JP5659508B2 - Extruded shaping pattern sheet manufacturing method and manufacturing apparatus - Google Patents

Description

  The present invention relates to a method and apparatus for producing a shaped pattern sheet capable of forming a pattern with a high shaping rate on a surface of a sheet-shaped resin material with high accuracy and high quality.

  Extrusion molding technology is a molding technology that can extrude a uniform sheet of resin material, a molding technology that can faithfully reproduce the irregular shaped pattern (transfer mold), and a multi-layer that can provide multiple functions at low cost. It consists of technology and is used in various fields.

  In particular, when a precise pattern such as a lens sheet for an optical member is required, a technique for forming a shaped pattern by extrusion molding is adopted from the viewpoint of low cost and continuity.

  In forming a shaping pattern on a sheet-shaped resin material in extrusion molding, a technique of combining a method using a pressing medium and a shaping medium and a method for controlling the fluidity of the resin material is widely used. Improvement of the sheet-shaped resin material into the mold at the time of pressing and prevention of shape loss at the time of peeling greatly influence the shaping rate. The shaping rate is a rate obtained by dividing the actual depth of the pattern mold by the depth of the mold.

  Such techniques relating to the improvement of molding of the sheet-shaped resin material and the prevention of the collapse of the sheet-shaped resin material are disclosed in Japanese Patent Application Laid-Open No. 2008-119950 (Patent Document 1) and Japanese Patent Application Laid-Open No. 2008-18629 (Cited Document 2).

JP 2008-111950 A JP 2008-18629 A

  In Patent Document 1, a heating device is disposed on the upstream side in the rotation direction of the shaping roll, and a cooling device is disposed on the downstream side, and the fluidity of the resin material is controlled by the heating device and the cooling device to improve mold filling. And trying to prevent out of shape.

  However, in the thing of this patent document 1, the part heated up with a heating apparatus is a shaping roll, and the temperature of resin material itself falls with external air. Even when the forming roll is sufficiently heated, if the temperature of the resin material decreases, the resin material cures before the resin material enters the forming pattern of the forming roll, and a sufficient forming rate is obtained. It can no longer be obtained. FIG. 3A schematically shows a state where the resin material J is not sufficiently filled with the shaping pattern a.

Further, in Patent Document 1, since a heating device and a cooling device are disposed on the same roll and temperature control is performed, accurate temperature adjustment is difficult, and it is sufficient to perform cooling after the temperature rise. The cooling effect is not obtained, and the shape is easily lost. FIG. 3 (B), a shaping pattern sheet J ₁ which shapeless occurs is shown schematically.

  On the other hand, in Patent Document 2, by providing a heat insulating layer inside the outermost layer of the shaping roll, temperature reduction of the resin material between the shaping roll and the pressing roll at the time of narrow pressure is prevented, and the mold to the shaping roll is used. A scheme for smooth entry is shown.

  However, also in this patent document 2, like patent document 1, the fall of the resin temperature before narrow pressure cannot be suppressed, and it is difficult to obtain a sufficient shaping rate. In addition, since a sufficient cooling effect cannot be obtained even when the sheet-shaped resin material is peeled off, the shape may be lost. Furthermore, since it is a special structure in which a heat insulating layer is provided inside the outermost layer of the shaping roll, there is a drawback that the introduction cost is increased.

  The present invention has been made paying attention to such points, and the object thereof is to form a shaped pattern sheet by narrowing the sheet-like resin material extruded from the die head with a pressing roll and a shaping roll. To provide a method and an apparatus for producing an extrusion-molding shaped pattern sheet capable of obtaining a shaped pattern sheet having a high shaping rate by improving the molding of the sheet-shaped resin material and preventing the loss of shape. It is in.

In order to solve the above-mentioned problems, the invention of claim 1 is directed to a transfer part in which a sheet-shaped resin material extruded from a die head of an extruder is adjacent to a forming roll having a forming pattern formed on a surface thereof and a pressing roll. In this method, a shaped pattern sheet is produced by pressing between the shaping roll and the pressing roll, and the pressing roll is a roll having a smaller diameter than the shaping roll, and the pressing roll of the die head is used as the pressing roll. The die head is formed such that the opposing surface has an arc shape corresponding to the arc shape of the surface of the pressing roll, and the surface facing the shaping roll of the die head has an arc shape corresponding to the arc shape of the surface of the shaping roll. wherein the press roll and the forming roll are adjacent is arranged above the expansion space of the transfer unit, a resin material introducing child to the transfer portion from the die head in this state Which is a shaping pattern sheet manufacturing method according to claim.

