CN111829904A - Inspection method, method for manufacturing resin film roll, and resin film roll - Google Patents

Inspection method, method for manufacturing resin film roll, and resin film roll Download PDF

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Publication number
CN111829904A
CN111829904A CN202010309273.XA CN202010309273A CN111829904A CN 111829904 A CN111829904 A CN 111829904A CN 202010309273 A CN202010309273 A CN 202010309273A CN 111829904 A CN111829904 A CN 111829904A
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China
Prior art keywords
resin film
roll
film roll
hardness distribution
layer
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Granted
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CN202010309273.XA
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Chinese (zh)
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CN111829904B (en
Inventor
加藤泰礼
水野浩辅
星野莉那
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Sumitomo Chemical Co Ltd
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Sumitomo Chemical Co Ltd
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N3/32—Investigating strength properties of solid materials by application of mechanical stress by applying repeated or pulsating forces
    • G01N3/34—Investigating strength properties of solid materials by application of mechanical stress by applying repeated or pulsating forces generated by mechanical means, e.g. hammer blows
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N3/40—Investigating hardness or rebound hardness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H18/00—Winding webs
    • B65H18/08—Web-winding mechanisms
    • B65H18/26—Mechanisms for controlling contact pressure on winding-web package, e.g. for regulating the quantity of air between web layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H18/00—Winding webs
    • B65H18/28—Wound package of webs
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
    • G01N33/44—Resins; Plastics; Rubber; Leather
    • G01N33/442—Resins; Plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2701/00—Handled material; Storage means
    • B65H2701/10—Handled articles or webs
    • B65H2701/17—Nature of material
    • B65H2701/175—Plastic
    • B65H2701/1752—Polymer film
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N2203/003—Generation of the force
    • G01N2203/0032—Generation of the force using mechanical means
    • G01N2203/0039—Hammer or pendulum
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N2203/0058—Kind of property studied
    • G01N2203/0076—Hardness, compressibility or resistance to crushing
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N2203/02—Details not specific for a particular testing method
    • G01N2203/026—Specifications of the specimen
    • G01N2203/0262—Shape of the specimen
    • G01N2203/0278—Thin specimens
    • G01N2203/0282—Two dimensional, e.g. tapes, webs, sheets, strips, disks or membranes

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Biochemistry (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Immunology (AREA)
  • Pathology (AREA)
  • Engineering & Computer Science (AREA)
  • Food Science & Technology (AREA)
  • Medicinal Chemistry (AREA)
  • Winding Of Webs (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)

Abstract

Provided are an inspection method capable of inspecting whether a striped defect exists in a resin film roll, a method for manufacturing the resin film roll, and the resin film roll. An inspection method according to an embodiment includes: a step of striking the surface (2a) of the resin film roll with a hammer while moving the hammer (30) in the axial direction of the resin film roll (2), measuring the deceleration until the hammer strikes the surface of the resin film roll and stops, and acquiring the change of the deceleration as a roll hardness distribution in the axial direction; and a determination step of determining whether the resin film roll is good or bad based on the roll hardness distribution, wherein in the determination step, the resin film roll is determined to be a good product when the 1 st condition (standard deviation which is standard deviation of the roll hardness distribution is less than or equal to 3) and the 2 nd condition (difference between maximum value and minimum value in the roll hardness distribution is less than or equal to 18G) are both satisfied, and the resin film roll is determined to be a defective product when at least one of the 1 st condition and the 2 nd condition is not satisfied.

Description

Inspection method, method for manufacturing resin film roll, and resin film roll
Technical Field
The invention relates to an inspection method, a method for manufacturing a resin film roll, and a resin film roll.
Background
The long resin film is wound in a roll shape as described in, for example, japanese patent application laid-open No. 2003-147092, and is stored or transported as a resin film roll, or is sold as a product.
When a long resin film is wound in a roll shape, air is likely to be involved together. When air is entrained in this manner, stripe-like defects that extend in the roll circumferential direction (the direction in which the resin film extends) are generated in the formed roll. Since the defect occurs in the roll, the presence or absence of the defect cannot be checked only by visually checking the appearance of the roll.
Disclosure of Invention
An object of the present invention is to provide an inspection method capable of inspecting the presence or absence of a striped defect in a resin film roll formed of a long resin film, and a method for manufacturing a resin film roll including the inspection method. Another object of the present invention is to provide a roll of resin film substantially free from streak-like defects.
The inspection method according to the present invention includes: a roll hardness distribution acquisition step of striking a surface of a resin film roll with a hammer while moving the hammer in an axial direction of the resin film roll formed by winding a resin film, measuring a deceleration until the hammer strikes the surface of the resin film roll and stops, and acquiring a change in the deceleration in the axial direction as a roll hardness distribution in the axial direction; and a determination step of determining whether the resin film roll is good or bad based on the roll hardness distribution, wherein in the determination step, the resin film roll is determined to be a good product when both of a1 st condition and a2 nd condition are satisfied, and the resin film roll is determined to be a defective product when at least one of the 1 st condition and the 2 nd condition is not satisfied, wherein the 1 st condition is a condition that a standard deviation, which is a standard deviation of the roll hardness distribution, is 3 or less, and the 2 nd condition is a condition that a difference between a maximum value and a minimum value in the roll hardness distribution is 18G or less.
The inventors of the present invention have found that the position where the streak-like defect exists is correlated with other positions in the roll hardness distribution obtained by using the above-described hammer. In the above-described inspection method, the coil hardness distribution is acquired in the coil hardness distribution acquisition step. Based on the obtained roll hardness distribution and the above-mentioned 1 st and 2 nd conditions, the quality of the resin film roll is judged. As a result, the presence or absence of the stripe-shaped defect in the roll, that is, whether or not the resin film roll is a good product can be checked.
