WO2020050351A1 - ポリエステルフィルムおよびその製造方法 - Google Patents
ポリエステルフィルムおよびその製造方法 Download PDFInfo
- Publication number
- WO2020050351A1 WO2020050351A1 PCT/JP2019/034909 JP2019034909W WO2020050351A1 WO 2020050351 A1 WO2020050351 A1 WO 2020050351A1 JP 2019034909 W JP2019034909 W JP 2019034909W WO 2020050351 A1 WO2020050351 A1 WO 2020050351A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- film
- polyester film
- polyester
- stretching
- metal plate
- Prior art date
Links
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
- B29C55/04—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique
- B29C55/06—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique parallel with the direction of feed
- B29C55/065—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique parallel with the direction of feed in several stretching steps
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
- B29C55/10—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial
- B29C55/12—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial
- B29C55/14—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial successively
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
- B29C55/10—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial
- B29C55/12—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial
- B29C55/14—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial successively
- B29C55/143—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial successively firstly parallel to the direction of feed and then transversely thereto
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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Definitions
- the present invention relates to a polyester film containing a polybutylene terephthalate resin and a polyethylene terephthalate resin, and a method for producing the same.
- a solvent-type paint mainly composed of a thermosetting resin has been applied to the inner and outer surfaces of a metal can for the purpose of preventing corrosion.
- the solvent type paint requires heating at a high temperature in order to form a coating film, and a large amount of solvent is generated at that time, so that there is a problem in terms of work safety and environment. Therefore, recently, as a corrosion prevention method using no solvent, coating of a metal plate with a thermoplastic resin has been proposed.
- the thermoplastic resins polyesters are particularly excellent in processability, heat resistance, and the like, and thus polyesters coated on metal plates are being developed.
- thermoplastic resin film As a method of coating the thermoplastic resin on the metal plate, a method of melting the thermoplastic resin and directly extruding it onto the metal plate, or directly pressing the thermoplastic resin film or through an adhesive, and thermocompression bonding to the metal plate There is a way. Above all, a method using a thermoplastic resin film is considered to be an effective method because the handling of the resin is easy, the workability is excellent, and the uniformity of the resin film thickness is also excellent. In addition, since the method using an adhesive has environmental and cost problems, a method of directly thermocompression bonding a film is advantageous and attracts attention.
- Metal cans coated with a thermoplastic resin film are manufactured by forming a laminated metal plate obtained by laminating a thermoplastic resin film on a metal plate such as a steel plate or an aluminum plate (including ones that have been subjected to surface treatment such as plating). You.
- Thermoplastic resin films used in such applications are required to have good thermal lamination properties with a metal plate, and also have excellent moldability of a can, that is, the film can be formed at the time of can molding. There is a demand for no occurrence of peeling, cracks, pinholes and the like.
- the outer film of the can after molding is required to be excellent in printability and transparency.
- the inner film of the metal does not lose its adhesion to the inner surface of the metal can, and the performance of coating the inner surface of the metal can does not decrease. It is required that the contents do not come into contact with the metal of the can and have excellent flavor and fragrance retention properties.
- polyester film for metal plate lamination for the purpose of imparting heat laminating properties and improving the moldability of the can, other components are mixed with the polyester, or the polyester is copolymerized.
- a method has been proposed.
- the present inventors have previously made polybutylene terephthalate (PBT) or 90 to 45% by mass of a polyester (A) mainly containing the same, and polyethylene terephthalate (PET) or a polyester (B) 10 mainly containing the same.
- PET polyethylene terephthalate
- B polyester
- a biaxially stretched film comprising up to 55% by mass has been proposed (Patent Documents 1 and 2).
- the films proposed therein have a high degree of crystallinity, and the laminated metal plate obtained by heat laminating the metal plate has excellent workability. In addition, the film does not become brittle even after retort sterilization and storage for a long time.
- a method of thermally laminating a polyester film to a metal plate a method of pressing a metal plate, which has been preheated to 160 to 250 ° C. in advance, and a film by pressure bonding with a roll, and then cooling to room temperature is used. is there.
- Patent Literature 3 discloses a stretched film suitable for being attached to a metal foil and cold-formed.
- the stretched film disclosed in Patent Document 3 has a large dry heat shrinkage when exposed to a high temperature of about 200 ° C., or has a poor balance of dry heat shrinkage in each direction. In some cases, it did not have the physical properties necessary for preventing corrosion of the inner and outer surfaces of the can.
- the polyester film used for the inner and outer surfaces of the metal can be thermally laminated in a wide temperature range from a relatively low temperature to a high temperature, and a laminated metal plate having excellent adhesion between the metal plate and the film can be obtained.
- it is required to have excellent processability (can-making properties) into cans, excellent transparency after can-making, and the ability to maintain excellent adhesion and coatability even after retort sterilization and long-term storage. Have been.
- the present invention solves the above-mentioned problems, can perform heat lamination with a metal plate in a wide temperature range, has excellent adhesion to a metal plate, and has good moldability (can-making properties).
- Another object of the present invention is to provide a polyester film which is excellent in transparency after forming a can and has excellent adhesion to a metal plate and coverage even after retort sterilization treatment and long-term storage.
- the present inventors have conducted intensive studies in order to solve the above-mentioned problems, and as a result, identified two or more polyesters having different crystallinities, that is, a polyester (A) mainly composed of polybutylene terephthalate and a polyester (B) mainly composed of polyethylene terephthalate.
- a polyester film obtained by stretching an unstretched sheet containing a specific ratio at a specific method and magnification can be heat-laminated with a metal plate in a wide temperature range, and has excellent adhesion to the metal plate.
- it has excellent moldability (canning properties) into cans, transparency after can molding, and excellent adhesion and covering properties to metal plates even after retort sterilization and long-term storage.
- the invention has been reached.
- the gist of the present invention is as follows.
- the mass ratio (A / B) of the polyesters (A) and (B) is 70/30 to 55/45
- An arbitrary direction on the film surface is set to 0 °
- Dry heat shrinkage (B) by heat treatment at 200 ° C. for 15 minutes in each of the four directions is 35% or less, and the difference between the maximum and minimum values of the dry heat shrinkage is 5% or less
- the polyester film wherein the thickness unevenness calculated by the following formula in the four directions is 10% or less.
- Thickness unevenness (%) ( Tmax ⁇ Tmin ) / Tave ⁇ 100
- T max maximum thickness in the direction of the polyester film 4
- T min minimum thickness in the direction of the polyester film 4
- T ave average thickness in the direction of the polyester film 4 (2) Melting point in the range of 200 to 223 ° C.
- the polyester film according to (1), (3) A method for producing the polyester film according to the above (1) or (2), wherein the unstretched sheet is stretched in the flow direction of the sheet (MD stretching), and then stretched in the width direction (TD).
- MD stretching is performed in two or more stages,
- Area magnification (X ⁇ Y) is 12.00 to 16.00
- a polyester film for laminating a metal plate comprising the polyester film according to (1) or (2), which is used for laminating a metal plate.
- a polyester film for laminating a metal can comprising the polyester film according to the above (1) or (2), which is used for laminating a metal can.
- the polyester film for metal can lamination according to (5) which is used for laminating the inner surface of a metal can.
- a laminated metal plate wherein the polyester film for metal plate lamination according to (4) is laminated on a metal plate.
- the polyester film of the present invention contains two types of polyester resins blended in a specific ratio, and has a uniform dry heat shrinkage in four directions including a 0 ° direction, a 45 ° direction, a 90 ° direction, and a 135 ° direction. As well as excellent uniformity of thickness. For this reason, even if the temperature range at the time of heat lamination with a metal plate is a relatively wide range from a relatively low temperature to a relatively high temperature, the polyester film of the present invention has excellent adhesion to the metal plate, and It has excellent moldability (can-making properties) and transparency after can molding, and retains excellent adhesion and coatability to metal plates even after retort sterilization and long-term storage.
