Extrusion molding device, film manufacturing system, and film manufacturing method

Abstract

The present invention relates to an extrusion molding device. The extrusion molding device (2) has a first flow path (231) through which a first molten resin passes, a second flow path (232) and a third flow path (233) through which a second molten resin passes, a first manifold (234), and a discharge port (241) that discharges the first molten resin and the second molten resin after passing through the first manifold (234). The second flow path (232) is connected to one end portion of the first manifold (234) in the width direction (TD). The third flow path (233) is connected to the other end portion of the first manifold (234) in the width direction (TD).

Description

TECHNICAL FIELD

[0001] The present application relates to an extrusion molding device, a film manufacturing system, and a film manufacturing method. BACKGROUND

[0002] Conventionally, an extrusion molding device that extrusion-molds a film formed of a brittle resin at the center and a ductile resin at both ends is known (for example, refer to Patent Literature 1).

[0003] The extrusion molding device has a first flow path through which a molten resin of the brittle resin flows, a second flow path through which a molten resin of the ductile resin flows, and a manifold that communicates with the first flow path. The second flow path merges with the first flow path midway.

[0004] PRIOR ART DOCUMENTS

[0005] PATENT LITERATURE

[0006] Patent Literature 1: Japanese Patent Application Laid-Open No. 2006-315275 SUMMARY

[0007] PROBLEMS TO BE SOLVED BY THE INVENTION

[0008] In the extrusion molding device described in the above Patent Literature 1, the molten resin of the ductile resin merges with the molten resin of the brittle resin midway in the first flow path. Therefore, when the molten resin of the ductile resin merges with the molten resin of the brittle resin, the flow of the brittle resin and the flow of the ductile resin become turbulent.

[0009] Then, the molten resin that has passed through the first flow path spreads in the width direction in the manifold. At this time, the turbulence of the flow of the brittle resin and the flow of the ductile resin is further promoted.

[0010] As a result, the thickness of the end portion of the molded film sometimes becomes uneven.

[0011] The present application provides an extrusion molding device, a film manufacturing system, and a film manufacturing method that can suppress the thickness of the end portion of a substrate extrusion-molded to become uneven.

[0012] METHOD FOR SOLVING THE PROBLEM

[0013] The present application [1] includes an extrusion molding device that has:

[0014] a first flow path through which a first molten resin passes;

[0015] a second flow path and a third flow path through which a second molten resin passes;

[0016] a first manifold having a first flow inlet communicating with the first flow path, a second flow inlet communicating with the second flow path, and a third flow inlet communicating with the third flow path; and

[0017] an ejection outlet through which the first molten resin and the second molten resin after passing through the first manifold are ejected,

[0018] wherein the first manifold extends along a flow direction from the first flow inlet toward the ejection outlet and extends in a width direction orthogonal to the flow direction, the first flow inlet is disposed at an upstream end of the first manifold in the flow direction and is disposed between both end portions of the first manifold in the width direction, the second flow inlet is disposed downstream of the first flow inlet in the flow direction and is disposed at one end portion of the first manifold in the width direction, and the third flow inlet is disposed downstream of the first flow inlet in the flow direction and is disposed at the other end portion of the first manifold in the width direction.

[0019] According to such a configuration, the second molten resin can be merged with the first molten resin at both end portions of the first manifold.

[0020] Accordingly, the second molten resin can be merged with both end portions of the first molten resin spread in the width direction in the first manifold.

[0021] Accordingly, it is possible to suppress the flow of the first molten resin and the flow of the second molten resin from becoming turbulent.

[0022] As a result, it is possible to suppress the thickness of the end portion of the substrate extrusion-molded to become uneven.

[0023] The present application [2] includes the extrusion molding device described in the above-mentioned [1], wherein the one end portion and the other end portion of the first manifold in the width direction extend along the flow direction, and the portion connected to the second flow inlet in the second flow path and the portion connected to the third flow inlet in the third flow path extend along the flow direction.

[0024] According to such a configuration, it is possible to supply the second molten resin to the first manifold along the flow direction, and to cause the second molten resin supplied to the first manifold to flow along the flow direction.

[0025] Accordingly, it is possible to further suppress the flow of the second molten resin from becoming turbulent.

[0026] As a result, it is possible to further suppress the thickness of the end portion of the substrate extrusion-molded to become uneven.

[0027] The present application [3] includes the extrusion molding device described in the above-mentioned [1] or [2], wherein,

[0028] The first manifold has an upstream portion spreading in the width direction from the first inlet, and a downstream portion extending in the flow direction from a downstream end of the upstream portion in the flow direction,

[0029] The second inlet is disposed at one end of the downstream portion in the width direction,

[0030] The third inlet is disposed at the other end of the downstream portion in the width direction.

[0031] According to such a configuration, the first molten resin can be spread in the width direction in the upstream portion of the first manifold, and the second molten resin can be merged with the width direction both ends of the first molten resin flowing in the flow direction in the downstream portion of the first manifold.

[0032] Thus, the flow of the first molten resin and the flow of the second molten resin can be further inhibited from being disturbed.

[0033] As a result, the thickness of the end portion of the substrate extrusion-molded can be further inhibited from becoming uneven.

[0034] The present application [4] includes the extrusion molding device described in the above [3], wherein the first inlet is circular, the outlet is flat extending in the width direction, and the downstream portion of the first manifold is flat extending in the width direction as viewed in the flow direction.

[0035] According to such a configuration, the first molten resin can be spread by the first manifold into a flat shape similar to the flat shape of the outlet, and the second molten resin can be merged with the width direction both ends of the first molten resin spread by the first manifold.

[0036] Thus, the flow of the first molten resin and the flow of the second molten resin can be further inhibited from being disturbed between the first manifold and the outlet.

[0037] As a result, the thickness of the end portion of the substrate extrusion-molded can be further inhibited from becoming uneven.

[0038] The present application [5] includes the extrusion molding device described in the above [4], wherein,

[0039] The second inlet has a shape along one end of the shape of the downstream portion in the width direction, and the third inlet has a shape along the other end of the shape of the downstream portion in the width direction.

[0040] According to such a configuration, the second molten resin has a shape in which an end portion along one end portion in the width direction of the downstream portion is formed at the stage when the second molten resin enters the downstream portion from the second flow inlet.

