JP7100933B1 - Laminated sheets and food packaging containers - Google Patents

Abstract

An object of the present invention is to provide a laminated sheet and a food packaging container which are excellent in moldability, exhibit a good appearance, and have excellent physical properties such as mechanical properties and heat resistance. The present invention is a laminated sheet comprising an inner layer and outer layers laminated on both sides of the inner layer; the inner layer comprises polypropylene resin, polyethylene resin, inorganic powder, and zinc stearate. , stearic acid, and polyethylene-based wax in predetermined proportions; and the outer layer includes a polypropylene-based resin. [Selection drawing] Fig. 1

Description

The present invention relates to laminated sheets and food packaging containers.

Conventionally, a two-kind three-layer sheet in which a sheet filled with an inorganic substance powder such as calcium carbonate in a polyolefin resin is used as an inner layer is known. Such laminated sheets are often used as materials for food packaging containers, synthetic papers, and the like because they have both excellent moldability derived from thermoplastic resins and flame retardancy and heat resistance derived from inorganic substance powders. Even now, various improved techniques are being proposed in order to further improve the formability and appearance of the laminated sheet, mechanical strength, acid resistance and other physical properties.

For example, Patent Document 1 describes a first resin layer containing a polyolefin resin and surface-treated heavy calcium carbonate in a mass ratio of 50:50 to 20:80, and a polyolefin resin and heavy calcium carbonate in a mass ratio of 50:50 to 99. A sheet in which a second resin layer containing a mass ratio of 1 is laminated is disclosed. This laminated sheet has the advantages that peeling between the resin layers is unlikely to occur and the surface smoothness is excellent. Patent Document 2 discloses a laminate having excellent heat resistance and acid resistance, which is provided with an outer layer of a thermoplastic resin on both sides of a thermoplastic resin layer containing more than 50% by mass of calcium carbonate. Patent Document 3 discloses a sheet material having an intermediate layer containing calcium carbonate and a resin and a surface layer made of a polypropylene-based resin, and having a specific tensile elongation. Patent Document 4 discloses a food container or the like in which synthetic paper containing 60 to 80% of calcium carbonate or the like is stored.

Japanese Unexamined Patent Publication No. 2020-023055 Japanese Patent Application Laid-Open No. 2021-126789 Japanese Unexamined Patent Publication No. 2021-112862 Utility Model Registration No. 3146349 Gazette

However, a sheet highly filled with an inorganic substance powder such as calcium carbonate may have a significantly reduced moldability as compared with a sheet containing only a polyolefin resin. The inner layer having a high amount of inorganic substance powder has a non-smooth surface, and particularly when the outer layer is thin, it tends to adversely affect the appearance of products such as vacuum-formed food packaging containers. In addition, since calcium carbonate or the like, which is an inorganic filler, is highly filled, mechanical strength such as tensile strength and elongation, and acid resistance may be lowered as compared with a molded product made of only a polyolefin resin. There were problems such as problems during use. For example, the laminated sheet described in Patent Document 1 has good appearance such as surface smoothness and interlayer strength, but there is room for improvement in terms of acid resistance and the like. Although the laminated sheets described in Patent Documents 2 to 4 can exhibit good acid resistance, they have problems in terms of appearance, strength, and formability.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a laminated sheet and a food packaging container having excellent molding processability, a good appearance, and excellent physical properties such as mechanical properties and heat resistance. ..

The present inventor defines the types and amounts of resins and additives in the inner layer of a laminated sheet including an inner layer made of a polyolefin resin highly filled with an inorganic substance powder and an outer layer containing a polypropylene resin. The present invention was completed with the finding that good appearance, mechanical properties, heat resistance, and processability can be obtained. More specifically, the present invention provides the following.

(1) A laminated sheet including an inner layer and an outer layer laminated on both sides of the inner layer.
The inner layer contains polypropylene-based resin, polyethylene-based resin, inorganic substance powder, zinc stearate, stearic acid, and polyethylene-based wax.
The mass ratio of the total of the polypropylene-based resin and the polyethylene-based resin to the inorganic substance powder is 10:90 to 50:50.
The content of the zinc stearate is 0.1% by mass or more and 1.0% by mass or less with respect to the entire inner layer.
The content of the stearic acid is 0.1% by mass or more and 1.6% by mass or less with respect to the entire inner layer.
The mass ratio of the zinc stearate to the stearic acid is 1: 1 to 1: 4.
The content of the polyethylene wax is 0.5% by mass or more and 3.0% by mass or less with respect to the entire inner layer, and the outer layer contains a polypropylene resin.
Laminated sheet.

(2) The polyethylene-based resin is
High-density polyethylene with an MFR (190 ° C., 21.6 kg) of 5 g / 10 minutes or more and 15 g / 10 minutes or less according to JIS K 6922-1 (ISO1133).
Includes linear low density polyethylene with MFR (190 ° C., 2.16 kg) according to JIS K 6922-1 (ISO1133) of 0.5 g / 10 min or more and 1.5 g / 10 min or less.
The mass ratio of the high-density polyethylene to the linear low-density polyethylene is 90:10 to 50:50.
The laminated sheet according to (1).

(3) The laminated sheet according to (1) or (2), wherein the polypropylene-based resin in the inner layer is a propylene homopolymer and / or a propylene block polymer.

(4) The laminated sheet according to any one of (1) to (3), wherein the inorganic substance powder is heavy calcium carbonate.

(5) The laminated sheet according to (4), wherein the average particle size of the heavy calcium carbonate by an air permeation method according to JIS M-8511 is 0.7 μm or more and 6.0 μm or less.

(6) The laminated sheet according to any one of (1) to (5), wherein the thickness of the outer layer is 2% or more and 10% or less, respectively, of the thickness of the entire laminated sheet.

(7) The laminated sheet according to any one of (1) to (6), which is a laminated sheet for vacuum forming.

(8) A food packaging container made of the laminated sheet according to any one of (1) to (7).

According to the present invention, there is provided a laminated sheet and a food packaging container which are excellent in molding processability, have a good appearance, and are also excellent in physical properties such as mechanical properties and heat resistance.

It is sectional drawing which shows one Embodiment of the laminated sheet of this invention.

Hereinafter, embodiments of the present invention will be described, but the present invention is not limited thereto.

≪Laminated sheet≫
The laminated sheet of the present invention is a laminated sheet including an inner layer and an outer layer laminated on both sides of the inner layer; the outer layer contains a polypropylene resin; the inner layer is a polypropylene resin, a polyethylene resin, and an inorganic material. It contains a substance powder, zinc stearate, stearic acid, and polyethylene wax in a predetermined ratio.

FIG. 1 is a schematic cross-sectional view showing a laminated sheet 1 which is an embodiment of the laminated sheet of the present invention. The laminated sheet 1 has a structure in which outer layers 12 and 13 are laminated on both surfaces of the inner layer 11. The materials of the inner layer 11 and the outer layers 12 and 13 will be described in detail later, but the inner layer 11 contains all the above-mentioned components in a predetermined amount, and the outer layers 12 and 13 are both made of polypropylene-based resin. As a result, the laminated sheet 1 is excellent in molding processability, exhibits a good appearance, has sufficient mechanical properties and heat resistance, is also excellent in physical properties such as acid resistance, and the inner layer 11 and the outer layers 12 and 13 are peeled off. It becomes a difficult-to-difficult laminate. The materials of the outer layer 12 and the outer layer 13 may be the same or different as long as they contain a polypropylene-based resin.

