JP2008045690A - Roll adjusting device, thin film forming device and thin film manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a roll adjusting device capable of obtaining desired linear pressure distribution in addition to uniform linear pressure distribution, and to provide a thin film forming device having the roll adjusting device, and a thin film manufacturing method using the thin film forming device. <P>SOLUTION: The roll adjusting device has an outer cell 1; an inner cell 2 provided in double pipe structure inside the outer cell 1; rubber 3 covering the inner cell 2; and a shaft 6 holding the inner cell 2. A forming roll 20 having coupling means 5 coupling the outer cell 1 and the shaft 6 at both ends of the outer cell 1 so that the outer cell 1 can be eccentric with respect to the inner cell 2, is moved relatively to another adjacently-arranged forming roll 21. The roll adjusting device also has a shaft moving mechanism 26 for moving the shaft 6, and an outer cell moving mechanism 46 for moving the outer cell 1. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a roll adjusting device capable of adjusting the linear pressure distribution of a forming roll generated between the opposite rolls, a thin film forming device having the roll adjusting device, and a thin film manufacturing method using the thin film forming device. .

  Conventionally, as a roll for press-molding a long sheet-like material with a pair of rolls, a roll using a hydraulic equal pressure, a crown adjusting roll using a number of hydraulic pillars, and the like have been disclosed (Patent Document 1). 2).

Further, as a roll for manufacturing a resin film / sheet, Patent Document 3 discloses a forming roll provided with an outer cylinder made of a thin metal thin film that can be elastically deformed, and an elastic body roll that can be elastically deformed and rotated inside the outer cylinder. Is disclosed. Patent Document 4 discloses a double pipe roll having a thin outer cylinder thickness t of 0.03 or less of the roll radius.
Japanese Patent Publication No. 58-46599 JP-A-6-65889 Japanese Patent No. 3422798 JP 11-235747 A

  However, in the case of the rolls disclosed in Patent Document 1 and Patent Document 2, a uniform nip can be obtained. However, a hydraulic device is necessary, and the apparatus becomes large and expensive.

  In addition, in the case of the roll disclosed in Patent Document 3, the outer cylinder is formed as a thin cell of about 1 mm so that it can be softly wound around the counterpart forming roll, and a thin sheet can be formed. There is a problem with durability. Furthermore, in the case of the example shown by FIGS. 11-17 of patent document 3, it has the structure where a cooling fluid and a bearing contact | connect inside a roll. For this reason, when the roll having such a structure is performed with, for example, 0.5 MPa of pressurized water (150 ° C.) (used frequently in temperature-controlling resin molding applications at 150 ° C.), maintainability such as lubrication and seal leakage, There may be a problem in durability.

  In the case of the roll disclosed in Patent Document 4, when the linear pressure (or nip pressure: force per 1 cm in length when pressing a pair of rolls) is changed, a uniform pressure is obtained in the width direction. There is a problem that there is no. FIG. 20 shows a calculation example of the linear pressure distribution based on the design example of the roll having the structure disclosed in Patent Document 4. The counterpart roll is assumed to have infinite rigidity. When the roll outer diameter is φ410 mm × 4.5 mm thickness × 900 mm length, if the linear pressure is 10 kg / cm and the crown amount is 0.4 mm in diameter difference, a substantially flat linear pressure distribution is obtained. However, when a double load is applied to the roll, the center becomes a concave shape, and conversely, a half load becomes a convex shape. For this reason, the roll having such a structure can be used only in the vicinity of the designed linear pressure in practical operation, and when the load is changed, a uniform pressure cannot be obtained in the width direction. Also, considering the durability, the adjustment range of the linear pressure must be narrowed. Therefore, it may be difficult to adapt to the requirement to change the nip pressure in accordance with the thickness of the sheet to be molded and the material. Further, since the linear pressure load is borne at the end of the outer cylinder, it is difficult to increase the linear pressure.

  In addition, in the case of a press-molding roll that presses a general rubber-coated roll against a metal roll, almost uniform linear pressure can be obtained, but the thermal conductivity of the rubber is bad, and sufficient heat transfer inside the roll is not possible. There is a problem that the sheet material cannot be cooled and heated from the rubber roll side.

  Accordingly, the present invention provides an adjusting device capable of obtaining a desired linear pressure distribution in addition to a uniform linear pressure distribution, a thin film forming device having the adjusting device, and a thin film manufacturing method using the thin film forming device. For the purpose.

  In order to achieve the above object, the roll adjusting apparatus of the present invention comprises an outer cell, an inner cell provided in the outer cell in a double tube structure, rubber covering the inner cell, and a shaft holding the inner cell. Other moldings that are arranged adjacent to each other so that the outer cell is decentered with respect to the inner cell and has connecting means for connecting the outer cell and the shaft at both ends of the outer cell. A roll adjusting device that moves relative to a roll, and includes an axis moving mechanism that moves an axis and an outer cell moving mechanism that moves an outer cell.

  The forming roll of the roll adjusting device of the present invention has a groove formed on the surface of the rubber, and a temperature adjusting liquid for cooling or heating the outer cell is circulated through a rotary joint provided inside the groove in the shaft. It may be.

  The roll adjusting device of the present invention can adjust the shaft moving mechanism and the outer cell moving mechanism to individually move the shaft and the outer cell, and can adjust various linear pressures. Obtainable.

  In the roll adjusting device of the present invention, the shaft moving mechanism can individually move both ends of the shaft, and the outer cell moving mechanism can individually move both ends of the outer cell. Thereby, various linear pressure distributions can be obtained.

  The shaft moving mechanism of the roll adjusting device of the present invention may include a bearing box having a bearing that rotates and holds the shaft and a slider that can slide on the rail, and a pressing device that slides the bearing box. Good.

  Even if the outer cell moving mechanism of the roll adjusting device of the present invention moves the outer cell by moving the outer cell axis having a cylindrical part attached to the flanges at both ends of the outer cell. Good.

