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WO2012102178A1 - Procédé et appareil de production d'un film de résine - Google Patents

Procédé et appareil de production d'un film de résine Download PDF

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Publication number
WO2012102178A1
WO2012102178A1 PCT/JP2012/051115 JP2012051115W WO2012102178A1 WO 2012102178 A1 WO2012102178 A1 WO 2012102178A1 JP 2012051115 W JP2012051115 W JP 2012051115W WO 2012102178 A1 WO2012102178 A1 WO 2012102178A1
Authority
WO
WIPO (PCT)
Prior art keywords
roll
resin film
film
cooling
resin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2012/051115
Other languages
English (en)
Japanese (ja)
Inventor
聡 白鳥
英俊 松本
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
AGC Inc
Original Assignee
Asahi Glass Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Asahi Glass Co Ltd filed Critical Asahi Glass Co Ltd
Priority to JP2012554756A priority Critical patent/JPWO2012102178A1/ja
Publication of WO2012102178A1 publication Critical patent/WO2012102178A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/222—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length characterised by the shape of the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B29C48/08—Flat, e.g. panels flexible, e.g. films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0063—Cutting longitudinally
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911—Cooling
    • B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
    • B29C48/914—Cooling drums
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent

Definitions

  • the present invention relates to a resin film manufacturing method and manufacturing apparatus, and in particular, eliminates slippage in the width direction due to shrinkage during cooling of the formed resin film, thereby suppressing optical distortion of the film and optical distortion.
  • the present invention relates to a resin film manufacturing method and a manufacturing apparatus in which the product yield is improved by reducing the variation of the resin.
  • Resin films used for optical applications are widely used for liquid crystal cells, retardation films, diffusion films, brightness enhancement films, etc. combined with optical disks and polarizing plates, for example.
  • the resin film used for these optical applications needs to make the optical distortion generated during the production as small as possible in order to exhibit predetermined optical characteristics.
  • a resin film is produced by setting the temperature of the first cooling roll (first cooling roll) to a predetermined temperature range with respect to the glass transition temperature or melting temperature of the resin.
  • a method is known (for example, refer to Patent Documents 1 and 2). These methods described in Patent Documents 1 and 2 are effective as a technique for reducing the optical distortion of a resin film having a smooth surface.
  • an optical resin film in addition to a resin film having a smooth surface, an optical resin film having a function of scattering light by forming an uneven shape on the surface of the resin film is required.
  • a resin film having a concavo-convex shape formed on the surface is obtained by extruding a molten transparent resin into a film shape from a die, a first cooling roll having a smooth outer peripheral surface, and a second rugged shape formed on the outer peripheral surface. It is obtained by being sandwiched between the cooling rolls, transferring the concavo-convex shape of the second cooling roll, winding it around the second cooling roll, and then taking it out with a take-up roll.
  • the present invention is intended to solve the above-described problems, and suppresses optical distortion of a resin film having an uneven surface formed on the surface, and reduces variation in optical distortion.
  • An object of the present invention is to provide a manufacturing method and a manufacturing apparatus.
  • the present inventors have reduced the optical distortion and reduced the optical distortion by suppressing the shrinkage of the resin film during cooling in the production of the resin film. Has been found to be able to be suppressed, and the present invention has been completed.
  • a molten thermoplastic resin (hereinafter also referred to as a molten resin) is extruded from a die into a film shape, and the extruded film-shaped molten resin is applied to the outer peripheral surface excluding both ends.
  • a molten resin molten thermoplastic resin
  • the apparatus for producing a resin film of the present invention includes an extrusion means having a die for extruding a molten thermoplastic resin into a film shape, a cooling roll having an uneven shape formed on the outer peripheral surface, and a predetermined interval between the cooling roll and the cooling roll.
  • the film-shaped molten resin extruded by the extruding unit is pressed between the cooling roll and the pressing unit to cool the thermoplastic resin while transferring the uneven shape to the surface.
  • the pressing means may be either mirror-finished or formed with a concavo-convex shape, and may be properly used according to the resin film to be produced.
