CN102310560A - The manufacturing approach of resin sheet - Google Patents

The manufacturing approach of resin sheet Download PDF

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Publication number
CN102310560A
CN102310560A CN2011101910439A CN201110191043A CN102310560A CN 102310560 A CN102310560 A CN 102310560A CN 2011101910439 A CN2011101910439 A CN 2011101910439A CN 201110191043 A CN201110191043 A CN 201110191043A CN 102310560 A CN102310560 A CN 102310560A
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CN
China
Prior art keywords
resin sheet
resin
shaped rollers
sheet
continuous
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN2011101910439A
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Chinese (zh)
Inventor
角谷英则
城本征治
滨松丰博
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sumitomo Corp
Sumitomo Chemical Co Ltd
Original Assignee
Sumitomo Chemical Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP2011135261A external-priority patent/JP2012144033A/en
Application filed by Sumitomo Chemical Co Ltd filed Critical Sumitomo Chemical Co Ltd
Publication of CN102310560A publication Critical patent/CN102310560A/en
Pending legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/24—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length
    • B29C41/26—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length by depositing flowable material on a rotating drum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/24—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length
    • B29C41/32—Making multilayered or multicoloured articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/24—Calendering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/44—Compression means for making articles of indefinite length
    • B29C43/46—Rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D7/00—Producing flat articles, e.g. films or sheets
    • B29D7/01—Films or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/44—Compression means for making articles of indefinite length
    • B29C43/46—Rollers
    • B29C2043/461—Rollers the rollers having specific surface features
    • B29C2043/463—Rollers the rollers having specific surface features corrugated, patterned or embossed surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911—Cooling
    • B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
    • B29C48/914—Cooling of flat articles, e.g. using specially adapted supporting means cooling drums
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2007/00—Flat articles, e.g. films or sheets
    • B29L2007/002—Panels; Plates; Sheets

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

Abstract

The present invention provides a kind of manufacturing approach that can realize improving the resin sheet of transferring rate.This manufacturing approach possesses pushes the resin of heating and melting state and the manufacturing process that makes continuous resin sheet from mould continuously.The continuous resin sheet of being made by sheet manufacturing process is the sandwich construction that on the thickness direction of sheet, has multilayer, and possesses the shape transferred thereon layer (A) on the formation sheet surface that is disposed at the shaped rollers side at least and be adjacent to 2 layers of the main stor(e)ies (B) of the rear side of shape transferred thereon layer.The MFR of shape transferred thereon layer (A) (with JISK7210 is standard, the measured value of under 200 ℃, loading 49N condition, measuring) is more than 1.5 with the ratio of the MFR of main stor(e)y (B).

Description

The manufacturing approach of resin sheet
Technical field
The present invention relates to the manufacturing approach that the surface has the resin sheet of shape.
Background technology
Has the method for the resin sheet (surface configuration transfer printing resin sheet) of shape as making the surface; Known use extruder; Under the heating and melting state, continuous resin sheet (continuously resin sheet) is extruded and made to resin from mould, use transfer mold and with the shape transferred thereon of transfer mold in the method (for example with reference to TOHKEMY 2009-220555 communique) on the surface of continuous resin sheet.In the method, between the 1st compression roller that separates on the thickness direction of sheet and the 2nd compression roller, sandwich continuous resin sheet and push, with the shape transferred thereon of the transfer mold on the surface that is formed at the 2nd compression roller in continuous resin sheet.
In recent years, with regard to the resin sheet that the surface is applied with shape, requirement be height with respect to the ratio of the spacing (configuration space) of cell configuration be the bigger shape of aspect ratio.But in the manufacturing approach of all the time resin sheet, with respect to the degree of depth of transfer mold, resin gets into fully, and the height of shape that is needed on resin sheet is also not necessarily abundant.Therefore, the maximum height H ' that need to improve the surface configuration that is needed on resin sheet with respect to the ratio of the groove depth H of transfer mold be transferring rate (H '/H).
Summary of the invention
The present invention accomplishes in order to solve such problem, and its purpose is to provide a kind of manufacturing approach that can realize improving the resin sheet of transferring rate.
The present invention provides the manufacturing approach of resin sheet; It possesses extrudes the resin of heating and melting state and the sheet manufacturing process that makes continuous resin sheet from mould continuously; Be formed with the transfer printing process of the shaped rollers of transfer mold with using in the sheet surface transfer transfer mold of continuous resin sheet at side face
It is characterized in that transfer printing process comprises following operation:
Transfer printing begins operation, the continuous resin sheet clamping extruding that will make by sheet manufacturing process with compression roller and shaped rollers, thus begin shape transferred thereon with the transfer mold of shaped rollers in continuous resin sheet,
The carrying operation, with transfer printing begin sheet surface transfer in the operation have transfer mold shape continuous resin sheet and shaped rollers the side face driving fit carry and
Stripping process is peeled off the continuous resin sheet of carrying in the carrying operation from the side face of shaped rollers;
The continuous resin sheet of being made by sheet manufacturing process is the sandwich construction that on the thickness direction of sheet, has multilayer; At least possess following 2 layers: transfer printing begin to be disposed in the operation shaped rollers side formation sheet surface shape transferred thereon layer (A) and be adjacent to the main stor(e)y (B) of the rear side of shape transferred thereon layer
The MFR of shape transferred thereon layer (A) is more than 1.5 with respect to the ratio of the MFR (with JISK7210 is standard, the measured value of under 200 ℃ of temperature, loading 49N, measuring) of main stor(e)y (B).
According to the manufacturing approach of this resin sheet of the present invention, can make resin sheet become sandwich construction, can make the flowability of the resin (a) that constitutes shape transferred thereon layer (A) be higher than the flowability of the resin (b) that constitutes main stor(e)y (B).In view of the above, resin (a) is got in the transfer mold, can realize the raising of transferring rate.Through the high stir-in resin of use in the resin (a) that constitutes superficial layer (A), thereby can realize improving the shape transferred thereon rate.
Here, transfer printing process comprises following operation:
Prepressing procedures is pushed thereby sandwich the continuous resin sheet of being made by sheet manufacturing process with pony press and compression roller,
Preparation carrying operation, with the prepressing procedures extruding obtain continuous resin sheet and compression roller the side face driving fit carry;
Begin in the operation in transfer printing, preferably will be by the continuous resin sheet clamping extruding of preparation carrying operation carrying with compression roller and shaped rollers.In view of the above,, the thickness and the sheet temperature of continuous resin sheet can be regulated simultaneously, the shape transferred thereon rate can be realized improving through the prepressing procedures that sandwiches with pony press and compression roller.
In addition; When the glass transition temperature that will constitute the resin (a) of shape transferred thereon layer (A) is made as Tg (a); The surface temperature of the shape transferred thereon layer (A) that the preferred side face that is about to shaped rollers joins is (Tg (a)+50) ℃～(Tg (a)+150) ℃ scope, and the surface temperature of the shape transferred thereon layer of just having peeled off from the side face of shaped rollers (A) is (Tg (a)-10) ℃～(Tg (a)+40) ℃ scope.
In addition, the thickness of preferable shape transfer printing layer (A) with respect to the ratio of the thickness of main stor(e)y (B) in 1/200～1/10 scope.If before the transfer printing shape, the scope of the thickness ratio of resin sheet (shape transferred thereon layer (A)/main stor(e)y (B)) 1/200～1/10 then can further realize improving transferring rate.
In addition, preferably be about to carry out before transfer printing begins operation, possessing surface heated heating process the shape transferred thereon layer (A) of the continuous resin sheet of carrying with the side face driving fit ground of compression roller.
In addition, in the preferred transfer mold, on the rotating shaft direction of shaped rollers and be provided with continuous slot part on a plurality of Zhou Fangxiang in shaped rollers, the configuration space P of a plurality of slot parts is 200 μ m～500 μ m.
In addition, in the preferred transfer mold, on the rotating shaft direction of shaped rollers and be provided with continuous slot part on a plurality of Zhou Fangxiang in shaped rollers, a plurality of slot parts equally spaced dispose.
In addition, in the preferred transfer mold, on the rotating shaft direction of shaped rollers and be provided with continuous slot part on a plurality of Zhou Fangxiang in shaped rollers, the depth H of a plurality of slot parts is 100 μ m～500 μ m.
In addition, in the preferred transfer mold, on the rotating shaft direction of shaped rollers and be provided with continuous slot part on a plurality of Zhou Fangxiang in shaped rollers, the depth H of slot part is that aspect ratio H/P is more than 0.3 with respect to the ratio of the configuration space P of a plurality of slot parts.
In addition, in the preferred transfer mold, on the rotating shaft direction of shaped rollers and be provided with continuous slot part on a plurality of Zhou Fangxiang in shaped rollers, the section shape perpendicular to the Zhou Fangxiang of shaped rollers of slot part is semicircular shape, approximate half-oval shaped or prismatic.
In addition, in the preferred transfer mold, on the rotating shaft direction of shaped rollers and be provided with continuous slot part on a plurality of Zhou Fangxiang in shaped rollers, the section shape perpendicular to the Zhou Fangxiang of shaped rollers of slot part is the shape that makes it to be adapted to form optical lens.
In the transfer mold; On the rotating shaft direction of shaped rollers and be provided with continuous slot part on a plurality of Zhou Fangxiang in shaped rollers; The configuration space P of a plurality of slot parts is 200 μ m～500 μ m and for uniformly-spaced; The depth H of slot part is 100 μ m～500 μ m, and aspect ratio (H/P) is more than 0.3, and the section shape perpendicular to the Zhou Fangxiang of shaped rollers of slot part is semicircular shape, approximate half-oval shaped or prismatic; If make it to be adapted to form the shape of optical lens, then be difficult to process the surface configuration transfer printing resin sheet of high transferring rate with manufacturing approach all the time.If use manufacturing approach, even then in the transfer mold of above-mentioned the sort of high transfer printing difficulty, also can process the surface configuration transfer printing resin sheet of high transferring rate based on resin sheet of the present invention.
