WO2012102273A1

WO2012102273A1 - Resin-sheet manufacturing method and shaped roll

Info

Publication number: WO2012102273A1
Application number: PCT/JP2012/051453
Authority: WO
Inventors: 豊博濱松
Original assignee: 住友化学株式会社
Priority date: 2011-01-28
Filing date: 2012-01-24
Publication date: 2012-08-02
Also published as: JP2012153125A

Abstract

This resin-sheet manufacturing method has: a sheet-manufacturing step in which a continuous resin sheet is manufactured by continuously extruding a molten resin from a die; and a transfer step in which a shaped roll having transfer molds formed in the outer surface thereof is used to transfer the shapes of said transfer molds to the surface of the continuous resin sheet. The transfer molds are arranged such that recesses adjacent in the long direction of the shaped roll are separated by intervals of 6 to 15 µm.

Description

Resin sheet manufacturing method and shape roll

The present invention relates to a method for producing a resin sheet having a shape on the surface, and a shape roll having a transfer mold for imparting a shape to the surface of the resin sheet.

As a method for producing a resin sheet having a shape on the surface (surface shape transfer resin sheet), an extruder is used to extrude the resin from a die in a heated and melted state, and a continuous resin sheet (continuous resin sheet) is produced and transferred. A method of transferring the shape of a transfer mold onto the surface of a continuous resin sheet using a mold is known (for example, see Patent Document 1: Japanese Patent Application Laid-Open No. 2009-220555). In this method, the continuous resin sheet is sandwiched and pressed between the first pressing roll and the second pressing roll that are separated in the thickness direction of the sheet, and the shape of the transfer mold formed on the surface of the second pressing roll is It is transferred to a continuous resin sheet.

JP 2009-220555 A

In recent years, a resin sheet having a shape on the surface has been required to have a shape with a large aspect ratio, which is a ratio of the height to the width of the unit shape. However, in the conventional method for producing a resin sheet, the height of the shape transferred to the resin sheet is not always sufficient with respect to the depth of the transfer mold. Therefore, an improvement in transfer rate (H / D), which is a ratio of the maximum height H of the surface shape transferred to the resin sheet to the maximum depth D of the transfer mold, is demanded.

The present invention has been made to solve such a problem, and an object of the present invention is to provide a method for producing a resin sheet capable of improving the transfer rate. The shape roll of the present invention is made to solve such problems, and aims to improve the transfer rate.

As a result of intensive studies to solve the above-mentioned problems, the present inventor has found that the resin sheet peeled from the transfer mold has an adjacent sheet-shaped portion at a valley portion (concave portion) formed between adjacent sheet-shaped portions. It was found that the shape transfer rate is reduced by the end portions of the two being close to each other and bonded together. Therefore, by performing transfer with an interval of 6 μm or more and 15 μm or less between the recesses of the transfer mold, it is possible to prevent the sheet-shaped portions from being combined in the resin sheet peeled from the transfer mold, and the transfer rate As a result, the present inventors have found that it is possible to improve the above.

That is, the present invention uses a sheet manufacturing process for continuously extruding a heat-melted resin from a die to manufacture a continuous resin sheet, and a shape roll having a transfer mold formed on the peripheral surface. And a transfer step of transferring the shape of the transfer mold to the surface. In the transfer mold, in the transfer mold, the concave portions adjacent to each other in the longitudinal direction of the shape roll are arranged with an interval of 6 μm or more and 15 mμ or less. A method for producing a resin sheet is provided.

According to such a method for producing a resin sheet of the present invention, in a transfer process using a transfer mold having a predetermined interval between adjacent shapes in the longitudinal direction of the shape roll, 6 μm or more between adjacent shapes. Since the interval of 15 μm or less is formed, the continuous resin sheet after being peeled off from the transfer mold is prevented from joining the ends of the convex portions even when the sheet shape expands. Thereby, in the sheet-shaped valley part, it is prevented that the edge part of adjacent convex part shape approaches too much, a desired convex part shape is ensured, and a shape transfer rate can be improved.

