KR101933218B1 - Method for producing film or resin plate with protective layer - Google Patents

Abstract

(PROBLEMS) To provide a method for manufacturing a resin plate or film in which a protective film is formed that does not cause defective adhesion of a protective film or breakage of a resin plate in a process of bonding a protective film.
A process for producing a resin plate (6) or a film by melt-kneading a thermoplastic resin with an extruder (1, 2), extruding it from a die (3) ) Or a film and a protective film 7 are superposed and supplied between a pair of protective film bonding rolls 81 and 82 to thereby adhere the protective film 7 to at least one surface of the resin plate 6 or the film At least one of the protective film fusing rolls 81 and 82 is provided with a non-contact portion 10 formed at both end portions of the protective film fusing rolls 81 and 82 and a non- And the distance from the rotation center axis of the protective film bonding rolls 81 and 82 to the surface of the non-contact portion is the distance from the rotation center axis of the protective film bonding rolls 81 and 82 to the surface of the contact portion (9) having a protective film formed thereon, ≪ / RTI >

Description

TECHNICAL FIELD [0001] The present invention relates to a method for producing a protective film,

The present invention relates to a method for producing a resin plate or film on which a protective film is formed.

The extruded resin plate or film made of a thermoplastic resin is used in a wide range such as interior or exterior of an automobile, exterior of a household electric appliance, optical use such as a liquid crystal television or a monitor. Generally, an extruded resin plate or film is formed by putting a plate-shaped or film-shaped molten thermoplastic resin extruded from a die between a first roll and a second roll, winding the same on a second roll, And wound up by a take-up roll to form a roll.

Patent Document 1 discloses a manufacturing method in which a resin sheet is not broken well in a process of producing a resin sheet such as an acrylic resin. In this method, in producing an extruded resin sheet in which a sheet-shaped molten thermoplastic resin extruded from a die is sandwiched between a first roll and a second roll and rolled around a second roll to form an extruded resin sheet, both ends of the second roll And the outer circumferential surface of the resin sheet has an outer diameter smaller than the outer diameter of the roll central portion. When the resin sheet is sandwiched between the first roll and the second roll, the resin sheet is sandwiched between the step and the first roll Thereby forming and molding.

The extruded resin plate or film (hereinafter sometimes simply referred to as " resin plate ") produced in this way may be further laminated with a protective film on the surface thereof depending on the application.

When a protective film is to be adhered to both sides or one side of a resin plate, a pair of protective film bonding rolls are usually used, and a protective film is adhered to the resin plate between these rolls. However, since the end portions of the resin plate and the protective film are unstable, if they are passed between the protective film bonding rolls, lifting may occur at the end portion of the protective film or wrinkles may occur in the protective film, resulting in breakage of the resin plate. Particularly, when the thickness of the resin plate is small and the resin plate is easily broken, when the protective film is wrinkled, a thickness distribution is generated in the width direction when the resin plate is sandwiched between the take-up rolls for transporting, So that cracks are liable to occur.

Japanese Patent Application Laid-Open No. 2009-149038

It is an object of the present invention to provide a method for manufacturing a resin plate in which a protective film is formed without causing defective bonding of a protective film or breakage of the resin plate in the process of bonding the protective film.

As a result of intensive investigations to solve the above problems, the present inventors have found that, in the step of adhering a protective film, the non-contact portions are formed at both ends of the outer circumferential surface of at least one of the protective film- And no breakage or breakage of the resin plate occurs. Thus, the present invention has been completed.

That is, the present invention has the following configuration.

(1) a step of melt-kneading a thermoplastic resin with an extruder, extruding the kneaded material from a die, cooling the material with a cooling roll to obtain a resin plate or film, and supplying the resin plate or film and a protective film between a pair of protective film- And a step of bonding the protective film to at least one surface of the resin plate or the film, wherein at least one protective film kneading roll is formed on both ends of the protective film kneading roll And a contact portion formed between the non-contact portion and the non-contact portion,

Wherein the distance from the rotation center axis of the protective film-bonding roll to the surface of the non-contact portion is smaller than the distance from the rotation center axis of the protective film-bonding roll to the surface of the contact portion.

