JP2010241458A - Resin-film-having tray, method for manufacturing the same, storing structure for optical film - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a tray that suppresses the generation of dust, has strength, prevents an optical film from being scratched by friction or the like even if the optical film is stored, and can be manufactured at low cost. <P>SOLUTION: The resin-film-having tray is obtained by processing a cushioning plate that has at least two fiber base material plates and a fiber core disposed between these plates, and formed so as to have a clearance between the base material plates by the core. The entire surface of the tray is covered with a resin film, and the clearance has negative pressure. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  The present invention relates to a tray with a resin film whose surface is covered with a resin film and a method for producing the same. The tray with the resin film can be used as a tray for storing and protecting optical films, foods, precision industrial parts and the like. In particular, the tray with a resin film of the present invention is useful for storing an optical film that dislikes dust and the like, and the tray with a resin film storing the optical film is suitably used as a storage structure for the optical film. Examples of the optical film include a polarizing plate, a retardation plate, an optical compensation film, a brightness enhancement film, and a film in which these are laminated.

  The punched optical film is usually stored in a tray designed according to the size of the optical film in a laminated state and transported in a protected state. At this time, the optical film is protected from dust such as dust and dust, and the optical film moves in the tray during transportation to cause friction between the optical films and friction between the optical film and the tray. It is required that the surface is not damaged.

  Conventionally, plastic trays have been used in the above applications. However, a mold is necessary for molding a plastic tray. In recent years, the size of trays has increased due to the increase in the size of televisions, and on the other hand, the types of trays have increased due to the production of a small variety of products, which has increased the cost of producing plastic trays. Moreover, the plastic tray produced corresponding to the enlarged optical film becomes heavy and its transportability is lowered. Furthermore, there has been a problem of curling due to stress during molding.

  On the other hand, it is conceivable to use a paper tray as the tray. The paper tray does not require a mold, can be reduced in weight, and has no curl problem. However, the paper tray has a problem of dust generation. In a clean room that handles optical films and the like, it is not possible to use what generates dust. Also, the paper tray is insufficient in terms of strength. To prevent such problems, dust generation is suppressed by using corrugated cardboard using dust-free paper or resin corrugated cardboard formed using a specific propylene / α-olefin random copolymer as the tray material. Has been proposed (Patent Documents 1 and 2). However, even with corrugated cardboard using dust-free paper, the amount of dust generation cannot be reduced sufficiently, and problems remain in terms of cost and strength. In addition, since resinous corrugated cardboard requires a special resin, there are problems in terms of manufacturing, handling, and cost.

JP 2003-103672 A JP 2004-050640 A

  The present invention provides a tray that can suppress dust generation, has strength, and can be manufactured at low cost without damaging the optical film due to rubbing or the like even when the optical film is stored, and a manufacturing method thereof. The purpose is to do.

  Another object of the present invention is to provide an optical film storage structure in which an optical film is stored in the tray.

  As a result of intensive studies to solve the above problems, the present inventors have found that the above object can be achieved by a tray with a resin film as shown below, and have completed the present invention.

That is, the present invention provides a buffer having a fibrous base plate of at least two layers and a fibrous core portion provided between the base plate and a gap formed between the base plates by the core portion. A tray obtained by processing a plate,
The present invention relates to a tray with a resin film, wherein the entire surface of the tray is covered with a resin film, and the gap is in a negative pressure state.

In the tray with a resin film, the resin film preferably has a water vapor permeability of 80 cm ³ / m ² · 24 h · atm or less.

  In the tray with a resin film, the resin film preferably has a tensile strength at break of 0.5 to 10 MPa and an elongation of 30 to 1000%.

  In the tray with a resin film, the resin film preferably has a polyethylene layer and a nylon layer. Furthermore, the resin film is preferably a polyethylene layer / nylon layer / polyethylene layer laminate (/ indicates that the layers are laminated in this order).

  In the tray with a resin film, cardboard can be used as the buffer plate.

  The tray with a resin film can be used, for example, for housing an optical film.

  The present invention also relates to an optical film housing structure, wherein the optical film is housed in the housing portion of the tray with a resin film for the optical film.

