JP2008080496A - Method for producing embossed shape sheet and its production method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To continuously shape an embossed shape with the depth of the shape being relatively shallow in relation to the total thickness of a sheet in good shape accuracy at a high shaping rate on the surface of the sheet. <P>SOLUTION: When a thermoplastic resin melted/kneaded by an extruder 11 is discharged in a shape of a sheet through a T die 12, one surface of the sheet article 16 is cooled by a first cooling/molding roll 13, the other surface of the sheet article 16 is pressed/nipped by a second cooling/molding roll 14 with an embossment shape formed, and the embossed shape sheet 16 with the embossment shape of a shallow groove depth transferred/given is molded continuously. Wherein the sheet article 16 immediately after being discharged from the T die 12 is irradiated/heated by an external heater 18 set in the gap between the T die 12 and the second cooling/molding roll 14. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for manufacturing an embossed shaped sheet and an apparatus for manufacturing the same, and in particular, embossed shaping in which an embossed shape is continuously transferred and shaped with a cooling molding roll on one or both sides of a thermoplastic resin sheet by a continuous extrusion method. The present invention relates to a sheet manufacturing method and a manufacturing apparatus thereof.

  Conventionally, the manufacturing method (or manufacturing apparatus) of this kind of embossed shaped sheet will be described with reference to FIGS. In the figure, an embossed shaped sheet manufacturing apparatus includes an extruder 11 for melt-kneading a thermoplastic resin, a T-die 12 for discharging the melt-kneaded product in a sheet shape in a horizontal direction, and a discharge from the T-die 12. An external heater 18 that heats the surface of the melted sheet-like material 16 with radiant heat, a first cooling molding roll 13 that pressurizes the heated sheet-like material 16, and a second embossed shape. The cooling forming (shaping) roll 14 and the third cooling forming roll 15 are provided. For example, a general-purpose thermoplastic resin such as acrylic resin, MS resin, polystyrene resin, PC resin, AS resin, etc. is melt-extruded and continuously embossed by press nip with a pair of embossing cooling molding rolls. When obtaining a sheet, when the total thickness T of the sheet is approximately 0.6 mm or more and the embossed mold depth H ′ is relatively shallow, the embossed shape is transferred to the sheet surface. The mold return phenomenon after release from the cooling forming roll becomes remarkable, and there is a limit to the continuous embossing shape with high shaping rate (H / H '), no variation, high shape accuracy, and continuous transfer shaping. It was.

  On the other hand, the embossed mold depth H ′ is shallow as described above with respect to the total thickness T of the sheet, and the total thickness T of the sheet is in a film forming region of 0.1 mm to 0.6 mm or less. The embossed shape is optimized by optimizing the combination of appropriate cooling forming roll diameter and pressing pressure, air gap (distance between T-die tip and cooling forming roll) and appropriate discharge resin temperature and cooling forming roll temperature. When an embossed shape with a mold depth H of about 6 to 60 μ is transferred and formed, the variation range of the formed shape is within 1% and the forming rate (H / H ′) is about 90% to 95%. Was possible.

  However, when the total thickness T of the sheet exceeds the film forming region of about 0.6 mm to 1.0 mm, the shaping rate is rapidly reduced from 70% to about 80%, and at the same time, the shaping rate is lowered. Along with this, the variation in the shaping height H increases approximately proportionally in both the extrusion direction and the extrusion width direction. For this reason, in particular, in the case of an embossed shaped sheet for optical applications, since it is necessary to add a mold return to the mold design shape to the mold depth H ′, it is necessary to make it deeper. At the same time as the difficulty level increased, there was a problem that variation in the transfer shape of the obtained embossed shaped sheet increased, resulting in performance quality that could not be put to practical use.

  Therefore, as disclosed in Japanese Patent Application Laid-Open No. 17-289000, shaping is performed by taking a long pressure holding time of the cooling shaping (molding) roll while backing up the back side of the sheet with a (mirror surface) belt. Manufacturing equipment that suppresses the improvement in rate and variation in shaping has been proposed, and some of them have been put into practical use.

  In addition, as disclosed in JP-A-16-258188, a method for producing a film having a small film thickness change amount by setting the distance from the die opening to the cooling drum (cooling roll) to 5 to 100 mm. Proposed.

