JP2013014441A - Method for manufacturing glass roll - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce the occurrence of winding misalignment and lift of a glass film in a glass roll as much as possible, when the glass film continuously formed by down-draw method is accommodated as a glass roll.SOLUTION: This method includes: a forming process S1 in which a glass film is continuously formed by the down-draw method and conveyed; an interim winding process S3 in which a base glass roll is manufactured by winding up the glass film in a roll while laying a protective film onto the glass film at the downstream end of the conveying route of the forming process S1; and a main winding process S4 in which, while unwinding a glass film from the base glass roll and conveying it to the downstream side, a final glass roll is manufactured by winding again the glass film while laying a protective film onto the glass film at the downstream end of the conveying route. In this method, tension in the winding direction applied on the glass film is made greater in the main winding process S4 than in the interim winding process S3.

Description

  The present invention relates to an improvement in manufacturing technology of a glass roll obtained by winding a glass film formed by a downdraw method into a roll.

  As is well known, a flat panel display (FPD) represented by a liquid crystal display, a plasma display, an organic EL display and the like has become the mainstream in recent years. As these FPD substrates, glass substrates are used to ensure various required characteristics such as airtightness, flatness, heat resistance, translucency, and insulation. The actual situation is that the glass substrate used in the FPD is being thinned from the viewpoint of weight reduction. In particular, in an FPD such as an organic EL display, it is conceivable that the display screen is bent and used, so that a thin glass substrate is required to provide flexibility.

  In addition, organic EL is being used as a flat light source such as a light source for indoor lighting by causing only three colors (for example, white) to emit light without causing the three primary colors to be flickered by a TFT unlike a display. The organic EL lighting device has an advantage that if the glass substrate is flexible, the light emitting surface can be freely deformed, and the usage is greatly expanded. For this reason, thinning of the glass substrate used in this type of lighting device has been promoted from the viewpoint of ensuring sufficient flexibility.

  Furthermore, since the touch panel is operated by rubbing the surface with a human finger or the like, a glass substrate is often used to ensure the robustness of the surface. With the widespread use of mobile terminals equipped with this type of touch panel, the glass substrate for the touch panel is also required to be thin to reduce the weight.

  In response to such a demand for thinning, a glass film that has been thinned to a film shape (for example, a thickness of 300 μm or less) has been developed. Since this glass film has moderate flexibility, it may be rolled up around the core together with a protective film so as to be rolled up and accommodated in a so-called glass roll (for example, patent document). 1). In this way, the storage space for the glass film is significantly reduced, so that the transportation efficiency can be improved. In addition, the roll-to-roll device can continuously perform various processes such as cutting and film formation on the glass film unwound from the upstream glass roll. Significant improvement can be achieved.

JP 2010-132350 A

  By the way, a glass film is often formed by a downdraw method. Therefore, when it is going to accommodate in the state of a glass roll, it will be necessary to wind up the glass film continuously shape | molded from the molded object which performs a downdraw method around a winding core.

  However, in this case, if too much tension is applied to the glass film during winding (for example, about 100 N with respect to a glass film having a width of 1 m), excessive tension acts on the softened glass film in the vicinity of the molded body. However, the thickness of the glass film becomes unstable, warping or undulation occurs, and in some cases, a fatal problem arises that the glass film is torn at the lower part.

  Therefore, it is practically difficult to wind the glass film with sufficient tension. For example, the wound glass film is likely to move in the width direction afterward to cause winding deviation. In addition, if the glass film is not wound with an appropriate tension, the glass film is lifted from the core in the state of a glass roll, and an unjustified gap may be formed between the glass films. If the glass film is wound or lifted (gap in the radial direction) as described above, the glass film is easily damaged and handling becomes very troublesome. Furthermore, in this case, since the glass film is irregularly wound up, the appearance of the glass roll is very deteriorated, which may be a factor of reducing the product value.

  In view of the above circumstances, when the present invention accommodates a glass film continuously formed by the downdraw method in the state of a glass roll, the glass film contained in the glass roll is not subject to winding deviation or lifting. The technical challenge is to reduce it as much as possible.

  A first invention created to solve the above-described problems includes a molding step of conveying a glass film downstream while continuously molding a glass film by a molding apparatus that executes a downdraw method, and a conveyance path of the molding step. The first protective film is rolled on the glass film at the downstream end of the first roll, wound into a roll shape, and conveyed to the downstream side while unwinding the glass film from the original glass roll. And at the downstream end of the transport path, the second protective film is overlaid on the glass film and rewound into a roll to produce a glass roll. It is characterized in that the tension in the winding direction acting on the glass film is made larger than the tension acting on the glass film in the first winding step. It is.

