JP2014028431A - Sheet manufacturing apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a sheet manufacturing apparatus capable of producing a mask suppressed in occurrence of pores with a high production efficiency from a composition containing particles and a resin component.SOLUTION: A sheet manufacturing apparatus 1 includes a cylinder 70, a kneader 2 including a kneading shaft 13 inserted into the cylinder 70, and a gear structure 4 including a pair of gears 32 and arranged on the discharge direction downstream side of the kneader 2. The cylinder 70 is formed with an introduction port 14 on one end side, and a discharge port 15 on the other end side. The kneading shaft 13 includes a paddle part 11a for kneading a composition between the introduction port 14 and the discharge part 15 in the axial direction of the kneading shaft 13, and a pipe part 12a having a smooth surface extending along the axial direction of the kneading shaft 13 without causing irregularity. The gear structure 4 is formed so as to transport a kneaded product Y discharged from the discharge part 15 while deforming to the rotation axis direction A1 of the gear 32.

Description

  The present invention relates to a sheet manufacturing apparatus, and more particularly to a sheet manufacturing apparatus configured to manufacture a sheet containing particles and a resin component.

  Conventionally, kneaders have been widely used for kneading powders and the like.

  As such a kneading machine, for example, a cylindrical casing provided with an input port for inputting an object to be processed and an output port for discharging, and a cylindrical casing disposed in the cylindrical casing, from the input port side to the discharge port side. On the other hand, there has been proposed a continuous biaxial kneader including a kneading shaft provided with a feed screw, a paddle, and a reverse screw sequentially (see, for example, Patent Document 1).

  And in such a continuous biaxial kneader, after putting a processed material (for example, powdery resin) into the cylindrical casing from the charging port, and kneading the processed material with a paddle provided on the kneading shaft, The kneaded product of the object to be processed is pushed out from the discharge port by a reverse screw to the outside of the cylindrical casing and discharged.

Japanese Patent Laid-Open No. 11-267483

  However, pores (voids) may be generated in the kneaded material that has been kneaded and discharged by the continuous biaxial kneader described in Patent Document 1. Such pores in the kneaded product may cause problems in various industrial products in which the kneaded product is used.

  Further, when a sheet is produced from a composition containing particles and a resin component using a continuous biaxial kneader described in Patent Document 1, after kneading the composition, the kneaded product is taken out from the kneader, Thereafter, it is necessary to adopt a batch production method in which the kneaded product is pressed, and there is a problem that the sheet manufacturing efficiency is low.

  Then, the objective of this invention is providing the sheet | seat manufacturing apparatus which can manufacture the sheet | seat with which generation | occurrence | production of the pore was suppressed from the composition containing particle | grains and a resin component with high manufacturing efficiency.

  In order to achieve the above object, a sheet manufacturing apparatus of the present invention is a sheet manufacturing apparatus configured to manufacture a sheet from a composition containing particles and a resin component. A kneading shaft that is inserted, and a kneading machine that discharges the kneaded material; a gear structure that includes a pair of gears and that is disposed on the downstream side in the discharging direction of the kneading machine; An introduction portion for introducing the composition into the cylinder is formed on the side, and a discharge portion for discharging the kneaded material kneaded with the composition to the outside of the cylinder is formed on the other end side. The kneading shaft is disposed between the introduction portion and the discharge portion in the axial direction of the kneading shaft, a kneading portion for kneading the composition, and disposed closer to the discharge portion than the kneading portion. No irregularities along the axis direction of the shaft A low-shear portion having a smooth surface extending in a straight line, and the gear structure is configured to convey the kneaded material discharged from the discharge portion while being deformed in a rotation axis direction of the gear. It is a feature.

  According to such a configuration, when the composition containing the particles and the resin component is introduced into the cylinder from the introduction portion, the composition is first kneaded by the kneading portion, and then the kneaded product is uneven. It passes through a low shear portion having a smooth surface extending so as not to be present, that is, a low shear portion in which shearing in a direction intersecting the axial direction of the kneading shaft is suppressed, and is discharged from the discharge portion. The discharged kneaded material is continuously conveyed in a sheet form while being deformed in the gear rotation direction by the gear structure.

  Therefore, a sheet in which the generation of pores is suppressed can be efficiently produced from a composition containing particles and a resin component.

  Further, since the kneaded product is deformed using the gear structure, the sheet can be produced by dispersing the particles in the resin component at a high blending ratio.

  In the sheet manufacturing apparatus of the present invention, it is preferable that the sheet is manufactured so that the volume ratio of the particles exceeds 30% by volume.

  According to such a structure, the sheet | seat in which the volume ratio of particle | grains exceeds 30 volume% can be manufactured efficiently.

  In the sheet manufacturing apparatus of the present invention, each of the pair of gears includes oblique teeth that mesh with each other, and the tooth trace of the oblique teeth extends from the downstream side in the rotational direction to the upstream side in the rotational direction of the pair of gears. It is preferable that it is inclined outward in the direction of the rotation axis as it goes.

  According to such a configuration, the kneaded material discharged from the kneader is surely spread so as to spread to both outer sides in the rotation axis direction by a pair of gear rotations in the gear structure.

  Therefore, a wide sheet can be produced reliably.

  In the sheet manufacturing apparatus of the present invention, the kneaded product is provided on the downstream side in the discharge direction of the kneader and the upstream side in the transport direction of the gear structure, and the kneaded product has a width along the discharge direction of the kneader. As described above, it is preferable to further include a supply unit configured to supply the gear structure from a direction intersecting the transport direction.

  According to such a configuration, the kneaded material discharged from the kneader can be smoothly supplied to the gear structure.

  Therefore, it is possible to efficiently manufacture a sheet in which the generation of pores is suppressed.

  In the sheet manufacturing apparatus of the present invention, it is preferable that the low shear portion is formed so that there is no unevenness over the entire circumferential surface.

  According to such a configuration, the shear in the direction intersecting the axial direction of the kneading shaft in the low shear portion is further suppressed.

  Therefore, the generation of pores in the kneaded product can be further suppressed.

  Further, in the sheet manufacturing apparatus of the present invention, the cylinder includes a vent portion for discharging the gas in the cylinder, and the vent portion is introduced in the axial direction of the kneading shaft rather than the low shear portion. It is suitable to arrange on the part side.

  According to such a configuration, after the air or moisture in the kneaded material is discharged to the outside of the cylinder, the kneaded material reaches the low shear portion.

  Therefore, the generation of pores in the kneaded product can be further suppressed.

  In the sheet manufacturing apparatus of the present invention, a movable support provided on the downstream side in the conveyance direction of the gear structure and configured to support and convey the sheet, and a gap with respect to the movable support It is preferable that the apparatus further includes a sheet adjusting unit including a doctor disposed so as to face the doctor.

  According to such a configuration, after the kneaded material is conveyed as a sheet while being deformed in the axial direction using the gear structure, the sheet deformed in the axial direction is supported and conveyed by the movable support. Pass through the gap with the doctor.

  Therefore, the sheet can be manufactured uniformly.

  The sheet manufacturing apparatus of the present invention can efficiently manufacture a sheet in which generation of pores is suppressed from a composition containing particles and a resin component.

FIG. 1 is a partially cutaway plan view of an embodiment of the sheet manufacturing apparatus of the present invention. FIG. 2 is a sectional view taken along the line AA in FIG. FIG. 3 shows a schematic configuration diagram of a kneader used in the sheet manufacturing apparatus shown in FIG. 4 shows a cross-sectional plan view of the discharge port side of the kneader shown in FIG. FIG. 5 is a cross-sectional plan view of a supply unit, a gear structure, and a sheet adjustment unit used in the sheet manufacturing apparatus shown in FIG. 6 is a side cross-sectional view of the supply unit, the gear structure, and the seat adjustment unit shown in FIG. 5, and shows a cross-sectional view along the line BB in FIG. 5. FIG. 7 shows an exploded perspective view of a pair of gears of the gear structure shown in FIG. FIG. 8 is a side sectional view for explaining the meshing of the pair of gears shown in FIG. 7, and (a) shows the downstream end of the convex surface of the inclined tooth of the first gear and the inclined tooth of the second gear. The state where the downstream end of the concave surface meshes, (b) is the state where the middle part of the convex surface of the inclined teeth of the first gear and the middle part of the concave surface of the inclined teeth of the second gear, (c) The state which the upstream side edge part of the convex surface of the inclined tooth of a 1st gear and the upstream edge part of the concave surface of the inclined tooth of a 2nd gear mesh | engage is shown. FIG. 9 shows a partially cutaway plan view of another embodiment of the sheet manufacturing apparatus of the present invention. FIG. 10 is a schematic configuration diagram of a kneader used in the sheet manufacturing apparatus shown in FIG. FIG. 11 is a plan sectional view of the discharge port side of the kneader shown in FIG. FIG. 12 is a plan sectional view on the discharge port side of another embodiment of the kneader used in the sheet manufacturing apparatus of the present invention. FIG. 13: shows sectional drawing of other embodiment (spline-like aspect) of the pipe part used for the sheet manufacturing apparatus of this invention. FIG. 14 shows a cross-sectional view of another embodiment (an aspect having a notch) of a pipe portion used in the sheet manufacturing apparatus of the present invention. FIG. 15: shows the disassembled perspective view of a pair of gears (mode which is a flat tooth) of other embodiment of the sheet manufacturing apparatus of this invention. FIG. 16 is a plan cross-sectional view of a supply unit, a gear structure, and a sheet adjustment unit of another embodiment of the sheet manufacturing apparatus of the present invention. 17 is a side cross-sectional view of the supply unit, the gear structure, and the seat adjustment unit shown in FIG. 16, and shows a cross-sectional view taken along the line CC of FIG. FIG. 18 is a plan cross-sectional view of a supply unit, a gear structure, and a sheet adjustment unit of another embodiment of the sheet manufacturing apparatus of the present invention. 19 is a side cross-sectional view of the supply unit, the gear structure, and the seat adjustment unit shown in FIG. 18, and shows a cross-sectional view taken along the line DD of FIG. FIG. 20 is a side sectional view for explaining the meshing of a pair of gears (involute curve shape) in another embodiment of the sheet manufacturing apparatus of the present invention. FIG. 21 is a side sectional view of a sheet adjustment unit of another embodiment of the sheet manufacturing apparatus of the present invention. FIG. 22 shows a digital microscope photograph of a cross section of the kneaded material of Example 2. FIG. 23 shows a digital microscope photograph of a cross section of the kneaded material of Comparative Example 2.

