JP4423713B2 - Manufacturing method of acrylic resin board with protective film - Google Patents

Manufacturing method of acrylic resin board with protective film Download PDF

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Publication number
JP4423713B2
JP4423713B2 JP23697799A JP23697799A JP4423713B2 JP 4423713 B2 JP4423713 B2 JP 4423713B2 JP 23697799 A JP23697799 A JP 23697799A JP 23697799 A JP23697799 A JP 23697799A JP 4423713 B2 JP4423713 B2 JP 4423713B2
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acrylic resin
protective film
resin plate
pressure
bonding
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JP2001062916A (en
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剛 安田
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Sumitomo Chemical Co Ltd
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Sumitomo Chemical Co Ltd
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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
    • 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
    • B29C66/71—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 composition of the plastics material of the parts to be joined

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Description

【０００１】
【発明の属する技術分野】
本発明は、少なくともその片面に、表面保護のための保護フィルムが貼り合わされた、保護フィルム付きアクリル系樹脂板の製造法に関するものである。
【０００２】
【従来の技術】
アクリル系樹脂板は、その名のとおり種々の厚みを有する板状で供給され、それが機械加工や熱成形などの二次加工の工程を経て、最終的な製品になるが、この二次加工の際に表面に傷が付くと商品価値が低下するため、通常は、少なくともその片面に保護フィルムが貼り合わされた保護フィルム付きアクリル系樹脂板として供給されたものを、当該保護フィルムを剥がさずにそのままで二次加工して製品を製造している。
【０００３】
上記保護フィルムとしては近時、これまでの紙製のものに代わって、たとえばポリオレフィン系やポリエステル系などの、樹脂のフィルムが一般化しつつある。
これは上記の樹脂フィルムが、とくに真空成形、プレス成形などの熱成形の際にアクリル系樹脂板の変形に追従して、剥がれたり加工の妨げになったりせずに変形する結果、熱成形時の表面保護としても有効に機能するからである〔たとえば特開昭６２−８２０１８号公報、特開平２−８８２１８号公報、特開平２−８８２１９号公報、特開平７−１６４５９８号公報、特表平７−５０２４６８号公報など〕。
【０００４】
【発明が解決しようとする課題】
ところが、従来の保護フィルム付きアクリル系樹脂板を、たとえば深ものの製品などを製造するために、通常よりも高温で熱成形すると、アクリル系樹脂板に保護フィルムを貼り合わせる際に両者の間に噛み込まれた気泡が膨張する結果、加熱軟化しているアクリル系樹脂板の表面に、かかる気泡による窪みや傷を生じるおそれがある。
【０００５】
本発明の目的は、アクリル系樹脂板に保護フィルムを貼り合わせる際に、両者の間に気泡が噛み込まれるのを極力防止して、たとえば深ものなどの、通常よりも高温での熱成形が必要な製品であっても、気泡による窪みや傷を生じることなく製造できる保護フィルム付きアクリル系樹脂板を得るための、製造法を提供することにある。
【０００６】
【課題を解決するための手段】
