WO2011148585A1 - 複積層体の製造方法及びその製造装置、複積層体 - Google Patents
複積層体の製造方法及びその製造装置、複積層体 Download PDFInfo
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- WO2011148585A1 WO2011148585A1 PCT/JP2011/002711 JP2011002711W WO2011148585A1 WO 2011148585 A1 WO2011148585 A1 WO 2011148585A1 JP 2011002711 W JP2011002711 W JP 2011002711W WO 2011148585 A1 WO2011148585 A1 WO 2011148585A1
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- 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
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/49—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using two or more extruders to feed one die or nozzle
- B29C48/495—Feed-blocks
-
- 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
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/50—Details of extruders
- B29C48/695—Flow dividers, e.g. breaker plates
-
- 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
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/50—Details of extruders
- B29C48/695—Flow dividers, e.g. breaker plates
- B29C48/70—Flow dividers, e.g. breaker plates comprising means for dividing, distributing and recombining melt flows
-
- 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
- B29L2007/00—Flat articles, e.g. films or sheets
- B29L2007/008—Wide strips, e.g. films, webs
-
- 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
- B29L2009/00—Layered products
-
- 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
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24174—Structurally defined web or sheet [e.g., overall dimension, etc.] including sheet or component perpendicular to plane of web or sheet
Definitions
- the present invention relates to a multi-layered body made of a polymer material having melt fluidity and curability, a manufacturing method thereof, and a manufacturing apparatus thereof.
- an optical interference film that selectively reflects or transmits light of a specific wavelength by light interference between these layers.
- a laminated film has a wavelength region of light that is selectively reflected or transmitted as a visible light region, such as a reflective polarizing plate, a coloring film, a film having a metallic luster, or a reflective mirror film. It is spreading to uses.
- the near-infrared is selectively cut, it can also be used as a solar-cut window covering film, and the multi-layered film is expected to be used for various purposes in the future.
- the above-mentioned multilaminate film is formed by laterally laminating in the thickness direction of the film using a multilayer extrusion technique (Patent Documents 1 and 2).
- This multi-layer extrusion technique passes various thermoplastic materials from various extruders through a multi-layer manifold die, a multi-layer feed block, and a film die, and fuses the individual streams in the feed block. And stacking into a die to form a stack.
- a first flow composed of separate superimposed layers of one or two or more materials is divided into a plurality of tributaries, and these tributaries determine a redirection and re-run. Positioned, individually expanded and contracted symmetrically, the resistance to each tributary flow is independently adjusted, the tributaries are recombined into a superimposed state, and a very large number of separate superimposed layers of one or more materials are formed. It is described that a second flow distributed to a predetermined gradient or other distribution state is formed.
- Patent Document 2 the dimensions of each part of the flow path have a predetermined relationship in order to reduce the variation between the laminations of the multilayer laminated film composed of at least two types of thermoplastic resin layers and having two or more laminated layers.
- a method for producing a multilayer laminated film using a laminating device having a filling structure is described.
- Patent Documents 1 and 2 are lamination of layers oriented in the lateral direction, there is a problem in that layer thickness unevenness occurs and the layers cannot be uniformized.
- Patent Document 3 a method and an apparatus for manufacturing a multi-layered product oriented in the vertical direction by dividing, rearranging, and recombining two or more viscous polymer fluids in the initial stage are disclosed. Proposed. Specifically, Patent Document 3 provides at least a first flow of a first curable fluid and a second flow of a second curable fluid, from the first fluid and the second fluid.
- Composing the first flow and the second flow to supply a composite flow of fluids comprising: dividing the composite flow into a plurality of branch flows each of which comprises a first fluid and a second fluid Longitudinally, including branching flow to be laterally adjacent to each other, and fusing a plurality of laterally adjacent flows to provide a vertically oriented multilayer stack
- a method for producing a multi-layer laminate oriented in the direction is described.
- the first flow is divided into two flows of the first fluid, and then the two flows of the first fluid and the second to provide the first flow and the third flow therein.
- a method is described that includes combining a second stream comprising combining streams.
- the manufacturing method according to Patent Document 3 is an arrangement mechanism that repeats vertical division and horizontal arrangement, and is a mechanism that has a short flow path from vertical division to left and right arrangement in order to shorten the overall length of the apparatus.
- the number of times increases, there is a problem in that unevenness in the thickness of the layer and collapse of the vertical arrangement occur due to disappearance of the layers at the left and right end portions of the obtained vertical arrangement product.
- FIG. 7 the L2 / L1 defined in this specification is 0.58.
- Comparative Example 2-1 and Comparative Example 2-4 in FIGS. 10 and 11 division, branching, rearrangement, and merging are performed.
- the influence of the unevenness increases each time division, branching, rearrangement, and merging are repeated, resulting in disturbance of the laminated cross section, There was a problem that the verticality was lowered.
- the ratio of the defective portion increases each time division and rearrangement are repeated, and the proportion of defective portions contained in the finally obtained multi-layered body is very high. There was a problem that the performance increased and the performance was adversely affected.
- the present invention has been made in order to solve the above-described problems, and it is possible to suppress the disappearance of layers at both end portions, to suppress uneven thickness of the layers or collapse of the vertical arrangement, and to provide a multi-layered product having more excellent uniformity.
- An object of the present invention is to provide a method for manufacturing a multi-layered product that can be manufactured and a manufacturing apparatus therefor.
- the method for producing the first multi-laminate according to the present invention is as follows.
- a laminated flow in which at least two molten resins are arranged in the longitudinal direction and adjacent to each other is divided into two vertically, and the divided laminated upper flow is a first laminated flow, and the lower laminated flow is a second laminated flow,
- the first laminar flow is guided leftward in the flow direction
- the second laminar flow is directed rightward in the flow direction
- the first laminar flow is directed toward the center of the flow direction.
- the second laminated flow is directed toward the upper left direction toward the center of the flow direction, and then the first laminated flow and the second laminated flow are rearranged adjacent to each other in the left-right direction.
- Step 1 (L channel) for joining A laminated flow in which at least two molten resins are arranged in the longitudinal direction and adjacent to each other is divided into two vertically, and the divided upper laminated flow is defined as a third laminated flow, and the lower laminated flow is defined as a fourth laminated flow.
- Step 2 (R channel) Guiding the third laminar flow to the right in the flow direction, guiding the fourth laminar flow to the left in the flow direction, and then directing the third laminar flow to the center of the flow direction.
- the fourth laminated flow is guided in the upper right direction toward the center of the flow direction, and then the third laminated flow and the fourth laminated flow are rearranged adjacent to each other in the left-right direction.
- Step 2 (R channel) to be merged The step 1 (L channel) and the step 2 (R channel) are alternately repeated in this order for at least three steps.
- the method for producing the second multi-laminate according to the present invention is as follows.
- a laminated flow in which at least two molten resins are arranged in the longitudinal direction and adjacent to each other is divided into two vertically, and the divided laminated upper flow is a first laminated flow, and the lower laminated flow is a second laminated flow,
- the first laminar flow is guided in the right direction toward the flow direction
- the second laminar flow is led in the left direction toward the flow direction
- the first laminar flow is directed toward the center of the flow direction.
- the second laminated flow is directed to the upper right direction toward the center of the flow direction, and then the first laminated flow and the second laminated flow are rearranged adjacent to each other in the left-right direction and merged.
- Step 2 The laminated flow in which at least two molten resins are arranged in the longitudinal direction and adjacent to each other is divided into two vertically, the divided upper laminated flow as the third laminated flow, and the lower laminated flow as the fourth laminated flow, The third laminar flow is led leftward in the flow direction, the fourth laminar flow is led rightward in the flow direction, and then the third laminar flow is directed toward the center of the flow direction. In the lower right direction, the fourth laminated flow is guided in the upper left direction toward the center of the flow direction, and then the third laminated flow and the fourth laminated flow are rearranged adjacent to each other in the left-right direction.
- Step 1 (L channel) to be merged, The step 2 (R flow path) and the step 1 (L flow path) are alternately repeated in this order for at least three steps or more.
- the third method for producing a multilayer laminate according to the present invention is as follows. At least two molten resins are arranged in the longitudinal direction and adjacent to each other to form a laminated flow having a predetermined width and thickness; At the dividing point, the laminated flow is divided into two in the vertical direction, the divided upper laminated flow is the first laminated flow, the lower laminated flow is the second laminated flow, At the bifurcation point, the first laminar flow is led leftward in the flow direction, and the second laminar flow is led rightward in the flow direction, At the midpoint, the first laminar flow is directed in the lower right direction toward the center of the flow direction, and the second laminar flow is directed in the upper left direction toward the center of the flow direction, A method for producing a multi-layered product in which the first laminated flow and the second laminated flow are rearranged adjacent to each other and merged at a joining point, A laminate having the predetermined width and thickness, where L1 is the longer length of the width and thickness of the layered flow and
- the fourth method for producing a multi-laminate according to the present invention is as follows. At least two molten resins are arranged in the longitudinal direction and adjacent to each other to form a laminated flow having a predetermined width and thickness; At the dividing point, the laminated flow is divided into two in the vertical direction, the divided upper laminated flow is the first laminated flow, the lower laminated flow is the second laminated flow, At the bifurcation point, the first laminar flow is led in the right direction toward the flow direction, and the second laminar flow is led in the left direction toward the flow direction, At the midpoint, the first laminar flow is directed in the lower left direction toward the center of the flow direction, and the second laminar flow is directed in the upper right direction toward the center of the flow direction, A method for producing a multi-layered product in which the first laminated flow and the second laminated flow are rearranged adjacent to each other and merged at a joining point, A laminate having the predetermined width and thickness, where L1 is the longer length of the width and thickness
- the fifth method for producing a multi-laminate according to the present invention is as follows. At least two molten resins are arranged in the longitudinal direction and adjacent to each other to form a laminated flow having a predetermined width and thickness; At the dividing point A2, the laminated flow is divided into two in the vertical direction, the divided upper laminated flow is the first laminated flow, the lower laminated flow is the second laminated flow, At the branch point B2, the first laminated flow is led in the left direction toward the flow direction, and the second laminated flow is led in the right direction in the flow direction, At the intermediate point C2, the first laminated flow is led in the lower right direction toward the center of the flow direction, and the second laminated flow is led in the upper left direction toward the center of the flow direction, A first step of rearranging and merging the first laminated flow and the second laminated flow adjacent to each other at a joining point D2, At the dividing point E2, the rearranged and merged laminated flow is divided into two vertically, the divided upper laminated flow is the third laminate
- the sixth method for producing a multi-laminate according to the present invention is as follows. At least two molten resins are arranged in the longitudinal direction and adjacent to each other to form a laminated flow having a predetermined width and thickness; At the dividing point A2, the laminated flow is divided into two in the vertical direction, the divided upper laminated flow is the first laminated flow, the lower laminated flow is the second laminated flow, At the branch point B2, the first laminar flow is guided in the right direction toward the flow direction, and the second laminar flow is led in the left direction in the flow direction, At the intermediate point C2, the first laminar flow is directed in the lower left direction toward the center of the flow direction, and the second laminar flow is directed in the upper right direction toward the center of the flow direction, A first step of rearranging and merging the first laminated flow and the second laminated flow adjacent to each other at a joining point D2, At the dividing point E2, the rearranged and merged laminated flow is divided into two vertically, the divided upper laminated flow
- the first apparatus for producing a multi-layered product comprises: A divided plate that vertically divides a laminated flow in which at least two molten resins are arranged in the longitudinal direction and adjacent to each other; A flow path for guiding the upper laminated flow divided by the dividing plate in the left direction, a flow path for guiding the lower laminated flow in the right direction, and a flow for guiding the upper laminated flow in the lower right direction toward the center.