  • a concavo-convex shape is applied to the outer peripheral surface so as to impart a desired concavo-convex shape to the surface of the thermoplastic resin extruded into a film shape by a pressing roll or a pressing belt.
  • the method and apparatus for producing a resin film of the present invention when the molten resin extruded into a film shape is cooled, it is produced by suppressing shrinkage in the width direction of the film-like molten resin on the cooling roll. As a result, the retardation of the resin film can be reduced. Moreover, according to the manufacturing method and manufacturing apparatus of the resin film of this invention, the dispersion
  • the quality (optical characteristics) of the obtained resin film becomes uniform, the product reliability is improved, and the region that can be used as a product in the obtained resin film is extremely wide, and the yield is very good.
  • the resin used in the present invention is a thermoplastic resin, and preferably an amorphous thermoplastic resin.
  • thermoplastic resin examples thereof include polysulfone, polystyrene, polycarbonate, polyvinyl chloride, cyclic polyolefin, polymethyl methacrylate (PMMA), and cellulose acetate resin.
  • PMMA polymethyl methacrylate
  • norbornene-based resins and polycarbonates that are cyclic polyolefins are preferably used because of excellent transparency, small intrinsic birefringence and photoelastic coefficient, and excellent heat resistance required in melt extrusion molding. It is done.
  • the resin is preferably a transparent resin.
  • the transparent means that the total light transmittance is 80% or more when both sheets have a smooth thickness of 100 ⁇ m. Means.
  • PMMA polymethyl methacrylate
  • aromatic polycarbonate resin aromatic polycarbonate resin
  • norbornene-based resin that is cyclic polyolefin resin can be preferably used.
  • thermoplastic resin An additive may be added to the thermoplastic resin as necessary.
  • Additives include UV absorbers, surfactants, impact agents, antistatic agents, antioxidants, lubricants, mold release agents, flame retardants, colorants such as dyes, pigments, etc., usually contained in resin films. Examples of known additives that can be used for this purpose are listed below.
  • a resin film manufacturing apparatus 1 as shown in FIG. 1 is used.
  • This apparatus includes an extruding means 2 comprising an extruder 2 for extruding a thermoplastic resin by heating and melting, and a die 3 for forming the molten thermoplastic resin into a film shape, and sandwiching and feeding the film-shaped thermoplastic resin from above and below.
  • a first cooling roll 4 that cools while rotating in the direction and transfers the shape of the outer peripheral surface thereof to form a resin film
  • a cooling molding means that includes a pressing roll 5 as a pressing means, and further a resin film
  • the second cooling roll 6 that cools the sheet and the feed roll 7 that further feeds the cooled resin film to the subsequent stage.
  • the extruder 2 heats and melts the resin raw material described above to make the thermoplastic resin a homogeneous state, and an extruder having the same structure as that used in a normal extrusion molding method can be used.
  • a thermoplastic resin supplied from above by a pellet dryer or a weighing hopper 8 is pumped to the die 3 while being heated and melted by a rotating screw.
  • the die 3 is for extruding a molten thermoplastic resin fed from the extruder 2 into a film in a molten state, and a T-die is usually used.
  • the die 3 may be a single-layer die that extrudes one type of molten resin as a single layer, or two or more types that are independently pumped from the extruder 2 such as a feed block die and a multi-manifold die.
  • a multilayer die that laminates and coextrudes molten resin may be used.
  • the film-like molten resin extruded from the die 3 is sandwiched between a first cooling roll 4 and a pressing roll 5 that are arranged opposite to each other, which will be described below.
  • the first cooling roll 4 is, for example, a metal roll having a diameter of about 250 to 1000 mm and an uneven shape formed on the outer peripheral surface.
  • a metal roll capable of controlling the temperature of the roll surface through a fluid, steam or the like inside a roll such as a mold roll, a satin roll, or a spiral roll having a hollow structure.
  • a predetermined concavo-convex shape is formed by sandblasting, engraving or the like in order to transfer to a film-like thermoplastic resin that is extruded from the extruder 2 and then cooled and solidified. Yes.
