JP4048283B2 - Equipment for manufacturing thermoplastic resin continuous laminated sheet - Google Patents

Description

The present invention relates to an apparatus for producing a thermoplastic resin continuous laminated sheet.

2 (a) and 2 (b), a thermoplastic resin continuous sheet [hereinafter sometimes abbreviated as a continuous sheet. ] (S) One side [FIG. 2 (a)] or both sides [FIG. ] (F) The thermoplastic resin continuous bonding sheet [Hereinafter, it may be abbreviated as a continuous bonding sheet. As a device for manufacturing (A), Patent Document 1 (Japanese Patent Laid-Open No. Hei 6-270366, page 3) discloses a manufacturing device (1 ') as shown in FIG. The production apparatus (1 ′) includes a die (2) that continuously extrudes the thermoplastic resin (P) heated and melted by the extruder (7) into a sheet shape, and a heat extruded from the die (2). A rolling roll (3) that is formed by rolling the plastic resin (P1) into a continuous sheet (S). The thermoplastic resin (P1) extruded from the die (2) is sandwiched between the first rolling roll (31) and the second rolling roll (32) and rolled, and then the second rolling roll (32). While being wound around, it is sandwiched between the second rolling roll (32) and the third rolling roll (33) and rolled again to form a continuous sheet (S). The continuous sheet (S) immediately after rolling is wound around the third rolling roll (33) and then taken up from the third rolling roll (33).
The surface temperature of the continuous sheet (S) after rolling is approximately the glass transition temperature (Tgs).

This production apparatus (1 ′) is a reheating, heating device (5 ′) for heating the continuous sheet (S) wound around the third rolling roll (33), and the continuous heating Also provided is a laminating roll (6 ′) for laminating the sheet (S) with the continuous film (F) on the third rolling roll (33). After being heated on the rolling roll (33), it is bonded to the continuous film (F) by the bonding roll (6 ′) on the third rolling roll (33).

According to this manufacturing apparatus (1 ′), the continuous sheet (S) having a surface temperature of about the glass transition temperature (Tgs) is heated immediately after rolling and then bonded to the continuous film (F). ) Even if it is a continuous film (F) with a glass transition temperature (Tgf) that is equal to or higher than the glass transition temperature (Tgs) of ) Can be obtained.

However, such a conventional production apparatus (1 ′) has a problem that the obtained continuous bonding sheet (A) is likely to be warped.

JP-A-6-270366, page 3

Therefore, the present inventor has intensively studied to develop an apparatus capable of producing a thermoplastic resin continuous bonding sheet without causing warpage, and as a result, the continuous bonding sheet is bent on the rolling roll. It is for heating a continuous sheet in a state, and after taking a continuous sheet from a rolling roll and heating it while keeping it flat, it is warped by configuring the manufacturing apparatus to bond a continuous film with a bonding roll. The present inventors have found that a continuous pasting sheet having no surface can be easily produced, and have reached the present invention.

That is, the present invention is an apparatus (1) for producing a thermoplastic resin continuous bonding sheet (A) in which a thermoplastic resin continuous film (F) is bonded to a thermoplastic resin continuous sheet (S) by thermal fusion. And
A die (2) for continuously extruding the heat-melted thermoplastic resin (P) into a sheet,
A rolling roll (3) that rolls the thermoplastic resin (P1) extruded from the die (2) to form a thermoplastic resin continuous sheet (S);
A holding mechanism (4) for holding the thermoplastic resin continuous sheet (S) flat after being rolled by the rolling roll (3),
A heating device (5) for heating the bonding surface (Sa) of the thermoplastic resin continuous sheet (S) held flat by the holding mechanism (4);
A heat comprising a bonding roll (6) for bonding a thermoplastic resin continuous film (F) to the thermoplastic resin continuous sheet (S) after being heated by the heating device (5). An apparatus (1) for producing a continuous continuous plastic resin sheet (A) is provided. FIG. 1 schematically shows an example of the production apparatus (1) of the present invention.

According to the manufacturing apparatus of the present invention, the thermoplastic resin continuous sheet after being rolled is heated while being held flat, and is bonded to the thermoplastic resin continuous film by a bonding roll and bonded. A thermoplastic resin continuous bonding sheet can be continuously produced without causing it to occur.