In addition, the resin (a) that preferably constitutes shape transferred thereon layer (A) is phenylethylene resin series or acrylic resin, and the resin (b) that constitutes main stor(e)y (B) is phenylethylene resin series or acrylic resin.
Description of drawings
[Fig. 1] is the summary pie graph of the described resin sheet manufacturing installation of expression embodiment of the present invention.
[Fig. 2] is the summary pie graph of the described resin sheet manufacturing installation of expression the 2nd embodiment of the present invention.
[Fig. 3] is the summary pie graph of the described resin sheet manufacturing installation of expression the 3rd embodiment of the present invention.
[Fig. 4] is the summary pie graph of the described resin sheet manufacturing installation of expression the 4th embodiment of the present invention.
[Fig. 5] is the summary pie graph of the described resin sheet manufacturing installation of expression the 5th embodiment of the present invention.
[Fig. 6] is the profile schema diagram that the layer of the described resin sheet of expression embodiment of the present invention constitutes.
[Fig. 7] is the three-dimensional pattern figure of the formation of the described resin sheet of expression embodiment of the present invention.
[Fig. 8] is the profile schema diagram that expression is formed at the recess of transfer mold and is formed at the convex shaped part of resin sheet.
[Fig. 9] is the flow chart of order of the manufacturing approach of expression embodiment of the present invention described resin sheet.
[Figure 10] is the profile schema diagram that the layer of the described resin sheet of expression other embodiments of the present invention constitutes.
[Figure 11] is the profile schema diagram of formation of a kind of embodiment of the expression permeation type visual display unit that possesses LGP of the present invention.
[Figure 12] is the rear mode figure of formation of a kind of embodiment of the expression planar light source device that possesses LGP of the present invention.
[Figure 13] is the rear mode figure of formation of other embodiments of the expression planar light source device that possesses LGP of the present invention.
[Figure 14] is the face model figure of formation of a kind of embodiment of the expression planar light source device that possesses LGP of the present invention.
[Figure 15] is the three-dimensional pattern figure of formation of other embodiments of expression LGP of the present invention.
[Figure 16] is the side ideograph of formation of a kind of embodiment of the expression permeation type visual display unit that possesses light diffusing sheet of the present invention.
[Figure 17] is the three-dimensional pattern figure of permeation type visual display unit shown in Figure 16.
[Figure 18] is the three-dimensional pattern figure of the light diffusing sheet that is made up of the described resin sheet of one embodiment of the present invention.
[Figure 19] is the major part amplification profile of lamp box of the installment state of display light diffuser plate.
[Figure 20] is the summary pie graph of the described resin sheet manufacturing installation of expression the 6th embodiment of the present invention.
[Figure 21] is the major part amplification profile that is installed on the intaglio plate transfer mold of the 2nd compression roller (shaped rollers).
[Figure 22] is the figure of the 1st variation (semicircular shape) of expression intaglio plate transfer mold.
[Figure 23] is the figure of the 2nd variation (approximate prismatic) of expression intaglio plate transfer mold.
The specific embodiment
With reference to the accompanying drawings embodiment of the present invention is described.In addition, identical or suitable key element is used identical symbol, omit the explanation of repetition.The dimensional ratios of accompanying drawing may not be consistent with the object of explanation.
(manufacturing installation of resin sheet) Fig. 1 is the summary pie graph of the described resin sheet manufacturing installation of expression embodiment of the present invention.Resin sheet manufacturing installation 50 is the devices that can be used in the manufacturing approach of the described resin sheet of embodiment of the present invention.Resin sheet manufacturing installation 50 possesses to be extruded the resin of heating and melting state continuously and obtains the mould 51 of continuous resin sheet 60 and the 1st compression roller (compression roller the present invention) 52A and the 2nd compression roller (shaped rollers among the present invention) 52B of the continuous resin sheet 60 that extruding is extruded from mould 51 from the both sides of thickness direction.
In addition, resin sheet manufacturing installation 50 possesses and is used to drop into as the resin input port 57 of the resin of raw material and the extruder 58 that is used to extrude from the resin input port 57 resins that drop into.The described resin sheet manufacturing installation 50 of this embodiment is become can be manufactured on the formation that the thickness direction laminated has the resin sheet 60 of sandwich construction, the situation to the continuous resin sheet 60 of making the sort of 2 layers of structure shown in Figure 10 in this embodiment describes.
The 1st compression roller 52A and the 2nd compression roller 52B are become can be around the formation of the rotating shaft rotation that is parallel to each other.The 1st compression roller 52A and the 2nd compression roller 52B are disposed on the thickness direction of resin sheet 60 dividually, and mutual side face interval is each other set according to the thickness of resin sheet 60.Like Fig. 8, Figure 21, Figure 22 and shown in Figure 23, corresponding with the concaveconvex shape that is needed on resin sheet 60 transfer mold 53 is formed at the side face of the 2nd compression roller 52B.The back is at length narrated.
(variation of the manufacturing installation of resin sheet) Fig. 2 is the summary pie graph of the described resin sheet manufacturing installation of expression the 2nd embodiment of the present invention.The difference of resin sheet manufacturing installation 50B shown in Figure 2 and resin sheet manufacturing installation 50 shown in Figure 1 does, possesses the 3rd compression roller 52C at the back segment of the 2nd compression roller (shaped rollers among the present invention) 52B.The 3rd compression roller 52C is and the 1st compression roller (compression roller among the present invention) formation that 52A is identical.Between the 3rd compression roller 52C and the 2nd compression roller 52B, sandwich continuous resin sheet 60 and push.
Fig. 3 is the summary pie graph of the described resin sheet manufacturing installation of expression the 3rd embodiment of the present invention.The difference of resin sheet manufacturing installation 50C shown in Figure 3 and resin sheet manufacturing installation 50 shown in Figure 1 does, possesses pony press 52D at the leading portion of the 1st compression roller (compression roller among the present invention) 52A.Pony press 52D is and the identical formation of the 1st compression roller 52A.Between pony press 52D and the 1st compression roller 52A, sandwich continuous resin sheet 60 and push.
Fig. 4 is the summary pie graph of the described resin sheet manufacturing installation of expression the 4th embodiment of the present invention.The difference of resin sheet manufacturing installation 50D shown in Figure 4 and resin sheet manufacturing installation 50B shown in Figure 2 is behind the 3rd compression roller 52C, to possess the 4th compression roller (back compression roller) 52E.The formation of other parts is identical with resin sheet manufacturing installation 50B shown in Figure 2.Between the 4th compression roller 52E and the 3rd compression roller 52C, sandwich continuous resin sheet 60 and push.State with shape transferred thereon layer 61 and the 4th compression roller 52E driving fit is carried continuous resin sheet 60.
Fig. 5 is the summary pie graph of the described resin sheet manufacturing installation of expression the 5th embodiment of the present invention.The difference of resin sheet manufacturing installation 50E shown in Figure 5 and resin sheet manufacturing installation 50C shown in Figure 3 is behind the 2nd compression roller (shaped rollers among the present invention) 52B, to possess the 3rd compression roller (back compression roller) 52C.The formation of other parts is and the identical formation of resin sheet manufacturing installation 50C shown in Figure 3.Between the 3rd compression roller 52C and the 2nd compression roller 52B, sandwich continuous resin sheet 60 and push.State with non-shape transferred thereon layer and the 3rd compression roller 52C driving fit is carried continuous resin sheet 60.
Like Fig. 1～shown in Figure 3, a plurality of rollers can be on above-below direction in abutting connection with the formation that is configured; Like Fig. 4 and shown in Figure 5, a plurality of rollers can be the formation that is configured to adjacency on the horizontal direction.In addition, a plurality of rollers can be the formation that on the direction that tilts with respect to horizontal direction, is configured to adjacency.In resin sheet manufacturing installation 50E shown in Figure 5,, can make upside half one (the 180 degree part) driving fit of resin and the 2nd compression roller 52B owing to the 3rd compression roller 52C is arranged in the backend configuration that is disposed at tertiary the 2nd compression roller (shaped rollers among the present invention).In addition, through making continuous resin sheet and the 3rd compression roller 52C driving fit, thereby can adjust the temperature of continuous resin sheet.
Figure 20 is the summary pie graph of the described resin sheet manufacturing installation of expression the 6th embodiment of the present invention.The difference of resin sheet manufacturing installation 50F shown in Figure 20 and resin sheet manufacturing installation 50C shown in Figure 3 does; When being about to sandwich continuous resin sheet 60, possesses the heater 59 that the sheet surface of shape transferred thereon layer 61 side of continuous resin sheet 60 is heated with the 1st compression roller 52A and the 2nd compression roller 52B.
Resin sheet manufacturing installation 50F possess with material resin extrude panel forming machine 54 for the sheet moulding, one group of compression roller group (52D of continuous resin sheet 60 moulding that are used for will extruding through extruding; 52A is 52B) with a pair of roller group (52G, 52H) that pulls that is used to pull continuous resin sheet 60.
Panel forming machine 54 possesses and is used for the 1st extruder (secondary extruder) 58A of material resin (a) heating and melting of shape transferred thereon layer (A) 61, is used for the 2nd extruder (main extruder) 58B of material resin (b) heating and melting of main stor(e)y (B) 62, supplies with feed sleeve pipe (feed block) 55 and the mould 51 that is used under the sheet state, extruding the resin in the feed sleeve pipe 55 at the resin of the 1st and the 2nd extruder 58A, 58B fusion.
