WO2017104444A1 - 樹脂組成物及びその製造方法 - Google Patents
樹脂組成物及びその製造方法 Download PDFInfo
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- WO2017104444A1 WO2017104444A1 PCT/JP2016/085897 JP2016085897W WO2017104444A1 WO 2017104444 A1 WO2017104444 A1 WO 2017104444A1 JP 2016085897 W JP2016085897 W JP 2016085897W WO 2017104444 A1 WO2017104444 A1 WO 2017104444A1
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- caprolactam
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L29/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal or ketal radical; Compositions of hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Compositions of derivatives of such polymers
- C08L29/02—Homopolymers or copolymers of unsaturated alcohols
- C08L29/04—Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/005—Processes for mixing polymers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/12—Powdering or granulating
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2329/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal, or ketal radical; Hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Derivatives of such polymer
- C08J2329/02—Homopolymers or copolymers of unsaturated alcohols
- C08J2329/04—Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2477/00—Characterised by the use of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Derivatives of such polymers
- C08J2477/02—Polyamides derived from omega-amino carboxylic acids or from lactams thereof
Definitions
- the present invention relates to a resin composition containing a saponified ethylene-vinyl ester copolymer (hereinafter sometimes referred to as “EVOH resin”) and nylon 6-based polyamide such as nylon 6, and a method for producing the same.
- EVOH resin saponified ethylene-vinyl ester copolymer
- nylon 6-based polyamide such as nylon 6
- the present invention relates to a resin composition containing an EVOH-based resin and a nylon 6-based polyamide with improved long-run moldability, a method for producing the same, and a method for improving the long-run moldability of the resin composition.
- EVOH-based resins are excellent in transparency, gas barrier properties, fragrance retention, solvent resistance, oil resistance, etc., so as food packaging materials, pharmaceutical packaging materials, industrial chemical packaging materials, agricultural chemical packaging materials, etc. It is used by being molded into a sheet or a container such as a bottle or cup.
- EVOH resin films are used for retort applications, taking advantage of their excellent gas barrier properties.
- the hot water treatment is performed for a long time as in the retort treatment, there are disadvantages that the gas barrier properties are lowered, the film is whitened, and the form cannot be maintained.
- a resin composition that can provide a packaging film that can retain its form even after hot water treatment a resin composition in which a polyamide-based resin is blended with an EVOH-based resin is known (for example, see Patent Document 1).
- nylon 6 is used as a polyamide-type resin.
- an amide bond in the polyamide resin interacts with an OH group and / or an ester group of the EVOH resin to form a network structure. is there.
- the formed cross-linked structure stays in the melt-kneader and becomes a gel-like product, which causes a poor appearance of the molded film. Further, when melt molding is continuously performed, the melt viscosity increases, which causes a decrease in long run moldability.
- Patent Document 1 by blending a specific inorganic salt, a decrease in gas barrier properties is suppressed, and stability of viscosity behavior is achieved.
- the stability of the viscosity behavior is measured by measuring the torque fluctuation using a plastic coder. Specifically, the smaller the change in torque value with time, the more specifically the torque T1 15 seconds after the start of kneading. It is judged that the longer the ratio of the torque T2 after 1 hour is, the better the long run moldability is.
- the present invention has been made in view of such circumstances, and the object of the present invention is to establish a more accurate evaluation method for long-run moldability, and based on this, contains EVOH-based resin and nylon 6-based polyamide.
- An object of the present invention is to improve the long-run moldability of the resin composition to be obtained, and to provide an improved resin composition.
- Torque rheometer measurement corresponds to the viscosity behavior when shearing with a biaxial screw and differs from the viscosity behavior during melt molding of a resin composition using an extruder with a single screw. It is thought that there was a case where the stability of the viscosity behavior due to the above and the actual long run formability did not match.
- a network structure may be developed and gelled by continuous melt molding, so that the viscosity behavior is assumed to be more complicated.
- the present inventor has reached the conclusion that if measurement is performed using a rotary rheometer, a shear close to the extrusion of a single screw can be applied, which is useful as a determination of long run formability.
- melt kneading and melt molding are performed at a high temperature of 100 ° C. or higher, it is usually considered that moisture is contained in a kneading machine or a melt molding machine, and also in a kneading or molding resin composition. I can't. Therefore, even if ⁇ -caprolactam is contained, it is considered that the ring-opening polymerization of ⁇ -caprolactam does not start. Therefore, conventionally, in a resin composition containing an EVOH resin and nylon 6, even if ⁇ -caprolactam is contained. Even if present, it was not thought to affect long run formability.
- the content of ⁇ -caprolactam is 200 ppm or less, preferably 100 ppm or less in the resin composition containing the saponified ethylene-vinyl ester copolymer and the nylon 6-based polyamide. It is characterized by.
- the nylon 6-based polyamide is preferably nylon 6.
- the mixing weight ratio of the saponified ethylene-vinyl ester copolymer and the nylon 6-based polyamide is preferably 50:50 to 99: 1. .
- a method for producing a resin composition of the present invention is a method for producing a resin composition pellet containing a saponified ethylene-vinyl ester copolymer and a nylon 6-based polyamide, wherein the nylon 6-based polyamide is in contact with water. Including a process.
- the contacting step is preferably performed in any one of the following i) to iv). i) Before mixing saponified ethylene-vinyl ester copolymer and nylon 6-based polyamide; ii) When mixing a saponified ethylene-vinyl ester copolymer and nylon 6 polyamide; iii) After mixing the saponified ethylene-vinyl ester copolymer and nylon 6 polyamide; iv) A combination of any two or more of i) to iii).
- the content of ⁇ -caprolactam in the resin composition is preferably 200 ppm or less.
- the present invention includes a method for improving the long run moldability of a resin composition containing a saponified ethylene-vinyl ester copolymer and a nylon 6 polyamide.
- the improvement method is a method of bringing the content of ⁇ -caprolactam to 200 ppm or less by bringing nylon 6-based polyamide into contact with water.
- the resin composition of the present invention is excellent in long-run moldability because the amount of ⁇ -caprolactam which is a residual monomer of nylon 6-based polyamide is reduced. According to the production method of the present invention, the resin composition of the present invention having excellent long-run moldability can be efficiently produced.
- the method for improving the long run moldability of the present invention is useful because it can be achieved by a simple method such as a water washing treatment of the resin composition or nylon 6-based polyamide which is a component thereof.
- the resin composition of the present invention is characterized in that, in a resin composition containing an EVOH-based resin and a nylon 6-based polyamide, the ⁇ -caprolactam content is 200 ppm or less.
- the EVOH resin used in the present invention is usually a resin obtained by saponifying a copolymer of ethylene and a vinyl ester monomer (ethylene-vinyl ester copolymer), and is a water-insoluble thermoplastic resin. Resin. That is, the EVOH-based resin mainly includes an ethylene structural unit and a vinyl alcohol structural unit, and in some cases includes a slight amount of vinyl ester structural unit remaining without being saponified.
- vinyl ester monomer vinyl acetate is typically used from the viewpoint of market availability and good impurity treatment efficiency during production.
- aliphatic vinyl esters such as vinyl formate, vinyl propionate, vinyl valerate, vinyl butyrate, vinyl isobutyrate, vinyl pivalate, vinyl caprate, vinyl laurate, vinyl stearate, vinyl versatate, benzoic acid, etc.
- Aromatic vinyl esters such as vinyl can be used.
- the vinyl ester monomers include aliphatic vinyl esters usually having 3 to 20 carbon atoms, preferably 4 to 10 carbon atoms, particularly preferably 4 to 7 carbon atoms, and these are usually used alone, but if necessary, A plurality of types may be used at the same time.
- Copolymerization of ethylene and a vinyl ester monomer can be carried out using any known polymerization method such as solution polymerization, suspension polymerization, and emulsion polymerization.
- the solvent used for such copolymerization include usually lower alcohols such as methanol, ethanol, propanol and butanol, ketones such as acetone and methyl ethyl ketone, and methanol is preferably used industrially.
- Saponification of the obtained ethylene-vinyl ester copolymer can also be performed by a known method.
- the catalyst used for saponification include alkali catalysts such as alkali metal hydroxides and alcoholates such as sodium hydroxide, potassium hydroxide, sodium methylate, sodium ethylate, potassium methylate, lithium methylate, and the like, Acid catalysts such as sulfuric acid, hydrochloric acid, nitric acid, metasulfonic acid, zeolite, and cation exchange resin are listed.
- the content of the ethylene structural unit in the EVOH-based resin is a value measured based on ISO 14663, and is usually 20 to 60 mol%, preferably 25 to 50 mol%, particularly preferably 25 to 35 mol%. If the content is too low, gas barrier properties and melt moldability under high humidity conditions tend to be reduced, and conversely if too high, gas barrier properties tend to be reduced.
