JP2008279625A - Method and apparatus for producing resin film - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin film producing means which can produce various films including an ultrathin film, a single layer film, and a multilayer film without the occurrence of thickness nonuniformity in spite of its simple composition and can easily and quickly change over the production. <P>SOLUTION: A liquid resin 2 with a drying assisting solvent added to a resin to be a film raw material is transferred onto the peripheral surface of an intaglio type roll 4 in which a large number of fine, shallow recesses are formed in the peripheral surface through a liquid supply roll 3, with the thickness reduced by removing an excess resin solution, is transferred onto the peripheral surface of a blanket roll 7 in which at least its peripheral part has flexibility and peelability, and is made a thin, semi-dried resin film 9, which is wound onto a winding roll 10 as a single layer resin film. Alternatively, it is put on a resin film or an ink film separately formed by a similar means and wound up as a multilayer resin film. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method and an apparatus for producing industrial films and other widely used resin films and sheets (hereinafter referred to as films).

There are several conventional methods and apparatuses for producing resin films (for example, “industrial plastic film”, written by Tomoyuki Minami and Atsushi Kosaka, published by Processing Technology Research Co., Ltd.). For example, the measures described in the following documents are often taken.
JP-A-8-183084 JP 2006-103289 A

  These belong to what is referred to as the T-die method, and a resin solution / molten resin selected according to the application of the resin film is ejected from a widening / casting die to form a film, which is a roller. Or they are cooled and cured while being sandwiched between endless belts, and long ones are wound up.

  However, the viscosity of the resin solution / molten resin is not always constant and is affected by slight changes in the degree of polymerization, composition, solid concentration, temperature, etc. Unevenness is likely to occur, and it is not easy to make the film thickness uniform. To cope with this, the apparatus has become highly accurate, complicated, and large.

  In addition, since the manufactured film thickness is not uniform, a part of the multilayer film that does not partially adhere to each other is generated, so that the process of multilayering is not easy and may result in a defective product.

  Furthermore, it was impossible to switch between the production of a single layer film and the production of a multilayer film with a single device, or the device was complicated and could not be handled easily and quickly, making it difficult to produce a small lot.

  The present invention intends to solve the problems caused by the conventional method and apparatus for producing a resin film. That is, the object of the present invention is to use a relatively simple method and apparatus, so that the film thickness can be made uniform without causing unevenness of the film, the film can be easily multilayered, and a single layer can be formed. It is an object of the present invention to provide a method and an apparatus for producing a resin film that can easily and quickly switch between the production of a multilayer film and a multilayer film, and that can also be produced in a small lot.

A 1st of the manufacturing method of the resin film which concerns on this invention is a thing for single layer films,
Liquid resin 2 in which a solvent that aids drying is added to the resin that is the raw material of the film,
Transferred to the outer peripheral surface of the intaglio roll 4 formed with a number of fine and shallow recesses 5 on the outer peripheral surface via the liquid supply roll 3,
In a state where the excess resin solution is removed and thinned, at least the outer peripheral portion is transferred to the outer peripheral surface of the blanket roll 7 having flexibility and resin peelability, and a thin resin film 9 in a semi-dried state there is obtained.
This is wound around the winding roll 10 as a single-layer resin film 12.

1st of the manufacturing apparatus of the resin film which concerns on B this invention is for implementing 1st of the said manufacturing method,
A tray 1 containing a liquid resin 2 in which a solvent that aids drying is added to a resin that is a raw material of the film;
A liquid supply roll 3 having a lower part immersed in the tray 1;
An intaglio roll 4 that has a number of fine recesses 5 formed on its outer peripheral surface and rotates so as to abut against the liquid supply roll 3;
A scraper 6 that comes into contact with the outer peripheral surface of the intaglio roll 4 to remove excess resin solution;
A blanket roll 7 that rotates so that at least the outer peripheral portion has good flexibility and resin solution peelability, and abuts against the intaglio roll 4;
Therefore, a receiving roll 8 for receiving a thin resin film 9 that is dry,
Thereafter, a take-up roll 10 for winding the resin film 9 as a single layer film 12 is provided.

