CN1721167A - 生产热塑性树脂层压片材的方法 - Google Patents

生产热塑性树脂层压片材的方法 Download PDF

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Publication number
CN1721167A
CN1721167A CNA2005100836866A CN200510083686A CN1721167A CN 1721167 A CN1721167 A CN 1721167A CN A2005100836866 A CNA2005100836866 A CN A2005100836866A CN 200510083686 A CN200510083686 A CN 200510083686A CN 1721167 A CN1721167 A CN 1721167A
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China
Prior art keywords
thermoplastic resin
sheet
laminating
membrane
film
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CNA2005100836866A
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English (en)
Inventor
长谷典昭
渡边耕一郎
野岛孝之
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JAPAN OIL AND GREASE Ltd
NOF Corp
Sumitomo Chemical Co Ltd
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JAPAN OIL AND GREASE Ltd
Sumitomo Chemical Co Ltd
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Application filed by JAPAN OIL AND GREASE Ltd, Sumitomo Chemical Co Ltd filed Critical JAPAN OIL AND GREASE Ltd
Publication of CN1721167A publication Critical patent/CN1721167A/zh
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    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1429—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface
    • B29C65/1432—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface direct heating of the surfaces to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/7858—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined
    • B29C65/7888—Means for handling of moving sheets or webs
    • B29C65/7894—Means for handling of moving sheets or webs of continuously moving sheets or webs
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/91423—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the joining tools using joining tools having different temperature zones or using several joining tools with different temperatures