(2) The protective film according to (1), wherein the non-contact portion is a slope formed so that a distance from a rotation center axis of the protective film-bonding roll to a surface of the non-contact portion decreases from an end portion of the contact portion toward both end portions of the protective film- A method for producing a resin plate or film.

(3) A method for producing a resin plate or a film, wherein the protective film described in (1) is discontinuously changed between the contact portion and the non-contact portion, the distance from the rotation center axis of the protective film bonding roll to the outer peripheral surface of the protective film-

(4) The production method according to (1), wherein the height difference in the radial direction of the protective film-bonding roll of the non-contact portion is 20 m to 3 mm.

(5) The production method according to any one of (1) to (4), wherein the thermoplastic resin is a polycarbonate resin or a methacrylic resin.

(6) The production method according to any one of (1) to (5), wherein the resin plate or the film has a thickness of 20 to 1500 μm.

According to the method for producing a resin plate or film with a protective film of the present invention, at least one of the pair of protective film fusing rolls, at least one of the protective film fusing rolls has a distance from the rotational center axis of the protective film- Since the edge of the resin plate or the film is not sandwiched by the protective film-bonding rolls, it is possible to prevent the adherence of the protective film (poor bonding) or wrinkles , Breakage of the resin plate, and the like do not occur.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic explanatory view showing a method of manufacturing a resin plate in which a protective film is formed according to an embodiment of the present invention. FIG.
Fig. 2 is a schematic cross-sectional view showing the protective film bonding step seen from the direction of arrow I in Fig.
3 is a front view showing another example of the protective film bonding roll used in the production method of the present invention.

A method of manufacturing a resin plate with a protective film of the present invention,

(A) a step (extrusion molding step) of melt-kneading a thermoplastic resin with extruders 1 and 2, extruding the mixture from the die 3, cooling the mixture with at least three cooling rolls to obtain a resin plate 6 or a film,

(B) A resin plate 6 or a film and a protective film 7 are stacked and fed between a pair of protective film fusing rolls 81 and 82 to form a protective film 7 on at least one surface of the resin plate 6 or the film, And at least one protective film fusing rolls 81 and 82 are provided between the non-contact portions 10 formed at both ends of the protective film fusing rolls 81 and 82 and between the non-contact portions 10 And the distance from the center axis of rotation of the protective film bonding rolls 81 and 82 to the surface of the non-contact portion 10 is smaller than the distance from the center of rotation of the protective film bonding rolls 81 and 82 to the contact portion 12, Is smaller than the distance to the surface of the substrate. Therefore, when the protective film 7 is placed on the resin plate 6 or the film by disposing the resin plate 6 or the both ends of the film so as to be positioned on the non-contact portion 10, The protective film bonding rolls 81 and 82 are not in contact with the resin plate 6 or the film on which the protective film 7 is formed.

In the manufacturing method of the present invention, the resin plate 6 or the non-contact portion 10 which is not in contact with the both end portions of the film is formed at both end portions of the outer peripheral surface of at least one of the protective film bonding rolls 81 and 82. This point will be described with reference to Fig.

Fig. 2 is a schematic view of the protective film binding roller 81 of Fig. 1 viewed from the direction of the arrow I. Fig.

As shown in Fig. 2, the protective film bonding roll 81 has a non-contact portion 10 formed on its end portion 811 by circumferentially circumferential surfaces. The non-contact portion 10 is formed by forming an inclined surface at the end portion 811 of the outer circumferential surface of the protective film bonding roll 81. The distance from the rotation center axis of the protective film bonding roll 81 to the surface of the non- (The distance from the center axis of rotation of the protective film-bonding roll 81 to the surface of the contact portion 12) of the central portion of the fusing roll 81 is smaller than the outer diameter. Here, the rotation center axis means an axis parallel to the longitudinal direction of the columnar body (protective film fusion rolls 81 and 82), and passing through the center of the circle on the cross section perpendicular to the axis. The central portion means the central portion of the cylindrical body in the rotation center axis direction.

