WO2013084734A1 - Method and device for manufacturing laminated sheet - Google Patents

Method and device for manufacturing laminated sheet Download PDF

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Publication number
WO2013084734A1
WO2013084734A1 PCT/JP2012/080425 JP2012080425W WO2013084734A1 WO 2013084734 A1 WO2013084734 A1 WO 2013084734A1 JP 2012080425 W JP2012080425 W JP 2012080425W WO 2013084734 A1 WO2013084734 A1 WO 2013084734A1
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WO
WIPO (PCT)
Prior art keywords
laminated sheet
laminated
laminating
film
cutting
Prior art date
Application number
PCT/JP2012/080425
Other languages
French (fr)
Japanese (ja)
Inventor
浅倉　孝郎
Original Assignee
富士フイルム株式会社
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Filing date
Publication date
Application filed by 富士フイルム株式会社 filed Critical 富士フイルム株式会社
Publication of WO2013084734A1 publication Critical patent/WO2013084734A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B29C65/485—Multi-component adhesives, i.e. chemically curing as a result of the mixing of said multi-components
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
    • B29C65/482—Drying adhesives, e.g. solvent based adhesives
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/52—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
    • B29C65/526—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive by printing or by transfer from the surfaces of elements carrying the adhesive, e.g. using brushes, pads, rollers, stencils or silk screens
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/024—Thermal pre-treatments
    • B29C66/0242—Heating, or preheating, e.g. drying
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/024—Thermal pre-treatments
    • B29C66/0244—Cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/028—Non-mechanical surface pre-treatments, i.e. by flame treatment, electric discharge treatment, plasma treatment, wave energy or particle radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
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    • B29C66/733—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
    • B29C66/7336—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light
    • B29C66/73365—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light at least one of the parts to be joined being transparent or translucent to visible light
    • B29C66/73366—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light at least one of the parts to be joined being transparent or translucent to visible light both parts to be joined being transparent or translucent to visible light
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/735—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the extensive physical properties of the parts to be joined
    • B29C66/7352—Thickness, e.g. very thin
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411—Roller, cylinder or drum types
    • B29C66/83413—Roller, cylinder or drum types cooperating rollers, cylinders or drums
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91421—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the joining tools
    • 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
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    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9161—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux
    • B29C66/91641—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux the heat or the thermal flux being non-constant over time
    • B29C66/91643—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux the heat or the thermal flux being non-constant over time following a heat-time profile
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C2793/009—Shaping techniques involving a cutting or machining operation after shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91921—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/20—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of continuous webs only

Definitions

  • the present invention relates to a method and apparatus for producing a laminated sheet, and in particular, a laminated sheet excellent in use as a transparent support for stereoscopic image printing sheets used for 3D printing and 3D printing and as a substrate for a diffusion cover for LED lighting.
  • the present invention relates to a manufacturing method and a manufacturing apparatus.
  • a recording sheet for recording a stereoscopic image there is a stereoscopic image printing sheet having a lens layer (for example, a lenticular lens) on one side of a resin-made transparent support and an image receiving layer for recording an image on the other side.
  • a lens layer for example, a lenticular lens
  • a lenticular lens sheet is bonded to one side of a transparent support (base material) made of paper, synthetic paper, plastic film, etc., and the dye receiving image is applied to the back side of the transparent support and dried.
  • a heat-sensitive transfer recording sheet for stereoscopic images provided with a layer is disclosed.
  • LEDs have started to enter the lighting field.
  • a point that differs greatly from incandescent light bulbs and fluorescent lamps that have been used up to now is that LEDs are point light sources.
  • the diffusion cover for LED illumination to which the light diffusibility which gives large concealment property and raises the utilization efficiency of light was given so that the lamp image of a point light source might be lost is calculated
  • a resin film for the illumination cover it is necessary to have rigidity sufficient to prevent falling or to bend by wind pressure or pressing. Therefore, a method of obtaining rigidity by sticking as thick a general-purpose resin film as possible with an adhesive for dry lamination to a thickness of 500 ⁇ m or more has been performed.
  • one resin film is fed from a roll, and after applying the adhesive for dry lamination on one side of the film, the solvent of the adhesive is dried at about 80 to 120 ° C. .
  • the method of sticking the other general purpose resin film on the adhesive surface which became a sticky state, and thermocompression bonding at the temperature comparable as the above-mentioned drying temperature is common (for example, nonpatent literature 1, patent literature 2).
  • the laminated film bonded in this way is cut into a predetermined size according to the use such as a stereoscopic image printing sheet, an LED illumination diffusion cover, and the like.
  • the conventional laminating method can also be used to wind the laminated film during winding (after the laminating step, the laminated film is once wound) Case), the adhesive surface of the adhesive for dry lamination is difficult to peel off after cutting the laminated film.
  • the adhesive surface of the adhesive for dry lamination is easily peeled off during transportation, winding and cutting of the laminated film.
  • the laminated sheet obtained by cutting into a predetermined size is likely to curl.
  • the resin film before pasting and the laminated film after pasting are wrapped and transported on a transport roller or the like, so that an external force in the bending direction is applied, and the curl is easily generated by curving in the transport direction of the roller.
  • the curl generated in the laminated film remains on the laminated sheet after cutting.
  • the degree of curling of the stereoscopic image printing sheet is not problematic as long as it is 4 mm or less, but the stereoscopic image printing sheet produced by the conventional laminating method is often 4 mm or more.
  • An object of the present invention is to provide a manufacturing method and a manufacturing apparatus for a laminated sheet suitable as a three-dimensional image printing sheet, a LED illumination diffusion cover, and the like because it is free from curling and has excellent flatness.
  • the method for producing a laminated sheet of the present invention includes a laminating step of laminating a plurality of strip-shaped resin films conveyed to achieve the above object with an adhesive for dry lamination, and forming the laminated film with a predetermined size.
  • the laminating film is formed by pressing the plurality of resin films at room temperature with a pair of laminating rollers,
  • the cutting step the laminated film is cut into a predetermined size before the solidification reaction of the adhesive for dry lamination in the laminated film is completed, and the laminated sheet obtained by the cutting is flattened after the cutting step. It has a flat surface stationary process which complete
  • room temperature pressure bonding refers to pressure bonding of a plurality of resin films in a room temperature state in which the pair of laminating rollers are not specially heated.
  • the roller surface temperature is in the range of 20 to 40 ° C.
  • it includes not heating the bonded resin film before bonding.
  • the laminated film having flexibility has flexibility.
  • “flexibility” of a laminated film or laminated sheet means that the adhesive surface is peeled off or the bent shape is fixed even when an external force in the bending direction acts on the laminated film or laminated sheet. Say no state. For example, the presence or absence of flexibility can be tested by winding a laminated film or laminated sheet around a 30 mm diameter cylinder.
  • the laminated film is cut to a predetermined size before the solidification reaction of the dry laminating adhesive is completed, and the laminated sheet is flattened in the flat surface standing step after the cutting step.
  • the solidification reaction was terminated in the state of standing on the top. As a result, a laminated sheet having no flatness and excellent flatness can be produced.
  • the state where the “solidification reaction is completed” is a state opposite to the above-mentioned “flexibility”, and when an external force in the bending direction is applied to the laminated film or the laminated sheet, the adhesive surface may be peeled off. A state where the bent shape is fixed.
  • the laminated film and the laminated sheet have flexibility in the bonding step and the cutting step leading to the flat surface standing step. Therefore, even if the force of a bending direction acts on a laminated film by conveyance and winding (when winding up before cutting) of a laminated film, an adhesive surface does not peel off or a curl is fixed.
  • timing for cutting the laminated film before the solidification reaction of the adhesive for dry lamination is completed can be grasped by a preliminary test or the like.
  • the resin film is a general-purpose resin film having a thickness of 150 to 200 ⁇ m and the thickness of the laminated sheet is 500 ⁇ m or more.
  • general-purpose resin film is not a custom-made product but a general product of resin films used for various applications, and is widely used for various applications such as food films and optical films.
  • a thick general-purpose resin film with a thickness of 150 to 200 ⁇ m By using a thick general-purpose resin film with a thickness of 150 to 200 ⁇ m, it is possible not only to achieve a desired thickness by bonding a small number of sheets, but also to reduce manufacturing costs.
  • a thick general-purpose resin film has higher rigidity than a thin resin film having a thickness of 100 ⁇ m or less as described above, it is bonded during transportation of a laminated film immediately after bonding, after winding, after cutting, etc. This is because the surface is easily peeled off and the present invention is particularly effective.
  • the flat surface standing step includes a flat surface heating step of heating the flat surface to promote the solidification reaction.
  • the heating temperature of the flat surface is preferably about 80 to 120 ° C., which is the drying temperature of the dry lamination adhesive.
  • the plurality of resin films are sandwiched between the pair of laminating rollers at a pressure of 0.2 to 0.4 MPa.
  • thermocompression bonding method sandwiching is usually performed at a pressure of about 0.4 to 0.5 MPa, but in the present invention, the pressure is lower than that. Thereby, it can prevent that the solidification reaction of the adhesive for dry lamination progresses too much.
  • the corona discharge treatment step of performing a corona discharge treatment on the bonding surface side of the resin film not provided with the dry laminating adhesive is provided before the bonding step. It is preferable.
  • the adhesiveness with the dry laminating adhesive is improved.
  • the adhesive force can be improved even in a state where the solidification reaction of the dry laminating adhesive is not completed.
  • the strength of the corona discharge treatment is preferably 0.1 kW / m 2 or more.
  • the two resin sheets fed out from the state wound in a roll shape by the feeding device are bonded together, and the inside of the roll of one resin film It is preferable that the side surface and the roll outer surface of the other resin film are bonded together.
  • the two resin films are wound by combining the roll inner surface of one resin film and the roll outer surface of the other resin film. If they are bonded so as to cancel the wrinkles, curling can be further prevented.
  • the production line for the laminated sheet has a roller conveying step for conveying the resin film and the laminated film with a roller, and a wrap angle of the conveyed film with respect to the roller Is 90 ° or more, the diameter of the roller is preferably 50 mm or more, and the transport tension is preferably 100 N or more and 300 N or less.
  • the wrap angle of the film with respect to the roller is 90 ° or more
  • the roller diameter is 50 mm or more
  • the conveyance tension is 100 N or more and 300 N or less.
  • the solidification reaction of the adhesive for dry lamination does not end within 24 hours when the bonding step is performed by room temperature pressure bonding.
  • the solidification reaction of the adhesive for dry lamination is completed in about 4 days.
  • the laminated sheet has a lens layer on one side and a transparent support or light source in the production of a three-dimensional image printing sheet having an image receiving layer for recording an image on the other side. It is preferable to be manufactured as a diffusion cover for LED lighting.
  • the laminated sheet manufacturing apparatus of the present invention is provided with a laminating apparatus that forms a laminated film by laminating a plurality of belt-shaped resin films to be conveyed with an adhesive for dry lamination, and the laminated film is predetermined.
  • a laminated sheet manufacturing apparatus provided with a cutting device that cuts into a laminated sheet of a size
  • the laminating temperature is a room temperature state when laminating the plurality of resin films with a pair of laminating rollers in the laminating apparatus
  • a control means for performing line control of the manufacturing apparatus so that the laminated film is cut to a predetermined size before the dry reaction of the dry lamination adhesive in the laminated film is completed.
  • the laminated sheet obtained by the cutting is placed on a flat surface in a stage subsequent to the cutting device, and the solid sheet is fixed. With a flat surface to stand apparatus to terminate the reaction.
  • the laminating temperature adjusting means adjusts the roller surface temperature of the pair of laminating rollers to 20 to 40 ° C.
  • the laminating temperature adjusting means is provided in the laminating apparatus to adjust the laminating temperature to room temperature (preferably 20 to 40 ° C.), and the adhesive for dry lamination in the laminated film is controlled by the control means for controlling the line of the manufacturing apparatus.
  • the laminated film was cut into a predetermined size with a cutting device. And the solidification reaction was made to complete
  • the flat surface stationary device includes a heating device for heating the flat surface.
  • the heating temperature of the flat surface is preferably about 80 to 120 ° C., which is the drying temperature of the dry lamination adhesive.
  • the resulting laminated sheet may be peeled off. No curling and excellent flatness.
  • Overall configuration diagram of laminated sheet manufacturing equipment for integrated production from resin film delivery to laminated sheet manufacturing Explanatory drawing explaining a cutting device and a flat surface stationary device
  • Explanatory drawing explaining another aspect of a flat surface stationary apparatus Overall configuration diagram of a laminated sheet manufacturing apparatus in which a winding process is provided between the bonding process and the cutting process.
  • FIG. 1 shows a case where the laminated sheet produced according to the present invention is applied to a three-dimensional image printing sheet as an example of a suitable use.
  • FIG. 1 illustrates an example in which two transparent general-purpose resin films are bonded together with an adhesive for dry lamination to form a transparent support (laminated sheet), two or more sheets may be bonded together.
  • the stereoscopic image printing sheet 10 is formed in a sheet shape (for example, a square sheet) of a predetermined size (for example, 12.7 cm ⁇ 17.8 cm), and a lens is formed on one surface of the transparent support 12. It has a layer 14 (a lenticular lens is illustrated in FIG. 1) and an image receiving layer 16 for recording an image on the other side, and a hard resin layer 18 is interposed between the transparent support 12 and the image receiving layer 16. .
  • the transparent support 12 is made of two transparent general-purpose resin films 12A and 12B bonded with a dry lamination adhesive 12C.
  • the number of the lenticular lenses which comprise the lens layer 14 was shown in the example of four, it is actually comprised with many.
  • the transparent support 12 preferably has as smooth a sheet surface as possible. Further, when the lens layer 14 is formed on one surface of the transparent support 12 by the extrusion laminating method, it is necessary to withstand the heat of the molten lens layer resin extruded from the extrusion die into a sheet shape, which is relatively heat resistant. It is preferable that it is resin with high property. Specifically, polycarbonate resin, polysulfone resin, biaxially stretched polyethylene terephthalate resin (PET), and the like can be given. In particular, a biaxially stretched polyethylene terephthalate resin is preferable from the viewpoint of good smoothness.
  • the thickness of the transparent support 12 must be 300 ⁇ m or more so that no image blur occurs when an image is formed on the stereoscopic image printing sheet 10 by a printing apparatus such as a thermal transfer ink sheet apparatus or an inkjet apparatus.
  • a transparent support 12 is used in which a plurality of general-purpose resin films 12A and 12B are bonded and thickened with an adhesive 12C for dry lamination.
  • the thickness of the transparent support 12 is more preferably 400 ⁇ m or more, and particularly preferably 500 ⁇ m or more.
  • the upper limit of the thickness of the transparent support body 12 was not described, it is possible to set the upper limit to the thickness at which the transparency as the three-dimensional image printing sheet 10 becomes defective due to being too thick.
  • Examples of the resin constituting the lens layer 14 include polymethyl methacrylate resin (PMMA), polycarbonate resin, polystyrene resin, methacrylate-styrene copolymer resin (MS resin), acrylonitrile-styrene copolymer resin (AS resin), and polypropylene resin.