Further, as disclosed in Japanese Patent Application Laid-Open No. 2001-049895, a technique for improving moldability by providing a heater that irradiates infrared rays in the vicinity of a die and heating the molten resin thin film with the heater has also been proposed. Yes.
JP-A-17-289000. Japanese Patent Laid-Open No. 16-258188. Japanese Patent Application Laid-Open No. 2001-049895.

  However, in the conventional techniques described in Patent Documents 1 to 3, it is difficult to provide a heater when the distance from the die opening to the cooling drum is small. In particular, the manufacturing apparatus described in Patent Document 1 has a problem in that the structure itself is complicated, the operability is increased, and the equipment cost of the apparatus is increased.

  In this kind of thermoplastic resin embossing shaped sheet molding, the embossing shape after releasing from the roll as the embossing shape becomes shallower and the pitch becomes finer than the total thickness T of the sheet. The mold return phenomenon becomes large. The reason for the occurrence of this type return phenomenon is considered as follows. That is, although the melted resin niped by the cooling shaping roll once fills the embossed individual shape grooves, cooling solidification proceeds toward the core, but after releasing from the cooling shaping roll, the thickness of the sheet is increased. It is considered that heat transfer occurs from the center toward the surface layer on the embossing shaping side, the resin softens again, and the shaping shape gradually becomes dull.

  On the other hand, in order to eliminate the mold return phenomenon, a mold sizing technique is generally used in which the embossed groove depth H ′ on the surface of the cooling molding roll is deepened in advance in consideration of the mold return phenomenon. However, when the transfer forming rate of the molded sheet with respect to the mold depth H ′ is approximately 90% or less, the variation in shape transfer accuracy increases rapidly as the sized mold depth increases. For this reason, the embossed shaped sheet obtained is not practically usable particularly for optical applications.

  Therefore, the present invention provides an embossed shape having a relatively low target shape height and a fine pitch with respect to the total thickness of the sheet, a high shaping rate, good shape transfer accuracy, and continuous. Therefore, a technical problem to be solved in order to be able to be shaped is generated, and the present invention aims to solve this problem.

  The present invention has been proposed in order to achieve the above object, and the invention according to claim 1 is characterized in that a thermoplastic resin is supplied to an extruder, melt-kneaded, and then discharged and extruded into a sheet through a T die. In a method for producing an embossed shaped sheet that is press-niped with a cooling molding roll and continuously embosses the embossed shape applied to the surface of the cooling molding roll, the sheet shape immediately after being extruded and extruded from the T-die An outer surface of an object is heated in the air by an external heater, and then a method for producing an embossed shaped sheet in which the shape is transferred by press nip with the cooling molding roll, wherein the external heater is an infrared heater, Emboss shaping system that irradiates and heats the surface of the sheet-like material in the air while reflecting the irradiation light of the external heater by the reflecting member provided on the surface of the tip of the die lip of the T die. To provide a door method of manufacturing.

  According to this manufacturing method, the surface of the sheet-like object is irradiated and heated in the air while the irradiation light of the external heater is reflected by a reflecting member provided on the surface of the tip of the die lip of the T die. In order to minimize the return phenomenon, the discharge resin temperature of the sheet-like material from the T die is appropriately set.

  That is, in order to minimize the mold return phenomenon in principle, the discharge resin temperature of the sheet-like material from the T die is set to be equal to or higher than the glass transition point Tg of the thermoplastic resin that can be bank-molded, and cooling is applied. What is necessary is just to raise the surface layer part of a sheet | seat just before a pressure nip with a shape roll to the temperature of a rubber transition area. All the present inventions are based on this principle.

  In the production method of the present invention, the resin temperature immediately after being discharged from the T die is the minimum operating temperature above the glass transition point Tg that can be bank-formed with a pair of cooling forming rolls, and the embossed shape is to be imparted. The surface layer portion of the sheet-like product is irradiated and heated with an external heater to raise the temperature of the rubber transition region, and then subjected to a pressure nip with a cooling molding roll. Thus, the inflow and filling of the molten resin into the embossed groove formed on the surface of the cooling molding roll is increased, and the heat transfer from the sheet center layer after release is suppressed.

  The invention according to claim 2 is the embossing according to claim 1, wherein the surface of the sheet-like material is irradiated and heated in the air while irradiating the surface of the cooling molding roll having the embossed shape with the irradiation light of the external heater. A method for producing a shaped sheet is provided.