- the saponification degree of the vinyl ester component in the EVOH-based resin is a value measured based on JIS K6726 (however, the EVOH-based resin is a solution uniformly dissolved in water / methanol solvent), and usually 90 to 100 mol%.
- the amount is preferably 95 to 100 mol%, particularly preferably 99 to 99.9 mol%.
- the melt flow rate (MFR) (210 ° C., load 2,160 g) of the EVOH-based resin is not particularly limited, but is 0.1 to 100 g / 10 minutes, more preferably 0.5 to 50 g / 10 minutes, particularly Is preferably 1 to 30 g / 10 min. If the melt flow rate is too smaller than this range, the inside of the extruder tends to be in a high torque state at the time of molding and the extrusion process tends to be difficult. If it is too large, the appearance of the molded product and the gas barrier Tend to decrease.
- the EVOH resin used in the present invention includes ethylene structural units, vinyl alcohol structural units (including unsaponified vinyl ester structural units), and a range that does not impair the effects of the present invention (for example, 10 mol% or less).
- the structural unit derived from the comonomer shown below may further be included.
- the comonomer include olefins such as propylene, 1-butene and isobutene, and unsaturated acids such as acrylic acid, methacrylic acid, crotonic acid, (anhydrous) phthalic acid, (anhydrous) maleic acid and (anhydrous) itaconic acid.
- acrylamides such as acid salts or quaternary salts thereof, methacrylamide, N-alkyl methacrylamide having 1 to 18 carbon atoms, N, N-dimethylmethacrylamide, 2-methacrylamide propanesulfonic acid or salts thereof, methacrylamide Methacrylamide such as propyldimethylamine or its acid salt or quaternary salt thereof, N-vinyl amide such as N-vinylpyrrolidone, N-vinylformamide, N-vinylacetamide, vinyl cyanide such as acrylonitrile, methacrylonitrile, etc.
- Vinyl ethers such as alkyl vinyl ethers having 1 to 18 carbon atoms, hydroxyalkyl vinyl ethers, alkoxyalkyl vinyl ethers, vinyl halides such as vinyl chloride, vinylidene chloride, vinyl fluoride, vinylidene fluoride, vinyl bromide, vinyl silanes, Allyl acetate, allyl chloride, allyl alcohol, dimethyl allyl alcohol, trimethyl- (3-acrylamido-3-dimethylpropyl) -ammonium chloride, acrylamido-2-methylpropanesulfonic acid, vinyl Ethylene carbonate, ethylene carbonate, and the like.
- vinyl ethers such as alkyl vinyl ethers having 1 to 18 carbon atoms, hydroxyalkyl vinyl ethers, alkoxyalkyl vinyl ethers, vinyl halides such as vinyl chloride, vinylidene chloride, vinyl fluoride, vinylidene fluoride, vinyl bromide, vinyl silanes, Ally
- N-acrylamidomethyltrimethylammonium chloride N-acrylamidoethyltrimethylammonium chloride, N-acrylamidopropyltrimethylammonium chloride, 2-acryloxyethyltrimethylammonium chloride, 2-methacryloxyethyltrimethylammonium chloride, 2-hydroxy-3- Cationic group-containing monomers such as methacryloyloxypropyltrimethylammonium chloride, allyltrimethylammonium chloride, methallyltrimethylammonium chloride, 3-butenetrimethylammonium chloride, dimethyldiallylammonium chloride, diethyldiallylammonium chloride, acetoacetyl group-containing monomers And so on.
- vinyl silanes include vinyl trimethoxysilane, vinylmethyldimethoxysilane, vinyldimethylmethoxysilane, vinyltriethoxysilane, vinylmethyldiethoxysilane, vinyldimethylethoxysilane, vinylisobutyldimethoxysilane, vinylethyldimethoxysilane, vinylmethoxydioxysilane.
- the EVOH-based resin used in the present invention may be an EVOH-based resin that has been “post-modified” such as urethanization, acetalization, cyanoethylation, or oxyalkyleneation.
- EVOH-based resins in which primary hydroxyl groups have been introduced into the side chains by copolymerization are preferred in that secondary moldability such as stretching treatment and vacuum / pressure forming is improved.
- 1) EVOH resin having a side chain 1,2-diol structural unit represented by the formula is preferred.
- R 1 , R 2 , and R 3 each independently represent a hydrogen atom or an organic group
- X represents a single bond or a bonded chain
- R 4 , R 5 , and R 6 represent each Independently represents a hydrogen atom or an organic group.
- the organic group in the 1,2-diol structural unit represented by the general formula (1) is not particularly limited, and examples thereof include a methyl group, an ethyl group, an n-propyl group, an isopropyl group, an n-butyl group, and an isobutyl group.
- saturated hydrocarbon groups such as tert-butyl group, aromatic hydrocarbon groups such as phenyl group and benzyl group, halogen atom, hydroxyl group, acyloxy group, alkoxycarbonyl group, carboxyl group and sulfonic acid group.
- R 1 to R 6 are preferably a saturated hydrocarbon group having 1 to 30 carbon atoms, particularly 1 to 15 carbon atoms, more preferably 1 to 4 carbon atoms, or a hydrogen atom, and most preferably a hydrogen atom. In particular, it is most preferable that R 1 to R 6 are all hydrogen.
- X in the general formula (1) is typically a single bond, but may be a bond chain.
- the bonding chain is not particularly limited, but is a hydrocarbon chain such as alkylene, alkenylene, alkynylene, phenylene, naphthylene or the like (these hydrocarbons may be substituted with a halogen atom such as a fluorine atom, a chlorine atom, or a bromine atom).
- R is independently an arbitrary substituent, preferably a hydrogen atom or an alkyl group, and m is a natural number, usually 1 to 30, preferably 1 to 15, and more preferably 1 to 10.
- —CH 2 OCH 2 — and a hydrocarbon chain having 1 to 10 carbon atoms are preferable, and a hydrocarbon chain having 1 to 6 carbon atoms, particularly 1 carbon atom, is preferable in terms of stability during production or use. It is preferable that
- the content is usually 0.1 to 20 mol%, further 0.1 to 15 mol%, particularly 0.1 to 0.1 mol%.
- the thing of 10 mol% is preferable.
- the most preferred structure is such that R 1 to R 6 are all hydrogen atoms and X is a single bond. That is, the structural unit represented by the following structural formula (1a) is most preferable.
- EVOH resin containing a 1,2-diol structural unit represented by the general formula (1) or (1a) depending on the type of monomer used for producing the EVOH resin, the following monomers or The saponification product can remain.
- the remaining monomer or saponified product thereof include 3,4-diol-1-butene, 3,4-diacyloxy-1-butene, 3-acyloxy-4-ol-1-butene, and 4-acyloxy-3-ol.
- nylon 6-based polyamide used in the present invention means a polyamide having a structural unit derived from ⁇ -caprolactam as a structural unit of a polymer molecule.
- Such nylon 6-based polyamides include ⁇ -caprolactam homopolymers, copolymers of ⁇ -caprolactam and other lactams, or combinations of ⁇ -caprolactam with other diamines and dicarboxylic acids (copolymer nylon 6).
- it is a homopolymer of ⁇ -caprolactam from the viewpoint of retort resistance to hot water treatment.
- the homopolymer of ⁇ -caprolactam is typically nylon 6.
- Nylon 6 which is a homopolymer of ⁇ -caprolactam is synthesized by ring-opening polymerization, anionic polymerization or the like of ⁇ -caprolactam.
- copolymer nylon 6 examples include a copolymerized polyamide (6/66 nylon) composed of ⁇ -caprolactam, hexamethylenediamine and adipic acid, and a condensation polymer of ⁇ -caprolactam and ⁇ -laurolactam (6/12 nylon). , ⁇ -caprolactam, hexamethylenediamine, adipic acid and ⁇ -laurolactam copolymer polyamide (6/66/12 nylon).
- the polyamide polymerization method is not particularly limited, and any known method such as hot melt polycondensation, lactam ring-opening polymerization, or solution polymerization can be used. Further, a monobasic acid such as acetic acid or benzoic acid, or a monoacid base such as hexylamine or aniline can be added as a molecular weight regulator during the polymerization. Further, if necessary, sodium phosphite, sodium hypophosphite, phosphorous acid, hypophosphorous acid, a heat stabilizer represented by hindered phenol, and a polymerization additive can be added.