According to a second aspect of the present invention, in the manufacturing method, the transfer material in which the pressing roll and the shaping roll are adjacent to each other so that the resin material heated and melted from the die head is extruded and along the surface of the shaping roll. It is characterized by flowing into

The invention of claim 3 introduces a sheet-shaped resin material extruded from a die head of an extrusion molding machine into a transfer portion where a shaping roll having a shaping pattern formed on the surface and a pressing roll are adjacent to each other, and the shaping roll. In the apparatus for producing a shaped pattern sheet by pressing with a pressing roll, the pressing roll is a roll having a smaller diameter than the shaping roll, and the surface of the die head that faces the pressing roll is the surface of the pressing roll. The surface of the die head facing the shaping roll has an arc shape corresponding to the arc shape of the surface of the shaping roll, and the die head has the pressing roll and the shaping shape. A shaped pattern sheet, wherein a roll is disposed in an expanded space above the adjacent transfer portion, and a resin material is introduced from the die head to the transfer portion. It is a manufacturing equipment.

  The invention of claim 4 is characterized in that the manufacturing apparatus further comprises position adjusting means capable of adjusting a position of the die head with respect to the transfer portion.

  According to the invention of claim 5, the resin material after pattern transfer can sequentially contact the section between the transfer portion and the portion where the resin material after pattern transfer peels off from the shaping roll. A plurality of cooling rolls are arranged in multiple stages.

  In the invention of claim 6, cooling air can be blown to the resin material after pattern transfer in a section between the transfer portion and the portion where the resin material after pattern transfer is peeled off from the shaping roll. An air blow device is provided.

According to the manufacturing method of the first aspect of the present invention, the pressing roll is a roll having a smaller diameter than the shaping roll, the surface facing the pressing roll of the die head is an arc shape corresponding to the arc shape of the surface of the pressing roll, Since the surface facing the shaping roll has an arc shape corresponding to the arc shape of the surface of the shaping roll , the die head is arranged in the expansion space above the transfer portion adjacent to the pressing roll and the shaping roll . When the resin material is pushed out from the die head toward the transfer section, the resin material reaches the transfer section almost instantaneously, and therefore the temperature drop due to contact with the outside air, that is, the decrease in fluidity can be accurately suppressed, and the forming roll It is possible to achieve a high filling rate with respect to the shaping pattern, and to obtain a shaping pattern sheet having a high shaping rate.

According to the manufacturing method of the invention of claim 2, the resin material heated and melted from the die head is extruded, and the pressing roll and the shaping roll are caused to flow into adjacent transfer portions along the surface of the shaping roll. The resin material passes through the transfer portion while being sandwiched between the shaping roll and the pressing roll at a predetermined pressure, and the shaping pattern on the surface of the shaping roll is transferred to the surface of the sheet-like resin material during this passage.

Furthermore, according to the manufacturing apparatus of the invention of claim 3, the pressing roll is a roll having a smaller diameter than the shaping roll, and the surface of the die head facing the pressing roll has an arc shape corresponding to the arc shape of the surface of the pressing roll. None, the surface of the die head facing the shaping roll has an arc shape corresponding to the arc shape of the surface of the shaping roll, and the die head is placed in the expanded space above the transfer section where the pressing roll and shaping roll are adjacent to each other Therefore, when the resin material is pushed out from the die head toward the transfer portion, the resin material reaches the transfer portion almost instantaneously, and therefore, it is possible to accurately suppress the temperature decrease due to contact with the outside air, that is, the decrease in fluidity. It is possible to achieve a high filling rate with respect to the shaping pattern of the shaping roll and obtain a shaping pattern sheet having a high shaping rate.

  According to the manufacturing apparatus of the fourth aspect of the present invention, since the position adjusting means capable of adjusting the position of the die head with respect to the transfer portion is provided, the position of the die head is appropriately adjusted according to the characteristics of the resin material, etc. Can be close.

  According to the manufacturing apparatus of the invention of claim 5, the resin material after pattern transfer sequentially contacts the section between the transfer portion and the portion where the resin material after pattern transfer peels off the shaping roll. Since the plurality of cooling rolls that can be provided are arranged in multiple stages, the resin material can be sufficiently and efficiently cooled to prevent the deformation of the mold during peeling.

  According to the manufacturing apparatus of the sixth aspect of the invention, cooling air is blown to the resin material after the pattern transfer in a section between the transfer portion and the portion where the resin material after the pattern transfer is peeled off from the shaping roll. Therefore, the resin material can be efficiently cooled to prevent the deformation of the mold at the time of peeling.

The schematic diagram of the shaping pattern sheet manufacturing apparatus which concerns on one Embodiment of this invention. (A) is a schematic diagram when the resin material mold is good, (B) is a schematic diagram when the pattern sheet mold is not collapsed. (A) is a schematic diagram when the resin material is not properly molded, and (B) is a schematic diagram when the pattern sheet is broken.

