JP4995163B2 - Manufacturing method of uneven thickness resin sheet - Google Patents

Manufacturing method of uneven thickness resin sheet Download PDF

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JP4995163B2
JP4995163B2 JP2008233376A JP2008233376A JP4995163B2 JP 4995163 B2 JP4995163 B2 JP 4995163B2 JP 2008233376 A JP2008233376 A JP 2008233376A JP 2008233376 A JP2008233376 A JP 2008233376A JP 4995163 B2 JP4995163 B2 JP 4995163B2
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resin sheet
roller
resin
sheet
temperature
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JP2010064386A (en
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卓弘 林
芳彦 佐野
隆一 勝本
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Fujifilm Corp
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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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/222—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length characterised by the shape of the surface
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B29C48/08—Flat, e.g. panels flexible, e.g. films
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/91—Heating, e.g. for cross linking
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911—Cooling
    • B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
    • B29C48/914—Cooling of flat articles, e.g. using specially adapted supporting means cooling drums
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911—Cooling
    • B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
    • B29C48/915—Cooling of flat articles, e.g. using specially adapted supporting means with means for improving the adhesion to the supporting means
    • B29C48/9155—Pressure rollers
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/918—Thermal treatment of the stream of extruded material, e.g. cooling characterized by differential heating or cooling
    • 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
    • B29C71/00—After-treatment of articles without altering their shape; Apparatus therefor
    • B29C71/02—Thermal after-treatment
    • 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0822—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using IR radiation
    • 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
    • B29C71/00—After-treatment of articles without altering their shape; Apparatus therefor
    • B29C71/02—Thermal after-treatment
    • B29C2071/022—Annealing
    • 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/12—Dielectric heating
    • B29C35/14—Dielectric heating for articles of indefinite length
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/24—Calendering
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/305—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets
    • 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
    • B29C71/00—After-treatment of articles without altering their shape; Apparatus therefor
    • B29C71/0063—After-treatment of articles without altering their shape; Apparatus therefor for changing crystallisation
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/25—Solid
    • B29K2105/253—Preform
    • B29K2105/256—Sheets, plates, blanks or films

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)

Description

本発明は、偏肉樹脂シートの製造方法に係り、特に、各種表示装置の背面に配される導光版や各種光学素子に使用するのに好適な偏肉樹脂シートの製造方法に関する。   The present invention relates to a method for manufacturing an uneven thickness resin sheet, and more particularly to a method for manufacturing an uneven thickness resin sheet suitable for use in a light guide plate and various optical elements disposed on the back surface of various display devices.

一般に、樹脂シートの押出成形においては、Ｔダイから押し出された溶融樹脂シートは、冷却ロールにより冷却され、その後、取引ロールにより引き取られながら搬送部での空冷により冷却・固化し、切断機で幅方向に切断されてシート状に成形される。   In general, in resin sheet extrusion molding, a molten resin sheet extruded from a T-die is cooled by a cooling roll, and then cooled and solidified by air cooling in a conveyance section while being taken up by a transaction roll, and is then cut by a cutting machine. Cut in the direction and formed into a sheet.

このようにして成形された樹脂シートは、成形時に、溶融させるための加熱、固化させるための冷却などの温度変化により、残留歪みが残存し易い。そのため、経時変化により形状が安定しなかったり、物性が充分に発揮されないという問題があった。   The resin sheet molded in this way tends to have residual strain due to temperature changes such as heating for melting and cooling for solidifying during molding. For this reason, there is a problem that the shape is not stable due to a change with time, and the physical properties are not sufficiently exhibited.

そこで、熱可塑性樹脂成形体品の残留歪みの緩和や変形を矯正する目的で、あるいは、結晶性熱可塑性樹脂成形品の結晶化を進行させて強度を高める目的で、いわゆるアニール処理が施されている。アニール処理は温度が高いほど短時間で大きな効果が得られるが、温度が高すぎると樹脂が溶融して所望の形状の成形体を得られないため、熱可塑性樹脂の場合は樹脂のガラス転移温度Ｔｇより２０〜４０℃低い温度、結晶性樹脂の場合は、実使用する最高温度より１０〜２０℃高い温度でアニールされるのが一般的である。   Therefore, so-called annealing treatment is applied for the purpose of relieving residual distortion and deformation of the thermoplastic resin molded article, or for the purpose of increasing the strength by promoting crystallization of the crystalline thermoplastic resin molded article. Yes. The higher the temperature, the greater the effect of annealing treatment, but the higher the temperature, the more the resin will melt and a molded product with the desired shape cannot be obtained. In the case of a thermoplastic resin, the glass transition temperature of the resin In the case of a crystalline resin that is 20 to 40 ° C. lower than Tg, it is generally annealed at a temperature that is 10 to 20 ° C. higher than the highest temperature actually used.

残留歪みの緩和や結晶化の進行の際には、局部的な体積変化が起こり、成形品の形状や寸法が若干変化するため、アニール処理は主に形状や寸法精度が厳しくない用途の成形品や、ほぼ等方的な形状の成形品で行われていた。シート状の成形品などでは厚み方向と長さ・幅方向の体積変化の挙動が異なるため、反りや波打ちなどの変形が起こりやすい。また、シートのサイズが大きいときには、昇温時に面内を均一に加熱することが困難であるため、不均一な昇温速度によっても変形が起こりやすい。平板でなく厚み分布がある形状の場合は、昇温速度が厚みによって局所的にことなるため、さらに変形が起こりやすかった。   When the residual strain is relaxed or crystallization progresses, a local volume change occurs, and the shape and dimensions of the molded product change slightly. Therefore, the annealing process is mainly used for products whose shape and dimensional accuracy are not strict. In addition, it has been performed with a molded product having an almost isotropic shape. A sheet-like molded product or the like is prone to deformation such as warping and undulation because the volume change behavior in the thickness direction and the length / width direction is different. In addition, when the size of the sheet is large, it is difficult to uniformly heat the surface during the temperature increase, and therefore deformation is likely to occur even with a non-uniform temperature increase rate. In the case of a shape having a thickness distribution instead of a flat plate, the rate of temperature increase locally varies depending on the thickness, and thus deformation is more likely to occur.

