WO2014017528A1 - 熱可塑性樹脂発泡フィルム及びその製造方法 - Google Patents
熱可塑性樹脂発泡フィルム及びその製造方法 Download PDFInfo
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- WO2014017528A1 WO2014017528A1 PCT/JP2013/070018 JP2013070018W WO2014017528A1 WO 2014017528 A1 WO2014017528 A1 WO 2014017528A1 JP 2013070018 W JP2013070018 W JP 2013070018W WO 2014017528 A1 WO2014017528 A1 WO 2014017528A1
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- thermoplastic resin
- resin foam
- cutting
- foam film
- foam
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04R—LOUDSPEAKERS, MICROPHONES, GRAMOPHONE PICK-UPS OR LIKE ACOUSTIC ELECTROMECHANICAL TRANSDUCERS; DEAF-AID SETS; PUBLIC ADDRESS SYSTEMS
- H04R7/00—Diaphragms for electromechanical transducers; Cones
- H04R7/02—Diaphragms for electromechanical transducers; Cones characterised by the construction
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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
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
- B29C67/0011—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for shaping plates or sheets
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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
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/046—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
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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
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
- B32B15/082—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising vinyl resins; comprising acrylic resins
-
- 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
- B32B15/00—Layered products comprising a layer of metal
- B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
-
- 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
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04R—LOUDSPEAKERS, MICROPHONES, GRAMOPHONE PICK-UPS OR LIKE ACOUSTIC ELECTROMECHANICAL TRANSDUCERS; DEAF-AID SETS; PUBLIC ADDRESS SYSTEMS
- H04R31/00—Apparatus or processes specially adapted for the manufacture of transducers or diaphragms therefor
- H04R31/003—Apparatus or processes specially adapted for the manufacture of transducers or diaphragms therefor for diaphragms or their outer suspension
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2079/00—Use of polymers having nitrogen, with or without oxygen or carbon only, in the main chain, not provided for in groups B29K2061/00 - B29K2077/00, as moulding material
- B29K2079/08—PI, i.e. polyimides or derivatives thereof
- B29K2079/085—Thermoplastic polyimides, e.g. polyesterimides, PEI, i.e. polyetherimides, or polyamideimides; Derivatives thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/38—Loudspeaker cones; Acoustic diaphragms
-
- 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
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0242—Acrylic resin
-
- 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
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0257—Polyamide
-
- 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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
-
- 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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/558—Impact strength, toughness
-
- 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
- B32B2457/00—Electrical equipment
-
- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04R—LOUDSPEAKERS, MICROPHONES, GRAMOPHONE PICK-UPS OR LIKE ACOUSTIC ELECTROMECHANICAL TRANSDUCERS; DEAF-AID SETS; PUBLIC ADDRESS SYSTEMS
- H04R2307/00—Details of diaphragms or cones for electromechanical transducers, their suspension or their manufacture covered by H04R7/00 or H04R31/003, not provided for in any of its subgroups
- H04R2307/025—Diaphragms comprising polymeric materials
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249978—Voids specified as micro
- Y10T428/249979—Specified thickness of void-containing component [absolute or relative] or numerical cell dimension
Definitions
- the present invention relates to a thermoplastic resin foam film and a method for producing a thermoplastic resin foam film.
- Patent Document 1 discloses a polyurethane foam having a thickness of 0.3 to 13 mm. It is disclosed. However, such a foam is disposed between two articles and deforms without a gap, and is not suitable as a core of a laminated structure material.
- Patent Document 2 proposes a laminated foam sheet made of polyphenylene ether resin and polystyrene resin and having a large heat shrinkage rate in a specific direction, and here, a foam film having a thickness of 0.25 to 0.5 mm is disclosed. ing. However, since this foamed film is obtained by strongly stretching in the extrusion direction for the purpose of increasing the heat shrinkage rate, the cells of the foamed film are greatly flattened in the thickness direction and lack compression strength.
- thermoplastic resin foam a method of using a band knife such as a traveling saw blade or a knife blade has been conventionally employed.
- a method of cutting is disclosed.
- Patent Document 4 describes that cutting is performed without destroying bubbles on the surface of the foam, there is no description about foam film production.
- cutting with a knife blade is disclosed as a cutting method, and a band saw is exemplified as the knife blade.
- a thin foam film is obtained by this method, it is caused by play (deflection) of the knife blade. Therefore, a foamed film with high thickness accuracy cannot be obtained.
