KR20120132389A - Device for producing resin films and resin films - Google Patents

Abstract

PURPOSE: A resin film manufacturing device and a resin film are provided to reduce surface protruding portions of a rubber roll and prevent the generation of detective portions generated in a flow direction of the resin film at a constant distance so that a quality becomes improved. CONSTITUTION: A resin film manufacturing device comprises a rubber roll(3) composed of a roll-shaped steel core(31) and a rubber layer(32). The rubber is formed on a surface of the steel core. The rubber layer is composed of an inner layer(32a) and an outer layer(32b). The inner layer is formed to be closed to the steel core and the outer layer is formed in an outer side of the inner layer. The inner layer is formed with HTV(High Temperature Vulcanizing) silicon rubber or RTV(Room Temperature Vulcanizing) silicon rubber with the durometer hardness of A60 to A80. The outer layer is formed with the RTV silicon rubber with the durometer hardness of A70 to A80.

Description

Manufacturing apparatus and resin film of resin film {DEVICE FOR PRODUCING RESIN FILMS AND RESIN FILMS}

This invention relates to the resin film provided with the optical characteristic, and the manufacturing apparatus of the resin film.

Optical sheets used for optical applications are widely used, for example, in liquid crystal cells, retardation films, diffusion films, brightness enhancement films and the like combined with polarizing plates.

The transmission characteristic and the reflection characteristic (henceforth "optical characteristic") of the light in an optical sheet are determined according to the material of an optical sheet, the state of the surface of an optical sheet, etc. As a material of an optical sheet, a resin material is used well. In the optical sheet, for example, there is a sheet provided with a function of forming irregularities on the surface of the resin film and scattering light.

Generally, the resin film in which the uneven | corrugated shape was formed in the surface is extruded from die | dye into the film form, and the transparent resin melt | dissolved is interposed between the 1st cooling roll of which the outer peripheral surface was smooth, and the 2nd cooling roll in which the uneven | corrugated shape was formed in the outer peripheral surface. It is obtained by transferring the said uneven | corrugated shape of a 2nd cooling roll, winding it around a 2nd cooling roll, and taking out with a take-up roll.

In patent document 1, the manufacturing method of a resin film is disclosed. In the manufacturing method of the resin film disclosed by patent document 1, the extruder which heats and melts the resin material which is a pelletized thermoplastic resin, and extrudes the melted resin, and the die which extrudes the resin of the molten state extruded from the extruder into a film form, And a resin film is manufactured using the resin film manufacturing apparatus provided with the some roll through resin extruded from the die into the film form.

Since the surface state of the some roll through resin is reflected by the surface state of a resin film, when it is going to form an unevenness | corrugation on the surface of a resin film, for example, the unevenness | corrugation is formed in a roll surface, and this is made into a plate, Warriors In the case where the surface of the resin film is to be flat, the roll surface is flat.

Japanese Unexamined Patent Publication No. 2009-196327

The fact that the surface state of a roll is reflected in the surface state of a resin film, if unnecessary unevenness | corrugation etc. exist in the roll surface, it will be reflected on the surface of the resin film until the unnecessary unevenness | corrugation, and a defect part will generate | occur | produce. Unnecessary unevenness | corrugation of a roll surface may be unevenness | corrugation resulting from the material which comprises a roll, for example, or unevenness | corrugation resulting from a manufacturing process of a roll.

The structure of the roll used for the manufacturing apparatus of a resin film consists of a roll-shaped iron core and the rubber layer formed in the iron core surface. Moreover, a rubber layer consists of two layers, and consists of an inner layer formed in the side near an iron core, and an outer layer formed in the outer side of an inner layer.

When the roll of such a structure is used, this inventor has the problem that the stripe-shaped defect part extended in the width direction generate | occur | produces on the surface of a resin film, and this defect part arises at a fixed interval in the flow direction of a resin film. Figured out.

The objective of this invention is providing the resin film manufacturing apparatus which can suppress generation | occurrence | production of a defect part, and can improve the quality, and the resin film manufactured by the said manufacturing apparatus.

This invention is a resin film manufacturing apparatus which manufactures the resin film which consists of a thermoplastic resin by a melt extrusion molding method,

Film forming means for extruding a thermoplastic resin in a molten state into a film to form a film;

A molding means comprising a first roll and a second roll, wherein the rotation axis of the first roll and the rotation axis of the second roll are parallel to each other, and are arranged such that the outer circumferential surface of the first roll and the outer circumferential surface of the second roll are in contact with each other. It is provided with the shaping | molding means which shape | molds the surface shape of a film-form thermoplastic resin by interposing between the made film-form thermoplastic resin between the outer peripheral surface of a said 1st roll, and the outer peripheral surface of a said 2nd roll,

One of the first roll and the second roll,

Core material consisting of a cylindrical or cylindrical metal member,

A rubber layer formed to cover the entire outer circumferential surface of the core material, the rubber layer comprising two layers of an inner layer formed on the side close to the core material and an outer layer formed on the outer side of the inner layer,

The said inner layer is a resin film manufacturing apparatus formed with either high temperature vulcanization silicone rubber or room temperature vulcanization silicone rubber.

