JP2006175706A - Photoreaction product sheets, method and apparatus for producing the sheets - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide photoreaction product sheets which can obtain a high precision coating thickness by applying a load alternately in both directions to the thickness direction of a laminate in an irradiation chamber for irradiation with light, its production method, and its production apparatus. <P>SOLUTION: By making the laminate 17 formed by being coated in the shape of a layer between sheet-like substrates 2 and 3 by a coating part 4, while a photoreaction product layer 8 is polymerized by ultraviolet rays radiated from a light source lamp 27 in the irradiation chamber 10, pass the upper and lower parts of load rolls 20-23 arranged in the irradiation chamber 10 alternately, a load is loaded alternately in the vertical direction of the laminate 17 from contacted load rolls 20-23. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a photoreaction product sheet produced by irradiating light to a laminate in which the photoreaction product is sandwiched in layers, a method for manufacturing the same, and an apparatus for manufacturing the photoreaction product sheet. The present invention relates to a photoreaction product sheet capable of obtaining a highly accurate coating thickness by alternately applying a load from both directions with respect to the thickness direction of the body, and a production method and apparatus thereof.

Conventionally, for example, an adhesive tape or an adhesive sheet having a structure in which an adhesive layer is sandwiched between two films as shown in FIG. 3 is widely known. Such pressure-sensitive adhesive tape or pressure-sensitive adhesive sheet is formed by applying a photoreaction product mainly composed of an acrylic monomer in a layer form on a light-transmitting film, and irradiating the coating film with energy rays such as ultraviolet rays and electron beams. It is formed by reacting.
However, since the photoreaction product used here has a remarkably low viscosity, it has been difficult to form an adhesive layer having a desired thickness on the film.

Therefore, a method for increasing the viscosity suitable for coating by adding a thixotropic agent such as fumed silica to the liquid photopolymerizable composition, or irradiating the liquid photoreaction product with light. A method of thickening to a viscosity suitable for coating by partially polymerizing is widely performed. Thereby, the coating thickness of the photoreaction product can be increased.
However, on the other hand, when the coating thickness is increased, the polymerization process due to light irradiation causes polymerization due to the effects of resin curing shrinkage, polymerization reaction heat generation, heat deformation due to lamp heat generation, tensile wrinkles due to film tension, etc. A difference in thickness occurs in the subsequent adhesive tape or adhesive sheet, or a wavy deformation occurs. As a result, the thickness accuracy is deteriorated, and when the obtained adhesive tape or adhesive sheet is rolled up, a so-called winding nest is formed between the wound layers, resulting in poor quality.

Here, as a method for improving the thickness accuracy, for example, in Japanese Patent Application Laid-Open No. 2001-89719 and Japanese Patent Application Laid-Open No. 2002-121111, a pair of rolls arranged at a predetermined interval in a light irradiation device that emits light is disclosed. The manufacturing method of the photoreaction product sheet | seat which adjusts thickness by letting pass is described.
JP 2001-89719 A (page 3 to page 5, FIG. 5) Japanese Patent Laid-Open No. 2002-12111 (pages 4 to 5, FIG. 1)

  However, in the manufacturing method of the photoreaction product sheets described in Patent Document 1 and Patent Document 2 described above, since the final thickness accuracy is determined by the gap between the rolls, high accuracy is required to maintain high accuracy. An expensive counter-roll with a gap adjustment mechanism had to be installed. In addition, it is necessary to set the gap between rolls strictly. If the setting is wrong, there is a possibility that the adhesive sticks out.

  The present invention has been made in order to solve the problems in the prior art, and even when a liquid photoreaction product is thickly applied to a sheet-like member, deformation of the laminate caused by the photopolymerization reaction is prevented. It is an object of the present invention to provide a photoreaction product sheet that can be corrected and a highly accurate coating thickness, and a method and an apparatus for producing the photoreaction product sheet.

  In order to achieve the above object, a method for producing a photoreaction product sheet according to claim 1 of the present application is directed to a laminate comprising a photoreaction product and a sheet-like member sandwiching the photoreaction product in a predetermined direction. In the method for producing a photoreaction product sheet in which the photoreaction product is polymerized by irradiating light from one or both sides of the laminate to be conveyed, the thickness of the laminate to be conveyed A load is alternately applied from both directions with respect to the vertical direction.

  Moreover, the manufacturing method of the photoreaction product sheet | seat which concerns on Claim 2 is a manufacturing method of the photoreaction product sheet | seat of Claim 1, From both directions with respect to the thickness direction of the said laminated body conveyed. The load applied alternately is characterized in that the polymerization rate of the photoreaction product to be polymerized is loaded in a predetermined state.

  The method for producing photoreaction product sheets according to claim 3 is the method for producing photoreaction product sheets according to claim 2, wherein the predetermined state is a state in which the polymerization rate is 70% or less. It is characterized by being.

  Moreover, the manufacturing method of the photoreaction product sheet | seat which concerns on Claim 4 is a thickness of the said laminated body conveyed in the manufacturing method of the photoreaction product sheet | seat in any one of Claim 1 thru | or 3. The load applied alternately from both directions with respect to the vertical direction is a load of 0.01 to 0.25 N per 1 cm width on the laminate.

  Moreover, the manufacturing method of the photoreaction product sheet | seat which concerns on Claim 5 is a thickness of the said laminated body conveyed in the manufacturing method of the photoreaction product sheet | seat in any one of Claim 1 thru | or 4. The load that is alternately loaded from both directions with respect to the vertical direction is loaded from the load roll that is in contact with the laminated body by passing alternately up and down through load rolls arranged at predetermined intervals. And

  Moreover, the manufacturing method of the photoreaction product sheet | seat which concerns on Claim 6 is a manufacturing method of the photoreaction product sheet | seat in any one of Claims 1 thru | or 5. The photoreaction product sheets produced by the production method are pressure-sensitive adhesive sheets.

