CN102762349A - 用于生产超宽宽度膜的浇铸带 - Google Patents
用于生产超宽宽度膜的浇铸带 Download PDFInfo
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Abstract
本发明涉及一种用于借助于溶剂浇铸过程来制造光学膜的浇铸带，更为具体地，涉及一种用于生产超宽宽度膜的浇铸带，该浇铸带被用于在制造用于液晶显示器的偏光器的膜或光学补偿膜时，通过浇铸掺杂剂来生产处于凝胶状态中的膜。
Description
技术领域
本发明涉及一种用于借助于溶剂浇铸过程（solvent casting process）来制造光学膜的浇铸带，更为具体地，涉及一种用于生产超宽宽度膜的浇铸带，该浇铸带在制造一种用于液晶显示器的偏光器的膜或光学补偿膜时，被用于通过浇铸掺杂剂（dope）来生产处于凝胶状态中的膜。
背景技术
酰化纤维素膜具有较高的透明度和机械性能，并且还具有完全不依赖于湿度和温度的尺寸稳定性。因此，它们作为要求那些特性的光学材料的支承件而被广泛地使用。通常，酰化纤维素膜通过浇铸掺杂剂制成，其中，该掺杂剂通过将带有聚合物的溶剂融化到连续的支承件上制成。
该浇铸方法可根据连续的支承件的类型而被主要划分为带式浇铸和鼓（drum）式浇铸。该带式浇铸是一种在带上浇铸掺杂剂、使溶剂变干并将其分离开、以及将膜传送至下一过程的方法，而鼓式浇铸是一种在鼓上浇铸掺杂剂、在未使它变干的情况下将它分离开，以及将膜传送至下一过程的方法。
通常，带式浇铸可制造多种膜，这是应为它能够控制膜的干燥条件，而鼓式浇铸可用于批量生产，这是因为它能够执行高速浇铸。这两种方法都应当精确地用机器加工出鼓和带的表面，该鼓和带为连续支承件，以实现液晶显示器所需的清洁表面。
为了精确地用机器加工出连续支承件的表面，需要精确地抛光带和鼓的表面。该带通过磨制和抛光由不锈钢制成的带制成，而该鼓通过在由碳钢制成的鼓上镀镍和硬铬并对其进行抛光而制成。
参见图1，虽然这在鼓中不是问题，但对于带来说，需要形成连接带的两端部的接缝11来获得连续支承件。焊接被广泛地用于形成该接缝，并且普遍地利用惰性气体钨极保护焊（TIG焊）和激光焊接。该焊接可在抛光之前执行，并且也可在抛光之后执行。应当对焊接部进行抛光以防止在制造膜中出现问题，这是因为焊接部在焊接之后可保留在带上。然而，完全地移除该焊接部是不可能的，并且通过肉眼看到该焊接部是可能的。因此，当偏光器或光学补偿膜通过利用生产的纤维素酰化物制成时，在焊接部被切掉的情况下利用一些产品。
近来，液晶显示器的尺寸逐渐增大，并且相应地，偏光器和光学补偿膜的宽度增大。因此，需要增大纤维素酰化物的宽度来适应宽度的增大并增大制造偏光器和光学补偿膜的产量。
由于宽度为2030mm或更大的鼓可通过现今已经研发的技术制成，因此，可制成较宽的膜，而可制造出最大宽度为2030mm的带是已知的。因此，可将两个带纵向地焊接以获得宽度超过2030mm的宽带；然而，通过焊接，在两条带之间的纵向中心处形成接缝，使得在制成的膜上留下了中央接缝的印痕，并且该膜本身无法被使用。
在带上浇铸的掺杂剂在膜中通过延展器（tender）和干燥器被分离开并制造而成。该膜从浇铸到分离过程中，在宽度方向上接触，使得由炉工执行必要的延展。该膜的尺寸在利用干燥器的干燥过程中大体上不变。通常，执行切断膜的两个端部的修边过程以平稳地传送该膜并保持整个膜的特性，并且，在浇铸过程、延展过程、和干燥过程之后，执行一到两次该修边过程。
因此，当利用宽度为2030mm的带时，可获得的膜的宽度为2030mm或更小。考虑到在实际浇铸中的稳定性、延展器中的延展、以及膜的两个端部的切断，可获得的最大宽度为1800mm，使得它随着宽度的增大而难于制造膜。
发明内容
技术问题
本发明提供一种用于生产超宽宽度膜的浇铸带，其使得在不会在制造膜时在膜上留下焊接部的印痕的情况下制造超宽宽度膜成为可能。
本发明提供一种用于生产超宽宽度膜的浇铸带，其使得通过利用用于利用激光进行的横向焊接的夹具而提高焊接部的质量成为可能。
解决该问题的技术方案
