WO2015115511A1 - エチレン-ビニルアルコール共重合体樹脂組成物及びその製造方法 - Google Patents
エチレン-ビニルアルコール共重合体樹脂組成物及びその製造方法 Download PDFInfo
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L53/00—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
- C08L53/02—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers of vinyl-aromatic monomers and conjugated dienes
- C08L53/025—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers of vinyl-aromatic monomers and conjugated dienes modified
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L29/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal or ketal radical; Compositions of hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Compositions of derivatives of such polymers
- C08L29/02—Homopolymers or copolymers of unsaturated alcohols
- C08L29/04—Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
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- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/04—Homopolymers or copolymers of ethene
- C08L23/08—Copolymers of ethene
- C08L23/0846—Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
- B29C49/04—Extrusion blow-moulding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/10—Metal compounds
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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- C08K3/32—Phosphorus-containing compounds
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L53/00—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
- C08L53/02—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers of vinyl-aromatic monomers and conjugated dienes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/558—Impact strength, toughness
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2439/00—Containers; Receptacles
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/32—Phosphorus-containing compounds
- C08K2003/321—Phosphates
- C08K2003/324—Alkali metal phosphate
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
- C08L2205/025—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
Definitions
- the present invention relates to a resin composition containing a modified ethylene-vinyl alcohol copolymer and an unmodified ethylene-vinyl alcohol copolymer, a method for producing the same, and a use thereof.
- Ethylene-vinyl alcohol copolymer (hereinafter sometimes abbreviated as EVOH) is excellent in transparency, gas barrier properties, aroma retention, solvent resistance, oil resistance, etc. It is used in a wide range of applications including various packaging containers such as containers, fuel containers, pharmaceutical packaging containers, industrial chemical packaging containers, and agricultural chemical packaging containers. When manufacturing such a molded product, secondary processing is often performed after melt-forming EVOH. For example, stretching for the purpose of improving the mechanical strength, and thermoforming a multilayer sheet including an EVOH layer to form a container are widely performed.
- Patent Document 1 describes a modified EVOH obtained by reacting a monovalent epoxy compound with a hydroxyl group of EVOH, and describes that the flexibility and secondary processability of EVOH are improved.
- Patent Document 2 describes a resin composition containing the modified EVOH and unmodified EVOH described in Patent Document 1, and the stretchability and transparency of the unmodified EVOH are significantly reduced without significantly reducing the barrier property and transparency. It is said that secondary workability can be improved.
- Patent Document 3 describes a fuel container having a layer made of the resin composition described in Patent Document 2.
- Patent Document 4 describes a packaging material having a layer of a composition having a plurality of endothermic peaks in a melting curve by DSC measurement, which is obtained by blending a plurality of EVOHs having different vinyl alcohol contents, and has a gas barrier property, It is described that it is excellent in mechanical properties and workability. However, in this case, it is not easy to achieve both gas barrier properties and secondary processability at a high level, and it is inevitable that transparency is lowered.
- Patent Document 5 discloses a modified EVOH obtained by copolymerization of ethylene, vinyl acetate and 3,4-diacetoxy-1-butene and then saponification, which is obtained by copolymerization of 3,4-dihydroxy-1-butene units. It is described that the modified EVOH is excellent in stretchability, gas barrier properties, appearance and strength. However, since 3,4-diacetoxy-1-butene has the same polymerization reactivity as vinyl acetate, most of it remains after polymerization when the copolymer is taken out at a low polymerization rate. Therefore, the load of cleaning and wastewater treatment increases, and an increase in manufacturing cost is inevitable.
- the present invention has been made in order to solve the above-mentioned problems, and is a modified ethylene-vinyl alcohol copolymer and unmodified ethylene which are excellent in barrier properties, impact resistance and secondary processability and excellent in productivity.
- a resin composition comprising a vinyl alcohol copolymer; Moreover, the suitable use of such a resin composition is provided. Furthermore, the suitable manufacturing method of such a resin composition is provided.
- the above problem is represented by the following formula (I), the content (mol%) of a, b and c with respect to all monomer units satisfies the following formulas (1) to (3), and the following formula (4) And a modified ethylene-vinyl alcohol copolymer (A) having a saponification degree (DS) defined by) of 90 mol% or more, and an ethylene unit content of 20 to 60 mol% and a saponification degree of 80 mol% or more.
- DS saponification degree
- R 1 , R 2 , R 3 and R 4 each independently represents a hydrogen atom or an alkyl group having 1 to 10 carbon atoms, and the alkyl group contains a hydroxyl group, an alkoxy group or a halogen atom. But you can.
- X, Y and Z each independently represent a hydrogen atom, a formyl group or an alkanoyl group having 2 to 10 carbon atoms.
- the weight ratio (A / B) of the modified ethylene-vinyl alcohol copolymer (A) and the unmodified ethylene-vinyl alcohol copolymer (B) is preferably 5/95 to 50/50.
- R 1 , R 2 , R 3 and R 4 of the modified ethylene-vinyl alcohol copolymer (A) are hydrogen atoms.
- X, Y and Z of the modified ethylene-vinyl alcohol copolymer (A) are each independently a hydrogen atom or an acetyl group.
- the oxygen permeation rate of the resin composition at 20 ° C. and 65% RH is preferably 100 cc ⁇ 20 ⁇ m / m 2 ⁇ day ⁇ atm or less.
- the resin composition preferably contains 10 to 500 ppm of alkali metal salt in terms of alkali metal element.
- a preferred embodiment of the resin composition is a barrier material.
- a film or sheet having a layer made of the resin composition is a preferred embodiment of the present invention. At this time, it is preferable to be stretched to an area magnification of 7 times or more.
- the film or sheet in which a layer made of the resin composition and a layer made of a thermoplastic resin other than the ethylene-vinyl alcohol copolymer are laminated is also a preferred embodiment of the present invention.
- a heat-shrinkable film or heat-shrinkable sheet made of the film or sheet is also a preferred embodiment of the present invention.
- a coextrusion blow molded container including a layer made of the resin composition and a layer made of a thermoplastic resin other than the ethylene-vinyl alcohol copolymer is also a preferred embodiment of the present invention.
- An extruded product containing the resin composition is also a preferred embodiment of the present invention.
- a thermoformed article containing the resin composition is also a preferred embodiment of the present invention.
- a fuel container containing the resin composition is also a preferred embodiment of the present invention.
- a copolymer of a modified ethylene-vinyl ester represented by the following formula (IV) is obtained by radical polymerization of ethylene, a vinyl ester represented by the following formula (II), and an unsaturated monomer represented by the following formula (III). After obtaining a polymer, it is saponified to produce the modified ethylene-vinyl alcohol copolymer (A) and then mixed with the unmodified ethylene-vinyl alcohol copolymer (B).
- the problem can also be solved by providing a method for producing the resin composition.
- R 5 represents a hydrogen atom or an alkyl group having 1 to 9 carbon atoms.
- R 1 , R 2 , R 3 and R 4 are the same as in formula (I).
- R 6 and R 7 each independently represents a hydrogen atom or an alkyl group having 1 to 9 carbon atoms.
- both resins are used.
- both resins are preferably mixed.
- the resin composition of the present invention containing a modified ethylene-vinyl alcohol copolymer and an unmodified ethylene-vinyl alcohol copolymer is excellent in barrier properties, impact resistance and secondary processability, and also in productivity. . Therefore, it can be used for various applications utilizing such characteristics. Moreover, according to the manufacturing method of this invention, the said resin composition can be manufactured efficiently.
- 2 is a 1 H-NMR spectrum of a modified EVAc obtained in Synthesis Example 1.
- 2 is a 1 H-NMR spectrum of a modified EVOH obtained in Synthesis Example 1.
- the resin composition of the present invention is represented by the following formula (I), the content (mol%) of a, b and c with respect to all monomer units satisfies the following formulas (1) to (3), and A modified ethylene-vinyl alcohol copolymer (A) having a saponification degree (DS) defined by the following formula (4) of 90 mol% or more, and an ethylene unit content of 20 to 60 mol% and a saponification degree 80 mol% or more of an unmodified ethylene-vinyl alcohol copolymer (B).
- R 1 , R 2 , R 3 and R 4 each independently represents a hydrogen atom or an alkyl group having 1 to 10 carbon atoms, and the alkyl group contains a hydroxyl group, an alkoxy group or a halogen atom. But you can.
- X, Y and Z each independently represent a hydrogen atom, a formyl group or an alkanoyl group having 2 to 10 carbon atoms.
- the modified EVOH (A) does not contain the monomer unit by having a monomer unit having a 1,3-diol structure in the main chain of the copolymer in addition to the ethylene unit and the vinyl alcohol unit. Since the crystallinity is lowered as compared with EVOH, impact resistance and secondary workability can be improved. Moreover, since the crystallization speed is also reduced as compared with EVOH not containing the monomer unit, the interlayer adhesion of the multilayer structure having a layer made of the modified EVOH (A) can also be improved. Further, this modified EVOH (A) can reduce the decrease in barrier properties due to the decrease in crystallinity due to the strong hydrogen bonding force of the 1,3-diol structure. As will be described later, this modified EVOH (A) can be produced at a low cost.
- the resin composition of the present invention improves impact resistance and secondary processability while minimizing a decrease in barrier performance. There is a big feature in that it can.
- R 1 , R 2 , R 3 and R 4 each independently represents a hydrogen atom or an alkyl group having 1 to 10 carbon atoms.
- R 1 , R 2 , R 3 and R 4 may be the same group or different.
- the structure of the alkyl group is not particularly limited, and may partially have a branched structure or a cyclic structure.
- the alkyl group may contain a hydroxyl group, an alkoxy group or a halogen atom.
- R 1 , R 2 , R 3 and R 4 are preferably a hydrogen atom or an alkyl group having 1 to 5 carbon atoms, and more preferably a hydrogen atom.
- alkyl group examples include linear or branched alkyl groups such as a methyl group, an ethyl group, an n-propyl group, an isopropyl group, an n-butyl group, an isobutyl group, a tert-butyl group, and a pentyl group. Can be mentioned.