  Moreover, the manufacturing apparatus of the photoreaction product sheet | seat which concerns on Claim 7 is a laminated body which consists of a photoreaction product and the sheet-like member which pinches | interposes the said photoreaction product in layers, The single side | surface of the said laminated body, In an apparatus for producing photoreaction product sheets having light irradiation means for polymerizing the photoreaction product by irradiating light from both sides, and conveying means for conveying the laminate in a predetermined direction, a predetermined interval And a load roll for alternately applying a load from both directions in the thickness direction of the laminated body to the laminated body conveyed by the conveying means.

  The apparatus for producing photoreaction product sheets according to claim 8 is the apparatus for producing photoreaction product sheets according to claim 7, wherein the loading roll is polymerized by the light irradiation means. A load is applied to the laminate with the polymerization rate of the photoreaction product in a predetermined state.

  The apparatus for producing photoreaction product sheets according to claim 9 is the apparatus for producing photoreaction product sheets according to claim 8, wherein the predetermined state is a state in which the polymerization rate is 70% or less. It is characterized by being.

  The apparatus for producing a photoreaction product sheet according to claim 10 is the apparatus for producing a photoreaction product sheet according to any one of claims 7 to 9, wherein the load roll is the laminate. A load of 0.01 to 0.25 N per 1 cm width is applied in the vertical direction.

  An apparatus for producing a photoreaction product sheet according to claim 11 is the apparatus for producing a photoreaction product sheet according to any one of claims 7 to 10, wherein the photoreaction product sheet is conveyed by the conveying means. The laminate passes through the load rolls arranged at a plurality of locations at predetermined intervals alternately, and the load roll applies a predetermined amount of load to the abutted laminate. .

  Furthermore, the photoreaction product sheets according to claim 12 are the method for producing photoreaction product sheets according to any one of claims 1 to 6 or any one of claims 7 to 11. It is the photoreaction product sheet | seat manufactured with the manufacturing apparatus of the photoreaction product sheet | seat described in above.

  In the method for producing the photoreaction product sheets according to claim 1 having the above-described configuration, the load is alternately applied from the double-sided direction with respect to the thickness direction of the laminated body to be transported. Without requiring equipment, it is possible to correct the deformation of the laminate caused by the polymerization by light irradiation. Therefore, it is possible to produce photoreaction product sheets having high thickness accuracy and no risk of quality defects.

  Further, in the method for producing photoreaction product sheets according to claim 2, since the polymerization rate of the photoreaction product subjected to the polymerization reaction is loaded to the laminate in a predetermined state, an appropriate range of the polymerization rate It is possible to correct the thickness of the laminate by applying a load based on the above, and it is possible to produce photoreaction product sheets having higher thickness accuracy.

  In the method for producing photoreaction product sheets according to claim 3, since the load is applied to the laminate in a state where the polymerization rate of the photoreaction product to be polymerized is 70% or less, an appropriate polymerization rate is obtained. It is possible to correct the thickness of the laminate by applying a load based on this range, and it is possible to produce photoreaction product sheets having higher thickness accuracy.

  Further, in the method for producing photoreaction product sheets according to claim 4, since a load of 0.01 to 0.25 N per 1 cm width is applied to the laminate, an appropriate range of load is applied to the laminate. It is possible to correct the thickness, and it is possible to produce photoreaction product sheets having higher thickness accuracy.

  Further, in the method for producing photoreaction product sheets according to claim 5, since the load is applied from the load roll abutted by the laminated body alternately passing through the load rolls arranged at predetermined intervals. It is possible to correct the deformation of the laminate caused by polymerization by light irradiation without requiring expensive equipment with high accuracy. Therefore, it is possible to produce photoreaction product sheets having high thickness accuracy.

  Further, in the method for producing photoreaction product sheets according to claim 6, since pressure-sensitive adhesive sheets are produced as photoreaction product sheets, it is high without requiring expensive equipment with high accuracy. It becomes possible to manufacture pressure-sensitive adhesive sheets having thickness accuracy.

  Moreover, in the manufacturing apparatus of the photoreaction product sheets according to claim 7, loads are alternately applied from both sides with respect to the thickness direction of the laminate to be conveyed by the load rolls arranged at a plurality of positions at predetermined intervals. Since it is loaded, it is possible to correct the deformation of the laminate caused by polymerization due to light irradiation without requiring expensive equipment with high accuracy. Therefore, it is possible to produce photoreaction product sheets having high thickness accuracy and no risk of quality defects.

  Further, in the photoreaction product sheet manufacturing apparatus according to claim 8, since the polymerization rate of the photoreaction product to be polymerized is loaded to the laminate in a predetermined state, an appropriate range of the polymerization rate is obtained. It is possible to correct the thickness of the laminate by applying a load based on the above, and it is possible to produce photoreaction product sheets having higher thickness accuracy.

  In the apparatus for producing photoreaction product sheets according to claim 9, since a load is applied to the laminate in a state where the polymerization rate of the photoreaction product to be polymerized is 70% or less, an appropriate polymerization rate is obtained. It is possible to correct the thickness of the laminate by applying a load based on this range, and it is possible to produce photoreaction product sheets having higher thickness accuracy.

  Moreover, in the manufacturing apparatus of the photoreaction product sheets according to claim 10, since a load of 0.01 to 0.25 N per 1 cm width is applied to the laminate, an appropriate range of load is applied to the laminate. It is possible to correct the thickness, and it is possible to produce photoreaction product sheets having higher thickness accuracy.

  Further, in the apparatus for producing photoreaction product sheets according to claim 11, the load is applied from the load roll abutted by the laminated body alternately passing through the load rolls arranged at predetermined intervals. It is possible to correct the deformation of the laminate caused by polymerization by light irradiation without requiring expensive equipment with high accuracy. Therefore, it is possible to produce photoreaction product sheets having high thickness accuracy.

  Moreover, in the apparatus for producing photoreaction product sheets according to claim 12, since pressure-sensitive adhesive sheets are produced as the photoreaction product sheets, it is high without requiring expensive equipment with high accuracy. It becomes possible to manufacture pressure-sensitive adhesive sheets having thickness accuracy.

