JP5522544B2 - Resin film roll and method for producing the same - Google Patents

Description

  The present invention relates to a resin film roll having excellent processability such as no scratches during processing, no meandering and displacement during conveyance, and good flatness and winding shape of a film, and a method for producing the same. More specifically, a resin film roll, particularly a flat panel, which has a very smooth winding shape and flatness while being highly smooth and can suppress the occurrence of scratches and displacement even when a functional layer is laminated on the film surface. The present invention relates to a resin film roll suitable for a display, a touch panel, and a surface decoration film, and a method for producing the same.

  Resin films are widely used for various applications because of their excellent physical properties and excellent productivity. Particularly in recent years, the amount used as a display material for flat panel display applications and touch panel applications, and as a base material for surface protection / decorative films, etc., has been increasing with the growth of the IT field. In such applications, high transparency is required, so there is almost no inert particles added as easy-to-slip materials to general packaging films and industrial material films, and a very smooth surface. have. Therefore, the transportability in the film manufacturing process and the processing process is poor, and the film layer is twisted on the transport roll, the surface is scratched due to the meander on the roll, or finally wound on the roll. The air layer entrained in the air may become difficult to escape and cause winding slippage.

  As a method for improving such a problem, a method of forming a protrusion shape by embossing at both end portions of a film has been proposed (Patent Document 1 and Patent Document 2). However, the demand for defects such as scratches on the film surface has become more severe with the recent increase in the definition of displays typified by touch panel applications. Therefore, scratches caused by rubbing on the film roll during film winding, transfer defects due to dust trapped between the layers, scratches generated in the processing process of laminating functional layers such as a hard coat layer applied on the film surface, etc. are highly advanced. There is an increasing need to manage.

  Patent Documents 1 and 2 disclose a technique for optimizing the amount of air that is wound when a film is wound into a roll shape by protrusion processing performed near both ends of the film roll. However, as described above, a high protrusion is required in order to newly exhibit the function of preventing scratching and shifting by the protrusion structure in a state where the functional layer is laminated on the film surface. As a result, when the resin film is wound into a roll, the hardness and shape of the roll become non-uniform due to the difference in film thickness between the protrusion structure part at the width direction end and the product part at the center part in the width direction. There was a problem that the flatness of the film deteriorated in the vicinity of the protrusion processing site. In recent years, in particular, slight flatness defects cause distortion of images, uneven thickness of functional layers, and defects, and therefore it is required to maintain flatness strictly. It was difficult to maintain a high level of flatness.

JP 2000-272003 A JP 2010-36519 A

  In view of the problems of the prior art, the object of the present invention is less likely to cause scratches and defects in the film processing step of laminating a functional layer on a film, and further suitable for processing in terms of preventing meandering and displacement during transportation. It is providing the resin film roll which is excellent in the flatness of a film, and its winding form, and its manufacturing method.

  In order to solve the above problems, the resin film roll according to the present invention has the following configuration.

(1) A resin film roll obtained by winding a resin film in the film longitudinal direction, and having a protrusion band composed of one or a plurality of protrusions in a film region having a distance from both ends of the film width direction of 100 mm or less, The protrusion band extends in the film longitudinal direction, the width (a) of the protrusion band is 5 to 20 mm, and the position of the protrusion band with respect to the film width direction changes along the film longitudinal direction. Characteristic resin film roll.

(2) The position of the protrusion band with respect to the film width direction changes periodically along the film longitudinal direction, and the amount of change (b) is not less than 1 and not more than 5 times the width (a) of the protrusion band. (1) Resin film roll.

(3) The roll diameter of the resin film roll is 300 to 800 mm, and the edge height in a film region whose distance from the film ends on both sides is within 100 mm is 200 to 1500 μm. (1) or (2) Resin film roll.

(4) The protrusion band is composed of an assembly of independent protrusions, the average area of each deformation portion in the protrusion band is 0.03 to 0.20 mm ² , and the area ratio of the deformation portion in the protrusion band The resin film roll according to any one of (1) to (3), wherein 3 to 10% by area and the average height of the protrusion band is 4 to 10 μm.

(5) The resin film roll of (1) to (4), wherein the resin constituting the resin film is made of polyethylene terephthalate resin, polyethylene naphthalate resin or polyphenylene sulfide resin.