- An array plate (L channel) having a channel and a channel for guiding the lower laminated flow toward the upper left direction toward the center;
- a set of L flow path type plates comprising: a parallel plate that rearranges and merges the stacked flows arranged in the left-right direction on the array plate (L flow path);
- a divided plate that vertically divides a laminated flow in which at least two molten resins are arranged in the longitudinal direction and adjacent to each other;
- an array plate (R channel) having a channel that guides the lower laminated flow toward the upper right direction toward the center
- a set of R flow path type plates comprising: a parallel plate that rearranges and merges the stacked flows arranged in the left-right direction on the array plate (R flow path), Two or more sets are
- the second multi-laminate manufacturing apparatus is as follows.
- a dividing plate that divides a laminated flow having a predetermined width and thickness formed by arranging and adjoining at least two molten resins in the vertical direction into two at the dividing point;
- An array plate (L flow path) having a flow path leading to the lower right direction and a flow path guiding the lower laminated flow toward the upper left direction toward the center;
- a set of L flow path type plates comprising a parallel plate that rearranges and joins the laminated flow arranged on the left and right by the arrangement plate (L flow path) at a merge point, When the length of the longer one of the width and thickness of the laminated flow is L1, and the length in the flow direction from the branch point to the confluence is L2,
- the laminated flow having the
- the third multi-laminate manufacturing apparatus comprises: A dividing plate that divides a laminated flow having a predetermined width and thickness formed by arranging and adjoining at least two molten resins in the vertical direction into two at the dividing point; At the bifurcation point, the flow path for guiding the upper laminated flow divided by the dividing plate in the right direction, the flow path for guiding the lower laminated flow in the left direction, and at the intermediate point, the upper laminated flow is directed toward the center.
- An array plate (R flow path) having a flow path that leads to the lower left direction and a flow path that leads the lower laminated flow toward the upper right direction toward the center;
- a set of R flow path type plates provided with a parallel plate that rearranges and merges the laminated flow arranged on the left and right by the arrangement plate (R flow path) at a merge point,
- a laminate having the predetermined width and thickness, where L1 is the longer length of the width and thickness of the layered flow and L2 is the length in the flow direction from the junction to the junction.
- the flow satisfies the relationship of L2 / L1 ⁇ 1.1.
- the fourth multi-laminate manufacturing apparatus is as follows.
- a dividing plate that vertically divides a laminated flow having a predetermined width and thickness formed by arranging and adjoining at least two molten resins in the vertical direction at a dividing point A2, and A flow path for guiding the upper laminated flow divided by the dividing plate to the left and a flow passage for guiding the lower laminated flow to the right at the branch point B2.
- An array plate (L flow path) having a flow path for guiding the upper laminated flow in the lower right direction toward the center and a flow path for guiding the lower laminated flow in the upper left direction toward the center at the intermediate point C2.
- a set of L flow path type plates comprising: a parallel plate that rearranges and merges the laminated flow arranged on the left and right by the arrangement plate (L flow path) at a junction D2.
- a dividing plate that vertically divides a laminated flow formed by arranging and adjoining at least two molten resins in a vertical direction at a dividing point E2, and A flow path for guiding the upper laminated flow divided by the dividing plate in the right direction and a flow path for guiding the lower laminated flow in the left direction at the branch point F2,
- An array plate (R flow path) having a flow path for guiding the upper laminated flow in the lower left direction toward the center and a flow path for guiding the lower laminated flow in the upper right direction toward the center at the intermediate point G2.
- Two or more sets of R flow path type plates alternately including two or more sets of R flow path type plates, each of which includes a parallel plate that rearranges and merges the stacked flow arranged left and right on the arrangement plate (R flow path) at the merge point H2.
- An apparatus for producing a multi-layered product The longer length of the width and thickness of the laminated flow is L1, and the length in the flow direction from the branch point B2 to the junction point D2 and / or the branch point F2 to the junction point H2 Is L2, the laminated flow having the predetermined width and thickness satisfies the relationship of L2 / L1 ⁇ 1.1.
- the multi-layered product according to the present invention is manufactured by any one of the first to sixth methods for manufacturing a multi-layered product according to the present invention.
- the local flow velocity unevenness generated in the flow path for forming the multi-layered product is small, and the stacking is hardly disturbed.
- the disappearance of the layers at both ends is suppressed, and the layer thickness unevenness is suppressed.
- the collapse of the vertical arrangement can be reduced, and the layer can be made uniform without reducing the thickness of the layer width at both ends.
- FIG. 1 It is a schematic diagram of the manufacturing apparatus of the multilayer body concerning Embodiment 1 of the present invention. It is a schematic diagram of the manufacturing apparatus of the multilayer body concerning Embodiment 1 of the present invention. It is a schematic diagram of a set of plates (LME). 2 is a photograph of a multilayered product according to Example 1-2 and Comparative Examples 1-2 to 1-5. 4 is a photograph of a multilayered product according to Example 1-3 and Comparative Example 1-6. It is a schematic diagram of the manufacturing apparatus of the double laminated body which concerns on Embodiment 2 of this invention. It is a schematic diagram of the manufacturing apparatus of the double laminated body which concerns on Embodiment 2 of this invention. FIG. FIG.
- stacking flow in each position of the L flow path of L2 / L1 2.0.
- 2 is a cross-sectional photograph of a multi-layered body according to Example 2-1 and Comparative Example 2-1. 2 is a cross-sectional photograph of a multilayered product according to Example 2-4 and Comparative Example 2-4. It is a schematic diagram of a set of plates (LME).
- Embodiment 1 a method for producing a multilayer laminate according to Embodiment 1 of the present invention will be described.
- the inventors of the present invention have intensively studied a multi-layered product that has small flow rate unevenness and can reduce layer thickness unevenness or collapse of vertical alignment.
- the layer arrangement mechanism affects the stabilization of the layer structure, and focusing on the fact that the arrangement in the same direction causes the layers at both ends to disappear and the shape of the central layer to collapse as the number of divisions increases.
- studies were made on a multi-layered product that does not cause uneven layer thickness, collapse of the arrangement, or disappearance of the layers at both ends.
- the present inventors have found an arrangement structure in which the arrangement is alternated between left and right after dividing the laminated flow, and the present invention has been completed.
- FIG. 1 and 2 are schematic views of a multi-layered body manufacturing apparatus according to Embodiment 1 of the present invention. Through the series of steps shown in FIG. 1 and the series of steps shown in FIG. 2, the multilayer body according to the present embodiment is manufactured.
- the split flow is divided by the splitting mechanism 11, the split flow is split by the splitting mechanism 12, the stacking flow is rearranged by the rearrangement merging mechanism 13, and the merging operation is performed by the stabilization mechanism. 14 is performed.
- splitting mechanism 11 the branching mechanism 12, the rearrangement merging mechanism 13 and the merging mechanism 14 will be described in detail.
- the laminated flow P1 is divided in a direction orthogonal to the longitudinal direction, that is, vertically divided, the upper laminated flow is defined as the first laminated flow P2, and the lower laminated flow is designated as the first.
- a split operation is performed to obtain two stacked flows P3.
- the laminated flows P2 and P3 divided by the dividing mechanism 11 lead the laminated flow P2 leftward in the flow direction in the branching mechanism 12 with reference to the line connecting the resin dividing point A1 and the intermediate point B1 in the flow direction.
- the flow is branched by guiding the laminated flow P3 in the right direction toward the flow direction. This is a branch operation.
- the branched laminated flows P2 and P3 are guided by the rearrangement merging mechanism 13 so that the laminated flow P2 is directed to the merging point C1 in the lower right direction toward the center of the flow direction.
- the laminated flows P2 and P3 are rearranged adjacent to each other in the left-right direction, and a laminated flow P4 is formed.
- it is preferable that the laminated flows P2 and P3 are led to the center in both the left-right direction and the up-down direction.
- the laminated flow P ⁇ b> 4 rearranged and joined is subjected to a joining operation in the stabilization mechanism 14.
- L flow path This series of steps 1 (see FIG. 1) is referred to as a left rotation flow path (hereinafter referred to as L flow path).
- the number of layers is increased by replacing the layered flow P4 obtained by the L channel as shown in FIG.
- the laminar flow P4 produced by the dividing mechanism 11, the branching mechanism 12, the rearrangement merging mechanism 13 and the stabilizing mechanism 14 of FIG. 1 is introduced.
- a division point D1 of the division mechanism 21 shown in FIG. 2 divides the laminated flow P4 in a direction orthogonal to the vertical direction, that is, vertically divided into two, forming a third laminated flow P5 and a fourth laminated flow P6.
- the operation is performed.
- the laminated flows P5 and P6 divided by the dividing mechanism 21 are branched by the branching mechanism 22 and the third laminated flow P5 is moved to the right in the flow direction with reference to a line connecting the resin dividing point D1 and the flow direction intermediate point E1. It is branched by guiding in the direction and guiding the fourth laminated flow P6 in the left direction toward the flow direction. This is a branch operation.
- the branched laminated flows P5 and P6 are led in the rearrangement merging mechanism 23 to the laminated flow P5 toward the merging point F1 toward the lower left direction toward the center of the flow direction, and the laminated flow P6 is led to the merging point F1.
- the laminated flows P5 and P6 are rearranged adjacent to each other in the left-right direction by being guided in the upper right direction toward the center in the flow direction, and a laminated flow P7 is formed.
- it is preferable that the laminated flows P5 and P6 are led to the center in both the left-right direction and the up-down direction.
- the laminated flow P ⁇ b> 7 rearranged and joined is subjected to a joining operation in the stabilization mechanism 24.
- R flow path This series of steps 2 (see FIG. 2) is referred to as a right rotation flow path (hereinafter referred to as R flow path).
- FIG. 3 shows a schematic diagram of a set of plates.
- An apparatus (hereinafter referred to as LME) having one set of divided plate, array plate, and parallel plate, that is, two sets of alternately combining a set of plates having an L flow path and a set of plates having an R flow path
- LME an apparatus having one set of divided plate, array plate, and parallel plate, that is, two sets of alternately combining a set of plates having an L flow path and a set of plates having an R flow path
- the dividing plate divides the laminated flow P1 in which at least two molten resins are arranged in the vertical direction and adjacent to each other into two vertically.
- the arrangement plate (L flow path) includes a flow path for guiding the upper laminated flow (first laminated flow: P2) divided by the dividing plate to the left and a lower laminated flow (second laminated flow: P3) to the right, a flow path that guides the first laminated flow P2 toward the lower right direction, and a flow path that guides the second laminated flow P3 toward the upper left direction.
- the parallel plate rearranges the stacked flows P2 and P3 arranged in the left-right direction by the arrangement plate and merges them as P4.
- the dividing plate divides the laminated flow P4 in which at least two molten resins are arranged in the vertical direction and adjacent to each other into two vertically.
