JP2009196206A - Method for manufacturing surface shape transferring resin sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for efficiently manufacturing a surface shape transferring resin sheet which transfers with good accuracy and rapidly the surface shape of a transfer mold. <P>SOLUTION: The method for manufacturing the surface shape transferring resin sheet comprises a sheet manufacturing process for manufacturing a continuous resin sheet by extruding continuously a resin from a die under a heat-melted condition, and a pressing process for pinching the continuous resin sheet and the transfer mold delivered continuously from a delivering roll by a first pressing roll and a second pressing roll. The pressing process comprises a first process of pinching the transfer mold between the continuous resin sheet and the first pressing roll or the second pressing roll, a second process of tightly sticking the transfer mold and the continuous resin sheet and conveying them, and a third process of releasing the transfer mold from the continuous resin sheet under a condition that the surface temperature of the continuous resin sheet is at the Vicat softening point or lower. The transfer mold is characterized by being composed of an organic material. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a manufacturing method and a manufacturing apparatus for a surface shape transfer resin sheet, and more particularly to a manufacturing method and a manufacturing apparatus for a resin sheet to which a transfer mold surface shape is transferred.

  As a method for producing a resin sheet having a shape on the surface (surface shape transfer resin sheet), using an extruder, a transfer mold to a continuous resin sheet (continuous resin sheet) obtained by extruding the resin from a die in a heated and melted state. There is known a method for transferring the surface shape (for example, Patent Document 1). In Patent Document 1, as shown in FIG. 6, the continuous resin sheet 1 continuously extruded from the die 3 is sandwiched between a first pressing roll 4 a and a second pressing roll 4 b provided with a transfer die 11. A method for transferring the surface shape of the transfer mold 11 to the continuous resin sheet 1 is disclosed. Although there is no description regarding the material which comprises a transfer type | mold in this patent document 1, as a transfer type | mold, the metal cylindrical thing normally inserted by the rotation roll, or engraving on the surface of a metal rotation roll etc. Those formed by the above method are generally used.

  However, in the manufacturing method using the conventional metal transfer mold, in order to transfer the surface shape of the transfer mold to the continuous resin sheet with high accuracy, it is necessary to slow down the transfer speed, which is not necessarily a productive method. I couldn't say there was.

Further, in Patent Document 1, it is considered that the transfer mold is a silicone rubber roll, but there is a problem that the silicone rubber roll surface is transferred to the back surface of the resin sheet, and only a product having no commercial value is obtained.
Japanese Patent Laid-Open No. 9-11328

  The present invention has been made in view of the above problems, and an object of the present invention is to provide a method and an apparatus capable of producing a surface shape transfer resin sheet efficiently by transferring the surface shape of a transfer mold accurately and quickly. To do.

  The present inventor has intensively studied to develop a method capable of producing a surface shape transfer resin sheet in which the surface shape of the transfer mold can be accurately and promptly transferred and the surface state does not deteriorate. The inventors have found that the object can be achieved by using a mold, and have reached the present invention.

  That is, the present invention provides a sheet pressing process in which a resin is continuously extruded from a die in a heated and melted state to manufacture a continuous resin sheet, and a transfer mold that is continuously sent out by a continuous resin sheet and a feed roll. A pressing step sandwiched between a roll and a second pressing roll, wherein the pressing step includes a first step of sandwiching the transfer mold between the continuous resin sheet and the first pressing roll or the second pressing roll, and a transfer mold. And a second step of bringing the continuous resin sheet into close contact with each other and a third step of peeling the transfer mold from the continuous resin sheet in a state where the surface temperature of the continuous resin sheet is equal to or lower than the Vicat softening point. It is related with the manufacturing method of the surface shape transcription | transfer resin sheet characterized by being comprised with the organic material.

  It is preferable to include a step of continuously winding the peeled transfer mold after the third step.

  Further, the present invention provides a continuous resin sheet having a surface shape obtained by sandwiching a continuous resin sheet between a die, a press roll, and a continuous roll to extrude a resin in a heated and melted state to produce a continuous resin sheet. A transfer mold that continuously transfers the transfer mold, and a winding roll that continuously winds the transfer mold while peeling the transfer mold from the continuous resin sheet. The transfer mold is made of an organic material. The present invention relates to an apparatus for manufacturing a surface shape transfer resin sheet.

