JP5333441B2 - 光学フィルムの製造方法および製造装置 - Google Patents
光学フィルムの製造方法および製造装置 Download PDFInfo
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- JP5333441B2 JP5333441B2 JP2010505571A JP2010505571A JP5333441B2 JP 5333441 B2 JP5333441 B2 JP 5333441B2 JP 2010505571 A JP2010505571 A JP 2010505571A JP 2010505571 A JP2010505571 A JP 2010505571A JP 5333441 B2 JP5333441 B2 JP 5333441B2
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- optical film
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- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 150000002978 peroxides Chemical class 0.000 description 1
- XNGIFLGASWRNHJ-UHFFFAOYSA-L phthalate(2-) Chemical compound [O-]C(=O)C1=CC=CC=C1C([O-])=O XNGIFLGASWRNHJ-UHFFFAOYSA-L 0.000 description 1
- 150000003021 phthalic acid derivatives Chemical class 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920006254 polymer film Polymers 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000011085 pressure filtration Methods 0.000 description 1
- BPJZKLBPJBMLQG-KWRJMZDGSA-N propanoyl (z,12r)-12-hydroxyoctadec-9-enoate Chemical compound CCCCCC[C@@H](O)C\C=C/CCCCCCCC(=O)OC(=O)CC BPJZKLBPJBMLQG-KWRJMZDGSA-N 0.000 description 1
- 238000005057 refrigeration Methods 0.000 description 1
- 230000002040 relaxant effect Effects 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000012748 slip agent Substances 0.000 description 1
- 238000003892 spreading Methods 0.000 description 1
- 230000007480 spreading Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 125000001424 substituent group Chemical group 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- BFKJFAAPBSQJPD-UHFFFAOYSA-N tetrafluoroethene Chemical group FC(F)=C(F)F BFKJFAAPBSQJPD-UHFFFAOYSA-N 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- 229910003470 tongbaite Inorganic materials 0.000 description 1
- 230000001131 transforming effect Effects 0.000 description 1
- 238000002834 transmittance Methods 0.000 description 1
- 229960002622 triacetin Drugs 0.000 description 1
- QORWJWZARLRLPR-UHFFFAOYSA-H tricalcium bis(phosphate) Chemical compound [Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O QORWJWZARLRLPR-UHFFFAOYSA-H 0.000 description 1
- WEAPVABOECTMGR-UHFFFAOYSA-N triethyl 2-acetyloxypropane-1,2,3-tricarboxylate Chemical compound CCOC(=O)CC(C(=O)OCC)(OC(C)=O)CC(=O)OCC WEAPVABOECTMGR-UHFFFAOYSA-N 0.000 description 1
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 description 1
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 1
- 239000003039 volatile agent Substances 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/0074—Production of other optical elements not provided for in B29D11/00009- B29D11/0073
-
- 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
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/07—Flat, e.g. panels
- B29C48/08—Flat, e.g. panels flexible, e.g. films
-
- 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
- B29C48/30—Extrusion nozzles or dies
- B29C48/305—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets
-
- 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
- B29C48/911—Cooling
- B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
