JP2009220555A - Manufacturing method of surface pattern transfer resin sheet and its manufacturing apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of surface pattern transfer resin sheets by precisely and quickly transferring the surface pattern of a transfer mold. <P>SOLUTION: The manufacturing method of surface pattern transfer resin sheets includes a sheet-manufacturing step to manufacture a continuous resin sheet by continuously extruding a resin molten by heat from a die, a first pressing step to put the continuous resin sheet between a first press roll and a second press roll, a transportation step to transport the continuous resin sheet with the second press roll to which the sheet sticks, and a second pressing step to put the transported continuous resin sheet between the second press roll and a third press roll. The third press roll is provided with a transfer mold on the surface. The transfer mold has a plurality of depressions. The pitch spacing between the depressions is 50-500 μm. The depth of the depressions is 3-500 μm. The pattern of the transfer mold arranged on the surface of the third press roll is transferred onto the continuous resin sheet in the second pressing step. <P>COPYRIGHT: (C)2010,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 the method using the extruder, as shown in FIG. 4, the continuous resin sheet 2 continuously extruded from the die 4 is sandwiched between the first pressing roll 5a and the second pressing roll 5b, and the second It conveys along the surface of the press roll 5b, and is pinched | interposed between the 2nd press roll 5b and the 3rd press roll 5c. Here, in Patent Document 1, a transfer mold is provided on the second pressing roll 5b, and the continuous resin sheet 2 is sandwiched between the first pressing roll 5a and the second pressing roll 5b provided with the transfer mold. Thus, a method has been proposed in which the surface shape of the transfer mold is transferred to the continuous resin sheet 2 to obtain a surface shape transfer resin sheet.

However, in such a conventional manufacturing method, 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, and it cannot be said that the method is necessarily high in productivity. .
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.

  As a result of intensive studies to achieve the above object, the present inventor has determined that the surface shape of the transfer mold can be accurately and quickly transferred by specifying the surface shape and transfer position of the transfer mold. The headline, the present invention has been reached.

  That is, the present invention provides a sheet manufacturing process in which a continuous resin sheet is manufactured by continuously extruding a resin from a die in a heated and melted state, and a first pressing process in which the continuous resin sheet is sandwiched between a first pressing roll and a second pressing roll. And a conveying step for conveying the continuous resin sheet while being in close contact with the second pressing roll, and a shape on the surface including the second pressing step for sandwiching the conveyed continuous resin sheet between the second pressing roll and the third pressing roll. The third pressing roll has a transfer mold on its surface, and the transfer mold is composed of a plurality of recesses, and the pitch interval between the recesses is 50 μm to 500 μm. The groove depth of the recess is 3 μm to 500 μm, and the continuous resin sheet is a surface shape in which a transfer mold provided on the surface of the third pressing roll is transferred in the second pressing step. The method for producing a transfer resin sheet.

  The recess preferably has a substantially semicircular cross section. Moreover, the said recessed part can be made into the shape whose cross-sectional shape is a triangle and whose vertex angle of this triangle is 40 degrees-160 degrees.

  In the present invention, the surface shape is continuously formed by sandwiching the continuous resin sheet between a die for producing a continuous resin sheet by continuously extruding a heat-melted resin, a pressing roll, and the pressing roll. An apparatus for producing a surface shape transfer resin sheet including a transfer roll for transferring to a resin sheet, wherein the transfer roll has a plurality of recesses formed on the surface thereof, and the pitch interval between the recesses is 50 μm to 500 μm. The present invention relates to an apparatus for producing a surface shape transfer resin sheet having a groove depth H of 3 μm to 500 μm.

  In the manufacturing apparatus, the recess preferably has a substantially semicircular cross section. Moreover, the said recessed part can be made into the shape whose cross-sectional shape is a triangle and whose vertex angle of this triangle is 40 degrees-160 degrees.

  According to the manufacturing method and the manufacturing apparatus of the present invention, the surface shape of the transfer mold can be transferred quickly and accurately, and the target surface shape transfer resin sheet can be manufactured with high productivity.

