JPWO2016159260A1 - 容器用ラミネート金属板 - Google Patents
容器用ラミネート金属板 Download PDFInfo
- Publication number
- JPWO2016159260A1 JPWO2016159260A1 JP2016545384A JP2016545384A JPWO2016159260A1 JP WO2016159260 A1 JPWO2016159260 A1 JP WO2016159260A1 JP 2016545384 A JP2016545384 A JP 2016545384A JP 2016545384 A JP2016545384 A JP 2016545384A JP WO2016159260 A1 JPWO2016159260 A1 JP WO2016159260A1
- Authority
- JP
- Japan
- Prior art keywords
- metal plate
- laminated
- layer
- resin layer
- film
- Prior art date
- 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.)
- Granted
Links
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- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 claims abstract description 43
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 claims abstract description 24
- WERYXYBDKMZEQL-UHFFFAOYSA-N butane-1,4-diol Chemical compound OCCCCO WERYXYBDKMZEQL-UHFFFAOYSA-N 0.000 claims abstract description 20
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Images
Classifications
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- B32B15/09—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyesters
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Abstract
Description
本発明において下地となる金属板2は、缶用材料として広く使用されている鋼板やアルミニウム板を用いることができ、特に下層が金属クロム、上層がクロム水酸化物となる二層皮膜の表面処理鋼板であるティンフリースチール(以下TFS)などが好適である。TFSの金属クロム、およびクロム水酸化物層の付着量は特に限定されないが、加工性や耐食性の観点から、金属クロム層は70〜200mg/m2、クロム水酸化物層は10〜30mg/m2の範囲とすることが望ましい。
本発明において金属板2にラミネートされるフィルム3は、ポリエステルを主成分とする少なくとも2層の積層樹脂層で構成され、二軸延伸されることなく無延伸のまま製膜されたものが使用される。過去に検討されてきた二軸延伸フィルムは、延伸工程により樹脂の分子鎖が特定方位に配向した配向結晶を有しており、フィルム強度は増すものの延性は損なわれる。この配向結晶が多く残存した場合、加工性を阻害する要因になる。このように二軸延伸フィルムラミネート金属板は、ラミネート時の入熱により大きく性能が変化し、そのコントロールに細心の注意を払う必要がある。特に、DI缶のような加工度の大きい成形では、樹脂の融点近傍の高温でラミネートして配向結晶をほとんどアモルファス(非晶)化させることで成形性を向上させている。その場合、高温ゆえにフィルムが流動し、金属板へのラミネート時に圧着ロールへの付着が発生するなどして生産性が落ちる要因になる可能性がある。無延伸フィルムであれば、ラミネート条件の緻密な制御を行う必要がないため、ラミネート性に優れている。
積層樹脂層の下層3aに形成される金属板2と接するポリエステル樹脂層は、レトルト殺菌処理後の白化を抑制するため、多価カルボン酸成分としてテレフタル酸を主成分とし、多価アルコール成分としてエチレングリコールと1,4−ブタンジオールを主成分とするポリエステルから構成される。多価カルボン酸成分のうちテレフタル酸が90モル%以上であり、好ましくは95モル%以上である。90モル%未満の場合、耐レトルト白化性を損ねる。多価アルコール成分中のエチレングリコールは30〜50モル%、1,4−ブタンジオールが50〜70モル%、それ以外の多価アルコール成分が10モル%以下である。エチレングリコールが30モル%より少ないと加工後の密着性を損ね、50モル%超になると耐レトルト白化性を損ねる。本発明の効果を妨げない範囲で、他のモノマーを10モル%以下共重合してもよい。
金属板2と接する下層3aのポリエステル樹脂層の上層3bに位置する表面側のポリエステル樹脂層(以下、主層とする)は、多価カルボン酸成分としてテレフタル酸を主成分とし、多価アルコール成分として1,4−ブタンジオールを主成分とするポリエステルから構成される。多価カルボン酸成分として、10モル%以下のテレフタル酸以外の多価カルボン酸を共重合したテレフタル酸を主成分としてもよい。例えば、多価カルボン酸成分として、10モル%以下のイソフタル酸を共重合したテレフタル酸を主成分とする。