この対策として、例えば下記の特許文献１では、平板を積層した状態で側面および上下面に固定板を設置してアニールすることにより、アニールによる変形を防止する方法が開示されている。しかしながら、この方法では対象物が平板である場合は、アニールでの変形を抑制することができるが、厚み分布のあるシートには適用することができなかった。また積層することにより、内部まで伝熱するのに時間がかかってしまうためアニール時間が長くなり、また、アニールのセッティングにも時間がかかるため生産性が著しく低下するという問題があった。   As a countermeasure, for example, Patent Document 1 below discloses a method of preventing deformation due to annealing by setting and fixing a fixing plate on the side and upper and lower surfaces in a state where flat plates are laminated. However, in this method, when the object is a flat plate, deformation due to annealing can be suppressed, but it cannot be applied to a sheet having a thickness distribution. In addition, since lamination takes time to transfer heat to the inside, the annealing time becomes long, and it takes time to set the annealing, so that productivity is remarkably lowered.

アニール時間を短くするために、例えば、下記の特許文献２、３には、加熱手段として遠赤外線を用いて連続的にアニールする方法が開示されている。
特開２００５−４７１２６号公報 特公平７−１１２７１５号公報 特開平１１−１７２０２６号公報 In order to shorten the annealing time, for example, the following Patent Documents 2 and 3 disclose a method of continuously annealing using far infrared rays as a heating means.
JP 2005-47126 A Japanese Patent Publication No.7-112715 JP-A-11-172026

特許文献２、３に記載されている方法および装置は、従来の温風加熱方式に比べて成形品の加熱時間が飛躍的に短くなり、アニール処理時間を短くすることが可能であった。しかしながら、大量にアニール処理を行う必要がある場合は、さらにアニール処理時間を短くする必要があった。   In the methods and apparatuses described in Patent Documents 2 and 3, the heating time of the molded product is remarkably shortened as compared with the conventional hot air heating method, and the annealing treatment time can be shortened. However, when it is necessary to perform a large amount of annealing treatment, it is necessary to further shorten the annealing treatment time.

本発明はこのような事情に鑑みてなされたものであり、従来よりさらにアニール処理を短くして、生産性を向上させることができる偏肉樹脂シートの製造方法を提供することを目的とする。   This invention is made | formed in view of such a situation, and it aims at providing the manufacturing method of the uneven thickness resin sheet which can shorten an annealing process conventionally and can improve productivity.

本発明の請求項１によれば、溶融した樹脂をダイからシート状に押し出す押出工程と、押し出した溶融樹脂シートを型ローラとニップローラで挟み、該型ローラの表面の加工形状を該溶融樹脂シートに転写し、冷却固化することにより樹脂シートを成形するシート成形工程と、前記樹脂シートを剥離ローラから剥離する剥離工程と、前記樹脂シートを加熱装置で加熱しながら、引取ローラで引っ張り搬送する搬送工程と、前記樹脂のガラス転移温度をＴｇとした時、前記樹脂シートの幅方向における表面の最高温度が（Ｔｇ−４０）℃以上Ｔｇ℃以下の温度で、前記樹脂シートを切断手段により所定の長さに切断する切断工程と、前記切断手段により切断された樹脂シートを、（Ｔｇ−４０）℃以上Ｔｇ℃以下の温度で連続的にアニール処理を行うアニール処理工程と、を有することを特徴とする偏肉樹脂シートの製造方法を提供する。   According to the first aspect of the present invention, the extrusion process of extruding the molten resin from the die into a sheet shape, the extruded molten resin sheet is sandwiched between the mold roller and the nip roller, and the processed shape of the surface of the mold roller is determined by the molten resin sheet A sheet forming step of forming a resin sheet by transferring to a sheet and cooling and solidifying, a peeling step of peeling the resin sheet from a peeling roller, and a conveyance of pulling and conveying the resin sheet by a heating device while heating the resin sheet And when the glass transition temperature of the resin is defined as Tg, the maximum temperature of the surface in the width direction of the resin sheet is (Tg−40) ° C. to Tg ° C. The step of cutting to length and the resin sheet cut by the cutting means are continuously annealed at a temperature of (Tg-40) ° C. or higher and Tg ° C. or lower. To provide a method of manufacturing uneven thickness resin sheet and having a annealing step of performing, the.

請求項１によれば、切断工程を樹脂シートの幅方向における表面の最高温度が（Ｔｇ−４０）℃以上Ｔｇ℃以下の温度を有する状態で切断を行い、さらに、次工程のアニール処理工程も（Ｔｇ−４０）℃以上Ｔｇ以下の温度で行っているので、切断工程後からアニール処理工程までに樹脂シートを冷却する必要がないため、アニール処理時間を減らすことができ、生産性を向上させることができる。   According to claim 1, the cutting step is performed in a state where the maximum surface temperature in the width direction of the resin sheet has a temperature of (Tg−40) ° C. or higher and Tg ° C. or lower. Since it is performed at a temperature of (Tg-40) ° C. or higher and Tg or lower, there is no need to cool the resin sheet from the cutting step to the annealing step, so the annealing time can be reduced and the productivity is improved. be able to.

請求項２は請求項１において、前記アニール処理工程は、前記樹脂シートを平面状の支持部材で支持して行うことを特徴とする。   A second aspect of the present invention according to the first aspect is characterized in that the annealing step is performed by supporting the resin sheet with a planar support member.

請求項２によれば、アニール処理工程時において、樹脂シートを平面状の支持部材で支持してアニール処理することで、高温で柔らかい状態の樹脂シートが自重により平らになり、樹脂シートの変形の矯正を容易に行うことができる。   According to the second aspect, in the annealing process, the resin sheet is supported by the planar support member and annealed, so that the resin sheet in a soft state at a high temperature is flattened by its own weight, and the resin sheet is deformed. Correction can be performed easily.

請求項３は請求項１または２において、前記樹脂シートの幅方向における厚み分布の、最厚部と最薄部の厚みの差が０．５ｍｍ以上５ｍｍ以下であることを特徴とする。   A third aspect is characterized in that, in the first or second aspect, the difference in thickness between the thickest part and the thinnest part of the thickness distribution in the width direction of the resin sheet is 0.5 mm or more and 5 mm or less.

請求項３によれば、厚み分布の最厚部と最薄部の差を上記範囲とすることにより、搬送工程およびアニール処理工程において、樹脂シートの温度調節を容易に行うことができるので、反りなどの形状変化を抑えることができる。   According to the third aspect, by setting the difference between the thickest portion and the thinnest portion of the thickness distribution within the above range, the temperature of the resin sheet can be easily adjusted in the transporting step and the annealing treatment step. The shape change such as can be suppressed.