  • PMMA polymethyl methacrylate resin
  • MS resin methacrylate-styrene copolymer resin
  • AS resin acrylonitrile-styrene copolymer resin
  • Polypropylene resin Polyethylene resins, polyethylene terephthalate resins, glycol-modified polyethylene terephthalate resins, polyvinyl chloride resins (PVC), thermoplastic elastomers, copolymers thereof, cycloolefin polymers, and the like.
  • polymethyl methacrylate resin PMMA
  • polycarbonate resin polystyrene resin
  • methacrylate-styrene copolymer resin MS resin
  • polyethylene resin polyethylene terephthalate resin
  • glycol modified polyethylene terephthalate resin it is more preferable to use glycol-modified polyethylene terephthalate resin. preferable.
  • the lens layer 14 has a thickness (T) of 50 ⁇ m to 200 ⁇ m, and has a lenticular lens shape on its surface.
  • the lenticular lens shape is formed, for example, with a lens radius (R) of 100 ⁇ m to 200 ⁇ m, a lens height (H) of 50 ⁇ m to 100 ⁇ m, and an inter-lens distance (P) of 100 ⁇ m to 318 ⁇ m.
  • R lens radius
  • H lens height
  • P inter-lens distance
  • the lenticular lens shape means a plate-like lens array in which long, long and long shaped lenses are arranged horizontally, that is, a shape in which cylindrical lenses are two-dimensionally arranged.
  • the image receiving layer 16 may be selected from a layer suitable for both a printing material that takes in and colors the color material transferred from the thermal transfer ink sheet device and a coloring device that takes in and drops the ink droplets ejected from the ink jet device. it can.
  • FIG. 2 shows a case where the laminated sheet manufactured according to the embodiment of the present invention is applied to the substrate 22 of the LED illumination diffusion cover 20 as another preferred application.
  • the LED illumination diffusion cover 20 in FIG. 2 is a case where a transparent general-purpose resin film 22A having a thickness of about 300 ⁇ m, for example, is bonded as a dry lamination adhesive 22B to form a substrate 22 (laminated sheet). .
  • a diffusion layer 24 is formed on one surface of the substrate 22, and a hard coat layer 26 (or a low refractive index layer) is formed on the opposite surface.
  • FIG. 2 shows an example in which three transparent general-purpose resin films 22A are bonded together, two sheets or four or more sheets may be bonded together.
  • Suitable examples of the material of the general-purpose resin film 22A constituting the substrate 22 include polyester and polyolefin.
  • the polyester include polyethylene terephthalate (PET, refractive index 1.67), polyethylene naphthalate (PEN), and the like.
  • other resin films include polyamide, polyether, polystyrene, polyesteramide, polycarbonate, polyphenylene sulfide, polyether ester, polyvinyl chloride, polyacrylic acid ester, and polymethacrylic acid ester.
  • a polyester resin is preferable, and at least one of the substrates 22 is more preferably made of polyethylene terephthalate (PET).
  • PET polyethylene terephthalate
  • the polyethylene terephthalate (PET) used as the substrate 22 is preferably a polyester resin melt-extruded into a film shape and biaxially stretched vertically and horizontally. Since it is oriented and crystallized by biaxial stretching and the strength and heat resistance are improved, it is suitable for use as the substrate 22 of the LED illumination diffusion cover.
  • PET polyethylene terephthalate
  • the stretching ratio is preferably stretched by 1.5 to 7 times in the vertical and horizontal directions, more preferably about 2 to 5 times.
  • the draw ratio is within the above range, sufficient mechanical strength and uniform thickness can be obtained.
  • PET film production methods and conditions can be appropriately selected from known methods and conditions.
  • the general-purpose resin film 22A on the side where the diffusion layer is provided is made of polyethylene terephthalate, so that The near-side general-purpose resin film 22A is preferably made of other plastics.
  • a material having a refractive index lower than that of polyethylene terephthalate (PET) is preferably used.
  • PET polyethylene terephthalate
  • acrylic resin such as (refractive index 1.5).
  • the thickness of the substrate 22 can be appropriately selected according to the purpose, but is preferably in the range of 300 ⁇ m to 1000 ⁇ m, for example.
  • the laminated sheet manufacturing apparatus 28 according to the first embodiment of the present invention will be described using an example of manufacturing the transparent support 12 (laminated sheet) described above by bonding two general-purpose resin films.
  • the manufacturing apparatus 28 according to the first embodiment is a case where the two general-purpose resin films 12A and 12B are sent from the sending apparatuses 30 and 38 to the production of the laminated sheet A in an integrated manner.
  • a first transparent general-purpose resin film 12A having a thickness of, for example, 180 ⁇ m is fed from the first feeding device 30 and is fed by a number of conveying rollers 32, 32.
  • the dry lamination adhesive 12C is applied to the back surface of the fed first general-purpose resin film 12A by the application device 34 (application process).
  • the application device 34 for applying the dry lamination adhesive 12C may be any device, but the dry lamination adhesive 12C can be applied thinly and uniformly on the back surface of the first general-purpose resin film 12A. ), Slot die method, rod coating method and the like can be suitably employed.
  • the drying device 36 for drying the dry lamination adhesive 12C has a plurality of drying zones, and preferably has a low temperature drying zone 36A, a high temperature drying zone 36B, and a cooling zone 36C from the inlet side. In the cooling zone 36C, it is preferable to cool the first general-purpose resin film 12A to substantially room temperature.
  • a polyurethane adhesive composition or a two-component curable adhesive composition for dry lamination can be suitably used as the dry lamination adhesive 12C.
  • the polyurethane adhesive composition is composed of an organic polyisocyanate, an organic polyol, an oxygen acid of phosphorus or a derivative thereof, an amine compound and an epoxy resin.
  • a two-component curable adhesive composition for dry lamination comprises an organic polymer polyol component such as polyester polyol and polyurethane polyol as a main agent, a bifunctional polyisocyanate compound and a trifunctional or higher polyfunctional polyisocyanate compound as a curing agent. It is composed of an organic polyisocyanate component.
  • the second general-purpose resin film 12B is sent out from the second delivery device 38 and is transported by a large number of transport rollers 32, 32... And corona discharge on the surface (bonding surface side) of the second general-purpose resin film 12B.
  • a corona discharge process is performed by the processing device 40.
  • the strength of the corona discharge treatment is preferably 0.1 KW / m 2 or more.
  • the wrap angle of the first and second general-purpose resin films 12A and 12B to be transported by the roller with respect to the transport roller 32 is 90 ° or more and the roller diameter is 50 mm or more. Furthermore, it is preferable that the conveyance tension be 100N or more and 300N or less. Thereby, since the force of a bending direction can act as much as possible with respect to 1st and 2nd general purpose resin film 12A, 12B, generation
  • the 1st and 2nd general purpose resin films 12A and 12B are pasted together by pasting device 42 which consists of a pair of laminating rollers 42A and 42B (bonding process).
  • the first general-purpose resin film 12A and the second general-purpose resin film 12B are sandwiched (nipped) by the pair of laminating rollers 42A and 42B, and are bonded by the dry lamination adhesive 12C.
  • the laminated film 44 is formed.
  • the laminating device 42 is provided with a laminating temperature adjusting means 43 that controls the laminating temperature when the first and second general-purpose resin films 12A and 12B are sandwiched between the pair of laminating rollers 42A and 42B to be a room temperature state. It is done.
  • the roller surfaces of the pair of laminating rollers 42A and 42B are maintained at 20 to 40 ° C. (room temperature state) by the laminating temperature adjusting means 43. That is, the laminating temperature adjusting means 43 heats the roller surface to 20 to 40 ° C. when the roller surface temperature falls below 20 ° C. in winter. This prevents the dry lamination adhesive 12C from being cooled and solidified. In the summer, when the roller surface temperature exceeds 40 ° C., the roller surface is cooled to 20 to 40 ° C. Thereby, the solidification reaction of the adhesive 12C for dry lamination is delayed.
  • the roller surface temperature can be measured with a non-contact type temperature sensor such as an infrared thermometer.
  • the first general-purpose resin film 12A and the second general-purpose resin film 12B are laminated by room temperature pressure bonding rather than conventional thermocompression bonding.
  • the solidification reaction of the dry laminating adhesive 12C does not proceed during the bonding process so that it becomes solidified or close to solidification. 44 maintains flexibility.
  • the nip force for nipping between the pair of laminating rollers 42A and 42B is preferably 0.2 to 0.4 MPa, which is lower than the nip force normally practiced by conventional thermocompression bonding. Thereby, it can suppress that the solidification reaction of the adhesive 12C for dry lamination progresses too much.
  • the other general-purpose resin film is bonded to the roll outer surface. That is, since the first and second general-purpose resin films 12A and 12B sent out from the state wound in a roll shape are wrinkled, the wrinkles of the two general-purpose resin films 12A and 12B are offset. It is preferable to stick together. Thereby, curling of the laminated sheet A caused by curling can be prevented.
  • the protective films 48A and 48B are bonded to the front surface (upper surface) and the back surface (lower surface) of the laminated film 44.
  • the protective film laminating device 46 includes a pair of nip rollers 46A and 46B, a first reel device 50A around which an upper protective film 48A is wound, and a second reel device 50B around which a lower protective sheet 48B is wound. .
  • multilayer film 44 from the bonding apparatus 42 to the protective film bonding apparatus 46 can also be roller conveyance
  • the belt conveyor conveyance by the belt conveyor apparatus 47 is still more preferable. This is because the conveyance surface is preferably as flat as possible to prevent curling during conveyance of the laminated film 44.
  • the laminated film 44 is conveyed to the cutting device 52 and cut into a predetermined size (cutting process). Also in this case, the conveyance of the laminated film 44 from the protective film laminating device 46 to the cutting device 52 is more preferably a belt conveyor conveyance by the belt conveyor device 49.
  • the cutting device 52 is mainly composed of a cutting machine 54 and a work holding machine 56 as shown in FIG.
  • the cutting machine 54 includes a rotation support unit 60 that rotatably supports the rotary saw blade 58, and a lift unit 62 that moves the rotary support blade 60 up and down and moves the rotary saw blade 58 to and from the cutting position. Is done.
  • the rotation support unit 60 incorporates a motor and power transmission means (not shown), and the rotational force of the motor is transmitted to the rotary saw blade 58 via the power transmission means.
  • a hydraulic cylinder device can be suitably used.
  • the rotary saw blade 58 has been described as the cutting blade, the present invention is not limited to this, and a knife cutter, a punching blade, or the like can be used.
  • the work holding machine 56 includes a pedestal 64 having a slot-like opening 64A so that the rotary saw blade 58 can enter the cutting position, a holding unit 66 that holds the laminated film 44 from the opposite side of the pedestal 64, and a holding unit 66. And moving means 68 for moving forward and backward with respect to the pedestal 64.
  • a slot-like opening 66A is also formed on the base 64 side of the holding portion 66 so that the rotary saw blade 58 can enter the cutting position.
  • the moving means 68 for example, a hydraulic cylinder device can be suitably used.
  • the laminated film 44 is cut into a predetermined size before the solidification reaction of the dry lamination adhesive 12C of the laminated film 44 is completed. Thereby, the laminated sheet A is obtained.
  • the laminated sheet A cut to a predetermined size is transported to the flat surface stationary device 70, where the flat surface is stationary.
  • the flat surface stationary device 70 mainly includes a belt conveyor device 74 provided with an endless belt 72 (for example, a metal belt such as stainless steel) having a smooth surface, and heating for heating the endless belt 72.
  • a belt conveyor device 74 provided with an endless belt 72 (for example, a metal belt such as stainless steel) having a smooth surface, and heating for heating the endless belt 72.
  • Device 76 for example, a metal belt such as stainless steel
  • the endless belt 72 is wound around a pair of rollers 78 and 78 that are spaced apart from each other by a predetermined distance in the horizontal direction, and moves around the pair of rollers 78 and 78. As a result, a flat surface 72 ⁇ / b> A is formed on the upper circumferential surface of the endless belt 72 for transporting the laminated sheet A in a stationary state.
  • the endless belt 72 that moves around is heated by the heating device 76.
  • the heating temperature of the endless belt 72 is preferably in the range of 80 to 120 ° C., which is equivalent to the drying temperature of the dry lamination adhesive 12C.
  • the laminated sheet A obtained by cutting is transported to the next stacking device 82 in a state of being stationary on the flat surface 72A of the endless belt 72. Then, the solidification reaction is terminated by heating the dry lamination adhesive 12 ⁇ / b> C in the laminated sheet A by the endless belt 72 heated by the heating device 76 during the conveyance.
  • the laminated film 44 and the laminated sheet A are flexible in the bonding step and the cutting step leading to the flat surface standing step. It has sex. Thereby, even if the force of a bending direction acts on the laminated
  • the surface can be prevented from peeling off or curling.
  • the laminated sheet manufacturing apparatus 28 solidifies the dry lamination adhesive 12 ⁇ / b> C until the laminated film 44 is laminated by the laminating apparatus 42 and is cut into the laminated sheet A having a predetermined size by the cutting apparatus 52. It is necessary not to terminate the reaction.
  • the manufacturing apparatus 28 is provided with a control means 80 for performing line control.
  • the line control of the control means 80 in the case of integrated production from the delivery from the delivery devices 30 and 38 of the two general-purpose resin films 12A and 12B to the production of the laminated sheet A includes the control of the line conveyance speed and the temperature of the line environment. There is control. That is, by controlling the line conveyance speed and the line environmental temperature, the time until the solidification reaction of the dry lamination adhesive 12C is controlled. Thus, the solidification reaction of the dry laminating adhesive 12 ⁇ / b> C is not terminated until the laminated film 44 is laminated by the laminating device 42 and is cut into the laminated sheet A having a predetermined size by the cutting device 52.
  • a relationship between a plurality of line environmental temperatures and an elapsed time until the solidification reaction of the dry lamination adhesive 12C at that time is completed by a preliminary test or the like may be obtained in advance and input to the control program of the control means 80. .
  • FIG. 5 shows another embodiment of the flat surface stationary device 70.
  • One belt conveyor device 74 and a heating device 76 described in FIG. 4 are further provided on the opposite side of the laminated sheet A, and a pair of endless shapes are provided.
  • the laminated sheet A is sandwiched between the belts 72 and 72.
  • the laminated sheet A is sandwiched between the pair of endless belts 72, 72, and the laminated sheet A is heated by the heating device 76 from the front and back of the laminated sheet A in a state where the laminated sheet A is surely flattened.
  • the solidification reaction ends. Therefore, it is possible to produce a laminated sheet A that is free from curling and has excellent flat surface properties.
  • the heating device 76 may be omitted.
  • the laminated sheet A that has finished the flat surface stationary step is sent to the accumulation device 82 and accumulated.
  • the laminated sheet manufacturing apparatus 84 in the second embodiment shown in FIG. 6 is a case where a winding device 86 for temporarily winding the laminated film 44 is provided between the bonding device 42 and the cutting device 52 described above. is there. Note that the same devices and members as those in FIG.
  • the laminated film 44 formed by the laminating device 42 is once wound up into a roll shape by the winding device 86.
  • the laminated film 44 taken up by the take-up device 86 is stored at a predetermined storage temperature for a predetermined time, and then rewound, and the protective film laminating device 46, the cutting device 52, and the flat surface stationary device 70 are wound. It is conveyed sequentially.
