EP2676907A1 - Method for manufacturing roll, and roll - Google Patents
Method for manufacturing roll, and roll Download PDFInfo
- Publication number
- EP2676907A1 EP2676907A1 EP12747644.8A EP12747644A EP2676907A1 EP 2676907 A1 EP2676907 A1 EP 2676907A1 EP 12747644 A EP12747644 A EP 12747644A EP 2676907 A1 EP2676907 A1 EP 2676907A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- roll
- long element
- alignment
- groove
- winding
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H23/00—Registering, tensioning, smoothing or guiding webs
- B65H23/04—Registering, tensioning, smoothing or guiding webs longitudinally
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H23/00—Registering, tensioning, smoothing or guiding webs
- B65H23/02—Registering, tensioning, smoothing or guiding webs transversely
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H18/00—Winding webs
- B65H18/08—Web-winding mechanisms
- B65H18/10—Mechanisms in which power is applied to web-roll spindle
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H18/00—Winding webs
- B65H18/08—Web-winding mechanisms
- B65H18/10—Mechanisms in which power is applied to web-roll spindle
- B65H18/106—Mechanisms in which power is applied to web-roll spindle for several juxtaposed strips
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H18/00—Winding webs
- B65H18/28—Wound package of webs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2301/00—Handling processes for sheets or webs
- B65H2301/40—Type of handling process
- B65H2301/41—Winding, unwinding
- B65H2301/414—Winding
- B65H2301/4148—Winding slitting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2301/00—Handling processes for sheets or webs
- B65H2301/40—Type of handling process
- B65H2301/41—Winding, unwinding
- B65H2301/417—Handling or changing web rolls
- B65H2301/4171—Handling web roll
- B65H2301/4173—Handling web roll by central portion, e.g. gripping central portion
- B65H2301/41732—Handling web roll by central portion, e.g. gripping central portion by crane
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2301/00—Handling processes for sheets or webs
- B65H2301/50—Auxiliary process performed during handling process
- B65H2301/51—Modifying a characteristic of handled material
- B65H2301/512—Changing form of handled material
- B65H2301/5121—Bending, buckling, curling, bringing a curvature
Definitions
- the present invention relates to a method for manufacturing a roll which is a long element such as adhesive tape rolled up, and relates to such a roll.
- a roll having a predetermined width is made through a manufacturing method in which a wide sheet is rolled up on a winding unit, and then cut at every predetermined width by using a cutter.
- this manufacturing method the thickness of the cutter and the angle of the blade edge are easily variable, and for this reason, dimensional error relative to the width direction easily becomes large at the center side of the roll where the blade edge is deeply inserted.
- a manufacturing method in which a wide sheet is cut before it is rolled up on the winding unit, thereby forming long elements having a predetermined width, and then winding these long elements on the winding unit while restricting the position in the width direction.
- PTL 1 discloses the following manufacturing method. Namely, an edge regulating roller is prepared which has a pair of flanges at both ends of the roller relative to the width direction. The flanges are tilted outwardly so that the distance between the flanges increases towards outside. This edge regulating roller is rotatably disposed at a reaching position of each long element to the roll. The long element is then rolled up while its positions relative to the width direction is regulated by having its ends relative to the width direction abut the flanges of the edge regulating roller.
- PTL 2 discloses the following manufacturing method. Namely, a guide block is prepared which has a pair of flanges at both ends of the guide block relative to the width direction. The flanges are tilted from the both ends by 0 to 20 degrees. This guide block is fixed to a reaching position of each long element to the roll. The long element is then rolled up while regulating its position relative to the width direction by having its ends abut the flanges of the guide block.
- the distance between the flanges increases from the base side towards the leading end side.
- the base parts of the flanges on the edge regulating roller or those of the guide block need to be approximated to the roll surface to the extent that the base parts of the flanges contact the roll surface.
- the adhesive agent oozing out from the long element may adhere to the flanges.
- This oozing-out adhesive agent causes an unstable braking force, between the roll and the flanges, consequently making the tension of the long element in process of being rolled up unstable; i.e., causes excessive tension or insufficient tension.
- This unstable tension may serve as a cause of significant variation in the width of the long element, leading to significant irregularity in the roll of the long element in the width direction.
- the present invention is made, and it is an object of the present invention to provide a method of manufacturing a roll, in which amount of irregularity in the roll of a long element is sufficiently reduced, even in cases of winding a narrow long element having an adhesive agent on a roll having a large diameter.
- An aspect of the present invention is a method of manufacturing a roll in which a long element having an adhesive agent and a predetermined width is wound by a winding unit so that the long element forms a plurality of wound layers in a radial direction from the winding unit to a roll surface, the method including: arranging, in a position distant from the roll surface, an alignment groove having a pair of groove side surfaces configured to contact both ends of the long element relative to the width direction; causing each of the pair of groove side surfaces to be on the same plane as the corresponding one of a pair of wound end surfaces formed by both ends of the wound layers relative to the width direction; and placing the long element on the alignment groove and winding the long element on the roll.
- the alignment groove when the long element is wound by the winding unit, the alignment groove is positioned so that each of the pair of groove side surfaces is on the same plane as the corresponding one of the pair of wound end surfaces formed by both ends of the wound layers relative to the width direction. Since the forwarding direction of the long element from the alignment groove to the roll surface matches with the winding direction of the roll, winding is carried out while the long element is positioned relative to the width direction by the alignment groove. At this time, even when the adhesive agent on the long element adheres to the alignment groove, the adhesive agent having adhered does not generate a braking force between the alignment groove and the roll surface, because the alignment groove is in a position distant from the roll surface.
- the long element is wound with a stable tension while being positioned relative to the width direction. Therefore, the amount of irregularity in the layers of the long element is sufficiently reduced, even in cases of winding a narrow long element having an adhesive agent on a roll having a large diameter.
- the aspect of the present invention may be adapted so that the alignment groove has a groove depth greater than the thickness of the long element.
- the above structure in which the groove depth is greater than the thickness of the long element causes the both ends of the long element relative to the width direction, having departed from the alignment groove to contact the groove side surfaces of the alignment groove longer than a case where the groove depth is smaller. Therefore, the groove side surfaces in contact with the both ends of the long element relative to the width direction improve the positional regulation of the long element relative to the width direction, It is therefore possible to further sufficiently reduce the irregularity in the layers of long element.
- the aspect of the present invention may be adapted so that the winding is carried out while the alignment groove is moved in a forwarding direction of the long element.
- the adhesive agent is less likely collected, as compared with a case where the adhesive agent is accumulated in a position where adhesion of the adhesive agent has occurred, because even when the adhesive agent adheres to the alignment groove, the adhesive agent having adhered moves in the forwarding direction of the long element, along with the alignment groove. Since a rapid increase in the amount of adhesive agent on the alignment groove is prevented, it is possible to variation in the tension of the long element caused by the adhesive agent staying in the alignment groove generating a braking force to forwarding of the long element. As the result, the width of the long element is stabilized from the beginning to the end of winding. Therefore, the amount of irregularity in the layers of the long element is made sufficiently small, even in cases of winding a narrow long element having an adhesive agent on a roll having a large diameter.
- the aspect of the present invention may be adapted so that the alignment roller having the alignment groove around its circumference is rotated about the axis of the alignment roller, thereby moving the alignment groove in the forwarding direction of the long element.
- the above structure enables adjustment of the relative position relation and the speed difference between the groove side surfaces of the alignment groove and the long element, by raising or reducing the rotation speed of the alignment roller. This facilitates adjustment of the bonding force amongst the wound layers on the roll to a desirable value.
- Another aspect of the present invention is a roll manufactured by the above described manufacturing method such that a maximum amount of irregularity in the both ends of the wound layers of the long element relative to the width direction is 0 mm to 1.0 mm, preferably, 0 mm to 0.7 mm, and more preferably 0 mm to not more than 0.5 mm.
- the above structure makes it easy to confirm that the roll is manufactured by the method of the present invention for manufacturing a roll.
- the present invention yields a roll having sufficiently small amount of irregularity in the layers of a long element on the roll.
