JP2021119240A - 生分解性ポリエステル組成物及びその使用 - Google Patents
生分解性ポリエステル組成物及びその使用 Download PDFInfo
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- JP2021119240A JP2021119240A JP2021074725A JP2021074725A JP2021119240A JP 2021119240 A JP2021119240 A JP 2021119240A JP 2021074725 A JP2021074725 A JP 2021074725A JP 2021074725 A JP2021074725 A JP 2021074725A JP 2021119240 A JP2021119240 A JP 2021119240A
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Abstract
Description
プラスチックは、幅広い用途に使用できる生産物を製造するために用いられる、安価で耐久性のある材料である。結果として、プラスチックの生産は、過去数十年飛躍的に増加している。これらのプラスチックの大部分は、一回使用の使い捨て用途に使用されるか、又は製造から1年以内に廃棄される短命の生産物(例えば、袋、トレイ、容器、ボトル、農業用フィルムなどを含む包装)に使用される。含まれるポリマーの耐久性及び生分解に対するそれらの高い耐性(高い分子量値、疎水性及び結晶性に起因する)のために、大量のプラスチックが、埋立地及び自然生息地に蓄積しており、世界的な環境問題の増大を生んでいる。
本発明は、生物学的エンティティのポリエステル分解活性を増強するための、プラスチック組成物中への制酸フィラー(複数)の使用に関する。より特定すると、本発明は、制酸フィラー(複数)及びポリエステル分解活性を有する生物学的エンティティの両方をポリエステル含有プラスチック組成物に加えて、生分解特性を有するプラスチック組成物を得ること、それによってこのプラスチック組成物から製造される分解性プラスチック製品を得ることを提案する。本発明によれば、生物学的エンティティ及び制酸フィラー(複数)を共にプラスチック組成物のポリエステル中に組み込むことで、最終プラスチック製品中へのそれらの均質な分散を導く。
(i)65〜95%の少なくとも1つのポリエステル、好ましくはPLA及び/又はPCL;
(ii)2〜25%の少なくとも1つの制酸フィラー、好ましくはハイドロタルサイト、炭酸カルシウム、タルク、雲母、粘土及び/又は水酸化カルシウムから選択される、制酸フィラー;
(iii)0,1〜10%のポリエステル分解活性を有する生物学的エンティティ、好ましくはプロテアーゼ。
a.本発明に係るプラスチック組成物を提供すること、及び
b.プラスチック製品を製造すること
を含み、工程bが、好ましくは、プラスチック組成物のポリエステルが部分的若しくは全体的に溶融した状態にある温度で実行され、かつ/又は、押出、押出混練、押出吹込成形、インフレーションフィルム成形、キャストフィルム押出、カレンダー加工及び熱成形、射出成形、圧縮成形、押出膨張、回転成形、しごき、被覆、層成形、拡張成形(expansion)、引抜成形、圧縮造粒並びに3D印刷によって実施される、方法に関する。
本発明は、改善された分解性を有する新規プラスチック組成物、及びそれらを生産するための方法に関する。より特定すると、本発明は、生物学的エンティティ及び前記生物学的エンティティの分解活性を増強するのに好適な制酸フィラーの両方を含む新規プラスチック組成物を提供する。本発明は、活性な生物学的エンティティの好適な分散及び分布割合を有するこのような組成物が、一回使用及び短命のプラスチック製品を生産するために特に有用であることを示す。
本開示は、以下の定義を参照することによって最もよく理解されよう。
本発明者等は、制酸フィラーの添加によって、ポリエステル及びポリエステル分解活性を有する生物学的エンティティを含むプラスチック組成物の分解性を改善することが可能であることを示した。ポリエステルと生物学的エンティティとの塊状物中に組み込まれた制酸フィラーの存在は、前記生物学的エンティティの活性を増強する。より特定すると、制酸フィラーの存在下でのポリエステル含有プラスチック組成物中の生物学的エンティティのデポリメラーゼ活性は、組成物中にこのような制酸フィラーがない場合より高い。それによって、本発明の組成物及び/又はこのような組成物で製造されたプラスチック製品の分解率は、このような制酸フィラーが除かれている組成物/プラスチック製品の分解率より改善される(すなわち、高い)。