When it is determined in the determining step that the resin film roll is defective, the resin film roll may be virtually divided into 1 st to nth regions (N is an integer of 3 or more) in the axial direction, the average value of each of the 1 st to nth regions in the roll hardness distribution may be calculated, and it may be further determined that a defect exists in a region in which the difference between the average value of each of the 1 st to nth regions and the average value of the entire 1 st to nth regions in the roll hardness distribution is 3G or more among the 1 st to nth regions. In this case, the position of the defect is easily determined.
In the roll hardness distribution obtaining step, the roll hardness distribution may be obtained while moving the hammer in the axial direction at a speed of 80mm/s or less.
The method for manufacturing a resin film roll according to the present invention includes: a preparation step of preparing a resin film; a roll forming step of winding the resin film around a winding shaft while winding the resin film around the winding shaft while pressing a contact roller against a surface of the resin film, thereby forming a resin film roll around which the resin film is wound; an inspection step of inspecting the resin film roll by the inspection method according to the present invention; a changing step of changing at least one of the long resin film prepared in the preparation step and the winding condition in the roll forming step when the resin film roll is determined to be defective in the inspection step; and a recovery step of recovering the resin film when the roll of resin film is judged to be a non-defective product in the inspection step.
The manufacturing method includes an inspection step of inspecting the resin film roll by the inspection method. Therefore, a roll of resin film substantially free from streaked defects (as non-defective products) can be reliably produced.
In the above manufacturing method, after the changing step is performed, the preparing step, the roll forming step, and the inspecting step may be further repeated.
In the above modification step, at least one of the following steps may be performed: a step of preparing a resin film having a uniform thickness in a direction orthogonal to a longitudinal direction of the resin film in the preparation step; and correcting a pressing force of the contact roller to the resin film in the roll forming step.
The resin film roll according to the present invention is a resin film roll formed by winding a resin film, wherein a surface of the resin film roll is struck with a hammer while the hammer is moved in an axial direction of the resin film roll, a deceleration until the hammer strikes the surface of the resin film roll and stops is measured, and when a change in the deceleration in the axial direction is obtained as a roll hardness distribution in the axial direction, a reference standard deviation as a standard deviation of the roll hardness distribution is 3 or less, and a difference between a maximum value and a minimum value in the roll hardness distribution is 18G or less.
The resin film roll does not substantially contain a streak-like defect. Therefore, when a product using a resin film is manufactured by winding the resin film from the resin film roll, it is easy to manufacture a product having desired characteristics.
When the resin film roll is virtually divided into 1 st to nth regions (N is an integer of 3 or more) in the axial direction, the difference between the average value of each of the 1 st to nth regions in the roll hardness distribution and the average value of the entire 1 st to nth regions in the roll hardness distribution may be less than 3G.
According to one aspect of the present invention, it is possible to provide an inspection method capable of inspecting the presence or absence of a striped defect in a resin film roll formed of a long resin film, and a method for manufacturing a resin film roll including the inspection method. According to another aspect of the present invention, a roll of resin film substantially free from streaked defects can be provided.
Drawings
Fig. 1 is a flowchart of a method for manufacturing a resin film roll including an inspection method according to an embodiment.
Fig. 2 is a schematic view of a winding apparatus for manufacturing a resin film roll.
FIG. 3 is a schematic illustration of a roll with striped defects.
Fig. 4 is a drawing for explaining a method of obtaining the roll hardness distribution.
Fig. 5 is a schematic view of the resin film roll viewed from the side of the hollow arrow in fig. 4.
Fig. 6 is a diagram showing an example of the roll hardness distribution in the case where the resin film roll is determined to be defective.
Fig. 7 is a diagram showing another example of the roll hardness distribution in the case where a defective resin film roll is determined.
Fig. 8 is a diagram showing an example of a roll hardness distribution in the case where the resin film roll is judged as a non-defective product.
Fig. 9 is a drawing for explaining another example of the contact roller.
Fig. 10 is a diagram for explaining an example of a conventional defect inspection method.
Fig. 11 is a drawing for explaining still another example of the contact roller.
-description of symbols-
Roll 2 … (roll of resin film), roll 2a …, roll 8 … touch roll, 30 … hammer, C … axial direction, F … resin film.
Detailed Description
Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the drawings, the same or corresponding portions are denoted by the same reference numerals, and redundant description thereof is omitted. The dimensional ratios in the drawings do not necessarily correspond to the dimensional ratios illustrated.
Fig. 1 is a flowchart of a method for manufacturing a resin film roll using an inspection method according to an embodiment. A method for manufacturing a resin film roll will be described.
As shown in fig. 1, when a resin film roll is manufactured, first, a long resin film is prepared (preparation step S01). Next, the prepared resin film is wound into a roll shape to form a resin film roll (roll forming step S02). Thereafter, the formed resin film roll is inspected for non-defective products by the inspection method according to the present invention (inspection step S03). In the inspection step S03, if the resin film roll is determined not to be a non-defective product, at least one of the prepared resin film and the winding conditions of the resin film roll is changed (changing step S04). On the other hand, in the inspection step S03, when the resin film roll is determined to be a non-defective product, the resin film roll is recovered (recovery step S05). When the resin film roll is determined to be a non-defective product, the preparation step S01 and the roll forming step S02 may be further performed under the same conditions as before the inspection step S03. When the changing step S04 is performed, the preparation step S01, the roll forming step S02, and the inspection step S03 may be repeated until the inspection step S03 determines that the resin film roll is a non-defective product. In this specification, the resin film roll includes not only a resin film roll that can be sold as a product but also a resin film roll that is not sold and is used in another process.
Next, an example of each step included in the method for manufacturing a resin film roll will be described in detail.