- the arrangement plate includes a flow path that guides the upper laminated flow (third laminated flow: P5) divided by the dividing plate in the right direction, and a lower laminated flow (fourth laminated flow: P6) to the left, a flow path to guide the third laminated flow P5 in the lower left direction, and a flow path to guide the fourth laminated flow P6 in the upper right direction.
- the parallel plates are rearranged and merged as P7 with the stacked flows P5 and P6 arranged in the left-right direction on the arrangement plate.
- a manufacturing apparatus for a multi-layered product is formed by arranging two or more sets of alternately combining one set of plates having the L flow path and one set of plates having the R flow path.
- the dividing plate 25 has one opening having a rectangular cross-sectional shape on the surface on which a laminated flow in which at least two molten resins are arranged in the longitudinal direction and adjacent to each other is introduced.
- two openings 28 each having a rectangular cross-sectional shape formed by being arranged at predetermined intervals in the vertical direction are formed on the opposite surface (outflow surface) of the divided plate.
- the array plate 26 has two openings having the same shape as the outflow surface of the divided plate on the surface adjacent to the divided plate, and the surface opposite to the side adjacent to the divided plate.
- the parallel plate 27 has two openings having the same shape as the outflow surface of the array plate on the surface adjacent to the array plate, and the surface opposite to the side adjacent to the array plate.
- the (outflow surface) has one opening 30 having a rectangular cross-sectional shape.
- the combination of the steps for increasing the number of layers is a step of increasing the number of layers by alternately combining at least three or more L flow paths and R flow paths. It is a step of alternately combining the flow channels / R flow channel / L flow channel / R flow channel /... Or R flow channel / L flow channel / R flow channel / L flow channel /.
- Embodiment 2 a method for producing a multilayer laminate according to Embodiment 2 of the present invention will be described.
- the inventors of the present invention have conducted intensive studies on a multi-layered body in which unevenness in the flow velocity is small and the stacking is hardly disturbed and the inclination of the layer can be reduced.
- the flow rate of the resin is high and the layer is inclined in the arrangement part having a short flow path and a sharply curved flow path, the flow of the laminar flow in the flow path is smooth.
- the present inventors have found that the verticality of the layer, which is an important element of the vertical arrangement, is dramatically improved in the long channel arrangement as compared with the arrangement in the same direction, and the present invention has been completed.
- FIG. 6 and 7 are schematic views of a multi-layered product manufacturing apparatus according to Embodiment 2 of the present invention.
- the multilayer body according to this embodiment is manufactured through a series of steps shown in FIG. That is, as shown in FIG. 6, the dividing operation of the laminated flow is performed by the dividing mechanism 11, the dividing operation of the laminated flow is performed by the branching mechanism 12, the relocation of the laminated flow is performed by the relocation merging mechanism 13, and the merging operation is performed. This is done by the stabilization mechanism 14.
- splitting mechanism 11 the branching mechanism 12, the rearrangement merging mechanism 13 and the merging mechanism 14 will be described in detail.
- molten resins that is, a laminated flow in which two or more layers of fluids are vertically arranged are passed through the manufacturing apparatus of this embodiment.
- the laminated flow P1 is divided into two in the vertical direction, the upper laminated flow is made the first laminated flow P2, and the lower laminated flow is made the second laminated flow P3. Is done.
- the laminated flows P2 and P3 divided by the dividing mechanism 11 are divided into the flowing direction in the branching mechanism 12 based on the line connecting the dividing point A2 and the intermediate point C2 in the flow direction at the branch point B2.
- the branched laminated flows P2 and P3 are led in the rearranged merging mechanism 13 at the intermediate point C2 to the merging point D2 toward the center of the flow direction in the right direction.
- the stacked flows P2 and P3 are rearranged adjacent to each other on the left and right to form a stacked flow P4.
- the laminated flows P2 and P3 are led to the center in both the left-right direction and the up-down direction.
- the rearranged and merged laminated flow P4 is subjected to a merging operation in the stabilization mechanism 14 at a merging point D2.
- this series of steps 10 is a left rotation channel (hereinafter referred to as L channel), the number of layers can be increased by repeating the L channel.
- L channel left rotation channel
- molten resins that is, a laminated flow in which two or more layers of fluids are vertically arranged are passed through the manufacturing apparatus of the present embodiment.
- the dividing mechanism 21 a dividing operation in which the laminated flow P4 is divided into two in the vertical direction at the dividing point E2, the upper laminated flow is the first laminated flow P5, and the lower laminated flow is the second laminated flow P6. Is done.
- the laminated flows P5 and P6 divided by the dividing mechanism 21 are divided into the flowing direction of the laminated flow P5 in the branching mechanism 22 on the basis of the line connecting the dividing point E2 and the intermediate point G2 in the flow direction at the branch point F2.
- the branched laminated flows P5 and P6 are guided by the rearrangement merging mechanism 23 to the left at the intermediate point G2 toward the merging point H2 toward the center of the flow direction.
- the stacked flows P5 and P6 are rearranged adjacent to each other on the left and right to form a stacked flow P7.
- it is preferable that the laminated flows P5 and P6 are led to the center in both the left-right direction and the up-down direction.
- the flow path shape which concerns on the rearrangement mechanism 13 from the branch mechanism 12 or the rearrangement mechanism 23 uses the bent shape, you may use a curved shape, and the shape is It is not particularly limited.
- the width W and the thickness H2 of the rectangular cross-sectional shape of the introduced laminated flow and the positional relationship between the branch point B2 and the merge point D2 satisfy the following formula (2). It is formed in a path shape or an R channel shape.
- L1 is the length of the longer one of the width W and the thickness H2 (longer diameter or long axis in the case of other than a rectangle), and L2 is from the branch point B2 or F2 to the junction D2 or H2. (This is the length in the direction of flow.)
- L1 and L2 when the relationship between L1 and L2 is L2 / L1 ⁇ 1.1, the flow velocity distribution difference in the flow path becomes small, so that the verticality can be prevented from being lowered. If it is less than 1.1, the flow velocity distribution difference in the flow path becomes large, so the laminar flow is disturbed and the laminated state is destroyed, which is not preferable. Further, since the cost increases as the apparatus becomes larger, it is preferable that 1.1 ⁇ L2 / L1 ⁇ 5.
- the size of L1 and L2 is theoretically infinite, but L1 and L2 are arbitrary sizes and limits depending on the specifications and performance of the extruder used and the cutting limit of the flow path shape mold used. A value is given.
- the flow path shape related to the rearrangement mechanism 13 from the branch mechanism 12 or the rearrangement mechanism 23 from the branch mechanism 22 is a bent shape, but the bending angle R is 40 degrees or less when viewed from the upper surface in the resin flow direction. Preferably there is.
- the bending angle is 40 degrees or less, it is alleviated that the maximum flow velocity of the flow velocity distribution is biased to the inside of the apparatus.
- FIG. 12 shows a schematic diagram of a set of plates.
- One set of plates refers to an apparatus in which a divided plate, an array plate, and a parallel plate are set as one set [hereinafter referred to as an LME (Layer Multiplexing Element). ].
- An apparatus for manufacturing a multi-layered product is formed by arranging one set of plates having an L flow path and one set of plates having an R flow path, either alone or in combination.
- the dividing plate divides a laminated flow P1 formed by arranging and adjoining at least two molten resins in the vertical direction into two in the vertical direction with respect to the vertical direction, that is, up and down.
- the arrangement plate (L flow path) includes a flow path for guiding the upper laminated flow (first laminated flow: P2) divided by the dividing plate to the left and a lower laminated flow (second laminated flow: P3). ) In the right direction, and then a flow path that guides the first laminated flow P2 in the right direction toward the center and a passage that guides the second laminated flow P3 in the left direction in the center.
- the stacked flows P2 and P3 arranged on the left and right by the arrangement plate are rearranged and merged as P4.
- the dividing plate divides a laminated flow P4 formed by arranging and adjoining at least two molten resins in the vertical direction into two directions perpendicular to the vertical direction, that is, up and down.
- the arrangement plate (R flow path) includes a flow path for guiding the upper laminated flow (third laminated flow: P5) divided by the dividing plate in the right direction and a lower laminated flow (fourth laminated flow: P6). ) In the left direction, and then a flow path that leads the third laminated flow P5 in the left direction toward the center and a flow path that leads the fourth laminated flow P6 in the right direction in the center.
- the stacked flows P5 and P6 arranged on the left and right by the arrangement plate are rearranged and merged as P7.
- a single-plate set having the L flow path or a set of plates having the R flow path is used alone to form a multi-laminate manufacturing apparatus.
- the dividing plate 25 has one opening having a rectangular cross-sectional shape on the surface on the side where a laminated flow formed by arranging and adjoining at least two molten resins in the longitudinal direction is adjacent.
- the array plate 26 has two openings having the same shape as the outflow surface of the divided plate on the surface adjacent to the divided plate, and the surface opposite to the side adjacent to the divided plate.
- the parallel plate 27 has two openings having the same shape as the outflow surface of the array plate on the surface adjacent to the array plate, and the surface opposite to the side adjacent to the array plate.
- the (outflow surface) has one opening 30 having a rectangular cross-sectional shape.
- FIG. 8 is an image diagram showing the flow velocity distribution of the laminated flows P2 and P3 at the mechanism entrance at each position of the dividing mechanism 11, the branching mechanism 12, the rearrangement mechanism 13, and the stabilization mechanism 14.
- the laminated flow P1 is divided up and down at a dividing point A2 of the dividing mechanism 11, and one of the laminated flows P2 flows upward. Therefore, at position 1 immediately after the division, the mold (plate) wall surface is affected by the viscosity. A speed difference is produced between the upper side and the lower side.
- the flow velocity distribution of the laminated flow has a maximum flow velocity at the center portion, but the laminated flow P2 is compressed in the width direction while moving upward and spreads in the thickness direction, and is bent leftward by the branch mechanism 12. Therefore, when introduced into the branching mechanism 12, as indicated by position 2, the flow velocity distribution of the laminar flow is shifted from the left and right centers, and the faster flow velocity distribution is biased toward the curved side of the flow path.
- the laminated flow P2 is guided from the branch point B2 by the branching mechanism 12 to the left in the flow direction with respect to the line connecting the resin dividing point A2 and the intermediate point C2 in the flow direction. Bends to the arrangement mechanism 13 in the lower right direction. For this reason, the flow velocity distribution in the cross section is greatly affected, and when the laminar flow P2 is introduced into the rearrangement mechanism 13, the maximum flow velocity of the laminar flow velocity distribution is biased to the inside of the apparatus as represented by position 3. become.
- the branched laminated flow P2 is guided by the rearrangement mechanism 13 in the lower right direction to the joining point D2 with reference to the line connecting the intermediate point C2 and the joining point D2 in the flow direction.
- the laminated flow P2 has a flow velocity distribution as represented by position 4 introduced into the merging mechanism.
- the scale of the flow velocity distribution is based on FIG. 8, and in FIG. 9, the flow velocity distribution difference in the flow path is smaller than the flow velocity distribution of FIG. , Can prevent the deterioration of verticality.
- the sizes of L1 and L2 are theoretically infinite, arbitrary sizes and limit values are given depending on the specifications and performance of the extruder used and the cutting limit of the flow path shape mold used. .