  FIG. 1 is a partially cutaway plan view of an embodiment of the sheet manufacturing apparatus of the present invention. FIG. 2 is a sectional view taken along the line AA in FIG. FIG. 3 shows a schematic configuration diagram of a kneader used in the sheet manufacturing apparatus shown in FIG. 4 shows a cross-sectional plan view of the discharge port side of the kneader shown in FIG. FIG. 5 is a cross-sectional plan view of a supply unit, a gear structure, and a sheet adjustment unit used in the sheet manufacturing apparatus shown in FIG. 6 is a side cross-sectional view of the supply unit, the gear structure, and the seat adjustment unit shown in FIG. 5, and shows a cross-sectional view along the line BB in FIG. 5. FIG. 7 shows an exploded perspective view of a pair of gears of the gear structure shown in FIG. FIG. 8 is a side sectional view for explaining the meshing of the pair of gears shown in FIG. 7, and (a) shows the downstream end of the convex surface of the inclined tooth of the first gear and the inclined tooth of the second gear. The state where the downstream end of the concave surface meshes, (b) is the state where the middle part of the convex surface of the inclined teeth of the first gear and the middle part of the concave surface of the inclined teeth of the second gear, (c) The state which the upstream side edge part of the convex surface of the inclined tooth of a 1st gear and the upstream edge part of the concave surface of the inclined tooth of a 2nd gear mesh | engage is shown.

  In FIG. 1, the right side of the page is “right side”, the left side of the page is “left side”, the lower side of the page is “front side”, the upper side of the page is “rear side”, and is indicated by a directional arrow. The description will be made assuming that the back side of the page is the “lower side”. Further, in FIG. 1, the right side is one side in the rotation axis direction of a pair of gears (described later), the left side is the other side in the rotation axis direction, the front side is one side in the intersecting direction (described later), and the rear The side is the other side in the cross direction. Further, the directions of the drawings after FIG. 2 are the same as those described in FIG.

  In FIG. 1, the sheet manufacturing apparatus 1 is configured to manufacture a sheet from a composition X containing particles and a resin component, which will be described later, and is formed, for example, in a substantially L shape in plan view. The sheet manufacturing apparatus 1 includes a kneader 2, a supply unit 3, a gear structure 4, a sheet adjustment unit 5, and a winding unit 6. The kneader 2, the supply unit 3, the gear structure 4, the sheet adjustment unit 5, and the winding unit 6 are arranged in a substantially L shape in plan view in the sheet manufacturing apparatus 1. That is, the sheet manufacturing apparatus 1 is configured to convey a composition X or a sheet 7 (see FIG. 2) described later in a substantially L shape in plan view.

  The kneader 2 is provided on the left side of the sheet manufacturing apparatus 1.

  As shown in FIGS. 3 and 4, the kneader 2 is a continuous biaxial kneader and includes a cylinder 70 and two kneading shafts 13.

  The cylinder 70 is formed in a substantially elliptic cylindrical shape extending in the left-right direction, and a composition X containing particles and a resin component is placed inside the cylinder 70 on the left end side (one end side) as shown in FIG. An introduction port 14 is provided as an introduction part for introduction. Further, on the right end side (the other end side), a discharge port 15 is provided as a discharge unit for discharging the kneaded material Y kneaded with the composition X to the outside of the cylinder 70.

  As shown in FIG. 3, the introduction port 14 is formed so as to penetrate the upper wall of the left end portion of the cylinder 70 and open upward.

  The discharge port 15 is formed at the right end of the cylinder 70 so as to open to the right.

  Examples of the cross-sectional shape of the discharge port 15 include a rectangular shape, an elliptical shape, and a circular shape, and an elliptical shape and a circular shape are preferable.

  Further, the cross-sectional area of the discharge port 15 is, for example, 15% or more, preferably 25% or more, and, for example, 50% or less, preferably 45% or less with respect to the cross-sectional area of the cylinder 70. .

  Further, a melt kneading part 6 a for melting and kneading the composition X is formed between the introduction port 14 and the discharge port 15 in the cylinder 70.

  The melt-kneading part 6a is provided with a plurality of (two) vent parts 7a for discharging the gas in the melt-kneading part 6a in the middle in the axial direction.

  Each vent portion 7 a is formed so as to penetrate the upper wall of the cylinder 70. That is, each vent portion 7 a and the inlet 14 are formed so as to be parallel to each other in the axial direction of the kneading shaft 13.

  Moreover, each vent part 7a is always closed and can be appropriately opened as necessary.

  More specifically, the plurality of vent portions 7 a are arranged in the left-right direction of the cylinder 70, the vent portion 7 a on the inlet side provided near the right side of the inlet port 14, and the discharge port side provided near the left side of the discharge port 15. Vent portion 7a.

  Further, the vent portion 7a on the discharge port 15 side is arranged on the left side of the pipe portion 12a (described later) and is connected to a pump (not shown), and suction force by driving the pump (not shown). As a result, the gas in the melt-kneading part 6a is sucked.

  The melt-kneading unit 6 a is provided with a heater (not shown), and the temperature of the melt-kneading unit 6 a is appropriately adjusted in blocks in the left-right direction of the cylinder 70.

  The kneading shaft 13 is inserted (arranged) into the cylinder 70. The kneading shaft 13 is a rotating shaft for mixing and shearing the composition X, and includes a drive shaft 8a, a feed screw portion 9a, a reverse screw portion 10a, a paddle portion 11a as a kneading portion, and a pipe as a low shear portion. The part 12a is integrally formed.

  Specifically, the kneading shaft 13 includes one drive shaft 8a, a plurality (four) of feed screw portions 9a, a plurality (two) of reverse screw portions 10a, and a plurality of (three) paddle portions 11a, One pipe portion 12a is provided.

  In addition, the feed screw part 9a, the reverse screw part 10a, the paddle part 11a, and the pipe part 12a can change the axial direction length and the number of installation suitably as needed.

  The plural (four) feed screw portions 9a are portions for conveying the composition X toward the discharge port 15, and specifically, a first feed portion 23a, a second feed portion 24a, and a third feed portion. 25a and the fourth feed portion 26a, which are arranged at an interval from each other in the axial direction of the drive shaft 8a.

  The first feed portion 23a is disposed at the left end portion of the kneading shaft 13, and overlaps the projection surface when the introduction port 14 and the vent portion 7a on the introduction port 14 side are projected in the radial direction of the drive shaft 8a. Has been placed. The first feed portion 23a is formed so that the axial length of the drive shaft 8a is the longest compared to other feed portions.

  The fourth feed portion 26a is disposed closest to the discharge port 15 of the four feed portions, and overlaps the projection surface when the vent portion 7a on the discharge port 15 side is projected in the radial direction of the drive shaft 8a. Is arranged. The fourth feed portion 26a is formed such that the axial length of the drive shaft 8a is approximately ½ of the first feed portion 23a.

  The second feed portion 24a and the third feed portion 25a are disposed between the first feed portion 23a and the fourth feed portion 26a, and the axial length of the drive shaft 8a is substantially the same as that of the first feed portion 23a. It is formed in 1/10.

  Further, as shown in FIG. 4, the feed screw portion 9 a includes a helical screw strip 20 a that protrudes from the outer peripheral surface of the drive shaft 8 a.

  Specifically, the screw strip 20a of the feed screw portion 9a is formed in a spiral shape in the same direction as the rotation direction (described later) of the drive shaft 8a. That is, the feed screw portion 9a includes a right spiral screw strip 20a.

  The pitch interval of the screw strip 20a in the feed screw portion 9a is, for example, 0.6 cm or more, preferably 1.5 cm or more, and for example, 2.0 cm or less.

  As shown in FIG. 3, the plurality of (two) reverse screw portions 10 a are formed of a first reverse portion 30 a and a second reverse portion 31 a, which are spaced from each other in the axial direction of the kneading shaft 13. Are arranged.

  The first reverse unit 30a is disposed between the first feed unit 23a and the second feed unit 24a and adjacent to the left side of the second feed unit 24a.

  The second reverse unit 31a is disposed adjacent to the left side of the third feed unit 25a between the second feed unit 24a and the third feed unit 25a.

  Further, the first reverse portion 30a and the second reverse portion 31a are formed so that the axial length of the drive shaft 8a is substantially the same. The axial direction length is about 1/20 of the 1st feed part 23a.

  Similarly to the feed screw portion 9a, the reverse screw portion 10a also includes a helical screw strip 20a protruding from the outer peripheral surface of the drive shaft 8a, as shown in FIG.

  On the other hand, the screw strip 20a of the reverse screw portion 10a is formed in a spiral shape opposite to the screw strip 20a of the feed screw portion 9a. That is, the reverse screw portion 10a includes a left spiral screw strip 20a.

  The pitch interval of the screw strip 20a in the reverse screw portion 10a is, for example, 0.6 cm or more, preferably 1.0 cm or more, and for example, 1.5 cm or less.

  As shown in FIG. 3, the plurality (three) of paddle portions 11a are portions for kneading the composition X. Specifically, the first paddle portion 27a, the second paddle portion 28a, and the third paddle portion 29a, which are arranged in the axial direction of the kneading shaft 13 and spaced from each other.

  The first paddle part 27a is disposed between the first feed part 23a and the first reverse part 30a.

  The second paddle part 28a is disposed between the second feed part 24a and the second reverse part 31a.

  The third paddle part 29a is disposed between the third feed part 25a and the fourth feed part 26a.

  Further, the first paddle portion 27a, the second paddle portion 28a, and the third paddle portion 29a are substantially the same in length in the axial direction of the drive shaft 8a, and are approximately １ ／ of the first feed portion 23a. Is formed.

  Further, as shown in FIG. 4, the paddle portion 11a includes a plurality of substantially elliptical paddle feathers 21a arranged in parallel along the axial direction of the drive shaft 8a.

  More specifically, the plurality of paddle blades 21a are arranged in parallel so that the major axis of each adjacent paddle blade 21a is displaced by about 90 ° in the axial direction of the drive shaft 8a.

  The pipe portion 12a is formed in a substantially cylindrical shape along the axial direction of the drive shaft 8a, and is formed so as not to be uneven over the entire circumferential surface.

  The pipe portion 12a is disposed at the right end portion of the kneading shaft 13, and is disposed adjacent to the right side of the fourth feed portion 26a. Further, the pipe portion 12a is formed so that the axial length of the drive shaft 8a is approximately ½ of the first feed portion 23a.

  That is, in the kneading shaft 13, as shown in FIG. 3, the first feed portion 23a, the first paddle portion 27a, the first reverse portion 30a, the second feed are sequentially arranged from the left end side to the right end side of the drive shaft 8a. The part 24a, the second paddle part 28a, the second reverse part 31a, the third feed part 25a, the third paddle part 29a, the fourth feed part 26a, and the pipe part 12a are arranged.

  That is, the kneading shaft 13 has a unit composed of a feed part, a paddle part, and a reverse part repeatedly arranged from the left end side to the right end side of the drive shaft 8a. In the right end unit, instead of the reverse part, A feed part and a pipe part are arranged.

  As shown in FIG. 4, the two kneading shafts 13 are arranged along the axial direction inside the cylinder 70, and are arranged in parallel with each other along the radial direction.

  In addition, the two kneading shafts 13 are arranged so as not to interfere with each other's rotational drive in their respective parts (feed screw part 9a, reverse screw part 10a, paddle part 11a).

  Further, both end portions of the drive shaft 8 a of the kneading shaft 13 protrude outward in the axial direction of the cylinder 70. Of the projecting ends, the right end side is connected to a drive source (not shown) in a relatively non-rotatable manner, and the left end side is supported by a support wall (not shown) in a relatively rotatable manner. That is, the kneading shaft 13 is rotationally driven around the axis of the drive shaft 8a by transmitting a drive force from a drive source (not shown) to the drive shaft 8a. Specifically, the kneading shaft 13 rotates clockwise in the axial direction of the drive shaft 8a when viewed from the inlet 14 side to the outlet 15 side.