The present invention is also a method for producing the tray with a resin film,
Processing a buffer plate having at least two layers of a fibrous base plate and a fibrous core portion provided between the base plate and having a gap between the base plate by the core portion. The tray obtained
Step (1) of inserting into the bag from the opening of the bag made of a resin film,
A step (2) of degassing the inside of the bag in which the tray has been inserted to create a negative pressure, and a step of sealing the bag by sealing the opening of the bag in the negative pressure state (3) ), And a method for producing a tray with a resin film.

  The tray with a resin film of the present invention uses a tray processed from a buffer plate (for example, corrugated paper) formed by a fiber base plate and a fiber core, and is lightweight and manufactured at low cost. Is possible. Moreover, the tray with a resin film of the present invention can be manufactured by a simple operation of putting the tray into the resin film and deaeration and sealing.

  On the other hand, in the tray with a resin film of the present invention, since the entire surface of the tray is covered with the resin film, there is no problem such as dust generation even though the buffer plate material forming the tray is fibrous. Moreover, since the space | gap of a buffer plate exists in a negative pressure state, the resin film is in the state closely_contact | adhered to the buffer plate, and the intensity | strength improves significantly with the tray with a resin film compared with the case of a tray alone. Even when an optical film or the like is stored in a tray with a resin film, the optical film comes into contact with the resin film, so that the optical film is not damaged by rubbing or the like, and the handleability is good.

  Moreover, the buffer plate used for the tray with a resin film of the present invention can be easily cut into a tray, etc., can be arbitrarily adjusted in size, and is easy to handle. Also, when discarding a tray with a resin film, the resin film and the tray (buffer plate) are in close contact (non-adhered) with a negative pressure, so the resin film and the tray can be separated by releasing the negative pressure. Can be recycled easily.

It is an example of sectional drawing of the tray with a resin film of this invention. It is an example of the top view of the tray with a resin film of this invention. It is an example of the tray used for the tray with a resin film of this invention. It is an example of sectional drawing of the storage structure of an optical film which stored the optical film in the storage part of the tray with a resin film of the present invention. It is an example of sectional drawing of the buffer board which forms the tray of this invention. It is an example of the schematic diagram which shows the manufacturing method of the tray with a resin film of this invention.

A: tray with resin film A ': tray x: wall portion y: storage portion 1: buffer plate 2: resin film B: optical film

  Hereinafter, the tray with a resin film of the present invention will be described with reference to the drawings.

  FIG. 1 shows an example of a cross-sectional view of a tray A with a resin film of the present invention. As shown in FIG. 1, in the tray A with a resin film of the present invention, the entire surface of the tray A ′ is covered with a resin film 2. The tray A ′ used in the present invention is formed by processing the buffer plate 1 and has a wall portion x at least at a part of the side portion. In the cross-sectional view of FIG. 1, walls x are provided on both sides of the tray. In FIG. 1, the wall portion x of the tray A ′ is formed by bending the end portions on both sides of the buffer plate 1.

  In the tray A ′ of FIG. 1, the wall portion x is perpendicular to the flat portion of the buffer plate 1, but the angle of the wall portion x can be set as appropriate. In general, the height of the wall portion is preferably about 10 to 80 mm, more preferably 20 to 40 mm, from the viewpoint of strength and workability. Further, the wall portion x can be three-dimensionally formed such that the cross section has various shapes such as a trapezoid, a rectangle, and a triangle with R. In forming the wall portion x in a three-dimensional manner, the end of the buffer plate 1 can be cut in advance so as to have a three-dimensional shape of various wall portions x and integrally formed with the flat surface portion. Only the part x can be formed. For example, the three-dimensional formation of the wall portion x can be performed by bending the end portion of the buffer plate 1 if the end portion of the buffer plate 1 is cut in advance. By forming the wall portion x in three dimensions, the strength of the wall portion x can be improved. Moreover, the wall part x can also form the edge part of the buffer plate 1 so that a cavity may be formed. By forming a cavity in the wall part x, the wall part x can be formed in three dimensions. On the other hand, when the wall part x which has a cavity is provided, in order to ensure the strength of the wall part x, the buffer plate 1 or the like can be separately inserted into the cavity. When the wall part x is formed three-dimensionally, the width of the wall part x is usually preferably about 10 to 80 mm and more preferably 20 to 30 mm.