本发明提供一种浇铸带，其中，在借助于溶剂浇铸过程来制造光学膜时，浇铸聚合物溶剂以形成凝胶状态的膜，其中，该浇铸带100包括横向焊接部111，这些横向焊接部111沿浇铸带100的横向方向形成以连接相邻的浇铸带区段110，使得相邻的浇铸带区段110在未纵向地形成焊接部的情况下被纵向地连接，并且当浇铸带区段110的宽度为tb时，横向焊接部111的宽度tw为9.95tb≤tw≤1.05tb，并且形成在横向焊接部111中的针孔的尺寸为20~50μm而深度不超过50μm。
在本发明中，横向焊接部111的宽度Ww可不超过2mm，横向焊接部111可制成为与浇铸带100的横剖面成20°的角度，并且浇铸带100的宽度可以是2000mm或更大。
本发明的有益效果
根据本发明，制造宽度为2000mm或更大而不留下焊接部的印痕的宽膜成为可能，这是因为纵向彼此相邻的浇铸带区段通过横向焊接部连接，而不是通过连接彼此横向相邻的浇铸带区段的纵向焊接部连接。
在通过利用激光进行的纵向焊接制成超宽宽度的浇铸带时，难于在焊接中固定带并且需要焊接长带，使得难于满足在制造光学膜中所需要的质量。然而，超宽宽度的浇铸带仅通过横向焊接制造而成，可利用夹具，使得在本发明中，在浇铸带区段固定的情况下执行横向焊接是可能的；因此，提高横向焊接部的质量是可能的。
此外，根据本发明，在满足面中相差、面上相差、和膜的厚度中的限制条件的同时，容易地制造具有必要宽度的膜是可能的，这是因为，制造宽膜而不会增大膜在光学膜的制造过程的延展过程中的伸长率是可能的。
附图说明
本发明的上述及其它目的、特征和优点将通过下面对于优选实施方式结合附图给出的描述而变得明白，附图中：
图1是相关领域的浇铸带的立体图；
图2是本发明的实施方式的立体图；
图3是本发明的实施方式的平面图。
主要元件的详细说明
100：浇铸带
110：浇铸带区段
111：横向焊接部
具体实施方式
在下文中，将参照附图对本发明的实施方式进行详细的描述。
本发明的实施方式涉及一种根据本发明的用于生产超宽宽度膜的浇铸带。
图2是本发明的实施方式的立体图，并且图3是本发明的实施方式的平面图。
制造光学铸件借助于溶剂浇铸来执行浇铸过程、分离过程、延展过程、干燥过程、和缠绕过程，该浇铸过程利用聚合物溶液将包含聚合物溶液的掺杂剂浇铸在带上以制造膜，该分离过程将在该浇铸过程中形成的凝胶状态的膜分离开，该延展过程利用延展器来延伸分离开的膜，该干燥过程使该延展后的膜变干，该缠绕过程缠绕该干燥后的膜。
本发明的实施方式涉及一种用在用于借助于溶剂浇铸来制造光学膜的浇铸过程中的带，即，一种用于制造超宽宽度膜的浇铸带，其中，浇铸包含聚合物溶剂的掺杂剂以形成凝胶状态的膜。
参见图2，用于制造超宽宽度膜的浇铸带100由五个浇铸带区段110组成。浇铸带区段110的尺寸和形状可以是相同的。
参见图2，在浇铸带100的纵向方向上彼此相邻的浇铸带区段110通过横向焊接部111连接。即，横向焊接部111为连接纵向布置的相邻的浇铸带区段110的接缝，以通过浇铸带区段110制成连续的带。横向焊接部111通过焊接形成，例如，通过钇铝石榴石（YAG）激光焊接或普通的激光焊接形成。
参见图3，当横向焊接部通过YAG焊形成时，横向焊接部111的宽度Ww可不超过1mm，并且当它通过普通的激光焊接形成时，横向焊接部111的宽度Ww可不超过2mm。当横向焊接部111的宽度是较大的时，焊接部可能会在膜上留下印痕，使得横向焊接部111的宽度Ww部超过2mm是优选的。
参见图3，横向焊接部111以与浇铸带100的横剖面成20°的θ角形成。这是为了防止横向焊接部111因在用于制造超宽宽度膜的浇铸带110中施加拉力的情况下，在操作中最大程度地分配施加至浇铸带区段110的力而破裂。
虽然在附图中并未示出，但在横向焊接部111中形成有针孔（pinhole），该针孔的尺寸为20~50μm且深度不超过50μm。焊接中形成砂眼（blowhole），并且它们在针孔中制成。可通过普通人的肉眼看到的针孔的最大尺寸为20μm。因此，50mm范围内的尺寸都不会产生问题，但更大的尺寸在用于LCD的膜的使用中存在限制。
另一方面，虽然在附图中并未示出，但当浇铸带区段110的厚度为tb时，横向焊接部的厚度tw为9.95tb≤tw≤1.05tb。即，横向焊接部111与其它部分之间的厚度差不超过5%。这是为了防止焊接部在溶剂浇铸中在膜上留下印痕。
