Source: https://patents.google.com/patent/US20040108621?oq=5998925
Timestamp: 2018-03-18 20:45:31
Document Index: 748111631

Matched Legal Cases: ['art 36', 'arts 13', 'art 36', 'art 36', 'art 36', 'art 36', 'art 36', 'art 36', 'arts 36']

US20040108621A1 - Method and apparatus for forming resin film - Google Patents
US20040108621A1
US20040108621A1 US10725053 US72505303A US2004108621A1 US 20040108621 A1 US20040108621 A1 US 20040108621A1 US 10725053 US10725053 US 10725053 US 72505303 A US72505303 A US 72505303A US 2004108621 A1 US2004108621 A1 US 2004108621A1
US10725053
US7674412B2 (en )
Joining the resins for the middle portion and for the edge portions in such a manner as to enclose both side edges in the crosswise direction of the resin film main body with the resin for the edge portions. (herein after referred to as “the joining method of the present invention”) can reduce the disorder at the boundary between the resins for the middle portion and for the edge portion, while preventing the film separation of the two resins. This makes it possible to avoid the inclusion of the resin for the middle portion in the trimmed-off selvages as much as possible, which in turn increases the recyclability of the selvages, and hence the yield and the productivity of the product.
[0023]FIG. 1 is a general block diagram of an apparatus for forming a resin film according to an embodiment of the present invention;
FIGS. 2(a) and 2(b) are front and side elevations, respectively, illustrating an extruding die with a feed block, and FIG. 2(c) is an enlarged view illustrating a joining part;
[0025]FIG. 3 is a sectional view showing a cross-sectional shape of the joining part of the feed block;
[0026]FIG. 4 is a cross-sectional view of a lamination resin formed by the joining part of the feed block;
[0027]FIG. 5 is a sectional view showing another cross-sectional shape of the joining part of the feed block;
[0028]FIG. 6 is a cross-sectional view of a lamination resin formed in Comparative Example 1;
[0029]FIG. 7 is a cross-sectional view of a lamination resin formed in Example 1;
[0030]FIG. 8 is a cross-sectional view of a lamination resin formed in Comparative Example 3;
[0031]FIG. 9 is a cross-sectional view of a lamination resin formed in Example 3;
[0032]FIG. 10 is a cross-sectional view of a lamination resin formed in Example 4;
[0033]FIG. 11 is a cross-sectional view of a lamination resin formed in Example 5; and
[0034]FIG. 12 is a sectional view showing one example of exchange structure provided to the feed block main body with which one joining part block can be exchanged for another.
[0036]FIG. 1 is a general block diagram of an apparatus 10 for forming a resin film according to an embodiment of the present invention. The apparatus will be described taking the case where a film-like laminate 27 is formed by laminating a support 22 with a resin film 11.
FIGS. 2(a), 2(b) and 2(c) illustrate an extruding die 12 with a feed block, and FIG. 2(a) is a front elevation of the extruding die 12, FIG. 2(b) is a side elevation of the extruding die 12, and FIG. 2(c) is an enlarged view illustrating a joining part 36, respectively.
As shown in FIGS. 2(a) and 2(b), the feed block 13 is detachably attached to the extruding die 12 by fastening each other's flange parts 13A, 12A with bolts 17. In the inside of the feed block 13, a trunk flow path 32, through which a resin A for the middle portion for forming a resin film main body 11A arranged in the middle portion of the resin film 11 in terms of its width direction flows, a pair of branch flow paths 34, 34, through which a resin B for the edge portions for forming both edge portions 11B of the resin film 11 in terms of its width direction flows, and a joining part 36, in which the pair of branch flow paths 34 join the trunk flow path 32, are formed. The joining part 36 is formed so that its cross section has such a shape as a pair of recessed branch flow paths 34 are fitted on the respective projecting edges of the trunk flow path 32, as shown in FIG. 3 (a cross-sectional view of the joining part 36 taken along the line 3-3 of FIG. 2(a)). This shape allows the resin A for the middle portion, which flows through the trunk flow path 32, and the resin B for the edge portions, which flows through the pair of branch flow paths 34, to join together at the joining part 36 and, as shown in FIG. 4, the resin B for the edge portions is applied to the side edge portions of the resin film main body 11A in such a manner as to enclose the side edges of the resin film main body with the resin B. A lamination resin 15 having been formed by lamination at the joining part 36 (refer to FIG. 4) is fed from the joining part 36 to the extruding die 12. The feed block 13 is so constructed that any one of a plurality of joining part blocks 13D having respective joining parts different in degree of enclosing the resin A for the middle portion with the resin B for the edge portions can be detachably attached thereto and any one of the joining part blocks 13D which specify the joining configuration is exchangeable for another depending on the condition under which resin films are formed. As for the exchange structure provided to the feed block 13 with which one joining part block 13D can be exchanged for another, for example, a structure can be suitably used which comprises a feed block main body 13B and a penetration 13C formed laterally in the feed block main body 13B and whose penetration 13C a joining part block 13D is inserted into or drawn out. A closure plate 13E for closing one end of the penetration 13C is detachably attached to the feed block main body 13B by, for example, bolting. The closure plate 13E may be provided on both ends of the penetration 13C. A plurality of joining part blocks 13D having respective joining parts 36 different in degree (L) to which the resin A for the middle portion is enclosed with the resin B for the edge portions are prepared and a joining part block 13D, which specifies the joining configuration, is exchanged for a more suitable one depending on the condition under which resin films are formed, such as difference in MFR between the resin A for the middle portion and the resin B for the edge portion, difference in extrusion rate between the resin A for the middle portion and the resin B for the edge portion, difference in resin temperature between the resin A for the middle portion and the resin B for the edge portions and the width of the resin film 11.