[ preparation Process ]
In the preparation step S01, a long resin film F shown in fig. 2 may be produced, or a long resin film F may be obtained by purchasing or the like. The resin film F can be produced by extrusion molding, for example. An example of the resin film F is an optical film. Examples of the material of the resin film F include polyester polymers, cellulose polymers, styrene polymers, polycarbonate polymers, polyolefin polymers, vinyl chloride polymers, amide polymers, imide polymers, sulfone polymers, polyether ether ketone polymers, polyphenylene sulfide polymers, vinyl alcohol polymers, vinylidene chloride polymers, vinyl butyral polymers, aryl ester polymers, polyoxymethylene (poly-oxymethylene) polymers, epoxy polymers, acrylic polymers, and blends of the above polymers, more specifically, acrylic polymers (for example, polyalkyl acrylate, polyalkyl methacrylate, etc.) and blends of the above polymers.
The length of the resin film F in the longitudinal direction is not particularly limited, and is, for example, in the range of 1000m to 10000m, preferably 1000m to 6000 m. The length of the resin film F in the width direction (direction orthogonal to the longitudinal direction) is not particularly limited, and may be, for example, 2.5m or less. The length in the width direction is usually 1000mm (1.0m) or more and 2500mm or less.
The thickness of the resin film F is not particularly limited, but is, for example, in the range of 10 μm to 150 μm, preferably 30 μm to 100 μm.
[ roll formation Process ]
In the roll forming step S02, as shown in fig. 2, the long resin film F prepared in the preparation step S01 is conveyed by a conveying roller R as a part of the conveying mechanism, and the resin film F is wound by the winding device 4. Thus, the resin film roll (hereinafter, simply referred to as "roll") 2 is formed, and for convenience of explanation, the resin film F in a roll form during winding may be referred to as a roll 2.
An example of the winding device 4 used in the roll forming step S02 will be described with reference to fig. 2. The winding device 4 includes a winding shaft 6, a contact roller 8, and a position adjustment mechanism 10.
The winding shaft 6 is a core for winding the resin film F. In the present embodiment, the winding shaft 6 is rotationally driven by a motor or the like, and the resin film F is wound around the winding shaft 6. Such a winding method is known as a center drive winding method (center drive method).
The winding device 4 may also be a surface-driven winding system. In the surface-drive winding method, a drive shaft (or a drive roller) different from the contact roller 8 is pressed against the resin film F to rotationally drive the drive shaft, and the winding shaft 6 around which the resin film F is wound is rotated by a frictional force generated in a contact area between the drive shaft and the resin film F. Thereby, the resin film F is wound around the winding shaft 6. Alternatively, the winding device 4 may employ a combined drive system in which the center drive winding system and the surface drive winding system are combined. In the surface-driven winding method, the contact roller 8 itself may be used instead of the drive shaft. The winding device 4 of the present embodiment adopts a surface-driven winding system unless otherwise specified.
The touch roller 8 is a roller for pressing the resin film F wound around the winding shaft 6 and applying a certain pressing force (hereinafter, also referred to as "touch pressure"). The touch pressure on the resin film F is, for example, 500N/m or less, preferably 400N/m or less, and more preferably 330N/m or less. The lower limit of the touch pressure is usually 10N/m, preferably 100N/m or the like. The contact roller 8 has a contact surface 8a that contacts the resin film F. The contact surface 8a is the outermost surface of the contact roller 8. The width of the contact surface 8a (the length in the direction of the rotation axis of the contact roller 8) is equal to or greater than the width of the resin film F (the length in the direction orthogonal to the longitudinal direction of the resin film F). The diameter (diameter) of the contact roller 8 is, for example, 30mm to 300mm, preferably 50mm to 200mm, and more preferably 120mm to 160 mm. The contact roller 8 is also sometimes called a nip roller, a dancer roller, a winding roller, or the like.
An example of the contact roller 8 will be described in detail with reference to fig. 2. The touch roll 8 has a roll body 12, a layer 1 14, and a layer 2 16.
The roller body 12 is a core material of the contact roller 8. The roller body 12 has a cylinder 18, a pair of end walls 19, and a pair of shaft portions 20. Examples of the material of the cylinder 18 include metal, carbon, and CFRP (carbon fiber reinforced plastic). Examples of the metal include iron, stainless steel, aluminum, and the like. Closing the openings at both ends of the cylinder 18. The cylinder 18 and a pair of end walls 19 form a hollow housing portion. A pair of shaft portions 20 are provided on the pair of end walls 19 concentrically with the axis of the cylinder 18. Fig. 2 shows one end wall 19 and one shaft portion 20 of the pair of end walls 19 and the pair of shaft portions 20. The pair of shaft portions 20 are rotatably supported by a pair of support members 22. The roller body 12 may have one shaft portion penetrating the pair of end walls 19.
In the present embodiment, the layer 1 14 is disposed outside the roller body 12 (specifically, outside the cylinder 18) in the radial direction of the roller body 12. The layer 1 14 covers the surface of the cylinder 18 of the roller body 12. In the present embodiment, the 1 st layer 14 is a layer having elasticity. Layer 1 is a base layer relative to layer 2 16. An example of a material for layer 1 14 is rubber. The layer 1 14 may be formed by winding a rubber sheet around the cylinder 18 in the circumferential direction, for example, or may be formed by forming a cylindrical portion with the rubber sheet and attaching the cylindrical portion to the roller body 12.
The Shore A hardness of the layer 1 14 is usually 50 to 80. The 1 st layer 14 is a layer for absorbing a reaction force (or collision) of a pressing force when the contact roller 8 is pressed against the resin film F. For example, the 1 st layer 14 is preferably not excessively thick from the viewpoint of preventing the contact roller 8 itself from being bent by the own weight of the contact roller 8. By preventing the contact roller 8 from flexing, the touch pressure is easily and uniformly applied in the width direction of the resin film F. On the other hand, the 1 st layer 14 is preferably not too thin in view of the ease of dispersion of the reaction force. By dispersing the reaction force, the touch pressure is easily applied uniformly in the width direction of the resin film F. Accordingly, the thickness of the layer 1 14 is usually 2mm to 15mm, preferably 3mm to 15mm, and more preferably 3mm to 12 mm.