C The second method for producing a resin film according to the present invention is for a multilayer film,
A liquid resin 2a in which a solvent that aids drying is added to the resin that is the raw material of the film,
Transferred to the outer peripheral surface of the intaglio roll 4 formed with a number of fine and shallow recesses 5 on the outer peripheral surface via the liquid supply roll 3,
In a state where the excess resin solution is removed and made thin, at least the outer peripheral portion is transferred to the outer peripheral surface of the blanket roll 7 having flexibility and resin peelability, and is then thinly dried there. age,
Subsequently, a thin resin film 9b or ink film separately formed by the same means is polymerized on the resin film 9a to form a multilayer,
This is wound around a winding roll 10 as a multilayer resin film 13.

2nd of the manufacturing apparatus of the resin film which concerns on D this invention is for implementing 2nd of the said manufacturing method,
A tray 1 containing a liquid resin 2a in which a solvent that aids drying is added to a resin that is a raw material of the film;
A liquid supply roll 3 having a lower part immersed in the tray 1;
An intaglio roll 4 that has a number of fine recesses 5 formed on its outer peripheral surface and rotates so as to abut against the liquid supply roll 3;
A scraper 6 that comes into contact with the outer peripheral surface of the intaglio roll 4 to remove excess resin solution;
At least the outer peripheral portion has good flexibility and resin solution peelability, the unit I is composed of a blanket roll 7 that rotates so as to abut against the intaglio roll 4, and the structure similar to the above, the liquid 2b in the tray 1 is a film It is equipped with two or more units II that are made by adding a solvent that aids drying to the liquid resin or ink used as the raw material of
And after the blanket roll 7 of the last unit II, a receiving roll 8 that also serves to polymerize the resin film 9b or ink film of the unit II on the resin film 9a of the unit I,
Thereafter, the take-up roll 10 is wound up as the multilayer film 13.

a) In the present invention, the resin film can be produced by a simple method and apparatus.
That is, the viscosity of the liquid resin is not always constant, and is affected by slight changes in the degree of polymerization, composition, solid concentration, temperature, etc., and thus the above-described conventional resin film manufacturing method / apparatus is likely to cause thickness unevenness. Accordingly, it is not easy to make the film thickness uniform, and in order to cope with this, the apparatus has become highly accurate, complicated, and large.

  On the other hand, in the present invention, as described above, the liquid supply roll 3, the intaglio roll 4 having many fine recesses 5 formed on the outer peripheral surface, the scraper 6, and at least the outer peripheral portion is flexible and resinous. It consists of a unit comprising a blanket roll 7 made of a material having good solution peelability, a receiving roll 8 and a take-up roll 10.

  Therefore, it is possible to apply the technology established in offset intaglio printing, and it is easy to make the method and apparatus small and simple, and the adjustment can be done easily and quickly, and the equipment cost can be greatly reduced. become.

b) In the method and apparatus for producing a resin film according to the present invention, it is possible to produce a film having a normal film thickness, for example, an ultra-thin film having a thickness of 1 μm or less, or a single layer to a film having different colors and patterns. it can.
That is, in the conventional method and apparatus for producing a resin film as described above, unless the apparatus is highly accurate, complicated, or large, unevenness in the film thickness is likely to occur and it is not easy to make the film thickness uniform. .

  On the other hand, in the present invention, as described above, the excess resin solution is transferred to the outer peripheral surface of the intaglio roll 4 formed with a large number of fine and shallow recesses 5 on the outer peripheral surface via the liquid supply roll 3. After the removal, the outer peripheral portion is transferred thinly to the outer peripheral surface of the blanket roll 7 made of a material having good flexibility and resin peelability, and then wound around the take-up roll 10 via the film receiving roll 8. Therefore, even in the case of uniform film thickness and ultra-thin film, the technology established by offset intaglio printing as described above can be applied, so the film thickness can be adjusted easily and quickly. Can be reliably manufactured by a simple method and apparatus.

  c) In the method and apparatus for producing a resin film according to the present invention, it is easy to carry out from an ultra-thin film to a thick film.

  That is, as described above, in the conventional method and apparatus for producing a resin film, it is not easy to make the film thickness uniform, and the process of multi-layering is not simple, so the produced multilayer film is partially adhered. The part which did not occur may occur.