- L2 / L1 is preferably L2 / L1 ⁇ 5 because enormous investment is required and the cost increases with the increase in size of the apparatus.
- a polymer material having melt fluidity and curability can be used, but the kind thereof is not particularly limited.
- the polymer material include polyolefin such as polyethylene and polypropylene; polyaromatic vinyl such as polystyrene; acrylic resin such as polymethyl methacrylate; polyvinyl alcohol; vinyl chloride resin; polyethylene terephthalate, polyethylene-2, 6- Polyester such as naphthalate and polybutylene terephthalate; Polyamide such as nylon 6 and nylon 66; Polycarbonate such as polybisphenol A carbonate; Polyoxymethylene; Polysulfone; Cycloolefin resin; Fluororesin; Polydimethylsiloxane Homopolymers such as thermoplastic resins such as silicone resins or copolymers thereof such as acrylic / styrene copolymers and ethylene / vinyl alcohol copolymers are mainly used. Min to the resin, and the like. Moreover, the mixture which combined
- the copolymer component may be a dicarboxylic acid component or a glycol component.
- the dicarboxylic acid component include aromatic compounds such as isophthalic acid, phthalic acid, and naphthalenedicarboxylic acid.
- An aliphatic dicarboxylic acid such as adipic acid, azelaic acid, sebacic acid, decanedicarboxylic acid, etc .
- an alicyclic dicarboxylic acid such as cyclohexanedicarboxylic acid, etc.
- examples of the glycol component include: Examples thereof include aliphatic diols such as butanediol and hexanediol; alicyclic diols such as cyclohexanedimethanol.
- elastomer natural rubber, isoprene rubber, thermoplastic elastomers such as polyamide-based, olefin-based, styrene-based, and urethane-based materials, or combinations thereof may be mentioned.
- thermosetting resins such as epoxy resins, phenol resins, urethane resins, and unsaturated polyester resins
- photocurable resins such as polyfunctional acrylic resins
- those that are less affected by the difference in melt viscosity between the resins are preferable.
- resins may be used as necessary, for example, plasticizers, process oils, liquids, lubricants, light stabilizers, flame retardants, anti-sticking agents, ultraviolet absorbers, antioxidants, foaming agents, photoinitiators, Organic or inorganic additives such as clouding agents, pigments, antistatic agents and blocking agents can be used alone or in combination of two or more.
- Multi-layered product As described above, by using the manufacturing method / manufacturing apparatus of the present invention, it is possible to manufacture a multi-layered product having excellent verticality of layers arranged in the vertical direction.
- the degree of variation in layer thickness was calculated by the following formula (4).
- Degree of variation in layer thickness standard deviation of entire layer / average thickness of layer (4)
- the average thickness of a layer means the average value of the thickness of each layer which consists of the same resin measured in the central part of each layer of a laminated body in at least 3 or more places. Since the end layer is theoretically half the thickness of the layer other than the end portion, the doubled value is used for the end layer.
- the average thickness of the layer was calculated by the following formula (5).
- Average thickness of the layer (d1 ⁇ 2 + d2 +... + D (N ⁇ 1) + dN) / N (5)
- N is an integer of 3 or more
- dN indicates the average thickness of the Nth layer.
- the standard deviation of the whole layer means the value of the standard deviation which calculated
- the angle of the layer refers to the angle of the intersection of the line connecting the midpoints of the upper and lower surfaces of each layer and the line connecting the midpoints on one surface of the upper and lower surfaces of each layer. The closer the angle of the layer is to 90 degrees, the more perpendicular the laminate is maintained.
- the effect of perpendicularity is confirmed by the average value from the third layer to the third layer from the right end layer of the laminate with respect to the flow direction, the average value of the center three layers of the laminate, and the left end portion of the laminate with respect to the flow direction. It determined by the average value from the 3rd layer to the 3rd layer from the layer.
- Example 1-1 Polymethyl methacrylate (PMMA, Parapet GF: manufactured by Kuraray Co., Ltd.) was used as the resin material used for the multilayer laminate, and ultramarine polymethyl methacrylate (PMMA, Parapet GF: manufactured by Kuraray Co., Ltd.) was used as the resin B.
- Resin A and Resin B were dried at 80 ° C. all day and night, and then supplied to an extruder (PSV type 22 mm: manufactured by Plaengi).
- Example 1-2 Polymethyl methacrylate (PMMA, Parapet GF: manufactured by Kuraray Co., Ltd.) was used as the resin material used for the multilayer laminate, and ultramarine polymethyl methacrylate (PMMA, Parapet GF: manufactured by Kuraray Co., Ltd.) was used as the resin B. Resin A and Resin B were dried at 80 ° C. all day and night, and then supplied to an extruder (PSV type 22 mm: manufactured by Plaengi).
- a laminated structure in which 33 layers of the resin A and the resin B were alternately laminated in the width direction in a resin structure having a width of 3 mm and a length of 30 mm was produced.
- Example 1-3 Polymethyl methacrylate (PMMA, Parapet GF: manufactured by Kuraray Co., Ltd.) was used as the resin material used for the multilayer laminate, and ultramarine polymethyl methacrylate (PMMA, Parapet GF: manufactured by Kuraray Co., Ltd.) was used as the resin B.
- Resin A and Resin B were dried at 80 ° C. all day and night, and then supplied to an extruder (PSV type 22 mm: manufactured by Plaengi).
- the laminated structure was cut out of the cross section and the width of each layer was measured.
- the measured values obtained at this time are shown in Table 2.
- This comparative example is based on a combination of conventional unidirectional arrangement methods.
- PSV type 22 mm manufactured by Praengi
- L / L1 0.58 L channel
- a structure in which 33 layers of the resin A layer and the resin B layer were alternately laminated in the width direction in a resin structure having a width of 3 mm and a length of 30 mm was produced.
- L / L1 0.58 L channel
- a structure in which 33 layers of the resin A layer and the resin B layer were alternately laminated in the width direction in a resin structure having a width of 3 mm and a length of 30 mm was produced.
- L flow path of L2 / L1 0.58 from the laminated inlet, that is, gold combined with L flow path / L flow path / L flow path / L flow path / L flow path / L flow path / L flow path / L flow path It was introduced into a multi-layer extrusion molding machine using a mold (plate).
- a structure in which 125 layers of the resin A layer and the resin B layer were alternately laminated in the width direction in a resin structure having a width of 3 mm and a length of 30 mm was produced.
- Example 1-2 and Comparative Examples 1-2 to 1-5 will be examined for a laminated structure in which 33 layers are laminated by changing the LME combination method.
- FIG. 4 shows a photograph of the multi-layered body according to Example 1-2 and Comparative Examples 1-2 to 1-5 in which the LME combination method was changed. Compared to Comparative Example 1-2, which is a combination of the same arrangements of the prior art, and Examples 1-2 and Comparative Examples 1-3 to 1-5, which combine the L channel and the R channel, It was found that the outermost layer was clearly present.
- Example 1-2 and Comparative Examples 1-3 to 1-5 are compared, as shown in FIG. 4, the layers are locally thinner in Comparative Examples 1-4 and 1-5. I confirmed.
- the disorder of the layer arrangement formed after passing through the third set of LMEs occurs in the fourth set of LMEs. It is thought to have occurred because it was incorporated into the array product by dividing and arranging.
- Comparative Example 1-4 the 9th and 24th layers from the left are thin, so that the disorder of the layer formed after passing the 2nd LME set is the 3rd and 4th LME passes. It is thought that it was taken in inside the array product. Considering the places considered to be disordered in this layer in comparison with the combination order, in Comparative Example 1-5, L flow path / L flow path / L flow path / R flow path, and in Comparative Example 1-3, L flow It turns out that it has arisen in the location which flowed with the path / L channel / R channel / R channel.
- Comparative Example 1-2 and Comparative Example 1- 5 can be estimated as follows. That is, each time the resin flows in the same direction, the disappearance point of the resin increases, so once a structure in which the upper and lower surface layer widths of the end layer are biased is formed, further division and arrangement are repeated as follows. It can be seen that the phenomenon occurs. That is, in Comparative Example 1-2, the disappearance of the layers at both ends is increased, while in Comparative Example 1-5, a thin layer is formed in the central portion, so that collapse to the array state occurs. Conceivable.
- Comparative Example 1-3 in Comparative Example 1-3, it can be seen that there are places where the lower layer of the 13th layer and the upper layer of the 21st layer are thinned.
- the portion where the layer seen in Comparative Example 1-3 is thin is found to have occurred after passing through one set when the occurrence location is examined while returning the number of sets. This point is the same as the difference in the width of the upper and lower layers of the edge that occurs when the laminar flow is tilted to the right, which is seen after passing the LME1 set. It is getting thinner. From the influence of the arrangement state in the first set, it can be seen that there are a few thin layers in the fourth set.
- Example 1-2 is the combination having the most advantageous effect for reducing the disappearance of the layers at both ends.
- Example 1-2 and Example 1-3 the upper and lower layer widths of the end layer after division / arrangement are obtained by alternately combining the L channel and the R channel. It can be presumed that the effect of reducing the disappearance of the layers at both end portions was obtained by averaging the bias.
- Example 1-2 and Example 1-3 it is preferable to alternately combine the L channel and the R channel.
- the difference in the layer widths observed on the upper and lower surface layers at both ends caused by the laminar flow gradient is the difference between the outermost part and the central part. It can be estimated that this is the cause of the disappearance of the layer.
- the manufacturing method by the alternating arrangement method of Examples 1-2 to 1-3 the difference in the layer widths observed on the upper and lower surface layers at both ends caused by the laminar flow gradient is alleviated, and the end portions are extremely reduced. By evenly averaging the layer width without decreasing the number of layers, it is considered that the effect of eliminating the disappearance of the endmost layer hardly occurs even when the division / arrangement is repeated.
- the local flow velocity unevenness generated in the flow path shape can be reduced, and the stacking is disturbed. It is difficult to occur and unevenness in the thickness of each layer can be reduced. Furthermore, since defective parts due to thickness unevenness are reduced, the disappearance of layers that occur each time division, branching, and rearrangement / merging are repeated is reduced, and the number of layers of alternately arranged layers of good quality is compared with the conventional one. Thus, it can be increased to 2 times or 4 times.
- Example 2-1 Polymethyl methacrylate (PMMA, Parapet GF: manufactured by Kuraray Co., Ltd.) was used as the resin material used for the multilayer laminate, and ultramarine polymethyl methacrylate (PMMA, Parapet GF: manufactured by Kuraray Co., Ltd.) was used as the resin B.
- Resin A and Resin B were dried at 80 ° C. all day and night, and then supplied to an extruder (PSV type 22 mm: manufactured by Plaengi).
- PSV type 22 mm: manufactured by Praengi an extruder
- it was introduced into the multi-layer extrusion molding machine using a die (plate) in which the L flow path of L2 / L1 2.0 was combined with the L flow path / L flow path / L flow path from the laminated flow inlet. .
- the above multi-layered product was cut out of the cross section and the width of each layer was measured. The measured values are shown in Table 4.
- PMMA polymethyl methacrylate
- Example 2-3 As a resin material used for the multi-layered body, the shear rate-dependent viscosity of polymethyl methacrylate (PMMA, Parapet GF: manufactured by Kuraray Co., Ltd.) was used for both resin A and resin B.