The shape and size of the laminated sheet 1 are not particularly limited, and can be a desired shape and size according to the purpose and application. For example, when used as a food packaging container, the thickness T of the entire sheet is preferably, for example, 100 μm to 2 mm, more preferably 150 to 900 μm, and particularly preferably 200 to 700 μm, but is not limited thereto.

The thicknesses T12 and T13 of the outer layers 12 and 13 are also not particularly limited. For example, T12 and T13 are laminated on both sides of an inner layer 11 having a thickness of 100 μm to 2 mm, further 150 to 900 μm, particularly 200 to 700 μm, and an outer layer of 7.5 to 45 μm, particularly 10 to 35 μm is laminated. It can be a structure. Further, T12 and T13 may be different. For example, among the outer layers 12 and 13, the layer on the side in contact with acidic foods such as dried plums and lemons can be thickened, and the layer on the opposite side that may be heated can be thinned.

In the laminated sheet 1, the thicknesses T12 and T13 of the outer layers 12 and 13 are 2% or more and 10% or less, respectively, and 3% or more and 9% or less, particularly 4% or more and 8% of the thickness T of the entire laminated sheet 1. The following is preferable. By setting the thickness of the outer layer to such a ratio with respect to the entire laminated sheet, the balance of physical properties such as moldability, appearance, and mechanical properties can be further improved.

Of course, the laminated sheet of the present invention can adopt an embodiment other than the above-mentioned laminated sheet 1. For example, it may be a laminated sheet in which two or three or more inner layers containing a predetermined amount of the above components are laminated and the outer layers are provided on both sides thereof, or a first layer such as an adhesive layer is directly above one or both sides of the inner layer. It is also possible to have a structure of four layers or five or more layers having three layers and the outer layers on both surfaces thereof. Further, even if the outer layer of the laminated sheet of the present invention is provided with a printing layer for ensuring aesthetics, a protective layer for preventing contamination, an adhesive layer for improving convenience during use, and the like, if desired. good.

The laminated sheet of the present invention preferably has a three-layer structure like the laminated sheet 1. With such a three-layer structure, molding by coextrusion or the like described later is easy. Further, since the laminated sheet of the present invention is particularly characterized by the material of the inner layer, it has excellent bondability with the outer layer containing a polypropylene resin, and has good peel resistance even without an intermediate layer such as an adhesive layer. Therefore, it is possible to develop high mechanical strength and good appearance.

<Inner layer>
As described above, the inner layer of the laminated sheet of the present invention contains a polypropylene resin, a polyethylene resin, an inorganic substance powder, zinc stearate, stearic acid, and a polyethylene wax, and meets the following requirements. Meet all.
(Requirement 1) The mass ratio of the total of polypropylene-based resin and polyethylene-based resin to the inorganic substance powder is resin: inorganic substance powder = 10: 90 to 50:50.
(Requirement 2) The content of zinc stearate is 0.1% by mass or more and 1.0% by mass or less with respect to the entire inner layer.
(Requirement 3) The content of stearic acid is 0.1% by mass or more and 1.6% by mass or less with respect to the entire inner layer.
(Requirement 4) The mass ratio of zinc stearate to stearic acid is zinc stearate: stearic acid = 1: 1 to 1: 4.
(Requirement 5) The content of the polyethylene wax is 0.5% by mass or more and 3.0% by mass or less with respect to the entire inner layer.

From the viewpoint of meeting needs such as improving the heat resistance of polyolefin resin products and reducing the amount of resin used, it is possible to add inorganic substance powder (for example, calcium carbonate) to the polyolefin resin so as to satisfy (Requirement 1), for example. , Has been known in the past. On the other hand, the present inventor has found that a composition satisfying (Requirement 1) greatly impairs the good molding processability of the polyolefin resin, may deteriorate the appearance of the laminated sheet, and further, mechanical strength and acid resistance. It was found that the physical properties such as may be deteriorated.

Therefore, as a result of further studies by the present inventor, a polypropylene resin and a polyethylene resin are used in combination as the polyolefin resin, and zinc stearate and stearate are used together with the inorganic substance powder so as to satisfy (Requirement 2) to (Requirement 5). It has been found that by blending an acid (octadecanoic acid) and a polyethylene-based wax, it is possible to suppress deterioration of the moldability of the laminated sheet and deterioration of the appearance.

Zinc stearate is known to act as a lubricant. Stearic acid is also known to act as a dispersant. However, even if other components known as lubricants and dispersants were blended with the polyethylene resin, the effect of the combination of zinc stearate and stearic acid could not be confirmed. Further, even when zinc stearate and stearic acid are combined, it is difficult to obtain a sufficient effect unless (Requirement 2) to (Requirement 4) are satisfied together with other requirements.

Then, the present inventor finds that such a deterioration suppressing effect such as molding processability and appearance is obtained when the polyethylene-based resin is a mixture of high-density polyethylene and linear low-density polyethylene, or when the polypropylene-based resin is a polypropylene homopolymer. And / or when it is a polypropylene block polymer, it has also been found that it can be further enhanced.

In the present invention, "molding processability" means the ease of molding or processing a laminated sheet by an arbitrary molding method. For example, the molding processability in the case of inflation molding a laminated sheet includes the ease of blowing. For example, the formability in the case of extrusion molding of a laminated sheet includes the ease of extrusion from a die. Further, when the laminated sheet is processed into a food packaging container by vacuum forming, for example, the sheet's followability to the mold and dimensional stability are included, and further, the surface of the flow mark, shark skin, etc. is included in the molding process. It includes the fact that problems such as deterioration of characteristics, tearing and delamination are unlikely to occur.

According to the present invention, firstly, as a result of suppressing the deterioration of the molding processability of the inner layer itself, the appearance of the obtained laminated sheet can be made good reflecting the surface state of the inner layer. Secondly, since the material of the inner layer is similar to that of the polypropylene-based resin of the outer layer in terms of physical properties such as heat melting characteristics, wrinkles and the like are less likely to occur during the molding process, and deterioration of the appearance of the obtained laminated sheet can be suppressed. Since the inner layer is also excellent in bondability with the outer layer in terms of material, it is possible to suppress deterioration of appearance and physical properties due to peeling between layers even when processing a laminated sheet into various molded products. Become. The appearance of the laminated sheet or the molded product can be evaluated, for example, by visually observing the state of the surface (smoothness, presence / absence of peeling or deformation, etc.).

Hereinafter, the configuration of the laminated sheet of the present invention will be described.

[Polypropylene resin]
The polypropylene-based resin in the present invention is not particularly limited as long as it is a resin containing at least a part of the repeating unit of propylene. For example, the polypropylene-based resin in the present invention includes a resin having a propylene component unit of 50% by mass or more. For example, a propylene homopolymer (propylene homopolymer), a copolymer with another monomer copolymerizable with propylene (propylene copolymer), and the like can be mentioned. These polypropylene-based resins can be used alone or in admixture of two or more.