- a monobasic acid such as acetic acid or benzoic acid
- a monoacid base such as hexylamine or aniline
- sodium phosphite, sodium hypophosphite, phosphorous acid, hypophosphorous acid, a heat stabilizer represented by hindered phenol, and a polymerization additive can be added.
- nylon 6-based polyamides may be sealed with carboxylic acid or amine.
- carboxylic acid having 6 to 22 carbon atoms or an amine.
- carboxylic acid used for sealing include aliphatic monocarboxylic acids such as caproic acid, caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, and behenic acid.
- amines used for sealing include aliphatic primary amines such as hexylamine, octylamine, decylamine, laurylamine, myristylamine, palmitylamine, stearylamine, and behenylamine, and aliphatic diamines such as hexamethylenediamine. And aromatic diamines such as metaxylenediamine.
- the relative viscosity of the nylon 6-based polyamide measured according to JIS K6810 is not particularly limited, but a relative viscosity of 2.0 to 6.5 is preferably used with a relative viscosity measured at 98% sulfuric acid concentration of 1% and a temperature of 25 ° C. It is done. If the relative viscosity is too low, the strength of the molded product tends to be impaired, and if it is too high, the injection weld strength tends to decrease.
- the relative viscosity of the nylon 6-based polyamide is more preferably 2.2 to 3.5. A plurality of nylon 6-based polyamides having different relative viscosities can be used.
- Nylon 6-based polyamides as described above usually contain ⁇ -caprolactam as a residual monomer. Although the content varies depending on the type and grade of nylon 6-based polyamide, commercially available nylon 6-based polyamide contains 5000 ppm or more of ⁇ -caprolactam as a residual monomer. In the resin composition of the present invention, the amount of residual ⁇ -caprolactam contained in the nylon 6-based polyamide conventionally used in the film field is reduced by the ⁇ -caprolactam amount reduction treatment described later.
- the content of the nylon 6-based polyamide in the resin composition can be appropriately selected according to the desired physical properties of the resin composition.
- the weight ratio of EVOH-based resin to nylon 6-based polyamide is 50:50 to 99: 1, preferably 60:40 to 97: 3, more preferably 70:30 to 95: 5, and particularly preferably 70:30 to 90:10. If the content ratio of the nylon 6-based polyamide is too high, the content ratio of the EVOH-based resin is relatively reduced, so that the gas barrier property tends to decrease. If the content ratio is too low, the EVOH-based resin after the hot water treatment There is a tendency that suppression of elution is insufficient. Further, when the content of nylon 6-based polyamide is increased, the long run moldability tends to decrease.
- the resin composition of the present invention may contain ⁇ -caprolactam as a residual monomer derived from nylon 6-based polyamide, but is characterized in that its content is 200 ppm or less. Preferably it is 150 ppm or less, More preferably, it is 100 ppm or less.
- the lower limit is preferably as small as possible, but the lower limit is usually about 10 ppm from the viewpoint of production efficiency.
- the resin composition pellets usually have a water content of about 0.1 to 0.2% by weight.
- a resin composition containing an EVOH-based resin and a nylon 6-based polyamide When melt-kneading and melt-molding a resin composition containing an EVOH-based resin and a nylon 6-based polyamide, high temperature and shearing force are applied to the resin composition, and therefore ⁇ -caprolactam is contained in the resin composition.
- the carboxyl group (—COOH) and the amino group (—NH 2 ) which are hydrolyzed by the water derived from the raw materials and the water present in the resin composition as described above, are melted and kneaded during the EVOH system. It is presumed that it reacts with the hydroxyl group (—OH) of the resin to easily form a crosslinked structure that causes thickening.
- the resin composition pellets are produced, if the resin composition absorbs moisture due to being left under high humidity conditions or being left in the air for a long time, the effect of thickening by ⁇ -caprolactam Is likely to appear.
- the tendency of thickening is suppressed by reducing ⁇ -caprolactam which is considered to be the cause. Therefore, when the resin composition retains a small amount of moisture as described above, the effect of the present invention is There is a tendency to be obtained more effectively.
- the resin composition of the present invention may contain a thermoplastic resin other than EVOH-based resin and nylon 6-based polyamide as long as it does not impair the gist of the present invention (for example, 30% by weight or less).
- a thermoplastic resin other than EVOH-based resin and nylon 6-based polyamide as long as it does not impair the gist of the present invention (for example, 30% by weight or less).
- polyamide resins other than nylon 6 polyamide linear low density polyethylene, low density polyethylene, ultra low density polyethylene, medium density polyethylene, high density polyethylene, and other polyethylenes, polypropylene, ethylene-propylene (Block and random) copolymers, propylene- ⁇ -olefin ( ⁇ -olefins having 4 to 20 carbon atoms) copolymers, polyolefins such as polybutene and polypentene, and these polyolefins are grafted with an unsaturated carboxylic acid or an ester thereof.
- Modified grafted polyolefins ionomers, ethylene-vinyl acetate copolymers, ethylene-acrylic acid copolymers, ethylene-acrylic acid ester copolymers, polyester resins, polyvinyl chloride, polyvinylidene chloride, acrylic resins, Po Examples include restyrene, vinyl ester resins, polyester elastomers, polyurethane elastomers, halogenated polyolefins such as chlorinated polyethylene and chlorinated polypropylene, aromatic or aliphatic polyketones, and polyalcohols obtained by reducing them.
- additives In the resin composition of the present invention, known additives can be appropriately blended in addition to the above components within a range that does not impair the spirit of the present invention (for example, 5% by weight or less). Specific examples of such additives include saturated aliphatic amides (such as stearic acid amide), unsaturated fatty acid amides (such as oleic acid amide), bis fatty acid amides (such as ethylene bisstearic acid amide), and fatty acid metals.
- saturated aliphatic amides such as stearic acid amide
- unsaturated fatty acid amides such as oleic acid amide
- bis fatty acid amides such as ethylene bisstearic acid amide
- fatty acid metals such as ethylene bisstearic acid amide
- Lubricants such as salts (eg, calcium stearate, magnesium stearate), low molecular weight polyolefins (eg, low molecular weight polyethylene having a molecular weight of about 500 to 10,000, or low molecular weight polypropylene); inorganic salts (eg, hydrotalcite); plastics Agents (for example, aliphatic polyhydric alcohols such as ethylene glycol, glycerin, hexanediol, etc.); oxygen absorbers (for example, inorganic iron oxides, reduced iron powders or those obtained by adding a water-absorbing substance, electrolyte, etc., Aluminum powder, potassium sulfite, photocatalytic titanium oxide, etc .; organic compounds As an oxygen absorber, ascorbic acid or its fatty acid ester or metal salt, hydroquinone, gallic acid, polyhydric phenols such as hydroxyl group-containing phenol aldehyde resin, bis-salicylaldehyde-imine co
- the resin composition of the present invention includes acids such as acetic acid and phosphoric acid, metal salts thereof such as alkali metals, alkaline earth metals and transition metals, and boric acid as a boron compound.
- acids such as acetic acid and phosphoric acid
- metal salts thereof such as alkali metals, alkaline earth metals and transition metals
- boric acid as a boron compound.
- a metal salt thereof may be added.
- the resin composition of the present invention can be prepared by mixing the above components.
- a mixing method include a melt mixing method and a solution mixing method. Among them, the melt mixing method is preferable from the viewpoint of productivity.
- the mixing order of the EVOH resin and the nylon 6 polyamide is not particularly limited.
- a high-concentration composition (generally called a masterbatch) obtained by blending an EVOH-based resin with an excess amount of nylon 6-based polyamide is blended, and the EVOH-based resin or A method of adding nylon 6-based polyamide, blending, and diluting can be mentioned.
- the apparatus used for melt kneading is not particularly limited, and a known melt kneader can be used. Examples thereof include a kneader ruder, a mixing roll, a Banbury mixer, a plast mill, and an extruder. In the case of an extruder, either a single screw or a twin screw extruder may be used, and a vent suction device, a gear pump device, a screen device, or the like may be provided as necessary.
- the resin temperature in the melt kneading is usually 150 to 300 ° C., preferably 220 to 280 ° C., although it depends on the composition of the resin composition.
- water, alcohol, or a water / alcohol mixed solution can be used as the solvent.
- the alcohol include 1 to 8 carbon atoms such as methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-methyl-1-propanol, 2-butanol, 2-methyl-2-propanol, etc. Is preferably 1 to 5, more preferably 1 to 3, and methanol is particularly preferably used because of its easy availability and low cost.
- the resin composition prepared as described above is usually provided in the form of pellets.
