JP6974966B2 - How to cut the resin film - Google Patents

Description

The present invention relates to a method for cutting a resin film.

Most of the resin films formed by various methods are cut to a desired width and used according to the intended use and product shape. However, a resin film having low mechanical strength produces a large amount of chips (cutting chips) at the time of cutting. Not only does the resin film with chips adhere to it become foreign matter, but it may also be damaged by the chips, or printing may be missed in the post-printing process, so cutting of the resin film with less chips. A method is required. As a method for cutting a resin film that reduces the generation of chips, for example, Patent Document 1 discloses a method for cutting a resin film with an auxiliary film applied. Further, Patent Document 2 specifies the inclination of the upper blade, the cutting edge angle of the upper blade, the amount of engagement between the upper blade and the lower blade, the contact pressure with the lower blade of the upper blade, and the running tension of the running polyester film. The method for producing a polyester film roll to be cut is disclosed as the range of.

Japanese Unexamined Patent Publication No. 2014-69295 Japanese Unexamined Patent Publication No. 2014-180716

The above-mentioned conventional technique requires a large amount of capital investment, and it is difficult to sufficiently reduce chipping and chips of the resin film. An object of the present invention is to provide a method for cutting a resin film, which has few chips and chips and can be stably and continuously cut.

As a result of diligent studies, the present inventors have completed the present invention including the following aspects.

That is, the present invention relates to the following [1] to [10].
[1] A method for cutting a resin film having a glass transition temperature of 90 ° C. or higher, wherein a cutting device having at least a pair of upper and lower blades is used to push the upper blade toward the lower blade side. A cutting method in which the amount is 0.05 to 0.35 mm and the tension of the resin film is 30 to 300 N / m.
[2] The cutting method according to [1], wherein the resin film is a thermoplastic resin film.
[3] The cutting method according to [2], wherein the thermoplastic resin constituting the thermoplastic resin film is a (meth) acrylic resin.
[4] The cutting method according to [3], wherein the (meth) acrylic resin is a composition containing a hard methacrylic resin and an elastomer.
[5] The cutting method according to [4], wherein the elastomer is a (meth) acrylic elastomer.
[6] The cutting method according to any one of [1] to [5], wherein the amount of engagement between the upper blade and the lower blade is 0.02 to 0.60 mm.
[7] Any of [1] to [6], wherein the upper blade and the lower blade are round blades, and the ratio of the peripheral speed of the upper blade to the peripheral speed of the lower blade is more than 0.8 and less than 1.2. How to cut it.
[8] Any of [1] to [7], wherein the material constituting the upper blade and the lower blade is high-speed tool steel, alloy tool steel, carbon tool steel, stainless steel, or cemented carbide steel. How to cut it.
[9] The cutting method according to any one of [1] to [8], wherein the holding angle between the resin film and the lower blade is 10 to 150 degrees.
[10] The cutting method according to any one of [1] to [9], wherein the thickness of the resin film is 10 to 500 μm.

INDUSTRIAL APPLICABILITY According to the present invention, there is provided a method for cutting a resin film which has few chips and chips and can be stably and continuously cut.

It is a schematic diagram which observes and exemplifies one aspect of the cutting method of the resin film of this invention from the width direction of a resin film. It is a schematic diagram which observes and exemplifies one aspect of the cutting method of the resin film of this invention from the flow direction of a resin film. It is a schematic diagram which illustrates the holding angle of a resin film and a lower blade in one aspect of the method of cutting a resin film of this invention.

Hereinafter, an example of an embodiment to which the present invention is applied will be described. The numerical values specified in the present specification are values obtained by the method disclosed in the embodiments or examples. Other embodiments are also included in the scope of the present invention as long as they are consistent with the gist of the present invention.

The method for cutting a resin film of the present invention is for cutting a resin film having a glass transition temperature of 90 ° C. or higher, and a cutting device having at least a pair of upper and lower blades is used to cut the resin film to the lower blade of the upper blade. The pushing amount of the resin film is 0.05 to 0.35 mm, and the tension of the resin film is 30 to 300 N / m.

(Cut method)
The cutting method of the present invention will be described in detail with reference to the drawings. However, the present invention is not limited to the following embodiments. FIG. 1 is a schematic view illustrating one aspect of the method for cutting a resin film of the present invention by observing it from the width direction of the resin film. The cutting device has at least a pair of upper blades 1 and lower blades 2, and may have two or more pairs of upper blades 1 and lower blades 2. The upper blade 1 and the lower blade 2 are arranged so as to sandwich the resin film 3 and in parallel with the transport direction of the resin film 3, the upper blade 1 is arranged on the upper surface side of the resin film 3, and the resin film 3 is further arranged. The lower blade 2 is arranged on the lower surface side. Further, the resin film 3 is inserted between the upper blade 1 and the lower blade 2 and cut while being conveyed. Further, the upper blade 1 may be supported so as to be rotatable by, for example, a rotation shaft P.

As the cutting method of the upper blade 1 and the lower blade 2, for example, a gobel type, a gang type, a disc type, a score cutter, a core cutter, a dish type, a cup type, a straight type, a round knife and the like can be adopted. Among these, the Goebel type is preferable from the viewpoint of being able to cut the resin film more stably and continuously (cutting stability). Further, from the viewpoint of further cutting stability, the upper blade 1 and the lower blade 2 are preferably round blades.

Examples of the material constituting the upper blade 1 and the lower blade 2 include metal and ceramics. The material constituting the upper blade 1 and the lower blade 2 is preferably a metal from the viewpoint of durability, and more preferably a high-speed tool steel, an alloy tool steel, a carbon tool steel, a stainless steel, or a super hard alloy. It is a steel, more preferably a super hard alloy steel. Further, it is also possible to adopt a material whose surface is treated with titanium nitride, titanium carbide, tungsten carbide or the like. As these materials constituting the upper blade 1 and the lower blade 2, one type may be used alone, or two or more types may be used in combination. The materials constituting the upper blade 1 and the lower blade 2 may be the same or different from each other, but are preferably the same from the viewpoint of durability.

