CN114223081A

CN114223081A - Method for manufacturing roll body and roll body

Info

Publication number: CN114223081A
Application number: CN202080054223.XA
Authority: CN
Inventors: 鸟本将宏; 大石惠; 秋山亮; 中泽辽; 马桥博大; 谷口章; 桥本浩二; 长町隆介; 中野雅允; 大原勇二
Original assignee: Dai Nippon Printing Co Ltd
Current assignee: Dai Nippon Printing Co Ltd
Priority date: 2019-07-09
Filing date: 2020-07-09
Publication date: 2022-03-22
Also published as: WO2021006314A1; JP2021107286A; KR20220029738A; TW202108488A

Abstract

The invention provides a method for manufacturing a roll body capable of effectively relieving a step difference caused by a winding starting end part of a sheet material and the roll body. According to one aspect of the present invention, there is provided a method of manufacturing a roll (10) including a winding core (11) and a long sheet (12) wound around an outer peripheral surface (11A) of the winding core (11), the method including: a step of applying a coating material (18) to the outer peripheral surface (11A) of the winding core (11) along the width direction (DR1) of the winding core (11); a step of disposing a winding start end (12A) in the longitudinal direction (DR2) of the sheet (12) on the outer peripheral surface (11A); and a step of winding the sheet (12) around the core (11) and filling at least the 1 st gap (13) with the coating material (18), wherein the coating or winding start end (12A) of the coating material (18) is disposed in such a manner that the coating material (18) comes into contact with or approaches the end surface (12A1) of the winding start end (12A) in the longitudinal direction (DR2), and the 1 st gap (13) is a gap which is located between the core (11) and the 1 st peripheral sheet (12) and comes into contact with the end surface (12A 1).

Description

Method for manufacturing roll body and roll body

Reference to related applications

The present application enjoys the benefit of priority of Japanese patent application 2019-.

Technical Field

The present invention relates to a method for manufacturing a roll and a roll.

Background

In many cases, sheets such as films are produced in a certain amount in a concentrated manner from the viewpoint of production efficiency, and are wound around a core and stored as a roll. In such a roll, a step is generated at the winding start end of the sheet. Specifically, a step difference occurs when the sheet shifts from week 1 to week 2, and also occurs after week 2. In addition, depending on the type of sheet, if the step occurs, the sheet may be deformed and may not be restored.

At present, the following techniques are proposed: the step is alleviated by attaching or embedding a buffer tape having high cushioning properties such as urethane resin to the outer peripheral surface of the core and embedding the sheet material in the buffer tape (see, for example, patent document 1); a step is alleviated by using a winding core having rubber on the outer peripheral surface and embedding the sheet material in the rubber; alternatively, a cushioning material having an elastic force is provided on the outer peripheral surface of the winding core along the end of the winding start end of the sheet (see, for example, patent document 2).

Documents of the prior art

Patent document

Patent document 1: japanese laid-open patent publication No. 2005-75521

Patent document 2: japanese patent laid-open publication No. 2013-199355

Disclosure of Invention

Problems to be solved by the invention

However, in the current situation, in any of the above-described techniques, the step cannot be effectively reduced.

Further, when the sheet is wound around the winding core, first, a fixing member such as a double-sided tape is attached to the outer peripheral surface of the winding core to fix a part of the sheet (for example, a winding start end portion).

The present invention has been made to solve the above problems. That is, an object of the present invention is to provide a method for manufacturing a roll body capable of effectively mitigating a step caused by a winding start end portion of a sheet material, and such a roll body. Another object of the present invention is to provide a method for manufacturing a roll body capable of effectively reducing a step caused by a fixing member, and such a roll body.

Means for solving the problems

The present invention includes the following inventions.

[1] A method of manufacturing a roll body including a roll core and an elongated sheet material wound around an outer peripheral surface of the roll core, the method comprising: applying a coating material to the outer peripheral surface of the winding core along a width direction of the winding core; disposing a winding start end portion in a longitudinal direction of the sheet on the outer peripheral surface; and a step of winding the web material around the core and filling at least a1 st gap with the coating material, wherein the coating material is applied or the winding start end portion is disposed so that the coating material comes into contact with or approaches a distal end surface of the winding start end portion in the longitudinal direction, and the 1 st gap is a gap between the core and the web material in the 1 st circumference and in contact with the distal end surface.

[2] A method of manufacturing a roll body including a roll core and an elongated sheet material wound around an outer peripheral surface of the roll core, the method comprising: disposing a winding start end portion in a longitudinal direction of the sheet on the outer peripheral surface; winding the sheet around the core for at least 1 circumference to obtain an intermediate roll having a1 st gap; a step of applying a coating material along the width direction of the winding core on the front surface of the sheet material constituting the outer peripheral surface of the intermediate winding body; and a step of winding the web material around the core again so that the coating material is interposed between the web materials after the coating material is applied, wherein the 1 st gap is a gap between the core and the web material in the 1 st circumference and in contact with a distal end surface of the winding start end portion in the longitudinal direction, and the coating material is applied to a1 st region corresponding to the 1 st gap in the front surface of the web material constituting the outer circumferential surface of the intermediate roll body.

[3] A method of manufacturing a roll body including a roll core and an elongated sheet material wound around an outer peripheral surface of the roll core, the method comprising: disposing a fixing member for fixing a portion of the sheet material to the core on the outer peripheral surface of the core in a width direction of the core, the fixing member having a1 st end surface extending in the width direction of the core and a2 nd end surface on a side opposite to the 1 st end surface; applying a coating material to the outer peripheral surface of the winding core along the width direction of the winding core; fixing a portion of the web material to the core by the fixing member; and a step of winding the web material around the core and filling at least either one of a2 nd gap and a 3 rd gap with the coating material after the coating material is applied and a part of the web material is fixed to the core, wherein the coating material is applied or the fixing member is disposed so that the coating material is positioned on the 1 st end surface side or the 2 nd end surface side and the coating material is in contact with or close to the 1 st end surface or the 2 nd end surface, or the coating material is positioned on the 1 st end surface side and the 2 nd end surface side and the coating material is in contact with or close to the 1 st end surface and the 2 nd end surface, respectively, the 2 nd gap is a gap between the core and the web material of the 1 st circumference and in contact with the 1 st end surface, and the 3 rd gap is a gap between the core and the web material of the 1 st circumference and in contact with the 2 nd end surface .

[4] A method of manufacturing a roll body including a roll core and an elongated sheet material wound around an outer peripheral surface of the roll core, the method comprising: disposing a fixing member for fixing a portion of the sheet material to the core on the outer peripheral surface of the core in a width direction of the core, the fixing member having a1 st end surface extending in the width direction of the core and a2 nd end surface on a side opposite to the 1 st end surface; fixing a portion of the web material to the core by the fixing member; winding the sheet around the core for at least 1 circumference to obtain an intermediate roll having a2 nd gap and a 3 rd gap; applying a coating material to a front surface of the sheet material constituting an outer peripheral surface of the intermediate roll along the width direction of the winding core; and a step of winding the web material around the core again after the application of the coating material, wherein the 2 nd gap is a gap between the core and the web material of the 1 st circumference and in contact with the 1 st end surface of the fixing member, the 3 rd gap is a gap between the core and the web material of the 1 st circumference and in contact with the 2 nd end surface of the fixing member, and the coating material is applied to at least one of a2 nd region corresponding to the 2 nd gap and a 3 rd region corresponding to the 3 rd gap in the front surface of the web material constituting the outer circumferential surface of the intermediate roll body.

[5] The production method according to any one of the above [1] to [4], wherein the coating material has fluidity.

[6] The production method according to any one of the above [1] to [5], wherein the coating material is a curable polymer composition.

[7] The production method according to any one of the above [1] to [6], wherein the coating material contains a coloring material or a luminescent material.

[8] The production method according to any one of the above [1] to [6], wherein the sheet has a resin film.

[9] The production method according to any one of the above [1] to [7], wherein the sheet contains an acrylic resin, a polyester resin, or a cycloolefin polymer resin.

[10] The production method according to the above [8] or [9], wherein the thickness of the sheet is 15 μm or more and 300 μm or less.

[11] The production method according to any one of the above [1] to [10], wherein the sheet is a laminate having a substrate and 1 or more functional layers laminated on the substrate.

[12] The production method according to any one of the above [1] to [11], wherein the sheet is used for an optical film, a polarizing plate, or a display device.

[13] A roll body comprising a roll core and an elongated sheet material wound around an outer peripheral surface of the roll core, wherein the roll body comprises: a1 st gap located between the core and the sheet in the 1 st circumference, and contacting a distal end surface of a winding start end portion in a longitudinal direction of the sheet in the 1 st circumference, the distal end surface being located in the longitudinal direction; and a1 st filling section filled in the 1 st gap and extending in the width direction of the core.

[14] The roll body according to the above [11], further comprising: a fixing member which is provided between the core and the sheet on the 1 st circumference and fixes a part of the sheet to the core, and which has a1 st end surface extending in the width direction of the core and a2 nd end surface on the opposite side of the 1 st end surface; a2 nd gap between the winding core and the 1 st peripheral web, the 2 nd gap being in contact with the 1 st end surface of the fixing member; a 3 rd gap between the winding core and the 1 st peripheral web and in contact with the 2 nd end surface of the fixing member; and at least one of a2 nd filling part filled in the 2 nd gap and extending in the width direction of the winding core and a 3 rd filling part filled in the 3 rd gap and extending in the width direction of the winding core.

[15] A roll body comprising a roll core and an elongated sheet material wound around an outer peripheral surface of the roll core, wherein the roll body comprises: a1 st gap located between the core and the sheet in the 1 st circumference, and contacting a distal end surface of a winding start end portion in a longitudinal direction of the sheet in the 1 st circumference, the distal end surface being located in the longitudinal direction; and a1 st nip portion that is provided in a1 st region corresponding to at least the 1 st gap between the sheets after the 1 st turn, and that extends in the width direction of the winding core.

[16] A roll body comprising a roll core and an elongated sheet material wound around an outer peripheral surface of the roll core, wherein the roll body comprises: a fixing member which is provided between the core and the sheet on the 1 st circumference and fixes a part of the sheet to the core, and which has a1 st end surface extending in the width direction of the core and a2 nd end surface on the opposite side of the 1 st end surface; a2 nd gap between the winding core and the 1 st peripheral web, the 2 nd gap being in contact with the 1 st end surface of the fixing member; a 3 rd gap between the winding core and the 1 st peripheral web and in contact with the 2 nd end surface of the fixing member; and at least one of a2 nd filling part filled in the 2 nd gap and extending in the width direction of the winding core and a 3 rd filling part filled in the 3 rd gap and extending in the width direction of the winding core.

[17] A roll body comprising a roll core and an elongated sheet material wound around an outer peripheral surface of the roll core, wherein the roll body comprises: a fixing member which is provided between the core and the sheet on the 1 st circumference and fixes a part of the sheet to the core, and which has a1 st end surface extending in the width direction of the core and a2 nd end surface on the opposite side of the 1 st end surface; a2 nd gap between the winding core and the 1 st peripheral web, the 2 nd gap being in contact with the 1 st end surface of the fixing member; a 3 rd gap between the winding core and the 1 st peripheral web and in contact with the 2 nd end surface of the fixing member; and at least one of a2 nd and a 3 rd intermediate portions, wherein the 2 nd intermediate portion is provided in a2 nd region corresponding to the 2 nd gap between the sheets after the 1 st cycle and extends in the width direction of the winding core, and the 3 rd intermediate portion is provided in a 3 rd region corresponding to the 3 rd gap between the sheets after the 1 st cycle and extends in the width direction of the winding core.

[18] The roll body according to the above [13] or [14], further comprising a4 th nip portion, the 4 th nip portion being provided continuously to the 1 st filling portion and being interposed between the sheet of the 1 st circumference and the sheet of the 2 nd circumference.

[19] The roll body according to the above [13] or [14], wherein in a case where there is no 4 th intervening portion provided continuously to the 1 st filling portion and interposed between the sheet in the 1 st circumference and the sheet in the 2 nd circumference, a ratio of a length L1 of the 1 st filling portion in the longitudinal direction of the sheet to a thickness T2 of the 1 st filling portion at a position in contact with the distal end surface is 90 or more, and in a case where there is the 4 th intervening portion, a ratio of a sum of a length L1 of the 1 st filling portion in the longitudinal direction of the sheet and a length L2 of the 4 th intervening portion in the longitudinal direction of the sheet to a thickness T2 of the 1 st filling portion at a position in contact with the distal end surface is 90 or more.

[20] The roll body according to [19], wherein, in a case where the 4 th interposed portion is not present, a ratio of an area S1 of a region sandwiched between the outer peripheral surface of the core and a front surface of the 1 st filling portion in a plane including the longitudinal direction of the sheet and the radial direction of the core to the thickness T2 of the 1 st filling portion is 3.0 or more, and in a case where the 4 th interposed portion is present, a ratio of a total of an area S1 of a region sandwiched between the outer peripheral surface of the core and a front surface of the 1 st filling portion in a plane including the longitudinal direction of the sheet and the radial direction of the core and an area S2 of a region sandwiched between the outer peripheral surface of the core and a front surface of the 4 th interposed portion to the thickness T2 of the 1 st filling portion is 3.0 or more.

[21] The roll according to item [17], wherein, when the thickness of the 2 nd interposed portion is measured in the longitudinal direction of the sheet, a ratio of a length L4 from a2 nd end of the 2 nd interposed portion opposite to the 1 st end on the fixing member side to a position where a maximum thickness T6 of the 2 nd interposed portion is reached in the longitudinal direction to the maximum thickness T6 of the 2 nd interposed portion is 12 or more.

[22] The roll according to [21], wherein a ratio of a cross-sectional area S3 of the 2 nd intermediate portion from the 2 nd end of the 2 nd intermediate portion to a position where the maximum thickness T6 is reached in a plane including the longitudinal direction of the sheet and a radial direction of the core is 2.5 or more to the maximum thickness T6 of the 2 nd intermediate portion.

[23] The roll body according to the above [15] or [17], wherein the sheet has a projection projecting in a radial direction of the winding core at each of both end portions extending in the longitudinal direction of the sheet.

[24] The roll body according to any one of the above [13] to [23], wherein the sheet has a resin film.

[25] The roll body according to any one of the above [13] to [23], wherein the sheet comprises an acrylic resin, a polyester resin, or a cycloolefin polymer resin.

[26] The roll according to the above [24] or [25], wherein the thickness of the sheet is 15 μm or more and 300 μm or less.

[27] The roll body according to item [13], wherein the 1 st filling part contains a coloring material or a luminescent material.

[28] The roll body according to the above [14] or [16], wherein the 2 nd filling part and the 3 rd filling part contain a coloring material or a light emitting material, respectively.

[29] The roll body according to item [15], wherein the 1 st sandwiching portion contains a coloring material or a light emitting material.

[30] The roll body according to the above [17], wherein the 2 nd sandwiching portion and the 3 rd sandwiching portion contain a coloring material or a light emitting material, respectively.

[31] The roll body according to item [13], wherein the 1 st filling portion comprises a cured product of a curable polymer composition.

[32] The roll body according to the above [14] or [17], wherein the 2 nd filling portion and the 3 rd filling portion each contain a cured product of a curable polymer composition.

[33] The roll body according to item [15], wherein the 1 st interposed portion contains a cured product of a curable polymer composition.

[34] The roll body according to item [17], wherein the 2 nd sandwiching portion and the 3 rd sandwiching portion each contain a cured product of a curable polymer composition.

[35] The production method according to any one of the above [13] to [34], wherein the sheet is a laminate having a substrate and 1 or more functional layers laminated on the substrate.

[36] The production method according to any one of the above [13] to [35], wherein the sheet is used for an optical film, a polarizing plate, or a display device.

Effects of the invention

According to one embodiment of the present invention, a method for manufacturing a roll body capable of effectively reducing a step caused by a winding start end portion of a sheet material, and such a roll body can be provided. Further, according to another aspect of the present invention, it is possible to provide a method for manufacturing a roll body capable of effectively mitigating a step caused by a fixing member, and such a roll body.

Drawings

Fig. 1 is a perspective view of a roll body according to embodiment 1.

Fig. 2 is a top view of a sample for determining the position of the in-plane phase difference to be measured.

Fig. 3 is an enlarged view of a part of the roll of fig. 1.

Fig. 4 is a diagram for explaining the dimensions of each component of the roll of fig. 1.

Fig. 5 is an enlarged view of the vicinity of the end portion of the 1 st filling portion of the roll of fig. 1.

Fig. 6 is a diagram illustrating a region R1 and a region R2 in the roll of fig. 1.

Fig. 7 is an enlarged view of a part of another roll body according to embodiment 1.

Fig. 8 is an enlarged view of a part of another roll body according to embodiment 1.

Fig. 9 is a top view of a roll for determining the measurement position of a laser displacement meter.

Fig. 10 is a schematic diagram of the amount of displacement with respect to the position produced based on the measurement by the laser displacement meter.

Fig. 11 is an enlarged view of a part of the image graph of fig. 10 to obtain the areas S1 and S2.

Fig. 12 is an enlarged view of a part of another roll body according to embodiment 1.

Fig. 13 is an enlarged view of a part of another roll according to embodiment 1.

Fig. 14 is an enlarged view of a part of another roll body according to embodiment 1.

Fig. 15 is an enlarged view of a part of another roll according to embodiment 1.

Fig. 16 is an enlarged view of a part of another roll body according to embodiment 1.

Fig. 17 (a) and 17 (B) are views schematically showing a process for manufacturing the roll body according to embodiment 1.

Fig. 18 (a) and 18 (B) are views schematically showing a process for manufacturing the roll body according to embodiment 1.

Fig. 19 (a) to 19 (C) are views schematically showing a manufacturing process of another roll according to embodiment 1.

Fig. 20 (a) and 20 (B) are views schematically showing another manufacturing process of the roll body according to embodiment 1.

Fig. 21 (a) and 21 (B) are views schematically showing another manufacturing process of the roll body according to embodiment 1.

Fig. 22 (a) to 22 (D) are views schematically showing other manufacturing steps of the roll body according to embodiment 1.

Fig. 23 (a) to 23 (C) are views schematically showing another manufacturing process of the roll body according to embodiment 1.

Fig. 24 (a) and 24 (B) are views schematically showing another manufacturing process of the roll body according to embodiment 1.

Fig. 25 is a perspective view of the roll body according to embodiment 2.

Fig. 26 is an enlarged view of a part of the roll of fig. 25.

Fig. 27 is a diagram for explaining the dimensions of each component of the roll of fig. 25.

Fig. 28 is a view showing the maximum thickness and length of the 2 nd interposed portion shown in fig. 25.

Fig. 29 is a diagram showing the sectional area S3.

Fig. 30 is an enlarged view of a part of another roll according to embodiment 2.

Fig. 31 is an enlarged view of a part of another roll according to embodiment 2.

Fig. 32 is an enlarged view of a part of another roll according to embodiment 2.

Fig. 33 is an enlarged view of a part of another roll according to embodiment 2.

Fig. 34 is an enlarged view of a part of another roll according to embodiment 2.

Fig. 35 is an enlarged view of a part of another roll according to embodiment 2.

Fig. 36 is an enlarged view of a part of another roll according to embodiment 2.

Fig. 37 is an enlarged view of a part of another roll according to embodiment 2.

Fig. 38 (a) to 38 (C) are views schematically showing a process for producing a roll according to embodiment 2.

Fig. 39 (a) and 39 (B) are views schematically showing a process for manufacturing the roll body according to embodiment 2.

Fig. 40 (a) is a graph showing the amount of displacement of the roll of example 7 with respect to the position around the 1 st filling part, fig. 40 (B) is a graph showing the amount of displacement of the roll of example 8 with respect to the position around the 1 st filling part, and fig. 40 (C) is a graph showing the amount of displacement of the roll of example 9 with respect to the position around the 1 st filling part.

Detailed Description

[ embodiment 1]

Hereinafter, a roll body according to embodiment 1 of the present invention will be described with reference to the drawings. Fig. 1 is a perspective view of a roll according to the present embodiment, fig. 2 is a plan view of a sample for specifying a position for measuring an in-plane phase difference, fig. 3 is an enlarged view of a part of the roll of fig. 1, fig. 4 is a view for explaining the dimensions of each component of the roll of fig. 1, and fig. 5 is an enlarged view of the vicinity of the end portion of the 1 st filling portion of the roll of fig. 1. Fig. 6 is a diagram showing a region R1 and a region R2 in the roll of fig. 1, fig. 9 is a plan view of the roll for specifying the measurement position of the laser displacement meter, fig. 10 is an image graph of the displacement amount with respect to the position created based on the measurement of the laser displacement meter, and fig. 11 is a diagram in which a part of the image graph of fig. 10 is enlarged to obtain the areas S1 and S2. Fig. 7, 8, 12 to 16 are enlarged views of a part of another roll body according to the present embodiment. Fig. 17 to 19 are views schematically showing a manufacturing process of the roll body according to the present embodiment. Fig. 20 to 24 are views schematically showing another manufacturing process of the roll body according to the present embodiment.

Scroll(s) < >

The roll 10 shown in fig. 1 includes a winding core 11 and an elongated sheet 12 wound around an outer peripheral surface 11A of the winding core 11. As shown in fig. 3, the roll 10 further includes: a1 st filling unit 14 for filling a1 st gap 13 between the core 11 and the web 12; a2 nd filling unit 16 for filling a2 nd gap 15 between the core 11 and the web 12; and a fixing member 17 for fixing a part of the sheet 12 to the core 11. The roll 10 further includes a4 th nip 18 provided continuously with the 1 st filling unit 14 and interposed between the sheet 12 in the 1 st circumference and the sheet 12 in the 2 nd circumference. The roll 10 shown in fig. 3 includes the 4 th interposed portion 18, but may not include the 4 th interposed portion as in the roll 10 shown in fig. 7. The sheet 12 is wound around the core 11 for a plurality of turns or more, for example, for 2 turns or more.

Winding core

The shape of the winding core 11 is not particularly limited, and is preferably cylindrical or cylindrical from the viewpoint of facilitating winding of the sheet 12. The winding core 11 shown in fig. 1 is cylindrical. When the winding core is cylindrical, the winding body 10 can be held by inserting a chuck member of the winding device into the hole 11B in the width direction DR1 of the winding core 11. In the case where the winding core is cylindrical, the winding core includes a shaft member penetrating the winding core, and the winding body can be held by the winding device by attaching the shaft member to the winding device.

The width W1 (see fig. 1) of the winding core 11 is not particularly limited, and may be, for example, 0.1m or more and 50m or less. The lower limit of the width W1 of the winding core 11 may be 0.2m or more, 0.3m or more, 0.7m or more, 1.0m or more, 1.5m or more, or 2m or more, and the upper limit may be 30m or less, 20m or less, 10m or less, 7m or less, 5m or less, 3.5m or less, 3m or less, or 2.5m or less. The width of the core can be determined as follows: the width of the core was measured at 10, and the arithmetic mean of the widths at 8 excluding the maximum and minimum values of the measured 10 widths was determined.

The outer diameter of the core 11 is not particularly limited, and may be, for example, 30mm or more and 8000mm or less. The lower limit of the outer diameter of the core 11 may be 90mm or more or 100mm or more, and the upper limit may be 5000mm or less, 3500mm or less, 2000mm or less, 1000mm or less, 700mm or less, 500mm or less, 350mm or less or 300mm or less. The outer diameter of the winding core can be determined as follows: the outer diameter of the winding core at 10 points was measured, and the arithmetic average of the outer diameters at 8 points excluding the maximum value and the minimum value from the measured outer diameters at 10 points was obtained.

When the core 11 is cylindrical, the inner diameter of the core 11 is not particularly limited, and may be 20mm or more and 7500mm or less. The lower limit of the inner diameter of the core 11 may be 50mm or more, 80mm or more, 120mm or more, 150mm or more, and the upper limit may be 4500mm or less, 3000mm or less, 1500mm or less, 900mm or less, 600mm or less, 400mm or less, 250mm or less, or 200mm or less. The inner diameter of the winding core can be determined as follows: the inner diameter of the core at 10 points was measured, and the arithmetic mean of the inner diameters at 8 points excluding the maximum value and the minimum value from the inner diameters at 10 points was obtained.

In order to alleviate the step caused by the winding start end of the sheet, there are also cases where: although a step is formed in a portion of the outer peripheral surface of the winding core that contacts the sheet so that the position of the winding start end of the sheet is reduced by the thickness of the sheet, the step is not formed in a portion of the outer peripheral surface 11A of the winding core 11 that contacts the sheet 12. By using the winding core 11 having no step at the above-described portion of the outer peripheral surface 11A, it is possible to cope with sheets 12 of various thicknesses. In the present specification, "no step is formed in a portion of the outer peripheral surface of the winding core in contact with the sheet" means that: the outer peripheral surfaces of the central portion of the core and the portion separated from the central portion by 100mm or more in the width direction of the core have no portion having a height difference of 3 μm or more. The step having the height difference of less than 3 μm may be formed in the portion of the outer peripheral surface 11A of the core 11 that contacts the sheet 12.

The material constituting the core 11 is not particularly limited. Examples of the material constituting the winding core 11 include paper, plastic, and metal. The paper also includes resin-impregnated paper. Examples of the plastic include Fiber Reinforced Plastics (FRP/Fiber Reinforced Plastics), polyolefins such as Polyethylene (PE) and polypropylene (PP), polyvinyl chloride (PVC), Polystyrene (PS), acrylonitrile-butadiene-styrene copolymer (ABS), phenol resin, and nylon. Among them, for example, in the case of performing coating processing for optical use, Fiber Reinforced Plastic (FRP) is preferable from the viewpoint of weight, processability, and strength. Examples of the fiber-reinforced plastic include a fiber-reinforced plastic obtained by mixing a main body made of an epoxy resin or a phenol resin with a fiber such as glass, an epoxy resin, polyester, carbon, or aramid. Examples of the metal include iron, stainless steel (SUS), and aluminum.

Sheet material

The sheet material 12 is elongated. Specifically, with respect to the sheet 12, the thickness is sufficiently thin with respect to the width, and the length is sufficiently long.

The width W2 (see fig. 1) of the sheet 12 is not particularly limited, and may be, for example, 0.1m or more and 50m or less. The "width of the sheet" in the present specification means a length of the sheet in a short side direction (a width direction of the core). The width W2 of the sheet 12 may have a lower limit of 0.2m or more, 0.3m or more, 0.5m or more, 1.0m or more, or 2.0m or more, and an upper limit of 30m or less, 20m or less, 10m or less, 7m or less, 5m or less, 3.5m or less, or 3m or less. The width of the sheet can be determined as follows: the width of the sheet was measured at 10 points, and the arithmetic average of the widths at 8 points excluding the maximum value and the minimum value among the measured widths at 10 points was determined.