- a conventionally known method that is, a hot cut method in which a molten resin composition is extruded into a strand form from a discharge port, cut in a molten state, and then cooled and solidified to produce a pellet; resin
- the strand cutting system which extrudes the solution or slurry of a composition in a coagulation bath, and cuts the strand of the resin composition obtained by cooling solidification is mentioned.
- the hot cut method may be cut in the atmosphere (air hot cut method), extruded into a cutter installation container filled with cooling water, and cut in cooling water (under water cut method).
- a hot cut system is preferably employed.
- the temperature of the cooling water in the underwater cutting method is a temperature at which the resin composition extruded in the molten state does not solidify (solidify) instantaneously. When it comes into contact with the cooling water before cutting, the temperature of the cooling water is It is preferably ⁇ 20 to 50 ° C., more preferably ⁇ 5 to 30 ° C.
- Cooling water is not limited to water.
- Water / alcohol mixtures aromatic hydrocarbons such as benzene; ketones such as acetone and methyl ethyl ketone; ethers such as dipropyl ether; organic esters such as methyl acetate, ethyl acetate, and methyl propionate it can.
- water or a water / alcohol mixed solution is used because it is easy to handle.
- the water / alcohol (weight ratio) is usually 90/10 to 99/1.
- the alcohol lower alcohols such as methanol, ethanol and propanol, specifically alcohols having 1 to 3 carbon atoms can be used, and methanol is preferably used industrially.
- the shape of the pellet usually depends on the manufacturing method of the pellet, and various shapes such as a columnar shape, a spherical shape, a rugby ball shape, a cube shape, a rectangular parallelepiped shape, and an indefinite shape can be used.
- the size and shape of the pellet can be adjusted by appropriately adjusting the nozzle diameter of the extruder to be used, the number of cutter blades, the number of rotations of the cutter blade, and the like.
- the diameter of the bottom surface is preferably 1 to 10 mm, particularly preferably 1.5 to 4 mm
- the length is preferably 1 to 10 mm, particularly 1.5 to 3 mm, and spherical.
- the diameter is preferably 1 to 10 mm, particularly 2 to 7 mm.
- the resin composition of the present invention has an ⁇ -caprolactam content of 200 ppm or less, preferably 150 ppm or less, more preferably 100 ppm or less.
- ⁇ -caprolactam content of 200 ppm or less, preferably 150 ppm or less, more preferably 100 ppm or less.
- nylon 6-based polyamide contains 5000 ppm or more of ⁇ -caprolactam as a residual monomer, depending on the grade. Therefore, in order to adjust the content of ⁇ -caprolactam in the resin composition to 200 ppm or less, a treatment for reducing the content of ⁇ -caprolactam is required.
- the treatment for reducing the content of ⁇ -caprolactam is not particularly limited, but a contact treatment with water is preferably employed.
- Reasons are that ⁇ -caprolactam is highly soluble in water and can be efficiently removed by washing, and that the resin composition by the reduction treatment of ⁇ -caprolactam can be hardly affected by drying after washing. It is done.
- the ⁇ -caprolactam reduction treatment may be performed at any of the resin composition preparation stage, the resin composition pellet manufacturing stage, and the resin composition pellet stage. That is, the contact treatment with water is preferably performed in any one of the following i) to iv).
- the contact treatment with water is preferably performed in any one of the following i) to iv).
- nylon 6-based polyamide is previously subjected to contact treatment with water and then mixed with EVOH-based resin; a dry blend of EVOH-based resin and nylon 6-based polyamide is subjected to contact treatment with water; A melt kneaded product of EVOH-based resin and nylon 6-based polyamide is subjected to contact treatment with water; subjected to contact treatment with water before supplying pellets of the resin composition to a molding machine; any combination of these For example, it is preferable to perform contact treatment with water.
- Examples of the contact method with water include immersion in water and stirring, circulation of the resin composition (preferably pellets) in water, exposure of the resin composition to running water, or resin composition (preferably pellets). ) By spraying a treatment liquid for cleaning. Further, it is effective to apply vibrations such as ultrasonic waves during immersion, but industrially, a method in which pellets are preferably immersed in water and stirred, or pellets are circulated in water is used.
- the contact time with water is preferably 5 minutes to 48 hours, more preferably 10 minutes to 24 hours, and the temperature of water is preferably 10 to 80 ° C., more preferably 20 to 60 ° C. If the contact time is too short, ⁇ -caprolactam tends to be insufficiently reduced, and if too long, the polyamide tends to hydrolyze. Further, if the temperature of water is too low, ⁇ -caprolactam tends to be insufficiently reduced, and if too high, polyamide tends to be hydrolyzed.
- a container used for the water washing treatment a container such as a plate tower such as a perforated plate tower or a bubble bell tower or a tower-type container such as a packed tower, or a container such as a beaker or a flask can be used.
- the resin composition and water can be contacted in either countercurrent or cocurrent flow, but from the viewpoint of substitution efficiency, it is preferable to contact them in countercurrent.
- containers, such as a beaker and a flask it is preferable to contact water with a stirrer, a stirring blade, etc. for the contact of a resin composition and water.
- drying methods can be employed. For example, fluidized drying in which resin composition pellets are mechanically or stirred and dispersed with hot air, or stationary drying in which resin composition pellets are not subjected to dynamic actions such as stirring and dispersion.
- the dryer for performing fluidized drying include, for example, a cylindrical / grooved stirring dryer, a circular tube dryer, a rotary dryer, a fluidized bed dryer, a vibrating fluidized bed dryer, and a conical rotary dryer.
- examples of the dryer for performing stationary drying include a batch-type box dryer that is a stationary material type, a band dryer that is a material transfer type, a tunnel dryer, and a vertical dryer. It is also possible to combine fluidized drying and stationary drying.
- a heating gas such as air or an inert gas (nitrogen gas, helium gas, argon gas, etc.) is used, and the temperature of the heating gas is set to 40 to 150 ° C. to improve productivity and the EVOH resin. It is preferable in terms of preventing thermal deterioration.
- the drying treatment time is usually from about 15 minutes to 72 hours, although it depends on the water content of the EVOH resin and its treatment amount, from the viewpoint of productivity and prevention of thermal degradation of the EVOH resin.
- the reduction treatment of ⁇ -caprolactam that is, the contact treatment between water and nylon 6-based polyamide is not limited to the case of nylon 6-based polyamide alone.
- the state of pellets It is also possible to do this.
- the resin composition produced as described above contains nylon 6-based polyamide formed from ⁇ -caprolactam as a constituent component, the content of ⁇ -caprolactam as a residual monomer is 200 ppm or less. It is low. For this reason, even in melt extrusion molding performed continuously, an increase in melt viscosity, particularly an increase over time in complex viscosity, is suppressed, and excellent long-run moldability is obtained. In addition, by reducing the amount of ⁇ -caprolactam in the resin composition, even if EVOH resin absorbs moisture during storage of the resin composition pellet, the tendency of the pellet to thicken due to such moisture absorption is suppressed. Can be expected.
- the ratio ( ⁇ (8hr) / ⁇ (5min)) of the complex viscosity ( ⁇ (8hr)) after 8 hours to the complex viscosity ( ⁇ (5min)) after 5 minutes measured at 240 ° C is less than 73 It can be.
- the ratio of the complex viscosity ( ⁇ (6hr)) after 6 hours to the complex viscosity ( ⁇ (20min)) after 20 minutes ( ⁇ (6hr) / ⁇ measured at 240 ° C. (20 min)) can be less than 35, preferably less than 33, more preferably less than 30.
- the complex viscosity of the resin composition usually exhibits a non-Newtonian behavior as shown in FIG. 1, and the rate of increase in viscosity from around 200 minutes increases. Therefore, even if the difference in the ratio is about 1, the difference in viscosity after one week (after 168 hours) becomes large and appears as a large difference with respect to melt moldability.
- the ⁇ -caprolactam content in the resin composition can be 200 ppm, preferably 150 ppm or less, more preferably 100 ppm or less, and long run moldability can be improved.
- the resin composition of the present invention can be pelletized by the above method.
- the diameter of the bottom surface is preferably 1 to 10 mm, particularly preferably 1.5 to 4 mm
- the length is preferably 1 to 10 mm, particularly preferably 1.5 to 3 mm
- the diameter is preferably 1 to 10 mm, particularly 2 to 7 mm.
- the moisture content of such pellets is usually about 0.01 to 1%, preferably 0.05 to 0.5%, particularly preferably 0.05 to 0.3%.
- the content of ⁇ -caprolactam is reduced in the resin composition of the present invention, an increase in the moisture content is important for melt kneading of the resin composition, thickening during melt molding, and further, long run moldability. It does not cause a decline. However, if the water content becomes too high, foaming may occur during pellet production or melt molding, so a low water content is preferable.
