copolymer, or a saponified product of an ethylene-vinyl acetate copolymer obtained by copolymerizing ethylene, vinyl acetate and an olefinically unsaturated monomer as a third component in an amount of not more than 10 mol~ based on the amount of the vinyl acetate component, and by subsequently saponifying the resultant copolymer; and is preferably one containing ethylene in an amount of from 20 to 60 mol~, more preferably from 20 to 55 mol~, and having a saponification degree of vinyl acetate component of at least 95 mol~. If the ethylene content is less than 20 mol~, the molded article obtained therefrom will be poor in certain properties, i.e. water resistance and hot water resistance, and the EVOH itself will readily gel, resulting in an increase in the number of fish eyes and streaks formed, thereby rendering the effect of the present invention difficult *Trade mark to produce. If the ethylene content exceeds 60 mol% or the saponification degree is less than 95 mol~, the gas barrier properties of obtained molded articles will be low, rendering the inherent characteristics of EVOH difficult to maintain.
A preferred EVOH composition is one comprising a salt of a metal belonging to group II of the Periodic Table in an amount converted to the metal of from 0.0005 to 0.05% by weight, an acidic substance having a pKa (acidity dissociation constant at 25C) of at least 3.5 and a boiling point under atmospheric pressure of at least 180C in an amount of from 0.002 to 0.2~ by weight, and a second acidic substance having a pKa of at least 3.5 and a boiling point under atmospheric pressure of not higher than 120C in an amount of from 0.01 to 0.2% by weight.
EVOH is generally obtained by adding a caustic alkali or an alkali metal alcoholate to an alcohol solution of an ethylene-vinyl acetate copolymer to effect saponification, and then removing by-produced sodium acetate and the like by washing. However, if the obtained EVOH is melt-molded as is, remarkable thermal decomposition occurs to sharply decrease its melt viscosity and to colour, and hence the EVOH is not usable. It is well known that the moldability is improved by adding an acid, by dipping into an acid solution, `- 1 337233 by adding a metal salt combined with an acid, or the like.
It has been said that, in particular, a process which com-prises, as mentioned above, adding an acid or a metal salt combined with an acid, as disclosed in Examin~d Published Japanese Patent Application No. 19242~1980 and Unexamined Japanese Patent Laid-~pen Nos. 91988/1976, 954/1977, gS5/1977 and 41204/1981, improves the moldability. This is true in the case of a short-period melt molding, and the process gives a molded article having a good appearance and being less coloured. However, in the case where continuous melt molding is performed over more than 24 hours, as the running time becomes longer; for single molded articles gelled matter or streaky irregularities are generated;a~
for co-extruded or co-injected multilayered structures, particularly those comprising interlayer adhesive layers of ethylenically unsaturated carboxylic acid or its anhydride, there is generated at the co-extrusion or co-injection, in addition to gelled matters, inter~acial instability, resulting in formation of a poor appearance with an overall wavy pattern. When this happens to a high degree, the overall irregularities grow and adjacent layers invade into each other, thereby forming holes or c~t~;ng breakage. Even whenthe appearance is not so poor, there often forms a minute pat-tern like an overall satin-like finish or a streaky pattern.
When such a co-extruded article or co-injected article is further processed, the appearance worsens and there is generated a net-like pattern on the entire surface.
The wavy roughness or the matte pattern on the surface of the co-extruded or co-injected article relates to the stability of a multi-layer flow. When the flow is highly unstable, a wavy surface roughness is generated; whereas the flow is unstable to a minor extent, a matte pattern or streaks result .
The present inventors have found that thus worsen1ng of the appearance of a molded article, particularly one having a multilayered structure can be effectively prevented by "preparing an E~OH such that it will exhibit a specific time-dependent viscosity change" and submitting the EVOH to melt molding at an appropriate temperature.
The present invention thus provides an EVOH for melt molding, which has such flow characteristics that:
when the time-dependent viscosity chan~e of the EVOH is mea-sured with a capillary rheometer (Koka Flow Tester), in the relationship between the heating time and the extrusion rate at at least one temperature in a range of from 10 to 80-C
higher than the melting point of the EVOH {by DSC (scanning speed: 10-C/min)}; the extrusion rate does not su~stantially increase for the initial 15 minutes, thereafter the extru-sion rate at any heating time after the initial 15 minutes until 2 hours is in a range of from 1/10 to 50 times that after the initial 15 minutes, and the extrusion rate at any time a~ter Z hours until 10 hours is at least once in a range of fro~ 2 to 50 times that after the initial t5 minutes. The extrusion rate measured with a capillary rheo-meter (Koka Flow Tester) herein means the value determined witha nozzle of 1 mm ~ x 10 mmL and under a load of lO kg.
- The extrusion rate after 2 hours until 10 hours should be at least once in a range of from 2 to S0 times that after the initial 15 minutes, and preferably increases steadily in this time range. The extrusion rate in the initial 15 minutes does not substantially increase, rather preferably decreases, the decreasing ratio being preferably as low as possible. For example, the extrusion rate after 15 minutes is preferably from 101/5 to 1, more preferably from 3/5 to 1 that at the start t0 minute). By submitting an EVOH having such flow characteristics to a melt molding, in particular to co-extrusion molding or co-injection molding with a hydrophobic thermoplastic resin and a thermoplastic resin modified with an ethylenically unsaturated carboxylic acid or its anhydride, there can be obtained a molded article and a multilayered laminate having a good appearance with no irregularities caused by an unstable interface, e.g. gelled matter, streaks or matte surface. The reason is not clear, but may be estimated to lie in the flow characteristics of the EVOH
composition, and further in an interaction between the EVOH
composition and the thermoplastic resin modified with an ethylenically unsaturated carboxylic acid or its anhydride.
The EVOH composition suitable for use in the present invention can be obtained for example by the following method.
25That is, it can be obtained by treating an EVOH with (A) a salt(s) of a metal belonging to group II of the Periodic Table, (B) an acidic substance having a pKa (acid dissociation constant at 25'C) of at least 3.5 and a boiling point under atmospheric pressure of at least 180-C, and (C) an acidic substance ha~ing a pKa of at least 3.5 and a boiling point under atmospheric pressure of not hiqher than 120-C.
Examples of the metals belonging to group II of the Periodic Table for the metal salt(s) (A) are beryllium (Be), magnesium (Mg), calcium (Ca), zinc (Zn) and barium (Ba); and examples of their salts include carbonates, acetates, sul-fates, phosphates, and the like. Among these salts, calcium acetate and magnesium acetate are preferred in view of con-trollability of the time-dependent viscosity change of EVOH
and of colour shade of the EVOH obtained. These metal salts may be used singly or in combinations of at least two.
Examples of the acidic substance having a pKa of at least 3.5 and a boiling point under atmospheric pressure of at least 180-C (B) are organic acids, e.g. succinic acid, adipic acid, benzoic acid, capric acid, citric acid, lauric acid, and the like; inorganic acidic substances, e.g.
boric acid, potassium monohydrogen phosphate, sodium monohy-drogen phosphate and the like; and, amino acids, e.g. as-paragic acid, aminoben~oic acid, glutamic acid and the like;
but not limited thereto. Among t~ese, acidic substances having boiling points of at least 250-C are preferred.
These substances may be used alone or in combinations of at -least two. 1 337233 Examples of the acidic substance having a pKa of at least 3.5 and a boiling point under atmospheric pressure of not higher than 120-C are acetoacetic acid, formic acid, acetic acid, and the like, among which acetic acid is preferred.
The above substances may be added to EVOK either by the direct addition thereof, followed by ~ixing, or by dipping EVOH into an aqueous solution prepared by dissolving them in water.
The incorporation ratios of the above substances in the EVOH are from 0.0005 to 0.05~ by weight, preferably from 0.00l to 0.03~ by weight converted into the weight of the corresponding metal for the metal salt (A), from 0.002 to 0.2% by weight, preferably from 0.005 to 0.1% by weight for the acidic substance having a pKa of at least 3.5 and a boiling point under atmospheric pressure of at least 180-C
(~), and from 0.01 to 0.2~ by weight, preferably from 0.02 to 0.1~ by weight for the substance having a pKa of at least 3.5 and a boiling point under atmospheric pressure of not higher than 120'C (C).
While it is preferred that the EVOH not contain sodium acetate by-produced at saponification, a content of about 0.05~ by weight does not impair the afore-described characteristics.
The incorporation ratios of the substances in EVOH aredetermined acoording to the followinq methods.
(1) Salt of a metal belonging to grouF II of the Periodic Table (A).
100 parts of EVOH is put in a porcelain crucible and then burned in an electric furnace. The residual ash is dissolved in a N/1~0 aqueous nitric acid solution and the solution is submitted to an atomic absorption analysis to determine the metal of the metal salt.
This invention relates to a multilayered structure utilizing an ethylene-vinyl alcohol copolymer (hereinafter referred to as EVOH) composition.
EVOH is a useful polymeric material having high gas barrier properties and transparency, as well as oil resistance and odour keeping property, and is widely used for films, sheets, containers and the like.
EVOH is obtained by saponifying ethylene-vinyl acetate copolymer with caustic alkali. However, the saponified product cannot be subjected to melt-molding as is because it readily undergoes thermal decomposition causing a large decrease in viscosity and severe colouring. A variety of means have been employed to improve the above. For example, Examined Published Japanese Patent Application Nos. 37664/1971 and 19242/1980 and Unexamined Japanese Patent Laid-Open Nos. 25048/1973, 88544/1976, 88545/1976 disclose the improvements by fully washing EVOH, adding an acid to EVOH, and by dipping EVOH in an acid solution. Further, unexamined Japanese Patent Laid-Open Nos. 854/1977, 955/1977 and 41204/1981 disclose a method which comprises improve the melt-moldability by adding a metal salt on the basis that some types of metal salts have marked effects on thermal stabilization.
.
1 }37233 The above-mentioned processes all principally attempt to decrease the time-dependent viscosity change in the melting operation, and can certainly give molded articles having good appearances when a short-period melt-molding is conducted.
However, at a continuous melt molding over 24 hours or longer, gelled matter or streaky irregularities appear on the molded article, causing the obtained articles to have an unacceptable appearance and finally to be unusable.
The above-described phenomena take place also when co-extruding or co-injecting an EVOH with a hydrophobic thermoplastic resin. Examined Published Japanese Patent Application Nos. 2984/1985, 35125/1983 and 39548/1985 disclose a method which comprises co-extruding an EVOH with a hydrophobic thermoplastic resin and, interposed between the two, another thermoplastic resin modified with an ethylenically unsaturated carboxylic acid or its anhydride. The process however has a drawback in that the appearance of the obtained multilayered structure gradually gets poorer.
An object of the present invention is to provide a molded article comprising no fish eyes or streaky irregularities even when a long-period melt-molding process is utilized.
To achieve the object stated above, the present invention provides a molded article prepared using an EVOH composition having such flow characteristics that: in the relationship between the heating time and the extrusion rate at at least one point in temperatures 10 to 80C higher than the melting point of the ethylene-vinyl alcohol copolymer, between the heating time and the extrusion rate measured with a capillary rheometer t 337233 (Koka* Flow Tester, available from Shimadzu Corp.), the extrusion rate does not substantially increase for the initial 15 minutes, thereafter the extrusion rate at any heating time after 15 minutes until 2 hours is in a range of from 1/10 to 50 times that after the initial 15 minutes, and the extrusion rate at any time after 2 hours until 10 hours is at least once in a range of from 2 to 50 times that after the initial 15 minutes.
