JP2018095341A - Contact pressure roller - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a contact pressure roller which suppresses a film from being electrostatically charged.SOLUTION: A contact pressure roller according to the present invention includes a substantially cylindrical core member and a rubber layer with which a surface of the core member is coated, a substantially spherical filler of 1-100 μm in mean particle size being contained in the rubber layer by 30-50% in volume content for the rubber layer. The rubber layer has a part where the filler is exposed from the surface of the rubber layer and/or a part where the surface of the rubber layer contains the filler to swell, and the roller has an external diameter of 25-130 mm.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a contact pressure roller.

  In the film production process and processing process, the film may be conveyed by various rollers and wound up in a roll shape. Since a film is generally an insulator, charging defects may occur in the film roll body due to friction with a roller or the like. This charging defect can be solved by disposing a static eliminator with needle-shaped electrodes in the process and neutralizing the charge. However, it is difficult to remove static charges locally on the film. Problems such as the occurrence of uneven coating of the solution and the loss of the metal vapor deposition film during vapor deposition occur.

  Generally, when a film is wound into a roll, a contact roller made of an elastic material such as rubber is pressed against the film roll in order to prevent wrinkles and displacement of the film roll and to suppress the edge height. . However, when winding a film that requires smoothness of the surface, such as an optical film, a base film for a magnetic recording medium, or a ribbon film for thermal transfer, the contact area between the film and the pressure roller is large due to the smoothness. Prone to charging defects.

  For such a problem, in Patent Document 1, an amorphous carbon-like film layer is formed on the outermost surface layer of the pressure roller to suppress wear on the surface of the pressure roller, and a low coefficient of friction is maintained. A technique for suppressing frictional charging is disclosed. Patent Document 2 discloses a technique for reducing the charging of the film by changing the charging characteristics of the surface layer of the pressure roller by including a charge control agent in the coating layer of the pressure roller.

JP 2008-81239 A Japanese Patent Application Laid-Open No. 2006-151569

  However, in today's optical films and base films for magnetic recording media, the smoothness of the film surface has further progressed, and the techniques disclosed in Patent Documents 1 and 2 cannot suppress charging defects.

  Therefore, an object of the present invention is to provide a contact roller that can suppress charging defects even in a smooth film.

  In order to achieve the above object, a roller of the present invention comprises a substantially cylindrical core member and a rubber layer coated on the surface of the core member, and an average particle diameter of 1 μm or more and 100 μm or less in the rubber layer. And a rubber layer containing a substantially spherical filler in a volume content of 30% or more and 50% or less with respect to the rubber layer, wherein the filler is on the surface of the rubber layer. And / or the surface of the rubber layer is raised with the filler contained therein, and the outer diameter of the roller is 25 mm or more and 130 mm or less.

  The “substantially cylindrical core member” refers to a cylindrical shape or a generally cylindrical shape as an overall shape, and includes a shape whose diameter varies somewhat depending on an axial portion, Specifically, the change in diameter is preferably within ± 10 mm. This includes a crown shape in which the diameter of the central portion in the axial direction is larger than both ends.

  The “average particle diameter” refers to the particle diameter (median diameter) at which the cumulative curve becomes 50% when the cumulative curve is obtained with the total volume being 100% in the particle size distribution.

  The “substantially spherical” is not limited to a true sphere, and means a value obtained by dividing a shortest diameter passing through the center of gravity by a long diameter is 0.5 or more.

  According to a preferred embodiment of the present invention, the rubber layer has a portion where the filler is exposed from the surface of the rubber layer, and the surface of the rubber layer is covered with an amorphous carbon-like film layer. Yes. Furthermore, the portion of the filler exposed from the rubber layer surface may also be covered with an amorphous carbon film layer.

  The “amorphous carbon film” refers to a hard film of amorphous carbon or carbon having an amorphous property as a crystal laminate.

  According to a preferred embodiment of the present invention, the rubber layer has a portion in which the surface of the rubber layer is raised including the filler therein, and the surface of the rubber layer is a layer of an amorphous carbon layer film. It is covered with.

  Moreover, according to the preferable form of this invention, the hardness of the said rubber layer is more than 55 degrees and 70 degrees or less by JIS-A.

  According to the present invention, when a film is wound, by using a contact pressure roller that can physically and chemically suppress charging due to contact with the film and friction, the charging defect of the film is suppressed, and the winding form quality is reduced. Can be obtained.