  According to such a method, the glass film wound up by the 1st winding process has a bigger tension | tensile_strength in the winding direction (conveyance direction of a glass film) than the 1st winding process by the 2nd winding process. It is rewound in the acted state. Therefore, in the 1st winding process which winds up directly the glass film shape | molded with the shaping | molding apparatus, it is not necessary to wind up by applying an excessive tension | tensile_strength to a glass film. In other words, in the first winding process, it is only necessary to apply tension to the glass film within a range that does not adversely affect the thickness of the glass film formed by the forming apparatus. Even if the film is misaligned or lifted, it can be corrected in the second winding process. That is, in the second winding process, even if a large tension is applied to the glass film, it does not adversely affect the molding of the glass film. While being applied, the glass film can be rewound to produce a glass roll.

  In the above method, in the first winding step, it is preferable that the tension in the winding direction acting on the first protective film is larger than the tension in the winding direction acting on the glass film.

  In this way, the movement of the glass film can be suppressed by the first protective film without applying a large tension directly to the glass film. That is, an effect equivalent to that obtained when a tension is directly applied to the glass film can be obtained. For this reason, it is possible to suppress the winding deviation and lifting of the glass film generated in the first winding process to a minimum range. In addition, since the glass film is securely pressed by the first protective film in the state of the original glass roll, when the glass fill is unwound from the original glass roll in the second winding process, the glass in the original glass roll. It is unlikely that the film will be unduly wound. When the glass film is tightened, rubbing occurs between the glass film and the protective film, so that there is a possibility that micro scratches may be formed on the surface of the glass film.

  In the above method, in the second winding step, the tension in the winding direction that acts on the glass film may be larger than the tension in the winding direction that acts on the second protective film.

  If it does in this way, in the glass roll manufactured at the 2nd winding-up process, ie, the glass roll used as a product, the situation where a wind gap and a lift arise afterwards by the tension which acts on glass film itself. Can be reliably prevented. In other words, since the glass film is not forcedly pressed by the second protective film and the glass film is not corrected, undue stress is unlikely to act on the glass film, and a stable packaging state can be maintained.

  In the above-described method, in the second winding process, it is preferable to convey the glass film while only supporting the surface on one side.

  If it does in this way, the surface of the other side of a glass film turns into a non-contact surface. Therefore, the surface of the glass film serving as the non-contact surface is less likely to be formed with minute scratches due to conveyance. Therefore, when manufacturing a glass substrate for FPD such as an organic EL display from this glass film, if the element or wiring is formed on the non-contact surface side of the glass film, the formation of the element or wiring is poor due to micro scratches. Therefore, it is possible to provide a highly reliable FPD.

  In the second winding step, the glass film is preferably wound so that the contact support surface of the glass film is positioned on the inner peripheral surface side of the glass roll.

  In this case, even if a micro-scratch occurs on the contact support surface of the glass film, the contact support surface is wound so that the contact support surface is positioned on the inner peripheral surface side of the glass roll. Only compressive stress acts. Therefore, even if a micro-scratch occurs on the contact support surface, it is difficult for a force that causes the micro-scratch to develop. In other words, a non-contact surface substantially free of micro-scratches is located on the outer peripheral surface side of the glass film on which a force that causes micro-scratches to develop is applied, so that the glass film is reliably damaged. It becomes possible to reduce it.

  In the above method, at least one of the first winding process and the second winding process, the glass film may be cut into a predetermined width by laser cutting and then wound. Here, laser cutting includes laser cleaving and laser fusing. Laser cleaving is a method of cutting a glass film by developing an initial crack using thermal stress generated by expansion by a heating action of a laser and contraction by a cooling action of a refrigerant. On the other hand, laser fusing is a method of cutting by injecting high-pressure gas into a portion where glass has been softened and melted by heating with laser energy.

  In this way, for example, when molded by the overflow down draw method, after cutting off the ineffective portion (ear portion) that is relatively thick formed at both ends in the width direction of the glass film, Can be wound up. It is also possible to wind the glass film after changing it to a desired width. And since these glass films are cut | disconnected by laser cutting, the advantage that it is hard to form the microcrack which causes a damage on the cut end surface of a glass film can be enjoyed.

  In the above method, the downdraw method is preferably an overflow downdraw method.

  If it does in this way, even if it does not process separately with respect to the surface of a glass film after shaping | molding, the outstanding smoothness with small surface roughness can be provided to the surface of a glass film.

