JP2014133380A - Roll for melt extrusion shaped forming, roll assembly for melt extrusion shaped forming, and method for melt extrusion forming - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a roll for melt extrusion shaped forming capable of achieving a sufficient improvement of transferability.SOLUTION: A roll 1 for melt extrusion shaped forming which is used in the melt extrusion forming of thermoplastic resin includes a roll body portion 10 inside of which is provided with a heat transfer medium flow channel 11, and an amorphous metal melt spray coating layer 13 that covers the surface of the roll body portion 10. The roll body portion 10 is made of a metallic material having a thermal conductivity of 40 W/m K or more and 100 W/m K or less, and the melt spray coating layer 13 is made of an amorphous metal having a thermal conductivity of 20 W/m K or less.

Description

  The present invention relates to a roll for melt extrusion shaping, a roll assembly for melt extrusion shaping, and a melt extrusion molding method.

  When carrying out melt extrusion molding of thermoplastic resin films, various functions are often obtained by transferring the fine concavo-convex structure to the film surface using a roll for melt extrusion molding having a fine concavo-convex structure on the surface. Has been granted. A film made of a thermoplastic resin having a fine concavo-convex structure on the surface is used for a light diffusion film, a matte film, and the like.

  In order to melt-extrusion such a film molded product, a film made of a molten thermoplastic resin flowing out from the lip portion of a T die or a coat hanger die (hereinafter sometimes simply referred to as “film”). ), A metal roll for melt extrusion molding with a fine concavo-convex structure on the surface (hereinafter sometimes referred to as “first roll”) and a press roll for pressure bonding (hereinafter referred to as “second roll”) It may be called). In general, the higher the die temperature, that is, the resin temperature, the higher the press pressure by the first roll and the second roll, and the higher the roll set temperature, the more the fine uneven structure is transferred. Improves.

  However, if the die temperature or the roll set temperature is too high, the molten thermoplastic resin cannot be cooled in time from the pressure bonding between the first roll and the second roll to the release of the film from the first roll. The film molded product sticks to the roll, and an appearance defect called a peel mark occurs. Therefore, there is a limit to increasing the die temperature and the roll set temperature. Further, with respect to the press pressure, roll bending occurs due to high pressure pressure bonding, and it becomes difficult to control the film thickness of the film molded product, or it becomes difficult to perform uniform transfer.

  For example, as a heating roll used for hot stretching of a plastic film, etc., an outer shell sleeve, an inner shell sleeve fitted in close contact with the inner shell, and a heating element placed in contact with the inner periphery of the inner shell sleeve, or Further, a heating roll made of a metal having excellent heat conductivity is described in, for example, Japanese Patent Laid-Open No. 6-128623. Here, the outer shell sleeve is made of, for example, stainless steel (thermal conductivity: 16 W / m · K) or the like, and the inner shell sleeve is made of, for example, copper or an alloy thereof, aluminum or an alloy thereof (thermal conductivity: about 200 W). / M · K to about 400 W / m · K).

JP-A-6-128623

  In the heating roll in JP-A-6-128623, it is said that the thermal crown can be reduced. However, when the heating roll disclosed in this patent publication is used as a roll for melt extrusion molding, the inner sleeve is made of a material having a high thermal conductivity, so that the film is cooled rapidly. However, there is a problem that the transferability of the fine concavo-convex shape cannot be sufficiently improved.

  Accordingly, an object of the present invention is to provide a roll for melt extrusion shaping that can sufficiently improve transferability, and a roll assembly for melt extrusion shaping provided with such a roll for melt extrusion shaping. Another object of the present invention is to provide a melt extrusion molding method using the roll assembly for melt extrusion molding.

The melt extrusion molding shaping roll of the present invention for achieving the above object (hereinafter sometimes referred to as “first roll” for convenience) is a melt extrusion used in thermoplastic resin melt extrusion molding. A roll for forming and shaping,
A roll main body provided with a heat medium flow path therein, which is manufactured from a metal material having a thermal conductivity of 40 W / m · K or higher and 100 W / m · K or lower;
A film of amorphous metal provided on the surface of the roll body, wherein the amorphous metal has a thermal conductivity lower than that of the metal material.