−炭酸塩又は金属炭酸塩、例えば炭酸カルシウム(又は石灰岩)、炭酸カリウム、炭酸マグネシウム、炭酸アルミニウム、炭酸亜鉛、炭酸銅
−水酸化物塩又は金属水酸化物、例えば水酸化カルシウム又は水酸化カリウム(カリ)又は水酸化マグネシウム又は水酸化アルミニウム又は水酸化ナトリウム(苛性ソーダ)
−ケイ酸塩、例えばケイ酸カルシウム、ケイ酸カリウム、ケイ酸マグネシウム(タルク)、ケイ酸アルミニウム(カオリン)、又は雲母などのそれらの混合物
−ハイドロタルサイト(水酸化アルミニウムマグネシウム炭酸塩、Mg6Al2CO3(OH)16・4(H2O))、例えば市販の合成品DHT−4A2又はDHT−4A
−金属酸化物又は酸化物塩、例えばマグネシウムの酸化物、カルシウムの酸化物、アルミニウムの酸化物、鉄酸化物、銅酸化物
−硫酸塩、例えば硫酸カルシウム(石膏)、硫酸バリウム
−リン酸カルシウム、ハイドロキシアパタイトのようなリン酸塩
−バーミキュライト、パリゴルスカイト−セピオライトなどの粘土、及びモンモリロナイトなどのスメクタイト由来の粘土。
本発明によれば、プラスチック組成物は、前記プラスチック組成物中に含有される少なくとも1つのポリエステルを分解するのに好適な生物学的エンティティを含む。本発明者等は、生物学的エンティティと共にプラスチック組成物中に組み込まれた制酸フィラー(複数)の存在が、それらの酵素活性を増加させ、それによってプラスチック組成物の分解性を増強することを示した。
本発明のある目的は、制酸フィラーと共にポリエステル中に組み込まれた活性な生物学的エンティティを含むプラスチック組成物を提供することである。本発明のプラスチック組成物は、環境条件において改善された分解性を有するプラスチック製品をさらに調製するために容易に使用してよい。
−65〜95%(重量換算)の少なくとも1つのポリエステル;
−2〜25%(重量換算)の少なくとも1つの制酸フィラー;
−0.1〜10%(重量換算)のポリエステル分解活性を有する生物学的エンティティ;と場合により
−少なくとも1つの追加のポリマー及び/又は添加剤及び/又は追加のフィラー。
−65〜95%(重量換算)のPLA;
−2〜25%(重量換算)の少なくとも1つの制酸フィラー、好ましくはハイドロタルサイト、炭酸カルシウム、水酸化カルシウム、タルク、雲母及び粘土から選択される制酸フィラー;
−0.1〜10%(重量換算)のPLA分解活性を有するプロテアーゼ;と場合により
−少なくとも1つの追加のポリマー及び/又は1つの添加剤及び/又は1つの追加のフィラー。
−5〜65%(重量換算)の第一のポリエステル;
−10〜60%(重量換算)の第二のポリエステル及び/又は天然ポリマー(例えば、デンプン又は小麦粉);
−2〜25%(重量換算)の少なくとも1つの制酸フィラー;
−0.1〜10%(重量換算)の、第一のポリエステルに対して分解活性を有する生物学的エンティティ;と場合により
−少なくとも1つの添加剤及び/又は1つの追加のフィラー。
−5〜65%(重量換算)のPLA;
−10〜60%(重量換算)の少なくとも1つの追加のポリエステル(PBAT、PHA、PBS又はPBSAから選択される)及び/又は天然ポリマー(デンプン又は小麦粉から選択される);
−2〜25%(重量換算)の、ハイドロタルサイト、炭酸カルシウム、水酸化カルシウム、タルク、雲母及び粘土から選択される少なくとも1つの制酸フィラー;
−0.1〜10%(重量換算)のPLA分解活性を有するプロテアーゼ;と場合により
−少なくとも1つの添加剤及び/又は1つの追加のフィラー。
本発明はまた、上記の通りのプラスチック組成物を調製するためのプロセスであって、(a)0.1%〜10%(重量換算)のポリエステル分解活性を有する生物学的エンティティをポリエステル及び制酸フィラーと混合する工程と、場合により、(b)前記工程(a)の混合物を固体形態にコンディショニングする工程を含む、プロセスに関する。ある特定の実施態様において、該プロセスは、工程(b)の前に、少なくとも1つの添加剤をポリエステル、生物学的エンティティ及び制酸フィラーと混合する工程をさらに含む。代替的に、このような添加剤を、工程(a)においてポリエステル、生物学的エンティティ及び制酸フィラーと混合することができる。
本発明はまた、改善された及び/又は制御された分解性を有するプラスチック製品を製造するためのこのようなプラスチック組成物の使用に関する。
