JP2001341188A - Roll for polymeric film sheet, apparatus and method for manufacturing polymeric film sheet using the same, and polymeric film sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method and an apparatus for continuously manufacturing a polymeric film sheet excellent in surface smoothness and the polymeric film sheet obtained using the same. SOLUTION: A roll for the polymeric film sheet has a coating layer comprising a silicon oxide compound containing fluorine-containing organosilane on its surface. The polymeric film sheet manufacturing apparatus has this roll, an extruder and a T-die or a hanger coat die. The polymeric film sheet manufacturing method using this apparatus is disclosed. The polymeric film sheet of which the maximum surface roughness (Rmax) is 0.1 μm or less is also disclosed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for efficiently producing a high heat resistant polymer sheet having excellent smoothness, a method for producing the same, and a method for producing the same. It relates to the produced polymer sheet.

[0002]

2. Description of the Related Art Various types of polymer films and sheets have been used for applications in the electronics industry. Of these uses,
As a material used as a substitute for a glass plate or a metal plate, there is a use such as a substrate for a liquid crystal display device which requires extremely good smoothness, that is, a very small surface roughness. Conventionally, when producing polymer films and sheets having good smoothness, a casting method of casting a polymer solution on a polished glass substrate or a polished steel belt and evaporating the solvent to obtain a film is widely used. Have been. However, casting has problems that it is difficult to obtain a film having a thickness of more than 200 μm, heat is required for heating to evaporate the solvent, and the solvent itself is often a harmful substance. .

On the other hand, there is extrusion as a method for producing a polymer film sheet which does not have the above-mentioned problems. Generally, when a film sheet is manufactured by extrusion, a film sheet extruded from a T die or a coat hanger die is taken up by a cooling roll and processed. However, when a film sheet is manufactured by such a method, there is a problem that a streak-shaped die line having a thickness defect derived from a die is generated. A method has been devised in which the take-up roll is made of a metal roll having a smooth polished surface, and the polymer film sheet is brought into close contact with the polymer film sheet by heating, not cooling, to reduce the die line. In order for the polymer to have a low glass transition point (T
g) or more;
If the amount is more than g, the adhesion to the metal surface is increased, so that there is a problem that a roll is generated and continuous production cannot be performed. Rolls that can prevent adhesion include rolls made of fluorinated rubber or polytetrafluoroethylene. However, these rolls cannot be polished like metals, and thus have a problem that sufficient smoothness cannot be obtained.

[0004]

SUMMARY OF THE INVENTION An object of the present invention is to provide a roll to which a polymer is unlikely to adhere in the production of a polymer sheet, and to provide a polymer sheet having excellent smoothness. An object of the present invention is to provide a method for efficiently producing a polymer film sheet having good smoothness.

[0005]

According to the present invention, there is provided (1) a roll for a polymer film sheet, wherein the roll surface is coated with a silicon oxide compound containing a fluorinated organosilane.
(2) For a polymer film sheet coated with an alkoxysilane solution containing at least one of the alkoxysilanes represented by the general formulas (1) to (3) as an essential component, and dehydration-condensed to coat the roll surface. roll,

Embedded image (Wherein FR ₁ represents an organic group containing fluorine, and FR ₂ to FR ₃
Represents an organic group containing fluorine or an organic group containing no fluorine, and FR ₁ to FR ₃ may be the same or different from each other, and R _{1 to} R ₃ may be an alkyl group and may be the same or different. (3) The maximum surface roughness (Rmax) of the roll is 0.1 μm.
m, the roll for a polymer film sheet according to item (1) or (2), (4) at least an extruder, T
A die or a coat hanger die, an apparatus for producing a polymer film sheet having the roll according to any one of (1) to (3), (5) at least an extruder, a T-die or a coat hanger die, and a roll having a take-up roll. In the apparatus for producing a molecular film sheet, the apparatus for producing a polymer film sheet, wherein the take-up roll is a roll according to any one of (1) to (3), (6) the polymer extruded from a T die or a coat hanger die In the production of polymer sheets that take up film sheets with take-up rolls,
The take-up roll to which the extruded polymer contacts first is the roll according to any one of (1) to (3), wherein the temperature of the take-up roll is equal to or higher than the glass transition temperature of the polymer. (7) a polymer sheet produced by the method for producing a polymer sheet according to (6),
(8) The polymer sheet according to (7), wherein the maximum surface roughness (Rmax) is 0.1 μm or less.

