Laminate, laminate manufacturing method, container, and container manufacturing method

Abstract

To provide a laminate which contains an inorganic filler, and has good tear resistance, impact resistance and rigidity.SOLUTION: A laminate has a first outer layer, a second outer layer, and an intermediate layer provided between the first outer layer and the second outer layer, wherein the first outer layer is formed of a first resin composition containing a first polyolefin-based resin, the second outer layer is formed of a second resin composition containing a second polyolefin-based resin, and the intermediate layer is formed of a third composition which contains a talc, an ethylene / α-olefin copolymer, and a third polyolefin-based resin other than the ethylene / α-olefin copolymer, and has a content ratio of the talc of more than 50 mass%. There is also provided a container which is formed by using the laminate.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a laminate, a method for manufacturing a laminate, a container, a method for manufacturing a container, and a composition. [Background technology]

[0002] Various techniques have been proposed for blending inorganic fillers into container and packaging materials to reduce the proportion of petroleum-derived raw materials. For example, Patent Document 1 below discloses a thermoforming sheet that satisfies specific requirements and is obtained by extrusion molding a composite material consisting of an inorganic filler primarily composed of talc, a polypropylene resin, high-density polyethylene, and an ethylene-containing auxiliary polymer, and a talc container for food packaging formed from the thermoforming sheet. Patent Document 2 below discloses a multilayer hollow container that contains 50 to 80% by weight of an inorganic filler, at least one layer of which is a composition consisting of 60 to 90% by weight of the inorganic filler and 40 to 10% by weight of a specific polyethylene, and that satisfies specific requirements. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2000-127237 [Patent Document 2] Japanese Patent Application Laid-Open No. 2014-162495 Summary of the Invention [Problem to be solved by the invention]

[0004] While increasing the proportion of inorganic filler in the container material is expected to improve the rigidity of the container, it may also result in a decrease in tear resistance and impact resistance. Therefore, there is a demand for a laminate that contains an inorganic filler and has good tear resistance, impact resistance, and rigidity when formed into a container shape. Therefore, a main object of the present invention is to provide a laminate that contains an inorganic filler and has good tear resistance, impact resistance, and rigidity. [Means for solving the problem]

[0005] That is, the present invention provides: A first outer layer, a second outer layer, and an intermediate layer provided between the first outer layer and the second outer layer, the first outer layer is made of a first resin composition containing a first polyolefin-based resin, the second outer layer is made of a second resin composition containing a second polyolefin-based resin, The present invention provides a laminate in which the intermediate layer is made of a third composition containing talc, an ethylene / α-olefin copolymer, and a third polyolefin resin other than the ethylene / α-olefin copolymer, and the talc content is more than 50% by mass. The content of the ethylene / α-olefin copolymer in the third composition may be 1% by mass or more and 30% by mass or less. The ethylene / α-olefin interpolymer contained in the third composition may be a metallocene-based ethylene / α-olefin interpolymer. The third polyolefin resin may include block polypropylene. The first resin composition and / or the second resin composition may further contain an inorganic filler. The first polyolefin resin and / or the second polyolefin resin may contain at least one selected from the group consisting of homopolypropylene, high-density polyethylene, and ethylene / α-olefin copolymer. The first polyolefin resin and / or the second polyolefin resin may contain the homopolypropylene, and the homopolypropylene may have a tensile modulus of elasticity of 1500 MPa or more. The first polyolefin resin and / or the second polyolefin resin may contain the homopolypropylene, and the homopolypropylene may have a tensile modulus of elasticity of 1700 MPa or more. The first polyolefin resin and / or the second polyolefin resin may include a combination of the homopolypropylene and the ethylene / α-olefin copolymer, and the homopolypropylene may have a tensile modulus of elasticity of 1700 MPa or more. The present invention also provides a container formed using the laminate. The expansion ratio of the container may be 2.0 or more. The present invention provides a first resin composition containing a first polyolefin resin; a second resin composition containing a second polyolefin resin; a third composition comprising talc, an ethylene / α-olefin copolymer, and a third polyolefin resin other than the ethylene / α-olefin copolymer, wherein the talc content is more than 50% by mass; Using a first outer layer made of the first resin composition; a second outer layer made of the second resin composition; and an intermediate layer disposed between the first outer layer and the second outer layer and comprising the third composition. The present invention provides A first outer layer, a second outer layer, and an intermediate layer provided between the first outer layer and the second outer layer, the first outer layer is made of a first resin composition containing a first polyolefin-based resin, the second outer layer is made of a second resin composition containing a second polyolefin-based resin, the intermediate layer is made of a third composition containing talc, an ethylene / α-olefin copolymer, and a third polyolefin resin other than the ethylene / α-olefin copolymer, and the talc content is more than 50% by mass; The laminate Also provided is a method for manufacturing a container, which includes molding with a solid state molding machine. In the solid-state molding machine, the amount of power consumed per unit volume of the laminate during molding of the container may be 90% or less of the amount of power consumed when the talc content in the third composition is 0 mass%. The present invention provides The present invention also provides a composition comprising talc, an ethylene / α-olefin copolymer, and a polyolefin resin other than the ethylene / α-olefin copolymer, wherein the content of the talc is more than 50% by mass. The composition may be a container material. The present invention provides A first outer layer, a second outer layer, and an intermediate layer provided between the first outer layer and the second outer layer, the first outer layer is made of a first resin composition containing a first polyolefin-based resin, the second outer layer is made of a second resin composition containing a second polyolefin-based resin, The present invention also provides a laminate in which the intermediate layer is made of a third composition containing an inorganic filler, an ethylene / α-olefin copolymer, and a third polyolefin resin other than the ethylene / α-olefin copolymer, and the content of the inorganic filler is more than 50 mass%. [Effects of the Invention]

[0006] The present invention provides a laminate that contains an inorganic filler and that can produce a container that has good tear resistance, impact resistance (particularly cold impact resistance, which is impact resistance at low temperatures), and rigidity. Note that the effects of the present invention are not limited to those described herein and may be any of the effects described in this specification. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 2 is a perspective view showing an example of a testing machine used in an evaluation test of cold impact resistance. [Figure 2] FIG. 1 is a front view showing a testing machine when a weight is dropped in a cold-shock resistance evaluation test. DETAILED DESCRIPTION OF THE INVENTION

[0008] Preferred embodiments for carrying out the present invention will be described below. The embodiments described below are representative embodiments of the present invention, and the scope of the present invention is not limited to these embodiments.

[0009] 1.Laminate

[0010] A laminate according to one embodiment of the present invention has a first outer layer, a second outer layer, and an intermediate layer disposed between the first outer layer and the second outer layer. The layer structure, shape, uses, and manufacturing method of the laminate will be described below.

[0011] 1-1.Layer structure of laminate

[0012] 1-1-1. First outer layer

[0013] The first outer layer is made of a first resin composition containing a first polyolefin resin. In this specification, a polyolefin resin is a polymer having 50 mol % or more of olefin-derived structural units out of 100 mol % of all structural units. The first polyolefin resin is made of one type or a combination of two or more types of polyolefin resins.

[0014] Examples of the polyolefin resin include olefin homopolymers and copolymers of olefins with other monomers. The copolymers of olefins with other monomers may be, for example, block copolymers or random copolymers. The olefin is preferably an α-olefin, more preferably propylene and ethylene. That is, the polyolefin resin is preferably a polyα-olefin resin, more preferably a polypropylene resin and a polyethylene resin.

[0015] Examples of the polypropylene resin include propylene homopolymers (homopolypropylenes) and copolymers of propylene and other monomers. The copolymers of propylene and other monomers may be, for example, block copolymers (block polypropylenes) or random copolymers (random polypropylenes).

