JP2014159137A - Film material and manufacturing method of film material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a film material capable of effectively preventing defects conventionally caused when taking-up the film material.SOLUTION: A film material 2 comprises: a base material 10; and a coating film 20 formed on the base material 10. The film material 2 includes a pair of non-product areas 4 each including a corresponding end portion in width direction, and a product area 3 located between the pair of non-product areas 4. The coating film 20 includes a thick part 21 thicker than a portion 20a located within the product area 3 and extending in a longer direction, at a location within each product area 4.

Description

  The present invention relates to a film material comprising a base material and a coating film, and a method for producing the film material.

  A film material is produced by forming a coating film on a substrate such as an optical film that is continuously conveyed, and the film material is wound up as a wound body. Of these film materials, portions in the vicinity of both end portions in the width direction are generally unfavorable for film forming accuracy and are difficult to be used as products. For this reason, a pair of non-product regions each including an end portion in the width direction corresponding to each other and a product region located between the pair of non-product regions are defined in the film material.

  When this film material is wound as a wound body, if the coating film on the base material located in the product area directly contacts the base material in the other part of the film material that comes to face, the film material is attached to the base material. Therefore, the quality of the coating film as a product may be impaired. Further, when the film material is wound, if air is caught between the film materials, a winding deviation due to the air is generated. Generation | occurrence | production of winding shift | offset | difference is not preferable when transporting and storing a wound body. In order to cope with the above-described problems when winding the film material, for example, when winding the film material, the side tape is sandwiched between both ends in the width direction of the substrate in the non-product region. An intermediate sheet is inserted so as to cover the entire surface of the film. Further, Patent Document 1 discloses that a gap is formed between film materials wound as a wound body by forming irregularities in a non-product region.

JP 2002-187148 A

  However, when winding the film material, the method of sandwiching the side tape at both ends in the width direction of the base material or sandwiching the wide intermediate paper on the coating film formed on the base material takes time and effort. Directly increase the production cost of the film material. In addition, when the film material is unwound from the wound body, it is necessary to remove these side tapes and intermediate paper, which is complicated. On the other hand, when using a base material in which unevenness is formed in the non-product region, the height of the unevenness must be changed depending on the thickness of the coating film formed on the base material. For this reason, it is necessary to prepare a base material for every thickness of a coating film, and lacks versatility. In the first place, when the thickness of the substrate is thin, sufficient unevenness cannot be formed in the non-product region, and this method cannot be employed. That is, the conventional method cannot sufficiently cope with a problem that may occur when a film material having a base material and a coating film provided on the base material is wound.

  The present invention has been made in consideration of such points, and an object of the present invention is to provide a film material that can effectively prevent the occurrence of problems that have conventionally occurred when winding the film material. To do. Moreover, an object of this invention is to provide the manufacturing method of the film material which can prevent effectively generation | occurrence | production of the malfunction which has arisen conventionally when winding up a film material.

A film material according to the present invention is a film material comprising a base material having a longitudinal direction and a width direction orthogonal to the longitudinal direction, and a coating film provided on the base material so as to extend in the longitudinal direction. ,
The film material includes a pair of non-product regions, and a product region located between the pair of non-product regions,
The said coating film contains the thick part which is thicker than the part located in the said product area | region, and extends in a longitudinal direction in the position which becomes in each non-product area | region.

  In the film material according to the present invention, the coating film has a main coating layer extending in the width direction from the product region to both the non-product regions, and an auxiliary coating layer provided in each non-product region. Each auxiliary coating layer may overlap the main coating layer in the entire region in the width direction of the auxiliary coating layer.

  In the film material according to the present invention, the main coating layer includes a first surface located on the substrate side, and a second surface located on the opposite side of the first surface, and the auxiliary coating layer comprises: The main coating layer may be provided on the second surface side.

  In the film material according to the present invention, the auxiliary coating layer may be provided between the main coating layer and the substrate.

  In the film material according to the present invention, the coating film has a main coating layer extending in the width direction from the product region to both the non-product regions, and an auxiliary coating layer provided in each non-product region. And each auxiliary coating layer overlaps with the main coating film in a partial region in the width direction of the auxiliary coating layer and is located outside the main coating layer in the other portion in the width direction. Good.

    In the film material according to the present invention, the main coating layer includes a first surface located on the substrate side and a second surface located on the opposite side of the first surface, and the auxiliary coating layer includes the first surface. The portion overlapping the main coating layer may be located on the second surface side of the main coating layer.

  The film material by this invention WHEREIN: The part which overlaps with the said main coating film layer of the said auxiliary coating film layer may be located between the said main coating film layer and the said base material.

  In the film material according to the present invention, the coating film may be formed as a single layer.

A method of manufacturing a film material according to the present invention is a method of manufacturing a film material including a pair of non-product regions and a product region located between the pair of non-product regions,
Supplying a coating liquid onto the substrate;
Curing a layer made of the coating solution supplied on the substrate to form a coating film, and
In the step of supplying the coating liquid, the coating is applied on the base material so that a thick portion having a thickness larger than a portion located in the product region of the coating film is formed in each non-product region. Supply liquid.

In the method for producing a film material according to the present invention, the step of supplying the coating liquid comprises:
Supplying a main coating liquid to the region of the base that extends from the product region to both the non-product regions in the width direction;
Supplying an auxiliary coating solution to an area within each non-product area,
The region to which the auxiliary coating solution is to be supplied may overlap with the region to which the main coating solution is to be supplied in at least a part in the width direction.

In the method for producing a film material according to the present invention, the step of curing the coating film comprises:
Curing the layer made of the main coating solution supplied to the substrate;
Curing the layer made of the auxiliary coating solution supplied to the substrate.

  In the step of supplying the coating liquid in the method for producing a film material according to the present invention, a single coating liquid may be supplied to the substrate so that the thickness of the coating film is increased in the thick portion. Good.

  According to the film material of the present invention, it is possible to effectively prevent the occurrence of problems that have conventionally occurred when winding the film material. In addition, according to the method for manufacturing a film material according to the present invention, it is possible to effectively prevent the occurrence of problems that have conventionally occurred when winding the film material.

