CN111829904B - Inspection method, method for producing resin film roll, and resin film roll - Google Patents

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

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Publication number
CN111829904B
CN111829904B CN202010309273.XA CN202010309273A CN111829904B CN 111829904 B CN111829904 B CN 111829904B CN 202010309273 A CN202010309273 A CN 202010309273A CN 111829904 B CN111829904 B CN 111829904B
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Prior art keywords
roll
resin film
hardness distribution
layer
condition
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CN202010309273.XA
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CN111829904A (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
    • G01N3/40—Investigating hardness or rebound hardness
    • 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
    • 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 the presence or absence of streak-like defects in a resin film roll, a method for manufacturing a resin film roll, and a resin film roll. An inspection method according to an embodiment includes: a step of striking the resin film roll surface (2 a) with a hammer while moving the hammer (30) in the axial direction of the resin film roll (2), measuring the deceleration until the hammer hits the resin film roll surface and stops, and obtaining a change in the deceleration as 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 the 1 st condition (the standard deviation, which is the standard deviation of the roll hardness distribution, is 3 or less) and the 2 nd condition (the difference between the maximum value and the minimum value in the roll hardness distribution is 18G or less) are satisfied, and the resin film roll is determined to be a bad product when at least one of the 1 st condition and the 2 nd condition is not satisfied.

Description

Inspection method, method for producing resin film roll, and resin film roll
Technical Field
The present 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 into a roll shape as described in, for example, japanese patent application laid-open No. 2003-147092, and is stored or transported as a roll of the resin film or sold as a product.
When the long resin film is wound into a roll, air is easily taken in together. As described above, when air is taken in, a streak-like defect extending in the circumferential direction of the roll (extending direction of the resin film) occurs in the formed roll. Since this defect occurs in the roll, the appearance of the roll cannot be inspected for defects by merely visual inspection.
Disclosure of Invention
An object of the present invention is to provide an inspection method capable of inspecting the presence or absence of a streak-like 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 that is substantially free of streak defects.
The inspection method according to the present invention includes: a roll hardness distribution obtaining step of striking a surface of a roll of a resin film by a hammer while moving the hammer in an axial direction of the roll of the resin film around which the resin film is wound, measuring a deceleration until the hammer hits the surface of the roll of the resin film and stops, and obtaining 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 the 1 st condition and the 2 nd condition are satisfied, and the resin film roll is determined to be a bad 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 application found that, in the roll hardness distribution obtained by using the hammer described above, the positions where streak-like defects exist are correlated with the other positions. In the above-described inspection method, the roll hardness distribution is obtained in the roll hardness distribution obtaining step. Based on the obtained roll hardness distribution and the above condition 1 and condition 2, the quality of the resin film roll was determined. As a result, it is possible to check whether or not the resin film roll is a good product, which is the existence of the streak-like defect in the roll.
In the case where the resin film roll is determined to be defective in the determining step, the resin film roll may be virtually divided into 1 st to nth regions (N is an integer of 3 or more) in the axis direction, and 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 a difference between the average value of each of the 1 st to nth regions and the average value of the 1 st to nth regions in the roll hardness distribution is 3G or more. 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 the hammer is moved 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 comprises: a preparation step of preparing a resin film; a roll forming step of winding the resin film around a 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 winding conditions of the long resin film prepared in the preparation step and the winding conditions 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 it is determined that the roll of the resin film is a good product in the inspection step.
The manufacturing method includes an inspection step of inspecting the resin film roll by the inspection method. Therefore, a resin film roll substantially free of streak-like defects (as a good product) can be reliably produced.
In the above manufacturing method, the preparation step, the roll forming step, and the inspection step may be further repeated after the changing step is performed.
In the changing 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 the pressing force of the contact roller against the resin film in the roll forming step.
In the resin film roll according to the present invention, the resin film roll is formed by winding a resin film, a hammer is struck on a surface of the resin film roll while being moved in an axial direction of the resin film roll, a deceleration until the hammer is stopped by striking the surface of the resin film roll 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 standard deviation, which is 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 streak defects. Therefore, when a product using a resin film is produced by winding out the resin film from the resin film, it is easy to produce a product having desired characteristics.
