KR20120112006A - Method and apparatus for forming knurling, solution film forming method, and polymer film - Google Patents

Abstract

PURPOSE: A knurling method and device, a solution film forming method, and a polymer film are provided to wind the polymer film around a winding core by preventing wrong winding or loose winding. CONSTITUTION: A knurling method is as follows. A material to be knurled is transferred to both edges(75e) of the surface of a polymer web in a width direction. Films are formed on both edges of the surface of the polymer web. Knurls(70) are formed when the formed films are dried. The films are composed of the material to be knurled.

Description

Knurling forming method and apparatus, solution film forming method, and polymer film {METHOD AND APPARATUS FOR FORMING KNURLING, SOLUTION FILM FORMING METHOD, AND POLYMER FILM}

The present invention relates to a knurling forming method and apparatus, a solution film forming method, and a polymer film.

Polymer films have been used in various fields as optical films and the like because of their excellent light transmittance, flexibility and light weight. Especially, the cellulose-ester type film using cellulose acylate etc. is used for the optical film. As an optical film, there exist a protective film, a retardation film, etc. of a polarizing plate, including the film for photosensitive. The protective film and retardation film of a polarizing plate are the structural members of the liquid crystal display device which the market expanded recently.

As a method of manufacturing a polymer film, a melt film forming method, a solution film forming method, and the like are known. According to such a manufacturing method, a strip-shaped polymer film can be obtained. The polymer film is stored in a film roll state from the handling point and transported. Therefore, the obtained strip-shaped polymer film is wound around a winding core at a predetermined winding tension to form a film roll.

Japanese Patent Laid-Open No. 11-262950 discloses a knurling forming method for preventing erroneous winding or loose winding of a polymer film in a film roll. This knurling formation method presses the knurling roller provided with many protrusions (knurl teeth) in the circumferential surface to the width direction both ends (henceforth an edge part) of a polymer film. By this knurling formation process, convex indentation (knurling) 201 as shown to FIG. 9 and FIG. 10 can be formed in the edge part 200e of the polymer film 200. FIG.

However, when the knurling 201 is formed by the method of Japanese Patent Laid-Open No. 11-262950, the portion pressed by the knurling roller is concavely deformed. In this way, the recessed part 202 is produced | generated in the film 200 by the pressure of a knurling roller. The knurling 201 is crushed due to the presence of the recess 202. In addition, when the winding tension of the polymer film 200 increases or the state in which the polymer film 200 is wound elapses for a long time, the knurling 201 becomes more likely to be crushed. Therefore, even when the knurling 201 is formed on the polymer film 200 by using the method of Japanese Patent Laid-Open No. 11-262950, as a result of the distortion of the knurling 201, the incorrect winding or loose winding of the polymer film 200 Get up

This invention solves such a subject and an object of this invention is to provide the knurling formation method and apparatus which are hard to be crushed, and the solution film forming method. Moreover, an object of this invention is to provide the polymer film provided with the knurling hard to be crushed.

The knurling formation method of this invention is a knurling formation method which forms a knurling in the width direction both edge part of the said polymer web. The knurling protrudes from the surface of the polymer web. The knurling forming method of the present invention includes an application step (step A) and a drying step (step B). In step A, the knurling forming material is sent toward both edges in the width direction of the surface to form a film at both edges in the width direction of the surface. The film is made of the knurling forming material. Step B obtains the knurling from the film by drying the film.

It is preferable that a knurling forming material contains the raw material polymer of the said polymer web.

In the step B, it is preferable to blow dry air on the back surface of the membrane and the polymer web.

In the said step B, it is preferable to convey the said polymer web using a conveying unit. In the said conveyance unit, a surface side conveyance roller and a back side conveyance roller are arranged in a zigzag form. The said surface side conveyance roller supports the said surface. The said back side conveyance roller supports the back surface of the said polymer film.

It is preferable that the said back side conveyance roller supports only the width direction center part of the said polymer web.

The solution film forming method of the present invention is a solution film forming method for producing a polymer web with dope. The said dope contains a polymer and a solvent. The said polymer web is knurled in the width direction both edge part. The knurling protrudes from the surface of the polymer web. The solution forming method includes a film forming step (C step), a flexible film drying step (D step), a peeling step (E step), a wet web drying step (step F), an application step (step G), and a coating film drying step (H). Step). In step C, the dope is continuously discharged toward the support to form a web-like flexible film on the support. The flexible film is made of the dope. Step D evaporates the solvent from the flexible membrane until the flexible membrane becomes self-supporting and can be transported. In step E, the flexible membrane which has undergone the membrane drying step is peeled from the support to be a wet web. Step F evaporates the solvent from the wet web to form the polymer web. Step G sends the knurling forming material toward the widthwise opposite edges of the surface of the wet web or the polymer web to form a film at both widthwise edges of the surface. The film is made of the knurling forming material. Step H obtains the knurling from the film by drying the film.

The knurling forming apparatus of this invention is a knurling forming apparatus which forms a knurling in the width direction edge part of the said polymer web. The knurling protrudes from the surface of the polymer web. A knurling forming apparatus is equipped with an application part and a drying unit. An applicator sends a knurling forming material toward the width direction both edge parts of the said surface, and forms a film | membrane in the width direction both edge parts of the said surface. The film is made of the knurling forming material. The drying unit obtains the knurling from the film by drying the film.

It is preferable that the said drying unit has a front side drying part and a back side drying part. The said surface drying part gives a drying air to the said film | membrane. The said back side drying part blows dry air on the back surface of the said polymer web.

It is preferable that the said drying unit is equipped with the conveying unit which conveys the said polymer web. In the said conveying unit, a surface support roller and a back surface support roller are arrange | positioned in zigzag form. The surface support roller supports the surface. The back surface supporting roller supports the back surface.