The shore a hardness of the 1 st layer 14 is a hardness obtained as a result of a test in accordance with JIS K6253 using a test piece formed of the same material as the 1 st layer 14 and having a thickness of 6mm and having a hardness of durometer type a (shore a).
The 2 nd layer 16 is disposed outside the 1 st layer 14 in the radial direction. The surface of the 2 nd layer 16 is the contact surface 8 a. The shore a hardness of layer 2 16 is less than the shore a hardness of layer 1 14. That is, the 2 nd layer 16 is a softer layer than the 1 st layer 14. Examples of shore a hardness of layer 2 16 are from 0 to 40/50 of shore a hardness of layer 1 14. For example, when the Shore A hardness of the layer 1 14 is 50 to 80, the Shore A hardness of the layer 2 16 is 0 to 40.
The thickness of the 2 nd layer 16 is not particularly limited, and is, for example, 0.5mm to 10mm, preferably 1mm to 10mm, and more preferably 1mm to 7 mm.
In the present embodiment, the 2 nd layer 16 is a porous layer. The porous layer is not particularly limited, and examples thereof include a foam material made of a resin (so-called foam). Examples of the resin constituting the porous layer include polyethylene and polyurethane.
The 2 nd layer 16 may be formed by, for example, curling 1 sheet of foam material in the circumferential direction of the 1 st layer 14, or may be formed by covering the outer surface of the 1 st layer 14 with a plurality of rectangular (or long) sheets of foam material so as not to generate gaps. When the outer surface of the 1 st layer 14 is covered with a plurality of rectangular (or long) foam members, for example, a plurality of rectangular (or long) foam members may be arranged in the circumferential direction so that the longitudinal direction of the plurality of rectangular (or long) foam members coincides with the direction of the rotation axis of the touch roller 8, or a plurality of rectangular (or long) foam members may be wound around the 1 st layer 14 in a direction (or in a spiral shape) crossing the direction of the rotation axis of the touch roller 8.
The 2 nd layer 16 may be detachably attached to the 1 st layer 14. For example, the 1 sheet of foam or the plurality of rectangular (or oblong) sheets of foam may be adhered to the outer surface of the 1 st layer 14 by a double-sided tape, a releasable adhesive, or the like.
The 2 nd layer 16 may have a plurality of laminated structures in the radial direction, for example, as long as it has the above shore a hardness relationship with respect to the 1 st layer 14. In the case where the 2 nd layer 16 has a laminated structure including a plurality of layers, if the 2 nd layer 16 having a laminated structure satisfies the above range of shore a hardness, the materials of the respective layers may be different.
The Shore A hardness of the layer 2 16 is the hardness obtained by preparing a test piece having a thickness of 6mm and made of the same material as that of the layer 2 16 and testing the test piece with a type A durometer in accordance with JIS K6253. Alternatively, when the 2 nd layer 16 has a laminated structure including a plurality of layers, the shore a hardness of each layer of the 2 nd layer 16 may be the hardness (shore a) of the durometer type a specified in JIS K6253 in each test piece having a thickness of 6mm, which is formed of the same material as that of each layer.
The contact roller 8 is rotatably supported by a pair of support members 22. The support member 22 may be plate-shaped or rod-shaped.
As shown by the open arrows in fig. 2, the position adjustment mechanism 10 is a mechanism that moves one of the take-up shaft 6 and the contact roller 8 relative to the other in order to bring the contact surface 8a of the contact roller 8 into contact with a pressing force that applies a constant touch pressure to the resin film F.
In the embodiment illustrated in fig. 2, the contact roller 8 is moved relative to the winding shaft 6. In the embodiment illustrated in fig. 2, the position adjustment mechanism 10 is a cylinder. The position adjustment mechanism 10 includes a cylinder main body 24 and a piston rod 26 that is extendable and retractable with respect to the cylinder main body 24. The piston rod 26 is coupled to the support member 22. Examples of the cylinder body as the position adjustment mechanism 10 include a hydraulic cylinder and an air cylinder. The position adjustment mechanism 10 may also be an actuator. The position adjustment mechanism 10 may be of a swing type, for example. For example, the end portions of the pair of support members 22 on the opposite side to the contact roller 8 may be swingably attached to the support shafts. In this case, the support shaft functions as the position adjustment mechanism 10. The pair of support members 22 may be a part of the position adjustment mechanism 10.
The position adjustment mechanism 10 may include a control unit that controls the cylinder, for example, so as to adjust the position of the touch roller 8 in accordance with the amount of the resin film F wound around the winding shaft 6 so that a constant touch pressure can be applied to the resin film F. The control unit may include a cylinder, for example.
By the position adjusting mechanism 10, even if the diameter of the roll 2 is changed by continuously winding the resin film F around the winding shaft 6, the contact roller 8 is retracted accordingly. As a result, a constant touch pressure can be applied to the contact area between the contact surface 8a and the surface of the resin film F. The contact area has a rectangular shape extending in the width direction of the resin film F.
[ inspection Process ]
In the inspection step S03, it is inspected whether or not the roll 2 formed in the roll forming step S02 is a non-defective product. Specifically, as shown in fig. 3, the presence or absence of a striped defect D generated in the roll 2 is checked. The defect D is, for example, a defect extending in the circumferential direction of the roll 2. The inspection step S03 inspects the roll 2 by an inspection method described later. As shown in fig. 1, the inspection method includes a coil hardness distribution acquisition step S03A and a determination step S03B.
< roll hardness distribution acquisition step >
In the roll hardness distribution obtaining step S03A, as shown in fig. 4 and 5, the hardness is usedMeasuringThe device 28 acquires a roll hardness distribution in the axial direction C of the roll 2. Fig. 5 is a schematic view of the roll 2 viewed from the side of the hollow arrow in fig. 4.