  According to the manufacturing method and the manufacturing apparatus of the present invention, the surface shape of the transfer mold can be accurately and quickly transferred, and the desired surface shape transfer resin sheet can be manufactured with good productivity and no surface state defects. can do. Further, a high transfer rate can be obtained regardless of the thickness of the continuous resin sheet.

  Hereinafter, the production method and production apparatus of the present invention will be described in more detail. In addition, in the following description, although demonstrated using drawing, what attached | subjected the same referential mark in drawing of this application has shown the same part or an equivalent part.

<Method for producing surface shape transfer resin sheet>
The production method of the present invention includes a sheet production process for producing a continuous resin sheet by continuously extruding a resin from a die in a heated and melted state, and a continuous resin sheet and a transfer mold by a first pressing roll and a second pressing roll. And a pressing step of sandwiching. The pressing step includes a first step in which the transfer mold is sandwiched between the continuous resin sheet and the first pressing roll or the second pressing roll, and a second step in which the transfer mold and the continuous resin sheet are brought into close contact with each other and conveyed. And a third step of peeling the transfer mold from the continuous resin sheet in a state where the surface temperature of the continuous resin sheet is equal to or lower than the Vicat softening point. In addition, after the third step, a step of continuously winding the appropriately separated transfer mold can be included.

  The manufacturing method of the present invention will be described in detail below together with a manufacturing apparatus that enables the method.

  1 and 2 schematically show a production apparatus that enables the production method of the surface shape transfer resin sheet. The manufacturing apparatus shown in FIG. 1 and FIG. 2 includes a die 3 that continuously extrudes a heated and melted resin to produce a continuous resin sheet 1, a pressing roll 4, and a continuous resin sheet 1 between the pressing roll 4. The transfer mold 9 for transferring the surface shape to the continuous resin sheet 1 by being sandwiched between, the feed roll 5 for continuously feeding the transfer mold 9 and the transfer mold 9 are continuously wound while being peeled from the continuous resin sheet. A take-up roll 8 to be taken. The said manufacturing apparatus may be provided with the touch rolls 6 and 7 which assist a conveyance suitably, when conveying a transfer type | mold.

<Sheet manufacturing process>
The sheet manufacturing process is a process of manufacturing a continuous resin sheet by continuously extruding a resin from a die in a heated and melted state.

  The resin used in the production method of the present invention usually includes a thermoplastic resin that becomes a molten state when heated, and specifically includes, for example, a styrene resin, an acrylic resin, a polyethylene resin, and a polypropylene resin. , Cyclic olefin polymer resin, acrylonitrile-butadiene-styrene (ABS) resin, polyethylene terephthalate (PET) resin, polycarbonate (PC) resin, and the like. In addition, as said resin, the thermosetting resin hardened | cured by heating in the range applicable to the manufacturing method of this invention may be sufficient.

  Additives such as a light diffusing agent, an ultraviolet absorber, a heat stabilizer, and an antistatic agent may be added to the resin.

The light diffusing agent may be an inorganic light diffusing agent or an organic light diffusing agent.
Examples of the inorganic light diffusing agent include particles of inorganic compounds such as calcium carbonate, barium sulfate, titanium oxide, aluminum hydroxide, silica, inorganic glass, talc, mica, white carbon, magnesium oxide, and zinc oxide. . The inorganic light diffusing agent may be surface-treated with a surface treatment agent such as a fatty acid.

  Examples of the organic light diffusing agent include organic compound particles such as styrene polymer particles, acrylic polymer particles, and siloxane polymer particles.

  When a light diffusing agent is added, the absolute value of the difference between the refractive index of the added light diffusing agent and the refractive index of the resin is usually 0.02 or more in terms of the effect of light diffusion, and the resulting surface shape In terms of light transmittance of the transfer resin sheet, it is usually 0.13 or less. When the light diffusing agent is added to the resin in this way, the surface shape transfer resin sheet obtained can be used as a light diffusing plate.

