JP2005254590A - Manufacturing method for continuous laminated thermoplastic-resin sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method which enables a continuous laminated sheet (A) to be manufactured by laminating a continuous film (F) on a continuous sheet (S) by heat seal, without making scratches on surfaces of laminating rolls (21 and 22) transferred onto the continuous film (F), and without causing damage to a surface treatment layer (Fh) of the continuous film (F). <P>SOLUTION: In this manufacturing method, the heat-sealable continuous film (F) for the continuous sheet, and a non-heat-sealable continuous protective film (B) for the continuous film are superposed on the continuous sheet (S) under a heated state in this order, fed to a section between a pair of rolls (21 and 21), and pressurized, so that the continuous sheet (S) and the continuous film (F) can be laminated together by heat seal. In the continuous film (F), the surface treatment layer (Fh) is provided on an unlaminated surface. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

TECHNICAL FIELD The present invention relates to a method for producing a thermoplastic resin continuous bonding sheet, and more particularly, to a method for producing a thermoplastic resin continuous bonding sheet in which a thermoplastic resin continuous film is bonded to a thermoplastic resin continuous sheet by thermal fusion bonding. .

Thermoplastic resin continuous bonding sheet [Hereinafter, it may be abbreviated as a continuous bonding sheet. ] (A) is a thermoplastic resin continuous sheet [hereinafter sometimes abbreviated as a continuous sheet] as shown in FIG. ] (S) on one side [FIG. 4 (a)] or on both sides [FIG. 4 (b)], a thermoplastic resin continuous film [hereinafter sometimes abbreviated as continuous film]. ] (F) is bonded. As the continuous film (F), in addition to the non-treated surface, a surface treatment layer (Fh) such as a hard coat layer on the non-bonding surface (Fb) opposite to the side to be bonded to the continuous sheet (S). ) Is used.

As a method for producing such a continuous laminated sheet (A), in Patent Document 1 (Japanese Patent Laid-Open No. 6-126854), as shown in FIG. 5, a continuous film (F) is applied to a heated continuous sheet (S). A method is disclosed in which the continuous film (F) is bonded to the continuous sheet (S) by thermal fusion by superimposing alone and pressing with a pair of bonding rolls (21, 22).

However, in such a conventional manufacturing method, when there is a scratch on the surface of the bonding roll (21, 22), the scratch may be transferred to the continuous film (F). In addition, when using a continuous film (F) with a non-bonding surface (Fb) provided with a surface treatment layer (Fh), the surface treatment layer (Fh) may be damaged. In particular, when the surface treatment layer (Fh) is a hard coat layer, there is a problem that cracks are likely to occur in the hard coat layer.

JP-A-6-126854

Therefore, even if the surface of the bonding roll has a scratch, the inventor does not transfer the scratch to the continuous film, and even if the continuous film is provided with a surface treatment layer, the surface treatment layer is removed. As a result of intensive investigations to develop a method that can produce a continuous laminated sheet without damaging, a continuous protective film that is non-heat-bondable to the continuous film is laminated on the continuous sheet in this order. If the surface of the laminating roll is scratched by applying pressure with a laminating roll and fusing it, the surface of the continuous film is not transferred to the continuous film. It has been found that a continuous laminated sheet can be produced without impairing the surface treatment layer even if a treatment layer is provided, and the present invention has been achieved.

That is, the present invention
The thermoplastic resin continuous sheet (S) is bonded to the thermoplastic resin continuous sheet with a heat-sealable thermoplastic resin continuous film (F) by heat-sealing, and the thermoplastic resin continuous sheet (S ) Is a method for producing a thermoplastic resin continuous bonding sheet (A) in which the thermoplastic resin continuous film (F) is bonded,
Further, using a continuous protective film (B) that is non-heat-fusible with respect to the thermoplastic resin continuous film,
In the heated thermoplastic resin continuous sheet (S), the thermoplastic resin continuous film (F) and the continuous protective film (B) are superposed in this order,
Pressurizing with a pair of bonding rolls (21, 22), the thermoplastic resin continuous film (F) is bonded to the thermoplastic resin continuous sheet (S) by thermal fusion, the heat The present invention provides a method for producing a plastic resin continuous laminated sheet (A). 1 to 3 schematically show an example of an apparatus (1) for producing a thermoplastic resin continuous laminated sheet (A) by the production method of the present invention.

