JP6897153B2 - Intermediate product roll - Google Patents

Description

The present invention relates to an intermediate product roll with less wrinkles, scratches and whitening.

In recent years, optical films, packaging film films, and films for various general industrial materials used as base materials for displays such as LCD TVs and smartphones have been widened and thinned in order to reduce their manufacturing costs. There is.

However, with the widening and thinning of the base film, there are problems that the winding shape becomes worse and that the base film has appearance defects such as wrinkles, deformation, and scratches. Then, as a method of alleviating such a problem, a method of winding the film by oscillating at least one of the selvage cutter and the winder is used.

Specifically, Patent Document 1 discloses a method of synchronizing the oscillations of the selvage cutter and the winder in the film width direction, and shifting the oscillation positions of both from the film end to wind the film. Has been done.

Japanese Unexamined Patent Publication No. 07-144814

However, in the method described in Patent Document 1, although the selvage cutter and the winder are synchronized in the width direction, the selvage cutter and the winder are different.

Therefore, when the method described in Patent Document 1 is used when winding the film in which the base material layer and the coat layer are laminated, the height of the end portion of the film roll is at the center depending on the conditions of the respective oscillation widths. It may be higher than the height of the portion, or the position of the end portion of the film roll may be uneven. In particular, under the condition that the oscillation width of the ear cutter is large, the coat layer portion may be included in the cutting removal portion.

If the height of the edge of the film roll is higher than the height of the center, the film may be wrinkled, and if the film is wound with wrinkles, scratches or whitening will occur. Further, if the positions of the end portions of the film roll are not aligned, it may be difficult to handle the film roll in a subsequent process. If the coat layer portion is included in the cut-removed portion, the cut-removed portion may not be reused as a recycled raw material.

An object of the present invention is to eliminate the drawbacks of the prior art and provide an intermediate product roll with less wrinkles, scratches and whitening.

In order to solve the above problems, the present invention has the following configuration.
(1) A method for producing an intermediate product roll of a film having a base material layer and having a coat layer on at least one surface of the base material layer, wherein the coat layers parallel to the longitudinal direction are laminated, on both sides. A step of cutting and removing the end portion in the film width direction and a step of winding the film are included in this order, and the step of cutting and removing the end portion in the film width direction on both sides is the step of cutting and removing the end portion in the width direction of the base material layer and the coat layer. It has a cutting means that reciprocates between the widthwise ends in parallel with the width direction, and the position closest to the widthwise end of the base material layer in the driving range of the cutting means and the widthwise end of the coat layer. A method for manufacturing an intermediate product roll, which satisfies 0 < ΔY / ΔX <1.0 when the distance is ΔX and the driving range of the cutting means is ΔY.
(2) The method for producing an intermediate product roll according to (1), which satisfies 10.0 ≦ ΔX ≦ 50.0 (mm).
(3) The method for producing an intermediate product roll according to (1) or (2), wherein the coat layer contains particles.
(4) The method for producing an intermediate product roll according to any one of (1) to (3), wherein the coat layer is an easy-adhesion layer.
(5) The step of unwinding the film from the intermediate product roll obtained by the method for manufacturing the intermediate product roll according to any one of (1) to (4), and the portion where the coat layer is not laminated from the unwound film. A method for producing a final product roll, which comprises a step of cutting and removing and a step of winding the film again.

According to the present invention, it is possible to optimize the amount of air bitten by the intermediate product roll in the process of winding the film, and suppress wrinkles, scratches, and whitening of the intermediate product roll.

FIG. 5 is a cross-sectional view obtained by cutting a film and a cutting means according to an embodiment of the present invention in a plane perpendicular to the longitudinal direction and the width direction, and is observed from a direction parallel to the longitudinal direction and perpendicular to the width direction. It is a perspective view which shows the cut part of the unwound film in Examples 8-14, 22-28, and Comparative Examples 5-8, 11 and 12.

