JP7084432B2 - Film roll manufacturing system and film roll manufacturing method - Google Patents

Description

The present invention relates to a film roll manufacturing system and a film roll manufacturing method.

Conventionally, a method for producing a film including a cutting process and a winding process is known. In the cutting step, both ends of the film in the width direction are cut into a wavy shape by periodically changing the cutting position in the width direction. In the winding step, the cut film is wound with the cut ends aligned (see, for example, Patent Document 1).

Japanese Unexamined Patent Publication No. 2016-78219

With the above method, the generation of gauge band may not be sufficiently suppressed.

The present invention provides a film roll manufacturing system capable of further suppressing the generation of gauge bands, and a film roll manufacturing method.

The present invention [1] manufactures a film roll by winding a narling processing machine that forms knurls at the edges of the film and the film on which the knurls are formed in a width direction orthogonal to the flow direction of the film. The nar has a wave shape extending in the flow direction while oscillating in the width direction, and the winder has a position of the nar in the width direction with respect to the film roll. Includes a film roll manufacturing system that winds the film so that it is aligned.

According to such a configuration, by aligning the positions of the knurls in the width direction with respect to the film roll, it is possible to uniformly form a gap between the films overlapping each other in the radial direction of the film roll.

Therefore, it is possible to secure a gap between the films overlapping each other, and it is possible to further suppress the generation of gauge bands.

The present invention [2] further comprises a slit processing machine that cuts the film to a predetermined width before the narling processing machine forms the knurl on the film, and the film is cut by the slit processing machine. The film roll manufacturing system of the above [1], wherein the edge in the width direction has a wave shape extending in the flow direction while oscillating in the width direction, and the nar has a wave shape extending along the edge. including.

According to such a configuration, the edges can be aligned by aligning the knurls with the winder.

In the present invention [3], the slit processing machine has a slit blade for cutting a film, the narling processing machine has an exit portion for emitting laser light, and the film is irradiated with the laser light. Includes the film roll manufacturing system of [2] above, wherein the slit blade and the exit portion are periodically movable in the width direction with respect to the film.

With such a configuration, the edges and knurls can be formed into a wave shape that periodically oscillates in the width direction.

In the present invention [4], the movement of the slit blade with respect to the film in the width direction is controlled based on the following formula (1), and the movement of the ejection portion with respect to the film in the width direction is controlled by the following formula (2). ), The film roll manufacturing system of the above [3] is included.

Equation (1): W (t) = W _max / 2 × sin (πV ₁ t / W _max )
Equation (2): W (n) = W _max / 2 × sin (πV ₁ (t-L / V ₂ ) / W _max )
(In the above formulas (1) and (2), W (t) indicates the position of the slit blade with respect to the film in the width direction, and W (n) indicates the position of the exit portion with respect to the film in the width direction. W _max indicates the maximum value of the moving distance of the slit blade in the width direction, t indicates the time, V ₁ indicates the moving speed of the slit blade in the width direction, and V ₂ indicates the moving speed of the film in the flow direction, and L indicates the transport distance of the film from the slit blade to the ejection portion.)
According to such a configuration, the movement of the exit portion can be made to follow the movement of the slit blade, and the knurl can be made to follow the edge.

The present invention [5] The film roll of the above [4], wherein the moving speed (V ₂ / V ₁ ) of the film in the flow direction with respect to the moving speed of the slit blade in the width direction is 1000 or more and 70,000 or less. Manufacturing system.

In the present invention [6], the film roll according to the above [4] or [5], wherein the maximum value (W _max ) of the moving distance of the slit blade in the width direction is 0.01 m or more and 0.2 m or less. Includes manufacturing system.

The present invention [7] manufactures a film roll by winding a narling step of forming knurls at the edges of the film and the film on which the knurls are formed in a width direction orthogonal to the flow direction of the film. Including the winding step, the nar has a wave shape extending in the flow direction while oscillating in the width direction, and in the winding step, the position of the nar in the width direction with respect to the film roll is Includes a method of making a film roll, which winds up the film so that it is aligned.

The present invention [8] further includes a slit step of cutting the film to a predetermined width before the narling step, and the edge of the film cut by the slit processing machine in the width direction is in the width direction. The method for producing a film roll according to the above [7], which has a wave shape extending in the flow direction while oscillating to, and the nar has a wave shape extending along the edge.

According to the film roll manufacturing system and the film roll manufacturing method of the present invention, the generation of gauge bands can be further suppressed.

FIG. 1 is a cross-sectional view of the film. FIG. 2 is a schematic configuration diagram of a film roll manufacturing system as an embodiment of the present invention. FIG. 3 is an explanatory diagram for explaining a slit process, a knurling process, and a winding process. FIG. 4 is a cross-sectional view of the film roll.