  As a die for continuously extruding the resin in a heated and melted state, the same metal T-die as that used in a normal extrusion molding method is used. In order to extrude the resin from the die in a heated and melted state, an extruder is used in the same manner as in a normal extrusion molding method. The extruder may be a single screw extruder or a twin screw extruder. The resin is heated in an extruder, sent to a die in a molten state, and extruded. The resin extruded from the die is continuously extruded into a sheet shape to form a continuous resin sheet.

  What is necessary is just to adjust the thickness of a continuous resin sheet suitably according to the use of the obtained sheet | seat, for example, when using as a light-diffusion plate, what is necessary is just to be 0.3 mm-3.0 mm. Moreover, even if it is a thick film of 3.0 mm or more, according to the production method of the present invention, it is possible to transfer well.

  The continuous resin sheet may be a single layer or includes two or more layers. When the continuous resin sheet is a single layer, when extruding the resin from the die in a heated and melted state, one type of resin may be supplied to the die and extruded as a single layer. The above resin may be supplied to the die and coextruded in a laminated state. In order to perform co-extrusion in a state where two or more kinds of resins are laminated, for example, a known two-type three-layer distribution type feed block may be used, and the resin may be supplied to the die via this.

<Pressing process>
In the pressing step, the continuous resin sheet and the transfer mold obtained in the sheet manufacturing step are sandwiched between a first pressing roll 4a and a second pressing roll 4b, which are pressing rolls 4, as shown in FIG. Specifically, the pressing step includes a first step of sandwiching the transfer mold between the continuous resin sheet and the first pressing roll or the second pressing roll, and a first step of bringing the transfer mold and the continuous resin sheet into close contact with each other. 2 processes and the 3rd process which peels a transcription | transfer mold from a continuous resin sheet in the state whose surface temperature of a continuous resin sheet is below a Vicat softening point.

  As the pressing roll, a metal roll usually made of a metal such as stainless steel or steel is used, and its diameter is usually 100 mm to 500 mm. When a metallic roll is used as the pressing roll, the surface thereof may be subjected to a plating treatment such as chrome plating, copper plating, nickel plating, or Ni-P plating. Further, the surface of the pressing roll may be a mirror surface, or may be a transfer surface on which unevenness such as embossing is fined if it is not necessary to transfer with high accuracy.

  The transfer mold is pressed against the surface of the continuous resin sheet, and the surface shape is transferred to the continuous resin sheet as a reverse mold.

  In the manufacturing method of the present invention, the transfer mold is made of an organic material. The organic material only needs to have heat resistance capable of maintaining the shape of the transfer mold even when repeatedly pressed against a continuous resin sheet immediately after being extruded from the die in a heated and melted state. For example, a thermosetting resin, A resin such as a thermoplastic resin is used.

  Examples of the thermosetting resin include phenol resin, epoxy resin, melamine resin, urea resin, polyimide resin (PI resin), unsaturated polyester resin, and alkyd resin.

  Examples of the thermoplastic resin include styrene resin, acrylic resin, polyethylene resin, polypropylene resin, cyclic olefin polymer resin, allylonitrile-butadiene-styrene resin (ABS resin), polyethylene terephthalate resin (PET resin), and polycarbonate resin. (PC resin), polyether sulfone resin (PES resin), thermoplastic polyimide resin (PI resin), and the like. Preferably, a thermoplastic resin having a Vicat softening point (JIS K7206-1999 A50) higher than the Vicat softening point of the resin extruded from the die by 40 ° C. or more is a crosslinked thermoplastic resin.

  Examples of the transfer mold include a film (organic material film) made of an organic material having a reverse shape of a target shape formed on the surface. The thickness of the organic material film is usually 0.05 mm to 5 mm, and when the organic material film having a thickness of less than 0.05 mm is used as a transfer mold, when inserted between the pressing roll and the continuous resin sheet, The pressure for transferring the shape of the transfer mold to the continuous resin sheet is not sufficiently transmitted, and the transfer tends to be insufficient.

  As shown in FIGS. 1 and 2, the transfer mold made of such an organic material film can be used by continuously transporting it continuously with a continuous resin sheet. In this case, the number of pressing rolls for transferring the transfer mold may be two, that is, the first pressing roll 4a and the second pressing roll 4b as shown in FIG. Three including the three press rolls 4c may be sufficient. When the transfer mold is sandwiched between the pressing roll and the continuous resin sheet, it may be between the first pressing roll and the continuous resin sheet as long as the surface on which the transfer mold is applied is in contact with the continuous resin sheet surface. It may be between the second pressing roll and the continuous resin sheet.