上記主層3bに顔料が添加された場合に、レトルト後に色調が変化するのを抑制するために、上記した2層の積層樹脂層のさらに上層(すなわち、主層3bのさらに上層)に最表層3cを形成するとよい。最表層3cのポリエステル樹脂層の厚みは、色調変化の抑制を安定して確保するために、1μm以上とすることが好ましい。膜厚上限としては、樹脂層全体が膜厚上限を超えない膜厚が確保されていればよい。樹脂組成は特に限定されるものではないが、製膜上の観点から金属板2と接する下層3aまたはその上層の主層3bと融点差が20℃以内であることが好ましく、同等の樹脂組成である事がさらに好ましい。
本発明は、加工性の観点から膜厚上限があり、限られた膜厚内で耐レトルト白化性、加工性、密着性、製缶後密着性を確保するために、積層樹脂層の上層(主層)3bと下層3aとの膜厚比率を特定の範囲とすることが好ましく、金属板2と接する下層3aの膜厚は、上層3bと下層3aとの合計膜厚の5%以上50%以下であることが好ましく、10%以上30%以下であることがさらに好ましい。膜厚比が10%未満だと製缶後の密着性に劣る場合がある。30%超の場合、性能上の劣化は無いが、生産性に劣る場合があるためコストアップにつながり好ましくない。
フィルム3全体の厚さは、金属板2にラミネートされた後の成形性、金属板2に対する被覆性、耐衝撃性、味特性の点で、内面側、外面側とも、3〜25μmであり、好ましくは8〜20μmである。フィルム厚みを3μm未満の薄膜とするためには、製膜上コストアップし、性能の安定的な確保も難しく、25μm超だと、コストアップする上、製缶性がかえって劣化するためである。
容器に加工前の本発明のフィルム3は、加工性の観点から、X線回折で、2θ=22.5°〜24.0°の範囲内に見られるピークの強度(I100)に対する2θ=15.5°〜17.0°の範囲内に見られるピークの強度(I011)の比(I011/I100)が0.2〜5.0の範囲内にあることを特徴とする。ポリブチレンテレフタレートは、結晶化速度が速いため延伸処理していなくても結晶が形成される。このように、ポリブチレンテレフタレートの結晶が形成されると、加工性に影響を及ぼすため、結晶量の制御が必要となる。
本発明のフィルム3の製造方法としては、公知のポリエステルフィルムの製造方法が適用できる。一例を挙げると、押出機を用いて樹脂ペレットをポリエステル樹脂の融解温度より高い温度で加熱溶融して、溶融したポリエステル樹脂をTダイからフィルム状に冷却したキャスティングロール上に押し出し、延伸せずに無延伸樹脂フィルムとしてコイラーに巻き取る。本発明のフィルム3には、金属板2との熱圧着性およびその後の密着性を更に向上させる目的で、共押出法やラミネート加工、あるいはコーティング加工により接着層を設けることができる。接着層は乾燥膜厚で1μm以下であることが好ましい。接着層は、特に限定されないが、エポキシ樹脂、ポリウレタン樹脂、ポリエステル樹脂やこれらの各種変性樹脂からなる熱硬化性樹脂層であることが好ましい。
金属板2を予め170〜250℃まで予熱しておき、これと本発明のフィルム3とを、金属板2より30℃、更には50℃以上低く温度制御されたロールによって圧接して熱圧着させた後、室温まで冷却する。これにより、本発明のフィルム3が連続的に金属板2にラミネートされ、ラミネート金属板1が製造される。
厚さ0.22mmの冷間圧延、焼鈍、調質圧延を施した鋼板(調質度T3CA)を、脱脂、酸洗後、クロムめっきを行い、クロムめっき鋼板(TFS)を製造した。クロムめっきは、CrO3、F−、SO4 2−を含むクロムめっき浴でクロムめっき、中間リンス後、CrO3、F−を含む化成処理液で電解した。その際、電解条件(電流密度・電気量など)を調整して金属クロム付着量とクロム水酸化物付着量を、Cr換算でそれぞれ120mg/m2、15mg/m2に調整した。
DI成形では、まずラミネート鋼板の両面に融点45℃のパラフィンワックスを50mg/m2塗布した後に、123mmφのブランクを打ち抜き、そのブランクを市販のカッピングプレスで、内径71mmφ、高さ36mmのカップに絞り成形した。次いでこのカップを市販のDI成形装置に装入して、ポンチスピード200mm/s、ストローク560mmで、再絞り加工および3段階のアイアニング加工で総リダクション率50%(それぞれのリダクション20%、19%、23%)を行い、最終的に缶内径52mmφ、缶高さ90mmの缶を成形した。なお、DI成形中には、水道水を50℃の温度で循環させた。製缶後の表面のスクラッチ状態を評価した(後述の(4)参照)。缶の内外面を対象とし、DI成形後の缶に125℃、60分間の条件でレトルト殺菌処理を実施した。この缶をレトルト殺菌処理装置から取り出した後に、成形後密着性として、缶口からのフィルム剥離が発生しているか否か、また剥離している場合には剥離長さ(缶口から何mm剥離しているか)を以下の評点で評価した。
◎:発生せず
○:5(mm)未満
△:20(mm)未満、5(mm)以上
×:20(mm)以上
成形可能であった缶の底部(缶外面側)を対象として耐レトルト白化性を評価した。具体的に、缶内に常温の水道水を満たした後、蓋を巻き締めて密閉した。その後、缶底部を下向きにして、蒸気式レトルト殺菌炉の中に配置し、125℃で90分間、レトルト殺菌処理を行った。レトルト殺菌処理の終了後、急速冷却を施し、底部の缶外面側の外観変化を目視で観察し、以下の評点で耐レトルト白化性を評価した。
◎:外観変化なし
○:外観にかすかな曇り(フィルム表面積で5%未満)発生
△:外観にかすかな曇り(フィルム表面積で5%以上10%未満)発生
×:外観が白濁(フィルム表面積で10%以上白化発生)
着色顔料(白、黄)が添加されたフィルムにおいて、レトルト殺菌処理後に色調が変化する場合があるため、耐変色性評価として、レトルト殺菌処理前後の色調変化を評価した。レトルト殺菌処理前後の表面色調は、日本電色工業製の分光色彩計SQ−2000を用いて調査した。レトルト殺菌処理前をL1 *、a1 *、b1 *、レトルト殺菌処理後を、L2 *、a2 *、b2 *として、次式(1)によりΔE*を求めた。耐変色性は、ΔE*に基づいて、以下の評点で評価した。