- Such moisture content can be measured, for example, by the following method. 10 g of pellets are taken in an aluminum cup, and the weight (C1 + P1) of the aluminum cup containing the aluminum cup alone (weight: C1) and the pellet (weight: P1) is measured. Then, the aluminum cup containing the pellets is subjected to heat treatment at 150 ° C. for 5 hours in a commercially available dryer (“SAFETY OVEN SPH-100” manufactured by Tabai Espec Co., Ltd.) which is not purged with nitrogen and is not evacuated.
- SAFETY OVEN SPH-100 manufactured by Tabai Espec Co., Ltd.
- the resin composition of the present invention contains EVOH-based resin and nylon 6-based polyamide, and is excellent in gas barrier properties. Therefore, it is suitable for food packaging materials, pharmaceutical packaging materials, industrial chemical packaging materials, agricultural chemical packaging materials, and the like. Used. In particular, since it is excellent in retort resistance, it is preferably used after being formed into a film or sheet as a food packaging material or a container such as a bottle or cup.
- the resin composition of the present invention is excellent in long run moldability, extrusion molding and injection molding which are continuous melt molding can be suitably employed. Even if it is continuously melt-molded for a long time, it is possible to operate the molding machine stably, and the resulting molded product is also excellent in appearance because the occurrence of gel-like products is suppressed. Since the product can be manufactured continuously and stably, it is excellent in productivity.
- a melt molding method an extrusion molding method (T-die extrusion, inflation extrusion, blow molding, melt spinning, profile extrusion, etc.) and an injection molding method can be employed.
- the melt molding temperature is usually selected from the range of 150 to 300 ° C. depending on the composition of the resin composition.
- a molded product obtained by molding the resin composition of the present invention alone may be used for various purposes, but it is preferable as a laminate in which other base materials are laminated in order to further increase the strength or provide other functions. Used.
- the laminate examples include those having at least one layer of the resin composition according to the present invention.
- the EVOH resin is provided on at least one surface of the resin composition layer of the present invention via an adhesive resin layer.
- a layer of a thermoplastic resin other than the resin composition of the present invention for example, a polyolefin resin such as polyethylene, a polyamide resin, an acrylic resin, etc. is laminated.
- the lamination of the resin composition layer and the base resin (layer) according to the present invention can be performed by a known method.
- a method of melt extrusion laminating a base resin on a film, sheet or the like of the resin composition of the present invention a method of melt extrusion laminating a resin composition of the present invention on a film or sheet of a base resin; a resin of the present invention Method of co-extrusion of composition and base resin; known adhesives such as organic titanium compounds, isocyanate compounds, polyester compounds, polyurethane compounds, etc. of the resin composition (layer) and base resin (layer) of the present invention
- a method of removing the solvent after coating the solution of the resin composition of the present invention on the base resin film or sheet a method of removing the solvent after coating the solution of the resin composition of the present invention on the base resin film or sheet.
- the co-extrusion method is preferred in consideration of cost and environment.
- the resin composition of the present invention is excellent in long run moldability, a method of co-extrusion with a thermoplastic resin can be suitably employed. Therefore, productivity improvement of the above laminated bodies can be aimed at.
- the complex viscosity (Pa ⁇ s) of the pellet of the resin composition was measured for a predetermined time after the start of applying the shear in a state where shear was applied under the following conditions using a rotary rheometer (manufactured by Anton Paar Co., Ltd., “MCR301”). The complex viscosity was measured. (Measurement condition) Under nitrogen atmosphere, measurement temperature: 240 ° C., strain: 5%, each frequency: 1 rad / sec
- EVOH-based resin As the EVOH-based resin, an EVOH resin having an ethylene content of 29 mol%, a saponification degree of 99.7 mol%, and an MFR of 4 g / 10 min (210 ° C, load of 2160 g) was used.
- Nylon 6-based polyamide “Novamid 1028EN” (nylon 6) manufactured by DSM was used.