[0041] As a result, even if the second molten resin entering the downstream portion from the second flow inlet does not spread in the width direction within the downstream portion, an end portion in which an end portion along the width direction of the downstream portion is formed can be formed.

[0042] Likewise, the second molten resin has a shape in which an end portion along the other end portion in the width direction of the downstream portion is formed at the stage when the second molten resin enters the downstream portion from the third flow inlet.

[0043] As a result, even if the second molten resin entering the downstream portion from the third flow inlet does not spread in the width direction within the downstream portion, an end portion in which the other end portion along the width direction of the downstream portion is formed can be formed.

[0044] The present application [6] includes the extrusion molding device described in the above [5], in which

[0045] The inner face on one side of the second flow inlet in the width direction is flush with the inner face on one side of the downstream portion in the width direction as viewed in the flow direction,

[0046] The inner face on the other side of the third flow inlet in the width direction is flush with the inner face on the other side of the downstream portion in the width direction as viewed in the flow direction.

[0047] According to such a configuration, even if the second molten resin entering the downstream portion from the second flow inlet does not spread in the width direction, the second molten resin can be caused to have a shape in which an end portion along one end portion in the width direction of the downstream portion is formed.

[0048] As a result, an end portion in which an end portion along the width direction of the downstream portion is formed can be formed.

[0049] In addition, even if the second molten resin entering the downstream portion from the third flow inlet does not spread in the width direction, the second molten resin can be caused to have a shape in which an end portion along the other end portion in the width direction of the downstream portion is formed.

[0050] As a result, an end portion in which the other end portion along the width direction of the downstream portion is formed can be formed.

[0051] The present application [7] includes the extrusion molding device described in the above [6], in which

[0052] The inner surface of one side of the second flow inlet in the thickness direction orthogonal to both the flow direction and the width direction is flush with the inner surface of one side of the downstream portion in the thickness direction,

[0053] The inner surface of the other side of the second flow inlet in the thickness direction is flush with the inner surface of the other side of the downstream portion in the thickness direction,

[0054] The inner surface of one side of the third flow inlet in the thickness direction is flush with the inner surface of one side of the downstream portion in the thickness direction,

[0055] The inner surface of the other side of the third flow inlet in the thickness direction is flush with the inner surface of the other side of the downstream portion in the thickness direction.

[0056] According to such a configuration, the second molten resin entering the downstream portion from the second flow inlet and the second molten resin entering the downstream portion from the third flow inlet can be prevented from spreading in the thickness direction.

[0057] Therefore, when the second molten resin enters the downstream portion from the second flow inlet and the third flow inlet, the flow of the second molten resin can be further suppressed from becoming turbulent.

[0058] The present application [8] includes the extrusion molding device according to any one of the above [1] to [7], further comprising a second manifold disposed between the first manifold and the discharge port and communicating with the first manifold,

[0059] The second manifold is longer than the first manifold in the width direction.

[0060] According to such a configuration, the first molten resin and the second molten resin after passing through the first manifold can be further spread in the width direction by the second manifold.

[0061] As a result, a substrate that is large in the width direction can be molded while suppressing the flow of the first molten resin and the flow of the second molten resin from becoming turbulent.

[0062] The present application [9] includes the extrusion molding device according to the above [8], comprising:

[0063] a feed block having the first manifold; and

[0064] a die having the discharge port and connected to the feed block.

[0065] The present application

[10] includes the extrusion molding device according to the above [9], wherein,

[0066] The die further has the above-mentioned second manifold.

[0067] The present application

[11] includes the extrusion molding device described in any one of the above-mentioned [1] to

[10] , in which

[0068] The flow rate of the second molten resin at the second flow inlet and the flow rate of the second molten resin at the third flow inlet are 0.5 times or more and 2.0 times or less of the flow rate of the first molten resin in the first manifold.

[0069] According to such a configuration, it is possible to make the flow rate of the second molten resin close to the flow rate of the first molten resin when the second molten resin and the first molten resin are combined.

[0070] As a result, it is possible to suppress the flow of the first molten resin and the flow of the second molten resin from becoming turbulent.

[0071] The present application

[12] includes the extrusion molding device described in the above-mentioned

[11] , in which

[0072] The flow rate of the second molten resin at the second flow inlet, the flow rate of the second molten resin at the third flow inlet, and the flow rate of the first molten resin in the first manifold are 0.1 m / min or more and 10 m / min or less.

[0073] The present application

[13] includes the extrusion molding device described in any one of the above-mentioned [1] to

[12] , in which

[0074] The viscosity of the first molten resin and the second molten resin is 100 Pa·s or more and 10,000 Pa·s or less.

[0075] The present application

[14] includes the extrusion molding device described in any one of the above-mentioned [1] to

[13] , in which

[0076] The first molten resin is a molten resin of a brittle resin,

[0077] The second molten resin is a molten resin of a ductile resin.

[0078] According to such a configuration, in the substrate obtained by molding, it is possible to reinforce both ends in the width direction of the portion formed of the brittle resin with the ductile resin.

[0079] The present application

[15] includes a film manufacturing system including:

[0080] The extrusion molding device described in any one of the above-mentioned [1] to

[14] ; and

[0081] A stretching device that stretches the substrate after the extrusion molding by the extrusion molding device.

[0082] The present invention

[16] includes a method for manufacturing a membrane, the method comprising:

[0083] An extrusion molding step of extruding a substrate using the extrusion molding apparatus described in any one of [1] to

[14] above; and

[0084] A stretching step is performed to stretch the substrate obtained by the extrusion molding step.

[0085] Effects of the Invention

[0086] According to the extrusion molding apparatus, film production system, and film production method of the present invention, it is possible to suppress unevenness in thickness at the end portion of an extrusion-molded substrate. BRIEF DESCRIPTION OF THE DRAWINGS

[0087] Figure 1 This is a cross-sectional view of a film produced by a film production system as one embodiment of the present invention.

[0088] Figure 2 This is a schematic diagram of the membrane manufacturing system.

[0089] Figure 3 Yes Figure 2 Explanatory diagram for explaining the die head and feed block of the extrusion molding device shown.