The hardness measuring instrument 28 has a hammer 30 provided on the bottom surface so as to strike the roll surface (resin film roll surface) 2 a. The hardness measuring instrument 28 strikes the roll surface 2a with the hammer 30, and measures the deceleration until the hammer 30 comes into contact with the roll surface 2a and stops. Since the deceleration differs according to the winding hardness of the roll 2 at the position struck by the hammer 30, the deceleration corresponds to the winding hardness. The hardness measurer 28 has a pair of spacing members 32 on the bottom surface at both sides of a hammer 30 for securing a gap between the roll surface 2a and the bottom surface so that the hammer 30 can strike the roll surface 2 a. An example of the hardness measuring instrument 28 is a RoQ roll hardness tester manufactured by ACA systems corporation. Although not particularly limited, the vibration frequency of the hammer 30 (the number of times of one second striking) is, for example, 30 to 70Hz, specifically 50Hz (average 35Hz), and the speed of the hammer 30 (the speed of one second striking) may be, for example, 0.1 to 0.5m/s, more specifically about 0.25 m/s.
In the roll hardness distribution obtaining step S03A, as shown in fig. 4, while the hardness measuring instrument 28 is moved from one end of the roll 2 to the other end, the roll surface 2a is struck with the hammer 30, the deceleration until the hammer 30 comes into contact with the roll surface 2a and stops is measured, and the change in the deceleration in the axial direction C is obtained as the roll hardness distribution. The moving speed of the hardness tester 28 is not particularly limited, and may be, for example, 80mm/s or less, preferably 70mm/s or less, more preferably 50mm/s or less, and 20mm/s or more.
< determination Process >
In the determination step S03B, the quality of the roll 2 is determined based on the obtained roll hardness distribution. Specifically, the roll 2 is determined as a non-defective product when both of the following 1 st and 2 nd conditions are satisfied, and the roll 2 is determined as a defective product when at least one of the 1 st and 2 nd conditions is not satisfied.
(Condition 1)
The standard deviation as the standard deviation of the coil hardness distribution is 3 or less.
(Condition 2)
The condition 2 is that the difference between the maximum value and the minimum value in the coil hardness distribution is 18G or less.
At both ends (measurement start point and measurement end point) of the roll 2, the winding hardness may be greatly different from the actual value due to measurement errors. Thus, typically both ends of the roll 2 or measurements at and near both ends are planed off when condition 1 and condition 2 are applied. For example, the above-described 1 st condition and 2 nd condition may be determined based on measurement values obtained by removing several points (for example, 5 points from both ends in the case of measurement at 1mm intervals) from both ends of all measurement values. In this way, in the case of shaving off the measured values at both ends or both ends and the vicinities thereof of the roll 2, the "reference standard deviation" is the standard deviation in all the measured values remaining after shaving off the measured values of the above-mentioned several points from all the measured values.
Examples of the roll hardness distribution are shown in fig. 6 to 8. Fig. 6 to 8 show roll hardness distributions obtained by measuring the winding hardness of the resin film roll described below while using a RoQ roll hardness tester manufactured by ACASystem as the hardness tester 28 and moving the hardness tester 28 at intervals of 1mm (hammer speed: about 0.25m/s) with the hardness tester 28 set at 50 mm/s.
FIG. 6 shows the roll hardness distribution of a resin film roll obtained by winding a polymethyl methacrylate resin film (thickness 80 μm, width direction length 1490mm, length direction 4100mm) by using the winding apparatus shown in FIG. 2.
FIG. 7 shows the roll hardness distribution of a resin film roll obtained by winding a polymethyl methacrylate resin film (thickness: 60 μm, width direction length 1490mm, length direction 3250mm) by using the winding apparatus shown in FIG. 2.
FIG. 8 shows the roll hardness distribution of a resin film roll obtained by winding a polymethyl methacrylate resin film (thickness 80 μm, width direction length 1490mm, length 3650mm) by using the winding apparatus shown in FIG. 2.
Fig. 6 and 7 show results obtained by actually measuring the winding hardness when the roll 2 is a defective product. Fig. 8 shows the results of actually measuring the hardness of the coil when the coil 2 is a non-defective product. In the roll 2 from which the measurement results of fig. 6 and 7 were obtained, as shown in fig. 3, a defect D was present in the vicinity of one end of the roll 2. The coil hardness distributions shown in fig. 6 to 8 are the results of the same conditions except for the different winding conditions.
Fig. 6 to 8 show measurement results obtained by removing 5 points from both ends of all the measurement values. The vertical axis in fig. 6 to 8 represents the hardness measurement value (G) of the hardness tester 28. The unit "G" of the hardness measurement represents the gravitational acceleration. The horizontal axis in fig. 6 to 8 indicates the position in the width direction of the roll 2 (position in the axial direction C). The positions of P1 and P2 on the horizontal axes of fig. 6 to 8 correspond to positions obtained by removing the measurement results at 5 points from both ends of all the measurement values.
When the roll 2 is determined to be defective in the determination step S03B, the position of the defect D may be determined as follows. That is, as shown in fig. 4, the volume 2 is virtually divided into 1 st to nth regions (N is an integer of 3 or more) in the axial direction C. The 1 st to nth regions are generally equal in length in the axial direction C. N may be an integer of 25 or less.