(6) The resin film roll according to (1) to (5), wherein the resin film has a surface roughness (SRa) of 5 nm or less and a ten-point average roughness (SRz) of 300 nm or less.

  Moreover, in order to achieve the said objective, the manufacturing method of the resin film roll which concerns on this invention has the following structures.

(7) The film band having a distance of 100 mm or less from both ends in the film width direction has a protrusion band composed of one or a plurality of protrusions, and the protrusion band extends in the film longitudinal direction. A method of manufacturing a resin film roll obtained by winding a resin film having a width (a) of 5 to 20 mm in the longitudinal direction of the film,
A protrusion applying step of providing a protrusion band with a protrusion applying roll in a film region having a distance from both ends of the resin film in the film width direction of 100 mm or less,
A cutting step of cutting the resin film at both ends in the film width direction;
A winding step of winding the resin film,
In the projection application step, the film width direction position of the projection application site in the projection application roll is periodically changed with respect to the width direction position of the film cutting site to be cut in the cutting step. Film roll manufacturing method.

(8) Periodically changing the position of the film cutting part to be cut in the cutting process with respect to the film width direction and the position of the film winding part to be wound up in the winding process with respect to the film width direction, and cutting the film The amount of change in the film width direction of the part and the film winding part in both the amount of change in the film width direction of the protrusion applying part in the protrusion applying roll relative to the position of the cutting part in the film width direction (7) The manufacturing method of the resin film roll of changing so that it may become larger.

  According to the present invention, there are few scratches and defects in the film processing step for laminating the functional layer on the film, etc., and it is excellent in workability in that it can prevent meandering and displacement during transportation, and the film winding shape is good. A resin film roll in which the flatness of the film is highly maintained can be obtained.

It is a schematic perspective view of the resin film roll which concerns on one embodiment of this invention. It is the schematic plan view which showed an example of the protrusion band in the resin film roll of this invention. It is the schematic plan view which showed the other example of the protrusion band in the resin film roll of this invention. It is the schematic perspective view which showed an example of the protrusion provision apparatus used for the manufacturing method of the resin film roll of this invention. It is the schematic perspective view which showed an example of the protrusion provision apparatus which has the protrusion provision roll used for the manufacturing method of the resin film roll of this invention which the position of a film width direction changes periodically. It is the schematic block diagram which showed an example of the protrusion provision process, the cutting process, and the winding process which were continuous with the film manufacturing process in the manufacturing method of the resin film roll of this invention. It is the schematic block diagram which showed an example of the protrusion provision process included in the slit process, the cutting process, and the winding-up process in the manufacturing method of the resin film roll of this invention.

  The resin film roll has a protrusion band composed of one or a plurality of protrusions in a region having a distance of 100 mm or less from the extreme ends on both sides in the width direction. By providing protrusion bands at both ends of the resin film roll, the film is prevented from shifting when the film is wound into a roll and when the film comes into contact with the transport roll, and between the films wound into a roll. By holding an appropriate air layer, it is possible to prevent scratches caused by rubbing the film and transfer defects due to minute dust between the film layers. In particular, in a film having a highly smooth surface, when there are no protrusion bands at both ends in the width direction, scratches due to rubbing during conveyance or winding, and deviation during winding are likely to occur. In addition, when the protrusion band is provided only at one end portion, there is a possibility that a sufficient effect may not be exhibited due to the deterioration of the balance between both end portions. In addition, about the position which forms a projection belt | band | zone, a projection belt | band | zone is provided so that the whole projection belt | band | zone may enter into the film area | region within the distance of 100 mm or less, preferably the film area | region within 50 mm from the width direction most end part. If the protrusion band is located in the inner region of the film that exceeds 100 mm from the outermost end, the air layer that has been wound on the center side of the film at the time of winding may be unevenly removed, or finally the functional layer There is a possibility that problems such as an increase in cost may occur due to a narrow film region that can be collected as a functional film product provided on the film surface.

