Laminate, packaging container, packaging product, and method for manufacturing laminate.

Abstract

To provide a laminate, a packaging container, a packaging product, and a method for manufacturing a laminate that can suppress a decrease in adhesion between the base film and the extruded resin layer, even when recycled resin is used in the extruded resin layer. [Solution] A laminate comprising a base film and an extruded resin layer, wherein the extruded resin layer has, in order from the base film side, a first resin layer containing a first resin and a second resin layer containing a second resin, the first resin does not contain recycled resin and the second resin contains recycled resin.

Description

Technical Field

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[0001] The present disclosure relates to a laminate, a packaging container, a packaging product, and a method for manufacturing a laminate.

Background Art

[0002] A laminate used for a flexible packaging container or the like generally includes a plurality of different types of films.

[0003] For example, Patent Document 1 below discloses a laminate including a stretched base material and a sealant layer, wherein the laminate includes an extruded resin layer containing polyethylene as a main component between the stretched base material and the sealant layer.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] By the way, in recent years, due to social situations such as waste management and responses to a recycling-based society, the use of recycled resins has been required.

[0006] However, when using a recycled resin for the polyethylene in the extruded resin layer of the laminate described in Patent Document 1 above, there was room for improvement in suppressing a decrease in adhesion between the stretched base material and the extruded resin layer.

[0007] An object of the present disclosure is to provide a laminate, a packaging container, a packaging product, and a method for manufacturing a laminate that can suppress a decrease in adhesion between a base film and an extruded resin layer even when using a recycled resin for the extruded resin layer. [[ID=……]]

Means for Solving the Problems

[0008] The inventors of this disclosure investigated the cause of the above-mentioned problems in the laminate described in Patent Document 1. First, recycled resin may contain foreign matter such as aluminum foil or fragments of vapor-deposited film, or resins other than the recycled resin (foreign resins). The inventors of this disclosure considered that these foreign matter and foreign resins (hereinafter also simply referred to as "foreign matter") tend to form clumps and create irregularities on the surface. Furthermore, the inventors of this disclosure considered that in Patent Document 1, these foreign matter and foreign resins appear on the surface of the extruded resin layer and come into contact with the base film, reducing the contact area between the base film and the extruded resin layer and thus reducing adhesion. As a result of further diligent investigation, the inventors of this disclosure found that the above-mentioned problems can be solved by the following disclosure.

[0009] In other words, one aspect of the present disclosure provides a laminate comprising a structure having a base film and an extruded resin layer, wherein the extruded resin layer has, in order from the base film side, a first resin layer containing a first resin and a second resin layer containing a second resin, wherein the first resin does not contain recycled resin and the second resin contains recycled resin.

[0010] In this laminate, within the structure, a first resin layer, which does not contain recycled resin, is interposed between the second resin layer, which contains recycled resin, and the base film. Therefore, even if the laminate is placed in a high-temperature environment and foreign matter mixed in the recycled resin appears on the surface of the second resin layer facing the first resin layer, contact between the base film and the foreign matter in the extruded resin layer is suppressed. As a result, even when recycled resin is used in the extruded resin layer, a decrease in adhesion between the base film and the extruded resin layer can be suppressed.

[0011] In the laminate described above, the first resin and the second resin may also contain polyolefin resins.

[0012] The laminate may further include an anchor coat layer between the base film and the extruded resin layer.

[0013] In this case, the anchor coat layer can further suppress the decrease in adhesion between the base film and the extruded resin layer. Furthermore, because the anchor coat layer positions the second resin layer further away from the base film, even if the foreign matter is a large mass with long protrusions, contact between these protrusions and the base film is suppressed.

[0014] In the laminate described above, the structure further comprises a second base film, the extruded resin layer is disposed between the base film and the second base film, and the extruded resin layer further comprises a third resin layer containing a third resin between the second resin layer and the second base film, the third resin does not necessarily have to contain recycled resin.

[0015] In this case, in the extruded resin layer, a third resin layer, which does not contain recycled resin, is interposed between the second resin layer, which contains recycled resin, and the second base film. Therefore, even if the laminate is placed in a high-temperature environment, for example, and foreign matter mixed in the recycled resin appears on the surface of the second resin layer on the side of the third resin layer, contact between the second base film and the foreign matter in the extruded resin layer is suppressed. For this reason, even if recycled resin is used in the extruded resin layer, a decrease in adhesion between the second base film and the extruded resin layer can be suppressed.

[0016] Another aspect of this disclosure is the provision of a packaging container comprising the laminate described above.