本発明の偏肉樹脂シートの製造方法によれば、切断工程からアニール処理工程において、温度を維持しながら連続的に行っているため、樹脂シートを冷却する必要がないので、アニール処理の時間を短くすることができ、生産性を向上させることができる。   According to the manufacturing method of the uneven thickness resin sheet of the present invention, since the temperature is maintained continuously in the annealing process from the cutting process, it is not necessary to cool the resin sheet. It can be shortened and productivity can be improved.

以下、添付図面に従って、本発明に係る偏肉樹脂シートの製造方法の好ましい実施の形態ついて説明する。   Hereinafter, preferred embodiments of a method for producing an uneven thickness resin sheet according to the present invention will be described with reference to the accompanying drawings.

図１は、本発明に係る樹脂シートの製造方法の全体工程図であり、図２は各工程における装置構成を示す概念図である。   FIG. 1 is an overall process diagram of a method for producing a resin sheet according to the present invention, and FIG. 2 is a conceptual diagram showing an apparatus configuration in each process.

図１に示すように、本発明の偏肉樹脂シートの製造方法は、主として、原料の計量や混合を行う原料工程１００、溶融した樹脂を連続してシート状（帯状）に押し出す押出工程１１２と、押し出した溶融樹脂シート１４ａを冷却固化することにより樹脂シート１４を成形するシート成形工程１１４と、樹脂シート１４を剥離する剥離工程１１５と、剥離された樹脂シート１４を次工程である切断工程１２４に搬送する搬送工程１１６と、樹脂シート１４を所定サイズ（長さ・幅）に裁切断する切断工程１２４と、樹脂シート１４を徐冷し、残留歪みの除去を行うアニール処理工程１２６とで構成される。   As shown in FIG. 1, the manufacturing method of the uneven thickness resin sheet of the present invention mainly includes a raw material process 100 for measuring and mixing raw materials, an extrusion process 112 for continuously extruding molten resin into a sheet shape (band shape), and Then, the extruded molten resin sheet 14a is cooled and solidified to form a resin sheet 14; a peeling process 115 for peeling the resin sheet 14; and a cutting process 124 for removing the peeled resin sheet 14 as the next process. A transporting process 116 for transporting the resin sheet 14, a cutting process 124 for cutting the resin sheet 14 into a predetermined size (length / width), and an annealing process process 126 for gradually cooling the resin sheet 14 and removing residual distortion. Is done.

以下、図２を参照に本発明が適用される樹脂シートの製造装置の主要な構成を説明する。   Hereinafter, the main structure of the resin sheet manufacturing apparatus to which the present invention is applied will be described with reference to FIG.

図２に示すように、原料工程１００では、原料サイロ１２８（又は原料タンク）及び添加物サイロ１３０（又は添加物タンク）から自動計量機１３２に送られた原料樹脂および添加物が自動計量され混合器１３４で原料樹脂と添加物が所定比率になるように混合される。   As shown in FIG. 2, in the raw material process 100, the raw resin and additive sent from the raw material silo 128 (or raw material tank) and additive silo 130 (or additive tank) to the automatic weighing machine 132 are automatically measured and mixed. In the vessel 134, the raw material resin and the additive are mixed at a predetermined ratio.

本発明に適用される原料樹脂の樹脂材料としては、熱可塑性樹脂を用いることができ、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（ＰＣ）、ポリスチレン樹脂（ＰＳ）、ＭＳ樹脂、ＡＳ樹脂、ポリプロピレン樹脂（ＰＰ）、ポリエチレン樹脂（ＰＥ）、ポリエチレンテレフタレート樹脂（ＰＥＴ）、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などが挙げられる。   As the resin material of the raw material resin applied to the present invention, a thermoplastic resin can be used, for example, polymethyl methacrylate resin (PMMA), polycarbonate resin (PC), polystyrene resin (PS), MS resin, AS resin. , Polypropylene resin (PP), polyethylene resin (PE), polyethylene terephthalate resin (PET), polyvinyl chloride resin (PVC), thermoplastic elastomer, or a copolymer thereof, cycloolefin polymer, and the like.

また、これらの熱可塑性樹脂に光拡散粒子を含んでもよく、光拡散粒子としては、例えば、シリコーンやシリカ、炭酸カルシウム、硫酸バリウム、水酸化アルミニウム、酸化チタン、ガラスビーズ、ケイ酸カルシウムなどの無機粒子やポリメチルメタクリレート粒子などが挙げられる。散乱粒子を添加する場合、最初に、原料樹脂に散乱粒子を所定濃度よりも高濃度に添加されたマスターペレットが造粒機で製造される。次いで、マスターバッチ方式を好適に採用することで、散乱粒子を所定濃度よりも高濃度に添加されたマスターペレットと散乱粒子が添加されていないベースペレットとが混合器１３４で所定比率混合される。散乱粒子以外の添加物を添加する場合も同様である。   Further, these thermoplastic resins may contain light diffusing particles. Examples of the light diffusing particles include inorganic materials such as silicone, silica, calcium carbonate, barium sulfate, aluminum hydroxide, titanium oxide, glass beads, and calcium silicate. Examples thereof include particles and polymethyl methacrylate particles. When adding scattering particles, first, master pellets in which scattering particles are added to a raw material resin at a concentration higher than a predetermined concentration are manufactured by a granulator. Next, by suitably adopting the master batch method, the master pellets to which the scattering particles are added at a higher concentration than the predetermined concentration and the base pellets to which the scattering particles are not added are mixed at a predetermined ratio by the mixer 134. The same applies when additives other than the scattering particles are added.

原料工程１００で適切に計量・混合された原料樹脂は押出工程１１２に送られる。   The raw resin appropriately weighed and mixed in the raw material process 100 is sent to the extrusion process 112.

押出工程１１２では、混合器１３４で混合された原料樹脂がホッパー１３６を介して押出機１３８に投入される。原料樹脂が押出機１３８により混練りされながら溶融される。押出機１３８は単軸式押出機及び多軸式押出機の何れでもよく、押出機１３８の内部を真空にするベント機能を含むものが好ましい。押出機１３８で溶融された原料樹脂は、スクリューポンプ又はギアポンプなどの定量ポンプ１４０により供給管１４２を介してダイ１２（例えばＴダイ）に送られる。ダイ１２からシート状に押し出された溶融樹脂シート１４ａは次にシート成形工程１１４に送られる。   In the extrusion step 112, the raw material resin mixed in the mixer 134 is charged into the extruder 138 through the hopper 136. The raw material resin is melted while being kneaded by the extruder 138. The extruder 138 may be either a single-screw extruder or a multi-screw extruder, and preferably includes a vent function that evacuates the interior of the extruder 138. The raw material resin melted by the extruder 138 is sent to a die 12 (for example, a T die) through a supply pipe 142 by a metering pump 140 such as a screw pump or a gear pump. The molten resin sheet 14 a extruded from the die 12 into a sheet is then sent to the sheet forming step 114.

