JP2010006073A - Method of manufacturing surface shape transfer resin sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a surface shape transfer resin sheet for accurately and quickly transferring the surface shape of a transfer mold. <P>SOLUTION: The surface shape transfer resin sheet is manufactured by a manufacturing apparatus 10 comprising a die 3 for continuously extruding resin 2 to obtain a continuous resin sheet 4; a pressure roll 5; and the transfer mold 6 holding the continuous resin sheet 4 between itself and the pressure roll 5 to transfer the surface shape to the continuous resin sheet. The transfer mold 6 is an organic material film wound on a rotating roll 7. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for producing a surface shape transfer resin sheet, and more particularly to a method for producing a resin sheet having a transfer mold surface shape transferred thereon.

  As a method of manufacturing the surface shape transfer resin sheet (1) by transferring the surface shape of the transfer mold (6) to the continuous resin sheet (3) obtained by extruding the resin (2) from the die (3) in a heated and melted state. In Patent Document 1 (Japanese Patent Laid-Open No. 9-11328), as shown in FIG. 1, a continuous resin sheet (B) continuously extruded from a die (3) is transferred to a pressing roll (5) and a transfer mold ( A method is disclosed in which the surface shape of the transfer mold (6) is transferred to the continuous resin sheet (3) by being sandwiched between the transfer mold (6) and the continuous resin sheet (3). Although there is no description about the material constituting the transfer mold (6) in the same document, the transfer mold (6) is usually a metal cylindrical shape fitted into the rotating roll (7), or a metal In general, the rotating roll (7) is formed on the surface by a method such as engraving.

Japanese Patent Laid-Open No. 9-11328

  However, in such a conventional manufacturing method, in order to transfer the surface shape of the transfer mold (6) to the continuous resin sheet (3) with high accuracy, it is necessary to slow down the transfer speed, which is necessarily a method with good productivity. I could not say.

  Therefore, the present inventor has intensively studied to develop a method capable of producing the surface shape transfer resin sheet (1) by transferring the surface shape of the transfer mold (6) accurately and quickly, and as a result, has reached the present invention. It was.

  That is, the present invention provides a continuous resin sheet (4) by continuously extruding the resin (2) from the die (3) in a heated and melted state, and transferring the obtained continuous resin sheet (4) to the pressing roll (5). A method of producing a surface shape transfer resin sheet (1) by transferring the surface shape of the transfer die (6) to the continuous resin sheet (4) by being sandwiched between the mold (6) and the transfer The present invention provides a method for producing the surface shape transfer resin sheet (1), wherein the mold (6) is made of an organic material.

  According to the production method of the present invention, the surface shape of the transfer mold (6) can be quickly and accurately transferred, and the target surface shape transfer resin sheet (1) can be produced with good productivity.

It is a figure which shows typically an example of the method of manufacturing a surface shape transfer resin sheet. It is a figure which shows typically another example of the method of manufacturing a surface shape transfer resin sheet. It is a figure which shows typically another example of the method of manufacturing a surface shape transfer resin sheet.

  Hereinafter, the manufacturing method of the present invention will be described with reference to FIGS. 1 to 3 schematically show a production apparatus (10) for a surface shape transfer resin sheet (1). This production apparatus (10) continuously gives a resin (2) in a heated and melted state. A die (3) that is extruded to obtain a continuous resin sheet (4), a pressing roll (5), and the continuous resin sheet (4) are sandwiched between the pressing roll (5), so that the surface shape is improved. A transfer mold (6) for transferring to the continuous resin sheet (5).

  The resin (2) used in the production method of the present invention may be a thermosetting resin that cures when heated, but usually includes a thermoplastic resin that becomes a molten state when heated. Specifically, for example, styrene resin, acrylic resin, polyethylene resin, polypropylene resin, cyclic olefin polymer resin, acrylonitrile-butadiene-styrene (ABS) resin, polyethylene terephthalate (PET) resin, polycarbonate (PC) resin, etc. Is mentioned.

  The resin (2) may contain additives such as a light diffusing agent, an ultraviolet absorber, a heat stabilizer, and an antistatic agent.

  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, and a high molecular weight having a weight average molecular weight of 500,000 to 5,000,000. Polymer particles, cross-linked polymer particles having a gel fraction measured as an insoluble content when dissolved in acetone, of 10% by mass or more are preferably used.

