Laminate, packaging material, and packaging bag

Abstract

To provide a laminate which has sufficient reliability and film formation property during heat sealing while containing a recycled material containing two or more kinds of resins, and is also excellent in appearance, and provide a packaging material and a packaging bag.SOLUTION: A laminate 10a includes a sealant film 1a, an adhesive layer 5, and a base material film 6 in this order. The sealant film 1a includes: a recycled material-containing layer 2 containing a recycled material containing two or more kinds of resins; and a sealant layer 3 laminated on a main surface far from the adhesive layer 5 of the recycled material-containing layer, and an arithmetic surface roughness of a surface S3a on a side opposite to the recycled material-containing layer 2 side of the sealant layer 3 is 0.5 μm or more and 5 μm or less.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a laminate, a packaging material, and a packaging bag. [Background technology]

[0002] In general, plastic films have properties such as light weight, chemical stability, ease of processing, flexibility and strength, and the ability to be mass-produced, and are therefore used in a wide variety of applications. Their applications are diverse, including packaging materials for food products, pharmaceuticals, etc., intravenous drip packs, shopping bags, posters, tapes, optical films used in LCD televisions, etc., protective films, window films attached to windows, greenhouses, building materials, etc. Specific materials include thermoplastic resins such as polyethylene, polypropylene, polystyrene, polymethyl methacrylate, polycarbonate, polyamide, polyethylene terephthalate, and polybutylene terephthalate, and thermosetting resins such as epoxy resin, polyurethane, and polyimide.

[0003] Appropriate plastic materials are selected depending on the application, and multiple types of plastics are sometimes layered together to form laminates. In addition, multiple plastic materials can be mixed in one layer to compensate for the shortcomings of a single material.

[0004] Recycling plastic products is expected to be a key part of addressing recent environmental issues, and various recycling methods are being considered. For example, PET bottles can be recycled by cleaning and crushing them, and then reused as raw materials, and chemical recycling technology has been established to convert them into monomers.

[0005] Furthermore, as a means of recycling polyethylene materials, the use of recycled polyethylene for applications such as films has been considered. For example, Patent Document 1 listed below proposes a sealant film containing recycled polyethylene resin. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] International Publication No. 2022 / 124229 Summary of the Invention [Problem to be solved by the invention]

[0007] Some recycled materials contain different types of resins. The present inventors have investigated the possibility of recycling such recycled materials as raw materials for sealant films, and have found that a sealant film having a layer containing recycled materials may have reduced reliability during heat sealing.

[0008] On the other hand, film products such as sealant films are required to have the property of being able to be molded without the occurrence of folds or wrinkles from the stage of film formation to winding (hereinafter also referred to as "film formability"). If the film has insufficient film formability, the film after winding is likely to have poor appearance due to folds or wrinkles.

[0009] Furthermore, when producing packaging materials with functions such as design and gas barrier properties, a base film provided with a functional layer such as a printed layer or a vapor deposition layer may be bonded to a sealant film with an adhesive. However, if the sealant film has low smoothness, air bubbles are likely to occur in the resulting laminate, which can easily cause poor appearance.

[0010] The present invention has been made in view of the above circumstances, and aims to provide a laminate, a packaging material, and a packaging bag that contain recycled materials containing two or more types of resins, have sufficient reliability and film-forming properties during heat sealing, and have excellent appearance. [Means for solving the problem]

[0011] In order to solve the above problems, the present inventors have investigated the factors that reduce reliability during heat sealing, and have found that when different types of resins are mixed in a layer containing recycled material, aggregates are formed by resin components other than the resin with the highest content ratio, and when these aggregates cause excessively large protrusions on the surface of the sealant film, air entrapment occurs during heat sealing. Based on this finding, the present inventors have conducted further investigations and found that a sealant film prepared so that the surface roughness of the sealant layer meets specific conditions can solve the above problems, leading to the completion of the present invention.

[0012] One aspect of the present invention relates to the following [1] to

[10] .

[0013] [1] A laminate comprising a sealant film, an adhesive layer, and a base film in this order, wherein the sealant film comprises a recycled material-containing layer containing recycled material containing two or more types of resin, and a sealant layer laminated on a main surface of the recycled material-containing layer remote from the adhesive layer, and wherein the arithmetic surface roughness of the surface of the sealant layer opposite to the recycled material-containing layer is 0.5 μm or more and 5 μm or less. [2] The laminate according to [1], wherein the adhesive layer contains a reaction-cured product of a solventless adhesive. [3] The laminate according to [1] or [2], wherein the thickness of the sealant layer is 5 μm or more and 70 μm or less. [4] The laminate according to any one of [1] to [3], wherein the maximum height H of the convex portions on the surface of the sealant layer is 0.5 μm or more and 10 μm or less, and the ratio [W / H] of the width W at half the maximum height H to the maximum height H of the convex portions having the maximum height H is 20 or less. [5] The laminate according to any one of [1] to [4], wherein the resin with the highest content ratio among the two or more resins contained in the recycled material is a polyethylene-based resin or a polypropylene-based resin. [6] The laminate according to any one of [1] to [5], further comprising an auxiliary layer laminated on a main surface of the recycled material-containing layer close to the adhesive layer. [7] The laminate according to [6], wherein the auxiliary layer contains the same type of virgin resin as the resin with the highest content in the recycled material-containing layer. [8] A packaging material comprising the laminate according to any one of [1] to [7]. [9] The packaging material described in [8], wherein the content of plastic material contained in the recycled material is 10% by mass or more based on the total amount of plastic material in the packaging material.

[10] A packaging bag made from the packaging material described in [8] or [9]. [Effects of the Invention]

[0014] According to the present invention, it is possible to provide a laminate, a packaging material, and a packaging bag that contain recycled materials containing two or more types of resins, have sufficient reliability and film-forming properties during heat sealing, and have excellent appearance. [Brief explanation of the drawings]

[0015] [Figure 1] 1 is a schematic cross-sectional view showing one embodiment of a laminate according to the present invention. [Figure 2] FIG. 2 is a schematic cross-sectional view illustrating the shape of a convex portion in the laminate shown in FIG. [Figure 3] FIG. 2 is a schematic cross-sectional view showing another embodiment of the sealant film according to the present invention. [Figure 4] FIG. 2 is a schematic cross-sectional view showing another embodiment of the laminate according to the present invention. [Figure 5] 1 is a schematic cross-sectional view showing one embodiment of a packaging material according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0016] Hereinafter, embodiments of the present invention will be described in detail. Note that Figures 1 to 5 are schematic diagrams, and the size and shape of each part are appropriately exaggerated for ease of understanding. Furthermore, the embodiments shown below are merely examples of configurations for embodying the technical idea of ​​the present invention, and the technical idea of ​​the present invention is not limited to the materials, shapes, structures, etc. of the components described below. Various modifications can be made to the technical idea of ​​the present invention within the technical scope defined by the claims.

[0017] <Laminate> The laminate of this embodiment includes a sealant film, an adhesive layer, and a base film, in this order. The sealant film also includes a recycled material-containing layer containing recycled material containing two or more resins, and a sealant layer laminated on the main surface of the recycled material-containing layer farther from the adhesive layer.

[0018] Fig. 1 is a schematic cross-sectional view showing one embodiment of a laminate. The laminate 10a shown in Fig. 1 includes a sealant film 1a in which a recycled material-containing layer 2 and a sealant layer 3 are laminated, and a base film 6 laminated on the recycled material-containing layer 2 of the sealant film 1a via an adhesive layer 5.

[0019] As shown in FIG. 1, the sealant film according to this embodiment comprises a recycled material-containing layer containing recycled material containing two or more types of resin, and a sealant layer laminated on the main surface of the recycled material-containing layer far from the adhesive layer.

