JP6140861B1 - Roll, film or sheet manufacturing apparatus provided with roll, and film or sheet manufacturing method - Google Patents

Abstract

A roll having a high degree of freedom in surface structure and capable of easily correcting the surface of the roll is provided. A roll 5 provided in an apparatus for producing a solid film or sheet from a liquid resin has a rotating shaft 51 attached to the apparatus main body. The roll 5 further has a fixed end portion 56 fixed to one end portion of the rotating shaft 51 and a free end portion 57 positioned on the opposite side of the fixed end portion 56 and is coaxial with the rotating shaft 51. 52 and a hollow sleeve 53 fitted to the outer surface of the roll main body 52 from the free end portion 57. [Selection] Figure 3

Description

  The present invention relates to a roll used for manufacturing a film or sheet, a film or sheet manufacturing apparatus including the roll, and a method of manufacturing a film or sheet using the roll.

  The process for producing a resin film or sheet can be classified into three main types: a melt extrusion method, a solution casting method, and a calendar molding method. In the melt extrusion method, a liquid resin melted at a high temperature is extruded from a flat die in a thin and wide width, and immediately after that, the resin is conveyed while being brought into contact with a cooling roll to obtain a cooled and solidified product. In the solution casting method, a resin solution dissolved in a solvent is poured into a roll from a flat die or the like to form a thin film, and then heated to evaporate the solvent to obtain a thin film product. In the calendering method, a heat-melted resin is poured onto two rolls extending in parallel to each other and having different rotation directions, and the resin is passed through a gap between the rolls and rolled into a film or a sheet to be molded. In any of these processes, a metal roll is often used to keep the resin in a liquid state thin and wide.

  For example, in the melt extrusion method, generally, the extruded molten resin is first cooled by a first roll, then cooled by a second roll having a different rotational direction from the first roll, and then, if necessary, It is cooled by a roll 3 or the like. Thus, the molten resin is cooled by one or more cooling rolls depending on the process.

  Patent Documents 1 to 3 disclose rolls used in iron making. The roll includes an inner arbor and an outer sleeve, and the sleeve can be exchanged to impart desirable surface properties to the roll.

  Patent Document 4 describes a resin sheet manufacturing apparatus in which flexible ultra-thin pipes are wound around a plurality of rolls in a belt shape, and a cooling means is provided for each roll. Since the resin film contacts the pipe in a long section along the surface of the ultrathin pipe, the sheet can be efficiently cooled.

JP 7-227605 A Japanese Utility Model Publication No. 62-113803 Japanese Utility Model Publication No. 62-113804 JP 2007-62245 A

  The cooling roll not only cools and solidifies the resin in a molten state at a high temperature and maintains its shape, but also plays a role of intentionally imparting surface properties such as glossiness and uneven shape. For example, when importance is attached to glossiness, a roll having a mirror surface with a very fine surface roughness is used. However, when a soft resin having no stiffness is cooled with a mirror-finished roll, the peelable sheet may be poor, and thus the cooled sheet may be stretched more than necessary and a desired product shape may not be obtained. In such a case, it is necessary to change the type of surface treatment (plating) applied to the cooling roll to a roll that has been subjected to a surface treatment excellent in peelability. When the uneven shape is imparted, the intended uneven shape is applied to the roll surface, but a sufficient amount of molten resin may not enter the recess and the shape may not be transferred sufficiently. In such a case, it is necessary to optimize the uneven shape of the roll.

  However, since the production of a roll requires a production period of several months and a great production cost, it cannot be easily changed or evaluated, and optimization may be difficult. When the techniques described in Patent Documents 1 to 3 are applied, it is easy to optimize the surface properties of the roll because only the sleeve needs to be replaced. However, in order to replace the sleeve, it is necessary to remove the roll from the main body of the manufacturing apparatus, replace the sleeve, and attach the roll again. The operation is considered to take about a day, and it is practically impossible to change the sleeve several times for the optimization of the sleeve. Since complicated work is required, problems such as variations in work safety and parallelism of rolls also occur. Moreover, the roll used for manufacture of resin has a long lifetime compared with the roll used by iron manufacture, and can be used semipermanently. For this reason, it is less necessary to periodically replace the roll, and it is more difficult to optimize the surface properties of the roll.

  Since the ultrathin pipe described in Patent Document 4 has a structure that spans a plurality of rolls, it can be used as a replaceable sleeve. However, because of the structure, it is practically impossible to impart an uneven shape to the thin-walled pipe, and there is a limit to the optimization of the surface properties of the roll.

  An object of the present invention is to provide a roll having a high degree of freedom in surface structure and capable of easily correcting the surface of the roll.