- the polyester film of the present invention is excellent in transparency after forming a can, it can be suitably used for an outer film of a metal can, and also has excellent coatability even after retort sterilization treatment and long-term storage. Therefore, it can be suitably used for the inner film of a metal can.
- the polyester film of the present invention is a polyester film containing a polyester (A) mainly composed of polybutylene terephthalate and a polyester (B) mainly composed of polyethylene terephthalate, and has a mass ratio of the polyesters (A) and (B). (A / B) needs to be 70/30 to 55/45.
- the polyester (A) mainly composed of polybutylene terephthalate in the present invention is not limited to a homopolybutylene terephthalate resin composed of only butylene terephthalate units, but 80 mol% or more, more preferably 90 mol% or more, and even 95 mol of butylene terephthalate units. % Or more.
- the polyester (A) is preferably a copolymer containing 90 mol% or more of butylene terephthalate units, and particularly preferably homopolybutylene terephthalate.
- the content of the butylene terephthalate unit in the polyester (A) is less than 80 mol%, the crystallinity, particularly the crystallization speed, is reduced, and the resulting film tends to have reduced adhesion and barrier properties after retort treatment. Become.
- the copolymerization component in the polyester (A) is not particularly limited, but as the acid component, isophthalic acid, phthalic acid, 2,6-naphthalenedicarboxylic acid, 5-sodium sulfoisophthalic acid, oxalic acid, succinic acid, adipic acid, sebacin Acids, azelaic acid, dodecane diacid, dimer acid, maleic anhydride, maleic acid, fumaric acid, itaconic acid, citraconic acid, mesaconic acid, dicarboxylic acids such as cyclohexanedicarboxylic acid, 4-hydroxybenzoic acid, ⁇ -caprolactone and lactic acid And the like.
- the acid component isophthalic acid, phthalic acid, 2,6-naphthalenedicarboxylic acid, 5-sodium sulfoisophthalic acid, oxalic acid, succinic acid, adipic acid, sebacin Acids,
- the alcohol component examples include ethylene glycol, diethylene glycol, 1,3-propanediol, neopentyl glycol, 1,6-hexanediol, cyclohexanedimethanol, triethylene glycol, polyethylene glycol, polypropylene glycol, polytetramethylene glycol, and bisphenol. A and bisphenol S ethylene oxide adducts. Further, a small amount of a trifunctional compound such as trimellitic acid, trimesic acid, pyromellitic acid, trimethylolpropane, glycerin, and pentaerythritol may be used. Two or more of these copolymer components may be used in combination.
- the polyester film of the present invention preferably has a melting point derived from the polyester (A) in the range of 200 to 223 ° C. If the melting point is lower than 200 ° C., the heat resistance of the film decreases. .
- the polyester (B) mainly composed of polyethylene terephthalate in the present invention is not limited to a homopolyethylene terephthalate resin comprising only ethylene terephthalate units, but is a copolymer containing at least 80 mol% of ethylene terephthalate units, especially 85 to 98 mol%. Preferably, there is.
- the copolymer component in the polyester (B) the same components as in the case of the polyester (A) can be used for both the acid component and the alcohol component.
- the polyester (B) preferably contains isophthalic acid as an acid component, and the content of isophthalic acid in the acid component is preferably 2 to 15 mol%, more preferably 3 to 10 mol%. Is more preferred.
- polyester film obtained by copolymerizing isophthalic acid in the above range tends to expand the temperature range of the heat lamination and improve the adhesion to the metal plate.
- the obtained polyester film has a tendency that thickness unevenness tends to be enlarged.
- Spots can be improved, and excellent adhesion and coverage to a metal plate can be obtained.
- the polyester film of the present invention preferably has a melting point derived from the polyester (B) in the range of 225 to 256 ° C, more preferably in the range of 230 to 256 ° C, and more preferably in the range of 235 to 256 ° C. More preferred. If the melting point of the polyester (B) is lower than 225 ° C., the resulting film will have whitening or white spots after the retort treatment, or will have reduced adhesion after the retort treatment. In particular, when the melting point of the polyester (B) is 225 ° C.
- the film has improved heat resistance, adhesion after retort treatment and after long-term storage, and has a problem of fusing with a jig during can processing. This is effective in reducing breakage trouble during the processing of the can body.
- the mass ratio (A / B) of the polyester (A) and the polyester (B) needs to be 70/30 to 55/45, and the effect of the present invention is sufficiently obtained.
- the ratio is preferably 67/33 to 58/42, and more preferably 63/37 to 60/40. If the proportion of the polyester (A) in the total mass of the polyester (A) and the polyester (B) exceeds 70% by mass, the resulting film will have reduced adhesion after retort treatment.
- the proportion of the polyester (B) exceeds 45% by mass, the proportion of the high-melting point component in the film increases, so that the adhesion between the film and the metal plate is reduced in metal plate lamination at low temperatures, Even after retort treatment, the adhesion is reduced.
- the proportion of the polyester (A) is in the range of 70 to 55% by mass, the laminated metal plate has good followability in forming when performing high-speed drawing and ironing at a high speed, and the film is unreasonable.
- the polyester film of the present invention needs to simultaneously satisfy the following conditions (1) to (3) in order to enable thermal lamination with a metal plate in a wide temperature range.
- (1) Dry heat shrinkage (A) by heat treatment at 160 ° C. for 30 minutes in all four directions (0 °, 45 °, 90 °, 135 °) of the film surface must be 20% or less. And preferably 5 to 18%, more preferably 10 to 16%. Further, the difference between the maximum value and the minimum value of the dry heat shrinkage must be 5% or less, preferably 4% or less, more preferably 3% or less.
- the dry heat shrinkage (B) by heat treatment at 200 ° C. for 15 minutes in each of the four directions must be 35% or less, preferably 10 to 33%, and more preferably 15 to 30%.
- % Is more preferable. Further, the difference between the maximum value and the minimum value of the dry heat shrinkage must be 5% or less, preferably 4% or less, more preferably 3% or less. (3)
- the thickness unevenness calculated by the following equation in the four directions needs to be 10% or less, preferably 8% or less, and more preferably 7% or less.
- Thickness unevenness (%) ( Tmax ⁇ Tmin ) / Tave ⁇ 100
- T max maximum thickness in the direction of the polyester film 4
- T min minimum thickness in the direction of the polyester film 4
- T ave average thickness in the direction of the polyester film 4
- the four directions of the film surface are directions at 45 °, 90 °, and 135 ° clockwise with respect to any one direction as the 0 ° direction. Above all, it is preferable that the flow direction (MD) of the film is 0 °.
- the limiting viscosity (IV) of the raw material polyester used for producing the film of the present invention is preferably 0.75 to 1.6 dl / g for the polyester (A), and 0.65 to 1 dl / g for the polyester (B).
- 0.0dl / g and the intrinsic viscosity after melt mixing is preferably 0.75 to 1.2dl / g.
- the film in the production of cans with a large capacity, in the process of drawing and ironing a laminated metal plate, the film can not follow it because the degree of deformation processing becomes large, voids or cracks occur, and from the outside Even the slight impact of this promotes peeling and crack growth from the metal plate. Therefore, in a can using a film on the inner surface, as a result of direct contact between the contents and the metal of the can due to voids and cracks, the taste and aroma retention may be reduced, or a problem may occur in flavor. Further, in a can using a film on the outer surface, the printed appearance is deteriorated in a portion where the film is whitened by voids.
- the polymerization method of the raw material polyester is not particularly limited, and examples thereof include a transesterification method and a direct polymerization method.
- the transesterification catalyst include oxides and acetates of Mg, Mn, Zn, Ca, Li, and Ti.
- the polycondensation catalyst include compounds such as oxides and acetates of Sb, Ti, and Ge. Since the polyester after polymerization contains monomers and oligomers, by-products such as acetaldehyde and tetrahydrofuran, it is preferable to carry out solid-phase polymerization at a temperature of 200 ° C. or more under reduced pressure or an inert gas flow.
