JP2014500342A - 積層可撓性包装材用の強固な接着剤 - Google Patents
積層可撓性包装材用の強固な接着剤 Download PDFInfo
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- JP2014500342A JP2014500342A JP2013535140A JP2013535140A JP2014500342A JP 2014500342 A JP2014500342 A JP 2014500342A JP 2013535140 A JP2013535140 A JP 2013535140A JP 2013535140 A JP2013535140 A JP 2013535140A JP 2014500342 A JP2014500342 A JP 2014500342A
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- adhesive
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- polyol
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- 239000012939 laminating adhesive Substances 0.000 claims abstract description 69
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- 239000012948 isocyanate Substances 0.000 claims abstract description 48
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- 125000005442 diisocyanate group Chemical group 0.000 description 17
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- QWGRWMMWNDWRQN-UHFFFAOYSA-N 2-methylpropane-1,3-diol Chemical compound OCC(C)CO QWGRWMMWNDWRQN-UHFFFAOYSA-N 0.000 description 4
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Abstract
Description
一般に、可撓性包装材からなる2層を、熱を施して押圧し、包装材外縁の薄い部分の周囲にて層を相互に融着させることにより、熱融着させる。食品または他の製品は、開口部を介して空洞内に導入され、層を互いに熱密封することにより、開口部を閉じる。密封された容器および封入された製品は、防腐のために加熱される。厳しい用途において、密封された容器および封入された製品は、100℃の水中で煮沸される。
可撓性包装材を保管することである。接着剤成分を完全に反応させた後、可撓性包装材をパウチ形状に形成する。残念ながら、より低い分子量のプレポリマーとポリオールを用いる貼合せ用接着剤の場合、このことに長い(二週間に至る)時間がかかり、使用できる前に、多量の高価な貼合せ用材料を貯蔵しなければならない。
成分Aは、1分子当たり2以上のイソシアネート基を有する少なくとも1つの化合物を含有する。イソシアネート基は遊離-NCO基であってもよいが、ブロック化された-NCO基またはマスク化された-NCO基であってもよい。1つの特定の実施態様は、成分A中に1つ以上のイソシアネート-官能化ポリウレタンプレポリマーを使用する。この開示に関連して、ポリウレタンプレポリマーは、例えば、ポリオール成分(または他の活性水素官能化化合物)と、少なくとも2の官能価を有する少なくとも1つのイソシアネートとの反応から生じるような化合物である。この反応は溶媒を用いることなく、または溶媒中で行える。用語「ポリウレタンプレポリマー」は、例えばポリオールと過剰のポリイソシアネートとの反応により形成されるような比較的低分子量の化合物のみならず、オリゴマーまたはポリマー化合物の両方を包含する。各末端または終端にてキャップ化された単一のポリオール部分とポリイソシアネート部分、および所望による、極めて少量の遊離ポリイソシアネートモノマーもしくはオリゴマー化合物もしくはポリマー化合物(1分子当たり2つ以上のポリオールを含有する)を含有する「完全な」ポリウレタンプレポリマーも使用できる。