  The protrusion band is composed of one or a plurality of protrusions. Here, the protrusion is a deformation in the height direction on the resin film surface, and a part of the protrusion has a convex shape with respect to the film surface. The deformation shape of the film surface is generally an uneven shape having a dent-like deformation and a convex deformation at the same time. By deforming the film surface into a convex shape, it becomes possible to prevent slipping during conveyance and winding, or to hold an appropriate air layer between the film layers when wound into a roll. Moreover, it is preferable that the protrusion band is an aggregate composed of a plurality of independent protrusions. An independent protrusion is a protrusion that is not continuous with other deformed portions when the deformed portion is observed and exists in an independent state. In the case where the protrusion band is composed of a plurality of independent protrusions, an appropriate air layer can be discharged from the gap between the protrusion bands, so that a better winding shape can be obtained.

Preferably has an average area of each deformed portion of said discrete protrusions is 0.03~0.20mm ^2, further preferably 0.05~0.18mm ^2. If the average area is less than 0.03 mm ² , the effect as a protrusion band may be insufficient, and the wound shape and scratches in the processing process may be deteriorated, or the deformation variation for each protrusion may increase. Yes, not preferred. Further, when the average area exceeds 0.20 mm ² , there is a tendency that the air layer on the roll center side is insufficiently discharged or the protrusion height is insufficient, and as a result, the wound shape and scratches in the processing process are deteriorated. There is fear and it is not preferable.

  The average height of the protrusion band is preferably 4 to 10 μm, and more preferably 5 to 8 μm. When the average height of the protrusion band is less than 4 μm, the protrusion height is insufficient, so that the effect of stabilizing the winding shape and preventing scratches at the time of processing is insufficient. When the average height exceeds 10 μm, the protrusion height Is too high, the rolled form and the flatness of the film tend to deteriorate.

  The area ratio of the deformed portion in the protrusion band (the area ratio of the deformed portion in the protrusion band) is preferably 3 to 10 area%. When the area ratio of the deformed portion is less than 3% by area, the protrusion area is small, so the wound shape and scratches during processing deteriorate, or the height of the protrusion band varies depending on the location with a slight change in conditions. This tendency is not preferable. In addition, when the area ratio of the deformed portion exceeds 10 area%, the protrusion height tends to be insufficient. As a result, the wound shape and scratches at the time of processing deteriorate, or high temperature and high pressure try to obtain a high protrusion. When the protrusion-imparting roll is pressed, the height of the protrusion band tends to vary depending on the location, which is not preferable.

  The width of the protrusion band is 5 to 20 mm, and preferably 7 to 15 mm. When the width of the protrusion band is less than 5 mm, the effect of preventing the deviation due to the protrusion band becomes insufficient, and there is a risk that the wound shape and scratches during processing will deteriorate. When the width of the protrusion band exceeds 20 mm, scratches may be deteriorated in the winding shape and the processing process due to insufficient discharge of the air layer at the center of the roll and a tendency for the protrusion height to be insufficient.

  The protrusion band is formed continuously in the longitudinal direction of the film roll. “Consecutively” as used herein refers to a state in which a protrusion band formed of an aggregate of one or a plurality of protrusions is formed without interruption. Specifically, the distance between the closest deformed portions is less than 20 mm. As shown, the protrusion band is formed without interruption over the entire length of the product part excluding the core of the film roll and the surplus part of the surface layer. If protrusion bands are not formed continuously, the holding force of the air roll existing between the films and the gripping force of the transport roll and the film during processing vary depending on the location, so the winding shape, flatness, and surface scratches deteriorate. There are things to do.

  The method of obtaining the film roll having the area of the deformed portion, the height of the protrusion, and the width of the deformation band is not particularly limited, and may be adjusted according to the conditions such as the design of the protrusion applying roll and the temperature / pressure at the time of applying the protrusion. Is possible.

  The amount of edge height in the region where the distance from the extreme end on both sides of the film roll is within 100 mm is preferably 200 to 1500 μm, and more preferably 300 to 1200 μm. When the height of the edge is less than 200 μm, the effect of preventing the deviation due to the protrusion band when the film is wound on a roll may be insufficient, which is not preferable. On the other hand, if it exceeds 1500 μm, the flatness of the film may be deteriorated, which is not preferable. In addition, as a method of adjusting the height of the helicopter to the above-mentioned range, there is a method of changing the width direction position of the protrusion band according to the film longitudinal direction position.