According to the production method of the present invention, the continuous film and the continuous protective film are superposed in this order on the continuous sheet and pressed between the pair of rolls. A continuous bonding sheet can be produced without transferring the film to a continuous film.

Hereinafter, the manufacturing method of the present invention will be described in detail with reference to FIGS.
In the production method of the present invention, the thermoplastic resin continuous sheet (A) is produced by laminating the thermoplastic resin continuous film (F) to the thermoplastic resin continuous sheet (S). The thermoplastic resin continuous sheet (S) is made of a thermoplastic resin and is a continuous sheet, for example, continuously manufactured by a method in which the thermoplastic resin (P) is heated and melted and extruded from the die (3). Is.

Examples of the thermoplastic resin (P) include acrylic resin, styrene resin, methyl methacrylate-styrene copolymer resin, polycarbonate resin, acrylonitrile-butadiene-styrene copolymer resin (ABS resin), and acrylonitrile-styrene copolymer resin. (AS resin), olefin resin such as vinyl chloride resin, polyethylene and polypropylene, polyester resin, polyacetal resin, fluororesin, nylon resin and the like. Such a thermoplastic resin may contain additives such as a heat stabilizer, an antioxidant, a light stabilizer, an ultraviolet absorber, a colorant, a plasticizer, and an antistatic agent. Moreover, you may contain the elastic body particle.

As shown in FIGS. 1 to 3, for example, an ordinary extruder (7) may be used to heat and melt the thermoplastic resin (P). By kneading while heating by the extruder (7), the thermoplastic resin (P) is in a molten state and sent to the die (3).

As the die (3), for example, a T die can be used. The thermoplastic resin heated and melted by the T die is extruded into a sheet shape to form a continuous sheet (S). The die (3) may be formed by extruding the thermoplastic resin (P) as a single layer, or may be formed by extruding in two or more layers. By using a die that extrudes in a single layer, a single-layer continuous sheet (S) is formed. A multilayer continuous sheet (S) is formed by coextrusion of two or more thermoplastic resins using a die that is extruded in multiple layers.

As shown in FIG. 3, the continuous sheet (S) extruded from the die (3) is directly sent between the bonding rolls (21, 22) and used for bonding with the continuous film (F). Moreover, as shown in FIG. 1 and FIG. 2, after rolling with a rolling roll, you may use for bonding. The diameter of the rolling roll is usually about 15 cm to 60 cm. The number of rolling rolls is not particularly limited as long as it is two or more so that the thermoplastic resin (P1) can be sandwiched and rolled, but the apparatus (1) shown in FIG. 1 has three rolling rolls (41, 42, 43). ) Is used. The extruded thermoplastic resin (P1) is first sandwiched between the first rolling roll (41) and the second rolling roll (42) and rolled, and then wound around the second rolling roll (42). Then, it is further rolled by being sandwiched between the second rolling roll (42) and the third rolling roll (43).

Immediately after being extruded from the die (3) or immediately after being rolled by the rolling rolls (41, 42, 43), the continuous sheet (S) is in a heated state, so immediately between the bonding rolls (21, 22). Or may be supplied between the laminating rolls (21, 22) after further heating.

In order to heat the continuous sheet (S) and then supply it between the bonding rolls (21, 22), for example, the heating device (5) may be used. As the heating device (5), a normal heating device such as an electric heater, an infrared heater, or a hot air heater can be used. The continuous sheet (S) may be heated only on the bonding surface (Sa) to be bonded to the continuous film (F), and when the continuous film (F) is bonded on both sides, both surfaces may be heated. . Moreover, when bonding on one side, you may heat only the bonding surface (Sa) and may heat both surfaces.