When the upper blade 1 and the lower blade 2 are round blades, the diameters of the upper blade 1 and the lower blade 2 are preferably 50 to 300 mm, more preferably 80 to 200 mm. Chips can be further reduced if the diameter is within the relevant range. The diameters of the upper blade 1 and the lower blade 2 may be the same or different, but from the viewpoint of cutting stability and stable transport, the diameter of the upper blade 1 is preferably smaller than the diameter of the lower blade 2. It is more preferable that the diameter of the upper blade 1 is 1/3 to 2/3 of the diameter of the lower blade 2.

The engagement amount L between the upper blade 1 and the lower blade 2 is preferably 0.02 to 0.60 mm, more preferably 0.05 to 0.50 mm, and further preferably 0.10 to 0.30 mm. .. When the meshing amount L is 0.02 mm or more, the resin film can be cut more stably and continuously, and when it is 0.60 mm or less, the friction between the upper blade 1 and the resin film 3 is reduced and the resin film is chipped. It can be further reduced.

FIG. 2 is a schematic view illustrating one aspect of the method for cutting a resin film of the present invention by observing from the flow direction of the resin film. FIG. 2A is a schematic view of a state in which the upper blade 1 is not pushed in the width direction of the resin film, and FIG. 2B is a schematic view when the upper blade 1 is pushed in the width direction of the resin film. It is a schematic diagram. In these schematic views, the morphological characteristics of the upper blade 1 are emphasized so that the state of deformation of the upper blade 1 before and after pushing the upper blade 1 can be easily understood. The amount of pushing of the upper blade 1 toward the lower blade 2 is determined after the upper blade 1 and the lower blade 2 come into contact with each other when the upper blade 1 is brought closer to the lower blade 2 from the direction perpendicular to the side surface of the lower blade 2. It means the amount of displacement (mm) until the center of the blade 1 further moves in the direction perpendicular to the side surface. The pushing amount can be adjusted by arranging the pressing dimension adjusting mechanism at the center of the upper blade 1 or the shaft P and moving the upper blade 1 in the width direction of the resin film by the pressing dimension adjusting mechanism. Further, the pushing amount is obtained by arranging a dial gauge on the upper blade 1 or the shaft P and measuring the moving dimension of the resin film in the width direction. For example, the pushing amount of the upper blade 1 at the moment when the upper blade 1 and the lower blade 2 come into contact with each other is 0.00 mm. When the pushing amount of the upper blade 1 exceeds 0.00 mm, the upper blade 1 is slightly deformed by the force received from the shaft P and the lower blade 2. On the other hand, when the pushing amount of the upper blade 1 is a negative value, the upper blade 1 is not in contact with the lower blade 2.

The pushing amount of the upper blade 1 to the lower blade 2 side is 0.05 to 0.35 mm, preferably 0.10 to 0.30 mm, and more preferably 0.15 to 0.25 mm. When the pushing amount is 0.05 mm or more, no gap is formed between the upper blade 1 and the lower blade 2, and the resin film can be cut stably and continuously. When the pushing amount is 0.35 mm or less, chipping and chips of the resin film can be reduced, and chipping and damage of the upper blade 1 and the lower blade 2 can be reduced.

The tension of the resin film at the time of cutting is 30 to 300 N / m, preferably 50 to 250 N, and more preferably 100 to 200 N. When the tension of the resin film is 30 N / m or more, vibration, bending, and wrinkles during film transport can be suppressed, and chipping can be reduced. Further, when the tension of the resin film is 300 N / m or less, breakage can be reduced.

FIG. 3 is a schematic view illustrating the holding angle between the resin film and the lower blade in one aspect of the method for cutting the resin film of the present invention. The holding angle θ between the resin film 3 and the lower blade 2 is a line segment connecting the point where the conveyed resin film 3 first contacts the lower blade 2 and the center of the lower blade 2, and the conveyed resin film 3 is the lower blade 2. This is the angle formed by the line segment connecting the point away from the bottom blade 2 and the center of the lower blade 2. The holding angle between the resin film 3 and the lower blade 2 is preferably 10 to 150 degrees, more preferably 30 to 120 degrees. When the holding angle is 10 degrees or more, the vibration of the resin film is suppressed, and chips can be further reduced. Further, when the holding angle is 150 degrees or less, the resistance between the resin film 3 and the lower blade 2 becomes small, and the chipping of the resin film can be further reduced. The upper blade 1 and the lower blade 2 are understood in the present technical field, and the upper blade 1 is not necessarily the upper blade 1 in the relative positional relationship between the upper blade 1 and the lower blade 2 when the resin film 3 is cut. It does not have to be located above the lower blade 2. For example, when cutting the resin film 3, the blade on the side that holds the resin film 3 can be the lower blade 2.

When the upper blade 1 and the lower blade 2 are round blades, the ratio of the peripheral speed of the upper blade 1 to the peripheral speed of the lower blade 2 ([peripheral speed of the upper blade 1 (m / min)] / [of the lower blade 2 Peripheral speed (m / min)]) is preferably more than 0.8 and less than 1.2, more preferably more than 0.95 and less than 1.05, and even more preferably more than 0.98 and less than 1.02. be. When the ratio of the peripheral speeds of the lower blade 2 and the upper blade 1 is within the relevant range, the resin film can be cut more stably and continuously. In order to control the ratio of the peripheral speeds of the lower blade 2 and the upper blade 1 within the above range, it is preferable that the peripheral speeds of the upper blade 1 and the lower blade 2 can be controlled by the drive motor.