上記課題を解決するために、発明者らは、アクリル系樹脂板の少なくとも片面に保護フィルムを重ね合わせて、一対の圧着ロール間を通過させて両者を貼り合わせる際の条件について、種々検討した。
その結果、上記圧着ロールの中、第１の圧着ロールは特に加熱機能を付加せず、第２の圧着ロールの温度を所定値よりも高く設定すると、アクリル系樹脂板と保護フィルムとの間に皺や気泡が噛み込まれるのが抑制されて、通常よりも高温で熱成形しても、気泡の膨張による窪みや傷などを生じない保護フィルム付きアクリル系樹脂板を製造できることを見いだした。
【０００７】
すなわち本発明の保護フィルム付きアクリル系樹脂板の製造方法は、アクリル系樹脂板の少なくとも片面に保護フィルムを重ね合わせて、加熱機能を有さない一対の第１の圧着ロール間を通過させて、次いで、少なくとも、当該保護フィルムを重ね合わせた側のロール温度が５０℃以上に設定された一対の第２の圧着ロール間を通過させて、上記アクリル系樹脂板の少なくとも片面に、上記保護フィルムを貼り合わせることを特徴とするものである。
【０００８】
【発明の実施の形態】
以下に本発明を、その実施に使用される装置の一例を示す図１を参照しつつ、説明する。図の例は、アクリル系樹脂板１の両面に、それぞれ保護フィルム２、２を貼り合わせて、保護フィルム付きアクリル系樹脂板１０を製造する場合を示している。
【０００９】
上記のうちアクリル系樹脂板１としては、たとえばポリメタクリル酸メチルや、メタクリル酸メチルを主成分とする共重合体などの、種々のアクリル系樹脂にて、たとえば製品規格に則った種々の厚みに形成された板材が用いられる。
また、かかるアクリル系樹脂板１としては、たとえば注型法（鋳込み重合法）、溶融押出法などの従来公知の種々の製造方法によって製造されたものが使用される。
【００１０】
このうち前者の注型法にて形成されたアクリル系樹脂板１は、アクリル系樹脂の持つ高い透明性に加えて表面の平滑性にすぐれるため、かかる注型法にて形成されたアクリル系樹脂板１を使用して、本発明の製造方法で製造された保護フィルム付きアクリル系樹脂板１０からは、当該本発明の構成を採用したことによる、前述した気泡の膨張による窪みや傷の発生を防止する効果と相まって、熱成形などの二次加工によって、表面の平滑性などにすぐれた、きわめて美麗な製品を製造することができる。
【００１１】
また後者の溶融押出法を採用した場合は、押出成形機から連続的に押出成形されるアクリル系樹脂板１を、引き続いて連続的に、図１に示す貼り合わせ装置に供給することもでき、その場合には、保護フィルム付きアクリル系樹脂板１０の、より一層、連続的かつ効率的な生産が可能となる。
上記アクリル系樹脂板１に貼り合わされる保護フィルム２としては、通常に用いられているのと同様の樹脂フィルムにて形成されたものが、いずれも使用可能である。
【００１２】
具体的にはたとえば、ポリエチレンフィルム、ポリプロピレンフィルムなどのポリオレフィン系フィルムや、あるいはポリエチレンテレフタレートフィルムなどのポリエステル系フィルム、あるいはこれらの積層フィルムなどが、好適な樹脂フィルムとしてあげられる。
樹脂フィルムの厚みはとくに限定されないが、およそ３０〜１００μｍ程度、とくに４０〜９０μｍ程度であるのが好ましい。
【００１３】
樹脂フィルムの厚みが３０μｍ未満では、保護フィルム２による、アクリル系樹脂板１の表面を保護する効果が不十分となって、熱成形などの二次加工の際に表面に傷が付くおそれがある。また、樹脂フィルムの経済性、および二次加工後の保護フィルム２のはく離のしやすさの点で、樹脂フィルムの厚みは１００μｍ以下であるのが好ましい。
【００１４】
樹脂フィルムの片面には、アクリル系樹脂板１への接着性を有する接着層が設けられる。
接着層は、樹脂フィルムとアクリル系樹脂板１とを、当該アクリル系樹脂板１の表面を侵すことなく接着できるとともに、二次加工後にアクリル系樹脂板１の表面から保護フィルム２を剥がした際に、当該アクリル系樹脂板１の表面に残らずにきれいに除去できる、保護フィルム用として従来公知の種々の接着剤、粘着剤にて形成される。
【００１５】
かかる接着層用の接着剤などの好適な例としては、これに限定されないがたとえば、エチレン−酢酸ビニル共重合体（ＥＶＡ）、超低密度ポリエチレン（ＶＬＤＰＥ）、線状低密度ポリエチレン（ＬＬＤＰＥ）などの低融点の熱可塑性樹脂中に、水添テルペン樹脂、テルペン樹脂、テルペンフェノール樹脂、石油樹脂などの粘着付与剤を添加した接着剤などがあげられる。
【００１６】
接着層の厚みは、二次加工時、とくに熱成形時に、アクリル系樹脂板１の変形に追従して剥がれない十分な接着性が確保されていればよく、通常はおよそ１０〜５０μｍ程度である。
上記の保護フィルム２は、たとえばインフレーション法、Ｔダイ押出法などで連続的に製造される樹脂フィルムの片面に、ロールコート法などによって、接着層を連続的に形成することにより製造される。
【００１７】