  • control means 80 is wound and stored in the winding device 86 so that the laminated film 44 can be cut by the cutting device 52 before the solidification reaction of the dry lamination adhesive 12C in the laminated film 44 is completed.
  • the storage time and storage temperature of the laminated film 44 are controlled.
  • the laminated film 44 wound around the winding device 86 is stored at room temperature, there is no problem if the laminated film 44 is unwound within 24 hours after winding and cut into a predetermined size by the cutting device 52.
  • the timing for cutting the laminated film 44 can also be adjusted. With this timing adjustment, the laminated film 44 can be unwound from the winding device 86 and cut and allowed to stand on a flat surface shortly before the solidification reaction of the dry lamination adhesive 12C is completed. Thereby, the heating device 76 of the flat surface stationary device 70 can be omitted.
  • the laminated sheet produced in the present invention is suitable for a stereoscopic image printing sheet and an LED illumination diffusion cover.
  • a reservoir device for preventing the film from loosening while the transport is stopped is provided in the manufacturing lines of the manufacturing devices 28 and 84. Provided.
  • DESCRIPTION OF SYMBOLS 10 Three-dimensional image printing sheet, 10A ... Three-dimensional image printing sheet original, 12 ... Transparent support, 12A ... First general-purpose resin film, 12B ... Second general-purpose resin film, 12C ... Adhesive for dry lamination, 14 ... Lens Layer, 16 ... image receiving layer, 18 ... hard resin layer, 20 ... diffusion cover for LED illumination, 22 ... substrate, 24 ... diffusion layer, 26 ... hard coat layer, 28 ... manufacturing apparatus (first embodiment), DESCRIPTION OF SYMBOLS 30 ... 1st delivery apparatus, 32 ... Conveyance roller, 34 ... Application
  • Pasting apparatus 43 ... Laminate temperature adjustment means, 44 ... Laminated film, 46 ... Laminating device, 47 ... Belt conveyor device, 48A ... Upper protective film, 48B ... Lower protective film, 49 ... Belt conveyor device, 50A ... First reel device, 50B ... No. Reel device 52 ... Cutting device 54 ... Cutting machine 56 ... Work holding machine 58 ... Rotating saw blade 60 ... Rotating support part 62 ... Elevating part 64 ... Pedestal 66 ... Pressing part 68 ... Moving means DESCRIPTION OF SYMBOLS 70 ... Flat surface stationary apparatus, 72 ... Endless belt, 72A ... Flat surface, 74 ... Belt conveyor apparatus, 76 ... Heating apparatus, 78 ... Roller, 80 ... Control means, 82 ... Accumulation apparatus, 84 ... Manufacturing apparatus (No. 1) Embodiment 2), A ... laminated sheet

Abstract

In the present invention, a laminated film is formed by laminating conveyed belt-shaped first and second general-purpose resin films together with a dry laminating adhesive using a lamination device. When the laminated film is to be cut into a laminated sheet of predetermined size using a cutter, the first and second general-purpose resin films are fed between a pair of laminating rollers kept at room temperature, the laminated film is cut into a laminated sheet of a predetermined size before the conclusion of a reaction in which the dry laminating adhesive in the laminated film solidifies, and the solidification reaction is allowed to conclude with the cut laminated sheet having been laid on a flat surface.

Description

積層シートの製造方法及び製造装置Method and apparatus for manufacturing laminated sheet
　本発明は積層シートの製造方法及び製造装置に係り、特に、３Ｄプリントや３Ｄ印刷に使用される立体画像用印画シートの透明支持体やＬＥＤ照明用拡散カバーの基板としての用途に優れた積層シートの製造方法及び製造装置に関する。 The present invention relates to a method and apparatus for producing a laminated sheet, and in particular, a laminated sheet excellent in use as a transparent support for stereoscopic image printing sheets used for 3D printing and 3D printing and as a substrate for a diffusion cover for LED lighting. The present invention relates to a manufacturing method and a manufacturing apparatus.
　従来、立体画像を記録する記録シートとして、樹脂製の透明支持体の一方面にレンズ層（例えばレンチキュラーレンズ）を有し、他方面に画像を記録する受像層を設けた立体画像用印画シートが知られている。 Conventionally, as a recording sheet for recording a stereoscopic image, there is a stereoscopic image printing sheet having a lens layer (for example, a lenticular lens) on one side of a resin-made transparent support and an image receiving layer for recording an image on the other side. Are known.
　例えば、特許文献１は、紙、合成紙、プラスチックフィルム等からなる透明支持体（基材）の一方面にレンチキュラーレンズシートを貼り合わせ、透明支持体の裏面に、塗工、乾燥して染料受像層を設けた立体画像用感熱転写記録シートが開示されている。 For example, in Patent Document 1, a lenticular lens sheet is bonded to one side of a transparent support (base material) made of paper, synthetic paper, plastic film, etc., and the dye receiving image is applied to the back side of the transparent support and dried. A heat-sensitive transfer recording sheet for stereoscopic images provided with a layer is disclosed.
　しかし、立体画像用印画シートの受像層に例えば熱転写インクシート装置やインクジェット装置等の印画装置によって画像を形成したときに、最適視点位置を外れた場合のクロストークにより感じる画像ボケが発生するという問題がある。この画像ボケを解消するには、透明支持体を３００μｍ以上の厚み（立体画像用印画シート全体の厚みが５００μｍ以上）に厚くすることが必要である。しかし、汎用されている樹脂製の透明フィルム（以下「汎用樹脂フィルム」という）の厚みは最も厚いものでも２００μｍ以下（通常は１００μｍ以下）であり、３００μｍ以上の厚みのフィルムを特注製造することはコスト面で問題がある。したがって、できるだけ厚手の汎用樹脂フィルムをドライラミ用接着剤で貼り合わせて透明支持体の厚みを厚くする方法が行われている。 However, when an image is formed on an image receiving layer of a stereoscopic image printing sheet by a printing device such as a thermal transfer ink sheet device or an ink jet device, an image blur caused by crosstalk occurs when the optimum viewpoint position is deviated. There is. In order to eliminate this image blur, it is necessary to increase the thickness of the transparent support to 300 μm or more (the total thickness of the three-dimensional image printing sheet is 500 μm or more). However, the thickness of the transparent resin film (hereinafter referred to as “general-purpose resin film”), which is widely used, is 200 μm or less (usually 100 μm or less) even if it is the thickest. There is a problem with cost. Therefore, a method of increasing the thickness of the transparent support by sticking as thick a general-purpose resin film as possible with an adhesive for dry lamination has been performed.
　また、近年の技術成長及びエネルギー消費の効率化を背景として、ＬＥＤが照明の分野に参入を始めている。今までの照明である白熱電球や、蛍光灯と大きく異なる点として、ＬＥＤが点光源であることが挙げられる。このため、ＬＥＤを照明として利用する場合には、点光源のランプイメージをなくすよう、隠蔽性が大きく且つ光の利用効率を高める光拡散性が付与されたＬＥＤ照明用拡散カバーが求められている。また、樹脂フィルムを照明用カバーに使用する場合には、落下防止のため、あるいは風圧や押圧によって撓まない程度の剛性が必要となる。したがって、できるだけ厚手の汎用樹脂フィルムをドライラミ用接着剤で貼り合わせて５００μｍ以上の厚みにすることによって剛性を得る方法が行われている。 Also, with the background of recent technological growth and energy consumption efficiency, LEDs have started to enter the lighting field. A point that differs greatly from incandescent light bulbs and fluorescent lamps that have been used up to now is that LEDs are point light sources. For this reason, when using LED as illumination, the diffusion cover for LED illumination to which the light diffusibility which gives large concealment property and raises the utilization efficiency of light was given so that the lamp image of a point light source might be lost is calculated | required. . Moreover, when using a resin film for the illumination cover, it is necessary to have rigidity sufficient to prevent falling or to bend by wind pressure or pressing. Therefore, a method of obtaining rigidity by sticking as thick a general-purpose resin film as possible with an adhesive for dry lamination to a thickness of 500 μm or more has been performed.
　従来、樹脂フィルムをドライラミ用接着剤で貼り合わせる方法としては、一方の樹脂フィルムをロールから送り出し、フィルム片面にドライラミ用接着剤を塗布した後、８０～１２０℃程度で接着剤の溶剤を乾燥させる。そして、粘着状態となった接着剤面に他方の汎用樹脂フィルムを貼り合わせて前述の乾燥温度と同程度の温度で加熱圧着する方法が一般的である（例えば非特許文献１、特許文献２）。このように貼り合わされた積層フィルムは、例えば立体画像用印画シート用、ＬＥＤ照明用拡散カバー等の用途に応じて所定サイズに切断される。 Conventionally, as a method of laminating a resin film with an adhesive for dry lamination, one resin film is fed from a roll, and after applying the adhesive for dry lamination on one side of the film, the solvent of the adhesive is dried at about 80 to 120 ° C. . And the method of sticking the other general purpose resin film on the adhesive surface which became a sticky state, and thermocompression bonding at the temperature comparable as the above-mentioned drying temperature is common (for example, nonpatent literature 1, patent literature 2). . The laminated film bonded in this way is cut into a predetermined size according to the use such as a stereoscopic image printing sheet, an LED illumination diffusion cover, and the like.
特開平６－２８２０１９号公報JP-A-6-282019 特開２００３－５３９２６号公報JP 2003-53926 A
　しかしながら、従来の貼り合わせ方法で複数枚の樹脂フィルム、例えば汎用樹脂フィルムをドライラミ用接着剤で貼り合わせると、次の問題が発生する。 However, when a plurality of resin films, for example, a general-purpose resin film are bonded with an adhesive for dry lamination by the conventional bonding method, the following problems occur.
　（１）汎用樹脂フィルム１枚の厚みが１００μｍ以下で薄く、剛性が小さい場合には従来の貼り合わせ方法でも積層フィルムの搬送中、巻取り後（貼合工程の後で積層フィルムを一旦巻き取る場合）、積層フィルムの切断後等においてドライラミ用接着剤の接着面が剥がれ難い。しかし、１枚の厚みが１５０～２００μｍの厚手で剛性が大きい汎用樹脂フィルムの場合には、積層フィルムの搬送中、巻取り後、切断後等においてドライラミ用接着剤の接着面が剥がれ易くなる。 (1) When a single general-purpose resin film has a thickness of 100 μm or less and is thin and has low rigidity, the conventional laminating method can also be used to wind the laminated film during winding (after the laminating step, the laminated film is once wound) Case), the adhesive surface of the adhesive for dry lamination is difficult to peel off after cutting the laminated film. However, in the case of a thick general-purpose resin film having a thickness of 150 to 200 μm and high rigidity, the adhesive surface of the adhesive for dry lamination is easily peeled off during transportation, winding and cutting of the laminated film.
　（２）また、従来の貼合わせ方法で行うと、所定サイズに切断して得られた積層シートにカールが生じ易い。貼り合わせ前の樹脂フィルムや、貼り合わせた後の積層フィルムは搬送ローラ等にラップして搬送されることによって曲げ方向の外力が加わり、ローラの搬送方向に湾曲してカールが発生し易い。この結果、積層フィルムにおいて発生したカールが切断後の積層シートにも残存してしまう。例えば、立体画像用印画シートのカールの程度は、４ｍｍ以下であれば問題ないが、従来の貼合わせ方法で製造した立体画像用印画シートは４ｍｍ以上となることが多い。 (2) Moreover, when it is performed by a conventional laminating method, the laminated sheet obtained by cutting into a predetermined size is likely to curl. The resin film before pasting and the laminated film after pasting are wrapped and transported on a transport roller or the like, so that an external force in the bending direction is applied, and the curl is easily generated by curving in the transport direction of the roller. As a result, the curl generated in the laminated film remains on the laminated sheet after cutting. For example, the degree of curling of the stereoscopic image printing sheet is not problematic as long as it is 4 mm or less, but the stereoscopic image printing sheet produced by the conventional laminating method is often 4 mm or more.
　本発明はこのような事情に鑑みてなされたもので、樹脂フィルム、特に厚手の汎用樹脂フィルムをドライラミネート用接着剤で貼り合わせて積層シートを製造しても、得られた積層シートに剥がれやカールがなく平坦性に優れているので、立体画像用印画シート用、ＬＥＤ照明用拡散カバー等として好適な積層シートの製造方法及び製造装置を提供することを目的とする。 The present invention has been made in view of such circumstances, and even if a laminated sheet is produced by laminating a resin film, particularly a thick general-purpose resin film, with an adhesive for dry lamination, the resulting laminated sheet may be peeled off. An object of the present invention is to provide a manufacturing method and a manufacturing apparatus for a laminated sheet suitable as a three-dimensional image printing sheet, a LED illumination diffusion cover, and the like because it is free from curling and has excellent flatness.
　本発明の積層シートの製造方法は前記目的を達成するために搬送される帯状の樹脂フィルムをドライラミ用接着剤で複数枚貼り合わせて積層フィルムを形成する貼合工程と、前記積層フィルムを所定サイズの積層シートに切断する切断工程とを備えた積層シートの製造方法において、前記貼合工程では、前記複数枚の樹脂フィルムを一対のラミネートローラで室温圧着することにより前記積層フィルムを形成し、前記切断工程では、前記積層フィルムにおけるドライラミ用接着剤の固化反応が終了する前に前記積層フィルムを所定サイズに切断すると共に、前記切断工程の後段に、前記切断して得られた積層シートを平坦面上に静置した状態で前記固化反応を終了させる平坦面静置工程を有する。 The method for producing a laminated sheet of the present invention includes a laminating step of laminating a plurality of strip-shaped resin films conveyed to achieve the above object with an adhesive for dry lamination, and forming the laminated film with a predetermined size. In the method for manufacturing a laminated sheet comprising a cutting step of cutting into the laminated sheet, the laminating film is formed by pressing the plurality of resin films at room temperature with a pair of laminating rollers, In the cutting step, the laminated film is cut into a predetermined size before the solidification reaction of the adhesive for dry lamination in the laminated film is completed, and the laminated sheet obtained by the cutting is flattened after the cutting step. It has a flat surface stationary process which complete | finishes the said solidification reaction in the state left still on.
　ここで、「室温圧着」とは、一対のラミネートローラを特別に加熱していない室温状態で複数枚の樹脂フィルムを圧着することを言い、例えばローラ表面温度が２０～４０℃の範囲である。更には、一対のラミネートローラを加熱しないこと以外に、貼り合わされる樹脂フィルムを貼り合わせ前に加熱しないことも含む。 Here, “room temperature pressure bonding” refers to pressure bonding of a plurality of resin films in a room temperature state in which the pair of laminating rollers are not specially heated. For example, the roller surface temperature is in the range of 20 to 40 ° C. Furthermore, in addition to not heating the pair of laminating rollers, it includes not heating the bonded resin film before bonding.
　本発明によれば、貼合工程において、複数枚の樹脂フィルムを室温圧着するようにしたので、貼合工程中におけるドライラミ用接着剤の固化反応の進行を抑制できる。これにより、従来の貼合わせ方法の加熱圧着のように、貼合工程中にドライラミ用接着剤の反応が進んで固化してしまうことがないので、貼り合わされた積層フィルムは柔軟性を有する。 According to the present invention, since a plurality of resin films are pressure-bonded at room temperature in the bonding step, the progress of the solidification reaction of the adhesive for dry laminating during the bonding step can be suppressed. Thereby, since the reaction of the adhesive for dry lamination does not proceed and solidify during the bonding step as in the case of thermocompression bonding in the conventional bonding method, the laminated film having flexibility has flexibility.