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Abstract

提供了生产热塑性树脂层压片材的方法，其中热塑性树脂薄膜以足够的粘合力被结合到热塑性树脂片材上，并且该层压片材通过以下步骤获得：在其被层压的表面的每一个具有在预定的特定范围内的温度时，将热塑性树脂薄膜和热塑性树脂片材夹持在层压辊之间，然后对它们进行压制。

Description

生产热塑性树脂层压片材的方法
技术领域
本发明涉及生产热塑性树脂层压片材的方法，并且具体地涉及这样一种生产热塑性树脂层压片材的方法，其中热塑性树脂薄膜通过热-焊接被层压到热塑性树脂片材上。
背景技术
日本公开待定专利出版物06-126854/1994公开了如图5所示的热塑性树脂层压片材(其也被仅仅称为“层压片材”)(A)的生产方法，其中热塑性树脂薄膜(其也被仅仅称为“薄膜”)(F)被层压到热塑性树脂片材(其也被仅仅称为“片材”)(S)的一个侧面上(如图4(a)所示)或者每个侧面上(如图4(b)所示)，并且该方法包括，如图5所示，在所述片材(S)处于加热状态下，将可热-焊接到所述片材(S)上的薄膜(F)本身迭加在所述片材(S)上，而不将薄膜(F)加热，并且将它们夹持在一对层压辊(21，22)之间，然后将它们用辊子(21，22)压制，以便将它们热-焊接在一起。
上述生产方法并不总是能够提供在片材(S)和薄膜(F)之间具有满意的结合强度的层压片材(A)。例如，当使用锯子将层压片材(A)切割时，薄膜(F)易于在切割表面脱层。
发明内容
因此，本申请的发明人已经进行了深入的研究，以便开发能够容易地生产热塑性树脂层压片材的方法，其中薄膜(F)以足够的粘合力被层压到片材(S)上。因此，本发明人已经发现，其中薄膜以足够的粘合力结合到片材(S)上的层压片材可以通过以下步骤获得：将它们夹持在层压辊之间，同时其被层压的表面的每一个(即片材(S)的层压表面和薄膜(F)的层压表面)具有处于预定特定范围内的温度，然后将它们压制，并且由此完成了本发明。
即，本发明提供了生产热塑性树脂层压片材(A)的方法，其中热塑性树脂薄膜(F)被层压在热塑性树脂片材(S)的至少一个表面上，所述方法包括以下步骤：
将热塑性树脂薄膜(F)迭加在处于加热状态的热塑性树脂片材(S)上；
将它们夹在一对层压辊子(21，22)之间；和
借助于层压辊子(21，22)对它们进行压制，以便将它们热-焊接在一起，
其中，在所述夹持步骤中，热塑性树脂片材(S)的层压表面(Sa)具有满足以下不等式(I)的温度(Ts)：
Tgs+5℃≤Ts≤Tgs+40℃                (I)
(其中“Ts”是热塑性树脂片材(S)的层压表面(Sa)的温度，和“Tgs”是热塑性树脂片材(S)的层压表面(Sa)的玻璃化转变温度)；并且
热塑性树脂薄膜(F)的层压表面(Fa)具有满足以下不等式(II)和(III)的温度(Tf)：
Tgf-15℃≤Tf≤Tgf+40℃               (II)
(其中“Tf”是热塑性树脂薄膜(F)的层压表面(Fa)的温度，和“Tgf”是热塑性树脂薄膜(F)的层压表面(Fa)的玻璃化转变温度)，和
Tf≥TgF+Tgs-Ts                       (III)
(其中Ts、Tf、Tgs和Tgf具有以上定义的含义)。
本发明的方法可以使用在图1中作为生产热塑性树脂层压片材(A)的一个实例显示的设备进行，其中热塑性树脂薄膜(F)可以层压在热塑性树脂片材(S)的至少一个侧面上。设备(1)包括一对层压辊(21，22)，该层压辊将热塑性树脂片材(S)和迭加在其上的热塑性树脂薄膜(F)夹持和压制，以便将它们热-焊接在一起，借此可以生产热塑性树脂层压片材(A)。该设备还包括加热器(8)，其将热塑性树脂薄膜(F)加热，使得薄膜(F)的层压表面(Fa)的温度(Tf)满足上述不等式(II)和(III)。此外，该设备可以包含用于加热热塑性树脂片材(S)的加热器，使得片材(S)的层压表面(Sa)的温度(Ts)满足上述不等式(I)。可选择地，层压辊(21，22)可以具有加热器的功能。应当指出，设备(1)被设置成使得借助于加热器(8)被加热的热塑性树脂薄膜(F)被迭加在热塑性树脂片材(S)上，并且它们被夹在辊子(21，22)之间并且被辊子(21，22)夹持。因此，本发明还提供了用于实施本发明方法的设备，其中该设备包括加热器(8)，借助于加热器(8)，热塑性树脂薄膜(F)的层压表面的温度(Tf)得到控制，和任选的加热器，通过该加热器热塑性树脂片材(S)的层压表面的温度(Ts)得到控制，使得满足不等式(I)、(II)和(III)。
