JP5784302B2 - Manufacturing method of resin plate or film with protective film - Google Patents

Description

  The present invention relates to a method for producing a resin plate or film with a protective film.

  Extruded resin plates or films made of thermoplastic resins are used in a wide range of applications such as interiors and exteriors of automobiles, exteriors of household electrical products, and optical applications such as liquid crystal televisions and monitors. Generally, an extruded resin plate or film is formed by sandwiching a plate-like or film-like molten thermoplastic resin extruded from a die between a first roll and a second roll, winding the second roll, and forming a take-off roll. It is manufactured by taking up while cooling the top of the transport roll and winding it into a roll.

  Patent Document 1 describes a manufacturing method in which a resin sheet is not easily broken in a manufacturing process of a resin sheet such as an acrylic resin. In this method, a sheet-like molten thermoplastic resin extruded from a die is sandwiched between a first roll and a second roll, and wound around the second roll to form an extruded resin sheet. Are formed on the outer peripheral surfaces of both end portions of the both sides of the roll sheet, and when the resin sheet is sandwiched between the first roll and the second roll, Is also sandwiched between the step and the first roll.

  The extruded resin plate or film thus produced (hereinafter sometimes simply referred to as “resin plate”) may further have a protective film bonded to the surface depending on the application.

  When bonding a protective film on both surfaces or one side of a resin board, a pair of protective film bonding roll is usually used, and the protective film is bonded to the resin board between these rolls. However, since the edge of the resin plate or the protective film is unstable, if it is passed between the protective film bonding rolls, the edge of the protective film may be lifted or the protective film may be wrinkled and the resin plate It may break. In particular, when the thickness of the resin plate is thin and easily cracked, if wrinkles enter the protective film, the thickness distribution occurs in the width direction when it is sandwiched between take-up rolls for conveyance, and it is pressed with uneven force. Therefore, the resin plate is easily cracked.

JP 2009-149038 A

  The subject of this invention is providing the manufacturing method of the resin board with a protective film which does not produce the bonding defect of a protective film, or the fracture | rupture of a resin board in the bonding process of a protective film.

  As a result of intensive studies to solve the above-mentioned problems, the present inventors, in the step of bonding the protective film, in at least one protective film bonding roll of the pair of protective film bonding rolls, both ends of the roll In order to complete the present invention, it is found that by forming a step having an outer diameter smaller than the outer diameter of the central portion of the roll on the outer peripheral surface of the portion, there will be no bonding failure of the protective film or breakage of the resin plate. It came.

That is, this invention consists of the following structures.
(1) Melting and kneading a thermoplastic resin with an extruder, extrusion molding from a die, cooling with at least three cooling rolls to obtain a resin plate or film, and a protective film and the resin plate or film A method for producing a resin plate with a protective film or a film, comprising a step of supplying a protective film between a pair of protective film bonding rolls and bonding the protective film to at least one surface of the resin plate or film. On the outer peripheral surfaces of both end portions of the two protective film bonding rolls, steps having an outer diameter smaller than the outer diameter of the center portion of the roll are formed, and both end portions of the resin plate or film are formed on the step forming portions. position and,
The step is a size such that the end of the resin plate or film is not sandwiched,
The thermoplastic resin is a polycarbonate resin or a methacrylic resin;
The method for producing a resin plate or film with a protective film , wherein the resin plate or film has a thickness of 20 to 1500 m .
(2) The manufacturing method according to (1), wherein the step is 20 μm to 3 mm.

  According to the method for producing a resin plate with a protective film or film of the present invention, in at least one protective film bonding roll of the pair of protective film bonding rolls, the outer diameter is the center of the roll on the outer peripheral surface of both ends of the roll. Since the protective film laminating roll does not pinch the end of the resin plate or film due to the formation of steps smaller than the outer diameter of the part, the protective film floats poorly (lamination failure) and wrinkles occur. There is an effect that the resin plate is not broken.