- PMMA polymethyl methacrylate
- the flow analysis was carried out by simulation.
- Example 2-4 Polymethylmethacrylate (PMMA, Parapet GF: manufactured by Kuraray Co., Ltd.) was used as the resin A as a material used for the multilayer laminate, and ultramarine polymethyl methacrylate (PMMA, Parapet GF: manufactured by Kuraray Co., Ltd.) was used as the resin B. Resin A and Resin B were dried overnight at 80 ° C., and then Resin A and Resin B were supplied to an extruder (PSV type 22 mm: manufactured by Praeneji).
- a multi-layered product was produced in which 129 layers of the resin A layer and the resin B layer were alternately laminated in the width direction in an extruded product having a thickness of 3 mm ⁇ width of 30 mm.
- FIG. 11 shows a cross-sectional view obtained by cutting out from the above multi-layered product.
- the flow analysis was carried out by simulation.
- a multi-layered product in which the layers of the resin A and the layer of the resin B were alternately stacked in the width direction in an extruded product having a thickness of 3 mm ⁇ width of 30 mm was produced.
- FIG. 11 shows a cross-sectional view cut out from the above multi-layered product.
- FIG. 8 changes to a flow in which the vertically arranged layers have an inclination. It can be seen that there is no significant change in the inclination of the vertically arranged layers in the channel 9.
- Example 2-4 From the cross-sectional photographs of the multi-layered product of Example 2-4 and Comparative Example 2-4, it can be seen that the alternate length channel arrangement method of Example 2-4 has improved verticality and the arrangement is almost complete. That is, the effect of suppressing the disappearance of the layers at both ends can be obtained while maintaining the perpendicularity of the layers.
- the local flow velocity unevenness and pressure distribution that occur in the flow path shape forming the multi-layered structure are reduced, the turbulence is less likely to occur in the stack, the inclination of each layer is reduced, and the perpendicularity of the vertically oriented layers It is possible to obtain a multi-layered product holding
- the production method and production apparatus of the multilaminate of the present invention are preferably applied to the production of highly functional films such as optical films utilizing light control such as polarizing plate protective films and optical compensation films of liquid crystal displays. Can do.
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Abstract
Description
少なくとも2つの溶融樹脂を縦方向に配列して隣接させた積層流を、上下に2分割し、分割した上部の積層流を第1の積層流、下部の積層流を第2の積層流とし、前記第1の積層流を流動方向に向かって左方向に導き、前記第2の積層流を流動方向に向かって右方向に導き、次いで、前記第1の積層流を流動方向の中心に向けて右下方向に、前記第2の積層流を流動方向の中心に向けて左上方向に導き、その後、前記第1の積層流と前記第2の積層流とを左右方向に隣接して再配置し合流させる工程1(L流路)と、
少なくとも2つの溶融樹脂を縦方向に配列して隣接させた積層流を、上下に2分割し、分割した上部の積層流を第3の積層流とし、下部の積層流を第4の積層流とし、前記第3の積層流を流動方向に向かって右方向に導き、前記第4の積層流を流動方向に向かって左方向に導き、次いで、前記第3の積層流を流動方向の中心に向けて左下方向に、前記第4の積層流を流動方向の中心に向けて右上方向に導き、その後、前記第3の積層流と前記第4の積層流とを左右方向に隣接して再配置し合流させる工程2(R流路)と、を有し、
前記工程1(L流路)、前記工程2(R流路)をこの順で、少なくとも3工程以上、交互に繰り返すことを特徴とするものである。
少なくとも2つの溶融樹脂を縦方向に配列して隣接させた積層流を、上下に2分割し、分割した上部の積層流を第1の積層流、下部の積層流を第2の積層流とし、前記第1の積層流を流動方向に向かって右方向に導き、前記第2の積層流を流動方向に向かって左方向に導き、次いで、前記第1の積層流を流動方向の中心に向けて左下方向に、前記第2の積層流を流動方向の中心に向けて右上方向に導き、その後、前記第1の積層流と前記第2の積層流とを左右方向に隣接して再配置し合流させる工程2(R流路)と、
少なくとも2つの溶融樹脂を縦方向に配列して隣接させた積層流を、上下に2分割し、分割した上部の積層流を第3の積層流、下部の積層流を第4の積層流とし、前記第3の積層流を流動方向に向かって左方向に導き、前記第4の積層流を流動方向に向かって右方向に導き、次いで、前記第3の積層流を流動方向の中心に向けて右下方向に、前記第4の積層流を流動方向の中心に向けて左上方向に導き、その後、前記第3の積層流と前記第4の積層流とを左右方向に隣接して再配置し合流させる工程1(L流路)と、を有し、
前記工程2(R流路)、前記工程1(L流路)をこの順で少なくとも3工程以上、交互に繰り返すことを特徴とするものである。
少なくとも2つの溶融樹脂を縦方向に配列し隣接させて所定の幅と厚みを有する積層流を形成し、
分割点において、前記積層流を上下に2分割し、分割した上部の積層流を第1の積層流とし、下部の積層流を第2の積層流とし、
分岐点において、前記第1の積層流を流動方向に向かって左方向に導き、前記第2の積層流を流動方向に向かって右方向に導き、
中間点において、前記第1の積層流を流動方向の中心に向かって右下方向に、前記第2の積層流を流動方向の中心に向かって左上方向に導き、
合流点において、前記第1の積層流と前記第2の積層流を左右に隣接して再配置し合流させる複積層体の製造方法であって、
前記積層流の前記幅と前記厚みのうち長い方の長さをL1とし、前記分岐点から前記合流点までの流動進行方向の長さをL2としたとき、前記所定の幅と厚みを有する積層流が、L2/L1≧1.1の関係を満たすものである。
少なくとも2つの溶融樹脂を縦方向に配列し隣接させて所定の幅と厚みを有する積層流を形成し、
分割点において、前記積層流を上下に2分割し、分割した上部の積層流を第1の積層流とし、下部の積層流を第2の積層流とし、
分岐点において、前記第1の積層流を流動方向に向かって右方向に導き、前記第2の積層流を流動方向に向かって左方向に導き、
中間点において、前記第1の積層流を流動方向の中心に向かって左下方向に、前記第2の積層流を流動方向の中心に向かって右上方向に導き、
合流点において、前記第1の積層流と前記第2の積層流を左右に隣接して再配置し合流させる複積層体の製造方法であって、
前記積層流の前記幅と前記厚みのうち長い方の長さをL1とし、前記分岐点から前記合流点までの流動進行方向の長さをL2としたとき、前記所定の幅と厚みを有する積層流が、L2/L1≧1.1の関係を満たすものである。
少なくとも2つの溶融樹脂を縦方向に配列し隣接させて所定の幅と厚みを有する積層流を形成し、
分割点A2において、前記積層流を上下に2分割し、分割した上部の積層流を第1の積層流とし、下部の積層流を第2の積層流とし、
分岐点B2において、前記第1の積層流を流動方向に向かって左方向に導き、前記第2の積層流を流動方向に向かって右方向に導き、
中間点C2において、前記第1の積層流を流動方向の中心に向かって右下方向に、前記第2の積層流を流動方向の中心に向かって左上方向に導き、
合流点D2において、前記第1の積層流と前記第2の積層流を左右に隣接して再配置し合流させる第1の工程と、
分割点E2において、前記再配置合流した前記積層流を上下に2分割し、分割した上部の積層流を第3の積層流とし、下部の積層流を第4の積層流とし、
分岐点F2において、前記第3の積層流を流動方向に向かって右方向に導き、前記第4の積層流を流動方向に向かって左方向に導き、
中間点G2において、前記第3の積層流を流動方向の中心に向かって左下方向に、前記第4の積層流を流動方向の中心に向かって右上方向に導き、
合流点H2において、前記第3の積層流と前記第4の積層流を左右に隣接して再配置し合流させる第2の工程とを備える複積層体の製造方法であって、
前記積層流の前記幅と前記厚みのうち長い方の長さをL1とし、前記分岐点B2から前記合流点D2、及び/又は前記分岐点F2から前記合流点H2までの流動進行方向の長さをL2としたとき、前記所定の幅と厚みを有する積層流が、L2/L1≧1.1の関係を満たすものである。
少なくとも2つの溶融樹脂を縦方向に配列し隣接させて所定の幅と厚みを有する積層流を形成し、
分割点A2において、前記積層流を上下に2分割し、分割した上部の積層流を第1の積層流とし、下部の積層流を第2の積層流とし、
分岐点B2において、前記第1の積層流を流動方向に向かって右方向に導き、前記第2の積層流を流動方向に向かって左方向に導き、
中間点C2において、前記第1の積層流を流動方向の中心に向かって左下方向に、前記第2の積層流を流動方向の中心に向かって右上方向に導き、
合流点D2において、前記第1の積層流と前記第2の積層流を左右に隣接して再配置し合流させる第1の工程と、
分割点E2において、前記再配置合流した前記積層流を上下に2分割し、分割した上部の積層流を第3の積層流とし、下部の積層流を第4の積層流とし、
分岐点F2において、前記第3の積層流を流動方向に向かって左方向に導き、前記第4の積層流を流動方向に向かって右方向に導き、