- the welded thick portion hits the surface of the cutting surface, so that a streaky cutting trace remains.
- the foam cut is a small piece, and thus a foam film having a desired thickness cannot be obtained.
- JP 2007-44972 A JP-A-2-151429 JP 2007-513213 A JP 2002-86577 A
- the present invention provides a thermoplastic resin foam film having high heat resistance, light weight, thin thickness, and good compression resistance, and further, a laminated foam film having high rigidity by lamination with aluminum foil or the like.
- An object of the present invention is to provide a manufacturing method for obtaining a thermoplastic resin foam film by cutting the thermoplastic resin foam.
- the present inventors use a poly (meth) acrylimide resin as a thermoplastic resin and obtain heat obtained by paying attention to specific characteristics of a foamed film.
- the foamed plastic resin film has good compression resistance, high heat resistance, can be made lighter and thinner than conventional ones, and structural materials using the thermoplastic resin foam film have higher rigidity than before. I found out that That is, the gist of the present invention is as follows.
- thermoplastic resin foam film substantially made of a thermoplastic resin, wherein the thermoplastic resin is a poly (meth) acrylimide resin, a density is 30 to 500 kg / m 3 , and an average cell diameter is 2
- thermoplastic resin foamed film having a thickness of 0.05 to 1.0 mm and a thickness of 500 ⁇ m.
- thermoplastic resin foam film [4] The method for producing a thermoplastic resin foam film according to [1], wherein the production method cuts a thermoplastic resin foam substantially composed of a poly (meth) acrylimide resin with a cutting blade.
- a cutting process comprising the steps of: At least one of the thermoplastic resin foam and the cutting blade is reciprocated, and the thermoplastic resin foam and the cutting blade slide in the stroke of at least one of the forward path and the return path, thereby the thermoplastic resin foam.
- a method for producing a foamed thermoplastic resin film in which flakes are substantially cut from a poly (meth) acrylimide-based resin.
- a flat plate in which the flakes are flattened while being heated at a glass transition temperature (Tg) [° C.]-100 ° C. of the poly (meth) acrylimide resin and a temperature [° C.] of the Tg or less.
- Tg glass transition temperature
- thermoplastic resin foam film having high heat resistance, light weight, thin thickness, and good compression resistance
- stacked the said thermoplastic resin foam film, aluminum foil, etc. has high rigidity, for example, is suitable as a diaphragm for speakers.
- a thermoplastic resin foam film with a high thickness precision can be obtained.
- thermoplastic resin foam film according to the present invention is a thermoplastic foam film substantially made of a thermoplastic resin, wherein the thermoplastic resin is a poly (meth) acrylimide resin and has a density of 30 to 500 kg / m. 3.
- the average cell diameter is 2 to 500 ⁇ m and the thickness is 0.05 to 1.0 mm.
- the thermoplastic resin foam film according to the present invention has a density of 30 to 500 kg / m 3 .
- the lower limit of the density may be 30 kg / m 3 or more, preferably 40 kg / m 3 or more, more preferably 55 kg / m 3 or more.
- the upper limit of the density may be 500 kg / m 3 or less, preferably 400 kg / m 3 or less, more preferably 300 kg / m 3 or less.
- the density is less than 30 kg / m 3 , a good foam film tends to be not obtained. In particular, it tends to be difficult to form a film in the cutting process of the manufacturing method described later.
- the density exceeds 500 kg / m 3 , the lightness may be impaired.
- the thermoplastic resin foam film according to the present invention has an average cell diameter of 2 to 500 ⁇ m.
- the lower limit of the average cell diameter may be 2 ⁇ m or more, preferably 5 ⁇ m or more, and more preferably 10 ⁇ m or more.
- the upper limit of the average cell diameter may be 500 ⁇ m or less, preferably 300 ⁇ m or less, more preferably 260 ⁇ m or less.
- the average cell diameter is less than 2 ⁇ m, it becomes a foamed film having a substantially low foaming ratio, resulting in an increase in density and a tendency to deteriorate lightness.
- the average cell diameter exceeds 500 ⁇ m a good foamed film tends not to be obtained. In particular, breakage occurs in the cutting process of the manufacturing method described later, and it tends to be difficult to form a film.
- the thermoplastic resin foam film according to the present invention has a thickness of 0.05 to 1.0 mm.
- the minimum of thickness should just be 0.05 mm or more, Preferably it is 0.07 mm or more, More preferably, it is 0.1 mm or more.