It is a schematic explanatory drawing which shows the manufacturing method of the resin board with a protective film concerning one embodiment of this invention. It is a schematic sectional drawing which shows the protective film bonding process seen from the arrow (I) direction in FIG. It is a front view which shows the other example of the protective film bonding roll used for the manufacturing method of this invention.

The production method of the resin plate with a protective film of the present invention is as follows.
(A) Melting and kneading a thermoplastic resin with an extruder, extrusion molding from a die, cooling with at least three cooling rolls to obtain a resin plate or film (extrusion molding process);
(B) supplying a resin plate or film between a pair of protective film bonding rolls, and bonding a protective film to at least one surface of the resin plate or film (bonding step);
Steps are formed on the outer peripheral surfaces of both ends of at least one protective film laminating roll, the outer diameter of which is smaller than the outer diameter of the center of the roll, and both ends of the resin plate or film, Located in the step forming portion. Hereinafter, each process will be described in detail.

(A) Extrusion molding step In the extrusion molding step, first, a thermoplastic resin is melt-kneaded by an extruder. The thermoplastic resin is not particularly limited as long as it is a melt processable resin. For example, polyvinyl chloride resin, acrylonitrile-butadiene-styrene resin, low density polyethylene resin, high density polyethylene resin, linear low density polyethylene resin, Polystyrene resin, polypropylene resin, acrylonitrile-styrene resin, cellulose acetate resin, ethylene-vinyl acetate resin, acrylic-acrylonitrile-styrene resin, acrylic-chlorinated polyethylene resin, ethylene-vinyl alcohol resin, fluorine resin, methacrylic resin, polyacetal resin, Polyamide resin, polyethylene terephthalate resin, polycarbonate resin, polysulfone resin, polyethersulfone resin, methylpentene resin, polyarylate resin, polybutylene tele In addition to general-purpose or engineering plastics such as tarate resins, resins containing alicyclic structure-containing ethylenically unsaturated monomer units, polyphenylene sulfide resins, polyphenylene oxide resins, polyether ether ketone resins, polyvinyl chloride elastomers, chlorine Rubber-like polymers such as polyethylene oxide, ethylene-ethyl acrylate resin, thermoplastic polyurethane elastomer, thermoplastic polyester elastomer, ionomer resin, styrene-butadiene block polymer, ethylene-propylene rubber, polybutadiene resin, acrylic rubber, and the like. One of these may be used, or two or more may be mixed and used.

  Among these, at least one selected from a polycarbonate resin, a methacrylic resin, a styrene resin, and a resin containing an alicyclic structure-containing ethylenically unsaturated monomer unit is preferable because of good optical properties. And methacrylic resins are more preferred. Further, the thermoplastic resin may be constituted by laminating at least two kinds of thermoplastic resins. That is, in this invention, it is good also as a laminated structure which has two or more thermoplastic resin layers by melt-kneading each two or more types of thermoplastic resins, using two or more extruders, and coextruding. In this case, the thermoplastic resin constituting each of the laminated thermoplastic resin layers is composed of a polycarbonate resin, a methacrylic resin, a styrene resin, and a resin containing an alicyclic structure-containing ethylenically unsaturated monomer unit. It is preferably at least one selected.

  Polycarbonate resins include those obtained by reacting a dihydric phenol and a carbonate precursor by an interfacial polycondensation method or a melt transesterification method, as well as those obtained by polymerizing a carbonate prepolymer by a solid phase transesterification method, or cyclic carbonates. Examples thereof include those obtained by polymerizing a compound by a ring-opening polymerization method.

