JP5030865B2 - Bulk roll and laminate manufacturing apparatus - Google Patents

Description

  The present invention relates to a laminate, a roll body thereof, and a laminate production apparatus, and more particularly to a laminate such as an optical film in which an organic film and an inorganic film are laminated on a support, a roll body thereof, and a laminate production apparatus. .

  In various devices such as optical devices, display devices such as liquid crystal displays and organic EL displays, semiconductor devices, and thin film solar cells, as functional films (functional sheets), gas barrier films, protective films, optical filters, antireflection films, etc. Optical films are used. As an example of such a functional film, an organic film mainly composed of a polymer is formed on a substrate such as a plastic film, and an inorganic film made of an inorganic material is formed as a hard thin film by a vacuum film forming method. A functional film (laminated film) formed is known.

  By the way, in the film manufacturing apparatus which manufactures a functional film etc., the cutting process which cuts a elongate film to a longitudinal direction according to a product width is performed. The cutting step is generally performed by passing a long film between the rotating lower blade and the rotating upper blade. At that time, if there is a hard thin film (for example, a magnetic layer of a magnetic tape or an inorganic film of the laminated film described above) on the film, there is a problem that the hard thin film is likely to be cracked. Therefore, by defining the cutting conditions, the shape of both ends of the magnetic tape after cutting is specified. For example, in Patent Document 1, the side surface of the back layer is arranged on the inner side of the side surface of the base at both ends of the magnetic tape. Further, Patent Document 2 suppresses the height of the bulge portion on the surface at both ends of the magnetic tape. By making the film (magnetic tape) after cutting into these shapes, cracking of the hard thin film can be suppressed.

The film (or tape) cut in this way is wound around a winding core in a roll shape. A roll body (hereinafter also referred to as a bulk) of a film wound in a roll shape is packaged as necessary, stored, and transferred to another process. At that time, in order to prevent the end face of the bulk roll from being damaged, a cushion or the like is provided to protect the end face of the bulk roll.
JP 2001-273629 A JP 2007-257697 A

  However, in the case where the film is a laminated film composed of the inorganic film, organic film, and substrate described above, by placing the cushion on the end face of the bulk roll, the cushion comes into contact with the end face of the bulk roll, and the inorganic film is cracked. There was a risk of it occurring.

  The present invention has been made in view of such circumstances, and even when it is wound into a roll, a laminate that can prevent cracking in a hard thin film, its bulk roll, and the laminate An object is to provide a manufacturing apparatus.

For the present invention to achieve the above object, a support, and a hard thin film of the surface layer has a thin than the support, and soft cushioning layer than the hard thin film is provided between the rigid film and the support member A bulk roll is provided, in which a laminated body in which both end faces in the width direction of the hard thin film are disposed inside the end face of the support or the buffer layer is wound in a roll shape. To do.

  According to the present invention, since both end faces of the hard thin film are arranged on the inner side of the end faces of the support and the buffer layer, the hard thin film does not protrude in the width direction even when wound in a roll shape. , Cracking of the hard thin film can be prevented.

For the present invention to achieve the above object, a support, and a hard thin film of the surface layer has a thin than the support, and soft cushioning layer than the hard thin film is provided between the rigid film and the support member And a traveling means for traveling the laminate having the same length as the product width of the laminate, and the outer peripheral surface of the laminate has a taper and the outer peripheral surface supports the laminate. And a laminated body that is disposed to face both side surfaces of the lower blade and has a taper on the outer peripheral portion of the side surface that faces the side surface of the lower blade, and is supported by the rotating lower blade. A disc-shaped upper blade for cutting is provided. A laminate manufacturing apparatus is provided.

  According to the present invention, since the laminate is cut using both side surfaces of the lower blade, both ends of the cut laminate are left-right symmetric. In addition, since the outer peripheral portion of the side surface of the lower blade and the outer peripheral portion of the side surface of the upper blade are tapered, both end portions of the laminated body after cutting are cut obliquely and more than the width of the surface supported by the lower blade The width of the opposite surface is increased. Therefore, the cut laminate has a substantially trapezoidal cross section. Thereby, the end surface of the hard thin film of a laminated body can be arrange | positioned inside a support body and a buffer layer.

