JPWO2020149174A1 - 紙容器用積層体および紙容器 - Google Patents
紙容器用積層体および紙容器 Download PDFInfo
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- JPWO2020149174A1 JPWO2020149174A1 JP2020566379A JP2020566379A JPWO2020149174A1 JP WO2020149174 A1 JPWO2020149174 A1 JP WO2020149174A1 JP 2020566379 A JP2020566379 A JP 2020566379A JP 2020566379 A JP2020566379 A JP 2020566379A JP WO2020149174 A1 JPWO2020149174 A1 JP WO2020149174A1
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- Prior art keywords
- unsaturated carboxylic
- carboxylic acid
- layer
- ethylene
- laminate
- 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.)
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Abstract
Description
なお、本実施形態において、「(メタ)アクリル酸」とはアクリル酸、メタクリル酸またはアクリル酸とメタクリル酸を意味し、エチレン・(メタ)アクリル酸・(メタ)アクリル酸エステル共重合体としてはエチレン・アクリル酸・アクリル酸エステル共重合体、エチレン・メタクリル酸・アクリル酸エステル共重合体、エチレン・アクリル酸・メタクリル酸エステル共重合体、エチレン・メタクリル酸・メタクリル酸エステル共重合体等が例示できる。
一方、前記エチレン・不飽和カルボン酸・不飽和カルボン酸エステル共重合体における不飽和カルボン酸に由来する構成単位の含有率の上限は、成膜加工性の観点から、20質量%以下が好ましく、15質量%以下がより好ましく、10質量%以下がさらに好ましい。
一方、前記エチレン・不飽和カルボン酸・不飽和カルボン酸エステル共重合体における不飽和カルボン酸エステルに由来する構成単位の含有率の上限は、加工性の観点から、20質量%以下が好ましく、15質量%以下がより好ましい。
第4の共重合成分としては、不飽和炭化水素(例えば、プロピレン、ブテン、1,3−ブタジエン、ペンテン、1,3−ペンタジエン、1−ヘキセン等)、ビニルエステル(例えば、酢酸ビニル、プロピオン酸ビニル等)、ビニル硫酸やビニル硝酸等の酸化物、ハロゲン化合物(例えば、塩化ビニル、フッ化ビニル等)、ビニル基含有1,2級アミン化合物、一酸化炭素、二酸化硫黄等が挙げられる。
第4の共重合成分に由来する構成単位のエチレン・不飽和カルボン酸・不飽和カルボン酸エステル共重合体中における含有比率は、生産・混合の観点から10質量%以下の範囲が好ましい。
第3の共重合成分に由来する構成単位のエチレン・不飽和カルボン酸共重合体中における含有比率は、生産・混合の観点から10質量%以下の範囲が好ましい。
上記エチレン・不飽和カルボン酸エステル共重合体に用いられる不飽和カルボン酸エステルとしては、炭素数4〜8の不飽和カルボン酸エステルが挙げられ、不飽和カルボン酸アルキルエステルが好ましく、具体的には、メタクリル酸イソブチル、メタクリル酸n−ブチル、メタクリル酸エチル、メタクリル酸メチル、アクリル酸イソブチル、アクリル酸n−ブチル、アクリル酸エチル、アクリル酸メチルの(メタ)アクリル酸エステルが挙げられる。これらの不飽和カルボン酸エステルは1種単独で用いてもよいし、2種以上を組み合わせて用いてもよい。これらの中でも、(メタ)アクリル酸イソブチルおよび(メタ)アクリル酸n−ブチルから選択される少なくとも1種(すなわち(メタ)アクリル酸ブチル)が好ましい。