  Further, the photoreaction product sheets according to claim 13 are photoreaction product sheets having a high thickness accuracy in which deformation of a laminate caused by polymerization by light irradiation is corrected, and a high-quality adhesive tape. It can be used as an adhesive sheet.

  Hereinafter, the photoreaction product sheets and the method and apparatus for producing the photoreaction product sheets according to the present invention will be described in detail with reference to the drawings based on the embodiments that are embodied. First, a schematic configuration of a photoreaction product sheet manufacturing apparatus 1 for manufacturing a photoreaction product sheet according to the present embodiment will be described with reference to FIG. FIG. 1 is a schematic perspective view showing the main part of the photoreaction product sheet manufacturing apparatus according to this embodiment. In the present embodiment, as a photoreaction product sheet manufacturing apparatus, a photoreaction product coated to a uniform thickness is photopolymerized by light from an irradiation chamber to form a pressure-sensitive adhesive layer. A manufacturing apparatus for manufacturing a pressure-sensitive adhesive sheet will be described as an example.

  As shown in FIG. 1, the photoreaction product sheet manufacturing apparatus 1 according to the present embodiment feeds out the sheet-like base materials 2 and 3 and predetermines the photoreaction product 6 to the sheet-like base materials 2 and 3. Coating section 4 for coating (coating) to a thickness (1.2 mm in this embodiment), liquid supply tank 14 for supplying photoreaction product 6 to coating section 4, and sheet-like substrate A photoreaction product layer 8 (see FIG. 2) composed of the photoreaction product 6 applied to 2 and 3 is irradiated with light, and a constant tension is applied to the photoreaction product sheet. Thus, it basically includes a transport roll 11 that transports the inside of the irradiation chamber 10, and a winding unit 12 that winds up the photoreaction product sheet that has been produced by polymerization. Hereinafter, the configuration of each unit will be described in detail.

  The coating unit 4 is composed of an upper surface roll 4A and a lower surface roll 4B, which are respectively arranged up and down at a predetermined interval, and a gap 16 formed between the upper surface roll 4A and the lower surface roll 4B is formed in the sheet-like base materials 2, 3 Is passed, the photoreaction product 6 is applied to the sheet-like substrates 2 and 3. Specifically, when the sheet-like base materials 2 and 3 fed out from the upper surface roll 4A and the lower surface roll 4B are transported along the gap 16, the liquid supply tank 14 is supplied to the space formed between the base materials. The photoreaction product 6 filled in is supplied, and a predetermined thickness (in this embodiment, a width slightly narrower than the width of the sheet-like base materials 2, 3) in the width direction of the sheet-like base materials 2, 3 is used. 1.2 mm).

  In addition, the liquid supply tank 14 is a photoreaction product 6 that becomes a coating liquid in a space portion of a predetermined capacity formed between the upper surface roll 4A and the lower surface roll 4B by the wall portion 15 attached to the lower surface roll 4B. Is a filled tank.

  The irradiation chamber 10 performs a photopolymerization reaction by irradiating light to the photoreaction product 6 applied between the sheet-like substrates 2 and 3. In this irradiation chamber 10, while supporting a pair of sheet-like base materials 2 and 3 (henceforth the laminated body 17. Refer FIG. 2) which pinched | interposed the photoreaction product layer 8 conveyed in the irradiation chamber 10. Load rolls 20 to 26 that load a predetermined amount of load in the thickness direction of the laminate 17 and a light source lamp 27 that irradiates ultraviolet rays as energy rays are provided. The photoreaction product layer 8 of the laminate 17 transported into the irradiation chamber 10 is irradiated with ultraviolet rays from the light source lamp 27 and starts a polymerization reaction accordingly, and after completion of the polymerization reaction, the pressure-sensitive adhesive layer 51 ( 3). The light source lamp 27 corresponds to the light irradiation means in the present invention.

Here, the load rolls 20 to 26 according to the present embodiment are arranged at a total of seven places in the irradiation chamber 10 at equal intervals, and the roll surface speed is adjusted to the conveyance speed of the laminate 17 by a separately provided drive motor. Are driven to synchronize with each other. Thereby, the inside of the irradiation chamber 10 can be conveyed without damaging the surface of the sheet-like base materials 2 and 3 with a laminated body. The load rolls 20 to 26 may be rotatably supported without being driven to rotate.
The load rolls 20 to 26 support the laminate 17 in the irradiation chamber 10 and apply a predetermined amount of load to the laminate 17 during the polymerization reaction based on the tension of the laminate 17 and the holding angle between the load rolls. The load is applied to correct the thickness of the laminate 17. Details of the thickness correction by the load rolls 20 to 26 will be described later.

Further, a plurality of light source lamps 27 are disposed above the stacked body 17 conveyed in the irradiation chamber 10, and light is irradiated toward the upper surface of the stacked body 17.
The light source lamp 27 emits a light wavelength in the same region as the absorption wavelength of the photopolymerization initiator added to the photoreaction product 6, for example, a low pressure mercury lamp, a medium pressure mercury lamp, a high pressure mercury lamp, a chemical lamp, a black light. A lamp, a microwave excitation mercury lamp, a metal hydride lamp, or the like is used. Moreover, the irradiation intensity | strength to the photoreaction product 6 by the light source lamp 27 is a factor which influences the polymer polymerization degree obtained, and 0.1-300 mW / cm <2> is desirable. In this embodiment, the polymerization is performed by irradiating light only from the upper surface direction of the laminate 17, but it is naturally possible to irradiate only from the lower surface direction or from both surfaces.