  As shown in FIG. 4, the inner peripheral surface of the cylinder 70 and the feed screw portion 9 a, the reverse screw portion 10 a, and the paddle portion 11 a of the kneading shaft 13 are spaced apart from each other in the radial direction of the kneading shaft 13. Are arranged to face each other. Further, the inner peripheral surface of the cylinder 70 and the pipe portion 12a are arranged with a large gap in the radial direction of the kneading shaft 13 as compared with other portions.

  As shown in FIG. 1, the supply unit 3 is provided on the right side of the kneader 2 and is formed to extend in the left-right direction. The supply unit 3 is connected to the kneader 2 by a connecting pipe 17.

  The connecting pipe 17 is formed in a substantially cylindrical shape having an axis common to the axis of the cylinder 70. The left end of the connecting pipe 17 is connected to the right end of the cylinder 70, and the right end of the connecting pipe 17 is connected to a supply unit inlet 18 (described later) of the supply unit 3.

  As shown in FIGS. 7 and 8, the supply unit 3 includes a first casing 21 and a supply screw 22.

  The first casing 21 has a rectangular shape in plan view extending in the left-right direction, and the front side is opened in the left-right direction. A supply portion inlet 18 is formed at the left end portion of the first casing 21, and a first storage portion 27 is formed at the front end portion of the first casing 21. The first casing 21 is provided with a first accommodating portion 19 that accommodates a supply screw 22 described below. The first accommodating part 19 includes a rear part 29 and a front part 30 communicating with the front side of the rear part 29. Each of the rear portion 29 and the front portion 30 has a substantially circular shape in a side sectional view, and is formed in the first casing 21 in the left-right direction.

  The supply unit inlet 18 communicates with the first storage unit 19 (rear part 29 and front part 30).

  The 1st storage part 27 is formed in the side cross sectional view substantially taper shape which becomes large toward the front.

  The supply screw 22 is housed in the first housing portion 19 and includes a first screw 23 and a second screw 24 that extend in the left-right direction and mesh with each other.

  The first screw 23 is accommodated in the rear portion 29 and includes blades 20 that are inclined with respect to the rotation direction R <b> 1 of the first screw 23. The pitch interval in the rotation axis direction of the blades 20 of the first screw 23 is, for example, 5 mm or more, preferably 10 mm or more, and for example, 50 mm or less, preferably 30 mm or less.

  The second screw 24 is accommodated in the front portion 30, has the same configuration and the same dimensions as the first screw 23, and rotates in the same direction as the first screw 23 while meshing with the first screw 23. It is configured.

  The length of the supply screw 22 (the first screw 23 and the second screw 24) in the rotation axis direction is set shorter than the width W0 of the first casing 21 by a minute clearance (not shown).

  The supply unit 3 is provided with a motor (not shown) connected to the supply screw 22 on the right side of the first casing 21.

  The supply unit 3 supplies the kneaded material Y to the gear structure 4 from the rear so as to have a width W0 along the discharge direction (left-right direction) of the kneader 2 (that is, the width W0 of the first casing 21). It is configured.

  As shown in FIGS. 6 and 7, the gear structure 4 includes a second casing 31 and a pair of gears 32. The gear structure 4 is also a gear pump in which the length W2 of the pair of gears 32 in the rotation axis direction A1 is long, and the kneaded material Y supplied from the supply unit 3 is conveyed to the sheet adjustment unit 5.

  As shown in FIGS. 5 and 6, the second casing 31 is continuously formed on the front side of the first casing 21, the rear and front are opened in the left-right direction, and the substantially rectangular shape in plan view extending in the left-right direction. Is formed. A second housing portion 40 that houses a pair of gears 32 is provided at the rear end portion of the second casing 31, and a gear discharge port 46 is formed at the front end portion. In addition, a second storage portion 28 and a discharge passage 44 that are communicated with the second storage portion 40 and the gear discharge port 46 are formed.

  The second accommodating portion 40 includes a lower portion 61 and an upper portion 62 that communicates with the first storage portion 27 and communicates with the upper side of the lower portion 61. Each of the lower part 61 and the upper part 62 has a substantially circular shape in a side sectional view, and is formed in the second casing 31 in the left-right direction.

  The gear discharge port 46 is partitioned by two discharge walls 45 formed at an interval in the vertical direction, and is formed to open forward. The discharge wall 45 is provided at the front end portion of the second casing 31 and includes a lower side wall 47 and an upper side wall 48.

  The lower side wall 47 has a thick flat plate shape extending in the left-right direction and the up-down direction, and each of its front surface and upper surface is formed flat.

  The upper side wall 48 has a flat bottom surface. Further, the upper side wall 48 has a substantially L shape in a side sectional view, and is formed such that the lower front end projects forward with respect to the upper front surface. That is, in the upper side wall 48, the lower front end portion is a protruding portion 63 as a doctor having a substantially rectangular shape in a side sectional view. The protruding length (that is, the length in the front-rear direction) of the protruding portion 63 is, for example, 2 mm or more, and is, for example, 150 mm or less and 50 mm or less. In addition, the thickness of the protrusion 63 (that is, the length in the vertical direction) is, for example, 2 mm or more, and is, for example, 100 mm or less, preferably 50 mm or less. The front surface of the protrusion 63 and the front surface of the lower side wall 47 are formed so as to be in the same position when projected in the vertical direction.

  The 2nd storage part 28 is connected to the front side of the 2nd accommodating part 40, and is formed in the side cross sectional view substantially U shape by which the back is opened.

  The discharge passage 44 communicates with the front side of the second storage portion 28 and also communicates with the rear side of the gear discharge port 46. The discharge passage 44 is formed in a substantially straight line extending forward when viewed from a side sectional view.

  As shown in FIG. 7, the pair of gears 32 is, for example, a double helical gear, and specifically includes a first gear 33 and a second gear 34.

  The first shaft 25 that is the rotation shaft of the first gear 33 is provided in the second casing 31 (see FIG. 8) so as to extend in the left-right direction.

  The second shaft 26 that is the rotation shaft of the second gear 34 is provided so as to extend in parallel with the first shaft 25 in the second casing 31 (see FIG. 8). Further, the second shaft 26 is disposed so as to face the first shaft 25 upward.

  Each of the first gear 33 and the second gear 34 is accommodated in the lower portion 61 and the upper portion 62.

  Each of the first gear 33 and the second gear 34 specifically includes inclined teeth 35 that mesh with each other.

  In the first gear 33, the tooth traces of the inclined teeth 35 are inclined outward in the rotational axis direction A1 from the downstream side in the rotational direction R2 of the first gear 33 toward the upstream side in the rotational direction R2. The oblique teeth 35 are integrally provided with first oblique teeth 36 and second oblique teeth 37 having different tooth traces. In the first gear 33, the first inclined teeth 36 are formed on the right side from the center in the axial direction of the first gear 33, and the second inclined teeth 37 are formed on the left side from the center in the axial direction of the first gear 33.

  Specifically, the tooth traces of the first inclined teeth 36 are inclined from the left side (center side) to the right side (right end side) from the downstream side in the rotation direction R2 toward the upstream side in the rotation direction R2. On the other hand, the tooth traces of the second oblique teeth 37 are formed symmetrically with respect to the tooth traces of the first oblique teeth 36 with respect to the central portion in the left-right direction of the first gear 33, and specifically, the rotational direction. As it goes from the downstream side of R2 to the upstream side in the rotational direction R2, it is inclined from the right side (center side) to the left side (left end side).

  The second gear 34 is formed symmetrically with respect to the first gear 33 and is configured to mesh with the first gear 33. Specifically, the third gear 34 meshes with the first gear teeth 36. 38 and a fourth inclined tooth 39 that meshes with the second inclined tooth 37 are integrally provided.

  As shown in FIG. 8, the pair of gears 32 are configured such that the meshing portions indicated by black circles are configured such that the first gear 33 and the second gear 34 are in point contact in a side sectional view. It is a side cross-section point contact type. In addition, the pair of gears 32 are formed in the shape of a helical winding of the first gear 33 and the second gear 34 along the tooth traces of the pair of gears 32. Also referred to as contact type.

  The inclined teeth 35 of the pair of gears 32 are provided at intervals in the rotational direction R2 and connect the concave surfaces 42 formed so as to be curved inward in the radial direction, and the concave surfaces 42. A curved surface 41 integrally provided with a convex surface 43 formed so as to curve radially outward from both circumferential ends is provided.

  Next, the meshing of the pair of gears 32 on the curved surface 41 will be described with reference to FIGS. 8 (a) to 8 (c).

  First, as shown in FIG. 8A, the downstream end portion in the rotational direction R2 of the convex surface 43 of the first gear 33 and the downstream end portion in the rotational direction R2 of the concave surface 42 of the second gear 34 are engaged with each other. 8A and 8B, when the first gear 33 and the second gear 34 rotate in the rotational direction R2, the convex surface 43 of the first gear 33 rotates in the rotational direction R2. The midway portion and the midway portion of the concave surface 42 of the second gear 34 in the rotational direction R2 mesh with each other. Subsequently, as shown in the arrow of FIG. 8B and FIG. 8C, when the first gear 33 and the second gear 34 rotate in the rotation direction R2, the convex surface 43 of the first gear 33 upstream of the rotation direction R2. The side end portion and the upstream end portion in the rotation direction R2 of the concave surface 42 of the second gear 34 mesh with each other. In other words, the meshing portion of the convex surface 43 of the first gear 33 and the concave surface 42 of the second gear 34 sequentially and sequentially moves to the downstream end portion, the middle portion, and the upstream end portion in the rotational direction R2 on each surface. .

  Subsequently, although not shown, the meshing portions of the concave surface 42 of the first gear 33 and the convex surface 43 of the second gear 34 are also sequentially arranged on the downstream end, the middle portion, and the upstream end in the rotational direction R2 on each surface. Move continuously.

  Therefore, the meshing portion of the curved surface 41 of the first gear 33 and the curved surface 41 of the second gear 34 moves continuously along the rotational direction R2. This movement of the meshing portion prevents formation of a storage portion 65 (see FIG. 20 described later) in which the kneaded material Y accumulates during conveyance of the kneaded material Y.

  The gear structure 4 is provided with a motor (not shown) connected to the first shaft 25 and the second shaft 26 of the pair of gears 32 on the right side of the supply screw 22.

  As shown in FIGS. 5 and 6, the seat adjustment portion 5 is provided on the front side of the gear structure 4 so as to include the protrusion 63 of the upper side wall 48, for example, the protrusion 63 in the gear structure 4 And a support roll 51 as a moving support. Further, as shown in FIG. 2, the sheet adjusting unit 5 includes a base material feed roll 56, a separator laminate roll 57, a rolling roll 58, and a separator feed roll 59.

  As shown in FIGS. 2 and 6, the protrusion 63 is discharged from the role of a wall that defines the gear discharge port 46 of the second casing 31 in the gear structure 4 and from the gear discharge port 46 in the sheet adjustment unit 5. It has both the role of a doctor (or knife) that adjusts the thickness of the sheet 7.

