JP3892246B2 - Method for producing gas barrier film - Google Patents
Method for producing gas barrier film Download PDFInfo
- Publication number
- JP3892246B2 JP3892246B2 JP2001114739A JP2001114739A JP3892246B2 JP 3892246 B2 JP3892246 B2 JP 3892246B2 JP 2001114739 A JP2001114739 A JP 2001114739A JP 2001114739 A JP2001114739 A JP 2001114739A JP 3892246 B2 JP3892246 B2 JP 3892246B2
- Authority
- JP
- Japan
- Prior art keywords
- film
- water
- gas barrier
- resin
- oxide
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
- 230000004888 barrier function Effects 0.000 title claims description 51
- 238000004519 manufacturing process Methods 0.000 title claims description 6
- 238000000576 coating method Methods 0.000 claims description 43
- 229920005989 resin Polymers 0.000 claims description 42
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- 239000011248 coating agent Substances 0.000 claims description 40
- -1 polypropylene Polymers 0.000 claims description 25
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- 229910052809 inorganic oxide Inorganic materials 0.000 claims description 21
- 229920001155 polypropylene Polymers 0.000 claims description 21
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 14
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 14
- 239000007787 solid Substances 0.000 claims description 14
- 239000005001 laminate film Substances 0.000 claims description 8
- 239000004925 Acrylic resin Substances 0.000 claims description 7
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- 229920002803 thermoplastic polyurethane Polymers 0.000 claims description 7
- 238000003851 corona treatment Methods 0.000 claims description 5
- 238000001125 extrusion Methods 0.000 claims description 3
- 239000010408 film Substances 0.000 description 80
- 239000007789 gas Substances 0.000 description 29
- 230000000052 comparative effect Effects 0.000 description 20
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 17
- 239000001301 oxygen Substances 0.000 description 17
- 229910052760 oxygen Inorganic materials 0.000 description 17
- 239000010410 layer Substances 0.000 description 15
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- 239000010409 thin film Substances 0.000 description 12
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- 238000000034 method Methods 0.000 description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 10
- 230000035699 permeability Effects 0.000 description 8
- LIVNPJMFVYWSIS-UHFFFAOYSA-N silicon monoxide Chemical compound [Si-]#[O+] LIVNPJMFVYWSIS-UHFFFAOYSA-N 0.000 description 8
- 238000007740 vapor deposition Methods 0.000 description 8
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- 239000000463 material Substances 0.000 description 7
- 238000005259 measurement Methods 0.000 description 7
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 7
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 6
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- MYMOFIZGZYHOMD-UHFFFAOYSA-N Dioxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 description 5
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- 239000004677 Nylon Substances 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
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- 125000001931 aliphatic group Chemical group 0.000 description 3
- 125000003118 aryl group Chemical group 0.000 description 3
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- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
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- 229910004298 SiO 2 Inorganic materials 0.000 description 2
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- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 2
- AMWRITDGCCNYAT-UHFFFAOYSA-L hydroxy(oxo)manganese;manganese Chemical compound [Mn].O[Mn]=O.O[Mn]=O AMWRITDGCCNYAT-UHFFFAOYSA-L 0.000 description 2
- 238000010030 laminating Methods 0.000 description 2
- RLAWWYSOJDYHDC-BZSNNMDCSA-N lisinopril Chemical compound C([C@H](N[C@@H](CCCCN)C(=O)N1[C@@H](CCC1)C(O)=O)C(O)=O)CC1=CC=CC=C1 RLAWWYSOJDYHDC-BZSNNMDCSA-N 0.000 description 2
- 229920001911 maleic anhydride grafted polypropylene Polymers 0.000 description 2
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- NDVLTYZPCACLMA-UHFFFAOYSA-N silver oxide Chemical compound [O-2].[Ag+].[Ag+] NDVLTYZPCACLMA-UHFFFAOYSA-N 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 125000000954 2-hydroxyethyl group Chemical group [H]C([*])([H])C([H])([H])O[H] 0.000 description 1
- QOXOZONBQWIKDA-UHFFFAOYSA-N 3-hydroxypropyl Chemical group [CH2]CCO QOXOZONBQWIKDA-UHFFFAOYSA-N 0.000 description 1
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- UXVMQQNJUSDDNG-UHFFFAOYSA-L Calcium chloride Chemical compound [Cl-].[Cl-].[Ca+2] UXVMQQNJUSDDNG-UHFFFAOYSA-L 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- QPLDLSVMHZLSFG-UHFFFAOYSA-N Copper oxide Chemical compound [Cu]=O QPLDLSVMHZLSFG-UHFFFAOYSA-N 0.000 description 1
