JP2005219847A - Roller for web manufacturing device, manufacturing device and manufacturing method for film roll by use of it, and film roll - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve problems of a web manufacturing device wherein yield is reduced and operation property is worsened due to scratch and wrinkle caused in a web. <P>SOLUTION: This roller for the web manufacturing device has a roller main body and a fiber structural body covering an outer peripheral face of the roller main body spirally. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

The present invention relates to a roller for a web manufacturing apparatus, a film roll manufacturing apparatus using the same, a manufacturing method, and a film roll.

In various rollers used in a web manufacturing apparatus, problems such as a decrease in yield and deterioration in operability occur due to scratches generated on the web. Various techniques have been developed to solve this problem.

  For example, a technique for preventing scratches by appropriately adjusting the draw ratio between the conveying rollers to prevent relative slip between the roller outer peripheral surface and the web is often used. Patent Document 1 discloses a technique for preventing flaws when a flannel is wound around a metal roller and a film is conveyed.

As for the technique for spirally covering the outer peripheral surface of the roller with a belt-like object, Patent Document 2 discloses a technique for facilitating replacement of the covering material by spirally winding a rubber or plastic belt around the roller surface. .
JP 2003-71918 A JP-A-3-272960

However, the conventional technology described above cannot completely eliminate the scratch problem in products with strict quality requirements.

  Scratches include foreign matter caught between the transport roller and the web, transfer scratches that are generated by transferring the unevenness of the outer surface of the hard transport roll to the web, and both in the state where the outer surface of the hard transport roller is in contact with the web. There are various forms such as a relative slippage between the two, and a biting foreign material or a scratch on the outer peripheral surface of the hard conveying roll that scratches the web.

  For scratches caused by foreign matter that has been bitten or unevenness on the outer peripheral surface of the transport roll, it is necessary to remove the foreign matter so that it does not contact the web, or to remove the unevenness by polishing it. Therefore, it is difficult to completely prevent scratches resulting from these defects.

  It is also effective to reduce the web transport tension and the web contact pressure, but in this case, the friction force between the transport roll and the web is reduced. There are problems such as inability to transport at high speed.

  It is also effective to prevent relative slip between the transport roller and the web, and a technique for adjusting the draw ratio between the transport rollers is widely used. However, even if there is a slight deviation between the roller circumferential speed and the web conveyance speed, scratches will occur, and this will cause defective products in products with strict quality requirements. It is difficult.

  Patent Document 1 discloses a technique for preventing scratches by covering the outer peripheral surface of a metal roller with flannel cloth. General fabrics such as flannel cloth have a structure in which warp and weft yarns are arranged at right angles and crossed vertically to form a flat surface. Stretchability and flexibility depend on the properties of the yarn itself, so it is highly stretchable. It is difficult to give the sexuality and flexibility, and the scratch cannot be completely eliminated.

  In addition, although the technique which coat | covers a strip | belt-shaped member on a roller outer peripheral surface spirally is disclosed by patent document 2, the material of a strip | belt-shaped member is limited to rubber | gum and plastic, and replacement | exchange of a coating | covering material is easy. The purpose of this is different from the purpose of scratch prevention, which is the object of the present invention.

A first object of the present invention is to provide a roller for a web manufacturing apparatus having a high scratch prevention effect, a second object is to provide a web manufacturing apparatus having a high scratch prevention effect, and a third object is a scratch prevention effect. The object of the present invention is to provide a high web manufacturing method and has the following configuration.
1. A roller for a web manufacturing apparatus, comprising: a roller main body; and a belt-like fiber structure having elasticity that is spirally coated on an outer peripheral surface of the roller main body.
2. 2. The roller for a web conveying device according to 1 above, wherein the fiber structure is a fiber structure made of chemically synthesized fibers and melt-cut in a band shape.
3. 3. A film roll manufacturing apparatus comprising the roller for a web manufacturing apparatus according to 1 or 2 above at least one place in a conveyance path of a plastic film.
4). A method for producing a film roll using the apparatus according to 3 above.

  In the present invention, “coiled in a spiral” means a state of being continuously wound in a screw shape. The smaller the gap between the fiber structures on the outer peripheral surface of the roller, the better. However, if the overlap occurs, the contact pressure between the fiber structure and the web will increase locally, so the web is likely to be scratched. Conversely, if the gap is too large, the gap will be exposed. The roller surface is in contact with the web, and the web is easily scratched. Since it is impossible in practice to make all the gaps zero, it is preferable that the gaps of the fiber structure have a value larger than zero, and more preferably 0.1 to 10 mm.