FIG. 1 is a schematic side view of a film slitting process using the contact pressure roller of the present invention. FIG. 2 is a cross-sectional view of a contact roller and an enlarged view of a roller surface layer portion according to an embodiment of the present invention. FIG. 3 is a cross-sectional view showing a contact state between a pressure roller and a film according to an embodiment of the present invention. FIG. 4 is a cross-sectional view of a contact pressure roller according to another embodiment of the present invention and an enlarged view of a roller surface layer portion. FIG. 5 is a cross-sectional view of a contact pressure roller according to still another embodiment of the present invention and an enlarged view of a roller surface layer portion. FIG. 6 is a cross-sectional view of a contact pressure roller according to still another embodiment of the present invention and an enlarged view of a roller surface layer portion. FIG. 7 is a cross-sectional view of a contact pressure roller according to still another embodiment of the present invention and an enlarged view of a roller surface layer portion. FIG. 8 is a cross-sectional view of a contact pressure roller according to still another embodiment of the present invention and an enlarged view of a roller surface layer portion. FIG. 9 is a cross-sectional view of a contact pressure roller according to still another embodiment of the present invention and an enlarged view of a roller surface layer portion.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, a preferred embodiment of a contact pressure roller according to the invention will be described in detail with reference to the accompanying drawings.

  FIG. 1 is a schematic side view showing an example in which the contact pressure roller of the present invention is applied to a slit process which is a part of a film manufacturing process and a processing process. Here, a slit process is a process of cut | disconnecting a film to a required size width and winding up in roll shape. In FIG. 1, the film 10 is unwound from the original fabric 6 and conveyed by the guide roller 7. Thereafter, the film 10 is divided in the width direction by the upper blade 9 on the lower blade roller 8, and is wound on the core 11 while pressing the contact pressure roller 5 to become a film roll 12. Further, the static eliminator 13 is installed toward the film roll 12.

  Each roller is rotatably supported by a bearing, and the bearing is appropriately supported by a frame or the like. The contact pressure roller 5, the guide roller 7, and the lower blade roller 8 may be driven rollers that rotate by frictional force with the film 10, or may be drive rollers that use a motor or the like. When driven by a motor or the like, the rotation speed of the roller is preferably substantially the same as the conveyance speed of the film 10 so that the roller and the film 10 do not slip and cause frictional charging of the film 10. The core 11 is preferably held by a chuck supported by a bearing and is driven to rotate by a motor or the like. Moreover, the electric potential of the film roll 12 can be kept low by the static eliminator 13 installed toward the film roll 12. The static eliminator 13 is a device that generates ions in the air and neutralizes the charged charges of the film 10 by the ions, and is used for the purpose of assisting the charging suppression effect of the contact roller 5 of the present invention. Further, a nip roller and a suction roller for gripping the film 10 and accurately controlling the tension and speed, a wrinkle stretching roller for widening the film 10 in the width direction, and the like may be disposed in the slit process as appropriate.

  A typical configuration of the contact roller according to the present invention is shown in FIGS. FIG. 2 is a cross-sectional view schematically showing a configuration as an example of the contact roller 5 of the present invention. The material of the core 1 is preferably a material having rigidity and strength that can withstand high pressure, such as a metal such as steel or aluminum, or a carbon fiber reinforced resin. A rubber layer 2 is coated on the surface of the cylindrical core 1. The type of the rubber layer 2 is not particularly limited. For example, natural rubber, nitrile rubber, chloroprene rubber, ethylene propylene rubber, silicone rubber, chlorosulfonated polyethylene rubber, urethane rubber, fluororubber, and mixtures thereof are used and used. Can be used as appropriate. The inventors of the present application generate particularly large frictional charge between the contact roller 5 and the film 10 in the winding portion 17 of the film 10 in FIG. I thought it would be a charging defect. As described above, the surface of optical films, base films for magnetic recording media, thermal transfer ribbon films, etc. has been smoothed, and the conventional contact pressure roller configuration cannot suppress charging defects due to friction. Therefore, in order to suppress frictional charging, the inventor of the present application has focused on the contact state between the contact roller 5 and the film 10. The inventor of the present application has found that, even if the surface of the film 10 is smooth, if the contact area between the film 10 and the contact pressure roller 5 is reduced, frictional charging can be suppressed. Therefore, the contact roller 5 of the present invention has the following characteristics.

  In the contact roller 5 of the present invention, as shown in the enlarged view of FIG. 2, the rubber layer 2 contains the filler 3, the portion where the filler 3 is exposed from the surface of the rubber layer 2, and the rubber layer. Since the surface of No. 2 has a raised portion including the filler 3 inside, the surface of the contact pressure roller 5 is uneven. The material of the filler 3 is not particularly limited, and examples thereof include alumina, silica, and carbon black. Moreover, in order to improve the dispersibility and filling property of the filler 3 in the rubber layer 2 and not to damage the surface of the film 10, a substantially spherical filler 3 can be applied.