- X, Y and Z each independently represent a hydrogen atom, a formyl group or an alkanoyl group having 2 to 10 carbon atoms.
- the formula (I) has a hydroxyl group
- X, Y or Z is a formyl group or an alkanoyl group
- the formula (I) has an ester group.
- the alkanoyl group an alkanoyl group having 2 to 5 carbon atoms is preferable, and an acetyl group, a propanoyl group, a butanoyl group, and the like are preferable examples. Among these, an acetyl group is particularly preferable.
- X, Y and Z are preferably all hydrogen atoms or a mixture containing hydrogen atoms.
- the monomer unit containing X is usually obtained by saponifying vinyl ester. Therefore, X is preferably a mixture of a hydrogen atom and a formyl group or an alkanoyl group having 2 to 10 carbon atoms. Considering the availability of the monomer (vinyl acetate) and the production cost, it is particularly preferable that X is a mixture of a hydrogen atom and an acetyl group.
- each of Y and Z may be only a hydrogen atom, or a mixture of a hydrogen atom and a formyl group or an alkanoyl group having 2 to 10 carbon atoms, more preferably a mixture of a hydrogen atom and an acetyl group. It may be.
- the contents (mol%) of a, b and c with respect to all monomer units satisfy the following formulas (1) to (3). 18 ⁇ a ⁇ 55 (1) 0.01 ⁇ c ⁇ 20 (2) [100 ⁇ (a + c)] ⁇ 0.9 ⁇ b ⁇ [100 ⁇ (a + c)] (3)
- A represents the content (mol%) of ethylene units relative to all monomer units, and is 18 to 55 mol%.
- a is preferably 22 mol% or more.
- a is preferably 50 mol% or less.
- c represents the content (mol%) of the monomer unit containing Y and Z shown at the right end in the formula (I) with respect to all the monomer units, and is 0.01 to 20 mol. %. If c is less than 0.01 mol%, the impact resistance and secondary processability of the resin composition of the present invention will be insufficient. c is preferably 0.1 mol% or more, and more preferably 0.5 mol% or more. On the other hand, when c exceeds 20 mol%, the crystallinity of the modified EVOH (A) is extremely lowered, and thus the barrier property of the resin composition of the present invention is lowered. c is preferably 10 mol% or less, and more preferably 5 mol% or less.
- the monomer units other than the ethylene unit and the monomer unit containing Y and Z shown at the right end in the formula (I) are vinyl alcohol units or vinyl. It is an ester unit.
- the formula (3) is not satisfied, the gas barrier property of the resin composition of the present invention is insufficient.
- the following formula (3 ′) is satisfied, and more preferably, the following formula (3 ′′) is satisfied. [100 ⁇ (a + c)] ⁇ 0.95 ⁇ b ⁇ [100 ⁇ (a + c)] (3 ′) [100 ⁇ (a + c)] ⁇ 0.98 ⁇ b ⁇ [100 ⁇ (a + c)] (3 ′′)
- the degree of saponification (DS) defined by the following formula (4) in the modified EVOH (A) is 90 mol% or more.
- DS [(total number of moles of hydrogen atoms among X, Y and Z) / (total number of moles of X, Y and Z)] ⁇ 100 (4)
- the total number of moles of hydrogen atoms among X, Y and Z indicates the number of moles of hydroxyl groups
- the total number of moles of X, Y and Z is the total number of moles of hydroxyl groups and ester groups.
- the saponification degree (DS) is preferably 95 mol% or more, more preferably 98 mol% or more, and even more preferably 99 mol% or more.
- the degree of saponification (DS) of the modified EVOH (A) can be obtained by a nuclear magnetic resonance (NMR) method.
- the content of the monomer units represented by a, b and c can also be obtained by the NMR method.
- the modified EVOH (A) is usually a random copolymer. The fact that it is a random copolymer can be confirmed from NMR and melting point measurement results.
- the preferred melt flow rate (MFR) of the modified EVOH (A) (at 190 ° C. under a load of 2160 g) is 0.1 to 30 g / 10 minutes, more preferably 0.3 to 25 g / 10 minutes, and even more preferably Is 0.5 to 20 g / 10 min.
- MFR melt flow rate
- those having a melting point near 190 ° C. or exceeding 190 ° C. were measured under a load of 2160 g and at a plurality of temperatures higher than the melting point. The value is extrapolated to 190 ° C.
- the modified EVOH (A) is composed of a mixture of two or more different types of modified EVOH (A)
- the content, saponification degree, and MFR of the monomer units represented by a, b, and c are as follows: The average value calculated from the weight ratio is used.
- the method for producing the modified EVOH (A) is not particularly limited.
- R 5 represents a hydrogen atom or an alkyl group having 1 to 9 carbon atoms.
- the alkyl group preferably has 1 to 4 carbon atoms.
- Examples of the vinyl ester represented by the formula (II) include vinyl formate, vinyl acetate, vinyl propionate, vinyl butyrate, vinyl isobutyrate, vinyl pivalate, vinyl versatate, and vinyl caproate. From the economical viewpoint, vinyl acetate is particularly preferred.
- R 1 , R 2 , R 3 and R 4 are the same as in formula (I).
- R 6 and R 7 each independently represents a hydrogen atom or an alkyl group having 1 to 9 carbon atoms.
- the alkyl group preferably has 1 to 4 carbon atoms.
- Examples of the unsaturated monomer represented by the formula (III) include 2-methylene-1,3-propanediol diacetate (1,3-diacetoxy-2-methylenepropane), 2-methylene-1,3-propanediol Examples include dipropionate and 2-methylene-1,3-propanediol dibutyrate. Of these, 2-methylene-1,3-propanediol diacetate is preferably used from the viewpoint of easy production. In the case of 2-methylene-1,3-propanediol diacetate, R 1 , R 2 , R 3 and R 4 are hydrogen atoms, and R 6 and R 7 are methyl groups.
- R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , a, b and c are the same as those in the formulas (I) to (III).
- the modified ethylene-vinyl ester copolymer thus obtained is then saponified.
- an unsaturated monomer represented by the following formula (V) may be copolymerized. Only the unit derived from the unsaturated monomer represented by (II) is saponified.
- R 1 , R 2 , R 3 and R 4 are the same as in formula (I).
- Examples of the unsaturated monomer represented by the formula (V) include 2-methylene-1,3-propanediol.
- the unsaturated monomer represented by the formula (III) and the formula (V) used in the present invention has high copolymerization reactivity with the vinyl ester monomer, the copolymerization reaction easily proceeds. Therefore, it is easy to increase the amount of modification and the degree of polymerization of the resulting modified ethylene-vinyl ester copolymer. In addition, even if the polymerization reaction is stopped at a low polymerization rate, the amount of unreacted unsaturated monomer remaining at the end of the polymerization is small, which is excellent in terms of environment and cost.
- the unsaturated monomer represented by the formulas (III) and (V) has one carbon atom having a functional group at the allylic position, such as allyl glycidyl ether and 3,4-diacetoxy-1-butene. It is only better than other monomers.
- the unsaturated monomer represented by the formula (III) has higher reactivity than the unsaturated monomer represented by the formula (V).
- a modified ethylene-vinyl ester copolymer is produced by copolymerizing ethylene, a vinyl ester represented by the above formula (II), and an unsaturated monomer represented by the above formula (III) or (V).
- the polymerization method at that time may be any of batch polymerization, semi-batch polymerization, continuous polymerization, and semi-continuous polymerization.
- well-known methods such as a block polymerization method, a solution polymerization method, a suspension polymerization method, and an emulsion polymerization method, are employable.
- a bulk polymerization method or a solution polymerization method in which polymerization proceeds in a solvent-free or solvent such as alcohol is usually employed.
- the use of an emulsion polymerization method is one option.
- the solvent used in the solution polymerization method is not particularly limited, but alcohol is preferably used, and for example, lower alcohols such as methanol, ethanol, and propanol are more preferably used.
- the amount of solvent used in the polymerization reaction solution may be selected in consideration of the viscosity average polymerization degree of the target modified EVOH (A) and the chain transfer of the solvent.
- the weight ratio (solvent / total monomers) is selected from the range of 0.01 to 10, preferably 0.05 to 3.
- the polymerization initiator used when copolymerizing ethylene, the vinyl ester represented by the above formula (II), and the unsaturated monomer represented by the above formula (III) or (V) is a known polymerization.
- the initiator is selected from azo initiators, peroxide initiators, and redox initiators depending on the polymerization method.
- examples of the azo initiator include 2,2′-azobisisobutyronitrile, 2,2′-azobis (2,4-dimethylvaleronitrile), and 2,2′-azobis (4-methoxy-2,4). -Dimethylvaleronitrile).
- peroxide initiator examples include percarbonate compounds such as diisopropyl peroxydicarbonate, di-2-ethylhexyl peroxydicarbonate, diethoxyethyl peroxydicarbonate; t-butyl peroxyneodecanate, ⁇ -Perester compounds such as cumylperoxyneodecanate and acetyl peroxide; acetylcyclohexylsulfonyl peroxide; 2,4,4-trimethylpentyl-2-peroxyphenoxyacetate and the like. Potassium persulfate, ammonium persulfate, hydrogen peroxide, or the like may be used in combination with the above initiator.
- the redox initiator is, for example, a polymerization initiator in which the peroxide initiator is combined with a reducing agent such as sodium hydrogen sulfite, sodium hydrogen carbonate, tartaric acid, L-ascorbic acid, or longalite.
- a reducing agent such as sodium hydrogen sulfite, sodium hydrogen carbonate, tartaric acid, L-ascorbic acid, or longalite.
- the amount of the polymerization initiator used varies depending on the polymerization catalyst and cannot be determined unconditionally, but is adjusted according to the polymerization rate.
- the amount of the polymerization initiator used is preferably from 0.01 to 0.2 mol%, more preferably from 0.02 to 0.15 mol%, based on the vinyl ester monomer.
