CN101537705A - Resin sheet manufacturing method - Google Patents

Abstract

The present invention provides a method of producing a resin sheet, comprising the steps of: nipping a sheet-like resin material extruded from a die by a mold roller and a plurality of nip rollers placed to face the mold roller, transferring shapes of asperities on a surface of the mold roller to the resin material, and peeling the resin material after the transfer off from the mold roller by winding the resin material around a peeling roller placed to face the mold roller.

Description

The method for preparing resin plate

The application is that international filing date is that August 22, international application no in 2005 are to be for PCT/JP2005/015583, national applications number 200580028302.9 and denomination of invention dividing an application for the application of " method for preparing resin plate ".

Technical field

The present invention relates to a kind of method for preparing resin plate, and more specifically, relate to a kind of preparation and be suitable for method as the resin plate of optical plate or the various optical elements settled at the back side of various display devices.

Background technology

Resin plate as various optical elements is used for various fields with Fresnel lens or biconvex lens.These resin plates have the rough form of rule in its surface, and described rough form provides the optical property as Fresnel lens or biconvex lens.

Advised preparing these resin plates the whole bag of tricks (referring to, Japanese Patent Application Publication 8-31025, Japanese Patent Application Publication 7-314567, Japanese Patent Application Publication 2003-53834 and Japanese Patent Application Publication 8-287530).In all these suggestions, consider the improvement of productivity ratio, use the roller forming method.

For example, in Japanese Patent Application Publication 8-31025, before peeling off resin plate, provide the cooling device of improvement, to improve transfer performance from roller.Japanese Patent Application Publication 7-314567 discloses a kind of by prepare the method for Fresnel lens around roller coiling mould (mold).

In Japanese Patent Application Publication 2003-53834, in format roll, settle heat insulating component, to improve productivity ratio and transfer performance.Among the Japanese Patent Application Publication 8-287530, use Corona discharge Treatment, to improve transfer performance and to reduce defective.

A kind of typical roller forming method of routine techniques has structure as shown in Figure 12.Device construction comprises: the mirror finish roller 4 that the sheet material that will be shaped to sheet material by the resin material 1 of extruder (not shown) fusion has the punch roll 3 of rough form, settles in the face of punch roll 3 with die head 2, its surface, and the mirror finish stripper roll 5 of settling on mirror finish roller 4 opposition sides.

Tabular resin material 1 by punch roll 3 and 4 clampings of mirror finish roller are extruded from die head 2 will be transferred on the resin material 1 in punch roll 3 lip-deep rough form, and resin material 1 is reeled around mirror finish stripper roll 5, thereby peel off from punch roll 3.

Summary of the invention

But all routine suggestions relate to the method for the resin plate for preparing relative thin, and are unwell to the thick relatively resin plate of preparation.Particularly, when the width when preparing along moulding has the resin plate of big thickness distribution, be very difficult to the section shape that obtains suiting.

For example, when extruding back roller moulding PMMA (plexiglass), if provide thickness distribution along width, and the thickness difference between thick and the thinnest part is equal to or greater than 1mm, then produces variety of issue, as producing inhomogeneities (by the contraction in resin curing process on the front or the back side, or distribute by the elastic recovery amount, the shrinkage hole that produces), reduced the transferring rate of surface configuration usually, or the sharp-pointed edge shape of transferability not.

Consider these situations, realized the present invention, and one object of the present invention is to provide a kind of method for preparing resin plate, this resin plate can access suitable section shape when resin plate that the width of preparation during along moulding has big thickness distribution, and is suitable for as optical plate or the various optical elements settled at the back side of various display devices.

To achieve these goals, a first aspect of the present invention provides a kind of method for preparing resin plate, this method may further comprise the steps: the tabular resin material that a plurality of nip rolls clampings of settling by the mould roller with in the face of the mould roller are extruded from die head, to be transferred to resin material in the lip-deep rough form of mould roller, resin material is peeled off from the mould roller around in the face of the resin material after the stripper roll coiling transfer printing of mould roller arrangement with passing through.

According to a first aspect of the invention,, rough form is transferred on the resin material, and, resin material is peeled off from the mould roller by around stripper roll coiling resin material by mould roller and the tabular resin material of a plurality of nip rolls clampings.Therefore, by using a plurality of nip rolls of settling in the face of the mould roller, if the width of resin plate during along moulding has big thickness distribution, and producing inhomogeneities on overleaf immediately after the first nip points moulding, then can proofread and correct inhomogeneities, maybe resin plate can be cooled off rapidly and sclerosis, with the distortion that prevents to cause by downstream rollers wrapped (coiling), and the section shape that obtains suiting.

In first aspect, along the width of resin material, the thickness difference between thick and the thinnest part preferably is equal to or greater than 1mm having under the situation that is transferred to the rough form on the resin material.In first aspect, the resin material thickness of thin part preferably is equal to or less than 5mm.So, when forming device has the resin material of the section shape that is difficult to moulding, can obtain benefit of the present invention.

In first aspect, preferably, between mould roller and a plurality of nip rolls and/or stripper roll, provide ribbon-shaped members, and by ribbon-shaped members and mould roller clamping resin material.Therefore, by using ribbon-shaped members, can increase apart from the clamping resin material, with the section shape that helps obtaining suiting.

To achieve these goals, a second aspect of the present invention provides a kind of method for preparing resin plate, this method may further comprise the steps: the tabular resin material that at least one nip rolls clamping of settling by the mould roller with in the face of the mould roller is extruded from die head, to be transferred to resin material in the lip-deep rough form of mould roller, with the resin material that passes through after stretching transfer printing on the tangent direction of mould roller and nip rolls, resin material is peeled off from the mould roller.

According to second aspect,, and rough form is transferred on the resin material by mould roller and the tabular resin material of at least one nip rolls clamping.Resin material after the transfer printing need be peeled off from the mould roller.Being different from routine techniques, is not that resin material is reeled and peeled off from the mould roller thus around stripper roll, but on the tangent direction of mould roller and nip rolls the stretching resin material.In the case, by a plurality of nip rolls, on the tangent direction of the nip rolls that mould roller and downstream position (at the downstream position on the resin material throughput direction) are located to settle, the stretching resin material.Therefore, can keep the flatness of the resin material peeled off from the mould roller, thereby can under situation about not making, peel off resin material from the mould roller by the rough form distortion of mould roller transfer to the resin material.This can prepare the resin plate with suitable section shape.

If as in the routine techniques around stripper roll coiling resin material, and peel off thus, reeling makes the resin material of peeling off from the mould roller lose flatness, thereby tends to make the rough form distortion of transfer printing.

To achieve these goals, a third aspect of the present invention provides a kind of method for preparing resin plate, this method may further comprise the steps: by mould roller and the ribbon-shaped members that provides between mould roller and a plurality of pressure rollers of settling in the face of the mould roller, the tabular resin material that clamping is extruded from die head, to be transferred to resin material in the lip-deep rough form of mould roller, with the resin material after the stretching transfer printing on the tangent direction of pressure roller by being positioned at downstream position at the mould roller with in a plurality of pressure rollers, resin material is peeled off from the mould roller.

As in a third aspect of the present invention, by using ribbon-shaped members, can with increase apart from the clamping resin material, with the section shape that helps obtaining suiting.

Of the present invention second or the third aspect, the temperature at the pick-up point place of preferred resin material on the mould roller is equal to or less than softening point (Ta).This be because, by and when the mould roller is peeled off resin material at stretching resin material on the tangent direction, resin material after just having peeled off is not supported in atmosphere, and resin material itself tends to be equal to or higher than softening point (Ta) distortion, and this may cause having the distortion of coarse patterns shape of the resin material of peeling off of Free Surface.

In the case, when by mould roller and at least one nip rolls clamping resin material, and when being transferred to the rough form of mould roller on the resin material, as in a second aspect of the present invention, preferably be provided for cooling off the device of the resin material in transfer process, as air nozzle.When in a third aspect of the present invention, providing ribbon-shaped members, preferably be provided for cooling off the device of ribbon-shaped members, with the back side (with the surface of the surface opposite that contacts the mould roller) cooling resin material from resin material.

Second or the third aspect, when preferably on the tangent direction that stretches, carrying, with resin material slow cool down in the slow cool down district.This is because even the resin material of peeling off from the mould roller has flatness, resin material also preferably keeps flatness, up to resin material cooling and sclerosis, and the rough form of transfer printing is completely fixed, to obtain to have the resin plate of suitable section shape.

To achieve these goals, a fourth aspect of the present invention provides a kind of method for preparing resin plate, this method may further comprise the steps: the tabular resin material that at least one nip rolls clamping of settling by the mould roller with in the face of the mould roller is extruded from die head, to be transferred to resin material in the lip-deep rough form of mould roller, with by the resin material after the transfer printing of stripper roll coiling, resin material is peeled off from the mould roller, stripper roll is settled in the face of the mould roller, and have 500mm or bigger major diameter, described major diameter is the twice of mould roller diameter or more times.

According to fourth aspect, as using stripper roll in the routine techniques, and stripper roll has 500mm or bigger major diameter, and described major diameter is the twice of mould roller diameter or more times.Use has large diameter stripper roll, can as of the present invention second or the third aspect in, allow to help obtaining the flatness of resin material at stretching resin material on the tangent direction of mould roller basically.

In second to the fourth aspect any one, preferably along the width of resin material, the thickness difference between thick and the thinnest part is equal to or greater than 1mm having under the situation that is transferred to the rough form on the resin material.Aspect first to fourth, the preferred resin material thickness of thin part is equal to or less than 5mm.So, when forming device has the resin material of the section shape that is difficult to moulding, can further provide benefit of the present invention.

To achieve these goals, a fifth aspect of the present invention provides a kind of method for preparing resin plate, this method may further comprise the steps: the tabular resin material that the first nip rolls clamping of settling by the first mould roller with in the face of the first mould roller is extruded from die head, to be transferred on the resin material in the lip-deep rough form of the first mould roller, by the resin material after the stripper roll coiling transfer printing of settling in the face of the first mould roller, resin material is peeled off from the first mould roller, resin material after the second nip rolls clamping of settling by the second mould roller with in the face of the second mould roller is peeled off and will being transferred on the resin material in the lip-deep rough form of the second mould roller.

According to the 5th aspect, preferably, rough form is transferred on the resin material, and peels off resin material from the first mould roller by the first mould roller and the tabular resin material of the first nip rolls clamping.Then, by the second mould roller and the second nip rolls clamping resin material, and rough form is transferred on the resin material.Therefore, use many group mould rollers and nip rolls, even the width of resin plate during along moulding has big thickness distribution, also can be by the section shape that makes shape obtain suiting gradually near design shape.