The width W2 of the web 12 is preferably less than the width W1 of the core 11. This enables the sheet 12 to be reliably held by the winding core 11.

The length of the sheet 12 may be, for example, 20m or more and 10000m or less. The "length of the sheet" in the present specification means the length of the sheet in the longitudinal direction. The length of the sheet 12 may have a lower limit of 30m or more, 40m or more, or 50m or more, and an upper limit of 9000m or less, or 8000m or less.

The thickness of the sheet 12 is not particularly limited, and may be, for example, 3 μm or more and 600 μm or less. The lower limit of the thickness of the sheet 12 may be 10 μm or more, 15 μm or more, 20 μm or more, or 30 μm or more, and the upper limit may be 500 μm or less, 400 μm or less, 300 μm or less, 200 μm or less, 110 μm or less, or 80 μm or less. When the film is preferable in accordance with the application, the film is not limited to this, but is preferably 3 μm or more and less than 50 μm, and more preferably 40 μm or less. The thickness of the sheet can be determined as follows: the thickness of the sheet was measured at 10 points, and the arithmetic average of the thicknesses at 8 points excluding the maximum value and the minimum value among the measured thicknesses at 10 points was determined. The step is difficult to be generated when the thickness of the sheet is large, but becomes more significant when the thickness is small. The present invention is particularly effective when the sheet has a small thickness (80 μm or less, less than 50 μm, and further 40 μm or less).

When the sheet 12 contains, for example, an acrylic resin, a polyester resin (particularly, polyethylene terephthalate), or a cycloolefin polymer resin, the thickness of the sheet 12 is preferably 15 μm or more and 300 μm or less. When the sheet 12 contains any of these resins, the step becomes more conspicuous as the thickness of the sheet becomes thinner, but when the thickness of the sheet is made extremely thin, the step tends to become smaller. For example, when a heating step of 50 ℃ or higher is provided in the subsequent step, if the sheet is thin, the deformation due to the step difference may be eliminated. However, if the thickness of the sheet is a certain thickness (for example, 15 μm or more), the deformation may not be eliminated even if the heating step is performed. Therefore, it is particularly effective when the thickness of the sheet 12 is 15 μm or more. In addition, in the case where the sheet 12 contains any of these resins, if the thickness of the sheet is too thick, a large amount of coating material is required. Therefore, the thickness of the sheet 12 is preferably 300 μm or less from the viewpoint of cost reduction. In addition, when any of these resins is contained, if the thickness exceeds 300 μm, a step may be less likely to occur. In the case where the sheet 12 contains any of these resins, the lower limit of the thickness of the sheet 12 is more preferably 20 μm or more, 35 μm or more, or 50 μm or more, and the upper limit of the thickness of the sheet 12 is more preferably 250 μm or less, 200 μm or less, 150 μm or less, or 100 μm or less. When any of these resins is contained, it is particularly effective for a thickness that is not too thin but not too thick.

Further, in the case where the fixing member 17 is provided, since the sheet 12 is disposed on the fixing member 17, the total thickness of the sheet 12 and the fixing member 17 affects the step caused by the winding start end portion of the sheet. Therefore, for example, assuming that the thickness of the fixing member 17 is 3 μm or more and 10 μm or less, the thickness of the sheet 12 is preferably small, and therefore the upper limit thereof is preferably 130 μm or less, and more preferably 90 μm or less. In addition, when the fixing member is an adhesive tape, if the thickness of the fixing member exceeds 15% of the thickness of the sheet, the above-described step is more likely to be affected. Therefore, the thickness of the sheet 12 is preferably not too thin, and the lower limit of the thickness of the sheet 12 is preferably 20 μm or more or 35 μm or more, for example.

Examples of the sheet include a film, a metal foil, and paper. The film may be, for example, a resin film. When the resin film is used in applications requiring light transmission (for example, optical film applications), the resin film preferably has light transmission. The resin constituting such a resin film is not particularly limited as long as it has light transmittance, and examples thereof include acrylic resins, polyolefin resins (polyethylene resins, polypropylene resins, and cycloolefin polymer resins), polycarbonate resins, polyacrylate resins, polyester resins (polyethylene terephthalate, polyethylene naphthalate, and the like), aromatic polyether ketone resins, polyether sulfone resins, acetyl cellulose resins (triacetyl cellulose resins, for example), polyimide resins, polyamideimide resins, polyamide resins, and mixtures of 2 or more of these resins. Among them, a resin film having high flexibility, for example, a resin film containing an acrylic resin, a polyolefin resin, a polyester resin, an acetyl cellulose resin, a polyimide resin, a polyamide imide resin, or a polyamide resin is easily deformed by a step difference caused by a winding start end portion of the sheet or a step difference caused by a fixing member, and thus the technique of the present invention is effective. Furthermore, in recent years, it has been desired to use a low moisture-permeable resin having low moisture permeability and little distortion in a large-sized display. In the case of a large-sized display, since the entire sheet width is often a product, even if a part of the sheet is deformed by a step, the entire sheet must be discarded. For example, acrylic resins, polyester resins, and cycloolefin polymer resins are preferably used for large-sized displays, and the technique of the present invention is particularly effective for sheets made of these resins because it can satisfactorily prevent deformation due to a step difference and can improve mass productivity. In addition, in the case where the final product requires thinness, for example, in the case of using a film having a thickness of less than 50 μm, the technique of the present invention is suitable for a film of any material.

When the sheet 12 is used for an optical film, particularly when the sheet contains an acrylic resin or a cycloolefin polymer resin, the in-plane retardation (retardation: Re) of the sheet 12 is preferably 10nm or less. The in-plane retardation Re of the sheet 12 of 10nm or less means that the optical strain is small, and it can be said that there is almost no residual stress at the time of producing the sheet 12. That is, when the in-plane retardation Re of the sheet 12 is 10nm or less, the polymer in the sheet 12 is uniform, and therefore, when the sheet 12 is wound in a long roll, a new step due to the polymer state in the sheet 12 is not easily formed by some steps, which is preferable. The upper limit of the in-plane retardation Re of the sheet 12 is more preferably 8nm or less or 4nm or less in view of the difficulty in causing color unevenness and blackening which are problems when used in combination with a polarizing sheet in display applications. In the case of an acrylic resin, in the case of optical applications, the phenomenon of whitening when bent as in the case of conventional acrylic resin films does not occur, and the haze value (total haze value) is preferably as small as 1% or less or 0.5% or less.

In addition, even when the sheet 12 is used for an optical film and contains a polyester resin, it is preferable that a new step is not easily generated due to the state of the polymer inside when the polymer in the sheet 12 is uniform, as described above. When the sheet 12 contains a polyester resin, stretching is indispensable for obtaining physical strength, and therefore, the sheet can be produced by biaxial stretching successively or simultaneously at substantially the same magnification in the longitudinal direction and the transverse direction in order to make the polymer state as uniform as possible. As a result, a sheet comprising a polyester resin having a smaller in-plane retardation than conventional sheets can be obtained. The small in-plane retardation means that the sheet has a thickness of 10 to 90 μm and an in-plane retardation of 1500nm or less, preferably 1200nm or less, more preferably 1000nm or less, and further preferably 800nm or less. In order to improve physical properties such as elastic modulus and tear strength of a biaxially stretched polyester plastic film, the in-plane retardation is preferably not too small, preferably 200nm or more, and more preferably 400nm or more.

In order to further improve the physical properties, it is preferable to consider the birefringence in the in-plane direction and also consider the balance with the birefringence in the film thickness direction. The index is an Nz coefficient. The Nz coefficient is influenced by crystallinity and orientation in the film, and thus relates to the characteristics of the entire sheet. In the case of polyethylene terephthalate, for example, the Nz coefficient is usually 2 to 4, and in particular, in the case of a long roll, the Nz coefficient is preferably 5 or more, more preferably 8 or more, and most preferably 10 or more, in that a new step is less likely to be generated due to a certain step in the polymer state in the sheet. The upper limit of the Nz coefficient is about 80, preferably 70 or less, and most preferably 50 or less.

The in-plane retardation (Re) is represented by the following equation (1): a refractive index nx in a slow axis direction which is a direction in which an in-plane refractive index of the sheet is maximum; a refractive index ny in a fast axis direction which is a direction orthogonal to the slow axis direction in the plane; and the thickness t (nm) of the sheet. As is clear from the following equation (1), when the in-plane retardation is small, the degree of orientation is low, and thus the bending resistance tends to be good. The in-plane retardation (Re) can be measured, for example, by a device available from Otsuka Denshi under the trade name "RETS-100", a device available from Otsuka Denshi Kabushiki Kaisha under the trade name "KOBRA-WR" or "PAM-UHR 100".

In-plane retardation (Re) ═ nx-ny) × t … (1)

The Nz coefficient is represented by the refractive index Nz in the thickness direction of the sheet, nx above and ny above by the following equation (2).

Nz coefficient (nx-Nz)/(nx-ny) (2)

In the case of measuring the above Re using RETS-100, the measurement can be performed as follows. First, in order to stabilize the light source of the RETS-100, the light source was left for 60 minutes or more after lighting. Then, the rotary analyzer method is selected, and the θ mode (angular direction phase difference measurement mode) is selected. By selecting the θ mode, the table becomes a tilt rotation table.

Next, the following measurement conditions are input to RETS-100.

(measurement conditions)

Delay measurement range: rotary polarization analysis method

Measurement point diameter: phi 5mm

The tilt angle range: -40 to 40 °

Measurement wavelength range: 400 nm-800 nm

The average refractive index of the sample (for example, N is 1.617 in the case of PET, and 1.5 in the case of an acrylic resin film).

Thickness: thickness measured separately by SEM and optical microscope

Next, background data was obtained without setting a sample in the apparatus. The device is set as a closed system, which is implemented each time the light source is lit.

The sample is then placed on a stage within the apparatus. The shape of the sample may be any shape, and may be, for example, a rectangular shape. The size of the sample may also be 50mm x 50 mm. In the case where a plurality of samples are present, all of them need to be arranged in the same orientation. For example, in order to set all samples in the same orientation, it is preferable to mark all samples with a symbol in advance.

After setting the sample, the stage was rotated 360 ° on the XY plane in an environment of a temperature of 23 ± 5 ℃ and a relative humidity of 50 ± 20%, and the fast axis and the slow axis were measured. After the measurement is finished, the slow axis is selected. Then, measurement is performed while tilting the table about the slow axis within a predetermined angle range, and data (Re) of the predetermined tilt angle range and the predetermined wavelength range is obtained in units of 10 °. The in-plane retardation Re was measured with light having a wavelength of 589nm at an incident angle of 0 °. The in-plane phase difference Re was measured at 5 points different in position. Specifically, as shown in fig. 2, 2 orthogonal virtual lines IL1 and IL2 passing through the center a1 of the sample SA are drawn. When the virtual lines IL1 and IL2 were drawn, the sample was divided into 4 partitions. Then, 1 point equidistant from the center a1, 4 points a2 to a4 in total, and 5 points in total of the center a1 and the points a2 to a4 were set in each section. Then, the arithmetic average of 3 points excluding the maximum value and the minimum value among the measured values at 5 points was taken as the in-plane phase difference Re.

The sheet 12 may have a single-layer structure or a laminated structure in which 2 or more layers are laminated. Specifically, the sheet 12 may be a single substrate or a single functional layer, and may be, for example, a laminate (e.g., an optical laminate) in which 1 or more functional layers are formed on a substrate. The "functional layer" in the present specification means a layer which intentionally exerts a certain function in the laminate. Specifically, examples of the functional layer include a primer layer, a hard coat layer, an impact absorbing layer, an antiglare layer, an antistatic layer, a conductive layer, a heat dissipating layer, an ultraviolet absorbing layer, a special wavelength transmitting layer, a color reproducibility improving layer, a liquid crystal layer, a retardation adjusting layer, a viewing angle adjusting layer, a reflective layer, a colored layer, an antireflection layer (a high refractive index layer, a low refractive index layer), an antifouling layer, a water repellent layer, an oil repellent layer, and the like, or a combination thereof. The "functional layer" in the present specification may have a single-layer structure or a laminated structure. However, in the present specification, the "functional layer" is a layer that is present even when the sheet 12 is used, and does not include a release liner that is peeled off when used. If the release liner is present on the sheet, defects are likely to occur, and a new step different from the above step is likely to occur. If the release liner is provided on the sheet 12, the sheet is wound around the core 11 with the release liner removed.

The use of the sheet 12 is not particularly limited, and examples thereof include optical use (optical film use, polarizing plate use, display device use), door and window use, automobile interior decoration use, battery member use, and food packaging material use. Among them, the technique of the present invention is particularly effective in optical applications because if the optical film has a step difference due to the winding start end portion of the sheet or a step difference due to the fixing member, the optical film may affect not only the appearance but also the light transmittance.

The sheet 12 includes a winding start end 12A (see fig. 3) and a winding end 12B (see fig. 1). In the roll body 10, the winding start end portion 12A is located inward (toward the winding core 11) of the winding end portion 12B. In the roll body 10, as shown in fig. 3, the distal end surface 12A1 of the winding start end portion 12A located in the longitudinal direction DR2 is substantially aligned with the later-described 2 nd end surface 17B of the fixing member 17 in a cross section along the longitudinal direction DR2 of the sheet 12 and the radial direction DR3 of the core 11. The term "substantially aligned" in the present specification means: the distance between the distal end surface 12A1 and the 2 nd end surface 17B in the longitudinal direction DR2 of the winding start end 12A is within ± 20% of the width W3 (see fig. 4) of the fixing member 17. The "+" means that the end face 12a1 protrudes from the 2 nd end face 17B, and the "-" means that the end face 12a1 is recessed from the 2 nd end face 17B (i.e., the 2 nd end face 17B protrudes from the end face 12a 1).

Fixed part

The fixing member 17 is used to fix a part of the sheet 12 to the outer peripheral surface 11A of the winding core 11. The fixing member 17 extends in the width direction DR1 of the winding core 11. This allows a part of the sheet 12 to be fixed to the outer peripheral surface 11A of the winding core 11 along the width direction DR1 of the winding core 11.

The fixing member 17 has a2 nd end surface 17B opposite to the 1 st end surface 17A. The 1 st end surface 17A and the 2 nd end surface 17B each extend in the width direction DR1 of the winding core 11.

In fig. 3, the fixing member 17 is in close contact with the outer peripheral surface 11A of the winding core 11 and the winding start end portion 12A of the sheet 12, and fixes the winding start end portion 12A of the sheet 12 to the outer peripheral surface 11A of the winding core 11. In addition, if it is the 1 st circumference of the sheet 12, the sheet 12 may be fixed at a portion other than the winding start end portion 12A. In fig. 3, the entire front surface of the fixing member 17 is in close contact with the winding start end portion 12A, but as shown in fig. 8, the 1 st filling portion 14 may enter between the winding start end portion 12A and the fixing member 17 as long as the winding start end portion 12A is fixed to the fixing member 17 to such an extent that it does not cause a problem at the time of winding, for example, to such an extent that the winding start end portion 12A does not peel off from the fixing member 17 at the time of winding.

The fixing member 17 is not particularly limited, and examples thereof include an adhesive member, an adhesive member such as a double-sided tape, and the like. The fixing member 17 may have elasticity (cushioning property). The adhesive member has adhesiveness on both sides.

The width W3 (see fig. 4) of the fixing member 17 is preferably 5mm or more and 100mm or less. If the width W3 of the fixing member 17 is 5mm or more, a part of the sheet 12 can be reliably fixed to the outer peripheral surface 11A of the core 11, and if it is 100mm or less, the sheet 12 can be wound without generating wrinkles in the sheet 12. The "width of the fixing member" in this specification means a distance from the 1 st end face to the 2 nd end face. The lower limit of the width W3 of the fixing member 17 is preferably 10mm or more, 20mm or more, or 30mm or more, and the upper limit is preferably 50mm or less or 40mm or less.

The thickness of the fixing member 17 is preferably 3 μm or more and 600 μm or less. If the thickness of the fixing member 17 is 3 μm or more, a part of the outer peripheral surface 11A of the core 11 can be reliably fixed, and if it is 600 μm or less, deformation of the sheet 12 can be further suppressed. The lower limit of the thickness of the fixing member 17 is preferably 5 μm or more, 10 μm or more, or 20 μm or more, and the upper limit is preferably 200 μm or less, 100 μm or less, or 50 μm or less. The thickness of the fixing member can be found by measuring the thickness of the fixing member at 10 and finding the arithmetic mean of the thickness at 10.

< 1 st gap >

The 1 st gap 13 is a gap in contact with the distal end surface 12A1 of the winding start end portion 12A located in the longitudinal direction DR2 (see fig. 3). Specifically, the 1 st gap 13 shown in fig. 3 is a gap surrounded by the outer peripheral surface 11A of the winding core 11, the back surface 12C of the 1 st peripheral sheet 12, the distal end surface 12A1 of the winding start end 12A, and the 2 nd end surface 17B of the fixing member 17. When the fixing member 17 is not provided, the 1 st gap is a gap surrounded by the outer peripheral surface of the winding core, the back surface of the sheet in the 1 st circumference, and the distal end surface of the winding start end.

The 1 st gap 13 is a gap in contact with the distal end surface 12a1, and is also a gap between the winding core 11 and the 1 st peripheral sheet 12 and in contact with the 2 nd end surface 17B, and is therefore also a 3 rd gap described later.

< 2 nd gap >

The 2 nd gap 15 is a gap contacting the 1 st end surface 17A of the fixing member 17. Specifically, the 2 nd gap 15 shown in fig. 3 is a gap surrounded by the outer peripheral surface 11A of the winding core 11, the back surface 12C of the 1 st peripheral sheet 12, and the 1 st end surface 17A of the fixing member 17.

< filling section 1>

The 1 st filling part 14 fills the 1 st gap 13. That is, the 1 st filling portion 14 contacts the outer peripheral surface 11A of the winding core 11, the back surface 12C of the 1 st peripheral sheet 12, the distal end surface 12A1 of the winding start end 12A, and the 2 nd end surface 17B of the fixing member 17. In the case where the fixing member 17 is not provided, the 1 st filling part is in contact with the outer peripheral surface of the winding core, the back surface of the 1 st peripheral sheet, and the distal end surface of the winding start end. The term "filled" in the present specification means a state in which the gap is substantially filled with the material constituting the filling portion. However, the filling portion may have a void (for example, a bubble) inside.

The sheet 12 has: an effective area for use as a product; and non-effective areas that are located on both sides of the effective area in the short side direction of the sheet 12 and that are not used as a product, the 1 st filling part 14 being present at least in the effective area. Since the effective region is a region used as a product, the 1 st filling part 14 is preferably present over the entire width of the effective region in the width direction DR1 of the winding core 11. The 1 st filling part 14 may be present in the ineffective region as long as it is present in the effective region, but if the 1 st filling part 14 is present in the ineffective region, the 1 st filling part 14 may also overflow from the sheet 12, and the ineffective region is a region that is not originally used as a product, and the step is not required to be reduced, so the 1 st filling part 14 may not be present in the ineffective region. The ineffective area is generally within 10mm to 30mm from both ends of the sheet in the short side direction to the inside, although it varies depending on the use of the sheet and the width of the sheet. When the 1 st filling portions 14 are present in the ineffective area, the 1 st filling portions 14 may be present at both ends of the sheet in the short side direction, but are preferably present at positions separated from the both ends toward the center of the sheet by 1mm or more (preferably 5mm or more, more preferably 10mm or more), from the viewpoint of suppressing the overflow.

The edge thickness T1 (see fig. 4 and 5) of the leading end portion 14A on the separation position P1 side where the sheet 12 in the 1 st peripheral edge of the 1 st filling unit 14 is separated from the core 11 is preferably thin because a new step may be formed by the thickness if the thickness is thick. As described later, depending on the purpose, the edge thickness T1 may be present to some extent rather than absent. The edge thickness T1 is preferably 50 μm or less, for example. From the viewpoint of being able to shorten the distance from the winding start end portion 12A to the point where the deformation due to the step difference of the winding start end portion 12A becomes invisible, that is, the deformation relaxation length, the edge thickness T1 is more preferably 30 μm or less, 20 μm or less, 10 μm or less, 5 μm or less, and still more preferably 2 μm or less. As the step caused by the winding start end portion is more reduced, the deformation of the sheet caused by the step is more reduced, and thus the deformation reduction length is shortened. The "deformation relaxation length" in the present specification is used not only to mean a length until the deformation of the sheet material due to the step difference caused by the winding start end portion is relaxed, but also to mean a length until the deformation of the sheet material due to the step difference caused by the fixing member becomes invisible in some cases. When the deformation relaxing length is used as a length to make the deformation of the sheet material due to the step difference of the fixing member invisible, the deformation relaxing length is a distance from the winding start end portion 12A to a point where the deformation due to the step difference of the fixing member 17 is invisible. The strain-relaxation length is preferably short, and more specifically, 100m or less, 75m or less, 60m or less, 50m or less, or 35m or less, 20m or less, or 15m or less. When the deformation relaxation length is 75m or less, the deformation of the sheet becomes more invisible, and thus the deformation is favorable. As described above, the deformation relaxing length is a length until the deformation of the sheet due to the step cannot be visually recognized, but the presence or absence of the step is determined as follows. First, in an indoor environment of 800Lux or more and 2000Lux or less, a long sheet is projected onto a white light source tube (a white LED lamp, a white fluorescent lamp, or the like), and it is determined that there is a step difference when there is a portion where the contour line of the white light source tube projected onto the sheet is deformed compared with other portions of the sheet, and it is determined that there is no step difference in the portion where the contour line of the white light source tube projected around the step difference is the same as the other portions of the sheet. The white light source tubes are arranged such that the longitudinal direction of the white light source tubes is along the longitudinal direction of the sheet. The length of the white light source tube can be changed according to the width and length of the sheet. Specifically, the length of the white light source tube is preferably the length of the portion where the step difference exists and the portion where the step difference does not exist in the sheet. This makes it easy to know the portion having the step difference. In addition, if the observation environment is the brightness as described above, the white light source tube itself may be lit or unlit. In the observation, it is important that the sheet is viewed as a white light source and that the outline of the sheet is visible. Therefore, as the observation condition, one that can clearly see the outline of the white light source tube is appropriately selected. For example, when the outline of the white light source tubes is more visible on the back surface of the sheet than on the front surface of the sheet, the white light source tubes may be projected on the back surface of the sheet to check whether or not there is a step. Specifically, for example, in the case of a laminate in which a functional layer such as an antiglare layer, which is less likely to cause reflection of a white light source tube, is laminated on the front side of a substrate, it may be difficult to confirm whether or not there is a step when viewed from the antiglare layer side. Therefore, in this case, the white light source tube can be reflected on the back surface side of the base material on which the antiglare layer is not laminated, and whether or not there is a step can be checked. This determination can also be applied to a roll for various applications such as a laminate in which 1 or more functional layers are laminated on a substrate, a laminate in which a polarizing sheet is attached, and the like. For example, when an antiglare layer is laminated on a substrate as a functional layer, the determination can be made as follows: the uneven shape exhibiting the antiglare function under pressure appears to be crushed in the portion having the step difference, and is colored by a shadow or the like. In addition, when various functional layers are laminated and the white light source tube is hard to be reflected on the viewing side surface of the roll or the opposite surface thereof, it can be determined as described above by: a coloring different from that of other portions is seen by shading or the like due to a change in shape.

In addition, in the case where the sheet 12 is a film having a thickness of 3 μm or more and less than 50 μm, since the sheet is more likely to be affected by the step caused by the winding start end portion 12A than in the case where the sheet is thick, the edge thickness T1 is preferably 10 μm or less, and more preferably 7 μm or less, 5 μm or less, and still more preferably 1 μm or less in the case where such a film is used, from the viewpoint of minimizing the deformation relaxation length.

The edge thickness T1 is preferably the above-described thickness from the viewpoint of minimizing the deformation relaxing length, but may be as follows: the surface of the winding core is subjected to surface finishing, and thus has irregularities. Since the material constituting the 1 st filling part is embedded in the end part of the 1 st filling part along the irregularities, a portion having the edge thickness T1 and a portion having no edge thickness T1 may be generated, and may be uneven. However, if the edge thickness T1 is thin, even if such unevenness occurs, no actual damage is caused. Therefore, when unevenness occurs due to unevenness, the edge thickness T1 is preferably thin, and specifically, for example, the edge thickness T1 is preferably 15 μm or less, 10 μm or less, 5 μm or less, and more preferably 1 μm or less.

On the other hand, there is also an effect due to the presence of the edge thickness T1. For example, the winding core is often reused after the roll body is used. Therefore, the winding core is required to have reworkability as follows: the core is reused by peeling off the filling section such as the 1 st filling section in contact with the core from the core, or by removing the filling section by washing or wiping. Therefore, for example, it is preferable that the 1 st filling part 14 is not bonded to the core 11 as described later. In the portion where the 1 st filling unit 14 contacts the winding core 11 and the sheet 12, the sheet 12 is preferably peeled cleanly from the 1 st filling unit 14. If the first filling unit 14 is broken by cohesion when the sheet 12 is peeled from the first filling unit 14, it may be difficult to cleanly peel the entire first filling unit 14 from the core 11. On the other hand, the presence of the edge thickness T1 is a starting point for peeling the sheet 12, and therefore, from the viewpoint of reworkability, it is preferable to have the edge thickness T1. For example, the edge thickness T1 is preferably 5 μm or more from the viewpoint of reworkability. The edge thickness T1 preferably varies depending on the material of the core or sheet, and the edge thickness T1 may be 1.5 μm or more, and further 5 μm or more. The upper limit of the edge thickness is preferably 30 μm or less because a new step may be formed depending on the thickness.

The measurement of the edge thickness T1 can be performed using a scanning optical interference type surface shape measuring instrument. Examples of such a surface shape measuring instrument include "New View" series manufactured by Zygo corporation.

Specifically, the edge thickness T1 can be obtained as follows using a scanning optical interference profilometer (product name "new view 7300", manufactured by Zygo). First, when all the sheets are fed out, the 1 st filling unit 14 may be attached to the sheet 12 side and peeled off from the core. When the 1 st filling portion 14 is attached to the fed sheet 12 side, 1 or more samples having a size of 0.5mm square or more including the distal end portion 14A of the 1 st filling portion 14 are obtained from the sheet. The sample is not limited to a square shape but may be a rectangular shape (e.g., 2 mm. times.5 mm) as long as it has a size of 0.5mm square or more. The sample is cut from any portion including the 1 st filling part 14 to which dirt, a fingerprint, or the like is not attached. Then, the edge thickness T1 of the 1 st filling part 14 was measured under the following measurement conditions. The edge thickness T1 may be determined as follows: the thickness of the edge at 10 was measured and the arithmetic mean of the thicknesses at 8 excluding the maximum and minimum values among the thicknesses measured at 10 was found.

