Importance

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Abstract

Extrusion-to-sheet production line and method comprise first and second rolls set to a predetermined gap through which a continuously-extruded sheet of molten plastic material passes to calender the sheet to a predetermined thickness. The sheet then passes through a nip formed between the second roll and a continuous belt looped around a third roll and a fourth roll spaced from one another. The belt comprises an embossing pattern of optical element shapes that is an inverse pattern of optical element shapes to be embossed at a first major surface of the sheet. The sheet remains in contact with the second roll until the sheet passes through the nip, where the pattern of optical element shapes on the belt is embossed into the first major surfaces of the sheet. Downstream of the third roll is a flat cooling area through which the belt passes while the first major surface of the sheet is still in contact with the embossing pattern on the belt. Downstream of the flat cooling area is a separation area where the belt separates from the sheet.

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First Claim