The molecular weight of the polypropylene resin is also not particularly limited. For example, a resin having a mass average molecular weight of about 50,000 or more and 500,000 or less, particularly 100,000 or more and 400,000 or less, can be used, but the resin is not limited thereto. Generally, the higher the molecular weight, the better the mechanical properties such as strength, and the lower the molecular weight, the better the moldability. Those having a mass average molecular weight of about 50,000 or more and less than 200,000 and those having a mass average molecular weight of about 200,000 or more and 500,000 or less can be used in combination. By using polypropylene-based resins having different molecular weights in combination, it is possible to improve moldability and reduce appearance defects of laminated sheets and molded products.

The polypropylene-based resin may also have any melting characteristics such as melt mass flow rate (MFR). For example, one having an MFR (230 ° C.) of about 0.3 to 3.0 g / 10 minutes can be used. Further, MFR (230 ° C.) is 1.0 to 3.0 g / 10 minutes, melt tension (230 ° C.) is 5 to 30 g, and MFR (230 ° C.) is 0.3 to 1.0 g / 10 minutes. It can also be used in combination with the one. It is also possible to improve the formability of the laminated sheet by using polypropylene-based resins having different melting characteristics together.

The copolymer of propylene and other monomers may be a random copolymer or a block copolymer, and may be a ternary copolymer as well as a binary copolymer. Examples of the copolymerization component (other monomer) include, but are not limited to, tetrafluoroethylene and vinyl acetate.

In the present invention, a propylene homopolymer, or a resin in which a small amount of other monomers is copolymerized, for example, less than 5% by mass, and / or a propylene block polymer is used. It should be noted that even in the propylene homopolymer, a structure as if an α-olefin such as hexene was copolymerized as a result of the polymerization may be partially contained, but in the present invention, such a polymer is also used. Widely included as a propylene homopolymer.

(Propene homopolymer)
Propylene homopolymer (hereinafter, may be abbreviated as "PP") is a polymer obtained by polymerizing only propylene, and is excellent in rigidity and heat resistance. Various products are commercially available, such as Wintech (registered trademark) and Novatec (registered trademark) of Nippon Polypro Co., Ltd., Noblen (registered trademark) of Sumitomo Chemical Co., Ltd., and Prime Polypro (registered trademark) of Prime Polymer Co., Ltd. ), Toray Co., Ltd.'s Treca (registered trademark), SABIC Petrochemicals' SABIC (registered trademark) PP, and Sun Aroma Co., Ltd.'s Sun Aroma (registered trademark). PP may be included. Multiple types of PP can be used in combination.

Propylene homopolymers are classified into isotactic PP, syndiotactic PP, atactic PP, hemiisotactic PP and the like according to the difference in stereoregularity. The laminated sheet of the present invention may contain any of these, and may have a branched structure, for example, a long-chain branched structure. Further, the isotactic triad fraction (mm) may be, for example, a structure having a high stereoregularity of 90% or more, a random structure, or a structure containing a trace component produced as a by-product during polymerization. It may be. It is also possible to use a plurality of these propylene homopolymers in combination.

(Propene block copolymer / propylene block polymer)
A propylene block copolymer is a copolymer composed of a block in which a propylene monomer is continuous and a block in which other monomer components are continuous. Here, the monomer component that copolymerizes with propylene is not particularly limited, and the block copolymer is not limited to the binary system, but may be a ternary system, a quaternary system, or the like. There are no particular restrictions on the copolymerization ratio of each monomer, the length of each block, the total molecular weight, and the like. In the present invention, block copolymers composed of propylene and other α-olefins and the like are preferable. Block copolymers of propylene and α-olefins have excellent compatibility with propylene homopolymers, so the inner layer itself exhibits improved mechanical properties and moldability, and also has excellent bondability with the outer layer. From this point of view, it is possible to obtain a laminated sheet having excellent physical properties such as good moldability, appearance, and mechanical properties.

Block copolymers of propylene and α-olefins are known and various varieties are commercially available. Examples include Novatec (registered trademark) of Nippon Polypro Co., Ltd., Prime Polypro (registered trademark) of Prime Polymer Co., Ltd., Umex (registered trademark) of Sanyo Kasei Kogyo Co., Ltd., SunAllomer (registered trademark) of SunAllomer Ltd., etc. However, the present invention is not limited to these, and any propylene block copolymer may be contained. It is also possible to use two or more types of block copolymers in combination. The copolymerization monomer with propylene is not particularly limited, and may be one or more monomer components selected from, for example, ethylene and α-olefin having 4 to 10 carbon atoms. Examples are ethylene, 1-butene, isobutylene, 1-pentene, 3-methyl-1-butene, 1-hexene, 3,4-dimethyl-1-butene, 1-heptene, 3-methyl-1-hexene, 1 -Although but not limited to octene.

Among these block copolymers, copolymers with ethylene, 1-butene, isobutylene, 1-hexene, and / or 1-octene, particularly ethylene, are preferable. Although the copolymerization ratio and the molecular weight are not particularly limited, the copolymer derived from α-olefin, which is a copolymerization monomer, is preferably 5% by mass or more, more preferably 7% by mass or more, and particularly preferably 8% by mass or more. A copolymer having the same constituent unit of 35% by mass or less, more preferably 25% by mass or less, still more preferably 20% by mass or less, particularly preferably 18% by mass or less can be used. .. Since these block copolymers are highly flexible and have excellent compatibility with propylene homopolymers, they exhibit particularly excellent mechanical properties and moldability when blended in the inner layer of the laminated sheet of the present invention.

The properties of block polymers as described above are diverse, for example, with a mass average molecular weight of 20,000 to 5,000,000, typically 50,000 to 1,000,000, especially 70,000 to 400,000. In the range of degree; density is in the range of 0.84 to 0.92 g / cm ³ , typically 0.85 to 0.91 g / cm ³ , and crystallinity is 0.5 to 40%, typically. In the range of about 5 to 25%; melt flow rate (2.16 kg according to ATM D1238, MFR at 230 ° C.) is 0.1 to 90 g / 10 minutes, typically 0.5 to 30 g / 10 minutes. The melting temperature can range from 120 to 180 ° C., typically 150 to 170 ° C., particularly 160 to 165 ° C., but is not limited to these, and any characteristics in the present invention. The propylene-α-olefin copolymer of the above can also be used.

In the present invention, the block copolymer is preferably a propylene-ethylene block copolymer composed of a propylene block and an ethylene-propylene copolymer block. More preferably, block copolymers having a propylene-derived constituent unit of 80% by mass or more and an ethylene-derived constituent unit of 20% by mass or less; in particular, a propylene-derived constituent unit of 82 to 92% by mass and an ethylene-derived constituent unit of 8 to 8% by mass. 18% by mass block copolymers; among them, block copolymers having 84 to 90% by mass of propylene-derived structural units and 10 to 16% by mass of ethylene-derived structural units are used.

The propylene-ethylene block copolymer as described above can be produced, for example, by polymerizing propylene alone and then copolymerizing ethylene, and is also referred to as propylene block polymer or block polypropylene. Generally, in a propylene-ethylene block polymer, a so-called sea-island structure is developed in which the phases of an ethylene block or an ethylene-propylene copolymer block are dispersed in a continuous phase in which propylene is polymerized. Ethylene-propylene copolymers are generally flexible, thus providing flexibility in the inner layer. Moreover, the continuous phase has almost the same composition as the propylene homopolymer, and is excellent in compatibility and bondability. Therefore, when it is used in the inner layer of the laminated sheet of the present invention, it is less likely to peel off from the outer layer, and good moldability, appearance, and mechanical properties are obtained.