- Resin composition No. 1 The nylon 6 was stirred in water at 60 ° C. for 12 hours to reduce ⁇ -caprolactam. After dry blending 10 parts of nylon 6 and 90 parts of EVOH resin that have been reduced by washing with water, they are charged into a feeder and melt-kneaded under the following conditions in a twin-screw extruder having two mixing zones. And then cut with a drum type pelletizer. 1 pellet was obtained.
- the obtained resin composition No. The amount of ⁇ -caprolactam in one pellet was measured based on the above method and found to be 61 ppm.
- Resin composition No. subjected to contact treatment with water 1 indicates that the amount of ⁇ -caprolactam was reduced.
- no. 1 and No. There was little difference between the complex viscosities of 2, but after that, a difference was gradually recognized.
- the 7-day aging change ⁇ 2 is predicted to be close to 3000, whereas the aging change ⁇ 1 is less than 73.
- the time-dependent change ⁇ 2 after 7 days is predicted to be about 2910. Therefore, it can be seen that the long run moldability of the resin composition can be improved by setting the ⁇ -caprolactam content to 200 ppm or less.
- Resin composition pellet No. Table 2 summarizes the complex viscosity and long-run moldability (change rate of complex viscosity with time) of 11-14.
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Abstract
Description
に関する。
このため、EVOH系樹脂及びナイロン6を含有する樹脂組成物のロングラン成形性の改善が求められるようになっている。
トルク型レオメータでの測定は、二軸スクリュでせん断を与えた場合の粘度挙動に対応し、単軸スクリュによる押出機を用いる樹脂組成物の溶融成形時の粘度挙動とは相違するため、トルク変動による粘度挙動の安定性と実際のロングラン成形性では一致しない場合があったのではないかと考えられる。特に、EVOH系樹脂とポリアミド系樹脂とを含有する樹脂組成物では、連続的な溶融成形でネットワーク構造物が発達してゲル化する場合もあるため、粘度挙動はより複雑となることが想定される。
本発明者は、この点について、回転型レオメータを用いる測定であれば、単軸スクリュの押出に近いせん断を与えることができ、ロングラン成形性の判定として有用であるとの結論に達した。
ナイロン6は、通常、水を介してε-カプロラクタムを開環重合させることにより合成される。従って、樹脂組成物に含有されるε-カプロラクタムは、ナイロン6の残留モノマーとしてのε-カプロラクタムである可能性が高い。
i)エチレン-ビニルエステル系共重合体ケン化物とナイロン6系ポリアミドとの混合前;
ii)エチレン-ビニルエステル系共重合体ケン化物とナイロン6系ポリアミドとの混合時;
iii)エチレン-ビニルエステル系共重合体ケン化物とナイロン6系ポリアミドとの混合後;
iv)i)~iii)のいずれか2つ以上の組み合わせ。
本発明のロングラン成形性の改善方法は、樹脂組成物またはその構成成分であるナイロン6系ポリアミドの水洗処理といった簡便な方法で達成することができるので、有用である。
本発明の樹脂組成物は、EVOH系樹脂及びナイロン6系ポリアミドを含有する樹脂組成物において、ε-カプロラクタム含有量を200ppm以下としたところに特徴がある。
〔EVOH系樹脂〕
本発明で用いられるEVOH系樹脂は、通常、エチレンとビニルエステル系モノマーの共重合体(エチレン-ビニルエステル系共重合体)をケン化させることにより得られる樹脂であり、非水溶性の熱可塑性樹脂である。すなわち、EVOH系樹脂は、エチレン構造単位とビニルアルコール構造単位を主とし、場合によってはケン化されずに残存した若干量のビニルエステル構造単位を含むものである。
かかる共重合に用いられる溶媒としては、通常、メタノール、エタノール、プロパノール、ブタノール等の低級アルコールやアセトン、メチルエチルケトン等のケトン類等が挙げられ、工業的には、メタノールが好適に使用される。
ケン化に使用される触媒としては、例えば、水酸化ナトリウム、水酸化カリウム、ナトリウムメチラート、ナトリウムエチラート、カリウムメチラート、リチウムメチラート等のアルカリ金属の水酸化物やアルコラートの如きアルカリ触媒、硫酸、塩酸、硝酸、メタスルフォン酸、ゼオライト、カチオン交換樹脂等の酸触媒が挙げられる。
前記コモノマーとしては、例えば、プロピレン、1-ブテン、イソブテン等のオレフィン類、アクリル酸、メタクリル酸、クロトン酸、(無水)フタル酸、(無水)マレイン酸、(無水)イタコン酸等の不飽和酸類あるいはその塩あるいは炭素数1~18のモノまたはジアルキルエステル類、アクリルアミド、炭素数1~18のN-アルキルアクリルアミド、N,N-ジメチルアクリルアミド、2-アクリルアミドプロパンスルホン酸あるいはその塩、アクリルアミドプロピルジメチルアミンあるいはその酸塩あるいはその4級塩等のアクリルアミド類、メタクリルアミド、炭素数1~18のN-アルキルメタクリルアミド、N,N-ジメチルメタクリルアミド、2-メタクリルアミドプロパンスルホン酸あるいはその塩、メタクリルアミドプロピルジメチルアミンあるいはその酸塩あるいはその4級塩等のメタクリルアミド類、N-ビニルピロリドン、N-ビニルホルムアミド、N-ビニルアセトアミド等のN-ビニルアミド類、アクリルニトリル、メタクリルニトリル等のシアン化ビニル類、炭素数1~18のアルキルビニルエーテル、ヒドロキシアルキルビニルエーテル、アルコキシアルキルビニルエーテル等のビニルエーテル類、塩化ビニル、塩化ビニリデン、フッ化ビニル、フッ化ビニリデン、臭化ビニル等のハロゲン化ビニル類、ビニルシラン類、酢酸アリル、塩化アリル、アリルアルコール、ジメチルアリルアルコール、トリメチル-(3-アクリルアミド-3-ジメチルプロピル)-アンモニウムクロリド、アクリルアミド-2-メチルプロパンスルホン酸、ビニルエチレンカーボネート、エチレンカーボネート等が挙げられる。
さらに、N-アクリルアミドメチルトリメチルアンモニウムクロライド、N-アクリルアミドエチルトリメチルアンモニウムクロライド、N-アクリルアミドプロピルトリメチルアンモニウムクロライド、2-アクリロキシエチルトリメチルアンモニウムクロライド、2-メタクリロキシエチルトリメチルアンモニウムクロライド、2-ヒドロキシ-3-メタクリロイルオキシプロピルトリメチルアンモニウムクロライド、アリルトリメチルアンモニウムクロライド、メタアリルトリメチルアンモニウムクロライド、3-ブテントリメチルアンモニウムクロライド、ジメチルジアリルアンモニウムクロリド、ジエチルジアリルアンモニウムクロライド等のカチオン基含有単量体、アセトアセチル基含有単量体等も挙げられる。
さらにビニルシラン類としては、ビニルトリメトキシシラン、ビニルメチルジメトキシシラン、ビニルジメチルメトキシシラン、ビニルトリエトキシシラン、ビニルメチルジエトキシシラン、ビニルジメチルエトキシシラン、ビニルイソブチルジメトキシシラン、ビニルエチルジメトキシシラン、ビニルメトキシジブトキシシラン、ビニルジメトキシブトキシシラン、ビニルトリブトキシシラン、ビニルメトキシジヘキシロキシシラン、ビニルジメトキシヘキシロキシシラン、ビニルトリヘキシロキシシラン、ビニルメトキシジオクチロキシシラン、ビニルジメトキシオクチロキシシラン、ビニルトリオクチロキシシラン、ビニルメトキシジラウリロキシシラン、ビニルジメトキシラウリロキシシラン、ビニルメトキシジオレイロキシシラン、ビニルジメトキシオレイロキシシラン等を挙げることができる。
以上のような変性物の中でも、共重合によって一級水酸基が側鎖に導入されたEVOH系樹脂は、延伸処理や真空・圧空成形などの二次成形性が良好になる点で好ましく、中でも下記(1)式で表される側鎖1,2-ジオール構造単位を有するEVOH系樹脂が好ましい。
R1~R6は通常炭素数1~30、特には炭素数1~15、さらには炭素数1~4の飽和炭化水素基または水素原子が好ましく、水素原子が最も好ましい。特に、R1~R6がすべて水素であるものが最も好ましい。
本発明で用いるナイロン6系ポリアミドとは、ポリマー分子の構成単位としてε-カプロラクタム由来の構成単位を有するポリアミドを意味する。かかるナイロン6系ポリアミドとしては、ε-カプロラクタムの単独重合体の他、ε-カプロラクタムと他のラクタム、あるいはε-カプロラクタムと他のジアミン及びジカルボン酸の組み合わせとの共重合体(共重合ナイロン6)が含まれ、好ましくは熱水処理に対する耐レトルト性能の点から、ε-カプロラクタムの単独重合体である。
ε-カプロラクタムのホモポリマーであるナイロン6は、ε-カプロラクタムの開環重合、アニオン重合などにより合成される。
ナイロン6系ポリアミドとしては、相対粘度が異なるものを複数用いることができる。