[0016] Examples of the polyethylene resin include ethylene homopolymers and copolymers of ethylene and other monomers. The copolymer of ethylene and other monomers is preferably an ethylene / α-olefin copolymer. The types and properties of the ethylene / α-olefin copolymer are described below in "1-1-3. Intermediate Layer." That is, the description of the ethylene / α-olefin copolymer contained in the intermediate layer also applies to the ethylene / α-olefin copolymer contained in the first resin composition. However, the type and properties of the ethylene / α-olefin copolymer contained in the first resin composition may differ from the type and properties of the ethylene / α-olefin copolymer contained in the intermediate layer described below. The ethylene / α-olefin copolymer contained in the first resin composition is preferably a metallocene-based ethylene / α-olefin copolymer. The description of the metallocene-based ethylene / α-olefin copolymer is also described below in "1-1-3. Intermediate Layer."

[0017] Examples of the polyethylene resins include high density polyethylene (HDPE), medium density polyethylene (MDPE), low density polyethylene (LDPE), very low density polyethylene (VLDPE), and linear low density polyethylene (LLDPE).

[0018] The first polyolefin resin contained in the first resin composition is preferably one or a combination of two or more poly-α-olefin resins, more preferably one or a combination of two or more selected from polypropylene resins and polyethylene resins. The first polyolefin resin more preferably contains at least one selected from the group consisting of homopolypropylene, high-density polyethylene, and ethylene / α-olefin copolymer. The first polyolefin resin particularly preferably contains homopolypropylene, a combination of homopolypropylene and high-density polyethylene, or a combination of homopolypropylene and ethylene / α-olefin copolymer. The combination of homopolypropylene and ethylene / α-olefin copolymer is particularly preferably a combination of homopolypropylene and metallocene-based ethylene / α-olefin copolymer. The inclusion of such a first polyolefin resin can improve the extensibility of the laminate during molding.

[0019] When the first polyolefin resin contains homopolypropylene, the density of the homopolypropylene is, for example, 0.880 g / cm 3 More than 0.920g / cm 3 Below, 0.885g / cm 3 More than 0.915g / cm 3 or less, or 0.890 g / cm 3 More than 0.910g / cm 3 It may be the following:

[0020] When the first polyolefin resin contains homopolypropylene, the homopolypropylene may have a melt flow rate (MFR) of, for example, 0.1 g / 10 min to 5.0 g / 10 min, 0.2 g / 10 min to 4.0 g / 10 min, 0.3 g / 10 min to 3.5 g / 10 min, 0.3 g / 10 min to 2.5 g / 10 min, or 0.4 g / 10 min to 2.0 g / 10 min. The MFR of the homopolypropylene is measured at 230°C under a load of 2.16 kg.

[0021] When the first polyolefin resin contains homopolypropylene, the lower limit of the tensile modulus of the homopolypropylene is, for example, 1400 MPa or more, preferably 1500 MPa or more, and more preferably 1600 MPa or more. Having the tensile modulus within this range can contribute to improving the rigidity of the laminate. The upper limit of the tensile modulus may be, for example, 2600 MPa or less, 2500 MPa or less, or 2400 MPa or less. When the first polyolefin resin contains a combination of homopolypropylene and an ethylene / α-olefin copolymer (particularly a combination of homopolypropylene and a metallocene-based ethylene / α-olefin copolymer), the tensile modulus of the homopolypropylene is preferably high, preferably 1700 MPa or more, more preferably 1800 MPa or more, even more preferably 1900 MPa or more, and particularly preferably 2000 MPa or more. Thus, the use of a combination of a homopolypropylene with a high tensile modulus and an ethylene / α-olefin copolymer is preferred to obtain a laminate with good tear resistance, impact resistance (particularly cold impact resistance, which is impact resistance at low temperatures), and rigidity. The tensile modulus of the homopolypropylene is a value measured in accordance with JIS K7161-1:2014.

[0022] When the first polyolefin resin contains high-density polyethylene, the density of the high-density polyethylene is, for example, 0.940 g / cm 3 More than 0.980g / cm 3 Below, 0.945g / cm 3 More than 0.975g / cm 3 or less, or 0.950 g / cm 3 More than 0.970g / cm 3 It may be the following:

[0023] When the first polyolefin resin contains high-density polyethylene, the MFR of the high-density polyethylene may be, for example, 0.1 g / 10 min to 2.0 g / 10 min, 0.1 g / 10 min to 1.0 g / 10 min, 0.1 g / 10 min to 0.5 g / 10 min, or 0.2 g / 10 min to 0.4 g / 10 min. The MFR of the high-density polyethylene is a value measured under conditions of a temperature of 190°C and a load of 2.16 kg.

[0024] When the first polyolefin resin contains a combination of homopolypropylene and high-density polyethylene, the mass ratio of the homopolypropylene and high-density polyethylene contained in the first polyolefin resin (homopolypropylene:high-density polyethylene) may be adjusted, for example, within the range of 50:50 to less than 100:more than 0, but is not particularly limited.

[0025] When the first polyolefin resin contains a combination of homopolypropylene and ethylene / α-olefin copolymer, the mass ratio of homopolypropylene to ethylene / α-olefin copolymer contained in the first polyolefin resin (homopolypropylene:ethylene / α-olefin copolymer) is preferably 99.5:0.5 to 50:50, more preferably 99:1 to 60:40, and even more preferably 95:5 to 70:30.

[0026] The one or more polyolefin resins that are the first polyolefin resin may be petroleum-derived or biomass-derived, or may be a combination of petroleum-derived and biomass-derived. The inclusion of a biomass-derived polyolefin resin in the first polyolefin resin can contribute to reducing the amount of petroleum-derived raw materials in the laminate.

[0027] The first resin composition may contain components other than the first polyolefin-based resin. The other components may be contained in the first resin composition to the extent that the effects of the present invention are not impaired. The other components may be, for example, an inorganic filler. That is, the first resin composition may further contain an inorganic filler. This can reduce the proportion of petroleum-derived raw materials contained in the laminate. Furthermore, the first resin composition may not contain components other than the first polyolefin-based resin. That is, the first resin composition may consist of the first polyolefin-based resin.

[0028] 1-1-2. Second outer layer

[0029] The second outer layer is made of a second resin composition containing a second polyolefin resin. The second polyolefin resin is made of one or a combination of two or more polyolefin resins. Examples of the polyolefin resin are described above in "1-1-1. First outer layer." In other words, the explanation regarding the first polyolefin resin also applies to the second polyolefin resin.

[0030] The second polyolefin resin contained in the second resin composition is preferably one or a combination of two or more poly-α-olefin resins, more preferably one or a combination of two or more selected from polypropylene resins and polyethylene resins. The second polyolefin resin more preferably contains at least one selected from the group consisting of homopolypropylene, high-density polyethylene, and ethylene / α-olefin copolymer. The second polyolefin resin particularly preferably contains homopolypropylene, a combination of homopolypropylene and high-density polyethylene, or a combination of homopolypropylene and ethylene / α-olefin copolymer. The combination of homopolypropylene and ethylene / α-olefin copolymer is particularly preferably a combination of homopolypropylene and metallocene-based ethylene / α-olefin copolymer. The inclusion of such a second polyolefin resin can improve the extensibility of the laminate during molding.

[0031] Examples of the properties and mass ratios of the homopolypropylene and high-density polyethylene in the second polyolefin resin may be as described above in "1-1-1. First outer layer." The ethylene / α-olefin copolymer in the second polyolefin resin may also be as described above in "1-1-1. First outer layer."

[0032] The one or more polyolefin resins that are the second polyolefin resin may be petroleum-derived or biomass-derived, or may be a combination of petroleum-derived and biomass-derived. The inclusion of a biomass-derived polyolefin resin in the second polyolefin resin can contribute to reducing the amount of petroleum-derived raw materials in the laminate.