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- 229920000742 Cotton Polymers 0.000 description 1
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- 229910020781 SixOy Inorganic materials 0.000 description 1
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 description 1
- KZNMRPQBBZBTSW-UHFFFAOYSA-N [Au]=O Chemical compound [Au]=O KZNMRPQBBZBTSW-UHFFFAOYSA-N 0.000 description 1
- XHCLAFWTIXFWPH-UHFFFAOYSA-N [O-2].[O-2].[O-2].[O-2].[O-2].[V+5].[V+5] Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[V+5].[V+5] XHCLAFWTIXFWPH-UHFFFAOYSA-N 0.000 description 1
- 239000006096 absorbing agent Substances 0.000 description 1
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- 239000000853 adhesive Substances 0.000 description 1
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- 238000007754 air knife coating Methods 0.000 description 1
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- 239000007864 aqueous solution Substances 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 125000004429 atom Chemical group 0.000 description 1
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- CXKCTMHTOKXKQT-UHFFFAOYSA-N cadmium oxide Inorganic materials [Cd]=O CXKCTMHTOKXKQT-UHFFFAOYSA-N 0.000 description 1
- CFEAAQFZALKQPA-UHFFFAOYSA-N cadmium(2+);oxygen(2-) Chemical compound [O-2].[Cd+2] CFEAAQFZALKQPA-UHFFFAOYSA-N 0.000 description 1
- 239000001110 calcium chloride Substances 0.000 description 1
- 229910001628 calcium chloride Inorganic materials 0.000 description 1
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 1
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 1
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- 229910000423 chromium oxide Inorganic materials 0.000 description 1
- 229910000428 cobalt oxide Inorganic materials 0.000 description 1
- IVMYJDGYRUAWML-UHFFFAOYSA-N cobalt(ii) oxide Chemical compound [Co]=O IVMYJDGYRUAWML-UHFFFAOYSA-N 0.000 description 1
- 238000001246 colloidal dispersion Methods 0.000 description 1
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- TYIXMATWDRGMPF-UHFFFAOYSA-N dibismuth;oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Bi+3].[Bi+3] TYIXMATWDRGMPF-UHFFFAOYSA-N 0.000 description 1
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- VXNZUUAINFGPBY-UHFFFAOYSA-N ethyl ethylene Natural products CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 1
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- 125000003055 glycidyl group Chemical group C(C1CO1)* 0.000 description 1
- 229910001922 gold oxide Inorganic materials 0.000 description 1
- 238000009998 heat setting Methods 0.000 description 1
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- IXCSERBJSXMMFS-UHFFFAOYSA-N hydrogen chloride Substances Cl.Cl IXCSERBJSXMMFS-UHFFFAOYSA-N 0.000 description 1
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- PJXISJQVUVHSOJ-UHFFFAOYSA-N indium(iii) oxide Chemical compound [O-2].[O-2].[O-2].[In+3].[In+3] PJXISJQVUVHSOJ-UHFFFAOYSA-N 0.000 description 1
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Landscapes
- Coating Of Shaped Articles Made Of Macromolecular Substances (AREA)
- Treatments Of Macromolecular Shaped Articles (AREA)
- Laminated Bodies (AREA)
- Shaping By String And By Release Of Stress In Plastics And The Like (AREA)
- Physical Vapour Deposition (AREA)
Description
【0001】
【発明の属する技術分野】
本発明は、食品、工業用品及び医薬品等を保護するために用いられる酸素ガスバリア性、水蒸気バリア性、透視性、耐溶剤性及びラミネート強度の優れたガスバリア性フィルムの製造方法に関する。
【0002】
【従来の技術】
ガスバリア性フィルム及びそれを用いた包装材は既に多く知られている。最も完璧なガスバリア性を有するものとしてはアルミニウム箔があるが、単独ではピンホール強度が弱く、特殊な例を除いて使用できず、殆どラミネートフィルムの中間層として使用されている。このラミネートフィルムのガスバリア性はほぼ完璧なものであるが、不透明のため内容物が見えないこと、また確実にヒートシールされたか判断しにくいこと等の欠点がある。
【0003】
他のガスバリア性フィルムとしてはポリ塩化ビニリデン(以下「PVDC」)のフィルム及びコーティングフィルムがよく知られている。特にPVDCのコーティングフィルムはよく知られ、酸素及び水蒸気のバリア性が必要な場合、ラミネート用基材フィルムとしてよく使用されている。PVDCは吸湿性が殆どなく、高湿下でも良好なガスバリア性を有するため、コーティング用の基材としては透湿度に関係なく種々のものが使用される。例えば、二軸延伸ポリプロピレン(OPP)、二軸延伸ナイロン(ONy)、二軸延伸ポリエステル(二軸延伸ポリエチレンテレフタレートの場合(OPET))、セロファン等のフィルムが使用されている。そしてラミネートされたフィルムはガスバリア性を生かし、乾燥・水物を問わず、種々の食品包装に利用されている。しかし、これらの包装材料は利用された後、家庭から一般廃棄物として廃棄されることとなるが、PVDCは燃焼により塩化水素ガスを生じることから、他材料への移行が強く望まれている。
【0004】
一方、ガスバリアフィルムとして、プラスチックフィルム上にアルミ等の金属蒸着や酸化アルミもしくは酸化珪素等を蒸着したもので、食品、工業用品及び医薬品等を容器で包装し酸素の透過を抑制することにより内容物の酸化を防止し、品質を長期間保つことが提案されている。例えば、特公昭53−12953号、特開平4−353532号公報には、厚さが5〜300μmのポリエチレンテレフタレート、セロファン、ナイロン、ポリプロピレン、ポリエチレン等のフレキシブルプラスチックフィルムの少なくとも片面に一般式SixOy(x=1,2,y=0,1,2,3)なる組成の珪素酸化物の厚さ100〜3000オングストロームの透明ガラス質薄膜層を設けた高度の耐透気性と耐透湿性を有する透明フレキシブルプラスチックフィルムが開示されている。
【0005】
このうち、一般的には、フィルム素材がポリエステル、ナイロン、セロファンのような極性基を有する樹脂である場合は、一般に、フィルムと無機酸化膜との密着強度が高く、ガスバリア性も良好である。しかしながら、ポリプロピレンのような極性基を有しないフィルムの表面に、無機酸化物からなる蒸着膜を形成させても、実用に耐えられる安定したガスバリア性は得られない。つまり、ポリプロピレンフィルムと蒸着膜との密着力が十分ではないので、この蒸着物にヒートシール性を付与するためにヒートシール性樹脂をラミネートする場合、該ラミネート物を用いて製袋や蓋シールの二次加工を行う場合、これら袋を用いたり、容器内に収容物を充填し、あるいは、ボイル・レトルト殺菌する場合などで、外部応力や熱が成形品に加わり、無機酸化物薄膜がポリプロピレンフィルムより剥離し、ガスバリア性が低下し、実用に耐えない問題がある。
【0006】
