JP2022052248A - Laminating apparatus and film laminate manufacturing method - Google Patents

Abstract

To provide a laminating apparatus for sticking films together and capable of stably laminating a first film and a second film by suppressing wrinkles generated on the second film.SOLUTION: An laminating apparatus comprises a first film unwinding part for unwinding a first film, a second film unwinding part for unwinding a second film, a laminating part for sticking the unwound first film and second film together to form a film laminate, and a winding part for winding the film laminate formed by sticking the first film and the second film together. The laminating part comprises a pair of laminate rollers sandwiching the first film and the second film. One roller of the laminate rollers has roller end diameter increasing means. The roller end roller diameter increasing means increases a roller diameter at a roller end and gives a reverse crown shape in which the roller diameter increases from a roller center part toward the roller end. A maximum outer diameter of the roller at the roller end can be changed by a stop ring.SELECTED DRAWING: Figure 4

Description

The present invention relates to a laminating apparatus for laminating films to each other and a method for manufacturing a film laminate.

The technology to continuously form a functional film by rewinding a long roll-up base material such as paper or plastic film and forming a film by a film forming method such as a gravure printing method or a vapor deposition method in vacuum is gold. It is used as a method for manufacturing optical films such as metallic glossy films used for silver threads, gas barrier films for food packaging, electrodes for film condensers, and antireflection. The demand for quality of these products is increasing year by year, and it is necessary to reduce the thickness and size of defects.

For example, for an optical film or the like, a long roll-shaped film is subjected to surface treatment such as coating and drying, and then returned to the roll-shaped film again. These may be performed multiple times, and foreign matter adhering before coating may be applied together, causing foreign matter defects, contact between the film surface and the roller, or winding in a roll-shaped film. It is possible that the film surface may be scratched due to misalignment, winding tightness, etc., and it is necessary to take measures against these.

Therefore, in order to meet these demands, it is considered effective to protect the film surface to ensure its performance, and it is known to laminate a protective film on the film surface.

As another method of utilizing the laminating technology, the laminating technology is also utilized in the method of laminating a base material having a thin film on the base base material to transfer the thin film to produce a multi-layered functional base material. ing.

Since laminating can be done by laminating two base materials, a method of inserting a laminated base material immediately before the take-up roll is also used, but in general, the base of the base is used. It is the mainstream that the material and the laminating base material are laminated by being nipated by two rollers. At this time, the two base materials need to be laminated on each other's planes, and if the base material has wrinkles or the like, gaps or the like are formed between the base base material and the laminated base material, resulting in poor adhesion. In order to solve this problem, the rollers shown in Patent Documents 1 and 2 have been proposed.

Patent Documents 1 and 2 show a technique for reducing wrinkles of a base material to be bonded at the time of laminating. In Patent Document 1, wrinkles of the base material can be reduced by arranging a guide member made of a rod-shaped body or a crown-shaped roller symmetrically curved in an arch shape immediately before the laminating roller.

In Patent Document 2, the tension in the width direction of the film immediately before the laminated portion is measured with respect to the transport direction of the film, and the two rollers of the laminated portion are formed into a crown shape (middle convex shape) or an inverted crown based on the measurement result. By controlling the shape (concave shape), it is possible to suppress the occurrence of wrinkles in the film.

In addition, at least one roller used for the laminating part has a structure in which both ends thereof can be deformed into an inverted crown shape by swelling, and wrinkling is suppressed by pulling the film outward in the width direction. In addition, there is a laminating part wrinkle removing roller method for laminating.

Japanese Unexamined Patent Publication No. 2008-168598 Japanese Unexamined Patent Publication No. 2013-226733

When laminating a second film such as a protective film on a first film such as a base material, or when the tension of the base material or protective film becomes excessive, the thickness distribution of the base material or protective film in the width direction of itself becomes large. Wrinkles may occur if there is a large deviation in the horizontal or parallel (alignment) between the rollers, or if the rollers are deformed due to the deflection or nip of the rollers due to their own weight. There is. In order to solve this problem, it is important to optimize the tension of the base material or the protective film, maintain the alignment above a certain level, and give the laminate roller sufficient rigidity.

