Multilayered structure and laminate, and method for production of the same

Patent metadata

Field	Value
Publication number	US-9744748-B2
Application number	US-201113638753-A
Country	US
Kind code	B2
Filing date	Mar 30, 2011
Priority date	Mar 31, 2010
Publication date	Aug 29, 2017
Grant date	Aug 29, 2017

Abstract

An object of the invention is to provide a multilayered structure having very superior gas barrier properties and being excellent in flex resistance, pinhole resistance, stretchability, thermoformability and interlayer adhesiveness, and having superior durability enabling characteristics such as high gas barrier properties to be maintained even if used with deformation such as flexion and/or stretching, and to provide a laminate in which the multilayered structure is used, and a production method thereof. Provided by the present invention is a multilayered structure in which at least 4 resin-layers constituted with a resin composition containing an ethylene-vinyl alcohol copolymer are contiguously laminated. A single layer of the resin layer has an average thickness of preferably no less than 0.01 μm and no greater than 10 μm. The average thickness is preferably no less than 0.1 μm and no greater than 1,000 μm. When the content of ethylene units of the ethylene-vinyl alcohol copolymer is no less than 3 mol % and no greater than 70 mol %, the saponification degree is preferably no less than 80 mol %.

First claim

The invention claimed is:

1. A multilayered structure, comprising at least 9 resin-layers, wherein the at least 9 resin-layers comprise in resin form a resin composition comprising an ethylene-vinyl alcohol copolymer and are each laminated with no intervening layer which is other than the ethylene-vinyl alcohol copolymer therebetween, and wherein the multilayered structure has an average thickness of no less than 0.1 μm and no greater than 1,000 μm, and an average thickness of a single layer of the at least 9 resin layers is no less than 0.01 μm and no greater than 10 μm.

2. The multilayered structure according to claim 1 , wherein the ethylene-vinyl alcohol copolymer has a content of ethylene units of no less than 3 mol % and no greater than 70 mol %, and a saponification degree of no less than 80 mol %.

3. The multilayered structure according to claim 1 , wherein:
the ethylene-vinyl alcohol copolymer comprises at least one selected from the group consisting of the structural units (I) and (II); and
a content of at least one selected from the structural units (I) and (II) with respect to the entire structural units is no less than 0.5 mol % and no greater than 30 mol %:

wherein:
R 1 , R 2 and R 3 each independently represent a hydrogen atom, an aliphatic hydrocarbon group having 1 to 10 carbon atoms, an alicyclic hydrocarbon group having 3 to 10 carbon atoms, an aromatic hydrocarbon group having 6 to 10 carbon atoms or a hydroxyl group;
two among R 1 , R 2 and R 3 may bind with one another,
such that in a case in which the two among R 1 , R 2 and R 3 both represent a hydrogen atom, the two do not bind with one another; and the aliphatic hydrocarbon group having 1 to 10 carbon atoms, the alicyclic hydrocarbon group having 3 to 10 carbon atoms and the aromatic hydrocarbon group having 6 to 10 carbon atoms optionally have a hydroxyl group, a carboxyl group or a halogen atom;
R 4 , R 5 , R 6 and R 7 each independently represent a hydrogen atom, an aliphatic hydrocarbon group having 1 to 10 carbon atoms, an alicyclic hydrocarbon group having 3 to 10 carbon atoms, an aromatic hydrocarbon group having 6 to 10 carbon atoms or a hydroxyl group;
R 4 and R 5 or R 6 and R 7 may bind with one another,
such that in a case in which both R 4 and R 5 or both R 6 and R 7 represent a hydrogen atom, the R 4 and R 5 or both R 6 and R 7 do not bind with one another; the aliphatic hydrocarbon group having 1 to 10 carbon atoms, the alicyclic hydrocarbon group having 3 to 10 carbon atoms and the aromatic hydrocarbon group having 6 to 10 carbon atoms optionally have a hydroxyl group, an alkoxy group, a carboxyl group or a halogen atom.

4. The multilayered structure according to claim 1 , wherein the resin composition further comprises a thermoplastic resin having an oxygen-scavenging ability.