- additives such as an antioxidant, a heat stabilizer, an ultraviolet absorber, and an antistatic agent can be added as needed.
- Antioxidants include, for example, hindered phenol compounds and hindered amine compounds
- heat stabilizers include, for example, phosphorus compounds
- ultraviolet absorbers include, for example, benzophenone compounds, benzotriazole compounds. And the like.
- a phosphorus compound as a conventionally known reaction inhibitor before, during, or after the polymerization. More preferably, it is added at the end of melt polymerization of
- the polyester film of the present invention is obtained by forming a melt-kneaded product containing the polyester (A) and the polyester (B) into a sheet and obtaining a non-stretched sheet. (MD stretching) and then stretching in the width direction (TD stretching).
- an unstretched sheet is obtained by forming a melt-kneaded product containing the polyester (A) and the polyester (B) into a sheet.
- the preparation of the melt-kneaded product may be performed according to a known method. For example, a raw material containing the polyester (A) and the polyester (B) is charged into an extruder equipped with a heating device, and is melted by heating to a predetermined temperature.
- an inorganic lubricant such as silica, alumina or kaolin to impart a slip property to the film surface in order to improve the processability during film production or can making.
- a silicone compound or the like can be contained.
- the addition amount of the inorganic lubricant is preferably 0.001 to 0.5% by mass, and more preferably 0.05 to 0.3% by mass.
- titanium dioxide can be added up to about 20% by mass for the purpose of hiding.
- the unstretched sheet can be obtained as a sheet-shaped molded body by extruding the melt-kneaded product with a T-die and cooling and solidifying it with a casting drum or the like whose temperature has been adjusted to room temperature or lower.
- the average thickness of the unstretched sheet is not particularly limited, but is generally 50 to 1000 ⁇ m, and preferably 100 to 800 ⁇ m. By setting the average thickness of the unstretched sheet within such a range, the stretching step can be performed more efficiently.
- the draw ratio (X / Y) which is the ratio of the MD draw ratio (X) expressed by the product of the draw ratios at each stage of the MD draw and the TD draw ratio (Y), is 0.82 to 1.10. It is necessary to be.
- the draw ratio (X / Y) may be 1.00 to 1.10. From the viewpoint of transparency after high-order drawing and ironing. More preferably, it is 1.05 to 1.10.
- the draw ratio (X / Y) is 0.85 from the viewpoint of adhesion between the film and the metal plate and long-term storage performance after retort treatment. It is preferably from 0.95 to 0.95, and more preferably from 0.85 to 0.90. Further, the area magnification (X ⁇ Y) needs to be 12.00 to 16.00. When producing a polyester film constituting the outer surface of the metal can, the area magnification (X ⁇ Y) is preferably 14.50 to 16.00 from the viewpoint of transparency after high-order drawing and ironing. . On the other hand, when a polyester film constituting the inner surface of a metal can is produced, it is preferably 12.50 to 14.00 from the viewpoint of the adhesion between the film and the metal plate and the long-term storage performance after retort treatment.
- the MD stretching step needs to be a multi-stage stretching method of two or more stages.
- MD stretching is generally performed using a peripheral speed difference between two or more rolls, but by using a multi-stage stretching method, stretching stress can be reduced, and the load on the rolls is reduced.
- the stretching temperature can be reduced and the fusion or winding of the film around the roll can be suppressed, it is possible to reduce the thickness unevenness in the film flow direction (MD). .
- MD stretching thickness unevenness in the film flow direction (MD) is reduced to TD stretching
- the thickness unevenness in the four directions defined in the present invention can be reduced.
- the temperature of the unstretched sheet before stretching is controlled in advance in the range of 25 to 60 ° C. If the temperature is less than 25 ° C., the unstretched sheet may break during stretching, and if the temperature exceeds 60 ° C., it may be wound around a roll.
- the MD stretching in the first stage preferably has a stretching temperature of 50 to 80 ° C., more preferably 55 to 75 ° C., and even more preferably 60 to 70 ° C.
- the stretching ratio of MD1 stretching is preferably 1.1 to 1.5 times. When the stretching ratio is 1.1 times or less, the stretching effect does not appear, and when the stretching ratio exceeds 1.5 times, the film is remarkably oriented and crystallized, and the stress increases in the second and subsequent stages of stretching, It is easy to break.
- the MD stretching step is preferably a multi-stage stretching method of two to three stages.
- the MD stretching at the n-th stage is referred to as MDn stretching.
- the MDn stretching preferably has a stretching temperature of 50 to 80 ° C, more preferably 55 to 75 ° C, and still more preferably 55 to 70 ° C. Also, the stretching ratio of MDn stretching is preferably 1.2 to 3.5 times.
- the stretching ratio is preferably increased stepwise so that the (n + 1) th stage stretching ratio ( Xn + 1 ) is higher than the nth stage stretching ratio ( Xn ), and the ratio ( Xn + 1 / Xn). ) Is more preferably 1.3 to 2.8 times.
- the MD stretching ratio (X) represented by the product of the stretching ratios in each stage is preferably 2.5 to 3.8 times, and preferably 2.8 to 3.5 times. Is more preferable.
- a known method such as passing a film through a heating roll or infrared heating between MD stretching rolls can be used alone or in combination.
- the method of heating the film with infrared rays between the stretching rolls can reduce the temperature of the stretching rolls, so that the fusion and winding of the film to the rolls are suppressed, and the thickness unevenness of the MD of the film is further reduced. It is possible to do.
- the MD-stretched film is subsequently continuously TD-stretched.
- the temperature of TD stretching is preferably from 60 to 100 ° C, more preferably from 70 to 95 ° C.
- the TD stretching ratio (Y) is adjusted depending on the required physical properties of the final film, but is preferably 2.7 times or more, more preferably 3.0 times or more, and particularly preferably 3.6 times or more.
- the film is stretched so that the draw ratio (X / Y) is 0.82 to 1.10 and the area ratio (X ⁇ Y) is 12.00 to 16.00. is necessary. If the polyester film is stretched without satisfying the above draw ratio ratio, the resulting polyester film has a poor balance of the dry heat shrinkage in the four directions, and the difference between the maximum value and the minimum value of the dry heat shrinkage is not significant. It tends to exceed the range specified by the present invention, and depending on the value of the area magnification (X ⁇ Y), the range specified by the present invention may not be satisfied in the dry heat shrinkage by heat treatment at 200 ° C. for 15 minutes. .
- a polyester film obtained by stretching with an area ratio (X ⁇ Y) exceeding 16.00 is a polyester film that can satisfy the range specified in the present invention in dry heat shrinkage by heat treatment at 200 ° C. for 15 minutes. It is difficult to obtain, and the polyester film obtained by stretching when the area ratio (X ⁇ Y) is less than 12.00 becomes difficult to satisfy the range specified in the present invention for uneven thickness, and the adhesion at the time of low-temperature heat lamination It tends to be poor.
- the TD-stretched film is subsequently subjected to a heat relaxation treatment for continuously reducing the width of the film in order to adjust the heat shrinkage characteristics and the like of the film.
- the heat relaxation treatment is preferably performed at 1 to 10% of the transverse stretching ratio.
- the film is cooled to Tg or less of the film to obtain a biaxially stretched film.
- the heat relaxation treatment after stretching is a step necessary for imparting dimensional stability of the film, and as a method therefor, a known method such as a method of blowing hot air, a method of irradiating infrared rays, or a method of irradiating microwaves Can be used.
- the method of blowing hot air is optimal because heating can be performed uniformly and accurately.
- the heat relaxation treatment temperature is preferably from 140 to 200 ° C, more preferably from 150 to 190 ° C, and even more preferably from 160 to 180 ° C.
- the heat relaxation treatment temperature is lower than 140 ° C., the dry heat shrinkage in the four directions in the present invention becomes large, and it becomes easy to obtain the film of the present invention.
- the heat relaxation treatment temperature exceeds 200 ° C., the heat laminating property with a metal plate is reduced, and it becomes difficult to obtain the film of the present invention.