As the 1st and the 2nd extruder 58A, 58B, for example can use known single lead screw ex truding briquetting machines such as single shaft extruder, two-axis extruder.The the 1st and the 2nd extruder 58A, 58B are equipped with the hopper (resin input port) 57 that is used in the cylinder of extruder, dropping into resin.
As feed sleeve pipe 55,, for example can use 2 kinds of 3 layers of distribution type, 2 kinds of 2 layers of known feed sleeve pipes such as distribution type so long as can just not have special qualification with the pattern of range upon range of state co-extrusion pressure to the resin of mould 51 supplies more than 2 kinds.
As mould 60,, then have no particular limits so long as co-extrusion is pressed the mould of usefulness.Can use the common metal system T mould that is used for extrinsion pressing etc.The width of the mouth of mould 60 (mould mouth 60a) is selected according to the width of target continuous resin sheet 60, for example is 300mm～3000mm.
Pony press 52D, the 1st compression roller 52A and the 2nd compression roller 52B are processed by columned metal system (for example stainless steel, iron steel etc.) roller respectively, are to have the chill roll of regulating its all surface temperatures (surface temperature) function.The side face of the 2nd compression roller 52B is provided with the intaglio plate transfer mold 53 that is used on continuous resin sheet 60, forming semiellipse convex shaped part 35 and groove 35b (with reference to Figure 18, Figure 19).
Shown in figure 21, in this intaglio plate transfer mold 53, as with semiellipse convex shaped part 35 mutually the semiellipse groove 70 of the slot part of transoid form many striateds along the Zhou Fangxiang of the 2nd compression roller 52B.That is, in intaglio plate transfer mold 53, the raised line 71 between semiellipse groove 70 and the adjacent semiellipse groove 70 alternatively disposes along the direction of principal axis of the 2nd compression roller 52B.
The profile that semiellipse groove 70 has approximate half-oval shaped perpendicular to the section of its length direction (Zhou Fangxiang).The depth H of semiellipse groove 70 is than the height H of semiellipse convex shaped part 35 ' bigger, for example be 100 μ m～500 μ m, be preferably 100 μ m～300 μ m.If depth H is excessive, then high fluidity polystyrene resin (constituting the resin (a) of shape transferred thereon layer 61) is difficult to enter into the front end of semiellipse groove 70.
In addition, the center of adjacent semiellipse groove 70 distance (spacing P) each other suitably confirms according to the shape of semiellipse convex shaped part 35, for example is 200 μ m～500 μ m, is preferably 250 μ m～450 μ m, further is preferably 300 μ m～400 μ m.During spacing P less than 200 μ m, exist resin to contact with the 2nd compression roller 53 and solidify at once maybe, its result: exist the resin (a) that constitutes shape transferred thereon layer (A) 61 not enter into the front end of semiellipse groove 70 and can't obtain the possibility of the transfer printing shape of target.On the other hand, when spacing P surpasses 500 μ m, exist the striped that with the naked eye just can on liquid crystal display, observe spacing maybe, or have the possibility that occurs the interference fringe pattern of liquid crystal display 10, blooming 41 etc.
In addition, by the height H of semiellipse groove 70 with respect to the vertical-horizontal proportion of ratio (H/P) expression of spacing P as being more than 0.3, to be preferably 0.5～0.7.In addition, the height H of semiellipse convex shaped part 35 ' result from the difference of the depth H of semiellipse groove 70 that intaglio plate transfer mold 53 is needed on continuous resin sheet 60 and transferring rate when forming semiellipse convex shaped part 35 (H '/H (%).
In addition, engine (not shown) is connected to the rotating shaft of each compression roller (52D, 52A, 52B).Pony press 52D and the 2nd compression roller 52B can rotate in the counterclockwise, and the 1st compression roller 52A can deasil rotate.That is, compression roller (52D, 52A, 52B) is by being " can rotate in the counterclockwise ", " can deasil rotate ", " can rotate in the counterclockwise " from top to bottom in proper order.In view of the above, can rotate simultaneously with the state of the continuous resin sheet 60 of whole rollers (52D, 52A, 52B) clamping.In addition, through suitably regulating the rotary speed of compression roller (52D, 52A, 52B), can adjust the transporting velocity of resin sheet 60.
The diameter of each compression roller (52D, 52A, 52B) is for example 100mm～500mm.In addition, when using metal system roller as compression roller (52D, 52A, 52B), can be in plating processing such as its surperficial embodiment such as chromium plating, copper facing, nickel plating, plating Ni-P.
In addition, be provided with the heater 59 that is used for surface (surface of the transfer printing side) heating of the shape transferred thereon layer 61 of the resin sheet of on the 1st compression roller 52A, carrying 60 near the 1st compression roller 52A.Heater 59 disposes with the side face spaced manner with the 1st compression roller 52A relatively, heats from the sheet face side of the shape transferred thereon layer 61 continuous resin sheet 60 to carrying.As heater 59, for example can use known heaters such as infrared heater.In addition, heater 59 can be the embedding line formula heater that is arranged on the route of the continuous resin sheet 60 of carrying, also can be the portable heater that operating personnel can be handed measure.
The a pair of roller group (52G, 52H) that pulls contains a pair of roller 52G, the 52H of pulling that sandwiches continuous resin sheet 60 from the thickness direction both sides.Roller is processed by columned metal system (for example stainless steel, iron steel etc.) respectively to pull roller 52G, 52H, so that the upper end that pulls roller 52H of downside is oppositely arranged with the mode that is in the height and position identical with the lower end of the 2nd compression roller (shaped rollers) 52B.In view of the above, owing to can under the height of just having seen off, support to carry out the level carrying from continuous resin sheet 60 ground that the 2nd compression roller 52B sees off, so can make the carrying resistance force diminishes.
(resin sheet continuously) next, describes the continuous resin sheet that utilizes the described manufacturing approach manufacturing of embodiment of the present invention.Figure 10 is the profile that the layer of the described continuous resin sheet of expression embodiment of the present invention constitutes.Figure 10 is the section that on the continuous direction (x direction) of continuous resin sheet and vertical direction (y direction, z direction), cuts out, and demonstrates surface configuration and is transferred preceding state.
Thickness direction (z direction) laminated that continuous resin sheet 60 has at sheet has the sandwich construction of multilayer, possesses shape transferred thereon layer (A) 61 and the main stor(e)y (B) 62 that constitute sheet surface 60a.For example surface configuration is needed on the shape transferred thereon layer (A) 61 with sheet surface 60a.Main stor(e)y (B) 62 on the thickness direction of sheet, be adjacent to the transfer printing shape and the rear side of shape transferred thereon layer (A) 61 be configured.
Resin sheet 60 can be 2 kinds 2 layers formation shown in figure 10 (shape transferred thereon layer (A)/main stor(e)y (B)) continuously; Also can be 2 kinds 3 layers (shape transferred thereon layers (A)/main stor(e)y (B)/back layer) as shown in Figure 6.Continuous resin sheet 60 shown in Figure 6 possesses the shape transferred thereon layer (A) 61 that constitutes sheet surface 60a, constitute the back layer 63 of sheet surface 60b and be sandwiched in the main stor(e)y (B) 62 of these shape transferred thereon layers (A) 61 and back layer 63.When being 2 kinds 3 layers, constituting shape transferred thereon layer 61 is identical resins with the resin of back layer 63.
Fig. 7 is the three-dimensional pattern figure of the formation of the described resin sheet of expression embodiment of the present invention.Fig. 7 representes continuous resin sheet 60 is cut to the size of regulation and the resin sheet 30 that forms.Resin sheet 30 can be as the infiltration type image device of stating after being equipped on 1, the planar light source device (backlight) 20 of 1B (with reference to Figure 11, Figure 16), the LGP of 20B 30 or light diffusing sheet 30C.As planar light source device (backlight) 20,20B, light sources such as LED are disposed at the side 33 of LGP 30, edge light (the エ Star ジ ラ イ ト) type that can penetrate to face side as the light that will inject from the side 33 of LGP 30.In addition, can dispose light sources to the side 33 of resin sheet and be used as LGP, also can be to the back side 32 configuration light sources of resin sheet and as light diffusing sheet (back is at length narrated).
When resin sheet is used as LGP 30, usually the irreflexive reflection processing of the light of injecting is from the side implemented to make in the back side 32 of resin sheet.As the method for printing that reflects processing, except serigraphy, can carry out ink jet printing.Perhaps, can not print, but utilize laser radiation and give the concavo-convex of examples of dot shaped as the reflection method for processing.
Be formed with on the surface 31 of resin sheet 30 and extend in the 1st direction (x direction of principal axis) and be disposed at a plurality of convex shaped parts 35 of the 2nd direction (y direction of principal axis) side by side perpendicular to the 1st direction.Have the concaveconvex shape that is formed at surface 31 convex shaped part 35 by after the transfer printing process stated and forming.
(LGP make use-case) next, describes the concrete use-case that makes of LGP with reference to Figure 11.Figure 11 is the profile schema diagram of formation of a kind of embodiment of the expression permeation type visual display unit that possesses LGP of the present invention.Figure 11 expresses permeation type visual display unit 1 with decomposing.
(permeation type visual display unit) permeation type visual display unit 1 possesses infiltration type image displaying part 10 and in Figure 11, is disposed at the planar light source device 20 of the rear side of infiltration type image displaying part 10.Shown in figure 11, planar light source device 20 is called z direction (thickness of slab direction) with the orientation of infiltration type image displaying part 10, is called x direction and y direction perpendicular to 2 directions and orthogonal 2 directions of z direction.
