JP2006117434A - Film winding device and film winding method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To remove static electricity carried by a film while removing air rolled in a film roll in a noncontact manner, when winding the film. <P>SOLUTION: An air blowing mechanism 122 is arranged in the vicinity of the peripheral surface of the film roll 124 of a film winding device 53 for winding the film 82 in a roll shape. The air blowing mechanism 122 is composed of an air nozzle 129, an air pipe 130, a blower 131 and an ion generator 135. When winding the film, high pressure air is generated by driving the blower 131, and air in of the air nozzle 129 is ionized by driving the ion generator 135. Since an pressing is performed by blowing air including ions upon the peripheral surface of the film roll 124, the static electricity carried by the film 82 can be removed while removing the air rolled in the film roll 124 in a noncontact manner. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a film winding apparatus and a film winding method for winding a long film into a roll shape.

  Generally, a plastic film used for a polarizing plate protective film for a liquid crystal display (LCD) is manufactured by a solution film forming method. In a film production line for producing a plastic film by using this solution casting method, for example, a polymer such as cellulose acetate is dissolved in a solvent together with various additives such as a plasticizer, a UV absorber and a slip agent to form a dope. . Then, the dope is cast onto a drum or a band which is an endless endless support, and is peeled off when having self-supporting properties. Next, the peeled soft film is dried with hot air while being conveyed by a pass roller to form a film.

  The film is continuously sent to the film take-up device located at the most downstream side of the line, and there are several cylindrical take-up cores made of resin, metal, wood, cardboard, etc., depending on the application and equipment capacity. It is wound up to a length of 100m to several thousand meters. And it is suitably packed with the form of the film roll wound up by roll shape, and becomes a product form. At this time, if the film winding speed is increased in the film winding apparatus with the improvement of the production capacity of the film production line, air may be caught together with the film. When air is entrained in the film roll, a film roll having a non-uniform air thickness is formed between the film layers. As a result, local black stripe-like deformation (hereinafter simply referred to as black stripe failure) occurs.

Therefore, as described in Patent Documents 1 and 2, for example, depending on the winding speed and thickness of the film, the winding diameter of the film roll, a winding tension is applied to the film wound on the film roll. In addition, a method of forcibly removing the air that has been taken up at the time of film winding is known by pressing a pressing roll such as a rayon roll on the circumferential surface of the film roll with a predetermined pressure. As a result, it is possible to prevent the occurrence of quality failure due to air entrainment.
2002-220143 (page 4, Fig. 1) 2002-255409 (5th page, Fig. 1)

  By the way, when the winding tension is applied to the film, if the force is too low, the winding pressure is weakened, so that the content of the air wound between the film layers of the film roll is increased, and the film is wound or wound. There is a risk that a so-called winding deviation in which the film wound on the film roll later shifts in the width direction may occur. On the other hand, if the winding tension is too high, the winding pressure increases, so that the occurrence of winding slippage can be prevented. However, since the film has slight thickness unevenness in the width direction, the film unevenness overlaps. Pressure is strongly applied to the locally thickened area. As a result, black stripe failure may occur.

  In addition, since the rayon roll is rubber-lined in order to enhance the protection against the film, the film roll is charged with static electricity due to sliding contact, contact, peeling, or the like between the rayon roll and the film roll. As a result, the floating dust is attracted by static electricity so as to be in the air, so that foreign matter may adhere to the film roll and cause foreign matter failure. Furthermore, there is a risk that quality failure such as coating unevenness failure may occur when secondary processing is performed due to static electricity.

  Further, as described above, since the film has slight thickness unevenness in the width direction, the pressing force becomes non-uniform in the film width direction even when the film is pressed with a lion roll. Therefore, the thickness between the film layers of the film roll becomes non-uniform, and there is a possibility that the amount of charge increases locally or a black streak failure occurs.

  The present invention is for solving the above-mentioned problem, while preventing the occurrence of quality failures such as winding misalignment and black streak failure, air that has been entrained at the time of film winding without using a pressing roll such as a rayon roll. A removable film winding device and a film winding method therefor are provided.

  The present invention relates to a film winding apparatus for winding a long film in a roll shape, an air spraying means for blowing and pressing air on a peripheral surface of the film roll when the film is wound in a roll shape, and an ion And an ion generating means for discharging the film by including the ions in the air.

  Further, the air blowing means is inclined in the film winding direction with respect to a perpendicular passing through the blowing point by the air blowing means on the peripheral surface of the film roll, and the air blowing means in the air blowing direction with respect to the perpendicular When the inclination angle is θ, θ is preferably set in the range of 15 ° to 45 °. Further, it is preferable that the inclination angle θ is gradually increased in accordance with an increase in the winding diameter of the film of the film roll.

  Moreover, it is preferable to provide a moving means for moving the air blowing means so as to keep the distance between the air blowing means and the peripheral surface of the film roll constant. Furthermore, tension control means for controlling the magnitude of tension applied to the film wound up in the roll shape is provided, and the tension control means reduces the tension as the film winding diameter increases. It is preferable.

  The tension control means preferably sets the tension at the initial stage of film winding to 450 N or less. Furthermore, it is preferable that the film winding speed is 30 m / min or more.

  Moreover, the said film is a cellulose acetate film, and it is preferable that the film thickness is 40-135 micrometers. Furthermore, the air pressure at which the air blowing means blows the air is preferably 2 to 10 kPa.

  Further, the present invention provides a film winding method for a film winding apparatus for winding a long film in a roll shape, by blowing air containing ions onto the peripheral surface of the film roll on which the film is wound in a roll shape. It is characterized by pressing.

  The film winding apparatus of the present invention comprises air blowing means for blowing air containing ions to the peripheral surface of the film roll, and ion generating means for containing ions in the air. The air entrained in the film roll can be forcibly removed without contact. As a result, regardless of the thickness of the film and the shape of the film roll, the winding radius of the film roll can be made uniform in the roll circumferential direction, so that the occurrence of winding or black streaks can be prevented. In addition, air can be removed without contact without using a pressure roll such as a rayon roll, and since the ions are included in the air to be blown, static electricity on the film can be removed. As a result, the occurrence of foreign object failure due to static electricity can be reduced.

  Further, the air blowing means is inclined in the film winding direction with respect to a perpendicular passing through the blowing point by the air blowing means on the peripheral surface of the film roll, and the air blowing means in the air blowing direction with respect to the perpendicular When the inclination angle is θ, θ is set in the range of 15 ° to 45 °, and thus air entrained in the film roll can be forcibly removed without contact.

  In addition, since the inclination angle θ is gradually increased in accordance with an increase in the winding diameter of the film roll, it is possible to match the amount of air entrained in and out of the film roll.

  Moreover, since the moving means for moving the air blowing means is provided so as to keep the distance between the air blowing means and the peripheral surface of the film roll, there is no possibility that the formation of the film roll is hindered.

  Also, as the roll diameter of the film roll is increased, the amount of tension applied to the film is reduced, so that the winding pressure is increased and black stripes and wrinkles are generated on the film roll. Is prevented.

  In the film winding method of the present invention, when the film is wound on a roll-shaped film roll, air containing ions is blown and pressed on the peripheral surface of the film roll. The static electricity on the film can be removed while forcibly removing the air entrained in the film roll at the time of removal without contact.

