WO2016006694A1 - エチレン-ビニルアルコール共重合体、樹脂組成物、及びこれらを用いた成形体 - Google Patents
エチレン-ビニルアルコール共重合体、樹脂組成物、及びこれらを用いた成形体 Download PDFInfo
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- WO2016006694A1 WO2016006694A1 PCT/JP2015/069930 JP2015069930W WO2016006694A1 WO 2016006694 A1 WO2016006694 A1 WO 2016006694A1 JP 2015069930 W JP2015069930 W JP 2015069930W WO 2016006694 A1 WO2016006694 A1 WO 2016006694A1
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Definitions
- the present invention relates to an ethylene-vinyl alcohol copolymer, a resin composition, a film, a vapor deposition film, a multilayer structure, a thermoformed container, a blow molded object, and a fuel container.
- melt molding using a resin composition is used for molding containers, films, sheets and the like.
- a resin composition can form a molded product having few defects such as streak and fish eye and excellent in appearance, and long-time operation characteristics (long run property) in which defects do not easily occur even after long-time melt molding. ) Is required.
- defects not only impair the appearance of the molded product, but also cause performance deterioration, so it is important to suppress the occurrence of defects.
- an ethylene-vinyl alcohol copolymer (hereinafter also referred to as “EVOH”) is a polymer material having excellent gas barrier properties such as oxygen, oil resistance, non-charging properties, mechanical strength, and the like. Therefore, the EVOH-containing resin composition is widely used as a molding material for molded articles such as containers.
- EVOH has a relatively active hydroxyl group in the molecule, oxidation and cross-linking reactions may occur in a high-temperature molten state even in an extruder with almost no oxygen, which may cause thermal degradation.
- a thermally deteriorated material accumulates inside the molding machine, and gel-like spots that cause fish eyes are likely to occur. For this reason, in the melt molding using the EVOH-containing resin composition, the long run property tends to be insufficient.
- an EVOH-containing resin composition (see Japanese Patent Application Laid-Open No. 11-60874) having improved long-run properties during melt molding by containing a boron compound, sodium acetate and magnesium acetate, and a conjugated polyene compound are melted.
- EVOH-containing resin composition (see Japanese Patent Application Laid-Open No. 9-71620) in which generation of gels and blisters by molding is suppressed, a specific carboxylic acid metal salt, and a hindered phenol-based antioxidant are included to improve thermal stability.
- An EVOH-containing resin composition (see JP-A-4-227744) that is excellent and suppresses the formation of an oxidizing gel at high temperatures has been developed.
- the EVOH-containing resin composition may be required to further suppress coloring such as yellowing in melt molding.
- a method has been proposed in which a predetermined amount of a metal salt is contained in the EVOH resin composition (see JP-A-2001-146539).
- the EVOH resin composition is capable of suppressing film breakage due to tension between rolls in film unwinding and processing during lamination with other thermoplastic resins and vapor deposition of aluminum after film formation (film resistance) (Breakability) may be required.
- the EVOH resin composition may be required to be excellent in slipperiness (blocking resistance) between films when stored as a film roll after film formation and slipperiness with a production roll during lamination processing, In response to this requirement, it has been proposed to contain an oxide and a boron compound (see Japanese Patent Application Laid-Open No. 2000-265024). Further, the film formed from the EVOH resin composition may be required to suppress the generation of pinholes (deposition defect suppression property) when performing the vapor deposition process. A surface treatment resin film having a molar ratio in a specific range has been proposed (see JP-A-2005-290108). However, the above-mentioned conventional resin composition and film cannot satisfy the above requirements.
- the EVOH resin composition may be used as a molded product such as a packaging material by being laminated with a thermoplastic resin mainly composed of a polyolefin-based resin or the like.
- This molded product may be reused as at least one layer of a multilayered structure including a polyolefin layer and an EVOH layer by collecting ends, defective products, and the like generated during molding and melt-molding. Therefore, the EVOH resin composition may be required to maintain excellent appearance and impact resistance when it is repeatedly collected and reused.
- an EVOH resin composition suitable for reuse has been proposed (see, for example, JP-A-3-72542), but the above requirement cannot be satisfied.
- a laminate comprising an EVOH layer formed of an EVOH resin composition and another thermoplastic resin layer is useful as a packaging material for boil sterilization or retort sterilization of food.
- the laminate is required to have “retort resistance” that can prevent water from entering the EVOH layer during the hot water boil and retort treatment.
- a method has been proposed in which an EVOH resin composition is blended with polyamide having high hot water resistance (hereinafter also referred to as “PA”) (see, for example, JP-A-10-80981).
- PA polyamide having high hot water resistance
- the EVOH resin composition containing the conventional PA increases the generation of kogation in the extruder, screw and die during long-time melt molding, etc. It is difficult to improve both retort resistance.
- the EVOH resin composition may be required to be suitable for secondary processing at the time of molding into a packaging material such as food, particularly improvement in heat stretchability and improvement in transparency.
- a packaging material such as food
- an EVOH resin composition containing two or more types of EVOH having different saponification degrees has been proposed (see JP 2000-212369 A).
- JP 2000-212369 A since the conventional EVOH resin composition tends to cause flow marks and coloring during a long run, it is difficult to achieve both the suppression of the flow marks and coloring during the long run and the improvement of heat stretchability.
- a gas barrier film including a base film formed of the EVOH resin composition and a metal deposition layer such as aluminum deposited on the base film may be used as a heat insulating material.
- the gas barrier film is required to suppress defects in the metal vapor deposition layer and improve the adhesion between the film and the metal vapor deposition layer.
- a method of containing an inorganic filler in a base film see JP 2002-310385 A
- a method of performing surface treatment on a base film see JP 2005-290108 A
- a packaging material including an EVOH layer formed of an EVOH resin composition may be used as a packaging container having excellent oxygen barrier properties by thermoforming.
- This packaging container is required to suppress the occurrence of defects in thermoforming, and to improve the appearance and strength.
- an EVOH resin composition to which a plasticizer, polyamide, etc. are added has been proposed (for example, special features). (See Kaiho 59-020345).
- a thermoformed container formed of the conventional EVOH resin composition has a risk of lowering gas barrier properties, and thus cannot satisfy the above requirements while maintaining the original characteristics of EVOH.
- a multilayer structure including an EVOH layer formed of an EVOH resin composition and another thermoplastic resin layer may be used as a blow molded container.
- the melt molding apparatus may be temporarily stopped and then restarted for resin switching or the like.
- the EVOH resin composition is required to have a performance (self-purge property) that can be quickly discharged from the melt molding apparatus so that the deteriorated resin composition remaining in the melt molding apparatus does not deteriorate the quality of the molded product.
- an EVOH resin composition containing an alkaline earth metal salt or the like has been proposed (see, for example, JP-A-5-255554).
- the conventional EVOH-containing resin composition has good self-purge properties. Is hard to say.
- the present invention has been made based on the circumstances as described above, and its purpose is excellent in the long run property of melt molding, and the occurrence of film formation defects such as film formation defects and streaks and coloring are suppressed, It is an object to provide an ethylene-vinyl alcohol copolymer, a resin composition, and a molded body using these, which are excellent in appearance.
- the present invention relates to an ethylene-vinyl alcohol copolymer (A) obtained by saponifying a copolymer of ethylene and vinyl ester, and comprising a differential refractive index detector and an ultraviolet-visible absorbance detector.
- A ethylene-vinyl alcohol copolymer obtained by saponifying a copolymer of ethylene and vinyl ester, and comprising a differential refractive index detector and an ultraviolet-visible absorbance detector.
- Ma molecular weight in terms of polymethyl methacrylate at the maximum value of the peak measured with a differential refractive index detector
- Mb in terms of polymethyl methacrylate at the maximum value of the absorption peak at a wavelength of 220 nm measured with an ultraviolet-visible absorbance detector
- the ethylene-vinyl alcohol copolymer When the ethylene-vinyl alcohol copolymer satisfies the condition expressed by the formula (1), it has excellent long-run property of melt molding, and suppresses generation and coloring of film forming defects such as streaks and film forming defects. it can. Therefore, the ethylene-vinyl alcohol copolymer can provide a molded article such as a multilayer structure having excellent appearance.
- the molecular weight measured after heat treatment at 220 ° C. for 50 hours under a nitrogen atmosphere is as follows: It is preferable to further satisfy the condition represented by the formula (2).
- (Ma-Mc) / Ma ⁇ 0.45 (2) Ma: molecular weight in terms of polymethyl methacrylate at the maximum value of the peak measured by the differential refractive index detector Mc: polymethyl methacrylate in terms of the maximum value of the absorption peak at a wavelength of 280 nm measured by the UV-visible absorbance detector Molecular weight
- the vinyl ester is preferably vinyl acetate.
- the content of acetaldehyde in vinyl acetate is preferably less than 100 ppm.
- an ethylene-vinyl alcohol copolymer (A) satisfying the above formula (1) can be easily prepared. Become.
- the present invention includes a resin composition containing the ethylene-vinyl alcohol copolymer. Since the resin composition contains the ethylene-vinyl alcohol copolymer, the resin composition is excellent in long run property of melt molding, and generation of film formation defects such as film formation defects and streaks and coloring are suppressed, and appearance is improved. Excellent.
- the resin composition may further contain an alkali metal salt (B1) of an organic acid.
- an alkali metal salt (B1) As content of this alkali metal salt (B1), 1 ppm or more and 1,000 ppm or less are preferable in metal conversion.
- a specific amount of the alkali metal salt (B1) coloring can be suppressed, and as a result, the appearance can be further improved. Further, it is possible to improve the interlaminar adhesive strength when a long run property and a multilayer structure are obtained.
- the resin composition may further contain an organic acid polyvalent metal salt (B2).
- an organic acid polyvalent metal salt (B2) As content of this polyvalent metal salt (B2), 1 ppm or more and 500 ppm or less are preferable in metal conversion.
- the resin composition may further contain inorganic particles (C).
- C inorganic particles
- the appearance after melt molding such as the color of the film end (roll end), the film rupture resistance, and the deposition defect suppression property.
- the adhesion strength of the deposited layer is further improved.
- the arithmetic mean roughness (Ra) of the surface of the film formed from the said resin composition becomes moderate, and blocking resistance and slipperiness improve.
- the resin composition may further contain a polyolefin (D).
- a polyolefin (D) When the resin composition further contains the polyolefin (D), excellent appearance and impact resistance can be maintained even when recovery and reuse are repeated.
- the resin composition may further contain polyamide (E).
- the mass ratio (A / E) between the ethylene-vinyl alcohol copolymer (A) and the polyamide (E) is preferably from 60/40 to 95/5.
- the resin composition includes an ethylene-vinyl alcohol copolymer (A) having an ethylene content of 10 mol% to 50 mol% and an ethylene content of 30 mol% to 60 mol%. It is good to further contain a polymer (F).
- the value obtained by subtracting the ethylene content of the ethylene-vinyl alcohol copolymer (A) from the ethylene content of the ethylene-vinyl alcohol copolymer (F) is preferably 8 mol% or more.
- the mass ratio (A / F) between the ethylene-vinyl alcohol copolymer (A) and the ethylene-vinyl alcohol copolymer (F) is preferably from 60/40 to 95/5.
- the resin composition contains a specific amount of the ethylene-vinyl alcohol copolymer (A) and the ethylene-vinyl alcohol copolymer (F) having an ethylene content in the above range, so that a flow mark during a long run can be obtained.
- coloring is suppressed and heat stretchability is excellent.
- a multilayer sheet excellent in appearance and heat stretchability can be formed.
- the packaging material and container which were excellent in external appearance and the flow mark was suppressed can be obtained from this multilayer sheet.
- the difference between the melting point of the ethylene-vinyl alcohol copolymer (A) and the melting point of the ethylene-vinyl alcohol copolymer (F) is preferably 15 ° C. or higher.
- the ethylene-vinyl alcohol copolymer (F) preferably has a structural unit represented by the following formula (3). Further, the content of this structural unit in the ethylene-vinyl alcohol copolymer (F) with respect to all vinyl alcohol units is preferably 0.3 mol% or more and 40 mol% or less. When the ethylene-vinyl alcohol copolymer (F) has the specific structural unit at the specific content, the heat stretchability is further improved.
- R 1 , R 2 , R 3 and R 4 are each independently a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms or an alkoxy group having 1 to 10 carbon atoms.
- Some or all of the hydrogen atoms of the hydrocarbon group may be substituted with a hydroxyl group, an alkoxy group, a carboxy group, or a halogen atom, and R 1 and R 2 are bonded to each other to form a ring structure. May be.
- the present invention includes a film made of the resin composition. Moreover, this invention includes a vapor deposition film provided with the said film and the metal vapor deposition layer laminated
- the present invention includes a multilayer structure having a first layer made of the resin composition.
- the present invention also includes a thermoformed container provided with the multilayer structure.
- the thermoformed container contains an ethylene-vinyl alcohol copolymer (A) satisfying the above specific conditions in the first layer. The occurrence of defects in thermoforming is suppressed, and the appearance is excellent and the strength is sufficient.
- the thermoforming container contains the ethylene-vinyl alcohol copolymer (A) satisfying the above-mentioned specific condition in the first layer, the thermoforming container is excellent in self-purge property in the manufacturing process, so that the manufacturing cost can be reduced. it can. Therefore, the thermoformed container can be used for various applications.
- the present invention includes a blow molded article provided with the multilayer structure.
- the blow molded article contains an ethylene-vinyl alcohol copolymer (A) satisfying the above specific conditions in the first layer. Since the occurrence of defects such as gelled blisters and streaks due to melt molding and coloring are suppressed, the appearance is excellent.
- the blow molded article contains the ethylene-vinyl alcohol copolymer (A) satisfying the above-mentioned specific condition in the first layer, it is excellent in self-purge property in the production process, and thus the production cost can be reduced. Therefore, the blow molded body can be used for various applications including a blow molded container.
- the blow molded body can be suitably used as a fuel container.
- ppm means the mass ratio of the content of each component, and 1 ppm is 0.0001 mass%.
- the ethylene-vinyl alcohol copolymer and resin composition of the present invention are excellent in the long run property of melt molding and can suppress the occurrence of film formation defects such as streaks and film formation defects and coloring. Therefore, the ethylene-vinyl alcohol copolymer and the resin composition can provide a molded article such as a multilayer structure having excellent appearance.
- the relationship between the molecular weight (logarithmic value) of EVOH, the signal value (RI) measured with a differential refractive index detector, and the absorbance (UV) measured with an absorbance detector (measurement wavelengths 220 nm and 280 nm) is schematically shown. It is a graph. It is a typical perspective view which shows the cup-shaped container which is one Embodiment of the thermoforming container of this invention. It is typical sectional drawing of the cup-shaped container of FIG. It is typical sectional drawing which shows the principal part of the cup-shaped container of FIG. It is a schematic diagram for demonstrating the manufacturing method of the cup-shaped container of FIG. It is a schematic diagram for demonstrating the manufacturing method of the cup-shaped container of FIG. It is a typical fragmentary sectional view showing the blow molding container which is one embodiment of the blow molding object of the present invention.
- the present invention includes an ethylene-vinyl alcohol copolymer, a resin composition, a film, a vapor deposition film, a multilayer structure, a thermoformed container, a blow molded object, and a fuel container.
- a resin composition ethylene-vinyl alcohol copolymer
- a film a vapor deposition film
- a multilayer structure a thermoformed container
- a blow molded object a fuel container.
- the ethylene-vinyl alcohol copolymer (A) (hereinafter also referred to as “EVOH (A)”) of the present invention is a saponified copolymer of ethylene and vinyl ester.
- the copolymerization method of ethylene and vinyl ester is not particularly limited, and for example, known methods such as solution polymerization, suspension polymerization, emulsion polymerization, and bulk polymerization can be used.
- the copolymerization method may be either a continuous type or a batch type.
- the lower limit of the ethylene content of EVOH (A) is preferably 10 mol%, more preferably 20 mol%, and even more preferably 25 mol%.
- the upper limit of the ethylene content of EVOH (A) is preferably 60 mol%, more preferably 55 mol%, still more preferably 50 mol%, and particularly preferably 40 mol%.
- vinyl acetate is preferably used from the viewpoint of industrial availability.
- This vinyl acetate usually contains a small amount of acetaldehyde as an inevitable impurity.
- the acetaldehyde content of vinyl acetate is preferably less than 100 ppm.
- the upper limit of the vinyl acetate acetaldehyde content is more preferably 60 ppm, even more preferably 25 ppm, and particularly preferably 15 ppm.
- EVOH (A) may contain other structural units derived from monomers other than ethylene and vinyl ester. Examples of such a monomer that gives other structural units include vinyl silane compounds and other polymerizable compounds. As content of another structural unit, 0.0002 mol% or more and 0.2 mol% or less are preferable with respect to all the structural units of EVOH (A).
- the lower limit of the saponification degree of the structural unit derived from the vinyl ester of EVOH (A) is usually 85 mol%, preferably 90 mol%, more preferably 98 mol%, further preferably 98.9 mol%. If the degree of saponification is less than the above lower limit, the thermal stability may be insufficient.
- the peak top molecular weight (Ma) is obtained by separating EVOH (A) after heat treatment at 220 ° C. for 50 hours in a nitrogen atmosphere using gel permeation chromatography (hereinafter also referred to as “GPC”). As shown schematically in FIG. 1 of the eluted EVOH (A), this is a value corresponding to the maximum value of the main peak of the signal ("RI" in FIG. 1) measured by the differential refractive index detector.
- the peak top molecular weight (Ma) in the present invention is a value in terms of polymethyl methacrylate (hereinafter also referred to as “PMMA conversion”) calculated using a calibration curve prepared by the method described later.
- the lower limit of the peak top molecular weight (Ma) is preferably 30,000, more preferably 35,000, further preferably 40,000, and particularly preferably 50,000.
- the upper limit of the peak top molecular weight (Ma) is preferably 100,000, more preferably 80,000, further preferably 65,000, and particularly preferably 60,000.
- Absorption peak molecular weights (Mb) and (Mc) Absorption peak molecular weights (Mb) and (Mc) are measured with a UV-visible absorbance detector by separating EVOH (A) by GPC under the same conditions as the measurement of peak top molecular weight (Ma) as schematically shown in FIG. This is a value corresponding to the maximum value of the absorption peak of the signal (“UV” in FIG. 1) at a specific wavelength.
- the absorption peak molecular weights (Mb) and (Mc) are molecular weights in terms of polymethyl methacrylate.
- the molecular weight of the absorption peak at a wavelength of 220 nm is expressed as “Mb”, and the molecular weight of the absorption peak at a wavelength of 280 nm is expressed as “Mc”.
- the lower limit of the absorption peak molecular weight (Mb) is preferably 30,000, more preferably 35,000, further preferably 40,000, particularly preferably 50,000.
- the upper limit of the absorption peak molecular weight (Mb) is preferably 75,000, more preferably 60,000, and further preferably 55,000.
- the lower limit of the absorption peak molecular weight (Mc) is preferably 35,000, more preferably 40,000, still more preferably 45,000, and particularly preferably 48,000.
- the upper limit of the absorption peak molecular weight (Mc) is preferably 75,000, more preferably 55,000, and even more preferably 50,000.
- the calibration curve is a monodisperse PMMA (Peak Top Molecular Weight: 1,944,000, 790,000, 467,400, 271,400, 144,000, 79,250, 35,300) manufactured by Agilent Technologies as a standard. , 13, 300, 7, 100, 1,960, 1,020, 690) are prepared for each of the differential refractive index detector and the absorbance detector. Analysis software is preferably used to create a calibration curve. In the PMMA measurement of this measurement, for example, a column capable of separating peaks of standard samples having both molecular weights of 1,944,000 and 271400 is used.
- the left side (Ma ⁇ Mb) / Ma of formula (1) is preferably less than 0.40, more preferably less than 0.30, and even more preferably less than 0.10.
- the main peak (P RI ) obtained from the differential refractive index detector in FIG. 1 and the absorption peak (P UV ) obtained from the UV-visible absorbance detector. (220 nm)) are close to each other.
- the value of the molecular weight difference (Ma ⁇ Mb) increases, it means that these two peaks (P RI , P UV (220 nm)) are separated.
- EVOH (A) when the value of the molecular weight difference (Ma ⁇ Mb) between the two peaks (P RI , P UV (220 nm)) is large, it means that there are many components that absorb ultraviolet light having a wavelength of 220 nm in a relatively low molecular weight component. To do. Therefore, when EVOH (A) does not satisfy the above formula (1), it means that there are many components that absorb ultraviolet light having a wavelength of 220 nm among components having relatively low molecular weight. And in this case, EVOH (A) is thermally deteriorated during melt molding using the resin composition containing EVOH (A), and stable work moldability cannot be obtained for a long time due to thickening due to coloring or gelation. Under molding conditions on the high temperature side, molding defects tend to become apparent.
- the effect of satisfying the above formula (1) is considered to be caused by the following reason. That is, EVOH generates a carbon-carbon double bond or a carbonyl group in the molecule that absorbs ultraviolet light having a wavelength of 220 nm by causing thermal degradation such as dehydration, and these groups promote gelation of the resin composition. .
- the gelation promoting action described above depends on the molecular weight of the thermally degraded EVOH. When the molecular weight of the thermally degraded EVOH is large, the promoting action is weak, and as the molecular weight decreases, the promoting action becomes stronger. Therefore, when EVOH satisfies the above-mentioned formula (1), that is, when a relatively high molecular weight can be maintained even after thermal degradation, it is considered that molding defects can be suppressed.
- EVOH (A) preferably satisfies the condition of the following formula (2).
- the left side (Ma ⁇ Mc) / Ma of formula (2) is more preferably less than 0.40, still more preferably less than 0.30, and particularly preferably less than 0.15.
- the main peak (P RI ) obtained from the differential refractive index detector and the absorption peak (P R ) obtained from the UV-visible absorbance detector. UV (280 nm)) is far away, and a component having a relatively low molecular weight absorbs ultraviolet light having a wavelength of 280 nm.
- EVOH may be thermally deteriorated during melt molding, and there is a risk that stable processing moldability may not be obtained for a long time due to thickening due to coloring or gelation, and molding defects tend to become apparent under molding conditions on the high temperature side. It is in.
- the effect of satisfying the above equation (2) is considered to be caused by the following reason. That is, in EVOH, a carbon-carbon double bond or a carbonyl group is generated in the molecule due to the thermal degradation described above, and then the thermal degradation further proceeds. The yellowing of the resin composition is promoted by this conjugated double bond.
- the above-mentioned yellowing promoting effect depends on the molecular weight of the thermally degraded EVOH as in the above-described gelling promoting action. When the molecular weight of the thermally degraded EVOH is large, the promoting action is weak and the molecular weight is small. Indeed, the above-mentioned promoting action becomes stronger. Therefore, when EVOH satisfies the above-mentioned formula (2), that is, when a relatively high molecular weight can be maintained even when thermal degradation proceeds, it is considered that molding defects can be further suppressed.
- Method for preparing EVOH (A) satisfying the condition represented by formula (1) in the preparation of conventional EVOH, (A) In the preparation of a copolymer of ethylene and vinyl ester as a raw material, a method of previously removing a radical polymerization inhibitor contained in vinyl ester, (B) In the preparation of a copolymer of ethylene and vinyl ester as a raw material, a method of making impurities contained in vinyl ester used for radical polymerization a specific amount, (C) In the preparation of a copolymer of ethylene and vinyl ester as a raw material, a method of setting the polymerization temperature to a specific range, (D) In the preparation of a copolymer of ethylene and vinyl ester as a raw material, a method of adding an organic acid in a polymerization step or a step of recovering and reusing unreacted vinyl ester after the polymerization step,
- radical polymerization inhibitor examples include those exemplified as the radical polymerization inhibitor added after radical polymerization in (H) described later.
- the method for removing the radical polymerization inhibitor examples include a method using column chromatography, a reprecipitation method, a distillation method, and the like, and a distillation method is usually employed.
- the vinyl ester has a boiling point lower than that of the radical polymerization inhibitor, so that a vinyl ester from which the polymerization inhibitor has been removed can be obtained from the top of the distillation column.
- the lower limit of the total content of impurities contained in the vinyl ester used for radical polymerization is preferably 1 ppm, more preferably 3 ppm, and even more preferably 5 ppm.
- an upper limit of the total content of the said impurity 1,200 ppm is preferable, 1,100 ppm is more preferable, 1,000 ppm is further more preferable.
- Examples of the impurities include aldehydes such as acetaldehyde, crotonaldehyde, and acrolein; acetals such as acetaldehyde dimethyl acetal, crotonaldehyde dimethyl acetal, and acrolein dimethyl acetal obtained by acetalizing the aldehyde with a solvent alcohol; ketones such as acetone; methyl acetate, acetic acid Examples include esters such as ethyl.
- acetaldehyde is likely to be produced in the production of vinyl acetate and the like, and EVOH (A) is likely to be prevented from satisfying the formula (1). Therefore, in this method, it is particularly preferable to reduce the content of acetaldehyde.
- a minimum of polymerization temperature of a copolymer of ethylene and vinyl ester 20 ° C is preferred and 40 ° C is more preferred.
- the upper limit of the polymerization temperature is preferably 90 ° C and more preferably 70 ° C.
- organic acid examples include hydroxycarboxylic acids such as glycolic acid, glyceric acid, malic acid, citric acid, lactic acid, tartaric acid, and salicylic acid; polyvalent acids such as malonic acid, succinic acid, maleic acid, phthalic acid, oxalic acid, and glutaric acid. Examples thereof include carboxylic acid.
- the lower limit of the amount of the organic acid added is preferably 1 ppm, more preferably 3 ppm, and even more preferably 5 ppm.
- 500 ppm is preferable, 300 ppm is more preferable, and 100 ppm is more preferable.
- the lower limit of the total content of impurities in the solvent used for the polymerization is preferably 1 ppm, more preferably 3 ppm, and even more preferably 5 ppm.
- the upper limit of the total content of the impurities 1,200 ppm is preferable, 1,100 ppm is more preferable, and 1,000 ppm is more preferable.
- the impurities of the solvent used for the polymerization include those exemplified as impurities contained in the above-mentioned vinyl ester.
- (G) A method using an azonitrile-based initiator or an organic peroxide-based initiator as a radical polymerization initiator used for radical polymerization of ethylene and a vinyl ester monomer
- azonitrile-based initiator examples include 2,2-azobisisobutyronitrile, 2,2-azobis- (2,4-dimethylvaleronitrile), 2,2-azobis- (4-methoxy-2,4- Dimethylvaleronitrile), 2,2-azobis- (2-cyclopropylpropionitrile) and the like.
- organic peroxides include acetyl peroxide, isobutyl peroxide, diisopropyl peroxycarbonate, diallyl peroxydicarbonate, di-n-propyl peroxydicarbonate, dimyristyl peroxydicarbonate, and di (2-ethoxyethyl).
- Peroxydicarbonate di (2-ethylhexyl) peroxydicarbonate, di (methoxyisopropyl) peroxydicarbonate, di (4-tert-butylcyclohexyl) peroxydicarbonate and the like.
- the addition amount when adding a radical polymerization inhibitor after radical polymerization is a specific amount with respect to the remaining undecomposed radical polymerization initiator. how to)
- the amount of radical polymerization inhibitor added after radical polymerization is preferably 5 molar equivalents or less with respect to the remaining undecomposed radical polymerization initiator.
- the radical polymerization inhibitor include compounds having a conjugated double bond and a molecular weight of 1,000 or less, which stabilize radicals and inhibit the polymerization reaction.
- radical polymerization inhibitor examples include isoprene, 2,3-dimethyl-1,3-butadiene, 2,3-diethyl-1,3-butadiene, 2-t-butyl-1,3-butadiene, 1 , 3-pentadiene, 2,3-dimethyl-1,3-pentadiene, 2,4-dimethyl-1,3-pentadiene, 3,4-dimethyl-1,3-pentadiene, 3-ethyl-1,3-pentadiene 2-methyl-1,3-pentadiene, 3-methyl-1,3-pentadiene, 4-methyl-1,3-pentadiene, 1,3-hexadiene, 2,4-hexadiene, 2,5-dimethyl-2 , 4-hexadiene, 1,3-octadiene, 1,3-cyclopentadiene, 1,3-cyclohexadiene, 1-methoxy-1,3-butadiene, 2-methoxy-1,3-but
- Conjugated dienes containing conjugated structures of double bonds include three carbons such as 1,3,5-hexatriene, 2,4,6-octatriene-1-carboxylic acid, eleostearic acid, tung oil, cholecalciferol A conjugated triene containing a conjugated structure containing a carbon double bond; cyclooctatetraene, 2,4,6,8-decatetraene-1-carboxylic acid, It includes polyenes such as conjugated polyene containing a conjugated structure of the carbon double bond - Nord, 4 or more carbons, such as retinoic acid.
- any one having a plurality of stereoisomers such as 1,3-pentadiene, myrcene, farnesene, etc. may be used.