  The average particle diameter of the filler 3 is 1 μm or more and 100 μm or less. A general contact roller 5 for winding a film 10 contains a filler 3 as a reinforcing material or a filler in the rubber layer 2. In order to facilitate the kneading of the rubber and the filler 3, The diameter is often less than 1 μm. However, when the particle diameter of the filler 3 is less than 1 μm, the surface of the contact pressure roller 5 is not formed with irregularities that reduce the contact area with the film 10, and there is no effect of preventing charging defects. On the other hand, when the particle size of the filler 3 exceeds 100 μm, the unevenness of the contact pressure roller 5 is too large, and the unevenness may be transferred to the surface of the film 10, which is not preferable. More preferably, the average particle diameter of the filler 3 is 1 μm or more and 50 μm or less. By setting it as this range, the effect which suppresses the transcription | transfer of the unevenness | corrugation to the surface of the film 10 is high also with respect to the film 10 in which smoothness is calculated | required.

  The volume content of the filler 3 with respect to the rubber layer 2 is 30% or more and 50% or less. If the volume content of the filler 3 with respect to the rubber layer 2 is less than 30%, the filler 3 for effectively reducing the contact area is insufficient, and charging defects cannot be suppressed. On the other hand, when the volume content of the filler 3 with respect to the rubber layer 2 exceeds 50%, the rubber state cannot be maintained and the roller cannot be molded. Here, when the volume content of the filler 3 with respect to the rubber layer 2 is more than 40% and 50% or less, although it can be molded as a roller, since the proportion of the filler 3 is slightly high and the rubber connection is poor, the contact roller 5 As a result, the filler 3 may easily fall off, or the rubber layer 2 may be cracked during production. Therefore, more preferably, the volume content of the filler 3 with respect to the rubber layer 2 is 30% or more and 40% or less. By setting it as this range, it becomes more difficult for the filler 3 to fall off from the surface of the rubber layer 2, and it can shape | mold without impairing the hardness of the rubber layer 2. FIG.

  It has been described that when the filler 3 is in the above range, irregularities are formed on the surface of the contact pressure roller 5 by the filler 3 and the contact area is reduced. However, the rubber layer 2 between the filler 3 and the filler 3 is completely on the film 10. It does not mean that they do not touch. FIG. 3 is a cross-sectional view schematically showing a contact state between the contact roller 5 and the film 10 according to an embodiment of the present invention. As shown in FIG. 3, the pressure roller 5 of the present invention has a protruding portion formed by the filler 3 being exposed from the surface of the rubber layer 2, and the surface of the rubber layer 2 bulges including the filler 3 inside. Although pressure is mainly applied to the convex part formed by doing, the contact state of the said convex part and the film 10 turns into point contact because the filler 3 is substantially spherical shape. Moreover, in the recessed part which consists of the exposed part of the rubber | gum formed in the circumference | surroundings of the said convex part, the pressure with the film 10 is small, and it will not contact with the film 10 partially in the filler 3 vicinity. As described above, the contact pressure roller 5 of the present invention reduces the contact area with the film 10 and the frictional force, and thus is effective in suppressing charging defects of the film 10.

Moreover, when the outer diameter of the contact pressure roller 5 is large, the deformation of the rubber layer 2 is large and the contact area increases. Therefore, when used as the contact pressure roller 5 for winding the film 10, the effect of blocking the air accompanying the inner layer of the film roll 12 is impaired, and the film 10 cannot be wound without winding defects such as wrinkles. . Furthermore, this increase in contact area makes it impossible to suppress charging defects. Using the contact theory, the contact area A at that time is as follows: the outer diameter of the contact roller 5 is D ₁ , the outer diameter of the film roll 12 is D ₂ , the elastic modulus of the rubber layer 2 is E, and the thickness of the rubber layer 2 is When the width of the film roll 12 is W and the contact pressure is P, the following formula 1 is obtained.

  Here, the elastic modulus E of the rubber layer 2 is expressed by the following formula 2 when the rubber hardness is S (Shore A).

  This contact area A is a result of macro deformation such as collapse of the rubber layer 2, and as described above, if this is large, charging defects are likely to occur. According to the knowledge of the present inventor, the charging defect can be suppressed by reducing the deformation of a minute region by containing the filler 3 in the rubber layer 2 and also by reducing the macro deformation such as the collapse of the rubber layer 2. I found.

Here, the outer diameter of the contact pressure roller 5 is 25 mm or more and 130 mm or less. If the outer diameter of the contact pressure roller 5 is less than 25 mm, the deflection of the contact pressure roller 5 becomes excessively large and pressure cannot be uniformly applied in the width direction of the film 10, leading to a winding shape defect such as wrinkles. . On the other hand, when the outer diameter of the contact pressure roller 5 exceeds 130 mm, the outer diameter D ₁ of the contact pressure roller 5 is large and the contact area A is large, as can be seen from Equation 1, and charging defects due to friction cannot be suppressed. More preferably, the outer diameter of the contact pressure roller 5 is 25 mm or more and 70 mm or less. By setting it as this range, the effect which interrupts | blocks the air which accompanies the inner layer of the film roll 12 is higher, and the film 10 can be wound up without the winding faults, such as wrinkles, and is suitable.