(measurement conditions)

Objective lens: 10 times of

Zoom: 1 times of

Measurement area: 2.17mm

·scan Length：5μm

·min mod：0.015

The thickness T2 (see fig. 4) of the 1 st filling portion 14 at the position in contact with the distal end surface 12a1 is preferably larger than the total thickness of the fixing member 17 and the sheet 12 when the fixing member 17 is present, and is preferably larger than the thickness of the sheet 12 when the fixing member 17 is not present. By setting the thickness T2 to such a thickness, the step caused by the winding start end portion 12A can be more effectively reduced. However, if the thickness T2 is too large, the step difference caused by the winding start end portion 12A can be alleviated, but the winding of the sheet 12 may be adversely affected. Therefore, for example, when the thickness of the sheet 12 is 50 μm or more and 200 μm or less, the thickness T2 is preferably 52 μm or more and 220 μm or less, more preferably 52 μm or more and 150 μm or less, and when the thickness of the sheet 12 is 3 μm or more and less than 50 μm, the thickness T2 is preferably 50.5 μm or more and 100 μm or less.

The thickness T2 of the 1 st filling part 14 at the position in contact with the distal end face 12a1 can be measured as follows. Regarding the thickness T2, the measurement method may be different between the case where the 4 th interposed portion 18 is present and the case where the 4 th interposed portion 18 is not present. In the case where the 4 th intervening portion 18 is not present, measurement can be performed using a laser displacement meter or a physical microscope, and in the case where the 4 th intervening portion 18 is present, measurement can be performed using a physical microscope. The measurement of the thickness T2 based on a laser displacement meter or a solid microscope was carried out in an environment at a temperature of 23. + -. 5 ℃ and a relative humidity of 50. + -. 20%.

The measurement of the thickness T2 based on the laser displacement meter can be performed as follows. The following measurement method is particularly effective when the sheet 12 is transparent and the 1 st filling portion is opaque (for example, in the case of coloring) because reflection of laser light is used. First, a jig and a laser displacement meter (for example, product name "LK-G30" manufactured by KEYENCE) for rotating the roll 10 are prepared and arranged at predetermined positions, respectively. The jig is inserted into the hole 11B in the width direction DR1 of the winding core 11 to rotatably hold the winding body 10. Further, although LK-G30 is given as an example of the laser displacement meter, an equivalent laser displacement meter such as a succeeding model may be used instead of LK-G30.

The laser displacement meter includes a laser light source and a light receiving element, and is a device capable of measuring displacement from a light receiving position in the light receiving element by receiving laser light emitted from the laser light source and reflected on the surface of the 1 st filling part 14 by the light receiving element.

The laser displacement meter is located above the roll 10, and 3 laser displacement meters are arranged so as to irradiate the front surface of the roll 10 with laser light. The laser displacement meter is arranged as follows. First, as shown in fig. 9, the 1 st position B1 and the 2 nd position B2 that trisect the width of the sheet 12 are determined. The 1 st position B1 is located on the 1 st end 12G1 side in the short side direction of the sheet 12 (the width direction DR1 of the core 11), and the 2 nd position B2 is located on the 2 nd end 12G2 side opposite to the 1 st end 12G 1. The 1 st laser displacement meter is disposed so as to irradiate the midpoint C1 between the 1 st position B1 and the 1 st end 12G1 with laser light, the 2 nd laser displacement meter is disposed so as to irradiate the midpoint C2 between the 1 st position B1 and the 2 nd position B2 with laser light, and the 3 rd laser displacement meter is disposed so as to irradiate the midpoint C3 between the 2 nd position B2 and the 2 nd end 12G2 with laser light.

Then, the roll 10 is attached to a jig, and the sheet 12 is fed out until the 1 st filling portion 14 overflows from the roll 10. Then, in the state where the 1 st filling part 14 is overflowed, the amount of displacement is continuously measured at a sampling period of 200 μ s by a laser displacement meter while rotating the core 11 at a rotation speed of 30mm/s, and a graph in which the horizontal axis is the position (mm) and the vertical axis is the amount of displacement (mm) is obtained (see fig. 10). This measurement is performed from the distal end portion 14A of the 1 st filling portion 14 toward the position in contact with the distal end surface 12a1, and in this measurement, the reference height (line where the amount of displacement is 0 mm) is taken as the height of the core 11, and the difference between the reference height and the amount of displacement of the 1 st filling portion 14 is taken as the thickness of the 1 st filling portion 14. In the graph, 1 scale on the horizontal axis is set to 5mm, and 1 scale on the vertical axis is set to 0.02 mm.

In this graph, the displacement amount increases from the distal end portion 14A at a portion where the 1 st filling portion 14 is present, but the displacement amount rapidly decreases after the position in contact with the distal end surface 12a1 in the 1 st filling portion 14. Therefore, the position E1 on the position displacement curve where the amount of displacement starts to decrease sharply is found in the graph. Then, the thickness T2 of the 1 st filling part 14 at the position in contact with the distal end surface 12a1 is determined by determining the difference between the displacement amount of the line at the displacement amount of 0mm and the displacement amount of the position E1.

The measurement of the thickness T2 based on a solid microscope can be performed as follows. First, the portion including the winding start end portion 12A, the 1 st filling portion 14, and the 2 nd peripheral sheet 12 is selected and fixed so as not to be crushed. Then, the fixed cross section of the portion was ground, and the thickness T2 of the 1 st filling part 14 was measured by a solid microscope (for example, product name "digital microscope VHX-7000", manufactured by KEYENCE corporation). Although the digital microscope VHX-7000 is exemplified as the actual microscope, an equivalent actual microscope such as a subsequent model may be used instead of VHX-7000.

Since both end portions 12G (see fig. 1) of the sheet 12 extending in the longitudinal direction DR2 are not used as products, the length of the 1 st filling part 14 in the width direction DR1 of the winding core 11 may be smaller than the width W2 of the sheet 12 as long as the length is equal to or greater than the effective region of the winding body 10 for commercialization.

The 1 st filling part 14 preferably contains a coloring material and a light emitting material. By including the coloring material and the light emitting material in the 1 st filling part 14, it is easy to visually check when the 1 st filling part 14 overflows from the roll 10. In addition, the thickness, length, etc. of the 1 st filling part 14 can be easily confirmed.

When the 1 st filling part 14 is colored, the color of the 1 st filling part 14 is not particularly limited, but white, gray, or the like is preferable from the viewpoint that the presence of the 1 st filling part 14 can be reliably recognized and the component of the 1 st filling part 14 is not easily conspicuous even if it adheres to the winding device.

In the case where the 1 st filling part 14 is colored, the 1 st filling part 14 contains a coloring material. When the 1 st filling part 14 is a cured product of a coating material, the coloring material is preferably a material that does not inhibit curing. The coloring material may be any of a pigment and a dye, or may be any of an organic coloring material and an inorganic coloring material. Specific examples of the coloring material include titanium oxide, carbon black, and a mixture thereof.

When the 1 st filling part 14 is colored, the content of the coloring material in the 1 st filling part 14 is preferably 0.1 mass% or more and 50 mass% or less. If the content of the coloring material is 0.1 mass% or more, the 1 st filling part 14 can be visually confirmed, and if it is 50 mass% or less, the reworkability can be maintained well even if the coloring material is an inorganic material or an organic material.

When the 1 st filling portion 14 contains a light emitting material, the light emitting material is not particularly limited, and examples thereof include a fluorescent material and a light accumulating material. When the 1 st filling part 14 contains a fluorescent material or a light accumulating material, the fluorescent material or the light accumulating material in the 1 st filling part 14 can be caused to emit light by irradiating the 1 st filling part 14 with light such as ultraviolet light or visible light.

The shape of the front face 14B of the 1 st filling part 14 is preferably convex upward. If the front surface 14B is formed in a convex shape which is convex upward, the sheet 12 can be lifted up compared with a concave shape which is concave downward, and thus the step can be reduced. Whether or not the shape of the front surface 14B is a convex shape protruding upward can be determined from the graph of the position displacement curve in the same manner as the thickness T2. Specifically, in the graph, the position where the 1 st filling part 14 is present is higher than the height of the core 11, and therefore the displacement amount increases. A position E2 (see fig. 10) which is an intersection of a line where the displacement amount starts to increase and the position displacement curve, the line having a displacement amount of 0mm, is grasped. Then, a virtual line IL3 (refer to fig. 10) passing through the position E1 and the position E2 is drawn. When the ratio of the number of peaks above the virtual line IL3 out of the number of peaks in the position displacement curve existing between the position E1 and the position E2 is 50% or more, it can be determined that the shape of the front surface 14B of the 1 st filling part 14 is convex upward, and when the ratio of the number of peaks below the virtual line IL3 out of the number of peaks 50% or more in the position displacement curve existing between the position E1 and the position E2 is less than 50%, it can be determined that the shape of the 1 st filling part 14 is concave downward. When the virtual line IL3 overlaps the position displacement curve, it is determined that the image is concave downward. In the graph for determining the shape of the 1

st filling part

14, 1 scale on the horizontal axis is set to 5mm, and 1 scale on the vertical axis is set to 0.02 mm.

When the shape of the front surface 14B of the 1 st filling part 14 is a convex shape protruding upward, the average distance D1 from the imaginary line IL3 to the displacement curve in the vertical axis direction is preferably 0.003mm or more. If the average distance D1 is 0.003mm or more, the sheet 12 can be effectively lifted, and therefore the step can be further reduced. The lower limit of the average distance D1 is more preferably 0.01mm or more. The upper limit of the average distance D1 is preferably 0.1mm or less, and more preferably 0.07mm or less, because it may cause a new step when the upper limit is excessively convex. The average distance D1 is a value obtained by reading 7 peaks that are convex upward with respect to the virtual line IL3 using the virtual line IL3 as a reference line and averaging 5 points excluding the maximum value and the minimum value. Further, the peak of the reading is a mountain portion, and a larger portion is selected.

The slope of the horizontal axis of the graph of the virtual line IL3 with respect to the position displacement curve is preferably 0.0020 to 0.0130, more preferably 0.0030 to 0.0070, and still more preferably 0.0050 to 0.0060. If the slope is 0.0050 or more, the filling material can be filled without dishing, and if the slope is 0.0060 or less, the filling material can be filled without significant bulging. The lower limit of the slope is preferably 0.0020 or more, 0.0030 or more, or 0.040 or more, and the upper limit is preferably 0.0130 or less, 0.0120 or less, or 0.0100 or less.

The thickness of the 1 st filling part 14 is preferably gradually increased from the vicinity of the separation position P1 toward the distal end surface 12a 1. By changing the thickness of the 1 st filling portion 14 in this way, a sudden height change of the sheet 12 in the radial direction DR3 of the winding core 11 (the normal direction of the outer peripheral surface 11A) can be suppressed, and thus a step caused by the winding start end portion 12A can be alleviated.

If the thickness of the 1 st filling part changes abruptly, there is a concern that: the deformation remains due to the thickness change, and the step difference caused by the winding start end portion cannot be sufficiently relaxed. Therefore, it is preferable to secure a sufficient length of the 1 st filling part with respect to the thickness of the sheet. However, when the length of the 1 st filling part is increased to cause other influences such as winding, the length of the 1 st filling part is intentionally made shorter than the optimum state, whereby the deformation relaxing length is made longer than the state having the optimum length of the 1 st filling part, but the deformation relaxing length can be made shorter than the state having no 1 st filling part. Therefore, when the 4 th interposed portion 18 is present as shown in fig. 4, it is preferable that the ratio ((length L1+ length L2)/thickness T2) of the 1 st filling portion 14 at the position in contact with the distal end surface 12a1) of the 1 st filling portion 14 to the thickness T2 of the 4 th interposed portion 18 in the longitudinal direction DR2 of the sheet 12, the ratio being the sum of the length L1 (see fig. 4) of the 1 st filling portion 14 along the longitudinal direction DR2 of the sheet 12 and the length L2 (see fig. 4). In the case where the 4 th interposed portion 18 is not present as shown in fig. 7, the ratio of the length L1 (see fig. 7) of the 1 st filling portion 14 along the longitudinal direction DR2 of the sheet 12 to the thickness T2 of the 1 st filling portion 14 at the position in contact with the distal end surface 12a1 (length L1/thickness T2) is preferably 90 or more. From the viewpoint of shortening the deformation relaxing length, the lower limit of these ratios is preferably 100 or more, 110 or more, 120 or more, or 140 or more. The upper limit of the ratio is not particularly limited, and may be 1200 or less, 1000 or less, 800 or less, 500 or less, or 300 or less, for example.

The length L1 is the length of the 1 st filling part 14 from the position in contact with the distal end surface 12a1 to the end on the separation position P1 side along the longitudinal direction DR2 of the sheet 12. The length L2 is the length from a position immediately above the distal end surface 12a1 of the sheet 12 in the longitudinal direction DR2 to the end on the side where the sheet 12 in the 1 st circumference contacts the sheet 12 in the 2 nd circumference. The length L1 and the length L2 can be determined from the graph of the position displacement curve in the same manner as the thickness T2. Specifically, first, the presence of the 4 th intervening portion is checked by a method described later. In the case where the 4 th interposed section is present, the position E1 and the position E2 are found from the graph of the position displacement curve. Next, a virtual line IL4 (see fig. 10) perpendicular to the line passing through the position E2 and having the displacement amount of 0mm is drawn. Next, assuming that the intersection of the virtual line IL4 and the line at which the displacement amount is 0mm is the position E3, the distance between the position E2 and the position E3 is obtained, whereby the total length of the length L1 and the length L2 can be obtained. In the case where the 4 th intervening section is not present, the length L1 can be obtained by obtaining the distance between the position E2 and the position E3 by the above-described method.

From the viewpoint of reducing the step difference, the length L1 is preferably as long as possible, and for example, when the thickness of the sheet 12 is 50 μm or more and 200 μm or less, the length L1 is preferably 110 μm or more, and for further shortening the deformation reducing length, is preferably 1mm or more, and more preferably 10mm or more. However, if the length L1 is too long, it is difficult to form the convex 1 st filling part which is convex upward in terms of processing, and there is a possibility that the thickness unevenness of the wave shape occurs in the 1 st filling part, and therefore, from the viewpoint of easily obtaining the convex 1 st filling part 14 which is convex upward and suppressing the thickness unevenness of the wave shape, the upper limit of the length L1 is preferably 100mm or less.

The above (length L1+ length L2)/thickness T2 and length L1/thickness T2 can roughly indicate the shape of the 1 st filling unit 14, but in order to more appropriately indicate the shape such as the upwardly convex shape of the 1 st filling unit 14, it is preferable to further use the area of the 1 st filling unit 14 on the plane including the longitudinal direction DR2 of the sheet 12 and the radial direction DR3 of the core 11. Specifically, when the 4 th interposed section 18 is present as shown in fig. 4, the ratio ((area S1+ area S2)/thickness T2) of the sum of the area S1 (see fig. 6) of the area R1 sandwiched between the outer peripheral surface 11A of the core 11 and the front surface 14B of the 1 st filling section 14 in the plane (the plane shown in fig. 4) including the longitudinal direction DR2 of the sheet 12 and the radial direction DR3 of the core 11 and the area S2 (see fig. 6) of the area R2 sandwiched between the outer peripheral surface 11A of the core 11 and the front surface 18A of the 4 th interposed section 18 to the thickness T2 of the 1 st filling section 14 at the position in contact with the end surface 12a1 is preferably 3.0 or more. The area S1 of the region R1 in fig. 6 indicates the cross-sectional area of the 1 st filling part 14. In fig. 6, an area S2 of the region R2 indicates the total of the cross-sectional area of the 4 th interposed portion 18, the cross-sectional area of the sheet 12 in the region R2, and the cross-sectional area of the fixing member 17 in the region R2. Fig. 6 shows a state in which the sheet 12 on the 1 st filling portion 14 and the 4 th intermediate portion 18 is peeled off and the 1 st filling portion 14 and the 4 th intermediate portion 18 are overflowed. In the case where the 4 th interposed part 18 is not present, the ratio of the area S1 of the region R1 sandwiched between the outer peripheral surface 11A of the core 11 and the front surface 14B of the 1 st filling part 14 in the plane (the plane shown in fig. 7) including the longitudinal direction DR2 of the sheet 12 and the radial direction DR3 of the core 11 to the thickness T2 of the 1 st filling part 14 (area S1/thickness T2) is preferably 3.0 or more. If these ratios are 3.0 or more, the total of the area S1 and the area S2 or the area S1 is large relative to the thickness T2, and therefore the sheet 12 can be efficiently lifted by the 1 st filling unit 14, whereby the step can be further reduced. From the viewpoint of further reducing the step difference, the lower limit of these ratios is preferably 4.0 or more, 5.0 or more, 6.0 or more, 7.0 or more, or 8.0 or more. The upper limit of the ratio is not particularly limited, and may be, for example, 50.0 or less, and may be, for example, 17.0 or less.

The sum of the area S1 and the area S2, or the area S1 can be obtained as follows: in the region from the position E2 to the position E3, the product of the thickness t at each measurement point MP and the width d between the measurement points MP is obtained as shown in fig. 11, and the products are summed up. The width between the measurement points can be determined from the sampling period, the rotation speed of the winding core, and the outer diameter of the winding core. Specifically, the width between the measurement points can be obtained by the following equation (3). In equation (3), d (μm) is the width between measurement points, Δ t(s) is the sampling period, r (rpm) is the rotational speed of the core, Φ (mm) is the outer diameter of the core, and π is the circumferential ratio.

d＝ΔT×(r/60)×φ×π×1000…(3)

As described above, the winding core is often reused after the use of the roll body, and therefore, reworkability is required. Therefore, the 1 st filling part 14 is preferably not bonded to the core 11. When the reworkability is good, the winding core is in a state of being reusable after the roll body is used. The "reusable state of the winding core" in the present specification means a state in which: by visually observing the entire outer peripheral surface of the core, there was no deposit that caused the step difference. The method of removal differs depending on the filling material used for the 1 st filling portion. When the crosslinking density is high and the hard layer is hard as in the case of a hard coat layer for display device applications, the thinner the thickness of the edge thickness T1, the easier it is to remove. On the other hand, when the cross-linking density is not so high as to have rubber elasticity, the thicker the edge thickness T1, the easier it is to remove. In either case, it is sufficient to visually confirm that no deposit causing the step difference remains. In addition, "adhesion" in the present specification is a concept including adhesion. Since the 1 st filling part 14 is not adhered to the core 11, the 1 st filling part 14 can be easily peeled off, and thus, excellent reworkability is obtained. More preferably, the 1 st filling part 14 is formed by cleaning or wiping the core 11, or by forming a tip from a blade-like member at the end of the 1 st filling part 14 so as not to damage the core 11, and is gradually peeled from the core 11 with a finger or the like. Further, the 1 st filling part 14 preferably contains substantially no adhesive component.

In a 90 ° peel test in which the constituent material of the 1 st filling part 14 is peeled perpendicularly to the outer peripheral surface 11A of the core 11, it is preferable that the constituent material is peeled from the outer peripheral surface 11A of the core 11 with a tensile force of less than 2.0N. When the constituent material is peeled off with a tensile force of less than 2.0N, the 1 st filling part 14 can be easily peeled off, and thus excellent reworkability is obtained, and when the constituent material is peeled off with a tensile force of 0.3N or less, the 1 st filling part 14 can be more easily peeled off, and thus excellent reworkability is obtained.

The 90 ° peel test was carried out using a sample and a spring type tensiometer (manufactured by Dai Messay instruments, Ltd.). Specifically, first, a mold larger than the sample size is prepared, and the mold is disposed on the outer peripheral surface 11A of the core 11. Then, the coating material for forming the 1 st filling part 14 is poured into the mold and cured as necessary to obtain a material layer. Then, the material layer was taken out from the mold, and cut into a size of 20mm × 100mm by a cutting machine or the like, to obtain 10 samples provided on the outer peripheral surface 11A of the core 11. Then, one end of the sample was held by a spring type tensiometer, and the sample was peeled at a peeling speed of 10 mm/sec by lifting the one end perpendicularly to the outer peripheral surface 11A of the core 11 while measuring the tensile force in an environment where the temperature was 25 ℃ and the relative humidity was 30% or more and 70% or less. Then, the arithmetic average of the tensile forces of 8 samples, except for the sample having the largest tensile force and the sample having the smallest tensile force, out of the 10 samples subjected to the 90 ° peel test was taken as the tensile force of the constituent material.

The tensile strength of the constituent material of the 1 st filling part 14 is preferably 3.0MPa or more. When the tensile strength of the constituent material is 3.0MPa or more, the 1 st filling part 14 is less likely to be torn when the 1 st filling part 14 is peeled off, and good reworkability can be obtained. From the viewpoint of obtaining excellent reworkability, the lower limit of the tensile strength of the constituent material is more preferably 3.2MPa or more or 3.4MPa or more. Further, since the cushioning property of the 1 st filling part is poor when the tensile strength of the constituent material is excessively high, the upper limit of the tensile strength of the constituent material is preferably 16.0MPa or less, 8.0MPa or less, or 5.5MPa or less in order to obtain good cushioning property.

The tensile strength of the above-mentioned constituent material may be determined in accordance with JIS K6251: 2017, and measured using a sample and a Tensilon Universal tester (product name "RTC-1310A", manufactured by A & D Co., Ltd.). Specifically, first, a mold larger than the sample size is prepared, and the mold is disposed on the outer peripheral surface 11A of the core 11. Then, a coating material for forming the 1 st filling part 14 is poured into the mold and cured as necessary to obtain a material layer. Then, the material layer was taken out of the die, and was cut with a cutter (for example, a dumbbell-shaped cutter in a stretched shape No. 2 manufactured by high molecular weight metering instruments) to a thickness of a predetermined range in accordance with JIS K6251: 2017, 10 samples were obtained. Then, the sample was kept at 25 ℃ for 24 hours. Then, the samples were subjected to a tensile test under conditions of an initial inter-grip distance of 20mm and a tensile rate of 100 mm/min in an environment of 25 ℃ and a relative humidity of 30% to 70% with a pair of grips of the Tensilon universal testing machine gripping both end portions in the longitudinal direction of the samples, and the tensile strength of the samples was measured. The arithmetic average of the tensile strengths of 8 samples, excluding the maximum value and the minimum value, out of the 10 samples was taken as the tensile strength of the above-mentioned constituent material.

The elongation at cutting of the constituent material of the 1 st filling part 14 is preferably 200% or more. When the elongation at cutting of the constituent material is 200% or more, the 1 st filling part 14 is easily stretched, and therefore, the 1 st filling part 14 is not easily torn when the 1 st filling part 14 is peeled off, and good reworkability can be obtained. From the viewpoint of obtaining excellent reworkability, the lower limit of the elongation at cutting of the constituent material is more preferably 250% or more, 300% or more, or 350% or more. The upper limit of the elongation at cutting of the constituent material may be 850% or less, 600% or less, or 500% or less. The elongation at cut of the above-mentioned constituent material can be measured in accordance with JIS K6251: 2017, the tensile strength was measured in the same manner as in the tensile strength measurement method using a sample and a Tensilon Universal tester (product name "RTC-1310A", manufactured by A & D Co., Ltd.).

The tear strength of the constituent material of the 1 st filling part 14 is preferably 1.0N/mm or more. When the tear strength of the constituent material is 1.0N/mm or more, the 1 st filling part 14 is not easily torn when the 1 st filling part 14 is peeled off, and good reworkability can be obtained. From the viewpoint of obtaining excellent reworkability, the lower limit of the tear strength of the constituent material is more preferably 2.0N/mm or more, 4.0N/mm or more, 6.0N/mm or more, 8.0N/mm or more, or 10N/mm or more. The upper limit of the tear strength of the constituent material may be 35N/mm or less, 30N/mm or less, or 25N/mm or less. The tear strength of the above-mentioned constituent material may be measured according to JIS K6252: 2007, measurement was performed using the sample and a Tensilon universal tester (product name "RTC-1310A", manufactured by A & D Co., Ltd.). The samples were prepared by the method described in the section of tensile strength.

The hardness of the constituent material of the 1 st filling part 14 measured by a type a durometer is preferably 95 ° or less. Pressure during winding is constantly applied to the end portion of the 1 st filling section, and further pressure may be applied due to a change with time or an environmental change (temperature, humidity, and/or pressure). In order to suppress the step difference caused by the distal end portion of the 1 st filling portion, it is effective that the distal end portion of the 1 st filling portion is thin, but by using a soft resin such that the hardness of the constituent material measured by an a-type durometer is 95 ° or less, the 1 st filling portion is deformed by the pressure at the time of winding the sheet, and the step difference caused by the distal end portion of the 1 st filling portion can be suppressed. The upper limit of the hardness is more preferably 95 ° or less, 80 ° or less, 70 ° or less, or 50 ° or less. On the other hand, in the case where the difference in hardness between the sheet and the 1 st filling portion is large, such as in the case where the sheet is hard and the 1 st filling portion is soft, if the 4 th intervening portion is not present, only the 1 st filling portion is compressed by the pressure at the time of winding the sheet, and the step difference caused by the winding start end portion is not sufficiently reduced, and there is a possibility that a slight deformation may occur in the sheet. Therefore, the lower limit of the hardness is preferably 10 ° or more, 15 ° or more, 20 ° or more, or 25 ° or more.

Hardness measurement by type a durometer in accordance with JIS K6253: 1997. Specifically, first, a mold larger than the sample size is prepared, and the mold is disposed on the outer peripheral surface 11A of the core 11. Then, a coating material for forming the 1 st filling part 14 is poured into the mold and cured as necessary to obtain a material layer. Then, the material layer was taken out of the mold and cut out by a cutting machine or the like to obtain 10 samples having a size of 100mm × 100mm and a thickness of 10 mm. Then, the hardness was measured using a type A durometer (product name "GS-719N (TYPEA)", manufactured by Telock, Ltd.) under an environment of 25 ℃ and 30% to 70% relative humidity. The arithmetic average of the hardnesses of 8 samples, excluding the maximum value and the minimum value, out of the 10 samples was taken as the hardness of the above-described constituent material.