　ここで、積層フィルム又は積層シートの「柔軟性」とは、積層フィルム又は積層シートに曲げ方向の外力が作用しても接着面が剥がれたり、曲がったままの形状が固定化されたりすることがない状態を言う。例えば３０ｍｍ直径の円柱に積層フィルム又は積層シートを巻き付けることにより、柔軟性の有無を試験することができる。 Here, “flexibility” of a laminated film or laminated sheet means that the adhesive surface is peeled off or the bent shape is fixed even when an external force in the bending direction acts on the laminated film or laminated sheet. Say no state. For example, the presence or absence of flexibility can be tested by winding a laminated film or laminated sheet around a 30 mm diameter cylinder.
　そして、切断工程では、ドライラミ用接着剤の固化反応が終了する前に積層フィルムを所定サイズに切断して積層シートにすると共に、切断工程の後の平坦面静置工程では、積層シートを平坦面上に静置した状態で固化反応を終了させるようにした。これにより、カールがなく平坦性に優れた積層シートを製造することができる。 In the cutting step, the laminated film is cut to a predetermined size before the solidification reaction of the dry laminating adhesive is completed, and the laminated sheet is flattened in the flat surface standing step after the cutting step. The solidification reaction was terminated in the state of standing on the top. As a result, a laminated sheet having no flatness and excellent flatness can be produced.
　ここで、「固化反応が終了」した状態とは、上記した「柔軟性」とは逆の状態であり、積層フィルム又は積層シートに曲げ方向の外力を作用させたときに、接着面が剥がれたり、曲がったままの形状が固定化されたりする状態を言う。 Here, the state where the “solidification reaction is completed” is a state opposite to the above-mentioned “flexibility”, and when an external force in the bending direction is applied to the laminated film or the laminated sheet, the adhesive surface may be peeled off. A state where the bent shape is fixed.
　「固化反応の終了」の確認試験としては、一般的には、ＪＩＳ　Ｋ ６８５４－３の「剥離接着強さ試験方法」に準じて確認する。しかし、簡易確認試験としては、上記したように３０ｍｍ直径の円柱に積層フィルム又は積層シートを巻き付けたときに接着面が剥離したり、曲がったままの形状が固定化されたりするかで確認してもよい。 As a confirmation test of “end of solidification reaction”, it is generally confirmed in accordance with “Test method of peel adhesion strength” of JIS K 6854-3. However, as a simple confirmation test, as described above, when a laminated film or a laminated sheet is wound around a cylinder having a diameter of 30 mm, the adhesive surface is peeled off or the bent shape is fixed. Also good.
　また、平坦面静置工程においてドライラミ用接着剤の固化が終了するので、平坦面静置工程に至る貼合工程や切断工程では積層フィルム及び積層シートは柔軟性を有している。これにより、積層フィルムの搬送や巻取り（切断の前に一旦巻き取る場合）によって積層フィルムに曲げ方向の力が作用しても接着面が剥がれたりカールが固定化したりすることがない。 Moreover, since the solidification of the adhesive for dry laminating is completed in the flat surface standing step, the laminated film and the laminated sheet have flexibility in the bonding step and the cutting step leading to the flat surface standing step. Thereby, even if the force of a bending direction acts on a laminated film by conveyance and winding (when winding up before cutting) of a laminated film, an adhesive surface does not peel off or a curl is fixed.
　なお、ドライラミ用接着剤の固化反応が終了する前に積層フィルムを切断するタイミングについては、予備試験等により把握できる。 It should be noted that the timing for cutting the laminated film before the solidification reaction of the adhesive for dry lamination is completed can be grasped by a preliminary test or the like.
　本発明の積層シートの製造方法においては、前記樹脂フィルムは、１枚の厚みが１５０～２００μｍの範囲の汎用樹脂フィルムであると共に、前記積層シートの厚みが５００μｍ以上であることが好ましい。 In the method for producing a laminated sheet of the present invention, it is preferable that the resin film is a general-purpose resin film having a thickness of 150 to 200 μm and the thickness of the laminated sheet is 500 μm or more.
　ここで、「汎用樹脂フィルム」とは、特注品ではなく色々な用途に用いられている樹脂フィルムの一般品を言い、食品用フィルム、光学用フィルム等の各種の用途に広く使用されているものを言う。 Here, “general-purpose resin film” is not a custom-made product but a general product of resin films used for various applications, and is widely used for various applications such as food films and optical films. Say.
　１枚の厚みが１５０～２００μｍの範囲の厚手の汎用樹脂フィルムを使用することで、少ない枚数の貼り合わせで目的の厚さにすることができるだけでなく、製造コストを低減できる。また、このような厚手の汎用樹脂フィルムは、上記したように１００μｍ以下の薄い樹脂フィルムに比べて剛性が大きいために、貼り合わせ直後の積層フィルムの搬送中、巻取り後、切断後等において接着面に剥がれが生じ易く、本発明が特に有効だからである。 By using a thick general-purpose resin film with a thickness of 150 to 200 μm, it is possible not only to achieve a desired thickness by bonding a small number of sheets, but also to reduce manufacturing costs. In addition, since such a thick general-purpose resin film has higher rigidity than a thin resin film having a thickness of 100 μm or less as described above, it is bonded during transportation of a laminated film immediately after bonding, after winding, after cutting, etc. This is because the surface is easily peeled off and the present invention is particularly effective.
　本発明の積層シートの製造方法においては、前記平坦面静置工程には、前記平坦面を加熱して前記固化反応を促進する平坦面加熱工程を有することが好ましい。 In the method for producing a laminated sheet of the present invention, it is preferable that the flat surface standing step includes a flat surface heating step of heating the flat surface to promote the solidification reaction.
　これにより、積層シートは平坦面に面接触した状態で加熱され、ドライラミ用接着剤の固化反応が終了するので、得られた積層シートは剥がれやカールがなく平坦性に優れている。この場合、平坦面の加熱温度としては、ドライラミ用接着剤の乾燥温度である８０～１２０℃程度に加熱することが好ましい。 This allows the laminated sheet to be heated while being in surface contact with the flat surface, and the solidification reaction of the dry laminating adhesive is completed. Thus, the obtained laminated sheet is excellent in flatness without peeling or curling. In this case, the heating temperature of the flat surface is preferably about 80 to 120 ° C., which is the drying temperature of the dry lamination adhesive.
　本発明の積層シ―トの製造方法においては、前記貼合工程では、前記複数枚の樹脂フィルムを前記一対のラミネートローラで０．２～０．４ＭＰａの圧力で挟み込むことが好ましい。 In the method for producing a laminated sheet of the present invention, it is preferable that in the bonding step, the plurality of resin films are sandwiched between the pair of laminating rollers at a pressure of 0.2 to 0.4 MPa.
　従来の貼合わせ方法の加熱圧着では、０．４～０．５ＭＰａ程度の圧力で挟み込むことが通常であるが、本発明ではその圧力よりも低くする。これにより、ドライラミ用接着剤の固化反応が進み過ぎることを防止できる。 In the conventional thermocompression bonding method, sandwiching is usually performed at a pressure of about 0.4 to 0.5 MPa, but in the present invention, the pressure is lower than that. Thereby, it can prevent that the solidification reaction of the adhesive for dry lamination progresses too much.
　本発明の積層シ―トの製造方法においては、前記貼合工程の前段に、前記ドライラミ用接着剤が付与されていない樹脂フィルムの貼合わせ面側にコロナ放電処理を施すコロナ放電処理工程を有することが好ましい。 In the method for producing a laminated sheet according to the present invention, the corona discharge treatment step of performing a corona discharge treatment on the bonding surface side of the resin film not provided with the dry laminating adhesive is provided before the bonding step. It is preferable.
　コロナ放電処理を施すことにより、樹脂フィルムの貼合わせ面を荒らすことができるので、ドライラミ用接着剤との接着性が向上する。これにより、複数枚の樹脂フィルム同士の貼り合わせた際の接着性が良くなるので、ドライラミ用接着剤の固化反応が終了していない状態でも接着力を向上できる。この場合、コロナ放電処理の強度としては、０．１ＫＷ／ｍ２以上であることが好ましい。 Since the bonding surface of the resin film can be roughened by performing the corona discharge treatment, the adhesiveness with the dry laminating adhesive is improved. Thereby, since the adhesiveness at the time of bonding a plurality of resin films is improved, the adhesive force can be improved even in a state where the solidification reaction of the dry laminating adhesive is not completed. In this case, the strength of the corona discharge treatment is preferably 0.1 kW / m 2 or more.
　本発明の積層シ―トの製造方法においては、前記貼合工程では、送出装置によってロール状に巻回された状態から送り出される２枚の樹脂シートを貼り合わすと共に、一方の樹脂フィルムのロール内側面と他方の樹脂フィルムのロール外側面とが合わさるように貼り合わすが好ましい。 In the manufacturing method of the laminated sheet of the present invention, in the bonding step, the two resin sheets fed out from the state wound in a roll shape by the feeding device are bonded together, and the inside of the roll of one resin film It is preferable that the side surface and the roll outer surface of the other resin film are bonded together.
　ロール状に巻回された状態から送り出された樹脂フィルムは巻き癖がついているので、一方の樹脂フィルムのロール内側面と他方の樹脂フィルムのロール外側面とを合わせて２枚の樹脂フィルムの巻き癖を相殺するように貼り合わせれば、カールの発生を一層防止できる。 Since the resin film sent out from the rolled state has a curl, the two resin films are wound by combining the roll inner surface of one resin film and the roll outer surface of the other resin film. If they are bonded so as to cancel the wrinkles, curling can be further prevented.
　本発明の積層シ―トの製造方法においては、前記積層シートの製造ラインに、前記樹脂フィルム及び前記積層フィルムをローラ搬送するローラ搬送工程を有し、前記搬送されるフィルムの前記ローラに対するラップ角度を９０°以上にすると共に、前記ローラの径を５０ｍｍ以上とし、搬送張力を１００Ｎ以上、３００Ｎ以下とすることが好ましい。 In the method for producing a laminated sheet of the present invention, the production line for the laminated sheet has a roller conveying step for conveying the resin film and the laminated film with a roller, and a wrap angle of the conveyed film with respect to the roller Is 90 ° or more, the diameter of the roller is preferably 50 mm or more, and the transport tension is preferably 100 N or more and 300 N or less.
　貼合工程前の樹脂フィルム及び貼合工程後の積層フィルムのローラ搬送において、フィルムのローラに対するラップ角度を９０°以上にすると共に、ローラ径を５０ｍｍ以上とし、搬送張力を１００Ｎ以上、３００Ｎ以下とすることにより、フィルムに対して曲げ方向の力ができるだけ作用しないようにできる。これにより、製造された積層シートのカール発生や剥がれを一層抑制できる。 In the roller conveyance of the resin film before the bonding step and the laminated film after the bonding step, the wrap angle of the film with respect to the roller is 90 ° or more, the roller diameter is 50 mm or more, and the conveyance tension is 100 N or more and 300 N or less. By doing so, the force in the bending direction can be prevented from acting on the film as much as possible. Thereby, curling generation | occurrence | production and peeling of the laminated sheet manufactured can be suppressed further.
　本発明の積層シ―トの製造方法においては、前記貼合工程と前記切断工程との間に、前記積層フィルムを巻取装置に一旦巻き取る巻取工程を有すると共に、巻き取った後２４時間以内に巻き戻して前記切断工程を行うことが好ましい。 In the manufacturing method of the lamination sheet of this invention, while having the winding process which winds up the said laminated | multilayer film once to a winding apparatus between the said bonding process and the said cutting process, 24 hours after winding up It is preferable to carry out the cutting step by rewinding within.
　室温圧着で貼合工程を行う場合、２４時間以内であれば、ドライラミ用接着剤の固化反応は終了しないからである。ちなみに、積層フィルムを２５℃の一定温度に保管した場合には、４日程度でドライラミ用接着剤の固化反応が完了する。 This is because the solidification reaction of the adhesive for dry lamination does not end within 24 hours when the bonding step is performed by room temperature pressure bonding. Incidentally, when the laminated film is stored at a constant temperature of 25 ° C., the solidification reaction of the adhesive for dry lamination is completed in about 4 days.
　本発明の積層シートの製造方法において、前記積層シートは、一方面にレンズ層を有すると共に他方面に画像を記録する受像層を有する立体画像用印画シートの製造における透明支持体、又は光源をＬＥＤとしたＬＥＤ照明用拡散カバーとして製造されることが好ましい。 In the method for manufacturing a laminated sheet according to the present invention, the laminated sheet has a lens layer on one side and a transparent support or light source in the production of a three-dimensional image printing sheet having an image receiving layer for recording an image on the other side. It is preferable to be manufactured as a diffusion cover for LED lighting.
　これにより、立体画像用印画シートでは画像ボケやカールを解消することができ、ＬＥＤ照明用拡散カバーでは所望の剛性を有し、且つ剥がれやカールがない照明用カバーを製造できるからである。 This is because image blur and curl can be eliminated in the stereoscopic image printing sheet, and an illumination cover having desired rigidity and free from peeling or curling can be manufactured in the LED illumination diffusion cover.
　本発明の積層シートの製造装置は前記目的を達成するために、搬送される帯状の樹脂フィルムをドライラミ用接着剤で複数枚貼り合わせて積層フィルムを形成する貼合装置と、前記積層フィルムを所定サイズの積層シートに切断する切断装置とを備えた積層シートの製造装置において、前記貼合装置には、前記複数枚の樹脂フィルムを一対のラミネートローラで挟み込んでラミネートする際のラミネート温度を室温状態に調整するラミネート温度調整手段を有すると共に、前記積層フィルムにおけるドライラミ用接着剤の固化反応が終了する前に前記積層フィルムを所定サイズに切断するように前記製造装置のライン制御を行う制御手段を有し、前記切断装置の後段に、前記切断して得られた積層シートを平坦面上に静置した状態で前記固化反応を終了させる平坦面静置装置を備えた。 In order to achieve the above object, the laminated sheet manufacturing apparatus of the present invention is provided with a laminating apparatus that forms a laminated film by laminating a plurality of belt-shaped resin films to be conveyed with an adhesive for dry lamination, and the laminated film is predetermined. In a laminated sheet manufacturing apparatus provided with a cutting device that cuts into a laminated sheet of a size, the laminating temperature is a room temperature state when laminating the plurality of resin films with a pair of laminating rollers in the laminating apparatus And a control means for performing line control of the manufacturing apparatus so that the laminated film is cut to a predetermined size before the dry reaction of the dry lamination adhesive in the laminated film is completed. Then, the laminated sheet obtained by the cutting is placed on a flat surface in a stage subsequent to the cutting device, and the solid sheet is fixed. With a flat surface to stand apparatus to terminate the reaction.
　本発明の積層シートの製造装置において、前記ラミネート温度調整手段は、前記一対のラミネートローラのローラ表面温度を２０～４０℃に調整する。 In the laminated sheet manufacturing apparatus of the present invention, the laminating temperature adjusting means adjusts the roller surface temperature of the pair of laminating rollers to 20 to 40 ° C.