The present invention is also characterized in that the outer layer is formed of a room temperature vulcanized silicone rubber.

In the present invention, the inner layer has a durometer hardness of A60? A80, and the outer layer has a durometer hardness of A70? A80.

In addition, the present invention, the inner layer and the outer layer is formed of a room temperature vulcanized silicone rubber having a durometer hardness of A70.

Moreover, this invention is further provided with the elastic support apparatus which elastically supports the one roll of the said 1st roll and the said 2nd roll to the other roll so that the outer peripheral surface of the said 1st roll and the outer peripheral surface of the said 2nd roll may abut. and,

The elastic support device,

A bearing part of the rotating shaft of the first roll or the second roll,

A horizontal movable part for moving the bearing part in a horizontal direction;

And a pneumatic cylinder for fixing the rod to the bearing portion and for providing an elastic support force to the roll via the bearing portion.

Moreover, this invention is a resin film provided with the optical characteristic,

Arithmetic mean roughness (Ra) based on JISB0601: 1994 is 1.1? 2.5 μm,

The ratio (Rz / Sm) of the ten point average roughness (Rz) and the uneven | corrugated average space | interval (Sm) based on JIS B0601: 1994 is 0.04? 0.10,

It is a resin film whose standard deviation of haze is 1.0 or less when a several point measurement is carried out at equal intervals in the flow direction at the time of manufacture, this is made into one measurement row, and a plurality of rows are measured at equal intervals in the width direction.

According to this invention, the structure of any one of the said 1st roll and said 2nd roll of a shaping | molding means was made into the core material which consists of a cylindrical or cylindrical metal member, and the rubber layer formed so that the whole outer peripheral surface of the said core material may be covered. The rubber layer was composed of two layers, an inner layer formed on the side close to the core material and an outer layer formed on the outside of the inner layer, and the inner layer was formed of either high temperature vulcanized silicone rubber or room temperature vulcanized silicone rubber.

Thereby, the convex part of the rubber roll surface which became the cause of a defect part is reduced, the generation | occurrence | production of the defect part which arises at a fixed interval in the flow direction of a resin film can be suppressed, and quality can be improved.

According to the present invention, the outer layer is preferably formed of a room temperature vulcanized silicone rubber, and the inner layer has a durometer hardness of A60? A80, and the outer layer has a durometer hardness of A70? It is more preferable that it is A80.

According to the present invention, most preferably, the inner layer and the outer layer are formed of a room temperature vulcanized silicone rubber having a durometer hardness of A70.

Moreover, according to this invention, the pneumatic cylinder was used for the elastic support apparatus which elastically supports the one roll of the said 1st roll and the said 2nd roll to the other roll.

In the past, the change in the surface state of the resin film can be suppressed by changing the position control by the servo motor to the pressure control.

Moreover, according to this invention, the arithmetic mean roughness Ra based on JISB0601: 1994 is 1.1? It is 2.5 micrometers, and the ratio (Rz / Sm) of the 10-point average roughness (Rz) and the uneven | corrugated average space | interval Sm based on JISB0601: 1994 is 0.04? It is 0.10 and the several-point measurement is carried out at equal intervals in the flow direction at the time of manufacture, this is made into one measurement row, and the standard deviation of the haze at the time of making a multiple row measurement at equal intervals in the width direction is 1.0 or less. Thereby, the resin film with which the haze which is an optical characteristic is uniform can be provided.

FIG. 1: is a figure which shows typically the structure of the resin film manufacturing apparatus 100 which is embodiment of this invention.
FIG. 2 is an enlarged view of the cross-sectional structure of the rubber roll 3 included in the manufacturing apparatus 100.
3 is a schematic view of the elastic support device 7 as seen from the rotation axis direction of the rubber roll 3.
4 is a cross-sectional view of the horizontal movable portion 73 and the rail 8 when cut by the cutting line AA in FIG. 3.
5 is a schematic plan view of the elastic support device 7 when viewed from above.

This invention is a manufacturing apparatus for manufacturing a resin film using a melt extrusion molding method, and is characterized by the structure of a roll and a roll pressurization apparatus.