Aspect the 5th, the lapping angle that preferably centers on the resin material of the second mould roller and second nip rolls coiling is all spent less than 5.Under such state,, the tabular resin material is carried under unbending situation by the second mould roller and the second nip rolls clamping resin material.

Aspect the 5th, the preferred downstream on the resin material moving direction of the second mould roller and second nip rolls, provide at least one group of mould roller and the nip rolls that have with the second mould roller and the second nip rolls same configuration, so that be transferred to the shape that the rough form of resin material moves closer to design.By the one group of second mould roller and second nip rolls, can obtain benefit to a certain degree, but, can obtain the bigger benefit of the present invention by being provided for many groups of machining gradually.

A sixth aspect of the present invention provides a kind of method for preparing resin plate, this method may further comprise the steps: the tabular resin material of extruding from die head by the first positive face mould roller with in the face of first back side mould roller clamping of first positive face mould roller arrangement, to be transferred on the resin material in the lip-deep rough form of the first positive face mould roller with in the lip-deep rough form of first back side mould roller, by the resin material after the stripper roll coiling transfer printing of settling in the face of the first positive face mould roller, resin material is peeled off from the first positive face mould roller, by the second positive face mould roller and in the face of second back side mould roller clamping of second positive face mould roller arrangement after peeling off resin material and will be transferred on the resin material in the lip-deep rough form of the second positive face mould roller with in the lip-deep rough form of second back side mould roller.

According to the 6th aspect, right when on the front and back of resin material, forming rough form by the first roller group, then by the second roller group to the transfer printing shape.Even resin plate has big thickness distribution along the width when the moulding, this also can approach the section shape that design shape obtains suiting by little by little making shape.

Aspect the 6th, the lapping angle that preferably centers on the resin material of the second positive face mould roller and second back side mould roller coiling is all spent less than 5.In this state, by the second positive face mould roller and second back side mould roller clamping resin material, thereby allow there be not conveying flat shape resin material under the crooked situation.

Aspect the 6th, the preferred downstream on the resin material moving direction of the second positive face mould roller and second back side mould roller, provide at least one group of positive face mould roller and the back side mould roller that have with the second positive face mould roller and second back side mould roller same configuration, so that be transferred to the shape that the rough form of resin material moves closer to design.By the one group of second positive face mould roller and second back side mould roller, can obtain benefit to a certain degree, but, can obtain the bigger benefit of the present invention by being provided for many groups of machining gradually.

Aspect the 6th, preferably on the surface of separate roller, form and the substantially the same rough form of lip-deep rough form at first back side mould roller.Have rough form stripper roll can with first positive face mould roller transfer printing shape synergistically, therefore can obtain the bigger benefit of the present invention.

A seventh aspect of the present invention provides a kind of method for preparing resin plate, this method may further comprise the steps: the tabular resin material that the second mirror finish roller clamping of settling by the first mirror finish roller with in the face of the first mirror finish roller is extruded from die head, shaping resin material is to have preset thickness, by the resin material behind the stripper roll coiling and molding of settling in the face of the first mirror finish roller, resin material is peeled off from the first mirror finish roller, resin material after mould roller and the nip rolls clamping settled in the face of the mould roller are peeled off and will being transferred on the resin material in the lip-deep rough form of mould roller.

According to the 7th aspect, the tabular resin material after will peeling off from the first mirror finish roller carries out transfer printing by mould roller and nip rolls.The section shape that this can obtain suiting, and help keeping the flatness of resin material.

Aspect the 7th, the lapping angle that preferably centers on the resin material of mould roller and nip rolls coiling is all spent less than 5.In this state, by mould roller and nip rolls clamping resin material, allowing is not having conveying flat shape resin material under the crooked situation.

Aspect the 7th, preferably provide many group mould rollers and nip rolls, so that be transferred to the shape that the rough form of resin material moves closer to design.By one group of mould roller and nip rolls, can obtain benefit to a certain degree, but by being provided for processing gradually many groups can obtain the bigger benefit of the present invention.

Aspect the 7th, preferably along the width of resin material, the thickness difference between thick and the thinnest part is equal to or greater than 1mm having under the situation that is transferred to the rough form on the resin material.

Aspect the 7th, the preferred resin material thickness of thin part is equal to or less than 5mm.So, when forming device has the resin material of the section shape that is difficult to moulding, can obtain benefit of the present invention.

As mentioned above, according to the present invention, even the resin plate that the width during along moulding has big thickness distribution, the also section shape that can obtain suiting.Be suitable for as optical plate or the various optical elements settled at the back side of various display devices by the resin plate of the present invention preparation.

The accompanying drawing summary

Fig. 1 is the structural map that adopts an example of resin plate production line of the present invention;

Fig. 2 is the perspective view of the resin material after the moulding, and wherein an one end surfaces is fallen by linear incision;

Fig. 3 is the perspective view of the resin material after the moulding, and wherein an one end surfaces is fallen by linear incision;

Fig. 4 is the structural map that adopts another example of resin plate production line of the present invention;

Fig. 5 is the structural map that adopts another example of resin plate production line of the present invention;

Fig. 6 is the structural map that adopts another example of resin plate production line of the present invention;

Fig. 7 is the structural map that adopts another example of resin plate production line of the present invention;

Fig. 8 is the structural map that adopts another example of resin plate production line of the present invention;

Fig. 9 A to 9E is the profile of the resin material in each forming step;

Figure 10 is the structural map that adopts another example of resin plate production line of the present invention;

Figure 11 is the structural map that adopts another example of resin plate production line of the present invention; With

Figure 12 is the structural map according to the resin plate production line of conventional embodiment.

Denotational description

10 resin plate production lines

12 die heads

14 resin materials

16 mould rollers

18 first nip rolls

20 second nip rolls

22 the 3rd nip rolls

24 stripper roll

26,28 cooling devices

30 slow cool down districts

Implement best mode of the present invention

Now, will be with reference to the accompanying drawings, describe a preferred embodiment (first embodiment) of preparation in accordance with the present invention in detail.Fig. 1 is the structural map of employing according to an example of resin plate preparation method's of the present invention resin plate production line.

Resin plate production line 10 comprises that the plate that is used for the resin material 14 by the fusion of extruder (not shown) is shaped to plate is with die head 12, have the mould roller 16 of rough form, a plurality of nip rolls (first nip rolls 18, second nip rolls 20 and the 3rd nip rolls 22) of settling in the face of mould roller 16, the stripper roll 24 of settling in the face of mould roller 16, cooling device 26 and 28 and slow cool down district 30 in its surface.

Form the slit sizes of die head 12, make the width of molten resin material 14 of moulding greater than the width of mould roller 16, and settle die head 12, make and to extrude between the mould roller 16 and first nip rolls 18 from the molten resin material 14 that die head 12 is extruded.

Mould roller 16 has the rough form of rule in its surface.As shown in Figure 2, Gui Ze rough form can be resin material 14 inverse shape after for example moulding.Fig. 2 is the perspective view of the resin material 14 after the moulding, and wherein its end surfaces 14A is fallen by linear incision.

Particularly, the back side of resin material 14 is smooth, and forms the linear rough form that is parallel to arrow on the surface of resin material 14.Arrow is represented the moving direction of resin material 14.Therefore, can be at the annular groove that is formed on the inverse shape on the end surfaces 14A on the surface of mould roller 16.To be described in the details of resin material 14 lip-deep coarse patterns shapes after a while.

As for the material of mould roller 16, can use various steel members, stainless steel, copper, zinc, brass, as its surface be lined with the plug of rubber these metal materials, be electroplate with Hcr, these metal materials of Cu or Ni, pottery and various composite.

As for the method that on mould roller 16 surfaces, forms coarse patterns, according to the material on coarse patterns (at interval, the degree of depth etc.) or mould roller 16 surfaces, the preferred usually combination of using NC lathe cut and polishing.Can use other known machining process (grinding, ultra sonic machinery processing or the processing of electric spark machinery etc.).

The surface roughness of mould roller 16 (Ra) preferably is equal to or less than 0.5 μ m, more preferably is equal to or less than 0.2 μ m.

On the direction of arrow of Fig. 1, rotate driving mould roller 16 by the drive unit that does not show with predetermined peripheral speed.Mould roller 16 also has temperature-adjusting device.Such temperature-adjusting device is provided, raises or its unexpected temperature reduces with control or the temperature that prevents the mould roller 16 that causes by hot resin material 14.

As for such temperature-adjusting device, the structure of the oil of the temperature that preferably using circulates in roller has adjusting.Have the structure that rotates the abutment by end, can realize the supply and the discharge of oil at roller.Use this temperature-adjusting device in the resin plate production line 10 in Fig. 1.

Nip rolls is such roller, and they are settled in the face of mould roller 16 and work in coordination with clamping resin materials 14 with mould roller 16, and the upstream side on moving direction, settle with the order of first nip rolls 18, second nip rolls 20 and the 3rd nip rolls 22.

Preferably with the surface mirror mirror polish of nip rolls 18,20 and 22.This surface can make the back side of the resin material 14 after the moulding satisfactory.Nip rolls 18,20 and 22 surface roughness (Ra) preferably are equal to or less than 0.5 μ m, more preferably are equal to or less than 0.2 μ m.

As for the material of nip rolls 18,20 and 22, can use various steel members, stainless steel, copper, zinc, brass, as its surface be lined with the plug of rubber these metal materials, be electroplate with Hcr, these metal materials of Cu or Ni, pottery and various composite.

On the direction of arrow of Fig. 1, rotate driving nip rolls 18,20 and 22 by the drive unit that does not show with predetermined peripheral speed.Can allow such structure, promptly in nip rolls 18,20 and 22, not provide drive unit, but drive unit preferably is provided, to obtain the satisfactory state at resin material 14 back sides.

When in nip rolls 18,20 and 22, providing drive unit, the preferred structure that uses with variable drive speed.Therefore, can use the method for operating that improves speed (at most in several percentages) gradually, so that nip rolls 18,20 and 22 peripheral speeds faster than mould roller 16.

Nip rolls 18,20 and 22 has not the pressue device that shows separately, thus can with mould roller 16 synergistically with predetermined pressure clamping resin material 14.Pressue device have nip rolls 18,20 and 22 and mould roller 16 between the vertical direction of contact point on the structure of exerting pressure, and can use various known devices, as motor driver, pneumatic cylinder or hydraulic cylinder.