In the present invention, the EVOH suited for obtaining a molded article having an excellent appearance is a saponified product of an ethylene-vinyl acetate copolymer, or a saponified product of an ethylene-vinyl acetate copolymer obtained by copolymerizing ethylene, vinyl acetate and an olefinically unsaturated monomer as a third component in an amount of not more than 10 mol~ based on the amount of the vinyl acetate component, and by subsequently saponifying the resultant copolymer; and is preferably one containing ethylene in an amount of from 20 to 60 mol~, more preferably from 20 to 55 mol~, and having a saponification degree of vinyl acetate component of at least 95 mol~. If the ethylene content is less than 20 mol~, the molded article obtained therefrom will be poor in certain properties, i.e. water resistance and hot water resistance, and the EVOH itself will readily gel, resulting in an increase in the number of fish eyes and streaks formed, thereby rendering the effect of the present invention difficult *Trade mark to produce. If the ethylene content exceeds 60 mol% or the saponification degree is less than 95 mol~, the gas barrier properties of obtained molded articles will be low, rendering the inherent characteristics of EVOH difficult to maintain.
A preferred EVOH composition is one comprising a salt of a metal belonging to group II of the Periodic Table in an amount converted to the metal of from 0.0005 to 0.05% by weight, an acidic substance having a pKa (acidity dissociation constant at 25C) of at least 3.5 and a boiling point under atmospheric pressure of at least 180C in an amount of from 0.002 to 0.2~ by weight, and a second acidic substance having a pKa of at least 3.5 and a boiling point under atmospheric pressure of not higher than 120C in an amount of from 0.01 to 0.2% by weight.
EVOH is generally obtained by adding a caustic alkali or an alkali metal alcoholate to an alcohol solution of an ethylene-vinyl acetate copolymer to effect saponification, and then removing by-produced sodium acetate and the like by washing. However, if the obtained EVOH is melt-molded as is, remarkable thermal decomposition occurs to sharply decrease its melt viscosity and to colour, and hence the EVOH is not usable. It is well known that the moldability is improved by adding an acid, by dipping into an acid solution, `- 1 337233 by adding a metal salt combined with an acid, or the like.
It has been said that, in particular, a process which com-prises, as mentioned above, adding an acid or a metal salt combined with an acid, as disclosed in Examin~d Published Japanese Patent Application No. 19242~1980 and Unexamined Japanese Patent Laid-~pen Nos. 91988/1976, 954/1977, gS5/1977 and 41204/1981, improves the moldability. This is true in the case of a short-period melt molding, and the process gives a molded article having a good appearance and being less coloured. However, in the case where continuous melt molding is performed over more than 24 hours, as the running time becomes longer; for single molded articles gelled matter or streaky irregularities are generated;a~
for co-extruded or co-injected multilayered structures, particularly those comprising interlayer adhesive layers of ethylenically unsaturated carboxylic acid or its anhydride, there is generated at the co-extrusion or co-injection, in addition to gelled matters, inter~acial instability, resulting in formation of a poor appearance with an overall wavy pattern. When this happens to a high degree, the overall irregularities grow and adjacent layers invade into each other, thereby forming holes or c~t~;ng breakage. Even whenthe appearance is not so poor, there often forms a minute pat-tern like an overall satin-like finish or a streaky pattern.
When such a co-extruded article or co-injected article is further processed, the appearance worsens and there is generated a net-like pattern on the entire surface.
The wavy roughness or the matte pattern on the surface of the co-extruded or co-injected article relates to the stability of a multi-layer flow. When the flow is highly unstable, a wavy surface roughness is generated; whereas the flow is unstable to a minor extent, a matte pattern or streaks result .
The present inventors have found that thus worsen1ng of the appearance of a molded article, particularly one having a multilayered structure can be effectively prevented by "preparing an E~OH such that it will exhibit a specific time-dependent viscosity change" and submitting the EVOH to melt molding at an appropriate temperature.
The present invention thus provides an EVOH for melt molding, which has such flow characteristics that:
when the time-dependent viscosity chan~e of the EVOH is mea-sured with a capillary rheometer (Koka Flow Tester), in the relationship between the heating time and the extrusion rate at at least one temperature in a range of from 10 to 80-C
higher than the melting point of the EVOH {by DSC (scanning speed: 10-C/min)}; the extrusion rate does not su~stantially increase for the initial 15 minutes, thereafter the extru-sion rate at any heating time after the initial 15 minutes until 2 hours is in a range of from 1/10 to 50 times that after the initial 15 minutes, and the extrusion rate at any time a~ter Z hours until 10 hours is at least once in a range of fro~ 2 to 50 times that after the initial t5 minutes. The extrusion rate measured with a capillary rheo-meter (Koka Flow Tester) herein means the value determined witha nozzle of 1 mm ~ x 10 mmL and under a load of lO kg.
- The extrusion rate after 2 hours until 10 hours should be at least once in a range of from 2 to S0 times that after the initial 15 minutes, and preferably increases steadily in this time range. The extrusion rate in the initial 15 minutes does not substantially increase, rather preferably decreases, the decreasing ratio being preferably as low as possible. For example, the extrusion rate after 15 minutes is preferably from 101/5 to 1, more preferably from 3/5 to 1 that at the start t0 minute). By submitting an EVOH having such flow characteristics to a melt molding, in particular to co-extrusion molding or co-injection molding with a hydrophobic thermoplastic resin and a thermoplastic resin modified with an ethylenically unsaturated carboxylic acid or its anhydride, there can be obtained a molded article and a multilayered laminate having a good appearance with no irregularities caused by an unstable interface, e.g. gelled matter, streaks or matte surface. The reason is not clear, but may be estimated to lie in the flow characteristics of the EVOH
composition, and further in an interaction between the EVOH
composition and the thermoplastic resin modified with an ethylenically unsaturated carboxylic acid or its anhydride.
The EVOH composition suitable for use in the present invention can be obtained for example by the following method.
25That is, it can be obtained by treating an EVOH with (A) a salt(s) of a metal belonging to group II of the Periodic Table, (B) an acidic substance having a pKa (acid dissociation constant at 25'C) of at least 3.5 and a boiling point under atmospheric pressure of at least 180-C, and (C) an acidic substance ha~ing a pKa of at least 3.5 and a boiling point under atmospheric pressure of not hiqher than 120-C.
Examples of the metals belonging to group II of the Periodic Table for the metal salt(s) (A) are beryllium (Be), magnesium (Mg), calcium (Ca), zinc (Zn) and barium (Ba); and examples of their salts include carbonates, acetates, sul-fates, phosphates, and the like. Among these salts, calcium acetate and magnesium acetate are preferred in view of con-trollability of the time-dependent viscosity change of EVOH
and of colour shade of the EVOH obtained. These metal salts may be used singly or in combinations of at least two.
Examples of the acidic substance having a pKa of at least 3.5 and a boiling point under atmospheric pressure of at least 180-C (B) are organic acids, e.g. succinic acid, adipic acid, benzoic acid, capric acid, citric acid, lauric acid, and the like; inorganic acidic substances, e.g.
boric acid, potassium monohydrogen phosphate, sodium monohy-drogen phosphate and the like; and, amino acids, e.g. as-paragic acid, aminoben~oic acid, glutamic acid and the like;
but not limited thereto. Among t~ese, acidic substances having boiling points of at least 250-C are preferred.
These substances may be used alone or in combinations of at -least two. 1 337233 Examples of the acidic substance having a pKa of at least 3.5 and a boiling point under atmospheric pressure of not higher than 120-C are acetoacetic acid, formic acid, acetic acid, and the like, among which acetic acid is preferred.
The above substances may be added to EVOK either by the direct addition thereof, followed by ~ixing, or by dipping EVOH into an aqueous solution prepared by dissolving them in water.
The incorporation ratios of the above substances in the EVOH are from 0.0005 to 0.05~ by weight, preferably from 0.00l to 0.03~ by weight converted into the weight of the corresponding metal for the metal salt (A), from 0.002 to 0.2% by weight, preferably from 0.005 to 0.1% by weight for the acidic substance having a pKa of at least 3.5 and a boiling point under atmospheric pressure of at least 180-C
(~), and from 0.01 to 0.2~ by weight, preferably from 0.02 to 0.1~ by weight for the substance having a pKa of at least 3.5 and a boiling point under atmospheric pressure of not higher than 120'C (C).
While it is preferred that the EVOH not contain sodium acetate by-produced at saponification, a content of about 0.05~ by weight does not impair the afore-described characteristics.
The incorporation ratios of the substances in EVOH aredetermined acoording to the followinq methods.
(1) Salt of a metal belonging to grouF II of the Periodic Table (A).
100 parts of EVOH is put in a porcelain crucible and then burned in an electric furnace. The residual ash is dissolved in a N/1~0 aqueous nitric acid solution and the solution is submitted to an atomic absorption analysis to determine the metal of the metal salt.
(2) Acidic substances having pKa's of at least 3.5 and boiling points under atmospheric pressure of not higher than 120-C (C).
Solutes contained in EVOH are extracted with a solvent, and the acidic substance in the extract is determined by neutralization titration. Determination of representative acidic substances are given below.
Formic acid A tight sealed container is filled with 100 parts of EVOH and 250 parts of water, and the contents are heated with stirring at 95-C for 3 hours to extract the formic acid in EVOH. Using a potassium permanganate solution as a titrating liquid, the ~ormic acid in the extract is determined by oxidation-reduction titration.
Acetic acid (HOAc) Acetic acid in EVOH is extracted with water in the same manner as for formic acid. Using an aqueous s~dium hydroxide solution as a titrating liquid, the acetic acid in the extract is determined by neutralization titration.
Solutes contained in EVOH are extracted with a solvent, and the acidic substance in the extract is determined by neutralization titration. Determination of representative acidic substances are given below.
Formic acid A tight sealed container is filled with 100 parts of EVOH and 250 parts of water, and the contents are heated with stirring at 95-C for 3 hours to extract the formic acid in EVOH. Using a potassium permanganate solution as a titrating liquid, the ~ormic acid in the extract is determined by oxidation-reduction titration.
Acetic acid (HOAc) Acetic acid in EVOH is extracted with water in the same manner as for formic acid. Using an aqueous s~dium hydroxide solution as a titrating liquid, the acetic acid in the extract is determined by neutralization titration.
(3) Acidic substances having pKa's of at least 3.5 and boil-ing points under atmospheric pressure of at least 180'C (B).
Solutes contained in EVOH are extracted with a solvent, and the acidic substance in the extract is determined ~y neutralization titration. Determination of representative acidic substances are given below.
Succinic acid The succinic acid in EVOH is extracted with water in the same manner as for formic acid. The extract is mixed with resorcinol and concentrated sulfuric acid, heated at 126 to 130-C, cooled, and then submitted to a determination by colorimetry.
Adipic acid The adipic acid in EVOH is extracted with water in the same manner as for formic acid. The extract is dried to solid, and the deposited adipic acid is dissolved in water, and the solution is submitted for neutralization titration to determine the adipic acid using an aqueous sodium hydroxide solution as a titrating liquid.
Benzoic acid This is determined in a manner similar to that for adipic acid.
CaDric acid A tight sealed container is filled with 100 parts of EVOH and 250 parts of ethanol, and the contents are heated with stirring at 80-C for 5 hours to extract the capric acid in EVOH. Using an aqueous sodium hydroxide solution as a titrating liquid, the capric acid in the extract is determined by neutralization titration.
Lauric acid This is determined in a manner similar to that for capric acid.
Succinic acid The succinic acid in EVOH is extracted with water in the same manner as for formic acid. The extract is mixed with acetic anhydride and heated. Pyridine is further added to the mixture, heated, cooled and then submitted to determination by colorimetry.
Boric acid Similar to the cases of analysis of the afore-mentioned metals, boric acid is determined by atomic absorption analysis.
Sodium dihydrogenphosPhate A tight sealed container is filled with 100 parts of EVOH and 250 parts of a 1 g/l aqueous solution of acetic acid, and the contents are heated with stirring at 95C for 3 hours to extract the sodium dihydrogenphosphate in EVOH.
The phosphate ion in the extract is determined by ion chromatography.
Potassium dihydro~enphosphate This is determined in the same manner as for sodium dihydrogenphosphate.