FIG. 1: is a figure which shows typically the structure of the manufacturing apparatus 100 of the resin film which is embodiment of this invention.

The resin film manufacturing apparatus 100 is an extruder 1, a filtration apparatus 12, a die 2, a rubber roll 3, a mat roll 4, a mirror surface roll 5, and a take-out. The roll 6 and the elastic support apparatus 7 are included.

The extruder 1 includes an extruder cylinder (not shown), a heater, and an extruder screw. The extruder 1 makes a thermoplastic resin melt by the heat from a heater, and the shear friction heat of an extruder screw in an extruder cylinder, and extrudes a molten thermoplastic resin (molten resin) with an extruder screw, and a filtration apparatus Send to (12).

The filtration apparatus 12 is equipped with the polymer filter, and performs a filtration process with respect to the molten resin extruded by the extruder 1. Specifically, it is filtered by passing molten resin through a polymer filter to remove foreign substances such as gelled products.

The die 2 extrudes into a film form the molten resin after a filtration process, and forms into a film. For example, the die 2 may use a T die.

In the rubber roll 3 and the mat roll 4, the rotation axes of the two rolls are arranged on the same horizontal plane. The rubber roll 3 and the mat roll 4 may be arrange | positioned so that outer peripheral surfaces may contact each other, and may form a nip part, and outer peripheral surfaces may be arrange | positioned at predetermined intervals (gap). What is necessary is just to set according to the characteristic calculated | required by the resin film to manufacture. Below, the case where it arrange | positions so that a nip part is formed is demonstrated.

The die 2 is formed above these rubber roll 3 and the mat roll 4, and the discharge port of the die 2 is open | released below and arrange | positioned. The discharge port of the die 2 is located vertically above the nip of these rubber roll 3 and the mat roll 4, and the film-like resin discharged from the die 2 extends vertically downward, and rotates the rubber roll. It is interposed between (3) and the mat roll 4.

When the film-like resin discharged from the die 2 is interposed between the rubber roll 3 and the mat roll 4, the rubber layer of the rubber roll 3 is along the outer circumferential surface of the mat roll 4 via the film-like resin. It is elastically deformed into a concave shape. As a result, the rubber roll 3 and the mat roll 4 are contacted by predetermined | prescribed nip length through film resin.

This nip length is a length which can transfer the uneven shape formed in the surface of the mat roll 4 to film-like resin. In order to make a nip length into a predetermined value, it can set arbitrarily by adjusting the rubber layer material, rubber layer thickness, etc. of the rubber roll 3, for example. It is preferable that the rubber roll 3 is comprised so that control of surface temperature is possible.

Since the film-like resin discharged from the die | dye 2 is a state with high flexibility, it is interposed between the rubber roll 3 and the mat roll 4, and the surface shape of the film according to the outer surface of each roll is obtained.

The rubber roll 3 consists of a metal core material and the rubber layer formed in the surface of a core material, and an iron core is used for a core material. The rubber roll 3 has an outer surface, that is, the surface of the rubber layer is formed flat, and flattens one surface of the rubber roll 3 side of the film-like resin. The detailed structure of the rubber roll 3 is mentioned later.

The mat roll 4 is a metal roll to which the minute unevenness | corrugation process was given to the surface, and transfers an uneven | corrugated shape to the other side of the mat roll 4 side of film-like resin. Specifically, for example, there may be mentioned a metal roll which can control the temperature of the surface of the roll by passing a fluid, steam, etc. through the inside of the roll, such as a drilled roll cut out of a metal mass, a spiral roll having a hollow structure, and the like, The metal roll in which the desired uneven | corrugated shape was formed in the outer peripheral surface by sandblasting, engraving, etc. can be used.

As an uneven | corrugated shape formed in the outer peripheral surface of the mat roll 4, it is 0.1 to arithmetic mean surface roughness Ra. In addition to the mat shape of 10 μm, the pitch and height are 5? The prism shape, lens shape, etc. which are 500 micrometers can be employ | adopted. Arithmetic mean surface roughness (Ra) is a value obtained by measuring with a surface roughness meter based on JISB0601-2001.

Both the rubber roll 3 and the mat roll 4 are kept at a temperature lower than the temperature of the film-like resin, and interposed between the rubber roll 3 and the mat roll 4, whereby the film-like resin is brought to a predetermined temperature. Cools down. By this cooling, the flexibility of film-like resin falls and it is conveyed with rotation of the mat roll 4 in the state wound by the outer peripheral surface of the mat roll 4.

