JP4093419B2 - Foam sheet, manufacturing method and manufacturing apparatus thereof - Google Patents

Description

  The present invention relates to a foam sheet. Specifically, the present invention is a light reflector for a planar light source used in a backlight mechanism for a display device such as a liquid crystal, such as a light reflector, separator materials for batteries, packaging materials, steel sheet laminate materials, etc. The present invention relates to a foam sheet that can be suitably used, a method for producing the foam sheet, a device suitable for use in the production, a light reflection plate using the foam sheet, and a display device.

  2. Description of the Related Art In recent years, many display devices such as liquid crystals that can be made thin have been used as display devices for notebook personal computers and desktop personal computers, televisions, mobile phones, and the like. For example, since a liquid crystal display device itself is not a light emitter, display can be performed by installing a planar light source called a backlight and irradiating light from the back side. In order to uniformly illuminate the entire screen, this backlight usually has a planar light source structure called a side light type or a direct type. In particular, since notebook PCs are desired to be thin and small, a sidelight type backlight (ie, a type that irradiates light from the side of the screen) is usually used for applications that enable thin liquid crystal displays. (See Patent Documents 1 and 2). On the other hand, for large screens such as liquid crystal televisions, the direct light type is adopted because it is not possible to increase the screen brightness with the sidelight method.

  In general, in the case of the side light method, a cold cathode ray tube is used as an illumination light source, light is uniformly propagated and diffused from the edge of the light guide plate within the surface of the light guide plate, and further from the light guide plate in the opposite direction to the liquid crystal screen. In order to efficiently reflect the diffused light toward the liquid crystal screen, a reflecting plate is provided under the light guide plate. On the other hand, in the direct type light system, cold cathode ray tubes are provided in parallel at the lower part of the liquid crystal screen, and the cold cathode ray tubes are arranged in parallel on the reflector. As the reflection plate, a flat plate or a cold cathode ray tube part formed into a semicircular concave shape is used.

  As described above, the reflector plays a large role in uniformly irradiating the entire screen of the liquid crystal display device. Reflectors that satisfy this role are required to have a high degree of reflection characteristics. Conventionally, a film containing fine bubbles inside, a film added with a white pigment, etc., alone or with these films and a metal plate A laminate of plastic plates has been used. As a film used for this reflector, a biaxially stretched white polyester film having a relatively small directivity in reflected light is often used. The biaxially stretched white polyester film is formed by adding a filler to a resin and stretching after forming a sheet to form fine voids.

  By the way, the liquid crystal display device has been mainly used for a notebook personal computer in the past, but in recent years, it has been increasingly used in various devices such as a desktop personal computer, a television, and a mobile phone display. Further, there is a demand for brighter and clearer images. Improvements for realizing a high-brightness and high-definition liquid crystal screen are being promoted, and the required characteristics for the reflector are becoming stricter. For this reason, studies for improving the reflection characteristics of the stretched white polyester film have been earnestly performed (see Patent Documents 2 and 3).

  However, in the stretched white polyester film, in order to increase the number of bubbles in order to improve the reflection characteristics, it is necessary to increase the amount of resin or particles incompatible with the polyester. For this reason, such an incompatible resin or particle is an impurity that absorbs light and causes a decrease in the reflection characteristics, and it is difficult to further improve the reflection characteristics. In addition, since the bubbles are formed by stretching, the size of the bubbles becomes almost uniform, and as a result, an undesirable phenomenon such as a decrease in reflectance of light having a specific wavelength may occur. Furthermore, in the case of a direct light type backlight, a corrugated molding process is required on the reflector, but the stretched white polyester film has a small residual elongation and is not suitable for such a molding process. .

As an alternative to the above stretched white polyester film, a polyester resin foam sheet obtained by holding a roll in a pressurized inert gas and impregnating the polyester resin sheet with an inert gas and then heating and foaming under normal pressure. (See Patent Document 4) (MCPET (registered trademark): available from Furukawa Electric Co., Ltd.).
The polyester resin foam sheet obtained by this method uses a bubble generation mechanism when the pressure of the inert gas is released, so that it contains impurities or bubbles are completely aligned like foaming by stretching. There is nothing to do. As a result, it is possible to improve the reflection characteristics as compared with the stretched white polyester film. Moreover, since it is not a stretched film, a shaping | molding process is also easy.

  Thus, said polyester resin foam sheet compensates the fault of a stretched white polyester film. However, since it takes time to impregnate the polyester resin sheet with an inert gas, productivity is not good. In addition, there is a drawback that the surface becomes rough because bubbles are easily broken on the surface of the sheet. Furthermore, if a non-foamed layer is to be provided on the surface, there is only a method of bonding the non-foamed sheet after foaming the polyester resin sheet, and there is a drawback in that the reflection characteristics are adversely affected.

On the other hand, a method for producing a foamed sheet obtained by melting and kneading a methyl methacrylate polymer and a foaming agent with an extruder to obtain a cylindrical foam, then drawing and cooling, and taking up into a cut sheet is known. (See Patent Document 5). Further, a method of forming a laminated article by extruding a sheet-shaped fine cell polymer material is known (see Patent Document 6). However, in these methods, the size of the bubbles cannot be controlled, so that the size of the bubbles becomes large, and a sufficient improvement in reflection characteristics cannot be expected.
In the method disclosed in Patent Document 6, the laminated body of the foamed sheet and the non-foamed sheet is assumed to be laminated by adhesion. However, in the lamination by adhesion, a boundary is formed at the lamination interface, so that reflection, refraction, and light absorption at the interface occur, and the total reflection characteristics are likely to be adversely affected.