Moreover, the conveyance roll 11 is comprised by a pair of upper and lower rolls, and is rotationally driven in the arrow direction of FIG. 1 by a drive motor (not shown). A constant tension is generated in the laminated body 17 that passes between the transport rolls as the transport roll 11 is driven to rotate, and the transport is performed in the irradiation chamber 10. Further, the photoreaction product sheet 50 obtained by completing the photopolymerization of the photoreaction product layer 8 of the laminate 17 is unloaded from the irradiation chamber 10 and taken up by the take-up unit 12.
Then, the target pressure-sensitive adhesive tape or pressure-sensitive adhesive sheet can be obtained by cutting the photoreaction product sheet 50 wound around the winding portion 12 into a predetermined size.

  Next, the photoreaction product sheet 50 manufactured by the photoreaction product sheet manufacturing apparatus 1 based on the laminate 17 and the laminate 17 formed by the coating unit 4 will be described. FIG. 2 is a cross-sectional view of the laminate 17 before the photopolymerization according to the present embodiment is cut in the width direction. FIG. 3 is a cross-sectional view of the photoreaction product sheet 50 after completion of photopolymerization according to the present embodiment, cut in the width direction.

  The laminated body 17 is comprised from the photoreaction product layer 8 pinched | interposed between the sheet-like base materials 2 and 3 and the sheet-like base materials 2 and 3 as shown in FIG.

  For the sheet-like substrates 2 and 3, for example, plastic films such as polyester films and polypropylene films, papers such as kraft paper and Japanese paper, metal foils such as alum foil, and the like are used. However, in the present embodiment, as described above, the light source lamp 27 provided in the irradiation chamber 10 irradiates light from the upper surface to the laminated body 17 to be conveyed and is sandwiched between the sheet-like substrates 2 and 3. Since the photopolymerization product layer 8 is subjected to photopolymerization, a light-transmitting film such as polyethylene terephthalate is used for the sheet-like substrate 2 located on the surface irradiated with light. In this embodiment, the polymerization is performed by irradiating light only from the upper surface, but it is naturally possible to irradiate from both sides. A permeable film is used.

  The photoreaction product 6 constituting the photoreaction product layer 8 contains a monomer or a partial polymer thereof and a photopolymerization initiator, and is polymerized by light irradiation to become a pressure-sensitive adhesive. Known materials such as acrylic, polyester, and epoxy are used. Among these, an acrylic photopolymerizable composition is particularly preferably used for the production of the photoreaction product sheet. Hereinafter, each component of the photoreaction product used in the present embodiment will be exemplified.

Moreover, in the photoreaction product sheet manufacturing apparatus 1 according to the present embodiment, as the photoreaction product 6, (meth) acrylic acid alkyl ester having an average of 2 to 14 carbon atoms in the alkyl group, together with this, A polymerizable monoethylenically unsaturated monomer is used. Here, as the (meth) acrylic acid alkyl ester, alkyl acrylate or methacrylate having 2 to 14 carbons in an alkyl group such as butyl acrylate, isononyl acrylate, isooctyl acrylate, 2-ethylhexyl acrylate or the like is used.
On the other hand, copolymerizable monoethylenically unsaturated monomers include polar monomers that are carboxylic acids such as acrylic acid, methacrylic acid, and maleic acid, or nitrogen-containing monomers such as acrylamide, N-vinylpyrrolidone, and acryloylmorpholine. Is used.

  In order to improve the holding property of the pressure-sensitive adhesive after polymerization, it is also useful to add a known cross-linking material such as an isocyanate compound or an epoxy compound or a polyfunctional (meth) acrylate as a cross-linking agent. is there. Examples of the polyfunctional (meth) acrylate include trimethylolpropane tri (meth) acrylate, pentaerythritol tetra (meth) acrylate, 1,2-ethylene glycol di (meth) acrylate, and 1,6-hexanediol di (meth). Acrylate or the like is used. If the amount of these cross-linking agents added is too large, the crosslink density increases and the necessary peeling force cannot be obtained, and if it is too small, the necessary condensing force cannot be obtained. An appropriate addition amount is 0.01 to 0.5 parts by weight with respect to 100 parts by weight of the photoreactive monomer, and an optimum addition amount is 0.02 to 0.3 parts by weight.

Examples of the photopolymerization initiator include ketals such as 2,2-dimethoxy-1,2-diphenylethane-1-one (for example, Irgacure 651: Ciba Specialty Chemicals), 1-hydroxy-cyclohexyl-phenyl-ketone ( For example, acetophenones such as Irgacure 184: Ciba Specialty Chemicals), benzoin ethers such as benzoin ethyl ether and benzoin propyl ether, halogenated ketones, acylphosphine oxides (for example, Lucyrin TPO: BASF) and others are known. A photopolymerization initiator is used. These photopolymerization initiators can be used in combination depending on the application.
Moreover, when the addition amount of the photopolymerization initiator is too large, a low molecular weight copolymer is likely to be formed, and when it is too small, the polymerization reaction is difficult to proceed. An appropriate addition amount is 0.01 to 2 parts by weight with respect to 100 parts by weight of the photoreactive monomer, and an optimum addition amount is 0.05 to 1 part by weight.

Furthermore, an inorganic or organic filler can be added to the photoreaction product 6 according to the present embodiment in order to increase the shear adhesive force and improve the workability. Examples of the inorganic filler include silica, calcium carbonate, clay, titanium oxide, glass balloon, and alumina balloon. As the organic filler, polyester beads, vinylidene chloride balloon, acrylic balloon and the like are used.
Moreover, in order to color the photoreaction product 6, a coloring pigment of the grade which does not inhibit photopolymerization can also be used. Black is often used as the adhesive, and in this case, it is colored with carbon black. The addition amount of carbon black is used in the range of 1 part by weight or less with respect to 100 parts by weight of the (meth) acrylate monomer. If it exceeds 1 part by weight, photopolymerization cannot be performed.

  Further, the viscosity of the photoreaction product 6 serving as a coating liquid at room temperature is preferably 1 Pas or more. Usually, the viscosity is adjusted by blending a thixotropic additive to adjust the viscosity to a viscosity suitable for coating, partially irradiating with light to photopolymerize, or thermally polymerizing.