[0017] According to the packaging container of this disclosure, even if recycled resin is used in the extruded resin layer of the laminate, the decrease in adhesion between the base film and the extruded resin layer can be suppressed, thereby suppressing a decrease in the strength of the packaging container. For this reason, according to the packaging container of this disclosure, even when contents are contained, leakage of contents due to impact or dropping during transportation is suppressed.

[0018] Another aspect of this disclosure is the provision of a packaged product comprising the packaging container described above and contents contained in the packaging container.

[0019] According to the packaging product of this disclosure, even if recycled resin is used in the extruded resin layer of the laminate, the decrease in adhesion between the base film and the extruded resin layer can be suppressed, thereby suppressing a decrease in the strength of the packaging container. For this reason, according to the packaging product of this disclosure, leakage of contents due to impact or dropping during transportation is suppressed.

[0020] A further aspect of this disclosure is a method for manufacturing a laminate comprising a structure having a base film and an extruded resin layer, the method comprising a structure forming step for forming the structure, the structure forming step comprising an extruded resin layer forming step for forming an extruded resin layer on the base film, wherein in the extruded resin layer forming step the extruded resin layer has, in order from the base film side, a first resin layer containing a first resin and a second resin layer containing a second resin, the first resin not containing recycled resin and the second resin containing recycled resin.

[0021] According to this method for manufacturing laminates, when forming the extruded resin layer, if the second resin contains recycled resin, foreign matter mixed in the recycled resin tends to appear on the surface. However, even in this case, since the first resin layer, which does not contain recycled resin, is interposed between the second resin layer and the base film, even if the laminate is placed in a high-temperature environment and foreign matter mixed in the recycled resin appears on the surface of the second resin layer on the side facing the first resin layer, contact between the base film and the foreign matter in the extruded resin layer is suppressed. Therefore, even when recycled resin is used in the extruded resin layer, it is possible to manufacture a laminate that can suppress a decrease in adhesion between the base film and the extruded resin layer.

[0022] In the method for manufacturing the laminate described above, in the extruded resin layer formation step, the extruded resin layer has, in order from the base film side, the first resin layer, the second resin layer, and the third resin layer containing the third resin, wherein the first resin and the third resin do not contain recycled resin, and the second resin contains recycled resin, and the structure formation step may further include, after the extruded resin layer formation step, a second base film placement step of placing the second base film on the third resin layer. [Effects of the Invention]

[0023] According to the present disclosure, there are provided a laminate, a packaging container, a packaging product, and a method for producing a laminate, which can suppress a decrease in adhesion between a base film and an extruded resin layer even when a recycled resin is used for the extruded resin layer.

Brief Description of the Drawings

[0024] [Figure 1] FIG. 1 is a cross-sectional view showing an embodiment of the laminate of the present disclosure. [Figure 2] FIG. 2 is a cross-sectional view showing an embodiment of the packaging product of the present disclosure. [Figure 3] FIG. 3 is a cross-sectional view showing another embodiment of the laminate of the present disclosure. [Figure 4] FIG. 4 is a cross-sectional view showing another embodiment of the laminate of the present disclosure. [Figure 5] FIG. 5 is a cross-sectional view showing another embodiment of the laminate of the present disclosure.

Modes for Carrying Out the Invention

[0025] <Laminate> Hereinafter, an embodiment of the laminate of the present disclosure will be described with reference to FIG. 1. FIG. 1 is a cross-sectional view showing an embodiment of the laminate of the present disclosure.

[0026] The laminate 100 shown in FIG. 1 includes a structure 50, and the structure includes a base film 10, an extruded resin layer 20, and a second base film 30. The extruded resin layer 20 has, in order from the base film 10 side, a first resin layer 21 containing a first resin, a second resin layer 22 containing a second resin, and a third resin layer 23 containing a third resin. The first resin and the third resin do not contain recycled resin, and the second resin contains recycled resin. The laminate 100 may further include an anchor coat layer 40 between the base film 10 and the extruded resin layer 20.

[0027] With this laminate 100, in the structure 50, a first resin layer 21, which does not contain recycled resin, is interposed between the second resin layer 22, which contains recycled resin, and the base film 10. Therefore, even if the laminate 100 is placed in a high-temperature environment, for example, and foreign matter mixed in the recycled resin appears on the surface of the second resin layer 22 on the side of the first resin layer 21, contact between the foreign matter and the base film 10 is suppressed. For this reason, even if recycled resin is used in the extruded resin layer 20, a decrease in adhesion between the base film 10 and the extruded resin layer 20 can be suppressed. Furthermore, in the extruded resin layer 20, a third resin layer 23, which does not contain recycled resin, is interposed between the second resin layer 22, which contains recycled resin, and the second base film 30. Therefore, even if the laminate 100 is placed in a high-temperature environment, for example, and foreign matter mixed in the recycled resin appears on the surface of the second resin layer 22 on the side of the third resin layer 23, contact between the foreign matter and the second base film 30 is suppressed. For this reason, even if recycled resin is used in the extruded resin layer 20, a decrease in adhesion between the second base film 30 and the extruded resin layer 20 can be suppressed.