  The hardness of the rubber layer 2 is preferably 40 ° or more and 80 ° or less in JIS-A. If the hardness of the rubber layer 2 is less than 40 ° according to JIS-A, the elastic modulus E of the rubber layer 2 is small as can be seen from Equation 2, and the contact area A is large in Equation 1, and charging by friction. We cannot suppress fault. On the other hand, when the hardness of the rubber layer 2 exceeds 80 ° according to JIS-A, the deformation of the rubber layer 2 is inhibited, and pressure cannot be uniformly applied in the width direction of the film 10, so Leads to. Here, in order to further reduce the contact area between the pressure roller 5 and the film 10 in winding the film 10 with a particularly smooth surface such as a magnetic recording medium base film and a thermal transfer ribbon film, It has been found that it is preferable to increase the hardness of the rubber layer 2 to further reduce the amount of deformation of the rubber during contact pressure. On the other hand, if the hardness of the rubber layer 2 is too high, the amount of deformation of the rubber cannot follow the thickness variation of the film 10, so the hardness of the rubber layer 2 is preferably more than 55 ° and less than 70 ° in JIS-A. More preferably, the hardness of the rubber layer 2 is 60 ° or more and 65 ° or less in JIS-A.

  The thickness of the rubber layer 2 is preferably 2 mm or more and 6 mm or less. In Formula 1, when the thickness t of the rubber layer 2 is large, the contact area A is large. When the thickness of the rubber layer 2 exceeds 6 mm, charging defects due to friction cannot be suppressed. On the other hand, if the thickness of the rubber layer 2 is less than 2 mm, the rubber layer 2 is restrained at the interface with the hard core 1, so the deformation of the rubber layer 2 is small and cannot follow the uneven thickness of the film 10. A pressure cannot be uniformly applied in the width direction of the film 10, which leads to a winding shape defect such as wrinkles.

  The contact pressure is preferably 800 N / m or less, and more preferably 400 N / m or less. In Formula 1, when the contact pressure P is within the above range, the contact area A is reduced, and charging defects due to friction are easily suppressed.

  Further, the contact pressure roller 5 effective for suppressing charging defects is not limited to the configuration shown in FIG. 2, but may be the configuration of the contact pressure roller 5 shown in FIGS. 4 and 5. In the configuration of the contact roller 5 in FIG. 4, as shown in the enlarged view in FIG. 4, the surface of the rubber layer 2 does not form a protruding portion including the filler 3 inside, and the filler 3 is formed in the rubber layer. The part exposed from the surface of 2 is formed. 5, the surface of the rubber layer 2 includes the filler 3 inside without exposing the filler 3 from the surface of the rubber layer 2 as shown in the enlarged view of FIG. 5. It forms a raised part. Also in these structures, since the unevenness | corrugation which reduces the contact area with the film 10 can be formed in the surface of the contact pressure roller 5, it has a sufficient charging fault suppression effect.

  The surface roughness of the film 10 applicable to the present invention is not particularly limited, but the pressure roller 5 of the present invention is particularly effective for suppressing charging of the film 10 having a smooth surface. 5 is suitable when the surface of the film 10 in contact with 5 has an arithmetic average roughness Ra specified by JIS B0601: 2013 of less than 5 nm. The surface of the film 10 in contact with the contact pressure roller 5 is specified by JIS B0601: 2013. It is more preferable when the arithmetic average roughness Ra is 2 nm or less.

  FIG. 6 is a cross-sectional view schematically showing another configuration of the contact roller 5 of the present invention. In the configuration of the contact roller 5 in FIG. 6, as shown in the enlarged view in FIG. 6, the portion where the filler 3 is exposed from the surface of the rubber layer 2 and the surface of the rubber layer 2 include the filler 3 inside. By having the raised portion, the amorphous carbon-like film 4 is coated on the outermost layer of the contact roller 5 having a concavo-convex shape formed on the surface. By having the amorphous carbon film 4 as the outermost surface layer of the pressure roller 5, only the very surface layer of the pressure roller 5 is cured without impairing the flexibility of the rubber layer 2, so that the contact area is further reduced. The effect is increased, the wear of the rubber layer 2 is prevented, and a low friction coefficient can be maintained, so that the effect of suppressing charging defects is further increased. Further, since the outermost layer of the contact pressure roller 5 is covered with the amorphous carbon-like film 4, it is possible to prevent the filler 3 from falling off the rubber layer 2 and becoming a foreign matter defect of the film 10. Here, the amorphous carbon film 4 is a hard carbon film having a specific solid structure (amorphous or amorphous as a crystal laminate) as described above. For example, methane, acetylene, etc. If a plasma CVD (chemical vapor deposition) using a hydrocarbon gas such as ethylene is used, a hard carbon film can be formed on a soft layer such as rubber. This film is called a diamond-like carbon film (DLC film). The film forming method of the amorphous carbon film 4 may be the method described in Patent Document 1. If the thickness of the amorphous carbon film 4 is too thin, it may be difficult to form a film with a uniform thickness. On the other hand, if the film is too thick, the flexibility of the rubber layer 2 is hindered. In some cases, it is preferably 0.1 μm or more and 10 μm or less.