- the polyester film of the present invention can be provided with an adhesive layer by a coextrusion method, a laminating process, or a coating process for the purpose of further improving thermocompression bonding with a metal plate and subsequent adhesion.
- the thickness of the adhesive layer is preferably 1 ⁇ m or less as a dry film thickness.
- the adhesive layer is not particularly limited, but is preferably a thermosetting resin layer made of an epoxy resin, a polyurethane resin, a polyester resin, or various modified resins thereof.
- one or more kinds of two or more kinds are used to improve the appearance and printability of the metal can body, and to improve the heat resistance and retort resistance of the film.
- a resin layer can be provided. These layers can be provided by a coextrusion method, a lamination or a coating process.
- the laminated metal plate of the present invention is obtained by laminating the above film directly on the metal plate or via an adhesive.
- the metal plate on which the film of the present invention is laminated include a steel plate, aluminum, and the like, and a chemical treatment such as chromic acid treatment, phosphoric acid treatment, electrolytic chromic acid treatment, and chromate treatment, and nickel, tin, zinc, aluminum, and gunmetal , Brass, or a metal plate subjected to various other plating treatments can be used.
- the metal plate As a method of laminating a film on a metal plate, the metal plate is preheated to 160 to 250 ° C., and the film and the film are pressed by a roll whose temperature is controlled by 30 ° C., and more than 50 ° C. lower than the metal plate. Then, after thermocompression bonding, a method of cooling to room temperature can be mentioned, whereby a laminated metal plate can be manufactured continuously.
- the method of heating the metal plate include a heater roll heat transfer method, an induction heating method, a resistance heating method, and a hot air transfer method. In particular, the heater roll heat transfer method is preferable from the viewpoint of facility costs and simplification of equipment. .
- a cooling method after lamination a method of dipping in a coolant such as water or a method of contacting with a cooling roll can be used.
- the laminated metal sheet obtained by the above method has good can-making properties, it can be processed as it is. However, after being heat-treated at a temperature 10 to 30 ° C. higher than the melting point of the polyester, it is rapidly cooled. By setting the film in an amorphous state, higher processability can be imparted.
- the metal container of the present invention is obtained by molding the above-mentioned laminated metal plate.
- the metal container has been processed to a form that can be filled with food and drink and can be used, and a portion of the metal container, for example, a can lid formed into a shape that can be tightened. Is also included.
- 3P cans three-piece cans
- 2P cans two-piece cans
- the metal container of the present invention has excellent retort resistance, flavor properties, and corrosion resistance, and is therefore suitable for various processed foods such as coffee, green tea, black tea, oolong tea, and particularly highly corrosive acidic beverages (fruit juice beverages) and milky beverages. Suitable for filling objects.
- polyester (A) A-1: Homopolybutylene terephthalate (PBT), IV 1.08 dl / g, Tm 223 ° C., containing 40 ppm of Ti catalyst. A-2: Polybutylene terephthalate (PBT / PBS5) copolymerized with 5 mol% of sebacic acid, IV 0.92 dl / g, Tm 217 ° C., containing 40 ppm of Ti catalyst. A-3: Polybutylene terephthalate (PBT / PBS12) copolymerized with 12 mol% of sebacic acid, IV 0.95 dl / g, Tm 204 ° C, containing 40 ppm of Ti catalyst.
- PBT Homopolybutylene terephthalate
- A-2 Polybutylene terephthalate (PBT / PBS5) copolymerized with 5 mol% of sebacic acid, IV 0.92 dl / g, Tm 2
- B-4 Polyethylene terephthalate (PET / PEI8) copolymerized with 8 mol% of isophthalic acid, IV 0.73 dl / g, Tm 228 ° C, 100 ppm Sb catalyst.
- B-5 Polyethylene terephthalate (PET / PEI12) copolymerized with 12 mol% of isophthalic acid, IV 0.65 dl / g, Tm 219 ° C., 100 ppm of Sb catalyst.
- B-6 Polyethylene terephthalate (PET / CHDM) copolymerized with 3.5 mol% of 1,4-cyclohexanedimethanol, IV 0.78 dl / g, Tm 240 ° C., containing 40 ppm of Ge catalyst.
- PET / CHDM Polyethylene terephthalate
- Tm Melting point
- Dry heat shrinkage (%) [(sample length after humidity control 1-sample length after humidity control 2) / sample length after humidity control 1] x 100
- FIG. Adhesiveness A polyester film and a tin-free steel plate having a thickness of 0.21 mm are stacked between a metal roll heated to a set temperature of 190 ° C. or 200 ° C. and a silicon rubber roll.
- the polyester film was supplied so as to be in contact with the silicone rubber roll, and was heated and bonded at a speed of 20 m / min. At a linear pressure of 4.9 ⁇ 10 4 N / m for 2 seconds. I got a board.
- a laminated metal plate was obtained in the same manner as described above, except that the set temperature of the metal roll was set to 220 ° C. and the heating and bonding time was changed to 1 second.
- a strip-shaped test piece having a width of 18 mm (the long side is the MD of the film, the short side is the TD of the film, the end is not laminated, and the laminated portion is secured to the MD by 8 cm or more. 10) were cut out.
- an adhesive tape specified in JIS Z-1522 was adhered to the film surface of the test piece, and a 180-degree peel test was performed at a speed of 10 mm / min with an autograph manufactured by Shimadzu Corporation to determine the peel strength. It was measured.
- the peel strength is 2.9 N or more, the peel interface of the laminated metal plate often shifts from the polyester film / tin-free steel plate to cohesive failure of the polyester film or film cutting by tension.
- the number of test pieces having a peel strength of 2.9 N or more is substantially 6 or more, preferably 8 or more, and more preferably 10 or more.
- FIG. Manufacturability The laminated metal plate obtained in E above was heated at 260 ° C. for 30 seconds using a hot air oven, and then rapidly cooled to perform an amorphous treatment. Using a die and a punch, the amorphous-processed laminated metal plate was drawn into a forming container having a bottom diameter of 65 mm and a height of 250 mm at a speed of 80 strokes / minute to form a two-piece can. After the obtained two-piece can was subjected to a retort treatment at 120 ° C. for 30 minutes, a 1% by mass saline solution was filled in the can, and a current value was measured when a voltage of 6 V was applied using the can body as an anode.
- the can-making property was evaluated based on the degree of the defect of the polyester film.
- the maximum value of the current value is 5 mA or less, preferably 4 mA or less, and more preferably 2.2 mA or less.
- Example 1 60 parts by mass of polyester (A-1), 40 parts by mass of polyester (B-1), and 0.08% by mass of agglomerated silica having an average particle size of 2.5 ⁇ m are dry-blended, and the mixture is extruded using a T-die. The resultant was extruded into a sheet at 275 ° C. for a residence time of 8 minutes, solidified by quenching, and obtained as an unstretched sheet such that the film after stretching had a thickness of 12 ⁇ m. Next, the obtained unstretched sheet was successively stretched by a biaxial stretching method.
- the first-stage MD stretching is performed at a magnification of 1.15 times so that the MD stretching ratio (X) becomes 3.45 times with a longitudinal stretching machine, and then continuously 3.00 times.
- the second stage MD stretching was performed at a magnification.
- the stretching temperature was 70 ° C. for both the first stage MD stretching and the second stage MD stretching.
- the end of the MD-stretched film was gripped by clips of a tenter-type transverse stretching machine, and stretched so that the TD stretching ratio (Y) became 3.70 times.
- the stretching ratio (X / Y) was 0.93 and the area ratio (X ⁇ Y) was 12.77.
- the heat relaxation treatment temperature is set to 160 ° C.
- the relaxation rate of the TD is set to 5.0%
- the heat relaxation treatment is performed for 4 seconds, and then cooled to room temperature and wound into a roll, and the polyester film having a thickness of 12 ⁇ m is formed. I got
- Example 2 Comparative Examples 1 to 16 Example 1 was repeated except that the types and mass ratios of the polyester (A) and the polyester (B) and the conditions of the sheet forming step, the stretching step, and the heat relaxation step were changed as shown in Tables 1, 4, and 7. In the same manner as described above, a polyester film was obtained.