  According to this manufacturing method, the irradiation light of the external heater directly heats the surface of the cooling forming roll provided with an embossed shape, and the other part directly irradiates the surface layer portion of the sheet-like material. In particular, when the embossed cooling forming roll material is made of copper plating, the temperature of the surface layer portion of the cooling forming (shaped) roll rises, and the sheet-like material is further layered in each fine embossed groove. Easy to enter.

In the invention of claim 3, when the maximum depth of the embossed shape to be transferred is H and the total thickness of the sheet is T,
0.6mm ≤ T ≤ 3.0mm
0.05 ≤ H / T ≤ 0.25
The manufacturing method of the embossing shaped sheet | seat of Claim 1 or 2 in the range of this is provided.

  According to this manufacturing method, when the relationship between the maximum depth H of the embossed shape and the total thickness T of the sheet is in the above range, even if the embossed shape is fine, the molten sheet-like material is embossed. Smoothly enters the groove of the shape, enhances the fillability compared to conventional, and suppresses the occurrence of the mold return phenomenon.

  In the invention of claim 4, the thermoplastic resin is supplied to an extruder, melted and kneaded, and then discharged and extruded into a sheet shape through a T-die, followed by pressure nip with a pair of cooling molding rolls, and applied to the surface of the cooling molding roll. The embossed shaped sheet manufacturing apparatus used in the method for manufacturing an embossed shaped sheet according to claim 1, 2 or 3, wherein the embossed shape formed is continuously transferred and shaped immediately after being discharged from the T die. An external heater for irradiating and heating the surface of the sheet-like material, and a reflecting member provided on the surface of the tip of the die lip of the T-die, the external heater being an infrared heater, and irradiating the irradiation light of the external heater with the reflection Provided is an embossed shaped sheet manufacturing apparatus configured to irradiate and heat the surface of the sheet-like material in the air while being reflected by a member.

  According to this configuration, the resin temperature immediately after being discharged from the T-die is a pair of cooling by irradiating and heating the surface of the sheet-like material in the air while reflecting the irradiation light of the external heater by the reflecting member. It is set to the minimum required operating temperature of Tg or higher that allows bank forming with the forming roll. Further, the surface layer portion of the sheet-like material on the side to be embossed is irradiated and heated by an external heater and raised to the temperature of the rubber transition region. Then, by pressurizing the sheet-like material with a cooling molding roll, the inflow and fullness of the resin into the embossed groove are increased, and the heat transfer from the sheet center layer after release is suppressed. In short, the present invention uses a general-purpose sheet forming apparatus for thermoplastic resin and is discharged from the T die by additionally applying an external heater to the gap between the T die and the cooling forming roll having the embossed shape. Embossing is performed while heating the surface layer portion of the sheet-like material immediately afterwards or the surface of the cooling forming roll for embossing shaping, or both simultaneously with radiant heat.

  Since the invention according to claim 1 can increase the inflow and fillability of the molten resin into the embossed groove and suppress the heat transfer from the sheet center layer after release, the total thickness T of the sheet can be reduced. An embossed shape having a relatively low target shape height H and a fine pitch can be continuously formed at a high forming rate and with high shape transfer accuracy.

  In the invention described in claim 2, since the temperature of the surface layer portion of the cooling shaping roll rises and the sheet-like material easily enters each fine embossed groove, in addition to the effect of the invention described in claim 1 Thus, a thermoplastic resin sheet provided with an embossed shape having a relatively low shape height H with respect to the total thickness T of the sheet can be continuously produced with higher shape transfer accuracy.

  Since the invention described in claim 3 can satisfactorily suppress the mold return phenomenon by mentioning the fullness of the molten sheet-like material into the fine embossed groove, in addition to the effect of the invention described in claim 1 or 2 Thus, a high-quality embossed shaped sheet with little variation in shape transfer accuracy can be easily obtained. In particular, the obtained embossed shaped sheet can be suitably used for optical applications.

  The invention according to claim 4 can increase the inflow and filling of the molten resin into each fine embossed groove, and can suppress the heat transfer from the sheet center layer after release, so that the total thickness of the sheet An embossed shape having a relatively low shape height H with respect to T and a fine pitch can be continuously shaped with a high shaping rate and with a good shape transfer accuracy. In addition, the operability is improved and the equipment cost of the apparatus is reduced.