2S Amino acids The amino acid in EVOH is extracted with water in the same manner as for formic acid. The amino acid in the extract is determined by a known amino acid analysis. For example, asparagic acid is determined by polarographic determination of the fumaric acid formed by treatinq the obtained extract with dimethyl sulfate.
The thus obtained EVOH is co-extruded or co-injected with a hydrophobic thermoplastic resin via a thermoplastic resin modified with an ethylenically unsaturated carboxylic acid or its anhydride. The melt viscosity of the EVOH
changes depending on temperature, and the influences of the afore-mentioned substances contained in the EVOH on the melt viscosity of the EVOH also vary depending on temperature, and further the time-dependent change of the melt viscosity changes in a complex manner depending on the temperature.
Selection of an appropriate moldinq temperature range therefore is necessary to achieve the afore-described specific time-dependent change.
The above-described EVOH used in this invention may, when submitted to melt moldinq, incorporate mixed therewith a conventional EVOH, for example one havinq an ethylene content different from the EVOH, other thermoplastic resin, additives, e.g. a plasticizer, and the like, in amounts not to adversely affect the object of the present invention.
Next, the hydrophobic thermoplastic resins used in co-extrudion molding or co-injection molding with the EVOH are explained. Preferred thermoplastic resins are polypropyl-ene-, polyethylene, ethylene-propylene copolymer, ethylene-vinyl acetate copoly~er, thermoplastic polyesters, e gpolyethylene terephthalate, polyamides, e.g. 6-Nylon* and 6,6-Nylon, polystyrene, polyvinyl chloride, polycarbonate and the like. They may be used singly, as copolymers or in ad~ixtures thereof. Particularly preferred among these are polypropylene, polyethylene, ethylene-propylene copolymer, thermoplastic polyesters, polystyrene, or copolymers or mixtures thereof.
Interlayer adhesives are often used when the EVOH and the hydrophobic thermoplastic resin are co-extruded or co-lS injected. As the interlayer adhesive, thermoplastic resinsmodified with an ethylenically unsaturated carboxylic acid or its anhydride are preferred. In view of the adhesive-ness with the EVOH layer and with the hydrophobic thermo-plastic resin layer, the interlayer adhesive is preferably a carboxyl-group containing modified olefin polymer comprising an olefin polymer chemically bonded (e.g. by addition reaction or by grafting) with an ethylenically unsaturated carboxylic acid or its anhydride. The olefin polymer herein is a polyolefin, e.g. polyethylene (low pressure, medium pressure or high pressure polyethylene), linear low density polyethylene, polypropylene or polybutene; a copolymer of an ol~f;n with a comonomer copolymerizable with the olefin * Trademark ~ 337233 (e.g. vinyl ester, unsaturated carboxylic acid ester, or the like), e.g. ethylene-vinyl acetate copolymer ar ethylene-ethyl acrylate copoly~er; or the like. Among the above, preferred are ethylene-vinyl acetate copolymer (containing from 5 to 55~ by weight of vinyl acetate) and ethylene-ethyl acrylate copolymer (containing from 8 to 35~ by weight of ethyl acrylate).
The ethylenically unsaturated carboxylic acid or its anhydride herein means an ethylenically unsaturated monocarboxylic acid, its ester, an ethylenically unsaturated dicarboxylic acid, its mono- or diester, its anhydride, among which ethylenically unsaturated dicarboxylic acid an-hydride is preferred. More concretely, mention can be made of maleic acid fumaric acid, itaconic acid, maleic anhydride, lS itaconic anhydride, monomethyl maleate, monoethyl maleate, diethyl maleate, monomethyl fumarate and the like, among which maleic anhydride is most preferred.
The amount of the ethylenically unsaturated carboxylic acid or its anhydride added or grafted to the olefin polymer (modification amount) is from 0.01 to 15% by weight, prefer-ably from 0.02 to 10~ by weight based on the weight of the oiefin polymer. The addition or grafting of the ethylenical-ly unsaturated carboxylic acid or its anhydride to the olefin polymer is conducted, for example, in the presence of a solvent, e.g. xylene and a catalyst, e.g. peroxide by radical polymerization or the like. The MI measured according to ASTM-D-1238-65T at 190-C of the thus obtained carboxyl-group containing modified polyolefin is 0.2 to 30 g/10 min, preferably 0.5 to 10 g/min. The adhesive resins may be used singly or in admixtures of more than two.
The co-extrusion of the E~OH with the hydrophobic thermoplastic resin may be performed by a multi-manifold confluence T-die method, by a feed-bloc~ confluence T-die method, or by inflation.
The thus obtained co-extrusion molded articles may be subjected to a secondary processinq to give various molded articles, e.g. films, sheets, tubes and bottles; for example:
(~) multilayered molded articles such as sheets and films are monoaxially or biaxially drawn and heat-treated into multilayered co-drawn sheets and films, (2) multilayered molded articles, e.g. sheets and films are rolled into multilayered rolled sheets and films, (3) multilayered molded articles, e.g. sheets and films are vacuum formed, pressure formed, vacuum-pressure formed, or isothermally molded into multilayered trays and cup-shaped containers, and (4) multilayered molded articles, e.g. pipes are stretch-blow molded or by a similar process molded into bottles or cup-shaped contai~ers.
The secondary processing methods are not limited to the above, but any known processing other than the above (e.g.
blow molding) may be employed.
Examples of the layer construction of the co-extruded laminates are, when the thermoplastic resin modified with an ethylenically unsaturated carboxylic acid or its anhydride is expressed as Ad, and the hydrophobic ther~oplastic resins as P and P', EVOH/Ad/P, P/Ad/EVOH/Ad/P, P/P'/Ad/EVO~/Ad/P, P/Ad/EVO~/Ad/P'/P and the like, wherein each layer may be a singte layer or, as occasions demand, a multilayer. The hydrophobic resin layer P' may be a layer of its blend with EVOH and/or Ad.
The thus obtained co-extruded laminates are, since they have excellent appearances and gas barrier properties, best suited for materials for food containers, e.g. deep-drawn containers, cup-shaped containers and bottles.
The co-injection can be performed by any known co-injection process. Also a multilayered preform can be obtained by a known process as disclosed in Unexamined Japanese Patent Laid-Open No. 152412/1986, which comprises injecting continuously and successively resins (P, Ad and EVOH), which resins have been melted a one time clamping operation, into a single preform mold through three injection cylinders. Then the layer constructionS are,for example, P/Ad/EVOH/Ad/P, P/Ad/EVOH/Ad/P/Ad/EVOH/Ad/P, and the like. Or, a multilayered preform or hollow container can be formed by a co-injection molding or a co-injection blow-molding using a co-injection nozzle shown in Unexamined Japanese Patent Laid-Open No. 34819/l985.
In the above co-injection moldings, as in the case of co-extrusion, the use of a conventional EVOH will cause, besides generation of gels, an unstable interfacial instability at interfaces where the EVOH layer and the interlayer adhesive resin layer, particularly an adhesive resin comprising a thermoplastic resin modified with an ethylenically unsaturated carboxylic acid or its anhydride joins (i.e. in hot runner nozzle or at the inside of a preform mold). The interfacial instability then causes a poor wavy appearance, interinvasion of the adjacent layers, other poor appearances, e.g. a matte surface and streaky surfaces, thereby rendering molded articles of high commercial value impossible to obtain. The EVOH prepared according to the invention described in the parent application, however, when melt molded at an appropriate temperature can effectively prevent the worsening of the appearance. The reason is thought to be similar to that in the case of co-extrusion.
Hereinbelow the invention will be further explained with reference to Examples, wherein "parts" or "~" means "parts by weight" or "~ by weight" unless otherwise specified. Reference is made in the Examples to the drawing in which:
FIGURE 1 shows the relationship between the heating time and the extrusion rate measured with a capillary rheometer (Koka Flow Tester). In the FIGURE, the points indicate as follows:
A: after 15 minutes, C: after 2 hours, B: after 1.75 hours or indicates a time where the extrusion rate is minimum between A and C.
D: after 5 hours.
EXAMPLES
Example 1 l 337233 A solution containing 45 parts of an ethylene-vinyl acetate copolymer having an ethylene content of 38 mol%, 50 parts of methanol and 1 part of sodium hydroxide was subiect-ed to saponification for 40 minutes at 110-C and under a pressure of 3.5 kg/cm2G, while methanol vapor was being blown thereinto. The methyl acetate formed during the reac-tion was, together with a portion of the methanol, removed from the system by distillation. The obtained saponified reaction mixture (saponification degree: 99.3 mol~) was extruded through a die having a hole of 2 mm diameter into a mixed solvent of 10% of methanol and 90% of water at S-C to coagulate into-a strand, and the coagulate was cut with a cutter to give pellets. The pellets were washed three times each time with 10 parts of ion-exchanged water based on 1 part of the pellets, and then dipped in an aqueous solution comprising 100 parts of ion-exchanged water containing 0.1% of acetic acid, 0.01% of benzoic acid, 0.03%
of calcium acetate and 0.01% of magnesium acetate, for 3 hours. After being dipped, the pellets were dewatered and dried. The pellets after drying contained 0.1% of moisture, 0.06% of acetic acid, 0.016% of benzoic acid, 0.015~ of calcium and 0.0025~ of magnesium. The melt index (190-C, under a load of 2160 g) and the melting point of the pellets was 2.5 g/10 min and 176C respectively. The relationship between the heating time at 220-C and the extrusion rate of the pellets was determined with a capillary rheometer (Koka Flow Tester) to give a result roughly shown in FIGURE 1, and the extrusion rates at points in FIGURE 1 were as shown in Table 1.
- l9A -_ Table t 1 337233 Point Heatin~ time (hr~ Extrusion rate (cm'/sec~
o 2.5 x 10~' A 0.25 2.0 x 10-' B~ 1.75 0.5 x 10-' C 2 0.6 x 10~' D 5 5.1 x 10-3 ~ B is a point where the extrusion rate is minimum between points A and C.
The pellets were extruded at 220-C into a flim having a thic~ness of 20 ~ (extruder: 20 mm~ , L/D = 2S, die: T-die, 200 mm wide). A continuous running of over 150 hourswas performed, during which no streaks were formed in thefilm and only 0.t to 0.3 pieces/m2 of visible gel-like fish eyes (small-block defects resembling fish eyes). The number of the fish eyes did not increase with time.
Separately, the pellets were co-extruded into a multi-layered film comprising the EVOH as an intermediate layer, a polyethylene modified with maleic anhydride (content of maleic anhydride and vinyl acetate: 0.5 wt~ and 20 wt~ res-pectively, MI: 1.8 g/10 min) as adhesive layers, and a low density polyethylene as inner and outer layers. The film construction was low density polyethylene/adhesive resin/
EVOK/adhesive resin/low density polyethylene ~thic~nesses:
~ /5 ~ /20 ~ /5 ~ /40 J~ (total 110 ~ )~. The film forming conditions were as follows.
_ A 60 mm-~ extruder, two 40 mm-~ extruders and two 65 mm-~ extruders were used for the EVOH, the adhesive resin and the low density polyethylene respectively. The die confluence system was one with a feed block (600 mm wide), the die temperature and the cooling roll temperatureS were 220 C and 50 C, take-up speed was 10 m/min, and the EVOH
resin temperature was 220 C. A con~nuous operation of over 150 hours was performed, during no streaks were formed in the film and only 0.1 to 0.3 pieces/mZ of visible gel-like fish eyes. The number of fish eyes did not increase with time. The sheet had a good appearance with no wavy pattern.
Reference Example t EVOH pellets were obtained in the same manner as in Example i1 from an EVOH containing 38 mol~ of ethylene and having a saponification degree of 99.3 mol~. One part of the pellets was washed three times each time with 10 parts of ion-exchanged water containing 0.05% of acetic acid and then dipped for 3 hours in 20 parts of ion-exchanged water containing 0.02% of adipic acid and 0.01~ of calcium acetate. After being dipped, the pellets were dewatered and dried. After the drying, the pellets contained 0.t% of moisture, 0.005% of acetic acid, 0.03% of adipic acid and 0.005% of calcium.