Moreover, the mirror surface roll 5 is formed in the opposite side to the rubber roll 3 of the mat roll 4. The mirror surface roll 5 consists of the cylindrical roll which has the same outer diameter as the rubber roll 3 and the mat roll 4, and a rotation axis is arrange | positioned on the same horizontal surface as the rotation axis of the rubber roll 3 and the mat roll 4; do.

The mirror surface roll 5 is a metal roll formed similarly to the mat roll 4, and the outer surface is mirror-processed.

The film-like resin is wound about half a turn around the lower outer peripheral surface of the mat roll 4, and then wound about 1/4 turn around the outer surface of the mirror surface roll 5, and is separated from the upper portion in the vertical direction of the mirror surface roll 5. It is taken by the take-up roll 6, and is taken out in a horizontal direction. In addition, in order to cool a resin film more gradually, several cooling rolls are formed between the mirror surface roll 5 and the take-up roll 6, and the film-like resin is wound from the mirror surface roll 5 to the next cooling roll sequentially. You may make it possible.

FIG. 2 is an enlarged view of the cross-sectional structure of the rubber roll 3 included in the manufacturing apparatus 100. The rubber roll 3 consists of the roll-shaped iron core 31 and the rubber layer 32 formed in the surface of the iron core 31. As shown in FIG. Moreover, the rubber layer 32 consists of two layers, and consists of the inner layer 32a formed in the side near the iron core 31, and the outer layer 32b formed in the outer side of the inner layer 32a.

As mentioned above, in the conventional rubber roll, the stripe-shaped defect part generate | occur | produces on the surface of a resin film over the whole width | variety of a resin film at regular intervals in the flow direction of a resin film. The surface state of a defective part becomes a state different from the surface state of another part, and a desired optical characteristic is not acquired in a defective part.

By the way, the rubber layer 32 is formed by sticking a layered rubber member to the outer surface of the iron core 31. In the conventional rubber layer, the inner layer is made of ethylene-propylene-diene rubber (EPDM), and the outer layer is made of room temperature vulcanizing (RTV) silicone rubber. When EPDM is used for the inner layer, the joint portion at the time of attaching the inner layer becomes a small convex portion, and even if the outer layer is formed, the convex portion cannot be absorbed entirely, and remains as a convex portion on the outer surface of the rubber layer. The joint part is parallel to the axial direction of the rubber roll, and the convex part also remains parallel to the axial direction on the outer surface. This convex part becomes a cause which produces a defective part on the surface of a resin film. The joint part is generated in one stripe part on the outer surface of the inner layer, and the convex part is also left in the same stripe part. Since the rubber roll is pressed against the film-like resin while rotating, the defective portion occurs at regular intervals in the flow direction in accordance with the rotation period of the rubber roll.

The inventors of the present invention formed the inner layer 32a from high temperature vulcanizing (HTV) silicone rubber instead of EPDM in order to suppress the occurrence of the convex portion of the rubber layer 32. The outer layer 32b was formed of the same RTV silicone rubber as in the prior art. Moreover, the hardness of the HTV silicone rubber of the inner layer 32a was A80 by the durometer hardness prescribed | regulated to JISK6253, and the hardness of the RTV silicone rubber of the outer layer 32b was A80 by the durometer hardness. Thereby, the defect part of the resin film which generate | occur | produced in the conventional rubber roll was reduced.

Moreover, in order to reduce the defect part, the material which forms the inner layer 32a was examined. The defect part was further reduced by changing the inner layer 32a to HTV silicone rubber of durometer hardness A60. At this time, the outer layer 32b was made into the RTV silicone rubber state of durometer hardness A80.

Here, by changing the outer layer 32b to an RTV silicone rubber having a durometer hardness A70, and changing the inner layer 32a to an RTV silicone rubber having the same durometer hardness A70 as the outer layer 32b, the defective portions of the streaks are almost made. It did not occur. Thus, when the inner layer 32a and the outer layer 32b are made of RTV silicone rubber of the same durometer hardness A70, it is not necessary to distinguish the inner layer 32a and the outer layer 32b clearly, and the durometer hardness is made to predetermined thickness. What is necessary is just to form the rubber layer 32 by the RTV silicone rubber of A70.

With respect to the two layers constituting the rubber layer 32 of the rubber roll 3, the durometer hardness is set to A60? It is formed of either HTV silicone rubber or RTV silicone rubber which is A80, and the outer layer 32b has a durometer hardness of A70? By forming from RTV silicone rubber which is A80, generation | occurrence | production of the defective part of a resin film can be suppressed.

In order to make the hardness of the rubber layer 32 into a predetermined value, it can implement arbitrarily by adjusting the crosslinking degree and a composition of the rubber material which comprises a rubber layer, for example.