  Hereinafter, embodiments of the present invention will be described in detail. However, the present invention is not limited to the embodiments listed here.

[material]
In the present embodiment, cellulose acylate is used as the polymer, and triacetyl cellulose (TAC) is particularly preferable as the cellulose acylate. Among cellulose acylates, those in which the substitution degree of the acyl group with respect to the hydrogen atom of the hydroxyl group of cellulose satisfies all of the following formulas (1) to (3) are more preferable. In the following formulas (1) to (3), A and B represent the substitution degree of the acyl group with respect to the hydrogen atom of the hydroxyl group of cellulose, A is the substitution degree of the acetyl group, and B is 3 to 3 carbon atoms. 22 is the substitution degree of the acyl group. In addition, it is preferable that 90 mass% or more of TAC is a particle | grain of 0.1 mm-4 mm.
(1) 2.5 ≦ A + B ≦ 3.0
(2) 0 ≦ A ≦ 3.0
(3) 0 ≦ B ≦ 2.9
The polymer used in the present invention is not limited to cellulose acylate.

  Solvents for preparing the dope include aromatic hydrocarbons (eg, benzene, toluene, etc.), halogenated hydrocarbons (eg, dichloromethane, chlorobenzene, etc.), alcohols (eg, methanol, ethanol, n-propanol, n-butanol, Diethylene glycol, etc.), ketones (eg, acetone, methyl ethyl ketone, etc.), esters (eg, methyl acetate, ethyl acetate, propyl acetate, etc.) and ethers (eg, tetrahydrofuran, methyl cellosolve, etc.). In the present invention, the dope means a polymer solution or dispersion obtained by dissolving or dispersing a polymer in a solvent.

  Among these, halogenated hydrocarbons having 1 to 7 carbon atoms are preferably used, and dichloromethane is most preferably used. In addition to dichloromethane, one kind of alcohol having 1 to 5 carbon atoms is used from the viewpoint of physical properties such as solubility of TAC, peelability from cast film support, mechanical strength of film, and optical properties of film. It is preferable to mix several kinds. 2 mass%-25 mass% are preferable with respect to the whole solvent, and, as for content of alcohol, 5 mass%-20 mass% are more preferable. Specific examples of the alcohol include methanol, ethanol, n-propanol, isopropanol, n-butanol and the like, but methanol, ethanol, n-butanol or a mixture thereof is preferably used.

  By the way, recently, for the purpose of minimizing the influence on the environment, studies have been conducted on the solvent composition when dichloromethane is not used. For this purpose, ethers having 4 to 12 carbon atoms, carbon atoms A ketone having 3 to 12 carbon atoms, an ester having 3 to 12 carbon atoms, and an alcohol having 1 to 12 carbon atoms are preferably used. These may be used in combination as appropriate. For example, a mixed solvent of methyl acetate, acetone, ethanol, and n-butanol can be mentioned. These ethers, ketones, esters and alcohols may have a cyclic structure. A compound having two or more functional groups of ether, ketone, ester, and alcohol (that is, —O—, —CO—, —COO—, and —OH) can also be used as the solvent.

In addition, about the detail of a cellulose acylate, it is [0 of Japanese Patent Application No. 2004-264464.
140] to [0195]. These descriptions are also applicable to the present invention. The same applies to additives such as solvents and plasticizers, deterioration inhibitors, UV absorbers (UV agents), optical anisotropy control agents, retardation control agents, dyes, matting agents, release agents, and release accelerators. From [0196] paragraph of Japanese Patent Application No. 2004-264464 to [0516]
It is described in detail in the paragraph.

[Dope production method]
First, a dope is manufactured using the above raw materials. FIG. 1 shows a dope production line 10. The dope production line 10 has a solvent tank 11 for storing the solvent, a dissolution tank 12 for mixing the solvent and TAC, a hopper 13 for supplying TAC, and an additive for storing the additive. An additive tank 14 is provided. Furthermore, the heating apparatus 15 for heating the swelling liquid mentioned later, the temperature controller 16 which adjusts the temperature of the prepared dope, and the filtration apparatus 17 are provided. Further, a flash device 30 for concentrating the prepared dope, a filtration device 31 and the like are also provided. A recovery device 32 for recovering the solvent and a regeneration device 33 for regenerating the recovered solvent are provided. The dope production line 10 is connected to a film production line 40 via a stock tank 41.

  The dope is manufactured by the following method using the dope manufacturing line 10. First, the valve 18 is opened, and the solvent is sent from the solvent tank 11 to the dissolution tank 12. Next, the TAC contained in the hopper 13 is fed into the dissolution tank 12 while being measured. In addition, the required amount of the additive solution is sent from the additive tank 14 to the dissolution tank 12 by opening and closing the valve 19.

  In addition to the method of sending the additive as a solution, for example, when the additive is liquid at room temperature, it can be sent to the dissolution tank 12 in the liquid state. Further, when the additive is solid, a method of feeding into the dissolution tank 12 using a hopper or the like is also possible. When a plurality of types of additives are added, a solution in which a plurality of types of additives are dissolved can be placed in the additive tank 14. Alternatively, a solution in which an additive is dissolved can be put in each of a plurality of additive tanks and sent to the dissolution tank 12 through independent pipes.

  In the above description, the order of putting into the dissolution tank 12 is the solvent (used in the meaning including the case of the mixed solvent), the TAC, and the additive, but it is not limited to this order. For example, a preferred amount of solvent can be fed after the TAC is metered into the dissolution tank 12. Further, it is not always necessary to add the additive to the dissolution tank 12 in advance, and it can be mixed in a mixture of TAC and a solvent (hereinafter, these mixtures may also be referred to as dope) in a later step.

  As shown in FIG. 1, the dissolution tank 12 includes a jacket 20 that wraps the outer surface thereof, and a first stirrer 22 that is rotated by a motor 21. Furthermore, as shown in FIG. 1, it is preferable that a second agitator 24 that is rotated by a motor 23 is attached to the dissolution tank 12. The first stirrer 22 is preferably provided with an anchor blade, and the second stirrer 24 is preferably a dissolver type eccentric stirrer. The melting tank 12 is adjusted in temperature by flowing a heat transfer medium inside the jacket 20, and a preferable temperature range is −10 ° C. to 55 ° C. By appropriately selecting and using the types of the first stirrer 22 and the second stirrer 24, the swelling liquid 25 in which the TAC is swollen in the solvent is obtained.

  Next, the swelling liquid 25 is sent to the heating device 15 by the pump 26. The heating device 15 is preferably a jacketed pipe, and further preferably has a configuration capable of pressurizing the swelling liquid 25. By using such a heating device 15, the dope 27 is obtained by dissolving the solid content in the swelling liquid 25 under heating conditions or under pressure and heating conditions. Hereinafter, this method is referred to as a heating dissolution method. In this case, the temperature of the swelling liquid 25 is preferably 50 ° C to 120 ° C. Moreover, the cooling dissolution method which cools the swelling liquid 25 to the temperature of -100 degreeC--30 degreeC can also be performed. TAC can be sufficiently dissolved in a solvent by appropriately selecting the heating dissolution method and the cooling dissolution method. After the dope 27 is brought to about room temperature by the temperature controller 16, the dope 27 is filtered by the filtering device 17 to remove impurities contained in the dope 27. The filtration filter used in the filtration device 17 preferably has an average pore diameter of 100 μm or less. The filtration flow rate is preferably 50 L / hr or more. The dope 27 after filtration is sent to a stock tank 41 in a film production line 40 through a valve 28 and stored therein.