FIG. 1 is a schematic perspective view showing a wound body obtained by winding a film material according to the first embodiment of the present invention. FIG. 2 is a schematic cross-sectional view showing a cross section along the normal direction of the film material shown in FIG. FIG. 3 is a schematic cross-sectional view corresponding to FIG. 2 and showing another example of the film material. FIG. 4 is a schematic cross-sectional view showing a cross section along the normal direction of the film material according to the second embodiment of the present invention. FIG. 5 is a schematic cross-sectional view corresponding to FIG. 4 and showing still another example of the film material. FIG. 6 is a schematic cross-sectional view showing a cross section along the normal direction of the film material according to the third embodiment of the present invention. FIG. 7 is a schematic view showing a method and an apparatus for producing the film material shown in FIG. FIG. 8 is a schematic perspective view showing a step of supplying the coating liquid onto the substrate in FIG. FIG. 9 is a diagram corresponding to FIG. 7 and is a schematic diagram illustrating another example of a method and apparatus for manufacturing a film material. FIG. 10 is a diagram corresponding to FIG. 7 and is a schematic diagram showing still another example of a method and apparatus for manufacturing a film material. FIG. 11 is a view corresponding to FIG. 8 and is a perspective view showing another example of supplying a coating liquid onto a substrate.

  Hereinafter, several embodiments of the present invention will be described with reference to the drawings. In the drawings attached to the present specification, for the sake of illustration and ease of understanding, the scale, the vertical / horizontal dimension ratio, and the like are appropriately changed and exaggerated from those of the actual product.

<< First Embodiment >>
First, the first embodiment will be described. 1 and 2 are views for explaining a first embodiment according to the present invention. Among these, FIG. 1 is a schematic perspective view showing a wound body obtained by winding the film material according to the first embodiment of the present invention, and FIG. 2 is along the normal direction of the film material shown in FIG. It is a schematic sectional drawing which shows a cross section.

  As shown in FIGS. 1 and 2, the film material 2 includes a base material 10 and a coating film 20 provided on the base material 10. The film material 2 wound around the core 7 is called a wound body 1. The core 7 is formed as a hollow member, more specifically in a cylindrical shape. Among these, the base material 10 of the film material 2 has a longitudinal direction and a width direction orthogonal to the longitudinal direction. As this base material 10, a sheet-like member is used, and as an example, a sheet-like member made of triacetyl cellulose (TAC), polyethylene terephthalate (PET), or polypropylene (PP) is used. Moreover, as for the thickness of the base material 10, the thing of about 70 micrometers-90 micrometers is used as an example. On the other hand, the coating film 20 is provided on the base material 10 so as to extend in the longitudinal direction. A coating film here means the film | membrane formed on the surface of the base material 10 by a coating process, and means the film | membrane formed by the film | membrane formed by coating and the coating process as an example.

  As shown in FIG. 2, the film material 2 includes a pair of non-product regions 4 each including an end portion in the width direction corresponding to each other, and a product region 3 positioned between the pair of non-product regions 4. It is out. In general, the film forming accuracy of the coating film 20 decreases in the vicinity of both ends in the width direction of the film material 2 located in the non-product region 4. For example, the position of the edge in the width direction of the coating film 20 is not stable, or the thickness of the coating film 20 changes, and is difficult to be used as a product. Therefore, normally, when the film material 2 is drawn out from the wound body 1 to manufacture a product, the non-product region 4 is cut and removed from the product region 3 using a cutting device.

  As shown in FIG. 2, the coating film 20 includes a thick portion 21 that is thicker than the portion 20 a located in the product region 3 and extends in the longitudinal direction at a position in each non-product region 4. . The thick portions 21 are provided as a pair separated in the width direction. Each thick portion 21 protrudes outward in the normal direction of the base material 10 from the portion 20a located in the product region 3, and has a convex shape. In the present embodiment, the protruding portion of the thick wall portion 21 is somewhat tapered as it goes outward in the normal direction. As an example, the thickness of the part 20a located in the product area | region 3 among the coating films 20 is formed in about 0.01-20 micrometers, and the thickness of the thick part 21 is formed in about 0.5-30 micrometers. .

  According to such a form of the coating film 20, when the film material 2 is wound as the wound body 1, the pair of thick portions 21 positioned in the non-product region 4 are overlapped and face each other. On the other hand, the coating film 20 located in the product region 3 is prevented from coming into close contact with the base material 10 that comes into contact with the base material 10 in the other part of the film material 2. Furthermore, the coating film 20 in a certain part of the film material 2 and the base material 10 in the other part of the film material 2 that overlap when the film material 2 is wound up are a pair of thick portions 21. In the region where the is formed, it is partly strongly contacted, and in the other region, it is spaced apart with some gaps without contact. As a result, air is engulfed between the coating film 20 of a certain part of the film material 2 and the substrate 10 of the other part of the film material 2 which are overlapped and face each other in the state where the film material 2 is wound up. However, the occurrence of winding deviation due to air is effectively suppressed. Although the details of such a phenomenon are unknown, when the film material 2 is wound, the air between the film material 2 that is about to be wound and the portion that has been wound up to that time is wound up. It is presumed that one of the reasons is that it is possible to remain in a gap formed between the pair of thick portions 21 of the film material 2 to be formed. Due to the above, the coating film 20 located in the product region 3 sticks to the base material 10 that faces the coating film 20, and the winding deviation of the wound body 1 due to the entrainment of air is reduced. Can be prevented.