The position for cutting the resin film is not particularly limited, and for example, a position of 50 mm or less from the edge in the width direction of the resin film may be cut, or a position of 1% or less of the width of the resin film may be cut from the edge. Alternatively, the center may be cut off. The position for cutting the resin film is preferably 1 mm or more from the end in order to further improve the cutting stability.

(Resin film)
The type of the resin film is not particularly limited as long as the glass transition temperature is 90 ° C. or higher, and examples thereof include a thermoplastic resin film and a thermosetting resin film. Examples of the thermoplastic resin constituting the thermoplastic resin film include polycarbonate resins such as bisphenol A polycarbonate; aromatics such as polystyrene, styrene-acrylonitrile resin, styrene-maleic anhydride resin, styrene-maleimide resin, and styrene-based thermoplastic elastomer. Group vinyl resin or hydrogen additive thereof; amorphous polyolefin, transparent polyolefin with finely divided crystal phase, polyolefin resin such as ethylene-methyl methacrylate resin; polymethyl methacrylate, styrene-methyl methacrylate resin, etc. (Meta) acrylic resin; polyester resin such as polyethylene terephthalate, cyclohexanedimethanol, polyethylene terephthalate partially modified with isophthalic acid, polyethylene naphthalate, polyallylate; polyamide resin; polyimide resin; polyether sulfone Resins; cellulose-based resins such as triacetyl cellulose resins; polyphenylene oxide-based resins and the like can be mentioned. In the present specification, the (meth) acrylic resin refers to a methacrylic resin and / or an acrylic resin. Further, a resin film made of a (meth) acrylic resin may be referred to as an "acrylic resin film". The (meth) acrylic resin may be a heat-resistant (meth) acrylic resin modified by imide cyclization, lactone cyclization, methacrylic acid modification, or the like. Examples of the thermosetting resin constituting the thermosetting resin film include a phenol-based resin, a urea-based resin, a melamine-based resin, an epoxy-based resin, a silicon-based resin, and a polyurethane-based resin. One of these resins constituting the resin film may be used alone, or two or more of them may be used in combination. The total content of the thermoplastic resin and the thermosetting resin in the resin film is preferably 80% by mass or more, more preferably 90% by mass or more, still more preferably 95% by mass or more. It may be 100% by mass.

The glass transition temperature of the resin film is 90 ° C. or higher, preferably 100 ° C. or higher, and more preferably 110 ° C. or higher. The upper limit of the glass transition temperature is not particularly limited, but is preferably 180 ° C. or lower, more preferably 170 ° C. or lower, still more preferably 150 ° C. or lower, from the viewpoint of further reducing chips. The glass transition temperature can be determined for the resin constituting the resin film in accordance with JIS K 7121, and specifically, it can be determined by the method described later in the examples. When the resin has a plurality of glass transition temperatures, the highest glass transition temperature value is adopted.

From the viewpoint of transparency and moldability, the resin film is preferably a thermoplastic resin film, and more preferably the thermoplastic resin constituting the thermoplastic resin film is a (meth) acrylic resin. Further, from the viewpoint of impact resistance, the (meth) acrylic resin preferably contains an elastomer, and examples of such a (meth) acrylic resin include a composition containing a hard methacrylic resin and an elastomer. .. When the (meth) acrylic resin is a composition containing a hard methacrylic resin and an elastomer, the total content of the hard methacrylic resin and the elastomer in the composition is preferably 80% by mass or more. , 90% by mass or more, more preferably 95% by mass or more, and may be 100% by mass.

The proportion of the structural unit derived from methyl methacrylate in the above-mentioned hard methacrylic acid resin is preferably 80% by mass or more, more preferably 90% by mass or more, still more preferably 95% by mass or more, and further. It is preferably 99% by mass or more, and particularly preferably 100% by mass. That is, the proportion of the structural unit derived from the monomer other than methyl methacrylate is preferably 20% by mass or less, more preferably 10% by mass or less, still more preferably 5% by mass or less, and further. It is preferably 1% by mass or less, and particularly preferably 0% by mass.

Examples of the monomer other than methyl methacrylate include methyl acrylate, ethyl acrylate, n-propyl acrylate, isopropyl acrylate, n-butyl acrylate, isobutyl acrylate, sec-butyl acrylate, and acrylic acid. tert-butyl, amyl acrylate, isoamyl acrylate, n-hexyl acrylate, 2-ethyl hexyl acrylate, pentadecyl acrylate, dodecyl acrylate, phenyl acrylate, benzyl acrylate, phenoxyethyl acrylate, acrylate Acrylic acid esters such as 2-hydroxyethyl, 2-ethoxyethyl acrylate, glycidyl acrylate, allyl acrylate, cyclohexyl acrylate, norbornyl acrylate, isobornyl acrylate; ethyl methacrylate, n-propyl methacrylate, methacrylic Isopropyl acid, n-butyl methacrylate, isobutyl methacrylate, sec-butyl methacrylate, tert-butyl methacrylate, amyl methacrylate, isoamyl methacrylate, n-hexyl methacrylate, 2-ethylhexyl methacrylate, methacrylic acid Pentadecyl, dodecyl methacrylate, phenyl methacrylate, benzyl methacrylate, phenoxyethyl methacrylate, 2-hydroxyethyl methacrylate, 2-ethoxyethyl methacrylate, glycidyl methacrylate, allyl methacrylate, cyclohexyl methacrylate, norbornyl methacrylate , Methacrylic acid esters other than methyl methacrylate such as isobornyl methacrylate; unsaturated carboxylic acids such as acrylic acid, methacrylic acid, maleic anhydride, maleic acid, and itaconic acid; Olefin such as: Conjugate diene such as butadiene, isoprene, Milsen; Aromatic vinyl compounds such as styrene, α-methylstyrene, p-methylstyrene, m-methylstyrene; acrylamide, methacrylicamide, acrylonitrile, methacrylonitrile, vinyl acetate. , Vinyl pyridine, vinyl ketone, vinyl chloride, vinylidene chloride, vinylidene fluoride and the like. One of these monomers may be used alone, or two or more thereof may be used in combination.