  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.

<Production apparatus for surface shape transfer resin sheet>
In the production apparatus of the present invention, the surface shape of the die is obtained by sandwiching the continuous resin sheet between the die that obtains a continuous resin sheet by continuously extruding the heated and melted resin, the press roll, and the press roll. And a transfer roll for transferring to a continuous resin sheet. In FIG. 2, an example of the manufacturing apparatus of the surface shape transcription | transfer resin sheet of this invention is shown typically. The apparatus shown in FIG. 2 includes a die 4 that continuously extrudes a heat-melted resin to obtain a continuous resin sheet 2 and a pressing roll 5. The press roll 5 includes a first press roll 5a for pressing the continuous resin sheet, a second press roll 5b, and a third press roll 5c, and includes a transfer die 6 on the surface of the third press roll 5c. A desired surface shape can be transferred to the continuous resin sheet 2 by sandwiching the continuous resin sheet 2 between the second press roll 5 b and the third press roll 5 c provided with the transfer die 6.

  In addition to the pressing roll 5, a roll that is technically irrelevant to the present invention may be provided. Such a roll is in contact with the continuous resin sheet. For example, a guide roll (touch roll) for conveying the continuous resin sheet to the first pressing roll, or a continuous resin sheet is in close contact with the second pressing roll. For example, a touch roll can be cited.

<Method for producing surface shape transfer resin sheet>
The method for producing a surface shape transfer resin sheet according to 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 the first resin roll and the second resin roll. A first pressing step sandwiched between the second pressing roll, a transporting step for transporting the continuous resin sheet while being in close contact with the second pressing roll, and a second pressing sandwiching the transported continuous resin sheet between the second pressing roll and the third pressing roll. Process.

<Sheet manufacturing process>
In the sheet manufacturing process, a continuous resin sheet is manufactured 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, the thermosetting resin which hardens | cures 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 obtained surface shape transfer resin sheet 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 diffusing plate, what is necessary is just to be 1.0 mm-3.0 mm.

  The continuous resin sheet may be a single layer or 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, and in the case of two or more layers, two or more types of resin are used. You may supply to a die | dye and co-extrusion in the 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.

<First pressing step>
The continuous resin sheet obtained by the said sheet manufacturing process is pinched | interposed simultaneously by the 1st press roll 5a and the 2nd press roll 5b by a 1st press process, as shown in FIG. As the first pressing roll and the second 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 metal rolls are used as the first and second pressing rolls, the surface thereof may be subjected to plating treatment such as chrome plating, copper plating, nickel plating, nickel-phosphorus plating, or the like. Further, the surface of the pressing roll may be a mirror surface, or may be a transfer surface provided with unevenness such as embossing if it is not necessary to transfer accurately.

<Conveying process>
A conveyance process is a process of conveying according to rotation of the 2nd press roll in the state where the continuous resin sheet was stuck to the 2nd press roll.

  In the first pressing step and the conveying step, the continuous resin sheet has a temperature lower than that of the heated and melted state extruded from the die due to cooling due to contact with the pressing roll and cooling due to contact with outside air. Thus, the continuous resin sheet is conveyed in a state where the temperature is lower than that in the heat-melted state, and is subjected to the next second pressing step. In addition, it is desirable that the pressing roll has a temperature adjusting function and can be adjusted to a desired temperature.

<Second pressing step>
In the second pressing step, the conveyed continuous resin sheet is sandwiched and pressed between the second pressing roll 5b and the third pressing roll 5c as shown in FIG. In the second pressing step, the transfer mold 6 provided on the surface of the third pressing roll 5c is transferred to the continuous resin sheet 2. In the present invention, the third pressing roll provided with the transfer mold is also referred to as a transfer roll. The transfer mold provided on the surface of the transfer roll is pressed against the surface of the continuous resin sheet and transferred to the continuous resin sheet with the surface shape as the reverse mold.