- the radical polymerization inhibitor include p-benzoquinone, hydroquinone, hydroquinone monomethyl ether, 2-phenyl-1-propene, 2-phenyl-1-butene, 2,4-diphenyl-4-methyl-1-pentene, 3, 5-diphenyl-5-methyl-2-heptene, 2,4,6-triphenyl-4,6-dimethyl-1-heptene, 3,5,7-triphenyl-5-ethyl-7-methyl-2- Nonene, 1,3-diphenyl-1-butene, 2,4-diphenyl-4-methyl-2-pentene, 3,5-diphenyl-5-methyl-3-heptene, 1,3,5-triphenyl-1 -Hexene, 2,4,6-triphenyl-4,6-dimethyl-2-heptene, 3,5,
- the lower limit of the residual monomer removal rate is preferably 99 mol%, more preferably 99.5 mol%, and even more preferably 99.8 mol%.
- the method for removing the residual monomer include a method using column chromatography, a reprecipitation method, a distillation method and the like, and the distillation method is preferable.
- a copolymer solution of ethylene and vinyl ester is continuously supplied from the upper part of the distillation column filled with Raschig rings at a constant rate, and an organic solvent vapor such as methanol is supplied from the lower part of the distillation column. Infuse. Thereby, the mixed vapor of the organic solvent and unreacted vinyl ester can be distilled from the top of the distillation column, and the copolymer solution of ethylene and vinyl ester from which the unreacted vinyl ester has been removed from the bottom of the distillation column. Can be taken out.
- antioxidant (J) Method of adding an antioxidant to a copolymer of ethylene and vinyl ester used for saponification
- a phenolic antioxidant, phosphorus antioxidant, sulfur type antioxidant, etc. are mentioned.
- phenolic antioxidants are preferable, and alkyl-substituted phenolic antioxidants are more preferable.
- phenolic antioxidants examples include 2-t-butyl-6- (3-t-butyl-2-hydroxy-5-methylbenzyl) -4-methylphenyl acrylate, 2,4-di-t-amyl- Acrylate compounds such as 6- (1- (3,5-di-t-amyl-2-hydroxyphenyl) ethyl) phenyl acrylate; 2,6-di-t-butyl-4-methylphenol, 2,6- Di-t-butyl-4-ethylphenol, octadecyl-3- (3,5-) di-t-butyl-4-hydroxyphenyl) propionate, 2,2′-methylene-bis (4-methyl-6-t -Butylphenol), 4,4'-butylidene-bis (4-methyl-6-tert-butylphenol), 4,4'-butylidene-bis (6-tert-butyl-m-cresol), 4,4 -Thiobis (3-methyl-6-t-butylphenol
- phosphorus antioxidants include triphenyl phosphite, diphenylisodecyl phosphite, phenyl diisodecyl phosphite, tris (nonylphenyl) phosphite, tris (dinonylphenyl) phosphite, tris (2-t-butyl- 4-methylphenyl) phosphite, tris (cyclohexylphenyl) phosphite, 2,2-methylenebis (4,6-di-t-butylphenyl) octyl phosphite, 9,10-dihydro-9-oxa-10-phos Phaphenanthrene-10-oxide, 10- (3,5-di-tert-butyl-4-hydroxybenzyl) -9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide, 10-decyloxy- 9,10-di
- sulfur-based antioxidant examples include dilauryl 3,3′-thiodipropionate, distearyl 3,3′-thiodipropionate, lauryl stearyl 3,3′-thiodipropionate, pentaerythritol-tetrakis- ( ⁇ -lauryl-thiopropionate), 3,9-bis (2-dodecylthioethyl) -2,4,8,10-tetraoxaspiro [5.5] undecane and the like.
- the lower limit of the content of the antioxidant is not particularly limited, but is 0.001 part by mass with respect to 100 parts by mass of the copolymer. Is preferable, and 0.01 mass part is more preferable.
- the upper limit of the content of the antioxidant is not particularly limited, but is preferably 5 parts by mass and more preferably 1 part by mass with respect to 100 parts by mass of the copolymer.
- the content of the antioxidant is less than the lower limit, it may be difficult to prepare EVOH (A) satisfying the formula (1).
- the content of the antioxidant exceeds the above upper limit, there is a possibility that an effect commensurate with an increase in cost due to an increase in the content may not be obtained.
- the content of acetaldehyde contained in the vinyl ester may not be in the above range.
- the lower limit of the acetaldehyde content is preferably 150 ppm, more preferably 250 ppm, and even more preferably 350 ppm.
- the process of removing acetaldehyde from vinyl acetate can be omitted by setting the content of acetaldehyde within the above range, the manufacturing cost can be reduced.
- it does not specifically limit as an upper limit of content of acetaldehyde in this case For example, it is 1,000 ppm.
- melt viscosity (melt flow rate) As a minimum of the melt flow rate of EVOH (A), 0.5 g / 10min is preferred, 1.0 g / 10min is more preferred, and 1.4 g / 10min is still more preferred.
- the upper limit of the melt flow rate of EVOH (A) is preferably 30 g / 10 min, more preferably 25 g / 10 min, further preferably 20 g / 10 min, particularly preferably 15 g / 10 min, further particularly preferably 10 g / 10 min. Most preferred is 1.6 g / 10 min.
- melt flow rate of EVOH (A) is less than the above lower limit or exceeds the above upper limit, the moldability and appearance may be deteriorated.
- the melt flow rate is a value measured in accordance with JIS-K7210 (1999) at a temperature of 190 ° C. and a load of 2,160 g.
- the resin composition of the present invention contains EVOH (A).
- the resin composition may contain an alkali metal salt (B1) of an organic acid in addition to EVOH (A).
- the resin composition may further contain a polyvalent metal salt (B2), inorganic particles (C), polyolefin (D), polyamide (E), EVOH (F), or a combination thereof.
- the resin composition may contain other optional components.
- the lower limit of the resin content in the resin composition is preferably 70% by mass, more preferably 90% by mass, and still more preferably 95% by mass.
- the “resin” refers to all resin components including EVOH (A), polyolefin (D), polyamide (E), EVOH (F) and other resins.
- the said resin composition can suppress coloring by containing the alkali metal salt (B1) of organic acid, As a result, an external appearance property can be improved more. Further, it is possible to improve the interlaminar adhesive strength when a long run property and a multilayer structure are obtained.
- the alkali metal constituting the alkali metal salt (B1) may be a single metal species or a plurality of metal species.
- Examples of the alkali metal include lithium, sodium, potassium, rubidium, and cesium. Sodium and potassium are more preferable from the viewpoint of industrial availability.
- Examples of the organic acid include formic acid, acetic acid, propionic acid, butyric acid, valeric acid, caproic acid, heptanoic acid, octanoic acid, nonanoic acid, decanoic acid, undecanoic acid, palmitic acid, stearic acid, succinic acid, linoleic acid, oleic acid
- Aliphatic carboxylic acids such as benzoic acid, salicylic acid, phthalic acid, etc .
- hydroxycarboxylic acids such as lactic acid, tartaric acid, citric acid, malic acid
- carboxylic acids such as ethylenediaminetetraacetic acid, p-toluenesulfonic acid, etc.
- sulfonic acid Among these organic acids, carboxylic acids are preferable, aliphatic carboxylic acids are more preferable, and acetic acid is more preferable.
- alkali metal salt (B1) examples include aliphatic carboxylates such as lithium, sodium and potassium, and aromatic carboxylates. Specific examples of the alkali metal salt (B1) include sodium acetate, potassium acetate, sodium stearate, potassium stearate, sodium salt of ethylenediaminetetraacetic acid, and the like. Of these, sodium acetate and potassium acetate are preferred as the alkali metal salt (B1).
- the said resin composition contains an alkali metal salt (B1)
- 1 ppm is preferable in metal conversion, and 5 ppm is More preferably, 10 ppm is further more preferable, and 80 ppm is particularly preferable.
- the upper limit of the content of the alkali metal salt (B1) is preferably 1,000 ppm, more preferably 800 ppm, further preferably 550 ppm, particularly preferably 250 ppm, and particularly preferably 150 ppm in terms of metal. If the content of the alkali metal salt (B1) is smaller than the lower limit, interlayer adhesion may be lowered. If the content of the alkali metal salt (B1) exceeds the above upper limit, it is difficult to reduce the coloration of the resin composition, and the appearance may be deteriorated.
- Multivalent metal salt of organic acid (B2) By containing a specific amount of the polyvalent metal salt (B2), the resin composition can suppress the generation of gels and bumps during long-time operation, and as a result, suppress the generation of kogation during long-time operation. Can be improved.
- a polyvalent metal salt (B2) particularly preferably a carboxylate, can be used to further prevent generation of gels and blisters during long-time operation. It can suppress effectively, As a result, the suppression property of the kogation at the time of long-time driving
- bivalent such as magnesium, calcium, barium, beryllium, zinc, copper, etc.
- the metal element that forms the metal salt is preferable, and among these, magnesium, calcium, and zinc are more preferable.
- Examples of the anion constituting the polyvalent metal salt (B2) include anions of organic acids exemplified as the organic acid of the alkali metal salt (B1). Among these, as the anion, a carboxylic acid anion is preferable, and an acetic acid anion is particularly preferable.
- the lower limit of the content of the polyvalent metal salt (B2) (content in the dry resin composition) is preferably 1 ppm in terms of metal element. 3 ppm is more preferred, 5 ppm is more preferred, 10 ppm is particularly preferred, 50 ppm is even more preferred, and 100 ppm is most preferred.
- the upper limit of the content of the polyvalent metal salt (B2) is preferably 500 ppm, more preferably 350 ppm, further preferably 300 ppm, and particularly preferably 250 ppm in terms of metal element. When the content is less than the above lower limit, the effect of suppressing gels and blisters during long-time operation of the resin composition becomes insufficient.
- the resin composition contains a resin other than EVOH such as polyolefin (D) or polyamide (E), it is preferable to contain a fatty acid metal salt as an alkali metal salt (B1) or a polyvalent metal salt (B2).
- a fatty acid metal salt as an alkali metal salt (B1) or a polyvalent metal salt (B2).
- the fatty acid metal salt a metal salt of a higher fatty acid having 10 to 26 carbon atoms such as lauric acid, stearic acid, myristic acid, behenic acid and montanic acid is preferable.
- the fatty acid metal salt include metal salts and zinc salts of Groups 2 and 3 of the Periodic Table, and among these, Group 2 metal salts of the Periodic Table such as calcium salts and magnesium salts. Is preferred.
- the lower limit of the content of the fatty acid metal salt is preferably 50 ppm, more preferably 100 ppm, even more preferably 150 ppm, and particularly preferably 200 ppm as the amount of salt relative to the resin component. 500 ppm is more particularly preferable, and 1,200 ppm is most preferable.
- the upper limit of the content of the fatty acid metal salt is preferably 10,000 ppm, more preferably 8,000 ppm, further preferably 5,000 ppm, particularly preferably 4,000 ppm, as the amount of salt relative to the resin content. 000 ppm is even more particularly preferred.
- the content of the fatty acid metal salt in the resin composition is a ratio with respect to the resin content in the resin composition, that is, a mass ratio of the salt with respect to the total mass of the resin components.
- the ratio with respect to the resin part in the made said resin composition is said.
- An inorganic particle (C) makes the arithmetic mean roughness (Ra) of the surface of the film formed from the said resin composition moderate, and improves blocking resistance and slipperiness.
- the inorganic particles (C) are particles mainly composed of an inorganic substance.
- the main component refers to a component having the largest content, for example, a component having a content of 50% by mass or more.
- silicon, aluminum, magnesium, zirconium, cerium, tungsten, molybdenum and combinations thereof are preferable.
- silicon, aluminum, magnesium, and combinations thereof are more preferable because they are easily available.
- Examples of the inorganic substance that is the main component of the inorganic particles (C) include oxides, nitrides, oxynitrides, and the like of the exemplified metal elements, and oxides are preferable.
- the lower limit of the average particle diameter of the inorganic particles (C) is preferably 0.5 ⁇ m, more preferably 1.5 ⁇ m, and even more preferably 2.5 ⁇ m.
- the upper limit of the average particle diameter of the inorganic particles (C) is preferably 10 ⁇ m, more preferably 8 ⁇ m, further preferably 5 ⁇ m, and particularly preferably 3 ⁇ m.
- the resin composition can improve the film rupture resistance, the deposition defect suppressing ability and the adhesion strength of the deposition layer, and can further improve the adhesion strength of the film.
- the “average particle size of the inorganic particles (C)” is a particle size distribution (particle size and relative particle size) calculated from light intensity distribution data of diffraction / scattered light measured using a laser diffraction particle size distribution measuring device. The amount obtained by multiplying the value obtained by multiplying the particle diameter and the relative particle amount by the sum of the relative particle amounts.
- the lower limit of the content of the inorganic particles (C) is preferably 50 ppm, more preferably 100 ppm, and even more preferably 150 ppm.
- the upper limit of the content of the inorganic particles (C) is preferably 5,000 ppm, more preferably 4,000 ppm, further preferably 3,000 ppm, particularly preferably 1,000 ppm, and particularly preferably 200 ppm.
- grain may be formed from 1 type, or 2 or more types of inorganic substances.
- Polyolefin (D) is, for example, polyethylene (low density, linear low density, medium density, high density, etc.); ethylene and ⁇ -olefins such as 1-butene, 1-hexene, 4-methyl-1-pentene Or an ethylene copolymer copolymerized with an acrylic ester; polypropylene; a propylene copolymer copolymerized with propylene and an ⁇ -olefin such as ethylene, 1-butene, 1-hexene, 4-methyl-1-pentene Copolymer; poly (1-butene), poly (4-methyl-1-pentene), the above-mentioned polyethylene, ethylene copolymer, polypropylene, propylene copolymer, poly (1-butene) or poly (4 -Methyl-1-pentene), an acid-modified polyolefin in which maleic anhydride is allowed to act; and an ionomer resin.
- polyethylene low density, linear low density, medium
- the polyolefin (D) is preferably a polypropylene resin such as polypropylene or a propylene copolymer, and a polyethylene resin such as polyethylene or an ethylene copolymer.
- a polyethylene resin is preferably used from the viewpoint of excellent secondary processability.
- the acid-modified polyolefin mentioned later is also preferable.
- the lower limit of the mass ratio (A / D) of EVOH (A) and polyolefin (D) in the resin composition is 0.1 / 99.9. Is preferable, 1/99 is more preferable, 2/98 is more preferable, and 4/96 is particularly preferable.
- the upper limit of the mass ratio (A / D) is preferably 99.9 / 0.1, more preferably 99/1, further preferably 50/50, particularly preferably 30/70, and more particularly 10/90. preferable.
- the total content of EVOH (A) and polyolefin (D) in the resin part of the said resin composition 50 mass% is preferable, 80 mass% is more preferable, and 90 mass% is further more preferable.
- the said resin composition can improve impact resistance more by making the content ratio of each resin component into the said range.
- the said resin composition contains polyolefin (D), as a minimum of content of polyolefin (D) in the resin part of the said resin composition, 0.1 mass% is preferable and 0.5 mass% is more preferable. 25 mass% is more preferable, 35 mass% is especially preferable, and 45 mass% is still more preferable. On the other hand, as an upper limit of content of polyolefin (D), 99.9 mass% is preferable, 99 mass% is more preferable, 98 mass% is further more preferable, 96 mass% is especially preferable. By making content of polyolefin (D) into the said range, the impact resistance of the said resin composition can be improved more.
- acid-modified polyolefin is preferable as the polyolefin (D).
- the resin composition contains an acid-modified polyolefin, aggregation of EVOH (A) in the resin composition in a micro region is suppressed, and as a result, defect generation suppression, appearance and strength in thermoforming are suppressed. Will be improved.
- the resin composition contains an acid-modified polyolefin as the polyolefin (D)
- it may contain only an acid-modified polyolefin, or may contain an acid-modified polyolefin and an unmodified polyolefin.
- Examples of the acid-modified polyolefin include an olefin polymer in which an unsaturated carboxylic acid or a derivative thereof is introduced through a chemical bond.
- unsaturated carboxylic acid and its derivative (s) ethylenically unsaturated carboxylic acid, its ester, its anhydride, etc. are mentioned, for example.
- Specific examples include ethylenically unsaturated monocarboxylic acids and esters thereof, ethylenically unsaturated dicarboxylic acids and mono- or diesters thereof, and anhydrides of ethylenically unsaturated dicarboxylic acids.
- ethylenically unsaturated dicarboxylic acids are exemplified.
- Acid anhydrides are preferred.
- Specific examples of the ethylenically unsaturated dicarboxylic acid include maleic acid, fumaric acid, itaconic acid, maleic anhydride, itaconic anhydride, maleic acid monomethyl ester, maleic acid monoethyl ester, maleic acid diethyl ester, and fumaric acid monomethyl ester. Of these, maleic anhydride is preferred.
- the olefin polymer is polyethylene (low pressure, medium pressure, high pressure, etc.), linear low density polyethylene, polypropylene, polyolefin such as boribten, or olefin and other monomers (vinyl ester, unsaturated carboxylic acid ester, etc.) (For example, ethylene-vinyl acetate copolymer, ethylene-acrylic acid ethyl ester copolymer, etc.).
- linear low density polyethylene, ethylene-vinyl acetate copolymer (vinyl acetate content is 5 mass% to 55 mass%), and ethylene-acrylic acid ethyl ester copolymer (acrylic acid ethyl ester). Is preferably 8% by mass or more and 35% by mass or less), more preferably linear low-density polyethylene and ethylene-vinyl acetate copolymer.
- the acid-modified polyolefin include maleic anhydride graft-modified polyolefin such as maleic anhydride graft-modified polyethylene and maleic anhydride graft-modified polypropylene; maleic anhydride graft-modified ethylene-propylene (block or random) copolymer, Examples thereof include a maleic anhydride graft-modified product of a copolymer of an olefin and a vinyl monomer such as a maleic anhydride graft-modified ethylene-ethyl acrylate copolymer and a maleic anhydride graft-modified ethylene-vinyl acetate copolymer.
- maleic anhydride graft-modified polyolefin such as maleic anhydride graft-modified polyethylene and maleic anhydride graft-modified polypropylene
- the lower limit of the addition amount or graft amount (modification degree) of the ethylenically unsaturated carboxylic acid or its anhydride to the olefin polymer is preferably 0.0001% by mass, preferably 0.001% by mass with respect to the olefin polymer. Is more preferable.
- the upper limit of the addition amount or graft amount is preferably 15% by mass, and more preferably 10% by mass. Examples of a method for addition reaction or graft reaction of an ethylenically unsaturated carboxylic acid or its anhydride to an olefin polymer include radical polymerization in the presence of a solvent (such as xylene) and a catalyst (such as a peroxide). Etc.
- the lower limit of the melt flow rate measured at 210 ° C. of the carboxylic acid-modified polyolefin thus obtained is preferably 0.2 g / 10 minutes, and more preferably 0.5 g / 10 minutes.
- the upper limit of the melt flow rate is preferably 30 g / 10 minutes, and more preferably 10 g / 10 minutes.
- the lower limit of the content of the acid-modified polyolefin in the resin component is preferably 1% by mass, more preferably 3% by mass, and even more preferably 5% by mass.
- As an upper limit of content of acid-modified polyolefin 20 mass% is preferable, 15 mass% is more preferable, and 10 mass% is further more preferable.
- Polyamide (E) is a resin containing an amide bond.
- the polyamide (E) is obtained by ring-opening polymerization of a lactam having 3 or more members, polycondensation of a polymerizable ⁇ -amino acid, polycondensation of a dibasic acid and a diamine, and the like.
- Examples of the polyamide (E) include polycapramide (nylon 6), poly- ⁇ -aminoheptanoic acid (nylon 7), poly- ⁇ -aminononanoic acid (nylon 9), polyundecanamide (nylon 11), polylauryl lactam (nylon).
- polyethylenediamine adipamide (nylon 26), polytetramethylene adipamide (nylon 46), polyhexamethylene adipamide (nylon 66), polyhexamethylene sebacamide (nylon 610), polyhexamethylene dodeca Mido (nylon 612), polyoctamethylene adipamide (nylon 86), polydecamethylene adipamide (nylon 108), caprolactam / lauryl lactam copolymer (nylon 6/12), caprolactam / ⁇ -aminononanoic acid copolymer Combined (Nylon 6/9 , Caprolactam / hexamethylene diammonium adipate copolymer (nylon 6/66), lauryl lactam / hexamethylene diammonium adipate copolymer (nylon 12/66), hexamethylene diammonium adipate / hexamethylene diammonium sebacate copolymer Copoly
- polyamide (E) aliphatic diamines introduced with substituents such as 2,2,4-trimethylhexamethylenediamine and 2,4,4-trimethylhexamethylenediamine as diamines; methylbenzylamine, metaxylylenediamine Aromatic amines such as these may be used, and these may be used to modify the polyamide.
- An aromatic dicarboxylic acid such as phthalic acid, xylylene dicarboxylic acid, alkyl-substituted terephthalic acid, alkyl-substituted isophthalic acid, or naphthalene dicarboxylic acid may be used, and modification to polyamide may be performed using these. Absent.
- polyamide (E) polycapramide (nylon 6) is preferable.
- a caprolactam / lauryl lactam copolymer (nylon 6/12) is also preferable.
- the content ratio of 6 units to 12 units is not particularly limited, but the lower limit of the content of 12 units is preferably 5% by mass.
- the upper limit of the content of 12 units is preferably 60% by mass, and more preferably 50% by mass.
- the lower limit of the mass ratio (A / E) of EVOH (A) and polyamide (E) in the resin composition is preferably 60/40, more preferably 65/35, still more preferably 70/30, and 75 / 25 is particularly preferred. Moreover, as an upper limit of this mass ratio (A / E), 95/5 is preferable, 90/10 is more preferable, 85/15 is further more preferable. When this mass ratio (A / E) is less than the lower limit, the properties such as gas barrier properties and oil resistance inherent to EVOH (A) may be impaired. Conversely, when the mass ratio (A / E) exceeds the above upper limit, the retort resistance of the resin composition may be reduced.
- the lower limit of the total content of EVOH (A) and polyamide (E) in the resin content of the resin composition is preferably 80% by mass, and 90% by mass. More preferred is 95% by mass.
- the total content of EVOH (A) and polyamide (E) in the resin component of the resin composition is particularly preferably 100% by mass.
- the said resin composition contains polyamide (E), as a minimum of content of the polyamide (E) in the resin part of the said resin composition, 4 mass% is preferable, 8 mass% is more preferable, 12 mass% Is more preferable.
- an upper limit of content of polyamide (E) 40 mass% is preferable, 35 mass% is more preferable, 30 mass% is further more preferable, 25 mass% is especially preferable.
- the retort resistance of the said resin composition may fall that content of polyamide (E) is less than the said minimum.
- the content of polyamide (E) exceeds the above upper limit, the content of EVOH (A) is lowered, and properties such as gas barrier properties and oil resistance may be impaired.
- the ethylene content of EVOH (A) is usually 10 mol% or more and 60 mol% or less.
- EVOH (F) is an ethylene-vinyl alcohol copolymer having a different ethylene content from EVOH (A).
- EVOH (F) is obtained by saponifying a copolymer of ethylene and a vinyl ester, similarly to EVOH (A).
- the resin composition contains EVOH (F)
- the ethylene content of EVOH (A) is usually 10 mol% or more and 50 mol% or less.
- the lower limit of the ethylene content of EVOH (F) is usually 30 mol%, preferably 34 mol%, more preferably 38 mol%.
- the upper limit of the ethylene content of EVOH (F) is usually 60 mol%, preferably 55 mol%, more preferably 52 mol%. If the ethylene content of EVOH (F) is less than the above lower limit, the effects of flexibility, secondary workability, and heat stretchability of the resin composition may not be satisfied. On the other hand, if the ethylene content of EVOH (F) exceeds the above upper limit, the gas barrier property of the resin composition may be lowered.
- the lower limit of the saponification degree of the structural unit derived from the vinyl ester in EVOH (F) is preferably 85 mol%, more preferably 90 mol%, still more preferably 98 mol%, and particularly preferably 98.9 mol%. Moreover, as an upper limit of the said saponification degree, 99.99 mol% is preferable, 99.98 mol% is more preferable, 99.95 mol% is further more preferable.
- the saponification degree of EVOH (F) within the above range, the heat stretchability of the resin composition can be further improved without impairing the thermal stability and gas barrier properties.
- the saponification degree is less than the lower limit, the thermal stability of the resin composition may be insufficient.
- the saponification degree exceeds the upper limit the time required for saponification increases, and the productivity of EVOH (F) may be reduced.
- the vinyl ester species used in the production of EVOH (F), the copolymerization component within the applicable range, and the amount used thereof can be the same as those of EVOH (A).
- EVOH (F) may be a modified ethylene-vinyl alcohol copolymer (hereinafter also referred to as “modified EVOH”) from the viewpoint of improving the flexibility, secondary processing characteristics, and heat stretchability of the resin composition.
- modified EVOH include EVOH having a structural unit represented by the following formula (3) (hereinafter also referred to as “structural unit (I)”).
- R 1 , R 2 , R 3 and R 4 are each independently a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms, or an alkoxy group having 1 to 10 carbon atoms. Part or all of the hydrogen atoms of the hydrocarbon group may be substituted with a hydroxyl group, an alkoxy group, a carboxy group, or a halogen atom. R 1 and R 2 may be bonded to each other to form a ring structure.
- the lower limit of the content of the structural unit (I) with respect to all vinyl alcohol units constituting EVOH (F) is preferably 0.3 mol%, more preferably 0.5 mol%, still more preferably 1 mol%. 0.5 mol% is particularly preferred, and 6 mol% is even more particularly preferred. On the other hand, as an upper limit of the content rate of the said structural unit (I), 40 mol% is preferable, 20 mol% is more preferable, 15 mol% is further more preferable, 10 mol% is especially preferable.
- the vinyl alcohol unit constituting EVOH refers to a structural unit represented by —CH 2 CH (OH) — and a structural unit in which the hydrogen atom of the hydroxyl group of this structural unit is substituted with another group.
- the method for producing the modified EVOH is not particularly limited, and examples thereof include a method obtained by reacting EVOH with a monovalent epoxy compound having a molecular weight of 500 or less.
- Examples of EVOH used as a raw material for the modified EVOH include the same EVOH (A) and EVOH (F) described above.
- an epoxy compound having 2 to 8 carbon atoms is preferable. From the viewpoint of easy handling of the compound and reactivity with EVOH, an epoxy compound having 2 to 6 carbon atoms is more preferable, and an epoxy compound having 2 to 4 carbon atoms is more preferable.
- monovalent epoxy compounds having a molecular weight of 500 or less include 1,2-epoxybutane, 2,3-epoxybutane, from the viewpoints of reactivity with EVOH and gas barrier properties of the obtained EVOH (F). Epoxypropane, epoxyethane and glycidol are preferred, and epoxypropane and glycidol are more preferred.
- the lower limit of the value obtained by subtracting the ethylene content of EVOH (A) from the ethylene content of EVOH (F) is usually 8 mol%, preferably 12 mol%, more preferably 15 mol%, and more preferably 18 mol%. Further preferred.
- the upper limit of the above value is preferably 40 mol%, more preferably 30 mol%, and even more preferably 20 mol%. If the ethylene content difference between EVOH (F) and EVOH (A) is less than the lower limit, the heat stretchability of the resin composition may be insufficient. On the other hand, when the ethylene content difference exceeds the upper limit, there is a risk that the flow mark suppression during the long run of the resin composition may be insufficient.
- the lower limit of the difference between the melting point of EVOH (A) and the melting point of EVOH (F) is preferably 12 ° C, more preferably 14 ° C, further preferably 15 ° C, and particularly preferably 17 ° C.
- the upper limit of the difference between the melting point of EVOH (A) and the melting point of EVOH (F) is preferably 80 ° C, more preferably 40 ° C, further preferably 34 ° C, and particularly preferably 20 ° C. If the difference in melting points is less than the lower limit, the heat stretchability of the resin composition may be insufficient. On the other hand, if the difference between the melting points exceeds the upper limit, the flow mark may not be sufficiently suppressed during a long run of the resin composition.
- the lower limit of the mass ratio (A / F) between EVOH (A) and EVOH (F) is usually 60/40, preferably 65/35, 70/30 is more preferred, and 85/15 is even more preferred.
- an upper limit of the said mass ratio (A / F) it is 95/5 normally, 93/7 is preferable and 91/9 is more preferable.
- the mass ratio (A / F) is less than the lower limit, the gas barrier property and oil resistance of the resin composition may be deteriorated.
- the said mass ratio (A / F) exceeds the said upper limit, there exists a possibility that the softness
- the said resin composition contains EVOH (F), as a minimum of the total content of EVOH (A) and EVOH (F), 80 mass% is preferable, 90 mass% is more preferable, 95 mass% is further 99.9% by mass is preferable.
- the said resin composition contains EVOH (F), as a minimum of content of EVOH (F) in the resin part of the said resin composition, 4 mass% is preferable, 6 mass% is more preferable, 7 mass% Is more preferable.
- the upper limit of the EVOH (F) content is preferably 40% by mass, more preferably 35% by mass, still more preferably 30% by mass, and particularly preferably 15% by mass. If the EVOH (F) content is less than the above lower limit, the flexibility, heat stretchability and secondary processability of the resin composition may be reduced. On the contrary, when the content of EVOH (F) exceeds the above upper limit, the content of EVOH (A) may decrease, and the gas barrier property and oil resistance of the resin composition may decrease.
- Other optional ingredients include, for example, antioxidants, ultraviolet absorbers, plasticizers, antistatic agents, lubricants, colorants, fillers, heat stabilizers such as hindered phenol compounds and hindered amine compounds, polyamides and polyolefins, etc. Other resins, hydrotalcite compounds and the like.