  In particular, the outer cell moving mechanism enables the outer cell bearing to have a bearing that rotatably holds the cylindrical portion of the outer cell shaft, a supporter fixed to the bearing housing, and the outer cell bearing to be slidable with respect to the support. You may have a slider and the cylinder which slides an outer cell bearing.

  Further, the outer cell moving mechanism includes a ring-shaped outer cell bearing having a bearing that rotatably holds the cylindrical portion of the outer cell shaft, and a ring that holds the outer cell bearing so that the position of the outer cell bearing can be adjusted by a radially arranged adjusting mechanism. It may have a shape supporter. Alternatively, the outer cell moving mechanism has a plurality of guide rollers that rotatably hold the cylindrical portion of the outer cell shaft, and the support holds the guide rollers, and the position of the bearing box is adjusted by a bolt that passes through a formed long hole. It may be fixed as possible. The structure of the outer cell moving mechanism having these configurations can be simplified.

  The thin film forming apparatus of the present invention has the roll adjusting apparatus of the present invention. Therefore, it is possible to cope with various changes in linear pressure distribution.

  Further, the thin film forming apparatus of the present invention has an inclined surface with a roll diameter reduced from the forming region end, which is the end of the sheet forming region for forming the sheet, to the roll end on at least one of the forming roll and the forming roll. It may be provided. By forming the inclined surface in this manner, contact with the counterpart forming roll 21 when the sheet 25 is thin can be avoided.

  The thin film manufacturing method of this invention manufactures a thin film by adjusting linear pressure distribution with the roll adjustment apparatus of the thin film formation apparatus of this invention.

  According to the present invention, a desired linear pressure distribution can be obtained in addition to a uniform linear pressure distribution.

  FIG. 1 shows a configuration of a film forming machine as an application example of the forming roll of the present embodiment.

  The film forming machine of this embodiment includes a T die 24, a forming roll 20 having the characteristics of the present invention, and forming rolls 21, 22, and 23. Each forming roll 20, 21, 22, 23 is arranged in parallel.

  The T die 24 extrudes a resin material from an extruder (not shown) into a sheet shape and guides it to a nip gap between a pair of molding rolls 21 and 20. As the sheet 25, a transparent clear sheet having a thickness of about 0.1 mm to 3 mm is used, and examples thereof include PC (polycarbonate) and PMMA (polymethyl methacrylate) resin materials. The forming roll 21 is fixedly installed, and the other forming rolls can be moved in the horizontal direction by a pressing device. The forming rolls 21 and 20 usually rotate at the same speed, and are formed to a constant thickness with a uniform pressure on the roll width. The sheet 25 is wound around the forming roll 21 side, nip-formed by the forming roll 22, then flowed downstream and cooled, and then wound or cut to produce a sheet.

  Next, FIG. 2 is a cross-sectional view taken along line AA of the forming roll 20 shown in FIG. 1, and FIG. 2 is an axial cross-sectional view of the forming roll 20 for explaining the roll operation when the forming roll 20 is loaded and unloaded. As shown in FIG. FIG. 4 shows a partially enlarged view of the forming roll 20 for explaining the configuration of the inner cell, rubber, and outer cell. FIG. 5 is a detailed cross-sectional view for explaining the bellows portion and the bearing box of the forming roll 20.

  The main specifications of the forming roll 20 are shown in Table 1.

  The forming roll 20 includes a shaft 6 rotatably supported by the bearing 14, an inner cell 2, a rubber 3 coated on the inner cell 2, an outer cell 1 disposed on the outer periphery of the rubber 3, and a shaft 6. It has a bellows 5 for connecting and holding the outer cell 1 via flanges 11 and 12, a motor 27 is connected to one end side (drive side) of the shaft 6, and a rotary joint 28 is connected to the other end side (operation side). Is provided.

The motor 27 is a drive device that rotationally drives the forming roll 20 at a predetermined rotational speed. The rotary joint 28 is a joint that allows the temperature adjusting liquid 16 to flow into and out of the forming roll 20 continuously even when the shaft rotates.
[Inner cell and rubber]
The inner cell 2 provided in the outer cell 1 in a double tube structure is made with high rigidity and is welded to the shaft 6. A pipe 13 is welded in the shaft 6, and a large number of holes 15 are formed in the shaft 6, so that the temperature adjustment liquid 16 flows through the pipe 13 and the holes 15.

  The rubber 3 covered on the outer periphery of the inner cell 2 has a groove 4 through which the temperature adjusting liquid 16 passes as shown in FIG. The shape of the groove 4 has various patterns as required, but is usually formed in a multi-spiral screw shape in the roll width direction (axial direction of the shaft 6). The cross section of the groove 4 is determined by the thickness of the outer cell 1, but in the case of the specification shown in Table 1, it is preferable that the rubber upper surface is 5 mm wide, the groove depth is 10 mm, and the groove pitch is about 20 mm. In this case, the opening ratio of the surface of the rubber 3 is 0.75 (75%). The temperature adjustment liquid 16 enters from the rotary joint 28 on the operation side, passes through the pipe 13, passes through the hole 15 of the drive side shaft, flows in the groove 4 of the rubber 3 of the inner cell 2, and exits from the operation side.

  In the case of a conventional full-surface rubber roll in which no groove is formed, since the thermal conductivity of the rubber itself is low and functions as a heat insulating material, the ability to cool and heat molding materials such as cells and sheet materials is low. On the other hand, in the case of the present embodiment, in the case of the groove shape shown in FIG. 4, the opening ratio of the surface of the rubber 3 is 75%, so the heat transfer area is large and the ability to cool and heat the molding material is high.

  Moreover, in the case of this embodiment, since it has the bellows 5 so that it may mention later, the outer cell 1 can be eccentric. For this reason, as shown in FIG. 3 (b), the outer cell 1 is decentered by applying a load from the nip side, and the gap 19 between the rubber 3 surface opposite to the nip and the outer cell 1 is enlarged. Will be. That is, when the forming roll 20 turns to the opposite side of the nip, the gap 19 between the surface of the rubber 3 and the outer cell expands according to the amount of eccentricity of the outer cell 1, and the temperature adjusting liquid 16 flows into the gap 19. Heat is transferred between the liquid preparation 16 and the cell. Since the molding roll 20 of this embodiment repeats this for every rotation, the capability of cooling and heating the molding material is high. In addition, as shown in FIG. 3A, the forming roll 20 is slightly lowered by its own weight because the outer cell 1 is supported by the bellows 5 when there is no load. The inner cell 2 and the outer cell 1 are on the same axis.