-- Z5 The extrusion rates with time were measured using a capillary rheometer (Xoka Flow Tester) to give results shown in Table 2. The extrusion rate st~;ly decreased with time.
The tendency was similar to that shown in FIGURE 1. 1 337233 Table 2 Heating time (hr) 0 0.25 2 4 Extrusion rate (10~'cm3/sec) 1.5 1.2 0.5 0.28 Heating time (hr) 6 8 t0 Extrusion rate (10~~cm~/sec) 0.20 0.18 0-15 The pellets were co-extruded into a multi-layered film comprising the EVOH as an intermediate layer, a polyethylene modified with maleic anhydride as adhesive layers, and a low denslty polyethylene as inner and outer layers, at a die temperature and resin temperature of both 200-C with the same apparatus and in the same conditions as in Example 1.
Then, 20 hours after the start up, gel-like fish eyes generated ~igorously in the E~OH layer as shown in Table 3, and the operation had to be stopped after 48 hours. Wavy irregularities had been formed on the surface from the start until the process was stopped.
. Table 3 Runninq time (hr) 5 10 15 20 30 40 48 No. of fish eyes (pcs~mZ~ 0.2 0.1 0.5 1.1 3.5 6.0 1t Reference Example 2 An ethylene-vinyl acetate copolymer was saponified, and the saponified product was coagulated, cut and washed in the same manner as in Example 1. One part of the pellets was dipped for 3 hours in 100 parts of ion-exchanged water containing 0.15~ of acetic acid, then dewater~d and dried.
~ 3372~3 'he pellets after the drying contained 0.l1% of moisture, 0.09% of acetic acid, 0.0005~ of calcium and not more than 0.0001% of magnesium. Measurement of the extrusion-rate change with time using a capillary rheometer (Koka Flow Tester) at 220-C gave results shown in Table 4, showing that the extrusion rate decre~sed steadily with time.
Table 4 Heating time (hr) 0 0.25 2 4 Extrusion rate (10~'cm'/sec) 2.4 2.2 0.65 0.40 Heating time (hr) 6 8 10 Extrusion rate (10~'cm'/sec~ 0.21 0.12 0.08 With the same apparatus and film construction as in Example 1, co-extrusion film formation was conducted at a die temperature and a resin temperature of both 220C. Fish eyes were formed with time as shown in Ta~le 5. The operation was stopped 20 hours after the start.
Table 5 Running time (hr) 3 6 9 l5 20 No. of fish eyes (pcs/m2) 0.2 0.4 1.1 7.2 15 Wavy irregularities in the EVOH layer were generated just after the start up and continued to generate until the process was stopped.
Example 2 An ethylene-propylene-vinyl acetate copolymer contain-ing 29 mol~ of ethylene and 1 mol~ of propylene was saponifi-ed, and the saponified product was coagulated and cut in thesame manner as in Example 1 to give pellets. One part of ;he thus obtained pellets was washed twice each time with 15 parts of ion-exchanged water, and then dipped for 3 hours in 100 parts of ion-exchanged water containing 0.05~ of acetic acid, 0.02% of sodium dihydrogenphosphate, 0.02~ of calcium acetate and 0.01% of magnesium acetate. The pellets were then dewatered and dried. The dried pellets had a saponifi-cation degree of 99.4 mol%, a melt index of 1.2 g/10 min and a melting point of 177-C. The pellets contained 0.09~ of moisture, 0.03% of acetic acid, 0.04% of sodium dihydrogen-10 phosphate, 0.01~ of calcium and 0.0025~ of magnesium.
Measurement of the relationship between heating time and the extrusion rate at 230-C using a capillary rheometer (Koka Flow Tester) gave results similar to those shown in FIGURE
1. The extrusion rates at points in FIGURE 1 were as given in Table;6.
Table 6 Point Heatin~ time ~hr) Extrusion rate (cm'/sec~
1.9 X 10-J
A 0.25 1.6 x 10-' B~ 0.75 0.8 x 10-' C 2 8.5 x 10~' D 3 8.2 x 10-' ~ B is a point where the extrusion rate is minimum between points A and C.
- 25 A film formation by tubular film co-extrusion was conducted with the E~OH pellets, a low density polyethylene ~Melt index (MI) measured according to ASTM-D1238: 1.2 g/10 _, min; hereinafter referred to as LDPE~ and a polyethylene modified with maleic anhydride (MI: 1.8 g/10 min, degree of modification with maleic anhydride: 0.5 wt~, and content of vinyl acetate: 20 wt%) to obtain a film having a thickness of 1t0 ~ . Various co~ditions employed were as given below.
1. Film construction Outer LDPE (20 ~ )/adhesive resin (10 ~ )/EVOH (20 ~ ) /adhesive resin (10 ~ )/inner LDPE (50 J~); (total: 110 -~) 2. Equipment (1) LDPE 65 mm~ extruder, L/D = 22 (2) Adhesive resin 40 mm~ extruder, L/D = 22 (3) EVOH 60 mm~ extruder, L/D = 28 (4) Die (3 kind/5 layer circular die) 75 mm~
3. Extrusion conditions (1) Temperature of 65 mm~ extruder: 230-C
(2) Temperature of 40 mm~ extruder: 220-C
(1) Temperature of 60 mm~ extruder: 230-C
(1) Resin temperature : 230-C
A continuous operation was carried out over 120 hours, durinq which no streaks or wavy irregularities were generated in the film. Fish eyes were generated only in small am~unts, and the film surface was clean. The generation of the fish eyes with time was as shown in Table 7.
Table 7 1 337233 Running time (hr) 24 48 72 96 120 No. of fish eyes (pcs~m2) 0.2 0.1 0.3 0.5 0.5 Examples 3 throu~h 9 Example 1 was repeated except that the conditions of treatment with acidic substances and metal salts were changed, to obtain pellets of EVOH's, analysis data of which are shown in Column A of Table 10. They exhibited time-dependent viscosity changes as shown in Column B of Table 10. These pellets were molded into films with the same 5-layer film-forming equipment of co-extrusion feed block confluence type as that used in Example 1. The film forming conditions and results of evaluation on the films are shown in Column C of Table 10. All the films had a good appearance with no wavy patterns.
Reference Example 3 An ethylene-propylene-vinyl acetate copolymer was saponified, and the saponified product was coagulated, cut and washed in the same manner as in Example 2. One part of the pellets was dipped for 3 hours in 150 parts of ion-exchanged water containing 0.02~ of adipic acid, thendewatered and dried. The pellets after the drying contained 0.09~ of moisture, 0.03~ of adipic acid, 0.0007~ of calcium and not more than 0.0001~ of magnesium. Measurement of the extrusion-rate change with time using a capillary rheometer (Koka Flow Tester) at 230-C gave results shown in Table 8, _ showing that the extrusion rate decreased steadily with tlme .
Table 8 ~eating time (hr) 0 0.25 2 4 Extrusion rate tlO~'cm'/sec) 2.1 1.8 1.1 0.55 Heating time (hr) 6 8 10 Extrusion rate (lO~'cm'/sec~ 0.19 0.08 O.OS
With the same equipment, film construction and conditions (i.e. resin temperature: 230-C) as those in Example 2, co-extrusion film formation was conducted. The number of fish eyes formed increased with time. (Table 9) Table 9 Running time (hr) 2 4 6 8 10 No. of fish eyes (pcs/mZ) 0.1 0.3 0.7 2.9 8.0 The film had a bad appearance with wavy irregularities.
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-- ~8-_ ~eference Examples 4 through 7 . l 337233 Example I was repeated except that the conditions of treatment with acidic substances and metal salts were changed, to obtain pellets of EVOH's, analysis data of which are shown in Column A of Table 11. They exhibited time-dependent viscosity changes shown in Column B of Table 11.
These pellets were molded into films with the same film forming equipment, conditions and film constructions as those in Example 1. The results of evaluation on the films are shown in Column C of Table 11.
A B C
Analysis results of pellet Ti~e-dependent change Filu foruation (C) (~) (A) \ Tine Ref. Acidic Acidic \ hr Tenperature No. of Ex. substance substance Metal sslt \ Extrusion rate (10-~ X cu~/sec) condition fish-eyes in No. havin~ havin~(substance) \ (-C) EVOH layer Ap.
a b.p. of a b.p. of 120-C 2 lôO C \ LDPE Ad EVOII llours No. of (sub- (sub- (uetal X) (oetal X) Tenp \ O 0.25 2 4 6 ô 10 65~ 40~ 6û~ run fish-~ stance) X stsnce) X C \ EXT. EXT. EXT. eyes/n2 C~ (HOAc) (Kll,PO~) (Ca- 10 0.4 1 40.22 0.01 acetate) - 22û 2.5 2.2 0.82 0.60 0.41 0.27 0.12 220 220 220 20 4.1 bad (PO,'~) 0.002 30 12 (NOAc) (~II,PO,) (Ca- (M~- 5 0.5 50.08 ~ 0.001acetate)scetate) 240 4.7 4.1 1.5 0.45 0.12 0.050.02 240 220 240 10 6.0 (pO,~~) 0.002~ O.OOOI 1s 14 (For~ic (Adipic (Ca- (M~- 10 0.4 --~
6acid) acid) acetate)sulfate) 215 1.9 1.7 1.1 O.ôl 0.52 0.31 0.09 215 215 215 20- 7.0 0.03 0.02 0.0004~ O.0001 30 21 _~J
(Foruic (Adipic (Ca- (Zn- 10 0.5 7acod) acid) acetate)Acetate) 220 2.4 2.2 0.90 0.65 0.42 0.25 0.12 22û 220 220 20 6.5 0.02 ~ 0.001 0.0040.0005 30 20 Notes: LDPE: Low density polyethylene Ad: Adhesive resin Ap.: Appearance _ Example 10 l 33723~
A multilayered sheet was co-extruded using the same equipment as that in Example 1 with the EVOH pellets for the intermediate layer, a polyethylene terephthalate (PET) as inner and outer layers and an ethylene-vinyl acetate copolymer modified with maleic anhydride as an adhesive resin. The molding conditions were as given below.
1. Film construction Outer PET/adhesive resin/EVOH/adhesive resin/inner PET
= 40 ~ /12 ~ /80 ~ /12 ~ /40 ll (total: 184 ~ ) 2. Resins used EVOH: one obtained in Example 1 PET : a polyethylene terephthalate resin having an inher-ent viscosity ~ ~ of 0.72 dl/g as determined at 30-C on a solution thereof dissolved in a mixed solvent of 50 wt% of phenol and 50 wt% of tetrachloroethane.
Adhesive resin: an ethylene-vinyl acetate copolymer modified with maleic anhydride (content of vinyl acetate: 24 mol%, degree of modification with maleic anhydride: 1.8 wt%) 3. Equipment (1) PET 65 mm~ extruder, L/D = 22 (2) Adhesive resin 40 mm~ extruder, L/D = 22 (3) EVOH 60 mm~ extruder, L/D = 28 (4) Die (3 kind/5 layer feed block type 600 mm wide 4. Extrusion conditions (1) Temperature of 65 mm~ extruder: 280-C
(2) Temperature of 40 mm~ extruder: 220-C
(3) Temperature of 60 mm~ extruder: 225-C 1 337233 (4) Resin temperature : 250-C
A continuous operation was conducted over 120 hours.
During the operation, no streaks were formed on the flim, and the number of gel-like fish eyes in the EVOH layer was 0.l to 0.3 pieces/m2 showing no tendency to increase with time. The film appearance was good.