  As shown in FIG. 2, specifically, the coating film 20 includes a main coating layer 22 extending from the product region 3 to both the non-product regions 4 in the width direction, and a pair provided in each non-product region 4. The auxiliary coating layer 23. Each auxiliary coating layer 23 overlaps the main coating layer 22 in the entire region in the width direction of the auxiliary coating layer 23. The thick part 21 is defined by the auxiliary coating layer 23 and the portion of the main coating layer 22 laminated on the auxiliary coating layer 23. According to such a form, since the coating film 20 including the thick part 21 can be formed only by laminating the main coating film layer 22 and the auxiliary coating film layer 23, the coating film 20 is a complicated work. Can be realized without the need for

  Here, since the main coating film layer 22 constitutes the coating film 20 in the product region 3 of the substrate 10 as a product, it is necessary to satisfy the quality as a product. On the other hand, since the auxiliary coating layer 23 does not constitute the coating film 20 in the product region 3 of the substrate 10 as a product, quality as a product is not required. Therefore, according to the configuration in which the coating film 20 including the thick portion 21 is formed by the laminated structure of the main coating layer 22 and the auxiliary coating layer 23, the thick portion 21 is formed in a desired shape. As such, the auxiliary coating layer 23 can be adjusted. As an example, by using a material having higher viscosity than the main coating layer 22 for the auxiliary coating layer 23, the shape of the auxiliary coating layer 23 is stabilized, and the thick portion 21 is easily formed into a desired shape. Alternatively, by using materials having different curing characteristics for the main coating layer 22 and the auxiliary coating layer 23, it becomes easy to form the thick portion 21 in a desired shape by utilizing the difference in the curing characteristics. As an example, an ultraviolet curable resin is used for the main coating layer 22, and a coating that cures by drying is used for the auxiliary coating layer 23. Layer 23 may be dried and cured. Thereby, after defining the contour of the main coating layer 22, the contour of the auxiliary coating layer 23 can be defined, so that the thick portion 21 can be easily formed in a desired shape.

  Thus, by forming the thick part 21 in a desired shape, when the film material 2 is wound as the wound body 1, the pair of thick parts 21 located in the non-product region 4 is formed into the thick part. The coating film 20 positioned in the product region 3 is surely brought into contact with the base material 10 in the other part of the film material 2 which is overlapped with the film 21 and comes to face each other. It can prevent more reliably that it adheres to the material 10. Further, air is interposed between the coating film 20 of one film material 2 that overlaps when the film material 2 is wound up and the base material of the other film material 2 that faces this coating film 20. Even if it is caught, the occurrence of winding deviation due to air is more effectively suppressed.

  The main coating layer 22 is formed so as to extend in the longitudinal direction. The main coating layer 22 includes a first surface 22a located on the base material 10 side and a second surface 22b located on the opposite side of the first surface 22a. The configuration of the main coating layer 22 is determined according to product specifications. As an example, when the film material 2 is used as a functional sheet to be bonded on a display device, the main coating layer 22 is used as a protective film (hard coat layer) for improving scratch resistance. It may be formed, may be formed as an anti-reflection film (anti-reflective layer) for preventing reflection of external light, or as an anti-glare layer (anti-glare layer) for preventing reflection of an external image It may be formed. As a material constituting the main coating layer 22, for example, a paint or an ultraviolet curable resin can be used.

  On the other hand, each auxiliary coating layer 23 is formed to extend in the longitudinal direction. As shown in FIG. 2, each auxiliary coating layer 23 is provided on the second surface 22 b side of the main coating layer 22. Each auxiliary coating layer 23 is somewhat tapered (becomes narrower) as it goes outward in the normal direction, that is, away from the base material 10 along the normal direction. Yes. In the illustrated example, each auxiliary coating layer 23 has a substantially trapezoidal shape with a rounded upper surface in a cross section along the normal direction of the film material.

  The material constituting the auxiliary coating layer 23 may be the same as or different from the material constituting the main coating layer 22. When the material constituting the auxiliary coating layer 23 and the material constituting the main coating layer 22 are different, as described above, the thick portion 21 is formed into a desired shape by utilizing the difference between these materials. Can do.

  As described above, since the auxiliary coating layer 23 does not constitute the coating film 20 in the product region 3 of the substrate 10 as a product, quality as a product is not required. Therefore, a material that does not satisfy the quality as a product and that is cheaper than the material that forms the main coating layer 22 may be applied to the material that forms the auxiliary coating layer 23. Thereby, the cost of the film material 2 can be reduced. Specifically, an inexpensive acrylic resin can be used as a material constituting the auxiliary coating layer 23.

  In addition, additives having various functions may be added to the auxiliary coating layer 23. As an example, the slipperiness may be improved by adding fine particles to the material constituting the auxiliary coating layer 23. In this case, the auxiliary coating layer 23 can be prevented from sticking to the substrate 10.

  As described above, the main coating layer 22 is in contact with the substrate 10 while extending in the longitudinal direction in both the product region 3 and the non-product region 4. On the other hand, the auxiliary coating layer 23 of the present embodiment is provided on the second surface 22b side of the main coating layer 22 and overlaps the main coating layer 22 in the entire region in the width direction of the auxiliary coating layer 23. ing. For this reason, the auxiliary coating layer 23 does not directly contact the base material 10. According to such a form, even if the coating film 20 is cured and the main coating layer 22 and the auxiliary coating layer 23 contract, the substrate 10 is longitudinal in both the product region 3 and the non-product region 4. Since the main coating layer 22 is in contact with the main coating layer 22 in a wide area, it is unlikely that the substrate 10 is locally pulled by the main coating layer 22 or the auxiliary coating layer 23. For this reason, it can suppress that wrinkles and a curl arise in the base material 10 when the base material 10 is pulled locally by the main coating film layer 22 or the auxiliary coating film layer 23.

  As described above, according to the present embodiment, when the film material 2 is wound up, the other part of the film material 2 where the pair of thick portions 21 located in the non-product region 4 face each other. This makes it possible to prevent the coating film 20 located in the product region 3 from coming into contact with the base material 10 that comes into contact with the base material 10. Moreover, when winding up the film material 2, the coating film 20 of one film material 2 to be superposed and the base material 10 of the other film material 2 facing the coating film 20 are a pair of thick parts. In the region where 21 is formed, it is allowed to make a partial strong contact, and in other regions, it is allowed to form a gap somewhat without being in close contact. As a result, even if air is caught between the coating film 20 of the film material 2 and the base material 10 that is overlapped with the film material 2 and faces, the occurrence of winding deviation due to the caught air is effective. Can be suppressed. Although the details of such a phenomenon are unknown, when the film material 2 is wound, the air between the film material 2 that is about to be wound and the portion that has been wound up to that time is wound up. It is presumed that one of the reasons is that it is possible to remain in a gap formed between the pair of thick portions 21 of the film material 2 to be formed.