As shown in FIG. 1, the production apparatus (1) of the present invention includes a die (2) for extruding a heat-melted thermoplastic resin (P). Examples of the thermoplastic resin (P) that is heated and melted and extruded from the die (2) include acrylic resin, styrene resin, methyl methacrylate-styrene copolymer resin, polycarbonate resin, acrylonitrile-butadiene-styrene copolymer resin. (ABS resin), acrylonitrile-styrene copolymer resin (AS resin), polyolefin resin such as vinyl chloride resin, polyethylene, polypropylene, polyester resin, polyacetal resin, fluororesin, nylon resin, etc., and these thermoplastic resins Are used alone or in combination of two or more. The thermoplastic resin (P) may contain additives such as a heat stabilizer, an antioxidant, a light stabilizer, an ultraviolet absorber, a colorant, a plasticizer, and an antistatic agent.

In order to heat and melt the thermoplastic resin (P), for example, an ordinary extruder (7) may be used. The thermoplastic resin (P) heated and melted while being kneaded by the extruder (7) is continuously extruded from the die (2).

By using a normal T die as the die (2), it can be extruded into a film. The die (2) may be formed by extruding the thermoplastic resin (P) in a single layer, or may be formed by extruding in two or more layers. By using a single layer extrusion die, a single layer thermoplastic resin continuous sheet (S) can be obtained, and by using a multilayer extrusion die, two or more types of thermoplastic resins can be coextruded. A multilayer thermoplastic resin continuous sheet (S) can be obtained.

The production apparatus (1) of the present invention includes a rolling roll (3) that rolls the thermoplastic resin (P1) extruded from the die (2) to form a continuous sheet (S). The diameter of the rolling roll (3) is usually about 15 cm to 60 cm. The thermoplastic resin (P1) extruded from the die (2) is rolled by a rolling roll (3). The number of rolling rolls (3) is not particularly limited as long as it is two or more so that the thermoplastic resin (P1) can be sandwiched and rolled, but in the apparatus (1) shown in FIG. 1, three rolling rolls (3) Is used. The extruded thermoplastic resin (P1) is first sandwiched between the first rolling roll (31) and the second rolling roll (32) and rolled, and then wound around the second rolling roll (32). While being rolled, it is rolled again by being sandwiched between the second rolling roll (32) and the third rolling roll (33), and formed into a continuous sheet (S).

The thickness of the continuous sheet (S) after rolling is usually about 1 mm to 20 mm and the width is usually about 200 mm to 2500 mm. The temperature of the continuous sheet (S) immediately after rolling is usually bonded to the continuous film (F). The glass transition temperature (Tgs) of the bonding surface (Sa) to be applied is in the range of ± 20 ° C.

The production apparatus (1) of the present invention includes a holding mechanism (4) that holds the thermoplastic resin continuous sheet (S) flat after being rolled by the rolling roll (3). In the manufacturing apparatus (1) shown in FIG. 1 as the holding mechanism (4), a plurality of guide rolls (4) arranged side by side on a horizontal plane are used. As the guide roll (4), for example, a commercially available roller table may be used. The continuous sheet (S) is conveyed while being held flat by the holding mechanism (4). The continuous sheet (S) does not need to be held strictly flat, and may be held substantially flat so that no stress remains.

The production apparatus (1) of the present invention includes a heating device (5) for heating the continuous sheet (S) held flat by the holding mechanism (4). The heating device (5) heats the continuous sheet (S) on the guide roll (7). As the heating device (5), a normal heating device such as an electric heater, an infrared heater, or a hot air heater can be used. A continuous sheet (S) should just heat the bonding surface (Sa) bonded with a continuous film (F), bonds a continuous film (F) on both surfaces, and is as shown in FIG.2 (b). What is necessary is just to heat both surfaces, when obtaining the continuous bonding sheet | seat (A) by which the continuous film (f) was bonded on both surfaces of the continuous sheet (S). In addition, when obtaining a continuous sheet in which the continuous film (f) is bonded only on one side of the continuous sheet (S) as shown in FIG. Only the bonding surface (Sa) to be heated may be heated, or not only the bonding surface (Sa) but also the both surfaces including the non-bonding surface (Sb) on the opposite side may be heated.