  In said method, it is preferable that the thickness of the said glass film is 1 micrometer or more and 300 micrometers or less.

  In this way, sufficient flexibility can be imparted to the glass film, so that when the glass film is wound, the situation in which undue stress acts on the glass film can be reduced. It will also help prevent damage to the film.

  The second invention created in order to solve the above problems is a glass roll manufacturing method in which a glass film is formed by a downdraw method, and the formed glass film is stacked on a protective film and wound into a roll. And it is characterized by winding up the said glass film and the said protective film, providing the tension | tensile_strength of the winding direction larger than the said glass film to the said protective film.

  According to such a method, the glass film can be tightened by the relatively large tension in the winding direction applied to the protective film without applying a large tension in the winding direction to the glass film. A glass roll having no looseness can be produced. In addition, when the glass film is wound, the glass film is not applied with a tension in the winding direction or the tension is small, so that the glass film is bent in a curved region so as to be substantially along the horizontal direction. Even so, the curvature of the curved region can be prevented from changing, and the glass film can be stably formed, and the glass film without warping or undulation or change in plate thickness can be wound.

  In said method, you may make it laser-cut the ineffective part (ear part) formed in the width direction both ends of the said glass film in the step until winding up a glass film in roll shape. Here, laser cutting includes laser cleaving and laser fusing. Laser cleaving is a method of cutting a glass film by developing an initial crack using thermal stress generated by expansion by a heating action of a laser and contraction by a cooling action of a refrigerant. On the other hand, laser fusing is a method of cutting by injecting high-pressure gas into a portion where glass has been softened and melted by heating with laser energy.

  If it does in this way, moderate smoothness can be easily provided to the cut surface which constitutes the both end surfaces of the width direction of a glass film, without giving post-processing, such as grinding. In addition, since a relatively large winding direction tension is applied to the protective film, the end face of the glass film and the protective film are easily in contact with each other. Does not bite into the protective film, and can maintain good separation between the glass film and the protective film. Further, when the glass film is wound up in a roll shape, fine scratches are hardly generated on both end faces of the glass film. Thereby, since the glass powder which generate | occur | produces by the chip | tip based on the fine damage | wound of the end surface of a glass film can be reduced, it becomes very advantageous also when ensuring the cleanliness of the front and back of a glass film.

  In the above method, the glass film and the protective film are preferably wound while the protective film is stacked on the outer peripheral surface side of the glass film so that the protective film is maintained in the outermost layer. .

  If it does in this way, a glass film can be easily clamped with a protective film, and a glass roll without a slack can be manufactured reliably.

  In the above method, the downdraw method is preferably an overflow downdraw method.

  In this way, since a glass film excellent in surface smoothness can be formed without any additional processing after forming, a glass roll excellent in surface accuracy can be easily produced.

  A third invention created to solve the above problems is a glass roll obtained by stacking a glass film formed by a downdraw method on a protective film and winding it into a roll shape, the protective film comprising: It is characterized in that a larger tension in the winding direction than that of the glass film is applied.

  According to such a structure, it can be set as the glass roll which wound up the glass film without a curvature, a wave | undulation, and a change of board thickness without loosening.

  Said structure WHEREIN: It is preferable that the thickness of the said glass film is 1 micrometer or more and 300 micrometers or less.

  In this way, appropriate flexibility can be imparted to the glass film. Therefore, unreasonable stress acting on the glass film when the glass film is wound can be reduced, and breakage can be prevented.

  Said structure WHEREIN: It is preferable that arithmetic mean roughness Ra of the both ends of the width direction of the said glass film is 0.1 micrometer or less.

  If it does in this way, appropriate smoothness can be provided to the both end surfaces of the width direction of a glass film. Since a relatively large winding direction tension is applied to the protective film, the end face of the glass film and the protective film are easily in contact with each other, but even when they are in contact, the end face is protected by smoothing the end face of the glass film. It is possible to maintain good separation between the glass film and the protective film without biting into the film.

  Said structure WHEREIN: It is preferable that the said protective film protrudes from the width direction both sides of the said glass film.

  If it does in this way, it will become possible to protect the width direction both end surfaces of a glass film with a protective film. Moreover, since the both ends of the glass film in the width direction are covered with the protective film, it is possible to prevent foreign substances from entering from the outside.