Nip rolls 18,20 and 22 can have the structure that prevents the bending that caused by the response of exerting pressure separately.The pad roller, the structure that makes the crown shape of apparatus that provide on the rear side (side opposite with mould roller 16) of nip rolls 18,20 and 22 is provided such structure, have intensity distributions improving the structure at the roller of the rigidity at the place, axle center of roller, with and the structure of combination.

Nip rolls 18,20 and 22 has temperature-adjusting device separately.

The temperature that is provided with for first nip rolls 18, second nip rolls 20 and the 3rd nip rolls 22, in the time of need be according to the material of resin material 14, resin material 14 fusings (for example, the shapes of the external diameter of the temperature slit outlet of die head 12), the transporting velocity of resin material 14, mould roller 16, the coarse patterns of mould roller 16 etc. are selected optimum value.

As for first nip rolls 18, second nip rolls 20 and the 3rd nip rolls 22 temperature-adjusting device separately, preferably using circulates in roller has the structure of the oil of regulating temperature.Have the structure that rotates the abutment by end, can realize the supply and the discharge of oil at roller.Use this temperature-adjusting device in the resin plate production line 10 in Fig. 1.

As for other temperature-adjusting device, can use various known devices, as have the structure that is incorporated into the double pipe heater in the roller, or near the structure of the dielectric heater that provides roller is provided.

In addition, in the resin plate production line 10 in Fig. 1, provide cooling device 26 and 28, with the temperature-adjusting device of auxiliary first nip rolls 18, second nip rolls 20 and the 3rd nip rolls 22.

Cooling device 26 and 28 all is an air nozzle.Settle the air nozzle of cooling device 26, air being blown on the resin material of carrying in the gap between second nip rolls 20 and the 3rd nip rolls 22 14, and settle the air nozzle of cooling device 28, air is blown on the 3rd nip rolls 22.Therefore, can be directly and also can be by the temperature of the 3rd nip rolls 22 control resin materials 14.

Temperature and quantity delivered (blowing flow) for cooling device 26 and 28 air, in the time of need be according to the material of resin material 14, resin material 14 fusings (for example, the shape of the external diameter of the temperature outlet of the slit of die head 12), the transporting velocity of resin material 14, mould roller 16, the coarse patterns of mould roller 16, nip rolls (first nip rolls 18, second nip rolls 20 and the 3rd nip rolls 22) temperature etc. is set, select optimum value.

Stripper roll 24 is such rollers, and it is settled in the face of mould roller 16, and by around stripper roll 24 coiling resin materials 14 resin material 14 being peeled off from mould roller 16, and is placed in across mould roller 16 and locates for 180 ° away from the downstream of first nip rolls 18.

Preferably with the surface mirror mirror polish of stripper roll 24.Such surface can make the state at resin material 14 back sides after the moulding satisfactory.The surface roughness of stripper roll 24 (Ra) preferably is equal to or less than 0.5 μ m, more preferably is equal to or less than 0.2 μ m.

As for the material of stripper roll 24, can use various steel members, stainless steel, copper, zinc, brass, as its surface be lined with the plug of rubber these metal materials, be electroplate with Hcr, these metal materials of Cu or Ni, pottery and various composite.

On the direction of arrow of Fig. 1, rotate driving stripper roll 24 by the drive unit that does not show with predetermined peripheral speed.Can allow such structure, drive unit promptly is not provided in stripper roll 24, but drive unit preferably is provided, to obtain the satisfactory state at resin material 14 back sides.

Stripper roll 24 has temperature-adjusting device.Regulate stripper roll 24 to have the suitable satisfied shape that temperature can obtain coarse patterns on resin material 14 surfaces that is provided with.

In order to monitor the surface temperature of each point on roller and resin material 14, preferably provide surface temperature measurement device (not shown).As for such surface temperature measurement device, can use various known measurement mechanisms, as infrared thermometer or radiation thermometer.

As for point by the surface temperature measurement measurement device, a plurality of points have been considered between the die head 12 and first nip rolls 18 along resin material 14 width, the a plurality of points along resin material 14 width after stripper roll 24 are along the surface (with the roller opposite surfaces) of a plurality of points of the width of the resin material 14 of reeling around mould roller 16 or stripper roll 24.

The monitoring result of surface temperature measurement device can be fed back to the temperature-adjusting device of each roller or die head 12 etc., with the temperature control of reflection to each roller etc.Can allow under the situation that the surface temperature measurement device is not provided operation by FEEDFORWARD CONTROL.

On the resin plate production line 10 in Figure 10 or on its downstream, can preferably be provided for detecting the tension detecting apparatus of resin material 14 tension force, or be used to detect the thickness detection apparatus (thickness transducer) of resin material 14 thickness.The testing result that obtains by checkout gear can be compared with the value of setting, and feed back to the stretching control of describing after a while.

Provide slow cool down district 30 (or annealed zone), to prevent the unexpected temperature change of resin material 14 on the downstream of stripper roll 24.For example, when unexpected temperature change took place in resin material 14, resin material 14 was a plasticity near surface, and was flexible in inside, and by the contraction that the curing of inside causes the shape on resin material 14 surfaces was degenerated.Between the front and back of resin material 14, also produce temperature difference, cause the warpage in the resin material 14.

As for slow cool down district 30, structure that can the usage level tunnel-shaped, it has temperature-adjusting device in the tunnel, and can control the chilling temperature curve of resin material 14.As for temperature-adjusting device, can use various known devices, as blowing the structure of air (hot-air or cold air) to resin material 14, perhaps use the structure of heater (nichrome heater, infrared heater, dielectric heater etc.) heating resin material 14 front and backs with controlled temperature with a plurality of nozzles.

On the downstream of slow cool down district 30 (or annealed zone), provide cleaning device (clear area), defect test device (test section), laminater, side cutting machine, horizontal cutting machine and stacking portion in the following sequence.

Laminater is the device that is used for adhering protective film on resin material 14 front and backs (film of being made by polyethylene etc.); the side cutting machine is the device that is used for along the width cutting two ends (waste part) of resin material 14, and horizontal cutting machine is the device that is used for resin material 14 is trimmed to predetermined length.

In said apparatus, can omit some devices according to using.

Then, will the method that the resin plate production line 10 that use among Fig. 1 prepares resin plate be described.

Resin material 14 as for the present invention's employing, can use thermoplastic resin, comprise, for example, plexiglass (PMMA), polycarbonate resin, polystyrene resin, MS resin, AS resin, acrylic resin, polyvinyl resin, pet resin, polyvinyl chloride (PVC), thermoplastic elastomer (TPE), its copolymer, cyclic olefin polymer etc.

The tabular resin material 14 that a plurality of nip rolls (first nip rolls 18, second nip rolls 20 and the 3rd nip rolls 22) clamping of settling by mould roller 16 with in the face of mould roller 16 is extruded from die head 12, give resin material 14 with the 16 lip-deep rough form transfer printings of mould roller, and resin material 14 is reeled around the stripper roll 24 of settling in the face of mould roller 16, thereby peel off from mould roller 16.

The resin material of peeling off on the mould roller 16 14 is carried in the horizontal direction, by slow cool down district 30, thus cooling at leisure.Then, take out the resin material 14 that to have eliminated distortion in the portion downstream at product and cut into predetermined length, and encapsulate as the resin plate product.

In preparation during resin plate, the extruded velocity of resin material 14 from die head 12 can be 0.1 to 50m/min, and preferred 0.3 to 30m/min.Therefore, the peripheral speed of mould roller 16 is mated with extruded velocity basically.

On the other hand, by the method for operating driving nip rolls (first nip rolls 18, second nip rolls 20 and the 3rd nip rolls 22) of so-called stretching control, feasible order with nip rolls 18,20 and 22 improves speed gradually, with the peripheral speed faster than mould roller 16.Tension values between the nip rolls 18,20 and 22 is preferably 0 to 3%, and more preferably 0 to 1%.

The nonuniform speed of preferred each roller of control setting value 1% within.

The press pressure of each nip rolls (first nip rolls 18, second nip rolls 20 and the 3rd nip rolls 22) on mould roller 16 preferably equals 0 to 200kN/m (0 to 200kgf/cm), more preferably the line pressure of 0 to 100kN/m (0 to 100kgf/cm) (supposition is that line contacts and the value of conversion by the surface contact of each nip rolls that strain causes).

Preferred single control nip rolls 18,20 and 22 and the temperature of stripper roll 24.So, preferably be equal to or less than the softening point Ta of resin in the temperature of the resin material 14 at stripper roll 24 places.In this respect, when plexiglass is used as resin material 14, the design temperature of stripper roll 24 can be 50 to 110 ℃.

Then, the shape details of the lip-deep coarse patterns of resin material 14 will be described in.As mentioned above, Fig. 2 is the perspective view of the resin material 14 after the moulding, and wherein its end surfaces 14A is fallen by linear incision.The back side of resin material 14 is smooth.

Resin material 14 lip-deep coarse patterns shapes are linear coarse patterns on longitudinal direction (direction of arrow among the figure).This pattern is included in the alternately V-type groove 50 that forms among the thick 14B of resin material 14, and comprise tapering part 52 and 52, described tapering part 52 and 52 has from the both sides of each V-type groove 50 to the linear thickness that reduces of the thinnest part 14C of resin material 14.Particularly, pattern has continuous shape, and wherein V-type groove 50 and tapering part 52 and 52 are as a unit (interval) the center line line symmetry with respect to V-type groove 50.

Among Fig. 2, resin material 14 thickness of the thinnest part 14C preferably is equal to or less than 5mm, more preferably is equal to or less than 2mm.Thickness difference between resin material 14 thick 14B and the thinnest part 14C preferably is equal to or greater than 1mm, more preferably is equal to or greater than 2.5mm.The various optical elements that this size allows resin material 14 to be used as optical plate aptly or to settle at the back side of various display devices.

When the resin material after the moulding 14 is used as optical plate, in V-type groove 50, settle cylindrical cold-cathode tube, and the light of launching from cold-cathode tube incides the inside of resin material 14 from the surface of V-type groove 50, by tapering part 52 and 52 reflections, and use at resin material 14 back sides of slave plate shape.

Therefore, when the resin material after the moulding 14 was used as optical plate, the width p of V-type groove 50 preferably was equal to or greater than 2mm, and the vertical angle θ 1 of V-type groove 50 is preferably 40 to 80 degree.The depth delta t of V-type groove 50 preferably is equal to or greater than 1mm, more preferably is equal to or greater than 2.5mm. Tapering part 52 and 52 inclination angle [theta] 2 are preferably 3 to 20 degree.Tapering part 52 and 52 width p2 preferably are equal to or greater than 5mm, more preferably are equal to or greater than 10mm.