  As raw materials for the film 10, polyethylene terephthalate, polyethylene naphthalate, polypropylene, polystyrene, polycarbonate, polyimide, polyphenylene sulfide, nylon, aramid, polyethylene, and the like are often used. These copolymers and polymer alloys are also used. The polymer alloy here is a polymer multicomponent system, and is a block copolymer by copolymerization or a polymer blend by mixing. Here, the inventor of the present application indicates that the charge train of the amorphous carbon-like film 4 is close to the charge train of the film 10 made of polyethylene terephthalate and a polymer alloy containing polyethylene terephthalate, and the friction between these two substances. It was found that the charge amount was small. Therefore, the contact roller 5 of the present invention is more preferably used for winding the film 10 using polyethylene terephthalate and a polymer alloy containing polyethylene terephthalate as a raw material. When polyethylene terephthalate is used as a polymer alloy, the other polymer is preferably compatible with polyester, and specifically, polyetherimide is preferred. Here, the charge column is a plurality of substances that are confirmed to be charged to which polarity when two substances are triboelectrically charged, and are arranged in order from positive to negative. The farther the positional relationship of the charge trains of the two substances, the greater the charge amount. That is, the contact roller 5 whose outermost layer is covered with the amorphous carbonaceous film 4 is wound on a film 10 made of polyethylene terephthalate having a smooth surface such as a base film for a magnetic recording medium or a ribbon film for thermal transfer. By applying to the removal, the problem of charging can be solved more suitably.

  Further, the contact roller 5 whose outermost layer is coated with the amorphous carbonaceous film 4 is not limited to the configuration shown in FIG. 6, but may have the configuration shown in FIGS. The configuration of the contact roller 5 in FIG. 7 is that, as shown in the enlarged view of FIG. 7, the surface of the rubber layer 2 does not form a raised portion including the filler 3 inside, and the filler 3 is rubber. An amorphous carbon-like film 4 is coated on the outermost layer of the contact pressure roller 5 on which the portion exposed from the surface of the layer 2 is formed. Further, the configuration of the contact roller 5 in FIG. 8 is that the filler 3 is not exposed from the surface of the rubber layer 2 and the filler 3 is included in the surface of the rubber layer 2 as shown in the enlarged view of FIG. An amorphous carbon film 4 is coated on the outermost layer of the contact pressure roller 5 where the raised portions are formed. Even in these configurations, the surface of the contact pressure roller 5 is formed with irregularities that reduce the contact area with the film 10, and a low coefficient of friction can be maintained on the outermost layer of the contact pressure roller 5, and the surface of the polyethylene terephthalate film and the charging roller can be charged. Since the amorphous carbonaceous film 4 having good compatibility is formed, it has a sufficient charging defect suppressing effect.

  Furthermore, as shown in FIGS. 6 to 8, the outermost surface layer of the pressure roller 5 is not limited to being completely covered with the amorphous carbon film 4, but as shown in FIG. The outermost layer may be partially covered with the amorphous carbon film 4. In the configuration of the contact roller 5 in FIG. 9, as shown in the enlarged view of FIG. 9, there is a portion where the filler 3 is exposed from the surface of the rubber layer 2, and only the surface of the rubber layer 2 is amorphous carbon. Covered with a membrane 4. When the pressure roller 5 is pressed against the film 10, the filler 3 itself is not deformed, and the filler 3 and the film 10 are in point contact. Therefore, these frictions hardly cause charging defects. On the other hand, the rubber layer 2 is deformed and has a slightly larger contact area with the film 10 than the filler 3. That is, in order to suppress charging defects, it is important to maintain a low friction coefficient on the surface of the rubber layer 2 and to have good compatibility between the surface of the rubber layer 2 and the film 10. Therefore, as shown in FIG. 9, even in the configuration in which only the surface of the rubber layer 2 is covered with the amorphous carbon film 4, the outermost layer of the contact pressure roller 5 as shown in FIGS. Although not as much as the structure covered with the amorphous carbon film 4, it has a sufficient effect of suppressing charging defects.

  Hereinafter, although an example is shown and explained concretely, the present invention is not restrict | limited at all by these examples.