The method for producing the hard methacrylic resin is not particularly limited, and it can be obtained by polymerizing one or more kinds of monomers containing methyl methacrylate, preferably 80% by mass or more, under suitable conditions.

Examples of the above-mentioned elastomer include (meth) acrylic elastomers; silicone-based elastomers; styrene-based thermoplastic elastomers such as SEPS, SEBS, and SIS; and olefin-based elastomers such as IR, EPR, and EPDM. Of these, (meth) acrylic elastomers are preferable from the viewpoint of transparency and toughness.

The type of the (meth) acrylic elastomer is not particularly limited, and examples thereof include an acrylic elastic polymer containing a structural unit derived from an acrylic acid acyclic alkyl ester as a main component. In the acrylic elastic polymer, the content of the structural unit derived from the acrylic acid acyclic alkyl ester is preferably 50 to 100% by mass, more preferably 70 to 99.8% by mass. The acyclic alkyl group in the acrylic acid acyclic alkyl ester has 4 to 8 carbon atoms, specifically, for example, an n-butyl group, an n-pentyl group, an n-hexyl group, an n-heptyl group, n. -Octyl groups and isomer groups thereof are preferable. Further, the acrylic elastic polymer may contain a structural unit derived from a monomer other than the acrylic acid acyclic alkyl ester, and examples of such a monomer include methyl methacrylate and ethyl methacrylate. Methacrylic acid alkyl esters such as styrene, styrene-based monomers such as alkyl styrene; unsaturated nitriles such as acrylonitrile and methacrylic nitrile; 2-chloroethyl vinyl ether; ethylene glycol (meth) acrylate, ethoxy-diethylene glycol acrylate, methoxy. -Alkylene glycol (meth) acrylates such as triethylene glycol acrylate, 2-ethylhexyl-diglycol acrylate, methoxy-polyethylene glycol acrylate, methoxydipropylene glycol acrylate, phenoxydiethylene glycol acrylate, phenoxy-polyethylene glycol acrylate, nonylphenol ethylene oxide adduct acrylate. And so on.

The acrylic elastic polymer may have a structural unit derived from the above acrylic acid acyclic alkyl ester and a structural unit derived from the crosslinkable monomer at random. Examples of the crosslinkable monomer include allyl (meth) acrylate, methallylyl (meth) acrylate, diallyl maleate, triethylene glycol diacrylate, polyethylene glycol diacrylate, 1,6-hexanediol diacrylate, and 1 , 9-Nonandiol diacrylate, trimethylolpropane triacrylate, pentaerythritol triacrylate, pentaerythritol tetraacrylate, dipentaerythritol hexaacrylate and the like. The content of the structural unit derived from the crosslinkable monomer in the acrylic elastic polymer is preferably 0.2 to 30% by mass from the viewpoint of toughness.

Further, since the effect of the present invention is more prominently exhibited, the (meth) acrylic elastomer includes (meth) acrylic elastic particles (A), an acrylic acid ester polymer block (b1), and methacrylic acid. It is preferably at least one selected from the group consisting of the (meth) acrylic block copolymer (B) bonded to the acid ester polymer block (b2).

The (meth) acrylic elastic particle (A) may be a particle made of a single polymer, or may be a particle in which at least two layers of polymers having different elastic moduli are formed. The (meth) acrylic elastic particles (A) are a layer containing the above-mentioned acrylic elastic polymer (a polymer containing a structural unit derived from an acrylic acid acyclic alkyl ester as a main component) and other polymers. It is preferably a multi-layered core-shell particle composed of a layer containing the core-shell particles, and a two-layered core-shell particle composed of a layer containing an acrylic elastic polymer and a layer containing a methacrylic polymer covering the outside thereof, or , A core-shell particle having a three-layer structure composed of a layer containing a methacrylic polymer, a layer containing an acrylic elastic polymer covering the outside thereof, and a layer containing a methacrylic polymer covering the outer side thereof. It is more preferable that the core-shell particles have a three-layer structure.
The methacrylic polymer constituting the core-shell particles is preferably a polymer containing a structural unit derived from a methacrylic acid acyclic alkyl ester as a main component. In the methacrylic polymer, the content of the structural unit derived from the methacrylic acid acyclic alkyl ester is preferably 50 to 100% by mass, more preferably 80 to 100% by mass. The methacrylic acid acyclic alkyl ester is preferably methyl methacrylate, and the methacrylic polymer constituting the core-shell particles may contain 80 to 100% by mass of the methyl methacrylate unit with the hard methacrylic acid resin. Most preferable from the viewpoint of miscibility.

From the viewpoint of transparency, toughness, and adhesiveness, the (meth) acrylic elastic particles (A) have a number average particle size of preferably 150 to 350 nm, more preferably 200 to 300 nm. The number average particle size of the (meth) acrylic elastic particles (A) is determined by dyeing a sample obtained by melting and kneading the (meth) acrylic elastic particles (A) with a hard methacrylic resin with ruthenium oxide. It is determined based on the observed micrographs. Here, ruthenium oxide stains the layer containing the acrylic elastic polymer, but does not stain the layer containing the methacrylic polymer, so that the number of the core-shell particles having a two-layer structure or the core-shell particles having a three-layer structure is described above. The average particle size is estimated to correspond to a value excluding the thickness of the outermost layer containing the methacrylic polymer.

The method for producing the (meth) acrylic elastic particle (A) is not particularly limited, and the (meth) acrylic elastic particle (A) can be produced by a method according to a known method (for example, International Publication No. 2016/121868, etc.).