- the polyester films obtained in Examples 1 to 32 had a mass ratio of the polyester (A) mainly composed of polybutylene terephthalate to the polyester (B) mainly composed of polyethylene terephthalate, the dry heat shrinkage in four directions, and the dry heat shrinkage in four directions. Since the difference between the maximum value and the minimum value of the dry heat shrinkage ratio and the thickness unevenness were within the range specified in the present invention, heat lamination in a wide temperature range was possible, and the adhesion to a metal plate was excellent, and Excellent in transparency, and excellent in transparency after can-making. Further, even when stored for a long time after the retort treatment, the adhesiveness to the metal plate was excellent, and the coatability was also excellent.
- the films of Examples 2, 22, 24, and 28 in which MD stretching was performed in three stages have improved thickness unevenness compared to the films of Examples 1, 21, 23, and 27 in which the MD stretching was performed in two stages, and before and after storage. Adhesion, can-making properties, and coating properties were further improved.
- the film of Example 13 was most excellent in the transparency after metallization required for the external film of the metal can because the stretch ratio and the area ratio were the most suitable conditions for the film for the external surface.
- the stretching ratio and the area ratio are the most suitable conditions for the film for the inner surface, the defect does not increase even when the film is stored for a long time after the retort treatment. It had the best covering property in long-term storage after retort treatment.
- the MD stretching was performed in one step, the thickness unevenness exceeded the range specified in the present invention, and thus, in the heat lamination at a low temperature, the adhesiveness was poor, and the can-making property and the coating property were poor.
- the draw ratios did not satisfy the range specified in the present invention, so that the dry heat shrinkage exceeded the range specified in the present invention. Since the difference in the values could not satisfy the range specified in the present invention, when the heat lamination temperature was high, the adhesion, can-making property and covering property were inferior, and the transparency after can-making was inferior.
- the area ratio in addition to the draw ratio did not satisfy the range specified in the present invention.
- the dry heat shrinkage ratio of the varnish cannot satisfy the range specified in the present invention, and therefore, the adhesiveness, can-making property, and coatability were poor, and the transparency after can-making was poor.
- the uneven thickness exceeded the range specified in the present invention. Therefore, in the heat lamination at a low temperature, adhesion, can-making property, The coatability was poor, and the transparency after can production was poor.
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Abstract
Description
しかしながら、ポリエステルフィルムは、金属板に熱ラミネートすることができる温度域が狭いため、熱ラミネート温度が高すぎたり、低すぎたりすると、得られるラミネート金属板は、ポリエステルフィルムと金属板との密着性が不十分となることがあり、またレトルト殺菌処理および長期間の保存後において、フィルムの密着性および被覆性が低下することがあった。
しかしながら、特許文献3に開示された延伸フィルムは、200℃程度の高温に晒された時の乾熱収縮率が大きくなったり、各方向の乾熱収縮率のバランスが劣っていることから、金属缶の内外面の腐食防止に必要な物性を有しない場合があった。
(1)ポリブチレンテレフタレートを主体とするポリエステル(A)と、ポリエチレンテレフタレートを主体とするポリエステル(B)とを含むポリエステルフィルムであって、
ポリエステル(A)と(B)の質量比(A/B)が70/30~55/45であり、
フィルム面における任意の方向を0°とし、その方向に対して時計回りに、45°、90°、135°の4方向における、160℃、30分の熱処理による乾熱収縮率(A)がいずれも20%以下であり、これらの乾熱収縮率の最大値と最小値の差が5%以下であり、
前記4方向における、200℃、15分の熱処理による乾熱収縮率(B)がいずれも35%以下であり、これらの乾熱収縮率の最大値と最小値の差が5%以下であり、
前記4方向における下式にて算出した厚み斑が10%以下であることを特徴とするポリエステルフィルム。
厚み斑(%)=(Tmax-Tmin)/Tave×100
Tmax:ポリエステルフィルム4方向における最大厚み
Tmin:ポリエステルフィルム4方向における最小厚み
Tave:ポリエステルフィルム4方向における平均厚み
(2)融点を、200~223℃の範囲と、225~256℃の範囲とに有することを特徴とする(1)記載のポリエステルフィルム。