In the case where 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, a difference between an average value of the 1 st to nth regions in the roll hardness distribution and an average value of the 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 streak-like 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 a resin film substantially free of streak-like 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 roll of resin film.
Fig. 3 is a schematic view of a roll with striped defects.
Fig. 4 is a drawing for explaining a method of obtaining a roll hardness distribution.
Fig. 5 is a schematic view of the case where the roll of resin film is viewed from the side of the outline arrow in fig. 4.
Fig. 6 is a diagram showing an example of a roll hardness distribution in the case where the resin film roll is judged to be defective.
Fig. 7 is a diagram showing another example of the roll hardness distribution in the case where the resin film roll is judged to be defective.
Fig. 8 is a diagram showing an example of a roll hardness distribution in the case where a resin film roll is judged to be a good product.
Fig. 9 is a drawing for explaining other examples of the contact roller.
Fig. 10 is a diagram illustrating an example of a conventional inspection method for defects.
Fig. 11 is a view for explaining still another example of the contact roller.
Symbol description-
Roll 2 … (roll of resin film), roll 2a …, roll 8 … contact roller, 30 … hammer, C … axis 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 repetitive description thereof will be omitted. The dimensional ratios in the drawings are not necessarily consistent with the dimensional ratios described.
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 roll of resin film will be described in brief.
As shown in fig. 1, in the case of manufacturing a roll of resin film, first, a long resin film is prepared (preparation step S01). Next, the prepared resin film is wound into a roll form to form a resin film roll (roll forming step S02). Then, the inspection method according to the present invention is used to inspect whether or not the formed roll of resin film is a good product (inspection step S03). In the inspection step S03, when it is determined that the resin film roll is not a good product, at least one of the winding conditions of the prepared resin film and the resin film roll is changed (a changing step S04). On the other hand, in the inspection step S03, when it is determined that the resin film roll is a good product, the resin film roll is recovered (recovery step S05). In the case where it is determined that the resin film roll is a good 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 preparing step S01, the roll forming step S02, and the inspecting step S03 may be repeated until the resin film roll is determined to be a good product in the inspecting step S03. In the present 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 but used in other processes.
Next, an example of each step included in the method for producing a resin film roll will be described in detail.
[ preparation procedure ]
In the preparation step S01, the long resin film F shown in fig. 2 may be produced, or the long resin film F may be obtained by purchase 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-based polymers, cellulose-based polymers, styrene-based polymers, polycarbonate-based polymers, polyolefin-based polymers, vinyl chloride-based polymers, amide-based polymers, imide-based polymers, sulfone-based polymers, polyether ether ketone-based polymers, polyphenylene sulfide-based polymers, vinyl alcohol-based polymers, vinylidene chloride-based polymers, vinyl butyral-based polymers, aryl ester-based polymers, polyoxymethylene-based (poly-oxymethylene) polymers, epoxy-based polymers and acrylic polymers, and blends of the above polymers, and 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. Generally, the length in the width direction is 1000mm (1.0 m) or more and 2500mm or less.
The thickness of the resin film F is not particularly limited, and is, for example, in the range of 10 μm to 150 μm, preferably 30 μm to 100 μm.
[ roll Forming Process ]
In the roll forming step S02, as shown in fig. 2, the long resin film F prepared in the preparation step S01 is wound by the winding device 4 while being conveyed by the conveying roller R as a part of the conveying mechanism. 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 shape during winding may be referred to as "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 adjusting 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 adopt a surface-driven winding method. In the surface-driven winding method, a driving shaft (or driving roller) different from the contact roller 8 is pressed against the resin film F, and the driving shaft is rotationally driven, so that the winding shaft 6 around which the resin film F is wound is rotated by friction force generated in a contact region between the driving shaft and the resin film F. Thereby, the resin film F is wound around the winding shaft 6. Alternatively, the winding device 4 may adopt a combined driving system of the center driving winding system and the surface driving winding system. In the surface-driven winding method, instead of the drive shaft, the contact roller 8 itself may be used. The winding device 4 of the present embodiment adopts a surface-driven winding method unless otherwise specified.