- the upper limit of thickness should just be 1.0 mm or less, Preferably it is 0.7 mm or less, More preferably, it is 0.5 mm or less. If the thickness is less than 0.05 mm, the rigidity may be impaired when a laminated foam film is formed. Moreover, when thickness exceeds 1.0 mm, use in a narrow site
- thermoplastic resin foam film according to the present invention is substantially made of a thermoplastic resin, and the thermoplastic resin is preferably a poly (meth) acrylimide resin. That is, the thermoplastic resin foam film according to the present invention is constituted by a resin composition substantially composed of a poly (meth) acrylimide resin.
- a thermoplastic resin foam film having high heat resistance can be obtained by using a poly (meth) acrylimide resin as the thermoplastic resin.
- the structure of each cell in the foam film can be made to be a substantially uniform structure, the same performance can be exhibited in the entire film, and a foam sheet having good compression resistance can be obtained. Become.
- Examples of the poly (meth) acrylimide resin used in the present invention include poly (meth) acrylimide constituting a poly (meth) acrylimide foam obtained by foaming a foamable cross-linked polymer described in Patent Document 3. It is possible to use a resin.
- the poly (meth) acrylimide foam described in Patent Document 3 is sold under the trade name ROHACELL (registered trademark).
- ROHACELL registered trademark
- those having the above average cell diameter of 10 to 260 ⁇ m can be suitably used, and those having such an average cell diameter include, for example, RC71RIST, RC71HF, RC71RIMA, RC110HP, etc. It is sold with the part number.
- thermoplastic resin and “substantially consisting of a poly (meth) acrylimide resin” do not impair the function of the finally obtained thermoplastic resin foam film. It means that any component other than the poly (meth) acrylimide resin can be included.
- thermoplastic resin foam film according to the present invention as described above can be produced by a method including the following steps. That is, a thermoplastic resin foam substantially made of a poly (meth) acrylimide resin is prepared in advance, and in the cutting step of cutting the foam with a cutting blade, at least one of the thermoplastic resin foam and the cutting blade. Poly (meth) acrylimide is obtained by intermittently cutting the thermoplastic resin foam by reciprocating one side and sliding the thermoplastic resin foam and the cutting blade in at least one of the forward path and the return path. It is a method of obtaining a thin piece substantially made of a resin as a foamed thermoplastic resin film.
- thermoplastic resin foam and the cutting blade slide means that the moving direction of the reciprocating motion and the direction of the blade line of the cutting blade are not parallel but have a predetermined angle. It means that the resin foam and the cutting blade come into contact with each other and both move relatively. And by doing in this way, the surface with the thermoplastic resin foam having a predetermined three-dimensional structure comes into contact with the cutting blade to start cutting, and the blade line of the cutting blade has a predetermined angle with the reciprocating motion. A thin piece can be obtained from the foam by moving relative to the foam while making contact with the foam.
- thermoplastic resin foam and the cutting blade are reciprocated, and the thermoplastic resin foam is used in at least one of the forward path and the return path. Slide the cutting blade.
- thermoplastic resin foam film obtained can improve the smoothness of the surface, and can improve the thickness accuracy in the vicinity of the center.
- a band knife such as a traveling saw blade or knife blade as the cutting blade, it is inferior in terms of surface smoothness and thickness accuracy.
- a cutting machine 2 shown in FIG. 1 includes a cutting table 4 that fixes a cutting blade 3 and a gantry 5 that can reciprocate along a rail (not shown) disposed on an upper surface thereof.
- the gantry 5 reciprocates in the direction of the arrow in the figure.
- the gantry 5 includes a fixing base 6 that fixes the thermoplastic resin foam 1 to the gantry 5, leg portions 7 that support the fixing base 6 on the cutting base 4, and the base 5 along the rails on the cutting base 4. And a pulley 8 (four in this example). Furthermore, the fixing base 6 of the gantry 5 includes a gripping part 9 that grips and fixes the thermoplastic resin foam 1 to the fixing base 6 and an adjustment part 10 for adjusting the thickness of the thin piece.
- the cutting edge of the cutting blade 3 (the left end of reference numeral 3 in FIG. 1) is positioned slightly above the left side of the drawing of the cutting table 4 and the cutting edge is made of thermoplastic resin. It is arranged so as to face the foam 1.