When the sheet is wound, the coating material flows to alleviate the step difference caused by the winding start end portion, but when the coating material is a curable polymer composition, if the coating material shrinks during subsequent curing, particularly when the 4 th intervening portion is not present, the step difference cannot be sufficiently alleviated by the 1 st filling portion, and the sheet may be slightly deformed. Therefore, the linear shrinkage rate of the constituent material of the 1 st filling part 14 is preferably 1.5% or less. When the linear shrinkage ratio of the constituent material is 1.5% or less, the 1 st filling part having excellent dimensional stability can be formed, and therefore, the step can be sufficiently reduced by the 1 st filling part. From the viewpoint of more sufficiently reducing the step difference, the upper limit of the linear shrinkage rate of the 1 st filling part 14 is more preferably 1.3% or less, 1.0% or less, and 0.7% or less. The lower limit of the heat shrinkage rate may be 0% or more.

The linear shrinkage of the above constituent material can be measured as follows. First, a mold having a thickness of 2mm and a size of 130mm square or more was prepared, and a coating material for forming the 1 st filling part 14 was poured into the mold and cured to obtain a sample (molded product). After complete curing, the dimensions of the sample were measured and compared with the dimensions of the inside of the mold, based on JIS K6249: the linear shrinkage rate was obtained in 2003. The arithmetic average of the linear shrinkage rates of 8 samples, excluding the maximum value and the minimum value, out of the 10 samples was taken as the linear shrinkage rate of the above constituent material.

The 1 st filling part 14 can be formed by flowing or deforming a filling material. In the case where the filler shows fluidity, it is not always necessary to show fluidity as long as fluidity is shown before or at the time of winding the sheet. The filler may be a coating material or a filler tape.

The coating material is a coatable material, for example, having fluidity when coated or when wound. The coating material having fluidity includes not only a liquid but also a material which changes from a liquid to a solid, a solid which has fluidity by heating, or a curable material. When the coating material is a curable material, the 1 st filling portion 14 is formed of a cured product of the curable material.

Examples of the coating material include a curable polymer composition, a thermoplastic resin, oil, starch, a binder, an adhesive, and a sol.

Examples of the curable polymer composition include a curable resin composition and a curable rubber composition. When a thermoplastic resin is used as a coating material, it is necessary to be heated to have fluidity during coating and winding.

The filling tape is a tape that becomes the 1 st filling part 14 by filling the 1 st gap 13, and is a tape or a gel tape having a property of spreading by capillary phenomenon under pressure when the sheet 12 is wound. The filler tape is used by being stuck or adhered to the outer peripheral surface 11A of the winding core 11.

As described above, the 1 st filling part is required to have reworkability. Here, if the filler (e.g., coating material) is a sealing material, the sealing material is strongly adhered to the core, and hence the reworkability is poor. On the other hand, since the mold release material is supposed to be taken out from the mold, the reworkability is excellent. Therefore, a mold release material is preferable as a filler (for example, a coating material) from the viewpoint of reworkability.

The shear viscosity of the filler (for example, a coating material) at a shear rate of 1/s at 25 ℃ is preferably 500 pas or less. For example, it is conceivable to adjust the shape of the filler before winding the sheet while spreading the filler (e.g., coating material) applied to the core with a doctor blade or the like. On the other hand, if the shear viscosity of the filler is 500Pa · s or less, the filler can be stretched into a desired shape by the pressure at the time of winding the sheet, and therefore, a special step of stretching the filler can be omitted. The shear viscosity is more preferably 200 pas or less. The shear viscosity is preferably 300Pa · s or less, 100Pa · s or less, or 50Pa · s or less, from the viewpoint of making the filler easily extensible.

On the other hand, from the viewpoint of shortening the strain-relaxation length, the shear viscosity is preferably 10Pa · s or more and 75Pa · s or less, and more preferably 20Pa · s or more and 50Pa · s or less. When the shear viscosity is 10Pa · s or more, the fluidity does not become excessively high, and therefore, the deformation of the sheet 12 can be alleviated, and when it is 75Pa · s or less, the deformation caused by the terminal portion of the 1 st filling portion can be suppressed.

Further, from the viewpoint of further suppressing the overflow of the filler, it is preferable that the shear viscosity is 15Pa · s or more, and further 20Pa · s or more, because the overflow of the filler from between the core 11 and the sheet 12 at the time of application can be suppressed. The shear viscosity is preferably 60 pas or more. If the shear viscosity is 60 pas or more, the fluidity of the filler is low, and the filler can be prevented from flowing out from between the core and the web due to the pressure at the time of application and/or winding.

The shear viscosity of the filler can be measured using a dynamic viscoelasticity measuring apparatus (for example, manufactured by Anton-Paar Japan). Specifically, the shear viscosity is determined by measuring the shear viscosity of the filler at a shear rate of 1[1/s ] 10 times using a parallel plate having a diameter of 25mm in an environment having a temperature of 25 ℃ and a relative humidity of 30% to 70%, and determining the arithmetic mean of 8 shear viscosities excluding the maximum value and the minimum value among the 10 shear viscosities measured.

The filler (e.g., coating material) is preferably free of volatile components such as solvents. By not containing a volatile component in the filler, the shape change such as cracks in the 1 st filling part 14 is small and the sheet mark is less likely to occur.

(coating Material)

The coating material can be applied when the first filling portion 1 is formed, but is preferably a material having low fluidity in the state of the roll 10. In the present specification, "low fluidity in the state of the roll" means that the coating material does not overflow from the roll during transportation or production of the roll. When the 1 st filling part 14 is formed in the 1 st gap 13, it is necessary to be able to apply the coating material, but if the fluidity of the coating material is high in the state of the roll 10, the 1 st filling part may overflow and be contaminated at the time of conveyance, manufacturing, and the like. On the other hand, if the coating material is a material that can be applied when forming the 1 st filling part 14 and has low flowability in the state of the roll 10, the 1 st filling part 14 can be formed in the 1 st gap 13, and the overflow or contamination of the 1 st filling part 14 can be suppressed. As such a material which can be applied when forming the first filling portion 1 but has low fluidity in the state of the roll 10, a curable polymer composition can be cited.

When the coating material is a curable polymer composition, examples of the coating material include an ionizing radiation-curable polymer composition (ionizing radiation-curable resin composition, ionizing radiation-curable rubber composition), a thermosetting polymer composition (thermosetting resin composition, thermosetting rubber composition), a room-temperature-curable polymer composition (polymer composition cured at room temperature of about 20 ° to 30 °) (room-temperature-curable resin composition, room-temperature-curable rubber composition), and the like.

Examples of the room temperature curable polymer composition include a two-component curable polymer composition comprising a base compound and a curing agent, and a one-component curable polymer composition cured by moisture in the air. The portion of the 1 st filling portion that is present in the center of the sheet is in a substantially sealed state in a state in which the sheet is wound, and therefore air is less likely to contact this portion, and there is a possibility that the curing is insufficient. On the other hand, in the case of a two-component curable polymer composition, if the main agent and the curing agent are mixed, the reaction starts, and therefore, the curing can be performed only by time control. The two-component curable polymer composition is preferable to the one-component curable polymer composition in that it is superior in storage stability.

Examples of the ionizing radiation curable polymer composition include compositions containing compounds having an ethylenically unsaturated group such as a (meth) acryloyl group, a vinyl group, or an allyl group. Examples of ionizing radiation to be irradiated when curing the ionizing radiation curable polymer composition include visible light, ultraviolet light, X-rays, electron beams, α -rays, β -rays, and γ -rays.

The ionizing radiation-curable polymer composition includes, for example, an acrylic gel composition which forms an acrylic gel by irradiation with ionizing radiation. The acrylic gel composition includes, for example, ethyl (meth) acrylate, n-propyl (meth) acrylate, isopropyl (meth) acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, n-hexyl (meth) acrylate, n-pentyl (meth) acrylate, isoamyl (meth) acrylate, octyl (meth) acrylate, isooctyl (meth) acrylate, isomyristyl (meth) acrylate, lauryl (meth) acrylate, nonyl (meth) acrylate, isononyl (meth) acrylate, isodecyl (meth) acrylate, tridecyl (meth) acrylate, stearyl (meth) acrylate, isostearyl (meth) acrylate, and the like. In the present specification, "(meth) acrylate" is meant to include both "acrylate" and "methacrylate".

Examples of the thermosetting polymer composition and the room temperature-curable polymer composition include a polyurethane resin composition, an epoxy resin composition, and a silicone composition. Among them, a silicone composition can be preferably used. The silicone composition includes a silicone gel composition and a silicone rubber composition, and both of them are preferable because the step and the deformation can be easily alleviated.

The "silicone gel cured product (silicone gel)" in the present specification, which is obtained by curing a silicone gel composition, is a cured product having an extremely low crosslinking density and containing an organopolysiloxane as a main component, and is a cured product obtained by curing a silicone gel composition according to JIS K2220: 2013(1/4 cone) with a penetration of 10-150. This corresponds to the case where the composition is measured in accordance with JIS K6249: the rubber hardness measurement of 2003 is different from the so-called silicone rubber composition and the silicone rubber cured product (rubber-like elastic body) in that the measurement value (rubber hardness value) is 0 and the hardness is low (i.e., soft) to the extent that an effective rubber hardness value is not exhibited.

The silicone rubber composition includes a one-component curable silicone rubber composition and a two-component curable silicone rubber composition. Among the one-pack curable silicone rubber compositions are condensation reaction curable rubber compositions that cure at room temperature and addition reactive rubber compositions that cure by heating. Further, the two-component curable silicone rubber composition includes a condensation reaction curable rubber composition and an addition reactive rubber composition which are cured at room temperature, and an addition reactive rubber composition which is cured by heating. In addition, the ionizing radiation curable rubber composition may be formed by modifying another resin in the silicone rubber composition. In the present invention, any curing method may be used, and among them, a two-component curable silicone rubber composition is preferable from the viewpoint of uniform curing and excellent storage stability.

Examples of the silicone rubber composition include an RTV (room Temperature vulcanizing) silicone rubber composition. The RTV silicone rubber composition has a smaller shrinkage rate than the ionizing radiation curable polymer composition, has good dimensional stability, and has excellent fluidity before curing, and therefore easily enters a gap between the core 11 and the sheet 12 or the sheet 12, and has low fluidity after curing. Further, since the RTV silicone rubber composition has deep-part curability, it is easy to uniformly perform a curing reaction regardless of the thickness at the time of coating. Further, since the composition is also excellent in releasability, the cured product is easily peeled off and can be reused as a roll.

The RTV silicone rubber composition includes a condensation reaction-curable RTV silicone rubber composition, an addition reaction-curable RTV silicone rubber composition, and the like, depending on the curing reaction mechanism. In the present invention, any of them can be preferably used. In the case of a condensation reaction-curable RTV silicone rubber composition, curing is not inhibited, and therefore, it is preferable that the curing shrinkage is smaller in the case of an addition reaction-curable RTV silicone rubber composition. In the present invention, there is a tendency that: the thickness of the coating material required for alleviating the step difference is increased as the curing shrinkage is larger, and therefore, in particular, an addition reaction curable RTV silicone rubber composition is preferably used for a thin sheet (for example, the sheet 12 has a thickness of 3 to 45 μm).

The RTV Silicone rubber composition is preferably a liquid Silicone rubber lsr (liquid Silicone rubber) because a special processing apparatus is not required.

In order to exhibit desired functions, functional components may be contained in the various compositions. For example, the silicone rubber composition is usually an electrical insulator, and therefore may be electrically charged by contact with the core 11, the sheet 12, or other substances. In this case, the silicone rubber composition may contain a conductive filler. This can prevent foreign matter such as dust from entering, and thus can prevent the foreign matter from causing the step.

Examples of the conductive filler to be mixed into the silicone rubber composition include carbon black (acetylene black, ketjen black), silver powder, gold-plated silica, graphite, conductive zinc oxide, and the like. In recent years, ion-conductive silicone rubbers have also been developed, and these can also be used.

In the silicone gel composition, any component may be blended within a range not impairing the object of the present invention. Examples of the optional component include a reaction inhibitor, an inorganic filler, an organopolysiloxane containing no silicon atom-bonded hydrogen atom and silicon atom-bonded alkenyl group, a heat resistance imparting agent, a flame retardancy imparting agent, a thixotropy imparting agent, a pigment, a dye, and the like.

The reaction inhibitor is a component for inhibiting the reaction of the composition, and specific examples thereof include acetylene-based, amine-based, carboxylate-based, phosphite-based, and the like reaction inhibitors.

Examples of the inorganic filler include: inorganic fillers such as fumed silica, crystalline silica, precipitated silica, hollow fillers, silsesquioxane, fumed titanium dioxide, magnesium oxide, zinc oxide, iron oxide, aluminum hydroxide, magnesium carbonate, calcium carbonate, zinc carbonate, layered mica, carbon black, diatomaceous earth, and glass fibers; and fillers obtained by subjecting these fillers to surface hydrophobization treatment with organosilicon compounds such as organoalkoxysilane compounds, organochlorosilane compounds, organoazane compounds and low-molecular-weight siloxane compounds. Further, silicone rubber powder, silicone resin powder, or the like may be blended.

When the coating material is an adhesive, the adhesive may be a denture stabilizer. Denture stabilizers can be broadly classified into denture adhesives and denture liners, and denture adhesives can be used as the adhesive. In the case of classifying the adhesive as a powder type, a cream type, or a tape type, for example, like a denture adhesive, the adhesive used as a coating material is a powder type or a cream type adhesive.

As for the adhesive, in addition to the adhesive itself exhibiting adhesiveness, adhesiveness can also be exhibited by moisture. The powder type adhesive exhibits adhesiveness by absorbing water when it comes into contact with moisture, for example. The cream-type adhesive is obtained by, for example, making a cohesive powder component into a cream with an ointment base, and exhibits tackiness.

The binder preferably contains a water-soluble polymer. Examples of the water-soluble polymer include, but are not particularly limited to, alginic acid, alginate salts (e.g., sodium alginate, potassium alginate, ammonium alginate, alginate esters, etc.), natural polymer compounds (e.g., gum arabic, tragacanth gum, locust bean gum, xanthan gum, guar gum, agar, gelatin, locust bean gum, carrageenan, etc.), cellulose polymers (e.g., methyl cellulose, sodium carboxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl methyl cellulose, hydroxypropyl cellulose, etc.), polyethylene glycol, polyvinyl pyrrolidone, polyvinyl alcohol, methyl vinyl ether, carboxyvinyl polymer, copolymer of acrylamide and acrylic acid, sodium polyacrylate, polyethylene oxide, and the like. These water-soluble polymers may be used alone in 1 kind, or may be used in combination of 2 or more kinds.

Among the above cellulose-based polymers, sodium carboxymethylcellulose is preferable. Sodium carboxymethylcellulose is the sodium salt of the polybasic carboxymethyl ether of cellulose, also known as sodium carboxymethylcellulose. Sodium carboxymethylcellulose is a powder that hydrates when wetted, exhibiting adhesive or elastic properties, thus imparting further adhesive properties to the adhesive.

The binder as a coating material may further contain an oily base, an aqueous base, a powder base, a gum base, an excipient, an emulsifier, a wetting agent, a pH adjuster, a viscosity adjuster, a plasticizer, a pigment, and the like, as long as the binder can be coated. Examples of such base agents and additives include those which have been widely used in denture stabilizers.

For example, an oily base is used when a binder is prepared in a paste form such as a cream form. Examples of the oily base include mineral oil components (e.g., liquid paraffin, vaseline, gelled hydrocarbon, etc.) generally used in nonaqueous binders (e.g., cream-type binders).

Examples of the cream-type adhesive include New Polygrip (registered trademark) S, New Polygrip (registered trademark) V, New Polygrip (registered trademark) no additive, Polydent (registered trademark) NEO dental stabilizers (all of which are manufactured by Glaxo Smith Kline consumamer Healthcare Japan), Tough Grip-free (registered trademark), and Collect (registered trademark) cut (manufactured by salt wild drug corporation).

When the coating material is an adhesive, the adhesive may be a denture liner (cushion type) of a denture stabilizer. The adhesive enhances adhesion by improving the edge sealing effect. Such an adhesive may contain, for example, a water-insoluble polymer. The water-insoluble polymer is not particularly limited, and examples thereof include polyethylene resins such as vinyl acetate resins.

Examples of the adhesive include Polydent (registered trademark) Cushion (manufactured by Glaxo Smith Kline Consumer Healthcare Japan), Tough Grip (registered trademark) Cushion transparency, Tough Grip (registered trademark) Cushion Pink, Soft Tough Grip (registered trademark) (both manufactured by Xiaolin pharmaceutical Co., Ltd.), Cushion Collet EZ (registered trademark) manufactured by YanYeseyi pharmaceutical Co., Ltd.), New Riodent White, and New Riodent Pink (both manufactured by Lion Corp.), and the like.

When the coating material is a sol, examples of the sol include a silica sol, an alumina sol, and a metal oxide sol such as a zirconia sol, a titania sol, a ceria sol, a tin oxide sol, or a niobium oxide sol.

In order to prevent the coating material from excessively flowing, and to allow the coating material to flow to the vicinity of a position (spaced position) P1 at which the sheet 12 in the 1 st circumference is spaced from the outer circumferential surface 11A of the core 11, the viscosity of the coating material at the time of coating is preferably appropriately adjusted.

The coating material is applied in a linear form, but the amount of the coating material applied per unit width is preferably such that the thicknesses T1 to T3 in the above-described ranges in the 1 st filling part 14 can be obtained. Specifically, for example, the lower limit of the coating amount per unit width of the coating material is preferably 0.2cm³More than m. If the amount of the coating material is too small, air may be mixed in when the coating material is applied by a syringe, and insufficient coating may occur when the coating material is difficult to be discharged from the syringe or when the coating material is applied by running a sheet, for example, but the amount of the coating material is 0.2cm³If the value is larger than/m, such a situation can be suppressed. Further, the upper limit of the coating amount per unit width of the coating material is preferably 3.5cm³And/m is less than or equal to. If the coating amount of the coating material is too large, the coating material may drip or a new step may be generated due to its own weight, but if the coating amount is 3.5cm³If the ratio is less than m, this can be suppressed. The lower limit of the amount of coating is more preferably 0.3cm³More preferably 2.0cm or more, and the upper limit of the coating amount is³Less than or equal to 1.5cm³And/m is less than or equal to.

(filling belt)

Examples of the constituent material of the filling tape include the adhesive, and the gel described in the above-mentioned column of the coating material. Examples of the gel include a silicone gel formed from the silicone gel composition, an acrylic gel formed from the acrylic gel composition, a polyolefin gel, a polyurethane gel, a butadiene gel, an isoprene gel, a butyl gel, a styrene-butadiene gel, an ethylene-vinyl acetate copolymer gel, an ethylene-propylene-diene terpolymer gel, and a fluorine gel. As the filling band, Touch Collect (registered trademark) II (manufactured by salt Seiyi pharmaceutical Co., Ltd.) or α GEL (registered trademark) (manufactured by Taica) can be used, for example.

The length of the filler tape is preferably equal to or greater than the width of the effective area in the width direction DR1 of the winding core 11. By setting the length of the filling tape to such a length, the 1 st filling portion can be formed over the entire width of the effective region, and thus, the step caused by the winding start end portion 12A of the sheet 12 can be alleviated over the entire width of the effective region. From the viewpoint of suppressing the filling tape from running out when the sheet 12 is wound, the filling tape is preferably disposed so as to be separated from both ends of the sheet 12 in the short side direction inward by 1mm or more, 10mm or more, or 30mm or more in the width direction DR1 of the winding core 11. The length of the filler tape means the length of the filler tape in the width direction DR 1.

The width of the filling band is preferably 5mm or more. By setting the width of the filling tape to such a width, the step caused by the winding start end portion 12A of the sheet 12 can be more effectively alleviated. The lower limit of the width of the filling band is more preferably 6mm or more, 7mm or more, or 8mm or more. From the viewpoint of suppressing overlapping of the filler tape, the upper limit of the width of the filler tape is preferably smaller than the outer peripheral length of the core 11. The width of the filling tape is the length of the filling tape in the longitudinal direction DR2 of the sheet 12.

The thickness of the filler tape is preferably equal to or greater than the height of the upper surface 12A2 of the winding start end portion 12A. By setting the thickness of the filler tape to such a thickness, the filler tape can be widely spread when the sheet 12 is wound, and therefore, the step caused by the winding start end portion 12A of the sheet 12 can be more effectively reduced. The thickness of the specific filling tape is, for example, preferably 52 μm or more and 220 μm or less when the thickness of the sheet 12 is 50 μm or more and 200 μm or less, and preferably 50.5 μm or more and 100 μm or less when the thickness of the sheet 12 is 3 μm or more and less than 50 μm.

< filling section 2>

The 2 nd filling part 16 fills the 2 nd gap 15. That is, the 2 nd filling portion 16 contacts the outer peripheral surface 11A of the winding core 11, the back surface 12C of the sheet 12, and the 1 st end surface 17A of the fixing member 17.

The physical properties such as tensile strength of the constituent material of the 2 nd filling part 16 are the same as those of the constituent material of the 1 st filling part 14, and therefore, the description thereof is omitted.

The 2 nd filling part 16 can be formed by applying or deforming a filling material. The filler may be a coating material or a filler tape. The filler, coating material, and filling tape are the same as those described in the filling section 14 of the 1 st embodiment, and therefore, the description thereof is omitted. The constituent material of the 2 nd filling part may be the same as or different from the constituent material of the 1 st filling part 14.

The thickness of the 2 nd filling portion 16 is preferably gradually reduced from the 1 st end surface 17A toward the 1 st peripheral edge of the sheet 12 to the vicinity of the reaching position P2 of the outer peripheral surface 11A of the core 11. By changing the thickness of the 2 nd filling part 16 in this way, a sudden change in the height direction of the sheet 12 can be suppressed, and therefore, a step caused by the fixing member 17 can be alleviated.

Since both end portions 12G of the sheet 12 extending in the longitudinal direction DR2 are not used as a product, the length of the 2 nd filling portion 16 in the width direction DR1 of the winding core 11 may be smaller than the width W2 of the sheet 12 as long as the length is equal to or greater than the effective region for commercialization in the winding body 10.

< 4 th intervening part >

Since the 1 st filling portion tends to be softer than the sheet, if the height of the 1 st filling portion at a position in contact with the distal end surface of the winding start end is the same as the height of the upper surface of the winding start end, there is a possibility that a step is generated at an angle between the distal end surface of the winding start end and the upper surface when the sheet is wound. In contrast, when the 4 th interposed portion 18 is formed, the 4 th interposed portion 18 can absorb the difference in hardness between the 1 st filling portion 14 and the sheet 12, and therefore the step difference in the angle between the distal end surface 12A1 of the winding start end portion 12A and the upper surface 12A2 can be reduced. Further, the presence of the 4 th intervening portion 18 can suppress concentration of stress in a portion of the step difference caused by the winding start end portion 12A, and can smooth the deformation of the sheet 12 after the 3 rd circumference, and thus can alleviate the step difference.

The 4 th interposed portion 18 preferably contains a coloring material and a light emitting material in the same manner as the 1 st filling portion 14. By including the coloring material and the light-emitting material in the 4 th interposed portion 18, the 4 th interposed portion 18 can be easily visually recognized when it overflows from the roll body 10. In addition, the presence of the 4 th interposed part 18 is easily confirmed. The coloring material and the light-emitting material contained in the 4 th interposed portion 18 are the same as those described in the column of the 1 st filling portion 14, and therefore, the description thereof is omitted.

When the sheet 12 is transparent and the 4 th interposed portion 18 is colored, the presence or absence of the 4 th interposed portion 18 can be easily confirmed by visual observation. Specifically, first, the sheet 12 is fed from the roll 10 until the surface of the sheet 12 reaches the 2 nd circumference. Then, in the roll 10 on which the sheet 12 in the 2 nd circumference became the surface, the vicinity of the winding start end portion 12A was visually observed, and whether or not a colored portion was present on the winding start end portion 12A was observed. When a colored portion is present at the winding start end portion 12A, it can be determined that the 4 th intervening portion 18 is present, and when a colored portion is not present, it can be determined that the 4 th intervening portion 18 is not present.

Even when the sheet 12 is transparent and the 4 th interposed portion 18 contains a light-emitting material, the presence or absence of the 4 th interposed portion 18 can be easily confirmed by visual observation in the same manner as described above. When the light-emitting material is a material that emits light by irradiation with light such as ultraviolet light or visible light, the presence or absence of the 4 th intermediate portion 18 is checked by irradiation with light.

When the thickness of the sheet 12 is 50 μm or more and 200 μm or less, the thickness T3 (see fig. 4) of the 4 th interposed portion 18 is preferably 2 μm or more and 110 μm or less. If the thickness T3 of the 4 th interposed portion 18 is within this range, the deformation relaxation length can be shortened while avoiding adverse effects on the winding of the sheet 12. Even when the thickness T3 of the 4 th interposed portion 18 exceeds 110 μm, the deformation relaxing length can be shortened, but the winding of the sheet 12 may be adversely affected.

When the thickness of the sheet 12 is 3 μm or more and less than 50 μm, and further 40 μm or less, the sheet 12 is more likely to be deformed by a step difference due to the winding start end portion 12A than when the thickness of the sheet 12 is thick. Therefore, the thickness T3 of the 4 th interposed part 18 is preferably 0.5 μm or more and 50 μm or less. If the thickness T3 of the 4 th interposed portion 18 is in this range, the deformation relaxing length can be shortened while avoiding adverse effects on the winding of the sheet 12.

The thickness T3 of the 4 th interposed portion 18 is set to the maximum thickness of the 4 th interposed portion 18. The thickness T3 of the 4 th sandwiched portion 18 is measured as follows. First, the portion including the winding start end portion 12A, the 4 th interposed portion 18, and the 2 nd peripheral sheet 12 is selected and fixed so as not to be crushed. Then, the cross section of the fixed portion was polished, and the thickness T3 of the 4 th interposed portion 18 was measured by a solid microscope (for example, product name "digital microscope VHX-7000", manufactured by KEYENCE).

The 4 th interposed portion 18 can be formed by applying or deforming a filler. The filler may be a coating material or a filler tape. The filler, coating material, and filling tape are the same as those described in the filling section 14 of the 1 st embodiment, and therefore, the description thereof is omitted. The constituent material of the 4 th interposed portion 18 may be the same as or different from the constituent material of the 1 st filling portion 14.

Other roll body

The distal end surface 12A1 of the winding start end 12A of the sheet 12 of the roll 10 and the 2 nd end surface 17B of the fixing member 17 are substantially aligned in a cross section along the longitudinal direction DR2 of the sheet 12 and the radial direction DR3 of the winding core 11, but as with the roll 20 shown in fig. 12, the distal end surface 12A1 of the winding start end 12A of the sheet 12 may protrude from the 2 nd end surface 17B of the fixing member 17. In this case, it may be: the 2 nd gap 15 is filled with the 2 nd filling portion 16, and the 3 rd filling portion 22 is located between the outer peripheral surface 11A of the winding core 11 and the back surface 12C of the 1 st peripheral sheet 12 and is filled in the 3 rd gap 21 on the 2 nd end surface 17B side.