The method for producing an intermediate product roll of the present invention is a method for producing an intermediate product roll of a film having a base material layer and having a coat layer on at least one surface of the base material layer, and is a coating method parallel to the longitudinal direction. A step of laminating the layers, a step of cutting and removing the film width direction ends on both sides, and a step of winding up the film are in this order, and the step of cutting and removing the film width direction ends on both sides is a step of cutting and removing the base material layer. It has a cutting means that reciprocates in parallel with the width direction between the width direction end portion and the width direction end portion of the coat layer, and the position and coat closest to the width direction end portion of the base material layer in the drive range of the cutting means. When the distance from the widthwise end of the layer is ΔX and the driving range of the cutting means is ΔY, ΔY / ΔX <1.0 is satisfied.

Here, the intermediate product roll means a roll obtained by winding the manufactured film once before making it into a final product. Normally, the film is unwound from this intermediate product roll, cut to an arbitrary width by slit processing, or the surface of the unwound film is subjected to various processing such as printing, and then the film is wound again. You can get the final product.

It is important that the intermediate product roll in the method for producing an intermediate product roll of the present invention is an intermediate product roll of a film having a base material layer and having a coat layer on at least one surface of the base material layer. Here, the base material layer refers to a sheet-like material obtained by melting a composition containing a thermoplastic resin as a main component, extruding the composition into a sheet shape, and then cooling the composition, and the coat layer refers to a sheet-like material obtained by producing a film. A layer that is laminated on the base material layer in the process. Here, the term "the main component of the thermoplastic resin" means that the content of the thermoplastic resin in the layer exceeds 50% by mass when the entire layer is 100% by mass.

The base material layer may have a single layer structure or a laminated structure as long as the effects of the present invention are not impaired. The thermoplastic resin that can be used as the main component of the base material layer is not particularly limited as long as the effects of the present invention are not impaired, and examples thereof include polyester resin, polyethylene resin, polypropylene resin, and polyethylene naphthalate resin. Be done.

The purpose of the coat layer is not particularly limited as long as it is a layer laminated on the base material layer in the process of producing the film, as long as the effect of the present invention is not impaired. The purpose of providing the coat layer is, for example, to impart functions such as easy adhesiveness, high hardness, easy slipperiness and adhesiveness to the film. The coat layer may be a single layer or a plurality of layers as long as the effects of the present invention are not impaired, and may be laminated on one side of the base material layer or on both sides of the base material layer. ..

Further, the coat layer can contain additives such as a curing agent, a surfactant, a cross-linking agent, and particles as long as the effects of the present invention are not impaired, and it is preferable that the coat layer contains particles. Since the coat layer contains particles, the surface of the coat layer has an appropriate roughness, so that the slipperiness of the film is improved. As a result, the take-up property of the intermediate product roll is improved, and the occurrence of wrinkles on the intermediate product roll is reduced.

As described above, the coat layer is laminated on the base material layer in order to impart functions such as easy adhesiveness, high hardness, easy slipperiness and adhesiveness to the film. Above all, in the present invention, the coat layer is preferably an easy-adhesion layer. Here, the easy-adhesion layer refers to a layer that facilitates adhesion of another layer to the layer opposite to the base material layer. The easy-adhesion layer can be applied in-line to the base material layer with a water-soluble coating liquid obtained by diluting the resin described later with water, or can be applied offline after the production of the base material layer is completed.

From the viewpoint of adhesion between the base material layer and the coat layer, the coat layer preferably contains at least one resin among a polyester resin, an acrylic resin, and a urethane resin. When the easy-adhesion layer contains these resins, the adhesion between the coat layer and the base material layer can be strengthened. Further, when the coat layer is an easy-adhesion layer or a plurality of layers including the easy-adhesion layer, not only the adhesion to the base material layer but also another functional layer such as a hard coat layer provided on the easy-adhesion layer is provided. Adhesion with and can be strengthened.