However, the occurrence of wrinkles may be caused by a change in the state such as the thickness distribution in the width direction of the first film such as a base material or the second film such as a protective film. For example, the base base material is affected by, for example, the coating film forming state in the previous step, and the entire surface of the base material is not always in the same state, and a phenomenon of curling may occur at the end of the film, for example. In this case, the tension in the width direction of the base material is non-uniform, which causes wrinkles when laminating the base material of the first film and the protective film of the second film.

In addition, a first film such as various base materials and a second film such as a protective film may be used even in the same process and device. There are various combinations of the first film and the second film to be used. Similarly, reduction of wrinkles is required in the combination of these various first films and second films.

In the apparatus described in Patent Document 1, a guide member composed of a rod-shaped body or a crown-shaped roller curved symmetrically in an arch shape is arranged immediately before the laminating roller, but there is a distance from the guide roller to the laminating roller. Therefore, even if wrinkles are suppressed by this guide roller, the tension in the width direction of the base material becomes non-uniform between the guide roller and the laminating roller, which causes wrinkles and causes laminating defects. It will occur.

In the apparatus described in Patent Document 2, since the shape of the laminating roller changes at any time depending on the wrinkle generation situation, the nip pressure in the width direction in laminating the first film such as a base material and the second film such as a protective film. It is expected that unevenness will appear. That is, when a large number of wrinkles occur on the second film such as the protective film, stable laminating is difficult.

Further, in the laminated wrinkle removing roller method, the amount of swelling at both ends of the roller is fixed, and the amount of swelling at both ends of the roller is not always optimal when laminating various types of substrates and protective films. , Wrinkles may not be sufficiently reduced in the laminated part.

The present invention has been made in view of the above problems, suppresses wrinkles generated on a second film such as a protective film as a laminated base material, and suppresses wrinkles, and is a second film such as a first film such as a base material and a protective film. It is an object of the present invention to provide a laminating apparatus capable of stably laminating a film and a method for producing a film laminate.

The present invention has been made to solve the above problems, and the invention according to claim 1 of the present invention is a laminating apparatus in which a long second film is bonded to a long first film to form a film laminate. The first film unwinding part that unwinds the long first film, the second film unwinding part that unwinds the long second film, and the unwound first film and the second film. It is provided with a laminating portion for forming a laminated film laminate and a winding portion for winding up the film laminate to which the first film and the second film are bonded, and the laminated portion is the first film and the first. (Ii) A pair of laminating rollers sandwiching the film are provided, one of the laminating rollers has a roller end diameter increasing means, and the roller end roller diameter increasing means increases the roller diameter of the roller end. The laminating device is provided with an inverted crown shape in which the roller diameter increases from the center of the roller toward the end of the roller, and the maximum outer diameter of the roller at the end of the roller can be changed by a stop ring.

According to the second aspect of the present invention, the roller end roller diameter increasing means has a gas injection portion built in the roller end, and the roller end roller diameter is changed by the internal pressure of the gas injection portion. The laminating device according to claim 1, wherein the laminating device is made by adjusting the expansion force of the injection portion.

According to the third aspect of the present invention, the roller end roller diameter increasing means has an elastic body built in the roller end, and the roller end roller diameter is changed by adjusting the elastic force of the elastic body. The laminating apparatus according to claim 1, wherein the laminating apparatus is made.

The invention according to claim 4 of the present invention is a film laminate manufacturing method for manufacturing a film laminate using the laminating apparatus according to any one of claims 1 to 3, wherein the first is long. The first film unwinding process for unwinding the film, the second film unwinding process for unwinding the long second film, and the unwound first film and the second film are sandwiched between a pair of laminating rollers and bonded together. The laminating step, the winding step of winding up the film laminate to which the first film and the second film are bonded, and the roller end diameter increasing means of one of the laminating rollers are the roller end. The first film is provided by increasing the roller diameter of the roller, giving an inverted crown shape in which the roller diameter increases from the center of the roller toward the end of the roller, and changing the maximum outer diameter of the roller at the end of the roller by the stop ring. And the step of adjusting the nip pressure in the width direction of the laminating roller when laminating the second film,
It is a film laminate manufacturing method characterized by containing.