[Polyethylene resin]
The polyethylene-based resin in the present invention is not particularly limited as long as it is a resin containing at least a part of the repeating unit of ethylene. For example, the polyethylene-based resin in the present invention includes a resin having an ethylene component unit of 50% by mass or more. The polyethylene-based resin may be used alone or in combination of two or more. The origin of the polyethylene-based resin is not particularly limited, and it may be synthesized or produced from a plant-derived raw material or the like.

Examples of the polyethylene-based resin include the following.
High-density polyethylene (HDPE): Polyethylene with a density of 0.942 g / cm ³ or more-Medium-density polyethylene: 0.930 g / cm ³ or more and 0.942 g / cm Polyethylene with a density of ³ or less-Low-density polyethylene (LDPE) ): Polyethylene having a density of 0.910 g / cm ³ or more and less than 0.930 g / cm ³・ Linear low density polyethylene (LLDPE): 0.911 g / cm ³ or more and less than 0.940 g / cm ³ Linear polyethylene / ultra-low density polyethylene (ULDPE): Polyethylene with a density of less than 0.910 g / cm ³ .

The polyethylene-based resin in the present invention is a metal salt of a functional group-containing polyethylene-based resin (ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, ethylene-methacrylic acid copolymer, ethylene-methacrylic acid copolymer). Ionomer), ethylene-acrylic acid alkyl ester copolymer, ethylene-methacrylic acid alkyl ester copolymer, maleic acid-modified polyethylene, etc.) are also included.

From the viewpoint that the effect of the present invention can be easily exerted, the polyethylene-based resin preferably contains both the following high-density polyethylene and linear low-density polyethylene. More preferably, the mass ratio of the high-density polyethylene to the linear low-density polyethylene is 90:10 to 50:50, more preferably 85:15 to 55:45, and particularly 80:20 to 60:40. In addition, "MFR" is an abbreviation for "melt mass flow rate".
High-density polyethylene with MFR (190 ° C., 21.6 kg) according to JIS K 6922-1 (ISO1133) of 5 g / 10 minutes or more and 15 g / 10 minutes or less. 2.16 kg) is a linear low-density polyethylene with a weight of 0.5 g / 10 minutes or more and 1.5 g / 10 minutes or less.

[Inorganic substance powder]
The inorganic substance powder in the present invention includes any component that can be blended with the resin, and for example, what is known as a filler can be preferably used. The inorganic substance powder may be used alone or in combination of two or more. Inorganic substance powders include both synthetic powders and those derived from natural minerals (crushed products such as minerals).

Examples of the inorganic substance powder include salts (carbonates, sulfates, silicates, phosphates, borates), oxides, or hydrates of metals (calcium, magnesium, aluminum, titanium, iron, zinc, etc.). The powder of the thing is mentioned.

Specifically, for example, calcium carbonate, magnesium carbonate, zinc oxide, titanium oxide, silica, alumina, clay, talc, kaolin, aluminum hydroxide, magnesium hydroxide, aluminum silicate, magnesium silicate, calcium silicate, sulfuric acid. Aluminum, magnesium sulfate, calcium sulfate, magnesium phosphate, barium sulfate, silica sand, carbon black, zeolite, molybdenum, diatomaceous soil, sericite, silas, calcium sulfite, sodium sulfate, potassium titanate, bentonite, wollastonite, dolomite, graphite And other powders can be mentioned.

The shape of the inorganic substance powder is not particularly limited, but may be in the form of particles (spherical, indefinite, etc.), flakes, granules, fibers, or the like.

The lower limit of the particle size of the inorganic substance powder is not particularly limited, but the average particle size is preferably 0.7 μm or more, more preferably 1.0 μm or more. The upper limit of the particle size of the inorganic substance powder is not particularly limited, but the average particle size is preferably 6.0 μm or less, more preferably 5.0 μm or less. In the present invention, the "average particle size" means a value calculated from the measurement result of the specific surface area by the air permeation method according to JIS M-8511. As a measuring device for the average particle size, for example, a specific surface area measuring device “SS-100 type” manufactured by Shimadzu Corporation can be preferably used.

(Heavy calcium carbonate)
The inorganic substance powder in the present invention preferably contains calcium carbonate, particularly heavy calcium carbonate, and more preferably composed exclusively of heavy calcium carbonate.

In the present invention, "heavy calcium carbonate" is obtained by mechanically pulverizing natural calcium carbonate or the like, and is a synthetic calcium carbonate (that is, light calcium carbonate) produced by a chemical precipitation reaction or the like. Is clearly distinguished. Heavy calcium carbonate is obtained, for example, by crushing and classifying natural calcium carbonate such as calcite (limestone, chalk, marble, etc.), shells, coral and the like.

It is known that heavy calcium carbonate contains particles having a wide particle size and is generally inferior in molding processability. However, according to the present invention, even a laminated sheet containing heavy calcium carbonate in the inner layer has good molding processability and the appearance of the molded product can be excellent.

As the pulverization method in the method for producing heavy calcium carbonate, either wet pulverization or dry pulverization can be adopted. From an economical point of view, dry pulverization that does not require a dehydration step or a drying step is preferable. The crusher used for crushing heavy calcium carbonate is not particularly limited, and examples thereof include an impact type crusher, a crusher using a crushing medium (ball mill or the like), a roller mill and the like. For the classification in the method for producing heavy calcium carbonate, conventionally known means such as air classification, wet cyclone, and decanter can be adopted.

The heavy calcium carbonate may or may not be surface-treated. The surface treatment can be performed at any time point (before pulverization, during pulverization, before classification, after classification, etc.) in the method for producing heavy calcium carbonate.

Examples of the surface treatment of heavy calcium carbonate include a physical method (plasma treatment and the like) and a chemical method (a method using a coupling agent, a surfactant and the like).

Among the surface treatments of heavy calcium carbonate, examples of the coupling agent used in the chemical method include a silane coupling agent and a titanium coupling agent.

Among the surface treatments of heavy calcium carbonate, examples of the surfactant used in the chemical method include anionic surfactants, cationic surfactants, nonionic surfactants, and amphoteric surfactants. More specifically, for example, higher fatty acids, higher fatty acid esters, higher fatty acid amides, higher fatty acid salts and the like can be mentioned.

By applying the above surface treatment, the dispersibility of heavy calcium carbonate can be enhanced. However, heavy calcium carbonate that has not been surface-treated is preferable because it can reduce the risk of odor generation due to thermal decomposition of the surface treatment agent during molding.

The form of the heavy calcium carbonate is not particularly limited, but is preferably particulate from the viewpoint of good dispersibility in the inner layer.

When the heavy calcium carbonate is in the form of particles, its average particle size is preferably 0.7 μm or more and 6.0 μm or less, more preferably 1.0 μm or more and 5.0 μm or less, and further preferably 1.5 μm or more and 3.0 μm. It is as follows. Further, it is preferable that the particle size distribution does not include particles having a particle size of 45 μm or more.