  According to the first invention as described above, after the glass film continuously formed by the downdraw method is wound in the first winding process, the glass film is first wound in the second winding process. Rewinding is performed in a state where a larger tension is applied in the winding direction than in the winding process. Therefore, even when the glass film is continuously formed by the downdraw method, an appropriate tension is imparted to the glass film through the first winding process and the second winding process, and the winding deviation or lift is caused. It is possible to produce a glass roll that is difficult to cause.

  In addition, according to the second and third inventions as described above, even without applying a large winding direction tension to the glass film, a relatively large winding direction tension applied to the protective film, Since the glass film can be tightened, it is possible to produce a glass roll that is unlikely to cause winding deviation or lifting.

It is a flowchart of the manufacturing method of the glass roll which concerns on embodiment of this invention. It is a figure for demonstrating the implementation condition of the shaping | molding process included in the manufacturing method of the glass roll which concerns on this embodiment, a cutting process, and a temporary winding process. It is a figure for demonstrating the implementation condition of this winding-up process included in the manufacturing method of the glass roll which concerns on this embodiment. It is a figure for demonstrating another implementation condition of this winding process included in the manufacturing method of the glass roll which concerns on this embodiment. It is a figure for demonstrating another implementation condition of this winding process included in the manufacturing method of the glass roll which concerns on this embodiment.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 is a flowchart of a glass roll manufacturing method according to the first embodiment of the present invention. The glass roll manufacturing method includes a forming step S1, a cutting step S2, a temporary winding step (first winding step) S3, and a main winding step (second winding step) S4.

  In this embodiment, the molding step S1 is performed by a molding apparatus 1 that executes an overflow downdraw method, as shown in FIG. The molding apparatus 1 includes a molding zone 2, a slow cooling (annealing) zone 3, and a cooling zone 4 in order from the top. In addition, the shaping | molding apparatus 1 may perform other downdraw methods, such as a slot downdraw method and a redraw method.

  In the molding zone 2, the molten glass Gm is supplied to the molded body 5 having a wedge-shaped cross-sectional shape, and the molten glass Gm overflowing on both sides from the top of the molded body 5 is fused and flowed down at its lower end. Then, a plate-like glass film G is formed from the molten glass Gm. The glass film G gradually increases in viscosity as it moves downward, and after reaching a sufficient viscosity to maintain the shape, the glass film G is dedistorted in the slow cooling zone 3 and further cooled to near room temperature in the cooling zone 4. The

  In the slow cooling zone 3 and the cooling zone 4, a roller group 6 having a pair of rollers is disposed at a plurality of locations from the upstream side to the downstream side of the conveyance path of the glass film G. The part is guided downward. In this embodiment, the roller disposed at the uppermost portion of the molding zone 2 in the molding apparatus 1 functions as a cooling roller for cooling both ends in the width direction of the glass film G, and the glass film G is moved downward. It also functions as a drive roller for pulling out. On the other hand, the remaining rollers in the forming apparatus 1 function as a free running roller, a pulling roller, and the like for guiding the glass film G downward.

  The glass film G formed in the forming step S1 is a long body having a thickness of 1 to 600 μm (preferably 1 to 300 μm, more preferably 10 to 200 μm), and examples thereof include a liquid crystal display, a plasma display, and an organic EL display. Used for glass substrates of devices such as FPD, solar cells, lithium ion batteries, digital signage, touch panels, electronic paper, etc., cover glasses for organic EL lighting, glass containers for medical products, window glass, laminated lightweight window glass, etc. Is done.

  The width of the glass film G is preferably 100 mm or more, more preferably 300 mm or more, and further preferably 500 mm or more. The glass film G is used for a wide variety of devices from small screen displays for small mobile phones to large screen displays such as large television receivers. Therefore, it is preferable to finally select the width of the glass film G according to the size of the substrate of the device used.

  Further, as the glass composition of the glass film G, various glass compositions such as silicate glass such as silica glass and borosilicate glass can be used, but alkali-free glass is preferable. When an alkali component is contained in the glass film G, a so-called soda blowing phenomenon occurs and the structure becomes rough. When the glass film G is curved, the glass film G is structurally rough due to deterioration over time. This is because breakage may occur from the part that has become. The alkali-free glass referred to here is a glass that does not substantially contain an alkali component. Specifically, the alkali metal oxide is 1000 ppm or less (preferably 500 ppm or less, more preferably 300 ppm. The following). Examples of the glass that satisfies this condition include OA-10G manufactured by Nippon Electric Glass Co., Ltd.