  The present invention continuously forms an embossed shape having a relatively low target shape height H and a fine pitch with respect to the total thickness T of the sheet with a high forming rate and shape transfer accuracy. The purpose of making it possible is to supply the thermoplastic resin to an extruder, melt and knead, then discharge and extrude it into a sheet through a T-die, press nip with a pair of cooling molding rolls, and apply to the surface of the cooling molding roll In the method for producing an embossed shaped sheet in which the embossed shape is continuously transferred and shaped, the surface of the sheet-like material immediately after being discharged from the T die is heated in the air by an external heater, and then the cooling forming roll A method of manufacturing an embossed shaped sheet in which a shape is transferred by pressurization nip, wherein the external heater is an infrared heater, and the irradiation light of the external heater is used as a surface of the tip of the die lip of the T die. While reflected by the reflecting member provided, realized by a surface of the sheet was adopted a method or apparatus for irradiating heated in air.

Embodiment
Hereinafter, preferred embodiments of the present invention will be described. In the present embodiment, a thermoplastic resin is supplied to an extruder and melt-kneaded, and then discharged and extruded into a sheet shape through a T-die, followed by pressure nip with a cooling molding roll having an embossed shape, and the surface of the cooling molding roll. This is applied to a method for producing an embossed shaped sheet in which the embossed shape applied to is continuously transferred and shaped.

  The outer surface of the sheet-like material immediately after being discharged and extruded from the T-die is heated in the air by an external heater, and then subjected to a pressure nip with a pair of cooling forming rolls for shape transfer. During this shape transfer, the sheet-like object is heated by the irradiation light of the external heater. In this case, the irradiation light is reflected by the reflecting member provided on the surface of the tip of the die lip of the T die, and the surface of the sheet-like object is reflected. Irradiation heating in the air.

  As shown in FIG. 1, a manufacturing apparatus (vertical extrusion molding apparatus) according to an embodiment of the present invention includes an extruder 11 that melt-kneads a thermoplastic resin, and discharges the melt-kneaded material in a sheet shape in a horizontal direction. A T die 12 to be discharged, an external heater 18 that heats the surface of the molten sheet-like material 16 discharged from the T-die 12 with radiant heat, and a first cooling that nips the heated sheet-like material 16 under pressure. A molding roll 13, a second cooling molding (shaping) roll 14 and a third cooling molding roll 15 provided with an emboss shape are provided.

  These three cooling forming rolls 13, 14, and 15 are arranged in this order in the upward direction, and the adjacent cooling forming rolls 13, 14, and 15 are configured to rotate in directions opposite to each other.

  As shown in FIG. 2, the external heater 18 is installed between the T die 12 and the second cooling forming roll 14. The external heater 18 may be a radiant heat heater such as a far-infrared heater, a mid-infrared heater, or a near-infrared heater, but instantaneously near the surface layer of the thermoplastic resin sheet 16 discharged from the T-die 12. In order to raise the temperature locally, a near-infrared heater or a mid-infrared heater is desirable from the relationship of the absorption wavelength of the thermoplastic resin. Note that reference numeral 17 in FIG. 2 denotes a bank.

  As shown in FIG. 3, a reflecting member 19 is provided on the upper surface of the tip of the die lip of the T die 12. Accordingly, the outer surface on the upper side of the sheet-like material 16 can be irradiated and heated in the air while the irradiation light of the external heater 18 is reflected by the reflecting member 19.

  When producing an embossed shaped sheet using this production apparatus, first, a thermoplastic resin is melt-kneaded by the extruder 11, and this melt-kneaded material is discharged into a sheet through the T-die 12. In this case, in order to prevent discharge unevenness, a gear pump (not shown) may be provided in the discharge portion of the extruder 11.

  Next, the molten sheet-like material 16 discharged from the T die 12 is irradiated and heated by an external heater 18. Immediately after the irradiation heating, the sheet-like material 16 is pressure-niped by the first cooling forming roll 13 and the second cooling forming roll 14, and the second cooling forming roll 14 having the embossed shape is formed into a sheet shape. In a state where the object 16 is wound, the sheet-like object 16 is cooled and solidified. Thereafter, the third cooling molding roll 15 cools the sheet surface on the opposite side of the embossed surface of the sheet-like material 16.