It is preferable that the said surface support roller has a large diameter roller part, and a small diameter roller part. The large diameter roller portion supports only the widthwise center portion of the polymer web. The said small diameter roller part is smaller in diameter than the said large diameter roller part, and is provided in the axial direction both ends of the said large diameter roller part.

The polymer film of this invention is equipped with a film base and knurling. The film base is web-shaped. The thickness of the said film base is the same in the width direction. The knurling is formed at both edge portions in the width direction of the film base. The said knurling protrudes from the surface of the said width direction both edge part. The knurling is made of a polymer contained in the film base. The thickness of the knurling is the same in the width direction.

According to the present invention, the recess 202, which was a problem in the case of the conventional method, does not exist in the polymer web. The knurling formed by this method is less likely to be crushed than the conventional one. Therefore, according to this invention, a polymer film can be wound up to a winding core, preventing erroneous winding and loose winding.

The above objects and advantages will be readily understood by those skilled in the art by reading the detailed description of the preferred embodiments with reference to the accompanying drawings.
1: is explanatory drawing which shows the outline | summary of a solution film forming installation.
2 is a perspective view showing an outline of a knurling forming apparatus.
It is a top view which shows the outline | summary of the 1st film which concerns on this invention.
4 is a cross-sectional view taken along the line IV-IV showing the outline of the first film according to the present invention.
It is a top view which shows the outline | summary of the 2nd film which concerns on this invention.
It is a top view which shows the outline | summary of the 3rd film which concerns on this invention.
7 is a cross-sectional view taken along the line VII-VII showing the outline of a third film according to the present invention.
8 is a front view showing the outline of the step roller.
It is sectional drawing which shows the outline | summary of a knurling film formed by the conventional method.
It is sectional drawing which shows the outline | summary of a knurling film formed by the conventional method.

 (Solution film production facility)

As shown in FIG. 1, the solution film-forming installation 10 is equipped with the film manufacturing part 10a, the knurling formation part 10b, and the winding-up part 10c. The film manufacturing part 10a makes the film 11 with the dope 14, and is equipped with the casting apparatus 15 and the drying apparatus 16. FIG. The dope 14 contains the polymer (referred to as a raw material polymer) 12 which becomes a raw material of the polymer film (henceforth a film) 11, and the solvent (henceforth a polymer solvent) 13 of the polymer 12. do. The conveyance path extended from the film manufacturing part 10a to the winding-up part 10c is formed by the conveyance roller 10r arranged in the substantially horizontal direction from the film manufacturing part 10a to the winding-up part 10c. The knurling formation part 10b is provided in the conveyance path formed by the conveyance roller 10r. The knurling forming part 10b is equipped with the knurling forming apparatus 17 which forms a knurling in the film 11. Reference numeral 74 is attached to the film 11 on which the knurling is formed. The winding-up part 10c is equipped with the winding device 18 which winds up the film 74. As shown in FIG.

 (Flexible device)

The casting apparatus 15 makes the wet film 19 from the dope 14. The casting apparatus 15 includes a casting chamber 27 that houses the casting die 21, the casting drum 22, the pressure reduction chamber 23, and the peeling roller 24.

The casting drum 22 is arrange | positioned so that an axial direction may be horizontal, and it can be rotated about an axis. The casting drum 22 rotates about an axis by the drive device which is not shown in figure, under control of a control part. By rotation of the casting drum 22, the circumferential surface of the casting drum 22 travels at a predetermined speed in a predetermined direction. The running direction of the circumferential surface of the casting drum 22 is called A direction below.

The cast drum 22 is preferably made of stainless steel, and more preferably made of SUS316 so as to have sufficient corrosion resistance and strength. It is preferable that chromium plating process performed on the circumferential surface of the casting drum 22 is Vickers hardness Hx700 or more, film thickness of 2 micrometers or more, so-called hard chromium plating.

The thermostat 28 is connected to the casting drum 22. The temperature controller 28 incorporates a temperature controller for adjusting the temperature of the heat transfer medium. The temperature controller 28 circulates the heat transfer medium adjusted to desired temperature between the temperature control part and the flow path provided in the casting drum 22. By circulation of this heat transfer medium, the temperature of the peripheral surface of the casting drum 22 can be maintained at a desired temperature.

The casting die 21 is provided above the casting drum 22. The casting die 21 has a slit outlet through which the dope 14 flows out at the tip. The casting die 21 is disposed so that the slit outlet is close to the casting drum 22. The dope 14 which flowed out from the casting die 21 flows on the circumferential surface of the casting drum 22, and forms the strip | belt-shaped casting film 30 as a result.

The pressure reduction chamber 23 is provided so as to be adjacent to the casting die 21 on the upstream side in the A direction than the casting die 21. Under the control of a control unit (not shown), the decompression chamber 23 can depressurize the upstream side of the flexible bead so that the pressure on the upstream side of the flexible bead becomes lower relative to the downstream side.

The peeling roller 24 is arrange | positioned rather than the casting die 21 in the downstream of A direction. The peeling roller 24 peels the casting film 30 formed on the circumferential surface, and sends it out from the outlet 27a of the casting chamber 27 as the wet film 19.

In addition, although illustration is abbreviate | omitted, the temperature (condensation point) in which the polymer solvent 13 which becomes gas in the casting chamber 27 can be maintained in a predetermined range by providing a condensation apparatus and a collection apparatus. The condensation apparatus condenses the polymer solvent 13 contained in the atmosphere in the casting chamber 27. The recovery apparatus recovers the condensed polymer solvent 13.