Then, will be described in resin material 14 lip-deep another kind of coarse patterns shapes.Fig. 3 is the perspective view of the resin material 14 after the moulding, and wherein its end surfaces 14A is fallen by linear incision.The back side of resin material 14 is smooth.

Resin material 14 lip-deep coarse patterns shapes are linear coarse patterns on longitudinal direction (direction of arrow among the figure).This pattern with saw-tooth profile comprise connect resin material 14 thick 14B and the thinnest part 14C alternately erect wall 54, and comprise tapering part 56, described tapering part 56 has top edge (thick 14B) from perpendicular wall 54 to the linear thickness that reduces of the thinnest part 14C of resin material 14.

Among Fig. 3, resin material 14 thickness of the thinnest part 14C preferably is equal to or less than 5mm, more preferably is equal to or less than 2mm.Thickness difference between resin material 14 thick 14B and the thinnest part 14C preferably is equal to or greater than 1mm, more preferably is equal to or greater than 2.5mm.The various optical elements that this size allows resin material 14 to be used as optical plate aptly or to settle at the back side of various display devices.

When the resin material after the moulding 14 is used as optical plate, on the side surface of perpendicular wall 54, settle cylindrical cold-cathode tube, and the light of launching from cold-cathode tube incides the inside of resin material 14 from the surface (side surface) of perpendicular wall 54, by tapering part 56 reflections, and use at resin material 14 back sides of slave plate shape.

Therefore, when the resin material after the moulding 14 was used as optical plate, the inclination angle of tapering part 56 was preferably 3 to 20 degree.

When the resin material after the moulding 14 is used as optical plate, can use other shape.For example, the V-type groove 50 in the resin material 14 among Fig. 2 has the V-type section, still, can use the section of other shape such as rectangle, trapezoidal, arc or parabola shaped section, and condition is that they satisfy optical property or mouldability.

Consider the surplus that resin material 14 shrinks, the lip-deep rough form of mould roller 16 needs not be the inverse shape of the resin material 14 in Fig. 2 or 3, and can depart from inverse shape, so that the shape of product of resin material 14 is shown in Fig. 2 or 3.

Then, another embodiment (second embodiment) of resin plate method produced according to the present invention will be described in detail.Fig. 4 be the resin plate production line 10 that adopts resin plate method produced according to the present invention ' structural map.To represent by identical reference number with identical or similar member in first embodiment among Fig. 1, and will the descriptions thereof are omitted.

In this embodiment, replace nip rolls (first nip rolls 18, second nip rolls 20 and the 3rd nip rolls 22) and stripper roll 24 in first embodiment, use clamping band 32, a plurality of pressure rollers 34,36,38 and 40 and deflector roll 42 and 44.

Resin plate production line 10 ' in, with resin plate production line 10 (first embodiment) in the relevant position of first nip rolls 18, second nip rolls 20, the 3rd nip rolls 22 and stripper roll 24, settle first pressure roller 34, second pressure roller 36, the 3rd pressure roller 38 and the 4th pressure roller 40, and they has substantially the same function.

But by clamping band 32 and mould roller 16 clamping resin materials 14 as the endless belt, this has increased the distance that resin material 14 is held, thereby helps the section shape that obtains suiting.

Preferably with the surface mirror mirror polish of clamping band 32.Such surface can obtain the satisfactory state at resin material 14 back sides after the moulding.The surface roughness of clamping band 32 (Ra) preferably is equal to or less than 0.5 μ m, more preferably is equal to or less than 0.2 μ m.

As for the material of clamping band 32, can use various steel members, stainless steel, surface be lined with rubber these metal materials, be electroplate with Hcr, these metal materials of Cu or Ni, pottery and various composite.

As mentioned above, pressure roller 34,36,38 and 40 have with first embodiment in the nip rolls identical functions, therefore the various structures of pressure roller can be identical with those of nip rolls in first embodiment, as have drive unit structure, have pressue device structure, have thermostatic structure, or prevent to cause crooked structure by pressure-responsive.

But, pressure roller 34,36,38 with 40 not with moulding after resin material 14 directly contact, so the surface finish state of pressure roller 34,36,38 and 40 can be than the surface finish state difference of the nip rolls in first embodiment.

Clamping band 32 is with at the uniform velocity mobile, this eliminated for first embodiment in the stretch needs of the corresponding structure of method of operating of control of what is called.If clamping band 32 is with at the uniform velocity mobile, not every pressure roller 34,36,38 and 40 and deflector roll 42 and 44 can have drive unit.

Deflector roll 42 and 44 requires to have and allows the function (drive unit) of clamping band 32 at the uniform velocity to carry, and have provide predetermined tension force to clamping band 32, with the function (tension-adjusting gear) that prevents to slide between clamping band 32 and pressure roller 34,36,38 and 40.

Tension-adjusting gear can have with first embodiment in each nip rolls in the pressue device identical construction that provides.Can provide tension-adjusting gear in one in deflector roll 42 and 44.

Resin plate production line 10 in Fig. 4 ' in, cooling device 45,46,47 and 48 provides as in the first embodiment, and has the temp regulating function of clamping band 32.Cooling device 45,46,47 and 48 can have with first embodiment in cooling device 26 and 28 identical construction.

Then, resin plate production line 10 among Fig. 4 ' the prepare method of resin plate will describe be used.

The tabular resin material 14 that clamping band 32 clampings of settling by mould roller 16 with in the face of mould roller 16 are extruded from die head 12 will be transferred on the resin material 14 in the rough form on the mould roller 16, and in the position of pressure roller 40, resin material 14 be peeled off from mould roller 16.

To carry in the horizontal direction from the resin material 14 that mould roller 16 is peeled off, by slow cool down district 30, thus cooling at leisure.Then, the resin material 14 that will eliminate distortion in product taking-up portion downstream cuts into predetermined length, and encapsulates as the resin plate product.

In preparation during resin plate, the extruded velocity of resin material 14 from die head 12 can be 0.1 to 50m/min, and preferred 0.3 to 30m/min.Therefore, the peripheral speed of mould roller 16 and clamping band 32 is mated with extruded velocity basically.

The press pressure of each pressure roller (first pressure roller 34, second pressure roller 36, the 3rd pressure roller 38 and the 4th pressure roller 40) on mould roller 16 preferably equals 0 to 200kN/m (0 to 200kgf/cm), more preferably the line pressure of 0 to 100kN/m (0 to 100kgf/cm) (supposition is that line contacts and the value of conversion by the surface contact of each nip rolls that strain causes).

Clamping band 32 tension force that produced by tension-adjusting gear (deflector roll 42 or 44) are 0.1 to 100kN/m (0.1 to 100kgf/cm) more preferably.

Then, will be with reference to the accompanying drawings, describe another embodiment (the 3rd embodiment) of resin plate method produced according to the present invention in detail.Fig. 5 is the structural map that adopts the resin plate production line of resin plate method produced according to the present invention.

Resin plate production line 100 comprises: a plurality of nip rolls (first nip rolls 18 and second nip rolls 20), cooling device 26 and the slow cool down district 30 that the plate that is used for the resin material 14 by the fusion of extruder (not shown) is shaped to plate is settled with the mould roller 16 that has rough form on die head 12, its surface, in the face of mould roller 16 (or annealed zone (correction zone of the warpage that is produced by one-sided heating etc.)).

Form the slit sizes of die head 12, make the width of molten resin material 14 of moulding greater than the width of mould roller 16, and settle die head 12, make and to extrude between the mould roller 16 and first nip rolls 18 from the molten resin material 14 that die head 12 is extruded.

Mould roller 16 has the rough form of rule in its surface.As shown in Figure 2, Gui Ze rough form can be resin material 14 inverse shape after for example moulding.

Particularly, the back side of resin material 14 is smooth, and forms the linear rough form that is parallel to arrow on the surface of resin material 14.Arrow is represented mobile (conveying) direction of resin material 14.Therefore, can be at the annular groove that is formed on the inverse shape on the end surfaces 14A on the surface of mould roller 16.In the details of resin material 14 lip-deep coarse patterns shapes as mentioned above.

Identical in the material of mould roller 16, the method that on mould roller 16 surfaces, forms coarse patterns, the surface roughness of mould roller 16, the rotatable driving of mould roller 16, the temperature-adjusting device of mould roller 16 etc. and first embodiment, and will the descriptions thereof are omitted.

Nip rolls is such roller, they settle in the face of mould roller 16 and with mould roller 16 collaborative clamping resin materials 14, and, settle with the order of first nip rolls 18 and second nip rolls 20 from the upstream side of moving direction.

Identical in nip rolls 18 and 20 surface state (surface roughness etc.), nip rolls 18 and 20 material, nip rolls 18 and 20 rotatable driving, nip rolls 18 and 20 pressue device, nip rolls 18 and 20 resistant to bending measures, nip rolls 18 and 20 temperature-adjusting device etc. and first embodiment, and will the descriptions thereof are omitted.

In the adjustment of nip rolls 18 and 20, the too low design temperature of first nip rolls 18 makes molten resin material 14 cool off suddenly, thereby does not preferably make resin material 14 distortion.The too high design temperature of second nip rolls 20 makes resin material 14 peel off from mould roller 16, and this does not preferably make the coarse patterns warpage after resin material 14 surfaces become freedom.

Design temperature for mould roller 16, first nip rolls 18 and second nip rolls 20, in the time of need be according to the material of resin material 14, resin material 14 fusings (for example, the shapes of the external diameter of the temperature slit outlet of die head 12), the transporting velocity of resin material 14, mould roller 16, the coarse patterns of mould roller 16 etc. are selected optimum value.

In addition, in the resin plate production line 100 in Fig. 5, provide cooling device 26, with the temperature-adjusting device of auxiliary first nip rolls 18 and second nip rolls 20.

Cooling device 26 is air nozzles.The air nozzle of cooling device 26 is placed between first nip rolls 18 and second nip rolls 20, on the back side (transfer surface opposite surfaces) with the resin material 14 that air is blown into conveying.Therefore, by roller 16,18 and 20 and cooling device 26, can control the temperature of resin material 14.

Temperature and quantity delivered (blowing flow) for cooling device 26 air, in the time of need be according to the material of resin material 14, resin material 14 fusings (for example, the shape of the external diameter of the temperature outlet of the slit of die head 12), the transporting velocity of resin material 14, mould roller 16, the coarse patterns of mould roller 16, nip rolls (first nip rolls 18 and second nip rolls 20) temperature etc. is set, select optimum value.

For monitor above-mentioned roller 16,18 and 20 and resin material 14 on the surface temperature of each point, surface temperature measurement device (not shown) preferably is provided.Surface temperature measurement device as for such can use various known devices, as infrared thermometer or radiation thermometer.