  The present invention is not limited to the vertical manufacturing apparatus described above, and other types of manufacturing apparatuses can be employed. 4 to 6 show a manufacturing apparatus according to another embodiment of the present invention. As shown in FIG. 4, the manufacturing apparatus includes a T-die 12 that discharges the melt-kneaded material downward in a sheet shape, a first cooling molding roll 20 that press-nips the sheet-like material 16, and an embossed shape. Are provided with a second cooling forming roll 21, and third and fourth cooling forming rolls 22 and 23.

  These four cooling forming rolls 20 to 23 are arranged side by side in this order, and an external heater 26 is disposed between the T die 12 and the first cooling forming 20. Further, as shown in FIG. 5, a reflecting member 27 is disposed on one side surface of the tip of the die lip of the T die. Accordingly, it is possible to irradiate and heat the surfaces on both sides of the sheet-like material 16 in the air while reflecting the irradiation light of the external heater 26 by the reflecting member 27.

  The arrangement method of the external heater 26 and the reflecting member 27 according to the present invention can be freely configured according to the purpose and design conditions. For example, as shown in FIG. 5, the position and size of the reflecting member 27 can be changed as appropriate according to the positional relationship between the T die 12 and the cooling forming roll 14. As the reflecting member 27, a known reflecting member such as a metal reflecting plate can be used.

  Furthermore, as shown in FIG. 6, external heaters 24 and 26 and reflecting members 15 and 27 can be provided on both sides of the T die 12. That is, external heaters 24 and 26 are disposed between the T die 12, the first cooling forming ((shaping)) roll 28, and the second cooling forming roll 21, respectively, and the die lip tip of the T die 12 is provided. Reflective members 25 and 27 can be provided on the surfaces of one side and the other side, respectively. According to this configuration, it is possible to irradiate and heat the surfaces on both sides of the sheet-like material 16 in the air while reflecting the irradiation light of the external heaters 24 and 26 by the reflecting members 25 and 27.

[Examples 1 to 5]
In Examples 1 to 5, embossed shaped sheets were produced using the extrusion molding apparatus of FIG. 3 in the above-described embodiment. The specific conditions of the manufacturing method in this case were as follows.
Extrusion resin: MS resin (p-MMA: PS = 80: 20)
Screw of extruder ... φ150mm
Extruder discharge rate ... 250Kg / h
T-die discharge width ... 1450mm
T-die discharge resin temperature: 220 ° C-240 ° C
T-die lip opening 2mm to 6mm
Distance (air gap) between the T-die and the first cooling forming roll and the second cooling forming roll: 140 mm
Diameter of first cooling forming roll ... φ400mm
Diameter of second cooling forming roll ... φ400mm
Embossed shape of second cooling molding roll: heating medium operating temperature of first cooling molding roller of cylindrical lens array with pitch 300 μm and embossed groove depth H′152 μm 70 ° C. to 80 ° C.
Heating medium operating temperature of second cooling forming roll ... 80 ° C to 90 ° C

  As the external heater 18, a near infrared heater manufactured by Heraeus Co., Ltd. (ZKC8000 / 1500G, 400V, 8KW) was used. The reflecting member was an aluminum sheet having a mirror surface polished.

[Comparative Examples 1-5]
In Comparative Examples 1 to 5, the same extrusion molding apparatus as in Examples 1 to 5 was used, but an external heater was not used and only the air gap was 100 mm. All other conditions are the same as in Examples 1-5.

  FIG. 9 shows a groove shape in the shaped roll groove 29 (embossed groove depth: H ′ = 0.152 mm, embossed groove pitch: P ′ = 0.302 mm) according to Examples and Comparative Examples, FIG. 10 shows an embossed shaped sheet 16 (H: embossed groove shaped height, P: embossed groove pitch, T: total sheet thickness) shaped according to Examples and Comparative Examples.

[Evaluation of embossing formability]
About each embossing shaping sheet obtained by the said Examples 1-5 and Comparative Examples 1-5, the shape accuracy of the embossing shape and the variation in shaping were measured using the shape measuring machine. In addition, the measurement of the embossed shape of the shaped sheet is performed using a contact-type shape measuring device (manufactured by Kosaka Laboratory Co., Ltd .: Surfcorder ET4000A) and an enlargement projector (manufactured by Mitutoyo Corporation: PJ-A3000, 200 times to 500 times) Was used.