  An example of the top view of the tray A with a resin film is shown in FIG. 2, for example. 2 corresponds to bb ′ in the sectional view of FIG. 1. In FIG. 2, a rectangular shape is illustrated as a top view of the tray A ′, but the shape of the top view can be appropriately determined according to the application to which the tray A with a resin film is applied. . As a shape of the top view, in addition to a rectangle, other polygonal shapes such as a triangle and a quadrangle are exemplified. In the rectangular tray A ′ shown in FIG. 2, the wall portion x is formed on four sides of the tray A ′. However, the wall portion x may not be provided on all four sides according to the application. In FIG. 2, the wall portion x is not provided at each corner portion of the rectangle, but the wall portion x can be appropriately provided at the corner portion. In FIG. 2, each corner of the rectangle is formed in a circle, but the shape of the corner is not particularly limited.

  The tray A ′ used for the tray A with a resin film is, for example, three-dimensional by cutting the end portions 1x and 1z of the buffer plate 1 as shown in FIG. 3 (1) and folding the end portions 1x. The wall part x can be formed. As shown in the enlarged view of FIG. 3B, the wall portion x is folded so that the cross-sectional view forms a trapezoid of a cavity. A reinforcing buffer plate 1 ′ is inserted in the cavity. Further, as shown in FIG. 3 (3), the end 1z of the buffer plate 1 is bonded to the back surface of the tray A ′ to improve the strength of the tray A ′.

  FIG. 4 is a cross-sectional view of the optical film storage structure in which the optical film B is stored in the storage portion Y (planar portion) of the tray A with resin film shown in FIG. Although FIG. 4 shows a state in which a plurality of optical films B are laminated, it is possible to simply store one optical film.

  Note that the shape of the tray shown in FIGS. 1 to 3 is merely an example. The size and shape of the tray can be designed according to the shape of the object to be stored (for example, an optical film). 1 to 3 show a tray designed for a rectangular optical film.

  Although the structure of the buffer plate 1 is not described in FIG. 1, the buffer plate 1 has at least two layers of fibrous base plate and a fibrous core portion provided between the base plate and the core portion. Thus, a gap is formed between the base plates. An example of a cross-sectional view taken along the line aa ′ of FIG. 1 is shown in FIG. In FIG. 5, a core portion 13 formed in a wave shape is disposed between the base plate 11 and the base plate 12. The core 13 can be fixed to the base plates 11 and 12 with an adhesive. In addition, in FIG. 5, although one set of structure of the base material board 11 and 12 and the core part 13 is described, the buffer board of this invention employ | adopts a structure which combined these structures two or more layers. Can do. As shown in FIG. 5, although the space | gap 14 is formed between the said core part 13 and the said base-plates 11 and 12, in the tray A with a resin film of this invention, the said space | gap 14 is in a negative pressure state. As a result, the tray A ′ formed from the buffer plate 1 and the resin film 2 are in close contact with each other.

  As the base plate and the core portion related to the buffer plate, those containing a fibrous material are used. Examples of the buffer plate using the fibrous material include a double-sided cardboard sheet, a multi-stage cardboard sheet, a double-sided cardboard sheet, a double-sided cardboard sheet, and a plastic cardboard sheet. In the cardboard structure, the base plate of the buffer plate corresponds to the liner, and the core portion corresponds to the core. As a fiber material, conventionally used various pulp fibers can be used. Examples of the pulp fiber used in the corrugated cardboard sheet include waste paper pulp obtained by refining waste paper such as corrugated cardboard, magazine waste paper, newspaper waste paper, and kraft pulp. For the pulp fiber, inorganic substances such as fillers are appropriately used. Can be blended. When a corrugated cardboard sheet is used as the buffer plate, the D4, C5, K5, K6, and K7 classes are appropriately selected according to the contents to be stored. However, when the contents are an optical film, the strength and processing From the viewpoints of property, cost, etc., it is preferable to use the K5 to K7F class. Further, by using a reinforced cardboard sheet as the reinforcing buffer plate (corrugated cardboard sheet) used for the cavity 3, it is possible to prevent the side part (wall part) of the tray from being bent or bent.