Laminating equipment and film laminating capable of suppressing wrinkles generated on a second film such as a protective film as a laminating base material and stably laminating a first film such as a base material and a second film such as a protective film. It has become possible to provide a body manufacturing method.

It is the schematic sectional drawing of the laminating apparatus using the laminating roller (wrinkle removing roller) which concerns on embodiment of this invention. It is a schematic perspective view when the laminating roller (wrinkle removing roller) which concerns on embodiment of this invention is nip with a laminating roller. It is a schematic explanatory drawing when the roller end portion of the laminating roller (wrinkle removing roller) which concerns on embodiment of this invention does not expand. FIG. 3A is a schematic front view of the laminate roller (wrinkle removal roller), and FIG. 3B is a schematic front view of the laminate roller (wrinkle removal roller) of the present invention excluding the elastic body. 3 (c) is a schematic cross-sectional view of a laminated roller (wrinkle removing roller), and FIG. 3 (d) is a schematic side view of the laminated roller (wrinkle removing roller). It is a schematic explanatory drawing when the roller end portion of the laminating roller (wrinkle removing roller) which concerns on embodiment of this invention expands. FIG. 4A is a schematic front view of the laminate roller (wrinkle removal roller), and FIG. 4B is a schematic front view of the laminate roller (wrinkle removal roller) of the present invention excluding the elastic body. 4 (c) is a schematic cross-sectional view of a laminated roller (wrinkle removing roller), and FIG. 4 (d) is a schematic side view of the laminated roller (wrinkle removing roller). It is a schematic perspective view explaining the structure of both ends of the roller core used for the laminating roller (wrinkle removing roller) which concerns on embodiment of this invention. It is a schematic side sectional view at the roller end portion when the laminating roller (wrinkle removing roller) which concerns on embodiment of this invention is nipled with a laminating roller.

Hereinafter, embodiments of the laminating apparatus according to the present invention will be described with reference to the drawings. The drawings used in the following description are for explaining the configuration of the embodiment of the present invention, and the sizes, thicknesses, dimensions, etc. of the illustrated parts are the actual laminating rollers (wrinkle removing rollers) and the drawings thereof. It may be different from the dimensional relationship of the laminating device using. Further, the embodiment of the present invention is not limited to the embodiments described below, and modifications such as design changes can be made based on the knowledge of those skilled in the art, and such modifications are added. These embodiments are also included in the scope of the embodiments of the present invention.

FIG. 1 is a schematic cross-sectional view of a laminating apparatus using a laminating roller (wrinkle removing roller) according to an embodiment of the present invention. FIG. 2 is a schematic perspective view when the laminating roller (wrinkle removing roller) according to the embodiment of the present invention is niped with the laminating roller. The laminating apparatus 100 using the laminating roller (wrinkle removing roller) 1 of the present invention unwinds and conveys the first unwinding film 41 from the first film unwinding roller 11 which is a film unwinding means, while the second winding. The unwinding film (laminated film or the like) 42 is unwound from the second film unwinding roller 12 which is the second film unwinding roll means. After that, the first unwinding film 41 and the second unwinding film (laminated film or the like) 42 are laminated by the laminating portion 101 which is a means for laminating them. The laminating portion 101 laminates the first unwinding film 41 and the second unwinding film (laminated film or the like) 42 between the wrinkle removing laminating roller (wrinkle removing roller) 1 and the laminating roller 2 of the present invention. .. The laminated film laminate 43 is wound by a take-up roller 21 which is a means for winding the film laminate 43.

