JP4843358B2 - 制御された反りを有する熱可塑性樹脂シートの製造方法 - Google Patents
制御された反りを有する熱可塑性樹脂シートの製造方法 Download PDFInfo
- Publication number
- JP4843358B2 JP4843358B2 JP2006115603A JP2006115603A JP4843358B2 JP 4843358 B2 JP4843358 B2 JP 4843358B2 JP 2006115603 A JP2006115603 A JP 2006115603A JP 2006115603 A JP2006115603 A JP 2006115603A JP 4843358 B2 JP4843358 B2 JP 4843358B2
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- Prior art keywords
- sheet
- warpage
- thermoplastic resin
- temperature
- roll
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
- B29C48/911—Cooling
- B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
- B29C48/915—Cooling of flat articles, e.g. using specially adapted supporting means with means for improving the adhesion to the supporting means
- B29C48/917—Cooling of flat articles, e.g. using specially adapted supporting means with means for improving the adhesion to the supporting means by applying pressurised gas to the surface of the flat article
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
- B29C48/918—Thermal treatment of the stream of extruded material, e.g. cooling characterized by differential heating or cooling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/25—Solid
- B29K2105/253—Preform
- B29K2105/256—Sheets, plates, blanks or films
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0037—Other properties
- B29K2995/0094—Geometrical properties
- B29K2995/0096—Dimensional stability
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2007/00—Flat articles, e.g. films or sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2011/00—Optical elements, e.g. lenses, prisms
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
- B29L2031/3475—Displays, monitors, TV-sets, computer screens
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Description
本発明の製造方法は、熱可塑性樹脂シートを押出成形するにあたり、押し出されたシートの温度が該シートを構成する熱可塑性樹脂のガラス転移温度(Tg)付近となる位置で、該シートに機械的に制御された反りを与えることを特徴とする。ここで、「反り」とは、熱可塑性樹脂シートが平坦な場合からのずれを意味し、具体的には、熱可塑性樹脂シートを吊り下げた状態で、押出成形の流れ方向(以下「縦方向」ということがある。)および押出成形の幅方向(以下「横方向」ということがある。)の相対する各辺の中央に糸を張った場合に、シートの中央部から糸までの距離を意味する。なお、シートが表面側に反った場合(すなわち、反りが上向きに凸状の場合)を+、シートが裏面側に反った場合(すなわち、反りが下向きに凸状の場合)を−で表記する。
ηsp/c=[η]+0.45×[η]2c
[η]=1.23×10−4M0.83
(ただし、c=0.7、[η]は極限粘度、Mは粘度平均分子量)
本発明の熱可塑性樹脂シートは、上記のような方法により製造される熱可塑性樹脂シートであり、例えば、液晶表示装置や医療用モニターなどのバックライトユニットに用いる光拡散板や建築物の建材として利用することができるが、液晶表示装置の表示性能を長期間にわたり安定化させることができるので、特に、15インチを超える液晶テレビやデスクトップ型パーソナルコンピュータの液晶ディスプレイに用いられる大型の液晶表示装置に、バックライトユニットの光拡散板として好適に用いられる。