[0020] (Recycled material containing layer) Examples of recycled materials contained in the recycled material-containing layer include post-consumer recycled (PCR) materials such as bottles and packaging bags for beverages, detergents, and seasonings that have been collected from the market, food containers for lunch boxes and instant noodles, packaging bags for food and garbage bags, and plastic products such as hangers, stationery, daily necessities, home appliances, and toys; and post-industry recycled (PIR) materials such as defective products that do not become products discharged from factories, scraps generated during the manufacturing process, and plastic products used for transportation and packaging.

[0021] In the sealant film of this embodiment, from the viewpoint of material recycling of plastic films, a laminate (packaging material) made by bonding together multiple types of resin sheets, a packaging bag made from such a laminate, a laminate (packaging material) made by bonding together the same types of resin sheets, or a packaging bag made from such a laminate, or a mixture of these, may be used. Examples of packaging bags include refill pouches for toiletries.

[0022] The recycled material contained in the recycled material-containing layer includes two or more resins. Examples of the two or more resins include thermoplastic resins, thermosetting resins, and cured products thereof (including crosslinked products). The two or more resins also include, for example, resin components (such as thermosetting resins) that constitute adhesives and their cured products.

[0023] Examples of thermoplastic resins include polyolefin resins, acrylic resins, polycarbonate resins, polyester resins, polyamide resins, etc. Examples of thermosetting resins include epoxy resins, polyurethane resins, polyimide resins, etc.

[0024] Examples of polyolefin resins include polyethylene-based resins such as low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), medium-density polyethylene (MDPE), high-density polyethylene (HDPE), and ethylene-α-olefin copolymers, as well as polypropylene-based resins such as homopolypropylene (PP), block polypropylene, random polypropylene, and propylene-α-olefin copolymers.

[0025] Examples of polyester resins include polyethylene terephthalate, polybutylene terephthalate, and polylactic acid.

[0026] An example of the polyamide resin is nylon 6.

[0027] The two or more resins may include a first resin that is contained in the recycled material at the highest ratio and a second resin that is incompatible with the first resin or that may form aggregates in the first resin. The type of resin contained in the recycled material-containing layer can be confirmed using a microscopic infrared spectrophotometer or the like.

[0028] The first resin and the second resin may be the following combinations: (a) Thermoplastic resins, thermosetting resins and their hardened products (b) Hydrocarbon-based resins and heteroatom-containing resins (c) A resin that dissolves in a predetermined solvent and a resin that does not dissolve in the predetermined solvent

[0029] Examples of the hydrocarbon resin in (b) include polyolefin resins and polystyrene resins, and examples of the heteroatom-containing resin include acrylic resins, polyester resins, and polyamide resins.

[0030] Examples of the predetermined solvent in (c) include aromatic hydrocarbons, chlorinated hydrocarbons, etc. Examples of resins that dissolve in the predetermined solvent include uncrosslinked resins, etc. Examples of resins that do not dissolve in the predetermined solvent include crosslinked resins, cured thermosetting resins, etc.

[0031] The first resin having the highest content in the recycled material may be a polyethylene resin or a polypropylene resin from the viewpoint of recycling packaging bags for pouch products, etc. In this case, the second resin may be, for example, at least one of polyester resin, polyamide resin, and a resin component constituting an adhesive and its cured product.

[0032] The content of the first resin in the recycled material-containing layer may be 75 to 98 mass %, 75 to 95 mass %, or 80 to 90 mass % based on the total mass of the recycled material-containing layer.

[0033] The content of the second resin in the recycled material-containing layer may be 2 to 33 parts by mass, 5 to 33 parts by mass, or 11 to 25 parts by mass relative to 100 parts by mass of the first resin.

[0034] The content of recycled material in the recycled material-containing layer may be 13% by mass or more, 33% by mass or more, 50% by mass or more, or 100% by mass, based on the total mass of the recycled material-containing layer.

[0035] The resin having the highest content in the recycled material-containing layer may be the same as the resin having the highest content in the recycled material, for example, at least one polyethylene resin selected from the group consisting of low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), medium-density polyethylene (MDPE), and high-density polyethylene (HDPE).

[0036] The recycled material-containing layer may contain virgin material such as virgin resin. The virgin material may be blended so that the resin with the highest content in the recycled material is the same as the resin with the highest content in the recycled material-containing layer. The virgin material may be, for example, the same as the polyolefin resin described above, and may be at least one polyethylene resin selected from the group consisting of low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), medium-density polyethylene (MDPE), and high-density polyethylene (HDPE).

[0037] The recycled material-containing layer may contain aggregates derived from the second resin, for example, and from the viewpoint of ensuring reliability during heat sealing, the aggregates may have a maximum diameter of 20 μm or less. If the maximum diameter of the aggregates is 20 μm or less, it becomes easier to prevent the formation of convex portions having a height of more than 10 μm or convex portions having a height of 0.5 μm to 10 μm and a width-to-height ratio at half the height of more than 20 on the surface of the sealant layer.

[0038] The recycled material-containing layer may contain aggregates with a maximum diameter of 40 μm to 100 μm, 50 μm to 90 μm, or 60 μm to 80 μm.

[0039] The agglomerates and their maximum diameters can be confirmed by the following method. The aggregates contained in the recycled material-containing layer can be confirmed as domains (hereinafter also referred to as "low transmission brightness regions") whose transmission brightness is lower than that of the surrounding area when the sealant film is observed through transmission from a direction in which the sealant film is viewed in plan view, and the maximum diameter of the low transmission brightness region can be obtained by the following procedure. (i) Using a stereomicroscope system SZX16 (product name, manufactured by Olympus Corporation), observation images (image size: 243 μm × 851 μm) of the sealant film in the planar direction are obtained at 10 random locations. (ii) The 10 images obtained are analyzed using WinROOF2021 (product name, manufactured by Mitani Corporation). In the image analysis, the low-transmittance brightness region and the surrounding high-transmittance brightness region are binarized to calculate the maximum diameter in each low-transmittance brightness region. Note that when binarizing, the visual shape of the low-transmittance brightness region can be matched with the colored range by appropriately combining the following operations. (a) Adjusting brightness and contrast to emphasize low-transparency areas (b) Adjust the threshold to match the visible low-transmittance brightness area with the colored range. (c) If there are areas where adjacent low-transmittance brightness areas are recognized as one area, or areas where perforated low-transmittance brightness areas are recognized as multiple areas, perform division or integration processing as necessary.

[0040] In order to reduce the maximum diameter of the aggregates in the recycled material-containing layer, for example, the following adjustment means can be mentioned. (a) Reducing the proportion of recycled material in the recycled material-containing layer (b) Increasing the content of the first resin in the recycled material. (c) When extruding a recycled material-containing layer, increase the screw rotation speed. (d) When extruding the recycled material-containing layer, the narrowing of the flow path is avoided as much as possible, and a mechanism is created in which elongation stress is not easily applied. (e) Recycled materials are used by mixing them with pelletized or virgin resin using a twin-screw extruder to form a masterbatch.

[0041] The recycled material-containing layer may have a thickness of 20 to 100 μm.

[0042] (sealant layer) The sealant layer has an uneven surface on the side opposite to the recycled material-containing layer, and the surface (for example, S shown in FIG. 1) 3aThe arithmetic surface roughness Ra of the film, as specified in JIS B 0601:2001, is 0.5 μm or more and 5 μm or less. If Ra is 5 μm or less, it is possible to prevent a decrease in reliability (for example, a decrease in low-temperature heat sealability) due to air entrapment when overlapping sealant films and heat sealing them. In addition, it is less likely that problems such as a decrease in impact resistance or puncture resistance due to a localized thinning of the thickness of the recessed portions will occur. On the other hand, if Ra is 0.5 μm or more, the coefficient of friction will not be too high, allowing for appropriate slip properties and making it less likely that wrinkles will occur during film formation.