　このように、貼合装置にラミネート温度調整手段を設けてラミネート温度を室温状態（好ましくは２０～４０℃）に調整すると共に、製造装置のライン制御を行う制御手段によって積層フィルムにおけるドライラミ用接着剤の固化反応が終了する前に積層フィルムを切断装置で所定サイズに切断するようにした。そして、平坦面静置装置によって切断して得られた積層シートを平坦面上に静置した状態で固化反応を終了させるようにした。 In this way, the laminating temperature adjusting means is provided in the laminating apparatus to adjust the laminating temperature to room temperature (preferably 20 to 40 ° C.), and the adhesive for dry lamination in the laminated film is controlled by the control means for controlling the line of the manufacturing apparatus Before the solidification reaction was completed, the laminated film was cut into a predetermined size with a cutting device. And the solidification reaction was made to complete | finish in the state which left the laminated sheet obtained by cut | disconnecting with a flat surface stationary apparatus on the flat surface.
　これにより、樹脂フィルム、特に厚手の汎用樹脂フィルムをドライラミネート用接着剤で貼り合わせて積層シートを製造しても、得られた積層シートに剥がれやカールがなく平坦性に優れた積層シートを製造できる。 As a result, even if a laminated sheet is produced by laminating a resin film, especially a thick general-purpose resin film with an adhesive for dry laminating, the laminated sheet obtained does not peel or curl and produces an excellent flat sheet it can.
　また、本発明の積層シートの製造装置においては、前記平坦面静置装置には、前記平坦面を加熱する加熱装置を備えることが好ましい。 In the laminated sheet manufacturing apparatus of the present invention, it is preferable that the flat surface stationary device includes a heating device for heating the flat surface.
　これにより、積層シートは平坦面に面接触した状態で加熱され、ドライラミ用接着剤の固化反応が終了するので、得られた積層シートは剥がれやカールがなく平坦性に優れている。この場合、平坦面の加熱温度としては、ドライラミ用接着剤の乾燥温度である８０～１２０℃程度に加熱することが好ましい。 This allows the laminated sheet to be heated while being in surface contact with the flat surface, and the solidification reaction of the dry laminating adhesive is completed. Thus, the obtained laminated sheet is excellent in flatness without peeling or curling. In this case, the heating temperature of the flat surface is preferably about 80 to 120 ° C., which is the drying temperature of the dry lamination adhesive.
　本発明の積層シートの製造方法及び製造装置によれば、樹脂フィルム、特に厚手の汎用樹脂フィルムをドライラミネート用接着剤で貼り合わせて積層シートを製造しても、得られた積層シートに剥がれやカールがなく平坦性に優れている。 According to the method and apparatus for producing a laminated sheet of the present invention, even if a laminated sheet is produced by laminating a resin film, particularly a thick general-purpose resin film with an adhesive for dry lamination, the resulting laminated sheet may be peeled off. No curling and excellent flatness.
　したがって、本発明の製造方法を実施することによって、立体画像用印画シート用、ＬＥＤ照明用拡散カバーとして好適な積層シートを製造することができる。 Therefore, by carrying out the production method of the present invention, it is possible to produce a laminated sheet suitable for a stereoscopic image printing sheet and a LED illumination diffusion cover.
立体画像用印画シートの層構成の一例を示す図。The figure which shows an example of the laminated constitution of the three-dimensional image printing sheet. ＬＥＤ照明用拡散カバーの層構成の一例を示す図。The figure which shows an example of the laminated constitution of the diffusion cover for LED lighting. 樹脂フィルムの送出から積層シートの製造までを一貫製造する積層シートの製造装置の全体構成図Overall configuration diagram of laminated sheet manufacturing equipment for integrated production from resin film delivery to laminated sheet manufacturing 切断装置及び平坦面静置装置を説明する説明図Explanatory drawing explaining a cutting device and a flat surface stationary device 平坦面静置装置の別態様を説明する説明図Explanatory drawing explaining another aspect of a flat surface stationary apparatus 貼合工程と切断工程との間に巻取工程を設けた積層シートの製造装置の全体構成図Overall configuration diagram of a laminated sheet manufacturing apparatus in which a winding process is provided between the bonding process and the cutting process.
　以下、添付図面に従って本発明の積層シートの製造方法及び製造装置の好ましい実施の形態について説明する。 Hereinafter, preferred embodiments of a method and apparatus for producing a laminated sheet according to the present invention will be described with reference to the accompanying drawings.
　先ず、本発明の実施の形態で製造された積層シートの好ましい用途として、立体画像用印画シートとＬＥＤ照明用拡散カバーとについて説明する。 First, as a preferable application of the laminated sheet manufactured in the embodiment of the present invention, a stereoscopic image printing sheet and an LED illumination diffusion cover will be described.
　［立体画像用印画シート］
　図１は、本発明によって製造された積層シートの好適な用途の一例として立体画像用印画シートに適用した場合である。図１では、２枚の透明な汎用樹脂フィルムをドライラミ用接着剤で貼り合わせて透明支持体（積層シート）とする例で説明するが、２枚以上を貼り合わせてもよい。 [3D image printing sheet]
FIG. 1 shows a case where the laminated sheet produced according to the present invention is applied to a three-dimensional image printing sheet as an example of a suitable use. Although FIG. 1 illustrates an example in which two transparent general-purpose resin films are bonded together with an adhesive for dry lamination to form a transparent support (laminated sheet), two or more sheets may be bonded together.
　図１に示されるように、立体画像用印画シート１０は、所定サイズ（例えば１２．７ｃｍ×１７．８ｃｍ）のシート形状（例えば四角形状シート）に形成され、透明支持体１２の一方面にレンズ層１４（図１にはレンチキュラーレンズを例示）を有すると共に他方面に画像を記録する受像層１６を有し、透明支持体１２と受像層１６との間に硬質性樹脂層１８が介在される。また、透明支持体１２は、２枚の透明な汎用樹脂フィルム１２Ａ、１２Ｂをドライラミ用接着剤１２Ｃで貼り合わせたものが使用されている。なお、レンズ層１４を構成するレンチキュラーレンズの数を４本の例で示したが、実際には多数本で構成される。 As shown in FIG. 1, the stereoscopic image printing sheet 10 is formed in a sheet shape (for example, a square sheet) of a predetermined size (for example, 12.7 cm × 17.8 cm), and a lens is formed on one surface of the transparent support 12. It has a layer 14 (a lenticular lens is illustrated in FIG. 1) and an image receiving layer 16 for recording an image on the other side, and a hard resin layer 18 is interposed between the transparent support 12 and the image receiving layer 16. . The transparent support 12 is made of two transparent general- purpose resin films 12A and 12B bonded with a dry lamination adhesive 12C. In addition, although the number of the lenticular lenses which comprise the lens layer 14 was shown in the example of four, it is actually comprised with many.
　透明支持体１２は、できるだけ平滑なシート表面を有することが好ましい。また、透明支持体１２の一方面に押出ラミネート法でレンズ層１４を形成する際に、押出ダイからシート状に押し出された溶融状態のレンズ層用樹脂の熱に耐える必要があり、比較的耐熱性の高い樹脂であることが好ましい。具体的には、ポリカーボネート樹脂、ポリスルホン樹脂、二軸延伸ポリエチレンテレフタレート樹脂（ＰＥＴ）等を挙げることができる。特に、平滑性が良好な点から、二軸延伸のポリエチレンテレフタレート樹脂が好ましい。 The transparent support 12 preferably has as smooth a sheet surface as possible. Further, when the lens layer 14 is formed on one surface of the transparent support 12 by the extrusion laminating method, it is necessary to withstand the heat of the molten lens layer resin extruded from the extrusion die into a sheet shape, which is relatively heat resistant. It is preferable that it is resin with high property. Specifically, polycarbonate resin, polysulfone resin, biaxially stretched polyethylene terephthalate resin (PET), and the like can be given. In particular, a biaxially stretched polyethylene terephthalate resin is preferable from the viewpoint of good smoothness.
　また、立体画像用印画シート１０に、熱転写インクシート装置やインクジェット装置等の印画装置によって画像を形成したときに画像ボケが発生しないように透明支持体１２の厚みは３００μｍ以上あることが必要であり、複数枚の汎用樹脂フィルム１２Ａ，１２Ｂをドライラミ用接着剤１２Ｃで貼り合わせて厚くした透明支持体１２が使用される。透明支持体１２の厚みは、４００μｍ以上がより好ましく、５００μｍ以上が特に好ましい。なお、透明支持体１２の厚みの上限を記載しなかったが、厚くし過ぎて立体画像用印画シート１０としての透明性に不具合がでる厚みを上限とすることができる。 Further, the thickness of the transparent support 12 must be 300 μm or more so that no image blur occurs when an image is formed on the stereoscopic image printing sheet 10 by a printing apparatus such as a thermal transfer ink sheet apparatus or an inkjet apparatus. A transparent support 12 is used in which a plurality of general- purpose resin films 12A and 12B are bonded and thickened with an adhesive 12C for dry lamination. The thickness of the transparent support 12 is more preferably 400 μm or more, and particularly preferably 500 μm or more. In addition, although the upper limit of the thickness of the transparent support body 12 was not described, it is possible to set the upper limit to the thickness at which the transparency as the three-dimensional image printing sheet 10 becomes defective due to being too thick.
　レンズ層１４を構成する樹脂としては、例えば、ポリメチルメタクリレート樹脂（ＰＭＭＡ）、ポリカーボネート樹脂、ポリスチレン樹脂、メタクリレート-スチレン共重合樹脂（ＭＳ樹脂）、アクリロニトリル-スチレン共重合樹脂（ＡＳ樹脂）、ポリプロピレン樹脂、ポリエチレン樹脂、ポリエチレンテレフタレート樹脂、グリコール変性ポリエチレンテレフタレート樹脂、ポリ塩化ビニル樹脂（ＰＶＣ）、熱可塑性エラストマー、又はこれらの共重合体、シクロオレフィンポリマー等が挙げられる。溶融押出しのし易さを考慮すると、例えば、ポリメチルメタクリレート樹脂（ＰＭＭＡ）、ポリカーボネート樹脂、ポリスチレン樹脂、メタクリレート-スチレン共重合樹脂（ＭＳ樹脂）、ポリエチレン樹脂、ポリエチレンテレフタレート樹脂、グリコール変性ポリエチレンテレフタレート樹脂のような溶融粘度の低い樹脂を用いるのが好ましい。また、レンズ層形成工程でのレンズ層パターンの転写のし易さや連写されたレンズ層１４の耐久性、あるいはレンズ層１４の割れにくさ等を考慮するとグリコール変性ポリエチレンテレフタレート樹脂を用いるのがより好ましい。 Examples of the resin constituting the lens layer 14 include polymethyl methacrylate resin (PMMA), polycarbonate resin, polystyrene resin, methacrylate-styrene copolymer resin (MS resin), acrylonitrile-styrene copolymer resin (AS resin), and polypropylene resin. , Polyethylene resins, polyethylene terephthalate resins, glycol-modified polyethylene terephthalate resins, polyvinyl chloride resins (PVC), thermoplastic elastomers, copolymers thereof, cycloolefin polymers, and the like. Considering the ease of melt extrusion, for example, polymethyl methacrylate resin (PMMA), polycarbonate resin, polystyrene resin, methacrylate-styrene copolymer resin (MS resin), polyethylene resin, polyethylene terephthalate resin, glycol modified polyethylene terephthalate resin It is preferable to use a resin having a low melt viscosity. Considering the ease of transfer of the lens layer pattern in the lens layer forming step, the durability of the continuously shot lens layer 14, or the difficulty of cracking the lens layer 14, it is more preferable to use glycol-modified polyethylene terephthalate resin. preferable.
　図１に示すように、レンズ層１４は５０μｍ～２００μｍの厚さ（Ｔ）を有し、その表面にレンチキュラーレンズ形状を備える。レンチキュラーレンズ形状は、例えば、１００μｍ～２００μｍのレンズ半径（Ｒ）、５０μｍ～１００μｍのレンズ高さ（Ｈ）、１００μｍ～３１８μｍのレンズ間距離（Ｐ）で形成される。ただし、この数値に限定されるものではない。レンチキュラーレンズ形状とは、縦方向に長いかまぼこ型のレンズを横に並べた板状のレンズアレイ、つまり、シリンドリカルレンズが２次元的に配列をもった形状を意味する。 As shown in FIG. 1, the lens layer 14 has a thickness (T) of 50 μm to 200 μm, and has a lenticular lens shape on its surface. The lenticular lens shape is formed, for example, with a lens radius (R) of 100 μm to 200 μm, a lens height (H) of 50 μm to 100 μm, and an inter-lens distance (P) of 100 μm to 318 μm. However, it is not limited to this value. The lenticular lens shape means a plate-like lens array in which long, long and long shaped lenses are arranged horizontally, that is, a shape in which cylindrical lenses are two-dimensionally arranged.
　受像層１６は、熱転写用インクシート装置から転写された色材を取り込んで着色するものと、インクジェット装置から吐出したインク液滴を取り込んで着色する両方の印画装置に適合した層を選択することができる。 The image receiving layer 16 may be selected from a layer suitable for both a printing material that takes in and colors the color material transferred from the thermal transfer ink sheet device and a coloring device that takes in and drops the ink droplets ejected from the ink jet device. it can.
　［ＬＥＤ照明用拡散カバー］
　図２は、本発明の実施の形態によって製造された積層シートの好適な他の用途としてＬＥＤ照明用拡散カバー２０の基板２２に適用した場合である。 [Diffusion cover for LED lighting]
FIG. 2 shows a case where the laminated sheet manufactured according to the embodiment of the present invention is applied to the substrate 22 of the LED illumination diffusion cover 20 as another preferred application.
　図２のＬＥＤ照明用拡散カバー２０は、厚みが例えば３００μｍ程度の透明な汎用樹脂フィルム２２Ａをドライラミ用接着剤２２Ｂで３枚貼り合わせたものが基板２２（積層シート）として形成される場合である。この基板２２の一方面には拡散層２４が形成されると共に、反対面にはハードコート層２６（又は低屈折率層）が形成される。 The LED illumination diffusion cover 20 in FIG. 2 is a case where a transparent general-purpose resin film 22A having a thickness of about 300 μm, for example, is bonded as a dry lamination adhesive 22B to form a substrate 22 (laminated sheet). . A diffusion layer 24 is formed on one surface of the substrate 22, and a hard coat layer 26 (or a low refractive index layer) is formed on the opposite surface.
　なお、図２では、３枚の透明な汎用樹脂フィルム２２Ａを貼り合わせた例であるが、２枚又は４枚以上を貼り合わせてもよい。 Although FIG. 2 shows an example in which three transparent general-purpose resin films 22A are bonded together, two sheets or four or more sheets may be bonded together.