  In addition, according to the present embodiment, the pair of thick portions 21 that are thicker than the portion 20a located in the product region 3 and extend in the longitudinal direction are the auxiliary coating layer 23 and the auxiliary coating layer. And a portion of the main coating layer 22 laminated on the substrate 23. According to such a form, when the film material 2 is unwound from the wound body 1, it is not necessary to perform a separate operation such as removing the side tape or the intermediate paper, and the base material is provided for each thickness of the coating film 20. There is no need to prepare 10. For this reason, compared with the conventional method, according to the present embodiment, the coating film 20 including the pair of thick portions 21 can be easily obtained without requiring a complicated operation without requiring a separate material. Can be formed. Therefore, according to the present embodiment, the coating film 20 located in the product region 3 sticks to the base material 10 that comes to face the coating film 20, and the wound body by air entrainment. 1 can be prevented, and a film material 2 that can be wound up as a wound body 1 having excellent practicality can be provided.

  In the first embodiment described above, an example in which the auxiliary coating layer 23 is provided on the second surface 22b side of the main coating layer 22 as shown in FIG. The arrangement of the auxiliary coating layer 23 is not limited to the example described above. FIG. 3 shows another arrangement example of the main coating layer 22 and the auxiliary coating layer 23. In the example shown in FIG. 3, the auxiliary coating layer 23 is provided between the main coating layer 22 and the substrate 10. Even in such a form, the thick coating portion 21 is defined by the auxiliary coating layer 23 and the portion of the main coating layer 22 laminated on the auxiliary coating layer 23. It is possible to obtain the same effect as that of the embodiment.

<< Second Embodiment >>
Next, a second embodiment of the present invention will be described with reference to FIG. FIG. 4 is a schematic cross-sectional view showing a cross section along the normal direction of the film material 2 according to the second embodiment of the present invention. The second embodiment described with reference to FIG. 4 differs in the arrangement of the main coating layer 22 and the auxiliary coating layer 23, but the other configurations can be configured in the same manner as in the first embodiment. it can. In the following description of the second embodiment and the drawings used in the following description, the parts that can be configured in the same manner as in the first embodiment described above are the same as the corresponding parts in the first embodiment described above. The same reference numerals as those used above will be used, and redundant explanation will be omitted.

  As shown in FIG. 4, the coating film 120 of the present embodiment is provided in each non-product area 4 and a main coating layer 122 extending from the product area 3 to both the non-product areas 4 in the width direction. A pair of auxiliary coating layers 123. Each auxiliary coating layer 123 overlaps with the main coating layer 122 in a partial region in the width direction of the auxiliary coating layer 123 and is positioned outward in the width direction of the main coating layer 122 in other portions. The portion of the main coating layer 122 that overlaps the auxiliary coating layer 123 and the portion of the auxiliary coating layer 123 that overlaps the main coating layer 122 are thicker than the portion 120 a located in the product region 3. A thick part 121 is defined. According to such a form, since the coating film 120 including the thick part 121 can be formed only by laminating the main coating film layer 122 and the auxiliary coating film layer 123, the coating film 20 is complicated. Can be realized without the need for

  In the present embodiment, as shown in FIG. 4, the main coating layer 122 includes a first surface 122a located on the substrate 10 side, a second surface 122b located on the opposite side of the first surface 122a, The portion of the auxiliary coating layer 123 that overlaps the main coating layer 122 is provided on the second surface 122 b side of the main coating layer 122.

  As described above, according to the present embodiment, when the film material 2 is wound up, the other part of the film material 2 where the pair of thick portions 121 located in the non-product region 4 face each other. This makes it possible to prevent the coating film 120 located in the product region 3 from coming into close contact with the base material 10 in contact with the base material 10. Further, when the film material 2 is wound, the coating film 120 of one film material 2 to be superposed on the base material 10 of the other film material 2 facing the coating film 120 has a pair of thick portions. It is allowed that a part of the region 121 is in strong contact with each other and a gap is formed in other regions without being in close contact. As a result, even if air is caught between the coating film 120 of the film material 2 and the base material 10 that is overlapped with the film material 2 and faces, the occurrence of winding deviation due to the caught air is effective. Can be suppressed.

  In addition, according to the present embodiment, the pair of thick portions 121 which are thicker than the portion 120a located in the product region 3 and extend in the longitudinal direction are the auxiliary coating layer 123 and the auxiliary coating layer. And a portion of the main coating film layer 122 laminated on 123. According to such a form, when the film material 2 is unwound from the wound body 1, there is no need to perform a separate operation such as removing the side tape or the intermediate paper, and the base material is provided for each thickness of the coating film 120. There is no need to prepare 10. For this reason, compared with the conventional method, according to the present embodiment, the coating film 120 including the pair of thick portions 121 can be easily performed without requiring a complicated operation without requiring a separate material. Can be formed. Therefore, according to the present embodiment, the coating film 120 located in the product region 3 sticks to the base material 10 that comes to face the coating film 120, and the wound body is caused by the entrainment of air. 1 can be prevented, and a film material 2 that can be wound up as a wound body 1 having excellent practicality can be provided.

  In the second embodiment described above, as shown in FIG. 4, an example in which the portion of the auxiliary coating layer 123 that overlaps the main coating layer 122 is located on the second surface 122 b side of the main coating layer 122. However, the arrangement of the main coating layer 122 and the auxiliary coating layer 123 is not limited to the above-described example. FIG. 5 shows another arrangement example of the main coating layer 122 and the auxiliary coating layer 123. In the example shown in FIG. 5, the portion of the auxiliary coating layer 123 that overlaps the main coating layer 122 is located between the main coating layer 122 and the substrate 10. Even in such a form, the thick portion 121 is formed by the portion overlapping the auxiliary coating layer 123 of the main coating layer 122 and the portion overlapping the main coating layer 122 of the auxiliary coating layer 123. Therefore, it is possible to obtain the same effects as the present embodiment.