  And the glass film G shape | molded by the above shaping | molding processes S1 is curved in the substantially horizontal direction by the attitude | position conversion roller group 7 which has several rollers which support the glass film G from the downward direction in the downward direction of the shaping | molding apparatus 1. FIG. Then, it is sent to the cutting step S2 while maintaining the posture. The posture changing roller group 7 may be omitted as appropriate.

  In the cutting step S <b> 2, the non-effective portions (ear portions) Gx formed at both ends in the width direction of the glass film G in the forming step S <b> 1 are cut and removed by the cutting device 8. The ineffective portion Gx is relatively thicker than the effective portion Ga at the center in the width direction of the glass film G.

  In detail, the cutting device 8 performs laser cleaving, and transporting means 9 for transporting the glass film G continuously formed by the forming device 1 to the downstream side in a substantially horizontal posture, and this transport The local heating means 10 that irradiates the glass film G placed on the means 9 with the laser beam L from the surface side to perform local heating, and the cooling water W from the surface side to the heating region heated by the local heating means 10. And a cooling means 11 for injecting water. If the glass film G is cut by laser cleaving in this way, moderate smoothness can be easily imparted to the cut surfaces constituting both end faces in the width direction of the glass film G without performing post-processing such as polishing. it can. Therefore, there is an advantage that the end face of the glass film G does not bite into the protective film F1, and the separation between the glass film G and the protective film F1 can be maintained well. Moreover, when winding the glass film G in roll shape, there also exists an advantage that the crack resulting from a fine crack becomes difficult to produce on the both end surfaces of the glass film G. Here, from the viewpoint of more surely enjoying the advantages as described above, the arithmetic average roughness Ra of the both ends in the width direction of the glass film G is preferably 0.1 μm or less, and is 0.05 μm or less. It is more preferable.

  In this embodiment, a carbon dioxide laser is used as the local heating means 10, but it may be a means capable of performing other local heating such as heating wire or hot air injection. The cooling means 11 injects the cooling water W as a refrigerant by air pressure or the like. This refrigerant can be a cooling liquid other than cooling water, a gas such as air or an inert gas, or a gas and a liquid. What mixed, Furthermore, what mixed solids, such as dry ice and ice, and the said gas and / or the said liquid, etc. may be sufficient. Note that the cutting device 8 may be one that performs folding along a scribe line using a diamond cutter, or one that performs laser fusing.

  By sending the glass film G to the downstream side by the conveying means 9, the heating area of the local heating means 10 is cut along the planned cutting line (the effective part Ga and the extending area) along the longitudinal direction of the glass film G prior to the cooling area of the cooling means 11. , The boundary portion with the ineffective portion Gx) is scanned from one end side. As a result, thermal stress is generated by expansion due to the heating action and contraction due to the cooling action of the refrigerant, and an initial crack (not shown) formed in advance at the tip portion of the planned cutting line propagates along the planned cutting line, and the glass Film G is continuously cleaved full body.

  And the ineffective part Gx of the cut | disconnected glass film G is bend | dispersed after being bent downward and isolate | separated from the effective part Ga. On the other hand, the effective portion Ga of the glass film G is sent to the temporary winding process S3.

  In the temporary winding step S3, the protective film F1 unwound from the protective roll 12 on the outer peripheral surface side of the glass film G (specifically, the effective portion Ga) so that the protective film F1 is maintained in the outermost layer. The glass film G and the protective film F1 are cut in the width direction by a cutting device (not shown), and the original glass roll 14 is manufactured. At this time, if too much tension is applied to the glass film G, excessive tension acts on the softened glass film G in the vicinity of the molded body 5 and the thickness of the glass film G becomes unstable. A fatal problem of tearing at the lower part of 5 can occur. Therefore, in the temporary winding process S3, tension (for example, 0 to 20 (less than) N / W in the width direction on the glass film G) is applied to the glass film G along the winding direction within a range that does not adversely affect the molding of the glass film G. Winding around the core 13 while acting m). Here, in temporary winding process S3, it is not necessary to make a tension | tensile_strength act on the glass film G positively, and only the minimum tension | tensile_strength which acts naturally when winding the glass film G may be made to act. .

