WO2009123044A1 - Procédé de fabrication d'une feuille de résine présentant une variation d'épaisseur - Google Patents

Procédé de fabrication d'une feuille de résine présentant une variation d'épaisseur Download PDF

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Publication number
WO2009123044A1
WO2009123044A1 PCT/JP2009/056260 JP2009056260W WO2009123044A1 WO 2009123044 A1 WO2009123044 A1 WO 2009123044A1 JP 2009056260 W JP2009056260 W JP 2009056260W WO 2009123044 A1 WO2009123044 A1 WO 2009123044A1
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WIPO (PCT)
Prior art keywords
resin sheet
roller
nip roller
elastic
elastic nip
Prior art date
Application number
PCT/JP2009/056260
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English (en)
Japanese (ja)
Inventor
佐野　大輔
勝本　隆一
永野　英男
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富士フイルム株式会社
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Application filed by 富士フイルム株式会社 filed Critical 富士フイルム株式会社
Priority to CN2009801115137A priority Critical patent/CN101980854A/zh
Priority to JP2010505824A priority patent/JPWO2009123044A1/ja
Publication of WO2009123044A1 publication Critical patent/WO2009123044A1/fr

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    • 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
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
    • 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
    • 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
    • B29C43/28—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • 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
    • B29C48/03—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
    • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • 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
    • B29C48/30—Extrusion nozzles or dies
    • 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
    • B29C48/91—Heating, e.g. for cross linking
    • 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
    • B29C48/915—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
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/0073—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor of non-flat surfaces, e.g. curved, profiled
    • 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
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
    • B29C63/04—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material by folding, winding, bending or the like
    • B29C63/044—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material by folding, winding, bending or the like continuously
    • 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
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/305—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets

Definitions

  • the present invention relates to a method for manufacturing an uneven thickness resin sheet.
  • Patent Document 1 describes a method in which a central portion is narrowed in advance so that the diameter of a nip roller (clamping roller) becomes constant when heated in order to prevent wrinkling.
  • Patent Document 2 describes a method of laminating using a belt.
  • Patent Document 3 describes a method of adjusting the nip pressure. JP 2006-159723 A JP 2001-129919 A JP-A-7-228060
  • the conventional laminating method is intended for a flat object, that is, an object to be laminated having a substantially constant thickness in the width direction. Therefore, when the material to be laminated has an uneven shape with a thickness distribution in the width direction, these methods may cause insufficient adhesion of the laminate film at the thin part, and the masking film is laminated uniformly. It was difficult to do.
  • the present invention has been made in view of such circumstances, and an object of the present invention is to provide a method for producing an uneven thickness resin sheet capable of uniformly adhering a masking film over its entire width.
  • a method of manufacturing an uneven thickness resin sheet includes a step of extruding a molten resin from a die into a sheet shape, sandwiching the extruded resin sheet between a mold roller and a nip roller, A step of molding the resin sheet into an uneven shape having a thickness distribution in the width direction, a step of peeling the resin sheet from the mold roller, and a shape matching the shape of the drive roller and the resin sheet. A step of laminating a masking film on the resin sheet by clamping with an elastic nip roller.
  • the masking film is uniformly laminated on the resin sheet having the uneven thickness by sandwiching the masking film with the elastic nip roller having a shape matching the shape of the drive roller and the resin sheet. be able to.
  • the elastic nip roller may be adjusted to a shape of the resin sheet so that a difference in curvature is in a range of 0 to 20% with respect to the resin sheet having the uneven shape. preferable.
  • the masking film can be laminated more uniformly on the resin sheet.
  • the pinching pressure between the elastic nip roller and the driving roller is in a range of linear pressure of 10 kgf / cm to 100 kgf / cm.
  • the masking film will cause poor adhesion over the entire width. This is because if the linear pressure is larger than 100 kgf / cm, the sandwiching pressure in the width direction is larger at both ends than the center, and wrinkles are likely to occur at the center.
  • the distribution of the pinching pressure with respect to the resin sheet by the elastic nip roller and the driving roller is in a range of 0 to 200%. This is because if the pinching pressure distribution is larger than 200%, the masking film may be wrinkled.
  • the pressure between the elastic nip roller and the driving roller may be adjusted by individually adjusting the supply pressure to the pneumatic cylinder connected to the both end bearings of the elastic nip roller. Preferably it is possible.
  • the elastic nip roller is deformed during pinching by bringing the bearing of the elastic nip roller into contact with an interference object attached in the traveling direction of the elastic nip roller during pinching. It is preferable to suppress.
  • the bending of the elastic nip roller at the time of clamping can be suppressed, and the influence of the clamping pressure distribution in the width direction on the resin sheet can be reduced.
  • the surface of the elastic nip roller is preferably formed of a material having a rubber hardness specified by JIS K6253 of 50 ° to 90 °. This is because, by setting the rubber hardness range to 50 ° to 90 °, various accuracies such as the shape of the elastic nip roller can be maintained.
  • the masking film is formed into the uneven thickness resin sheet by being clamped by the elastic nip roller having a shape matched to the shape of the drive roller and the resin sheet.
  • the entire width can be uniformly laminated.
  • FIG. 1 is an explanatory view illustrating an example of an uneven thickness resin sheet
  • FIG. 2 is a process diagram for explaining the flow of the manufacturing method of the uneven thickness resin sheet to which the present invention is applied
  • FIG. 3 is a conceptual diagram of an uneven thickness resin sheet manufacturing apparatus to which the present invention is applied.
  • FIG. 4 is an explanatory view for explaining the configuration of the molding cooling roller.
  • FIG. 5A is a side view of a laminating apparatus
  • FIG. 5B is a front view of the laminating apparatus
  • FIG. 6 is a graph showing the clamping pressure distribution
  • FIG. 7A is an explanatory diagram showing the relationship between the shape of the elastic nip roller and the resin sheet when the curvature of the resin sheet and the curvature of the elastic nip roller substantially match
  • FIG. 7B is an explanatory diagram showing a relationship between the shape of the elastic nip roller and the resin sheet when the curvature of the elastic nip roller is larger than the curvature of the resin sheet.
  • warpage measuring device 79 ... stocker, 82 ... masking roll, 84 ... masking film, 86 ... Roller 88 ... Cutting machine 90 ... Cutting machine 90A ... Laser cutting device 100 ... Resin sheet 200 ... Laminating device 202 ... Elastic drive roller 204 ... Elastic nip Over La, 206 ... bearing, 208 ... pneumatic cylinder, 210 ... regulator, 212 ... power air source, 214 ... bearing height adjustment mechanism, 216 ... elastic tensioning roller
  • FIG. 1 shows an example of a resin sheet having an uneven thickness produced from the present invention. This resin sheet is not uniform in thickness in the width direction and has a thickness distribution.
  • a large-screen liquid crystal panel such as a large-screen liquid crystal television uses a resin sheet 100 having a thick central portion and thin both ends as shown in FIG.
  • the resin sheet 100 includes a light incident surface 102 on which light from the light source unit is incident, a light emitting surface 104 that emits planar light, and a light reflecting surface that guides light from the light incident surface 102 to the light emitting surface 104. 106 and a facing surface 108 located on the opposite side of the light incident surface 102.