  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 (2) is usually 0.02 or more in terms of the effect of light diffusion. The surface shape transfer resin sheet (1) is usually 0.13 or less in terms of light transmittance.

  The surface shape transfer resin sheet (1) produced by adding a light diffusing agent to the resin (2) can be used as a light diffusing plate.

  As the die (3), a metal T-die that is the same as that used in a normal extrusion molding method is used.

  In order to extrude the resin (2) from the die (3) in a heated and melted state, an extruder (8) is used in the same manner as in a normal extrusion molding method. The extruder (8) may be a single screw extruder or a twin screw extruder. The resin (2) is heated in the extruder (8), sent to the die (3) in a molten state, and extruded.

  In extruding the resin (2) from the die (3) in a heated and melted state, one type of resin (2) may be supplied to the die (3) and extruded in a single layer, or two or more types may be extruded. The resin (2) may be supplied and coextruded in a laminated state. To co-extrusion with two or more types of resin (2) laminated, for example, a two-type three-layer distribution type feed block (not shown) is used, and the resin is supplied to the die (3) via this. To do.

  The resin (2) extruded from the die (3) is normally continuously extruded into a sheet shape to form a continuous resin sheet (4).

The obtained continuous resin sheet (4) is sandwiched between the pressing roll (5) and the transfer mold (6).
As the pressing roll (5), a metal roll made of a metal such as stainless steel or steel is usually used, and its diameter is usually 100 mm to 500 mm. When a metallic roll is used as the pressing roll (5), the surface thereof may be subjected to a plating treatment such as chrome plating, copper plating, nickel plating, nickel-phosphorus plating. Further, the surface of the pressing roll (5) 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 (6) is pressed against the surface of the continuous resin sheet (4) and transferred to the continuous resin sheet (4) with the surface shape as the reverse mold.

  In the production method of the present invention, the transfer mold (6) is made of an organic material. The organic material should have heat resistance that can maintain the shape of the transfer mold (6) even when repeatedly pressed against the continuous resin sheet (4) immediately after being extruded from the die (3) in the heated and melted state. For example, a resin such as a thermosetting resin or 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, alkyd resin, and the like.

  Examples of the thermoplastic resin include styrene resin, acrylic resin, polyethylene resin, polypropylene resin, tubular 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 (2) extruded from the die (3) by 40 ° C. or more, a crosslinked thermoplastic resin, or the like. .

  Examples of the transfer mold (6) include an organic material film (6) having a reverse mold of a desired shape formed on the surface. The thickness of the organic material film is usually 0.1 mm to 5 mm.

For example, as shown in FIG. 1, this organic material film (6) can be used as a transfer mold (6) in a state of being wound around a rotating roll (7). In this case, as shown in FIG. 1, the two pressing rolls (5) may be a first pressing roll (51) and a second pressing roll (52). When two pressing rolls (51, 52) are used, the continuous resin sheet (4) is usually sandwiched between the first pressing roll (51) and the transfer mold (6) as shown in FIG. After pressing, it is wound around the transfer mold (6), and then pressed between the second pressing roll (52) and the transfer mold (6) in this state.
Further, the pressing roll (5) may be one as shown in FIG.

  As the transfer mold (6), for example, as shown in FIG. 3, the organic material film (6) is used as it is, and the organic material film (6) is superposed on the continuous resin sheet (4) to form a pressure roll (6). The surface shape of the organic material film (6) may be transferred to the continuous resin sheet (4) by pressing between 5) and the rotating roll (7). The organic material film (6) after being transferred to the continuous resin sheet (4) is usually sent out of the system and is usually wound on a winding roll (not shown).

  Examples of the surface shape of the transfer mold (6) include a shape in which a large number of V grooves are provided in parallel. The apex angle of the V-groove is usually 160 ° or less, and is usually 40 ° or more in terms 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 is usually 10 μm or more, and preferably 50 μm or more in that the transfer mold can be easily prepared. The manufacturing method of the present invention has a V-groove depth of 10 μm or more and a pitch of 500 μm or less It is suitable for.