[0033] The second resin composition may contain components other than the second polyolefin-based resin. The other components may be contained in the second resin composition to the extent that the effects of the present invention are not impaired. The other components may be, for example, an inorganic filler. That is, the second resin composition may further contain an inorganic filler. This can reduce the proportion of petroleum-derived raw materials contained in the laminate. Furthermore, the second resin composition may not contain any components other than the second polyolefin-based resin. That is, the second resin composition may consist of the second polyolefin-based resin.

[0034] The one or more resins contained in the second polyolefin resin may be entirely the same as or partly or entirely different from the one or more resins contained in the first polyolefin resin. That is, the second polyolefin resin may be the same as or different from the first polyolefin resin. Furthermore, the composition of the second resin composition containing the second polyolefin resin may be the same as or different from the composition of the first resin composition containing the first polyolefin resin. That is, the composition of the second outer layer may be the same as or different from the composition of the first resin composition.

[0035] In the laminate of this embodiment, the first polyolefin resin and the second polyolefin resin are preferably the same, the first resin composition and the second resin composition are preferably the same, and the first outer layer and the second outer layer are preferably the same in composition. Using a common raw material for the first and second outer layers in this way can contribute to simplifying the manufacturing process of the laminate or reducing manufacturing costs.

[0036] 1-1-3. Middle class

[0037] The intermediate layer is made of a third composition containing an inorganic filler, an ethylene / α-olefin copolymer, and a third polyolefin resin other than the ethylene / α-olefin copolymer, with the inorganic filler content exceeding 50% by mass.

[0038] Examples of the inorganic filler include talc, calcium carbonate, magnesium carbonate, calcium oxide, magnesium oxide, calcium hydroxide, magnesium hydroxide, aluminum hydroxide, calcium silicate, magnesium silicate, calcium sulfate, barium sulfate, calcium sulfite, titanium dioxide, silicon dioxide, glass, clay, and diatomaceous earth. The inorganic filler contained in the third composition may be, for example, one or a combination of two or more of these inorganic fillers, and is preferably talc and / or calcium carbonate, and more preferably talc.

[0039] The content of the inorganic filler in the third composition is greater than 50% by mass, preferably greater than 51% by mass, and more preferably greater than 55% by mass. Such a high content of inorganic filler can improve the rigidity of the laminate and reduce the proportion of petroleum-derived raw materials contained in the laminate. The content of the inorganic filler is preferably 80% by mass or less, more preferably 75% by mass or less, and even more preferably 70% by mass or less. By setting the content at this upper limit, the extensibility of the laminate during molding processing can be improved. A preferred range of the content of the inorganic filler may be a combination selected from the above-mentioned lower and upper limits, and is preferably greater than 50% by mass but less than 80% by mass, more preferably 51% by mass or more but less than 80% by mass, even more preferably 55% by mass or more but less than 80% by mass, particularly preferably 55% by mass or more but less than 75% by mass, or 55% by mass or more but less than 70% by mass.

[0040] The ethylene / α-olefin copolymer contained in the third composition is a copolymer of ethylene and an α-olefin. The ethylene / α-olefin copolymer contained in the third composition is preferably a metallocene-based ethylene / α-olefin copolymer. The metallocene-based ethylene / α-olefin copolymer is a copolymer produced by polymerizing ethylene and an α-olefin in the presence of a metallocene catalyst. The metallocene-based ethylene / α-olefin copolymer is preferably a metallocene-based plastomer. In this specification, the metallocene-based plastomer is a metallocene-based ethylene / α-olefin copolymer having a density lower than that of a very low density polyethylene resin (VLDPE). The density of the metallocene-based plastomer is, for example, 0.920 g / cm 3 When a commercially available product is used as the metallocene plastomer, the product may be selected from, for example, "Yumerit" manufactured by Ube Maruzen Polyethylene Co., Ltd., "Evolue" manufactured by Prime Polymer Co., Ltd., "Kernel" and "Harmolex" manufactured by Japan Polyethylene Corporation, and the like.

[0041] The density of the ethylene / α-olefin copolymer is preferably 0.870 g / cm 3 More preferably, 0.880 g / cm 3 or more, and even more preferably 0.890 g / cm 3 More preferably, 0.900 g / cm 3 The density is preferably 0.920 g / cm or more. 3 or less, more preferably 0.915 g / cm 3 or less, and even more preferably 0.910 g / cm 3 A preferred numerical range of the density may be a combination selected from the above-mentioned lower limit and upper limit, and is preferably 0.870 g / cm 3 More than 0.920g / cm 3 or less, more preferably 0.880 g / cm 3 More than 0.915g / cm 3 or less, and even more preferably 0.890 g / cm 3 More than 0.915g / cm 3Below 0.890 g / cm, particularly preferably 3 More than 0.910g / cm 3 or less, or 0.900 g / cm 3 More than 0.910g / cm 3 The density is preferably within this range in order to obtain a laminate having good tear resistance, impact resistance (particularly cold impact resistance, which is impact resistance at low temperatures), and rigidity. The density of the ethylene / α-olefin copolymer is a value measured in accordance with JIS K7112:1999.

[0042] The MFR of the ethylene / α-olefin copolymer is preferably 1.0 g / 10 min or more, more preferably 1.5 g / 10 min or more, even more preferably 1.8 g / 10 min or more, particularly preferably 2.0 g / 10 min or more, or 2.1 g / 10 min or more. The MFR is preferably 3.5 g / 10 min or less, more preferably 3.0 g / 10 min or less, even more preferably 2.5 g / 10 min or less, particularly preferably 2.3 g / 10 min or less. The preferred range of MFR may be a combination selected from the above-mentioned lower and upper limits, and is preferably 1.0 g / 10 min to 3.5 g / 10 min, more preferably 1.5 g / 10 min to 3.5 g / 10 min, even more preferably 1.8 g / 10 min to 3.5 g / 10 min, particularly preferably 2.0 g / 10 min to 3.5 g / 10 min, 2.1 g / 10 min to 3.5 g / 10 min, 2.1 g / 10 min to 3.0 g / 10 min, 2.1 g / 10 min to 2.5 g / 10 min, or 2.1 g / 10 min to 2.3 g / 10 min. The MFR within such a range is preferred to obtain a laminate having good tear resistance, impact resistance (particularly cold impact resistance), and rigidity. The MFR of the ethylene / α-olefin copolymer is a value measured in accordance with JIS K6922-2:2018 under conditions of a temperature of 190°C and a load of 2.16 kg.

[0043] The third composition contains a third polyolefin resin other than the ethylene / α-olefin copolymer (hereinafter, also simply referred to as "third polyolefin resin"). Examples of the polyolefin resin may be as described above in "1-1-1. First outer layer."

[0044] The third polyolefin resin contained in the third composition is preferably one or a combination of two or more poly-α-olefin resins, more preferably one or a combination of two or more polypropylene resins. The third polyolefin resin particularly preferably contains block polypropylene. When the third polyolefin resin contains block polypropylene, the third polyolefin resin may further contain homopolypropylene. That is, the third polyolefin resin preferably contains a combination of block polypropylene and homopolypropylene.

[0045] When the third polyolefin resin contains a block polypropylene, the density of the block polypropylene is preferably 0.880 g / cm 3 More preferably, 0.885 g / cm 3 or more, and even more preferably 0.890 g / cm 3 More preferably, 0.892 g / cm 3 or more, or 0.895 g / cm 3 The density is preferably 0.920 g / cm or more. 3 or less, more preferably 0.915 g / cm 3 or less, and even more preferably 0.913 g / cm 3 Below 0.910 g / cm, particularly preferably 3 A preferred numerical range of the density may be a combination selected from the above-mentioned lower limit and upper limit, and is preferably 0.880 g / cm 3 More than 0.920g / cm 3 or less, more preferably 0.885 g / cm 3 More than 0.915g / cm 3or less, and even more preferably 0.890 g / cm 3 More than 0.915g / cm 3 Below 0.892 g / cm, particularly preferably 3 More than 0.913g / cm 3 or less, or 0.895 g / cm 3 More than 0.910g / cm 3 The following is the result.