The contact 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"). An example of the touch pressure to the resin film F is 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, etc. 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 rotation axis direction 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). Examples of the diameter (diameter) of the contact roller 8 are 30mm to 300mm, preferably 50mm to 200mm, more preferably 120mm to 160mm. The contact roller 8 is sometimes also called a pinch roller, a dancer roller, a wind-up roller, or the like.
An example of the contact roller 8 will be described in detail with reference to fig. 2. The contact roller 8 has a roller body 12, a layer 1 14 and a layer 2 16.
The roller body 12 is a core material that contacts the 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 metals include iron, stainless steel, aluminum, and the like. The openings at both ends of the cylinder 18 are closed. The cylinder 18 and the pair of end walls 19 form a hollow housing portion. A pair of shaft portions 20 are provided to the pair of end walls 19 concentrically with the axis of the cylinder 18. Fig. 2 illustrates 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 1 st layer 14 is disposed outside the roller body 12 (specifically, outside the cylinder 18) in the radial direction of the roller body 12. Layer 1 14 covers the surface of cylinder 18 provided in roll body 12. In the present embodiment, the 1 st layer 14 is a layer having elasticity. Layer 1 14 is the base layer relative to layer 2 16. An example of a material for layer 1 14 is rubber. The 1 st layer 14 may be formed by winding a rubber sheet around the circumference of the cylinder 18, or may be formed by forming a tube portion from the rubber sheet in advance and attaching the tube portion to the roller body 12.
The a shore hardness of layer 1 14 is typically 50 to 80. The 1 st layer 14 is a layer for absorbing a reaction force (or collision) of the pressing force in the case of pressing the contact roller 8 against the resin film F. For example, from the viewpoint of preventing the contact roller 8 itself from bending due to the self weight of the contact roller 8, the 1 st layer 14 is preferably not excessively thick. By preventing the contact roller 8 itself from flexing, the touch pressure is easily and uniformly applied along the width direction of the resin film F. On the other hand, from the viewpoint of easy dispersion of the reaction force, it is preferable that the 1 st layer 14 is not excessively thin. By dispersing the reaction force, the touch pressure is easily and uniformly applied along the width direction of the resin film F. Therefore, the thickness of the 1 st layer 14 is usually 2mm to 15mm, preferably 3mm to 15mm, and more preferably 3mm to 12mm.
The a shore hardness of the 1 st layer 14 is a hardness as a result of a test piece formed of the same material as the 1 st layer 14 and having a thickness of 6mm being tested in accordance with JIS K6253 in terms of 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 layer 2 16 is contact surface 8a. The layer 2 16 has a shore a hardness less than the shore a hardness of the layer 1 14. That is, layer 2 16 is a softer layer than layer 1 14. Examples of the A Shore hardness of the 2 nd layer 16 are 0 to 40/50 of the A Shore hardness of the 1 st layer 14. For example, in the case where the a shore hardness of the 1 st layer 14 is 50 to 80, the a shore hardness of the 2 nd layer 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 7mm.
In the present embodiment, the 2 nd layer 16 is a porous layer. The porous layer is not particularly limited, and a foam material (so-called foam) composed of a resin is exemplified. Examples of the resin constituting the porous layer include polyethylene and polyurethane.
Layer 2 16 may be formed, for example, by crimping 1 sheet of foam material around layer 1 14, or may be formed by covering the outer surface of layer 1 14 with a plurality of rectangular (or elongated) sheets of foam material in a manner that does not create gaps. When the outer surface of the 1 st layer 14 is covered with a plurality of rectangular (or long-strip-shaped) foam materials, for example, the plurality of rectangular (or long-strip-shaped) foam materials may be arranged in the longitudinal direction in accordance with the direction of the rotation axis of the contact roller 8, and the plurality of rectangular (or long-strip-shaped) foam materials may be arranged in the circumferential direction, or the plurality of rectangular (or long-strip-shaped) foam materials may be wound around the 1 st layer 14 transversely to the direction of the rotation axis of the contact roller 8 (or spirally).