1. 1. Film Roll Manufacturing System As shown in FIG. 1, the film F includes a base material S and a film C. The base material S has a first surface S1 and a second surface S2 in the thickness direction of the base material S. The coating film C is arranged on the first surface S1 of the base material S. The coating film C covers the first surface S1 of the base material S. The coating film C may be an easy-adhesive layer. When the film C is an easy-adhesive layer, the film F is an easy-adhesive film. The easy-adhesive film is used, for example, as a polarizing plate of an image display device such as a mobile device, a car navigation device, a monitor for a personal computer, and a television. Specifically, the easy-adhesive film is used as a protective film that protects the polarizing element of the polarizing plate. The easy-adhesive film is bonded to the polarizing element via an adhesive layer. The easy-adhesive film is an easy-adhesive layer and is bonded to a polarizing element.

As shown in FIG. 2, the film roll R manufacturing system 1 includes an extruder 2, a first stretching machine 4A, a coating machine 3, a second stretching machine 4B, a slit processing machine 5, and knurling. A machine 6 and a winder 7 are provided.

(1) Extrusion molding machine The extrusion molding machine 2 extrudes the base material S (extrusion molding step). The base material S extruded from the extruder 2 has a sheet shape.

The base material S is made of a thermoplastic resin. Examples of the thermoplastic resin include acrylic resin, polyolefin resin, cyclic polyolefin resin, polyester resin, polycarbonate resin, polystyrene resin, polyamide resin, polyimide resin, acetate resin (diacetyl cellulose, triacetyl cellulose, etc.) and the like.

When an easy-adhesive film used as a protective film for a polarizing element is produced, acrylic resin is preferable as the material of the base material S.

Further, when producing an easy-adhesion film used as a protective film for a polarizing element, the acrylic resin may be an acrylic resin having a glutaric acid anhydride structure or an acrylic resin having a lactone ring structure. Acrylic resin having a glutaric acid anhydride structure and acrylic resin having a lactone ring structure have high heat resistance, high transparency, and high mechanical strength, so that the polarizing plate has a high degree of polarization and excellent durability. Suitable for manufacturing. Acrylic resins having a glutaric acid anhydride structure are described in JP-A-2006-283013, JP-A-2006-335902, and JP-A-2006-274118. Acrylic resins having a lactone ring structure are described in JP-A-2000-230016, JP-A-2001-151814, JP-A-2002-120326, JP-A-2002-254544, and JP-A-2005-146084. Has been done.

Further, the base material S may contain a thermoplastic resin other than the acrylic resin in addition to the acrylic resin. By containing another thermoplastic resin, it is possible to cancel the birefringence of the acrylic resin and obtain an easily adhesive film having excellent optical anisotropy. In addition, the mechanical strength of the easy-adhesive film can be improved.

The base material S may contain additives such as antioxidants, stabilizers, reinforcing materials, ultraviolet absorbers, flame retardants, antistatic agents, colorants, fillers, plasticizers, lubricants and fillers. ..

(2) First Stretching Machine The first stretching machine 4A heats the base material S obtained by the extrusion molding step and then stretches the base material S in the flow direction MD of the base material S (first stretching step).

(3) Coating machine The coating machine 3 applies a coating liquid to the first surface S1 of the base material S extruded by the extrusion molding step (coating step). The first surface S1 of the base material S may be subjected to surface treatment such as corona treatment and plasma treatment after the extrusion molding step and before the coating step.

Examples of the coating machine 3 include a bar coater, a gravure coater, and a kiss coater.

When producing an easy-adhesive film, the coating liquid is an easy-adhesive composition for forming an easy-adhesive layer.

The easy-adhesion layer contains a binder resin and fine particles.

Examples of the binder resin include thermosetting resins such as urethane resin and epoxy resin, and thermoplastic resins such as acrylic resin and polyester resin. When the easy-adhesive film is used as a protective film for a stator, the binder resin is preferably a thermosetting resin. A plurality of types of binder resin can be used in combination.

Examples of the fine particles include oxides such as silicon oxide (silica), titanium oxide (titania), aluminum oxide (alumina), and zirconium oxide (zirconia), and carbonates such as calcium carbonate, such as calcium silicate and silicate. Examples include silicates such as aluminum acetate and magnesium silicate, such as silicate minerals such as talc and kaolin, such as phosphates such as calcium phosphate. When the easy-adhesive film is used as a protective film for a stator, the fine particles are preferably an oxide, more preferably silicon oxide. A plurality of types of fine particles can be used in combination.