- a roll manufacturing method of present embodiment is a method in which a long element 72 having an adhesive agent and having a predetermined width is rolled up on a winding unit 8, thereby manufacturing a roll 73 having a plurality of wound layers 73b of the long element 72 in a radial direction, from the winding unit 8 to the roll surface 73a.
- the method includes an alignment roller setting process, a long element setting process, an unwinding process, a cutting process, an alignment and winding process, and a take-out process.
- the roll 73 is detailed later.
- An alignment roller preparation process is a process of selecting a desirable alignment roller 6 from a plurality of types of alignment rollers 6, and mounting the alignment roller 6 to an alignment devise 2. Specifically, as shown in Fig. 1 , specification of a product such as the diameter and width of a roll 73 to be produced which is shown in FIG. 4 , and the thickness of the wound layer 73b (long elements 72) is read out. Then, an alignment roller 6 having a groove width corresponding to the width of the long elements 72 and a groove depth which is two or more times the thickness of the wound layer 73b is selected from the plurality of types of alignment rollers 6. The selected alignment roller 6 is then moved from storage, and the rotation shaft 63 of the alignment roller 6 is rotatably mounted to a not-shown roller-supporting structure of the alignment device 2.
- a long element setting process is a process carried out subsequent to the alignment roller preparation process, and is a process for enabling winding of a long element 72 corresponding to the roll 73 to be produced.
- a plurality of winding units 8 each corresponding to the width of the wound layer 73b (long elements 72) of the roll 73 are mounted to a winding roller 51.
- Each of the winding units 8 is movable in the width direction of the winding roller 51.
- the intervals between the winding units 8 are adjusted so that the position of each of the winding unit 8 and the position of each alignment groove 62 of the corresponding alignment roller 6 relative to the vertical direction match with each other.
- the positional relationship is adjusted as follows.
- the distance between the winding unit 8 and the alignment roller 6 can be increased or decreased, the distance between the winding unit 8 and the alignment roller 6 is reduced to the extent that the alignment roller 6 is close to the circumference of the winding roller 51.
- the winding unit 8 is engaged with the alignment groove 62 of the alignment roller 6. This way, the alignment groove 62 of the alignment roller 6 and the winding unit 8 are positioned to match each other, relative to the vertical direction.
- a plate-like or a belt-like position adjusting member is placed in the vertical direction. Using this position adjusting member as the reference, the positions of the winding unit 8 and that of the alignment groove 62 of the alignment roller 6 are adjusted. Note that a laser beam may be used as the position adjusting member. When the position adjustment is completed as described above, all the winding units 8 are fixed to the winding roller 51.
- a sheet roll 7 formed by a sheet 71 whose thickness is the same as the thickness of the wound layer 73b (long elements 72) of the roll 73.
- the sheet roll 7 is taken out from a not-shown roll storage and is conveyed to the unwind device 3 by a suspending device 91 of the roll conveyance device 9. Note that the sheet roll 7 has a thickness which is at least the thickness of the long element 72, and has a width which is two or more times the width of the long element 72.
- the sheet roll 7 is then set to the unwind device 3.
- the leading end portion of the sheet 71 positioned on the outer surface of sheet roll 7 is unwound by an operator and is forwarded to a cutting apparatus 4, through a conveyance path formed by guide rollers or the like.
- the sheet 71 is cut into a plurality of long elements 72 each having the roll width, by the cutting apparatus 4.
- long elements 72 odd-number th long elements 72 when counted in a width direction are directed downward, while even-number th long elements 72 when counted in the width direction are directed upward.
- the long elements 72 directed downwards are each placed on an alignment groove 62 of the corresponding alignment roller 6 on the lower side as is the case of placing a belt on a pulley, and are brought into a setting-standby state during which the leading end portion is the free end.
- the long elements 72 directed upwards are each placed on the alignment groove 62 of the corresponding alignment roller 6 on the upper side, and are brought into the setting-standby state during which the leading end portion is the free end.
- each long element 72 is fixed to the corresponding winding unit 8 disposed immediately below or immediately above. That is, a pair of groove side surfaces 62a of the alignment groove 62 and a pair of wound end surfaces 73c formed by both ends of the wound layer 73b relative to the width direction are disposed so that each groove side surface 62a and the corresponding end of the wound layer 73b are present on the same plane.
- the positions of the long element 72 and the winding unit 8 match with each other relative to the vertical direction, therefore the length of the long element 72 easily directed and fixed to the winding direction of the winding unit 8.
- This operation of fixing may be done by adhering the adhesive agent on the long elements 72 to the winding unit 8.
- the distance between the winding unit 8 and the alignment roller 6 can be increased or reduced, the distance between the winding unit 8 and the alignment roller 6 is reduced to the extent that the alignment roller 6 is nearby the circumference of the winding roller 51.
- the winding unit 8 is engaged with the alignment groove 62, and the groove bottom surface 62b of the alignment groove 62 is pressed against the long element 72 in the direction of the winding unit 8.
- the fixed state of the winding roller 51 and the winding unit 8 is temporarily released.
- the state of the winding unit 8 fixed relative to the width direction of the winding roller 51 is maintained by the groove side surfaces 62a, while the winding unit 8 is rotatable about the winding roller 51.
- the winding unit 8 is rotatable, while its positional relation to the alignment groove 62 is maintained. After that, as shown in Fig. 2 , the winding unit 8 is rotated by an operator to get rid of slackness of the long element 72. When the slackness of all the long elements 72 are gotten rid of, the winding roller 51 and the winding unit 8 are again brought into the fixed state. Then, the distance between the winding unit 8 and the alignment roller 6 is increased.
- the unwinding process, the cutting process, and the aligning and winding process are carried out at the same time after the long element setting process.
- the unwinding process is a process of unwinding the sheet 71 of the sheet roll 7 set to the unwind device 3 at a predetermined forwarding speed.
- the cutting process is a process for cutting the sheet 71 unwound from the unwind device 3 into a plurality of long elements 72 having a predetermined width.
- the aligning and winding process is a process for winding the long elements 72 to the winding units 8, at the same time.
- rotation of the winding units 8 on the wind device 5 and rotation of the sheet roll 7 on the unwind device 3 are started at the same time.
- the rotation speed of the wind device 5 and that of the unwind device 3 are adjusted to keep the constant tension of the sheet 71 and the long elements 72 being conveyed. This way, cutting width by the cutting apparatus 4 is stabilized, thus highly accurately forming the long elements 72 each having a predetermined width. Then, aligning and winding process takes place at the wind device 5 at a stable operation.
- the rolls 73 are manufactured as follows. Namely, as shown in Fig. 3 and Fig. 4 , while the alignment groove 62 having the pair of groove side surfaces 62a in contact with the both ends of the long elements 72 relative to the width direction is disposed in a position distant from the roll surface 73a, and the pair of groove side surfaces 62a and the pair of wound end surfaces 73c formed by the both ends of the wound layers 73b relative to the width direction are disposed so that each groove side surface 62a is on the same plane as the corresponding one of the wound end surface 73c, each of the long elements 72 is placed on the corresponding alignment groove 62 having a groove depth greater than the layer thickness of the wound layers 73b and is moved and wound in a winding direction (forwarding direction) which corresponds to the rotating direction of the winding roller 51.
- a winding direction forwarding direction
- the distance in the above description that the alignment groove 62 is disposed in a position distant from the roll surface 73a is preferably set so that the length of the long element 72 with respect to the groove depth of the alignment groove 62 is such that (1) the possibility of having the alignment roller 6 contact the roll surface 73a due to mechanical vibration or the like is prevented, and (2) an oscillation errors of the long elements 72 relative to the width direction is an insignificant level.
- the alignment groove 62 is positioned so that each of a pair of wound end surfaces 73c formed by the both ends of the wound layers 73b relative to the width direction is on the same plane as the corresponding one of a pair of groove side surfaces 62a. Since the forwarding direction of the long element 72 from the alignment groove 62 to the roll surface 73a matches with the winding direction on the roll 73, the long element 72 is wound while being positioned relative to the width direction by the alignment groove 62.
- the alignment groove 62 having a groove depth greater than the thickness of the long element 72 causes the both ends of the long element 72 relative to the width direction having departed the alignment groove 62 to be in contact with the groove side surfaces 62a of the alignment groove 62 longer than a case where the groove depth is smaller.