- the total content of other optional components of the resin composition is usually 1% by mass or less.
- filler examples include glass fiber, ballastite, calcium silicate, talc, montmorillonite and the like.
- hindered phenol compounds, hindered amine compounds, hydrotalcite compounds, and the like exemplified as the heat stabilizer may be added to the resin composition.
- the addition amount is usually 0.01% by mass or more and 1% by mass or less.
- the lower limit of the melt flow rate of the resin composition is preferably 0.5 g / 10 min, more preferably 1.0 g / 10 min, and further preferably 1.4 g / 10 min.
- the upper limit of the melt flow rate of the resin composition is preferably 30 g / 10 min, more preferably 25 g / 10 min, further preferably 20 g / 10 min, particularly preferably 15 g / 10 min, and particularly preferably 10 g / 10 min. Most preferred is 1.6 g / 10 min.
- EVOH (A) pellets, alkali metal salt (B1), other optional components, etc. if necessary, melt kneaded, EVOH (A) pellets And the like may be immersed in a solution containing each component.
- a ribbon blender, a high-speed mixer kneader, a mixing roll, an extruder, an intensive mixer, etc. can be used for mixing a pellet and another component.
- the resin composition can be obtained by melt molding using EVOH (A) pellets having an alkali metal salt (B1) or other component adhered to the surface by dry blending.
- the method of uniformly blending the inorganic particles (C) in the resin composition includes (1) the step of copolymerizing ethylene and vinyl ester in the method of producing an ethylene-vinyl alcohol copolymer, and In the step (2) of saponifying the copolymer obtained in the step (1), for example, a method of adding inorganic particles (C) or the like in the step (1), A method of adding inorganic particles (C) and the like in the step (2), A method of adding inorganic particles (C) or the like to EVOH obtained by the above step (2), A method of adding inorganic particles (C) or the like when melt-molding EVOH obtained by the above step (2), The method of using these methods together is mentioned.
- a method of adding the inorganic particles (C) and the like to the EVOH obtained in the step (2) from the viewpoint of easy control of the content of the inorganic particles (C) and the like in the resin composition, a method of adding the inorganic particles (C) and the like to the EVOH obtained in the step (2), and A method of adding inorganic particles (C) or the like is preferable when melt-forming EVOH obtained in step (2), and a method of adding inorganic particles (C) or the like to EVOH obtained in step (2) is more preferable. preferable.
- a method for adding inorganic particles (C) or the like to the resin composition for example, a method in which inorganic particles (C) or the like are previously blended in EVOH and pellets are granulated, or a chip of a dry resin composition is redissolved.
- inorganic particles (C) and the like can be more uniformly dispersed in EVOH (A)
- a method in which the inorganic particles (C) and the like are preliminarily mixed with EVOH and pellets are granulated is preferable.
- the inorganic particles (C) are added to a solution in which EVOH (A) is dissolved in a good solvent such as a water / methanol mixed solvent, and the mixed solution is extruded into a poor solvent from a nozzle or the like to precipitate and By pelletizing and / or solidifying it, pellets in which inorganic particles (C) and the like are uniformly mixed with EVOH (A) can be obtained.
- the resin composition is molded into various molded products such as a film, a sheet, a container, a pipe, a hose, and a fiber by melt molding or the like.
- film generally refers to a film having an average thickness of less than about 300 ⁇ m
- sheet refers to a film generally having an average thickness of about 300 ⁇ m or more.
- melt molding method include extrusion molding, cast molding, inflation extrusion molding, blow molding, melt spinning, injection molding, and injection blow molding.
- the melt molding temperature varies depending on the melting point of EVOH (A), but is preferably about 150 ° C. or higher and 270 ° C. or lower.
- the said molded object is formed from the said resin composition, it is excellent in external appearance property.
- These molded bodies can be pulverized and molded again for reuse. It is also possible to uniaxially or biaxially stretch films, sheets, fibers, and the like.
- the molded body obtained by the above melt molding or the like may be subjected to secondary processing molding such as bending, vacuum molding, blow molding, press molding or the like, if necessary, to obtain a target molded body.
- the said film consists of the said resin composition, and contains a single layer film and a multilayer film. Since the said film consists of the said resin composition, it is excellent in external appearance property, and when the said resin composition contains an inorganic particle (C), it is excellent also in film fracture resistance. Furthermore, when the said resin composition contains polyamide (E), a molded object provided with the said film can be used suitably for boil sterilization or for retort sterilization.
- the lower limit of the arithmetic average roughness (Ra) of at least one surface of the film measured in accordance with JIS-B0601 is preferably 0.05 ⁇ m, more preferably 0.10 ⁇ m, still more preferably 0.15 ⁇ m, 0.20 ⁇ m is particularly preferable.
- the upper limit of the arithmetic average roughness (Ra) of at least one surface of the film is preferably 1.0 ⁇ m, more preferably 0.8 ⁇ m, still more preferably 0.6 ⁇ m, and particularly preferably 0.4 ⁇ m.
- the lower limit of the average length (RSm) of the contour curve element on at least one surface of the film measured in accordance with JIS-B0601 is preferably 50 ⁇ m, more preferably 100 ⁇ m, further preferably 150 ⁇ m, particularly 200 ⁇ m. preferable.
- the upper limit of the average length (RSm) of the contour curve element on at least one surface of the film is preferably 1,000 ⁇ m, more preferably 800 ⁇ m, still more preferably 600 ⁇ m, and particularly preferably 400 ⁇ m.
- the method for producing the film for example, a cast molding process in which the resin composition is melt-extruded on a casting roll, a process of stretching an unstretched film obtained from the resin composition in the cast molding process (uniaxial stretching process, sequential And a method having a biaxial process, a simultaneous biaxial stretching process, an inflation molding process, and the like.
- the said resin composition contains an inorganic particle (C)
- film rupture resistance can be improved more by manufacturing the said film by the above-mentioned method.
- the multilayer structure has a first layer (hereinafter, also referred to as “the resin composition layer”) made of the resin composition. That is, the multilayer structure includes a first layer and another layer stacked on at least one surface of the first layer.
- the multilayer structure can be formed into an arbitrary molded product such as a film, a sheet, a tape, a cup, a tray, a tube, a bottle, and a pipe.
- the said multilayered structure contains the vapor deposition film which vapor-deposited the metal to the said film, this vapor deposition film is mentioned later.
- the multilayer structure examples include multilayer sheets, multilayer pipes, multilayer fibers, and the like.
- the thermoplastic resin layer formed from a thermoplastic resin is preferable.
- the multilayer structure includes the first layer and the thermoplastic resin layer, so that appearance and heat stretchability are improved.
- a layer made of an ethylene-vinyl alcohol copolymer and a layer made of polyolefin are preferable.
- the polyolefin include those exemplified as the above-mentioned polyolefin (D), and polypropylene resins such as polypropylene and propylene copolymers and polyethylene resins such as polyethylene and ethylene copolymers are preferable. .
- thermoplastic resin layer As a resin for forming the thermoplastic resin layer, High density, medium density or low density polyethylene; Polyethylene copolymerized with vinyl acetate, acrylic acid ester, or ⁇ -olefins such as butene and hexene; Ionomer resin; Polypropylene homopolymer; Polypropylene copolymerized with ⁇ -olefins (especially ⁇ -olefins having 4 to 20 carbon atoms) such as ethylene, butene and hexene; Olefins such as polybutene and polypentene, or copolymers thereof; Polyolefins such as modified polypropylene blended with rubber polymers; Resins obtained by adding or grafting maleic anhydride to these resins; Polyesters such as polyethylene terephthalate; Polyester elastomers; Polyamides such as nylon-6 and nylon-66; Polystyrene, polyvinyl chloride, acrylic resins, vinyl ester resins, polyure
- polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, polystyrene, polyamide, and polyester are preferable as the resin for forming the thermoplastic resin layer.
- a thermoplastic resin layer with a resin film, as this resin film, an unstretched polypropylene film and a nylon 6 film are preferable.
- Each layer of the multilayer structure may be laminated via an adhesive resin.
- adhesive resin used for formation of the said adhesive resin layer the above-mentioned acid modified polyolefin is preferable and carboxylic acid modified polyolefin is more preferable.
- the carboxylic acid-modified polyolefin includes a modified olefinic polymer containing a carboxy group obtained by chemically bonding an ethylenically unsaturated carboxylic acid, its ester or its anhydride to an olefin polymer by an addition reaction, a graft reaction or the like.
- a coalescence can be used suitably.
- the production method of the multilayer structure is not particularly limited, for example, extrusion lamination method, dry lamination method, extrusion blow molding method, coextrusion lamination method, coextrusion sheet molding method, coextrusion pipe molding method, Examples include a coextrusion blow molding method, a co-injection molding method, and a solution coating method. Moreover, you may melt-extrude a thermoplastic resin, adhesive resin, etc. to the molded object (film, sheet
- the film or a multilayer structure including the film and a film, sheet, or the like of another substrate may be laminated using a known adhesive such as an organic titanium compound, an isocyanate compound, or a polyester compound.
- the method for producing the multilayer structure is preferably a coextrusion laminating method and a coextrusion molding method, and more preferably a coextrusion molding method.
- the resin composition layer and the thermoplastic resin layer can be easily and reliably manufactured.
- the multilayer structure is excellent in appearance and heat stretchability.
- the said resin composition contains polyamide (E), retort resistance can be achieved effectively.
- the multi-layered laminate obtained by such a method is further subjected to secondary processing after reheating within a range below the melting point of EVOH (A) by a method such as vacuum / pressure deep drawing or blow molding. May be applied.
- the co-extrusion method of the resin composition and the thermoplastic resin or the like is not particularly limited, and examples thereof include a multi-manifold merging method T-die method, a feed block merging method T-die method, and an inflation method.
- each resin such as EVOH (A), polyolefin, other thermoplastic resin, and adhesive resin individually to the thermoforming apparatus.
- the melt-molding temperature varies depending on the melting point of EVOH (A) contained in the resin composition, but is preferably 150 ° C or higher and 250 ° C or lower. . If the melt molding temperature is lower than the lower limit, melt molding may be difficult. When the melt molding temperature exceeds the upper limit, the thermal degradation of EVOH (A) is accelerated, and there is a risk of inferior appearance and reduced impact resistance due to thermal degradation, particularly when repeatedly recovered and reused.
- Extrusion molding of each layer is performed by operating an extruder equipped with a single screw at a predetermined temperature.
- the temperature of the extruder for forming the resin composition layer is, for example, 170 ° C. or higher and 240 ° C. or lower, and the temperature of the extruder for forming a layer composed of other components is, for example, 200 ° C. or higher and 240 ° C. or lower.
- the temperature of the extruder for forming the agent layer is, for example, 160 ° C. or higher and 220 ° C. or lower.
- the temperature of an extruder shall be 200 degreeC or more and 240 degrees C or less, for example.
- the layer structure of the multilayer structure is not particularly limited, but from the viewpoints of moldability, cost, etc., the thermoplastic resin layer / the resin composition layer / thermoplastic resin layer, the resin composition layer / adhesiveness Typical examples include resin layer / thermoplastic resin layer, thermoplastic resin layer / adhesive resin layer / resin composition layer / adhesive resin layer / thermoplastic resin layer.
- the layer configuration of thermoplastic resin layer / resin composition layer / thermoplastic resin layer is preferable, and more specifically, a layer made of thermoplastic polyester is directly on both sides of the layer made of the resin composition. A laminated structure is more preferable.
- the thermoplastic resin layers of both outer layers may be layers made of different resins or may be layers made of the same resin. .
- Examples of a method for forming a molded product using the multilayer structure include a stretch heating stretch forming method, a vacuum forming method, a pressure forming method, and a vacuum / pressure forming method. These moldings are usually performed in a temperature range below the melting point of EVOH. Among these, the hot stretch molding method and the vacuum / pressure forming method are preferable.
- the heat stretch molding method is a method in which the multilayer structure is heated and stretched in one direction or a plurality of directions.
- the vacuum / pressure forming method is a method in which the multilayer structure is heated and formed using both vacuum and compressed air.
- the molded article uses the multilayer structure described above, it can be easily and reliably produced by molding by the hot stretch molding method or the vacuum / pressure forming method, has excellent appearance, and suppresses the flow mark. Can be. Moreover, when the said resin composition contains polyamide (E), retort resistance can be improved more.
- Particularly preferable examples of the molded article include a packaging material formed by a hot stretch molding method, and a container formed by a vacuum / pressure forming method.
- thermoforming examples include a method of forming a film-like or sheet-like multilayer structure into a cup or tray by vacuum forming, pressure forming, vacuum air forming, or the like.
- blow molding the method of shape
- thermoplastic resin to be used is preferably a resin that can be stretched within the range of the heat stretching temperature represented by the following formula (4).
- X is the melting point (° C.) of EVOH (A).
- Y is a heating stretching temperature (° C.).
- the molded body can also be molded by a co-injection stretch blow molding method using the above-described resin composition and another resin composition.
- the co-injection stretch blow molding method is a method in which a preform having a multilayer structure is obtained by co-injection molding using two or more kinds of resin compositions, and then this preform is subjected to heat stretch blow molding.
- the molded product can be easily and reliably manufactured, has excellent appearance, and the flow mark is suppressed.
- the said other resin composition the said thermoplastic resin etc. are mentioned, for example.
- scrap generated when performing thermoforming such as extrusion molding and blow molding may be reused by blending with the thermoplastic resin layer, or may be used as a separate recovery layer.
- the above molded body may be subjected to secondary processing molding such as bending, vacuum molding, blow molding, press molding, or the like, if necessary, to obtain a desired molded product.
- the molded body includes a layer formed from the resin composition having the above-described properties, it can be suitably used for thermoformed containers such as food packaging containers and fuel containers.
- thermoformed container provided with the multilayer structure can be molded according to the purpose, heat sealed as necessary to make a container, filled in the container, and used for transportation and storage.
- contents both foods and non-foods can be used, and any of dried foods, water-containing foods, and oil-containing foods may be used.
- the container provided with the said multilayered structure can also be used for a boil process and a retort process.
- a material in which polypropylene is used for both outer layers or a material having a thick EVOH layer is preferably used.
- Packaging materials A packaging material provided with the multilayer structure will be described. By providing the multilayer structure, the packaging material has excellent gas barrier properties, and the gas barrier properties are maintained even when subjected to physical stress such as deformation or impact.
- the packaging material is formed by laminating at least one layer of the film and at least one other layer.
- the other layer include a polyester layer, a polyamide layer, a polyolefin layer, a paper layer, an inorganic vapor deposition film layer, an EVOH layer, and an adhesive layer.
- the number of layers in the packaging material and the order of lamination are not particularly limited. However, when heat sealing is performed, at least the outermost layer is a heat-sealable layer.
- the polyolefin layer may contain a pigment when the packaging material is configured as a laminate tube container or the like described later.
- the packaging material is used for packaging foods, beverages, chemicals such as agricultural chemicals and pharmaceuticals, medical equipment, machine parts, industrial materials such as precision materials, and clothing.
- the packaging material is preferably used for applications that require barrier properties against oxygen and for applications in which the inside of the packaging material is replaced with various functional gases.
- the packaging material is formed in various forms depending on the application, for example, a vertical bag filling and sealing bag, a vacuum packaging bag, a pouch with a spout, a laminated tube container, a container lid, and the like.
- the vapor deposition film of the present invention includes a film made of the resin composition (hereinafter also referred to as “base film”) and a metal vapor deposition layer laminated on the base film.
- the said vapor deposition film may be equipped with the resin coat layer laminated
- the upper limit of oxygen permeability measured at 40 ° C. of the deposited film at a humidity of 90% RH on the deposited layer side and 0% RH on the substrate film side is preferably 5 mL / m 2 ⁇ day ⁇ atm, and 3 mL / m. 2 ⁇ day ⁇ atm is more preferable, 2 mL / m 2 ⁇ day ⁇ atm is more preferable, 1 mL / m 2 ⁇ day ⁇ atm is particularly preferable, and 0.1 mL / m 2 ⁇ day ⁇ atm is particularly preferable.
- the oxygen permeability is not more than the above upper limit, the period during which the degree of vacuum in the internal space of a container or the like formed by the packaging material provided with the vapor deposition film can be maintained.
- the oxygen permeability (mL / m 2 ⁇ day ⁇ atm) is the amount of oxygen (ml) permeating the vapor deposition film, the vapor deposition film area (m 2 ), the transmission time (day), and one side of the vapor deposition film The value divided by the difference (atm) between the oxygen gas pressure on the side and the oxygen gas pressure on the other side.
- the oxygen permeability is, for example, “5 mL / m 2 ⁇ day ⁇ atm or less”, 5 mL of oxygen per 1 m 2 of film per day under a pressure difference of oxygen gas of 1 atm. Represents transmission.
- the oxygen permeability is 40 ° C.
- the humidity on one metal vapor deposition layer side is 90% RH
- the humidity on the other metal vapor deposition layer side is 0% RH. It shall be measured by
- the lower limit of the volatile content contained in the vapor-deposited film is not particularly limited, but is preferably 0.01% by mass, more preferably 0.03% by mass, and even more preferably 0.05% by mass.
- the upper limit of the volatile content is preferably 1.1% by mass, more preferably 0.5% by mass, and still more preferably 0.3% by mass.
- the said vapor deposition film when applying the said vapor deposition film to a vacuum heat insulating body, it is preferable that content of the volatile matter in the said vapor deposition film is as small as possible. This is because the volatile matter generated from the deposited film penetrates into the vacuum part of the vacuum heat insulating body, and as a result, the degree of vacuum inside the vacuum heat insulating body may decrease and the heat insulating performance may deteriorate.
- the content of volatile matter is obtained from the mass change before and after drying at 105 ° C. for 3 hours by the following formula.
- Volatile content (mass%) [(mass before drying ⁇ mass after drying) / mass after drying] ⁇ 100
- Base film A base film consists of the said resin composition.
- As a manufacturing method of a base film the method similar to the manufacturing method of the said film, etc. are mentioned.
- the upper limit of the oxygen permeability of the base film is preferably 50 mL ⁇ 20 ⁇ m / m 2 ⁇ day ⁇ atm, more preferably 10 mL ⁇ 20 ⁇ m / m 2 ⁇ day ⁇ atm, and 5 mL ⁇ 20 ⁇ m / m 2 ⁇ day ⁇ atm. Is more preferable, and 1 mL ⁇ 20 ⁇ m / m 2 ⁇ day ⁇ atm is particularly preferable.
- the value of oxygen permeability is a value measured at 20 ° C. and 65% RH.
- the oxygen permeability (mL ⁇ 20 ⁇ m / m 2 ⁇ day ⁇ atm) of the base film is based on the amount of oxygen (ml) permeating the base film when the average thickness of the base film is 20 ⁇ m. It means a value obtained by dividing the material film area (m 2 ), the transmission time (day), and the difference (atm) between the oxygen gas pressure on one side of the base film and the oxygen gas pressure on the other side.
- the oxygen permeability of the base film is, for example, “50 mL ⁇ 20 ⁇ m / m 2 ⁇ day ⁇ atm”
- the oxygen gas pressure difference is 1 when the average thickness of the base film is 20 ⁇ m. It represents that 50 mL of oxygen permeates per 1 m 2 of film per day under atmospheric pressure.
- the upper limit of the average thickness of the base film is not particularly limited, but is preferably 30 ⁇ m, more preferably 25 ⁇ m, and further preferably 20 ⁇ m. On the other hand, as a minimum of average thickness of the above-mentioned substrate film, 5 micrometers is preferred, 7 micrometers is more preferred, and 10 micrometers is still more preferred.
- the base film forming method is not particularly limited, and examples thereof include a melting method, a solution method, a calendar method, and the like. Among these, a melting method is preferable. Examples of the melting method include a casting method and an inflation method, and among these, the casting method is preferable.
- stretching may be performed.
- the stretching method is not particularly limited, and any of uniaxial stretching, simultaneous biaxial stretching, and sequential biaxial stretching may be used.
- the lower limit of the draw ratio in terms of area is preferably 8 times, more preferably 9 times.
- the upper limit of the draw ratio is preferably 12 times, more preferably 11 times.
- stretch spots may easily remain, whereas when the upper limit is exceeded, the film may be easily broken during stretching.
- the lower limit of the moisture content of the raw material before stretching is preferably 2% by mass, more preferably 5% by mass, and still more preferably 10% by mass.
- As an upper limit of the moisture content of the raw fabric before stretching 30% by mass is preferable, 25% by mass is more preferable, and 20% by mass is further preferable. If the water content is less than the above lower limit, stretch spots are likely to remain. In particular, when stretching with a tenter, the stretch ratio in the portion close to the grip becomes high, so that tearing in the vicinity of the grip may easily occur. On the other hand, when the moisture content exceeds the above upper limit, the elastic modulus of the stretched portion is low, the difference from the unstretched portion is not sufficient, and stretched spots may easily remain.
- the stretching temperature varies somewhat depending on the moisture content of the original fabric before stretching and the stretching method, but is generally 50 ° C. or higher and 130 ° C. or lower.
- As the stretching temperature in order to obtain a biaxially stretched film with few stretch spots, 70 ° C. or higher and 100 ° C. or lower is preferable in simultaneous biaxial stretching, and 70 ° C. or higher in longitudinal stretching with a roll in sequential biaxial stretching. 100 ° C. or lower is preferable, and 80 ° C. or higher and 120 ° C. or lower is preferable in stretching in the width direction with a tenter.
- the metal vapor deposition layer mainly secures gas barrier properties in the vapor deposition film.
- This metal vapor deposition layer is laminated
- the metal vapor deposition layer may be laminated
- the gas barrier property is further improved and the stability of the gas barrier can be obtained. That is, even if a defect occurs in one metal vapor deposition layer due to physical impact or the like, the gas barrier property as a vapor deposition film is suitably maintained by maintaining the barrier property of the other metal vapor deposition layer.
- Examples of the material for forming the metal deposition layer include aluminum, silicon, magnesium, zinc, tin, nickel, titanium, one or more oxides, carbides, nitrides, and the like.
- Aluminum may be used alone or in combination. It is preferable to do.
- the vapor deposition film which is light and is rich in a softness
- the lower limit of the average thickness of the metal vapor deposition layer is preferably 15 nm, more preferably 20 nm, further preferably 30 nm, and particularly preferably 60 nm.
- As an upper limit of the average thickness of a metal vapor deposition layer 200 nm is preferable, 130 nm is more preferable, and 80 nm is further more preferable.
- gas barrier property may become inadequate that the average thickness of a metal vapor deposition layer is less than the said minimum.
- the average thickness of a metal vapor deposition layer exceeds the said upper limit, it will become easy to generate
- the average thickness of each layer is the said range, and it is still more preferable that the sum total of the average thickness of several layers is the said range.
- the average thickness of a metal vapor deposition layer is the average value of the thickness in arbitrary 10 points
- the lower limit of the average particle diameter of vapor deposition particles such as aluminum particles in the metal vapor deposition layer is not particularly limited, but is preferably 10 nm, more preferably 15 nm, and even more preferably 20 nm.
- the upper limit of the average particle diameter of the deposited particles is preferably 150 nm, more preferably 125 nm, still more preferably 100 nm, particularly preferably 75 nm, and most preferably 50 nm.
- the average particle diameter of the vapor deposition particles is obtained by observing the surface of the metal vapor deposition layer with a scanning electron microscope and adding the maximum value of the plurality of vapor deposition particles existing in the same direction (the maximum diameter in the fixed direction) as the number of measured particles. It means the average value divided.
- an average particle diameter means the particle diameter (primary particle diameter) of the vapor deposition particle which comprises a granule, when vapor deposition particle forms the granule.
- the surface temperature of the base film at the time of vapor deposition is set to 60 ° C. or less
- the content of volatile components contained in the base film before the vapor deposition is set to 1.1% by mass or less
- Before the vapor deposition The surface of the base film is modified by plasma treatment
- condition (1) it is preferable to satisfy the condition (1), and it is more preferable to further satisfy at least one of the conditions (2) and (3) in addition to the condition (1).
- the upper limit of the surface temperature of the base film during vapor deposition is preferably 60 ° C, more preferably 55 ° C, and even more preferably 50 ° C.
- 0 degreeC is preferable, 10 degreeC is more preferable, and 20 degreeC is further more preferable.
- the upper limit of the volatile content is preferably 1.1% by mass, more preferably 0.5% by mass, and still more preferably 0.3% by mass.
- content of a volatile matter is calculated
- examples of the discharge gas include nitrogen gas, helium, neon, argon, krypton, xenon, and radon. Among these, nitrogen, helium and argon are preferable, and nitrogen is more preferable from the viewpoint of cost reduction.
- the resin coat layer suppresses damage to the metal deposition layer due to bending or the like in film processing such as lamination, for example, after the deposition film is manufactured.
- the vapor deposition film provided with such a resin coat layer can suppress a decrease in gas barrier properties.
- the resin coat layer may contain, for example, a vinyl alcohol polymer (ethylene-vinyl alcohol copolymer, polyvinyl alcohol, etc.), and may contain a swellable inorganic layered silicate as necessary.
- Swellable inorganic layered silicate improves the strength of the resin coating layer.
- the swellable inorganic layered silicate include swellable montmorillonite, swellable synthetic smectite, and swellable fluoromica-based minerals.
- the lower limit of the content of the swellable inorganic layered silicate with respect to the vinyl alcohol polymer in the resin coat layer is not particularly limited, but is preferably 0.5% by mass in terms of solid content, more preferably 1% by mass, 3% by mass is more preferable, and 5% by mass is particularly preferable.
- the upper limit of the content of the swellable inorganic layered silicate with respect to the vinyl alcohol polymer in the resin coat layer is not particularly limited, but is preferably 55% by mass, more preferably 40% by mass in terms of solid content, 30 mass% is further more preferable and 20 mass% is especially preferable. If the content of the swellable inorganic layered silicate is smaller than the lower limit, the strength of the resin coat layer may not be sufficiently improved. On the other hand, when the content of the swellable inorganic layered silicate exceeds the above upper limit, the flexibility of the resin coat layer may be lowered, and defects such as cracks may be easily generated.
- the lower limit of the average thickness of the resin coat layer is not particularly limited, but is preferably 0.001 ⁇ m in order to obtain effective gas barrier properties.
- the upper limit of the average thickness of the resin coat layer is not particularly limited, but is preferably 10 ⁇ m and more preferably 2 ⁇ m.
- the method for laminating the resin coating layer on the metal vapor deposition layer is not particularly limited, but a coating method and a laminating method are preferable.
- Coating methods include, for example, a direct gravure method, a reverse gravure method, a micro gravure method, a two roll beat coat method, a bottom feed three reverse coat method, and the like; a doctor knife method; a die coat method; a dip coat method; Coating method; a coating method combining these and the like.
- the interface between the metal vapor-deposited layer and the resin coat layer may be subjected to a corona treatment, a treatment with an anchor coating agent, or the like.
- thermoplastic resin layer a layer mainly composed of a thermoplastic resin (hereinafter referred to as “thermoplastic resin layer”), a paper layer, and the like.
- thermoplastic resin layer may be laminated on any of the base film, the metal vapor deposition layer, and the resin coat layer, or may be a layer that functions as an adhesive layer.
- This thermoplastic resin layer may be formed from a stretched film, may be formed from an unstretched film, or may be formed by coating.
- thermoplastic resin forming the other layer examples include polyolefins such as polyethylene and polypropylene, polyesters such as polyethylene terephthalate, polyamides, and ethylene-vinyl alcohol copolymers.
- the vapor deposition film is a laminate of a metal vapor deposition layer on a substrate film containing EVOH (A), the occurrence of vapor deposition omission during vapor deposition, the generation of cracks during vapor deposition film processing such as lamination, Excellent adhesion strength of the metal deposition layer. For this reason, the said vapor deposition film is applicable to various uses. As a use of the said vapor deposition film, a packaging material, a vacuum heat insulating body, etc. are mentioned, for example.
- Packaging materials Hereinafter, a packaging material provided with the said vapor deposition film is demonstrated.
- This packaging material is formed by, for example, secondary processing a vapor deposition film or a laminated film provided with this vapor deposition film.
- the said packaging material is excellent in gas barrier property by providing the said vapor deposition film, and the gas barrier property is maintained also when receiving physical stress, such as a deformation
- the packaging material is formed by laminating at least one deposited film and at least one other layer.
- the other layer include a polyester layer, a polyamide layer, a polyolefin layer, a paper layer, an inorganic vapor deposition film layer, an EVOH layer, and an adhesive layer.
- the packaging material is used for packaging foods, beverages, chemicals such as agricultural chemicals and pharmaceuticals, medical equipment, machine parts, industrial materials such as precision materials, and clothing.
- the packaging material is preferably used for applications that require barrier properties against oxygen and for applications in which the inside of the packaging material is replaced with various functional gases.
- the packaging material is formed in various forms depending on the application, for example, a vertical bag filling and sealing bag, a vacuum packaging bag, a pouch with a spout, a laminated tube container, a container lid, and the like.
- the vertical bag-filling-seal bag is used for packaging, for example, liquids, viscous bodies, powders, solid roses, foods, beverages and the like in a combination of these.
- the vertical bag-filling sealing bag is formed by heat-sealing the deposited film.