  By the way, as described above, the method of once preparing the swelling liquid 25 and then using the swelling liquid 25 as the dope 27 requires a longer time as the concentration of TAC is increased, which is problematic in terms of manufacturing cost. There is a case. In that case, it is preferable to prepare a dope having a concentration lower than the target concentration and then perform a concentration step for obtaining the target concentration. When using such a method, the dope filtered by the filtering device 17 is sent to the flash device 30 via the valve 28, and a part of the solvent in the dope is evaporated in the flash device 30. The solvent gas generated by the evaporation is condensed by a condenser (not shown) to become a liquid and is recovered by the recovery device 32. The recovered solvent is regenerated as a dope preparation solvent by the regenerator 33 and reused. This reuse is effective in terms of cost.

  Further, the concentrated dope 27 is extracted from the flash device 30 by the pump 34. Furthermore, it is preferable that a bubble removal process is performed to remove bubbles generated in the dope 27. As this defoaming method, various known methods are applied, for example, an ultrasonic irradiation method. The dope 27 is subsequently sent to the filtering device 31 to remove foreign matter. In addition, it is preferable that the temperature of dope 27 in the case of filtration is 0 degreeC-200 degreeC. The dope 27 is sent to the stock tank 41 and stored.

  By the above method, the dope 27 whose TAC concentration is 5 mass% to 40 mass% can be manufactured. More preferably, the TAC concentration is from 15% by mass to 30% by mass, and most preferably from 17% by mass to 25% by mass. The concentration of the additive (mainly a plasticizer) is preferably in the range of 1% by mass or more and 20% by mass or less when the total solid content in the dope is 100% by mass. In addition, from the [0517] paragraph of Japanese Patent Application No. 2004-264464 about the raw material in the solution casting method which obtains a TAC film, a raw material, the dissolution method and addition method of an additive, the filtration method, dope manufacturing methods, such as defoaming [0616] The paragraph is detailed. These descriptions are also applicable to the present invention.

[Solution casting method]
Next, a method for producing a film using the dope 27 obtained above will be described. FIG. 2 is a schematic view showing a film production line 40. However, the present invention is not limited to the film production line as shown in FIG. The film production line 40 includes a stock tank 41, a filtration device 42, a casting die 43, a casting band 46 stretched around rotating rollers 44 and 45, a tenter dryer 47, and the like. Further, an ear-cutting device 50, a drying chamber 51, a cooling chamber 52, a film winding device (hereinafter simply referred to as a winding device) 53, and the like are arranged.

  An agitator 61 that is rotated by a motor 60 is attached to the stock tank 41. The stock tank 41 is connected to the casting die 43 via the pump 62 and the filtration device 42.

As a material of the casting die 43, precipitation hardening type stainless steel is preferable, and its thermal expansion coefficient is preferably 2 × 10 ⁻⁵ (° C. ⁻¹ ) or less. And what has the corrosion resistance substantially equivalent to SUS316 in the forced corrosion test with the electrolyte aqueous solution can be used as the material of the casting die 43, and further immersed in a mixed solution of dichloromethane, methanol and water for 3 months. Even if it has corrosion resistance, no pitting (perforation) occurs at the gas-liquid interface. Furthermore, it is preferable that the casting die 43 is manufactured by grinding a material that has passed one month or more after casting. As a result, the dope 27 flows uniformly in the casting die 43, and streaks and the like are prevented from occurring in the casting film described later. The finishing accuracy of the wetted surface of the casting die 43 is preferably 1 μm or less in terms of surface roughness, and the straightness is preferably 1 μm / m or less in any direction. The slit clearance of the casting die 43 can be adjusted in the range of 0.5 mm to 3.5 mm by automatic adjustment. About the corner | angular part of the liquid-contacting part of the lip | tip end of the casting die 43, R is 50 micrometers or less over the whole width. Moreover, it is preferable that the shear rate inside the casting die 43 is adjusted to be 1 (1 / sec) to 5000 (1 / sec).

  The width of the casting die 43 is not particularly limited, but is preferably 1.01 to 1.3 times the width of the film as the final product. Moreover, it is preferable to attach a temperature controller to the casting die 43 so that the temperature during film formation is maintained at a predetermined temperature. The casting die 43 is preferably a coat hanger type. Furthermore, it is more preferable that thickness adjusting bolts (heat bolts) are provided at predetermined intervals in the width direction of the casting die 43 and the casting die 43 is provided with an automatic thickness adjusting mechanism using a heat bolt. The heat bolt is preferably formed into a film by setting a profile according to the amount of pump 62 (preferably a high precision gear pump) according to a preset program. Further, feedback control may be performed by an adjustment program based on a profile of a thickness meter (for example, an infrared thickness meter) (not shown) in the film production line 40. The thickness difference between any two points in the width direction of the product film, excluding the casting edge portion, can be adjusted within 1 μm, and the difference between the minimum value and the maximum value in the width direction thickness can be adjusted to 3 μm or less. Preferably, adjusting to 2 μm or less is more preferable. Moreover, it is preferable to use the one whose thickness accuracy is adjusted to ± 1.5 μm or less.

More preferably, a cured film is formed at the lip end of the casting die 43. A method for forming the cured film is not particularly limited, and examples thereof include ceramic coating, hard chrome plating, and a nitriding method. When ceramics are used as the cured film, those that can be ground, have low porosity, are not brittle, have good corrosion resistance, have good adhesion to the casting die 43, and have no adhesion to the dope are preferable. Specific examples include tungsten carbide (WC), Al ₂ O ₃ , TiN, Cr ₂ O _{3 and the} like, and WC is particularly preferable. The WC coating can be performed by a thermal spraying method.

  In order to prevent the dope flowing out to the slit end of the casting die 43 from locally drying and solidifying, it is preferable to attach a solvent supply device (not shown) to the slit end. In this case, a solvent for solubilizing the dope (for example, a mixed solvent of 86.5 parts by mass of dichloromethane, 13 parts by mass of acetone, and 0.5 parts by mass of n-butanol) is used at both ends of the casting bead and at the end of the die slit. And it is preferable to supply to the periphery vicinity of the three-phase contact line which external air forms. Moreover, it is preferable to supply at 0.1 mL / min to 1.0 mL / min to each one side of the end portion in order to prevent mixing of foreign matters into the cast film. In addition, as a pump which supplies this liquid, it is preferable to use a pump with a pulsation rate of 5% or less.

  A casting band 46 is provided below the casting die 43 so as to span the rotating rollers 44 and 45. The rotating rollers 44 and 45 are rotated by a driving device (not shown), and the casting band 46 travels endlessly with the rotation. It is preferable that the casting band 46 can move at a moving speed, that is, a casting speed of 10 m / min to 200 m / min. In order to set the surface temperature of the casting band 46 to a predetermined value, it is preferable that the heat transfer medium circulating device 63 is attached to the rotating rollers 44 and 45. It is preferable that the surface temperature of the casting band 46 can be adjusted to -20 ° C to 40 ° C. A heat transfer medium flow path (not shown) is formed in the rotating rollers 44 and 45 used in the present embodiment, and the heat transfer medium maintained at a predetermined temperature passes through the flow path. The temperatures of the rotating rollers 44 and 45 are maintained at a predetermined value.