Since the end portion 61 of the resin plate 6 is not sandwiched by the protective film bonding rolls 81 and 82 by having the protective film bonding roll 81 having such a noncontact portion 10, The protective film 7 is not pressed by the protective film bonding rolls 81 and 82 at the end 61 of the resin plate 6 which is difficult to be bonded and the resin plate 6 is not broken due to unfavorable bonding.

In the radial direction of the protective film bonding roll 81 in the non-contact portion 10 in at least one protective film bonding roll (the protective film bonding roll 81 in FIGS. 1 and 2) among the pair of protective film bonding rolls 81 and 82 The height difference A of the resin plate 6 may be a size that does not allow the end portion 61 of the resin plate 6 to be sandwiched therebetween and is preferably 20 占 퐉 to 3 mm and more preferably 50 占 퐉 to 2 mm. The height difference A in the outer diameter direction of the protective film bonding roll 81 in the noncontact portion 10 is a value obtained by dividing the outer peripheral surface of the non-contact portion 10 in the cross section passing through the noncontact portion 10 including the center axis of rotation of the protective film- The distance from the rotation central axis in the rotation center axis direction of the protective film composite roll 81 to the outer peripheral surface of the protective film composite roll 81 and the minimum distance from the rotation center axis to the surface constituting the non- .

When the height difference A of the non-contact portion 10 is less than 20 占 퐉, since the non-contact portion 10 is too small, the end portion of the resin plate may also be caught in the protective film bonding roll. On the other hand, if the height difference A of the non-contact portion 10 exceeds 3 mm, there is a fear that the end portion will wave like a wave and the feeding of the resin plate will become unstable.

2, the non-contact portion 10 is formed so that the end portion 811 of the protective film bonding roll 81 is inclined gently. The non-contact portion 10 is not limited to this shape, and the protective film bonding roll 81 May be any shape as long as it does not press the resin plate 6 or both ends of the film. For example, it may be formed in a stepped shape like the non-contact portion 11 shown in Fig. The non-contact portion 11 has the elevation difference A 'and the elevation difference A' is the same as the elevation difference A of the non-contact portion 10.

Each step will be described in detail below.

(A) Extrusion molding process

In the extrusion molding step, the thermoplastic resin is first melted and kneaded by an extruder. The thermoplastic resin is not particularly limited as long as it is a melt-processable resin. Examples of the thermoplastic resin include a polyvinyl chloride resin, an acrylonitrile-butadiene-styrene resin, a low density polyethylene resin, a high density polyethylene resin, a linear low density polyethylene resin, a polystyrene resin, Acrylonitrile-styrene resin, acrylic-chlorinated polyethylene resin, ethylene-vinyl alcohol resin, fluororesin, methacrylic resin, poly-acrylonitrile-styrene resin, cellulose acetate resin, A polyamide resin, a polyamide resin, a polyethylene terephthalate resin, a polycarbonate resin, a polysulfone resin, a polyether sulfone resin, a methylpentene resin, a polyarylate resin, a polybutylene terephthalate resin and an ethylenically unsaturated monomer unit containing an alicyclic structure Containing resin, poly Polyvinyl chloride elastomer, chlorinated polyethylene, ethylene-ethyl acrylate resin, thermoplastic polyurethane elastomer, thermoplastic polyester elastomer, acrylonitrile-butadiene-styrene copolymer resin, A styrene-butadiene block polymer, an ethylene-propylene rubber, a polybutadiene resin, and an acrylic rubber, and they may be used alone or in combination of two or more.