  In the present invention, a roll (touch roll) in contact with the continuous resin sheet and the transfer mold may be provided as long as the roll is irrelevant in terms of transfer technology for assisting conveyance or adhesion between the continuous resin sheet and the pressing roll. Such a roll may be installed between the die and the pressing roll, or may be installed at a position where the continuous resin sheet is in contact with the second pressing roll. Further, as shown in FIG. 1, a touch roll 6 is installed at a position in contact with the first pressing roll 4a, or a desired contact with the transfer mold to peel the continuous resin sheet and the transfer mold via the pressing roll 4 is desired. You may install the touch roll 7 in a position.

  The transfer mold may be cut simultaneously with the continuous resin sheet and then cut together with the continuous resin sheet by a cutting machine normally located on the downstream side of the manufacturing apparatus. After the shape transfer surface is cooled below the Vicat softening point, the transfer mold may be peeled off and continuously wound up by a winding roll. In addition, simultaneous conveyance means conveying without making a shift | offset | difference in the state which the transfer mold | type and the continuous resin sheet contact | adhered.

  The winding speed of the continuous resin sheet depends on the size of the extruder and pressing roll for molding the resin sheet, or the thickness of the resin sheet to be molded, but as one aspect, an extruder with a screw diameter of φ40 mm, a pressing diameter of φ200 mm When a roll device is used, the winding speed is preferably 0.3 to 0.8 rpm, more preferably 0.45 to 0.65 rpm. If the speed is less than 0.3 rpm, the production amount may not be sufficiently secured. If the speed exceeds 0.8 rpm, the continuous resin sheet cannot be sufficiently cooled until the continuous resin sheet is peeled off from the transfer mold. The accuracy of the shape transferred to the sheet may not be maintained.

  The surface temperature of the pressing roll is desirably lower than the discharge temperature of the resin sheet, preferably 70 ° C to 120 ° C, more preferably 75 ° C to 100 ° C. If the surface temperature of these rolls is less than 70 ° C., the surface temperature of the transfer mold is low, so the fluidity of the resin on the surface of the continuous resin sheet is poor, and as a result, the transfer rate may deteriorate. On the other hand, when the temperature exceeds 120 ° C., the continuous resin sheet cannot sufficiently cool down until the resin sheet and the transfer mold are peeled off, and the accuracy of the shape transferred to the continuous resin sheet may not be maintained.

  As the surface shape of the transfer mold, for example, a shape in which a large number of V-grooves are provided in parallel can be mentioned. The apex angle of the V-groove is usually 160 ° or less, and is usually preferably 40 ° or more from the viewpoint of easy preparation. The depth (H) of the V-groove is usually 10 μm or more and usually 500 μm or less because it is easy to produce. The pitch of the V-groove means the distance between the deepest portions of adjacent V-grooves, and is usually 10 μm or more, preferably 50 μm or more in that a transfer mold can be easily prepared. This is suitable for a case where the depth is 10 μm or more and the pitch is 500 μm or less.

  Thus, the target surface shape transfer resin sheet can be produced by continuously transferring the surface shape of the transfer mold onto the continuous resin sheet. The obtained surface shape transfer resin sheet is usually further cooled and then cut into single sheets, and used as, for example, a prism sheet constituting a liquid crystal display device. Further, when a resin to which a light diffusing agent is added is used, it is used as a light diffusing plate whose shape is transferred to the surface.

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

Example 1
<Resin material used in Examples>
As a continuous resin sheet, a sheet having a two-layer three-layer structure was prepared using the following intermediate layer resin and surface layer resin.