  The width of the casting band 46 is not particularly limited, but it is preferable to use a casting band 46 having a range of 1.05 to 1.5 times the casting width of the dope 27. The length is preferably 50 m to 150 m, the thickness is 1 mm to 5 mm, and the surface is preferably polished so that the surface roughness is 0.05 μm or less. The casting band 46 is preferably made of stainless steel, and more preferably made of SUS316 so as to have sufficient corrosion resistance and strength. Further, it is preferable to use a non-uniform thickness of the casting band 46 of 0.5% or less.

It is also possible to use the rotating rollers 44 and 45 directly as a support. In this case, it is preferable that the rotation can be rotated with high accuracy so that the rotation unevenness is 0.2 mm or less, and the average roughness of the surfaces of the rotating rollers 44 and 45 is 0.01 μm or less. preferable. Therefore, the surface of the rotating roller is subjected to chrome plating or the like so as to have sufficient hardness and durability. In addition, it is necessary to suppress the surface defects of the support (the casting band 46 and the rotating rollers 44 and 45) to the minimum. Specifically, there is no pinhole of 30 μm or more, and the number of pinholes of 10 μm or more and less than 30 μm is 1 / m ² or less, and the number of pinholes of less than 10 μm is preferably ² / m ² or less.

  The casting die 43, the casting band 46, and the like are housed in a casting chamber 64. The casting chamber 64 is provided with a temperature control facility 65 for keeping the internal temperature at a predetermined value, and a condenser (condenser) 66 for condensing and recovering the volatile organic solvent. A recovery device 67 for recovering the condensed and liquefied organic solvent is provided outside the casting chamber 64. Further, it is preferable that a decompression chamber 68 for controlling the pressure of the back surface of the casting bead formed from the casting die 43 to the casting band 46 is disposed, and this is also used in this embodiment. .

  Air blowing ports 70, 71, 72 are provided near the peripheral surface of the casting band 46 in order to evaporate the solvent in the casting film 69. Further, a wind shielding plate 73 is provided at the air blowing port 70 in the vicinity of the casting die 43 in order to suppress variation in the surface state of the casting film 69 caused by blowing dry air to the casting film 69 immediately after casting. It is preferable.

  The crossover portion 80 is provided with a blower 81, and the ear-cutting device 50 downstream of the tenter dryer 47 is used for finely cutting the waste at the side end portion (referred to as an ear) of the cut film 82. Crusher 90 is connected.

  The drying chamber 51 is provided with a number of rollers 91, and an adsorption / recovery device 92 for adsorbing / recovering the solvent gas generated by evaporation is attached. In FIG. 2, the cooling chamber 52 is provided downstream of the drying chamber 51, but a humidity control chamber (not shown) may be provided between the drying chamber 51 and the cooling chamber 52. Further, downstream of the cooling chamber 52, a knurling roller 94 is provided for embossing knurling on both edges of the film 82.

  An ear clip device 95 is disposed downstream of the knurling roller 94. The edge-cutting device 95 cuts and removes excess portions of both edges of the film 82 to which knurling is applied by oscillating cutting while adjusting both edge positions of the film 82 with an edge position controller (not shown). The crusher 90 described above is also connected to the ear clip device 95, but is not shown in order to prevent complication of the drawing. The winding device 53 is an embodiment of the present invention. In the present embodiment, the winding device 53 is a biaxial turret type winding so that the film 82 that is continuously conveyed can be continuously wound, as will be described in detail later. The device is used.

  Next, an example of a method for manufacturing the film 82 using the above-described film manufacturing line 40 will be described below. The dope 27 is always made uniform by the rotation of the stirrer 61. The dope 27 may be mixed with additives such as a plasticizer and an ultraviolet absorber even during the stirring.

The dope 27 is sent to the filtering device 42 by the pump 62 and filtered there, and then is cast from the casting die 43 onto the casting band 46. The driving of the rotating rollers 44 and 45 is preferably adjusted so that the tension generated in the casting band 46 is 10 ⁴ N / m to 10 ⁵ N / m. Further, the relative speed difference between the casting band 46 and the rotating rollers 44 and 45 is adjusted to be 0.01 m / min or less. The speed fluctuation of the casting band 46 is preferably 0.5% or less, and the meandering in the width direction when the casting band 46 rotates once is preferably 1.5 mm or less. In order to control the meandering, a detector (not shown) for detecting the positions of both ends of the casting band 46 is provided, and based on the measured value, feedback control is performed on a position controller (not shown) of the casting band 46, It is more preferable to adjust the position of the casting band 46. Further, it is preferable to adjust the casting band 46 immediately below the casting die 43 so that the vertical position fluctuation accompanying the rotation of the rotary roller 55 is 200 μm or less. The temperature of the casting chamber 64 is preferably set to −10 ° C. to 57 ° C. by the temperature control equipment 65. The solvent evaporated inside the casting chamber 64 is recovered by the recovery device 67 and then regenerated and reused as a dope preparation solvent.

  A casting bead is formed from the casting die 43 to the casting band 46, and a casting film 69 is formed on the casting band 46. The temperature of the dope 27 at the time of casting is preferably −10 ° C. to 57 ° C. Further, in order to stabilize the casting bead, the back surface of the casting bead is preferably controlled to a desired pressure value by the decompression chamber 68. The back surface of the bead is preferably decompressed in the range of −2000 Pa to −10 Pa than the front surface. Further, it is preferable that a jacket (not shown) is attached to the decompression chamber 68 and the temperature is controlled so that the internal temperature is kept at a predetermined temperature. The temperature of the decompression chamber 68 is not particularly limited, but is preferably set to be equal to or higher than the condensation point of the organic solvent used. In order to keep the shape of the casting bead desired, it is preferable to attach a suction device (not shown) to the edge portion of the casting die 43. The edge suction air volume is preferably in the range of 1 L / min to 100 L / min.

  The casting film 69 moves as the casting band 46 travels. At this time, drying air is applied to the casting film 69 by the air blowing ports 70, 71, 72, and evaporation of the solvent is promoted. The surface of the casting film 69 may fluctuate due to the blowing of the dry air, but the wind shielding plate 73 suppresses the fluctuation. The surface temperature of the casting band 46 is preferably -20 ° C to 40 ° C.

  After the casting film 69 has self-supporting properties, the casting film 69 is peeled off from the casting band 46 while being supported by the peeling roller 75 as a wet film 74. The amount of residual solvent at the time of stripping is preferably 20% by mass to 250% by mass based on the solid content. Thereafter, the transfer section 80 provided with a large number of rollers is conveyed, and the wet film 74 is fed into the tenter dryer 47. In the transfer part 80, the drying of the wet film 74 is advanced by sending the drying air of desired temperature from the air blower 81. FIG. At this time, the temperature of the drying air is preferably 20 ° C to 250 ° C. In the transition section 80, it is also possible to apply a draw tension to the wet film 74 by making the rotational speed of the downstream roller faster than the rotational speed of the upstream roller.