  On the other hand, in the present invention, since the technique established by offset intaglio printing can be applied as described above, it is easy to make the film thickness uniform. Further, by replacing the intaglio roll 4 with different depths of the fine recesses 5 on the outer peripheral surface, films 12 having various film thicknesses from ultra-thin films of 1 μm or less to relatively thick films, Thirteen productions are possible.

  d) In the method and apparatus for producing a resin film according to the present invention, it is possible to easily and quickly switch from the production of a single layer film to the production of a multilayer film.

  That is, as described above, in the conventional method and apparatus for producing a resin film, it is not possible to switch between the production of a single layer film and the production of a multilayer film. It took time and effort.

On the other hand, in the method and apparatus for producing a resin film according to the present invention, the resin film 9b or ink film separately formed by the unit having the same structure as the resin film 9a substantially dried through the blanket roll 7 as described above. Can be easily produced for the multilayer film 13 such as a thick single-layer film 12 or a colored film.
Therefore, not only the production of the single-layer film 12 but also the addition of the unit makes it easy to switch to the production of the multilayer film 13 and can cope with the production of a small lot unlike the conventional case.

  As described above, the manufacturing apparatus in the present invention includes a unit I composed of the tray 1, the liquid supply roll 3, the intaglio roll 4, the scraper 6, and the blanket roll 7, and the receiving roll 8, as described above. It is comprised with the winding roll 10 (for example, refer FIG. 1).

  A unit II consisting of a tray 1, a liquid supply roll 3, an intaglio roll 4, a scraper 6 and a blanket roll 7 is additionally provided so that it can be prepared for the production of multilayer films and thick films. It is desirable to operate it in combination with the unit I. The number of units II may be one or more depending on the number of layers and the film thickness (see, for example, FIG. 2).

  Each of the rolls 3, 4, 7, 8, and 10 is preferably exchangeable with one having a different width or outer diameter so that it can be used for production of various types of films. It is desirable that the fine recess 5 on the outer peripheral surface can be replaced with one having a different depth or pattern.

  The resin 2, 2a used as the raw material of the film is selected and determined depending on the use as a film, etc. For example, vinyl, polyester, polyethylene, acetylcellulose, acrylic, urethane, or a copolymer of these with other liquids What is necessary is just to use. For example, screen printing ink, gravure offset ink, or the like may be used in order to obtain a multi-colored multi-colored film containing a pattern or the like.

  The solvent added to them is, for example, an aromatic hydrocarbon or halogenated hydrocarbon type, and it is desirable to use, for example, methyl ethylene ketone, acetone, toluene or xylene. The reason why the solvent is added here is to allow the liquid resin, ink, etc. to be transferred to the intaglio roll 4 via the liquid supply roll 3 and then to the blanket roll 7 to be dried. .

  The fine and shallow recesses 5 formed on the outer peripheral surface of the intaglio roll 4 are provided with a plurality of evenly spaced substantially over the entire outer peripheral surface of the roll 4, and the shape thereof may be, for example, a fine small recess. Further, it may be a mesh or fine groove with fine intervals. Further, it is usually formed in units of microns with its width and depth, and the forming means may be, for example, laser processing or etching.

  The fine and shallow recess 5 is formed on the outer peripheral surface of the intaglio roll 4 because when the outer peripheral surface of the intaglio roll 4 is scraped with the scraper 6, so-called "bottom scraping" occurs in part. This is to prevent the occurrence of a defective portion in a part of the film or, on the contrary, slightly thicker to cause “moire” or the like to form a uniform film thickness as a whole.

  The blanket roll 7 has at least an outer peripheral portion with flexibility such as silicon resin so that the liquid is evenly transferred by contact with the intaglio roll 4 and the next peeling is performed smoothly. It is made of a material with good resin releasability.

  1 to 4 show an embodiment of an apparatus used for carrying out the method for producing a resin film according to the present invention, FIG. 1 is an apparatus for a single layer film, and FIG. 2 is the simplest 2 as an example of a multilayer film. 1 shows an apparatus for a layer film. Although not shown, each of the rollers 3, 4, 7, 8, and 10 is rotated in synchronization with the motor and the timing belt.