Intermediate layer resin: Styrene resin pellets (“HRM40” manufactured by Toyo Styrene Co., Ltd., refractive index 1.59, Vicat softening point 106.8 ° C.)
Surface layer resin: Styrene-methyl methacrylate copolymer resin (“MS200NT” manufactured by Nippon Steel Chemical Co., Ltd., styrene unit 80% by mass, methyl methacrylate unit 20% by mass, refractive index 1.57, pellet form, Vicat softening point 102.1 ° C)
<Manufacture of surface shape transfer sheet>
After the resin is supplied from the resin charging port 2 and melted and kneaded in the kneader 10 capable of kneading the two types separately, the intermediate layer resin and the two-type three-layer distribution type feed block (manufactured by Tanabe Plastics) The surface layer resin is supplied, the intermediate layer resin becomes the intermediate layer, and the surface layer resin is sent to the die 3 (T die) so as to have a structure laminated on both surfaces of the intermediate layer. A continuous resin sheet 1 having a three-layer structure in which surface layers were laminated on both surfaces of the layer was obtained continuously.

  The intermediate layer resin was supplied to a vented single screw extruder (manufactured by Tanabe Plastics Co., Ltd.) having a screw diameter of 40 mm, heated and melted, and supplied to the above-mentioned two-type three-layer distribution type feed block at 250 ° C. The resin for the surface layer was supplied to a single screw extruder with a screw diameter of 20 mm (manufactured by Tanabe Plastics Co., Ltd.), heated and melted, and supplied at 250 ° C. to the above-described two-type three-layer distribution type feed block.

  A T-die having a width of 250 mm and a lip interval of 2.5 mm was used. The obtained continuous resin sheet had a width of 249 mm and a thickness of 2.0 mm.

  As shown in FIG. 1, when the continuous resin sheet 1 coextruded from the die 3 (T die) is continuously sandwiched and conveyed between the first pressing roll 4a and the second pressing roll 4b. The transfer mold 9 (organic material film) unwound from the unwinding roll 5 and sandwiched between the touch roll 6 and the first pressing roll 4a and conveyed in close contact with the first pressing roll 4a is continuous with the first pressing roll 4a. After sandwiching and pressing between the resin sheets 1, they were conveyed simultaneously with the continuous resin sheet 1. The continuous resin sheet 1 and the transfer mold 9 that are simultaneously conveyed are cooled over time, and the transfer mold 9 is separated from the continuous resin sheet 1 at the position of the touch roll 7 shown in FIG. A surface shape transfer resin sheet A to which the surface shape of the transfer mold 9 was transferred was obtained. At this time, the surface temperature of the continuous resin sheet 1 on the transfer mold 9 side at the position a immediately before the continuous resin sheet 1 and the transfer mold 9 contact each other is 255 ° C., and immediately after the transfer mold 9 indicated by f in FIG. The surface temperature of the shape surface of the surface shape transfer resin sheet A was 86 ° C. Moreover, the production speed of the surface shape transfer resin sheet A at this time is 0.55 m / min, and the obtained surface shape transfer resin sheet A has a thickness of 0.05 mm on both sides of the intermediate layer having a thickness of 1.60 mm. The surface layer was of a multilayer structure with a total thickness of 1.70 mm.

  As the transfer mold 9 (organic material film), an acrylic resin layer is laminated on one side of a polyethylene terephthalate resin film to a thickness of 230 μm. An isosceles triangle V groove having a height of 24 μm provided with a pitch of 48 μm was used. The transfer mold 9 is used so as to be conveyed simultaneously with the continuous resin sheet so that the V-groove of the transfer mold 9 is perpendicular to the extrusion direction of the continuous resin sheet. The V-groove of the organic material film) maintained the same shape as before the start of production.

  The obtained surface shape transfer resin sheet A has a shape corresponding to the transfer mold transferred to the surface, the transfer rate is 98%, and the striped appearance defect attached to the surface when peeling from the transfer mold ( (Tack mark) was not seen.

  As the first pressing roll 4a, a metal roll having a diameter of 200 mm and a mirror-finished surface was used at 95 ° C. As the second pressing roll 4b, a metal roll having a diameter of 200 mm and a mirror-finished surface was used at 97 ° C. As the third pressing roll 4c, a metal roll having a diameter of 200 mm and a mirror-finished surface was used at 110 ° C.

<Evaluation of surface shape transfer resin sheet (transfer rate)>
After cutting the obtained surface shape transfer resin sheet A and mirror-finishing the cross section, the depth of the prism transferred to the surface (observed with “VK-8500” manufactured by KEYENCE Inc.) N) is measured, and from the depth (H) of the prism in the transfer mold 9, the formula (1)
β = N / H × 100 (%) (1)
To calculate the transfer rate.

