JP2013252593A - Method of manufacturing resin sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of obtaining a resin sheet of desired shape by cutting a resin sheet to be cut unwound from a roll, that is, a method of setting the resin sheet to a predetermined size after a tension applied to the resin sheet is eliminated.SOLUTION: A method of manufacturing a resin sheet includes a step A of unwinding a sheet to be cut from a roll, and a step B of forming a resin sheet of desired size by cutting the unwound sheet to be cut with a punching blade. The punching blade includes a cutting edge X for cutting the sheet to be cut in the direction perpendicular to the unwinding direction of the sheet to be cut, and a rectangular cutting edge Y opening to the upstream side or downstream side in the sheet unwinding direction.

Description

  The present invention relates to a method for producing a resin sheet, and more particularly to a method for producing a resin sheet including a step of obtaining a resin sheet having a desired size by cutting a sheet to be cut.

  In order to obtain a resin sheet having a desired size, the resin sheet to be cut may be cut. For example, a resin sheet having a desired size is obtained by cutting with a cutting blade while conveying a long cut resin sheet. As such a cutting blade, a punching blade called a Thomson blade is known (see, for example, Patent Documents 1 to 3). The Thomson blade is usually a punching blade closed in a loop; cutting with the Thomson blade provides a resin sheet having a fixed shape corresponding to the shape of the Thomson blade.

JP-A-7-314392 JP-A-8-197500 JP 2011-83895 A

  In addition, the cut resin sheet to be cut may be set as a roll body wound up in a roll shape, and the resin sheet may be cut by unwinding the cut resin sheet from the roll body. A certain amount of tension is applied to the resin sheet to be cut that is wound on the roll body. Therefore, the resin sheet obtained by cutting the resin sheet to be cut that has been unwound from the roll body contracts with the release of the tension, and the size changes (reduces).

  As described above, tension is applied to the resin sheet to be cut in the roll body, but the magnitude of the tension is not constant and varies depending on the winding position. More specifically, the tension applied to the cut resin sheet being wound away from the core is higher than the tension applied to the cut resin sheet being wound around the core. Is bigger.

  Therefore, the resin sheet obtained by cutting the to-be-cut resin sheet wound away from the core is more than the resin sheet obtained by cutting the to-be-cut resin sheet wound in the vicinity of the core. It is easy to shrink because the tension is relaxed. In this way, even if a plurality of resin sheets having the same shape are obtained by cutting the resin sheet to be cut in a state where the tension remains, resin sheets having different shapes may be formed by releasing the tension. . This is because the tension applied to each resin sheet is not the same.

  Therefore, the present invention is a method for obtaining a resin sheet having a desired shape by cutting a resin sheet to be cut that has been unwound from a roll body, and the size of the resin sheet after the tension applied to the resin sheet is eliminated. Provide a consistent method.

That is, this invention relates to the manufacturing method of the resin sheet shown below.
[1] From the roll body in which the sheet to be cut is wound in a roll shape, the process A for winding the sheet to be cut, and the wound sheet to be cut are cut with a punching blade to obtain a resin sheet of a desired size. A process for producing a resin sheet comprising the step B of obtaining,
The manufacturing method in which the said punching die has the cutting blade which cuts a to-be-cut sheet perpendicular | vertical with respect to the unwinding direction of the said to-be-cut sheet | seat, and the rectangular-shaped cutting blade opened to the sheet unwinding direction.

[2] The cutting blade Y is open on the upstream side in the sheet unwinding direction, and the cutting blade X is adjacent to the cutting blade Y on the downstream side. Production method.
[3] The cutting blade Y is open on the downstream side in the sheet unwinding direction, and the cutting blade X is adjacent to the cutting blade Y on the upstream side. Production method.
[4] The manufacturing method according to [1], wherein the cutting blade Y has a comb-shaped blade that divides the cutting region into two or more regions.

[5] The manufacturing method according to [1], wherein a cycle including the step A and the step B is repeated to obtain a plurality of resin sheets.
[6] The length of unwinding the sheet to be cut from the roll body in step A in the initial cycle and the length of unwinding the sheet to be cut from the roll body in step A in the late cycle are different lengths. [5] The manufacturing method as described in.
[7] The length of unwinding the sheet to be cut from the roll body in step A in the initial cycle is longer than the length of unwinding the sheet to be cut from the roll body in step A in the late cycle. Manufacturing method.