熱可塑性樹脂のガラス転移温度(Tg)は、示差走査熱量計(商品名:Thermo Plus DSC8230、(株)リガク製)を用いて、JIS K 7121に準拠して測定した。具体的には、試料を示差走査熱量計にセットし、180℃で10分間保持した後、80℃に急冷し、安定したところで、20℃/分の速さで、180℃まで昇温し、得られたDSC曲線からガラス転移温度(Tg)を求めた。
押し出されたシートの温度は、放射温度計(商品名:IR−TAF、(株)チノー製)を用いて測定した。なお、反り制御ロールの位置におけるシートの表面温度および裏面温度は、実質的に同一であるので、シートの表面温度をシートの温度とした。
反りの大きさは、縦1,000mm×横1,000mmの熱可塑性樹脂シートを、横方向の一辺を端部付近で3等分する位置に孔をあけ、これに紐を通してシートを吊り下げ、この状態でシートの縦方向および横方向の相対する各辺の中央に糸を張り、シートの中央部から糸までの距離を鋼尺で測定した。なお、反りが上向きに凸状の場合を+、反りが下向きに凸状の場合を−で表記する。
幅1,200mmのTダイス、直径300mmの第1、第2および第3冷却ロール、直径200mmの反り制御ロール、ガイドロール、ならびに引取ロールを備えたシート押出機(その構成は図1に示すシート押出機と同様である。)を用いて、以下のようにして、ポリカーボネート系樹脂シートを製造した。
例えば、図2に示すように、剥離ライン18からガイドロール15までをシートが上向きに凸状になるように上下1組の反り制御ロール17(上下ロール温度:95℃)を配置したこと、さらに詳しくは、反り制御ロールの高さを、平坦なシートが得られる高さを基準にして、上側に2cm移動させたこと以外は、参考例と同様にして、ポリカーボネート系樹脂シートを得た。得られたシートの反りを測定した結果を表1に示す。
例えば、図2に示すように、剥離ライン18からガイドロール15までをシートが上向きに凸状になるように反り制御ロール17(上下ロール温度:95℃)を配置したことと、上側の反り制御ロールとして、逆クラウニング形状のロールを用い、下側の反り制御ロールとして、クラウニング形状のロールを用いたこと、さらに詳しくは、各々クラウニング量2cmの上下1組の反り制御ロールの高さを、平坦なシートが得られる高さを基準にして、上側に2cm移動させたこと以外は、参考例と同様にして、ポリカーボネート系樹脂シートを得た。なお、反り制御ロールの位置におけるシートの温度は、(Tg−10℃)であった。得られたシートの反りを測定した結果を表1に示す。
例えば、図3に示すように、剥離ライン18からガイドロール15までをシートが下向きに凸状になるように上下1組の反り制御ロール17(上下ロール温度:95℃)を配置したこと、さらに詳しくは、反り制御ロールの高さを、平坦なシートが得られる高さを基準にして、下側に4cm移動させたこと以外は、参考例と同様にして、ポリカーボネート系樹脂シートを得た。なお、反り制御ロールの位置におけるシートの温度は、(Tg−5℃)であった。得られたシートの反りを測定した結果を表1に示す。
例えば、図3に示すように、剥離ライン18からガイドロール15までをシートが下向きに凸状になるように上下1組の反り制御ロール17を配置したことと、上下の反り制御ロールの温度差を調節したこと、さらに詳しくは、反り制御ロール(上ロール温度:100℃、下ロール温度:80℃)の高さを、平坦なシートが得られる高さを基準にして、下側に4cm移動させたこと以外は、参考例と同様にして、ポリカーボネート系樹脂シートを得た。なお、反り制御ロールの位置におけるシートの温度は、(Tg+10℃)であった。得られたシートの反りを測定した結果を表1に示す。
熱可塑性樹脂としてポリスチレン系樹脂(商品名:HH203、PSジャパン(株)製);ガラス転移温度(Tg):108℃)を使用し、成形温度を約220℃、反り制御ロール17の温度を上下60℃にしたこと以外は、実施例1と同様にして、ポリスチレン系樹脂シートを得た。得られたシートの反りを測定した結果を表1に示す。
熱可塑性樹脂としてメタクリル系樹脂(商品名:スミペックスEX、住友化学(株)製;ガラス転移温度(Tg):97℃)を使用し、成形温度を約250℃、反り制御ロール17の温度を上下80℃にしたこと以外は、実施例1と同様にして、メタクリル系樹脂シートを得た。得られたシートの反りを測定した結果を表1に示す。
熱可塑性樹脂としてポリカーボネート系樹脂(商品名:ユーピロンE2000FN、三菱エンジニアリングプラスチック(株)製;ガラス転移温度(Tg):154℃)を使用し、このポリカーボネート系樹脂100質量%に、微粒子としてシリカ球状微粒子(商品名:シーホスターKE−P150、(株)日本触媒製;平均粒子径:1.33〜1.83μm)を0.5質量%混合したこと以外は、実施例1と同様にして、ポリカーボネート系樹脂シートを得た。得られたシートの反りを測定した結果を表1に示す。
反り制御ロールの位置におけるシートの温度を(Tg+30℃)に設定したこと以外は、それぞれ実施例1〜3と同様にして、ポリカーボネート系樹脂シートを得た。得られたシートの反りを測定した結果を表1に示す。
反り制御ロールの位置におけるシートの温度を(Tg−30℃)に設定したこと以外は、それぞれ実施例1〜3と同様にして、ポリカーボネート系樹脂シートを得た。得られたシートの反りを測定した結果を表1に示す。
11 ダイス
12 第1冷却ロール
13 第2冷却ロール
14 第3冷却ロール
15 ガイドロール
16 引取ロール
17 反り制御ロール
18 剥離ライン
20 熱可塑性樹脂シート
Claims (7)
- 熱可塑性樹脂シートを押出成形するにあたり、押し出されたシートの温度が該シートを構成する熱可塑性樹脂のガラス転移温度(Tg)±20℃の範囲内となる位置で、前記シートが上下1組の反り制御ロール間を通過するようにし、該反り制御ロールを平坦なシートが得られる高さから上側に2cm以下、下側に4cm以下の範囲内で移動させて配置することにより、該シートに機械的に制御された反りを与えることを特徴とする制御された反りを有する熱可塑性樹脂シートの製造方法。