(3)上記(1)または(2)記載のポリエステルフィルムを製造するための方法であって、未延伸シートを、シートの流れ方向に延伸(MD延伸)し、次いで、巾方向に延伸(TD延伸)する延伸工程において、
MD延伸を2段以上で行ない、
MD延伸の各段における延伸倍率の積で表されるMD延伸倍率(X)と、TD延伸倍率(Y)とを、
延伸倍率比(X/Y)が0.82~1.10
面倍率(X×Y)が12.00~16.00
を満たすように延伸することを特徴とするポリエステルフィルムの製造方法。
(4)上記(1)または(2)記載のポリエステルフィルムからなり、金属板のラミネートに用いられることを特徴とする金属板ラミネート用ポリエステルフィルム。
(5)上記(1)または(2)記載のポリエステルフィルムからなり、金属缶のラミネートに用いられることを特徴とする金属缶ラミネート用ポリエステルフィルム。
(6)金属缶の内面のラミネートに用いられることを特徴とする(5)記載の金属缶ラミネート用ポリエステルフィルム。
(7)金属缶の外面のラミネートに用いられることを特徴とする(5)記載の金属缶ラミネート用ポリエステルフィルム。
(8)上記(4)記載の金属板ラミネート用ポリエステルフィルムが、金属板に積層されてなることを特徴とするラミネート金属板。
(9)上記(8)記載のラミネート金属板が成形されてなる金属容器。
本発明のポリエステルフィルムは、ポリブチレンテレフタレートを主体とするポリエステル(A)と、ポリエチレンテレフタレートを主体とするポリエステル(B)とを含むポリエステルフィルムであって、ポリエステル(A)と(B)の質量比(A/B)は、70/30~55/45であることが必要である。
また、アルコール成分としては、エチレングリコール、ジエチレングリコール、1,3-プロパンジオール、ネオペンチルグリコール、1,6-ヘキサンジオール、シクロヘキサンジメタノール、トリエチレングリコール、ポリエチレングリコール、ポリプロピレングリコール、ポリテトラメチレングリコール、ビスフェノールAやビスフェノールSのエチレンオキシド付加体等が挙げられる。
さらに、トリメリット酸、トリメシン酸、ピロメリット酸、トリメチロールプロパン、グリセリン、ペンタエリスリトール等の3官能化合物等を少量用いてもよい。
これらの共重合成分は2種以上併用してもよい。
ポリエステル(B)における共重合成分としては、酸成分、アルコール成分ともに、ポリエステル(A)の場合と同様の成分を用いることができる。中でも、ポリエステル(B)は、酸成分としてイソフタル酸を含有することが好ましく、酸成分におけるイソフタル酸の含有量は、2~15モル%であることが好ましく、中でも3~10モル%であることがより好ましい。
ポリエステル(A)とポリエステル(B)の合計質量におけるポリエステル(A)の割合が70質量%を超えると、得られるフィルムは、レトルト処理後の密着性が低下する。一方、ポリエステル(B)の割合が45質量%を超えると、フィルム中の高融点成分の割合が高くなるため、低温での金属板ラミネート加工において、フィルムと金属板との密着性が低下し、レトルト処理後にも密着性が低下する。
特に、ポリエステル(A)の割合が70~55質量%の範囲の場合、ラミネート金属板は、高速で、高次の絞りしごき加工を行う場合の成形加工追随性が良好であり、フィルムは、無理な変形によるボイドの発生による白化現象や、マイクロクラックの発生が無く、かつ金属板との密着性に優れ、レトルト処理後に長期間保存した場合においても、金属板に対する密着性および被覆性が良好である。その結果、内面にフィルムを使用した缶は、長期保存後においても、金属板が被覆されているため、耐食性(内容物の保護性、保味保香性、フレーバー維持性)に優れたものとなる。また、外面にフィルムを使用した缶においては、さびの発生がなく、また印刷図柄の光沢度がよいなど、商品価値の高い製品が得られ、外面のフィルムは、缶そのもののデザイン性を損なわない程度の透明性を有する。
(1)フィルム面の4方向(0°、45°、90°、135°)における、160℃、30分の熱処理による乾熱収縮率(A)がいずれも20%以下であることが必要であり、5~18%であることが好ましく、10~16%であることがより好ましい。また、これらの乾熱収縮率の最大値と最小値の差が5%以下であることが必要であり、4%以下であることが好ましく、3%以下であることがより好ましい。
(2)前記4方向における、200℃、15分の熱処理による乾熱収縮率(B)がいずれも35%以下であることが必要であり、10~33%であることが好ましく、15~30%であることがより好ましい。また、これらの乾熱収縮率の最大値と最小値の差が5%以下であることが必要であり、4%以下であることが好ましく、3%以下であることがより好ましい。
(3)前記4方向における下式にて算出した厚み斑が10%以下であることが必要であり、8%以下であることが好ましく、7%以下であることがより好ましい。
厚み斑(%)=(Tmax-Tmin)/Tave×100
Tmax:ポリエステルフィルム4方向における最大厚み
Tmin:ポリエステルフィルム4方向における最小厚み
Tave:ポリエステルフィルム4方向における平均厚み
上記(1)~(3)の条件が同時に満たされない場合、得られるラミネート金属板のフィルムは、熱ラミネート時の温度によって、金属板に対する密着性や被覆性が不十分となることがあり、またレトルト処理および長時間の保存後において、金属板に対する密着性が低下することがある。さらに、ラミネート金属板は、缶への成形性も低下することがある。なお、フィルム面の4方向とは、任意の一方向を0°方向とし、その方向に対して時計回りに45°、90°、135°の方向をいう。中でも、フィルムの流れ方向(MD)を0°とすることが好ましい。
本発明のフィルムを製造するために用いる原料ポリエステルの極限粘度(IV)は、ポリエステル(A)では0.75~1.6dl/gであることが好ましく、ポリエステル(B)では0.65~1.0dl/gであることが好ましく、溶融混合した後の極限粘度は0.75~1.2dl/gであることが好ましい。
ポリエステルの極限粘度が上記範囲より低いと、ラミネート金属板の高次加工時に、フィルムが破断し、生産性が極端に低下する。特に、容量が大きい缶の製造では、ラミネート金属板を絞りしごき加工する工程において、フィルムは、変形加工度が大きくなるため、それに追随できず、ボイドが発生したり、クラックが発生し、外部からのわずかな衝撃によってすら、金属板からの剥離やクラックの成長が助長される。
したがって、内面にフィルムを用いた缶では、ボイドやクラックによって、内容物と缶の金属とが直接接触する結果、保味保香性が低下したり、フレーバー性に問題が生じたりする。また、外面にフィルムを用いた缶では、ボイドによりフィルムが白化した部分において、印刷外観が低下する。また、ボイドやクラックによって、長期保存時に缶が腐食する問題が生じるおそれがある。
一方、ポリエステルの極限粘度が上記範囲を超えると、樹脂を溶融してフィルムを生産する工程において、溶融押出機にかかる負荷が大きくなり、生産速度を犠牲にせざるを得なかったり、押出機中の樹脂の溶融滞留時間が長くなりすぎて、ポリエステル樹脂間の反応が進みすぎ、フィルムの特性の劣化を招き、結果的にラミネート金属板の物性低下をもたらす。また、あまりに極限粘度の高いポリエステルは、重合時間や重合プロセスが長く、コストを押し上げる要因ともなる。
溶融混練物の調製は、公知の方法に従って実施すればよい。例えば、加熱装置を備えた押出機に、ポリエステル(A)とポリエステル(B)を含む原料を投入し、所定温度に加熱することによって溶融させる。
溶融混練物の調製にあたり、フィルム製造時や製缶時の工程通過性をよくするため、シリカ、アルミナ、カオリン等の無機滑剤を少量添加して、フィルム表面にスリップ性を付与することが望ましい。さらに、フィルム外観や印刷性を向上させるため、たとえば、シリコーン化合物等を含有させることもできる。無機滑剤の添加量は、0.001~0.5質量%であることが好ましく、0.05~0.3質量%であることが好ましい。また、滑剤の機能と併用して、隠蔽性の目的から二酸化チタンを20質量%程度まで添加することもできる。
未延伸シートは、この溶融混練物をTダイにより押し出し、室温以下に温度調節したキャスティングドラム等により冷却固化させることによって、シート状の成形体として得ることができる。
未延伸シートの平均厚みは、特に限定されないが、一般的には50~1000μmであり、100~800μmであることが好ましい。未延伸シートは、平均厚みをこのような範囲内に設定することによって、より効率的に延伸工程を実施することができる。