  • the resin sheet is preferably configured such that the difference between the thickness of the thickest portion and the thinnest portion in the width direction of the sheet is in the range of 0.5 mm to 5.0 mm, and is 0.5 mm to 3.0 mm. Is more preferable.
  • the thickness difference between the thickest part and the thinnest part is 0.5 mm or less
  • lamination can be performed by a conventional method. This is because when the thickness difference is larger than 3.0 mm, the masking film is likely to be wrinkled before the nip, and when the thickness difference is larger than 5.0 mm, wrinkles are prominent.
  • FIG. 2 is an example of an overall process diagram for producing a resin sheet to which the present invention is applied
  • FIG. 3 is a conceptual diagram of a resin sheet production apparatus equipped with various devices for performing each process.
  • the resin sheet manufacturing method to which the present invention is applied mainly includes a raw material process 10 for measuring and mixing raw materials, and an extrusion process for continuously extruding molten resin into a sheet shape (band shape). 12 and a molding step 14 in which the extruded resin sheet is sandwiched between a mold roller and a nip roller, and the resin sheet is cooled and solidified while being molded into a shape having a thickness distribution in the width direction, and the solidified resin sheet is gradually cooled.
  • a cooling step 16 a warpage measuring step 18 for measuring pass / fail with respect to a predetermined standard regarding the warpage of the slowly cooled resin sheet, and if the warp exceeds a predetermined standard, the resin sheet is fed back to the molding step 14 and the slow cooling step 16
  • a control step 20 for controlling the cooling rate and the slow cooling rate in the width direction to be uniform, and a masking film for surface protection on the front and back surfaces of the resin sheet
  • a laminating process 22 a cutting process 24 for cutting the resin sheet to a predetermined size (length / width) to form individual resin sheets, and a stacking process 26 for stacking the cut resin sheets. Is done.
  • the raw material resin and the additive sent from the raw material silo 28 (or raw material tank) and the additive silo 30 (or additive tank) to the automatic weighing machine 32 are automatically measured.
  • the mixer 34 the raw material resin and the additive are mixed at a predetermined ratio.
  • master pellets in which the scattering particles are added to the raw material resin at a concentration higher than a predetermined concentration are manufactured by a granulator.
  • the master pellets to which the scattering particles are added at a higher concentration than the predetermined concentration and the base pellets to which the scattering particles are not added are mixed at a predetermined ratio by the mixer 34. The same applies when additives other than the scattering particles are added.
  • thermoplastic resin can be used as the raw material resin applied to the present invention.
  • PMMA polymethyl methacrylate resin
  • PC polycarbonate resin
  • PS polystyrene resin
  • MS resin AS resin
  • PP polypropylene resin
  • PE Polyethylene resin
  • PET polyethylene terephthalate resin
  • PVC polyvinyl chloride resin
  • thermoplastic elastomer or a copolymer thereof, cycloolefin polymer, and the like.
  • the raw material resin mixed in the mixer 34 is put into the extruder 38 through the hopper 36.
  • the raw material resin is melted while being kneaded by the extruder 38.
  • the extruder 38 may be either a single-screw extruder or a multi-screw extruder, and preferably includes a vent function that evacuates the inside of the extruder 38.
  • the raw material resin melted by the extruder 38 is sent to a die 44 (for example, a T die) through a supply pipe 42 by a metering pump 40 such as a screw pump or a gear pump.
  • the resin sheet A extruded from the die 44 into a sheet shape is sent to the molding step 14.
  • the resin sheet A extruded from the die 44 is sandwiched between the mold roller 46 and the nip roller 48.
  • the resin sheet A is cooled and solidified while being formed into a shape having a thickness distribution in the width direction.
  • the solidified resin sheet A is peeled off by the peeling roller 50.
  • the resin sheet A that has undergone the molding step 14 is then sent to the slow cooling step 16.
  • the slow cooling step (or annealing step) 16 is provided in order to prevent a rapid temperature change of the resin sheet A downstream of the peeling roller 50.
  • a sudden temperature change occurs in the resin sheet A, for example, the inside of the resin sheet A becomes elastic even though the vicinity of the surface of the resin sheet A is in a plastic state. The surface shape of the sheet A may be deteriorated.
  • the resin sheet A tends to warp. In particular, when the resin sheet A has a thickness distribution in the width direction, the resin sheet A is likely to warp.
  • the slow cooling step 16 is provided with a tunnel-like slow cooling zone 54 (or annealing zone) having an inlet and an outlet.
  • a tunnel-like slow cooling zone 54 or annealing zone having an inlet and an outlet.
  • the resin sheet A is heated by the heating device 55 and gradually naturally cooled.
  • forced cooling is performed by applying cold air to the resin sheet A.
  • the heating device 55 provided in the first half of the slow cooling zone 54 a structure in which air (hot air) whose temperature is controlled from a plurality of nozzles is jetted toward the resin sheet A, a nichrome wire heater, an infrared heater, a dielectric heating device, and the like
  • various known means such as a structure for heating the resin sheet A can be employed.
  • a shape holding device 56 is provided.
  • a plurality of air nozzle devices 74 that blast and convey the resin sheet A by blowing cold air are provided on the upper and lower sides of the slow cooling zone 54 with the resin sheet A interposed therebetween.