Furthermore, a method of obtaining a porous or foamable film or sheet by causing a gas to act on the resin composition in an extruder is known (see Patent Documents 7 to 9). However, in the method disclosed in Patent Document 7, even if the concentration of the inert gas in the polymer is kept low, the bubbles only increase and cannot be used for a light reflecting plate by fine foaming. In addition, even by the method disclosed in Patent Document 8, the gas concentration after the sheet is once changed may cause variation in the gas concentration on both sides of the sheet, and the foaming part and the part that does not foam much are mixed. Cause non-uniformity. Furthermore, in the method disclosed in Patent Document 9, there is a disadvantage that the bubble size grows large during stretching.
As described above, it is difficult to control the size and shape of the bubbles in the foam sheet, although it is very important.

JP 63-62104 A JP 2003-160682 A JP 2001-305313 A Japanese Patent No. 2713556 JP 2000-86795 A JP-T-2001-510749 JP 2002-338726 A JP 2000-119432 A Japanese Patent No. 2902242

  Therefore, the limitations of the reflection characteristics of the conventional biaxially stretched white polyester film described above, the difficulty of molding, and the size and shape of the bubbles are optimized according to the application, the productivity is good, the surface is beautiful and the light There was a problem to develop a fine foam sheet suitable for a reflector.

The above problems are solved by the present invention described below.
That is, the present invention is an unstretched foamed sheet comprising a thermoplastic resin, and 80% or more of the bubbles contained in the sheet have a cell diameter in the range of 0.1 to 20 μm, and the porosity Relates to a foamed sheet of 20 to 80%.
In another aspect of the present invention, a step of forming a molten polymer of a thermoplastic resin in which a gas is dissolved in a non-foamed state, and generating bubbles by exposing the sheet to a vacuum under a temperature condition of 50 to 200 ° C. And a step of causing the foamed sheet to be produced.
In still another aspect of the present invention, the present invention relates to a method for producing a foam sheet, which comprises coextruding a thermoplastic resin in which a gas is dissolved and a thermoplastic resin in which a gas is not dissolved.

In still another aspect of the present invention, an extruder having a screw, a cylinder, and a temperature control mechanism for the cylinder is supplied from a high-pressure gas supply unit provided on the inner surface of a part of the cylinder, outside the cylinder. The present invention relates to an extrusion apparatus for producing a foam sheet, which is provided with a nozzle for introducing a gas to be produced.
In still another aspect of the present invention, a vacuum chamber apparatus having a chamber capable of reducing the pressure inside the casting roll and / or the casting roll of the sheet forming machine and a sealing mechanism, and a vacuum associated with the vacuum chamber apparatus. The present invention relates to a foam sheet manufacturing apparatus in which a generator is arranged.

  As a result of intensive studies, the present inventor shows a gas phase occupancy ratio so as to have fine bubbles in a range of 0.1 to 20 μm and a bubble density of a certain level or more while being an unstretched cast sheet. When the porosity is in the range of 20 to 80%, as a foam sheet to be used for a light reflecting plate or the like, the surface beauty, easy moldability, and good productivity that are not found in the conventional foam sheets can be obtained. I found out.

Since the foamed sheet of the present invention is an unstretched sheet, it can be easily molded according to the application to which the foamed sheet is applied. Here, the term “non-stretched” means that uniaxial or biaxial stretching is not performed for the purpose of causing the sheet to be oriented, and stretching that occurs with casting or sheeting is allowed.
In the foamed sheet according to the present invention, 80% or more of the bubbles contained in the sheet have a bubble diameter in the range of 0.1 to 20 μm, so that good reflection characteristics can be obtained. It is preferable that 80% or more of the bubbles contained in the sheet have a bubble diameter in the range of 0.4 μm to 8 μm. When the bubble diameter is too small, a light interference effect or the like is caused, so that sufficient reflection cannot be obtained. On the other hand, if the bubble diameter is too large, it is necessary to increase the thickness of the sheet in order to have a certain number of interfaces, and as a result, the mechanical strength of the sheet becomes weak or thicker than the desired film thickness. It may be difficult to put it into practical use, such as when design is required.
Moreover, since the cell diameter was uniform in the conventional stretched sheet, there was a problem such as a decrease in the reflectance of light of a specific wavelength. However, in the foam sheet of the present invention, the cell diameter contained in the sheet was normal. The distribution is advantageous in that good reflection characteristics can be obtained.

  Since the foamed sheet according to the present invention has a porosity in the range of 20 to 80%, good reflection characteristics can be obtained. The porosity corresponds to the density of bubbles contained in the foamed sheet and represents the gas phase occupation ratio of the sheet, and can be determined from the density of the sheet and the resin used and the sheet volume. The porosity of the sheet is preferably 50 to 70%. In order to maintain the spherical shape of the bubble, the theoretical maximum porosity is about 70%, and if it exceeds this, the bubble collapses and good reflection characteristics cannot be obtained. Because. On the other hand, when the porosity is too low, the density of the bubbles becomes too low, so that desired reflection characteristics cannot be obtained.

  When the foamed sheet is used as a reflector used in a direct light type backlight unit, the foamed sheet is usually molded at a molding temperature of 100 ° C. or more. In order to facilitate such molding processing and to exhibit good reflection characteristics, the foamed sheet according to the present invention has a tensile elongation at break of 100% or more measured in an atmosphere of 100 ° C., and 100 ° C., 100 The tensile stress at% elongation is preferably 50 MPa or less. The tensile elongation at break is preferably 150% or more, and the tensile stress is preferably 0 to 30 MPa or less.