Among them, at least one resin selected from a polycarbonate resin, a methacrylic resin, a styrene resin, and a resin containing an ethylenic unsaturated monomer unit containing an alicyclic structure is preferable from the standpoint of good optical characteristics, and a polycarbonate resin and a methacrylic resin Is more preferable. The thermoplastic resin may be constituted by laminating at least two kinds of thermoplastic resins. That is, in the present invention, two or more thermoplastic resins may be melt-kneaded and co-extruded using two or more extruders to form a laminated structure having two or more thermoplastic resin layers. In this case, the thermoplastic resin constituting each of the thermoplastic resin layers to be laminated is at least one selected from a resin containing a polycarbonate resin, a methacrylic resin, a styrene-based resin, and an ethylenic unsaturated monomer unit containing an alicyclic structure desirable.

The polycarbonate resin is obtained by reacting a divalent phenol and a carbonate precursor with an interfacial polycondensation method or a melt transesterification method. In addition, a polycarbonate resin obtained by polymerizing a carbonate prepolymer by a solid-phase ester exchange method, or a cyclic carbonate compound by a ring- And the like.

Examples of the dihydric phenol include hydroquinone, resorcinol, 4,4'-dihydroxydiphenyl, bis (4-hydroxyphenyl) methane, bis {(4- ) Phenyl) methane, 1,1-bis (4-hydroxyphenyl) ethane, 1,1-bis (4-hydroxyphenyl) (Bisphenol A), 2,2-bis {(4-hydroxy-3-methyl) phenyl} propane, 2,2- Bis {(3-isopropyl-4-hydroxy) phenyl} propane, 2,2-bis {(4-hydroxy-3,5-dibromo) phenyl} propane, (4-hydroxyphenyl) -3-methylbutane, 2,2-bis (4-hydroxyphenyl) (4-hydroxyphenyl) -3,3-dimethylbutane, 2,4-bis (4-hydroxyphenyl) -2-methylbutane, 2,2- Bis (4-hydroxyphenyl) -4-methylpentane, 1,1-bis (4-hydroxy Bis (4-hydroxyphenyl) -3,3,5-trimethylcyclohexane, 9,10-bis (4-hydroxyphenyl) -4-isopropylcyclohexane, (4-hydroxyphenyl) fluorene, 9,9-bis {(4-hydroxy-3-methyl) phenyl} fluorene, Diisopropylbenzene,?,? '-Bis (4-hydroxyphenyl) -m-diisopropylbenzene,?,?' Bis (4-hydroxyphenyl) -5,7-dimethyladamantane, 4,4'-dihydroxydiphenyl sulfone, 4,4'-dihydroxydiphenyl sulfoxide, 4,4'-di 4,4'-dihydroxydiphenyl ketone, 4,4'-dihydroxydiphenyl ether, and 4,4'-dihydroxyphenyl ester. These may be used alone or in combination of two or more thereof. Or a mixture of two or more of them may be used.

Among them, bisphenol A, 2,2-bis {(4-hydroxy-3-methyl) phenyl} propane, 2,2- Bis (4-hydroxyphenyl) -3-methylbutane, 2,2-bis (4-hydroxyphenyl) (4-hydroxyphenyl) -3,3,5-trimethylcyclohexane and?,? '-Bis (4-hydroxyphenyl) -m-diisopropylbenzene, which are obtained from at least one bisphenol selected from the group consisting of Homopolymers of bisphenol A and copolymers of bisphenol A and 2,2-bis (4-hydroxyphenyl) -3,3,5-trimethylcyclohexane with bisphenol A, (4-hydroxy-3-methyl) phenyl} propane and at least one bivalent phenol selected from?,? '-Bis (4-hydroxyphenyl) -m-diisopropylbenzene Do.

As the carbonate precursor, for example, a carbonyl halide, a carbonate ester, or a haloformate may be used, and specific examples thereof include phthalo, diphenyl carbonate or dihaloformate of a dihydric phenol.