As shown in FIGS. 2(a) and 2(b), the extruding die 12 comprises a manifold 28 and a slit 30, and the lamination resin 15 fed into the extruding die 12 is spread in the width direction of the extruding die 12 (the width direction of the resin film 11), run through the slit 30 and extruded from the extruding die 12 outside.
Film Disorder at
Width-Direction Die Joining Separation Boundary
Resin Used Layering System Width Configuration of Resins between Resins
Comparative A: MFR 10 g/10 min plus Feed block 1 m None Rather
Example 1 A: MFR 10 g/10 min plus Feed block ″ None Small
Comparative A: MFR 10 g/10 min plus Die system ″ Observed Small
Example 2 A: MFR 10 g/10 min plus Feed block ″ None Small
Comparative A1: MFR 10 g/10 min plus Feed block ″ None Large
Example 3 A1: MFR 10 g/10 min plus Feed block ″ None Rather
Example 4 A1: MFR 10 g/10 min plus Feed block ″ None Small
Comparative A: MFR 10 g/10 min plus Feed block 2 m None Large
Example 5 A: MFR 10 g/10 min plus Feed block ″ None Rather
1. A method of forming a resin film from a resin for a middle portion to form a resin film main body of the resin film and a resin for edge portions to form both side edge portions in a crosswise direction of the resin film, the method comprising the steps of:
joining the resin for the middle portion in a molten state and the resin for the edge portions in a molten state in such a manner as to enclose both side edges in the crosswise direction of the resin film main body with the resin for the edge portions; and
extruding the joined resins through an extruding die to form the resin film.
2. The method as defined in claim 1, wherein a degree of enclosing the resin for the middle portion with the resin for the edge portions is adjusted according to a difference in MFR between the resins.
3. The method as defined in claim 1, wherein a degree of enclosing the resin for the middle portion with the resin for the edge portions is adjusted according to a difference in extrusion rate between the resins.
4. The method as defined in claim 1, wherein a degree of enclosing the resin for the middle portion with the resin for the edge portions is adjusted according to a difference in resin temperature between the resins.
5. The method as defined in claim 1, wherein a degree of enclosing the resin for the middle portion with the resin for the edge portions is adjusted according to a width of the resin film.
6. An apparatus for forming a resin film from a resin for a middle portion to form a resin film main body of the resin film and a resin for edge portions to form both side edge portions in a crosswise direction of the resin film, the apparatus comprising:
a feed block which includes a joining part where the resin for the middle portion in a molten state and the resin for the edge portions in a molten state are joined in such a manner as to enclose both side edges in the crosswise direction of the resin film main body with the resin for the edge portions; and
a trunk flow path through which the resin for the middle portion flows and a pair of branch flow paths through which the resin for the edge portions flows are joined at the joining part in the feed block; and
a cross-sectional shape of the joining part is formed to allow the side edges of the resin film main body to be enclosed with the resin for the edge portions.
the feed block is adapted to be detachably provided with any one of a plurality of joining part blocks having respective joining parts different in degree of enclosing the side edges of the resin film main body with the resin for the edge portions; and
9. The apparatus as defined in claim 8, wherein the condition under which the resin film is formed includes at least one of a difference in MFR, an extrusion rate and resin temperature between the resin for the middle portion and the resin for the edge portions and a width of the resin film.
US10725053 2002-12-03 2003-12-02 Method and apparatus for forming resin film Active 2024-10-14 US7674412B2 (en)
US20040108621A1 true true US20040108621A1 (en) 2004-06-10
US7674412B2 US7674412B2 (en) 2010-03-09
US20150217496A1 (en) * 2012-08-22 2015-08-06 Windmöller & Hölscher Kg Film product
JP4066604B2 (en) 2001-02-16 2008-03-26 富士フイルム株式会社 Method of forming a resin film
US6461138B2 (en) * 1997-08-22 2002-10-08 Fuji Photo Film Co., Ltd. Device for forming multilayer sheets and extrusion die therefor
US7494331B2 (en) 2009-02-24 grant