- the angle formed by the blade line of the cutting blade 3 and the reciprocating direction of the thermoplastic resin foam 1 is not particularly limited, but the cutting line is perpendicular to the cutting direction on the cutting surface.
- the angle (bias angle) formed with respect to is preferably 5 to 85 °. In this case, when the thermoplastic resin foam 1 and the cutting blade 3 are in contact, the cutting surface of the thermoplastic resin foam 1 and the blade line of the cutting blade 3 are not parallel, but are at an angle. Therefore, it becomes easy to suppress the foaming of the thermoplastic resin foam during cutting.
- the reciprocating motion of the thermoplastic resin foam or the cutting blade in the manufacturing method according to the present invention is not limited to the case of reciprocating completely on the shaft.
- a case involving a slight vertical movement is included.
- the configuration of the adjusting unit 10 for adjusting the thickness of the flakes is not particularly limited, and may be provided with a mechanism that keeps applying a constant load to the thermoplastic resin foam 1 or for each cutting. Further, a mechanism capable of feeding a certain amount of the thermoplastic resin foam 1 may be provided.
- the former include, but are not limited to, those that apply a predetermined pressing force to the thermoplastic resin foam 1 via the grip 9 by an elastic body or the like.
- Examples of the latter include those equipped with a mechanism for adjusting the distance between the grip portion 9 and the blade line of the cutting blade 3 to a predetermined height, and known ones can be appropriately employed.
- the usable area is wide because the thickness accuracy of the foam film end portion is good, it is preferable to have a mechanism capable of adjusting the feed amount of the latter thermoplastic resin foam 1 to a predetermined amount.
- the density of the thermoplastic resin foam is preferably 30 to 500 kg / m 3 .
- the lower limit of the density is preferably 30 kg / m 3 or more, more preferably 40 kg / m 3 or more, and still more preferably 55 kg / m 3 or more.
- the upper limit of the density is preferably 500 kg / m 3 or less, more preferably 400 kg / m 3 or less, and still more preferably 300 kg / m 3 or less. If the density is less than 30 kg / m 3 , the thickness accuracy may be impaired, and if it exceeds 500 kg / m 3 , the foamed film may be cracked during cutting.
- thermoplastic resin foam is not particularly limited as long as it is capable of performing the cutting process as described above and is not a film shape.
- a cubic shape, a rectangular parallelepiped shape, a cylindrical shape, an elliptical column shape, etc. Can be mentioned.
- Such a thermoplastic resin foam is available as the specific ROHACELL (registered trademark) described above.
- thermoplastic resin foam film according to the present invention it is possible to use the flakes immediately after the end of the cutting process as the thermoplastic resin foam film according to the present invention as it is, but when the thermoplastic resin foam is cut, the flakes are wound as if they were scraps. It becomes difficult to handle. Therefore, the flakes obtained in the cutting step are brought to a temperature [° C.] that is not less than the glass transition temperature (Tg) [° C.]-100 [° C.] of the poly (meth) acrylimide resin constituting the flakes. It is preferable to perform flattening while heating (flattening step).
- flattening while heating means pressing with a weak pressure on the flat surface portion while heating, such as ironing, sandwiching between two flat plates, and putting in a heating oven.
- the curl may not be sufficiently taken, and when the heating temperature exceeds Tg, the thickness accuracy may be lowered due to further expansion or crushing of the foam film.
- the glass transition temperature (Tg) of the poly (meth) acrylimide resin is increased from 40 ° C. to 250 ° C. at a rate of 10 ° C./min from 1 to 10 mg of the sample in, for example, differential scanning calorimetry (DSC). Warm, hold at this temperature for 5 minutes, then cool down from 250 ° C. to 40 ° C. at a rate of 10 ° C./minute, hold at that temperature for 5 minutes, and again from 40 ° C. to 250 ° C. at a rate of 10 ° C./minute. It can be determined from the inflection point of the chart when the temperature is raised.
- DSC differential scanning calorimetry
- the pressure for pressing the flakes is preferably 0.1 MPa or less because the foamed film is not crushed.
- the flakes after the cutting step and the flattening step can be suitably used as they are for various applications as the thermoplastic resin foam film according to the present invention.
- the laminated foam film which improved rigidity can be obtained by laminating
- the aluminum foil laminated on the thermoplastic resin foam film preferably has a thickness of 0.005 to 0.12 mm, and a thickness of 0.01 to 0.05 mm. It is more preferable. If the thickness is less than 0.005 mm, the aluminum foil may be wrinkled during lamination, and if the thickness exceeds 0.12 mm, the lightness may be impaired.