  Thus, the desired surface shape transfer resin sheet (1) can be produced by transferring the surface shape of the transfer mold (6) to the continuous resin sheet (4). The obtained surface shape transfer resin sheet (1) 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 (2) 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
[Production of light diffusing agent masterbatch]
52 parts by mass of styrene resin pellets (“HRM40” manufactured by Toyo Styrene Co., Ltd., refractive index 1.59, Vicat softening point 106.8 ° C.), siloxane polymer particles [cross-linked polymer particles, “Trefyl DY33- 719 ", refractive index 1.42, volume average particle diameter 2 [mu] m] 4.0 parts by mass, UV absorber [Sumisorb 200" manufactured by Sumitomo Chemical Co., Ltd., powder] and heat stabilizer [manufactured by Sumitomo Chemical Co., Ltd. [Sumilyzer GP], powder form] After dry blending 2.0 parts by mass, it is put into a twin screw extruder with a screw diameter of 65 mm from a hopper, kneaded while being heated and melted, extruded into a strand at 250 ° C., and pellets The light diffusing agent master batch (pellet shape) was obtained. In the twin-screw extruder, the resin temperature in the vicinity of the hopper was 200 ° C., and extrusion was performed at 250 ° C. while raising the temperature.

[Manufacture of surface layer resin]
Styrene-methyl methacrylate copolymer resin [“MS200NT” manufactured by Nippon Steel Chemical Co., Ltd., styrene unit 80 mass%, methyl methacrylate unit 20 mass%, refractive index 1.57, pellet form, Vicat softening point 102.1 ° C. 75.8 parts by mass, acrylic polymer particles [cross-linked polymer particles, “Sumipex XC1A” manufactured by Sumitomo Chemical Co., Ltd., refractive index 1.49, volume average particle diameter 25 μm] 23 parts by mass, ultraviolet absorber [manufactured by ADEKA After dry blending 1 part by weight of “LA-31”, powdered] and 0.2 parts by weight of “Sumilyzer GP”, powdered by Sumitomo Chemical Co., Ltd., a hopper is put into a twin screw extruder with a screw diameter of 65 mm. Was melted and kneaded while heating, extruded into a strand at 250 ° C., and then cut into pellets to obtain a surface layer resin (pellet). In the twin-screw extruder, the resin temperature in the vicinity of the hopper was 200 ° C., and extrusion was performed at 250 ° C. while raising the temperature.

[Manufacture of surface shape transfer sheet]
Supplying the resin for the intermediate layer and the resin for the surface layer (2) to the two-type, three-layer distribution type feed block (manufactured by Tanabe Plastics), the intermediate layer resin becomes the intermediate layer, and the surface layer resin is laminated on both sides of the intermediate layer A continuous resin sheet (4) having a three-layer structure in which the surface layers were laminated on both surfaces of the intermediate layer was continuously obtained by feeding to a T-die (3) so as to obtain the structured structure and co-extrusion.

The resin for the intermediate layer was obtained by dry blending 97 parts by mass of styrene resin pellets (“HRM40” manufactured by Toyo Styrene Co., Ltd., refractive index 1.59) and 3 parts by mass of the light diffusing agent masterbatch obtained above, and then having a screw diameter of 40 mm. It was supplied to a single screw extruder with a vent (manufactured by Tanabe Plastics Co., Ltd.) (8), heated and melted, and supplied at 250 ° C. to the above-mentioned two-type three-layer distribution type feed block.
For the surface layer resin, the surface layer resin obtained above is supplied as it is to a single screw extruder with a vent with a screw diameter of 20 mm (manufactured by Tanabe Plastics) (8), heated and melted, and the above two types and three layers distribution type at 250 ° C. Supplied to the feed block. A T-die (3) having a width of 250 mm and a lip interval of 2 mm was used. The obtained continuous resin sheet (4) had a width of 243 mm and a thickness of 1.5 mm.

  As shown in FIG. 1, a continuous resin sheet (4) coextruded from a T die (3) is continuously formed on an organic material film [transfer mold] (6) provided on the surface of a rotating roll (7). Between the transfer mold (6) and the second pressing roll (52) in a state where the transfer mold (6) and the second pressing roll (52) are wound around the transfer mold (6). By pressing between them, the surface shape of the transfer mold (6) was transferred to the surface of the continuous resin sheet (4) to obtain a surface shape transfer resin sheet (1). The production rate of the surface shape transfer resin sheet (1) at this time was 0.68 m / min.