In the method for producing an intermediate product roll of the present invention, it is important to have a step of laminating coat layers parallel to the longitudinal direction, a step of cutting and removing the end portions in the film width direction on both sides, and a step of winding the film in this order. Is. Here, the longitudinal direction means a direction parallel to the transport surface of the film and the film advances during film production, and the width direction means a direction parallel to the transport surface of the film and orthogonal to the longitudinal direction.

In the film manufacturing process, the film usually travels parallel to the longitudinal direction. Therefore, when the coat layer is applied in-line to the base material layer, if a coating device is provided at one place during the manufacturing process, the coat layer is laminated in parallel with the longitudinal direction as the film progresses. Therefore, the mode having the step of laminating the coat layers parallel to the longitudinal direction is the mode in which the coat layers can be laminated most easily and evenly.

By having a step of cutting and removing the end portions in the film width direction on both sides after the step of laminating the coat layers parallel to the longitudinal direction, it is possible to remove a part of the portion where the coat layer is not applied. Here, the film width direction end portion refers to an area between the width direction end portion of the base material layer and the width direction end portion of the coat layer.

In the method for producing an intermediate product roll of the present invention, as shown in FIG. 1, the step of cutting and removing the film width direction ends on both sides is the width direction end portion of the base material layer and the width direction end portion of the coat layer. It is important to have a cutting means that reciprocates between them in parallel with the width direction. With such an embodiment, it is possible to reduce the difference in the strength of winding tightness between the central portion of the roll and the end portion of the roll, and to reduce the occurrence of winding deviation. Here, the roll central portion refers to the central portion when the intermediate product roll is viewed from the width direction, and the roll end portion refers to the end portion when the intermediate product roll is viewed from the width direction.

When manufacturing an intermediate product roll of a film having a coat layer on one surface of the base material layer, the widthwise end of the film is directed toward the surface side having the coat layer due to the drying shrinkage of the coat layer during the manufacturing process. May warp. Further, even in the case of producing an intermediate product roll of a film having coat layers having different thicknesses and / or compositions on both sides of the base material layer, the degree of drying shrinkage of each coat layer is different, and similarly, the film The widthwise edge may warp.

When the film is wound with the end portion in the width direction warped, the winding diameter at the roll end portion becomes larger than the winding diameter at the center portion of the roll as the winding diameter increases. If the film is continuously wound in this state, the winding shape gradually deteriorates and wrinkles may occur.

The method for producing an intermediate product roll of the present invention is to cut and remove a part of the film width direction end portion by having a cutting means between the width direction end portion of the base material layer and the width direction end portion of the coat layer. Therefore, the warp of the film due to the above-mentioned mechanism can be reduced. As a result, the winding diameter at the end of the roll can be made about the same as the winding diameter at the center of the roll, and the occurrence of wrinkles in the film can be reduced. The positions of the two cutting means in the longitudinal direction are not particularly limited as long as the effects of the present invention are not impaired, but are preferably equal to each other. The longitudinal positions of the two cutting means "equal to each other" mean that the straight line obtained when the two cutting means are connected is parallel to the width direction.

Further, by setting the driving range of the cutting means between the widthwise end portion of the base material layer and the widthwise end portion of the coat layer, the cutting target is only the base material layer. Therefore, it is possible not only to cut and remove the portion gripped by the clip during the film manufacturing process, but also to reduce the occurrence of scratches due to the dust derived from the coat layer being caught in the intermediate product roll.

A cutting means that reciprocates in parallel with the width direction from the viewpoint of reducing wrinkles of the film that occur when the winding shape gradually deteriorates as the winding diameter at the end of the roll becomes larger than the winding diameter at the center of the roll. Is preferably reciprocating in parallel with the width direction at a constant cycle.

Here, the cutting means refers to a means capable of cutting a film, and specific examples thereof include a cutter blade and a round blade. In the method for producing an intermediate product roll of the present invention, any cutting means may be used as long as the effects of the present invention are not impaired, but from the viewpoint of small size, low cost, and easy installation during the process, the cutter blade is used. It is preferable to use it.