[0028] The following describes the base film 10, anchor coat layer 40, extruded resin layer 20, and second base film 30 in detail.

[0029] (1) Base film Examples of the base film 10 include resin films, paper base films, barrier films, and sealant films.

[0030] Examples of resin films include polyester resins such as polyethylene terephthalate (PET) and polybutylene terephthalate (PBT), polyamide resins (PA), stretched polyolefins (OPP), and stretched polyethylene (OPE). These resin films can be used as substrate films for printing. Examples of paper-based films include paper substrates and films in which a resin layer is formed on a paper substrate. Examples of resin layers include polyolefin resins such as polyethylene and polypropylene. Examples of barrier films include metal foils such as aluminum foil, ethylene vinyl alcohol copolymer (EVOH) films, metal vapor-deposited films such as aluminum vapor-deposited films, and transparent vapor-deposited films. The above-mentioned resin films can be used as the films for metal vapor-deposited films and transparent vapor-deposited films. Examples of sealant films include unstretched polypropylene (CPP), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), and ethylene vinyl acetate copolymer (EVA).

[0031] The thickness of the base film 10 is designed according to the required functions of the base film 10 and the size of the packaging container formed using the laminate 100, and is not particularly limited, but may be, for example, 200 μm or less, 100 μm or less, 80 μm or less, or 50 μm or less. The thickness of the base film 10 may be 5 μm or more, 10 μm or more, 15 μm or more, 20 μm or more, or 30 μm or more.

[0032] The surface of the base film 10 on the side facing the extruded resin layer 20 may be pre-treated. Examples of surface treatments include corona treatment, plasma treatment, and flame treatment.

[0033] (2) Anchor coat layer The anchor coat layer 40 is provided between the base film 10 and the extruded resin layer 20. The anchor coat layer 40 further suppresses the decrease in adhesion between the base film 10 and the extruded resin layer 20.

[0034] The materials constituting the anchor coat layer 40 are not particularly limited as long as they can improve the adhesion between the base film 10 and the extruded resin layer 20, but they usually include resin. It is preferable that the resin is not recycled resin. The resin preferably includes a polyurethane resin. In this case, the anchor coat layer 40 containing the polyurethane resin makes it easier to relieve stress generated in the base film 10 or the extruded resin layer 20. Such polyurethane resins are composed of reaction products of, for example, organosilanes or organometallic compounds, polyol compounds, and isocyanate compounds. The organosilane is, for example, a trifunctional organosilane or a hydrolysate of a trifunctional organosilane. The organometallic compound is, for example, a metal alkoxide or a hydrolysate of a metal alkoxide. The metal elements contained in the organometallic compound are, for example, Al, Ti, Zr, etc. The hydrolysates of organosilanes and metal alkoxides each only need to have at least one hydroxyl group. From the viewpoint of transparency, the polyol compound is preferably an acrylic polyol. The isocyanate compound mainly functions as a crosslinking agent or a curing agent. The polyol compound and the isocyanate compound may be monomers or polymers.

[0035] The thickness of the anchor coat layer 40 is not particularly limited and may be 0.02 μm or more, 0.05 μm or more, 0.1 μm or more, 0.2 μm or more, 0.4 μm or more, 0.5 μm or more, 0.7 μm or more, or 1.0 μm or more. The thickness of the anchor coat layer 40 may be 5 μm or less, 2.5 μm or less, or 1.5 μm or less.

[0036] (3) Extruded resin layer The extruded resin layer 20 includes a first resin layer 21, a second resin layer 22, and a third resin layer 23.

[0037] (1st resin layer) The first resin does not contain recycled resin. In other words, the first resin consists solely of non-recycled resin (virgin resin). Here, recycled resin refers to material recycled resin, chemical recycled resin, or mixtures thereof. The first resin contained in the first resin layer 21 is a non-recycled resin, and examples of non-recycled resins include polyolefin resins, polyester resins, and polyamide resins. Among these, polyolefin resins are preferred. In this case, advantages such as suitability for extrusion processing at relatively low temperatures and excellent heat sealability can be obtained. Examples of polyolefin resins include LDPE, LLDPE, high-density polyethylene (HDPE), EVA, and polypropylene (PP).

