JP4259980B2 - 五層共押出二軸延伸ポリプロピレンパール光沢合成紙及びその製造法 - Google Patents
五層共押出二軸延伸ポリプロピレンパール光沢合成紙及びその製造法 Download PDFInfo
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- JP4259980B2 JP4259980B2 JP2003366145A JP2003366145A JP4259980B2 JP 4259980 B2 JP4259980 B2 JP 4259980B2 JP 2003366145 A JP2003366145 A JP 2003366145A JP 2003366145 A JP2003366145 A JP 2003366145A JP 4259980 B2 JP4259980 B2 JP 4259980B2
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- weight
- layer
- paper
- polypropylene
- mfi
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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- 238000004519 manufacturing process Methods 0.000 title claims description 16
- 229920006378 biaxially oriented polypropylene Polymers 0.000 title claims description 12
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- 229920005989 resin Polymers 0.000 claims description 60
- -1 polypropylene Polymers 0.000 claims description 57
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 56
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 54
- 239000004743 Polypropylene Substances 0.000 claims description 41
- 229920001155 polypropylene Polymers 0.000 claims description 41
- 239000000203 mixture Substances 0.000 claims description 40
- 239000002131 composite material Substances 0.000 claims description 32
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- 239000002344 surface layer Substances 0.000 claims description 27
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- KGRVJHAUYBGFFP-UHFFFAOYSA-N 2,2'-Methylenebis(4-methyl-6-tert-butylphenol) Chemical compound CC(C)(C)C1=CC(C)=CC(CC=2C(=C(C=C(C)C=2)C(C)(C)C)O)=C1O KGRVJHAUYBGFFP-UHFFFAOYSA-N 0.000 claims description 8
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 claims description 8
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- MCPKSFINULVDNX-UHFFFAOYSA-N drometrizole Chemical compound CC1=CC=C(O)C(N2N=C3C=CC=CC3=N2)=C1 MCPKSFINULVDNX-UHFFFAOYSA-N 0.000 claims description 6
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- 239000005909 Kieselgur Substances 0.000 claims description 4
- 239000003795 chemical substances by application Substances 0.000 claims description 4