Example ll An ethylene-vinyl acetate copolymer containing 32 mol~
of ethylene was saponified, and the saponified product was coagu~ated and cut in the same manner as in Example I to give pellets (melting point: 18l-C). One part of the pellets was washed twice each time with l0 parts of ion-exchanged water, then dipped for 4 hours in 100 parts of ion-exchanged water containing 0.03~ of acetic acid, 0.02~ of benzoic acid, 0.015~ of calcium acetate and 0.01% of zinc acetate, and thereafter dewatered and dried. The pellets after the drying had a saponification degree of 99.S mol~
and a melt index of l.3 g/l0 min, and contained 0.tS~ of moisture, 0.01~ of acetic acid, 0.03~ of benzoic acid, 0.008~ of calcium and 0.004~ of zinc.
The extrusion rates were measured at 250-C with various heating times using a capillary rheometer (Koka Flow Tester). The relationship between the heating time and the extrusion rate was of a type similar to that shown in FIGURE
1. The extrusion rates corresponding to the points in FIGURE 1 are as shown in Table 12.
-3~-`~ Table 12 Point Heatin~ time (hr) Extrusion rate (cm~/sec~
o 6.1 x 10-' A 0.25 4.7 x 10-' 5- B~ 0.8 2.1 x 10-' C 2 9.2 x 10-' D 3 30 x 10-' ~ B is a point where the extrusion rate is minimum between points A and C.
A polyethylene terephthalate resin (inherent viscosity [~ ] = 0.85 dl/g, melting point: 265-C), the EVOH obtained above and an ethylene-vinyl acetate copolymer modified with maleic anhydride (contents of vinyl acetate and maleic anhy-dride: 24 wt~ and 1.1 wt% respectively) as an adhesive resin were separately fed through three extruders, the extrusion temperatures being 250-C for the EVOH resin, 278-C for the polyethylene terephthalate resin (PET) and 250-C for the adhesive resin, to a multilayered cylindrical die to join together therein, with the resin temperatures at the die of 280 C for PET and 250-C for the EVOH resin and the adhesive resin, to be extruded into a 3 kind/5 layer pipe having a construction of outer PET/adhesive resin/EVOH/adhesive resin /inner PET = 1.0 mm/0.1 mm/0.3 mm/0.1 mm/2.0 mm (total wall thickness: 3.5 mm), and an outer pipe diameter of 25.0 mm.
A continuous operation was conducted over 120 hours.
No streaks or ~elled matter formed, and a multilayer _ ipe having a good appearance was obtained. l 3 3 7 2 3 3 The thus obtained multilayered pipe was cut to 13.0 cm.
The cut piece was sealed at one end and provided on another end with a neck capable of mounting a cap, to form a multi-layered preform. The preform obtained was heated to 105-C
and biaxially-draw blown by elongation using an extension rod and by air-blowing into a multilayered bottle having a capacity of 1 liter. The thus obtained multilayered bottle had excellent carbon dioxide gas barrier properties and was well suited for a container for carbonated drinks.
Reference Example 8 An ethylene-vinyl acetate copolymer containing 32 mol~
of ethylene was saponified, and the saponified product was coagulated and cut in the same manner as in Example 1 to give pellets. One part of the pellets was washed twice each time with 10 parts of ion-exchanged water, then dipped for 4 hours in 100 parts of ion-exchanged water containing 0.03~
of acetic acid, and thereafter dewatered and dried. The pellets after the drying had a saponification degree of 99.S
mol~ and a melt index of 1.3 g/10 min, and contained 0.15 of moisture and 0.0l% of acetic acid.
The extrusion rates were measured at 250-C with various heating times using a capillary rheometer (Koka Flow Tester) to give the results shown in Table 13.
Table 13 ~eating time (hr) 0 0.25 2 4 Extrusion rate (10~'cm'/sec) 6.1 5.2 2.4 1.1 Heating time (hr) 6 8 10 Extrusion rate (10~ 3 cm3 /sec) 0.51 0.22 0-07 A polyethylene terephthalate resin (inherent viscosity [~ ] = 0.85 dl/g, melting point: 265C), the EVOH obtained above and an ethylene-vinyl acetate copolymer modified with maleic anhydride tcontents of vinyl acetate and maleic anhydride: 24 wt% and 1.1 wt% respectively) as an adhesive resin were extruded through the same equipment and under the same conditions as those in Example 11 into a 3 kind/5 layer pipe having a construction of outer PET/adhesive resin/EVOH/
adhesive resin/inner PET = 1.0 mm/0.1 mm/0.3 mm/0.1 mm/2.0 mm (total wall thickness: 3.5 mm), and an outer pipe diame-ter of 25.0 mm. Three hours after the start up, streaks began to generate and became more remar~able with progress of time, thus forcing the operation to be. stopped after 6 hours. A t-liter multilayered bottle was prepared by blow molding a multilayered preform obtained from the pipe.
However, a bottle with a good appearance could not be obtained because of the generation of streaks.
Example 12 Dry pellets having a melting point of 181-C and other properties shown below were prepared from an ethylene-vinyl acetate copolymer containing 32 mol% of ethylene in the same _.~anner as in Example 1. 1 3 3 7 2 3 3 Saponification degree : 99.3 mol%
Melt index : 4.8 g/10 min Content of acetic acid : 0.02 Content of benzoic acid : 0.02 Content of calcium : 0.006 Content of magnesium : 0.002~
Measurement of the relationship between the heating time and the extrusion rate at 260-C with a capillary rheometer (Koka Flow Tester) gave results similar to those shown in FIGURE 1, and the extrusion rates corresponding to the points in FIGURE 1 are as shown in Table 14.
Table 14 Point Heating time (hr)Extrusion rate (cmJ~sec~
0 41 x 10~ 3 A 0.25 25 x 10-3 B* 0.6 9.8 x 10~ 3 C 2 18 x 10~' D 4 60 x 10~ 3 20~ B is a point where the extrusion rate is minimum between points A and C.
A PET having an inherent viscosity [~ ~ = 0.73 dl/g, and a melting point of 258-C, the EVOH obtained above and an ethylene-vinyl acetate copolymer modified with maleic anhy-25dride ( melt index: 4.0 g/10 min; contents of vinyl acetate and maleic anhydride: 24 wt~ and 1.1 wt~ respectively) as an lhesive resin (Ad) were extruded through co-injection e~uipment comprising three injection cylinders and a single preform die into a 3 kind/5 layer preform having a construc-tion of PET/Ad/EVOH/Ad/PET = 1.0 mm/0.1 mm/0.3 mm/0.1 mm/2.0 mm (average wall thicknesses at body), and an outer diameter and a length of 25.0 mm-and 130 mm respectively. A continu-ous operation was conducted over 120 hours. No streaks or gelled matters were formed, and a preform having a good appearance was obtained. The thus obtained preform was heat-ed to 105-C and biaxially-draw blown by elongation using an extension rod and by air blowing into a multilayered bottle having a capacity of 1 liter. The thus obtained multilayer-ed bottle had excellent carbon dioxide gas barrier properties and was well suited for containers for various drinks.
Reference Example 9 An EVOH of the following characteristics was prepared.
Ethylene content : 32 mol~
Saponification degree : 99.3 mol%
Melt index : 4.8 g/10 min Content of acetic acid : 0.01%
The extrusion rates were measured at 260C with various heating times using a capillary rheometer (Koka Flow Tester) to give the results shown in Table 15.
- ` ~ 1 337233 Table 15 Heating time (hr) o 0.25 2 4 Extrusion rate (lO~'cm'/sec) 41 20 9.5 5.2 Heating time (hr) 6 8 10 Extrusion rate (10~'cm'/sec) 1.90.08 0.04 A multilayered preform was molded by co-injection with the same eauipment and the same conditions as those in Example 12. Four hours after the start of the molding, streaks increased in number and the ~reform was biaxially draw-blown into a bottle of l-liter capacity. The bottle was poor in appearance having many streaks.
Solutes contained in EVOH are extracted with a solvent, and the acidic substance in the extract is determined ~y neutralization titration. Determination of representative acidic substances are given below.
Succinic acid The succinic acid in EVOH is extracted with water in the same manner as for formic acid. The extract is mixed with resorcinol and concentrated sulfuric acid, heated at 126 to 130-C, cooled, and then submitted to a determination by colorimetry.
Adipic acid The adipic acid in EVOH is extracted with water in the same manner as for formic acid. The extract is dried to solid, and the deposited adipic acid is dissolved in water, and the solution is submitted for neutralization titration to determine the adipic acid using an aqueous sodium hydroxide solution as a titrating liquid.
Benzoic acid This is determined in a manner similar to that for adipic acid.
CaDric acid A tight sealed container is filled with 100 parts of EVOH and 250 parts of ethanol, and the contents are heated with stirring at 80-C for 5 hours to extract the capric acid in EVOH. Using an aqueous sodium hydroxide solution as a titrating liquid, the capric acid in the extract is determined by neutralization titration.
Lauric acid This is determined in a manner similar to that for capric acid.
Succinic acid The succinic acid in EVOH is extracted with water in the same manner as for formic acid. The extract is mixed with acetic anhydride and heated. Pyridine is further added to the mixture, heated, cooled and then submitted to determination by colorimetry.
Boric acid Similar to the cases of analysis of the afore-mentioned metals, boric acid is determined by atomic absorption analysis.
Sodium dihydrogenphosPhate A tight sealed container is filled with 100 parts of EVOH and 250 parts of a 1 g/l aqueous solution of acetic acid, and the contents are heated with stirring at 95C for 3 hours to extract the sodium dihydrogenphosphate in EVOH.
The phosphate ion in the extract is determined by ion chromatography.
Potassium dihydro~enphosphate This is determined in the same manner as for sodium dihydrogenphosphate.
2S Amino acids The amino acid in EVOH is extracted with water in the same manner as for formic acid. The amino acid in the extract is determined by a known amino acid analysis. For example, asparagic acid is determined by polarographic determination of the fumaric acid formed by treatinq the obtained extract with dimethyl sulfate.
The thus obtained EVOH is co-extruded or co-injected with a hydrophobic thermoplastic resin via a thermoplastic resin modified with an ethylenically unsaturated carboxylic acid or its anhydride. The melt viscosity of the EVOH
changes depending on temperature, and the influences of the afore-mentioned substances contained in the EVOH on the melt viscosity of the EVOH also vary depending on temperature, and further the time-dependent change of the melt viscosity changes in a complex manner depending on the temperature.
Selection of an appropriate moldinq temperature range therefore is necessary to achieve the afore-described specific time-dependent change.
The above-described EVOH used in this invention may, when submitted to melt moldinq, incorporate mixed therewith a conventional EVOH, for example one havinq an ethylene content different from the EVOH, other thermoplastic resin, additives, e.g. a plasticizer, and the like, in amounts not to adversely affect the object of the present invention.
Next, the hydrophobic thermoplastic resins used in co-extrudion molding or co-injection molding with the EVOH are explained. Preferred thermoplastic resins are polypropyl-ene-, polyethylene, ethylene-propylene copolymer, ethylene-vinyl acetate copoly~er, thermoplastic polyesters, e gpolyethylene terephthalate, polyamides, e.g. 6-Nylon* and 6,6-Nylon, polystyrene, polyvinyl chloride, polycarbonate and the like. They may be used singly, as copolymers or in ad~ixtures thereof. Particularly preferred among these are polypropylene, polyethylene, ethylene-propylene copolymer, thermoplastic polyesters, polystyrene, or copolymers or mixtures thereof.