  In the second pressing step, the continuous resin sheet is pressed again by the second pressing roll and the transfer roll, peeled off from the second pressing roll, is in close contact with the transfer roll, and is then conveyed according to the rotation of the transfer roll. . At that time, if the continuous resin sheet is sufficiently in close contact with the transfer roll without being pressed between the second press roll and the transfer roll, the surface temperature of the continuous resin sheet is between the second press roll and the transfer roll. May be slightly larger than the thickness of the continuous resin sheet.

  The transfer mold is composed of a plurality of recesses provided on the surface of the transfer roll, and the pitch interval between the recesses is usually 10 μm or more, preferably 50 μm or more because the transfer mold can be easily produced. In the method and the manufacturing apparatus, it is preferable when the pitch interval of the recesses is 200 μm to 500 μm, and the groove depth of the recesses is 3 μm to 500 μm. FIG. 1 shows an example of the transfer mold surface. As shown in FIG. 1, the plurality of recesses are provided in parallel at regular intervals d. The pitch interval (P) of the recesses refers to the distance between the groove portions of the adjacent recesses, and the groove depth (H) of the recesses refers to the distance from the transfer roll surface circumference to the groove portion of the recesses.

  Examples of the shape of the transfer mold include a substantially semicircular recess (substantially semicircular recess) having a substantially semicircular shape as shown in FIG. The pitch interval (P) between adjacent semicircular recesses is usually 10 μm or more, preferably 50 μm or more, from the viewpoint of easy production of the transfer roll. The production method of the present invention has a pitch interval (P) of 200 μm. It is suitable in the range of ˜500 μm. The groove depth (H) of the substantially semicircular recess is suitable for the production method of the present invention in the range of 3 μm to 500 μm. Here, the pitch interval (P) and the groove depth (H) in the transfer mold are not necessarily constant in the entire transfer mold, and include cases where they are different between adjacent recesses. Further, the substantially semicircle is not limited to a shape having a semicircular cross-section as shown in FIG. 1. For example, as shown in FIG. 3, a cylindrical body is parallel to its axis, The shape may be any arc shape of the cross section when cut by a plane that does not include the axis, or the shape of the cross section is a semi-elliptical arc shape, a flat curved shape that is a part of the semi-elliptical arc shape, etc. It may be. The “substantially semicircular concave portion” includes such a concave portion having a substantially semicircular cross section.

  The shape of the transfer mold provided on the surface of the transfer roll is not limited to a groove having a substantially semicircular cross-sectional shape. For example, many V-shaped grooves (V-shaped recesses) are parallel to the circumference of the transfer roll. The provided shape is mentioned. In this case, the cross-sectional shape is a triangle. The apex angle of the V-shaped groove (triangle) is usually 160 ° or less, and usually 40 ° or more in terms of easy production. The pitch interval (P) of the V-shaped grooves (triangles) is usually 10 μm or more, preferably 50 μm or more in that the transfer roll can be easily manufactured. However, the production method of the present invention has a pitch interval (P) of It is suitable in the range of 200 μm to 500 μm.

  As a method for producing the transfer mold, the surface of the transfer roll made of stainless steel, steel, or the like is subjected to plating treatment such as chrome plating, copper plating, nickel plating, nickel-phosphorous plating, and then applied to the plated surface. The shape may be processed by performing removal processing using a diamond tool or a metal grindstone, laser processing, or chemical etching, but is not particularly limited to these methods.

  Further, the surface of the transfer roll may be subjected to plating treatment such as chromium plating, copper plating, nickel plating, nickel-phosphorous plating, etc. at a level that does not impair the accuracy of the surface shape after the transfer mold is formed.

  By transferring the surface shape (transfer mold) of the transfer roll to the continuous resin sheet in the second pressing step, the target surface shape transfer resin sheet can be produced. 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. In addition, when a resin to which a light diffusing agent is added is used, it can be suitably used as a light diffusing plate whose shape is transferred to the surface.

  EXAMPLES Hereinafter, although an Example is given and this invention is demonstrated in detail, this invention is not limited to these.