  The thickness of the buffer plate (for example, a corrugated cardboard sheet) is usually preferably about 2 to 10 mm, more preferably 3 to 8 mm.

  When a rectangular tray as shown in FIGS. 2 and 3 is formed using a corrugated cardboard sheet as the buffer plate 1, the direction M of the core used for the corrugated cardboard sheet (due to the corrugated uneven part of the core) By processing the direction (recognized from the front surface or the back surface) so as to be inclined with respect to the four sides of the rectangular tray, the rectangular tray can be prevented from being folded parallel to the four sides, and the strength of the rectangular tray is improved. be able to. Moreover, when using a multi-stage corrugated cardboard sheet, the strength of the buffer plate (tray) can be improved by intersecting the direction of the front core and the direction of the back core. Further, as shown in FIG. 3A, if the buffer plate 1 is cut in advance so that the center direction M is inclined with respect to the four sides of the rectangular tray, the tray A obtained from the buffer plate 1 is obtained. In ′, the direction of the center of the end 1z bonded to the back side can be made to intersect the direction of the center on the front side.

  Subsequently, the manufacturing method of the tray with a resin film of this invention is demonstrated. The outline of the manufacturing method is shown in FIG. FIG. 6 illustrates a case where a rectangular tray A ′ formed by the buffer plate 1 and having wall portions x on four sides is used.

  First, as shown in FIG. 6 (1), the rectangular tray A ′ is put into the bag through the opening K of the bag F made of the resin film 2 (1). The shape and size of the bag are appropriately selected according to the shape and size of the tray so that the bag is not too large and the tray can be easily inserted into the bag. For the rectangular tray A ′, a rectangular bag is preferable, and a rectangular bag having only four sides opened is used. In FIG. 6, the opening K is provided along the long side of the rectangular tray A ′. However, the opening K may be provided along the short side of the rectangular tray A ′. In addition, the insertion of the tray A 'into the bag F can be easily performed through the deaeration process (2) and the sealing process (3), resulting in poor sealing and wrinkles due to the resin film 2 (bag F). It is preferable to provide a tolerance T of about 50 to 150 mm at the end of the tray A ′ and the opening K so as not to be inserted.

  After the inserting step (1), next, a step (2) of degassing and depressurizing the inside of the bag in which the tray is inserted is performed. A state in which the tray is inserted into the bag is shown in FIG. Although deaeration is performed in the state of FIG. 6B, various means can be adopted as the deaeration means, for example, a vacuum pump, an ejector, or the like is used. Specifically, the inside of the bag is depressurized by deaeration from the opening K of the bag using a vacuum pump or the like. The negative pressure is a lower pressure when the atmospheric pressure is 0 kPa. The degree of negative pressure is such that the tray and the resin film are brought into close contact with each other. The negative pressure is preferably adjusted so that the ultimate vacuum is -30 kPa or less, more preferably -50 kPa or less. The deaeration time is usually about 3 to 60 seconds, preferably about 5 to 40 seconds, more preferably about 7 to 20 seconds, and further preferably about 9 to 15 seconds. If the deaeration time is long, it is not preferable in terms of production efficiency, and the shape of the tray may be deformed. If the deaeration time is shortened, air remains in the bag and it becomes impossible to make negative pressure. Further, the deaeration speed (exhaust speed) is preferably about 50 to 2000 liter / minute, more preferably about 50 to 1650 liter / minute, and further preferably about 180 to 800 liter / minute.