  Hereinafter, the shaping pattern sheet manufacturing apparatus which concerns on one Embodiment of this invention is demonstrated.

  FIG. 1 is a conceptual diagram showing the configuration of the shaped pattern sheet manufacturing apparatus. This manufacturing apparatus includes a shaping roll 1 and a pressing roll 2, and a fine uneven-shaped shaping pattern a is formed on the surface of the shaping roll 1 as a transfer mold.

  The shaping roll 1 and the pressing roll 2 are disposed adjacent to each other, and a transfer portion P is formed between the adjacent ones. The shaping roll 1 rotates counterclockwise in the figure, and the pressing roll 2 rotates clockwise. The pressing roll 2 is a roll having a diameter sufficiently smaller than the diameter of the shaping roll 1. For example, the diameter of the pressing roll 2 is about 1/6 of the diameter of the shaping roll 1.

  The T-die head 3 of the extrusion molding machine is disposed above the adjacent portion of the shaping roll 1 and the pressure roll 2, that is, the transfer portion P, and the resin material heated and melted from the T-die head 3 is pushed out toward the transfer portion P. It is. The shaping roll 1 is a roll having an effective width longer than the width of the resin material extruded from the T die head 3.

  The T die head 3 is disposed in the vicinity of the transfer portion P where the shaping roll 1 and the pressing roll 2 are adjacent to each other. The pressing roll 2 is a roll having a sufficiently small diameter with respect to the diameter of the shaping roll 1. Therefore, a wide expansion space can be secured above the adjacent portion between the shaping roll 1 and the pressing roll 2, and therefore the T die head 3. Can be arranged close to the transfer portion P.

  That is, if the shaping roll 1 and the pressing roll 2 are rolls having substantially the same diameter, the expansion space formed above the adjacent portion is narrowed, and therefore the T die head 3 is close to the adjacent portion. It becomes difficult to arrange. However, in this embodiment, the diameter of the pressing roll 2 is sufficiently small with respect to the diameter of the shaping roll 1, and therefore, the widening angle above the adjacent portion is widened to obtain a wide expanded space. Therefore, the T die head 3 can be disposed in the wide expansion space so that the T die head 3 can be brought close to the transfer portion P.

  The surface 3a facing the shaping roll 1 of the T die head 3 is an arc shape corresponding to the arc shape of the surface of the shaping roll 1, and the surface 3b facing the pressing roll 2 is an arc of the surface of the pressing roll 2. It has an arc shape corresponding to the shape. For this reason, the T-die head 3 can be brought closer to the transfer portion P.

  A position adjusting mechanism 4 is attached to the T die head 3, and the position of the T die head 3 can be appropriately adjusted by the position adjusting mechanism 4. The position adjustment mechanism 4 is driven using a motor or hydraulic means.

  A peeling roll 5 is disposed adjacent to the shaping roll 1 at a position almost opposite to the pressing roll 2 with respect to the shaping roll 1. A plurality of cooling rolls 6 are arranged on the downstream side in the rotation direction of the shaping roll 1 with the transfer portion P as a reference. The cooling roll 6 is provided in a multistage manner so as to be adjacent to the shaping roll 1 between the pressing roll 2 and the peeling roll 5 and to be evenly arranged along the rotation direction of the shaping roll 1. The peeling roll 5 and each cooling roll 6 rotate in the opposite direction to the shaping roll 1.

  Each cooling roll 6 is provided with a temperature adjusting mechanism 7, and the temperature adjusting mechanism 7 can adjust the temperature of each cooling roll 6 to set it to a desired temperature. Further, an air blowing device 8 is disposed on the shaping roll 1, and the air blowing device 8 can blow cooling air onto the shaping roll 1.

  Next, operation | movement of this shaping pattern sheet manufacturing apparatus is demonstrated.

  The resin material J heated and melted from the T-die head 3 of the extrusion molding machine in a state where the shaping roll 1, the pressing roll 2, the peeling roll 5, and the respective cooling rolls 6 are rotated toward the transfer portion P is a sheet shape. Extruded. The extruded resin material J flows between the shaping roll 1 and the pressing roll 2 and along the surface of the shaping roll 1, and at a predetermined pressure between the shaping roll 1 and the pressing roll 2. It passes through the transfer portion P while being sandwiched, and the shaping pattern on the surface of the shaping roll 1 is transferred to the surface of the sheet-like resin material J during this passage.

The resin material J to which the shaping pattern is transferred is conveyed to the arrangement side of each cooling roll 6 while being held on the surface of the shaping roll 1, and is contacted with each cooling roll 6 and blown out from the air blowing device 8. Cooled by air. The peeling the roll 5 and a portion contacting are successively peeled from the surface of the forming roll 1 is fed as the shaped pattern sheet J ₁ in the next step.