<< Third Embodiment >>
Next, a third embodiment of the present invention will be described with reference to FIG. FIG. 6 is a schematic cross-sectional view showing a cross section along the normal direction of the film material 2 according to the third embodiment of the present invention. The third embodiment described with reference to FIG. 6 is different in the configuration of the coating film, but the other configurations can be configured in the same manner as in the first embodiment. In the following description of the third embodiment and the drawings used in the following description, parts that can be configured in the same manner as in the above-described first embodiment will be described with respect to corresponding parts in the above-described first embodiment. The same reference numerals as those used above will be used, and redundant explanation will be omitted.

  As shown in FIG. 6, the coating film 220 is formed so as to extend in the longitudinal direction. The coating film 220 includes a thick portion 221 that is thicker than the portion 220 a located in the product region 3 and extends in the longitudinal direction at a position in each non-product region 4. In the present embodiment, the coating film 220 is formed as a single layer 222.

  As described above, according to the present embodiment, when the film material 2 is wound, the other part of the film material 2 where the pair of thick portions 221 positioned in the non-product region 4 face each other. This makes it possible to prevent the coating film 220 located in the product region 3 from coming into close contact with the base material 10 in contact with the base material 10. Further, when the film material 2 is wound, the coating film 220 of one film material 2 and the base material 10 of the other film material 2 facing the coating film 220 are superposed on each other. In the region where 221 is formed, it is possible to make a partial strong contact, and in other regions, it is allowed to form a gap without being in close contact. As a result, even if air is caught between the coating film 220 of the film material 2 and the base material 10 that is overlapped with the film material 2 and faces, the occurrence of winding deviation due to the caught air is effective. Can be suppressed.

  In addition, according to the present embodiment, the pair of thick portions 221 that are thicker than the portion 220 a located in the product region 3 and extend in the longitudinal direction are formed as a single layer 222. include. According to such a form, when the film material 2 is unwound from the wound body 1, there is no need to perform a separate operation such as removing the side tape or the intermediate paper, and the base material is provided for each thickness of the coating film 220. There is no need to prepare 10. For this reason, compared with the conventional method, according to the present embodiment, the coating film 220 including the pair of thick portions 221 can be easily performed without requiring a complicated operation without requiring a separate material. Can be formed. Therefore, according to the film material 2 of the present embodiment, the coating film 220 located in the product region 3 sticks to the base material 10 that comes to face the coating film 220, and the air winding It is possible to provide a film material 2 that can prevent winding displacement of the wound body 1 due to wrapping and can be wound up as a wound body 1 that is excellent in practicality.

≪Manufacturing method≫
A method and apparatus for manufacturing the film material 2 in the first embodiment shown in FIG. 2 will be described with reference to FIGS. 3, the second embodiment shown in FIG. 4 and its modification shown in FIG. 5, and the film material of the third embodiment shown in FIG. 2 can be produced by appropriately changing the method and apparatus for producing 2.

  7 is a schematic view showing a method and an apparatus for producing the film material 2 shown in FIG. 2, and FIG. 8 is a perspective view showing a process and an apparatus for supplying a coating liquid onto the base material 10 in FIG. . The coating film forming apparatus 50 shown in FIG. 7 includes a pair of non-product regions 4 each including a corresponding end in the width direction, and a product region 3 positioned between the pair of non-product regions 4. This is an apparatus for manufacturing the material 2 (see FIG. 2). As shown in FIG. 7, the coating film forming apparatus 50 is unwound from the roll-shaped raw fabric 51 and the unwinding portion 52 that unwinds the substrate 10 and the roll-shaped raw fabric 51, and is continuously conveyed. The coating solution supply unit 63 that applies the coating solution to the substrate 10, the coating film forming unit 70 that cures the coating solution on the substrate 10 to form a coating film, and the coating film forming unit 70 forms the coating film 20. And a winding portion 54 that winds the base material 10 on which the wire is formed on the core 7.

  Among these, as shown in FIG. 8, the coating liquid supply unit 63 supplies the main coating liquid 64 to the region of the base material 10 that extends from the product region 3 to both the non-product regions 4 in the width direction. A supply unit 66 and an auxiliary coating solution supply unit 68 that supplies the auxiliary coating solution 65 to the regions in each non-product region 4 are provided. Two auxiliary coating solution supply units 68 are provided, and these auxiliary coating solution supply units 68 are provided at positions facing both ends of the main coating solution supply unit 66.

  The main coating solution supply unit 66 is, for example, a slot die type, and a main coating solution supply pipe 67 is connected to the upper surface of the main coating solution supply unit 66. A main coating liquid discharge port 66b that opens along the width direction of the substrate 10 is provided on the lower surface of the main coating liquid supply unit 66, and the main coating liquid supply pipe 67 passes through the main coating liquid discharge port 66b. The main coating liquid 64 is discharged onto the substrate 10.

  On the other hand, the auxiliary coating liquid supply unit 68 for supplying the auxiliary coating liquid 65 is, for example, a slot die type, and an auxiliary coating liquid supply pipe 69 is connected to the upper surface of the auxiliary coating liquid supply unit 68. An auxiliary coating liquid discharge port 68b that opens along the width direction of the substrate 10 is provided on the lower surface of the auxiliary coating liquid supply unit 68, and the auxiliary coating liquid supply pipe 69 passes through the auxiliary coating liquid discharge port 68b. The auxiliary coating liquid 65 is discharged to the non-product area 4 of the substrate 10.