- the method for laminating the aluminum foil on the thermoplastic resin foam film is not particularly limited, and methods such as an adhesive, a pressure-sensitive adhesive, and heat fusion can be adopted. From the viewpoint of thickness accuracy of the material, it is preferable to laminate with an adhesive or an adhesive material.
- the adhesive used when laminating is preferably solventless and has a small shrinkage, such as an epoxy adhesive, an acrylic adhesive, a cyanoacrylate adhesive, a urethane adhesive, a hot melt adhesive, etc.
- the present invention is not limited to these examples.
- thermoplastic resin foam film and laminated foam film according to the present invention can be suitably used particularly as a speaker diaphragm.
- it is particularly suitable as a speaker diaphragm built in a portable terminal such as a mobile phone, a smartphone, a portable game machine, or a tablet personal computer.
- a portable terminal such as a mobile phone, a smartphone, a portable game machine, or a tablet personal computer.
- the amount of current flowing through the coil used in the speaker portion increases due to a demand from the market for increasing the volume, and the amount of heat generation tends to increase.
- the thermoplastic resin foam film according to the present invention and the laminated foam film using the same have high heat resistance because it uses a poly (meth) acrylimide resin for the foam film, and can be used in these portable terminals. It is.
- the weight of the speaker diaphragm is said to directly affect the acoustic characteristics, and it is said that the lower the weight, the easier it is to vibrate, thus making it easier to increase the volume. Since the thermoplastic resin foam film according to the present invention and the laminated foam film using the same have a predetermined average cell diameter and the density is in a predetermined range, it is easy to reduce the weight. The volume can be easily increased.
- ⁇ Measurement of foam film thickness> Using a thickness gauge, a sample of 450 mm ⁇ 300 mm was cut out except the sample peripheral edge 30 mm, the thickness was randomly measured at 30 locations, and the average thickness was calculated by arithmetic average. In addition, the difference between the maximum value and the minimum value was calculated.
- thermoplastic resin foam films all had a density of 71 kg / m 3 , an average thickness of 0.30 mm, a difference between the maximum value and the minimum value of 0.03 mm, and a minimum edge thickness of 0.28 mm. . Moreover, the surface was smooth.
- an aluminum foil having a thickness of 0.012 mm is pasted on both surfaces of the obtained thermoplastic resin foam film using an epoxy resin two-component adhesive (Chemedine Co., Ltd., 1500), a highly rigid laminated foam A film was obtained.
- the laminated foam film has high heat resistance, light weight, high rigidity, and can be expected as a diaphragm for a speaker.
- thermoplastic resin foam film obtained by flattening was measured in the same manner as in Examples 1 to 3.
- the evaluation results are shown in Table 1.
- Each of the thermoplastic resin foam films had an average thickness of 0.20 mm, a difference between the maximum value and the minimum value of 0.02 mm, and a minimum edge thickness of 0.19 mm. Moreover, the surface was smooth. Further, when an aluminum foil having a thickness of 0.012 mm was pasted in the same manner as in Examples 1 to 3, a highly rigid laminated foam film was obtained.
- the laminated foam film has high heat resistance, light weight, high rigidity, and can be expected as a diaphragm for a speaker.
- Example 7 Examples 1 to 3 except that RC110HP (60 mm ⁇ 90 mm ⁇ 10 mm, density 110 kg / m 3 ) of ROHACELL (registered trademark), which is a box-shaped foam made of polymethacrylimide resin manufactured by Daicel-Evonik Co., Ltd., was used. Using the same cutting machine as No. 3, cutting was performed with a target thickness of 0.30 mm, and flattening was performed in the same manner as in Examples 1 to 3. The thermoplastic resin foam film obtained by flattening was measured in the same manner as in Examples 1 to 3. The evaluation results are shown in Table 1.
- thermoplastic resin foam film had an average thickness of 0.30 mm, a difference between the maximum value and the minimum value of 0.02 mm, and a minimum edge thickness of 0.29 mm. Moreover, the surface was smooth. Further, when an aluminum foil having a thickness of 0.012 mm was pasted in the same manner as in Examples 1 to 3, a highly rigid laminated foam film was obtained.
- the laminated foam film has high heat resistance, light weight, high rigidity, and can be expected as a diaphragm for a speaker.