過剰量の未反応ポリイソシアネートモノマーは、最初に得られたポリウレタンプレポリマー反応生成物から所望により除去される。
ポリオールとは、多官能アルコール、すなわち、分子中に1つ以上のOH基を有する化合物を意味する。
成分Bは、分子上に少なくとも2つの第1級OH基および分子上に2つの第2級OH基を有する一分子あたり少なくとも4つのヒドロキシル基を含む高官能性ポリエステルポリオールと、分子上に3つのOH基を含む三官能性ポリオールと、分子上に2つのOH基を含む二官能性ポリオールとの混合物を含有する。
式中、mおよびnは、同一または異なる整数であり、それらは、少なくとも1であり、m+nは少なくとも4であり、およびR1、R2およびR3は、炭化水素基である(好ましくは2〜20個の炭素原子を含有する)。R1は、m+1の結合価を有し(m個のOH基がそこに結合し)、R2は2の結合価を有し、およびR3はn+1の結合価を有する(n個のOH基がそこに結合する)。炭化水素基は直鎖または分岐状であってもよく、脂肪族、脂環式、芳香族またはアラルキルであってもよく、飽和または不飽和であってもよい。例えば、R1およびR3は、それぞれ−CH2−CH−CH2−基であってもよい。R2は、例えば−(CH2)O−基であってもよい(式中、oは2〜18の整数である)。
式中、qおよびrは同一または異なる整数であり、それらは、それぞれ、少なくとも1の値を有し、q+rは少なくとも4であり、R4、R5、R7およびR8は、同一または異なる(好ましくは2〜20個の炭素原子を含有する)炭化水素基であってもよく、およびR6は炭化水素基およびポリオキシアルキレン基からなる群から選択される二価の基である。R4はq+1の結合価を有し(q個のOH基がそこに結合し)、R5およびR7はそれぞれ2価であり、およびR8はr+1の結合価を有する(r個のOH基がそこに結合する)。炭化水素基は直鎖または分岐状であってもよく、脂肪族、脂環式、芳香族またはアラルキルであってもよく、飽和または不飽和であってもよい。例えば、R4およびR8は、それぞれ−CH2−CH−CH2−基であってもよい。例えば、R5、R6およびR7は、−(CH2)O−基であってもよい(式中、oは2〜18の整数である)。R6は、例えば、-[(CH2)S-CHR9-O]t-(CH2)u−CHR10に相当する基であり、式中、sおよびuは、1〜3の整数であり、tは少なくとも1であり、およびR9およびR10は、H、メチルまたはエチルから成る群から独立して選択される(ただし、tが1よりも大きい場合、(CH2)S-CHR9-O基におけるR9は、それぞれ同一または異なってもよい)。例えば、ポリオキシアルキレン基は、ポリオキシエチレン基、ポリオキシプロピレン基およびポリオキシテトラメチレン基から成る群から選択できる。一般式(II)の高官能性ポリエステルポリオールは、一般に、アルコールの各ヒドロキシル基とジカルボン酸の1分子が反応するようにして、二官能性アルコールとジカルボン酸との反応により調製できる。ジカルボン酸から誘導される残存する未反応の酸基は、その後、1分子当たり3個以上のヒドロキシル基を含有する1以上のポリオールと反応させる。ジカルボン酸とポリオールは、例えば、一般構造(I)の高官能性ポリエステルポリオールに関連する上記例示の化合物であることができる。二官能性アルコールは、
1分子当たり2つのヒドロキシル基を含有する任意のモノマー性、オリゴマー性、またはポリマー性化合物であることができ、例えば、エチレングリコール、ジエチレングリコール、トリエチレングリコール、ポリエチレングリコール、1,2-プロピレングリコール、1,3-プロピレングリコール、ジプロピレングリコール、トリプロピレングリコール、ポリプロピレングリコール、ネオペンチルグリコール、2−メチル−1,3-プロパンジオール、1,4−ブタンジオール、ポリテトラヒドロフランジオール、ビスフェノールA、ビスフェノールFなどである。1実施態様において、約200〜約3000の分子量を有するポリエーテルグリコール(特に、ポリプロピレングリコール)が使用される。
成分A−1:70重量%の、Air Productsから入手できるTDI−系プレポリマー(7.45%NCO)と、30重量%の、Bayer Chemical Co.から入手できるMDI−系プレポリマー(22.9%NCO)を含有するブレンド。成分A−1は、12重量%のNCO含有量を有する。