  In the present invention, “stretchability” of the fiber structure is defined as follows. The fiber structure is cut into a square having a length of 120 mm and a width of 120 mm to prepare a sample sheet, which is placed in the horizontal direction, and two sides facing each other in a tension-free state are spaced 100 mm apart over the entire width. Hold each vise uniformly and without slipping during the experiment. In this state, when tension is applied in the opposite direction (tensile direction) of the two sides, the entire fiber structure can be stretched to 110 mm or more without breaking, and after stretching to 110 mm, When the vise is moved in the opposite direction of the tension direction at a speed of 1 mm / second to release the tension and return to the state of no tension again, the average interval in the tension direction of the first gripped part by the vise is 100 mm. The characteristic of restoring within the range of ˜105 mm is said to have “stretchability” in the tension direction. The sample sheet is a fiber structure having stretchability when the warp yarn direction or the weft yarn direction is produced as the length direction, respectively, and the above experiment is performed for both directions, and the stretchability is obtained in either direction. evaluate. In the case of a knitted or non-woven fabric, a sample sheet is prepared with an arbitrary direction as a length direction, and when stretchability is recognized in this direction, it is evaluated that the fiber structure has stretchability. The above experiment is performed in the air at a room temperature of 25 ° C. and a relative humidity of 40% in principle. However, when it is clear that the use state of the roll is far from this, the temperature and humidity in the use state are clear. It shall be performed in other environments. In addition, when an appropriate experiment cannot be performed, such as when the fiber structure cannot be cut to the above-mentioned dimensions, the fiber structure is cut to an experimentally-capable dimension, and the above numerical values are evaluated in proportion to the dimensions in the tension direction. Although the objective of this invention can be achieved if it is a stretchable fiber structure in which stretchability is recognized in one direction, a fiber structure in which stretchability is recognized in two orthogonal directions is more preferable.

  In the present invention, the “fiber structure” is a general term for fabrics such as woven fabrics, knitted fabrics, and nonwoven fabrics composed of natural fibers or chemical fibers. Natural fibers collected from animals and plants include cotton, hemp, wool, and silk. Chemical fibers made by chemically synthesizing wood, petroleum, natural gas, etc. include rayon, nylon, polyester, polyurethane, and acrylic. and so on. For example, knitting is generally a fiber structure having stretchability in the present invention. Although many woven fabrics and non-woven fabrics do not have stretchability, fabrics and non-woven fabrics using elastic yarns that have stretchability may be stretchable.

  In the present invention, “melt-cut in a strip shape” means that when a fiber structure is slit in a strip shape, the fiber structure is cut into a strip shape while melting the cut surface with a blade heated to a melting point or higher of the fiber. is there.

According to the present invention, at least one of the effects listed below can be achieved.
1. Since the outer peripheral surface of the roller is covered with a stretchable fiber structure, if a foreign object is caught between the transport roller and the web, the gap between the fibers expands due to the extension of the fiber, and the foreign object is taken into the gap. There are more cases where the web can be prevented from being scratched by preventing contact between the foreign matter and the web than when the web does not have stretchability.
2. If the fibers are bent by the force that the foreign material is pressed against the fiber structure and the fiber structure is largely recessed, the contact pressure between the foreign material and the web can be kept low to prevent the web from being scratched. More than if not.
3. Since the outer peripheral surface of the roller is spirally covered with the fiber structure, the degree of freedom of tension to be applied in order to properly cover the outer peripheral surface of the fiber structure is high. In addition, since tension can remain after coating, the tension of the fiber structure acts in the direction of tightening the outer peripheral surface of the roller, and the fiber structure is loosened or twisted due to frictional force with the web or centrifugal force during rotation. You can reduce wrinkles.
4). When a minute speed difference between the roller surface peripheral speed and the web conveyance speed is generated, the fiber structure is distorted to absorb the speed difference and easily prevent the web from being scratched.
5). If the fiber structure is melt-cut in a belt shape, the end face is not released and fiber waste is not generated.

  The roller for a web production apparatus according to the present invention has very few defects such as scratches and wrinkles, enables production of a higher quality film roll, and contributes to yield improvement and cost reduction.

Embodiments of the present invention will be described in detail below, but the present invention is not limited to the embodiments including the following examples, can achieve the objects of the invention, and does not depart from the gist of the invention. Various changes within the scope are naturally possible.

  An embodiment of the present invention will be described below with reference to FIGS. FIG. 1 is a schematic perspective view of a conveying roller as an example of an embodiment of the present invention. The roller main body 1 and the belt-like fiber structure 3 having elasticity that covers the outer peripheral surface 2 of the roller in a spiral shape are configured.

The material of the roller outer peripheral surface 2 is not particularly limited, and may be, for example, metal, resin or rubber. However, in order to prevent loosening and twisting of the fiber structure and not impair the workability of the roller, Of course, the surface and the fiber structure may be fixed with an adhesive tape or a sheet having an appropriate friction coefficient, or the friction coefficient of the roller outer peripheral surface may be adjusted.