  The wet film 74 sent to the tenter dryer 47 is dried while being conveyed while being gripped by clips at both ends. Moreover, it is preferable to divide the inside of the tenter dryer 47 into temperature zones and adjust the drying conditions appropriately for each of the zones. It is also possible to stretch the wet film 74 in the width direction using the tenter dryer 47. Thus, it is preferable to stretch at least one direction between the casting direction and the width direction of the wet film 74 by 0.5% to 300% by the crossover 80 and / or the tenter dryer 47.

  The wet film 74 is dried to a predetermined residual solvent amount by the tenter dryer 47 and then sent downstream as a film 82. Both ends of the film 82 are cut at both edges by the ear-cutting device 50. The cut side end portion is sent to the crusher 90 by a cutter blower (not shown). By the crusher 90, the film side end portion is crushed into chips. Since this chip is reused for dope preparation, this method is effective in terms of cost. In addition, although it can also be skipped about the cutting process of this film both ends, it is preferable to carry out in any one from the said casting process to the process of winding up the said film.

  The film 82 from which both ends have been cut off is sent to the drying chamber 51 and further dried. Although the temperature in the drying chamber 51 is not specifically limited, It is preferable that it is the range of 50 to 160 degreeC. In the drying chamber 51, the film 82 is conveyed while being wound around a roller 91, and the solvent gas generated by evaporation here is adsorbed and recovered by an adsorption recovery device 92. The air from which the solvent component has been removed is blown again as dry air inside the drying chamber 51. The drying chamber 51 is more preferably divided into a plurality of sections in order to change the drying temperature. In addition, if a preliminary drying chamber (not shown) is provided between the ear opener 50 and the drying chamber 51 and the film 82 is preliminarily dried, the film temperature is prevented from rising rapidly in the drying chamber 51. The shape change of the film 82 can be further suppressed.

  The film 82 is cooled to approximately room temperature in the cooling chamber 52. A humidity control chamber (not shown) may be provided between the drying chamber 51 and the cooling chamber 52, and air adjusted to a desired humidity and temperature can be blown to the film 82 in this humidity control chamber. It is preferable. Thereby, it is possible to suppress the occurrence of curling of the film 82 and the occurrence of winding failure when winding.

  Both edges of the film 82 cooled to substantially room temperature in the cooling chamber 52 are knurled by embossing by a knurling roller 94. In addition, it is preferable that the unevenness | corrugation of the knurled location is 1 micrometer-200 micrometers. Then, excess portions at both edges of the film 82 to which the knurling is applied are cut and removed by the ear-cleaving device 95.

  Finally, the film 82 is wound into a roll by the winding device 53. At this time, the film 82 to be wound is preferably at least 100 m in the longitudinal direction (casting direction). Further, the width of the film 82 is preferably 600 mm or more, and more preferably 1300 mm or more and 1800 mm or less. The present invention is also effective when it is larger than 1800 mm. The present invention is also applied when manufacturing a thin film having a thickness of 15 μm or more and 135 μm or less.

  In the solution casting method of the present invention, at the time of casting a dope, two or more kinds of dopes can be simultaneously laminated co-casting or sequentially laminated co-casting. Furthermore, you may combine both casting. When performing simultaneous lamination and co-casting, a casting die to which a feed block is attached may be used, or a multi-manifold casting die may be used. It is preferable that at least one of the thickness of the layer on the air surface side and the thickness of the layer on the support side is 0.5% to 30% of the thickness of the entire film. Furthermore, when performing simultaneous lamination co-casting, it is preferable that the high-viscosity dope is wrapped with the low-viscosity dope when the dope is cast from the die slit to the support. Moreover, when performing simultaneous lamination | stacking co-casting, it is preferable that the dope which contact | connects an external field has a larger alcohol composition ratio than an internal dope among the casting beads formed from a die slit to a support body.

From casting die, decompression chamber, support structure, co-casting, peeling method, stretching, drying conditions of each process, handling method, curl, winding method after flatness correction, solvent recovery method, film recovery method The details are described in paragraphs [0617] to [0889] of Japanese Patent Application No. 2004-264464. These descriptions are also applicable to the present invention.

[Performance / Measurement method]
(Curl degree / thickness)
The performance of the wound cellulose acylate film and the measuring method thereof are disclosed in Japanese Patent Application No. 200.
No. 4-264464, paragraphs [0112] to [0139]. These are also applicable to the present invention.

[surface treatment]
It is preferable that at least one surface of the cellulose acylate film is surface-treated. The surface treatment is preferably at least one of vacuum glow discharge treatment, atmospheric pressure plasma discharge treatment, ultraviolet irradiation treatment, corona discharge treatment, flame treatment, acid treatment or alkali treatment.

[Functional layer]
(Antistatic, hardened layer, antireflection, easy adhesion, antiglare)
At least one surface of the cellulose acylate film may be undercoated.

Further, it is preferable to use the cellulose acylate film as a base film as a functional material provided with another functional layer. The functional layer is an antistatic layer, a cured resin layer,
It is preferable to provide at least one layer selected from an antireflection layer, an easy adhesion layer, an antiglare layer, and an optical compensation layer.

The functional layers preferably contain at least one surfactant 0.1mg / m ² ~1000mg / m ² containing. Further, the functional layers preferably contain at least one sort of plasticizers in the 0.1mg / m ² ~1000mg / m ² containing. Further, the functional layers preferably contain at least one sort of matting agents in the 0.1mg / m ² ~1000mg / m ² containing. Further, the functional layers preferably contain at least one sort of antistatic agents 1mg / m ² ~1000mg / m ² containing. The surface treatment functional layer imparting method for realizing various functions and properties on the cellulose acylate film is described in Japanese Patent Application No. 2004-264464, paragraphs [0890] to [1087]. It is included. These are also applicable to the present invention.

(Use)
The cellulose acylate film is particularly useful as a polarizing plate protective film. Usually, two polarizing plates each having a cellulose acylate film bonded to a polarizer are bonded to a liquid crystal layer to produce a liquid crystal display device. However, the arrangement of the liquid crystal layer and the polarizing plate is not limited,
Various known arrangements can be employed. Japanese Patent Application No. 2004-264464 describes in detail TN type, STN type, VA type, OCB type, reflection type, and other examples of liquid crystal display devices. This method can also be applied to the present invention. In addition, the application was provided with an optically anisotropic layer,
There are also descriptions of cellulose acylate films and cellulose acylate films imparted with antireflection and antiglare functions. Furthermore, the use as an optical compensation film is also described as a biaxial cellulose acylate film imparting appropriate optical performance. This can also be used as a polarizing plate protective film. These descriptions are also applicable to the present invention.
Details are described in paragraphs [1088] to [1265] of Japanese Patent Application No. 2004-264464.

  Moreover, the cellulose triacetate film (TAC film) which is excellent in an optical characteristic by the manufacturing method of this invention can be obtained. The TAC film can be used as a polarizing plate protective film or a base film of a photographic photosensitive material. Further, it can be used as an optical compensation film for improving the viewing angle dependency of a liquid crystal display device such as a television. In particular, it is effective for applications that also serve as a protective film for a polarizing plate. Therefore, it is used not only for the conventional TN mode but also for the IPS mode, OCB mode, VA mode, and the like. Moreover, you may comprise a polarizing plate using the said film for polarizing plate protective films.