[0043] From the above viewpoint, the Ra may be 0.5 μm or more and 4 μm or less, 0.5 μm or more and 3 μm or less, 0.5 μm or more and 2 μm or less, 0.5 μm or more and 1.5 μm or less, 1.0 μm or more and 4 μm or less, 1.0 μm or more and 3 μm or less, or 1.0 μm or more and 2 μm or less.

[0044] Methods for adjusting the Ra include, in addition to the method of adjusting the maximum diameter of the aggregates described above, changing the thickness of the sealant layer, incorporating an antiblocking agent into the sealant layer, and forming predetermined irregularities on the surface of the sealant layer (for example, pressing a nip roll against the molten resin when cooling and solidifying it during film formation).

[0045] From the viewpoint of ensuring reliability during heat sealing, the surface of the sealant layer (S shown in Figure 2) 3a ) in the convex part (P shown in Figure 2 3a ) is the height (H shown in Figure 2 3a From the same viewpoint, the width at half the height of the convex portion (W shown in FIG. 2) may be 10 μm or less, 0.5 to 9 μm, or 0.5 to 8 μm. 3a ) may be 200 μm or less, may be 1 to 150 μm, or may be 1 to 100 μm. FIG. 2 is a schematic cross-sectional view for explaining the shape of the protrusions in the sealant film shown in FIG. 1. As shown in FIG. 2, the protrusions P 3aThe surface S of the sealant layer 3 is formed by the aggregates 50 generated in the recycled material-containing layer. 3a It may also be caused by the uplift of

[0046] The convex portions on the surface of the sealant layer may have a maximum height H of 0.5 μm or more and 10 μm or less, and the ratio [W / H] of the width W at half the maximum height H to the maximum height H of the convex portions having the maximum height H may be 20 or less, or the above H may be 0.5 to 9 μm and the ratio [W / H] may be 1 to 18. This is advantageous in terms of (a) improving the recycled material content in the recycled material-containing layer, (b) improving the recycled material content in the sealant film by reducing the thickness of the sealant layer, and (c) improving productivity by being able to reduce the pressure applied during cooling or hot pressing during film formation.

[0047] The material for forming the sealant layer may be a thermoplastic resin or other material that has adequate flexibility and good processability, for example, suitability for processing using an extruder. Examples of such materials include low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), medium-density polyethylene (MDPE), high-density polyethylene (HDPE), and polypropylenes having homopolymers, random copolymers, and block copolymers; ethylene-vinyl acetate copolymers obtained by copolymerizing olefins such as low-density polyethylene (LDPE) with vinyl acetate; and ethylene-methyl acrylate copolymers (EMA), ethylene-ethyl acrylate copolymers (EEA), ethylene-butyl acrylate copolymers (EBA), and ethylene-methacrylic acid copolymers (EMAA) obtained by modifying the side chains of olefins. These materials may be used alone or in combination.

[0048] From the viewpoint of heat sealing property, the sealant layer may contain the same type of resin as the resin with the highest content in the recycled material-containing layer, and virgin resin may be blended to achieve this. For example, if the resin with the highest content in the recycled material-containing layer is a polyethylene-based resin, the sealant layer may contain a polyethylene-based resin, or the polyethylene-based resin may be the main component (e.g., the content in the sealant layer is 95% by mass or more). Also, if the resin with the highest content in the recycled material-containing layer is a polypropylene-based resin, the sealant layer may contain a polypropylene-based resin, or the polypropylene-based resin may be the main component (e.g., the content in the sealant layer is 95% by mass or more).

[0049] From the viewpoint of film processability, the MFR of the polyethylene resin may be 0.05 to 15 g / 10 min, or 0.1 to 8 g / 10 min. The MFR here refers to a value measured in accordance with JIS K7210 (190°C, load 2.16 kg).

[0050] From the viewpoint of film processability, the MFR of the polypropylene resin may be 0.05 to 20 g / 10 min, or 0.1 to 10 g / 10 min. The MFR here refers to a value measured in accordance with JIS K7210 (230°C, load 2.16 kg).

[0051] From the viewpoint of heat sealing property and rigidity, the crystallinity of the polypropylene resin as measured by the heat of fusion using a differential scanning calorimeter (DSC) may be 25% or more and 60% or less, or 30% or more and 55% or less.

[0052] In this specification, the crystallinity of a polypropylene-based resin is calculated from the ratio of the heat of fusion ΔHm obtained by integrating the endothermic peak during melting of the sample to the heat of fusion ΔH100 of a completely crystalline body having a crystallinity of 100% obtained by theoretical calculation, according to the following formula: Crystallinity [%]=(ΔHm / ΔH100)×100 The heat of fusion ΔH100 of a completely crystalline substance can be the value described in the following document. For example, the ΔH100 of polypropylene can be 207 J / g. Reference: Japan Society of Plastics Processing: Plastic Materials in Molding Processing, 335 (2011), Morikita Publishing Co., Ltd.

[0053] From the viewpoint of the stability of heat sealing performance, the sealant layer may not contain recycled materials.

[0054] The thickness of the sealant layer may be 5 μm or more and 70 μm or less. In this case, it is easy to prevent the aggregates contained in the recycled material-containing layer from being exposed from the sealant layer, and it is easy to ensure the rigidity of the sealant film as a whole and increase the recycled material content in the sealant film. This allows for more effective material recycling of recycled materials containing two or more resins in the sealant film. The thickness of the sealant layer may be 5 μm or more and 50 μm or less, 5 μm or more and 40 μm or less, 5 μm or more and 30 μm or less, 5 μm or more and 20 μm or less, 10 μm or more and 65 μm or less, 10 μm or more and 60 μm or less, 10 μm or more and 55 μm or less, 10 μm or more and 50 μm or less, 10 μm or more and 40 μm or less, 10 μm or more and 30 μm or less, 15 μm or more and 60 μm or less, or 20 μm or more and 60 μm or less.

[0055] The recycled material-containing layer and the sealant layer may contain additives such as compatibilizers, nucleating agents, reinforcing fillers, antioxidants, heat stabilizers, weathering agents, light stabilizers, plasticizers, UV absorbers, antistatic agents, flame retardants, flame retardant aids, slip agents, antiblocking agents, antifogging agents, lubricants, pigments, dyes, dispersants, copper inhibitors, neutralizing agents, bubble inhibitors, weld strength improvers, natural oils, synthetic oils, waxes, etc. The additives may be used alone or in combination of two or more.

[0056] Examples of nucleating agents and reinforcing fillers include talc, silica, clay, montmorillonite, calcium carbonate, lithium alumina carbonate, titanium oxide, metals such as aluminum, iron, silver, and copper, hydroxides such as aluminum hydroxide and magnesium hydroxide, celluloses such as cellulose microfibrils and cellulose acetate, fibrous fillers such as glass fibers, polyethylene terephthalate fibers, nylon fibers, polyethylene naphthalate fibers, aramid fibers, vinylon fibers, and polyacrylate fibers, carbons such as carbon nanotubes, and elastomers such as ethylene propylene rubber (EPR).

[0057] Examples of the antioxidant include phenolic compounds, organic phosphite compounds, and thioether compounds.

[0058] Examples of the heat stabilizer and light stabilizer include hindered amine compounds.

[0059] Examples of the ultraviolet absorber include benzophenone compounds, benzotriazole compounds, and benzoate compounds.

[0060] Examples of the antistatic agent include nonionic compounds, cationic compounds, and anionic compounds.

[0061] Examples of the flame retardant include halogen-based compounds, phosphorus-based compounds, nitrogen-based compounds, inorganic compounds, boron-based compounds, silicone-based compounds, sulfur-based compounds, and red phosphorus-based compounds.