MD延伸の各段における延伸倍率の積で表されるMD延伸倍率(X)と、TD延伸倍率(Y)との比である延伸倍率比(X/Y)は、0.82~1.10であることが必要である。金属缶の外面を構成するポリエステルフィルムを製造する場合は、高次の絞りしごき加工後の透明性の観点で、延伸倍率比(X/Y)は、1.00~1.10であることが好ましく、1.05~1.10であることがより好ましい。一方、金属缶の内面を構成するポリエステルフィルムを製造する場合は、フィルムと金属板との密着性、レトルト処理後の長期保存性能の観点で、延伸倍率比(X/Y)は、0.85~0.95であることが好ましく、0.85~0.90であることがより好ましい。
また、面倍率(X×Y)は、12.00~16.00であることが必要である。金属缶の外面を構成するポリエステルフィルムを製造する場合は、高次の絞りしごき加工後の透明性の観点で、面倍率(X×Y)は、14.50~16.00であることが好ましい。一方、金属缶の内面を構成するポリエステルフィルムを製造する場合は、フィルムと金属板との密着性、レトルト処理後の長期保存性能の観点で12.50~14.00であることが好ましい。
1段目のMD延伸(MD1延伸)は、延伸温度が50~80℃であることが好ましく、55~75℃であることがより好ましく、60~70℃であることがさらに好ましい。
また、MD1延伸の延伸倍率は、1.1~1.5倍であることが好ましい。延伸倍率が1.1倍以下では、延伸効果が現れず、延伸倍率が1.5倍を超えると、フィルムは、配向結晶化が著しく進行し、2段階目以降の延伸において応力が高くなり、破断しやすくなる。
MDn延伸は、延伸温度が50~80℃であることが好ましく、55~75℃であることがより好ましく、55~70℃であることがさらに好ましい。
また、MDn延伸の延伸倍率は、1.2~3.5倍であることが好ましい。
延伸倍率は、n段目の延伸倍率(Xn)よりも(n+1)段目の延伸倍率(Xn+1)が高くなるように、段階的に増加させることが好ましく、比(Xn+1/Xn)は、1.3~2.8倍であることがより好ましい。
また、この多段延伸において、各段における延伸倍率の積で表されるMD延伸倍率(X)は、2.5~3.8倍であることが好ましく、2.8~3.5倍であることがより好ましい。
TD延伸の温度は、60~100℃であることが好ましく、70~95℃であることがより好ましい。
TD延伸の倍率(Y)は、最終的なフィルムの要求物性に依存し調整されるが、2.7倍以上、さらには3.0倍以上、特に3.6倍以上であることが好ましい。
延伸後の熱弛緩処理は、フィルムの寸法安定性を付与するために必要な工程であり、その方法として、熱風を吹き付ける方法、赤外線を照射する方法、マイクロ波を照射する方法等の公知の方法を用いることができる。このうち、均一に精度良く加熱できることから熱風を吹き付ける方法が最適である。
熱弛緩処理温度は140~200℃であることが好ましく、150~190℃であることがより好ましく、160~180℃であることがさらに好ましい。熱弛緩処理温度が140℃未満であると、本発明における4方向の乾熱収縮率が大きくなり、本発明のフィルムを得ることが困難となりやすい。また、熱弛緩処理温度が200℃を超えると、金属板との熱ラミネート性が低下し、本発明のフィルムを得ることが困難となりやすい。
また、金属板と熱圧着するフィルムの反対側には、金属缶体の外観や印刷性を向上させたり、フィルムの耐熱性や耐レトルト性等を向上させるために、1種もしくは2種以上の樹脂層を設けることができる。これらの層は、共押出法やラミネートあるいはコーティング加工により設けることができる。
本発明のフィルムがラミネートされる金属板として、鋼板、アルミ等が挙げられ、クロム酸処理、リン酸処理、電解クロム酸処理、クロメート処理等の化成処理や、ニッケル、スズ、亜鉛、アルミ、砲金、真鍮、その他の各種メッキ処理などを施した金属板を用いることができる。
金属板の加熱方法としては、ヒーターロール伝熱方式、誘導加熱方式、抵抗加熱方式、熱風伝達方式等が挙げられ、特に、設備費および設備の簡素化の点から、ヒーターロール伝熱方式が好ましい。
また、ラミネート後の冷却方法として、水等の冷媒中に浸漬する方法や、冷却ロールと接触させる方法を用いることができる。
本発明の金属容器は、その優れた耐レトルト性、フレーバー性、耐食性から、コーヒー、緑茶、紅茶、ウーロン茶、特に腐食性の高い酸性飲料(果汁飲料)や乳性飲料といった各種加工食品等の内容物を充填する場合に適している。
実施例および比較例におけるフィルムの原料、および、特性値の測定法は、次の通りである。
ポリエステル(A)
A-1:ホモポリブチレンテレフタレート(PBT)、IV1.08dl/g、Tm223℃、Ti触媒40ppm含有。
A-2:セバシン酸5モル%を共重合したポリブチレンテレフタレート(PBT/PBS5)、IV0.92dl/g、Tm217℃、Ti触媒40ppm含有。
A-3:セバシン酸12モル%を共重合したポリブチレンテレフタレート(PBT/PBS12)、IV0.95dl/g、Tm204℃、Ti触媒40ppm含有。
B-1:ホモポリエチレンテレフタレート(PET)、IV0.75dl/g、Tm255℃、Ge触媒40ppm含有。
B-2:ホモポリエチレンテレフタレート(PET)、IV0.64dl/g、Tm255℃、Sb触媒100ppm含有。
B-3:イソフタル酸5モル%を共重合したポリエチレンテレフタレート(PET/PEI5)、IV0.81dl/g、Tm233℃、Sb触媒100ppm含有。
B-4:イソフタル酸8モル%を共重合したポリエチレンテレフタレート(PET/PEI8)、IV0.73dl/g、Tm228℃、Sb触媒100ppm含有。
B-5:イソフタル酸12モル%を共重合したポリエチレンテレフタレート(PET/PEI12)、IV0.65dl/g、Tm219℃、Sb触媒100ppm含有。
B-6:1,4-シクロヘキサンジメタノール3.5モル%を共重合したポリエチレンテレフタレート(PET/CHDM)、IV0.78dl/g、Tm240℃、Ge触媒40ppm含有。
A.フィルム測定位置
フィルムの各物性は、製膜したポリエステルフィルムの巾方向の中央部を測定した。
Perkin Elmer社製DSCを用い、20℃/分で昇温時の融点を測定した。測定サンプルとして、フィルムを溶融後、100℃/分以上の速度で急冷して非晶状態としたものを用いた。
ポリエステルフィルムを23℃×50%RHで2時間調湿した後、フィルムの流れ方向(MD)を0°方向とし、MDから時計回りに45°方向、90°方向(TD)、135°方向の4方向において、測定方向に100mm、測定方向に対して垂直方向に10mmとなるようにポリエステルフィルムを裁断し、試料(各方向において5枚ずつ)を採取した(調湿1後の試料)。
採取した試料は、160℃、30分間、または200℃、15分間の条件で乾燥空気中に晒した後に、23℃×50%RH環境にて2時間調湿した(調湿2後の試料)。乾熱収縮率は、調湿1後と調湿2後の試料長さを測定し、次式にて算出した。算出された5枚の平均値を採用した。
乾熱収縮率(%)=[(調湿1後の試料長さ-調湿2後の試料長さ)÷調湿1後の試料長さ]×100
ポリエステルフィルムを23℃×50%RH環境にて2時間調湿した後、フィルムの流れ方向(MD)を0°方向とし、MDから時計回りに45°方向、90°方向(TD)、135°方向の4方向へ厚みゲージ(ハイデンハイン社製 HEIDENHAIN-METRO MT1287)を用いて、それぞれ10mm間隔で厚みを10点ずつ計40点測定した。
厚み斑は、この40点の測定値における最大厚みをTmax、最小厚みをTmin、平均厚みをTaveとし、次式を用いて算出した。
厚み斑(%)=(Tmax-Tmin)/Tave×100
設定温度190℃または200℃に加熱した金属ロールと、シリコンゴムロールとの間に、ポリエステルフィルムと厚みが0.21mmのティンフリースチール板とを重ね合わせて、金属ロールにティンフリースチール板が接し、シリコンゴムロールにポリエステルフィルムが接するように供給し、速度20m/分、線圧4.9×104N/mで2秒間加熱接着し、その後、氷水中に浸漬し、冷却してラミネート金属板を得た。
また、金属ロールの設定温度を220℃に設定し、加熱接着時間を1秒間に変更した以外は、上記と同様にして、ラミネート金属板を得た。
得られたラミネート金属板から、幅18mmの短冊状の試験片(長辺がフィルムのMD、短辺がフィルムのTDであり、端部はラミネートせず、ラミネートされた部分がMDに8cm以上確保されるようにする)を10枚切り出した。次に、この試験片のフィルム面に、JIS Z-1522に規定された粘着テープを貼り付け、島津製作所社製オートグラフで、10mm/分の速度で180度剥離試験を行い、その剥離強力を測定した。剥離強力が2.9N以上である場合、ラミネート金属板の剥離界面がポリエステルフィルム/ティンフリースチール板から、ポリエステルフィルムの凝集破壊や引張によるフィルム切断に移行する場合が多く認められたため、2.9Nを本発明における密着性評価の基準とし、2.9N以上の剥離強力を有する試験片の枚数により、ポリエステルフィルムとティンフリースチール板との密着性を評価した。2.9N以上の剥離強力を有する試験片の枚数が、実質的には6枚以上であり、8枚以上が好ましく、10枚全てであることがより好ましい。
