WO2013038866A1

WO2013038866A1 - Method for manufacturing film

Info

Publication number: WO2013038866A1
Application number: PCT/JP2012/070812
Authority: WO
Inventors: 達希萩原
Original assignee: コニカミノルタアドバンストレイヤー株式会社
Priority date: 2011-09-15
Filing date: 2012-08-16
Publication date: 2013-03-21
Also published as: KR102014559B1; JP5971253B2; JPWO2013038866A1; KR20140063680A

Abstract

A method for manufacturing a film, wherein a molten resin is pinched between a TR external peripheral face (124) and a CR external peripheral face (126) while the relationships Ry_TR ≤ 0.2S, Ry_CR ≤ 0.2S, and 1.5 ≤ Ry_TR/Ry_CR ≤ 4.0 are satisfied, the relationship 10¹ ≤ E_TR/E_CR ≤ 10³ is satisfied, and the relationship 1°C ≤ (T_CR - T_TR) ≤ 100°C is satisfied, where Ry_TR is the surface roughness, E_TR is the elasticity, and T_TR is the temperature of the TR external peripheral face (124) of a touch roll (104), and Ry_CR is the surface roughness, E_CR is the elasticity, and T_CR is the temperature of the CR external peripheral face (126) of a cast roll (102). The uniformity of pinching by the touch roll and the cast roll can thereby be stabilized, the stability of peeling from the touch roll can be enhanced, and the film can be endowed with highly precise flatness.

Description

Film production method

The present invention relates to a film production method for producing a film by narrowing a molten resin between a touch roll and a cast roll.

In recent years, films using thermoplastic resins (thermoplastic resins) have been used in liquid crystal display devices and the like that are widely spread. As a film forming method using a thermoplastic resin, for example, a highly productive film forming method such as a melt casting film forming method is known.

As one of the typical film forming methods among films produced by the melt casting film forming method, a molten resin containing a thermoplastic resin is extruded from the casting die onto the surface of the cast roll, and the extruded film shape. A method of obtaining a film by sandwiching the molten resin with a cast roll and a touch roll. At this time, since the pressure applied to the film affects the orientation state of the resin, it is important to perform the clamping with a sufficiently uniform pressure.

Therefore, in a method for producing a film by sandwiching a molten resin with two rolls, improvement of a touch roll that eliminates residual distortion and can be uniformly sandwiched with a wide width has been performed (for example, Patent Documents 1 to 3). ).

Japanese Patent Laid-Open No. 11-235747 Japanese Patent Laid-Open No. 2002-36332 Japanese Patent No. 3422798

However, the techniques of Patent Documents 1 to 3 cannot cope with the improvement of the touch rolls alone when forming a film at high speed. That is, there is a problem of a peeling horizontal stage where a horizontal stage is formed in the molten resin when peeling from the cast roll, a problem of a horizontal stage where a horizontal stage is generated in the molten resin when the pressure is narrowed, and the molten resin is not partially in contact with the touch roll. The problem of touch omission and the non-uniformity of the narrow pressure caused unevenness in the width direction such as the edges and the center, resulting in problems such as uneven pressing.

The present invention has been made in view of the above problems, stabilizes the uniformity of the narrow pressure by the touch roll and the cast roll, improves the peeling stability from the touch roll during high-speed film formation, and a film. It aims at providing the manufacturing method of the film which can obtain the flatness of this with high precision.

In order to solve the above-mentioned problem, the method for producing a film according to the first aspect includes a step of narrowing the molten resin extruded from the casting die between the pressing portion of the touch roll and the pressing portion of the cast roll. In the method for producing a film, the surface roughness of the pressing portion in the touch roll is Ry _TR, and the surface roughness in the cast roll is Ry _CR And satisfying the relationship of Ry _TR ≦ 0.2S and 1.5 ≦ Ry _TR / Ry _CR ≦ 4.0, the elasticity of the touch roll is E _TR, and the elasticity of the cast roll is When _ECR is set, the relationship of 10 ¹ ≦ E _TR / E _CR ≦ 10 ³ is satisfied.