按照本发明，提供了热塑性树脂层压片材，其中热塑性树脂薄膜以足够的粘合力被结合到热塑性树脂片材上。
附图说明
图1图解地显示了用于生产本发明热塑性树脂层压片材的设备的一个实例。
图2图解地显示了用于生产本发明热塑性树脂层压片材的设备的另一个实例。
图3图解地显示了用于生产本发明热塑性树脂层压片材的设备的另一个实例。
图4(a)和图4(b)分别显示了形成热塑性树脂层压片材的要素。
图5图解地显示了用于生产普通方法的热塑性树脂层压片材的设备的一个实例。
在附图中，附图标记或者字母表示以下要素：
1和1’            用于生产热塑性树脂层压片材的设备
3                 模头
5                 用于加热片材的加热器
6                 支持机械装置(导辊)
7                 挤出机
8                 用于加热薄膜的加热器
21，22            层压辊
41                第一压延辊
42                第二压延辊
43                第三压延辊
91，92            拉伸辊
A                 热塑性树脂层压片材
C                 接触周边长度(弧长)
F                 热塑性树脂薄膜
F1                原料薄膜辊
Fa                层压表面
Fb                非层压表面
Fh                表面处理层
P                 热塑性树脂
S                 热塑性树脂片材
Sa                层压表面
Sb                非层压表面
具体实施方式
参考图1到4，以下将详细说明本发明，尤其是其方法。图1到3的每一个图解地显示了实施本发明方法以生产热塑性树脂层压片材(A)的设备的实例。图4图解地显示了通过本发明生产方法生产的热塑性树脂层压片材(A)的层状结构。
用于本发明生产方法中的热塑性树脂片材(S)包含热塑性树脂。形成片材(S)的热塑性树脂的实例包括丙烯酸树脂、苯乙烯树脂、甲基丙烯酸甲酯-苯乙烯共聚物树脂、聚碳酸酯树脂、丙烯腈-丁二烯-苯乙烯三元共聚物树脂(ABS树脂)、丙烯腈-苯乙烯共聚物树脂(AS树脂)、氯乙烯树脂、聚烯烃树脂例如聚乙烯和聚丙烯、聚酯树脂、聚缩醛树脂、氟树脂例如聚偏二氟乙烯(PVDF)、尼龙树脂及其他热塑性树脂。这类热塑性树脂可以包含添加剂，例如热稳定剂、抗氧化剂、光稳定剂、紫外线吸收剂、着色剂、增塑剂和抗静电剂。此外，热塑性树脂可以包含弹性颗粒。可以使用两种或多种类型的热塑性树脂来制备热塑性树脂片材(S)。
作为所述热塑性树脂片材(S)，可以使用例如热塑性连续片材(S)，其在挤出过程中被连续地生产，其中热塑性树脂(P)被加热和熔融，然后通过模头(3)挤出，如图1到3所示。
为了加热和熔融热塑性树脂(P)，可以使用挤出机(7)。在被挤出机(7)捏和时，热塑性树脂(P)被加热和熔融，从而将熔融状态的树脂提供给模头(3)。
处于加热和熔融状态的热塑性树脂被连续地通过模头(3)挤出，成为片材形式，因此形成热塑性树脂连续片材(S)。例如，可以将T-模头用作模头(3)。模头(3)可以将热塑性树脂(P)挤出形成单层形式或者多层形式，例如双层形式或者三层形式。通过使用将热塑性树脂(P)挤出形成单层形式的模头，获得了单层热塑性树脂片材(S)。通过使用将树脂挤出形成多层形式的模头来共挤出两种或多种类型的热塑性树脂，获得了多层的热塑性树脂片材(S)。
从模头(3)挤出的热塑性树脂片材(S)可以按原样直接插入到层压辊(21，22)之间的间隙中，以便将其用于与薄膜(F)层压。可选择地，从模头(3)挤出的热塑性树脂片材(S)可以用压延辊(41、42、43)辊轧，然后进行层压，如图1到3所示。当片材(S)被辊轧时，压延辊(41、42、43)的直径可以为不小于大约15厘米和不大于大约60厘米。压延辊(3)的数目不被特别地限制，只要该数目是两个或两个以上，该数目允许压延辊(3)将热塑性树脂片材(S)夹持和辊轧。在示于图1到3中的设备(1)中，使用了三个压延辊(41、42、43)。使用所示的生产设备(1)，从模头(3)挤出的热塑性树脂片材(S)首先通过夹在第一压延辊(41)和第二压延辊(42)之间而被辊轧，然后在缠绕和附着在第二压延辊(42)上的同时，进一步通过夹在第二压延辊(42)和第三压延辊(43)之间而被进一步辊轧。在刚刚从模头(3)挤出之后或者在刚刚由压延辊(41、42、43)辊轧之后，热塑性树脂片材(S)处于加热的状态，并且其层压表面(Sa)的温度(Ts)可以在[Tgs-20℃]和[Tgs+20℃]之间的范围内，其中Tgs是片材(S)的层压表面(Sa)的玻璃化转变温度。