  A First, in FIG. 1, reference numeral 1 denotes a tray, which contains a resin liquid 2 which is a raw material for a film, to which a solvent is added so that it can be easily dried. Here, a liquid vinyl resin is used, and methyl ethylene ketone is added here as a solvent to help drying. Although not shown, a certain amount is replenished into the tray 1 by a lower pump.

  Reference numeral 3 denotes a liquid supply roll, the lower part of which is immersed in the liquid resin 2 in the tray 1, and the liquid resin 2 is transferred by rotating while contacting the intaglio roll 4 described later. .

  The intaglio roll 4 rotates while contacting the outer peripheral surface of the liquid supply roll 3 as described above. Here, the intaglio roll 4 is made of SKD (alloy tool steel for wear-resistant deformation) and has an outer diameter of about 100 mm and a lateral width of about 150 mm. Many fine recesses 5 into which the liquid resin can enter are formed over the entire outer periphery. Here, the recess 5 is formed by laser processing to form a large number of fine round holes with an inner diameter of about 50 μ at intervals of about 50 μ and a depth of about 10 μ.

  The fine recess 5 is not limited to a round hole, but may be a hole having another shape, a combination thereof, or a mesh-like or lattice-like recess. The formation may be performed by etching.

  The intaglio roll 4 has several types of intaglio rolls 4 with different sizes, intervals, depths, and the like of the fine recesses 5, and the types, uses, and film thicknesses of the raw materials of the resin film to be manufactured. It can be exchanged according to differences.

  Reference numeral 6 denotes a scraper, which is a plate having a width corresponding to the width of the outer peripheral surface of the intaglio roll 4, here made of ceramic, abutting on the outer peripheral surface of the rotating intaglio roll 4, and adhering thereto. The excess liquid resin is scraped off.

  7 indicates a blanket roll, which rotates while abutting on the outer peripheral surface of the intaglio-shaped roll 4, but is flexible on the outer peripheral portion of the core material made of aluminum alloy and uniformly in contact with the outer peripheral surface of the intaglio-shaped roll 4; The resin film 9 is peelable so that the resin film 9 can be easily transferred to the outer peripheral surface of the next receiving roll 8. Here, the size of the roll 7 has an outer diameter of about 100 mm and a lateral width of about 150 mm.

  The receiving roll 8 rotates while contacting the outer peripheral surface of the blanket roll 7 as described above, and receives the resin film 9 that is in a dry state, and is peeled off from the blanket roll 7. Is to be transferred. Here, an aluminum alloy having an outer diameter of about 80 mm and a width of about 150 mm is used.

  Reference numeral 10 denotes a take-up roll of a resin film. The resin film 9 passed through the receiving roll 8 is taken up as a resin film. Here, like the receiving roll 8, it is made of an aluminum alloy and has an outer diameter of about 80 mm and a width of about A 150 mm one is used.

The implementation state of the manufacturing method of the single layer film using the apparatus for the single layer film is as follows.
When the rolls 3, 4, 7, 8, and 10 are rotated via the motor and the timing belt, the liquid vinyl resin 2 in the tray 1 is rotated while abutting the liquid vinyl resin 2 in the lower part by the liquid supply roll 3 immersed therein. It is transferred to the outer peripheral surface of the shape roll 4.

  Next, when the outer peripheral surface of the intaglio roll 4 is scratched by the scraper 6, a resin film 9 having a thin film thickness is formed on the outer peripheral surface of the intaglio roll 4 as shown in FIG. At this time, a large number of fine and shallow recesses 5 are formed on the outer peripheral surface of the intaglio roll 4 and the liquid resin 2 has entered the recesses 5, so that the outer peripheral surface is scratched by the scraper 6. However, since the edge only abuts on the peripheral portion of each recess 5, a part of the resin film on the outer peripheral surface is not lost due to so-called “bottoming”.

