JP2009220268A - Slitter device using rotating round blade, method of manufacturing sheet-like article by using the slitter device, and sheet-like article obtained by the method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a slitter device providing a sheet-like article with a neat cut surface and having cutting edges causing less wear and chipping and having a long service life. <P>SOLUTION: This slitter device uses rotating round blades, or an upper blade and a lower blade having a difference in the hardness of approximately 10 or more in HRC. More specifically, for example, if one of the upper and lower blades is made of tool steel, the other is made of a cemented carbide or a ceramic, and if one is made of a cemented carbide, the other is made of a ceramic. The cut surface of the sheet-like article is neat, the cutting edges are thereby less worn and chipped, and the service life of the cutting edges is extended. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a slitter device using a rotating round blade, a method for producing a sheet-like material using the same, and a sheet-like material obtained thereby. More specifically, the present invention relates to a slitter device having a long rotating round blade and a beautiful cut surface of a cut sheet-like article, a method for producing a sheet-like article using the slitter apparatus, and a sheet-like article obtained thereby.

  Conventionally, a long sheet wound in a roll shape is automatically fed, and the sheet is inserted between a pair of upper and lower rotary blades installed in the width direction orthogonal to the feeding direction. The slitter device using a so-called rotating round blade that cuts the sheet to a desired width by means of various paper products such as inkjet paper and copy paper, drug sheets such as plaster sheets and patch materials, polarizing films and retardations It is often used in the field of optical films represented by films and the like. In such applications, when slitting a composite sheet-like material having at least one base sheet and at least one adhesive layer (for example, a polarizing film comprising a polarizing film and a protective film via an adhesive layer) with a desired width The adhesive that forms the adhesive layer adheres to the surface of the blade, and the blade itself has adhesive force, so that the film substrate and the adhesive layer are peeled off as the blade moves, and the cut end is distorted. Furthermore, there are drawbacks such that the adhesive adheres to the cut surface of the cut sheet and the commercial value is lowered.

  In order to solve such inconvenience, a method of covering the surface of the blade with a fluororesin or the like (see Patent Documents 1 and 2) is disclosed, but a slitter device using a rotating round blade interlaces the upper blade and the lower blade. In order to cut the sheet, the coated resin is peeled off due to rubbing of both blades, and the coating effect is lost, or the fluororesin peeled off from the blade may be mixed into the cut film as a foreign object. It is not always satisfactory in the field that dislikes mixing. In addition, the slitter device using a rotating round blade has a structure that cuts the sheet-like material at the contact points of the outer circumferences of the upper blade and the lower blade. Due to shaft runout and round blade processing accuracy, etc., the blade tip of the round blade has a large thrust runout, leading to severe chipping and wear of the blade edge. The rate drops. Further, if the cutting edge is worn and loses sharpness, there is a disadvantage that the sharpness of the cut surface of the sheet-like object is lost and the commercial value is lowered.

JP-A-8-197487 (released August 6, 1996) Japanese Patent Laying-Open No. 2005-288833 (released on October 20, 2005)

  An object of the present invention is to provide a slitter device using a rotating round blade having a beautiful cut surface of a sheet-like material after cutting, little wear and chipping of the blade edge, and a long service life of the blade.

  The main point of the present invention is that a sheet is inserted between the upper blade and the lower blade by rotating a pair of annular upper blades and lower blades while bringing their opposing surfaces into contact with each other at their outer peripheral edges. To provide a slitter device using a rotating round blade characterized by using a cutting tool made of a material having different hardness for an upper blade and a lower blade in a slitter device using a rotating round blade for cutting a shaped article. is there.

  Another one of the present invention is a slitter device using a rotating round blade described in the main point of the present invention, wherein the blade material of the upper blade and the lower blade is tool steel-carbide, tool steel-ceramic, carbide -It consists of at least one of the combination which consists of ceramics.

  Another embodiment of the present invention is a composite sheet in which a sheet-like article to be cut has at least one base sheet and at least one adhesive layer in the slitter apparatus using the rotating round blade described in the main point of the present invention. It is a shaped article.

  This invention also provides the manufacturing method of a sheet-like object using the slitter apparatus using the above-mentioned rotary round blade of this invention. In particular, the present invention provides a method for producing a sheet-like material in which the sheet-like material is a composite sheet-like material having at least one substrate sheet and at least one adhesive layer.

