CN101331012A - 光学用棱镜膜 - Google Patents

光学用棱镜膜 Download PDF

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CN101331012A
CN101331012A CNA2006800440433A CN200680044043A CN101331012A CN 101331012 A CN101331012 A CN 101331012A CN A2006800440433 A CNA2006800440433 A CN A2006800440433A CN 200680044043 A CN200680044043 A CN 200680044043A CN 101331012 A CN101331012 A CN 101331012A
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coextrusion
foil
plastic foil
thickness
layer
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J·施密特
A·拉施茨
C·罗斯
C·克罗默尔
H·哈林格
D·伯斯
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Roehm GmbH Darmstadt
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Evonik Roehm GmbH
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Abstract

本发明涉及一种具有棱镜结构的共挤出箔片，制备具有棱镜结构的共挤出箔片的方法及其用途。

Description

光学用棱镜膜
技术领域
本发明涉及一种具有棱镜结构的共挤出塑料箔片，制备具有棱镜结构的共挤出塑料箔片的方法及其用途。
背景技术
对于不同的用途，工业界已经开发出对塑料表面结构化的方法，其中塑料适用于这个目的。例如，在热塑性塑料的情况下对表面的结构化优选通过处于适当的温度下的表面上的压印设备的作用来实现。(Becker-Braun，Kunststoff-Handbuch[塑料手册]，Vol.1，543-544，Hanser-Verlag 1990；K.Stockhert，Veredeln von
Figure A20068004404300041
[塑料表面的整理]，Hanser 175)。可商购的产品尤其是基于PMMA的具有特征结构化表面的塑料嵌板。这些产品尤其通过在三辊磨光组(压印机)中随着压印同时挤出而制得。其中一个辊(压印辊)已经具有了片状结构的负结构。在结构化片的情况中，目标是使得辊结构的复制质量最优化。通过设定最小熔融粘度和最高辊温度来实现该目标。更进一步的，如实践中可见，在辊隙(即光滑辊和结构辊之间的距离)最窄处之前的压力最大值应该较高，以转移最大的压印力。当工业化生产结构化的嵌板时，上述的三个条件的结果是不可避免的妥协。
根据现有技术，结构化表面的塑料片的生产具有局限，特别是其中对结构的细度和精度有特别严格的要求时。
对上述参数的适合的调整存在有限的可能：由于大部分塑料融体会粘附在热的金属上，因此辊温不能按需要升高。这种粘附的趋势导致从压印辊上分离变得困难，其开始于某一辊温。塑料的融体粘度不能选为与需要的一样低，例如通过设定高的熔体温度，这是因为否则辊隙上的压印力会变得太小。
通过这个过程制备的并具有这些限制的片材的复制精度不足以用于特定用途，即，精细结构没有得到正确地成形或者被舍入了。因此就有了提供一种方法的目标，这种方法能制备结构化的表面并且能够满足上述的要求，例如使用具有非常精细表面结构的压印辊的高精度复制。
另一个问题是具有结构化表面的薄箔片的制备。DE 4407468限制片的厚度为0.5-25毫米。涂覆的相对低粘度层的厚度被限制在0.2-5毫米。得到的制品为厚度0.7-30毫米的实心嵌板。很难将片材生产技术转化到薄的箔片上来。
另一个目标为提供一种具有结构化表面的薄箔片。
US 5175030描述了一种制备具有棱镜结构的箔片的方法。复杂的分批过程将树脂涂覆到精巧的箔片上，并且使用了原版进行压印并用紫外辐射使复合物固化。之后将原版与微结构的薄膜分离。缺点不仅包括分批生产技术的高成本，此外，还有受限的箔片尺寸。原版的最大尺寸约为1200×1200毫米。
另一个目标为提供一种具成本有效的、连续方法。
发明内容
通过制备具有棱镜结构的共挤出塑料箔片的连续方法，上述目的已经得以实现，该方法的特征在于在挤出过程中将厚度为0.10-0.35毫米的基体箔片和低粘度层共挤出，随后通过包括具有结构化表面的辊的可加热压光辊组使箔片复合体结构化。
具体实施方式
使用装有两个挤出机和包括具有结构化表面的辊(压印辊)的压光辊组的挤出系统，来制备共挤出塑料箔片，其中低粘度层涂覆到高粘度基体箔片上。随后共挤出塑料箔片通过在压光辊组中的压印辊进行结构化。高粘度基体箔片的使用可以保证提供了足够的压印力。基体箔片和共挤出层都优选为热塑性塑料。
可使用的热塑性塑料为聚丙烯酸酯，特别是PMMA，聚碳酸酯，聚烯烃，低密度聚乙烯，高密度聚乙烯，聚丙烯，聚对苯二甲酸乙二醇酯，聚氯乙烯，聚苯乙烯，聚酰胺。低粘度共挤出层可以更有效地由与基体箔片等级相同的塑料组成，但是，也可由足够与其相容的塑料组成。(J.E.Johnson，Kunststoffberater 10，538-541(1976))。可以说明的通用原则就是共挤出材料的熔体粘度要符合用于复制高精度的注塑组合物所需的粘度。特别优选使用聚碳酸酯，这是因为1.58的折射系数对于光学用途具有良好的适应性。根据实施例，使用聚碳酸酯可以保证有效的对光偏折。
共挤出层优选由低粘度材料组成。在材料中还可加入流动促进剂。合适的流动促进剂为低分子量的化合物，例子为低分子量的聚甲基丙烯酸甲酯。
高粘度基体箔片和低粘度共挤出层之间的MVR(熔体体积流动速率)比例理想为1:20至1:8，优选1:10。