When the average particle size of the heavy calcium carbonate is in the above range, the dispersibility in the inner layer is good, and it is possible to prevent an excessive increase in viscosity during the production of the laminated sheet. Further, the heavy calcium carbonate particles are less likely to protrude from the inner layer or the surface of the laminated sheet and fall off, or the surface texture, mechanical strength, etc. are not impaired, so that the effect of the present invention can be more easily exerted.

When the heavy calcium carbonate is in the form of particles, its irregularity can be expressed by the degree of spheroidization of the shape, that is, the roundness. The lower the roundness, the higher the indeterminate form. When the heavy calcium carbonate is in the form of particles, its roundness is preferably 0.50 or more and 0.95 or less, more preferably 0.55 or more and 0.93 or less, and further preferably 0.60 or more and 0.90. It is as follows.

In the present invention, "roundness" is a value obtained by dividing the projected area of a particle by the area of a circle having the same peripheral length as the projected peripheral length of the particle ((projected area of the particle) / (projected peripheral length of the particle). It means the area of a circle with the same perimeter)). The method for measuring the roundness is not particularly limited, but for example, it can be specified by analyzing a projection drawing of particles obtained by a scanning microscope, a stereomicroscope, or the like with commercially available image analysis software. Specifically, the projected area of the particle (A), the area of the circle having the same perimeter as the projected perimeter of the particle (B), the radius (r) of the circle having the same perimeter as the projected perimeter of the particle, and the particle. It can be calculated by the following formula based on the measurement result of the projected perimeter (PM) of.
"Roundness" = A / B = A / πr ² = A × 4π / (PM) ²

[Zinc stearate and stearic acid]
If zinc stearate (CAS registry number: 557-05-1) and stearic acid (octadecanoic acid, CAS registry number: 57-11-4) can be blended in the inner layer so as to satisfy the requirements of the present invention, their forms and the like may be. Not particularly limited.

[Polyethylene wax]
The polyethylene wax that can be suitably used in the present invention is not particularly limited. For example, it can be arbitrarily selected from polyethylene wax obtained by thermal decomposition of high molecular weight polyethylene, polyethylene wax obtained by free group polymerization of ethylene in the high pressure method, polyethylene wax obtained by polymerizing ethylene in the presence of a catalyst, and the like. Can be done. A wax obtained by copolymerizing an α-olefin such as propylene or butene may be used.

The molecular weight of the polyethylene wax is also not particularly limited. For example, a polyethylene wax having a number average molecular weight (Mn) measured by gel permeation chromatography (GPC) in the range of about 800 to 7,000, particularly about 1,000 to 5,000 can be blended.

The polyethylene wax may also have any physical characteristics. For example, a polyethylene wax having a density in the range of 0.870 to 0.960 g / cm ³ , particularly 0.900 to 0.940 g / cm ³ can be blended.

[Composition of inner layer]
The composition of the inner layer in the laminated sheet of the present invention contains a polypropylene resin, a polyethylene resin, an inorganic substance powder, zinc stearate, stearic acid, and a polyethylene wax, and the above (Requirement 1) to There is no particular limitation except that all of (Requirement 5) are satisfied. Preferred embodiments of the composition of the inner layer are described in detail below.

(Resin composition)
In the inner layer, the composition ratio of the polypropylene-based resin and the polyethylene-based resin is not particularly limited. For example, the mass ratio of polypropylene-based resin: polyethylene-based resin may be 50:50 to 80:20, particularly 60:40 to 70:30. When the ratio of both resins is within such a range, the physical properties such as the formability, appearance, and mechanical properties of the laminated sheet can be improved in a well-balanced manner. Preferably, the mass ratio of propylene homopolymer and / or propylene block polymer: high density polyethylene: linear low density polyethylene is 55 to 75:35 to 15: 3 to 18, especially 60 to 70:30 to 20: 5. It is set to ~ 15. If the compounding ratio of the resin is within such a range, the formability, appearance, and physical properties of the laminated sheet can be further improved in a well-balanced manner.

Regarding (Requirement 1), the mass ratio of the resin component to the inorganic substance powder (total of polypropylene-based resin and polyethylene-based resin: inorganic substance powder) in the inner layer is 10:90 to 50:50, preferably 20: It is 80 to 45:55, more preferably 30:70 to 40:60.

The upper limit of the content of the resin component is preferably 40% by mass or less, more preferably 35% by mass or less, based on the entire inner layer. The lower limit of the content of the resin component is preferably 15% by mass or more, more preferably 25% by mass or more, based on the entire inner layer.

The upper limit of the content of the inorganic substance powder is preferably 80% by mass or less, more preferably 70% by mass or less, based on the entire inner layer. The lower limit of the content of the inorganic substance powder is preferably 55% by mass or more, more preferably 60% by mass or more, based on the entire inner layer.

Regarding (Requirement 2), the content of zinc stearate is 0.1% by mass or more and 1.0% by mass or less with respect to the entire inner layer. The lower limit of the zinc stearate content is preferably 0.2% by mass or more, more preferably 0.3% by mass or more, based on the entire inner layer. The upper limit of the zinc stearate content is preferably 0.9% by mass or less, more preferably 0.8% by mass or less, based on the entire inner layer.

Regarding (Requirement 3), the content of stearic acid is 0.1% by mass or more and 1.6% by mass or less with respect to the entire inner layer. The lower limit of the content of stearic acid is preferably 0.2% by mass or more, more preferably 0.3% by mass or more, based on the entire inner layer. The upper limit of the content of stearic acid is preferably 1.5% by mass or less, more preferably 1.4% by mass or less, based on the entire inner layer.

Regarding (Requirement 4), the mass ratio of zinc stearate to stearic acid (zinc stearate: stearic acid) in the inner layer is 1: 1 to 1: 4, preferably 1: 1 to 1: 3. It is preferably 1: 1 to 1: 2.

Regarding (Requirement 5), the content of the polyethylene wax is 0.5% by mass or more and 3.0% by mass or less with respect to the entire inner layer. The lower limit of the content of the polyethylene wax is preferably 0.6% by mass or more, more preferably 0.7% by mass or more, based on the entire inner layer. The upper limit of the content of the polyethylene wax is preferably 2.5% by mass or less, more preferably 2.0% by mass or more, based on the entire inner layer.

[Other components in the inner layer]
The inner layer of the laminated sheet of the present invention may further contain any component in addition to the above components as long as the effect of the present invention is not impaired. Such components can be used alone or in combination of two or more. In addition, the type and blending amount of such a component can be appropriately set according to the effect to be obtained and the like.

Ingredients that can be contained in the inner layer include lubricants (other than zinc stearate and polyethylene wax), dispersants (other than stearic acid), plasticizers and softeners (other than polyethylene wax), polypropylene resins, and polyethylene resins. Examples thereof include deterioration inhibitors such as resins, antistatic agents, coloring agents, and antioxidants, flame retardant agents, and foaming agents.

(Glidant)
As the lubricant, any one that can be blended in a general-purpose resin composition can be used, and examples thereof include paraffin wax, sorbitan ester, glycerin ester, magnesium stearate, stearoamide and the like. However, in the present invention, since the inner layer contains zinc stearate and polyethylene wax that can also function as a lubricant, the composition may be such that the lubricant as described above is not separately added.

(Dispersant)
Examples of the dispersant include sodium polyacrylic acid, polyglycerin fatty acid ester, sorbitan fatty acid ester and the like.