The surface temperature T of the mat roll 4 is (Th-60 ° C) ≤ T ≤ (Th + 30 ° C) with respect to the heat deformation temperature Th of the film-like resin, and preferably (Th-30 ° C) )? T? (Th + 20 ° C), more preferably (Th-20 ° C)? T? (Th + 10 ° C).

The surface temperature of the rubber roll 3 is 0? 70 degreeC, Preferably it is 20? It is good to set it in the range of 40 degreeC. Especially when the surface temperature of the rubber roll 3 exceeds 70 degreeC, there exists a possibility that a resin film may adhere to the rubber roll 3 surface and stick to the rubber roll 3.

The surface temperature of each of the cooling rolls after the mirror surface roll 5 and the mirror surface roll 5 may be set to any surface temperature, and is not particularly limited, but is usually ± ± relative to the heat deformation temperature (Th) of the thermoplastic resin. About 15 degreeC is preferable.

The heat distortion temperature (Th) of the thermoplastic resin is not particularly limited, but is usually 60? 200 ° C. The heat distortion temperature (Th) of a thermoplastic resin is the temperature measured based on ASTMD-648.

The take-up roll 6 consists of a pair of upper roll 6a and lower roll 6b. As upper roll 6a and lower roll 6b, a rubber roll, a metal roll, etc. are mentioned, for example. The lower roll 6b is connected to rotation drive means, such as an electric motor, and is arrange | positioned so that the upper roll 6a can rotate freely so that it may contact this lower roll 6b, and it will be rotated by the lower roll 6b. The upper roll 6a is also rotated by this. Therefore, the upper roll 6a and the lower roll 6b rotate at the same circumferential speed. In addition, as long as the circumferential speeds of the upper roll 6a and the lower roll 6b are the same, the structure opposite to the above structure, that is, the upper roll 6a is connected to the rotation driving means, and the upper roll 6a and You may arrange | position so that the lower roll 6b may rotate freely so that it may contact, and the upper roll 6a and the lower roll 6b may be connected to rotation drive means.

The resin film as a product taken out by the takeout roll 6 has a thickness of 30? It is preferable that it is 300 micrometers. On the other hand, when the thickness is less than 30 micrometers, a resin film may not be stably obtained by said roll structure, and when exceeding 300 micrometers, it may become difficult to handle as a film. The thickness of a resin film can be adjusted with the thickness of the film-form resin extruded from the die 2, the contact thickness of the rubber roll 3 and the mat roll 4, and the length of a nip part.

Since the resin film is provided with a concave-convex shape on the surface and is provided with a function of scattering light, for example, in addition to a liquid crystal cell, a retardation film, a diffusion film, a brightness enhancement film, etc. combined with a polarizing plate, a film for automobile interiors, lighting Although it can apply to a film, a film for building materials, etc., this invention is not limited to these uses.

3 is a schematic view of the elastic support device 7 as seen from the rotation axis direction of the rubber roll 3. 4 is a cross-sectional view of the horizontal movable portion 73 and the rail 8 when cut by the cutting plane line A-A in FIG. 3. 5 is a schematic plan view of the elastic support device 7 when viewed from above.

As mentioned above, the rubber roll 3 is elastically supported by the mat roll 4 by the elastic support apparatus 7 so that the outer peripheral surface of the rubber roll 3 and the outer peripheral surface of the mat roll 4 may abut.

The elastic support device 7 includes a bearing portion 72 of the rotary shaft 33 of the rubber roll 3, a horizontal movable portion 73 for moving the bearing portion 72 in the horizontal direction, and a bearing portion 72. It includes a pneumatic cylinder (71) for fixing the rod and giving elastic support force to the roll via the bearing portion (72).

The bearing part 72 should just be a member which rotatably supports the rotating shaft 33 of the rubber roll 3, and can use a sliding bearing, a rolling bearing, etc.

In addition, the bearing portion 72 is formed in a rectangular parallelepiped shape in which a through hole portion 72a for supporting the rotating shaft 33 is formed in the center portion while the rotating shaft 33 penetrates. The horizontal movable portion 73 is fixed to the lower surface of the bearing portion 72. The horizontal movable portion 73 is a guide portion in which an inner space is formed as if the rail 8 extending in a direction parallel to the abutment direction of the rubber roll 3 and the mat roll 4 is drawn from above and both sides. . The horizontal movable part 73 slides along the rail 8, and the bearing part 72 also slides along the rail 8 with the horizontal movable part 73. Both the bearing portion 72 and the horizontal movable portion 73 are formed to support the rotation shaft 33 on each of the end portions in the axial direction of the rotation shaft 33.