  When the resin material J is pushed out from the T die head 3 toward the transfer part P, the resin material J reaches the transfer part P almost instantaneously because the T die head 3 is disposed at a position close to the transfer part P. Therefore, a temperature decrease due to contact with the outside air, that is, a decrease in fluidity can be accurately suppressed, and a high filling mold for the shaping pattern a of the shaping roll 1 can be achieved. FIG. 2A schematically shows a state where the resin material J is sufficiently mold-filled with respect to the shaping pattern a. The position of the T die head 3 can be adjusted by the position adjusting mechanism 4 and can be arranged at an appropriate position close to the transfer portion P.

The resin material J after the shaping pattern is transferred is conveyed so as to sequentially contact the plurality of cooling rolls 6, but is sufficiently and efficiently cooled by the plurality of cooling rolls 6 that are sequentially contacted. Therefore, the fluidity of the resin material J can be accurately reduced, and thereby, it is possible to accurately prevent the loss of shape when peeling from the shaping roll 1 by contact with the peeling roll 5. FIG. 2 (B), their shape without shaping pattern sheet J ₁ is shown schematically.

  Each cooling roll 6 can be adjusted to an appropriate temperature by the temperature adjusting mechanism 7. In addition, the resin material J is further cooled by the air blow device 8 together with the cooling roll 6, and therefore the cooling efficiency can be further enhanced.

Through such a process, the flowability of the sheet-shaped resin material J is optimized, and a high-filling mold is inserted at the time of clamping, and the mold pattern of the high-molding rate is stably and continuously formed in order to prevent the deformation of the mold at the time of peeling. it can be obtained sheet _{J 1.}

1 ... forming roll 2 ... pressing rolls 3 ... T die head 4 ... position adjusting mechanism 5 ... stripping roll 6 ... chill roller 7 ... temperature adjusting mechanism 8 ... air blow device a ... shaping pattern J ... resin material J 1 _... shaping pattern Sheet P ... Transfer section

Claims (6)

A sheet-shaped resin material extruded from a die head of an extrusion molding machine is introduced into a transfer portion where a shaping roll having a shaping pattern formed on the surface and a pressing roll are adjacent to each other, and sandwiched between the shaping roll and the pressing roll. A method for producing a shaped pattern sheet,
The pressing roll is a roll having a smaller diameter than the shaping roll, and the surface of the die head that faces the pressing roll has an arc shape corresponding to the arc shape of the surface of the pressing roll, and faces the shaping roll of the die head. The surface to be formed is an arc shape corresponding to the arc shape of the surface of the shaping roll, and the die head is arranged in an expansion space above the transfer portion where the pressing roll and the shaping roll are adjacent to each other. A method for producing a shaped pattern sheet, wherein a resin material is introduced from the die head into the transfer portion. The resin material melted by heating from the die head is extruded, and the pressing roll and the shaping roll are caused to flow into the adjacent transfer section so as to follow the surface of the shaping roll. Manufacturing method of shaped pattern sheet. A sheet-shaped resin material extruded from a die head of an extrusion molding machine is introduced into a transfer portion where a shaping roll having a shaping pattern formed on the surface and a pressing roll are adjacent to each other, and sandwiched between the shaping roll and the pressing roll. In an apparatus for manufacturing shaped pattern sheets,
The pressing roll is a roll having a smaller diameter than the shaping roll, and the surface of the die head facing the pressing roll has an arc shape corresponding to the arc shape of the surface of the pressing roll, and the shaping roll of the die head The surface facing the arcuate shape corresponding to the arc shape of the surface of the shaping roll, the die head is disposed in the expansion space above the transfer portion adjacent to the pressing roll and the shaping roll , An apparatus for producing a shaped pattern sheet, wherein a resin material is introduced from the die head into the transfer portion. The shaping pattern sheet manufacturing apparatus according to claim 3 , further comprising a position adjusting unit capable of adjusting a position of the die head with respect to the transfer unit. In a section between the transfer portion and the part where the resin material after pattern transfer is peeled off from the shaping roll, a plurality of cooling rolls that can sequentially contact the resin material after pattern transfer in multiple stages The shaping pattern sheet manufacturing apparatus according to claim 3 or 4 , wherein the shaping pattern sheet manufacturing apparatus is provided. An air blowing device capable of blowing cooling air to the resin material after pattern transfer is disposed in a section between the transfer portion and the portion where the resin material after pattern transfer is peeled off from the shaping roll. The shaping pattern sheet manufacturing apparatus according to any one of claims 3 to 5 , wherein the shaping pattern sheet manufacturing apparatus is provided.

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