かかる問題は、例えば、特開2000−263722号にあるように、酢酸エチル、トルエン、メチルエチルケトン等の有機溶剤系樹脂コーティング液を用いると改善される方向にあるが、環境問題、人体への影響、コスト等を考えると水系コーティング剤の開発が望まれている。特開平7−126419号、特開平8−245816号公報にはポリプロピレンフィルムにポリビニルアルコール(PVA)を含有する水溶性樹脂コーテイング液を塗布した後、金属または無機化合物を蒸着する例が示されている。しかしながら、これらの例では、乾燥後のコーテイング層を形成する樹脂成分がポリビニルアルコールを主成分とするため、低湿側の酸素バリア性能が良好でも、高湿側では著しいバリア性能の低下を起きること、更には、ポリプロピレンフィルムとコーティング層間又はコーティング層と蒸着薄膜層間の密着強度が十分でないことなどの問題が残されている。
また、特開平8−92400号公報には、PVAの代わりにエチレン・ビニルアルコール共重合体(以下「EVOH」)を用いる場合の開示があるが、EVOHの場合も、高湿下でのバリア性の低下は改善されるが、その反面、オレフィン系樹脂層とAC層との密着性は低下してしまい、ガスバリア性と密着性の両方を満足させるものではない。
【0007】
【発明が解決しようとする課題】
本発明は、以上のようなガスバリア性フィルムの現状を踏まえ、PVDCコートOPP(いわゆるK−OP)に代わる安価な包装材料でとして、ポリプロピレン系樹脂フィルムに、有機溶剤臭のない環境にやさしい水系AC剤をコーテイングし、無機酸化物薄膜を蒸着したガスバリア性フィルムであって、低湿側のみならず高湿側でもガスバリア性に優れ、更にこれの二次加工時や使用時に無機酸化物薄膜が剥離してガスバリア性が低下するようなことがなく、しかも透視性、耐溶剤性に優れたガスバリア性フィルムを提供することを目的とする。
【0008】
【課題を解決するための手段】
本発明は、以上の目的のために鋭意検討した結果達成されたものであって、ポリプロピレン系樹脂を溶融押出して得た未延伸のフィルムを縦方向に延伸し、コロナ放電処理を行い、次いで該縦延伸フィルムのコロナ処理面に、水溶性アクリル樹脂(a)、水溶性ウレタン樹脂(b)及びポリビニルアルコール(c)とからなり、固形分での重量比が下記式(1)〜(3)を満たす水溶性樹脂コーティング液を塗布し、横方向に延伸した後、該コーティング面上に無機酸化物の蒸着膜を形成することを特徴とするガスバリア性フィルムの製造方法に関する。
【式2】
50wt%≦(a)+(c)≦70wt% (1)
30wt%≦(b)≦50wt% (2)
1≦(a)/(c)≦3 (3)
【0009】
【発明の実施の形態】
以下、本発明を詳細に説明する。本発明では、ポリプロピレン基材フィルムに、特定の水溶性コーテイング液を、いわゆるインラインコーテイング法にて塗布、延伸し、最後に無機酸化物を蒸着するものである。水溶性アクリル樹脂(a)、ポリビニルアルコール(c)と無機酸化物を組み合わせることにより良好なガスバリア性が得られる。また、水溶性ウレタン樹脂(b)とポリビニルアルコール(c)を組み合わせることにより、コロナ放電処理したポリプロピレン表面の水酸基やパーオキサイド基と(b)や(c)に含まれる極性基との強固な結合と、蒸着薄膜中の無機原子や酸素原子と(b)や(c)に含まれる極性基との強固な結合が得られ、最終的に基材と無機酸化物蒸着膜の十分な密着強度が得られる。
【0010】
基材層用のポリプロピレン系樹脂はプロピレンホモポリマー、プロピレン・エチレン共重合体、プロピレン・ブテン−1共重合体、プロピレン・4−メチルペンテン−1共重合体等のプロピレン系樹脂、分岐低密度ポリエチレン、リニア−ポリエチレン等のエチレン系樹脂、あるいは、α,β−不飽和カルボン酸で変性したポリプロピレン系樹脂が利用できる。これらは2種以上混合して用いてもよいし、あるいは、積層して用いてもよい。更に目的に応じて、滑剤、酸化防止剤、紫外線吸収剤、帯電防止剤、抗ブロッキング剤、抗菌剤、核剤等を極微量から数十%まで含有していてもよい。
【0011】
水溶性樹脂コーティング液に用いる水溶性アクリル樹脂(a)としては特に限定されるものではないが、濡れ性の点で、エマルジョンタイプより粒子径の小さい、コロイダルディスパージョンタイプや水溶性タイプの方が好ましい。具体的にはメチル(メタ)アクリレート、エチル(メタ)アクリレート、プロピル(メタ)アクリレート、ブチル(メタ)アクリレートや、2−ヒドロキシエチル(メタ)アクリレート、3−ヒドロキシプロピル(メタ)アクリレート等の水酸基を有する物や、グリシジル(メタ)アクリレート等のエポキシ基を有するもの等から選ばれるモノマー単位の1種または2種以上を含有する水分散型の(共)重合体であればよく、この時、(メタ)アクリルアミド、(メタ)アクリル酸、(メタ)アクリル酸ソーダ、(メタ)アクリル酸カリ等の(メタ)アクリル酸系モノマー単位を含んでいてもよい。また、構成成分の異なる(共)重合体の2種以上を併用して用いてもよい。
【0012】
該水溶性アクリル樹脂(a)は後述するポリビニルアルコール(c)と共に酸素バリア性に寄与し、両者は固形分の重量比で50〜70wt%であることが好ましい。50wt%未満では十分なガスバリア性能が得られなく、逆に70wt%より多くなるとガスバリア性能は良好ながら、無機酸化物蒸着膜への印刷等の場合の耐溶剤性が劣ってしまう。
【0013】
また、水溶性アクリル樹脂(a)とポリビニルアルコール(c)の配合比は固形分の重量比で1≦(a)/(c)≦3であるのが好ましく、(a)/(c)の値が1未満ではポリビニルアルコール(c)主体となり、高湿側の酸素バリア性が低下してしまうばかりでなく、製袋品等でのボイル・レトルト加熱時の剥離の原因となる。一方、3より大きくなると基材と無機酸化物蒸着膜との十分な密着強度が得られなくなる。
【0014】
水溶性樹脂コーティング液に用いる水溶性ウレタン樹脂(b)としては特に限定されるものではないが、ディスパージョンタイプが好ましく、脂肪族または芳香族ポリエーテル系ウレタン、脂肪族または芳香族ポリエステル系ウレタン、脂肪族または芳香族ポリカーボネート系ウレタン等が挙げられる。これらの1種または2種以上を併用してもよい。
該水溶性ウレタン樹脂(b)は耐溶剤性に寄与し、固形分濃度の重量比で30〜50wt%であることが好ましい。30wt%未満では無機酸化物蒸着膜への印刷等の場合の耐溶剤性が劣ってしまうばかりでなく、基材からのブリード物等を抑える効果が弱くなる。一方、50wt%より多くなると十分なガスバリア性能が得られないだけでなく、樹脂コーティング膜が固くなる。
【0015】
水溶性樹脂コーティング液に用いるポリビニルアルコールとしては特に限定されるものではないが、コーティング液の粘度とポリビニルアルコールを含むコーティング膜の酸素バリア性の点から重合度が300〜2000、鹸化度が85〜99.5mol%であるものが好ましい。
以上の水溶性樹脂コーティング液中の固形分濃度は均一塗布できれば特に限定されるものではないが、通常1〜10wt%、好ましくは2〜5wt%である。なお、該水溶性樹脂コーティング液には、消泡剤、乳化剤、帯電防止剤、ブロッキング防止剤、粘度調整剤等の各種添加物を目的に応じて適宜添加してもよい。
【0016】
基材への水溶性樹脂コーティング液の塗布は、例えば、スプレーコート法、エアナイフコート法、メタリングバーコート法、マイヤーバーコート法、グラビアロールコート法、リバースロールコート法、キスロールコート法、またはこれらの組み合わせによる各種コーティング方式を採用することができる。水溶性樹脂コーティング液の適性粘度保持が難しい場合や、均一塗布が困難な場合は該コーティング液を、例えば30〜90℃に加温して用いてもよい。
【0017】
塗布厚みは、WET膜厚みで通常10〜60μmの範囲であり、横延伸、熱固定後、ロール状に巻き取った時の状態で通常0.01〜2μm、好ましくは0.03〜1μmとなるように選択される。0.01μm未満では凹凸の激しいポリプロピレン系樹脂表面を十分に平滑にすることができず、従って十分な酸素バリア性が得られない。また、基材からのブリード物等を抑える効果が弱くなってしまう。一方、2μmより厚くなると、ロール状に巻き取った時、ブロッキングを起こし易くなるばかりか、コスト的にも高いものになってしまう。
【0018】
本発明での蒸着前の延伸フィルムは次のように製造される。即ち、前記ポリプロピレン系樹脂を、単層、または多層でフィルム状に溶融押出し、この未延伸フィルムを通常120〜140に加熱したロール群の周速差を利用して通常3〜8倍縦方向に延伸した後、コロナ放電処理を行い、該縦延伸フィルムのコロナ処理面に水溶性樹脂コーティング液を塗液し、テンターで横方向に通常4〜12倍に延伸し、必要に応じて熱固定を行い、一般的は、最後に、フィルム両端をトリミングし、ロール状に巻き取ることにより製造される。
【0019】
上記のコロナ放電処理の量は、通常30〜100w・分/m2とする。30w・分/m2 未満ではポリプロピレン系樹脂の表面を十分に改質することが難しく、水溶性樹脂コーティング液との十分な密着強度が得られない。逆に100w・分/m2 を越えると放電スパークが大きくなり、塗膜に白化筋模様を生じるような場合にはこれが塗布ムラの原因となってしまう。また、コロナ放電処理したフィルム表面の表面張力レベルは35ダイン/cm以上、好ましくは40〜50ダイン/cmであるのが望ましい。
【0020】
上記の延伸フィルムは、好ましくは、基材層が肉厚10〜100μmの二軸延伸ポリポリプロピレンフィルムで、少なくとも片方の面に肉厚0.01〜2μmの水溶性樹脂コーティング液膜の一軸延伸フィルムが積層された構造体である。また、その透視性は良好であり、フィルムの全光線透過率が、通常85%以上、好ましくは90%以上である。
【0021】
以上の延伸フィルムのコーテイング面には無機酸化物を蒸着する。この場合の無機酸化物とは、金属、非金属、亜金属の酸化物であり、具体例としては、酸化アルミニウム、酸化亜鉛、酸化アンチモン、酸化インジウム、酸化カルシウム、酸化カドミウム、酸化銀、酸化金、酸化クロム、珪素酸化物、酸化コバルト、酸化ジルコニウム、酸化スズ、酸化チタン、酸化鉄、酸化銅、酸化ニッケル、酸化白金、酸化パラジウム、酸化ビスマス、酸化マグネシウム、酸化マンガン、酸化モリブデン、酸化バナジウム、酸化バリウム等が挙げられるが、高度な酸素ガスバリア性、水蒸気バリア性及び透視性とを兼ね備え、かつ工業的に安価であるという点で、珪素酸化物、酸化アルミニウムが特に好ましい。かかる珪素酸化物、酸化アルミニウムは各々単独で使用してもよいし、混合物として使用してもよい。尚、無機酸化物には、微量の金属、非金属、亜金属単体やそれらの水酸化物、また、可撓性を向上させる目的で適宜炭素又は弗素が含まれていてもよい。
【0022】
蒸着膜の形成には膜の均一性、基材との密着力等の点から真空蒸着法が好ましく、抵抗加熱法、高周波誘導加熱法、電子ビーム法等が挙げられる。珪素酸化物を真空蒸着法により形成する場合は、蒸着源材料としてSiO、SiO2、またはこれらの混合物、更にSiとSiO2の混合物などが採用され、同時に酸素ガスを供給しながら行う反応蒸着法も採用できる。また、酸化アルミニウムを真空蒸着法により形成する場合は、蒸着源材料として酸化アルミニウムの粉末や固形物が採用されるが、アルミニウム金属を用いて酸素ガスを導入しなが行う反応蒸着法の方が、非結晶性で可撓性のある酸化アルミニウム薄膜層を形成できる点でより好ましい。蒸着膜の厚みに特に制限はなく、無機酸化物の種類等によっても異なるが、酸素ガスバリア性及び水蒸気バリア性、透視性、コスト等の点から、通常50〜2000オングストローム、好ましくは100〜500オングストロームである。
【0023】