[0090] Figure 4A yes Figure 2 The AA section of the feed block shown, Figure 4B Observed from the downstream side of the flow direction Figure 2 Side view of the die head shown.

[0091] Figure 5 This is a correlation diagram showing the variation in thickness of the substrate obtained in Examples.

[0092] Figure 6 It is a correlation diagram showing the variation in thickness of the substrate obtained in the comparative example.

[0093] Explanation of symbols

[0094] 1. Membrane manufacturing system

[0095] 2 Extrusion molding device

[0096] 4A No. 1 stretching device

[0097] 4B Second stretching device

[0098] 23 Feed Block

[0099] 24 die head

[0100] 231 1st flow path

[0101] 232 2nd flow path

[0102] 233 3rd flow path

[0103] 234 1st Manifold

[0104] 234A upstream section

[0105] 234B downstream section

[0106] 241 Spout

[0107] 242 Second Manifold

[0108] P1 1st inlet

[0109] P2 Second inlet

[0110] P3 3rd inlet

[0111] S substrate DETAILED DESCRIPTION

[0112] 1. Membrane manufacturing system

[0113] The film F production system 1 will be described.

[0114] like Figure 1 As shown, the film F comprises a substrate S and a film C. The substrate S has a first surface S1 and a second surface S2 in the thickness direction of the substrate S. The film C is arranged on the first surface S1 of the substrate S. The film C covers the first surface S1 of the substrate S. The film C can be an easy-adhesion layer. When the film C is an easy-adhesion layer, the film F is an easy-adhesion film. The easy-adhesion film can be used for polarizing plates of image display devices such as mobile devices, car navigation devices, computer monitors, and televisions. In detail, the easy-adhesion film can be used as a protective film for the polarizer of the polarizer. The easy-adhesion film is bonded to the polarizer via an adhesive layer. The easy-adhesion film is bonded to the polarizer via the easy-adhesion layer.

[0115] like Figure 2 As shown, the manufacturing system 1 of the film F includes: an extrusion molding device 2, a first stretching device 4A as an example of a stretching device, a coating device 3, a second stretching device 4B as an example of a stretching device, a slit processing device 5, a knurling processing device 6, and a winding device 7.

[0116] (1) Extrusion molding device

[0117] The extrusion molding device 2 performs extrusion molding (extrusion molding step) of the base material S. The base material S extruded from the extrusion molding device 2 has a sheet shape.

[0118] The substrate S is formed of a thermoplastic resin. As the thermoplastic resin, for example, an acrylic resin, a polyolefin resin, a cyclic polyolefin resin, a polyester resin (polyethylene terephthalate, etc.), a polycarbonate resin, a polystyrene resin, a polyamide resin, a polyimide resin, an acetate resin (cellulose diacetate, cellulose triacetate, etc.), or the like can be exemplified.

[0119] In the case of manufacturing the easily-adhesive film used as the protective film of the polarizer, as the material of the substrate S, an acrylic resin can be preferably exemplified.

[0120] In addition, in the case of manufacturing the easily-adhesive film used as the protective film of the polarizer, the acrylic resin can be an acrylic resin having a glutaric anhydride structure, an acrylic resin having a lactone ring structure. The acrylic resin having a glutaric anhydride structure, and the acrylic resin having a lactone ring structure are suitable for the manufacturing of the polarizing plate having high degree of polarization and excellent durability, because they have high heat resistance, high transparency, and high mechanical strength. The acrylic resin having a glutaric anhydride structure is described in Japanese Patent Application Publication No. 2006-283013, Japanese Patent Application Publication No. 2006-335902, Japanese Patent Application Publication No. 2006-274118. The acrylic resin having a lactone ring structure is described in Japanese Patent Application Publication No. 2000-230016, Japanese Patent Application Publication No. 2001-151814, Japanese Patent Application Publication No. 2002-120326, Japanese Patent Application Publication No. 2002-254544, Japanese Patent Application Publication No. 2005-146084.

[0121] In addition, the substrate S can contain, in addition to the acrylic resin, other thermoplastic resins other than the acrylic resin. By containing other thermoplastic resins, the birefringence of the acrylic resin can be eliminated, and an easily-adhesive film having excellent optical isotropy can be obtained. In addition, the mechanical strength of the easily-adhesive film can be improved.

[0122] Note that the substrate S can contain an antioxidant, a stabilizer, a reinforcing material, an ultraviolet absorber, a flame retardant, an antistatic agent, a colorant, a filler, a plasticizer, a lubricant, a filler, and the like.

[0123] (2) First stretching device

[0124] The first stretching device 4A stretches (first stretching step) the substrate S obtained by the extrusion molding step after heating the substrate S.

[0125] (3) Coating device

[0126] The coating device 3 coats the first surface S1 of the substrate S after extrusion molding by the extrusion molding step (coating step). Note that the first surface S1 of the substrate S can be subjected to surface treatment such as corona treatment, plasma treatment, or the like after the extrusion molding step and before the coating step.

[0127] As the coating device 3, for example, a wire bar coater, a gravure coater, a roll kiss coater, or the like can be given.

[0128] In the case of manufacturing the easy-adhesion film, the coating liquid is an easy-adhesion composition for forming an easy-adhesion layer.

[0129] The easy-adhesion layer contains an adhesive resin and a fine particle.

[0130] As the adhesive resin, for example, a thermosetting resin such as a urethane resin, an epoxy resin, or the like, a thermoplastic resin such as an acrylic resin, a polyester resin, or the like can be given. In the case where the easy-adhesion film is used as a protective film for a polarizing plate, the adhesive resin is preferably a thermosetting resin. The adhesive resin can be used in combination of a plurality of kinds.

[0131] As the fine particle, for example, an oxide such as silicon oxide (silica), titanium oxide (titania), aluminum oxide (alumina), zirconium oxide (zirconia), or the like, a carbonate such as calcium carbonate, or the like, a silicate such as calcium silicate, aluminum silicate, magnesium silicate, or the like, a silicate mineral such as talc, kaolin, or the like, a phosphate such as calcium phosphate, or the like can be given. In the case where the easy-adhesion film is used as a protective film for a polarizing plate, the fine particle is preferably an oxide, and more preferably silicon oxide. The fine particle can be used in combination of a plurality of kinds.