シート成形工程１１４では、ダイ１２から押し出された溶融樹脂シート１４ａが、型ローラ１６とニップローラ１８とで挟まれる。溶融樹脂シート１４ａが幅方向に厚み分布を持つ形状に成形されながら、冷却・固化される。固化した樹脂シート１４は剥離ローラ２０で剥離される（剥離工程）。シート成形工程１１４を経た樹脂シート１４は次に搬送工程１１６に送られる。   In the sheet forming step 114, the molten resin sheet 14 a extruded from the die 12 is sandwiched between the mold roller 16 and the nip roller 18. The molten resin sheet 14a is cooled and solidified while being formed into a shape having a thickness distribution in the width direction. The solidified resin sheet 14 is peeled off by the peeling roller 20 (peeling step). The resin sheet 14 that has undergone the sheet forming step 114 is then sent to a conveying step 116.

搬送工程１１６は、剥離ローラ２０から剥離された樹脂シート１４を切断工程１２４に搬送する工程である。搬送は引取ロール２４により樹脂シートが引っ張れることにより行う。本発明は、搬送工程において樹脂シート１４を加熱し、その余熱を利用してアニール処理工程を行っている。そのため、搬送工程において、加熱装置を用いて、樹脂シートの温度調節を行っている。   The transporting process 116 is a process of transporting the resin sheet 14 peeled from the peeling roller 20 to the cutting process 124. The conveyance is performed by the resin sheet being pulled by the take-up roll 24. In the present invention, the resin sheet 14 is heated in the transport process, and the annealing process is performed using the remaining heat. Therefore, in the conveyance process, the temperature of the resin sheet is adjusted using a heating device.

搬送工程１１６により温度制御され搬送された樹脂シート１４は、切断工程１２４に送られる。切断工程１２４は樹脂シート１４を所定長さに切り揃える工程である。また、樹脂シート１４の幅方向両端部分（耳部）を切除する工程を有することもできる。切断手段１７４としては、レーザーカッター、電子ビーム切断、超音波カッターなどを用いることができる。また、受け刃と押し当て刃とからなるギロチンタイプの切断手段を用いることもできる。   The resin sheet 14 whose temperature is controlled and conveyed by the conveying step 116 is sent to the cutting step 124. The cutting step 124 is a step of cutting the resin sheet 14 to a predetermined length. Moreover, it can also have the process of excising the width direction both ends (ear part) of the resin sheet 14. FIG. As the cutting means 174, a laser cutter, an electron beam cutting, an ultrasonic cutter, or the like can be used. A guillotine-type cutting means composed of a receiving blade and a pressing blade can also be used.

また、樹脂シートに形成された形状が複数の厚肉部を有している場合には、切断工程１２４において、その形状の継ぎ目で搬送方向に切断する工程も有することができる。   Further, when the shape formed on the resin sheet has a plurality of thick portions, the cutting step 124 can also include a step of cutting in the conveyance direction at the joint of the shape.

また、樹脂シート１４は、シート成形工程１１４で所定の形状に成形されるが、樹脂シート１４の両縁部は、その形状において中央部に比較して寸法精度が悪くなる。また、残留歪みも大きくなるので、切断することが好ましい。切断部分は、樹脂シート１４の両端部各２０〜３０ｍｍ切断することが好ましい。樹脂シートの両縁部は図２に示すように、樹脂シートを搬送方向と直交する方向に切断する前に切断することもできるし、所定の形状にシートを切断し、アニール処理を行う前に切断することもできる。   Moreover, although the resin sheet 14 is shape | molded by the predetermined | prescribed shape in the sheet | seat shaping | molding process 114, both edge parts of the resin sheet 14 become worse in dimensional accuracy compared with a center part in the shape. Moreover, since residual distortion also becomes large, it is preferable to cut | disconnect. The cut part is preferably cut at 20 to 30 mm at both ends of the resin sheet 14. As shown in FIG. 2, both edges of the resin sheet can be cut before cutting the resin sheet in a direction perpendicular to the conveying direction, or before cutting the sheet into a predetermined shape and performing an annealing treatment. It can also be cut.

切断された樹脂シート１４の一部は回収ボックス１７６で回収され、回収された樹脂は廃棄又は再利用される。   A part of the cut resin sheet 14 is collected in a collection box 176, and the collected resin is discarded or reused.

切断された樹脂シート１４は、ローラ１９４により駆動されるコンベアベルト１９６で、アニール処理工程１２６に搬送される。アニール処理工程は、樹脂シート１４の急激な温度変化を防止するために設けられたものである。樹脂シート１４に急激な温度変化を生じた場合、たとえば、樹脂シート１４の表面近傍が塑性状態になっているのに、樹脂シート１４の内部が弾性状態であり、この部分の硬化による収縮で樹脂シート１４の表面形状が悪化する。また、樹脂シート１４の表裏面に温度差を生じ、樹脂シート１４に反りを生じる不具合もある。   The cut resin sheet 14 is conveyed to the annealing process 126 by the conveyor belt 196 driven by the roller 194. The annealing process is provided to prevent a rapid temperature change of the resin sheet 14. When a sudden temperature change occurs in the resin sheet 14, for example, the inside of the resin sheet 14 is in an elastic state while the vicinity of the surface of the resin sheet 14 is in a plastic state. The surface shape of the sheet 14 is deteriorated. Further, there is a problem that a temperature difference occurs between the front and back surfaces of the resin sheet 14 and the resin sheet 14 is warped.

次に上記各工程のうち、本発明の特徴をなすシート成形工程１１４からアニール処理工程１２６の詳細について図３および図４により説明する。   Next, among the above steps, details of the sheet forming step 114 to the annealing step 126 that characterize the present invention will be described with reference to FIGS.