  Examples of the dihydric phenol include hydroquinone, resorcinol, 4,4′-dihydroxydiphenyl, bis (4-hydroxyphenyl) methane, bis {(4-hydroxy-3,5-dimethyl) phenyl} methane, 1,1-bis. (4-hydroxyphenyl) ethane, 1,1-bis (4-hydroxyphenyl) -1-phenylethane, 2,2-bis (4-hydroxyphenyl) propane (commonly called bisphenol A), 2,2-bis {( 4-hydroxy-3-methyl) phenyl} propane, 2,2-bis {(4-hydroxy-3,5-dimethyl) phenyl} propane, 2,2-bis {(4-hydroxy-3,5-dibromo) Phenyl} propane, 2,2-bis {(3-isopropyl-4-hydroxy) phenyl} propane, 2,2-bis {(4- Droxy-3-phenyl) phenyl} propane, 2,2-bis (4-hydroxyphenyl) butane, 2,2-bis (4-hydroxyphenyl) -3-methylbutane, 2,2-bis (4-hydroxyphenyl) -3,3-dimethylbutane, 2,4-bis (4-hydroxyphenyl) -2-methylbutane, 2,2-bis (4-hydroxyphenyl) pentane, 2,2-bis (4-hydroxyphenyl) -4 -Methylpentane, 1,1-bis (4-hydroxyphenyl) cyclohexane, 1,1-bis (4-hydroxyphenyl) -4-isopropylcyclohexane, 1,1-bis (4-hydroxyphenyl) -3,3 5-trimethylcyclohexane, 9,9-bis (4-hydroxyphenyl) fluorene, 9,9-bis {(4-hydroxy- -Methyl) phenyl} fluorene, α, α'-bis (4-hydroxyphenyl) -o-diisopropylbenzene, α, α'-bis (4-hydroxyphenyl) -m-diisopropylbenzene, α, α'-bis ( 4-hydroxyphenyl) -p-diisopropylbenzene, 1,3-bis (4-hydroxyphenyl) -5,7-dimethyladamantane, 4,4′-dihydroxydiphenylsulfone, 4,4′-dihydroxydiphenylsulfoxide, 4, Examples include 4′-dihydroxydiphenyl sulfide, 4,4′-dihydroxydiphenyl ketone, 4,4′-dihydroxydiphenyl ether, and 4,4′-dihydroxydiphenyl ester. These may be used alone or in combination of two or more. May be.

  Among them, bisphenol A, 2,2-bis {(4-hydroxy-3-methyl) phenyl} propane, 2,2-bis (4-hydroxyphenyl) butane, 2,2-bis (4-hydroxyphenyl) -3- Methylbutane, 2,2-bis (4-hydroxyphenyl) -3,3-dimethylbutane, 2,2-bis (4-hydroxyphenyl) -4-methylpentane, 1,1-bis (4-hydroxyphenyl)- A homopolymer or copolymer obtained from at least one bisphenol selected from the group consisting of 3,3,5-trimethylcyclohexane and α, α′-bis (4-hydroxyphenyl) -m-diisopropylbenzene is preferred. In particular, homopolymers of bisphenol A, and 1,1-bis (4-hydroxyphenyl) -3,3,5-trimethyl At least one selected from rucyclohexane and bisphenol A, 2,2-bis {(4-hydroxy-3-methyl) phenyl} propane, and α, α'-bis (4-hydroxyphenyl) -m-diisopropylbenzene A copolymer with a dihydric phenol is preferred.

  As the carbonate precursor, for example, carbonyl halide, carbonate ester or haloformate is used, and specific examples include phosgene, diphenyl carbonate, dihaloformate of dihydric phenol, and the like.

  The methacrylic resin is a polymer containing 50% by weight or more of methyl methacrylate units as monomer units. The content of methyl methacrylate units is preferably 70% by weight or more, and may be 100% by weight. The polymer having a methyl methacrylate unit of 100% by weight is a methyl methacrylate homopolymer obtained by polymerizing methyl methacrylate alone.

