JP7280207B2 - Touch roller, winder, film roll manufacturing system, and film roll manufacturing method - Google Patents

Description

The present invention relates to a touch roller, a winder, a film roll manufacturing system, and a film roll manufacturing method.

2. Description of the Related Art Conventionally, a winder provided with a roller (ray-on roll) in contact with a film roll is known (see, for example, Patent Literature 1).

JP 2006-193327 A

In the winding machine as described in Patent Document 1, the contact pressure between the roller and the film roll may become uneven in the width direction of the film.

If the contact pressure between the roller and the film roll becomes uneven in the width direction of the film, problems such as wrinkling of the film roll may occur.

The present invention provides a touch roller, a winder, a film roll manufacturing system, and a film roll manufacturing method that can suppress the occurrence of defects such as wrinkling of the film roll.

The present invention [1] winds up the film having a first knurl formed at one end in the width direction perpendicular to the flow direction of the film and a second knurl formed at the other end in the width direction. A touch roller provided in a winder that manufactures a film roll, the touch roller having a contact portion that contacts the film roll when the winder is winding the film, the contact portion A touch roller is disposed between the first knurl and the second knurl in the width direction.

With such a configuration, the contact portion does not contact the first knurl and the second knurl.

This can prevent the touch roller from excessively pressing both ends of the film roll.

Therefore, the touch roller can be brought into contact with the film roll with a uniform pressing force across the width direction.

As a result, it is possible to suppress the occurrence of defects such as wrinkling of the film roll.

The present invention [2] comprises a roller body extending in the width direction and a shaft rotatable together with the roller body, the roller body being a first taper arranged at one end of the roller body in the width direction. a second taper arranged at the other end of the roller body in the width direction; and the contact portion arranged between the first taper and the second taper in the width direction and extending in the width direction. and the touch roller of [1] above.

According to such a configuration, the first taper is formed at one end of the roller body in the width direction. Therefore, the contact pressure against the film roll can be reduced at one end of the roller body in the width direction.

A second taper is formed at the other end of the roller body in the width direction. Therefore, the contact pressure against the film roll can be reduced at the other end of the roller body in the width direction.

In summary, the contact pressure against the film roll can be reduced at both ends of the roller body in the width direction by the first taper and the second taper.

Therefore, the touch roller can be prevented from excessively pressing both ends of the film roll, and the touch roller can be brought into contact with the film roll with a more uniform pressing force across the width direction.

As a result, it is possible to further suppress the occurrence of defects such as wrinkling of the film roll.

In the present invention [3], the shaft is arranged in the center of the roller body in the radial direction of the roller body, extends in the width direction, and the roller body contacts the film roll in the radial direction. a first layer and a second layer disposed between the first layer and the shaft, wherein the first layer is made of a first elastic material; and the second layer comprises the first elastic material. It includes the touch roller of [2] above, which is made of a second elastic material that is softer than the material.

With such a configuration, the second elastic material is softer than the first elastic material, so that the second layer can be deformed following the deformation of the first layer.

Therefore, deformation of the first layer according to the surface of the film roll can be allowed while the touch roller is in contact with the film roll.

Thereby, the touch roller can be brought into contact with the film roll with a uniform pressing force across the width direction.

As a result, it is possible to further suppress the occurrence of defects such as wrinkling of the film roll.

The present invention [4] includes a winding machine comprising a winding unit that winds the film to manufacture the film roll, and the touch roller according to any one of the above [1] to [3].

According to such a configuration, since the above-described touch roller is provided, it is possible to suppress the occurrence of defects such as wrinkling of the film roll.

The present invention [5] includes a film roll manufacturing system comprising a knurling machine for forming the first knurls and the second knurls on the film, and the winder of [4] above.

With such a configuration, since the winding machine described above is provided, it is possible to prevent problems such as wrinkling of the film roll from occurring.