  When heated water or water of 100 ° C. or less is used as the temperature adjusting liquid 16, the heating and cooling performance is high because the specific heat of water is large. On the other hand, when oil is used as the temperature adjustment liquid 16, the specific heat is lower than that of water (for example, 0.5). Therefore, it is better to increase the flow rate or increase the aperture ratio than when water is used as the temperature adjustment liquid. Heating and cooling performance can be improved. In such a case, it is possible to cope with such a groove shape that increases the aperture ratio.

  Moreover, the groove | channel 4 may not only be formed in the roll width direction, but a fine groove may be further formed in the rotation direction of the roll. When the number of roll rotations increases, the pressure difference between the grooves 4 formed adjacent to each other in the roll width direction increases, but the grooves formed in the rotation direction communicate with each other between the adjacent grooves 4. The pressure difference at can be reduced. In addition, the temperature adjusting liquid 16 can easily pass through the gap between the surface of the bank 4 a forming the grooves 4 and the inner surface of the outer cell 1 of the rubber 3.

The spring constant of the rubber 3 is determined by calculating from the rubber hardness, strength resistance, thickness, and aperture ratio. The outer periphery of the rubber 3 is formed in a crown shape in accordance with the linear pressure (nip size). In other words, the rubber 3 is formed in a shape that gradually increases in thickness as it goes from both ends in the axial direction toward the center.
[Outside cell]
The outer cell 1 is elastically supported by the shaft 6 via a bellows 5 at the roll end. The inner diameter of the outer cell 1 is made slightly larger than the outer diameter of the inner cell 2. In the case of this embodiment, the outer cell 1 has an inner diameter that is approximately 1 mm larger than the outer diameter of the rubber 3 of the inner cell 2 in order to ensure temperature expansion and ease of assembly. Further, both end portions of the outer periphery of the outer cell 1 are provided with inclined surfaces of about 1 mm from the width slightly wider than the sheet width toward the roll end, and the diameter of the roll end surface is reduced by about 2 mm. Thereby, contact with the other forming roll 21 when the sheet 25 is thin can be avoided. In other words, as shown in FIG. 6A, the outer cell 1 of the forming roll 20 decreases the roll diameter from the forming region end 60 which is the end of the region where the sheet 25 is formed toward the roll end 61. An inclined surface (taper) 18 is formed. By forming the inclined surface 18, it is possible to avoid contact with the counterpart forming roll 21 when the sheet 25 is thin. Further, as shown in FIG. 6B, the inclined surface 18 may be formed on the counterpart forming roll 21. Due to such a configuration, a gap 19 of about 0.5 mm is formed between the rubber 3 of the inner cell 2. Further, the eccentric movement of the outer cell 1 at the time of the nip is about 1 mm at the roll end of the outer cell 1 including rubber bending and roll bending. However, since the gap is about this level, the slip between the outer cell 1 and the outer periphery of the rubber 3 of the inner cell 2 is about 0.5% and there is no problem.

Even when the aperture ratio is 75%, the contact point between the bank portion 4a of the rubber 3 and the outer cell 1 is sufficiently secured. Further, since the groove 4 of the rubber 3 of the inner cell 2 has a multi-spiral structure, the contact point between the rubber 3 of the inner cell 2 and the outer cell 1 moves smoothly and continuously, and vibration of the outer cell 1 does not occur. .
[Bellows]
The bellows 5 of this embodiment is a bellows made of concentric multi-stage metal thin plates having stretchability, springiness, and airtight sealing. That is, as shown in FIG. 5, the bellows 5 has two cone-shaped concentric metal thin plates 5p1 and two concentric cylindrical metal thin plates 5p2 that are alternately arranged and welded together. Is. The inner peripheral side of the bellows 5 is welded to the flange 12, and the outer peripheral side is welded to the outer cell 1. The flange 12 is fastened by a bolt 8 to a flange 11 fitted to the shaft 6. The flange 11 and the flange 12 are sealed with an O-ring seal 7.

The bellows 5 of the present embodiment has the following three functions.
1. 1. The outer cell 1 can be eccentric with respect to the inner cell 2. 2. A shaft coupling function for transmitting torque between the outer cell 1 and the inner cell 2. Sealing function of the temperature adjusting liquid 16 The bellows 5 having the bellows structure described above has a characteristic that it is bent in the radial direction but has high rigidity in the twisting direction. For this reason, the driving force of the motor 27 can be driven with high rigidity via the bellows 5, and has rigidity not to be defeated by resistance and disturbance due to roll press, and the sliding resistance of the rubber 3 of the inner cell 2, and can smoothly rotate the roll. . Further, the bellows 5 has a non-backlash structure that is continuous and seamlessly formed, has no backlash, and can be driven smoothly.

  In addition to the structure shown in FIG. 5, the following structure is applicable as the structure of the bellows 5.

  The bellows 5b shown in FIG. 7 is provided between the flange 33 screwed to the outer cell 1 and the flange 12 fitted into the shaft 6 and spaced apart from the flange 33 in the axial direction. The bellows 5b can reduce the size of the forming roll 20 in the radial direction, and has a waveform having a low rigidity and a small spring constant, so that the flexibility in the eccentric direction can be further increased.

