WO2008075811A1 - Dispositif de fabrication d'un film optique et procédé de fabrication du dispositif - Google Patents

Dispositif de fabrication d'un film optique et procédé de fabrication du dispositif Download PDF

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Publication number
WO2008075811A1
WO2008075811A1 PCT/KR2006/005821 KR2006005821W WO2008075811A1 WO 2008075811 A1 WO2008075811 A1 WO 2008075811A1 KR 2006005821 W KR2006005821 W KR 2006005821W WO 2008075811 A1 WO2008075811 A1 WO 2008075811A1
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WO
WIPO (PCT)
Prior art keywords
resin
die
flexible band
flexible
film
Prior art date
Application number
PCT/KR2006/005821
Other languages
English (en)
Inventor
Bang Duk Kim
Sei Jin Oh
Jin Won Kim
Original Assignee
Cheil Industries Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Cheil Industries Inc. filed Critical Cheil Industries Inc.
Priority to CN200680056710XA priority Critical patent/CN101563203B/zh
Publication of WO2008075811A1 publication Critical patent/WO2008075811A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/222—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length characterised by the shape of the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/24—Calendering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B29C48/08—Flat, e.g. panels flexible, e.g. films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911—Cooling
    • B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
    • B29C48/914—Cooling of flat articles, e.g. using specially adapted supporting means cooling drums
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911—Cooling
    • B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
    • B29C48/9145—Endless cooling belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911—Cooling
    • B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
    • B29C48/915—Cooling of flat articles, e.g. using specially adapted supporting means with means for improving the adhesion to the supporting means
    • B29C48/9155—Pressure rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
    • B29C2043/023—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface having a plurality of grooves
    • B29C2043/025—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface having a plurality of grooves forming a microstructure, i.e. fine patterning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/44—Compression means for making articles of indefinite length
    • B29C43/48—Endless belts
    • B29C2043/483—Endless belts cooperating with a second endless belt, i.e. double band presses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/44—Compression means for making articles of indefinite length
    • B29C43/48—Endless belts
    • B29C2043/486—Endless belts cooperating with rollers or drums
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/022—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2033/00—Use of polymers of unsaturated acids or derivatives thereof as moulding material
    • B29K2033/04—Polymers of esters
    • B29K2033/08—Polymers of acrylic acid esters, e.g. PMA, i.e. polymethylacrylate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2017/00—Carriers for sound or information
    • B29L2017/001—Carriers of records containing fine grooves or impressions, e.g. disc records for needle playback, cylinder records
    • B29L2017/003—Records or discs
    • B29L2017/005—CD''s, DVD''s

Definitions

  • the present invention relates to an apparatus and method for manufacturing an optical film having superior optical characteristics, and more particularly, to an apparatus and method for manufacturing an optical film that has a smooth surface and superior optical characteristics and that can be used as a protective film for interior components of LCD or an optical storage media, such as DVD, which employs a blue-ray.
  • optical films useful for such components are required to have characteristics such as an optical isotropy, a suitable phase difference, and the like. Particularly, for an optical film used for a large screen, it is necessary to have very uniform optical characteristics.
  • Today's tendency in display manufacture is focused on development of displays that have a wider screen and a slimmer thickness, and thus, there is a need of an optical film that has an optical isotropy with as slim a thickness as possible, a low phase difference, and, if necessary, a sufficient thermal resistance.
  • high-density DVD products using a blue-ray as a light source such as blue-ray discs, have a thin protective film on their surface.
  • the film is required to have superior optical characteristics and a highly uniform thickness.
  • Typical examples of methods for manufacturing such a thin optical film, having an optical isotropy and a low phase difference include a solvent-casting method, which includes dissolving a polymer in a solvent, applying the dissolved polymer to an upper surface of a flexible band and volatilizing the solvent, and a melt-extrusion method, which includes melting a resin in an extruder, extruding the molten resin through a die and processing the extruded resin with metal or rubber rolls.