  The amorphous metal preferably has a thermal conductivity of 20 W / m · K or less, more preferably a thermal conductivity of 10 W / m · K or less. In addition, although it does not limit, 3 W / m * K can be mentioned as a lower limit of the heat conductivity of an amorphous metal.

In order to achieve the above object, a roll assembly for melt extrusion shaping according to the present invention is opposed to a roll for melt extrusion shaping (first roll) and a roll for melt extrusion shaping. A crimping roll (hereinafter sometimes referred to as a “second roll” for convenience),
The roll for melt extrusion shaping is composed of the roll for melt extrusion shaping of the present invention.

In order to achieve the above object, the melt extrusion molding method of the present invention comprises:
It consists of a roll for melt extrusion shaping (first roll) and a roll for pressure bonding (second roll) arranged opposite to the roll for melt extrusion shaping,
The roll for melt extrusion shaping is a melt extrusion molding method using a roll assembly for melt extrusion shaping formed from the roll for melt extrusion shaping of the present invention,
A film molded product is obtained by passing the molten thermoplastic resin extruded from a die between a roll for melt extrusion molding (first roll) and a roll for pressure bonding (second roll). And The film molded product includes a sheet molded product.

  The roll for melt extrusion molding of the present invention, the roll for melt extrusion molding constituting the roll assembly for melt extrusion molding of the present invention, or the melt extrusion molding method of the present invention. Formed on the film surface of amorphous metal in rolls for melt extrusion shaping (hereinafter, these rolls for melt extrusion shaping may be collectively referred to as “first roll of the present invention”). The fine concavo-convex structure thus formed can be formed by a method such as sand blasting, electric discharge machining, or chemical etching. The surface roughness is not particularly specified and can be appropriately set depending on the application. For example, in the case of a light diffusion film, 10-20 micrometers can be illustrated by 10-point average roughness Rz.

  The method for forming the amorphous metal film is not particularly limited, but a preferable method is a high-speed flame spraying method. In the case of a thermal spray coating, it itself has a fine concavo-convex structure, and in some cases, it can be used as a roll for melt extrusion molding without carrying out the roughening treatment. In the case of performing the surface roughening treatment, it is more effective to perform the treatment after polishing the sprayed coating surface of the amorphous metal to about 1.0 S (arithmetic average surface roughness Ra of 0.25 μm). Since uniformity is ensured, it is preferable.

  In some cases, the first roll can be used as a mirror roll, and in this case, the surface roughness is preferably at least 0.2 S or less (the arithmetic average surface roughness Ra is 0.05 μm or less). When used as a mirror roll, since the polished surface is transferred, a very flat plain film molded product can be formed. That is, in addition to improving the mirror transferability at the film end, it is easy to crush the thick part due to the neck-in at the film end, so that the entire surface can be pressed uniformly, and press bonding called press omission is performed. It is possible to suppress the occurrence of a missing portion.

Furthermore, in the first roll or the like of the present invention, the outer diameter of the roll body portions at room temperature D _o, the distance T _s from the surface of the roll main body portion to the heating medium flow _path, the thickness of the coating layer of amorphous metal when a T _a, the following can be exemplified as _{D o, T s, T a} .
D _o : 200 mm to 800 mm
T _s : 5 mm to 40 mm
T _a : 0.1 to 3.0 mm

  Based on the selection of the material (thermal conductivity) and thickness of the amorphous metal, the degree of the cooling delay effect of the molten thermoplastic resin in contact with the first roll can be controlled. In the temperature range from room temperature (25 ° C.) to 300 ° C., it is preferable that the linear expansion coefficient of the amorphous metal is substantially equal to the linear expansion coefficient of the metal material constituting the roll body. This is because the first roll needs to be set to a desired set temperature at the time of melt extrusion molding, so that the amorphous metal is prevented from cracking due to the temperature rise of the first roll.