Here, the surface temperature of the continuous resin sheet immediately after being peeled off from the shape roll is preferably in the range of (Tg + 5) ° C. to (Tg + 50) ° C. with respect to the glass transition temperature Tg of the resin. Thereby, it is possible to improve the production efficiency while improving the transfer rate. When considering only the improvement of the transfer rate, the surface temperature of the continuous resin sheet immediately after being peeled from the shape roll is (Tg−10) ° C. to (Tg + 5) ° C. with respect to the glass transition temperature Tg of the resin. Although it is preferable that the temperature is in the range, it is difficult to improve the production efficiency in this temperature range. However, when the surface temperature of the continuous resin sheet is in the range of (Tg + 5) ° C. to (Tg + 50) ° C., it is possible to improve the production efficiency while improving the transfer rate.

In addition, the present invention is applied to a sheet manufacturing apparatus that continuously extrudes a heated and melted resin from a die to manufacture a continuous resin sheet, and is a shape roll for transferring the shape of a transfer mold onto the surface of the continuous resin sheet. The circumferential surface of the shape roll is provided with a plurality of concave portions continuous in the circumferential direction of the shape roll, and the concave portions adjacent to each other in the longitudinal direction of the shape roll have an interval of 6 μm or more and 15 μm or less. A shape roll is provided that is spaced apart.

According to such a shape roll of the present invention, the transfer mold formed on the peripheral surface has an interval of 6 μm or more and 15 μm or less between adjacent shapes in the longitudinal direction of the shape roll. In the continuous sheet after being peeled off from the transfer mold, even if the sheet shape expands, bonding between the ends of the protruding portions is prevented, and a desired protruding portion shape is ensured. As a result, the shape transfer rate can be improved.

According to the present invention, in the resin sheet to which the shape is transferred, since adjacent shapes are prevented from being bonded to each other, it is possible to provide a method for manufacturing a resin sheet capable of improving the shape transfer rate. it can. Moreover, according to the shape roll of this invention, since the adjacent shape is prevented from couple | bonding together in the resin sheet to which the shape was transferred, the shape transfer rate can be improved.

It is a schematic block diagram which shows the resin sheet manufacturing apparatus which concerns on embodiment of this invention. It is a schematic block diagram which shows the resin sheet manufacturing apparatus which concerns on 2nd Embodiment of this invention. It is a schematic block diagram which shows the resin sheet manufacturing apparatus which concerns on 3rd Embodiment of this invention. It is a perspective view which shows typically the structure of the resin sheet which concerns on embodiment of this invention. It is sectional drawing which shows typically the recessed part formed in the transcription | transfer mold, and the convex-shaped part formed in the resin sheet. It is a figure which expands and shows the trough part formed between the convex-shaped parts which a resin sheet adjoins. It is a flowchart which shows the procedure of the manufacturing method of the resin sheet which concerns on embodiment of this invention.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In addition, the same code | symbol is attached | subjected to the same or equivalent element, and the overlapping description is abbreviate | omitted. The dimensional ratios in the drawings do not necessarily match those described.

(Resin sheet manufacturing equipment)
FIG. 1 is a schematic configuration diagram illustrating a resin sheet manufacturing apparatus according to an embodiment of the present invention. The resin sheet manufacturing apparatus 50 is an apparatus that can be used in the resin sheet manufacturing method of the present invention. The resin sheet manufacturing apparatus 50 includes a die 51 that continuously extrudes a heated and melted resin to obtain a continuous resin sheet 60, and a first pressing roll that presses the continuous resin sheet 60 extruded from the die 51 from both sides in the thickness direction. 52A and a second pressing roll 52B.

Also, the resin sheet manufacturing apparatus 50 includes a resin charging port 57 for charging a resin as a raw material, and an extruder 58 for pressing the resin charged from the resin charging port 57.