- B29C48/914—Cooling of flat articles, e.g. using specially adapted supporting means cooling drums
-
- 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
- B29C48/911—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
- B29C48/9155—Pressure rollers
-
- 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
- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/0018—Combinations of extrusion moulding with other shaping operations combined with shaping by orienting, stretching or shrinking, e.g. film blowing
-
- 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
- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
-
- 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
- B29C48/91—Heating, e.g. for cross linking
-
- 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
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0037—Other properties
- B29K2995/0072—Roughness, e.g. anti-slip
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Health & Medical Sciences (AREA)
- Ophthalmology & Optometry (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
Description
前記一対の回転ロールにおけるニップの入口近傍であって、前記一対の回転ロールのうち少なくとも一方の回転ロールの表面近傍に、遮蔽板を設け、かつ該遮蔽板を加熱して、前記回転ロールの回転に伴って発生する同伴エアを加熱することを特徴とする光学フィルムの製造方法。
前記溶融物が前記一対の回転ロールに挟み込まれるニップの入口近傍であって、前記一対の回転ロールのうち少なくとも一方の回転ロールの表面近傍に、加熱される遮蔽板を備えたことを特徴とする光学フィルムの製造装置。
2:フィルター
3:スタチックミキサー
4:流延ダイ
5:第1回転ロール(第1冷却ロール)
6:第2回転ロール(タッチロール)
7:第2冷却ロール
8:第3冷却ロール
9:11:13:14:15:搬送ロール
10:未延伸フィルム
12:延伸機
16:巻取り装置
21a:21b:保護フィルム
22a:22b:位相差フィルム
23a:23b:フィルムの遅相軸方向
24a:24b:偏光子の透過軸方向
25a:25b:偏光子
26a:26b:偏光板
27:液晶セル
29:液晶表示装置
41a:41b:リップ部
42:溶融物
45a:45b:遮蔽板
46a:46b:同伴エアの方向
47:ニップ
70:局所排気装置
71:吸引ノズル
72:排気ファン
73:冷却器
74:フィルタ
75:差圧計
76:配管
77:ヒーター
本発明に係る光学フィルムの製造方法および製造装置は、いわゆる溶融流延法に基づくものであり、すなわち、溶融した熱可塑性樹脂を含むフィルム構成材料を流延ダイのリップ部よりフィルム状に押出し、当該溶融物を一対の回転ロールで挟むことにより冷却固化させて光学フィルムを製造する。
(溶融押出工程)
本工程では、熱可塑性樹脂を含むフィルム構成材料を混合し、押出し機1を用いて、溶融した後、所望によりフィルタ2およびスタチックミキサー3を経由させて、流延ダイ4から溶融物42をフィルム状に、第1回転ロール5上に押し出す。その際、本発明においては、溶融押出されたフィルム状溶融物42を、所定の環境下で、第1回転ロール5に外接させるとともに、第2回転ロール6により第1回転ロール5表面に所定の圧力で押圧する。第1回転ロール5は、前記一対の回転ロールの一方を構成するものであり、第1冷却ロールまたは冷却ドラムとも呼ばれるものである。第2回転ロール6は、前記一対の回転ロールの他方を構成するものであり、タッチロールとも呼ばれるものである。
式(II) 0≦X≦2.5
特にセルロースアセテートプロピオネートが好ましく用いられ、中でも1.9≦X≦2.5であり、0.1≦Y≦0.9であることが好ましい。上記アシル基で置換されていない部分は通常水酸基として存在している。
(延伸・巻き取り工程)
本工程では、第3冷却ロール8から剥離ロール9によって剥離された未延伸のフィルム10を、ダンサーロール(フィルム張力調整ロール)11を経て延伸機12に導き、そこでフィルム10を延伸した後、巻取り装置16により巻き取る。延伸により、フィルム中の分子が配向される。
[光学フィルム]
本発明で得られる光学フィルムは厚みムラや光学歪みが十分に防止されている。
本発明で得られる光学フィルムの厚さは、用途に応じて適宜選択されてよい。例えば、本発明の光学フィルムを位相差フィルムや偏光板保護フィルムとして使用する場合、厚さは、10〜500μmが好ましい。特に、下限は20μm以上、好ましくは35μm以上である。上限は150μm以下、好ましくは120μm以下である。特に好ましい範囲は25〜90μmである。
(実施例1)
(ペレットの作成)
セルロースアセテートプロピオネート 100質量部
(アセチル基の置換度1.95、プロピオニル基の置換度0.7、数平均分子量75000、温度130℃で5時間乾燥、ガラス転移温点Tg=174℃)
トリメチロールプロパントリス(3,4,5−トリメトキシベンゾエート)
10質量部
IRGANOX−1010(チバ・スペシャルティ・ケミカルズ社製) 1質量部
SumilizerGP(住友化学社製) 1質量部
上記材料に、マット剤としてシリカ粒子(アエロジルR972V(日本アエロジル社製))0.05質量部、紫外線吸収剤として、TINUVIN360(チバ・スペシャルティ・ケミカルズ社製)0.5質量部を加え、窒素ガスを封入したV型混合機で30分混合した後、ストランドダイを取り付けた2軸押し出し機(PCM30(株)池貝社製)を用いて240℃で溶融させ、長さ4mm、直径3mmの円筒形のペレットを作製した。この時のせん断速度は、25(/s)に設定した。
(フィルムの製造)
フィルムを図1〜図3に示す製造装置で製造した。
遮蔽板45b;ロール6と同心円の円弧形状ステンレス製、厚み10mm、x2=0.3mm、y2=70mm、z2=10mm、加熱温度=120℃
局所排気装置として、図2に示す装置70を用いた。α=5mm