  The methacrylic resin may be a copolymer of methyl methacrylate and another monomer that can be copolymerized with the methyl methacrylate. Examples of other monomers that can be copolymerized with methyl methacrylate include methacrylic acid esters other than methyl methacrylate. Examples of the methacrylic acid esters include ethyl methacrylate, butyl methacrylate, cyclohexyl methacrylate, phenyl methacrylate, benzyl methacrylate, 2-ethylhexyl methacrylate, 2-hydroxyethyl methacrylate and the like. Also, acrylic esters such as methyl acrylate, ethyl acrylate, butyl acrylate, cyclohexyl acrylate, phenyl acrylate, benzyl acrylate, 2-ethylhexyl acrylate, 2-hydroxyethyl acrylate, methacrylic acid, acrylic acid Unsaturated acids such as, halogenated styrenes such as chlorostyrene and bromostyrene, substituted styrenes such as vinyltoluene and alkyl styrenes such as α-methylstyrene, acrylonitrile, methacrylonitrile, maleic anhydride, phenylmaleimide, cyclohexyl Examples include maleimide. Such monomers may be used alone or in combination of two or more.

  The methacrylic resin may be a resin composition by adding a rubbery polymer. Thereby, since it becomes difficult to crack at the time of shaping | molding, a yield can be improved. Examples of the rubber-like polymer include an acrylic multilayer polymer, and a graft copolymer obtained by graft-polymerizing an ethylenically unsaturated monomer in a proportion of 95 to 20 parts by weight to 5 to 80 parts by weight of a rubber-like polymer. Etc.

  Examples of the acrylic multilayer structure polymer include those having a rubber elastic layer or an elastomer layer in an amount of 20 to 60 parts by weight and having a hard layer at the outermost layer, and further having a hard layer as the innermost layer. You may do it.

  The rubber elastic layer or the elastomer layer is a layer of an acrylic polymer having a glass transition point (Tg) of less than 25 ° C., for example, lower alkyl acrylate and methacrylate, lower alkoxy acrylate, cyanoethyl acrylate, acrylamide, and hydroxy lower alkyl acrylate. And a polymer obtained by crosslinking one or more monoethylenically unsaturated monomers such as hydroxy lower methacrylate, acrylic acid and methacrylic acid with allyl methacrylate or polyfunctional monomer.

  The hard layer is a layer of an acrylic polymer having a Tg of 25 ° C. or higher, and is composed of alkyl methacrylate having an alkyl group having 1 to 4 carbon atoms alone or as a main component, and other alkyl methacrylate, alkyl acrylate, styrene, substituted It may be a cross-linked polymer made of a copolymer of a monofunctional monomer such as styrene, acrylonitrile, methacrylonitrile and the like, and further polymerized by adding a polyfunctional monomer. As the rubber-like polymer described above, for example, those described in JP-B-55-27576, JP-A-6-80739, JP-A-49-23292 and the like can be used.

  In a graft copolymer obtained by graft-polymerizing an ethylenically unsaturated monomer at a ratio of 95 to 20 parts by weight to 5 to 80 parts by weight of a rubbery polymer, examples of the rubbery polymer include polybutadiene rubber and acrylonitrile. / Butadiene copolymer rubber, diene rubber such as styrene / butadiene copolymer rubber, acrylic rubber such as polybutyl acrylate, polypropyl acrylate, poly-2-ethylhexyl acrylate, and ethylene / propylene / non-conjugated diene rubber Etc. Examples of the ethylenic monomer include styrene, acrylonitrile, alkyl (meth) acrylate, and the like, and an acrylic unsaturated monomer is preferable. These may be used alone or in combination of two or more. Also good. As the above-mentioned graft copolymer, for example, those described in JP-A Nos. 55-147514 and 47-9740 can be used.

  The addition amount of the rubber-like polymer is preferably 0 to 100 parts by weight, and more preferably 3 to 50 parts by weight with respect to 100 parts by weight of the methyl methacrylate resin. If the amount of the rubbery polymer added is too large, the rigidity of the extruded plate is lowered, which is not preferable.