Moreover, the film manufacturing method according to the second aspect is the film manufacturing method according to the first aspect, wherein the surface temperature of the touch roll is _TTR, and the surface temperature of the cast roll is _TCR. In this case, the relationship of 1 ° C. ≦ (T _CR −T _TR ) ≦ 100 ° C. is satisfied.

According to the manufacturing method of the film according to the first or second aspect, by satisfying the relation of 1.5 ≦ Ry TR _/ Ry _CR, it is possible to improve the peeling stability from the touch roll. Moreover, the uniformity of the narrow pressure by a touch roll and a cast roll can be stabilized by satisfy | filling the relationship of 10 < ¹ ><= _ETR / _ECR . Furthermore, by satisfying the relationship of Ry _TR ≦ 0.2S, Ry _TR / Ry _CR ≦ 4.0, and E _TR / E _CR ≦ 10 ³ , it becomes possible to obtain the flatness of the film with high accuracy. . As a result, a high quality film can be manufactured.

According to the film manufacturing method according to the second aspect, the uniformity of the narrow pressure between the touch roll and the cast roll can be further stabilized by satisfying the relationship of (T _CR -T _TR ) ≦ 100 ° C. It becomes possible. Further, by satisfying the relationship of 1 ° C. ≦ (T _CR −T _TR ), it is possible to further improve the peeling stability from the touch roll even during high-speed film formation. As a result, a higher quality film can be produced.

FIG. 1 is a schematic view showing a film manufacturing apparatus according to an embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In addition, drawing is shown typically and the size of a structure, positional relationship, etc. are not illustrated correctly.

<1. Overview of film production equipment>
In the production of a film using the melt casting method, a thermoplastic resin melt is used as a raw material for producing the film. Specifically, the thermoplastic resin melt is a viscous fluid in which additives necessary for the thermoplastic resin melt are mixed. As raw materials for various thermoplastic melts, resin pellets and powdery resin compounds are used.

<1-1. Basic configuration>
FIG. 1 is a schematic diagram of a film manufacturing apparatus 100 according to the embodiment. In the film manufacturing apparatus 100, the film is manufactured using the melt casting film forming method.

A film manufacturing apparatus 100 shown in FIG. 1 includes a cast roll (first cooling roll) 102, a touch roll 104, a second cooling roll 106, a third cooling roll 108, a peeling roll 110, a longitudinal stretching preheating roll 18, and a longitudinal stretching machine 112a. , A transverse stretching machine 112b, a winder 114, a casting die 116, an extruder 118, and a control unit 160.

In the extruder 118, the resin is melted at 200 to 300 ° C. in the extruder 150, the melt of the resin is filtered by a leaf disk type filter 152, and in the static mixer 154, the resin in the resin at the tube wall and the tube center. The resin components are made uniform. Thereby, a thermoplastic resin melt is generated, and the thermoplastic resin melt is sent from the extruder 118 to the casting die 116. In addition, the required additive which concerns on this embodiment is previously mixed with resin before putting into the extruder 150. FIG.

The casting die 116 is close to and faces the outer peripheral surface of the cast roll 102 (hereinafter referred to as the CR outer peripheral surface 126).

When the film _FOP is manufactured by the film manufacturing apparatus 100, the cast roll 102 rotates and the CR outer peripheral surface 126 travels in the vicinity of the casting die 116. At this time, the liquid (thermoplastic resin melt) in which the thermoplastic resin is melted is supplied from the extruder 118 to the casting die 116, so that the thermoplastic resin melt is transferred from the casting die 116 to the CR outer peripheral surface 126. A cast film F _C (molten resin) of the thermoplastic resin melt is formed by being cast and narrowed by the roll outer surface (hereinafter referred to as TR outer peripheral surface 124) of the touch roll 104 and the CR outer peripheral surface 126. Is done. Of CR outer peripheral surface 126, the first section _{R AB} from Sema圧position _{P A} up to the stripping position _{P B} along the running direction of the CR outer peripheral surface 126, the casting film _{F C} of the thermoplastic resin melt is It is formed. Incidentally, Sema圧position P _A, of the TR outer peripheral surface 124 is a position where the thermoplastic resin melt which is cast by the casting die 116 is pressurized narrow at a cast roll 102 and the touch roll 104, a release position P _B is the position where the casting film _{F C} is peeled off from the CR outer peripheral surface 126.