Interlayer adhesives are often used when the EVOH and the hydrophobic thermoplastic resin are co-extruded or co-lS injected. As the interlayer adhesive, thermoplastic resinsmodified with an ethylenically unsaturated carboxylic acid or its anhydride are preferred. In view of the adhesive-ness with the EVOH layer and with the hydrophobic thermo-plastic resin layer, the interlayer adhesive is preferably a carboxyl-group containing modified olefin polymer comprising an olefin polymer chemically bonded (e.g. by addition reaction or by grafting) with an ethylenically unsaturated carboxylic acid or its anhydride. The olefin polymer herein is a polyolefin, e.g. polyethylene (low pressure, medium pressure or high pressure polyethylene), linear low density polyethylene, polypropylene or polybutene; a copolymer of an ol~f;n with a comonomer copolymerizable with the olefin * Trademark ~ 337233 (e.g. vinyl ester, unsaturated carboxylic acid ester, or the like), e.g. ethylene-vinyl acetate copolymer ar ethylene-ethyl acrylate copoly~er; or the like. Among the above, preferred are ethylene-vinyl acetate copolymer (containing from 5 to 55~ by weight of vinyl acetate) and ethylene-ethyl acrylate copolymer (containing from 8 to 35~ by weight of ethyl acrylate).
The ethylenically unsaturated carboxylic acid or its anhydride herein means an ethylenically unsaturated monocarboxylic acid, its ester, an ethylenically unsaturated dicarboxylic acid, its mono- or diester, its anhydride, among which ethylenically unsaturated dicarboxylic acid an-hydride is preferred. More concretely, mention can be made of maleic acid fumaric acid, itaconic acid, maleic anhydride, lS itaconic anhydride, monomethyl maleate, monoethyl maleate, diethyl maleate, monomethyl fumarate and the like, among which maleic anhydride is most preferred.
The amount of the ethylenically unsaturated carboxylic acid or its anhydride added or grafted to the olefin polymer (modification amount) is from 0.01 to 15% by weight, prefer-ably from 0.02 to 10~ by weight based on the weight of the oiefin polymer. The addition or grafting of the ethylenical-ly unsaturated carboxylic acid or its anhydride to the olefin polymer is conducted, for example, in the presence of a solvent, e.g. xylene and a catalyst, e.g. peroxide by radical polymerization or the like. The MI measured according to ASTM-D-1238-65T at 190-C of the thus obtained carboxyl-group containing modified polyolefin is 0.2 to 30 g/10 min, preferably 0.5 to 10 g/min. The adhesive resins may be used singly or in admixtures of more than two.
The co-extrusion of the E~OH with the hydrophobic thermoplastic resin may be performed by a multi-manifold confluence T-die method, by a feed-bloc~ confluence T-die method, or by inflation.
The thus obtained co-extrusion molded articles may be subjected to a secondary processinq to give various molded articles, e.g. films, sheets, tubes and bottles; for example:
(~) multilayered molded articles such as sheets and films are monoaxially or biaxially drawn and heat-treated into multilayered co-drawn sheets and films, (2) multilayered molded articles, e.g. sheets and films are rolled into multilayered rolled sheets and films, (3) multilayered molded articles, e.g. sheets and films are vacuum formed, pressure formed, vacuum-pressure formed, or isothermally molded into multilayered trays and cup-shaped containers, and (4) multilayered molded articles, e.g. pipes are stretch-blow molded or by a similar process molded into bottles or cup-shaped contai~ers.
The secondary processing methods are not limited to the above, but any known processing other than the above (e.g.
blow molding) may be employed.
Examples of the layer construction of the co-extruded laminates are, when the thermoplastic resin modified with an ethylenically unsaturated carboxylic acid or its anhydride is expressed as Ad, and the hydrophobic ther~oplastic resins as P and P', EVOH/Ad/P, P/Ad/EVOH/Ad/P, P/P'/Ad/EVO~/Ad/P, P/Ad/EVO~/Ad/P'/P and the like, wherein each layer may be a singte layer or, as occasions demand, a multilayer. The hydrophobic resin layer P' may be a layer of its blend with EVOH and/or Ad.
The thus obtained co-extruded laminates are, since they have excellent appearances and gas barrier properties, best suited for materials for food containers, e.g. deep-drawn containers, cup-shaped containers and bottles.
The co-injection can be performed by any known co-injection process. Also a multilayered preform can be obtained by a known process as disclosed in Unexamined Japanese Patent Laid-Open No. 152412/1986, which comprises injecting continuously and successively resins (P, Ad and EVOH), which resins have been melted a one time clamping operation, into a single preform mold through three injection cylinders. Then the layer constructionS are,for example, P/Ad/EVOH/Ad/P, P/Ad/EVOH/Ad/P/Ad/EVOH/Ad/P, and the like. Or, a multilayered preform or hollow container can be formed by a co-injection molding or a co-injection blow-molding using a co-injection nozzle shown in Unexamined Japanese Patent Laid-Open No. 34819/l985.
In the above co-injection moldings, as in the case of co-extrusion, the use of a conventional EVOH will cause, besides generation of gels, an unstable interfacial instability at interfaces where the EVOH layer and the interlayer adhesive resin layer, particularly an adhesive resin comprising a thermoplastic resin modified with an ethylenically unsaturated carboxylic acid or its anhydride joins (i.e. in hot runner nozzle or at the inside of a preform mold). The interfacial instability then causes a poor wavy appearance, interinvasion of the adjacent layers, other poor appearances, e.g. a matte surface and streaky surfaces, thereby rendering molded articles of high commercial value impossible to obtain. The EVOH prepared according to the invention described in the parent application, however, when melt molded at an appropriate temperature can effectively prevent the worsening of the appearance. The reason is thought to be similar to that in the case of co-extrusion.
Hereinbelow the invention will be further explained with reference to Examples, wherein "parts" or "~" means "parts by weight" or "~ by weight" unless otherwise specified. Reference is made in the Examples to the drawing in which:
FIGURE 1 shows the relationship between the heating time and the extrusion rate measured with a capillary rheometer (Koka Flow Tester). In the FIGURE, the points indicate as follows:
A: after 15 minutes, C: after 2 hours, B: after 1.75 hours or indicates a time where the extrusion rate is minimum between A and C.
D: after 5 hours.
EXAMPLES
Example 1 l 337233 A solution containing 45 parts of an ethylene-vinyl acetate copolymer having an ethylene content of 38 mol%, 50 parts of methanol and 1 part of sodium hydroxide was subiect-ed to saponification for 40 minutes at 110-C and under a pressure of 3.5 kg/cm2G, while methanol vapor was being blown thereinto. The methyl acetate formed during the reac-tion was, together with a portion of the methanol, removed from the system by distillation. The obtained saponified reaction mixture (saponification degree: 99.3 mol~) was extruded through a die having a hole of 2 mm diameter into a mixed solvent of 10% of methanol and 90% of water at S-C to coagulate into-a strand, and the coagulate was cut with a cutter to give pellets. The pellets were washed three times each time with 10 parts of ion-exchanged water based on 1 part of the pellets, and then dipped in an aqueous solution comprising 100 parts of ion-exchanged water containing 0.1% of acetic acid, 0.01% of benzoic acid, 0.03%
of calcium acetate and 0.01% of magnesium acetate, for 3 hours. After being dipped, the pellets were dewatered and dried. The pellets after drying contained 0.1% of moisture, 0.06% of acetic acid, 0.016% of benzoic acid, 0.015~ of calcium and 0.0025~ of magnesium. The melt index (190-C, under a load of 2160 g) and the melting point of the pellets was 2.5 g/10 min and 176C respectively. The relationship between the heating time at 220-C and the extrusion rate of the pellets was determined with a capillary rheometer (Koka Flow Tester) to give a result roughly shown in FIGURE 1, and the extrusion rates at points in FIGURE 1 were as shown in Table 1.
- l9A -_ Table t 1 337233 Point Heatin~ time (hr~ Extrusion rate (cm'/sec~
o 2.5 x 10~' A 0.25 2.0 x 10-' B~ 1.75 0.5 x 10-' C 2 0.6 x 10~' D 5 5.1 x 10-3 ~ B is a point where the extrusion rate is minimum between points A and C.
The pellets were extruded at 220-C into a flim having a thic~ness of 20 ~ (extruder: 20 mm~ , L/D = 2S, die: T-die, 200 mm wide). A continuous running of over 150 hourswas performed, during which no streaks were formed in thefilm and only 0.t to 0.3 pieces/m2 of visible gel-like fish eyes (small-block defects resembling fish eyes). The number of the fish eyes did not increase with time.
Separately, the pellets were co-extruded into a multi-layered film comprising the EVOH as an intermediate layer, a polyethylene modified with maleic anhydride (content of maleic anhydride and vinyl acetate: 0.5 wt~ and 20 wt~ res-pectively, MI: 1.8 g/10 min) as adhesive layers, and a low density polyethylene as inner and outer layers. The film construction was low density polyethylene/adhesive resin/
EVOK/adhesive resin/low density polyethylene ~thic~nesses:
~ /5 ~ /20 ~ /5 ~ /40 J~ (total 110 ~ )~. The film forming conditions were as follows.
_ A 60 mm-~ extruder, two 40 mm-~ extruders and two 65 mm-~ extruders were used for the EVOH, the adhesive resin and the low density polyethylene respectively. The die confluence system was one with a feed block (600 mm wide), the die temperature and the cooling roll temperatureS were 220 C and 50 C, take-up speed was 10 m/min, and the EVOH
resin temperature was 220 C. A con~nuous operation of over 150 hours was performed, during no streaks were formed in the film and only 0.1 to 0.3 pieces/mZ of visible gel-like fish eyes. The number of fish eyes did not increase with time. The sheet had a good appearance with no wavy pattern.
Reference Example t EVOH pellets were obtained in the same manner as in Example i1 from an EVOH containing 38 mol~ of ethylene and having a saponification degree of 99.3 mol~. One part of the pellets was washed three times each time with 10 parts of ion-exchanged water containing 0.05% of acetic acid and then dipped for 3 hours in 20 parts of ion-exchanged water containing 0.02% of adipic acid and 0.01~ of calcium acetate. After being dipped, the pellets were dewatered and dried. After the drying, the pellets contained 0.t% of moisture, 0.005% of acetic acid, 0.03% of adipic acid and 0.005% of calcium.
-- Z5 The extrusion rates with time were measured using a capillary rheometer (Xoka Flow Tester) to give results shown in Table 2. The extrusion rate st~;ly decreased with time.
The tendency was similar to that shown in FIGURE 1. 1 337233 Table 2 Heating time (hr) 0 0.25 2 4 Extrusion rate (10~'cm3/sec) 1.5 1.2 0.5 0.28 Heating time (hr) 6 8 t0 Extrusion rate (10~~cm~/sec) 0.20 0.18 0-15 The pellets were co-extruded into a multi-layered film comprising the EVOH as an intermediate layer, a polyethylene modified with maleic anhydride as adhesive layers, and a low denslty polyethylene as inner and outer layers, at a die temperature and resin temperature of both 200-C with the same apparatus and in the same conditions as in Example 1.
Then, 20 hours after the start up, gel-like fish eyes generated ~igorously in the E~OH layer as shown in Table 3, and the operation had to be stopped after 48 hours. Wavy irregularities had been formed on the surface from the start until the process was stopped.
. Table 3 Runninq time (hr) 5 10 15 20 30 40 48 No. of fish eyes (pcs~mZ~ 0.2 0.1 0.5 1.1 3.5 6.0 1t Reference Example 2 An ethylene-vinyl acetate copolymer was saponified, and the saponified product was coagulated, cut and washed in the same manner as in Example 1. One part of the pellets was dipped for 3 hours in 100 parts of ion-exchanged water containing 0.15~ of acetic acid, then dewater~d and dried.
~ 3372~3 'he pellets after the drying contained 0.l1% of moisture, 0.09% of acetic acid, 0.0005~ of calcium and not more than 0.0001% of magnesium. Measurement of the extrusion-rate change with time using a capillary rheometer (Koka Flow Tester) at 220-C gave results shown in Table 4, showing that the extrusion rate decre~sed steadily with time.