  As shown in FIG. 7, the coating solution on the substrate 10 is cured downstream of the main coating solution supply unit 66 and the auxiliary coating solution supply unit 68 in the conveyance direction of the substrate 10 (indicated by an arrow in FIG. 1). The coating film formation part 70 which makes it form the coating film 20 is provided. The coating film forming unit 70 supplies the main coating solution curing unit 71 that cures the main coating solution 64 supplied from the main coating solution supply unit 66 onto the substrate 10 and the auxiliary coating solution supply unit 68 supplies the substrate 10 to the substrate 10. An auxiliary coating solution curing unit 72 that cures the prepared auxiliary coating solution 65. Among these, as the main coating solution curing unit 71, for example, an ultraviolet irradiation device that forms the main coating layer 22 by irradiating the main coating solution 64 on the substrate 10 with ultraviolet rays and curing the main coating solution 64. Used. On the other hand, as the auxiliary coating solution curing unit 72, for example, a drying furnace that forms the auxiliary coating layer 23 by drying and curing the auxiliary coating solution 65 on the substrate 10 is used. The auxiliary coating solution curing unit 72 is not limited to a drying furnace, and any other type can be used as long as the auxiliary coating solution 65 on the substrate 10 can be cured to form the auxiliary coating layer 23. May be used. For example, the auxiliary coating liquid curing unit 72 that cures the auxiliary coating liquid 65 on the substrate 10 by heat or light energy may be used as the auxiliary coating liquid curing unit 72.

  In the present embodiment, the main coating liquid 64 is applied from the main coating liquid supply unit 66 so as to extend from the product region 3 to both the non-product regions 4 in the width direction. On the other hand, the auxiliary coating liquid 65 is applied in the non-product area 4 from the auxiliary coating liquid supply unit 68, and the auxiliary coating liquid 65 overlaps the main coating liquid 64 in the entire area in the width direction of the auxiliary coating liquid 65. Become. When the main coating solution 64 and the auxiliary coating solution 65 are cured by the coating film forming unit 70, the thick portions 21 that are thicker than the portion 20 a located in the product region 3 and extend in the longitudinal direction are formed on each non-coated portion. It is formed at a position in the product area 4.

  Next, a method for manufacturing the film material 2 shown in FIG. 2 using the coating film forming apparatus 50 as described above will be described.

  The manufacturing method of the film material 2 according to the present embodiment includes a step of supplying a coating liquid onto the base material 10 and a step of forming a coating film 20 by curing a layer made of the coating liquid supplied onto the base material 10. And comprising. Among these, in the step of supplying the coating liquid, the base material 10 is formed so that the thick portion 21 having a thickness larger than the portion located in the product region 3 of the coating film 20 is formed in each non-product region 4. Supply the coating solution on top. Hereinafter, each step will be described in detail.

  First, the process of supplying the coating liquid will be described. As shown in FIGS. 7 and 8, the step of supplying the coating liquid includes the step of supplying the main coating liquid 64 to the region of the base material 10 extending from the product region 3 to both the non-product regions 4 in the width direction. And supplying the auxiliary coating liquid 65 to the area in each non-product area 4. Specifically, after the base material 10 is continuously unwound from the unwinding roll 52, the main coating liquid is supplied to the region of the base material 10 that extends from the product region 3 to both the non-product regions 4 in the width direction. The main coating liquid 64 is supplied from the unit 66. Next, the auxiliary coating liquid 65 is supplied from the auxiliary coating liquid supply unit 68 to the areas in each non-product area 4. The region to which the auxiliary coating solution 65 is to be supplied overlaps with the region to which the main coating solution 64 is to be supplied in at least a part in the width direction. When the region to which the auxiliary coating solution 65 is to be supplied overlaps the region to which the main coating solution 64 is to be supplied, the thick portion 21 that is thicker than the portion located in the product region 3 is coated. A film 20 is formed in each non-product region 4.

  Next, the process of forming the coating film 20 by curing the coating solution on the substrate 10 will be described. As shown in FIG. 7, the step of forming the coating film 20 includes a step of curing the layer made of the main coating solution 64 supplied to the base material 10 and a layer made of the auxiliary coating solution 65 supplied to the base material 10. And a step of curing. Specifically, the main coating solution curing unit 71 irradiates the main coating solution 64 on the substrate 10 with ultraviolet rays, and the main coating solution 64 is cured, whereby the main coating layer 22 is applied to the substrate 10. It is formed. Further, the auxiliary coating solution 65 on the substrate 10 is dried and cured by the auxiliary coating solution curing unit 72, whereby the auxiliary coating layer 23 is formed on the substrate 10. The film material 2 is obtained by the base material 10 and the coating film 20 formed on the base material 10.

  The film material 2 obtained in this way is wound as the wound body 1 around the winding core 7 in the winding portion 54. At this time, the pair of thick portions 21 located in the non-product region 4 of the film material 2 abuts on the base material 10 in the other part of the film material 2 that comes to face, thereby the product region 3. It is prevented that the coating film 20 located inside adheres to the base material 10 that comes to face. Furthermore, the coating film 20 of one film material 2 to be superposed and the base material 10 of the other film material 2 facing this coating film 20 are partially in the region where the pair of thick portions 21 are formed. In other areas, it is allowed to form some gaps without close contact. As a result, even if air is caught between the coating film 20 of the film material 2 and the base material 10 that is overlapped with the film material 2 and faces, the occurrence of winding deviation due to the caught air is effective. Can be suppressed. This prevents the coating film 20 located in the product region 3 from sticking to the base material 10 that faces the coating film 20 and the winding displacement of the wound body 1 due to air entrainment. It is possible to provide the wound body 1 that is excellent in practicality.

  As described above, according to the present embodiment, the base portion is formed so that the thick portion 21 whose thickness is thicker than the portion located in the product region 3 of the coating film 20 is formed in each non-product region 4. A coating solution is supplied onto the material 10. And the layer which consists of a coating liquid supplied on the base material 10 is hardened, and the coating film 20 containing the thick part 21 is formed. According to such a form, when the film material 2 is unwound from the wound body 1, there is no need for a separate operation for removing the side tape and the intermediate paper, and the base material 10 is provided for each thickness of the coating film 20. There is no need to prepare. For this reason, the coating film 20 containing a pair of thick part 21 can be formed easily, without requiring a complicated operation | work. Therefore, according to the present embodiment, the coating film 20 located in the product region 3 in the wound body 1 to be manufactured sticks to the base material 10 that comes to face the coating film 20, and A film material 2 that can prevent winding displacement of the wound body 1 due to air entrainment and that can provide the wound body 1 in an embodiment that is excellent in practicality can be manufactured.