  Then, the laminate 17 formed by the coating unit 4 is passed through the irradiation chamber 10 of the photoreaction product sheet manufacturing apparatus 1, so that the photoreaction product is based on the light emitted from the light source lamp 27. Layer 8 is photopolymerized. Thereafter, when the polymerization reaction is almost completed by irradiating for a predetermined time (polymerization rate of 90% or more), the pressure-sensitive adhesive layer 51 can be obtained, and the photoreaction having the pressure-sensitive adhesive layer 51 as shown in FIG. A product sheet 50 is produced.

  Next, a manufacturing process for manufacturing the photoreaction product sheet 50 by the photoreaction product sheet manufacturing apparatus 1 configured as described above will be described below.

  First, the sheet-like base materials 2 and 3 are fed out from the vertical direction by the upper surface roll 4A and the lower surface roll 4B, respectively. When the fed sheet-like base materials 2 and 3 pass through the gap 16 formed between the upper surface roll 4A and the lower surface roll 4B, the photoreaction product 6 in the liquid supply tank 14 becomes the sheet-like substrate. Coating is performed between the materials 2 and 3 in layers (in this embodiment, a thickness of 1.2 mm). As a result, a laminate 17 in which the photoreaction product layer 8 is sandwiched in the center as shown in FIG. 2 is formed.

  Thereafter, the laminate 17 formed by the coating unit 4 is conveyed to the irradiation chamber 10 that irradiates ultraviolet rays as energy rays in accordance with the rotational driving of the conveyance roll 11. The laminated body 17 conveyed in the irradiation chamber 10 is irradiated with ultraviolet rays from the light source lamp 27, thereby starting a polymerization reaction. The intensity of the ultraviolet light of the light source lamp 27 and the conveyance speed of the laminate 17 are set so that the polymerization reaction of the photoreaction product layer 8 is almost completed while the laminate 17 passes through the irradiation chamber 10. The meaning that the polymerization reaction is almost completed means that the polymerization rate is 90% or more.

Moreover, in the manufacturing method of the photoreaction product sheet | seat which concerns on this embodiment, it is the load roll arrange | positioned in the irradiation chamber 10 between the polymerization reaction start of the photoreaction product layer 8 until a polymerization reaction is substantially completed. Pass between 20-26.
Here, in the polymerization process by light irradiation, the photoreaction product sheet after polymerization is affected by the shrinkage of resin curing, polymerization heat generation of the photoreaction product, thermal deformation due to lamp heat generation, tensile wrinkles due to film tension, etc. A difference in thickness occurs or a wavy deformation occurs. However, by applying a load in the thickness direction of the laminate based on the load rolls 20 to 26, the thickness can be flattened and highly accurate thickness adjustment can be performed.

The laminated body 17 conveyed in the irradiation chamber 10 first passes through the upper surface of the load roll 20 when it reaches the load roll 20, and then passes through the lower surface of the roll in the load roll 21. Further, the next load roll 22 passes the roll upper surface, and the load roll 23 passes the roll lower surface. And the laminated body 17 to which the fixed tension | tensile_strength was provided by the conveyance roll 11 contact | abuts on the roll surface of the load rolls 20-23 by making the upper and lower sides of the load rolls 20-23 pass alternately, and the contacted load roll A load is applied from 20 to 23 in the vertical direction.
FIG. 4 shows an example of a load roll 21 that loads a structure in which a load is applied by the load rolls 20 to 23 by passing the laminate 17 through the lower surface of the roll among the load rolls arranged in the irradiation chamber 10. It is the schematic diagram shown as follows.

  As shown in FIG. 4, the laminated body 17 is brought into contact with the lower surface of the load roll 21 by passing the laminated body 17 alternately up and down in the load rolls 20 to 23. At that time, the laminate 17 has a predetermined magnitude of tension T due to the rotational drive of the transport roll 11, and a load N is applied in the vertical direction of the laminate 17 by the load roll 21 in contact therewith. Here, the load N to be loaded is determined by the tension T applied to the laminated body 17 by the transport roll 11 and the holding angle φ of the laminated body 17 by the load roll 21. Specifically, the relationship “N = T × sin φ” holds, and the load N applied from the load roll 21 increases as the tension T and the holding angle φ increase.

  On the other hand, when the laminated body 17 passes the load rolls 24-26 which are the latter half of superposition | polymerization, it passes the roll upper surface uniformly, without applying a load. This is because at this point, the polymerization has already progressed to a certain level, and even if a load is applied, the effect of adjusting the thickness hardly appears. However, it is naturally possible to allow the load rolls 24 to 26 to alternately pass up and down.

  In order to prevent the deformation of the sheet in the polymerization process and maintain the thickness accuracy, it is desirable to load the load rolls 20 to 23 alternately above and below the polymerization rate in the range of 0 to 70%. . Thereby, the photoreaction product sheet 50 having high thickness accuracy can be manufactured. On the other hand, even if a load is applied at a position where the polymerization rate exceeds 70%, the fluctuation of the photoreaction product layer 8 cannot be corrected, and the thickness cannot be adjusted sufficiently.

  Moreover, the magnitude | size of the load loaded on the laminated body 17 with the load rolls 20-23 is 0.01-0.25N when converted per unit width 1cm of the sheet-like base materials 2 and 3. As shown in FIG. Thereby, the photoreaction product sheet 50 having high thickness accuracy can be manufactured. On the other hand, if it is smaller than 0.01N, the load is too small and the effect of adjusting the thickness hardly appears. If it is larger than 0.25N, the load is too large and the thickness difference is increased.

  Then, the photoreaction product sheet 50 having the thickness adjusted by the load rolls 20 to 26 and the pressure-sensitive adhesive layer 51 formed by photopolymerization is unloaded from the irradiation chamber 10 and passes between the transport rolls 11. Then, it is wound up by the winding unit 12. And the target adhesive tape etc. can be obtained by cutting the wound photoreaction product sheet | seat 50 to a predetermined magnitude | size.