  • the uneven shape formed on the outer peripheral surface of the first cooling roll 4 includes a mat shape having a maximum roughness (Rmax) of 0.1 to 10 ⁇ m, a prism shape having a pitch and height of 1 ⁇ m to 3 mm, and a lenticular shape.
  • Rmax a maximum roughness
  • a desired concavo-convex shape and concavo-convex pattern can be adopted according to a resin film having a required function such as a concavo-convex shape for giving desired characteristics such as a lens shape and the like.
  • the maximum roughness (Rmax) is a value obtained by measuring with a surface roughness meter in accordance with JIS B0601-2001.
  • the uneven shape is a central portion 4 a portion excluding both ends of the outer peripheral surface of the first cooling roll 4. It is formed only on the outer peripheral surface.
  • This concavo-convex shape is transferred to the surface of the resin film as a product, and a resin film having a concavo-convex shape reversed from the concavo-convex shape of the first cooling roll 4 is obtained. Further, both end portions 4b of the outer peripheral surface of the first cooling roll 4 are mirror-finished.
  • the both end portions 4b of the first cooling roll 4 are mirror-finished so that the resin film 50 comes into close contact with the mirror-surface portion and resists the shrinkage force of the resin film 50 generated during cooling.
  • the edge is constrained on the first cooling roll.
  • contraction to the roll center direction of the both edges of the resin film 50 can be suppressed.
  • the mirror surface processing means processing in which the maximum roughness (Rmax) of the outer peripheral surface is within a range of 0.8 ⁇ m or less so that it can be in close contact with the resin film. If Rmax is 0.1 ⁇ m, it is practically sufficient.
  • the range to be mirror-finished is provided so that both ends of the resin film to be wound overlap from the both ends of the first cooling roll 4 to the inside.
  • the overlap between the mirror-finished region and the resin film is preferably 30 mm or more in the width direction, and the shrinkage of the resin film can be effectively suppressed and the product range can be widened to 50 to 100 mm. More preferred.
  • the range for mirror finishing is 5 to 20% of the surface length of the first cooling roll 4 from the end (for example, in the case of a cooling roll having a total length of 1600 mm, the one end is 80 to 320 mm). It is preferable at such points.
  • the right and left ends do not have to be the same, such as the right end 150 mm and the left end 200 mm, but preferably the left and right ends are the same or the difference between the left and right ends is within 50 mm.
  • the surface length of a roll means the maximum length of the roll 4 in the axial direction in FIG.
  • the temperature control of the first cooling roll 4 is performed by controlling the surface temperature of the first cooling roll 4 by a known control method such as PID control or ON-OFF control. That's fine.
  • the pressing roll 5 is, for example, a pressing roll having a diameter of about 250 to 1000 mm and having an outer peripheral surface such as a rubber roll or a metal elastic roll made of an elastic body.
  • examples of the rubber roll include a silicon rubber roll and a fluorine rubber roll, and it is also possible to employ a material in which sand is mixed to improve releasability.
  • a range of Shore hardness A50 ° to A90 ° measured in accordance with JIS K6253 is preferably used.
  • the hardness of the rubber roll can be arbitrarily set, for example, by adjusting the degree of crosslinking and composition of the rubber constituting the rubber roll.
  • examples of the metal elastic roll include those in which the inside of the roll is made of rubber and those in which fluid is injected, and the outer peripheral portion is made of a metal thin film having flexibility. . Specifically, when a silicon rubber roll is coated with a cylindrical stainless steel thin film having a thickness of about 0.2 to 1 mm, or a fluid such as water or oil is injected, the thickness is about 2 to 5 mm. A cylindrical thin film made of stainless steel is fixed at the end of the roll, and a fluid is sealed inside.
  • the pressure roll 5 is configured to be temperature-controllable.
  • a backup cooling roll may be attached to each roll.
  • the temperature of the fluid may be controlled by a known control method such as PID control or ON-OFF control.