  Further, according to the present embodiment, the auxiliary coating liquid 65 is supplied so that the area to which the auxiliary coating liquid 65 is to be supplied overlaps the area to which the main coating liquid 64 is to be supplied in at least a part in the width direction. By doing so, the coating film 20 including the thick part 21 can be formed. That is, the coating film 20 including the thick part 21 can be formed very easily without requiring complicated work.

  Further, according to the present embodiment, the step of forming the coating film 20 includes the step of curing the layer made of the main coating solution 64 supplied to the substrate 10 and the auxiliary coating solution 65 supplied to the substrate 10. Curing the layer consisting of. According to such a form, since the outline of the auxiliary coating layer 23 can be defined after the outline of the main coating layer 22 is defined, the thick portion 21 can be easily formed into a desired shape. Thereby, in the wound body 1 obtained by winding the film material 2 to be manufactured, the coating film 20 located in the product region 3 is stuck to the base material 10 that comes to face the coating film 20, And the winding shift | offset | difference of the wound body 1 by entrainment of air can be prevented reliably.

  In addition, the coating-film formation apparatus 50 and coating-film formation method which were mentioned above are not limited to said aspect, A various change can be added.

  In the coating film forming method described above, the step of supplying the main coating liquid 64 to the region of the base material 10 extending from the product region 3 to both the non-product regions 4 in the width direction, and the region in each non-product region 4 The step of supplying the auxiliary coating liquid 65 is performed, and a thick portion 21 that is thicker than the portion 20 a located in the product region 3 of the coating film 20 is formed in each non-product region 4. Although the example to do was shown, the formation method of the thick part 21 is not limited to the example mentioned above. In the step of supplying the coating liquid, a single coating liquid may be supplied to the substrate 10 so that the thickness of the coating film 20 is increased in the thick portion 21. According to such a form, the coating film 20 including the thick part 21 is formed by supplying a single coating liquid to the base material 10 so that the thickness of the coating film 20 is increased in the thick part 21. can do. That is, the coating film 20 including the thick part 21 can be formed very easily without requiring complicated work.

  In the coating film forming method described above, as shown in FIG. 7, the example in which the auxiliary coating solution 65 is supplied from the auxiliary coating solution supply unit 68 after the main coating solution 64 is supplied from the main coating solution supply unit 66 is shown. The order of supplying the main coating liquid 64 and the auxiliary coating liquid 65 is not limited to the above-described example. FIG. 9 shows another example of a method for supplying the main coating liquid 64 and the auxiliary coating liquid 65. In the example shown in FIG. 9, after supplying the auxiliary coating solution 65 from the auxiliary coating solution supply unit 68, the main coating solution 64 is supplied from the main coating solution supply unit 66. In this case, since the auxiliary coating liquid 65 can be provided between the main coating liquid 64 and the substrate 10, the coating film forming apparatus 50 shown in FIG. 9 is shown in the film material 2 shown in FIG. It is suitable for manufacturing the film material 2.

  In the coating film forming apparatus 50 described above, as shown in FIG. 7, after supplying the main coating solution 64 and the auxiliary coating solution 65 from the main coating solution supply unit 66 and the auxiliary coating solution supply unit 68, respectively, the main coating solution curing unit Although the example in which the main coating liquid 64 is cured by 71 and the auxiliary coating liquid 65 is cured by the auxiliary coating liquid curing unit 72 has been shown, the order in which these steps are performed is not limited to the example described above. FIG. 10 shows another example of the order in which these steps are performed. In the example shown in FIG. 10, the main coating liquid 64 is supplied from the main coating liquid supply unit 66, the main coating liquid 64 is cured by the main coating liquid curing unit 71, and then the auxiliary coating liquid 65 is supplied from the auxiliary coating liquid supply unit 68. And the auxiliary coating liquid 65 is cured by the auxiliary coating liquid curing unit 72. Even if it is such a form, the effect similar to this Embodiment can be acquired.

  Further, in the coating film forming apparatus 50 described above, as shown in FIG. 8, an example in which the main coating liquid supply unit 66 and the auxiliary coating liquid supply unit 68 are of the slot die type is shown. The form of the auxiliary coating liquid supply unit 68 is not limited to the above-described example. As the main coating liquid supply section 66 and the auxiliary coating liquid supply section 68, a coating means known per se can be adopted. As an example, FIG. 11 shows a perspective view of a coating film forming apparatus 50a using a slide curtain type as the auxiliary coating liquid supply unit. In the aspect shown in FIG. 11, a pair of slide curtain type auxiliary coating liquid supply sections 78 are provided on the downstream side of the main coating liquid supply section 66. The auxiliary coating liquid 65 is supplied from the auxiliary coating liquid supply unit 78 to the non-product region 4 of the substrate 10. However, as the auxiliary coating liquid supply unit 68, for example, a roll coating method such as gravure coating, a nozzle coating method, a bar coating method, or the like may be employed.

  EXAMPLES Hereinafter, although this invention is demonstrated in detail using an Example, this invention is not limited to this Example. As described below, film materials according to Examples and Comparative Examples were prepared, and the amount of winding deviation and the degree of sticking were evaluated for wound bodies prepared by winding each film material.

[Example 1]
The film material according to Example 1 corresponds to the film material shown in FIG. As a base material, a sheet made of triacetyl cellulose (TAC) having a width of 1330 mm and a thickness of 80 μm was used. After applying the main coating solution to the product area and the non-product area of the base material so that the final film thickness is 15 μm using a die coating type film forming apparatus at a line speed of 70 m / min, the final film thickness is 5 μm. The auxiliary coating solution was applied to the peripheral area of the base material in each non-product area. The main coating liquid was a composition containing an ultraviolet curable resin used for forming a hard coat layer for a display device, and the auxiliary coating liquid was a composition similar to the main coating liquid. Thereafter, the main coating solution and the auxiliary coating solution were cured by irradiating with ultraviolet rays to form a main coating layer and an auxiliary coating layer. The formed main coating layer had a width of 1270 mm. The auxiliary coating layer was formed so as to overlap the main coating layer in the entire region in the width direction of the auxiliary coating layer.