A.本発明のプラスチック組成物を提供すること;及び
B.前記プラスチック組成物をプラスチック製品に成形すること。
1A−押出プロセスによるプラスチック組成物を製造するプロセス
配合物A〜E(表3)を、制酸フィラーとしての炭酸カルシウム(CaCO3)又は水酸化カルシウム(Ca(OH)2)のPLA組成物の分解を増加させる能力を評価するために調製した。
−液体窒素中に浸漬し、Ultra Centrifugal Mill ZM 200システムを使用して微粉化したPLAペレットから得られた粉末形態(<500μm)下の、PLA(ポリ乳酸ポリマー、NatureWorks製のPLA 4043D)、
−PLAを分解する能力を有することが知られている固体形態下の、Novozymes製のSavinase(登録商標)16L(Degradation of Polylactide by commercial proteases; Y.Oda, A. Yonetsu, T. Urakami and K. Tonomura; 2000)。固体形態のSavinase(登録商標)16Lを、市販の液体形態から3.5kDa膜での限外濾過、透析濾過、デキストリンの添加及びフリーズドライによる乾燥によって得た。
−デキストリン(Terreos製のMALDEX 190 Wheat)又は炭酸カルシウム(OMYA製のCaCO3)又は水酸化カルシウム(Sigma Aldrich製のCa(OH)2)。
実施例1Aから得たプラスチック組成物の生分解性を評価した。
2A−押出プロセスによるプラスチック組成物を製造するプロセス
以下の配合物A〜C(表4)を、制酸フィラーとしての炭酸カルシウム(CaCO3)単独又は水酸化カルシウム(Ca(OH)2)と混合された炭酸カルシウム(CaCO3)のPLA組成物の分解を増加させる能力を評価するために調製した。
−実施例1Aに記載の通りの粉末形態のPLA、炭酸カルシウム及び水酸化カルシウム、
−固体形態下のActinomadura keratinilytica株由来のプロテアーゼ酵素。Actinomadura keratinilytica由来の固体形態のプロテアーゼを、発酵プロセス、続く、3.5kDa膜での限外濾過、透析濾過、デキストリンの添加及びアトマイゼーションによる乾燥から得た。このようなプロテアーゼは、特許WO 2016/062695に記載の通りのPLAを分解することが知られている。
実施例2Aから得たプラスチック組成物の生分解性を評価した。
3A−押出プロセスによるプラスチック組成物を製造するプロセス
無機合成酸捕捉剤(DHT4−A2)及び無機天然酸捕捉剤(CaCO3)の両方の効率を評価及び比較した。
実施例3Aから得たプラスチック組成物の生分解性を評価した。
4A−押出プロセスによるプラスチック組成物を製造するプロセス
炭酸カルシウム(CaCO3)のより高い濃度での効率を評価した。
実施例4Aから得たプラスチック組成物の生分解性を評価した。
5A−押出プロセスによるプラスチック組成物を製造するプロセス
この実験によれば、PLA組成物中に含有されるEverlase(登録商標)の分解活性を増強する炭酸カルシウムの能力を評価した。
−配合物A=PLA95%+Everlase(登録商標)5%
−配合物B=PLA90%+Everlase(登録商標)5%+炭酸カルシウム5%
前記プラスチック組成物の生分解性をさらに試験した。
6A−押出プロセスによるプラスチック組成物を製造するプロセス
2つの配合物A及びB(表7)を調製して、PCLを含有するプラスチック組成物に対する炭酸カルシウムの影響を評価した。
−粉末形態のPCL(ポリカプロラクトンポリマー、Perstorp製のCAPA 6500)。PCLは、液体窒素中に浸漬し、Ultra Centrifugal Mill ZM 200システムを使用して微粉化したPCL顆粒から得られた粉末形態(<1mm)下で使用される。
−PCLを分解することが知られている、固体形態下のリパーゼ酵素(Amano製のAmano Lipase PS)、及び
−炭酸カルシウム(OMYA製)。
前記プラスチック組成物の生分解性をさらに評価した。
Claims (15)
- 少なくとも1つのポリエステル、ポリエステル分解活性を有する生物学的エンティティ及び少なくとも1つの制酸フィラーを含むプラスチック組成物であって、生物学的エンティティがプラスチック組成物の総重量を基準として11%(重量換算)未満を占める、プラスチック組成物。