  The main thermoplastic resin constituting the foamed sheet according to the present invention is preferably a resin having a high melt tension in order to promote fine foaming. Accordingly, a thermoplastic resin having a melt flow rate (according to ASTM D1238-98) showing fluidity in the molten state of 0.5 to 44 g / 10 minutes is preferable, and fluidity in the molten state is 1.4 to 30 g / 10. More preferable is a thermoplastic resin for a minute. The fluidity of the thermoplastic resin can be determined according to measurement conditions (temperature, load, etc.) relating to various polymers described in ASTM D1238-98.

  Specific examples of the thermoplastic resin that can be used in the present invention include, for example, acrylic resins, methacrylic resins, polyolefins, polyamides, polyesters, polycarbonates, styrene resins, polyethers, polyurethanes, polyphenylene sulfides, polyester amides, polyether esters, Examples thereof include, but are not limited to, polyvinyl chloride, modified polyphenylene ether, polyarylate, polysulfone, polyimide, polyetherimide, polyamideimide, copolymers containing these as main components, and mixtures thereof.

In particular, it is preferable to use an acrylic resin and / or methacrylic resin as the main thermoplastic resin constituting the foamed sheet according to the present invention, because particularly good fine foamability and moldability can be obtained, and the transparency of the resin itself is high. As a result, reflection at the bubble interface is also improved. Furthermore, the light resistance is also excellent, and the raw material resin can be obtained relatively inexpensively.
Specific examples of such acrylic resin or methacrylic resin include, for example, acrylic acid ester or methacrylic acid ester homopolymer or acrylic acid ester or methacrylic acid ester of 50% by weight or more, and one or more other vinyl monomers. Among them, a copolymer of 50% by weight or more of a methacrylic acid ester and one or more other vinyl monomers is preferable, and in particular, 50% by weight of a methacrylic acid alkyl ester is preferable. A copolymer of 50% by weight or less of the acrylic acid alkyl ester and 49% by weight or less of one or more vinyl monomers copolymerizable with at least one of the methacrylic acid alkyl ester and the acrylic acid alkyl ester is preferable. . The acrylic acid alkyl ester contained in the copolymer is preferably 0.1% by weight to 40% by weight, and more preferably 1% by weight to 15% by weight. The above acrylic resins or methacrylic resins may be used alone or in combination.

  Examples of such acrylates include methyl acrylate, ethyl acrylate, butyl acrylate, cyclohexyl acrylate, phenyl acrylate, benzyl acrylate, 2-ethylhexyl acrylate, 2-hydroxyethyl acrylate, and the like. In particular, methyl acrylate and ethyl acrylate are preferred. Examples of the methacrylic acid ester include methyl methacrylate, ethyl methacrylate, butyl methacrylate, cyclohexyl methacrylate, phenyl methacrylate, benzyl methacrylate, 2-ethylhexyl methacrylate, 2-hydroxyethyl methacrylate, and the like. In particular, methyl methacrylate and ethyl methacrylate are preferable. Other vinyl monomers that can be copolymerized include, in addition to the above acrylic ester or methacrylic ester, for example, unsaturated acids such as acrylic acid and methacrylic acid, styrene, α-methylstyrene, acrylonitrile, methacrylonitrile. , Maleic anhydride, phenylmaleimide, cyclohexylmaleimide and the like.

  The weight average molecular weight (Mw) of the acrylic resin or methacrylic resin is preferably 40,000 to 400,000, more preferably 60,000 to 300,000. When Mw is too small, the mechanical strength of the obtained foamed sheet may not be sufficient, and when Mw is too large, the melt viscosity increases and the extrusion performance may decrease.

  Further, the above acrylic resin or methacrylic resin may contain a rubber-like polymer. By blending the rubber-like polymer into the acrylic resin or methacrylic resin, the viscosity and toughness of the resin are improved, so that a foam sheet having good impact resistance can be obtained.

  In the thermoplastic resin of the present invention, a small amount, preferably in the range of 0 to 3% by weight, within a range that does not impair the reflective properties of the foam sheet, Antioxidants, stabilizers, processing aids, plasticizers, antistatic agents, impact aids, foaming agents, fillers, matting agents, mold release agents, flame retardants, UV absorbers, UV inhibitors, pigments, Various additives such as dyes, lubricants, and optical brighteners may be blended.

  Among these, as the fine inorganic particles functioning as a bubbling nucleating agent, those capable of forming pores by themselves are preferable, for example, calcium carbonate, magnesium carbonate, zinc carbonate, titanium oxide (anatase type, rutile type), zinc oxide. Barium sulfate, zinc sulfide, basic tin carbonate, mica titanium, antimony oxide, magnesium oxide, calcium phosphate, silica, alumina, mica, talc, kaolin and the like can be used. Among these, it is particularly preferable to use calcium carbonate and barium sulfate, which have low absorption in the visible light region of 400 to 70 Onm. If there is absorption in the visible light region, there may be a problem that the luminance decreases.

  Examples of the gas dissolved in the thermoplastic resin in the extruder in order to form bubbles in the sheet include carbon dioxide, nitrogen, butane, helium, and argon. Among these, carbon dioxide and nitrogen are preferable because they have low gas permeability and can be handled safely at low cost, and these may be used alone or in combination.