本発明の製造方法で得られたガスバリア性フィルムは用途に応じてそのまま用いてもよいし、更に蒸着膜上にヒートシール層または保護層などを設けてもよい。ヒートシール層としては特に制限はなく、通常無延伸ポリプロピレン、ポリエチレン、エチレン−酢酸ビニル系共重合体、エチレン−アクリル酸系共重合体、或いはエチレン−酢酸ビニル系共重合体、エチレン−アクリル酸系共重合体などのエチレン系のアイオノマーなどが挙げられる。ヒートシール層は通常ドライラミネート法或いは押し出し法によって設けられる。厚さは、通常20〜100μm、好ましくは40〜80μmである。また、保護層は、ポリエステル、ナイロン、エチレン−ビニルアルコール共重合体などのフィルムをラミネートするか、あるいは、耐熱性のあるエポキシ樹脂、メラミン樹脂、ウレタン樹脂、ポリエステル樹脂などをコーティングすることなどによって設けられる。
【0024】
【実施例】
以下、実施例により、本発明を詳細に説明するが、これにより本発明の範囲は特に限定されるものではない。
以下の例において得られたフィルムの評価は下記の方法によって行ったものである。なお、ラミネートフィルムとあるのは、本発明のガスバリア性フィルムの無機酸化物薄膜面に、厚さ50μmの無延伸ポリプロピレンフィルムを二液硬化型ポリウレタン系接着剤を用いてドライラミネートし、40℃で3日間エージングさせたものであり、ヒートシール層が設けられているガスバリア性の付与された樹脂成型品を意味する。
【0025】
<MFR[g/10分]>
JIS K−6758により荷重2160g、測定温度190℃で測定した。<水溶性樹脂コーティング層の厚さ[μm]>
巻き取った延伸フィルムの断面を透過型電子顕微鏡(日立製作所製H−600型)で観察し、測定した。
<蒸着膜の厚さ[オングストローム]>
理学電機工業社製の蛍光X線装置を使用し、Siとしての蒸着膜の厚さを測定した。
<全光線透過率[%]及びヘイズ>
日本電色工業製ヘイズメータNDH300A型を使用して測定した。
<黄色度>
日本電色工業製色差計Z−Σ80型を使用して測定した。
<耐溶剤性>
酢酸エチルを染み込ませた綿棒を用い、無機酸化物薄膜面の上から一定方向に表面を軽く5回擦り、無機酸化物薄膜の剥離状況を光学顕微鏡(200倍)で観察し、下記の基準で判定した。
○・・・・擦った部分が剥離していない。
△・・・・擦った部分が少し剥離している。
×・・・・擦った部分が剥離している。
【0026】
<酸素透過率[cc/m2・24h・atm]>
ラミネートフィルムを用い、モダンコントロール社製のOX−TRAN2/20型酸素透過率測定装置を使用し、温度25℃、相対湿度80%の条件下、及び温度25℃、相対湿度90%の条件下で測定した。
<水蒸気透過度(透湿度)[g/m2・24h]>
ラミネートフィルムのヒートシール層を内面にして表面積が約100cm2の袋を作り、塩化カルシウムを適量入れた後、密封した。これを40℃・90%RHの雰囲気に7日間放置し、重量増加量から水蒸気透過度を求めた。
<ラミネート強度[g/15mm]>
ラミネートフィルムから切り出した幅15mm、長さ10cmの短冊状試験片を用い、島津製作所オートグラフAG−I型を使用し、ロードセル5kg、テストスピード300mm/分での180°剥離強度から求めた。
【0027】
実施例1及び比較例1
ポリプロピレン樹脂として日本ポリケム(株)製『ノバテックPP FL6CK』(MFR2.4、融点161℃)を使用し、押出機温度220℃で溶融してTダイよりシート状に押し出し、これを30℃のキャストロールに密着させて未延伸のシートを得た。次に、周速の異なる加熱ロール群からなる縦延伸機を用い、この未延伸シートを130℃の温度で最終的に5倍になるよう多段延伸し、続いてコーティングする面側を90w・分/m2 の条件でコロナ放電処理を施した。次に、固形分重量比が表1の実施例1及び比較例1となるように調整した水溶性樹脂コーティング液(固形分濃度約2.5wt%)をメタリングバーコーターを用いてWET膜厚さ約15μmにコーティングし、続いて150℃のテンターオーブン内に導入し、横方向に10倍延伸し、158℃で熱固定し、厚さ20μmのコーティングフィルムを得た。コーティング層の厚さはいずれも約0.04μmであった。
【0028】
上記各々のフィルムの水溶性樹脂コーティング面に、1×10-5Torrの高真空にした後酸素を導入して4×10-5Torrの真空下とし、電子ビーム加熱方式で純度99.9%の一酸化珪素(SiO)を加熱蒸発させ、蒸着膜積層延伸フィルムを得た。得られたフィルムはそのままの状態で、蒸着膜の厚さ、全光線透過率、ヘイズ、黄色度を測定し、耐溶剤性を評価した。次に、ラミネートフィルムとした後、酸素透過率、水蒸気透過率、及びラミネート強度を測定した。結果を表−2の実施例1及び比較例1に示す。比較例1の組成では根本的な酸素バリア性能が十分でない。
【0029】
実施例2及び比較例2
実施例1において、水溶性樹脂コーティング液の固形分重量比を表―1の実施例2及び比較例2に示される組成に変更した点、及び水溶性樹脂コーティング面に、8×10-5Torrの高真空にした後酸素を導入して3×10-4Torrの真空下として、純度99.99%のアルミニウム金属を加熱蒸発させた点以外は、実施例1と同様にして蒸着膜積層延伸フィルムを得た。各物性の測定結果を表―2の実施例2及び比較例2に示す。比較例2の組成では高湿側(25℃×90%RH)の酸素バリア性能が好ましくない。
【0030】
実施例3及び比較例3
ポリプロピレン樹脂として日本ポリケム(株)製『ノバテックPP FL6CK』(MFR2.4、融点161℃)と、無水マレイン酸グラフトポリプロピレン(MFR2.3;無水マレイン酸グラフト率0.05wt%;融点138℃)を使用し、これらを別々の押出機で各々220℃で溶融し、フィードブロック内で層状に重ね、T−ダイより押し出して未延伸シートを作成した(無水マレイン酸グラフトポリプロピレン層の厚みは全体の13%であった)点、及び水溶性樹脂コーティング液の固形分重量比を表1の実施例3及び比較例3に示される組成に変更した点以外は、実施例1と同様にして蒸着膜積層延伸フィルムを得た。各物性の測定結果を表2の実施例3及び比較例3に示す。比較例3の組成では耐溶剤性が好ましくない。
【0031】
実施例4及び比較例4
実施例2において、水溶性樹脂コーティング液の固形分重量比を表―1の実施例4及び比較例4に示される組成に変更し、かつ該コーティング液の固形分濃度を約5wt%とした(コーティング層の厚さはいずれも約0.08μmであった)点以外は、実施例2と同様にして蒸着膜積層延伸フィルムを得た。各物性の測定結果を表―2の実施例4及び比較例4に示す。比較例4の組成では酸素バリア性、耐溶剤性、ラミネート強度いずれも十分でない。
【0032】
比較例5
実施例1において、水溶性樹脂コーティング液をコーティングしない点以外は、実施例1と同様にして蒸着膜積層延伸フィルムを得た。各物性の測定結果を表―2の比較例5に示す。この構成では酸素バリア性、耐溶剤性、ラミネート強度いずれも好ましくない。
比較例6
実施例1において、蒸着する前のコーティングフィルムをサンプルとした。各物性の測定結果を表―2の比較例6に示す。この構成では特に酸素バリア性が好ましくない。
【0033】
【表1】
【0034】
表−1におけるコーテイング樹脂(a),(b),(c)は以下の通りである。
<水溶性アクリル樹脂(a)>
アクリル1:日本純薬(株)製『ジュリマーFC−80』(配合量は固形分濃度30%として計算)
<水溶性ウレタン樹脂(b)>
ウレタン1:ゼネカ(株)製『NeoRez R−9603』(配合量は固形分濃度34%として計算)
ウレタン2:大日本インキ化学工業(株)製『ハイドラン AP−30』(配合量は固形分濃度20%として計算)
<ポリビニルアルコール(c)>
PVA1:日本合成化学工業(株)製『ゴーセノールN−300(重合度1650〜1700 鹸化度98〜99mol%)』
PVA2:日本合成化学工業(株)製『ゴーセノールGM−14(重合度1650〜1700 鹸化度86.5〜89mol%)』
上記PVA1,PVA2(顆粒状)の水への溶解方法は同製品のカタログを参照し、(c)を溶解させた水溶液に(a)液と(b)液を追加して水溶性樹脂コーティング液を調整した。
【0035】
【表2】
【0036】
【発明の効果】
本発明により得られる、ガスバリア性フィルム、即ち、無機酸化物薄膜が蒸着されたポリプロピレン系樹脂成形品は、低湿側のみならず高湿側でもガスバリア性に優れ、更に、これの二次加工時や使用時に金属酸化物薄膜が剥離してガスバリア性が低下するようなことがなく、併せて透視性、耐溶剤性に優れるので、PVDCコートOPPに代わる安価な包装材料として食品、工業用品及び医薬品等を保護するために用いられる包装用樹脂成形品として広く供することができる。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a gas barrier film having excellent oxygen gas barrier properties, water vapor barrier properties, transparency, solvent resistance, and laminate strength, which is used for protecting foods, industrial articles, pharmaceuticals, and the like.
[0002]
[Prior art]
Many gas barrier films and packaging materials using the same are already known. Aluminum foil has the most perfect gas barrier property, but it has a low pinhole strength by itself and cannot be used except for special cases, and is almost used as an intermediate layer of a laminate film. The gas barrier property of this laminate film is almost perfect, but there are drawbacks such as the fact that the contents cannot be seen due to the opaqueness, and that it is difficult to determine whether the heat sealing has been reliably performed.
[0003]