  Even if a scraped portion of the resin film 9 is caused by scraping off the scraper 6, the liquid resin 2 entering each recess 5 replenishes / repairs the missing portion. . Therefore, the resin film 9 on the outer peripheral surface of the intaglio roll 4 after scraping by the scraper 6 has a very uniform film thickness as a whole, and “moreer” that occurs when the film thickness is uneven is not generated here. For example, a resin film 9 having a thickness of about 1 μm is formed.

  The resin film 9 on the outer peripheral surface of the intaglio roll 4 gradually begins to dry from the outer peripheral surface (see FIG. 3 above), and then, as shown in FIG. It is transferred to the outer peripheral surface of. At this time, the intaglio roll 4 of the blanket roll 7 is in contact with the next blanket roll 7, and the outer peripheral part is formed of the silicon material having flexibility as described above in accordance with the rotation. The resin film 9 can be transferred accurately and reliably because it is easily in close contact with the roll 4.

  While the resin film 9 transferred to the outer peripheral surface of the blanket roll 7 adheres to and rotates, natural drying is promoted by the action of methyl ethylene ketone added as a solvent and is almost dried.

  The resin film 9 is transferred from the outer peripheral surface of the blanket roll 7 to the outer peripheral surface of the receiving roll 8 rotating in contact with the roll 7. Again, since the outer peripheral portion of the blanket roll 7 is rich in peelability, the resin film 9 is easily peeled from the outer peripheral surface of the blanket roll 7 and is easily and accurately transferred to the outer peripheral surface of the receiving roll 8.

  The resin film 9 is then wound up by a winding roll 10, whereby a long and thin single-layer resin film 9 is manufactured.

  B Next, as a multilayer film, a production method and apparatus for a two-layer film are shown in FIG. 2, but here, it is a case of a multilayer film with a color pattern on a resin layer as a base.

  The difference from the manufacturing apparatus for the single layer film is that the first unit I is the same structure as the tray 1 to the blanket roll 7 of the first apparatus for the single layer, and then the same structure is used. It is provided as a second unit, and a receiving roll 8 and a take-up roll 10 are provided after the blanket roll 7 of the second unit II.

  In the tray 1 in the first unit, here is a liquid resin 2a in which a polyester resin is liquefied and acetone is added as a solvent. It is transferred to the outer peripheral surface of the intaglio roll 4 via the liquid supply roll 3 and the excess is removed by the scraper 6, and then gradually from the outer peripheral surface. While being dried, the outer peripheral portion is transferred to the outer peripheral surface of the blanket roll 7 (see FIG. 4) to form a thin resin film 9a, and in this state, it is half-dried.

  In this case as well, since the outer periphery of the fine and shallow recesses 5 formed on the outer peripheral surface of the intaglio roll 4 and the outer periphery of the blanket roll 7 are made of silicon with good flexibility and peelability, the blanket roll 10 helps to form a uniform and thin resin film 9a on the outer peripheral surface.

  The resin film 9a is sent to the second unit II instead of being sent to the receiving roll 8 and the take-up roll 10 as in the embodiment of the single layer film. In the tray 1 of the second unit II, here is a liquid 2b obtained by adding acetone as a solvent to the screen printing ink, which is transferred to the intaglio roll 4 via the liquid supply roll 3, and is then scraper 6 After removing the excess ink, a thin ink film 9b is transferred to the blanket roll 7, and in this state, it is half dried.

  Also in this case, as in the case of the single-layer film, the fine and shallow recesses 5 formed on the outer peripheral surface of the intaglio roll 4 and the outer peripheral portion of the blanket roll 7 with good flexibility and peelability are the blanket roll. 7 helps to form a uniform and thin ink film 9b on the outer peripheral surface.

  In the second unit II, the thin ink film 9b is integrally polymerized on the thin resin film 9a serving as a base sent from the first unit I, and this causes the receiving rolls 8, 8 to be polymerized. The multilayer film 13 having a colored ink layer is formed by being multilayered and then wound on the winding roll 10. In FIG. 2, reference numeral 11 denotes a support roll that eliminates sagging of the dendrite.

Since the above is a two-layer film, the first unit I and the second unit II are used. However, in order to increase the number of layers, the number of units may be increased as in the third unit. The second embodiment is an example in which a colored ink film 9b is multilayered on a resin film 9a as a base. However, a resin film using different types of resin materials may be polymerized and multilayered. This is as described above. It is also possible to form an ink film first and polymerize the resin film on the ink film to form a multilayer.