The 1 st to nth average values corresponding to the 1 st to nth regions in the roll hardness distribution are calculated, and it is further determined that the defect D exists in a region in which the difference between the 1 st to nth average values and the average value of the 1 st to nth regions in the roll hardness distribution (hereinafter referred to as "reference average value") is 3G or more among the 1 st to nth regions. Fig. 4 shows a case where N is 3, and a case where the volume 2 is virtually divided into the 1 st to 3 rd regions a1, a2, and A3. The 1 st to nth areas may be, for example, areas obtained by dividing the volume 2 by N. As described above, when the measured values of the several points are planed from both ends of all the measured values, the average value of each of the 1 st to nth regions and the reference average value may be calculated for the roll hardness distribution formed by all the remaining measured values of the measured values where the several points are planed from both ends of all the measured values. The case where the entire volume 2 is divided into the 1 st to nth areas is exemplified, but the 1 st to nth areas need not be the areas into which the entire volume 2 is divided. For example, when several measured values are shaved from both ends of all the measured values as described above, the reel area corresponding to the shaving valid measured value acquisition range may be divided into the 1 st to nth areas.
< Change procedure >
If it is determined in the inspection step S03 that the roll 2 is defective (if no in the inspection step S03 of fig. 1), the changing step S04 is performed. In the changing step S04, at least one of the winding conditions in the resin film F prepared in the preparation step S01 and the roll forming step S02 is changed.
(example of modification of the resin film F prepared in the preparation step S01)
The resin film F is changed to, for example, a resin film F having a more uniform thickness in the width direction (direction orthogonal to the longitudinal direction) of the resin film F. When the resin film F is prepared by manufacturing the resin film F, the manufacturing conditions of the resin film F are changed. For example, the condition for extrusion molding may be adjusted so that the thickness of the resin film F in the width direction is uniform. When the resin film F is purchased and prepared, the purchased resin film F may be replaced with another resin film F.
(example of modification of winding conditions)
When the winding condition is changed, for example, the touch pressure and the conveyance speed are corrected. The touch pressure can be adjusted by the position adjustment mechanism 10. The touch pressure may also be adjusted according to the structure of the contact roller 8. Therefore, the touch pressure can be adjusted by changing the contact roller 8.
For example, in the touch roller 8, at least one of the thickness of the 1 st layer 14, the shore a hardness of the 1 st layer 14, the thickness of the 2 nd layer 16, and the shore a hardness of the 2 nd layer 16 may be changed, or a touch roller not provided with the 2 nd layer 16 (that is, a touch roller in which the surface of the 1 st layer is a touch surface) may be changed, or a touch roller not provided with the 1 st layer 14 may be used. As the contact roller 8, a contact roller 34 shown in fig. 9 may be used.
The touch roll 34 differs from the touch roll 8 in that a layer 2 36 is provided instead of the layer 2 16. Layer 2 36 has an inner layer 38 and an outer layer 40. Both the inner layer 38 and the outer layer 40 are porous layers (e.g., sponge layers). The shore a hardness of inner layer 38 and outer layer 40 is less than the shore a hardness of layer 1, 14, and the shore a hardness of inner layer 38 is less than the shore a hardness of outer layer 40. In other words, inner layer 38 and outer layer 40 are softer than layer 1 14, and outer layer 40 is harder than inner layer 38. For example, the Shore A hardness of the inner layer 38 is 0 to 20, and the Shore A hardness of the outer layer 40 is 20 to 40. Since the shore a hardness of the inner layer 38 is smaller than that of the outer layer 40, when a region having a shore a hardness of 20 is included in one of the inner layer 38 and the outer layer 40, the other region having a shore a hardness of 20 is not included. The inner layer 38 may be detachable from the 1 st layer 14, for example. The outer layer 40 may be detachable from the inner layer 38.
When the changing step S04 is performed, the preparation step S01, the roll forming step S02, the inspection step S03, and the changing step S04 are repeated until the inspection step S03 determines that the roll 2 is a non-defective product.
< recovery Process >
If the roll 2 is judged to be a non-defective product in the inspection step S03 (if yes in the inspection step S03 of fig. 1), the recovery step S05 is performed.
In the recovery step S05, the preparation step S01 and the roll forming step S02, which are performed to form the roll 2 determined as a non-defective product in the inspection step S03, are performed again, and the roll 2 as a non-defective product roll is manufactured and recovered.
Thus, the roll 2 (non-defective roll) recovered in the recovery step S05 is a resin film roll in which the roll hardness distribution obtained when the same step as the roll hardness distribution obtaining step S03A included in the inspection step S03 is performed on the roll 2 satisfies both the above-described 1 st condition and 2 nd condition. That is, the roll 2 as a non-defective product is a resin film roll substantially free of the defect D.
Further, in the roll 2 as the non-defective product collected in the collection step S05, when the roll 2 is virtually divided into the 1 st to nth regions in the axial direction C and the 1 st to nth average values corresponding to the 1 st to nth regions in the roll hardness distribution obtained as described above are calculated, the difference between the 1 st to nth average values and the reference average value may be less than 3G. That is, the roll 2 as a non-defective product is a resin film roll substantially free of the defect D in all of the 1 st to nth regions. The 1 st to nth region division method and the average value and reference average value calculation method are the same as those described in the determination step S03B.
In the above-described method for manufacturing a resin film roll, since the inspection method according to one embodiment is adopted in the inspection step S02 shown in fig. 1, a resin film roll substantially free of the defect D shown in fig. 3 can be reliably manufactured. The following description will be specifically made.
It is considered that the defect D is caused by wrinkles or the like formed by air being entrained together when the resin film F is wound in the roll forming step S02. The presence or absence of the defect D is conventionally performed by a method of irradiating the roll 2 with light from a light source 42 disposed on one side of the roll 2 and visually observing the transmitted light, as shown in fig. 10. In this method, since the portion where the defect D occurs is darkened, the presence or absence of the defect D can be determined. Fig. 3 schematically shows a defect D occurring in such appearance inspection. However, since the inspection is performed visually, subjectivity is easily affected. Further, even when the defect D is not present in the vicinity of the surface layer, the method of fig. 10 cannot determine the presence or absence of the defect D.
The present inventors have conducted intensive studies on the judgment of the presence or absence of defect D. As a result, it was found that the roll hardness at the position of the defect D is greatly different from that at the position where the defect D is not present, that is, the roll hardness distribution has a correlation with the generation position of the defect D. Further, it is found that the defect D can be determined to be present when either one of the 1 st condition and the 2 nd condition described in the determination step S03B is not satisfied.