  Moreover, in this embodiment, the tension | tensile_strength of the winding direction larger than the glass film G is made to act on the protective film F1 in temporary winding process S3. Specifically, for example, a tension of 0.8 to 400 N / m in the width direction is applied to the protective film F1. As for the tension of the protective film F1, for example, a rotational speed difference is provided between the original glass roll 14 and the protective roll 12, or a tension roller 15 as illustrated is interposed between the original glass roll 14 and the protective roll 12. It is given by. In this way, the movement of the glass film G can be suppressed by the protective film F1 without applying a large tension directly to the glass film G. That is, it is possible to obtain the same effect as when a tension is directly applied to the glass film G. For this reason, it is possible to suppress the winding deviation and the lifting of the glass film G generated in the temporary winding step S3 to the minimum range. Moreover, since the glass film G is reliably pressed down by the protective film F1 in the state of the original glass roll 14, when unwinding the glass film G from the original glass roll 14 in the main winding process S4 described later, It is difficult to cause a situation in which the glass film G in the glass roll 14 is unduly wound.

  The thickness of the protective film F1 for the original glass roll 14 is preferably 20 to 1000 μm (more preferably 25 to 500 μm). Moreover, in order to protect the width direction both end surfaces of the glass film G from various contact, it is preferable that the width | variety of the protective film F1 is larger than the width | variety of the effective part Ga of the glass film G. That is, it is preferable that the protective film F1 protrudes on both sides in the width direction of the effective portion Ga of the glass film G.

  Moreover, since the temperature of the glass film G may be 50 degreeC or more at the stage which performs temporary winding process S3, it is preferable that the protective film F1 does not change by softening etc. at about 100 degreeC.

  The protective film F1 is preferably an elastic film. Thereby, the original glass roll 14 without a looseness can be produced, giving the tension | tensile_strength of the appropriate winding direction to the protective film F1. Here, the tensile elastic modulus of the protective film F1 is preferably 1 to 5 GPa.

  The protective film F1 is preferably provided with conductivity. If it does in this way, when taking out the glass film G from the original glass roll 14, since it becomes difficult to produce peeling electrification between the glass film G and the protective film F1, the protective film F1 can be easily peeled from the glass film G. You can enjoy the benefits. As a method for imparting conductivity to the protective film F1, for example, when the protective film F1 is made of a resin, a component that imparts conductivity, such as polyethylene glycol, may be added to the protective film F1. In addition, when the protective film F1 is a slip sheet, it is possible to engrave conductive fibers into the slip sheet. Furthermore, it is possible to impart conductivity to the protective film F1 by forming a conductive film such as ITO on the surface of the protective film F1.

  Specifically, as the protective film F1, for example, ionomer film, polyethylene film, polypropylene film, polyvinyl chloride film, polyvinylidene chloride film, polyvinyl alcohol film, polyester film, polycarbonate film, polystyrene film, polyacrylonitrile film, ethylene Use resin films such as vinyl acetate copolymer films, ethylene-vinyl alcohol copolymer films, ethylene-methacrylic acid copolymer films, polyamide films, polyimide films, cellophane and other organic resin films (synthetic resin films). Can do. Further, from the viewpoint of securing the buffer performance, a foamed resin film such as a polyethylene foamed resin film or a composite material in which the foamed resin film is laminated on the above resin film can be used as the protective film F1. Furthermore, you may disperse | distribute lubricants, such as a silica which makes the sliding between the glass films G favorable to said resin film. If it does in this way, the shift | offset | difference of both winding length which arises by the difference of the slight winding diameter of the glass film G and the protective film F1 can be absorbed by the slipperiness of the protective film F1. The same applies to the protective film F2 for the glass roll 16 described later.

  In addition, the matter regarding said protective film F1 is also the same also about the protective film F2 for the glass roll 16 mentioned later.

  And the former glass roll 14 manufactured by temporary winding process S3 as mentioned above is sent to this winding process S4, and is rewound.

  In the main winding step S4, as shown in FIG. 3, the glass film G (specifically, the effective portion Ga) unwound from the original glass roll 14 is wound again by a roll-to-roll device. The glass roll 16 used as a product is manufactured.

  Specifically, in this embodiment, after the glass film G unwound from the original glass roll 14 at the unwinding position P1 is guided in a substantially circumferential shape while being rotated by a roller group 17 composed of a plurality of rollers, The glass roll 16 is manufactured by rewinding around the core 18 at the take-up position P2. If the glass film G is guided in this way, an appropriate tension is easily applied to the glass film G even between the rollers of the roller group 17.

  At this time, at the unwinding position P1, the protective film F1 is peeled off from the glass film G, and the protective film F1 is wound up as the protective roll 19. On the other hand, at the winding position P2, while the protective film F2 newly unwound from another protective roll 20 is superposed on the outer peripheral surface side of the glass film G so that the state in which the protective film F2 is in the outermost layer is maintained. It is wound around the core 18. Then, after the protective film F1 is overlaid on the glass film G and wound around the core 18 by a predetermined length, the protective film F2 (or the glass film G and the protective film F2) is cut in the width direction by a cutting device (not shown). The glass roll 16 is manufactured. In this embodiment, the protective film F2 is the same type as the protective film F1 used in the temporary winding process S3.