  According to the present invention, since both end faces of the hard thin film are arranged on the inner side of the end faces of the support and the buffer layer, the hard thin film does not protrude in the width direction even when wound in a roll shape. , Cracking of the hard thin film can be prevented.

  DESCRIPTION OF EMBODIMENTS Hereinafter, preferred embodiments of a laminate, a bulk roll thereof, and a laminate manufacturing apparatus according to the present invention will be described with reference to the accompanying drawings. First, the laminated body (laminated film) which concerns on this invention is demonstrated.

  FIG. 1 is a conceptual diagram of a laminated film. In the laminated film 10 shown in the figure, an organic film 12 containing a predetermined polymer as a main component is formed (formed) on the surface of a base material B (film raw fabric), and a vacuum film is formed on the organic film 12. An inorganic film 14 is formed by a film method.

  The type of the substrate B is not particularly limited, and various types of resin films such as PET films and various metal sheets such as aluminum sheets can be used to form the organic film 12 and the inorganic film 14 by vacuum film formation. If it is, all the various base materials (base film) currently utilized for various functional films, such as a gas barrier film, an optical film, and a protective film, can be utilized. Moreover, the base material B may have a surface on which various films such as a protective film and an adhesive film are formed.

  The organic film 12 is a film mainly composed of a radiation curable monomer or oligomer. Specifically, the monomer or oligomer used is preferably a monomer or oligomer that has two or more ethylenically unsaturated double bonds and undergoes addition polymerization upon irradiation with light. Examples of such monomers and oligomers include compounds having at least one addition-polymerizable ethylenically unsaturated group in the molecule and having a boiling point of 100 ° C. or higher at normal pressure. Examples include monofunctional acrylates and monofunctional methacrylates such as polyethylene glycol mono (meth) acrylate, polypropylene glycol mono (meth) acrylate and phenoxyethyl (meth) acrylate; polyethylene glycol di (meth) acrylate, polypropylene glycol di (meth) ) Acrylate, trimethylolethane triacrylate, trimethylolpropane tri (meth) acrylate, trimethylolpropane diacrylate, neopentyl glycol di (meth) acrylate, pentaerythritol tetra (meth) acrylate, pentaerythritol tri (meth) acrylate, di Pentaerythritol hexa (meth) acrylate, dipentaerythritol penta (meth) acrylate, hexane All di (meth) acrylate, trimethylolpropane tri (acryloyloxypropyl) ether, tri (acryloyloxyethyl) isocyanurate, tri (acryloyloxyethyl) cyanurate, glycerin tri (meth) acrylate; multifunctional such as trimethylolpropane and glycerin Polyfunctional acrylates and polyfunctional methacrylates such as those obtained by adding ethylene oxide or propylene oxide to alcohol and then (meth) acrylated can be mentioned.

  Further, urethane acrylates described in JP-B-48-41708, JP-B-50-6034 and JP-A-51-37193; JP-A-48-64183, JP-B-49-43191 And polyester acrylates described in JP-B-52-30490; polyfunctional acrylates and methacrylates such as epoxy acrylates which are reaction products of epoxy resin and (meth) acrylic acid.

  Among these, trimethylolpropane tri (meth) acrylate, pentaerythritol tetra (meth) acrylate, dipentaerythritol hexa (meth) acrylate, and dipentaerythritol penta (meth) acrylate are preferable. In addition, “polymerizable compound B” described in JP-A-11-133600 can also be mentioned as a preferable example.

  Examples of the photopolymerization initiator or photopolymerization initiator system used include vicinal polyketaldonyl compounds disclosed in US Pat. No. 2,367,660 and acyloin described in US Pat. No. 2,448,828. Ether compounds, aromatic acyloin compounds substituted with α-hydrocarbons described in US Pat. No. 2,722,512, polynuclear quinone compounds described in US Pat. Nos. 3,046,127 and 2,951,758, US Pat. No. 3549367, a combination of a triarylimidazole dimer and a p-aminoketone, a benzothiazole compound and a trihalomethyl-s-triazine compound described in JP-B-51-48516, U.S. Pat. No. 4,239,850 Trihalomethyl-triazine compounds described, USA And tri halomethyl oxadiazole compounds as described in Patent No. 4,212,976 A1. In particular, trihalomethyl-s-triazine, trihalomethyloxadiazole, and triarylimidazole dimer are preferable.