 (Drying device)

The drying apparatus 16 forms the film 11 from the wet film 19 by evaporating the polymer solvent 13 from the wet film 19. The drying apparatus 16 includes the pin tenter 35, the slitter 36, the roller drying chamber 37, and the cooling chamber 38. In the moving part 40 between the flexible chamber 27 and the pin tenter 35, the strip-shaped wet film 19 sent out from the flexible chamber 27 was pinned to the pin tenter 35 using the some roller 41. FIG. Return to

The pin tenter 35 has many pin plates (not shown) hold | maintained through the both ends of the width direction of the wet film 19, and this pin plate runs on track. Dry air is sent to the wet film 19 which travels by holding a pin plate. In the pin tenter 35, the polymer solvent 13 evaporates from the wet film 19 by the contact of the wet film 19 and dry wind.

The slitter 36 separates the edge portion of the wet film 19. This separated edge portion is sent to a crusher (not shown) by blowing, finely cut, and reused as a raw material such as dope.

In the roller drying chamber 37, many rollers 45 are arranged in a zigzag shape. The wet film 19 is conveyed while being wound by the roller 45. An adsorption recovery apparatus 46 is connected to the roller drying chamber 37. The adsorption recovery apparatus 46 recovers the polymer solvent 13 evaporated from the wet film 19 by adsorption. By recovering the polymer solvent 13 in the roller drying chamber 37, since the condensation point of the polymer solvent 13 in the roller drying chamber 37 is adjusted in a fixed range, the inside of the roller drying chamber 37 is conveyed. In the meantime, the polymer solvent 13 is evaporated from the wet film 19. As a result, the film 11 is obtained from the wet film 19.

In the cooling chamber 38, the film 11 is cooled until the temperature of the film 11 becomes substantially room temperature.

 (Winding device)

The winding apparatus 18 is equipped with the winding core 51, the winding core drive part (not shown), and the winding chamber 54 which has the press roller 52. As shown in FIG. The outer diameter of the winding core 51 is 100 mm or more and 500 mm or less, for example. By the control unit (not shown), the winding core drive unit rotates the winding core 51 at a predetermined speed. As a result, the film 74 is wound up to the winding core 51 by a predetermined winding tension, and becomes the film roll 55. The press roller 52 presses the film 74 wound by the winding core 51 toward the winding core 51 or the film roll 55 wound by the winding core 51. Thereby, the film 74 can be wound, preventing the mixing of air between the films 74.

 (Knurling forming device)

As shown to FIG. 1 and FIG. 2, the knurling forming apparatus 17 is an application | coating die 61d and a drying unit which are arrange | positioned in order from the conveyance direction (X direction) upstream side of the film 11 toward downstream. 62). The drying unit 62 consists of the front side drying duct 62a and the back side drying duct 62b. The coating die 61d and the front side drying duct 62a are disposed on one surface side of the film 11, and the back side drying duct 62b faces the front side drying duct 62a on the other surface side of the film 11. Is placed. Moreover, the coating die 61d, the front side drying duct 62a, and the back side drying duct 62b are arrange | positioned at the width direction (Y direction) both ends of the conveyance path of the film 11. Moreover, the support roller 61r is arrange | positioned so that the coating die 61d may face the other surface side of the film 11.

Here, the film 11 consists of the edge part 11e provided in the Y direction both ends, and the center part 11c between the edge part 11e. The edge part 11e is a part in which knurling is formed. The center part 11c is a part finally used as an optical film.

The coating die 61d has a slot outlet for extruding the knurling forming liquid 64 and is disposed so as to face the edge portion 11e supported by the support roller 61r. The front side drying duct 62a is provided with the ventilation port which sends out the drying wind 63a toward the edge part 11e of one surface side, and is arrange | positioned so that the ventilation port may face the edge part 11e of one surface side. The back side drying duct 62b is provided with the ventilation port which sends out the drying wind 63b toward the edge part 11e of the other surface side, and is arrange | positioned so that a ventilation port may face the edge part 11e of the other surface side.

The knurling forming liquid 64 contains the knurling raw material 65 and the solvent (knurling solvent) 66 of a knurling raw material. It is preferable that the density | concentration of the knurling raw material 65 in the knurling forming liquid 64 is 25 mass% or more and 35 mass% or less, for example.

Although the knurling raw material 65 is not specifically limited, It is preferable that it is a polymer. Moreover, the knurling solvent 66 will not be specifically limited if the knurling raw material 65 can be melt | dissolved.

Next, the operation of the present invention will be described. By the pump (not shown), the dope 14 is sent to the casting die 21, as shown in FIG. The temperature of the dope 14 is adjusted substantially constant in the range of 30 degreeC or more and 35 degrees C or less by the thermostat installed in the casting die 21. As shown in FIG.

The temperature controller 28 controls so that the temperature of the circumferential surface of the casting drum 22 may be substantially constant in the range of -20 degreeC or more and 20 degrees C or less. The casting drum 22 rotates about an axis. As a result, the circumferential surface travels in the A direction. It is preferable that the running speed of a circumferential surface is 10 m / min or more and 200 m / min or less. As for the minimum of the traveling speed of a circumferential surface, it is more preferable that it is 20 m / min, ie, the traveling speed of a circumferential surface is 20 m / min or more.

 (Film forming step, peeling step)

In the casting chamber 27, a film forming step and a peeling step are performed. The film forming step is a step of forming a band-like cast film 30 made of the dope 14 on the peripheral surface of the cast drum 22. A peeling process is a process which peels the casting film 30 from the peripheral surface of the casting drum 22, and sets it as the wet film 19. FIG. The casting die 21 flows the dope 14 toward the circumferential surface of the casting drum 22 from the slit outlet. The dope 14 which flows out forms the strip | belt-shaped flexible film 30 on the circumferential surface. The casting drum 22 cools the casting membrane 30 until the casting membrane 30 becomes self-supporting and can be conveyed. By the cooling by the casting drum 22, the dope 14 which comprises the casting membrane 30 turns into a gel shape, and as a result, the casting membrane 30 becomes self-supporting and can be conveyed. The peeling roller 24 peels the flexible film 30 which became independent and conveyable from the casting drum 22 as the wet film 19, and guides it to the pin tenter 35 through the moving part 40. FIG.