[0132] The coating liquid (easy-adhesion composition) contains a resin component, the above-described fine particle, and a dispersion medium.

[0133] As the resin component, a film (easy-adhesion layer) of the above-described adhesive resin is formed by the stretching step described later. In the case where the adhesive resin is a urethane resin, as the resin component, for example, an aqueous urethane resin can be given. As the aqueous urethane resin, for example, a non-reactive aqueous urethane resin such as an emulsion of a urethane resin, a reactive aqueous urethane resin such as an emulsion of a urethane resin in which an isocyanate group is protected with a blocking agent, or the like can be given. In the case where the adhesive resin is a urethane resin, the coating liquid can contain a urethane curing catalyst (triethylamine or the like), an isocyanate monomer.

[0134] As the dispersion medium, for example, water, an alcohol such as methanol, ethanol, or the like, a ketone such as acetone, methyl ethyl ketone, or the like, or the like can be given.

[0135] (4) Second stretching device

[0136] The second stretching device 4B dries the coating liquid applied in the coating step. The coating liquid thus becomes the aforementioned film C. Furthermore, the second stretching device 4B heats the substrate S with the film C formed thereon and then stretches it in the width direction TD of the substrate S (a second stretching step). The width direction TD is perpendicular to the flow direction MD. By stretching the substrate S with the film C formed thereon through the second stretching step, the aforementioned film F is obtained.

[0137] (5) Slit processing device

[0138] The slit processing device 5 cuts the film F stretched in the stretching step into a predetermined width (slit step).

[0139] (6) Knurling processing device

[0140] The knurling device 6 forms knurling on both ends in the width direction of the film F cut into a predetermined width by the slit process (knurling process). The knurling is formed by laser or by a heated embossing roller.

[0141] (7) Winding device

[0142] The winding device 7 winds up the film F on which the knurling has been formed in the knurling step (winding step). By completing the winding step, a roll of the film F can be obtained.

[0143] 2. Details of the extrusion molding device

[0144] Next, the details of the extrusion molding device 2 will be described.

[0145] like Figure 3 As shown, in this embodiment, the base material S molded by the extrusion molding device 2 has a main body portion M and two reinforcing portions R1 and R2 in the width direction TD.

[0146] The main body portion M extends in the width direction TD and is formed of a brittle resin.

[0147] The brittle resin is a thermoplastic resin that is easily broken when bent. Specifically, the brittle resin is a resin that can withstand less than 50 flexural cycles in a flexural strength test using a 200 g load as specified in JIS P 8115:2001.

[0148] The flexural strength test was performed using BE-202 (manufactured by TESTER SANGYO) as a testing machine under the following conditions.

[0149] <Flexural Strength Test Conditions>

[0150] Test piece dimensions: width 15 mm, length 110 mm

[0151] Test speed: 175 cpm

[0152] Bending angle: 135°

[0153] Load: 200 g weight

[0154] Curvature radius R of bending jig: 0.38 mm

[0155] Opening of bending jig: 0.25 mm

[0156] In the present embodiment, the main body portion M is in an unstretched state and is formed of a brittle resin. The unstretched state refers to a state before the base material S extrusion-molded is stretched in the flow direction MD or the width direction TD after the extrusion-molding process.

[0157] The present embodiment is preferable in a case where the number of times of resistance to bending of the main body portion M is less than 10, and is more preferable in a case where the number of times of resistance to bending of the main body portion M is less than 5.

[0158] Specifically, as the brittle resin, an acrylic resin can be cited.

[0159] The reinforcing portion R1 reinforces one end portion of the main body portion M in the width direction TD. The reinforcing portion R1 is disposed at one end portion of the base material S in the width direction TD. The reinforcing portion R1 covers one end portion of the main body portion M in the width direction TD. The reinforcing portion R1 is formed of a ductile resin.

[0160] The ductile resin refers to a resin among the above-described thermoplastic resins, the number of times of resistance to bending in the above-described resistance to bending strength test of which is 50 times or more.

[0161] As the ductile resin, for example, a polycarbonate resin, a polyester resin, a mixture of a polycarbonate resin and a polyester resin, and the like can be cited.

[0162] The reinforcing portion R2 reinforces the other end portion of the main body portion M in the width direction TD. The reinforcing portion R2 is disposed at the other end portion of the base material S in the width direction TD. The reinforcing portion R2 is disposed at the opposite side of the main body portion M from the reinforcing portion R1 in the width direction TD. The reinforcing portion R2 covers one end portion of the main body portion M in the width direction TD. The reinforcing portion R2 is formed of a ductile resin.

[0163] In detail, the extrusion molding device 2 is provided with a first cylinder 21, a second cylinder 22, a feeding block 23, and a die 24.

[0164] (1) First Cylinder

[0165] The first cylinder 21 melts a first resin that is a raw material of the main body portion M of the base material S. The first resin becomes a first molten resin by melting. As the first resin, for example, the brittle resin described above can be cited. That is, the first molten resin is a molten resin of the brittle resin.

[0166] The viscosity of the first molten resin is, for example, 100 Pa-s or more, preferably 500 Pa-s or more, and, for example, 10,000 Pa-s or less, preferably 2,000 Pa-s or less.

[0167] (2) Second Cylinder

[0168] The second cylinder 22 melts a second resin that is a raw material of the reinforcing portions R1, R2 of the base material S. The second resin becomes a second molten resin by melting. As the second resin, the ductile resin described above can be cited. That is, the second molten resin is a molten resin of the ductile resin.

[0169] The viscosity of the second molten resin is, for example, 100 Pa-s or more, preferably 500 Pa-s or more, and, for example, 10,000 Pa-s or less, preferably 2,000 Pa-s or less.

[0170] (3) Feeding Block

[0171] The feeding block 23 is connected to the first cylinder 21 and the second cylinder 22. The feeding block 23 supplies the first molten resin from the first cylinder 21 and the second molten resin from the second cylinder 22 to the die 24.

[0172] The feeding block 23 has a first flow path 231, a second flow path 232, a third flow path 233, and a first manifold 234. In other words, the extrusion molding device 2 has the first flow path 231, the second flow path 232, the third flow path 233, and the first manifold 234.