< gap No. 3>

The 3 rd gap 21 is a gap contacting the 2 nd end surface 17B of the fixing member 17. Specifically, the 3 rd gap 21 shown in fig. 12 is a gap surrounded by the outer peripheral surface 11A of the winding core 11, the back surface 12C of the 1 st peripheral sheet 12, and the 2 nd end surface 17B of the fixing member 17.

< filling section 3>

The 3 rd filling part 22 is the same as the 2 nd filling part 16 except that it is filled in the 3 rd gap 21, and thus, explanation thereof is omitted.

The roll 10 has the 2 nd filling part 16 filled in the 2 nd gap 15, but from the viewpoint of reducing the step caused by the winding start end 12A of the sheet 12, the 1 st filling part 14 may be filled in the 1 st gap 13, and therefore the 2 nd filling part 16 may not be filled in the 2 nd gap 15 as in the roll 30 shown in fig. 13. The 2 nd gap 15 of the roll 30 is a hollow.

The roll 10 has the 1 st filling part 14 filled in the 1 st gap 13, but from the viewpoint of reducing the step difference caused by the fixing member 17, the 2 nd filling part 16 may be filled in the 2 nd gap 15, and therefore the 1 st filling part 14 may not be filled in the 1 st gap 13 as in the roll 40 shown in fig. 14. The 1 st gap 13 of the roll 40 is a hollow.

The roll 10 includes 1 fixing member 17, but may include 2 or more fixing members as shown in fig. 15. In the roll 50 shown in fig. 15, in addition to the fixing member 17, a fixing member 51 is provided on the 1 st end surface 17A side of the fixing member 17. In the roll 50 shown in fig. 15, since the distal end surface 12A1 of the winding start end 12A of the sheet 12 protrudes beyond the 2 nd end surface 17B of the fixing member 17, in order to suppress a step difference caused by the fixing member 17, it is preferable that the 2 nd gap 15 is filled with the 2 nd filling part 16, and the 3 rd gap 21 is filled with the 3 rd filling part 22. Similarly, in the roll 50 shown in fig. 15, in order to suppress the step caused by the fixing member 51, it is preferable that a2 nd filling part 53 is filled in a2 nd gap 52 on a1 st end surface 51A side to be described later of the fixing member 51, and a 3 rd filling part 55 is filled in a 3 rd gap 54 on a2 nd end surface 51B side to be described later of the fixing member 51.

< fixing Member >

The fixing member 51 has a2 nd end surface 51B opposite to the 1 st end surface 51A. The 1 st end face 51A and the 2 nd end face 51B each extend in the width direction DR1 of the winding core 11. The fixing member 51 is the same as the fixing member 17, and therefore, description thereof is omitted.

< 2 nd gap >

The 2 nd gap 52 is a gap contacting the 1 st end surface 51A of the fixed member 51. Specifically, the 2 nd gap 52 shown in fig. 15 is a gap surrounded by the outer peripheral surface 11A of the winding core 11, the back surface 12C of the 1 st peripheral sheet 12, and the 1 st end surface 51A of the fixing member 51.

< gap No. 3>

The 3 rd gap 54 is a gap contacting the 2 nd end surface 51B of the fixing member 51. Specifically, the 3 rd gap 54 shown in fig. 15 is a gap surrounded by the outer peripheral surface 11A of the winding core 11, the back surface 12C of the 1 st peripheral sheet 12, and the 2 nd end surface 51B of the fixing member 51.

< filling part 2 and filling part 3>

The 2 nd filling part 53 is the same as the 2 nd filling part 16 except that it is filled in the 2 nd gap 52, and thus, explanation thereof is omitted here. The 3 rd filling part 55 is the same as the 2 nd filling part 16 except that it is filled in the 3 rd gap 54, and thus, explanation thereof is omitted.

The roll 10 includes the fixing member 17, but may not include the fixing member 17 as in the roll 60 shown in fig. 15.

In fig. 12, 13, 15, and 16, length L1, length L2, thickness T2, thickness T3, area S1, and area S2 are not shown, but in the

roll

20, 30, 50, and 60, length L1, length L2, thickness T2, thickness T3, (length L1+ L2)/thickness T2, (area S1+ S2)/thickness T2 are the same as in the case of the roll 10.

All of the

wound bodies

20, 30, 50, and 60 include the 4 th interposed portion 18, but may not include the 4 th interposed portion. In this case, the length L1/thickness T2 and the area S1/thickness T2 are the same as those of the roll 10 shown in fig. 7.

In fig. 13, the entire front surface of the fixing member 17 is in close contact with the winding start end portion 12A, but the 1 st filling part 14 may be inserted between the winding start end portion 12A and the fixing member 17 as in the roll body 10 shown in fig. 8.

Method for manufacturing roll

The roll 10 can be manufactured by the following method, for example. First, as shown in fig. 17 (a), the fixing member 17 is disposed on the outer peripheral surface 11A of the winding core 11 along the width direction DR1 of the winding core 11.

After the fixing member 17 is disposed, the

coating materials

201 and 202 are applied to the outer peripheral surface 11A of the core 11 along the width direction DR1 of the core 11 by using a coating device such as a dispenser or a syringe as shown in fig. 17 (B). The coating material 201 is applied so as to contact the 2 nd end surface 17B of the fixing member 17, and the coating material 202 is applied so as to contact the 1 st end surface 17A of the fixing member 17. In this case, for example, 2 coating apparatuses may be used to simultaneously coat the

coating materials

201 and 202.

In the above description, the coating material 201 is applied so as to contact the 2 nd end surface 17B, and the coating material 202 is applied so as to contact the 1 st end surface 17A, but when the wettability of the coating material is high and the viscosity of the coating material is low, if the coating material is applied so as to contact the 2 nd end surface and the 1 st end surface, the coating material may be impregnated between the winding start end portion and the fixing member and wet and spread between the winding start end portion and the back surface of the sheet. The coating material can be controlled to be in a preferable state, but if there is excessive dipping or wet spreading, curing occurs at an uncontrollable position, and as a result, a new step may be generated. Further, when the viscosity of the filler is high (for example, a band-shaped material) or when the wettability of the coating material is low, since the filler or the coating material is likely to be solidified in a state of being wet-spread only to the vicinity of the arrangement when the filler or the coating material is arranged, when the filler or the coating material is not sufficiently wet-spread by winding in the subsequent step, the amount of the material solidified in a state of being thick near the winding start end may increase, and conversely, the step difference may increase. Therefore, the coating material 201 is preferably applied so as to be close to the 2 nd end surface 17B of the fixing member 17, and the coating material 202 is preferably applied so as to be close to the 1 st end surface 17A of the fixing member 17. The "proximity" in the present specification means a position clearly separated from the winding start end or the fixing member. For example, even if the coating material is a material having a low viscosity, the separation distance from the winding start end or the fixing member is preferably 0.3mm or more. The separation distance is preferably 0.5mm or more, and from the viewpoint of the most stability, preferably 1mm or more. If the separation distance is too large, it is difficult to obtain the effect of reducing the step difference, and therefore, it is preferable to adjust the distance within a range in which the 1 st filling part 14 shown in fig. 3 and the like can be formed. For example, the upper limit of the separation distance is preferably 10mm or less, 7mm or less, and more preferably 5mm or less. In addition, if the separation distance exceeds 10mm, the coating material may flow down before the web is wound, depending on the diameter of the core, in addition to the possibility that the 1 st gap is not filled. When the viscosity of the coating material is low, the coating amount can be increased. The separation distance is determined as follows: at measurement 10, the arithmetic mean of the separation distances at 8, except the maximum and minimum, of the 10 measured separation distances is found.

When the viscosity of the coating material is high, the coating material is hard to spread, and therefore, it is preferable that the separation distance is short, and when the viscosity of the coating material is low, if the separation distance is too small, the coating material may be present in a large amount on the fixing member, and if the separation distance is too large, the coating material may not be sufficiently filled in the target gap due to spreading in other directions, and therefore, it is preferable that the separation distance is not too small and is not too large.

In the above, the

coating materials

201 and 202 are applied to both sides of the fixing member 17 simultaneously after the fixing member 17 is disposed on the outer peripheral surface 11A of the core 11, but the application of the

coating materials

201 and 202 and the disposition of the fixing member 17 may be performed in the order of the following manufacturing methods (1) to (3). Among them, the following production method (2) is preferable. The same applies to

coating materials

204 and 205 described later.

The production method (1) is a method of: after the fixing member 17 is disposed on the outer peripheral surface 11A of the winding core 11, the coating material 201 is applied to the fixing member 17 at the 2 nd end surface 17B side so as to be separated by the distance, and then the coating material 202 is applied to the fixing member 17 at the 1 st end surface 17A side so as to be separated by the distance.

The production method (2) is a method of: after the coating material 201 is applied to the outer peripheral surface 11A of the winding core 11, the fixing member 17 is disposed at the distance from the coating material 201, and then the coating material 202 is applied to the fixing member 17 on the side opposite to the coating material 201 at the distance from the fixing member 17. By performing the application of the

coating materials

201 and 202 and the arrangement of the fixing member 17 in this order, it is possible to stably arrange the coating materials with a distance therebetween, and it is possible to suppress the application of an excessive amount of the

coating materials

201 and 202 to the fixing member 17, and therefore it is possible to suppress the occurrence of a new step in the fixing member 17.

The production method (3) is a method of: after coating

materials

201 and 202 are applied to the outer peripheral surface 11A of the winding core 11 at a predetermined interval, a fixing member 17 is disposed between the

coating materials

201 and 202.

In the case where the 1 st filling part 14 is formed but the 2 nd filling part 16 is not formed, it is preferable that the coating material 201 is first applied, and then the fixing member 17 is disposed at the distance from the coating material 201, and in the case where the 2 nd filling part 16 is formed but the 1 st filling part 14 is not formed, it is preferable that the coating material 202 is first applied, and then the fixing member 17 is disposed at the distance from the coating material 202.

The

coating materials

201 and 202 are preferably applied to the width of the effective area or more in the width direction DR1 of the core 11. By applying the

coating materials

201 and 202 in this way, the coating materials 201 to 205 can be present in the 1 st filling part and the 2 nd filling part over the entire width of the effective region, and thus, the step difference caused by the winding start end portion of the sheet 12 and the step difference caused by the fixing member 17 can be alleviated over the entire width of the effective region. From the viewpoint of suppressing the

coating materials

201 and 202 from overflowing when the sheet 12 is wound, the

coating materials

201 and 202 are preferably applied so as to be separated from both ends in the short side direction of the sheet 12 toward the inside in the width direction DR1 of the core 11 by 1mm or more, 10mm or more, or 30mm or more.

The coating material 201 is preferably coated so that the width of the coating material 201 is 5mm or more, 10mm or more, or 30mm or more. By applying the coating material 201 in this manner, the step caused by the winding start end portion 12A of the sheet 12 can be more effectively reduced. From the viewpoint of suppressing overlapping of the coating materials, the upper limit of the width of the coating material 201 is preferably smaller than the outer circumference of the core 11.

The coating material 202 is preferably coated so that the width of the coating material 202 is 0.5mm or more, 1mm or more, or 5mm or more. By applying the coating material 202 in this manner, the step caused by the fixing member 17 can be more effectively reduced. From the viewpoint of suppressing the overlapping of the coating materials, the upper limit of the width of the coating material 202 is preferably smaller than the outer peripheral length of the core 11.

The coating material 201 is preferably applied so that the thickness of the coating material 201 is equal to or greater than the height of the upper surface 12A2 of the winding start end portion 12A. By applying the coating material 201 in this way, a sufficient amount of the coating material 201 can be applied, and thus the step caused by the winding start end portion 12A of the sheet 12 can be more effectively reduced. The thickness of the specific coating material 201 is, for example, preferably 52 μm or more and 2000 μm or less when the thickness of the sheet 12 is 50 μm or more and 200 μm or less, and preferably 50.5 μm or more and 2000 μm or less when the thickness of the sheet 12 is 3 μm or more and less than 50 μm. The thickness of the coating material 201 is the thickness before the sheet 12 is wound.

The coating material 202 is preferably applied so that the thickness of the coating material 202 becomes equal to or more than the height of the front surface of the fixing member 17. By applying the coating material 202 in this manner, a sufficient amount of the coating material 202 can be applied, and thus the step caused by the fixing member 17 can be more effectively reduced. The lower limit of the thickness of the coating material 202 is preferably 3 μm to 12 μm when the thickness of the fixing member 17 is 3 μm to 10 μm. The thickness of the coating material 202 is the thickness before the sheet 12 is wound.

After the

coating materials

201, 202 are applied, as shown in fig. 18 (a), the winding start end portion 12A is disposed such that the distal end surface 12A1 of the winding start end portion 12A of the sheet 12 is in contact with the coating material 201 and the sheet 12 covers the coating material 202. Specifically, the winding start end portion 12A of the sheet 12 is attached to the fixing member 17, and the winding start end portion 12A is fixed to the outer peripheral surface 11A of the winding core 11 via the fixing member 17.

After the winding start end portion 12A of the sheet 12 is fixed to the core 11, the sheet 12 is wound along the outer peripheral surface 11A of the core 11 as shown in fig. 18 (B). When the sheet 12 is wound, the

coating materials

201 and 202 flow and spread, and therefore the coating material 201 is filled in the 1 st gap 13 and the coating material 202 is filled in the 2 nd gap 15, and the 1 st filling portion 14 filled in the 1 st gap 13 and the 2 nd filling portion 16 filled in the 2 nd gap 15 are formed. Thereby, the roll 10 is obtained. In order to reliably expand the coating material 201 and the like and fill the 1 st gap 13 and the like, it is preferable to wind the sheet 12 over 1000m when the sheet 12 exceeds 1000m, and wind the entire length of the sheet 12 when the sheet 12 is less than 1000 m.

In the case where the

coating materials

201 and 202 are curable polymer compositions, the curable polymer compositions are cured after the sheet 12 is wound for at least the 2 nd circumference. In the case where the curable polymer composition is a one-component curable polymer composition (moisture-curable polymer composition), the composition can be cured by reacting with humidity in the air and leaving the composition at room temperature, and thus can be cured without using a special apparatus such as a heating apparatus or an ionizing radiation irradiation apparatus. In the case where the curable polymer composition is a two-component curable polymer composition, the main component and the curing agent may be mixed and cured.

The roll 20 can be manufactured by the following method, for example. First, the fixing member 17 is disposed on the outer peripheral surface 11A of the winding core 11 along the width direction DR1 of the winding core 11.

After the fixing member 17 is disposed, the coating material 203 to 205 is applied to the outer peripheral surface 11A of the core 11 along the width direction DR1 of the core 11 by using a coating device such as a dispenser or a syringe, as shown in fig. 19 (a). The coating material 204 is applied so as to contact the 1 st end surface 17A of the fixing member 17, and the coating material 205 is applied so as to contact the 2 nd end surface 17B of the fixing member 17. The coating material 203 is applied to a portion separated from the 2 nd end surface 17B of the fixing member 17 and the coating material 205. The coating material 203 may be applied so as to be close to the distal end surface 12A1 of the winding start end 12A of the sheet 12, the coating material 204 may be applied so as to be close to the 1 st end surface 17A of the fixing member 17, and the coating material 205 may be applied so as to be close to the 2 nd end surface 17B of the fixing member 17. Further, the coating materials 203 to 205 are applied after the fixing member 17 is disposed on the outer peripheral surface 11A of the core 11, but the fixing member 17 may be disposed such that the coating material 204 comes into contact with or approaches the 1 st end surface 17A of the fixing member 17 and the coating material 205 comes into contact with or approaches the 2 nd end surface 17B of the fixing member 17 after the coating materials 203 to 205 are applied.

After the coating materials 203 to 205 are applied, as shown in fig. 19 (B), the winding start end portion 12A is disposed such that the distal end surface 12A1 of the winding start end portion 12A of the sheet 12 is in contact with the coating material 203 and the sheet 12 covers the

coating materials

204 and 205, respectively. Specifically, the winding start end portion 12A of the sheet 12 is attached to the fixing member 17, and the winding start end portion 12A is fixed to the outer peripheral surface 11A of the winding core 11 via the fixing member 17.

After the winding start end portion 12A of the sheet 12 is fixed to the core 11, the sheet 12 is wound along the outer peripheral surface 11A of the core 11 as shown in fig. 19 (C). When the sheet 12 is wound, the coating materials 203 to 205 flow and spread, so that the coating material 203 fills the 1 st gap 13, the coating material 204 fills the 2 nd gap 15, and the coating material 205 fills the 3 rd gap 21, thereby forming the 1 st filling portion 14 filling the 1 st gap 13, the 2 nd filling portion 16 filling the 2 nd gap 15, and the 3 rd filling portion 22 filling the 3 rd gap 21. Thereby, the roll 20 is obtained. In order to reliably expand the coating material 203 and the like and fill the 1 st gap 13 and the like, it is preferable to wind the sheet 12 over 1000m when the sheet 12 exceeds 1000m, and wind the entire length of the sheet 12 when the sheet 12 is less than 1000 m.

In the above-described manufacturing methods, the coating materials 201 to 205 are fluidized by winding the sheet 12, but the coating material 201 and the like may be fluidized in advance before winding the sheet 12. However, since the number of steps increases when the coating material 201 and the like are fluidized before the sheet 12 is wound, it is preferable to fluidize the coating materials 201 to 205 by winding the sheet 12.

In the above-described manufacturing method, the coating materials 201 to 205 are applied using an application device such as a dispenser or a syringe, but the coating materials 201 to 205 may be applied using a die having a slit together with the application device. By coating the coating materials 201 to 205 using a die having a slit, local variations in thickness, width, and the like of the coating materials 201 to 205 can be reduced. The material of the mold is not particularly limited, and examples thereof include resin and metal.

Specifically, first, as shown in fig. 20 (a), a mold 210 having a slit 210A is prepared. The die 210 is used to apply the coating material 201. The length, width, and depth of the slit 210A are the same as those of the coating material 201, and therefore, the description thereof is omitted.

After the mold 210 is prepared, as shown in fig. 20 (B), the mold is disposed on the outer peripheral surface 11A of the core 11 along the width direction DR1 of the core 11. The mold 210 is configured to: when the mold 210 is viewed from directly above, the inner surface of the slit on the side of the fixing member 17 in the width direction overlaps or approaches the 2 nd end surface 17B of the fixing member 17.

After the die 210 is disposed on the outer peripheral surface 11A of the core 11, the coating material 201 is supplied into the slit 210A as shown in fig. 20 (B) by using a coating device such as a dispenser or a syringe. The application device may be a dispenser or a syringe, but also a spray or die coater. Then, if necessary, the excess coating material 201 existing on the surface of the mold 210 is scraped off by a doctor blade or the like. Then, the mold 210 is removed, whereby the coating material 201 can be disposed on the outer peripheral surface 11A of the core 11. The subsequent steps are the same as the above-described steps for the

roll bodies

10 and 20. The coating materials 202 to 205 may be arranged in the same order using a die 210 having a slit 210A.

Instead of applying the coating materials 201 to 205, a filler tape may be disposed on the outer peripheral surface 11A of the core 11. Specifically, as shown in fig. 21 (a), a coating material 201 is applied to the front surface of a base material 221 in a band-like shape by a coating device such as a dispenser or a syringe, thereby forming a laminate 220 including the base material 221 and a filler tape 222 made of the coating material 201. Here, the filling tape 222 is formed of the coating material 201, but the coating material 201 may not be used as long as the filling tape is formed of a material that expands by the pressure at the time of winding the sheet.

The material of the substrate 221 is not particularly limited, and examples thereof include polyester resins such as polyethylene terephthalate, cellulose resins such as triacetyl cellulose, and acrylic resins. A known release film may be used as the substrate 221. When the coating material 201 is applied to the front surface of the base 221, it is preferable that the pair of bit lines 221A are drawn in advance on the base 221 and the coating material 201 is applied along the pair of bit lines 221A. By providing the pair of bit lines 221A on the base 221 in advance, the positional displacement of the coating material 201 can be suppressed. When the coating material 201 is applied to the front surface of the base material 221, the base material 221 is preferably wound out at a constant speed by using a winding-out apparatus while the coating apparatus is fixed. By winding out the base material 221 at a constant speed, coating unevenness can be suppressed.

After the laminated body 220 is formed, as shown in fig. 21 (B), the laminated body 220 is stuck or brought into close contact with the outer peripheral surface 11A of the core 11 so that the filler tape 222 is in contact with the outer peripheral surface 11A of the core 11. The filler tape 222 is adhered or closely attached so as to be in contact with or close to the 2 nd end surface 17B of the fixing member 17. Then, the base material 221 is peeled off. This allows the filler tape 222 to be disposed on the outer peripheral surface 11A of the winding core 11. The subsequent steps are the same as the above-described steps for the

roll bodies

10 and 20.

In the above, the laminate having 1 base material and the filler tape was formed, but a laminate having 2 base materials, a filler tape and a thickness adjusting member may be formed. Specifically, as shown in fig. 22 (a), the coating material 201 is applied to the front surface of the 1 st base material 231 by a coating device such as a dispenser or a syringe.

Then, as shown in fig. 22 (B), the 2 nd base material 233 is stacked from above the coating material 201 so as to sandwich the coating material 201 and the thickness adjusting member 232 having a desired thickness for making the coating material 201 have a desired thickness, thereby forming the laminated body 230. Examples of the thickness adjusting member 232 include a spacer and a particle. The peel strength of the 2 nd base material 233 from the coating material 201 is preferably smaller than the peel strength of the 1 st base material 231 from the coating material 201. By satisfying such a relationship, the 2 nd base material 233 can be easily peeled. The peel strength of the 2 nd base material 233 was measured by the following measurement method using a tensile tester (product name "single column type material tester STA-1150", manufactured by a & D corporation). To measure the peel strength, first, a double-sided tape (No. 751B, manufactured by Temple of Kyoto Co., Ltd.) was attached to a glass plate having a length of 30cm X a width of 2.5 cm. On the other hand, the laminate 230 was cut into a size of 200mm in length × 25mm in width, and the 1 st base material 231 side was adhered with a double-sided tape on a glass plate, and held by a pair of jigs of a tensile testing machine. Then, the laminate 230 bonded to the glass plate is held by a pair of jigs of a tensile tester. When the laminate 230 is held by the jig, the 2 nd base material 233 is slightly peeled from the laminate 230 by a human hand to prepare a starting end, one jig holds the 2 nd base material 233, and the other jig holds the glass plate and the laminate 230. Then, in this state, the 2 nd base material 233 was peeled under the conditions of a peeling speed of 300 mm/min, a peeling distance of 50mm, and a peeling angle of 180 °, and the peeling strength of the coating material 201 and the 2 nd base material 233 at this time was measured. The peel strength is an arithmetic average of 3 measured values. The peel strength of the 1 st base material 231 was also measured in the same manner as the peel strength of the 2 nd base material 233. As the 1 st base material 231 and the 2 nd base material 233, the same base material as the base material 221 can be used.

After the laminated body 230 is formed, a predetermined pressure is applied to the laminated body 230. Thereby, the thickness of the coating material 201 becomes a desired thickness. Then, the stacked body 230 is cut into a tape shape. Thereby, the laminate 230 having the filler tape 234 made of the coating material 201 is formed.

Thereafter, as shown in fig. 22 (C), the 2 nd base material 233 is peeled off. In this state, as shown in fig. 22 (D), the laminate 230 is stuck or brought into close contact with the outer peripheral surface 11A of the core 11 so that the filler tape 234 comes into contact with the outer peripheral surface 11A of the core 11. The filler tape 234 is adhered or closely attached to the 2 nd end surface 17B of the fixing member 17 so as to be in contact with or close to it. Then, the 1 st substrate 231 is peeled off. This allows the filler tape 234 to be disposed on the outer peripheral surface 11A of the winding core 11. The subsequent steps are the same as the above-described steps for the

roll bodies

10 and 20. The filler tape can be disposed on the outer peripheral surface 11A of the core 11 in the same order as the filler tape 234 instead of the coating materials 202 to 205.

In addition, the transfer may be performed while forming the filling band using a mold. By transferring the filling tape using the mold, the filling tape can be easily provided at the same time as the fixing member 17. Specifically, first, as shown in fig. 23 (a), a mold 241 is prepared. The mold 241 has an opening 241A. The mold 241 is preferably opened so that the side surface of the mold 241 in the longitudinal direction can be easily removed from the mold 241. The mold 241 is U-shaped, for example. The mold 241 is not particularly limited, and may be formed of, for example, resin, metal, or the like. The length, width, and depth of the opening 241A of the mold 241 are the same as those of the filling band, and therefore, description thereof is omitted here.

After the mold 241 is prepared, as shown in fig. 23 (B), the coating material 201 is poured into the mold 241 to form the filling band 242. Then, as shown in fig. 23 (C), the mold 241 is pressed so that the filling tape 242 contacts the outer peripheral surface 11A of the core 11. When the coating material 201 is a material exhibiting adhesiveness due to moisture when the mold 241 is pressed, the surface of the filling tape 242 is preferably wetted with water in advance to be pasted. The surface of the filler tape 242 is pasted and adhered to the outer peripheral surface 11A of the winding core 11.

The mold 241 is then removed from the filler strip 242. This enables the filler tape 242 to be disposed on the outer peripheral surface 11A of the winding core 11. The subsequent steps are the same as the above-described steps for the

roll bodies

10 and 20. The filler tape can be disposed on the outer peripheral surface 11A of the core 11 in the same order as the filler tape 242 in place of the coating materials 202 to 205.

The filler tape may be transferred to the outer peripheral surface 11A of the core 11 by offset printing. By forming the filler tape by offset printing and transferring, time management becomes easy, and the filler tape can be set at a set time and position with high accuracy. Specifically, first, as shown in fig. 24 (a), a coating material 201 is applied to an outer peripheral surface of an intermediate transfer body 251 (for example, an intermediate transfer roller) by a coating device such as a dispenser or a syringe to form a filling belt 252. Then, as shown in fig. 24 (B), the filler tape 252 formed on the outer peripheral surface of the intermediate transfer body 251 is transferred to the outer peripheral surface 11A of the core 11 by an offset printing method. This enables the filler tape 252 to be disposed on the outer peripheral surface 11A of the winding core 11. The subsequent steps are the same as the above-described steps for the

roll bodies

10 and 20. The filler tape can be disposed on the outer peripheral surface 11A of the core 11 in the same order as the filler tape 252 in place of the coating materials 202 to 205.