  The position of the protrusion band with respect to the film width direction varies depending on the position of the film in the longitudinal direction. Further, the amount of change (b) [mm] and the width (a) [mm] of the protrusion band preferably satisfy the relational expression a ≦ b ≦ 5a, and more preferably satisfy the relational expression 2a ≦ b ≦ 4a. . If the position of the projection band in the width direction does not change, when the film is rolled up, the diameter of the projection band part becomes larger than the diameter of the film product part. This deteriorates the flatness and processability of the film. In addition, when the amount of change (b) in the width direction position of the projection band is less than the width (a) of the projection band, the effect of reducing the overlap of the projection bands described above is insufficient and the flatness and workability deteriorate. This is not preferable. In particular, in recent years, slight flatness defects cause image distortion, functional layer thickness unevenness, and defects, and thus it is required to strictly maintain flatness. In addition, when the amount of change in the width direction of the protrusion band (b) exceeds five times the width of the protrusion band (a), the function of preventing the deviation due to the protrusion band when wound in a roll shape becomes insufficient, The ratio of the area that cannot be used as a product part due to the protrusion band increases, which is not preferable.

  It is preferable that the position of the protrusion band in the width direction changes periodically. By periodically changing the position, it is preferable because the winding shape and the height of the helicopter can be made uniform regardless of the position in the longitudinal direction such as the core part, the center part, and the surface layer part of the resin film roll. When the change is irregular, unevenness occurs in the overlapping state of the protrusion bands depending on the position, which may lead to local winding form / planarity defect and workability deterioration. The period of the position change is preferably 0.3 m to 200 m in the longitudinal direction, and more preferably 5 m to 100 m.

  The roll diameter of the resin film roll is preferably 300 to 800 mmφ. If it is less than 300 mmφ, the film length is short and the production efficiency is lowered, which is not preferable. If it exceeds 800 mmφ, the height of the helicopter roll becomes large, and it may be difficult to maintain good flatness.

  As described above, by periodically changing the position in the width direction of the projection band according to the longitudinal position direction, even when a high projection band is formed, the overlap of the projection band portion can be optimized when wound on the film roll. It is possible to control the amount of roll edge over the entire length. As a result, a resin film roll having a very good winding shape and flatness and excellent workability can be obtained.

  As a method for applying the protrusion band, for example, by pressing the protrusion applying roll, the unevenness stamped on the protrusion applying roll is transferred to the surface of the resin film, or a part of the resin surface is melted by laser treatment to form the protrusion. Examples of the forming method are exemplified, but a method using a protrusion imparting roll is preferable from the viewpoint of productivity and safety. Furthermore, in order to prevent dust generated at the time of providing the protrusion or to provide a stable and high protrusion, a method of pressing the protrusion applying roll against the resin film surface while heating is preferable. The temperature of the protrusion-imparting roll at this time is preferably (Tg-50) (° C.) or more and (Tg + 30) (° C.) or less when the melting point of the resin film is Tg (° C.). If the temperature of the protrusion-applying roll is less than (Tg-50) (° C.), high protrusions may not be applied, and if it exceeds (Tg + 30) (° C.), the resin adheres to the protrusion-applying roll and deteriorates. However, it may be a drawback. Moreover, it is preferable that it is 300-2000N about the pressing force of a protrusion provision roll, and it is further more preferable that it is 500-1500N. When the pressing force is low, the protrusion height may be insufficient, and when it is too high, the protrusion height variation may increase. In order to prevent variation in the height of the protrusion, it is preferable to use a structure in which a load is held from both sides of the protrusion-applying roll because pressure uniformity is improved.

  The method for producing a resin film roll is a step of providing a protrusion band with a protrusion applying roll in an area of 100 mm from both ends in the width direction of the resin film, and the position of the protrusion applying roll in the film width direction is periodic. It is preferable to use the manufacturing method which has the process of providing the protrusion characterized by changing, the process of cutting both ends in the width direction of the resin film (cutting process), and the process of winding up the resin film (winding process). In the step of providing the protrusion band, the position of the protrusion band is periodically changed with respect to the position in the film width direction by periodically changing the position in the width direction of the protrusion applying roll. In addition, adopting a method of making the amplitude of change and the period of change of the protrusion-applying roll variable makes it possible to select optimum conditions for various purposes such as the thickness and width of the resin film and the processing method. This is preferable because it becomes possible. Further, as a method for periodically changing the position in the width direction of the protrusion band, for example, a method in which the uneven pattern itself on the protrusion providing roll as illustrated in FIG. 5 is periodically changed in the width direction is also a preferable example. As mentioned. When such a method is used, the position of the protrusion band in the width direction can be easily changed without using a device that changes the protrusion-applying roll device in the width direction.