上記のアクリル系樹脂板１と、２枚の保護フィルム２、２とを、図１の装置を用いて貼り合わせるには、まず別工程で製造された、所定の厚みを有するアクリル系樹脂板１を図中白矢印で示すように、また当該アクリル系樹脂板１の両面に貼り合わされる２枚の保護フィルム２、２を、当該保護フィルム２、２を巻回した２本のロール２０、２０から、送りローラ３、３を介して図中実線の矢印で示すように、それぞれ第１の圧着ロール４、４間および第２の圧着ロール５，５間に供給する。
【００１８】
そして、供給されたアクリル系樹脂板１と２枚の保護フィルム２、２とを、上記一対の圧着ロール４、４間を通過させることで、互いに貼り合わせる。
かかる貼り合わせの工程においては、前述したように第１のロール４，４の温度は特に加熱機能を付加せず常温で通過させ、第２のロール温度５，５を５０℃以上に加熱し、このロール間を通過させる。
すなわち第２のロール温度が５０℃未満である場合には、アクリル系樹脂板１と保護フィルム２との間に気泡が噛み込まれるのを抑制する効果が得られず、従来同様に熱成形時に、両者の間に噛み込まれた気泡が膨張して、製品の表面に窪みや傷などが発生してしまう。
【００１９】
なお上記のうちロール温度は、気泡が噛み込まれるのを抑制する効果を考慮すると、上記の範囲内でもとくに８０℃以上であるのが好ましく、８５℃以上であるのがさらに好ましい。
またロール温度は、これに限定されないが、およそ１５０℃以下であるのが好ましい。ロール温度が１５０℃を超えた場合には、保護フィルム２が、アクリル系樹脂板１の表面よりも圧着ロール４の表面に付着しやすくなって、アクリル系樹脂板１と保護フィルム２とを良好に貼り合わせできなくなるおそれがある。
【００２０】
なお本発明においては、一対の圧着ロール５，５のうち、少なくとも保護フィルム２を重ね合わせた側が、上記のロール温度に加熱されていれば、他方は加熱されていても、いなくてもよいが、とくにこの例の場合のようにアクリル系樹脂板１の両面にそれぞれ保護フィルム２、２を貼り合わせる場合は、一対の圧着ロール５，５がともに、上記のロール温度に加熱されているのが、両面の保護フィルム２、２ともに気泡の発生を抑制できるために好ましい。
【００２１】
各圧着ロール５を上記のロール温度に加熱するには、たとえばその近傍にヒータを設けたり、あるいは個々の圧着ロール５の内部に、熱媒体を用いたヒータや、電磁誘導加熱方式のヒータなどを組み込んだりすればよい。
各圧着ロール４、４および５、５は、たとえば金属などの種々の材料にて形成することができるが、アクリル系樹脂板１に保護フィルム２を良好に貼り合わせるためには、一対の圧着ロール４、４および５、５のうち少なくとも一方の、少なくとも表面が、ゴムなどの弾性を有する材料にて形成されているのが好ましい。また、とくに前述した、保護フィルム２の圧着ロール４、４および５、５への付着などを防止するためには、上記の弾性材料として、シリコーンゴムを使用するのが好ましい。
【００２２】
本発明においては、圧着ロール４，４は加熱機能を有さないロールを用いることを必須とする。該圧着ロール４，４に圧着ロール５，５と同様の加熱機能を付与させ、５０℃以上で加圧する場合には気泡の巻き込みは防止し得るものの、表面保護フィルムの貼合時に皺が入る場合がある。
【００２３】
上記の圧着ロール４、４および５、５間を通過させる、アクリル系樹脂板１と保護フィルム２とを重ね合わせたものの送り速度は、アクリル系樹脂板１と保護フィルム２との間に気泡が噛み込まれるのを抑制する効果を考慮すると、２０ｍ／分以下、好ましくは１２ｍ／分以下である。
また上記送り速度は、保護フィルム付きアクリル系樹脂板１０の生産性などを考慮すると、１ｍ／分以上、好ましくは５ｍ／分である。
【００２４】
貼り合わせの工程における、上述したロール温度、送り速度以外の他の条件についてはとくに限定されないが、圧着ロール５のロール線圧は、１ｋｇｆ／ｃｍ以上であるのが好ましい。
ロール線圧が１ｋｇｆ／ｃｍ未満では、アクリル系樹脂板１と保護フィルム２との間に気泡が噛み込まれるのを抑制する効果が不十分になって、従来ほどではないにしろ、熱成形時に両者の間に噛み込まれた気泡が膨張して、製品の表面に窪みや傷などが発生するおそれがある。
【００２５】
なおロール線圧は、気泡の噛み込みを防止する効果を考慮すると、上記の範囲内でもとくに２ｋｇｆ／ｃｍ以上、より好ましくは４ｋｇｆ／ｃｍ以上である。ただしロール線圧は、圧着ロール５自体や、あるいは圧着ロール５を保持する部材などの強度や耐久性などを考慮すると、その上限が、およそ２０ｋｇｆ／ｃｍ程度であるのが好ましい。
【００２６】
また図の例では、アクリル系樹脂板１と保護フィルム２、２とを水平方向に送りつつ貼り合わせ処理しているが、送り方向は垂直方向であってもよい。
アクリル系樹脂板１と保護フィルム２、２の送りは、第１の圧着ロール４、４および第２の圧着ロール５、５のうちの少なくとも１つを回転駆動させて行ってもよいし、別に送り装置を設けて、これらの圧着ローラはいずれも、かかる送り部材によるアクリル系樹脂板１と保護フィルム２、２の送りにしたがって、従動回転するだけとしてもよい。