应当指出，在本发明中提到的玻璃化转变温度用以指本发明领域中所使用的普通的玻璃化转变温度，并且其按照JIS K 7121(相当于ASTM D 3418)进行测量。
热塑性树脂片材(S)可以具有大约1毫米到大约20毫米的厚度，和大约200毫米到大约2500毫米的宽度。
用于本发明生产方法中的热塑性树脂薄膜(F)包含热塑性树脂。在从辊(F1)缠出时，可以使用热塑性树脂连续薄膜，其已经被卷成原料薄膜辊(F1)。可选择地，薄膜(F)可以是叶片薄膜的形式。当薄膜(F)是叶片形式的时，薄膜(F)可以被一个接一个地插入到层压辊(21，22)之间的间隙中。形成薄膜(F)的热塑性树脂的实例包括，与上述用于片材(S)的热塑性树脂类似地，丙烯酸树脂、苯乙烯树脂、甲基丙烯酸甲酯-苯乙烯共聚物树脂、聚碳酸酯树脂、ABS树脂、氯乙烯树脂、聚烯烃树脂、聚酯树脂、聚缩醛树脂、氟树脂、尼龙树脂等等。
热塑性树脂薄膜(F)可以包含添加剂，例如热稳定剂、抗氧化剂、光稳定剂、紫外线吸收剂、着色剂、增塑剂和抗静电剂。此外，薄膜(F)可以包含弹性颗粒。包含弹性颗粒的热塑性树脂薄膜(F)倾向于具有优异的柔顺性，因此其能够容易地被处理，这在薄膜被使用时是优选的。弹性颗粒的实例包括丙烯酸酯共聚物树脂颗粒、聚丁二烯橡胶颗粒、苯乙烯-丁二烯共聚物橡胶颗粒、丁二烯-丙烯酸酯共聚物橡胶颗粒及其他弹性颗粒。
热塑性树脂薄膜(F)可以是由单一层制成的单层薄膜或者可以是其中两种或多种类型的层被层压的多层薄膜。薄膜(F)的厚度可以小于片材(S)的厚度，并且为大约50μm到大约1000μm，并且薄膜(F)的宽度可以与热塑性树脂片材(S)的宽度相似或者相同。
作为热塑性树脂薄膜(F)，使用了具有可与片材(S)热-焊接的性能的薄膜，即其能够借助于热-焊接被层压到热塑性树脂片材(S)上。例如，薄膜(F)可以是具有层压表面(Fa)的薄膜，该层压表面(Fa)由与热塑性树脂片材(S)的层压表面(Sa)的材料相同的材料制成。此外，当片材(S)的层压表面(Sa)由丙烯酸树脂或者甲基丙烯酸甲酯-苯乙烯共聚物树脂制成时，薄膜(F)可以是具有层压表面(Fa)的薄膜，该层压表面(Fa)由丙烯酸树脂、甲基丙烯酸甲酯-苯乙烯共聚物树脂、苯乙烯树脂、ABS树脂、氟树脂、尼龙树脂等等制成。薄膜(F)的层压表面(Fa)可以经受表面处理，以便有助于与热塑性树脂片材(S)的热-焊接。
热塑性树脂薄膜(F)的非层压表面(Fb)(即相对于层压表面(Fa)的另一个表面)可以在其上配置有至少一个表面处理层(Fh)。这类表面处理层还可以被称为功能覆盖层，因为其为薄膜(F)提供需要的功能。表面处理层(Fh)的实例包括提高表面硬度的硬涂层、抑制可见光的表面反射的抗反射层、提供防眩目性能的防眩层、阻断具有特定波长的光的光阻断层、提供抗静电性的抗静电层、提供导电性的导电层、调节色调的色调较正层、提高薄膜(F)和如上所述的表面处理层之间的粘合力的内聚层，或者当使用许多的表面处理层时提高两个表面处理层之间的粘合力的内聚层。表面处理层(Fh)可以具有大约0.1微米到大约50微米的厚度。
任选的硬涂层可以作为单层形成，并且可以例如是固化层，其通过多官能单体的固化(或者聚合)形成。例如，可以举例以下层：
利用活化能量射线，例如紫外线、电子射线等等，将至少一种多官能可聚合化合物固化而形成的固化层，该多官能可聚合化合物具有至少两个选自丙烯酰基基团和甲基丙烯酰基基团的基团(例如聚氨酯丙烯酸酯、聚酯丙烯酸酯、聚醚丙烯酸酯、聚氨酯甲基丙烯酸酯、聚酯甲基丙烯酸酯、聚醚甲基丙烯酸酯等等)；和
通过加热以使交联层硬化而形成的固化层，该交联层包括聚硅氧烷基材料、蜜胺基材料或者环氧树脂基材料，该材料是用于树脂的可交联的原材料。
特别地，从层的耐久性和处理的角度讲，通过固化以使聚氨酯丙烯酸酯聚合形成的固化层和由用于树脂的聚硅氧烷基可交联原材料制造的固化层是优异的。硬涂层可以具有大约1微米到大约20微米的厚度。