[0173] (3-1) First Flow Path

[0174] The first flow path 231 is connected to the first cylinder 21. The first molten resin is supplied from the first cylinder 21 to the first flow path 231. The first molten resin supplied from the first cylinder 21 passes through the first flow path 231. The first flow path 231 is connected to the first flow inlet P1 of the first manifold 234. The first flow inlet P1 will be described later.

[0175] (3-2) Second Flow Path

[0176] The second flow path 232 is connected to the second cylinder 22. The second molten resin is supplied from the second cylinder 22 to the second flow path 232. The second molten resin supplied from the second cylinder 22 passes through the second flow path 232. The second flow path 232 is connected to the second flow inlet P2 of the first manifold 234. The second flow inlet P2 will be described later. The portion of the second flow path 232 connected to the second flow inlet P2 extends along the flow direction MD. Thus, the second molten resin after passing through the second flow path 232 can be supplied to the first manifold 234 along the flow direction MD.

[0177] (3-3) Third flow path

[0178] The third flow path 233 is connected to the second cylinder 22. The second molten resin is supplied from the second cylinder 22 to the third flow path 233. The second molten resin supplied from the second cylinder 22 passes through the third flow path 233. The third flow path 233 is connected to the third flow inlet P3 of the first manifold 234. The third flow inlet P3 will be described later. The portion of the third flow path 233 connected to the third flow inlet extends along the flow direction MD. Thus, the second molten resin after passing through the third flow path 233 can be supplied to the first manifold 234 along the flow direction MD.

[0179] (3-4) First manifold

[0180] The first manifold 234 is disposed between the first flow path 231 and the die 24. In other words, the first manifold 234 is disposed between the first flow path 231 and the ejection port 241. The ejection port 241 will be described later. The first manifold 234 is connected to the first flow path 231. The first manifold 234 extends along the flow direction MD. In other words, the flow direction MD is the direction from the first flow inlet PI toward the ejection port 241. The first manifold 234 also extends along the width direction TD. The first manifold 234 spreads the first molten resin entering the first manifold 234 in the width direction TD.

[0181] In detail, the first manifold 234 has an upstream portion 234A, a downstream portion 234B, a first flow inlet PI, a second flow inlet P2, and a third flow inlet P3.

[0182] (3-4-1) Upstream portion

[0183] The upstream portion 234A is connected to the first flow path 231. The upstream portion 234A is disposed between the downstream portion 234B and the first flow path 231 in the flow direction MD. The upstream portion 234A spreads from the first flow inlet PI toward the width direction TD.

[0184] Specifically, the upstream portion 234A has an inner surface S11 and an inner surface S12 in the width direction. The inner surface S11 extends from the first inlet P1 toward one side in the width direction TD. The inner surface S11 curves toward the flow direction MD as it approaches the width direction TD. The inner surface S12 is located on the opposite side of the first inlet P1 from the inner surface S11 in the width direction TD. The inner surface S12 extends from the first inlet P1 toward the other side in the width direction TD. The inner surface S12 curves toward the flow direction MD as it approaches the width direction TD. The upstream portion 234A causes the first molten resin entering the first manifold 234 from the first inlet P1 to spread in the width direction TD along the inner surface S11 and the inner surface S12.

[0185] (3-4-2) Downstream part

[0186] The downstream portion 234B extends in the flow direction MD from the downstream end of the upstream portion 234A in the flow direction MD. Thus, the downstream portion 234B causes the first and second molten resins within the first manifold 234 to flow along the flow direction MD. The length of the downstream portion 234B in the width direction TD is the same as the length of the downstream end of the upstream portion 234A in the width direction TD. One end and the other end of the downstream portion 234B in the width direction TD extend along the flow direction MD. The one end of the downstream portion 234B in the width direction TD corresponds to one end of the first manifold 234 in the width direction TD, and the other end of the downstream portion 234B in the width direction TD corresponds to the other end of the first manifold 234 in the width direction TD. In other words, the one end and the other end of the first manifold 234 in the width direction TD extend along the flow direction MD.

[0187] like Figure 4A As shown, when viewed in the flow direction MD, the downstream portion 234B has a flat shape extending in the width direction TD. Thus, the first molten resin is expanded by the first manifold 234 into a flat shape that approximates the flat shape of the discharge outlet 241, and the second molten resin is caused to merge with both ends of the first molten resin expanded by the first manifold 234 in the width direction TD. This further reduces the flow disturbances of the first and second molten resins between the first manifold 234 and the discharge outlet 241. Consequently, uneven thickness at the ends of the extruded substrate S can be further reduced. More specifically, the downstream portion 234B has a rectangular shape extending in the width direction TD.

[0188] Note that the width of the downstream portion 234B in the thickness direction perpendicular to both the flow direction MD and the width direction TD is shorter than the diameter of the first inlet P1.

[0189] The flow rate of the first molten resin in the downstream portion 234B of the first manifold 234 is, for example, 0.1 m / min or more, preferably 1 m / min or more, and for example, 10 m / min or less, preferably 5 m / min or less.

[0190] (3-4-3) 1st inlet

[0191] like Figure 3 As shown, the first inlet P1 communicates with the first flow path 231. The first inlet P1 is located at the upstream end of the first manifold 234 in the flow direction MD. The first inlet P1 is located between the two ends of the first manifold 234 in the width direction TD. The first inlet P1 is located between the second inlet P2 and the third inlet P3 in the width direction TD. The first inlet P1 is located at the center of the first manifold 234 in the width direction TD. The first inlet P1 is circular in shape.

[0192] (3-4-4) Second inlet

[0193] The second inlet P2 communicates with the second flow path 232. The second inlet P2 is located downstream of the first inlet P1 in the flow direction MD. The second inlet P2 is located at one end of the first manifold 234 in the width direction TD. This allows the second molten resin to merge with the first molten resin at one end of the first manifold 234. Consequently, the second molten resin can merge with the first molten resin, which has been expanded in the width direction by the first manifold 234. This prevents disturbances in the flows of the first and second molten resins. Consequently, uneven thickness at the end of the extruded substrate S can be prevented.