  • the air nozzle device 74 a well-known device used when a web-like conveyance object is floated and conveyed can be used. Thereby, the resin sheet A is cooled to about normal temperature in a non-contact state where it does not contact the roller.
  • the resin sheet A cooled in the slow cooling step 16 is taken up by the nip type feed roller 76 and sent to the warp measurement step 18.
  • the warpage measuring device 78 determines whether the warpage of the resin sheet A is acceptable or not with respect to a predetermined standard.
  • control step 20 feeds back the information to the molding step 14 and the slow cooling step 16, and the cooling rate in the resin sheet width direction and The slow cooling rate is controlled to be uniform.
  • a laminating step 22, a cutting step 24, and a loading step 26 are provided in this order downstream of the warp measuring step 18.
  • the laminating step 22 is a step of attaching a protective film (film such as polyethylene) to the front and back surfaces of the resin sheet A.
  • the masking film 84 rewound from the masking roll 82 is supplied to the front and back surfaces of the resin sheet A, and is laminated by passing through a pair of rollers 86, that is, an elastic nip roller and a driving roller.
  • the cutting step 24 includes a step of cutting the resin sheet A along a direction orthogonal to the transport direction and trimming it to a predetermined length, and a step of cutting both ends of the resin sheet A along the transport direction. .
  • the resin sheet is cut into individual resin sheets by passing through the cutting step 24.
  • a cutting machine of a type including a receiving blade 88A and a pressing blade 88B can be suitably used.
  • a laser cutting device can be used conveniently.
  • a laser cutting device 90A using laser light can be used as shown in FIG. Thereafter, in the loading step 26, the cut individual resin sheets are loaded on the stocker 79.
  • FIG. 4 is a schematic configuration diagram of a resin sheet manufacturing apparatus in the molding process.
  • the mold roller 46 is formed in a concave shape with a thin central portion and thick both ends.
  • the nip roller 48 is formed in a substantially flat shape.
  • a reverse shape for molding the resin sheet is formed on the roller surface of the mold roller 46.
  • the high-temperature resin sheet A pushed out from the die 44 is formed into a shape having a thickness distribution by being narrowed (nip) by the mold roller 46 and the nip roller 48 with a predetermined nip pressure.
  • the resin sheet A is molded such that the central portion has a thick portion.
  • the nip roller 48 is provided with a pressure device (not shown) so that the resin sheet A with the mold roller 46 can be clamped with a predetermined pressure.
  • Each of the pressurizing devices is configured to apply pressure in the normal direction at the contact point between the nip roller 48 and the mold roller 46.
  • Various known means such as a motor driving device, an air cylinder, and a hydraulic cylinder are used. Can be adopted.
  • the peeling roller 50 is disposed opposite to the mold roller 46 and is a roller for peeling the resin sheet A from the mold roller 46 by winding the resin sheet A, and is disposed 180 degrees downstream of the mold roller 46.
  • various steel members stainless steel, copper, zinc, brass, those metal materials made of a metal core and a rubber lining on the surface, these metal materials are made of HCr Those plated with Cu, Cu, Ni, etc., ceramics, and various composite materials can be used.
  • FIGS. 5A and 5B are schematic configuration diagrams of a laminating apparatus in a laminating process.
  • FIG. 5A is a side view of the laminating apparatus
  • FIG. 5B is a front view thereof.
  • the laminating apparatus 200 includes a fixed elastic driving roller 202 and an elastic nip roller 204 constituting a pair of rollers.
  • the elastic nip roller 204 is shaped so as to have a concave shape in which the central portion is thin and both ends are thick, in accordance with the resin sheet A having an uneven thickness. As a result, the elastic nip roller 204 can be uniformly adhered to the resin sheet A.
  • the surface of the elastic nip roller 204 is made of, for example, silicon rubber (SR), styrene butadiene rubber (SBR), chloroprene rubber (CR), chlorosulfonated polyethylene (CSM), acrylonitrile butadiene rubber (NBR), urethane rubber (U ), Ethylene propylene rubber (EPT), chlorinated polyethylene rubber (CPE), fluorine rubber (FPM), hydrogenated nitrile rubber (HNBR), butyl rubber (IIR), hyperon rubber (CMS), and the like. It is not done.
  • silicon rubber SR
  • SBR styrene butadiene rubber
  • CR chloroprene rubber
  • CSM chlorosulfonated polyethylene
  • NBR acrylonitrile butadiene rubber
  • U urethane rubber
  • EPT Ethylene propylene rubber
  • CPE chlorinated polyethylene rubber
  • FPM fluorine rubber
  • HNBR hydrogenated
  • the surface hardness of the elastic nip roller 204 is preferably 90 ° or less, more preferably 70 ° or less, as the rubber hardness specified by JIS K6253.
  • the surface of the elastic nip roller 204 is preferably mirror-finished with a surface roughness (Ra) in the range of 0.1 to 1.0 ⁇ m.
  • Bearings 206 that rotatably support the elastic nip roller 204 are provided at both ends of the elastic nip roller 204.
  • Pneumatic cylinders 208 are connected to bearings 206, respectively.
  • Each pneumatic cylinder 208 is connected to a power air source 212 via a regulator 210.
  • the regulator 210 can arbitrarily adjust the absolute value of the pressure between the elastic nip rollers 204 and the pressure balance between both ends of the elastic nip rollers 204, and can cope with the mechanical loss difference of the pneumatic cylinder 208.
  • the regulators 210 installed in each of the pneumatic cylinders 208 are excellent in flow rate and pressure characteristics, and are preferably a precision type having a mechanism for always discharging excess pressure in order to adjust to a constant pressure.
  • the bearing height adjusting mechanism 214 is provided in the traveling direction of the bearing 206 of the elastic nip roller 204 at the time of clamping.
  • the stop position of the bearing 206 is adjusted by the bearing height adjusting mechanism 214.