任选的抗反射层可以具有单层结构，该单层结构只具有单一的低折射率层，或者具有多层结构，该多层结构具有许多的层，例如具有高折射率层和低折射率层的双层结构；具有中等折射率层、高折射率层和低折射率层的三层结构，具有高折射率层、低折射率层、高折射率层和低折射率层的四层结构。应当注意到，上述折射率层是以其从最接近于薄膜(F)到最远离薄膜(F)的位置的次序指出的。在抗反射层作为表面处理层(Fh)提供的情况下，当优选地还提供其他层例如硬涂层时，所述其他层通常位于抗反射层和薄膜(F)之间。特别地，在抗反射层和薄膜(F)之间存在硬涂层是优选的，因为提高了表面硬度。
如上所述的表面处理层(Fh)可以通过任何普通的涂布技术形成，例如湿涂布方法、干涂布方法等等。从产率和生产成本的角度讲，湿涂布方法是优选的，它们当中更优选的是辊式涂布方法，因为其允许表面处理层的连续形成。如上所述的热塑性树脂薄膜(F)可以被层压到热塑性树脂片材(S)的一个侧面上，如图1所示，或者层压到热塑性树脂片材(S)的每个侧面上，如图2和3所示。
在按照本发明的方法中，在热塑性树脂薄膜(F)被迭加在热塑性树脂片材(S)上之后，它们被插入到一对层压辊(21，22)之间的间隙中，使得它们被所述辊子夹持。层压辊(21，22)是将片材(S)和薄膜(F)夹持和压制以将它们层压在一起的辊子。层压辊(21，22)的直径可以为大约5厘米到大约30厘米。层压辊(21，22)的表面可以是金属的，例如不锈钢，但是从保护薄膜(F)的非层压表面(Fb)的角度讲，所述表面优选由橡胶制成。这样的辊可以被称为橡胶辊。作为形成橡胶辊的表面的橡胶材料，可以举例硅橡胶、丁基橡胶和乙烯-丙烯-二烯三元共聚物橡胶(EPDM橡胶)。
层压辊(21，22)可以是拉伸辊，如图1和2所示，其本身借助于驱动机构例如马达(未显示)旋转，以便将片材(S)和薄膜(F)拉伸，或者它们可以是自由辊，如图3所示，其本身不被驱动，而是与拉伸辊(91，92)同步旋转，该拉伸辊(91，92)由驱动机构(未显示)驱动，以便在层压之后将层压片材(A)拉伸。
夹在一对辊子(21，22)之间的片材(S)和薄膜(F)由这些辊子(21，22)压制。考虑到足够的热-焊接，压制优选使用不小于500N/m(大约50kgf/m)的线压力进行。此外，当薄膜(F)在其非层压表面(Fb)上具有表面处理层(Fh)时，并且特别是当这样的表面处理层(Fh)包括抗反射层和/或硬涂层时，压制优选使用不大于3000N/m(大约300kgf/m)的线压力进行，以防止表面处理层(Fh)的任何损坏(例如开裂)。
在本发明的方法中，在片材(S)和薄膜(F)由层压辊(21，22)夹持时，热塑性树脂片材(S)的层压表面(Sa)具有满足上述不等式(I)的温度(Ts)，热塑性树脂薄膜(F)的层压表面(Fa)具有满足上述不等式(II)和(III)的温度(Tf)。当片材的层压表面(Sa)具有低于(Tgs+5℃)的温度(Ts)时，或者当薄膜的层压表面(Fa)具有低于(Tgf-15℃)的温度(Tf)时，或者该温度不满足不等式(III)时，难以获得具有足够的粘合力的层压。此外，当片材的层压表面(Sa)具有高于(Tgs+40℃)的温度(Ts)时，或者当薄膜的层压表面(Fa)具有高于(Tgf+40℃)的温度(Tf)时，往往难以借助于层压辊(21，22)进行压制。
为了使热塑性树脂片材的层压表面具有满足不等式(I)的温度(Ts)，片材(S)可以借助于片材加热器(5)加热，如图1到3所示。作为片材加热器(5)，可以使用任何普通的加热器，例如电加热器、红外线加热器、热空气加热器等等。热塑性树脂片材(S)的层压表面(Sa)通常被加热。当片材(S)的两个表面被薄膜(F)层压时，片材(S)的两个表面通常均被加热。当片材的一个表面被薄膜层压时，可以仅仅将作为层压表面(Sa)的片材(S)的所述一个表面加热，或者可以将片材(S)的两个表面加热。
当片材(S)通过压延辊辊轧时，在围绕辊子(41、42、43)通过时其可以被加热。优选，将离开辊子(43)的片材(S)在所述片材保持平的状态时被加热，因为这样的保持步骤倾向于生产具有较小翘曲的层压片材(A)。为了加热片材，同时将其保持在平的状态，可以使用例如支持机械装置(6)。在图1到3中举例说明的生产设备(1)，作为支持机械装置(6)，使用了许多的导辊(6)，其被平行地和水平地布置。这样的导辊(6)可以是例如市售可得的那些，它们作为辊台销售。片材(S)优选在由支持机械装置(6)保持在平的状态时被输送，在这期间其通过加热器被加热。应当注意到，片材(S)不一定需要保持精确地平的状态，并且可以一般地保持为这样一种平的状态，使得可以不残余应力。
在刚刚离开模头(3)之后或者在刚刚由压延辊(41、42、43)辊轧之后片材(S)的表面温度(Ts)，如图1到4所示，可以已经处于满足不等式(I)的范围内，并且在此情况下，片材(S)可以按照原样被插入到辊子(21，22)之间的间隙中，而不被加热。