【００２７】
その他、本発明の要旨を変更しない範囲で、種々の変更を施すことができる。
【００２８】
【実施例】
以下に本発明を、実施例、比較例に基づいて説明するが、本発明の構成は、これらの実施例に限定されるものではない。
実施例１
図１に示すように、アクリル系樹脂板１〔住友化学（株）製の商品名スミペックＳＡ、厚み５ｍｍの注型板〕と、ロールから繰り出した２枚の保護フィルム２、２〔いずれも東レ合成フィルム（株）製の品番＃７５７１、高密度ポリエチレン（ＨＤＰＥ）製の厚み７５μｍの樹脂フィルムの片面に、接着層が形成されたもの〕とを、各保護フィルム２の接着層がアクリル系樹脂板１側となるように重ね合わせて、一対の圧着ロール４、４〔いずれもその表面がシリコーンゴムにて形成されたもの、直径１６０ｍｍ〕の間を通過させて互いに貼り合わせたのち、かかる一対の圧着ロール４、４の後方、６００ｍｍの位置に配置した一対の第２の圧着ロール５、５〔やはり、いずれもその表面がシリコーンゴムにて形成されたもの、直径１６０ｍｍ〕の間を通過させて圧着して、保護フィルム付きアクリル系樹脂板を製造した。
【００２９】
圧着ロール４、４による貼り合わせの条件は、ロール温度２０℃〔両ロール共通〕、線圧１０ｋｇｆ／ｃｍ、送り速度５．０ｍ／分とし、第２の圧着ロール５、５による圧着の条件は、ロール温度１５０℃〔両ロール共通〕、線圧１０ｋｇｆ／ｃｍ、送り速度５．０ｍ／分とした。
製造された保護フィルム付きアクリル系樹脂板を目視にて観察したところ、アクリル系樹脂板と保護フィルムとの間に皺や気泡は確認できなかった。
【００３０】
つぎにこの保護フィルム付きアクリル系樹脂板１０を、図２に示すように、縦Ｙ1＝３００ｍｍ、横Ｘ1＝３００ｍｍの正方形に切り出し、ついで板表面温度１８０℃の条件で真空成形して、その中心部に、縦Ｙ2＝１７０ｍｍ、横Ｘ2＝１７０ｍｍ、高さＨ1＝７０ｍｍの、直方体状の凸部１０ａを有する成形品を製造した。
【００３１】
そして成型品の表裏両面から保護フィルムを剥がしたのち、両面を目視にて観察したところ、窪みや傷などは全く観察されなかった。
【００３２】
比較例１
圧着ロール４、４による貼り合わせの条件のうちロール温度を２０℃〔両ロール共通〕とし、かつ第２の圧着ロール５、５による圧着の条件のうちロール温度を２０℃〔両ロール共通〕としたこと以外は実施例１と同様にして保護フィルム付きアクリル系樹脂板を製造した。
【００３３】
製造された保護フィルム付きアクリル系樹脂板を目視にて観察したところ、アクリル系樹脂板と保護フィルムとの間に、その全面にわたって、多数の気泡が確認された。
またかかる保護フィルム付きアクリル系樹脂板を用いて、実施例１と同条件で真空成形して、同寸法の成形品を製造し、その表裏両面から保護フィルムを剥がしたのち、両面を目視にて観察したところ、成形品の両面の全面にわたって、多数の窪みや傷などが観察された。
【００３４】
比較例２
実施例１において、圧着ロール４、４による貼り合わせの条件のうちロール温度を１５０℃〔両ロール共通〕としたこと以外は実施例１と同様にして保護フィルム付きアクリル系樹脂板を製造した。
製造された保護フィルム付きアクリル系樹脂板を目視にて観察したところ、アクリル系樹脂板と保護フィルムとの間に、気泡の発生は見られないものの、フィルムに皺が発生し、保護フィルムの端部に熱収縮によると考えられる剥がれが確認された。
【００３５】
【発明の効果】
以上、詳述したように本発明の製造方法によれば、アクリル系樹脂板に保護フィルムを貼り合わせる際に、保護フィルムに皺が発生するのを防止すると共に、両者の間に気泡が噛み込まれるのを極力防止して、たとえば深ものなどの、通常よりも高温での熱成形が必要な製品であっても、気泡による窪みや傷を生じることなく製造できる保護フィルム付きアクリル系樹脂板を製造できるという特有の作用効果を奏する。
【図面の簡単な説明】
【図１】本発明の保護フィルム付きアクリル系樹脂板の製造方法を実施するために使用される装置の一例を示す概略図である。
【図２】実施例、比較例で製造された保護フィルム付きアクリル系樹脂板の特性を評価するために、かかるアクリル系樹脂板から形成した成形品の外観を示す斜視図である。
【符号の簡単な説明】
１ アクリル系樹脂板
２ 保護フィルム
４ 第１の圧着ロール
５ 第２の圧着ロール
１０ 保護フィルム付きアクリル系樹脂板[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing an acrylic resin plate with a protective film, in which a protective film for surface protection is bonded to at least one surface thereof.