[Example 1]
In the slitting process of the film 10 shown in FIG. 1, using the contact roller 5 of FIG. 2, the width is 1000 mm, the average thickness is 5 μm, and the surface is an arithmetic average roughness Ra = 2 nm as defined in JIS B0601: 2013. A polyethylene terephthalate (PET) film was wound around a core 11 made of glass fiber reinforced resin at a winding speed of 120 m / min and a winding length of 15000 m to obtain a film roll 12. The contact pressure roller 5 was pressed against the core 11 with an air cylinder so that the contact pressure was 300 N / m. The contact roller 5 has a surface length of 1100 mm and an outer diameter of 70 mm, and the rubber layer 2 is a chloroprene rubber having a thickness of 5 mm and a hardness of 50 ° (JIS-A). The filler 3 was substantially spherical alumina having an average particle diameter of 4 μm, and the volume content of the filler 3 with respect to the rubber layer 2 was 33%. The material of the core 1 was STKM13A defined in JIS G3445: 2016.

[Example 2]
As the contact pressure roller 5, the roller shown in FIG. 2 was used. The filler 3 was substantially spherical alumina having an average particle diameter of 4 μm, and the volume content of the filler 3 with respect to the rubber layer 2 was 46%. Other conditions were the same as in Example 1.

[Example 3]
As the contact pressure roller 5, the roller shown in FIG. 2 was used. The filler 3 was substantially spherical alumina having an average particle diameter of 4 μm, and the volume content of the filler 3 with respect to the rubber layer 2 was 39%. Other conditions were the same as in Example 1.

[Example 4]
As the contact pressure roller 5, the roller shown in FIG. 2 was used. The filler 3 was substantially spherical alumina having an average particle size of 95 μm, and the volume content of the filler 3 relative to the rubber layer 2 was 33%. Other conditions were the same as in Example 1.

[Example 5]
As the contact pressure roller 5, the roller shown in FIG. 2 was used, and the contact roller 5 had a surface length of 1100 mm and an outer diameter of 120 mm. Other conditions were the same as in Example 1.

[Example 6]
2 was used as the contact pressure roller 5, and the rubber layer 2 was made of chloroprene rubber having a thickness of 5 mm and a hardness of 75 ° (JIS-A). Other conditions were the same as in Example 1.

[Example 7]
The film 10 was a polypropylene (PP) film having a width of 1000 mm, an average thickness of 5 μm, and a surface having an arithmetic average roughness Ra = 10 nm as defined in JIS B0601: 2013. Other conditions were the same as in Example 1.

[Example 8]
As the contact pressure roller 5, the roller shown in FIG. 6 was used, and the rubber layer 2 was made of chloroprene rubber having a thickness of 5 mm and a hardness of 50 ° (JIS-A). The filler 3 was substantially spherical alumina having an average particle diameter of 4 μm, and the volume content of the filler 3 with respect to the rubber layer 2 was 33%. A DLC film having a thickness of 1 μm was formed as an amorphous carbon film 4 on the outermost layer of the contact roller 5. Other conditions were the same as in Example 1.

[Example 9]
As the contact pressure roller 5, the roller shown in FIG. 2 was used, and the rubber layer 2 was made of chloroprene rubber having a thickness of 5 mm and a hardness of 60 ° (JIS-A). The filler 3 was substantially spherical alumina having an average particle diameter of 4 μm, and the volume content of the filler 3 with respect to the rubber layer 2 was 33%. Other conditions were the same as in Example 1.

[Example 10]
A roller shown in FIG. 6 was used as the contact roller 5, and the rubber layer 2 was made of chloroprene rubber having a thickness of 5 mm and a hardness of 60 ° (JIS-A). The filler 3 was substantially spherical alumina having an average particle diameter of 4 μm, and the volume content of the filler 3 with respect to the rubber layer 2 was 33%. A DLC film having a thickness of 1 μm was formed as an amorphous carbon film 4 on the outermost layer of the contact roller 5. Other conditions were the same as in Example 1.

[Comparative Example 1]
As the contact pressure roller 5, a core 1 made of a material STKM13A and coated with chloroprene rubber having a thickness of 5 mm and a hardness of 50 ° (JIS-A) was used. The rubber layer 2 did not contain a substantially spherical filler having an average particle size of 1 μm or more and 100 μm or less, and no DLC film as the amorphous carbon film 4 was formed. Other conditions were the same as in Example 1.

[Comparative Example 2]
A chloroprene rubber having a thickness of 5 mm and a hardness of 50 ° (JIS-A) is coated and molded on the core 1 of the material STKM13A, and a DLC film, which is an amorphous carbon film 4, is formed on the outermost layer of the contact roller 5. I used something. The rubber layer 2 did not contain a substantially spherical filler having an average particle diameter of 1 μm to 100 μm. Other conditions were the same as in Example 1.

[Comparative Example 3]
As the contact pressure roller 5, the roller shown in FIG. 2 was used. The filler 3 was substantially spherical alumina having an average particle diameter of 4 μm, and the volume content of the filler 3 with respect to the rubber layer 2 was 62%. Other conditions were the same as in Example 1.

[Comparative Example 4]
As the contact pressure roller 5, the roller shown in FIG. 2 was used. The filler 3 was substantially spherical alumina having an average particle diameter of 200 μm, and the volume content of the filler 3 relative to the rubber layer 2 was 33%. Other conditions were the same as in Example 1.