  The support roll 51 is disposed so as to face the protrusion 63 so that a gap 50 is provided. The rotation axis of the support roll 51 is parallel to the first shaft 25 and the second shaft 26 of the pair of gears 32, and specifically extends in the left-right direction as shown in FIG. Further, as shown in FIG. 6, the rotation axis of the support roll 51 is arranged so as to overlap with the gear discharge port 46 and the protrusion 63 when projected in the front-rear direction. The support roll 51 is configured to support and convey the sheet.

  Accordingly, the support roll 51 is configured to pass the sheet through the gap 50.

  As shown in FIG. 2, the base material feed roll 56 is provided below the support roll 51 with a gap. The rotation axis of the base material feed roll 56 extends in the left-right direction, and the base material 8 is wound around the peripheral surface of the base material feed roll 56 in a roll shape.

  The separator laminating roll 57 and the rolling roll 58 are provided in front of the support roll 51 with a space therebetween. The rotation axes of the separator laminate roll 57 and the rolling roll 58 are arranged so as to extend in the left-right direction. The separator laminating roll 57 is disposed on the upper side of the rolling roll 58 so as to be pressed against the rolling roll 58.

  The rolling roll 58 is configured to be capable of rolling with respect to the sheet 7 and the substrate 8 upon receiving a pressure from the separator laminating roll 57, and the upper end portion of the rolling roll 58 is a support roll when projected in the front-rear direction. It arrange | positions so that it may become the same position as the upper end part of 51. FIG.

  The separator delivery roll 59 is provided on the diagonally upper front side of the separator laminate roll 57 with a gap therebetween. The rotation axis of the separator feed roll 59 extends in the left-right direction, and the separator 9 is wound around the peripheral surface of the separator feed roll 59 in a roll shape.

  The winding unit 6 is provided in front of the sheet adjustment unit 5 and includes a tension roll 52 and a winding roll 53.

  The tension roll 52 is provided in front of the rolling roll 58 at an interval. Specifically, the upper end of the tension roll 52 is located at the same position as the upper end of the rolling roll 58 when projected in the front-rear direction. It is arranged so that. The rotation axis of the tension roll 52 is formed to extend in the left-right direction.

  The take-up roll 53 is disposed to face the tension roll 52 at a diagonally lower front side with a space therebetween. The rotation axis of the take-up roll 53 extends in the left-right direction, and is configured so that the laminated sheet 10 can be taken up in a roll shape on the peripheral surface of the take-up roll 53.

  The dimensions of the sheet manufacturing apparatus 1 are appropriately set according to the types and blending ratios of the particles and resin components used and the width W1 and thickness T1 of the target sheet 7.

  As shown in FIG. 5, the width W0 of the first casing 21 is, for example, the relationship between the length W2 of the pair of gears 32 in the rotation axis direction and the following equation (1), preferably the relationship of the following equation (2): More preferably, it is set so as to satisfy the relationship of the following formula (3).

W2-100 (mm) ≦ W0 ≦ W2 + 150 (mm) (1)
W2-50 (mm) ≦ W0 ≦ W2 + 100 (mm) (2)
W2-20 (mm) ≦ W0 ≦ W2 + 50 (mm) (3)
As shown in FIG. 7, the length W2 of the pair of gears 32 in the rotation axis direction can be appropriately selected according to the width W1 of the sheet 7 to be manufactured. Specifically, the width W0 of the first casing 21 described above. And is, for example, 70% or more, preferably 80% or more, and, for example, 100% or less with respect to the width W1 of the sheet 7.

  Specifically, the length W2 in the rotation axis direction of the pair of gears 32 is, for example, 200 mm or more, preferably 300 mm or more, and, for example, 2000 mm or less.

  The gear diameter of the pair of gears 32 (the diameter (outer diameter) of the gears 32) is set so that the pair of gears 32 is not distorted by the pressure during conveyance of the kneaded material. , Preferably, it is 20 mm or more, for example, 200 mm or less, preferably 80 mm or less.

  The tooth depth of the pair of gears 32 is, for example, 1 mm or more, preferably 3 mm or more, and for example, 30 mm or less, preferably 20 mm or less.

  The pitch interval of the inclined teeth 35 in the rotation axis direction A1 is, for example, 5 mm or more, preferably 10 mm or more, and for example, 30 mm or less, preferably 25 mm or less. Further, the angle (inclination angle) of the tooth traces of the inclined teeth 35 with respect to the rotation axis of the pair of gears 32 is, for example, 5 degrees or more, preferably 10 degrees or more, more preferably 15 degrees or more. For example, it is less than 90 degrees, preferably 85 degrees or less, more preferably 80 degrees or less.

  As shown in FIGS. 5 and 6, the longitudinal distance L1 of the gap 50 is appropriately set according to the dimension of the gear discharge port 46, and is, for example, 10 μm or more, preferably 30 μm or more. , 1000 μm or less, preferably 800 μm or less.

  Hereinafter, a method for manufacturing the sheet 7 from a composition containing particles and a resin component using the sheet manufacturing apparatus 1 will be described.

  The particles include powder, granules, powders, and powders, and examples of the material forming the particles include inorganic materials and organic materials. Preferably, an inorganic material is used.

  Examples of the inorganic material include carbide, nitride, oxide, carbonate, sulfate, metal, clay mineral, and carbon-based material.

  Examples of the carbide include silicon carbide, boron carbide, aluminum carbide, titanium carbide, and tungsten carbide.

  Examples of the nitride include silicon nitride, boron nitride (BN), aluminum nitride (AlN), gallium nitride, chromium nitride, tungsten nitride, magnesium nitride, molybdenum nitride, and lithium nitride.

Examples of the oxide include silicon oxide (silica, including spherical fused silica powder, crushed fused silica powder, etc.), aluminum oxide (alumina, Al ₂ O ₃ ), magnesium oxide (magnesia), titanium oxide, cerium oxide, Examples thereof include iron oxide and beryllium oxide. Furthermore, as the oxide, for example, indium tin oxide or antimony tin oxide doped with metal ions can be used.

  Examples of the carbonate include calcium carbonate.

  Examples of the sulfate include calcium sulfate (gypsum).

  Examples of the metal include copper (Cu), silver, gold, nickel, chromium, lead, zinc, tin, iron, palladium, or an alloy thereof (such as solder).

  Examples of clay minerals include montmorillonite, magnesia montmorillonite, tetsu montmorillonite, tetsu magnesian montmorillonite, beidellite, aluminian beidelite, nontronite, aluminian nontronite, support stone, aluminian support stone, Examples include hectorite, soconite, and stevensite.

  Examples of the carbon-based material include carbon black, graphite, diamond, fullerene, carbon nanotube, carbon nanofiber, nanohorn, carbon microcoil, and nanocoil.

In addition, examples of the material include a material having specific physical properties, and a heat conductive material (for example, a heat conductive material selected from carbide, nitride, oxide and metal, specifically, BN, AlN, Al _2). O ₃ ), an electrically conductive material (for example, an electrically conductive material selected from metals and carbon-based materials, specifically Cu), an insulating material (for example, nitride, oxide, etc.) BN, silica, etc.), magnetic materials (for example, oxides, metals, specifically, ferrites (soft magnetic ferrite, hard magnetic), iron, etc.). The material having specific physical properties may overlap with the material exemplified above.

  The thermal conductivity of the heat conductive material is, for example, 10 W / m · K or more, preferably 30 W / m · K or more, and for example, 2000 W / m · K or less.

Further, the electrical conductivity of the electrically conductive material is, for example, 10 ⁶ S / m or more, preferably 10 ⁸ S / m or more, and usually 10 ¹⁰ S / m or less.

The volume resistance of the insulating material is 1 × 10 ¹⁰ Ω · cm or more, preferably 1 × 10 ¹² Ω · cm or more, and for example, 1 × 10 ²⁰ Ω · cm or less.

  The magnetic material has a magnetic permeability (μ ″ at a wavelength of 2.45 GHz), for example, 0.1 to 10.

  Moreover, the shape of particle | grains is not specifically limited, For example, plate shape, scale shape, particle shape (indefinite shape), spherical shape etc. are mentioned.

  The average value of the maximum length of particles (in the case of a spherical shape, the average particle diameter) is, for example, 0.1 μm or more, preferably 1 μm or more, and, for example, 1000 μm or less, preferably 100 μm or less. But there is.

  The aspect ratio of the particles is, for example, 2 or more, preferably 10 or more, and is, for example, 10,000 or less, preferably 5000 or less.

The specific gravity of the particles is, for example, 0.1 g / cm ³ or more, preferably 0.2 g / cm ³ or more, and for example, 20 g / cm ³ or less, preferably 10 g / cm ³ or less. .

  These particles can be used alone or in combination of two or more.

  The resin component can disperse the particles, that is, a dispersion medium (matrix) in which the particles are dispersed and contains an insulating component, and examples thereof include resin components such as a thermosetting resin component and a thermoplastic resin component. It is done.

  Examples of the thermosetting resin component include epoxy resins, thermosetting polyimides, urea resins, melamine resins, unsaturated polyester resins, diallyl phthalate resins, silicone resins, thermosetting urethane resins, and the like.

  Examples of the thermoplastic resin component include acrylic resin, polyolefin (for example, polyethylene, polypropylene, ethylene-propylene copolymer, etc.), polyvinyl acetate, ethylene-vinyl acetate copolymer, polyvinyl chloride, polystyrene, polyacrylonitrile, Polyamide, polycarbonate, polyacetal, polyethylene terephthalate, polyphenylene oxide, polyphenylene sulfide, polysulfone, polyethersulfone, polyetheretherketone, polyallylsulfone, thermoplastic polyimide, thermoplastic urethane resin, polyaminobismaleimide, polyamideimide, polyetherimide, Bismaleimide triazine resin, polymethylpentene, fluororesin, liquid crystal polymer, olefin-vinyl alcohol copolymer, polymer Ionomer, polyarylate, acrylonitrile - ethylene - styrene copolymers, acrylonitrile - butadiene - styrene copolymer, acrylonitrile - styrene copolymer, polystyrene - polyisobutylene copolymer and the like.

  These resin components can be used alone or in combination of two or more.

  Among the resin components, the thermosetting resin component is preferably an epoxy resin, and the thermoplastic resin component is preferably a polystyrene-polyisobutylene copolymer.

  The epoxy resin is in a liquid, semi-solid, or solid form at normal temperature.

  Specifically, as the epoxy resin, for example, bisphenol type epoxy resin (for example, bisphenol A type epoxy resin, bisphenol F type epoxy resin, bisphenol S type epoxy resin, hydrogenated bisphenol A type epoxy resin, dimer acid modified bisphenol type) Epoxy resin, etc.), novolac type epoxy resin, naphthalene type epoxy resin, fluorene type epoxy resin (eg, bisarylfluorene type epoxy resin), triphenylmethane type epoxy resin (eg, trishydroxyphenylmethane type epoxy resin), etc. Aromatic epoxy resins such as nitrogen-containing ring epoxy resins such as triepoxypropyl isocyanurate and hydantoin epoxy resins such as aliphatic epoxy resins, alicyclic epoxy resins, Glycidyl ether type epoxy resins, and glycidyl amine type epoxy resin.