　基板２２を構成する汎用樹脂フィルム２２Ａの材質としては、例えば、ポリエステル、ポリオレフィンなどが好適に挙げられる。ポリエステルとしては、例えば、ポリエチレンテレフタレート（ＰＥＴ、屈折率１．６７）、ポリエチレンナフタレート（ＰＥＮ）などが挙げられる。その他の樹脂フィルムとしては、例えば、ポリアミド、ポリエーテル、ポリスチレン、ポリエステルアミド、ポリカーボネート、ポリフェニレンスルフィド、ポリエーテルエステル、ポリ塩化ビニル、ポリアクリル酸エステル、ポリメタクリル酸エステルなどが挙げられる。 Suitable examples of the material of the general-purpose resin film 22A constituting the substrate 22 include polyester and polyolefin. Examples of the polyester include polyethylene terephthalate (PET, refractive index 1.67), polyethylene naphthalate (PEN), and the like. Examples of other resin films include polyamide, polyether, polystyrene, polyesteramide, polycarbonate, polyphenylene sulfide, polyether ester, polyvinyl chloride, polyacrylic acid ester, and polymethacrylic acid ester.
　これらの中でも、ポリエステル樹脂が好ましく、基板２２の少なくとも１つはポリエチレンテレフタレート（ＰＥＴ）で構成されることがより好ましい。 Among these, a polyester resin is preferable, and at least one of the substrates 22 is more preferably made of polyethylene terephthalate (PET).
　基板２２として用いられるポリエチレンテレフタレート（ＰＥＴ）は、ポリエステル樹脂を溶融押出しでフィルム状にし、縦及び横に二軸延伸により成形したものであることが好ましい。二軸延伸によって配向結晶化し、強度・耐熱性が向上するため、ＬＥＤ照明用拡散カバーの基板２２として用いるのに好適となる。 The polyethylene terephthalate (PET) used as the substrate 22 is preferably a polyester resin melt-extruded into a film shape and biaxially stretched vertically and horizontally. Since it is oriented and crystallized by biaxial stretching and the strength and heat resistance are improved, it is suitable for use as the substrate 22 of the LED illumination diffusion cover.
　延伸倍率には特に制限はないが、縦横方向にそれぞれ、１．５～７倍で延伸したもので
あることが好ましく、より好ましくは２～５倍程度である。延伸倍率が上記範囲内であると、充分な機械的強度、及び均一な厚みが得られる。 There is no particular limitation on the stretching ratio, but it is preferably stretched by 1.5 to 7 times in the vertical and horizontal directions, more preferably about 2 to 5 times. When the draw ratio is within the above range, sufficient mechanical strength and uniform thickness can be obtained.
　これらＰＥＴフィルムの製造方法及び条件は、公知の方法及び条件を適宜選択して用いることができる。 These PET film production methods and conditions can be appropriately selected from known methods and conditions.
　なお、一方の汎用樹脂フィルム２２Ａをポリエチレンテレフタレートとし、他方の汎用樹脂フィルム２２Ａを他のプラスチックとする場合には、拡散層を設ける側の汎用樹脂フィルム２２Ａをポリエチレンテレフタレートで構成して、照明器具に近い側の汎用樹脂フィルム２２Ａを他のプラスチックで構成することが好ましい。照明器具に近い側の汎用樹脂フィルム２２Ａに用いる他のプラスチックとしては、ポリエチレンテレフタレート（ＰＥＴ）よりも屈折率の低い材料を用いることが好ましく、例えば、ポリカーボネート（屈折率１．５８）、ポリメチルメタクリレート（屈折率１．５）等のアクリル樹脂などを適用することが好ましい。 When one general-purpose resin film 22A is made of polyethylene terephthalate and the other general-purpose resin film 22A is made of another plastic, the general-purpose resin film 22A on the side where the diffusion layer is provided is made of polyethylene terephthalate, so that The near-side general-purpose resin film 22A is preferably made of other plastics. As another plastic used for the general-purpose resin film 22A on the side close to the lighting fixture, a material having a refractive index lower than that of polyethylene terephthalate (PET) is preferably used. For example, polycarbonate (refractive index 1.58), polymethyl methacrylate It is preferable to apply acrylic resin such as (refractive index 1.5).
　基板２２の厚みは、目的に応じて適宜選択することができるが、例えば、３００μｍ～１０００μｍの範囲が好ましい。 The thickness of the substrate 22 can be appropriately selected according to the purpose, but is preferably in the range of 300 μm to 1000 μm, for example.
　［積層シートの製造方法及び製造装置］
　（製造装置の第１の実施の形態）
　次に、本発明の第１の実施の形態における積層シートの製造装置２８について、２枚の汎用樹脂フィルムを貼り合わせて上記した透明支持体１２（積層シート）を製造する例で説明する。第１の実施の形態の製造装置２８は、送出装置３０、３８から２枚の汎用樹脂フィルム１２Ａ，１２Ｂを送出してから積層シートＡの製造までを一貫製造する場合である。 [Manufacturing method and manufacturing apparatus of laminated sheet]
(First Embodiment of Manufacturing Apparatus)
Next, the laminated sheet manufacturing apparatus 28 according to the first embodiment of the present invention will be described using an example of manufacturing the transparent support 12 (laminated sheet) described above by bonding two general-purpose resin films. The manufacturing apparatus 28 according to the first embodiment is a case where the two general- purpose resin films 12A and 12B are sent from the sending apparatuses 30 and 38 to the production of the laminated sheet A in an integrated manner.
　図３に示すように、第１送出装置３０から例えば厚みが１８０μｍの帯状の透明な第１汎用樹脂フィルム１２Ａ（例えば二軸延伸のＰＥＴフィルム）が送り出されて多数の搬送ローラ３２、３２…によりローラ搬送される。送り出された第１汎用樹脂フィルム１２Ａの裏面には、塗布装置３４によってドライラミ用接着剤１２Ｃが塗布される（塗布工程）。ドライラミ用接着剤１２Ｃを塗布する塗布装置３４としては、どのような装置でもよいが、第１汎用樹脂フィルム１２Ａの裏面にドライラミ用接着剤１２Ｃを薄く且つ均一に塗布できる例えばグラビアコータ方式（図３）、スロットダイ方式、ロッド塗布方式等を好適に採用できる。 As shown in FIG. 3, a first transparent general-purpose resin film 12A having a thickness of, for example, 180 μm (for example, a biaxially stretched PET film) is fed from the first feeding device 30 and is fed by a number of conveying rollers 32, 32. Rolled. The dry lamination adhesive 12C is applied to the back surface of the fed first general-purpose resin film 12A by the application device 34 (application process). The application device 34 for applying the dry lamination adhesive 12C may be any device, but the dry lamination adhesive 12C can be applied thinly and uniformly on the back surface of the first general-purpose resin film 12A. ), Slot die method, rod coating method and the like can be suitably employed.
　次に、第１汎用樹脂フィルム１２Ａは乾燥装置３６内を通過してドライラミ用接着剤１２Ｃ中の溶剤を飛ばしてドライ化する。これにより、ドライラミ用接着剤１２Ｃの粘着性が発揮される（乾燥工程）。ドライラミ用接着剤１２Ｃを乾燥する乾燥装置３６は、複数の乾燥ゾーンを有しており、入口側から低温乾燥ゾーン３６Ａ、高温乾燥ゾーン３６Ｂ、冷却ゾーン３６Ｃの各ゾーンを有することが好ましい。冷却ゾーン３６Ｃでは第１汎用樹脂フィルム１２Ａを略室温まで冷却することが好ましい。 Next, the first general-purpose resin film 12A passes through the drying device 36 and is dried by removing the solvent in the dry lamination adhesive 12C. Thereby, the adhesiveness of the adhesive 12C for dry lamination is exhibited (drying process). The drying device 36 for drying the dry lamination adhesive 12C has a plurality of drying zones, and preferably has a low temperature drying zone 36A, a high temperature drying zone 36B, and a cooling zone 36C from the inlet side. In the cooling zone 36C, it is preferable to cool the first general-purpose resin film 12A to substantially room temperature.
　ドライラミ用接着剤１２Ｃとしては、ポリウレタン接着剤組成物あるいは２液硬化型のドライラミ用接着剤組成物を好適に使用することができる。ポリウレタン接着剤組成物は、有機ポリイソシアネートと，有機ポリオールにリンの酸素酸又はその誘導体と，アミン化合物及びエポキシ樹脂とを配合して構成される。 As the dry lamination adhesive 12C, a polyurethane adhesive composition or a two-component curable adhesive composition for dry lamination can be suitably used. The polyurethane adhesive composition is composed of an organic polyisocyanate, an organic polyol, an oxygen acid of phosphorus or a derivative thereof, an amine compound and an epoxy resin.
　２液硬化型のドライラミ用接着剤組成物は、主剤としてポリエステルポリオール，ポリウレタンポリオール等の有機ポリマーポリオール成分と、硬化剤として２官能ポリイソシアネート化合物と３官能以上の多官能ポリイソシアネート化合物と、からなる有機ポリイソシアネート成分とから構成される。 A two-component curable adhesive composition for dry lamination comprises an organic polymer polyol component such as polyester polyol and polyurethane polyol as a main agent, a bifunctional polyisocyanate compound and a trifunctional or higher polyfunctional polyisocyanate compound as a curing agent. It is composed of an organic polyisocyanate component.
　一方、第２送出装置３８から第２汎用樹脂フィルム１２Ｂが送り出されて多数の搬送ローラ３２、３２…によりローラ搬送されると共に、第２汎用樹脂フィルム１２Ｂの表面（貼合せ面側）にコロナ放電処理装置４０によってコロナ放電処理が施される。コロナ放電処理の強度としては、０．１ＫＷ／ｍ２以上であることが好ましい。このコロナ放電処理により、第２汎用樹脂フィルム１２Ｂの表面が荒らされて粗面化し、ドライラミ用接着剤１２Ｃとの接着性が向上する。 On the other hand, the second general-purpose resin film 12B is sent out from the second delivery device 38 and is transported by a large number of transport rollers 32, 32... And corona discharge on the surface (bonding surface side) of the second general-purpose resin film 12B. A corona discharge process is performed by the processing device 40. The strength of the corona discharge treatment is preferably 0.1 KW / m 2 or more. By this corona discharge treatment, the surface of the second general-purpose resin film 12B is roughened and roughened, and the adhesiveness with the dry lamination adhesive 12C is improved.
　なお、ローラ搬送される第１及び第２の汎用樹脂フィルム１２Ａ，１２Ｂの搬送ローラ３２に対するラップ角度を９０°以上にすると共に、ローラ径を５０ｍｍ以上の太径とすることが好ましい。更には、搬送張力を１００Ｎ以上、３００Ｎ以下とすることが好ましい。これにより、第１及び第２の汎用樹脂フィルム１２Ａ，１２Ｂに対して曲げ方向の力ができるだけ作用しないようにできるので、製造された積層シートＡのカール発生や剥がれを一層抑制できる。 In addition, it is preferable that the wrap angle of the first and second general- purpose resin films 12A and 12B to be transported by the roller with respect to the transport roller 32 is 90 ° or more and the roller diameter is 50 mm or more. Furthermore, it is preferable that the conveyance tension be 100N or more and 300N or less. Thereby, since the force of a bending direction can act as much as possible with respect to 1st and 2nd general purpose resin film 12A, 12B, generation | occurrence | production and peeling of the laminated sheet A which were manufactured can be suppressed further.
　次に、一対のラミネートローラ４２Ａ，４２Ｂからなる貼合装置４２によって第１及び第２の汎用樹脂フィルム１２Ａ，１２Ｂが貼り合わされる（貼合工程）。この貼合工程では、第１汎用樹脂フィルム１２Ａと第２汎用樹脂フィルム１２Ｂとが一対のラミネートローラ４２Ａ，４２Ｂによって挟み込まれ（ニップされ）、ドライラミ用接着剤１２Ｃによって貼り合わされる。これにより積層フィルム４４が形成される。 Next, the 1st and 2nd general purpose resin films 12A and 12B are pasted together by pasting device 42 which consists of a pair of laminating rollers 42A and 42B (bonding process). In this bonding step, the first general-purpose resin film 12A and the second general-purpose resin film 12B are sandwiched (nipped) by the pair of laminating rollers 42A and 42B, and are bonded by the dry lamination adhesive 12C. Thereby, the laminated film 44 is formed.
　この貼合装置４２には、第１及び第２の汎用樹脂フィルム１２Ａ、１２Ｂを一対のラミネートローラ４２Ａ，４２Ｂで挟み込んでラミネートする際のラミネート温度を室温状態に制御するラミネート温度調整手段４３が設けられる。 The laminating device 42 is provided with a laminating temperature adjusting means 43 that controls the laminating temperature when the first and second general- purpose resin films 12A and 12B are sandwiched between the pair of laminating rollers 42A and 42B to be a room temperature state. It is done.
　そして、一対のラミネートローラ４２Ａ，４２Ｂのローラ表面は、ラミネート温度調整手段４３によって２０～４０℃（室温状態）に維持される。即ち、ラミネート温度調整手段４３は、冬場にローラ表面温度が２０℃を下回る場合にはローラ表面を２０～４０℃になるように加熱する。これにより、ドライラミ用接着剤１２Ｃが冷却固化されることを防止する。また、夏場にローラ表面温度が４０℃を上回る場合にはローラ表面を２０～４０℃になるように冷却する。これにより、ドライラミ用接着剤１２Ｃの固化反応を遅らせる。なお、図示しないが、ローラ表面温度は赤外線温度計のように非接触型の温度センサで測定することができる。 The roller surfaces of the pair of laminating rollers 42A and 42B are maintained at 20 to 40 ° C. (room temperature state) by the laminating temperature adjusting means 43. That is, the laminating temperature adjusting means 43 heats the roller surface to 20 to 40 ° C. when the roller surface temperature falls below 20 ° C. in winter. This prevents the dry lamination adhesive 12C from being cooled and solidified. In the summer, when the roller surface temperature exceeds 40 ° C., the roller surface is cooled to 20 to 40 ° C. Thereby, the solidification reaction of the adhesive 12C for dry lamination is delayed. Although not shown, the roller surface temperature can be measured with a non-contact type temperature sensor such as an infrared thermometer.
　即ち、本発明の実施の形態では、従来の加熱圧着ではなく室温圧着によって、第１汎用樹脂フィルム１２Ａと第２汎用樹脂フィルム１２Ｂとをラミネートする。これにより、従来の貼合あわせ方法の加熱圧着のように、貼合工程中にドライラミ用接着剤１２Ｃの固化反応が進んで固化あるいは固化に近い状態になることがないので、貼り合わされた積層フィルム４４には柔軟性が維持される。 That is, in the embodiment of the present invention, the first general-purpose resin film 12A and the second general-purpose resin film 12B are laminated by room temperature pressure bonding rather than conventional thermocompression bonding. As a result, unlike the conventional heat bonding of the bonding method, the solidification reaction of the dry laminating adhesive 12C does not proceed during the bonding process so that it becomes solidified or close to solidification. 44 maintains flexibility.
　この場合、一対のラミネートローラ４２Ａ、４２Ｂでニップするニップ力としては、従来の加熱圧着で通常実施されていたニップ力よりも低い、０．２～０．４ＭＰａの圧力範囲で行うことが好ましい。これにより、ドライラミ用接着剤１２Ｃの固化反応が進み過ぎることを抑制できる。 In this case, the nip force for nipping between the pair of laminating rollers 42A and 42B is preferably 0.2 to 0.4 MPa, which is lower than the nip force normally practiced by conventional thermocompression bonding. Thereby, it can suppress that the solidification reaction of the adhesive 12C for dry lamination progresses too much.