(Example 2)
A surface shape transfer resin sheet B was obtained in the same manner as in Example 1 except that the width of the continuous resin sheet was 258 mm and the thickness was 1.5 mm.

  At this time, the surface temperature of the continuous resin sheet 1 on the transfer mold 9 side at the position a immediately before the continuous resin sheet 1 and the transfer mold 9 shown in FIG. 1 contact each other is 260 ° C., and the transfer indicated by f in FIG. The surface temperature of the shape surface of the surface shape transfer resin sheet B immediately after the mold 9 was peeled was 78 ° C. Moreover, the production speed of the surface shape transfer resin sheet B at this time is 0.65 m / min, and the obtained surface shape transfer resin sheet B has a thickness of 0.05 mm on both surfaces of the intermediate layer having a thickness of 1.13 mm. The surface layer had a multilayer structure with a total thickness of 1.23 mm.

  As with Example 1, the temperature conditions of the pressing rolls were set such that the first pressing roll 4a was 95 ° C, the second pressing roll was 97 ° C, and the third pressing roll was 110 ° C.

  The transfer rate of the obtained surface shape transfer resin sheet B was 91%, and no tack mark was seen on the surface.

(Example 3)
As shown in FIG. 2, the transfer mold 9 (organic material film) was sandwiched between the second pressing roll 4b and the continuous resin sheet 1 and pressed, and thereafter the continuous resin sheet 1 was transported simultaneously. The surface shape transfer resin sheet C was obtained in the same manner as in Example 1.

  At this time, the surface temperature of the continuous resin sheet 1 on the transfer mold 9 side at the position b immediately before the continuous resin sheet 1 and the transfer mold 9 contact each other is 249 ° C., and the transfer mold 9 indicated by g in FIG. The surface temperature of the shape surface of the surface shape transfer resin sheet C immediately after the heating was 81 ° C. Moreover, the production speed of the surface shape transfer resin sheet C at this time is 0.55 m / min, and the obtained surface shape transfer resin sheet C has a thickness of 0.05 mm on both surfaces of the intermediate layer having a thickness of 1.57 mm. The surface layer was of a multilayer structure with a total thickness of 1.67 mm.

  As in Example 1, the temperature conditions of the pressing rolls were set such that the first pressing roll 4a was 95 ° C, the second pressing roll 4b was 97 ° C, and the third pressing roll 4c was 110 ° C.

  The transfer rate of the obtained surface shape transfer resin sheet C was 86%, and no tack mark was seen on the surface.

Example 4
A surface shape transfer resin sheet D was obtained in the same manner as in Example 3 except that the width of the continuous resin sheet was 258 mm and the plate thickness was 1.5 mm.

  At this time, the surface temperature on the transfer mold 9 side of the continuous resin sheet 1 at the position b immediately before the continuous resin sheet 1 and the transfer mold 9 contact each other is 258 ° C., and the transfer mold 9 indicated by g in FIG. The surface temperature of the shape surface of the surface shape transfer resin sheet D immediately after the heating was 77 ° C. Moreover, the production speed of the surface shape transfer resin sheet D at this time is 0.65 m / min, and the obtained surface shape transfer resin sheet D has a thickness of 0.05 mm on both surfaces of the 1.11 mm thick intermediate layer. The surface layer was of a multilayer structure with a total thickness of 1.21 mm.

  As in Example 3, the temperature conditions of the respective press rolls were set such that the first press roll 4a was 95 ° C, the second press roll 4b was 97 ° C, and the third press roll 4c was 110 ° C.

  The transfer rate of the obtained surface shape transfer resin sheet D was 98%, and no tack mark was seen on the surface.

(Comparative Example 1)
As shown in FIG. 3, immediately after the transfer mold 9 (organic material film) is sandwiched between the first pressing roll 4a and the continuous resin sheet 1 and pressed, the continuous resin sheet 1 and the transfer mold 9 are peeled off. The surface shape transfer resin sheet E was obtained in the same manner as in Example 1 except for the above.