[0002]
[Prior art]
As the name suggests, acrylic resin plates are supplied in the form of plates with various thicknesses, which are processed into secondary products such as machining and thermoforming. When the surface is scratched, the commercial value is lowered, so usually, at least one side of the protective film is attached as an acrylic resin plate with a protective film and the protective film is not peeled off. The product is manufactured by secondary processing as it is.
[0003]
As the protective film, a resin film such as a polyolefin-based resin or a polyester-based resin is becoming more popular than the conventional paper-made ones.
This is because the above-mentioned resin film follows the deformation of the acrylic resin plate during thermoforming such as vacuum forming and press forming, and deforms without peeling or interfering with processing. This is also because it effectively functions as a surface protection of the surface [for example, JP-A-62-82018, JP-A-2-88218, JP-A-2-88219, JP-A-7-164598, 7-502468 gazette etc.].
[0004]
[Problems to be solved by the invention]
However, when a conventional acrylic resin plate with a protective film is thermoformed at a higher temperature than usual in order to produce a deep product, for example, it is bitten between the two when the protective film is bonded to the acrylic resin plate. As a result of the entrained bubbles expanding, the surface of the acrylic resin plate that has been softened by heating may be indented or damaged by the bubbles.
[0005]
The object of the present invention is to prevent bubbles from being caught between the two when the protective film is bonded to the acrylic resin plate as much as possible. An object of the present invention is to provide a production method for obtaining an acrylic resin plate with a protective film that can be produced without causing dents or scratches due to bubbles even if it is a necessary product.
[0006]
[Means for Solving the Problems]
In order to solve the above-mentioned problems, the inventors have made various studies on the conditions for laminating a protective film on at least one surface of an acrylic resin plate and passing between a pair of pressure-bonding rolls to bond them together.
As a result, among the above-described pressure-bonding rolls, the first pressure-bonding roll does not particularly add a heating function, and when the temperature of the second pressure-bonding roll is set to be higher than a predetermined value, it is between the acrylic resin plate and the protective film. It has been found that it is possible to produce an acrylic resin plate with a protective film that suppresses entrapment of wrinkles and bubbles and does not cause dents or scratches due to expansion of bubbles even when thermoformed at a higher temperature than usual.
[0007]
That is, in the method for producing an acrylic resin plate with a protective film of the present invention, the protective film is superimposed on at least one surface of the acrylic resin plate, and passed between a pair of first pressure-bonding rolls that do not have a heating function. Next, at least one side of the acrylic resin plate is passed through the pair of second pressure-bonding rolls at which the roll temperature on the side where the protective film is overlapped is set to 50 ° C. or higher. It is characterized by bonding.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
In the following, the present invention will be described with reference to FIG. 1 which shows an example of an apparatus used for its implementation. The example of a figure has shown the case where the protective film 2 and 2 are bonded together on both surfaces of the acrylic resin board 1, respectively, and the acrylic resin board 10 with a protective film is manufactured.
[0009]
Among the above, the acrylic resin plate 1 is made of various acrylic resins such as polymethyl methacrylate and a copolymer having methyl methacrylate as a main component, for example, in various thicknesses according to product standards. The formed plate material is used.
Moreover, as this acrylic resin board 1, what was manufactured by conventionally well-known various manufacturing methods, such as a casting method (casting polymerization method) and a melt extrusion method, is used, for example.
[0010]
Among these, the acrylic resin plate 1 formed by the former casting method has excellent surface smoothness in addition to the high transparency of the acrylic resin, and therefore the acrylic resin plate formed by such a casting method. From the acrylic resin plate 10 with a protective film manufactured by the manufacturing method of the present invention using the resin plate 1, the occurrence of the dents and scratches due to the expansion of the bubbles described above by adopting the configuration of the present invention. Combined with the effect of preventing the above, it is possible to produce a very beautiful product with excellent surface smoothness by secondary processing such as thermoforming.
[0011]
When the latter melt extrusion method is adopted, the acrylic resin plate 1 continuously extruded from the extruder can be continuously supplied to the laminating apparatus shown in FIG. In that case, the continuous and efficient production of the acrylic resin plate 10 with the protective film becomes possible.
As the protective film 2 to be bonded to the acrylic resin plate 1, any of those formed with the same resin film as that normally used can be used.
[0012]
Specifically, for example, a polyolefin film such as a polyethylene film or a polypropylene film, a polyester film such as a polyethylene terephthalate film, or a laminated film thereof can be cited as a suitable resin film.
The thickness of the resin film is not particularly limited, but is preferably about 30 to 100 μm, particularly about 40 to 90 μm.