[0046] When the third polyolefin resin contains a block polypropylene, the MFR of the block polypropylene is preferably 0.1 g / 10 min or more, more preferably 0.2 g / 10 min or more, even more preferably 0.3 g / 10 min or more, and preferably 2.0 g / 10 min or less, more preferably 1.5 g / 10 min or less, even more preferably 1.0 g / 10 min or less, particularly preferably 0.8 g / 10 min or less, 0.6 g / 10 min or less, or 0.5 g / 10 min or less. The preferred range of the MFR may be a combination selected from the above-mentioned lower and upper limits, and is preferably 0.1 g / 10 min or more and 2.0 g / 10 min or less, more preferably 0.1 g / 10 min or more and 1.5 g / 10 min or less, even more preferably 0.1 g / 10 min or more and 1.0 g / 10 min or less, and particularly preferably 0.1 g / 10 min or more and 0.8 g / 10 min or less, 0.2 g / 10 min or more and 0.6 g / 10 min or less, or 0.3 g / 10 min or more and 0.5 g / 10 min or less. The MFR of the block polypropylene is a value measured under conditions of a temperature of 230°C and a load of 2.16 kg.

[0047] When the third polyolefin resin contains a combination of block polypropylene and homopolypropylene, the homopolypropylene preferably has a high tensile modulus of elasticity, preferably 1700 MPa or more, more preferably 1800 MPa or more, even more preferably 1900 MPa or more, and particularly preferably 2000 MPa or more. In this way, by combining the block polypropylene with the homopolypropylene having a high tensile modulus of elasticity, the rigidity of the laminate can be improved.

[0048] The third composition may contain components other than the inorganic filler, the ethylene / α-olefin copolymer, and the third polyolefin resin. Examples of such components include resins other than the ethylene / α-olefin copolymer and the third polyolefin resin, and additives. The third composition preferably does not contain components other than the inorganic filler, the ethylene / α-olefin copolymer, and the third polyolefin resin, i.e., preferably consists of the inorganic filler, the ethylene / α-olefin copolymer, and the third polyolefin resin.

[0049] The total content of the ethylene / α-olefin copolymer and the third polyolefin resin in the third composition is less than 50% by mass, preferably 49% by mass or less, and more preferably 45% by mass or less. The total content of the ethylene / α-olefin copolymer and the third polyolefin resin is preferably 20% by mass or more, more preferably 25% by mass or more, and even more preferably 30% by mass or more. A preferred range for this total content may be a combination selected from the above-mentioned lower and upper limits, and is preferably 20% by mass or more and less than 50% by mass, more preferably 20% by mass or more and 49% by mass or less, even more preferably 20% by mass or more and 45% by mass or less, and particularly preferably 25% by mass or more and 45% by mass or less, or 30% by mass or more and 45% by mass or less.

[0050] The content of the ethylene / α-olefin copolymer in the third composition is preferably 1% by mass or more, more preferably 2% by mass or more, even more preferably 3% by mass or more, and particularly preferably 4% by mass or more. At such a lower limit, the tear resistance and impact resistance (particularly cold impact resistance) of the laminate can be improved. The content of the ethylene / α-olefin copolymer in the third composition is preferably 30% by mass or less, more preferably 20% by mass or less, even more preferably 15% by mass or less, and particularly preferably 11% by mass or less. At such an upper limit, a decrease in the rigidity of the laminate can be prevented. A preferred numerical range for the content of the ethylene / α-olefin copolymer may be a combination selected from the above-mentioned lower and upper limits, and is preferably 1% by mass or more and 30% by mass or less, more preferably 1% by mass or more and 20% by mass or less, even more preferably 1% by mass or more and 15% by mass or less, particularly preferably 2% by mass or more and 15% by mass or less, 3% by mass or more and 15% by mass or less, or 4% by mass or more and 11% by mass or less. When the content of the ethylene / α-olefin copolymer is within the above range, a laminate having a better balance of tear resistance, impact resistance (particularly cold impact resistance), and rigidity can be obtained.

[0051] Generally, a layer with a high inorganic filler content tends to have lower impact resistance, tear resistance, and extensibility during molding. Specifically, the impact resistance and tear resistance of a layer with a high inorganic filler content may be lower than that of a layer without an inorganic filler. Furthermore, the extensibility of a layer with a high inorganic filler content during molding may be lower than that of a layer without an inorganic filler, which may result in holes being formed in the layer or uneven layer thickness during molding. On the other hand, the laminate of this embodiment has good impact resistance, tear resistance, and extensibility during molding, despite having an intermediate layer with a high inorganic filler content of more than 50% by mass. Specifically, the laminate of this embodiment has good impact resistance because the intermediate layer contains an ethylene / α-olefin copolymer and a third polyolefin resin. Furthermore, the laminate of this embodiment has first and second outer layers on the outside of the intermediate layer, thereby having good tear resistance and good extensibility during molding.

[0052] In the laminate of this embodiment, the third composition having a high inorganic filler content improves the rigidity of the laminate and can also contribute to reducing the amount of petroleum-derived raw materials in the laminate. Therefore, the present invention can also provide the composition containing more than 50 mass% of an inorganic filler (e.g., talc). That is, the present invention can also provide a composition comprising an inorganic filler (e.g., talc), an ethylene / α-olefin copolymer, and a polyolefin resin other than the ethylene / α-olefin copolymer, and having a content of the inorganic filler (e.g., talc) of more than 50 mass%. The composition according to one embodiment of the present invention may be particularly a laminate material, i.e., a laminate composition. Furthermore, the laminate may be used for a container, as described below. Therefore, the composition may be particularly a container material, i.e., a container composition. Details of the container are as described below in "2. Container," and the composition can be used to form the container described below in "2. Container."

[0053] 1-1-4. Other layers

[0054] The laminate of this embodiment only needs to have a first outer layer, a second outer layer, and an intermediate layer provided between the first outer layer and the second outer layer, and may also have one or more other layers. The one or more other layers may be located outside or inside the first outer layer and / or the second outer layer. Alternatively, the laminate may not include the other layers. That is, the laminate may be composed of a first outer layer, a second outer layer, and an intermediate layer provided between the first outer layer and the second outer layer.

[0055] 1-2. Shape of laminate

[0056] The laminate according to this embodiment is preferably in the form of a sheet or a film. That is, the laminate is preferably a sheet or a film. The thickness of the sheet may be, for example, 0.2 mm to 2.5 mm, 0.3 mm to 2.2 mm, or 0.5 mm to 2.0 mm. The thickness of the film may be, for example, 10 μm to 200 μm.

[0057] As will be described later, the present invention also provides a container formed using the laminate. That is, the shape of the laminate may be the shape of a container.

[0058] 1-3. Uses of laminates

[0059] The laminate of this embodiment has good tear resistance, impact resistance (particularly cold impact resistance), and rigidity when formed into a container. Therefore, the laminate may be used to form a container, i.e., may be for use as a container. Details of the container are as described below in "2. Container," and the laminate of this embodiment can be used to form the container described below in "2. Container."

[0060] 1-4. Manufacturing method of laminate

[0061] The laminate of this embodiment is produced using the first resin composition, the second resin composition, and the third composition. That is, the present invention also provides a method for producing a laminate, which includes using a first resin composition containing a first polyolefin resin, a second resin composition containing a second polyolefin resin, and a third composition containing an inorganic filler (e.g., talc), an ethylene / α-olefin copolymer, and a third polyolefin resin other than the ethylene / α-olefin copolymer, wherein the inorganic filler (e.g., talc) content exceeds 50 mass %, to obtain a laminate having a first outer layer made of the first resin composition, a second outer layer made of the second resin composition, and an intermediate layer provided between the first outer layer and the second outer layer and made of the third composition.