[0062] Examples of the flame retardant aid include antimony compounds, zinc compounds, bismuth compounds, magnesium hydroxide, and clay silicates.

[0063] Examples of the anti-blocking agent include acrylic particles, styrene particles, styrene-acrylic particles and crosslinked products thereof, polyurethane particles, polyester particles, silicon particles, fluorine particles, copolymers thereof, zeolite, pyrophyllite, talc, smectite, vermiculite, mica, chlorite, kaolin minerals, clay compound particles such as sepiolite, silica, titanium oxide, alumina, silica alumina, zirconia, zinc oxide, strontium oxide, aluminum hydroxide, strontium carbonate, strontium chloride, strontium sulfate, strontium nitrate, strontium hydroxide, and glass particles.

[0064] In the sealant film of the present embodiment, the ratio Tr / Ts of the thickness Tr of the recycled material-containing layer to the thickness Ts of the sealant layer may be 0.3-16, 0.5-14, or 0.7-12.

[0065] Fig. 3 is a schematic cross-sectional view showing another embodiment of the sealant film. The sealant film 1b shown in Fig. 3 comprises a recycled material-containing layer 2, a sealant layer 3 laminated on one main surface of the recycled material-containing layer 2, and an auxiliary layer 4 laminated on the other main surface of the recycled material-containing layer 2. In this case, too, the surface S of the sealant layer 3 opposite to the recycled material-containing layer 2 side is 3b The arithmetic surface roughness Ra specified in JIS B 0601:2001 can satisfy the above-mentioned conditions.

[0066] Fig. 4 is a schematic cross-sectional view showing another embodiment of the laminate of the present embodiment. The laminate 10b shown in Fig. 4 includes the sealant film 1b shown in Fig. 3 and a base film 6 laminated on the auxiliary layer 4 of the sealant film 1b via an adhesive layer 5.

[0067] The auxiliary layer 4 may be configured to contain a high-density resin in order to further increase the rigidity of the sealant film 1b, and may be configured to contain a resin having a density similar to that of the resin constituting the sealant layer 3 (for example, a density difference of 0.1 kg / m 2) in order to suppress curling due to thermal shrinkage of the sealant film 1b. 3The resin may contain a compound selected from the group consisting of hydroxybenzoates, ...

[0068] Furthermore, when auxiliary layer 4 is intended to function as a laminating layer, it may have the same configuration as the above-described sealant layer 3. Furthermore, auxiliary layer 4 may contain the same type of resin as the resin with the highest content in recycled material-containing layer 2. In this case, higher laminating strength makes it easier to improve adhesion with other layers.

[0069] The auxiliary layer 4 may contain one or more of the above-mentioned additives, if necessary.

[0070] Furthermore, when auxiliary layer 4 is made to function as a laminate layer, the arithmetic surface roughness Ra, as defined in JIS B 0601:2001, of the surface of auxiliary layer 4 opposite to recycled material-containing layer 2 may be 0.03 μm or more and 5 μm or less, 0.04 μm or more and 3 μm or less, or 0.05 μm or more and 2 μm or less. In this case, when another layer is laminated on the laminate layer via an adhesive, it becomes easy to prevent lamination defects caused by the occurrence of defective areas where the adhesive does not adhere.

[0071] The Ra of the auxiliary layer 4 can be adjusted by changing the thickness of the auxiliary layer 4. In this case, the thickness of the auxiliary layer may be 5 μm or more and 100 μm or less, 10 μm or more and 90 μm or less, or 20 μm or more and 80 μm or less, from the viewpoints of suppressing lamination defects and reducing costs.

[0072] The auxiliary layer 4 may further include a gas barrier layer on the side opposite to the recycled material-containing layer 2. In this case, the laminate may have improved gas barrier properties (e.g., oxygen barrier properties and water vapor barrier properties). The gas barrier layer may have a single-layer structure or a multilayer structure.

[0073] Examples of gas barrier layers include vapor-deposited layers (vapor-deposited films) made of metals or inorganic oxides, metal foils such as aluminum foil, and films of ethylene-vinyl alcohol copolymers, polyamide resins, polyvinylidene chloride resins, polyacrylonitrile resins, etc.

[0074] The vapor-deposited layer may have a single layer structure or a multilayer structure. Examples of the vapor-deposited layer include a vapor-deposited layer composed of a metal such as aluminum, and an inorganic oxide such as aluminum oxide, silicon oxide, magnesium oxide, calcium oxide, zirconium oxide, titanium oxide, boron oxide, hafnium oxide, and barium oxide.

[0075] The deposition layer can be formed by a conventionally known method, for example, physical vapor deposition (PVD) methods such as vacuum deposition, sputtering, and ion plating, and chemical vapor deposition (CVD) methods such as plasma chemical vapor deposition, thermal chemical vapor deposition, and photochemical vapor deposition, and can be appropriately selected depending on the deposition material, etc.

[0076] When the vapor-deposited layer is an aluminum vapor-deposited film, the OD value thereof may be from 2 to 3.5 in terms of productivity, oxygen barrier property, and water vapor barrier property of the laminate. Note that, in this specification, the OD value refers to the value measured in accordance with JIS-K-7361.

[0077] When the vapor-deposited layer is an inorganic oxide layer using silicon oxide, the O / Si ratio of the inorganic oxide layer may be 1.5 or more from the viewpoint of transparency. Furthermore, the O / Si ratio may be 2.0 or less from the viewpoint of barrier properties. To obtain the above-mentioned effects more fully, the O / Si ratio of the inorganic oxide layer may be 1.5 or more and 2.0 or less, or 1.6 or more and 1.8 or less.

[0078] The O / Si ratio of the inorganic oxide layer can be determined by X-ray photoelectron spectroscopy (XPS). For example, an X-ray photoelectron spectrometer (manufactured by JEOL Ltd., trade name: JPS-90MXV) is used as the measurement device, and measurements can be performed using a non-monochromated MgKα (1253.6 eV) X-ray source at an X-ray output of 100 W (10 kV-10 mA). For quantitative analysis to determine the O / Si ratio, relative sensitivity factors of 2.28 for O1s and 0.9 for Si2p can be used.

[0079] The thickness of the vapor-deposited layer may be 1 nm or more and 150 nm or less, 5 nm or more and 60 nm or less, or 5 nm or more and 40 nm or less. When the thickness of the vapor-deposited layer is 1 nm or more, oxygen barrier property and water vapor barrier property are easily obtained. When the thickness of the vapor-deposited layer is 150 nm or less, cracks in the vapor-deposited layer are easily prevented, and the recyclability of the laminate is easily maintained.

[0080] The auxiliary layer 4 provided with the gas barrier layer may have the same configuration as the above-described sealant layer 3. When the auxiliary layer 4 contains a polyolefin resin, the polyolefin resin preferably has high crystallinity from the viewpoints of printability, vapor deposition suitability, strength, and heat resistance. The polyolefin resin may be a virgin resin.

[0081] When the polyolefin resin is polyethylene, high-density polyethylene (HDPE) and medium-density polyethylene (MDPE) are preferred from the viewpoints of printability, strength, and heat resistance, and medium-density polyethylene is more preferred from the viewpoint of suitability for stretching. When the polyolefin resin is polypropylene, the crystallinity determined by the heat of fusion using a differential scanning calorimeter (DSC) may be 40% or more or 45% or more from the viewpoints of printability, strength, and heat resistance, and may be 60% or less or 55% or less from the viewpoint of impact resistance.

[0082] The content of non-recycled resin (virgin resin, etc.) in auxiliary layer 4, on which the gas barrier layer is provided, can be made higher than the content of non-recycled resin in the recycled-material-containing layer. In this case, partial swelling due to aggregates on the surface of the recycled-material-containing layer can be smoothed, improving the mechanical properties and appearance of the laminate.