[0038] The thickness of the first resin layer 21 is not particularly limited, but is preferably 2 μm or more, more preferably 5 μm or more, and especially preferably 10 μm or more. The thickness of the first resin layer 21 may be, for example, 60 μm or less, 40 μm or less, or 20 μm or less.

[0039] The ratio of the thickness of the first resin layer 21 to the extruded resin layer 20 should be greater than 0% and less than 100%, but from the viewpoint of further suppressing the decrease in adhesion between the extruded resin layer 20 and the base film 10, it is preferably 10% or more, more preferably 20% or more, and particularly preferably 30% or more. From the viewpoint of reducing environmental impact, the ratio of the thickness of the first resin layer 21 to the extruded resin layer 20 is preferably 70% or less, more preferably 60% or less, and particularly preferably 50% or less.

[0040] (2nd resin layer) The number of second resin layers 22 may be one or multiple. The second resin contained in the second resin layer 22 includes recycled resin. The second resin may consist solely of recycled resin, or it may consist of a mixture of recycled resin and non-recycled resin. Examples of recycled resins include material-recycled resins and chemical-recycled resins. These can be used individually or in combination. However, the laminate 100 is particularly useful when the recycled resin includes material recycled resin. This is because when the recycled resin includes material recycled resin, foreign matter tends to be easily mixed into the second resin layer 22. Recycled resin can be obtained through PIR (Post Industrial Recycle), which recycles scraps generated as processing losses during manufacturing before they reach the market, or through PCR (Post Consumer Recycle), which collects and recycles used products from consumers. Examples of recycled resins include recycled polyolefin resins, recycled polyester resins, and recycled polyamide resins. Among these, recycled polyolefin resins are preferred. In this case, advantages such as suitability for extrusion processing at relatively low temperatures and excellent heat sealability can be obtained. Examples of recycled polyolefin resins include recycled LDPE, recycled LLDPE, recycled high-density polyethylene (HDPE), recycled EVA, and recycled polypropylene (PP). As the non-recycled resin, the same type as the first resin in the first resin layer 21 can be used. The non-recycled resin contained in the second resin may be the same as or different from the non-recycled resin in the first resin. If there are multiple second resin layers 22, it is sufficient that the second resin contained in at least one of the multiple second resin layers 22 contains recycled resin. For example, the second resin contained in only one second resin layer 22 may contain recycled resin, or all of the second resin contained in the second resin layers 22 may contain recycled resin.

[0041] In the second resin layer 22, the content of recycled resin in the second resin is not particularly limited, but from the viewpoint of reducing environmental impact, it is preferably 20% by mass or more, more preferably 40% by mass or more, and particularly preferably 60% by mass or more. However, from the viewpoint of further suppressing the decrease in adhesion between the extruded resin layer 20 and the base film 10, the content of recycled resin in the second resin is preferably 95% by mass or less, more preferably 90% by mass or less, and particularly preferably 85% by mass or less.

[0042] The thickness of the second resin layer 22 is not particularly limited and may be, for example, 2 μm or more, 5 μm or more, or 10 μm or more. The thickness of the second resin layer 22 may be, for example, 60 μm or less, 40 μm or less, or 20 μm or less.

[0043] The ratio of the total thickness of the second resin layer 22 to the thickness of the extruded resin layer 20 should be greater than 0% and less than 100%, but from the viewpoint of reducing environmental impact, it is preferably 10% or more, more preferably 20% or more, and particularly preferably 30% or more. From the viewpoint of further suppressing the decrease in adhesion between the extruded resin layer 20 and the base film 10, the ratio of the total thickness of the second resin layer 22 to the thickness of the extruded resin layer 20 is preferably 70% or less, more preferably 60% or less, and particularly preferably 50% or less.

[0044] (3rd resin layer) The third resin included in the third resin layer 23 can be the same resin as the first resin. The non-recycled resin of the third resin may be the same as or different from the non-recycled resin of the first resin.

[0045] The thickness of the third resin layer 23 is not particularly limited and may be, for example, 2 μm or more, 5 μm or more, or 10 μm or more. The thickness of the third resin layer 23 may be, for example, 60 μm or less, 40 μm or less, or 20 μm or less.

[0046] The ratio of the thickness of the third resin layer 23 to the extruded resin layer 20 should be greater than 0% and less than 100%, but from the viewpoint of further suppressing the decrease in adhesion between the extruded resin layer 20 and the second base film 30, it is preferably 10% or more, more preferably 20% or more, and particularly preferably 30% or more. From the viewpoint of reducing environmental impact, the ratio of the thickness of the third resin layer 23 to the extruded resin layer 20 is preferably 70% or less, more preferably 60% or less, and particularly preferably 50% or less.