(Plasticizer)
Examples of the plasticizer include acetyltributyl citrate, triethyl citrate, acetyltriethyl citrate, dibutyl phthalate, diaryl phthalate, dimethyl phthalate, diethyl phthalate, di-2-methoxyethyl phthalate, dibutyl tartrate, o. -Benzoylbenzoic acid ester, diacetin, epoxidized soybean oil and the like can be mentioned. However, in the present invention, since the inner layer contains a polyethylene-based wax that can also function as a plasticizer, the composition may be such that the above-mentioned plasticizer is not separately blended.

(Softener)
Examples of the softening agent include, but are not limited to, hydrocarbon oils such as paraffin oils, naphthenic oils and aromatic oils; vegetable oils such as castor oil, linseed oil and epoxidized soybean oil. By blending these softeners in an amount of, for example, 0.5 to 5% by mass, particularly about 1 to 2% by mass with respect to the entire inner layer, flexibility is imparted to the inner layer, and the formability of the entire laminated sheet and the machine It is possible to further improve the strength. However, in the present invention, since the inner layer contains a polyethylene-based wax that can also function as a softener, the composition may be such that the softener as described above is not separately blended.

(Polypropylene resin and resin other than polyethylene resin)
As a resin other than polypropylene-based resin and polyethylene-based resin,
Polyolefin resins such as polypropylene resins, polymethyl-1-pentene, ethylene-cyclic olefin copolymers;
Polyamide-based resins such as nylon-6, nylon-6,6, nylon-6,10, nylon-6,12;
Aromatic polyester resins such as polyethylene terephthalate and its copolymers, polyethylene naphthalate, and polybutylene terephthalate;
Polystyrene resins such as atactic polystyrene, syndiotactic polystyrene, acrylonitrile-styrene (AS) copolymer, acrylonitrile-butadiene-styrene (ABS) copolymer;
Polyvinyl chloride resin such as polyvinyl chloride and polyvinylidene chloride;
Polyphenylene sulfide;
Examples thereof include polyether resins such as polyethersulphon, polyetherketone, and polyetheretherketone.
However, from the viewpoint that the effect of the present invention can be easily exerted, the inner layer in the laminated sheet of the present invention does not contain a resin other than the polypropylene-based resin and the polyethylene-based resin, or even if it contains a small amount (for example, with respect to the entire inner layer). 1.0% by mass or less) is preferable.

As the colorant, any of conventionally known organic pigments, inorganic pigments or dyes can be used. Examples of the organic pigment include azo-based, anthraquinone-based, phthalocyanine-based, quinacridone-based, isoindoleinone-based, geoosazine-based, perinone-based, quinophthalone-based, and perylene-based pigments. Examples of the inorganic pigment include ultramarine, titanium oxide, titanium yellow, iron oxide (red ocher), chromium oxide, zinc oxide, carbon black and the like.

Examples of the antioxidant include phosphorus-based antioxidants, phenol-based antioxidants, pentaerythritol-based antioxidants, and the like.

Examples of the flame retardant include halogen-based flame retardants, phosphorus-based flame retardants, non-phosphorus-based non-halogen flame retardants such as metal hydrates, and the like.

Examples of the effervescent agent include aliphatic hydrocarbons (propane, butane, pentane, hexane, heptane, etc.), alicyclic hydrocarbons (cyclobutane, cyclopentane, cyclohexane, etc.), halogenated hydrocarbons (chlorodifluoromethane, etc.). , Dichlorofluoromethane, trifluoromethane, trichlorofluoromethane, dichloromethane, dichlorofluoromethane, dichlorodifluoromethane, chloromethane, chloroethane, dichlorotrifluoroethane, dichloropentafluoroethane, tetrafluoroethane, difluoroethane, pentafluoroethane, trifluoroethane, dichloro Examples thereof include tetrafluoroethane, trichlorotrifluoroethane, tetrachlorodifluoroethane, perfluorocyclobutane, etc.), inorganic gases (carbon dioxide, nitrogen, air, etc.), water, and the like.

[Manufacturing method of inner layer]
The inner layer of the laminated sheet of the present invention can be produced by using the above-mentioned components based on a method conventionally known as a method for producing a general-purpose sheet or the like. For example, it can be produced by mixing components, melt-kneading, molding into a sheet-like material or a film-like material, and the like.

The timing of mixing and melt-kneading can be appropriately set according to the molding method (extrusion molding, injection molding, vacuum forming, etc.) to be adopted. For example, the mixing may be performed before charging from the hopper of the molding machine or at the same time as molding. The melt kneading may be performed by, for example, a twin-screw kneader or the like. Further, it is also possible to manufacture the inner layer at the same time as forming the outer layer by a manufacturing method such as coextrusion.

<Outer layer>
The laminated sheet of the present invention includes an outer layer containing a polypropylene-based resin laminated on both sides of the inner layer. Since the outer layer contains a polypropylene-based resin, the physical properties such as the formability, heat resistance, and mechanical strength of the laminated sheet can be made excellent in a well-balanced manner.

In a preferred embodiment of the laminated sheet of the present invention, 80% by mass, more preferably 90% by mass or more, still more preferably 95% by mass or more of the entire outer layer is composed of polypropylene-based resin. The outer layer of the laminated sheet of the present invention is made of a polypropylene resin except for a small amount of additives and an unavoidable mixture (for example, a polymerization catalyst and a polymerization inhibitor used in the production of a polypropylene resin, a by-product resin, etc.). Is preferable.

Here, "consisting of polypropylene-based resin" means that, for example, 97% by mass or more, particularly 99% by mass or more of the outer layer is composed of polypropylene-based resin and does not substantially contain other resins or inorganic substance powder fillers. Means. It does not mean that the inclusion of a small amount of the additive is excluded, and the above-mentioned additive to be blended in the inner layer can also be blended in the outer layer. For example, the outer layer contains 0.1 to 2.0 parts by mass of processing aids such as lubricants, plasticizers and antistatic agents, deterioration inhibitors such as antioxidants, and coloring agents such as carbon black and pigments. In particular, it may be contained in an amount of about 0.2 to 1.0 parts by mass.

(Polypropylene resin in the outer layer)
The polypropylene-based resin constituting the outer layer is not limited, and the same polypropylene-based resin as described above can be used as the component of the inner layer. For example, the same resin as the polypropylene-based resin selected as the component of the inner layer may be used, or another kind of polypropylene-based resin may be used. It is also possible to use a plurality of types of polypropylene-based resins in combination.

It is desirable that the polypropylene-based resin constituting the outer layer is preferably composed of propylene homopolymer in an amount of 50% by mass or more, more preferably 80% by mass or more, and particularly preferably the unavoidable mixture. The propylene homopolymer is not particularly limited, and for example, the resin exemplified as a component of the inner layer can be used.

The polypropylene-based resin constituting the outer layer also has an MFR (230 ° C.) of about 0.3 to 5.0 g / 10 minutes, especially an MFR (230 ° C.) of 0.3 to 3.0 g / 10 minutes. The melt tension (230 ° C.) is preferably about 5 to 30 g. If the resin constituting the outer layer has such melting characteristics, it is possible to easily produce a laminated sheet having excellent bondability with the inner layer and having good appearance and physical properties.