The methacrylic resin is a polymer containing 50% by weight or more of methyl methacrylate as a monomer unit. The content of the methyl methacrylate unit 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 other monomers copolymerizable with the methyl methacrylate. Examples of other monomers copolymerizable with methyl methacrylate include methacrylic acid esters other than methyl methacrylate. Examples of such methacrylic acid esters include ethyl methacrylate, butyl methacrylate, cyclohexyl methacrylate, phenyl methacrylate, benzyl methacrylate, 2-ethylhexyl methacrylate, methacrylic acid 2 -Hydroxyethyl, and the like. Examples of the acrylic acid esters such as methyl acrylate, ethyl acrylate, butyl acrylate, cyclohexyl acrylate, phenyl acrylate, benzyl acrylate, 2-ethylhexyl acrylate and 2-hydroxyethyl acrylate; unsaturated acids such as methacrylic acid and acrylic acid; Halogenated styrenes such as styrene and bromostyrene, substituted styrenes such as vinyltoluene and alkylstyrenes such as? -Methylstyrene, acrylonitrile, methacrylonitrile, maleic anhydride, phenylmaleimide, cyclohexylmaleimide And so on. These monomers may be used alone or in combination of two or more.

The methacrylic resin may be a resin composition obtained by adding a rubber-like polymer. This makes it possible to improve the yield since it is not easily broken at the time of molding. Examples of the rubber-like polymer include an acrylic multi-layer structured polymer, a graft copolymer obtained by graft-polymerizing an ethylenically unsaturated monomer at a ratio of 95 to 20 parts by weight to a rubber-like polymer of 5 to 80 parts by weight, and the like.

Examples of the acrylic multi-layer structure polymer include a rubber elastic layer or a layer of an elastomer at a ratio of 20 to 60 parts by weight, and having a hard layer at the outermost layer. Even if the innermost layer further has a hard layer do.

The rubber-elastic layer or layer of elastomer is a layer of an acrylic polymer having a glass transition point (Tg) of less than 25 占 폚, for example a lower alkyl acrylate and methacrylate, a lower alkoxy acrylate, a cyanoethyl acrylate, Amide, hydroxy lower alkyl acrylate, hydroxy lower methacrylate, acrylic acid, methacrylic acid, etc., with allyl methacrylate, polyfunctional monomer, or the like.

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

Graft copolymers obtained by graft-polymerizing 5 to 80 parts by weight of a rubber-like polymer at a ratio of 95 to 20 parts by weight of an ethylenically unsaturated monomer, wherein the rubber-like polymer includes, for example, polybutadiene rubber, acrylonitrile / butadiene rubber Polybutyl acrylate, polypropyl acrylate, and acrylic rubber such as poly-2-ethylhexyl acrylate, and ethylene / propylene / non-conjugated diene rubber, and the like, . Examples of the ethylenic monomer include styrene, acrylonitrile, and alkyl (meth) acrylate. Acrylic unsaturated monomers are preferred, and they may be used singly or in combination of two or more . As the graft copolymer described above, for example, those described in JP-A-55-147514 and JP-A-47-9740 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, based on 100 parts by weight of the methyl methacrylate resin. If the addition amount of the rubber-like polymer is too large, the rigidity of the pressure-pressing becomes low, which is not preferable.

The styrene-based resin is a polymer containing a styrene monofunctional monomer unit as a main component, 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 a copolymer of a styrene monofunctional monomer and a monofunctional monomer copolymerizable therewith.

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; alkylstyrenes such as vinyltoluene and? -Methylstyrene; and the like. That is, the styrene monofunctional monomer is a compound having a styrene skeleton and having one radically polymerizable double bond in the molecule.

The monofunctional monomer copolymerizable with the styrene monofunctional monomer is a compound which has one radically polymerizable double bond in the molecule and can be copolymerized with the styrene monofunctional monomer as the double bond, and examples thereof include methyl methacrylate, methacryl Methacrylic acid esters such as methyl ethyl, butyl methacrylate, cyclohexyl methacrylate, phenyl methacrylate, benzyl methacrylate, 2-ethylhexyl methacrylate, and 2-hydroxyethyl methacrylate, methyl acrylate Acrylic acid esters such as ethyl acrylate, butyl acrylate, cyclohexyl acrylate, phenyl acrylate, benzyl acrylate, 2-ethylhexyl acrylate and 2-hydroxyethyl acrylate, acrylonitrile and the like, Methacrylic acid esters are preferably used, and they may be used alone or in combination of two or more.