[0047] (Extruded resin layer) The thickness of the extruded resin layer 20 is not particularly limited, but is preferably 6 μm or more, more preferably 15 μm or more, and especially preferably 30 μm or more. However, the thickness of the extruded resin layer 20 may be 180 μm or less, 120 μm or less, or 60 μm or less.

[0048] (4) Second base film As the second base film 30, a film similar to the base film 10 can be used. The material of the second base film 30 may be the same as or different from the material of the base film 10, and can be changed as appropriate depending on the application. When the laminate 100 is used as a packaging film to form a packaging container, and the base film 10 is, for example, a resin film or a barrier film, the second base film 30 may be made of a sealant film. Alternatively, if the laminate 100 is used as a packaging film to form a packaging container, and the base film 10 is, for example, a sealant film, the second base film 30 may be composed of a resin film or a barrier film.

[0049] The thickness of the second base film 30 is designed according to the required functions of the second base film 30 and the size of the packaging container formed using the laminate 100, and is not particularly limited, but may be, for example, 200 μm or less, 100 μm or less, 80 μm or less, or 50 μm or less. The thickness of the second base film 30 may be 5 μm or more, 10 μm or more, 15 μm or more, 20 μm or more, or 30 μm or more. The thickness of the second base film 30 may be the same as or different from that of the base film 10.

[0050] The surface of the second base film 30 on the side facing the extruded resin layer 20 may be pre-treated. Examples of surface treatments include corona treatment, plasma treatment, and flame treatment.

[0051] <Method for manufacturing laminates> Next, a method for manufacturing the laminate 100 will be described. The method for manufacturing the laminate 100 includes a structure formation step for forming the structure 50. The structure formation process includes an extruded resin layer formation step in which an extruded resin layer 20 is formed on a base film 10, and a second base film placement step in which a second base film 30 is placed on a third resin layer 23 after the extruded resin layer formation step.

[0052] In the extruded resin layer formation process, the extruded resin layer 20 has, in order from the base film 10 side, a first resin layer 21 containing a first resin, a second resin layer 22 containing a second resin, and a third resin layer 23 containing a third resin, and is formed such that the first and third resins do not contain recycled resin, while the second resin contains recycled resin. An anchor coat layer 40 may be formed on the base film 10 before forming the extruded resin layer 20 on the base film 10. The anchor coat layer 40 can be formed, for example, by applying an anchor coat layer forming composition to the surface of the base film 10 and heating it.

[0053] The extruded resin layer 20 can be formed by co-extruding a first resin layer forming resin composition, a second resin layer forming resin composition, and a third resin layer forming resin composition from each of a plurality of extruders through a die (mold) having a plurality of slits, bringing them into contact with the surface of the base film 10, and then bringing them into contact with a cooling mold (cooling roll) to solidify the first resin layer forming resin composition, the second resin layer forming composition, and the third resin layer forming resin composition. At this time, the base film 10, the resin composition for forming the first resin layer, the resin composition for forming the second resin layer, and the resin composition for forming the third resin layer, along with the second base film 30, are pressed against a cooling roll using a pressure roll to solidify the resin composition for forming the first resin layer, the resin composition for forming the second resin layer, and the resin composition for forming the third resin layer into a film. Furthermore, the recycled resin in the second resin contained in the second resin layer forming composition uses, for example, roughly granular plastic processed products (pellets) as raw materials. Pellets can be obtained by a melting method, in which recycled products are heated and melted, and then cooled and solidified, or by a non-melting method, in which recycled products are molded into roughly granular shapes without melting. Thus, the resin composition for forming the first resin layer becomes the first resin layer 21, the composition for forming the second resin layer becomes the second resin layer 22, and the composition for forming the third resin layer becomes the third resin layer 23.

[0054] In the above extruded resin layer formation process, if the first resin, second resin, and third resin in each of the first resin layer 21, second resin layer 22, and third resin layer 23 contain multiple types of resins, the extruded resin layer 20 may be formed such that the ratio of the compatibilizer to 100 parts by mass of the total of the multiple types of resins and the compatibilizer for the multiple types of resins is less than 1 part by mass. Here, the compatibilizer is a material that makes multiple types of resins compatible. In the first resin layer 21, the second resin layer 22, and the third resin layer 23, the ratio of the compatibilizer to 100 parts by mass of the total of multiple types of resins and compatibilizers may be 0.8 parts by mass or less, 0.5 parts by mass or less, or 0 parts by mass or less, or it may be 0 parts by mass. In this case, if the first resin, second resin, and third resin are composed of one type of resin, no compatibilizer is included in each of the first resin layer 21, the second resin layer 22, and the third resin layer 23. That is, the proportion of the compatibilizer is 0 parts by mass.

