Manufacturing apparatus for film of non-uniform thickness and manufacturing method for film of non-uniform thickness

Patent metadata

Field	Value
Publication number	US-10035289-B2
Application number	US-201515310955-A
Country	US
Kind code	B2
Filing date	Mar 19, 2015
Priority date	Jun 4, 2014
Publication date	Jul 31, 2018
Grant date	Jul 31, 2018

Abstract

The manufacturing apparatus of the present invention comprises a die for extruding a resin plate and a first roller and a second roller for molding the resin plate. The manufacturing apparatus further comprises: an inner deckel for dividing the resin plate and pre-forming a thick section; and a main molding section provided on the first roller and/or the second roller for molding a non-uniform thickness section from the thick section.

First claim

What is claimed is:

1. An apparatus for manufacturing a non-uniform-thickness film comprising a die for extruding a resin plate, and a first roller and a second roller for molding the resin plate, wherein the apparatus comprises:
a preliminary molding section provided at the die and configured to mold an uneven portion to the resin plate, the uneven portion being uneven in thickness; and
a main molding section provided on at least one of the first roller and the second roller in order to mold a non-uniform-thickness portion from the uneven portion, wherein
the main molding section comprises:
a pair of truncated-cone-shaped portions and a disc-shaped portion sandwiched between the pair of truncated-cone-shaped portions on the first roller, the pair of truncated-cone-shaped portions being symmetrically arranged with respect to the disc-shaped portion such that smaller-diameter faces of the truncated-cone-shaped portions face the disc-shaped portion and larger-diameter faces of the truncated-cone-shaped portions face outer ends of the first roller; and
a column-shaped portion provided on the second roller, where a diameter of the disc-shaped portion is larger than a diameter of a larger-diameter face of the truncated-cone-shaped portion.

2. The manufacturing apparatus according to claim 1 , wherein
the preliminary molding section divides and extrudes the resin plate at the die.

3. The manufacturing apparatus according to claim 2 , wherein
the preliminary molding section is provided with one or more deckels in the die.

4. The manufacturing apparatus according to claim 1 , wherein
the preliminary molding section comprises the die and a second die for extruding a second resin plate having a width that differs from a width of the resin plate.

5. The manufacturing apparatus according to claim 4 , wherein
the die and the second die are arranged side by side such that the resin plate extruded from the die and the second resin plate extruded from the second die join to form a joined resin plate having the uneven portion.

6. The manufacturing apparatus according to claim 4 , wherein
the preliminary molding section comprises an inner deckel in the second die in order to narrow a resin flow path in the second die.

7. The manufacturing apparatus according to claim 1 , wherein
the preliminary molding section has one or more notched portions provided at a lip section of an extrusion port of the die.

8. The manufacturing apparatus according to claim 7 , wherein
the notched portion is one of semicircular, semi-elliptic, dorm-shaped or polygonal.

9. The manufacturing apparatus according to claim 8 , wherein
the polygonal shape is one of a triangle, a rectangle or a trapezoid.

10. The manufacturing apparatus according to claim 1 , wherein
the manufacturing apparatus is configured to form the uneven portion to the extruded resin plate,
the manufacturing apparatus is configured to provide the resin plate having the uneven portion between the pair of the truncated-cone-shaped portions of the first roller and the column-shaped portion of the second roller to shape a molded body, and
the manufacturing apparatus is configured to form and provide a connecting portion to the molded body when the uneven portion is passed between the disc-shaped portion of the first roller and the column-shaped portion of the second roller.

11. The manufacturing apparatus according to claim 1 , wherein
the pair of truncated-cone-shaped portions and the disc-shaped portion configuring the first roller are integrally arranged on the same axis.

12. The manufacturing apparatus according to claim 1 , wherein
the disc-shaped portion is connected with the smaller-diameter faces of the pair of truncated-cone-shaped portions.

13. The manufacturing apparatus according to claim 1 , wherein
the first roller further comprises a column-shaped portion.

14. The manufacturing apparatus according to claim 13 , wherein
the column-shaped portion of the first roller is connected with each of the larger-diameter faces of the truncated-cone-shaped portions of the first roller.

15. The manufacturing apparatus according to claim 10 , wherein
the non-uniform-thickness portion of the molded body is formed such that the thickness thereof changes from one side part to the other side part that are parallel to an extruding direction of the resin plate.

16. The manufacturing apparatus according to claim 1 , wherein
a surface of at least one of the pair of truncated-cone-shaped portions is provided with a dot pattern.

17. The manufacturing apparatus according to claim 1 , further comprising:
a cutter section for cutting a molded body formed from the extruded resin plate passing through the first roller and the second roller.

18. The manufacturing apparatus according to claim 10 , wherein
the molded body of the non-uniform-thickness film comprises multiple molded sub-bodies, which are connected via the connecting portion.

19. The manufacturing apparatus according to claim 1 , wherein a diameter of the disc-shaped portion is larger than a diameter of the larger-diameter faces of the pair of truncated-cone-shaped portions.

20. An apparatus for manufacturing a non-uniform-thickness film comprising a die for extruding a resin plate, and a first roller and a second roller for molding the resin plate, wherein the apparatus comprises:
a preliminary molding section provided at the die and configured to mold an uneven portion to the resin plate, the uneven portion being uneven in thickness; and
a main molding section provided on at least one of the first roller and the second roller in order to mold a non-uniform-thickness portion from the uneven portion, wherein
the main molding section comprises:
a column-shaped portion and a first disc-shaped portion provided on the first roller; and
a truncated-cone-shaped portion and a second disc-shaped portion provided on the second roller, wherein
the second disc-shaped portion is connected with a smaller-diameter face of the truncated-cone-shaped portion.

21. The manufacturing apparatus according to claim 20 , wherein
the manufacturing apparatus is configured to form and provide a non-uniform-thickness portion to a molded body of the non-uniform-thickness film when the extruded resin plate is passed between the column-shaped portion of the first roller and the truncated-cone-shaped portion of the second roller, and
the manufacturing apparatus is configured to form and provide a connecting portion to the molded body when the extruded resin plate is passed between the first disc-shaped portion of the first roller and the second disc-shaped portion of the second roller.

22. The manufacturing apparatus according to claim 20 , wherein
the truncated-cone-shaped portion is a pair of truncated-cone-shaped portions, which are symmetrically arranged to sandwich the second disc-shaped portion.

23. The manufacturing apparatus according to claim 20 , wherein
the respective portions configuring the first roller and the second roller are integrally arranged on the same axis.

24. The manufacturing apparatus according to claim 20 , wherein
the second roller further comprises a column-shaped portion.

25. The manufacturing apparatus according to claim 24 , wherein
the column-shaped portion of the second roller is connected with a larger-diameter face of the truncated-cone-shaped portion of the second roller.

Assignees

• Mitsubishi Gas Chemical Co
• Mgc Filsheet Co Ltd

Inventors

• Tokita Atsuhiro

Classifications

• B29C2043/466

  the rollers having specific shape, e.g. non cylindrical rollers, conical rollers · CPC title

• B29C48/30

  Extrusion nozzles or dies (extrusion characterised by the shape or cross-section of the extruded article B29C48/03) · CPC title

• B29C69/02

  of moulding techniques only · CPC title

• B29C48/914

  Cooling drums · CPC title

• B29C43/46 Primary

  Rollers · CPC title