In the method for producing an intermediate product roll of the present invention, when the film has a coat layer on one side of the base material layer, the cutting means is the base material layer as shown in FIG. 1 as long as the effect of the present invention is not impaired. It may be on the side, on the coat layer side, or on both sides. However, from the viewpoint of preventing components derived from the coat layer from entering the cut-removed film, it is preferably on the substrate layer side.

Further, by having a step of winding the film after the step of cutting and removing the end portions in the film width direction on both sides, an intermediate product roll can be obtained.

The method for producing an intermediate product roll of the present invention is the widthwise end of the base material layer in the driving range of the cutting means from the viewpoint of reducing the occurrence of wrinkles, scratches, and whitening of the film wound on the intermediate product roll. It is important to satisfy ΔY / ΔX <1.0 when the distance between the position close to the portion and the end portion in the width direction of the coat layer is ΔX and the driving range of the cutting means is ΔY. Here, "satisfying ΔY / ΔX <1.0" means that both cutting means on both sides satisfy ΔY / ΔX <1.0.

With such an embodiment, the occurrence of wrinkles in the film due to the height of the end portion of the intermediate product roll due to the warp of the end portion of the base material layer caused by the step of cutting and removing the end portions in the film width direction on both sides is reduced. can do. As a result, it is possible to reduce the occurrence of scratches and whitening of the film wound on the intermediate product roll.

Here, whitening refers to a defect caused by the fact that the surfaces of the wound film rub against each other and a large number of scratches having a width and length of nano level are generated on the film surface. The presence or absence of whitening can be evaluated by shining light on the film sample from the front using a three-wavelength light source in a dark room and confirming whether or not there is a portion that looks white.

Usually, in the process of winding a film, a surface pressure is applied to the surface of the film due to the influence of tension generated when the film is wound. Then, as the diameter of the roll increases, the surface pressure applied to the inner layer portion of the roll increases. As a result, the air accumulated between the film layers of the intermediate product roll is pushed out, and the films sprinkled on the roll rub against each other, resulting in whitening. That is, whitening is more likely to occur as the diameter of the roll increases.

When ΔY / ΔX ≧ 1.0, a part of the coat layer is included in the cut-removed film. If the cut-removed film does not contain components derived from the coat layer, it can be melted after recovery and used again as a raw material for the base material layer. However, when a film containing a component derived from the coat layer is also used as a raw material for the base material layer, foreign matter defects and scratches due to the component derived from the coat layer may occur in the base material layer.

That is, if the coat layer is formed so that the end portion of the coat layer is parallel to the longitudinal direction, the coating layer-derived component is contained in the cut-removed film by setting ΔY / ΔX <1.0. Can be prevented.

However, although the widthwise end of the coat layer is normally formed parallel to the longitudinal direction, the coating liquid for forming the coating layer is formed due to uneven thickness of the film or excessive supply of the coating liquid at the time of coating. It may protrude outward when viewed from the width direction. Even in such a case, it is more preferable that ΔY / ΔX ≦ 0.9 from the viewpoint of preventing the coating layer-derived component from entering the cut-removed film.

Further, in the step of cutting and removing the film width direction ends on both sides, the film width direction ends on both sides are cut and removed by using a cutting means that reciprocates in parallel with the width direction. Then, the film is wound in the process of winding the film. At this time, as the value of ΔY / ΔX increases, the shape of the end portion of the intermediate product roll becomes uneven, which may make it difficult to handle in the subsequent process. Therefore, ΔY / ΔX ≦ 0.8. Is even more preferable.

ΔY / ΔX becomes a value larger than 0 due to the presence of a cutting means that reciprocates in parallel with the width direction between the widthwise end portion of the base material layer and the widthwise end portion of the coat layer. Further, the lower limit value of ΔY / ΔX is not particularly limited as long as it is a value larger than 0 as long as the effect of the present invention is not impaired, but 0.1 is sufficient from the viewpoint of fully exerting the effect of the present invention. 0.3 is preferable, and 0.5 is more preferable.