As another gas barrier film, a polyvinylidene chloride (hereinafter “PVDC”) film and a coating film are well known. In particular, a coating film of PVDC is well known, and is frequently used as a base film for lamination when oxygen and water vapor barrier properties are required. Since PVDC has almost no hygroscopic property and has a good gas barrier property even under high humidity, various substrates are used regardless of moisture permeability. For example, films such as biaxially stretched polypropylene (OPP), biaxially stretched nylon (ONy), biaxially stretched polyester (in the case of biaxially stretched polyethylene terephthalate (OPET)), and cellophane are used. The laminated film makes use of gas barrier properties and is used for various food packaging regardless of whether it is dry or water. However, after these packaging materials are used, they are discarded as household waste from households. However, since PVDC generates hydrogen chloride gas by combustion, there is a strong demand for the transition to other materials.
[0004]
On the other hand, as a gas barrier film, a metal film such as aluminum or aluminum oxide or silicon oxide is vapor-deposited on a plastic film, and food, industrial goods, pharmaceuticals, etc. are wrapped in a container and the contents are controlled by suppressing oxygen permeation. It has been proposed to prevent oxidation and to maintain the quality for a long time. For example, in Japanese Patent Publication No. 53-12953 and Japanese Patent Application Laid-Open No. 4-353532, a general formula SixOy (x) is formed on at least one surface of a flexible plastic film such as polyethylene terephthalate, cellophane, nylon, polypropylene, polyethylene, etc. = 1, 2, y = 0, 1, 2, 3) A transparent flexible film having a high degree of air resistance and moisture resistance provided with a transparent glassy thin film layer having a thickness of 100 to 3000 angstroms of silicon oxide composition A plastic film is disclosed.
[0005]
Of these, generally, when the film material is a resin having a polar group such as polyester, nylon, and cellophane, the adhesion strength between the film and the inorganic oxide film is generally high, and the gas barrier property is also good. However, even if a vapor-deposited film made of an inorganic oxide is formed on the surface of a film such as polypropylene that does not have a polar group, a stable gas barrier property that can withstand practical use cannot be obtained. That is, since the adhesion between the polypropylene film and the deposited film is not sufficient, when laminating a heat-sealable resin to impart heat sealability to the deposited product, the laminate is used for bag making and lid sealing. When secondary processing is performed, when these bags are used, the contents are filled in the container, or when boil and retort are sterilized, external stress and heat are applied to the molded product, and the inorganic oxide thin film becomes a polypropylene film. There is a problem that the film is more peeled, the gas barrier property is lowered, and cannot be practically used.
[0006]
For example, as described in JP-A No. 2000-263722, such a problem tends to be improved by using an organic solvent-based resin coating solution such as ethyl acetate, toluene, and methyl ethyl ketone. However, environmental problems, effects on the human body, In view of cost and the like, development of a water-based coating agent is desired. JP-A-7-126419 and JP-A-8-245816 show examples in which a metal or inorganic compound is deposited after a water-soluble resin coating solution containing polyvinyl alcohol (PVA) is applied to a polypropylene film. . However, in these examples, since the resin component forming the coating layer after drying is mainly composed of polyvinyl alcohol, even if the oxygen barrier performance on the low humidity side is good, the barrier performance is significantly lowered on the high humidity side. Furthermore, problems such as insufficient adhesion strength between the polypropylene film and the coating layer or between the coating layer and the deposited thin film layer remain.
Japanese Patent Application Laid-Open No. 8-92400 discloses a case where an ethylene / vinyl alcohol copolymer (hereinafter referred to as “EVOH”) is used instead of PVA. In the case of EVOH, barrier properties under high humidity are also disclosed. However, on the other hand, the adhesion between the olefinic resin layer and the AC layer is lowered, which does not satisfy both the gas barrier property and the adhesion.
[0007]
[Problems to be solved by the invention]
The present invention is based on the present state of the gas barrier film as described above, and is an inexpensive packaging material that replaces PVDC-coated OPP (so-called K-OP). It is a gas barrier film coated with an agent and deposited with an inorganic oxide thin film, which has excellent gas barrier properties not only on the low-humidity side but also on the high-humidity side. In addition, the inorganic oxide thin film peels off during secondary processing and use. It is an object of the present invention to provide a gas barrier film that does not deteriorate gas barrier properties and is excellent in transparency and solvent resistance.