- These groove side surfaces 62a in contact with the both ends of the long element 72 relative to the width direction improves the accuracy in position regulation relative to the width direction.
- the irregularity in the roll of long element 72 is further sufficiently reduced.
- the adhesive agent oozing out from the both ends of the long element 72 may adhere to the alignment groove 62.
- the alignment groove 62 is fixed, the adhesive agent once adhered to the alignment groove 62 induces collection of more adhesive agent to the alignment groove 62.
- the adhesive agent accumulated in the alignment groove 62 sticks the adhesive agent on the long element 72 of each wound layer 73b, and generates a braking force between the alignment groove 62 and the long element 72 during the winding. Rapid increase in the amount of accumulated adhesive agent causes an excessively large tension to the long element 72 being wound.
- the rapidly increased tension causes a change in the width of the long element 72, which may cause an increase in the amount of irregularity relative to the width direction, amongst the wound layers 73b of the long element.
- the width of the long element 72 therefore is stabilized from the beginning to the end of winding, which enables sufficient reduction of the amount of irregularity relative to the width direction of each wound layer 73b in the roll of the long element 72, even when winding a narrow long element 72 to a roll having a large diameter.
- the alignment roller 6 of the present embodiment may be rotatably supported by the alignment device 2, or may be supported so that its rotation speed is adjustable by means of adjusting the rotation drive force of the alignment device 2.
- the way of supporting to enable adjustment of rotation speed is such that the alignment groove 62 is moved in the forwarding direction of the long element 72 when the alignment roller 6 is rotated about its axis.
- the support is such that the rotation speed is adjustable, it is possible to adjust the relative positional relation and the difference in the speed of the groove side surfaces 62a of alignment groove 62 and the long elements 72 simply by adjusting the rotation speed of the alignment roller 6. Therefore, the adhesive force among the wound layers 73b of the roll 73 is easily adjusted to a desirable value.
- the wind device 5 and the unwind device 3 are stopped. After that, all the long elements 72 are cut between the roll 73 and the alignment roller 6, and enters the setting-standby state as shown in Fig. 1 .
- the rolls 73 are carried out to a post process by using a not-shown take-out device such as a carrier or a roll conveyance device 9. Further, before the take-out, the work for setting in the long element setting process shown in FIG. 2 is carried out by pulling out the winding rollers 51 from the rolls 73, and setting them to the wind device 5.
- the amount of irregularity in the both ends of the wound layers 73b of the long element 72 relative to the width direction is 0 mm to 1.0 mm, preferably 0 mm to 0.7 mm, and more preferably 0 mm to 0.5 mm, irrespective of the winding diameter of the roll 73 (or the width L4 of the long element 72) as shown in Fig. 5 .
- the thickness L1 of each wound layer 73b (long element 72) is set to be 0.05 mm to 5.3 mm.
- the sheet 71 includes at least a separation layer 711 and an adhesive layer 712.
- the sheet 71 is manufactured by applying an adhesive agent composition solution on a separation film to serve as the separation layer 711 to form an applied layer, and drying this applied layer to form the adhesive layer 712.
- the adhesive agent composition solution may contain an inorganic filler as needed.
- the method of applying the adhesive agent composition solution is not particularly limited. For example, a comma coating, a fountain method, a gravure method, or the like may be adopted as the method of applying the adhesive agent.
- the thickness of application may be suitably set so that the thickness L3 of the adhesive layer 712 resulting at the end, after the applied layer is dried, is within a range of 0.025 mm to 5.0 mm.
- the viscosity of the adhesive agent composition solution is not particularly limited; however, is preferably 400 to 2500 mPa ⁇ s, and more preferably, 800 to 2000 mPa ⁇ s.
- the separation film (separation layer 711) is not particularly limited and any traditionally known separation film is adoptable.
- the separation film is such that a separation coating layer such as a silicone layer or the like is formed on a surface of the base material of the separation film to which the adhesive layer is pasted.
- example materials for the separation film includes: paper materials such as glassine paper and a resin film made of polyethylene, polypropylene, polyester, or the like.
- the thickness L2 of the separation film is set to be 0.025 mm to 0.3 mm.
- the present embodiment deals with a case where the long elements 72 (sheet 71) has an adhesive layer 712 as in the case of an adhesive tape or the like; however, the present invention is not limited to this, and the present invention may be applied to winding of any given long element 72 having no adhesive layer 712.
- the long element 72 may be elastic tape used for fixing cushions or the like on a frame of a display of a laptop computer or a word processor, or a non-adhesive tape such as magnetic tape, ink ribbons, photo films, long paper tape, or the like.
- a roll manufacturing device 1 capable of carrying out each process in the manufacturing method of the present embodiment.
- the manufacturing method of the present embodiment is also implemented by roll manufacturing devices having other structures.
- the roll manufacturing device 1 includes: a roll conveyance device 9 for conveying a sheet roll 7; an unwind device 3 configured to unwind a sheet 71 from the sheet roll 7; a cutting apparatus 4 configured to cut the sheet 71 into a plurality of long elements 72 each having a predetermined width; an alignment device 2 configured to aligning the long elements 72 while regulating the positions of the long elements relative to the width direction; a wind device 5 configured to wind the long elements 72 to form rolls 73; and a take-out device configured to take out the rolls 73 formed by the wind device 5 to a subsequent process.
- the roll conveyance device 9 has a function of carrying out an alignment roller setting process, and is configured to convey, to any given position, the sheet roll 7 from a not-shown previous process in which the sheet roll 7 is manufactured and stored.
- the roll conveyance device 9 includes: a rail 92 disposed so as to enable trafficking above the devices for carrying out each of the processes; at least one suspending device 91 capable of moving along the rail 92; and a not-shown conveyance control device.
- the suspending device 91 is capable of suspending the sheet roll 7 at its core 7a and elevating the sheet roll 7.
- the conveyance control device is configured to manage and control the operation of the suspending device 91 based on production plan information so as to convey a sheet roll 7 for a predetermined product to a predetermined position.
- the unwind device 3 On the downstream side of the roll conveyance device 9 relative to the forwarding direction of the sheet 71 is an unwind device 3.
- the unwind device 3 has a function of carrying out the long element setting process and the unwinding process, and includes a core-holder configured to detachably hold the core 7a of the sheet roll 7; a rotation drive device configured to rotate the core-holder with a given rotation speed and a given torque; a rotation control device configured to control the rotation speed of the rotation drive device.
- a cutting apparatus 4 On the downstream side of the unwind device 3 is a cutting apparatus 4.
- the cutting apparatus 4 has a function of carrying out the long element setting process and the cutting process, and includes: a plurality of cutting blades 41; a cutting blade holder configured to hold the cutting blades 41 so that the cutting blades 41 are positioned in given positions relative to the width direction; a cutting blade drive mechanism configured to rotate the cutting blades 41 at a given rotation speed, and a cutting roller 42 to which the sheet 71 and the blade edges of the cutting blades 41 abut.
- Each alignment device 2 has a function of carrying out the long element setting process and the aligning and winding process.
- On the downstream side of the alignment device 2 is a wind device 5.
- the wind device 5 has a function of carrying out the long element setting process and the aligning and winding process.
- the wind device 5 detachably has the winding roller 51, and a not-shown rotation drive device configured to rotate the winding roller 51 at a given rotation speed.
- the winding roller 51 has a diameter that can be inserted into the winding unit 8. Further, the winding roller 51 has a plurality of pressing members capable of projecting to the outer side than the roller surface. The pressing members switch the state of the winding unit 8 and the winding roller 51 between an inserted state and a fixed state.
- On the downstream side of the wind device 5 is a take-out device.
- the take-out device is capable of taking out the products.
- the take-out device may be a bogie capable of carrying thereon the roll 73, or a roll conveyance device 9.
- the alignment roller 6 for use in the roll manufacturing device 1 having the above structure has a cylindrical roll main body 60; one or more alignment grooves 62 formed on the circumference of the roll main body 60; and a pair of rotation shafts 63 ( Fig. 1 ) projecting from both ends of the roll main body 60.