[0194] In detail, Figure 4A As shown, the second inlet port P2 is located at one end of the downstream portion 234B in the width direction TD. This allows the first molten resin to be expanded in the width direction TD at the upstream portion 234A of the first manifold 234. After the second molten resin is expanded in the width direction TD, it can be joined at the downstream portion 234B of the first manifold 234 with the first molten resin flowing in the flow direction MD at one end in the width direction TD. Consequently, disturbances in the flows of the first and second molten resins at the one end in the width direction TD can be further suppressed. Consequently, uneven thickness at the end of the extruded substrate S can be further suppressed.

[0195] Here, the second molten resin that has passed through the second flow inlet P2 enters one end portion of the width direction TD of the downstream portion 234B, and therefore does not spread in the width direction TD within the downstream portion 234B. Therefore, there is a possibility that the second molten resin cannot be molded into a desired shape within the downstream portion 234B. For example, when the second flow inlet P2 is circular in shape in contrast to the rectangular shape of the downstream portion 234B, there is a possibility that the end portion becomes circular in shape.

[0196] In this regard, the second flow inlet P2 is quadrangular. That is, the second molten resin enters one end portion of the width direction TD of the rectangular downstream portion 234B from the quadrangular second flow inlet P2. Therefore, at the stage at which the second molten resin enters the downstream portion 234B from the second flow inlet P2, the second molten resin has a shape that follows the shape of the one end portion along the width direction TD of the downstream portion 234B. As a result, even if the second molten resin that has entered the downstream portion 234B from the second flow inlet P2 does not spread in the width direction TD within the downstream portion 234B, it is possible to form an end portion that follows the shape of the one end portion along the width direction TD of the downstream portion 234B.

[0197] Note that the shape of the second flow inlet P2 is not limited to quadrangular as long as it is a shape that follows the shape of the one end portion along the width direction TD of the downstream portion 234B.

[0198] It is preferable that the inner face S31 of one side of the second flow inlet P2 in the width direction TD be flush with the inner face S21 of one side of the downstream portion 234B in the width direction TD as viewed from the flow direction MD. Therefore, even if the second molten resin that has entered the downstream portion 234B from the second flow inlet P2 does not spread in the width direction TD, it is possible to make the second molten resin follow the shape of the one end portion along the width direction TD of the downstream portion 234B. As a result, it is possible to form an end portion that follows the shape of the one end portion along the width direction TD of the downstream portion 234B.

[0199] Note that the inner face S31 can not be flush with the inner face S21. There can be a difference in height between the inner face S31 and the inner face S21 to the extent that it is possible to form an end portion that follows the shape of the one end portion along the width direction TD of the downstream portion 234B.

[0200] When viewed in the flow direction MD, the inner surface S32 on one side of the second inlet P2 in the thickness direction is flush with the inner surface S23 on one side of the downstream portion 234B in the thickness direction. When viewed in the flow direction MD, the inner surface S33 on the other side of the second inlet P2 in the thickness direction is flush with the inner surface S24 on the other side of the downstream portion 234B in the thickness direction. This prevents the second molten resin entering the downstream portion 234B from the second inlet P2 from spreading in the thickness direction. As a result, the flow of the second molten resin can be further suppressed when entering the downstream portion 234B from the second inlet P2.

[0201] It should be noted that the inner surface S32 may not be flush with the inner surface S23, and the inner surface S33 may not be flush with the inner surface S24. A height difference may exist between the inner surface S32 and the inner surface S23, and between the inner surface S33 and the inner surface S24, to such an extent that an end portion of the shape along the width direction TD of the downstream portion 234B can be formed.

[0202] The flow rate of the second molten resin at the second inlet P2 is, for example, 0.5 times or more, preferably 0.7 times or more, and for example, 1.5 times or less, the flow rate of the first molten resin at the downstream portion 234B of the first manifold 234. Therefore, when the second molten resin and the first molten resin are joined at one end in the width direction TD, the flow rate of the second molten resin can be made close to that of the first molten resin. As a result, disturbances in the flows of the first and second molten resins can be suppressed.

[0203] Specifically, the flow rate of the second molten resin at the second inlet P2 is, for example, 0.1 m / min or more, preferably 1 m / min or more, and for example, 10 m / min or less, preferably 5 m / min or less.

[0204] (3-4-5) The third inlet

[0205] like Figure 3 As shown, the third inlet P3 communicates with the third flow path 233. The third inlet P3 is located downstream of the first inlet P1 in the flow direction MD. The third inlet P3 is located at the other end of the first manifold 234 in the width direction TD. This allows the second molten resin to merge with the first molten resin at the other end of the first manifold 234. Therefore, the second molten resin can merge with the first molten resin that has been expanded in the width direction TD by the first manifold 234. This prevents disturbances in the flows of the first and second molten resins. Consequently, uneven thickness at the end of the extruded substrate S can be prevented.

[0206] In detail, Figure 4AAs shown, the third flow inlet P3 is disposed at the other end portion of the downstream portion 234B in the width direction TD. Thereby, after the first molten resin is spread in the width direction TD in the upstream portion 234A of the first manifold 234, the second molten resin can be merged with the other end portion of the width direction TD of the first molten resin flowing along the flow direction MD in the downstream portion 234B of the first manifold 234. Therefore, at the other end portion of the width direction TD, the flow of the first molten resin and the flow of the second molten resin can be further suppressed from being disturbed. As a result, the thickness of the end portion of the substrate S extrusion-molded can be further suppressed from becoming uneven.

[0207] The third flow inlet P3 is also a quadrangle like the second flow inlet P2. That is, the second molten resin enters the other end portion of the width direction TD of the oblong downstream portion 234B from the quadrangular third flow inlet P3. Thereby, at the stage of the second molten resin entering the downstream portion 234B from the third flow inlet P3, the second molten resin has a shape following the shape along the other end portion of the width direction TD of the downstream portion 234B. As a result, even if the second molten resin entering the downstream portion 234B from the third flow inlet P3 is not spread in the width direction TD within the downstream portion 234B, an end portion following the shape along the other end portion of the width direction TD of the downstream portion 234B can be formed.

[0208] Note that the shape of the third flow inlet P3 is only required to be a shape following the shape along the other end portion of the width direction TD of the downstream portion 234B, and is not limited to a quadrangle.