为了使薄膜(F)具有其温度(Tf)满足不等式(II)和(III)的层压表面(Fa)，在生产设备(1)中的加热器(加热设备)(8)可以用来加热薄膜(F)，如图1到3所示。
在示于图1中的生产设备(1)中，层压辊(21，22)之一(21)与薄膜(F)接触并且由感应加热或者作为用于加热薄膜(F)的加热器(8)的加热器被加热。在示于图2中的生产设备(1)中，一对辊子(21，22)分别与薄膜(F)接触，并且可以作为用于加热薄膜(F)的加热器(8)。辊子(21，22)之一或两者被加热，以作为用于加热薄膜(F)的加热器(即加热辊)，借此薄膜(F)可以在围绕辊子(21，22)通过并且与其接触时被加热。因此加热的薄膜(F)按照原样被插入到辊子(21，22)之间的间隙中。
在被辊子(21，22)夹持之前薄膜(F)接触辊子(21)的接触周边长度(C)(参考图1中的双头箭头)是足够长的，以便薄膜(F)的层压表面(Fa)具有满足不等式(II)和(III)的温度(Tf)。当薄膜(F)由层压辊(21)加热时，其中当围绕所述辊子通过时接触周边长度(C)为20毫米到300微米，可以容易地生产包含具有较少折皱的薄膜(F)的层压片材(A)，其横向收缩比例不大于20％，这是优选的。
在示于图3中的生产设备(1)中，用于加热薄膜的加热器(8)被提供在原材料辊(F1)和层压辊(21)之间。作为这样的加热器(8)，可以使用任何普通的一种，例如电加热器、红外线加热器、热空气加热器等等。当热塑性树脂薄膜(F)使用这样的加热器(8)加热时，薄膜可以从将与片材(S)层压的层压表面(Fa)的侧面加热。可选择地，薄膜可以从非层压表面(Fb)的侧面加热，只要层压表面的温度(Tf)满足不等式(II)和(III)。
对于通过本发明方法生产的热塑性层压片材(A)，热塑性树脂薄膜(F)以足够的粘合力被结合到热塑性树脂片材(S)上。因此，甚至当层压片材(A)使用例如电锯切割时，很少观察到薄膜(F)与片材(S)的脱层。
本发明将通过实施例进一步详细地解释。然而本发明不被限制在这些实施例和上述实例中。在以下实施例的每一个中，丙烯酸树脂片材的层压表面温度(Ts)以及丙烯酸树脂薄膜的层压表面温度(Tf)，两者都刚好是在用层压辊夹持之前的温度，通过红外线辐射温度计(由Keyence公司制造的“IT2-80”)测量。
实施例
实施例1
如图1所示，通过挤出机(7)将具有105℃的玻璃化转变温度(Tgs)的丙烯酸树脂(P)加热、熔融和捏和，并且挤出通过模头(3)，然后用三个各自具有200毫米直径的压延辊(41、42、43)辊轧，获得连续丙烯酸树脂片材(S)，其具有2毫米的厚度和200毫米的宽度。将如此获得的片材(S)，在借助于导辊(6)被一般水平地支持的同时，通过远红外加热器(5)从其两个表面加热，并且将该片材(S)提供到一对各自具有100毫米直径的层压辊(21，22)之间的间隙中。控制加热器(5)的功率，使得刚好在被层压辊(21，22)夹持前，丙烯酸树脂片材(S)的层压表面(Sa)具有115℃的温度(Ts)。
另一方面，将具有单一丙烯酸树脂层的丙烯酸树脂连续薄膜(F)，其玻璃化转变温度(Tgf)为80℃并且厚度为125微米，没有进行表面处理，从原料薄膜材料辊(F1)展开，并且其围绕层压辊(21，22)的一个(21)通过，其中接触周边长度(C)为40mm。这样的薄膜(F)被放置在上述丙烯酸树脂连续片材(S)的一个表面(Sa)上，然后它们由层压辊(21，22)夹持。在其上缠绕薄膜(F)的层压辊(21)起加热辊的作用，并且辊子(21)的温度被控制，使得丙烯酸树脂薄膜(F)的层压表面(Fa)刚好在被夹持之前具有110℃的温度(Tf)。
使用一对层压辊(21，22)，将如此夹持的丙烯酸树脂连续片材(S)和丙烯酸树脂连续薄膜(F)压制在一起，其中线压力为大约2000N/m，以便将它们热-焊接，借此生产丙烯酸树脂层压片材(A)，其中丙烯酸树脂薄膜(F)被层压在丙烯酸树脂片材(S)的一个表面(Sa)上，如图4(a)所示。在层压片材(A)的薄膜(F)上没有观察到折皱。将片材(A)切成叶片。使用电锯，从没有薄膜(F)的非层压表面(Sb)的侧面将叶片形式的层压片材切割。在切割剖面上没有观察到薄膜(F)的脱层。
实施例2