[0083] When a gas barrier layer is provided, the thickness of auxiliary layer 4 may be 20 μm or more, 40 μm or more, or 80 μm or more from the viewpoint of gas barrier properties and adhesion, and may be 150 μm or less, 120 μm or less, or 100 μm or less from the viewpoint of reducing the total thickness when used as a packaging material.

[0084] The sealant film according to the present embodiment can be produced by a conventionally known method, for example, a method of extrusion laminating a recycled material-containing film formed from a resin composition constituting the recycled material-containing layer with a resin composition constituting the sealant layer, or a method of forming the recycled material-containing layer and the sealant layer by coextrusion molding.

[0085] In the former method, the recycled material-containing film can be produced by melting the resin composition constituting the recycled material-containing layer in an injection molding machine or extrusion molding machine (e.g., a twin-screw extruder) and then forming the film in a T-die through a feed block or multi-manifold, or by an inflation method. The recycled material can be produced by collecting, cleaning, and pulverizing various types of plastic waste, melt-molding them in an extruder, and pelletizing them. For extrusion lamination, an extrusion laminating machine or the like can be used.

[0086] In the latter method, for example, a sealant film can be produced by melt-kneading and co-extruding the resin composition constituting the recycled material-containing layer and the resin composition constituting the sealant layer using a multi-layer extrusion molding machine.

[0087] The resin composition constituting the recycled material-containing layer may contain only recycled material, or may further contain virgin resin or additives to impart various desired properties such as viscosity adjustment, mechanical property reinforcement, etc. Furthermore, when the recycled material and virgin resin are mixed, they may be dry-blended in which the virgin resin and the recycled material are simultaneously charged into a hopper and melt-kneaded to form a film, or they may be melt-blended in which the virgin resin and the recycled material are separately melt-kneaded in a twin-screw extruder to form a masterbatch.

[0088] In order to reduce the maximum area and maximum aspect ratio of the low transmittance brightness region in the recycled material-containing layer, the layer may be pelletized using a twin-screw extruder, molded under high shear conditions, or an acid-modified polyolefin resin or the like may be blended as a compatibilizer.

[0089] The film can be cooled in a manner consistent with the molding machine used, and for example, in the T-die method, air cooling methods such as an air chamber, vacuum chamber, or air knife, or water cooling methods such as dipping a cooling roll in a cold water pan can be used. When imparting a surface texture by shaping, a method in which a molten resin is poured into the contact area between a nip roll made of silicone rubber, NBR rubber, fluororesin, or the like and a cooling roll made of machined metal, with a pressure of 0.1 MPa or more applied, and then cooled.

[0090] The sealant film may be subjected to a surface modification treatment to improve suitability for subsequent processes. For example, the surface to be laminated may be subjected to a surface modification treatment to improve printability and lamination suitability when laminating with other layers or substrate films. Examples of surface modification treatments include methods for oxidizing the film surface to express functional groups, such as corona discharge treatment, plasma treatment, and flame treatment, and wet process modifications such as coating with an easy-adhesion layer.

[0091] The method for producing the sealant film is not limited to the above-mentioned method, and the sealant film produced by the molding machine may be subjected to in-line or off-line stretching treatment. There are no limitations on the addition of other necessary steps or additives as appropriate.

[0092] (Base film) The base film 6 is not particularly limited as long as it has mechanical strength and dimensional stability, and examples of the base film 6 that can be used include plastic film, paper, nonwoven fabric, etc. Examples of materials that can be used for the plastic film include polyesters such as polyethylene terephthalate (PET) and polyethylene naphthalate, polyolefins such as polyethylene and polypropylene, polystyrene, polyamides such as 6-nylon, polycarbonate, polyacrylonitrile, and polyimide.

[0093] The base film 6 is preferably a stretched film from the viewpoint of mechanical strength and dimensional stability.

[0094] By containing the same type of resin (also referred to as "the same resin") as the resin with the highest content in the sealant film, the laminate (or packaging material) as a whole can be made into a mono-material, improving the recyclability of the laminate (or packaging material). In this case, all layers constituting the sealant film (for example, the sealant layer, or the sealant layer and auxiliary layer) may contain the same type of resin as the resin with the highest content in the recycled material-containing layer.

[0095] The content of the same resin in the laminate (or packaging material) may be 90% by mass or more, based on the total amount of the laminate (or packaging material). In this case, the laminate (or packaging material) can be said to be a (mono-material) packaging material made of a single material. From the perspective of further improving recyclability, the content of the same resin in the laminate (or packaging material) may be 92.5% by mass or more, or 95% by mass or more, based on the total amount of the laminate (or packaging material).

[0096] From the viewpoint of transparency, the haze value of the base film 6 may be 30% or less, or may be 20% or less. In this specification, the haze value of the film refers to the value measured in accordance with JIS K 7105.

[0097] The substrate film 6 may be subjected to a surface treatment, which can improve adhesion to adjacent layers. The method of surface treatment is not particularly limited, and examples include physical treatments such as corona discharge treatment, ozone treatment, low-temperature plasma treatment using oxygen gas and / or nitrogen gas, and glow discharge treatment, as well as chemical treatments such as oxidation treatment using chemicals.

[0098] An anchor coating layer may be provided on the surface of the base film 6 using a conventionally known anchor coating agent.

[0099] The thickness of the base film 6 may be 10 μm or more and 50 μm or less, or 12 μm or more and 30 μm or less. When the thickness of the base film is 10 μm or more, it is easy to improve the strength of the laminate. Furthermore, when the thickness of the base film is 50 μm or less, it is easy to maintain the processability of the laminate.

[0100] (adhesive layer) The adhesive layer 5 is a layer that bonds the base film 6 and the sealant film. For example, in the laminate 10a, the recycled material-containing layer 2 of the sealant film and the base film 6 are bonded via the adhesive layer 5, and in the laminate 10b, the auxiliary layer 4 of the sealant film and the base film 6 are bonded via the adhesive layer 5.

[0101] The adhesive constituting the adhesive layer is not particularly limited, but a dry laminating adhesive or a solvent-free adhesive (also called a "solvent-free adhesive") can be used.

[0102] Examples of adhesives for dry lamination include two-component curing urethane adhesives, polyester urethane adhesives, polyether urethane adhesives, acrylic adhesives, polyester adhesives, polyamide adhesives, epoxy adhesives, etc. When the laminate (or packaging material) is used for packaging bags for retort use, a two-component curing urethane adhesive that is retort resistant can be used.

[0103] Examples of solvent-free adhesives include two-component curing polyurethane adhesives in which a base material such as polyester polyol, polyether polyol, or acrylic polyol is reacted with an aromatic or aliphatic isocyanate compound having two or more functional groups as a curing agent. Such adhesives react with heat or the like (for example, the hydroxyl groups of the base material react with the isocyanate groups of the curing agent) to harden, thereby forming an adhesive layer. In this case, the adhesive layer can also be referred to as an adhesive layer (also referred to as a "solvent-free adhesive layer") made of a reaction-cured product of the solvent-free adhesive.

[0104] From the viewpoint of improving adhesiveness, the solventless adhesive may have, for example, an equivalent ratio (NCO group / OH group molar ratio) of the isocyanate groups of the curing agent to the hydroxyl groups of the main agent of 0.5 to 5. Whether the adhesive layer was formed using a solventless adhesive rather than a solvent-based adhesive can be determined by analysis, for example, by Fourier transform infrared spectroscopy.