  As the degassing device, for example, LOS-NT (vacuum pump degassing specification / vacuum pump pressure setting range capacity: 490 kPa, exhaust speed: 180 liters / min, ultimate vacuum: −91.3 kPa) manufactured by Fuji Impulse Co., Ltd. LOS-NTW manufactured by Fuji Impulse Co., Ltd. (Ejector specification <Air source external compressor> / Compressor pressure setting range capacity: 540 kPa, exhaust speed: 1650 liters / minute, ultimate vacuum: -56.9 kPa) and the like. As the degassing device, for example, when using LOS-NT manufactured by Fuji Impulse, the degassing time is about 5 to 30 seconds, preferably about 9 to 20 seconds. When NTW is used, the deaeration time is about 5 to 20 seconds, preferably about 9 to 15 seconds.

  Furthermore, the step (3) of sealing the opening K of the bag in the negative pressure state to seal the bag is performed. By this sealing step (3), a tray A with a resin film is obtained. As shown in FIG. 6 (3), in the obtained tray A with a resin film, the opening K is sealed by a sealing process S. The sealing step (3) can be performed after the deaeration step (2) or together with the deaeration step (2). Any means that can seal the opening K may be used as the sealing means. For example, a method of heat sealing a resin film, a method of bonding a resin film with an adhesive, or the like can be employed.

  In FIG. 6 (3), in the obtained tray A with a resin film, the resin film 2 is shown not to be in close contact with a part of the side of the tray A ′. FIG. 6 (3) shows a state in which the tolerance T is given to the resin film 2 with respect to the tray A ′ when the attached tray A is produced. Thus, the entire surface of the tray A ′ is covered with the resin film 2.

  What was formed from various materials can be used as a resin film used for the tray with a resin film of this invention. Examples of the resin film material include low density polyethylene, linear polyethylene, medium density polyethylene, high density polyethylene, ultra low density polyethylene, random copolymer polypropylene, block copolymer polypropylene, homopolyprolene, polybutene, and polymethylpentene. Polyolefins such as ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, ethylene- (meth) acrylic acid copolymer, ethylene- (meth) acrylic acid ester (random, alternating) copolymer, ethylene- Butene copolymer, ethylene-hexene copolymer, polyurethane, polyester such as polyethylene terephthalate, nylon 6, nylon 6,6, nylon 6,12 etc. nylon, polyimide, polyetheretherketone, polyvinyl chloride, polysalt Vinylidene, fluorine resins, cellulose resins and the like. The resin film may be formed by individually or blending these resin materials. Moreover, as a resin film, the laminated body of the resin film obtained from these resin materials can be used. The said laminated body can be obtained by bonding each resin film with an adhesive etc. or coextruding each resin material. Even when the coextruded laminate is obtained, each resin material can be coextruded together with the adhesive layer to form a laminate. Furthermore, as a resin film, the laminated body which has metal foil, such as an aluminum foil layer, can be used with each resin layer. As the resin film of the present invention, a laminate of a resin film is preferable because of its good flexibility and sealing properties, and in particular, a laminate coextruded with an adhesive layer is preferable from the viewpoint of strength and adhesion.

  In addition, the thickness of the resin film used in the present invention is preferably about 50 to 120 μm, more preferably 60 to 80 μm, from the viewpoint of providing adhesion to the tray and strength. Even in the case where the resin film is a laminate, the thickness of the laminate is preferably in the above range.

Various resin films can be used as the resin film, and those having a water vapor permeability of 50 cm ³ / m ² · 24 h · atm or less are preferable. When the water vapor permeability increases, the negative pressure state between the resin film and the tray in the obtained tray with a resin film is eliminated with time, and the strength tends to decrease. The water vapor permeability is preferably 80 cm ³ / m ² · 24 h · atm or less, more preferably 60 cm ³ / m ² · 24 h · atm or less. The water vapor permeability is a value measured under conditions of 23 ° C. and 65% RH in JIS K7126.

  The resin film preferably has a tensile strength at break of 0.5 to 10 MPa, more preferably 1 to 6 MPa, still more preferably 2 to 3 MPa, and an elongation percentage of 30 to 1000% from the viewpoint of strength and adhesion. More preferably, it is 100-700%, More preferably, it is 400-600%. In addition, the resin film has a Young's modulus of preferably 100 to 1000 MPa, more preferably 200 to 600 MPa, and still more preferably 200 to 600 MPa from the viewpoint of strength and adhesion. The tensile breaking strength, the elongation rate, and the Young's modulus are values measured in accordance with JIS K7127.