  Next, the value of the load applied to the laminate 17 by the load rolls 20 to 26, the polymerization rate of the photoreaction product layer 8 when the load is applied, and the thickness accuracy of the photoreaction product sheet 50 after production The relationship between the photoreaction product sheets 50 of Examples 1 to 6 and Comparative Examples 1 to 5 produced according to the present invention will be described in comparison with each other.

Example 1
In Example 1, 0.2 parts by weight of Irgacure 651 as a photopolymerization initiator was first added to a mixed monomer solution consisting of 90 parts by weight of 2-ethylhexyl acrylate and 10 parts by weight of acrylamide, and irradiated with ultraviolet light in a nitrogen atmosphere. Polymerized syrup was obtained (polymerization rate 8%). Further, 0.2 parts by weight of photopolymerization initiator Irgacure 184, 0.15 parts by weight of 1,6-hexanediol diacrylate as a crosslinking agent, and pigment (Microlith Black CT: Ciba Specialty Chemicals, containing carbon black 35%) and 0.02 parts by weight of glass balloon (Cellstar Z-27: Tokai Kogyo Co., Ltd.) 10 parts by weight are mixed to obtain the desired photoreaction product 6 as a coating liquid. Produced.

  After defoaming this photoreaction product 6 with a predetermined defoaming device, the photoreaction product 6 was supplied into the liquid supply tank 14 and applied to the sheet-like base materials 2 and 3 to a thickness of 1.2 mm. . On the other hand, as the sheet-like substrates 2 and 3, non-adhesive-treated 50 μm-thick PET separators were used. .

  Load rolls that apply load to the laminate 17 are provided at a total of 20 locations, and the 10 rolls on the coating unit 4 side are alternately passed through the laminate 17 to load the laminate 17 and transport it. The 10 rolls on the roll 11 side were uniformly pass lines that allowed the upper surface of the roll to pass.

Here, the load N applied as described above is determined by the tension T applied to the laminate 17 by the transport roll 11 and the holding angle φ of the laminate 17 by the load roll (see FIG. 4).
Accordingly, the number of rotations of the transport roll 11 (the tension T applied to the laminated body 17 is determined) and the positions of the ten load rolls that pass alternately up and down (the holding angle φ of the laminated body 17 with respect to the loaded roll are determined). ) Was adjusted to adjust the load N applied in the vertical direction of the laminate 17 from the load roll.

  As shown in FIG. 5, the photoreaction product sheet according to Example 1 has a polymerization rate of 15%, a holding angle φ of 5 degrees, and a tension T applied to a width of 20 cm of 11 when a load is applied by a loading roll. .5N was manufactured by the above manufacturing method and apparatus.

  Here, as a means for comparing the thickness accuracy of the photoreaction product sheet, one surface of the photoreaction product sheet 50 after light irradiation is placed on a flat plate, and the difference is obtained by measuring the height of the standard point and the highest point. Was quantified as the amount of sheet change. As a result, the sheet deformation amount of the photoreaction product sheet was 1 mm.

(Examples 2 to 4)
In Examples 2 to 4, the same photoreaction product 6 as in Example 1 was used, and the same conditions were applied to the number of loaded rolls, the pass line, the ultraviolet irradiation device, and the polymerization rate when a load was applied by the loaded rolls. Thus, a photoreaction product sheet was prepared.

  However, in Examples 2 to 4, as shown in FIG. 5, by adjusting the holding angle φ and the tension T, respectively, the load N applied in the vertical direction of the stacked body 17 is changed under the conditions changed. A photoreaction product sheet was produced by the production method and apparatus.

  Specifically, in Example 2, the holding angle φ was 5 degrees, and the tension T applied to a 20 cm width was 20N. In Example 3, the holding angle φ was 5 degrees, and the tension T applied to a 20 cm width was 46N. In Example 4, the holding angle φ was 10 degrees, and the tension T applied to a width of 20 cm was 26N.

  Here, as in Example 1, when the sheet deformation amount of the photoreaction product sheet was measured, the photoreaction product sheet according to Example 2 was 1.2 mm. The photoreaction product sheet according to Example 3 was 0.2 mm. The photoreaction product sheet according to Example 3 was 1.2 mm.

(Comparative Examples 1-4)
In Comparative Examples 1 to 4, the same photoreaction product 6 as in Example 1 was used, and the same conditions were applied with respect to the number of loaded rolls, pass line, ultraviolet irradiation device, and polymerization rate when a load was applied by the loaded rolls. Thus, a photoreaction product sheet was prepared.

  However, in Comparative Examples 1 to 4, as shown in FIG. 5, by adjusting the holding angle φ and the tension T, respectively, the load N applied in the vertical direction of the stacked body 17 is changed under the condition changed. A photoreaction product sheet was produced by the production method and apparatus.

  Specifically, Comparative Example 1 was fabricated with a holding angle φ of 0 degree, that is, without applying a load from a load roll. In Comparative Example 2, the holding angle φ was 15 degrees, and the tension T applied to a 20 cm width was 25N. In Comparative Example 3, the holding angle φ was 25 degrees, and the tension T applied to a 20 cm width was 20N. In Comparative Example 4, the holding angle φ was 30 degrees, and the tension T applied to a 20 cm width was 46N.

  Here, as in Example 1, when the sheet deformation amount of the photoreaction product sheet was measured, the photoreaction product sheet according to Comparative Example 1 was 3.5 mm. The photoreaction product sheet according to Comparative Example 2 was 2.5 mm. The photoreaction product sheet according to Comparative Example 3 was 4 mm. The photoreaction product sheet according to Comparative Example 4 was 5 mm.

(Examples 5 and 6)
In Examples 5 and 6, the same photoreaction product 6 as in Example 3 was used, the number of load rolls, the pass line, the ultraviolet irradiation device, the holding angle φ (5 degrees) with respect to the load rolls, the laminate 17 A photoreaction product sheet was produced under the same conditions as in Example 3 with respect to the tension T (46 N) applied to the 20 cm width.