According to the present embodiment, since the 1 st gap 13 is filled with the 1 st filling part 14, the part of the 1 st peripheral sheet 12 on the 1 st filling part 14 can be gently lifted from the separation position P1 toward the distal end surface 12a 1. This can alleviate the step caused by the winding start end 12A of the sheet 12.

According to the present embodiment, since the 2 nd filling part 16 is filled in the 2 nd gap 15, the part of the sheet 12 in the 1 st circumference on the 2 nd filling part 16 can be gently lowered from the 1 st end surface 17A toward the reaching position P2. This can effectively reduce the step caused by the fixing member 17.

In the roll 20, since the 3 rd gap 21 is filled with the 3 rd filling part 22, the part of the sheet 12 in the 1 st circumference on the 3 rd filling part 22 can be gently lifted. This can more effectively reduce the step caused by the fixing member 17.

When the sheet is deformed, the sheet has a portion that cannot be used as a product, and therefore, the effective length of the sheet is compensated for to ensure the effective length. That is, if the portion of the sheet that is not a product due to deformation becomes long, the sheet loss increases. In contrast, according to the present embodiment, since the step caused by the winding start end portion 12A of the sheet 12 and the step caused by the fixing members 17 and 51 can be alleviated, the deformation of the sheet 12 can be suppressed. This can reduce sheet loss.

Hereinafter, a roll body according to embodiment 2 of the present invention will be described with reference to the drawings. Fig. 25 is a perspective view of the roll of the present embodiment, fig. 26 is an enlarged view of a part of the roll of fig. 25, fig. 27 is a view for explaining the dimensions of each constituent element of the roll of fig. 25, fig. 28 is a view when the maximum thickness and length of the 2 nd interposed portion shown in fig. 25 are measured, and fig. 29 is a view showing a cross-sectional area S3. Fig. 30 to 37 are enlarged views of a part of another roll of the present embodiment, and fig. 38 and 39 are views schematically showing a manufacturing process of the roll of the present embodiment.

Scroll(s) < >

The roll body 70 shown in fig. 25 includes a winding core 11 and an elongated sheet material 12 wound around an outer peripheral surface 11A of the winding core 11. As shown in fig. 25, the roll body 70 further includes: a1 st nip portion 71 and a2 nd nip portion 72 provided between the sheets 12 after the 1 st week; and a fixing member 17 for fixing a part of the web 12 to the core 11. The sheet 12 is wound around the core 11 for a plurality of turns, for example, 2 turns or more. Since the 1 st gap 13 and the 2 nd gap 15 are hollow, the 1 st gap 13 is not filled with the 1 st filling part 14, and the 2 nd gap 15 is not filled with the 2 nd filling part 16 in the roll 70.

< 1 st clamping part >)

The 1 st nip portion 71 is provided between the sheets 12 after the 1 st week. Specifically, the 1 st interposed portion 71 is sandwiched between the lower sheet 12 positioned below the 1 st interposed portion 71 (on the core 11 side) and in contact with the 1 st interposed portion 71, and the upper sheet 12 positioned above the 1 st interposed portion 71 and in contact with the 1 st interposed portion 71. Therefore, the sheet 12 is inevitably present in the 1 st nip portion 71. The 1 st interposed portion 71 is provided between the sheets 12 in the 1 st and subsequent cycles, and specifically, the 1 st interposed portion 71 is provided at least in the 1 st region 12D corresponding to the 1 st gap 13 between the sheets 12 in the 1 st and subsequent cycles. Further, the 1 st interposed portion 71 extends in the width direction DR1 of the winding core 11.

The thickness of the edge T4 (see fig. 27) of the end portion 71A of the 1 st interposed section 71 on the separation position P3 (see fig. 26) side where the upper sheet 12 is separated from the lower sheet 12 is preferably small because a new step may be formed due to the thickness. Specifically, for example, the edge thickness T4 is preferably 50 μm or less. From the viewpoint of shortening the strain-relaxation length, the edge thickness T4 is more preferably 10 μm or less, and still more preferably 2 μm or less.

In addition, in the case where the sheet 12 is a film having a thickness of 3 μm or more and less than 50 μm, since the sheet is more susceptible to the influence of the step caused by the winding start end portion 12A than in the case where the sheet is thick, the edge thickness T4 is preferably 10 μm or less, and more preferably 5 μm or less, and still more preferably 1 μm or less, in the case where such a film is used, from the viewpoint of minimizing the deformation relaxation length.

The edge thickness T4 can be measured by the same method as that of the edge thickness T1 using a scanning optical interference profilometer (product name "New View 7300", manufactured by Zygo). In addition, the measurement can be performed as follows. First, a portion including the end 71A, the lower sheet 12 in contact with the end 71A, and the upper sheet 12 is cut out, and a cross section of the portion is obtained by cutting or grinding with a cutter, and measurement is performed by observation with a solid microscope (for example, product name "digital microscope VHX-7000", manufactured by KEYENCE corporation).

As shown in fig. 26 and 27, the 1 st intermediate portion 71 includes: a1 st portion 71B interposed in a1 st region 12D corresponding to the 1 st gap 13; and a2 nd portion 71C located on the reaching position P4 (see fig. 26) side where the sheet 12 on the upper side of the 1 st portion 71B reaches the sheet 12 on the lower side. The 1 st interposed portion 71 includes not only the 1 st portion 71B but also the 2 nd portion 71C, and thus can suppress concentration of stress at a portion of the step difference caused by the winding start end portion 12A, and can smooth the deformation of the sheet 12 on the upper side and the sheet 12 thereafter, and thus can alleviate the step difference.

The thickness T5 (see fig. 27) of the 2 nd portion 71C is preferably 2 μm or more and 300 μm or less. If the thickness T5 of the 2 nd portion 71C is within this range, the adverse effect on the winding of the sheet 12 can be avoided, and the above-described deformation relaxing length can be shortened. In addition, even when the thickness T3 of the 2 nd portion 71C exceeds 300 μm, the deformation relaxing length can be shortened, but the winding of the sheet 12 may be adversely affected.

The thickness T5 of portion 2 71C is the maximum thickness of portion 2 71C. The thickness T5 of the 2 nd part 71C can be measured by the same method as the edge thickness T1 using a scanning type optical interference profilometer (product name "New View 7300", manufactured by Zygo corporation). Alternatively, the measurement may be performed as follows. First, the portion including the lower sheet 12, the 2 nd portion 71C, and the upper sheet 12 is selected and fixed so as not to be crushed. Then, the section of the fixed portion was ground, and the thickness T5 of the 2 nd portion 71C was measured by a solid microscope (for example, product name "digital microscope VHX-7000", manufactured by KEYENCE Co., Ltd.).

If the thickness of the 1 st interposed portion changes abruptly, the portion of the thickness that changes may remain deformed, and the step caused by the winding start end portion may not be sufficiently reduced. Therefore, it is preferable to secure a sufficient length of the 1 st nip portion with respect to the thickness of the sheet. However, when the length of the 1 st interposed portion is increased to cause other influences such as winding, the deformation relaxing length is increased as compared with a state in which the length of the 1 st interposed portion is optimal, but the deformation relaxing length can be shortened as compared with a state in which the length of the 1 st interposed portion is not provided, by intentionally making the length of the 1 st interposed portion shorter than the optimal state. Therefore, it is preferable that the ratio (length L3/distance D2) between the length L3 of the 1 st interposed portion 71 from the position corresponding to the distal end surface 12A1 to the end portion on the side of the separation position P3 and the distance D2 (see fig. 27) from the outer peripheral surface 11A of the core 11 to the upper surface 12A2 of the winding start end portion 12A is 1 or more. From the viewpoint of shortening the deformation relaxation length, the ratio is preferably 5 or more, and more preferably 50 or more.

The length L3 may be measured as follows. First, the lower sheet 12 and the upper sheet 12 are left, and the other sheets 12 are wound out. Here, if the sheet 12 is transparent or translucent, the region where the 1 st sandwiched portion 71 exists can be visually confirmed. Therefore, the length L3 is obtained by measuring the distance from the distal end surface 12A1 of the winding start end 12A to the end on the separation position P3 side of the 1 st interposed portion 71 at 10 points in the width direction of the sheet 12 by using a ruler or a tape measure while observing the sheet 12 through the sheet 12. On the other hand, when the sheet 12 cannot be seen through, first, a portion including the lower sheet 12, the 1 st interposed portion 71, and the upper sheet 12 is selected so as not to be crushed. Then, this portion was fixed, polished to form a cross section, and the distance from the position corresponding to the distal end surface 12a1 to the end on the side of the separation position of the 1 st intermediate section was measured with a solid microscope (for example, product name "digital microscope VHX-7000", manufactured by KEYENCE corporation).

The longer the length L3, the better, for example, when the thickness of the sheet 12 is 50 μm or more and 200 μm or less, the length L3 is preferably 110 μm or more, and in order to further shorten the deformation relaxation length, it is preferably 1mm or more, and more preferably 10mm or more.

The physical properties such as tensile strength of the constituent material of 1 st interposed portion 71 are the same as those of the constituent material of 1 st filling portion 14, and the material of 1 st interposed portion 71 is the same as that of 1 st filling portion 14, and therefore, the description thereof is omitted.

2 nd clamping part

The 2 nd nip portion 72 is provided between the sheets 12 after the 1 st week. Therefore, the sheet 12 is always present in the 2 nd nip portion 72. The 2 nd interposed portion 72 is provided between the sheets 12 in the 1 st and subsequent cycles, and specifically, the 2 nd interposed portion 72 is provided in the 2 nd area 12E corresponding to at least the 2 nd gap 15 between the sheets 12 in the 1 st and subsequent cycles. The 2 nd interposed portion 72 extends in the width direction DR1 of the winding core 11.

The 2 nd interposed portion 72 is provided between the same sheets 12 as the 1 st interposed portion 71 (for example, between the sheet 12 in the 2 nd circumference and the sheet 12 in the 3 rd circumference), but the 2 nd interposed portion 72 may be provided between sheets 12 different from the 1 st interposed portion 71.

The maximum thickness T6 (see fig. 27 and 28) of the 2 nd interposed portion 72 is preferably 0.01mm or more. If the maximum thickness T6 of the 2 nd interposed portion 72 is 0.01mm or more, the step caused by the fixing member 17 can be effectively reduced. From the viewpoint of more effectively reducing the step difference, the maximum thickness T6 is more preferably 0.02mm or more, 0.03mm or more, or 0.04mm or more. On the other hand, if the maximum thickness T6 is too thick, the step difference caused by the winding start end portion 12A can be reduced, but the winding of the sheet 12 may be adversely affected. Therefore, the upper limit of the maximum thickness T6 is preferably 0.2mm or less or 0.1mm or less.

The maximum thickness T6 can be measured by the same method as the thickness T2 using a laser displacement meter or a solid microscope. When the maximum thickness T6 is measured by the laser displacement meter, first, the roll 70 is attached to a jig and 3 laser displacement meters are arranged at predetermined positions, as in the measurement of the thickness T2 and the like, and thereafter, the sheet 12 is fed until the 2 nd interposed portion 72 is exposed from the roll 70. Then, while the 2 nd intermediate unit 72 is exposed, the displacement amount is continuously measured by a laser displacement meter at a sampling period of 200 μ s while the core 11 is rotated at a rotation speed of 30mm/s, and a graph is obtained in which the horizontal axis is set to the position (mm) and the vertical axis is set to the displacement amount (mm). In the measurement, the reference height (line where the displacement amount is 0 mm) is set as the height of the core 11, and the difference between the reference height and the height of the 2 nd intermediate portion 72 is set as the thickness of the 2 nd intermediate portion 72, from the 2 nd end 72B of the 2 nd intermediate portion 72 opposite to the 1 st end 72A on the side of the fixed member 17 toward the 1 st end 72A. Then, the maximum thickness T6 of the 2 nd intermediate portion 72 is determined by determining the difference between the line of the displacement amount of 0mm and the displacement amount at the position where the displacement amount is the highest. The graph obtained substantially represents a plane containing the longitudinal direction of the sheet and the radial direction of the winding core. In the graph, 1 scale on the horizontal axis is set to 5mm, and 1 scale on the vertical axis is set to 0.02 mm. In fig. 27, the 1 st end 72A exists directly above the fixing member 17.

The measurement of the maximum thickness T6 based on a solid microscope can be performed as follows. First, a portion including the lower sheet 12, the 2 nd nip portion 72, and the upper sheet 12 is selected and fixed so as not to be crushed. Then, the cross section of the fixed portion was polished, and the maximum thickness T6 of the 2 nd intermediate unit 72 was measured by a solid microscope (for example, product name "digital microscope VHX-7000", manufactured by KEYENCE corporation).

When the thickness of the 2 nd interposed portion 72 is measured along the longitudinal direction DR2 of the sheet 12, the ratio (length L4/maximum thickness T6) between the length L4 (see fig. 27) from the 2 nd end 72B of the 2 nd interposed portion 72 to the position where the maximum thickness T6 of the 2 nd interposed portion 72 is obtained in the longitudinal direction DR2 and the maximum thickness T6 (see fig. 27 and 28) of the 2 nd interposed portion 72 is preferably 12 or more. If the ratio is 12 or more, residual deformation in the vicinity of the 2 nd end 72B of the 2 nd interposed portion 72 can be suppressed, and if the thickness of the 2 nd interposed portion is too thick, the windability may be deteriorated due to, for example, coming off from a perfect circle during winding, but if the ratio is 12 or more, the 2 nd interposed portion 72 is not too thick, and thus the windability can be suppressed from being deteriorated. Further, if the thickness of the 2 nd intervening portion is too thick, there is a possibility that a new deformation may occur due to the 2 nd intervening portion, but if the ratio is 12 or more, it is possible to suppress the occurrence of such a new deformation. From the viewpoint of shortening the deformation relaxation length, the lower limit of the ratio is preferably 25 or more, 50 or more, 75 or more, 100 or more, 125 or more, 150 or more, 175 or more, or 200 or more. From the viewpoint of effectively mitigating the step difference caused by the above-described fixing member, the maximum thickness T6 of the 2 nd interposed portion 72 is preferably larger, and therefore the upper limit of the ratio is preferably 2000 or less, 1000 or less, 500 or less, or 375 or less, for example.

From the viewpoint of reducing the step difference, the length L4 is preferably as long as possible, and for example, when the thickness of the sheet 12 is 50 μm or more and 200 μm or less, the length L4 is preferably 5.0mm or more, and in order to further shorten the deformation reducing length, is more preferably 7.0mm or more, and is further preferably 9.0mm or more. However, if the length L4 is too long, it is difficult to form the 2 nd intermediate portion having a convex front surface in the region R3 (see fig. 28) from the 2 nd end 72B of the 2 nd intermediate portion to the position of the maximum thickness T6 from the viewpoint of processing, and since there is a possibility that the wavy thickness unevenness occurs in the 2 nd intermediate portion, the upper limit of the length L4 is preferably 20mm or less from the viewpoint that the front surface 72C of the 2 nd intermediate portion 72 in the region R3 is easily convex and the wavy thickness unevenness is suppressed.

The length L4 can be obtained from a graph of the position displacement curve in the same manner as the maximum thickness T6. Specifically, first, when the 2 nd end 72B of the 2 nd intervening portion 72 is present, the displacement amount increases, and therefore, the 1 st position, which is the intersection of the line where the displacement amount is 0mm and the position displacement curve at the position where the displacement amount starts to increase, is found from the graph of the position displacement curve. Then, an imaginary line passing through the position where the displacement amount becomes the highest and perpendicular to the line where the displacement amount is 0mm is drawn. Then, the length L4 can be obtained by determining the distance between the 1 st position and the 2 nd position by using the intersection of the virtual line and the line at the displacement amount of 0mm as the 2 nd position.

The length L4/maximum thickness T6 can be approximately the shape of the 2 nd interposed portion 72, but in order to more appropriately show the convex shape of the front surface 72C, the cross-sectional area of the 2 nd interposed portion 72 is preferably used. Specifically, it is preferable that the ratio of the cross-sectional area S3 (see fig. 28) of the 2 nd interposed portion 72 from the 2 nd end 72B to the position of the maximum thickness T6 in the plane (the plane shown in fig. 28) including the longitudinal direction DR2 of the sheet 12 and the radial direction DR3 of the core 11 to the maximum thickness T6 of the 2 nd interposed portion 72 (cross-sectional area S3/maximum thickness T6) be 2.5 or more. If the ratio is 2.5 or more, the cross-sectional area S3 of the 2 nd intermediate portion 72 is large relative to the maximum thickness T6, and therefore the sheet 12 can be efficiently lifted by the 2 nd intermediate portion 72, whereby the step can be further reduced. From the viewpoint of further reducing the step difference, the lower limit of the cross-sectional area S3/maximum thickness T6 is preferably 3.0 or more, 3.5 or more, 4.0 or more, 5.0 or more, 5.5 or more, 6.0 or more, 6.5 or more, or 7.0 or more. The upper limit of the cross-sectional area S3/maximum thickness T6 is not particularly limited, and may be, for example, 20.0 or less, 17.5 or less, 15.0 or less, or 12.5 or less, or 10.0 or less. The cross-sectional area S3 is a cross-sectional area of the region R3 of the 2 nd intermediate portion 72 (in fig. 29, a cross-sectional area of a region surrounded by a solid line in the 2 nd intermediate portion 72), and can be obtained as follows: the product of the thickness at each measurement point and the width between each measurement point in the region from the 1 st position to the 2 nd position in the graph of the position displacement curve is obtained and summed up.

The physical properties such as tensile strength of the constituent material of the 2 nd interposed portion 72 are the same as those of the constituent material of the 2 nd filling portion 16, and the material of the 2 nd interposed portion 72 is the same as that of the 2 nd filling portion 16, and therefore, the description thereof is omitted.

As described later, in the sheet 12 (upper sheet 12) located outside the 1 st intermediate portion 71 and the 2 nd intermediate portion 72 in the radial direction DR3, the step caused by the winding start end portion 12A of the sheet 12 and the step caused by the fixing member 17 can be suppressed, but in the sheet 12 (lower sheet 12) located inside the 1 st intermediate portion 71 and the 2 nd intermediate portion 72 in the radial direction DR3 (on the core 11 side), the step caused by the winding start end portion 12A of the sheet 12 and the step caused by the fixing member 17 cannot be suppressed. Therefore, the 1 st and 2

nd sandwiching portions

71 and 72 are preferably provided as far as possible inside the radial direction DR3 (for example, between the sheet 12 in the 1 st circumference and the sheet 12 in the 2 nd circumference, or between the sheet 12 in the 2 nd circumference and the sheet 12 in the 3 rd circumference).

Other roll body

In the roll 70, the distal end surface 12A1 of the winding start end 12A of the sheet 12 and the 2 nd end surface 17B of the fixing member 17 are substantially aligned in a cross section along the longitudinal direction DR2 of the sheet 12 and the radial direction DR3 of the core 11, but the distal end surface 12A1 of the winding start end 12A of the sheet 12 may protrude from the 2 nd end surface 17B of the fixing member 17 as in the roll 80 shown in fig. 30. In this case, not only the 2 nd interposed portion 72 but also the 3 rd interposed portion 81 may be interposed in the 2 nd area 12E between the sheets 12 and the 3 rd area 12F corresponding to the 3 rd gap 21 on the 2 nd end surface 17B side between the sheets 12.

< 3 rd intervening part >

The 3 rd interposed portion 81 is the same as the 2 nd interposed portion 72 except that it is interposed in the 3 rd region 12F corresponding to the 3 rd gap 21, and therefore, explanation thereof is omitted.

In the roll body 70, the 2 nd interposed portion 72 is provided in the 2 nd area 12E between the sheets 12, but from the viewpoint of reducing the step difference caused by the winding start end portion 12A of the sheet 12, the 1 st interposed portion 71 may be provided in the 1 st area 12D between the sheets 12, and therefore, the 2 nd interposed portion 72 may not be provided in the 2 nd area 12E between the sheets 12 as in the roll body 90 shown in fig. 31. With regard to the roll 90 shown in fig. 31, in the 2 nd area 12E, the sheets 12 are closely attached to each other.

In the roll 70, the 1 st interposed portion 71 is provided in the 1 st region 12D between the sheets 12, but from the viewpoint of reducing the step difference caused by the fixing member 17, the 2 nd interposed portion 72 may be provided in the 2 nd region 12E between the sheets 12, and therefore the 1 st interposed portion 71 may not be provided in the 1 st region 12D between the sheets 12 as in the roll 100 shown in fig. 32. In the roll 100 shown in fig. 32, in the 1 st region 12D, the sheets 12 are closely attached to each other.

The roll 70 includes the 1 st interposed portion 71, but the 1 st filling portion 14 may be provided instead of the 1 st interposed portion 71 as in the roll 110 shown in fig. 33. That is, the 1 st filling portion 14 may be filled in the 1 st gap 13, and the 2 nd intervening portion 72 may be provided in the 2 nd region 12E between the sheets 12.

The 2 nd interposed portion 72 of the roll 110 is provided between the sheet 12 in the 2 nd circumference and the sheet 12 in the 3 rd circumference, but the 2 nd interposed portion 72 may be provided between the sheet 12 in the 1 st circumference and the sheet 12 in the 2 nd circumference as in the roll 120 shown in fig. 34.

The roll 70 includes the 2 nd interposed portion 72, but the 2 nd filling portion 16 may be provided instead of the 2 nd interposed portion 72 as in the roll 130 shown in fig. 35. That is, the 1 st intermediate portion 71 may be provided in the 1 st region 12D between the sheets 12, and the 2 nd filling portion 16 may be filled in the 2 nd gap 15.

The roll body 70 includes the fixing member 17 for fixing the sheet 12 to the outer peripheral surface 11A of the winding core 11, but may not include the fixing member 17 as in the roll body 140 shown in fig. 36.

The sheet 12 of the roll 70 has a uniform thickness, but as in the roll 150 shown in fig. 37, projections 12H projecting outward in the radial direction DR3 of the winding core 11 may be formed on both ends 12G extending in the longitudinal direction of the sheet 12. When the viscosity of the filler (e.g., coating material), the 1 st intermediate portion 71, the 2 nd intermediate portion 72, or the 3 rd intermediate portion 81 is low, or when the thickness of the sheet is uniform, there is a concern that: the filler material (e.g., coating material, etc.) overflows from between the sheets, so that the filler material, etc., is present at an undesired location. In contrast, by forming the convex portions 12H on the both end portions 12G of the sheet 12, it is possible to suppress the filling material (for example, coating material or the like) from overflowing at the both end portions 12G after the filling material is disposed, for example, after the coating material is applied. Further, both end portions 12G of the sheet 12 are portions which are cut out and not used as a product, and therefore even if such convex portions 12H are provided at both end portions 12G of the sheet, there is no problem with the product. The convex portion 12H may be formed by knurling or coating, or may be formed by attaching a tape (e.g., a side tape). In the case of the coating process, the same material as that of the 1 st filling part 14 can be used.

In the roll 150 shown in fig. 37, the convex portions 12H are provided on all of the both end portions 12G of the sheet 12, but the convex portions 12H may be provided locally. For example, the convex portion 12H may be provided locally at a position where the 1 st interposed portion 71 is interposed between both end portions 12G extending in the longitudinal direction of the sheet 12, at a position where the 2 nd interposed portion 72 is interposed between both end portions 12G extending in the longitudinal direction of the sheet 12, and/or at a position where the 3 rd interposed portion 81 is interposed between both end portions 12G extending in the longitudinal direction of the sheet 12. If the convex portion 12H is present at a position sandwiching the 1 st sandwiching portion 71, it is possible to suppress overflow of the filler (e.g., coating material) and the 1 st sandwiching portion 71, if the convex portion 12H is present at a position sandwiching the 2 nd sandwiching portion 72, it is possible to suppress overflow of the filler (e.g., coating material) and the 2 nd sandwiching portion 72, and if the convex portion 12H is present at a position sandwiching the 3 rd sandwiching portion 81, it is possible to suppress overflow of the filler (e.g., coating material) and the 3 rd sandwiching portion 81.

In fig. 31 to 36, the distance D2, the length L3, the length L4, the maximum thickness T6, and the cross-sectional area S3 are not shown, but in the case where the 1 st interposed section 71 is present, the distance D2, the length L3, the length L3, and the distance D2 are the same as those in the case of the roll body 70, and in the case where the 2 nd interposed section 72 is present, the length L4, the length L4, the maximum thickness T6, and the cross-sectional area S3, the maximum thickness T6 are the same as those in the case of the roll body 70.

In fig. 33 and 34, the entire front surface of the fixing member 17 is in close contact with the winding start end portion 12A, but the 1 st filling part 14 may enter between the winding start end portion 12A and the fixing member 17, similarly to the roll 10 shown in fig. 8.

Method for manufacturing roll

The roll 70 can be manufactured by the following method, for example. First, as shown in fig. 38 (a), the fixing member 17 is disposed on the outer peripheral surface 11A of the winding core 11 along the width direction DR1 of the winding core 11.

After the fixing member 17 is disposed, as shown in fig. 38 (B), the winding start end portion 12A of the sheet 12 is fixed to the outer peripheral surface 11A of the winding core 11 by the fixing member 17 such that the distal end surface 12A1 of the winding start end portion 12A of the sheet 12 is substantially aligned with the 2 nd end surface 17B of the fixing member 17.

After the winding start end portion 12A of the sheet 12 is fixed to the outer peripheral surface 11A of the winding core 11, the sheet 12 is wound along the outer peripheral surface 11A of the winding core 11 for at least 1 circumference as shown in fig. 38 (C). Thereby, the intermediate roll 73 having the 1 st gap 13 and the 2 nd gap 15 is obtained.

After the intermediate roll 73 is obtained, as shown in fig. 39 (a), the

coating materials

206 and 207 are applied to the front surface 12I of the sheet 12 constituting the outer peripheral surface 73A of the intermediate roll 73 along the width direction DR1 of the winding core 11. The coating material 206 is applied to at least the 1 st region 12D corresponding to the 1 st gap 13, and the coating material 207 is applied to at least the 2 nd region 12E corresponding to the 2 nd gap 15. The coating materials 74, 75 are the same as the

coating materials

201, 202, and therefore, the description thereof is omitted here.

After the

coating materials

206 and 207 are applied, the web 12 is wound around the core 11 again as shown in fig. 39 (B). Thus, since the

coating materials

206 and 207 flow and spread, the coating material 206 is provided in the 1 st region 12D between the sheets 12, and the coating material 207 is provided in the 2 nd region 12E between the sheets 12, thereby forming the 1 st intermediate portion 71 and the 2 nd intermediate portion 72. Thus, the roll 70 is obtained. When at least one of the

coating materials

206 and 207 is a curable material, the curable material is cured after the sheet 12 is wound again.