<Raw materials>
Translucent resin R1: Styrene resin (Toyo Styrene “HRM40”, refractive index 1.59)
Translucent resin R2: MS resin (Nippon Steel Chemical "MS200NT", refractive index 1.57, styrene / methyl methacrylate = 80 parts by mass / 20 parts by mass)
Crystalline resin C1: Propylene-ethylene random copolymer resin (manufactured by Sumitomo Chemical Co., Ltd., “FSX20L8”, propylene unit content 99 mass% or more, ethylene unit content 1 mass% or less)
UV absorber: benzotriazole UV absorber; 2,2′-methylenebis [6-2H-benzotriazol-2-yl] -4- (1,1,3,3-tetramethylbutyl) phenol (manufactured by ADEKA) “Adeka Stub LA31”)
Light stabilizer: Hindered amine light stabilizer (manufactured by Ciba Specialty Chemicals Co., Ltd., “Tinuvin XT 855FF”)
Nucleating agent: Organophosphate nucleating agent; 2,2-methylenebis (4,6-di-tert-butylphenyl) sodium phosphate (manufactured by ADEKA, “ADK STAB NA11”)
Antioxidant: Phosphorous antioxidant; Tris (2,4-di-t-butylphenyl) phosphite (Ciba Specialty Chemicals Co., Ltd., “Irg168”)
<Master batch>
Surface master batch MA: 98.7 parts by mass of crystalline resin C1, 0.5 parts by mass of UV absorber (LA31), 0.5 parts by mass of light stabilizer (Tinvin XT 855FF), nucleating agent (ADK STAB NA11) 1 part by mass and 0.2 part by mass of an antioxidant (Irg168) were dry blended to obtain a blend. This blend was put into a hopper of a 65 mm twin screw extruder, melt-mixed in a cylinder at 225 ° C. to 260 ° C., and then extruded into a strand to be pelletized to obtain a pellet-shaped surface layer master batch MA.

  Intermediate layer master batch MB: 94.0 parts by mass of crystalline resin C1, 2.0 parts by mass of nucleating agent (ADK STAB NA11), 4.0 parts by mass of antioxidant (Irg168) were dry blended to obtain a blended product. . This blend was put into a hopper of a 65 mm twin screw extruder, melted and mixed in a cylinder at 225 ° C. to 260 ° C., then extruded into a strand shape and pelletized to obtain a pellet-shaped intermediate layer master batch MB.

<Transfer type>
As the transfer mold, semicircular recessed grooves A to D having the shapes described in Table 1 or V recessed grooves E to H having the shapes described in Table 3 were used.

  In Table 1 below, P, d, and H indicate distances of the cross-sectional shape of the replica of the semicircular recess applied to the transfer mold shown in FIG. 1, and “pitch interval P” indicates the groove portion of the adjacent recess. The distance “flat portion width d” is the width of the flat portion between adjacent recesses, and “groove depth H” is the distance between the transfer mold surface circumference and the groove portion. The “aspect ratio A” is the ratio of the groove depth H to the pitch interval P and H / P. Each of the semicircular recesses A to D has a cylindrical lens (cylindrical lens) shape, and each groove is formed in parallel at equal intervals (pitch interval P). As shown in FIG. 3, the cylindrical lens 8 is a lens having at least one surface shaped like a part of a cylinder. For example, the cylindrical lens 8 has a shape obtained by dividing a cylinder into two in the axial direction. Say.

  In Table 3 below, P, H, and Θ represent distances or angles of the cross-sectional shape of the replica of the V-shaped recess applied to the transfer mold shown in FIG. 5, and “pitch interval P” is the adjacent recess. The groove-to-groove distance, “groove depth H” indicates the vertical distance to the apex angle of the recess, and “Θ” indicates the apex angle (vertex angle) of the V-shaped recess. Each of the V-shaped grooves E to H has a prism lens (rectangular lens) shape, and the grooves are formed in parallel at equal intervals (pitch intervals P) as shown in FIG. The replica shown in FIG. 5 is an inverted shape of the obtained sheet.