As for point by the surface temperature measurement measurement device, a plurality of points have been considered between the die head 12 and first nip rolls 18 along resin material 14 width, the a plurality of points along resin material 14 width after second nip rolls 20 are along the surface (with the roller opposite surfaces) of a plurality of points of the width of the resin material 14 of reeling around mould roller 16.

The monitoring result of surface temperature measurement device can be fed back to each roller 16,18 and 20 or the temperature-adjusting device of die head 12 etc., with the temperature control of reflection to each roller 16,18 and 20 etc.Can allow under the situation that the surface temperature measurement device is not provided operation by FEEDFORWARD CONTROL.

In the resin plate production line 100 in Fig. 5 or on its downstream, can preferably be provided for detecting the tension detecting apparatus of resin material 14 tension force, or be used to detect the thickness detection apparatus (thickness transducer) of resin material 14 thickness.The testing result that obtains by checkout gear can be compared with the value of setting, and feed back to the stretching control of foregoing description.

Provide slow cool down district 30 (or annealed zone), to prevent the unexpected temperature change of resin material 14 after peeling off from mould roller 16.

For example, when resin being reeled around roller and have in the structure of mould roller 16, first nip rolls 18 and second nip rolls 20 moulding, inside compressive residual stress that produces in resin plate and tensile stress are by partly or entirely surperficial heating is discharged (annealing), to proofread and correct warpage.

To identical in the description in the defective of the unexpected temperature change of resin material 14 and slow cool down district 30 and first embodiment, and will omit.

On the downstream of slow cool down district 30 (or annealed zone), provide the cleaning device (clear area), defect test device (test section), laminater, side cutting machine, horizontal cutting machine and the stacking portion that do not show in the following sequence.These the device with first embodiment in identical, and general the descriptions thereof are omitted.

Then, will the method that the resin plate production line 100 that use among Fig. 5 prepares resin plate be described.

Identical in the resin material 14 that the present invention adopts and first embodiment.

The tabular resin material 14 that two nip rolls (first nip rolls 18 and second nip rolls 20) clamping of settling by mould roller 16 with in the face of mould roller 16 is extruded from die head 12, and give resin material 14 with the 16 lip-deep rough form transfer printings of mould roller.Then, the tangent that the resin material after the transfer printing 14 is carried out mould roller 16 and nip rolls 20 stretches, thereby peels off from mould roller 16.Different with routine techniques is that resin material 14 is do not center on the stripper roll coiling when mould roller 16 is peeled off, and is therefore indeformable the process of peeling off from the rough form that mould roller 16 is transferred on the resin material 14.

Resin material 14 preferably is equal to or less than the softening point (Ta) of resin material 14 in the temperature of the pick-up point from mould roller 16.This be because, when by stretching resin material 14 tangentially and with resin material 14 when mould roller 16 is peeled off, resin material 14 after just having peeled off does not support in air, these are different with the resin material 14 that supported by stripper roll in the routine techniques, if and resin material 14 is soft at softening point (Ta) or higher maintenance, then resin material 14 itself may be sagging, thereby cause the rough form distortion of transfer printing.Describe the example of two nip rolls, but can allow a nip rolls, or three or more nip rolls.

Then, the resin material of peeling off from mould roller 16 14 slow cool down district 30 (or annealed zone) by slow cool down in, on the direction that tangent stretches, be transferred, that is, upwards carry in the upper right side among Fig. 5.Resin material 14 is by slow cool down district 30 (or annealed zone), thus by slow cool down.Then, the resin material 14 that will eliminate distortion in product taking-up portion downstream cuts into predetermined length, and encapsulates as the resin plate product.

Resin material 14 is cooled off when carrying on the tangent draw direction at leisure, thereby is cooled off at leisure when keeping flatness from the resin material 14 that mould roller 16 is peeled off, and can be fixed in the coarse patterns shape that keeps transfer printing.Therefore, even have the section shape that the resin material of big thickness distribution also can obtain suiting along the width when the moulding.

In preparation during resin plate, the extruded velocity of resin material 14 from die head 12 can be 0.1 to 50m/min, and preferred 0.3 to 30m/min.Therefore, the peripheral speed of mould roller 16 is mated with extruded velocity basically.

On the other hand, preferably the method for operating by so-called stretching control drives nip rolls (first nip rolls 18 and second nip rolls 20), and feasible order with nip rolls 18 and 20 improves speed gradually, with the peripheral speed faster than mould roller 16.Tension values between the nip rolls 18 and 20 is preferably 0 to 3%, and more preferably 0 to 1%.

Preferred each roller 16,18 of control and 20 nonuniform speed setting value 1% within.

The press pressure of each nip rolls (first nip rolls 18 and second nip rolls 20) on mould roller 16 preferably equals 0 to 200kN/m (0 to 200kgf/cm), more preferably the line pressure of 0 to 100kN/m (0 to 100kgf/cm) (supposition is that line contacts and the value of conversion by the surface contact of each nip rolls that strain causes).

The preferred temperature control that nip rolls 18 and 20 are set separately, the feasible temperature that can reduce roller with the order of first nip rolls 18 and second nip rolls 20.So as mentioned above, the temperature of the resin material 14 at the pick-up point place on mould roller 16 preferably is equal to or less than the softening point (Ta) of resin.For example, when plexiglass is used as resin material 14, the temperature of resin material 14 at the pick-up point place is preferably 50 to 110 ℃.

Then, with another embodiment (the 4th embodiment) of describing according to resin plate preparation method of the present invention.Fig. 6 is the structural map that adopts the resin plate production line 110 of resin plate method produced according to the present invention.To represent by identical reference number with identical or similar member in the 3rd embodiment among Fig. 5, and will the descriptions thereof are omitted.

In the 4th embodiment, replace the nip rolls (first nip rolls 18 and second nip rolls 20) in the 3rd embodiment, use clamping band 32 and a plurality of pressure roller 34,37 and 39.

Resin plate production line 110, the first pressure rollers 34 and second pressure roller 37 be positioned in resin plate production line 100 (the 3rd embodiment) in first nip rolls 18 and second nip rolls, 20 corresponding positions, and have substantially the same function.Ring gripping band 32 is around first pressure roller 34 and second pressure roller 37, and the 3rd pressure roller 39 coilings of facing 16 arrangements of mould roller across the clamping band between roller 34 and 37 32.Therefore, by clamping band 32 and mould roller 16 clamping resin materials 14 as the endless belt, this has increased the distance that resin material 14 is held, thereby helps the section shape that obtains suiting.

Identical in the material of the surface state of clamping band 32 (surface roughness etc.), clamping band 32 etc. and second embodiment, and will the descriptions thereof are omitted.

As mentioned above, pressure roller 34,37 and 39 have with the 3rd embodiment in the nip rolls identical functions, therefore the various structures of pressure roller can be identical with those of nip rolls in the 3rd embodiment, as have drive unit structure, have pressue device structure, have thermostatic structure, or prevent to cause crooked structure by pressure-responsive.

But, pressure roller 34,37 with 39 not with moulding after resin material 14 directly contact, so the surface finish state of pressure roller 34,37 and 39 can be than the surface finish state difference of the nip rolls in the 3rd embodiment.

Clamping band 32 is with at the uniform velocity mobile, this eliminated for the 3rd embodiment in the stretch needs of the corresponding structure of method of operating of control of what is called.If clamping band 32 is with at the uniform velocity mobile, not every pressure roller 34,37 and 39 can have drive unit.

First pressure roller 34 and second pressure roller 37 require to have and allow the function (drive unit) of clamping band 32 at the uniform velocity to carry, and have provide predetermined tension force to clamping band 32, with the function (tension-adjusting gear) that prevents between clamping band 32 and pressure roller 34,37 and 39 to slide.Tension-adjusting gear can have with the 3rd embodiment in each nip rolls in the pressue device identical construction that provides.

In the resin plate production line 110 among Fig. 6, cooling device 26 is as providing in the 3rd embodiment, and has the temp regulating function of clamping band 32.Cooling device 26 can have with the 3rd embodiment in cooling device 26 and 28 identical construction.Among Fig. 6, only show a cooling device 26, still, can provide a plurality of cooling devices.Therefore, clamping band 32 itself is cooled, thereby increased the distance of from its back side (surface of the surface opposite that contacts with the mould roller) cooling resin material 14, be equal to or less than softening point (Ta) thereby help the temperature of resin material 14 at pick-up point P place be reduced to.

Then, will the method that the resin plate production line 110 that use among Fig. 6 prepares resin plate be described.

The tabular resin material 14 that clamping band 32 clampings of settling by mould roller 16 with in the face of mould roller 16 are extruded from die head 12 will be transferred on the resin material 14 in the rough form on the mould roller 16.Then, the tangent that the resin material after the transfer printing 14 is carried out the mould roller and be positioned at the pressure roller 37 of downstream position in a plurality of pressure rollers 34,37 and 39 stretches, thereby peels off from mould roller 16.

Then, the resin material of peeling off from mould roller 16 14 slow cool down district 30 (or annealed zone) by slow cool down in, on the direction that tangent stretches, be transferred, that is, upwards carry in the upper right side among Fig. 6.Resin material 14 is by slow cool down district 30 (or annealed zone), thus by slow cool down.Then, the resin material 14 that will eliminate distortion in product taking-up portion downstream cuts into predetermined length, and encapsulates as the resin plate product.Therefore, even have the section shape that the resin material of big thickness distribution also can obtain suiting along the width when the moulding.

In preparation during resin plate, the extruded velocity of resin material 14 from die head 12 can be 0.1 to 50m/min, and preferred 0.3 to 30m/min.Therefore, the peripheral speed of mould roller 16 and clamping band 32 is mated with extruded velocity basically.

The press pressure of each nip rolls (first pressure roller 34, second pressure roller 37 and the 3rd pressure roller 39) on mould roller 16 preferably equals 0 to 200kN/m (0 to 200kgf/cm), more preferably the line pressure of 0 to 100kN/m (0 to 100kgf/cm) (supposition is that line contacts and the value of conversion by the surface contact of each nip rolls that strain causes).The tension force of the clamping band 32 that is produced by tension-adjusting gear (deflector roll 42 or 44) is 0.1 to 100kN/m (0.1 to 100kgf/cm) more preferably.

Then, with another embodiment (the 5th embodiment) of describing in detail according to resin plate preparation method of the present invention.Fig. 7 is the structural map that adopts the resin plate production line 120 of resin plate method produced according to the present invention.To represent by identical reference number with identical or similar member in third and fourth embodiment in Fig. 5 and 6, and will the descriptions thereof are omitted.