Here, gelation includes a state in which the fluidity of the dope is lost, in addition to the state in which the colloidal solution is solidified in a jelly shape. In the case where the solute is a polymer, when the solute is a polymer, fluidity is lost while the solvent is maintained in the molecular chain of the solute, and as a result, the fluidity of the solution is lost and the solute is a low molecule. In the case of the solvent, the interaction between the molecules of the solvent and the molecules of the solute includes a state in which the fluidity of the solution is lost.

It is preferable that the solvent content of the cast film 30 at the time of peeling is 200 weight% or more and 300 weight% or less. In addition, in this invention, what showed the quantity of the polymer solvent 13 contained in the cast film 30 and each film on a dry basis is taken as solvent content. Moreover, the measuring method collects a sample from the film of object, and computes it as (x-y) / y * x100, when the weight of this sample is x and the weight after drying a sample is y.

 (Wet Film Drying Process)

In the pin tenter 35 and the roller drying chamber 37, the wet film drying process which evaporates the polymer solvent 13 from the wet film 19 is performed. The pin tenter 35 conveys the wet film 19 by running the pin which supports the both ends of the wet film 19. FIG. In addition, the pin tenter 35 blows dry air into the wet film 19 and evaporates the polymer solvent 13 from the wet film 19. The slitter 36 cuts both ends of the wet film 19 sent out from the pin tenter 35. The wet film 19 whose both ends were cut is sent to the roller drying chamber 37. Dry air is sent to the wet film 19 conveying the roller drying chamber 37, and the polymer solvent 13 is evaporated from the wet film 19. FIG. As a result, the wet film 19 becomes the film 11. The solvent content of the film 11 in the outlet of the roller drying chamber 37 becomes 5 weight% or less.

 (Knurling forming process)

As shown in FIG. 2, the knurling forming apparatus 17 performs a knurling forming process. In a knurling formation process, the application | coating process which flows out the knurling forming liquid 64 toward the edge part 11e, and the drying process which evaporates the knurling solvent 66 from the liquid film 68 are performed in order.

 (Coating step)

The temperature of the knurling forming liquid 64 is adjusted substantially constant in the range of 30 degreeC or more and 35 degrees C or less by the thermostat installed in the coating die 61d. The application die 61d continuously flows out the knurling forming liquid 64 toward the edge portion 11e supported by the support roller 61r. The knurling forming liquid 64 which flowed out from the slot of the coating die 61d has the liquid film 68 extended in the X direction of the film 11 in the edge part 11e of one surface side of the film 11. Form.

 (Drying step)

The front side drying duct 62a sends out the drying wind 63a toward the liquid film 68. The back side drying duct 63b sends out the drying wind 63b toward the edge part 11e of the other surface of the film 11. The temperature of each drying wind 63a, 63b is 60 degreeC or more and 100 degrees C or less, for example. The knurling solvent 66 is evaporated from the liquid film 68 by the contact with each dry wind 63a, 63b. By the drying process, the liquid film 68 becomes the knurling 70 which consists of a knurling raw material 65. FIG.

 (Winding process)

After passing through the cooling chamber 38, the film 11 which passed the knurling formation process, ie, the film 74, is sent to the winding-up chamber 54. As shown in FIG. In the winding chamber 54, the film 74 in which knurling was formed is wound by the press roller 52, and is wound up by the winding core 51 by predetermined winding tension (70 N / m or more and 200 N / m or less). Thereby, the film roll 55 is obtained from the film 74.

As shown in FIG. 3 and FIG. 4, the film 74 includes a film base 75 having substantially the same thickness in the width direction and a knurling 70 formed at the edge portion 75e of the film base 75. Equipped. The film base 75 corresponds to the film 11 obtained by the film formation process-the wet film drying process, and the knurling 70 is formed by the knurling formation process. And in the width direction Y, the area | region of the edge part 75e corresponds to the area | region of the edge part 11e, and the area | region of the center part 75c is corresponded to the area | region of the center part 11c.

The knurling 70 formed in the edge portion 75e of the film base 75 protrudes from the surface 75a and extends in the longitudinal direction of the film 74. The thickness of the film base 75 is the same in the width direction, and there is no recess 202 (see FIGS. 8 and 9) in the film base 75. The thickness of the knurling 70 is also the same in the width direction, and the recess 202 (see FIGS. 8 and 9) does not exist in the knurling 70. "The thickness of the film base 75 and the knurling 70 is the same" should just be 0.2 micrometer or less in thickness thickness (the minimum value removed from the maximum value of thickness) in the width direction, and it is more preferable that it is 0.1 micrometer or less.

In this invention, since the knurling 70 was formed by application | coating of the knurling forming liquid 64, the recessed part 202 formed when the knurling forming roller is pressed to the film base 75 (FIG. 8 and FIG. Does not occur. For this reason, since the knurling 70 becomes hard to be crushed, erroneous winding and loose winding of a polymer film can be suppressed reliably.

However, when using the film 74 taken out of the film roll 55 as an optical film, the edge part 75e in which the knurling 70 was formed is cut off. Therefore, the knurling raw material 65 is preferably the same as the raw material polymer 12. When the raw material polymer 12 is a mixture of a some compound, it is preferable that the knurling raw material 65 is the same as any component of the raw material polymer 12. Thereby, it becomes easy to reuse the cut | disconnected edge part 75e for preparation of dope.

In the said embodiment, although the knurling forming liquid 64 was flowed out continuously, this invention is not limited to this, You may flow out the knurling forming liquid 64 intermittently. The null rings 70 formed in this way are arranged in the longitudinal direction so as to be spaced apart from each other as shown in FIG. 5.