Tables 2 and 4 show the manufacturing conditions of each Example and Comparative Example and the shape transfer rate T (%) of the obtained surface shape transfer resin sheet. The shape transfer rate T (%) is defined by the following formula (1). In Formula (1), the concave groove depth of the cross-sectional shape of the molded sheet is an actual measurement value of the maximum groove depth of the concave portion of the obtained surface shape transfer resin sheet.
Shape transfer rate T (%) = recessed groove depth of cross-sectional shape of molded sheet / recessed groove depth of replica cross-sectional shape H × 100 (1)

Example 1
The translucent resin R1 is melt-kneaded by a first extruder having a temperature in the cylinder of 190 ° C. to 250 ° C. and supplied to the feed block. On the other hand, the translucent resin R2 is melt-kneaded by a second extruder having a temperature in the cylinder of 190 ° C. to 250 ° C. and supplied to the feed block.

  The translucent resin R1 supplied from the first extruder to the feed block becomes a main layer, and the translucent resin R2 supplied from the second extruder to the feed block becomes a surface layer (both surfaces of the main layer). A surface shape transfer resin sheet (1) comprising a three-layer laminate having a thickness of 2.0 mm is subjected to coextrusion molding at an extrusion resin temperature of 250 ° C. and pressing and cooling with a pressing roll 5 shown in FIG. Was made.

  In the production of the surface shape transfer resin sheet (1), in order to press the continuous resin sheet discharged from the extruder, a first pressing roll 5a is disposed on the upper side of the sheet, and a second pressing roll 5b is disposed on the lower side. After being pressed by the first pressing roll 5a and the second pressing roll 5b, it is conveyed in close contact with the surface of the second pressing roll 5b, and cooled at that time.

  Thereafter, the sheet is pressed by the second pressing roll 5b and a third pressing roll 5c (transfer roll) having a transfer mold 6 on the surface. The transfer roll is formed with a substantially semicircular groove A shown in Table 1 as a transfer mold. When the second press roll 5b and the third press roll 5c are pressed, the continuous resin sheet (1) The surface mold transfer resin sheet (1) can be obtained by transferring the opposite shape of the groove A having a substantially semicircular recess to the upper surface side of the surface layer.

  During the production, the temperature of each roll surface was adjusted such that the first pressing roll 5a was 70 ° C, the second pressing roll 5b was 88 ° C, and the third pressing roll 5c (transfer roll) was 94 ° C.

  The shape transfer rate T of the shape transferred to the surface shape transfer resin sheet (1) obtained in Example 1 was 90.4%.

(Example 2)
A continuous resin sheet (2) composed of a three-layer laminate was obtained in the same manner as in Example 1 except that the pressure of the pressing roll was adjusted so that the thickness of the continuous resin sheet was 1.5 mm. At that time, the third pressing roll 5c (transfer roll) is formed with a substantially semicircular recessed groove A on the circumference of the roll surface, and on the upper surface side of the surface layer of the continuous resin sheet (2). The opposite shape of the circular groove A is transferred to obtain the surface shape transfer resin sheet (2).

  The shape transfer rate T of the shape transferred to the surface shape transfer resin sheet (2) obtained in Example 2 was 96.1%.

(Example 3)
The translucent resin R1 is melt-kneaded by a third extruder having a temperature in the cylinder of 190 ° C. to 250 ° C. and supplied to the feed block. On the other hand, the translucent resin R2 is melt-kneaded by a fourth extruder having a temperature in the cylinder of 190 ° C. to 250 ° C. and supplied to the feed block.

  The translucent resin R1 supplied from the third extruder to the feed block becomes the main layer, and the translucent resin R2 supplied from the fourth extruder to the feed block becomes the surface layer (both surfaces of the main layer). A continuous resin sheet (3) composed of a three-layer laminate having a thickness of 2.0 mm was produced by co-extrusion molding at an extrusion resin temperature of 250 ° C. and pressing and cooling with a pressing roll.