By the movement of the bearing part 72 and the horizontal movable part 73, the supported rotating shaft 33 can move to a horizontal direction. The rubber roll 3 and the mat roll 4 are arrange | positioned so that it may adjoin in a horizontal direction, and the rubber roll 3 and the mat roll 4 can abut or carry out by the movement of the rotating shaft 33. FIG.

Moreover, the pneumatic cylinder 71 is formed so that the stroke direction of the rod 71a may become parallel to a horizontal direction, and the rod 71a is the side which is far from the mat roll 4 among the side surfaces of the bearing part 72, namely resin. It is fixed to the side surface of the conveyance direction upstream of a film. The pneumatic cylinder 71 is fixed so that the rubber roll 3 and the mat roll 4 may form the nip of a predetermined size. The mat roll 4 is fixed so as not to move, and in the state where the rubber roll 3 and the mat roll 4 are in contact with each other, the bearing portion 72 presses in the direction in which the rod 71a contracts at a constant pressure, and the air pressure The cylinder 71 pushes back the bearing part 72 via the rod 71a by the force matched with this pressure by compressed air.

When film-like resin is interposed in the nip part of the rubber roll 3 and the mat roll 4, a force is applied to the direction in which the rubber roll 3 is separated by the mat roll 4. This force tries to push the rod 71a of the pneumatic cylinder 71 through the bearing portion 72, but pushes the bearing portion 72 back through the rod 71a by the enclosed compressed air, The force is maintained.

Conventionally, the servomotor detects the horizontal displacement of the rotary shaft 33 of the rubber roll 3 when the film-like resin is interposed in the roll by a force transducer, and the position of the rubber roll 3 is fixed. The position control of the rotating shaft 33 was implemented using the. However, it is difficult to follow the thickness fluctuation of film-like resin, etc., and it was not possible to reduce the dispersion | variation in the surface state of a resin film, ie, the dispersion | variation in an optical characteristic.

As described above, by changing the pressure control so that the pressing force is constant by the pneumatic cylinder 71, it is possible to sufficiently follow the fluctuations in the thickness of the film-like resin or the like, thereby reducing the variation in the surface state of the resin film.

In addition, you may provide the pneumatic cylinder 81 on the opposite side to the pneumatic cylinder 71. The pneumatic cylinder 81 is formed so that the stroke direction of the rod 81a may be parallel to the horizontal direction, and the rod 81a is the side close to the mat roll 4 among the side surfaces of the bearing portion 72, that is, of the resin film. It is formed so that the side surface of the conveyance direction downstream may abut. The pneumatic cylinder 81 is fixed together with the pneumatic cylinder 71 so that the rubber roll 3 and the mat roll 4 may form the nip of a predetermined size. When the thickness of film-like resin changes, the distance of the rubber roll 3 and the mat roll 4 will fluctuate. When the bearing portion 72 presses the rod 71a in the contracting direction due to the variation of the distance, the pneumatic cylinder 71 opens the bearing portion 72 via the rod 71a by compressed air. Push back. Since the rod 81a is not fixed to the bearing portion 72, when the bearing portion 72 fluctuates beyond the stroke of the rod 81a, the bearing portion 72 is separated from the rod 81a. Moreover, when the bearing part 72 extends the rod 71a by the fluctuation of distance, the bearing part 72 abuts on the rod 81a, and the bearing part 72 further moves the rod 81a. When pressurized, the pneumatic cylinder 81 pushes back the bearing part 72 via the rod 81a by compressed air.

The thermoplastic resin used as a raw material of the resin film manufactured by the manufacturing apparatus of this invention is demonstrated.