As the resin film that can satisfy such requirements, it is preferable to use a laminate in which a plurality of resin materials or metal foils are combined from the viewpoint of water vapor permeability and balance between flexibility and strength. The laminate preferably has a flexible layer and a reinforcing layer. From this viewpoint, the resin film preferably satisfies the water vapor permeability (80 cm ³ / m ² · 24 h · atm or less), and is preferably a laminate of a flexible layer and a reinforcing layer. The flexible layer preferably has a Young's modulus of 10 to 2000 MPa, more preferably 100 to 1000 MPa, and further preferably 200 to 500 MPa. The reinforcing layer has a tensile strength at break of 1 MPa or more, more preferably 2 MPa or more, and more preferably 2 to 6 MPa. In the laminate, the flexible layer is preferably a polyethylene layer, and the reinforcing layer preferably has a nylon layer. As a specific example of such a laminate, a laminate having at least a polyethylene layer and a nylon layer is preferable. In particular, a laminate of polyethylene layer / nylon layer / polyethylene layer is preferable. The laminate preferably has a structure of polyethylene layer adhesive layer / nylon layer / adhesive layer / polyethylene layer. Specific examples of the laminate having the structure of polyethylene layer adhesive layer / nylon layer / adhesive layer / polyethylene layer include, for example, Laminar Ace NK-3 (thickness 70 μm, water vapor permeability 7.8 cm ³⁾ manufactured by Krillon Kasei Co., Ltd. / M ² · 24 h · atm, tensile breaking strength 2.1 to 2.7 MPa, elongation 470 to 590%, Young's modulus 300 to 380 MPa), laminar ace NK-4 (thickness 80 μm, others are the same), etc. .

Examples of laminates other than the above include polyethylene terephthalate layer / aluminum foil layer / polyethylene layer. Specifically, for example, a film manufactured by MICS (thickness: 80 μm, water vapor transmission rate: 4.9 cm ³ / m ² · 24 h)・ Atm, tensile breaking strength 2.0 to 2.6 MPa, elongation 470%, Young's modulus 340 MPa), film (thickness 80 μm, water vapor permeability 8 cm ³ / m ² · 24 h · atm, tensile breaking strength 2.0 to 2.6 MPa, elongation 470%, Young's modulus 340 MPa) and the like. Examples of the laminate include polyethylene terephthalate layer / aluminum vapor deposition layer or aluminum foil layer / polyethylene layer. Specifically, for example, IA series manufactured by Fuji Impulse Co., Ltd. (thickness 74 to 80 μm, water vapor transmission rate) 1.0 cm ³ / m ² · 24 h · atm or less, tensile break strength 3.67 to 4.12 MPa, elongation 115 to 120% Pa). Examples of the laminate include polyethylene layer / ethylene-vinyl alcohol copolymer / polyethylene layer. Specifically, for example, Hylamina VK-10 (thickness 70 μm, water vapor permeability 4. 9 cm ³ / m ² · 24 h · atm, tensile strength at break 2.8 MPa, elongation 540%, Young's modulus 420 MPa). Examples of other laminates include “SUPEREN” manufactured by Ube Film Co., “TOCello TAF” manufactured by Tosero Co., Ltd., and the like.

  The tray with a resin film of the present invention can be used as a tray for various stored items. In particular, since dust and the like are not generated, it is suitable as a storage tray for optical films and the like. Examples of the optical film include a polarizing plate, a retardation plate, an optical compensation film, a brightness enhancement film, and a film in which these are laminated.

  A polarizing plate having a transparent protective film on one or both sides of a polarizer is generally used. The surface of the transparent protective film to which the polarizer is not adhered may be subjected to a hard coat layer, an antireflection treatment, an antisticking treatment, or a treatment for diffusion or antiglare.

  Examples of the retardation plate include a birefringent film obtained by uniaxially or biaxially stretching a polymer material, a liquid crystal polymer alignment film, and a liquid crystal polymer alignment layer supported by a film.