Layer 2 16 may be removably attached to layer 1 14. For example, the 1 sheet of foam or a plurality of rectangular (or oblong) sheets of foam may be adhered to the outer surface of the 1 st layer 14 by double-sided tape, 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-described relation of the a shore hardness 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-described range of a shore hardness, the materials of the respective layers may also be different.
The a shore hardness of the 2 nd layer 16 is a hardness obtained by preparing a test piece having a thickness of 6mm formed of the same material as the 2 nd layer 16 and performing a test with a type a durometer in accordance with JIS K6253. Alternatively, in the case where the 2 nd layer 16 has a laminated structure including a plurality of layers, the a shore 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 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 outline arrows in fig. 2, the position adjustment mechanism 10 is a mechanism for moving one of the winding 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 the pressing force that imparts a constant touch pressure to the resin film F.
In the embodiment illustrated in fig. 2, a case is shown in which the contact roller 8 is moved with respect 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 body 24 and a piston rod 26 that is extendable and retractable with respect to the cylinder body 24. The piston rod 26 is coupled to the support member 22. Examples of the cylinder block 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, one end of the pair of support members 22 on the opposite side to the contact roller 8 may be swingably attached to the support shaft. In this case, the support shaft functions as the position adjustment mechanism 10. The pair of support members 22 may be part of the position adjustment mechanism 10.
The position adjustment mechanism 10 may include a control unit that adjusts the position of the contact roller 8, for example, to control the cylinder so that a constant touch pressure can be applied to the resin film F, according to the amount of the resin film F wound around the winding shaft 6. 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 region has a rectangular shape extending in the width direction of the resin film F.
[ inspection procedure ]
In the inspection step S03, it is inspected whether or not the roll 2 formed in the roll forming step S02 is a good product. Specifically, as shown in fig. 3, the presence or absence of the streak-like 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 roll hardness distribution acquisition step S03A and a determination step S03B.
Roll hardness distribution acquiring step
In the roll hardness distribution obtaining step S03A, as shown in fig. 4 and 5, hardness is used Measurement of The device 28 obtains a roll hardness distribution in the axial direction C of the roll 2. Fig. 5 is a schematic view of the roll 2 as seen from the side of the outline 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) 2a. The hardness measurer 28 strikes the roll surface 2a with the hammer 30, and measures deceleration until the hammer 30 hits 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 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 2a. An example of the hardness measurer 28 is a RoQ roll durometer manufactured by ACA System corporation. Although not particularly limited, the vibration frequency (the number of one-second strokes) of the hammer 30 is, for example, 30 to 70Hz, specifically 50Hz (average 35 Hz), and the speed (the one-second stroke speed) of the hammer 30 may be, for example, about 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, the roll surface 2a is struck with the hammer 30 while the hardness measuring instrument 28 is moved from one end to the other end of the roll 2, the deceleration until the hammer 30 comes to rest against the roll surface 2a is measured, and a change in the deceleration in the axis direction C is obtained as a roll hardness distribution. The movement speed of the hardness measuring instrument 28 is not particularly limited, and is, for example, 80mm/s or less, preferably 70mm/s or less, more preferably 50mm/s or less, and may be 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, when the following condition 1 and condition 2 are both satisfied, the roll 2 is judged as a good product, and when at least one of the condition 1 and condition 2 is not satisfied, the roll 2 is judged as a bad product.
(condition 1)
The standard deviation of the coil hardness distribution is 3 or less.
(condition 2)
Condition 2 is that the difference between the maximum value and the minimum value in the roll 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 significantly different from the actual value due to measurement errors. Therefore, the measured values of both ends of the roll 2 or both ends and the vicinity thereof are usually shaved off when the condition 1 and the condition 2 are applied. For example, the 1 st condition and the 2 nd condition may be determined based on the measured values after the measured values of several points (for example, 5 points from both ends in the case of measuring at 1mm intervals) are scraped off from both ends of the total measured values. Thus, in the case of the measured values of both ends or both ends and the vicinity thereof of the roll 2 being shaved, the above-mentioned "standard deviation of reference" is the standard deviation of all the measured values remaining after the measured values of the above-mentioned several points are shaved out from all the measured values.