The styrene resin may be a resin composition obtained by adding a rubber-like polymer. As the rubber-like polymer, the same rubber-like 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, based on 100 parts by weight of the styrene-based resin. If the amount of the rubber-like polymer to be added is too large, the rigidity of the pressure-pressing is lowered, which is not preferable.

Examples of the resin containing an alicyclic structure-containing ethylenic unsaturated monomer unit include a norbornene polymer, a vinyl alicyclic hydrocarbon polymer, and the like. The resin is characterized by containing an alicyclic structure in the repeating unit of the polymer. The alicyclic structure may be present in any of the main chain and / or the side chain, and it is preferable that the alicyclic structure contains an alicyclic structure in the main chain from the viewpoint of light transmittance.

Specific examples of the resin containing the alicyclic structure-containing ethylenic unsaturated monomer unit include a norbornene polymer, a monocyclic olefin polymer, a cyclic conjugated diene polymer, a vinyl alicyclic hydrocarbon polymer, and hydrogenated products thereof And the like. Among them, a norbornene polymer hydrogenated product, a vinyl alicyclic hydrocarbon polymer or a hydrogenated product thereof is preferable from the viewpoint of light transmittance, and a norbornene polymer hydrogenated product is more preferable.

The thermoplastic resin may be added with a light diffusing agent, a gloss removing agent, an ultraviolet absorber, a surfactant, an impact resistance agent, a high molecular weight antistatic agent, an antioxidant, a flame retardant, a lubricant, a dye and a pigment depending on the purpose.

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

The molten resin melt-kneaded by the extruder is extruded from a die, cooled with at least three cooling rolls, and molded into a resin plate or a film. Will be described in detail with reference to Fig.

BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is a schematic explanatory view showing a method of manufacturing a resin plate in which a protective film according to an embodiment of the present invention is formed; FIG. As shown in Fig. 1, a thermoplastic resin is placed in an extruder (1, 2), and melt kneading is carried out as described above. Although two extruders are used in Fig. 1, the number of extruders may be one, or three or more, and the number of extruders may be suitably changed according to the number of laminated resin layers and the type of resin to be used.

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

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 typically used. For example, in the case of extruding a thermoplastic resin into a single layer, a single-layer die or the like other than a T-die is also used. When two or more thermoplastic resins are laminated and pneumatically delivered, a multilayered die such as a feed block die or a multi- do.

The molten resin 4 extruded from the die 3 is molded and cooled in 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 cooling roll is preferably 3 to 5 rolls.

In Fig. 1, the cooling unit 5 has three cooling rolls 51, 52 and 53 arranged substantially in the horizontal direction. The cooling rolls 51, 52 and 53 are the first cooling roll 51, the second cooling roll 52 and the rear cooling roll 53 in this order along the direction in which the molten resin 4 is picked up. These cooling rolls 51, 52, and 53 are configured such that at least one roll is connected to a rotation drive means such as a motor, and each roll is rotated at a predetermined peripheral velocity.

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

The surface temperature Tr of the cooling rolls 51, 52 and 53 is preferably (Th-20 占 폚)? Tr? (Th + 20 占 폚) with respect to the heat distortion temperature Th of the thermoplastic resin, (Th-15 占 폚)? Tr? (Th + 10 占 폚), and more preferably (Th-10 占 폚)? Tr? Th + 5 占 폚. When the surface temperature Tr is lower than (Th-20 占 폚), the resin tends to peel off from the roll, and a touch mist tends to easily occur. When the surface temperature Tr is higher than (Th + 20 占 폚), the resin is not uniformly peeled off from the roll, and a line in the width direction due to the impact at the peeling of the roll, have.