  At this time, the surface temperature on the transfer mold 9 side of the continuous resin sheet 1 at the position a immediately before the continuous resin sheet 1 and the transfer mold 9 contact each other is 261 ° C., and the transfer mold 9 indicated by c in FIG. The surface temperature of the shape surface of the surface shape transfer resin sheet E immediately after the heating was 141 ° C. Moreover, the production speed of the surface shape transfer resin sheet E at this time is 0.55 m / min, and the obtained surface shape transfer resin sheet E has a thickness of 0.05 mm on both surfaces of the intermediate layer having a thickness of 1.56 mm. The surface layer was of a multilayer structure with a total thickness of 1.66 mm.

  As in Example 1, the temperature conditions of the pressing rolls were set such that the first pressing roll 4a was 95 ° C, the second pressing roll 4b was 97 ° C, and the third pressing roll 4c was 110 ° C.

  The transfer rate of the obtained surface shape transfer resin sheet D was 53%, and many tack marks were seen on the surface.

(Comparative Example 2)
As shown in FIG. 4, immediately after the transfer mold 9 (organic material film) was sandwiched between the second pressing roll 4b and the continuous resin sheet 1 and pressed, the continuous resin sheet 1 and the transfer mold 9 were peeled off. The surface shape transfer resin sheet F was obtained in the same manner as in Example 3.

  At this time, the surface temperature on the transfer mold 9 side of the continuous resin sheet 1 at the position b immediately before the continuous resin sheet 1 and the transfer mold 9 contact each other is 259 ° C., and the transfer mold 9 indicated by d in FIG. The surface temperature of the shape surface of the surface shape transfer resin sheet F immediately after the heating was 119 ° C. Further, the production speed of the surface shape transfer resin sheet F at this time is 0.55 m / min, and the obtained surface shape transfer resin sheet F has a thickness of 0.05 mm on both surfaces of the intermediate layer having a thickness of 1.57 mm. The surface layer was of a multilayer structure with a total thickness of 1.67 mm.

  As in Example 3, the temperature conditions of the respective press rolls were set such that the first press roll 4a was 95 ° C, the second press roll 4b was 97 ° C, and the third press roll 4c was 110 ° C.

  The transfer rate of the obtained surface shape transfer resin sheet F was 73%, and many tack marks were seen on the surface.

(Comparative Example 3)
As shown in FIG. 5, the transfer mold 9 (organic material film) was sandwiched between the third pressing roll 4 c and the continuous resin sheet 1 and pressed, and then transferred simultaneously with the continuous resin sheet 1. The surface shape transfer resin sheet G was obtained in the same manner as in Example 1.

  At this time, the surface temperature of the continuous resin sheet 1 on the transfer mold 9 side at the position e immediately before the continuous resin sheet 1 and the transfer mold 9 contact each other is 122 ° C., and the transfer mold 9 indicated by f in FIG. The surface temperature of the shape surface of the surface shape transfer resin sheet G immediately after the heating was 112 ° C. Moreover, the production speed of the surface shape transfer resin sheet G at this time is 0.55 m / min, and the obtained surface shape transfer resin sheet G has a thickness of 0.05 mm on both surfaces of the intermediate layer having a thickness of 1.71 mm. The surface layer had a multilayer structure with a total thickness of 1.81 mm.

  As in Example 1, the temperature conditions of the pressing rolls were set such that the first pressing roll 4a was 95 ° C, the second pressing roll 4b was 97 ° C, and the third pressing roll 4c was 110 ° C.

  The transfer rate of the obtained surface shape transfer resin sheet G was 5%, and no tack mark was seen on the surface.

(Comparative Example 4)
As shown in FIG. 6, the transfer mold 11 (the same organic material film as in Example 1) is wound around and fixed to the second pressing roll 4a in advance, and the continuous resin sheet 1 that is continuously conveyed is transferred to the first pressing roll 4a. A surface shape transfer resin sheet H was obtained in the same manner as in Example 1 except that the sheet was pressed with the second pressing roll 4b and pressed with the second pressing roll 4b and the third pressing roll 4c.