  These epoxy resins can be used alone or in combination of two or more.

  The epoxy equivalent of the epoxy resin is, for example, 100 g / eq. Or more, preferably 180 g / eq. In addition, for example, 1000 g / eq. Hereinafter, preferably 700 g / eq. It is as follows. Moreover, when an epoxy resin is a normal temperature solid state, a softening point is 20-90 degreeC, for example.

  Moreover, an epoxy resin can be prepared as an epoxy resin composition by containing a hardening | curing agent and a hardening accelerator, for example.

  The curing agent is a latent curing agent (epoxy resin curing agent) that can cure the epoxy resin by heating. For example, a phenol compound, an amine compound, an acid anhydride compound, an amide compound, a hydrazide compound, an imidazoline compound, and the like. Is mentioned. In addition to the above, urea compounds, polysulfide compounds, and the like are also included.

  The phenol compound contains a phenol resin, for example, a novolac type phenol resin obtained by condensing phenol and formaldehyde in the presence of an acidic catalyst, for example, phenol synthesized from phenol and dimethoxyparaxylene or bis (methoxymethyl) biphenyl. Examples include aralkyl resins such as biphenyl aralkyl resins, such as dicyclopentadiene type phenol resins, such as cresol novolac resins, such as resole resins.

  Examples of the amine compound include polyamines such as ethylenediamine, propylenediamine, diethylenetriamine, and triethylenetetramine, or amine adducts thereof such as metaphenylenediamine, diaminodiphenylmethane, and diaminodiphenylsulfone.

  Examples of the acid anhydride compound include phthalic anhydride, maleic anhydride, tetrahydrophthalic anhydride, hexahydrophthalic anhydride, 4-methyl-hexahydrophthalic anhydride, methyl nadic acid anhydride, and pyromellitic acid. Anhydride, dodecenyl succinic anhydride, dichlorosuccinic anhydride, benzophenone tetracarboxylic acid anhydride, chlorendic acid anhydride and the like can be mentioned.

  Examples of the amide compound include dicyandiamide and polyamide.

  Examples of the hydrazide compound include adipic acid dihydrazide.

  Examples of the imidazoline compound include methyl imidazoline, 2-ethyl-4-methyl imidazoline, ethyl imidazoline, isopropyl imidazoline, 2,4-dimethyl imidazoline, phenyl imidazoline, undecyl imidazoline, heptadecyl imidazoline, 2-phenyl-4-methyl. Examples include imidazoline.

  These curing agents can be used alone or in combination of two or more.

  The curing accelerator is a curing catalyst, for example, an imidazole compound such as 2-phenylimidazole, 2-methylimidazole, 2-ethyl-4-methylimidazole, 2-phenyl-4-methyl-5-hydroxymethylimidazole, For example, tertiary amine compounds such as triethylenediamine and tri-2,4,6-dimethylaminomethylphenol, such as triphenylphosphine, tetraphenylphosphonium tetraphenylborate, tetra-n-butylphosphonium-o, o-diethylphospho Phosphorus compounds such as rosioate, for example, quaternary ammonium salt compounds, for example, organometallic salt compounds, for example, derivatives thereof and the like. These curing accelerators can be used alone or in combination of two or more.

  The mixing ratio of the curing agent in the epoxy resin composition is, for example, 0.5 parts by mass or more, preferably 1 part by mass or more, and for example, 200 parts by mass or less, preferably 100 parts by mass of the epoxy resin. Is 150 parts by mass or less, and the blending ratio of the curing accelerator is, for example, 0.1 parts by mass or more, preferably 0.2 parts by mass or more, and for example, 10 parts by mass or less, preferably It is also 5 parts by mass or less. Moreover, when a hardening | curing agent contains a phenol resin, the hydroxyl group of a phenol resin is 0.5 mol or more with respect to 1 mol of epoxy groups of an epoxy resin in an epoxy resin composition, Preferably, it is 0.00. It is 8 mol or more, and for example, it is adjusted to be 2.0 mol or less, preferably 1.2 mol or less.

  The above-mentioned curing agent and / or curing accelerator can be prepared and used as a solvent solution and / or a solvent dispersion dissolved and / or dispersed with a solvent, if necessary.

  Examples of the solvent include organic solvents such as ketones such as acetone and methyl ethyl ketone (MEK), esters such as ethyl acetate, and amides such as N, N-dimethylformamide. Examples of the solvent also include aqueous solvents such as water, for example, alcohols such as methanol, ethanol, propanol, and isopropanol.

  The curable resin component and the thermoplastic resin component can be used alone or in combination, respectively.

  The melt viscosity at 80 ° C. of the resin component (when the thermosetting resin component is contained, the resin component in which the thermosetting resin component is in an A stage state) is, for example, 10 mPa · s or more, preferably 50 mPa · s. For example, it is 10000 mPa · s or less.

  The softening temperature (ring and ball method) of the resin component is, for example, 80 ° C. or less, preferably 70 ° C. or less, and for example, 20 ° C. or more, preferably 35 ° C. or more.

  Specifically, the mixing ratio of the particles and the resin component is such that the volume ratio of the particles in the sheet 7 exceeds, for example, 30% by volume, preferably 35% by volume or more, preferably 40% by volume or more. Is set to be 60% by volume or more, more preferably 70% by volume or more, for example, 98% by volume or less, preferably 95% by volume or less.

  The mixing ratio of the particles and the resin component based on mass is set so as to be the volume ratio of the particles in the sheet 7 described above.

  The resin component includes, for example, a polymer precursor (for example, a low molecular weight polymer including an oligomer) and / or a monomer in addition to the above-described components (polymerized products).

  These resin components can be used alone or in combination.

  Then, as shown in FIG. 2, a composition X containing particles and a resin component is charged into the introduction port 14.

  In the sheet manufacturing apparatus 1, the kneader 2, the supply unit 3, and the gear structure 4 are adjusted to a predetermined temperature and rotation speed. The temperature of the kneader 2, the supply unit 3, and the gear structure 4 is, for example, higher than the softening temperature when the resin component contains a thermoplastic resin component, and the resin component is a thermosetting resin. When it contains a component, it is lower than its curing temperature, specifically, for example, 50 ° C or higher, preferably 70 ° C or higher, and for example, 200 ° C or lower, preferably 150 ° C or lower. But there is.

  Further, the base material 8 is wound around the base material feed roll 56 in advance.

  Examples of the substrate 8 include polypropylene film, ethylene-propylene copolymer film, polyester film (PET, etc.), plastic films such as polyvinyl chloride, paper such as kraft paper, cotton cloth, soft cloth, etc. And non-woven fabrics such as polyester non-woven fabric and vinylon non-woven fabric, for example, metal foil. The thickness of the base material 8 is appropriately selected according to the purpose and use thereof, and is, for example, 10 to 500 μm. In addition, the surface of the base material 8 can also be mold-released.

  Further, the separator 9 is wound around the separator feed roll 59 in advance.

  Examples of the separator 9 are the same as those of the substrate 8, and the surface of the separator 9 can also be surface-treated. The thickness of the separator 9 is appropriately selected according to its purpose and application, and is, for example, 10 to 500 μm.

  Next, the composition X is introduced into the cylinder 70 from the inlet 14 of the cylinder 70.

  In the kneader 2, the particles and the resin component contained in the composition X are kneaded and extruded by the rotation of the kneading shaft 13 while being heated by a heater (not shown), and the particles are dispersed in the resin component. Y reaches the supply section inlet 18 in the supply section 3 from the discharge port 15 through the connecting pipe 17 as shown in FIG. 5 (kneading extrusion process).

  Specifically, as shown in FIG. 3, when a driving force from a driving source (not shown) is transmitted to the driving shaft 8a, the kneading shaft 13 is driven to rotate, and the composition X is stirred by the first feed portion 23a. However, it is conveyed toward the first paddle portion 27a.

  At this time, the cylinder 70 (melt kneading part 6a) located outside the first feed part 23a is adjusted to, for example, 15 to 20 ° C. by a heater (not shown). In addition, air or the like that has entered the inside of the cylinder 70 with the introduction of the composition X is released to the outside of the cylinder 70 by opening the vent portion 7a on the introduction port 14 side.

  Next, the conveyed composition X is kneaded in the first paddle part 27a.

  At this time, the melt-kneading part 6a located outside the first paddle part 27a is adjusted to, for example, 40 to 80 ° C. by a heater (not shown).

  The kneaded composition X is pushed out toward the first reverse portion 30a by the pushing force of the composition X conveyed by the rotational drive of the first feed portion 23a.

  Most of the composition X extruded toward the first reverse portion 30a passes through the first reverse portion 30a and reaches the second feed portion 24a. On the other hand, part of the extruded composition X is returned to the first paddle part 27a by the rotational drive of the first reverse part 30a and kneaded again.

  Thereby, the kneading of the composition X is promoted and the conveyance speed of the composition X is adjusted.

  Next, the composition X that has passed through the first reverse portion 30a is conveyed toward the second paddle portion 28a and the second reverse portion 31a by the second feed portion 24a.

  Thus, the composition X passes through the second paddle part 28a and the second reverse part 31a while being kneaded, similarly to the first paddle part 27a and the first reverse part 30a.

  At this time, the melt-kneading part 6a located outside the second paddle part 28a is adjusted to, for example, 60 to 120 ° C. by a heater (not shown).

  Next, the composition X that has passed through the second reverse portion 31a is conveyed to the third paddle portion 29a by the subsequent third feed portion 25a, and is further kneaded in the third paddle portion 29a. Thereby, the composition X is prepared as the kneaded material Y.

  At this time, the melt-kneading part 6a located outside the third paddle part 29a is adjusted to, for example, 80 to 140 ° C. by a heater (not shown).

  And the kneaded material Y is extruded by the rotational drive of the kneading shaft 13, and reaches the 4th feed part 26a.

  At this time, a vacuum pump (not shown) connected to the vent portion 7a on the discharge port 15 side is driven to depressurize the inside of the cylinder 70, whereby moisture, volatile components, etc. in the kneaded product Y are melted and kneaded portion 6a. Is discharged outside.

The pressure (degree of vacuum) inside the cylinder 70 is, for example, 1 Pa or more, preferably 10 Pa or more, for example, 5.0 × 10 ⁴ Pa or less, preferably 1.0 × 10 ⁴ Pa or less, Preferably, it is 5.0 × 10 ³ Pa or less.

  Thereby, the pores in the kneaded material Y can be reduced.

  Next, the kneaded material Y is conveyed to the pipe portion 12a by the fourth feed portion 26a.

  As described above, the pipe portion 12a is formed so that there is no unevenness over the entire circumferential surface. Therefore, in the pipe portion 12a, the kneaded product Y is prevented from being sheared in a direction intersecting the axial direction of the kneading shaft 13, and is smoothly moved along the axial direction of the pipe portion 12a.

  Then, the kneaded product Y is discharged from the discharge port 15.

  Thus, a kneaded product Y in which the generation of pores is suppressed is prepared from the composition X.