  Next, a two-shaft turret type winding device 53 embodying the present invention will be described with reference to FIG. The winding device 53 is roughly divided into a turret arm 112, a holding base 113 for rotatably holding the turret arm 112, a winding core 114 set at both ends of the turret arm 112, a motor 115, a pulse generator 116, and a tension measuring roller. 117, a guide roller 118, a dancer roller 119, a dancer mechanism 120, a tension measurement sensor 121, an air blowing mechanism 122, and a control unit 123. The winding device 53 forms a film roll 124 by continuously winding a film 82 manufactured by a film forming device, a drying device, etc. (not shown) in a roll shape with a winding core 114 rotatably held by a turret arm 112. To do.

  When the winding radius (winding thickness) of the film roll 124 reaches a predetermined length, the film 82 is cut at a predetermined position by a film cutter (not shown) or the like. Further, the tip of the cut film 82 is wound around an empty core 114 set at the tip of the turret arm 112 by a winding device (not shown). Thereafter, the turret arm 112 is rotated by a predetermined angle, and the core 114 around which the leading end of the film 82 is wound is set at the winding position. Further, the film roll 124 that has been wound up is set at the take-out position. At the take-out position, after the film roll 124 is taken out, an empty core 114 is set.

  The winding core 114 set at the winding position is rotationally driven by a motor 115, and when the winding core 114 is rotated in the clockwise direction in the drawing, the film 82 is wound around the film roll 124. As the motor 115, a pulse motor or the like is often used. The winding speed at which the film 82 is wound can be controlled by controlling the frequency of the motor control pulse signal sent to the motor 115 from a motor driver (not shown). In the present embodiment, the winding speed is preferably 30 m / min or more.

  The pulse generator 116 is connected to one of the pass rollers 127 arranged on the film transport path, and converts the rotation of the pass roller 127 into a pulse signal. This pulse signal is sent to the control unit 123. The control unit 123 counts the number of pulses of the pulse signal, thereby calculating the winding amount of the film 82 wound around the winding core 114 and calculating the winding radius of the film 82 based on the calculation result.

  The tension measuring roller 117 and the guide roller 118 are disposed upstream of the pass roller 127 in the conveying direction, and a dancer roller 119 is held between the rollers 117 and 18 by the dancer mechanism 120 so as to be movable in the vertical direction in the figure. . A tension measuring sensor 121 is connected to the tension measuring roller 117. The tension measuring sensor 121 detects the winding tension applied to the film 82 wound around the film roll 124. The dancer mechanism 120 adjusts the amount of winding tension during film winding by adjusting the weight applied to the dancer roller 119.

  At this time, if the winding tension applied to the film 82 is strong, the winding pressure of the film roll 124 becomes strong and black stripe failure or wrinkle occurs. Conversely, if the winding tension is weak, the winding pressure becomes weak. Winding deviation occurs. For this reason, the control unit 123 determines that the winding tension applied to the film 82 is within a predetermined range according to the winding speed and thickness of the film 82 based on the detection signal from the tension measuring sensor 121, for example, in the present embodiment. Then, the dancer mechanism 120 is controlled so as to be within the range of 300 to 450N.

  Furthermore, if the winding tension applied to the film 82 during film winding is not reduced as the winding radius (winding amount) of the film roll 124 increases, the winding pressure increases and black lines and wrinkles are generated. Will occur. Therefore, the control unit 123 controls the dancer mechanism 120 to reduce the winding tension applied to the film 82 as the winding radius of the film roll 124 increases. For example, in this embodiment, the winding tension of the film 82 is set to be 410 N at the start of film winding when the winding speed of the film 82 is 100 m / min, the thickness is 80 μm, the width is 1340 mm, and the total winding length is 4000 m. It is set to reduce to 350 N at the end of winding.

  The air blowing mechanism 122 forcibly removes air that has been wound in a non-contact manner when the film is wound, by blowing air onto the peripheral surface of the film roll 124 and performing air pressing, unlike a lion roll. For this reason, the air blowing mechanism 122 is disposed in the vicinity of the winding start position where the film 82 is wound around the film roll 124. The arrangement position of the air blowing mechanism 122 is not limited to this, and the film winding is performed when the winding start position is set to 0 ° around the central axis of the film roll 124 (winding core 114). You may arrange | position within the range of 60 degrees-240 degrees toward a direction.

  The air blowing mechanism 122 includes an air nozzle 129, a blower 131 connected to the air nozzle 129 via an air pipe 130, a shift mechanism 132 that moves the air nozzle 129 (and the swing mechanism 133) in the left-right direction in the figure, and an air nozzle. The swing mechanism 133 changes the air blowing angle by tilting 129 and the ion generator 135 provided in the air nozzle 129 and generating ions. Although not shown in the drawing, the air pipe 130 is provided with an automatic valve that controls the blowing of air, a dehumidifier that adjusts the humidity (dew point) of air, a heat exchanger that adjusts the temperature of air, and the like. It has been.

  The air nozzle 129 is formed with a slit-shaped opening 129 a parallel to the rotation axis of the film roll 124. If the length of the opening 129a in the longitudinal direction is longer than the width of the film 82, air enters from the side surface of the film roll 124 during air pressing, and the air removal efficiency is lowered. Therefore, it is preferable that the length of the opening 129a in the longitudinal direction is slightly shorter than the length of the film 82 in the width direction.

  The blower 131 is an air blowing source and generates high-pressure air having a predetermined pressure. In the present embodiment, the pressure of the air generated by the air blower 131 is preferably 2 to 10 kPa. The air generated by the blower 131 is blown from the opening 129a of the air nozzle 129 to the peripheral surface of the film roll 124 with a uniform air pressure (spraying pressure) in the longitudinal direction through the air pipe 130 and the like. As described above, air is blown from the opening 129a of the air nozzle 129 to the circumferential surface of the film roll 124 with a uniform air pressure over the longitudinal direction thereof, so that the air caught in the film roll 124 can be contacted without contact. By removing, the winding radius of the film roll 124 can be made uniform over the circumferential direction of the roll.

  The shift mechanism 132 moves the air nozzle 129 and the swing mechanism 133 as the winding radius increases so that the distance between the opening 129a and the peripheral surface of the film roll 124 can be kept constant even when the winding radius of the film roll 124 increases. Move to the right in the figure. Any mechanism may be used as the shift mechanism 132 as long as the air nozzle 129 and the like can be moved. Thereby, even if the winding radius of the film roll 124 becomes large at the time of film winding, the distance between the opening 129a and the peripheral surface of the film roll 124 can be kept constant. In the present embodiment, the distance between the opening 129a and the peripheral surface of the film roll 124 is set to 3 to 30 mm.

  As shown in FIGS. 4 and 5, the swing mechanism 133 moves the air nozzle 129 in the film winding direction by an inclination angle θ1 with respect to a perpendicular L passing through the air blowing point C by the air nozzle 129 on the peripheral surface of the film roll 124. Can tilt. This inclination angle θ1 can be set in the range of 15 to 45 °. Further, at the start of film winding, the angle θ2 formed between the film 82 and the peripheral surface of the film roll 124 is large as shown in FIG. 4, so that the amount of air to be wound increases, and the film roll 124 as shown in FIG. When the thickness is increased, the angle θ2 is reduced, so that the amount of air that is entrained is also reduced. Therefore, in this embodiment, the inclination angle θ1 is set to about 30 ° at the start of film winding (see FIG. 4). Then, in order to match the amount of air in the winding and the outside of the winding, the inclination angle θ1 is gradually increased in response to the winding radius of the film roll 124 being increased and the amount of air being reduced being reduced ( (See FIG. 5).