中間点G2において、前記第3の積層流を流動方向の中心に向かって右下方向に、前記第4の積層流を流動方向の中心に向かって左上方向に導き、
合流点H2において、前記第3の積層流と前記第4の積層流を左右に隣接して再配置し合流させる第2の工程とを備える複積層体の製造方法であって、
前記積層流の前記幅と前記厚みのうち長い方の長さをL1とし、前記分岐点B2から前記合流点D2、及び/又は前記分岐点F2から前記合流点H2までの流動進行方向の長さをL2としたとき、前記所定の幅と厚みを有する積層流が、L2/L1≧1.1の関係を満たすものである。
少なくとも2つの溶融樹脂を縦方向に配列して隣接させた積層流を、上下に2分割する分割プレートと、
前記分割プレートで分割された上部の積層流を左方向に導く流路と下部の積層流を右方向に導く流路と、次いで、前記上部の積層流を中心に向けて右下方向に導く流路と前記下部の積層流を中心に向けて左上方向に導く流路と、を有する配列プレート(L流路)と、
前記配列プレート(L流路)で左右方向に配列させた積層流を再配置し合流する並列プレートと、を備える1組のL流路型プレートと、
少なくとも2つの溶融樹脂を縦方向に配列して隣接させた積層流を、上下に2分割する分割プレートと、
前記分割プレートで分割された上部の積層流を右方向に導く流路と下部の積層流を左方向に導く流路と、次いで、前記上部の積層流を中心に向けて左下方向に導く流路と前記下部の積層流を中心に向けて右上方向に導く流路と、を有する配列プレート(R流路)と、
前記配列プレート(R流路)で左右方向に配列させた積層流を再配置し合流する並列プレートと、を備える1組のR流路型プレートとを、
交互に2組以上配置させることを特徴とするものである。
少なくとも2つの溶融樹脂を縦方向に配列し隣接させて形成した所定の幅と厚みを有する積層流を、分割点において上下に2分割する分割プレートと、
分岐点において、前記分割プレートで分割された上部の積層流を左方向に導く流路と下部の積層流を右方向に導く流路と、中間点において、前記上部の積層流を中心に向かって右下方向に導く流路と前記下部の積層流を中心に向かって左上方向に導く流路と、を有する配列プレート(L流路)と、
前記配列プレート(L流路)で左右に配列させた積層流を、合流点において、再配置し合流する並列プレートと、を備える1組のL流路型プレートであって、
前記積層流の前記幅と前記厚みのうち長い方の長さをL1とし、前記分岐点から前記合流点までの流動進行方向の長さをL2としたとき、
前記所定の幅と厚みを有する積層流が、L2/L1≧1.1の関係を満たすものである。
少なくとも2つの溶融樹脂を縦方向に配列し隣接させて形成した所定の幅と厚みを有する積層流を、分割点において上下に2分割する分割プレートと、
分岐点において、前記分割プレートで分割された上部の積層流を右方向に導く流路と下部の積層流を左方向に導く流路と、中間点において、前記上部の積層流を中心に向かって左下方向に導く流路と前記下部の積層流を中心に向かって右上方向に導く流路と、を有する配列プレート(R流路)と、
前記配列プレート(R流路)で左右に配列させた積層流を、合流点において、再配置し合流する並列プレートと、を備える1組のR流路型プレートであって、
前記積層流の前記幅と前記厚みのうち長い方の長さをL1とし、前記分岐点から前記合流点までの流動進行方向の長さをL2としたとき、前記所定の幅と厚みを有する積層流が、L2/L1≧1.1の関係を満たすものである。
少なくとも2つの溶融樹脂を縦方向に配列し隣接させて形成した所定の幅と厚みを有する積層流を、分割点A2において上下に2分割する分割プレートと、
分岐点B2において、前記分割プレートで分割された上部の積層流を左方向に導く流路と下部の積層流を右方向に導く流路と、
中間点C2において、前記上部の積層流を中心に向かって右下方向に導く流路と前記下部の積層流を中心に向かって左上方向に導く流路と、を有する配列プレート(L流路)と、
前記配列プレート(L流路)で左右に配列させた積層流を、合流点D2において、再配置し合流する並列プレートと、を備える1組のL流路型プレートと、
少なくとも2つの溶融樹脂を縦方向に配列し隣接させて形成した積層流を、分割点E2において上下に2分割する分割プレートと、
分岐点F2において、前記分割プレートで分割された上部の積層流を右方向に導く流路と下部の積層流を左方向に導く流路と、
中間点G2において、前記上部の積層流を中心に向かって左下方向に導く流路と前記下部の積層流を中心に向かって右上方向に導く流路と、を有する配列プレート(R流路)と、
前記配列プレート(R流路)で左右に配列させた積層流を、合流点H2において、再配置し合流する並列プレートと、を備える1組のR流路型プレートとを、交互に2組以上配置させた複積層体の製造装置であって、
前記積層流の前記幅と前記厚みのうち長い方の長さをL1とし、前記分岐点B2から前記合流点D2、及び/又は前記分岐点F2から前記合流点H2までの流動進行方向の長さをL2としたとき、前記所定の幅と厚みを有する積層流が、L2/L1≧1.1の関係を満たすものである。
以下、本発明の実施形態1に係る複積層体を製造する方法について説明する。
本発明者らは、流速ムラが小さく、層の厚みムラあるいは縦配列の崩れを低減できる複積層体について鋭意検討を行った。特に、層の配列化機構が層構造の安定化に影響することを確認し、同一方向による配列は、分割数増加に伴い、両端部の層が消失し、中央層の形状が崩れる点に着目し、層の厚みムラや配列の崩れ、両端部の層の消失を生じない複積層体について検討を重ねた。
その結果、本発明者らは、積層流を分割した後、配列を左右交互にする配列構造を見出し、本発明を完成するに至った。
図1に示す一連の工程と図2に示す一連の工程を経て、本実施形態に係る複積層体が製造される。
分割プレートと配列プレートと並列プレートを1組した装置(以下、LMEという。)、すなわち、L流路を有する1組のプレートと、R流路を有する1組のプレートを交互に組み合わせた2組以上を配置させて複積層体の製造装置が形成される。
分割プレートは、少なくとも2つの溶融樹脂を縦方向に配列して隣接させた積層流P1を、上下に2分割する。配列プレート(L流路)は、上記の分割プレートで分割された上部の積層流(第1の積層流:P2)を左方向に導く流路と、下部の積層流(第2の積層流:P3)を右方向に導く流路と、次いで、第1の積層流P2を中心に向けて右下方向に導く流路と、第2の積層流P3を中心に向けて左上方向に導く流路を有する。並列プレートは、上記の配列プレートで左右方向に配列させた積層流P2、P3を再配置しP4として合流する。
分割プレートは、少なくとも2つの溶融樹脂を縦方向に配列して隣接させた積層流P4を、上下に2分割する。配列プレート(R流路)は、上記の分割プレートで分割された上部の積層流(第3の積層流:P5)を右方向に導く流路と、下部の積層流(第4の積層流:P6)を左方向に導く流路と、次いで、第3の積層流P5を中心に向けて左下方向に導く流路と、第4の積層流P6を中心に向けて右上方向に導く流路を有する。並列プレートは、上記の配列プレートで左右方向に配列させた積層流P5、P6をP7として再配置し合流する。
層配列数=2n+1+1 (1)
(ここで、nはLMEの組数を示す。)
図3に示すように、分割プレート25は、少なくとも2つの溶融樹脂を縦方向に配列して隣接させた積層流が導入される側の面に、断面形状が矩形の1つの開口部を有するとともに、分割プレートの上記反対側の面(流出面)に、上下方向に所定間隔おいて配列して形成した断面形状が矩形の2つの開口部28を有する。また、配列プレート26は、上記の分割プレートに隣接する側の面に、分割プレートの流出面と同一形状の2つの開口部を有するとともに、上記の分割プレートに隣接する側とは反対側の面(流出面)に、左右方向に所定間隔をおいて配列して形成した断面形状が矩形の2つの開口部29を有する。さらに、並列プレート27は、上記の配列プレートに隣接する側の面に、配列プレートの流出面と同一形状の2つの開口部を有するとともに、上記の配列プレートに隣接する側とは反対側の面(流出面)に、断面形状が矩形の1つの開口部30を有する。
以下、本発明の実施形態2に係る複積層体を製造する方法について説明する。
本発明者らは、流速ムラが小さく積層に乱れが生じにくく、層の傾きが低減できる複積層体について鋭意検討を行った。特に、短流路かつ急激な湾曲の流路を有している配列部分で樹脂の流速が速くなっているとともに、層の傾斜が生じる点に着目し、流路内の積層流の流れをスムーズにするために分割後の配列部分の流路の長路化による層の垂直性向上への影響について検討を重ねた。
その結果、本発明者らは、長流路配列では同一方向配列に比べて、縦配列の重要要素となる層の垂直性が飛躍的に向上することを見出し、本発明を完成するに至った。
図6に示す一連の工程によって、本実施形態に係る複積層体を製造する。すなわち、図6に示すように、積層流の分割操作を分割機構11によって行い、積層流の分岐操作を分岐機構12によって行い、積層流の再配置を再配置合流機構13によって行い、合流操作を安定機構14によって行う。
この一連の工程20(図7参照)を右回転流路(以下、R流路という。)とする。
(L1は、前記幅Wと前記厚みH2のうち長い方(矩形以外の場合は長径または長軸)の長さであり、L2は、前記分岐点B2又はF2から前記合流点D2又はH2までの流動進行方向における長さである。)
1組のプレートとは、分割プレートと配列プレートと並列プレートを1組とした装置[以下、LME(Layer Multipling Element)という。]をいう。
L流路を有する1組のプレートと、R流路を有する1組のプレートを単独もしくは組み合わせ配置させて複積層体の製造装置を形成する。
分割プレートは、少なくとも2つの溶融樹脂を縦方向に配列し隣接させて形成した積層流P4を、縦方向に対して垂直方向、すなわち上下に2分割する。配列プレート(R流路)は、上記の分割プレートで分割された上部の積層流(第3の積層流:P5)を右方向に導く流路と下部の積層流(第4の積層流:P6)を左方向に導く流路と、次いで、第3の積層流P5を中心に向かって左方向に導く流路と第4の積層流P6を中心に向かって右方向に導く流路を有する。並列プレートは、上記の配列プレートで左右に配列させた積層流P5、P6を再配置しP7として合流する。
(ここで、nはLMEの組数を示す。)
図12に示すように、分割プレート25は、少なくとも2つの溶融樹脂を縦方向に配列し隣接させて形成した積層流が導入される側の面に、断面形状が矩形の1つの開口部を有するとともに、分割プレートの上記反対側の面(流出面)に、上下方向に所定間隔おいて配列して形成した断面形状が矩形の2つの開口部28を有する。また、配列プレート26は、上記の分割プレートに隣接する側の面に、分割プレートの流出面と同一形状の2つの開口部を有するとともに、上記の分割プレートに隣接する側とは反対側の面(流出面)に、左右方向に所定間隔おいて配列して形成した断面形状が矩形の2つの開口部29を有する。さらに、並列プレート27は、上記の配列プレートに隣接する側の面に、配列プレートの流出面と同一形状の2つの開口部を有するとともに、上記の配列プレートに隣接する側とは反対側の面(流出面)に、断面形状が矩形の1つの開口部30を有する。
図8は、分割機構11、分岐機構12、再配置機構13、安定機構14の各ポジションにおいて、機構入り口における積層流P2、P3の流速分布を表すイメージ図である。
本発明において使用される樹脂は、溶融流動性があり、硬化性がある高分子材料を用いることができるが、その種類は特に限定されるものではない。高分子材料としては、例えば、ポリエチレン、ポリプロピレンのようなポリオレフィン;ポリスチレンのようなポリ芳香族ビニル;ポリメチルメタクリレートのようなアクリル樹脂;ポリビニルアルコール;塩化ビニル樹脂;ポリエチレンテレフタレート、ポリエチレン- 2 , 6 - ナフタレート、ポリブチレンテレフタレートのようなポリエステル;ナイロン6、ナイロン6 6のようなポリアミド;ポリビスフェノールAカーボネートのようなポリカーボネート;ポリオキシメチレン;ポリスルフォン;シクロオレフィン系樹脂;フッ素樹脂;ポリジメチルシロキサン等のシリコーン系樹脂等の熱可塑性樹脂等の単独重合体あるいはこれらの共重合体、例えば、アクリル・スチレン系共重合体、エチレン・ビニルアルコール共重合体を主成分とする樹脂等を挙げることができる。また、これらを2種以上組み合わせた混合物であってもよい。