The continuous sheet (S) may be heated while being wound on the rolling rolls (41, 42, 43), but the continuous sheet (S) after leaving the rolling roll (43) is held flat. It is preferable that heating is performed while a continuous bonding sheet (A) with less warpage is obtained. In order to heat the continuous sheet (S) while holding it flat, for example, a holding mechanism (6) may be used. In the manufacturing apparatus (1) shown in FIG. 1 as the holding mechanism (6), a plurality of guide rolls arranged side by side on a horizontal plane are used. As the guide roll (6), for example, a commercially available roller table may be used. The continuous sheet (S) is conveyed while being held flat by the holding mechanism (6). The continuous sheet (S) does not need to be held strictly flat, and may be held substantially flat so that no stress remains. The heating device (5) heats the continuous sheet (S) conveyed on the guide roll (5).

The thickness of the continuous sheet (S) is usually about 1 mm to 20 mm, and the width is usually about 200 mm to 2500 mm.

The thermoplastic resin continuous film (F) is made of a thermoplastic resin and is a continuous film. Here, examples of the thermoplastic resin include acrylic resin, styrene resin, methyl methacrylate-styrene copolymer, polycarbonate resin, ABS resin, vinyl chloride resin, polyolefin resin, polyester resin, polyacetal resin, and polyvinylidene fluoride (PVDF) resin. And fluororesin such as nylon resin.

The thermoplastic resin continuous film (F) may contain additives such as a heat stabilizer, an antioxidant, a light stabilizer, an ultraviolet absorber, a colorant, a plasticizer, and an antistatic agent. Moreover, you may contain the elastic particle. The continuous film (F) containing elastic particles is usually preferably used because it is excellent in flexibility and easy to handle. Examples of the elastic particles include acrylate copolymer resin particles, polybutadiene rubber particles, styrene-butadiene copolymer rubber particles, and butadiene-acrylate copolymer rubber particles.

The thermoplastic resin continuous film (F) may be a single layer film composed of a single layer, or may be a multilayer film in which two or more layers are laminated. The thickness is usually about 50 μm to 1000 μm, and the width may be the same as that of the continuous sheet (S).

As the thermoplastic resin continuous film (F), a film that is heat-fusible to the continuous sheet (S), that is, a film that can be bonded to the continuous sheet (S) by heat-sealing is used. For example, as a continuous film, a film whose bonding surface (Fa) is the same as the bonding surface (Sa) of the continuous sheet is used. The thermoplastic resin continuous film (F) is bonded to the continuous sheet (S) at the bonding surface (Fa) by thermal fusion, and the continuous sheet (S) and the heat are bonded to the bonding surface (Fa). A surface treatment may be applied so as to facilitate fusion.

Moreover, the surface treatment layer (Fh) may be provided in the non-bonding surface (Fb) on the opposite side to the bonding surface bonded with a continuous sheet. Examples of the surface treatment layer (Fh) include a hard coat layer. Further, an antireflection layer may be further provided on the hard coat layer to constitute a surface treatment layer together with the hard coat layer. By bonding the continuous film (F) provided with the hard coat layer (Fh), a continuous bonding sheet (A) having a high surface hardness can be obtained. The thickness of the surface treatment layer (Fh) is usually about 0.1 μm to 50 μm. Such a continuous film (F) may be bonded to one side of the continuous sheet (S) as shown in FIG. 1, or may be bonded to both sides as shown in FIG.

In the production method of the present invention, a continuous protective film (B) is further used. The continuous protective film (B) is usually a continuous film made of a resin, for example, a polyolefin resin such as polyethylene or polypropylene, a fluorine resin such as a polyester resin or PVDF resin, a nylon resin, an acrylic resin, a styrene resin, or methacrylic acid. A continuous film made of methyl-styrene copolymer resin, ABS resin, vinyl chloride resin or the like is used.