- the or each alignment groove 62 is formed on the circumference of the roll main body 60.
- the axis of the roll main body 60 coincides with the axis of the rotation shaft 63. This way, when the alignment roller 6 rotates about its axis while being fixed relative to the width direction (axial direction), the alignment groove 62 is moved at the same position relative to the width direction.
- the alignment groove 62 is formed by the circumferential surface of the roll main body 60, and the groove side surface walls 61 formed on the circumferential surface of the roll main body 60.
- the circumferential surface of the roll main body 60 forms a flat groove bottom surface 62b of the alignment groove 62, while the groove side surface walls 61 form flat groove side surfaces 62a of the alignment groove 62.
- the alignment groove 62 having a groove bottom surface 62b parallel to the axial direction of the alignment roller 6 and the groove side surfaces 62a matching with radial directions of the alignment roller 6 form a rectangular cross section such that an outer portion relative to a radial direction of the alignment roller 6 is opened.
- the groove width A2 of the alignment groove 62 substantially matches with the width L4 of the long element 72. Note that, by the groove width A2 of the alignment groove 62 substantially matching with the width L4 of the long element 72, it means that the groove width A2 matches with the width L4 so that the amount of irregularity in the roll 73 relative to the width direction is within an allowable range.
- the groove width A2 of the alignment groove 62 may match with the width L4 of the long element 72, or be greater or smaller than the width L4 of the long element 72, provided that the amount of irregularity in the roll 73 relative to the width direction is within the allowable range.
- the groove depth A1 of the alignment groove 62 is set to be twice or more the thickness L1 of the long element 72. With the groove depth A1 greater than the thickness of wound layers 73b, the alignment groove 62 enables each of the pair of groove side surfaces 62a to be on the same plane as the corresponding one of the pair of wound end surfaces 73c formed by both ends of the wound layers 73b relative to the width direction.
- the width A3 of the groove side surface wall 61 may be the same as or different from the groove width A2 of the alignment groove 62.
- the lower wind device 5 is able to wind the odd number th or the even number th long elements 72 from the cutting apparatus 4 and having a predetermined width and the upper wind device 5 is able to wind the odd number th or the even number th long elements 72.
- the alignment rollers 6 to be mounted to the upper or lower alignment device 2 may have different groove widths A2 of the groove side surface wall 61. In this case, by setting two different cutting widths in the cutting apparatus 4, it is possible to wind two different types of long elements 72 by the wind devices 5.
- the present embodiment deals with a case where the top portion of the groove side surface wall 61 of the alignment roller 6 is flat, i.e. , the top portion has a surface matching with the axial direction; however, the present invention is not limited to this.
- the top portion 613 of the groove side surface wall 61 of the alignment roller 6 may be curved so as to project radially outward.
- the top portion 613 of the groove side surface wall 61 guiding the long element 72 towards the alignment groove 62 prevents deterioration in the accuracy of alignment of each of the wound layers 73b on the roll 73, damages, bending, contamination or the like of the end portion of the roll 73 relative to the width direction.
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- Registering, Tensioning, Guiding Webs, And Rollers Therefor (AREA)
Abstract
In order to obtain a roll (73) having a sufficiently small amount of irregularity in the layers of long element (72) on the roll (73), an alignment groove (62) provided with a pair of groove side surfaces (62a, 62a) that are in contact with both ends in the width direction of the long element (72) is disposed at a position distant from a roll surface (73a), the pair of groove side surfaces (62a, 62a) and a pair of wound end surfaces (73c) formed by both ends in the width direction of a plurality of wound layers (73b) are disposed so as to be present on the same plane, and the long element (72) is hung on the alignment groove (62) and forwarded for winding.
Description
- The present invention relates to a method for manufacturing a roll which is a long element such as adhesive tape rolled up, and relates to such a roll.
- In some cases, a roll having a predetermined width is made through a manufacturing method in which a wide sheet is rolled up on a winding unit, and then cut at every predetermined width by using a cutter. However, in this manufacturing method, the thickness of the cutter and the angle of the blade edge are easily variable, and for this reason, dimensional error relative to the width direction easily becomes large at the center side of the roll where the blade edge is deeply inserted. In view of this problem, in some cases, there is adopted a manufacturing method in which a wide sheet is cut before it is rolled up on the winding unit, thereby forming long elements having a predetermined width, and then winding these long elements on the winding unit while restricting the position in the width direction.
- More specifically,
PTL 1 discloses the following manufacturing method. Namely, an edge regulating roller is prepared which has a pair of flanges at both ends of the roller relative to the width direction. The flanges are tilted outwardly so that the distance between the flanges increases towards outside. This edge regulating roller is rotatably disposed at a reaching position of each long element to the roll. The long element is then rolled up while its positions relative to the width direction is regulated by having its ends relative to the width direction abut the flanges of the edge regulating roller. - Further,
PTL 2 discloses the following manufacturing method. Namely, a guide block is prepared which has a pair of flanges at both ends of the guide block relative to the width direction. The flanges are tilted from the both ends by 0 to 20 degrees. This guide block is fixed to a reaching position of each long element to the roll. The long element is then rolled up while regulating its position relative to the width direction by having its ends abut the flanges of the guide block. -
- [PTL 1] Japanese Unexamined Patent Publication No.
31645/1987 Tokukaishou 62-31645 - [PTL 2] Japanese Unexamined Patent Publication No.
48623/1994 Tokukaihei 6-48623 - However, in the above traditional structure in which the flanges of the edge regulating roller or those of the guide block are tilted towards outside from the both ends relative to the width direction, the distance between the flanges increases from the base side towards the leading end side. For this reason, to prevent deterioration in the accuracy of positional regulation of the long element relative to the width direction, the base parts of the flanges on the edge regulating roller or those of the guide block need to be approximated to the roll surface to the extent that the base parts of the flanges contact the roll surface. When the long element has an adhesive agent, the adhesive agent oozing out from the long element may adhere to the flanges. This oozing-out adhesive agent causes an unstable braking force, between the roll and the flanges, consequently making the tension of the long element in process of being rolled up unstable; i.e., causes excessive tension or insufficient tension. This unstable tension may serve as a cause of significant variation in the width of the long element, leading to significant irregularity in the roll of the long element in the width direction.
- Particularly, in
PTL 2 where the guide block is fixed, a part where the adhesive agent has adhered causes adhesion of more adhesive agent, accumulating a large amount of adhesive agent in a short period of time. This leads to a significant amount of irregularity in the roll of the long element, relative to the width direction. Further, in cases of winding a narrow long element on a roll of a large roll diameter, the accuracy of the position regulation of the long element is easily deteriorated, increasing the swinging range of the roll surface To add this, width of the long element is easily affected by the tension. As the result, irregularity in the roll of long element becomes significant. - In view of the above problem, the present invention is made, and it is an object of the present invention to provide a method of manufacturing a roll, in which amount of irregularity in the roll of a long element is sufficiently reduced, even in cases of winding a narrow long element having an adhesive agent on a roll having a large diameter.
- An aspect of the present invention is a method of manufacturing a roll in which a long element having an adhesive agent and a predetermined width is wound by a winding unit so that the long element forms a plurality of wound layers in a radial direction from the winding unit to a roll surface, the method including: arranging, in a position distant from the roll surface, an alignment groove having a pair of groove side surfaces configured to contact both ends of the long element relative to the width direction; causing each of the pair of groove side surfaces to be on the same plane as the corresponding one of a pair of wound end surfaces formed by both ends of the wound layers relative to the width direction; and placing the long element on the alignment groove and winding the long element on the roll.
- In the above structure, when the long element is wound by the winding unit, the alignment groove is positioned so that each of the pair of groove side surfaces is on the same plane as the corresponding one of the pair of wound end surfaces formed by both ends of the wound layers relative to the width direction. Since the forwarding direction of the long element from the alignment groove to the roll surface matches with the winding direction of the roll, winding is carried out while the long element is positioned relative to the width direction by the alignment groove. At this time, even when the adhesive agent on the long element adheres to the alignment groove, the adhesive agent having adhered does not generate a braking force between the alignment groove and the roll surface, because the alignment groove is in a position distant from the roll surface.