As infiltration type image displaying part 10, for example can enumerate the LCDs that straight line polarizer 12,12 is disposed at the two sides of liquid crystal cells 11.At this moment, permeation type visual display unit 1 is liquid crystal indicator (a perhaps LCD TV).Liquid crystal cells 11, polarizer 12,12 are operable to be the element that all the time is used for permeation type visual display units 1 such as liquid crystal indicator.But go out known liquid crystal cells such as TFT type, STN type as liquid crystal cells 11 illustrations.
(planar light source device) Figure 12 is the rear mode figure of formation of a kind of embodiment of the expression planar light source device that possesses LGP of the present invention; Figure 13 is the rear mode figure of formation of other embodiments of the expression planar light source device that possesses LGP of the present invention, and Figure 14 is the face model figure of formation of a kind of embodiment of the expression planar light source device that possesses LGP of the present invention.Like Figure 11～shown in Figure 14, the led light source (point source of light) 22 that planar light source device 20 possesses LGP (optical sheet) 30, relatively disposes with the side 33 of LGP 30.In addition, in the face side of LGP 30, between LGP 30 and infiltration type image displaying part 10, can be the formation that disposes various films 41.As various films 41, can enumerate diffusion barrier, prism film, brightness enhancement film etc.
(light source) led light source 22 is as the point source of light of planar light source device 20 and play a role, and is shown in figure 12, relatively disposes with extending in the axial side 33,33 of the y of LGP 30.A plurality of led light sources 22 are 33 length direction (y direction of principal axis) along the side, is configured discretely.The configuration space of led light source 22 is generally 5mm～20mm.Point source of light can be configured with the mode relative with 4 limits of LGP 30, can be on relative 2 limit (with reference to Figure 12) of x direction of principal axis, be configured on 2 relative limits of y direction of principal axis, can be the formation (with reference to Figure 13 and Figure 14) that only is configured on 1 limit.In addition, point source of light is not limited to led light source, can be other point source of light.And then light source is not limited to point source of light, can be the formation that disposes linear light source (cold-cathode tube).
Led light source 22 can be a White LED, also can dispose a plurality of LED and constitute a light source cell at a place.For example as a light source cell, can be with the LED of red, green, blue different three looks near being configured side by side.And the light source cell with a plurality of LED is configured along above-mentioned configuration direction discretely.In this case, preferred different LED is configured with being positioned as close to each other.
As led light source, can use to have the various photodistributed light sources that go out, the luminous intensity of the normal direction of led light source (z direction of principal axis) is maximum, preferably having the half breadth that luminous intensity distributes is the photodistributed light source that of 40 degree～80 degree.In addition, as the type of led light source, particularly, can enumerate lambert (Lambertian) type, bullet cut, side emission type etc.
(LGP) is like Figure 12～shown in Figure 14; LGP 30 forms rectangle; The size that shape is looked on the plane is selected with the mode of the picture dimension that is suitable for target permeation type visual display unit 10; (L1 * L2) be generally more than 250mm * 440mm is preferably the above big molded dimension of 500mm * 800mm to the length on 2 vertical limits.The plane of LGP 30 is looked shape and is not limited to rectangle, can be square, but following if there is not special qualification, then describes with rectangle.
LGP 30 is formed by the translucent resin of printing opacity, and forms tabular.In addition, LGP 30 can be a sheet, also can be membranaceous.The thickness T of preferred LGP 30 is 1.0mm～4.5mm.
LGP 30 possesses at the relative a pair of interarea (31,32) of z direction of principal axis (thickness direction), in the relative a pair of side 33,33 of X-direction and in the relative a pair of side 34,34 of Y direction.Interarea (31,32) forms on the direction of reporting to the leadship after accomplishing a task with side (33,34).
Interarea (31) in the relative a pair of interarea of z direction of principal axis plays a role as penetrating the outgoing plane 31 of planar light.Outgoing plane 31 is disposed at infiltration type image displaying part 10 sides, and the opposing party's interarea (back side 32) is disposed at and infiltration type image displaying part 10 opposition sides.In addition, with the position on 32 opposites, the back side, be applied with the light that makes in the LGP 30 reflector plate 42 to outgoing plane 31 lateral reflections.
(reflection processing) like Figure 12 and shown in Figure 13, implements to make the irreflexive reflection processing of light (for example serigraphy) to the back side 32 of LGP 30 in addition.As the method for printing that reflects processing, except serigraphy, can carry out ink jet printing.Perhaps, as the reflection method for processing, can not printing, but utilize laser radiation to give the concavo-convex of examples of dot shaped.In the LGP 30 of this embodiment, as reflection processing, printing be the round dot pattern.In the printing of round dot pattern, use be printing ink with the diffusion particle that makes light diffusion.In addition, the diameter that constitutes each round dot 38 (printed dot) of round dot pattern separately becomes big mode from light source side and coordinates to change to be accompanied by.For example, making apart near the round dot diameter in the zone the sidepiece in the near zone of light source is about 516 μ m, and making apart near the round dot diameter in the zone the screen central authorities in light source zone farthest is about 904 μ m, and the round dot diameter that makes both zone lines is about 729 μ m.
(concaveconvex shape) Fig. 7 is the three-dimensional pattern figure of formation of a kind of embodiment of expression LGP of the present invention, and Figure 15 is the three-dimensional pattern figure of formation of other embodiments of expression LGP of the present invention.Be formed with as a plurality of convex shaped parts 35 at outgoing plane 31 to the axial outside of z protrusion.Convex shaped part 35 extends in x direction of principal axis (direction), a plurality of y direction of principal axis that are disposed at side by side.
In addition,, can enumerate prism shape, semicircular shape, sub-elliptical shape etc. as the shape of convex shaped part 35, the shape that preferably in 1 convex shaped part 35 (shape unit), changes continuously, for example semi-circular shape or half-oval shaped are than prism shape more preferably.In addition, preferred convex shaped part 35 to extend direction parallel with the ejaculation direction from the light of light source.In addition, can be on the direction (y direction of principal axis) of convex shaped part 35 adjacency, at the convex shaped part 35 of adjacency, be formed with planar portions between 35.In addition, as the shape of convex shaped part, in addition, can be optical lens shape.
Fig. 8 is the enlarged drawing of convex shaped part on the x direction of principal axis in the presentation graphs 7.Here, convex shaped part 35 satisfies H * T/P >=0.23... (1) and gets final product.Wherein, P is the interval (μ m) of the convex shaped part 35,35 of adjacency, and H is the height (μ m) of convex shaped part 35, and T is sheet thickness (mm).As shown in Figure 8, P is the summit 35a of the convex shaped part 35 of adjacency, the distance between the 35a at interval.The height H of convex shaped part 35 is the lower end 35b of convex shaped part 35 and the distance between the 35a of summit.The sheet thickness T is the summit 35a of convex shaped part 35 and the distance at the back side 32.
(constituent material of LGP) LGP 30 is formed by translucent resin.The refractive index of translucent resin is generally 1.49～1.59.As LGP 30 employed translucent resins, mainly use methacrylic resin.As LGP 30 employed translucent resins, can use other resin, can use the resin of polystyrene.As translucent resin, can use acrylic resin, styrene resin, carbonate resin, cyclic olefin resin, MS resin (acrylic acid and cinnamic copolymer) etc.
LGP is applied to liquid crystal indicator (permeation type visual display unit 1), can in LGP 30, adds additives such as light diffusing agent, ultra-violet absorber, heat stabilizer, photopolymerization stabilizing agent.
(light diffusing sheet make use-case) next with reference to Figure 16, describes the use-case that makes of light diffusing sheet.Figure 16 is the side ideograph that the expression infiltration type image that possesses light diffusing sheet of the present invention shows the formation of a kind of embodiment of adorning.Figure 17 is the three-dimensional pattern figure of permeation type visual display unit shown in Figure 16.
(permeation type visual display unit) permeation type visual display unit 1B possesses infiltration type image displaying part 10, in Figure 16, is disposed at the planar light source device 20B of the rear side of infiltration type image displaying part 10.Shown in figure 16, the orientation of planar light source device 20B and infiltration type image displaying part 10 is called z direction (thickness of slab direction), be called x direction and y direction perpendicular to 2 directions and orthogonal 2 directions of z direction.
As infiltration type image displaying part 10, for example can enumerate the LCDs that straight line polarizer 12,12 is disposed at the two sides of liquid crystal cells 11.At this moment, permeation type visual display unit 1 is liquid crystal indicator (a perhaps LCD TV).Liquid crystal cells 11, polarizer 12,12 are operable to be the element that all the time is used for permeation type visual display units 1 such as liquid crystal indicator.As liquid crystal cells 11, but illustration goes out known liquid crystal cells such as TFT type, STN type.
Planar light source device (back light system) 20B possesses: have the rear wall 23 of Square consisting of two isosceles right-angled triangles shape and from the periphery of the rear wall 23 resin system lamp box 25 of the open slim case shape of sidewall 24 and the front face side of (face side) four jiaos of frame shapes setting up integratedly forwards; The light diffusing sheet 30C that is arranged at a plurality of linear light source 22B in the lamp box 25 and the open surface 26 (front) of lamp box 25 is blocked.
That is, with regard to the lamp box 25 of case shape, the profile of its open surface 26 is provided with linear light source 22B by sidewall 24 subregions of four jiaos of frame shapes in the space that is surrounded by sidewall 24 and rear wall 23.At rear wall 23 inner faces of lamp box 25, for example integrally be equipped with and be used to make the light injected to rear wall 23 sides from linear light source 22B reflecting plate 42 (with reference to Figure 11) to open surface 26 lateral reflections of case.