  Subsequently, as shown in FIG. 1, the kneaded material Y is supplied to the supply unit 22 by the rotation of the supply screw 22, and the width W0 along the discharge direction of the kneader 2, that is, the left-right direction (the width W0 of the first casing 21). ) To the gear structure 4 in the direction intersecting the discharge direction (specifically, the direction orthogonal to the discharge direction), specifically from the rear to the front (supply process). That is, the kneaded material Y pushed out from the kneader 2 to the right side and reaching the supply unit 3 via the connecting pipe 17 is turned 90 degrees in the conveyance direction in the supply unit 3. Specifically, the kneaded material Y is supplied to the gear structure 4 via the first reservoir 27 so as to have a width W0 along the left-right direction while the conveyance direction is changed from the right to the front. That is, in the supply unit 3, discharge in the discharge direction (left-right direction) of the kneaded product Y (that is, transport in the transport direction of the supply screw 22) and supply of the kneaded product Y to the gear structure 4 proceed simultaneously. .

  Thereafter, the kneaded material Y is deformed in the rotational axis direction A1 of the pair of gears 32 in the gear structure 4, is formed as a sheet, and is conveyed forward (deformation conveying step).

  Specifically, the kneaded material Y is spread from the center portion in the rotation axis direction A <b> 1 to both ends by meshing of the pair of gears 32, and is formed as a sheet 7. And it is conveyed ahead.

  Specifically, as shown in FIG. 6, the kneaded material Y is from the upper end portion and the lower end portion of the front portion of the first storage portion 27, between the lower portion 61 of the second storage portion 40 and the first gear 33, The space between the upper portion 62 of the second housing portion 40 and the second gear 34 is pushed forward along the rotation direction R <b> 2 of the pair of gears 32, and reaches the second storage portion 28.

  At this time, the kneaded material Y in the second reservoir 28 is prevented by the pair of gears 32 from flowing backward (returning backward) to the first reservoir 27 via the meshing portion of the inclined teeth 35 (see FIG. 8). However, it is pushed out in the left-right direction by the meshing portion of the inclined teeth 35 and formed as a sheet 7.

  Specifically, as shown in FIG. 7, in the right side portion of the gear structure 4, the center of the pair of gears 32 in the rotation axis direction A <b> 1 due to the engagement of the first and third inclined teeth 36 and 38. It is spread from the section toward the right end. On the other hand, in the left side portion of the gear structure 4, the second inclined teeth 37 and the fourth inclined teeth 39 are engaged with each other, and the pair of gears 32 are pushed toward the left end portion from the center portion in the rotation axis direction A <b> 1. .

  Thereby, the sheet 7 can be obtained from the kneaded material Y.

  Subsequently, as shown in FIGS. 5 and 6, the obtained sheet 7 reaches the gear discharge port 46 through the second storage portion 28 and the discharge passage 44, and then passes from the gear discharge port 46 to the support roll 51. The ink is discharged (conveyed).

  Specifically, the base material 8 fed from the base material feed roll 56 (see FIG. 2) is laminated on the peripheral surface of the support roll 51, and the sheet 7 is supported via the base material 8. While being supported by 51, it is conveyed in the rotation direction of the support roll 51.

  The sheet 7 conveyed from the gear discharge port 46 is once conveyed behind the support roll 51 via the base material 8, and the thickness is immediately adjusted by the protrusion 63 and the peripheral surface of the support roll 51. Specifically, the excess kneaded material Y is scraped off by the protrusion 63 on the surface of the base material 8 supported by the support roll 51 and adjusted to a sheet 7 having a desired thickness T1 and a desired width W1 (gap). Passing process).

  The thickness T1 of the sheet 7 is substantially the same as the longitudinal distance L1 of the gap 50, specifically, for example, 50 μm or more, preferably 100 μm or more, more preferably 300 μm or more, 1000 μm or less, preferably 800 μm or less, more preferably 750 μm or less.

  Subsequently, as shown in FIG. 2, the base material 8 on which the sheets 7 are laminated is conveyed from the support roll 51 toward the separator laminating roll 57 and the rolling roll 58, and the separator laminating roll 57 and the rolling roll 58. In the meantime, the separator 9 is laminated on the upper surface of the sheet 7. Thereby, the sheet | seat 7 is obtained as the laminated sheet 10 by which the base material 8 and the separator 9 were each laminated | stacked on both surfaces (lower surface and upper surface).

  Thereafter, the laminated sheet 10 passes through the tension roll 52 and is subsequently wound up into a roll shape by the winding roll 53 (winding step).

  In the sheet manufacturing apparatus 1, when the resin component contains a thermosetting resin component, the thermosetting resin in the sheet 7 is heated after being heated by the kneader 2 and then wound around the winding roll 53. The component is in the B stage state, and the thermosetting resin component in the sheet 7 wound around the winding roll 53 is also in the B stage state.

  And according to the sheet manufacturing apparatus 1, when the composition X containing the particles and the resin component is introduced into the cylinder 70 from the introduction port 14, the composition X is first kneaded by the paddle portion 11a, Thereafter, the kneaded material Y passes through the pipe portion 12 a in which shearing in the direction intersecting the axial direction of the kneading shaft 13 is suppressed, and is discharged from the discharge port 15. The discharged kneaded material Y is continuously conveyed in a sheet shape while being deformed by the gear structure 4 in the rotation axis direction A1 of the gear 32.

  Therefore, the sheet 7 in which the generation of pores is suppressed can be efficiently produced from the composition X.

  Moreover, since the kneaded material Y is deformed using the gear structure 4, the sheet 7 can be produced by dispersing the particles in the resin component at a high blending ratio.

  Further, since the sheet 7 is passed through the gap 50 while being supported and conveyed by the support roll 51, the viscosity of the sheet 7 is ensured even over a wide range (for example, melt viscosity at 80 ° C. is 1 to 10000 Pa · s). The sheet 7 can be obtained.

  As a result, it is possible to efficiently manufacture the sheet 7 in which the particles are uniformly dispersed in the resin component at a high blending ratio.

  In the kneading machine 2, the kneading shaft 13 is disposed between the introduction port 14 and the discharge port 15 in the axial direction thereof on the side of the discharge port 15 with respect to the paddle part 11a and the paddle part 11a. And a pipe portion 12a formed so as not to exist.

  Therefore, after the composition X is kneaded by the paddle portion 11a, the kneaded kneaded product Y passes through the pipe portion 12a in which shearing in the direction intersecting the axial direction of the kneading shaft 13 is suppressed, and the discharge port 15 is discharged.

  As a result, the generation of pores in the kneaded material Y can be suppressed.

  The melt-kneading part 6a includes a vent part 7a on the introduction port 14 side and a vent part 7a on the discharge port 15 side. Each of these vent portions 7 a is disposed closer to the introduction port 14 than the pipe portion 12 a in the axial direction of the kneading shaft 13.

  Therefore, after the air, moisture, and the like of the composition X and the kneaded product Y are discharged to the outside of the melt-kneading unit 6a, the kneaded product Y reaches the pipe 12a.

  The sheet 7 thus formed can be used as a sealing sheet in various industrial fields, for example.

  As a result, generation of pores in the kneaded material Y can be further suppressed.

  In general, when a sealing sheet is used, it is necessary to transport the sealing sheets prepared in the form of individual pieces or to arrange the sealing sheets one by one on the object to be sealed. For this reason, the tact time is long, and further, handling may be disadvantageous in that the sealing sheet is damaged when the sealing sheet is taken out from a tray or the like. Furthermore, in order to mass-produce a sealing sheet, many sheet manufacturing apparatuses are required.

  On the other hand, since the sheet 7 obtained by the sheet manufacturing apparatus 1 is manufactured in a roll shape, the sealing target can be continuously sealed by the sheet 7. In addition, the handling properties described above can be improved, and a large number of long sheets 7 can be manufactured with a small number of sheet manufacturing apparatuses 1 required. Furthermore, the cost required for sealing can be reduced. That is, the tact time can be shortened, the handling property can be improved, and the investment cost can be reduced.

  In addition, when the sheet 7 is used as a heat radiating sheet and combined with a flexible circuit board (composite circuit board), the heat radiating sheet manufactured in a roll shape can be simply and low manufactured by roll-to-roll. A composite circuit board can be manufactured at low cost.

  Further, if the mixing ratio of the particles in the sheet 7 exceeds 30% by volume, the sheet 7 has specific physical properties (for example, heat dissipation (thermal conductivity), conductivity (conductivity), insulation, magnetic properties. Etc.).

  Therefore, the sheet 7 can be suitably used as, for example, a heat conductive sheet such as a heat radiating sheet, a conductive sheet such as an electrode material or a current collector, for example, an insulating sheet, such as a magnetic sheet, and the like.

  Furthermore, when the particles are formed of an insulating material and the resin component contains an insulating thermosetting resin component, the sheet 7 is replaced with a thermosetting insulating resin sheet such as a thermosetting resin sheet. (Specifically, it can also be suitably used as a sealing sheet).

  As shown in FIG. 7, if the length W2 of the pair of gears 32 in the rotation axis direction is 200 mm or more, the wide sheet 7 having the width W1 can be suitably used for a wide range of applications.

  5 and 6, the first casing 21 and the second casing 31 are integrally formed. For example, although not shown, the first casing 21 and the second casing 31 are divided. It can also be formed.

  FIG. 9 shows a partially cutaway plan view of another embodiment of the sheet manufacturing apparatus of the present invention. FIG. 10 is a schematic configuration diagram of a kneader used in the sheet manufacturing apparatus shown in FIG. FIG. 11 is a plan sectional view of the discharge port side of the kneader shown in FIG. FIG. 12 is a plan sectional view on the discharge port side of another embodiment of the kneader used in the sheet manufacturing apparatus of the present invention. FIG. 13: shows sectional drawing of other embodiment (spline-like aspect) of the pipe part used for the sheet manufacturing apparatus of this invention. FIG. 14 shows a cross-sectional view of another embodiment (a mode having a notch) of a pipe portion used in the sheet manufacturing apparatus of the present invention. FIG. 15: shows the disassembled perspective view of a pair of gears (mode which is a flat tooth) of other embodiment of the sheet manufacturing apparatus of this invention. FIG. 16 is a plan cross-sectional view of a supply unit, a gear structure, and a sheet adjustment unit of another embodiment of the sheet manufacturing apparatus of the present invention. 17 is a side cross-sectional view of the supply unit, the gear structure, and the seat adjustment unit shown in FIG. 16, and shows a cross-sectional view taken along the line CC of FIG. FIG. 18 is a plan cross-sectional view of a supply unit, a gear structure, and a sheet adjustment unit of another embodiment of the sheet manufacturing apparatus of the present invention. 19 is a side cross-sectional view of the supply unit, the gear structure, and the seat adjustment unit shown in FIG. 18, and shows a cross-sectional view taken along the line DD of FIG. FIG. 20 is a side sectional view for explaining the meshing of a pair of gears (involute curve shape) in another embodiment of the sheet manufacturing apparatus of the present invention. FIG. 21 is a side sectional view of a sheet adjustment unit of another embodiment of the sheet manufacturing apparatus of the present invention. In the subsequent drawings, members corresponding to the above-described parts are denoted by the same reference numerals, and detailed description thereof is omitted.