樹脂シートの製造ライン１０は、押出機１３８によって溶融された原料樹脂をシート状に賦形するためのダイ１２と、表面に偏肉形状が形成された型ローラ１６と、型ローラ１６に対向配置されるニップローラ１８と、型ローラ１６に対向配置される剥離ローラ２０と、樹脂シート１４の温度を制御する加熱装置２２と、により構成される。   The resin sheet production line 10 includes a die 12 for shaping the raw material resin melted by the extruder 138 into a sheet shape, a mold roller 16 having an uneven thickness formed on the surface, and a mold roller 16 facing the mold roller 16. The nip roller 18 is formed, the peeling roller 20 is disposed opposite to the mold roller 16, and the heating device 22 that controls the temperature of the resin sheet 14.

ダイ１２より押し出したシート状の溶融樹脂シート１４ａを、型ローラ１６と型ローラ１６に対向配置されるニップローラとで挟圧し、型ローラ１６表面の偏肉形状の反転型を樹脂シート１４に転写して成形し、樹脂シート１４を型ローラ１６に対向配置される剥離ローラ２０に巻き掛けることにより徐冷し、歪みが除去された状態で、搬送される。   The sheet-shaped molten resin sheet 14 a extruded from the die 12 is pressed between the mold roller 16 and a nip roller disposed opposite to the mold roller 16, and the uneven shape inverted mold on the surface of the mold roller 16 is transferred to the resin sheet 14. Then, the resin sheet 14 is gradually cooled by being wound around a peeling roller 20 disposed opposite to the mold roller 16, and is transported in a state where distortion is removed.

この樹脂シートの製造において、ダイ１２の樹脂シート１４の押し出し速度は、０．１〜５０ｍ／分、好ましくは０．３〜３０ｍ／分の値が採用できる。したがって、型ローラ１６の周速も略これに一致させる。なお、各ローラの速度ムラは、設定値に対して、１％以内に制御することが好ましい。   In the production of this resin sheet, the extrusion speed of the resin sheet 14 of the die 12 can be 0.1 to 50 m / min, preferably 0.3 to 30 m / min. Accordingly, the peripheral speed of the mold roller 16 is also substantially matched with this. In addition, it is preferable to control the speed unevenness of each roller within 1% with respect to the set value.

ニップローラ１８の型ローラ１６への押し付け圧は、線圧換算（各ニップローラの弾性変形による面接触を線接触と仮定して換算した値）で、０〜２００ｋＮ／ｍ（ｋｇｆ／ｃｍ）とすることが好ましく、０〜１００ｋＮ／ｍ（ｋｇｆ／ｃｍ）とするのがより好ましい。   The pressing pressure of the nip roller 18 against the mold roller 16 should be 0 to 200 kN / m (kgf / cm) in terms of linear pressure (value converted assuming that the surface contact due to elastic deformation of each nip roller is linear contact). Is more preferable, and 0 to 100 kN / m (kgf / cm) is more preferable.

型ローラ１６の表面には、例えば、図４（ａ）、（ｂ）に示される偏肉樹脂シートを成形するための反転形状が形成されている。図４は、成形後の樹脂シート１４の断面図である。すなわち、樹脂シート１４の裏面は平面であり、樹脂シート１４の表面には、走行方向に平行な直線状の偏肉形状面が形成されている。したがって、型ローラ１６の表面には、図４（ａ）、（ｂ）に示す形成後の樹脂シート１４の反転形状のエンドレス溝を形成すればよい。本発明の樹脂シートの製造方法により製造される偏肉樹脂シートの厚みは、樹脂シートの最厚部の厚みをＤｍａｘ、最薄部の厚みをＤｍｉｎとしたとき、最厚部と最薄部の厚み差Ｄｍａｘ−Ｄｍｉｎが０．５ｍｍ以上５ｍｍ以下であることが好ましく、より好ましくは０．５ｍｍ以上３ｍｍ以下であることがさらに好ましい。また、図４（ｂ）に示すように、厚肉の部分が２ヶ所以上ある場合のピッチＬは２００ｍｍ以上あることが好ましく、より好ましくは４００ｍｍ以上である。   On the surface of the mold roller 16, for example, a reverse shape for forming the uneven thickness resin sheet shown in FIGS. 4A and 4B is formed. FIG. 4 is a cross-sectional view of the resin sheet 14 after molding. That is, the back surface of the resin sheet 14 is a flat surface, and a linear uneven shape surface parallel to the traveling direction is formed on the surface of the resin sheet 14. Therefore, an endless groove having an inverted shape of the resin sheet 14 after the formation shown in FIGS. 4A and 4B may be formed on the surface of the mold roller 16. The thickness of the uneven thickness resin sheet produced by the method for producing a resin sheet of the present invention is such that the thickness of the thickest part of the resin sheet is Dmax and the thickness of the thinnest part is Dmin. The thickness difference Dmax−Dmin is preferably 0.5 mm or more and 5 mm or less, more preferably 0.5 mm or more and 3 mm or less. Moreover, as shown in FIG.4 (b), when there are two or more thick parts, the pitch L is preferably 200 mm or more, and more preferably 400 mm or more.

型ローラ１６の材質としては、各種鉄鋼部材、ステンレス鋼、銅、亜鉛、真鍮、これらの金属材料を芯金として、表面にゴムライニングしたもの、これらの金属材料にＨＣｒメッキ、Ｃｕメッキ、Ｎｉメッキなどのメッキを施したもの、セラミックス、及び各種の複合材料が採用できる。   The material of the mold roller 16 includes various steel members, stainless steel, copper, zinc, brass, and a metal lining of these metal materials, and a rubber lining on the surface. These metal materials are HCr plated, Cu plated, Ni plated. Those plated with ceramics, ceramics, and various composite materials can be used.

型ローラ表面の逆蒲鉾形状の形成は、ローラ表面の材質にもよるが、一般的にはＮＣ旋盤による切削加工と仕上げバフ加工との組み合わせが好ましく採用できる。また、他の公知の加工方法（切削加工、超音波加工、放電加工、など）も採用できる。型ローラ表面の表面粗さは、中心線平均粗さＲａで０．５μｍ以下とするのが好ましく、０．２μｍ以下とするのがより好ましい。型ローラ１６は、図示しない駆動手段により、所定の周速度で回転駆動される。   The formation of an inverted saddle shape on the surface of the mold roller depends on the material of the roller surface, but generally a combination of cutting with an NC lathe and finishing buffing can be preferably employed. Also, other known processing methods (cutting, ultrasonic processing, electric discharge processing, etc.) can be employed. The surface roughness of the mold roller surface is preferably 0.5 μm or less, and more preferably 0.2 μm or less, in terms of the center line average roughness Ra. The mold roller 16 is rotationally driven at a predetermined peripheral speed by driving means (not shown).