In addition to this, the outer cell 1 is eccentric with respect to the inner cell 2 and has a shaft coupling function for transmitting torque between the outer cell 1 and the inner cell 2, and further, a mechanism having a sealing function for the temperature adjusting liquid 16 is realized. Therefore, in addition to the bellows described above, a shaft coupling structure shown in FIGS. 8 and 9 may be used. In other words, in the configuration example shown in FIGS. 8 and 9, the flange 33 is disposed on the outer cell 1 side, the flange 12 is disposed on the shaft 6 side, and these are connected by the shaft coupling 5d to form the membrane seal 7a. With a sealed structure. The shaft coupling 5d includes two hubs 5d1, a spacer 5d2, and a plurality of steel thin plates 5d3. The spacer 5d2 is disposed between the two hubs 5d1, and the plurality of disks 5d3 are disposed between the hub 5d1 and the spacer 5d2. One hub 5d1 is screwed to the flange 33, and the other hub 5d1 is screwed to the flange 12. Through holes are formed in the disk 5d3 at equal intervals in the circumferential direction. Some of the through holes are used for screw connection with the hub 5d1, and the other through holes are used for screw connection with the spacer 5d2. It is done. In the shaft coupling 5d, the outer cell 1 can be eccentric with respect to the inner cell 2 by connecting the hub 5d1 and the spacer 5d2 via a disk 5d3 that is a plurality of leaf springs. Further, since the two hubs 5d1 are integrated by the spacer 5d2, the disk 5d3, and a screw that couples them together, torque transmission between the outer cell 1 and the inner cell 2 is enabled. 8 and FIG. 9 differs in the arrangement of the membrane seal 7a for sealing the temperature adjustment liquid 16. In the configuration example of FIG. 8, the membrane seal 7a is disposed on the inner peripheral surface side of the shaft coupling 5d, whereas in the configuration example of FIG. 9, the membrane seal 7a is screwed to the outer cell 1 and the shaft 33 6 is provided between the flange 12 and the flange 12. The membrane seal 7a is preferably a fiber reinforced rubber seal or the like, and can achieve a pressure resistance of about 0.5 MPa. In the case of the configuration of FIG. 9, a backup plate 51 is provided adjacent to the membrane seal 7a. The backup plate 51 prevents the membrane seal 7a from protruding due to the pressure of the temperature adjusting liquid 16. Since friction is generated on the hub 5d1 side of the backup plate 51 by the eccentric operation of the shaft coupling 5d, it is preferable to provide a non-lubricated slide plate (not shown). The membrane seal 7a can withstand an eccentricity of about several millimeters by using a fiber reinforced rubber.
[First outer cell rotation guide mechanism]
The forming roll 20 of the present embodiment weakens the spring stiffness in the eccentric direction of the bellows 5, thereby increasing the load deflection of the outer cell 1 and weakening the eccentric reaction force, thereby obtaining a more uniform linear pressure distribution. Moreover, as shown in FIG. 11 and FIG. 12 described later, the forming roll 20 of the present embodiment can obtain a more uniform linear pressure distribution even if the roll pressing load is changed. However, if the spring stiffness in the radial direction is excessively weakened by making the bellows 5 multi-stage or thin, or if the molding resistance of the molding material is increased, the rotation of the outer cell 1 may be staggered. .

  The rotation guide mechanism of the present embodiment can suppress such fluctuation of rotation of the outer cell 1 and change the linear pressure distribution characteristics.

  As shown in FIG. 5, the rotation guide mechanism of the present embodiment includes an axis moving mechanism 26 a that translates the shaft 6 of the forming roll 20 in the arrangement direction (horizontal direction) of the forming rolls 21, 22, and 23, and the outer cell 1. And an outer cell moving mechanism 46 that is eccentric with respect to the shaft 6.

  The configurations of the shaft moving mechanism 26a and the outer cell moving mechanism 46 will be described with reference to FIGS. FIG. 10 is a view of the forming roll 20 viewed in the axial direction, and a forming roll 21 (not shown) is arranged on the left side of the forming roll 20.

  The shaft moving mechanism 26 a includes a bearing box 39 and a pressing device 26.

  The bearing box 39 includes a bearing 14 that rotates and holds the shaft 6, and the bearing box 39 is provided with a slider 40 at a lower portion thereof, and can move horizontally on the two rails 41. Yes. Note that a part of the roll nip load moves to the outer cell bearing 36 at the time of crown adjustment, and a moment is generated in the bearing box 39, but the two rails 41 endure it and prevent the bearing box 39 from rotating. The bearing 14 of FIG. 5 shows the structure of the drive side with a motor, and is a combination of a deep groove ball bearing and a double row Roni bearing. The operation side bearing on the opposite side of the roll is provided with only roller bearings to allow thermal expansion.

  The pressing device 26 is a hydraulic cylinder, the cylinder body is attached to a fixed portion 70, and the rod side is connected to a bearing box 39. In FIG. 10, when the cylinder 47 is moved to the left side by the pressing device 26, the shaft 6 held by the bearing box 39 moves in a direction to be pressed against the forming roll 21, and a nip load is applied to the counterpart roll 21. Conversely, when the cylinder 47 is moved to the right side in FIG. 10 by the pressing device 26, the shaft 6 moves away from the forming roll 21 and releases the nip load on the counterpart roll 21. In this way, the shaft moving mechanism 26 a moves the shaft 6 in the horizontal direction by the pressing device 26 and adjusts the nip load with respect to the counterpart roll 21.

  Next, the outer cell moving mechanism 46 will be described (FIGS. 5 and 10).

  The outer cell moving mechanism 46 includes an outer cell bearing 36, a cylinder 47, sliders 48 and 49, and a support 38.

  The outer cell bearing 36 rotatably supports outer cell shafts 35 provided at both ends of the outer cell 1 by bearings 37. As shown in FIG. 5, the outer cell shaft 35 has a configuration having an attachment portion 35 a attached to the flange 33 of the outer cell 1 and a cylindrical portion 35 b having a cylindrical shape. The attachment portion 35a is fixed to the flange 33 with bolts. The inner diameter of the cylindrical portion 35b is larger than the outer diameter of the shaft 6, and a gap 44 is formed therebetween. Further, the outer peripheral portion of the cylindrical portion 35 b is rotatably held by a bearing 37 of the outer cell bearing 36. The outer cell bearing 36 is prevented from rotating by sliders 48 and 49. In FIG. 10, the slider 48 provided in the upper part is a slide bearing type and the lower slider 49 is a roller type. However, the slider 48 may be 48 in both the upper and lower sides.