Resin plate production line 120 in the 5th embodiment comprises: the plate that is used for the resin material 14 by the fusion of extruder (not shown) is shaped to plate is with die head 12, have the mould roller 16 of rough form, first nip rolls of settling in the face of mould roller 16 18, stripper roll 62, cooling device 26 and slow cool down district 30 (or annealed zone) in its surface.Among Fig. 7, show one first nip rolls 18, but a plurality of nip rolls can be provided.

Stripper roll 62 has the 500mm of being equal to or greater than, and preferably is equal to or greater than the major diameter of 1000mm, and this major diameter is the twice of mould roller 16 diameters or more times, preferred four times or more times.

Identical in the rotatable driving of the surface roughness of the material of stripper roll 62, stripper roll 62, stripper roll 62 etc. and first embodiment, and will the descriptions thereof are omitted.

Stripper roll 62 has temperature-adjusting device.Such temperature-adjusting device is provided, raises or its unexpected temperature reduces with control or the temperature that prevents the stripper roll 62 that causes by hot resin material 14.

As for such temperature-adjusting device, preferably using circulates in roller has the structure of the oil of regulating temperature.Have the structure that rotates the abutment by end, can realize the supply and the discharge of oil at roller.As for other temperature-adjusting device, can use various known devices, as have the structure of the double pipe heater in stripper roll of being incorporated into 62, or near the structure of the dielectric heater that provides stripper roll 62 is provided.

Then, will the method that the resin plate production line 120 that use among Fig. 7 prepares resin plate be described.

The tabular resin material 14 that first nip rolls, 18 clampings of settling by mould roller 16 with in the face of mould roller 16 are extruded from die head 12, and give resin material 14 with the 16 lip-deep rough form transfer printings of mould roller.Then, resin material after the transfer printing 14 is reeled around stripper roll 62, thereby peel off from mould roller 16, described stripper roll 62 is to settle in the face of mould roller 16, and have the major diameter that is equal to or greater than 500mm, this major diameter is the twice of mould roller 16 diameters or more times.

Use has large diameter stripper roll 62 and allows as in third and fourth embodiment resin material 14 being carried out tangentially stretching basically of mould roller 16.Therefore, even in the stripping process when using stripper roll 62, the rough form that is transferred on the resin material 14 is also indeformable.

Particularly, in the 5th embodiment, resin material 14 is reeled around the stripper roll 62 with larger radius of curvature, thereby prevents the rough form distortion of transfer printing.In the 5th embodiment, the resin material of peeling off 14 is supported by stripper roll 62, and also by stripper roll 62 coolings, with cooling and sclerosis rough form, this has eliminated for the needs that are used for the temperature at the resin material 14 at pick-up point P place is reduced to the high control accuracy that is equal to or less than softening point.

Then, the resin material 14 that will peel off from mould roller 62 be carried in the direction that tangent stretches, and in slow cool down district 30 (or annealed zone) slow cool down.Resin material 14 is by slow cool down district 30 (or annealed zone), thus by slow cool down.Then, the resin material 14 that will eliminate distortion in product taking-up portion downstream cuts into predetermined length, and encapsulates as the resin plate product.Therefore, even have the section shape that the resin material of big thickness distribution also can obtain suiting along the width when the moulding.

In preparation during resin plate, the extruded velocity of resin material 14 from die head 12 can be 0.1 to 50m/min, and preferred 0.3 to 30m/min.Therefore, the peripheral speed of mould roller 16 is mated with extruded velocity basically.

The press pressure of first nip rolls 18 on mould roller 16 preferably equals 0 to 200kN/m (0 to 200kgf/cm), more preferably the line pressure of 0 to 100kN/m (0 to 100kgf/cm) (supposition is that line contacts and the value of conversion by the surface contact of each nip rolls that strain causes).

Then, with another embodiment (the 6th embodiment) that is described in detail with reference to the attached drawings according to resin plate preparation method of the present invention.Fig. 8 is the structural map that adopts the resin plate production line of resin plate method produced according to the present invention.

Resin plate production line 130 comprises: the plate die head 12 that is used for the resin material 14 by the fusion of extruder (not shown) is shaped to plate; The first mould roller 16 that has rough form in its surface; First nip rolls 18 in the face of 16 arrangements of the first mould roller; Stripper roll 24 in the face of 16 arrangements of the first mould roller; The second mould roller 76 in the arranged downstream of the upside of resin material 14, stripper roll 24; Settle second nip rolls 77 of (downside at resin material 14 is settled) in the face of the second mould roller 76 across resin material 14; The 3rd mould roller of settling at the upside of downstream resin material 14 again 78; Settle the 3rd nip rolls 79 of (downside at resin material 14 is settled) in the face of the 3rd mould roller 78 across resin material 14; The 4th mould roller of settling at the upside of downstream resin material 14 again 80; Settle the 4th nip rolls 81 of (downside at resin material 14 is settled) in the face of the 4th mould roller 80 across resin material 14; The 5th mould roller of settling at the upside of downstream resin material 14 again 82; And the 5th nip rolls 83 of settling (downside at resin material 14 is settled) across resin material 14 in the face of the 5th mould roller 82.

Form the slit sizes of die head 12, make the width of molten resin material 14 of moulding greater than the width of the first mould roller 16, and settle die head 12, make and to extrude between the first mould roller 16 and first nip rolls 18 from the molten resin material 14 that die head 12 is extruded.

Each mould roller (the first mould roller, 16 to the 5th mould rollers 82) has the rough form of rule in its surface.As shown in Figure 2, Gui Ze rough form can be resin material 14 inverse shape after for example moulding.

Particularly, the back side of resin material 14 is smooth, and forms the linear rough form that is parallel to arrow on the surface of resin material 14.Arrow is represented mobile (conveying) direction of resin material 14.Therefore, can be at the annular groove that is formed on the inverse shape on the end surfaces 14A on the surface of mould roller 16.In the details of resin material 14 lip-deep coarse patterns shapes as mentioned above.

But even adopt this annular groove that forms in the first mould roller 16 (the mould roller of upstream-most position), resin material 14 also is difficult to follow described shape usually, and can resin material 14 be formed design shape by the mould roller in downstream.Therefore, can provide many group mould rollers, so that the rough form that is transferred to resin material 14 is little by little near design shape.

Fig. 9 A to 9E is the profile of the resin material 14 in the corresponding shaping step.Fig. 9 A is depicted as the section that just goes out die head 12 resin material 14 afterwards.Middle Fig. 9 B, 9C and 9D are depicted as and make resin material 14 little by little near the section of the process of design shape.

Therefore, can on each mould roller surface, form the annular groove of the inverse shape of this shape.The section of the dotted line among Fig. 9 A to 9D (broken folding-double dotted line) expression product design shape.

Identical in the material of each mould roller, the method that on each mould roller, forms coarse patterns, the surface roughness of each mould roller, the rotatable driving of each mould roller, the temperature-adjusting device of each mould roller etc. and first embodiment, and will the descriptions thereof are omitted.

Nip rolls (first nip rolls, 18 to the 5th nip rolls 83) is such roller, and it is settled in the face of mould roller (the first mould roller, 16 to the 5th mould rollers 82), and works in coordination with clamping resin material 14 with the mould roller.

Stripper roll 24 is such rollers, it is placed in the face of the first mould roller 16, with the first mould roller, 16 collaborative clamping resin materials 14, by around stripper roll 24 coiling resin materials 14 and resin material 14 is peeled off from the first mould roller 16, and be placed in across the first mould roller 16 and locate for 180 ° away from the downstream of first nip rolls 18.

Preferably with the surface mirror mirror polish of nip rolls and stripper roll 24.This surface can make the state at resin material 14 back sides after the moulding satisfactory.The surface roughness of nip rolls and stripper roll 24 (Ra) preferably is equal to or less than 0.5 μ m, more preferably is equal to or less than 0.2 μ m.

As for the material of nip rolls and stripper roll 24, can use various steel members, stainless steel, copper, zinc, brass, as its surface be lined with the plug of rubber these metal materials, be electroplate with Hcr, these metal materials of Cu or Ni, pottery and various composite.

On the direction of arrow of Fig. 8, rotate driving nip rolls and stripper roll 24 by the drive unit that does not show with predetermined peripheral speed.Can allow such structure, making does not provide drive unit in each nip rolls, but in order to obtain the satisfactory state at resin material 14 back sides, preferably provides drive unit.

When in each mould roller and each nip rolls, providing drive unit, the preferred structure that uses with variable drive speed.Can use such method of operating: with the second mould roller 76 and second nip rolls 77, the 3rd mould roller 78 and the 3rd nip rolls 79, the 4th mould roller 80 and the 4th nip rolls 81, and the order of the 5th mould roller 82 and the 5th nip rolls 83, little by little improve speed (at the most within several percentages), thereby faster than the peripheral speed of the first mould roller 16.

Nip rolls and stripper roll 24 have the pressue device that does not show separately, thereby can enough predetermined pressure clamping resin material 14 between mould roller and nip rolls and stripper roll 24.Pressue device has the structure of exerting pressure on the direction perpendicular to the contact point between mould roller and nip rolls and the stripper roll 24, and can use various known devices, as motor driver, pneumatic cylinder or hydraulic cylinder.

Identical in each nip rolls in the structure of the bending that preventing of providing in each nip rolls and stripper roll 24 caused by the response plus-pressure and first embodiment.

Nip rolls and stripper roll 24 have temperature-adjusting device separately.Individually control temperature-adjusting device, thus can be with stripper roll 24, the second mould roller 76 and second nip rolls 77, the 3rd mould roller 78 and the 3rd nip rolls 79, the 4th mould roller 80 and the 4th nip rolls 81, and the order of the 5th mould roller 82 and the 5th nip rolls 83 reduces the roller temperature.This can make the shape of resin material 14 lip-deep coarse patterns satisfactory.

The too low design temperature of first nip rolls 18 cools off molten resin material 14 suddenly, thereby does not preferably cause resin material 14 distortion.The too high design temperature of the 5th nip rolls 83 makes resin material 14 peel off from the 5th mould roller 82, and this does not preferably make the warpage of coarse patterns after the surperficial freedom of resin material 14.

The design temperature that stripper roll 24 is too low has increased the viscosity of resin material 14, thereby does not preferably stop resin material 14 to be reeled around stripper roll 24.

Design temperature for mould roller, stripper roll 24 and nip rolls, in the time of need be according to the material of resin material 14, resin material 14 fusings (for example, the slit outlet of die head 12) temperature, the transporting velocity of resin material 14, the external diameter of the first mould roller 16, the coarse patterns shape of the first mould roller 16 etc. are selected optimum value.