<Manufacturing method of laminated sheet>
The laminated sheet of the present invention can be produced from the above-mentioned raw materials by any known method. For example, the inner layer and the outer layer molded into a sheet shape may be laminated by a calendar roll, or the inner layer and the outer layer may be coextruded to form a laminated sheet. For example, using a multi-layer T-die type twin-screw extrusion molding machine, it is also possible to perform melt kneading of raw materials for the inner layer and coextrusion molding of the inner and outer layers in the same process. It is also possible to apply an extrusion inflation method using a plurality of annular dies.

[T-die method]
As the T-die type molding machine, a known multi-manifold die, a feed block, a static mixer, or the like can be used. For example, a feed block having 11 or more fine slits may be used. By using such a feed block, there are few foreign substances due to thermal deterioration, and high-precision lamination is possible.

A casting film is obtained by extruding a laminated sheet discharged from a die onto a cooling body such as a casting drum and cooling and solidifying the laminated sheet. At this time, an electrode such as a wire, a tape, a needle, or a knife may be used to bring the discharged sheet into close contact with the cooling body by electrostatic force to quench and solidify the sheet. As a method of bringing the discharged sheet into close contact with the cooling body, a method of blowing air from a slit-shaped, spot-shaped or planar device, and a method of using a nip roll are also preferable.

(Stretching)
The extruded laminated sheet may or may not be subsequently subjected to a stretching step. For example, by stretching 1.01 to 10.0 times, particularly 1.1 to 3.0 times, in the uniaxial direction or the multiaxial direction in the vertical direction and / or the horizontal direction, the adhesion between layers and the surface appearance can be obtained. Furthermore, it is possible to improve the mechanical strength.

For example, when forming a casting film, longitudinal stretching can be performed at a temperature higher than the glass transition temperature of polypropylene resin or the like by 10 ° C. or more, with a peripheral speed difference between roll groups such as casting drums. Lateral stretching can be performed, for example, by hanging the molded sheet on a tenter.

[Inflation method]
There are no particular restrictions on the inflation method. For example, an extruder with an annular die is used to extrude the laminate of the inner and outer layers into a tube shape, and air supplied from a blower or the like is blown to cool and solidify the laminate, and then the laminated sheet (film) is taken up by a take-up machine. ) Can be manufactured. As the molding machine, blower, film picking machine and the like that can be used in this molding method, a wide range of commercially available devices can be used.

The conditions of the air-cooled inflation method are not particularly limited, but for example, the die diameter is φ50 mm to φ500 mm, the die lip width is 0.8 mm to 4.0 mm, the blow ratio is 1.5 to 5, the molding temperature is 170 to 250 ° C., and particularly 170. Good molding stability can be realized by setting the molding speed to about ~ 220 ° C. and the molding speed to 5 to 100 m / min, particularly 10 to 50 m / min.

In addition to the air-cooled inflation method, it is also possible to manufacture a laminated sheet by applying a method such as a water-cooled inflation method or a tubular biaxial stretching method. Further, the laminated sheet can also be stretched by appropriately using sequential biaxial stretching by a tenter, simultaneous biaxial stretching, and simultaneous biaxial stretching by a double inflation device.

<Characteristics of laminated sheet>
Since the laminated sheet of the present invention has an inner layer and an outer layer having the above-mentioned composition, it is excellent in molding processability, exhibits a good appearance, and is also excellent in physical properties such as mechanical properties and heat resistance. It also has the advantage that delamination is unlikely to occur. Moreover, since it is excellent in molding processability, it is useful as a material for various molded products.

In a preferred embodiment of the laminated sheet of the present invention, the inner layer contains 55 to 80% by mass of inorganic substance powder, and the thickness of the outer layer composed of polypropylene-based resin is 2 to 2 to the thickness of the entire laminated sheet. It is 10%. Therefore, the ratio of the inorganic substance powder to the entire laminated sheet is typically about 45 to 75% by mass, particularly about 50 to 65% by mass. Further, as a result, the specific gravity of the entire laminated sheet is approximately 1.15 to 1.75, particularly about 1.35 to 1.55.

As described above, the laminated sheet of the present invention does not necessarily have a large specific gravity even though the inner layer contains a large amount of inorganic substance powder. Therefore, the molded product made of the laminated sheet of the present invention has an advantage of having not only heat resistance and flame retardancy but also light weight. The laminated sheet of the present invention is also useful as a material for various molded products from this point.

≪Molded product≫
The laminated sheet of the present invention can be used as it is as a sheet-like material or a film-like material, but can be molded into various molded products by molding by an arbitrary molding method.

There are no restrictions on the uses and shapes of molded products, and molded products include, for example, films, sheets, containers (food containers, etc.), daily necessities (various disposable products, etc.), automobile parts, electrical and electronic parts, and various consumables (building). It can be something in the field of members, etc.).

<Food packaging container>
Since the outer layer of the laminated sheet of the present invention is made of a polypropylene-based resin, it has the advantages of having a clean surface and being resistant to contamination. Therefore, the laminated sheet of the present invention is particularly useful as a material for food packaging containers. The present invention also includes a food packaging container made of the above-mentioned laminated sheet.

<Molding method>
The method for forming the laminated sheet of the present invention is not particularly limited, and any method according to the intended use and shape can be adopted. For example, one end of a cylindrical laminated sheet after inflation molding can be heat-sealed and molded into a bag-shaped object such as a plastic shopping bag. It is also possible to process into more complicated shapes. As described above, the laminated sheet of the present invention is excellent in molding processability and mechanical properties and is unlikely to cause delamination, so that it is useful as various molding materials, and can be used, for example, as a vacuum forming laminated sheet.

<Laminate sheet for vacuum forming>
The present invention also includes the above-mentioned laminated sheet, which is a laminated sheet for vacuum forming.

(Vacuum forming)
In vacuum forming, a sheet or plate-shaped thermoplastic resin is softened by applying heat, and it is pressed against the mold to suck the air between the thermoplastic resin and the mold from below, creating a state close to vacuum, and the mold is created. This is a molding method in which a thermoplastic resin is brought into close contact with the material to create a desired shape. It has the advantages that products of various shapes such as large size and thin-walled molded products can be manufactured at low cost, partial design changes are easy, and small lot production is possible. Therefore, it is used in the manufacture of various molded products such as food trays and food packs. The laminated sheet of the present invention is extremely useful as a material for such vacuum forming.

Hereinafter, the present invention will be described in more detail by way of examples, but the present invention is not limited to these examples.

[Example 1, Comparative Example 1]
<Manufacturing of laminated sheet>
Each component shown in Table 1 described later was mixed and kneaded using an HTM50 type non-directional rotary twin-screw extruder (manufactured by CTC Co., Ltd.) to prepare raw material pellets for an inner layer. The pellets prepared in this way and the polypropylene resin-1 pellets described later are melt-extruded using a screw extruder, the inner and outer layers are co-extruded from the feed block type T-die, and then quenched on a cooling roll. Then, a three-layer sheet having an inner layer thickness of about 0.36 mm and each outer layer thickness of about 0.02 mm was obtained. The unit of the numerical value of the composition in the table is "mass%".

In the table, "lubricant: dispersant" means the mass ratio of the lubricant to the dispersant contained in the inner layer. "Zn stearate: stearic acid" means the mass ratio of zinc stearate to the lubricant stearate contained in the inner layer.