(light source) linear light source 22B for example is that diameter is the cylindric lamp of 2mm～4mm.A plurality of linear light source 22B are with to the back side 32 of light diffusing sheet 22B and the empty state of opening certain intervals, and sky is opened equal spacing and is configured in parallel to each other.
From the viewpoint of power saving, the center interval Q each other of preferred adjacent linear light source 22B is 30mm～60mm.In addition, from the viewpoint of slimming, the back side 32 of preferred light diffuser plate 30C (the for example central portion at the back side 32) is 10mm～20mm with the distance R at the center of linear light source 22B.In addition, preferred interval Q is 2.5～4.0 with respect to the ratio (Q/R) of distance R.Special preferred interval Q is 40mm～55mm, and distance R is 13mm～17mm.In addition, the number of linear light source 22B is inevitable by the size (picture dimension of permeation type visual display unit 1B) of lamp box 25 and Q and determining at interval, and for example in the liquid crystal indicator 1 of 32 types, preferred 6～10.In addition, in Figure 16 and Figure 17, only represent linear light source 22B with 5 in order to be easy to carry out diagram.
In addition, as linear light source 22B, for example can use known cartridge lamps such as fluorescent lamp (cold-cathode tube), Halogen lamp LED, tungsten lamp.In addition, as the light source of planar light source device 20B, can replace linear light source 22B and use light emitting diode point source of lights such as (LED) etc.
(light diffusing sheet) Figure 18 is the three-dimensional pattern figure of the light diffusing sheet that formed by the described resin sheet of one embodiment of the present invention.Figure 19 is the major part amplification profile of lamp box of the installment state of expression light diffusing sheet.Shown in figure 18, light diffusing sheet 30C forms and essentially identical four jiaos tabular of the shaped as frame shape of the sidewall 24 of lamp box 25.
Light diffusing sheet 30C is the range upon range of at least photopermeability multilayer light diffusing sheet that 2 layers of resin bed is arranged and get on thickness direction Z, and it possesses shape transferred thereon layer (A) (front layer) 61 that is formed by the high fluidity resin and the main stor(e)y (B) (back layer) 62 that is formed by the lazy flow resin.
In addition, in light diffusing sheet 30C, can contain light diffusing agent (light diffusion particle) as required.As light diffusing agent; As long as particle different for refractive index and can diffused transmission light with the translucent resin of formation light diffusing sheet 30C; Just have no particular limits; For example, can enumerate calcium carbonate, barium sulfate, titanium oxide, aluminium hydroxide, silica, glass, talcum, mica, white carbon, magnesia, zinc oxide etc. as the light diffusing agent of inorganic system.They can be to have implemented the surface-treated product with aliphatic acid etc.
In addition; For example as the light diffusing agent of organic system; Can enumerate styrenic particle, acrylic acid series polymeric compounds particle, siloxane-based polymers particle etc., preferably can enumerate weight average molecular weight and be 500,000～5,000,000 heavy polymer particle, the gel fraction when being dissolved in acetone is the above cross-linking polymer particles of 10 quality %.Above-mentioned light diffusing agent can use perhaps with also using more than 2 kinds individually.
When light diffusing sheet 30C contained light diffusing agent, the cooperation ratio of light diffusing agent was 0.001～1 weight portion with respect to translucent resin 100 weight portions, is preferably 0.001～0.01 weight portion.In addition, light diffusing agent can as with the parent sizing material of above-mentioned translucent resin.In addition, from the viewpoint of light diffusing, the absolute value of the difference of the refractive index of translucent resin and the refractive index of light diffusing agent is generally 0.01～0.20, is preferably 0.02～0.15.
In addition, in light diffusing sheet 30C, for example can add various additives such as ultra-violet absorber, heat stabilizer, anti-oxidant, weather resisting agent, light stabilizer, fluorescent whitening agent, processing stabilizers as required.
As ultra-violet absorber, there is not special qualification, for example can enumerate phenyl salicytate and be ultra-violet absorber, benzophenone series ultra-violet absorber, triazine is that ultra-violet absorber, BTA are ultra-violet absorber etc.When adding ultra-violet absorber, preferably add ultra-violet absorber 0.1～3 weight portion with respect to translucent resin 100 weight portions.As long as in above-mentioned scope, just can suppress to keep the outward appearance of light diffusing sheet well to the oozing out of the surface of ultra-violet absorber.
As heat stabilizer, have no particular limits, for example can enumerate manganese compound, ketonic compound etc.When adding heat stabilizer; Preferably when adding ultra-violet absorber; With respect to 1 weight portion of the ultra-violet absorber in the translucent resin; Add heat stabilizer with the ratio below 2 weight portions,, add heat stabilizer 0.01～1 weight portion more preferably with respect to 1 weight portion of the ultra-violet absorber in the translucent resin.
In addition, as anti-oxidant, restriction especially for example can not enumerated hindered phenol compound, hindered amine compound etc.When adding anti-oxidant, preferably add anti-oxidant 0.1～3 weight portion with respect to translucent resin 100 weight portions.
And shown in figure 19, the parallel position of linear light source 22B in semiellipse convex shaped part 35 and lamp box 25 makes the back side 32 of light diffusing sheet 30C and sidewall 24 butts of lamp box 25, and is fixed in lamp box 25.In view of the above, the open surface 26 of lamp box 25 is blocked by light diffusing sheet 30C.
(constituent material of resin sheet) formed by translucent resin by LGP or the light diffusing sheet that resin sheet forms.The refractive index of translucent resin is generally 1.49～1.59.As LGP or the employed translucent resin of light diffusing sheet, mainly can use methacrylic resin.As LGP or the employed translucent resin of light diffusing sheet, can use other resin, can use phenylethylene resin series.As translucent resin, can use acrylic resin, styrene resin, carbonate resin, cyclic olefin resin, MS resin (acrylic acid and cinnamic copolymer) etc.
In addition, resin sheet 60 shown in Figure 10 is made up of shape transferred thereon layer (A) 61 and main stor(e)y (B) 62, and the MFR (a) of the resin (a) of formation shape transferred thereon layer (A) is more than 1.5 with respect to the ratio (MFR (a)/MFR (b)) of the MFR (b) of the resin (b) that constitutes main stor(e)y (B).MFR (a) and MFR (b) are to be standard with JISK7210, the measured value of under 200 ℃ of temperature, 49N loading condition, measuring (MFR:Melt flow rate).This ratio is preferred below 10, if surpass it, then the thickness on top layer becomes non-constant, or is easy to generate current mark (flow mark)
As the resin (a) that constitutes shape transferred thereon layer (A), can enumerate the thermoplastic resin that utilizes heating and become molten condition usually.Preferred resin (a) is phenylethylene resin series or acrylic resin.Resin (a) can be other resin, can be carbonate resin, cyclic olefin resin, MS resin (acrylic acid and cinnamic copolymer) etc.Above-mentioned resin can add additives such as light diffusing agent, ultra-violet absorber, heat stabilizer, antistatic additive.
As the resin (b) that constitutes main stor(e)y (B), can enumerate the thermoplastic resin that utilizes heating and become molten condition usually.Preferred resin (b) is phenylethylene resin series or acrylic resin.Resin (b) can be other resin, can be carbonate resin, cyclic olefin resin, MS resin (acrylic acid and cinnamic copolymer) etc.Above-mentioned resin can add additives such as light diffusing agent, ultra-violet absorber, heat stabilizer, antistatic additive.
(example of MFR value) when being phenylethylene resin series, can make MFR (a) is 5g/10min～15g/10min at the resin (a) that constitutes shape transferred thereon layer (A) and the resin (b) that constitutes main stor(e)y (B), and making MFR (b) is 0.5g/10min～2.0g/min.
In addition, when being acrylic resin, can make MFR (a) is 0.4g/10min～3.0g/10min at the resin (a) that constitutes shape transferred thereon layer (A) and the resin (b) that constitutes main stor(e)y (B), and making MFR (b) is 0.1g/10min～2.0g/min.
(manufacturing approach of resin sheet) describes the manufacturing approach of the described resin sheet of embodiment of the present invention.Fig. 9 is the flow chart of order of the manufacturing approach of expression embodiment of the present invention described resin sheet.The manufacturing approach of the resin sheet of this embodiment for example can use Fig. 1～Fig. 5 and resin sheet manufacturing installation 50 shown in Figure 20 to implement.As shown in Figure 9; The manufacturing approach of the resin sheet of this embodiment possesses to be extruded the resin of heating and melting state and with the sheet manufacturing process (S1) of continuous resin sheet moulding with use the transfer mold (shaped rollers) that is formed at side face and transfer mold is needed on the transfer printing process (S2) of continuous resin sheet from mould continuously.
(sheet manufacturing process) extrudes resin continuously from mould 51 with the heating and melting state and makes continuous resin sheet 60 in sheet manufacturing process.Can enumerate the thermoplastic resin that utilizes heating and become molten condition as the employed resin of manufacturing approach of the present invention.
As the mould of above-mentioned resin being extruded continuously with the heating and melting state 51, can use and employed identical metal T mould of common extrusion moulding etc.As far as resin being extruded from mould 51 with the heating and melting state, identical with common extrusion moulding, can use extruder 58.Extruder 58 can be the single shaft extruder, can be two-axis extruder.Resin heats in extruder 58, sends into mould 51 and extrudes with the state of fusion.The resin of extruding from mould 51 becomes sheet continuously and is extruded, and becomes continuous resin sheet 60.