Examples of the roll hardness distribution are shown in fig. 6 to 8. Fig. 6 to 8 are roll hardness distributions based on the results of measuring the winding hardness of the resin film roll described below using a RoQ roll durometer manufactured by ACASystem corporation as the hardness measuring instrument 28, with the hardness measuring instrument 28 set at 50mm/s and moving at 1mm intervals (speed of hammer: about 0.25 m/s).
FIG. 6 is a 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 length 4100 mm) using the winding apparatus shown in FIG. 2.
FIG. 7 is a roll hardness distribution of a roll of a resin film obtained by winding a polymethyl methacrylate resin film (thickness 60 μm, length 1490mm in the width direction, length 3250mm in the length direction) using the winding apparatus shown in FIG. 2.
FIG. 8 is a roll hardness distribution of a roll of a resin film obtained by winding a polymethyl methacrylate resin film (thickness 80 μm, width direction length 1490mm, length direction length 3650 mm) using the winding device shown in FIG. 2.
Fig. 6 and 7 show the results obtained by actually measuring the winding hardness when the roll 2 is defective. Fig. 8 shows the result of actually measuring the roll hardness when the roll 2 is a good product. In the roll 2 from which the measurement results of fig. 6 and 7 are obtained, as shown in fig. 3, a defect D exists near one end of the roll 2. The roll hardness distributions shown in fig. 6 to 8 are the results of the same conditions except that the winding conditions are different.
Fig. 6 to 8 show measurement results obtained by removing 5 points from both ends of the entire measurement values. The vertical axis of fig. 6 to 8 shows the hardness measurement value (G) of the hardness measuring instrument 28. The unit "G" of the hardness measurement value indicates the gravitational acceleration. The horizontal axis in fig. 6 to 8 represents the position in the width direction (the position in the axis direction C) of the roll 2. The positions of P1 and P2 on the horizontal axis in fig. 6 to 8 correspond to positions obtained by removing 5 points from both ends of all measured values.
If it is determined in the determination step S03B that the roll 2 is defective, the position of the defect D may be determined as follows. That is, as shown in fig. 4, the roll 2 is virtually divided into 1 st to nth regions (N is an integer of 3 or more) in the axis direction C. In general, the lengths in the axial direction C of the 1 st to nth regions are uniform. N may be an integer of 25 or less.
The 1 st to nth averages 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 averages 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 in the 1 st to nth regions. Fig. 4 shows a case where n=3, and shows a case where volume 2 is virtually divided into 1 st to 3 rd areas A1, A2, A3. The 1 st to nth regions may be, for example, regions obtained by dividing the roll 2 by N. As described above, when the measured values of the above-mentioned several points are shaved off from both ends of the total measured values, the average value of each of the 1 st to nth areas and the reference average value may be calculated for the roll hardness distribution formed by all the remaining measured values of the above-mentioned several points are shaved off from both ends of the total measured values. The case where the entire roll 2 is divided into the 1 st to nth regions is illustrated, but the 1 st to nth regions need not be the regions where the entire roll 2 is divided. For example, in the case of shaving out the measurement values of several points from both ends of all the measurement values as described above, the roll region corresponding to the acquisition range of the effective measurement values to be shaved off may be divided into the 1 st to nth regions.
< procedure for changing >)
When it is determined in the inspection step S03 that the roll 2 is defective (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 of the resin film F prepared in the preparing step S01 and the winding conditions in the winding step S02 are 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 thickness of the resin film F in the width direction may be uniformly adjusted by adjusting the conditions of extrusion molding. When the resin film F is purchased and prepared, the resin film F may be replaced with another resin film F purchased.
(example of change 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 can also be adjusted according to the structure of the touch roller 8. Therefore, the touch pressure can also be adjusted by changing the touch roller 8.
For example, at least one of the thickness of the 1 st layer 14, the a shore hardness of the 1 st layer 14, the thickness of the 2 nd layer 16, and the a shore hardness of the 2 nd layer 16 may be changed in the contact roller 8, or a contact roller not provided with the 2 nd layer 16 (that is, a contact roller having a contact surface on the surface of the 1 st layer) may be changed, or conversely, a contact roller not provided with the 1 st layer 14 may be used. Further, as the contact roller 8, a contact roller 34 shown in fig. 9 may be used.