The cylinder 47 is attached to the bearing box 39 and connected to the support 38. An outer cell bearing 36 is attached to the support 38. Since the support 38 is configured to be slidable in the horizontal direction by the sliders 48 and 49, the outer cell bearing 36 can give or release a load nip to the counterpart roll by pushing and pulling the cylinder 47. . The cylinder 47 is provided so as to be slidable in the arrangement direction of the forming rolls 21, 22, and 23, and the stroke may be 10 mm or less.
[Line pressure distribution of forming roll]
The rigidity of the bellows 5 in the eccentric direction is about 1/5 of the bending rigidity due to the nip load of a general normal roll having the same cell thickness while securing the spring strength that can withstand the roll rotation operation. When a load is applied, the bellows 5 of the outer cell 1 bends, and the inner cell 2 supports most of the load via the rubber 3.

  Here, FIG. 11 shows changes in the linear pressure distribution when the roll pressure load is changed when the rubber 3 having the crown shape and the outer cell bearing 36 are free, that is, when the cylinder 47 in FIG. Show. FIG. 11 shows changes in linear pressure distribution when the roll pressing load is changed to three types of 50 N / cm, 100 N / cm, and 200 N / cm, that is, a total of four times.

  When the roll pressing load is doubled, the linear pressure distribution becomes slightly concave, but the fluctuation range is within ± 4.5%. When the roll pressing load is halved, the linear pressure distribution is slightly convex, but the fluctuation range is within a range of ± 9%. As described above, according to the forming roll 20 of the present embodiment, a flat linear pressure having a fluctuation range of the linear pressure distribution of ± 9% or less can be obtained even when the roll pressing load is changed four times in total. In addition, according to the forming roll 20 of the present embodiment, the roll pressing load is changed by a total of 4 times or more to increase the fluctuation range, but it can be used with a substantially flat linear pressure.

  On the other hand, in the case of the conventional example, when the linear pressure is changed as shown in FIG. 20, the linear pressure distribution is largely changed, so that the linear pressure cannot be changed in actual operation.

  Next, FIG. 12 shows a change in linear pressure distribution when the roll pressing load is changed in a state where the crown-shaped rubber 3 and the outer cell bearing 36 are adjusted and supported. The roll pressing load was changed to three types of 50 N / cm, 100 N / cm, and 200 N / cm, that is, a total of 4 times.

  In the example shown in FIG. 11, when the value of the linear pressure is changed from the design value, the linear pressure distribution is not flat but slightly. However, if the outer cell moving mechanism 46 (cylinder 47) is given a force that opposes the force corresponding to the spring reaction force of the bellows 5, the distribution can be flattened even if the linear pressure is changed. In the case of the double linear pressure of 200 N / cm in FIG. 12, a pulling force is applied to the cylinder 47 to weaken the load at the roll end of the outer cell 1. Thereby, a flat linear pressure distribution is obtained. In the case of the 1/2 double linear pressure 50 N / cm in FIG. 12, a pressing force is applied to the cylinder 47 to increase the load at the roll end of the outer cell 1. Thereby, a flat linear pressure distribution is obtained.

  Next, FIG. 13 shows the results when the linear pressure distribution is changed at no load. The rubber has a crown shape. The load support of the outer cell bearing 36 includes: a: pull load support of the outer cell bearing box 36, b: free outer cell bearing box 36 (no load support), c: pushing load of the outer cell bearing box 36 Three types of support were performed. Here, a: Forming rolls for three types: a: pulling load support of the outer cell bearing box 36, b: free outer cell bearing box 36 (no load support), c: support of pushing load of the outer cell bearing box 36 The deformation model is schematically shown in FIG.

  FIG. 14A shows a state in which the outer cell moving mechanism 46 performs a pulling operation (a force is applied to the outer cell 1 in a direction in which the forming roll 21 is pulled away from the counterpart roll 22). By the pulling operation of the outer cell moving mechanism 46, a force in the F1 direction is applied to the outer cell 1. Since the inner cell 2 of this embodiment is more rigid than the outer cell, the outer cell 1 is deformed more, and the outer cell 1 is deformed into a convex shape due to the rubber reaction force of the inner roll. Therefore, the linear pressure distribution is also a convex linear pressure distribution as shown in FIG. In FIG. 14, since the deformation of the inner cell 2 is small, it is ignored.

  FIG. 14B shows a state in which the outer cell moving mechanism 46 does not apply any force to the outer cell bearing box 36 and is free. In this case, no force is applied to the outer cell 1. The outer cell 1 is not deformed, and the rubber 3 of the inner roll inside the roll has a rubber crown on the surface, so that the central portion is in contact with the outer cell 1. The bellows 5 is not deformed and there is no eccentricity other than its own weight. In this state, when the design linear pressure of 100 N / cm is applied to the roll, the center is slightly increased, but eccentric movement occurs due to compression of the rubber and deflection of the inner roll, and reaction force due to the eccentricity of the bellows 5 is generated. As a result, as shown in FIG. 13B, the line pressure is a uniform nip with a flat line pressure.

  FIG. 14C shows a state in which the outer cell moving mechanism 46 performs a pushing operation (a force is applied to the outer cell 1 in the direction in which the molding roll 21 is pressed against the counterpart roll 22). A force in the F2 direction is applied to the outer cell 1 by the pushing operation of the outer cell moving mechanism 46. As a result, the outer cell 1 becomes concave with respect to the counterpart roll 22. Therefore, the linear pressure distribution is also a concave linear pressure distribution as shown in FIG.

  Next, FIG. 15 shows a linear pressure distribution when the direction in which the force is applied to the outer cell bearing box 36 is varied on the left and right.

  In FIG. 5C, the left outer cell bearing box 36 is pulled excessively and at the same time the force of the left pressing cylinder 26 is weakened, and the right outer cell bearing box 36 is pressed excessively and at the same time the force of the right pressing cylinder 26 is increased. The linear pressure distribution is shown. In this case, the linear pressure has a distribution rising to the right. The center of the roll tends to rise to the right, but when the outer cell 1 is thin, the force does not reach the center and the center becomes flat.