- heat sealing is performed, a layer that can be heat-sealed as a layer that is usually inside the vertical bag-filling sealing bag in the vapor-deposited film, or as both a layer that is inside and outside the vertical bag-filling sealing bag It is necessary to arrange.
- the heat-sealable layer is only on the inner side of the vertical bag-filling seal bag, the body part is usually sealed by gluing.
- the body part is usually sealed by applying an envelope.
- a polyolefin layer (hereinafter also referred to as “PO layer”) is preferable.
- the layer structure of the vertical bag-filled sealing bag the vapor deposition film / polyamide layer / PO layer, the vapor deposition film / PO layer, and the PO layer / the vapor deposition film / PO layer are preferable, and an adhesive layer may be provided between the layers. .
- this said vapor deposition film is laminated
- the packaging material is excellent in gas barrier properties as described above, and the gas barrier properties are maintained even when subjected to physical stress such as deformation or impact. Therefore, according to the vertical bag making filling seal bag which is an example of the said packaging material, the quality deterioration of the content can be suppressed over a long period of time.
- a vacuum packaging bag is used for the purpose of packaging in a vacuum state, for example, for storing food, beverages, and the like.
- the layer structure of the vacuum packaging bag the vapor deposition film / polyamide layer / PO layer and the polyamide layer / the vapor deposition film / PO layer are preferable, and an adhesive layer may be provided between the layers. Since such a vacuum packaging bag is provided with the vapor deposition film, it is particularly excellent in gas barrier properties after heat sterilization performed after vacuum packaging.
- the spout pouch is used for packaging liquid substances such as liquid drinks such as soft drinks, jelly drinks, yogurt, fruit sauces, seasonings, functional water, and liquid foods.
- liquid drinks such as soft drinks, jelly drinks, yogurt, fruit sauces, seasonings, functional water, and liquid foods.
- the vapor deposition film / polyamide layer / PO layer and the polyamide layer / the vapor deposition film / PO layer are preferable, and an adhesive layer may be provided between the layers. Since such a pouch with a spout includes the vapor deposition film, it has excellent gas barrier properties, and the gas barrier properties are maintained even when subjected to physical stress such as deformation or impact. Therefore, the spout pouch can prevent the contents from being altered even after transportation and after long-term storage.
- Laminated tube container Laminated tube container are used, for example, for packaging cosmetics, drugs, pharmaceuticals, foods, toothpastes and the like.
- the laminated tube container is preferably composed of PO layer / deposited film / PO layer, PO layer / pigment-containing PO layer / PO layer / deposited film / PO layer, and an adhesive layer may be provided between the layers. Since such a laminated tube container is provided with the vapor deposition film, it has excellent gas barrier properties, and the gas barrier properties are maintained even when subjected to physical stress such as deformation or impact.
- the container lid is a container lid filled with processed meat products, processed vegetable products, processed fishery products, foods such as fruits, and the like.
- the vapor deposition film / polyamide layer / PO layer and the vapor deposition film / PO layer are preferable, and an adhesive layer may be provided between the layers. Since such a container lid material is provided with the vapor deposition film, it has excellent gas barrier properties, and even when subjected to physical stress such as deformation or impact, the gas barrier properties are maintained. Quality deterioration can be suppressed over a long period of time.
- a vacuum heat insulator is used for an application that needs to be kept cold or warm.
- the vacuum heat insulating material include those in which a core material such as polyurethane foam is sealed in a vacuum state in an outer packaging material.
- the outer packaging material is formed, for example, by heat-sealing a pair of laminated films formed by laminating at least one layer of the deposited film and at least one other layer.
- the other layer include a polyester layer, a polyamide layer, a polyolefin layer, and an adhesive layer, and preferably include a polyolefin layer that is a heat-sealable layer.
- the number of layers in the outer packaging material and the order of lamination are not particularly limited, but the outermost layer is preferably a heat-sealable layer (for example, a polyolefin layer).
- the layer structure of the outer packaging material the vapor deposition film / polyamide layer / PO layer and the polyamide layer / the vapor deposition film / PO layer are preferable, and an adhesive layer may be provided between the layers.
- this said vapor deposition film is laminated
- Such a vacuum heat insulator has an excellent gas barrier property because the outer packaging material includes a vapor deposition film. Therefore, since the said vacuum heat insulating body can hold
- thermoformed container including the multilayer structure
- the thermoformed container is used in various fields such as food, cosmetics, medical chemicals, and toiletries where oxygen barrier properties are required.
- the said thermoforming container is formed as what has an accommodating part by thermoforming the said multilayered structure, for example.
- the accommodating portion is a portion that accommodates contents such as food.
- the shape of this accommodating part is determined corresponding to the shape of the contents.
- the thermoformed container is formed as, for example, a cup-shaped container, a tray-shaped container, a bag-shaped container, a bottle-shaped container, a pouch-shaped container, or the like.
- the form of the accommodating part can be expressed by a drawing ratio (S) as one index.
- the drawing ratio (S) is a value obtained by dividing the depth of the deepest part of the container by the diameter of the largest circle inscribed in the opening of the container. That is, the drawing ratio (S) means that the larger the value is, the deeper the container is, and the smaller the value is, the shallower the container is.
- the drawing ratio (S) is large, and when it is tray-shaped, the drawing ratio (S) is small.
- the diameter of the maximum diameter circle inscribed in the opening of the container is, for example, a circle diameter when the opening of the housing portion is circular, a short diameter (short axis length), or a rectangle when the opening is elliptical. In some cases, it is the length of the short side.
- the drawing ratio (S) has a suitable value depending on whether the multilayer structure for forming the thermoformed container is a film or a sheet, that is, the thickness of the multilayer structure.
- the lower limit of the drawing ratio (S) is preferably 0.2, more preferably 0.3, and even more preferably 0.4.
- the lower limit of the drawing ratio (S) is preferably 0.3, more preferably 0.5, and even more preferably 0.8.
- a film means a soft thing with an average thickness of less than 0.2 mm
- a sheet has a thickness larger than a film, for example, an average thickness is 0.2 mm or more and is flexible. Say things.
- thermoforming container another layer is laminated on at least one of the one surface side and the other surface side of the first layer.
- one surface side is an inner surface side of the housing portion when the multilayer structure is used as the thermoforming container, and the other surface side is an outer surface side of the housing portion. is there.
- Thickness ratio (I / O) between the total average thickness I of the other layers laminated on one surface side of the first layer and the total average thickness O of the other layers laminated on the other surface side of the first layer 1) is preferably 1/99, more preferably 30/70. Moreover, as an upper limit of the said ratio (I / O), 70/30 is preferable and 55/45 is more preferable.
- the average thickness of all layers or a single layer of the multilayer structure is an average value of thicknesses measured by observation with an optical microscope for samples cut out from a plurality of locations of the multilayer structure using a microtome, and is the total thickness of the thermoformed container. It substantially corresponds to the thickness of the layer or monolayer.
- the lower limit of the overall average thickness of the thermoformed container is preferably 300 ⁇ m, more preferably 500 ⁇ m, and even more preferably 700 ⁇ m.
- the upper limit of the overall average thickness of the thermoformed container is preferably 10,000 ⁇ m, more preferably 8,500 ⁇ m, and even more preferably 7,000 ⁇ m.
- the overall average thickness of the thermoformed container refers to the average thickness of all the layers in the accommodating portion of the thermoformed container, and the measurement method is the same as the method for measuring the total average thickness of the multilayer structure described above. . If the overall average thickness of the thermoformed container exceeds the above upper limit, the production cost may increase.
- the overall average thickness of the thermoformed container is smaller than the lower limit, the rigidity cannot be maintained and the thermoformed container may be easily destroyed. Accordingly, it is important that the overall average thickness of the thermoformed container is set to a thickness corresponding to the capacity and application.
- first layer a layer mainly composed of a thermoplastic resin (hereinafter also referred to as “(2) layer”), (1 ) Layer and (2) layer, which are mainly composed of carboxylic acid-modified polyolefin (hereinafter also referred to as “(3) layer”) and recovery layer (hereinafter also referred to as “(4) layer”). ) And the like.
- first layer a layer mainly composed of a thermoplastic resin
- (2) layer which are mainly composed of carboxylic acid-modified polyolefin
- (4) layer recovery layer
- (1) layer, (2) layer, (3) layer, and (4) layer will be described in detail.
- the layer is a layer mainly composed of EVOH (A) made of the resin composition.
- A EVOH
- the upper limit of the average thickness of the (1) layer is preferably 5.0%, more preferably 4.5%, and still more preferably 4.1% with respect to the total average thickness.
- the (2) layer is mainly composed of a thermoplastic resin which is disposed on the inner surface side and the outer surface side of the (1) layer and whose solubility parameter calculated from the Fedors equation is 11 (cal / cm 3 ) 1/2 or less. It is a layer to do.
- a thermoplastic resin having a solubility parameter calculated by this formula of 11 (cal / cm 3 ) 1/2 or less is excellent in moisture resistance.
- the solubility parameter calculated from the Fedors equation is a value represented by (E / V) 1/2 .
- thermoplastic resin that is the main component of the layer is not particularly limited as long as the solubility parameter is 11 (cal / cm 3 ) 1/2 or less.
- polyethylene linear low Density polyethylene, low density polyethylene, medium density polyethylene, high density polyethylene, etc.
- ethylene-vinyl acetate copolymer ethylene-propylene copolymer
- polypropylene copolymer of propylene and ⁇ -olefin having 4 to 20 carbon atoms.
- Olefin homopolymers or copolymers such as polybutene and polypentene, polystyrene, polyvinyl chloride, polyvinylidene chloride, acrylic resins, vinyl ester resins, polyurethane elastomers, polycarbonate, chlorinated polyethylene, chlorinated polypropylene, etc. It is done. Of these, polyethylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, polypropylene, and polystyrene are preferable, and high-density polyethylene is more preferable.
- the lower limit of the density of the high-density polyethylene is preferably 0.93 g / cm 3 and more preferably 0.95 g / cm 3 from the viewpoints of rigidity, impact resistance, moldability, drawdown resistance, gasoline resistance, and the like. 0.96 g / cm 3 is more preferable.
- the upper limit of the density of the high-density polyethylene is preferably 0.98 g / cm 3 .
- the upper limit of the melt flow rate is preferably 0.5 g / 10 minutes, and more preferably 0.1 g / 10 minutes.
- the said high-density polyethylene can be used selecting it normally from a commercial item normally.
- the (2) layer may contain other optional components similar to those of the (1) layer as long as the effects of the present invention are not impaired.
- the lower limit of the average thickness of the layer is not particularly limited, but is preferably 5%, more preferably 8%, and even more preferably 10% with respect to the total average thickness of the layers.
- the upper limit of the average thickness of the (2) layer is not particularly limited, but is preferably 70%, more preferably 60%, and even more preferably 50% with respect to the total average thickness of the layers.
- a layer is a layer which is arrange
- the (3) layer can function as an adhesive layer between the (1) layer and another layer such as the (2) layer.
- the carboxylic acid-modified polyolefin has a carboxy group obtained by chemically bonding an ethylenically unsaturated carboxylic acid or an anhydride thereof to an olefin polymer by an addition reaction, a graft reaction or the like, or an anhydride group thereof. It refers to an olefin polymer.
- Examples of the ethylenically unsaturated carboxylic acid and its anhydride include monocarboxylic acid, monocarboxylic acid ester, dicarboxylic acid, dicarboxylic acid monoester, dicarboxylic acid diester, and dicarboxylic acid anhydride.
- Specific examples include maleic acid, fumaric acid, itaconic acid, maleic anhydride, itaconic anhydride, maleic acid monomethyl ester, maleic acid monoethyl ester, maleic acid diethyl ester, and fumaric acid monomethyl ester.
- dicarboxylic anhydrides such as maleic anhydride and itaconic anhydride are preferred, and maleic anhydride is more preferred.
- Examples of the olefin polymer to be a base polymer include polyolefins such as low density, medium density or high density polyethylene, linear low density polyethylene, polypropylene, boribten; Examples thereof include a copolymer of an olefin and a comonomer such as an ethylene-vinyl acetate copolymer and an ethylene-ethyl acrylate copolymer.
- the comonomer is not particularly limited as long as it is a monomer copolymerizable with an olefin, and examples thereof include vinyl esters and unsaturated carboxylic acid esters.
- Examples of the olefin polymer include linear low density polyethylene, ethylene-vinyl acetate copolymer having a vinyl acetate content of 5% by mass to 55% by mass, and ethyl acrylate content of 8% by mass to 35%.
- An ethylene-ethyl acrylate copolymer having a mass% or less is preferred, and a linear low density polyethylene and an ethylene-vinyl acetate copolymer having a vinyl acetate content of 5 mass% to 55 mass% are more preferred.
- the carboxylic acid-modified polyolefin is an addition reaction or graft reaction of the ethylenically unsaturated carboxylic acid or its anhydride to the olefin polymer in the presence of a solvent such as xylene and a catalyst such as peroxide. It is obtained by introducing.
- the lower limit of the amount of carboxylic acid or its anhydride added to the olefin polymer or the graft amount (degree of modification) is preferably 0.01% by mass, preferably 0.02% by mass relative to the olefin polymer. % Is more preferable.
- the upper limit of the addition amount or graft amount (degree of modification) is preferably 15% by mass, more preferably 10% by mass, based on the olefin polymer.
- the (3) layer may contain other optional components similar to the (1) layer in addition to the carboxylic acid-modified polyolefin as long as the effects of the present invention are not impaired.
- the lower limit of the average layer thickness is not particularly limited, but is preferably 0.3%, more preferably 0.6%, and further 1.2% with respect to the total average layer thickness. preferable.
- the upper limit of the average layer thickness is preferably 12%, more preferably 9%, and even more preferably 6%.
- the layer is a layer containing EVOH (A), a thermoplastic resin, and a carboxylic acid-modified polyolefin.
- the (4) layer is formed using the recovered material of the (1) layer, the (2) layer, and the (3) layer in the manufacturing process of the thermoformed container. Examples of the recovered material include burrs generated in the manufacturing process of the thermoformed container, rejected products, etc. Since the thermoformed container further has a layer (4) as such a recovery layer, such burrs and non-certified products can be reused, and the resin used at the time of manufacturing the thermoformed container can be reused. Loss can be reduced.
- the (4) layer can be used in place of the above-mentioned (2) layer, but generally, the mechanical strength of the (4) layer is often lower than that of the (2) layer. It is preferable to use a laminate of 2) and (4) layers.
- the (4) layer is preferably arranged on the outer layer side than the (1) layer.
- a recovery layer can be arranged as a (4) layer on both sides of the (1) layer.
- the upper limit of the EVOH (A) content in the layer is preferably 9.0% by mass. (4) If the EVOH (A) content in the layer exceeds the above upper limit, cracks are likely to occur at the interface with the (2) layer, and the entire thermoformed container may be destroyed starting from the crack. is there. In addition, as a minimum of content of EVOH (A) in a (4) layer, it is 3.0 mass%, for example.
- the lower limit of the average thickness of the layer is not particularly limited, but is preferably 10%, more preferably 20%, and even more preferably 30% with respect to the average thickness of all layers.
- the upper limit of the average layer thickness is preferably 60%, more preferably 55%, and even more preferably 50% with respect to the total average layer thickness.
- the multilayer structure used for the thermoforming container can be formed using a coextrusion molding apparatus.
- the multilayer structure includes, for example, (1) the resin composition for forming a layer, (2) a resin composition for forming a layer, (3) a resin composition for forming a layer, and (4) a resin composition for forming a layer.
- Products can be formed as having a predetermined layer structure by charging them into separate extruders and co-extrusion with these extruders.
- Extrusion molding of each layer is performed by operating an extruder equipped with a single screw at a predetermined temperature.
- the temperature of the extruder which forms a layer shall be 170 degreeC or more and 240 degrees C or less, for example.
- the temperature of the extruder which forms a (2) layer shall be 200 degreeC or more and 240 degrees C or less, for example.
- the temperature of the extruder which forms (3) layer shall be 160 degreeC or more and 220 degrees C or less, for example.
- the temperature of the extruder for forming the (4) layer is, for example, 200 ° C. or higher and 240 ° C. or lower.
- thermoformed container can be formed by heating and softening the multilayer structure such as a film or a sheet, and then molding it into a mold shape.
- thermoforming methods for example, vacuum or compressed air is used, and if necessary, a plug is used to form a mold (straight method, drape method, air slip method, snapback method, plug assist method, etc.), press molding The method of doing is mentioned.
- Various molding conditions such as molding temperature, degree of vacuum, pressure of compressed air, molding speed, and the like are appropriately set depending on the plug shape, mold shape, raw material film and sheet properties, and the like.
- the molding temperature is not particularly limited as long as the resin can be softened sufficiently to be molded, and a suitable temperature range varies depending on the configuration of the multilayer structure such as a film or a sheet.
- thermoforming a film it is desirable that the film is not heated so high that the film is melted by heating or the unevenness of the metal surface of the heater plate is transferred to the film, but not so low that shaping is not sufficient.
- the lower limit of the specific film heating temperature is usually 50 ° C., preferably 60 ° C., and more preferably 70 ° C.
- As an upper limit of the heating temperature of a film it is 120 degreeC normally, 110 degreeC is preferable and 100 degreeC is more preferable.
- a sheet when thermoformed, it may be formed at a higher temperature than in the case of a film.
- the heating temperature of the sheet is, for example, 130 ° C. or higher and 180 ° C. or lower.
- the method for producing the thermoformed container includes a step of forming a first layer using a resin composition containing EVOH (A) and (1) a step of thermoforming a multilayer structure including the layer. Is preferred.
- the layer (2) in the outermost layer. That is, (2) layer / (3) layer / (1) layer / (3) layer / (2) layer (hereinafter referred to as “(inner surface) (2) / (3) / (1) / (3) / (2) (outer surface) ”is preferable from the viewpoint of impact resistance.
- (inner surface) (2) / (3) / (1) / (3) / (4) / (2) (outer surface) and (inner surface) (2) / () among these 4) / (3) / (1) / (3) / (4) / (2) (outer surface) is preferable.
- the resins constituting each layer may be the same or different.
- thermoformed container Next, the thermoformed container will be specifically described taking the cup-shaped container shown in FIGS. 2 and 3 as an example.
- the cup-shaped container is merely an example of the thermoformed container, and the following description of the cup-shaped container does not limit the scope of the present invention.
- FIG. 3 includes a cup body 2 and a flange portion 3 as an accommodating portion.
- the cup-shaped container 1 is used by accommodating the contents in the cup body 2 and sealing the lid 7 on the flange portion 3 so as to close the opening 4 of the cup body 2.
- the seal include a resin film, a metal foil, and a metal resin composite film.
- a metal resin composite film in which a metal layer is laminated on a resin film is preferable.
- the resin film include a polyethylene film and a polyethylene terephthalate film.
- Metal foil and a metal vapor deposition layer are preferable, and aluminum foil is more preferable from a viewpoint of gas barrier property and productivity.
- the cup-shaped container 1 can be obtained by thermoforming the multilayer structure such as a film or sheet.
- the multilayer structure preferably includes at least (1) layers, and other layers are preferably stacked on the (1) layers. Examples of other layers include (2) layer, (3) layer, and (4) layer.
- the structure shown in FIG. 4 is preferable.
- (2) layer 12 is laminated via (3) layer 13 on one surface side of layer 11 (on the inner surface 5 side of cup body 2 of cup-shaped container 1).
- the (4) layer 14 and (2) layer 12 are laminated on the other surface side (the outer surface 6 side of the cup body 2 of the cup-shaped container 1) via the (3) layer 13.
- the cup-shaped container 1 is manufactured by heating and softening a continuous multilayer structure 20 such as a film or sheet using a heating device 30 as shown in FIG. Is done.
- the heating device 30 includes a pair of heaters 31 and 32, and the continuous multilayer structure 20 can pass between the heaters 31 and 32.
- the heating apparatus 30 what is heated with a hot press can also be used.
- the mold apparatus 40 is suitable for thermoforming by a plug assist method, and includes a lower mold 50 and an upper mold 51 accommodated in a chamber (not shown).
- the lower mold 50 and the upper mold 51 are individually movable in the vertical direction, and the continuous multilayer structure 20 can pass between the lower mold 50 and the upper mold 51 in the separated state.
- the lower mold 50 has a plurality of recesses 52 for forming the accommodating part of the cup-shaped container 1.
- the upper mold 51 includes a plurality of plugs 53 that protrude toward the lower mold 50.
- the plurality of plugs 53 are provided at positions corresponding to the plurality of recesses 52 of the lower mold 50. Each plug 53 can be inserted into the corresponding recess 52.
- the lower mold 50 is moved up with respect to the continuous multilayer structure 20 softened by the heating device 30 to be in close contact with the lower mold 50 and the continuous multilayer structure.
- the body 20 is slightly lifted to apply tension to the continuous multilayer structure 20.
- the plug 53 is inserted into the recess 52 by moving the upper mold 51 downward.
- the upper mold 51 is moved upward to separate the plug 53 from the recess 52, and then the inside of the chamber (not shown) is evacuated, so that the continuous multilayer structure 20 is removed from the recess 52. Adhere to the inner surface of. Then, the shape is fixed by cooling the molding part by air injection. Subsequently, as shown in FIG. 6D, a chamber (not shown) is opened to the atmosphere, and the lower mold 50 is moved downward to release the lower mold 50 to obtain a primary molded product. By cutting this primary molded product, the cup-shaped container 1 shown in FIGS. 2 and 3 is obtained.
- thermoforming container by thermoforming the single layer structure provided only with the 1st layer which consists of the said resin composition.
- thermoforming method, shape of the thermoforming container, and the like can be the same as those of the thermoforming container.
- the blow molded body includes the multilayer structure.
- the blow molded body can be used for, for example, a blow molded container.
- the blow molded body will be described in detail by taking the blow molded container 105 shown in FIG. 7 as an example.
- FIG. 7 is a partial cross-sectional view of the peripheral wall of the blow molded container 105.
- the blow molded container 105 in FIG. (1) A layer 101 containing EVOH (A) as a main component, (2) (1)
- the main component is a thermoplastic resin which is disposed on one side and the other side of the layer and has a solubility parameter calculated from the Fedors equation of 11 (cal / cm 3 ) 1/2 or less.
- a layer 104 containing a thermoplastic resin having a solubility parameter of 11 (cal / cm 3 ) 1/2 or less and a carboxylic acid-modified polyolefin is provided.
- the blow-molded container 105 has (2) layer 102, (3) layer 103, (1) layer 101, (3) layer 103, (4) from the container inner surface 106 toward the container outer surface 107. ) Layer 104 and (2) layer 102 in this order.
- the lower limit of the overall average thickness of the blow molded container 105 is preferably 300 ⁇ m, more preferably 500 ⁇ m, and even more preferably 1,000.
- the upper limit of the overall average thickness of the blow molded container 105 is preferably 10,000 ⁇ m, more preferably 8,500 ⁇ m, and even more preferably 7,000 ⁇ m.
- the overall average thickness of the blow-molded container 105 refers to the average thickness at the body of the blow-molded container 105. If the overall average thickness exceeds the upper limit, the weight increases, and for example, when used in a fuel container such as an automobile, the fuel efficiency is adversely affected and the manufacturing cost may increase. On the other hand, if the overall average thickness is smaller than the lower limit, the rigidity cannot be maintained, and there is a risk of being easily destroyed. Therefore, it is important to set the overall average thickness to a thickness corresponding to the capacity and application.
- (1) layer 101, (2) layer 102, (3) layer 103, and (4) layer 104 are, for example, the (1) layer, (2) layer, Since it can be the same as the (3) layer and the (4) layer, the description thereof is omitted.
- the blow molded container 105 is preferably manufactured by a method having a step of blow molding using a resin composition containing EVOH (A) as a main component. Specifically, (1) a dry EVOH-containing resin composition pellet for forming the layer 101, (2) high-density polyethylene for forming the layer 102, (3) an adhesive resin for forming the layer 103, and (4) For example, (2) layer / (3) layer / (1) layer / (3) layer / (4) at a temperature of 100 ° C. or higher and 400 ° C.
- the blow-molded container is not limited to the form shown in FIG. 7 described above, and may be provided with at least a (1) layer. Specifically, the (4) layer or the like as the recovery layer may not be provided. Furthermore, other layers may be laminated. Moreover, you may abbreviate
- the blow-molded container includes (2) layers
- (4) layers such as a collection layer are included, (inner) 2/3/1/3/4/2 (outer), (inner) 2/4/3/1/3/4/2 (Outside), (Inside) 4/3/1/3/4 (Outside) arrangement is preferable (Inside) 2/3/1/3/4/2 (Outside), (Inside) 2/4/3
- the arrangement of 1/3/4/2 (outside) is more preferable.
- a structure including the (4) layer may be used instead of the (2) layer. In the case where a plurality of (1) to (4) layers are used, the resins constituting each layer are the same or different. May be.
- the fuel container includes the blow molded body.
- the fuel container may further include a filter, a fuel gauge, a baffle plate, and the like in addition to the blow molded body. Since the fuel container is provided with the blow molded container, it is excellent in appearance, gas barrier properties, oil resistance, and the like, and therefore is suitably used as a fuel container.
- the fuel container is a fuel container mounted on an automobile, a motorcycle, a ship, an aircraft, a generator, an industrial or agricultural device, or a portable fuel container for supplying fuel to these fuel containers. Means a container for storing fuel.
- the fuel examples include gasoline, particularly oxygen-containing gasoline blended with methanol, ethanol, MTBE, or the like, but also includes heavy oil, light oil, kerosene, and the like.
- the fuel container is particularly preferably used as a fuel container for oxygen-containing gasoline.
- EVAc ethylene-vinyl acetate copolymer
- the neutralized reaction solution was transferred from the reactor to a drum can and allowed to stand at room temperature for 16 hours to be cooled and solidified into a cake. Thereafter, the cake-like resin was drained using a centrifuge (“H-130” manufactured by Kokusan Centrifuge Co., Ltd., rotating at 1200 rpm). Next, the center part of the centrifuge was washed while continuously supplying ion exchange water from above, and the step of washing the resin with water was performed for 10 hours. The conductivity of the cleaning liquid 10 hours after the start of cleaning was 30 ⁇ S / cm (measured with “CM-30ET” manufactured by Toa Denpa Kogyo Co., Ltd.).
- the washed resin was dried at 60 ° C. for 48 hours using a dryer to obtain powdered EVOH.
- the stirring was stopped and the temperature of the dissolution tank was lowered to 65 ° C. and left for 5 hours to defoam the above EVOH water and methanol solution.
- Synthesis Example 5 EVOH was synthesized in the same manner as in Synthesis Example 1 except that the acetaldehyde content, ethylene content and saponification degree of vinyl acetate were as shown in Table 1, and 50 ppm of tartaric acid was further added to vinyl acetate.
- Methanol was added to the precipitated polyvinyl acetate to obtain a 40% by mass methanol solution of polyvinyl acetate with a vinyl acetate monomer removal rate of 99.8%. Further, a part of the obtained methanol solution was collected, and a 10% by mass methanol solution of sodium hydroxide was added so that the molar ratio of sodium hydroxide to vinyl acetate units in polyvinyl acetate was 0.1, When the gelled product was formed, the gel was pulverized and subjected to Soxhlet extraction with methanol for 3 days. The obtained polyvinyl alcohol was dried and the viscosity average degree of polymerization was measured. As a result, the degree of polymerization was 1,700. This was used as an index of the degree of polymerization of polyvinyl acetate.
- the PVA synthesized in Comparative Synthesis Example 3 was used as the resin composition of Comparative Example 2.
- the degree of saponification such as EVOH shown in Table 1 the ethylene content, the alkali metal content, and the like were measured by the method described below.
- “-” indicates that the molecular weight was not measured because the resin was not dissolved in the solvent.
- the portion of 3.1 ppm to 3.7 ppm is 95
- the measurement data of ° C. was adopted
- the measurement data of 40 ° C. was adopted for the portion of 3.7 ppm to 4 ppm
- the total amount of the methine hydrogen was quantified as the total value thereof.
- the hydrogen peak of water or a hydroxyl group shifts to the high magnetic field side by increasing the measurement temperature. Therefore, it analyzed using the measurement result of both 40 degreeC and 95 degreeC as follows. From the spectrum measured at 40 ° C. above, the integrated value (I 1 ) of the peak of chemical shift of 3.7 ppm to 4 ppm and the integrated value (I 2 ) of the peak of chemical shift of 0.6 ppm to 1.8 ppm were obtained. .
- the integrated value (I 3 ) of the peak of chemical shift of 3.1 ppm to 3.7 ppm, the integrated value of the peak of chemical shift (I 4 ) of 0.6 ppm to 1.8 ppm, and The integrated value (I 5 ) of the peak of chemical shift from 1.9 ppm to 2.1 ppm was determined.
- the peak of the chemical shift of 0.6 ppm to 1.8 ppm is mainly derived from methylene hydrogen
- the peak of the chemical shift of 1.9 ppm to 2.1 ppm is in the unsaponified vinyl acetate unit. It is derived from methyl hydrogen. From these integrated values, the ethylene content was calculated by the following formula (5), and the saponification degree was calculated by the following formula (6).