FIG. 3 is a schematic explanatory view when the roller end of the laminate roller (wrinkle removing roller) according to the embodiment of the present invention does not expand, and FIG. 3A is a schematic front view of the laminating roller (wrinkle removing roller). 3 (b) is a schematic front view of the laminated roller (wrinkle removing roller) of the present invention excluding the elastic body, and FIG. 3 (c) is a schematic view of the laminated roller (wrinkle removing roller). FIG. 3D is a schematic side view of a laminating roller (wrinkle removing roller).

FIG. 4 is a schematic explanatory view when the roller end portion of the laminating roller (wrinkle removing roller) according to the embodiment of the present invention is expanded. FIG. 4A is a schematic front view of the laminate roller (wrinkle removal roller), and FIG. 4B is a schematic front view of the laminate roller (wrinkle removal roller) of the present invention excluding the elastic body. 4 (c) is a schematic cross-sectional view of a laminated roller (wrinkle removing roller), and FIG. 4 (d) is a schematic side view of the laminated roller (wrinkle removing roller).

The laminated roller (wrinkle removing roller) 1 has a laminated roller (wrinkle removing roller) shaft 55 that supports the entire roller at both ends, and the roller portion that comes into contact with the second unwinding film 42 is covered with an elastic body (rubber or the like) 51. ing. When the first unwinding film 41 and the second unwinding film 42 do not have wrinkles and it is not necessary to reduce wrinkles in the laminating portion 101, the laminating roller (wrinkle removing roller) 1 is a roller as shown in FIG. 3 (a). Use the same diameter over the entire width direction. If the first unwinding film 41 and the second unwinding film 42 are wrinkled in the laminating portion 101 and it is necessary to reduce wrinkles, the laminating roller (wrinkle removing roller) 1 has both ends of the rollers as shown in FIG. 4A. It is used by transforming it into a roller with a tapered shape whose outer diameter is gradually larger than that of the inside from a position where the outside of the roller is from the center of the roller toward both outsides. The portions corresponding to both ends of the second unwinding film 42 unwound and conveyed from the second film unwinding roller 12, which is the second film unwinding roll means, are such that both ends of the second unwinding film 42 are on the outside. As the outer diameter of the roller increases, the second unwinding film 42 comes into contact with the roller, so that the transport tension increases toward the outside of both ends, and the wrinkles generated on the second unwinding film 42 become outward. By flowing, it is finally possible to eliminate wrinkles.

FIG. 3B shows a schematic front view of the laminated roller (wrinkle removing roller) 1 of the present invention excluding the elastic body of the outer peripheral portion when the roll end portion does not expand. FIG. 4B is a schematic front view of the laminated roller (wrinkle removing roller) 1 of the present invention excluding the elastic body on the outer peripheral portion of the laminating roller (wrinkle removing roller) 1 when the roller end is expanded. When the elastic body (rubber or the like) 51 on the outer peripheral portion is removed from the roller (wrinkle removing roller) 1, it is covered with the laminated roller (wrinkle removing roller) roller core 56. The elastic body taper deformed portion 51a of the elastic body 51 that forms the spread of the roller end of the laminated roller (wrinkle removing roller) 1 is a roller core tapered deformed portion 56a of the laminated roller (wrinkle removing roller) roller core 56 inside the elastic body 51. Made by.

FIG. 3 (c) is a schematic cross-sectional view of the laminate roller (wrinkle removing roller) 1 when the roller end of the laminating roller (wrinkle removing roller) 1 does not expand, and FIG. 4 (c) is a schematic cross-sectional view of the laminating roller (wrinkle removing roller) 1. It is a schematic cross-sectional view of the laminating roller (wrinkle removing roller) 1 when the roller end portion of the removing roller) 1 is expanded.

Here, the roller end roller diameter increasing means has a gas injection part 61 such as a tube built in the roller end, and the roller end roller diameter can be changed by the gas injection part (tube) due to the internal pressure of the gas injection part (tube) 61. It is done by adjusting the expansion force of 61.