  The styrene resin is a polymer having a styrene monofunctional monomer unit as a main component, and specifically, a polymer containing 50% by weight or more of a styrene monofunctional monomer unit. The styrene resin may be a homopolymer of a styrene monofunctional monomer, or may be a copolymer of a styrene monofunctional monomer and a monofunctional monomer copolymerizable therewith. Good.

  Examples of the styrene monofunctional monomer include substituted styrene in addition to styrene. Examples of the substituted styrene include halogenated styrenes such as chlorostyrene and bromostyrene, and alkylstyrenes such as vinyltoluene and α-methylstyrene. That is, the styrene monofunctional monomer is a compound having a styrene skeleton and one double bond capable of radical polymerization in the molecule.

  A monofunctional monomer that can be copolymerized with a styrenic monofunctional monomer has one radical-polymerizable double bond in the molecule that can be copolymerized with the styrene monofunctional monomer. Polymerizable compounds, for example, methacrylic acid esters such as methyl methacrylate, ethyl methacrylate, butyl methacrylate, cyclohexyl methacrylate, phenyl methacrylate, benzyl methacrylate, 2-ethylhexyl methacrylate, 2-hydroxyethyl methacrylate Acrylates such as methyl acrylate, ethyl acrylate, butyl acrylate, cyclohexyl acrylate, phenyl acrylate, benzyl acrylate, 2-ethylhexyl acrylate, 2-hydroxyethyl acrylate, and acrylonitrile. Meta, such as methyl methacrylate Acrylic acid esters are preferably used, used alone or in combination of two or more, respectively.

  The styrenic resin may be a resin composition by adding a rubbery polymer. As the rubbery polymer, the same rubbery polymer that can be added to the above-mentioned methyl methacrylate resin can be used. The addition amount of the rubber-like polymer is preferably 0 to 100 parts by weight, more preferably 3 to 50 parts by weight with respect to 100 parts by weight of the styrene resin. If the amount of the rubbery polymer added is too large, the rigidity of the extruded plate is lowered, which is not preferable.

  Examples of the resin containing an alicyclic structure-containing ethylenically unsaturated monomer unit include a norbornene polymer and a vinyl alicyclic hydrocarbon polymer. The resin is characterized by containing an alicyclic structure in the repeating unit of the polymer. The alicyclic structure may be present in either the main chain and / or the side chain, but from the viewpoint of light transmittance, those containing an alicyclic structure in the main chain are preferred.

  Specific examples of the resin containing an alicyclic structure-containing ethylenically unsaturated monomer unit include a norbornene polymer, a monocyclic olefin polymer, a cyclic conjugated diene polymer, and a vinyl alicyclic hydrocarbon system. Examples thereof include polymers and hydrogenated products thereof. Among these, from the viewpoint of light transmittance, a norbornene polymer hydrogenated product, a vinyl alicyclic hydrocarbon polymer or a hydride thereof is preferable, and a norbornene polymer hydrogenated product is more preferable.

  The thermoplastic resin includes, for example, a light diffusing agent, a matting agent, an ultraviolet absorber, a surfactant, an impact resistant agent, a polymer antistatic agent, an antioxidant, a flame retardant, a lubricant, depending on the purpose. Dyes, pigments and the like may be added.

  The temperature at which the thermoplastic resin is melt-kneaded is not particularly limited, and may be appropriately set in consideration of the melting point of the thermoplastic resin to be used.

The molten resin melt-kneaded by an extruder is extruded from a die, cooled by at least three cooling rolls, and formed into a resin plate or film. This will be described in detail with reference to FIG.
FIG. 1 is a schematic explanatory view showing a method for producing a resin plate with a protective film according to an embodiment of the present invention. As shown in FIG. 1, the thermoplastic resin is put into extruders 1 and 2 and melt-kneaded as described above. In FIG. 1, two extruders are used, but the number of extruders may be one or three or more, and may be appropriately changed depending on the number of resin layers stacked and the type of resin used. Good.