  The thickness of the amorphous metal coating layer can be uniform or intentionally non-uniform. For example, a roll body is preliminarily crowned, an amorphous metal film is provided thereon, and the film surface is flattened by polishing or the like, so that the center of the roll body is thin. A thick film layer can be formed at the end of the film. Thereby, uniform cooling of the molten resin (film) can be achieved. The crown shape is a shape having a curvature such that the distance from the surface of the roll body to the heat medium flow path is thick at the center of the roll body and thin at the end of the roll body. Is to make the outermost diameter constant with respect to the rotation axis direction of the roll body.

  Furthermore, in the first roll or the like of the present invention, it is preferable that the metal material constituting the roll main body portion includes, for example, at least one of carbon steel, chromium steel, chromium molybdenum steel, cast iron, and tungsten steel. Specifically, for example, it is more preferable to include chromium molybdenum steel SCM440 which is a structural alloy steel material. The amorphous metal forming the film is preferably a nickel-based or zirconium-based material, for example, in the case of classification by main constituent elements. It is also important to select an amorphous metal that does not cause crystallization due to heat reception during melt extrusion. The thermal conductivity at room temperature of each material is as shown in Table 1 below.

[Table 1]
Carbon steel: 45-53 W / m · K
Chrome steel: 52-60W / m · K
Chromium molybdenum steel: 40 to 48 W / m · K
Cast iron: 48W / m · K
Tungsten steel: 53-66 W / m · K
Nickel-based amorphous metal: 7-9W / m · K
Zirconium-based amorphous metal: 5-7 W / m · K

  The processing accuracy of the surface of the roll main body is preferably as high as possible, and the center runout is desirably 10 mm / 1000 mm or less, more preferably 5/1000 mm or less. The surface roughness of the surface of the roll body is preferably about at least 0.4 S by buffing finish. In order to prevent the generation of rust, a thin plating layer having a thickness of 10 μm or less may be provided.

Furthermore, in the first roll or the like of the present invention, the width of the sheet molded product that is melt-extruded by using the roll for melt-extrusion shaping is W, and in the rotation axis direction of the roll for melt-extrusion shaping When the length of the amorphous metal film surface is X,
W> X
It is preferable to satisfy
20mm ≦ W−X ≦ 100mm
Is preferably satisfied. The length (X) of the film surface of the amorphous metal can be the same as the effective length of the roll body in the rotational axis direction of the roll for melt extrusion molding, or the roll body It can also be shorter than the effective length of the part.

  In general, in melt extrusion molding of a thermoplastic resin, the molten thermoplastic resin flowing out from the lip portion of the die necks in at an air gap immediately before coming into contact with the roll for melt extrusion molding, and in adjusting the lip opening degree. The extreme end of the film may become extremely thick beyond control. In molding a precision-shaped film molded product, the thickest part at the end of the film can be a transfer inhibiting factor, which is not preferable. A step may be provided at the end of the roll main body so as not to press the thick part of the end, but in the roll for melt extrusion molding in the present invention, the length of the amorphous metal coating surface is long. Since the thickness (X) can be set in advance smaller than the width (W) of the film molded product, it is not necessary to provide a step at the end of the roll main body.

  In the first roll or the like of the present invention, the roll main body portion may be a so-called drilled roll in which a circular heat medium flow path is provided in parallel to the axial direction from the side surface of the roll main body portion by a cutting drill. Also, a double-pipe roll described below, which is also referred to as a spiral roll, has a heat medium flow path in a spiral shape. Note that the number of heat medium flow paths is essentially arbitrary. Examples of the heat medium include water and heat medium oil.