なお、本実施形態において、「(メタ)アクリル酸」とは、アクリル酸、メタクリル酸またはアクリル酸とメタクリル酸を意味し、エチレン・(メタ)アクリル酸エステル共重合体としてはエチレン・アクリル酸エステル共重合体、エチレン・メタクリル酸エステル共重合体等が例示できる。
不飽和カルボン酸に由来する構成単位の含有率の下限を上記範囲とすることにより、接着層120とバリア層130との接着性、特に、後述するように、バリア層130としてアルミ箔を用いた場合の接着性をより高めることができる。一方、不飽和カルボン酸に由来する構成単位の含有率の上限を上記範囲とすることにより、樹脂加工時(成膜)に発泡やゲルなどの不具合を生じるリスクが低減され、安定した成膜加工が可能となる。
不飽和カルボン酸エステルに由来する構成単位の含有率の下限を上記範囲とすることにより、接着層120とバリア層130との接着性、特に、後述するように、バリア層130としてPETを用いた場合の接着性をより高めることができる。不飽和カルボン酸エステルに由来する構成単位の含有率の上限を上記範囲とすることにより、加工性に優れる。
本実施形態に係る樹脂組成物(A)において、上述したエチレン・不飽和カルボン酸・不飽和カルボン酸エステル共重合体、エチレン・不飽和カルボン酸共重合体及びエチレン・不飽和カルボン酸エステル共重合体の合計含有量は、接着性の観点から、樹脂組成物(A)の全体を100質量%としたとき、好ましくは60質量%以上、より好ましくは90質量%以上、特に好ましくは95質量%以上である。
本実施形態に係る紙容器用積層体100の製造方法において、押出工程における押出ラミネーション温度は、上述した樹脂組成物(A)よって適宜設定されるため特に限定されないが、積層体の接着性をより一層良好にする観点から、200℃以上であることが好ましく、250℃以上であることがより好ましく、280℃以上であることが特に好ましい。
押出工程における押出ラミネーション温度の上限は特に限定されないが、例えば、350℃以下である。
図2は、実施形態2に係る紙容器用積層体100の積層構造を示す概略断面図である。本実施形態の紙容器用積層体100は、実施形態1で説明した積層体140を構成する紙基材層110の外表面側に熱可塑性樹脂層150を積層し、バリア層130の外表面側にシーラント層160を積層した積層構造を有する。
上述した各実施形態の紙容器用積層体100は、ゲーブルトップ型紙容器やブリック型紙容器などの紙容器の材料として好適に用いられる。紙容器用積層体100から紙容器を製造する方法は、特に限定されないが、周知の紙容器成形機を用いて加熱成形する方法が挙げられる。紙容器用積層体100を用いて形成される紙容器は、バブリングが抑制されるとともに、接着層120とバリア層130との接着性に優れる。このため、当該紙容器は内容物の保護性に優れるとともに、保存期間の延長を図ることができる。
各樹脂組成物について、JIS K7210:1999に準拠し、190℃、2160g荷重におけるMFRを測定した。MFRについて得られた結果を表1に示す。
外層から順に以下の層構成を有する2種類の紙容器用積層体を作製した。
<層構成(a)>
第1層(熱可塑性樹脂層):LDPE(低密度ポリエチレン、三井・デュポンポリケミカル株式会社製、ミラソン16P MFR3.7g/10min、密度923kg/m3)、厚さ20μm
第2層(紙基材層):コップ原紙(王子エフテック株式会社製、米坪260g/m2)
第3層(接着層、上記樹脂組成物含有):樹脂組成は表1を参照、厚さ30μm
第4層(接着層):樹脂組成物(三井・デュポンポリケミカル株式会社製、ニュクレルN0908C、MFR8g/10min、密度930kg/m3、メタクリル酸含有率9質量%)、厚さ10μm
第5層(アンカーコート層):アンカーコート剤(大日精化工業株式会社製、セイカダイン2710A+セイカダイン2710C、固形濃度7質量%、2g(wet)/m2塗布)
第6層(バリア層):PET(ポリエチレンテレフタレートフィルム、東レ株式会社製、ルミラー、厚さ12μm)