Above-mentioned continuous resin sheet 60 is a sandwich construction, thereby to the resin that mould 51 is supplied with more than 2 kinds, carries out coextrusion with range upon range of state.For the resin more than 2 kinds is carried out for example using known 2 kinds 3 layers distribution type feed sleeve pipe for the coextrusion with range upon range of state, supply with resins to mould 51 via this sleeve pipe.
In addition, the thickness of continuous resin sheet 60 is suitably adjusted according to the purposes of the sheet of gained and is got final product.When for example continuous resin sheet 60 being used as LGP 30 or light diffusing sheet 30C, sheet thickness preferred range is 1.0mm～4.5mm.
(transfer printing process) transfer printing process (S2) comprises following operation:
Transfer printing begins operation (S3), through will pushing by continuous resin sheet 60 clampings that sheet manufacturing process (S1) makes with the 1st compression roller (compression roller) 52A and the 2nd compression roller (shaped rollers) 52B,
Carrying operation (S4), make transfer printing begin extruding in the operation (S3) and continuous resin sheet 60 carry with the side face driving fit ground of shaped rollers 52B,
Stripping process (S5) will be carried the continuous resin sheet 60 of carrying in the operation (S4) and peel off from the side face (transfer mold 53) of shaped rollers 52B.
(transfer printing begins operation) is as shown in Figure 1, utilizes transfer printing to begin operation (S3), with the 1st compression roller 52A and the 2nd compression roller 52B from the both sides of the thickness direction of sheet simultaneously with continuous resin sheet 60 clampings of gained the above-mentioned manufacturing process (S1) and push.
At this moment, when the glass transition temperature that will constitute the resin (a) of shape transferred thereon layer (A) is made as Tg (a), be about in succession to be preferably the scope of (Tg (a)+50 ℃)～(Tg (a)+150 ℃) in the surface temperature of the continuous resin sheet 60 of the 2nd compression roller 52B.The adjustment of surface temperature can be through extruder 58 the change of design temperature of change, mould 51 of design temperature adjust.In addition, the surface temperature of resin sheet 60 can be used infra-red thermometer and carry out instrumentation continuously.
In addition, when being about to carry out transfer printing and beginning operation, can carry out the heating process that the sheet surface of the shape transferred thereon layer 61 of the continuous resin sheet 60 carried with the side face driving fit ground of the 1st compression roller 52A is heated.
Begin in the operation (S3) in this transfer printing, will be based on the shape transferred thereon of the transfer mold 53 on the surface that is formed at the 2nd compression roller (shaped rollers) 52B in continuous resin sheet 60.In addition, in the present invention, the 2nd compression roller 52B that possesses transfer mold is also referred to as transfer roll.The transfer mold that above-mentioned transfer roll surface possesses telescopes the surface of continuous resin sheet 60, with reverse its surface configuration is needed on continuous resin sheet 60.
As the 1st and the 2nd compression roller 52A, 52B, the metal system roller that uses stainless steel, iron and steel etc. to constitute usually by metal, they typically have a diameter from 100mm～500mm.The metal system of use roller is as these the 1st and the 2nd compression roller 52A, and during 52B, its surface for example can be implemented the plating of chromium plating, copper facing, nickel plating, nickel plating-phosphorus etc. and handled.In addition, the surface of the 1st compression roller 52A (side face) can be minute surface, also can be that enforcement has concavo-convex transfer surfaces such as embossing.
(carrying operation) carrying operation (S4) is so that the continuous state of the side face driving fit of resin sheet 60 and the 2nd compression roller 52B, follows the rotation of the 2nd compression roller 52B and the operation of carrying.
(stripping process) stripping process (S5) is the operation that continuous resin sheet 60 is peeled off from the side face of the 2nd compression roller 52B.
At this moment, with respect to the glass transition temperature Tg (a) of the resin (a) that constitutes shape transferred thereon layer (A), the surface temperature of the resin (a) of the preferred continuous resin sheet of just having peeled off from the 2nd compression roller 52B 60 is (Tg (a)-10) ℃～(Tg (a)+40) ℃ scope.When the surface temperature of resin (a) was lower than this scope, production efficiency no longer uprised.When the surface temperature of resin (a) was higher than above-mentioned temperature range, the shape that is needed on continuous resin sheet 60 was because heat and turn back to original state easily, so the easy variation of transferring rate.The preferred scope of surface temperature of the resin of just having peeled off from the 2nd compression roller 52B (a) is (Tg (a)-5) ℃～(Tg (a)+10) ℃ a scope.
In addition, when the glass transition temperature that will constitute the resin (b) of main stor(e)y (B) was made as Tg (b), the glass transition temperature Tg (a) that constitutes the resin (a) of superficial layer (A) can be (Tg (b)+2) ℃＜Tg (a) ℃＜scope of (Tg (b)+20) ℃.
In addition, after peeling off from the 2nd compression roller 52B, the thickness of shape transferred thereon layer (A) is 1/200～1/10 scope with respect to the ratio of the thickness of main stor(e)y (B).When little and thickness ratio was bigger than 1/10 than 1/200, the raising of transferring rate was insufficient at thickness ratio.
(transfer mold) Fig. 8 is the profile schema diagram that expression is formed at the recess of transfer mold and is formed at the convex shaped part of resin sheet.Transfer mold 53 is formed by a plurality of recesses on the surface of being located at shaped rollers 52B.For example, recess is on the Zhou Fangxiang of shaped rollers 52B, to form continuously.The spacing of recess is generally more than the 30 μ m, be preferably more than the 50 μ m, but in manufacturing approach of the present invention and manufacturing installation, the intervals of preferred recess is 200 μ m～500 μ m that the groove depth H of recess is 100 μ m～500 μ m.The intervals of recess (P) is meant the distance of (bottom each other) between the slot part of recess of adjacency, and the groove depth of recess (H) is meant from the surperficial circumference of shaped rollers 52B and begins the distance till the slot part (bottom) to recess.
In addition, the groove depth of recess (H) is that aspect ratio (H/P) for example is more than 0.3, to be preferably 0.4～0.7 with respect to the ratio of the intervals (P) of recess.
In addition, as the section shape of the recess of transfer mold 53, can enumerate semi-circular shape, half-oval shaped etc.In addition, can be V-shape shape with the pairing acute angle part of prism shape.
Preparation method as above-mentioned transfer mold; After the plating of the surperficial embodiment of the transfer roll that formed by above-mentioned stainless steel, iron and steel etc. such as chromium plating, copper facing, nickel plating, nickel plating-phosphorus etc. is handled; Sometimes remove processing, Laser Processing or chemical etching to what this plating face used diamond blade, metal whetstone etc.; Thereby shape is processed, but be not particularly limited to these methods.
In addition, after having formed above-mentioned transfer mold, for example with the level of the precision of not damaging surface configuration, the surface of transfer roll can be implemented the plating of chromium plating, copper facing, nickel plating, nickel plating-phosphorus etc. and handled.
For more critically, reappearance forms the groove shape of above-mentioned transfer mold well, is preferably the combination of lathe and diamond blade, is preferably below the 5 μ m at the thickness of the chromium plating of implementing on the copper, further be preferably below the 2 μ m.
(variation of the manufacturing approach of resin sheet) for example can be implemented the 2nd extrusion process as the variation of manufacturing approach after carrying operation (S4).The 2nd extrusion process can use resin sheet manufacturing installation 50B shown in Figure 2 to implement.In the 2nd extrusion process, push through the continuous resin sheet of carrying by carrying operation (S4) with the 2nd compression roller (shaped rollers) 52B and the 3rd compression roller 52C clamping 60.The continuous resin sheet 60 that extruding in the 2nd extrusion process is got is peeled off (stripping process) from the 2nd compression roller, after carrying with the side face driving fit ground of the 3rd compression roller 52C, peels off from the side face of the 3rd compression roller 52C.
In addition, other the variation as manufacturing approach for example can begin operation (S3) before in transfer printing, implements the prepressing procedures of extruding in advance.Prepressing procedures can be used resin sheet manufacturing installation 50C shown in Figure 3 and implement.In prepressing procedures, through pushing in advance by continuous resin sheet 60 clampings of sheet manufacturing process (S1) manufacturing with pony press 52D and the 1st compression roller 52A.(preparation carrying operation) carried on continuous resin sheet 60 that pushes and get and the side face driving fit of the 1st compression roller 52A ground; Utilize the 1st and the 2nd compression roller 52A, 52B to carry out transfer printing and begin operation (S3); Produce effect to improving transferring rate, preferably use this manufacturing approach.
In addition, near the 1st compression roller 52A, can be provided for the heater that the surface of the continuous resin sheet 60 on the 1st compression roller 52A, carried is heated.Heater disposes with the side face spaced manner with the 1st compression roller 52A relatively, heats from the continuous resin sheet of face side to carrying.As heater, for example can use known heaters such as infrared heater.
(effect) is in the manufacturing approach of resin sheet of the present invention; Through only making the shape transferred thereon layer be better flowability; And make main stor(e)y is lower flowability; Thereby make the recess shapes that is easy to flow into transfer mold based on the skin section of resin (a), from the shape of the resin of the recess shapes that still is easy to keep to flow into transfer mold 53 after transfer mold 53 is peeled off.In view of the above, the shape transferred thereon rate is improved.Therefore, can on resin sheet, form the high surface configuration of aspect ratio.
Enumerate 1～4 couple of the present invention of embodiment (embodiment) and explain in more detail, but the present invention is not limited to these embodiment.