Casting film _{F C} is cooled and solidified in CR outer peripheral surface 126, it is peeled off from the CR outer peripheral surface 126. Casting film F _C peeled from CR outer peripheral surface 126 is subjected to pass to the second cooling roller 106 and the third cooling roller 108 traveling along the traveling path which meanders in a zigzag, longitudinal stretching through the longitudinal stretching pre-heating roll 18 It is led to the machine 112a, where it is stretched in the longitudinal direction (longitudinal direction). Following lead to transverse stretching machine 112b casting film F _C and where it is stretched in the transverse direction (width direction), is wound by a winder 114. Thus, a roll of the film _{F OP} is produced.

<1-2. Operation control>
In the film manufacturing apparatus 100, the control unit 160 includes a hardware configuration such as a storage unit and a CPU, and implements various functions by executing a program in the storage unit on the CPU or the like, for example. Specifically, the control unit 160 controls the operation timing of each component including the extruder 118 and the cast roll 102. Accordingly, the timing of each operation including the supply of the thermoplastic resin melt from the extruder 118 to the casting die 116 and the rotation of the cast roll 102 (CR outer peripheral surface 126) and the touch roll 104 (TR outer peripheral surface 124) is appropriately determined. Be controlled.

<2. Film production method>
Based on the film manufacturing apparatus 100 shown in FIG. 1, roughness (surface roughness), elasticity, and temperature on the TR outer peripheral surface 124 of the touch roll 104 and the CR outer peripheral surface 126 of the cast roll 102 are appropriately changed. The film _FOP is manufactured by the melt casting film forming method using the prepared film manufacturing apparatus.

Here, as a means for adjusting the roughness, the roughness can be adjusted by changing the abrasive in the final polishing of each surface of the TR outer peripheral surface 124 and the CR outer peripheral surface 126 according to the target roughness. Further, as the means for adjusting the elasticity, the TR outer peripheral surface 124 and the CR outer peripheral surface 126 are adjusted by the material and surface processing method, or the TR outer peripheral surface 124 and the CR outer peripheral surface 126 are constituted by thin metal outer cylinder rolls. If it is, adjustment can be performed by the thickness of the outer cylinder. Further, the temperature adjusting means for the TR outer peripheral surface 124 and the CR outer peripheral surface 126 is adjusted by a temperature adjusting device including a heater or the like.

<2-1. Production conditions of examples and comparative examples>
The phenomenon that after passing through the Sema圧position _{P A} in the casting film _{F C} is peeled off from the TR outer circumferential surface 124, adhesion between the CR outer peripheral surface 126 and the casting film _{F C} is, TR outer peripheral surface 124 and the casting film _{F C} Peeling becomes stable if the adhesive strength is exceeded. That is, the adhesion between the TR outer peripheral surface 124 and the casting film _{F C} (or adhesive force between the CR outer peripheral surface 126 and the casting film _{F C)} rather than itself, CR outer circumferential surface 126, between the casting film _{F C} and adhesion, TR outer peripheral surface 124, the difference between the adhesion force between the casting film F _C (ratio) has an important meaning. Therefore, regarding the adhesion, not only the performance of the conventional touch roll 104 alone but also the balance of the performance with the opposing cast roll 102 is important, and a design that considers the two rolls in total is required.