  In the drawing, “d” shows a linear pressure distribution when the left outer cell bearing box 36 is pulled excessively, the right outer cell bearing box 36 is pushed excessively, and the force of the pressing cylinder 26 is the same on the left and right. In this case, the linear pressure has a distribution that rises to the right, but the average value of the left and right roll linear pressures is the same, resulting in an S-shaped curve.

  In addition, if the left and right operations are reversed, the linear pressure distribution is reversed. The crown adjustment function increases the thickness of the outer cell and increases the rigidity, so that a force and a smooth curve can be obtained up to the center of the roll. A smooth curve can be obtained by increasing the thickness of the rubber layer.

  The forming roll 20 of the present embodiment can obtain a substantially uniform linear pressure even if the roll pressing load is changed by four times or more by utilizing the deflection followability of the bellows, and is further controlled by the outer cell moving mechanism 46. Thus, a flatter linear pressure can be obtained, which is suitable for forming a thin sheet. That is, in the case of a thin sheet having a sheet thickness of 0.5 mm or less, a portion that cannot be roll-pressed easily occurs due to uneven thickness of the sheet. Since this part does not become a mirror surface, it is better that one of the rolls has flexible followability. In the case of the forming roll 20 of the present embodiment, it is possible to cope with uneven thickness of the sheet by adjusting the crown or changing the linear pressure curve. Further, by increasing the roll pressurizing load and increasing the linear pressure, it is possible to cope with the uneven thickness of the sheet and eliminate the portion that cannot be pressed.

  When a shaft coupling 5d other than the example bellows shown in FIG. 9 is used, the seal 7a may use a U-shaped packing or other end face seal.

  Further, the forming roll 20 of the present embodiment can be used as a cooling roll for rapidly cooling food, medicine, and amorphous metal as a sheet-like material. The temperature adjustment liquid 16 may be room temperature water or oil. Further, the temperature adjusting liquid 16 may be a cooling roll made of a gas or liquid such as refrigerant refrigerant gas or ammonia. In this case, the inside of the roll is in a negative pressure state at −25 ° C.

  The forming roll 20 of the present embodiment can also be used as a uniform nip roll that does not involve heating and cooling.

  Further, the forming roll 20 of the present embodiment does not need to strictly determine the strength of the inner cell 2 and the outer cell 1, and a uniform nip can be obtained even if the strength of each other is equal. However, the forming roll 20 of the present embodiment is basically made by increasing the strength of the inner cell 2 that receives the load and making the outer cell 1 thin and light. Further, it is preferable to make the mating roll 21 with high rigidity. Further, when the forming roll of this embodiment is used with an increased linear pressure, it is preferable to design a uniform nip roll having high rigidity by increasing the strength of the inner cell 2 and the outer cell 1 and increasing the rubber hardness.

Moreover, if the shaping roll 20 of this embodiment is made into the same external shape as the existing shaping roll, it can be exchanged, and this roll can be applied to an old facility and exchanged for use. The bearing 14, the motor 27, the rotary joint 28, etc. can be used. There is no need for a hydraulic device or control device to obtain a uniform nip (linear pressure).
[Effect of this embodiment]
As described above, according to the forming roll of this embodiment, the following effects can be obtained.
1. The crown of the outer cell 1 can be adjusted by inserting and pulling the cylinder 47 of the outer cell moving mechanism, and various linear pressure distributions can be obtained.
2. Bellows can be used as a connecting means for the outer cell, and the device is simple and simple (low cost).

Since it uses a rubber roll structure that has been used and has been used for the bellows 5, there are no mechanically sliding parts, and a simple structure can be made inexpensive.
3. As a forming roll, the cooling and heating ability for the molding material is high.

In resin film / sheet molding applications that require a temperature control function, the rubber 3 of the inner cell 2 inside the molding roll 20 has a large number of temperature control grooves, and the temperature control liquid 16 is in direct contact with the outer cell 1. As a forming roll, the sheet has high cooling and heating ability. For this reason, a sheet | seat can be rapidly cooled and when a transparent sheet is shape | molded, high transparency can be obtained.
4). High durability at high temperature and high pressure.

It is necessary to adjust the temperature of the resin PC (polycarbonate) sheet to 300 ° C. during melt extrusion and to 150 ° C. for the roll. Oil or heated water is used for the temperature adjustment liquid 16, but generally heated water is used. The bellows 5 of the forming roll 20 of the present embodiment has durability against heated water pressurized to 0.5 MPa as the temperature adjusting liquid 16.
5. The bellows 5 may be a combination of another shaft coupling 5 and the seal 7. Even if the cylinder 47 is free, the reaction force of the outer cell is smaller than that of the bellows and a flatter linear pressure curve is obtained.
6). 6. A uniform linear pressure distribution can be obtained over the entire roll width by changing the roll pressure load. The forming roll 20 of this embodiment can obtain a substantially uniform linear pressure distribution even when the cylinder 47 is unloaded (free) and the roll pressing load is changed from 0.5 to 2 times.
8). When the sheet 25 is thin, the roll ends of one or both of the pair of forming rolls 20 and 21 are tapered, so that direct contact between the rolls can be prevented and a thin film sheet can be formed.
[Other Embodiments]
[Second outer cell rotation guide mechanism]
Next, a manual screw adjustment type outer cell moving mechanism 146 different from the above-described configuration will be described with reference to FIGS. 16 and 17. FIG. 16 is a partially enlarged cross-sectional view of the outer cell moving mechanism 146 and the shaft moving mechanism 26a. FIG. 17 is a cross-sectional view of the outer cell moving mechanism 146 in the BB direction shown in FIG.

  The outer cell moving mechanism 146 includes an outer cell bearing 136 and an adjusting mechanism 43a.