- This way, from the beginning to the end of winding the long element, the long element is wound with a stable tension while being positioned relative to the width direction. Therefore, the amount of irregularity in the layers of the long element is sufficiently reduced, even in cases of winding a narrow long element having an adhesive agent on a roll having a large diameter.
- The aspect of the present invention may be adapted so that the alignment groove has a groove depth greater than the thickness of the long element.
- The above structure in which the groove depth is greater than the thickness of the long element causes the both ends of the long element relative to the width direction, having departed from the alignment groove to contact the groove side surfaces of the alignment groove longer than a case where the groove depth is smaller. Therefore, the groove side surfaces in contact with the both ends of the long element relative to the width direction improve the positional regulation of the long element relative to the width direction, It is therefore possible to further sufficiently reduce the irregularity in the layers of long element.
- The aspect of the present invention may be adapted so that the winding is carried out while the alignment groove is moved in a forwarding direction of the long element.
- In the structure, the adhesive agent is less likely collected, as compared with a case where the adhesive agent is accumulated in a position where adhesion of the adhesive agent has occurred, because even when the adhesive agent adheres to the alignment groove, the adhesive agent having adhered moves in the forwarding direction of the long element, along with the alignment groove. Since a rapid increase in the amount of adhesive agent on the alignment groove is prevented, it is possible to variation in the tension of the long element caused by the adhesive agent staying in the alignment groove generating a braking force to forwarding of the long element. As the result, the width of the long element is stabilized from the beginning to the end of winding. Therefore, the amount of irregularity in the layers of the long element is made sufficiently small, even in cases of winding a narrow long element having an adhesive agent on a roll having a large diameter.
- The aspect of the present invention may be adapted so that the alignment roller having the alignment groove around its circumference is rotated about the axis of the alignment roller, thereby moving the alignment groove in the forwarding direction of the long element.
- The above structure enables adjustment of the relative position relation and the speed difference between the groove side surfaces of the alignment groove and the long element, by raising or reducing the rotation speed of the alignment roller. This facilitates adjustment of the bonding force amongst the wound layers on the roll to a desirable value.
- Another aspect of the present invention is a roll manufactured by the above described manufacturing method such that a maximum amount of irregularity in the both ends of the wound layers of the long element relative to the width direction is 0 mm to 1.0 mm, preferably, 0 mm to 0.7 mm, and more preferably 0 mm to not more than 0.5 mm.
- The above structure makes it easy to confirm that the roll is manufactured by the method of the present invention for manufacturing a roll.
- The present invention yields a roll having sufficiently small amount of irregularity in the layers of a long element on the roll.
-
- [
Fig. 1] FIG. 1 is an explanatory diagram showing a process of a method for manufacturing a roll. - [
Fig. 2] FIG. 2 is an explanatory diagram showing a process of a method for manufacturing a roll. - [
Fig. 3] FIG. 3 is an explanatory diagram showing a process of a method for manufacturing a roll. - [
Fig. 4] FIG. 4 is an explanatory diagram showing positional relation between an alignment roller and a roll. - [
Fig. 5] FIG. 5 is an explanatory diagram showing layers of the roll. - [
Fig. 6] FIG. 6 is an explanatory diagram showing layers of the roll. - The following describes a preferable embodiment of the present invention, with reference to attached drawings.
- A roll manufacturing method of present embodiment, as shown in
Fig. 4 , is a method in which along element 72 having an adhesive agent and having a predetermined width is rolled up on awinding unit 8, thereby manufacturing aroll 73 having a plurality ofwound layers 73b of thelong element 72 in a radial direction, from thewinding unit 8 to theroll surface 73a. As shown inFig. 1 , the method includes an alignment roller setting process, a long element setting process, an unwinding process, a cutting process, an alignment and winding process, and a take-out process. Theroll 73 is detailed later. - An alignment roller preparation process is a process of selecting a
desirable alignment roller 6 from a plurality of types ofalignment rollers 6, and mounting thealignment roller 6 to an alignment devise 2. Specifically, as shown inFig. 1 , specification of a product such as the diameter and width of aroll 73 to be produced which is shown inFIG. 4 , and the thickness of thewound layer 73b (long elements 72) is read out. Then, analignment roller 6 having a groove width corresponding to the width of thelong elements 72 and a groove depth which is two or more times the thickness of thewound layer 73b is selected from the plurality of types ofalignment rollers 6. The selectedalignment roller 6 is then moved from storage, and therotation shaft 63 of thealignment roller 6 is rotatably mounted to a not-shown roller-supporting structure of thealignment device 2. - A long element setting process is a process carried out subsequent to the alignment roller preparation process, and is a process for enabling winding of a
long element 72 corresponding to theroll 73 to be produced. Specifically, a plurality of windingunits 8 each corresponding to the width of thewound layer 73b (long elements 72) of theroll 73 are mounted to a windingroller 51. Each of the windingunits 8 is movable in the width direction of the windingroller 51. - After the above, the intervals between the winding
units 8 are adjusted so that the position of each of the windingunit 8 and the position of eachalignment groove 62 of thecorresponding alignment roller 6 relative to the vertical direction match with each other. Specifically, the positional relationship is adjusted as follows. When the distance between the windingunit 8 and thealignment roller 6 can be increased or decreased, the distance between the windingunit 8 and thealignment roller 6 is reduced to the extent that thealignment roller 6 is close to the circumference of the windingroller 51. Then, while the distance between the windingunit 8 and thealignment roller 6 is increased as needed by a worker, the windingunit 8 is engaged with thealignment groove 62 of thealignment roller 6. This way, thealignment groove 62 of thealignment roller 6 and the windingunit 8 are positioned to match each other, relative to the vertical direction. - Further, when the distance between the winding
unit 8 and thealignment roller 6 is fixed, a plate-like or a belt-like position adjusting member is placed in the vertical direction. Using this position adjusting member as the reference, the positions of the windingunit 8 and that of thealignment groove 62 of thealignment roller 6 are adjusted. Note that a laser beam may be used as the position adjusting member. When the position adjustment is completed as described above, all the windingunits 8 are fixed to the windingroller 51. - Next, a
sheet roll 7 formed by asheet 71 whose thickness is the same as the thickness of thewound layer 73b (long elements 72) of theroll 73. Thesheet roll 7 is taken out from a not-shown roll storage and is conveyed to the unwinddevice 3 by a suspendingdevice 91 of theroll conveyance device 9. Note that thesheet roll 7 has a thickness which is at least the thickness of thelong element 72, and has a width which is two or more times the width of thelong element 72. Thesheet roll 7 is then set to the unwinddevice 3. - After that, the leading end portion of the
sheet 71 positioned on the outer surface ofsheet roll 7 is unwound by an operator and is forwarded to acutting apparatus 4, through a conveyance path formed by guide rollers or the like. Thesheet 71 is cut into a plurality oflong elements 72 each having the roll width, by the cuttingapparatus 4. Of theselong elements 72, odd-number thlong elements 72 when counted in a width direction are directed downward, while even-number thlong elements 72 when counted in the width direction are directed upward. Thelong elements 72 directed downwards are each placed on analignment groove 62 of thecorresponding alignment roller 6 on the lower side as is the case of placing a belt on a pulley, and are brought into a setting-standby state during which the leading end portion is the free end. On the other hand, thelong elements 72 directed upwards are each placed on thealignment groove 62 of thecorresponding alignment roller 6 on the upper side, and are brought into the setting-standby state during which the leading end portion is the free end. - After that, the leading end portion of each
long element 72 is fixed to the corresponding windingunit 8 disposed immediately below or immediately above. That is, a pair of groove side surfaces 62a of thealignment groove 62 and a pair ofwound end surfaces 73c formed by both ends of thewound layer 73b relative to the width direction are disposed so that eachgroove side surface 62a and the corresponding end of thewound layer 73b are present on the same plane. At this time, the positions of thelong element 72 and the windingunit 8 match with each other relative to the vertical direction, therefore the length of thelong element 72 easily directed and fixed to the winding direction of the windingunit 8. This operation of fixing may be done by adhering the adhesive agent on thelong elements 72 to the windingunit 8. - When the distance between the winding
unit 8 and thealignment roller 6 can be increased or reduced, the distance between the windingunit 8 and thealignment roller 6 is reduced to the extent that thealignment roller 6 is nearby the circumference of the windingroller 51. This way, the windingunit 8 is engaged with thealignment groove 62, and thegroove bottom surface 62b of thealignment groove 62 is pressed against thelong element 72 in the direction of the windingunit 8. Then, the fixed state of the windingroller 51 and the windingunit 8 is temporarily released. As the result, as shown inFig. 5 , the state of the windingunit 8 fixed relative to the width direction of the windingroller 51 is maintained by thegroove side surfaces 62a, while the windingunit 8 is rotatable about the windingroller 51. That is, the windingunit 8 is rotatable, while its positional relation to thealignment groove 62 is maintained. After that, as shown inFig. 2 , the windingunit 8 is rotated by an operator to get rid of slackness of thelong element 72. When the slackness of all thelong elements 72 are gotten rid of, the windingroller 51 and the windingunit 8 are again brought into the fixed state. Then, the distance between the windingunit 8 and thealignment roller 6 is increased. - The unwinding process, the cutting process, and the aligning and winding process are carried out at the same time after the long element setting process. The unwinding process is a process of unwinding the