Table 4 Heating time (hr) 0 0.25 2 4 Extrusion rate (10~'cm'/sec) 2.4 2.2 0.65 0.40 Heating time (hr) 6 8 10 Extrusion rate (10~'cm'/sec~ 0.21 0.12 0.08 With the same apparatus and film construction as in Example 1, co-extrusion film formation was conducted at a die temperature and a resin temperature of both 220C. Fish eyes were formed with time as shown in Ta~le 5. The operation was stopped 20 hours after the start.
Table 5 Running time (hr) 3 6 9 l5 20 No. of fish eyes (pcs/m2) 0.2 0.4 1.1 7.2 15 Wavy irregularities in the EVOH layer were generated just after the start up and continued to generate until the process was stopped.
Example 2 An ethylene-propylene-vinyl acetate copolymer contain-ing 29 mol~ of ethylene and 1 mol~ of propylene was saponifi-ed, and the saponified product was coagulated and cut in thesame manner as in Example 1 to give pellets. One part of ;he thus obtained pellets was washed twice each time with 15 parts of ion-exchanged water, and then dipped for 3 hours in 100 parts of ion-exchanged water containing 0.05~ of acetic acid, 0.02% of sodium dihydrogenphosphate, 0.02~ of calcium acetate and 0.01% of magnesium acetate. The pellets were then dewatered and dried. The dried pellets had a saponifi-cation degree of 99.4 mol%, a melt index of 1.2 g/10 min and a melting point of 177-C. The pellets contained 0.09~ of moisture, 0.03% of acetic acid, 0.04% of sodium dihydrogen-10 phosphate, 0.01~ of calcium and 0.0025~ of magnesium.
Measurement of the relationship between heating time and the extrusion rate at 230-C using a capillary rheometer (Koka Flow Tester) gave results similar to those shown in FIGURE
1. The extrusion rates at points in FIGURE 1 were as given in Table;6.
Table 6 Point Heatin~ time ~hr) Extrusion rate (cm'/sec~
1.9 X 10-J
A 0.25 1.6 x 10-' B~ 0.75 0.8 x 10-' C 2 8.5 x 10~' D 3 8.2 x 10-' ~ B is a point where the extrusion rate is minimum between points A and C.
- 25 A film formation by tubular film co-extrusion was conducted with the E~OH pellets, a low density polyethylene ~Melt index (MI) measured according to ASTM-D1238: 1.2 g/10 _, min; hereinafter referred to as LDPE~ and a polyethylene modified with maleic anhydride (MI: 1.8 g/10 min, degree of modification with maleic anhydride: 0.5 wt~, and content of vinyl acetate: 20 wt%) to obtain a film having a thickness of 1t0 ~ . Various co~ditions employed were as given below.
1. Film construction Outer LDPE (20 ~ )/adhesive resin (10 ~ )/EVOH (20 ~ ) /adhesive resin (10 ~ )/inner LDPE (50 J~); (total: 110 -~) 2. Equipment (1) LDPE 65 mm~ extruder, L/D = 22 (2) Adhesive resin 40 mm~ extruder, L/D = 22 (3) EVOH 60 mm~ extruder, L/D = 28 (4) Die (3 kind/5 layer circular die) 75 mm~
3. Extrusion conditions (1) Temperature of 65 mm~ extruder: 230-C
(2) Temperature of 40 mm~ extruder: 220-C
(1) Temperature of 60 mm~ extruder: 230-C
(1) Resin temperature : 230-C
A continuous operation was carried out over 120 hours, durinq which no streaks or wavy irregularities were generated in the film. Fish eyes were generated only in small am~unts, and the film surface was clean. The generation of the fish eyes with time was as shown in Table 7.
Table 7 1 337233 Running time (hr) 24 48 72 96 120 No. of fish eyes (pcs~m2) 0.2 0.1 0.3 0.5 0.5 Examples 3 throu~h 9 Example 1 was repeated except that the conditions of treatment with acidic substances and metal salts were changed, to obtain pellets of EVOH's, analysis data of which are shown in Column A of Table 10. They exhibited time-dependent viscosity changes as shown in Column B of Table 10. These pellets were molded into films with the same 5-layer film-forming equipment of co-extrusion feed block confluence type as that used in Example 1. The film forming conditions and results of evaluation on the films are shown in Column C of Table 10. All the films had a good appearance with no wavy patterns.
Reference Example 3 An ethylene-propylene-vinyl acetate copolymer was saponified, and the saponified product was coagulated, cut and washed in the same manner as in Example 2. One part of the pellets was dipped for 3 hours in 150 parts of ion-exchanged water containing 0.02~ of adipic acid, thendewatered and dried. The pellets after the drying contained 0.09~ of moisture, 0.03~ of adipic acid, 0.0007~ of calcium and not more than 0.0001~ of magnesium. Measurement of the extrusion-rate change with time using a capillary rheometer (Koka Flow Tester) at 230-C gave results shown in Table 8, _ showing that the extrusion rate decreased steadily with tlme .
Table 8 ~eating time (hr) 0 0.25 2 4 Extrusion rate tlO~'cm'/sec) 2.1 1.8 1.1 0.55 Heating time (hr) 6 8 10 Extrusion rate (lO~'cm'/sec~ 0.19 0.08 O.OS
With the same equipment, film construction and conditions (i.e. resin temperature: 230-C) as those in Example 2, co-extrusion film formation was conducted. The number of fish eyes formed increased with time. (Table 9) Table 9 Running time (hr) 2 4 6 8 10 No. of fish eyes (pcs/mZ) 0.1 0.3 0.7 2.9 8.0 The film had a bad appearance with wavy irregularities.
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-- ~8-_ ~eference Examples 4 through 7 . l 337233 Example I was repeated except that the conditions of treatment with acidic substances and metal salts were changed, to obtain pellets of EVOH's, analysis data of which are shown in Column A of Table 11. They exhibited time-dependent viscosity changes shown in Column B of Table 11.
These pellets were molded into films with the same film forming equipment, conditions and film constructions as those in Example 1. The results of evaluation on the films are shown in Column C of Table 11.
A B C
Analysis results of pellet Ti~e-dependent change Filu foruation (C) (~) (A) \ Tine Ref. Acidic Acidic \ hr Tenperature No. of Ex. substance substance Metal sslt \ Extrusion rate (10-~ X cu~/sec) condition fish-eyes in No. havin~ havin~(substance) \ (-C) EVOH layer Ap.
a b.p. of a b.p. of 120-C 2 lôO C \ LDPE Ad EVOII llours No. of (sub- (sub- (uetal X) (oetal X) Tenp \ O 0.25 2 4 6 ô 10 65~ 40~ 6û~ run fish-~ stance) X stsnce) X C \ EXT. EXT. EXT. eyes/n2 C~ (HOAc) (Kll,PO~) (Ca- 10 0.4 1 40.22 0.01 acetate) - 22û 2.5 2.2 0.82 0.60 0.41 0.27 0.12 220 220 220 20 4.1 bad (PO,'~) 0.002 30 12 (NOAc) (~II,PO,) (Ca- (M~- 5 0.5 50.08 ~ 0.001acetate)scetate) 240 4.7 4.1 1.5 0.45 0.12 0.050.02 240 220 240 10 6.0 (pO,~~) 0.002~ O.OOOI 1s 14 (For~ic (Adipic (Ca- (M~- 10 0.4 --~
6acid) acid) acetate)sulfate) 215 1.9 1.7 1.1 O.ôl 0.52 0.31 0.09 215 215 215 20- 7.0 0.03 0.02 0.0004~ O.0001 30 21 _~J
(Foruic (Adipic (Ca- (Zn- 10 0.5 7acod) acid) acetate)Acetate) 220 2.4 2.2 0.90 0.65 0.42 0.25 0.12 22û 220 220 20 6.5 0.02 ~ 0.001 0.0040.0005 30 20 Notes: LDPE: Low density polyethylene Ad: Adhesive resin Ap.: Appearance _ Example 10 l 33723~
A multilayered sheet was co-extruded using the same equipment as that in Example 1 with the EVOH pellets for the intermediate layer, a polyethylene terephthalate (PET) as inner and outer layers and an ethylene-vinyl acetate copolymer modified with maleic anhydride as an adhesive resin. The molding conditions were as given below.
1. Film construction Outer PET/adhesive resin/EVOH/adhesive resin/inner PET
= 40 ~ /12 ~ /80 ~ /12 ~ /40 ll (total: 184 ~ ) 2. Resins used EVOH: one obtained in Example 1 PET : a polyethylene terephthalate resin having an inher-ent viscosity ~ ~ of 0.72 dl/g as determined at 30-C on a solution thereof dissolved in a mixed solvent of 50 wt% of phenol and 50 wt% of tetrachloroethane.
Adhesive resin: an ethylene-vinyl acetate copolymer modified with maleic anhydride (content of vinyl acetate: 24 mol%, degree of modification with maleic anhydride: 1.8 wt%) 3. Equipment (1) PET 65 mm~ extruder, L/D = 22 (2) Adhesive resin 40 mm~ extruder, L/D = 22 (3) EVOH 60 mm~ extruder, L/D = 28 (4) Die (3 kind/5 layer feed block type 600 mm wide 4. Extrusion conditions (1) Temperature of 65 mm~ extruder: 280-C
(2) Temperature of 40 mm~ extruder: 220-C
(3) Temperature of 60 mm~ extruder: 225-C 1 337233 (4) Resin temperature : 250-C
A continuous operation was conducted over 120 hours.
During the operation, no streaks were formed on the flim, and the number of gel-like fish eyes in the EVOH layer was 0.l to 0.3 pieces/m2 showing no tendency to increase with time. The film appearance was good.
Example ll An ethylene-vinyl acetate copolymer containing 32 mol~
of ethylene was saponified, and the saponified product was coagu~ated and cut in the same manner as in Example I to give pellets (melting point: 18l-C). One part of the pellets was washed twice each time with l0 parts of ion-exchanged water, then dipped for 4 hours in 100 parts of ion-exchanged water containing 0.03~ of acetic acid, 0.02~ of benzoic acid, 0.015~ of calcium acetate and 0.01% of zinc acetate, and thereafter dewatered and dried. The pellets after the drying had a saponification degree of 99.S mol~
and a melt index of l.3 g/l0 min, and contained 0.tS~ of moisture, 0.01~ of acetic acid, 0.03~ of benzoic acid, 0.008~ of calcium and 0.004~ of zinc.
The extrusion rates were measured at 250-C with various heating times using a capillary rheometer (Koka Flow Tester). The relationship between the heating time and the extrusion rate was of a type similar to that shown in FIGURE
1. The extrusion rates corresponding to the points in FIGURE 1 are as shown in Table 12.
-3~-`~ Table 12 Point Heatin~ time (hr) Extrusion rate (cm~/sec~
o 6.1 x 10-' A 0.25 4.7 x 10-' 5- B~ 0.8 2.1 x 10-' C 2 9.2 x 10-' D 3 30 x 10-' ~ B is a point where the extrusion rate is minimum between points A and C.
A polyethylene terephthalate resin (inherent viscosity [~ ] = 0.85 dl/g, melting point: 265-C), the EVOH obtained above and an ethylene-vinyl acetate copolymer modified with maleic anhydride (contents of vinyl acetate and maleic anhy-dride: 24 wt~ and 1.1 wt% respectively) as an adhesive resin were separately fed through three extruders, the extrusion temperatures being 250-C for the EVOH resin, 278-C for the polyethylene terephthalate resin (PET) and 250-C for the adhesive resin, to a multilayered cylindrical die to join together therein, with the resin temperatures at the die of 280 C for PET and 250-C for the EVOH resin and the adhesive resin, to be extruded into a 3 kind/5 layer pipe having a construction of outer PET/adhesive resin/EVOH/adhesive resin /inner PET = 1.0 mm/0.1 mm/0.3 mm/0.1 mm/2.0 mm (total wall thickness: 3.5 mm), and an outer pipe diameter of 25.0 mm.
A continuous operation was conducted over 120 hours.