  • the former method can provide an optical film having a uniform thickness and superior optical characteristics
  • this method includes a difficulty related to the recovery of the solvent without exposure to atmosphere and a problem of low economic efficiency due to its low production rate irrespective of the high cost of equipment.
  • the latter method can be performed using inexpensive equipment and can have a high production rate, it has problems in that the optical film has low uniformity in thickness and low optical characteristics.
  • one of typical methods for manufacturing the optical film is a method wherein, after being melted and extruded, a resin is passed between cooling rolls to have a smooth surface and a uniform thickness.
  • This method has shortcomings as follows:
  • a bank is formed between the rolls that causes the generation of a die line on the film in the event where the bank is non-uniformly formed.
  • the film may have a bending characteristic depending on the difference in the cooling rate or cooling degree of both surfaces of the film and such bending characteristic of the film may substantially reduce the worth of a product.
  • this method is more conducive to manufacturing an isotropic film.
  • one surface of the film brought into contact with the roll is smooth whereas the other surface contacting air is rough, there is limitation in the optical applications of the film.
  • the film due to features of the process wherein only a single surface is brought into contact with the rolls, the film exhibits a bending characteristic, which causes degradation of the product.
  • the present invention has been made to solve the problems of the prior art, and it is an aspect of the present invention to provide an apparatus and method for manufacturing an optical film that has a low uniform phase difference, high optical isotropy, superior thickness uniformity, superior surface roughness, and long-term dimensional stability at high temperatures.
  • an apparatus for manufacturing an optical film which comprises: an extruder to compress and discharge a molten resin; a die provided to the extruder to determine a thickness of the resin extruding through the die; a flexible band to which the resin extruding through the die is applied; and a calender roll disposed on a path conveying the resin applied to the flexible band to compress an air contact surface of the resin.
  • an apparatus for manufacturing an optical film which comprises: an extruder to compress and discharge a molten resin; a die provided to the extruder to determine a thickness of the resin extruding through the die; a flexible band to which the resin extruding through the die is applied; and a flexible compression band disposed on a path conveying the resin applied to the flexible band to compress an air contact surface of the resin.
  • a method for manufacturing an optical film which uses an apparatus for manufacturing the optical film, the apparatus comprising: an extruder to compress and discharge a molten resin; a die provided to the extruder to determine a thickness of the resin extruding through the die; a flexible band to which the resin extruding through the die is applied; and a calender roll or a flexible compression band disposed on a path conveying the resin applied to the flexible band to compress an air contact surface of the resin, wherein a separation between the die and the flexible band is 30 mm or less and a pressure applied by the calender roll or the flexible compression band is 10 bars or less.
  • an optical film can be formed to have superior optical characteristics such as a low uniform phase difference and a low haze, low-shrinkage and bending characteristics, and superior surface characteristics and thickness uniformity by applying a molten resin to a flexible band and processing the surface of the applied resin at a low pressure with the calender roll or the flexible compression band.
  • Fig. 1 is a diagram of an apparatus for manufacturing an optical film according to a first embodiment of the present invention
  • Fig. 2 is a diagram of an apparatus for manufacturing an optical film according to a second embodiment of the present invention.
  • Fig. 3 is a diagram of a conventional apparatus for manufacturing an optical film using a calender roll
  • Fig. 4 is a diagram of a conventional apparatus for manufacturing an optical film using a cooling roll.
  • an apparatus for manufacturing an optical film comprises an extruder to compress and discharge a molten resin; a die provided to the extruder to determine a thickness of the resin extruding through the die; a flexible band to which the resin extruding through the die is applied; and a calender roll disposed on a path conveying the resin applied to the flexible band to compress an air contact surface of the resin.