  • a bearing height adjusting mechanism 214 or the like that can arbitrarily adjust the height by pushing and pulling the taper block with a motor can be used.
  • a masking roll 82 attached to a simple shaft with a brake is provided on the upper and lower sides of the resin sheet A on the upstream side of the elastic nip roller 204 and the elastic drive roller 202.
  • Elastic tension adjusting rollers 216 are provided between the upper masking roll 82 and the elastic nip roller 204 and between the lower masking roll 82 and the elastic driving roller 202, respectively.
  • a thermoplastic resin can be used, and examples thereof include polypropylene resin (PP), polyethylene resin (PE), and polyethylene terephthalate resin (PET).
  • the thickness of the masking film 84 is preferably 0.2 mm or less, and more preferably 0.1 mm or less.
  • the resin sheet A is sandwiched between the fixed elastic drive roller 202 and the elastic nip roller 204 that is lowered by the pneumatic cylinder 208 connected to the both end bearings 206.
  • the elastic drive roller 202 is rotated clockwise by a connected motor, and conveys the resin sheet A in the direction of the arrow.
  • the masking film 84 is sent from the masking roll 82 to the elastic driving roller 202 and the elastic nip roller 204 via the elastic tension adjusting roller 216.
  • the masking film 84 is pinched by the elastic drive roller 202 and the elastic nip roller 204 from the vertical direction. Resin sheet A is laminated with masking film 84.
  • the elastic nip roller 204 since the shape of the elastic nip roller 204 is matched with the shape of the resin sheet, the elastic nip roller 204 can uniformly hold the masking film 84 against the resin sheet A.
  • FIG. 6 is a graph showing the clamping pressure distribution on the resin sheet in the laminating process.
  • the vertical axis represents pressure
  • the horizontal axis represents the distance in the width direction of the resin sheet A.
  • a curve a indicates the relationship between the pressure and the distance when the elastic nip roller uniformly clamps the resin sheet.
  • the curve a shows a uniform pressure value across the entire width direction of the resin sheet and is a straight line. In this case, the pressure distribution of the clamping pressure is 0%, which is the most preferable mode.
  • curve b shows the relationship between pressure and distance when the elastic nip roller is lowered by the pneumatic cylinder and the force for pinching the resin sheet is increased.
  • the shape of the elastic nip roller is matched to the shape of the resin sheet, so that the masking film is uniformly laminated on the resin sheet even if the pinching pressure distribution is 200%. be able to. If the pressure average value in the distance direction is Pave, the pinching pressure distribution can be obtained by (Pmax ⁇ Pmin) ⁇ 100 / Pave.
  • FIGS. 7A and 7B show the relationship between the shape of the resin sheet A and the elastic nip roller 204.
  • FIG. 7A shows the relationship when the curvature R1 of the resin sheet A and the curvature R2 of the elastic nip roller 204 substantially coincide.
  • the difference between the curvature R1 and the curvature R2 is substantially 0%.
  • FIG. 7B shows the relationship when the curvature R2 of the elastic nip roller 204 is larger than the curvature R1 of the resin sheet A.
  • the curvature R2 of the elastic nip roller 204 and the curvature R1 of the resin sheet A are not necessarily matched. However, if the difference is too large, there is a possibility that the adhesive strength of the masking film is insufficient at both ends of the resin sheet A as in the conventional case.
  • the difference between the curvature R1 and the curvature R2 is preferably in the range of 0 to 20%.
  • Example 1 PMMA (Asahi Kasei 80NH, glass transition temperature 110 ° C.) was extruded from a T die set at a temperature of 255 ° C. at 100 kg / hr and passed through a nip roller, a mold roller, a peeling roller, and a slow cooling zone at a conveyance speed of 1 m / min. A resin sheet was obtained which was made into a sheet shape and had a cross-sectional shape in the width direction as shown in FIG. The resin sheet had a width of 650 mm, a thinnest part of 2 mm, and a thickest part of 3.8 mm.
  • the resin sheet is sandwiched between an elastic nip roller (maximum diameter 195 mm at both ends and minimum diameter 192.1 mm at the center) and an elastic drive roller (diameter 195 mm), and a masking film (PE made 0.1 mm thick) is attached to the resin sheet. It was inserted into the upper surface and laminated. At this time, the position of the elastic nip roller was adjusted so as to stop at a position lowered by 1.0 mm from the position in contact with the resin sheet, and pinched with a linear pressure of 50 kg / cm. As a result, the masking film could be adhered to the entire surface of the resin sheet.
  • Example 2 When the linear pressure was gradually increased under the conditions of Example 1, it was possible to uniformly laminate the masking film on the resin sheet without wrinkles at the center at 100 kg / cm. At this time, the distribution in the width direction was 200%.
  • Example 1 Compared to Example 1, flat diameter 195 m not processed so as to be in close contact with the resin sheet The masking film was laminated on a resin sheet. As a result, the masking film did not adhere between 100 mm on both ends of the resin sheet. Moreover, when the pinching distribution in the width direction was measured, the pinching pressure at both ends 100 mm was zero.
  • Example 2 In contrast to Example 1, the elastic nip roller was clamped at a linear pressure of 100 kg / cm with an elastic nip roller (maximum diameter 195 mm at both ends and minimum diameter 192.5 mm at the center). As a result, the masking film was not adhered between 10 mm at both ends.
  • Example 3 Under the conditions in Example 1, the stop position of the elastic nip roller is gradually lowered and adjusted so that it stops when it reaches 2.0 mm from the position in contact with the resin sheet. did. As a result, wrinkles were generated in the masking film at the center of the resin sheet. The pinching distribution in the width direction at this time was 210%.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)