Hard methacrylic resin and (meth) acrylic elastic particles (A) when the (meth) acrylic resin is a composition containing a hard methacrylic resin and (meth) acrylic elastic particles (A). From the viewpoint of transparency, hardness, melt viscosity, toughness, slipperiness, adhesion to the protective film, etc., the content ratio of the hard methacrylic resin and the (meth) acrylic elastic particles (A) is 100 in total. The content of the (meth) acrylic elastic particles (A) with respect to parts by mass is preferably 1 to 30 parts by mass, more preferably 10 to 25 parts by mass, and further preferably 15 to 20 parts by mass.

In the (meth) acrylic block copolymer (B), the bonding state between the polymer block (b1) and the polymer block (b2) is not particularly limited, and is represented by, for example, (b1)-(b2). Block Polymers; Triblock Polymers Represented by (b1)-(b2)-(b1) or (b2)-(b1)-(b2); (b1)-((b2)-(b1)) _n , (b1)-((b2)-(b1)) _n- (b2), (b2)-((b1)-(b2)) _n (n is an integer) multi-block copolymer; ((B1)-(b2)) _n- X, ((b2)-(b1)) _{A star block copolymer represented by n-} X (X is a coupling residue) can be mentioned. From the viewpoint of productivity, the diblock copolymer represented by (b1)-(b2) is represented by (b2)-(b1)-(b2) or (b1)-(b2)-(b1). A triblock copolymer is preferable, and the triblock copolymer represented by (b2)-(b1)-(b2) is preferable from the viewpoint of the fluidity of the resin composition at the time of melting and the surface smoothness and haze of the resin film. Coalescence is more preferred. In this case, the two polymer blocks (b2) bonded to both ends of the polymer block (b1) have the type of the constituent monomer, the ratio of the structural unit derived from the methacrylic acid ester, the weight average molecular weight and the conformation. Each of the sexes may be the same or different independently. Further, the (meth) acrylic block copolymer (B) may further contain another polymer block.

The polymer block (b1) constituting the (meth) acrylic block copolymer (B) has a structural unit derived from an acrylic acid ester as a main structural unit. The ratio of the structural unit derived from the acrylic acid ester in the polymer block (b1) is preferably 50% by mass or more, more preferably 70% by mass or more, still more preferably 90% by mass or more, and particularly preferably. Is 100% by mass.

Examples of the acrylic acid ester include methyl acrylate, ethyl acrylate, n-propyl acrylate, isopropyl acrylate, n-butyl acrylate, isobutyl acrylate, sec-butyl acrylate, tert-butyl acrylate, and acrylic. Amil acid, isoamyl acrylate, n-hexyl acrylate, cyclohexyl acrylate, 2-ethylhexyl acrylate, pentadecyl acrylate, dodecyl acrylate, isobornyl acrylate, phenyl acrylate, benzyl acrylate, phenoxyethyl acrylate, acrylate Examples thereof include 2-hydroxyethyl, 2-methoxyethyl acrylate, glycidyl acrylate, and allyl acrylate. A polymer block (b1) can be formed by polymerizing these acrylic acid esters alone or in combination of two or more. Above all, from the viewpoint of economy, impact resistance and the like, the polymer block (b1) is preferably obtained by polymerizing n-butyl acrylate alone.

The polymer block (b1) may contain a structural unit derived from a monomer other than the acrylic acid ester, and the proportion thereof is preferably 50% by mass or less, more preferably 30% by mass or less, still more preferably. It is 10% by mass or less, and particularly preferably 0% by mass.

Examples of the monomer other than the acrylic acid ester include methacrylic acid ester, unsaturated carboxylic acid, aromatic vinyl compound, olefin, conjugated diene, acrylonitrile, methacrylicnitrile, acrylamide, methacrylamide, vinyl acetate and vinyl pyridine. Examples include vinyl ketone, vinyl chloride, vinylidene chloride, vinylidene fluoride and the like. A polymer block (b1) can be formed by copolymerizing one of these monomers other than the acrylic acid ester alone or in combination of two or more with the above-mentioned acrylic acid ester.

The polymer block (b2) constituting the (meth) acrylic block copolymer (B) has a structural unit derived from a methacrylic acid ester as a main structural unit. The proportion of the structural unit derived from the methacrylic acid ester in the polymer block (b2) is preferably 80% by mass or more, more preferably 90% by mass or more, still more preferably 95% by mass or more, and particularly preferably. Is 100% by mass.

Examples of the methacrylic acid ester include methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, sec-butyl methacrylate, tert-butyl methacrylate and methacrylic acid. Amil acid, isoamyl methacrylate, n-hexyl methacrylate, cyclohexyl methacrylate, 2-ethylhexyl methacrylate, pentadecyl methacrylate, dodecyl methacrylate, isobornyl methacrylate, phenyl methacrylate, benzyl methacrylate, phenoxyethyl methacrylate, methacrylic acid. Examples thereof include 2-hydroxyethyl, 2-methoxyethyl methacrylate, glycidyl methacrylate, and allyl methacrylate. Among these, from the viewpoint of improving transparency and heat resistance, methacrylic acid such as methyl methacrylate, ethyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, tert-butyl methacrylate, cyclohexyl methacrylate, and isobornyl methacrylate Alkyl esters are preferred, and methyl methacrylate is more preferred. A polymer block (b2) can be formed by polymerizing these methacrylic acid esters alone or in combination of two or more.

The polymer block (b2) may contain a structural unit derived from a monomer other than the methacrylate ester, and the proportion thereof is preferably 20% by mass or less, more preferably 10% by mass or less, still more preferably. It is 5% by mass or less, and particularly preferably 0% by mass.