- Alkali metal content The alkali metal content was quantified using a spectroscopic analyzer. Specifically, 0.5 g of dried EVOH pellets was added to a pressure-resistant container made of Teflon (registered trademark) manufactured by Actac Corporation, and 5 mL of nitric acid (for precision analysis manufactured by Wako Pure Chemical Industries, Ltd.) was added. After standing for 30 minutes, the container is covered with a cap lip with a rupture disk, and the microwave high-speed decomposition system (“Speedwave MWS-2” by Actac Co.) is used at 150 ° C. for 10 minutes, then 180 ° C. for 10 minutes. Treatment was performed to decompose the dry EVOH pellets.
- Teflon registered trademark
- nitric acid for precision analysis manufactured by Wako Pure Chemical Industries, Ltd.
- melt viscosity (melt flow rate)
- the melt viscosity (melt flow rate) was measured according to JIS-K7210 (1999) at a temperature of 190 ° C. and a load of 2,160 g.
- the GPC measurement was performed using “GPCmax” of VISCOTECH.
- the molecular weight was calculated based on the signal intensity detected by the differential refractive index detector and the UV-visible absorbance detector.
- VISCOTECH's “TDA305” and “UV Detector 2600” were used.
- As the detection cell of this absorbance detector a cell having an optical path length of 10 mm was used.
- As the GPC column “GPC HFIP-806M” manufactured by Showa Denko KK was used.
- analysis software “OmniSEC (Version 4.7.0.406)” attached to the apparatus was used.
- HFIP hexafluoroisopropanol
- the mobile phase 20 mmol / L sodium trifluoroacetate-containing HFIP was used.
- the mobile phase flow rate was 1.0 mL / min.
- the sample injection amount was 100 ⁇ L, and measurement was performed at a GPC column temperature of 40 ° C.
- the sample in which the viscosity average degree of polymerization of PVA exceeds 2,400 was subjected to GPC measurement using an appropriately diluted sample (100 ⁇ L).
- the absorbance at the sample concentration of 1.00 mg / mL was calculated from the measured value by the following formula (7).
- ⁇ (mg / mL) is the concentration of the diluted sample.
- Absorbance (1.00 / ⁇ ) ⁇ Measured value of absorbance (7)
- PMMA polymethyl methacrylate
- Agilent Technologies peak top molecular weight: 1,944,000, 790,000, 467,400, 271,400, 144,000, 79, 250, 35, 300, 13, 300, 7, 100, 1, 960, 1, 020 or 690
- the peak intensity obtained from the differential refractive index detector is expressed in “mV” and is used as a standard sample by American Polymer Standard Corp.
- PMMA sample PMMA 85K: weight average molecular weight 85,450, number average molecular weight 74,300, intrinsic viscosity 0.309
- the peak intensity was 358.31 mV.
- a single layer film was produced by continuous operation under the above conditions, and the number of defects per 17 cm film length was counted for each film produced 10 hours after the start of operation and 50 hours later.
- the number of defects was counted using a film defect inspection apparatus ("AI-10" from Frontier System).
- the detection camera in this film defect inspection apparatus was installed so that the lens position might be a distance of 195 mm from the film surface.
- Film formation defects are “good (A)” when the number of defects is less than 50, “slightly good (B)” when 50 or more and less than 200, and “bad (C)” when 200 or more defects. Judged as.
- the EVOH resin compositions of Examples 1 to 5 As shown in Table 2, in the EVOH resin compositions of Examples 1 to 5, film formation defects, streaks, and coloring of the roll end portions formed after 10 hours and 50 hours from the start of operation were suppressed. . That is, the EVOH resin compositions of Examples 1 to 5 were able to form films having excellent long run properties during melt molding and excellent appearance.
- Example 6 Coextrusion sheet forming method (with extrusion temperature) A multilayer sheet was produced using the EVOH resin composition obtained in Example 4, and the appearance was evaluated. Specifically, the EVOH resin composition, the ethylene- ⁇ -olefin copolymer, and the carboxylic acid-modified polyolefin are charged into separate extruders, and the ethylene- ⁇ -olefin copolymer / carboxylic acid-modified polyolefin / EVOH resin composition is charged.
- the feed block die (width 600 mm) was operated at 250 ° C.
- the set temperature of the feed block die (width: 600 mm) was 250 ° C., which was about 10 ° C. higher than usual. As a result of evaluating the appearance of the sheet after continuous molding for 10 hours, the film surface was good.
- each inorganic particle (C) was calculated as an oxide equivalent value by quantifying the metal element by the same method as the method for measuring the alkali metal content described above. That is, it calculated as silicon oxide, aluminum oxide, magnesium oxide, zirconium oxide, cerium oxide, tungsten oxide, and / or molybdenum oxide. When a plurality of metals were included, the amount was calculated as a plurality of metal oxide amounts. The amount of the phosphoric acid compound was calculated as a phosphate radical equivalent value by quantifying phosphorus element. The boron compound content was calculated as a boron element equivalent value.
- inorganic particles (C) As inorganic particles (C) containing silicon atoms, “Silicia 380” (average particle size 9.0 ⁇ m) or “Silicia 310P” (average particle size 2.7 ⁇ m) of Fuji Silysia Chemical Co., Ltd. is classified by pulverization and sieving, Adjusted to the desired size.
- the average particle size of the inorganic particles (C) was measured using a “laser diffraction particle size distribution measuring device (SALD-2200)” manufactured by Shimadzu Corporation. As an evaluation sample, 5 g of 50 cc pure water and inorganic particles (C) to be measured were added to a glass beaker, stirred using a spatula, and then subjected to dispersion treatment for 10 minutes with an ultrasonic cleaner.
- SALD-2200 laser diffraction particle size distribution measuring device
- the particle diameter is determined from the light intensity distribution data of the diffraction / scattered light of the particles.
- Distribution was calculated.
- the average particle size was determined by dividing the integrated value of the value obtained by multiplying the measured particle size by the relative particle amount by the total relative particle amount.
- the average particle diameter is the average diameter of the particles.
- the obtained multilayer structure was cut with a microtome to expose the cross section. This cross section was observed using a scanning electron microscope (SEM), and the thickness of the metal deposition layer was measured. SEM observation was performed using a backscattered electron detector using “ZEISS ULTRA 55” manufactured by S.I. Inano Technology.
- the EVOH resin composition of Example 10 was formed into a film, and a film was produced according to a method using a simultaneous biaxial stretching machine.
- the physical properties of the film were evaluated, and the film surface measured according to JIS-B0601 was measured.
- the arithmetic average roughness (Ra) was 0.28 ⁇ m
- the average length (RSm) of the contour curve elements was 298 ⁇ m, both of which were judged as A.
- yellow coloring was not seen in the roll end surface after winding up as a roll, but it was A determination.
- the number of breaks during film processing was 1 and was A.
- the average thickness of the vapor deposition layer in the manufactured multilayer structure was 50 nm.
- the vapor deposition defect of the first multilayer structure was 9 pieces / m 2 and the vapor deposition defect of the multilayer structure 100 was 12 pieces / m 2 , both of which were A judgments. From this, the increase in deposition defects over time was A.
- the adhesion strength between the vapor-deposited layer of the multilayer structure and the EVOH film layer was 530 g / 15 mm, which was A judgment.
- the obtained multilayer structure (multilayer structure having an aluminum deposition layer) EVOH film is an intermediate layer, and PET film (“E5000” of Toyobo Co., Ltd.) is an outer layer (multilayer structure (multilayer structure having an aluminum deposition layer).
- CPP unstretched polypropylene film
- RXC-18 unstretched polypropylene film
- thickness 60 ⁇ m is an inner layer (multilayer structure (multilayer structure having an aluminum deposition layer) EVOH)
- an adhesive for dry laminating Takelac A-385 / A-50 (Mitsui Chemicals Co., Ltd., mass ratio of 6/1, mixed with a solid content concentration of 23% by mass)
- the multilayer structure EVOH film was sandwiched between the adhesive surfaces.
- the PET film and the CPP film were bonded together and aged at 40 ° C. for 5 days to obtain a multilayer structure having a layer structure of PET / adhesive layer / EVOH layer / adhesive layer / CPP.
- the obtained multilayer structure was heat-sealed and formed into a pouch and filled with 100 g of water.
- Table 4 shows the evaluation results for films and multilayer structures produced using each EVOH resin composition.
- films produced using the EVOH resin compositions of the examples are excellent in appearance and film break resistance.
- the multilayer structure obtained by vapor-depositing a metal on a film among the multilayer structures has few deposition defects and is excellent in adhesion strength between the deposited layer and the EVOH film layer.
- those in which EVOH (A) is outside the specified range of formula (1) are inferior in these characteristics.
- EVOH resin composition having polyolefin (D)> [Example 11] 5.5 parts by mass of EVOH resin composition of Example 1, 87 parts by mass of low density polyethylene (LDPE) which is an unmodified polyolefin as polyolefin (D) (“HZ8200B” of Prime Polymer Co., Ltd.), anhydrous which is an acid-modified polyolefin A mixture was obtained by mixing 7.5 parts by mass of maleic acid-modified polyethylene (“Admer GT-6A” from Mitsui Chemicals, Inc.) and 0.15 parts by mass of zinc stearate as a fatty acid metal salt.
- LDPE low density polyethylene
- Admer GT-6A Admer GT-6A” from Mitsui Chemicals, Inc.
- the above mixture was melt-kneaded under the pelletizing conditions shown below to obtain 20 kg of the EVOH resin composition of Example 10 having the composition shown in Table 5.
- the obtained EVOH resin composition was melted and kneaded again, and the operation of taking it out from the kneader was repeated.
- the resin composition (hereinafter referred to as “resin”) was melted and kneaded five times (hereinafter also referred to as “recovery number”). 20 kg of each of the composition (also referred to as “composition (J)”) was also obtained.
- the melt kneading temperature of these resin compositions was carried out at 250 ° C., which is higher than usual, while the normal EVOH kneading temperature condition is about 150 ° C. to 250 ° C. Moreover, the fatty acid metal salt was made into content with the mass at the time of preparing a mixture.
- Example 12 to 14 and Comparative Example 4 An EVOH resin composition and a resin composition (J) obtained by melting and kneading this EVOH resin composition a plurality of times were used in the same manner as in Example 11 except that the components of the types and blending amounts shown in Table 5 were used. Produced.
- Resin composition (J) extruder: single screw, diameter 65 mm, L / D 22, temperature 200 ° C. to 240 ° C.
- EVOH resin compositions of Examples 11 to 14 and Comparative Example 4 polyethylene (“HZ8200B” of Prime Polymer Co., Ltd.), adhesive resin (“Admer GT-6A” of Mitsui Chemicals, Inc.), and resin composition (J ) Using a blow molding machine (“TB-ST-6P” manufactured by Suzuki Kogyo Co., Ltd.) and cooling at 210 ° C. and a mold internal temperature of 15 ° C.
- grains observed in a photograph was measured, and this was made into the particle size.
- the film or sheet was cut perpendicular to the extrusion direction, and the cut surface was photographed from the vertical direction.
- the blow-molded containers produced using the EVOH resin compositions of the examples were less likely to cause streaking and coloring and were superior in appearance as compared with the comparative examples.
- the blow molded containers of Examples 11 to 14 were excellent in impact resistance in the multilayer containers containing the resin composition (J) which was repeated 5 times.
- the blow molded containers of Examples 12 to 14 were excellent in impact resistance even in the multilayer container containing the resin composition (J) which was repeated 10 times. Therefore, the resin composition containing polyolefin (D) prevents thickening due to thermal degradation of the EVOH component during repeated collection, suppresses aggregation of the EVOH component in the resin composition, and reduces impact resistance. It turns out that the effect to prevent is shown. Therefore, it turned out that the said resin composition containing polyolefin (D) can be used suitably for a blow molding container.
- Example 15 [Preparation of EVOH Resin Composition of Example 15]
- the EVOH resin composition of Example 15 shown in Table 6 was prepared in the same manner as in Example 1.
- the above-prepared monolayer film commercially available biaxially stretched nylon 6 film (Unitika's “Emblem ON”, average thickness 15 ⁇ m) and commercially available unstretched polypropylene film (Mitsui Chemicals Tosero CP “Tosero CP” ”, Average thickness 60 ⁇ m), each cut into A4 size, apply dry laminate adhesive on both sides of single layer film, dry laminate so that outer layer is nylon 6 film and inner layer is unstretched polypropylene film The obtained laminate film was dried at 80 ° C. for 3 minutes to evaporate the diluted solution to obtain a transparent multilayer sheet consisting of three layers.
- the dry laminating adhesive “Takelac A-385” manufactured by Mitsui Chemicals, Inc.
- a single layer film was produced by continuous operation under the above conditions, and after 8 hours from the start of operation, the resin was switched to low density polyethylene (“Novatech LF128” from Nippon Polyethylene Co., Ltd.), and a film was formed under the same conditions for 30 minutes. . Thereafter, the die was disassembled to remove the low-density polyethylene, the amount of koge adhering to the surface of the dice channel was measured, and the kogation inhibitory property was evaluated according to the following evaluation criteria. “Good (A)”: less than 0.01 g “Slightly good (B)”: 0.01 g or more and less than 1.0 g “Poor (C)”: 1.0 g or more
- the EVOH resin composition of the example and the multilayer sheet formed from this EVOH resin composition are excellent in the suppression of kogation generation and retort resistance in the molding machine during long-time operation.
- the EVOH resin composition of Comparative Example having a molecular weight correlation outside the specified range and the multilayer sheet formed from this EVOH resin composition are inferior in the suppression of kogation generation or retort resistance in the molding machine.
- Example 22 [Preparation of EVOH Resin Composition of Example 22]
- the EVOH resin composition of Example 22 shown in Table 8 was prepared in the same manner as in Example 1.
- Example 23 ⁇ Preparation of resin composition containing EVOH (F)>
- the EVOH resin composition of Example 1 and the EVOH (F) synthesized in Synthesis Example 6 were dry blended at a mass ratio (EVOH (A) / EVOH (F)) of 80/20, and then a twin-screw extruder (Inc. Extrusion pelletization was performed in a nitrogen atmosphere using “2D25W” manufactured by Toyo Seiki Seisakusho, 25 mm ⁇ , die temperature 220 ° C., screw rotation speed 100 rpm, and the resin composition pellets of Example 22 were obtained.
- Examples 24 to 27 and Comparative Example 6 The mass ratio (EVOH (A) / EVOH (F)) shown in Table 9 shows the EVOH resin compositions of Examples 2 to 4, Example 22 and Comparative Example 1 and EVOH (F) synthesized in Synthesis Examples 6 to 8.
- the resin composition pellets (dried EVOH pellets) of Examples 24 to 27 and Comparative Example 6 were obtained in the same manner as in Example 23 except that the mixture was mixed in the above.
- a single layer film was produced by continuous operation under the above conditions, and the appearance of each film produced 8 hours after the start of operation was visually evaluated.
- the flow mark suppression is “A (good)” when no flow mark is observed, and “B (somewhat good)” when the flow mark is small or occurrence frequency is small, and the flow mark is large and occurrence frequency is high.
- the case was evaluated as “C (defect)”.
- films formed using the resin compositions of the examples are excellent in flow mark suppression, color suppression, and heat stretchability.
- the resin composition of the comparative example in which the molecular weight correlation in EVOH (A) is outside the specified range it was found that the flow mark inhibitory property, the coloring inhibitory property, and the heat stretchability were inferior.
- Example 28 [Preparation of base film] To 100 parts by mass of the EVOH resin composition pellets of Example 1, synthetic silica (“Silicia 310P” manufactured by Fuji Silysia Chemical Co., Ltd .; average particle diameter of 2.7 ⁇ m measured by the laser method) is set to 0.03 parts by mass. Dry blending is performed using a tumbler, melted at 240 ° C., extruded from a die onto a casting roll, and simultaneously blown with air at a wind speed of 30 m / second using an air knife, and an unstretched film having a thickness of 170 ⁇ m Got. This film was brought into contact with warm water at 80 ° C.
- synthetic silica Siliconicia 310P” manufactured by Fuji Silysia Chemical Co., Ltd .; average particle diameter of 2.7 ⁇ m measured by the laser method
- a biaxially stretched film (base film) having a total width of 3.6 m was obtained by heat treatment for 5 seconds. While rolling this base film, a width of 80 cm was slit centered on the central position in the entire width of the film to obtain a roll having a length of 4,000 m. Furthermore, a base film was continuously formed, and a total of 100 rolls having a length of 4,000 m were collected. The obtained base film had a volatile content of 0.15% by mass. Moreover, there was no odor at the time of preparation of a base film. This base film was packed with an aluminum foil laminate film to prevent moisture absorption.
- the biaxially stretched film has a surface temperature of 38 ° C., and the biaxially stretched film has a running speed of 200 m / min.
- the vapor deposition film was obtained by vapor-depositing aluminum on one side of the stretched film.
- the thickness of aluminum in the metal vapor deposition layer was 70 nm.
- the evaluation of the vapor deposition defect of the obtained vapor deposition film and the adhesion strength of the metal vapor deposition layer were both good.
- the volatile content from the deposited film was the same in all rolls and was good.
- Example 29 to 32 and Comparative Example 7 Using the EVOH resin composition pellets shown in Table 10, a biaxially stretched film (base film) was produced in the same manner as in Example 28, and a metal vapor deposition layer was formed to obtain a vapor deposition film. In Example 32, after aluminum was deposited on one side of the biaxially stretched film, aluminum was also deposited on the other side of the biaxially stretched film.
- the deposited films of Examples 28 to 32 and Comparative Example 7 were operated in the same manner as in the evaluation of the EVOH resin compositions of Examples 7 to 10 and Comparative Example 3 described above, and the thickness of the metal deposited layer, the number of deposition defects (deposition defects) Inhibition) and adhesion strength were measured and evaluated. The results are shown in Table 10.
- the vapor deposition film provided with this base film can suppress vapor deposition omission that occurs during vapor deposition. Excellent adhesion strength.
- Example 33 A PET film (“E5000” manufactured by Toyobo Co., Ltd .: average thickness of 12 ⁇ m) was laminated on one side of the vapor-deposited film of Example 31, and an unstretched polypropylene film (CPP film) (“Mitsui Chemical Tosero” “ RXC-21 ”: average thickness 50 ⁇ m) was laminated to obtain a laminated film. About this laminated film, the oxygen permeability was measured. The results are shown in Table 11.
- the oxygen permeability was measured in accordance with JIS-K7126 (isobaric method) (2006) using a sample obtained by cutting a part of the laminated film, and an oxygen permeability measuring device ("MOCON OX-TRAN 2/20" manufactured by Modern Control Co., Ltd.). : Detection limit value 0.01 mL / m 2 ⁇ day ⁇ atm).
- the measurement conditions were a temperature of 40 ° C., a humidity on the oxygen supply side of 90% RH, a humidity on the carrier gas side of 0% RH, an oxygen pressure of 1 atm, and a carrier gas pressure of 1 atm.
- the surface of the metal vapor-deposited layer is the oxygen supply side and the base material.
- the exposed surface side of the film was the carrier gas side.
- Example 34 to 36 and Comparative Example 8 A laminated film was prepared in the same manner as in Example 33 except that the layer configuration was as shown in Table 11, and the oxygen permeability was measured. The results are shown in Table 11.
- “VM-PET 1510” average thickness: 12 ⁇ m) manufactured by Toray Film Processing Co., Ltd. was used.
- Example 36 the vapor deposition film obtained in Example 32 was used in place of the vapor deposition film of Example 31 in Example 33.
- Comparative Example 8 the vapor deposition film obtained in Comparative Example 7 was used in place of the vapor deposition film of Example 31 in Example 33.
- the laminated films of Examples 33 to 36 had lower oxygen permeability and superior gas barrier properties than the laminated film of Comparative Example 8.
- thermoformed container Next, examples of the thermoformed container will be described.
- thermoformed container ⁇ Production of thermoformed container> [Examples 37 to 40 and Comparative Example 9] Thermoformed containers were produced using the EVOH resin compositions of Examples 1 to 4 and Comparative Example 1 by the method described later.
- the extruder equipped with the screw is set to a temperature of 170 ° C. to 240 ° C.
- the carboxylic acid-modified polyolefin is set to a diameter of 40 mm
- thermoformed containers About the thermoformed container shape
- thermoformed container formed from a multilayer sheet 20 minutes, 40 minutes, and 10 hours after the start of the coextrusion molding apparatus, and the opening was a film having a three-layer structure (polyethylene 40 ⁇ m / Aluminum foil 12 ⁇ m / polyethylene terephthalate 12 ⁇ m) was heat sealed and covered.
- This thermoformed container was cooled at ⁇ 40 ° C. for 3 days, 10 thermoformed containers were dropped from a height of 6 m so that the opening was on top, and the number of broken thermoformed containers was evaluated.
- the impact resistance 20 minutes after the start of the coextrusion molding apparatus is an indicator of self-purge properties.
- thermoformed containers of Examples 37 to 40 were less streaky and colored than the thermoformed container of Comparative Example 9, and were excellent in appearance. Further, the thermoformed containers of Examples 37 to 40 were excellent in impact resistance even if they were formed 20 minutes after the start-up of the coextrusion molding apparatus.
- the thermoformed containers of Examples 37 to 40 are gel-like bushings that reduce the impact resistance in a short time from the start of the coextrusion molding apparatus by using an EVOH-containing resin composition having excellent self-purge properties. It was found that the occurrence of the above was suppressed.
- Blow molded containers were produced using the EVOH resin compositions of Examples 1 to 4 and Comparative Example 1 and the recovered resin prepared from this EVOH resin composition.
- this extruded pellet was further extruded into pellets using the same extruder and conditions, and the same operation was performed 4 times (total of 5 blends in the extruder) to obtain a recovered resin. It was.
- the blow-molded container of the example was excellent in appearance and the like, with streak generation and coloring suppressed. Further, the blow molded containers of the examples were excellent in impact resistance even if they were molded 20 minutes after restarting the molding apparatus. For this reason, the blow-molded container of the example uses an EVOH-containing resin composition having excellent self-purge properties, so that the occurrence of gelled blisters that reduce impact resistance occurs in a short time after re-startup. I found out.
- the ethylene-vinyl alcohol copolymer and resin composition of the present invention are excellent in the long run property of melt molding and can suppress the occurrence of film formation defects such as streaks and film formation defects and coloring. Therefore, the ethylene-vinyl alcohol copolymer and the resin composition can provide a molded article such as a multilayer structure having excellent appearance.