It is a side view which shows the apparatus in the case of manufacturing a single layer film by this invention. It is a side view which shows the apparatus in the case of manufacturing a multilayer film by this invention. In FIG. 1, it is a partial expanded sectional view which shows the resin film formation state in the intaglio roll in manufacture of a multilayer film. In FIG. 1, it is a partial expanded sectional view which shows the transfer state from the intaglio roll to the blanket roll in manufacture of a multilayer film.

Explanation of symbols

I-first unit II-second unit 1-tray 2-liquid resin 2a-liquid resin 2b-ink liquid 3-liquid supply roll 4-intaglio roll 5-recess 6-scraper 7-blanket roll 8,8- Receiving roll 9-resin film 9a-resin film 9b-ink film 10-winding roll 11-support roll 12-single layer film 13-multilayer film

Claims (4)

The liquid resin 2 in which a solvent that aids drying is added to the resin that is the raw material of the film is transferred via the liquid supply roll 3 to the outer peripheral surface of the intaglio roll 4 in which a large number of fine shallow recesses 5 are formed on the outer peripheral surface. And
In a state where the excess resin solution is removed and thinned, at least the outer peripheral portion is transferred to the outer peripheral surface of the blanket roll 7 having flexibility and resin peelability, and a thin resin film 9 in a semi-dried state there is obtained.
A method for producing a resin film, characterized in that it is wound on a take-up roll 10 as a single-layer resin film 12. Liquid resin 2a in which a solvent that aids drying is added to the resin that is the raw material of the film,
Transferred to the outer peripheral surface of the intaglio roll 4 formed with a number of fine and shallow recesses 5 on the outer peripheral surface via the liquid supply roll 3,
In a state where the excess resin solution is removed and made thin, at least the outer peripheral portion is transferred to the outer peripheral surface of the blanket roll 7 having flexibility and resin peelability, and is then thinly dried there. age,
Subsequently, a thin resin film 9b or ink film separately formed by the same means is polymerized on the resin film 9a to form a multilayer,
A method for producing an important film, wherein the film is wound on a winding roll 10 as a multilayer resin film 13. A tray 1 containing a liquid resin 2 in which a solvent that aids drying is added to a resin that is a raw material of the film;
A liquid supply roll 3 having a lower part immersed in the tray 1;
An intaglio roll 4 that has a number of fine recesses 5 formed on its outer peripheral surface and rotates so as to abut against the liquid supply roll 3;
A scraper 6 that comes into contact with the outer peripheral surface of the intaglio roll 4 to remove excess resin solution;
A blanket roll 7 that rotates so that at least the outer peripheral portion has good flexibility and resin solution peelability, and abuts against the intaglio roll 4;
Therefore, a receiving roll 8 for receiving a thin resin film 9 that is dry,
A resin film manufacturing apparatus comprising a winding roll 10 that winds the resin film 9 as a single layer film 12 thereafter. A tray 1 containing a liquid resin 2a in which a solvent that aids drying is added to a resin that is a raw material of the film;
A liquid supply roll 3 having a lower part immersed in the tray 1;
An intaglio roll 4 that has a number of fine recesses 5 formed on its outer peripheral surface and rotates so as to abut against the liquid supply roll 3;
A scraper 6 that comes into contact with the outer peripheral surface of the intaglio roll 4 to remove excess resin solution;
At least the outer peripheral portion has good flexibility and resin solution peelability, the unit I is composed of a blanket roll 7 that rotates so as to abut against the intaglio roll 4, and the structure similar to the above, the liquid 2b in the tray 1 is a film It is equipped with two or more units II that are made by adding a solvent that aids drying to the liquid resin or ink used as the raw material of
And after the blanket roll 7 of the last unit II, a receiving roll 8 that also serves to polymerize the resin film 9b or ink film of the unit II on the resin film 9a of the unit I,
An apparatus for producing a resin film, comprising a take-up roll 10 for winding as a multilayer film 13 thereafter.