[0209] It is preferable that the inner face S41 of the other side of the third flow inlet P3 in the width direction TD is flush with the inner face S22 of the other side of the downstream portion 234B in the width direction TD, as viewed from the flow direction MD. Thereby, even if the second molten resin entering the downstream portion 234B from the third flow inlet P3 is not spread in the width direction TD, the second molten resin can be made to follow the shape along the other end portion of the width direction TD of the downstream portion 234B. As a result, an end portion following the shape along the other end portion of the width direction TD of the downstream portion 234B can be formed.

[0210] Note that the inner face S41 can not be flush with the inner face S22. A height difference can exist between the inner face S41 and the inner face S22 to the extent that an end portion following the shape along the other end portion of the width direction TD of the downstream portion 234B can be formed.

[0211] When viewed in the flow direction MD, the inner surface S42 on one side of the third inlet P3 in the thickness direction is flush with the inner surface S23 on one side of the downstream portion 234B in the thickness direction. When viewed in the flow direction MD, the inner surface S43 on the other side of the third inlet P3 in the thickness direction is flush with the inner surface S24 on the other side of the downstream portion 234B in the thickness direction. This prevents the second molten resin entering the downstream portion 234B from the third inlet P3 from spreading in the thickness direction. As a result, the flow of the second molten resin can be further suppressed when entering the downstream portion 234B from the third inlet P3.

[0212] It should be noted that the inner surface S42 may not be flush with the inner surface S23, and the inner surface S43 may not be flush with the inner surface S24. A height difference may exist between the inner surface S42 and the inner surface S23, and between the inner surface S43 and the inner surface S24, to such an extent that an end portion of the shape along the width direction TD of the downstream portion 234B can be formed.

[0213] The flow rate of the second molten resin at the third inlet P3 is, for example, 0.5 times or more, preferably 0.7 times or more, and for example, 1.5 times or less, the flow rate of the first molten resin at the downstream portion 234B of the first manifold 234. This allows the flow rate of the second molten resin to approach that of the first molten resin when the second molten resin merges with the first molten resin at the other end in the width direction TD. As a result, disturbances in the flows of the first and second molten resins can be suppressed.

[0214] Specifically, the flow rate of the second molten resin at the third inlet P3 is, for example, 0.1 m / min or more, preferably 1 m / min or more, and for example, 10 m / min or less, preferably 5 m / min or less.

[0215] (4) Die head

[0216] like Figure 3 As shown, the die head 24 is connected to the feed block 23. The die head 24 has a nozzle 241 and a second manifold 242. In other words, the extrusion molding device 2 has the nozzle 241 and the second manifold 242.

[0217] (4-1) Spout

[0218] The discharge port 241 discharges the first molten resin and the second molten resin that have passed through the first manifold 234 and the second manifold 242 .

[0219] like Figure 4BAs shown, the discharge port 241 has a flat shape extending in the width direction TD. More specifically, the discharge port 241 has a rectangular shape extending in the width direction TD. The discharge port 241 is longer in the width direction TD than the downstream portion 234B of the first manifold 234. The width of the discharge port 241 in the thickness direction is narrower than the width of the downstream portion 234B of the first manifold 234 in the thickness direction.

[0220] (4-2) Second manifold

[0221] like Figure 3 As shown, the second manifold 242 is disposed between the first manifold 234 and the discharge port 241. The second manifold 242 communicates with the first manifold 234. The second manifold 242 extends along the flow direction MD. The second manifold 242 also extends in the width direction TD. The second manifold 242 is longer than the first manifold 234 in the width direction TD. This allows the first and second molten resins, after passing through the first manifold 234, to be further spread in the width direction TD through the second manifold 242. As a result, disturbances in the flows of the first and second molten resins can be suppressed, and a substrate S that is larger in the width direction TD can be formed.

[0222] Specifically, the second manifold 242 includes an upstream portion 242A and a downstream portion 242B.

[0223] (4-2-1) Upstream part

[0224] The upstream portion 242A communicates with the first manifold 234. The upstream portion 242A is arranged between the downstream portion 242B and the first manifold 234 in the flow direction MD. The upstream portion 242A extends from the first manifold 234 in the width direction TD.

[0225] Specifically, the upstream portion 242A has an inner surface S51 and an inner surface S52 in the width direction TD. The inner surface S51 extends from the first manifold 234 toward one side in the width direction TD. The inner surface S51 curves toward the flow direction MD as it approaches the one side in the width direction TD. The inner surface S52 is located on the opposite side of the first manifold 234 from the inner surface S51 in the width direction TD. The inner surface S52 extends from the first manifold 234 toward the other side in the width direction TD. The inner surface S52 curves toward the flow direction MD as it approaches the other side in the width direction TD. Thus, the upstream portion 242A causes the first and second molten resins entering the second manifold 242 from the first manifold 234 to spread in the width direction TD along the inner surface S51 and inner surface S52.

[0226] (4-2-2) Downstream part

[0227] The downstream portion 242B extends from the downstream end of the upstream portion 242A in the flow direction MD. Thus, in the downstream portion 242B, the first molten resin and the second molten resin in the second manifold 242 flow along the flow direction MD. The downstream portion 242B has the same width as the downstream end of the upstream portion 242A. One end portion and the other end portion of the downstream portion 242B in the width direction TD extend along the flow direction MD. The one end portion of the downstream portion 242B in the width direction TD is the one end portion of the second manifold 242 in the width direction TD. The other end portion of the downstream portion 242B in the width direction TD is the other end portion of the second manifold 242 in the width direction TD. That is, the one end portion and the other end portion of the second manifold 242 in the width direction TD extend along the flow direction MD. The downstream portion 234B is the same shape as the discharge port 241 as viewed in the flow direction MD. The downstream portion 234B communicates with the discharge port 241.

[0228] 3. Modified example

[0229] (1) The extrusion molding device 2 can not have the feeding block 23. In this case, the first manifold 234 can be provided to the die 24.

[0230] (2) The extrusion molding device 2 can not have the second manifold 242. In this case, the first manifold 234 can communicate with the discharge port 241.

[0231] (3) The first molten resin can not be a molten resin of a brittle resin. The first molten resin can be a molten resin of a ductile resin different from the second molten resin.

[0232] (4) The film F manufacturing system 1 can not have the coating device 3.

[0233] (5) The film F manufacturing system 1 can not have the first stretching device 4A. The base material S can be stretched in the flow direction MD and the width direction TD by the second stretching device 4B (two-way simultaneous stretching).