  The foam sheet of the present invention preferably has a reflectance in the visible light range of 85% or more and a total light transmittance of 10% or less as a foam sheet particularly suitable for light reflectors because of its beautiful surface.

  The foam sheet according to the present invention may have an embossed pattern transferred on at least one side. Such embossing is performed by transferring a pattern onto a thermoplastic resin sheet on a casting roll having a fine pattern formed on the surface, or once winding a foam sheet formed into a plain casting roll onto the roll. After that, it can be carried out by a method of transferring the pattern onto the sheet again by using a calendar device having a fine pattern on the surface. Examples of the fine pattern include a satin pattern, a checkered pattern, a hemispherical pattern, a chevron pattern, a pyramid pattern, or a composite pattern thereof for efficiently reflecting light.

  The thickness of the foamed sheet according to the present invention is preferably 20 to 500 μm, and more preferably 35 to 350 μm. If the thickness is too small, it becomes difficult to ensure the flatness of the sheet, and unevenness in brightness tends to occur when used as a light reflecting plate. On the other hand, if the thickness is too large, the moldability may deteriorate.

  The foamed sheet according to the present invention may be a laminated sheet having two or more layers formed by arranging at least one layer according to the purpose of use. In the case of a laminated sheet, the ratio of the sublayer portion / main layer portion is preferably 1/200 to 1/3, and more preferably 1/50 to 1/4. In the case of a sub-layer part / main layer part / sub-layer part three-layer laminated sheet or a laminated sheet of three or more layers, the ratio is expressed as the sum of both sub-layer parts / main layer part. In addition to the foamed sheet, at least one non-foamed layer may be disposed on the laminated sheet. The foamed sheet according to the present invention is preferably disposed in the laminated sheet as the main layer part.

  The laminated sheet according to the present invention may be formed by coextrusion, extrusion lamination, thermal lamination, coating, vapor deposition or the like. Especially, the lamination sheet by co-extrusion is preferable. In such a laminated sheet, for example, polymers from a foam layer main extruder and a non-foamed layer sub-extruder are joined together in a manifold part in a die or a feed block part installed before entering the die. Can be formed. Since this coextruded laminated sheet does not need to be provided with an adhesive layer, it is advantageous in terms of reflection characteristics and at the same time has good productivity. More preferably, by making the main raw material composition of the main extrusion layer and the sub-extrusion layer the same, the influence of the interface between the main layer and the sublayer can be reduced, for example, there is no boundary between the foamed portion and the non-foamed portion. Therefore, it can be advantageous particularly when used as a light reflecting plate.

  Moreover, this co-extrusion laminated sheet has not only a two-layer structure of a main layer (A layer) and a sub-layer (B layer), but also a three-layer structure of (B layer) (A layer) (B layer), B layer) (A layer) (B layer) (A layer) ... (B layer) (A layer) (B layer) can also have a multi-layered structure, bubble formation state in the thickness direction It is very effective in that it can be controlled easily.

  In another aspect of the present invention, the extruder includes a screw, a cylinder, and a temperature control mechanism for the cylinder, and is supplied to a part of the inner surface of the cylinder from a high-pressure gas supply unit provided outside the cylinder. The present invention relates to an extrusion apparatus for producing a foam sheet, which is provided with a nozzle for introducing a gas. Such an extrusion apparatus is suitable for manufacturing the foamed sheet or the laminated sheet according to the present invention. Here, the high pressure is preferably a pressure that exceeds the critical point. For example, in the case of carbon dioxide gas advantageous for extrusion gas foaming, the critical point is a temperature of 31.1 ° C. and a pressure of 7.52 MPa. Therefore, the high-pressure gas supply unit is preferably an apparatus capable of supplying various gases in a state exceeding their critical points.

  The extrusion apparatus that can be used in the present invention may be any of a single-screw extruder, a twin-screw extruder, a tandem extruder that connects single-screw extruders, and a tandem extruder that combines a twin-screw extruder and a single-screw extruder. . The cylinder part of the extruder is equipped with a heater for heating, an air cooling device for cooling, a temperature control device including a water cooling device or an oil cooling device, and these can be controlled in 5-10 blocks. Is preferred. The cylinder is preferably blocked in the same section as the temperature control portion. The screw is generally divided into a zone for mainly feeding a raw material resin, a zone for melting and compressing the resin, and a compression kneading zone. The dimensions of the screw are optimally designed according to the resin used.

A nozzle for dissolving a gas in the resin melted in the extruder is installed inside the extrusion apparatus, and is preferably disposed in a melt compression zone of a screw dimension. Specifically, the nozzle is installed on the inner surface of one block portion of the cylinder located in the melt compression zone in order to introduce gas supplied from a high-pressure gas supply unit provided outside.
The shape of the nozzle is preferably a structure having fine holes, for example, a pore diameter of 30 μm or less and a porosity of 25% or less, on the inner surface of one block portion of the cylinder. A ring-shaped removable nozzle made of ceramics is installed. Such a ring-shaped metal is preferably composed of a material obtained by sintering metal powder or metal fiber.

In still another aspect of the present invention, a vacuum chamber apparatus having a chamber capable of reducing the pressure inside the casting roll and / or the casting roll of the sheet forming machine and a sealing mechanism, and a vacuum associated with the vacuum chamber apparatus. The present invention relates to a foam sheet manufacturing apparatus in which a generator is arranged. Such a manufacturing apparatus is suitable for manufacturing the foamed sheet or laminated sheet according to the present invention.
In order to obtain a desired foamed sheet, it is preferable that such a vacuum chamber apparatus can reduce the pressure inside the depressurizable chamber to 30 KPa or less.