  The present invention also provides a sheet-like material that is cut using a slitter device using the above-described rotating round blade of the present invention. In particular, the cut sheet-like material provides a composite sheet-like material having at least one base sheet and at least one adhesive layer.

  In a slitter device using a rotating round blade, it is a simple method of selecting and using blades with different hardness for the upper blade and lower blade to be used, and there is less wear and chipping of the blade edge compared to the conventional method, and the service life of the blade is reduced. In addition to providing a long slitter device, it is possible to provide a sheet-like material having a long continuous operation time and a sheet-like material having a beautiful cut surface.

The schematic of the slitter apparatus using the rotary round blade used for this invention is shown. The schematic which the bearing part of a slitter apparatus is an angular ball bearing is shown. It is a schematic sectional drawing which shows the shape of the holder surface which touches the round blade surface. It is the schematic which shows the toe-in of an upper blade and a lower blade. It is the schematic which shows the superimposition of an upper blade and a lower blade. It is the schematic which shows the width | variety (lap | wrap) of the outer peripheral part with which an upper blade and a lower blade overlap. It is a figure which shows the condition of the blade edge | tip of the cemented carbide round blade at the time of 2500m cutting | disconnecting an optical sheet with the structure (carbide-high-speed steel) of the main cutter which concerns on Experimental example 1. FIG. It is a figure which shows the cut surface of the optical sheet at the time of 2500m cutting | disconnection of an optical sheet with the structure (super hard-high-speed steel) of the main cutter which concerns on Experimental example 1. FIG. It is a figure which shows the blade edge | tip condition of the upper blade and lower blade after an optical sheet is cut | disconnected by 2500 m with the structure (carbide-high-speed steel) of the main cutter which concerns on Experimental example 1. FIG. It is a side view of the roll which wound up the optical sheet slit using the slitter apparatus of this cutter structure (carbide-high-speed steel) concerning Experimental example 1. It is a figure which shows the condition of the tool blade edge at the time of cutting | disconnecting an optical sheet by 300 m with the structure (high-speed steel-high-speed steel) of the main cutter which concerns on a comparative example. It is a figure which shows the cut surface of the optical sheet at the time of 300-m cutting | disconnecting an optical sheet with the structure (high-speed steel-high-speed steel) of this cutter concerning a comparative example. It is a figure which shows the blade edge | tip condition of the upper blade and lower blade after an optical sheet is cut | disconnected 300m by the structure (high-speed steel-high-speed steel) of the main cutter which concerns on a comparative example. It is a side view of the roll which wound up the optical sheet slit using the slitter apparatus of this cutter structure (high-speed steel-high-speed steel) which concerns on a comparative example.

  Hereinafter, the present invention will be described in more detail with reference to the drawings. FIG. 1 is a schematic view showing a cutting state of a sheet-like material using a pair of rotating round blades according to an embodiment of the present invention. Usually, the slit device used in the manufacturing process of the optical sheet has a plurality of rotating round blades composed of a pair of upper blades and lower blades shown in FIG. 1 at desired slit positions along the width direction of the long sheet, When the long sheet is inserted along the longitudinal direction, the long sheet is continuously cut along the longitudinal direction with the desired width. Here, in order to simplify the drawing, Description will be made using only a pair of rotating round blades. In the figure, reference numeral 1 is an upper blade, 2 is a lower blade, 3 is a long sheet, 4 is a shaft, 5 is a width of the outer peripheral portion where the upper blade and the lower blade overlap, 6 and 7 are holders, 6a and 7a are holder surfaces, Reference numeral 8 denotes a bearing, 9 denotes a speed reducer, and 10 denotes a motor.

  The upper blade 1 is formed in an annular shape, and is clamped and fixed by holders 6 and 7 after being inserted into the shaft 4. In FIG. 1, the holder 6 is formed integrally with the shaft 4. The other end of the shaft 4 on which the annular blade is installed is supported by a bearing 8, and an upper blade 1 fixed by a motor 10 via a speed reducer 9 is configured to be rotatable, and the lower blade 2 is also an upper blade 1. It is configured to be rotatable in the same manner as in FIG. At the time of rotation, the upper blade 1 and the lower blade 2 are arranged so as to overlap each other at the outer periphery (FIG. 5). The width 5 (FIG. 6) of the outer peripheral portion where the upper blade 1 and the lower blade 2 overlap is referred to as a lap, and is not unambiguous depending on the object to be cut, the cutting thickness, and / or the blade diameter, but the amount of lap is usually 0. It is carried out in the range of 1 mm to 1.5 mm. The fluctuation of the lapping amount during operation causes unevenness in the sharpness of the blade and affects the quality of the cut surface. Therefore, it is recommended to use a machine with high machining accuracy so that there is no shaft runout or tool misalignment. .