ナイロン6系ポリアミドの含有量比率が高くなりすぎると、相対的にEVOH系樹脂の含有割合が減少するため、ガスバリア性が低下する傾向にあり、低くなりすぎると、熱水処理後のEVOH系樹脂の溶出抑制が不十分となる傾向がある。また、ナイロン6系ポリアミドの含有量が増大すると、ロングラン成形性が低下する傾向があるが、本発明では、ロングラン成形性低下の原因であるε-カプロラクタム量を低減することで、上述のEVOH系樹脂:ナイロン6系ポリアミドの重量比において、ナイロン6系ポリアミドの含有比が増大しても、ロングラン成形性の要求を充足することができる。
本発明の樹脂組成物には、ナイロン6系ポリアミド由来の残留モノマーとしてのε-カプロラクタムが含有され得るが、その含有量が200ppm以下であるところに特徴がある。好ましくは150ppm以下、より好ましくは100ppm以下である。なお、下限としては小さければ小さいほどよいが、生産効率の点から、下限値は、通常10ppm程度である。
すなわち、EVOH系樹脂は水酸基を豊富に有するため、ポリオレフィンやポリスチレン等の他の代表的な熱可塑性樹脂に比べて樹脂中に水分子を保持する傾向がある。EVOH系樹脂及びポリアミドを含有する樹脂組成物のペレットを作成する場合、樹脂組成物を100℃以上の高温で溶融してペレット化して製造されることから、一般に原料樹脂中に存在していた水分は蒸発していると考えられるが、得られる樹脂組成物のペレットは通常0.1~0.2重量%程度の水分を有する。
EVOH系樹脂及びナイロン6系ポリアミドを含有する樹脂組成物の溶融混錬時、溶融成形時には、高温、せん断力が樹脂組成物にかかるため、樹脂組成物中にε-カプロラクタムが含有されていると、上記のような原料由来の水分や樹脂組成物中に存在する水分により加水分解し、生成されたカルボキシル基(-COOH)、アミノ基(-NH2)が、溶融混錬中に、EVOH系樹脂の水酸基(-OH)と反応して、増粘の原因となるような架橋構造を形成しやすくなると推測される。特に、樹脂組成物ペレットの製造後、高湿度条件下で放置されたり、空気中で長期間放置されるなどにより、樹脂組成物が湿分を吸湿した場合、さらにε-カプロラクタムによる増粘の影響が表れやすいと考えられる。
本発明においては、原因と考えられるε-カプロラクタムを低減することにより増粘傾向を抑制しているので、樹脂組成物が上述のように水分を少量保持していた場合に、本発明の効果がより効果的に得られる傾向がある。
本発明の樹脂組成物は、EVOH系樹脂、ナイロン6系ポリアミド以外の熱可塑性樹脂を、本発明の趣旨を阻害しない範囲(例えば30重量%以下)であれば含有してもよい。
具体的には、例えば、ナイロン6系ポリアミド以外のポリアミド系樹脂、直鎖状低密度ポリエチレン、低密度ポリエチレン、超低密度ポリエチレン、中密度ポリエチレン、高密度ポリエチレン等のポリエチレン類、ポリプロピレン、エチレン-プロピレン(ブロックおよびランダム)共重合体、プロピレン-α-オレフィン(炭素数4~20のα-オレフィン)共重合体、ポリブテン、ポリペンテン等のポリオレフィン類、これらポリオレフィン類を不飽和カルボン酸又はそのエステルでグラフト変性したグラフト化ポリオレフィン類、アイオノマー、エチレン-酢酸ビニル共重合体、エチレン-アクリル酸共重合体、エチレン-アクリル酸エステル共重合体、ポリエステル系樹脂、ポリ塩化ビニル、ポリ塩化ビニリデン、アクリル系樹脂、ポリスチレン、ビニルエステル系樹脂、ポリエステルエラストマー、ポリウレタンエラストマー、塩素化ポリエチレン、塩素化ポリプロピレン等のハロゲン化ポリオレフィン、芳香族または脂肪族ポリケトン、更にこれらを還元して得られるポリアルコール類等が挙げられる。
本発明の樹脂組成物は、本発明の趣旨を阻害しない範囲(例えば5重量%以下)において、上記成分以外に公知の添加剤を適宜配合することができる。
かかる添加剤としては、具体的には、飽和脂肪族アミド(例えばステアリン酸アミド等)、不飽和脂肪酸アミド(例えばオレイン酸アミド等)、ビス脂肪酸アミド(例えばエチレンビスステアリン酸アミド等)、脂肪酸金属塩(例えばステアリン酸カルシウム、ステアリン酸マグネシウム等)、低分子量ポリオレフィン(例えば分子量500~10,000程度の低分子量ポリエチレン、又は低分子量ポリプロピレン等)などの滑剤;無機塩(例えばハイドロタルサイト等);可塑剤(例えばエチレングリコール、グリセリン、ヘキサンジオール等の脂肪族多価アルコールなど);酸素吸収剤(例えば無機系酸素吸収剤として、還元鉄粉類又はこれに吸水性物質や電解質等を加えたもの、アルミニウム粉、亜硫酸カリウム、光触媒酸化チタン等;有機化合物系酸素吸収剤として、アスコルビン酸又はその脂肪酸エステルや金属塩、ハイドロキノン、没食子酸、水酸基含有フェノールアルデヒド樹脂等の多価フェノール類、ビス-サリチルアルデヒド-イミンコバルト、テトラエチレンペンタミンコバルト、コバルト-シッフ塩基錯体、ポルフィリン、大環状ポリアミン錯体、ポリエチレンイミン-コバルト錯体等の含窒素化合物と、遷移金属との配位結合体、テルペン化合物、アミノ酸類とヒドロキシル基含有還元性物質の反応物、トリフェニルメチル化合物等;高分子系酸素吸収剤として、窒素含有樹脂と遷移金属との配位結合体(例えばMXDナイロンとコバルトの組合せ)、三級水素含有樹脂と遷移金属とのブレンド物(例えばポリプロピレンとコバルトの組合せ)、炭素-炭素不飽和結合含有樹脂と遷移金属とのブレンド物(例えばポリブタジエンとコバルトの組合せ));光酸化崩壊性樹脂(例えばポリケトン);アントラキノン重合体(例えばポリビニルアントラキノン)又はこれらの配合物に、光開始剤(ベンゾフェノン等),過酸化物補足剤(市販の酸化防止剤等),消臭剤(活性炭等)を添加したものなど;熱安定剤;光安定剤;酸化防止剤;紫外線吸収剤;着色剤;帯電防止剤;界面活性剤;抗菌剤;アンチブロッキング剤;スリップ剤;充填材(例えば無機フィラー等)等が挙げられる。
さらには、本発明の目的を阻害しない範囲において、本発明の樹脂組成物に酢酸、リン酸等の酸類やそのアルカリ金属、アルカリ土類金属、遷移金属等の金属塩、ホウ素化合物としてのホウ酸またはその金属塩を添加してもよい。これらは樹脂の熱安定性を向上させることができる。
本発明の樹脂組成物は、以上のような成分を混合することによって調製できる。かかる混合方法としては、溶融混合法、溶液混合法等が挙げられる。中でも生産性の点からは溶融混合法が好ましい。
EVOH系樹脂とナイロン6系ポリアミドを同時に溶融混練する方法;EVOH系樹脂(又はナイロン6系ポリアミド)を予め溶融したところに、ナイロン6系ポリアミド(又はEVOH系樹脂)を配合し、溶融混練する方法;EVOH系樹脂にナイロン6系ポリアミドを過剰量含有させてブレンドした高濃度組成物(一般にマスターバッチとも呼ばれる)を製造しておき、かかる組成物に、所望の混合比率にしたがって、EVOH系樹脂又はナイロン6系ポリアミドを加えてブレンドし、希釈する方法が挙げられる。
ペレットの製造方法としては、従来より公知の方法、すなわち、溶融状態の樹脂組成物を吐出口からストランド状に押出し、溶融状態でカットした後、冷却固化してペレットを作製するホットカット方式;樹脂組成物の溶液又はスラリーを凝固浴中に押出し、冷却固化により得られた樹脂組成物のストランドをカットするストランドカット方式が挙げられる。
溶融混錬法により樹脂組成物を調製する場合、ホットカット方式が好ましく採用される。
ペレットのサイズ、形状は、使用する押出機のノズルの口径、カッター刃の枚数、カッター刃の回転数等を適宜調整することにより、調整することができる。
本発明の樹脂組成物は、ε-カプロラクタムの含有量が200ppm以下、好ましくは150ppm以下、より好ましくは100ppm以下である。
一般に市販のナイロン6系ポリアミドでは、グレードにもよるが、残留モノマーとしてε-カプロラクタムが5000ppm以上含有されている。従って、樹脂組成物におけるε-カプロラクタムの含有量を200ppm以下に調整するためには、ε-カプロラクタムの含有量を低減するための処理が必要となる。
i)エチレン-ビニルエステル系共重合体ケン化物とナイロン6系ポリアミドとの混合前;
ii)エチレン-ビニルエステル系共重合体ケン化物とナイロン6系ポリアミドとの混合時;
iii)エチレン-ビニルエステル系共重合体ケン化物とナイロン6系ポリアミドとの混合後;
iv)i)~iii)のいずれか2つ以上の組み合わせ。
具体的には、予めナイロン6系ポリアミドについて、水との接触処理を施した後、EVOH系樹脂と混合する;EVOH系樹脂とナイロン6系ポリアミドのドライブレンド物を水との接触処理に供する;EVOH系樹脂とナイロン6系ポリアミドの溶融混錬物を、水との接触処理に供する;樹脂組成物のペレットを成形機に供給する前に水との接触処理に供する;これらのいずれかの組み合わせなどにより、水との接触処理を行うことが好ましい。
一方、EVOH系樹脂とナイロン6系ポリアミドの混合物の状態で行う場合には、EVOH系樹脂に含まれる残留モノマー等の不純物の低減処理も図ることができ、ひいては最終成形品の品質向上に役立つという点で好ましい。
また、樹脂組成物中のε-カプロラクタム量を低減することで、たとえ樹脂組成物ペレットの保存中にEVOH樹脂が吸湿するようなことがあっても、かかる吸湿によるペレットの増粘傾向が抑制されることを期待できる。
従って、上記比の差が1程度であっても、1週間後(168時間後)の粘度差は大きくなり、溶融成形性に関して大きな差となって現れる。
アルミカップにペレットを10gとり、アルミカップ単体(重量:C1)、ペレット(重量:P1)を入れたアルミカップの重量(C1+P1)をそれぞれ測定する。そして、ペレットを入れたアルミカップを窒素置換、真空引きがなされていない市販の乾燥機(タバイエスペック株式会社製『SAFETY OVEN SPH-100』)にて150℃、5時間加熱処理を行なう。加熱処理後は乾燥機よりペレットを入れたアルミカップを取り出し、乾燥剤の入ったデシケーター内にて30分間静置してペレットの温度を室温まで戻し、加熱処理後のペレット(重量:P2)を入れたアルミカップの重量(C1+P2)を測定し、下記数式により、含水率(重量%)を算出する。
本発明の樹脂組成物は、EVOH系樹脂とナイロン6系ポリアミドを含有しており、ガスバリア性に優れているので、食品包装材料、医薬品包装材料、工業薬品包装材料、農薬包装材料等として好適に用いられる。特に耐レトルト性に優れているので、食品包装材料としてのフィルムやシート或いはボトルやカップ等の容器に成形されて利用されることが好ましい。
かかる溶融成形方法としては、押出成形法(T-ダイ押出、インフレーション押出、ブロー成形、溶融紡糸、異型押出等)、射出成形法を採用することができる。溶融成形温度は、樹脂組成物の組成に応じて、通常150~300℃の範囲から選択される。
尚、例中「部」とあるのは、重量基準を意味する。