- the polymerization temperature is not particularly limited, but is suitably about room temperature to 150 ° C., preferably 40 ° C. or higher and lower than the boiling point of the solvent used.
- the effect of the present invention is not inhibited. If present, it may be copolymerized in the presence of a chain transfer agent.
- the chain transfer agent include aldehydes such as acetaldehyde and propionaldehyde; ketones such as acetone and methyl ethyl ketone; mercaptans such as 2-hydroxyethanethiol; and phosphinic acid salts such as sodium phosphinate monohydrate. . Of these, aldehydes and ketones are preferably used.
- the amount of chain transfer agent added to the polymerization reaction solution is determined according to the chain transfer coefficient of the chain transfer agent and the degree of polymerization of the target modified ethylene-vinyl ester copolymer.
- the amount is preferably 0.1 to 10 parts by mass with respect to parts by mass.
- the modified ethylene-vinyl ester copolymer thus obtained can be saponified to obtain the modified EVOH (A) used in the present invention.
- the vinyl ester unit in the copolymer is converted into a vinyl alcohol unit.
- the ester bond derived from the unsaturated monomer represented by the formula (III) is simultaneously hydrolyzed and converted into a 1,3-diol structure.
- different types of ester groups can be simultaneously hydrolyzed by a single saponification reaction.
- the saponification reaction is usually performed in a solution of alcohol or hydrous alcohol.
- the alcohol preferably used at this time is a lower alcohol such as methanol or ethanol, and particularly preferably methanol.
- the alcohol or hydrous alcohol used in the saponification reaction may contain other solvents such as acetone, methyl acetate, ethyl acetate, and benzene as long as the weight is 40% by weight or less.
- the catalyst used for the saponification is, for example, an alkali metal hydroxide such as potassium hydroxide or sodium hydroxide, an alkali catalyst such as sodium methylate, or an acid catalyst such as mineral acid.
- the temperature at which saponification is carried out is not limited, but is preferably in the range of 20 to 120 ° C.
- the product is pulverized, washed and dried to obtain a modified EVOH (A).
- the modified EVOH (A) used in the present invention is represented by ethylene, the vinyl ester represented by the above formula (II), and the above formula (III) or (V) as long as the effects of the present invention are not inhibited. It may contain structural units derived from other ethylenically unsaturated monomers that are copolymerizable with unsaturated monomers. Examples of such ethylenically unsaturated monomers include ⁇ -olefins such as propylene, n-butene, isobutylene, and 1-hexene; acrylic acid and its salts; unsaturated monomers having an acrylate group.
- Methacrylic acid and salts thereof unsaturated monomer having a methacrylic acid ester group; acrylamide, N-methylacrylamide, N-ethylacrylamide, N, N-dimethylacrylamide, diacetoneacrylamide, acrylamidepropanesulfonic acid and salts thereof; Acrylamidepropyldimethylamine and salts thereof (eg, quaternary salts); methacrylamide, N-methylmethacrylamide, N-ethylmethacrylamide, methacrylamidepropanesulfonic acid and salts thereof, methacrylamidepropyldimethylamine and salts thereof (eg Grade salt); methyl vinyl ether, ethyl vinyl ether, n-propyl vinyl ether, i-propyl vinyl ether, n-butyl vinyl ether, i-butyl vinyl ether, t-butyl vinyl ether, dodecyl vinyl ether, stearyl vinyl ether, 2,3-diacetoxy-1-
- unmodified EVOH (B) is blended with the modified EVOH (A) obtained as described above.
- the unmodified EVOH (B) used in the present invention is a monomer unit containing Y and Z shown at the right end in the formula (I) (shown by the formula (III) or (V)).
- EVOH which does not contain a structural unit derived from an unsaturated monomer
- general-purpose EVOH which has been widely used conventionally can be used.
- the ethylene unit content of unmodified EVOH (B) is 20 to 60 mol%.
- the ethylene unit content is preferably 22 mol% or more, and more preferably 24 mol% or more.
- the barrier property of the resin composition of the present invention is insufficient.
- the ethylene unit content is preferably 55 mol% or less, and more preferably 50 mol% or less.
- the saponification degree of unmodified EVOH (B) is 80 mol% or more.
- the degree of saponification is the proportion of saponified vinyl copolymer units. When the saponification degree is less than 80 mol%, the gas barrier property of the resin composition of the present invention becomes insufficient.
- the degree of saponification is preferably 95 mol% or more, and more preferably 99 mol% or more.
- Unmodified EVOH (B) is ethylene, vinyl ester represented by the above formula (II), and unsaturated monomer represented by the above formula (III) or (V) as long as the effects of the present invention are not inhibited. It may contain a small amount of structural units derived from other ethylenically unsaturated monomers that can be copolymerized with the polymer. As other ethylenically unsaturated monomers, those exemplified in the description of the modified EVOH (A) can be used. The content of structural units derived from other ethylenically unsaturated monomers is usually 10% or less of the total monomer units, preferably 5% or less, more preferably 2%. It is as follows. It is further preferable that the structural unit derived from other ethylenically unsaturated monomers is not substantially contained.
- the preferred melt flow rate (MFR) of unmodified EVOH (B) (at 190 ° C. under a load of 2160 g) is 0.1 to 30 g / 10 minutes, more preferably 0.3 to 25 g / 10 minutes, even more preferred. Is 0.5 to 20 g / 10 min. However, those having a melting point near 190 ° C. or exceeding 190 ° C. were measured under a load of 2160 g and at a plurality of temperatures higher than the melting point. The value is extrapolated to 190 ° C.
- the weight ratio (A / B) of the modified EVOH (A) to the unmodified EVOH (B) is preferably 5/95 to 50/50.
- the weight ratio (A / B) is more preferably 8/92 or more.
- the weight ratio (A / B) exceeds 50/50, the barrier property of the resin composition may be insufficient.
- the weight ratio (A / B) is more preferably 40/60 or less.
- the resin composition of the present invention can contain other additives in addition to the modified EVOH (A) and the unmodified EVOH (B).
- reinforcing agents such as thermoplastic resins other than EVOH, plasticizers, lubricants, stabilizers, surfactants, colorants, ultraviolet absorbers, antistatic agents, desiccants, crosslinking agents, metal salts, fillers, and various fibers Etc. can be blended.
- the resin composition of this invention contains an alkali metal salt.
- an alkali metal salt By containing an alkali metal salt, interlayer adhesion when laminated with a resin other than EVOH is improved.
- the cationic species of the alkali metal salt is not particularly limited, but sodium salt or potassium salt is preferable.
- the anionic species of the alkali metal salt is not particularly limited. It can be added as a carboxylate, carbonate, bicarbonate, phosphate, hydrogen phosphate, borate, hydroxide or the like.
- the content of the alkali metal salt in the resin composition of the present invention is preferably 10 to 500 ppm in terms of alkali metal element.
- interlayer adhesion may be insufficient, and more preferably 50 ppm or more.
- the melt stability may be insufficient, and is more preferably 300 ppm or less.
- the resin composition of the present invention contains a phosphoric acid compound.
- a phosphoric acid compound By containing the phosphoric acid compound in this way, coloring during melt molding can be prevented.
- the phosphoric acid compound used for this invention is not specifically limited, Various acids, such as phosphoric acid and phosphorous acid, its salt, etc. can be used.
- the phosphate may be contained in any form of a first phosphate, a second phosphate, and a third phosphate, but the first phosphate is preferable.
- the cationic species is not particularly limited, but is preferably an alkali metal salt. Among these, sodium dihydrogen phosphate and potassium dihydrogen phosphate are preferable.
- the content of the phosphoric acid compound in the resin composition of the present invention is preferably 5 to 200 ppm in terms of phosphate radical.
- the content of the phosphoric acid compound is less than 5 ppm, coloring resistance at the time of melt molding may be insufficient.
- the content of the phosphoric acid compound exceeds 200 ppm, the melt stability may become insufficient, and is more preferably 160 ppm or less.
- the resin composition of the present invention may contain a boron compound.
- a boron compound used in the present invention is not particularly limited, and examples thereof include boric acids, boric acid esters, borates, and borohydrides.
- Specific examples of boric acids include orthoboric acid, metaboric acid, and tetraboric acid.
- Examples of boric acid esters include triethyl borate and trimethyl borate.
- Examples include alkali metal salts of acids, alkaline earth metal salts, and borax.
- orthoboric acid hereinafter sometimes simply referred to as boric acid is preferable.
- the content of the boron compound in the resin composition of the present invention is preferably 20 to 2000 ppm or less in terms of boron element.
- the content of the boron compound is less than 20 ppm, suppression of torque fluctuation during heating and melting may be insufficient, and more preferably 50 ppm or more.
- the content of the boron compound exceeds 2000 ppm, gelation tends to occur and the moldability may deteriorate, and more preferably 1000 ppm or less.
- the resin composition of the present invention preferably has an oxygen transmission rate at 20 ° C. and 65% RH of 100 cc ⁇ 20 ⁇ m / m 2 ⁇ day ⁇ atm or less.
- the oxygen transmission rate is more preferably 10 cc ⁇ 20 ⁇ m / m 2 ⁇ day ⁇ atm or less, and further preferably 5 cc ⁇ 20 ⁇ m / m 2 ⁇ day ⁇ atm or less.
- the method for producing the resin composition of the present invention is not particularly limited. It is preferable that the modified EVOH (A) is produced and then mixed with the unmodified EVOH (B).
- the mixing method is not particularly limited, but is usually mixed in a molten state.
- the method of melt mixing is not particularly limited, and an extruder, an intensive mixer, a Banbury mixer, a kneader, or the like can be used. At this time, the above-mentioned various additives can be simultaneously added and kneaded.
- the modified EVOH (A) and the unmodified EVOH (B) are replaced with an alkali metal salt, phosphoric acid.
- a method of mixing both resins after contacting with an aqueous solution containing a compound or a boron compound is preferable. In this case, after contacting one of the modified EVOH (A) and the unmodified EVOH (B) with an aqueous solution containing those components, it can be mixed with the other resin not containing those components. However, in order to obtain a stable addition effect, it is preferable to mix both resins after bringing both resins into contact with an aqueous solution.