  Moreover, although three press rolls were used at the time of the said manufacture, in order to press the continuous resin sheet discharged from the extruder, the 1st press roll was arrange | positioned at the upper side and the 2nd press roll was arrange | positioned at the lower side. Further, the continuous resin sheet (3) is cooled while being transported in close contact with the second pressing roll, and then is transported in close contact with the third pressing roll (transfer roll), and then the fourth pressing roll. To be taken over. At this time, the continuous resin sheet is not pressed between the second pressing roll and the transfer roll, and between the transfer roll and the fourth pressing roll, and a gap is left open.

  In the transfer roll, a groove B having a substantially semicircular recess is formed on the circumference of the roll surface, and an opposite type of the groove B having a substantially semicircular recess is formed on the upper surface side of the surface layer of the continuous resin sheet (3). After being transferred, a surface shape transfer resin sheet (3) can be obtained.

  During the production, the surface temperature of each roll was 78 ° C. for the first pressing roll, 78 ° C. for the second pressing roll, and 98 ° C. for the transfer roll.

  The shape transfer rate T of the shape transferred to the surface shape transfer resin sheet (3) obtained in Example 3 was 78.6%.

Example 4
A continuous resin sheet (4) comprising a three-layer laminate having a thickness of 1.5 mm in the same manner as in Example 3 except that the thickness of the continuous resin sheet is adjusted to 1.5 mm by adjusting the pressure of the pressing roll. Got.

  The transfer roll is formed with a substantially semicircular recess groove B on the circumference of the roll surface, and on the upper surface side of the surface layer of the continuous resin sheet (4), there is an opposite type of the approximately semicircular recess groove B. After being transferred, a surface shape transfer resin sheet (4) can be obtained.

  The shape transfer rate T of the shape transferred to the surface shape transfer resin sheet (4) obtained in Example 4 was 92.8%.

(Comparative Example 1)
As shown in FIG. 4, instead of the third pressing roll 5c, a transfer mold was provided on the surface of the second pressing roll 5b, and the operation was performed in the same manner as in Example 2 except that the cooling temperature was changed. A continuous resin sheet (5) was obtained. The continuous resin sheet (5) is cooled while being in close contact with the second pressing roll 5b, which is a transfer roll, and then taken up by the third pressing roll 5c. At that time, there was a gap between the transfer roll and the third pressing roll 5c, and the continuous resin sheet was not pressed between these rolls.

  The transfer roll has a substantially semicircular recess groove C formed on the circumference of the roll surface. On the lower surface side of the surface layer of the continuous resin sheet (5), an opposite type of the substantially semicircular recess groove C is formed. The surface shape transfer resin sheet (5) can be obtained by being transferred.

  During the production, the temperature of each roll surface was set to 50 ° C. for the first pressing roll, 80 ° C. for the second pressing roll (transfer roll), and 90 ° C. for the third pressing roll.

  The shape transfer rate T of the shape transferred to the surface shape transfer resin sheet (5) obtained in Comparative Example 1 was 30.0%.

(Comparative Example 2)
Except for changing the transfer mold and the cooling temperature, the third pressing roll is equipped with a transfer mold, and pressing and cooling are performed with the pressing roll and the transfer roll, as in Example 1. A continuous resin sheet (6) consisting of a laminate of layers was obtained.

  The transfer roll has a substantially semicircular recess groove C formed on the circumference of the roll surface, and an opposite type of the substantially semicircular recess groove C is formed on the lower surface side of the surface layer of the continuous resin sheet (6). After being transferred, a surface shape transfer resin sheet (6) can be obtained.

  The temperature of each roll surface at the time of the said manufacture set the temperature of the 1st press roll to 70 degreeC, the temperature of the 2nd press roll (transfer roll) to 108 degreeC, and set the temperature of the 3rd press roll to 88 degreeC.

  The shape transfer rate T of the shape transferred to the surface shape transfer resin sheet (6) obtained in Comparative Example 2 was 40.0%.