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- IAJNXBNRYMEYAZ-UHFFFAOYSA-N ethyl 2-cyano-3,3-diphenylprop-2-enoate Chemical compound C=1C=CC=CC=1C(=C(C#N)C(=O)OCC)C1=CC=CC=C1 IAJNXBNRYMEYAZ-UHFFFAOYSA-N 0.000 claims 1
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- FPAFDBFIGPHWGO-UHFFFAOYSA-N dioxosilane;oxomagnesium;hydrate Chemical compound O.[Mg]=O.[Mg]=O.[Mg]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O FPAFDBFIGPHWGO-UHFFFAOYSA-N 0.000 description 2
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Description
図1に示すように、公知の三層共押出二軸延伸パール光沢合成紙20の構造は、最上層に配置した紙面層或いは樹脂層A1、中間層の発泡層B1、最下層の紙面層或いは樹脂層C1の三層積層構造である。
1.五層共押出二軸延伸パール光沢合成紙15の発泡層Cは、その発泡性の空間調節はより弾力的であるため、生産速度の向上と品質安定に役立つ。
公知の三層共押出二軸延伸パール光沢合成紙20は、比重の小さい製品を生産する場合、発泡層B1の比重を非常に低くしなければならず、発泡層B1に大量の無機フィラーを添加して延伸発泡効果を達成する必要があった。 しかし大量の無機フィラーを添加すると、押出時に摩擦熱が大量に発生し、樹脂材が過度に溶融して生産に障害が起こるため、速度を落として摩擦熱を 減少させなければならず、生産コストと品質安定に不利であった。
五層共押出二軸延伸パール光沢合成紙15の生産時には、各層に分散して比重の調整ができるため、速度を落として摩擦熱を避ける必要がなく、五層共押出二軸延伸パール光沢合成紙15の品質が安定し、生産速度が向上する 。
三層共押出二軸延伸パール光沢合成紙20の隠蔽性品質を向上するには、三層共押出に軸延伸パール光沢合成紙20の各層或いはそのうちの一層に集中して大量の無機粉末を添加する必要があるが、無機粉末を大量に添加すると生産性が悪くなり、製品の生産効率に影響する。
五層共押出二軸延伸パール光沢合成紙15の隠蔽性品質を向上するには、各層に平均して無機粉末を添加する方法で生産することにより、各層の無機粉末添加量を削減できるため、生産効率に影響しないだけでなく、五層共押出二軸延伸パール光沢合成紙15の隠蔽効果を向上できる。
三層共押出二軸延伸パール光沢合成紙20の紙面静電防止性と平滑性を改善する助剤は、紙面層A1や紙面層C1への添加には適さないため、厚さのある発泡層B1ni添加しなければならなかった。
五層共押出二軸延伸パール光沢合成紙15の紙面静電防止性と平滑性を改善する助剤は、薄い第二層の紙面層或いは樹脂層B及び第四層の紙面層或いは樹脂層Dに添加できるため、紙面静電防止性及び平滑性の助剤用量が少なくてすみ、コストを低下できるほか、最上層の紙面層或いは樹脂層Aの印刷品質を確保及び制御できる。
三層共押出二軸延伸パール光沢合成紙20の紙面層A1或いは紙面層C1は、明度と光沢が発泡層B1の発泡性と添加した無機フィラーの影響を受けやすく、また各層間の強度も弱く剥離しやすかった。
五層共押出二軸延伸ポリプロピレンパール光沢合成紙15は、発泡層と隠蔽層として中間にはさむ発泡層Cを選ぶことができ、最上層の紙面層或いは樹脂層Aと第二層の紙面層或いは樹脂層B、或いは第四層の紙面層或いは樹脂層Dと最下層の紙面層或いは樹脂層Eは、樹脂層構造にでき、五層共押出二軸延伸ポリプロピレンパール光沢合成紙15は高い明度と紙面光沢を具えるようになり、製品の剛性も各層間の強度も三層共押出二軸延 伸パール光沢合成紙20より優れている。
表1に示すように、公知の三層共押出二軸延伸パール光沢合成紙20の厚さはほぼ30〜250μmだが、本発明の五層共押出二軸延伸パール光沢合成紙15の厚さは30〜300μmに達するため、五層共押出二軸延伸パール光沢合成紙15は製品の厚さを増進できる。
1.樹脂原料:例えばポリプロピレン、ポリエチレン、脂肪族炭化水素。
2.無機粉末及び添加剤の複合粒(マスターバッチ)。炭酸カルシウム(重質或いは軽質)、二酸化チタン(アナターゼ型或いはルチル型)、珪藻土、白土、酸化カルシウム、二酸化珪素或いは硫酸バリウムのグループから一種或いは一種以上を選択でき、表面処理を経てからそのうち一種或いは二種以上を混合して粒径0.05〜15μmの複合粒(マスターバッチ)を製造する。