  • the metal thin film of the metal elastic roll or the surface shape of the rubber roll may be selected according to the resin film to be manufactured. That is, when embossing only one surface of the resin film, the outer peripheral surface of the pressing roll 5 is smooth, and when embossing both surfaces of the resin film, the first cooling roll is formed on the outer peripheral surface of the pressing roll 5. It is sufficient to provide a concavo-convex shape as in FIG. When embossing is performed on both surfaces of the resin film, the uneven shape on the outer peripheral surface of the pressing roll 5 and the uneven shape on the outer peripheral surface of the first cooling roll 4 may be similar patterns or different patterns. Good.
  • the press roll 5 and the 1st cooling roll 4 are the predetermined space
  • the predetermined interval may be set as appropriate so that the surface shape of each roll can be sufficiently transferred to the extruded film-like molten resin.
  • the second cooling roll 6 has, for example, a diameter of about 250 to 1000 mm, is a metal roll, a rubber roll, etc., and is a cooling roll capable of controlling the temperature of the outer peripheral surface.
  • This 2nd cooling roll 6 is arbitrary structures, and even if it comprises so that the resin film 50 by which the surface shape was transcribe
  • the resin film 50 having the surface shape transferred by the first cooling roll 4 and the pressing roll 5 is passed through the second cooling roll 6 while being wound around the first cooling roll 4, the resin film 50 is Since it can cool gradually in steps, the optical distortion of the resin film 50 can be made smaller. Furthermore, by winding on the 1st cooling roll 4, the contact time of the thermoplastic resin solidifying and the outer peripheral surface of the 1st cooling roll 4 can be ensured stably, and uneven
  • the second cooling roll 6 is not particularly limited as long as the temperature can be controlled as described above, and for example, a cooling roll conventionally used in extrusion molding can be employed. Specific examples include a mold roll, a satin roll, a spiral roll, and the like.
  • the surface of the second cooling roll 6 is not particularly limited as long as it can stably wind the resin film 50 that has been cooled and solidified without slipping, and may be smooth and have an uneven shape. Also good. In addition, you may make it cool more gradually in steps using a 3rd, 4th, ..., and several cooling roll.
  • the feed roll 7 has a diameter of about 90 to 150 mm, for example, and is formed of a metal roll, a rubber roll, or the like.
  • the feed roll 7 only needs to be able to stably feed the cooled resin film 50 to the subsequent stage, and the outer peripheral surface thereof may be smooth or may have an uneven shape.
  • the first cooling roll 4, the pressing roll 5, the second cooling roll 6 and the feed roll 7 transfer the surface shape of the roll to the film-like thermoplastic resin extruded from the extruder 2,
  • the width of the roll is larger than the width of the extruded resin film, for example, about 50 to 100 mm larger than the width of the resin film Is preferred.
  • a cutting means or the like may be provided.
  • thermoplastic resin supplied from the top is heated and melted by the pellet dryer or the weighing hopper 8, and the thermoplastic resin (molten resin) melted by the rotating screw is transferred from the extruder 2 to the die 3.
  • the molten resin is extruded from the die 3 into a film.
  • the extruded film-like molten resin is sandwiched between the first cooling roll 4 and the pressing roll 5 described above, and the outer peripheral surface shapes of the first cooling roll 4 and the pressing roll 5 are transferred.
  • the film-shaped molten resin is cooled at the same time as the uneven shape of the outer peripheral surface of the roll is transferred, and a cooling molding process is performed.
  • the uneven shape is fixed to the film, and the film shape is stabilized.
  • shrinkage occurs during this cooling, and the shrinkage in the width direction of the resin film mainly affects the characteristics of the product.
  • the resin film shrinks while sliding on the roll surface and the film width decreases, but at this time, the resin film slips greatly at both ends of the roll.
  • the degree of shrinkage varies from place to place. Then, the optical characteristics of the obtained resin film differ at the center and both ends, and a homogeneous resin film cannot be obtained.
  • both end portions of the resin film in contact with the mirror surface portion 4b of the first cooling roll 4 are mirror-finished as in the present invention.