  The results of Examples 1 to 5 are shown in [Table 1], and the results of Comparative Examples 1 to 5 are shown in [Table 2].

  As shown in Table 1, according to Examples 1 to 5, by heating the surface of the sheet-like material 16 immediately after being discharged from the T die 12 by the external heater 18, the shaping rate (H / H ′ ) Reached 93% to 98%, and the variation range of the embossed shaping height in both the extrusion direction and the extrusion width direction was within ± 0.6% to 2%. Further, the embossed shaping pitch P was within the range of 0.5% to 0.6%, which is the range of the heat shrinkage rate of the thermoplastic resin, and no variation occurred.

  Further, when a mid-infrared heater (Hereus Co., Ltd. (BSG3750 / 1500, 230V, 3.75 KW)) is used as the external heater 18, the shaping rate (H / H ′) is 90% to 93%. The variation range of the height was within ± 0.6% to 2%, and the shaping rate was slightly lower than when the near infrared heater was used (details are omitted).

  On the other hand, as shown in [Table 2], according to Comparative Example 1 (sheet thickness T = 0.6 mm), in comparison with Example 1 above, a pair of cooling forming rolls were further packed with an air gap. Although the resin temperature immediately before the press nip at 13 and 14 is substantially the same as in the case of Example 1, the forming rate is reduced to about 60% and the variation in forming height is ± It deteriorated from 3% to ± 7%.

  Moreover, according to Comparative Example 2, when the sheet thickness T was as thick as 3 mm, the shaping rate further decreased to 53%, and in addition, the variation in shaping height was increased to ± 7%.

  Furthermore, according to Comparative Example 4 and Comparative Example 5, even when the cooling forming roll device is changed from a vertical type to a horizontal type cooling forming roll device, the forming rate is 54% to 60%, and the variation in forming is ± 3%. From the results, it was ± 7%, which was inferior in both the shaping rate and variation compared to Examples 4 and 5.

  Thus, in any of Comparative Examples 1 to 5, the sheet thickness T is in the range of 0.6 mm to 3 mm, and the apparatus condition without an external heater is 50% to 70%. It was.

  Furthermore, in Comparative Examples 1 to 5, the variation in the shaping height in the extrusion direction and the extrusion width direction with respect to each shape also produced a variation of ± 3% to ± 7% or more, particularly embossing for optical applications. As a shaped sheet, the required design performance could not be obtained.

  As described above, in the present invention, the surface of the sheet-like material is irradiated and heated in the air while reflecting the irradiation light of the external heater by the die lip tip-side reflecting member of the T die, thereby reducing the discharge resin temperature of the sheet-like material. The glass transition point Tg of the thermoplastic resin that can be bank-molded is set to be higher than the glass transition point Tg, and the surface layer portion immediately before being pressure-niped by the cooling shaping roll is raised to the temperature of the rubber transition region, so that the mold return phenomenon is minimized. I was able to.

  That is, the resin temperature immediately after the discharge from the T die is the minimum required operating temperature that is equal to or higher than the glass transition point Tg that can be bank-formed by a pair of cooling forming rolls. The surface layer portion was irradiated with an external heater and heated to the temperature of the rubber transition region, and then pressure-niped with a cooling shaping roll. Thereby, the inflow and filling property of the molten resin to the embossed groove were improved, and the heat transfer from the sheet center layer after release was suppressed.

  Thus, in the manufacture of a general-purpose extruded sheet using a roll shaping device for a vertical cooling forming roll or a horizontal cooling forming roll, the shape height H is relatively low with respect to the total thickness T of the sheet. A thermoplastic resin sheet having an embossed shape with a fine pitch could be continuously produced, and the forming rate and shape transfer accuracy were significantly improved as compared with the conventional one.

  The present invention can be variously modified without departing from the spirit of the present invention, and the present invention naturally extends to the modified ones.