- the method for molding the resin composition of the present invention is not particularly limited. Although it can also shape
- melt molding method include methods such as extrusion molding, injection molding, inflation molding, press molding, and blow molding. Among these, extrusion molding is a suitable molding method, and various extruded products can be obtained.
- a preferred embodiment of the resin composition of the present invention is a barrier material.
- the resin composition of the present invention has excellent barrier properties against fuels such as gasoline and various chemicals in addition to gases such as oxygen.
- the film and sheet having a layer made of the resin composition of the present invention are suitable for use because they are required to be flexible and are often stretched after melt molding.
- the film and the sheet may be a single-layer product made of the resin composition of the present invention, or may be a multilayer structure including another thermoplastic resin layer.
- the molded product made of the resin composition of the present invention is often used as a multilayer structure in which a layer made of the resin composition and a layer made of a thermoplastic resin other than EVOH are laminated.
- the thermoplastic resin other than EVOH is a thermoplastic resin other than EVOH, which is a broad concept including modified EVOH (A) and unmodified EVOH (B).
- A modified EVOH
- B unmodified EVOH
- a configuration in which the resin composition layer of the present invention is used as an intermediate layer, and other thermoplastic resins are arranged in outer layers on both sides thereof is preferable. It is also preferable that the resin composition layer and another thermoplastic resin layer are bonded via an adhesive resin layer.
- the resin composition layer of the present invention has a barrier property, and its thickness is usually 3 to 250 ⁇ m, preferably 10 to 100 ⁇ m.
- the thermoplastic resin used in the outer layer is not particularly limited, and is appropriately selected in consideration of required performance and applications such as moisture permeability, heat resistance, heat sealability, and transparency.
- the thickness of the entire multilayer structure is not particularly limited, but is usually 15 to 6000 ⁇ m.
- a multilayer film or a multilayer sheet, a coextrusion blow molding container, a co-injection blow molding container, etc. are mentioned.
- thermoplastic resin layers laminated with the layer made of the resin composition of the present invention include polyolefins such as polyethylene, polypropylene, ethylene-vinyl acetate copolymer, ethylene- (meth) acrylic acid ester copolymer; polyamide Polyester, polystyrene, polyvinyl chloride, acrylic resin, polyvinylidene chloride, polyacetal, polycarbonate, and the like.
- the multilayer structure can be obtained by various production methods, and a coextrusion method, a dry laminating method, a sand laminating method, an extrusion laminating method, a coextrusion laminating method, a solution coating method and the like can be adopted.
- the co-extrusion method is a method in which the resin composition of the present invention and another thermoplastic resin are simultaneously extruded from an extruder, laminated in a molten state, and discharged into a multilayer film from a die outlet.
- stacking the resin composition layer of this invention and another thermoplastic resin layer on both sides of an adhesive resin layer is preferable.
- the adhesive resin it is preferable to use a polyolefin having a carboxyl group, a carboxylic anhydride group or an epoxy group.
- a polyolefin having a carboxyl group, a carboxylic anhydride group or an epoxy group is excellent in adhesiveness with the resin composition of the present invention and adhesiveness with other thermoplastic resins not containing a carboxyl group, a carboxylic anhydride group or an epoxy group.
- polyolefin containing a carboxyl group examples include a polyolefin copolymerized with acrylic acid or methacrylic acid.
- carboxyl groups contained in the polyolefin may be present in the form of a metal salt.
- polyolefin having a carboxylic anhydride group examples include polyolefins graft-modified with maleic anhydride or itaconic acid.
- polyolefin resin containing an epoxy group the polyolefin which copolymerized glycidyl methacrylate is mentioned.
- polyolefins having a carboxyl group, a carboxylic acid anhydride group, or an epoxy group polyolefins modified with a carboxylic acid anhydride such as maleic anhydride, particularly polyethylene and polypropylene are preferable from the viewpoint of excellent adhesiveness.
- the melt-formed product thus obtained is further subjected to secondary processing.
- a molded article containing the resin composition of the present invention is excellent in secondary processability.
- the secondary processing method include uniaxial stretching, biaxial stretching, stretch blow molding, thermoforming, and rolling.
- a film or sheet stretched at a high magnification is a preferred embodiment of the present invention.
- a film or sheet that is stretched to an area magnification of 7 times or more is a particularly preferred embodiment.
- a thermoformed product is also a preferred embodiment of the present invention.
- crosslinking by radiation irradiation or the like may be performed.
- a heat shrink film or a heat shrink sheet is also a preferred embodiment of the present invention.
- the melt-molded product to be subjected to the secondary processing may be a single-layer product made of the resin composition of the present invention, or may be a multilayer structure including another thermoplastic resin layer.
- the molded product of the present invention Since the molded product of the present invention thus obtained is excellent in barrier properties, impact resistance and secondary processability, it is molded into various shapes such as films, cups and bottles, and is suitably used as various containers. be able to. Among them, a useful application is a fuel container.
- the resin composition of the present invention is suitable as a fuel container because it is excellent in impact resistance, excellent in secondary workability, and excellent in fuel barrier properties.
- a coextrusion blow molded container or a thermoformed container is suitable as the fuel container.
- Synthesis example 1 (1) Synthesis of Modified Ethylene-Vinyl Alcohol Copolymer (Modified EVAc) Vinyl acetate (formula (II)) was placed in a 50 L pressure reaction vessel equipped with a jacket, a stirrer, a nitrogen inlet, an ethylene inlet and an initiator inlet.
- Modified EVAc Modified Ethylene-Vinyl Alcohol Copolymer
- Vinyl acetate (formula (II) was placed in a 50 L pressure reaction vessel equipped with a jacket, a stirrer, a nitrogen inlet, an ethylene inlet and an initiator inlet.
- R 5 is a methyl group (hereinafter referred to as VAc) 21 kg, methanol (hereinafter referred to as MeOH) 2.1 kg, 2-methylene-1,3-propanediol diacetate (in formula (III), R 5 1 , R 2 , R 3 and R 4 are hydrogen atoms, R 6 and R 7 are methyl groups: 1,3-diacetoxy-2-methylenepropane and the same compound (hereinafter referred to as MPDAc) After raising the temperature to 60 ° C., nitrogen was bubbled for 30 minutes to replace the inside of the reaction vessel with nitrogen. Next, ethylene was introduced so that the reaction vessel pressure (ethylene pressure) was 4.2 MPa.
- modified ethylene-vinyl acetate copolymer in which structural units derived from MPDAc are introduced by copolymerization (sometimes referred to herein as modified EVAc). A 20% by mass MeOH solution was added.
- modified EVOH modified ethylene-vinyl alcohol copolymer
- the modified EVOH precipitated by decantation was collected and pulverized with a mixer.
- the obtained modified EVOH powder was put into a 1 g / L acetic acid aqueous solution (bath ratio 20: 20 L of aqueous solution with respect to 1 kg of powder) and washed with stirring for 2 hours.
- a modified EVOH hydrous pellet from which the residue was removed was obtained.
- the water-containing pellet is poured into an aqueous solution (bath ratio 20) having a sodium acetate concentration of 0.525 g / L, an acetic acid concentration of 0.8 g / L, and a phosphoric acid concentration of 0.007 g / L, and is immersed for 4 hours with periodic stirring. It was. This was drained and dried at 80 ° C. for 3 hours and at 105 ° C. for 16 hours to obtain modified EVOH composition pellets containing acetic acid, sodium salt and phosphate compound.
- FIG. 1 shows the 1 H-NMR spectrum of the modified EVAc obtained in Synthesis Example 1.
- Each peak in the spectrum is assigned as follows.
- the integral value of 0.6 to 1.0 ppm is x
- the integral value of 1.0 to 1.85 ppm is y
- the integral value of 3.7-4.1 ppm is z, 4.4-5.
- the integrated value of 3 ppm is w
- the content of ethylene units (a: mol%), the content of vinyl ester units (b: mol%) and the content of structural units derived from MPDAc (c: mol%) are Are calculated according to the following equations.
- the ethylene unit content (a) was 32.0 mol%
- the vinyl ester unit content (b) was 64.1 mol%
- the MPDAc-derived structural unit content (c) was It was 3.9 mol%.
- the values of a, b and c in the modified EVAc are the same as the values of a, b and c in the modified EVOH after saponification treatment.
- the ester group contained in the MPDAc-derived structural unit is also saponified into a hydroxyl group. It is clear.
- the degree of saponification was calculated from the peak intensity ratio of methyl protons (1.85 to 2.1 ppm) of vinyl acetate units and methine protons (3.15 to 4.15 ppm) of vinyl alcohol units.
- the degree of saponification of the modified EVOH was 99.9 mol% or more.
- Sodium salt content and phosphate compound content in the modified EVOH composition 0.5 g of the modified EVOH composition pellets obtained in (4) above was placed in a Teflon (registered trademark) pressure vessel, and concentrated therein. Nitric acid (5 mL) was added and decomposed at room temperature for 30 minutes. After 30 minutes, the lid was covered, and decomposition was carried out by heating at 150 ° C. for 10 minutes and then at 180 ° C. for 5 minutes with a wet decomposition apparatus (manufactured by Actac Co., Ltd .: “MWS-2”), and then cooled to room temperature. This treatment liquid was transferred to a 50 mL volumetric flask and diluted with pure water.
- a wet decomposition apparatus manufactured by Actac Co., Ltd .: “MWS-2”
- the contained metal was analyzed with the ICP emission spectroscopic analyzer ("OPTIMA4300DV" manufactured by PerkinElmer Co., Ltd.), and the contents of sodium element and phosphorus element were determined.
- the sodium salt content was 150 ppm in terms of sodium element, and the phosphate compound content was 10 ppm in terms of phosphate radical.