Further, as long as the cutting means on both sides both satisfy ΔY / ΔX <1.0, the values of ΔY / ΔX in each width direction may be equal to or different from each other, but the cutting means on both sides move in the same direction. In this case, it is preferable that they are equal to each other from the viewpoint that the parts necessary for the product are disposed of in the next step and thereafter and the productivity deteriorates.

The driving mode of the cutting means on both sides is not particularly limited as long as both cutting means satisfy ΔY / ΔX <1.0, but a mode in which the cutting means on both sides are driven synchronously is preferable. Synchronously driving means that when one cutting means is driven, the other cutting means is also driven, and when one cutting means is stopped, the other cutting means is also stopped.

The driving direction of the cutting means on both sides is not particularly limited as long as both cutting means satisfy ΔY / ΔX <1.0, but the driving direction of one cutting means is the driving direction of the other cutting means. It is preferably in the opposite direction. This is because it is easy to handle and process, for example, it is easy to align the film when it is fed out from the surface layer of the intermediate product roll in the next process.

In the method for producing an intermediate product roll of the present invention, the value of ΔX is not particularly limited as long as it satisfies ΔY / ΔX <1.0 as long as the effect of the present invention is not impaired, but the value is intermediate without impairing the productivity of the film. From the viewpoint of suppressing the occurrence of wrinkles, scratches, and whitening in the product roll, it is preferable to satisfy 10.0 ≦ ΔX ≦ 50.0 (mm), and it is more preferable to satisfy 20.0 ≦ ΔX ≦ 35.0 (mm). preferable.

When ΔX exceeds 50.0 (mm), the ratio of ΔX to the length in the film width direction increases, and the portion to be cut and removed in the manufacturing process increases accordingly, resulting in a significant decrease in film productivity. There is. Further, when the coat layer contains particles, the base material layer is inferior in slipperiness to the coat layer, so that the ratio of ΔX to the length in the film width direction becomes large, so that the film is wound up. At this time, wrinkles are likely to occur near the end of the intermediate product roll, and the frequency of scratches and whitening may increase.

Further, when ΔX is less than 10.0 (mm), the coating layer component may be mixed in the cut and removed portion and cannot be used as a recycled raw material, so that the productivity of the film may be significantly lowered. Further, in the method for producing an intermediate product roll of the present invention, both ends in the film width direction are formed between the step of cutting and removing the end portions in the film width direction at both ends and the step of winding the film, if necessary. May be subjected to a nerling process. In such a mode, the air caught between the films when the film is wound is appropriately released, so that the occurrence of winding misalignment and the occurrence of wrinkles, scratches, and whitening of the film can be suppressed. ..

The thickness of the film in the method for producing an intermediate product roll of the present invention is not particularly limited as long as the effect of the present invention is not impaired, but is usually 1 μm or more and 500 μm or less. When the thickness of the film exceeds 500 μm, the film is thick and has sufficient elasticity, so that the frequency and degree of wrinkles, scratches, and whitening can be suppressed to a low level. On the other hand, the lower limit of the film thickness is 1 μm from the viewpoint of feasibility. Considering the above viewpoint, the thickness of the film capable of maximizing the effect of the present invention is 4.1 μm or more and 125 μm or less, and more preferably 20 μm or more and 125 μm or less.

The method for producing a final product roll of the present invention includes a step of unwinding a film from an intermediate product roll obtained by the above-mentioned method for producing an intermediate product roll, and cutting and removing a portion of the unwound film where a coat layer is not laminated. It is important to have a step and a step of winding the film again.

As described above, the intermediate product roll of the present invention has a stable shape with a small change in roll diameter in the width direction, and has few wrinkles, scratches, and whitening defects. Therefore, by having a step of unwinding the film from the intermediate product roll obtained by the above-mentioned manufacturing method of the intermediate product roll and a step of winding the film again, there are few wrinkles, scratches, and whitening defects caused by the intermediate product roll. You can get the final product roll.