The production apparatus (1) of the present invention includes a laminating roll (6) for laminating the continuous film (F) on the continuous sheet (S) after being heated by the heating apparatus (5). The bonding roll (6) is usually used as a pair as shown in FIG. The pair of laminating rolls (6) may be configured to be driven to rotate and serve as take-up rolls to take the continuous sheet (S) from the rolling roll (3). Further, it may be configured to be driven to rotate while being synchronized with the rolling roll (3) and to be pulled without substantially applying a stretching force to the rolled continuous sheet (S). The bonding roll (6) may be a metal roll whose surface is made of a metal material such as stainless steel, but among both surfaces of the continuous film (F), the bonding surface to be bonded to the continuous sheet ( The bonding roll in contact with the continuous film (F) is preferably a rubber roll having a surface made of a rubber material in that the non-bonding surface (Fb) opposite to Fa) is hard to be damaged. The diameter of the bonding roll (6) is usually about 5 cm to 30 cm.

Examples of the thermoplastic resin continuous film (F) include an acrylic resin film, a styrene resin film, a methyl methacrylate-styrene copolymer resin film, a polycarbonate resin film, an ABS resin film, a vinyl chloride resin film, a polyolefin resin film, and a polyester resin. Examples include films, polyacetal resin films, fluororesin films such as polyvinylidene fluoride (PVDF) resin films, nylon resin films, etc., and bonded by bonding with the bonding surface (Sa) of the thermoplastic resin continuous sheet (S). What can be used is appropriately selected and used. The thickness of the continuous film is usually about 50 μm or more and 1000 μm or less, and its width is about the same as that of the continuous sheet (S). Such a continuous film (F) is usually unwound from the raw roll (F1) by the laminating roll (6), and then introduced between the laminating rolls (6) and sandwiched with the continuous sheet (S), and heated. Bonded by fusion.

The thermoplastic resin continuous film (F) may contain elastic particles. The continuous film (F) containing elastic particles is excellent in flexibility and is relatively easy to handle. Examples of the elastic particles include acrylic acid ester copolymer rubber particles, polybutadiene rubber particles, styrene-butadiene copolymer rubber particles, and butadiene-acrylic acid ester copolymer rubber particles. Further, additives such as a heat stabilizer, an antioxidant, a light stabilizer, an ultraviolet absorber, a colorant, a plasticizer, and an antistatic agent may be included. The thermoplastic resin continuous film (F) may be a single layer film or a multilayer film in which two or more kinds of films are laminated.

The bonding surface (Fa) of the thermoplastic resin continuous film (F) may be untreated, or may be used after being subjected to a surface treatment so as to be easily heat-sealed with the continuous sheet. The non-bonding surface (Fb) may be untreated, but for example, a surface treatment layer may be provided. An example of the surface treatment layer is a hard coat layer. By providing the hard coat layer, a continuous bonding sheet (A) having a sufficient surface height can be obtained. An antireflection layer may be further provided on the hard coat layer. The thickness of the surface treatment layer is usually about 0.1 μm to 50 μm.

In the production apparatus (1) of the present invention, the glass transition temperature (Tgf) of the bonding surface (Fa) of the continuous film (F) is the glass transition temperature (Tgs) of the bonding surface (Sa) of the continuous sheet (S). 30 ° C lower than the glass transition temperature (Tgs) of the continuous sheet bonding surface (Sa) 20 ° C lower (Tgs-20 ° C) or higher, 40 ° C higher (Tgs + 40 ° C.) or lower, preferably used. For example, when the continuous sheet (S) is an acrylic resin continuous sheet or a methyl methacrylate-styrene copolymer resin, the continuous film (F) Is preferably used when it is an acrylic resin film, a methyl methacrylate-styrene copolymer resin film, a styrene resin film, an ABS resin film, a fluororesin film, a nylon resin film, or the like.

The thermoplastic resin continuous sheet (S) is preferably immediately bonded to the thermoplastic resin continuous film (F) after heating by the heating device (5), and the temperature of the bonding surface (Sa) is the temperature of the continuous film. Temperature (Tgf + 5 ° C) higher than the glass transition temperature (Tgf) of the bonding surface (Fa) usually by 5 ° C or higher, usually 50 ° C higher than the glass transition temperature (Tgs) of the bonding surface (Sa) of the continuous sheet In the state below (Tgs + 50 ° C.), the continuous film (F) is bonded by a bonding roll (5). The continuous sheet (S) is preferably bonded to the continuous film (F) with a bonding roll (6) while being kept flat after heating.