As the continuous protective film (B), a film that is non-heat-bondable to the continuous film (F) is used. For example, when an acrylic resin film, a styrene resin film, a methyl methacrylate-styrene copolymer resin film or the like is used as a continuous film, a polyolefin resin, a polyester resin, a fluororesin, a nylon resin, etc. as the continuous resin film (B) A film consisting of

If the continuous protective film (B) is excellent in flexibility, the surface treatment layer (Fh) is damaged when the surface treatment layer (Fh) is formed on the non-bonding surface of the continuous film (F). It is preferable at the point that it is easier to obtain a continuous bonding sheet (A) without it.

The thickness of the continuous protective film (B) is usually about 20 μm to 1000 μm, and the width is about the same as the continuous sheet (S) and the continuous film (F) to be used.

In the production method of the present invention, the continuous film (F) and the continuous protective film (B) are superposed on the continuous sheet (S) and supplied between the bonding rolls (21, 22). The continuous film (F) and the continuous protective film (B) are superposed on the continuous sheet (S) in this order.

As shown in FIG. 1, the continuous film (F) and the continuous protective film (B) may be superposed on the continuous sheet (S) while being individually unwound from individual rolls (F1, B1). In addition, as shown in FIG. 2, a raw roll (BF1) in which a continuous film (F) and a continuous protective film (B) are wound in advance is prepared in advance, and the roll is wound from this raw roll (BF1). You may superimpose with a continuous sheet (S), taking out.

The laminating rolls (21, 22) are rolls that are used as a pair for pressurizing and laminating the continuous sheet (S) and the continuous film (F). Such bonding rolls (21, 22) may have a surface made of a rubber material such as hard rubber, or may be made of a metal material such as stainless steel. The bonding roll may be heated or may be cooled. The laminating rolls (21, 22) are rotationally driven and become take-up rolls, and may be configured to take up from the rolling roll while applying tension to the continuous sheet (S), or almost the same as the rolling roll. You may be comprised so that it may be rotationally driven so that it may rotate with the same circumferential speed, and it may take out, without applying tension | tensile_strength to the continuous sheet after rolling. The diameter of the bonding roll (21, 22) is usually about 5 cm to 30 cm.

Between the bonding rolls (21, 22), the continuous sheet (S), the continuous film (F), and the continuous protective film (B) supplied in a superimposed manner are pressurized. Since the continuous sheet (S) is in a heated state, the continuous sheet (S) and the continuous film (F) are heat-sealed and bonded by being pressed between the bonding rolls (21, 22). Here, the continuous film (F) is overlapped with the continuous protective film (B) and continuously supplied between the bonding rolls (21, 22). Pressurized by rolls (21, 22). For this reason, even if there are scratches or the like on the bonding rolls (21, 22), the scratches are not transferred to the continuous film (F). On the other hand, since the continuous protective film (B) is non-heat-sealable with respect to the continuous film (F), the continuous protective film (B) is not thermally fused to the continuous film (F).

When the temperature of the heated continuous sheet (S) is equal to or higher than the softening temperature, the continuous sheet (S) supplied between the bonding rolls (21, 22) is pressed by the bonding roll (21, 22). It may be rolled.

The continuous sheet (S), the continuous film (F), and the continuous protective film (B) that are overlaid may pass between a pair of bonding rolls after passing through a pair of bonding rolls. In the apparatus shown in FIG. 3, three bonding rolls (21, 22, 23) are used, and immediately after being extruded from the die (3), the heated continuous sheet (S) is a continuous film (F) and Supplied between the first bonding roll (21) and the second bonding roll (22) together with the continuous protective film (B), and after being pressurized here, wound around the second bonding roll (22) However, it is further supplied between the 2nd bonding roll (22) and the 3rd bonding roll (23), and is further pressurized here. These first laminating roll (21), second laminating roll (22) and third laminating roll (23) also serve as rolling rolls (41, 42, 43), and the temperature of the continuous sheet (S) May be configured to roll the continuous sheet (S).