Examples of the monomer other than the methacrylic acid ester include acrylic acid ester, unsaturated carboxylic acid, aromatic vinyl compound, olefin, conjugated diene, acrylonitrile, methacrylonitrile, acrylamide, methacrylamide, vinyl acetate, vinyl pyridine, and the like. Examples include vinyl ketone, vinyl chloride, vinylidene chloride, vinylidene fluoride and the like. A polymer block (b2) can be formed by copolymerizing a monomer other than these methacrylic acid esters alone or in combination of two or more with the above-mentioned methacrylic acid ester.

The proportion of the polymer block (b2) in the (meth) acrylic block copolymer (B) is the polymer block (b1) from the viewpoints of transparency, surface hardness, moldability, surface smoothness, and impact resistance. It is preferably 40% by mass or more, more preferably 43% by mass or more, and further preferably 47% by mass or more with respect to 100% by mass of the total of the polymer block (b2) and the polymer block (b2). Further, it is preferably 70% by mass or less, more preferably 65% by mass or less, and further preferably 60% by mass or less.

The method for producing the (meth) acrylic block copolymer (B) is not particularly limited, and a method according to a known method (for example, International Publication No. 2016/121868, etc.) can be adopted. For example, a method of living polymerization of the monomers constituting each polymer block is generally used, and an organic alkali metal compound is used as a polymerization initiator in the presence of a mineral acid such as an alkali metal salt or an alkaline earth metal salt. A method of anion polymerization using an organic alkali metal compound as a polymerization initiator; a method of anion polymerization in the presence of an organic aluminum compound; a method of polymerizing using an organic rare earth metal complex as a polymerization initiator; an α-halogenated ester compound. Examples thereof include a method of radical polymerization in the presence of a copper compound using the above as an initiator. Further, a method of polymerizing the monomers constituting each block using a polyvalent radical polymerization initiator or a polyvalent radical chain transfer agent to produce a mixture containing a (meth) acrylic block copolymer (B), etc. Can also be mentioned.

When the (meth) acrylic resin is a composition containing a hard methacrylic resin and a (meth) acrylic block copolymer (B), the hard methacrylic resin and the (meth) acrylic block copolymer (B) are used. ) Is the content ratio of the (meth) acrylic block copolymer with respect to 100 parts by mass of the total of the hard methacrylic resin and the (meth) acrylic block copolymer (B) from the viewpoint of surface hardness and impact resistance. The content of (B) is preferably 1 to 35 parts by mass, more preferably 8 to 25 parts by mass, and further preferably 12 to 21 parts by mass.

The resin film can be used with various additives such as polymer processing aids, light stabilizers, ultraviolet absorbers, antioxidants, heat stabilizers, lubricants, and antistatic agents as needed, as long as the effects of the present invention are not impaired. It may contain agents, pigments, dyes, fillers, impact-resistant aids and the like. One type of additive may be used alone, or two or more types may be used in combination at any ratio. From the viewpoint of mechanical properties and surface hardness of the resin film, it is preferable not to contain a large amount of foaming agent, filler, matting agent, light diffusing agent, softening agent and plasticizer. The content of the additive in the resin film is preferably 20% by mass or less, more preferably 10% by mass or less, further preferably 5% by mass or less, and may be 0% by mass. ..

(Molding method of resin film)
The method for preparing the material for the resin film is not particularly limited, and examples thereof include a method of melt-kneading the above-mentioned thermoplastic resin or thermosetting resin, or the above-mentioned various additives added as needed. .. Examples of the device for kneading include a kneader luder, a twin-screw extruder, a single-screw extruder, a mixing roll, a Banbury mixer and the like. Of these, a twin-screw extruder is preferable from the viewpoint of kneading property, and a twin-screw extruder with a vent is more preferable from the viewpoint of color suppression. It is preferable to operate the twin-screw extruder with a vent under reduced pressure or by circulating nitrogen. The shear rate during melt-kneading is preferably 10 to 1000 / sec. The temperature at the time of kneading is preferably 110 to 300 ° C, more preferably 180 to 300 ° C, and even more preferably 230 to 270 ° C. The resin composition melt-kneaded by an extruder is extruded into a strand shape and can be cut with a pelletizer or the like into pellets.

The resin film is obtained by molding the material of the above-mentioned resin film. The molding method is not particularly limited. For example, known molding methods such as extrusion molding (T-die method, etc.), injection molding, compression molding, inflation molding, blow molding, calendar molding, cast molding, vacuum molding, etc. can be adopted, and the extrusion molding method is preferably adopted. NS. According to the extrusion molding method, particularly the T-die method, it is possible to obtain a resin film having improved toughness, excellent handleability, and an excellent balance between toughness and surface hardness and rigidity. The extruder used in the extrusion molding method, particularly the T-die method, preferably has a single-screw screw or a double-screw screw. Further, from the viewpoint of suppressing the coloring of the resin film, it is preferable to melt-extrude the resin film under reduced pressure using a vent. Further, from the viewpoint of obtaining a resin film having a uniform thickness, it is preferable to connect a gear pump to the extruder and melt-extrude it through a polymer filter in order to further reduce fisheye defects. Further, from the viewpoint of suppressing oxidative deterioration, it is preferable to perform melt extrusion under a nitrogen stream. The temperature of the material discharged from the extruder is preferably 230 to 290 ° C, more preferably 240 to 280 ° C.

From the viewpoint of surface smoothness and thickness uniformity of the resin film, it is preferable to take and press the extruded film-like molten resin between the mirror surface rolls or the mirror surface belts. It is preferable that the mirror surface roll or the mirror surface belt is made of metal. The linear pressure between the mirror surface rolls or the mirror surface belts is preferably 10 N / mm or more, more preferably 30 N / mm or more, from the viewpoint of surface smoothness. The surface temperature of the mirror surface roll or the mirror surface belt is preferably 60 ° C. or higher, more preferably 70 ° C. or higher, from the viewpoint of surface smoothness, haze, appearance, and the like. Further, it is preferably 130 ° C. or lower, and more preferably 100 ° C. or lower.