  • the resin film is in close contact with the roll 4 and cooled while resisting the shrinkage force. That is, the shrinkage in the width direction that occurs during cooling of the resin film is effectively suppressed, and a homogeneous resin film can be obtained without greatly changing the optical characteristics of the central portion and both end portions.
  • the resin film 50 having the concavo-convex shape transferred thereon is wound around the first cooling roll 4 and further wound around the second cooling roll 6 to be cooled. Further, the resin film 50 is further fed to the subsequent stage by the feed roll 7 while being wound around the second cooling roll 6.
  • the treatment as required includes, for example, measurement of product thickness, inspection of foreign matter, insertion of a masking film, cutting, and the like.
  • the resin film 50 obtained by the present invention includes a central portion 50a to which the concavo-convex shape is transferred and both end portions 50b formed on the mirror surface.
  • this resin film 50 since the product is the central portion 50a, it is preferable to cut the unnecessary both end portions 50b with a cutting means or the like before forming a roll-shaped article.
  • the resin film 50 fed by the feed roll 7 may be cut into a desired size instead of a roll-shaped article and handled as a sheet.
  • the first cooling roll 4 the pressing roll 5, so that the resin film 50 is stretched without loosening and further does not have a force to stretch in the flow direction of the resin film 50.
  • the peripheral speed of each roll is not particularly limited because it depends on the discharge amount of the extruder and the thickness and width of the film, but it is usually preferably 5 to 30 m / min for each roll.
  • the surface temperature of the first cooling roll is preferably (Tg ⁇ 70 to Tg + 30) ° C., and (Tg ⁇ 60 to Tg + 10) ° C. when the glass transition point of the thermoplastic resin is expressed as Tg. Is more preferable.
  • the surface temperature of the pressing roll is preferably (Tg-100 to Tg-50) ° C., more preferably (Tg-90 to Tg-60) ° C. If these surface temperatures are too low, the uneven shape of the first cooling roll 4 cannot be transferred sufficiently, unevenness occurs in the uneven shape of the resin film 50, and sufficient optical characteristics cannot be obtained, and the surface temperature is too high. As a result, optical distortion increases.
  • the surface temperature of the first cooling roll is (Tg ⁇ 70 to Tg + 30) ° C.
  • the surface temperature of the pressing roll is (Tg ⁇ 100 to Tg ⁇ 50) ° C.
  • the temperature of the cooling roll is preferably (Tg-100 to Tg-20) ° C. from the viewpoint of stabilizing the retardation (phase difference) low.
  • the second cooling roll 6 is disposed obliquely below the first cooling roll 4, but may be disposed vertically below the first cooling roll 4. Further, the positions of the first cooling roll 4 and the pressing roll 5 may be reversed up and down. In this case, the second cooling roll 6 is disposed obliquely above or vertically above the first cooling roll 4.
  • the molten resin is extruded from the horizontally arranged die 3, but as shown in FIG. 4, the molten resin may be extruded from the vertically arranged die 3. Also in this case, a metal elastic roll, a rubber roll, or the like is preferably used as the pressing roll 5.
  • the pressing roll 5 is used as the pressing means.
  • a pressing belt 15 may be used as the pressing means.
  • the pressing belt 15 is preferably a metal seamless belt, and is preferably provided with an uneven shape. In the pressing belt 15, the contact area when pressing is significantly increased as compared with the roll, which is effective in reducing distortion. 4 and 5, parts having the same functions as those shown in FIG. 1 are denoted by the same reference numerals.
  • the resin film 50 obtained by the apparatus and method of the present invention has an optical distortion, specifically, a maximum value in a measurement range of retardation (hereinafter also referred to as phase difference) at 590 nm by an automatic birefringence meter.
  • 50 nm or less preferably 20 nm or less, more preferably 15 nm or less and 10 nm or less.
  • the retardation is within the above range, and the variation in retardation is preferably 20 nm or less, the variation is more preferably 7 nm or less, and the variation is 5 nm or less.
  • the variation in retardation means a difference between the maximum value and the minimum value in the measurement range.