[0013]
If the thickness of the resin film is less than 30 μm, the effect of protecting the surface of the acrylic resin plate 1 by the protective film 2 becomes insufficient, and the surface may be damaged during secondary processing such as thermoforming. . Moreover, it is preferable that the thickness of a resin film is 100 micrometers or less at the point of the economical efficiency of a resin film, and the ease of peeling of the protective film 2 after secondary processing.
[0014]
An adhesive layer having adhesiveness to the acrylic resin plate 1 is provided on one side of the resin film.
The adhesive layer can bond the resin film and the acrylic resin plate 1 without damaging the surface of the acrylic resin plate 1 and when the protective film 2 is peeled off from the surface of the acrylic resin plate 1 after the secondary processing. In addition, it is formed of various adhesives and pressure-sensitive adhesives that are conventionally known for protective films that can be removed cleanly without remaining on the surface of the acrylic resin plate 1.
[0015]
Suitable examples of the adhesive for the adhesive layer include, but are not limited to, ethylene-vinyl acetate copolymer (EVA), very low density polyethylene (VLDPE), linear low density polyethylene (LLDPE), and the like. And an adhesive obtained by adding a tackifier such as a hydrogenated terpene resin, a terpene resin, a terpene phenol resin, and a petroleum resin to the low melting point thermoplastic resin.
[0016]
The thickness of the adhesive layer only needs to ensure sufficient adhesiveness that does not peel off following the deformation of the acrylic resin plate 1 during secondary processing, particularly thermoforming, and is usually about 10 to 50 μm. .
Said protective film 2 is manufactured by forming an adhesive layer continuously by the roll coat method etc. on the single side | surface of the resin film manufactured continuously by the inflation method, T-die extrusion method etc., for example.
[0017]
In order to bond the acrylic resin plate 1 and the two protective films 2 and 2 together using the apparatus shown in FIG. 1, first, the acrylic resin plate 1 having a predetermined thickness manufactured in a separate process. As shown by white arrows in the figure, two protective films 2 and 2 that are bonded to both surfaces of the acrylic resin plate 1 and two rolls 20 and 20 wound with the protective films 2 and 2 are wound. Then, as shown by solid arrows in the drawing, the feed rollers 3 and 3 are supplied between the first pressure-bonding rolls 4 and 4 and between the second pressure-bonding rolls 5 and 5, respectively.
[0018]
Then, the supplied acrylic resin plate 1 and the two protective films 2 and 2 are bonded to each other by passing between the pair of pressure-bonding rolls 4 and 4.
In the bonding step, as described above, the temperature of the first rolls 4 and 4 is not particularly added to the heating function, and is passed at room temperature, and the second roll temperatures 5 and 5 are heated to 50 ° C. or higher. Pass between these rolls.
That is, when the second roll temperature is less than 50 ° C., the effect of suppressing air bubbles from being caught between the acrylic resin plate 1 and the protective film 2 is not obtained, and at the time of thermoforming as before. The air bubbles caught between the two expands, and a dent or scratch is generated on the surface of the product.
[0019]
Of the above, the roll temperature is preferably 80 ° C. or higher, and more preferably 85 ° C. or higher, even within the above range, in consideration of the effect of suppressing the entrapment of bubbles.
Moreover, although roll temperature is not limited to this, It is preferable that it is about 150 degreeC or less. When the roll temperature exceeds 150 ° C., the protective film 2 is more easily attached to the surface of the pressure-bonding roll 4 than the surface of the acrylic resin plate 1, and the acrylic resin plate 1 and the protective film 2 are good. There is a risk that it will not be possible to attach to the.
[0020]
In the present invention, if at least the side of the pair of pressure-bonding rolls 5 and 5 on which the protective film 2 is superposed is heated to the above-mentioned roll temperature, the other may or may not be heated. However, particularly when the protective films 2 and 2 are bonded to both surfaces of the acrylic resin plate 1 as in this example, the pair of pressure-bonding rolls 5 and 5 are both heated to the above-described roll temperature. However, both of the protective films 2 and 2 on both sides are preferable because generation of bubbles can be suppressed.
[0021]
In order to heat each crimping roll 5 to the above-mentioned roll temperature, for example, a heater is provided in the vicinity thereof, or a heater using a heat medium, an electromagnetic induction heating type heater, or the like is provided inside each crimping roll 5. Or just install it.
Each crimping roll 4, 4 and 5, 5 can be formed of various materials such as metal, for example, but in order to bond the protective film 2 to the acrylic resin plate 1 satisfactorily, a pair of crimping rolls It is preferable that at least the surface of at least one of 4, 4, and 5, 5 is formed of an elastic material such as rubber. In particular, in order to prevent the adhesion of the protective film 2 to the pressure-bonding rolls 4, 4, 5, 5 and the like, it is preferable to use silicone rubber as the elastic material.