Further, by having a step of cutting and removing the portion where the coat layer is not laminated from the unwound film, the portion to be the final product and the portion to be discarded can be easily separated.

To cut and remove the portion where the coat layer is not laminated from the unwound film, the film unwound from the intermediate product is cut and removed in the longitudinal direction by a fixed cutting means while reciprocating the intermediate product roll in parallel with the width direction. By cutting, the end portion in the width direction of the coat layer and the portion located outside the end portion in the width direction of the coat layer when the film is observed from the width direction are removed from the film.

Here, "cutting the film in the longitudinal direction" means that if the intermediate product roll is fixed, the cut portion of the film becomes parallel to the longitudinal direction, but the intermediate product roll reciprocates in parallel with the width direction. This means that the cut portion of the film deviates from the line parallel to the longitudinal direction by that amount.

The means for cutting and removing the portion where the coat layer is not laminated from the unwound film is not particularly limited as long as the effect of the present invention is not impaired, and for example, a leather blade, a shear blade, a round blade, or the like can be used. it can. Further, the portion where the coat layer is not laminated can be cut and removed, for example, in the air or on a grooved roll. Further, it is also preferable to remove the chips by using a dust remover, blown air, suction air or the like after cutting the film, from the viewpoint of preventing the final product roll from entraining the chips.

Further, the film obtained by cutting and removing the portion where the coat layer is not laminated may be wound as one final product roll, or may be cut in the longitudinal direction before being wound as the final product roll, and a plurality of films may be wound. May be rolled up as a final product roll. In order to obtain a plurality of final product rolls, as a means for cutting the film in the longitudinal direction, the same means as the means for cutting and removing the portion where the coat layer is not laminated can be adopted from the unwound film. It is also preferable to remove the chips by using a dust remover, blown air, suction air, or the like after cutting the film.

According to the present invention, it is possible to obtain an intermediate product roll which has a stable shape with a small change in roll diameter in the width direction, has few wrinkles and scratches, and suppresses the occurrence of whitening defects. The intermediate product roll of the present invention includes an optical film used as a base material for displays mainly used for LCD TVs and smartphones, a film for packaging materials, a film for various general industrial materials, and other base materials. It can be suitably used when producing a film.

Hereinafter, the present invention will be described in more detail with reference to examples, but the present invention is not limited thereto.

<Measurement method (intermediate product roll)>
a. ΔX
With the intermediate product roll placed on the roll stocker, the maximum distance from the end in the width direction of the coat layer to the end in the width direction of the base material layer was measured at three points using a steel scale, and the average value was ΔX (mm). And said.

b. Evaluation of wrinkles With the intermediate product roll placed on the roll stocker, the appearance of the roll was visually confirmed and judged according to the following criteria.
A: When there are no wrinkles, or when there are wrinkles only in the range of less than 100 mm from the end of the intermediate product roll B: There are wrinkles in the range of 100 mm or more and less than 300 mm from the end of the intermediate product roll, but 300 mm from the end of the intermediate product roll. When there are no wrinkles in the above range C: When there are wrinkles in the range of 300 mm or more from the end of the intermediate product roll c. Evaluation of Scratches The film was unwound by 50 m with the intermediate product roll placed on the roll stocker, and then a sample having an intermediate product roll width (width direction) × 1.5 m (longitudinal direction) was cut out. Next, the sample was irradiated with light by a floodlight in a dark room, and the number of scratches having a maximum major axis of 1 mm or more (hereinafter, may be simply referred to as the number of scratches) was visually inspected. Based on the obtained results, scratches were evaluated according to the following criteria.
A: The number of scratches is 10 or less B: The number of scratches is 11 or more and 50 or less C: The number of scratches is 51 or more Here, the maximum major axis is the outer circumference of the scratches so that the linear distance is maximized. The straight line distance between these two points when two points are taken above. The same applies to "evaluation of g. Scratches" of the measuring method (final product roll).