The present invention [6] is a film roll comprising a knurling step of forming the first knurl and the second knurl in the film, and a winding step of winding the film with the winding machine of [4] above. including the manufacturing method of

According to such a method, since the film is wound by the winder described above, it is possible to suppress the occurrence of defects such as wrinkling of the film roll.

According to the touch roller, the winder, the film roll manufacturing system, and the film roll manufacturing method of the present invention, it is possible to suppress the occurrence of defects such as wrinkling of the film roll.

FIG. 1 is a cross-sectional view of a film wound by a winder as one embodiment of the present invention. FIG. 2 is a schematic configuration diagram of a film roll manufacturing system as one embodiment of the present invention. FIG. 3 is a cross-sectional view of a touch roll as one embodiment of the present invention.

1. Film Roll Manufacturing System As shown in FIG. The substrate S has a first surface S<b>1 and a second surface S<b>2 in the thickness direction of the substrate S. The coating C is arranged on the first surface S1 of the substrate S. As shown in FIG. The coating C covers the first surface S1 of the base material S. As shown in FIG. Coating C may be an easy-adhesion layer. When the coating C is an easy-adhesion layer, the film F is an easy-adhesion film. Easy-adhesive films are used, for example, in polarizing plates of image display devices such as mobile devices, car navigation devices, personal computer monitors, and televisions. Specifically, the easily adhesive film is used as a protective film for protecting the polarizer of the polarizing plate. The easily adhesive film is attached to the polarizer via the adhesive layer. The easy-adhesion film is an easy-adhesion layer and is attached to the polarizer.

As shown in FIG. 2, a 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 slitting machine 5, and a knurling machine. A machine 6 and a winder 7 are provided.

(1) Extruder The extruder 2 extrudes the substrate S (extrusion process). The substrate S extruded from the extruder 2 has a sheet shape.

The substrate S is made of a thermoplastic resin. Examples of thermoplastic resins include acrylic resins, polyolefin resins, cyclic polyolefin resins, polyester resins, polycarbonate resins, polystyrene resins, polyamide resins, polyimide resins, acetate resins (diacetyl cellulose, triacetyl cellulose, etc.).

When manufacturing an easily adhesive film used as a protective film for a polarizer, the material of the substrate S is preferably an acrylic resin.

Moreover, when producing an easily adhesive film used as a protective film for a polarizer, the acrylic resin may be an acrylic resin having a glutaric anhydride structure or an acrylic resin having a lactone ring structure. Acrylic resins having a glutaric anhydride structure and acrylic resins having a lactone ring structure have high heat resistance, high transparency, and high mechanical strength. Suitable for manufacturing. Acrylic resins having a glutaric 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. It is

In addition to the acrylic resin, the base material S may contain a thermoplastic resin other than the acrylic resin. By containing other thermoplastic resin, the birefringence of the acrylic resin can be canceled, and an easily adhesive film having excellent optical isotropy can be obtained. Also, the mechanical strength of the easily 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 substrate S obtained by the extrusion molding step, and then stretches the substrate S in the flow direction MD (first stretching step).

(3) Coating Machine The coating machine 3 applies a coating liquid to the first surface S1 of the substrate S extruded in the extrusion process (coating process). The first surface S1 of the substrate S may be subjected to surface treatment such as corona treatment or plasma treatment after the extrusion process and before the coating process.

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

When manufacturing an easy-adhesion film, a coating liquid is an easy-adhesion composition for forming an easy-adhesion layer.

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

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

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

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

The resin component forms the above-described binder resin film (easy-adhesion layer) by the stretching step described later. When the binder resin is a urethane resin, examples of the resin component include a water-based urethane resin. Examples of water-based urethane resins include non-reactive water-based urethane resins that are emulsions of urethane resins, and reactive water-based urethane resins that are emulsions of urethane resins in which isocyanate groups are 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 dispersion media include water, 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 in the coating step. As a result, the coating liquid becomes the film C described above. Further, the second stretching machine 4B heats the substrate S on which the film C is formed, and then stretches it in the width direction TD of the substrate S (second stretching step). The width direction TD is orthogonal to the machine direction MD. In the second stretching step, the substrate S having the film C formed thereon is stretched to obtain the film F described above.