Examples of the thermoplastic resin that can be used in the present invention include rubber-reinforced styrene resins such as polystyrene, high impact polystyrene, and medium impact polystyrene, styrene-acrylonitrile copolymer (SAN resin), and acrylonitrile-butyl acryl. Lateral rubber-styrene copolymer (AAS resin), acrylonitrile-ethylenepropyl rubber-styrene copolymer (AES), acrylonitrile-polyethylene-styrene copolymer (ACS), ABS resin (e.g. acrylonitrile Styrene resins such as butadiene-styrene copolymer, acrylonitrile-butadiene-styrene-alphamethylstyrene copolymer, acrylonitrile-methyl methacrylate-butadiene-styrene copolymer), polymethyl methacrylate (PMMA) Olefin resins such as acrylic resins such as acrylic resin, low density polyethylene (LDPE), high density polyethylene (HDPE), and polypropylene (PP), polyvinyl chloride, Vinyl chloride-based resins such as polyvinylidene chloride, vinyl chloride-based copolymer resins such as ethylene-vinyl acetate copolymer, ethylene-vinyl chloride copolymer, polyethylene terephthalate (PETP, PET), polybutylene terephthalate (PBTP, PBT Polycarbonate resins such as polyester resins, polycarbonate (PC), modified polycarbonates, polyamide resins such as polyamide 66, polyamide 6, polyamide 46, polyoxymethylene copolymer, polyoxy) Polyacetal (P0M) resins such as methylene homopolymers, other engineering resins, super engineering resins such as polyethersulfone (PES), polyetherimide (PEI), thermoplastic polyimide (TPI), polyetherketone ( PEK), polyether ether ketone (PEEK), polyphenylene sulfide (PSU), cellulose acetate (CA), cellulose acetate butyrate (CAB), ethyl Liquid crystal polymers, such as cellulose derivatives, such as a cellulose (EC), a liquid crystal polymer, and a liquid crystalline aromatic polyester, are mentioned. In addition, thermoplastic polyurethane elastomer (TPU), thermoplastic styrene butadiene elastomer (TSBC), thermoplastic polyolefin elastomer (TPO), thermoplastic polyester elastomer (TPEE), thermoplastic vinyl chloride elastomer (TPVC), thermoplastic polyamide elastomer (TPAE), etc. Thermoplastic elastomers may also be used. In the present embodiment, a blend of one or more thermoplastic resins may be used, or an additive may be used.

As a resin film manufactured by the said manufacturing apparatus, the resin film with which the haze which is an optical characteristic is uniform is obtained.

The arithmetic mean roughness (Ra) of the resin film of this invention based on JISB0601: 1994 is 1.1? 2.5 µm, preferably 1.5? 2.1 μm. Moreover, the ratio (Rz / Sm) of the 10-point average roughness Rz and the uneven | corrugated average space | interval Sm based on JIS BO601: 1994 is 0.04? 0.10, preferably 0.05? 0.09.

Here, Rz / Sm is a parameter having correlation with haze. The larger the ratio, the larger the inclination angle of the unevenness on the surface of the resin film, and the incident light to the resin film is strongly scattered, so that the haze increases. By defining the range of Rz / Sm, the resin film of this invention is specified by the film which has a surface state used as the haze of a preferable range.

In addition, the resin film of this invention measures a plurality of points (preferably 8 or more points) at equal intervals in the flow direction at the time of manufacture, makes it one measurement row, and a plurality of rows (preferably at equal intervals in the width direction) For example, the standard deviation of the total measurement results (128 points) at the time of measuring 16 columns or more) is 1.0 or less. Thereby, the resin film of the uniform surface state with little variation in haze is obtained.

Example

Polycarbonate (Caliber 301-10, manufactured by Sumitomo Dow Co., Ltd.) was used as the thermoplastic resin as a raw material. The raw material resin was melted and extruded by a single-screw extruder (manufactured by Toshiba Machine Co., Ltd.) having a cylinder diameter of 115 mm, and the film-shaped resin was discharged at 330 kg / h by a T die having a total width of 1900 mm having a set temperature of 270 ° C. Was discharged.

The rubber roll 3 and the mat roll 4 are arrange | positioned at intervals, and nip so that it may adhere to the discharged film-like resin. The mirror surface roll 5 was arrange | positioned at intervals of the mat roll 4 and 1.5 mm. The mat roll 4 is an iron roll (surface chromium plating process) of 400 mm in outer diameter, and is a roll which provided the micro uneven shape (Ra = 2.7 micrometer) in the surface by the blast process. The rubber roll 3 has an RTV silicone rubber layer having a durometer hardness A70 having a thickness of 10 mm as the rubber layer 32 (the inner layer 32a and the outer layer 32b having the same durometer hardness A70 as the rubber layer 32 on the iron core surface having an outer diameter of 380 mm. It is a roll which formed one layer by silicone rubber.

The surface temperature of the rubber roll 3 was 40 degreeC, the surface temperature of the mat roll 4 was 130 degreeC, and the surface temperature of the mirror surface roll 5 was 140 degreeC.

The pneumatic cylinder 71 set the air pressure upstream of the operation side to 0.5 Mpa, the air pressure downstream of the operation side to 0.14 MPa, the air pressure upstream of the drive side to 0.5 MPa, and the air pressure downstream of the drive side to 0.16 MPa.

The resin film produced had a thickness of 130 µm and a width dimension of 1700 mm.