ニップローラ１８は、型ローラ１６に対向配置され、型ローラ１６とで樹脂シート１４を挟圧するためのローラである。ニップローラ１８の材質としては、各種鉄鋼部材、ステンレス鋼、銅、亜鉛、真鍮、これらの金属材料を芯金として、表面にゴムライニングしたもの、これらの金属材料にＨＣｒメッキ、Ｃｕメッキ、Ｎｉメッキなどのメッキを施したもの、セラミックス、および各種の複合材料が採用できる。   The nip roller 18 is disposed so as to face the mold roller 16 and is a roller for sandwiching the resin sheet 14 with the mold roller 16. The material of the nip roller 18 is a variety of steel members, stainless steel, copper, zinc, brass, a metal lining of these metal materials, a rubber lining on the surface, HCr plating, Cu plating, Ni plating, etc. on these metal materials These materials, ceramics, and various composite materials can be used.

ニップローラ１８の表面は鏡面状に加工されていることが好ましく、中心線平均粗さＲａで０．５μｍ以下とするのが好ましく、０．２μｍ以下とするのがより好ましい。このような平滑な表面とすることにより、成形後の樹脂シート１４の裏面を良好な状態にできる。また、ニップローラ１８は、図示しない駆動手段により、所定の周速度で回転駆動される。尚、ニップローラ１８に駆動手段を設けない構成も可能であるが、樹脂シート１４の裏面を良好な状態にできる点より、駆動手段を設けることが好ましい。   The surface of the nip roller 18 is preferably processed into a mirror shape, and the center line average roughness Ra is preferably 0.5 μm or less, and more preferably 0.2 μm or less. By setting it as such a smooth surface, the back surface of the resin sheet 14 after a shaping | molding can be made into a favorable state. The nip roller 18 is rotationally driven at a predetermined peripheral speed by a driving means (not shown). In addition, although the structure which does not provide a drive means in the nip roller 18 is also possible, it is preferable to provide a drive means from the point which can make the back surface of the resin sheet 14 a favorable state.

ニップローラ１８には、図示しない加圧手段が設けられており、型ローラ１６との間の樹脂シート１４を所定の圧力で挟圧できるようになっている。この加圧手段は、いずれも、ニップローラ１８と型ローラ１６との接触点における法線方向に圧力を印加する構成のもので、モータ駆動手段、エアシリンダ、油圧シリンダ等の公知の各種手段が採用できる。   The nip roller 18 is provided with a pressing means (not shown) so that the resin sheet 14 between the nip roller 18 and the mold roller 16 can be clamped with a predetermined pressure. Each of the pressurizing means is configured to apply pressure in the normal direction at the contact point between the nip roller 18 and the mold roller 16, and various known means such as a motor driving means, an air cylinder, and a hydraulic cylinder are employed. it can.

ニップローラ１８には、挟圧力の反力による撓みが生じにくくなるような構成を採用することもできる。このような構成としては、ニップローラ１８の背面側（型ローラ１６の反対側）に図示しないバックアップローラを設ける構成、ローラの軸方向中央部の剛性が大きくなるような強度分布を付けたローラの構成、及びこれらを組み合わせた構成などが採用できる。   The nip roller 18 may be configured to be less likely to bend due to the reaction force of the clamping pressure. As such a configuration, a back-up roller (not shown) is provided on the back side of the nip roller 18 (opposite side of the mold roller 16), and a roller configuration is provided with a strength distribution that increases the rigidity of the central portion in the axial direction of the roller. , And combinations of these can be employed.

また、剥離ローラ２０は、型ローラ１６に対向配置され、樹脂シート１４を巻き掛けることにより樹脂シート１４を型ローラ１６より剥離するためのローラで、型ローラ１６の１８０度下流側に配置される。剥離ローラ２０の表面は鏡面状に加工されていることが好ましい。このような表面とすることにより、成形後の樹脂シート１４の裏面を良好な状態にできる。そして、剥離ローラ表面の表面粗さは、中心線平均粗さＲａで０．５μｍ以下とするのが好ましく、０．２μｍ以下とするのがより好ましい。剥離ローラ２０の材質としては、各種鉄鋼部材、ステンレス鋼、銅、亜鉛、真鍮、これらの金属材料を芯金として、表面にゴムライニングしたもの、これらの金属材料にＨＣｒメッキ、Ｃｕメッキ、Ｎｉメッキ等のメッキを施したもの、セラミックス、及び各種の複合材料が採用できる。剥離ローラ２０は、図示しない駆動手段により、所定の周速度で矢印方向に回転駆動される。尚、剥離ローラ２０に駆動手段を設けない構成も可能であるが、樹脂シート１４の裏面を良好な状態にできる点より、駆動手段を設けることが好ましい。   The peeling roller 20 is disposed opposite to the mold roller 16 and is a roller for peeling the resin sheet 14 from the mold roller 16 by winding the resin sheet 14, and is disposed 180 degrees downstream of the mold roller 16. . The surface of the peeling roller 20 is preferably processed into a mirror surface. By setting it as such a surface, the back surface of the resin sheet 14 after a shaping | molding can be made into a favorable state. The surface roughness of the surface of the peeling roller is preferably 0.5 μm or less, more preferably 0.2 μm or less in terms of the center line average roughness Ra. The material of the peeling roller 20 includes various steel members, stainless steel, copper, zinc, brass, and a metal lining of these metal materials, and a rubber lining on the surface. These metal materials are HCr plated, Cu plated, Ni plated. For example, ceramics and various composite materials can be used. The peeling roller 20 is rotationally driven in the direction of the arrow at a predetermined peripheral speed by a driving means (not shown). In addition, although the structure which does not provide a drive means in the peeling roller 20 is also possible, it is preferable to provide a drive means from the point which can make the back surface of the resin sheet 14 a favorable state.

シート成形工程１１４および後の搬送工程１１６においては、加熱装置２２を設けることが好ましい。加熱装置２２は、図３に示すように、型ロール近傍、剥離ローラ近傍、搬送工程の樹脂シート１４の下面側および上面側に設置する。加熱装置２２としては、温風や遠赤外線ヒーター、近赤外線ヒーターなどの非接触のものであれば、特に限定されず用いることができるが、加熱効率の点から遠赤外線ヒーターを用いることが好ましい。   In the sheet forming step 114 and the subsequent conveying step 116, it is preferable to provide the heating device 22. As shown in FIG. 3, the heating device 22 is installed in the vicinity of the mold roll, in the vicinity of the peeling roller, and on the lower surface side and the upper surface side of the resin sheet 14 in the conveying step. The heating device 22 is not particularly limited as long as it is a non-contact type such as warm air, a far infrared heater, or a near infrared heater, but a far infrared heater is preferably used from the viewpoint of heating efficiency.