なお、第4層および第5層は、第3層(接着層)と第6層(バリア層)との接着性が第2層(紙基材層)と第3層(接着層)との層間で生じるバブリング性に影響しないように設けた層である。
65mmФ押出機(L/D=28)を有する押出ラミネーターを使用し、加工条件A(ダイ下温度315℃、エアーギャップ110mm、加工速度80m/分)で第2層へインラインでコロナ処理を施した後、第1層の溶融膜を押出し、積層フィルム(A積層体)を作製した。
加工条件B(ダイ下温度290℃、エアーギャップ110mm、加工速度80m/分)で第6層のPETフィルムのコロナ処理面へアンカーコート剤をインラインで塗布し(第5層形成)、第4層の溶融膜を押出し、積層フィルム(B積層体)を作製した。
加工条件C(ダイ下温度315℃、エアーギャップ110mm、加工速度80m/分)でA積層体の第2層の外表面にインラインでコロナ処理を施した後、A積層体の第2層の外表面とB積層体の第4層の外表面との間に第3層となる溶融膜を押出し、紙容器用積層体を作製した。
第1層(熱可塑性樹脂層):LDPE(低密度ポリエチレン、三井・デュポンポリケミカル株式会社製、ミラソン16P MFR3.7g/10min、密度923kg/m3)、厚さ20μm
第2層(紙基材層):コップ原紙(王子エフテック株式会社製、米坪260g/m2)
第3層(接着層、上記樹脂組成物含有):樹脂組成は表1を参照、厚さ30μm
第4層(接着層):LDPE(低密度ポリエチレン、三井・デュポンポリケミカル株式会社製、ミラソン11P MFR7.2g/10min、密度917kg/m3)、厚さ10μm
第5層(アンカーコート層):アンカーコート剤(大日精化工業株式会社製、セイカダイン2710A+セイカダイン2710C、固形濃度7質量%、2g(wet)/m2塗布)
第6層(バリア層):PET(ポリエチレンテレフタレートフィルム、東レ株式会社製、ルミラー、厚さ12μm)
なお、第4層および第5層は、第3層(接着層)と第6層(バリア層)との接着性が第2層(紙基材層)と第3層(接着層)との層間で生じるバブリング性に影響しないように設けた層である。
65mmФ押出機(L/D=28)を有する押出ラミネーターを使用し、加工条件A(ダイ下温度315℃、エアーギャップ110mm、加工速度80m/分)で第2層へインラインでコロナ処理を施した後、第1層の溶融膜を押出し、積層フィルム(A積層体)を作製した。
加工条件B(ダイ下温度315℃、エアーギャップ110mm、加工速度80m/分)で第6層のPETフィルムのコロナ処理面へアンカーコート剤をインラインで塗布し(第5層形成)、第4層の溶融膜を押出し、積層フィルム(B積層体)を作製した。
加工条件C(ダイ下温度315℃、エアーギャップ110mm、加工速度80m/分)でA積層体の第2層の外表面にインラインでコロナ処理を施した後、A積層体の第2層の外表面とB積層体の第4層の外表面との間に第3層となる溶融膜を押出し、紙容器用積層体を作製した。
層構成(a)の第6層面および層構成(b)の第6層面に、バブリング現象評価装置(実用新案登録第3152258号参照)を用いて下記条件でバブリング性評価を実施した。
設定温度:190℃
熱風風量:3m3/時間
孔径:2mm
孔数:1個
吹き出し孔とサンプルとの距離:7mm
熱風加熱開始時点より、加熱面に変化が生じるか否かを目視で観察し、熱風加熱開始時点から変化が生じるまでに要した時間を計測した。同一サンプルにて上記計測を5回実施し、その平均時間を算出した。バブリング性について得られた結果を表1に示す。
Al箔に対する接着強度および透明蒸着フィルム(片面へ無機化合物が蒸着されたPETフィルム、12μm)の未コート面に対する接着強度を以下の要領で測定した。
PET(12μm)/アンカーコート剤・LDPE(15μm)/Al箔(7μm)/接着層(上記樹脂組成物含有、表1参照)(30μm)/LL−Film(40μm)
<透明蒸着フィルムの未コート面に対する接着強度(d)>