In the said embodiment, although one knurling 70 was formed in one edge part 75e, this invention is not limited to this. For example, as shown in FIG. 6 and FIG. 7, in one edge portion 75e, a plurality of knurlings 70 extending in the longitudinal direction may be provided. In addition, when providing plural knurlings 70 extending in the longitudinal direction, the distance between the knurlings 70 (distance between adjacent knurlings 70 and the knurlings 70) is larger than the width of the knurlings 70. It is desirable to be narrow. As a result, deformation of the null ring 70 is suppressed.

You may apply the knurling forming liquid 64 to the whole edge part 11e. Thereby, the knurling 70 can be formed in the whole edge part 75e.

As the knurling forming material, a molten polymer may be used instead of the knurling forming liquid 64. By extruding the molten polymer from the application die 61d, a film made of the molten polymer can be formed. And the knurling 70 can be formed by cooling the film | membrane which consists of molten polymers.

In addition, you may perform a knurling formation process in a wet film drying process. In this case, the timing of performing a knurling formation process may be between the pin tenter 35 and the roller drying chamber 37, and may be in the roller drying chamber 37 or the cooling chamber 38, for example. Moreover, after winding the film 11 once and performing the predetermined | prescribed process (for example, an extending process) with respect to the film 11 taken out from this film roll, you may perform a knurling formation process.

In the above embodiment, the flexible drum 22 is used as the support of the dope 14, but as the support of the dope 14, a drive roller (drive roller) or a free roller (non-drive roller) is used. An endless band may be used. Moreover, you may evaporate the polymer solvent 13 from the casting film 30 on a support body.

As for the length of the film 74, it is more preferable that it is 2000 m or more and 8000 m or less, for example.

It is preferable that it is 600 mm or more, and, as for the width W ₇₅ (refer FIG. 4) of the film base 75, it is more preferable that they are 1400 mm or more and 2500 mm or less. In addition, the present invention, even when the width (W ₇₅₎ of the film base 75 is greater than 2500mm is effective. The base film (see Fig. 4), the thickness (d ₇₅₎ of 75, is more than 200μm 30μm or less is preferred, and is more preferably 40μm or less than 150μm and more preferably 40μm or less than 100μm.

It is preferable that the width W ₇₀ of the knurling 70 is 10 mm or more and 30 mm or less. The thickness (d ₇₀₎ of the knurl (70) is preferably 1μm or less than 20μm.

In the said embodiment, although this invention was used when the knurling 70 is formed in the film 11 obtained by the solution film forming method, it is seen also when forming a knurling 70 in the film obtained by the melt film forming method. The invention can be applied.

In addition, in the said embodiment, although the conveyance path of the film 11 was formed linearly in the X direction downstream from the coating die 61d, this invention is not limited to this, It is downstream in the X direction than the coating die 61d. On the side, the form of the conveying paths of the films 11 and 74 is viewed from the side by the conveying rollers arranged in a zigzag shape from the film production section 10a to the winding section 10c. It is good also as a conveyance path (refer FIG. 1) of the wet film 19 formed in 37). By arrange | positioning a conveyance roller in this way, the space for performing a drying process can be suppressed. It is preferable to use a step roller as a conveyance roller which supports one surface side of the films 11 and 74 and conveys the films 11 and 74. Moreover, as a conveyance roller which supports the other surface side of the films 11 and 74 and conveys the films 11 and 74, you may use a normal conveyance roller, ie, a conveyance roller with a constant diameter in an axial direction, You may use a roller.

As shown in FIG. 8, the step | step roller 80 consists of the large diameter roller part 80c and the small diameter roller part 80e. The large diameter roller part 80c supports only the product part 11c and the center part 74c. The small diameter roller part 80e is provided in the axial direction both ends of the large diameter roller part 80c, and is small in diameter compared with the large diameter roller part 80c. The step roller 80 can support only the product portion 11c and the center portion 74c by the large-diameter roller portion 80c. The film 11, 74 can be conveyed, maintaining the non-contact state of the edge parts 11e and 74e by such a step roller 80. FIG. In addition, the case where the film 11 is supported is shown in FIG. 8, and illustration is abbreviate | omitted about the case where the film 74 is supported.

In addition, you may use a single-axis roller instead of the step roller. The single-axis roller omits the small diameter roller portion 80e of the step roller 80.

In addition, as a conveying method of the films 11 and 74 in the X direction downstream from the application | coating die 61d, you may let off the floating wind, without using a conveyance roller. Floating wind is the wind supplied from below with respect to the film surface of the films 11 and 74 so that the films 11 and 74 may float.

In addition, although the front side drying duct 62 and the back side drying duct 63 were used as a drying means, this invention is not limited to this, The back side drying duct 63 is abbreviate | omitted using the front side drying duct 62 as a drying means. You may also

 (Raw polymer)

In the said embodiment, the polymer used as a raw material of a polymer film is not specifically limited. When performing a solution film forming method, as a raw material polymer, a cellulose acylate, a cyclic polyolefin, etc. are mentioned, for example. On the other hand, when performing a melt film forming method, a cellulose acylate, a lactone ring containing polymer, a cyclic polyolefin, polycarbonate etc. are mentioned as a raw material polymer, for example. Among them, preferred are cellulose acylate and cyclic polyolefin, and preferred among them are cellulose acylate including acetate group and propionate group, and cyclic polyolefin obtained by addition polymerization, and more preferably cyclic polyolefin obtained by addition polymerization.

