JP7146667B2 - 電子レンジ耐性を有する発泡断熱紙容器用シートの製造方法 - Google Patents
電子レンジ耐性を有する発泡断熱紙容器用シートの製造方法 Download PDFInfo
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- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
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- B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
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- B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
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Description
従来、この用途に使用される断熱容器としては、発泡ポリスチレン製の容器が知られていたが、容器全体を発泡させているため嵩が大きく、ゴミが増加するという問題があった。また、紙製の容器比べると強度が低く、硬い内容物(麺塊等)を入れたまま輸送すると破損しやすいという課題があった。
本発明の発泡断熱紙容器用シートを構成する紙基材には特に限定はないが、クラフト紙や上質紙を用いることができる。また、容器としての強靭さを実現する観点から紙基材の坪量は150~400g/m2好ましく、更に好ましくは、250~350g/m2である。さらに、ポリエチレンを好適に発泡させる観点から紙基材に含まれる水分は5~10重量%が好ましく、6~8重量%がより好ましい。
本発明におけるポリエチレン樹脂は、ラミネート適性及び発泡性に優れるため本発明において必須の成分である。ここで、発泡層に用いられるポリエチレン樹脂の密度は923~930 kg/m3である必要があり、924~926 kg/m3がより好ましい。密度923kg/m3未満のポリエチレン樹脂を使用すると、電子レンジ調理した際に発泡セル同士が結合して肥大化して、火脹れが生じる。また、容器が冷却されると、火膨れが発生した領域では発泡断熱層が潰れて、断熱性が損なわれる。
押出ラミネートの方法としては、シングルラミネート法、タンデムラミネート法、サンドウィッチラミネート法、共押出ラミネート法などを適宜選択することができる。
樹脂がエアギャップを通過する過程でポリエチレン樹脂表面に酸化被膜が生じる。この酸化被膜は内側のポリエチレン樹脂層と比較すると強靭であるため、部分的な過発泡を抑えて、均一な発泡層を実現することができる。したがって、酸化被膜を保持したままラミネートすることが重要である。
一般的に、Tダイから押し出されたポリエチレン樹脂の厚みは均一ではなく、Tダイから押し出された直後が最も厚く、ニップされる直前が最も薄くなる。さらに、エアギャップを広げた場合には、ニップ直前のポリエチレン樹脂の厚みは、エアギャップを広げる前よりもさらに薄くなる。このため、エアギャップを広げることで、ニップ直前のポリエチレン樹脂の厚みが薄くなり、ニップの際にポリエチレン樹脂に掛かる力が緩慢になるため、酸化被膜が消失を抑制することができる。
(工程1)紙基材の片面に、中密度ポリエチレン樹脂(A)を押出ラミネートして水蒸気遮断層を形成した。
(工程2)次いで非ラミネート面に低密度ポリエチレン樹脂(B)を押出ラミネートして発泡層を形成し、発泡断熱紙容器用シートC1(以下「シートC1」という)を製造した。ラミネート条件の詳細は以下の通りである。
紙基材:水分量23g/m2、坪量320g/m2
中密度ポリエチレン樹脂(A1):東ソー社製「ペトロセンLW04-1」、MFR6.5g/10分、密度940kg/m3
押出温度(Tダイ出口温度):320℃
引取速度(ラミネート速度):80m/分
エアギャップ:130mm
エアギャップ通過時間:0.10秒
厚さ:40μm(ポリエチレン樹脂層の中央部の厚さ)
低密度ポリエチレン樹脂(B1);密度925 kg/m3、融点112℃、MFR8.0g/10分
押出温度(Tダイ出口温度):320℃
引取速度(ラミネート速度):60m/分
エアギャップ:160mm
エアギャップ通過時間:0.16秒
厚さ:70μm(ポリエチレン樹脂層の中央部の厚さ)
実体顕微鏡(ニコン社製「MULTIZOOM AZ100M(カメラ:DS-Ri1)」)を用いて、シートC1~C7及びシートD1~D4から得られた発泡断熱容器の発泡層を観察した。この際、実施例1(図1)と同じように微細で均一な発泡セルが観察された場合を「○:良好」、比較例1(図2)に示すような大きく不均一な発泡セルが観察された場合を「×:不良」、実施例1と比較例1の間のレベルを「△:普通」とした。