Thus, the continuous bonding sheet (A) in which the continuous film (F) is bonded to the continuous sheet (S) is obtained, and the continuous protective film (B) is bonded to the surface of the continuous bonding sheet (A). Has been. Since this continuous protective film (B) is not thermally fused with the continuous film (F), it can be easily peeled off, for example, it can be used as it is as a protective film for protecting the surface of the continuous laminated film (A). it can.

EXAMPLES Hereinafter, although an Example demonstrates this invention in detail, this invention is not limited by this Example.

Example 1
As shown in FIG. 1, an acrylic resin (glass transition temperature 100 ° C.) is kneaded while being heated and melted using a 40 mm extruder (7), extruded from a T-die (3) at 265 ° C., and a first rolling roll [stainless steel Steel, diameter 200 mm] (41) and second rolling roll [stainless steel, diameter 200 mm] (42), and then wound on second rolling roll (42), then this second rolling roll An acrylic resin continuous sheet (thickness 2 mm, width 200 mm) (S) was continuously produced by sandwiching and rolling between (42) and a third rolling roll (stainless steel, diameter 200 mm) (43). The temperature of the surface of the acrylic resin continuous sheet (S) immediately after leaving the third rolling roll (43) was 101 ° C. on both sides.

While taking the acrylic resin continuous sheet (S) immediately after leaving the third rolling roll (43) with a pair of laminating rolls (made of hard rubber, diameter 100 mm) (21, 22), a plurality of guide rolls (6) While being kept flat above, the two sides were heated by two electric heaters (5) arranged on the upper and lower sides. Acrylic resin continuous film [thickness 125 μm] (F) and polyethylene continuous film [thickness 60 μm] (B) are wound from the original fabric rolls (F1, B1) on the lower surface of the acrylic resin continuous sheet (S) after heating. While taking out, they were superposed in this order and continuously supplied and sandwiched between the bonding rolls (21, 22). As the acrylic resin continuous film (F), one having a hard coat layer as a surface treatment layer (Fh) on one side [non-bonding side] (Fb) and an antireflection layer thereon is used. As shown to (a), it supplied so that it might be bonded with an acrylic resin continuous sheet (S) by the surface [bonding surface] (Fa) on the opposite side. The acrylic resin continuous sheet (S), acrylic resin continuous film (F) and polyethylene continuous film (B) supplied between the bonding rolls (21, 22) are pressed by the bonding roll (21, 22) A continuous bonding sheet (A) was obtained in which the acrylic resin continuous film (F) was bonded to only one side of the resin continuous sheet (S) by heat sealing.

After pasting, the polyethylene continuous film (B) could be easily peeled from the continuous pasting sheet (A). When the obtained continuous bonding sheet (A) was visually observed, no cracks were observed in the hard coat layer and the antireflection layer (Fh), and no transfer scratches from the bonding roll were observed.

Example 2
A surface of the acrylic resin continuous film (F) (non-bonded surface) (Fb) as a surface treatment layer (Fh) on the hard coating layer and an antireflection layer on the surface (Fb) on the surface (Fb) in advance The polyethylene continuous film (B) was overlapped and wound up to obtain a raw roll (FB1).

As shown in FIG. 2, the embodiment is such that the acrylic resin continuous film (F) and the polyethylene continuous film (B) are unwound from the raw roll (FB1) and supplied between the bonding rolls (21, 22). In the same manner as in No. 1, a continuous laminated sheet (A) in which the acrylic resin continuous film (F) was bonded only to one side of the acrylic resin continuous sheet (S) was obtained.