紙面層或いは樹脂層A≒紙面層或いは樹脂層E≧紙面層或いは樹脂層B≒紙面層或いは樹脂層D≧発泡層C
であり範囲は、1.5〜12/1〜15/0.5〜7/1〜15/1.5〜12である。
このうち、二酸化珪素、炭酸カルシウム、タルカムパウダー、硫酸バリウム、珪藻土、静電防止剤、粘着防止剤、紫外線防止剤の複合粒(マスターバッチ)を組成し、主にポリプロピレン及びポリエチレンを簿財樹脂とする。
二酸化珪素、炭酸カルシウム、タルカムパウダー、硫酸バリウム、珪藻土など無機粉末は、粒径選択範囲を0.05〜15μmとし、複合粒濃度を15〜75%の範囲に製造するとよい。
本発明の五層共押出二軸延伸パール光沢合成紙15の発泡層Cは、抽気装置を具える一台のツインスクリュー主押出機3により、温度160〜280℃のもとで、ポリプロピレン88〜46重量%、ポリエチレン0〜15重量%、炭酸カルシウム40〜70%含有複合粒(マスターバッチ)5〜20重量%、二酸化チタン30〜60%含有複合粒(マスターバッチ)5〜20重量%、紫外線吸収剤1〜2重量%、酸化防止剤1〜2重量%を含有する混合物に対し、ツインスクリュー主押出機3前端のフィーダで均一に攪拌した後、ツインスクリュー主押出機3内に進入させ、混練並びに抽気し、混合物をTダイヘッドの第三層流路に圧入する。
単面紙面に優良な孔版、平版、凸版、凹版印刷性を具える170μm五層共押出二軸延伸パール光沢合成紙15である。
最上層を紙面層Aとし、組成をポリプロピレン(MFI:6)48重量%、ポリエチレン(MFI:0.05)30重量%、二酸化チタン(40%)複合粒(マスターバッチ)15重量%、炭酸カルシウム(60%)複合粒(マスターバッチ)15重量%、粘着防止剤2重量%、紫外線吸収剤1重量%、酸化防止剤1重量%とする。
第二層を紙面層Bとし、組成をポリプロピレン(MFI:3)71重量%、炭酸カルシウム(60%)複合粒(マスターバッチ)15重量%、二酸化チタン(40%)複合粒(マスターバッチ)15重量%、静電防止剤7重量%、酸化防止剤1重量%、紫外線吸収剤1重量%とする。
第三層を発泡層Cとし、組成をポリプロピレン(MFI:2.4)78重量%、炭酸カルシウム(60%)複合粒(マスターバッチ)15重量%、二酸化チタン(40%)複合粒(マスターバッチ)5重量%、酸化防止剤1重量%、紫外線吸収剤1重量%とする。
第四層を紙面層Dとし、組成をポリプロピレン(MFI:3)71重量%、炭酸カルシウム(60%)複合粒(マスターバッチ)15重量%、二酸化チタン(40%)複合粒(マスターバッチ)15重量%、静電防止剤7重量%、酸化防止剤1重量%、紫外線吸収剤1重量%とする。
第五層を紙面層Eとし、組成をポリプロピレン(MFI:6)95重量%、粘着防止剤3重量%、酸化防止剤1重量%、紫外線吸収剤1重量%とする。
1.五層共押出二軸延伸パール光沢合成紙15の比重を下げるとき、発泡層構 造に設定できる層は四層あり、公知の三層共押出二軸延伸パール光沢合 成紙20では発泡層構造にできるのは二層のみであるのに比較して、五 層共押出二軸延伸パール光沢合成紙15では炭酸カルシウムが一層の発 泡層に集中しすぎるという欠点を減少でき、これにより生産速度を向上 でき、コストが低下する。
2.五層共押出二軸延伸パール光沢合成紙15の隠蔽構造は四層に設定でき、 公知の三層共押出二軸延伸パール光沢合成紙20では二層にのみ設定で きるのに比較して、五層共押出二軸延伸パール光沢合成紙15では二酸 化チタンが一層の隠蔽構造のみに集中しすぎるという欠点を減少でき、 これにより生産速度と生産効率が向上する。
3.静電防止剤といった添加剤は、比較的薄い第二層紙面層或いは樹脂層B、 或いは第四層紙面層或いは樹脂層Dのみに添加すればよく、公知の三層 共押出二軸延伸パール光沢合成紙20では厚い発泡層B1に添加しなけ ればならないのに比較して、添加剤の使用コストを低下できる。
単両面光沢面で優良な孔版、平版、凸版、凹版印刷性を具える90μm五層共押出二軸延伸パール光沢合成紙15である。特許の三層構造に比べ、剛性、明度に優れ、層間強度が増強された。
最上面の紙面層Aと最下層の紙面層Eの組成をそれぞれポリプロピレン(MFI:6)94重量%、酸化防止剤2重量%、粘着防止剤2重量%、紫外線吸収剤2重量%とする。
第二層の紙面層Bと第四層の紙面層Dの組成をそれぞれポリプロピレン(MFI:6)93重量%、静電防止剤5重量%、酸化防止剤1重量%、紫外線吸収剤1重量%とする。
第三層の発泡層Cの組成を、ポリプロピレン(MFI:3)68重量%、炭酸カルシウム(60%)複合粒(マスターバッチ)15重量%、二酸化チタン(40%)複合粒(マスターバッチ)15重量%、酸化防止剤1重量%、紫外線吸収剤1重量%とする。
2 シングルスクリュー副押出機
3 ツインスクリュー主押出機
4 シングルスクリュー副押出機
5 シングルスクリュー副押出機
6 冷却成型装置
7 縦方向延伸装置
8 横方向延伸装置
9 コロナ処理装置
10 巻取り機
15 五層共押出二軸延伸パール光沢合成紙
20 三層共押出二軸延伸パール光沢合成紙