[0105] A solvent-free adhesive can be used as the adhesive constituting the adhesive layer from the viewpoint of improving the appearance of the laminate. When a base film and a sealant film are bonded together using a dry laminating adhesive, the adhesive dissolved in a solvent is usually applied to the base film, the solvent is removed in a drying oven, and then the sealant film is bonded. While the dry laminating adhesive after solvent removal is hard and has a low degree of freedom in shape deformation, solvent-free adhesives have a high degree of freedom in shape deformation during bonding, and therefore solvent-free adhesives are more likely to conform to the surface shape of even uneven sealant films. Therefore, a solvent-free adhesive layer formed using a solvent-free adhesive is less likely to generate bubbles due to voids between the base film and the sealant film, and can also improve adhesion.

[0106] Incidentally, solvent-free adhesives have the advantage of having a low environmental impact during the manufacturing process and being able to be applied thinner than solvent-based adhesives. Therefore, adhesive layers formed with solvent-free adhesives tend to be thin. In the laminate of this embodiment, when an adhesive layer formed with a solvent-free adhesive is combined with the sealant film of this embodiment, which has sufficiently small surface irregularities, high adhesive strength can be obtained with a smaller amount of adhesive applied, and a good appearance can be obtained with reduced bubble generation.

[0107] The adhesive layer may be chlorine-free from the viewpoint of suppressing discoloration of recycled resins and the like after recycling and the generation of odors due to heat treatment.

[0108] From the viewpoint of environmental consideration, the adhesive layer may be formed from a biomass material.

[0109] The thickness of the adhesive layer may be 0.3 μm or more and 5.0 μm or less. From the viewpoint of adhesive strength, the thickness of the adhesive layer may be 0.3 μm or more, 0.5 μm or more, or 1 μm or more, and from the viewpoint of recyclability, the thickness may be 5.0 μm or less, 3.5 μm or less, or 2.5 μm or less. When the thickness of the adhesive layer is equal to or less than the above upper limit, the ratio of monomaterials in the laminate (or packaging material) can be increased.

[0110] From the viewpoint of material recycling, the laminate of this embodiment may have a plastic material content of 10% by mass or more, or 25% by mass or more, based on the total amount of plastic material in the laminate. When the laminate of this embodiment is used for a laminate packaging material, materials other than plastic (for example, adhesives, printing inks, aluminum foil, etc.) may be excluded from the weight calculation.

[0111] Examples of plastic materials contained in recycled materials (so-called recycled plastics) include resins contained in the recycled materials contained in the recycled material-containing layer according to the present embodiment. Pre-consumer materials among recycled plastics may be calculated by multiplying the weight by 1 / 2.

[0112] <Packaging material> The packaging material of this embodiment includes the laminate of this embodiment.

[0113] The packaging material of the present embodiment may further include a functional layer such as a printed layer, etc. These functional layers may be provided on the above-mentioned base film.

[0114] The printed layer may be formed on the surface of the base film on which the sealant film is provided, in which case the printed layer can be prevented from coming into contact with the outside air and from deteriorating over time.

[0115] The print layer may represent letters, patterns, symbols, or a combination thereof.

[0116] From the viewpoint of producing a packaging material with less environmental impact, the printed layer may be formed using ink derived from biomass.

[0117] The method for forming the printed layer is not particularly limited, and any conventionally known printing method such as gravure printing, offset printing, flexographic printing, etc. Among these, flexographic printing may be used from the viewpoint of environmental load.

[0118] Each layer in the packaging material of this embodiment may contain the additives described above.

[0119] Fig. 5 is a schematic cross-sectional view showing one embodiment of a packaging material. The packaging material 100 shown in Fig. 5 includes a sealant film 1b having an auxiliary layer 4, and a base film 6 having a gas barrier layer 12 laminated onto the auxiliary layer 4 via an adhesive layer 5.

[0120] The packaging material of this embodiment can be modified in various ways in addition to the configuration described above, and may have the following configuration. (a) Sealant film of this embodiment / adhesive layer / gas barrier film / adhesive layer / substrate film (b) Sealant film / adhesive layer / gas barrier film of this embodiment (c) Sealant film of this embodiment / gas barrier layer (e.g., vapor deposition layer) / adhesive layer / substrate film Examples of the gas barrier film include metal foils such as aluminum foil, and films of ethylene-vinyl alcohol copolymers, polyamide resins, polyvinylidene chloride resins, polyacrylonitrile resins, and the like.

[0121] From the viewpoint of material recycling, the content of plastic material contained in the packaging material of this embodiment may be 10% by mass or more, or 25% by mass or more, based on the total amount of plastic material in the packaging material. When the packaging material of this embodiment is a laminate packaging material, materials other than plastic (for example, adhesives, printing inks, aluminum foil, etc.) may be excluded from the weight calculation.

[0122] Examples of plastic materials contained in recycled materials (so-called recycled plastics) include resins contained in the recycled materials contained in the recycled material-containing layer according to the present embodiment. Pre-consumer materials among recycled plastics may be calculated by multiplying the weight by 1 / 2.

[0123] The packaging material of this embodiment can be used for stand-up pouches, three-sided bags, two-sided bags, gusseted bags, pouches with spouts, pouches with beaks, and the like.

[0124] <Packaging bag> The packaging bag of this embodiment is made from the packaging material of this embodiment described above. The manufacturing style of the packaging bag is not particularly limited, but the packaging bag may be a stand-up pouch, a three-sided bag, a two-sided bag, a gusset bag, a pouch with a spout, a pouch with a beak, or the like. [Example]

[0125] The present invention will be specifically explained below with reference to examples, but the present invention is not limited to these examples.

[0126] <Preparing recycled materials> (Recycled material 1) The recycled material 1 was obtained by compressing, cutting, and granulating a film consisting of an LLDPE film (Mitsui Chemicals Tocello, product name "TUX FC-S," 100 μm thick), an adhesive layer, a PET film (Toray Advanced Film, product name "VM-PET 1310," 12 μm thick, aluminum vapor deposition), an adhesive layer, and an Ny film (Toyobo, product name "Harden Film N1100," 15 μm thick). The adhesive layer was formed by dry lamination using an adhesive mixture of DiC Dry LX-500 (DIC Graphics, product name) as the base agent, KW75 (DIC Graphics, product name) as the curing agent, and NC401 (Toyo Ink, product name) as the solvent.

[0127] (Recycled material 2) Recycled material 2 was obtained by compressing, cutting, and shaping into granules a film consisting of an LLDPE film (manufactured by Mitsui Chemicals Tohcello, product name "TUX FC-S," film thickness 100 μm), an adhesive layer, an HDPE film (manufactured by Tamapoly, product name "HF31," film thickness 35 μm), an adhesive layer, and an HDPE film (manufactured by Tamapoly, product name "HF31," film thickness 35 μm) laminated in that order. The adhesive layer was formed in the same manner as for recycled material 1.

[0128] <Preparation of sealant film and laminate> Example 1 The recycled material 1 was placed in the hopper extruding the recycled material-containing layer, and LLDPE (Prime Polymer, product name "Evolue SP1540") with 6000 ppm of antiblocking agent (Prime Polymer, product name "EAZ-20") added by dry blending was placed in the hopper extruding the sealant layer. A 30 μm-thick recycled material-containing layer and a 70 μm-thick sealant layer were coextruded using a single-screw multi-layer extruder to produce a sealant film. The screw rotation speed during extrusion of the recycled material-containing layer was 16 rpm, and narrowing of the flow path before the T-die was minimized to minimize elongational stress. The molten resin was cooled using an air knife and a cooling roll with a matte, uneven surface (surface roughness Rz: 6 μm) sandblasted.

[0129] Next, a solvent-free adhesive TSN-4864A / TSN-4864B3 (manufactured by Toyo-Morton Co., Ltd.) (a mixture of the base agent TSN-4864A and the curing agent TSN-4864B3 in a weight ratio of 1:1) was applied to a silica-deposited PET film (manufactured by TOPPAN Holdings Co., Ltd., "GL-RD," PET film thickness 12 μm, silica-deposited). 2 The coated film was then laminated to the recycled material-containing layer of the sealant film to prepare a laminate.