  • an apparatus for manufacturing an optical film comprises: an extruder to compress and discharge a molten resin; a die provided to the extruder to determine a thickness of the resin extruding through the die; a flexible band to which the resin extruding through the die is applied; and a flexible compression band disposed on a path conveying the resin applied to the flexible band to compress an air contact surface of the resin.
  • a method for manufacturing an optical film employs an apparatus for manufacturing the optical film, which comprises: an extruder to compress and discharge a molten resin; a die provided to the extruder to determine a thickness of the resin extruding through the die; a flexible band to which the resin extruding through the die is applied; and a calender roll or a flexible compression band disposed on a path conveying the resin applied to the flexible band to compress an air contact surface of the resin, wherein a separation between the die and the flexible band is 30 mm or less and a pressure applied by the calender roll or the flexible compression band is 10 bars or less.
  • Fig. 1 is a diagram of an apparatus for manufacturing an optical film according to a first embodiment of the present invention.
  • the apparatus according to the first embodiment comprises an extruder 100 to compress and discharge a molten resin, a die 120 provided to the extruder 100 to determine the thickness of the resin 10 extruding through the die, a flexible band 200 to which the resin 10 extruding through the die 120 is applied, and a calender roll 300 disposed on a path conveying the resin 10 applied to the flexible band 200 to compress an air contact surface of the resin.
  • a separation between the die 120 and the flexible band 200 is
  • This distance is to prevent the resin 10 from suffering from orientation of a polymer chain while the resin is extruded through the die 120.
  • the air contact surface of the resin refers to an upper surface of the resin, which is opposite the surface of the resin contacting the flexible band 200 and is brought into contact with the calender roll 300 while being conveyed by the flexible band 200.
  • the die 120 is a part that determines the primary thickness of the film. According to this embodiment, since a high pressure is not exerted between the flexible band 200 and the calender roll 300, there is no need of capability to adjust a film thickness in great degree.
  • the primary thickness of the film is determined by the die.
  • the die is the same as that used for manufacturing a conventional optical film having a high quality, and if necessary, may further comprise a ceramic coating such as tungsten carbide on the surface thereof.
  • the present invention is characterized in that the separation between the die 120 and the flexible band 200 is very small.
  • the die 120 is 30 mm or less, and preferably 15 mm or less. In this regard, it is desirable that the die 120 does not contact the flexible band 200.
  • the resin 10 undergoes free fall due to gravity, during which the orientation of a polymer chain occurs in the resin 10, causing deterioration of optical characteristics of a final product.
  • the flexible band 200 is a metallic belt disposed between two or more rotational rolls 220 to move in a caterpillar manner.
  • the surface roughness of the flexible band 200 directly affects the surface quality of the resin 10, and thus, the flexible band 200 preferably has an Rz (ten point height roughness) of 0.1 or less, and, more preferably, 0.07 or less, where Rz is the difference between the average distance of the five highest peaks and the average distance of the five lowest valleys measured from a certain straight line (reference line) parallel to the mean line over a given sampling length in a cross-sectional roughness profile.
  • the temperature of the flexible band 200 may be controlled by controlling the temperature of the rotational rolls 220 or by using a separate heater or cooler.
  • the resin 10 is conveyed between the flexible band 200 and the calender roll 300 with the aim of making both surfaces of an optical film of the resin 10 very flat while providing a minute thickness adjustment effect.
  • a relatively low pressure is exerted between the flexible band 200 and the calender roll 300.
  • An effective pressure between the flexible band 200 and the calender roll 300 is 10 bars or less, and more preferably 5 bars or less.
  • a higher pressure therebetween can cause a phase difference in the film and such an undesired phase difference can cause deterioration in the optical characteristics of the final product.
  • Examples of the resin 10 may include polycarbonate-based resins, polymethylmethacrylate-based resins, ring polymer-based resins, polynorbornene-based resins, and polyethylene terephthalate-based resins. Particularly, in the case where any of the resins such as polycarbonate and the like is used for optical applications, various kinds of additives are added to the resin to complement or impart mechanical properties, where such resins contain oligomer or monomer of a low molecular weight therein.