[0055] <Packaging products> Next, embodiments of the packaging product of this disclosure will be described with reference to Figure 2. Figure 2 is a cross-sectional view showing one embodiment of the packaging product of this disclosure. In Figure 2, the same reference numerals are used for components that are the same as those in Figure 1, and redundant descriptions are omitted. As shown in Figure 2, the packaged product 300 comprises a packaging bag 200 as a packaging container and contents C contained within the packaging bag 200. The packaging bag 200 shown in Figure 2 comprises a pair of laminates 100. Here, the second base film 30 of the laminate 100 is made of a sealant film, and the base film 10 is made of, for example, a resin film or a barrier film. The packaging bag 200 can be obtained by using a pair of laminates 100 and heat-sealing the peripheral edges of the laminates 100 with the second base films 30 facing each other to form a heat-sealed portion.

[0056] According to this packaging product 300, even if recycled resin is used in the extruded resin layer 20 of the laminate 100, a decrease in adhesion between the base film 10 and the extruded resin layer 20 can be suppressed, and a decrease in adhesion between the second base film 30 and the extruded resin layer 20 can be suppressed, thereby suppressing a decrease in the strength of the packaging bag 200 (especially the heat-sealed portion). For this reason, according to the packaging product 300, leakage of contents C due to impact or dropping during transportation is suppressed.

[0057] The packaging bag 200 can also be obtained by folding one laminate 100 and heat-sealing the peripheral edge of the laminate 100 with the second base film 30 facing each other to form a heat-sealed portion.

[0058] Examples of packaging bags 200 include three-sided pouches, four-sided pouches, standing pouches, gusset pouches, pillow packaging bags, etc. The packaging bag 200 may further have a spout or a zipper depending on the application.

[0059] Contents C are not particularly limited and may include food, liquids, pharmaceuticals, electronic components, etc.

[0060] In the above embodiment, the packaging container is made up of a packaging bag, but the packaging container of this disclosure may be made up of a liquid paper container or a laminated tube instead of a packaging bag.

[0061] Furthermore, although the structure 50 has a second base film 30 in the above embodiment, the structure 50 does not have to have a second base film 30. Also, if the structure 50 does not have a second base film 30, the extruded resin layer 20 does not have to have a third resin layer 23, as shown in the laminate 110 in Figure 3.

[0062] Furthermore, although the above embodiment shows that the laminate has only one structure 50, the laminate may have multiple structures. For example, the laminate of this disclosure may have an additional structure 51 on top of the structure 50, as shown in the laminate 120 in Figure 4. The structure 51 comprises, in order from the structure 50 side, an extruded resin layer 20 and a base film 10. Furthermore, the laminate of this disclosure may have an additional structure 52 on top of the structure 50, as shown in the laminate 130 in Figure 5, with the structure 50 and the structure 52 connected via an adhesive layer 60. The structure 52 comprises, in order from the structure 50 side, a base film 10, an extruded resin layer 20 and a second base film 30.

[0063] A specific example of the laminate of this disclosure is a laminate having the following configuration. (A) Base film (PET) / Extruded resin layer (PE / PE (including recycled PE) / PE) / Second base film (aluminum foil) / Extruded resin layer (PE / PE (including recycled PE) / PE) / Base film (LDPE) (B) Base film (PE / paper) / Extruded resin layer (PE / PE (including recycled PE) / PE) / Second base film (aluminum foil) / Adhesive / Base film (PET) / Extruded resin layer (PE / PE (including recycled PE)) (C) Base film (OPP) / Extruded resin layer (PE / PE (including recycled PE) / PE) / Second base film (CPP)

[0064] The laminates of this disclosure can be used not only as packaging containers, but also as industrial materials (e.g., release paper for labels), building materials (e.g., decorative sheets), and the like.