  According to the method for producing a resin sheet of the present invention, a resin sheet having a desired shape can be obtained by cutting the cut resin sheet wound up in a roll shape while unwinding.

It is a figure which shows the manufacture flow of a resin sheet. It is a figure explaining the mechanism which adjusts the cutting size of a resin sheet in manufacture of a resin sheet. It is a figure which shows the example of the punching blade used for manufacture of a resin sheet.

  The method for producing a resin sheet of the present invention includes a step A in which a sheet to be cut is wound from a roll body in which the sheet to be cut is wound in a roll shape, and the wound sheet to be cut is cut with a punching blade, And a step B of forming a resin sheet having a desired size. By repeating step A and step B, a plurality of resin sheets can be obtained.

  The roll body in which the sheet to be cut is wound into a roll is usually obtained by winding the sheet to be cut around a core. When the sheet to be cut is wound around the core while applying a tension in the winding direction to the sheet to be cut, the wound sheet to be cut can be smoothly wound without being waved. However, the tension applied to the cut sheet wound away from the core is likely to be higher than the tension applied to the cut sheet wound around the core. That is, different tension is applied to the cut sheet of the roll body depending on the winding part.

  There are no particular restrictions on the type of resin constituting the sheet to be cut, the thickness of the sheet, the width and length of the sheet. Examples of resin types include polyester, polyolefin, polyamide, polyesteramide, polyether, polyimide, polyamideimide, polystyrene, polycarbonate, polyphenylene sulfide, polyetherester, polyvinyl chloride, poly (meth) acrylic ester, ethylene Although vinyl acetate copolymer etc. are included, it does not restrict | limit in particular.

  In step A, the sheet to be cut is unwound from the roll body and sent to the cutting section. The sheet to be cut may be unwound by rotating a take-up shaft that winds the unwound sheet.

  In step B, the cut sheet sent to the cutting section is cut to obtain a resin sheet having a desired shape. The sheet to be cut is preferably cut with a punching blade. The punching blade is usually a mold formed into a shape to be punched. The blade of the punching blade is usually made of metal and may be fixed by a substrate. By pressing the blade of the punching blade against the non-cutting member, the non-cutting member is cut according to the mold.

  The punching blade for cutting the cut sheet used in the step B includes a cutting blade X for cutting the cut sheet perpendicular to the unwinding direction of the cut sheet, and an upstream side or a downstream side in the sheet unwinding direction. And a rectangular cutting blade Y opened toward the front (see FIGS. 3A to 3D).

  The cutting blade X cuts the sheet perpendicular to the unwinding direction of the sheet to be cut. That is, the sheet is cut in the width direction of the sheet. The cutting blade X may cut the entire width of the sheet, but may not cut the end in the width direction. However, the length in the sheet width direction of the cutting blade X is preferably the same as or longer than the length in the width direction of the opening of the cutting blade Y (see E in FIG. 3AB).

  The cutting blade Y is a rectangular cutting blade, but is not closed and opens in one direction. That is, it is preferable that the cutting blade Y has the opening E on the upstream side in the unwinding direction (see FIG. 3A) or has the opening E on the downstream side (see FIG. 3B). Typically, the rectangular blade constituting the cutting blade Y does not have one side on the upstream side or the downstream side in the unwinding direction among the four sides of the rectangle.

  The cutting blade X and the cutting blade Y are arranged along the unwinding direction. The arrangement order of the cutting blade X and the cutting blade Y differs depending on whether the opening E of the cutting blade Y is on the upstream side or the downstream side of the cutting blade Y. When the opening E of the cutting blade Y is on the upstream side in the unwinding direction, the cutting blade X is preferably adjacent to the downstream side with respect to the cutting blade Y (see FIG. 3A). On the other hand, when the opening E of the cutting blade Y is on the downstream side in the unwinding direction, the cutting blade X is preferably adjacent to the upstream side of the cutting blade Y (see FIG. 3B).

  The distance G (see FIG. 3A) between the cutting blade X and the cutting blade Y is preferably 5 mm to 30 mm. When the gap G is too short, there is a tendency that the remaining cut portion between the cut out resin sheets is accompanied by the cut resin sheet. Moreover, since the loss in a process increases when the said space | interval G is too long, it is unpreferable.