In the inspection step S03, a roll hardness distribution in the axial direction C of the roll 2 is obtained. If the coil hardness distribution does not satisfy either of the 1 st and 2 nd conditions, the coil 2 is determined to be defective, and if both of the 1 st and 2 nd conditions are satisfied, the coil 2 is determined to be non-defective. Therefore, the quality of the roll 2 can be determined after the roll 2 is formed. Further, since the quality of the roll 2 is determined based on the roll hardness distribution, the quality of the roll 2 can be objectively determined.
The inspection step S03 will be specifically described based on the measurement results shown in fig. 6, 7, and 8.
In fig. 6, the standard deviation in the coil hardness distribution was 3.2, the maximum value of the coil hardness was 143.1G, and the minimum value was 113.3G. That is, the difference between the maximum value and the minimum value of the coil hardness was 29.80G. Therefore, the resin film roll corresponding to the result shown in fig. 6 does not satisfy the conditions 1 and 2.
In fig. 7, the standard deviation of the coil hardness distribution was 2.9, the maximum value of the coil hardness was 148.0G, and the minimum value was 118.7G. That is, the difference between the maximum value and the minimum value of the coil hardness was 29.30G. Therefore, the resin film roll corresponding to the result shown in fig. 7 satisfies condition 1 but does not satisfy condition 2.
On the other hand, in fig. 8, the standard deviation of the coil hardness distribution was 1.9, the maximum value of the coil hardness was 144.5G, and the minimum value was 133.6G. That is, the difference between the maximum value and the minimum value of the coil hardness was 10.90G. Therefore, both of the resin film rolls corresponding to the results shown in fig. 8 satisfy the conditions 1 and 2.
As a result of the visual inspection described with reference to fig. 10, the resin film roll having the roll hardness distribution shown in fig. 6 to 8 was inspected, and as a result, stripe-shaped defects were observed in the resin film roll having the roll hardness distribution shown in fig. 6 and 7, while stripe-shaped defects were not observed in the resin film roll having the roll hardness distribution shown in fig. 8. Further, even when the resin film roll having the roll hardness distribution shown in fig. 8 was taken out, no streaky defect was observed. That is, in the inspection step S03, the quality of the volume 2 can be determined.
In the method for manufacturing a resin film roll including the inspection step S03, since the changing step S04 is performed based on the result of the inspection step S03, the roll 2 (i.e., non-defective roll) substantially free of the defect D can be manufactured.
In the embodiment in which the touch roller 8 includes the 1 st layer 14 and the 2 nd layer 16, even if the surface of the resin film F has irregularities, the 2 nd layer 16 follows the irregularities of the surface of the resin film F, and by interposing the 1 st layer 14 between the roller main body 12 and the 2 nd layer 16, it is possible to absorb the strong pressure generated at the convex portion of the resin film F by the hardness (or elasticity) of the 1 st layer 14. As a result, the touch pressure is easily applied uniformly in the width direction to the contact area between the contact roller 8 and the resin film F. Therefore, when the resin film F is wound, the entanglement of air is easily prevented. Therefore, the roll 2 substantially free of the defect D is more easily manufactured. Since the touch roller 8 can be adjusted using the thickness, shore a hardness, and the like of the 1 st layer 14 and the 2 nd layer 16 as parameters, the winding conditions in the step S04 can be easily changed.
In the case where the 2 nd layer 16 is detachable from the 1 st layer 14, for example, the 2 nd layer 16 can be easily changed in the changing step S04. Therefore, the time for manufacturing the roll 2 as a non-defective product can be shortened.
For example, when the contact roller 34 shown in fig. 9 is used instead of the contact roller 8, the contact roller 34 has the inner layer 38 of the 2 nd layer 36 that is softer than the outer layer 40, and thus can follow the irregularities on the surface of the resin film F. Since the 2 nd layer 36 has the outer layer 40 harder than the inner layer 38, deterioration and damage (reduction, abrasion, etc.) of the 2 nd layer 36 can be prevented as compared with the case where the inner layer 38 is directly brought into contact with the resin film F. Further, the length of the contact area between the contact roller 34 and the resin film F in the short direction is likely to be shortened. Therefore, the surface of the resin film F can be reliably pressed with a more constant touch pressure, and the entrainment of air can be further prevented. Therefore, in the embodiment using the touch roll 34 in the roll forming step S02, the roll 2 substantially free of the defect D can be more easily manufactured.
As described above, in the embodiment in which the area in which the defect D is present in the virtually divided 1 st to nth areas of the roll 2 is specified in the roll 2, as shown in fig. 4, when the roll 2 is virtually divided into the 1 st to nth areas (N is 3 in fig. 4), the 1 st to nth average values corresponding to the 1 st to nth areas in the roll hardness distribution may be calculated, and it may be determined that the defect D is present in the area in which the difference between the 1 st to nth average values and the reference average value is 3G or more among the 1 st to nth areas. In this case, since the position where the defect D occurs in the axial direction C of the roll 2 can be specified, the changing step S04 is easily performed so that the defect D does not occur. For example, in the case of producing the resin film F by extrusion molding, the thickness of the resin film F at the position where the defect D is generated can be easily and reliably adjusted. Therefore, the time for manufacturing the roll 2 as a non-defective product can be shortened.
The roll 2 obtained by the manufacturing method of the present invention can be a stock roll used for manufacturing other products from the roll 2. Since the resin film F drawn out from the roll 2 has substantially no defect D, a product having desired characteristics can be produced from the blank roll.