  • the measurement range may be, for example, a range of 100 mm from the film end (hereinafter also referred to as film end) and a range of 50 mm from the center of the film (hereinafter also referred to as film central).
  • the film end refers to a contact portion (50b in FIG. 3) of the resin film obtained by the above-described production method of the present invention and both ends of the resin film on which the mirror-finished portion of the cooling roll is applied. Part), or the end of the embossing region inside the contact part, and the end of the resin film that has been embossed is the width direction end.
  • the maximum value of the retardation of the film end in the range of 100 mm from the film end and the center of the film in the range of 50 mm uniformly from the center of the film is both 15 nm or less. It is preferably 13 nm or less, more preferably 10 nm or less.
  • the maximum retardation value at the film end and the maximum retardation value at the center of the film are not necessarily the same.
  • the maximum retardation value at the film edge may be 15 nm or less, and the maximum retardation value at the center of the film may be different from 10 nm or less.
  • the haze value of the resin film 50 obtained by the apparatus and method of the present invention may be appropriately selected depending on the application. For example, when a light diffusing film is used, it is usually preferable that the haze value is 50% or more.
  • the thickness of the resin film 50 obtained by the apparatus and method of the present invention is preferably in the range of 30 to 500 ⁇ m, for example, when the resin film 50 is used as a light diffusion film. If the thickness is less than 30 ⁇ m, the roll structure of the present invention cannot stably obtain the resin film 50, and if it exceeds 500 ⁇ m, it is difficult to handle as a film.
  • the thickness of the resin film 50 can be adjusted by the thickness of the film-like molten resin extruded from the die 3, the distance between the first cooling roll 4 and the pressing roll 5, and the like. As a width of the resin film 50, for example, a preferable range is 200 to 2000 mm.
  • the thickness of the resin film 50 is preferably in the range of approximately 500 ⁇ m to 2 mm, and is appropriately set according to the required application.
  • the thickness of the resin film 50 exceeds 500 ⁇ m, it is not easy to handle it as a roll-shaped article wound around a winding core. It is preferable to handle as
  • the resin film 50 has an uneven shape formed on the surface and has a function of scattering light, for example, a film for automobile interior, a film for lighting, a film for building materials, etc. in addition to a diffusion film, a brightness enhancement film, and the like. Applicable to. Further, as a concavo-convex shape, it can be applied to a prism sheet by forming a desired prism shape, and to a lens sheet, a lenticular lens sheet, or the like by giving a desired lens shape.
  • the present invention will be described in more detail with reference to examples, but it is needless to say that the present invention is not limited to these examples.
  • the structure of the manufacturing apparatus of the used resin film is as follows.
  • Extruder 2 Screw diameter 110 mm, single screw type.
  • Die 3 T die, extrusion lip width 1473 mm, lip gap 0.8 mm.
  • First cooling roll 4 The outer diameter is 400 mm ⁇ and the width is 1677 mm. Both end portions of the outer peripheral surface are mirror-finished with a width of 223.5 mm and a maximum roughness (Rmax) of 0.4 ⁇ m.
  • Pressing roll 5 A silicon rubber roll having a hardness of A70 ° having an outer diameter of 300 mm ⁇ and an outer peripheral surface polished to a maximum roughness (Ra) of 1 ⁇ m.
  • the first cooling roll 4 was arranged in parallel.
  • Second cooling roll 6 a heat-resistant rubber rubber roll having an outer diameter of 300 mm ⁇ .
  • Feed roll 7 A feed roll made of a silicon rubber roll having an outer diameter of 150 mm.
  • the extruder 2, the die 3, the first cooling roll 4, the pressing roll 5, the second cooling roll 6, and the feed roll 7 are arranged as shown in FIG. 1, and the first cooling roll 4 and the pressing roll 5 are electrically driven. It was configured to connect to a motor and rotate at a predetermined peripheral speed, and no driving force was provided to the second cooling roll 6 and the feed roll 7.