 (Cellulose acylate)

As cellulose acylate, triacetyl cellulose (TAC) is particularly preferable. And in a cellulose acylate, it is more preferable that the ratio which esterifies the hydroxyl group of a cellulose by carboxylic acid, ie, the substitution degree of an acyl group, satisfy | fills all of following formula (I)-(III). In the following formulas (I) to (III), A and B represent a degree of substitution of an acyl group, A is a degree of substitution of an acetyl group, and B is a substitution of an acyl group having 3 to 22 carbon atoms. It is also. Moreover, it is preferable that 90 weight% or more of TAC is 0.1 mm-4 mm of particle | grains.

 (I) 2.0≤A + B≤3.0

 (II) 0≤A≤3.0

 (III) 0≤B≤2.9

The glucose units bound to β-1,4 constituting the cellulose have free hydroxyl groups on the 2nd, 3rd, and 6th positions. The cellulose acylate is a polymer (polymer) in which part or all of these hydroxyl groups are esterified with an acyl group having 2 or more carbon atoms. Acyl substitution degree means the ratio (100% esterification is substitution degree 1) which the hydroxyl group of a cellulose esterifies in 2nd, 3rd, and 6th positions, respectively.

As for all the acylation substitution degree, ie, DS2 + DS3 + DS6, 2.00-3.00 are preferable, More preferably, it is 2.22-2.90, Especially preferably, it is 2.40-2.88. Moreover, as for DS6 / (DS2 + DS3 + DS6), 0.28 or more are preferable, More preferably, it is 0.30 or more, Especially preferably, it is 0.31-0.34. Here, DS2 is the substitution degree by the acyl group of the 2nd hydroxyl group of a glucose unit (henceforth "the acyl substitution degree of 2nd position"), and DS3 is the substitution degree by the acyl group of the 3rd hydroxyl group (hereinafter, "3 DS6 is the degree of substitution by the acyl group of the hydroxyl group on the 6th position (hereinafter also referred to as "the acyl substitution degree on the 6th position").

Only one kind of acyl group may be used for the cellulose acylate of the present invention, or two or more kinds of acyl groups may be used. When using two or more types of acyl groups, it is preferable that one is an acetyl group. When the sum of substitution degree by hydroxyl groups of 2nd, 3rd and 6th position is DSA, and the sum of substitution degree by acyl groups other than the acetyl group of 2nd, 3rd and 6th hydroxyl group is DSB, The value is more preferably 2.22 to 2.90, and particularly preferably 2.40 to 2.88. Moreover, DSB is 0.30 or more, Especially preferably, it is 0.7 or more. Moreover, although 20% or more of the DSB is a substituent of a 6th-position hydroxyl group, More preferably, 25% or more is a substituent of a 6th-position hydroxyl group, 30% or more is more preferable, Especially 33% or more is a substituent of a 6th-position hydroxyl group. desirable. Moreover, the 6th substitution degree of a cellulose acylate is 0.75 or more, Furthermore, the cellulose acylate which is 0.80 or more and especially 0.85 or more is mentioned. A solution (dope) in which solubility is preferable can be produced by such cellulose acylate. In particular, in a non-chlorine-based organic solvent, a good solution can be produced. In addition, it is possible to produce a solution having a low viscosity and good filterability.

The cellulose which is a raw material of cellulose acylate may be one obtained from any of a linter and a pulp.

The acyl group having 2 or more carbon atoms of the cellulose acylate of the present invention may be either an aliphatic group or an aryl group, and is not particularly limited. These are, for example, alkylcarbonyl esters, alkenylcarbonyl esters or aromatic carbonyl esters of cellulose, aromatic alkylcarbonyl esters, and the like, and may each have a substituted group. Such preferred examples include propionyl, butanoyl, pentanoyl, hexanoyl, octanoyl, decanoyl, dodecanoyl, tridecanoyl, tetradecanoyl, hexadecanoyl, octadecanoyl, iso-butanoyl, t-butayl Noyl, cyclohexanecarbonyl, oleoyl, benzoyl, naphthylcarbonyl, cinnamoyl and the like. Among these, propionyl, butanoyl, dodecanoyl, octadecanoyl, t-butanoyl, oleyl, benzoyl, naphthylcarbonyl, cinnamoyl and the like are more preferable, and particularly preferably propionyl and butanoyl .

 (Polymer solvent)

As a polymer solvent for preparing dope, aromatic hydrocarbons (for example, benzene, toluene, etc.), halogenated hydrocarbons (for example, dichloromethane, chlorobenzene, etc.), alcohols (for example, methanol, ethanol, n-propanol) , n-butanol, diethylene glycol and the like), ketones (e.g. acetone, methyl ethyl ketone and the like), esters (e.g. methyl acetate, ethyl acetate, propyl acetate and the like) and ethers (e.g. tetrahydro Furan, a methyl cellosol part, etc.) etc. are mentioned. In addition, in this invention, dope means the polymer solution and dispersion liquid obtained by melt | dissolving or disperse | distributing a polymer in a solvent.

Among these, halogenated hydrocarbons having 1 to 7 carbon atoms are preferably used, and dichloromethane is most preferably used. From the viewpoints of physical properties such as solubility of TAC, peelability from the support of the flexible membrane, mechanical strength of the film, and optical properties of the film, it is preferable to mix one or several alcohols having 1 to 5 carbon atoms in addition to dichloromethane. Do. 2 weight%-25 weight% are preferable with respect to the whole solvent, and, as for content of alcohol, 5 weight%-20 weight% are more preferable. Specific examples of the alcohol include methanol, ethanol, n-propanol, isopropanol, n-butanol and the like, but methanol, ethanol, n-butanol or a mixture thereof is preferably used.