  The thickness of the film molded product obtained by the melt extrusion molding method of the present invention can be 0.05 mm to 0.5 mm. Moreover, in the roll for melt extrusion molding of the present invention, the roll assembly for melt extrusion molding or the melt extrusion molding method, the thermoplastic resin is a polycarbonate resin, an acrylic resin, a polystyrene resin, a thermoplastic polyester resin, Although it can be set as the structure which is a thermoplastic resin selected from the group which consists of cyclic polyolefin resin and polymethyl-1-pentene resin, especially polycarbonate resin is suitable. Additives such as heat stabilizers, mold release agents, UV absorbers and the like can be appropriately added to these resins. And the obtained film molding can be used as a light-diffusion film or an antireflection film as an optical member, or can be used as a matte film as a design member.

As the melt extrusion molding machine constituting the melt extrusion molding apparatus, a known melt extrusion molding machine may be used. Melt extrusion machines are usually
A heating cylinder (also called a barrel) for plasticizing and melting the raw thermoplastic resin having a die, and
A hopper attached to the heating cylinder for supplying the raw material thermoplastic resin to the heating cylinder,
It has. As a melt extruder suitable for use in the melt extrusion molding method of the present invention, a well-known single screw extruder including a vent type extruder and a tandem type extruder, a parallel type twin screw extruder and a conical type twin screw extruder are used. A well-known twin screw extruder can be used, and the structure, configuration, and type of the die are essentially arbitrary, and examples thereof include a T die and a coat hanger die. The heating cylinder is generally composed of a supply unit (feed zone), a compression unit (compression zone), and a metering unit (metering zone). A die is disposed downstream of the metering unit, and a hopper is provided in the supply unit. It is attached. Depending on the melt extrusion molding machine to be used, the heating cylinder may have a hermetic structure, and modification may be required so that an inert gas can be introduced into the heating cylinder. The raw material thermoplastic resin charged in the hopper is sent to the compression section as a solid in the heating cylinder supply section, and plasticization and melting of the raw material thermoplastic resin proceeds before and after the compression section, and is measured by the weighing section. Extruded through the die. In addition, what is necessary is just to provide an exhaust port (vent part) in the compression part or the downstream (for example, between a compression part and a measurement part), when providing an exhaust port (vent part). The type, structure, and configuration of the heating cylinder, screw, and hopper are essentially arbitrary, and known heating cylinders, screws, and hoppers can be used.

  As the roll assembly in the present invention, it is suitable for forming a film having a thickness of 300 μm or less, and it is possible to use a molding apparatus dedicated to a thin film capable of only one-side pressure bonding, or a sheet having a thickness of 300 μm or more It is also possible to use a molding apparatus dedicated to thick sheets that can be pressed on both sides by a three-roll configuration. In the case of a sheet forming apparatus, the roll arrangement may be vertical type, horizontal type, or its hybrid type. Examples of the roll that can be used as the second roll (pressure bonding roll) include a metal rigid roll, a metal elastic roll, and a rubber roll. Here, as a metal elastic roll, the thing which made the thickness of the metal outer cylinder thin about 2 mm, the thing which wound the thin metal sleeve on the rubber roll, etc. are contained.

The pressing pressure of the first roll and the second roll (linear pressure: the pressing force divided by the width of the film molded product) is arbitrary within the allowable range of roll rigidity, but as an example of a preferable linear pressure, 5-150 kg / cm. The set temperature of the first roll is often set to a temperature lower by about 10 ° C. than the glass transition temperature of the resin used, but can be adjusted as appropriate depending on how the release mark appears.

  The molding speed of the film molded product can be adjusted as appropriate according to the film thickness, but is preferably about 2 to 20 m / min so as not to cause a transfer failure phenomenon due to insufficient resin cooling. In the speed region, the cooling delay effect of the melt extrusion molding shaping roll of the present invention is most prominent, and it is easy to achieve both transferability improvement and release mark suppression.