The operation of the laminating roller (wrinkle removing roller) 1 is to insert gas into the gas injecting part (tube) 61 from the gas inserting parts 63 at both ends of the laminating roller (wrinkle removing roller) 1 to form a gas injecting part (tube) 61. The gas injection portion (tube) 61 pushes up the roller core taper deformed portion 56a to realize a tapered spread on both ends of the laminate roller (wrinkle removing roller) 1. The taper amount of the tapered spread is obtained by defining the retaining ring hooking portion 64 attached to the end of the roller core taper deformed portion 56a against the retaining ring (for taper) 65a. Therefore, the taper amount of the tapered spread at both ends of the laminating roller (wrinkle removing roller) 1 is defined by the inner diameter of the retaining ring (for taper) 65a. Therefore, if a plurality of retaining rings (for taper) 65a having different inner diameters are prepared and used, a laminated roller (wrinkle removing roller) 1 having various taper amounts can be obtained, and the taper amount of taper spread suitable for various degrees of wrinkles. Can be. Further, when the first unwinding film 41 and the second unwinding film 42 do not have wrinkles and it is not necessary to reduce wrinkles in the laminating portion 101, a laminating roller (wrinkle removing roller) is used by using a retaining ring 65 having a taper of 0. ) 1 can also be used with the same diameter in the entire width direction of the roller.

As another structure, the laminating roller (wrinkle removing roller) shaft 55 and the laminating roller (wrinkle removing roller) roller core 56 are connected via a bearing 60, and the laminating roller (wrinkle removing roller) shaft 55 and the gas injection portion ( A bush 62 is provided between the tubes) 61. Therefore, even if both ends of the laminating roller (wrinkle removing roller) shaft 55 are fixed, the other members can rotate in the circumferential direction.

FIG. 5 is a schematic perspective view illustrating the structure of both ends of the roller core used in the laminated roller (wrinkle removing roller) 1 according to the embodiment of the present invention. FIGS. 3 (c) and 4 (c) show that the roller core tapered deformed portion 56a is deformed by the gas injection portion (tube) 61 to provide tapered spreads at both ends of the laminate roller (wrinkle removing roller) 1. However, in order to realize this deformation, slits 56b are provided at both ends of the laminate roller (wrinkle removing roller) roller core 56. The slits 56b are arranged at equal intervals in the circumferential direction at both ends of the laminated roller (wrinkle removing roller) roller core 56, and the slit length of the slit 56b is from both ends to the position where the taper is desired to be realized toward the center side of the roller in the roller width direction. prepare. Through this slit 56b, the gas injection portion (tube) 61 pushes up the roller core tapered deformed portion 56a evenly from the inside in the radial direction, and the slit 56b expands so as to be larger toward the roller end side, thereby realizing a tapered shape. ing. If the number of slits 56b is two or more, it can be expanded, but the larger the number, the more the slits can be deformed in a shape closer to a perfect circle, so six or more slits are desirable. In addition, the roller core taper deformed portion 56a is used by fixing it with the amount of deformation within the elastic deformation.

FIG. 6 is a schematic side sectional view of a roller end portion when the laminating roller (wrinkle removing roller) 1 according to the embodiment of the present invention is niped with the laminating roller. The laminated roller (wrinkle removing roller) 1 has an outer diameter that increases from the inside to the outside of the roller, that is, has an inverted crown shape. At that time, if the laminated roller 2 and the laminated roller 2 are niped while maintaining the inverted crown shape, the central portion of the roller floats and the central portions of the first unwinding film 41 and the second unwinding film 42 are not niped. Will be. However, in the laminated roller (wrinkle removing roller) 1 of the present invention, the expanded portions at both ends are expanded by injecting a gas such as compressed air, and the pressure of the gas can be changed, for example, the laminated roller (wrinkle removing roller). By expanding with a pressure much smaller than the nip pressure of the take roller) 1 and the laminate roller 2, the portion in contact with the laminate roller 2 as shown in FIG. 6 is crushed at the time of niping, so that the central portion of the roller floats. There is no such thing.

In this way, by adjusting the gas that injects the expansion force at both ends, the pressure balance at the time of niping in the film width direction when the first unwinding film 41 and the second unwinding film 42 are bonded is adjusted. Can be done. By adjusting this pressure balance and keeping the entire width nip pressure of the laminating roller (wrinkle removing roller) 1 and the laminating roller 2 within the effective nip pressure range, good laminating can be performed.