  However, in Examples 5 and 6, as shown in FIG. 5, by changing the ultraviolet irradiation intensity, light was applied by the production method and apparatus under the condition that the polymerization rate when changing the load by the load roll was changed. A reaction product sheet was prepared.

  Specifically, Example 5 was prepared with a polymerization rate of 60% when a load was applied by a load roll. Moreover, Example 6 produced the polymerization rate at the time of applying a load with a load roll at 70%.

  Here, as in Example 3, when the amount of deformation of the photoreaction product sheet was measured, the photoreaction product sheet according to Example 5 was 0.6 mm. The photoreaction product sheet according to Example 6 was 1.2 mm.

(Comparative Example 5)
In Comparative Example 5, the same photoreaction product 6 as in Example 3 was used, and the number of load rolls, pass line, ultraviolet irradiation device, holding angle φ (5 degrees) with respect to the load roll, 20 cm of the laminate 17. Regarding the tension T (46N) applied to the width, a photoreaction product sheet was produced under the same conditions as in Example 3.

  However, in Comparative Example 5, as shown in FIG. 5, the photoreaction was generated by the production method and apparatus under the condition that the polymerization rate was changed when the load was applied by the load roll by changing the ultraviolet irradiation intensity. A product sheet was prepared.

  Specifically, Comparative Example 5 was produced with a polymerization rate of 80% when a load was applied by a load roll.

  Here, as in Example 3, when the amount of deformation of the photoreaction product sheet was measured, the photoreaction product sheet according to Comparative Example 5 was 4.1 mm.

(Evaluation results)
Next, a comparative study is performed based on the evaluation results of the thickness accuracy of the photoreaction product sheets 50 according to Examples 1 to 6 and Comparative Examples 1 to 5 manufactured under the above conditions. FIG. 5 (A) is a diagram showing the production conditions and sheet deformation amount of each photoreaction product sheet produced by changing the applied load, and FIG. 5 (B) shows the polymerization rate when loaded. It is the figure which showed the manufacturing conditions and sheet deformation amount of each photoreaction product sheet | seat manufactured by changing. FIG. 6 is a graph showing a comparison of sheet deformation amounts based on the value of the load applied by the load rolls for the photoreaction product sheets manufactured based on the above conditions.

As shown in FIG. 6, in the evaluation results of the photoreaction product sheets according to Examples 1 to 4 and Comparative Examples 1 to 4 in which the polymerization rate is fixed and the load N applied in the vertical direction is changed, the laminate is obtained. It can be seen that the photoreaction product sheet of Example 3 having a load per unit width of 1 cm of 0.20 N / cm has the least sheet deformation amount and high thickness accuracy. Then, it can be seen that when the load N applied is reduced or increased as compared with Example 3, the sheet deformation amount gradually increases and the thickness accuracy decreases.
Here, the photo-reaction product sheets of Examples 1 to 4 have a sheet deformation amount of 2 mm or less, and are judged to have thickness accuracy with no problem in use as a product. On the other hand, in the photoreaction product sheets of Comparative Examples 1 to 4, the sheet deformation amount is 2 mm or more, and the deformation amount exceeds the allowable range.

  Therefore, in order to prevent the deformation of the sheet due to the polymerization process and maintain the thickness accuracy, the magnitude of the load applied to the laminate 17 by the load roll is 0.01 to 1 per unit width of the laminate 17. It can be seen that 0.25N is desirable. In particular, when a load of around 0.20 N is applied, it is possible to obtain a photoreaction product sheet with good thickness accuracy.

On the other hand, in the evaluation results of the photoreaction product sheets of Examples 3, 5-6, and Comparative Example 5 in which the load N applied in the vertical direction is fixed and the polymerization rate when the load is applied is changed, the polymerization results are low. It can be seen that the more the load is applied in the rate state, the smaller the sheet deformation amount and the higher the thickness accuracy. Then, it can be seen that as the load is applied at a high polymerization rate, the sheet deformation gradually increases and the thickness accuracy decreases.
Here, the photoreaction product sheets of Examples 3 and 5 to 6 have a sheet deformation amount of 2 mm or less, and are judged to have thickness accuracy with no problem in use as a product. On the other hand, in the photoreaction product sheet of Comparative Example 5, the sheet deformation amount is 2 mm or more, and the deformation amount exceeds the allowable range.

  Therefore, it can be seen that in order to prevent the deformation of the sheet in the polymerization process and to maintain the thickness accuracy, it is desirable to apply the load by alternately passing the load rolls in the range of the polymerization rate of 0 to 70%. In particular, when a load is applied in the range of 0 to 60%, it is possible to obtain a photoreaction product sheet having a good thickness accuracy with a sheet change amount of 1 mm or less.

As described in detail above, in the photoreaction product sheet manufacturing apparatus 1 and manufacturing method according to the present embodiment, the coating unit 4 is formed by being applied in layers between the sheet-like substrates 2 and 3. While the laminated body 17 is subjected to the polymerization reaction of the photoreaction product layer 8 by the ultraviolet light irradiated from the light source lamp 27 in the irradiation chamber 10, the upper and lower sides of the load rolls 20 to 23 disposed in the irradiation chamber 10 are moved up and down. Since the load is applied in the vertical direction of the laminated body 17 from the contacted load rolls 20 to 23 by alternately passing, the laminated body produced by the polymerization reaction without requiring expensive equipment with high accuracy. It is possible to correct 17 deformations. Therefore, it becomes possible to manufacture the photoreaction product sheet 50 having a high thickness accuracy and no risk of quality defects.
Moreover, it is appropriate by making the magnitude | size of the load loaded into the laminated body 17 with the load rolls 20-23 into 0.01-0.25N in conversion per unit width 1cm of the sheet-like base materials 2 and 3. It becomes possible to manufacture the photoreaction product sheet 50 having high thickness accuracy based on the magnitude of the load.
Furthermore, by applying the load by alternately passing the load rolls 20 to 23 in the range of the polymerization rate of 0 to 70%, a high thickness accuracy in which the polymerization rate when loading the load is in an appropriate range is achieved. The photoreaction product sheet 50 can be manufactured.
And the photoreaction product sheet | seat 50 manufactured with the manufacturing apparatus 1 and the manufacturing method of the photoreaction product sheet | seat which concerns on this embodiment has the high thickness precision by which the deformation | transformation of the laminated body which arises by superposition | polymerization by light irradiation was corrected. It is a sheet and can be used as a pressure-sensitive adhesive tape, pressure-sensitive adhesive sheet or the like having high quality.