  In the embodiment of FIG. 1, the kneading machine 2 is arranged on the left side of the sheet manufacturing apparatus 1 so as to extend in the left-right direction. For example, as shown in FIG. It can also be arranged to extend in the front-rear direction.

  In the embodiment of FIG. 9, the cylinder 70 is formed in a substantially elliptical shape extending in the front-rear direction, as shown in FIG.

  The introduction port 14 is formed so as to penetrate the upper wall of the rear end portion of the cylinder 70 and open upward.

  The discharge port 15 is formed so as to pass through the right wall at the front end of the cylinder 70 and open to the right, and is arranged so as to be continuous with the connecting pipe 17 extending in the left-right direction.

  Examples of the cross-sectional shape of the discharge port 15 include a rectangular shape, an elliptical shape, and a circular shape, and an elliptical shape and a circular shape are preferable.

  Moreover, the cross-sectional area of the discharge port 15 is, for example, 7% or more with respect to the cross-sectional area of the cylinder 70, and is, for example, 50% or less, preferably 20% or less.

  As shown in FIG. 10, the kneading shaft 13 includes one drive shaft 8a, a plurality (four) of feed screw portions 9a, a plurality (three) of reverse screw portions 10a, and a plurality (three) of paddles. A portion 11a and one pipe portion 12a are provided.

  Specifically, in the kneading shaft 13 of the embodiment of FIG. 3, the kneading shaft 13 of the embodiment of FIG. 9 includes one more reverse screw portion 10a with respect to the two reverse screw portions 10a. As shown in FIGS. 10 and 11, the reverse screw portion 10a is disposed adjacent to the pipe portion 12a on the front side of the pipe portion 12a.

  That is, a plurality of (three) reverse screw portions 10a are formed from the first reverse portion 30a, the second reverse portion 31a, and the third reverse portion 32a, which are spaced apart from each other in the axial direction of the kneading shaft 13. It arrange | positions and the 3rd reverse part 32a is arrange | positioned at the front-end part by the side of the discharge outlet 15. FIG.

  The third reverse portion 32a is formed such that the axial length of the drive shaft 8a is the longest compared to the other reverse portions. The axial length of the drive shaft 8a is approximately ¼ of the first feed portion 23a.

  The pipe portion 12a is formed between the fourth feed portion 26a and the third reverse portion 32a, and is disposed so as to include the discharge port 15 when projected in the left-right direction.

  Note that the kneading machine 2 shown in FIG. 10 is supplied via the connecting pipe 17 so that the axial direction of the kneading shaft 13 and the axial direction of the supply screw 22 are parallel to each other as shown by the phantom line in FIG. It can also be arranged behind the part 3.

  Also by this, generation | occurrence | production of the pore in the kneaded material Y can be suppressed similarly to above-mentioned embodiment of FIG.

  In the embodiment of FIG. 4, the pipe portion 12 a is formed in a substantially cylindrical shape. For example, as shown in FIG. 12, the pipe portion 12 a is narrower from the introduction port 14 side toward the discharge port 15 side. It can also be formed in a tapered shape. In addition, although not shown in figure, the pipe part 12a can also be formed so that it may become wide toward the discharge port 15 side from the inlet 14 side.

  12 illustrates the aspect in which the pipe portion 12a in FIG. 4 is formed in a tapered shape, but the present invention is not limited thereto, and the pipe portion 12a in FIG. 11 can also be formed in a tapered shape.

  Also by this, generation | occurrence | production of the pore in the kneaded material Y can be suppressed similarly to above-mentioned embodiment of FIG.

  Further, in FIG. 4, the pipe portion 12 a is formed so as not to be uneven over the entire circumferential surface, but it is sufficient that the pipe portion 12 a has a smooth surface extending so as not to be uneven along the axial direction of the kneading shaft 13. For example, it can be formed in a spline shape.

  As the pipe part 12a formed in a spline shape, from the aspect (FIG. 13) having the protrusions 34a extending radially outward in the radial direction of the pipe part 12a, or from the circumferential surface of the pipe part 12a, the radial direction The aspect (FIG. 14) which has the notch part 35a notched inside is mentioned.

  In the embodiment shown in FIG. 13, the pipe portion 12a includes a plurality of (eight) protrusions 34a that extend radially outward in the radial direction of the pipe portion 12a.

  The plurality of (eight) projecting portions 34a extend along the axial direction of the kneading shaft 13, and are arranged at equal intervals in the circumferential direction on the outer peripheral surface of the pipe portion 12a.

  In the embodiment shown in FIG. 14, the pipe portion 12a includes a plurality (eight) cutout portions 35a that are cut out inward in the radial direction of the pipe portion 12a.

  The plurality (eight) cutout portions 35a extend along the axial direction of the kneading shaft 13, and are arranged at equal intervals in the circumferential direction on the outer peripheral surface of the pipe portion 12a.

  Also by these, generation | occurrence | production of the pore in the kneaded material Y can be suppressed similarly to embodiment mentioned above of FIG.

  In the embodiment of FIG. 7, the pair of gears 32 is provided with the inclined teeth 35. For example, as shown in FIG. 15, instead of the inclined teeth 35, the pair of gears 32 are parallel to the rotation axis direction A1 (with respect to the rotation axis). It is also possible to provide flat teeth 64 that extend in a straight line.

  Preferably, as in the embodiment of FIG. 7, the pair of gears 32 is provided with inclined teeth 35. As a result, the kneaded material is inclined outward in the rotational axis direction A1 from the downstream side in the rotational direction R2 of the gear 32 toward the upstream side in the rotational direction R2. It is surely spread so as to spread to both outer sides in the rotation axis direction A1. Therefore, the wide sheet 7 can be obtained more reliably.

  5 and 6, the supply screw 22 is provided in the supply unit 3. For example, as shown in FIGS. 16 to 19, the supply screw 22 is not provided in the supply unit 3. The part 3 can also be composed of the first casing 21.

  In FIGS. 16 and 17, the supply unit 3 includes a first casing 21.

  The first casing 21 is not provided with the first accommodating portion 19 (see FIG. 8), and is provided with the supply portion inlet 18 and the first storage portion 27.

  The first reservoir 27 is formed in a generally tapered shape (triangular shape) in a plan view in which the width (length) in the front-rear direction becomes narrower (shorter) as it goes to the right. Moreover, the 1st storage part 27 is formed in the side cross-section substantially taper shape (triangle) shape where an up-down direction width | variety (length) becomes narrow (short) as it goes ahead.

  In the embodiment of FIGS. 5, 6, 16, and 17, the kneaded material from the kneader 2 through the connecting pipe 17 to the supply unit inlet 18 is extruded in the kneading and extruding step in the first storage unit 27 ( The gear structure 4 is supplied from the right to the front so as to have a width W0 along the discharge direction.

  Further, in the embodiment shown in FIGS. 16 and 17, the kneaded product pushed out from the kneader 2 reaches the first storage unit 27 via the supply unit inlet 18, and moves back and forth as the first storage unit 27 moves rightward. Since the directional length is formed short, the kneaded material is pressed by the wall (rear wall) of the first reservoir 27 toward the front as it is pushed rightward in the first reservoir 27, and the gear structure. Supplied to the body 4. Furthermore, in the supply unit 3, the pressing force applied to the kneaded product increases as it goes to the right, so that the kneaded product can be supplied to the gear structure 4 more smoothly.

  On the other hand, the embodiment shown in FIGS. 5 and 6 uses the supply screw 22, so that the kneaded product Y can be smoothly supplied to the gear structure 4 as compared with the embodiments shown in FIGS. 16 and 17. .

  On the other hand, as shown in the phantom line of FIG. 1 and FIGS. 18 and 19, the kneader 2 is provided behind the supply unit 3 so that the discharge direction of the kneader 2 is along the front-rear direction. 2 can also be connected to the rear end of the first casing 21 via the connecting pipe 17.

  In the phantom line of FIG. 1 and the embodiment of FIGS. 18 and 19, the sheet manufacturing apparatus 1 is formed in a substantially I-shape (straight line) in a plan view extending in the front-rear direction. The structure 4, the sheet adjustment unit 5, and the winding unit 6 are arranged in a substantially I-shaped (straight) shape in plan view that is long in the front-rear direction in the sheet manufacturing apparatus 1.

  The kneaded material discharged from the kneader 2 reaches the first casing 21 via the connecting pipe 17. And in the 1st storage part 27, a kneaded material is supplied to the gear structure 4, being expanded in the left-right direction (width direction). That is, the discharge direction of the kneaded material by the kneading machine 2 matches the supply direction of the kneaded material Y to the gear structure 4.

  Preferably, the first storage is performed so that the kneaded material has a width W0 along the left-right direction while changing the conveyance direction from the right to the front as in the embodiments of FIGS. The gear structure 4 is supplied via the portion 27.

  Thereby, the width W0 of the kneaded material supplied to the gear structure 4 can be expanded more reliably. Therefore, the wide sheet 7 can be more reliably manufactured.

  In the embodiment of FIG. 2, the winding unit 6 is provided in the sheet manufacturing apparatus 1, and the long laminated sheet 10 that is long in the transport direction is wound up in a roll shape by the winding roll 53. Although not shown, the sheet manufacturing apparatus 1 is not provided with the winding unit 6 and the long laminated sheet 10 is used as it is, or it is divided and cut into a suitable length (conveyance direction length) a plurality of times. It can also be used.

  Preferably, as in the embodiment of FIG. 2, the winding unit 6 is provided in the sheet manufacturing apparatus 1, and the long laminated sheet 10 is wound into a roll shape by the winding roll 53. Thereby, the obtained roll-shaped laminated sheet 10 can be transported efficiently and with excellent workability and at a low cost.

  In the embodiment of FIG. 7, the inclined teeth 35 of the pair of gears 32 are formed in a point contact type curved shape, but may be formed in an involute curved shape as shown in FIG. 20, for example. it can.

  Preferably, as in the embodiment of FIG. 7, the inclined teeth 35 of the pair of gears 32 are formed in a point contact type curve.

  According to the embodiment of FIG. 7, unlike the embodiment of FIG. 20, the storage portion 65 where the kneaded material is accumulated can be prevented from being formed on the concave surface 42 in the movement of the meshing portions of the pair of gears 32. .

  However, according to the embodiment of FIG. 20, when the resin component contains a thermosetting resin component, a cured product is generated in the storage portion 65 and mixed with the product sheet 7, the quality of the sheet 7 is improved. May decrease.

  On the other hand, according to the embodiment of FIG. 7, the generation of the cured product and the mixing into the sheet 7 can be prevented, so that the quality of the sheet 7 can be improved.

  In the embodiment of FIG. 6, the gear discharge port 46 is directed forward. For example, although not illustrated, when the adhesiveness of the sheet 7 is low (for example, the melt viscosity at 80 ° C. is 5000 Pa · s or less, Specifically, the gear discharge port 46 can be preferably directed upward in the range of 1 to 5000 Pa · s. On the other hand, when the sheet 7 has high adhesiveness (for example, the melt viscosity at 80 ° C. is 5000 Pa · s). The gear discharge port 46 can be preferably directed downward at a value exceeding s, specifically exceeding 5000 Pa · s and not exceeding 10,000 Pa · s.