[0022]
In the present invention, it is essential that the pressure-bonding rolls 4 and 4 are rolls having no heating function. When the pressure rolls 4 and 4 have the same heating function as the pressure rolls 5 and 5 and pressurize at 50 ° C. or higher, bubbles can be prevented from entrainment, but wrinkles occur when the surface protective film is bonded. There is.
[0023]
The feeding speed of the laminate of the acrylic resin plate 1 and the protective film 2 that passes between the pressure-bonding rolls 4, 4, 5, and 5 is such that bubbles are generated between the acrylic resin plate 1 and the protective film 2. Considering the effect of suppressing biting, it is 20 m / min or less, preferably 12 m / min or less.
The feed rate is 1 m / min or more, preferably 5 m / min, considering the productivity of the acrylic resin plate 10 with a protective film.
[0024]
The conditions other than the above-described roll temperature and feed rate in the bonding step are not particularly limited, but the roll linear pressure of the pressure-bonding roll 5 is preferably 1 kgf / cm or more.
When the roll linear pressure is less than 1 kgf / cm, the effect of suppressing air bubbles from being caught between the acrylic resin plate 1 and the protective film 2 becomes insufficient, and at the time of thermoforming, if not as much as conventional. There is a possibility that the air bubbles caught between the two expands and a dent or a flaw is generated on the surface of the product.
[0025]
Note that the roll linear pressure is 2 kgf / cm or more, more preferably 4 kgf / cm or more, even within the above range, considering the effect of preventing the bubble from being caught. However, the upper limit of the roll linear pressure is preferably about 20 kgf / cm in consideration of the strength and durability of the pressure-bonding roll 5 itself or a member for holding the pressure-bonding roll 5.
[0026]
In the example of the figure, the acrylic resin plate 1 and the protective films 2 and 2 are bonded together while being fed in the horizontal direction, but the feeding direction may be the vertical direction.
The acrylic resin plate 1 and the protective films 2 and 2 may be fed by rotating and driving at least one of the first pressure-bonding rolls 4 and 4 and the second pressure-bonding rolls 5 and 5. A feeding device may be provided, and any of these pressure-bonding rollers may be rotated only in accordance with the feeding of the acrylic resin plate 1 and the protective films 2 and 2 by the feeding member.
[0027]
In addition, various changes can be made without departing from the scope of the present invention.
[0028]
【Example】
The present invention will be described below based on examples and comparative examples, but the configuration of the present invention is not limited to these examples.
Example 1
As shown in FIG. 1, an acrylic resin plate 1 (trade name Sumipec SA manufactured by Sumitomo Chemical Co., Ltd., a casting plate having a thickness of 5 mm) and two protective films 2 and 2 [both of which are manufactured by Toray Industries, Inc. Synthetic Film Co., Ltd., product number # 7571, a high-density polyethylene (HDPE) resin film having a thickness of 75 μm with an adhesive layer formed on one side], and the adhesive layer of each protective film 2 is an acrylic resin After being laminated so as to be on the plate 1 side and passing between a pair of pressure-bonding rolls 4 and 4 (both whose surfaces are formed of silicone rubber, diameter 160 mm) and pasting each other, the pair A pair of second pressure-bonding rolls 5 and 5 arranged at a position 600 mm behind the pressure-bonding rolls 4 and 4 (both of which the surface is formed of silicone rubber, diameter 160 m Crimp is passed between] was prepared the protective film with an acrylic resin plate.
[0029]
The conditions for bonding with the pressure-bonding rolls 4 and 4 are as follows: roll temperature 20 ° C. (common to both rolls), linear pressure 10 kgf / cm, feed rate 5.0 m / min. The roll temperature was 150 ° C. [common to both rolls], the linear pressure was 10 kgf / cm, and the feed rate was 5.0 m / min.
When the manufactured acrylic resin plate with a protective film was visually observed, no wrinkles or bubbles were observed between the acrylic resin plate and the protective film.
[0030]
Next, as shown in FIG. 2, this acrylic resin plate 10 with a protective film is cut into a square of length Y 1 = 300 mm and width X 1 = 300 mm, and then vacuum-formed at a plate surface temperature of 180 ° C. A molded product having a rectangular parallelepiped convex portion 10a having a longitudinal Y 2 = 170 mm, a lateral X 2 = 170 mm, and a height H 1 = 70 mm was produced at the center.
[0031]
And after peeling off a protective film from both front and back of a molded article, when both surfaces were observed visually, a hollow, a crack, etc. were not observed at all.
[0032]
Comparative Example 1
Among the bonding conditions of the pressure-bonding rolls 4 and 4, the roll temperature is 20 ° C. (common to both rolls), and among the pressure-bonding conditions of the second pressure-bonding rolls 5 and 5, the roll temperature is 20 ° C. (common to both rolls). Except that, an acrylic resin plate with a protective film was produced in the same manner as in Example 1.