sheet 71 of thesheet roll 7 set to the unwinddevice 3 at a predetermined forwarding speed. The cutting process is a process for cutting thesheet 71 unwound from the unwinddevice 3 into a plurality oflong elements 72 having a predetermined width. The aligning and winding process is a process for winding thelong elements 72 to the windingunits 8, at the same time. - Specifically, rotation of the winding
units 8 on thewind device 5 and rotation of thesheet roll 7 on the unwinddevice 3 are started at the same time. The rotation speed of thewind device 5 and that of the unwinddevice 3 are adjusted to keep the constant tension of thesheet 71 and thelong elements 72 being conveyed. This way, cutting width by the cuttingapparatus 4 is stabilized, thus highly accurately forming thelong elements 72 each having a predetermined width. Then, aligning and winding process takes place at thewind device 5 at a stable operation. - In the aligning and winding process, the
rolls 73 are manufactured as follows. Namely, as shown inFig. 3 andFig. 4 , while thealignment groove 62 having the pair of groove side surfaces 62a in contact with the both ends of thelong elements 72 relative to the width direction is disposed in a position distant from theroll surface 73a, and the pair of groove side surfaces 62a and the pair ofwound end surfaces 73c formed by the both ends of the wound layers 73b relative to the width direction are disposed so that eachgroove side surface 62a is on the same plane as the corresponding one of thewound end surface 73c, each of thelong elements 72 is placed on thecorresponding alignment groove 62 having a groove depth greater than the layer thickness of the wound layers 73b and is moved and wound in a winding direction (forwarding direction) which corresponds to the rotating direction of the windingroller 51. - The distance in the above description that the
alignment groove 62 is disposed in a position distant from theroll surface 73a is preferably set so that the length of thelong element 72 with respect to the groove depth of thealignment groove 62 is such that (1) the possibility of having thealignment roller 6 contact theroll surface 73a due to mechanical vibration or the like is prevented, and (2) an oscillation errors of thelong elements 72 relative to the width direction is an insignificant level. - In the above described winding method, when the
long element 72 is wound on the windingunit 8, thealignment groove 62 is positioned so that each of a pair ofwound end surfaces 73c formed by the both ends of the wound layers 73b relative to the width direction is on the same plane as the corresponding one of a pair ofgroove side surfaces 62a. Since the forwarding direction of thelong element 72 from thealignment groove 62 to theroll surface 73a matches with the winding direction on theroll 73, thelong element 72 is wound while being positioned relative to the width direction by thealignment groove 62. Even when an adhesive agent on thelong element 72 adheres to thealignment grooves 62, this adhesive agent having adhered does not generate a braking force between thealignment grooves 62 and theroll surface 73a, because thealignment groove 62 is positioned distant from theroll surface 73a. This way, from the beginning to the end of winding thelong element 72, thelong element 72 is wound at a stable tension while being positioned relative to the width direction. Therefore, even when a narrowlong element 72 having an adhesive agent is wound on a roll having a large diameter, the amount of irregularity in the roll of thelong element 72 relative to the width direction is sufficiently reduced. - Further, the
alignment groove 62 having a groove depth greater than the thickness of thelong element 72 causes the both ends of thelong element 72 relative to the width direction having departed thealignment groove 62 to be in contact with the groove side surfaces 62a of thealignment groove 62 longer than a case where the groove depth is smaller. These groove side surfaces 62a in contact with the both ends of thelong element 72 relative to the width direction improves the accuracy in position regulation relative to the width direction. Thus, the irregularity in the roll oflong element 72 is further sufficiently reduced. - Further, the following effects are also achievable by winding the
long element 72 while moving thealignment groove 62 in the forwarding direction of thelong element 72. - Specifically, when the
long element 72 is wound while its position relative to the width direction is regulated by thealignment groove 62, the adhesive agent oozing out from the both ends of thelong element 72 may adhere to thealignment groove 62. When thealignment groove 62 is fixed, the adhesive agent once adhered to thealignment groove 62 induces collection of more adhesive agent to thealignment groove 62. This way, a large quantity of adhesive agent accumulates in thealignment groove 62 in a short period of time. The adhesive agent accumulated in thealignment groove 62 sticks the adhesive agent on thelong element 72 of eachwound layer 73b, and generates a braking force between thealignment groove 62 and thelong element 72 during the winding. Rapid increase in the amount of accumulated adhesive agent causes an excessively large tension to thelong element 72 being wound. The rapidly increased tension causes a change in the width of thelong element 72, which may cause an increase in the amount of irregularity relative to the width direction, amongst the wound layers 73b of the long element. - To the contrary, when the
long element 72 is wound while thealignment groove 62 is moved in the forwarding direction of thelong element 72, even when the adhesive agent adheres to thealignment groove 62, the adhesive agent having adhered moves in the forwarding direction of thelong element 72 along with thealignment groove 62. This way, adhesion of the adhesive agent is less likely be promoted as compared with a case where the adhesive agent is accumulated in a position where the adhesion has occurred. Since a rapid increase in the amount of accumulated adhesive agent in thealignment groove 62 is prevented, it is possible to reduce variation in the tension of thelong element 72 caused by the adhesive agent having been accumulated in thealignment groove 62 acting as a brake force for forwarding thelong element 72. The width of thelong element 72 therefore is stabilized from the beginning to the end of winding, which enables sufficient reduction of the amount of irregularity relative to the width direction of eachwound layer 73b in the roll of thelong element 72, even when winding a narrowlong element 72 to a roll having a large diameter. - Note that the
alignment roller 6 of the present embodiment may be rotatably supported by thealignment device 2, or may be supported so that its rotation speed is adjustable by means of adjusting the rotation drive force of thealignment device 2. Specifically, the way of supporting to enable adjustment of rotation speed is such that thealignment groove 62 is moved in the forwarding direction of thelong element 72 when thealignment roller 6 is rotated about its axis. When the support is such that the rotation speed is adjustable, it is possible to adjust the relative positional relation and the difference in the speed of the groove side surfaces 62a ofalignment groove 62 and thelong elements 72 simply by adjusting the rotation speed of thealignment roller 6. Therefore, the adhesive force among the wound layers 73b of theroll 73 is easily adjusted to a desirable value. - When the roll diameter of the
roll 73 becomes a predetermined roll diameter, thewind device 5 and the unwinddevice 3 are stopped. After that, all thelong elements 72 are cut between theroll 73 and thealignment roller 6, and enters the setting-standby state as shown inFig. 1 . Therolls 73 are carried out to a post process by using a not-shown take-out device such as a carrier or aroll conveyance device 9. Further, before the take-out, the work for setting in the long element setting process shown inFIG. 2 is carried out by pulling out the windingrollers 51 from therolls 73, and setting them to thewind device 5. - In each of the
rolls 73 manufactured by the manufacturing method having the above processes, the amount of irregularity in the both ends of the wound layers 73b of thelong element 72 relative to the width direction is 0 mm to 1.0 mm, preferably 0 mm to 0.7 mm, and more preferably 0 mm to 0.5 mm, irrespective of the winding diameter of the roll 73 (or the width L4 of the long element 72) as shown inFig. 5 . Note that the thickness L1 of eachwound layer 73b (long element 72) is set to be 0.05 mm to 5.3 mm. - Specifically, the
sheet 71 includes at least aseparation layer 711 and an adhesive layer 712. Thesheet 71 is manufactured by applying an adhesive agent composition solution on a separation film to serve as theseparation layer 711 to form an applied layer, and drying this applied layer to form the adhesive layer 712. Note that the adhesive agent composition solution may contain an inorganic filler as needed. The method of applying the adhesive agent composition solution is not particularly limited. For example, a comma coating, a fountain method, a gravure method, or the like may be adopted as the method of applying the adhesive agent. The thickness of application may be suitably set so that the thickness L3 of the adhesive layer 712 resulting at the end, after the applied layer is dried, is within a range of 0.025 mm to 5.0 mm. The viscosity of the adhesive agent composition solution is not particularly limited; however, is preferably 400 to 2500 mPa·s, and more preferably, 800 to 2000 mPa·s. - The separation film (separation layer 711) is not particularly limited and any traditionally known separation film is adoptable. Specifically, for example, the separation film is such that a separation coating layer such as a silicone layer or the like is formed on a surface of the base material of the separation film to which the adhesive layer is pasted. Further, example materials for the separation film includes: paper materials such as glassine paper and a resin film made of polyethylene, polypropylene, polyester, or the like. The thickness L2 of the separation film is set to be 0.025 mm to 0.3 mm.