- 前記反り制御ロールの形状を選択することにより、前記シートに機械的に制御された反りを与える請求項1記載の製造方法。
- 前記反り制御ロールの温度を上下で調節して前記シート上下面の冷却速度に差を生じさせることにより、前記シートにさらに熱的に制御された反りを与える請求項1または2記載の製造方法。
- 前記反り制御ロールの位置またはその下流側で、前記シート上下面の温度差を調節して前記シート上下面の冷却速度に差を生じさせることにより、前記シートにさらに熱的に制御された反りを与える請求項1〜3のいずれか1項記載の製造方法。
- 前記シートを構成する熱可塑性樹脂が微粒子を含有する請求項1〜4のいずれか1項記載の製造方法。
- 前記微粒子が(メタ)アクリル系樹脂、スチレン系樹脂、ポリウレタン系樹脂、ポリエステル系樹脂、シリコーン系樹脂、フッ素系樹脂、ガラス、スメクタイト、カオリナイト、シリカおよびアルミナよりなる群から選択される1種以上から形成される請求項5記載の製造方法。
- 前記シートを構成する熱可塑性樹脂がポリカーボネート系樹脂、(メタ)アクリル系樹脂、スチレン系樹脂、アクリル−スチレン系樹脂およびノルボルネン系樹脂よりなる群から選択される請求項1〜6のいずれか1項記載の製造方法。
Priority Applications (5)
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JP2006115603A JP4843358B2 (ja) | 2006-04-19 | 2006-04-19 | 制御された反りを有する熱可塑性樹脂シートの製造方法 |
PCT/JP2007/058286 WO2007119851A1 (ja) | 2006-04-19 | 2007-04-16 | 制御された反りを有する熱可塑性樹脂シートの製造方法 |
TW096113297A TW200744820A (en) | 2006-04-19 | 2007-04-16 | Process for producing thermoplastic resin sheet with controlled warpage |
KR1020087024466A KR101016997B1 (ko) | 2006-04-19 | 2007-04-16 | 제어된 휨을 가지는 열가소성 수지시트의 제조방법 |
US11/785,534 US20070267773A1 (en) | 2006-04-19 | 2007-04-18 | Process for producing thermoplastic resin sheet with controlled warpage |
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JP2006115603A JP4843358B2 (ja) | 2006-04-19 | 2006-04-19 | 制御された反りを有する熱可塑性樹脂シートの製造方法 |
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JP (1) | JP4843358B2 (ja) |
KR (1) | KR101016997B1 (ja) |
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JP5289891B2 (ja) * | 2008-10-28 | 2013-09-11 | 出光興産株式会社 | 熱可塑性樹脂シートの製造装置およびその製造方法 |
JP5378867B2 (ja) * | 2009-04-21 | 2013-12-25 | 出光興産株式会社 | 熱可塑性樹脂製エンボスシートの製造方法および製造装置 |
JP2011191611A (ja) * | 2010-03-16 | 2011-09-29 | Sumitomo Chemical Co Ltd | 光学シートの製造方法 |
JP5525390B2 (ja) * | 2010-09-03 | 2014-06-18 | 住友化学株式会社 | 熱可塑性樹脂押出板 |
KR102015336B1 (ko) | 2017-06-12 | 2019-08-28 | 삼성전자주식회사 | 반도체 패키지 기판의 휨 감소 방법 및 휨 감소 장치 |
US11173644B2 (en) | 2017-09-26 | 2021-11-16 | Davis-Standard, Llc | Casting apparatus for manufacturing polymer film |
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US3499072A (en) * | 1967-05-03 | 1970-03-03 | Lundvall & Associates | Method for forming cylindrical sleeves from thermoplastic resin sheets |
US4792427A (en) * | 1983-05-13 | 1988-12-20 | Nanik Division Wausau Metals Corporation | Method for making light-transmitting slats for blind |
JPS60143926A (ja) * | 1983-12-30 | 1985-07-30 | Nippon Petrochem Co Ltd | 凹凸シートの成形装置 |