The first pressing roll 52A and the second pressing roll 52B are configured to be rotatable around rotation axes parallel to each other. 52 A of 1st press rolls and the 2nd press roll 52B are spaced apart and arrange | positioned in the thickness direction of the resin sheet 60, and the space | interval of mutual peripheral surfaces is set according to the thickness of the resin sheet 60. FIG. As shown in FIG. 6, a transfer mold 53 corresponding to the concavo-convex shape transferred to the resin sheet 60 is formed on the peripheral surface of the second pressing roll 53. Details will be described later. The second pressing roll 52B corresponds to the shape roll of the present invention.

(Modification of resin sheet manufacturing equipment)
FIG. 2 is a schematic configuration diagram showing a resin sheet manufacturing apparatus according to the second embodiment of the present invention. The resin sheet manufacturing apparatus 50B shown in FIG. 2 is different from the resin sheet manufacturing apparatus 50 shown in FIG. 1 in that a third pressing roll 52C is provided after the second pressing roll (shape roll) 52B. . The third pressing roll 52C has the same configuration as the first pressing roll 52A. The third pressing roll 52C sandwiches and presses the continuous resin sheet 60 between the second pressing roll 52B.

FIG. 3 is a schematic configuration diagram showing a resin sheet manufacturing apparatus according to the third embodiment of the present invention. The difference between the resin sheet manufacturing apparatus 50C shown in FIG. 3 and the resin sheet manufacturing apparatus 50 shown in FIG. 1 is that a preloading roll 52D is provided upstream of the first pressing roll 52A. The preload roll 52D has the same configuration as the first pressing roll 52A. The preload roll 52D sandwiches and presses the continuous resin sheet 60 between the first press roll 52A.

(Continuous resin sheet)
The continuous resin sheet manufactured by the manufacturing method according to the embodiment of the present invention will be described. FIG. 4 is a perspective view schematically showing the configuration of the resin sheet according to the embodiment of the present invention. In FIG. 4, the resin sheet 30 formed by cutting the continuous resin sheet 60 into a predetermined size is shown. The resin sheet 30 can be used as a light guide plate of a surface light source device (backlight) mounted on a transmissive image device. The backlight can be used as an edge light type in which a light source such as an LED is disposed on the side surface 33 of the light guide plate and light incident from the side surface 33 of the light guide plate is emitted to the front side. In addition, a light source may be arrange | positioned with respect to the side surface 33 of a resin sheet, and it may be used as a light-guide plate, and a light source may be arrange | positioned with respect to the back surface 32 of a resin sheet, and may be used as a diffusion plate.

When using a resin sheet as a light guide plate, the rear surface 32 of the resin sheet is usually subjected to a reflection process for irregularly reflecting light incident from the side surface. As a printing method performed as reflection processing, ink jet printing may be performed in addition to silk printing. Or as a method of reflection processing, you may give a dot-shaped unevenness | corrugation by laser irradiation instead of printing.

The surface 31 of the resin sheet 30 extends in the first direction (x-axis direction) and has a plurality of convex shapes arranged side by side in a second direction (y-axis direction) orthogonal to the first direction. A portion 35 is formed. The concavo-convex shape having the convex portions 35 formed on the surface 31 is formed by a transfer process described later.

(Constituent material of resin sheet)
The light guide plate made of a resin sheet is made of a translucent resin. The translucent resin is a resin that transmits light. The refractive index of the translucent resin is usually 1.49 to 1.59. As the translucent resin used for the light guide plate (30), methacrylic resin is mainly used. As the translucent resin used for the light guide plate (30), other resins may be used, or styrene resins may be used. As the translucent resin, an acrylic resin, a styrene resin, a carbonate resin, a cyclic olefin resin, an MS resin (a copolymer of acrylic and styrene), or the like can be used.

As the resin constituting the resin sheet 30 (60), there is usually a thermoplastic resin that becomes a molten state when heated. Specifically, an acrylic resin, a styrene resin, a carbonate resin, a cyclic olefin resin, an MS resin (a copolymer of acrylic and styrene), and the like can be given. In addition, the thermosetting resin which hardens | cures by heating in the range applicable to the manufacturing method of this invention may be sufficient. Additives such as a light diffusing agent, an ultraviolet absorber, a heat stabilizer, and an antistatic agent may be added to the resin.