By the way, in order to minimize the effect on the environment in recent years, the examination of the solvent composition in the case of not using dichloromethane is advanced, and about this purpose, the ether and carbon atom of 4-12 carbon atoms are studied. Ketones having 3 to 12 carbon atoms, esters having 3 to 12 carbon atoms and alcohols having 1 to 12 carbon atoms are preferably used. These may be mixed and used suitably. For example, the mixed solvent of methyl acetate, acetone, ethanol, n-butanol is mentioned. Such ethers, ketones, esters and alcohols may have a cyclic structure. Moreover, the compound which has two or more of functional groups of ether, ketone, ester, and alcohol (namely, -O-, -CO-, -COO-, and -OH) can also be used as a solvent.

The details of the cellulose acylate are described in paragraphs [0140] to [0195] in Japanese Patent Laid-Open No. 2005-104148. Such a description is also applicable to this invention. Moreover, the same applies to additives such as a solvent, a plasticizer, a deterioration inhibitor, an ultraviolet absorber (UV agent), an optically anisotropic control agent, a retardation control agent, a dye, a mat agent, a release agent, a peeling accelerator, and the like. Paragraphs [0196] to [0516] are described in detail.

In addition, in the said embodiment, although the knurling 70 is formed by application | coating of the knurling forming liquid 64 and drying of the liquid film 68, it is not limited to this method. For example, the knurling 70 is applied from a coating step of applying a coating liquid containing a monomer and a solvent, a drying step of evaporating the solvent from the coating liquid, and a polymerization step of polymerizing monomers contained in the coating liquid. You may form. The monomer contained in a coating liquid needs to be a polymer of a crosslinked structure by a superposition | polymerization process.

 (Usage)

The polymer film of this invention is useful as a polarizing plate protective film or retardation film. An optically anisotropic layer, an antireflection layer, an antiglare function layer, etc. may be provided to this polymer film, and it may be set as a high function film.

EXAMPLE

 (Experiment 1)

The knurling forming liquid 64 was created with the following prescription. The knurling forming liquid 64 of this prescription was made into knurling forming liquid A. The compound used for preparation of a knurling forming liquid (A) is shown below.

Cellulose triacetate (acetization degree: 60.8%) 100 parts by mass

Plasticizer A (triphenyl phosphate) 7.6 parts by mass

Plasticizer B (diphenyl phosphate) 3.8 parts by mass

Silicon dioxide (average particle diameter: 15 nm, Mohs hardness: about 7) 0.05 parts by mass

Solid content

378 parts by mass of dichloromethane

68 parts by mass of methanol

It added to the mixed solvent which consists of these suitably, stirred and melt | dissolved, and prepared the knurling forming liquid (A).

In the knurling formation part 10b, as shown in FIG. 2, the knurling formation liquid A was apply | coated to the both edge parts 11e of the film 11, and the liquid film 68 was formed. The length of the liquid film 68 in the Y direction was 10 mm, respectively. Then, the film 11 which has the liquid film 68 was sent to the conveyance path of the film 11 which arrange | positions the normal conveyance roller and the step roller 80 in a zigzag form. The front side drying duct 62a sends out the drying wind 63a (temperature 100 degreeC) for 20 second toward the liquid film 68, and the back side drying duct 63b dries toward the edge part of the other surface of the film 11 Wind 63b (temperature 100 degreeC) was sent out for 20 second. Drying of the liquid film 68 obtained the film 74 which has a film base 75 and a set of knurling 70 formed in the both edge part 75e of the film base 75. The thickness d ₇₅ of the film base 75 was 60 μm. The thickness d ₇₀ of the knurling 70 was 6 μm. The width W ₇₀ of the knurling 70 was 10 mm. Moreover, the largest difference in thickness between the film base 75 and the knurling 70 was 0.1 μm.

 (Experiments 2-3)

Except having made the thickness d ₇₅ of the film base 75, the thickness d 70 of the knurling ₇₀ , and the width W ₇₀ shown in Table 1, it carried out similarly to Experiment 1, and the film 74 Got.

Knurling Forming Method d ₇₅ d ₇₀ W ₇₀ Evaluation results  (μm)  (μm)  (mm) One 2 Experiment 1 A 60 6 10 A A Experiment 2 A 40 4 10 A A Experiment 3 A 40 5 20 A A Experiment 4 B 60 6 10 A A Experiment 5 B 40 4 10 A A Experiment 6 B 40 5 20 A A Experiment 7 C 60 6 10 C B Experiment 8 C 40 4 10 C B

 (Experiments 4-6)

100 mass parts of dipentaerythritol hexaacrylate (made by DPHA Nippon Kayaku) was melt | dissolved in 103 mass parts methyl ethyl ketone, and the solution 1 was obtained. 3 parts by mass of a photopolymerization initiator (Irgacure 907, manufactured by Chiba Co., Ltd.) were dissolved in 10 parts by mass of methyl ethyl ketone to obtain a solution 2. The solution 2 was added to the solution 1, and the knurling forming liquid 64 was prepared. This knurling forming liquid 64 was made into knurling forming liquid B. FIG.

In the knurling formation part 10b, the knurling formation liquid B was apply | coated to both edge parts 11e, and the coating film was formed. The length of the coating film in the Y direction was 10 mm in Experiment 4, 5 and 20 mm in Experiment 6. Then, the film 11 which has a coating film was sent to the conveyance path formed by arrange | positioning the normal conveyance roller and the step roller 80 in a zigzag shape. The front side drying duct 62a sends out the drying wind 63a (temperature 80 degreeC) for 20 second toward a coating film, and the back side drying duct 63b carries out the edge part 11e of the other surface of the film 11. The drying wind 63b (temperature 100 degreeC) was sent for 20 second. After drying the coating film, an ultraviolet-ray having an illuminance of 400 mW / cm ² and an irradiation dose of 300 mJ / cm ² was irradiated with a 240 W / cm air-cooled metal halide lamp (manufactured by Igraphix Co., Ltd.) under a nitrogen purge (0.1% or less of oxygen concentration). The coating film was irradiated. By ultraviolet irradiation, the film 74 which has the knurling 70 which consists of a polymer in the both edge part 75e of the film base 75 was obtained. The thickness d ₇₅ of the film base 75, the thickness d 70 of the knurling ₇₀ , and the width W ₇₀ are as shown in Table 1.