The contact roller 34 is different from the contact roller 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 inner layer 38 and outer layer 40 are porous layers (e.g., sponge layers). The inner layer 38 and the outer layer 40 have a shore hardness less than the shore hardness of the 1 st layer 14, and the inner layer 38 has a shore hardness less than the shore hardness of the 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 inner layer 38 has an A Shore hardness of 0 to 20 and the outer layer 40 has an A Shore hardness of 20 to 40. Since the internal layer 38 has a lower shore a hardness than the external layer 40, when the illustrated region having a shore a hardness of 20 is included in one of the internal layer 38 and the external layer 40, the region having a shore a hardness of 20 is not included in the other. The inner layer 38 may be detachable from the 1 st layer 14, for example. Outer layer 40 may be detachable from inner layer 38.
When the changing step S04 is performed, the preparing step S01, the roll forming step S02, the inspecting step S03, and the changing step S04 are repeated until the inspecting step S03 determines that the roll 2 is a good product.
< recovery procedure >)
When it is determined in the inspection step S03 that the roll 2 is a good product (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 to be a good product in the inspection step S03, are performed again, and the roll 2 as a good product roll is manufactured and recovered.
As a result, the roll 2 (acceptable roll) collected in the collection step S05 is a resin film roll whose roll hardness distribution obtained when the same step as the roll hardness distribution obtaining step S03A of the inspection step S03 is performed on the roll 2 satisfies the condition 1 and the condition 2. That is, the roll 2 as a good product is a resin film roll substantially free of the defect D.
Further, in the roll 2 as a good product collected in the collection step S05, when virtually dividing the roll 2 into the 1 st to nth regions in the axis direction C, when the 1 st to nth average values corresponding to the 1 st to nth regions in the obtained roll hardness distribution are calculated, the difference between the 1 st to nth average values and the reference average value may be smaller than 3G. That is, the roll 2 as a good product is a resin film roll substantially free of the defect D in the 1 st to nth regions. The method of dividing the 1 st to nth regions and the method of calculating the average value and the reference average value are the same as those described in the determination step S03B.
In the above-described method for producing 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 having substantially no defect D shown in fig. 3 can be produced reliably. Hereinafter, description will be made specifically.
The defect D is considered to be caused by wrinkles or the like formed by air being taken in together when the resin film F is wound in the winding step S02. As shown in fig. 10, the presence or absence of the defect D is conventionally performed by a method of visually observing transmitted light by irradiating the roll 2 with light from a light source 42 disposed on one side of the roll 2. In this method, the portion where the defect D is generated becomes dark, and therefore, the presence or absence of the defect D can be determined. Fig. 3 schematically shows a defect D occurring in such an appearance inspection. However, visual inspection is easy to affect subjectivity. Further, even when the defect D is not 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 determination of the presence or absence of defect D. As a result, it was found that the roll hardness was significantly different at the position of the defect D than at the position where the defect D was not present, that is, the roll hardness distribution had a correlation with the position where the defect D was generated. Further, it was found that if either the condition 1 or the condition 2 described in the determination step S03B is not satisfied, it can be determined that the defect D is present.
In the inspection step S03, a roll hardness distribution is obtained in the axial direction C of the roll 2. If the roll hardness distribution does not satisfy either the 1 st condition or the 2 nd condition, the roll 2 is judged as defective, and if both the 1 st condition and the 2 nd condition are satisfied, the roll 2 is judged as acceptable. 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 of the roll hardness distribution is 3.2, the maximum value of the roll hardness is 143.1G, and the minimum value is 113.3G. That is, the difference between the maximum value and the minimum value of the roll hardness was 29.80G. Therefore, the condition 1 and the condition 2 are not satisfied in the resin film roll corresponding to the result shown in fig. 6.