5. The multilayered structure according to claim 1 , wherein the resin composition further comprises a desiccant.

6. The multilayered structure according to claim 1 , wherein the resin composition has a melt viscosity (η 1 ) as determined at a temperature of 210° C. and a shear rate of 10/sec being no less than 1×10 2 Pa·s and no greater than 1×10 4 Pa·s and a melt viscosity (η 2 ) as determined at a temperature of 210° C. and a shear rate of 1,000/sec being no less than 1×10 1 Pa·s and no greater than 1×10 3 Pa·s, and a ratio (η 2 /η 1 ) of the melt viscosity satisfies formula (1):
−0.8≦(½)log 10 (η 2 /η 1 )≦−0.1  (1).

7. The multilayered structure according to claim 1 , comprising as part of the at least 9 resin layers a layer A and a layer B comprising in resin form resin compositions, respectively, that are different with one another in terms of at least one characteristic selected from the group consisting of formulation, blend ratio and structure of the ethylene-vinyl alcohol copolymer.

8. The multilayered structure according to claim 7 , wherein the layer A and the layer B are alternately laminated.

9. The multilayered structure according to claim 7 , wherein a difference between contents of ethylene units of an ethylene-vinyl alcohol copolymer of the layer A and contents of ethylene units of an ethylene-vinyl alcohol copolymer of the layer B is no less than 3 mol % and no greater than 50 mol %.

10. The multilayered structure according to claim 7 , wherein only one resin composition of the layer A and the layer B comprises a thermoplastic resin having an oxygen-scavenging ability.

11. The multilayered structure according to claim 7 , wherein only one resin composition of the layer A and the layer B comprises a desiccant.

12. The multilayered structure according to claim 7 , wherein a ratio (η 2B /η 2A ) of a melt viscosity (η 2B ) of the resin composition of the layer B to a melt viscosity (η 2A ) of the resin composition of the layer A as determined at a temperature of 210° C. and a shear rate of 1,000/sec is 0.1 or greater and 10 or less.

13. The multilayered structure according to claim 1 , wherein resin compositions of the at least 9 resin-layers are identical.

14. A laminate, comprising the multilayered structure according to claim 1 , and a layer of a thermoplastic resin other than the ethylene-vinyl alcohol copolymer laminated on the multilayered structure.

15. The laminate according to claim 14 having an average thickness of no less than 1 μm and no greater than 5,000 μm.

16. The laminate according to claim 14 , wherein:
a resin composition of a layer positioned outermost of the multilayered structure comprises at least one metal salt selected from the group consisting of an alkali metal salt, an alkaline earth metal salt and a metal salt of a group IV d-block element of the periodic table; and
the thermoplastic resin layer is laminated so as to be in contact with the layer positioned outermost of the multilayered structure.

17. The laminate according to claim 14 , which is suitable for food packaging.

18. A method for producing the multilayered structure according to claim 1 , the method comprising forming the multilayered structure by a multilayer coextrusion process with a resin composition comprising an ethylene-vinyl alcohol copolymer.

19. A method for producing the laminate according to claim 14 , the method comprising forming the laminate by a multilayer coextrusion process with a resin composition comprising an ethylene-vinyl alcohol copolymer and a thermoplastic resin.

20. The multilayered structure according to claim 1 , wherein the average thickness of a single layer of the at least 9 resin layers is no less than 0.01 μm and no greater than 7 μm.

Assignees

• Tai Shinji
• Kawai Hiroshi
• Yamakoshi Satoshi
• Isoyama Kouta
• Hikasa Masao
• Kuraray Co

Inventors

• Tai Shinji
• Kawai Hiroshi
• Yamakoshi Satoshi
• Isoyama Kouta
• Hikasa Masao

Classifications

• B29C48/21

  the layers being joined at their surfaces · CPC title

• B32B2250/05

  5 or more layers · CPC title

• B32B27/28

  comprising synthetic resins not wholly covered by any one of the sub-groups {B32B27/30 - B32B27/42} · CPC title

• B29K2995/0069

  non-permeable · CPC title

• B32B27/302

  comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers · CPC title