In addition, “polymerization initiator C” described in JP-A-11-133600 can also be mentioned as a preferable example. The amount of the photopolymerization initiator used is preferably 0.01 to 20% by mass, more preferably 0.5 to 10% by mass, based on the solid content of the coating solution. Light irradiation for the polymerization of the liquid crystalline compound is preferably performed using ultraviolet rays. The irradiation energy ^is preferably ^{20mJ / cm 2 ~50J / cm 2} , further preferably 100 to 2000 mJ / cm ^2. In order to accelerate the photopolymerization reaction, light irradiation may be performed under heating conditions.

  Examples of a method for forming the organic film 12 include a normal solution coating method, a vacuum film forming method, and the like. Examples of the solution coating method include a dip coating method, an air knife coating method, a curtain coating method, a roller coating method, a wire bar coating method, a gravure coating method, a slide coating method, or a hopper described in US Pat. No. 2,681,294. It can apply | coat by the extrusion-coating method which uses-. After coating, it is preferable to dry the coating solution with a heater or hot air, and then to irradiate with UV (ultraviolet rays) to polymerize the radiation curable monomer or oligomer.

In addition, acrylate and methacrylate are subject to polymerization inhibition by oxygen in the air. Therefore, in the present invention, when these are used as the organic film 12, it is preferable to lower the oxygen concentration or oxygen partial pressure during polymerization. When the oxygen concentration during polymerization is lowered by the nitrogen substitution method, the oxygen concentration is preferably 2% or less, and more preferably 0.5% or less. When the oxygen partial pressure during polymerization is reduced by the decompression method, the total pressure is preferably 1000 Pa or less, and more preferably 100 Pa or less. In addition, it is particularly preferable to perform ultraviolet polymerization by irradiating energy of ² J / cm ² or more under a reduced pressure condition of 100 Pa or less.

  In the present invention, the polymerization rate of the monomer is preferably 80% or more, more preferably 85% or more, and further preferably 90% or more. The polymerization rate here means the ratio of the reacted polymerizable groups among all polymerizable groups in the monomer mixture (for example, acrylate and methacrylate, acryloyl group and methacryloyl group).

  The organic film 12 is preferably smooth and has a high film hardness. The smoothness of the organic film 12 is preferably 10 nm or less, and more preferably 2 nm or less, as an average roughness (Ra value) of 10 μm square.

Furthermore, the film hardness of the organic film 12 preferably has a certain degree of hardness. The preferable hardness is preferably 100 N / mm ² or more, more preferably 200 N / mm ² or more as the indentation hardness when measured by the nanoindentation method. The pencil hardness is preferably HB or higher, more preferably H or higher.

  The kind of the inorganic film 14 is not particularly limited, and various inorganic materials can be used. The method for producing the inorganic film 14 is not particularly limited, but it is preferably formed by a vacuum film forming method, and for example, CVD, plasma CVD, sputtering, vacuum deposition, ion plating, or the like is used.

  The hardness of the inorganic film 14 is preferably HRC 70 or higher. Since the inorganic film 14 having such hardness is likely to be cracked at the time of cutting, the effect of the present invention becomes remarkable. Further, the thickness of the inorganic film 14 is preferably 100 nm or less, and particularly preferably 50 nm or less. Since the thin inorganic film 14 is easily cracked at the time of cutting, the effect of the present invention becomes remarkable.

  When manufacturing protective films for various devices and devices such as display devices such as organic EL displays and liquid crystal displays, a silicon oxide film or the like is formed as the inorganic film 14.

  Further, when an optical film such as a light reflection preventing film, a light reflection film, or various filters is manufactured, a film made of a material having or exhibiting a desired optical characteristic is formed as the inorganic film 14.

  The laminate of the present invention is not limited to the three layers of the base material B, the organic film 12, and the inorganic film 14, and a plurality of layers of the organic film 12 are provided between the base material B and the inorganic film 14. It may be a configuration.