The resin film may be formed into a film and then stretched. The stretching treatment improves the mechanical strength of the resin film and makes it less likely to crack. The stretching method is not particularly limited, and examples thereof include a simultaneous biaxial stretching method, a sequential biaxial stretching method, a tuber stretching method, and a rolling method. The temperature at the time of stretching is preferably 5 ° C. or higher than the glass transition temperature of the material, and preferably 40 ° C. or higher than the glass transition temperature of the material. If the material has multiple glass transition temperatures, the highest value is adopted as the reference for the stretching temperature. The stretching rate is preferably 100-5000% / min. The stretching treatment preferably has a heat fixing step after the stretching step. By heat fixing, a resin film having less heat shrinkage can be obtained.

The resin film may be colored. As a coloring method, for example, a method of impregnating a material itself forming a resin film with a pigment and / or a dye to color the material itself before film formation; the resin film is immersed in a liquid in which a dye is dispersed to color the material itself. Examples include dyeing methods.

The resin film may be printed on at least one side. Patterns and colors such as patterns, characters, and figures are added by printing. The pattern may be chromatic or achromatic.

The resin film may be a single-layer film, but is a laminated film in which another layer such as a layer made of a metal and / or a metal oxide and another thermoplastic resin layer is laminated on at least one surface. May be good. The method of laminating the other layers is not particularly limited and can be joined directly or via an adhesive layer. As the other layer, one layer or a plurality of layers can be laminated.

Examples of the thermoplastic resin constituting the above-mentioned other thermoplastic resin layer include a polycarbonate resin, a polyethylene terephthalate resin, a polyamide resin, a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyvinyl chloride resin, and the like. (Meta) acrylic resin, ABS (acrylonitrile-butadiene-styrene copolymer), ethylene vinyl alcohol resin, polyvinyl butyral resin, polyvinyl acetal resin, styrene thermoplastic elastomer, olefin thermoplastic elastomer, acrylic heat Examples include plastic elastomers. When the resin film is a laminated film in which other layers such as another thermoplastic resin layer are laminated, the glass transition temperature of at least one layer may be within the above range.

The thickness of the resin film is preferably 10 to 500 μm, more preferably 20 to 300 μm, still more preferably 30 to 250 μm, and even more preferably 50 to 100 μm.

(Use)
The use of the cut resin film obtained by the cutting method of the present invention is not particularly limited, and for example, vehicle decorative parts such as vehicle exteriors and vehicle interiors; building materials such as wall materials, window films, window frames, and bathroom wall materials. Parts; Daily miscellaneous goods such as tableware, toys, musical instruments; Home appliance decoration parts such as vacuum cleaner housing, television housing, air conditioner housing; Interior parts such as kitchen door covering materials; Ship parts; Touch panel covering materials, personal computer housings, mobile phones Electronic communication devices such as telephone housings; optical components such as liquid crystal protective plates, light guide plates, light guide films, polarizing element protective films, polarizing plate protective films, retardation films, front plates and surface materials of various displays, and diffuser plates; Examples thereof include solar power generation members such as solar cells or panel surface materials for solar power generation.

Above all, it is suitable for optical applications such as members used for display devices such as liquid crystal display devices, for example, a polarizing element protective film, a polarizing plate protective film, a retardation film, a brightness improving film, a liquid crystal substrate, a light diffusion sheet, and a prism sheet. It can be used, and in particular, it can be more preferably used by a polarizing element protective film or a retardation film.

Further, the cut resin film obtained by the cutting method of the present invention can be suitably used for decoration applications such as metallic decoration. The decoration method is not particularly limited, and a known method can be adopted.

Hereinafter, the present invention will be specifically described with reference to Examples, but the present invention is not limited to these Examples. Each evaluation method of the resin film cutting method adopted in the following Examples and Comparative Examples is shown below.

[Glass-transition temperature]
The resin constituting the resin film is heated to 230 ° C. using a differential scanning calorimeter according to JIS K 7121, then cooled to room temperature, and then raised from room temperature to 230 ° C. at 10 ° C./min. The midpoint glass transition temperature obtained by the differential scanning calorimetry at the time of the second temperature rise when the temperature was raised was adopted. When the resin has multiple glass transition temperatures, the highest glass transition temperature value was adopted.

[Cut stability]
The stability when continuously cutting a resin film having a length of 3000 m was evaluated as follows. If it is B or higher according to the following evaluation criteria, it can be put into practical use.
A: The length of each uncut portion is less than 1 m.
B: The length of each uncut portion is 1 to 500 m.
C: The length of each uncut portion is over 500 m.

[Chip]
Five points were arbitrarily selected from the cut surface of the cut resin film, observed with a laser microscope (LEXT OLS4100 manufactured by Olympus Corporation) at a magnification of 50 times, and evaluated as follows. If it is B or higher according to the following evaluation criteria, it can be put into practical use.
A: There is a chip at the position below 1 point.
B: There is a chip at the position of 2 to 3 points.
C: There is a chip at the position of 4 to 5 points.

[Chips]
The cut resin film was cut out by 1 m in the flow direction, irradiated with an electric lamp (LED LENDSER M-17R) from the thickness direction of the resin film, and the vicinity of the cut portion of the resin film was observed. In the flow direction of the resin film, the spacing between the positions where the chips were observed together was evaluated as follows. If it is B or higher according to the following evaluation criteria, it can be put into practical use.
A: There is no clumped chips, or there is only one place.
B: There are two or more collected chips, and the smallest of the intervals is more than 10 cm.
C: There are two or more collected chips, and the smallest of the intervals is 10 cm or less.