(Comparative Example)

Using a servo motor instead of a pneumatic cylinder, the pressing force of the rubber roll 3 and the mat roll 4 was 1.5 at the operating side. 1.6 kN, drive side 1.8? It carried out similarly to the Example except having set to 1.9 kN.

(Assessment Methods)

The optical characteristic of the obtained resin film was evaluated by measuring the haze of a resin film. Haze measurement of the sample was measured using the haze meter HM-150 (made by Murakami Color Technology Research Institute). The evaluation sample extract | collected one wheel (length 1600mm) wound around the roll, measured 8 points at equal intervals in the flow direction, made it into one measurement row, and measured 16 rows at equal intervals in the width direction. Therefore, the measurement position is 128 points in total.

The standard deviation was calculated from the haze of 8 points | pieces for every measurement column, and the arithmetic mean value of the calculated standard deviation of 16 columns was computed.

The arithmetic mean of standard deviation of the sample of the resin film manufactured by the Example was small as 0.58, and the arithmetic mean of the standard deviation of the sample of the resin film manufactured by the comparative example was 1.74, and was large compared with the Example. This has shown that the Example of the variation of the haze in the flow direction and the width direction of a resin film is smaller than a comparative example.

Moreover, it measured about arithmetic mean roughness Ra and the ratio (Rz / Sm) of the 10-point average roughness (Rz) and the average space | interval Sm of unevenness | corrugation. These were measured using the surface roughness measuring instrument sub test SJ-201 by Mitsutoyo Corporation. The measurement position is 128 points similarly to haze. Both the Example and the comparative example computed the arithmetic mean value of the measured value in 128 points. In the Example, Ra (average value) was 1.6 µm and Rz / Sm (average value) was 0.065. In the comparative example, Ra (average value) was 1.6 µm and Rz / Sm (average value) was 0.058.

1: extruder
2: Die
3: rubber roll
4: matt roll
5: mirror roll
6: takeover roll
7: elastic support device
8: rail
31: iron core
32: rubber layer
32a: inner layer
32b: outer layer
33:
71: pneumatic cylinder
71a: load
72: bearing part
73: horizontal movable part
100: resin film production apparatus

Claims (6)

As a resin film manufacturing apparatus which manufactures the resin film which consists of thermoplastic resins by the melt-extrusion molding method,
Film forming means for extruding a thermoplastic resin in a molten state into a film to form a film;
As a molding means which consists of a 1st roll and a 2nd roll, and is arranged so that the rotating shaft of the said 1st roll and the rotating shaft of a said 2nd roll may be parallel, and the outer peripheral surface of the said 1st roll and the outer peripheral surface of a said 2nd roll contact, It is provided with the shaping | molding means which shape | molds the surface shape of a film-form thermoplastic resin by interposing between the made film-form thermoplastic resin between the outer peripheral surface of a said 1st roll, and the outer peripheral surface of a said 2nd roll,
One of the first roll and the second roll,
Core material consisting of a cylindrical or cylindrical metal member,
A rubber layer formed to cover the entire outer circumferential surface of the core material, the rubber layer comprising two layers of an inner layer formed on the side close to the core material and an outer layer formed on the outer side of the inner layer,
The said inner layer is a resin film manufacturing apparatus formed with either high temperature vulcanization silicone rubber or room temperature vulcanization silicone rubber. The method of claim 1,
The outer layer is a resin film production apparatus formed of room temperature vulcanized silicone rubber. The method of claim 1,
The inner layer has a durometer hardness of A60? A80, and the outer layer has a durometer hardness of A70? Resin film manufacturing apparatus which is A80. The method of claim 1,
The inner layer and the outer layer are formed of a room temperature vulcanized silicone rubber having a durometer hardness of A70. The method according to any one of claims 1 to 4,
And an elastic support device for elastically supporting one roll of the first roll and the second roll to the other roll so that the outer circumferential surface of the first roll and the outer circumferential surface of the second roll abut,
The elastic support device,
A bearing part of the rotating shaft of the first roll or the second roll,
A horizontal movable part for moving the bearing part in a horizontal direction;
And a pneumatic cylinder for fixing the rod to the bearing portion and giving elastic support to the roll via the bearing portion. As a resin film given optical characteristics,
Arithmetic mean roughness (Ra) based on JISB0601: 1994 is 1.1? 2.5 μm,
The ratio (Rz / Sm) of the ten point average roughness (Rz) and the uneven | corrugated average space | interval (Sm) based on JIS B0601: 1994 is 0.04? 0.10,
The resin film whose standard deviation of haze is 1.0 or less when a several point measurement is carried out at equal intervals in the flow direction at the time of manufacture, this is made into one measurement row, and a plurality of rows are measured at equal intervals in the width direction.

Images