The heat distortion temperature (Th) of the thermoplastic resin is not particularly limited, but is usually about 60 to 200 占 폚. The thermal deformation temperature (Th) of the thermoplastic resin is a temperature measured in accordance with ASTM D-648. As for the surface temperature Tr when two or more kinds of thermoplastic resins are co-extruded by co-extrusion to form a laminated structure, a thermoplastic resin having the highest thermal deformation temperature (Th) among two or more different thermoplastic resins As a reference.

The molten resin 4 is thus cooled in 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 占 퐉, more preferably 30 to 1000 占 퐉. The resin plate 6 is supplied to the following bonding process.

(B)

In the bonding step, the resin plate obtained in the above extrusion forming step is supplied between the pair of protective film bonding rolls, and a 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. 1 to 3. Fig.

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

The resin plate 6 supplied between the protective film bonding rolls 81 and 82 is bonded to the protective film 7 to be supplied at the same time to obtain the resin plate 9 on which the protective film is formed. 1, the protection film 7 is applied only to one side of the resin plate 6. However, if the protection film is also supplied from the side of the protection film bonding roll 82, (7).

As the protective film 7 used in the manufacturing method of the present invention, for example, a thin film made of a resin in which an adhesive layer is formed on polyethylene, polypropylene, polyethylene terephthalate or nylon, a metal such as ITO, tin or aluminum, A thin film deposited on a resin plate, and the like. The thickness of the protective film 7 is not particularly limited, but is preferably 20 to 100 占 퐉, more preferably 30 to 70 占 퐉.

The protective film 7 is attached to the resin plate 6 by, for example, supplying the heated protective film 7 and the resin plate 6 between the protective film bonding rolls 81 and 82, Way ; A method of laminating the protective film 7 and the resin plate 6 with an adhesive interposed therebetween and pressing them with the protective film bonding rolls 81 and 82 to give a bonding. When the protective film 7 can be peeled off, it may simply be laminated with the resin plate 6. In the present invention, the term " bonding " also includes such merely laminated aspects.

The resin plate provided with the protective film obtained by the manufacturing method of the present invention is used in a very wide range such as interior or exterior of automobiles, exterior of household electric appliances, optical use such as liquid crystal television and monitor.

Example

Hereinafter, the present invention will be specifically described with reference to examples and comparative examples, but the present invention is not limited to these examples.

The configuration of the extrusion apparatus used in the examples and the comparative examples is as follows.

Extruder (1): An extruder with a screw diameter of 130 mm, uniaxial, vent formed (manufactured by Hitachi, Ltd.).

Extruder (2): An extruder (manufactured by Hitachi, Ltd.) having a screw diameter of 50 mm and a uniaxial bent.

Dye (I): T die (resin outlet port width 1650 mm, lip interval 1 mm (manufactured by Hitachi, Ltd.)) and feed block (resin outlet port width 150 mm, ).

Dye (II): T die (resin outlet port width 1650 mm, lip interval 1 mm (Hitachi Shipbuilding Co., Ltd.)) and feed block (resin outlet port width 150 mm, ).

Cooling unit: Three horizontal rolls, 1800 mm in surface length and 350 mmφ in diameter.

Resins used in Examples and Comparative Examples are as follows.

Polycarbonate resin 1 (PC1): "Caliba 301-10" manufactured by Sumitomo Dairy Company.

Polycarbonate Resin 2 (PC2): 0.38 wt% of benzotriazole based UVA (Tinuvin 360) was added to 100 wt% of "Caliba 301-10" to "Caliba 301-10" manufactured by Sumitomo DOW Co., One Resin.

Methacrylic resin 1 (PMMA1): Copolymer of methyl methacrylate / methyl acrylate = 94/6 (by mass ratio).

Methacrylic resin 2 (PMMA2): copolymer of methyl methacrylate / methyl acrylate = 98/2 (by mass ratio).

(Examples 1 to 12 and Comparative Examples 1 to 3)

The resins shown in Table 1 were melted and kneaded in a first extruder and a second extruder, respectively, and fed to a feed block having a T die, to perform co-extrusion molding.