(embodiment 1, comparative example 1) uses resin sheet manufacturing installation 50C shown in Figure 3 to make 1 described of embodiment 1 and comparative example.The condition of employed manufacturing installation 50 below is shown.The screw diameter of extruder 58 is made as 40mm, will be made as based on the extrusion capacity of extruder 58 2kg/ hour.Line (ラ イ Application) speed was made as 0.32m/ minute, sheet wide (length of Y direction) is made as 25cm.As the shape of the transfer mold of the 2nd compression roller 52B, with spacing P be made as 600 μ m, depth H is made as 300 μ m.(pony press 52D/ the 1st compression roller 52A/ the 2nd compression roller 52B) is made as 80 ℃/80 ℃/80 ℃ with roll temperature.
In embodiment 1, make the PMMA plate of sheet thickness 4mm through extrusion molding (sheet manufacturing process).In embodiment 1, use 2 kinds resin to make the resin sheet (with reference to Fig. 6) of 3-tier architecture.
In the resin (a) that constitutes superficial layer (A), use the copolymer of methyl methacrylate and methyl acrylate.The specification of resin (a) is as follows.
Weight ratio: methyl methacrylate/methyl acrylate=98/2
MFR (a): 1.5g/10 minute (200 ℃, 49N loading condition)
Glass transition temperature Tg (a): 107 ℃
Thickness (one-sided): 0.1mm
In addition, under 230 ℃, 37N (3.8kgf) loading condition, measure the MFR of resin (a), be 9.4g/10 minute.
In the resin (b) that constitutes main stor(e)y (B), use the copolymer of methyl methacrylate and methyl acrylate.The specification of resin (b) is as follows.
Weight ratio: methyl methacrylate/methyl acrylate=94/6
MFR (b): 0.24g/10 minute (200 ℃, 49N loading condition)
Glass transition temperature Tg (b): 102 ℃
Thickness: 3.8mm
In addition, under 230 ℃, 37N (3.8kgf) loading condition, measure the MFR of resin (b), be 1.5g/10 minute.
Superficial layer (A) is 1/38 with the ratio of the thickness of main stor(e)y (B).
In comparative example 1, use above-mentioned resin (b) to make the resin sheet of single layer structure.Except 3-tier architecture is become the single layer structure, identical with the above embodiments.
In embodiment 1, the surface temperature of the resin sheet of just having peeled off from the 2nd compression roller 52B is 105 ℃, and the shape height H ' of this moment is 183 μ m, the shape transferred thereon rate (=H '/H) be 61%.In comparative example 1, the surface temperature of the resin sheet of just having peeled off from the 2nd compression roller 52B is 105 ℃, and the shape height H ' of this moment is 168 μ m, the shape transferred thereon rate (=H '/H) be 56%.
The experimental condition and the result of the test of following table 1 expression embodiment 1 and comparative example 1.It is qualified that the shape transferred thereon rate is that situation more than 60% is judged to be.
[table 1]
Figure BSA00000534112800231
(embodiment 2,3, comparative example 2) use resin sheet manufacturing installation 50C shown in Figure 3 to make 2 described of embodiment 2,3 and comparative examples.The condition of employed manufacturing installation 50C below is shown.The screw diameter of extruder 58 is made as 120mm, will be made as based on the extrusion capacity of extruder 58 700kg/ hour.In embodiment 2,3, linear velocity was made as 2.85m/ minute, in comparative example 2, linear velocity was made as 2.83m/ minute.Embodiment 2,3, and comparative example 2 all is made as 135cm with sheet wide (length of Y direction).Shape as the transfer mold of the 2nd compression roller 52B is made as 400 μ m with spacing P, and depth H is made as 222 μ m.In embodiment 2, (pony press 52D/ the 1st compression roller 52A/ the 2nd compression roller 52B) is made as 80 ℃/85 ℃/97 ℃ with roll temperature, in embodiment 3, is made as 80 ℃/85 ℃/87, in comparative example 2, is made as 80 ℃/85 ℃/95 ℃.
In embodiment 2,3, make the PMMA plate of sheet thickness 3mm through extrusion molding (sheet manufacturing process).In embodiment 2,3, use 2 kinds resin to make the resin sheet (with reference to Fig. 6) of 3-tier architecture.
In the resin (a-2) that constitutes superficial layer (A), use the copolymer of methyl methacrylate and methyl acrylate.The specification of resin (a-2) is as follows.
Weight ratio: methyl methacrylate/methyl acrylate=95/5
MFR (a): 1.4g/10 minute (200 ℃, 49N loading condition)
Glass transition temperature Tg (a): 102 ℃
Thickness (one-sided): (embodiment 2) 0.2mm: (embodiment 3) 0.2mm
In addition, under 230 ℃, 37N (3.8kgf) loading condition, measure the MFR of resin (a-2), be 10.0g/10 minute.
In the resin (b) that constitutes main stor(e)y (B), use the copolymer of methyl methacrylate and methyl acrylate.The specification of resin (b) is as follows.
Weight ratio: methyl methacrylate/methyl acrylate=94/6
MFR (b): 0.24g/10 minute (200 ℃, 49N loading condition)
Glass transition temperature Tg (b): 102 ℃
Thickness: (embodiment 2) 2.6mm: (embodiment 3) 2.6mm
In addition, under 230 ℃, 37N (3.8kgf) loading condition, measure the MFR of resin (b), be 1.5g/10 minute.
In comparative example 2, use above-mentioned resin (b) to make the resin sheet of single layer structure.
In embodiment 2, the surface temperature of the resin sheet of just having peeled off from the 2nd compression roller 52B is 124 ℃, and the shape height H of this moment is 155 μ m, the shape transferred thereon rate (=H '/H) be 61%.In embodiment 3, the surface temperature of the resin sheet of just having peeled off from the 2nd compression roller 52B is 119 ℃, and the shape height H of this moment is 167 μ m, the shape transferred thereon rate (=H '/H) be 75%.In comparative example 2, the surface temperature of the resin sheet of just having peeled off from the 2nd compression roller 52B is 123 ℃, and the shape height H of this moment is 127 μ m, the shape transferred thereon rate (=H '/H) be 57%.
The experimental condition and the result of the test of following table 2 expression embodiment 2,3 and comparative example 2.It is qualified that the shape transferred thereon rate is that situation more than 60% is judged to be.
[table 2]
Figure BSA00000534112800251
(embodiment 4, comparative example 3) use resin sheet manufacturing installation 50C shown in Figure 3 to make 3 described of embodiment 4 and comparative examples.The condition of employed manufacturing installation 50C below is shown.The screw diameter of extruder 58 is made as 120mm, will be made as based on the extrusion capacity of extruder 58 1000kg/ hour.In embodiment 4, linear velocity was made as 4.08m/ minute, in comparative example 3, linear velocity was made as 3.52m/ minute.With regard to sheet wide (length of Y direction), in embodiment 4, be made as 120cm, in comparative example 3, be made as 135cm.Shape as the transfer mold of the 2nd compression roller 52B is made as 400 μ m with spacing P, and depth H is made as 222 μ m.In embodiment 4, (pony press 52D/ the 1st compression roller 52A/ the 2nd compression roller 52B) is made as 80 ℃/85 ℃/87 ℃ with roll temperature, in comparative example 3, is made as 80 ℃/85 ℃/98 ℃.
In embodiment 4, make the PMMA plate of sheet thickness 3mm through extrusion molding (sheet manufacturing process).In embodiment 4, use 2 kinds of resins to make the resin sheet (with reference to Fig. 6) of 3-tier architecture.
In the resin (a-2) that constitutes superficial layer (A), use the copolymer of methyl methacrylate and methyl acrylate.The specification of resin (a-2) is as follows.
Weight ratio: methyl methacrylate/methyl acrylate=95/5
MFR (a-2): 1.4g/10 minute (200 ℃, 49N loading condition)
Glass transition temperature Tg (a): 102 ℃
Thickness (one-sided): 0.15mm
In addition, under 230 ℃, 37N (3.8kgf) loading condition, measure the MFR of resin (a-2), be 10.0g/10 minute.
In the resin (b) that constitutes main stor(e)y (B), use the copolymer of methyl methacrylate and methyl acrylate.The specification of resin (b) is as follows.
Weight ratio: methyl methacrylate/methyl acrylate=94/6
MFR (b): 0.24g/10 minute (200 ℃, 49N loading condition)
Glass transition temperature Tg (b): 102 ℃
Thickness: 2.7mm
In addition, under 230 ℃, 37N (3.8kgf) loading condition, measure the MFR of resin (b), be 1.5g/10 minute.
In comparative example 3, use above-mentioned resin (b) to make the resin sheet of single layer structure.
In embodiment 4, the surface temperature of the resin sheet of just having peeled off from the 2nd compression roller 52B is 135 ℃, and the shape height H of this moment is 155 μ m, the shape transferred thereon rate (=H '/H) be 70%.In comparative example 3, the surface temperature of the resin sheet of just having peeled off from the 2nd compression roller 52B is 131 ℃, and the shape height H of this moment is 127 μ m, the shape transferred thereon rate (=H '/H) be 57%.
The experimental condition and the result of the test of following table 3 expression embodiment 4 and comparative example 3.It is qualified that the shape transferred thereon rate is that situation more than 60% is judged to be.
[table 3]
Figure BSA00000534112800271
Fast and the low embodiment 4 of roll temperature (87 ℃) of linear velocity (4.08m/ minute) reaches the shape transferred thereon rate (70%) that is higher than comparative example 3.
Next, based on embodiment 5,6, the present invention will be described for comparative example 4, but the present invention is not limited to following embodiment.
(raw material of resin sheet) prepared the material of following (1)～(2) as the raw material of resin sheet.