  As the transfer type [organic material film] (6), an acrylic resin layer (thickness of 30 μm) is laminated on one side of a polyethylene terephthalate resin film (thickness of 125 μm). A metal rotating roll (with an isosceles triangular V-groove having a height of 25 μm and a pitch of 50 μm was used so that the V-groove was perpendicular to the extrusion direction of the continuous sheet (4). Used by wrapping around 7). In the obtained surface shape transfer resin sheet (1), the shape corresponding to the transfer mold (6) is accurately transferred to the surface, and the V groove of the organic material film after the production is The same shape was maintained.

As the first pressing roll (51), a metal roll having a diameter of 200 mm and a mirror-finished surface was used at 95 ° C.
As the rotating roll (7), a metal roll having a diameter of 200 mm and a mirror-finished surface was used at 89 ° C.
As the second pressing roll (52), a metal roll having a diameter of 200 mm and a mirror-finished surface was used at 112 ° C.
The obtained surface shape transfer resin sheet (1) had a multilayer structure with a total thickness of 1.5 mm in which a surface layer with a thickness of 0.05 mm was laminated on both surfaces of an intermediate layer with a thickness of 1.4 mm.

[Evaluation of surface shape transfer resin sheet]
After cutting the obtained surface shape transfer resin sheet (1) and mirror-finishing the cross section, the depth of the prism transferred to the surface was observed with an ultra-deep shape measuring microscope ("VK-8500" manufactured by KEYENCE). (N) is measured, and from the depth (H) of the prism in the transfer mold (6), the formula (1)
β = N / H × 100 (%) (1)
The transfer rate was found to be 98%. Further, no striped appearance defect (tack mark) was observed on the surface of the obtained surface shape transfer resin sheet (1) when it was peeled off from the transfer mold (6).
The results are shown in Table 1.

Comparative Example 1
The same operation as in Example 1 was performed except that a cylinder made of a nickel electroformed plate was used as the transfer mold (6) instead of the organic material film, and was fitted into the rotating roll (7). The production speed of the surface shape transfer resin sheet (1) at this time is 0.66 m / min. In addition, as the nickel electroformed plate (6), an isosceles triangle V groove having an apex angle of 90 ° and a height (H) of 25 μm is perpendicular to the extrusion direction of the continuous resin sheet (4). Those provided at a pitch of 50 μm were used. The transfer rate (β) of the obtained surface shape transfer resin sheet (1) was 62%, and many tack marks were observed on the surface.

  Next, the surface shape transfer resin is adjusted by adjusting the supply speed of the resin (2) from the extruder (8) and the rotation speed of the first pressing roll (51), the second pressing roll (52) and the rotating roll (7). When the production speed of the sheet (1) was 0.58 m / min, the transfer rate (β) of the obtained surface shape transfer resin sheet (1) was 76%, and many tack marks were seen on the surface. .

  Furthermore, when the production rate was 0.41 m / min, the transfer rate (β) of the obtained surface shape transfer resin sheet (1) was 98%, and a slight tack mark was seen on the surface.

  The results of Comparative Example 1 are summarized in Table 1.

Table 1
━━━━━━━━━━━━━━━━━━━━━━━
Production rate Transfer rate (β) Tack mark
(m / min) (%)
━━━━━━━━━━━━━━━━━━━━━━━
Example 1 0.68 98 None
Comparative Example 1 0.666 62 many
0.58 76 more
0.41 98 Slight
━━━━━━━━━━━━━━━━━━━━━━━

1: Surface shape transfer resin sheet 2: Resin 3: Die 4: Continuous resin sheet 5: Press roll 51: First press roll 52: Second press roll 6: Transfer mold (film made of organic material) 7: Rotating roll 8: Extruder 10: Surface shape transfer resin sheet manufacturing equipment

Claims (2)

The resin is continuously extruded from the die in the molten state to obtain a continuous resin sheet,
It is a method for producing a surface shape transfer resin sheet by transferring the surface shape of the transfer mold to the continuous resin sheet by sandwiching the obtained continuous resin sheet between a pressing roll and a transfer mold,
The method for producing a surface shape transfer resin sheet, wherein the transfer mold is an organic material film wound around a rotating roll. A die that continuously extrudes the resin in a heated and molten state to obtain a continuous resin sheet;
A pressing roll;
A transfer mold for transferring the surface shape to the continuous resin sheet by sandwiching the continuous resin sheet with the pressing roll;
The apparatus for producing a surface shape transfer resin sheet, wherein the transfer mold is an organic material film wound around a rotating roll.

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