The coating liquid (easy-adhesive composition) contains a resin component, the above-mentioned fine particles, and a dispersion medium.

The resin component forms the above-mentioned binder resin film (easy-adhesive layer) by the stretching step described later. When the binder resin is a urethane resin, examples of the resin component include an aqueous urethane resin. Examples of the water-based urethane resin include a non-reactive water-based urethane resin which is an emulsion of a urethane resin, and for example, a reaction-type water-based urethane resin which is an emulsion of a urethane resin in which an isocyanate group is protected with a blocking agent. When the binder resin is a urethane resin, the coating liquid may contain a urethane curing catalyst (such as triethylamine) and an isocyanate monomer.

Examples of the dispersion medium include water, for example, alcohols such as methanol and ethanol, and ketones such as acetone and methyl ethyl ketone.

(4) Second Stretching Machine The second stretching machine 4B dries the coating liquid applied by the coating step. As a result, the coating liquid becomes the above-mentioned film C. Further, the second stretching machine 4B heats the base material S on which the coating film C is formed, and then stretches the base material S in the width direction TD of the base material S (second stretching step). The width direction TD is orthogonal to the flow direction MD. By the second stretching step, the base material S on which the film C is formed is stretched, and the above-mentioned film F is obtained.

The thickness of the film F is, for example, 20 μm or more and 100 μm or less.

(5) Slit processing machine The slit processing machine 5 cuts the film F stretched by the stretching step into a predetermined width. The slit processing machine 5 cuts the film F to a predetermined width before the knurling machine 6 forms knurling on the film F, that is, before the knurling step described later (slit step).

The width of the cut film F is, for example, 1000 mm or more and 3000 mm or less.

As shown in FIG. 3, each of the edges E1 and E2 in the width direction TD of the cut film F has a wave shape. Each of the edges E1 and E2 extends in the flow direction MD while oscillating in the width direction TD.

Specifically, the slit processing machine 5 has slit blades 5A and 5B.

The slit blade 5A (first slit blade) cuts the film F. By cutting the film F by the slit blade 5A, the edge E1 is formed at one end of the film F in the width direction as a cutting edge.

The slit blade 5A can periodically move in the width direction TD with respect to the film F. By cutting the film F conveyed in the flow direction MD with the slit blade 5A that periodically moves in the width direction TD, the edge E1 becomes a wave shape.

The movement of the slit blade 5A with respect to the film F in the width direction TD is controlled based on the following equation (1).

Equation (1): W (t) = W _max / 2 × sin (πV ₁ t / W _max )
(In the above formula (1), W (t) indicates the position of the slit blade 5A with respect to the film F in the width direction TD, and W _max indicates the maximum value of the moving distance of the slit blade 5A in the width direction TD. Indicates the time, and V ₁ indicates the moving speed of the slit blade 5A in the width direction TD.)
W _max is, for example, 0.01 m or more, preferably 0.05 m or more, and for example, 0.2 m or less, preferably 0.15 m or less.

The moving speed (V ₂ / V ₁ ) of the film F in the flow direction MD with respect to the moving speed of the slit blade 5A in the width direction TD is, for example, 1000 or more, preferably 5000 or more, more preferably 8000 or more, for example, 70000. Hereinafter, it is preferably 35,000 or less, more preferably 15,000 or less.

Specifically, the moving speed (V ₁ ) of the slit blade 5A in the width direction TD is, for example, 0.001 m / min or more, preferably 0.003 m / min or more, and for example, 0.1 m / min or less. , Preferably 0.01 m / min or less.

The moving speed (V ₂ ) of the film F in the flow direction MD is, for example, 30 m / min or more, preferably 40 m / min or more, and for example, 70 m / min or less, preferably 60 m / min or less.

The slit blade 5B (second slit blade) is arranged away from the slit blade 5A in the width direction TD. The slit blade 5B cuts the film F. By cutting the film F by the slit blade 5B, the edge E2 is formed at the other end of the film F in the width direction as a cutting edge. The slit blade 5B periodically moves in the width direction TD with respect to the film F in the same manner as the slit blade 5A, while maintaining the widthwise distance from the slit blade 5A. As a result, the edge E2 has almost the same wave shape as the edge E1.

(6) Knurling machine The knurling machine 6 forms knurling at both ends in the width direction of the film F cut to a predetermined width by the slitting process. That is, the knurling machine 6 forms knurling at the end portion of the film F in the width direction (knurling step). The term "narl" refers to irregularities formed at both ends of the film F in the width direction. The knurling machine 6 forms knurls K1 and K2 on the film F.