(5) Slitting Machine The slitting machine 5 cuts the film F stretched in the stretching process into a predetermined width (slitting process).

(6) Knurling Machine The knurling machine 6 forms knurls at both ends in the width direction of the film F cut to a predetermined width by the slitting process (knurling process). In addition, the "knurl" refers to unevenness formed on both ends of the film F in the width direction. By forming "knurls" at both ends of the film F in the width direction, a slight gap can be formed between the overlapping films F in the radial direction of the film roll R when the film F is wound. Specifically, the knurling machine 6 forms a first knurl K1 (see FIG. 3) and a second knurl K2 (see FIG. 3) on the film F. As shown in FIG.

As shown in FIG. 3, the first knurl K1 is formed at one end of the film F in the width direction TD. The second knurl K2 is formed at the other end of the film F in the width direction TD.

The first knurl K1 and the second knurl K2 are formed by a laser. The first knurl K1 and the second knurl K2 may be formed by a heated embossing roll.

(7) Winder As shown in FIG. 1, the winder 7 winds up the film F on which knurls are formed by the knurling process (winding process). A film roll R can be obtained by completing the winding process. That is, the winder 7 manufactures the film roll R by winding the film F having the first knurl K1 and the second knurl K2.

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

2. Details of Winding Machine The winding machine 7 includes a winding section 11 and a touch roller 12 .

(1) Winding Unit The winding unit 11 winds the film F to manufacture the film roll R. As shown in FIG. The winding unit 11 holds the winding core W. As shown in FIG. The winding unit 11 rotates the winding core W. The film F is wound around a rotating core W. As shown in FIG.

(2) Touch roller 12
As shown in FIG. 3, the touch roller 12 includes a shaft 12A and a roller body 12B.

(2-1) Shaft The shaft 12A is arranged in the center of the roller body 12B in the radial direction of the roller body 12B. The shaft 12A extends in the width direction TD. The shaft 12A has a cylindrical shape. The shaft 12A is made of metal. It should be noted that the shaft 12A may have a cylindrical shape having a through hole penetrating in the width direction TD. Moreover, the outer peripheral surface of the shaft 12A may have a polygonal shape.

(2-1) Roller Body The roller body 12B is rotatable together with the shaft 12A. The roller body 12B is arranged on the outer peripheral surface of the shaft 12A. The roller body 12B covers the shaft 12A. The roller body 12B extends in the width direction TD. The roller body 12B has a cylindrical shape. The diameter of the roller body 12B is larger than the diameter of the shaft 12A.

(2-1-2) Shape of Roller Body The roller body 12B has a first taper 121, a second taper 122, and a contact portion 123. As shown in FIG.

The first taper 121 is arranged at one end of the roller body 12B in the width direction TD. The first taper 121 is inclined toward the shaft 12A toward one side in the width direction TD. The first taper 121 inclines in a direction away from the film roll R toward one side in the width direction TD. Note that the first taper 121 does not have to extend to the shaft 12A. The first taper 121 is separated from the first knurl K1. The first taper 121 may face the first knurl K1 in the radial direction of the roller body 12B. By forming the first taper 121 at one end of the roller body 12B in the width direction TD, the contact pressure against the film roll R can be reduced at one end of the roller body 12B in the width direction TD.

The second taper 122 is arranged at the other end of the roller body 12B in the width direction TD.
The second taper 122 is inclined toward the shaft 12A toward the other side in the width direction TD. The second taper 122 inclines in a direction away from the film roll R toward the other side in the width direction TD. Note that the second taper 122 does not have to extend to the shaft 12A. The second taper 122 is spaced from the second knurl K2. The second taper 122 may face the second knurl K2 in the radial direction of the roller body 12B. By forming the second taper 122 at the other end of the roller body 12B in the width direction TD, the contact pressure to the film roll R can be reduced at the other end of the roller body 12B in the width direction TD.