低粘度共挤出层的厚度取决于功能。结构的压印要求过程参数要精确而且适当地调整。对于适当的调整存在有限的可能：辊子温度不能按需要升高，这是因为大部分塑料熔体会粘附到金属上。这种粘附的趋势导致从压印辊上分离变得困难，其开始于某一辊温。塑料的融体粘度不能选为与需要的一样低，例如通过设定高熔体温度，这是因为否则辊隙上的压印力会变得太小。
如果共挤出层调整至更高的粘度，通过配对辊压力施加的力就不足以达成可接受的压印。
因此共挤出层的层厚度产生特殊的影响。为了良好的结构复制，层厚度应该构成压印辊的至少1/4结构高度。
令人惊奇的是，已经发现由低粘度塑料组成的很厚的共挤出层的应用导致压印出均匀的棱镜结构，即使--与DE 4407468的陈述相反--低粘度共挤出层超过压印辊的结构最大深度。
如果适当并且理想地适应过程参数，就可以省略任何脱模剂的使用。尽管如此，如果在共挤出层中需要脱模剂，本领域的技术人员可使用现有技术中已知的材料(H.F Mark等人，Encyclopedia ofPolymer Science & Engineering，Index Volume pp.307-324，J.Wiley 1990；Ullmann’s Encyclopedia of Industrial Chemistry，第5版，Vol.A20，479-483，VCH 1992；R.Gaechter，H.MullerKunststoffadditive[塑料添加剂]，第3版，Carl Hanser Verlag1989)。
共挤出层中使用的脱模剂的含量优选为0-0.34重量％，基于共挤出物的重量。特别可以提及高级醇。
在共挤出组合物中使用脱模剂降低了熔体粘附在热金属上的趋势。因此，在压印过程中压印辊的温度可以显著提高。作为指示可能提到了高于共挤出组合物的玻璃化温度Tg最多70℃。(玻璃化温度Tg是已知的或可以计算出来(参考资料Brandrup-Immergut，PolymerHandbook，第五章，J.Wiley，Viewge-Esser，Kunststoff-Handbuch[聚合物手册]，第4卷，333-340，Carl Hanser 1975)。
本发明过程的一个可能的方法为：共挤出系统本质上由主挤出机、共挤出机和共挤出工具组成。
通过共挤出工具来决定挤出箔片的最大宽度。通常挤出箔片的宽度为400-2000毫米。箔片的厚度同样也受到共挤出过程条件的限制，通常基体箔片的厚度为0.10-0.35毫米，并且对于通过低粘度材料形成的层，主要决定因素是以结构化为目标的功能。然而，它的层厚度通常为0.006-0.075毫米。压印棍的结构深度理想为0.025-0.070毫米。
在共挤出工具中，将通过主挤出机加热至适合温度的基体模塑组合物，和通过共挤出机加热至适合温度的低粘度模塑组合物混合。对于基体模塑组合物的模头温度，有如下近似指导：
基体模塑组合物                   加工温度(℃)
聚甲基丙烯酸甲酯                 230-290
聚苯乙烯                         190-230
聚碳酸酯                         250-300
从共挤出工具形成的共挤出物在压光辊组上传送，其中一个辊--作为压印辊--被设计为其表面具有所需结构化箔片结构的负结构。在压力施加辊和压印辊之间存在辊隙。为了允许最大压印力的转移，这里的最大压力在最窄点之前较高。压光辊组的其他方面与现有技术相符。具有结构化表面的挤出箔片在支持滚筒上传输。随后它们可以被切割和/或卷绕成所需的长度。之后外形显示压印辊表面的精确复制。
已经发现有可能第一次提供了具有任何所需长度的具有棱镜结构的共挤出塑料箔片，其中基体箔片的厚度为0.10-0.35毫米。
在具有棱镜结构的共挤出塑料箔片中，基体箔片与共挤出层的MVR比例为1:20到1:8，优选1:10。
共挤出层的厚度可以至少为结构高度的一半。与DE 4407468相反，共挤出层的厚度可以大于压印辊上的结构深度。
本发明制备的箔片的应用部分通过光学材料提供。由于光学应用需要高质量的材料，因此本过程优选在无尘室条件下进行。对于这种具有特殊意义的用途，当作为显示器的背面照明箔片时，应在100级的无尘室条件中进行操作，这是由于环境空气中的灰尘会造成箔片上不可接受的污染。
下述实施例用于为本发明提供更好的说明，而不应该将发明限制为这些公开的特征。
实施例
实施例1
在共挤出系统内将MVR值为6的聚碳酸酯和MVR值为66的低粘度聚碳酸酯共挤出。
基体箔片的宽度为1800毫米和厚度为150微米，及共挤出层的厚度为25微米。
在使用具有棱镜结构的压印棍的可加热的压光辊组(在此情况下三辊压光辊组)上传送共挤出物。压印辊的结构深度为50微米。将压印辊加热至大约200℃。共挤出箔片以20米/分钟的速度在压印辊上传送。
产品是一种由聚碳酸酯组成的共挤出塑料箔片，其对棱镜结构复制良好，产品适用于光学用途，例如为显示器的背面照明。
实施例2
在共挤出系统内将MVR值为6的聚碳酸酯和MVR值为66的低粘度聚碳酸酯共挤出。
基体箔片的宽度为400毫米和厚度为500微米，及共挤出层的厚度为70微米。
在使用具有棱镜结构的压印棍的可加热的压光辊组(在此情况下三辊压光辊组)上传送共挤出物。压印辊的结构深度为50微米。将压印辊加热至大约200℃。共挤出箔片以2米/分钟的速度在压印辊上传送。
产品是一种由聚碳酸酯组成的共挤出塑料箔片，其对棱镜结构复制良好，产品适用于光学用途，例如为显示器的背面照明。
实施例3
在共挤出系统内将MVR值为3的聚碳酸酯和MVR值为60的低粘度聚碳酸酯共挤出。
基体箔片的宽度为400毫米和厚度为500微米，及共挤出层的厚度为70微米。在使用具有棱镜结构的压印棍的可加热的三辊压光辊组上传送共挤出物。压印辊的结构深度为50微米。
将压印辊加热至大约200℃。共挤出箔片以2米/分钟的速度在压印辊上传送。
产品是一种由聚碳酸酯组成的共挤出塑料箔片，其对棱镜结构复制良好，产品适用于光学用途，例如为显示器的背面照明。
实施例4
在共挤出系统内将MVR值为1.2的聚甲基丙烯酸甲酯和MVR值为12的低粘度聚甲基丙烯酸甲酯共挤出。
基体箔片的宽度为400毫米和厚度为800微米，及共挤出层的厚度为25微米。在使用具有棱镜结构的压印棍的三辊压光辊组上传送共挤出物。压印辊的结构深度为100微米。
将压印辊加热至大约180℃。共挤出箔片以2米/分钟的速度在压印辊上传送。
产品是一种由聚甲基丙烯酸酯组成的共挤出塑料箔片，其对棱镜结构复制非常好。