The nal K1 (first nal) is formed at one end of the film F in the width direction TD. Knar K1 extends along the edge E1. Knar K1 has substantially the same wave shape as edge E1. That is, Nar K1 extends in the flow direction MD while oscillating in the width direction TD. The knurl K1 is disposed away from the edge E1 in the width direction TD. The distance D1 between Nar K1 and the edge E1 in the width direction TD is, for example, 5 mm or less.

The knurl K2 (second knurl) is formed at the other end of the film F in the width direction TD. Knar K2 extends along the edge E2. Nar K2 has substantially the same wave shape as edge E2. The Nar K2 is located away from the edge E2 in the width direction TD. The distance D2 between Nar K2 and the edge E2 in the width direction TD is, for example, 5 mm or less.

Specifically, the knurling processing machine 6 forms knurls K1 and K2 by irradiating the film F with a laser beam. The knurling machine 6 has emission portions 6A and 6B.

The emitting portion 6A (first emitting portion) faces one end of the film F in the width direction. The emitting unit 6A emits laser light toward the film F. The emitting portion 6A follows the slit blade 5A and periodically moves in the width direction TD with respect to the film F. As a result, Nar K1 extends along the edge E1 and has almost the same wave shape as the edge E1.

The movement of the emitting unit 6A with respect to the film F in the width direction TD is controlled based on the following equation (2).

Equation (2): W (n) = W _max / 2 × sin (πV ₁ (t-L / V ₂ ) / W _max )
In the above equation (2), W (n) indicates the position of the emitting portion 6A with respect to the film F in the width direction TD, W _max indicates the maximum value of the moving distance of the slit blade 5A in the width direction TD, and t is. , V ₁ indicates the moving speed of the slit blade 5A in the width direction TD, V ₂ indicates the moving speed of the film F in the flow direction MD, and L indicates the moving speed from the slit blade 5A to the exit portion 6A. The transport distance of the film F is shown.

By controlling the movement of the exiting portion 6A with respect to the film F in the width direction TD in this way, the movement of the emitting portion 6A can be made to follow the movement of the slit blade 5A, and the knurl K1 can be made to follow the edge E1.

The emitting portion 6B (second emitting portion) faces the other end of the film F in the width direction. The emitting unit 6B emits laser light toward the film F in the same manner as the emitting unit 6A. The emitting portion 6B follows the slit blade 5B and periodically moves in the width direction TD with respect to the film F in the same manner as the emitting portion 6A follows the slit blade 5A. As a result, Nar K2 extends along the edge E2 and has almost the same wave shape as the edge E2.

(7) Winding machine The winding machine 7 winds up the film F on which knurling is formed by the knurling process. When the winding step is completed, the film roll R can be obtained. That is, the winder 7 winds the film F on which the knurls K1 and K2 are formed to manufacture the film roll R (winding step).

The winder 7 winds the film F so that the positions of the knurls K1 and K2 in the width direction are aligned with respect to the film roll R. As shown in FIG. 4, "the positions of the nals are aligned" means that the nals K1 overlap each other and the nals K2 overlap each other in the radial direction of the film roll R.

Specifically, the winder 7 periodically moves the film roll R in the width direction TD so as to follow the slit blade 5A. As a result, the film F is wound so that the knurls K1 overlap each other and the knurls K2 overlap each other in the radial direction of the film roll R.

Here, when the film F is stretched in the above-mentioned stretching step, a thick portion may be formed in a part of the film F in the width direction TD.

In this respect, the winder 7 winds the film F while periodically moving the film roll R in the width direction TD. As a result, the film F can be wound while shifting the thick portion of the film F in the width direction TD.

Therefore, it is possible to suppress the thick portions of the film F from being stacked in the radial direction of the film roll R, and to suppress the generation of gauge bands. The gauge band means a band-shaped convex portion generated in a specific portion in the width direction of the film roll R by stacking thick portions of the film F in the radial direction of the film roll R.

Further, by aligning the positions of the knurls K1 and K2 in the width direction with respect to the film roll R, a gap can be uniformly formed between the films F overlapping each other in the radial direction of the film roll R.

Therefore, it is possible to secure a gap between the films F that overlap each other, and it is possible to further suppress the generation of the gauge band.

Further, as described above, since Nar K1 has a wave shape extending along the edge E1 and Nar K2 has a wave shape extending along the edge E2, by aligning the Nar K1 and K2, the edges E1 and E2 are aligned. Can also be arranged.

The type of the winder 7 is not limited. Examples of the winder 7 include a turret winder and the like.