  • the diffused substances or gases are stuck to the die 120 or to the surface of the calender roll 300 or flexible band 200, causing defect such as a die line.
  • a gas discharge device 150 is disposed around the die 120 to suck the additives, oligomer and monomer emitted from the resin and to forcibly discharge these substances to the outside.
  • the separation between the die 120 and the flexible band 200 is set to be small, it is possible to minimize the disadvantageous effect possibly caused by the gas discharge device 150.
  • the gas discharge device 150 is not an essential component of the present invention. Depending on features of a process using resins, since some resins generate little or no gas, a process or apparatus can exist that does not require the gas discharge device. Furthermore, in the case where a sufficient number of vents are provided at the middle of the extruder, requirement for the gas discharge device is reduced.
  • Fig. 2 is a diagram of an apparatus for manufacturing an optical film according to a second embodiment of the invention.
  • the apparatus comprises an extruder 100 to compress and discharge a molten resin, a die 120 provided to the extruder 100 to determine the thickness of the resin extruding through the die 100, a flexible band 200 to which the resin extruding through the die 120 is applied, and a flexible compression band 400 disposed on a path conveying the resin applied to the flexible band to compress an air contact surface of the resin.
  • the flexible compression band 400 has the same function as that of the calender roll 300 shown in Fig. 1 and is disposed on a path conveying the resin 10 to compress the air contact surface of the resin 10.
  • the flexible compression band 400 is disposed between two or more rotational rolls 410 and 420 to move in a caterpillar manner.
  • the flexible compression band 400 can be formed of metal, plastic, rubber, etc., most preferably, the flexible compression band 400 is formed of metal when considering a degree of mold release with respect to a molding resin. A principle of compressing a resin with the flexible compression band
  • the flexible compression band 400 is supported and rotated by the two rotational rolls 410 and 420 positioned above the flexible band 200.
  • the resin 10 experiences pressure between the flexible band 200 and the flexible compression band 400, and thus is adjusted in thickness.
  • an effective pressure exerted between the flexible band 200 and the flexible compression band 400 is 10 bars or less, and more preferably 5 bars or less, which are the same as those of the first embodiment wherein the pressure is applied by the calender roll 300 as shown in Fig. 1.
  • the method employs an apparatus for manufacturing an optical film, which comprises an extruder to compress and discharge a molten resin; a die provided to the extruder to determine a thickness of the resin extruding through the die; a flexible band to which the resin extruding through the die is applied; and a calender roll or a flexible compression band disposed on a path conveying the resin applied to the flexible band to compress an air contact surface of the resin, wherein, preferably, a separation between the die and the flexible band is 30 mm or less while preventing the die from contacting the flexible band, a pressure applied by the calender roll or the flexible compression band is 10 bars or less, and the flexible band has a conveying speed in the range of 5 ⁇ 100 m/min.
  • the film is peeled off from the flexible band at a temperature of Tg (glass transition temperature) or less, and measured with respect to the thickness and phase difference thereof, followed by a stretching process, if necessary.
  • Tg glass transition temperature
  • the separation between the die and the flexible band is preferably small to prevent the orientation in the resin, and an excessive pressure exerted on the resin can cause deterioration of the optical characteristics resulting from generation of stress.
  • the conveying speed of the flexible band is directly related to production rate. A production rate exceeding 100 m/min can cause deterioration of the optical characteristics due to the orientation in the resin by a rapid flow of the resin during the discharge of a great amount of resin through the die, whereas a production rate less than 5 m/min decreases economic performance.
  • the flexible band preferably has a conveying speed in the range of 5 ⁇ 100 m/min.
  • optical film prepared by the apparatus and method according to the invention will be compared with optical films (Comparative Examples 1 and 2) prepared using a conventional calender roll or cooling roll.