◎:ΔE*≦5.0
○:5.0<ΔE*≦10
×:ΔE*>10
上記(1)の成形後密着性の評価時に、DI成形を行った際に外面側に発生したスクラッチの面積率を目視して、以下の評点で製缶性を評価した。
◎:0%
○:5%未満
△:20%未満、5%以上
×:20%以上
2 金属板
3 フィルム
3a 積層樹脂層の下層
3b 積層樹脂層の上層(主層)
3c 積層樹脂層3bのさらに上層(最表層)
Claims (4)
- 金属板の片面もしくは両面に多価カルボン酸成分と多価アルコール成分とが重合されたポリエステルを主成分とする少なくとも2層の積層樹脂層を具備した容器用ラミネート金属板であって、
前記積層樹脂層の金属板と接する下層のポリエステル樹脂層は、多価カルボン酸成分のうちテレフタル酸が90モル%以上であり、多価アルコール成分のうちエチレングリコールが30〜50モル%、1,4−ブタンジオールが50〜70モル%、それ以外の多価アルコール成分が10モル%以下であり、
前記積層樹脂層の上層の主層であるポリエステル樹脂層は、多価カルボン酸成分のうちテレフタル酸が90モル%以上であり、多価アルコール成分のうち1,4−ブタンジオールが90モル%以上となるポリエステルから構成され、合計厚みが3〜25μmであり、X線回折で、2θ=22.5°〜24.0°の範囲内に見られるピークの強度(I100)に対する2θ=15.5°〜17.0°の範囲内に見られるピークの強度(I011)の比(I011/I100)が0.2〜5.0の範囲内にあることを特徴とする容器用ラミネート金属板。 - 前記積層樹脂層のうち、金属板と接する下層の膜厚比率が樹脂の前記積層樹脂層の合計厚みに対して10〜30%であることを特徴とする請求項1に記載の容器用ラミネート金属板。
- 前記積層樹脂層に着色顔料が含有されることを特徴とする請求項1または2に記載の容器用ラミネート金属板。
- 前記積層樹脂層のさらに上層に、1μm以上のポリエステル樹脂が積層され、樹脂層全体の合計膜厚が3〜25μmであることを特徴とする請求項1〜3のいずれか1項に記載の容器用ラミネート金属板。
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PCT/JP2016/060725 WO2016159260A1 (ja) | 2015-03-31 | 2016-03-31 | 容器用ラミネート金属板 |
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US10815347B2 (en) * | 2016-08-11 | 2020-10-27 | Toray Plastics (America), Inc. | Blush-resistant film including pigments |
JP7195052B2 (ja) * | 2018-03-01 | 2022-12-23 | 東洋鋼鈑株式会社 | 容器用樹脂被覆金属板、その樹脂被覆金属板からなる容器、及びその樹脂被覆金属板の製造方法 |
JP7080125B2 (ja) * | 2018-07-30 | 2022-06-03 | 東洋鋼鈑株式会社 | ポリエステル樹脂被覆金属板、ポリエステル樹脂被覆金属板の製造方法、そのポリエステル樹脂被覆金属板からなる容器及び容器蓋 |
JP7028370B2 (ja) * | 2019-07-31 | 2022-03-02 | Jfeスチール株式会社 | 樹脂被覆金属板及び容器 |
MX2022001002A (es) * | 2019-07-31 | 2022-02-16 | Jfe Steel Corp | Lamina de metal recubierta con resina, contenedor y metodo para mejorar la propiedad de blanqueamiento en retorta. |
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WO2016159260A1 (ja) | 2016-10-06 |
CN107428131B (zh) | 2019-08-16 |
EP3278980A1 (en) | 2018-02-07 |
PH12017550089A1 (en) | 2018-02-12 |
ES2877517T3 (es) | 2021-11-17 |
AU2016240880A1 (en) | 2017-09-14 |
US10427381B2 (en) | 2019-10-01 |
US20180029334A1 (en) | 2018-02-01 |
AU2016240880B2 (en) | 2018-09-13 |
MY174920A (en) | 2020-05-21 |
KR20170125889A (ko) | 2017-11-15 |
CN107428131A (zh) | 2017-12-01 |
PH12017550089B1 (en) | 2018-02-12 |
CA2982829C (en) | 2020-02-25 |
JP6011753B1 (ja) | 2016-10-19 |
EP3278980A4 (en) | 2018-12-05 |
CA2982829A1 (en) | 2016-10-06 |
EP3278980B1 (en) | 2021-06-02 |
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KR101992556B1 (ko) | 2019-06-24 |
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