  The melt-kneaded resin is supplied to the die 3 and extruded from the die 3 as a plate-like molten resin 4. As shown in FIG. 1, when two extruders are used, a plate-like molten resin in which the thermoplastic resin is melt-kneaded in each of the extruders 1 and 2 and co-extruded from the die 3 and laminated and integrated. 4 is obtained.

  Examples of the extruders 1 and 2 include a single screw extruder and a twin screw extruder. As the die 3, a T die is usually used. For example, when a thermoplastic resin is extruded in a single layer, a single-layer die or the like is also used in addition to a T die. When two or more thermoplastic resins are laminated and co-extruded, a feed block die and a multi-manifold die are used. Multi-layer dies such as are also used.

  The molten resin 4 extruded from the die 3 is molded and cooled by the cooling unit 5. In the manufacturing method of the present invention, at least three cooling rolls used in the cooling unit 5 are provided. The number of cooling rolls is preferably 3-5.

  In FIG. 1, the cooling unit 5 includes three cooling rolls 51, 52, and 53 arranged to face each other in a substantially horizontal direction. The cooling rolls 51, 52, 53 are a first cooling roll 51, a second cooling roll 52, and a rear-stage cooling roll 53 in order along the direction of taking the molten resin 4. These cooling rolls 51, 52, and 53 are configured such that at least one roll is connected to a rotation driving means such as a motor, and each roll rotates at a predetermined peripheral speed.

  The cooling rolls 51, 52, 53 are not particularly limited, and normal cooling rolls used in conventional extrusion molding can be employed. Specific examples include a drilled roll, a spiral roll, a metal elastic roll, and a rubber roll. The surface state of the cooling rolls 51, 52, 53 may be, for example, a mirror surface, or may have a pattern or unevenness.

  The surface temperature (Tr) of the cooling rolls 51, 52, 53 is preferably (Th−20 ° C.) ≦ Tr ≦ (Th + 20 ° C.), more preferably (Th), relative to the thermal deformation temperature (Th) of the thermoplastic resin. −15 ° C.) ≦ Tr ≦ (Th + 10 ° C.), more preferably (Th−10 ° C.) ≦ Tr ≦ (Th + 5 ° C.). When the surface temperature (Tr) is lower than (Th-20 ° C.), the resin tends to be peeled off from the roll and a touch error tends to occur. In addition, when the surface temperature (Tr) is higher than (Th + 20 ° C.), it becomes difficult for the resin to be uniformly peeled from the roll, and a line in the width direction due to an impact at the time of roll peeling called a tuck mark tends to occur. is there.

  In addition, although it does not specifically limit as heat deformation temperature (Th) of a thermoplastic resin, Usually, it is about 60-200 degreeC. The heat distortion temperature (Th) of the thermoplastic resin is a temperature measured according to ASTM D-648. In addition, regarding the surface temperature (Tr) when the extruded plate is made into a laminated structure by co-extrusion of two or more different thermoplastic resins, the thermal deformation temperature (Th) is the highest among the two or more different thermoplastic resins. Based on high thermoplastic resin.

  The molten resin 4 is thus cooled by the cooling unit 5 and molded into the resin plate 6. The thickness of the resin plate 6 is not particularly limited. For example, the resin plate 6 is preferably 20 to 1500 μm, and more preferably 30 to 1000 μm. The resin plate 6 is subjected to the following bonding process.

(B) Bonding step In the bonding step, the resin plate obtained in the extrusion molding step is supplied between a pair of protective film bonding rolls, and the protective film is bonded to at least one surface of the resin plate. . The bonding process will be described in detail with reference to FIGS.

  The resin plate 6 obtained in the above-described extrusion molding process is supplied to a pair of protective film bonding rolls 81 and 82. The protective film bonding rolls 81 and 82 are rubber rolls, for example, and are disposed on the downstream side of the cooling unit 5.