In fig. 7, the standard deviation of the roll hardness distribution was 2.9, the maximum value of the roll 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 roll hardness was 29.30G. Therefore, in the resin film roll corresponding to the result shown in fig. 7, the condition 1 is satisfied and the condition 2 is not satisfied.
On the other hand, in fig. 8, the standard deviation of the reference in the roll hardness distribution is 1.9, the maximum value of the roll hardness is 144.5G, and the minimum value is 133.6G. That is, the difference between the maximum value and the minimum value of the roll hardness was 10.90G. Therefore, both of the conditions 1 and 2 are satisfied in the resin film roll corresponding to the result shown in fig. 8.
As a result of examining the resin film roll having the roll hardness distribution shown in fig. 6 to 8 by the visual examination described in fig. 10, streak-like defects were observed in the resin film roll having the roll hardness distribution shown in fig. 6 and 7, whereas no streak-like defects were observed in the resin film roll having the roll hardness distribution shown in fig. 8. Further, even when the roll of the resin film having the roll hardness distribution shown in fig. 8 was drawn out, no streak-like defect was observed. That is, in the inspection step S03, the quality of the roll 2 can be determined.
In the method for producing a resin film roll including the inspection step S03, the modification step S04 is performed based on the result of the inspection step S03, and therefore, the roll 2 (i.e., a good roll) substantially free of the defect D can be produced.
In the embodiment in which the contact roller 8 includes the 1 st layer 14 and the 2 nd layer 16, even if there are irregularities on the surface of the resin film F, the 2 nd layer 16 follows the irregularities on the surface of the resin film F, and by sandwiching the 1 st layer 14 between the roller main body 12 and the 2 nd layer 16, a strong pressure generated at the convex portion of the resin film F can be absorbed by the hardness (or elasticity) of the 1 st layer 14. As a result, the touch pressure is easily and uniformly applied to the contact area between the contact roller 8 and the resin film F in the width direction. Therefore, when the resin film F is wound, air is easily prevented from being involved. Therefore, it is easier to manufacture the roll 2 substantially free of the defect D. Since the contact 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 condition in the changing step S04 can be easily changed.
When the 2 nd layer 16 is detachable from the 1 st layer 14, the modification of the 2 nd layer 16 is easy in the modification step S04, for example. Therefore, the time for manufacturing the roll 2 as a good product can be shortened.
When the contact roller 34 shown in fig. 9 is used instead of the contact roller 8, for example, the inner layer 38 of the 2 nd layer 36 of the contact roller 34 is softer than the outer layer 40, and thus can follow the irregularities of 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 contacted with the resin film F. Further, the length in the short side direction of the contact area between the contact roller 34 and the resin film F is easily shortened. Therefore, the surface of the resin film F can be reliably pressed with a more constant touch pressure, and air entrainment can be further prevented. Therefore, in the roll forming step S02, in the embodiment using the contact roller 34, it is easier to manufacture the roll 2 substantially free of the defect D.
As described above, in the embodiment in which the region in which the defect D exists in the 1 st to nth regions of the roll 2 that are virtually divided is determined as the roll 2 that is determined to be defective, as shown in fig. 4, when the roll 2 is virtually divided into the 1 st to nth regions (n=3 in fig. 4), the 1 st to nth average values corresponding to the 1 st to nth regions in the roll hardness distribution may be calculated, and it may be determined that the defect D exists in the region in which the difference between the 1 st to nth average values and the reference average value in the 1 st to nth regions is 3G or more. In this case, since the position where the defect D occurs in the axial direction C of the roll 2 can be specified, the modification step S04 is easily performed so that the defect D does not occur. For example, in the case of manufacturing the resin film F by extrusion molding, it is easy to reliably adjust the thickness of the resin film F at the position where the defect D is generated. Therefore, the time for manufacturing the roll 2 as a good product can be shortened.
The roll 2 obtained by the manufacturing method of the present invention can be set as a blank roll for manufacturing other products. Since the resin film F drawn 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 have a 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 passed through the contact roller as the roller body 12 itself, and the rotary shaft may be rotatably supported by a pair of support members 22. The roller body 12 may have a cylindrical housing portion (solid housing portion) and a pair of shaft portions 20, for example. In this case, the pair of shaft portions 20 are provided concentrically with the axis of the housing portion on both end surfaces in the axial direction of the housing portion.