　また、第１送出装置３０及び第２送出装置３８にロール状に巻回された状態から送り出される２枚の汎用樹脂フィルム１２Ａ，１２Ｂを貼り合わす際に、一方の汎用樹脂フィルムのロール内側面と他方の汎用樹脂フィルムのロール外側面とが合わさるように貼り合わせることが好ましい。即ち、ロール状に巻回された状態から送り出された第１及び第２の汎用樹脂フィルム１２Ａ，１２Ｂは巻き癖がついているので、２枚の汎用樹脂フィルム１２Ａ，１２Ｂの巻き癖を相殺するように貼り合わせることが好ましい。これにより、巻き癖に起因する積層シートＡのカール発生を防止できる。 In addition, when the two general- purpose resin films 12A and 12B fed out from the state wound in a roll shape on the first delivery device 30 and the second delivery device 38 are bonded together, It is preferable that the other general-purpose resin film is bonded to the roll outer surface. That is, since the first and second general- purpose resin films 12A and 12B sent out from the state wound in a roll shape are wrinkled, the wrinkles of the two general- purpose resin films 12A and 12B are offset. It is preferable to stick together. Thereby, curling of the laminated sheet A caused by curling can be prevented.
　次に、積層フィルムは４４、保護フィルム貼合装置４６において、積層フィルム４４の表面（上面）と裏面（下面）とに保護フィルム４８Ａ，４８Ｂが貼り合わされる。保護フィルム貼合装置４６は、一対のニップローラ４６Ａ，４６Ｂと、上保護フィルム４８Ａを巻回した第１リール装置５０Ａと、下保護シート４８Ｂを巻回した第２リール装置５０Ｂと、で構成される。このように積層フィルム４４に保護フィルム４８Ａ，４８Ｂを貼り合わせることにより、最終品である積層シートＡが製造されてから立体画像用印画シートやＬＥＤ照明用拡散カバー等の用途に使用されるまでの保管、搬送等において積層シートＡの表裏面を傷等から保護する。 Next, in the laminated film 44, in the protective film laminating apparatus 46, the protective films 48A and 48B are bonded to the front surface (upper surface) and the back surface (lower surface) of the laminated film 44. The protective film laminating device 46 includes a pair of nip rollers 46A and 46B, a first reel device 50A around which an upper protective film 48A is wound, and a second reel device 50B around which a lower protective sheet 48B is wound. . By sticking the protective films 48A and 48B to the laminated film 44 in this way, from the production of the final laminated sheet A to the use for applications such as a stereoscopic image printing sheet and LED illumination diffusion cover. The front and back surfaces of the laminated sheet A are protected from scratches and the like during storage, transportation, and the like.
　なお、貼合装置４２から保護フィルム貼合装置４６までの積層フィルム４４の搬送は、ローラ搬送も可能であるが、ベルトコンベア装置４７によるベルトコンベア搬送が一層好ましい。積層フィルム４４の搬送中のカールを防止するには、搬送面ができるだけ平坦なことが好ましいからである。 In addition, although conveyance of the laminated | multilayer film 44 from the bonding apparatus 42 to the protective film bonding apparatus 46 can also be roller conveyance, the belt conveyor conveyance by the belt conveyor apparatus 47 is still more preferable. This is because the conveyance surface is preferably as flat as possible to prevent curling during conveyance of the laminated film 44.
　次に、積層フィルム４４は、切断装置５２に搬送されて所定サイズに切断される（切断工程）。この場合も、保護フィルム貼合装置４６から切断装置５２までの積層フィルム４４の搬送は、ベルトコンベア装置４９によるベルトコンベア搬送が一層好ましい。 Next, the laminated film 44 is conveyed to the cutting device 52 and cut into a predetermined size (cutting process). Also in this case, the conveyance of the laminated film 44 from the protective film laminating device 46 to the cutting device 52 is more preferably a belt conveyor conveyance by the belt conveyor device 49.
　切断装置５２は、図４に示すように、主として、切断機５４とワーク保持機５６とで構成される。 The cutting device 52 is mainly composed of a cutting machine 54 and a work holding machine 56 as shown in FIG.
　切断機５４は、回転鋸刃５８を回転自在に支持する回転支持部６０と、回転支持部６０を昇降させて回転鋸刃５８を切断位置に移動させたり退避させたりする昇降部６２とで構成される。回転支持部６０には、図示しないモータ及び動力伝達手段等が内蔵されており、モータの回転力が動力伝達手段を介して回転鋸刃５８に伝達される。昇降部６２としては、例えば油圧シリンダ装置を好適に使用できる。なお、切断刃として回転鋸刃５８で説明したが、これに限定するものではなく、ナイフカッターや打ち抜き刃等も使用できる。 The cutting machine 54 includes a rotation support unit 60 that rotatably supports the rotary saw blade 58, and a lift unit 62 that moves the rotary support blade 60 up and down and moves the rotary saw blade 58 to and from the cutting position. Is done. The rotation support unit 60 incorporates a motor and power transmission means (not shown), and the rotational force of the motor is transmitted to the rotary saw blade 58 via the power transmission means. As the elevating part 62, for example, a hydraulic cylinder device can be suitably used. Although the rotary saw blade 58 has been described as the cutting blade, the present invention is not limited to this, and a knife cutter, a punching blade, or the like can be used.
　ワーク保持機５６は、回転鋸刃５８が切断位置まで進入可能なようにスロット状の開口６４Ａを有する台座６４と、台座６４の反対側から積層フィルム４４を抑え付ける抑え部６６と、抑え部６６を台座６４に対して進退移動する移動手段６８とで構成される。 The work holding machine 56 includes a pedestal 64 having a slot-like opening 64A so that the rotary saw blade 58 can enter the cutting position, a holding unit 66 that holds the laminated film 44 from the opposite side of the pedestal 64, and a holding unit 66. And moving means 68 for moving forward and backward with respect to the pedestal 64.
　抑え部６６の台座６４側にも、回転鋸刃５８が切断位置まで進入可能なようにスロット状の開口６６Ａが形成される。また、移動手段６８としては、例えば油圧シリンダ装置を好適に使用できる。 A slot-like opening 66A is also formed on the base 64 side of the holding portion 66 so that the rotary saw blade 58 can enter the cutting position. As the moving means 68, for example, a hydraulic cylinder device can be suitably used.
　そして、切断工程では、積層フィルム４４のドライラミ用接着剤１２Ｃの固化反応が終了する前に積層フィルム４４を所定サイズに切断する。これにより、積層シートＡが得られる。 In the cutting step, the laminated film 44 is cut into a predetermined size before the solidification reaction of the dry lamination adhesive 12C of the laminated film 44 is completed. Thereby, the laminated sheet A is obtained.
　次に、所定サイズに切断された積層シートＡは、平坦面静置装置７０に搬送されて平坦面静置が行われる。 Next, the laminated sheet A cut to a predetermined size is transported to the flat surface stationary device 70, where the flat surface is stationary.
　図４に示すように、平坦面静置装置７０は、主として表面が平滑な無端状ベルト７２（例えばステンレス等の金属製ベルト）を備えたベルトコンベア装置７４と、無端状ベルト７２を加熱する加熱装置７６とで構成される。 As shown in FIG. 4, the flat surface stationary device 70 mainly includes a belt conveyor device 74 provided with an endless belt 72 (for example, a metal belt such as stainless steel) having a smooth surface, and heating for heating the endless belt 72. Device 76.
　無端状ベルト７２は、水平方向に所定距離離間された一対のローラ７８，７８に掛け渡されて、一対のローラ７８，７８間を周回移動する。これにより、無端状ベルト７２の上側周回面に積層シートＡを静置した状態で搬送するための平坦面７２Ａが形成される。 The endless belt 72 is wound around a pair of rollers 78 and 78 that are spaced apart from each other by a predetermined distance in the horizontal direction, and moves around the pair of rollers 78 and 78. As a result, a flat surface 72 </ b> A is formed on the upper circumferential surface of the endless belt 72 for transporting the laminated sheet A in a stationary state.
　また、周回移動する無端状ベルト７２は、加熱装置７６によって加熱される。無端状ベルト７２の加熱温度としては、上記したドライラミ用接着剤１２Ｃの乾燥温度と同等の８０～１２０℃の範囲が好ましい。このように無端状ベルト７２は加熱される場合には、金属製ベルトを使用することが好ましい。 Further, the endless belt 72 that moves around is heated by the heating device 76. The heating temperature of the endless belt 72 is preferably in the range of 80 to 120 ° C., which is equivalent to the drying temperature of the dry lamination adhesive 12C. Thus, when the endless belt 72 is heated, it is preferable to use a metal belt.
　上記の如く構成された平坦面静置装置７０では、切断して得られた積層シートＡを無端状ベルト７２の平坦面７２Ａ上に静置した状態で次の集積装置８２まで搬送する。そして、この搬送中に加熱装置７６で加熱された無端状ベルト７２によって積層シートＡにおけるドライラミ用接着剤１２Ｃを加熱することにより固化反応を終了させる。 In the flat surface stationary device 70 configured as described above, the laminated sheet A obtained by cutting is transported to the next stacking device 82 in a state of being stationary on the flat surface 72A of the endless belt 72. Then, the solidification reaction is terminated by heating the dry lamination adhesive 12 </ b> C in the laminated sheet A by the endless belt 72 heated by the heating device 76 during the conveyance.
　このように、最終工程である平坦面静置工程においてドライラミ用接着剤１２Ｃの固化反応が終了するので、平坦面静置工程に至る貼合工程や切断工程では積層フィルム４４及び積層シートＡは柔軟性を有している。これにより、貼合わせ直後の積層フィルム４４の搬送中、巻取り後（第２の実施の形態参照）、切断工程後において、積層フィルム４４や積層シートＡに曲げ方向の力が作用しても接着面が剥がれたり、カールしたりすることを抑制できる。 In this way, since the solidification reaction of the dry lamination adhesive 12C is completed in the flat surface standing step which is the final step, the laminated film 44 and the laminated sheet A are flexible in the bonding step and the cutting step leading to the flat surface standing step. It has sex. Thereby, even if the force of a bending direction acts on the laminated | multilayer film 44 or the laminated sheet A after conveyance (refer 2nd Embodiment) and after a cutting process during conveyance of the laminated | multilayer film 44 immediately after bonding, it adhere | attaches. The surface can be prevented from peeling off or curling.
　このように、積層シートの製造装置２８は、貼合装置４２で積層フィルム４４がラミネート形成されてから切断装置５２で所定サイズの積層シートＡに切断されるまでは、ドライラミ用接着剤１２Ｃの固化反応を終了させないようにする必要がある。 As described above, the laminated sheet manufacturing apparatus 28 solidifies the dry lamination adhesive 12 </ b> C until the laminated film 44 is laminated by the laminating apparatus 42 and is cut into the laminated sheet A having a predetermined size by the cutting apparatus 52. It is necessary not to terminate the reaction.
　このため、図３に示すように、製造装置２８には、ライン制御を行うための制御手段８０が設けられる。 For this reason, as shown in FIG. 3, the manufacturing apparatus 28 is provided with a control means 80 for performing line control.
　２枚の汎用樹脂フィルム１２Ａ，１２Ｂの送出装置３０、３８からの送出から積層シートＡの製造までを一貫製造する場合の制御手段８０のライン制御としては、ライン搬送速度の制御、ライン環境の温度制御がある。即ち、ライン搬送速度及びライン環境温度を制御することによって、ドライラミ用接着剤１２Ｃの固化反応が終了するまでの時間を制御する。これにより、貼合装置４２で積層フィルム４４がラミネート形成されてから切断装置５２で所定サイズの積層シートＡに切断されるまでは、ドライラミ用接着剤１２Ｃの固化反応を終了させないようにする。予め予備試験等により、複数のライン環境温度と、そのときのドライラミ用接着剤１２Ｃの固化反応が終了するまでの経過時間との関係を求め、制御手段８０の制御プログラムに入力しておくとよい。 The line control of the control means 80 in the case of integrated production from the delivery from the delivery devices 30 and 38 of the two general- purpose resin films 12A and 12B to the production of the laminated sheet A includes the control of the line conveyance speed and the temperature of the line environment. There is control. That is, by controlling the line conveyance speed and the line environmental temperature, the time until the solidification reaction of the dry lamination adhesive 12C is controlled. Thus, the solidification reaction of the dry laminating adhesive 12 </ b> C is not terminated until the laminated film 44 is laminated by the laminating device 42 and is cut into the laminated sheet A having a predetermined size by the cutting device 52. A relationship between a plurality of line environmental temperatures and an elapsed time until the solidification reaction of the dry lamination adhesive 12C at that time is completed by a preliminary test or the like may be obtained in advance and input to the control program of the control means 80. .
　図５は、平坦面静置装置７０の別態様であり、図４で説明したベルトコンベア装置７４と加熱装置７６とを、積層シートＡを挟んだ反対側に更に１基設け、一対の無端状ベルト７２，７２で積層シートＡを挟み込むようにしたものである。 FIG. 5 shows another embodiment of the flat surface stationary device 70. One belt conveyor device 74 and a heating device 76 described in FIG. 4 are further provided on the opposite side of the laminated sheet A, and a pair of endless shapes are provided. The laminated sheet A is sandwiched between the belts 72 and 72.
　これにより、積層シートＡが一対の無端状ベルト７２，７２で挟み込まれ、積層シートＡを確実に平坦化した状態で、積層シートＡの表裏から加熱装置７６で加熱されてドライラミ用接着剤１２Ｃの固化反応が終了する。したがって、更にカールがなく平坦面性に優れた積層シートＡを製造することができる。 As a result, the laminated sheet A is sandwiched between the pair of endless belts 72, 72, and the laminated sheet A is heated by the heating device 76 from the front and back of the laminated sheet A in a state where the laminated sheet A is surely flattened. The solidification reaction ends. Therefore, it is possible to produce a laminated sheet A that is free from curling and has excellent flat surface properties.
　なお、本発明の実施の形態では、平坦面静置工程中に積層シートＡのドライラミ用接着剤１２Ｃの固化反応を終了させることが重要であり、無端状ベルト７２を加熱装置７６で加熱しなくてもドライラミ用接着剤１２Ｃの固化反応が終了する場合には、加熱装置７６を省略することもできる。 In the embodiment of the present invention, it is important to end the solidification reaction of the dry lamination adhesive 12C of the laminated sheet A during the flat surface standing step, and the endless belt 72 is not heated by the heating device 76. However, when the solidification reaction of the dry lamination adhesive 12C is completed, the heating device 76 may be omitted.
　最後に、平坦面静置工程を終了した積層シートＡは、集積装置８２に送られて集積される。 Finally, the laminated sheet A that has finished the flat surface stationary step is sent to the accumulation device 82 and accumulated.
　（製造装置の第２の実施の形態）
　図６に示す第２の実施の形態における積層シートの製造装置８４は、上記した貼合装置４２と切断装置５２との間に、積層フィルム４４を一旦巻き取る巻取装置８６を設けた場合である。なお、図１と同じ装置及び部材は同符号を付すると共に説明は省略する。 (Second Embodiment of Manufacturing Apparatus)
The laminated sheet manufacturing apparatus 84 in the second embodiment shown in FIG. 6 is a case where a winding device 86 for temporarily winding the laminated film 44 is provided between the bonding device 42 and the cutting device 52 described above. is there. Note that the same devices and members as those in FIG.