No streaks or ~elled matter formed, and a multilayer _ ipe having a good appearance was obtained. l 3 3 7 2 3 3 The thus obtained multilayered pipe was cut to 13.0 cm.
The cut piece was sealed at one end and provided on another end with a neck capable of mounting a cap, to form a multi-layered preform. The preform obtained was heated to 105-C
and biaxially-draw blown by elongation using an extension rod and by air-blowing into a multilayered bottle having a capacity of 1 liter. The thus obtained multilayered bottle had excellent carbon dioxide gas barrier properties and was well suited for a container for carbonated drinks.
Reference Example 8 An ethylene-vinyl acetate copolymer containing 32 mol~
of ethylene was saponified, and the saponified product was coagulated and cut in the same manner as in Example 1 to give pellets. One part of the pellets was washed twice each time with 10 parts of ion-exchanged water, then dipped for 4 hours in 100 parts of ion-exchanged water containing 0.03~
of acetic acid, and thereafter dewatered and dried. The pellets after the drying had a saponification degree of 99.S
mol~ and a melt index of 1.3 g/10 min, and contained 0.15 of moisture and 0.0l% of acetic acid.
The extrusion rates were measured at 250-C with various heating times using a capillary rheometer (Koka Flow Tester) to give the results shown in Table 13.
Table 13 ~eating time (hr) 0 0.25 2 4 Extrusion rate (10~'cm'/sec) 6.1 5.2 2.4 1.1 Heating time (hr) 6 8 10 Extrusion rate (10~ 3 cm3 /sec) 0.51 0.22 0-07 A polyethylene terephthalate resin (inherent viscosity [~ ] = 0.85 dl/g, melting point: 265C), the EVOH obtained above and an ethylene-vinyl acetate copolymer modified with maleic anhydride tcontents of vinyl acetate and maleic anhydride: 24 wt% and 1.1 wt% respectively) as an adhesive resin were extruded through the same equipment and under the same conditions as those in Example 11 into a 3 kind/5 layer pipe having a construction of outer PET/adhesive resin/EVOH/
adhesive resin/inner PET = 1.0 mm/0.1 mm/0.3 mm/0.1 mm/2.0 mm (total wall thickness: 3.5 mm), and an outer pipe diame-ter of 25.0 mm. Three hours after the start up, streaks began to generate and became more remar~able with progress of time, thus forcing the operation to be. stopped after 6 hours. A t-liter multilayered bottle was prepared by blow molding a multilayered preform obtained from the pipe.
However, a bottle with a good appearance could not be obtained because of the generation of streaks.
Example 12 Dry pellets having a melting point of 181-C and other properties shown below were prepared from an ethylene-vinyl acetate copolymer containing 32 mol% of ethylene in the same _.~anner as in Example 1. 1 3 3 7 2 3 3 Saponification degree : 99.3 mol%
Melt index : 4.8 g/10 min Content of acetic acid : 0.02 Content of benzoic acid : 0.02 Content of calcium : 0.006 Content of magnesium : 0.002~
Measurement of the relationship between the heating time and the extrusion rate at 260-C with a capillary rheometer (Koka Flow Tester) gave results similar to those shown in FIGURE 1, and the extrusion rates corresponding to the points in FIGURE 1 are as shown in Table 14.
Table 14 Point Heating time (hr)Extrusion rate (cmJ~sec~
0 41 x 10~ 3 A 0.25 25 x 10-3 B* 0.6 9.8 x 10~ 3 C 2 18 x 10~' D 4 60 x 10~ 3 20~ B is a point where the extrusion rate is minimum between points A and C.
A PET having an inherent viscosity [~ ~ = 0.73 dl/g, and a melting point of 258-C, the EVOH obtained above and an ethylene-vinyl acetate copolymer modified with maleic anhy-25dride ( melt index: 4.0 g/10 min; contents of vinyl acetate and maleic anhydride: 24 wt~ and 1.1 wt~ respectively) as an lhesive resin (Ad) were extruded through co-injection e~uipment comprising three injection cylinders and a single preform die into a 3 kind/5 layer preform having a construc-tion of PET/Ad/EVOH/Ad/PET = 1.0 mm/0.1 mm/0.3 mm/0.1 mm/2.0 mm (average wall thicknesses at body), and an outer diameter and a length of 25.0 mm-and 130 mm respectively. A continu-ous operation was conducted over 120 hours. No streaks or gelled matters were formed, and a preform having a good appearance was obtained. The thus obtained preform was heat-ed to 105-C and biaxially-draw blown by elongation using an extension rod and by air blowing into a multilayered bottle having a capacity of 1 liter. The thus obtained multilayer-ed bottle had excellent carbon dioxide gas barrier properties and was well suited for containers for various drinks.
Reference Example 9 An EVOH of the following characteristics was prepared.
Ethylene content : 32 mol~
Saponification degree : 99.3 mol%
Melt index : 4.8 g/10 min Content of acetic acid : 0.01%
The extrusion rates were measured at 260C with various heating times using a capillary rheometer (Koka Flow Tester) to give the results shown in Table 15.
- ` ~ 1 337233 Table 15 Heating time (hr) o 0.25 2 4 Extrusion rate (lO~'cm'/sec) 41 20 9.5 5.2 Heating time (hr) 6 8 10 Extrusion rate (10~'cm'/sec) 1.90.08 0.04 A multilayered preform was molded by co-injection with the same eauipment and the same conditions as those in Example 12. Four hours after the start of the molding, streaks increased in number and the ~reform was biaxially draw-blown into a bottle of l-liter capacity. The bottle was poor in appearance having many streaks.
Claims (7)
1. A multilayered structure comprising an ethylene-vinyl alcohol copolymer layer and a hydrophobic thermoplastic resin layer, said ethylene-vinyl alcohol copolymer exhibiting such flow characteristics that:
in the relationship between the heating time and the extrusion rate at at least one point in temperatures 10 to 80°C
higher than the melting point of said ethylene-vinyl alcohol copolymer measured with a capillary rheometer the extrusion rate does not substantially increase for the initial 15 minutes, thereafter the extrusion rate at any heating time after 15 minutes until 2 hours is in a range of from 1/10 to 50 times that after the initial 15 minutes, and the extrusion rate at any time after 2 hours until 10 hours is at least once in a range of from
in the relationship between the heating time and the extrusion rate at at least one point in temperatures 10 to 80°C
higher than the melting point of said ethylene-vinyl alcohol copolymer measured with a capillary rheometer the extrusion rate does not substantially increase for the initial 15 minutes, thereafter the extrusion rate at any heating time after 15 minutes until 2 hours is in a range of from 1/10 to 50 times that after the initial 15 minutes, and the extrusion rate at any time after 2 hours until 10 hours is at least once in a range of from
2 to 50 times the extrusion rate after the initial 15 minutes.
2. A multilayered structure as defined in claim 1, wherein said ethylene-vinyl alcohol copolymer exhibits a flow characteristic in the relationship between the heating time and the extrusion rate at a melt-molding temperature having an extrusion rate after 15 minutes of from 1/5 to 1 times the extrusion rate at the start.
2. A multilayered structure as defined in claim 1, wherein said ethylene-vinyl alcohol copolymer exhibits a flow characteristic in the relationship between the heating time and the extrusion rate at a melt-molding temperature having an extrusion rate after 15 minutes of from 1/5 to 1 times the extrusion rate at the start.
3. A multilayered structure as defined in claim 1, wherein said ethylene-vinyl alcohol copolymer exhibits such flow characteristics in the relationship between the heating time and the extrusion rate at a melt-molding temperature that the extrusion rate after 2 hours through 10 hours increases with time in this time period.
4. A multilayered structure as defined in claim 1, wherein said hydrophobic thermoplastic resin is at least one member selected from the group consisting of polypropylene, polyethylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, thermoplastic polyester, polyamide, polystyrene, polyvinyl chloride, polycarbonate, and copolymers obtained by polymerization of monomers constituting the foregoing.
5. A multilayered structure comprising an ethylene-vinyl alcohol copolymer layer and a hydrophobic thermoplastic resin layer laminated thereon via a thermoplastic resin modified with an ethylenically unsaturated carboxylic acid or its anhydride, said ethylene-vinyl alcohol copolymer exhibiting such flow characteristics that:
in the relationship between the heating time and the extrusion rate at at least one point in temperatures 10 to 80°C
higher than the melting point of said ethylene-vinyl alcohol copolymer measured with a capillary rheometer the extrusion rate does not substantially increase for the initial 15 minutes, thereafter the extrusion rate at any heating time after 15 minutes until 2 hours is in a range of from 1/10 to 50 times that after the initial 15 minutes, and the extrusion rate at any time after 2 hours until 10 hours is at least once in a range of from 2 to 50 times the extrusion rate after the initial 15 minutes.
in the relationship between the heating time and the extrusion rate at at least one point in temperatures 10 to 80°C
higher than the melting point of said ethylene-vinyl alcohol copolymer measured with a capillary rheometer the extrusion rate does not substantially increase for the initial 15 minutes, thereafter the extrusion rate at any heating time after 15 minutes until 2 hours is in a range of from 1/10 to 50 times that after the initial 15 minutes, and the extrusion rate at any time after 2 hours until 10 hours is at least once in a range of from 2 to 50 times the extrusion rate after the initial 15 minutes.
6. A multilayered structure as defined in claim 5, wherein said thermoplastic resin modified with an ethylenically unsaturated carboxylic acid or its anhydride is an olefin polymer modified with an ethylenically unsaturated carboxylic acid or its anhydride.
7. A multilayered laminate as defined in claim 6, wherein said olefin polymer is selected from the group consisting of ethylene-vinyl acetate copolymer, and ethylene-ethyl acrylate copolymer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000616944A CA1337233C (en) | 1987-09-07 | 1994-11-08 | Multilayered structure utilizing an ethylene-vinyl alcohol copolymer composition |
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP62224296A JP2667830B2 (en) | 1987-09-07 | 1987-09-07 | Ethylene-vinyl alcohol copolymer composition |
| JP62-224296 | 1987-09-07 | ||
| CA000576561A CA1335223C (en) | 1987-09-07 | 1988-09-06 | Ethylene-vinyl alcohol copolymer composition and multilayered structure utilizing the same |
| CA000616944A CA1337233C (en) | 1987-09-07 | 1994-11-08 | Multilayered structure utilizing an ethylene-vinyl alcohol copolymer composition |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000576561A Division CA1335223C (en) | 1987-09-07 | 1988-09-06 | Ethylene-vinyl alcohol copolymer composition and multilayered structure utilizing the same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1337233C true CA1337233C (en) | 1995-10-10 |
Family
ID=25672100
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000616944A Expired - Lifetime CA1337233C (en) | 1987-09-07 | 1994-11-08 | Multilayered structure utilizing an ethylene-vinyl alcohol copolymer composition |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1337233C (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115477805A (en) * | 2021-06-16 | 2022-12-16 | 长春石油化学股份有限公司 | Ethylene-vinyl alcohol copolymer resin particle composition, ethylene-vinyl alcohol copolymer film formed therefrom, and multilayer structure |
-
1994
- 1994-11-08 CA CA000616944A patent/CA1337233C/en not_active Expired - Lifetime
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115477805A (en) * | 2021-06-16 | 2022-12-16 | 长春石油化学股份有限公司 | Ethylene-vinyl alcohol copolymer resin particle composition, ethylene-vinyl alcohol copolymer film formed therefrom, and multilayer structure |
| CN115477803A (en) * | 2021-06-16 | 2022-12-16 | 长春石油化学股份有限公司 | Ethylene-vinyl alcohol copolymer resin particle composition, ethylene-vinyl alcohol copolymer film formed therefrom, and multilayer structure |
| CN115477804A (en) * | 2021-06-16 | 2022-12-16 | 长春石油化学股份有限公司 | Ethylene-vinyl alcohol copolymer resin particle composition, ethylene-vinyl alcohol copolymer film formed therefrom, and multilayer structure |
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