透明蒸着フィルム(12μm)/接着層(上記樹脂組成物含有、表1参照)(30μm)/LL−Film(40μm)
上記層構成(c)、(d)で使用した具体的な材料は以下のとおりである。
PET:ポリエチレンテレフタレートフィルム、東レ株式会社製、ルミラー、厚さ12μm
アンカーコート剤:大日精化工業株式会社製、セイカダイン2710A+C、固形濃度7wt%、2g(wet)/m2塗布
LDPE:低密度ポリエチレン、弊社製、ミラソン16P、MFR3.7g/10分、密度923kg/m3
Al箔:アルミニウム箔、株式会社UACJ製、1N30、厚さ7μm
LL−Film:三井化学東セロ株式会社製、低密度ポリエチレンフィルムTUX−MCS、厚さ40μm
透明蒸着フィルム(片面へ無機化合物が蒸着されたPETフィルム、12μm)
65mmФ押出機(L/D=28)を有する押出ラミネーターを使用し、加工条件D(ダイ下温度320℃、エアーギャップ:110mm、加工速度80m/分)でPETフィルムへアンカーコート剤をインラインで塗布し、PETフィルムとAl箔との間へLDPEの溶融膜を押出し、積層フィルム(C積層体)を作製した。加工条件E(ダイ下温度315℃、エアーギャップ:110mm、加工速度80m/分)でC積層体とLL−Film層間へ上記樹脂組成物からなる溶融膜を押出し、Al箔への接着強度測定用の積層体を作製した。
一方、加工条件F(ダイ下温度315℃、エアーギャップ:110mm、加工速度80m/分)で透明蒸着PETの未コート面とLL−Film層間へ上記樹脂組成物からなる溶融膜を押出し、透明蒸着PETへの接着強度測定用の積層体を作製した。
層構成(c)の積層体におけるAl箔と接着層との層間の接着強度、および層構成(d)の積層体における透明蒸着PETと接着層との層間の接着強度を剥離強度試験機(インテスコ社製、IM−20X−ST型引張試験機)を用いて下記条件で測定した。接着強度について得られた結果を表1に示す。なお、接着強度に関しては、紙容器として使用する場合の実用上の基準として、0.8N/15mm以上であることが求められる。
形状:流れ方向(MD)へ15mm幅の短冊状
剥離強度測定速度:300mm/分
剥離角度:T剥離
110 紙基材層
120 接着層
130 バリア層
140 積層体
150 熱可塑性樹脂層
160 シーラント層
Claims (7)
- 紙基材層、接着層およびバリア層が上記の順序で積層された積層体を含み、
前記接着層がエチレン・不飽和カルボン酸・不飽和カルボン酸エステル共重合体、エチレン・不飽和カルボン酸共重合体、エチレン・不飽和カルボン酸エステル共重合体からなる群から選ばれ、少なくとも前記エチレン・不飽和カルボン酸・不飽和カルボン酸エステル共重合体を含む1種以上を含有する樹脂組成物(A)を含み、
JIS K7210:1999に準拠し、190℃、2160g荷重における前記樹脂組成物(A)のメルトフローレート(MFR)が9.0g/10分以下である、紙容器用積層体。 - 前記樹脂組成物(A)中の樹脂成分全体に対する不飽和カルボン酸に由来する構成単位の含有率が1質量%以上20質量%以下である請求項1に記載の紙容器用積層体。
- 前記樹脂組成物(A)中の樹脂成分全体に対する不飽和カルボン酸エステルに由来する構成単位の含有率が1質量%以上20質量%以下である、請求項1または2に記載の紙容器用積層体。
- 前記バリア層の外表面に積層されたシーラント層をさらに含む、請求項1乃至3のいずれか1項に記載の紙容器用積層体。
- 前記紙基材層の外表面に積層された熱可塑性樹脂層をさらに含む、請求項1乃至4のいずれか1項に記載の紙容器用積層体。
- 請求項1乃至5のいずれか1項に記載の紙容器用積層体を用いて得られる紙容器。
- 請求項1乃至5のいずれか1項に記載の紙容器用積層体を製造するための製造方法であって、
前記紙基材層および前記バリア層との間に前記接着層を溶融押出ラミネーションすることにより、前記紙基材層および前記バリア層を接着する押出工程を含む、製造方法。
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