  In the laminated film 10 configured as described above, the inorganic film 14 is formed as the hardest and thin hard thin film, and the organic film 12 is formed as a buffer layer softer than the inorganic film 14. When such a laminated film 10 is cut into a product width and then wound into a roll shape, there is a problem that the inorganic film 14 is easily broken. This invention is the laminated film 10 which eliminates such a problem, and the shape of the both ends of the width direction is prescribed | regulated.

  As shown in FIG. 1, the inorganic film 14 is disposed on the inner side of the base material B and the organic film 12 on both end faces in the width direction of the laminated film 10. In this embodiment, the base material B protrudes to the outermost side, the inorganic film 14 is disposed on the innermost side, and the inorganic film 14 is retracted inward by a predetermined length L with respect to the base material B. . Thereby, the whole cross-sectional shape of the laminated film 10 is formed in a substantially trapezoid. Here, the length L is determined according to the thickness of the laminated film 10, and is formed with a thickness of 20 to 30 μm, for example, when the laminated film 10 is 100 μm.

  The laminated film 10 formed in this way is wound around the core 16 in a roll shape as shown in FIG. 2, and stored or transferred as a bulk roll. Moreover, as shown in FIG. 3, it is packaged in a packaging material 18 as necessary, and stored or transported in a state where the packaging material 18 is stopped by a tape 19. A mode in which the bulk roll is double-wrapped with the packaging material 18 is possible.

  The bulk roll thus formed is stored or transported in a state where a cushion material is applied to the end portion or the end portion is supported by a V block. In that case, a cushion material and a V block may contact the end surface of a bulk roll. Therefore, in the case of a conventional bulk roll (that is, in the case of a bulk roll formed by winding the laminated film 10 in which the inorganic film 14 protrudes from the base material B or the organic film 12 at at least one end), the inorganic film 14 May be pressed and cracks may occur. In particular, when there is an organic film 12 serving as a buffer layer between the inorganic film 14 and the base material B, the buffer layer is pressed and crushed, so that the inorganic film 14 tends to protrude outward and the inorganic film 14 is easily broken. There was a problem.

  In contrast, in the present embodiment, the inorganic film 14 is disposed on the inner side of the base material B and the organic film 12 on the end face of the laminated film 10. Therefore, the inorganic film 14 is in the retracted state on the end surface of the bulk roll around which the laminated film 10 is wound, and the inorganic film 14 can be touched even when a cushion material or the like comes into contact with the end surface of the bulk roll. In this case, the inorganic film 14 can be prevented from cracking. In particular, in the present embodiment, since the end face of the inorganic film 14 is arranged on the innermost side, even if the organic film 12 is crushed during the formation of the bulk roll, there is no possibility that the inorganic film 14 protrudes to the outside. It is possible to reliably prevent the film 14 from cracking.

  Next, the manufacturing apparatus which manufactures the bulk roll of the laminated film 10 mentioned above is demonstrated.

  FIG. 4 is a side view schematically showing the configuration of the cutting device 20 of the present embodiment. The cutting device 20 shown in the figure is a device that cuts the long laminated film 10 with the product width, and is mainly composed of a sending unit 30, a cutting unit 40, and a winding unit 50. The laminated film 10 travels in the direction of the white arrow in FIG. 4 by controlling the driving of the delivery unit 30 and the winding unit 50 or by controlling traveling means such as a feed roller (not shown). ing. In the traveling direction of the laminated film 10, a sending unit 30, a cutting unit 40, and a winding unit 50 are arranged in order from the upstream side.

  A wide laminated film 10 before cutting is mounted on the delivery unit 30 in a state of being wound around the core 32 in a roll shape. The laminated film 10 is delivered from the delivery unit 30 and conveyed to the cutting unit 40 through the guide roller 34.

  FIG. 5 is a front view showing the cutting part 40. As shown in the figure, the cutting part 40 includes a plurality of pairs of upper and lower rotary blades 42 and 44 that are paired in a vertical direction. SK material, SUS material, etc. are used for the material of the rotation upper blade 42 and the rotation lower blade 44, and tungsten carbide etc. are used suitably.