  The cutting blade X and the cutting blade Y may be configured as separate members, but may be integrated. When integrated, the cutting blade X and the cutting blade Y can maintain the positional accuracy as compared with the case where the cutting blade Y moves separately, and the dimensions of the cut sheet are preferable. For integration, the cutting blade X and the cutting blade Y may be fixed to one substrate, or the cutting blade X and the cutting blade Y are connected and fixed by a connecting member Z or the like as shown in FIG. 3C. May be. The connecting member Z may be a rod shape, but may be a cutting blade. It is preferable that the connecting member Z is a cutting blade because the cut resin sheet and the remaining cutting portion can be easily separated.

  The cutting blade Y may have a blade that divides the cutting region into two or more regions. FIG. 3D shows an example of a cutting blade Y that divides the cutting region into two regions. As shown in FIG. 3D, the cutting blade Y is preferably a comb-shaped cutting blade. Thus, by dividing the cutting region into two or more regions, two or more resin films can be manufactured (cut out) in one step B.

  As described above, according to the method for producing a resin sheet of the present invention, a plurality of resin sheets can be obtained by repeating the cycle of Step A and Step B. This will be described with reference to FIG. In FIG. 1, the example which manufactures a resin sheet using a punching blade among FIG. 3A is demonstrated.

  In FIG. 1A, the sheet 15 to be cut is unwound from the roll body 10, sent to the cutting part R to the cutting sheet 15 (step A <b> 0), and the cutting sheet 15 sent to the cutting part R is cut with a punching blade. (Step B0). In FIG. 1A, in step B0, the part cut by the cutting blade X constituting the punching blade (see FIG. 3A) is indicated by x (0), and the part cut by the cutting blade Y is indicated by y (0). ing. As shown in FIG. 1A, the resin sheet is not cut out in step B0. This is because the cutting blade Y constituting the punching blade has the opening E, and the resin sheet cannot be cut out.

  Next, as shown in FIG. 1B, the sheet 15 to be cut is further unwound from the roll body 10, another area of the sheet 15 to be cut is disposed in the cutting part R (step A <b> 1), and sent to the cutting part R. The cut sheet 15 thus cut is cut with a punching blade (step B1). In FIG. 1B, the part cut | disconnected by the cutting blade X which comprises a punching blade in process B1 is shown by x (1), and the part cut | disconnected by the cutting blade Y is shown by y (1). As shown in FIG. 1B, in step B1, the resin sheet S (1) that is a region surrounded by y (0) and x (1) is cut out.

  Further, as shown in FIG. 1C, the sheet 15 to be cut is further unwound from the roll body 10, and another region of the sheet 15 to be cut is arranged in the cutting part R (step A2), and sent to the cutting part R. The cut sheet 15 thus cut is cut with a punching blade (step B2). In FIG. 1C, in step B2, the part cut by the cutting blade X constituting the punching blade is indicated by x (2), and the part cut by the cutting blade Y is indicated by y (2). As shown in FIG. 1C, in step B2, the resin sheet S (2), which is a region surrounded by y (1) and x (2), is cut out.

  As described above, after the sheet to be cut is fed out in step A1 in the initial stage of unwinding from the roll body, the resin sheet S (1) is cut out in step B1; , The resin sheet S (2) is cut out in step B2. By repeating this, a plurality of resin sheets S can be efficiently manufactured (cut out).

  Furthermore, the resin sheet manufacturing method of the present invention is characterized in that the size (cutout size) of the resin sheet S obtained in a plurality of steps B is not the same. As described above, the tension applied to the cut resin sheet wound around the roll body varies depending on the winding position. Therefore, the amount of the resin sheet obtained by cutting the resin sheet to be cut shrinks after the cutting is not the same. Therefore, in the present invention, the size of the resin sheet obtained by cutting the resin sheet to be cut (cutout size) is not constant, and the cutout size is changed so that the size after contraction of each resin sheet is the same. Yes.

  Specifically, it is preferable to increase the cut-out size of the resin sheet at the initial stage of unwinding from the roll body 10; and to decrease the cut-out size of the resin sheet at the later stage of unwinding from the roll body 10.

  FIG. 2A shows a cutting state of the sheet to be cut by the cutting blade at the initial stage of unwinding from the roll body 10. A resin sheet S (1) that is a region surrounded by the cut portion y (0) and the cut portion x (1) is obtained. The cut part y (0) and the cut part x (1) intersect in a “T” shape at the end in the unwinding direction of the cut part y (0).