  Further, it is preferable that the contact pressure between the upper blade and the lower blade does not fluctuate so much for the purpose of reducing the sharpness of the cut surface of the sheet-like material, generation of cutting waste and adhesion of the adhesive to the blade. The fluctuation of the contact pressure causes chipping and uneven wear on the rotating round blade, and has a drawback that the life of the round blade is remarkably shortened. For grasping the fluctuation of the contact pressure at the cutting edge, the runout width (thrust runout) of the outermost circumference (cutting edge) of the round blade during rotation with the vertical axis as a base point can be used. This thrust run-out can be improved by stacking from various viewpoints, such as the holder surface that comes into contact with the blade surface, the smoothness improvement by precision machining of the blade surface, the equipment structure used, and the selection of materials and equipment to be used. is necessary.

  Conventionally, in a slitting device using a rotating round blade, generally, the hardness is Rockwell hardness C scale (hereinafter referred to as HRC) of 60 to 70 (specifically 62) SKD (die steel) or SKH. So-called tool steel such as (high-speed steel) is used, and when there is a strong demand for high-precision finishing and polishing cycle, carbide (hard metal) of HRC68-83, and zirconia depending on the application It is known to use ceramic blades such as alumina. However, there are no known publications that use blades made of materials having different hardnesses for the upper blade and the lower blade, the life of the blade, and the quality of the cut surface. The present invention provides a slitter device using a blade made of materials having different hardnesses for an upper blade and a lower blade. Specifically, the upper blade and the lower blade may have a hardness difference of about 5 or more, preferably about 8 or more, more preferably about 10 or more in HRC, and more specifically, one of them is a tool. In the case of steel (more preferably high-speed steel), the other may be made of carbide or ceramics, and if one is made of carbide, the other may be a blade made of ceramics. In the present invention, the ceramic blade is a commercially available zirconia, alumina, or the like. When a round blade having such a material structure is used, the effect that the cutting surface of the sheet-like material is beautiful, the chipping of the blade edge is small, and the service life of the blade is long is exhibited. In addition, even in the slit of a composite sheet-like material having an adhesive layer, there is little adhesion of the adhesive to the surface of the blade, and a cut surface with little adhesion of the adhesive to the sheet cutting surface can obtain a beautiful sheet-like material it can.

  As the bearing 8 for supporting the shaft 4 shown in FIG. 1, a general-purpose ball bearing is normally used as shown in FIG. 9 of Japanese Patent Laid-Open No. 2007-038331. However, an angular ball bearing is used in combination with the back as shown in FIG. Thus, the thrust runout of the cutting edge can be reduced by about 10 μm to 20 μm. Further, when a hydrostatic air bearing is used for such a bearing, the thrust runout can be further reduced by about 5 μm as compared with the angular ball bearing, and the cutting resistance can be greatly reduced.

Further, as shown in FIG. 3, the upper blade 1 is inserted into the shaft, the holder surfaces 6a and 7a that are in contact with the upper blade 1 of the holders 6 and 7 that clamp and fix the upper blade 1 are grooved, and the upper blade 1 By reducing the contact area with the flat surface, it is possible to reduce the thrust runout width as compared with the case of not processing.
The shape of the portion of the holders 6 and 7 in contact with the round blade plane may be any structure as long as it can be uniformly clamped on the round blade plane, and the contact portion may form a ring shape or a sea or island structure. These structures described above are also preferably applied to the holders 6 and 7 of the lower blade 2. In FIG. 3, an example in which the processing is performed on both the holders 6 and 7 is shown. However, any one of them can be performed as necessary.

  Cutting a sheet-like object with a rotating round blade has a drive source such as a motor on one of the upper blade and the lower blade, and the other is driven to rotate using the force received from the outer peripheral edge of the facing blade. Although the structure is used, these rotational drive sources have both the upper blade and the lower blade, so that it is possible to cut more actively into the sheet-like material than both. Resistant to external disturbances. Also, since the rotation speed of the upper and lower blades can be changed, the cutting conditions can be set even for materials having anisotropy in the thickness direction of the sheet-like material, composite sheet-like materials having an adhesive layer, and difficult-to-cut sheet-like materials Recommended because it increases the degree of freedom.