The contact portion 123 is arranged between the first taper 121 and the second taper 122 in the width direction TD. The contact portion 123 extends in the width direction TD from the first taper 121 to the second taper 122 . The contact portion 123 contacts the film roll R while the winder 7 is winding the film F. As shown in FIG.

An angle θ1 between surface S11 of contact portion 123 and surface S12 of first taper 121 is greater than 90°. The angle θ1 is preferably 100° or more. When the angle θ1 is larger than the above lower limit, it is possible to reduce the contact pressure on the film roll R at one end of the roller body 12B in the width direction TD. The angle θ1 is smaller than 180°, preferably 160° or less.

An angle θ2 between surface S11 of contact portion 123 and surface S13 of second taper 122 is greater than 90°. The angle θ2 is preferably 100° or more. Angle θ2 is preferably the same as angle θ1. When the angle θ2 is larger than the above lower limit, the contact pressure against the film roll R can be reduced at the other end of the roller body 12B in the width direction TD. The angle θ2 is smaller than 180°, preferably 160° or less.

With the touch roller 12 in contact with the film roll R, the contact portion 123 is arranged between the first knurl K1 and the second knurl K2 in the width direction TD. While the touch roller 12 is in contact with the film roll R, the contact portion 123 is separated from the first knurl K1 and the second knurl K2 in the width direction. In other words, the touch roller 12 does not contact the first knurl K1 and the second knurl K2.

Thereby, it is possible to prevent the touch roller 12 from excessively pressing both ends of the film roll R. Therefore, the touch roller 12 can be brought into contact with the film roll R with a uniform pressing force across the width direction. As a result, in the winding process, it is possible to suppress the occurrence of defects such as wrinkling of the film roll R.

Further, as described above, the first taper 121 and the second taper 122 can reduce the contact pressure against the film roll R at both ends of the roller body 12B in the width direction TD.

Therefore, the touch roller 12 can be prevented from excessively pressing both ends of the film roll R, and the touch roller 12 can be brought into contact with the film roll R with a more uniform pressing force across the width direction TD.

As a result, it is possible to further suppress the occurrence of defects such as wrinkling of the film roll R.

(2-2-2) Layer Structure of Roller Body The roller body 12B has a first layer L1 and a second layer L2 in the radial direction. In other words, the roller body 12B has multiple layers in the radial direction.

The first layer L1 is a skin layer of the roller body 12B in the radial direction. The first layer L1 is arranged at least on the surface S11 of the contact portion 123 . The first layer L1 may be disposed on all of the surface S11 of the contact portion 123, the surface S12 of the first taper 121, and the surface S13 of the second taper 122. The first layer L1 is in contact with the film roll R. The first layer L1 is made of a first elastic material.

Examples of the first elastic material include rubbers such as acrylonitrile-butadiene rubber (NBR), silicone rubber, fluororubber, chloroprene rubber, urethane rubber (polyurethane elastomer), acrylonitrile-butadiene rubber (NBR) sponge, and silicone rubber sponge. , fluororubber sponge, chloroprene rubber sponge, and urethane sponge (polyurethane foam).

The hardness of the first elastic material is, for example, A60 or higher, preferably A70 or higher, and for example, A90 or lower, preferably A80 or lower.

The hardness is measured by the method defined in JIS K 6253-3:2012.

When the outer diameter φ1 of the touch roller 12 is 120 mm, the diameter φ2 of the shaft 12A is 100 mm, and the thickness t of the roller body 12B is 10 mm, the thickness of the first layer L1 is, for example, 5 mm or less, preferably 3 mm or less, for example, 1 mm or more.

The second layer L2 is arranged radially between the first layer L1 and the shaft 12A. The second layer L2 contacts the first layer L1. In this embodiment, the second layer L2 also contacts the shaft 12A. The second layer L2 is made of a second elastic material.