[Comparative Example 5]
As the contact pressure roller 5, the roller shown in FIG. 2 was used, the surface length was 1100 mm, and the outer diameter was 220 mm. Other conditions were the same as in Example 1.

[Comparative Example 6]
The contact roller 5 is made of chloroprene rubber having a thickness of 5 mm and a hardness of 50 ° (JIS-A) coated on the core 1 of the material STKM13A. The DLC film which is the amorphous carbon-like film 4 was not formed. As the film 10, a polyethylene terephthalate (PET) film having a width of 1000 mm, an average thickness of 5 μm, and a surface having an arithmetic average roughness Ra = 5 nm as defined in JIS B0601: 2013 and rougher than other conditions was used. Other conditions were the same as in Example 1.

[Comparative Example 7]
The contact roller 5 is made of chloroprene rubber having a thickness of 5 mm and a hardness of 50 ° (JIS-A) coated on the core 1 of the material STKM13A. 3 and no DLC film, which is an amorphous carbon film 4, was formed. The film 10 was a polypropylene (PP) film having a width of 1000 mm, an average thickness of 5 μm, and an arithmetic average roughness Ra = 10 nm whose surface is defined by JIS B0601: 2013. Other conditions were the same as in Example 1.

[Method for evaluating charging defects]
After rolling up, the occurrence of charging defects was confirmed. The presence or absence of charging defects was evaluated by sprinkling toner for copying on the film 10. Toner adheres to the charged portion. If no charging defect is confirmed in 100, “◎”, if charging defect is confirmed in 1 to 3 out of 100, “◯”, charging defect in 4 out of 100 is 9 When the number was confirmed below, it was judged as “Δ”, and when 10 or more of 100 charging defects were confirmed, it was judged as “x”.

[Evaluation method of transfer marks]
After winding up, the occurrence of transfer marks was confirmed. “○” indicates that no transfer trace is confirmed in 100, “△” indicates that transfer trace is 1 to 9 in 100, and “△” indicates transfer trace in 10 or more. If it was, it was determined as “×”.

[Wrinkle evaluation method]
After rolling up, the occurrence of wrinkles was confirmed. “O” when 3 or less wrinkles are confirmed in 100, “△” when 4 or more wrinkles are confirmed in 100 or less, and “△” when wrinkles are confirmed in 10 or more out of 100. It was determined as “x”.

[Method for evaluating surface condition of contact roller]
The surface state of the contact pressure roller 5 after winding 10 film rolls 12 was confirmed. When there is no particular problem, “◯”, when the filler 3 is removed from a part of the rubber layer 2, and when wear powder is generated on the surface of the contact pressure roller 5, “△”, When the rubber layer 2 was brittle and the rubber layer 2 collapsed at the molding stage, it was determined as “x”.

  Table 1 summarizes the conditions and evaluation results of Examples 1 to 10 and Comparative Examples 1 to 7. In the table, the conditions surrounded by the thick-lined cells are the parts where the conditions are changed from the first embodiment.

  In Examples 1 to 10, the rubber layer 2 of the contact roller 5 contains substantially spherical alumina particles having an average particle diameter of 1 μm or more and 100 μm or less in a volume content of 30% or more and 50% or less. And the outer diameter of the contact pressure roller 5 is 25 mm or more and 130 mm or less, the contact area with the film roll 12 is smaller than that of the normal contact pressure roller 5, and good results for charging defects are obtained. Met.

  In Example 2, the rubber layer 2 of the pressure roller 5 contains 46% of substantially spherical alumina particles having an average particle diameter of 4 μm exceeding the volume content of 40%, so that the surface of the pressure roller 5 is slightly increased. As a result, the filler 3 was detached, and the abrasion powder of the rubber layer 2 was slightly adhered to the surface of the contact roller 5.

  In Example 4, the rubber layer 2 of the contact roller 5 contained substantially spherical alumina particles having an average particle size of 95 μm, resulting in slight transfer marks.

  In Example 5, since the outer diameter of the contact pressure roller 5 was 120 mm, the rubber layer 2 was slightly deformed and wrinkles were slightly generated.

  In Example 6, since the rubber layer 2 of the contact roller 5 is a high hardness rubber having a hardness of 75 °, a better result was obtained with respect to charging defects, but the deformation of the rubber layer 2 was slightly Inhibited, resulting in slight wrinkling.

  In Example 7, PP was used as a raw material for the film 10. Many fibrils were formed in the PP film, which is a crystalline polymer, and the arithmetic average roughness Ra was 10 nm, which was rough as compared with the PET film, and the result for the charging defect was better than the PET film.

  In Example 8, a DLC film is formed on the outermost layer of the contact roller 5, wear of the surface of the contact roller 5 is prevented, and PET is used as a raw material for the film 10. Since the charged column and the charged column of the film 10 are close to each other, a better result with respect to the charging defect is obtained.