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- Physics & Mathematics (AREA)
- Acoustics & Sound (AREA)
- Signal Processing (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Multimedia (AREA)
- Diaphragms For Electromechanical Transducers (AREA)
- Laminated Bodies (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
Abstract
Description
〔2〕前記〔1〕記載の熱可塑性樹脂発泡フィルムの少なくとも片面にアルミニウム箔を積層した積層発泡フィルム。
〔3〕前記〔1〕記載の熱可塑性樹脂発泡フィルム又は前記〔2〕記載の積層発泡フィルムを用いたスピーカー用振動板。
〔4〕前記〔1〕記載の熱可塑性樹脂発泡フィルムの製造方法であって、該製造方法は、ポリ(メタ)アクリルイミド系樹脂から実質的になる熱可塑性樹脂発泡体を切削刃により切削する切削工程を含んでなり、該切削工程において、
熱可塑性樹脂発泡体及び前記切削刃のうちの少なくとも一方を往復運動させ、往路及び復路のうちの少なくとも一方の行程において熱可塑性樹脂発泡体と切削刃が摺動することにより前記熱可塑性樹脂発泡体を間歇的に切削してポリ(メタ)アクリルイミド系樹脂から実質的になる薄片を得る、熱可塑性樹脂発泡フィルムの製造方法。
〔5〕前記薄片を、前記ポリ(メタ)アクリルイミド系樹脂のガラス転移温度(Tg)[℃]-100[℃]以上かつ前記Tg以下の温度[℃]にて加熱しつつ平板化する平板化工程を更に含む、前記〔4〕記載の熱可塑性樹脂発泡フィルムの製造方法。
また、後述するように熱可塑性樹脂発砲フィルムをスピーカー用として使用する場合、音響特性を均一にする観点から、熱可塑性樹脂発泡フィルムの厚みの最大値と最小値の差が小さい方が好ましい。
本発明で用いるポリ(メタ)アクリルイミド系樹脂としては、例えば、特許文献3に記載の発泡性架橋ポリマーを発泡させて得られるポリ(メタ)アクリルイミド-フォームを構成するポリ(メタ)アクリルイミド系樹脂を用いることが可能である。特許文献3に記載のポリ(メタ)アクリルイミド-フォームは、ROHACELL(登録商標)という商品名で販売されている。ROHACELL(登録商標)の中でも、上述した平均セル径が10~260μmのものを好適に用いることが可能であり、このような平均セル径を有するものは、例えば、RC71RIST、RC71HF、RC71RIMA、RC110HP等の品番で販売されている。
尚、本発明において「熱可塑性樹脂から実質的になる」、「ポリ(メタ)アクリルイミド系樹脂から実質的になる」とは、最終的に得られる熱可塑性樹脂発泡フィルムの機能を害さない範囲で、ポリ(メタ)アクリルイミド系樹脂以外の任意の成分を含み得ることを意味する。
即ち、予めポリ(メタ)アクリルイミド系樹脂から実質的になる熱可塑性樹脂発泡体を準備し、この発泡体を切削刃により切削する切削工程において、熱可塑性樹脂発泡体及び切削刃のうちの少なくとも一方を往復運動させ、往路及び復路のうちの少なくとも一方の行程において熱可塑性樹脂発泡体と切削刃が摺動することにより前記熱可塑性樹脂発泡体を間歇的に切削してポリ(メタ)アクリルイミド系樹脂から実質的になる薄片を熱可塑性樹脂発泡フィルムとして得る方法である。
本発明において、「熱可塑性樹脂発泡体と切削刃が摺動する」とは、往復運動の移動方向と切削刃の刃線の方向が、平行ではなく、所定の角度を有するように、熱可塑性樹脂発泡体と切削刃とが接触して両者が相対的に移動することを意味する。そして、このようにすることにより、所定の立体構造を有する熱可塑性樹脂発泡体のある面と切削刃とが当接して切削を開始し、切削刃の刃線が、往復運動と所定角度有するように発泡体と接触し、切り込みを入れつつ、発泡体に対して相対的に移動して、発泡体から薄片を得ることができる。
上記(ii)の切削工程では、熱可塑性樹脂発泡体を往復運動させ、薄片を得るに際して、図1で示すような切削機を用いることができる。尚、図1中、符号1、3、4で示した部分は断面図である。