Examples of the second elastic material include the same material as the first elastic material described above.

The second elastic material is softer than the first elastic material. Since the second elastic material is softer than the first elastic material, the second layer L2 can also deform following the deformation of the first layer L1. Therefore, the first layer L1 can be allowed to deform according to the surface of the film roll R while the touch roller 12 is in contact with the film roll R. Thereby, the touch roller 12 can be brought into contact with the film roll R with a uniform pressing force across the width direction. As a result, it is possible to further suppress the occurrence of defects such as wrinkling of the film roll R.

The hardness of the second elastic material is, for example, A15 or higher, preferably A20 or higher, and for example, A50 or lower, preferably A40 or lower.

The thickness of the second layer L2 is greater than or equal to the thickness of the first layer L1. When the outer diameter φ1 of the touch roller 12 is 120 mm, the diameter φ2 of the shaft 12A is 100 mm, and the thickness t of the roller body 12B is 10 mm, the thickness of the second layer L2 is, for example, 5 mm or more, preferably It is 7 mm or more and, for example, 9 mm or less.

The ratio of the thickness of the first layer L1 to the thickness of the second layer L2 (thickness of the first layer L1/thickness of the second layer L2) is, for example, 1/10 or more, preferably 1/8 or more. , 1/2 or less, preferably 1/3 or less.

4. Modifications (1) The touch roller 12 may not have the first taper 121 and the second taper 122 .

(2) The use of the winder 7 is not limited to extrusion molding. For example, the base material S may be unwound from a roll of the base material S, and the unwound base material S may be stretched and wound up by the winder 7 .

(3) The method for manufacturing the film roll R may not include the coating step.

(4) The layer structure of the roller body 12B is not limited to the two-layer structure. As long as the deformation of the first layer L1 is allowed, a laminated structure of three or more layers may be used.

(5) The production system 1 for the film F may not include the first stretching machine 4A. After the coating step, the substrate S may be stretched in the machine direction MD and the width direction TD (simultaneous biaxial stretching) by the second stretching machine 4B.

1 manufacturing system 6 knurling machine 7 winder 11 winder 12 touch roller 12A shaft 12B roller body 121 first taper 122 second taper 123 contact part K1 first knurl K2 second knurl L1 first layer L2 second layer R film roll

Claims (6)

A film roll is produced by winding the film having a first knurl formed at one end in the width direction perpendicular to the flow direction of the film and a second knurl formed at the other end in the width direction. A touch roller provided in a winding machine,
a shaft;
a roller body extending in the width direction and rotatable together with the shaft;
with
The roller body is
a first taper arranged at one end of the roller body in the width direction;
a second taper arranged at the other end of the roller body in the width direction;
a contact portion disposed between the first taper and the second taper in the width direction, extending in the width direction, and contacting the film roll when the winder is winding the film;
has
The contact portion is arranged between the first knurl and the second knurl in the width direction ,
A touch roller , wherein the first taper and the second taper are spaced from the film . The first taper faces the first knurl and is separated from the first knurl in the radial direction of the roller body,
2. The touch roller according to claim 1, wherein the second taper faces and is separated from the second knurl in the radial direction of the roller body. The shaft is arranged in the center of the roller body in the radial direction of the roller body and extends in the width direction,
The roller body, in the radial direction,
a first layer in contact with the film roll;
a second layer disposed between the first layer and the shaft;
the first layer is made of a first elastic material;
3. The touch roller according to claim 1 , wherein the second layer is made of a second elastic material that is softer than the first elastic material. A winding unit that winds the film to manufacture the film roll;
A winding machine comprising the touch roller according to any one of claims 1 to 3. a knurling machine for forming the first knurls and the second knurls on the film;
A film roll manufacturing system comprising the winding machine according to claim 4 . a knurling step of forming the first knurl and the second knurl in the film;
and a winding step of winding the film with the winding machine according to claim 4 .

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