When using a thermoplastic resin continuous film (F) in which a surface treatment layer is formed, cracking of the surface treatment layer is likely to occur if the surface treatment layer is largely bent. Therefore, a laminating roll (6) at an introduction angle (α) of 90 ° or less. ) Is preferably introduced in between. Here, the introduction angle (α) is an angle of the thermoplastic resin continuous film (F) with respect to the thermoplastic resin continuous sheet (S), and is a value exceeding 0 ° and less than 180 °. When trying to introduce the continuous film (F) at an introduction angle (α) of less than 90 °, the continuous film (F) unwound from the raw roll (F1) becomes a rolling roll (3), a holding mechanism (4), It may interfere with the heating device (5), etc., but in this case, a heating device (5) having a low height is appropriately selected and used, or a holding roll (4) with a small diameter guide roll The heating device (5) may be disposed close to the continuous sheet (S) and the distance between the rolling roll (3) and the laminating roll (6) may be set large. Since the production apparatus (1) of the present invention heats the continuous sheet (S) after being rolled by the rolling roll (3) and then bonds it by the bonding roll (6), it is bonded to the rolling roll (3). The distance between the combined rolls (6) can be set large.

According to the production apparatus (1) of the present invention, the thermoplastic resin (P) that has been heated and melted is extruded into a sheet shape, rolled into a thermoplastic resin continuous sheet (S), and then the continuous sheet (S) While holding flat, the bonding surface (Sa) is heated and bonded to the thermoplastic resin continuous film (F), so the thermoplastic resin continuous bonding sheet (A) is produced without causing warpage. be able to. The obtained continuous bonding sheet (A) is cut into a predetermined length, for example, to obtain a thermoplastic resin sheet bonding sheet (A ′).

EXAMPLES Hereinafter, although an Example demonstrates this invention in detail, this invention is not limited by this Example.

Example 1
As shown in FIG. 1, an acrylic resin (glass transition temperature 100 ° C.) is kneaded while being heated and melted using a 40 mm extruder (7), extruded from a T-die (2) at 265 ° C. Steel, diameter 200 mm] (31) and the second rolling roll [stainless steel, diameter 200 mm] (32), and then wound around the second rolling roll (32), then this second rolling roll An acrylic resin continuous sheet (thickness 2 mm, width 200 mm) (S) was continuously produced by sandwiching and rolling between (32) and a third rolling roll (stainless steel, diameter 200 mm) (33). The temperature of the surface of the acrylic resin continuous sheet (S) immediately after leaving the third rolling roll (33) was 101 ° C. on both sides.

While holding the acrylic resin continuous sheet (S) immediately after rolling with a pair of laminating rolls (6) (made of hard rubber, diameter 100 mm) and holding it flat on a plurality of guide rolls (4), only the upper surface thereof Was heated from above by an electric heater (5). Acrylic resin film (thickness 125μm, glass transition temperature (Tgf) on the bonding surface side is 88 ° C) (F) is introduced so as to overlap only the heated surface side (upper side) with the acrylic resin continuous sheet (S) after heating Acrylic resin film only on one side (upper surface) of acrylic resin continuous sheet (S) as shown in FIG. 2 (a), introduced between sandwiching rolls (6) at an angle (α) of 60 °, sandwiched, and crimped. An acrylic resin continuous bonding sheet (A) in which (F) was bonded by heat sealing was obtained. In addition, the temperature of the bonding surface (Sa) of the acrylic resin continuous sheet (S) immediately before being sandwiched between the bonding rolls (6) was 97 ° C. Moreover, the acrylic resin continuous sheet (S) was sent between the bonding rolls (6) while being flat after heating. The obtained acrylic resin continuous bonding sheet (A) was not warped, and the acrylic resin continuous sheet (S) and the acrylic resin continuous film (F) were bonded by heat fusion with sufficient strength.

Example 2
Except for increasing the output of the electric heater (5) and heating so that the temperature of the bonding surface (Sa) of the acrylic resin continuous sheet (S) immediately before being sandwiched between the bonding rolls (5) becomes 106 ° C, By operating in the same manner as in Example 1, an acrylic resin continuous bonding sheet (A) was obtained. This acrylic resin continuous bonding sheet was not warped, and the acrylic resin continuous sheet and the acrylic resin continuous film were bonded by heat fusion with sufficient strength.

Example 3
Except for increasing the output of the electric heater (5) and heating so that the temperature of the bonding surface (Sa) of the acrylic resin continuous sheet (S) immediately before being sandwiched between the bonding rolls (6) is 115 ° C, By operating in the same manner as in Example 1, an acrylic resin continuous bonding sheet (A) was obtained. This acrylic resin continuous bonding sheet (A) was not warped, and the acrylic resin continuous sheet (S) and the acrylic resin continuous film (F) were bonded by heat fusion with sufficient strength.