In the method of manufacturing the roll 70, the

coating materials

206 and 207 are not applied using the die 210 having the slit 210A, but the

coating materials

206 and 207 may be applied using the die 210 having the slit 210A as in embodiment 1. In addition, the 1 st and 2 nd

intermediate portions

71 and 72 may be formed by a filler sheet instead of the

coating materials

206 and 207 by the same method as in embodiment 1.

According to the present embodiment, since the 1 st nip portion 71 is provided in the 1 st region 12D between the sheets 12, the portion of the sheet 12 in the 1 st nip portion 71 can be gently lifted toward the distal end surface 12a1 side. This can effectively reduce the step caused by the winding start end 12A of the sheet 12.

According to the present embodiment, since the 2 nd sandwiching portion 72 is provided in the 2 nd area 12E between the sheets 12, the portion of the sheet 12 on the 2 nd sandwiching portion 72 can be gently lifted. This can effectively reduce the step caused by the fixing member 17.

Further, since the step caused by the winding start end portion 12A of the sheet 12 and the step caused by the fixing member 17 can be alleviated, the deformation of the sheet 12 can be suppressed.

When the 1 st gap is filled with the 1 st filling portion and the 2 nd gap is filled with the 2 nd filling portion, the 1 st filling portion and the 2 nd filling portion may flow to a portion where no pressure is applied. In contrast, in the present embodiment, since the 1 st and 2

nd intervening portions

71 and 72 are provided between the sheets 12, the material constituting the 1 st and 2

nd intervening portions

71 and 72 is less likely to flow and less likely to overflow.

Examples

The present invention will be described in detail with reference to examples, but the present invention is not limited to these descriptions. FIG. 40 (A) is a graph showing the displacement amount of the roll of example 7 with respect to the position around the 1 st filling part,

fig. 40 (B) is a graph showing the amount of displacement of the roll of example 8 with respect to the position around the 1 st filling part, and fig. 40 (C) is a graph showing the amount of displacement of the roll of example 9 with respect to the position around the 1 st filling part.

< preparation of composition for hard coat layer >

First, each component was blended so as to have the following composition, thereby obtaining a composition 1 for a hard coat layer.

(composition for hard coat 1)

Pentaerythritol triacrylate (product name "KAYARAD-PET-30", manufactured by Nippon Kabushiki Kaisha): 60 parts by mass

Photopolymerization initiator (1-hydroxycyclohexyl phenyl ketone, product name "Omnirad 184", manufactured by IGM Resins b.v.): 5 parts by mass

Silicone leveling agents (product name "Seika Beam 10-28", manufactured by Dai Nissan chemical industries Co., Ltd., solid content 10%): 0.1 part by mass

Silica particles (product name "SIRMIBK-H84", manufactured by CIK Nanotech Co., Ltd., average particle diameter 30nm, solid content 30%): 3 parts by mass

Methyl isobutyl ketone (MIBK): 80 parts by mass

Cyclohexanone: 20 parts by mass

< example 1>

First, a rectangular double-sided tape having a length of 1380mm, a width of 20mm and a thickness of 10 μm as a fixing member was adhered to the outer peripheral surface of a cylindrical winding core made of a fiber-reinforced plastic having an inner diameter of 153mm, an outer diameter of 167mm and a width of 1600mm along the width direction of the winding core.

After the double-sided tape is applied, the winding core is held by a clamping member of the winding device and fixed to the winding device. Then, 2 pieces of one-pack curable silicone resin composition (product name "Hapio Seal Pro HG", manufactured by Campe Hapio) as a coating material were applied under an environment of 25 ℃ so as to be in contact with the 1 st end face and the 2 nd end face of the double-sided tape extending in the width direction of the core, respectively. The color of the silicone resin composition is gray. In addition, the silicone resinThe shear viscosity of the composition during coating is 180 Pa.s, and the coating amount of the silicone resin composition per unit width along the width direction of the core is 1cm³The coating patterns of m are respectively coated in a linear shape.

Then, the long-side winding starting end of an acrylic resin film (in-plane retardation Re: 5nm) having a length of 3000m, a width of 1340mm and a thickness of 80 μm as a sheet was attached to the double-sided adhesive tape along the width direction of the core, thereby fixing the acrylic resin film to the outer peripheral surface of the core. The acrylic resin film is configured to: the end surface of the acrylic resin film in the longitudinal direction of the winding start end comes into contact with the silicone resin composition, and is substantially aligned with the 2 nd end surface of the double-sided tape in the radial direction of the core.

Then, the acrylic resin film is entirely wound around the core by the winding device, and the silicone resin composition is filled in the 1 st gap between the core and the acrylic resin film in the 1 st circumference and in contact with the end face of the winding start end portion of the acrylic resin film, and the silicone resin composition is filled in the 2 nd gap between the core and the acrylic resin film in the 1 st circumference and in contact with the 1 st end face of the double-sided tape. Thus, a roll was obtained. In the roll, the silicone resin composition was cured to form a1 st filling part having a length of 20mm, a width of 1340mm and a maximum thickness of 300 μm, which was filled in the 1 st gap, and a2 nd filling part having a length of 20mm, a width of 1340mm and a maximum thickness of 300 μm, which was filled in the 2 nd gap.

The shear viscosity of the silicone resin composition was measured using a dynamic viscoelasticity measuring apparatus manufactured by Anton-Paar Japan. Specifically, the shear viscosity of the silicone resin composition was determined as follows: the shear viscosity at a shear rate of 1[1/s ] was measured at 25 ℃ using a parallel plate having a diameter of 25 mm. The viscosity of the silicone resin composition was determined as follows: the viscosity of the silicone resin composition was measured 10 times, and the arithmetic average of 8 shear viscosities was obtained excluding the maximum value and the minimum value among the 10 viscosities measured. The shear viscosity of the coating material used in the other examples below was measured in the same manner as in example 1.

The in-plane retardation Re of the acrylic resin film was measured by using a retardation film-optical material inspection apparatus (product name "RETS-100", manufactured by Otsuka Denshi Co., Ltd.). Specifically, first, the light source is turned on and left for 60 minutes or more in order to stabilize the light source of the RETS-100. Then, the rotary analyzer method is selected, and the θ mode (angular direction phase difference measurement mode) is selected. By selecting the θ mode, the table becomes a tilt rotation table.

Next, the following measurement conditions are input to RETS-100.

(measurement conditions)

Delay measurement range: rotary polarization analysis method

Measurement point diameter: phi 5mm

The tilt angle range: -40 to 40 °

Measurement wavelength range: 400 nm-800 nm

Average refractive index of the sample: 1.5

Thickness: 80 μm

Next, no sample was set in the apparatus, and background data was obtained. The device is set as a closed system, which is implemented each time the light source is lit.

The sample is then placed on a stage within the apparatus. The size of the sample was 50mm by 50 mm.

After setting the sample, the stage was rotated 360 ° on the XY plane in an environment at a temperature of 23 ℃ and a relative humidity of 50%, and the fast axis and the slow axis were measured. After the measurement is finished, the slow axis is selected. Then, measurement is performed while tilting the table about the slow axis within a predetermined angle range, and data (Re) of the predetermined tilt angle range and the predetermined wavelength range is obtained in units of 10 °. The in-plane phase difference Re was measured at 5 points different in position. Specifically, as shown in fig. 2, the measurement was performed at 5 points in total, namely, the center a1 and the points a2 to a4 of the sample. Then, the arithmetic average of 3 points excluding the maximum value and the minimum value among the measured values of 5 points was taken as the in-plane phase difference Re.

< example 2>

A roll was obtained in the same manner as in example 1 except that a two-component curable silicone rubber composition (product name "KE-24", manufactured by shin-Etsu chemical Co., Ltd.) was used in place of the silicone resin composition for forming the 1 st and 2 nd filling parts in example 2. The silicone rubber composition was white when mixed, and the shear viscosity of the silicone rubber composition when applied was 75Pa · s.

< example 3>

A roll was obtained in the same manner as in example 1 except that a two-component curable silicone rubber composition (product name "ELASTOSIL (registered trademark) M4503", manufactured by asahi kogaku corporation, condensation-curable) was used in place of the silicone resin composition for forming the 1 st filling part and the 2 nd filling part in example 3. The silicone rubber composition was white when mixed, and the shear viscosity when applied was 40 pas. Further, the silicone rubber composition does not contain a volatile component and an adhesive component.

In the 90 ° peel test in which the constituent material of the 1 st filling part in the roll of example 3 was peeled perpendicularly to the outer peripheral surface of the core at a peeling speed of 10 mm/min, the constituent material was peeled off at a tensile force of 0.2N.

The 90 ° peel test was performed using a sample and a spring type tensiometer (manufactured by Dai Messay instruments, Ltd.). Specifically, first, a mold larger than the sample size is prepared, and the mold is disposed on the outer peripheral surface of the core. Then, a two-component curable silicone rubber composition (product name "ELASTOSIL (registered trademark) M4503", manufactured by asahi kok silicone co., ltd., condensation-curable) was injected into the mold and cured to obtain a material layer. Then, the material layer was taken out from the mold, and cut out to a size of 20mm × 100mm by a cutting machine, to obtain a sample provided on the outer peripheral surface of the core. Then, one end of the sample was held by a spring type tensiometer, and the sample was peeled at a peeling speed of 10 mm/sec by lifting the one end perpendicularly to the outer peripheral surface of the core while measuring the tensile force in an environment of 25 ℃ and 50% relative humidity. Then, of the 10 samples subjected to the 90 ° peel test, the arithmetic average of the tensile forces of the 8 samples except for the sample having the largest tensile force and the sample having the smallest tensile force was taken as the tensile force of the constituent material.

The material constituting the 1 st filled portion in the roll of example 3 had a tensile strength of 3.5MPa, an elongation at cut of 450%, and a tear strength of 12.0N/mm. The hardness of the constituent material of the 1 st packed portion measured by a type a durometer was 28 °, and the linear shrinkage of the constituent material of the 1 st packed portion was 0.10%.

The tensile strength of the constituent material of the 1 st filling part was measured in accordance with JIS K6251: 2017, and measured by using a sample and a Tensilon universal tester (product name "RTC-1310A", manufactured by A & D Co., Ltd.). Specifically, first, a mold larger than the sample size is prepared, and the mold is disposed on the outer peripheral surface of the core. Then, a two-component curable silicone rubber composition (product name "ELASTOSIL (registered trademark) M4503", manufactured by asahi kogaku corporation, condensation-curable) for forming the 1 st filling part was injected into the mold and cured to obtain a material layer. Then, the material layer was taken out of the die, and was punched out with a dumbbell-shaped punch cutter of tensile No. 2, manufactured by high molecular weight metering instruments, into a material having a thickness in the range of JIS K6251: 2017, to obtain a sample. Then, the sample was kept at 25 ℃ for 24 hours. Then, the samples were subjected to a tensile test under conditions of an initial inter-gripper distance of 20mm and a tensile rate of 100 mm/min in an environment of 25 ℃ and a relative humidity of 50% while both end portions in the longitudinal direction of the samples were gripped by a pair of grippers of the Tensilon universal testing machine, and the tensile strength of the samples was measured. Then, the arithmetic average of the tensile strengths of 8 samples, excluding the maximum value and the minimum value, out of the 10 samples was taken as the tensile strength of the above-mentioned constituent material.

The elongation at cut of the constituent material of the 1 st filling part was measured in accordance with JIS K6251: 2017, the tensile strength was measured by using a sample and a Tensilon universal tester (product name "RTC-1310A", manufactured by A & D Co., Ltd.). Then, the arithmetic average of the elongation at cutting of 8 samples out of the 10 samples except the maximum value and the minimum value was taken as the elongation at cutting of the constituent material.

The tear strength of the constituent material of the 1 st filling part was measured in accordance with JIS K6252: 2007, the tensile strength was measured in the same manner as the tensile strength measurement method using a sample and a Tensilon universal tester (product name "RTC-1310A", manufactured by A & D corporation). Then, the arithmetic average of the tear strengths of 8 samples, excluding the maximum value and the minimum value, out of the 10 samples was taken as the tear strength of the above-mentioned constituent material.

The hardness measurement based on type a durometer of the constituent material of the 1 st filling part was in accordance with JIS K6253: 1997 measured. Specifically, first, a mold larger than the sample size is prepared, and the mold is disposed on the outer peripheral surface of the core. Then, a two-component curable silicone rubber composition (product name "ELASTOSIL (registered trademark) M4503", manufactured by asahi kogaku corporation, condensation-curable) for forming the 1 st filling part was injected into the mold, and cured as necessary to obtain a material layer. Then, the material layer was taken out of the mold and cut out by a cutting machine or the like to obtain a sample having a size of 100mm × 100mm and a thickness of 10 mm. Then, the hardness was measured using a type A durometer (product name "GS-719N (TYPEA)", manufactured by Telock, Ltd.) under an environment of 25 ℃ and 50% relative humidity. Then, the arithmetic average of the hardnesses of 8 samples, excluding the maximum value and the minimum value, out of the 10 samples was taken as the hardness of the above-described constituent material.

The linear shrinkage rate of the 1 st filling part can be measured as follows. First, a mold having a thickness of 2mm and a square size of 130mm was prepared, and a two-component curable silicone rubber composition (product name "ELASTOSIL (registered trademark) M4503", manufactured by asahi wakker silicone co., ltd., condensation-curable) for forming the 1 st filling part was injected into the mold and cured to obtain a sample (molded product). After complete curing, the dimensions of the sample were measured and compared with the dimensions of the inside of the mold, based on JIS K6249: the linear shrinkage rate was obtained in 2003. The arithmetic average of the linear shrinkage rates of 8 samples, excluding the maximum value and the minimum value, out of the 10 samples was taken as the linear shrinkage rate of the above constituent material.

< example 4>

A roll was obtained in the same manner as in example 1 except that in example 4, a two-component curable silicone rubber composition (product name "ELASTOSIL (registered trademark) M4601", manufactured by asahi kogaku corporation, addition-reactive) was used instead of the silicone resin composition for forming the 1 st filling part and the 2 nd filling part. The silicone rubber resin composition was white when mixed, and the shear viscosity of the silicone rubber composition when applied was 20 pas.

< example 5>

A roll was obtained in the same manner as in example 1 except that a two-component curable polyurethane resin composition (product name "human skin gel", manufactured by Excsel Corporation, ltd.) was used in place of the silicone resin composition for forming the 1 st and 2 nd filling parts in example 5. The polyurethane resin composition was white when mixed, and the shear viscosity of the polyurethane resin composition when applied was 6.5 pas.

< example 6>

First, a rectangular double-sided tape having a length of 1380mm, a width of 20mm and a thickness of 10 μm as a fixing member was adhered to the outer peripheral surface of a cylindrical winding core made of fiber-reinforced plastic having an inner diameter of 153mm, an outer diameter of 167mm and a width of 1600mm in the width direction of the winding core.

After the double-sided tape is applied, the winding core is held by a clamping member of the winding device and fixed to the winding device. Then, the winding start end portion in the longitudinal direction of a polyethylene terephthalate film (PET film, in-plane retardation Re: 1000nm, Nz coefficient: 20) having a length of 3000m, a width of 1490mm and a thickness of 80 μm as a sheet was stuck to a double-sided tape along the width direction of the core, thereby fixing the PET film to the outer peripheral surface of the core.

Then, the PET film was wound by a winding device for 1 week to obtain an intermediate roll. The intermediate roll body has a1 st gap between the winding core and the 1 st circumferential PET film and in contact with the distal end surface of the winding start end of the PET film, and a2 nd gap between the winding core and the 1 st circumferential PET film and in contact with the 1 st end surface of the double-sided tape.

After obtaining the intermediate roll, a one-pack curable silicone resin composition (product name "Hapio Seal Pro HG", manufactured by Campe Hapio) as a coating material was applied to the front surface of the PET film constituting the outer peripheral surface of the intermediate roll in the width direction of the core in an environment of 25 ℃. The viscosity of the silicone resin composition during coating was 180Pa · s, and the coating amount per unit width of the silicone resin composition along the width direction of the core was 1cm³The coating is applied linearly in the form of a/m. Specifically, the silicone resin composition is applied to the 1 st region corresponding to the 1 st gap and the 2 nd region corresponding to the 2 nd gap, respectively.

After the silicone resin composition was applied, the entire PET film was wound around the core again by the winding device so that the silicone resin composition was interposed between the 1 st and 2 nd regions of the PET film. Thus, a roll was obtained. In the roll body, the silicone resin composition was cured to form a1 st interposed portion having a length of 20mm, a width of 1340mm and a maximum thickness of 300 μm provided in a1 st region between the PET films, and a2 nd interposed portion having a length of 20mm, a width of 1340mm and a maximum thickness of 300 μm provided in a2 nd region between the PET films.

The in-plane retardation Re of the PET film used in example 6 was measured in the same manner as the in-plane retardation Re of the acrylic resin film used in example 1. However, in this case, the average refractive index N of the sample was set to 1.617.

< example 7>

In example 7, an acrylic resin film having a length of 3000m, a width of 1340mm and a thickness of 85 μm as a sheet, specifically, a laminate composed of an acrylic resin film and a hard coat layer was used, and the silicone rubber compositions for forming the 1 st and 2 nd filling parts were applied in an amount of 0.3cm per unit width along the width direction of the core³A roll was obtained in the same manner as in example 3, except that the coating was applied linearly in the form of/m.

The laminate is formed as follows. First, an acrylic resin film having a length of 3000m, a width of 1340mm and a thickness of 80 μm used in example 1 was fed from a take-up roll to a coating section of the unit 1 using a continuous coater, and the composition 1 for a hard coat layer was coated to form a coating film. Then, the coating film was dried at 70 ℃ for 60 seconds in a drying section to evaporate the solvent in the coating film, and the cumulative light amount in the curing section was 150mJ/cm²By irradiating ultraviolet rays to cure the coating film, a hard coat layer having a thickness of 5.0 μm and a coating width of 1300mm was formed, and a laminate having a length of 3000m and a thickness of 85 μm was obtained.

< example 8>

In example 8, the silicone rubber composition for forming the 1 st and 2 nd filling parts was applied in an amount of 0.5cm per unit width along the width direction of the core³A roll was obtained in the same manner as in example 7, except that the coating was applied linearly in the form of a line,/m.

< example 9>

In example 9, the silicone rubber composition for forming the 1 st and 2 nd filling parts was applied in an amount of 0.8cm per unit width along the width direction of the core³A roll was obtained in the same manner as in example 7, except that the coating was applied linearly in the form of a line,/m.

< example 10>

In example 10, the amount of the silicone rubber composition for forming the 1 st and 2 nd filling parts applied per unit width was 1cm³A roll was obtained in the same manner as in example 9, except that the coating was applied linearly in the form of a line,/m.

< example 11>

In example 11, the shear viscosity at the time of application of the two-component curable silicone rubber composition for forming the 1 st filling part and the 2 nd sandwiching part was set to 2Pa · s, and the application amount per unit width was set to 1.5cm³Except for the point,/m, a roll was obtained in the same manner as in example 9.

< example 12>

In example 12, the shear viscosity at the time of application of the silicone rubber composition for forming the 1 st filling part and the 2 nd sandwiching part was set to 6.5Pa · s, and the amount of application per unit width was set to 1.2cm³Except for the point,/m, a roll was obtained in the same manner as in example 9.

< example 13>

First, a cylindrical winding core made of fiber-reinforced plastic having an inner diameter of 153mm, an outer diameter of 167mm, and a width of 1600mm was held by a clamping member of the winding device and fixed to the winding device. Then, 1 two-component curable silicone rubber composition (product name "ELASTOSIL (registered trademark) M4503", manufactured by Asahi Kawaki Kaisha, condensation-curable) as a coating material was applied in an environment of 25 ℃ in the width direction of the core. The viscosity of the silicone rubber composition at the time of application was 180 pas, and the amount of the silicone rubber composition applied per unit width along the width direction of the core was 1cm³The coating is applied linearly in the form of a/m.

Then, a rectangular double-sided tape having a length of 1380mm, a width of 20mm and a thickness of 10 μm as a fixing member was attached along the width direction of the core so that the separation distance between the double-sided tape and the two-component curable silicone rubber composition was 3 mm. The separation distance is determined as follows: the 10 sites were measured, and the arithmetic mean of the 8 separation distances excluding the maximum and minimum values among the 10 separation distances was determined. In the following examples, the separation distance is also determined in this manner.

Then, the laminate having a length of 3000m, a width of 1340mm, and a thickness of 85 μm, which was a sheet material, was fixed to the outer peripheral surface of the core by attaching the winding start end portion in the longitudinal direction of the laminate to the double-sided tape along the width direction of the core, as in example 7. The laminate is disposed such that the end surface of the laminate in the longitudinal direction of the winding start end of the laminate comes into contact with the silicone rubber composition and is substantially aligned with the 2 nd end surface of the double-sided adhesive tape in the radial direction of the winding core.

Then, the laminate was wound around the core by a winding device, and a1 st gap located between the core and the laminate in the 1 st circumference and in contact with the end surface of the winding start end of the laminate was filled with a silicone rubber composition.

Then, the laminate was wound by a winding apparatus for 1 week to obtain an intermediate roll. The intermediate roll body has a2 nd gap located between the winding core and the 1 st peripheral laminate and in contact with the 1 st end surface of the double-sided tape.

After obtaining the intermediate roll, a two-component curable silicone rubber composition (product name "ELASTOSIL (registered trademark) M4503", manufactured by asahi kok silicone co., ltd., condensation-curable) as a coating material was applied to the front surface of the laminate constituting the outer peripheral surface of the intermediate roll in the width direction of the core under an environment of 25 ℃. The viscosity of the silicone rubber composition at the time of application was 180 pas, and the amount of the silicone rubber composition applied per unit width along the width direction of the core was 1cm³The coating is applied linearly in the form of a/m. Specifically, the silicone rubber composition is applied to the 2 nd region corresponding to the 2 nd gap.

After the silicone rubber composition was applied, the entire laminate was wound around the core again by the winding apparatus so that the silicone rubber composition was interposed in the 2 nd region between the laminates. Thus, a roll was obtained. In the roll, the silicone rubber composition was cured, and a1 st filling portion having a width of 1340mm was formed in the 1 st gap, and a2 nd sandwiching portion having a width of 1340mm was formed in the 2 nd region between the stacked bodies.

< example 14>

A roll was obtained in the same manner as in example 11 except that a two-component curable silicone rubber composition (product name "ELASTOSIL (registered trademark) M4601", manufactured by asahi kogaku corporation, addition-reactive) was used in example 12 instead of the two-component curable silicone rubber composition (product name "ELASTOSIL (registered trademark) M4503", manufactured by asahi kogaku corporation, condensation-curable) for forming the 1 st filling part and the 2 nd sandwiching part. The shear viscosity of the silicone rubber composition at the time of application was 10 pas.

< example 15>

In example 15, the shear viscosity at the time of application of the two-component curable silicone rubber composition for forming the 1 st filling part and the 2 nd sandwiching part was set to 10Pa · s, and the application amount per unit width was set to 0.8cm³A roll was obtained in the same manner as in example 13, except that the separation distance between the double-sided adhesive tape and the two-component curable silicone rubber composition was set to 3 mm.

< example 16>

In example 16, the shear viscosity at the time of application of the two-component curable silicone rubber composition for forming the 1 st filling part and the 2 nd sandwiching part was set to 10Pa · s, and the application amount per unit width was set to 1.2cm³A roll was obtained in the same manner as in example 13, except that the separation distance between the double-sided adhesive tape and the two-component curable silicone rubber composition was set to 3 mm.

< comparative example 1>

A roll was obtained in the same manner as in example 1, except that the coating material was not applied to comparative example 1.

< comparative example 2>

A roll was obtained in the same manner as in comparative example 1, except that the laminate used in example 7 was used instead of the acrylic resin film in comparative example 2.

In the roll bodies of examples 1 to 16, the edge thickness T1 of the 1 st filling part was measured. The edge thickness T1 was measured using a scanning type optical interference profilometer (product name "New View 7300", manufactured by Zygo). Specifically, when all of films such as acrylic resin films and PET films or the laminate are fed, the 1 st filling part may adhere to the laminate side and be peeled off from the core. Then, 1 or more samples having a size of 2mm × 5mm including the 1 st filled portion were cut out from the laminate. The sample was cut from any portion including the end portion of the 1 st filling part and to which no dirt, fingerprint, or the like had adhered. Then, under the following measurement conditions, the edge thickness T1 of the 1 st filling part was measured. The edge thickness T1 was determined by measuring the edge thickness at 10 and determining the arithmetic mean of the thicknesses at 8 excluding the maximum and minimum of the measured thicknesses at 10.

(measurement conditions)

Objective lens: 10 times of

Zoom: 1 times of

Measurement area: 2.17mm

·scan Length：5μm

·min mod：0.015

Temperature: 23 deg.C

Relative humidity: 50 percent of

< measurement of deformation relaxation Length >

In the rolls of examples and comparative examples, the lengths of the film such as an acrylic resin film or a PET film, or the laminate, in which the step caused by the winding start end portion and the step caused by the double-sided tape were relaxed were measured. Specifically, since the step decreases from the winding start end to the winding end, the film or the laminate is first fed out while measuring the feeding length (m) of the film or the laminate until the step is visually recognized. Then, the film or the laminate was cut at a place where the step difference was observed. The film or laminate is visually observed by reflected light in a state where a white LED lamp is reflected on the film or laminate in an indoor environment of 800Lux or more and 2000Lux or less in a state where a polyvinyl alcohol film is bonded to the cut portion of the film or laminate. Then, the distance from the point where the step difference was not visible to the winding start end was measured and taken as the deformation relaxation length. Here, it is determined that there is a step in the case where the contour line of the white LED lamp reflected on the film or the laminate is deformed compared with the other portion of the film or the laminate, and it is determined that there is no step in the portion where the contour line of the white LED lamp reflected on the periphery where the step is present is the same as the other portion of the film or the laminate. The white LED lamp is disposed such that the longitudinal direction of the white LED lamp is along the longitudinal direction of the film or the laminate. The length of the white LED lamp is the length of the portion where the step difference exists and the portion where the step difference does not exist in the film or the laminate. In the observation, one side capable of clearly seeing the lines of the white LED lamp is appropriately selected, and the white LED lamp is reflected on the film or the laminate so that the outline thereof can be seen. The visual observation was performed from all angles (180 ° to 180 °) with reference to the normal direction of the surface of the film or the laminate (0 °).