  In addition, as shown in FIG. 1, the upper blade 1 and the lower blade 2 may have parallel rotation axes, but the portion of the object to be cut that comes into contact with the film-like object first is the cutting point. As shown in FIG. 4, when one rotary shaft of the two rotary blades is slightly inclined (within a horizontal plane) (for example, 0.1 ° to 2.0 °) with respect to the rotary shaft of the other blade. The upper blade and the lower blade are always in contact at one point (referred to as a toe-in angle). For this reason, the sharpness of the blade is improved compared to the case where the two upper and lower rotary blades are arranged in parallel with respect to the rotation axis, and the cutting edge does not touch the cross section of the sheet after cutting again by escaping the cutting edge. In the case of a composite sheet-like material having a sticky layer and damage to the sheet due to the rubbing of the blade, it is possible to obtain a sheet-like material having a beautiful cut surface free of adhesion material and chips.

EXAMPLES Hereinafter, although an Example demonstrates this invention in detail, this invention is not limited to this Example.
In the slitter apparatus using the rotating round blade shown in FIG. 1, a polarizing film having a thickness of 30 μm made of polyvinyl alcohol (referred to as PVA) (Kuraray Vinylon VF-PS # 7500, polymerization degree 2400, saponification degree 99.99 mol% or more) The Kuraray Co., Ltd. PVA film was immersed and dyed in an aqueous solution containing iodine / potassium iodide, uniaxially stretched, and then immersed in an aqueous potassium iodide / boric acid solution and treated with boric acid. Obtained) as a protective film from above and below, a 75 μm thick triacetyl cellulose film (referred to as TAC film) (TD80UL H manufactured by Fuji Film Co., Ltd.), and a 25 μm thick acrylic adhesive (adhesive layer) on the surface of the TAC film ( Product name P-3132) manufactured by Lintec, and further, a polyethylene terephthalate having a thickness of 38 μm Using an optical sheet obtained by bonding a Lat-based protective film (trade name AS3-304, manufactured by Fujimori Kogyo Co., Ltd.), slitting is performed under the following conditions, and the cutting surface of the sheet-like material, the life of the rotating round blade, the tip of the blade The adhesion state of the adhesive was tested. The result is shown.

(Experimental example 1)
Blade diameter: 98 mm, blade thickness: 2 mm, blade edge angle: 40 °, HRC76 carbide round blade (Kyocera Corporation, Φ98 × 2T-FW35) is the upper blade 1, blade diameter: 98 mm diameter, blade thickness : 2 mm, cutting edge angle: 40 °, HRC64 high speed steel blade (SKH51, manufactured by Toyo Knife Co., Ltd., 40 ° T) was disposed as the lower blade 2. The rotary round blade had a toe-in angle of 0.5 ° and a lap amount of 0.4 mm. Using this slitter device, the above-described optical sheet was operated at a line speed of 10 m / min and a cutter peripheral speed of 11 m / min. The blade runout (thrust runout) at this time was 10 μm for the upper blade and 9 μm for the lower blade. After slitting the optical sheet at 2500 m under these conditions, the chipping of the upper blade and the lower blade and the wear state of the blade edge were examined with an optical microscope, but no chipping or blade wear was observed. Further, the cut surface of the optical sheet was beautiful with almost no sticking or sticking of the adhesive.
The photomicrographs showing these situations are shown in FIGS. 7 to 9, and the digital photo is shown in FIG. Fig. 7 shows the state of the cutting edge of the carbide round blade (upper blade) when the optical sheet is cut 2500 m with the configuration of this blade (carbide-high-speed steel), and the left figure shows the cutting edge state before cutting. The figure on the right shows the situation of the cutting edge after cutting.
FIG. 8A is a view showing a cut surface of the optical sheet when the optical sheet is cut by 2500 m with the structure of the present cutter (carbide-high speed steel), and FIG. 8B is a perspective view of the cut surface.
FIG. 9A shows the state of the cutting edge of the upper blade after cutting the optical sheet by 2500 m with the structure of the present blade (carbide-high speed steel), and FIG. 9B shows the cutting edge of the lower blade after cutting 2500 m. .
FIG. 10 is a digital photograph showing a cross section of a roll obtained by winding a slit optical sheet using a slitter device having the present blade configuration (carbide-high speed steel).