  The sheet molding machine that can be used in the present invention usually comprises an extruder for melting resin, a flat die for forming a sheet, a cast roll for cooling the sheet, a sheet take-up device, and a winding device. Is done. The flat die is preferably a T die, and examples include a multi-manifold type that is laminated inside the die and a feed block device that is laminated immediately before the die. The cast roll usually has a temperature control function, and the temperature control method may be combined with a method in which cooling water, hot water, oil, or the like is circulated, or in addition to an induction heating method. The sheet take-up device may have a roll temperature control function following the cast roll, and may also be provided with a thickness measurement device, defect detection device, antistatic device, surface treatment device such as corona treatment and frame treatment. It is. The winding device can include a turret mechanism, a touch roll mechanism, a rewinding mechanism, a tension control device, and the like.

  The chamber apparatus usable in the present invention is a box-shaped apparatus having a cross section along the curvature of the roll above the roll in the take-up apparatus following the cast roll or the cast roll, and having a width corresponding to the sheet, The inside of the chamber can be evacuated and decompressed by a vacuum pump provided outside. The chamber box has a sealing mechanism for maintaining a vacuum, and includes a plurality of rooms as necessary.

  A sealing mechanism attached to a chamber apparatus usable in the present invention includes an inlet-side inlet seal, an outlet outlet seal, and side seals arranged on both sides with respect to the sheet flow direction. As the seal, a labyrinth seal type, a contact roller type seal type, or the like can be adopted. As the side seal, a labyrinth seal type, a contact guide type, or the like can be adopted.

Although the preferable specific example is demonstrated below about the manufacturing method of the foam sheet by this invention, this invention is not limited to these specific examples.
First, if necessary, a thermoplastic resin chip as a raw material that has been heated and / or dried is preheated into a main extruder (A) capable of foam extrusion and a sub-extruder (B) that does not perform foaming. ). The main extruder (A) is supplied with gas, preferably under supercritical conditions, by a gas supply apparatus placed outside the apparatus. Inside the main extruder (A), the molten thermoplastic resin and gas are sufficiently kneaded, and the gas is dissolved in the thermoplastic resin and extruded.

  The polymer (a) extruded from the main extruder (A) and the polymer (b) extruded from the sub-extruder (B) are made into three layers (b) (a) (b) in the feed block. Are then fed to a T die and discharged into a sheet. At this time, in the polymer (a), the gas supply amount is adjusted so as to be in a non-foamed sheet state in which gas is dissolved but not foamed.

  The sheet discharged from the T die is landed on a casting roll and cooled. At this time, the sheet is usually a transparent uniform sheet. After cooling to a predetermined temperature on the casting roll, the sheet is introduced into a take-up roll following the casting roll. Next, the sheet is exposed to a vacuum state by a vacuum chamber provided on the take-up roll. Then, a sheet | seat produces a fine foam and changes to a super-white sheet | seat. Thereafter, the sheet is wound on a roll by a winder.

The foamed sheet or laminated sheet according to the present invention can be produced by a method including a step of foaming by extruding a thermoplastic resin in which a gas is dissolved. In this case, foaming may be performed without using the vacuum chamber device, and a non-foamed or foamed sheet may be passed through the vacuum chamber device.
In one aspect, the present invention is a process in which a molten polymer of a thermoplastic resin in which a gas is dissolved is extruded and formed into a sheet, and bubbles are generated by exposing the sheet to a vacuum at a temperature of 50 to 200 ° C. The present invention relates to a method for producing a foam sheet including a process. Such a production method is suitable for production of the foamed sheet or laminated sheet according to the present invention, and the respective steps are preferably continuous. Here, the temperature condition is more preferably 70 to 120 ° C.

In the present invention, “to form a sheet in a non-foamed state” means that the gas is dissolved in the molten resin polymer, but is formed into a sheet without foaming when being discharged at the die portion, and the gas to be dissolved This can be done by reducing the amount and / or controlling the discharge conditions. Since the non-foamed sheet has a gas dissolved in the polymer, it can be easily foamed by applying a stimulus such as reduced pressure to the sheet.
The post-foaming method after forming into a sheet is preferable in that the bubble generation state can be easily controlled by adjusting the conditions such as the temperature of the sheet and the pressure reduction, and therefore the bubble size and the number of bubbles can be easily optimized.

  In one embodiment of the present invention, the foam sheet can be produced by co-extrusion of a thermoplastic resin in which a gas is dissolved and a thermoplastic resin that does not dissolve the gas. Such a manufacturing method is suitable for manufacturing the foamed sheet or laminated sheet according to the present invention.

  Thus, the foamed sheet of the present invention can be obtained by using a sheeting apparatus and a vacuum chamber apparatus following gas supply extrusion. Therefore, it is possible to produce a sheet excellent in reflection characteristics, workability, and surface smoothness in-line with high productivity.

The foamed sheet or laminated sheet according to the present invention can be suitably used as a light reflecting plate. Such a light reflecting plate may be obtained by molding the foamed sheet or the laminated sheet.
The molding process in the present invention means that a molded body is obtained by performing vacuum molding, pressure molding, press molding, calendering, or the like using a temperature-controlled mold.

  The present invention will be described in detail below based on examples, but the present invention is not limited to such examples.