A1 紙面層或いは樹脂層
B1 紙面層或いは樹脂層
C1 発泡層
A 紙面層或いは樹脂層
B 紙面層或いは樹脂層
C 発泡層
D 紙面層或いは樹脂層
E 紙面層或いは樹脂層
Claims (5)
- 30〜300μmの五層積層構造物であり、最上層の紙面層或いは樹脂層A、第二層の紙面層或いは樹脂層B、中間にはさむ発泡層C、第四層の紙面層或いは樹脂層D、及び最下層の紙面層或いは樹脂層Eを共に重ねて構成し、
最上層の紙面層或いは樹脂層A及び最下層の紙面層或いは樹脂層EのMFIは1.5〜12、その組成は、それぞれポリプロピレン96〜36重量%、ポリエチレン0〜30重量%、粘着防止剤2〜5重量%、二酸化チタン30〜60%含有の複合粒0〜15重量%、炭酸カルシウム40〜70%含有の複合粒0〜15重量%、紫外線吸収剤1〜2重量%、酸化防止剤1〜2重量%であり、
第二層の紙面層或いは樹脂層B及び第四層の紙面層或いは樹脂層DのMFIは1〜15、その組成は、それぞれポリプロピレン97〜54重量%、ポリエチレン0〜15重量%、二酸化チタン30〜60%含有の複合粒0〜15重量%、炭酸カルシウム40〜70%含有の複合粒0〜15重量%、静電防止剤1〜7重量%、紫外線吸収剤1〜2重量%、酸化防止剤1〜2重量%であり、
中間にはさむ発泡層CのMFIは0.5〜7、その組成は、ポリプロピレン88〜46重量%、ポリエチレン0〜15重量%、炭酸カルシウム40〜70%含有の複合粒5〜15重量%、二酸化チタン30〜60%含有の複合粒5〜15重量%、及び紫外線吸収剤1〜2重量%、酸化防止剤1〜2重量%であることを特徴とする五層共押出二軸延伸ポリプロピレンパール光沢合成紙。 - 170μmの五層積層構造物であり、
最上層の紙面層Aの組成は、ポリプロピレン48重量%、そのMFIは6、ポリエチレン30重量%、そのMFIは0.05、二酸化チタン40%含有の複合粒15重量%、炭酸カルシウム60%含有の複合粒15重量%、粘着防止剤2重量%及び紫外線吸収剤1重量%、酸化防止剤1重量%であり、
第二層の紙面層Bの組成は、ポリプロピレン71重量%、そのMFIは3、炭酸カルシウム60%含有の複合粒15重量%、二酸化チタン40%含有の複合粒15重量%、静電防止剤7重量%、酸化防止剤1重量%、紫外線吸収剤1重量%であり、
第三層の発泡層Cの組成は、ポリプロピレン78重量%、そのMFIは2.4、炭酸カルシウム60%含有の複合粒15重量%、二酸化チタン40%含有の複合粒5重量%、酸化防止剤1重量%、紫外線吸収剤1重量%であり、
第四層の紙面層Dの組成は、ポリプロピレン71重量%、そのMFIは3、炭酸カルシウム60%含有の複合粒15重量%、二酸化チタン40%含有の複合粒15重量%、静電防止剤7重量%、酸化防止剤1重量%、紫外線吸収剤1重量%であり、
第五層の紙面層Eの組成は、ポリプロピレン95重量%、そのMFIは6、粘着防止剤3重量%、酸化防止剤1重量%、紫外線防止剤1重量%であることを特徴とする請求項1記載の五層共押出二軸延伸ポリプロピレンパール光沢合成紙。 - 90μmの五層積層構造物であり、
最上層の紙面層A及び最下層の紙面層Eの組成は、それぞれポリプロピレン94重量%、そのMFIは6、酸化防止剤2重量%、粘着防止剤2重量%、紫外線吸収剤2重量%であり、
第二層の紙面層B及び第四層の紙面層Dの組成は、それぞれポリプロピレン93重量%、そのMFIは6、静電防止剤5重量%、酸化防止剤1重量%、紫外線吸収剤1重量%であり、
第三層の発泡層Cの組成は、ポリプロピレン68重量%、そのMFIは3、炭酸カルシウム60%含有の複合粒15重量%、二酸化チタン40%含有の複合粒15重量%、酸化防止剤1重量%、紫外線吸収剤1重量%であることを特徴とする請求項1記載の五層共押出二軸延伸ポリプロピレンパール光沢合成紙。 - 五層共押出二軸延伸プロセスを経て、厚さ30〜300μmの五層積層構造物に製造する製造法であり、
(a)最上層の紙面層或いは樹脂層A及び最下層の紙面層或いは樹脂層EはMFIが1.5〜12、それぞれ、ホッパ抽気を具える二台のシングルスクリュー副押出機により、温度160〜280℃のもとで、ポリプロピレン96〜36重量%、ポリエチレン0〜30重量%、粘着防止剤2〜5重量%、二酸化チタン30〜60%含有の複合粒0〜15重量%、炭酸カルシウム40〜70%含有の複合粒0〜15重量%、紫外線吸収剤1〜2重量%、酸化防止剤1〜2重量%を含有する混合物に対し、それぞれシングルスクリュー副押出機前端のフィーダにより均一に攪拌した後、シングルスクリュー副押出機内に進入させ、混練並びに抽気し、それぞれ混合物をTダイヘッドの第一層と第五層の流路に圧入し、
(b)第二層と第四層の紙面層或いは樹脂層B及び紙面層或いは樹脂層DはMFIが1〜15、それぞれ、ホッパ抽気を具える二台のシングルスクリュー副押出機により、温度160〜280℃のもとで、ポリプロピレン97〜54重量%、ポリエチレン0〜15重量%、二酸化チタン30〜60%含有の複合粒0〜15重量%、炭酸カルシウム40〜70%含有の複合粒0〜15重量%、静電防止剤1〜7重量%、紫外線防止剤1〜2重量%、酸化防止剤1〜2重量%を含有する混合物に対し、それぞれシングルスクリュー副押出機前端のフィーダにより均一に攪拌した後、シングルスクリュー副押出機内に進入させ、混練並びに抽気し、それぞれ混合物をTダイヘッドの第二層と第四層の流路に圧入し、