上記の樹脂の中でも、樹脂間に溶融粘度差による影響の少ないものが好ましい。
上述したように、本発明の製造方法/製造装置を用いることにより、縦方向に配列された層の垂直性に優れる複積層体を製造することができる。
<積層数・積層の厚み>
積層体の層構成は、精密低速切断機(11-1180:ビューラー社製)を用いて、積層構造が断面に表出するように断片(幅方向-厚み方向断面)を切り出し、ミクロトーム(REM-700:ダイワ光機工業社製)を用いて、切り出した断片の表面の平坦化を行った。そして、切り出したサンプルは、偏光顕微鏡(BX50:オリンパス社製)及びカラーレーザー顕微鏡(VK-9500:キーエンス社製)により光学顕微鏡観察を行った。
押出機から押し出された樹脂A、Bの吐出量が同一である場合、層の厚みのバラつき度合は、各層の厚みを測定し、その全層における厚みのバラつきを百分率で表した。
層の厚みのバラつき度合=全体の層の標準偏差/層の平均厚み (4)
上記式(4)において、層の平均厚みとは、積層体の各層の中央部で、少なくとも3ヶ所以上において測定した、同じ樹脂からなる各層の厚みの平均値をいう。端部の層は、理論的に端部以外の層の半分の厚みとなることから、両端部の層は、2倍した値を用いる。
層の平均厚み=(d1×2+d2+・・・・+d(N-1)+dN)/N (5)
(ここで、Nは3以上の整数であり、dNはN番目の層の平均厚みを示す。)
また、全体の層の標準偏差とは、積層構造体の各層d1からdNの厚みと層の平均厚みの値を平均としてもとめた標準偏差の値をいう。
層の角度とは、各層の上下表面の中点を結んだ線と、各層の上下表面一方の面において、中点を結んだ線の交点の角度をいう。
層の角度が90度に近いほど、その積層体の垂直性が保たれていることを表している。垂直性の効果確認は、流動方向に対して積層体の右端部層より3層目から3層までの平均値、積層体の中央3層の平均値、流動方向に対して積層体の左端部層より3層目から3層までの平均値によって決定した。
複積層体に使用する樹脂材料として、ポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Aとし、群青のポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Bとした。樹脂Aおよび樹脂Bは、一昼夜80℃で乾燥した後、押出機(PSV型22mm:プラエンジ社製)に供給した。
これにより、幅3mm×長さ30mmの樹脂構造体の中に、幅方向に樹脂Aの層と樹脂Bの層が、交互に17層積層された積層構造体を作製した。
複積層体に使用する樹脂材料として、ポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Aとし、群青のポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Bとした。樹脂Aおよび樹脂Bは、一昼夜80℃で乾燥した後、押出機(PSV型22mm:プラエンジ社製)に供給した。
これにより、幅3mm×長さ30mmの樹脂構造体の中に、幅方向に樹脂Aの層と樹脂Bの層が、交互に33層積層された積層構造体を作製した。
複積層体に使用する樹脂材料として、ポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Aとし、群青のポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Bとした。樹脂Aおよび樹脂Bは、一昼夜80℃で乾燥した後、押出機(PSV型22mm:プラエンジ社製)に供給した。
これにより、幅3mm×長さ30mmの樹脂構造体の中に、幅方向に樹脂Aの層と樹脂Bの層が、交互に129層積層された構造体を作製した。
複積層体に使用する樹脂材料として、ポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Aとし、群青のポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Bとした。樹脂Aおよび樹脂Bは、一昼夜80℃で乾燥した後、押出機(PSV型22mm:プラエンジ社製)に供給した。
これにより、幅3mm×長さ30mmの樹脂構造体の中に、幅方向に樹脂Aの層と樹脂Bの層が、交互に17層積層された積層構造体を作製した。
(比較例1-2)
複積層体に使用する樹脂材料として、ポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Aとし、群青のポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Bとした。樹脂Aおよび樹脂Bは、一昼夜80℃で乾燥した後、押出機(PSV型22mm:プラエンジ社製)に供給した。
これにより、幅3mm×長さ30mmの樹脂構造体の中に、幅方向に樹脂Aの層と樹脂Bの層が、交互に33層積層された構造体を作製した。
本比較例は、従来の同一方向配列方式の組み合わせによるものである。
複積層体に使用する樹脂材料として、ポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Aとし、群青のポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Bとした。樹脂Aおよび樹脂Bは、一昼夜80℃で乾燥した後、押出機(PSV型22mm:プラエンジ社製)に供給した。
これにより、幅3mm×長さ30mmの樹脂構造体の中に、幅方向に樹脂Aの層と樹脂Bの層が、交互に33層積層された構造体を作製した。
複積層体に使用する樹脂材料として、ポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Aとし、群青のポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Bとした。樹脂Aおよび樹脂Bは、一昼夜80℃で乾燥した後、押出機(PSV型22mm:プラエンジ社製)に供給した。
これにより、幅3mm×長さ30mmの樹脂構造体の中に、幅方向に樹脂Aの層と樹脂Bの層が、交互に33層積層された構造体を作製した。
複積層体に使用する材料として、ポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Aとし、群青のポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Bとした。樹脂Aおよび樹脂Bは、一昼夜80℃で乾燥した後、押出機(PSV型22mm:プラエンジ社製)に供給した。
これにより、幅3mm×長さ30mmの樹脂構造体の中に、幅方向に樹脂Aの層と樹脂Bの層が、交互に33層積層された構造体を作製した。
複積層体に使用する材料として、ポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Aとし、群青のポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Bとした。樹脂Aおよび樹脂Bは、一昼夜80℃で乾燥した後、押出機(PSV型22mm:プラエンジ社製)に供給した。
これにより、幅3mm×長さ30mmの樹脂構造体の中に、幅方向に樹脂Aの層と樹脂Bの層が交互に125層積層された構造体を作製した。
従来の同一方式配列の組み合わせである比較例1-2と、L流路とR流路を組み合わせた実施例1-2,比較例1-3~1-5と比べると、後者はいずれも、最外層の層がはっきりと存在していることがわかった。
複積層体に使用する樹脂材料として、ポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Aとし、群青のポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Bとした。樹脂Aおよび樹脂Bは、一昼夜80℃で乾燥した後、押出機(PSV型22mm:プラエンジ社製)に供給した。
これにより、厚み3mm×幅30mmの押出成形体の中に、幅方向に樹脂Aの層と樹脂Bの層が、交互に17層積層された複積層体を作製した。
複積層体に使用する樹脂材料として、ポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)のせん断速度依存の粘度を樹脂A、樹脂Bともに用いた。
樹脂Aおよび樹脂Bは、それぞれ温度235℃の溶融状態とし、吐出比が樹脂A/樹脂B=1/1になるように設定し、積層流入り口からL2/L1=2.0のL流路を用いてシミュレーション[流動解析ソフト「POLYFLOW」(アンセス・ジャパン社製)]による流動解析を実施した。
複積層体に使用する樹脂材料として、ポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)のせん断速度依存の粘度を樹脂A、樹脂Bともに用いた。
複積層体に使用する材料としてポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Aとし、群青のポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Bとした。樹脂Aおよび樹脂Bは、一昼夜80℃で乾燥した後、樹脂Aおよび樹脂Bを押出機(PSV型22mm:プラエンジ社製)に供給した。
これにより、厚み3mm×幅30mmの押出成形体の中に、幅方向に樹脂Aの層と樹脂Bの層が交互に129層積層された複積層体を作製した。
複積層体に使用する樹脂材料として、ポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Aとし、群青のポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Bとした。樹脂Aおよび樹脂Bは、一昼夜80℃で乾燥した後、押出機(PSV型22mm:プラエンジ社製)に供給した。
これにより、厚み3mm×幅30mmの押出成形体の中に、幅方向に樹脂Aの層と樹脂Bの層が、交互に17層積層された複積層体を作製した。
複積層体に使用する樹脂材料としてポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)のせん断速度依存の粘度を樹脂A、樹脂Bともに用いた。
複積層体に使用する樹脂材料としてポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)のせん断速度依存の粘度を樹脂A、樹脂Bともに用いた。
複積層体に使用する樹脂材料としてポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Aとし、群青のポリメチルメタクリレート(PMMA、パラペットGF:クラレ社製)を樹脂Bとした。樹脂A、樹脂Bは、一昼夜80℃で乾燥した後、樹脂Aおよび樹脂Bを押出機(PSV型22mm:プラエンジ社製)に供給した。
これにより、厚み3mm×幅30mmの押出成形体の中に、幅方向に樹脂Aの層と樹脂Bの層が交互に積層された複積層体を作製した。
11 L流路の分割機構
12 L流路の分岐機構
13 L流路の再配置合流機構
14 L流路の安定機構
A1 L流路の分割機構の分割点
B1 L流路の流動方向の中間点
C1 L流路の再配置合流機構の合流点
A2 L流路の分割機構の分割点
B2 L流路の流動方向の分岐点
C2 L流路の流動方向の中間点
D2 L流路の再配置合流機構の合流点
P1 積層流
P2 L流路の分割機構で上方向に分割された積層流
P3 L流路の分割機構で下方向に分割された積層流
P4 L流路の再配置合流機構で合流した積層流
2 R流路の全工程
21 R流路の分割機構
22 R流路の分岐機構
23 R流路の再配置合流機構
24 R流路の積層流安定機構
25 分割プレート
26 配列プレート
27 並行プレート
28 開口部
29 開口部
30 開口部
D1 R流路の分割機構の分割点
E1 R流路の流動方向の中間点
F1 R流路の再配置合流機構の合流点
D2 R流路の分割機構の分割点
E2 R流路の流動方向の分岐点
F2 R流路の流動方向の中間点
G2 R流路の再配置合流機構の合流点
P5 R流路の分割機構で上方向に分割された積層流
P6 R流路の分割機構で下方向に分割された積層流
P7 R流路の再配置合流機構で合流した積層流
Claims (16)