  • Example 1 First, an aromatic polycarbonate resin (manufactured by Sumitomo Dow, trade name: Caliber 301-22; glass transition point (Tg): 155 ° C.) was obtained by melt-kneading while heating to 260 ° C. in the extruder 2.
  • the resin composition was extruded as a film from the die 3 in a molten state. In this case, since the width of the obtained film contracted in the air, the width of the extrusion lip of the die 3 was smaller than 1473 mm and became 1380 mm.
  • the film-like resin composition extruded from the die 3 is supplied so as to be sandwiched between the rotating first cooling roll 4 and the pressing roll 5, while cooling the film-like resin composition,
  • corrugated shape of the 1st cooling roll 4 is transcribe
  • This resin film was wound around the second cooling roll 6, it was cooled while being sequentially fed to the subsequent stage by the feed roll 7.
  • the 1st cooling roll 4, the press roll 5, and the 2nd cooling roll 6 are made to become fixed temperature, circulating cooling water inside, and set temperature of the circulating water to 97 degreeC and 45 degreeC, respectively. 137 ° C.
  • the surface temperature of the 1st cooling roll 4 was about 95 degreeC
  • the surface temperature of the press roll 5 was about 70 degreeC
  • the surface temperature of the 2nd cooling roll 6 was about 130 degreeC.
  • the resin film 50 that passed through the second cooling roll 6 was sampled in the state of 50a in FIG. 3 to obtain a resin film having a width of 1380 mm and a thickness of 130 ⁇ m.
  • the resin film obtained here had good thickness accuracy, and was 130 ⁇ m ⁇ 1 ⁇ m here.
  • Comparative Example 1 As a first cooling roll, a resin film was obtained under the same conditions as in Example 1 using a resin film manufacturing apparatus having the same configuration as in Example 1 except that the entire outer peripheral surface had an uneven shape. It was.
  • Example 2 For each resin film obtained in Example 1 and Comparative Example 1, the positional distribution of the retardation was measured for a further central part 1200 mm of the roll central part 1230 mm that was not mirror-finished, and the results are shown in FIGS. 6 and 7, respectively. It was.
  • the resin film obtained in Example 1 has a maximum retardation value of about 7 nm in the measurement range, whereas the maximum value obtained in Comparative Example 1 is about 18 nm. It was. While the variation of the retardation of Example 1 was about 6 nm, the variation of the retardation of Comparative Example 1 was as large as about 11 nm. In addition, the maximum retardation value at the end of the film of Example 1 is about 5 nm, whereas the maximum retardation value at the center of the film is about 7 nm, indicating that the optical homogeneity is high.
  • the maximum retardation value at the film edge of Comparative Example 1 is about 18 nm, whereas the maximum retardation value at the center of the film is about 9 nm, which is inferior in optical homogeneity to Example 1.
  • a concavo-convex shape is imparted to the film surface and a small optical distortion is obtained only by using a roll having a simple structure in which both end surfaces of the outer peripheral surface are mirror-finished as a cooling roll. It is done.
  • Example 1 even when the molding was continuously performed for 48 hours, the retardation of the resin film was stable at 10 nm or less and the deviation was within 5 nm.
  • the optical distortion of the resin film to be manufactured is suppressed by suppressing the shrinkage in the width direction of the film-like molten resin on the cooling roll.
  • the phase difference can be reduced, the variation in the width direction of the phase difference of the obtained resin film can be suppressed, and the resin film for various uses can be produced uniformly and with a good production yield.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)

Abstract

La présente invention se rapporte à un procédé et à un appareil de production d'un film de résine qui présente une surface concave-convexe, dans laquelle une déformation optique est supprimée et qui présente peu de variation. Un procédé de production d'un film de résine comporte les étapes suivantes : une étape d'extrusion, lors de laquelle une résine thermoplastique en fusion est extrudée sous la forme d'un film depuis une filière (3), la résine thermoplastique extrudée du type film est acheminée entre un premier rouleau de refroidissement (4), sur la surface périphérique extérieure duquel, à l'exception des parties bords, est formé un motif concave-convexe et la surface périphérique extérieure des parties bords du premier rouleau de refroidissement (4) est soumise à un fini miroir, et un moyen de pressage (5) disposé à une distance prescrite du premier rouleau de refroidissement (4) d'une manière telle que les parties bords du film de résine viennent en contact avec les parties bords au fini miroir du premier rouleau de refroidissement (4) ; et une étape de refroidissement et de formage, lors de laquelle on donne à une composition de résine la forme d'un film de résine par pressage de la résine thermoplastique sur le premier rouleau de refroidissement (4) par le moyen de pressage (5) de manière à refroidir la résine thermoplastique et à transférer le motif concave-convexe du premier rouleau de refroidissement (4) sur la surface de la résine thermoplastique.