  At this time, the surface temperature of the continuous resin sheet 1 on the transfer mold 11 side at the position b immediately before the continuous resin sheet 1 and the transfer mold 11 contact each other is 258 ° C., and the transfer mold 11 indicated by d in FIG. 6 is peeled off. The surface temperature of the shape surface of the surface shape transfer resin sheet H immediately after the treatment was 123 ° C. Moreover, the production speed of the surface shape transfer resin sheet H at this time is 0.55 m / min, and the obtained surface shape transfer resin sheet H has a thickness of 0.05 mm on both surfaces of the intermediate layer having a thickness of 1.83 mm. The surface layer had a multilayer structure with a total thickness of 1.93 mm.

  As in Example 1, the temperature conditions of the pressing rolls were set such that the first pressing roll 4a was 95 ° C, the second pressing roll 4b was 97 ° C, and the third pressing roll 4c was 110 ° C.

  The transfer rate of the obtained surface shape transfer resin sheet H was 62%, and many tack marks were seen on the surface.

  Table 1 shows the conditions and results of Examples and Comparative Examples.

  As is apparent from Table 1, a transfer mold made of an organic material is used, and a first mold for sandwiching the transfer mold between the continuous resin sheet and the first pressing roll or the second pressing roll, and the transfer mold And a second step of bringing the continuous resin sheet into close contact with each other and a third step of peeling the transfer mold from the continuous resin sheet in a state where the surface temperature of the continuous resin sheet is equal to or lower than the Vicat softening point. The surface shape transfer resin sheets A to D of Examples 1 to 4 manufactured by the above manufacturing method have a very high transfer rate compared to the surface shape transfer resin sheets E to H obtained in Comparative Examples 1 to 4, It can also be seen that this is a preferable transfer result in which no tack mark is observed. Moreover, in Examples 1-4, it turns out that it is excellent in productivity from the favorable production rate and the transfer rate of the surface shape transfer resin sheet obtained.

  It should be understood that the embodiments and examples disclosed herein are illustrative and non-restrictive in every respect. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

It is a schematic diagram which shows the manufacturing method and manufacturing apparatus of the surface shape transfer resin sheet in Example 1 and 2. It is a schematic diagram which shows the manufacturing method and manufacturing apparatus of the surface shape transfer resin sheet in Example 3 and 4. It is a schematic diagram which shows the manufacturing method and manufacturing apparatus of the surface shape transfer resin sheet in the comparative example 1. It is a schematic diagram which shows the manufacturing method and manufacturing apparatus of the surface shape transfer resin sheet in the comparative example 2. It is a schematic diagram which shows the manufacturing method and manufacturing apparatus of the surface shape transfer resin sheet in the comparative example 3. It is a schematic diagram which shows the manufacturing method and manufacturing apparatus of the conventional surface shape transfer resin sheet.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 Continuous resin sheet, 2 resin inlet, 3 die | dye, 4 press roll, 4a 1st press roll, 4b 2nd press roll, 4c 3rd press roll, 5 unwinding roll, 6,7 touch roll, 8 winding roll 9,11 Transfer type, 10 Kneading machine.

Claims (3)

A sheet production process for producing a continuous resin sheet by continuously extruding a resin from a die in a heated and melted state;
A pressing step of sandwiching the continuous resin sheet and the transfer mold continuously fed by the feeding roll between the first pressing roll and the second pressing roll,
The pressing step includes a first step of sandwiching the transfer mold between the continuous resin sheet and the first pressing roll or the second pressing roll;
A second step of transporting the transfer mold and the continuous resin sheet in close contact with each other;
A third step of peeling the transfer mold from the continuous resin sheet in a state where the surface temperature of the continuous resin sheet is equal to or lower than the Vicat softening point;
The transfer mold is a method for producing a surface shape transfer resin sheet made of an organic material.   The method for producing a surface shape transfer resin sheet according to claim 1, further comprising a step of continuously winding the peeled transfer mold after the third step. Transfer that transfers the surface shape to the continuous resin sheet by sandwiching the continuous resin sheet between a die that continuously extrudes the resin in a heated and melted state to produce a continuous resin sheet, a pressure roll, and the pressure roll. A mold, a feed roll for continuously feeding the transfer mold, and a winding roll for continuously winding the transfer mold while peeling the transfer mold from the continuous resin sheet,
An apparatus for producing a surface shape transfer resin sheet, wherein the transfer mold is made of an organic material.

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