[0062] The laminate may be obtained by a manufacturing method known in the art. Examples of such manufacturing methods include coextrusion and lamination (e.g., thermal lamination and dry lamination). When using the coextrusion method, for example, the first resin composition, the second resin composition, and the third composition are each placed in an independent extruder and heated and melted, and then these melts are laminated and extruded through a multi-layer die to obtain a laminate. When using the lamination method, for example, a first outer layer made of the first resin composition, an intermediate layer made of the third composition, and a second outer layer made of the second resin composition are bonded together by heat or an adhesive to obtain a laminate. By using the coextrusion method, molding and lamination can be performed simultaneously, and the manufacturing process can be simplified compared to the lamination method. Therefore, the laminate of this embodiment may be manufactured by, for example, the coextrusion method.

[0063] 2. Container

[0064] The laminate has good tear resistance, impact resistance (particularly cold impact resistance), and rigidity in the shape of a container. Therefore, the present invention also provides a container formed using the laminate. A container according to one embodiment of the present invention has good tear resistance, impact resistance (particularly cold impact resistance), and rigidity, similar to the laminate. The laminate used in the container of this embodiment is as explained above in "1. Laminate," and this explanation also applies to this embodiment. The shape, use, and manufacturing method of the container will be explained in order below.

[0065] 2-1. Container shape

[0066] The container of this embodiment may include, for example, a bottom surface, a side surface extending upward from the periphery of the bottom surface, and an opening surrounded by the upper end of the side surface. The container may further include, for example, a flange portion formed by extending outward from the opening.

[0067] In the container, the shape of the bottom and the opening may be, for example, circular, elliptical, polygonal, or approximately polygonal, but is not particularly limited. The shapes of the bottom and the opening may be the same or different. The side surface may be perpendicular to the bottom, or may be tapered or inverted tapered. The shape of the container having the bottom, side surface, and opening may be, for example, a cylindrical shape with a bottom or an inverted truncated cone with a bottom, but is not particularly limited.

[0068] The container of this embodiment may be, for example, a container formed by drawing using the laminate. The drawing may be, for example, deep drawing. That is, the container of this embodiment may be a deep drawn container. In this specification, a deep drawn container means a container having an expansion ratio of 2.5 or more. In this specification, the expansion ratio of a container is the ratio of the total area of the side and bottom surfaces to the area of the opening, and is a value calculated by the following formula. The larger the expansion ratio, the more deeply the container is drawn. Container expansion ratio = (side area + bottom area) / opening area

[0069] The expansion ratio of the container may be, for example, 2.0 or more, 2.5 or more, 3.0 or more, 4.0 or more, or 5.0 or more. The laminate used for the container has good extensibility when formed into the container shape, so a container with such an expansion ratio can be obtained. The expansion ratio is preferably 7.0 or less, more preferably 6.0 or less. By setting the expansion ratio at this upper limit, it is possible to prevent the thickness of the side portion of the container from becoming excessively thin so as to be unsuitable for practical use.

[0070] 2-2. Use of container

[0071] As shown in the examples below, the container of this embodiment has good impact resistance at low temperatures (specifically, impact resistance at -20°C). Therefore, the container is suitable for storing the contents in a refrigerator or freezer. That is, the container may be, for example, for refrigerator storage or freezer storage, and preferably for freezer storage.

[0072] Furthermore, in the container of this embodiment, since the intermediate layer containing the inorganic filler is present between the first outer layer and the second outer layer, if the first and second outer layers do not contain an inorganic filler, contact between the inorganic filler in the intermediate layer and the contents of the container can be prevented. Therefore, the container may contain contents that require consideration from a hygienic standpoint, such as food. That is, the container may be, for example, for food. Furthermore, since the container has good impact resistance at low temperatures, the container may be, for example, for refrigerated or frozen foods, preferably for frozen foods.

[0073] 2-3. Container manufacturing method

[0074] The container of this embodiment can be produced by a production method including a step of molding the laminate described above in "1. Laminate" using a solid-state molding machine. That is, the present invention also provides a container production method including a step of molding, using a solid-state molding machine, a laminate having a first outer layer, a second outer layer, and an intermediate layer provided between the first and second outer layers, wherein the first outer layer is made of a first resin composition containing a first polyolefin resin, the second outer layer is made of a second resin composition containing a second polyolefin resin, and the intermediate layer is made of a third composition containing an inorganic filler (e.g., talc), an ethylene / α-olefin copolymer, and a third polyolefin resin other than the ethylene / α-olefin copolymer, the inorganic filler (e.g., talc) content being greater than 50 mass%.

[0075] In this specification, a solid-state molding machine refers to a machine that produces molded products by a solid-state molding method, in which a laminate is heated and molded into a laminate in a non-molten (solid or semi-solid) state. Specifically, the non-molten laminate is a laminate that has been heated at a temperature lower than the melting point of the resin with the highest melting point contained in the laminate and higher than the crystallization temperature of the resin with the lowest crystallization temperature contained in the laminate. That is, the method for manufacturing a container according to this embodiment may include the steps of heating the laminate at a temperature lower than the melting point of the resin with the highest melting point contained in the laminate and higher than the crystallization temperature of the resin with the lowest crystallization temperature contained in the laminate, and molding the heated laminate.

[0076] Compared with melt molding, which molds a molten laminate, the solid-state molding method produces a lower laminate temperature during molding, and requires less heat when heating the laminate. Furthermore, since the heat required to heat an inorganic filler is generally the same as that required to raise the temperature to the same temperature as the resin, the heat required to heat a laminate containing an inorganic filler in the solid-state molding method is less than that required to heat a laminate without an inorganic filler. Therefore, the use of the solid-state molding method reduces the amount of electricity required in the manufacturing process, thereby enabling energy savings.

[0077] In the container manufacturing method according to this embodiment, the solid-state molding method is preferably solid-state pressure molding. That is, the container manufacturing method preferably includes a step of molding the laminate using a solid-state pressure molding machine. In this specification, a solid-state pressure molding machine refers to a machine that produces a molded product using solid-state pressure molding, in which a laminate is heated, the laminate in a non-molten (solid or semi-solid) state is pressurized with compressed air, and the laminate is tightly attached to a mold for molding. The heating temperature of the laminate to obtain a non-molten laminate in the solid-state pressure molding method is the same as that of the solid-state molding method described above. Like the solid-state molding method described above, the solid-state pressure molding method enables energy savings in the manufacturing process. Because a solid-state pressure molding machine is capable of applying high pressure to the laminate, it is suitable for manufacturing deep-draw containers, which require deep stretching of the laminate. That is, the container manufacturing method according to this embodiment may preferably be a deep-draw container manufacturing method that includes molding the laminate using a solid-state pressure molding machine.

[0078] In the method for manufacturing a container according to this embodiment, the power consumption of the solid-state molding machine (particularly, a solid-state pressure molding machine) is less than the power consumption when the content of the inorganic filler (e.g., talc) in the third composition is 0% by mass. Specifically, in the solid-state molding machine (particularly, a solid-state pressure molding machine), the power consumption per unit volume of the laminate during molding of the container can be 90% or less of the power consumption when the content of the inorganic filler (e.g., talc) in the third composition is 0% by mass. The power consumption per unit volume of the laminate during molding of the container [kW·h / cm 3 ] is calculated by multiplying the power [kW] measured by connecting a wattmeter to the wiring of the main breaker of the solid-state molding machine (especially the compressed air solid-state molding machine) by the time [h] required to mold 10,000 containers, and then expressing this as the power consumption [kW h] in terms of the volume [cm ] of the laminate per shot. 3 The value is calculated by dividing the volume of the laminate per shot [cm 3 ] is a value calculated by the thickness [cm] x width [cm] x feed [cm] of the laminate fed to a solid-state molding machine (particularly a solid-state pressure molding machine) to mold 10,000 containers. [Example]

[0079] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to these examples.