In order to monitor the surface temperature of each point on roller and the resin material 14, preferably provide surface temperature measurement device (not shown).As for such surface temperature measurement device, can use various known measurement mechanisms, as infrared thermometer and radiation thermometer.

As for point by the surface temperature measurement measurement device, a plurality of points have been considered between the die head 12 and first nip rolls 18 along resin material 14 width, the a plurality of points along resin material 14 width after stripper roll 24 are along the surface (with the roller opposite surfaces) of a plurality of points of the width of the resin material 14 of reeling around the first mould roller 16 or stripper roll 24.

The monitoring result of surface temperature measurement device can be fed back to the temperature-adjusting device of each roller or die head 12 etc., with the temperature control of reflection to each roller etc.Can allow under the situation that the surface temperature measurement device is not provided operation by FEEDFORWARD CONTROL.

In the resin plate production line 130 in Fig. 8 or on its downstream, can preferably be provided for detecting the tension detecting apparatus of resin material 14 tension force, or be used to detect the thickness detection apparatus (thickness transducer) of resin material 14 thickness.The testing result that obtains by checkout gear can be compared with the value of setting, and feed back to the stretching control of describing after a while.

In the resin plate production line 130 in Fig. 8, can provide cooling device.For example, air nozzle is provided, be blown into each nip rolls with the air that will have controlled temperature and controlled quatity, temperature control with auxiliary each nip rolls, air nozzle perhaps is provided, with the air that will have controlled temperature and controlled quatity from being blown into the back side of resin material 14 between the nip rolls, and the temperature of assisted resin material 14 control.

When such cooling device is provided, amount of supplied air (blowing flow) for cooling device, in the time of need be according to the material of resin material 14, resin material 14 fusings (for example, the slit outlet of die head 12) temperature, the transporting velocity of resin material 14, the external diameter of the first mould roller 16, the coarse patterns shape of the first mould roller 16, the design temperature of nip rolls etc. are selected optimum value.

On the downstream of production line 130, can provide slow cool down district 30 (or annealed zone (correction zone of the warpage that causes by one-sided heating)).Provide such slow cool down district, to prevent the unexpected temperature change of resin material 14 in resin plate production line 130 downstreams.

For example, when resin is reeled around roller, and in the structure with the first mould roller 16, first nip rolls 18 and stripper roll 24 during moulding, inside compressive residual stress that produces in resin material 14 and tensile stress discharge (annealing) by part or all of surface heating, with the correction warpage.

For example, when unexpected temperature change took place in resin material 14, resin material 14 was a plasticity near surface, and was flexible in inside, and by the contraction that the curing of inside causes the shape on resin material 14 surfaces was degenerated.Between the front and back of resin material 14, also produce temperature difference, cause the warpage in the resin material 14.

Identical in cleaning device (clear area), defect test device (test section), laminater, side cutting machine, horizontal cutting machine and the stacking portion that slow cool down district (or annealed zone), resin plate production line 130 downstreams (downstream in slow cool down district) in Fig. 8 provide and first embodiment, and will the descriptions thereof are omitted.

Then, will the method that the resin plate production line 130 that use among Fig. 8 prepares resin plate be described.

The resin material 14 that the present invention adopts can be with first embodiment in identical thermoplastic resin.To omit its detailed description.

The tabular resin material 14 that first nip rolls, 18 clampings of settling by the first mould roller 16 with in the face of the first mould roller 16 are extruded from die head 12, to be transferred on the resin material 14 in the first mould roller, 16 lip-deep rough form, and resin material 14 is reeled around the stripper roll 24 of settling in the face of the first mould roller 16, thereby peel off from the first mould roller 16.Before peeling off,, and will be transferred on the resin material 14 in the first mould roller, 16 lip-deep rough form also by the first mould roller 16 and stripper roll 24 clamping resin materials 14.

To carry in the horizontal direction from the resin material 14 that the first mould roller 16 is peeled off, second nip rolls, 77 clampings of settling by the second mould roller 76 with in the face of the second mould roller 76 then, and will be transferred on the resin material 14 in the second mould roller, 76 lip-deep rough form.Then, the 3rd nip rolls 79 clamping resin materials of settling by the 3rd mould roller 78 with in the face of the 3rd mould roller 78 14, and will be transferred on the resin material 14 in the 3rd mould roller 78 lip-deep rough form.Then, the 4th nip rolls 81 clamping resin materials of settling by the 4th mould roller 80 with in the face of the 4th mould roller 80 14, and will be transferred on the resin material 14 in the 4th mould roller 80 lip-deep rough form.Then, the 5th nip rolls 83 clamping resin materials of settling by the 5th mould roller 82 with in the face of the 5th mould roller 82 14, and will be transferred on the resin material 14 in the 5th mould roller 82 lip-deep rough form.

Then, resin material 14 is by slow cool down district (or annealed zone), thus cooling at leisure as required, and take out the resin material 14 that portion downstream will eliminate distortion at product and cut into predetermined length, and encapsulate as the resin plate product.

In preparation during resin plate, the extruded velocity of resin material 14 from die head 12 can be 0.1 to 50m/min, and preferred 0.3 to 30m/min.Therefore, the peripheral speed of the first mould roller 16 is mated with extruded velocity basically.

On the other hand, method of operating driving mould roller (the second mould roller 76, the 3rd mould roller 78, the 4th mould roller 80 and the 5th mould roller 82) and nip rolls (second nip rolls 77, the 3rd nip rolls 79, the 4th nip rolls 81 and the 5th nip rolls 83) in succession by so-called stretching control, make with second, third, the order of the 4th and the 5th roller improves speed gradually, with the peripheral speed faster than the first mould roller 16.Tension values between each mould roller and each nip rolls is preferably 0 to 3%, and more preferably 0 to 1%.

The nonuniform speed of preferred each roller of control setting value 1% within.

Each nip rolls (first nip rolls, 18 to the 5th nip rolls 83) and stripper roll 24 press pressure on each mould roller (the first mould roller, 16 to the 5th mould rollers 82) preferably equals 0 to 200kN/m (0 to 200kgf/cm), more preferably the line pressure of 0 to 100kN/m (0 to 100kgf/cm) (supposition is that line contacts and the value of conversion by the surface contact of each nip rolls that strain causes).

For resin material 14 products that obtain predetermined thickness, except the suitable control of the press pressure of each nip rolls, can preferably use the suitable control in space between each nip rolls (first nip rolls, 18 to the 5th nip rolls 83) and stripper roll 24 and each mould roller (the first mould roller, 16 to the 5th mould rollers 82).

Preferably individually set the temperature control of nip rolls (first nip rolls, 18 to the 5th nip rolls 83) and stripper roll 24, thereby can reduce the roller temperature with the order of stripper roll 24, second nip rolls 77, the 3rd nip rolls 79, the 4th nip rolls 81 and the 5th nip rolls 83.

So the temperature of resin material 14 at the 5th nip rolls 83 places preferably is equal to or less than the softening point (Ta) of resin.When polymethyl methacrylate resin was used as resin material 14, the design temperature of the 5th nip rolls 83 can be 50 to 110 ℃.

Then, will another embodiment (the 7th embodiment) of resin plate method produced according to the present invention be described.Figure 10 is the structural map that adopts the resin plate production line 140 of resin plate method produced according to the present invention.To represent by identical reference number with identical or similar member in the 6th embodiment among Fig. 8, and will the descriptions thereof are omitted.

In this embodiment, replace nip rolls (first nip rolls 18 and the 5th nip rolls 83) and stripper roll 24 in the 6th embodiment, use back side mould roller (first back side mould roller, 35 to the 5th back side mould rollers 93) and stripper roll 24 '.Identical in positive face mould roller (first positive face mould roller 16 to the 5th positive face mould rollers 82) and the 6th embodiment, and corresponding to the first mould roller, 16 to the 5th mould rollers 82 in the 6th embodiment.

In resin plate production line 140,, on the surface of resin plate 14, form the coarse patterns shape by positive face mould roller (first positive face mould roller 16 to the 5th positive face mould rollers 82) as the 6th embodiment.Be with the different of the 6th embodiment, also on the back side of resin plate 14, form the coarse patterns shape.

As mentioned above, nip rolls and stripper roll 24 identical functions in back side mould roller (first back side mould roller, 35 to the 5th back side mould rollers 93) and stripper roll 24 ' have and the 6th embodiment, therefore the various structures of roller can be identical with those of nip rolls in the 6th embodiment, polishing condition as the surface, structure with drive unit, structure with pressue device has thermostatic structure, or prevents the structure of the bending that response pressure causes.

But, overleaf mould roller (first back side mould roller, 35 to the 5th back side mould rollers 93) and stripper roll 24 ' the surface on form the coarse patterns shape, thereby in the structure that prevents the bending that response pressure causes, be difficult to adopt structure that provides the pad roller on the rear side (side opposite) at roller and the structure that makes the crown shape of apparatus with each mould roller.

In the resin plate production line 140 in Figure 10,, can provide cooling device or slow cool down district (or annealed zone) as needed in the 6th embodiment, and its structure with the 6th embodiment in identical.

Then, will the method that the resin plate production line 140 that use among Figure 10 prepares resin plate be described.

The tabular resin material 14 that first back side mould roller 35 clampings of settling by the first mould roller 16 with in the face of the first mould roller 16 are extruded from die head 12, to be transferred on the resin material 14 at the first mould roller 16 and first back side mould roller, 35 lip-deep rough form, and resin material 14 is centered on stripper roll 24 ' coiling, thereby peel off from the first mould roller 16.

To carry in the horizontal direction from the resin material 14 that the first mould roller 16 is peeled off, then in succession by mould roller (the second mould roller, 76 to the 5th mould rollers 82) and back side mould roller (second back side mould roller, 87 to the 5th back side mould rollers 93) clamping, and will give on the front and back of resin material 14 at mould roller (the second mould roller, 76 to the 5th mould rollers 82) and the lip-deep rough form transfer printing of back side mould roller (second back side mould roller, 87 to the 5th back side mould rollers 93).Then, resin material 14 is by slow cool down district (or annealed zone), thus cooling at leisure as required, and take out the resin material 14 that portion downstream will eliminate distortion at product and cut into predetermined length, and encapsulate as the resin plate product.

In preparation during resin plate, the extruded velocity of resin material 14 from die head 12 can be 0.1 to 50m/min, and preferred 0.3 to 30m/min.Therefore, the peripheral speed of the first mould roller 16 and first back side mould roller 35 is mated with extruded velocity basically.