[0008]
[Means for Solving the Problems]
The present invention has been achieved as a result of diligent investigations for the above-mentioned purpose, and an unstretched film obtained by melt-extrusion of a polypropylene resin is stretched in the machine direction, subjected to corona discharge treatment, and then The corona-treated surface of the longitudinally stretched film comprises a water-soluble acrylic resin (a), a water-soluble urethane resin (b), and polyvinyl alcohol (c), and the weight ratio in solid content is represented by the following formulas (1) to (3). The present invention relates to a method for producing a gas barrier film, characterized in that a water-soluble resin coating solution satisfying the above condition is applied and stretched in the transverse direction, and then an inorganic oxide vapor deposition film is formed on the coating surface.
[Formula 2]
50 wt% ≦ (a) + (c) ≦ 70 wt% (1)
30 wt% ≤ (b) ≤ 50 wt% (2)
1 ≦ (a) / (c) ≦ 3 (3)
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail. In the present invention, a specific water-soluble coating solution is applied to a polypropylene base film by a so-called in-line coating method and stretched, and finally an inorganic oxide is deposited. Good gas barrier properties can be obtained by combining a water-soluble acrylic resin (a), polyvinyl alcohol (c) and an inorganic oxide. In addition, by combining the water-soluble urethane resin (b) and the polyvinyl alcohol (c), a strong bond between the hydroxyl group or peroxide group on the corona discharge-treated polypropylene surface and the polar group contained in the (b) or (c) And a strong bond between the inorganic atom or oxygen atom in the deposited thin film and the polar group contained in (b) or (c) is obtained, and finally the sufficient adhesion strength between the substrate and the deposited inorganic oxide film is obtained. can get.
[0010]
The polypropylene resin for the base material layer is a propylene resin such as propylene homopolymer, propylene / ethylene copolymer, propylene / butene-1 copolymer, propylene / 4-methylpentene-1 copolymer, branched low density polyethylene, etc. An ethylene resin such as linear polyethylene or a polypropylene resin modified with an α, β-unsaturated carboxylic acid can be used. Two or more of these may be used in combination, or may be used in a stacked manner. Further, depending on the purpose, lubricants, antioxidants, ultraviolet absorbers, antistatic agents, antiblocking agents, antibacterial agents, nucleating agents, and the like may be contained from a very small amount to several tens of percent.
[0011]
The water-soluble acrylic resin (a) used in the water-soluble resin coating solution is not particularly limited, but in terms of wettability, the colloidal dispersion type or the water-soluble type has a smaller particle diameter than the emulsion type. preferable. Specifically, hydroxyl groups such as methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, butyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, and 3-hydroxypropyl (meth) acrylate are used. Or a water-dispersed (co) polymer containing one or more monomer units selected from those having an epoxy group such as glycidyl (meth) acrylate. (Meth) acrylic acid-based monomer units such as (meth) acrylamide, (meth) acrylic acid, (meth) acrylic acid soda, and (meth) acrylic acid potassium may be included. Moreover, you may use together and use 2 or more types of the (co) polymer from which a structural component differs.
[0012]
The water-soluble acrylic resin (a) contributes to oxygen barrier properties together with polyvinyl alcohol (c) described later, and both are preferably 50 to 70 wt% in terms of the weight ratio of the solid content. If it is less than 50 wt%, sufficient gas barrier performance cannot be obtained. Conversely, if it exceeds 70 wt%, the gas barrier performance is good, but the solvent resistance in printing on an inorganic oxide vapor-deposited film is poor.
[0013]
The blending ratio of the water-soluble acrylic resin (a) and the polyvinyl alcohol (c) is preferably 1 ≦ (a) / (c) ≦ 3 in terms of the weight ratio of the solid content, and the ratio of (a) / (c) If the value is less than 1, it becomes the main component of polyvinyl alcohol (c), which not only deteriorates the oxygen barrier property on the high humidity side, but also causes peeling at the time of boil / retort heating in bag-made products. On the other hand, if it exceeds 3, sufficient adhesion strength between the substrate and the inorganic oxide vapor deposition film cannot be obtained.
[0014]
The water-soluble urethane resin (b) used in the water-soluble resin coating liquid is not particularly limited, but is preferably a dispersion type, aliphatic or aromatic polyether urethane, aliphatic or aromatic polyester urethane, Aliphatic or aromatic polycarbonate urethane can be used. One or two or more of these may be used in combination.
The water-soluble urethane resin (b) contributes to solvent resistance and is preferably 30 to 50 wt% in terms of the weight ratio of the solid content concentration. If it is less than 30 wt%, not only the solvent resistance in the case of printing on an inorganic oxide vapor-deposited film will be inferior, but also the effect of suppressing bleed from the substrate will be weak. On the other hand, if it exceeds 50 wt%, not only a sufficient gas barrier performance cannot be obtained, but also the resin coating film becomes hard.
[0015]
The polyvinyl alcohol used in the water-soluble resin coating liquid is not particularly limited, but the polymerization degree is 300 to 2000 and the saponification degree is 85 to 85 from the viewpoint of the viscosity of the coating liquid and the oxygen barrier property of the coating film containing polyvinyl alcohol. What is 99.5 mol% is preferable.
The solid content concentration in the above water-soluble resin coating solution is not particularly limited as long as it can be uniformly applied, but is usually 1 to 10 wt%, preferably 2 to 5 wt%. In addition, you may add suitably various additives, such as an antifoamer, an emulsifier, an antistatic agent, an antiblocking agent, a viscosity modifier, to this water-soluble resin coating liquid according to the objective.
[0016]
Application of the water-soluble resin coating liquid to the substrate is, for example, a spray coating method, an air knife coating method, a metering bar coating method, a Mayer bar coating method, a gravure roll coating method, a reverse roll coating method, a kiss roll coating method, or Various coating methods based on these combinations can be employed. When it is difficult to maintain the proper viscosity of the water-soluble resin coating liquid, or when uniform application is difficult, the coating liquid may be heated to, for example, 30 to 90 ° C.
[0017]
The coating thickness is usually in the range of 10 to 60 μm in terms of WET film thickness, and is usually 0.01 to 2 μm, preferably 0.03 to 1 μm in the state of being rolled up after transverse stretching and heat setting. Selected as If the thickness is less than 0.01 μm, the surface of the polypropylene resin with severe irregularities cannot be sufficiently smoothed, and therefore sufficient oxygen barrier properties cannot be obtained. Moreover, the effect which suppresses the bleed material etc. from a base material will become weak. On the other hand, when it becomes thicker than 2 μm, when it is wound up in a roll shape, it is not only easy to cause blocking, but also the cost becomes high.
[0018]
The stretched film before vapor deposition in the present invention is produced as follows. That is, the polypropylene-based resin is melt-extruded into a single-layer or multi-layer film, and the unstretched film is heated to 120 to 140, and usually 3 to 8 times in the vertical direction using the difference in peripheral speed of the roll group. After stretching, a corona discharge treatment is performed, a water-soluble resin coating solution is applied to the corona-treated surface of the longitudinally stretched film, and it is usually stretched 4 to 12 times in the transverse direction with a tenter, and heat-fixed as necessary. In general, the film is manufactured by trimming both ends of the film and winding it into a roll.
[0019]
The amount of the corona discharge treatment is usually 30 to 100 w · min / m 2 . If it is less than 30 w · min / m 2 , it is difficult to sufficiently modify the surface of the polypropylene resin, and sufficient adhesion strength with the water-soluble resin coating solution cannot be obtained. On the other hand, if it exceeds 100 w · min / m 2 , the discharge spark becomes large, and when a whitening streak pattern is formed on the coating film, this causes uneven coating. The surface tension level of the corona discharge treated film surface is 35 dynes / cm or more, preferably 40 to 50 dynes / cm.
[0020]
The stretched film is preferably a biaxially stretched polypolypropylene film having a base layer thickness of 10 to 100 μm and a uniaxially stretched film of a water-soluble resin coating liquid film having a thickness of 0.01 to 2 μm on at least one surface. Is a laminated structure. Further, the transparency is good, and the total light transmittance of the film is usually 85% or more, preferably 90% or more.