  In the embodiment of FIG. 2, the sheet manufacturing apparatus 1 is provided with the separator laminating roll 57, the rolling roll 58, and the separator feeding roll 59, and the separator 9 is laminated on the upper surface of the sheet 7. However, without providing the separator laminating roll 57, the rolling roll 58, and the separator delivery roll 59, the sheet manufacturing apparatus 1 is configured, and the upper surface of the sheet 7 being conveyed before being wound around the winding roll 53 is exposed. Can do. In this case, the base material 8 is laminated only on the lower surface of the sheet 7, and the laminated sheet 10 composed of the sheet 7 and the base material 8 is wound up in a roll shape in the winding roll 53, Since the winding roll 53 is laminated in the radial direction, the sheet 7 is covered and protected by the base material 8 in the winding roll 53.

  In the embodiment of FIG. 6, the support roll 51 is used as the moving support, but for example, as shown in FIG. 21, the substrate 8 can be used as the moving support.

  In FIG. 21, the support roll 51 includes a first support roll 54 and a second support roll 55 that is disposed to face the first support roll 54 at an interval above the first support roll 54. Moreover, the 1st support roll 54 and the 2nd support roll 55 are arrange | positioned so that the gear discharge port 46 and the protrusion part 63 may be pinched | interposed when projected in the front-back direction. Further, the base material 8 is laminated on the rear end surface and the lower end surface of the first support roll 54 and the rear end surface and the upper end surface of the second support roll 55, and between the first support roll 54 and the second support roll 55. A base material 8 is provided across the projecting portion 63 with a gap 50 therebetween.

  According to the sheet manufacturing apparatus 1 of FIG. 21, the sheet 7 conveyed from the gear structure 4 is transferred from the gear discharge port 46 to the base material 8 spanned between the first support roll 54 and the second support roll 55. The ink is discharged (conveyed).

  The thickness of the sheet 7 discharged from the gear discharge port 46 is adjusted by the protrusion 63 and the base material 8. Specifically, the excess kneaded material Y is scraped off by the protrusions 63 on the surface of the substrate 8 and formed as a sheet 7 having a desired thickness T1 and a desired width W1.

  The embodiment of FIG. 21 can also provide the same operational effects as the embodiment of FIG.

  Preferably, the embodiment of FIG. 6 is adopted.

  In the embodiment of FIG. 6, the gap 50 can be more reliably secured by the support roll 51, or the front-rear direction distance L <b> 1 of the gap 50 can be adjusted. Therefore, the thickness T1 of the obtained sheet 7 can be reliably controlled.

  Although not shown, the sheet manufacturing apparatus 1 is not provided with the protrusion 63, that is, the sheet adjusting unit 5 is not provided, and the sheet manufacturing apparatus 1 is connected to the kneader 2, the supply unit 3, the gear structure 4, and the winding. It can also consist of part 6. In this embodiment, the sheet 7 conveyed from the gear structure 4 is directly wound up by the winding unit 6.

  In the present invention, the sheet includes the concept of a tape or a film.

  The present invention can combine a plurality of the above-described embodiments.

  Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples, but the present invention is not limited to these.

Examples 1 and 2
In the formulation (unit: parts by mass) shown in Table 1, each component (composition X) was introduced from the introduction port 14 of the kneader 2 of the sheet manufacturing apparatus 1 (dimensions and apparatus configuration are shown in Table 2) shown in FIG. As a result, a sheet 7 having a thickness of 500 μm was obtained. The sheet 7 prepared and prepared according to Formulation Example 1 was referred to as Example 1, and the sheet 7 prepared and prepared according to Formulation Example 2 was referred to as Example 2.

Examples 3 and 4
Each component (composition X) in Formulation Example 2 (unit: parts by mass) shown in Table 1 is introduced into the inlet 14 of the kneader 2 of the sheet manufacturing apparatus 1 (dimensions and apparatus configuration shown in Table 2) shown in FIG. The sheet 7 having a thickness of 500 μm was obtained. In addition, the sheet 7 prepared by the kneading machine 2 having a pressure (vacuum degree) inside the cylinder 70 of 5000 Pa prepared according to the prescription example 1 is set as the example 3, and the sheet 7 prepared by the prescription example 2 A sheet 7 produced by kneading with a kneader 2 having a pressure (degree of vacuum) of 70 at 300 Pa was taken as Example 4.

Comparative Examples 1 and 2
A kneader 2 (ordinary feed screw type) was prepared in which the pipe portion 12a of the kneader 2 of the sheet manufacturing apparatus 1 shown in FIG. 9 was changed to a feed screw portion 9a.

  A sheet 7 having a thickness of 500 μm was obtained by introducing each component (composition X) in the formulation shown in Table 1 from the inlet 14 of the kneader 2 of the sheet manufacturing apparatus. The sheet 7 prepared according to Formulation Example 1 was referred to as Comparative Example 1, and the sheet 7 prepared according to Formulation Example 2 was referred to as Comparative Example 2.

(Evaluation)
In each example and each comparative example, the kneaded material immediately before being supplied to the supply unit 3 (kneaded material discharged from the discharge port 15 of the kneader 2) is taken out, and the number of pores in the kneaded material is measured as follows. did. The results are shown in Table 3.
(1) Porosity measurement The sheet | seat obtained in each Example and each comparative example was externally processed into the substantially circular shape of diameter 10mm-13mm, and the sample was produced.

  Each sample was put into a drier set at 175 ° C. for 1 hour to be cured. Then, each sample was taken out from the dryer, and each put into the predetermined container and cooled.

  On the other hand, an embedding resin for embedding each sample was prepared. Specifically, Epofix cold embedding resin (two-component mixed type of epoxy resin and curing agent) is blended with 3 parts by mass of curing agent with respect to 25 parts by mass of epoxy resin to embed the required amount A resin was prepared.

  Next, the embedding resin was poured into a container in which each sample was accommodated so that each sample was completely immersed. And it stood until resin for embedding | curing completely hardened (at room temperature and about 25 degreeC, 7 to 8 hours). Thus, an embedded sample in which each sample was embedded was produced.

  Next, the embedded sample is taken out of the container, and is cut using a precision cutting machine (Isomet 1000 manufactured by BUEHLER) so that the sample is positioned at the center portion of the cut surface. )

  The cut surface of each obtained test piece was polished by the following apparatus and conditions.

Polishing apparatus and polishing condition polishing machine: AUTOMET 3000 manufactured by BUEHLER
1) Initial polishing conditions Polishing paper count: No. 240, polishing paper pedestal rotation speed: 50 rpm (1/60 s ⁻¹ ), sample pressure: 5-8 MPa, polishing time: 3-5 min
2) Second stage polishing conditions Polishing paper count: 600, polishing paper pedestal rotation speed: 50 rpm (1/60 s ^-1 ), sample pressure: 8-10 MPa, polishing time 3-5 min
3) Third-stage polishing conditions Instead of the polishing paper, polishing powder (MICROPOLISH 0.3) mixed with an appropriate amount of water was used.

Polishing base rotation speed: 60 rpm (1/60 s ⁻¹ ), sample pressing force: 10-15 MPa, polishing time 5-10 min
The number of pores and the pore diameter were observed with a digital microscope (manufactured by KEYENCE: VHX-500, observation magnification: 100 times) for a range of 2 mm × 2 mm of the sample in each polished specimen. FIG. 22 shows a digital microscope photograph of a cross section of the sample of Example 2. FIG. 23 shows a digital microscope photograph of a cross section of the sample of Comparative Example 2.

  In Example 1, Example 3, Example 4, and Comparative Example 1, 5 ranges of 2 mm × 2 mm were observed.

  In Example 2, three areas of 2 mm × 2 mm were observed.

  In Comparative Example 2, two ranges of 2 mm × 2 mm were observed.

The abbreviations in Table 1 are shown below.
YSLV-80XY: Epoxy resin (manufactured by Nippon Steel Chemical Co., Ltd.)
MEH7851SS: Phenolic resin (Maywa Kasei)
2PHZ-PW: Imidazole (manufactured by Shikoku Chemicals)
SIBSTAR: Elastomer (polystyrene-polyisobutylene copolymer) (manufactured by Kaneka Corporation)
Filler: 0.1 part by mass of a silane coupling agent (KBM403, manufactured by Shin-Etsu Chemical Co., Ltd.) is added to 100 parts by mass of an inorganic filler (fused silica) (FB-9454, manufactured by Denki Kagaku Kogyo Co., Ltd.) , Surface treated.
# 20: Carbon black (Mitsubishi Chemical Corporation)

DESCRIPTION OF SYMBOLS 1 Sheet manufacturing apparatus 2 Kneading machine 3 Supply part 4 Gear structure 5 Sheet adjustment part 7 Sheet 7a Vent part 11a Paddle part 12a Pipe part 13 Kneading shaft 14 Inlet 15 Discharge port 32 Gear 33 First gear 34 Second gear 34a Projection Part 35 Inclined tooth 51 Support roll 63 Projection part 70 Cylinder X Composition Y Kneaded material

Claims (7)

A sheet manufacturing apparatus configured to manufacture a sheet from a composition containing particles and a resin component,
A kneader including a cylinder and a kneading shaft inserted into the cylinder, and discharging a kneaded material;
A pair of gears, and a gear structure disposed downstream in the discharge direction of the kneader,
The cylinder has an introduction part for introducing the composition into the cylinder on one end side, and a kneaded material kneaded with the composition on the other end side for discharging the mixture to the outside of the cylinder. A discharge part is formed,
The kneading shaft is disposed between the introduction portion and the discharge portion in the axial direction of the kneading shaft, a kneading portion for kneading the composition, and disposed closer to the discharge portion than the kneading portion. A low-shear portion having a smooth surface extending so as not to be uneven along the axial direction of
The sheet manufacturing apparatus, wherein the gear structure is configured to convey the kneaded material discharged from the discharge unit while being deformed in a rotation axis direction of the gear.   The sheet manufacturing apparatus according to claim 1, wherein the sheet manufacturing apparatus is configured to manufacture the sheet in which a volume ratio of the particles exceeds 30% by volume. Each of the pair of gears includes oblique teeth that mesh with each other;
The inclined tooth trace of the oblique tooth is inclined outward in the rotational axis direction from the downstream side in the rotational direction of the pair of gears toward the upstream side in the rotational direction. The sheet manufacturing apparatus described. Provided on the downstream side in the discharge direction of the kneader and on the upstream side in the transport direction of the gear structure, and the kneaded material has a width along the discharge direction of the kneader from the direction intersecting the transport direction. The sheet manufacturing apparatus according to claim 1, further comprising a supply unit configured to supply the gear structure.   The sheet manufacturing apparatus according to any one of claims 1 to 4, wherein the low-shear portion is formed so as not to be uneven over the entire circumferential surface. The cylinder includes a vent portion for discharging the gas in the cylinder,
6. The sheet manufacturing apparatus according to claim 1, wherein the vent portion is disposed closer to the introduction portion in an axial direction of the kneading shaft than the low shear portion. A movable support provided downstream of the gear structure in the conveyance direction and configured to support and convey the sheet; and a doctor disposed to face the movable support so as to provide a gap. The sheet manufacturing apparatus according to claim 1, further comprising a sheet adjusting unit including