  The inner diameter of the outer cell bearing 136 is larger than the outer diameter of the cylindrical portion 35 b of the outer cell shaft 35, and the shape thereof is a ring shape, and the cylindrical portion 35 b of the outer cell shaft 35 is rotatably held by the bearing 37. The inner diameter of the ring-shaped support 138 is larger than the outer diameter of the outer cell bearing 136. The support 138 holds the cylindrical portion of the outer cell bearing 136 disposed in the support 138 in an eccentric manner with respect to the shaft 6 by an adjustment mechanism 43 a provided radially on the support 138. In addition to the above-described cylinder 47 being attached, the support 138 includes an attachment portion 38a attached to the bearing box 39 and a cylindrical portion 38b having a cylindrical shape. The mounting portion 38a is fixed by a bearing box 39 bolt. The inner diameter of the cylindrical portion 38b is larger than the outer diameter of the outer cell bearing 136, and eight adjusting mechanisms 43a are provided radially on the circumference thereof. Further, the outer cell bearing 136 is provided with a detent 51, which is guided by the hole of the support 138 to prevent it from rotating.

  As shown in FIG. 11, the outer cell shaft 35 has a configuration having an attachment portion 35 a attached to the flange 33 of the outer cell 1 and a cylindrical portion 35 b having a cylindrical shape. The attachment portion 35a is fixed to the flange 33 with bolts. The cylindrical portion 35 b has an inner diameter larger than the outer diameter of the shaft 6, and an outer peripheral portion thereof is rotatably held by a bearing 37 of the outer cell bearing 136.

  The adjustment mechanism 43a includes a bolt 42 and a nut 43, and adjusts the positions of the outer cell bearing 136 and the outer cell shaft 35 by tightening or loosening the bolt 42, whereby the outer cell 1 is eccentric with respect to the shaft 6. Let In the case of this example, the eccentric direction is not limited to the horizontal direction and can be in other directions.

  The outer cell bearing 136 is prevented from rotating by sliders 48 and 49. In FIG. 10, the slider 48 provided in the upper part is a slide bearing type and the lower slider 49 is a roller type. However, the slider 48 may be 48 in both the upper and lower sides. The bearing box 39 rotates and supports the shaft 6 with two bearings 14 and 56.

  The outer cell moving mechanism 146 of the present embodiment is suitable for an application that does not need to provide a strict uniform nip with a simpler and cheaper structure than that of the first embodiment.

First, during operation, the three bolts 42 on the pressing device 26 side in FIG. Since there are not only the operating side but also the driving side, the total is 6. By loosening these bolts, an eccentricity e is generated by the roll load. In the state of the eccentricity e, the eight bolts 42 on one side are evenly tightened to fix the outer cell bearing 136. The bolt 42 is basically a free load because no load is applied to the outer cell 1, and the linear pressure distribution shown in FIG. 11 is obtained. The linear pressure distribution is flat at 100 N / cm, and is slightly convex and concave at 50 N / cm and 200 N / cm. If necessary, the linear pressure distribution in FIG. 12 and the linear pressure distributions in FIGS. 13 and 15 can be adjusted by pushing and pulling the bolt 42 of the outer cell pushing device 46. When the outer cell 1 is pushed and pulled with the bolt 42, a reaction force is generated in the bearing housing 39, but since the bearings 14 and 56 are installed on the shaft 6 and the bearing 39, the bearing housing can withstand the reaction force of the bolt 42. Even if the load ratio between the outer cell 1 and the inner cell 2 changes due to the crown adjustment, the roll 20 can be operated.
[Third outer cell rotation guide mechanism]
Next, a guide roller type outer cell moving mechanism 246 that is further different from the above-described configuration will be described with reference to FIGS. FIG. 18 is a partially enlarged cross-sectional view of the outer cell moving mechanism 246 and the shaft moving mechanism 26a. FIG. 19 is a view of the outer cell moving mechanism 246 in the BB direction shown in FIG.

  Four outer cell moving mechanisms 246 of this example are installed on the operation side and the driving side on the upper, lower, left and right sides of the outer cell shaft 35, and are fixed to the bearing housing 39 by the support 52. An elongated hole 54 is formed in the support 52, and the elongated hole 54 is fixed to the bearing housing 39 through a bolt 55. Each of the supports 52 can be adjusted in the direction of the center of the roll by the long holes 54. The drive-side bearing box 39 supports the shaft 6 with two bearings of a bearing 14 and a bearing 56. The operation side bearing uses two roller-type bearings that can tolerate thermal expansion. The four guide rollers 50 can guide the rotating outer cell shaft 35 to stabilize the roll rotation, or can apply an eccentric load as in the second example.

  The outer cell moving mechanism 246 of the present embodiment is also suitable for an application that does not require a strict uniform nip with a simpler and cheaper structure than that of the first embodiment, similarly to the outer cell moving mechanism 146 described above.

  First, during operation, in FIG. 19, a bolt for fixing the support 52 of the guide roller 50 on the pressing device 26 side is loosened to make the outer cell 1 free in the horizontal direction and apply a roll load. An eccentricity e occurs due to the roll load. The guide roller 50 is positioned in the state of the eccentricity e, and the bolt is tightened and fixed. Since the guide roller 50 basically has no load applied to the outer cell 1, the guide roller 50 is a free load and has the linear pressure distribution shown in FIG. 11. The linear pressure distribution is flat at 100 N / cm, and is slightly convex and concave at 50 N / cm and 200 N / cm. If necessary, the linear pressure distribution of FIG. 12 and the linear pressure distributions of FIGS. 13 and 15 can be adjusted by pushing and pulling the guide roller 50 of the outer cell pushing device 46. By pushing and pulling the guide roller 50 with the bolt 53, a reaction force is generated in the outer cell 1 and the bearing housing 39, but since the two bearings 14 and 56 are installed on the shaft 6 and the bearing housing 39, the bearing housing is the bolt 53. Withstands the reaction force of the roller 50. Even if the load ratio between the outer cell 1 and the inner cell 2 changes due to the crown adjustment, the roll 20 can be operated.