- Synthesis example 2 Polymerization was carried out in the same manner as in Synthesis Example 1 (1) except that the amount of MeOH was 6.3 kg, the ethylene pressure was 3.7 MPa, the amount of initiator was 4.2 g, and MPDAc was not charged. It was. After 4 hours, when the polymerization rate of VAc reached 44%, the reaction was cooled to stop the polymerization. Subsequently, the same treatment as in Synthesis Example 1 was performed to produce an unmodified EVOH composition pellet containing a sodium salt of 135 ppm in terms of sodium element and a phosphate compound in terms of phosphate radical of 11 ppm. The results evaluated in the same manner as in Synthesis Example 1 are summarized in Table 1.
- Synthesis example 3 Polymerization was conducted in the same manner as in Synthesis Example 1 (1) except that the amount of initiator was 8.4 g and the amount of MPDAc charged was 0.5 kg. After 6 hours, when the polymerization rate of VAc reached 52%, the reaction was cooled to stop the polymerization. Subsequently, the results of producing and evaluating modified EVOH composition pellets in the same manner as in Synthesis Example 1 are summarized in Table 1.
- Synthesis example 4 Modified EVAc was synthesized in the same manner as in Synthesis Example 3 to obtain a methanol solution of modified EVAc. Subsequently, a saponification treatment was performed in the same manner as in (2) of Synthesis Example 1 except that a MeOH solution of sodium hydroxide was added at a rate of 3.7 mL / min. Subsequently, the results of producing and evaluating modified EVOH composition pellets in the same manner as in Synthesis Example 1 are summarized in Table 1.
- Synthesis example 5 In Synthesis Example 1 (1), the amount of MeOH is 1.1 kg, the ethylene pressure is 3.8 MPa, the amount of MPDAc is 2.0 kg, and 16.8 g of initiator is added 5 hours after the start of polymerization. Polymerization was carried out in the same manner except that. After 10 hours, when the polymerization rate of VAc reached 9%, it was cooled and the polymerization was stopped. Subsequently, the results of producing and evaluating modified EVOH composition pellets in the same manner as in Synthesis Example 1 are summarized in Table 1.
- Synthesis Example 6 The same as in Synthesis Example 1 (1) except that the amount of MeOH was 1.1 kg, the amount of initiator was 16.8 g, the ethylene pressure was 6.0 MPa, and the amount of MPDAc charged was 1.1 kg. Polymerization was carried out by the method. After 4 hours, the polymerization was stopped by cooling when the polymerization rate of VAc reached 22%. Subsequently, the results of producing and evaluating modified EVOH composition pellets in the same manner as in Synthesis Example 1 are summarized in Table 1.
- Synthesis example 7 Polymerization was conducted in the same manner as in Synthesis Example 1 (1) except that the amount of MeOH was 6.3 kg, the amount of initiator was 4.2 g, the ethylene pressure was 2.9 MPa, and MPDAc was not added. went. After 4 hours, the polymerization was stopped by cooling when the polymerization rate of VAc reached 50%. Table 1 summarizes the results of evaluation by producing unmodified EVOH composition pellets by processing in the same manner as in Synthesis Example 1.
- Synthesis example 8 Polymerization was carried out in the same manner as in Synthesis Example 1 (1) except that the amount of MeOH was 4.2 kg, the amount of initiator was 4.2 g, the ethylene pressure was 5.3 MPa, and MPDAc was not added. went. After 3 hours, the polymerization was stopped by cooling when the polymerization rate of VAc reached 29.3%. Table 1 summarizes the results of evaluation by producing unmodified EVOH composition pellets by processing in the same manner as in Synthesis Example 1.
- Synthesis Example 9 The same as in Synthesis Example 1 (1) except that the amount of MeOH was 2.5 kg, the amount of initiator was 8.4 g, the ethylene pressure was 3.4 MPa, and the amount of MPDAc charged was 0.77 kg. Polymerization was carried out by the method. After 4 hours, when the polymerization rate of VAc reached 32%, it was cooled and the polymerization was stopped. Subsequently, the results of producing and evaluating modified EVOH composition pellets in the same manner as in Synthesis Example 1 are summarized in Table 1.
- a single-layer film was formed under the above conditions to obtain a single-layer film of the EVOH composition.
- Cylinder temperature supply part 175 ° C, compression part 220 ° C, weighing part 220 ° C Die temperature: 220 ° C Screw rotation speed: 40-100rpm Discharge rate: 0.4 to 1.5 kg / hour Take-up roll temperature: 80 ° C Take-up roll speed: 0.8 to 3.2 m / min Film thickness: 20 to 150 ⁇ m
- the temperature conditions of the extruder at the time of producing a single layer film were set according to melting
- Cylinder temperature Supply unit: 175 ° C
- Compressed part melting point of EVOH composition + 30 to 45 ° C.
- Measuring section melting point of EVOH composition +30 to 45 ° C.
- Die temperature melting point of EVOH composition + 30-45 ° C.
- Example 2 A monolayer film was prepared and evaluated in the same manner as in Example 1 (1) except that the modified EVOH composition pellets were 10 parts by weight and the unmodified EVOH composition pellets were 90 parts by weight. The results are summarized in Table 2.
- Example 3 A monolayer film was produced and evaluated in the same manner as in Example 1 (1) except that 30 parts by weight of the modified EVOH composition pellets and 70 parts by weight of the unmodified EVOH composition pellets were used. The results are summarized in Table 2.
- Example 4 A monolayer film was prepared and evaluated in the same manner as in Example 1 (1) except that 45 parts by weight of the modified EVOH composition pellets and 55 parts by weight of the unmodified EVOH composition pellets were used. The results are summarized in Table 2.
- Example 5 A monolayer film was produced and evaluated in the same manner as in Example 1 (1) except that the modified EVOH composition pellets were 70 parts by weight and the unmodified EVOH composition pellets were 30 parts by weight. The results are summarized in Table 2.
- Example 6 In Example 1 (1), the modified EVOH composition pellet obtained in Synthesis Example 3 was used in place of the modified EVOH composition pellet obtained in Synthesis Example 1, and 30 parts by weight of the modified EVOH composition pellet, unmodified A single layer film was produced and evaluated in the same manner except that the EVOH composition pellet was 70 parts by weight. The results are summarized in Table 2.
- Example 7 In Example 1 (1), the modified EVOH composition pellet obtained in Synthesis Example 4 was used in place of the modified EVOH composition pellet obtained in Synthesis Example 1, and 30 parts by weight of the modified EVOH composition pellet was unmodified. A single layer film was produced and evaluated in the same manner except that the EVOH composition pellet was 70 parts by weight. The results are summarized in Table 2.
- Example 8 In Example 1 (1), the modified EVOH composition pellet obtained in Synthesis Example 5 was used in place of the modified EVOH composition pellet obtained in Synthesis Example 1, and 30 parts by weight of the modified EVOH composition pellet was unmodified. A single layer film was produced and evaluated in the same manner except that the EVOH composition pellet was 70 parts by weight. The results are summarized in Table 2.
- Example 9 In Example 1 (1), the modified EVOH composition pellet obtained in Synthesis Example 6 was used in place of the modified EVOH composition pellet obtained in Synthesis Example 1, and 30 parts by weight of the modified EVOH composition pellet, unmodified A single layer film was produced and evaluated in the same manner except that the EVOH composition pellet was 70 parts by weight. The results are summarized in Table 2.
- Example 10 In Example 1 (1), the unmodified EVOH composition pellets obtained in Synthesis Example 7 were used in place of the unmodified EVOH composition pellets obtained in Synthesis Example 2, and 30 parts by weight of the modified EVOH composition pellets were obtained. A single-layer film was produced and evaluated in the same manner except that the amount was 70 parts by weight of the unmodified EVOH composition pellets. The results are summarized in Table 2.
- Example 11 In Example 1 (1), the modified EVOH composition pellets obtained in Synthesis Example 8 were used in place of the unmodified EVOH composition pellets obtained in Synthesis Example 2, and 30 parts by weight of the modified EVOH composition pellets were obtained. A single-layer film was produced and evaluated in the same manner except that the amount was 70 parts by weight of the unmodified EVOH composition pellets. The results are summarized in Table 2.
- Example 1 Comparative Example 1 In Example 1 (1), a single layer film was prepared and evaluated in the same manner except that only unmodified EVOH was used and dry blending and melt kneading with modified EVOH were not performed. The results are summarized in Table 1. It can be seen that a single-layer film consisting only of unmodified EVOH is inferior in stretchability.
- Comparative Example 2 In Comparative Example 1, a monolayer film was produced and evaluated in the same manner except that the pellet obtained in Synthesis Example 7 was used instead of the unmodified EVOH composition obtained in Synthesis Example 2. The results are summarized in Table 2. It can be seen that a single-layer film consisting only of unmodified EVOH is inferior in stretchability.
- Comparative Example 3 In Comparative Example 1, a single layer film was produced and evaluated in the same manner except that the pellet obtained in Synthesis Example 8 was used instead of the unmodified EVOH composition obtained in Synthesis Example 2. The results are summarized in Table 2. It can be seen that a single-layer film consisting only of unmodified EVOH is inferior in stretchability.
- Comparative Example 4 In Comparative Example 1, a single layer film was prepared and evaluated in the same manner except that the modified EVOH composition pellet obtained in Synthesis Example 1 was used instead of the unmodified EVOH composition obtained in Synthesis Example 2. went. The results are summarized in Table 2. It can be seen that a single-layer film composed only of modified EVOH is inferior in oxygen barrier properties.
- Comparative Example 5 In Comparative Example 1, a single-layer film was prepared and evaluated in the same manner except that the modified EVOH composition pellet obtained in Synthesis Example 3 was used instead of the unmodified EVOH composition obtained in Synthesis Example 2. went. The results are summarized in Table 2. It can be seen that a single-layer film composed only of modified EVOH is inferior in oxygen barrier properties.
- Example 12 Production of blow molded container After dry blending 10 parts by weight of the modified EVOH composition pellets obtained in Synthesis Example 9 and 90 parts by weight of the unmodified EVOH composition pellets obtained in Synthesis Example 2, a twin-screw extruder And then kneaded and pelletized to obtain resin composition pellets.