- 0.1%〜50%(重量換算)の間、好ましくは2%〜25%の間の制酸フィラーを含む、請求項1に記載のプラスチック組成物。
- 制酸フィラーが、無機制酸フィラー、好ましくは炭酸塩、金属、水酸化物塩、ハイドロタルサイト群、タルク、雲母及び粘土から選択される無機制酸フィラーである、請求項1又は2に記載のプラスチック組成物。
- 生物学的エンティティが、ポリエステル分解活性を有する少なくとも1つの酵素及び/又はポリエステル分解活性を有する酵素を発現する少なくとも1つの微生物を含む、先行請求項のいずれか一項に記載のプラスチック組成物。
- 生物学的エンティティが、デポリメラーゼ、エステラーゼ、リパーゼ、クチナーゼ、カルボキシルエステラーゼ、プロテアーゼ及びポリエステラーゼから、好ましくはリパーゼ及びプロテアーゼから選択される、先行請求項のいずれか一項に記載のプラスチック組成物。
- ポリエステルが、PLA、PCL、PBAT、PHA及びPBSから、好ましくはPLA及びPCLから選択される、先行請求項のいずれか一項に記載のプラスチック組成物。
- 別の合成ポリマー、好ましくはPBAT、PHA、PBSから選択される合成ポリマー、並びに/又は少なくとも1つの天然ポリマー、好ましくはデンプン、小麦粉及びセルロースから選択される天然ポリマー、並びに/又は少なくとも1つの添加剤、好ましくは可塑剤、着色剤、加工助剤、難燃剤及び光安定剤からなる群より選択される添加剤をさらに含む、先行請求項のいずれか一項に記載のプラスチック組成物。
- プラスチック組成物の総重量を基準として以下を含む、先行請求項のいずれか一項に記載のプラスチック組成物:
−65〜95%の少なくとも1つのポリエステル、
−2〜25%の少なくとも1つの制酸フィラー、好ましくはハイドロタルサイト、炭酸カルシウム、タルク、雲母、粘土及び/又は水酸化カルシウムから選択される、制酸フィラー、
−0.1〜10%のポリエステル分解活性を有する生物学的エンティティ。 - PLA、PLA分解活性を有する生物学的エンティティ及び制酸フィラー(ハイドロタルサイト、炭酸カルシウム、タルク、雲母、粘土及び水酸化カルシウムから選択される)を含む、先行請求項のいずれか一項に記載のプラスチック組成物。
- 先行請求項のいずれか一項に記載のプラスチック組成物を調製するためのプロセスであって、(a)0.1%〜10%(重量換算)の間のポリエステル分解活性を有する生物学的エンティティをポリエステル及び制酸フィラーと混合する工程と、(b)前記工程(a)の混合物を固体形態にコンディショニングする工程とを含む、プロセス。
- 混合工程(a)が、ポリエステルが部分的若しくは全体的に溶融した状態にある温度で、かつ/又は、押出機、好ましくは二軸スクリュー押出機、より好ましくは共回転式二軸スクリュー押出機中で実施される、請求項10に記載のプロセス。
- プラスチック製品の製造のための、請求項1〜9に記載のプラスチック組成物の使用。
- 請求項1〜9のいずれか一項に請求される通りのプラスチック組成物から製造されたプラスチック製品であって、プラスチック組成物の生物学的エンティティが、プラスチック製品の少なくとも1つのポリエステルを分解するのに好適である、プラスチック製品。
- (a)請求項1〜9のいずれか一項に定義した通りのプラスチック組成物を提供する工程であって、生物学的エンティティが、前記プラスチック組成物の少なくとも1つのポリエステルを分解するのに好適である、工程、及び
(b)前記プラスチック組成物を前記プラスチック製品に変換する工程を含む、ポリエステル含有プラスチック製品を製造するための方法であって、
工程(b)が、前記プラスチック組成物のポリエステルが部分的若しくは全体的に溶融した状態にある温度で実行され、かつ/又は、押出、押出混練、押出吹込成形、インフレーションフィルム成形、キャストフィルム押出、カレンダー加工及び熱成形、射出成形、圧縮成形、押出膨張、回転成形、しごき、被覆、層成形、拡張成形(expansion)、引抜成形、圧縮造粒並びに3D印刷によって実施される、方法。 - 少なくとも1つのポリエステルを含むプラスチック製品の生分解性を増加させるための方法であって、ポリエステルを、前記ポリエステルを分解するのに好適な生物学的エンティティと、そして、制酸フィラーと混合して、プラスチック組成物を得ることと、前記プラスチック組成物でプラスチック製品をさらに製造することとを含む、方法。
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