[0006]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The roll for a polymer film sheet of the present invention has a surface coated with a silicon oxide compound containing fluorine-containing organosilane. When this compound is coated on the surface of a metal or glass, a surface having a very low surface energy due to segregation of fluorine-containing groups on the surface, that is, a surface to which a polymer having a temperature of Tg or higher is difficult to adhere is obtained. Similarly, polytetrafluoroethylene having a low surface energy is formed by cutting because it is insoluble in a solvent, but cannot be polished because of its low hardness, so that a smooth surface cannot be obtained. On the other hand, since the precursor of the silicon oxide compound containing the fluorine-containing organosilane represented by the general formulas (1) to (3) in the present invention is solvent-soluble, the metal roll base before coating is smoothed. A roll having a smooth surface can be obtained by coating the precursor solution after polishing and then drying and dehydrating and condensing to obtain a roll for a polymer film sheet which is less likely to cause adhesion problems and is smooth. Can be done.

[0007] Examples of the alkoxysilane represented by the general formula (1) in the present invention include:

Embedded image Etc., but are not limited to these. As an example of the alkoxysilane represented by the general formula (2),

Embedded image Etc., but are not limited to these. As an example of the alkoxysilane represented by the general formula (3),

Embedded image Etc., but are not limited to these.

When a smooth sheet is obtained by using the polymer film sheet roll of the present invention, the maximum value Rmax of the surface roughness is preferably 0.1 μm or less. Here, Rmax refers to a case where an arbitrary position on the roll surface is scanned and scanned at a width of 2 mm. In the case of manufacturing a sheet having an uneven shape such as a prism sheet, it is also possible to transfer and form the sheet by using a roll having an uneven shape.

The polymer film sheet roll of the present invention is suitable for use in a film sheet manufacturing apparatus by extrusion, since a polymer having a temperature of Tg or higher does not easily adhere thereto. In particular, it is suitable for obtaining a film sheet on which the roll surface has been transferred by using this for the roll that is first contacted by the polymer extruded when taking out using a plurality of rolls. Furthermore, it is effective to set the temperature of the roll to Tg or higher of the polymer at the end.

Examples of polymers that can be used in the polymer sheet of the present invention include polyethylene, polypropylene, polyvinyl chloride, polycarbonate, polyethylene terephthalate, polybutylene terephthalate, polymethyl methacrylate, polyamide, polysulfone, and polyether. Examples thereof include, but are not limited to, sulfone, polyetherimide, polyesterimide, and polyetheretherketone. Among these, sheets having good smoothness, such as polymethyl methacrylate, polyether sulfone, and polycarbonate, are excellent as optical materials and materials for the electronic industry. The smoothness is Rmax
Is preferably 0.1 μm or less.

[0011]

EXAMPLES The present invention will be described below with reference to examples and comparative examples, but the present invention is not limited to the examples. The optical properties of the sheet were measured by the following methods. (1) Sheet thickness 20 m in the width direction of the polymer sheet with a contact type dial gauge
Average value measured at m intervals. (2) Maximum surface roughness of polymer sheet (Rmax) Contact type precision step meter (manufactured by TENCOR INSTRUMENTS, AlPHA-ST)
EP200) is the maximum value of the concavities and convexities measured over the entire width of the polymer sheet at a scan width of 2 mm in the width direction. (3) Maximum surface roughness of the roll surface (Rmax) The maximum value of the unevenness when a 2 mm width is measured at an arbitrary position on the roll in the width direction using a contact type surface roughness meter manufactured by Mitutoyo Corporation.