Subsequently, the extruded molten resin was formed in a cooling unit having three cooling rolls to obtain two layers (Examples 6, 7 and Comparative Example 3) or three layers (Example 6 , 7, and Comparative Example 3).

The resulting resin plate was sandwiched with a protective film between a pair of protective film-bonding rolls each having a non-contact portion of 1.5 mm formed on one end of the roll, and one side of the resin plate (Examples 1 to 4 and 6, Comparative Examples 1 and 2) (Sunnyite PAC2A-30T, manufactured by Sun A Kaken Co., Ltd., polyethylene film, thickness 30 占 퐉) on both sides (Examples 5, 7 to 12 and Comparative Example 3) ).

Each of the resin plates having the protective film thus formed was produced, and the state of the resin plate on which the protective film was formed was visually observed. The results are shown in Table 1.

As shown in Table 1, in the resin plates on which the protective films of Examples 1 to 12 were formed, there were no problems such as poor adhesion of the protective film and breakage of the resin plate. On the other hand, in the resin plate in which the protective film was formed in Comparative Examples 1 to 3 in which the noncontact portion was not formed on the protective film bonding roll, the end portion of the protective film did not adhere to the resin plate and was lifted (Comparative Example 1) And the plates were broken (Comparative Examples 2 and 3).

1, 2 ... Extruder
3 ... die
4 … Molten resin
5 ... Cooling unit
51, 52, 53 ... Cooling roll
6 ... Resin plate
61 ... End of resin plate
7 ... Shield
81, 82 ... Shield film fusion roll
811 ... The end of the protective film bonding roll
9 ... Resin plate with protective film
10, 11 ... Noncontact portion
12 ... Contact
A, A '... Height difference of non-contact part

Claims (12)

A step of 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 a film,
A resin plate or a protective film formed thereon, and a step of supplying the resin plate or film and a protective film between a pair of protective film bonding rolls to peelably adhere the protective film to at least one surface of the resin plate or film, A method for producing a film,
The at least one protective film-bonding roll has a non-contact portion formed at both ends of the protective film-bonding roll and a contact portion formed between the non-contact portion and the non-
The distance from the rotation center axis of the protective film composite roll to the surface of the non-contact portion is smaller than the distance from the rotation center axis of the protective film composite roll to the surface of the contact portion,
Both ends of the resin plate or film are located in the non-contact portion,
The height difference in the radial direction of the protective film-bonding roll of the non-contact portion is such that the end portion of the resin plate or film is not fitted,
Wherein the thermoplastic resin is a polycarbonate resin or a methacrylic resin,
Wherein the resin plate or film has a thickness of 20 to 1500 占 퐉. The method according to claim 1,
Wherein a height difference in the radial direction of the protective film-bonding roll of the non-contact portion is 20 mu m to 3 mm. A step of 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 a film,
A protective film which is a thin film formed of a resin film or a film and a pressure-sensitive adhesive layer comprising a resin is superposed and supplied between a pair of protective film bonding rolls to peelably adhere the protective film to at least one surface of the resin film or film A method for producing a resin plate or film having a protective film,
The at least one protective film-bonding roll has a non-contact portion formed at both ends of the protective film-bonding roll and a contact portion formed between the non-contact portion and the non-
The distance from the rotation center axis of the protective film composite roll to the surface of the non-contact portion is smaller than the distance from the rotation center axis of the protective film composite roll to the surface of the contact portion,
Both ends of the resin plate or film are located in the non-contact portion,
Wherein a height difference in the radial direction of the protective film-bonding roll of the non-contact portion is a size such that the end portion of the resin plate or the film is not sandwiched therebetween. The method of claim 3,
Wherein a height difference in the radial direction of the protective film-bonding roll of the non-contact portion is 20 mu m to 3 mm. The method according to claim 3 or 4,
Wherein the thermoplastic resin is a polycarbonate resin or a methacrylic resin. The method of claim 3,
Wherein the resin plate or film has a thickness of 20 to 1500 mu m. delete delete delete delete delete delete

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