  The rotating lower blade 44 is formed in a cylindrical shape and is rotatably supported by an apparatus main body (not shown) via a shaft 48. The rotating lower blade 44 is connected to a motor (not shown) via a shaft 48 and is driven to rotate by this motor. The rotation direction and peripheral speed of the rotating lower blade 44 are not particularly limited, but are controlled to rotate in the same direction as the traveling direction of the laminated film 10 and at a circumferential speed equal to the traveling speed of the laminated film 10, for example. The

  The rotating lower blade 44 is divided into three parts, and a spacer 49 is disposed between the rotating lower blades 44. Of the three rotary lower blades 44, the width of the central rotary lower blade 44 is the same as the product width, and both side surfaces 44a act as circular cut surfaces.

  On the other hand, the rotary upper blade 42 is formed in a thin disk shape. The rotating upper blade 42 is rotatably supported by an apparatus main body (not shown) via a shaft 46, and the shaft 46 is disposed in parallel with the shaft 48 described above. Note that the shaft 46 may be driven or rotated by a motor (not shown). The rotation direction and peripheral speed of the rotary upper blade 42 are not particularly limited, but are set to rotate in the same direction as the traveling direction of the laminated film 10 and at a peripheral speed equal to the traveling speed of the laminated film 10, for example. The

  The rotating upper blade 42 is arranged so that the lower end portion enters between the rotating lower blades 44 (that is, overlapped when viewed from the side). The overlap amount is set according to the thickness of the laminated film 10 and is set so that the laminated film 10 can be cut reliably (for example, about 0.5 mm). Further, the rotary upper blade 42 is arranged such that the side surface a thereof faces the side surface 44a of the rotary lower blade 44 and acts as a cut surface.

  FIG. 6 shows a situation where the laminated film 10 is cut by the rotating upper blade 42 and the rotating lower blade 44. As shown in the figure, the outer peripheral portion of the side surface 42a of the rotary upper blade 42 is chamfered over one circumference to form a taper 42b. Further, the outer peripheral portion of the side surface 44a of the rotating lower blade 44 is chamfered over the entire circumference to form a taper 44b. For this reason, when the rotary upper blade 42 is pushed into the rotary lower blade 44 side, the laminated film 10 is obliquely cut by a two-dot chain line connecting the tip 42c of the rotary upper blade 42 and the tip 44c of the rotary lower blade 44. Thereby, as for the laminated | multilayer film 10 after a cutting | disconnection, the inorganic film 14 is arrange | positioned innermost in the end surface of the width direction, and the base material B is arrange | positioned outermost. In addition, the chamfering of the rotating upper blade 42 and the rotating lower blade 44 is set according to the thickness of the laminated film 10, and is set to 5 to 25 μm, for example.

  In the cutting part 40 of this Embodiment, it is comprised by the left-right symmetry centering on the center of the width direction of the laminated film 10 as a symmetry center. Therefore, in the laminated film 10 after cutting, the inorganic film 14 is disposed on the innermost side and the base material B is disposed on the outermost side at both ends in the width direction. Thereby, the cross-sectional shape of the laminated film 10 after cutting becomes a substantially trapezoid.

  As shown in FIG. 4, the laminated film 10 cut by the cutting unit 40 is sent to the winding unit 50 through the guide roller 54 and wound around the winding core 16 in a roll shape. Thereby, the bulk roll which wound the laminated | multilayer film 10 is formed. At that time, the organic film 12 serving as a buffer layer is crushed by being pressed, but in this embodiment, the organic film 12 is crushed because the inorganic film 14 is retracted to the innermost side at the end face in the width direction of the laminated film 10. Even in this case, the inorganic film 14 does not protrude outward. Therefore, even if a cushion material or the like comes into contact with the end face of the bulk roll, it does not come into contact with the inorganic film 14, so that the inorganic film 14 can be prevented from being cracked.