  On the other hand, FIG. 2B shows the cutting state of the sheet to be cut by the cutting blade in the latter stage of unwinding from the roll body 10. That is, FIG. 2B shows the cutting state of the sheet to be cut by the cutting blade after repeating the cycle including step A and step B a certain number of times from the state of FIG. 2A. A resin sheet S (n + 1) which is a region surrounded by the cut part y (n) and the cut part x (n + 1) is obtained. The cut portions y (n) and x (n + 1) intersect in a “ten” shape. In other words, the protruding portion U is located upstream of the cutting portion y (n) in the unwinding direction. Therefore, the cutout size of the resin sheet S (n + 1) is smaller than the cutout size of the resin sheet S (1).

  The sheet to be cut in FIG. 2A is a sheet to be cut that has been wound at a position away from the core in the roll body 10, and a relatively high tension is applied thereto. Therefore, the resin sheet S (1) cut out therefrom has a large shrinkage rate due to the relaxation of the tension. On the other hand, the to-be-cut sheet | seat cut | disconnected in FIG. 2B is a to-be-cut sheet | seat wound up in the roll body 10 in the position close | similar to a core, and relatively low tension is applied. Therefore, the resin sheet S (n + 1) cut out therefrom has a small shrinkage rate due to the relaxation of the tension. As described above, since the cutout size of the resin sheet S (1) is set larger than the cutout size of the resin sheet S (n + 1), the size of the resin sheet S (1) after the tension relaxation and the resin sheet The size of S (n + 1) can be made the same.

  In the method for producing a resin sheet of the present invention, in order to adjust the cut-out size of the resin sheet S, the unwinding amount (unwinding length) of the sheet to be cut from the roll body in the step A may be adjusted. That is, if the unwinding amount in the process A is reduced, the cut-out size of the resin sheet S cut in the process B is reduced: If the unwinding amount in the process A is increased, the resin sheet S to be cut in the process B is reduced. The cutout size increases.

  As described above, in the method for producing a resin sheet of the present invention, the cutout size of the resin sheet S is not constant; the cutout size of the resin sheet S is set so that the size of the resin sheet S after contraction is constant. Can be adjusted. It is preferable to set how much the cutout size of the resin sheet S is changed based on an actual measurement of the shrinkage rate of the cut sheet wound around the roll body 10.

  In the method for producing a resin sheet of the present invention, it is possible to obtain a plurality of resin sheets having the same size after the tension is alleviated by cutting the cut sheet unwound from the roll body. Therefore, for example, it is particularly useful when manufacturing a large number of resin sheets of the same size.

10 Roll body 15 Sheet to be cut E Opening portion G Gap between cutting blade X and cutting blade Y R Cutting portion S, S (1), S (2) Resin sheet U Overhang portion X Cutting blade Y Cutting blade Z Connection portion x (0), x (1), x (2), x (n), x (n + 1) cutting part y (0), y (1), y (2), y (n), y (n +1) Cutting part

Claims (7)

Step A for unwinding the sheet to be cut from the roll body in which the sheet to be cut is wound into a roll, and Step B for obtaining a resin sheet of a desired size by cutting the unwound sheet to be cut with a punching blade A method for producing a resin sheet comprising:
The punching blade has a cutting blade X that cuts the cut sheet perpendicular to the unwinding direction of the cut sheet, and a rectangular cutting blade Y that opens upstream or downstream in the sheet unwinding direction. A manufacturing method.   The manufacturing method according to claim 1, wherein the cutting blade Y is open on the upstream side in the sheet unwinding direction, and the cutting blade X is adjacent to the cutting blade Y on the downstream side.   The manufacturing method according to claim 1, wherein the cutting blade Y opens to the downstream side in the sheet unwinding direction, and the cutting blade X is adjacent to the cutting blade Y on the upstream side.   The said cutting blade Y is a manufacturing method of Claim 1 which has a comb-shaped blade which divides the cutting area | region into two or more area | regions.   The manufacturing method of Claim 1 which repeats the cycle containing the said process A and the said process B, and obtains a some resin sheet.   The length of unwinding the sheet to be cut from the roll body in step A in the initial cycle and the length of unwinding the sheet to be cut from the roll body in step A in the late cycle are different lengths. Production method. The manufacturing method according to claim 5, wherein the length of winding the sheet to be cut from the roll body in step A in the initial cycle is longer than the length of winding the sheet to be cut from the roll body in step A in the late cycle. .

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