The present invention relates to a roll provided in an apparatus for producing a solid film or sheet from a liquid resin. Roll has a central axis, connected to the rotary drive device, having an axis of rotation you rotate about a central axis by a rotational driving device. The roll further has a fixed end fixed to one end of the rotating shaft, and a free end located on the opposite side of the fixed end, and a roll body coaxial with the rotating shaft, from the free end A hollow sleeve fitted on the outer surface of the roll body.

  Since the hollow sleeve can be fitted to the outer surface of the roll body from the free end of the roll body, it can be easily replaced. Moreover, since there is no big restriction | limiting in the structure of a sleeve, the characteristic of a surface can be adjusted freely. Furthermore, since the hollow sleeve is configured to be fitted to the outer surface of the roll body from the free end, it is not necessary to remove the roll body from the apparatus body when replacing the sleeve.

  Therefore, according to the invention, it is possible to provide a roll having a high degree of freedom in the surface structure and capable of easily correcting the surface of the roll.

It is the schematic of the manufacturing apparatus of the film or sheet of this invention. It is a perspective view of the roll of this invention. It is a disassembled perspective view of the roll of this invention. It is a flowchart which shows the replacement | exchange procedure of the sleeve in the roll of this invention. It is a flowchart which shows the replacement | exchange procedure of the sleeve in an integrated roll.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 is a schematic view of a production apparatus for producing a solid film or sheet from a liquid resin. The manufacturing apparatus 1 is a small apparatus used as a test facility for the manufacturing apparatus itself. In the test apparatus, it is not necessary to use a roll having the same diameter and width as the production machine, and a roll having a small diameter and a narrow width can be used. Illustration of an extruder, resin piping, etc. is omitted. The manufacturing apparatus 1 includes an apparatus main body 2, a flat die 3 attached to the apparatus main body 2, and a sheet cooling / winding device 4. The sheet cooling / winding device 4 includes a plurality of rolls for cooling while conveying a molten resin or a solidified film or sheet.

  In this embodiment, all the rolls have a cantilever structure extending in parallel from each other in the same direction from the apparatus main body 2. That is, one end of the roll is supported by the apparatus main body 2 and the other end is a free end not supported by the apparatus main body 2. There are no drive shafts, cooling pipes, casings, etc. on the free end side of the roll, and it is easily accessible by personnel for device operation and sheet manufacturing. For this reason, the free end part side of a roll may be called the operation side.

  The molten resin F discharged from the flat die 3 is wound after being solidified by the first cooling roll 5 and the second cooling roll 7. A touch roll 6 adjacent to the first cooling roll 5 via a minute clearance is provided, and a roll pair is formed together with the first cooling roll 5. The molten resin F is cooled while being pressed between the first cooling roll 5 and the touch roll 6 to become a solid sheet F ′, and is given a surface gloss. The 1st cooling roll 5 cools the contact surface with the 1st cooling roll 5 of the molten resin F, and provides surface glossiness. The surface of the touch roll 6 is mirror-finished, and the back surface of the molten resin F is supplementarily cooled, and surface gloss is imparted to the back surface of the molten resin F. The touch roll 6, the first cooling roll 5, and the second cooling roll 7 are provided with a temperature control mechanism (not shown) through which cooling water circulates. The manufacturing apparatus 1 further includes a third cooling roll 8 and a winding shaft 9. The sheet F ′ on which the molten resin F has been solidified is further cooled by the third cooling roll 8 and wound around the winding shaft 9.

  The first cooling roll 5 contacts the completely melted resin F and plays an important role in cooling and solidifying the resin F while transferring the surface shape corresponding to the surface roughness of the roll to the resin F. In the present embodiment, a sleeve replacement type roll is adopted as the first cooling roll 5, and the sleeve can be easily replaced from the operation side.

  2 and 3 show the structure of the sleeve type roll. 2 is a perspective view of the roll, and FIG. 3 is an exploded perspective view of the roll showing a state in which the sleeve is pulled out from the roll body. The roll 5 includes a rotary shaft 51 attached to the apparatus main body 2, a roll main body 52 fixed to the rotary shaft 51, and a sleeve 53 fitted into the roll main body 52. Although the rotating shaft 51 and the roll main body 52 are integrally formed, they may be fixed to each other by an appropriate method such as welding, bolting, or press fitting.

  The rotating shaft 51 is rotatably supported by the apparatus main body 2 by bearings (not shown) near both ends thereof. One end of the rotating shaft 51 is connected to a rotation driving device (not shown) including a gear connected to a motor. A key groove 54 for receiving a key for connecting the rotary shaft 51 and the rotary drive device is provided at one end of the rotary shaft 51. A rotary joint (not shown) for supplying and discharging cooling water is provided at one end of the rotating shaft 51. A cooling water flow path (not shown) communicating with the rotary joint is provided inside the rotary shaft 51.