Example 4
Two sides of the acrylic resin continuous sheet (S) are heated by two electric heaters (5) provided on both sides of the acrylic resin continuous sheet (S), and the same acrylic resin continuous film as used in Example 1 ( F) was introduced at the same introduction angle (α) as in Example 1, overlapped, and operated in the same manner as in Example 1 except that it was sandwiched between the bonding rolls (6) and pressed, and FIG. A film-bonded acrylic resin continuous sheet (A) in which the thermoplastic resin continuous film (F) was bonded to both surfaces of the acrylic resin continuous sheet (S) as shown in FIG.
In addition, as for the temperature of the bonding surface (Sa) of the acrylic resin continuous sheet (S) just before being pinched | interposed into the bonding roll (6), one surface was 111 degreeC and the other surface was 112 degreeC. This acrylic resin continuous bonding sheet (A) did not warp, and the acrylic resin continuous film (F) was bonded to both sides of the acrylic resin continuous sheet (S) by heat fusion with sufficient strength.

Comparative Example 1
Except that heating by the electric heater (5) was stopped and the laminating roll (6) was heated, the same operation as in Example 1 was conducted, and the acrylic resin continuous sheet (S) and the acrylic resin continuous film (F) were adhered. Could not be pasted.

Comparative Example 2
As shown in FIG. 3, after the rolling, the heating device (5 ′) for heating the acrylic resin continuous sheet (S) wound around the third rolling roll (33), and the third rolling roll (33) Using the production apparatus (1 ′) provided with the laminating roll (6 ′) for laminating the acrylic resin continuous film (F) to the acrylic resin continuous sheet (S) after heating with the third rolling roll (33) After heating the acrylic resin continuous sheet (S) above, except that the bonding surface (Sa) is bonded to the acrylic resin continuous film (F) at 97 ° C. with this bonding roll (6 ′). The acrylic resin continuous laminated sheet (A) in which the acrylic resin continuous sheet (S) and the acrylic resin continuous film (F) were bonded with sufficient strength by thermal fusion by operating in the same manner as in Example 1. However, this continuous bonding sheet (A) tends to be warped.

It is a schematic diagram which shows an example of the manufacturing apparatus of the thermoplastic resin continuous bonding sheet | seat of this invention. It is a schematic diagram which shows the layer structure of a thermoplastic resin continuous bonding sheet. It is a schematic diagram which shows the manufacturing apparatus of the conventional thermoplastic resin continuous bonding sheet | seat.

Explanation of symbols

1: Manufacturing apparatus 1 ′ for thermoplastic resin continuous bonding sheet of the present invention: Conventional manufacturing apparatus for thermoplastic resin continuous bonding sheet 2: Die 3: Roll roll 31: First rolling roll 32: Second rolling roll
33: Third rolling roll 4: Holding mechanism (guide roll) 5, 5 ': Heating device 6, 6': Pasting roll 7: Extruder P, P1: Thermoplastic resin S: Thermoplastic resin continuous sheet Sa: Pasting Bonding surface F: Thermoplastic resin continuous film Fa: Bonding surface Fb: Non-bonding surface F1: Raw roll A: Thermoplastic resin continuous bonding sheet A ': Thermoplastic resin sheet bonding sheet

Claims (2)

This is a method for producing a thermoplastic resin continuous laminated sheet in which a thermoplastic resin continuous film is bonded to a continuous thermoplastic resin sheet by thermal fusion. The heated and melted thermoplastic resin is extruded into a sheet and rolled. After making the thermoplastic resin continuous sheet, the bonded surface is heated while holding the obtained thermoplastic resin continuous sheet flat, and bonded to the thermoplastic resin continuous film , and the thermoplastic resin continuous film is bonded. the glass transition temperature of the mating face (Fa) (Tgf) is characterized in that a thermal glass transition temperature of the thermoplastic resin lamination surface of the continuous sheet (Tgs) 30 ° C. lower temperatures (Tgs-30 ℃) more than The manufacturing method of the said thermoplastic resin continuous bonding sheet | seat . The thermoplastic resin continuous sheet is an acrylic resin continuous sheet or a methyl methacrylate-styrene copolymer resin continuous sheet, and the thermoplastic resin continuous film is an acrylic resin film, a methyl methacrylate-styrene copolymer resin film, a styrene resin film, The manufacturing method according to claim 1 , which is an ABS resin film, a fluororesin film, or a nylon resin film.

Images