Abstract

La présente invention porte sur un procédé de fabrication d'une feuille de résine présentant une variation d'épaisseur. Ledit procédé comprend les étapes suivantes : le maintien d'une feuille de résine (A) par un rouleau de matrice (46) et un rouleau pinceur (48) et la formation de la feuille de résine (A) en une forme avec une variation d'épaisseur ayant une répartition d'épaisseur dans la direction latérale, le délaminage de la feuille de résine (A) par le rouleau de matrice (48) et le laminage d'un film de masquage (84) sur la feuille de résine (A) par pressage et maintien de la feuille de résine (A) par un rouleau d'entraînement et un rouleau pinceur élastique (204) selon une forme telle qui correspond à la forme de la feuille de résine (A). Par conséquent, le film de masquage (84) peut être laminé de manière uniforme sur toute la surface de la feuille de résine (A).
PCT/JP2009/056260 2008-03-31 2009-03-27 Procédé de fabrication d'une feuille de résine présentant une variation d'épaisseur WO2009123044A1 (fr)

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WO2010089944A1 (fr) * 2009-02-03 2010-08-12 富士フイルム株式会社 Procédé et dispositif de fabrication d'une feuille de résine présentant une épaisseur irrégulière
KR101938709B1 (ko) 2017-02-13 2019-01-15 주식회사 테크아이 라미네이팅 방법 및 장치

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CN103144235A (zh) * 2013-02-05 2013-06-12 朝阳浪马轮胎有限责任公司 轮胎气密层的生产工艺及装置

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JPH01308615A (ja) * 1988-06-07 1989-12-13 Toyoda Gosei Co Ltd 自動車用装飾モールの製造方法
JP2001096618A (ja) * 1999-10-01 2001-04-10 Katsura Roller Seisakusho:Kk ラミネーター用ゴムローラ
JP2008509016A (ja) * 2004-08-06 2008-03-27 ブレヤー ゲーエムベーハー マシーネンファブリク 押出された熱可塑性樹脂から板材を製造する方法
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WO2010089944A1 (fr) * 2009-02-03 2010-08-12 富士フイルム株式会社 Procédé et dispositif de fabrication d'une feuille de résine présentant une épaisseur irrégulière
KR101938709B1 (ko) 2017-02-13 2019-01-15 주식회사 테크아이 라미네이팅 방법 및 장치

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