　図６に示すように、貼合装置４２によって形成された積層フィルム４４は、巻取装置８６によってロール状に一旦巻き取られる。次に、巻取装置８６に巻き取られた積層フィルム４４は、所定の保管温度で所定時間保管された後、巻き戻されて保護フィルム貼合装置４６、切断装置５２、平坦面静置装置７０へ順次搬送される。 As shown in FIG. 6, the laminated film 44 formed by the laminating device 42 is once wound up into a roll shape by the winding device 86. Next, the laminated film 44 taken up by the take-up device 86 is stored at a predetermined storage temperature for a predetermined time, and then rewound, and the protective film laminating device 46, the cutting device 52, and the flat surface stationary device 70 are wound. It is conveyed sequentially.
　そして、制御手段８０は、積層フィルム４４におけるドライラミ用接着剤１２Ｃの固化反応が終了する前に積層フィルム４４を切断装置５２で切断可能なように、巻取装置８６に巻回されて保管されている積層フィルム４４の保管時間及び保管温度を制御する。 Then, the control means 80 is wound and stored in the winding device 86 so that the laminated film 44 can be cut by the cutting device 52 before the solidification reaction of the dry lamination adhesive 12C in the laminated film 44 is completed. The storage time and storage temperature of the laminated film 44 are controlled.
　ちなみに、巻取装置８６に巻回された積層フィルム４４を室温保管するのであれば、巻き取った後２４時間以内に巻き戻して切断装置５２で積層フィルム４４を所定サイズに切断すれば問題ない。 Incidentally, if the laminated film 44 wound around the winding device 86 is stored at room temperature, there is no problem if the laminated film 44 is unwound within 24 hours after winding and cut into a predetermined size by the cutting device 52.
　このように、積層フィルム４４を巻取装置８６に一旦巻き取って保管することで、第１の実施の形態の一貫製造に比べて、製造ラインのフレキティビリティ化を図ることができるだけでなく、積層フィルム４４を切断するタイミングも調整できる。このタイミング調整により、ドライラミ用接着剤１２Ｃの固化反応が終了する少し前に、積層フィルム４４を巻取装置８６から巻き戻して切断と平坦面静置とを行うことができる。これにより、平坦面静置装置７０の加熱装置７６を省略することが可能である。 In this way, by temporarily winding and storing the laminated film 44 on the winding device 86, not only can the production of the production line be more flexible than the integrated production of the first embodiment, The timing for cutting the laminated film 44 can also be adjusted. With this timing adjustment, the laminated film 44 can be unwound from the winding device 86 and cut and allowed to stand on a flat surface shortly before the solidification reaction of the dry lamination adhesive 12C is completed. Thereby, the heating device 76 of the flat surface stationary device 70 can be omitted.
　以上説明したように、本発明の積層シートの製造方法及び製造装置によれば、樹脂フィルム、特に厚手の汎用樹脂フィルムをドライラミネート用接着剤で貼り合わせて積層シートを製造しても、得られた積層シートに剥がれやカールがなく平坦性に優れている。したがって、本発明で製造した積層シートは、立体画像用印画シート用、ＬＥＤ照明用拡散カバーとして好適である。 As described above, according to the method and apparatus for producing a laminated sheet of the present invention, even if a laminated sheet is produced by laminating a resin film, particularly a thick general-purpose resin film, with an adhesive for dry lamination, it can be obtained. The laminated sheet is excellent in flatness without peeling or curling. Therefore, the laminated sheet produced in the present invention is suitable for a stereoscopic image printing sheet and an LED illumination diffusion cover.
　なお、図示しなかったが、切断装置５２での切断中は、積層フィルム４４の搬送は停止するので、製造装置２８、８４の製造ラインには、搬送停止中のフィルム弛みを防止するリザーバ装置が設けられる。 Although not shown in the figure, since the transport of the laminated film 44 is stopped during the cutting by the cutting device 52, a reservoir device for preventing the film from loosening while the transport is stopped is provided in the manufacturing lines of the manufacturing devices 28 and 84. Provided.
　１０…立体画像用印画シート、１０Ａ…立体画像用印画シート原反、１２…透明支持体、１２Ａ…第１汎用樹脂フィルム、１２Ｂ…第２汎用樹脂フィルム、１２Ｃ…ドライラミ用接着剤、１４…レンズ層、１６…受像層、１８…硬質性樹脂層、２０…ＬＥＤ照明用拡散カバー、２２…基板、２４…拡散層、２６…ハードコート層、２８…製造装置（第１の実施の形態）、３０…第１送出装置、３２…搬送ローラ、３４…塗布装置、３６…乾燥装置、３８…第２送出装置、４０…コロナ放電処理装置、４２…貼合装置、４３…ラミネート温度調整手段、４４…積層フィルム、４６…貼合装置、４７…ベルトコンベア装置、４８Ａ…上保護フィルム、４８Ｂ…下保護フィルム、４９…ベルトコンベア装置、５０Ａ…第１リール装置、５０Ｂ…第２リール装置、５２…切断装置、５４…切断機、５６…ワーク保持機、５８…回転鋸刃、６０…回転支持部、６２…昇降部、６４…台座、６６…抑え部、６８…移動手段、７０…平坦面静置装置、７２…無端状ベルト、７２Ａ…平坦面、７４…ベルトコンベア装置、７６…加熱装置、７８…ローラ、８０…制御手段、８２…集積装置、８４…製造装置（第２の実施の形態）、Ａ…積層シート DESCRIPTION OF SYMBOLS 10 ... Three-dimensional image printing sheet, 10A ... Three-dimensional image printing sheet original, 12 ... Transparent support, 12A ... First general-purpose resin film, 12B ... Second general-purpose resin film, 12C ... Adhesive for dry lamination, 14 ... Lens Layer, 16 ... image receiving layer, 18 ... hard resin layer, 20 ... diffusion cover for LED illumination, 22 ... substrate, 24 ... diffusion layer, 26 ... hard coat layer, 28 ... manufacturing apparatus (first embodiment), DESCRIPTION OF SYMBOLS 30 ... 1st delivery apparatus, 32 ... Conveyance roller, 34 ... Application | coating apparatus, 36 ... Drying apparatus, 38 ... 2nd delivery apparatus, 40 ... Corona discharge treatment apparatus, 42 ... Pasting apparatus, 43 ... Laminate temperature adjustment means, 44 ... Laminated film, 46 ... Laminating device, 47 ... Belt conveyor device, 48A ... Upper protective film, 48B ... Lower protective film, 49 ... Belt conveyor device, 50A ... First reel device, 50B ... No. Reel device 52 ... Cutting device 54 ... Cutting machine 56 ... Work holding machine 58 ... Rotating saw blade 60 ... Rotating support part 62 ... Elevating part 64 ... Pedestal 66 ... Pressing part 68 ... Moving means DESCRIPTION OF SYMBOLS 70 ... Flat surface stationary apparatus, 72 ... Endless belt, 72A ... Flat surface, 74 ... Belt conveyor apparatus, 76 ... Heating apparatus, 78 ... Roller, 80 ... Control means, 82 ... Accumulation apparatus, 84 ... Manufacturing apparatus (No. 1) Embodiment 2), A ... laminated sheet

Claims (12)

  1. 　搬送される帯状の樹脂フィルムをドライラミ用接着剤で複数枚貼り合わせて積層フィルムを形成する貼合工程と、前記積層フィルムを所定サイズの積層シートに切断する切断工程とを備えた積層シートの製造方法において、
    　前記貼合工程では、前記複数枚の樹脂フィルムを一対のラミネートローラで室温圧着することにより前記積層フィルムを形成し、
    　前記切断工程では、前記積層フィルムにおけるドライラミ用接着剤の固化反応が終了する前に前記積層フィルムを所定サイズに切断すると共に、
    　前記切断工程の後段に、前記切断して得られた積層シートを平坦面上に静置した状態で前記固化反応を終了させる平坦面静置工程を有する積層シートの製造方法。     Production of a laminated sheet comprising a laminating step of laminating a plurality of strip-shaped resin films to be conveyed with an adhesive for dry lamination to form a laminated film, and a cutting step of cutting the laminated film into a laminated sheet of a predetermined size In the method
    In the bonding step, the laminated film is formed by room temperature pressure bonding of the plurality of resin films with a pair of laminating rollers,
    In the cutting step, before the solidification reaction of the adhesive for dry lamination in the laminated film is completed, the laminated film is cut into a predetermined size,
    The manufacturing method of the lamination sheet which has the flat surface stationary process which complete | finishes the said solidification reaction in the state which left the laminated sheet obtained by the said cutting | disconnection on the flat surface after the said cutting process.
  2. 　前記樹脂フィルムは、１枚の厚みが１５０～２００μｍの範囲の汎用樹脂フィルムであると共に、前記積層シートの厚みが５００μｍ以上である請求項１に記載の積層シートの製造方法。 The method for producing a laminated sheet according to claim 1, wherein the resin film is a general-purpose resin film having a thickness of 150 to 200 µm, and the laminated sheet has a thickness of 500 µm or more.
  3. 　前記平坦面静置工程には、前記平坦面を加熱して前記固化反応を促進する平坦面加熱工程を有する請求項１又は２に記載の積層シートの製造方法。 The method for producing a laminated sheet according to claim 1 or 2, wherein the flat surface standing step includes a flat surface heating step of heating the flat surface to promote the solidification reaction.
  4. 　前記貼合工程では、前記複数枚の樹脂フィルムを前記一対のラミネートローラで０．２～０．４ＭＰａの圧力で挟み込む請求項１～３の何れか１の積層シートの製造方法。 The method for producing a laminated sheet according to any one of claims 1 to 3, wherein in the laminating step, the plurality of resin films are sandwiched between the pair of laminating rollers at a pressure of 0.2 to 0.4 MPa.
  5. 　前記貼合工程の前段に、前記ドライラミ用接着剤が付与されていない樹脂フィルムの貼合わせ面側にコロナ放電処理を施すコロナ放電処理工程を有する請求項１～４の何れか１の積層シートの製造方法。 The laminated sheet according to any one of claims 1 to 4, further comprising a corona discharge treatment step of performing a corona discharge treatment on the bonding surface side of the resin film to which the dry laminating adhesive is not applied, before the bonding step. Production method.
  6. 　前記貼合工程では、送出装置によってロール状に巻回された状態から送り出される２枚の樹脂シートを貼り合わすと共に、一方の樹脂フィルムのロール内側面と他方の樹脂フィルムのロール外側面とが合わさるように貼り合わす請求項１～５の何れか１の積層シートの製造方法。 In the bonding step, the two resin sheets fed out from the state wound in a roll shape by the feeding device are bonded together, and the inner surface of the roll of one resin film and the outer surface of the roll of the other resin film are combined. The method for producing a laminated sheet according to any one of claims 1 to 5, wherein the laminated sheets are bonded together as described above.
  7. 　前記積層シートの製造ラインに、前記樹脂フィルム及び前記積層フィルムをローラ搬送するローラ搬送工程を有し、前記搬送されるフィルムの前記ローラに対するラップ角度を９０°以上にすると共に、前記ローラの径を５０ｍｍ以上とし、搬送張力を１００Ｎ以上、３００Ｎ以下とする請求項１～６の何れか１の積層シートの製造方法。 The production line for the laminated sheet has a roller conveyance step for conveying the resin film and the laminated film with a roller. The wrap angle of the film to be conveyed with respect to the roller is set to 90 ° or more, and the diameter of the roller is set. The method for producing a laminated sheet according to any one of claims 1 to 6, wherein the thickness is 50 mm or more and the conveyance tension is 100 N or more and 300 N or less.
  8. 　前記貼合工程と前記切断工程との間に、前記積層フィルムを巻取装置に一旦巻き取る巻取工程を有すると共に、巻き取った後２４時間以内に巻き戻して前記切断工程を行う請求項１～７の何れか１の積層シートの製造方法。 2. A winding step of winding the laminated film around a winding device between the bonding step and the cutting step, and rewinding within 24 hours after winding to perform the cutting step. A method for producing a laminated sheet according to any one of 1 to 7.
  9. 　前記積層シートは、一方面にレンズ層を有すると共に他方面に画像を記録する受像層を有する立体画像用印画シートの製造における透明支持体、又は光源をＬＥＤとしたＬＥＤ照明用拡散カバーとして製造される請求項１～８の何れか１の積層シートの製造方法。 The laminated sheet is produced as a transparent support in the production of a stereoscopic image printing sheet having a lens layer on one side and an image receiving layer on the other side, or as a diffusion cover for LED illumination using LED as a light source. The method for producing a laminated sheet according to any one of claims 1 to 8.
  10. 　搬送される帯状の樹脂フィルムをドライラミ用接着剤で複数枚貼り合わせて積層フィルムを形成する貼合装置と、前記積層フィルムを所定サイズの積層シートに切断する切断装置とを備えた積層シートの製造装置において、
    　前記貼合装置には、前記複数枚の樹脂フィルムを一対のラミネートローラで挟み込んでラミネートする際のラミネート温度を室温状態に調整するラミネート温度調整手段を有すると共に、
    　前記積層フィルムにおけるドライラミ用接着剤の固化反応が終了する前に前記積層フィルムを所定サイズに切断するように前記製造装置のライン制御を行う制御手段を有し、
    　前記切断装置の後段に、前記切断して得られた積層シートを平坦面上に静置した状態で前記固化反応を終了させる平坦面静置装置を備えた積層シートの製造装置。     Production of a laminated sheet comprising a laminating device for laminating a plurality of belt-shaped resin films to be conveyed with an adhesive for dry lamination to form a laminated film, and a cutting device for cutting the laminated film into a laminated sheet of a predetermined size In the device
    The laminating apparatus has a laminating temperature adjusting means for adjusting the laminating temperature when laminating the plurality of resin films with a pair of laminating rollers to a room temperature state,
    Control means for performing line control of the manufacturing apparatus so as to cut the laminated film into a predetermined size before the solidification reaction of the adhesive for dry lamination in the laminated film is completed;
    An apparatus for producing a laminated sheet, comprising a flat surface stationary device that terminates the solidification reaction in a state where the laminated sheet obtained by cutting is placed on a flat surface at a subsequent stage of the cutting device.
  11. 　前記ラミネート温度調整手段は、前記一対のラミネートローラのローラ表面温度を２０～４０℃に調整する請求項１０に記載の積層シートの製造装置。 The laminated sheet manufacturing apparatus according to claim 10, wherein the laminating temperature adjusting means adjusts the roller surface temperature of the pair of laminating rollers to 20 to 40 ° C.
  12. 　前記平坦面静置装置には、前記平坦面を加熱する加熱装置を備える請求項１０又は１１に記載の積層シートの製造装置。 The apparatus for producing a laminated sheet according to claim 10 or 11, wherein the flat surface stationary device includes a heating device for heating the flat surface.
PCT/JP2012/080425 2011-12-09 2012-11-26 Method and device for manufacturing laminated sheet WO2013084734A1 (en)

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