- the extrusion temperature and die temperature of each resin are set to 210 ° C. with a blow molding machine TB-ST-6P manufactured by Suzuki Wood Works, and it has a layer structure of HDPE / adhesive resin / resin composition / adhesive resin / HDPE.
- a three-kind five-layer parison was extruded, blown in a mold at 15 ° C., and cooled for 20 seconds to obtain a 500 mL multilayer container.
- the container could be molded without any particular problems. Further, the appearance of the container was good.
- a multilayer sheet (HDPE / adhesive resin / resin composition / Adhesive resin / HDPE) was prepared.
- the layer configuration of the sheet was 450 ⁇ m for HDPE resin (“HZ8200B” manufactured by Mitsui Chemicals) for the inner and outer layers, 50 ⁇ m each for the adhesive resin (“Admer GT4” manufactured by Mitsui Chemicals), and 75 ⁇ m for the resin composition for the intermediate layer.
- thermoformed container is a cup-shaped container having an internal volume of about 150 ml.
- the evaluation results are shown in Table 3.
- thermoformed container 140 ml of model gasoline ⁇ mixture of ratio of toluene (45 wt%): isooctane (45 wt%): methanol (10 wt%) ⁇ to the thermoformed container obtained in (9) above.
- Put the co-extruded sheet obtained in the above (8) in a circular shape and place it on the top of the cup, then shape it by hot plate welding with the lid completely closed so that the contents do not leak, A cup-shaped container filled with model gasoline was obtained. This was left in an atmosphere of 40 ° C. and 65% RH, and the weight loss of the cup after 14 days (average value of n 6) was determined. The amount of weight loss was 0.32 g.
- the evaluation results are shown in Table 3.
- Example 12 Comparative Example 6 In Example 12, except that only the unmodified EVOH composition pellets produced in Synthesis Example 2 were used, blow molded containers, thermoformed containers and injection pieces were produced and evaluated in the same manner. The results are summarized in Table 3. It can be seen that a container consisting only of unmodified EVOH is inferior in impact resistance and secondary processability.
- Example 12 Comparative Example 7 In Example 12, except that only the modified EVOH composition pellets produced in Synthesis Example 9 were used, blow molded containers, thermoformed containers and injection pieces were produced and evaluated in the same manner. The results are summarized in Table 3. It turns out that the container which consists only of modified
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Abstract
Description
0.01≦c≦20 (2)
[100-(a+c)]×0.9≦b≦[100-(a+c)] (3)
DS=[(X、Y及びZのうち水素原子であるものの合計モル数)/(X、Y及びZの合計モル数)]×100 (4)
0.01≦c≦20 (2)
[100-(a+c)]×0.9≦b≦[100-(a+c)] (3)
DS=[(X、Y及びZのうち水素原子であるものの合計モル数)/(X、Y及びZの合計モル数)]×100 (4)
18≦a≦55 (1)
0.01≦c≦20 (2)
[100-(a+c)]×0.9≦b≦[100-(a+c)] (3)
[100-(a+c)]×0.9≦b≦[100-(a+c)] (3)
[100-(a+c)]×0.95≦b≦[100-(a+c)] (3’)
[100-(a+c)]×0.98≦b≦[100-(a+c)] (3”)
DS=[(X、Y及びZのうち水素原子であるものの合計モル数)/(X、Y及びZの合計モル数)]×100 (4)
(1)変性エチレン-ビニルアルコール共重合体(変性EVAc)の合成
ジャケット、攪拌機、窒素導入口、エチレン導入口及び開始剤添加口を備えた50L加圧反応槽に、酢酸ビニル(式(II)において、R5がメチル基:以下、VAcと称する)を21kg、メタノール(以下、MeOHと称する)を2.1kg、2-メチレン-1,3-プロパンジオールジアセテート(式(III)において、R1、R2、R3及びR4が水素原子で、R6及びR7がメチル基:1,3-ジアセトキシ-2-メチレンプロパンと同一化合物:以下、MPDAcと称する)を1.1kg仕込み、60℃に昇温した後、30分間窒素バブリングして反応槽内を窒素置換した。次いで反応槽圧力(エチレン圧力)が4.2MPaとなるようにエチレンを導入した。反応槽内の温度を60℃に調整した後、開始剤として16.8gの2,2’-アゾビス(2,4-ジメチルバレロニトリル)(和光純薬工業株式会社製「V-65」)をメタノール溶液として添加し、重合を開始した。重合中はエチレン圧力を4.2MPaに、重合温度を60℃に維持した。4.5時間後にVAcの重合率が34%となったところで冷却して重合を停止した。反応槽を開放して脱エチレンした後、窒素ガスをバブリングして脱エチレンを完全に行った。次いで減圧下で未反応のVAcを除去した後、MPDAc由来の構造単位が共重合により導入された変性エチレン-酢酸ビニル共重合体(本明細書中、変性EVAcと称することがある)にMeOHを添加して20質量%MeOH溶液とした。
ジャケット、攪拌機、窒素導入口、還流冷却器及び溶液添加口を備えた10L反応槽に(1)で得た変性EVAcの20質量%MeOH溶液4715gを仕込んだ。この溶液に窒素を吹き込みながら60℃に昇温し、水酸化ナトリウムの濃度が2規定のMeOH溶液を14.7mL/分の速度で2時間添加した。水酸化ナトリウムMeOH溶液の添加終了後、系内温度を60℃に保ちながら2時間攪拌してケン化反応を進行させた。その後酢酸を254g添加してケン化反応を停止した。その後、80℃で加熱攪拌しながら、イオン交換水3Lを添加し、反応槽外にMeOHを流出させ、変性エチレン-ビニルアルコール共重合体(以下、変性EVOHと称する)を析出させた。デカンテーションにより析出した変性EVOHを収集し、ミキサーで粉砕した。得られた変性EVOH粉末を1g/Lの酢酸水溶液(浴比20:粉末1kgに対して水溶液20Lの割合)に投入して2時間攪拌洗浄した。これを脱液し、さらに1g/Lの酢酸水溶液(浴比20)に投入して2時間攪拌洗浄した。これを脱液したものを、イオン交換水(浴比20)に投入して攪拌洗浄を2時間行い脱液する操作を3回繰り返して精製を行った。次いで、酢酸0.5g/L及び酢酸ナトリウム0.1g/Lを含有する水溶液10Lに4時間攪拌浸漬してから脱液し、これを60℃で16時間乾燥させることで変性EVOHの粗乾燥物を503g得た。
ジャケット、攪拌機及び還流冷却器を備えた3L攪拌槽に、(2)を2回繰返して得た変性EVOHの粗乾燥物758g、水398g及びMeOH739gを仕込み、85℃に昇温して溶解させた。この溶解液を径4mmのガラス管を通して5℃に冷却した水/MeOH=90/10の混合液中に押し出してストランド状に析出させ、このストランドをストランドカッターでペレット状にカットすることで変性EVOHの含水ペレットを得た。得られた変性EVOHの含水ペレットの含水率をメトラー社製ハロゲン水分計「HR73」で測定したところ、55質量%であった。
上記(3)で得た変性EVOHの含水ペレット1577gを1g/Lの酢酸水溶液(浴比20)に投入して2時間攪拌洗浄した。これを脱液し、さらに1g/Lの酢酸水溶液(浴比20)に投入して2時間攪拌洗浄した。脱液後、酢酸水溶液を更新し同様の操作を行った。酢酸水溶液で洗浄してから脱液したものを、イオン交換水(浴比20)に投入して攪拌洗浄を2時間行い脱液する操作を3回繰り返して精製を行い、ケン化反応時の触媒残渣が除去された、変性EVOHの含水ペレットを得た。当該含水ペレットを酢酸ナトリウム濃度0.525g/L、酢酸濃度0.8g/L、リン酸濃度0.007g/Lの水溶液(浴比20)に投入し、定期的に攪拌しながら4時間浸漬させた。これを脱液し、80℃で3時間、及び105℃で16時間乾燥させることによって、酢酸、ナトリウム塩及びリン酸化合物を含有した変性EVOH組成物ペレットを得た。