[Manufacturing example]
80 parts by mass of a methacrylic polymer (weight average molecular weight 30,000) obtained by referring to Synthesis Example 4 of International Publication No. 2016/121868, and a three-layer structure (meth) obtained by referring to Synthesis Example 8 of the same publication. ) 20 parts by mass of acrylic elastic particles were mixed with a Henshell mixer to obtain pellets of a thermoplastic resin composition using a twin-screw extruder with a vent having a screw diameter of 75 mm set at 260 ° C. The pellets are supplied to the hopper of a single-screw extruder with a vent, melt-kneaded at 260 ° C., passed through a gear pump, a filter device, and a static mixer in this order, and discharged in the form of a film from a T-die with a lip opening of 1 mm. A metal elastic roll having a mirror surface and a surface temperature of 90 ° C. and a metal rigid body roll are sandwiched and cooled without a bank to prepare an acrylic resin film made of a methacrylic resin and having a thickness of 80 μm and a width of 1400 mm. , Rolled into a film roll. The glass transition temperature of the obtained acrylic resin film was 117 ° C.

The upper and lower blades used are described below.
Upper blade: round blade, Goebel type, diameter 98 mm, single blade, made of cemented carbide Steel Lower blade: round blade, Goebel type, diameter 150 mm, single blade, made of cemented carbide steel

[Example 1]
The acrylic resin film obtained in the production example was unwound from the film roll and conveyed at a speed of 30 m / min. The upper blade is arranged on the upper surface side of the acrylic resin film so as to sandwich the acrylic resin film being transported and parallel to the transport direction of the acrylic resin film, and the lower blade is further placed on the lower surface side of the acrylic resin film. After arranging, the positions 10 mm from both ends of the acrylic resin film were cut. At this time, the meshing amount of the upper blade and the lower blade is 0.05 mm, the pushing amount of the upper blade to the lower blade side is 0.10 mm, the tension of the acrylic resin film at the time of cutting is 120 N / m, and the lower blade The ratio of the peripheral speed of the upper blade to the peripheral speed was 1.0, and the holding angle between the acrylic resin film and the lower blade was 70 degrees. The evaluation results are shown in Table 1.

[Examples 2 to 11 and Comparative Examples 1 to 8]
In Example 1, the amount of engagement between the upper blade and the lower blade, the amount of pushing the upper blade toward the lower blade side, the tension of the acrylic resin film, and the thickness of the acrylic resin film were changed as shown in Table 1. The acrylic resin film was cut in the same manner as in Example 1. The evaluation results are shown in Table 1.

In Examples 1 to 11, the amount of engagement between the upper blade and the lower blade is 0.02 to 0.60 mm, and the amount of pushing the upper blade toward the lower blade side is 0.05 to 0, as compared with Comparative Examples 1 to 7. Since it was .35 mm and the tension of the acrylic resin film was 30 to 300 N / m, the cutting stability was excellent and chipping and chips could be reduced.
In Comparative Example 1, the acrylic resin film could not be cut because the pushing amount of the upper blade to the lower blade side was less than 0.05 mm.
In Comparative Example 2, since the pushing amount of the upper blade to the lower blade side was more than 0.35 mm, stable and continuous cutting was not possible, and many chips were observed.
In Comparative Example 3, the acrylic resin film could not be cut because the pushing amount of the upper blade to the lower blade side was less than 0.05 mm.
In Comparative Example 4, since the pushing amount of the upper blade to the lower blade side was more than 0.35 mm, the cutting was stable, but many chips and chips were observed.
In Comparative Example 5, since the tension of the acrylic resin film at the time of cutting was less than 30 N, many chips were observed.
In Comparative Example 6, the acrylic resin film could not be cut because the pushing amount of the upper blade to the lower blade side was less than 0.05 mm.
In Comparative Example 7, since the pushing amount of the upper blade to the lower blade side was less than 0.05 mm, stable and continuous cutting could not be performed.
In Comparative Example 8, since the pushing amount of the upper blade to the lower blade side was more than 0.35 mm, the cutting was stable, but many chips were observed.

1 Upper blade 2 Lower blade 3 Resin film 3a Cut resin film P Upper blade shaft L Engagement amount between upper blade and lower blade θ Holding angle between resin film and lower blade

Claims (10)

A method for cutting a resin film that cuts a thermoplastic resin film having a glass transition temperature of 90 ° C. or higher. A cutting device having at least a pair of upper and lower blades is used, and the upper blade and the lower blade are round blades. The cross section of the upper blade has a curved shape, the amount of pushing from the concave surface side of the upper blade to the lower blade side is 0.05 to 0.35 mm, and the tension of the resin film is 30 to 300 N / m. , How to cut. You regulated by the upper edge of the push-in amount of the pressing dimension adjustment mechanism, the cutting method according to claim 1. The cutting method according to claim 2, wherein the thermoplastic resin constituting the thermoplastic resin film is a (meth) acrylic resin. The cutting method according to claim 3, wherein the (meth) acrylic resin is a composition containing a hard methacrylic resin and an elastomer. The cutting method according to claim 4, wherein the elastomer is a (meth) acrylic elastomer. The cutting method according to any one of claims 1 to 5, wherein the amount of engagement between the upper blade and the lower blade is 0.02 to 0.60 mm. The cutting method according to any one of claims 1 to 6, wherein the ratio of the peripheral speed of the upper blade to the peripheral speed of the lower blade is more than 0.8 and less than 1.2. The cutting according to any one of claims 1 to 7, wherein the material constituting the upper blade and the lower blade is high-speed tool steel, alloy tool steel, carbon tool steel, stainless steel, or cemented carbide steel. Method. The cutting method according to any one of claims 1 to 8, wherein the holding angle between the resin film and the lower blade is 10 to 150 degrees. The cutting method according to any one of claims 1 to 9, wherein the resin film has a thickness of 10 to 500 μm.

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