[Evaluation methods]
1. Reflectivity Reflectance is in the visible light range with a spectrophotometer U-3410 (manufactured by Hitachi, Ltd.) and a φ60 integrating sphere 130-0632 (manufactured by Hitachi, Ltd.) and a 10 ° C. inclined spacer attached. The reflectance at (380 to 780 nm) was determined for both sides of the foamed sheet or laminated sheet, and the higher value was taken as the reflectance.

2. Porosity The porosity is the ratio of the volume of bubbles to the volume of the resin sheet. The volume of the sample was determined from the thickness and area of the sheet, the weight was measured, and the porosity was determined using the following formula.
Porosity (%) = (1− (weight / resin density) / volume) × 100

3. Sheet thickness For measuring the thickness of a foamed sheet or laminated sheet, 10 measurement points are provided at equal intervals in the width direction of the foamed sheet or laminated sheet, and the thickness of the measured point is measured using a thickness gauge (a thickness gauge manufactured by teclock). After measuring, the average of the measured values at each point was taken as the thickness of the foamed sheet.

4). Total light transmittance The total light transmittance was evaluated for the foamed sheet and the laminated sheet according to JIS K7105: 1981.

5. Tensile elongation at break The tensile elongation at break is 300 mm / min after holding a 10 mm wide, 100 mm long sheet in a 100 ° C. atmosphere for 5 minutes using a Tensilon UCT-100 tensile tester manufactured by Orientec Co., Ltd. It is an average value of the breaking elongation in the longitudinal direction and the transverse direction when the sheet is stretched by.

6). Tensile stress Tensile stress was stretched at 300 mm / min after holding a sheet of 10 mm width and 100 mm length in a 100 ° C. atmosphere for 5 minutes using a Tensilon UCT-100 tensile tester manufactured by Orientec Co., Ltd. It is an average value of stress values at the time of 100% elongation in the longitudinal direction and lateral direction of the sheet.

[Example 1]
Optical acrylic resin (Sumitomo Chemical Co., Ltd. Sumipex MGSS) heated in advance at 120 ° C for 4 hours is used as a raw material. This is the first stage, 35mm, L / D is 34 single screw extruder, 2 stages 50 mm, L / D is supplied to a tandem configuration extruder of 28 single screw extruder, and further from a high pressure gas supply device installed outside the extruder at 38 ° C. and 15 MPa exceeding the supercritical condition, Carbon dioxide gas was supplied to a nozzle provided in the cylinder part of the melt compression part of the first stage extruder, and dissolved and kneaded in the resin. At this time, the supply amount of carbon dioxide gas was 0.38 kg / h with respect to the discharge amount of the extruder 14.7 kg / h. The extrusion temperature at this time was 240 ° C. for the first stage and 200 ° C. for the second stage.
When this was discharged from a die having a slit width of 150 mm and a slit gap of 0.8 mm to form a sheet, a white foam sheet having an average thickness of 230 μm and a width of 88 mm was obtained.
This sheet was cut with a microtome without crushing the film cross section, and the cut cross section was observed at 500 times using a scanning electron microscope S-2100A type (manufactured by Hitachi, Ltd.). The center was 14 μm, and 80% or more of the bubbles had a bubble diameter in the range of 20 μm or less. The porosity due to bubbles was 76% calculated from the density.
After shaving off the rough surface, the reflectance of this sheet in the visible light range was measured and found to be 85% and the total light transmittance was 6%.
Furthermore, using a film strength and elongation automatic measuring device (Tensilon AMF / RTA-100 manufactured by Orientec Co., Ltd.), sample size: width 10 mm × sample length 100 mm, temperature 100 ° C., tensile speed: 300 mm / min. When measured, the tensile elongation at break was 141%, 100 ° C., and the tensile stress at 100% elongation was 12.0 MPa. As a precaution, when a simple molding test was performed, the moldability was good.

[Example 2]
Except that the discharge rate of the extruder was 14.3 kg / h, and carbon dioxide gas was supplied at a rate of 0.03 kg / h, sheeting was performed in the same manner as in Example 1 to obtain a transparent smooth A sheet was obtained. When this sheet was heated to 90 ° C. and placed in a desiccator (vacuum container) and depressurized to 28 kPa, it foamed and became cloudy.
When the obtained white sheet (average thickness: 205 μm) was observed in the same manner as in Example 1, the cell diameter was 10 μm at the center and 85% or more of the bubbles had a cell diameter in the range of 20 μm or less. . The porosity was 56%. The sheet had a reflectance in the visible light range of 88% and a total light transmittance of 7%. The surface condition was somewhat rough, but the reflectance did not decrease.
The tensile elongation at break at 100 ° C. was 195%, and the tensile stress at 100 ° C. and 100% elongation was 12.5 MPa.

[Example 3]
The transparent sheet obtained by the same method as in Example 2 was put in a desiccator while being heated to 50 ° C., and the pressure was reduced to 28 kPa.
As a result, the obtained foamed sheet had a reduced bubble size, and the bubble diameter was 7 μm at the center and 100% of the bubbles had a bubble diameter in the range of 20 μm or less. The porosity was 32%. This sheet had a reflectance in the visible light range of 89% and a total light transmittance of 10%. There was no problem with the surface condition.