(Production method of resin sheet)
The manufacturing method of the resin sheet which concerns on embodiment of this invention is demonstrated. FIG. 7 is a flowchart showing a procedure of a resin sheet manufacturing method according to the embodiment of the present invention. The resin sheet manufacturing method of the present embodiment can be implemented using, for example, a resin sheet manufacturing apparatus 50 shown in FIGS. As shown in FIG. 7, the resin sheet manufacturing method of this embodiment includes a sheet manufacturing process (S1) in which a resin in a heated and melted state is continuously extruded from a die to form a continuous resin sheet, and a transfer mold on the peripheral surface. A transfer step (S2) for transferring the shape of the transfer mold to the continuous resin sheet using the (form roll) 53 formed thereon.

(Sheet manufacturing process)
In the sheet manufacturing process, the resin is continuously extruded from the die 51 in a heated and melted state to manufacture the continuous resin sheet 60. Examples of the resin used in the production method of the present invention include thermoplastic resins that are in a molten state when heated.

As the die 51 for continuously extruding the resin in a heated and melted state, a metal T-die similar to that used in a normal extrusion method is used. In order to extrude the resin from the die 51 in a heated and melted state, an extruder 58 is used in the same manner as in a normal extrusion molding method. The extruder 58 may be a single screw extruder or a twin screw extruder. The resin is heated in the extruder 58, sent to the die 51 in a molten state, and extruded. The resin extruded from the die 51 is continuously extruded into a sheet shape to form a continuous resin sheet 60.

In addition, what is necessary is just to adjust the thickness of the continuous resin sheet 60 suitably according to the use of the obtained sheet | seat. For example, when the continuous resin sheet 60 is used as the light guide plate (30), a preferable range of the sheet thickness is 1.0 mm or more and 4.5 mm or less.

(Transfer process)
The transfer step (S2) is a pressing step in which the continuous resin sheet 60 manufactured in the sheet manufacturing step (S1) is pressed by being sandwiched between the first pressing roll (pressing roll) 52A and the second pressing roll (shape roll) 52B. (S3), a transport step (S4) for transporting the continuous resin sheet 60 pressed in the pressing step (S3) while being in close contact with the peripheral surface of the shape roll 52B, and a continuous resin transported in the transport step (S4) And a peeling step (S5) for peeling the sheet 60 from the peripheral surface (transfer mold 53) of the shape roll 52B.

(Pressing process)
As shown in FIG. 1, the continuous resin sheet 60 obtained in the sheet manufacturing step (S1) includes a first pressing roll 52A and a second pressing roll 52B in the thickness direction of the sheet, as shown in FIG. It is sandwiched and pressed from both sides at the same time.

At this time, the surface temperature of the continuous resin sheet 60 immediately before coming into contact with the second pressing roll 52B is in a range of 180 ° C. to 250 ° C. The surface temperature can be adjusted by changing the set temperature of the extruder 58 and changing the set temperature of the die 51. In addition, the surface temperature of the continuous resin sheet 60 can be measured using an infrared thermometer.

In this pressing step (S3), the shape of the transfer mold 53 formed on the surface of the second pressing roll (shape roll) 52B is transferred to the continuous resin sheet 60. In the present invention, the second pressing roll 52B provided with the transfer mold 53 is also referred to as a transfer roll. The transfer mold 53 provided on the surface of the transfer roll is pressed against the surface of the continuous resin sheet 60, and the surface shape is transferred to the continuous resin sheet 60 as a reverse mold.

Here, in the pressing step of the transfer step of the present embodiment, in the transfer mold 53 of the shape roll 52B, the adjacent recess shapes 54 are arranged with a predetermined interval (S: 6 μm to 15 μm). A transfer mold 53 is formed on the circumferential surface of the shape roll 52B. In the transfer mold 53, a plurality of concave shapes 54 that are continuous in the circumferential direction are arranged side by side in the longitudinal direction (Y direction) of the shape roll 52B. In the transfer mold 53, a flat portion 55 having a width S of 6 μm or more and 15 μm or less is formed between the recessed

shapes

54 and 54 adjacent to each other in the longitudinal direction Y of the shape roll 52B. The flat part 55 is continuously formed in the circumferential direction of the shape roll 52B. In the pressing step of the present embodiment, the convex shape is transferred to the surface of the continuous resin sheet 60 using the transfer mold 53 in which the flat portion 55 is formed between the adjacent

concave shapes

54 and 54.