  And in this main winding process S4, as shown in FIG. 1, the tension | tensile_strength b of the winding direction which acts on the glass film G is made larger than the tension a which acts on the glass film G in temporary winding process S3. Yes. Specifically, for example, a tension of 10 to 500 N / m in the width direction is applied to the glass film G. The tension | tensile_strength of this glass film G is provided by providing a rotational speed difference between the original glass roll 14 and the glass roll 16, for example. If it does in this way, even if winding shift and a lift will arise in the glass film G contained in the former glass roll 14 manufactured by temporary winding process S3, it will be enough for glass film G in this winding process S4. Tension can be applied to correct these winding deviations and rewind.

  In this main winding step S4, a larger tension in the winding direction may be applied to the glass film G than the protective film F2. Specifically, for example, it is preferable to apply a tension of 0.8 to 400 N / m in the width direction to the protective film F2. The tension of the protective film F2 is, for example, by providing a rotational speed difference between the glass roll 16 and the protective roll 20 or by interposing a tension roller 21 as illustrated between the glass roll 16 and the protective roll 20. Is granted. In this case, the magnitude relationship between the tension in the winding direction that acts on the protective film F2 in the final winding step S4 and the tension in the winding direction that acts on the protective film F1 in the temporary winding step S3 is particularly limited. Instead, it can be appropriately set in consideration of various requirements (F1 tension <F2 tension, F1 tension = F2 tension, F1 tension> F2 tension).

  Moreover, in this winding-up process S4, as shown in FIG. 3, while conveying only the surface of one side of the glass film G in contact support, the contact support surface is located in the inner peripheral surface side of the glass roll 16. As shown in FIG. Thus, the glass film G is wound up. In this way, even if a micro-scratch occurs on the contact support surface of the glass film G, the glass film G is wound so that the contact support surface is located on the inner peripheral surface side of the glass roll 16. In the glass roll 16, only the compressive stress acts on the inner peripheral surface side of the glass film G. Therefore, even if a fine flaw occurs on the contact support surface, a force that causes the fine flaw to act acts. hard. In other words, the non-contact surface substantially free of micro-scratches is located on the outer peripheral surface side of the glass film G on which a force that causes micro-scratches to develop is applied. Can be reliably reduced. In this embodiment, also in the temporary winding step S3, only the surface on one side of the glass film G is contact-supported, and the contact support surface is set on the same side as the contact support surface in the main winding step S4. Has been.

  In addition, this invention is not limited to said 1st Embodiment, It can implement with a various form. For example, as shown in FIG. 4, the cutting step may be executed also in the main winding step S4. Specifically, a glass film G (specifically, an effective portion Ga) unwound from the original glass roll 14 is cut in the width direction and divided into a plurality (two in the illustrated example) of glass films G having a desired width. A plurality of glass rolls 16 may be manufactured at the same time by overlaying the protective film F2 on each glass film G and winding it around the core 18.

  Moreover, in said embodiment, although the surface located in the inner peripheral surface side in the state of the original glass roll 14 was demonstrated as a contact support surface of the glass film G at the time of conveyance, as shown in FIG. It is good also considering the surface located in the outer peripheral surface side in the state of the original glass roll 14 as a contact support surface of the glass film G at the time of conveyance. In the above embodiment, the case where the contact support surface is wound so as to be positioned on the inner peripheral surface side of the glass roll 16 has been described. However, the winding is performed so as to be positioned on the outer peripheral surface side of the glass roll 16. You may be made to do.

  Furthermore, in the above-described embodiment, in the main winding step S4, the case where the glass film G that has been unwound from the original glass roll 14 is guided while being rotated in a substantially circumferential shape and then wound is described, FIG. As shown, the glass film G unwound from the original glass roll 14 may be linearly guided and wound up.

  Moreover, in said embodiment, although the case where this winding process S4 is performed only once after temporary winding process S3 was demonstrated, the process which rewinds the glass film G further after this winding process S4 May be included one or more times.

  Next, the manufacturing method of the glass roll which concerns on 2nd Embodiment of this invention is demonstrated. In addition, this 2nd Embodiment can be implemented by the same aspect shown in FIG. 1, and the point which performs temporary winding process S3 as a final winding process which manufactures the glass roll used as a final product is different.