[Example 4]
The transparent sheet obtained by the same method as in Example 2 was placed in a desiccator while being heated to 140 ° C., and the pressure was reduced to 28 kPa.
As a result, the obtained foamed sheet increased in bubble size and variation. The bubble diameter was 18 μm at the center and 80% of the bubbles had a bubble diameter in the range of 20 μm or less. The porosity was 61%. The sheet had a reflectance in the visible light range of 86% and a total light transmittance of 9%. There were traces of broken bubbles on the surface.

[Example 5]
Extrusion was performed in two stages using the same materials, equipment and operating conditions as in Example 1 using the main extruder (A layer), and a single-screw extruder of 45 mm and L / D of 34 was used as the sub-extruder. The same resin as the main extruder (Sumitomo Chemical Co., Ltd. Sumipex MGSS) was extruded without supplying carbon dioxide (layer B), and both were co-extruded in a feed block installed immediately before the die ( B layers) / (A layers) / (B layers) were laminated into a three-layer structure and formed into a sheet in the same manner as in Example 2. Furthermore, it was exposed to reduced pressure in a desiccator and foamed in the same manner as in Example 2.
Unlike the Example 2, the obtained white laminated sheet (average thickness: 245 μm) had a very smooth surface. When observed by the same method as in Example 1, the bubble diameter was 8 μm at the center and 90% of the bubbles had a bubble diameter in the range of 20 μm or less. The porosity was 50%. The sheet had a reflectance in the visible light range of 89% and a total light transmittance of 9%.
The tensile elongation at break at 100 ° C. was 163%, and the tensile stress at 100 ° C. and 100% elongation was 13.3 MPa.

[Comparative Example 1]
A white foamed sheet was obtained in the same manner as in Example 1 except that the amount of carbon dioxide was increased to 0.6 kg / h. However, there were frequent bubbles immediately after the die and explosions occurred. Further, a wave phenomenon was observed on the sheet surface, and the porosity increased to 85%.

[Comparative Example 2]
When a sheet was formed in the same manner as in Example 1 except that the amount of carbon dioxide gas was reduced to 0.1 kg / h, a translucent sheet was obtained. The bubble diameter was distributed in the range of 20 to 100 μm, and large bubbles of 50 μm or more occupied 50% or more.

[Comparative Example 3]
When a sheet was formed in the same manner as in Example 1 except that the amount of carbon dioxide was further reduced to 0.05 kg / h, a substantially transparent sheet was obtained. However, in some places, bubbles with a size of 2 mm or more appeared irregularly.

[Comparative Example 4]
When a sheet was formed in the same manner as in Example 1 except that carbon dioxide was not supplied, a transparent sheet was obtained. The sheet was decompressed with a desiccator in the same manner as in Example 2, but no generation of bubbles was observed.

[Comparative Example 5]
The transparent unfoamed sheet obtained in Example 2 was placed in a desiccator while being heated to 40 ° C. and decompressed, but no generation of bubbles was observed.
[Comparative Example 6]
When the transparent unfoamed sheet obtained in Example 2 was put into a desiccator while being heated to 210 ° C. and depressurized, the surface was foamed like a balloon in some places.
[Comparative Example 7]
The transparent unfoamed sheet obtained in Example 2 was put into a desiccator while being heated to 90 ° C. in the same manner as in Example 2, and the pressure was reduced. The obtained sheet had larger bubbles growing than the sheet obtained in Example 2, and the bubble diameter was 30 μm at the center and 60% of the bubbles had a bubble diameter of 20 μm or less. This sheet had a reflectance in the visible light range of 75% and a total light transmittance of 6%.

The foam sheet of the present invention is applicable to reflectors, packaging materials, steel sheet laminating materials, separator materials, etc. due to its whiteness, weather resistance, heat retention, insulation, fine bubble content, etc. The scope of application is not limited to these. The foam sheet of the present invention can be particularly suitably used as a light reflecting plate for a planar light source used in a backlight mechanism of a liquid crystal display device.