The details of each component in the laminated sheet are as follows. Hereinafter, the "average particle size" is a value calculated from the measurement result of the specific surface area by the air permeation method according to JIS M-8511 using the specific surface area measuring device "SS-100 type" manufactured by Shimadzu Corporation. Is.

(Polypropylene resin)
-Polypropylene resin-1: propylene homopolymer, MFR (230 ° C): 0.5 g / 10 minutes-Polypropylene resin-2: Block polypropylene (polyethylene and ethylene-propylene copolymer block phases are dispersed in homopolypropylene. Structure), MFR (230 ° C): 0.5 g / 10 minutes

(Polyethylene resin)
-Polyethylene resin-1: High-density polyethylene, density: 0.950 g / cm ³ , MFR (190 ° C, 21.6 kg): 7.5 g / 10 minutes-Polyethylene resin-2: Linear low-density polyethylene, Density: 0.918 g / cm ³ , MFR (190 ° C, 2.16 kg): 1.0 g / 10 minutes

(Inorganic substance powder)
-Heavy calcium carbonate particles (average particle size: 2.2 μm, no surface treatment)

(Glidant)
・ Zn stearate: Zinc stearate ・ Mg stearate: Magnesium stearate ・ Stearoamide

(Dispersant)
・ Stearic acid / Na polyacrylic acid: Sodium polyacrylate

(Softener)
・ PE wax: Polyethylene wax ・ Oil: Hydrocarbon oil

<Vacuum forming of laminated sheet>
The laminated sheet produced as described above was preheated with a far-infrared heater, and then molded into a tray-shaped container having a bottom diameter of 50 mmφ, an opening diameter of 50 mmφ, a height of 30 mm, and a flange width of 5 mm by a vacuum forming machine. The obtained container was evaluated for formability, appearance, and strength according to the following criteria. The test results are shown in Tables 1 and 2 below, together with the composition of the inner layer.

(Formability)
Each container after molding was visually observed and measured, and the ease of molding of each laminated sheet was evaluated according to the following criteria.
A: It was molded to the size of the target value, and no distortion of the shape was observed.
B: A part of the dimensions was different from the target value, but no distortion of the shape was visually observed.
C: Slight distortion of the container shape was visually observed.
D: The shape of the container was clearly distorted.

(Appearance of molded product)
The surface condition of the molded container obtained from each laminated sheet was visually observed and evaluated according to the following criteria.
A: Very smooth and good appearance.
B: It has a smooth appearance, though not as much as A.
C: Some unevenness is observed on the surface.
D: Many irregularities are observed on the surface.

(Strength of molded product)
The molded container obtained from each laminated sheet was bent with both hands, and the mechanical strength was evaluated according to the following criteria.
A: No cracks, tears, or delamination occurred at the degree of bending.
B: Bending caused some cracks and delamination.
C: Due to bending, large cracks, crevices, and delamination occurred.
D: It broke when bent.

As shown in Table 1, any of the laminated sheets of Examples 1-1 to 1-3 in which the inner layer contains all the essential components of the present invention and all of the above (Requirements 1) to (Requirements 5) are satisfied. However, the moldability, the appearance of the molded product, and the strength of the molded product were well-balanced and excellent. On the other hand, in the laminated sheets of Comparative Examples 1-1 to 1-7 in which any of the essential components of the inner layer is not contained or even one of (Requirements 1) to (Requirements 5) is not satisfied, the formability and the molded product are formed. The appearance of the product and the strength of the molded product were both poor.

Except that the blending amount of polypropylene-based resin-1 was 5% by mass, the blending amount of polyethylene-based resin-1 and polyethylene-based resin-2 was 1% by mass, and the blending amount of inorganic substance powder was 90% by mass. An attempt was made to prepare a laminated sheet with the same composition as in Example 1-2 (Comparative Example 1-8), but it was impossible to prepare raw material pellets for an inner layer.

[Example 2, Comparative Example 2]
As the polypropylene-based resin for the inner layer, polypropylene-based resin-2 was used instead of polypropylene-based resin-1, and the same operation as in Example 1 was carried out except that the composition of the inner layer was as shown in Table 2. The evaluation results are shown in Table 2 together with the composition of the inner layer.

As shown in Table 2, the laminates of Examples 2-1 to 2-4 of the present invention in which the inner layer contains all the essential components of the present invention and all of the above (Requirements 1) to (Requirements 5) are satisfied. In the sheet, the moldability, the appearance of the molded product, and the strength of the molded product were well-balanced and excellent. On the other hand, the laminated sheets of Comparative Examples 2-1 to 2-6 that do not contain any of the essential components of the inner layer or do not satisfy even one of (Requirements 1) to (Requirements 5) have a moldability and a molded product. The appearance of the product and the strength of the molded product were both poor.

In the above test, even when an inflation molded product was produced instead of the extruded molded product, the same tendency as described above was shown.

1 Laminated sheet 11 Inner layer 12 Outer layer 13 Outer layer

Claims (8)

A laminated sheet including an inner layer and an outer layer laminated on both sides of the inner layer.
The inner layer contains polypropylene-based resin, polyethylene-based resin, inorganic substance powder, zinc stearate, stearic acid, and polyethylene-based wax.
The polypropylene-based resin, the polyethylene-based resin, and the polyethylene-based wax are different components from each other.
The mass ratio of the total of the polypropylene-based resin and the polyethylene-based resin to the inorganic substance powder is 10:90 to 50:50.
The content of the zinc stearate is 0.1% by mass or more and 1.0% by mass or less with respect to the entire inner layer.
The content of the stearic acid is 0.1% by mass or more and 1.6% by mass or less with respect to the entire inner layer.
The mass ratio of the zinc stearate to the stearic acid is 1: 1 to 1: 4.
The content of the polyethylene wax is 0.5% by mass or more and 3.0% by mass or less with respect to the entire inner layer, and the outer layer contains a polypropylene resin.
Laminated sheet. The polyethylene resin is
High-density polyethylene with an MFR (190 ° C., 21.6 kg) of 5 g / 10 minutes or more and 15 g / 10 minutes or less according to JIS K 6922-1 (ISO1133).
Includes linear low density polyethylene with MFR (190 ° C., 2.16 kg) according to JIS K 6922-1 (ISO1133) of 0.5 g / 10 min or more and 1.5 g / 10 min or less.
The mass ratio of the high-density polyethylene to the linear low-density polyethylene is 90:10 to 50:50.
The laminated sheet according to claim 1. The laminated sheet according to claim 1 or 2, wherein the polypropylene-based resin in the inner layer is a propylene homopolymer and / or a propylene block polymer. The laminated sheet according to any one of claims 1 to 3, wherein the inorganic substance powder is heavy calcium carbonate. The laminated sheet according to claim 4, wherein the average particle size of the heavy calcium carbonate by an air permeation method according to JIS M-8511 is 0.7 μm or more and 6.0 μm or less. The laminated sheet according to any one of claims 1 to 5, wherein the thickness of the outer layer is 2% or more and 10% or less, respectively, of the thickness of the entire laminated sheet. The laminated sheet according to any one of claims 1 to 6, which is a laminated sheet for vacuum forming. A food packaging container made of the laminated sheet according to any one of claims 1 to 7.

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