[0065] <Summary of this disclosure> The summary of this disclosure is as follows: [1] A laminate comprising a base film and an extruded resin layer, The extruded resin layer comprises, in order from the substrate film side, a first resin layer containing a first resin and a second resin layer containing a second resin. The first resin does not contain recycled resin, A laminate in which the second resin contains recycled resin. [2] The laminate according to [1], comprising the first resin and the second resin being polyolefin resins. [3] The laminate according to [1] or [2], further comprising an anchor coat layer between the base film and the extruded resin layer. [4] The structure further comprises a second base film, The extruded resin layer is placed between the base film and the second base film. The extruded resin layer further comprises a third resin layer containing a third resin between the second resin layer and the second substrate film. The laminate according to any one of [1] to [3], wherein the third resin does not contain recycled resin. A packaging container comprising a laminate as described in any of [5][1] to [4]. The packaging container described in [6][5], A packaged product comprising contents contained in the aforementioned packaging container. [7] A method for manufacturing a laminate comprising a base film and an extruded resin layer, The process includes a structure forming step for forming the aforementioned structure, The structure formation step includes an extruded resin layer formation step in which an extruded resin layer is formed on the base film, A method for manufacturing a laminate, wherein in the extruded resin layer forming step, the extruded resin layer has, in order from the substrate film side, a first resin layer containing a first resin and a second resin layer containing a second resin, and the first resin does not contain recycled resin, while the second resin contains recycled resin. [8] In the extruded resin layer formation step, the extruded resin layer is formed such that, in order from the base film side, it comprises the first resin layer, the second resin layer, and the third resin layer containing the third resin, wherein the first and third resins do not contain recycled resin, and the second resin contains recycled resin. The method for manufacturing a laminate according to [7], wherein the structure formation step further includes a second base film placement step of placing a second base film on the third resin layer after the extruded resin layer formation step. [Examples]

[0066] The present disclosure will be described in detail below with reference to examples, but the present disclosure is not limited to these examples.

[0067] <Fabrication of laminates> (Example 1) First, a PET film with a thickness of 12 μm was prepared as the base film. Then, a two-component curing polyurethane adhesive (anchor coat agent) was applied to one side of the PET film and dried to form an anchor coat layer containing polyurethane resin. Here, the polyurethane resin was a non-recycled resin. On the other hand, a composition for forming resin layer 1 containing virgin polyethylene (virgin PE) and a composition for forming resin layer 2 containing virgin PE and recycled polyethylene resin (recycled PE) were prepared. In this case, recycled polyethylene was used as the recycled PE. Furthermore, in the composition for forming resin layer 1, the virgin PE content was 100% by mass, and in the composition for forming resin layer 2, the virgin PE and recycled PE content were 20% by mass and 80% by mass, respectively.

[0068] Next, the composition for forming resin layer 1 and the composition for forming resin layer 2 were heated to 300°C, and by co-extrusion, extruded resin layers comprising resin layer 1 and resin layer 2 were formed on the surface of the anchor coat layer, starting from the PET film side. At this time, resin layer 1 was formed so as to be in contact with the base film, and the thickness of both resin layer 1 (first resin layer) and resin layer 2 (second resin layer) was 10 μm. This is how we obtained the laminated material.

[0069] (Example 2) First, a PET film with a thickness of 12 μm was prepared as the base film. Then, a two-component curing polyurethane adhesive (anchor coat agent) was applied to one side of the PET film and dried to form an anchor coat layer. The polyurethane resin used was a non-recycled resin. On the other hand, a composition for forming resin layer 1 containing virgin polyethylene (virgin PE), a composition for forming resin layer 2 containing virgin PE and recycled polyethylene resin (recycled PE), and a composition for forming resin layer 3 containing virgin polyethylene (virgin PE) were prepared. In this case, recycled polyethylene was used as the recycled PE. Furthermore, in the composition for forming resin layer 1, the virgin PE content was 100% by mass, in the composition for forming resin layer 2, the virgin PE and recycled PE content was 20% by mass and 80% by mass, respectively, and in the composition for forming resin layer 3, the virgin PE content was 100% by mass.

[0070] Next, a 40 μm thick linear low-density polyethylene (LLDPE) film was prepared as the second base film. Next, the composition for forming resin layer 1, the composition for forming resin layer 2, and the composition for forming resin layer 3 were heated to 300°C, and by co-extrusion, extruded resin layers comprising resin layer 1, resin layer 2, and resin layer 3 were formed between the PET film and the LLDPE film in that order from the PET film side. At this time, resin layer 1 was formed so as to be in contact with the base film, and the thickness of resin layer 1 (first resin layer), resin layer 2 (second resin layer), and resin layer 3 (third resin layer) was set to 5 μm each. This is how we obtained the laminated material.

[0071] (Example 3) A laminate was obtained in the same manner as in Example 2, except that the base film was changed from a 12 μm thick PET film to a 25 μm thick OPE film.

[0072] (Comparative Example 1) A laminate was obtained in the same manner as in Example 1, except that the composition for forming resin layer 1 containing virgin PE was changed to a composition for forming resin layer 1 containing virgin PE and recycled PE, and the content of virgin PE and recycled PE in the composition for forming resin layer 1 was set to 20% by mass and 80% by mass, respectively.