The press pressure of each back side mould roller (first back side mould roller, 35 to the 5th back side mould rollers 93) and stripper roll 24 ' on each mould roller (the first mould roller, 16 to the 5th mould rollers 82) preferably equals 0 to 200kN/m (0 to 200kgf/cm), more preferably the line pressure of 0 to 100kN/m (0 to 100kgf/cm) (the surface contact of each nip rolls that supposition is caused by strain be line contact and the value of conversion).

For resin material 14 products that obtain predetermined thickness, except each back side mould roller (first back side mould roller, 35 to the 5th back side mould rollers 93) and stripper roll 24 ' the suitable control of press pressure, can preferably use each back side mould roller (first back side mould roller, 35 to the 5th back side mould rollers 93) and stripper roll 24 ' and each mould roller (the first mould roller, 16 to the 5th mould rollers 82) between the suitable control in space.

Preferably individually control back side mould roller (first back side mould roller, 35 to the 5th back side mould rollers 93) and stripper roll 24 ' temperature control, make can with stripper roll 24 ', the order of second back side mould roller 87, the 3rd back side mould roller 89, the 4th back side mould roller 91 and the 5th back side mould roller 93 reduces the roller temperature.

So the temperature of resin material 14 at mould roller 93 places, the 5th back side preferably is equal to or less than the softening point Ta of resin.When polymethyl methacrylate resin was used as resin material 14, the design temperature of the 5th back side mould roller 93 can be 50 to 110 ℃.

According to the 7th embodiment of using resin plate production line 140, can on the front and back of resin material 14, form predetermined coarse patterns.The coarse patterns that goes up overleaf comprises: disclosed fine pattern, prism shape (its spacing is 10 to 200 μ m, and vertical angle is 45 to 100 °), biconvex lens, Fresnel lens, particle embossing (light is diffusion patterned) etc. in Japanese Patent Application Publication 7-314567.

When the resin material after the moulding 14 is used as the photosphere plate, can preferably adopt production line 140.

For example, during PMMA after the roller moulding is extruded, if provide thickness distribution along width, and shown in Fig. 2 and 3, thickness difference between thick and the thinnest part is big, according to the machining condition, often produces so-called shrinkage hole in overleaf by contraction in the solidification process of resin.

Particularly, at the thickness portion of resin material 14, cooling velocity there are differences between the surface of resin material 14 and inside.So, in resin material 14 corresponding surface portions, produce recess in the internal contraction of solidifying after the delay.

For example, when the moulding biconvex lens, often provide and the corresponding narrow recessed groove of curved surface in overleaf.

On the other hand, overleaf mould roller (first back side mould roller, 35 to the 5th back side mould rollers 93) and stripper roll 24 ' the surface on form coarse inverse shape, thereby the back side of resin material 14 becomes smooth having under the situation of shrinkage hole.Adopt this method, the benefit of this embodiment can be provided for biconvex lens or the resin material 14 with design shape, make the back side become smooth as in Fig. 2 and 3.

Then, will another embodiment (the 8th embodiment) of resin plate method produced according to the present invention be described.Figure 11 is the structural map that adopts the resin plate production line 150 of resin plate method produced according to the present invention.To represent by identical reference number with identical or similar member in the 6th embodiment among Fig. 8, and will the descriptions thereof are omitted.

In this embodiment, replace the first mould roller 16 in the 6th embodiment, adopt mirror finish roller 17.Identical in other structure and the 6th embodiment, and only be the title difference of roller.Particularly, only to be title different with in the 6th embodiment those for mirror finish roller 17 (corresponding to the first mirror finish roller in claims), the first mould roller 76, the second mould roller 78, the 3rd mould roller 80 and the 4th mould roller 82.First nip rolls 18 is corresponding to the second mirror finish roller in claims.

In resin plate production line 150, as in the sixth embodiment, on the surface of resin plate 14, form the coarse patterns shape by mould roller (the first mould roller, 76 to the 4th mould rollers 82).Is with the different of the 6th embodiment, on the surface of resin plate 14, do not form the coarse patterns shape, and resin plate 14 is smooth, up to resin material 14 by stripper roll 24.

Mirror finish roller 17 only is with first the different of mould roller 16 in the 6th embodiment, does not form the coarse patterns shape from the teeth outwards, therefore will omit the description that mirror finish roller 17 is constructed.The surface of mirror finish roller 17 can be with first nip rolls 18 in the 6th embodiment surperficial identical, and the surface roughness of mirror finish roller 17 (Ra) preferably is equal to or less than 0.5 μ m, more preferably is equal to or less than 0.2 μ m.

Then, will method that use resin plate production line 150 to prepare resin plate be described.

The tabular resin material 14 that first nip rolls, 18 clampings of settling by mirror finish roller 17 with in the face of mirror finish roller 17 are extruded from die head 12, resin material 14 is shaped to flat board with predetermined thickness, and resin material 14 is reeled around the stripper roll 24 of settling in the face of mirror finish roller 17, thereby peel off from mirror finish roller 17.Before peeling off, also by mirror finish roller 17 and stripper roll 24 clamping resin materials 14, so that resin material 14 is rolled into preset thickness.

To carry in the horizontal direction from the resin material 14 that mirror finish roller 17 is peeled off, second nip rolls, 77 clampings of settling by the first mould roller 76 with in the face of the first mould roller 76 then, and will be transferred on the resin material 14 in the first mould roller, 76 lip-deep rough form.Then, the 3rd nip rolls 79 clamping resin materials of settling by the second mould roller 78 with in the face of the second mould roller 78 14, and will be transferred on the resin material 14 in the second mould roller, 78 lip-deep rough form.Then, the 4th nip rolls 81 clamping resin materials of settling by the 3rd mould roller 80 with in the face of the 3rd mould roller 80 14, and will be transferred on the resin material 14 in the 3rd mould roller 80 lip-deep rough form.Then, the 5th nip rolls 83 clamping resin materials of settling by the 4th mould roller 82 with in the face of the 4th mould roller 82 14, and will be transferred on the resin material 14 in the 4th mould roller 82 lip-deep rough form.

Then, resin material 14 is by slow cool down district (or annealed zone), thus cooling at leisure as required, and take out the resin material 14 that portion downstream will eliminate distortion at product and cut into predetermined length, and encapsulate as the resin plate product.

In preparation during resin plate, the extruded velocity of resin material 14 from die head 12 can be 0.1 to 50m/min, and preferred 0.3 to 30m/min.Therefore, the peripheral speed of the first mould roller 16 is mated with extruded velocity basically.

On the other hand, method of operating driving mould roller (the first mould roller 76, the second mould roller 78, the 3rd mould roller 80 and the 4th mould roller 82) and nip rolls (second nip rolls 77, the 3rd nip rolls 79, the 4th nip rolls 81 and the 5th nip rolls 83) in succession by so-called stretching control, feasible order with the first, second, third and the 4th roller improves speed gradually, with the peripheral speed faster than mirror finish roller 17.Tension values between each mould roller and each nip rolls is preferably 0 to 3%, and more preferably 0 to 1%.

Each nip rolls (first nip rolls, 18 to the 5th nip rolls 83) and stripper roll 24 press pressure on mirror finish roller 17 and each mould roller (the first mould roller, 76 to the 4th mould rollers 82) preferably equals 0 to 200kN/m (0 to 200kgf/cm), more preferably the line pressure of 0 to 100kN/m (0 to 100kgf/cm) (supposition is that line contacts and the value of conversion by the surface contact of each nip rolls that strain causes).

For resin material 14 products that obtain predetermined thickness, except the suitable control of the press pressure of each nip rolls, can preferably use the suitable control in space between each nip rolls (first nip rolls, 18 to the 5th nip rolls 83), stripper roll 24, mirror finish roller 17 and each mould roller (the first mould roller, 76 to the 4th mould rollers 82).

The temperature control of preferred control nip rolls (first nip rolls, 18 to the 5th nip rolls 83) separately and stripper roll 24, thus can reduce the roller temperature with the order of stripper roll 24, the second mould roller 76 and second nip rolls 77, the 3rd nip rolls 79, the 4th nip rolls 81 and the 5th nip rolls 83.

So the temperature of resin material 14 at the 5th nip rolls 83 places preferably is equal to or less than the softening point (Ta) of resin.When polymethyl methacrylate resin was used as resin material 14, the design temperature of the 5th nip rolls 83 can be preferably 50 to 110 ℃.

The aforesaid method for preparing resin plate according to the present invention is even the width during along moulding has the section shape that the resin plate of big thickness distribution also can obtain suiting.

Though described the embodiment of the method for resin plate produced according to the present invention, the invention is not restricted to described embodiment, and can adopt various aspects.

For example,, can adopt the various aspects that are different from embodiment, as long as they have identical functions for the quantity and the arrangement of nip rolls or pressure roller.

For temperature-adjusting device, cooling device (26 etc.) and slow cool down district 30, can adopt the various aspects that are different from embodiment, as long as they have identical functions.

Claims (6)

1. method for preparing resin plate, this method may further comprise the steps:

The tabular resin material of from die head, extruding by the first positive face mould roller with in the face of first back side mould roller clamping of described first positive face mould roller arrangement;

To be transferred on the described resin material in the lip-deep rough form of the described first positive face mould roller with in the lip-deep rough form of described first back side mould roller;

By the resin material after the stripper roll coiling transfer printing of settling in the face of the described first positive face mould roller, described resin material is peeled off from the described first positive face mould roller;

By the second positive face mould roller with in the face of the resin material after described the peeling off of second back side mould roller clamping of the described second positive face mould roller arrangement; With

To be transferred on the described resin material in the lip-deep rough form of the described second positive face mould roller with in the lip-deep rough form of described second back side mould roller.

2. the method for preparing resin plate according to claim 1, the lapping angle that wherein centers on the described resin material of the described second positive face mould roller and described second back side mould roller coiling is all spent less than 5.

3. the method for preparing resin plate according to claim 1 and 2, the downstream on the described resin material moving direction of the described second positive face mould roller and described second back side mould roller wherein, at least one group of positive face mould roller and the back side mould roller that have same configuration with the described second positive face mould roller and described second back side mould roller are provided, move closer to design shape so that be transferred to the rough form of described resin material.

4. the method for preparing resin plate according to claim 1 and 2 wherein on the surface of described stripper roll, forms and the substantially the same rough form of lip-deep rough form at described first back side mould roller.

5. the method for preparing resin plate according to claim 1 and 2, wherein having under the situation that is transferred to the rough form on the described resin material, along the width of described resin material, the thickness difference between thick and the thinnest part is equal to or greater than 1mm.

6. the method for preparing resin plate according to claim 1 and 2, wherein said the resin material thickness of thin part are equal to or less than 5mm.

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