 (Experiment 7)

The knurling roller was pressed to the edge part of a film, and the film which has knurling in both edge parts was obtained. The cross-sectional shape of this film is substantially the same as FIG. The thickness dx of the film at the bottom of the recess 202 is the thickness d ₇₅ of Table 1, and the height hx from the bottom of the recess 202 to the top of the knurling 201 is Table 1. In the thickness d ₇₀ of, the maximum width Wx of the knurling 201 is shown in the width W ₇₀ of Table 1, respectively.

 (Experiment 8)

Thickness (dx) (denoted as thickness (d ₇₅ ) in Table 1), height (hx) (denoted as thickness (d ₇₀ ) in Table 1), maximum width (Wx) (width in Table 1 (W ₇₀ ) Film was obtained in the same manner as in Experiment 7 except that Table 1 was shown in Table 1).

The following evaluation was performed about the film 74 obtained by the experiments 1-6, and the film obtained by experiments 7, 8.

1. Oscillation Evaluation

Using the particle counter, the number of dust of 1 micrometer or more of magnitude | size contained in the obtained film 74 and the atmosphere of the edge part vicinity of a film was counted, and it evaluated based on the following reference | standard.

A: The number of dusts per 1 ft <^3> was one or less.

B: The number of dusts per 1 ft ³ was two or more and nine or less.

C: 1ft number of ^third parties dust, was more than 10.

In oscillation evaluation, A and B are pass and C is fail.

2. Edge deformation evaluation

The scale of flapping deformation was evaluated about the obtained film 74 and the edge part (range from the end to 10 mm) of the film. Here, the gap height (DELTA) H between the part which protrudes on one surface side, and the part which protrudes on the other surface side among the film 74 and the edge part of a film as an index of the magnitude | size of the flapping deformation is as follows. Evaluation was performed based on the criteria.

A: ΔH was less than 1 mm.

B: (DELTA) H was 1 mm or more.

In edge part deformation evaluation, A is a pass and B is a rejection.

Table 1 shows the evaluation results for each evaluation item. In addition, the number in the evaluation result of Table 1 represents the number attached to the evaluation item mentioned above. In addition, A shown in the knurling formation method of Table 1 represents "coating of a knurling forming liquid", B represents "polymerization of a coating liquid", and C represents "pressing of a knurling roller."

Claims (11)

A knurling forming method, wherein knurling is formed at both edges in a width direction of a polymer web, and the knurling is formed to protrude from a surface of the polymer web.
(A) sending a knurling forming material toward both edges in the width direction of the surface to form a film at both edges in the width direction of the surface; And,
(B) obtaining said knurling from said film by drying said film; Equipped with
And said film comprises a knurling forming material. The method of claim 1,
And said knurling forming material comprises a raw polymer of said polymeric web. The method of claim 1,
In the step B, the knurling forming method to blow dry air on the back of the film and the polymer web. The method of claim 1,
In the step B, the polymer web is conveyed using a conveying unit, and the conveying unit comprises a surface side conveying roller and a back side conveying roller arranged in a zigzag shape, and the surface side conveying roller supports the surface. And said back side conveyance roller supports the back surface of the said polymer film. The method of claim 4, wherein
The said back side conveyance roller is a knurling formation method which supports only the width direction center part of the said polymer web. A method of forming a polymer web with a dope, wherein the dope comprises a polymer and a solvent, the polymer web has knurling formed at both edges in a width direction thereof, and the knurling is formed to protrude from the surface of the polymer web. To
(C) continuously flowing dope toward the support to form a web-like flexible film on the support;
(D) evaporating the solvent from the flexible membrane until the flexible membrane becomes self-supporting and can be conveyed;
(E) peeling off the flexible membrane which has undergone the membrane drying process from the support to form a wet web;
(F) evaporating the solvent from the wet web to form the polymer web;
(G) sending a knurling forming material toward both widthwise edges of the surface of the wet web or polymer web to form a film at both widthwise edges of the surface; And,
(H) obtaining said knurling from said film by drying said film,
The flexible membrane is made of the dope,
The film forming method of the said film consists of said knurling forming material. A knurling forming apparatus, wherein knurling is formed on both widthwise edges of the polymer web, and the knurling is formed to protrude from the surface of the polymer web.
An applicator which sends a knurling forming material toward both edges of the surface in the width direction, and forms a film on both edges of the surface in the width direction;
A drying unit for obtaining said knurling from said film by drying said film,
And the film is a knurling forming device comprising the knurling forming material. The method of claim 7, wherein
The drying unit has a front drying unit and a back drying unit, the front drying unit blows dry air to the film, and the back drying unit blows dry air to the back surface of the polymer web. The method according to claim 8,
The drying unit includes a conveying unit for conveying the polymer web, the conveying unit comprising a surface supporting roller and a rear support roller arranged in a zigzag shape, wherein the surface supporting roller supports the surface and supports the rear surface. A knurling forming apparatus for supporting the back surface of the roller. The method of claim 9,
The surface supporting roller has a large diameter roller portion and a small diameter roller portion, the large diameter roller portion supports only the widthwise center portion of the polymer web, and the small diameter roller portion is smaller in diameter than the large diameter roller portion and is installed at both ends of the large diameter roller in the axial direction. Knurling forming device. In the polymer film,
And a web-shaped film base and a knurling formed on both edges in the width direction of the film base to protrude from the surface of the width direction both edges, wherein the thickness of the film base is the same as the width direction. The polymer film formed from the polymer contained in the said film base part, and the thickness of the said knurling is the same as the width direction.

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