Therefore, the manufacturing conditions according to the present embodiment are classified into the following four categories. That is,
(Condition 1), the roughness of the TR outer peripheral surface 124 in Sema圧position _{P A} _(Ry TR), the roughness of the CR outer peripheral surface 126 _{(Ry CR),} and, the TR roughness _{Ry TR} for CR roughness _{Ry CR} A condition using the ratio (Ry _TR / Ry _CR );
(Condition 2), the elastic of the CR outer peripheral surface 126 in Sema圧position _{P A} _{(E CR)} 1 and elasticity of the TR outer peripheral surface 124 when the representation ratio _{(E TR)} _(E TR _{/ E CR)} As a condition using
(Condition 3), the conditions used a temperature difference between the temperature _{(T TR)} and the temperature of the CR outer peripheral surface 126 _{(T CR)} of TR outer peripheral surface 124 in Sema圧position _{P A} of _(T CR _{-T TR);}
(Condition 4) is a condition using the film forming speed.

<2-1-1. Example and Comparative Example in Case Study (Experiment) A>
The produced film _{F OP} in the following case studies A, referred to as Examples 1A ~ 4A and Comparative Examples 1A ~ 6A. In case study A, as shown in Table 1 below, (Condition 1) and (Condition 2) were changed.

Further, as shown in Table 2 below, (Condition 3) and (Condition 4) were performed in a constant manner in any of Examples 1A to 4A and Comparative Examples 1A to 6A in Table 1 below. Specifically, in (Condition 3), the temperature (T _TR ) of the TR outer peripheral surface 124 is 70 ° C., the temperature (T _CR ) of the CR outer peripheral surface 126 is 120 ° C., and the temperature difference (T _CR −T _TR ) is The test was carried out at a constant temperature of 50 ° C., and at a film forming speed of (Condition 4) of 10 m / min.

As specific conditions in Table 1, with respect to the roughness of condition 1, in each production of Examples 1A to 4A and Comparative Examples 3A, 5A, and 6A, a specified range of 1.5 ≦ Ry _TR / Ry _CR ≦ 4.0 The values of Ry _TR and Ry _CR were changed. In Comparative Example 1A, 2A, each preparation of 4A _{_{is, 1.5 ≦ Ry TR / Ry CR}} ≦ 4.0 is changed outside the specified range of, in Comparative Example 1A 0.5 Comparative Example 2A 1, comparative In Example 4A, it was set to 5. In the production of Comparative Example 3A, Ry _CR was set to 0.25, and in the remaining Comparative Examples and Examples 1A to 4A, Ry _CR was set to 0.2S. Furthermore, in the manufacture of Comparative Examples 3A and 4A, Ry _TR was set to 0.50, and in the remaining Comparative Examples and Examples 1A to 4A, Ry _TR was set to 0.2S.

Regarding the elasticity of Condition 2, in each production of Examples 1A to 4A and Comparative Examples 1A to 4A, the values of E _TR and E _CR were changed within the specified range of 10 ¹ ≦ E _TR / E _CR ≦ 10 ³ . . In Comparative Example 5A, in each production of 6A, it is changed outside the specified range of ^{_{_{10 1 ≦ E TR / E CR}}} ≦ 10 3, Comparative Example 5A 10 ^0, which is a comparative Example 2A in 10 ^4.

<2-1-2. Example and Comparative Example in Case Study (Experiment) B>
The produced film _{F OP} in the following case studies B, referred to as Example 1B ~ 6B and Comparative Examples 1B ~ 6B. In Case Study B, (Condition 4) and (Condition 3) were changed as shown in Table 3 below.

Further, as shown in Table 4 below, (Condition 1) and (Condition 2) were carried out in a constant manner in any of Examples 1B to 6B and Comparative Examples 1B to 6B in Table 3 below. Specifically, in (Condition 1), Ry _TR is 0.10, Ry _CR is 0.15, and Ry _TR / Ry _CR is constant at 1.5, and in (Condition 2), E _TR / E _CR was defined as 10 ¹ constant.