(Comparative Example 3)
A surface shape transfer resin sheet (7) having a thickness of 1.5 mm is operated in the same manner as in Comparative Example 1 except that the transfer roll is formed with a substantially semicircular recess groove D on the circumference of the roll surface. Got.

  The shape transfer rate T of the shape transferred to the surface shape transfer resin sheet (7) obtained in Comparative Example 3 was 48.0%.

(Comparative Example 4)
A surface shape transfer resin sheet (8) having a thickness of 2.0 mm, which is operated in the same manner as in Comparative Example 2 except that the transfer roll is formed with a substantially semicircular recessed groove D on the circumference of the roll surface. Got.

  The shape transfer rate T of the shape transferred to the surface shape transfer resin sheet (8) obtained in Comparative Example 4 was 65.0%.

(Example 5)
After 95 parts by mass of crystalline resin C1 and 5 parts by mass of intermediate layer masterbatch MB are dry blended, they are melt kneaded in a first extruder having a temperature in the cylinder of 190 ° C. to 260 ° C. and supplied to the feed block To do. On the other hand, the surface master batch MA is melt-kneaded by a second extruder having a temperature in the cylinder of 190 ° C. to 260 ° C. and supplied to the feed block.

  A dry blend of the crystalline resin C1 supplied from the first extruder to the feed block and the intermediate layer master batch MB becomes a main layer, and a surface layer master batch MA supplied from the second extruder to the feed block is Three layers having a thickness of 1.5 mm are formed by performing co-extrusion molding at an extrusion resin temperature of 250 ° C. so as to be both surfaces (surface layers) of the main layer, and pressing and cooling with a pressing roll 5 shown in FIG. A surface shape transfer resin sheet (9) composed of a laminate was prepared.

  In the production of the surface shape transfer resin sheet (9), in order to press the continuous resin sheet discharged from the extruder, the first pressing roll 5a was disposed on the upper side of the sheet and the second pressing roll 5b was disposed on the lower side. After being pressed by the first pressing roll 5a and the second pressing roll 5b, it is conveyed in close contact with the surface of the second pressing roll 5b, and cooled at that time.

  Thereafter, the sheet is pressed by the second pressing roll 5b and a third pressing roll 5c (transfer roll) having a transfer mold 6 on the surface. The transfer roll has a V-shaped groove E shown in Table 3 as a transfer mold. When the second press roll 5b and the third press roll 5c are pressed, the continuous resin sheet (9) On the upper surface side of the surface layer, a mold in which the convex portions and concave portions of the V-shaped groove E shown in FIG. 5 are transferred is transferred to obtain a surface shape transfer resin sheet (9).

  During the production, the temperature of each roll surface was adjusted such that the first pressing roll 5a was 80 ° C, the second pressing roll 5b was 78 ° C, and the third pressing roll 5c (transfer roll) was 115 ° C.

(Example 6)
A surface shape transfer resin sheet (10) was produced in the same manner as in Example 5 except that a transfer roll having a V-shaped groove F shown in Table 3 was used as the transfer die 6.

(Example 7)
A surface shape transfer resin sheet (11) was produced in the same manner as in Example 5 except that a transfer roll having a V-shaped groove G shown in Table 3 was used as the transfer mold 6.

(Example 8)
A surface shape transfer resin sheet (12) was produced in the same manner as in Example 5 except that a transfer roll having a V-shaped groove H shown in Table 3 was used as the transfer die 6.

Example 9
Surface shape transfer resin comprising a three-layer laminate in the same manner as in Example 5, except that the thickness of the continuous resin sheet was adjusted to 1.0 mm by adjusting the pressure of the pressure roll and the temperature of each pressure roll was changed. A sheet (13) was obtained. At that time, the third pressing roll 5c (transfer roll) is formed with a V-shaped groove E shown in Table 3 on the circumference of the roll surface as the transfer mold 6, and the surface shape transfer resin sheet (13 ) Is transferred onto the upper surface side of the surface layer of the V-shaped groove E shown in FIG. 5, and the surface shape imparting resin sheet (13) can be obtained.