< confirmation of Presence of intervention site >

In examples 3, 7 to 16, it was confirmed whether or not the 4 th interposed portion was present at the winding start end portion. Specifically, first, the laminate is fed from the roll until the front face of the laminate reaches the 2 nd circumference. Then, in the roll body in which the laminate in the 2 nd circumference became the front surface, the vicinity of the winding start end was visually observed, and the presence or absence of a colored portion at the winding start end was observed. When a colored portion is present at the winding start end portion, it is confirmed that the 4 th intervening portion is present, and when a colored portion is not present, it is confirmed that the 4 th intervening portion is not present. The observer is 15 persons, and when all the observers consider that the colored portion is present at the winding start end portion, it is determined that the 4 th intermediate portion is present.

< measurement of slopes of L1, L1+ L2, T2, S1, S1+ S2, IL 3>

In the roll bodies of examples 3, 7 to 16, when the presence of the 4 th interposed part was not confirmed, the length L1, the thickness T2 and the area S1 were measured, and the length L1/the thickness T2 and the area S1/the thickness T2 were determined. When the presence of the 4 th interposed section was confirmed, length L1+ length L2, thicknesses T1, T2, and area S1+ area S2 were measured, and (length L1+ length L2)/thickness T2, (area S1+ area S2)/thickness T2 were obtained. The lengths L1 and L2, the thickness T2, and the areas S1 and S2 refer to the portions shown in fig. 4 to 8.

Specifically, first, a jig for rotating the roll body and a laser displacement meter (product name "LK-G30", manufactured by KEYENCE) were prepared, and they were disposed at predetermined positions, respectively. The jig is inserted into a hole in the width direction of the winding core, and rotatably holds the winding body.

The laser displacement meter was located above the roll, and 3 units were arranged so as to irradiate the front surface of the roll with laser light. The arrangement position of the laser displacement meter is as follows. First, the 1 st position and the 2 nd position that equally divide the width 3 of the laminated body are determined. The 1 st position is located on the 1 st end side in the transverse direction of the laminate, and the 2 nd position is located on the 2 nd end side opposite to the 1 st position. The 1 st laser displacement meter is disposed so as to irradiate a laser beam onto a midpoint between the 1 st position and the 1 st end, the 2 nd laser displacement meter is disposed so as to irradiate a laser beam onto a midpoint between the 1 st position and the 2 nd position, and the 3 rd laser displacement meter is disposed so as to irradiate a laser beam onto a midpoint between the 2 nd position and the 2 nd end.

Then, the roll was mounted on a jig, and the acrylic resin film was fed out from the roll until the 1 st filling portion was exposed. Then, in the state where the 1 st filling part was exposed, the core was rotated at a rotation speed of 30mm/s in an environment of a temperature of 23 ℃ and a relative humidity of 50%, while the amount of displacement was continuously measured by a laser displacement meter at a sampling period of 200 μ s, and graphs were obtained in which the horizontal axis was the position (mm) and the vertical axis was the amount of displacement (mm) (see fig. 40 (a) to 40 (C)). The measurement is performed from the tip end of the 1 st filling part toward the position in contact with the tip end surface, and in the measurement, the reference height (line with a displacement amount of 0 mm) is taken as the height of the core, and the difference between the heights of the core and the 1 st filling part is taken as the thickness of the 1 st filling part. The graph obtained substantially represents a plane containing the longitudinal direction of the sheet and the radial direction of the winding core. In the graph, 1 scale on the horizontal axis is set to 5mm, and 1 scale on the vertical axis is set to 0.02 mm.

In this graph, a position on the position displacement curve where the displacement amount starts to decrease sharply is set as a position E1. When the presence of the 4 th intervening portion was not confirmed, the thickness T2 of the 1 st filling portion at the position in contact with the distal end surface was determined by determining the difference between the displacement amount of the line with the displacement amount of 0mm and the displacement amount of the position E1.

When the presence of the 4 th interposed portion was confirmed, the thickness T2 was measured by the following method. First, a sample of 2cm × 2cm including the winding start end portion 12A, the 1 st filling portion 14, and the 2 nd circumference sheet 12 was picked up and fixed so that the portion was not crushed. Then, the cross section of the fixed sample was ground, and the thickness T2 of the 1 st filling part was measured by a solid microscope (product name: digital microscope VHX-7000, manufactured by KEYENCE corporation) under an environment of 23 ℃ and 50% relative humidity. The measurement of thickness T2 based on a solid microscope was performed under dark field and reflected light at a magnification of 500 times with on-axis epi-illumination selected as illumination for the digital microscope.

When the presence of the 4 th interposed section was not confirmed, the length L1 was determined from the graph of the position displacement curve in the same manner as the thickness T2. Specifically, first, the position E1 is identified from the graph, and the intersection of the line at which the displacement amount starts to increase and the position displacement curve is defined as the position E2. Then, an imaginary line IL4 that passes through the position E1 and is perpendicular to the line at the displacement amount of 0mm is drawn. Then, the intersection of the virtual line IL4 and the line at the displacement amount of 0mm was set as the position E3, and the distance between the position E2 and the position E3 was obtained, whereby the length L1 was obtained. The area S1 is calculated as follows: in the region from the position E2 to the position E3, the product of the thickness at each measurement point and the width between each measurement point is obtained and summed. Based on the above equation (3), the width between the measurement points was obtained from the sampling period, the rotation speed of the core, and the outer diameter of the core, and the result was 6.24 μm. When the presence of the 4 th intervening section was confirmed, the length L1+ the length L2 was determined in the same manner as the length L1 when the presence of the 4 th intervening section was not confirmed.

When the presence of the 4 th interposed section was not confirmed, the length L1, the thickness T2, and the area S1 were used to determine the length L1/the thickness T2, and the area S1/the thickness T2. When the presence of the 4 th interposed section was confirmed, (length L1+ length L2)/thickness T2, (area S1+ area S2)/thickness T2 was determined using the sum of the determined length L1 and length L2 and the sum of thickness T2, area S1 and area S2.

In the graph, a virtual line IL3 (see fig. 40 a to 40C) passing through the position E1 and the position E2 is drawn, and the slope of the virtual line IL3 is obtained.

< L4, T6, S3 measurement >

In the wraps of examples 13 to 16, the length L4, the maximum thickness T6 and the cross-sectional area S3 were measured, and the length L4/the maximum thickness T6 and the cross-sectional area S3/the maximum thickness T6 were determined. The length L4 and the maximum thickness T6 indicate portions shown in fig. 27, and the cross-sectional area S3 indicates portions shown in fig. 29. The length L4, the maximum thickness T6, and the cross-sectional area S3 were measured using a jig for rotating the roll and a laser displacement meter (product name "LK-G30", manufactured by KEYENCE Co., Ltd.). Specifically, first, the roll was attached to a jig in the same manner as the measurement of the length L1 and the like, 3 laser displacement meters were placed at predetermined positions, and then the laminate was fed out from the roll until the 2 nd interposed portion was exposed. Then, in a state where the 2 nd intermediate portion is exposed, the displacement amount is continuously measured by a laser displacement meter at a sampling period of 200 μ s while rotating the core at a rotation speed of 30mm/s in an environment where the temperature is 23 ℃ and the relative humidity is 50%, and a graph in which the horizontal axis is a position (mm) and the vertical axis is a displacement amount (mm) is obtained. The measurement is performed from the 2 nd end of the 2 nd interposed portion opposite to the 1 st end on the double-sided tape side toward the 1 st end, and in the measurement, the reference height (line with a displacement amount of 0 mm) is taken as the height of the core, and the difference between the heights of the core and the 2 nd interposed portion is taken as the thickness of the 2 nd interposed portion. The graph obtained substantially represents a plane containing the longitudinal direction of the sheet and the radial direction of the winding core. In the graph, 1 scale on the horizontal axis is set to 5mm, and 1 scale on the vertical axis is set to 0.02 mm.

In this graph, the maximum thickness T6 of the 2 nd intermediate portion is determined by observing the position where the displacement amount is the highest, and determining the difference between the line where the displacement amount is 0mm and the displacement amount at that position.

From this graph, the 1 st position, which is the intersection of the line at which the displacement amount starts to increase and the position displacement curve, is found. Then, an imaginary line passing through the position where the displacement amount becomes the highest and perpendicular to the line where the displacement amount is 0mm is drawn. Then, the intersection of the virtual line and the line of displacement amount 0mm was defined as the 2 nd position, and the distance between the 1 st position and the 2 nd position was determined, thereby determining the length L4. The sectional area S3 is calculated as follows: the product of the thickness at each measurement point and the width between each measurement point is obtained in the region from the 1 st position to the 2 nd position, and the product is summed up. Based on the above equation (3), the width between the measurement points was obtained from the sampling period, the rotation speed of the core, and the outer diameter of the core, and the result was 6.24 μm.

Using the obtained length L4, maximum thickness T6, and cross-sectional area S3, length L4/maximum thickness T6 and cross-sectional area S3/maximum thickness T6 were obtained.

The results are shown in tables 1 to 3 below.

[ Table 1]

[ Table 2]

[ Table 3]

With the roll body of comparative example 1, both the deformation relaxing length of the winding start end portion and the deformation relaxing length of the double-sided adhesive tape were long. This is considered to be because: since the 1 st gap is a hollow, the step difference caused by the winding start end portion of the acrylic resin film is large, and since the 2 nd gap is a hollow, the step difference caused by the double-sided tape is large. In contrast, in the wound bodies of examples 1 to 12, both the deformation relaxing length of the winding start end portion and the deformation relaxing length of the double-sided tape were shorter than those of the wound body of comparative example 1. This is considered to be because: in the roll bodies of examples 1 to 5 and 7 to 15, the step difference caused by the winding start end portion of the acrylic resin film was small because the 1 st gap was filled with the 1 st filling portion, and the step difference caused by the double-sided tape was small because the 2 nd gap was filled with the 2 nd filling portion or the 2 nd intervening portion was interposed in the region corresponding to the 2 nd gap. In example 6, since the 1 st interposed portion was interposed in the 1 st region corresponding to the 1 st gap, the step caused by the winding start end portion of the PET film was small, and since the 2 nd interposed portion was interposed in the 2 nd region corresponding to the 2 nd gap, the step caused by the double-sided tape was small.

In the first filling portions of the wound bodies of examples 3, 8 to 16, the length L1/the thickness T2 or (length L1+ length L2)/the thickness T2 was 90 or more, and/or the area S1/the thickness T2 or (area S1+ area S2)/the thickness T2 was 3.0 or more, and therefore, the deformation relaxation length at the winding start end portion was shorter than that of the wound body of example 7 in which the length L1/the thickness T2 was smaller than 90.

In the 2 nd interposed portions of the wound bodies of examples 13 to 16, the length L4/maximum thickness T6 was 12 or more and/or the cross-sectional area S3/maximum thickness T6 was 2.5 or more, and therefore the deformation relaxation length of the double-sided tape was short.

In the roll bodies of examples 1, 2, 6 and 13, the shear viscosity of the silicone resin composition and the silicone rubber composition at the time of coating was 60Pa · s or more, and therefore, the above-mentioned composition was not confirmed in the case of protruding from between the core and the acrylic resin film or the PET film both at the time of coating and at the time of applying the pressure at the time of winding. In the roll bodies of examples 3, 4, 7 to 10, the shear viscosity of the composition at the time of coating was less than 60Pa · s but 15Pa · s or more, and therefore, although there was no overflow at the time of coating, the overflow of the composition was confirmed when the pressure at the time of winding was applied. In examples 5, 11, 12, and 14 to 16, since the shear viscosity of the composition at the time of application was less than 15Pa · s, it was confirmed that the composition was overflowed from between the core and the acrylic resin film.

In addition, the roll of example 3 was subjected to a reworkability test. Specifically, first, the acrylic resin film is unwound to expose the 1 st filling portion. Then, a start end is made with a blade-like member at the end of the 1 st filling part so as not to damage the core, and the 1 st filling part is tried to be slowly peeled off from the core with fingers. The evaluation criteria for reworkability were as follows: the case where the 1 st filling part was cleanly peeled off was good, and the case where the 1 st filling part was partially left in the core due to breakage or the like was bad. In such evaluation, the roll of example 3 was good because the 1 st filling part was cleanly peeled off. Incidentally, as a result of the reworkability test, the roll bodies of examples other than example 3 were also excellent in reworkability as in the case of the filled part 1 of example 3. In the roll body of the example other than example 3, the tensile strength of the constituent material of the 1 st filled portion was 3.0MPa to 5.5MPa, the elongation at cut was 250% to 600%, the tear strength was 6N/mm to 25N/mm, the hardness of the constituent material of the 1 st filled portion measured by a type a durometer was 10 ° to 50 ° and the linear shrinkage of the constituent material of the 1 st filled portion was 0% to 1.0%. As shown in Table 1, the marginal thickness T1 of the 1 st filling part of the roll bodies of examples 1 to 16 was in the range of 1.5 μm to 20 μm. When the 1 st filling part is peeled off, or when the edge is cleaned or wiped, the 1 st filling part is easily peeled off or removed although the edge thickness T1 is small.

In examples 1 to 12, the silicone resin composition or the silicone rubber composition was applied so as to contact the 1 st end face and the 2 nd end face of the double-sided tape, but in examples 1 to 12, the silicone resin composition or the silicone rubber composition was applied so that the separation distance between the silicone resin composition or the silicone rubber composition and the double-sided tape was 1mm, or the double-sided tape was disposed, and as a result, a roll body was stably manufactured, and the obtained roll body was also substantially the same as the above-described evaluation results or measurement results of the roll body of examples 1 to 12, respectively. Similarly, in examples 1 to 12, the silicone resin composition or the silicone rubber composition was applied or the double-sided tape was disposed so that the separation distance between the silicone resin composition or the silicone rubber composition and the double-sided tape was 3mm, and as a result, the wound body was stably manufactured, and the obtained wound body was also substantially the same as the above-described evaluation results or measurement results of the wound bodies of examples 1 to 12. In these cases, the following sequence is performed: first, a silicone resin composition or the like is applied in a linear shape along the width direction of the core, then the double-sided tape is disposed such that the separation distance between the 2 nd end surface of the double-sided tape and the silicone resin composition or the like is 1mm or 3mm, and further the silicone resin composition or the like is applied in a linear shape along the width direction of the core such that the separation distance between the 1 st end surface of the double-sided tape and the silicone resin composition or the like is 1mm or 3 mm.

Further, in example 2, the silicone rubber composition was applied or the double-sided tape was disposed so that the separation distance between the silicone rubber and the double-sided tape was 5mm, and as a result, a roll body could be stably manufactured, and the obtained roll body was also substantially the same as the above-described evaluation result or measurement result of the roll body of example 2. The edge thickness T1 was 2 μm. In this case, the following sequence is performed: first, a silicone rubber composition was applied in a linear shape along the width direction of the core, and then the double-sided tape was disposed such that the separation distance between the 2 nd end surface of the double-sided tape and the silicone rubber composition was 5mm, and further the silicone rubber composition was applied in a linear shape along the width direction of the core such that the separation distance between the 1 st end surface of the double-sided tape and the silicone rubber composition was 5 mm.

In example 3, a silicone rubber composition having a shear viscosity at the time of application of 40Pa · s was used, but when the shear viscosity at the time of application is 7Pa · s and the separation distance between the double-sided tape and the silicone rubber composition is 11mm, for example, the silicone rubber composition located on the 1 st end surface side of the double-sided tape flows to the opposite side to the double-sided tape side. Similarly, when the silicone rubber composition was disposed so as to contact the 1 st end face and the 2 nd end face of the double-sided tape with the shear viscosity of 250Pa · s, it was difficult to sufficiently flow the acrylic resin film even when it was wound, and therefore, after curing, although small, another step was generated at the winding start end portion.

Description of the reference symbols

10. 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150: a roll body;

11: a winding core;

11A: an outer peripheral surface;

12: a sheet material;

12A: a winding start end portion;

12A 1: a distal end face;

12D: region 1;

12E: a2 nd region;

12F: a 3 rd region;

12G: an end portion;

12H: a convex portion;

13: 1 st gap;

14: the 1 st filling part;

15. 52: the 2 nd gap;

16. 53: a2 nd filling part;

17. 51: a fixing member;

17A, 51A: 1 st end face;

17B, 51B: a2 nd end surface;

21. 54: a 3 rd gap;

22. 55: a 3 rd filling part;

71: a1 st sandwiching part;

72: a2 nd sandwiching part;

73: an intermediate roll;

81: a 3 rd clamping part;

201-207: and coating the material.

Claims

1. A method of manufacturing a roll body including a core and a long sheet material wound around an outer peripheral surface of the core,

the method for manufacturing the roll body comprises the following steps:

applying a coating material to the outer peripheral surface of the winding core along a width direction of the winding core;

disposing a winding start end portion in a longitudinal direction of the sheet on the outer peripheral surface; and

a step of winding the web material around the core and filling the coating material into at least the 1 st gap,

the coating material is applied or the winding start end portion is disposed so that the coating material is in contact with or close to a distal end surface of the winding start end portion in the longitudinal direction,

the 1 st gap is a gap between the core and the 1 st peripheral web and in contact with the end surface.

2. A method of manufacturing a roll body including a core and a long sheet material wound around an outer peripheral surface of the core,

the method for manufacturing the roll body comprises the following steps:

disposing a winding start end portion in a longitudinal direction of the sheet on the outer peripheral surface;

winding the sheet around the core for at least 1 circumference to obtain an intermediate roll having a1 st gap;

a step of applying a coating material along the width direction of the winding core on the front surface of the sheet material constituting the outer peripheral surface of the intermediate winding body; and

a step of wrapping the web material around the core again after the coating material is applied, so that the coating material is interposed between the web materials,

the 1 st gap is a gap between the core and the sheet in the 1 st circumference and in contact with a distal end surface of the winding start end portion in the longitudinal direction,

the coating material is applied to a1 st region corresponding to the 1 st gap in the front surface of the sheet material constituting the outer peripheral surface of the intermediate roll.

3. A method of manufacturing a roll body including a core and a long sheet material wound around an outer peripheral surface of the core,

the method for manufacturing the roll body comprises the following steps:

disposing a fixing member for fixing a portion of the sheet material to the core on the outer peripheral surface of the core in a width direction of the core, the fixing member having a1 st end surface extending in the width direction of the core and a2 nd end surface on a side opposite to the 1 st end surface;

applying a coating material to the outer peripheral surface of the winding core along the width direction of the winding core;

fixing a portion of the web material to the core by the fixing member; and

a step of winding the web material around the core and filling at least one of the 2 nd gap and the 3 rd gap with the coating material after the coating material is applied and a part of the web material is fixed to the core,

the coating of the coating material or the arrangement of the fixing member is performed in such a manner that the coating material is positioned on the 1 st end face side or the 2 nd end face side and the coating material is in contact with or close to the 1 st end face or the 2 nd end face, or the coating material is positioned on the 1 st end face side and the 2 nd end face side respectively and the coating material is in contact with or close to the 1 st end face and the 2 nd end face,

the 2 nd gap is a gap between the core and the 1 st peripheral web and in contact with the 1 st end face,

the 3 rd gap is a gap between the winding core and the 1 st peripheral web and in contact with the 2 nd end face.

4. A method of manufacturing a roll body including a core and a long sheet material wound around an outer peripheral surface of the core,

the method for manufacturing the roll body comprises the following steps:

fixing a portion of the web material to the core by the fixing member;

winding the sheet around the core for at least 1 circumference to obtain an intermediate roll having a2 nd gap and a 3 rd gap;

applying a coating material to a front surface of the sheet material constituting an outer peripheral surface of the intermediate roll along the width direction of the winding core; and

a step of winding the web material around the core again after the coating material is applied,

the 2 nd gap is a gap between the winding core and the 1 st peripheral web and in contact with the 1 st end surface of the fixing member,

the 3 rd gap is a gap between the winding core and the 1 st peripheral web and in contact with the 2 nd end surface of the fixing member,

the coating material is applied to at least one of a2 nd area corresponding to the 2 nd gap and a 3 rd area corresponding to the 3 rd gap on the front surface of the sheet material constituting the outer peripheral surface of the intermediate roll body.

5. The roll manufacturing method according to any one of claims 1 to 4, wherein,

the coating material has fluidity.

6. The roll manufacturing method according to any one of claims 1 to 5, wherein,

the coating material is a curable polymer composition.

7. The roll manufacturing method according to any one of claims 1 to 6, wherein,

the coating material contains a coloring material or a luminescent material.

8. The roll manufacturing method according to any one of claims 1 to 7, wherein,

the sheet has a resin film.

9. The roll manufacturing method according to any one of claims 1 to 7, wherein,

the sheet comprises an acrylic resin, a polyester resin or a cycloolefin polymer resin.

10. The roll manufacturing method according to claim 8 or 9, wherein,

the sheet has a thickness of 15 to 300 [ mu ] m.

11. The roll manufacturing method according to any one of claims 1 to 10, wherein,

the sheet is a laminate having a base material and 1 or more functional layers laminated on the base material.

12. The roll manufacturing method according to any one of claims 1 to 11, wherein,

the sheet is used for an optical film, a polarizing plate, or a display device.

13. A roll body comprising a roll core and a long sheet material wound around the outer peripheral surface of the roll core,

the roll body is provided with:

a1 st gap located between the core and the sheet in the 1 st circumference, and contacting a distal end surface of a winding start end portion in a longitudinal direction of the sheet in the 1 st circumference, the distal end surface being located in the longitudinal direction; and

and a1 st filling section which is filled in the 1 st gap and extends in the width direction of the winding core.

14. The roll of claim 13, wherein,

the roll body further includes:

a fixing member which is provided between the core and the sheet on the 1 st circumference and fixes a part of the sheet to the core, and which has a1 st end surface extending in the width direction of the core and a2 nd end surface on the opposite side of the 1 st end surface;

a2 nd gap between the winding core and the 1 st peripheral web, the 2 nd gap being in contact with the 1 st end surface of the fixing member;

a 3 rd gap between the winding core and the 1 st peripheral web and in contact with the 2 nd end surface of the fixing member; and

at least one of a2 nd filling part filled in the 2 nd gap and extending in the width direction of the winding core and a 3 rd filling part filled in the 3 rd gap and extending in the width direction of the winding core.

15. A roll body comprising a roll core and a long sheet material wound around the outer peripheral surface of the roll core,

the roll body is provided with:

and a1 st nip portion provided in a1 st region corresponding to at least the 1 st gap between the sheets after the 1 st turn, and extending in a width direction of the winding core.

16. A roll body comprising a roll core and a long sheet material wound around the outer peripheral surface of the roll core,

the roll body is provided with:

17. A roll body comprising a roll core and a long sheet material wound around the outer peripheral surface of the roll core,

the roll body is provided with:

at least one of a2 nd sandwiching unit provided in a2 nd region corresponding to the 2 nd gap between the sheets after the 1 st cycle and extending in the width direction of the winding core, and a 3 rd sandwiching unit provided in a 3 rd region corresponding to the 3 rd gap between the sheets after the 1 st cycle and extending in the width direction of the winding core.

18. The roll body according to claim 13 or 14,

the roll body further includes a4 th nip portion, and the 4 th nip portion is provided continuously with the 1 st filling portion and is interposed between the sheet in the 1 st circumference and the sheet in the 2 nd circumference.

19. The roll body according to claim 13 or 14,

in the absence of a4 th intervening portion provided continuously from the 1 st filling portion and interposed between the sheet in the 1 st circumference and the sheet in the 2 nd circumference, a ratio of a length L1 of the 1 st filling portion in the longitudinal direction of the sheet to a thickness T2 of the 1 st filling portion at a position in contact with the distal end surface is 90 or more, and in the presence of the 4 th intervening portion, a ratio of a sum of a length L1 of the 1 st filling portion in the longitudinal direction of the sheet and a length L2 of the 4 th intervening portion in the longitudinal direction of the sheet to a thickness T2 of the 1 st filling portion at a position in contact with the distal end surface is 90 or more.

20. The roll of claim 19, wherein,

in the absence of the 4 th interposed portion, a ratio of an area S1 of a region sandwiched between the outer peripheral surface of the core and the front surface of the 1 st filling portion in a plane including the longitudinal direction of the sheet and the radial direction of the core to the thickness T2 of the 1 st filling portion is 3.0 or more, and in the presence of the 4 th interposed portion, a ratio of a sum of an area S1 of a region sandwiched between the outer peripheral surface of the core and the front surface of the 1 st filling portion in a plane including the longitudinal direction of the sheet and the radial direction of the core and an area S2 of a region sandwiched between the outer peripheral surface of the core and the front surface of the 4 th interposed portion to the thickness T2 of the 1 st filling portion is 3.0 or more.

21. The roll of claim 17,

when the thickness of the 2 nd sandwiching portion is measured along the longitudinal direction of the sheet, a ratio of a length L4 from a2 nd end of the 2 nd sandwiching portion opposite to a1 st end on the fixing member side to a position where a maximum thickness T6 of the 2 nd sandwiching portion is reached in the longitudinal direction to the maximum thickness T6 of the 2 nd sandwiching portion is 12 or more.

22. The roll of claim 21, wherein,

a ratio of a cross-sectional area S3 of the 2 nd interposed portion from the 2 nd end of the 2 nd interposed portion to a position where the maximum thickness T6 is obtained in a plane including the longitudinal direction of the sheet and the radial direction of the winding core to the maximum thickness T6 of the 2 nd interposed portion is 2.5 or more.

23. The roll of claim 15 or 17, wherein,

the sheet has, at both ends extending in the longitudinal direction of the sheet, convex portions projecting in the radial direction of the winding core.

24. The roll body according to any one of claims 13 to 23,

the sheet has a resin film.

25. The roll body according to any one of claims 13 to 23,

the sheet comprises an acrylic resin, a polyester resin, and a cycloolefin polymer resin.

26. The roll of claim 24 or 25, wherein,

the sheet has a thickness of 15 to 300 [ mu ] m.

27. The roll of claim 13, wherein,

the 1 st filling part contains a coloring material or a luminescent material.

28. The roll of claim 14 or 16, wherein,

the 2 nd filling part and the 3 rd filling part contain a coloring material or a light emitting material, respectively.

29. The roll of claim 15, wherein,

the 1 st sandwiching portion includes a coloring material or a light emitting material.

30. The roll of claim 17,

the 2 nd sandwiching portion and the 3 rd sandwiching portion respectively contain a coloring material or a light emitting material.

31. The roll of claim 13, wherein,

the 1 st filling part contains a cured product of a curable polymer composition.

32. The roll of claim 14 or 16, wherein,

the 2 nd filling part and the 3 rd filling part each contain a cured product of a curable polymer composition.

33. The roll of claim 15, wherein,

the 1 st sandwiching unit includes a cured product of a curable polymer composition.

34. The roll of claim 17,

the 2 nd and 3 rd sandwiching parts each contain a cured product of a curable polymer composition.

35. The roll body according to any one of claims 13 to 34,

36. The roll of any one of claims 13 to 35,

the sheet is used for an optical film, a polarizing plate, or a display device.