The main and preferred embodiments of the present invention include the following.
[1] An unstretched foamed sheet comprising a thermoplastic resin, wherein 80% or more of the bubbles contained in the sheet have a cell diameter in the range of 0.1 to 20 μm and a porosity of 20 to A foam sheet that is 80%.
[2] The foamed sheet according to the above [1], wherein the tensile breaking elongation measured in an atmosphere at 100 ° C is 100% or more, and the tensile stress at 100 ° C and 100% elongation is 50 MPa or less.
[3] The foamed sheet according to the above [1] or [2], wherein the thermoplastic resin has a molten state fluidity (according to ASTM D1238-98) of 0.5 to 44 g / 10 min.
[4] The foamed sheet according to any one of [1] to [3], wherein the thermoplastic resin is an acrylic resin and / or a methacrylic resin.
[5] The foam sheet according to any one of the above [1] to [4], containing 0 to 3% by weight of a nucleating agent.
[6] The foam sheet according to any one of [1] to [5], wherein an embossed pattern is transferred on at least one side.
[7] A laminated sheet having two or more layers, wherein the foamed sheet according to any one of [1] to [6] is disposed at least one layer.
[8] The laminated sheet according to the above [7], wherein at least one non-foamed layer is disposed.
[9] The sheet according to any one of [1] to [8], wherein the reflectance in the visible light range is 85% or more and the total light transmittance is 10% or less.
[10] A light reflecting plate using the sheet according to any one of [1] to [9].
[11] A light reflector in which the sheet according to [10] is molded.
[12] A display device using the light reflecting plate according to [10] or [11].
[13] The method for producing a sheet according to any one of [1] to [9], including a step of foaming by extruding a thermoplastic resin in which a gas is dissolved.
[14] A step of forming a molten polymer of a thermoplastic resin in which a gas is dissolved in a non-foamed state,
Generating bubbles by exposing the sheet to a vacuum at a temperature of 50 to 200 ° C.,
A method for producing a foam sheet.
[15] A step of forming a molten polymer of a thermoplastic resin in which a gas is dissolved in a non-foamed state,
Generating bubbles by exposing the sheet to a vacuum at a temperature of 50 to 200 ° C.,
The manufacturing method of the sheet | seat in any one of said [1]-[9] containing.
[16] Any one of [1] to [9] and [13] to [15], wherein a thermoplastic resin in which a gas is dissolved and a thermoplastic resin in which a gas is not dissolved are coextruded. The manufacturing method of the sheet | seat of description.
[17] An extruder equipped with a screw, a cylinder, and a temperature control mechanism for the cylinder, wherein a gas supplied from a high-pressure gas supply unit provided outside the cylinder is introduced into an inner surface of a part of the cylinder. An extrusion apparatus for producing a foam sheet, comprising a nozzle for producing the foam sheet.
[18] An extruder equipped with a screw, a cylinder, and a temperature control mechanism for the cylinder, wherein a gas supplied from a high-pressure gas supply unit provided outside the cylinder is introduced into an inner surface of a part of the cylinder. The apparatus for producing a sheet according to any one of [1] to [9], further comprising a nozzle for the purpose.
[19] The extrusion apparatus according to [17] or [18], wherein the nozzle is made of a ring-shaped metal or ceramic having fine holes.
[20] The extrusion apparatus according to [19], wherein the ring-shaped metal is made of a material obtained by sintering metal powder or metal fiber.
[21] Foam formed by disposing a vacuum chamber device having a chamber capable of decompressing the inside and a sealing mechanism, and a vacuum generator attached to the vacuum chamber device, after the casting roll and / or the casting roll of the sheet forming machine Sheet manufacturing equipment.
[22] The above-mentioned structure in which a vacuum chamber apparatus provided with a chamber capable of decompressing the inside and a sealing mechanism, and a vacuum generation apparatus associated with the vacuum chamber apparatus are arranged after the casting roll and / or the casting roll of the sheet forming machine. [1] to [9] The sheet manufacturing apparatus according to any one of [9] to [9].
[23] The manufacturing apparatus according to [21] or [22], wherein the vacuum chamber device is capable of depressurizing the interior of the depressurizable chamber to 30 KPa or less.

FIG. 1 is a schematic explanatory view showing a sheet manufacturing apparatus according to an embodiment of the present invention. FIG. 2 is a schematic explanatory view showing a longitudinal section of an extrusion apparatus nozzle portion in an embodiment of the present invention. FIG. 3 is a schematic explanatory view showing a cross section obtained by cutting the extrusion device nozzle portion shown in FIG. 2 at position A.

Explanation of symbols

1 Extruder 1
1a Extruder 2
2 Feed block 3 Dies 4 Cast roll 5 Take-up roll 1
5a Take-up roll 2
6 Vacuum chamber 7 Vacuum pump 8 Sheet 11 Cylinder block 11a Cylinder block 12 of nozzle part Screw 13 Heater 14 Nozzle block 14a Nozzle media 14b Vent hole 15 Gas inlet

Claims (12)

  An unstretched foamed sheet comprising an acrylic resin and / or a methacrylic resin, wherein 80% or more of the bubbles contained in the sheet have a cell diameter in the range of 0.1 to 20 μm, and a porosity of 20 A light reflector using a foam sheet of -80%.   2. The light reflecting plate according to claim 1, wherein the foamed sheet has a tensile elongation at break of 100% or more measured in an atmosphere of 100 ° C. and a tensile stress at 100 ° C. and 100% elongation of 50 MPa or less. In an unstretched foam sheet comprising an acrylic resin and / or a methacrylic resin , the acrylic resin and / or the methacrylic resin has a melted fluidity (according to ASTM D1238-98) of 0.5 to 44 g / 10 min. The light reflecting plate according to claim 1 or 2.   The light reflecting plate according to claim 1, wherein the foamed sheet contains 0 to 3% by weight of a nucleating agent.   The light reflecting plate according to claim 1, wherein an embossed pattern is transferred to at least one surface of the foam sheet.   The light-reflecting plate according to any one of claims 1 to 5, wherein the foamed sheet is a laminated sheet of two or more layers in which at least one layer of the foamed sheet according to any one of claims 1 to 5 is disposed.   The light reflecting plate according to claim 6, wherein the foamed sheet that is a laminated sheet has at least one non-foamed layer disposed.   The light reflecting plate according to claim 1, wherein the foamed sheet has a reflectance in the visible light range of 85% or more and a total light transmittance of 10% or less. The light reflecting plate according to claim 1, wherein the light reflecting plate is a molded body that has been molded .   A display device using the light reflecting plate according to claim 1. The foam sheet,
A process of extruding and sheeting a molten polymer of acrylic resin and / or methacrylic resin in which gas is dissolved, in a non-foamed state;
Generating bubbles by exposing the sheet to a vacuum at a temperature of 50 to 200 ° C.,
The manufacturing method of the light reflecting plate in any one of Claims 1-3 manufactured by the process including this.   The method for producing a light reflecting plate according to claim 11, wherein an acrylic resin and / or methacrylic resin in which gas is dissolved and a thermoplastic resin in which gas is not dissolved are coextruded.

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