[0130] Example 2 A sealant film was produced in the same manner as in Example 1, except that the extrusion rate of each layer was adjusted (the screw rotation speed when extruding the recycled material-containing layer was changed to 43 rpm) to form a recycled material-containing layer with a thickness of 80 μm and a sealant layer with a thickness of 20 μm. Next, a laminate was produced in the same manner as in Example 1, except that this sealant film was used.

[0131] Example 3 A sealant film was produced in the same manner as in Example 1, except that the extrusion rate of each layer was adjusted (the screw rotation speed when extruding the recycled material-containing layer was changed to 48 rpm) to form a recycled material-containing layer with a thickness of 90 μm and a sealant layer with a thickness of 10 μm. Next, a laminate was produced in the same manner as in Example 1, except that this sealant film was used.

[0132] Example 4 A sealant film was produced in the same manner as in Example 1, except that the molten resin was cooled under a pressure of 1.4 MPa using a nip roll (material: fluororesin) and a cooling roll having a matte texture (surface roughness Rz: 6 μm) formed by sandblasting, and that the extrusion rate of each layer was adjusted to form a recycled material-containing layer having a thickness of 90 μm and a sealant layer having a thickness of 10 μm. Next, a laminate was produced in the same manner as in Example 1, except that this sealant film was used.

[0133] Example 5 A sealant film was produced in the same manner as in Example 1, except that recycled material 2 was charged into a hopper for extruding the recycled material-containing layer, and the extrusion rate of each layer was adjusted (the screw rotation speed when extruding the recycled material-containing layer was changed to 43 rpm) to form a recycled material-containing layer with a thickness of 80 μm and a sealant layer with a thickness of 20 μm. Next, a laminate was produced in the same manner as in Example 1, except that this sealant film was used.

[0134] Example 6 A sealant film was produced in the same manner as in Example 5, except that the extrusion rate of each layer was adjusted (the screw rotation speed when extruding the recycled material-containing layer was changed to 48 rpm) to form a recycled material-containing layer with a thickness of 90 μm and a sealant layer with a thickness of 10 μm. Next, a laminate was produced in the same manner as in Example 1, except that this sealant film was used.

[0135] Example 7 A sealant film was produced in the same manner as in Example 5, except that the extrusion rate of each layer was adjusted (the screw rotation speed when extruding the recycled material-containing layer was changed to 51 rpm) to form a recycled material-containing layer with a thickness of 95 μm and a sealant layer with a thickness of 5 μm. Next, a laminate was produced in the same manner as in Example 1, except that this sealant film was used.

[0136] Example 8 A sealant film was produced in the same manner as in Example 5, except that the molten resin was cooled under a pressure of 1.4 MPa using a nip roll (material: fluororesin) and a cooling roll having a matte texture (surface roughness Rz: 6 μm) formed by sandblasting, and the extrusion rate of each layer was adjusted (the screw rotation speed when extruding the recycled material-containing layer was changed to 48 rpm) to form a recycled material-containing layer having a thickness of 90 μm and a sealant layer having a thickness of 10 μm. Next, a laminate was produced in the same manner as in Example 1, except that this sealant film was used.

[0137] Example 9 Recycled material 1 was placed in the hopper that extrudes the recycled material-containing layer, LLDPE (Prime Polymer, product name "Evolue SP1540") to which 6000 ppm of antiblocking agent (Prime Polymer, product name "EAZ-20") had been added by dry blending was placed in the hopper that extrudes the sealant layer, and LLDPE (Prime Polymer, product name "Evolue SP2040") was placed in the hopper that extrudes the auxiliary layer. Using a single-screw multi-layer extruder, a 20 μm thick auxiliary layer, an 80 μm thick recycled material-containing layer, and a 20 μm thick sealant layer were co-extruded to produce a sealant film. The screw rotation speed when extruding the recycled material-containing layer was 43 rpm, and the narrowing of the flow path before the T-die was avoided as much as possible to create a mechanism that was less susceptible to elongational stress, and the molten resin was cooled using an air knife and a cooling roll that had been sandblasted to form a matte uneven surface (surface roughness Rz: 6 μm). Next, a laminate was produced in the same manner as in Example 1, except that this sealant film was used.

[0138] Example 10 A sealant film was produced in the same manner as in Example 2, except that recycled material 1 and LLDPE (manufactured by Prime Polymer Co., Ltd., product name "Evolue SP2040") were charged into a hopper for extruding the recycled material-containing layer at a weight ratio of 1:1. Next, a laminate was produced in the same manner as in Example 1, except that this sealant film was used.

[0139] Example 11 A sealant film was produced in the same manner as in Example 2, except that block PP (manufactured by Japan Polypropylene Corporation, product name "Novatec PP BC6DRF") to which 6000 ppm of an antiblocking agent (manufactured by Prime Polymer, product name "EAZ-20") was added by dry blending was placed into the hopper that extrudes the sealant layer. Next, a laminate was produced in the same manner as in Example 1, except that this sealant film was used.

[0140] Example 12 A sealant film was produced in the same manner as in Example 1. Next, using this sealant film, a laminate was produced in the same manner as in Example 1, except that a solvent-based adhesive containing an organic solvent, "Takelac A626 (manufactured by Mitsui Chemicals, Inc.)" and "Takenate A-50 (manufactured by Mitsui Chemicals, Inc.)," ​​mixed at a weight ratio of 8:1, was used instead of the solventless adhesive.

[0141] Example 13 A sealant film was produced in the same manner as in Example 2. Next, using this sealant film, a laminate was produced in the same manner as in Example 1, except that a solvent-based adhesive containing an organic solvent, "Takelac A626 (manufactured by Mitsui Chemicals, Inc.)" and "Takenate A-50 (manufactured by Mitsui Chemicals, Inc.)," ​​mixed at a weight ratio of 8:1, was used instead of the solventless adhesive.

[0142] Example 14 A sealant film was produced in the same manner as in Example 3. Next, using this sealant film, a laminate was produced in the same manner as in Example 1, except that a solvent-based adhesive containing an organic solvent, "Takelac A626 (manufactured by Mitsui Chemicals, Inc.)" and "Takenate A-50 (manufactured by Mitsui Chemicals, Inc.)," ​​mixed at a weight ratio of 8:1, was used instead of the solventless adhesive.

[0143] Example 15 A sealant film was produced in the same manner as in Example 4. Next, using this sealant film, a laminate was produced in the same manner as in Example 1, except that a solvent-based adhesive containing an organic solvent, "Takelac A626 (manufactured by Mitsui Chemicals, Inc.)" and "Takenate A-50 (manufactured by Mitsui Chemicals, Inc.)," ​​mixed at a weight ratio of 8:1, was used instead of the solventless adhesive.

[0144] Example 16 A sealant film was produced in the same manner as in Example 5. Next, using this sealant film, a laminate was produced in the same manner as in Example 1, except that a solvent-based adhesive containing an organic solvent, "Takelac A626 (manufactured by Mitsui Chemicals, Inc.)" and "Takenate A-50 (manufactured by Mitsui Chemicals, Inc.)," ​​mixed at a weight ratio of 8:1, was used instead of the solventless adhesive.

[0145] Example 17 A sealant film was produced in the same manner as in Example 6. Next, using this sealant film, a laminate was produced in the same manner as in Example 1, except that a solvent-based adhesive containing an organic solvent, "Takelac A626 (manufactured by Mitsui Chemicals, Inc.)" and "Takenate A-50 (manufactured by Mitsui Chemicals, Inc.)," ​​mixed at a weight ratio of 8:1, was used instead of the solventless adhesive.