  • An optical polycarbonate film was prepared using an apparatus as shown in Fig. 1.
  • the molten resin was applied to a flexible band 200 through a die 120, in which a distance between die lips of the die 120 can automatically and independently be adjusted.
  • a separation between the die 120 and the flexible band 200 was maintained at 8 mm, and gas discharge devices 150 were disposed at front and rear sides of the die to remove sublimated or vaporized substances.
  • the resin 10 applied to an upper surface of the flexible band 200 was processed to allow a surface (air contact surface) of the resin 10 opposite the flexible band to have superior surface characteristics, too, while passing through the calender roll 300.
  • a pressure between the calender roll 300 and the flexible band 200 was maintained at 2 bars.
  • the resin was passed through a non-contact type thickness measuring system (not shown), where information of the resin was transmitted to a die system and used for adjustment of the distance between the die lips by a thermal expansion bolt system.
  • a pressure between the calender rolls 30 was set to be 30 bars, and a separation from the die 120 to a bank defined between the calender rolls 30 was 8 cm.
  • the resin After being passed through a total of three calender rolls, the resin was passed through the same thickness measuring system as that of Example. Finally, a film having a thickness of 100 ⁇ m was obtained.
  • the resin was applied in a tangential direction on the roll surface, wound around the cooling roll 40 by about 180 degrees, and then separated from the cooling roll 40.
  • the film prepared according to the present invention is superior in view of optical characteristics and has a lower shrinkage rate and better thickness uniformity compared with the film prepared using the conventional calender roll or cooling roll.
  • Such a low shrinkage rate means that the film has a high dimensional stability at high temperatures for a long period. Additionally, it can be confirmed by comparison with the comparative examples that the film of Example has a very low thickness deviation as well as the low shrinkage rate. With regard to a haze and die line, although the method using a plurality of calender roll as in Comparative Example 1 is known to provide superior characteristics, it can be seen from Table 1 that the film of Example also provides an equivalent level of superior characteristics.
  • the film of Example exhibits a very low phase difference compared with that of the film by the conventional melt-extrusion method, which means that a very low external stress is generated in the film of Example during the process of manufacturing the film.
  • the film experiences a bending phenomenon related to a round shape of the rolls.
  • Comparative Example 2 also experienced such a bending phenomenon due to the round shape of the rolls, whereas Comparative Example 1 did not suffer from the bending phenomenon.
  • a very strict procedure and time consumption were required to establish process conditions in order to prevent or remove such a bending phenomenon.
  • the film of the present invention has high levels of various optical characteristics, long-term dimensional stability at high temperatures, low bending characteristics, and superior surface characteristics.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention concerne un dispositif et un procédé de fabrication d'un film optique présentant des caractéristiques optiques supérieures. Le film optique présente une surface lisse et des caractéristiques optiques supérieures et peut être employé en tant que film protecteur pour un composant intérieur d'un écran à cristaux liquides ou un support de stockage optique tel qu'un DVD Blu-ray. Le dispositif comporte une extrudeuse destinée à comprimer et à expulser une résine fondue, un moule équipant l'extrudeuse, destiné à déterminer une épaisseur de la résine extrudée au travers du moule, une bande flexible sur laquelle la résine extrudée au travers du moule est appliquée, et un rouleau de calandrage ou une bande de compression flexible disposée sur une voie convoyant la résine appliquée sur la bande flexible afin de comprimer la surface de contact avec l'air de la résine. L'invention concerne également un procédé de fabrication du film optique au moyen de ce dispositif.
PCT/KR2006/005821 2006-12-20 2006-12-28 Dispositif de fabrication d'un film optique et procédé de fabrication du dispositif WO2008075811A1 (fr)

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KR1020060131386A KR100730415B1 (ko) 2006-12-20 2006-12-20 광학필름 제조장치 및 이를 이용한 광학필름 제조방법

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KR100730415B1 (ko) 2007-06-19

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