As the first and second

pressing rolls

52A and 52B, metal rolls made of a metal such as stainless steel or steel are usually used, and the diameter is usually 100 mm to 500 mm. When metal rolls are used as the first and second

pressing rolls

52A and 52B, the surface thereof may be subjected to a plating treatment such as chrome plating, copper plating, nickel plating, nickel-phosphorous plating. Further, the surface (circumferential surface) of the first pressing roll 52A may be a mirror surface or may be a transfer surface provided with unevenness such as embossing.

(Conveying process)
The transporting step (S4) is a step of transporting the continuous resin sheet 60 according to the rotation of the second pressing roll 52B in a state where the continuous resin sheet 60 is in close contact with the peripheral surface of the second pressing roll 52B.

(Peeling process)
A peeling process (S5) is a process of peeling the continuous resin sheet 60 from the surrounding surface of the 2nd press roll 52B.

At this time, the surface temperature of the resin of the continuous resin sheet 60 immediately after being peeled from the second pressing roll 52B is in the range of (Tg + 5) ° C. to (Tg + 50) ° C. with respect to the glass transition temperature Tg of the resin. Is preferred. Thereby, it is possible to improve the production efficiency while improving the transfer rate. When the surface temperature of the resin is lower than the above temperature range, for example, when the temperature range is (Tg−10) ° C. to (Tg + 5) ° C., the transfer rate can be improved. It becomes difficult to improve efficiency. When the surface temperature of the resin is higher than the above range of (Tg + 5) ° C. to (Tg + 50) ° C., the shape transferred to the continuous resin sheet 60 is restored to its original shape by heat, and the transfer rate deteriorates. become.

(Shape roll, transfer mold)
FIG. 5 is a cross-sectional view schematically showing the concave portion formed in the transfer mold and the convex portion formed in the resin sheet. The shape roll according to the present embodiment can be applied to a sheet manufacturing apparatus 50 that continuously extrudes a heated and melted resin from a die to manufacture a continuous resin sheet, and gives an uneven shape to the sheet surface of the continuous resin sheet 60. Is to do. The shape roll 52B is formed of a columnar body or a cylindrical body, and a transfer mold 53 is formed on the peripheral surface thereof.

In the transfer mold 53 according to the present embodiment, as described above, a plurality of concave shapes continuous in the circumferential direction of the shape roll 52B are provided side by side in the longitudinal direction (direction Y) of the shape roll 52B. The transfer mold 53 has a flat portion 55 between the concave shapes 54 adjacent to each other in the longitudinal direction Y.

The pitch P of the concave shape 54 is usually 30 μm or more, preferably 50 μm or more. However, in the manufacturing method and manufacturing apparatus of the present invention, it is suitable when the pitch interval P of the concave shape 54 is 30 μm to 800 μm. And the groove depth D of the concave shape 54 is 30 μm to 500 μm. The pitch interval (P) of the concave shape 54 refers to the distance between the groove portions (bottom portions) of the adjacent concave portions 54, and the groove depth (D) of the concave shape 54 refers to the surface circumference of the shape roll 52B. The distance to the groove part (bottom part) of the recessed part 54 is said.

Further, as the size of the transfer mold 53, for example, the width S of the roll flat portion 55 can be 8 μm, and the depth D of the concave shape 54 can be 145 μm.

Also, examples of the cross-sectional shape of the concave portion 54 of the transfer mold 53 include a semicircular shape and a semielliptical shape. Further, it may be a V shape having an acute angle portion corresponding to the prism shape.