[0080] (1) Test Example 1: Evaluation of Containers

[0081] (1-1) Manufacturing of laminated sheets and containers

[0082] A laminated sheet (laminate) and a container were produced using the following raw materials and according to the following production procedure.

[0083] a. Raw materials [talc] Nippon Talc Co., Ltd. Average particle size: 15 μm [Homopolypropylene (A) (H-PP(A))] MFR (Temperature 230°C, Load 2.16 kg): 0.5 g / 10 min Density: 0.9g / cm 3 Tensile modulus: 1600 MPa [Homopolypropylene (B) (H-PP(B))] MFR (temperature 230°C, load 2.16 kg): 1.6 g / 10 min Density: 0.9g / cm 3 Tensile modulus: 2000 MPa [Block polypropylene (B-PP)] MFR (temperature 230°C, load 2.16 kg): 0.4 g / 10 min Density: 0.9g / cm 3 [High density polyethylene (HDPE)] MFR (temperature 190℃, load 2.16kg): 0.3g / 10 minutes Density: 0.96g / cm 3 [Metallocene-based ethylene / α-olefin copolymer (metallocene-based plastomer)] MFR (temperature 190℃, load 2.16kg): 2.2g / 10 minutes Density: 0.9g / cm 3

[0084] b. Manufacturing procedure Example 1 A compound masterbatch was prepared by kneading 71.2% by mass of talc and 28.8% by mass of block polypropylene using a twin-screw extruder. 100 parts by mass of this compound was blended with 9.4 parts by mass of block polypropylene and 10.8 parts by mass of a metallocene-based ethylene / α-olefin copolymer, and the blend was kneaded using a twin-screw extruder. This resulted in a third composition containing 55.9% by mass of talc, 33.3% by mass of block polypropylene, and 10.8% by mass of a metallocene-based ethylene / α-olefin copolymer. A first resin composition and a second resin composition, each consisting of 100% by mass of homopolypropylene (A), were prepared using a single-screw extruder. The first resin composition, the second resin composition, and the third composition were kneaded and extruded. This resulted in a three-layer laminate sheet having, in that order, a first outer layer made of the first resin composition, an intermediate layer made of the third composition, and a second outer layer made of the second resin composition. During the kneading and extrusion process, the extrusion conditions were set so that the thickness of the first outer layer was 15 μm, the thickness of the intermediate layer was 770 μm, and the thickness of the second outer layer was 15 μm. The thickness of the resulting laminate sheet was 0.80 mm. The laminate sheet was molded by solid-state pressure molding using a solid-state pressure molding machine to obtain a container in the shape of an inverted truncated cone with a bottom. The diameter (caliber) of the opening of the container was 96 mm, the depth was 41 mm, and the expansion ratio was 2.1.

[0085] Example 2 100 parts by mass of the compound of Example 1 was blended with 13.7 parts by mass of block polypropylene and 6.5 parts by mass of metallocene-based ethylene / α-olefin copolymer and kneaded using a twin-screw extruder. This produced a third composition containing 55.9% by mass of talc, 37.6% by mass of block polypropylene, and 6.5% by mass of metallocene-based ethylene / α-olefin copolymer. A single-screw extruder was used to produce a first resin composition and a second resin composition, each consisting of 50% by mass of homopolypropylene (A) and 50% by mass of high-density polyethylene. A laminate sheet and a container were then obtained using the same procedure as in Example 1. The thickness of each layer of the laminate sheet, the sheet thickness, and the shape of the container were the same as in Example 1.

[0086] Example 3 100 parts by mass of the compound of Example 1 was blended with 14.8 parts by mass of block polypropylene and 4.3 parts by mass of metallocene-based ethylene / α-olefin copolymer and kneaded using a twin-screw extruder. This resulted in a third composition containing 55.9% by mass of talc, 39.8% by mass of block polypropylene, and 4.3% by mass of metallocene-based ethylene / α-olefin copolymer. A laminate sheet was then obtained using the same procedure as in Example 1. However, during the kneading / extrusion process, the extrusion conditions were set so that the first outer layer had a thickness of 30 μm, the intermediate layer had a thickness of 740 μm, and the second outer layer had a thickness of 30 μm. The thickness of the resulting laminate sheet was 0.80 mm. The laminate sheet was molded in the same manner as in Example 1 to obtain a container. The shape of the container was the same as in Example 1.

[0087] Example 4 A third composition was prepared using the same procedure as in Example 1. A first resin composition and a second resin composition each consisting of 50% by mass of homopolypropylene (A) and 50% by mass of high-density polyethylene were prepared using a single-screw extruder. A laminate sheet and a container were then obtained using the same procedure as in Example 1. The thickness of each layer of the laminate sheet, the sheet thickness, and the shape of the container were the same as in Example 1.

[0088] Example 5 A laminate sheet was obtained using the same procedure as in Example 4. However, during the kneading extrusion process, the extrusion conditions were set so that the thickness of the first outer layer was 30 μm, the thickness of the intermediate layer was 740 μm, and the thickness of the second outer layer was 30 μm. The thickness of the obtained laminate sheet was 0.80 mm. The laminate sheet was molded in the same manner as in Example 1 to obtain a container. The shape of the container was the same as in Example 1.

[0089] Example 6 A third composition was prepared using the same procedure as in Example 3. A first resin composition and a second resin composition, each consisting of 80% by mass of homopolypropylene (B) and 20% by mass of a metallocene-based ethylene / α-olefin copolymer, were prepared using a single-screw extruder. The first resin composition, the second resin composition, and the third composition were kneaded and extruded. Thereafter, a laminate sheet and a container were obtained using the same procedure as in Example 1. The thickness of each layer of the laminate sheet, the sheet thickness, and the shape of the container were the same as in Example 3.

[0090] Example 7 100 parts by mass of the compound of Example 1 was blended with 14.8 parts by mass of homopolypropylene (B) and 4.3 parts by mass of a metallocene-based ethylene / α-olefin copolymer, and kneaded using a twin-screw extruder. This produced a third composition containing 55.9% by mass of talc, 14.8% by mass of homopolypropylene (B), 25.0% by mass of block polypropylene, and 4.3% by mass of a metallocene-based ethylene / α-olefin copolymer. A laminate sheet and a container were then obtained using the same procedures as in Example 6. The thickness of each layer of the laminate sheet, the sheet thickness, and the shape of the container were the same as in Example 6.

[0091] (Comparative Example 1) A compound masterbatch was prepared by kneading 61.3% by mass of talc, 19.3% by mass of homopolypropylene (A), and 19.4% by mass of high-density polyethylene using a twin-screw extruder. 7.0 parts by mass of high-density polyethylene was blended with 100 parts by mass of the compound and kneaded using a twin-screw extruder. This produced a third composition containing 57.0% by mass of talc, 17.2% by mass of homopolypropylene (A), and 25.8% by mass of high-density polyethylene. A first resin composition and a second resin composition, each consisting of 40% by mass of homopolypropylene (A) and 60% by mass of high-density polyethylene, were prepared using a single-screw extruder. The first resin composition, the second resin composition, and the third composition were kneaded and extruded. This resulted in a three-layer laminate sheet having, in that order, a first outer layer made of the first resin composition, an intermediate layer made of the third composition, and a second outer layer made of the second resin composition. During the kneading and extrusion process, the extrusion conditions were set so that the thickness of the first outer layer was 35 μm, the thickness of the intermediate layer was 780 μm, and the thickness of the second outer layer was 35 μm. The thickness of the resulting laminate sheet was 0.85 mm. The laminate sheet was molded by solid-state pressure molding using a solid-state pressure molding machine to obtain a container in the shape of an inverted truncated cone with a bottom. The diameter (caliber) of the opening of the container was 88 mm, the depth was 55 mm, and the expansion ratio was 2.6.