  Moreover, as an optical film used for this invention, what laminated | stacked the other optical layer on the polarizing plate is mention | raise | lifted. Other optical layers are not particularly limited. For example, a reflecting plate, a semi-transmissive plate, a retardation plate (including wavelength plates such as 1/2 and 1/4), a viewing angle compensation film, an optical compensation film, and a brightness enhancement film. Etc. can be laminated.

  Moreover, the optical film mentioned above can also be provided with an adhesive layer. As the laminated optical film, one laminated with the adhesive layer can be used. In addition, a separator is usually temporarily attached to the exposed surface of the adhesive layer until it is put into practical use for the purpose of preventing contamination. Furthermore, the optical film can be protected by providing a surface protective film on the surface of the optical film where the adhesive layer is not provided.

  The present invention will be described more specifically with reference to the following examples and comparative examples. However, the present invention is not limited to these examples and comparative examples.

Example 1
(Create tray)
After punching the cardboard sheet (K5 class) into a flat plate shape of the tray and cutting it as shown in Fig. 3 (1), the rectangular tray shown in Fig. 3 (2): front side and (3): back side is created. did. The long side of the rectangle was 900 mm, the short side was 450 mm, the wall width was 25 mm, and the height was 30 mm. A reinforced corrugated sheet was inserted into the cavity of the wall.

(Resin film)
From the following resin film 1, a rectangular bag (long side: 1000 mm, short side: 550 mm) (one long side as an opening and the other three sides sealed) was used in accordance with the tray.
Resin film 1: Laminar Ace NK-3 (thickness 70 μm, water vapor permeability 7.8 cm ³ / manufactured by Krillon Kasei Co., Ltd.), which is a laminate having a structure of polyethylene layer adhesive layer / nylon layer / adhesive layer / polyethylene layer. m ² · 24 h · atm, tensile breaking strength 2.1 to 2.7 MPa, elongation 470 to 590%, Young's modulus 300 to 380 MPa).

(Create tray with resin film)
The tray was put into the recording bag through the opening of the bag made of the resin film 1. Next, the inside of the bag in which the tray is inserted is degassed for 12 seconds by a vacuum sealer LOS-NTW with a nozzle manufactured by Fuji Impulse, and the inside of the bag is made negative pressure, and the opening of the bag Was sealed with a sealing pressure of 0.55 MPa, the bag was sealed, and a tray with a resin film was obtained. The obtained tray with a resin film was in a state where the resin film 1 was in close contact with the tray.

Examples 2-6
A tray with a resin film was obtained in the same manner as in Example 1 except that the following resin films 2 to 6 were used instead of the resin film 1 in Example 1. The obtained tray with a resin film was in a state where the resin film 1 was in close contact with the tray.

Resin film 2: Laminar Ace NK-4 (thickness 80 μm, water vapor transmission rate 7.8 cm ³ / made by Crillon Kasei Co., Ltd.), which is a laminate having a structure of polyethylene layer adhesive layer / nylon layer / adhesive layer / polyethylene layer. m ² · 24 h · atm, tensile breaking strength 2.1 to 2.7 MPa, elongation 470 to 590%, Young's modulus 300 to 380 MPa).
Resin film 3: IA bag (aluminum laminate, thickness 80 μm, water vapor transmission rate 0.1 cm ³ / m ² .multidot.m), which is a laminate having a structure of polyethylene terephthalate layer / aluminum foil layer / polyethylene layer. 24 h · atm or less, tensile breaking strength 3.67 to 4.12 MPa, elongation 115 to 120% Pa).
Resin film 4: IA bag (aluminum-deposited transparent moisture-proof bag, thickness 74 μm, water vapor permeability 1.0 cm ³ / made by Fuji Impulse Corp., which is a laminate having the structure of polyethylene terephthalate layer / aluminum vapor deposition layer / polyethylene layer m ² · 24 h · atm or less, tensile breaking strength 3.87 MPa, elongation 115 to 120%).
Resin film 5: Hiramina VK-10 (thickness 70 μm, water vapor transmission rate 4.9 cm ³ / m) manufactured by Krillon Kasei Co., Ltd., which is a laminate having the structure of polyethylene layer / ethylene-vinyl alcohol copolymer / polyethylene layer. ² · 24 h · atm, tensile breaking strength 2.8 MPa, elongation 540%, Young's modulus 420 MPa).
Resin film 6: Low density polyethylene LDPE manufactured by Nissin Chemical Industry Co., Ltd. (thickness 80 μm, water vapor transmission rate 5.9 cm ³ / m ² · 24 h · atm, tensile breaking strength 2 MPa, elongation 600 to 700).