Using the cutting apparatus shown in FIG. 4, cutting was performed by changing the conditions of the laminated film (support (base material), buffer layer (organic film), hard thin film (inorganic film), thickness, etc.)). Then, the laminated film having a length of 1000 m after being cut was wound around a 7-inch core to form a bulk roll, and then packed with cushions on both sides. The bulk roll was evaluated for the presence or absence of cracks in the hard thin film according to the following criteria.
X: Hard film cracks are observed with the naked eye.
(Triangle | delta): Although it cannot confirm with the naked eye, a crack and partial detachment | leave are recognized with an optical microscope (x500).
○: Although it cannot be confirmed with the naked eye, cracks are observed with an optical microscope (× 500), but no separation is observed.
A: No cracking or separation is observed even with an optical microscope (× 500).

FIG. 7 shows the conditions of the laminated film and the evaluation results. In FIG. 7, PC means polycarbonate, PET means polyethylene terephthalate, and DPHA means dipentaerythritol hexaacrylate. In FIG. 7, L is positive when the inorganic film 14 is disposed inside the base material B, and zero when the inorganic film 14 protrudes at the same level as the base material B (comparative example). . Furthermore, the thickness coefficient was calculated | required as follows as a coefficient which shows the thickness of the inorganic film 14, the thickness of the organic film 12, and the relationship of the hardness.
Thickness coefficient = {(thickness of the inorganic film 14) / (hardness of the inorganic film 14 [Hc])} × {(hardness of the organic film 12 [Hc]) / (thickness of the organic film 12)
The larger the thickness coefficient is, the harder and thinner the inorganic film 14 is, or the thicker and softer the organic film 12 is. When the thickness coefficient is 2 or more, the effect of the present invention becomes remarkable.

  As can be seen from FIG. 9, in Comparative Example 1 in which the inorganic film 14 protrudes to the same extent as the base material B on the end face in the width direction of the laminated film 10, the inorganic film 14 was cracked on the end face of the bulk roll. On the other hand, in Examples 1-7 in which the inorganic film 14 was arranged on the inner side of the base material B, it was possible to suppress cracking of the inorganic film 14 that occurred on the end face of the bulk roll. In particular, the results were obtained that Examples 1 to 6 having a large thickness coefficient of 8.5 or more were preferable to Example 7 having a small thickness coefficient. Further, as can be seen from Examples 4 to 6, the result that L is preferably 10 μm or more, more preferably 20 μm or more, and further preferably 30 μm or more is obtained.

Sectional drawing which shows the laminated | multilayer film of this Embodiment typically Perspective view showing bulk roll of laminated film The perspective view which shows the package which packaged the bulk roll of FIG. Side view which shows typically the manufacturing apparatus of the laminated film of this Embodiment The front view which shows typically the structure of the cutting part of FIG. Explanatory drawing showing the cutting state Table showing the results of the examples

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Laminated film, 12 ... Organic film, 14 ... Inorganic film, 16 ... Winding core, 18 ... Packaging material, 20 ... Manufacturing apparatus of laminated film, 30 ... Sending part, 32 ... Core, 40 ... Cutting part, 42 ... Rotating upper blade, 44 ... Rotating lower blade, 46 ... Shaft, 48 ... Shaft, 49 ... Spacer, 50 ... Winding part

Claims (3)

A support, provided with a hard thin film of the surface layer has a thin than the support, and a soft buffer layer than the hard thin film is provided between the rigid film and the support member, both ends in the width direction of the hard thin film A bulk roll comprising a laminate in which a surface is disposed inside an end face of the support or the buffer layer and wound in a roll shape. The buffer layer is 100 N / mm when measured by the nanoindentation method. ² The bulk roll of Claim 1 which has the above indentation hardness. A support, and a hard thin film of the surface layer has a thin than the support, a traveling means for traveling the laminate and a soft buffer layer than the hard thin film is provided between the rigid film and the support member ,
A lower blade that is formed in a cylindrical shape having the same length as the product width of the laminate, has a taper on the outer periphery of both side surfaces thereof, and supports the laminate on the outer periphery thereof;
A disk-shaped disc that is disposed to face both side surfaces of the lower blade and has a taper on the outer peripheral portion of the side surface that faces the side surface of the lower blade, and cuts the laminate supported by the rotating lower blade. Upper blade,
An apparatus for producing a laminate, comprising:

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