  The first roll or the like of the present invention comprises a roll body portion made of a metal material and a film made of an amorphous metal, and the thermal conductivity of the metal material constituting the roll body portion is 40 W / m · K or more, 100 W / m · K. Since the thermal conductivity of the amorphous metal constituting the coating layer is specified to be lower than the thermal conductivity of the metal material, it is possible to obtain a cooling rate suitable for the production of a thermoplastic resin film molded product. Is possible. In addition, since the roll body is made of a metal material having a high thermal conductivity and the coating layer is made of an amorphous metal having a low thermal conductivity, cooling of the molten thermoplastic resin (film) immediately after contact with the first roll is delayed. The time required for transferring the optical pattern and the like can be increased, so that the transfer rate of the fine relief structure can be improved and the film molded product immediately before leaving the first roll is sufficiently cooled. Therefore, generation | occurrence | production of the peeling mark in a film molded product can be prevented effectively.

FIG. 1 (A) is a schematic cross-sectional view of a roll for melt extrusion shaping of Example 1, and FIG. 1 (B) is a roll set for die and melt extrusion shaping of Example 1. It is a conceptual diagram which shows arrangement | positioning of a solid | solid. FIG. 2 is a schematic cross-sectional view of a roll for melt extrusion molding in Example 2A.

  Hereinafter, the present invention will be described based on examples with reference to the drawings. However, the present invention is not limited to the examples, and various numerical values and materials in the examples are examples.

  Example 1 relates to a roll for melt extrusion molding, a roll assembly for melt extrusion molding, and a melt extrusion molding method of the present invention. A schematic cross-sectional view of the first roll 1 when the roll (first roll) 1 for melt extrusion molding in Example 1 is cut along a virtual plane including the rotation axis is shown in FIG. And the conceptual diagram of the arrangement | positioning state of the roll assembly for melt extrusion molding shaping | molding is shown in FIG.1 (B).

The first roll 1 of Example 1 is a roll for melt extrusion molding used in melt extrusion molding of a thermoplastic resin,
A roll main body 10 provided with a heat medium flow path 11 therein, and
An amorphous metal spray coating 13 covering the surface of the roll body 10;
Consists of. And the roll main-body part 10 is manufactured from the metal material which has the heat conductivity of 40 W / m * K or more and 100 W / m * K or less. The sprayed coating 13 is made of an amorphous metal having a thermal conductivity of 20 W / m · K or less. Specifically, it is as shown in Table 2 below.

  As shown in FIG. 1B, the roll assembly for melt extrusion molding in Example 1 is disposed to face the first roll 1 and the first roll 1 in Example 1 described above. It consists of a second roll 5 for pressure bonding. In Example 1, the 2nd roll 5 is comprised from the rubber roll made from a fluororesin.

In Example 1, the roll main body portion 10 was a so-called drilled roll in which a circular heat medium passage 11 was provided in parallel to the axial direction from the side surface of the roll main body portion 10 by a cutting drill. An outer diameter D _o of the roll body portion 10 in the normal temperature, the value of the distance T _s from the surface of the roll body portion 10 to the heat medium flow path is shown in Table 2. In addition, the number of the heat medium flow paths 11 is essentially arbitrary. Heat medium oil was used as a heat medium for the roll body 10. Thermal spray coating 13 is manufactured by high-speed flame spraying, the thickness T _a was 1.0 mm.

  A mat pattern is formed on the surface of the amorphous metal spray coating 13 by sandblasting. A series of processing was performed in the order of thermal spraying, polishing, and sandblasting. Using a UV curable resin GLX18-73N (refractive index: 1.49) manufactured by Gure Lab Co., Ltd., a transparent replica of the surface of the sprayed coating 13 was prepared, and its haze value (turbidity) was measured. there were.

When the width of the sheet molded product that is melt-extruded using the melt extrusion shaping roll is W, and the length of the sprayed coating 13 in the rotation axis direction of the melt extrusion shaping roll is X,
W> X
Is satisfied. Alternatively,
20mm ≦ W−X ≦ 100mm
Is satisfied. Specific values of X and W are shown in Table 2 below. The length (X) of the thermal spray coating 13 is the same as the effective length of the roll body 10 in the rotation axis direction of the roll for melt extrusion molding. The “effective length of the roll main body” means a portion designed so that the surface temperature of the roll main body is substantially uniform.