加熱装置２２による加熱は、切断工程１２４における切断において、樹脂のガラス温度をＴｇとしたとき、樹脂シート１４の幅方向における表面の最高温度が（Ｔｇ−４０）℃以上の温度で切断できるように加熱を行う。より好ましくは、（Ｔｇ−３０）℃以上である。また、切断工程時の温度の上限は、Ｔｇ℃以下であることが好ましく、より好ましくは（Ｔｇ−１０）℃以下である。上記温度で行うことにより、次のアニール処理工程１２６において、その余熱を利用してアニール処理を行うことができる。   Heating by the heating device 22 is such that the maximum temperature of the surface in the width direction of the resin sheet 14 can be cut at a temperature of (Tg−40) ° C. or higher when the glass temperature of the resin is Tg in the cutting in the cutting step 124. Heat. More preferably, it is (Tg-30) ° C. or higher. Moreover, it is preferable that the upper limit of the temperature at the time of a cutting process is Tg degrees C or less, More preferably, it is (Tg-10) degrees C or less. By performing at the above temperature, the annealing process can be performed using the remaining heat in the next annealing process step 126.

搬送工程における加熱は、剥離ローラ２０による剥離後は、まず、樹脂シート１４の下面側（型がついていない面側）から加熱装置２２ｃにより加熱することが好ましい。樹脂シート１４の上面側（型がついている面側）から加熱しすぎると、その後の熱収縮で変形してしまい、所望の形状の樹脂シートを得ることができない場合があるからである。少なくとも樹脂シート１４の表面温度がＴｇ以上の時は、樹脂シートの下面側から加熱することが好ましい。   It is preferable that the heating in the transporting process is first performed by the heating device 22c from the lower surface side (the surface side without the mold) of the resin sheet 14 after being peeled off by the peeling roller 20. This is because if the resin sheet 14 is heated too much from the upper surface side (the surface side where the mold is attached), the resin sheet 14 is deformed by the subsequent heat shrinkage, and a resin sheet having a desired shape may not be obtained. When at least the surface temperature of the resin sheet 14 is equal to or higher than Tg, it is preferable to heat from the lower surface side of the resin sheet.

樹脂シート１４は切断工程１２４の後に、アニール処理工程１２６に送られる。アニール処理は、樹脂シート１４を平らな面の上に、樹脂シートの平面側を下にして置き、熱処理を行うことにより、自重を利用して樹脂シートの変形・反りを矯正し、残留歪みを徐協する工程である。   The resin sheet 14 is sent to the annealing process 126 after the cutting process 124. In the annealing process, the resin sheet 14 is placed on a flat surface with the flat side of the resin sheet facing down, and heat treatment is performed to correct the deformation and warpage of the resin sheet using its own weight, thereby reducing residual distortion. It is a process of slow cooperation.

アニール処理工程１２６としては、水平方向のトンネル形状とし、トンネル内部に温度調節手段を設け、樹脂シートの冷却温度プロファイルを制御できる構成が採用できる。温度調節手段としては、複数のノズルより温度制御されたエア（温風または冷風）を樹脂シート１４に向けて噴出させる構成、加熱手段（ニクロム線ヒーター、赤外線ヒーター、誘電加熱手段など）により樹脂シート１４の表裏面をそれぞれ加熱する構成など、公知の各手段が採用できる。   As the annealing process 126, a configuration is adopted in which a horizontal tunnel shape is provided, temperature adjusting means is provided inside the tunnel, and the cooling temperature profile of the resin sheet can be controlled. As the temperature adjusting means, a structure in which air (hot air or cold air) whose temperature is controlled from a plurality of nozzles is jetted toward the resin sheet 14, and a resin sheet by a heating means (nichrome wire heater, infrared heater, dielectric heating means, etc.) Each well-known means, such as the structure which heats each 14 front and back, can be employ | adopted.

アニール処理工程における樹脂シート１４を支持する支持部材としては、図３に示すようなスチールベルト１９８を用いることもでき、耐熱性の高いフッ素樹脂含浸繊維のベルトやステンレスチェーンなどを用いることもできる。支持部材が平面性を有している方が、アニール処理後の樹脂シートの平面度に反映されるため、支持部材の平面度としては樹脂シートを支持する領域において０．５ｍｍ以下であることが好ましく、より好ましくは０．３ｍｍ以下である。   As a support member for supporting the resin sheet 14 in the annealing process, a steel belt 198 as shown in FIG. 3 can be used, and a belt of heat-resistant fluororesin-impregnated fiber or a stainless chain can be used. Since the direction in which the support member has flatness is reflected in the flatness of the resin sheet after the annealing treatment, the flatness of the support member may be 0.5 mm or less in the region where the resin sheet is supported. Preferably, it is 0.3 mm or less.

アニール処理工程１２６の雰囲気温度（アニール温度）は（Ｔｇ−４０）℃以上（Ｔｇ-１０）℃以下が好ましく、より好ましくは（Ｔｇ−３０）℃以上（Ｔｇ−１０）℃以下である。湿度は乾燥状態であることが好ましい。また、樹脂シートの温度は、切断工程１２４の樹脂シートの温度である（Ｔｇ-４０）℃以上を維持するように搬送工程１１６において加熱を行う。より好ましくは（Ｔｇ−３０）℃以上である。また、上限はＴｇ℃以下が好ましく、より好ましくは（Ｔｇ−１０）℃以下である。搬送工程１１６において加熱した後、その余熱でアニール処理工程１２６を行うことにより、途中で、冷却・加熱などの工程を行う必要がないため、装置を簡略化できるとともに、アニール処理の時間も短縮することができるので、生産性良く偏肉樹脂シートの製造をすることができる。   The atmospheric temperature (annealing temperature) in the annealing process 126 is preferably (Tg-40) ° C. or higher and (Tg-10) ° C. or lower, more preferably (Tg-30) ° C. or higher and (Tg-10) ° C. or lower. The humidity is preferably in a dry state. The temperature of the resin sheet is heated in the conveying step 116 so as to maintain (Tg−40) ° C. or higher which is the temperature of the resin sheet in the cutting step 124. More preferably, it is (Tg-30) ° C. or higher. Further, the upper limit is preferably Tg ° C or lower, more preferably (Tg-10) ° C or lower. By performing the annealing process 126 with the remaining heat after heating in the transfer process 116, it is not necessary to perform processes such as cooling and heating in the middle, so that the apparatus can be simplified and the annealing process time is also shortened. Therefore, the uneven thickness resin sheet can be manufactured with high productivity.