第1冷却ロール及び第2冷却ロールは直径40cmのステンレス製とし、表面にハードクロムメッキを施した。又、内部には温度調整用のオイル(冷却用流体)を循環させて、ロール表面温度を制御した。弾性タッチロールは、直径30cmとし、内筒と外筒はステンレス製とし、外筒の表面にはハードクロムメッキを施した。外筒の肉厚は2mmとし、内筒と外筒との間の空間に温度調整用のオイル(冷却用流体)を循環させて弾性タッチロールの表面温度を制御した。
(実施例2〜15)
遮蔽板45a、45bの条件を表1に示すように変更したこと以外、実施例1と同様の方法により、フィルムを製造した。
(比較例1)
遮蔽板45a、45bを加熱しなかったこと以外、実施例1と同様の方法により、フィルムを製造した。
(比較例2)
遮蔽板45a、45bを設けなかったこと以外、実施例1と同様の方法により、フィルムを製造した。
(評価)
クロスニコルによる評価:2枚の偏光板を直交状態にし、その間にフィルムを設置して目視によりムラを観察した。
△;わずかにムラが見えるが実用上問題なし;
×;ムラが明確に見え、実用上問題。
Claims (8)
- 溶融した熱可塑性樹脂を含むフィルム構成材料を流延ダイのリップ部よりフィルム状に押出し、該溶融物を一対の回転ロールで挟むことにより冷却固化させて光学フィルムを製造する方法であって、
前記一対の回転ロールにおけるニップの入口近傍であって、前記一対の回転ロールのうち少なくとも一方の回転ロールの表面近傍に、遮蔽板を設け、かつ該遮蔽板を加熱して、前記回転ロールの回転に伴って発生する同伴エアを加熱することを特徴とする光学フィルムの製造方法。 - 前記遮蔽板が、回転ロール軸方向に対する垂直断面において、該遮蔽板が表面近傍に設けられた回転ロールと同心円の円弧形状を有することを特徴とする請求の範囲第1項に記載の光学フィルムの製造方法。
- 前記遮蔽板と該遮蔽板が表面近傍に設けられた回転ロールとの間隙を0.5〜10mmに保つことを特徴とする請求の範囲第1項または第2項に記載の光学フィルムの製造方法。
- 前記遮蔽板の寸法が、該遮蔽板が表面近傍に設けられた回転ロールの回転方向の長さで10〜300mmであることを特徴とする請求の範囲第1項から第3項のいずれか1項に記載の光学フィルムの製造方法。
- 前記遮蔽板が80〜260℃に加熱されることを特徴とする請求の範囲第1項から第4項のいずれか1項に記載の光学フィルムの製造方法。
- 前記リップ部より押し出された溶融物から発生する昇華物質を含むガスを、前記リップ部の両側または片側に前記リップ部の全長に亘り設けられた吸引ノズルにより吸引することを特徴とする請求の範囲第1項から第5項のいずれか1項に記載の光学フィルムの製造方法。
- 前記遮蔽板と前記流延ダイとの間に前記吸引ノズルを設けることを特徴とする請求の範囲第6項に記載の光学フィルムの製造方法。
- 溶融した熱可塑性樹脂を含むフィルム構成材料を流延ダイのリップ部よりフィルム状に押出し、該溶融物を一対の回転ロールで挟むことにより冷却固化させて光学フィルムを製造する装置であって、
前記溶融物が前記一対の回転ロールに挟み込まれるニップの入口近傍であって、前記一対の回転ロールのうち少なくとも一方の回転ロールの表面近傍に、加熱される遮蔽板を備えたことを特徴とする光学フィルムの製造装置。
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BR112018000507B1 (pt) | 2015-07-10 | 2023-01-24 | Berry Global, Inc | Processo para a fabricação de um filme respirável microporoso |
US11472085B2 (en) | 2016-02-17 | 2022-10-18 | Berry Plastics Corporation | Gas-permeable barrier film and method of making the gas-permeable barrier film |
KR101934486B1 (ko) * | 2016-09-20 | 2019-01-02 | 주식회사 엘지화학 | 슬립성이 우수한 광학 필름, 및 이를 포함하는 편광판 |
WO2020012721A1 (ja) * | 2018-07-09 | 2020-01-16 | ユニプレス株式会社 | プレス成形物の連続成形方法及びプレス成形物の連続成形装置 |
CN111099416B (zh) * | 2019-12-03 | 2020-08-28 | 南京贝迪电子有限公司 | 一种导光膜生产装置 |
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- 2009-03-18 WO PCT/JP2009/055288 patent/WO2009119408A1/ja active Application Filing
- 2009-03-18 JP JP2010505571A patent/JP5333441B2/ja not_active Expired - Fee Related
- 2009-03-18 US US12/933,842 patent/US20110018149A1/en not_active Abandoned
- 2009-03-18 KR KR1020107021087A patent/KR101554376B1/ko active IP Right Grant
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JPS54100470A (en) * | 1978-01-25 | 1979-08-08 | Toray Ind Inc | Device for cooling molten polymer film |
JP2007125833A (ja) * | 2005-11-07 | 2007-05-24 | Kaneka Corp | フィルム成形方法、及びフィルム成形装置 |
JP2007160628A (ja) * | 2005-12-12 | 2007-06-28 | Fujifilm Corp | 熱可塑性樹脂フィルムの製造方法及び装置並びに熱可塑性樹脂フィルム |
JP2007307896A (ja) * | 2006-04-19 | 2007-11-29 | Fujifilm Corp | セルロース系樹脂フィルム及びその製造方法 |
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CN101977753A (zh) | 2011-02-16 |
KR20100132505A (ko) | 2010-12-17 |
WO2009119408A1 (ja) | 2009-10-01 |
US20110018149A1 (en) | 2011-01-27 |
JPWO2009119408A1 (ja) | 2011-07-21 |
KR101554376B1 (ko) | 2015-09-18 |
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