成分A3およびB−22を、約1.7:1の重量比で混合し、貼合わせ用接着剤を形成した。成分A3およびB−23を、約1.6:1の重量比で混合し、強固な貼合わせ用接着剤を形成した。各混合接着剤の粘度を、最初および5分間隔で検査した。結果を以下の表以下および図1に示す。
強固な接着剤に長い可使時間を付与することは、当業者であれば、常套の接着剤と比べて、本発明の接着剤がよりゆっくりと硬化し、結果としてよりゆっくりと強度が増すことを予測できる。高加速度を測定する1方法は、所定の時間における接着強度を測定することである。
成分A-3およびB-22を、1.2:1、1.7:1、および2:1の重量比で混合し、一組の、比較例における貼合せ接着剤を形成した。成分A-3およびB-23を、1.2:1、1.6:1、および2:1の重量比で混合し、一組の、強固な貼合せ接着剤を形成した。
成分A-3およびB-22を、1.2:1、1.7:1、および2:1の重量比で混合し、一組の、比較例における貼合せ接着剤を形成した。成分A-3およびB-23を、1.2:1、1.6:1、および2:1の重量比で混合し、一組の、強固な貼合せ接着剤を形成した。
ポリウレタン貼合わせ接着剤に関する更に厳しい耐熱試験は、煮沸試験と称される。成分A-3およびB-22を、1.2:1、1.7:1、および2:1の重量比で混合し、一組の、比較例における貼合せ接着剤を形成した。成分A-3およびB-23を、1.2:1、1.6:1、および2:1の重量比で混合し、一組の、強固な貼合せ接着剤を形成した。
予め規定した硬化時間の後に、パウチに水を充填し、密閉し、30分間煮沸した。
試験は、貼合せ接着剤を高温および高圧に曝し、使用する間に直面する可撓性包装の条件をシミュレートした。結果を以下の表に示す。
FDA準拠は、泳動試験により試験される場合に、食品と接触する用途における可撓性包装材中の第1級芳香族アミンの濃度が、検出限界(2ppb、20億分の1)を下回ることを要求する(BfR試験法とも称される)。貼合せ用接着剤中の過剰量のイソシアネートは包装された製品に含まれる水と反応し、第1級芳香族アミンを形成し得る。従って、過剰量のイソシアネートの使用は接着強度を増加させるが、過剰量の第1級芳香族アミンも生じさせ、光泳動試験での失敗を避けるために、最終的な包装材の硬化時間を長引かせてしまう。
A−3とB−22を標準量(1.7:1)の混合比で混合することにより製造された比較例の貼合せ用接着剤は、許容できる試験結果をもたらし、完全にイソシアネートを反応させるのに72時間の硬化を必要とする。他の比較例のポリウレタン貼合せ接着剤は、許容できる試験結果をもたらし、完全にイソシアネートを反応させるのに、通常72時間以上の硬化時間を必要とする。強固な貼合せ接着剤は、より早く硬化し、標準量(1.6:1)の混合比の場合僅か48時間の硬化で光泳動試験をパスし、比較例の貼合せ接着剤と比べて、24時間も硬化時間を減少させる。過剰量のイソシアネート(2:1の混合比または25重量%の過剰量)であっても、強固な接着剤は、わずか72時間の硬化時間でBfR泳動試験をパスする積層品を製造し、過剰量のイソシアネート(2:1の混合比または25重量%の過剰量)を有する比較例の接着剤を用いては、このような結果を得ることはできない。
接着強度の損失を防ぐのに従来から言われているように、
可撓性包装材用途における一価アルコールの推奨される限度は極めて低い(<3900mg/1連(ream)以下)。発明者は、4000mg/連から16000mg/連までの範囲の種々の量のDowanol PMを成分A-3とB-23の接着剤混合物に添加した。驚くべきことに、より高い量であっても強固な接着剤の耐熱性に悪影響は生じなかった。強固な接着剤を用いて製造したパウチは、24時間の硬化後に煮沸試験を行っても許容可能な接着強度をもたらした。
以下の成分を調製した。
アジピン酸、イソフタル酸およびジエチレングリコールに基づくポリエステルポリオールと1025の平均分子量を有するポリプロピレングリコールとの混合物および4,4’-MDIを反応させて調製したMDI系プレポリマー(NCO=12%)