樹脂組成物のペレットをヘキサフルオロイソプロパノールにて溶解した後、メタノールに再沈殿させ、ポリマーを除去し、高速液体クロマトグラフ分析により、ε-カプロラクタムを定量した。
尚、高速液体クトマトグラフ分析には、装置:日本分光社製 PU- 2085Plus 型、カラム:Imtakt製Unison UK-C18(4.6mmID×150mm,3m)を用いた。
樹脂組成物のペレットの複素粘度(Pa・s)を、回転型レオメータ(アントンパール社製、『MCR301』)を用い、下記条件にてせん断を与えた状態で、せん断付与開始から所定時間後の複素粘度を測定した。
(測定条件)
窒素雰囲気下、測定温度:240℃、歪み:5%、各周波数:1rad/sec
(1)EVOH系樹脂
EVOH系樹脂として、エチレン含有量29モル%、ケン化度99.7モル%、MFR4g/10分(210℃、荷重2160g)のEVOH樹脂を用いた。
DSM社製「ノバミッド1028EN」(ナイロン6)を用いた。
上記ナイロン6を、60℃の水中で12時間撹拌することにより、ε-カプロラクタムの低減処理を行った。水洗による低減処理を行ったナイロン6の10部とEVOH系樹脂90部とをドライブレンドした後、フィーダーに仕込み、ミキシングゾーンを2箇所有する2軸押出機にて下記条件で溶融混練し、ストランド状に押出してドラム式ペレタイザーで切断し、樹脂組成物No.1のペレットを得た。
・2軸押出機:直径32mm
・押出機設定温度:
C2/C3/C4/C5/C6/C7/C8/C9/C10/C11/C12/C13/C14/C15/C16/H/D=120/180/180/200/230/230/以降220 ℃
この樹脂組成物No.1のペレットについて、上記複素粘度の測定方法に基づき、5分間隔で480分間、複素粘度を測定した。480分間の複素粘度変化を図1(点線)に示す。得られた粘度曲線から、7日(168時間)後の複素粘度を外挿により求め(図1の一点鎖線)、さらに下記式で示す経時変化率△1、△2を算出した。得られた結果を表1に示す。
経時変化率△1=η(8hr)/η(5min)
経時変化率△2=η(7day)/η(5min)
経時変化率が大きいほど、ロングラン成形性が劣ることを意味する。
洗浄処理を行わなかったナイロン6を用いた以外は、No.1と同様にして樹脂組成物のペレットを製造した。得られたペレットのε-カプロラクタム量を測定したところ、240ppmであった。このペレットについて、複素粘度を測定し、ロングラン成形性を評価した。480分間の複素粘度変化を図1(実線)に示す。得られた粘度曲線から、7日後の複素粘度を外挿により求め(図1の二点鎖線)、さらに経時変化率△1、△2を算出した。得られた結果を表1に示す。
そして、図1からわかるように、せん断付与から約200分後までは、No.1とNo.2の複素粘度はほとんど差異が認められなかったが、その後、徐々に差が認められるようになった。
経時変化△1が73以上であるNo.2の樹脂組成物のペレットでは、7日の経時変化△2は3000近くになると予測されるのに対して、経時変化△1が73未満のNo.1の樹脂組成物のペレットでは、7日後の経時変化△2は2910程度となることが予測される。
したがって、ε-カプロラクタム含有量を200ppm以下とすることで、樹脂組成物のロングラン成形性を改善できることがわかる。
(1)ペレットNo.11
上記で製造した樹脂組成物No.1のペレット(ペレットNo.11)について、上記複素粘度の測定方法に基づき、せん断付与開始から20分後、6時間後の複素粘度を測定した。測定結果、及び下記式により、複素粘度の経時変化率△3を求めた。
経時変化率△3=η(6hr)/η(20min)
上記で製造した樹脂組成物No.2のペレット(ペレットNo.12)について、No.11と同様にして、せん断付与開始から20分後、6時間後の複素粘度を測定し、さらに上記で定義される複素粘度の経時変化率△3を求めた。
かかる測定に用いた樹脂組成物ペレットNo.12の含水率は、0.5重量%であった。No.12とNo.2とは、同一の組成を有する樹脂組成物を原料として作製されたペレットであるが、湿分が高めになっていた。
上記ナイロン6のε-カプロラクタムの低減処理について、水洗処理温度を60℃、水中での撹拌時間を4時間に変更した。低減処理後のナイロン6の10部とEVOH系樹脂90部とをドライブレンドして得られた樹脂組成物を用いて、No.1と同様にペレット化した(ペレットNo.13)。
こうして得られたペレットNo.13中のε-カプロラクタム量を上記方法に基づいて測定したところ、120ppmであった。この樹脂組成物ペレットNo.13について、No.11と同様にして、複素粘度を測定し、さらに上記で定義される複素粘度の経時変化率△3を求めた。
上記ナイロン6のε-カプロラクタムの低減処理について、水洗処理温度を20℃、水中での撹拌時間を4時間に変更した。かかる低減処理を行ったナイロン6の10部とEVOH系樹脂90部とをドライブレンドして得られた樹脂組成物を用いて、No.1と同様にペレット化した(ペレットNo.14)。
得られたペレットNo.14中のε-カプロラクタム量を上記方法に基づいて測定したところ、145ppmであった。このペレットNo.14について、No.11と同様にして、複素粘度を測定し、さらに上記で定義される複素粘度の経時変化率△3を求めた。
従って、樹脂組成物ペレット中のε-カプロラクタム量を低減すること、すなわち200ppm以下、好ましくは100ppm以下に低減することは、ロングラン成形性の改善に有効であることがわかる。
Claims (8)
- エチレン-ビニルエステル系共重合体ケン化物及びナイロン6系ポリアミドを含有する樹脂組成物において、
ε-カプロラクタムの含有量が200ppm以下であることを特徴とする樹脂組成物。 - エチレン-ビニルエステル系共重合体ケン化物及びナイロン6系ポリアミドを含有する樹脂組成物において、
ε-カプロラクタムの含有量が100ppm以下であることを特徴とする樹脂組成物。 - 前記ナイロン6系ポリアミドは、ナイロン6であることを特徴とする請求項1又は2に記載の樹脂組成物。
- エチレン-ビニルエステル系共重合体ケン化物とナイロン6系ポリアミドの混合重量比率(エチレン-ビニルエステル系共重合体ケン化物:ナイロン6系ポリアミド)は、50:50~99:1であることを特徴とする請求項1~3のいずれか1項に記載の樹脂組成物。
- エチレン-ビニルエステル系共重合体ケン化物及びナイロン6系ポリアミドを含有する樹脂組成物ペレットの製造方法であって、
前記ナイロン6系ポリアミドが水と接触する工程を含むことを特徴とする樹脂組成物の製造方法。 - 前記接触工程は、下記i)~iv)のいずれかにおいて行われることを特徴とする請求項5に記載の樹脂組成物の製造方法。
i)エチレン-ビニルエステル系共重合体ケン化物とナイロン6系ポリアミドとの混合前;
ii)エチレン-ビニルエステル系共重合体ケン化物とナイロン6系ポリアミドとの混合時;
iii)エチレン-ビニルエステル系共重合体ケン化物とナイロン6系ポリアミドとの混合後;
iv)i)~iii)のいずれか2つ以上の組み合わせ。 - 前記接触工程により、樹脂組成物中のε-カプロラクタムの含有量を200ppm以下とすることを特徴とする請求項5または6に記載の樹脂組成物の製造方法。
- エチレン-ビニルエステル系共重合体ケン化物及びナイロン6系ポリアミドを含有する樹脂組成物ペレットのロングラン成形性の改善方法であって、
前記ナイロン6系ポリアミドと水を接触させることにより、前記樹脂組成物ペレット中のε-カプロラクタムの含有量を200ppm以下とする改善方法。
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EP (1) | EP3392304B1 (ja) |
JP (1) | JP6770686B2 (ja) |
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2016
- 2016-12-02 WO PCT/JP2016/085897 patent/WO2017104444A1/ja active Application Filing
- 2016-12-02 JP JP2016574473A patent/JP6770686B2/ja active Active
- 2016-12-02 CN CN201680072640.0A patent/CN108368320B/zh active Active
- 2016-12-02 EP EP16875427.3A patent/EP3392304B1/en active Active
- 2016-12-13 TW TW105141126A patent/TWI706985B/zh active
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2018
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JPS62106944A (ja) * | 1985-11-05 | 1987-05-18 | Nippon Synthetic Chem Ind Co Ltd:The | 樹脂組成物 |
JPH09188758A (ja) * | 1995-11-06 | 1997-07-22 | Mitsubishi Chem Corp | カプロラクタムよりポリアミド樹脂を製造する方法 |
JP2004010902A (ja) * | 1995-11-06 | 2004-01-15 | Mitsubishi Chemicals Corp | カプロラクタムよりポリアミド樹脂を製造する方法 |
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CN108368320A (zh) | 2018-08-03 |
TW201731943A (zh) | 2017-09-16 |
US11512197B2 (en) | 2022-11-29 |
US20180291192A1 (en) | 2018-10-11 |
EP3392304A4 (en) | 2019-08-14 |
CN108368320B (zh) | 2021-04-23 |
JP6770686B2 (ja) | 2020-10-21 |
JPWO2017104444A1 (ja) | 2018-10-04 |
EP3392304A1 (en) | 2018-10-24 |
TWI706985B (zh) | 2020-10-11 |
EP3392304B1 (en) | 2024-03-06 |
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