(Evaluation)
In the trays with resin film of Examples 1 to 6 obtained using the resin films 1 to 6, the entire surface of the tray was covered with the resin film, and generation of dust or the like was not recognized. Moreover, the following evaluation was performed about the tray with a resin film of Examples 1-6. As Comparative Example 1, a case where the tray is used as it is is shown.

(Strength: Film tear test 1)
A plate having a diameter of 90 mm was placed in the storage portion (front side) of the tray with a resin film, and a 100 g cylinder (diameter 120 mm) was dropped vertically from a height of 30 cm. In the trays with resin film of Examples 1 to 6, the film was not torn. In Examples 1 and 2, the trace of the bottom of the cylinder is slightly left on the film. In Examples 3 to 5, the mark of the corner of the cylinder is left on the film. In Example 6, the cylinder is left. The trace of the corner of was clearly left on the film. As a result of conducting the same test for Comparative Example 1, the state after the angle of the cylindrical object remained slightly.

(Strength: Film tear test 2)
A 1000 g cylindrical object (diameter: 120 mm) was dropped directly from the height of 30 cm onto the storage part (front side) of the tray with resin film. In the trays with resin film of Examples 1 to 5, the film was not torn. In Examples 1 to 5, the marks of the corners of the cylindrical object remained clearly on the film. In Example 6, the film was broken. As a result of conducting the same test for Comparative Example 1, the state after the angle of the cylindrical object remained clear.

(Negative pressure over time)
The tray with a resin film of Example 1 obtained by using the resin films 1 to 5 maintained a negative pressure state over time (2000 hours). On the other hand, the negative pressure of the tray with the resin film of Example 6 obtained using the resin film 6 was released after 20 hours. In addition, about the tray with a resin film of Example 6, as a result of performing said intensity | strength: film tearing test 1 and 2 in the state by which the negative pressure was cancelled | released, it was a state where the maintenance of a form was difficult.

Claims (9)

Processing a buffer plate having at least two layers of a fibrous base plate and a fibrous core portion provided between the base plate and having a gap between the base plate by the core portion. A tray obtained by
A tray with a resin film, wherein the entire surface of the tray is covered with a resin film, and the gap is in a negative pressure state. The tray with a resin film according to claim 1, wherein the resin film has a water vapor permeability of 80 cm ³ / m ² · 24 h · atm or less.   The tray with a resin film according to claim 1 or 2, wherein the resin film has a tensile breaking strength of 0.5 to 10 MPa and an elongation of 30 to 1000%.   The tray with a resin film according to claim 1, wherein the resin film is a laminate having a polyethylene layer and a nylon layer.   The tray with a resin film according to claim 4, wherein the resin film is a laminate of polyethylene layer / nylon layer / polyethylene layer.   The tray with a resin film according to claim 1, wherein the buffer plate is cardboard.   The tray with a resin film according to claim 1, wherein the tray with a resin film is used for storing an optical film.   An optical film storage structure, wherein the optical film is stored in the storage portion of the tray with a resin film for an optical film according to claim 7. It is a manufacturing method of the tray with a resin film in any one of Claims 1-7,
Processing a buffer plate having at least two layers of a fibrous base plate and a fibrous core portion provided between the base plate and having a gap between the base plate by the core portion. The tray obtained
Step (1) of inserting into the bag from the opening of the bag made of a resin film,
A step (2) of degassing the inside of the bag in which the tray has been inserted to create a negative pressure, and a step of sealing the bag by sealing the opening of the bag in the negative pressure state (3) ), And a method for producing a tray with a resin film.

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