<< Embodiment 1 >> 3,3 represented by formula (4)
87.3 3-trifluoropropyltrimethoxysilane
0 g (0.4 mol) and tetramethoxysilane 91.33
g (0.6 mol) was dissolved in 1000 g of 2-propanol. After 10.0 g of water was further added and stirred, the mixture was left at room temperature for 12 hours. This solution was coated with Rmax =
The surface was coated with a silicon oxide compound containing fluorinated organosilane by dip coating on a steel roll having a diameter of 500 mm polished to 0.04 μm, pre-drying at 80 ° C., and then curing in a nitrogen atmosphere at 200 ° C. for 2 hours. A roll for a polymer film sheet was prepared. Using an extruder equipped with a coat hanger die, an extrusion temperature of 3
Polyether sulfone at 50 ° C (hereinafter abbreviated as PES)
, And the surface whose temperature was controlled at 225 ° C. was taken up by a roll coated with a silicon oxide compound containing fluorinated organosilane, and the surface whose temperature was controlled at 120 ° C. at the same rotation speed was Rmax = 0.
After passing through a steel roll having a diameter of 500 mm polished to 04 μm, the film was wound up to obtain a PES film having a thickness of 200 μm. The Tg of PES was 220 ° C. P obtained
Rmax of the ES film was 0.04 μm.

Example 2 Dimethoxymethyl-3,3,3-trifluoropropylsilane 4 represented by the formula (8)
0.45 g (0.2 mol) and tetramethoxysilane 12
1.78 g (0.8 mol) were dissolved in 1000 g of 2-propanol. After 10.0 g of water was further added and stirred, the mixture was left at room temperature for 12 hours. This solution is treated with Rm
ax = 0.04 μm, dip-coated on a 500 mm diameter steel roll, pre-dried at 80 ° C, and then cured in a nitrogen atmosphere at 170 ° C for 2 hours to coat the surface with a silicon oxide compound containing fluorinated organosilane The prepared roll for a polymer film sheet was produced. Using an extruder equipped with a coat hanger die, polycarbonate (hereinafter abbreviated as PC) at an extrusion temperature of 300 ° C.
, And the surface whose temperature was controlled at 160 ° C. was taken up by a roll coated with a silicon oxide compound containing fluorine-containing organosilane, and the surface whose temperature was controlled at 80 ° C. at the same rotation speed was Rmax. =
After passing through a steel roll having a diameter of 500 mm polished to 0.04 μm, it was wound up to obtain a PC film having a thickness of 100 μm. The Tg of PC was 140 ° C. P obtained
Rmax of the C film was 0.03 μm.

<< Comparative Example >> Example 1 except that a 500 mm diameter steel roll whose surface was polished to Rmax = 0.04 μm was used instead of a roll whose surface was coated with a silicon oxide compound containing fluorine-containing organosilane.
When PES was extruded in the same manner as in
There was a problem that PES could not be peeled off and adhered to the roll controlled at 5 ° C., and a film could not be formed stably.

[0015]

By using the polymer film sheet roll of the present invention, the polymer film sheet manufacturing apparatus using the same, and the polymer film sheet manufacturing method, a polymer sheet having good surface smoothness can be stably obtained. As a result, continuous production can be performed efficiently.

Claims (8)

[Claims] 1. A roll for a polymer film sheet, wherein the roll surface is coated with a silicon oxide compound containing a fluorine-containing organosilane. 2. A roll surface is coated by applying an alkoxysilane solution containing at least one of the alkoxysilanes represented by the general formulas (1) to (3) as an essential component, followed by dehydration condensation to coat the roll surface. For polymer film sheet. Embedded image (Wherein, FR ₁ represents an organic group containing fluorine, and FR ₂ to FR
₃ represents an organic group containing fluorine or an organic group containing no fluorine, FR ₁ to FR ₃ may be the same or different, and R _{1 to} R ₃ may be an alkyl group and may be the same. May be different) 3. The polymer film sheet roll according to claim 1, wherein the maximum surface roughness (Rmax) of the roll is 0.1 μm or less. 4. An apparatus for producing a polymer film sheet having at least an extruder, a T die or a coat hanger die, and a roll according to claim 1. 5. An apparatus for producing a polymer film sheet having at least an extruder, a T die or a coat hanger die, and a take-up roll, wherein the take-up roll is a roll according to any one of claims 1 to 3. manufacturing device. 6. A method for producing a polymer sheet in which a polymer film sheet extruded from a T-die or a coat hanger die is taken by a take-up roll, wherein the extruded polymer is brought into first contact with a take-up roll. The method for producing a polymer sheet according to any one of the preceding claims, wherein the temperature of the take-up roll is equal to or higher than the glass transition temperature of the polymer. 7. A polymer sheet produced by the method for producing a polymer sheet according to claim 6. 8. The maximum surface roughness (Rmax) is 0.1 μm.
The polymer sheet according to claim 7, wherein