[0033]
When the manufactured acrylic resin plate with a protective film was visually observed, a large number of bubbles were observed across the entire surface between the acrylic resin plate and the protective film.
Also, using such an acrylic resin plate with a protective film, vacuum-molding under the same conditions as in Example 1 to produce a molded product of the same dimensions, and after peeling off the protective film from both the front and back surfaces, both sides are visually observed As a result of observation, numerous depressions and scratches were observed over the entire surface of both sides of the molded product.
[0034]
Comparative Example 2
In Example 1, an acrylic resin plate with a protective film was produced in the same manner as in Example 1 except that the roll temperature was 150 ° C. [common to both rolls] among the bonding conditions by the pressure-bonding rolls 4 and 4.
When the manufactured acrylic resin plate with a protective film was visually observed, no bubbles were observed between the acrylic resin plate and the protective film, but wrinkles occurred on the film, and the edges of the protective film Peeling considered to be due to heat shrinkage was confirmed on the part.
[0035]
【The invention's effect】
As described above in detail, according to the manufacturing method of the present invention, when the protective film is bonded to the acrylic resin plate, the protective film is prevented from wrinkling and air bubbles are caught between the two. An acrylic resin plate with a protective film that can be produced without causing dents or scratches due to bubbles, even for products that require thermoforming at a higher temperature than usual, such as deep products. There is a unique effect that it can be manufactured.
[Brief description of the drawings]
FIG. 1 is a schematic view showing an example of an apparatus used for carrying out the method for producing an acrylic resin plate with a protective film of the present invention.
FIG. 2 is a perspective view showing an appearance of a molded product formed from such an acrylic resin plate in order to evaluate the characteristics of the acrylic resin plate with a protective film manufactured in Examples and Comparative Examples.
[Brief description of symbols]
DESCRIPTION OF SYMBOLS 1 Acrylic resin board 2 Protective film 4 1st press roll 5 2nd press roll 10 Acrylic resin board with protective film

Claims (5)

アクリル系樹脂板の少なくとも片面に保護フィルムを重ね合わせて、加熱機能を有さない一対の第１の圧着ロール間を通過させて、次いで、少なくとも、当該保護フィルムを重ね合わせた側のロール温度が５０℃以上に設定された一対の第２の圧着ロール間を通過させて、上記アクリル系樹脂板の少なくとも片面に、上記保護フィルムを貼り合わせることを特徴とする保護フィルム付きアクリル系樹脂板の製造法。A protective film is overlaid on at least one surface of the acrylic resin plate, passed between a pair of first pressure-bonding rolls not having a heating function, and then at least the roll temperature on the side where the protective film is overlaid is Production of an acrylic resin plate with a protective film, wherein the protective film is bonded to at least one surface of the acrylic resin plate by passing between a pair of second pressure-bonding rolls set to 50 ° C. or higher. Law. 一対の圧着ロール間を通過させる、アクリル系樹脂板と保護フィルムとを重ね合わせたものの送り速度が２０ｍ／分以下である請求項１記載の保護フィルム付きアクリル系樹脂板の製造法。2. The method for producing an acrylic resin plate with a protective film according to claim 1, wherein a feeding speed of a laminate of the acrylic resin plate and the protective film, which is passed between a pair of pressure-bonding rolls, is 20 m / min or less. 圧着ロールのロール線圧が１ｋｇｆ／ｃｍ以上である請求項１記載の保護フィルム付きアクリル系樹脂板の製造法。The method for producing an acrylic resin plate with a protective film according to claim 1, wherein the linear pressure of the pressure-bonding roll is 1 kgf / cm or more. 一対の圧着ロール間を通過して互いに貼り合わされたアクリル系樹脂板と保護フィルムとをさらに、一対の第２の圧着ロール間を通過させて圧着する請求項１記載の保護フィルム付きアクリル系樹脂板の製造法。The acrylic resin plate with a protective film according to claim 1, wherein the acrylic resin plate and the protective film, which are bonded to each other through a pair of pressure-bonding rolls, are further bonded by passing between a pair of second pressure-bonding rolls. Manufacturing method. 保護フィルムとして、その片面にアクリル系樹脂板への接着性を有する接着層を設けた、ポリオレフィン系またはポリエステル系のフィルムを使用する請求項１記載の保護フィルム付きアクリル系樹脂板の製造法。The method for producing an acrylic resin plate with a protective film according to claim 1, wherein a polyolefin-based or polyester-based film provided with an adhesive layer having adhesiveness to the acrylic resin plate on one side is used as the protective film.
JP23697799A 1999-08-24 1999-08-24 Manufacturing method of acrylic resin board with protective film Expired - Fee Related JP4423713B2 (en)

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JP5471419B2 (en) * 2009-12-22 2014-04-16 東洋紡株式会社 Hard coat film for molding with protective film
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