PCT/JP2012/051115 2011-01-28 2012-01-19 Procédé et appareil de production d'un film de résine Ceased WO2012102178A1 (fr)

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JP2014174197A (ja) * 2013-03-06 2014-09-22 Fuji Xerox Co Ltd 画像転写装置
JP2017144654A (ja) * 2016-02-18 2017-08-24 信越ポリマー株式会社 フィルムキャパシタ用の樹脂フィルムの製造方法
JP2018001470A (ja) * 2016-06-29 2018-01-11 信越ポリマー株式会社 樹脂シートの製造装置及び樹脂シートの製造方法
WO2019039932A1 (fr) * 2017-08-25 2019-02-28 Top Glove International Sdn Bhd Méthode de gaufrage d'un film de gant et film de gant produit à partir de celui-ci
JP2019209616A (ja) * 2018-06-05 2019-12-12 ダイセル・エボニック株式会社 シート及びシートの製造方法
EP3505581A4 (fr) * 2016-08-29 2020-04-22 Zeon Corporation Procédé de production d'une feuille adhésive
CN113334721A (zh) * 2021-05-31 2021-09-03 安徽嘉阳新材料科技有限公司 装饰膜在线一次性压纹方法
CN117087134A (zh) * 2023-08-28 2023-11-21 信义汽车玻璃(深圳)有限公司 Pvb胶片定型装置及pvb胶片定型方法

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TWI816118B (zh) * 2021-05-10 2023-09-21 日商芝浦機械股份有限公司 延伸膜製造裝置

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Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014174197A (ja) * 2013-03-06 2014-09-22 Fuji Xerox Co Ltd 画像転写装置
JP2017144654A (ja) * 2016-02-18 2017-08-24 信越ポリマー株式会社 フィルムキャパシタ用の樹脂フィルムの製造方法
JP2018001470A (ja) * 2016-06-29 2018-01-11 信越ポリマー株式会社 樹脂シートの製造装置及び樹脂シートの製造方法
EP3505581A4 (fr) * 2016-08-29 2020-04-22 Zeon Corporation Procédé de production d'une feuille adhésive
WO2019039932A1 (fr) * 2017-08-25 2019-02-28 Top Glove International Sdn Bhd Méthode de gaufrage d'un film de gant et film de gant produit à partir de celui-ci
JP2020531305A (ja) * 2017-08-25 2020-11-05 トップ グローブ インターナショナル エスディーエヌ ビーエイチディー 手袋のフィルムをエンボス加工する方法及びこの方法で製造される手袋のフィルム
JP7018886B2 (ja) 2017-08-25 2022-02-14 トップ グローブ インターナショナル エスディーエヌ ビーエイチディー 手袋のフィルムをエンボス加工する方法及びこの方法で製造される手袋のフィルム
JP2019209616A (ja) * 2018-06-05 2019-12-12 ダイセル・エボニック株式会社 シート及びシートの製造方法
JP7107756B2 (ja) 2018-06-05 2022-07-27 ポリプラ・エボニック株式会社 シート及びシートの製造方法
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CN113334721A (zh) * 2021-05-31 2021-09-03 安徽嘉阳新材料科技有限公司 装饰膜在线一次性压纹方法
CN117087134A (zh) * 2023-08-28 2023-11-21 信义汽车玻璃(深圳)有限公司 Pvb胶片定型装置及pvb胶片定型方法

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