  In Example 9, since the rubber layer 2 of the contact roller 5 is a high hardness rubber having a hardness of 60 °, a better result was obtained with respect to charging defects.

  Furthermore, in Example 10, the DLC film was formed on the outermost layer of the high hardness rubber having a hardness of 60 ° in the rubber layer 2, and the best result was obtained with respect to charging defects.

  On the other hand, in Comparative Examples 1 and 2, since the rubber layer 2 of the contact pressure roller 5 does not contain the filler 3 having an average particle diameter of 1 μm or more and 100 μm or less, the contact area between the contact pressure roller 5 and the film 10 is large, and charging defects The incidence was high.

  In Comparative Example 3, the rubber layer 2 of the contact pressure roller 5 contains substantially spherical alumina particles having an average particle diameter of 4 μm in a volume content of 62% exceeding 50%. The result was that molding was impossible.

  In Comparative Example 4, since the rubber layer 2 of the pressure roller 5 contains approximately spherical alumina particles having an average particle diameter of more than 100 μm and 200 μm, irregularities on the surface of the pressure roller 5 become excessively large, and the occurrence rate of transfer marks is high. The result was.

  In Comparative Example 5, although the rubber layer 2 of the contact pressure roller 5 contained substantially spherical alumina particles having an average particle diameter of 4 μm and a volume content of 33%, the outer diameter of the contact pressure roller 5 was 220 mm exceeding 130 mm. As a result, the contact area between the pressure roller 5 and the film 10 is increased, the charging defect occurrence rate is high, and the effect of blocking the air accompanying the inner layer of the film roll 12 is impaired. 12 resulted in wrinkles.

  In Comparative Example 6, the rubber layer 2 of the contact roller 5 does not contain the filler 3 having an average particle diameter of 1 μm or more and 100 μm or less as in Comparative Example 1, but the arithmetic average roughness Ra = 5 nm and relatively rough surface. As a result of applying the film 10, almost no charging defects occurred.

  In Comparative Example 7, as a result of applying the PP film 10 having an arithmetic average roughness Ra = 10 nm and a relatively rough surface, the rubber layer 2 of the pressure roller 5 does not contain the filler 3 having an average particle diameter of 1 μm to 100 μm. However, almost no charging defects occurred. However, as compared with Example 7 in which the rubber layer 2 of the contact pressure roller 5 contained the filler 3 having an average particle diameter of 1 μm or more and 100 μm or less, the incidence of charging defects was slightly increased.

  Thus, according to the present invention, the film 10 can be obtained by using the contact pressure roller 5 that contains the filler 3 in the rubber layer 2, has an uneven shape on the surface, and has a small deformation amount of the rubber layer 2. Even when the film is smooth, charging of the film 10 is suppressed, and the film roll 12 having no charging defects can be provided.

  The present invention can be applied not only to a contact pressure roller used for winding a film into a roll but also to a sheet-like material handling technique, but the application range is not limited thereto.

1: Core 2: Rubber layer 3: Filler 4: Amorphous carbon film (DLC film)
5: Contact roller 6: Original fabric 7: Guide roller 8: Lower blade roller 9: Upper blade 10: Film 11: Core 12: Film roll 13: Static eliminator 14: Unwinding unit 15: Conveying unit 16: Slit unit 17 : Winding part A: conveyance direction B: contact pressure roller surface layer part C: contact pressure roller surface layer part D: contact pressure roller surface layer part E: contact pressure roller surface layer part F: contact pressure roller surface layer part G: contact pressure roller surface layer part H: Contact roller surface layer

Claims (5)

A substantially cylindrical core member;
A rubber layer coated on the surface of the core member, wherein a substantially spherical filler having an average particle size of 1 μm or more and 100 μm or less is contained in the rubber layer at a volume content of 30% or more and 50% or less with respect to the rubber layer. A contact pressure roller including a rubber layer,
The rubber layer has a portion where the filler is exposed from the surface of the rubber layer, and / or a portion where the surface of the rubber layer protrudes including the filler inside,
A contact pressure roller having an outer diameter of 25 mm or more and 130 mm or less.   The pressure roller according to claim 1, wherein the rubber layer has a portion where the filler is exposed from the surface of the rubber layer, and the surface of the rubber layer is covered with an amorphous carbon-like film layer.   The contact roller according to claim 2, wherein a portion of the filler exposed from the surface of the rubber layer is covered with an amorphous carbon-like film layer.   2. The contact pressure according to claim 1, wherein the rubber layer has a portion in which the surface of the rubber layer is raised with the filler contained therein, and the surface of the rubber layer is covered with an amorphous carbon layered film layer. roller.   The pressure roller according to claim 1, wherein the rubber layer has a hardness of more than 55 ° and not more than 70 ° according to JIS-A.

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