- Note that the present embodiment deals with a case where the long elements 72 (sheet 71) has an adhesive layer 712 as in the case of an adhesive tape or the like; however, the present invention is not limited to this, and the present invention may be applied to winding of any given
long element 72 having no adhesive layer 712. For example, thelong element 72 may be elastic tape used for fixing cushions or the like on a frame of a display of a laptop computer or a word processor, or a non-adhesive tape such as magnetic tape, ink ribbons, photo films, long paper tape, or the like. - Next, the following describes a
roll manufacturing device 1 as shown inFig. 1 , capable of carrying out each process in the manufacturing method of the present embodiment. Needless to say that the manufacturing method of the present embodiment is also implemented by roll manufacturing devices having other structures. - The
roll manufacturing device 1 includes: aroll conveyance device 9 for conveying asheet roll 7; an unwinddevice 3 configured to unwind asheet 71 from thesheet roll 7; acutting apparatus 4 configured to cut thesheet 71 into a plurality oflong elements 72 each having a predetermined width; analignment device 2 configured to aligning thelong elements 72 while regulating the positions of the long elements relative to the width direction; awind device 5 configured to wind thelong elements 72 to form rolls 73; and a take-out device configured to take out therolls 73 formed by thewind device 5 to a subsequent process. - The
roll conveyance device 9 has a function of carrying out an alignment roller setting process, and is configured to convey, to any given position, thesheet roll 7 from a not-shown previous process in which thesheet roll 7 is manufactured and stored. Specifically, theroll conveyance device 9 includes: arail 92 disposed so as to enable trafficking above the devices for carrying out each of the processes; at least one suspendingdevice 91 capable of moving along therail 92; and a not-shown conveyance control device. The suspendingdevice 91 is capable of suspending thesheet roll 7 at itscore 7a and elevating thesheet roll 7. The conveyance control device is configured to manage and control the operation of the suspendingdevice 91 based on production plan information so as to convey asheet roll 7 for a predetermined product to a predetermined position. - On the downstream side of the
roll conveyance device 9 relative to the forwarding direction of thesheet 71 is an unwinddevice 3. The unwinddevice 3 has a function of carrying out the long element setting process and the unwinding process, and includes a core-holder configured to detachably hold thecore 7a of thesheet roll 7; a rotation drive device configured to rotate the core-holder with a given rotation speed and a given torque; a rotation control device configured to control the rotation speed of the rotation drive device. On the downstream side of the unwinddevice 3 is acutting apparatus 4. Thecutting apparatus 4 has a function of carrying out the long element setting process and the cutting process, and includes: a plurality of cuttingblades 41; a cutting blade holder configured to hold thecutting blades 41 so that thecutting blades 41 are positioned in given positions relative to the width direction; a cutting blade drive mechanism configured to rotate thecutting blades 41 at a given rotation speed, and a cuttingroller 42 to which thesheet 71 and the blade edges of thecutting blades 41 abut. - On the downstream side of the
cutting apparatus 4 are twoalignment devices 2. Thesealignment devices 2 are symmetrically arranged relative to an up/down direction. Eachalignment device 2 has a function of carrying out the long element setting process and the aligning and winding process. On the downstream side of thealignment device 2 is awind device 5. Thewind device 5 has a function of carrying out the long element setting process and the aligning and winding process. - The
wind device 5 detachably has the windingroller 51, and a not-shown rotation drive device configured to rotate the windingroller 51 at a given rotation speed. The windingroller 51 has a diameter that can be inserted into the windingunit 8. Further, the windingroller 51 has a plurality of pressing members capable of projecting to the outer side than the roller surface. The pressing members switch the state of the windingunit 8 and the windingroller 51 between an inserted state and a fixed state. On the downstream side of thewind device 5 is a take-out device. The take-out device is capable of taking out the products. For example, the take-out device may be a bogie capable of carrying thereon theroll 73, or aroll conveyance device 9. - As shown in
Fig. 4 , thealignment roller 6 for use in theroll manufacturing device 1 having the above structure has a cylindrical rollmain body 60; one ormore alignment grooves 62 formed on the circumference of the rollmain body 60; and a pair of rotation shafts 63 (Fig. 1 ) projecting from both ends of the rollmain body 60. The or eachalignment groove 62 is formed on the circumference of the rollmain body 60. Further, the axis of the rollmain body 60 coincides with the axis of therotation shaft 63. This way, when thealignment roller 6 rotates about its axis while being fixed relative to the width direction (axial direction), thealignment groove 62 is moved at the same position relative to the width direction. - As shown in
Fig. 5 , thealignment groove 62 is formed by the circumferential surface of the rollmain body 60, and the grooveside surface walls 61 formed on the circumferential surface of the rollmain body 60. The circumferential surface of the rollmain body 60 forms a flat groovebottom surface 62b of thealignment groove 62, while the grooveside surface walls 61 form flat groove side surfaces 62a of thealignment groove 62. Thus, thealignment groove 62 having agroove bottom surface 62b parallel to the axial direction of thealignment roller 6 and the groove side surfaces 62a matching with radial directions of thealignment roller 6 form a rectangular cross section such that an outer portion relative to a radial direction of thealignment roller 6 is opened. - There are a plurality of types of
alignment rollers 6 havingalignment grooves 62 of various groove depths A1 in combination with various groove widths A2. The groove width A2 of thealignment groove 62 substantially matches with the width L4 of thelong element 72. Note that, by the groove width A2 of thealignment groove 62 substantially matching with the width L4 of thelong element 72, it means that the groove width A2 matches with the width L4 so that the amount of irregularity in theroll 73 relative to the width direction is within an allowable range. In other words, the groove width A2 of thealignment groove 62 may match with the width L4 of thelong element 72, or be greater or smaller than the width L4 of thelong element 72, provided that the amount of irregularity in theroll 73 relative to the width direction is within the allowable range. - Further, the groove depth A1 of the
alignment groove 62 is set to be twice or more the thickness L1 of thelong element 72. With the groove depth A1 greater than the thickness of wound layers 73b, thealignment groove 62 enables each of the pair of groove side surfaces 62a to be on the same plane as the corresponding one of the pair ofwound end surfaces 73c formed by both ends of the wound layers 73b relative to the width direction. - The width A3 of the groove
side surface wall 61 may be the same as or different from the groove width A2 of thealignment groove 62. For example, inFig. 1 , when thealignment rollers 6 with the same width A3 and the groove width A2 are arranged to the upper andlower alignment devices 2, thelower wind device 5 is able to wind the odd number th or the even number thlong elements 72 from the cuttingapparatus 4 and having a predetermined width and theupper wind device 5 is able to wind the odd number th or the even number thlong elements 72. - Further, the
alignment rollers 6 to be mounted to the upper orlower alignment device 2 may have different groove widths A2 of the grooveside surface wall 61. In this case, by setting two different cutting widths in thecutting apparatus 4, it is possible to wind two different types oflong elements 72 by thewind devices 5. - The present embodiment deals with a case where the top portion of the groove
side surface wall 61 of thealignment roller 6 is flat, i.e. , the top portion has a surface matching with the axial direction; however, the present invention is not limited to this. For example, as shown inFig. 6 , the top portion 613 of the grooveside surface wall 61 of thealignment roller 6 may be curved so as to project radially outward. In this case, even when the accuracy in the position regulation of thelong elements 72 is deteriorated due to vibration or the like, the top portion 613 of the grooveside surface wall 61 guiding thelong element 72 towards thealignment groove 62 prevents deterioration in the accuracy of alignment of each of the wound layers 73b on theroll 73, damages, bending, contamination or the like of the end portion of theroll 73 relative to the width direction. - The embodiment of the present invention thus described is solely to serve as an example of the present invention, and is not to limit the present invention. Specific structures may be suitably modified. Further, the work and effects described in the embodiment of the present invention are no more than examples achieved by a preferred mode of the present invention, and the work and effects therefore shall not be limited to those described in the embodiment of the present invention.