図1に示す切削機2は、切削刃3を固定する切削台4と、その上面に配されたレール(図示せず)に沿って往復運動可能な架台5とを備える。架台5は図中の矢印方向に往復運動する。また、架台5は、熱可塑性樹脂発泡体1を架台5に固定する固定台6と、固定台6を切削台4上で支持する脚部7と、架台5を切削台4上のレールに沿って摺動するための滑車8(本例では4つ備える)とを備える。更に、架台5の固定台6は、熱可塑性樹脂発泡体1を把持して固定台6に固定する把持部9と、薄片の厚みを調整するための調整部10とを備える。
また、本例では、切削刃3の刃先(図1中の符号3の左端)は、切削台4のうちの図面の左側部分よりも僅かに図面の上側に位置するとともに、刃先が熱可塑性樹脂発泡体1に向かうように配されている。
本発明の積層発泡フィルムにおいて、熱可塑性樹脂発泡フィルムに積層されるアルミニウム箔は、厚さが0.005~0.12mmであることがより好ましく、厚さが0.01~0.05mmであることがより好ましい。厚みが0.005mmを下回ると積層の際にアルミニウム箔に皺が入る場合があり、厚さが0.12mmを超えると軽量性が損なわれる場合がある。
厚みゲージを用いて、450mm×300mmのサンプルについて、サンプル周辺端部30mmを除いて切り出し、ランダムに30箇所で厚みを測定し、算術平均により平均厚みを算出した。併せて、最大値と最小値の差を算出した。
上記発泡フィルムの厚み測定を行ったサンプルについて、縦横の長さ及び重量を測定し、縦横の長さと平均厚みから体積を算出し、重量を体積で除して算出した。
KEYENCE製VHX-900およびVH-Z20R装置を使い、200倍レンズ(RZ×20~×200)により、発泡体フィルム(フィルム化できなかったものは箱形状発泡体)の表面からセル径を直接観察し、これらの装置に付属の計測ツールにより、代表的な大きさのセルを5個選択し、それぞれのセル壁間の2点間を測定した。このうち最大値と最小値の中間値(平均値)を平均セル径とした。
尚、平板化前後でセル径が変化しないことは確認した。
切削工程中又は同工程後の薄片の外観を目視により観察した。
ダイセル・エボニック株式会社製のポリメタクリルイミド樹脂からなる箱形状の発泡体であるROHACELL(登録商標)のRC71RIST、RC71HFおよびRC71RIMA(何れも、60mm×90mm×10mm、密度71kg/m3)を用い、この箱形状発泡体を、以下の切削機を用いて目標厚み0.30mmに設定して切削を行った(切削工程)。
使用した切削機は、レール上を床面に平行に往復運動する架台があり、該架台の下部に発泡体を固定し、往路又は復路において発泡体側に刃先が向くように固定された刃の上を発泡体が往復することで切削を行い、切削毎、即ち一往復毎に発泡体が目標切削厚み分下がってくることで連続的に切削を行う構成の切削機(図1参照)である。なお、バイアス角は10°に設定した。
切削された薄片は巻癖が強く、直径40mm程度の巻物状になっていた。
切削工程で得られた巻物状の薄片を2枚のアルミ板に挟み、110℃に設定した熱風オーブン中にて10分加熱して平板化して、熱可塑性樹脂発泡フィルムを得た(平板化工程)。
その後、放冷して取り出し、各測定を行った。評価結果を表1に示す。尚、熱可塑性樹脂発泡フィルムは何れも、密度が71kg/m3、平均厚みが0.30mm、厚みの最大値と最小値の差が0.03mm、端部最小厚みが0.28mmであった。また、その表面は、平滑であった。
得られた熱可塑性樹脂発泡フィルムの両面に、エポキシ樹脂系2液型接着剤(セメダイン株式会社製、1500)を用いて、厚さ0.012mmのアルミニウム箔を貼付したところ、剛性の高い積層発泡フィルムが得られた。積層発泡フィルムは、耐熱性が高く、軽量で、剛性が高く、スピーカー用振動板として期待できるものであった。
実施例1~3と同様の箱形状発泡体を用い、実施例1~3と同じ切削機を用いて目標厚み0.20mmに設定して切削を行い、実施例1~3と同様にして平板化を行った。平板化して得られた熱可塑性樹脂発泡フィルムについて、実施例1~3と同様にして測定を行った。評価結果を表1に示す。尚、何れの熱可塑性樹脂発泡フィルムも、平均厚みが0.20mm、厚みの最大値と最小値の差が0.02mm、端部最小厚みが0.19mmであった。また、その表面は、平滑であった。