  The roll body 52 is a cylindrical rotating body having a larger diameter than the rotating shaft 51. The roll body 52 has a central axis 55 that is coaxial with the rotary shaft 51, and rotates around the central axis 55 together with the rotary shaft 51. The roll main body 52 has a fixed end portion 56 fixed to one end portion of the rotating shaft 51 and a free end portion 57 located on the opposite side of the fixed end portion 56 with respect to the central shaft 55. Therefore, the roll main body 52 has a cantilever structure in which the fixed end portion 56 is fixed to the rotating shaft 51. A fixed end 56 of the roll body 52 is provided with a flange 60 for positioning the sleeve 53. Two keys 58 extending in parallel with the central axis 55 from the inner surface of the flange 60 toward the free end 57 are formed on the outer surface of the roll body 52 (only one key 58 is provided). Is shown). Inside the roll body 52, a cooling water channel (not shown) communicating with the channel inside the rotating shaft 51 is provided.

  The sleeve 53 has a hollow cylindrical shape that is fitted to the outer surface of the roll body 52. One end of the sleeve 53 has two key grooves 59 that fit into the key 58 (only one key groove 59 is shown). By fitting the sleeve 53 into the roll main body 52 so that the key 58 matches the key groove 59 of the sleeve 53, the sleeve 53 can be rotated integrally with the roll main body 52. A screw hole 62 into which a screw 61 for fixing the sleeve 53 can be inserted is provided at the distal end on the operation side of the sleeve 53. The sleeve 53 is firmly fixed to the roll body 52 by screwing the screw 61 with sufficient torque and pressing the tip of the screw 61 against the roll body 52. As a result, the sleeve 53 is prevented from slipping out to the operation side when the sheet is manufactured. The keyway 59 provided in the sleeve 53 and the screw hole 62 reduce the effective length in the width direction of the roll 5 (the width direction region in contact with the sheet). However, the cooling water cannot be sufficiently circulated and the temperature becomes unstable. Since it is not provided in the area | region which a sheet | seat contact | connects, it does not become a problem substantially.

Example 1
Hereinafter, the present invention will be described in more detail by way of examples. The sleeve type roll 5 shown in FIG. 2 has a diameter of the roll 5 (outer diameter of the sleeve 53) of 250 mm, a width of 350 mm (the width of the sleeve 53 is 340 mm), and a thickness of the sleeve 53 is 10 mm (the inner diameter of the sleeve 53 is 230 mm). It is. Two keys 58 and two screw holes 62 for fixing the sleeve 53 are provided. The sleeve 53 is made of carbon steel and its weight is approximately 20 kg. Therefore, it is possible to remove the sleeve 53 by hand when replacing the sleeve 53, and it is also possible to suspend and replace the sleeve 53 with a crane or the like in consideration of safety. FIG. 4 shows a procedure for replacing the sleeve 53 in the embodiment. When exchanging the sleeve 53 by hand, the tool necessary for the exchange is only one hexagon wrench used for loosening and fixing the screw 60. In consideration of safety, a crane was used for attaching and detaching the sleeve 53, and when one worker performed the work, the time required for the replacement was 8 minutes.

  FIG. 5 shows, as a comparative example, a procedure for replacing a cooling roll of a general both-support (both-end) system. This method requires many steps because the entire roll must be desorbed and attached, and in the case of a roll that is used for the first time after a new production, it is necessary to attach accessory parts, and the number of work steps increases. The sheet manufacturing apparatus of the comparative example has a both-support type roll, and the roll width is 1200 mm. The roll includes a touch roll, a first cooling roll, and a second cooling roll. The first cooling roll was replaced. Since newly installed rolls have already been used several times, bearings and the like have already been installed. The roll change was performed according to FIG. 5, and it took 75 minutes for work by two people. Both supporting rolls of the comparative example were relatively wide. However, if the width is equivalent to the sleeve type roll of the embodiment, the roll is lighter and the bearing case is also downsized. However, since all of the replacement procedures in FIG. 5 need to be performed and there is no significant difference in the complexity of the work, the replacement time is estimated to be about 60 minutes reduced by about 15 minutes at most.