発泡断熱紙容器に水200gを入れ、電子レンジ(1000W)で5分加熱処理し、処理直後の発泡断熱紙容器の外観を観察した。この際、火膨れが発生していないものを「○:良好」、直径5mm以下の火膨れが発生するものを「△:普通」、直径5mmより大きい火膨れが発生するものを「×:不良」とした。
Claims (3)
- 紙基材の少なくとも片面にポリエチレン樹脂をラミネートする発泡断熱紙容器用シートの製造方法であって、
ラミネート条件が、エアギャップ150mm以上、引取速度65m/分以下、であり、
且つ、
ポリエチレン樹脂の密度が923~930kg/m3である、ことを特徴とする発泡断熱紙容器用シートの製造方法。 - ポリエチレン樹脂の融点が111~115℃であることを特徴とする請求項1記載の発泡断熱紙容器用シートの製造方法。
- ラミネート後のポリエチレン樹脂の厚みが30~150μmであることを特徴とする請求項1又は2いずれか記載の発泡断熱紙容器用シートの製造方法。
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JP2019028273A JP7146667B2 (ja) | 2019-02-20 | 2019-02-20 | 電子レンジ耐性を有する発泡断熱紙容器用シートの製造方法 |
BR112021016475-8A BR112021016475A2 (pt) | 2019-02-20 | 2020-02-18 | Método para produzir uma folha resistente a microondas para um recipiente de papel de espuma com isolamento térmico |
US17/281,141 US20210339518A1 (en) | 2019-02-20 | 2020-02-18 | Method for producing microwave-resistant sheet for heat-insulating foamed paper container |
PCT/JP2020/006156 WO2020171032A1 (ja) | 2019-02-20 | 2020-02-18 | 電子レンジ耐性を有する発泡断熱紙容器用シートの製造方法 |
CN202080005243.8A CN112739525B (zh) | 2019-02-20 | 2020-02-18 | 具有耐微波性的发泡隔热纸容器用片材的制造方法 |
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US6521734B1 (en) * | 1997-09-30 | 2003-02-18 | Japan Polyolefins Co., Ltd. | Low-density polyethylene resin for laminating, composition thereof, laminates produced therefrom and process for producing the same |
JP6385701B2 (ja) * | 2014-04-01 | 2018-09-05 | 三井・デュポンポリケミカル株式会社 | 包装材用樹脂組成物及び包装用積層体 |
JP2019111650A (ja) * | 2017-12-20 | 2019-07-11 | 日本ポリエチレン株式会社 | 発泡性積層体及びそれを用いた発泡積層体並びに容器 |
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JP2005119147A (ja) | 2003-10-16 | 2005-05-12 | Kaneka Corp | ポリプロピレン系樹脂積層発泡シートの製造方法、積層発泡シート及びその成形体 |
JP2007090662A (ja) | 2005-09-28 | 2007-04-12 | Du Pont Mitsui Polychem Co Ltd | 発泡樹脂層を有する積層フィルム又はシートとその製造方法 |
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WO2008129653A1 (ja) | 2007-04-10 | 2008-10-30 | Du Pont-Mitsui Polychemicals Co., Ltd. | 発泡樹脂層を有する積層フィルム又はシートとその製造方法 |
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JP2015535035A (ja) | 2012-11-20 | 2015-12-07 | ダウ グローバル テクノロジーズ エルエルシー | 高い溶融強度を有する低密度エチレン系ポリマー |
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US20210339518A1 (en) | 2021-11-04 |
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