As specific conditions in Table 3, with respect to the temperature of Condition 3, in the production of Examples 1B to 6B, the values of T _TR and T _CR are within the specified range of 1 ° C. ≦ (T _CR −T _TR ) ≦ 100 ° C. Has been changed. Further, in each production of Comparative Examples 1B to 6B, the temperature was changed outside the specified range of 1 ° C. ≦ (T _CR −T _TR ) ≦ 100 ° C., −120 ° C. in Comparative Examples 1B and 4B, and 0 in Comparative Examples 2B and 5B. The temperature was 20 ° C. in Comparative Examples 3B and 6B.

The film forming speed under condition 4 was 20 m / min (high-speed film formation) in each production of Examples 1B to 3B and Comparative Examples 1B to 3B, and 10 m / min in each production of Examples 4B to 6B and Comparative Examples 4B to 6B. It was minutes.

<2-2. Performance verification of film according to this embodiment>
The production results obtained for Examples 1A to 4A and Comparative Examples 1A to 6A are shown in Table 5 below, and the production results obtained for Examples 1B to 6B and Comparative Examples 1B to 6B are shown in Table 6 below. Has been.

Here, as shown in the following table 5 and table 6, the quality evaluation items, and as a valuation described, (Evaluation 1) Peeling stability of the casting film F _C from TR outer peripheral surface 124, (Evaluation 2 ) flatness of the film F _OP, and was evaluated by (evaluation 3) narrow圧均one due the casting roll 102 and the touch roll 104.

Specifically, (Evaluation 1) with respect to delamination stability of the casting film F _C from TR outer peripheral surface 124, is irradiated with light of a point light source at an angle of 45 degrees with respect to the film F _OP, it is projected onto the plain screen Observe the image, if the horizontal unevenness in the short direction cannot be confirmed, ○ (good judgment), if it is a weak level that can be confirmed but does not cause a problem, △ (allowable range judgment), the unevenness is confirmed as a product If it was a level which cannot be used, it was set as x (defect determination) and evaluated in three steps.

With respect to the plane of the (Evaluation 2) film F _OP, irradiated with light of a point light source at an angle of 45 degrees with respect to the film F _OP, to observe the image projected onto the plain screen, if confirmed stripes longitudinally The evaluation was made in three stages, with ◯, if it was a weak level that could be confirmed but not causing a problem, and △ if the level was streaky and could not be used as a product.

(Evaluation 3) With respect to the narrow pressure uniformity due to the casting roll 102 and the touch roll 104, is irradiated with light of a point light source from the front to the film F _OP, to observe the image projected onto the plain screen, longitudinal 3m When there was no occurrence of touch omission (local unclamped portion) over a range of ◯, the number was 2 or less, and the case of 3 or more was evaluated as x.

<2-2-1. Manufacturing results for Case Study A>

As shown in Table 5, (Evaluation 1) In the peel stability of the casting film F _C from TR outer peripheral surface 124, for any of Examples 1A ~ 4A and Comparative Examples 3A ~ 6A, in the range of ○ On the other hand, as for Comparative Examples 1A and 2A, a result of x was obtained. Therefore, in order to improve the peel stability of the casting film _{F C} from the touch roll 104 (TR outer circumferential surface 124), it is necessary to satisfy the relation of 1.5 ≦ _{_Ry} TR / _Ry _CR It was confirmed.

(Evaluation 2) In the flatness of the film F _{OP, each} of Examples 1A to 4A and Comparative Examples 1A, 2A, and 5A is ○, whereas Comparative Examples 3A, 4A, and 6A are indicated by ×. Results were obtained. From this, in order to obtain the flatness of the film F _OP with high accuracy, Ry _TR ≦ 0.2S, Ry _CR ≦ 0.2S, Ry _TR / Ry _CR ≦ 4.0, and E _TR / E _CR It was confirmed that it was necessary to satisfy the relationship of ≦ 10 ³ .