[Example 2]
The film material according to Example 2 corresponds to the film material shown in FIG. The film material according to Example 2 was different from the film material according to Example 1 in the arrangement of the main coating film layer and the auxiliary coating film layer, and was otherwise the same. Specifically, after the main coating liquid is applied to the product area and the non-product area of the base material, the auxiliary coating liquid is overlapped with the main coating film in a partial area in the width direction of the auxiliary coating layer to be formed and the others. It applied in each non-product area | region of a base material so that it might be located in the width direction outer side of the main coating film layer in this part. Thereafter, in the same manner as in Example 1, the main coating solution and the auxiliary coating solution were cured by irradiating ultraviolet rays to form a main coating layer and an auxiliary coating layer.

[Comparative Example 1]
The film material according to Comparative Example 1 was configured such that the auxiliary coating layer was not provided with respect to the film material according to Example 1, and was the same as the film material according to Example 1 in other respects.

(Evaluation of amount of winding deviation and sticking)
About the wound body which winds up the film material which concerns on Example 1, Example 2, and Comparative Example 1 obtained above, the amount of winding shifts and the degree of sticking were evaluated. The evaluation results are shown in Table 1. The amount of winding misalignment is determined by measuring the difference between the end of the film material positioned most outward in the width direction and the end of the film material positioned most inward in the width direction on the side end surface on one side of the wound body. Evaluation was made by measuring. In Table 1, when the amount of winding deviation was 50 mm or less, it was evaluated as “◎”, and when the amount of winding deviation exceeded 50 mm, it was evaluated as “x”. In actual transportation of the wound body, the amount of winding deviation of 50 mm or less does not have an adverse effect and is sufficiently acceptable. On the other hand, with respect to the degree of sticking, it was visually evaluated whether or not the coating film had adhered to the base material located in the product region in the state where the film material was drawn out from the wound body. In Table 1, when the adhesion of the coating film was confirmed, it was evaluated as “x”, and when the adhesion of the coating film was not confirmed, it was evaluated as “◎”.

  As understood from Table 1, both Example 1 and Example 2 showed very good results for both the amount of winding deviation and the degree of sticking. In Comparative Example 1, the quality required for the wound body could not be satisfied with respect to the amount of winding deviation and the degree of sticking.

DESCRIPTION OF SYMBOLS 1 Roll body 2 Film material 3 Product area | region 4 Non-product area | region 10 Base material 20,120,220 Coating film 21,121,221 Thick part 22,122,222 Main coating layer 23,123,223 Auxiliary coating layer 50 Coating film forming apparatus 63 Coating liquid supply section 64 Main coating liquid 65 Auxiliary coating liquid 66 Main coating liquid supply section 68 Auxiliary coating liquid supply section 70 Coating film forming section 71 Main coating liquid curing section 72 Auxiliary coating liquefaction section 78 Auxiliary coating liquid supply Part

Claims (12)

A base material having a longitudinal direction and a width direction orthogonal to the longitudinal direction;
A coating material provided on the substrate so as to extend in the longitudinal direction, and a film material comprising:
The film material includes a pair of non-product regions, and a product region located between the pair of non-product regions,
The said coating film is a film material which contains the thick part which is thicker than the part located in the said product area | region, and extends in a longitudinal direction in the position which becomes in each non-product area | region. The coating film
A main coating layer extending in the width direction from the product region to both the non-product regions;
An auxiliary coating layer provided in each non-product area,
2. The film material according to claim 1, wherein each auxiliary coating layer overlaps the main coating layer in the entire region in the width direction of the auxiliary coating layer. The main coating layer includes a first surface located on the substrate side, and a second surface located on the opposite side of the first surface,
The film material according to claim 2, wherein the auxiliary coating layer is provided on the second surface side of the main coating layer.   The film material according to claim 2, wherein the auxiliary coating layer is provided between the main coating layer and the substrate. The coating film
A main coating layer extending in the width direction from the product region to both the non-product regions;
An auxiliary coating layer provided in each non-product area,
Each auxiliary coating layer overlaps with the main coating film in a partial region in the width direction of the auxiliary coating layer, and is positioned outside in the width direction of the main coating layer in the other portion.
The film material according to claim 1. The main coating layer includes a first surface located on the substrate side, and a second surface located on the opposite side of the first surface,
The film material according to claim 5, wherein a portion of the auxiliary coating layer that overlaps the main coating layer is located on the second surface side of the main coating layer.   The film material according to claim 5, wherein a portion of the auxiliary coating layer that overlaps the main coating layer is located between the main coating layer and the substrate.   The film material according to claim 1, wherein the coating film is formed as a single layer. A method of manufacturing a film material including a pair of non-product regions and a product region located between the pair of non-product regions,
Supplying a coating liquid onto the substrate;
Curing a layer made of the coating solution supplied on the substrate to form a coating film, and
In the step of supplying the coating liquid, the coating is applied on the base material so that a thick portion having a thickness larger than a portion located in the product region of the coating film is formed in each non-product region. A method for producing a film material, which supplies a liquid. The step of supplying the coating liquid includes
Supplying a main coating liquid to the region of the base that extends from the product region to both the non-product regions in the width direction;
Supplying an auxiliary coating solution to an area within each non-product area,
The method for producing a film material according to claim 9, wherein the region to which the auxiliary coating liquid is to be supplied overlaps with the region to which the main coating liquid is to be supplied in at least a part in the width direction. The step of forming the coating film includes
Curing the layer made of the main coating solution supplied to the substrate;
The method for producing a film material according to claim 10, comprising: curing a layer made of the auxiliary coating solution supplied to the substrate.   The manufacturing method of the film material of Claim 9 which supplies a single coating liquid to the said base material so that the thickness of the said coating film may become thick in the said thick part in the process of supplying the said coating liquid.

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