変性EVAc中の、エチレン単位含有率(式(IV)におけるaモル%)、酢酸ビニル由来の構造単位の含有量(式(IV)におけるbモル%)及びMPDAc由来の構造単位の含有量(式(IV)におけるcモル%)は、ケン化前の変性EVAcを1H-NMR測定して算出した。
・0.6-1.0ppm:末端部位エチレン単位のメチレンプロトン(4H)
・1.0-1.85ppm:中間部位エチレン単位のメチレンプロトン(4H)、MPDAc由来の構造単位の主鎖部位メチレンプロトン(2H)、酢酸ビニル単位のメチレンプロトン(2H)
・1.85-2.1ppm:MPDAc由来の構造単位のメチルプロトン(6H)と酢酸ビニル単位のメチルプロトン(3H)
・2.4-2.6ppm:DMSO
・3.7-4.1ppm:MPDAc由来の構造単位の側鎖部位メチレンプロトン(4H)
・4.4-5.3ppm:酢酸ビニル単位のメチンプロトン(1H)
a=[(2x+2y-z-4w)/(2x+2y+z+4w)]×100
b=[8w/(2x+2y+z+4w)]×100
c=[2z/(2x+2y+z+4w)]×100
ケン化後の変性EVOHについても同様に1H-NMR測定を行った。上記(2)で得られた変性EVOHの粗乾燥物を、内部標準物質としてテトラメチルシラン、添加剤としてテトラフルオロ酢酸(TFA)を含むジメチルスルホキシド(DMSO)-d6に溶解し、500MHzの1H-NMR(日本電子株式会社製:「GX-500」)を用いて80℃で測定した。図2に、合成例1で得られた変性EVOHの1H-NMRスペクトルを示す。1.85~2.1ppmのピーク強度が大幅に減少していることから、酢酸ビニルに含まれるエステル基に加え、MPDAc由来の構造単位に含まれるエステル基もケン化されて水酸基になっていることは明らかである。ケン化度は酢酸ビニル単位のメチルプロトン(1.85~2.1ppm)と、ビニルアルコール単位のメチンプロトン(3.15~4.15ppm)のピーク強度比より算出した。変性EVOHのケン化度は99.9モル%以上であった。
上記(4)で得られた変性EVOH組成物ペレットについて、JIS K7121に準じて、30℃から215℃まで10℃/分の速度にて昇温した後100℃/分で-35℃まで急冷して再度-35℃から195℃まで10℃/分の昇温速度にて測定を実施した(セイコー電子工業株式会社製示差走査熱量計(DSC)「RDC220/SSC5200H」)。温度の校正にはインジウムと鉛を用いた。2ndランのチャートから前記JISにしたがって融解ピーク温度(Tpm)を求め、これを変性EVOHの融点とした。融点は151℃であった。
上記(4)で得られた変性EVOH組成物ペレット0.5gをテフロン(登録商標)製圧力容器に入れ、ここに濃硝酸5mLを加えて室温で30分間分解させた。30分後蓋をし、湿式分解装置(株式会社アクタック製:「MWS-2」)により150℃で10分間、次いで180℃で5分間加熱することで分解を行い、その後室温まで冷却した。この処理液を50mLのメスフラスコに移し純水でメスアップした。この溶液について、ICP発光分光分析装置(パーキンエルマー社製「OPTIMA4300DV」)により含有金属の分析を行い、ナトリウム元素及びリン元素の含有量を求めた。ナトリウム塩含有量は、ナトリウム元素換算値で150ppmであり、リン酸化合物含有量は、リン酸根換算値で10ppmであった。
合成例1の(1)において、MeOH量を6.3kgにし、エチレン圧力を3.7MPaにし、開始剤の量を4.2gにし、MPDAcを仕込まなかった以外は、同様の方法で重合を行った。4時間後にVAcの重合率が44%となったところで冷却し重合を停止した。引き続き、合成例1と同様に処理してナトリウム元素換算値で135ppmのナトリウム塩と、リン酸根換算値で11ppmのリン酸化合物を含有する未変性EVOH組成物ペレットを製造した。合成例1と同様に評価した結果を、表1にまとめて示す。
合成例1の(1)において、開始剤の量を8.4gにし、MPDAcの仕込量を0.5kgにした以外は、同様の方法で重合を行った。6時間後にVAcの重合率が52%となったところで冷却し重合を停止した。引き続き、合成例1と同様に変性EVOH組成物ペレットを製造して評価した結果を、表1にまとめて示す。
合成例3と同様にして変性EVAcを合成し、変性EVAcのメタノール溶液を得た。引き続き、水酸化ナトリウムのMeOH溶液を3.7mL/分の速度で添加した以外は、合成例1の(2)と同様の方法でケン化処理した。引き続き、合成例1と同様に変性EVOH組成物ペレットを製造して評価した結果を、表1にまとめて示す。
合成例1の(1)において、MeOHの量を1.1kgにし、エチレン圧力を3.8MPaにし、MPDAcの仕込量を2.0kgにし、重合開始から5時間後に開始剤を16.8g追加添加した以外は、同様の方法で重合を行った。10時間後にVAcの重合率が9%となったところで冷却し重合を停止した。引き続き、合成例1と同様に変性EVOH組成物ペレットを製造して評価した結果を、表1にまとめて示す。
合成例1の(1)において、MeOH量を1.1kgにし、開始剤の量を16.8gにし、エチレン圧力を6.0MPaにし、MPDAcの仕込量を1.1kgにした以外は、同様の方法で重合を行った。4時間後にVAcの重合率が22%となったところで冷却し重合を停止した。引き続き、合成例1と同様に変性EVOH組成物ペレットを製造して評価した結果を、表1にまとめて示す。
合成例1の(1)において、MeOH量を6.3kgにし、開始剤の量を4.2gにし、エチレン圧力を2.9MPaにし、MPDAcを添加しなかった以外は、同様の方法で重合を行った。4時間後にVAcの重合率が50%となったところで冷却し重合を停止した。引き続き、合成例1と同様に処理して未変性EVOH組成物ペレットを製造して評価した結果を、表1にまとめて示す。
合成例1の(1)において、MeOH量を4.2kgにし、開始剤の量を4.2gにし、エチレン圧力を5.3MPaにし、MPDAcを添加しなかった以外は、同様の方法で重合を行った。3時間後にVAcの重合率が29.3%となったところで冷却し重合を停止した。引き続き、合成例1と同様に処理して未変性EVOH組成物ペレットを製造して評価した結果を、表1にまとめて示す。
合成例1の(1)において、MeOH量を2.5kgにし、開始剤の量を8.4gにし、エチレン圧力を3.4MPaにし、MPDAcの仕込量を0.77kgにした以外は、同様の方法で重合を行った。4時間後にVAcの重合率が32%となったところで冷却し重合を停止した。引き続き、合成例1と同様に変性EVOH組成物ペレットを製造して評価した結果を、表1にまとめて示す。
(1)フィルムの作製
合成例1で得られた変性EVOH組成物ペレット5重量部と合成例2で得られた未変性EVOH組成物ペレット95重量部をドライブレンドした後、二軸押出機にて溶融混練してからペレット化した。得られたペレットを用いて、株式会社東洋精機製作所製20mm押出機「D2020」(D(mm)=20、L/D=20、圧縮比=2.0、スクリュー:フルフライト)を用いて以下の条件にて単層製膜を行い、EVOH組成物の単層フィルムを得た。
シリンダー温度:供給部175℃、圧縮部220℃、計量部220℃
ダイ温度:220℃
スクリュー回転数:40~100rpm
吐出量:0.4~1.5kg/時間
引取りロール温度:80℃
引取りロール速度:0.8~3.2m/分
フィルム厚み:20~150μm
シリンダー温度:
供給部:175℃
圧縮部:EVOH組成物の融点+30~45℃
計量部:EVOH組成物の融点+30~45℃
ダイ温度:EVOH組成物の融点+30~45℃
上記(1)で得られた厚さ150μmの単層フィルムを株式会社東洋精機製作所製パンタグラフ式二軸延伸装置にかけ、80℃で2×2倍~4×4倍の延伸倍率において同時二軸延伸を行うことにより熱収縮フィルムを得た。フィルムが破れずに延伸できた最大の延伸倍率を最大延伸倍率とした。最大延伸倍率は3倍(面積倍率9倍)であった。また、3×3倍の延伸倍率で延伸して得られた熱収縮フィルムを、以下の基準に従い評価したところB判定であった。それらの結果を表2に示す。
A:延伸ムラ及び局部的偏肉が認められず、外観が良好であった。
B:延伸ムラ又は局部的偏肉が生じた。
C:延伸ムラ又は局部的偏肉が生じた。または、フィルムに破れが生じた。
上記(2)で得られた延伸倍率3×3の熱収縮フィルムを10cm×10cmにカットし、80℃の熱水に10秒浸漬させ、シュリンク率(%)を下記のように算出した。シュリンク率は、65.5%であった。結果を表2に示す。
シュリンク率(%)={(S-s)/S}×100
S:シュリンク前のフィルムの面積
s:シュリンク後のフィルムの面積
上記(1)で得られた厚さ20μmの単層フィルムを20℃、85%RHの条件下で3日間調湿後、同条件下で酸素透過速度の測定(Mocon社製「OX-TORAN MODEL 2/21」)を行った。その結果、酸素透過速度(OTR)は1.4cc・20μm/m2・day・atmであった。結果を表2に示す。
実施例1の(1)において、変性EVOH組成物ペレット10重量部、未変性EVOH組成物ペレット90重量部にした以外は、同様の方法で単層フィルムを作製及び評価を行った。結果を、表2にまとめて示す。
実施例1の(1)において、変性EVOH組成物ペレット30重量部、未変性EVOH組成物ペレット70重量部にした以外は、同様の方法で単層フィルムを作製及び評価を行った。結果を、表2にまとめて示す。
実施例1の(1)において、変性EVOH組成物ペレット45重量部、未変性EVOH組成物ペレット55重量部にした以外は、同様の方法で単層フィルムを作製及び評価を行った。結果を、表2にまとめて示す。
実施例1の(1)において、変性EVOH組成物ペレット70重量部、未変性EVOH組成物ペレット30重量部にした以外は、同様の方法で単層フィルムを作製及び評価を行った。結果を、表2にまとめて示す。
実施例1の(1)において、合成例1で得られた変性EVOH組成物ペレットの代わりに合成例3で得られた変性EVOH組成物ペレットを用い、変性EVOH組成物ペレット30重量部、未変性EVOH組成物ペレット70重量部にした以外は、同様の方法で単層フィルムを作製及び評価を行った。結果を、表2にまとめて示す。