(Evaluation 3) In the uniformity of the narrow pressure between the cast roll 102 and the touch roll 104, each of Examples 1A to 4A and Comparative Examples 1A to 4A and 6A is ○, whereas Comparative Example 5A Resulted in x. From this, in order to stabilize the uniformity of the narrow pressure by the cast roll 102 and the touch roll 104, it was confirmed that it was necessary to satisfy the relationship of 10 ¹ ≦ E _TR / E _CR .

From the above evaluations 1 to 3, Ry _TR ≦ 0.2S, Ry _CR ≦ 0.2S, 1.5 ≦ Ry _TR / Ry _CR ≦ 4.0, and 10 ¹ ≦ E _TR / E _CR ≦ 10 ³ If the relationship is satisfied, it is assumed that a high-quality film can be produced.

<2-2-2. Manufacturing results for Case Study B>

As shown in Table 6, (Evaluation 1) In the peel stability of the casting film _{F C} from TR outer peripheral surface 124, Example 1B ~ 6B and Comparative Examples 1B, for any of the 4B ~ 6B, with ○ On the other hand, the results of Δ were obtained for Comparative Examples 2B and 3B. Therefore, in order to better the release stability of the casting film F _C from the touch roll 104 (TR outer circumferential surface 124), at the time of high-speed film of about 20 m / min, especially, 1 ° C. ≦ It was confirmed that it was necessary to satisfy the relationship (T _CR -T _TR ).

(Evaluation 2) With respect to the flatness of the film F _{OP, each} of Examples 1B to 6B and Comparative Examples 4B to 6B is ○, whereas Comparative Example 1B to 3B has a result of Δ. It was. From this, in order to obtain the flatness of the film F _OP with higher accuracy, the relationship of 1 ° C. ≦ (T _CR −T _TR ) ≦ 100 ° C. is particularly required at the time of high-speed film formation of about 20 m / min. It was confirmed that it was necessary to meet.

(Evaluation 3) In the uniformity of the narrow pressure between the cast roll 102 and the touch roll 104, all of Examples 1B to 6B and Comparative Examples 2B to 6B are ◯, whereas for Comparative Example 1B, A result of Δ was obtained. From this, in order to further stabilize the uniformity of the narrow pressure between the cast roll 102 and the touch roll 104, (T _CR -T _TR ) ≦ 100, especially at the time of high-speed film formation of about 20 m / min. It was confirmed that it was necessary to satisfy the relationship of ° C.

From the above evaluations 1 to 3, Ry _TR ≦ 0.2S, Ry _CR ≦ 0.2S, 1.5 ≦ Ry _TR / Ry _CR ≦ 4.0, and at the time of high-speed film formation of about 20 m / min, and A film of higher quality is manufactured when the relationship of 1 ° C. ≦ (T _CR −T _TR ) ≦ 100 ° C. is satisfied while satisfying the relationship of 10 ¹ ≦ E _TR / E _CR ≦ 10 ^3. It is assumed that this is possible.

100 film manufacturing apparatus 104 touch roll 124 TR outer peripheral surface 102 a cast roll 126 CR outer peripheral surface 160 controller 118 extruder F _OP film F _C casting film P _A Sema圧position P _B peeling position R _AB first section

Claims

In the method for producing a film, including a step of narrowing a molten resin extruded from a casting die between a touch roll and a cast roll, and obtaining a film by feeding the molten resin from the cast roll side,
When the surface roughness of the touch roll is Ry TR, and the surface roughness of the cast roll is Ry CR , Ry TR ≦ 0.2S, Ry CR ≦ 0.2S, and 1.5 ≦ Ry TR / Satisfies the relationship of Ry CR ≦ 4.0,
The elasticity of the touch roll and E TR, when the elasticity of the E CR of the casting rolls, characterized by satisfying the relation of 10 1 ≦ E TR / E CR ≦ 10 3,
A method for producing a film.
It is a manufacturing method of the film of Claim 1, Comprising:
Wherein the temperature of the surface and T TR of the touch roll, the temperature of the surface of the casting rolls when the T CR, and satisfies a 1 ℃ ≦ (T CR -T TR ) ≦ 100 ℃ relationship,
A method for producing a film.