It is the schematic of the manufacturing apparatus of the embossing shaped sheet which concerns on Example 1 of embodiment of this invention. It is an enlarged view around the external heater of FIG. It is an enlarged view around the external heater of the manufacturing apparatus of the embossing shaped sheet which concerns on Example 2 of this invention. It is the schematic of the manufacturing apparatus of the embossing shaped sheet which concerns on Example 3 of this invention. It is the aspect which installed one external heater in the manufacturing apparatus of the embossing shaped sheet | seat of Example 3 of Embodiment, Comprising: It is an enlarged view which shows the circumference | surroundings of this external heater. It is the aspect which installed the two external heaters in the manufacturing apparatus of the embossing shaped sheet | seat of Embodiment 3, and is an enlarged view which shows the circumference | surroundings of this external heater. It is the schematic of the manufacturing apparatus which shows the manufacturing apparatus of the conventional embossing shaped sheet | seat, and concerns on a vertical-type cooling molding roll apparatus. It is the schematic of the manufacturing apparatus which shows the manufacturing apparatus of the conventional embossing shaped sheet, and concerns on a horizontal type cooling molding roll apparatus. The groove shape cross section in the shaping roll (Embossed groove depth: H ′ = 0.152 mm, Embossed groove pitch: P ′ = 0.302 mm) according to Examples and Comparative Examples is shown. It is sectional drawing which shows the embossing shaped sheet | seat (H: Embossed groove shaping height, P: Embossed groove pitch, T: Sheet | seat thickness) which concerns on the Example and the comparative example.

Explanation of symbols

11 Extruder 12 T-die for sheet molding
13 Vertical first cooling forming roll 14 Vertical second cooling forming roll (cooling shaping roll for embossing)
15 Vertical third cooling molding roll 16 Sheet (embossed sheet)
17 Bank 18 External heater 19 on the side of the vertical second cooling forming roll 19 Reflective member 20 for the external heater on the side of the vertical second cooling forming roll Horizontal first cooling forming roll 21 Horizontal type second cooling forming Roll (cooling shaping roll for embossing)
22 Horizontal third cooling forming roll 23 Horizontal fourth cooling forming roll 24 External heater 25 on horizontal first cooling forming roll Reflective member 26 for external heater on horizontal first cooling forming roll side External heater 27 on the second cooling molding roll side Reflective member 28 for the external heater on the horizontal second cooling molding roll side First cooling molding roll (cooling shaping roll for embossing shape imparting)

Claims (4)

The thermoplastic resin is supplied to an extruder, melted and kneaded, then discharged and extruded into a sheet shape through a T-die, and press-niped with a pair of cooling molding rolls to continuously form the embossed shape applied to the surface of the cooling molding roll. In the method for producing an embossed shaped sheet for transfer shaping,
A method for producing an embossed shaped sheet in which an outer surface of a sheet-like material immediately after being extruded and extruded from the T-die is heated in the air by an external heater and then subjected to a pressure nip with the cooling molding roll to transfer the shape. And
The external heater is an infrared heater, and the surface of the sheet-like material is irradiated and heated in the air while reflecting the irradiation light of the external heater by a reflecting member provided on the surface of the tip of the die lip of the T die. A method for producing an embossed shaped sheet.   2. The embossed shaped sheet according to claim 1, wherein the surface of the sheet-like material is irradiated and heated in the air while irradiating the surface of the cooling molding roll provided with the embossed shape with irradiation light of the external heater. Manufacturing method. When the maximum depth of the embossed shape to be transferred is H and the total thickness of the sheet is T,
0.6mm ≤ T ≤ 3.0mm
0.05 ≤ H / T ≤ 0.25
The method for producing an embossed shaped sheet according to claim 1, wherein the embossed shaped sheet is in the range. The thermoplastic resin is supplied to an extruder, melted and kneaded, then discharged and extruded into a sheet shape through a T-die, and press-niped with a pair of cooling molding rolls to continuously form the embossed shape applied to the surface of the cooling molding roll. An embossed shaped sheet manufacturing apparatus used in the method for manufacturing an embossed shaped sheet according to claim 1, 2 or 3 for transfer shaping,
An external heater that irradiates and heats the surface of the sheet-like material immediately after being extruded and extruded from the T die, and a reflecting member provided on the surface of the die lip tip of the T die, and the external heater is an infrared heater, An apparatus for producing an embossed shaped sheet, wherein the surface of the sheet-like material is irradiated and heated in the air while the irradiation light of the external heater is reflected by the reflecting member.

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