重复实施例1，除了控制远红外加热器(5)的功率，使得丙烯酸树脂片材(S)的层压表面(Sa)在刚好被层压辊夹持之前具有的温度(Ts)为120℃，同时辊子(21)的温度被控制，使得丙烯酸树脂连续薄膜(F)的层压表面(Fa)在刚好被层压辊夹持之前具有的温度(Tf)为70℃，借此生产了丙烯酸树脂层压片材(A)，其中丙烯酸树脂薄膜(F)被层压在丙烯酸树脂片材(S)的一个表面(Sa)上。在层压片材(A)的薄膜(F)上没有观察到折皱。如实施例1中所述，将片材(A)切成叶片，并且使用电锯将叶片形式的层压片材切割。在切割剖面上没有观察到薄膜(F)的脱层。
实施例3
重复实施例1，除了控制远红外加热器(5)的功率，使得丙烯酸树脂片材(S)的层压表面(Sa)在刚好被层压辊夹持之前具有的温度(Ts)为130℃，同时控制所述辊子的温度，使得使用具有单一丙烯酸树脂层的丙烯酸连续薄膜(F)，所述丙烯酸树脂层具有的玻璃化转变温度(Tgf)为105℃并且厚度为125微米，没有进行表面处理，用以代替具有80℃的玻璃化转变温度的薄膜，借此生产了丙烯酸树脂层压片材(A)，其中丙烯酸树脂薄膜(F)被层压在丙烯酸树脂片材(S)的一个表面(Sa)上。在层压片材(A)的薄膜(F)上没有观察到折皱。如实施例1中所述，将片材(A)切成叶片，并且使用电锯将叶片形式的层压片材切割。沿着切割剖面没有观察到薄膜(F)的脱层。
实施例4
重复实施例1，除了控制远红外加热器(5)的功率，使得丙烯酸树脂片材(S)的层压表面(Sa)在刚好被层压辊夹持之前具有的温度(Ts)为130℃，同时使用具有单一丙烯酸树脂层的丙烯酸连续薄膜(F)(NOF公司制造的REALOOK 4700)，所述丙烯酸树脂层具有的玻璃化转变温度(Tgf)为105℃，在非层压表面(Fb)上具有抗反射层(Fh)，用以代替具有80℃的玻璃化转变温度的薄膜，借此生产了丙烯酸树脂层压片材(A)，其中丙烯酸树脂薄膜(F)被层压在丙烯酸树脂片材(S)的一个表面(Sa)上。在层压片材(A)的薄膜(F)上没有现察到折皱。如实施例1中所述，将片材(A)切成叶片，并且使用电锯将叶片形式的层压片材切割。在切割剖面上没有观察到薄膜(F)的脱层。
对比例1
重复实施例1，除了控制远红外加热器(5)的功率，使得丙烯酸树脂片材(S)的层压表面(Sa)刚好在用层压辊夹持之前具有90℃的温度(Ts)，借此生产了丙烯酸树脂层压片材(A)，其中丙烯酸树脂薄膜(F)被层压在丙烯酸树脂片材(S)的一个表面(Sa)上。在层压片材(A)的薄膜(F)上没有观察到折皱。如实施例1中所述，将片材(A)切成叶片，并且使用电锯将叶片形式的层压片材切割。在切割剖面上观察到薄膜(F)的脱层。
实施例5
如图2所示，通过挤出机(7)将具有105℃的玻璃化转变温度(Tgs)的丙烯酸树脂(P)加热、熔融和捏和，并且挤出通过模头(3)，然后用三个各自具有200毫米直径的压延辊(41、42、43)辊轧，获得连续丙烯酸树脂片材(S)，其具有2mm的厚度和200毫米的宽度。将如此获得的片材，在借助于导辊(6)被一般水平地支持的同时，通过远红外加热器(5)从其两个表面加热，并且将该片材提供到一对各自具有100毫米直径的层压辊(21，22)之间的间隙中。控制加热器的功率，使得刚好在被层压辊(21，22)夹持前，丙烯酸树脂片材(S)的层压表面(Sa)具有115℃的温度(Ts)。
另一方面，将具有单一丙烯酸树脂层的丙烯酸树脂连续薄膜(F)，该丙烯酸树脂层的玻璃化转变温度(Tgf)为80℃并且厚度为125微米，没有进行表面处理，从两个原料薄膜材料辊(F1)的每一个展开，并且每个薄膜围绕层压辊(21，22)的每一个通过，其中接触周边长度(C)为40毫米。将这样的薄膜(F)的每一个放置在片材(S)的每个侧面上，并且薄膜(F)和片材(S)由层压辊(21，22)夹持。分别在层压辊(21，22)上安装加热器，并且控制加热器的功率，使得每个丙烯酸树脂薄膜(F)的层压表面(Fa)在刚好被夹持之前具有的温度(Tf)为110℃。
使用一对层压辊(21，22)，将如此夹持的丙烯酸树脂连续片材(S)和在所述片材(S)的两侧上的丙烯酸树脂连续薄膜(F)压制在一起，其中线压力为大约2000N/cm，以便将它们热-焊接，借此生产丙烯酸树脂层压片材(A)，其中丙烯酸树脂薄膜(F)被层压在丙烯酸树脂片材(S)的每个表面(Sa)上，如图4(b)所示。在层压片材(A)的薄膜(F)上没有观察到折皱。将片材(A)切成叶片。使用电锯将叶片形式的层压片材切割。在切割剖面上没有观察到薄膜(F)的脱层。
上述说明性的实施例1到5和对比例的条件示于以下表1：
表1
  丙烯酸树脂连续片材  丙烯酸树脂连续薄膜   脱层*)
  Tgs(℃)   Ts(℃)  Tgf(℃)   Tf(℃)
 实施例1   105   115  80   110   否
 实施例2   105   120  80   70   否