  The stretchable fiber structure 3 is preferably a knitted fabric or a woven fabric composed of elastic yarn such as spandex. A fiber structure composed of fibers made of a material having good charge compatibility with the web is more preferable because it can prevent electrostatic defects due to charging. In the case of a fabric composed of elastic yarn such as spandex, a material having good charge compatibility with the web to be produced is used for the cover yarn of the outermost layer, and a multilayer structure yarn using elastic yarn is used for the core yarn. It is preferable because it can prevent electrostatic defects due to.

  In order to prevent the fiber structure 3 from loosening or twisting, it is preferable to coat the fiber structure in a spiral shape. In that case, if the width of the fiber structure is too narrow, the number of man-hours required for the coating operation increases, and a longer fiber structure is required to cover the entire roller surface, but conversely if the width is too wide Since it is difficult to apply tension to the fiber structure during the covering operation and handling during the covering operation is deteriorated, the width of the fiber structure is preferably 25 mm to 500 mm. In addition, there exists an advantage that a fiber structure can be coat | covered without removing a roller shaft end by coat | covering helically. In addition, when coating the fiber structure in a spiral shape, if the tension applied is too strong, the gap between the fibers is clogged and the effect of taking in foreign matter is reduced, but conversely if the tension applied is too weak, the fiber structure is In order to cause loosening and twisting, the longitudinal tension of the fiber structure in the coated state is preferably in the range of 10 to 2000 (N / 1 m width). In addition, the width of the fiber structure in a state where tension is applied in the length direction can be measured in advance, and the length direction tension of the fiber structure in the covered state can be calculated backward from the width of the fiber structure in the covered state. .

  The fiber structure 3 needs to be cut to a predetermined width in advance in order to cover it in a spiral shape, but when the fiber structure is composed of chemically synthesized fibers, the cut surface is unraveled and fiber waste is generated. In order to prevent this, it is preferable that the material is melt-cut with a blade or the like heated above the melting point of the fiber raw material.

  Since the roller for a web manufacturing apparatus according to the present invention has a high scratch-preventing effect, it is preferably used in a web, for example, a plastic film manufacturing apparatus that has severe quality requirements regarding scratches. FIG. 2 is a schematic view of a general plastic film manufacturing process. The molten polymer, in which the thermoplastic resin is melted, is extruded into a sheet form from the die 4, wound around a cooling drum 5, rapidly cooled and solidified, stretched in the longitudinal direction and the width direction by a biaxial stretching device 6, and wound by a winder 9. Make product 10. Thereafter, if necessary, the slitter 12 slits the intermediate product 11 to a predetermined width and winds up the final product 14. It is preferable to use the web production apparatus roller according to the present invention for the winder 9 of the film production apparatus and the conveyance roller 10 of the conveyance unit 7 of the slitter 12.

Example 1
A roller for a web manufacturing apparatus in the form of FIG. 1 was produced. As the roller body 1, a roller made of chloroprene rubber having a JIS-A hardness of 60 ° with a thickness of 5 mm and an outer diameter of 200 mm and a surface length of 250 mm was used.

  As the fiber structure 3, a product number MTK100 × 10 of a clean cloth “Toraysee” # 73001TR type manufactured by Toray Industries, Inc., which is a knitted fabric made of polyester super extra fine fibers, was used. A sheet having a thickness of 0.45 mm and a length of 10 m is cut into a strip shape having a width of 100 mm by a heat cutter. For the stretchability in the length direction of this fiber structure, three sample sheets cut into a length of 120 mm and a width of 100 mm were prepared, and the above-described evaluation was performed in the length direction (FIG. 3a is a schematic diagram showing this state). ), The dimensions after releasing the tension of all the sample sheets were restored to 102 mm to 104 mm, and it was confirmed that they had elasticity.