[0073] (Comparative Example 2) In forming the extruded resin layer, resin layer 2 and resin layer 3 were not formed, and a single-layer extruded resin layer with a thickness of 15 μm consisting only of resin layer 1 was formed using a resin layer 1 forming composition containing virgin PE and recycled PE. The laminate was obtained in the same manner as in Example 2, except that the content of virgin PE and recycled PE in the resin layer 1 forming composition was 20% by mass and 80% by mass, respectively.

[0074] (Comparative Example 3) In forming the extruded resin layer, resin layer 2 and resin layer 3 were not formed, and a single-layer extruded resin layer with a thickness of 15 μm consisting only of resin layer 1 was formed using a resin layer 1 forming composition containing virgin PE. The laminate was obtained in the same manner as in Example 2, except that the virgin PE content in the resin layer 1 forming composition was 100% by mass.

[0075] <Evaluation of laminates> (1) Useability of recycled resins The recycled resin content in the laminates of the examples and comparative examples was determined. The results are shown in Tables 1 and 2. In Tables 1 and 2, the criteria for "○" and "×" are as follows: "○" indicates that recycled resin is being utilized (high recycled resin utilization rate), and "×" indicates that recycled resin is not being utilized (low recycled resin utilization rate). (standard) ○: The recycled resin content in the laminate is 10% by mass or more. ×: The recycled resin content in the laminate is less than 10% by mass.

[0076] (2) Adhesion The laminates of the examples and comparative examples were observed in cross-section in the thickness direction using an optical microscope, and the area near the interface between the base film and the extruded resin layer was observed. The results are shown in Tables 1 and 2. In Tables 1 and 2, the criteria for "○" and "×" are as follows: "○" indicates good adhesion between the base film and the extruded resin layer, and "×" indicates poor adhesion between the base film and the extruded resin layer. (standard) ○: No unadhered areas were observed between the base film and the extruded resin layer. ×: An unadhered area was observed between the base film and the extruded resin layer.

[0077] [Table 1]

[0078] [Table 2]

[0079] As shown in Tables 1 and 2, the laminate of the example received a "○" rating for both recycled resin utilization and adhesion. In contrast, the laminate of the comparative example received a "×" rating for either recycled resin utilization or adhesion. Therefore, it has been confirmed that, according to the laminate of this disclosure, even when recycled resin is used in the extruded resin layer, the decrease in adhesion between the base film and the extruded resin layer can be suppressed. [Explanation of symbols]

[0080] 10...Base film, 20...Extruded resin layer, 21...First resin layer, 22...Second resin layer, 23...Third resin layer, 30...Second base film, 40...Anchor coat layer, 100, 110, 120, 130...Laminate, 200...Packaging bag (packaging container), 300...Packaged product.

Claims

1. A laminate comprising a structure having a base film and an extruded resin layer, The extruded resin layer comprises, in order from the substrate film side, a first resin layer containing a first resin and a second resin layer containing a second resin. The first resin does not contain recycled resin. A laminate in which the second resin includes recycled resin.

2. The laminate according to claim 1, wherein the first resin and the second resin each contain a polyolefin resin.

3. The laminate according to claim 1, further comprising an anchor coat layer between the base film and the extruded resin layer.

4. The aforementioned structure further comprises a second base film, The extruded resin layer is placed between the base film and the second base film. The extruded resin layer further comprises a third resin layer containing a third resin between the second resin layer and the second substrate film. The laminate according to claim 1, wherein the third resin does not contain recycled resin.

5. A packaging container comprising a laminate according to any one of claims 1 to 4.

6. The packaging container according to claim 5, A packaged product comprising contents contained in the aforementioned packaging container.

7. A method for manufacturing a laminate comprising a structure having a base film and an extruded resin layer, The process includes a structure forming step for forming the aforementioned structure, The structure formation step includes an extruded resin layer formation step in which an extruded resin layer is formed on the base film, A method for manufacturing a laminate, wherein in the extruded resin layer forming step, the extruded resin layer has, in order from the base film side, a first resin layer containing a first resin and a second resin layer containing a second resin, and the first resin does not contain recycled resin, while the second resin contains recycled resin.

8. In the extruded resin layer formation step, the extruded resin layer has, in order from the substrate film side, the first resin layer, the second resin layer, and the third resin layer containing the third resin, wherein the first and third resins do not contain recycled resin, and the second resin contains recycled resin. The method for manufacturing a laminate according to claim 7, wherein the structure formation step further includes a second base film placement step of placing a second base film on the third resin layer after the extruded resin layer formation step.

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