[Table 2]
Metal material: Chromium molybdenum steel SCM440
Thermal conductivity: 43 to 48 W / m · K (value in the operating temperature range from room temperature to about 300 ° C.)
Thermal spray coating: Topy Industries, Ltd. GALOA-SN2102 (nickel-based amorphous metal)
Thermal conductivity: 8.0 to 8.5 W / m · K (value in the operating temperature range from room temperature to about 300 ° C.)
D _o : 300 mm
T _s : 25 mm
T _a : 1.0 mm
X: 600 mm
W: 650 mm

  In Example 1, polycarbonate resin (PC resin, polycarbonate resin “Iupilon E2000” manufactured by Mitsubishi Engineering Plastics Co., Ltd.) was used as the thermoplastic resin. Moreover, the nominal thickness of the film molded product obtained by the melt extrusion molding method of Example 1 is 150 μm, and the width W is as shown in Table 2. The obtained film molded article is a light diffusion film, and has a fine uneven structure (mat pattern).

  In Example 1, by using a known melt extrusion molding apparatus, the molten thermoplastic resin extruded from the die is passed between the first roll 1 and the second roll 5 to obtain a sheet shape. A pressure was applied to the molten thermoplastic resin to obtain a film molded product. Here, a coat hanger die having a width of 800 mm was used as the die. The melt extrusion molding conditions are shown in Table 3 below.

[Table 3]
Die temperature: 280 ° C
Line speed: 5.0 m / min
First roll temperature: 135 ° C
Second roll temperature: 60 ° C
Linear pressure level: 10 kg / cm

  The molded film molded product had no appearance defect due to defective release from the thermal spray coating 13 such as a release mark, and the haze value was 63%.

  As Comparative Example 1, a first roll was produced in the same manner as in Example 1 except that the thermal spraying treatment of amorphous metal was not performed. A transparent replica of the surface of the cylindrical member was prepared using UV curable resin GLX18-73N, and its haze value was measured. As a result, it was 87%, and it was confirmed that the mat pattern was substantially the same as in Example 1. did. And the film molded product was shape | molded on the conditions similar to Example 1. FIG.

  In the molded film molded product, no appearance defect due to a mold release failure such as a release mark was generated, but when the haze value was measured, it was 55%, and the transferability was clearly poor.

  FIG. 2 shows a schematic cross-sectional view of the first roll 2 when the roll (first roll) 2 for melt extrusion molding in Example 2A is cut along a virtual plane including the rotation axis.

In Example 2A, the roll body 20 was a double-pipe roll, also called a spiral roll, in which the heat medium flow path 21 is spiral. Table 4 below shows the specifications of the roll body 20 and the thermal spray coating 23 in the first roll 2 of Example 2A. Similar to Example 1, the amorphous metal coating 23 was provided on the surface of the roll body 20 by high-speed flame spraying, and the thickness was 1.00 mm. Furthermore, the distance (T _s ) from the outer surface of the roll body 20 to the heat medium passage 21 was set to 24 mm. As shown in FIG. 2, a continuous partition wall (partition wall) 22 extending spirally along the rotation axis of the roll main body 30 is provided in the heat medium passage 21. In addition, the number of the partition 22 can be provided arbitrarily. Heat medium oil was used as a heat medium for the roll body 20. Further, the surface of the thermal spray coating 23 was polished to make the surface roughness about 0.2S. Moreover, unlike Example 1, the metal elastic roll which gave the hard chrome plating was used as a 2nd roll.