同时，浇铸带100的宽度为2000或更大，例如，2000mm或2030mm，这是所述领域中的最大带宽。
本发明具有下列优点，即，通过减小形成在横向焊接部中的针孔的尺寸和深度，并减小横向焊接部111与其它部分之间的厚度差，使得制造宽度为1800mm或更大的超宽宽度膜而不会将该横向焊接部111印在该膜上是可能的。即，当通过溶剂浇铸来制造光学膜时，与普通的模压浇铸成型相比，该膜的表面状态极大地受到该带的表面状态的影响；然而，根据本发明，在没有留下焊接部印痕的情况下获得宽膜是可能的。
当超宽宽度的浇铸带100通过利用激光的纵向焊接制造而成时，将左侧带固定至横向左侧，并将连接至左侧带的右侧带固定至横向右侧是不可能的，这是因为无法利用夹具，使得由于劣质的纵向焊接，而在焊接部中容易地产生缺陷。本发明通过执行横向地焊接该浇铸带100的横向焊接、而非纵向地焊接该浇铸带100的纵向焊接来制造用于生产超宽宽度膜的浇铸带。另一方面，当通过利用激光横向焊接来制造超宽宽度的浇铸带100时，可利用夹具，使得在本发明中，在浇铸带区段110被固定的情况下执行横向焊接是可能的；因此，提高横向焊接部111的质量是可能的。
本发明具有如下优点：在满足面内相位差、面上相位差、和膜的厚度的有限条件的同时，容易地制造具有必要宽度的膜，这是因为制造宽膜而不会增大膜在光学膜的制造过程的延展过程中的伸长度是可能的。
Claims (4)
1.一种用于生产超宽宽度膜的浇铸带，其中，在借助于溶剂浇铸过程来制造光学膜时，浇铸聚合物溶剂以形成凝胶状态的膜，其中，所述浇铸带100包括横向焊接部111，所述横向焊接部111沿所述浇铸带100的横向方向形成以连接相邻的浇铸带区段110，使得所述相邻的浇铸带区段在未纵向地形成焊接部的情况下被纵向地连接，并且当所述浇铸带区段110的宽度为tb时，所述横向焊接部111的宽度tw为9.95tb≤tw≤1.05tb，并且形成在所述横向焊接部111中的针孔的尺寸为20～50μm并且深度不超过50μm。
2.根据权利要求1所述的用于生产超宽宽度膜的浇铸带，其中，所述横向焊接部111的宽度Ww不超过2mm。
3.根据权利要求2所述的用于生产超宽宽度膜的浇铸带，其中，所述横向焊接部111制成为与所述浇铸带100的横剖面成20°的角度。
4.根据权利要求3所述的用于生产超宽宽度膜的浇铸带，其中，所述浇铸带100的宽度为2000mm或更大。
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| PCT/KR2010/008090 WO2011074789A2 (en) | 2009-12-14 | 2010-11-16 | Casting belt for producing transcendental wide width film |
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| KR101389520B1 (ko) | 2014-04-25 |
| CN102762349B (zh) | 2016-02-17 |
| KR20110067192A (ko) | 2011-06-22 |
| TW201136739A (en) | 2011-11-01 |
| EP2512767A4 (en) | 2014-07-16 |
| JP2013513498A (ja) | 2013-04-22 |
| JP5727505B2 (ja) | 2015-06-03 |
| EP2512767B1 (en) | 2016-01-27 |
| EP2512767A2 (en) | 2012-10-24 |
| US20120276240A1 (en) | 2012-11-01 |
| WO2011074789A3 (en) | 2011-11-10 |
| WO2011074789A2 (en) | 2011-06-23 |
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