(Example 2)
The most concerned about using a sleeve-type cooling roll is a decrease in sheet cooling efficiency. The roll main body 52 can be adjusted to a predetermined set temperature because the cooling water circulates. However, the amount of heat is not efficiently transmitted to the sleeve 53, and the temperature on the surface of the sleeve 53 may not be sufficiently controlled. In this embodiment, the roll body 52 and the sleeve 53 are made of the same material of carbon steel so that the thermal expansion at the set temperature of the roll is the same between the roll body 52 and the sleeve 53. The size of the gap was made as small as possible. By matching the thermal expansion coefficients of the roll body 52 and the sleeve 53, it is possible to suppress a change in the clearance between the roll body 52 and the sleeve 53 when the sleeve-type roll is heated or cooled. As a result, a change in the amount of heat transfer between the roll body 52 and the sleeve 53 is suppressed, and deformation of the sleeve 53 due to thermal expansion of the roll body 52, a change in roundness, and the like are less likely to occur. The integrated roll and the sleeve-type roll were connected to a water circulation device having the same specification cooling / cooling function, and the temperature of the roll was adjusted at the same set temperature. Table 1 shows the results of measuring the surface temperature of an integrated roll (comparative example) and a sleeve-type roll (example) having the same outer dimensions under conditions of an outside air temperature of 8 ° C. and a roll set temperature of 30 ° C. and 45 ° C. . Although there is a relatively large difference between the outside air temperature and the set temperature of 22 ° C and 37 ° C, it turns out that the surface temperature of the sleeve type roll is almost the same as that of the integrated roll, and the cooling capacity of the sleeve type roll does not decrease. did. In the table, “non-operating side” means the side opposite to the operating side.

  The present invention has been described above by taking the sheet manufacturing apparatus 1 by the melt extrusion method as an example, but the present invention can also be applied to a solution casting method and a calendar method. When the sleeve type roll of the present invention is applied to the solution casting method, a sleeve type roll can be adopted as a roll into which the solution is poured. Thereby, the effect by various roll surface treatments can be verified in the process of evaporating the solvent on the roll to obtain a solidified film. In the calendar method, the sleeve type roll of the present invention can be applied to a roll in a rolling process. Further, by applying the sleeve type roll of the present invention to a roll that finally cools and solidifies the resin, various uneven shapes can be tried. Thus, efficient verification experiments can be performed in a short time by any of the melt extrusion method, the solution casting method, and the calendar method. Therefore, the present invention can be applied to the entire film or sheet manufacturing process using rolls. Furthermore, the roll to which the present invention is applied is not limited to a roll through which a molten liquid resin passes, and may be a roll through which a solid film or a solid sheet passes. Further, the present invention can be applied not only to a test apparatus but also to a small-scale production apparatus. For example, the sleeve-type roll of the present invention can be suitably applied when products with different surface treatments are produced in small quantities.

DESCRIPTION OF SYMBOLS 1 Film or sheet manufacturing apparatus 2 Apparatus main body 5 First cooling roll 6 Touch roll 7 Second cooling roll 51 Rotating shaft 52 Roll main body 53 Sleeve 54 Key groove 55 Central axis 56 Fixed end 57 Free end 58 Key 59 Keyway 60 Screw 61 Screw hole F Resin F 'Sheet

Claims (6)

A roll provided in an apparatus for producing a solid film or sheet from a liquid resin,
Has a central axis, connected to the rotary drive device, the rotary shaft you rotate about said central axis by said rotary drive device,
A roll body coaxial with the rotary shaft, having a fixed end fixed to one end of the rotary shaft and a free end located on the opposite side of the fixed end;
A hollow sleeve fitted to the outer surface of the roll body from the free end.   2. The key according to claim 1, wherein a key extending in parallel with a central axis of the roll body is provided in the vicinity of the fixed end portion of the outer surface of the roll body, and the sleeve has a key groove that fits the key. roll.   The roll according to claim 1, further comprising: a screw hole penetrating a side surface of the sleeve; and a screw that contacts the roll body through the screw hole. The roll according to any one of claims 1 to 3,
A roll pair is formed with the roll, and another roll through which a liquid resin, a solid film or a solid sheet passes through a gap between the roll and the roll,
A film or sheet manufacturing apparatus, comprising: an apparatus main body provided with the rotation shaft of the roll and the rotation driving device for the rotation shaft.   The manufacturing apparatus according to claim 4, wherein the manufacturing apparatus is a test manufacturing apparatus. A rotating shaft attached to the device body;
A roll body coaxial with the rotary shaft, having a fixed end fixed to one end of the rotary shaft and a free end located on the opposite side of the fixed end;
A method for producing a film or a sheet using a production apparatus having a roll having
Fitting a hollow sleeve from the free end to the outer surface of the roll body;
Passing a liquid resin, a solid film, or a solid sheet through a gap between the roll fitted with the sleeve and another roll while rotating the rotating shaft, and manufacturing a film or sheet Method.

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