 实施例3   105   130  105   110   否
 实施例4   105   130  105   110   否
 对比例1   105   90  80   110   是
 实施例5   105   115  80   110   否
脱层*)：“否”指在切割剖面上没有观察到脱层，而“是”指在切割剖面上观察到脱层。

Claims (12)

1.用于生产热塑性树脂层压片材的方法，其中热塑性树脂薄膜被层压在热塑性树脂片材的至少一个表面上，所述方法包括以下步骤：
将热塑性树脂薄膜迭加在处于加热状态的热塑性树脂片材上；
将它们夹持在一对层压辊之间；
和
用层压辊将它们压制，以便将它们热-焊接在一起，
其中，在所述夹持步骤中，热塑性树脂片材的层压表面具有满足以下不等式(I)的温度(Ts)：
Tgs+5℃≤Ts≤Tgs+40℃              (I)
(其中“Ts”是热塑性树脂片材的层压表面的温度，和“Tgs”是热塑性树脂片材的层压表面的玻璃化转变温度)；和
热塑性树脂薄膜的层压表面具有满足以下不等式(II)和(III)的温度(Tf)：
Tgf-15℃≤Tf≤Tgf+40℃             (II)
(其中“Tf”是热塑性树脂薄膜的层压表面的温度，和“Tgf”是热塑性树脂薄膜的层压表面的玻璃化转变温度)，和
Tf≥Tgf+Tgs-Ts                     (III)
(其中Ts，Tf，Tgs和Tgf与以上定义的相同)。
2.权利要求1的用于生产热塑性树脂层压片材的方法，其中热塑性树脂片材的层压表面包含至少一种选自以下的树脂：丙烯酸树脂和甲基丙烯酸甲酯-苯乙烯共聚物树脂，并且热塑性树脂薄膜的层压表面包含至少一种选自以下的树脂：丙烯酸树脂、甲基丙烯酸甲酯-苯乙烯共聚物树脂、苯乙烯树脂、丙烯腈-丁二烯-苯乙烯三元共聚物树脂、氟树脂和尼龙树脂。
3.权利要求1的用于生产热塑性树脂层压片材的方法，其中热塑性树脂薄膜在其非层压表面上包括表面处理层，并且所述压制借助于层压辊使用不大于3000N/m的线压力进行。
4.权利要求3的用于生产热塑性树脂层压片材的方法，其中表面处理层包括硬涂层和/或抗反射层。
5.权利要求1的用于生产热塑性树脂层压片材的方法，其中与热塑性树脂薄膜接触的所述一对层压辊之一被加热，并且当热塑性树脂薄膜围绕所述加热的层压辊通过时，热塑性树脂薄膜与如此加热的层压辊接触和被其加热，然后热塑性树脂薄膜与热塑性树脂片材一起由所述一对层压辊夹持。
6.权利要求5的用于生产热塑性树脂层压片材的方法，其中所述热塑性树脂薄膜与加热的层压辊接触的接触周边长度为20毫米到300毫米。
7.用于生产热塑性树脂层压片材的设备，其中热塑性树脂薄膜被层压在热塑性树脂片材的至少一个表面上，该设备包括：
一对层压辊，借助于该层压辊，热塑性树脂片材和迭加在该热塑性树脂片材上的热塑性树脂薄膜在将它们压制和热-焊接之前被夹持；和
加热器，其用于加热热塑性树脂薄膜，使得在夹持下满足以下不等式(II)和(III)：
Tgf-15℃≤Tf≤Tgf+40℃                 (II)
(其中“Tf”是热塑性树脂薄膜的层压表面的温度，和“Tgf”是热塑性树脂薄膜的层压表面的玻璃化转变温度)，和
Tf≥Tgf+Tgs-Ts                         (III)
(其中“Ts”是热塑性树脂片材的层压表面的温度，和“Tgs”是热塑性树脂片材的层压表面的玻璃化转变温度，和Tf和Tgs与以上定义的相同)。
8.权利要求7的用于生产热塑性树脂层压片材的设备，其还包括用于加热热塑性树脂片材的加热器，使得在夹持下，满足以下不等式(I)：
Tgs+5℃≤Ts≤Tgs+40℃                  (I)。
9.权利要求7的生产热塑性树脂层压片材的设备，其中用于加热热塑性树脂薄膜的加热器是与热塑性树脂薄膜接触的层压辊之一。
10.权利要求8的生产热塑性树脂层压片材的设备，其中用于加热热塑性树脂薄膜的加热器是与热塑性树脂薄膜接触的层压辊之一。
11.权利要求9的用于生产热塑性树脂层压片材的设备，其中所述设备具有这样一种作用，使得热塑性树脂薄膜与加热的层压辊接触的接触周边长度为20毫米到300毫米。
12.权利要求10的用于生产热塑性树脂层压片材的设备，其中所述设备具有这样一种作用，使得热塑性树脂薄膜与加热的层压辊接触的接触周边长度为20毫米到300毫米。
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