(Experimental example 2)
In Experimental Example 1, as the upper blade, the blade diameter: 98 mm, the blade thickness: 2 mm, the blade edge angle: 40 °, the HRC73 zirconia round blade (manufactured by Kyocera Corporation), and the lower blade as the same high speed as used in Experimental Example 1 Slit processing was performed under the same conditions as in Experimental Example 1 except that a steel blade was used. The blade runout (thrust runout) at this time was 8 μm for the upper blade and 9 μm for the lower blade. After slitting 2500 m under these conditions, the chipping of the upper blade, the lower blade, and the wear state of the blade edge were examined with an optical microscope, but no chipping or blade edge wear was observed. Further, the cut surface of the optical sheet was beautiful with almost no sticking or sticking of the adhesive.

(Comparative experiment example)
In the experimental example, the slit test was performed under the same conditions as in the experimental example, except that the same high-speed steel (SKH51) as used in Experimental Example 1 was used for both the upper blade material and the lower blade material. The rotary round blade had a toe-in angle of 0.5 ° and a lap amount of 0.4 mm. Using this slitter device, the above-described optical sheet was operated at a line speed of 10 m / min and a cutter peripheral speed of 11 m / min. The blade runout (thrust runout) at this time was 10 μm for the upper blade and 9 μm for the lower blade. Under the same conditions, the same optical sheet as used in the experimental example was cut, but the adhesive length was noticeable and the adhesive was also sticking to the cutting edge when the cutting length was about 300 m. As a result of observation, the blade edge was worn and chipped, deteriorated to a shabby state, and a remarkable adhesion of the adhesive was observed.
The photomicrographs showing these situations are shown in FIGS. 11 to 13 and the digital photo is shown in FIG. FIG. 11 shows the state of the tool edge when the optical sheet is cut by 300 m with the configuration of the main cutter (high-speed steel-high-speed steel), the left figure shows the state of the cutting edge before cutting, and the right figure shows the state after cutting. The cutting edge situation.
Fig.12 (a) is a figure which shows the cut surface of the optical sheet at the time of 300m cutting | disconnection by the structure (high-speed steel-high-speed steel) of this cutter, and FIG.12 (b) is a perspective view of a cut surface.
FIG. 13A shows the state of the cutting edge of the upper blade after cutting 300 m in the configuration of the present blade (high-speed steel-high-speed steel), and FIG. 13B shows the cutting edge state of the lower blade.
FIG. 14 is a digital photograph showing a cross section of a roll obtained by winding a slit optical sheet using a slitter device having the present blade configuration (high-speed steel-high-speed steel).

  According to the present invention, a slitter device having excellent characteristics can be provided. Therefore, it can be expected to be used in the field of optical films represented by paper products such as ink jet paper and copy paper, drug sheets such as plaster sheets and patch materials, and polarizing films and retardation films.

1 Upper blade 2 Lower blade 3 Long sheet 4 Shaft 5 Wrap 6 Holder (integrated with shaft 4)
6a Holder surface 7 Holder 7a Holder surface 8 Bearing 9 Reducer 10 Motor

Claims (8)

  Rotating a pair of annular upper blades and lower blades while rotating the opposing surfaces at their outer peripheral edges and cutting the sheet-like material inserted between the upper blades and the lower blades A slitter device using a rotating round blade, characterized in that a cutter made of materials having different hardnesses is used for an upper blade and a lower blade in a slitter device using a round blade.   The slitter device using a rotating round blade according to claim 1, wherein the blade material of the upper blade and the lower blade has a difference of 5 or more on the Rockwell hardness C scale.   The slitter using the rotating round blade according to claim 1 or 2, wherein the blade material of the upper blade and the lower blade is at least one of a combination of tool steel-carbide, tool steel-ceramics, and carbide-ceramics. apparatus.   The slitter device using the rotating round blade according to any one of claims 1 to 3, wherein the sheet to be cut is a composite sheet having at least one base sheet and at least one adhesive layer.   A slitter device using the rotating round blade according to claim 1 is used.   6. The method for producing a sheet-like material according to claim 5, wherein the sheet-like material is a composite sheet-like material having at least one substrate sheet and at least one adhesive layer.   A sheet-like material cut by using a slitter device using the rotating round blade according to claim 1.   The sheet-like material according to claim 7, wherein the sheet-like material is a composite sheet-like material having at least one substrate sheet and at least one adhesive layer.

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