[Table 4]
Metal material: Carbon steel S45C
Thermal conductivity: 45 to 51 W / m · K (value in the operating temperature range from room temperature to about 300 ° C.)
Thermal spray coating: Topy Industries, Ltd. GALOA-SN2102 (nickel-based amorphous metal)
Thermal conductivity: 8.0 to 8.5 W / m · K (value in the operating temperature range from room temperature to about 300 ° C.)
D _o : 450.00 mm
T _s : 24 mm
T _a : 1.0 mm
X: 400 mm
W: 450 mm

  In Example 2A, a polycarbonate resin (PC resin, polycarbonate resin “Iupilon S1000” manufactured by Mitsubishi Engineering Plastics Co., Ltd.) was used as the thermoplastic resin. Moreover, the nominal thickness of the film molded product obtained in the melt extrusion molding method of Example 2A is 180 μm, and the width W is as shown in Table 4. The use of the obtained film molded product is a film for thermoforming.

  Even in Example 2A, by using a well-known melt extrusion molding apparatus, the molten thermoplastic resin extruded from the die is passed between the first roll 2 and the second roll, thereby forming a sheet-like shape. Pressure was applied to the molten thermoplastic resin to obtain a film molded product. Here, a coat hanger die having a width of 550 mm was used as the die. The melt extrusion molding conditions are shown in Table 5 below.

[Table 5]
Die temperature: 280 ° C
Line speed: 8.0 m / min
First roll temperature: 135 ° C
Second roll temperature: 120 ° C
Linear pressure level: 20 kg / cm

  As a result of the appearance inspection of the molded plain film, no press omission was observed, and no peeling pattern generated at the time of peeling from the first roll was observed.

  As Example 2B, the first roll was formed by thermal spraying an amorphous metal (GALOA-SN1105, iron-based amorphous metal manufactured by Topy Industries, Ltd.) having a thermal conductivity of 16 W / m · K to form a film having a thickness of 1 mm. Was made. This sprayed coating was polished to a surface roughness of about 0.2S. And the film molded product was shape | molded on the conditions similar to Example 2A.

  The appearance of the molded plain film was relatively good, and no peeling pattern was observed. However, the occurrence of press omission was negligible.

  Moreover, as Comparative Example 2A, the roll body was manufactured only with S45C to constitute the first roll. That is, no low thermal conductivity material is used. The distance from the outer surface of the roll body to the heat medium flow path was 25 mm. A thin hard chrome plating layer having a thickness of 50 μm was provided on the surface of the roll main body, and the surface roughness was set to 0.1 S by polishing. And the film molded product was shape | molded on the conditions similar to Example 2A. As a result of carrying out the appearance inspection of the molded plain film, a large amount of press breakage was observed in the film, and it was unusable for use.

  Furthermore, as Comparative Example 2B, using the same first roll as Comparative Example 2A, only the set temperature of the first roll was increased by 10 ° C. and molded at 145 ° C. to obtain a film molded product. As a result of the appearance inspection of the molded plain film, although the press omission disappeared completely, a peeling pattern generated when peeling from the first roll occurred, and the appearance was poor.

  The evaluation results of Example 1 and Example 2A, Comparative Example 1, Example 2B, Comparative Example 2A, and Comparative Example 2B are summarized in Table 6 below.

[Table 6]
Roll body part Thermal spray coating Set temperature Haze value Peelability Example 1 SCM440 Yes 135 ° C 63% Good Comparative Example 1 SCM440 No 135 ° C 55% Good

Roll body portion Low heat conductive material property Setting temperature Inadequate pressure bonding Peelability Example 2A S45C 8.5 W / m · K 135 ° C. None Good Example 2B S45C 16 W / m · K 135 ° C. Yes (very small) Good Comparative Example 2A ℃ Yes (many) Good Comparative Example 2B S45C-145 ℃ No Bad

  As mentioned above, although this invention was demonstrated based on the preferable Example, this invention is not limited to these Examples. The roll for melt extrusion shaping described in the examples, the roll assembly for melt extrusion shaping, the configuration, structure, materials used, melt extrusion molding conditions, etc. of the melt extrusion molding apparatus are examples, Can be changed.