  In detail, in this 2nd Embodiment, as shown in FIG. 1, while forming the glass film G by the down draw method, the protective film F1 was piled up on the outer peripheral side of the shape | molded glass film G, and a glass film The glass roll used as a final product is manufactured by winding in roll shape, providing the tension | tensile_strength of the winding direction larger than G to the protective film F1. And the tension | tensile_strength of the winding direction larger than the glass film G is provided to the protective film F1 in the state by which the glass roll manufactured in this way was wound up.

  Here, the tension | tensile_strength provided to the protective film F1 and the tension | tensile_strength provided to the glass film G are the tension | tensile_strength (for example, the width direction to the glass film G) demonstrated by temporary winding process S3 demonstrated in said 1st Embodiment. 0 to 20 (less than) N / m, the same as the protective film F1 in the width direction 0.8 to 400 N / m).

  The present invention can be suitably used for glass substrates used in flat panel displays such as liquid crystal displays and organic EL displays, and devices such as solar cells, and cover glasses such as organic EL lighting.

DESCRIPTION OF SYMBOLS 1 Molding device 2 Molding zone 3 Slow cooling zone 4 Cooling zone 5 Molded body 7 Attitude change roller group 8 Cutting device 9 Conveying means 10 Local heating means 11 Cooling means 14 Original glass roll 16 Glass roll F1, F2 Protective film G Glass film

Claims (16)

A molding step of conveying the glass film downstream while continuously molding the glass film by a molding apparatus that executes the downdraw method;
A first winding step for producing a base glass roll by laminating a first protective film on the glass film at the downstream end of the conveying path of the forming step and winding it into a roll;
The glass film is conveyed from the original glass roll to the downstream side while being unwound, and at the downstream end of the conveyance path, a second protective film is overlapped on the glass film and rewound into a roll to produce a glass roll. 2 winding process,
The manufacturing method of the glass roll characterized by making the tension | tensile_strength of the winding direction which acts on the said glass film at the said 2nd winding process larger than the tension | tensile_strength which acts on the said glass film at the said 1st winding process.   2. The glass according to claim 1, wherein, in the first winding step, the tension in the winding direction acting on the first protective film is made larger than the tension in the winding direction acting on the glass film. Roll manufacturing method.   The tension in the winding direction that acts on the glass film in the second winding step is made larger than the tension in the winding direction that acts on the second protective film. Glass roll manufacturing method.   The method for producing a glass roll according to any one of claims 1 to 3, wherein in the second winding step, the glass roll is conveyed while being in contact with and supported only on one surface of the glass film.   5. The method for producing a glass roll according to claim 4, wherein in the second winding step, the glass film is wound so that the contact support surface of the glass film is positioned on an inner peripheral surface side of the glass roll. .   6. At least one of the first winding step and the second winding step, wherein the glass film is cut to a predetermined width by laser cutting and then wound. The manufacturing method of the glass roll of description.   The said downdraw method is an overflow downdraw method, The manufacturing method of the glass roll of any one of Claims 1-6 characterized by the above-mentioned.   The thickness of the said glass film is 1 micrometer or more and 300 micrometers or less, The manufacturing method of the glass roll of any one of Claims 1-7 characterized by the above-mentioned. While forming a glass film by a downdraw method, the method is a method for producing a glass roll in which the formed glass film is stacked on a protective film and wound into a roll,
A method for producing a glass roll, wherein the glass film and the protective film are wound up while applying a greater tension in the winding direction than the glass film to the protective film.   The method for producing a glass roll according to claim 9, wherein ineffective portions formed at both ends in the width direction of the glass film are laser-cut at a stage until the glass film is wound into a roll shape.   The glass film and the protective film are wound up while the protective film is stacked on the outer peripheral surface side of the glass film so that the protective film is maintained in the outermost layer. Or the manufacturing method of the glass roll of 10.   The method for producing a glass roll according to claim 9, wherein the downdraw method is an overflow downdraw method. A glass roll formed by a downdraw method, overlaid on a protective film and wound into a roll,
The glass roll characterized by the tension | tensile_strength of the winding-up direction larger than the said glass film being provided to the said protective film.   The glass roll according to claim 13, wherein the glass film has a thickness of 1 μm to 300 μm.   The glass roll according to claim 13 or 14, wherein the arithmetic average roughness Ra of both end faces in the width direction of the glass film is 0.1 µm or less.   The glass roll according to any one of claims 13 to 15, wherein the protective film protrudes from both sides in the width direction of the glass film.

Images