  In the manufacturing method of this invention, the level | step difference A whose outer diameter is smaller than the outer diameter of a roll center part is formed in the outer peripheral surface of the both ends of at least 1 protective film bonding roll, respectively. This point will be described with reference to FIG.

  FIG. 2 is a schematic cross-sectional view showing the protective film bonding step as seen from the direction of arrow (I) in FIG. As shown in FIG. 2, the protective film bonding roll 81 is formed with a step A at the end 811 where the outer diameter is smaller than the outer diameter of the roll center. Since the edge part 61 of the resin board 6 is not pinched | interposed into the protective film bonding rolls 81 and 82 because the protective film bonding roll 81 has such a level | step difference A, the resin board 6 which cannot bond the protective film 7 easily. The protective film 7 is not pasted to the end portion 61, so that poor bonding due to excessive pasting and breakage of the resin plate 6 do not occur.

  Among the pair of protective film bonding rolls 81 and 82, in at least one protective film bonding roll (the protective film bonding roll 81 in FIGS. 1 and 2), the step A is sandwiched between the end portions 61 of the resin plate 6. The size is not limited, and is preferably 20 μm to 3 mm, more preferably 50 μm to 2 mm.

  When the level difference A is less than 20 μm, the level difference A is too small, and the end portion of the resin plate may be sandwiched between the protective film bonding rolls. On the other hand, if the level difference A exceeds 3 mm, the end portion undulates and the feeding of the resin plate may become unstable.

  In FIG. 2, the end 811 of the protective film bonding roll 81 is formed with a step A so as to be gently inclined, but the step is not limited to such a shape, for example, as shown in FIG. 3. The step A ′ may be used.

  The resin plate 6 supplied between the protective film bonding rolls 81 and 82 is bonded to the protective film 7 supplied at the same time to obtain the resin plate 9 with a protective film. In addition, in FIG. 1, although it is an example which bonds a protective film only to the single side | surface of the resin board 6, if a protective film is further supplied also from the protective film bonding roll 82 side, it will protect on both surfaces of the resin board 6 The membrane is bonded.

  As the protective film 7 used in the production method of the present invention, for example, a thin film made of a resin in which an adhesive layer is provided on polyethylene, polypropylene, polyethylene terephthalate or nylon, a metal such as ITO, tin or aluminum is used as the resin plate. And a thin film deposited on the substrate. The thickness of the protective film 7 is not specifically limited, Preferably it is 20-100 micrometers, More preferably, it is 30-70 micrometers.

  The method of bonding the protective film 7 to the resin plate 6 is, for example, a method of supplying the heated protective film 7 and the resin plate 6 between the protective film bonding rolls 81 and 82 and pressurizing and welding them. A method of laminating the protective film 7 and the resin plate 6 via an adhesive and pressurizing them with the protective film bonding rolls 81 and 82 to bond them. When the protective film 7 can be peeled off, the protective film 7 may be simply stacked on the resin plate 6. In the present invention, “bonding” includes such a mode of simply laminating.

  The resin film with a protective film obtained by the production method of the present invention is used in a very wide range such as the interior and exterior of automobiles, the exterior of household electrical products, and optical applications such as liquid crystal televisions and monitors.

  EXAMPLES Hereinafter, although an Example and a comparative example are given and this invention is demonstrated concretely, this invention is not limited to these Examples.

The configuration of the extrusion apparatus used in the examples and comparative examples is as follows.
Extruder 1: An extruder with a screw diameter of 130 mm, a single screw, and a vent (manufactured by Hitachi Zosen Corporation).
Extruder 2: Screw diameter 50 mm, single screw, vented extruder (manufactured by Hitachi Zosen).
Die (I): T-die (resin discharge port width 1650 mm, lip interval 1 mm (manufactured by Hitachi Zosen)) and feed block (resin discharge port width 150 mm, 2-type 3-layer distribution (manufactured by Hitachi Zosen)) Combination with.
Die (II): T die (resin discharge port width 1650 mm, lip interval 1 mm (manufactured by Hitachi Zosen)) and feed block (resin discharge port width 150 mm, 2-type 2-layer distribution (manufactured by Hitachi Zosen)) Combination with.
Cooling unit: horizontal type, three cooling rolls having a surface length of 1800 mm and a diameter of 350 mmφ.