また、実施例1~3と同様にして厚さ0.012mmのアルミニウム箔を貼付したところ、剛性の高い積層発泡フィルムが得られた。積層発泡フィルムは、耐熱性が高く、軽量で、剛性が高く、スピーカー用振動板として期待できるものであった。
ダイセル・エボニック株式会社製のポリメタクリルイミド樹脂からなる箱形状の発泡体であるROHACELL(登録商標)のRC110HP(60mm×90mm×10mm、密度110kg/m3)を用いた以外は、実施例1~3と同じ切削機を用いて目標厚み0.30mmにして切削を行い、実施例1~3と同様にして平坦化を行った。平板化して得られた熱可塑性樹脂発泡フィルムについて、実施例1~3と同様にして測定を行った。評価結果を表1に示す。尚、熱可塑性樹脂発泡フィルムは、平均厚みが0.30mm、厚みの最大値と最小値の差が0.02mm、端部最小厚みが0.29mmであった。また、その表面は、平滑であった。
また、実施例1~3と同様にして厚さ0.012mmのアルミニウム箔を貼付したところ、剛性の高い積層発泡フィルムが得られた。積層発泡フィルムは、耐熱性が高く、軽量で、剛性が高く、スピーカー用振動板として期待できるものであった。
ダイセル・エボニック株式会社製のポリメタクリルイミド樹脂からなる箱形状の発泡体であるROHACELL(登録商標)のRC71IG、RC71XT、RC71WF、RC71SおよびRC71IG-F(何れも、60mm×90mm×10mm、密度71kg/m3)を用いた以外は、実施例1~3と同じ切削機を用いて目標厚み0.30mmにして切削を行ったが、いずれも切削段階で破壊が起こり、フィルム状のものが得られなかった。評価結果を表1に示す。表1中、比較例1~5の平均セル径は箱形状の発砲体の値である。
ダイセル・エボニック株式会社製のポリメタクリルイミド樹脂からなる箱形状の発泡体であるROHACELL(登録商標)のRC51HFおよびRC51RIST(何れも、60mm×90mm×10mm、密度51kg/m3)を用いた以外は、実施例1~3と同じ切削機を用いて目標厚み0.30mmにして切削を行ったが、いずれも切削段階で破壊が起こり、良好なフィルム状のものが得られなかった。評価結果を表1に示す。表1中、比較例6~7の平均セル径は箱形状の発砲体の値である。
2 切削機
3 切削刃
4 切削台
5 発泡体を所定量繰り出し可能な架台
6 固定台
7 脚部
8 滑車
9 把持部
10 調整部
Claims (5)
- 熱可塑性樹脂から実質的になる熱可塑性樹脂発泡フィルムであって、
前記熱可塑性樹脂がポリ(メタ)アクリルイミド系樹脂であり、密度が30~500kg/m3、平均セル径が2~500μm、厚みが0.05~1.0mmである、熱可塑性樹脂発泡フィルム。 - 請求項1記載の熱可塑性樹脂発泡フィルムの少なくとも片面にアルミニウム箔を積層した積層発泡フィルム。
- 請求項1記載の熱可塑性樹脂発泡フィルム又は請求項2記載の積層発泡フィルムを用いたスピーカー用振動板。
- 請求項1記載の熱可塑性樹脂発泡フィルムの製造方法であって、
該製造方法は、ポリ(メタ)アクリルイミド系樹脂から実質的になる熱可塑性樹脂発泡体を切削刃により切削する切削工程を含んでなり、該切削工程において、前記熱可塑性樹脂発泡体及び前記切削刃のうちの少なくとも一方を往復運動させ、往路及び復路のうちの少なくとも一方の行程において熱可塑性樹脂発泡体と切削刃が摺動することにより前記熱可塑性樹脂発泡体を間歇的に切削してポリ(メタ)アクリルイミド系樹脂から実質的になる薄片を得る、熱可塑性樹脂発泡フィルムの製造方法。 - 前記薄片を、前記ポリ(メタ)アクリルイミド系樹脂のガラス転移温度(Tg)[℃]-100[℃]以上、かつ前記Tg以下の温度[℃]にて加熱しつつ平板化する平板化工程を更に含む、請求項4記載の熱可塑性樹脂発泡フィルムの製造方法。
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US10028060B2 (en) | 2016-08-22 | 2018-07-17 | 4A Manufacturing Gmbh | Temperature stable membrane plate structure for a loudspeaker |
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