[0021]
An inorganic oxide is deposited on the coating surface of the above stretched film. The inorganic oxide in this case is a metal, non-metal, or sub-metal oxide, and specific examples include aluminum oxide, zinc oxide, antimony oxide, indium oxide, calcium oxide, cadmium oxide, silver oxide, and gold oxide. , Chromium oxide, silicon oxide, cobalt oxide, zirconium oxide, tin oxide, titanium oxide, iron oxide, copper oxide, nickel oxide, platinum oxide, palladium oxide, bismuth oxide, magnesium oxide, manganese oxide, molybdenum oxide, vanadium oxide, Although barium oxide etc. are mentioned, a silicon oxide and aluminum oxide are especially preferable at the point which has high oxygen gas barrier property, water vapor | steam barrier property, and transparency, and is industrially cheap. Such silicon oxide and aluminum oxide may be used alone or as a mixture. The inorganic oxide may contain trace amounts of metals, non-metals, sub-metals or their hydroxides, and carbon or fluorine as appropriate for the purpose of improving flexibility.
[0022]
For the formation of the deposited film, a vacuum deposition method is preferable from the viewpoint of film uniformity and adhesion to the substrate, and examples thereof include a resistance heating method, a high frequency induction heating method, and an electron beam method. When silicon oxide is formed by a vacuum deposition method, a reactive deposition method in which SiO, SiO 2 , or a mixture thereof, and a mixture of Si and SiO 2 are employed as an evaporation source material and oxygen gas is supplied simultaneously. Can also be adopted. In addition, when aluminum oxide is formed by vacuum deposition, aluminum oxide powder or solid material is adopted as a deposition source material. However, reactive vapor deposition using an aluminum metal with oxygen gas introduced is preferred. It is more preferable in that an amorphous and flexible aluminum oxide thin film layer can be formed. Although there is no restriction | limiting in particular in the thickness of a vapor deposition film, Although it changes also with kinds, etc. of inorganic oxides, from points, such as oxygen gas barrier property and water vapor | steam barrier property, transparency, and cost, Usually 50-2000angstrom, Preferably it is 100-500angstrom. It is.
[0023]
The gas barrier film obtained by the production method of the present invention may be used as it is depending on the application, or a heat seal layer or a protective layer may be further provided on the deposited film. The heat seal layer is not particularly limited, and is usually unstretched polypropylene, polyethylene, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, or ethylene-vinyl acetate copolymer, ethylene-acrylic acid system. And ethylene ionomers such as copolymers. The heat seal layer is usually provided by a dry lamination method or an extrusion method. The thickness is usually 20 to 100 μm, preferably 40 to 80 μm. The protective layer is provided by laminating a film of polyester, nylon, ethylene-vinyl alcohol copolymer, or by coating with a heat-resistant epoxy resin, melamine resin, urethane resin, polyester resin, or the like. It is done.
[0024]
【Example】
EXAMPLES Hereinafter, although an Example demonstrates this invention in detail, this does not specifically limit the scope of the present invention.
The film obtained in the following examples was evaluated by the following method. Note that the laminate film means that an unstretched polypropylene film having a thickness of 50 μm is dry-laminated using a two-component curable polyurethane adhesive on the inorganic oxide thin film surface of the gas barrier film of the present invention at 40 ° C. It means a resin molded product that has been aged for 3 days and has a gas barrier property provided with a heat seal layer.
[0025]
<MFR [g / 10 min]>
Measured according to JIS K-6758 at a load of 2160 g and a measurement temperature of 190 ° C. <Thickness of water-soluble resin coating layer [μm]>
The cross section of the wound stretched film was observed with a transmission electron microscope (H-600 type manufactured by Hitachi, Ltd.) and measured.
<Thickness of deposited film [Angstrom]>
Using a fluorescent X-ray apparatus manufactured by Rigaku Denki Kogyo Co., Ltd., the thickness of the deposited film as Si was measured.
<Total light transmittance [%] and haze>
It measured using the Nippon Denshoku Industries haze meter NDH300A type.
<Yellowness>
Measurement was performed using a color difference meter Z-Σ80 manufactured by Nippon Denshoku Industries Co., Ltd.
<Solvent resistance>
Using a cotton swab soaked with ethyl acetate, the surface of the inorganic oxide thin film was rubbed lightly 5 times in a fixed direction, and the peeling state of the inorganic oxide thin film was observed with an optical microscope (200 times). Judged.
○: The rubbed part is not peeled off.
Δ: The rubbed part is slightly peeled off.
× ··· The rubbed part is peeled off.
[0026]
<Oxygen permeability [cc / m 2 · 24h · atm]>
Using an OX-TRAN 2/20 type oxygen permeability measuring device manufactured by Modern Control Co., Ltd. using a laminate film, under conditions of a temperature of 25 ° C. and a relative humidity of 80%, and a temperature of 25 ° C. and a relative humidity of 90% It was measured.
<Water vapor permeability (moisture permeability) [g / m 2 · 24h]>
A bag with a surface area of about 100 cm 2 was made with the heat seal layer of the laminate film as the inner surface, and after putting an appropriate amount of calcium chloride, it was sealed. This was left in an atmosphere of 40 ° C. and 90% RH for 7 days, and the water vapor permeability was determined from the weight increase.
<Lamination strength [g / 15mm]>
Using a strip-shaped test piece having a width of 15 mm and a length of 10 cm cut out from the laminate film, Shimadzu Autograph AG-I type was used, and the 180 ° peel strength at a load cell of 5 kg and a test speed of 300 mm / min was obtained.
[0027]
Example 1 and Comparative Example 1
Using “NOVATEC PP FL6CK” (MFR 2.4, melting point 161 ° C.) manufactured by Nippon Polychem Co., Ltd. as a polypropylene resin, it is melted at an extruder temperature of 220 ° C. and extruded into a sheet form from a T die, which is cast at 30 ° C. An unstretched sheet was obtained by closely contacting the roll. Next, using a longitudinal stretching machine composed of a group of heating rolls having different peripheral speeds, this unstretched sheet is stretched in multiple stages so as to be finally 5 times at a temperature of 130 ° C., and then the surface side to be coated is 90 w · min. Corona discharge treatment was performed under the conditions of / m 2 . Next, a water-soluble resin coating solution (solid content concentration of about 2.5 wt%) adjusted so that the weight ratio of the solid content becomes Example 1 and Comparative Example 1 in Table 1 was measured using a metalling bar coater. The film was coated to a thickness of about 15 μm, subsequently introduced into a tenter oven at 150 ° C., stretched 10 times in the transverse direction, and heat-set at 158 ° C. to obtain a coating film having a thickness of 20 μm. The thickness of each coating layer was about 0.04 μm.
[0028]
A high vacuum of 1 × 10 −5 Torr was applied to the water-soluble resin-coated surface of each of the above films, and oxygen was introduced to create a vacuum of 4 × 10 −5 Torr. The purity was 99.9% by electron beam heating. The silicon monoxide (SiO) was evaporated by heating to obtain a vapor-deposited laminated stretched film. The obtained film was left as it was, and the thickness, total light transmittance, haze, and yellowness of the deposited film were measured to evaluate the solvent resistance. Next, after forming a laminate film, oxygen permeability, water vapor permeability, and laminate strength were measured. The results are shown in Example 1 and Comparative Example 1 in Table-2. In the composition of Comparative Example 1, the fundamental oxygen barrier performance is not sufficient.