  Although not shown, the ion generator 135 includes a plurality of needle-type electrodes. By applying a high voltage to the needle-type electrodes, air (air) around the electrodes is ionized. Thereby, the air containing ion can be sprayed on the surrounding surface of the film roll 124 at the time of an air press. The film 82 wound around the film roll 124 may be charged by sliding contact with a plurality of pass rollers when being transported on the film transport path. However, by blowing air containing ions, the film 82 is tinged. It is possible to reduce the amount of charge by eliminating static electricity. As a result, it is possible to prevent the occurrence of foreign matter failure due to static electricity. As the ion generator 135, any generator may be used as long as it can generate ions (air is ionized).

  The drive of the blower 131, the shift mechanism 132, the swing mechanism 133, and the ion generator 135 is also controlled by the control unit 123. The controller 123 starts driving the ion generator 135 at the start of film winding to ionize the air around the ion generator 135, that is, the air inside the air nozzle 129. Next, the control unit 123 starts driving the motor 115 and starts winding the film 82. At the same time, the control unit 123 starts driving the blower 131 to generate air having a predetermined pressure, so that the air containing ions is removed from the film roll. Air press is performed on the peripheral surface of 124. Thereby, the air entrained in the film roll 124 can be removed in a non-contact manner without using a lion roll. At the same time, static electricity on the film 82 can be removed. Then, when the winding of the film 82 is started, the control unit 123 calculates the winding radius of the film roll 124 based on the pulse signal from the pulse generator 116, and the opening 129a and the peripheral surface of the film roll 124 are obtained. The shift mechanism 132 is driven so as to maintain a certain distance, and the swing mechanism 133 is driven so that the inclination angle θ1 of the air nozzle becomes smaller as the film roll 124 becomes thicker.

  Next, the operation of this embodiment will be described. When the core 114 is set on the gantry 12 and the leading end of the film 82 sent from the upstream side of the film transport path is wound around the core 114 by a winding device (not shown), the control unit 123 drives the shift mechanism 132. The air nozzle 129 is moved to a predetermined position, and the swing mechanism 133 is driven to tilt the air nozzle 129 by a predetermined inclination angle θ1. At the same time, the control unit 123 drives the ion generator 135 to ionize the air in the air nozzle 129, and at the same time, the dancer mechanism 120 so that the winding tension at the start of film winding becomes a predetermined value within 300 to 450N. Drive.

  Next, the control unit 123 drives the motor 115 to start winding the film 82 at a predetermined winding speed of 30 m / min or more. At the same time, the control unit 123 drives the blower 131 to generate air of 2 to 10 kPa, and air-presses air containing ions from the opening 129a onto the peripheral surface of the film roll 124. As a result, the air entrained in the film roll 124 at the time of film winding can be forcibly removed. As a result, regardless of the thickness of the film 82 and the shape of the film roll 124, the thickness of the air between the film layers of the film roll 124 can be made uniform, and the winding radius of the film roll 124 can be made uniform in the roll circumferential direction. . Accordingly, it is possible to prevent the occurrence of winding deviation and black streaks. Further, since air can be removed without contact without using a pressing roll such as a rayon roll, the film 82 is not likely to be charged. Further, by blowing air containing ions, the static electricity on the film 82 can be removed, so that the occurrence of foreign matter failure due to static electricity can be reduced.

  When the film winding is started, the control unit 123 counts the number of pulses of the pulse signal sent from the pulse generator 116, and determines the winding amount of the film 82 wound on the film roll 124 (core 114). Further, the winding radius of the film roll 124 is calculated from the winding amount. And the control part 123 controls the dancer mechanism 120, and reduces the tension | tensile_strength provided to the film 82 according to the calculated winding radius becoming long. As a result, the occurrence of winding wrinkles and black stripe failures can be prevented. At the same time, the control unit 123 drives the shift mechanism 132 to move the air nozzle 129 so that the distance between the opening 129a and the peripheral surface of the film roll 124 is kept constant based on the calculated winding radius. At the same time, the swing mechanism 133 is driven so that the inclination angle θ1 of the air nozzle 129 increases as the film roll 124 becomes thicker.

  When winding of the film 82 is completed, the drive of the blower 131 is stopped and the shift mechanism 132 is driven to retract the air nozzle 129 to a predetermined position. Next, the film 82 is cut at a predetermined position using a film cutter (not shown) or the like. When the cutting of the film 82 is completed, the leading end of the cut film 82 is wound around an empty core 114 set at the leading end of the turret arm 112 by a winding device (not shown). Then, the turret arm 112 is rotated by a predetermined length, the core 114 is set at the winding position, and the film roll 124 after winding is set at the take-out position. At the take-out position, after the film roll 124 is taken out, an empty core 114 is set.

  In the present embodiment, only one air blowing mechanism 122 (air nozzle 129) is provided on the peripheral surface of the film roll 124, but the present invention is not limited to this, and two or more air blowing mechanisms 122 are provided. Also good. For example, as shown in FIG. 6, the film roll 124 (winding core 114) is centered on the central axis, and the winding start position at which the film 82 is wound on the film roll 124 is 0 °. A first air blowing mechanism 140 is provided at a position of °, and a second air blowing mechanism 141 is provided at a position of 180 degrees.

  The first and second air blowing mechanisms 140 and 141 are simplified in illustration as appropriate in order to prevent complication of the drawings, but have the same configuration as the air blowing mechanism 122, and the first and second air nozzles 143a and 143a, respectively. 143b, first and second blowers 144a and 144b, first and second ion generators 145a and 145b, and the like. Thereby, since air press can be performed using the two air nozzles 143a and 143b, the air removal efficiency can be further increased. Moreover, it is not necessary to make the pressure of the air generated by each of these blowers 144a and 144b the same. For example, the air pressure generated by the first blower 144a is made lower than that of the second blower 144b. The first air blowing mechanism 140 may be preliminarily pressed to remove air to some extent, and then the second air blowing mechanism 141 may be used to perform the main press to completely remove the remaining air.

  In this embodiment, the air blowing angle of the air nozzle 129 can be changed by the swing mechanism 133. However, the present invention is not limited to this, and the air blowing direction to the opening 129a is changed. An air blowing angle may be changed by providing a base and changing the angle of the base.

  In the present embodiment, the description has been made by taking the biaxial turret type winding device 53 as an example, but the present invention is not limited to this, and the uniaxial type or the turret type film winding of three or more axes is used. The present invention may also be applied to a capture device.

  Further, the present invention is not limited to the film winding device of the film forming line for forming the cellulose acetate film for the polarizing plate protective film for LCD, but a protective film used for displays other than LCD, PET (polyethylene) The film can be applied to a film winder that winds various films such as terephthalate) film, triacetyl cellulose film, heat-sensitive recording paper, magnetic recording tape, photographic film, metal film, adhesive tape, and the like into a roll.