  In addition, the temperature of each roll surface was adjusted at the time of the said manufacture so that the 1st press roll 5a might be 100 degreeC, the 2nd press roll 5b might be 98 degreeC, and the 3rd press roll 5c (transfer roll) might be 119 degreeC.

(Example 10)
A surface shape transfer resin sheet (14) was produced in the same manner as in Example 9 except that a transfer roll in which a V-shaped groove F shown in Table 3 was formed as the transfer mold 6 was used.

(Example 11)
A surface shape transfer resin sheet (15) was produced in the same manner as in Example 9, except that a transfer roll in which a V-shaped groove G shown in Table 1 was used as the transfer mold 6 was used.

Example 12
A surface shape transfer resin sheet (16) was produced in the same manner as in Example 9 except that a transfer roll having a V-shaped groove H shown in Table 1 was used as the transfer mold 6.

  It can be seen that the surface shape transfer resin sheets (9) to (16) produced in Examples 5 to 12 each have a shape transfer rate T of 95% and are excellent in transfer rate (transfer performance).

  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.

  The surface shape transfer resin sheet obtained using the production method and production apparatus of the present invention can be applied to various applications by selecting an additive to the raw material resin. Moreover, since the surface shape transfer resin sheet obtained using the production method and production apparatus of the present invention is excellent in transfer rate, it is particularly suitable as a light diffusion plate using a light diffusing agent as an additive.

It is a schematic diagram of the cross-sectional shape of the replica of the semicircular recessed groove | channel currently given to the transcription | transfer mold. It is a schematic diagram of an example of the manufacturing apparatus used for manufacture of the surface shape transfer resin sheet of this invention. It is a schematic diagram of a cylindrical lens. It is a schematic diagram of the manufacturing apparatus used for manufacture of the conventional surface shape transfer resin sheet. It is a schematic diagram of the cross-sectional shape of the replica of the groove | channel of the V-shaped dent given to the transcription | transfer mold.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 Transfer type | mold surface, 2 Continuous resin sheet, 3 Resin inlet, 4 Dies, 5 Press roll, 5a 1st press roll, 5b 2nd press roll, 5c 3rd press roll, 6 Transfer mold, 7 Extruder, 8 Cylindrical lens.

Claims (6)

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 first pressing step of sandwiching the continuous resin sheet between a first pressing roll and a second pressing roll;
A transporting step of transporting the continuous resin sheet while being in close contact with the second pressing roll;
A second pressing step of sandwiching the conveyed continuous resin sheet between the second pressing roll and the third pressing roll,
The third pressing roll has a transfer mold on its surface,
The transfer mold includes a plurality of recesses, the pitch interval between the recesses is 50 μm to 500 μm, and the groove depth of the recesses is 3 μm to 500 μm.
The said continuous resin sheet is a manufacturing method of the surface shape transfer resin sheet by which the transfer type | mold with which the said 3rd press roll surface was equipped in said 2nd press process is transcribe | transferred.   The method for producing a surface shape transfer resin sheet according to claim 1, wherein the recess has a substantially semicircular cross section.   2. The method for producing a surface shape transfer resin sheet according to claim 1, wherein the concave portion has a triangular cross-sectional shape and an apex angle of the triangle is 40 ° to 160 °. 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 surface shape transfer resin sheet manufacturing apparatus including a roll,
The transfer roll is a surface shape transfer resin sheet manufacturing apparatus in which a plurality of recesses are formed on a surface thereof, a pitch interval between the recesses is 50 μm to 500 μm, and a groove depth H of the recesses is 3 μm to 500 μm.   The apparatus for producing a surface shape transfer resin sheet according to claim 4, wherein the recess has a substantially semicircular cross section.   5. The apparatus for producing a surface shape transfer resin sheet according to claim 4, wherein the recess has a triangular cross-sectional shape and an apex angle of the triangle is 40 ° to 160 °.

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