Note that the present invention is not limited to the above-described embodiment, and various improvements and modifications can be made without departing from the scope of the present invention.
For example, in this embodiment, as a means for applying the coating liquid to the sheet-like base materials 2 and 3, the sheet-like base material 2 in which the coating liquid in the liquid supply tank 14 is fed from the upper surface roll 4 </ b> A and the lower surface roll 4 </ b> B, respectively. However, the coating liquid is directly applied to the sheet-like base materials 2 and 3 with a die coater, roll coater, comma coater, die coater, etc. It can also be cured.

  The present invention provides a method for producing a photoreaction product sheet that can be flattened and highly accurately adjusted when producing a photoreaction product sheet obtained by photopolymerization of a photoreaction product. And an apparatus can be provided.

It is a perspective schematic diagram showing the important section of the photoreaction product sheet manufacturing device concerning this embodiment. It is sectional drawing which cut | disconnected the laminated body before the photopolymerization based on this embodiment in the width direction. It is sectional drawing which cut | disconnected the photoreaction product sheet | seat after the photopolymerization concerning this embodiment in the width direction. It is the schematic diagram which showed the structure where a load is loaded with a load roll. (A) The figure which showed the manufacturing conditions and sheet deformation amount of each photoreaction product sheet | seat manufactured by changing the load applied, (B) It manufactured by changing the polymerization rate at the time of a load. It is the figure which showed the manufacturing conditions and sheet deformation amount of each photoreaction product sheet. It is the graph which compared and showed the sheet deformation amount based on the value of the load loaded with the load roll about the photoreaction product sheet manufactured based on each condition.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Manufacturing apparatus of photoreaction product sheet 2, 3 Sheet-like base material 4 Coating part 4A Upper surface roll 4B Lower surface roll 6 Photoreaction product 8 Photoreaction product layer 10 Irradiation chamber 11 Conveyance roll 17 Laminated body 20-26 Load Roll 27 Light source lamp 50 Photoreaction product sheet 51 Pressure-sensitive adhesive layer

Claims (13)

A laminate comprising a photoreaction product and a sheet-like member that sandwiches the photoreaction product in layers is conveyed in a predetermined direction, and the light is irradiated by irradiating light from one or both sides of the conveyed laminate. In the method for producing photoreaction product sheets for polymerizing the reaction product,
A method for producing photoreaction product sheets, wherein a load is alternately applied from both directions with respect to the thickness direction of the laminate to be conveyed.   The load that is alternately applied from both directions with respect to the thickness direction of the laminate to be conveyed is that the polymerization rate of the photoreaction product to be polymerized is loaded in a predetermined state. Item 2. A process for producing a photoreaction product sheet according to Item 1.   The said predetermined state is a state whose polymerization rate is 70% or less, The manufacturing method of the photoreaction product sheets of Claim 2 characterized by the above-mentioned.   The load applied alternately from both directions with respect to the thickness direction of the laminated body to be conveyed is a load of 0.01 to 0.25 N per 1 cm width on the laminated body. The method for producing a photoreaction product sheet according to any one of claims 1 to 3.   The load that is alternately loaded from both directions with respect to the thickness direction of the stacked body to be conveyed is the load that is contacted by the stacked body alternately passing up and down through load rollers arranged at predetermined intervals. The method for producing a photoreaction product sheet according to any one of claims 1 to 4, wherein the photoreaction product sheet is loaded from a roll.   The photoreaction product sheet according to any one of claims 1 to 5, wherein the photoreaction product sheet produced by the method for producing the photoreaction product sheet is a pressure-sensitive adhesive sheet. Manufacturing method of physical sheets. A laminate comprising a photoreaction product and a sheet-like member for sandwiching the photoreaction product in layers;
A light irradiation means for polymerizing the photoreaction product by irradiating light from one or both sides of the laminate;
In the manufacturing apparatus for photoreaction product sheets having a transport means for transporting the laminate in a predetermined direction,
A photoreaction characterized by comprising load rolls that are disposed at a plurality of locations at predetermined intervals and that alternately load loads from both directions in the thickness direction of the laminate on the laminate conveyed by the conveying means. Product sheet manufacturing equipment.   8. The photoreaction product according to claim 7, wherein the load roll applies a load to the laminate in a predetermined state of a polymerization rate of the photoreaction product polymerized by the light irradiation means. Sheet manufacturing equipment.   The said predetermined state is a state whose polymerization rate is 70% or less, The manufacturing apparatus of the photoreaction product sheets of Claim 8 characterized by the above-mentioned.   10. The production of the photoreaction product sheets according to claim 7, wherein the load roll applies a load of 0.01 to 0.25 N per 1 cm width to the laminated body. apparatus. The laminate transported by the transport means passes through the load rolls arranged at a plurality of locations at predetermined intervals alternately up and down,
The said load roll applies a predetermined amount of load with respect to the said laminated body which contact | abutted, The manufacturing apparatus of the photoreaction product sheets in any one of Claim 7 thru | or 10 characterized by the above-mentioned.   The photoreaction product sheet according to any one of claims 7 to 10, wherein the photoreaction product sheet produced by the photoreaction product sheet production apparatus is a pressure-sensitive adhesive sheet. Material sheet manufacturing equipment.   The method for producing a photoreaction product sheet according to any one of claims 1 to 6, or the apparatus for producing a photoreaction product sheet according to any one of claims 7 to 12. Photoreaction product sheets produced.

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