[Example]
Next, in order to clarify the effect of the present invention, this embodiment using an air nozzle 129 (air blowing mechanism 122) as a removing means for removing air entrained during film winding, and a lion roll (not shown). In the comparative example using), when the winding speed, the pressure (air pressure, the pressing force), and the winding tension at the start of winding (at the start of winding) are each changed, Each was evaluated and compared. The film 82 used for the evaluation was a cellulose acetate film having a film thickness (thickness) of 80 μm and a width of 1340 mm.

  As a comparative example, as shown in Table 1 below, “Comparative Example 1” in which the winding speed is 100 m / min, the pressing force of the lion roll is 45 N, and the winding tension at the beginning of winding is 410 N, and the winding speed is "Comparative Example 2" with 150m / min, pressing force of the lion roll 45N, winding tension at the beginning of winding 410N, winding speed 150m / min, pressing force of the lion roll 45N, winding at the beginning of winding Evaluation was performed in a total of three comparative examples, “Comparative Example 3” with a tension of 620 N.

  In addition, as shown in Table 1 below, “Example 1” in which the winding speed is 100 m / min, the air pressure of the blower 131 is 6 kPa, and the winding tension at the beginning of winding is 410 N, as shown in Table 1 below. “Example 2” in which the take-up speed is 150 m / min, the air pressure of the blower 131 is 6 kPa, the take-up tension at the start of winding is 410 N, the take-up speed is 150 m / min, the air pressure of the blower 131 is 6 kPa, and the start of winding The evaluation was performed in three examples, “Example 3”, in which the winding tension was 620 N.

  As an evaluation item, when winding the film 82 by 4000 m, it was evaluated whether or not the film 82 was wound with an appropriate winding hardness without causing winding slippage or air entrainment. “Black stripe failure” that evaluates whether or not a black stripe failure has occurred in the film roll 124, and “Charge amount” that evaluates the amount of charge on the surface of the film 82 wound around the film roll 124. ”Was evaluated with a total of three items.

  In the evaluation of “winding hardness”, in order to evaluate whether or not the film has been wound at an appropriate winding hardness, the winding radius of the film roll 124 after winding is uniform in the circumferential direction. Evaluated whether or not. Specifically, as shown in FIG. 7, the lengths of the winding radii L1 and L2 extending from the winding core 114 of the film roll 124, which has been wound up, to the upward and downward directions in the drawing, respectively. The operator measures. And the vertical diameter difference (DELTA) L which is the difference of L1 and L2 was computed from the measurement result, and it evaluated as described in Table 2 below. In this evaluation, “X” when the vertical diameter difference ΔL is ΔL ≧ 5 mm is “Δ” when 3 mm ≦ ΔL <5 mm, “◯” when 2 mm ≦ ΔL <3 mm, and “」 ”when ΔL <2 mm. Was determined.

  In the evaluation of “black stripe failure”, the peripheral surface of the film roll 124 after completion of winding was visually inspected to evaluate whether or not a black stripe failure occurred. Then, “X” was determined when a black streak failure occurred, and “◯” was determined when no black streak failure occurred.

  In the evaluation of “charge amount”, the film roll 124 after winding is set in the film delivery device 150 as shown in FIG. 8, and the charge amount of the film 82 sent out from the film roll 124 is measured. For this reason, one of the pass rollers 151 that support the film 82 sent out from the film delivery device 150 is grounded (grounded), and the surface electrometer 152 is disposed at a position facing the film 82 supported by the pass roller 59. Keep it. Then, the surface charge amount of the film 82 sent out from the film roll 124 was continuously measured by a surface potential meter 152 and evaluated as described in Table 3 below. This evaluation is “x” when the measured value S of the charge amount is ± 20 V or more, “△” when the measured value S is less than ± 20 V and ± 10 V or more, “◯” when less than ± 10 V and ± 5 V or more, and “±” or less than ± 5 V When it was judged as “◎”.

  Table 4 below shows the evaluation results of the determinations for each of the three evaluation items for Comparative Examples 1 to 3 and Examples 1 to 3.

  As shown in Table 4, by air-pressing with air containing ions instead of pressing with a lion roll, the winding radius of the film roll 124 becomes uniform in the circumferential direction of the roll, and the occurrence of winding deviation, black streaks, etc. It was confirmed that it can be prevented. At the same time, it was confirmed that the static electricity on the film 82 can be removed.

It is explanatory drawing which shows a dope manufacturing line. It is explanatory drawing which shows a film manufacturing line. It is the schematic of the film winding apparatus which implemented this invention. It is explanatory drawing for demonstrating the inclination-angle of the air nozzle of the film winding apparatus at the time of film winding start. It is explanatory drawing for demonstrating the inclination-angle of an air nozzle when a film roll becomes thick. It is the schematic which showed the other Example which provided the some air nozzle (air spraying mechanism) in the film winding apparatus, and the state at the time of film winding start is shown. It is explanatory drawing for demonstrating winding radius L1, L2 of the film roll measured in order to evaluate the winding hardness of a film roll. It is the schematic which showed an example of the charge amount measurement of the film wound up by the film roll.

Explanation of symbols

DESCRIPTION OF SYMBOLS 53 Film winding device 82 Film 112 Turret 113 Holding stand 114 Winding core 115 Motor 120 Dancer mechanism 121 Tension measurement sensor 122 Air blowing mechanism 123 Control part 124 Film roll 129 Air nozzle 129a Opening 131 Blower 132 Shift mechanism 133 Swing mechanism 135 Ion Generator

Claims (10)

In a film winding device for winding a long film into a roll,
Air blowing means for blowing air onto the peripheral surface of the film roll when the film is wound into a roll; and
An apparatus for winding a film, comprising: ion generating means for generating ions and removing the charge of the film by including the ions in the air.   The air blowing means is inclined in the film winding direction with respect to a normal passing through the blowing point by the air blowing means on the peripheral surface of the film roll, and the air blowing direction is inclined with respect to the normal in the air blowing direction. The film winding apparatus according to claim 1, wherein θ is set in a range of 15 ° to 45 °, where is θ.   3. The film winding apparatus according to claim 2, wherein the inclination angle [theta] is gradually increased in accordance with an increase in the winding diameter of the film of the film roll.   The moving means for moving the air blowing means is provided so as to keep the distance between the air blowing means and the peripheral surface of the film roll constant. Film take-up device. Tension control means for controlling the magnitude of tension applied to the film wound up in the roll shape is provided,
5. The film winding apparatus according to claim 1, wherein the tension control means reduces the tension as the winding diameter of the film increases.   6. The film winding apparatus according to claim 5, wherein the tension control means sets the tension at the initial stage of the film winding to 450 N or less.   The film winding apparatus according to any one of claims 1 to 6, wherein the film winding speed is set to 30 m / min or more.   The film winding device according to any one of claims 1 to 7, wherein the film is a cellulose acetate film, and the film thickness is 40 to 135 µm.   The film winder according to any one of claims 1 to 8, wherein an air pressure at which the air blowing means blows the air is 2 to 10 kPa. In the film winding method of the film winding device for winding a long film into a roll,
A method for winding a film, characterized in that air containing ions is blown and pressed on a peripheral surface of a film roll wound with the film.

Images