At the same time, the sample sheet was held for 1 minute while being pulled in the length direction so that the tension was constant 98 N / width (980 N / 1 m width), and the width (predetermined width) of the sample sheet was measured.
In addition, regarding the width direction, since it cannot be cut to a length of 120 mm in the tension direction, as shown in FIG. 3 b, three sample sheets were prepared by cutting the sheet into a length of 80 mm × width of 100 mm, and the above-described evaluation was performed. . That is, the sample sheet was placed in the horizontal direction, and the two sides in the length direction were uniformly held by a vise across the entire width with an interval of 80 mm in the width direction, and stretched to 88 mm by applying tension in the width direction. Thereafter, how much the length was restored when it was shrunk at a speed of 1 mm / second was evaluated by measuring it three times at a time (FIG. 3b is a schematic diagram showing this state). As a result of the evaluation, all were restored to 82 mm to 84 mm and confirmed to be stretchable. Next, tension is applied to the “Toraysee” in the length direction so that the gap between the sheets is 5 mm, and the spiral is coated as shown in FIG. 1, and the roller surface is coated with the predetermined width obtained by the above measurement. It was made to become. The “Toraysee” was fixed by a method in which both ends of the sheet were cut obliquely with scissors, and the cut surface was fixed to a roller with an adhesive tape so that the cut surface was not exposed.
Example 2
The test was performed under the same conditions as in Example 1 except that the sheet was cut into strips having a width of 100 mm with commercially available scissors.
Comparative Example 1
Clean cloth “Toraysee” # 52600TR type product number MT100 × 10 which is a fabric using the same roller body as in Example 1 and using a polyester super extra long fiber as a fiber structure for both warp and weft Was used. A sheet having a thickness of 0.15 mm and a length of 10 m is cut by a heat cutter into a strip shape having a width of 100 mm. A test was performed under the same conditions as in Example 1 using a roller for a web manufacturing apparatus in which the fabric was spirally coated on the outer peripheral surface of the roller. The woven fabric was subjected to the same stretchability measurement as in Example 1, and it was confirmed that neither the length direction nor the width direction had stretchability.
Comparative Example 2
The same roller body as in Example 1 was used, and an artificial leather “Exaine” manufactured by Toray Industries, Inc., which is a sheet-like nonwoven fabric made of ultrafine fibers made of polyester and polyurethane as raw materials, was used as the fiber structure. The nonwoven fabric was cut into a strip having a width of 100 mm with a heat cutter, and the test was performed under the same conditions as in Example 1 using a roller for a web manufacturing apparatus constituted by coating the outer peripheral surface of the roller with a spiral. The nonwoven fabric was subjected to the same stretchability measurement as in Example 1, and it was confirmed that neither the length direction nor the width direction had stretchability.
Comparative Example 3
The same roller body as in Example 1 was used, and the test was performed under the same conditions as in Example 1 with the roller outer peripheral surface remaining as chloroprene rubber.

FIG. 4 is a schematic perspective view of an apparatus in which Examples 1 and 2 and Comparative Examples 1 to 3 were evaluated. As shown in FIG. 4, two web manufacturing apparatus rollers connected to the motor 27 and the motor 28 so as to be individually driven as shown in FIG. 4 are used. The distance between the two rollers is 455 mm, and a biaxially stretched polyester film (thickness 100 μm) 16 bonded between two rollers is applied, the film tension is 196 N / m, the conveyance speed is 100 m / min, the motor 17 and the motor 18 A test was conducted to investigate the number of scratches attached to the film by operating for 2 hours with a difference of 0.1% in the rotation speed and relative slip between the film and the roller.
The experimental results in Examples 1 and 2 and Comparative Examples 1 to 3 are shown in Table 1. In addition, the film flaw in a table | surface represents the generation | occurrence | production number of film flaws with a length of 100 micrometers or more which generate | occur | produced in the test.
In Example 1, film scratches did not occur and the fiber structure did not loosen, but in Example 2 and Comparative Example 2, fiber debris that contributed to film scratches occurred from the end face or surface of the fiber structure. In Comparative Examples 1 and 2, it was confirmed that the fiber structures were loosened and adjacent to each other overlapped or the interval was widened.

The present invention can be used as a conveyance roller of a web manufacturing apparatus, and is particularly suitable for a manufacturing apparatus for a plastic film.

It is a schematic perspective view of the conveyance roller for web production apparatuses which is an example of an embodiment of the invention. It is a general | schematic flowchart of the manufacturing process of a general plastic film. It is the schematic which shows the elasticity evaluation method of the length direction of the fiber structure in Example 1. FIG. It is the schematic which shows the elasticity evaluation method of the width direction of the fiber structure in Example 1. FIG. It is a schematic perspective view of the apparatus which evaluated Example 1, 2 and Comparative Examples 1-3.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Roller body 2 Roller surface 3 Fiber structure 4 Base 5 Cooling drum 6 Biaxial stretching device 7 Conveying unit 8 Winding unit 9 Winder 10 Conveying roll 11 Intermediate product 12 Slitter 13 Pressing roll 14 Final product 15 Plastic film 16 Endless belt Biaxially stretched polyester film 17 motor 18 motor 18 motor

Claims (4)

A roller for a web manufacturing apparatus, comprising: a roller main body; and a belt-like fiber structure having elasticity that is spirally coated on an outer peripheral surface of the roller main body. The roller for a web conveying device according to claim 1, wherein the fiber structure is a fiber structure made of chemically synthesized fibers and melt-cut into a belt shape. An apparatus for manufacturing a film roll, comprising the roller for a web manufacturing apparatus according to claim 1 or 2 at least at one or more places in a conveyance path of a plastic film. The manufacturing method of the film roll using the apparatus of Claim 3.

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