(1) amorphous resin (main stor(e)y (B)): lazy flow polystyrene resin (Japan styrene Co., Ltd. system " HRM40 ")
MFR (b): 1.3g/10 minute (200 ℃, 49N loading condition)
(2) amorphous resin (shape transferred thereon layer (A)): high fluidity polystyrene resin (Japan Polystyrene Inc.'s system " G490N ")
MFR (a): 7.0g/10 minute (200 ℃, 49N loading condition)
(formation of the manufacturing installation of resin sheet) used the device with formation identical with resin sheet manufacturing installation shown in Figure 20.
In addition, as compression roller, prepared the surperficial minute surface chill roll of having implemented chromium plating.
In addition, as the transfer mold that is installed on compression roller, prepared the transfer mold A shown in the table 4.The slot part of half-oval shaped equally spaced is formed at transfer mold A abreast with the mode along the Zhou Fangxiang of compression roller.In addition, in table 4, " spacing P " and " depth H " is respectively the value by aforesaid embodiment definition.
[table 4]
Figure BSA00000534112800281
(embodiment 5; 6 and comparative example 4) at first; To the main extruder of multilayer extruder and the amorphous resin shown in the secondary extruder difference supply schedule 2 with main extruder (screw diameter 40mm)/secondary extruder (screw diameter 20mm); After under 210 ℃～250 ℃ of bowl temperatures, carrying out melting mixing, supply with to 2 layers of distribution type feed sleeve pipe.
Next; T mould via wide 300mm; Under 240 ℃～250 ℃ of T mold temperatures, be sheet with resin extruded in the feed sleeve pipe; Make the resin of supplying with to the feed sleeve pipe from secondary extruder become shape transferred thereon layer (high fluidity resin bed) 61, the resin of supplying with to the feed sleeve pipe from main extruder becomes main stor(e)y (lazy flow resin bed) 62.
Then; With pony press (minute surface chill roll) 52D and the 1st compression roller (minute surface chill roll) 52A clamping through extruding continuous resin sheet 60; Carry in the state on the surface of the 1st compression roller 52A with spooling; Carry out clamping with the 1st compression roller 52A and the 2nd compression roller (shaped rollers) 52B, carry in the state on the surface of the 2nd compression roller 52B with spooling, with pull roller 52G, 52H pulls the continuous resin sheet of peeling off from the 2nd compression roller 52B 60.In view of the above, obtain that the transfer printing of high fluidity resin bed has concave shape and surface configuration transfer printing resin sheet.And, obtain by following formula the resin sheet of gained shape transferred thereon rate T (=H '/H).The result is shown in table 5.
[table 5]
The manufacturing approach of described resin sheet so according to the embodiment of the present invention can improve the shape transferred thereon rate of resin sheet.
More than, based on its embodiment the present invention has been carried out explanation particularly, but the present invention is not limited to above-mentioned embodiment.In the above-described embodiment; Continuous resin sheet as sandwich construction; Both sides at thickness direction form the formation that has shape transferred thereon layer (A) and be sandwiched in the main stor(e)y (B) between this shape transferred thereon layer (A); Constitute a lateral plate surface of shape that transfer printing has transfer mold as superficial layer (A) by resin (a), sheet surface in addition can be made up of other resins different with resin (a).For example constitute other sheet surface, can make the continuous resin sheet of 2 layers of structure by resin (b).
In addition, in the above-described embodiment, as resin sheet, LGP or light diffusing sheet are illustrated, but also can make other resin sheet.Resin sheet manufacturing approach of the present invention is effective to the manufacturing of the shape LGP backlight that is equipped on liquid crystal TV and shape diffuser plate.The present invention is effective especially to the manufacturing of high shape LGP of aspect ratio and shape diffuser plate.
In addition; In the above-described embodiment; Use Fig. 1～Fig. 5 and resin sheet manufacturing installation 50,50B, 50C, 50D, 50E, 50F shown in Figure 20 to carry out the manufacturing of continuous resin sheet, but can use the resin sheet manufacturing installation that to carry out other manufacturing processes.
In addition; The surface temperature of the preferred continuous resin sheet of just having peeled off from shaped rollers is with respect to the glass transition temperature Tg (a) of the resin (a) that constitutes shape transferred thereon layer (A) scope for (Tg (a)-10) ℃～(Tg (a)+30) ℃, but also can be other temperature range.
The surface temperature of the continuous resin sheet of just having peeled off from shaped rollers in addition, can be the scope of Tg (b) ℃～Tg (a) ℃ with respect to the glass transition temperature Tg (b) of the resin (b) that constitutes main stor(e)y (B).
According to the manufacturing approach of the described resin sheet of above-mentioned embodiment of the present invention, can realize being needed on the raising of transferring rate of the shape of resin sheet.

Claims (12)

1. the manufacturing approach of a resin sheet; Possess the resin of heating and melting state is extruded and the sheet manufacturing process that makes continuous resin sheet from mould continuously; Be formed with the transfer printing process of the shaped rollers of transfer mold with using at side face in the said transfer mold of sheet surface transfer of said continuous resin sheet; Wherein, said transfer printing process comprises following operation:
Transfer printing begins operation, the said continuous resin sheet clamping extruding that will make by said manufacturing process with compression roller and said shaped rollers, thus begin shape transferred thereon with the said transfer mold of said shaped rollers in said continuous resin sheet,
The carrying operation, make said transfer printing begin the surface transfer of sheet described in the operation have said transfer mold shape said continuous resin sheet and said shaped rollers the side face driving fit carry and
Stripping process is peeled off the said continuous resin sheet of carrying in the said carrying operation from the side face of said shaped rollers;
The said continuous resin sheet of being made by said manufacturing process is the sandwich construction that has multilayer at the thickness direction of sheet; At least possess following 2 layers: said transfer printing begin to be disposed in the operation said shaped rollers side said surface of formation shape transferred thereon layer A and be adjacent to the main stor(e)y B of the rear side of said shape transferred thereon layer
The said MFR of said shape transferred thereon layer A is more than 1.5 with respect to the ratio of the MFR of said main stor(e)y B, and wherein, said MFR is to be standard with JISK7210, the measured value of under 200 ℃, loading 49N condition, measuring.
2. method according to claim 1, wherein, said transfer printing process comprises following operation:
Prepressing procedures, thus with pony press and said compression roller sandwich that the said continuous resin sheet of being made by said manufacturing process pushes and
Preparation carrying operation, make the said continuous resin sheet that in said prepressing procedures, pushes and said compression roller the side face driving fit carry;
Begin in the operation in said transfer printing, will be with said compression roller and said shaped rollers by the said continuous resin sheet clamping extruding of said preparation carrying operation carrying.
3. method according to claim 1 and 2; Wherein, When the glass transition temperature of the resin a that constitutes said shape transferred thereon layer A is made as Tg (a); The surface temperature that is about to the said shape transferred thereon layer A that the said side face with said shaped rollers joins is (Tg (a)+50) ℃～(Tg (a)+150) ℃ scope, and the surface temperature of the said shape transferred thereon layer A that has just peeled off from the said side face of said shaped rollers is (Tg (a)-10) ℃～(Tg (a)+40) ℃ scope.
4. according to each described method in the claim 1～3, wherein, the thickness of said shape transferred thereon layer A is 1/200～1/10 scope with respect to the ratio of the thickness of said main stor(e)y B.
5. according to each described method in the claim 1～4, wherein, be about to carry out to possess surface heated heating process before said transfer printing begins operation with the said shape transferred thereon layer A of the said continuous resin sheet of carrying with said compression roller driving fit.
6. according to each described method in the claim 1～5; Wherein, In the said transfer mold, on the rotating shaft direction of said shaped rollers and be provided with continuous slot part on a plurality of Zhou Fangxiang in said shaped rollers, the configuration space P of a plurality of said slot parts is 200 μ m～500 μ m.
7. according to each described method in the claim 1～6, wherein, in the said transfer mold, on the rotating shaft direction of said shaped rollers and be provided with continuous slot part on a plurality of Zhou Fangxiang in said shaped rollers, a plurality of said slot parts equally spaced dispose.
8. according to each described method in the claim 1～7; Wherein, In the said transfer mold, on the rotating shaft direction of said shaped rollers and be provided with continuous slot part on a plurality of Zhou Fangxiang in said shaped rollers, the depth H of a plurality of said slot parts is 100 μ m～500 μ m.
9. according to each described method in the claim 1～8; Wherein, In the said transfer mold; On the rotating shaft direction of said shaped rollers and be provided with continuous slot part on a plurality of Zhou Fangxiang, be more than 0.3 with respect to the aspect ratio H/P of the ratio of the configuration space P of a plurality of said slot parts as the depth H of said slot part in said shaped rollers.
10. according to each described method in the claim 1～9; Wherein, In the said transfer mold; On the rotating shaft direction of said shaped rollers and be provided with continuous slot part on a plurality of Zhou Fangxiang in said shaped rollers, the section shape perpendicular to the Zhou Fangxiang of said shaped rollers of said slot part is semicircular shape, approximate half-oval shaped or prismatic.
11. according to each described method in the claim 1～10; Wherein, In the said transfer mold; On the rotating shaft direction of said shaped rollers and be provided with continuous slot part on a plurality of Zhou Fangxiang in said shaped rollers, the section shape perpendicular to the Zhou Fangxiang of said shaped rollers of said slot part is the shape that makes it to be adapted to form optical lens.
12. according to each described method in the claim 1～11, wherein, the resin a that constitutes said shape transferred thereon layer A is phenylethylene resin series or acrylic resin, the resin b that constitutes said main stor(e)y B is phenylethylene resin series or acrylic resin.
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Application publication date: 20120111