[0146] Example 18 A sealant film was produced in the same manner as in Example 7. Next, using this sealant film, a laminate was produced in the same manner as in Example 1, except that a solvent-based adhesive containing an organic solvent, "Takelac A626 (manufactured by Mitsui Chemicals, Inc.)" and "Takenate A-50 (manufactured by Mitsui Chemicals, Inc.)," ​​mixed at a weight ratio of 8:1, was used instead of the solventless adhesive.

[0147] Example 19 A sealant film was produced in the same manner as in Example 8. Next, using this sealant film, a laminate was produced in the same manner as in Example 1, except that a solvent-based adhesive containing an organic solvent, "Takelac A626 (manufactured by Mitsui Chemicals, Inc.)" and "Takenate A-50 (manufactured by Mitsui Chemicals, Inc.)," ​​mixed at a weight ratio of 8:1, was used instead of the solventless adhesive.

[0148] Example 20 A sealant film was produced in the same manner as in Example 9. Next, using this sealant film, a laminate was produced in the same manner as in Example 1, except that a solvent-based adhesive containing an organic solvent, "Takelac A626 (manufactured by Mitsui Chemicals, Inc.)" and "Takenate A-50 (manufactured by Mitsui Chemicals, Inc.)," ​​mixed at a weight ratio of 8:1, was used instead of the solventless adhesive.

[0149] (Comparative Example 1) Except for not adding an antiblocking agent to the sealant layer, a sealant film was produced in the same manner as in Example 1. Next, a laminate was produced in the same manner as in Example 1, except for using this sealant film.

[0150] (Comparative Example 2) A sealant film was produced in the same manner as in Example 1, except that the extrusion rate of each layer was adjusted (the screw rotation speed when extruding the recycled material-containing layer was changed to 51 rpm) to form a recycled material-containing layer with a thickness of 95 μm and a sealant layer with a thickness of 5 μm. Next, a laminate was produced in the same manner as in Example 1, except that this sealant film was used.

[0151] (Comparative Example 3) A sealant film was produced in the same manner as in Example 1, except that recycled material 2 was charged into a hopper for extruding the recycled material-containing layer, no antiblocking agent was added to the sealant layer, and the extrusion rate of each layer was adjusted (the screw rotation speed when extruding the recycled material-containing layer was changed to 43 rpm) to form a recycled material-containing layer with a thickness of 80 μm and a sealant layer with a thickness of 20 μm. Next, a laminate was produced in the same manner as in Example 1, except that this sealant film was used.

[0152] Comparative Example 4 A sealant film was produced in the same manner as in Example 1, except that recycled material 2 was charged into a hopper for extruding the recycled material-containing layer, and the extrusion rate of each layer was adjusted (the screw rotation speed when extruding the recycled material-containing layer was changed to 52 rpm) to form a recycled material-containing layer having a thickness of 98 μm and a sealant layer having a thickness of 2 μm. Next, a laminate was produced in the same manner as in Example 1, except that this sealant film was used.

[0153] (Comparative Example 5) Except for changing the amount of antiblocking agent added to 600 ppm, a sealant film was produced in the same manner as in Example 1. Next, a laminate was produced in the same manner as in Example 1, except for using this sealant film.

[0154] <Surface roughness of sealant layer> The arithmetic surface roughness Ra of the surface of the sealant layer opposite to the recycled material-containing layer side was measured in accordance with JIS B 0601:2001 standard.

[0155] <Reliability evaluation of sealant> Using a Tester Sangyo heat sealer (model TP-701-B), the sealant film heat seal layers were overlapped and sealed with a sealing pressure of 0.2 MPa, a sealing time of 1 second, and a sealing width of 10 mm. The heat sealing temperature was set to a temperature approximately 20°C above the melting point of the heat seal layer material (130°C for LLDPE, 180°C for PP). The heat seal area was then observed under a microscope and the seal was measured at 1 mm. 2 The area percentage of bubbles present in the observation area was calculated. When the area percentage of bubbles was between 0% and less than 5%, it was marked "◎", when it was between 5% and less than 10%, it was marked "〇", when it was between 10% and less than 20%, it was marked "△", and when it was 20% or more, it was marked "×".

[0156] <Convex part of laminate layer> Using a Keyence laser microscope (VK-X200 / VK-X210), the maximum height H of the convex portion on the surface of the laminate layer opposite the recycled material-containing layer (the difference in height between the highest peak and the deepest valley in a given section) and the width W at half the maximum height H of the convex portion were measured, and the ratio [W / H] to the maximum height H was calculated.

[0157] <Film-forming property evaluation> The appearance of the film was visually observed from film formation to winding, and the film formability was evaluated according to the following criteria. "Good": No folds or wrinkles were observed in the film from production to winding, and no defects in appearance due to folds or wrinkles were observed in the film after winding. "X": Folds and wrinkles occur during the process from film formation to winding, and poor appearance due to the folds and wrinkles is observed in the film after winding.

[0158] <Appearance evaluation of laminates (packaging materials)> The laminates (packaging materials) produced in each of the Examples and Comparative Examples were evaluated as follows. Each laminate obtained in each Example and Comparative Example was cut into a 100 mm square and evaluated based on the following criteria. [Judgment criteria] ◎: No bubbles with a diameter of 0.1 mm or more ○: Bubbles with a diameter of 0.1 mm or more and less than 0.5 mm are present △: Bubbles with a diameter of 0.5 mm or more and less than 1 mm are present ×: Bubbles with a diameter of 1 mm or more are present

[0159] [Table 1]

[0160] [Table 2]

[0161] [Table 3]

[0162] [Table 4]

[0163] As shown in Tables 1 to 4, it was confirmed that the laminates of Examples 1 to 20 contained recycled materials and yet had sufficient reliability and film-forming properties during heat sealing, and also had excellent appearance. Therefore, according to the present invention, material recycling of recycled materials containing two or more resins can be realized in laminates and packaging materials. [Explanation of symbols]

[0164] 1a, 1b... sealant film, 2... recycled material-containing layer, 3... sealant layer, 4... auxiliary layer, 5... adhesive layer, 6... base film, 10a, 10b... laminate, 12... gas barrier layer, 50... aggregate, 100... packaging material.

Claims

1. A laminate comprising, in this order, a sealant film, an adhesive layer, and a base film, wherein the sealant film comprises a recycled material-containing layer containing a recycled material containing two or more types of resin, and a sealant layer laminated on a main surface of the recycled material-containing layer remote from the adhesive layer, and wherein the arithmetic surface roughness of the surface of the sealant layer opposite to the recycled material-containing layer side is 0.5 μm or more and 5 μm or less.

2. The laminate according to claim 1 , wherein the adhesive layer comprises a reaction-cured product of a solventless adhesive.

3. The laminate according to claim 1 , wherein the sealant layer has a thickness of 5 μm or more and 70 μm or less.

4. 2. The laminate according to claim 1, wherein the maximum height H of the convex portions on the surface of the sealant layer is 0.5 μm or more and 10 μm or less, and the ratio [W / H] of the width W at half the maximum height H to the maximum height H of the convex portions having the maximum height H is 20 or less.

5. The laminate according to claim 1 , wherein the resin having the largest content ratio among the two or more types of resin contained in the recycled material is a polyethylene-based resin or a polypropylene-based resin.

6. The laminate according to claim 1 , further comprising an auxiliary layer laminated to a major surface of the recycled material-containing layer adjacent to the adhesive layer.

7. The laminate according to claim 6 , wherein the auxiliary layer contains the same type of virgin resin as the resin having the highest content in the recycled material-containing layer.

8. A packaging material comprising the laminate according to any one of claims 1 to 7.

9. 9. The packaging material according to claim 8, wherein the content of plastic material contained in the recycled material is 10% by mass or more based on the total amount of plastic material in the packaging material.

10. A packaging bag made from the packaging material according to claim 8.

11. A packaging bag made from the packaging material according to claim 9.

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