It is a lineblock diagram of a film forming machine which is an example to which a forming roll of the present invention is applied. It is sectional drawing in the AA of the forming roll of this invention shown in FIG. It is an axial direction sectional view of a forming roll explaining roll operation at the time of loading of a forming roll of the present invention, and no load. It is a partially expanded view for demonstrating the structure of the inner cell of the shaping | molding roll of this invention, rubber | gum, and an outer cell. It is detailed sectional drawing for demonstrating the bellows part of a forming roll of this invention, and a bearing box. It is a front view of the edge part inclined surface of the forming roll of this invention. It is a partial cross section figure of the forming roll which shows the example of the bellows applicable as a connection means of this invention. It is a partial cross section figure of the forming roll which shows the shaft coupling applicable as a connection means of this invention. It is a partial cross section figure of the other example of the forming roll which shows the shaft coupling applicable as a connection means of this invention. It is the figure seen from the axial direction of the forming roll for demonstrating the structure of an outer cell bearing and a bearing box. It is a linear pressure distribution figure of the forming roll of the present invention in the state where an outer cell bearing is free. It is a linear pressure distribution figure of the forming roll of the present invention in the state where the outer cell bearing was adjusted. It is a figure which shows the example of the linear pressure distribution by a difference in the load direction of an outer cell bearing, and the presence or absence of a load. It is a deformation | transformation model at the time of crown adjustment of this invention. It is a figure which shows the change of the linear pressure distribution at the time of changing a roll pressurization load. It is sectional drawing which shows the example of the other outer cell moving mechanism of this invention. It is a front view of the outer cell moving mechanism shown in FIG. It is sectional drawing which shows the example of the further another outer cell moving mechanism of this invention. It is a front view of the outer cell moving mechanism shown in FIG. It is a linear pressure distribution figure which shows an example of the calculation result of the linear pressure distribution of the conventional forming roll.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Outer cell 2 Inner cell 3 Rubber | gum 4 Groove | channel 4a Bank part 5, 5b Bellows (connection means)
5d shaft coupling 5d2 spacer 5d3 disk 5d1 hub 5p1, 5p2 metal thin plate 6 shaft 7 seal 7a membrane seal 8, 42, 53, 55 bolt 10 step 11, 12, 33 flange 13 pipe 14 bearing 15 hole 16 temperature adjustment liquid 18 inclined surface (Taper)
19 Gap 20, 21, 22, 23 Forming roll 24 Die 25 Sheet 26 Press cylinder 26 Pressing device 26a Shaft moving mechanism 27 Motor 28 Rotary joint 35b, 38b Cylindrical part 35 Outer cell shaft 35a, 38a Mounting part 36 Outer cell bearing 36 Outer Cell bearing box 37, 39, 56 Bearing 38, 52, 138 Support 39 Bearing box 40, 48, 49 Slider 41 Rail 43 Nut 43a Adjustment mechanism 46, 146, 246 Outer cell movement mechanism 46 Device 47 Cylinder 50 Guide roller 51 Backup plate 54 Long hole 70 Fixed part 136 Outer cell bearing

Claims (11)

An outer cell (1), an inner cell (2) provided in a double tube structure in the outer cell (1), a rubber (3) covering the inner cell (2), and the inner cell (2 ) And a shaft (6) for holding the outer cell (1) at an end of the outer cell (1) so that the outer cell (1) can be eccentric with respect to the inner cell (2). Roll adjustment for moving a forming roll (20) having connecting means (5) for connecting (1) and the shaft (6) relative to another adjacent forming roll (21). A device,
An axis moving mechanism (26a) for moving the axis (6);
A roll adjusting device having an outer cell moving mechanism (46) for moving the outer cell (1).   In the molding roll (20), a groove (4) is formed on the surface of the rubber (3), and the inside of the groove (4) is provided via a rotary joint (28) provided on the shaft (6). The roll adjusting device according to claim 1, wherein a temperature adjusting liquid (16) for cooling or heating the outer cell (1) circulates.   The shaft moving mechanism (26a) individually moves both ends of the shaft (6), and the outer cell moving mechanism (46, 146, 246) individually moves both ends of the outer cell (1). The roll adjustment apparatus according to claim 1 or 2.   The shaft moving mechanism (26a) includes a bearing box (39) having a bearing (14) that rotates and holds the shaft (6) and a slider (40) that can slide on the rail (41), and the bearing box. The roll adjusting device according to any one of claims 1 to 3, further comprising a pressing device (26) for sliding (39).   The outer cell moving mechanism (46) moves the outer cell shaft (35) having a cylindrical part (35b) attached to the flanges (33) at both ends of the outer cell (1). The roll adjusting device according to any one of claims 1 to 4, wherein the outer cell (1) is moved.   The outer cell moving mechanism (46) includes an outer cell bearing (36) having a bearing (37) for rotatably holding the cylindrical portion (35b) of the outer cell shaft (35), and the bearing box (39). A supporter (38) fixed to the slider, a slider (48, 49) that allows the outer cell bearing (36) to slide relative to the support (38), and a slide of the outer cell bearing (36). 6. A roll adjusting device according to claim 5, comprising a cylinder (47).   The outer cell moving mechanism (46) includes a ring-shaped outer cell bearing (136) having a bearing (37) for rotatably holding the cylindrical portion (35b) of the outer cell shaft (35), and the outer cell. The roll adjusting device according to claim 5, further comprising a ring-shaped supporter (138) that holds the bearing (36) in a radially adjustable manner by an adjusting mechanism (43 a) arranged radially.   The outer cell moving mechanism (46) has a plurality of guide rollers (50) for rotatably holding the cylindrical portion (35b) of the outer cell shaft (35), and a support (238) The roll adjusting device according to claim 5, wherein the roll adjusting device is fixed to the bearing housing (39) by a bolt (55) passing through the formed long hole (54).   A thin film forming apparatus having the roll adjusting apparatus according to claim 1.   At least one of the forming roll (20) and the forming roll (21) has a roll diameter from the forming region end (60), which is the end of the sheet forming region for forming the sheet (25), toward the roll end (61). The thin film forming apparatus according to claim 9, wherein an inclined surface (18) having a reduced height is provided.   The thin film manufacturing method which adjusts a linear pressure distribution with the said roll adjustment apparatus of the said thin film formation apparatus of Claim 10, and manufactures a thin film.

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