d. Evaluation of bleaching A sample was cut out as described in the section "evaluation of scratches", and the sample was exposed to light from the front using a three-wavelength light source in a dark room, and bleaching was evaluated according to the following criteria.
A: There is no part that looks white when reflected.
B: A part that looks white when reflected is slightly observed.
C: The part that looks white when reflected is clearly observed.

e. In the recovery raw material cutting step, 1 m of the cut-removed film edge was sampled, and a light source was applied to the film edge to confirm and evaluate whether the coat layer was applied.
A: The coat layer is not applied to the edge of the film.
B: A coat layer is applied to the edge of the film in the longitudinal direction (1 m sampling direction), and the total length of the edges is less than 10 cm.
C: A coat layer is applied to the edge of the film in the longitudinal direction (1 m sampling direction), and the total length of the edges is 10 cm or more.

<Measurement method (final product roll)>
f. Evaluation of Scratches After unwinding one outermost layer of the film with the final product roll placed on the roll stocker, a sample of the final product roll width (width direction) × 1.5 m (longitudinal direction) was cut out. Next, the sample was irradiated with light by a floodlight in a dark room, and the number of scratches having a maximum major axis of 1 mm or more was visually inspected. Based on the obtained results, scratches were evaluated according to the following criteria.
A: The number of scratches is 10 or less B: The number of scratches is 11 or more and 50 or less C: The number of scratches is 51 or more g. Evaluation of bleaching A sample was cut out as described in the section "evaluation of scratches", and the sample was exposed to light from the front using a three-wavelength light source in a dark room, and bleaching was evaluated according to the following criteria.
A: There is no part that looks white when reflected.
B: A part that looks white when reflected is slightly observed.
C: The part that looks white when reflected is clearly observed.

(Example 1)
Polyethylene terephthalate, which is substantially free of inert particles, is dried at a temperature of 180 ° C. for 5 hours under a reduced pressure of 3 torr, put into an extruder, melted at a temperature of 280 ° C., and then filtered through a filter with a filtration accuracy of 8 μm. After filtration, it was extruded into a sheet from the mouthpiece. The extruded sheet-like material was cooled and solidified on a cooling roll having a surface temperature of 20 ° C. by an electrostatic application casting method to obtain a substantially amorphous unstretched film. This unstretched film was stretched 3.2 times at a surface temperature of 93 ° C. by a longitudinal stretching machine composed of rolls, and cooled to obtain a uniaxially stretched film. Using a bar coater on both sides of this uniaxially stretched film, 5 parts by mass of the following melamine-based cross-linking agent solution and 1 mass of colloidal silica particles having an average particle size of 0.1 μm were added to 100 parts by mass of the polyester resin emulsion. After applying the partially added film as a coating liquid, it is stretched 3.5 times in the width direction at a temperature of 97 ° C. in the same oven, and then heat-treated in the same oven at a temperature of 228 ° C. for 20 seconds to make the thickness. A biaxially stretched laminated film having a mass of 50 μm was obtained. After the heat treatment process in the stainless steel oven, the cutter blades are reciprocated in parallel with the width direction so that ΔX is 10 mm and the drive range (ΔY) is 5 mm, and the edges in the width direction of the films on both sides are cut and removed to form a biaxial structure. Both side width direction ends of the stretched laminated film were cut and removed. The film was wound with a winder. Table 1 shows the evaluation results of the obtained intermediate product rolls. The arrangement of each cutting means, the cutting start time, and the driving direction of each cutting means satisfy the following conditions.
Arrangement of each cutting means: Arranged so that the positions in the longitudinal direction are equal to each other.
Cutting start time: Cutting by two cutting means started at the same time.
Drive direction of each cutting means: The two cutting means were driven so that the driving directions were opposite to each other.

(Examples 2 to 7, 15 to 21, Comparative Examples 1 to 4, 9, 10)
An intermediate product roll was obtained in the same manner as in Example 1 except that the values of ΔX and ΔY and the thickness of the film were as shown in Table 1. Table 1 shows the evaluation results of the obtained intermediate product rolls.