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Abstract
Description
(Ma-Mb)/Ma<0.45 ・・・(1)
Ma:示差屈折率検出器で測定されるピークの最大値におけるポリメタクリル酸メチル換算の分子量
Mb:紫外可視吸光度検出器で測定される波長220nmでの吸収ピークの最大値におけるポリメタクリル酸メチル換算の分子量
(Ma-Mc)/Ma<0.45 ・・・(2)
Ma:示差屈折率検出器で測定されるピークの最大値におけるポリメタクリル酸メチル換算の分子量
Mc:紫外可視吸光度検出器で測定される波長280nmでの吸収ピークの最大値におけるポリメタクリル酸メチル換算の分子量
本発明のエチレン-ビニルアルコール共重合体(A)(以下、「EVOH(A)」ともいう)は、エチレンとビニルエステルとの共重合体をけん化したものである。
EVOH(A)のビニルエステルに由来する構造単位のけん化度の下限としては、通常85モル%であり、90モル%が好ましく、98モル%がより好ましく、98.9モル%がさらに好ましい。このけん化度が上記下限未満であると、熱安定性が不十分となるおそれがある。
ピークトップ分子量(Ma)は、窒素雰囲気下、220℃で50時間熱処理した後のEVOH(A)をゲルパーミションクロマトグラフィー(以下、「GPC」ともいう)を用いて分離し、このときにカラムから溶出されるEVOH(A)の図1に模式的に示すように示差屈折率検出器において測定されるシグナル(図1中の「RI」)のメインピークの最大値に対応する値である。本発明におけるピークトップ分子量(Ma)は、後述の方法により作成される検量線を用いて算出されるポリメタクリル酸メチル換算(以下、「PMMA換算」ともいう)の値である。
吸収ピーク分子量(Mb)及び(Mc)は、図1に模式的に示すようにピークトップ分子量(Ma)の測定と同じ条件でGPCによりEVOH(A)を分離し、紫外可視吸光度検出器において測定される特定波長でのシグナル(図1中の「UV」)の吸収ピークの最大値に相当する値である。この吸収ピーク分子量(Mb)及び(Mc)は、ポリメタクリル酸メチル換算の分子量である。なお、波長220nmにおける吸収ピークの分子量は、「Mb」として表記し、波長280nmにおける吸収ピークの分子量は「Mc」として表記する。
検量線は、例えば標品としてAgilent Technologies社の単分散のPMMA(ピークトップ分子量:1,944,000、790,000、467,400、271,400、144,000、79,250、35,300、13,300、7,100、1,960、1,020、690)を測定し、示差屈折率検出器及び吸光度検出器のそれぞれについて作成する。検量線の作成には、解析ソフトを用いることが好ましい。なお、本測定のPMMAの測定においては、例えば1,944,000と271,400との両分子量の標準試料同士のピークが分離できるカラムを用いる。
EVOH(A)は、下記式(1)で表される条件を満たすものである。
式(1)で表される条件を満たすEVOH(A)を調製する方法としては、従来のEVOHの調製において、
(A)原料であるエチレンとビニルエステルとの共重合体の調製において、ビニルエステルに含まれるラジカル重合禁止剤を予め除去する方法、
(B)原料であるエチレンとビニルエステルとの共重合体の調製において、ラジカル重合に用いるビニルエステルに含まれる不純物を特定量とする方法、
(C)原料であるエチレンとビニルエステルとの共重合体の調製において、重合温度を特定範囲とする方法、
(D)原料であるエチレンとビニルエステルとの共重合体の調製において、重合工程、又は上記重合工程後に未反応のビニルエステルを回収再利用する工程において有機酸を添加する方法、
(E)原料であるエチレンとビニルエステルとの共重合体の調製において、重合に用いる溶媒の不純物を特定量とする方法、
(F)原料であるエチレンとビニルエステルとの共重合体の調製において、重合に用いる溶媒とビニルエステルとの質量比(溶媒/ビニルエステル)を高める方法、
(G)エチレンとビニルエステルモノマーとをラジカル重合する際に使用するラジカル重合開始剤として、アゾニトリル系開始剤又は有機過酸化物系開始剤を用いる方法、
(H)原料であるエチレンとビニルエステルとの共重合体の調製において、ラジカル重合後にラジカル重合禁止剤を添加する場合の添加量を残存する未分解のラジカル重合開始剤に対して特定量とする方法、
(I)残存するビニルエステルが極力除去されたエチレンとビニルエステルとの共重合体のアルコール溶液をけん化反応に用いる方法、
(J)けん化に用いるエチレンとビニルエステルとの共重合体に酸化防止剤を添加する方法等
が挙げられ、(A)~(J)を適宜組み合わせてもよい。また、(A)~(J)により、式(2)で表される条件を満たすEVOH(A)を調製することもできる。(A)~(J)の方法について以下で説明する。
上記ラジカル重合禁止剤としては、後述する(H)でラジカル重合後に添加するラジカル重合禁止剤として例示するものと同様のもの等が挙げられる。また、ラジカル重合禁止剤を除去する方法としては、カラムクロマトグラフィーを用いる方法、再沈法、蒸留法等が挙げられ、通常蒸留法が採用される。蒸留法によりラジカル重合禁止剤を除去する場合、ビニルエステルの沸点はラジカル重合禁止剤の沸点よりも低いため、蒸留塔頂部から重合禁止剤が除去されたビニルエステルを得ることができる。
ラジカル重合に用いるビニルエステルに含まれる不純物の合計含有量の下限としては、1ppmが好ましく、3ppmがより好ましく、5ppmがさらに好ましい。また、上記不純物の合計含有量の上限としては、1,200ppmが好ましく、1,100ppmがより好ましく、1,000ppmがさらに好ましい。
エチレンとビニルエステルとの共重合体の重合温度の下限としては、20℃が好ましく、40℃がより好ましい。一方、上記重合温度の上限としては、90℃が好ましく、70℃がより好ましい。
本方法は、重合系への有機酸の添加により、ビニルエステルのアルコールによる加アルコール分解や微量の水分による加水分解を抑制することで、アセトアルデヒド等のアルデヒドの生成を抑制できる。上記有機酸としては、グリコール酸、グリセリン酸、リンゴ酸、クエン酸、乳酸、酒石酸、サリチル酸等のヒドロキシカルボン酸;マロン酸、コハク酸、マレイン酸、フタル酸、シュウ酸、グルタル酸等の多価カルボン酸などが挙げられる。
重合に用いる溶媒の不純物の合計含有量の下限としては、1ppmが好ましく、3ppmがより好ましく、5ppmがさらに好ましい。上記不純物の合計含有量の上限としては、1,200ppmが好ましく、1,100ppmがより好ましく、1,000ppmがさらに好ましい。重合に用いる溶媒の不純物としては、例えば上述のビニルエステルに含まれる不純物として例示したもの等が挙げられる。
上記重合に用いる溶媒とビニルエステルとの質量比(溶媒/ビニルエステル)の下限としては、0.03が好ましい。一方、上記質量比(溶媒/ビニルエステル)の上限としては、例えば0.4である。
アゾニトリル系開始剤としては、例えば2,2-アゾビスイソブチロニトリル、2,2-アゾビス-(2,4-ジメチルバレロニトリル)、2,2-アゾビス-(4-メトキシ-2,4-ジメチルバレロニトリル)、2,2-アゾビス-(2-シクロプロピルプロピオニトリル)等が挙げられる。有機過酸化物としては、例えばアセチルパーオキシド、イソブチルパーオキシド、ジイソプロピルパーオキシカーボネート、ジアリルパーオキシジカーボネート、ジ-n-プロピルパーオキシジカーボネート、ジミリスチルパーオキシジカーボネート、ジ(2-エトキシエチル)パーオキシジカーボネート、ジ(2-エチルヘキシル)パーオキシジカーボネート、ジ(メトキシイソプロピル)パーオキシジカーボネート、ジ(4-tert-ブチルシクロヘキシル)パーオキシジカーボネート等が挙げられる。
ラジカル重合後にラジカル重合禁止剤を添加する場合の添加量としては、残存する未分解のラジカル重合開始剤に対して、5モル当量以下が好ましい。上記ラジカル重合禁止剤としては、例えば共役二重結合を有する分子量1,000以下の化合物であって、ラジカルを安定化させて重合反応を阻害する化合物等が挙げられる。具体的な上記ラジカル重合禁止剤としては、イソプレン、2,3-ジメチル-1,3-ブタジエン、2,3-ジエチル-1,3-ブタジエン、2-t-ブチル-1,3-ブタジエン、1,3-ペンタジエン、2,3-ジメチル-1,3-ペンタジエン、2,4-ジメチル-1,3-ペンタジエン、3,4-ジメチル-1,3-ペンタジエン、3-エチル-1,3-ペンタジエン、2-メチル-1,3-ペンタジエン、3-メチル-1,3-ペンタジエン、4-メチル-1,3-ペンタジエン、1,3-ヘキサジエン、2,4-ヘキサジエン、2,5-ジメチル-2,4-ヘキサジエン、1,3-オクタジエン、1,3-シクロペンタジエン、1,3-シクロヘキサジエン、1-メトキシ-1,3-ブタジエン、2-メトキシ-1,3-ブタジエン、1-エトキシ-1,3-ブタジエン、2-エトキシ-1,3-ブタジエン、2-ニトロ-1,3-ブタジエン、クロロプレン、1-クロロ-1,3-ブタジエン、1-ブロモ-1,3-ブタジエン、2-ブロモ-1,3-ブタジエン、フルベン、トロポン、オシメン、フェランドレン、ミルセン、ファルネセン、センブレン、ソルビン酸、ソルビン酸エステル、ソルビン酸塩、アビエチン酸等の2個の炭素-炭素二重結合の共役構造を含む共役ジエン;1,3,5-ヘキサトリエン、2,4,6-オクタトリエン-1-カルボン酸、エレオステアリン酸、桐油、コレカルシフェロール等の3個の炭素-炭素二重結合を含む共役構造を含む共役トリエン;シクロオクタテトラエン、2,4,6,8-デカテトラエン-1-カルボン酸、レチノール、レチノイン酸等の4個以上の炭素-炭素二重結合の共役構造を含む共役ポリエンなどのポリエンが挙げられる。なお、1,3-ペンタジエン、ミルセン、ファルネセン等のように、複数の立体異性体を有するものについては、そのいずれを用いても良い。上記ラジカル重合禁止剤としては、p-ベンゾキノン、ヒドロキノン、ヒドロキノンモノメチルエーテル、2-フェニル-1-プロペン、2-フェニル-1-ブテン、2,4-ジフェニル-4-メチル-1-ペンテン、3,5-ジフェニル-5-メチル-2-ヘプテン、2,4,6-トリフェニル-4,6-ジメチル-1-ヘプテン、3,5,7-トリフェニル-5-エチル-7-メチル-2-ノネン、1,3-ジフェニル-1-ブテン、2,4-ジフェニル-4-メチル-2-ペンテン、3,5-ジフェニル-5-メチル-3-ヘプテン、1,3,5-トリフェニル-1-ヘキセン、2,4,6-トリフェニル-4,6-ジメチル-2-ヘプテン、3,5,7-トリフェニル-5-エチル-7-メチル-3-ノネン、1-フェニル-1,3-ブタジエン、1,4-ジフェニル-1,3-ブタジエン等の芳香族系化合物も挙げられる。
残存モノマーの除去率の下限としては、99モル%が好ましく、99.5モル%がより好ましく、99.8モル%がさらに好ましい。残存モノマーを除去する方法としては、例えばカラムクロマトグラフィーを用いる方法、再沈法、蒸留法等が挙げられ、蒸留法が好ましい。蒸留法で残存モノマーを除去する場合、ラシヒリングを充填した蒸留塔の上部からエチレンとビニルエステルとの共重合体溶液を一定速度で連続的に供給し、蒸留塔下部よりメタノール等の有機溶媒蒸気を吹き込む。これにより、蒸留塔頂部より上記有機溶媒と未反応ビニルエステルとの混合蒸気を留出させることができ、蒸留塔底部より未反応のビニルエステルが除去されたエチレンとビニルエステルとの共重合体溶液を取り出すことができる。ここで、「残存モノマーの除去率」とは、エチレンとビニルエステルとの共重合体のアルコール溶液について除去処理前後のモノマー含有量を測定し、以下の式で算出される値である。
残存モノマーの除去率(モル%)={1-(除去後の残存モノマー含有量/除去前の残存モノマー含有量)}×100
上記酸化防止剤としては、特に限定されないが、例えばフェノール系酸化防止剤、リン系酸化防止剤、硫黄系酸化防止剤等が挙げられる。上記酸化防止剤としては、これらの中でフェノール系酸化防止剤が好ましく、アルキル置換フェノール系酸化防止剤がより好ましい。
EVOH(A)のメルトフローレートの下限としては、0.5g/10minが好ましく、1.0g/10minがより好ましく、1.4g/10minがさらに好ましい。一方、EVOH(A)のメルトフローレートの上限としては、30g/10minが好ましく、25g/10minがより好ましく、20g/10minがさらに好ましく、15g/10minが特に好ましく、10g/10minがさらに特に好ましく、1.6g/10minが最も好ましい。EVOH(A)のメルトフローレートが上記下限未満である場合、又は上記上限を超える場合、成形性及び外観性が悪化するおそれがある。なお、メルトフローレートは、JIS-K7210(1999)に準拠し、温度190℃、荷重2,160gで測定した値である。
本発明の樹脂組成物は、EVOH(A)を含有する。当該樹脂組成物は、EVOH(A)以外に有機酸のアルカリ金属塩(B1)を含有するとよい。また、当該樹脂組成物は、多価金属塩(B2)、無機粒子(C)、ポリオレフィン(D)、ポリアミド(E)、EVOH(F)又はこれらの組み合わせをさらに含有するとよい。さらに、当該樹脂組成物は、他の任意成分を含有してもよい。
当該樹脂組成物は、有機酸のアルカリ金属塩(B1)を含有することで、着色を抑制することができ、その結果、外観性をより高めることができる。また、ロングラン性及び多層構造体とした際の層間接着力を向上させることができる。
当該樹脂組成物は、多価金属塩(B2)を特定量含有することで、長時間運転時のゲルやブツの発生を抑制することができ、その結果、長時間運転時のコゲ発生の抑制性を向上させることができる。特に、当該樹脂組成物が後述するポリアミド(E)を含有する場合、多価金属塩(B2)、特に好ましくはカルボン酸塩を含有することで、長時間運転時のゲルやブツの発生をより効果的に抑制することができ、その結果、長時間運転時のコゲ発生の抑制性及び耐レトルト性をより向上させることができる。
無機粒子(C)は、当該樹脂組成物から形成されるフィルムの表面の算術平均粗さ(Ra)を適度なものとし、耐ブロッキング性及び滑り性を向上させるものである。ここで、無機粒子(C)とは、無機物を主成分とする粒子をいう。主成分とは、最も含有量が多い成分をいい、例えば含有量が50質量%以上の成分をいう。
ポリオレフィン(D)は、例えばポリエチレン(低密度、直鎖状低密度、中密度、高密度等);エチレンと、1-ブテン、1-ヘキセン、4-メチル-1-ペンテンなどのα-オレフィン類又はアクリル酸エステルとを共重合したエチレン系共重合体;ポリプロピレン;プロピレンと、エチレン、1-ブテン、1-ヘキセン、4-メチル-1-ペンテンなどのα-オレフィン類とを共重合したプロピレン系共重合体;ポリ(1-ブテン)、ポリ(4-メチル-1-ペンテン)、上述のポリエチレン、エチレン系共重合体、ポリプロピレン、プロピレン系共重合体、ポリ(1-ブテン)又はポリ(4-メチル-1-ペンテン)に無水マレイン酸を作用させた酸変性ポリオレフィン;アイオノマー樹脂などを含んでいる。ポリオレフィン(D)としては、これらの中で、ポリプロピレン、プロピレン系共重合体等のポリプロピレン系樹脂、及びポリエチレン、エチレン系共重合体等のポリエチレン系樹脂が好ましい。特に、当該樹脂組成物からなる層を有する多層構造体を食品包装材として用いる場合には、二次加工性に優れる観点から、ポリエチレン系樹脂が好ましく用いられる。また、ポリオレフィン(D)としては、後述する酸変性ポリオレフィンも好ましい。
ポリアミド(E)は、アミド結合を含む樹脂である。ポリアミド(E)は、3員環以上のラクタムの開環重合、重合可能なω-アミノ酸の重縮合、二塩基酸とジアミンとの重縮合等によって得られる。ポリアミド(E)としては、例えばポリカプラミド(ナイロン6)、ポリ-ω-アミノヘプタン酸(ナイロン7)、ポリ-ω-アミノノナン酸(ナイロン9)、ポリウンデカンアミド(ナイロン11)、ポリラウリルラクタム(ナイロン12)、ポリエチレンジアミンアジパミド(ナイロン26)、ポリテトラメチレンアジパミド(ナイロン46)、ポリヘキサメチレンアジパミド(ナイロン66)、ポリヘキサメチレンセバカミド(ナイロン610)、ポリヘキサメチレンドデカミド(ナイロン612)、ポリオクタメチレンアジパミド(ナイロン86)、ポリデカメチレンアジパミド(ナイロン108)、カプロラクタム/ラウリルラクタム共重合体(ナイロン6/12)、カプロラクタム/ω-アミノノナン酸共重合体(ナイロン6/9)、カプロラクタム/ヘキサメチレンジアンモニウムアジペート共重合体(ナイロン6/66)、ラウリルラクタム/ヘキサメチレンジアンモニウムアジペート共重合体(ナイロン12/66)、ヘキサメチレンジアンモニウムアジペート/ヘキサメチレンジアンモニウムセバケート共重合体(ナイロン66/610)、エチレンジアンモニウムアジペート/ヘキサメチレンジアンモニウムアジペート共重合体(ナイロン26/66)、カプロラクタム/ヘキサメチレンジアンモニウムアジペート/ヘキサメチレンジアンモニウムセバケート共重合体(ナイロン6/66/610)、ポリヘキサメチレンイソフタルアミド(ナイロン6I)、ポリヘキサメチレンテレフタルアミド(ナイロン6T)、ヘキサメチレンイソフタルアミド/テレフタルアミド共重合体(ナイロン6I/6T)等が挙げられる。
EVOH(F)は、EVOH(A)とはエチレン含有量の異なるエチレン-ビニルアルコール共重合体である。EVOH(F)は、EVOH(A)と同様に、エチレンとビニルエステルとの共重合体をけん化して得られる。当該樹脂組成物がEVOH(F)を含有する場合、EVOH(A)のエチレン含有量としては通常10モル%以上50モル%以下である。
他の任意成分としては、例えば酸化防止剤、紫外線吸収剤、可塑剤、帯電防止剤、滑剤、着色剤、充填剤、ヒンダードフェノール系化合物やヒンダードアミン系化合物などの熱安定剤、ポリアミドやポリオレフィン等の他の樹脂、ハイドロタルサイト化合物などが挙げられる。当該樹脂組成物の他の任意成分の合計含有量としては、通常1質量%以下である。
当該樹脂組成物のメルトフローレートの下限としては、0.5g/10minが好ましく、1.0g/10minがより好ましく、1.4g/10minがさらに好ましい。一方、当該樹脂組成物のメルトフローレートの上限としては、30g/10minが好ましく、25g/10minがより好ましく、20g/10minがさらに好ましく、15g/10minが特に好ましく、10g/10minがさらに特に好ましく、1.6g/10minが最も好ましい。当該樹脂組成物のメルトフローレートが上記下限未満である場合、又は上記上限を超える場合、成形性及び外観性が悪化するおそれがある。
当該樹脂組成物の製造方法としては、例えばEVOH(A)のペレットと共に、必要に応じてアルカリ金属塩(B1)や他の任意成分等を混合して溶融混練する方法、EVOH(A)のペレットを各成分が含まれる溶液に浸漬させる方法などが挙げられる。なお、ペレットと他の成分との混合には、例えばリボンブレンダー、高速ミキサーコニーダー、ミキシングロール、押出機、インテンシブミキサー等を用いることができる。また、ドライブレンドにより表面にアルカリ金属塩(B1)や他の成分を付着させたEVOH(A)のペレットを用いて溶融成形することにより、当該樹脂組成物を得ることもできる。
無機粒子(C)を含有する当該樹脂組成物の製造方法としては、以下の方法を好適に用いることができる。すなわち、無機粒子(C)を当該樹脂組成物中に均一にブレンドさせる方法としては、エチレン-ビニルアルコール共重合体を製造する方法における、エチレンとビニルエステルとを共重合させる(1)工程、及び工程(1)により得られた共重合体をけん化する(2)工程において、例えば
上記工程(1)において無機粒子(C)等を添加する方法、
上記工程(2)において無機粒子(C)等を添加する方法、
上記工程(2)により得られたEVOHに無機粒子(C)等を添加する方法、
上記工程(2)により得られたEVOHを溶融成形する際に無機粒子(C)等を添加する方法、
これらの方法を併用する方法などが挙げられる。
ポリオレフィン(D)を含有する当該樹脂組成物の製造方法としては、樹脂を溶融ブレンドする際に用いられる単軸又は二軸スクリュー押出機を好適に用いることができる。添加順序としては、特に限定されず、EVOH(A)を含有する樹脂成分、ポリオレフィン(D)及び脂肪酸金属塩などのその他の任意成分を同時に又は適当な順序で押出機へ投入し溶融混練させる方法が好適に採用される。また、任意成分を溶融混練時に添加してもよい。
当該樹脂組成物は、溶融成形等により、フィルム、シート、容器、パイプ、ホース、繊維等の各種の成形体に成形される。ここで、フィルムとは、通常300μm程度未満の平均厚みを有するものをいい、シートとは、通常300μm程度以上の平均厚みを有するものをいう。溶融成形の方法としては、例えば押出成形、キャスト成形、インフレーション押出成形、ブロー成形、溶融紡糸、射出成形、射出ブロー成形等が挙げられる。溶融成形温度としては、EVOH(A)の融点等により異なるが、150℃以上270℃以下程度が好ましい。当該成形体は、上述の当該樹脂組成物から形成されるので、外観性に優れる。これらの当該成形体は再使用の目的で粉砕し再度成形することも可能である。また、フィルム、シート、繊維等を一軸又は二軸延伸することも可能である。上記溶融成形等により得られた当該成形体は、必要に応じて、曲げ加工、真空成形、ブロー成形、プレス成形等の二次加工成形を行って、目的とする成形体にしてもよい。
当該フィルムは、当該樹脂組成物からなり、単層フィルム及び多層フィルムを含む。当該フィルムは、当該樹脂組成物からなるため、外観性に優れ、また当該樹脂組成物が無機粒子(C)を含有する場合、耐フィルム破断性にも優れる。さらに、当該樹脂組成物がポリアミド(E)を含有する場合、当該フィルムを備える成形体は、ボイル殺菌用又はレトルト殺菌用に好適に用いることができる。
当該フィルムの製造方法としては、例えば当該樹脂組成物をキャスティングロール上に溶融押出するキャスト成形工程、このキャスト成形工程で当該樹脂組成物から得られる無延伸フィルムを延伸する工程(一軸延伸工程、逐次二軸工程、同時二軸延伸工程、インフレーション成形工程等)を有する方法などが挙げられる。当該樹脂組成物が無機粒子(C)を含有する場合、当該フィルムを上述の方法により製造することで、耐フィルム破断性をより向上できる。
当該多層構造体は、当該樹脂組成物からなる第1層(以下、「当該樹脂組成物層」ともいう)を有する。つまり、当該多層構造体は、第1層と、この第1層の少なくとも一方の面に積層される他の層とを備える。当該多層構造体は、例えばフィルム、シート、テープ、カップ、トレイ、チューブ、ボトル、パイプ等の任意の成形品に成形できる。
高密度、中密度又は低密度のポリエチレン;
酢酸ビニル、アクリル酸エステル、又はブテン、ヘキセン等のα-オレフィン類を共重合したポリエチレン;
アイオノマー樹脂;
ポリプロピレンホモポリマー;
エチレン、ブテン、ヘキセン等のα-オレフィン(特に炭素数4~20のα-オレフィン)類を共重合したポリプロピレン;
ポリブテン、ポリペンテン等のオレフィンの単独又はその共重合体;
ゴム系ポリマーをブレンドした変性ポリプロピレン等のポリオレフィン類;
これらの樹脂に無水マレイン酸を付加又はグラフトした樹脂;
ポリエチレンテレフタレート等のポリエステル;ポリエステルエラストマー;ナイロン-6、ナイロン-66等のポリアミド;ポリスチレン、ポリ塩化ビニル、アクリル系樹脂、ビニルエステル系樹脂、ポリウレタン、ポリウレタンエラストマー、ポリカーボネート、ポリ酢酸ビニル、塩素化ポリエチレン、塩素化ポリプロピレンなどを用いることができる。熱可塑性樹脂層を形成する樹脂としては、これらの中で、ポリエチレン、ポリプロピレン、エチレン-プロピレン共重合体、エチレン-酢酸ビニル共重合体、ポリスチレン、ポリアミド及びポリエステルが好ましい。また、熱可塑性樹脂層を樹脂フィルムにより形成する場合、この樹脂フィルムとしては無延伸ポリプロピレンフィルム及びナイロン6フィルムが好ましい。
当該多層構造体の各層間は接着性樹脂を介して積層されていてもよい。上記接着性樹脂層の形成に使用される接着性樹脂としては、上述の酸変性ポリオレフィンが好ましく、カルボン酸変性ポリオレフィンがより好ましい。
当該多層構造体の製造方法としては、特に限定されるものではないが、例えば押出ラミネート法、ドライラミネート法、押出ブロー成形法、共押出ラミネート法、共押出シート成形法、共押出パイプ成形法、共押出ブロー成形法、共射出成形法、溶液コート法等が挙げられる。また、当該樹脂組成物から得られる成形体(フィルム、シート等)に熱可塑性樹脂、接着性樹脂等を溶融押出してもよい。さらに、当該フィルム又はこの当該フィルムを含む多層構造体と他の基材のフィルム、シート等とを有機チタン化合物、イソシアネート化合物、ポリエステル系化合物等の公知の接着剤を用いてラミネートしてもよい。当該多層構造体の製造方法としては、これらの中で、共押出ラミネート法及び共押出成形法が好ましく、共押出成形法がより好ましい。当該樹脂組成物層と熱可塑性樹脂層とが上記方法により積層されることで、容易かつ確実に製造することができ、その結果、当該多層構造体は、外観性及び加熱延伸性により優れる。また、当該樹脂組成物がポリアミド(E)を含有する場合、耐レトルト性を効果的に達成できる。なお、このような方法で得られた多層構成の積層体に対して、さらに真空圧空深絞り成形、ブロー成形等の方法により、EVOH(A)の融点以下の範囲で再加熱後、二次加工を施してもよい。
X-110≦Y≦X-10 ・・・(4)
当該多層構造体を備える包装材料について説明する。上記包装材料は、当該多層構造体を備えることで、ガスバリア性に優れ、変形や衝撃などの物理的ストレスを受けた際にもそのガスバリア性が維持される。
本発明の蒸着フィルムは、当該樹脂組成物からなるフィルム(以下、「基材フィルム」ともいう)と、この基材フィルムに積層される金属蒸着層とを備える。当該蒸着フィルムは、上述した層以外に、金属蒸着層に積層される樹脂コート層、及びその他の層を備えてもよい。
基材フィルムは、当該樹脂組成物からなる。基材フィルムの製造方法としては、当該フィルムの製造方法と同様の方法などが挙げられる。
上記基材フィルム形成方法としては、特に限定されず、例えば溶融法、溶液法、カレンダー法等が挙げられ、これらの中で溶融法が好ましい。溶融法としては、キャスト法、インフレーション法が挙げられ、これらの中でキャスト法が好ましい。
金属蒸着層は、当該蒸着フィルムにおいて主としてガスバリア性を確保するものである。この金属蒸着層は、基材フィルム上に積層されている。金属蒸着層は、基材フィルムの両面に積層されていても、基材フィルム片面のみに積層されていてもよいが、基材フィルムの両面に積層されていることが好ましい。金属蒸着層を基材フィルムの両面に積層することで、ガスバリア性をより向上させ、ガスバリアの安定性が得られる。すなわち、一方の金属蒸着層に物理的衝撃等により欠陥が生じても、他方の金属蒸着層がバリア性を維持することにより、蒸着フィルムとしてのガスバリア性が好適に維持される。
(2)蒸着前の基材フィルムに含まれる揮発分の含有量を1.1質量%以下にする
(3)蒸着前の基材フィルムの表面をプラズマ処理し改質する
樹脂コート層は、蒸着フィルム製造後の工程、例えばラミネーション等のフィルム加工における屈曲等による金属蒸着層の損傷を抑制するものである。このような樹脂コート層を備える蒸着フィルムはガスバリア性の低下を抑制できる。樹脂コート層は、例えばビニルアルコール系重合体(エチレン-ビニルアルコール共重合体、ポリビニルアルコールなど)を含んでいてもよく、必要に応じて膨潤性無機層状ケイ酸塩を含んでいてもよい。
その他の層としては、例えば熱可塑性樹脂を主成分とする層(以下、「熱可塑性樹脂層」という)、紙層等が挙げられる。
当該蒸着フィルムは、EVOH(A)を含有する基材フィルム上に金属蒸着層を積層したものであるため、蒸着時の蒸着抜けの発生、ラミネーション等の蒸着フィルム加工時のクラックの発生を抑え、金属蒸着層の密着強度に優れる。このため、当該蒸着フィルムは、様々な用途に適用できる。当該蒸着フィルムの用途としては、例えば包装材、真空断熱体等が挙げられる。
以下、当該蒸着フィルムを備える包装材について説明する。この包装材は、例えば蒸着フィルム又はこの蒸着フィルムを備える積層フィルム等を二次加工することで形成される。上記包装材は、当該蒸着フィルムを備えることで、ガスバリア性に優れ、変形や衝撃などの物理的ストレスを受けた際にもそのガスバリア性が維持される。
縦製袋充填シール袋は、例えば液体、粘稠体、粉体、固形バラ物、これらを組み合わせた形態の食品、飲料物等を包装するために使用される。縦製袋充填シール袋は、当該蒸着フィルムをヒートシールすることで形成される。ヒートシールが行われる場合、通常当該蒸着フィルムにおける縦製袋充填シール袋の内側となる層、又は縦製袋充填シール袋の内側となる層及び外側となる層の両方として、ヒートシール可能な層を配置することが必要である。ヒートシール可能な層が縦製袋充填シール袋の内側のみにある場合、通常胴体部は合掌貼りによりシールされる。ヒートシール可能な層が縦製袋充填シール袋の内側及び外側の両方にある場合、通常胴体部は封筒貼りによりシールされる。ヒートシール可能な層としては、ポリオレフィン層(以下、「PO層」ともいう)が好ましい。縦製袋充填シール袋の層構成としては、当該蒸着フィルム/ポリアミド層/PO層、当該蒸着フィルム/PO層、PO層/当該蒸着フィルム/PO層が好ましく、層間に接着層を設けてもよい。また、基材フィルムの片面にのみ金属蒸着層が形成されている当該蒸着フィルムを適用する場合、この当該蒸着フィルムは、金属蒸着層が基材フィルムよりも外側に配置されるように積層されていても、金属蒸着層が基材フィルムより内側に配置されるように積層されていてもよい。上記包装材は、上述のようにガスバリア性に優れ、変形や衝撃などの物理的ストレスを受けた際にもそのガスバリア性が維持される。そのため、上記包装材の一例である縦製袋充填シール袋によれば、内容物の品質劣化を長期間にわたって抑制できる。
真空包装袋は、真空状態で包装することが望まれる用途、例えば食品、飲料物等の保存に使用される。真空包装袋の層構成としては、当該蒸着フィルム/ポリアミド層/PO層、ポリアミド層/当該蒸着フィルム/PO層が好ましく、層間に接着層を設けてもよい。このような真空包装袋は、当該蒸着フィルムを備えることから、真空包装後に行われる加熱殺菌後のガスバリア性に特に優れる。
スパウト付パウチは、液状物質、例えば清涼飲料等の液体飲料、ゼリー飲料、ヨーグルト、フルーツソース、調味料、機能性水、流動食などを包装するために使用される。このスパウト付パウチの層構成としては、当該蒸着フィルム/ポリアミド層/PO層、ポリアミド層/当該蒸着フィルム/PO層が好ましく、層間に接着層を設けてもよい。このようなスパウト付パウチは、当該蒸着フィルムを備えるため、ガスバリア性に優れ、変形や衝撃などの物理的ストレスを受けた際にもそのガスバリア性が維持される。そのため、スパウト付パウチは、輸送後及び長期保存後においても、内容物の変質を防ぐことが可能である。