1, 2 ... 1st roll, 5 ... 2nd roll, 10, 20 ... Roll body part, 11, 21 ... Heat medium flow path, 13, 23 ... Amorphous metal film, 22 ... Partition walls

Claims (15)

A roll for melt extrusion molding used in melt extrusion molding of a thermoplastic resin,
A roll main body provided with a heat medium flow path therein, the roll main body manufactured from a metal material having a thermal conductivity of 40 W / m · K or more and 100 W / m · K or less;
An amorphous metal film provided on the surface of the roll body, wherein the amorphous metal has a thermal conductivity lower than the thermal conductivity of the metal material. Rolls.   The roll for melt extrusion molding according to claim 1, wherein the amorphous metal has a thermal conductivity of 20 W / m · K or less. When the distance from the surface of the roll main body portion to the heating medium flow path and T _s, and the thickness of the film and T _a,
5mm ≦ T _s ≦ 40mm
0.1 mm ≦ T _a ≦ 3.0 mm
The roll for melt extrusion molding shaping according to claim 1 or 2, wherein:   The roll for melt extrusion molding according to any one of claims 1 to 3, wherein the metal material includes at least one of carbon steel, chromium steel, and chromium molybdenum steel.   The roll for melt extrusion molding according to any one of claims 1 to 4, wherein the amorphous metal contains at least one of nickel and zirconium.   The roll for melt extrusion molding according to any one of claims 1 to 5, wherein the ten-point average roughness Rz of the film is 10 to 20 µm. A roll assembly for melt extrusion shaping including a roll for melt extrusion shaping, and a crimping roll disposed opposite to the roll for melt extrusion shaping,
The melt extrusion shaping roll is:
A roll main body provided with a heat medium flow path therein, the roll main body manufactured from a metal material having a thermal conductivity of 40 W / m · K or more and 100 W / m · K or less;
An amorphous metal film provided on the surface of the roll body, wherein the amorphous metal has a thermal conductivity lower than the thermal conductivity of the metal material. Roll assembly.   The roll assembly for melt extrusion molding according to claim 7, wherein the amorphous metal has a thermal conductivity of 20 W / m · K or less. A roll for melt extrusion shaping, and a crimping roll arranged opposite to the melt extrusion shaping roll,
The melt extrusion shaping roll is:
A roll main body provided with a heat medium flow path therein, the roll main body manufactured from a metal material having a thermal conductivity of 40 W / m · K or more and 100 W / m · K or less;
A roll assembly for melt extrusion shaping, comprising a film of amorphous metal provided on the surface of the roll body, the film having a thermal conductivity lower than that of the metal material. A melt extrusion molding method using
A melt extrusion molding method characterized in that a sheet-molded product is obtained by passing a molten thermoplastic resin extruded from a die between the melt extrusion molding shaping roll and the crimping roll.   The melt extrusion molding method according to claim 9, wherein the amorphous metal has a thermal conductivity of 20 W / m · K or less. The width of the sheet molded product that is melt-extruded using the melt-extrusion shaping roll is W, and the length of the film in the rotational axis direction of the melt-extrusion shaping roll is X. When
W> X
The melt extrusion molding method according to claim 9 or 10, wherein: The width of the sheet molded product that is melt-extruded using the melt-extrusion shaping roll is W, and the length of the film in the rotational axis direction of the melt-extrusion shaping roll is X. When
20mm ≦ W−X ≦ 100mm
The melt extrusion molding method according to any one of claims 9 to 11, wherein:   The melt extrusion molding method according to any one of claims 9 to 12, wherein the thickness of the sheet molded product is 0.05 mm to 0.5 mm.   The thermoplastic resin is at least one thermoplastic resin selected from the group consisting of a polycarbonate resin, an acrylic resin, a polystyrene resin, a thermoplastic polyester resin, a cyclic polyolefin resin, and a polymethyl-1-pentene resin. The melt extrusion molding method according to any one of claims 9 to 13.   The melt extrusion molding method according to claim 9, wherein the sheet molded article is a light diffusion film.

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