The resin film F may be a polarizing film or a retardation film produced by further stretching a film produced by extrusion molding as exemplified.
The 1 st layer 14 and the 2 nd layer 16 of the contact roller 8 are exemplified as 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 by the 1 st layer 14 and the 2 nd layer 16 is present, for example, the 1 st layer 14 may be a porous layer or 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 it is a layer having 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 contact roller 44 is different from the contact roller 8 in that a 2 nd layer 46 is provided in place of the 2 nd layer 16. The relationship of the a shore hardness of layer 2 46 to layer 1 21 is the same as in the case of layer 2 16, and examples of the material of layer 2 46 are the same as in the case of layer 2 16. Hereinafter, the layer 2 46 will be described centering on the point of difference from the layer 2 16.
The 2 nd layer 46 has a plurality of regions 46a, 46b, 46c in order along the width direction. The thickness of the regions 46a, 46b, 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 different 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 of the layer 2 46 in the width direction 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 various embodiments. The above-described various embodiments and modifications can be appropriately combined within a range not departing from the gist of the present invention.

Claims (8)

1. An inspection method is provided with:
a roll hardness distribution obtaining step of striking a surface of a roll of a resin film by a hammer while moving the hammer in an axial direction of the roll of the resin film around which the resin film is wound, measuring a deceleration until the hammer hits the surface of the roll of the resin film and stops, and obtaining 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 judging step, the resin film roll is judged to be a qualified product when both the 1 st condition and the 2 nd condition are satisfied, and the resin film roll is judged to be a defective product when at least one of the 1 st condition and the 2 nd condition is not satisfied,
the condition 1 is a condition in which a standard deviation of the roll hardness distribution, that is, a standard deviation of a reference is 3 or less,
the condition 2 is a condition that a difference between a maximum value and a minimum value in the roll hardness distribution is 18G or less, where G is a unit of a hardness measurement value of roll hardness, which represents gravitational acceleration.
2. The inspection method according to claim 1, wherein,
when it is determined that the product is defective in the determination step,
virtually dividing the resin film roll into 1 st to N th regions in the axial direction, N being an integer of 3 or more,
and calculating the average value of each of the 1 st to N th regions in the roll hardness distribution, and further determining that defects exist in regions having a difference of 3G or more between the average value of each of the 1 st to N th regions and the average value of the entire 1 st to N th regions in the roll hardness distribution.
3. The inspection method according to claim 1 or 2, wherein,
in the roll hardness distribution obtaining step, the roll hardness distribution is obtained while the hammer is moved 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 pressing a contact roller against a surface of the resin film, by winding the resin film around the winding shaft, thereby forming a resin film roll around which the resin film is wound;
An inspection step of inspecting the roll of resin film 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 preparing step and the winding condition in the winding step when the resin film roll is determined to be defective in the inspecting step; and
and a recovery step of recovering the resin film when the roll of the resin film is judged to be a good product in the inspection step.
5. The method for producing a roll of resin film according to claim 4, wherein,
after the changing step, the preparing step, the roll forming step, and the inspecting step are further repeated.
6. The method for producing a roll of resin film according to claim 4, wherein,
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 the pressing force of the contact roller against the resin film in the roll forming step.
7. A resin film roll is formed by winding a resin film,
the method includes striking a surface of the roll of resin film with a hammer while moving the hammer along an axis direction of the roll of resin film, measuring a deceleration until the hammer hits the surface of the roll of resin film and stops, and, when a change in the deceleration in the axis direction is obtained as a roll hardness distribution in the axis direction, a reference standard deviation, which is 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, wherein G is a unit of a hardness measurement value of the roll hardness and represents a gravitational acceleration.
8. The roll of resin film according to claim 7, wherein,
when the roll of the resin film is virtually divided into 1 st to nth regions in the axial direction, a difference between an average value of the 1 st to nth regions in the roll hardness distribution and an average value of the 1 st to nth regions in the roll hardness distribution as a whole is less than 3G, where N is an integer of 3 or more.
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