ラミネートチューブ容器は、例えば化粧品、薬品、医薬品、食品、歯磨等を包装するために使用される。このラミネートチューブ容器の層構成としては、PO層/当該蒸着フィルム/PO層、PO層/顔料含有PO層/PO層/当該蒸着フィルム/PO層が好ましく、層間に接着層を設けてもよい。このようなラミネートチューブ容器は、当該蒸着フィルムを備えるためガスバリア性に優れ、変形や衝撃などの物理的ストレスを受けた際にもそのガスバリア性が維持される。
容器用蓋材は、畜肉加工品、野菜加工品、水産加工品、フルーツ等の食品などが充填される容器の蓋材である。この容器用蓋材の層構成としては、当該蒸着フィルム/ポリアミド層/PO層、当該蒸着フィルム/PO層が好ましく、層間に接着層を設けてもよい。このような容器用蓋材は、当該蒸着フィルムを備えるためにガスバリア性に優れ、変形や衝撃などの物理的ストレスを受けた際にもそのガスバリア性が維持されるため、内容物である食品の品質劣化を長期間にわたって抑制できる。
真空断熱体は、保冷や保温が必要な用途に使用されるものである。この真空断熱体としては、例えば外包材内にポリウレタンフォーム等の芯材が真空状態で封入されるものが挙げられる。外包材は、例えば少なくとも1層の当該蒸着フィルムと、少なくとも1層の他の層とを積層することによって形成される一対の積層フィルムをヒートシールすることで形成される。他の層としては、例えばポリエステル層、ポリアミド層、ポリオレフィン層、接着層等が挙げられ、ヒートシール可能な層であるポリオレフィン層を含むことが好ましい。外包材における層数及び積層順には特に制限はないが、最外層がヒートシール可能な層(例えばポリオレフィン層)とされることが好ましい。外包材の層構成としては、当該蒸着フィルム/ポリアミド層/PO層、ポリアミド層/当該蒸着フィルム/PO層が好ましく、層間に接着層を設けてもよい。また、基材フィルムの片面にのみ金属蒸着層が形成されている当該蒸着フィルムを適用する場合、この当該蒸着フィルムは、金属蒸着層が基材フィルムよりも外側に配置されるように積層されていても、金属蒸着層が基材フィルムより内側に配置されるように積層されていてもよい。このような真空断熱体は外包材が蒸着フィルムを備えるためにガスバリア性に優れる。従って、当該真空断熱体は、長期間にわたって断熱効果を保持できることから、冷蔵庫、給湯設備、炊飯器等の家電製品用の断熱材;壁部、天井部、屋根裏部、床部等に用いられる住宅用断熱材;車両屋根材;自動販売機等の断熱パネルなどに利用できる。
以下、当該多層構造体を備える当該熱成形容器について説明する。当該熱成形容器は、酸素バリア性が要求される用途、例えば食品、化粧品、医化学薬品、トイレタリー等の種々の分野で利用される。当該熱成形容器は、例えば当該多層構造体を熱成形することで、収容部を有するものとして形成される。
収容部は、食品等の内容物を収容する部分である。この収容部の形状は、内容物の形状に対応して決定される。具体的には、当該熱成形容器は、例えばカップ状容器、トレイ状容器、バッグ状容器、ボトル状容器、パウチ状容器等として形成される。
(1)層は、当該樹脂組成物からなるEVOH(A)を主成分とする層である。(1)層の平均厚みの下限としては、特に限定されるものではないが、バリア性及び機械強度等の観点から、全層平均厚みに対して、0.5%が好ましく、1.0%がより好ましく、1.5%がさらに好ましい。一方、(1)層の平均厚みの上限としては、全層平均厚みに対して、5.0%が好ましく、4.5%がより好ましく、4.1%がさらに好ましい。
(2)層は、(1)層の内面側及び外面側に配置され、Fedorsの式から算出する溶解性パラメータが11(cal/cm3)1/2以下である熱可塑性樹脂を主成分とする層である。この式によって算出される溶解性パラメータが11(cal/cm3)1/2以下である熱可塑性樹脂は、耐湿性に優れる。なお、Fedorsの式から算出される溶解性パラメータとは、(E/V)1/2で表される値である。上記式中、Eは分子凝集エネルギー(cal/mol)であり、E=Σeiで表される。なお、eiは蒸発エネルギーである。また、Vは分子容(cm3/mol)であり、V=Σvi(vi:モル体積)で表される。
(3)層は、(1)層と(2)層との間に配置され、カルボン酸変性ポリオレフィンを主成分とする層である。(3)層は、(1)層と(2)層等の他の層との間の接着層として機能させることができる。なお、上記カルボン酸変性ポリオレフィンとは、オレフィン系重合体にエチレン性不飽和カルボン酸又はその無水物を付加反応、グラフト反応等により化学的に結合させて得られるカルボキシ基又はその無水物基を有するオレフィン系重合体のことをいう。
低密度、中密度又は高密度ポリエチレン、直鎖状低密度ポリエチレン、ポリプロピレン、ボリブテン等のポリオレフィン;
エチレン-酢酸ビニル共重合体、エチレン-アクリル酸エチル共重合体等のオレフィンとコモノマーとの共重合体などが挙げられる。上記コモノマーとしては、オレフィンと共重合し得るモノマーであれば特に限定されず、例えばビニルエステル、不飽和カルボン酸エステル等が挙げられる。上記オレフィン系重合体としては、直鎖状低密度ポリエチレン、酢酸ビニル含有量が5質量%以上55質量%以下であるエチレン-酢酸ビニル共重合体、及びアクリル酸エチル含有量が8質量%以上35質量%以下であるエチレン-アクリル酸エチル共重合体が好ましく、直鎖状低密度ポリエチレン及び酢酸ビニル含有量が5質量%以上55質量%以下であるエチレン-酢酸ビニル共重合体がより好ましい。
(4)層は、EVOH(A)、熱可塑性樹脂及びカルボン酸変性ポリオレフィンを含有する層である。また、(4)層は、当該熱成形容器の製造工程における(1)層、(2)層及び(3)層の回収物を用いて形成されることが好ましい。回収物としては、当該熱成形容器の製造工程において発生するバリ、検定の不合格品等が挙げられる。当該熱成形容器がこのような回収層としての(4)層をさらに有することで、かかるバリや検定の不合格品を再利用することができ、当該熱成形容器の製造時に使用される樹脂のロスを低減できる。
当該熱成形容器に用いる多層構造体は、共押出成形装置を用いて形成できる。この多層構造体は、例えば(1)層を形成する当該樹脂組成物、(2)層を形成する樹脂組成物、(3)層を形成する樹脂組成物、(4)層を形成する樹脂組成物を別々の押出機に仕込み、これらの押出機で共押出することで所定の層構成を有するものとして形成できる。
当該熱成形容器は、フィルム、シート等の当該多層構造体を加熱して軟化させた後に、金型形状に成形することで形成することができる。熱成形方法としては、例えば真空又は圧空を用い、必要によりプラグを併せ用いて金型形状に成形する方法(ストレート法、ドレープ法、エアスリップ法、スナップバック法、プラグアシスト法等)、プレス成形する方法などが挙げられる。成形温度、真空度、圧空の圧力、成形速度等の各種成形条件は、プラグ形状や金型形状、原料フィルムやシートの性質等により適当に設定される。
(内表面)(2)/(3)/(1)/(3)/(4)/(2)(外表面)、
(内表面)(2)/(4)/(3)/(1)/(3)/(4)/(2)(外表面)、
(内表面)(4)/(3)/(1)/(3)/(4)(外表面)等が挙げられる。なお、これらの層構成において(2)層の代わりに(4)層を備える層構成であってもよい。層構成としては、これらの中でも(内表面)(2)/(3)/(1)/(3)/(4)/(2)(外表面)、及び(内表面)(2)/(4)/(3)/(1)/(3)/(4)/(2)(外表面)が好ましい。なお、(1)層~(4)層がそれぞれ複数用いられている場合、それぞれの層を構成する樹脂は同一でも異なっていてもよい。
次に、当該熱成形容器について、図2及び図3に示すカップ状容器を例にとって、具体的に説明する。但し、カップ状容器は当該熱成形容器の一例に過ぎず、以下のカップ状容器の説明は、本発明の範囲を限定するものではない。
カップ状容器1は、図5に示すようにフィルム状、シート状等の連続多層構造体20を加熱装置30により加熱して軟化させた後に、金型装置40を用いて熱成形することで製造される。
加熱装置30は、一対のヒーター31、32を備えるものであり、これらのヒーター31、32の間を連続多層構造体20が通過可能とされている。なお、加熱装置30としては、熱プレスにより加熱するものを用いることもできる。
金型装置40は、プラグアシスト法による熱成形に適するものであり、チャンバー(図示略)内に収容される下型50及び上型51を備える。下型50及び上型51は、それぞれ個別に上下方向に移動可能であり、離間状態において、これらの下型50及び上型51の間を連続多層構造体20が通過可能とされている。下型50は、カップ状容器1の収容部を形成するための複数の凹部52を有する。上型51は、下型50に向けて突出する複数のプラグ53を備える。複数のプラグ53は、下型50の複数の凹部52に対応した位置に設けられている。各プラグ53は、対応する凹部52に挿入可能である。
まず、図5及び図6(A)に示すように、加熱装置30により軟化させた連続多層構造体20に対して、下型50を上動させることで下型50に密着させると共に連続多層構造体20を若干持ち上げて連続多層構造体20にテンションを付与する。次に、図6(B)に示すように、上型51を下動させることでプラグ53を凹部52に挿入する。
なお、当該樹脂組成物からなる第1層のみを備える単層構造体を熱成形することで当該熱成形容器を形成してもよい。この場合の熱成形方法や熱成形容器の形状等は、当該熱成形容器と同様とすることができる。
当該ブロー成形体は、当該多層構造体を備える。当該ブロー成形体は、例えばブロー成形容器等に使用できる。以下、当該ブロー成形体について、図7に示すブロー成形容器105を例にとって、具体的に説明する。なお、図7はブロー成形容器105の周壁の部分断面図である。
(1)EVOH(A)を主成分とする層101、
(2)(1)層の一方の面側及び他方の面側に配置され、Fedorsの式から算出する溶解性パラメータが11(cal/cm3)1/2以下である熱可塑性樹脂を主成分とする一対の層102、
(3)(1)層101と(2)層102との間に配置され、カルボン酸変性ポリオレフィンを主成分とする一対の層103、及び
(4)EVOH(A)、Fedorsの式から算出する溶解性パラメータが11(cal/cm3)1/2以下である熱可塑性樹脂、及びカルボン酸変性ポリオレフィンを含有する層104を備える。
当該ブロー成形容器105は、EVOH(A)を主成分とする樹脂組成物を用いてブロー成形する工程を有する方法により製造することが好ましい。具体的には、(1)層101を形成する乾燥EVOH含有樹脂組成物ペレット、(2)層102を形成する高密度ポリエチレン等、(3)層103を形成する接着性樹脂、及び(4)層104を形成する回収樹脂等を用い、ブロー成形機にて100℃以上400℃以下の温度で、例えば(2)層/(3)層/(1)層/(3)層/(4)層/(2)層(以降、(内)2/3/1/3/4/2(外)のように表す)の4種6層パリソンを用いてブロー成形し、金型内温度10℃以上30℃以下で10秒間以上30分間以下冷却し、全層平均厚み300μm以上10,000μm以下の中空容器を成形することができる。
当該ブロー成形容器は、上述した図7の形態に限定されず、少なくとも(1)層を備えていればよい。具体的には、回収層としての(4)層等を備えなくてもよい。さらに、他の層が積層されてもよい。また、接着性がよい樹脂の組合せを選択することで、接着層としての(3)層を省略してもよい。
当該燃料容器は、当該ブロー成形体を備える。当該燃料容器は、当該ブロー成形体以外に、フィルター、残量計、バッフルプレート等をさらに備えていてもよい。当該燃料容器は、当該ブロー成形容器を備えることで、外観性、ガスバリア性、耐油性等にも優れるため燃料容器として好適に用いられる。ここで、燃料容器とは、自動車、オートバイ、船舶、航空機、発電機、工業用若しくは農業用機器等に搭載された燃料容器、又はこれら燃料容器に燃料を補給するための携帯用燃料容器、さらには燃料を保管するための容器を意味する。また、燃料としては、ガソリン、特にメタノール、エタノール又はMTBE等をブレンドした含酸素ガソリン等が代表例として挙げられるが、その他、重油、軽油、灯油等も含まれるものとする。これらのうち、当該燃料容器は含酸素ガソリン用燃料容器として特に好適に用いられる。
[合成例1](EVOHペレットの合成)
(エチレン-酢酸ビニル共重合体の重合)
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250L加圧反応槽に、酢酸ビニルを83kg、メタノール(以下、MeOHと称する)を14.9kg仕込み、60℃に昇温した後、反応液に窒素ガスを30分間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4.0MPa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12.3g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の「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4.0MPaに、重合温度を60℃に維持した。5時間後、酢酸ビニルの重合率が40%となったところで冷却して重合を停止した。反応槽からエチレンを排気し、さらに反応液に窒素ガスをバブリングしてエチレンを完全に除去した。次いで減圧下で未反応の酢酸ビニルを除去した後、エチレン-酢酸ビニル共重合体(以下EVAcと称する)を得た。合成に使用する酢酸ビニルは、表1に示す含有量のアセトアルデヒドを添加したものを用いた。
得られたEVAc溶液にメタノールを加え、濃度15質量%のEVAc溶液を得た。このEVAcのメタノール溶液253.4kg(溶液中のEVAcが38kg)に、水酸化ナトリウムを10質量%含むメタノール溶液76.6L(EVAc中の酢酸ビニルユニットに対してモル比0.4)を添加して60℃で4時間撹拌することにより、EVAcのけん化を行った。反応開始から6時間後、酢酸9.2kg及び水60Lを添加して上記反応液を中和し、反応を停止させた。
中和した上記反応液を反応器からドラム缶に移して16時間室温で放置し、ケーキ状に冷却固化させた。その後、遠心分離機(国産遠心器株式会社の「H-130」、回転数1200rpm)を用いて、上記ケーキ状の樹脂を脱液した。次に、遠心分離機の中央部に、上方よりイオン交換水を連続的に供給しながら洗浄し、上記樹脂を水洗する工程を10時間行った。洗浄開始から10時間後の洗浄液の伝導度は、30μS/cm(東亜電波工業株式会社の「CM-30ET」で測定)であった。
上記洗浄後の樹脂を乾燥機を用いて60℃で48時間乾燥し、粉末状のEVOHを得た。乾燥した粉末状のEVOH20kgを水及びメタノール混合溶液(質量比:水/メタノール=4/6)43Lに溶解させ、80℃で12時間撹拌した。次に、撹拌を止めて溶解槽の温度を65℃に下げて5時間放置し、上述のEVOHの水及びメタノール溶液の脱泡を行った。そして、直径3.5mmの円形の開口部を有する金板から、5℃の水及びメタノール混合溶液(質量比:水/メタノール=9/1)中に押出してストランド状に析出させ、切断することで直径約4mm、長さ約5mmの含水EVOHペレットを得た。
上記含水EVOHペレットを遠心分離機で脱液し、さらに大量の水を加え脱液する操作を繰り返し行って洗浄し、EVOHペレットを得た。得られたEVOHのけん化度は99モル%であった。
酢酸ビニルのアセトアルデヒド含有量、エチレン含有量及びけん化度を表1に示すものとした以外は合成例1と同様にしてEVOHを合成した。
酢酸ビニルのアセトアルデヒド含有量、エチレン含有量及びけん化度を表1に示すものとし、かつ酢酸ビニルに酒石酸50ppmをさらに添加した以外は合成例1と同様にしてEVOHを合成した。
(ポリ酢酸ビニルの合成)
撹拌機、温度計、窒素導入チューブ、還流管を備え付けた6Lセパラブルフラスコに、予め脱酸素し、アセトアルデヒドを500ppm含有する酢酸ビニルモノマー2,555質量部、アセトアルデヒドジメチルアセタールを50ppm含有するメタノール945質量部、及び酒石酸1質量%メタノール溶液(酢酸ビニルモノマーに対する添加量が20ppm)を仕込み、窒素気流下、60℃に調整した。なお、還流管には-10℃のエチレングリコール水溶液を循環させた。その後、ジ-n-プロピルパーオキシジカーボネートの0.55質量%メタノール溶液18.6mLを添加し重合を開始した。重合開始後、重合終了までジ-n-プロピルパーオキシジカーボネートの同メタノール溶液を20.9mL/時間の速度で添加し続け、重合中の温度を60℃に保ち重合を行った。重合開始から4時間後、重合溶液の固形分濃度が25.1質量%となった時点で、重合液中に未分解で残存するジ-n-プロピルパーオキシジカーボネートの3倍モル等量に相当するソルビン酸0.0141質量部を含有するメタノール1,200質量部を添加し、重合液を冷却し重合を停止した。なお、重合停止時の酢酸ビニルモノマーの重合率は35.0%であった。室温まで冷却した後、水流アスピレータ減圧下、酢酸ビニルモノマー及びメタノールを留去し、ポリ酢酸ビニルを析出させた。析出したポリ酢酸ビニルにメタノール3,000質量部を添加し、30℃で加温しつつポリ酢酸ビニルを溶解した後、再び水流アスピレータ減圧下で留去する操作を3回繰り返した。析出したポリ酢酸ビニルにメタノールを添加し、酢酸ビニルモノマーの除去率99.8%のポリ酢酸ビニルの40質量%のメタノール溶液を得た。また、得られたメタノール溶液の一部を採取し、ポリ酢酸ビニル中の酢酸ビニル単位に対する水酸化ナトリウムのモル比が0.1となるように水酸化ナトリウムの10質量%メタノール溶液を添加し、ゲル化物が生成した時点でゲルを粉砕し、メタノールでソックスレー抽出を3日間行った。得られたポリビニルアルコールを乾燥し、粘度平均重合度測定を実施した結果、重合度は1,700であった。これをポリ酢酸ビニルの重合度の指標とした。
(ポリビニルアルコールの合成)
比較合成例2で合成したポリ酢酸ビニルの40質量%のメタノール溶液に対して、総固形分濃度(けん化濃度)が30質量%となるように、水酸化ナトリウムの8質量%メタノール溶液(メタノール及びポリ酢酸ビニル中の酢酸ビニル単量体単位に対する水酸化ナトリウムのモル比が0.020)を撹拌下に加え、40℃でけん化反応を開始した。けん化反応の進行に伴ってゲル化物が生成した時点でゲルを粉砕し、粉砕後のゲルを40℃の容器に移し、けん化反応の開始から60分経過した時点で、メタノール、酢酸メチル及び水(質量比25/70/5)の溶液に浸漬し、中和処理した。得られた膨潤ゲルを遠心分離し、膨潤ゲルの質量に対して2倍の質量のメタノールを添加及び浸漬し30分間放置した後、遠心分離する操作を4回繰り返し、60℃で1時間、100℃で2時間乾燥してポリビニルアルコール(PVA)を得た。
合成例1~5並びに比較合成例1で得られたEVOHのペレット及び比較合成例3で得られたPVA20kgを酢酸水溶液及びイオン交換水を用いて洗浄した後、酢酸ナトリウムを含む水溶液で浸漬処理を行った。この浸漬処理用水溶液と樹脂組成物チップとを分離して脱液した後、熱風乾燥機に入れて80℃で4時間乾燥を行い、さらに100℃で16時間乾燥を行って、実施例1~5及び比較例1の樹脂組成物(以下、「EVOH樹脂組成物」ともいう)を乾燥ペレットとして得た。また、比較合成例3で合成したPVAを比較例2の樹脂組成物とした。この乾燥ペレットを用い、以下に説明する方法にて、表1に示すEVOH等のけん化度、エチレン含有量、アルカリ金属含有量等の測定を行った。なお、表1において「-」は、溶媒に樹脂が溶解しなかったため分子量測定を行っていないことを示す。
乾燥EVOHペレットを凍結粉砕により粉砕した。得られた粉砕EVOHを呼び寸法1mmのふるい(標準フルイ規格JIS-Z8801準拠)でふるい分けした。このふるいを通過したEVOH粉末5gを100gのイオン交換水中に浸漬し、85℃で4時間撹拌した後、脱液して乾燥する操作を二回行った。得られた洗浄後の粉末EVOHを用いて、下記の測定条件で1H-NMRの測定を行い、下記解析方法でエチレン含有量及びけん化度を求めた。
装置名 :超伝導核磁気共鳴装置(日本電子株式会社の「Lambda500」)
観測周波数 :500MHz
溶媒 :DMSO-d6
ポリマー濃度 :4質量%
測定温度 :40℃及び95℃
積算回数 :600回
パルス遅延時間:3.836秒
サンプル回転速度:10Hz~12Hz
パルス幅(90°パルス):6.75μsec
40℃での測定では、3.3ppm付近に水分子中の水素のピークが観測され、EVOHのビニルアルコール単位のメチン水素のピークのうちの、3.1ppm~3.7ppmの部分と重なった。一方、95℃での測定では、上記40℃で生じた重なりは解消するものの、4ppm~4.5ppm付近に存在するEVOHのビニルアルコール単位の水酸基の水素のピークが、EVOHのビニルアルコール単位のメチン水素のピークのうちの、3.7ppm~4ppmの部分と重なった。すなわち、EVOHのビニルアルコール単位のメチン水素(3.1ppm~4ppm)の定量については、水又は水酸基の水素のピークとの重複を避けるために、3.1ppm~3.7ppmの部分については、95℃の測定データを採用し、3.7ppm~4ppmの部分については40℃の測定データを採用し、これらの合計値として当該メチン水素の全量を定量した。なお、水又は水酸基の水素のピークは測定温度を上昇させることで高磁場側にシフトすることが知られている。従って、以下のように40℃及び95℃の両方の測定結果を用いて解析した。上記の40℃で測定したスペクトルより、3.7ppm~4ppmのケミカルシフトのピークの積分値(I1)及び0.6ppm~1.8ppmのケミカルシフトのピークの積分値(I2)を求めた。
アルカリ金属含有量の測定は、分光分析装置を用いて定量した。具体的には、乾燥EVOHペレット0.5gをアクタック社のテフロン(登録商標)製耐圧容器に添加し、硝酸(和光純薬工業社の精密分析用)5mLを添加した。30分放置後、ラプチャーディスク付きキャップリップにて容器に蓋をし、マイクロウェーブ高速分解システム(アクタック社の「スピードウェーブ MWS-2」)にて150℃、10分、次いで180℃、10分の処理を行って乾燥EVOHペレットを分解させた。なお、上述の処理では乾燥EVOHペレットの分解が完了できていない場合、処理条件を適宜調節した。得られた分解物を10mLのイオン交換水で希釈し、全液を50mLのメスフラスコに移しとり、イオン交換水で定容することで分解溶液を得た。ICP発光分光分析装置(パーキンエルマージャパン社の「Optima 4300 DV」)を用い、上記分解溶液をNaの波長589.592nmで定量分析することで、アルカリ金属含有量を測定した。
溶融粘度(メルトフローレート)は、JIS-K7210(1999)に準拠し、温度190℃、荷重2,160gで測定した。
(測定サンプルの準備)
測定サンプルは、窒素雰囲気下、EVOHを220℃で50時間加熱することで作製した。
GPC測定は、VISCOTECH社の「GPCmax」を用いて行った。分子量は、示差屈折率検出器及び紫外可視吸光度検出器で検出されるシグナル強度に基づいて算出した。示差屈折率検出器及び紫外可視吸光度検出器としては、VISCOTECH社の「TDA305」及び「UV Detector2600」を用いた。この吸光度検出器の検出用セルとしては、光路長が10mmのものを用いた。GPCカラムとしては、昭和電工株式会社の「GPC HFIP-806M」を用いた。また、解析ソフトとしては、装置付属の「OmniSEC(Version 4.7.0.406)」を用いた。
測定サンプルを採取し、トリフルオロ酢酸ナトリウム20mmol/Lを含有するヘキサフルオロイソプロパノール(以下「HFIP」という)に溶解し、0.100wt/vol%溶液を調製した。測定には、0.45μmのポリテトラフルオロエチレン製フィルターでろ過した溶液を用いた。測定サンプルの溶解は、室温にて一晩静置することで行った。
吸光度=(1.00/α)×吸光度の測定値 ・・・(7)
標品として、Agilent Technologies社のポリメタクリル酸メチル(以下「PMMA」と略記する)(ピークトップ分子量:1,944,000、790,000、467,400、271,400、144,000、79,250、35,300、13,300、7,100、1,960、1,020又は690)を測定し、示差屈折率検出器及び吸光度検出器のそれぞれについて、溶出容量をPMMA分子量に換算するための検量線を作成した。各検量線の作成には、上記解析ソフトを用いた。なお、本測定においてはPMMAの測定において、1,944,000及び271,400の両分子量の標準試料同士のピークが分離できるカラムを用いた。
このようにして得られた実施例1~5及び比較例1のEVOH樹脂組成物について、製膜欠点及びフィルム外観性(ストリーク及びロール端部の着色)を以下のように評価した。評価結果は、表2に示した。なお、比較例2のPVAについては、ゲル化が激しく製膜が不可であったため、製膜欠陥及びフィルム外観性の評価を行っておらず、これらのEVOH樹脂組成物及びPVAの評価項目は、表2に「-」と示した。
単軸押出し装置(株式会社東洋精機製作所の「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、各乾燥EVOH樹脂組成物ペレットから厚み20μmの単層フィルムを作製した。このときの各条件は以下に示す通りである。
スクリュー回転数:40rpm
ダイス幅:30cm
引取りロール温度:80℃
引取りロール速度:3.1m/分
運転開始10時間後、50時間後に作製されたフィルムについて、目視にて外観性(ストリーク)を下記評価基準により評価した。また、フィルム100mを紙管に巻き取ったロールを作製し、ロールの端部の黄変による着色を評価した。
良好(A) :ストリークは認められなかった
やや良好(B):ストリークが確認された
不良(C) :多数のストリークが確認された
良好(A) :無色
やや良好(B):黄変
不良(C) :著しく黄変
実施例4で得られたEVOH樹脂組成物を使用して多層シートを作製し、外観性を評価した。具体的には、EVOH樹脂組成物、エチレン-α-オレフィン共重合体、及びカルボン酸変性ポリオレフィンを別々の押出機に仕込み、エチレン-α-オレフィン共重合体/カルボン酸変性ポリオレフィン/EVOH樹脂組成物/カルボン酸変性ポリオレフィン/エチレン-α-オレフィン共重合体(平均膜厚:200μm/25μm/50μm/25μm/200μm)の構成を有する全層平均厚み500μmである3種5層の多層シートを共押出シート成形装置により得た。押出成形は、エチレン-α-オレフィン共重合体については直径65mm、L/D=22の一軸スクリューを備えた押出機を200℃~240℃の温度とし、カルボン酸変性ポリオレフィンについては直径40mm、L/D=26の一軸スクリューを備えた押出機を160℃~220℃の温度とし、EVOH樹脂組成物については直径40mm、L/D=22の一軸スクリューを備えた押出機を160℃~240℃の温度として、フィードブロック型ダイ(巾600mm)を250℃で運転した。フィードブロック型ダイ(巾600mm)の設定温度は、通常より約10℃高い250℃とし、10時間連続成形した後のシートの外観性を評価した結果、膜面は良好であった。
各無機粒子(C)の含有量は、上述のアルカリ金属含有量の測定法と同様の方法により金属元素を定量し、酸化物換算値として算出した。すなわち、酸化ケイ素、酸化アルミニウム、酸化マグネシウム、酸化ジルコニウム、酸化セリウム、酸化タングステン、及び/又は酸化モリブデンとして算出した。複数の金属を含む場合は、複数の金属酸化物量として算出した。リン酸化合物の量は、リン元素を定量しリン酸根換算値として算出した。ホウ素化合物の含有量は、ホウ素元素換算値として算出した。
Na :589.592nm
K :766.490nm
Mg :285.213nm
Ca :317.933nm
P :214.914nm
B :249.667nm
Si :251.611nm
Al :396.153nm
Zr :343.823nm
Ce :413.764nm
W :207.912nm
Mo :202.031nm
ケイ素原子を含む無機粒子(C)として、富士シリシア化学株式会社の「サイリシア380」(平均粒子径9.0μm)又は「サイリシア310P」(平均粒子径2.7μm)を粉砕及びふるいにより分級し、所望のサイズに調整した。
無機粒子(C)の平均粒子径は、株式会社島津製作所の「レーザー回折式粒度分布測定装置(SALD-2200)」を用いて測定を行った。評価サンプルは、ガラスビーカーに50ccの純水と測定する無機粒子(C)を5g添加して、スパチュラを用いて撹拌し、その後超音波洗浄機で10分間、分散処理を行った。次に、分散処理を行った無機粒子(C)を含む液を装置のサンプラ部に添加し吸光度が安定になった時点で測定を行い、粒子の回折/散乱光の光強度分布データから粒子径分布(粒子径及び相対粒子量)を計算した。平均粒子径は、測定された粒子径と相対粒子量とを掛けた値の積算値を相対粒子量の合計で割って求めた。なお、平均粒子径は粒子の平均直径である。
[実施例7~10及び比較例3]
実施例1~4及び比較例1のEVOH樹脂組成物に、表3の通りに無機粒子(C)を添加し、実施例7~10及び比較例3のEVOH樹脂組成物の乾燥ペレットを得た。
後述する方法でフィルム及び多層構造体を製造し、このフィルム及び多層構造体を用いて実施例7~10及び比較例3のEVOH樹脂組成物の評価を行った。
上記得られた乾燥EVOHペレットを用いて240℃にて溶融し、ダイからキャスティングロール上に押出すと同時にエアーナイフを用いて空気を風速30m/秒で吹き付け、平均厚み170μmのEVOH未延伸フィルムを得た。このEVOH未延伸フィルムを80℃の温水に10秒接触させ、テンター式同時二軸延伸機を用い、90℃雰囲気下で縦方向に3.2倍、横方向に3.0倍延伸し、さらに170℃に設定したテンター内にて5秒間熱処理を行い、フィルム端部をカットすることにより以下の二軸延伸フィルムを得た。
フィルム平均厚み :12μm
フィルム平均幅 :50cm
フィルム平均巻長さ:4,000m
本数 :100
上記得られた二軸延伸フィルムを紙管に巻き取り、フィルム端部の色を肉眼で以下のように判定した。
A:着色なし
B:うすい黄色
C:着色
上記得られた二軸延伸フィルムの表面について、株式会社キーエンス「形状測定レーザマイクロスコープ VK-X200」を用い、JIS-B0610-2001に準拠し、算術平均粗さ(Ra)と輪郭曲線要素の平均長さ(RSm)の測定を行った。測定はn=100で行い、その平均値を各測定値とした。Ra及びRSmのそれぞれについて以下のように判定した。
算術平均粗さ(Ra)
A:0.20μm以上0.40μm以下
B:0.15μm以上0.20μm未満又は0.40μmを超え0.60μm以下
C:0.10μm以上0.15μm未満又は0.60μmを超え0.80μm以下
輪郭曲線要素の平均長さ(RSm)
A:200μm以上400μm以下
B:150μm以上200μm未満又は400μmを超え600μm以下