上記Eで得られたラミネート金属板を、120℃で30分間レトルト処理後、50℃で3ヶ月保存した後、ラミネート金属板から、幅18mmの短冊状の試験片(長辺がフィルムのMD、短辺がフィルムのTD)を10枚切り出し、上記Eと同様に剥離強力を測定した。上記Eと同様に、10枚の試験片のうち、剥離強力が2.9N以上である試験片の枚数によって、保存試験後のポリエステルフィルムとティンフリースチール板との密着性を評価した。
上記Eで得られたラミネート金属板を、熱風オーブンを用いて260℃で30秒間の加熱した後、急冷することによって、アモルファス処理した。アモルファス処理したラミネート金属板を、ダイスとポンチを使用し、底面直径65mm、高さ250mmの成形容器に、80ストローク/分の速度で絞りしごき成形を行い、2ピース缶を作成した。
得られた2ピース缶に120℃、30分間のレトルト処理を行った後に、1質量%の食塩水を缶内部に満たし、缶体を陽極にして6Vの電圧をかけた時の電流値を測定し、ポリエステルフィルムの欠陥の程度により製缶性を評価した。電流が多く流れるほど欠陥が多いことを示す。実用的には、電流値の最大値が5mA以下であり、4mA以下であることが好ましく、2.2mA以下であることがより好ましい。
上記Gの製缶性の評価において、120℃、30分間のレトルト処理を行った後、50℃で3ヶ月保存した。その後、Gと同様の方法で電流値を測定した。内面フィルムとして用いる場合には、50℃、3ヶ月の保存試験後において実用的には、電流値の最大値が5mA以下であり、4mA以下であることが好ましく、2.2mA以下であることがより好ましい。
黒色印刷された金属板(L値は14.0)を用い、上記Eの方法でラミネート金属板を得た後、上記Gの方法で2ピース缶を作製し、色差計(日本電色工業社製 簡易型分光色差計 NF333、光源:F8、視角:10度)を用いて、外面フィルムがラミネートされた金属板の黒色印刷部のL値を測定した。
測定されたL値が小さい程、黒色の度合いが強く、外面フィルムは、印刷外観へ及ぼす影響は少なく、L値が大きい程、黒色の度合いが弱く、外面フィルムは、白化し、印刷外観に悪影響を与える。
黒色印刷部のL値が14.0である金属板に外面フィルムがラミネートされた金属缶は、実用的には、L値が30未満であることが好ましく、20未満であることがより好ましく、16未満であることがさらに好ましい。
ポリエステル(A-1)60質量部とポリエステル(B-1)40質量部、さらに平均粒径2.5μmの凝集シリカ0.08質量%をドライブレンドし、これをTダイを備えた押出機を用いて275℃、滞留時間8分でシート状に押出し、急冷固化して延伸後のフィルムの厚みが12μmとなるように未延伸シートを得た。
次いで、得られた未延伸シートを逐次二軸延伸法にて延伸した。まず、縦延伸機にてMD延伸倍率(X)が3.45倍となるように、1.15倍の倍率で第1段目のMD延伸を行った後、連続的に3.00倍の倍率で第2段目のMD延伸を行った。なお、延伸温度は、第1段目のMD延伸、第2段目のMD延伸ともに70℃で行った。さらに引続き、MD延伸されたフィルムの端部を、テンター式横延伸機のクリップに把持し、TD延伸倍率(Y)が3.70倍となるように延伸した。これらの延伸によって、延伸倍率比(X/Y)は0.93であり、面倍率は(X×Y)は12.77であった。
次いで、熱弛緩処理温度を160℃とし、TDの弛緩率を5.0%として、4秒間の熱弛緩処理を施した後、室温まで冷却してロール状に巻き取り、厚さ12μmのポリエステルフィルムを得た。
ポリエステル(A)とポリエステル(B)の種類と質量比を、またシート成形工程、延伸工程および熱弛緩処理工程の条件を、表1、4、7に示すように変更した以外は、実施例1と同様にして、ポリエステルフィルムを得た。
特に、MD延伸を3段で行った実施例2、22、24、28のフィルムは、2段で行った実施例1、21、23、27のフィルムよりも厚み斑が改善され、保存前後における密着性、製缶性、被覆性がさらに向上した。
実施例13のフィルムは、延伸倍率比および面倍率が外面用フィルムに最も好適な条件であるため、金属缶の外面フィルムに求められる製缶後の透明性に最も優れていた。
実施例6のフィルムは、延伸倍率比および面倍率が内面用フィルムに最も好適な条件であるため、レトルト処理後に長期保存した場合であっても欠点が増加せず、金属缶の内面フィルムに求められるレトルト処理後の長期保存における被覆性に最も優れていた。
比較例3~6のフィルムは、ポリエステル(B)の割合が45質量%を超えているため、製缶後の透明性が低く、レトルト処理後に長期保存した際の被覆性に劣り、比較例6のフィルムは、低温での金属板ラミネート加工において、フィルムと金属板との密着性に劣る結果となった。
比較例11の、MD延伸を1段で行なったフィルムは、厚み斑が本発明で規定する範囲を超え、このため、低温での熱ラミネートにおいて、密着性に劣り、製缶性、被覆性においては、低温だけでなく高温での熱ラミネートにおいても劣り、透明性に劣っていた。
比較例7、10、14のフィルムは、延伸倍率比が本発明で規定する範囲を満たさなかったため、乾熱収縮率が本発明の規定する範囲を超え、さらに乾熱収縮率の最大値と最小値の差が本発明で規定する範囲を満足できなかったため、熱ラミネート温度が高いと、密着性、製缶性、被覆性が劣り、製缶後の透明性に劣る結果となった。
比較例8~9、12~13のフィルムは、延伸倍率比に加えて面倍率も本発明で規定する範囲を満たさなかったため、乾熱収縮率の最大値と最小値の差に加えて4方向の乾熱収縮率が本発明で規定する範囲を満足できないことがあり、このため、密着性、製缶性、被覆性に劣り、製缶後の透明性に劣るものであった。
比較例15のフィルムは、面倍率が本発明で規定する範囲を下回っていたため、厚み斑が本発明で規定する範囲を超え、このため、低温での熱ラミネートにおいて、密着性、製缶性、被覆性に劣り、製缶後の透明性に劣るものであった。
比較例16のフィルムは、面倍率が本発明で規定する範囲を超えているため、乾熱収縮率の最大値と最小値の差が本発明で規定する範囲を超え、このため、熱ラミネート温度が高いと、密着性、製缶性、被覆性に劣り、製缶後の透明性に劣るものであった。
Claims (9)
- ポリブチレンテレフタレートを主体とするポリエステル(A)と、ポリエチレンテレフタレートを主体とするポリエステル(B)とを含むポリエステルフィルムであって、
ポリエステル(A)と(B)の質量比(A/B)が70/30~55/45であり、
フィルム面における任意の方向を0°とし、その方向に対して時計回りに、45°、90°、135°の4方向における、160℃、30分の熱処理による乾熱収縮率(A)がいずれも20%以下であり、これらの乾熱収縮率の最大値と最小値の差が5%以下であり、
前記4方向における、200℃、15分の熱処理による乾熱収縮率(B)がいずれも35%以下であり、これらの乾熱収縮率の最大値と最小値の差が5%以下であり、
前記4方向における下式にて算出した厚み斑が10%以下であることを特徴とするポリエステルフィルム。
厚み斑(%)=(Tmax-Tmin)/Tave×100
Tmax:ポリエステルフィルム4方向における最大厚み
Tmin:ポリエステルフィルム4方向における最小厚み
Tave:ポリエステルフィルム4方向における平均厚み - 融点を、200~223℃の範囲と、225~256℃の範囲とに有することを特徴とする請求項1記載のポリエステルフィルム。
- 請求項1または2記載のポリエステルフィルムを製造するための方法であって、未延伸シートを、シートの流れ方向に延伸(MD延伸)し、次いで、巾方向に延伸(TD延伸)する延伸工程において、
MD延伸を2段以上で行ない、
MD延伸の各段における延伸倍率の積で表されるMD延伸倍率(X)と、TD延伸倍率(Y)とを、
延伸倍率比(X/Y)が0.82~1.10
面倍率(X×Y)が12.00~16.00
を満たすように延伸することを特徴とするポリエステルフィルムの製造方法。 - 請求項1または2記載のポリエステルフィルムからなり、金属板のラミネートに用いられることを特徴とする金属板ラミネート用ポリエステルフィルム。
- 請求項1または2記載のポリエステルフィルムからなり、金属缶のラミネートに用いられることを特徴とする金属缶ラミネート用ポリエステルフィルム。
- 金属缶の内面のラミネートに用いられることを特徴とする請求項5記載の金属缶ラミネート用ポリエステルフィルム。
- 金属缶の外面のラミネートに用いられることを特徴とする請求項5記載の金属缶ラミネート用ポリエステルフィルム。
- 請求項4記載の金属板ラミネート用ポリエステルフィルムが、金属板に積層されてなることを特徴とするラミネート金属板。
- 請求項8記載のラミネート金属板が成形されてなる金属容器。
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