The transfer mold 53 is manufactured by applying a plating treatment such as chromium plating, copper plating, nickel plating, nickel-phosphorous plating to the surface of a transfer roll made of stainless steel, steel, etc. On the other hand, the removal may be performed using a diamond tool, a metal grindstone, or the like, laser processing, or chemical etching may be performed to form the shape, but the method is not particularly limited.

Further, the surface of the transfer roll may be subjected to plating treatment such as chromium plating, copper plating, nickel plating, nickel-phosphorous plating, etc. at a level that does not impair the accuracy of the surface shape after the transfer mold 53 is formed.

(Modified example of resin sheet manufacturing method)
As a modification of the manufacturing method, for example, the second pressing step may be performed after the transporting step (S4). The second pressing step can be performed using a resin sheet manufacturing apparatus 50B shown in FIG. In the second pressing step, the continuous resin sheet 60 conveyed in the conveying step (S4) is pressed by being sandwiched between the second pressing roll (shape roll) 52B and the third pressing roll 52C. The continuous resin sheet 60 pressed in the second pressing step is peeled from the second pressing roll (peeling step) and conveyed while being in close contact with the peripheral surface of the third pressing roll 52C, and then the circumference of the third pressing roll 52C. Peel from the surface.

Further, as another modified example of the manufacturing method, for example, a preloading step of pressing in advance may be performed before the pressing step (S3). The preloading step can be performed using a resin sheet manufacturing apparatus 50C shown in FIG. In the preloading process, the continuous resin sheet 60 manufactured in the sheet manufacturing process (S1) is pressed in advance by being sandwiched between the preloading roll 52D and the first pressing roll 52A. The pressed continuous resin sheet 60 is conveyed in close contact with the peripheral surface of the first pressing roll 52A, and the pressing step (S3) is performed by the first and second

pressing rolls

52A and 52B.

(Function)
In the manufacturing method and shape roll of the resin sheet of the present invention, in the transfer mold 53, the adjacent recess shapes 54 are arranged with an interval S of 6 μm or more and 15 μm or less and the transfer process is executed. In the continuous resin sheet 60 after being peeled off, the end portions in the Y direction of the convex shape 35 are prevented from being bonded to each other even if the sheet shape expands. Thereby, in the sheet-shaped valley part 35b, the end part of the adjacent convex part shape 35 does not approach too much, The desired convex part shape 35 is ensured and a shape transfer rate improves.

FIG. 6 is an enlarged view showing a trough formed between adjacent convex portions of the resin sheet. As shown in FIG. 6, in the trough part 35b formed between the convex part shapes 35 and 35 which adjoin the resin sheet 60, the coupling | bonding of the edge parts of the convex part shape 35 is prevented, and the flat part 55 of a shape roll A gap corresponding to is formed.

(Example)
EXAMPLES Hereinafter, although Example 1 is given and this invention is demonstrated in detail, this invention is not limited to these.

(Example 1, Comparative Example 1)
The sheet | seat which concerns on Example 1 and Comparative Example 1 was created using the resin sheet manufacturing apparatus 50C shown in FIG. The conditions of the manufacturing apparatus 50C used are shown below. The screw diameter of the extruder 58 was 120 mm, and the amount of extrusion by the extruder 58 was 700 kg / hr. In Example 1, the line speed was 2.75 m / min, and in Comparative Example 1, the line speed was 2.83 m / min. The sheet width was 135 cm in both Example 1 and Comparative Example 1. In both Example 1 and Comparative Example 1, the roll temperature (preload roll 52D / first pressing roll 52A / second pressing roll 52B) was set to 80 ° C./85° C./95° C.

In Example 1 and Comparative Example 1, a PMMA plate having a sheet thickness of 3 mm was formed by extrusion molding (sheet manufacturing process). In Example 1 and Comparative Example 1, a single-layered resin sheet (see FIG. 4) was prepared.