Further, in the present embodiment, the tapered shape is realized by the pressure of the gas injected into the gas injection portion (tube) 61, but the taper shape is realized by arranging a spring and changing the spring constant, not limited to the gas. ) 61 and the gas inside the gas can have the same effect as adjusting the pressure. Therefore, a spring may be used instead of the gas injection part (tube) 61 and the gas.

As described above, according to the laminating apparatus using the laminating roller (wrinkle removing roller) of the present invention, it is possible to produce a film laminate without wrinkles.

In the laminating apparatus and the film laminate manufacturing method of the present invention, since a second film such as a protective film can be bonded to a first film such as a roll-up base material, a metallic glossy film or food used for gold and silver threads. It can be used for manufacturing gas barrier films for packaging, electrodes for film capacitors, optical films for antireflection, etc., and for manufacturing multilayer films transferred by laminating a functional layer on a base substrate.

1 ... Laminate roller (wrinkle removal roller)
1a ... Wrinkle removal roller (with the elastic body on the outer circumference removed)
2 ... Laminate roller 11 ... First film unwinding roller 12 ... Second film unwinding roller 21 ... Winding roller 31 ... Free roller 41 ... First unwinding film 42 ...・ ・ Second unwinding film 43 ・ ・ ・ Film laminate 51 ・ ・ ・ Elastic body (rubber, etc.)
51a ... Elastic body taper deformed part 55 ... Laminate roller (wrinkle removing roller) shaft 56 ... Laminate roller (wrinkle removing roller) Roller core 56a ... Roller core Tapered deformed part 56b ... Slit 60 ...・ ・ Bearing 61 ・ ・ ・ Gas injection part (tube)
62 ... Bush 63 ... Gas insertion part 64 ... Retaining ring hooking part 65 ... Retaining ring 65a ... Retaining ring (for taper)
100 ... Laminating device 101 ... Laminating part

Claims (4)

It is a laminating device that forms a film laminate by laminating a long second film on a long first film.
The first film unwinding part that unwinds the long first film,
The second film unwinding part that unwinds the long second film,
A laminating part that forms a film laminate by laminating the unwound first film and second film,
A winding unit that winds up the film laminate to which the first film and the second film are bonded,
Equipped with
The laminating portion includes a pair of laminating rollers that sandwich the first film and the second film.
One of the laminated rollers has a roller end diameter increasing means.
The roller end roller diameter increasing means increases the roller diameter of the roller end portion, imparts an inverted crown shape in which the roller diameter increases from the roller center portion toward the roller end portion, and also provides a roller end roller diameter increasing means. A laminating device characterized in that the maximum outer diameter can be changed by a stop ring. The roller end roller diameter increasing means has a gas injection portion built in the roller end, and the roller end roller diameter can be changed by adjusting the expansion force of the gas injection portion due to the internal pressure of the gas injection portion. The laminating apparatus according to claim 1, wherein the laminating apparatus is used. The roller end roller diameter increasing means has an elastic body built in the roller end, and the roller end roller diameter is changed by adjusting the elastic force of the elastic body. The laminating device described in. A film laminate manufacturing method for manufacturing a film laminate using the laminating apparatus according to any one of claims 1 to 3.
The process of unwinding the first film, which unwinds the long first film,
The second film unwinding process, which unwinds a long second film,
A laminating process in which the unwound first film and second film are sandwiched between a pair of laminating rollers and bonded together.
The winding step of winding up the film laminate in which the first film and the second film are bonded together,
The roller end diameter increasing means of one of the laminated rollers increases the roller diameter of the roller end, and imparts an inverted crown shape in which the roller diameter increases from the center of the roller toward the end of the roller. A step of adjusting the nip pressure in the width direction of the laminated roll when the first film and the second film are bonded by changing the maximum outer diameter of the roller at the end of the roller by the retaining ring.
A method for producing a film laminate, which comprises.

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