The roller body 12 may not include the pair of shaft portions 20. In this case, a rotary shaft may be prepared separately from the contact roller 8, and the rotary shaft may be rotatably supported by the pair of support members 22 by passing the rotary shaft through the contact roller as the roller main body 12 itself. The roller body 12 may have, for example, a cylindrical casing portion (solid casing portion) and a pair of shaft portions 20. In this case, the pair of shaft portions 20 are provided on both end surfaces of the housing portion in the axial direction, respectively, concentrically with the axis of the housing portion.
The resin film F may be a polarizing film or a retardation film produced by further subjecting a film produced by extrusion molding to stretching treatment or the like as exemplified above.
The 1 st layer 14 and the 2 nd layer 16 of the touch roller 8 are exemplified by the case where the 1 st layer 14 is, for example, a rubber layer and the 2 nd layer 16 is a foam layer, but if the relationship of the hardness exemplified in the 1 st layer 14 and the 2 nd layer 16 is satisfied, for example, the 1 st layer 14 may be a porous layer and the 2 nd layer 16 may be a non-porous layer. The material of the 2 nd layer 16 may be rubber as long as the 2 nd layer 16 has a shore a hardness smaller than that of the 1 st layer.
The contact roller may also be the contact roller 44 shown in fig. 11. The touch roller 44 is different from the touch roller 8 in that a layer 2 46 is provided instead of the layer 2 16. The shore a hardness of the 2 nd layer 46 with respect to the 1 st layer 21 is the same as in the case of the 2 nd layer 16, and examples of the material of the 2 nd layer 46 are the same as in the case of the 2 nd layer 16. Hereinafter, the 2 nd layer 46 will be described centering on the difference from the 2 nd layer 16.
The 2 nd layer 46 has a plurality of regions 46a, 46b, 46c in this order in the width direction. The thickness of the regions 46a, 46b and 46c is the same. At least one of the regions 46a, 46b, and 46c has a shore a hardness that is different from the shore a hardness of the other regions. For example, region 46a has the same shore a hardness as region 46c and is less than (or greater than) the shore a hardness of region 46 b. The difference in shore a hardness can be achieved by the difference in the materials used.
In fig. 11, the case where the 2 nd layer 46 has three regions in the width direction is illustrated, but the number of regions is not limited to three. The shore a hardness of the plurality of regions in the width direction of the 2 nd layer 46 and the length of each region in the width direction may be set so that a uniform touch pressure can be applied to the resin film F in the width direction.
The present invention is not limited to the above-described embodiments. The various embodiments and modifications described above can be combined as appropriate within a scope not departing from the gist of the present invention.

Claims (8)

1. An inspection method includes:
a roll hardness distribution acquisition step of striking a surface of a resin film roll with a hammer while moving the hammer in an axial direction of the resin film roll formed by winding a resin film, measuring a deceleration until the hammer comes into contact with the surface of the resin film roll and stops, and acquiring a change in the deceleration in the axial direction as a roll hardness distribution in the axial direction; and
a determination step of determining the quality of the resin film roll based on the roll hardness distribution,
in the determination step, the resin film roll is determined as a non-defective product when both of the 1 st and 2 nd conditions are satisfied, and the resin film roll is determined as a defective product when at least one of the 1 st and 2 nd conditions is not satisfied,
the 1 st condition is a condition that a standard deviation of the coil hardness distribution, which is a standard deviation of 3 or less,
the 2 nd condition is a condition that a difference between a maximum value and a minimum value in the coil hardness distribution is 18G or less.
2. The inspection method according to claim 1,
when the determination step determines that the product is defective,
virtually dividing the resin film roll into 1 st to Nth regions in the axial direction, wherein N is an integer of 3 or more,
calculating the average value of each of the 1 st to nth regions in the roll hardness distribution, and further determining that there is a defect in a region in which the difference between the average value of each of the 1 st to nth regions and the average value of the entire 1 st to nth regions in the roll hardness distribution is 3G or more among the 1 st to nth regions.
3. The inspection method according to claim 1 or 2,
in the coil hardness distribution acquisition step, the coil hardness distribution is acquired while moving the hammer in the axial direction at a speed of 80mm/s or less.
4. A method for manufacturing a resin film roll, comprising:
a preparation step of preparing a resin film;
a roll forming step of winding the resin film around a winding shaft while winding the resin film around the winding shaft while pressing a contact roller against a surface of the resin film, thereby forming a resin film roll around which the resin film is wound;
an inspection step of inspecting the resin film roll by the inspection method according to any one of claims 1 to 3;
a changing step of changing at least one of the long resin film prepared in the preparation step and the winding condition in the roll forming step when the resin film roll is determined to be defective in the inspection step; and
and a recovery step of recovering the resin film when the roll of resin film is judged to be a non-defective product in the inspection step.
5. The method of manufacturing a resin film roll according to claim 4,
after the changing step, the preparing step, the roll forming step, and the inspecting step are further repeated.
6. The method of manufacturing a resin film roll according to claim 4,
in the changing step, at least one of the following steps is performed:
a step of preparing a resin film having a uniform thickness in a direction orthogonal to a longitudinal direction of the resin film in the preparation step; and
and correcting a pressing force of the contact roller to the resin film in the roll forming step.
7. A resin film roll is a resin film roll formed by winding a resin film,
the method includes the steps of striking a surface of a resin film roll with a hammer while moving the hammer in an axial direction of the resin film roll, measuring a deceleration until the hammer stops by striking the surface of the resin film roll, and when a change in the deceleration in the axial direction is obtained as a roll hardness distribution in the axial direction, a reference standard deviation as a standard deviation of the roll hardness distribution is 3 or less, and a difference between a maximum value and a minimum value in the roll hardness distribution is 18G or less.
8. The resin film roll according to claim 7,
when the resin film roll is virtually divided into 1 st to nth regions in the axial direction, the difference between the average value of each of the 1 st to nth regions in the roll hardness distribution and the average value of the entire 1 st to nth regions in the roll hardness distribution is less than 3G, where N is an integer of 3 or more.
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