A copolymer of methyl methacrylate and methyl acrylate was used as the resin constituting the resin sheet according to Example 1 and Comparative Example 1. The resin specifications are shown below.
Weight ratio: methyl methacrylate / methyl acrylate = 94/6
MFR: 1.5g / 10min
Glass transition temperature Tg: 102 ° C
Thickness: 3.0mm

As the shape of the transfer mold 53 of the second pressing roll 52B, in Example 1, the pitch P is 400 μm, the depth D is 222 μm, the width S of the flat portion 55 is 8 μm, and in Comparative Example 1, the pitch P is 400 μm and the depth The thickness D was 222 μm, and the width S of the flat portion 55 was 4 μm.

In Example 1, the surface temperature of the resin sheet immediately after being peeled from the second pressing roll 52B is 122 ° C., and the shape height H at this time is 145 μm, and the shape transfer rate (= H / D). Was 65%. In Comparative Example 1, the surface temperature of the resin sheet immediately after being peeled from the second pressing roll 52B is 123 ° C., and the shape height H at this time is 127 μm, and the shape transfer rate (= H / D) Was 57%.

Table 1 below shows the test conditions and test results of Example 1 and Comparative Example 1.

Thus, according to the method for producing a resin sheet according to the embodiment of the present invention, the shape transfer rate of the resin sheet can be improved.

As mentioned above, although this invention was concretely demonstrated based on the embodiment, this invention is not limited to the said embodiment.

In the above embodiment, the light guide plate is described as the resin sheet, but other resin sheets may be created. The resin sheet manufacturing method of the present invention is effective for manufacturing a shape light guide plate and a shape diffusion plate mounted on a backlight of a liquid crystal TV, for example. The present invention is particularly effective for manufacturing a shape light guide plate and a shape diffusion plate having a high aspect ratio.

In the above embodiment, the continuous resin sheet is manufactured using the resin

sheet manufacturing apparatuses

50, 50B, and 50C shown in FIGS. 1 to 3, but the resin sheet manufacturing apparatus capable of performing other manufacturing processes. May be used.

The surface temperature of the continuous resin sheet immediately after being peeled from the shape roll is preferably in the range of (Tg + 5) ° C. or more and (Tg + 50) ° C. or less with respect to the glass transition temperature Tg of the resin. It may be in the temperature range.

According to the resin sheet manufacturing method of the present invention, it is possible to prevent adjacent shapes from being joined to each other in the resin sheet to which the shape is transferred, and to improve the shape transfer rate. According to the shape roll of the present invention, in the resin sheet to which the shape is transferred, adjacent shapes are prevented from being combined with each other, and the shape transfer rate can be improved.

50, 50B, 50C ... resin sheet manufacturing apparatus, 51 ... die, 52A ... first press roll, 52B ... second press roll (shape roll), 52C ... third press roll, 52D ... preload roll, 53 ... transfer mold, 54 ... concave shape, 55 ... flat part, 57 ... resin inlet, 58 ... extruder, 60 ... continuous resin sheet.

Claims

A sheet manufacturing process for continuously extruding a heat-melted resin from a die to manufacture a continuous resin sheet;
In a resin sheet manufacturing method comprising a transfer step of transferring the shape of the transfer mold to the sheet surface of the continuous resin sheet using a shape roll having a transfer mold formed on the peripheral surface,
The said transfer type | mold WHEREIN: The resin sheet manufacturing method by which the recessed part adjacent to the longitudinal direction of the said shape roll is arrange | positioned at intervals of 6 micrometers or more and 15 micrometers or less.
The resin sheet production according to claim 1, wherein the surface temperature of the continuous resin sheet immediately after being peeled from the shape roll is in the range of (Tg + 5) ° C to (Tg + 50) ° C with respect to the glass transition temperature Tg of the resin. Method.
It is applied to a sheet manufacturing apparatus that continuously extrudes a heated and melted resin from a die to manufacture a continuous resin sheet, and is a shape roll for transferring the shape of a transfer mold to the sheet surface of the continuous resin sheet,
On the peripheral surface of the shape roll, a plurality of recesses that are continuous in the circumferential direction of the shape roll are provided side by side in the longitudinal direction of the shape roll, and the recesses that are adjacent to each other in the longitudinal direction of the shape roll A shape roll arranged with a gap.