[0092] (Comparative Example 2) A third composition was prepared by kneading 34.5% by mass of talc, 26.2% by mass of homopolypropylene (A), and 39.3% by mass of high-density polyethylene using a twin-screw extruder. A first resin composition and a second resin composition, each consisting of 40% by mass of homopolypropylene (A) and 60% by mass of high-density polyethylene, were prepared using a single-screw extruder. The first resin composition, the second resin composition, and the third composition were kneaded and extruded. This resulted in a three-layer laminate sheet having, in this order, a first outer layer made of the first resin composition, an intermediate layer made of the third composition, and a second outer layer made of the second resin composition. During the kneading and extrusion process, the extrusion conditions were set so that the thickness of the first outer layer was 30 μm, the thickness of the intermediate layer was 740 μm, and the thickness of the second outer layer was 30 μm. The sheet thickness of the resulting laminate sheet was 0.80 mm. The laminated sheet was molded by solid-state pressure molding using a solid-state pressure molding machine to obtain a container in the shape of an inverted truncated cone with a bottom. The opening diameter (caliber) of the container was 96 mm, the depth was 41 mm, and the expansion ratio was 2.1.

[0093] (Comparative Example 3) 100 parts by mass of the compound of Example 1 was blended with 20.2 parts by mass of high-density polyethylene and kneaded using a twin-screw extruder. This produced a third composition containing 55.9% by mass of talc, 23.9% by mass of block polypropylene, and 20.2% by mass of high-density polyethylene. A laminate sheet and a container were then obtained using the same procedures as in Example 1. The thickness of each layer of the laminate sheet, the sheet thickness, and the shape of the container were the same as in Example 1.

[0094] (1-2) Container evaluation

[0095] The containers of Examples 1 to 7 and Comparative Examples 1 to 3 were evaluated as follows.

[0096] a. Side surface damage during molding and mold reproducibility Containers that did not break on the side during container molding were evaluated as good (◯), those with low shape reproducibility were evaluated as poor (△), and containers with breakage on the side were evaluated as poor (×). In this specification, a container with poor shape reproducibility means a container that did not break on the side but did not reproduce the shape of the mold, or a container that did not break on the side and reproduced the shape of the mold but was partially thin and uneven in thickness, making it unsuitable for practical use. A laminated sheet used for a container with a good (◯) evaluation result can be said to have good extensibility during molding processing.

[0097] b.Tear resistance The tear resistance of the containers was measured according to the following procedure in accordance with JIS K6252-1:2015. First, the side of the container was cut with scissors and punched out with the blade of a punching die for angle-shaped test specimens to prepare angle-shaped unnotched test specimens. Both ends of the test specimen were clamped in the chucks of a universal testing machine ("Strograph VES5D" manufactured by Toyo Seiki Seisakusho Co., Ltd.) and pulled upward at a test speed of 50 mm / min. The maximum point strength, which is the force (unit: N / cm) required when the test specimen began to tear, was measured. A higher maximum point strength indicates better tear resistance and less tearing. Based on the measured maximum point strength, the tear resistance of the containers was evaluated as follows. (Maximum point strength): (Evaluation) 1000N / cm or more: Excellent tear resistance (A) 750N / cm or more but less than 1000N / cm: Good tear resistance (B) Less than 750N / cm: Poor tear resistance (C)

[0098] c. Cold shock resistance 50% breaking energy E below 50To estimate the tensile strength, a preliminary test was conducted using 10 containers (n = 10). The main test was then conducted using the procedure described below. A testing machine 20, as shown in Figures 1 and 2, was used in the preliminary and main tests. The testing machine 20 includes a weight 21 with a vertically slidable weight and a base 22 to which a pedestal 23 (see Figure 2) on which the container is placed is fixed. As shown in Figure 2, the container 10 to be tested was placed on the pedestal 23, which in turn was fixed on the base 22. In the main test, the containers (n = 20 or more) were first stored at -20°C for 24 hours or more. Then, as shown in Figure 2, the container 10 was placed horizontally on the pedestal 23 of the testing machine 20, and a weight 21 weighing 1.0 kg was dropped from above the horizontal container 10 (i.e., from above the side). If even a small crack or break occurred in the opening of the container, the container was deemed to have been destroyed. By the staircase method, 50% breaking energy E 50 The 50% fracture energy E (unit: J) was calculated. 50 The larger the value, the better the cold impact resistance. 50 Based on the values, the cold shock resistance of the container was evaluated as follows. (50% destruction energy E 50 ):(evaluation) 0.9J or more: Particularly good cold impact resistance (A) 0.6J or more but less than 0.9J: Good cold impact resistance (B) 0.3J or more but less than 0.6J: Poor cold impact resistance (C) Less than 0.3J: Particularly poor cold impact resistance (D)

[0099] d. Stiffness The container was placed with its bottom side facing up in a universal testing machine ("Strograph VES5D" manufactured by Toyo Seiki Seisakusho Co., Ltd.), and a load was applied from above at a test speed of 50 mm / min. The force (unit: kgf) required when the container began to collapse was measured. A larger measured value indicates better rigidity. Based on the measured value, the rigidity of the container was evaluated as follows: (Measurement): (Evaluation) 25kgf or more: Particularly good rigidity (A) 15kfg or more but less than 25kgf: Good rigidity (B) 5kgfg or more and less than 15kgf: Fairly good rigidity (C) Less than 5kgf: Poor rigidity (D)

[0100] The evaluation results are shown in the following Table 1. In the following Table 1, "%" means "% by mass."

[0101] [Table 1]

[0102] Comparing the results of Example 1 and Comparative Example 3 shown in Table 1 above, it can be seen that the inclusion of a metallocene-based ethylene / α-olefin copolymer in the intermediate layer improves tear resistance and cold impact resistance. Comparing the results of Examples 1 to 3, it can be seen that the impact resistance improves as the content of the metallocene-based ethylene / α-olefin copolymer increases, and the rigidity improves as the content of the metallocene-based ethylene / α-olefin copolymer decreases. These results demonstrate that adjusting the content of the metallocene-based ethylene / α-olefin copolymer makes it possible to obtain a laminate sheet (laminate) with a good balance of tear resistance, cold impact resistance, and rigidity. Furthermore, comparing the results of Examples 6 and 7, it can be seen that the inclusion of homopolypropylene (B) (tensile modulus: 2000 MPa) in the intermediate layer slightly reduces tear resistance and cold impact resistance, but improves rigidity. These results demonstrate that the homopolypropylene with a high tensile modulus contained in the intermediate layer contributes to improving the rigidity of the laminate sheet (laminate).

[0103] Example 8 A laminate sheet was obtained using the same procedure as in Example 5. However, during the kneading and extrusion process, the extrusion conditions were set so that the thickness of the first outer layer was 50 μm, the thickness of the intermediate layer was 1300 μm, and the thickness of the second outer layer was 50 μm. The sheet thickness of the obtained laminate sheet was 1.40 mm. The laminate sheet was molded by solid-state pressure molding using a solid-state pressure molding machine to obtain a container in the shape of an inverted truncated cone with a bottom. The diameter (caliber) of the opening of the container was 77 mm, the depth was 120 mm, and the expansion ratio was 5.4. The container was evaluated according to "a. Side surface damage during molding and mold reproducibility." The container did not experience side surface damage during molding and had sufficient mold reproducibility. These results demonstrate that the laminate sheet (laminate) of the present invention is suitable for manufacturing deep-draw containers.

[0104] (2) Test Example 2: Measurement of power consumption

[0105] (2-1) Manufacturing of laminated sheets and containers According to the following manufacturing procedures, laminate sheets (laminates) and containers of Comparative Examples 4 and 5 were manufactured. Details of the raw materials used were as described in "a. Raw materials" of Test Example 1 above.