-
- 1
- Roll manufacturing device
- 2
- Alignment device
- 3
- Unwind device
- 4
- Cutting apparatus
- 5
- Wind device
- 6
- Alignment roller
- 7
- Sheet roll
- 8
- Winding unit
- 9
- Roll conveyance device
- 10
- Take-out device
- 61
- Groove side surface wall
- 62
- Alignment groove
- 62a
- Groove side surface
- 62b
- Groove bottom surface
- 63
- Rotation shaft
- 71
- Sheet
- 72
- Long elements
- 73
- Roll
- 73a
- Roll surface
- 73b
- Wound layer
- 73c
- Wound end surfaces
Claims (8)
- A method of manufacturing a roll in which a long element having an adhesive agent and a predetermined width is wound by a winding unit so that the long element forms a plurality of wound layers in a radial direction from the winding unit to a roll surface, the method comprising:arranging, in a position distant from the roll surface, an alignment groove having a pair of groove side surfaces configured to contact both ends of the long element relative to the width direction;causing each of the pair of groove side surfaces to be on the same plane as the corresponding one of a pair of wound end surfaces formed by both ends of the wound layers relative to the width direction; andplacing the long element on the alignment groove and winding the long element on the roll.
- The method according to claim 1, wherein
the alignment groove has a groove depth greater than the thickness of the long element. - The method according to claim 2, wherein
the winding is carried out while the alignment groove is moved in a forwarding direction of the long element. - The method according to claim 3, wherein
the alignment roller having the alignment groove around its circumference is rotated about the axis of the alignment roller, thereby moving the alignment groove in the forwarding direction of the long element. - A roll manufactured by the manufacturing method according to claim 1, wherein
a maximum amount of irregularity in the both of the wound layers of the long element relative to the width direction is 0 mm to not more than 1.0 mm. - A roll manufactured by the manufacturing method according to claim 2, wherein
a maximum amount of irregularity in the both of the wound layers of the long element relative to the width direction is 0 mm to not more than 1.0 mm. - A roll manufactured by the manufacturing method according to claim 3, wherein
a maximum amount of irregularity in the both ends of the wound layers of the long element relative to the width direction is 0 mm to not more than 1.0 mm. - A roll manufactured by the manufacturing method according to claim 4, wherein
a maximum amount of irregularity in the both ends of the wound layers of the long element relative to the width direction is 0 mm to not more than 1.0 mm.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2011028269A JP5835905B2 (en) | 2011-02-14 | 2011-02-14 | Roll manufacturing method |
PCT/JP2012/052957 WO2012111523A1 (en) | 2011-02-14 | 2012-02-09 | Method for manufacturing roll, and roll |
Publications (1)
Publication Number | Publication Date |
---|---|
EP2676907A1 true EP2676907A1 (en) | 2013-12-25 |
Family
ID=46672448
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP12747644.8A Withdrawn EP2676907A1 (en) | 2011-02-14 | 2012-02-09 | Method for manufacturing roll, and roll |
Country Status (7)
Country | Link |
---|---|
US (1) | US20130327869A1 (en) |
EP (1) | EP2676907A1 (en) |
JP (1) | JP5835905B2 (en) |
KR (1) | KR20140009351A (en) |
CN (1) | CN103380073B (en) |
TW (1) | TWI565584B (en) |
WO (1) | WO2012111523A1 (en) |
Family Cites Families (14)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS6012561U (en) * | 1983-07-02 | 1985-01-28 | ロ−ム株式会社 | Wide adhesive tape narrower dividing device |
JPS6231645A (en) | 1985-07-30 | 1987-02-10 | Fuji Photo Film Co Ltd | Method and device for taking-up magnetic tape |
JP3199079B2 (en) | 1992-07-24 | 2001-08-13 | ソニー株式会社 | Method and apparatus for winding long body |
JPH10167528A (en) * | 1996-12-09 | 1998-06-23 | Nitto Kakozai Kk | Narrow-width collective roll tape and its manufacture |
JPH10297801A (en) * | 1997-04-30 | 1998-11-10 | Sony Corp | Slitter |
JP3818610B2 (en) * | 1997-10-20 | 2006-09-06 | 東邦テナックス株式会社 | Prepreg winding device |
JPH11240653A (en) * | 1998-02-25 | 1999-09-07 | Dainippon Printing Co Ltd | Slit base material take-up device |
US7040822B2 (en) * | 2003-06-04 | 2006-05-09 | Hellermanntyton Corporation | Portable printing system |
ITMI20041669A1 (en) * | 2004-08-26 | 2004-11-26 | S I A T Societa Internaz | METHOD AND MACHINE FOR CUTTING A SELF-ADHESIVE TAPE IN A MULTIPLE OF THIN TAPES AND FOR THEIR REWINDING. |
JP4386442B2 (en) * | 2005-03-22 | 2009-12-16 | 富士フイルム株式会社 | Web winding device and spacer |
WO2009118826A1 (en) * | 2008-03-25 | 2009-10-01 | 株式会社イトウ六 | Process for producing long adhesive tape roll of extra fine width and apparatus therefor |
CN201235559Y (en) * | 2008-08-08 | 2009-05-13 | 西安华邦机械有限公司 | Gantry type double-shaft cutting machine |
CN201447253U (en) * | 2009-07-21 | 2010-05-05 | 罗永辉 | Surface slitting rewinder |
CN201573992U (en) * | 2009-10-22 | 2010-09-08 | 东莞光群雷射科技有限公司 | On-line slitting and winding machine |
-
2011
- 2011-02-14 JP JP2011028269A patent/JP5835905B2/en not_active Expired - Fee Related
-
2012
- 2012-02-09 KR KR1020137024241A patent/KR20140009351A/en active IP Right Grant
- 2012-02-09 CN CN201280008820.4A patent/CN103380073B/en not_active Expired - Fee Related
- 2012-02-09 EP EP12747644.8A patent/EP2676907A1/en not_active Withdrawn
- 2012-02-09 US US13/985,220 patent/US20130327869A1/en not_active Abandoned
- 2012-02-09 WO PCT/JP2012/052957 patent/WO2012111523A1/en active Application Filing
- 2012-02-13 TW TW101104536A patent/TWI565584B/en not_active IP Right Cessation
Non-Patent Citations (1)
Title |
---|
See references of WO2012111523A1 * |
Also Published As
Publication number | Publication date |
---|---|
US20130327869A1 (en) | 2013-12-12 |
CN103380073A (en) | 2013-10-30 |
TWI565584B (en) | 2017-01-11 |
WO2012111523A1 (en) | 2012-08-23 |
JP5835905B2 (en) | 2015-12-24 |
CN103380073B (en) | 2015-11-25 |
JP2012166885A (en) | 2012-09-06 |
KR20140009351A (en) | 2014-01-22 |
TW201242759A (en) | 2012-11-01 |
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