After pasting, the polyethylene continuous film (B) could be easily peeled from the continuous pasting sheet (A). When the obtained continuous bonding sheet (A) was visually observed, no cracks were observed in the hard coat layer and the antireflection layer (Fh), and no transfer scratches from the bonding roll were observed.

Comparative Example 1
The same operation as in Example 1 was performed, except that only the acrylic resin continuous sheet (S) and the acrylic resin continuous film (F) were supplied between the bonding rolls (21, 22) without using the polyethylene continuous film (B). Thus, a continuous bonding sheet (A) was obtained.

When the obtained continuous bonding sheet (A) was visually observed after bonding, many cracks and transfer scratches from the bonding roll were observed in the hard coat layer and the antireflection layer (Fh).

Example 3
In place of the acrylic resin continuous film (F) used in Example 1, an acrylic resin continuous film (F) having no surface treatment layer (Fh) on both sides was used in the same manner as in Example 1 for continuous application. A composite sheet (A) was obtained.

After pasting, the polyethylene continuous film (B) could be easily peeled from the continuous pasting sheet (A). When the obtained continuous bonding sheet (A) was visually observed, no transfer scratches from the bonding roll were observed on the surface.

Comparative Example 2
The same operation as in Example 3 was carried out except that only the acrylic resin continuous sheet (S) and the acrylic resin continuous film (F) were supplied between the bonding rolls (21, 22) without using the polyethylene continuous film (B). Thus, a continuous bonding sheet (A) was obtained.

After the pasting, when the obtained continuous pasting sheet (A) was visually observed, the surface was found to have transfer scratches from the pasting roll.

It is a figure which shows typically an example of the apparatus for manufacturing a thermoplastic resin continuous bonding sheet | seat by the manufacturing method of this invention. It is a figure which shows typically an example of the apparatus for manufacturing a thermoplastic resin continuous bonding sheet | seat by the manufacturing method of this invention. It is a figure which shows typically an example of the apparatus for manufacturing a thermoplastic resin continuous bonding sheet | seat by the manufacturing method of this invention. It is a figure which shows typically the cross-sectional structure of a thermoplastic resin continuous bonding sheet. It is a figure which shows typically an example of the apparatus for manufacturing a thermoplastic resin continuous bonding sheet | seat by the conventional method.

Explanation of symbols

A: Thermoplastic resin continuous bonding sheet S: Thermoplastic resin continuous sheet Sa: Bonding surface Sb: Non-bonding surface F: Thermoplastic resin continuous film Fa: Bonding surface Fb: Non-bonding surface
Fh: Surface treatment layer
F1: Raw roll B: Continuous protective film B1: Raw roll
BF1: Raw roll P: Thermoplastic resin 1: Manufacturing equipment 1 ': Manufacturing equipment
21, 22, 23: Bonding roll 3: Die
41, 42, 43: Rolling roll 5: Heating device 6: Holding mechanism (guide roll)
7: Extruder

Claims (2)

The thermoplastic resin continuous sheet (S) is bonded to the thermoplastic resin continuous sheet with a heat-sealable thermoplastic resin continuous film (F) by heat-sealing, and the thermoplastic resin continuous sheet (S ) Is a method for producing a thermoplastic resin continuous bonding sheet (A) in which the thermoplastic resin continuous film (F) is bonded,
Further, using a non-thermally fusible continuous protective film (B) for the thermoplastic resin continuous film, the thermoplastic resin continuous sheet (S) in a heated state, the thermoplastic resin continuous film (F), and The continuous protective film (B) is overlaid in this order, pressed with a pair of bonding rolls, and the thermoplastic resin continuous film (F) is thermally fused to the thermoplastic resin continuous sheet (S). The manufacturing method of the said thermoplastic resin continuous bonding sheet | seat (A) characterized by making it bond. The manufacturing method according to claim 1, wherein the thermoplastic resin continuous film (F) is a thermoplastic resin continuous film provided with a surface treatment layer (Fh) on a non-bonding surface.

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