(Example 8)
The film is unwound while reciprocating the intermediate product roll obtained in Example 1 in parallel with the width direction, and the unwinding portion of the film unwound from the intermediate product roll (10 or less in FIG. 2, simply referred to as the unwinding portion). There is a center point when observed from the longitudinal direction (11 in FIG. 2), and a point on the unwinding portion located between the center point and the widthwise end of each coat layer (12 in FIG. 2). The film is cut into four parts in the longitudinal direction, chips are removed with a dust remover, the film of the portion not including the widthwise end of the coat layer is wound, and two final products having the same roll width are wound up. Got a roll. The film unwound from the intermediate product roll was cut on the grooved roll by a slitter equipped with a round blade. One of the two final product rolls obtained was arbitrarily selected, and each item was evaluated as described in the measurement method (final product roll). The evaluation results are shown in Table 1.

(Examples 9 to 14, 22 to 28, Comparative Examples 5 to 8, 11, 12)
The final product rolls obtained from the intermediate product rolls of Examples 2 to 7, 15 to 21 and Comparative Examples 1 to 4, 9, and 10 by the method described in Example 8 are described in the measuring method (final product roll). Each item was evaluated as follows. The evaluation results are shown in Table 1. The final product rolls obtained from the intermediate product rolls of Examples 2 to 7 and 15 to 21 were designated as Examples 9 to 14 and 22 to 28 in order, and obtained from the intermediate product rolls of Comparative Examples 1 to 4, 9 and 10. The final product rolls obtained were designated as Comparative Examples 5 to 8, 11 and 12 in order.

In Comparative Example 9, the cutting means reaches the coated end, and in Comparative Examples 4 and 10, the cutting means reaches the inside of the coated end.

INDUSTRIAL APPLICABILITY According to the present invention, it is possible to provide an intermediate product roll with less wrinkles, scratches and whitening. The film in the intermediate product roll of the present invention is suitably used as an optical film for a base material of a display such as an LCD TV or a smartphone, a film for a packaging material, a film for various general industrial materials, and another base film. Can be done.

1 Base material layer 2 Coat layer 3 Cutting means 4 Width direction end of base material layer 5 Width direction end of coat layer 6 Driving range of cutting means (ΔY)
7 Position closest to the end in the width direction in the drive range of the cutting means 8 ΔX
9 Intermediate product roll 10 Unwinding part (unwinding part) of the film unwound from the intermediate product roll
11 Center point when observing the unwinding part from the width direction 12 Point on the unwinding part located between the center point when observing the unwinding part from the width direction and the end of each coat layer

Claims (5)

A method for producing an intermediate product roll of a film having a base material layer and having a coat layer on at least one surface of the base material layer, a step of laminating coat layers parallel to the longitudinal direction, and film width directions on both sides. It has a step of cutting and removing the end part and a step of winding the film in this order.
The step of cutting and removing the film width direction ends on both sides has a cutting means that reciprocates between the width direction end portion of the base material layer and the width direction end portion of the coat layer in parallel with the width direction.
When the distance between the position closest to the widthwise end of the base material layer and the widthwise end of the coat layer in the driving range of the cutting means is ΔX and the driving range of the cutting means is ΔY, 0 < ΔY. A method for producing an intermediate product roll, which comprises satisfying / ΔX <1.0. The method for producing an intermediate product roll according to claim 1, wherein 10.0 ≦ ΔX ≦ 50.0 (mm) is satisfied. The method for producing an intermediate product roll according to claim 1 or 2, wherein the coat layer contains particles. The method for producing an intermediate product roll according to any one of claims 1 to 3, wherein the coat layer is an easy-adhesion layer. A step of unwinding a film from an intermediate product roll obtained by the method for producing an intermediate product roll according to any one of claims 1 to 4, and a step of cutting and removing a portion from which the coat layer is not laminated from the unwound film. A method for producing a final product roll, which comprises a step of winding the film again.

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