[0234] (6) The film F manufacturing system 1 can not have the first stretching device 4A and the second stretching device 4B. That is, the film F manufacturing system 1 can not stretch the film F. In this case, the film F can not be wound but cut to a given size and loaded.

[0235] (7) The film F manufacturing system 1 can not have the knurling device 6. The mask film can be attached to the film F and wound.

[0236] Example

[0237] Next, the present application will be described based on examples and comparative examples. The present application is not limited by the following examples.

[0238] Example

[0239] like Figure 3 As shown, molten polycarbonate (tough resin) and molten acrylic resin (brittle resin) were combined at both ends of a feed block manifold to form a substrate through extrusion molding. During molding, the thickness of the molded substrate was continuously measured 100 times across the width using an in-line traverse infrared thickness gauge.

[0240] Comparative Example

[0241] As described in Japanese Patent Application Laid-Open No. 2006-315275, a substrate was extruded by combining molten polycarbonate (tough resin) and molten acrylic resin (brittle resin) using a brittle resin flow path in a feed block. The thickness of the resulting substrate was measured in the same manner as in the Examples.

[0242] like Figure 5 and Figure 6 As shown, the variation F1 of the thickness at the end of the substrate in the example is smaller than the variation F2 of the thickness at the end of the substrate in the comparative example. In other words, the example can better suppress the unevenness of the thickness at the end of the substrate than the comparative example.

[0243] It should be noted that the above invention is provided in the form of exemplary embodiments of the present invention, but this is only an example and is not to be construed as limiting. Modifications of the present invention that can be understood by those skilled in the art are also included in the claims.

[0244] Industrial Applicability

[0245] The extrusion molding apparatus, film production system, and film production method of the present invention can be used to produce films such as easy-adhesion films.

Claims

1. An extrusion molding apparatus having: a first flow path through which a first molten resin passes; a second flow path and a third flow path through which a second molten resin passes; a first manifold having a first flow inlet communicating with the first flow path, a second flow inlet communicating with the second flow path, and a third flow inlet communicating with the third flow path; and a discharge port discharging the first molten resin and the second molten resin after passing through the first manifold, the first manifold extending along a flow direction from the first flow inlet toward the discharge port, and extending in a width direction orthogonal to the flow direction, the first flow inlet being disposed at an upstream end of the first manifold in the flow direction, and being disposed between both end portions of the first manifold in the width direction, the second flow inlet being disposed downstream of the first flow inlet in the flow direction, and being disposed at one end portion of the first manifold in the width direction, the third flow inlet being disposed downstream of the first flow inlet in the flow direction, and being disposed at the other end portion of the first manifold in the width direction, the first manifold having: an upstream portion spreading from the first flow inlet in the width direction, and a downstream portion extending from a downstream end of the upstream portion in the flow direction, the second flow inlet being disposed at one end portion of the downstream portion in the width direction, and having a shape following one end portion of the downstream portion along the width direction, the third flow inlet being disposed at the other end portion of the downstream portion in the width direction, and having a shape following the other end portion of the downstream portion along the width direction.

2. The extrusion molding apparatus according to claim 1, wherein the one end portion and the other end portion of the first manifold in the width direction extend along the flow direction, and a portion of the second flow path connected to the second flow inlet, and a portion of the third flow path connected to the third flow inlet extend along the flow direction.

3. The extrusion molding apparatus according to claim 1, wherein the first flow inlet is a circular shape, the discharge port is a flat shape extending in the width direction, and the downstream portion of the first manifold is a flat shape extending in the width direction, as viewed from the flow direction.

4. The extrusion molding apparatus according to claim 1, wherein an inner face of one side of the second flow inlet in the width direction is flush with an inner face of one side of the downstream portion in the width direction, as viewed from the flow direction, and an inner face of the other side of the third flow inlet in the width direction is flush with an inner face of the other side of the downstream portion in the width direction, as viewed from the flow direction.

5. The extrusion molding apparatus according to claim 4, wherein an inner face of one side of the second flow inlet in a thickness direction orthogonal to both the flow direction and the width direction is flush with an inner face of one side of the downstream portion in the thickness direction, as viewed from the flow direction. wherein ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ the inner face on the other side of the third flow inlet in the thickness direction is flush with the inner face on the other side of the downstream portion in the thickness direction as viewed in the flow direction, the inner face on one side of the third flow inlet in the thickness direction is flush with the inner face on one side of the downstream portion in the thickness direction as viewed in the flow direction, the inner face on the other side of the third flow inlet in the thickness direction is flush with the inner face on the other side of the downstream portion in the thickness direction as viewed in the flow direction.

6. The extrusion molding device according to claim 1, further comprising a second manifold disposed between the first manifold and the die outlet, and communicating with the first manifold. the second manifold is longer than the first manifold in the width direction.

7. The extrusion molding device according to claim 6, comprising: a feeding block having the first manifold; and a die head having the die outlet and connected to the feeding block.

8. The extrusion molding device according to claim 7, wherein the die head further has the second manifold.

9. The extrusion molding device according to claim 1, wherein the flow rate of the second molten resin at the second flow inlet and the flow rate of the second molten resin at the third flow inlet are 0.5 times or more and 1.5 times or less of the flow rate of the first molten resin in the first manifold.

10. The extrusion molding device according to claim 9, wherein the flow rate of the second molten resin at the second flow inlet, the flow rate of the second molten resin at the third flow inlet, and the flow rate of the first molten resin in the first manifold are 0.1 m / min or more and 10 m / min or less.

11. The extrusion molding device according to claim 1, wherein the viscosity of the first molten resin and the second molten resin is 100 Pa-s or more and 10,000 Pa-s or less.

12. The extrusion molding device according to claim 1, wherein the first molten resin is a molten resin of a brittle resin, the second molten resin is a molten resin of a ductile resin.

13. A film manufacturing system comprising: the extrusion molding device according to claim 1; and a stretching device that stretches a base material that has been subjected to extrusion molding by the extrusion molding device.

14. A film manufacturing method comprising: an extrusion molding process of extrusion molding a base material by the extrusion molding device according to claim 1; and a stretching process of stretching the base material obtained by the extrusion molding process.

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