アニール処理後は５℃／ｍｉｎ以下の速度で徐冷することが好ましく、２℃／ｍｉｎ以下の速度で徐冷することが好ましい。   After the annealing treatment, it is preferable to slowly cool at a rate of 5 ° C./min or less, and it is preferable to slowly cool at a rate of 2 ° C./min or less.

また、図２、図３においては、切断工程１２４の後、樹脂シート１４を水平方向に移動し、アニール処理工程１２６を行っているが、図５に示すように、切断した樹脂シート１４を１枚ずつ上下方向に移動させてアニール処理工程を行うこともできる。上記構成とすることにより、樹脂シート１４のサイズが大きくなった場合においても、設備を小型化することができ、設備が大型化することを防止することができる。   2 and 3, after the cutting step 124, the resin sheet 14 is moved in the horizontal direction and the annealing treatment step 126 is performed. As shown in FIG. It is also possible to perform the annealing process by moving up and down one by one. By setting it as the said structure, even when the size of the resin sheet 14 becomes large, an installation can be reduced in size and an enlargement of an installation can be prevented.

本発明が適用される樹脂シートの製造方法のフローを説明する工程図である。It is process drawing explaining the flow of the manufacturing method of the resin sheet to which this invention is applied. 本発明が適用される樹脂シートの製造装置の概念図である。It is a conceptual diagram of the manufacturing apparatus of the resin sheet to which this invention is applied. 樹脂シートの製造装置のシート成形工程からアニール処理工程を示す構成図である。It is a block diagram which shows an annealing process from the sheet | seat formation process of the manufacturing apparatus of a resin sheet. 樹脂シートの形状の一例を示す断面図である。It is sectional drawing which shows an example of the shape of a resin sheet. 樹脂シートの製造装置の別の態様を示す構成図である。It is a block diagram which shows another aspect of the manufacturing apparatus of a resin sheet.

符号の説明Explanation of symbols

１２…ダイ、１４…樹脂シート、１４ａ…溶融樹脂シート、１６…型ローラ、１８…ニップローラ、２０…剥離ローラ、２２…加熱装置、２４…引取ローラ、２６…測定基盤、１００…原料工程、１１２…押出工程、１１４…シート成形工程、１１５…剥離工程、１１６…搬送工程、１２４…切断工程、１２８…原料サイロ、１３０…添加物サイロ、１３２…自動計量機、１３４…混合器、１３６…原料樹脂がホッパー、１３８…押出機、１４０…定量ポンプ、１４２…供給管、１７４…切断手段、１７６…回収ボックス、１９４…ローラ、１９６…コンベアベルト、   DESCRIPTION OF SYMBOLS 12 ... Die, 14 ... Resin sheet, 14a ... Molten resin sheet, 16 ... Mold roller, 18 ... Nip roller, 20 ... Peeling roller, 22 ... Heating device, 24 ... Take-off roller, 26 ... Measurement base, 100 ... Raw material process, 112 ... extrusion process, 114 ... sheet forming process, 115 ... peeling process, 116 ... conveying process, 124 ... cutting process, 128 ... raw material silo, 130 ... additive silo, 132 ... automatic weighing machine, 134 ... mixer, 136 ... raw material Resin is a hopper, 138 ... extruder, 140 ... metering pump, 142 ... supply pipe, 174 ... cutting means, 176 ... collection box, 194 ... roller, 196 ... conveyor belt,

Claims (3)

溶融した樹脂をダイからシート状に押し出す押出工程と、
押し出した溶融樹脂シートを型ローラとニップローラで挟み、該型ローラの表面の加工形状を該溶融樹脂シートに転写し、冷却固化することにより樹脂シートを成形するシート成形工程と、
前記樹脂シートを剥離ローラから剥離する剥離工程と、
前記樹脂シートを加熱装置で加熱しながら、引取ローラで引っ張り搬送する搬送工程と、
前記樹脂のガラス転移温度をＴｇとした時、前記樹脂シートの幅方向における表面の最高温度が（Ｔｇ−４０）℃以上Ｔｇ℃以下の温度で、前記樹脂シートを切断手段により所定の長さに切断する切断工程と、
前記切断手段により切断された樹脂シートを、（Ｔｇ−４０）℃以上Ｔｇ℃以下の温度で連続的にアニール処理を行うアニール処理工程と、を有することを特徴とする偏肉樹脂シートの製造方法。 An extrusion process of extruding the molten resin from the die into a sheet,
A sheet forming step of forming the resin sheet by sandwiching the extruded molten resin sheet between a mold roller and a nip roller, transferring the processed shape of the surface of the mold roller to the molten resin sheet, and cooling and solidifying;
A peeling step of peeling the resin sheet from a peeling roller;
A conveying step of pulling and conveying the resin sheet with a take-up roller while heating with a heating device;
When the glass transition temperature of the resin is Tg, the maximum temperature of the surface in the width direction of the resin sheet is (Tg−40) ° C. to Tg ° C. A cutting step for cutting;
An annealing process step of continuously annealing the resin sheet cut by the cutting means at a temperature of (Tg-40) ° C. or higher and Tg ° C. or lower. . 前記アニール処理工程は、前記樹脂シートを平面状の支持部材で支持して行うことを特徴とする請求項１に記載の偏肉樹脂シートの製造方法。   The method of manufacturing an uneven thickness resin sheet according to claim 1, wherein the annealing treatment step is performed by supporting the resin sheet with a planar support member. 前記樹脂シートの幅方向における厚み分布の、最厚部と最薄部の厚みの差が０．５ｍｍ以上５ｍｍ以下であることを特徴とする請求項１または２に記載の偏肉樹脂シートの製造方法。   The thickness difference of the thickness direction in the width direction of the said resin sheet WHEREIN: The difference of the thickness of the thickest part and the thinnest part is 0.5 mm or more and 5 mm or less, The manufacture of the uneven thickness resin sheet of Claim 1 or 2 characterized by the above-mentioned. Method.
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