[0106] Comparative Example 4 A third composition was prepared by kneading 60.0% by mass of homopolypropylene (A) and 40.0% by mass of high-density polyethylene using a twin-screw extruder. A first resin composition and a second resin composition, each consisting of 50% by mass of homopolypropylene (A) and 50% by mass of high-density polyethylene, were prepared using a single-screw extruder. The first resin composition, the second resin composition, and the third composition were kneaded and extruded. This resulted in a three-layer laminate sheet having, in this order, a first outer layer made of the first resin composition, an intermediate layer made of the third composition, and a second outer layer made of the second resin composition. During the kneading and extrusion process, the extrusion conditions were set so that the thickness of the first outer layer was 40 μm, the thickness of the intermediate layer was 1120 μm, and the thickness of the second outer layer was 40 μm. The sheet thickness of the resulting laminate sheet was 1.20 mm. The laminated sheet was molded by solid-state pressure molding using a solid-state pressure molding machine to obtain a container in the shape of an inverted truncated cone with a bottom. The diameter (caliber) of the opening of the container was 71 mm, the depth was 47 mm, and the expansion ratio was 2.3.

[0107] (Comparative Example 5) A laminate sheet was obtained using the same procedure as in Comparative Example 2. However, during the kneading extrusion process, the extrusion conditions were set so that the thickness of the first outer layer was 40 μm, the thickness of the intermediate layer was 1120 μm, and the thickness of the second outer layer was 40 μm. The thickness of the obtained laminate sheet was 1.20 mm. Thereafter, a container was obtained using the same procedure as in Comparative Example 4. The thickness of each layer of the laminate sheet, the sheet thickness, and the shape of the container were the same as in Comparative Example 4.

[0108] (2-2) Evaluation of the container

[0109] The containers of Comparative Examples 4 and 5 were evaluated according to the procedure described in "a. Side surface breakage during molding and mold reproducibility" in Test Example 1 above.

[0110] (2-3) Measuring power consumption For the containers of Comparative Examples 4 and 5 and the containers of Example 5 and Comparative Example 2 produced in Test Example 1, the power consumption per unit volume of the laminated sheet during container molding in a solid-state pressure molding machine was measured according to the procedure described below.

[0111] A power meter (manufactured by Hioki E.E. Corporation, product name: Clamp-on Power Logger, model number: PW3365-10) was connected (clamped) to the wiring of the main breaker of the solid-state pressure molding machine to measure the power [kW], which was then multiplied by the time [h] required to mold 10,000 containers to convert it into the amount of power [kW·h]. Furthermore, the volume [cm3] per shot of the laminated sheet fed to the solid-state pressure molding machine was calculated. 3 ] (sheet thickness [cm] × sheet width [cm] × sheet feed [cm]) was calculated. By dividing the above amount of power consumption by the volume of the laminated sheet per shot, the amount of power consumption per unit volume of the laminated sheet [kW·h / cm 3 ] was calculated.

[0112] The results of the above evaluations and measurements are shown in the following Table 2. In the following Table 2, "%" means "% by mass."

[0113] [Table 2]

[0114] When the talc content in the third composition was 0 mass% (Comparative Example 4), the power consumption was 0.565 kW·h / cm 3 In contrast, when the talc content in the third composition was 55.9% by mass (Example 5), the power consumption was 0.488 kW h / cm 3 When the power consumption of Comparative Example 4 was taken as 100%, the power consumption of Example 5 was 86.4% of the power consumption of Comparative Example 4 (0.488 kW·h / cm 3 ] / 0.565[kW·h / cm 3] × 100 ≒ 86.4) This result supports the idea that when the talc content in the third composition exceeds 50% by mass, the amount of power consumed can be reduced to 90% or less compared to when the talc content is 0% by mass.

Claims

1. a first outer layer, a second outer layer, and an intermediate layer provided between the first outer layer and the second outer layer; the first outer layer is made of a first resin composition containing a first polyolefin-based resin, the second outer layer is made of a second resin composition containing a second polyolefin-based resin, the first polyolefin-based resin and / or the second polyolefin-based resin comprises homopolypropylene, a combination of homopolypropylene and high-density polyethylene, or a combination of homopolypropylene and metallocene-based ethylene / α-olefin copolymer; the intermediate layer comprises talc, a metallocene-based ethylene / α-olefin copolymer, and a third polyolefin-based resin other than the metallocene-based ethylene / α-olefin copolymer (excluding high-density polyethylene); the third polyolefin resin includes block polypropylene or a combination of block polypropylene and homopolypropylene, The talc content is more than 50% by mass, a third composition having a content of the metallocene-based ethylene / α-olefin copolymer of 1% by mass or more and 11% by mass or less; Laminate.

2. The laminate according to claim 1 , wherein the first resin composition and / or the second resin composition further contains an inorganic filler.

3. the first polyolefin resin and / or the second polyolefin resin contains the homopolypropylene, The laminate according to claim 1 or 2, wherein the homopolypropylene has a tensile modulus of 1500 MPa or more.

4. the first polyolefin resin and / or the second polyolefin resin contains the homopolypropylene, The laminate according to claim 1 or 2, wherein the homopolypropylene has a tensile modulus of 1700 MPa or more.

5. the first polyolefin-based resin and / or the second polyolefin-based resin comprises a combination of the homopolypropylene and the metallocene-based ethylene / α-olefin copolymer; The laminate according to claim 1 or 2, wherein the homopolypropylene has a tensile modulus of 1700 MPa or more.

6. A container formed using the laminate according to any one of claims 1 to 5.

7. The container according to claim 6, wherein the deployment ratio of the container is 2.0 or more.

8. a first resin composition containing a first polyolefin-based resin; a second resin composition containing a second polyolefin-based resin; The present invention relates to a polyolefin resin composition comprising talc, a metallocene-based ethylene / α-olefin copolymer, and a third polyolefin resin other than the metallocene-based ethylene / α-olefin copolymer (excluding high-density polyethylene), The talc content is more than 50% by mass, a third composition having a content of the metallocene-based ethylene / α-olefin copolymer of 1% by mass or more and 11% by mass or less; Using a first outer layer made of the first resin composition; a second outer layer made of the second resin composition; and an intermediate layer formed between the first outer layer and the second outer layer and comprising the third composition; the first polyolefin-based resin and / or the second polyolefin-based resin comprises homopolypropylene, a combination of homopolypropylene and high-density polyethylene, or a combination of homopolypropylene and metallocene-based ethylene / α-olefin copolymer; The third polyolefin resin includes block polypropylene or a combination of block polypropylene and homopolypropylene. A method for manufacturing a laminate.

9. a first outer layer, a second outer layer, and an intermediate layer provided between the first outer layer and the second outer layer; the first outer layer is made of a first resin composition containing a first polyolefin-based resin, the second outer layer is made of a second resin composition containing a second polyolefin-based resin, the first polyolefin-based resin and / or the second polyolefin-based resin comprises homopolypropylene, a combination of homopolypropylene and high-density polyethylene, or a combination of homopolypropylene and metallocene-based ethylene / α-olefin copolymer; the intermediate layer comprises talc, a metallocene-based ethylene / α-olefin copolymer, and a third polyolefin-based resin other than the metallocene-based ethylene / α-olefin copolymer (excluding high-density polyethylene); the third polyolefin resin includes block polypropylene or a combination of block polypropylene and homopolypropylene, The talc content is more than 50% by mass, a third composition having a content of the metallocene-based ethylene / α-olefin copolymer of 1% by mass or more and 11% by mass or less; The laminate Molding the mixture by a solid-state molding machine. Container manufacturing method.

10. In the solid-phase molding machine, the amount of power consumed per unit volume of the laminate during molding of the container is: The method for manufacturing a container according to claim 9 , wherein the power consumption is 90% or less of the amount of power consumed when the content of the talc in the third composition is 0% by mass.

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