[0029]
Example 2 and Comparative Example 2
In Example 1, the solid content weight ratio of the water-soluble resin coating solution was changed to the composition shown in Example 2 and Comparative Example 2 of Table 1, and 8 × 10 −5 Torr on the water-soluble resin coating surface. Vapor deposition of the deposited film was carried out in the same manner as in Example 1 except that oxygen was introduced and the vacuum was set to 3 × 10 −4 Torr and the aluminum metal with a purity of 99.99% was heated and evaporated. A film was obtained. The measurement results of each physical property are shown in Example 2 and Comparative Example 2 in Table-2. In the composition of Comparative Example 2, the oxygen barrier performance on the high humidity side (25 ° C. × 90% RH) is not preferable.
[0030]
Example 3 and Comparative Example 3
As a polypropylene resin, “NOVATEC PP FL6CK” (MFR 2.4, melting point 161 ° C.) manufactured by Nippon Polychem Co., Ltd. and maleic anhydride grafted polypropylene (MFR 2.3; maleic anhydride graft ratio 0.05 wt%; melting point 138 ° C.) These were melted at 220 ° C. in separate extruders, layered in a feed block, and extruded from a T-die to produce an unstretched sheet (the maleic anhydride grafted polypropylene layer had a total thickness of 13 %), And the solid content weight ratio of the water-soluble resin coating solution was changed to the compositions shown in Example 3 and Comparative Example 3 in Table 1 in the same manner as in Example 1 except that the deposited film was laminated. A stretched film was obtained. The measurement results of each physical property are shown in Example 3 and Comparative Example 3 in Table 2. In the composition of Comparative Example 3, the solvent resistance is not preferred.
[0031]
Example 4 and Comparative Example 4
In Example 2, the weight ratio of the solid content of the water-soluble resin coating liquid was changed to the composition shown in Example 4 and Comparative Example 4 in Table 1, and the solid content concentration of the coating liquid was about 5 wt% ( A vapor-deposited laminated stretched film was obtained in the same manner as in Example 2 except that the thickness of each coating layer was about 0.08 μm. The measurement results of each physical property are shown in Example 4 and Comparative Example 4 in Table-2. In the composition of Comparative Example 4, the oxygen barrier properties, solvent resistance, and laminate strength are not sufficient.
[0032]
Comparative Example 5
In Example 1, the vapor deposition film lamination | stacking stretched film was obtained like Example 1 except the point which does not coat a water-soluble resin coating liquid. The measurement results of each physical property are shown in Comparative Example 5 in Table-2. In this configuration, oxygen barrier properties, solvent resistance, and laminate strength are not preferable.
Comparative Example 6
In Example 1, the coating film before vapor deposition was used as a sample. The measurement results of each physical property are shown in Comparative Example 6 of Table-2. In this configuration, the oxygen barrier property is not particularly preferable.
[0033]
[Table 1]
[0034]
The coating resins (a), (b) and (c) in Table 1 are as follows.
<Water-soluble acrylic resin (a)>
Acrylic 1: “Jurimer FC-80” manufactured by Nippon Pure Chemicals Co., Ltd.
<Water-soluble urethane resin (b)>
Urethane 1: “NeoRez R-9603” manufactured by Zeneca Co., Ltd. (calculated based on a solid content concentration of 34%)
Urethane 2: “Hydran AP-30” manufactured by Dainippon Ink & Chemicals, Inc. (calculated as a solid content of 20%)
<Polyvinyl alcohol (c)>
PVA1: “GOHSENOL N-300 (degree of polymerization 1650 to 1700 saponification degree 98 to 99 mol%)” manufactured by Nippon Synthetic Chemical Industry Co., Ltd.
PVA2: “GOHSENOL GM-14 (degree of polymerization 1650 to 1700 saponification degree 86.5 to 89 mol%)” manufactured by Nippon Synthetic Chemical Industry Co., Ltd.
For the method of dissolving PVA1 and PVA2 (granular) in water, refer to the catalog of the product, and add (a) and (b) to the aqueous solution in which (c) is dissolved to add a water-soluble resin coating solution. Adjusted.
[0035]
[Table 2]
[0036]
【The invention's effect】
A gas barrier film obtained by the present invention, that is, a polypropylene resin molded article on which an inorganic oxide thin film is deposited, has excellent gas barrier properties not only on the low humidity side but also on the high humidity side. Since the metal oxide thin film does not peel off during use and the gas barrier property is not lowered, and it has excellent transparency and solvent resistance, food, industrial goods, pharmaceuticals, etc. can be used as an inexpensive packaging material to replace PVDC-coated OPP. It can be widely used as a resin molded product for packaging that is used to protect the film.
Claims (2)
【式1】
An unstretched film obtained by melt extrusion of a polypropylene resin is stretched in the machine direction and subjected to corona discharge treatment. Next, a water-soluble acrylic resin (a), a water-soluble urethane resin ( b) and polyvinyl alcohol (c), and a water-soluble resin coating solution having a weight ratio in solid content satisfying the following formulas (1) to (3) is applied and stretched in the transverse direction, and then on the coating surface A method for producing a gas barrier film, comprising forming a vapor-deposited film of an inorganic oxide on the substrate.
[Formula 1]
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JP4917299B2 (en) * | 2005-11-09 | 2012-04-18 | 三井化学東セロ株式会社 | Stretched molded body and method for producing the same |
JP5720315B2 (en) * | 2011-03-08 | 2015-05-20 | 凸版印刷株式会社 | Evaluation method of vapor deposition film |
JP5736283B2 (en) * | 2011-09-12 | 2015-06-17 | 中本パックス株式会社 | Rust-proof laminated film |
JP6191221B2 (en) * | 2013-04-25 | 2017-09-06 | 凸版印刷株式会社 | Water-based coating agent and gas barrier film |
JP6876265B2 (en) * | 2016-06-08 | 2021-05-26 | 凸版印刷株式会社 | Gas barrier film |
WO2018088104A1 (en) * | 2016-11-08 | 2018-05-17 | Dic株式会社 | Gas barrier multilayer film, and method for enhancing oxygen barrier properties of gas barrier multilayer film |
JP2020040254A (en) * | 2018-09-07 | 2020-03-19 | 大日本印刷株式会社 | Laminate for packaging material and packaging material |
JP2020157716A (en) * | 2019-03-28 | 2020-10-01 | 大日本印刷株式会社 | Base material, laminate for packaging material and packaging material |
JP7182069B2 (en) * | 2018-08-31 | 2022-12-02 | 大日本印刷株式会社 | Laminates for packaging materials and packaging materials |
JP2020040256A (en) * | 2018-09-07 | 2020-03-19 | 大日本印刷株式会社 | Laminate substrate, laminate for packaging material and packaging material |
JP2020040253A (en) * | 2018-09-07 | 2020-03-19 | 大日本印刷株式会社 | Laminate for packaging material and packaging material |
JP7282300B2 (en) | 2018-08-31 | 2023-05-29 | 大日本印刷株式会社 | Laminates for packaging materials and packaging materials |
JP2020040257A (en) * | 2018-09-07 | 2020-03-19 | 大日本印刷株式会社 | Laminate substrate, laminate for packaging material and packaging material |
JP2020040259A (en) * | 2018-09-07 | 2020-03-19 | 大日本印刷株式会社 | Laminate for packaging material and packaging material |
JP2020203405A (en) * | 2019-06-14 | 2020-12-24 | 大日本印刷株式会社 | Laminate and packaging bag |
JP2020203406A (en) * | 2019-06-14 | 2020-12-24 | 大日本印刷株式会社 | Laminate and packaging bag |
EP4205974A4 (en) * | 2020-08-31 | 2024-02-07 | Toppan Inc. | Gas barrier layered body, packaging material, packaging bag and tube container |
CN117467942A (en) * | 2023-11-02 | 2024-01-30 | 宁波大东南万象科技有限公司 | Preparation method and application of double-sided metallized polypropylene film |
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