実施例1の(1)において、合成例1で得られた変性EVOH組成物ペレットの代わりに合成例4で得られた変性EVOH組成物ペレットを用い、変性EVOH組成物ペレット30重量部、未変性EVOH組成物ペレット70重量部にした以外は、同様の方法で単層フィルムを作製及び評価を行った。結果を、表2にまとめて示す。
実施例1の(1)において、合成例1で得られた変性EVOH組成物ペレットの代わりに合成例5で得られた変性EVOH組成物ペレットを用い、変性EVOH組成物ペレット30重量部、未変性EVOH組成物ペレット70重量部にした以外は、同様の方法で単層フィルムを作製及び評価を行った。結果を、表2にまとめて示す。
実施例1の(1)において、合成例1で得られた変性EVOH組成物ペレットの代わりに合成例6で得られた変性EVOH組成物ペレットを用い、変性EVOH組成物ペレット30重量部、未変性EVOH組成物ペレット70重量部にした以外は、同様の方法で単層フィルムを作製及び評価を行った。結果を、表2にまとめて示す。
実施例1の(1)において、合成例2で得られた未変性EVOH組成物ペレットの代わりに合成例7で得られた未変性EVOH組成物ペレットを用い、変性EVOH組成物ペレット30重量部、未変性EVOH組成物ペレット70重量部にした以外は、同様の方法で単層フィルムを作製及び評価を行った。結果を、表2にまとめて示す。
実施例1の(1)において、合成例2で得られた未変性EVOH組成物ペレットの代わりに合成例8で得られた未変性EVOH組成物ペレットを用い、変性EVOH組成物ペレット30重量部、未変性EVOH組成物ペレット70重量部にした以外は、同様の方法で単層フィルムを作製及び評価を行った。結果を、表2にまとめて示す。
実施例1の(1)において、未変性EVOHのみを用い、変性EVOHとのドライブレンドと溶融混練を行わなかった以外は、同様の方法で単層フィルムの作製及び評価を行った。結果を、表1にまとめて示す。未変性EVOHのみからなる単層フィルムは延伸性に劣ることがわかる。
比較例1において、合成例2で得られた未変性EVOH組成物の代わりに合成例7で得られたペレットを用いた以外は、同様の方法で単層フィルムを作製及び評価を行った。結果を、表2にまとめて示す。未変性EVOHのみからなる単層フィルムは延伸性に劣ることがわかる。
比較例1において、合成例2で得られた未変性EVOH組成物の代わりに合成例8で得られたペレットを用いた以外は、同様の方法で単層フィルムを作製及び評価を行った。結果を、表2にまとめて示す。未変性EVOHのみからなる単層フィルムは延伸性に劣ることがわかる。
比較例1において、合成例2で得られた未変性EVOH組成物の代わりに合成例1で得られた変性EVOH組成物ペレットを用いた以外は、同様の方法で単層フィルムを作製及び評価を行った。結果を、表2にまとめて示す。変性EVOHのみからなる単層フィルムは酸素バリア性に劣ることがわかる。
比較例1において、合成例2で得られた未変性EVOH組成物の代わりに合成例3で得られた変性EVOH組成物ペレットを用いた以外は、同様の方法で単層フィルムを作製及び評価を行った。結果を、表2にまとめて示す。変性EVOHのみからなる単層フィルムは酸素バリア性に劣ることがわかる。
(5)ブロー成形容器の作製
合成例9で得られた変性EVOH組成物ペレット10重量部と合成例2で得られた未変性EVOH組成物ペレット90重量部をドライブレンドした後、二軸押出機にて溶融混練してからペレット化し、樹脂組成物ペレットを得た。一方、高密度ポリエチレン(HDPE)として三井石油化学製「HZ8200B」(190℃、2160g荷重におけるMFR=0.01g/10分)、接着性樹脂として三井化学製「アドマーGT4」(190℃、2160g荷重下におけるMFR=0.2g/10分)を用いた。鈴木製工所製ブロー成形機TB-ST-6Pにて各樹脂の押出温度及びダイス温度を210℃に設定し、HDPE/接着性樹脂/樹脂組成物/接着性樹脂/HDPEの層構成を有する3種5層パリソンを押し出し、15℃の金型内でブローし、20秒冷却して、500mLの多層容器を得た。前記容器の胴部における平均厚みは2175μmであり、各層の厚みは、(内側)HDPE/接着性樹脂/樹脂組成物/接着性樹脂/HDPE(外側)=1000/50/75/50/1000μmであった。容器は特に問題なく成形できた。また、容器の外観は良好であった。
上記(5)で得られた多層容器にモデルガソリン{トルエン(45重量%):イソオクタン(45重量%):メタノール(10重量%)の比の混合物}300mlを入れ、アルミホイルを用いて漏れがないように完全に栓をしたうえで40℃、65%RHの雰囲気下に放置して、14日後のボトル重量減少量(n=6の平均値)を求めた。重量減少量は0.41gであった。評価結果を表3に示す。
上記(5)で得られた多層容器に、エチレングリコールを内容積に対して60%充填し、-40℃の冷凍室に3日間放置した後コンクリート上に落下させ、ボトルの破壊(容器内部のエチレングリコールが漏れる)する落下高さを求めた。破壊高さは、n=30の試験結果を用いて、JIS試験法(K7211の「8.計算」の部分)に示される計算方法を用いて、50%破壊高さを求めた。破壊高さは6.5mであった。評価結果を表3に示す。
上記(5)で作製した変性EVOHと未変性EVOHを含むペレットを用い、3種5層共押出装置を用いて、多層シート(HDPE/接着性樹脂/樹脂組成物/接着性樹脂/HDPE)を作製した。シートの層構成は、内外層のHDPE樹脂(三井化学製「HZ8200B」)が450μm、接着性樹脂(三井化学製「アドマーGT4」)が各50μm、中間層の樹脂組成物が75μmであった。
上記(8)で得られた多層シートを熱成形機(浅野製作所製:真空圧空深絞り成形機「FX-0431-3型」)にて、シート温度を160℃にして、圧縮空気(気圧5kgf/cm2)により丸カップ形状(金型形状:上部75mmφ、下部60mmφ、深さ75mm、絞り比S=1.0)に熱成形することにより、熱成形容器を得た。成形条件を以下に示す。
ヒーター温度:400℃
プラグ :45φ×65mm
プラグ温度 :150℃
金型温度 :70℃
上記(9)で得られた熱成形容器にモデルガソリン{トルエン(45重量%):イソオクタン(45重量%):メタノール(10重量%)の比の混合物}140mlを入れて、前記(8)で得られた共押出シートを円形に切断したものをカップ上部にのせたのち、内容物が漏れないように完全にふたをした状態で熱板溶着法により成形し、内部にモデルガソリンを封入したカップ型容器を得た。これを40℃、65%RHの雰囲気下に放置して、14日後のカップ重量減少量(n=6の平均値)を求めた。重量減少量は0.32gであった。評価結果を表3に示す。
上記(5)で作製した変性EVOHと未変性EVOHを含むペレットを用い、射出成形機(日精製、FS-80S)を用いて、射出片を作製し、アイゾット試験機を用いて、室温の条件で、JIS K7110に準じて衝撃強度を求めた。10個の射出片を測定し、測定結果の平均値を衝撃強度とした。衝撃強度は24kJ/m2であった。評価結果を表3に示す。
実施例12において、合成例2で作製した未変性EVOH組成物ペレットのみを用いた以外は、同様の方法でブロー成形容器、熱成形容器及び射出片を作製し、評価を行った。結果を、表3にまとめて示す。未変性EVOHのみからなる容器は耐衝撃性及び二次加工性に劣ることがわかる。
実施例12において、合成例9で作製した変性EVOH組成物ペレットのみを用いた以外は、同様の方法でブロー成形容器、熱成形容器及び射出片を作製し、評価を行った。結果を、表3にまとめて示す。変性EVOHのみからなる容器は燃料のバリア性に劣ることがわかる。
Claims (17)
- 下記式(I)で表され、全単量体単位に対するa、b及びcの含有率(モル%)が下記式(1)~(3)を満足し、かつ下記式(4)で定義されるケン化度(DS)が90モル%以上である変性エチレン-ビニルアルコール共重合体(A)と、エチレン単位含有率が20~60モル%でケン化度が80モル%以上の未変性エチレン-ビニルアルコール共重合体(B)とを含む樹脂組成物。
18≦a≦55 (1)
0.01≦c≦20 (2)
[100-(a+c)]×0.9≦b≦[100-(a+c)] (3)
DS=[(X、Y及びZのうち水素原子であるものの合計モル数)/(X、Y及びZの合計モル数)]×100 (4) - 前記変性エチレン-ビニルアルコール共重合体(A)と前記未変性エチレン-ビニルアルコール共重合体(B)の重量比(A/B)が5/95~50/50である、請求項1に記載の樹脂組成物。
- 前記変性エチレン-ビニルアルコール共重合体(A)のR1、R2、R3及びR4が水素原子である、請求項1又は2に記載の樹脂組成物。
- 前記変性エチレン-ビニルアルコール共重合体(A)のX、Y及びZが、それぞれ独立に水素原子又はアセチル基である、請求項1~3のいずれかに記載の樹脂組成物。
- 20℃、65%RHにおける酸素透過速度が100cc・20μm/m2・day・atm以下である、請求項1~4のいずれかに記載の樹脂組成物。
- さらに、アルカリ金属元素換算で10~500ppmのアルカリ金属塩を含有する、請求項1~5のいずれかに記載の樹脂組成物。
- 請求項1~6のいずれかに記載の樹脂組成物からなるバリア材。
- 請求項1~6のいずれかに記載の樹脂組成物からなる層を有するフィルム又はシート。
- 面積倍率7倍以上に延伸されてなる、請求項8に記載のフィルム又はシート。
- 前記樹脂組成物からなる層とエチレン-ビニルアルコール共重合体以外の熱可塑性樹脂からなる層が積層された、請求項8又は9に記載のフィルム又はシート。
- 請求項8~10のいずれかに記載のフィルム又はシートからなる熱収縮フィルム又は熱収縮シート。
- 請求項1~6のいずれかに記載の樹脂組成物からなる層及びエチレン-ビニルアルコール共重合体以外の熱可塑性樹脂からなる層を含む共押出ブロー成形容器。
- 請求項1~6のいずれかに記載の樹脂組成物を含む押出成形品。
- 請求項1~6のいずれかに記載の樹脂組成物を含む熱成形品。
- 請求項1~6のいずれかに記載の樹脂組成物を含む燃料容器。
- エチレン、下記式(II)で示されるビニルエステル、及び下記式(III)で示される不飽和単量体をラジカル重合させて下記式(IV)で示される変性エチレン-ビニルエステル共重合体を得た後に、それをケン化して、前記変性エチレン-ビニルアルコール共重合体(A)を製造してから、未変性エチレン-ビニルアルコール共重合体(B)と混合することを特徴とする、請求項1~6のいずれかに記載の樹脂組成物の製造方法。
- 前記変性エチレン-ビニルアルコール共重合体(A)及び前記未変性エチレン-ビニルアルコール共重合体(B)の少なくとも一方の樹脂を、アルカリ金属塩を含む水溶液と接触させてから、両樹脂を混合する請求項16に記載の樹脂組成物の製造方法。
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