Claims (13)

1.制备具有棱镜结构的共挤出塑料箔片的连续方法，其特征在于在挤出过程中将厚度为0.10-0.35毫米的基体箔片和低粘度层共挤出，随后通过包括具有结构化表面的辊的可加热压光辊组使箔片复合体结构化。
2.根据权利要求1的制备共挤出塑料箔片的连续方法，其特征在于在挤出过程中将厚度为0.10-0.35毫米的基体箔片和厚度构成结构高度至少1/4的低粘度层共挤出。
3.根据权利要求2的制备共挤出塑料箔片的连续方法，其特征在于挤出过程中共挤出了基体箔片和厚度大于结构高度的低粘度层。
4.根据权利要求1的制备共挤出塑料箔片的连续方法，其特征在于基体箔片和低粘度层的MVR比例为1∶8到1∶20。
5.根据权利要求1的制备共挤出塑料箔片的连续方法，其特征在于压印辊的温度高于共挤出组合物的玻璃化转变温度最多70℃。
6.根据权利要求1的制备共挤出塑料箔片的连续方法，其特征在于共挤出组合物还含有脱模剂。
7.具有棱镜结构的共挤出塑料箔片，其特征在于基体箔片的厚度为0.10-0.35毫米。
8.具有棱镜结构的共挤出塑料箔片，其特征在于基体箔片和共挤出层的MVR比例为1∶20到1∶8。
9.根据权利要求7的共挤出塑料箔片，其特征在于基体箔片和共挤出层的MVR比例为1∶10。
10.根据权利要求7的共挤出塑料箔片，其特征在于共挤出层的厚度构成结构高度的至少1/4。
11.根据权利要求7的共挤出塑料箔片，其特征在于共挤出层的厚度大于结构深度。
12.根据权利要求1的方法制备的共挤出塑料箔片用于光学应用的用途。
13.根据权利要求1的方法制备的共挤出塑料箔片用于显示器背面照明的用途。
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