- 少なくとも2つの溶融樹脂を縦方向に配列して隣接させた積層流を、上下に2分割し、分割した上部の積層流を第1の積層流、下部の積層流を第2の積層流とし、前記第1の積層流を流動方向に向かって左方向に導き、前記第2の積層流を流動方向に向かって右方向に導き、次いで、前記第1の積層流を流動方向の中心に向けて右下方向に、前記第2の積層流を流動方向の中心に向けて左上方向に導き、その後、前記第1の積層流と前記第2の積層流とを左右方向に隣接して再配置し合流させる工程1(L流路)と、
少なくとも2つの溶融樹脂を縦方向に配列して隣接させた積層流を、上下に2分割し、分割した上部の積層流を第3の積層流とし、下部の積層流を第4の積層流とし、前記第3の積層流を流動方向に向かって右方向に導き、前記第4の積層流を流動方向に向かって左方向に導き、次いで、前記第3の積層流を流動方向の中心に向けて左下方向に、前記第4の積層流を流動方向の中心に向けて右上方向に導き、その後、前記第3の積層流と前記第4の積層流とを左右方向に隣接して再配置し合流させる工程2(R流路)と、を有し、
前記工程1(L流路)、前記工程2(R流路)をこの順で、少なくとも3工程以上、交互に繰り返すことを特徴とする複積層体の製造方法。 - 少なくとも2つの溶融樹脂を縦方向に配列して隣接させた積層流を、上下に2分割し、分割した上部の積層流を第1の積層流、下部の積層流を第2の積層流とし、前記第1の積層流を流動方向に向かって右方向に導き、前記第2の積層流を流動方向に向かって左方向に導き、次いで、前記第1の積層流を流動方向の中心に向けて左下方向に、前記第2の積層流を流動方向の中心に向けて右上方向に導き、その後、前記第1の積層流と前記第2の積層流とを左右方向に隣接して再配置し合流させる工程2(R流路)と、
少なくとも2つの溶融樹脂を縦方向に配列して隣接させた積層流を、上下に2分割し、分割した上部の積層流を第3の積層流、下部の積層流を第4の積層流とし、前記第3の積層流を流動方向に向かって左方向に導き、前記第4の積層流を流動方向に向かって右方向に導き、次いで、前記第3の積層流を流動方向の中心に向けて右下方向に、前記第4の積層流を流動方向の中心に向けて左上方向に導き、その後、前記第3の積層流と前記第4の積層流とを左右方向に隣接して再配置し合流させる工程1(L流路)と、を有し、
前記工程2(R流路)、前記工程1(L流路)をこの順で少なくとも3工程以上、交互に繰り返すことを特徴とする複積層体の製造方法。 - 前記積層流の断面形状が矩形であることを特徴とする請求項1または2に記載の複積層体の製造方法。
- 少なくとも2つの溶融樹脂を縦方向に配列し隣接させて所定の幅と厚みを有する積層流を形成し、
分割点において、前記積層流を上下に2分割し、分割した上部の積層流を第1の積層流とし、下部の積層流を第2の積層流とし、
分岐点において、前記第1の積層流を流動方向に向かって左方向に導き、前記第2の積層流を流動方向に向かって右方向に導き、
中間点において、前記第1の積層流を流動方向の中心に向かって右下方向に、前記第2の積層流を流動方向の中心に向かって左上方向に導き、
合流点において、前記第1の積層流と前記第2の積層流を左右に隣接して再配置し合流させる複積層体の製造方法であって、
前記積層流の前記幅と前記厚みのうち長い方の長さをL1とし、前記分岐点から前記合流点までの流動進行方向の長さをL2としたとき、前記所定の幅と厚みを有する積層流が、L2/L1≧1.1の関係を満たす複積層体の製造方法。 - 少なくとも2つの溶融樹脂を縦方向に配列し隣接させて所定の幅と厚みを有する積層流を形成し、
分割点において、前記積層流を上下に2分割し、分割した上部の積層流を第1の積層流とし、下部の積層流を第2の積層流とし、
分岐点において、前記第1の積層流を流動方向に向かって右方向に導き、前記第2の積層流を流動方向に向かって左方向に導き、
中間点において、前記第1の積層流を流動方向の中心に向かって左下方向に、前記第2の積層流を流動方向の中心に向かって右上方向に導き、
合流点において、前記第1の積層流と前記第2の積層流を左右に隣接して再配置し合流させる複積層体の製造方法であって、
前記積層流の前記幅と前記厚みのうち長い方の長さをL1とし、前記分岐点から前記合流点までの流動進行方向の長さをL2としたとき、前記所定の幅と厚みを有する積層流が、L2/L1≧1.1の関係を満たす複積層体の製造方法。 - 少なくとも2つの溶融樹脂を縦方向に配列し隣接させて所定の幅と厚みを有する積層流を形成し、
分割点A2において、前記積層流を上下に2分割し、分割した上部の積層流を第1の積層流とし、下部の積層流を第2の積層流とし、
分岐点B2において、前記第1の積層流を流動方向に向かって左方向に導き、前記第2の積層流を流動方向に向かって右方向に導き、
中間点C2において、前記第1の積層流を流動方向の中心に向かって右下方向に、前記第2の積層流を流動方向の中心に向かって左上方向に導き、
合流点D2において、前記第1の積層流と前記第2の積層流を左右に隣接して再配置し合流させる第1の工程と、
分割点E2において、前記再配置合流した前記積層流を上下に2分割し、分割した上部の積層流を第3の積層流とし、下部の積層流を第4の積層流とし、
分岐点F2において、前記第3の積層流を流動方向に向かって右方向に導き、前記第4の積層流を流動方向に向かって左方向に導き、
中間点G2において、前記第3の積層流を流動方向の中心に向かって左下方向に、前記第4の積層流を流動方向の中心に向かって右上方向に導き、
合流点H2において、前記第3の積層流と前記第4の積層流を左右に隣接して再配置し合流させる第2の工程とを備える複積層体の製造方法であって、
前記積層流の前記幅と前記厚みのうち長い方の長さをL1とし、前記分岐点B2から前記合流点D2、及び/又は前記分岐点F2から前記合流点H2までの流動進行方向の長さをL2としたとき、前記所定の幅と厚みを有する積層流が、L2/L1≧1.1の関係を満たす複積層体の製造方法。 - 少なくとも2つの溶融樹脂を縦方向に配列し隣接させて所定の幅と厚みを有する積層流を形成し、
分割点A2において、前記積層流を上下に2分割し、分割した上部の積層流を第1の積層流とし、下部の積層流を第2の積層流とし、
分岐点B2において、前記第1の積層流を流動方向に向かって右方向に導き、前記第2の積層流を流動方向に向かって左方向に導き、
中間点C2において、前記第1の積層流を流動方向の中心に向かって左下方向に、前記第2の積層流を流動方向の中心に向かって右上方向に導き、
合流点D2において、前記第1の積層流と前記第2の積層流を左右に隣接して再配置し合流させる第1の工程と、
分割点E2において、前記再配置合流した前記積層流を上下に2分割し、分割した上部の積層流を第3の積層流とし、下部の積層流を第4の積層流とし、
分岐点F2において、前記第3の積層流を流動方向に向かって左方向に導き、前記第4の積層流を流動方向に向かって右方向に導き、
中間点G2において、前記第3の積層流を流動方向の中心に向かって右下方向に、前記第4の積層流を流動方向の中心に向かって左上方向に導き、
合流点H2において、前記第3の積層流と前記第4の積層流を左右に隣接して再配置し合流させる第2の工程とを備える複積層体の製造方法であって、
前記積層流の前記幅と前記厚みのうち長い方の長さをL1とし、前記分岐点B2から前記合流点D2、及び/又は前記分岐点F2から前記合流点H2までの流動進行方向の長さをL2としたとき、前記所定の幅と厚みを有する積層流が、L2/L1≧1.1の関係を満たす複積層体の製造方法。 - 前記第1の工程と前記第2の工程を交互に繰り返すことを特徴とする請求項6または7に記載の複積層体の製造方法。
- 前記L2/L1が、1.1≦L2/L1≦5であることを特徴とする請求項4乃至8のいずれか1項に記載の複積層体の製造方法。
- 少なくとも2つの溶融樹脂を縦方向に配列して隣接させた積層流を、上下に2分割する分割プレートと、
前記分割プレートで分割された上部の積層流を左方向に導く流路と下部の積層流を右方向に導く流路と、次いで、前記上部の積層流を中心に向けて右下方向に導く流路と前記下部の積層流を中心に向けて左上方向に導く流路と、を有する配列プレート(L流路)と、
前記配列プレート(L流路)で左右方向に配列させた積層流を再配置し合流する並列プレートと、を備える1組のL流路型プレートと、
少なくとも2つの溶融樹脂を縦方向に配列して隣接させた積層流を、上下に2分割する分割プレートと、
前記分割プレートで分割された上部の積層流を右方向に導く流路と下部の積層流を左方向に導く流路と、次いで、前記上部の積層流を中心に向けて左下方向に導く流路と前記下部の積層流を中心に向けて右上方向に導く流路と、を有する配列プレート(R流路)と、
前記配列プレート(R流路)で左右方向に配列させた積層流を再配置し合流する並列プレートと、を備える1組のR流路型プレートとを、
交互に2組以上配置させることを特徴とする複積層体の製造装置。 - 前記積層流の断面形状が矩形であることを特徴とする請求項10項に記載の複積層体の製造装置。
- 少なくとも2つの溶融樹脂を縦方向に配列し隣接させて形成した所定の幅と厚みを有する積層流を、分割点において上下に2分割する分割プレートと、
分岐点において、前記分割プレートで分割された上部の積層流を左方向に導く流路と下部の積層流を右方向に導く流路と、中間点において、前記上部の積層流を中心に向かって右下方向に導く流路と前記下部の積層流を中心に向かって左上方向に導く流路と、を有する配列プレート(L流路)と、
前記配列プレート(L流路)で左右に配列させた積層流を、合流点において、再配置し合流する並列プレートと、を備える1組のL流路型プレートであって、
前記積層流の前記幅と前記厚みのうち長い方の長さをL1とし、前記分岐点から前記合流点までの流動進行方向の長さをL2としたとき、
前記所定の幅と厚みを有する積層流が、L2/L1≧1.1の関係を満たす複積層体の製造装置。 - 少なくとも2つの溶融樹脂を縦方向に配列し隣接させて形成した所定の幅と厚みを有する積層流を、分割点において上下に2分割する分割プレートと、
分岐点において、前記分割プレートで分割された上部の積層流を右方向に導く流路と下部の積層流を左方向に導く流路と、中間点において、前記上部の積層流を中心に向かって左下方向に導く流路と前記下部の積層流を中心に向かって右上方向に導く流路と、を有する配列プレート(R流路)と、
前記配列プレート(R流路)で左右に配列させた積層流を、合流点において、再配置し合流する並列プレートと、を備える1組のR流路型プレートであって、
前記積層流の前記幅と前記厚みのうち長い方の長さをL1とし、前記分岐点から前記合流点までの流動進行方向の長さをL2としたとき、前記所定の幅と厚みを有する積層流が、L2/L1≧1.1の関係を満たす複積層体の製造装置。 - 少なくとも2つの溶融樹脂を縦方向に配列し隣接させて形成した所定の幅と厚みを有する積層流を、分割点A2において上下に2分割する分割プレートと、
分岐点B2において、前記分割プレートで分割された上部の積層流を左方向に導く流路と下部の積層流を右方向に導く流路と、
中間点C2において、前記上部の積層流を中心に向かって右下方向に導く流路と前記下部の積層流を中心に向かって左上方向に導く流路と、を有する配列プレート(L流路)と、
前記配列プレート(L流路)で左右に配列させた積層流を、合流点D2において、再配置し合流する並列プレートと、を備える1組のL流路型プレートと、
少なくとも2つの溶融樹脂を縦方向に配列し隣接させて形成した積層流を、分割点E2において上下に2分割する分割プレートと、
分岐点F2において、前記分割プレートで分割された上部の積層流を右方向に導く流路と下部の積層流を左方向に導く流路と、
中間点G2において、前記上部の積層流を中心に向かって左下方向に導く流路と前記下部の積層流を中心に向かって右上方向に導く流路と、を有する配列プレート(R流路)と、
前記配列プレート(R流路)で左右に配列させた積層流を、合流点H2において、再配置し合流する並列プレートと、を備える1組のR流路型プレートとを、交互に2組以上配置させた複積層体の製造装置であって、
前記積層流の前記幅と前記厚みのうち長い方の長さをL1とし、前記分岐点B2から前記合流点D2、及び/又は前記分岐点F2から前記合流点H2までの流動進行方向の長さをL2としたとき、前記所定の幅と厚みを有する積層流が、L2/L1≧1.1の関係を満たす複積層体の製造装置。 - 前記L2/L1が、1.1≦L2/L1≦5であることを特徴とする請求項12乃至14のいずれか1項に記載の複積層体の製造装置。
- 請求項1乃至9のいずれか1項に記載の複積層体の製造方法により製造されたものである複積層体。
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