(c)第三層の発泡層CはMFIが0.5〜7、抽気装置を具える一台のツインスクリュー主押出機により、温度160〜280℃のもとで、ポリプロピレン88〜46重量%、ポリエチレン0〜15重量%、炭酸カルシウム40〜70%含有の複合粒5〜20重量%、二酸化チタン30〜60%含有の複合粒5〜20重量%、紫外線吸収剤1〜2重量%、酸化防止剤1〜2重量%を含有する混合物に対し、ツインスクリュー主押出機前端のフィーダにより均一に攪拌した後、ツインスクリュー主押出機内に進入させ、混練並びに抽気し、混合物をTダイヘッドの第三層流路に圧入し、
(d)Tダイヘッドを経て押出成型した五層積層構造物は、冷却成型装置によって温度15〜70℃のもと、五層積層板に成型され、
(e)縦方向延伸装置に導入して、温度155〜155℃のもと、プロセス(d)の五層積層板に対し縦方向に2.5〜7倍の延伸を行い、
(f)横方向延伸装置に導入して、温度140〜200℃のもと、プロセス(e)の五層積層板に対し横方向に5〜15倍の延伸を行い、
(g)コロナ処理装置によって、縦方向及び横方向延伸を経た五層積層板に20〜120kwで高周波コロナ処理を行い、
(h)巻取り機で巻き取って30〜300μmの五層共押出二軸延伸ポリプロピレンパール光沢合成紙完成品とする、
以上のプロセスから成ることを特徴とする30〜300μmの五層共押出二軸延伸ポリプロピレンパール光沢合成紙の製造法。 - 二酸化チタン又は炭酸カルシウム含有の複合粒は、ポリプロピレン及びポリエチレンをキャリアー樹脂とし、重質或いは軽質の炭酸カルシウム、二酸化チタン、珪藻土、白土、酸化カルシウム、二酸化珪素及び硫酸バリウムのグループから一種或いは一種以上を選択したものと混合し、粒径0.05〜15μmの複合粒に製造することを特徴とする請求項4記載の五層共押出二軸延伸ポリプロピレンバール光沢合成紙の製造法。
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US10/722,403 US7041243B2 (en) | 2003-10-27 | 2003-11-28 | 5-layer co-extruded biaxial-oriented polypropylene synthetic paper and its production process |
EP20030027445 EP1537991B1 (en) | 2003-10-27 | 2003-12-01 | 5-layer co-extruded biaxial-oriented polypropylene synthetic paper and its production process |
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US10/722,403 US7041243B2 (en) | 2003-10-27 | 2003-11-28 | 5-layer co-extruded biaxial-oriented polypropylene synthetic paper and its production process |
EP20030027445 EP1537991B1 (en) | 2003-10-27 | 2003-12-01 | 5-layer co-extruded biaxial-oriented polypropylene synthetic paper and its production process |
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- 2003-11-28 US US10/722,403 patent/US7041243B2/en not_active Expired - Lifetime
- 2003-12-01 EP EP20030027445 patent/EP1537991B1/en not_active Expired - Fee Related
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US7041243B2 (en) | 2006-05-09 |
EP1537991A1 (en) | 2005-06-08 |
EP1537991B1 (en) | 2007-04-25 |
US20050118410A1 (en) | 2005-06-02 |
JP2005125708A (ja) | 2005-05-19 |
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