US4789515A (en) * | 1988-01-11 | 1988-12-06 | Chi Yu Simon S | Method for fabricating stiff polymeric plastic slats for venetian blinds |
US4943224A (en) * | 1989-02-10 | 1990-07-24 | General Electric Company | Apparatus employing integral dielectric heater for roll forming thermoplastic material |
JP3084462B2 (ja) * | 1992-01-24 | 2000-09-04 | 大日本印刷株式会社 | 透過型スクリーン |
JPH079538A (ja) * | 1993-06-22 | 1995-01-13 | Sekisui Chem Co Ltd | 合成樹脂シ−トの押出成形方法 |
DE69630219T2 (de) * | 1995-06-09 | 2004-07-22 | Mitsubishi Rayon Co., Ltd. | Geformte kunststoffgegenstände mit kratzfester organischer harter beschichtungsschicht und beschlagtreier organischer harter beschichtungsschicht, verfahren zu deren herstellung, und beschichtungsmaterialen dafür |
JP3736695B2 (ja) * | 1996-05-20 | 2006-01-18 | 富士写真フイルム株式会社 | ポリエステル支持体の製造方法およびポリエステル支持体、それを用いた写真感光フイルム |
JP3665199B2 (ja) * | 1998-02-02 | 2005-06-29 | 株式会社クラレ | 透過型スクリーンの製造方法 |
JP3765681B2 (ja) * | 1998-12-18 | 2006-04-12 | 富士写真フイルム株式会社 | ポリエステルフィルムの製造方法 |
US7195727B2 (en) * | 1999-10-13 | 2007-03-27 | Guardian Industries Corp. | Extruded automotive trim and method of making same |
JP2002120249A (ja) * | 2000-10-16 | 2002-04-23 | Sumitomo Chem Co Ltd | 熱可塑性樹脂シートの製造方法 |
US6569957B2 (en) * | 2000-11-03 | 2003-05-27 | Eastman Chemical Company | Blends of polycarbonate and polyester and sheets and films formed therefrom |
JP2002250807A (ja) * | 2000-12-22 | 2002-09-06 | Dainippon Printing Co Ltd | レンズシート、それを用いたプロジェクションスクリーン、及びレンズシートの成形方法 |
JP3863393B2 (ja) * | 2001-06-26 | 2006-12-27 | 住友化学株式会社 | 光学スクリーン用シート状部材の製造方法 |
JP2005088310A (ja) * | 2003-09-16 | 2005-04-07 | Sumitomo Chemical Co Ltd | 熱可塑性樹脂板の製造方法 |
KR101159724B1 (ko) * | 2004-09-30 | 2012-06-28 | 소니 가부시키가이샤 | 광학 시트, 백라이트 및 액정 표시 장치 |
JP2006218648A (ja) * | 2005-02-08 | 2006-08-24 | Kuraray Co Ltd | 透過型スクリーンの製造方法及び製造装置 |
-
2006
- 2006-04-19 JP JP2006115603A patent/JP4843358B2/ja not_active Expired - Fee Related
-
2007
- 2007-04-16 TW TW096113297A patent/TW200744820A/zh unknown
- 2007-04-16 WO PCT/JP2007/058286 patent/WO2007119851A1/ja active Application Filing
- 2007-04-16 KR KR1020087024466A patent/KR101016997B1/ko not_active IP Right Cessation
- 2007-04-18 US US11/785,534 patent/US20070267773A1/en not_active Abandoned
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KR101016997B1 (ko) | 2011-02-23 |
KR20080099345A (ko) | 2008-11-12 |
WO2007119851A1 (ja) | 2007-10-25 |
JP2007283700A (ja) | 2007-11-01 |
TW200744820A (en) | 2007-12-16 |
US20070267773A1 (en) | 2007-11-22 |
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