2. 2. Modification example (1) The slit blades 5A and 5B do not have to move in the width direction TD. The edges E1 and E2 do not have to be cut into a wavy shape. In this case, the emitting portion 6A periodically moves in the width direction TD independently of the slit blade 5A. Further, the exiting portion 6B periodically moves in the width direction TD together with the emitting portion 6A independently of the slit blade 5B. Further, the winder 7 periodically moves the film roll R in the width direction TD so as to follow the emitting portion 6A.

(2) The emitting units 6A and 6B do not have to move in the width direction TD. For example, the emitting units 6A and 6B may be able to change the emitting direction of the laser beam to the width direction TD.

(3) Nar K1 and K2 may be formed by heated embossed rolls.

(4) The knurling processing machine 6 may include a transport member for transporting the film F and a cleaning device for cleaning the transport member. The transport member may be a transport roller or a transport belt. In the cleaning device, the end portion (nar K1 or nar K2) of the film F is formed on the surface of the transport member at the timing when the emission portion 6A or the emission portion 6B moves toward the inside of the film F in the width direction TD. The part in contact with the part) may be cleaned.

(5) The application of the film roll R manufacturing system 1 is not limited to extrusion molding. For example, the base material S may be unwound from the roll of the base material S, the unwound base material S may be stretched, and the base material S may be wound up by the winder 7.

(6) The method for producing the film roll R does not have to include a coating step.

(7) The film F manufacturing system 1 does not have to include the first stretching machine 4A. The base material S may be stretched (biaxial simultaneous stretching) in the flow direction MD and the width direction TD by the second stretching machine 4B after the coating step.

1 Manufacturing system 5 Slit processing machine 5A Slit blade 6 Narling processing machine 6A Ejector 7 Winder E1 Edge K1 Nar R film roll

Claims (8)

A knurling machine that forms knurling at the edges of the film in the width direction orthogonal to the flow direction of the film.
The film is provided with a winder for producing a film roll by winding the film on which the nal is formed.
The nar has a wave shape extending in the flow direction while oscillating in the width direction.
The winder is a film roll manufacturing system, characterized in that the film is wound so that the positions of the knurls are aligned with respect to the film roll in the width direction. Further, the knurling machine is provided with a slit processing machine that cuts the film to a predetermined width before forming the knurling on the film.
The edge of the cut film in the width direction has a wave shape extending in the flow direction while oscillating in the width direction.
The film roll manufacturing system according to claim 1, wherein the nal has a wavy shape extending along the edge. The slit processing machine has a slit blade for cutting a film.
The knurling machine has an exit portion that emits laser light, and forms the knurl by irradiating the film with the laser light.
The film roll manufacturing system according to claim 2, wherein the slit blade and the emitting portion are periodically movable with respect to the film in the width direction. The movement of the slit blade with respect to the film in the width direction is controlled based on the following equation (1).
The film roll manufacturing system according to claim 3, wherein the movement of the emitting portion with respect to the film in the width direction is controlled based on the following formula (2).
Equation (1): W (t) = W _max / 2 × sin (πV ₁ t / W _max )
Equation (2): W (n) = W _max / 2 × sin (πV ₁ (t-L / V ₂ ) / W _max )
(In the above formulas (1) and (2), W (t) indicates the position of the slit blade with respect to the film in the width direction, and W (n) indicates the position of the exit portion with respect to the film in the width direction. W _max indicates the maximum value of the moving distance of the slit blade in the width direction, t indicates the time, V ₁ indicates the moving speed of the slit blade in the width direction, and V ₂ indicates the moving speed of the film in the flow direction, and L indicates the transport distance of the film from the slit blade to the ejection portion.) The film roll according to claim 4, wherein the moving speed (V ₂ / V ₁ ) of the film in the flow direction with respect to the moving speed of the slit blade in the width direction is 1000 or more and 70,000 or less. Manufacturing system. The production of the film roll according to claim 4 or 5, wherein the maximum value (W _max ) of the moving distance of the slit blade in the width direction is 0.01 m or more and 0.2 m or less. system. A knurling step of forming knurling at the edges of the film in a width direction orthogonal to the flow direction of the film.
It comprises a winding step of winding the film on which the nal is formed to produce a film roll.
The nar has a wave shape extending in the flow direction while oscillating in the width direction.
A method for producing a film roll, which comprises winding the film so that the positions of the knurls in the width direction are aligned with the film roll in the winding step. Further, a slitting step of cutting the film to a predetermined width is included before the knurling step.
The edge of the cut film in the width direction has a wave shape extending in the flow direction while oscillating in the width direction.
The method for producing a film roll according to claim 7, wherein the nal has a wavy shape extending along the edge.

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