Resins used in Examples and Comparative Examples are as follows.
Polycarbonate resin 1 (PC1): “Caliver 301-10” manufactured by Sumitomo Dow Co., Ltd.
Polycarbonate resin 2 (PC2): Benzotriazole-based UVA (Tinuvin 360) added to Sumitomo Dow Co., Ltd.'s "Caliver 301-10" 0.38% by weight with respect to 100% by weight of "Caliver 301-10" Resin.
Methacrylic resin 1 (PMMA1): Copolymer of methyl methacrylate / methyl acrylate = 94/6 (mass ratio).
Methacrylic resin 2 (PMMA2): Copolymer of methyl methacrylate / methyl acrylate = 98/2 (mass ratio).

(Examples 1-12 and Comparative Examples 1-3)
The resins shown in Table 1 were melted and kneaded in the first extruder and the second extruder, respectively, and supplied to a feed block to which a T-die was attached to perform coextrusion molding.

  Next, the extruded molten resin was formed into a film by a cooling unit having three cooling rolls, and two layers (Examples 6 and 7 and Comparative Example 3) having the total thickness (target value) described in Table 1 or A laminated resin plate having three layers (other than Examples 6 and 7 and Comparative Example 3) was produced.

  The obtained resin plate was sandwiched with a protective film between a pair of protective film bonding rolls provided with a step of 1.5 mm at one roll end, and one side of the resin plate (Examples 1 to 4, 6, Comparative Example) 1 and 2) or both surfaces (Examples 5, 7 to 12 and Comparative Example 3) were bonded with a protective film (polyethylene film “Sanitec PAC2A-30T” manufactured by Sanei Kaken Co., Ltd., thickness 30 μm).

  Thus, the resin board with a protective film was produced, respectively, and the state of the obtained resin board with a protective film was observed visually. The results are shown in Table 1.

  As shown in Table 1, in the resin plates with protective films of Examples 1 to 12, problems such as poor bonding of the protective films and breakage of the resin plates were not observed. On the other hand, in the resin plate with a protective film of Comparative Examples 1 to 3 in which no step is provided on the protective film bonding roll, the end of the protective film floats without being bonded to the resin plate (Comparative Example 1), or protection. There was a problem that wrinkles occurred in the film and the resin plate was broken (Comparative Examples 2 and 3).

DESCRIPTION OF SYMBOLS 1, 2 Extruder 3 Die 4 Molten resin 5 Cooling unit 51, 52, 53 Cooling roll 6 Resin plate 61 End part of resin plate 7 Protective film 81, 82 Protective film bonding roll 811 End part of protective film bonding roll 9 Resin plate with protective film A, A 'step

Claims (2)

Melting and kneading the thermoplastic resin with an extruder, extruding from a die, and cooling with at least three cooling rolls to obtain a resin plate or film;
Supplying the protective film and the resin plate or film between a pair of protective film bonding rolls, and bonding the protective film to at least one surface of the resin plate or film; and
A method for producing a protective film-coated resin plate or film comprising:
On the outer peripheral surface of both ends of at least one protective film laminating roll, steps each having an outer diameter smaller than the outer diameter of the roll center are formed, and both ends of the resin plate or film form the steps. Located in the part
The step is a size such that the end of the resin plate or film is not sandwiched,
The thermoplastic resin is a polycarbonate resin or a methacrylic resin;
The method for producing a resin plate or film with a protective film , wherein the resin plate or film has a thickness of 20 to 1500 m .   The manufacturing method according to claim 1, wherein the step is 20 μm to 3 mm.

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