C:100μm以上150μm未満又は600μmを超え800μm以下
上記得られた二軸延伸フィルムをスリッターにかけ、フィルムロールに100N/mの張力をかけて巻きとったときの破断回数を評価し、以下のように判定した。
A:0~1回/100本
B:2~4回/100本
C:5~7回/100本
上記得られた100本の二軸延伸フィルムを用い、日本真空技術株式会社のバッチ式蒸着設備EWA-105を使用して、フィルム走行速度200m/分で、フィルム片側にアルミニウムを蒸着させ、多層構造体(蒸着フィルム)を得た。
上記得られた多層構造体をミクロトームでカットし、断面を露出させた。この断面を走査型電子顕微鏡(SEM)を用いて観察し、金属蒸着層の厚みを測定した。SEM観察はエス・アイ・アイナノテクノロジー社の「ZEISS ULTRA 55」を使用し、反射電子検出器を用いて行った。
上記得られた多層構造体の1本目のロールをスリッターにかけて、フィルム下部から100Wの蛍光灯を当てながら巻きだし、幅0.5m長さ2mに渡ってn=10で蒸着欠点数を数え、その平均値を1m2あたりの蒸着欠点数とし、以下のように判定した。
A:0~20個/m2
B:21~40個/m2
C:41~60個/m2
上記得られた多層構造体の100本目のロールをスリッターにかけて、フィルム下部から100Wの蛍光灯を当てながら巻きだし、幅0.5m長さ2mに渡ってn=10で蒸着欠点数を数え、その平均値を1m2あたりの蒸着欠点数とし、以下のように判定した。
A:0~20個/m2
B:21~40個/m2
C:41~60個/m2
EVOH樹脂組成物の溶融成形のロングラン性を示すものとして、蒸着欠点数の経時的な増加度合いについて評価を行い、以下のように判定した。
A:多層構造体1本目と100本目での蒸着欠点のランク差がなかったもの
B:多層構造体1本目と100本目での蒸着欠点のランク差が1つあったもの
C:多層構造体1本目と100本目での蒸着欠点のランク差が2つあったもの
上記得られた多層構造体の金属蒸着層側の表面に、ドライラミネート用接着剤(三井化学株式会社の「タケラックA-385/A-50(6/1の質量比で混合し、固形分濃度23質量%の酢酸エチル溶液としたもの)」を第一理化株式会社のバーコーターNo.12を用いてコートし、50℃で5分間熱風乾燥させた後、80℃に加熱したニップロールにて、PETフィルム(東洋紡株式会社の「E5000」:平均厚み12μm)とラミネートを行った。このとき、フィルムの半分は、間にアルミホイルを挟むことで貼りあわされない部分も用意した。その後、40℃で72時間養生し、ラミネートフィルムを得た。得られたラミネートフィルムをアルミ蒸着の境目を中心として100mm×15mmの短冊に裁断し、引っ張り試験機により引っ張り速度10mm/分にてT型剥離試験を5回行った。得られた測定値の平均値を密着強度とした。密着強度は、以下のように判定した。
A:500g/15mm以上
B:450以上500g/15mm未満
C:400以上450g/15mm未満
実施例10のEVOH樹脂組成物を製膜し、同時二軸延伸機を用いた方法に従い、フィルムを製造し、各物性の評価を行ったところ、JIS-B0601に準拠し測定されたフィルム表面の算術平均粗さ(Ra)は0.28μm、輪郭曲線要素の平均長さ(RSm)は298μmでありともにA判定であった。また、ロールとして巻き取った後のロール端面に黄色の着色が見られず、A判定であった。さらに、フィルム加工時における破断回数は1回であり、A判定であった。製造した多層構造体(アルミ蒸着層を有する多層構造体)における蒸着層の平均厚みは50nmであった。その多層構造体1本目の蒸着欠点は9個/m2、多層構造体100本目の蒸着欠点は12個/m2であり、ともにA判定であった。このことから、経時的な蒸着欠点の増加はA判定であった。上記多層構造体の蒸着層とEVOHフィルム層との密着強度は530g/15mmであり、A判定であった。
得られたEVOH樹脂組成物について、240℃にて溶融し、ダイからキャスティングロール上に押出し、フィルム端部をカット後、巻き取ることによりフィルムロールを得た。外観性に優れたフィルムロールを得ることができた。
上記得られた多層構造体(アルミ蒸着層を有する多層構造体)EVOHフィルムを中間層、PETフィルム(東洋紡株式会社の「E5000」)を外層(多層構造体(アルミ蒸着層を有する多層構造体)の金属蒸着層側)、無延伸ポリプロピレンフィルム(以下、CPPと略称する;東セロ株式会社の「RXC-18」、厚み60μm)を内層(多層構造体(アルミ蒸着層を有する多層構造体)のEVOH層側)として、PETの片面及びCPPの片面にドライラミネート用接着剤(三井化学株式会社の「タケラックA-385/A-50(6/1の質量比で混合し、固形分濃度23質量%の酢酸エチル溶液としたもの)」をバーコーターを用いてコートし、50℃で5分間熱風乾燥させた後、接着剤面で多層構造体EVOHフィルムを挟み込むようにしてPETフィルムとCPPフィルムを貼合わせ、40℃で5日間エージングを行って、PET/接着剤層/EVOH層/接着剤層/CPPの層構成を有する多層構造体を得た。次に、得られた多層構造体をヒートシールしてパウチに成形し、水100gを充填した。
[実施例11]
実施例1のEVOH樹脂組成物5.5質量部、ポリオレフィン(D)として未変性ポリオレフィンである低密度ポリエチレン(LDPE)87質量部(株式会社プライムポリマーの「HZ8200B」)、酸変性ポリオレフィンである無水マレイン酸変性ポリエチレン(三井化学株式会社の「アドマーGT-6A」)7.5質量部、及び脂肪酸金属塩としてステアリン酸亜鉛0.15質量部を混合して混合物を得た。
押出機:株式会社東洋精機製作所製二軸押出機「ラボプラストミル」
スクリュー径:25mmφ
スクリュー回転数:100rpm
フィーダー回転数:100rpm
シリンダー、ダイ温度設定:C1/C2/C3/C4/C5/D
=180℃/230℃/250℃/250℃/250℃/250℃
表5に記載の種類及び配合量の各成分を用いた以外は、実施例11と同様にしてEVOH樹脂組成物と、このEVOH樹脂組成物を複数回溶融混練した樹脂組成物(J)とを作製した。
共押出成形装置を用い、実施例11~14及び比較例4のEVOH樹脂組成物、ポリオレフィン(ポリエチレン)、カルボン酸変性ポリオレフィン(三井化学アドマー社の「QF-500」)、及び樹脂組成物(J)を別々の押出機に仕込み、全層厚みが1000μmの4種6層となる多層シート(層構成:ポリオレフィン層300μm/カルボン酸変性ポリオレフィン層50μm/EVOH層50μm/カルボン酸変性ポリオレフィン層50μm/樹脂組成物(J)層400μm/ポリオレフィン層150μm)を作製した。
実施例11~14及び比較例4のEVOH樹脂組成物の押出機:単軸スクリュー、直径40mm、L/D=26、温度170℃~240℃
ポリオレフィンの押出機:単軸、スクリュー直径40mm、L/D=22、温度160℃~210℃
樹脂組成物(J)の押出機:単軸スクリュー、直径65mm、L/D=22、温度200℃~240℃
カルボン酸変性ポリオレフィンの押出機:単軸スクリュー、直径40mm、L/D=26、温度160℃~220℃)
フィードブロック型ダイ(巾600mm)、温度255℃
共押出成形装置にて得られた多層シート(共押出成形装置の立ち上げから30分後、及び24時間後を採取)を15cm角に裁断し、浅野製作所社のバッチ式熱成形試験機にてシート温度150℃の条件で、カップ状(金型形状70φ×70mm、絞り比S=1.0)に熱成形(圧空:5kg/cm2、プラグ:45φ×65mm、シンタックスフォーム、プラグ温度:150℃、金型温度:70℃)することで熱成形容器を作製した。
実施例11~14及び比較例4のEVOH樹脂組成物について、以下の方法でブロー成形容器を製造することでその性能を評価した。このブロー成形容器の構成及び評価結果を表5に示す。
回収回数が10回目の樹脂組成物(J)を回収層に使用してブロー成形した3L容器について、目視にてスジ及び着色を下記基準にて評価し、外観性の評価とした。
「良好(A)」:スジは認められなかった。
「やや良好(B)」:スジが確認された。
「不良(C)」:多数のスジが確認された。
「良好(A)」:無色
「やや良好(B)」:黄変
「不良(C)」:激しく黄変
回収回数1、5、10回のEVOH樹脂組成物又は樹脂組成物(J)を回収層に使用してブロー成形した3L容器に、プロピレングリコールを2.5L充填し、開口部をポリエチレン40μm/アルミ箔12μm/ポリエチレンテレフタレート12μm構成のフィルムで熱シールして蓋をした。このタンクを-40℃で3日間冷却し、開口部が上になるように6mの高さから落下させ、破壊した個数で評価した(n=10)。
「良好(A)」:3個未満
「やや良好(B)」:3個以上6個未満
「不良(C)」:6個以上
ブロー成形容器を該容器側面と直角の方向にミクロトームで丁寧に切断し、さらにメスを用いて回収層を取り出した。露出した断面に減圧雰囲気下で白金を蒸着した。白金が蒸着された断面を走査型電子顕微鏡(SEM)を用いて10,000倍に拡大して写真撮影した。この写真中のEVOHの粒子20個程度を含む領域を選択し、該領域中に存在する各々の粒子像の粒径を測定し、その平均値を算出して、これを平均分散粒子径とした。なお、各々の粒子の粒径については、写真中に観察される粒子の長径(最も長い部分)を測定し、これを粒径とした。なお、上記フィルム又はシートの切断は押出方向に垂直に行い、切断面に対して、垂直方向からの写真撮影を行った。
「良好(A)」:1.5μm未満
「やや良好(B)」:1.5μm以上2.5μm未満
「不良(C)」:2.5μm以上
実施例1と同様に操作し、表6に示す実施例15のEVOH樹脂組成物を調製した。
[実施例16~21及び比較例5]
実施例1~4及び15、並びに比較例1のEVOH樹脂組成物と、ポリアミド(E)(宇部興産株式会社の「Ny1018A」(ナイロン6))と、多価金属塩(B2)として酢酸マグネシウム・4水和物、酢酸亜鉛・2水和物又は酢酸カルシウム・2水和物とを表7に示す各含有量になるように混合し、ドライブレンド後、二軸押出機(株式会社東洋精機製作所、2D25W、25mmφ)を用い、ダイ温度250℃,スクリュー回転数100rpm)の押出条件で、窒素雰囲気下で押出しペレット化を行い、目的の樹脂組成物ペレットを得た。
単軸押出装置(株式会社東洋精機製作所、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、上記得られた各樹脂組成物ペレットから厚み20μmの単層フィルムを作製した。このときの各押出条件は以下に示す通りである。
押出温度:250℃
スクリュー回転数:40rpm
ダイス幅:30cm
引取りロール温度:80℃
引取りロール速度:3.1m/分
上記得られた実施例16~21及び比較例5の樹脂組成物について以下の評価を行った。評価結果を表7に示す。
単軸押出装置(株式会社東洋精機製作所の「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、各乾燥樹脂組成物ペレットから厚み20μmの単層フィルムを作製した。このときの各条件は以下に示す通りである。
押出温度:250℃
スクリュー回転数:40rpm
ダイス幅:30cm
引取りロール温度:80℃
引取りロール速度:3.1m/分
「良好(A)」 :0.01g未満
「やや良好(B)」:0.01g以上1.0g未満
「不良(C)」 :1.0g以上
上記得られた多層シートを用いて、12×12cm内寸の四方をシ-ルしたパウチを作製した。内容物は水とした。これをレトルト装置(株式会社日阪製作所の高温高圧調理殺菌試験機、「RCS-40RTGN」)を使用して、120℃で20分のレトルト処理を実施した。レトルト処理後、表面水を拭き20℃、65%RHの高温高湿の部屋で1日放置してから耐レトルト性を評価した。耐レトルト性は、透明性が確保されている場合は「良好(A)」と評価し、まだらに白化している場合は「やや良好(B)」と、全面が白化している場合は「不良(C)」と評価した。
実施例1と同様に操作し、表8に示す実施例22のEVOH樹脂組成物を調製した。
[合成例6]
上記合成例1のEVOH(A)の合成方法と同様にして、エチレン含有量が44モル%でけん化度が99モル%のEVOH(F)のペレットを合成した。このEVOH(F)の融点は、165℃であった。
上記合成例1のEVOH(A)の合成方法と同様にして、エチレン含有量が35モル%でけん化度が99モル%のEVOH(F)のペレットを合成した。このEVOH(F)の融点は、177℃であった。
上記合成例6で得られたエチレン含有量が44モル%でけん化度が99モル%のEVOH(F)とエポキシプロパンとを用い、東芝機械株式会社の「TEM-35BS」(37mmφ、L/D=52.5)を使用して、バレルC2及びC3が200℃、バレルC4~C15が240℃、回転数が400rpmの条件下、エポキシプロパンをC9から圧入することにより、変性EVOH(F)を合成した。得られた変性EVOH(F)の変性度は、全ビニルアルコール単位に対して8モル%であった。このEVOH(F)の融点は、155℃であった。
[実施例23]
実施例1のEVOH樹脂組成物、及び合成例6で合成したEVOH(F)を質量比(EVOH(A)/EVOH(F))80/20でドライブレンドした後、二軸押出機(株式会社東洋精機製作所の「2D25W」、25mmφ,ダイ温度220℃,スクリュー回転数100rpm)を用い、窒素雰囲気下で押出しペレット化を行い実施例22の樹脂組成物ペレットを得た。
実施例2~4、実施例22及び比較例1のEVOH樹脂組成物と、合成例6~8で合成したEVOH(F)とを表9に示す質量比(EVOH(A)/EVOH(F))で混合した以外は実施例23と同様にして、実施例24~27及び比較例6の樹脂組成物ペレット(乾燥EVOHペレット)を得た。
このようにして得られた各樹脂組成物について、以下の方法を用いて評価した。評価結果を表9に合わせて示す。
単軸押出装置(株式会社東洋精機製作所の「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、上記得られた各樹脂組成物ペレットから厚み150μmの単層フィルムを作製した。成形条件を以下に示す。
押出温度:210℃
スクリュー回転数:100rpm
ダイス幅:15cm
引取りロール温度:80℃
引取りロール速度:0.9m/分
上記成形において、8時間後に得られたフィルムを目視にて着色を観察し、下記基準により評価した。
「A(良好)」 :無色
「B(やや良好)」:黄変
「C(不良)」 :著しく黄変
上記得られたフィルムを株式会社東洋精機製作所のパンタグラフ式二軸延伸装置にて80℃で30秒間予熱後、延伸倍率3×3倍で同時二軸延伸を行い、延伸フィルムを得た。加熱延伸性は、得られた延伸フィルムを目視で観察し、下記基準により評価した。
「A(良好)」 :クラックが全く発生しなかった
「B(やや良好)」:局所的にクラックが発生した
「C(不良)」 :全体的にクラックが発生した
[実施例28]
[基材フィルムの作製]
実施例1のEVOH樹脂組成物ペレット100質量部に対して、合成シリカ(富士シリシア化学株式会社の「サイリシア310P」;レーザー法で測定された平均粒子径2.7μm)を0.03質量部になるようにタンブラーを用いてドライブレンドを行い、240℃にて溶融し、ダイからキャスティングロール上に押出すと同時にエアーナイフを用いて空気を風速30m/秒で吹付け、厚み170μmの未延伸フィルムを得た。このフィルムを80℃の温水に10秒接触させ、テンター式同時二軸延伸設備により90℃にて縦方向に3.2倍、横方向に3.0倍延伸し、さらに170℃に設定したテンター内にて5秒間熱処理を行い、全幅3.6mの二軸延伸フィルム(基材フィルム)を得た。この基材フィルムを巻き返しながら、フィルム全幅における中央位置を中心にして幅80cmをスリットし、長さ4,000mのロールを得た。さらに、連続して基材フィルムを製膜し、長さ4,000mのロールを合計100本採取した。得られた基材フィルムの揮発分は0.15質量%であった。また、基材フィルムの作製時の臭気は無かった。この基材フィルムは、吸湿を防止するためにアルミニウム箔ラミネートフィルムで梱包した。
基材フィルムに対して、バッチ式蒸着設備(日本真空技術株式会社の「EWA-105」)を用い、二軸延伸フィルムの表面温度38℃、二軸延伸フィルムの走行速度200m/分として二軸延伸フィルムの片面にアルミニウムを蒸着させることで蒸着フィルムを得た。金属蒸着層のアルミニウムの厚みは70nmであった。
表10に示すEVOH樹脂組成物ペレットを用いて、実施例28と同様に二軸延伸フィルム(基材フィルム)を作製し、さらに金属蒸着層を形成して蒸着フィルムを得た。なお、実施例32については、二軸延伸フィルムの片面にアルミニウムを蒸着後、さらに二軸延伸フィルムの他方の面にもアルミニウムを蒸着した。
実施例31の蒸着フィルムの片面にPETフィルム(東洋紡株式会社の「E5000」:平均厚み12μm)を積層すると共に蒸着フィルムのもう片面に無延伸ポリプロピレンフィルム(CPPフィルム)(三井化学東セロ株式会社の「RXC-21」:平均厚み50μm)を積層して積層フィルムを得た。この積層フィルムについて、酸素透過度を測定した。その結果を表11に示す。
酸素透過度は、積層フィルムの一部を切り取った試料を用いて、JIS-K7126(等圧法)(2006)に準拠し、酸素透過率測定装置(モダンコントロール社の「MOCON OX-TRAN2/20」:検出限界値0.01mL/m2・day・atm)を用いて測定した。測定条件は、温度が40℃、酸素供給側の湿度が90%RH、キャリアガス側の湿度が0%RH、酸素圧が1気圧、キャリアガス圧力が1気圧とした。積層フィルムの酸素透過率測定装置への設置方法は、基材フィルムの片面に金属蒸着層が形成された蒸着フィルムを用いた積層フィルムの場合、金属蒸着層の表面側を酸素供給側、基材フィルムの露出面側をキャリアガス側とした。基材フィルムの両面に金属蒸着層が形成された蒸着フィルムを用いた積層フィルムの場合は、酸素供給側とキャリアガス側とを選ばず設置した。
層構成を表11に示す通りとした以外は実施例33と同様にして積層フィルムを調製し、酸素透過度を測定した。その結果を表11に示す。なお、表11に示す蒸着PETフィルムとしては東レフィルム加工株式会社の「VM-PET 1510」(平均厚み12μm)を使用した。また実施例36では実施例33における実施例31の蒸着フィルムの代わりに実施例32で得た蒸着フィルムを用いた。さらに、比較例8では実施例33における実施例31の蒸着フィルムの代わりに比較例7で得た蒸着フィルムを用いた。
[実施例37~40及び比較例9]
後述する方法により、実施例1~4及び比較例1のEVOH樹脂組成物を用いて熱成形容器を作製した。
共押出成形装置を用い、(2)層を形成するホモポリプロピレン(三菱ノーブレン社の「PY220」)、(1)層を形成する実施例1~4及び比較例1のEVOH樹脂組成物、(3)層を形成するカルボン酸変性ポリオレフィン(三井化学アドマー社の「QF-500」)を別々の押出機に仕込み、(2):425μm/(3):50μm/(1):50μm/(3):50μm/(2):425μmの層構成を有する全層平均厚みが1,000μmの多層シートを作製した。押出成形は、ホモポリプロピレンについては直径65mm、L/D=22の一軸スクリューを備えた押出機を200℃~240℃の温度とし、EVOH樹脂組成物については直径40mm、L/D=26の一軸スクリューを備えた押出機を170℃~240℃の温度とし、カルボン酸変性ポリオレフィンについては直径40mm、L/D=26の一軸スクリューを備えた押出機を160℃~220℃の温度として、フィードブロック型ダイ(巾600mm)を255℃で運転することにより実施した。
共押出成形装置にて得られた多層シート(共押出成形装置の立ち上げから30分後、及び24時間後を採取)を15cm角に裁断し、浅野製作所社のバッチ式熱成形試験機にてシート温度150℃の条件で、カップ状(金型形状70φ×70mm、絞り比S=1.0)に熱成形(圧空:5kg/cm2、プラグ:45φ×65mm、シンタックスフォーム、プラグ温度:150℃、金型温度:70℃)することで熱成形容器を作製した。
上記得られた樹脂組成物、多層シート及び熱成形容器について、以下に説明する手法に従い、モータートルク変動、外観性及び耐衝撃性を評価した。評価結果について表12に示す。
EVOHペレット60gをラボプラストミル(株式会社東洋精機製作所の「20R200」二軸異方向)にて100rpm、260℃で混練したときのトルク変化を測定した。モータートルクの評価は、混練開始から5分後のトルクを測定し、トルク値がその5分後のトルクの1.5倍になるまでの時間として評価した。この時間が長いほど、粘度変化が少なく、ロングラン性に優れていることを示す。
A:60分以上
B:40分以上60分未満
C:20分以上40分未満
共押出成形装置の立ち上げ開始から30分後、6時間後に得られた多層シートを用いて成形した熱成形容器について、目視にてストリーク及び着色を下記基準にて評価した。
A(良好):ストリークは認められなかった。
B(やや良好):ストリークが確認された。
C(不良):多数のストリークが確認された。
A(良好):無色
B(やや良好):黄変
C(不良):著しく黄変
共押出成形装置の立ち上げ開始から20分後、40分後、及び10時間後の多層シートから形成した熱成形容器に、エチレングリコールを250mL入れ、開口部を3層構造のフィルム(ポリエチレン40μm/アルミ箔12μm/ポリエチレンテレフタレート12μm)で熱シールして蓋をした。この熱成形容器を-40℃で3日間冷却し、開口部が上になるように6mの高さから10個の熱成形容器を落下させ、破壊した熱成形容器の個数で評価した。なお、共押出成形装置の立ち上げ開始から20分後の耐衝撃性がセルフパージ性の指標となる。
A(良好):3個未満
B(やや良好):3個以上6個未満
C(不良):6個以上
ブロー成形容器は、実施例1~4及び比較例1のEVOH樹脂組成物と、このEVOH樹脂組成物により調製した回収樹脂とを用いて作製した。
実施例1~4及び比較例1のEVOH樹脂組成物4質量部、高密度ポリエチレン(三井化学株式会社の「HZ8200B」、190℃-2,160g荷重におけるメルトフローレート(MFR)=0.01g/10分)86質量部、及び接着性樹脂(三井化学株式会社の「ADMER GT-6A」、190℃-2,160gにおけるメルトフローレート=0.94g/10分)10質量部をドライブレンド後、二軸押出機(株式会社東洋精機製作所の「2D25W」、;25mmφ、ダイ温度220℃、スクリュー回転数100rpm)を用い、窒素雰囲気下で押出しペレット化を行った。また、モデル回収樹脂を得るために、この押出ペレットをさらに同押出機及び同条件で押出しペレット化を実施、同作業を4回(押出機でのブレンドは計5回)実施し回収樹脂を得た。
上記EVOH樹脂組成物の乾燥ペレット、上記高密度ポリエチレン、上記接着性樹脂、及び上記回収樹脂を用い、鈴木製工所社のブロー成形機「TB-ST-6P」にて210℃で、(内側)高密度ポリエチレン/接着性樹脂/EVOH樹脂組成物/接着性樹脂/回収樹脂/樹脂組成物(外側)の4種6層パリソンを2時間放流し、2時間加熱状態のまま運転を停止させた。その後運転を再開し、各所定時間後に製造したブロー成形容器を評価した。なお、ブロー成形容器の製造においては、金型内温度15℃で20秒間冷却し、全層平均厚み1,000μm((内側)高密度ポリエチレン/接着性樹脂/EVOH樹脂組成物/接着性樹脂/回収樹脂/樹脂組成物(外側)=(内側)340/50/40/50/400/120μm(外側))の3Lタンクを成形した。このタンクの底面直径は100mm、高さは400mmであった。
このようにして得られた各ブロー成形容器について、以下のように評価した。評価結果を表13に合わせて示す。
乾燥樹脂組成物ペレット60gをラボプラストミル(株式会社東洋精機製作所の「20R200」二軸異方向)100rpm、260℃で混練し、混練開始から5分後のトルク値が1.5倍になるまでの所要時間を測定し、以下の評価基準で評価した。
「良好(A)」:60分以上
「やや良好(B)」:40分以上60分未満
「不良(C)」:40分未満
再立ち上げ40分後に成形した3Lタンクについて、目視にてストリーク及び着色を下記基準にて評価し、外観性の評価とした。
「良好(A)」:ストリークは認められなかった。
「やや良好(B)」:ストリークが確認された。
「不良(C)」:多数のストリークが確認された。
「良好(A)」:無色
「やや良好(B)」:黄変
「不良(C)」:著しく黄変
再立ち上げ20分後、40分後、及び10時間後にブロー成形した3Lタンクに、プロピレングリコールを2.5L充填し、開口部をポリエチレン40μm/アルミ箔12μm/ポリエチレンテレフタレート12μm構成のフィルムで熱シールして蓋をした。このタンクを-40℃で3日間冷却し、開口部が上になるように6mの高さから落下させ、破壊した個数で評価した(n=10)。再立ち上げ20分後の耐衝撃性がセルフパージ性の指標となる。
「良好(A)」:3個未満
「やや良好(B)」:3個以上6個未満
「不良(C)」:6個以上
2 カップ本体
3 フランジ部
4 開口
5 内表面
6 外表面
7 蓋
11 (1)層(EVOH層)
12 (2)層(熱可塑性樹脂層)
13 (3)層(ポリオレフィン層)
14 (4)層(回収層)
20 連続多層構造体
30 加熱装置
31,32 ヒーター
40 金型装置
50 下型
51 上型
52 凹部
53 プラグ
101 (1)層(エチレン-ビニルアルコール共重合体層)
102 (2)層(熱可塑性樹脂層)
103 (3)層(カルボン酸変性ポリオレフィン層)
104 (4)層(エチレン-ビニルアルコール共重合体、熱可塑性樹脂、カルボン酸変性ポリオレフィンを含有する層)
105 ブロー成形容器
106 容器内部表面
107 容器外部表面
Claims (18)
- エチレンとビニルエステルとの共重合体をけん化して得られるエチレン-ビニルアルコール共重合体(A)であって、
示差屈折率検出器及び紫外可視吸光度検出器を備えるゲルパーミエーションクロマトグラフを用い、窒素雰囲気下、220℃、50時間熱処理後に測定した分子量が、下記式(1)で表される条件を満たすことを特徴とするエチレン-ビニルアルコール共重合体。
(Ma-Mb)/Ma<0.45 ・・・(1)
Ma:示差屈折率検出器で測定されるピークの最大値におけるポリメタクリル酸メチル換算の分子量
Mb:紫外可視吸光度検出器で測定される波長220nmでの吸収ピークの最大値におけるポリメタクリル酸メチル換算の分子量 - 示差屈折率検出器及び紫外可視吸光度検出器を備えるゲルパーミエーションクロマトグラフを用い、窒素雰囲気下、220℃、50時間熱処理後に測定した分子量が、下記式(2)で表される条件をさらに満たす請求項1に記載のエチレン-ビニルアルコール共重合体。
(Ma-Mc)/Ma<0.45 ・・・(2)
Ma:示差屈折率検出器で測定されるピークの最大値におけるポリメタクリル酸メチル換算の分子量
Mc:紫外可視吸光度検出器で測定される波長280nmでの吸収ピークの最大値におけるポリメタクリル酸メチル換算の分子量 - 上記ビニルエステルが酢酸ビニルであり、この酢酸ビニルのアセトアルデヒドの含有量が100ppm未満である請求項1又は請求項2に記載のエチレン-ビニルアルコール共重合体。
- 請求項1、請求項2又は請求項3に記載のエチレン-ビニルアルコール共重合体を含有する樹脂組成物。
- 有機酸のアルカリ金属塩(B1)をさらに含有し、
上記アルカリ金属塩(B1)の含有量が金属換算で1ppm以上1,000ppm以下である請求項4に記載の樹脂組成物。 - 有機酸の多価金属塩(B2)をさらに含有し、
上記多価金属塩(B2)の含有量が金属換算で1ppm以上500ppm以下である請求項4又は請求項5に記載の樹脂組成物。 - 無機粒子(C)をさらに含有し、
上記無機粒子(C)の含有量が50ppm以上5,000ppm以下である請求項4、請求項5又は請求項6に記載の樹脂組成物。 - ポリオレフィン(D)をさらに含有する請求項4、請求項5又は請求項6に記載の樹脂組成物。
- ポリアミド(E)をさらに含有し、
上記エチレン-ビニルアルコール共重合体(A)と上記ポリアミド(E)との質量比(A/E)が60/40以上95/5以下である請求項4、請求項5又は請求項6に記載の樹脂組成物。 - 上記エチレン-ビニルアルコール共重合体(A)のエチレン含有量が10モル%以上50モル%以下であり、
エチレン含有量が30モル%以上60モル%以下のエチレン-ビニルアルコール共重合体(F)をさらに含有し、
上記エチレン-ビニルアルコール共重合体(F)のエチレン含有量から上記エチレン-ビニルアルコール共重合体(A)のエチレン含有量を減じた値が8モル%以上であり、
上記エチレン-ビニルアルコール共重合体(A)と上記エチレン-ビニルアルコール共重合体(F)との質量比(A/F)が60/40以上95/5以下である請求項4、請求項5又は請求項6に記載の樹脂組成物。 - 上記エチレン-ビニルアルコール共重合体(A)の融点と上記エチレン-ビニルアルコール共重合体(F)の融点との差が15℃以上である請求項10に記載の樹脂組成物。
- 請求項4から請求項12のいずれか1項に記載の樹脂組成物からなるフィルム。
- 請求項13に記載のフィルムと、このフィルムに積層される金属蒸着層とを備える蒸着フィルム。
- 請求項4から請求項12のいずれか1項に記載の樹脂組成物からなる第1層を有する多層構造体。
- 請求項15に記載の多層構造体を備える熱成形容器。
- 請求項15に記載の多層構造体を備えるブロー成形体。
- 請求項17に記載のブロー成形体を備える燃料容器。
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EP3587460A1 (en) | 2020-01-01 |
SG11201700230YA (en) | 2017-02-27 |
EP3168242A1 (en) | 2017-05-17 |
MY179585A (en) | 2020-11-11 |
BR112017000444B1 (pt) | 2022-02-08 |
EP3168242B1 (en) | 2020-10-21 |
TW201615674A (zh) | 2016-05-01 |
EP3587460B1 (en) | 2023-04-05 |
KR20170029597A (ko) | 2017-03-15 |
EP3168242A4 (en) | 2018-03-07 |
CN106795232B (zh) | 2019-04-23 |
KR101890108B1 (ko) | 2018-08-22 |
US20170183426A1 (en) | 2017-06-29 |
TWI701265B (zh) | 2020-08-11 |
CN106795232A (zh) | 2017-05-31 |
BR112017000444A2 (pt) | 2017-11-07 |
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