A−2/B−27の貼合せ接着剤組成物は、低い領域にて許容できない熱(70℃)接着強度を有したが、通常および高い混合比においては、許容できる熱接着強度を有した。A−2/B−28の貼合せ接着剤組成物は、いずれの混合比でも許容できる熱(70℃)接着強度を有した。A−2/B−27の貼合せ接着剤組成物は、いずれの混合比でも第一級アミンを検出できなかった。A−2/B−28の貼合せ接着剤組成物は、低い混合比では第一級アミンを検出した。あらゆる範囲における可使時間の欠如は、貼合せ接着剤として許容できない。低い混合比から高い混合比の全域に亘り許容できない接着剤強度を有することは、A−2/B−27貼合せ接着剤組成物が強固でないことを示す。低い混合比で第一級アミンを溶出することは、A−2/B−28貼合せ接着剤組成物が強固でないことを示す。
Claims (16)
- 成分Aおよび成分Bとを含有する、可撓性包装材を貼合せるための強固な2成分系接着剤であって、
該成分Aは、イソシアネート官能化化合物を含有し、
成分Bは、分子上に少なくとも2つの第1級OH基および分子上に2つの第2級OH基を有する一分子あたり少なくとも4つのヒドロキシル基を含む高官能性ポリオールと、分子上に3つのOH基を含む三官能性ポリオールとの混合物とを含有する、接着剤。 - 成分Bが分子上に2つのOH基を含む二官能性ポリオールを含有する請求項1に記載の貼合せ接着剤。
- 成分Bが、分子上に少なくとも2つの第1級OH基および分子上に2つの第2級OH基を有する一分子あたり少なくとも4つのヒドロキシル基を含む高官能性ポリオールを約50wt%〜約90wt%;分子上に3つのOH基を含む三官能性ポリオールを約5wt%〜約30wt%;分子上に2つのOH基を含む二官能性ポリオールを約0wt%〜約20wt%含有する、請求項1に記載の貼合せ接着剤。
- 1つの高官能性ポリオールがポリエステルポリオールである、請求項1に記載の貼合せ接着剤。
- 三官能性ポリオールがポリエーテルポリオールである、請求項1に記載の2成分系貼合せ接着剤。
- 分子上に2つのOH基を含む二官能性ポリエステルポリオールを約5重量%〜約20重量%さらに含有する、請求項1に記載の2成分系貼合せ接着剤。
- 成分Aがイソシアネート官能化ポリウレタンプレポリマーを含有する、請求項1に記載の貼合せ接着剤。
- 請求項1の接着剤から成る硬化反応製品により相互に貼合せた2つのフィルムを含む可撓性包装材。
- 成分Aが、イソシアネート官能化ポリウレタンプレポリマーを含有し、および成分Bが、分子上に少なくとも2つの第1級OH基および分子上に2つの第2級OH基を有する一分子あたり少なくとも4つのヒドロキシル基を含む高官能性ポリオールと、分子上に3つのOH基を含む三官能性ポリオールとの混合物とを含有する、
所定の重量比で該成分Aと該成分Bの混合物を含む可撓性包装材を製造する転写ロール貼合せ装置における使用に適する2成分系接着剤であって;
該接着剤は、少なくとも約25分の、粘度が二倍になるまでの可使時間を有し、24時間の硬化後に少なくとも200gmsの熱接着強度を有し、3日の硬化後にて許容できるBfR泳動を有し、成分A:成分Bの範囲が予め規定した重量比と比べて25%少ない成分Aを含有する範囲から、予め規定した重量比と比べて25%多い成分Aを含有する範囲を通じて、接着剤の性能が維持される、接着剤。 - 接着剤が、約30分の、粘度が二倍になるまでの可使時間を有し、24時間の硬化後に少なくとも200gmsの熱接着強度を有し、48時間の硬化後に許容できるBfR泳動を有し、これらの各成分が、成分A:成分Bの範囲が予め規定した重量比と比べて25%少ない成分Aを含有する範囲から、予め規定した重量比と比べて25%多い成分Aを含有する範囲を通じて存在する、接着剤。
- 第1ポリオレフィンまたは第1ポリエステルから成る第1層;第1ポリオレフィンとは同一または異なっていてもよい第2ポリオレフィン、第1ポリエステルとは同一または異なっていてもよい第2ポリエステル、または金属箔から成る第2層および、該第1層と該第2層を接着させる請求項13に記載の接着剤からなる硬化反応製品を含む、可撓性包装材。
- 予め規定した重量比で請求項13に記載の貼合せ接着剤の成分Aと成分Bとを混合して接着剤混合物を形成し、
該接着剤混合物を、第1の可撓性フィルムの一面の少なくとも一部に施し、
該第1の可撓性フィルムと該第2の可撓性フィルムの間に該接着剤混合物を介在させて、第1の可撓性フィルムと該第2の可撓性フィルムを接合させ、
該接着剤混合物を硬化させることを含む、可撓性フィルム積層体の製造方法。
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