  The position in the width direction of the cutting part in the cutting process and the winding part in the winding process periodically changes in the width direction with respect to the film before the cutting process is performed, and the amount of change in the width direction is the protrusion. It is preferable that the width direction position change amount (b) [mm] with respect to the film after the band cutting step is larger. The resin film is manufactured by various methods, but in any of the methods, the resin film generally has a thickness unevenness fixed in the film width direction. May cause unevenness in the hardness of the resin film roll, and flatness may deteriorate. Therefore, as described above, the cutting portion and the winding portion are periodically changed in the width direction with respect to the film formed, and increasing the amount of change can reduce the hardness unevenness in the central portion of the film roll. It is preferable because it improves and the flatness becomes extremely good.

  An example of the apparatus used for the manufacturing method of the resin film roll is shown in FIGS. The projection application roll 12 used in the projection application process 22, the cutter 15 used in the cutting process, and the film winding site in the winding process (corresponding to the position of the resin film roll 1) are films as illustrated in FIG. It may be installed continuously in the film forming apparatus, or may be installed in an apparatus that performs a step of slitting the intermediate product once wound up as illustrated in FIG. The protrusion band may be applied only to one surface of the film or to both surfaces, and can be appropriately selected depending on the processing method and film characteristics.

  The resin used for the resin film is not particularly limited. For example, polyester resins such as polyethylene terephthalate and polyethylene naphthalate, cellulose resins such as triacetyl cellulose, acrylic resins such as polymethyl (meth) acrylate, polystyrene and acrylonitrile.・ Styrene resins such as styrene copolymers, polycarbonate resins, polyethylene, polypropylene, ethylene / propylene copolymers, olefinic resins such as alicyclic polyolefins such as norbornene, vinyl chloride resins, nylon and aromatic polyamides Resin, imide resin, polyphenylene sulfide resin, polyether sulfone resin, vinylidene chloride resin, vinyl alcohol resin, vinyl butyral resin, arylate resin, polyoxy Styrene resins, such as epoxy resin or blend of these resins can be used. In particular, when used as a base film for flat panel displays, touch panels, surface protective films, and decorative films, polyethylene terephthalate and polyethylene naphthalate resins with excellent mechanical properties, thermal properties, and transparency are also used for mold release. When used as a process paper, a polyphenylene sulfide resin excellent in heat resistance and chemical resistance can be mentioned as a preferred resin.

  The polyethylene terephthalate resin and / or polyethylene naphthalate resin preferably used for the resin film has an intrinsic viscosity (measured in o-chlorophenol at 25 ° C. according to JIS K7367 2000) of 0.4 to 1.2 dl / g. Is preferable, and it is more preferable to be within the range of 0.5 to 0.8 dl / g.

  The polyphenylene sulfide resin that can be preferably used for the resin film is typically poly-p-phenylene sulfide, and includes p-phenylene sulfide units of 90 mol% or more, preferably 95 mol% or more. It is a polymer. Moreover, as long as it is less than 10 mol%, preferably less than 5 mol% of the repeating units, other units containing a copolymerizable sulfide bond may be contained. As the repeating unit of less than 10 mol%, preferably less than 5 mol% of the repeating unit, for example, a trifunctional unit, an ether unit, a sulfone unit, a ketone unit, a meta bond unit, an aryl unit having a substituent such as an alkyl group, Examples include biphenyl units, terphenylene units, vinylene units and carbonate units. One or more of these can coexist. In this case, the structural unit may be either a random type or a block type. The melt viscosity of the polyphenylene sulfide resin is not particularly limited as long as melt kneading is possible, but is in the range of 100 to 2000 Pa · s at a temperature of 315 ° C. and a shear rate of 1,000 (1 / sec). It is preferable that it is in the range of 200 to 1,000 Pa · s.

  In the resin film, various additives such as antioxidants, heat stabilizers, weathering stabilizers, UV absorbers, organic lubricants, pigments, dyes, organic or inorganic fine particles, fillers, antistatic agents, A nucleating agent, a crosslinking agent, etc. may be added to such an extent that the characteristics are not deteriorated. The resin film may be a laminated structure having two or more layers. As the laminated structure, for example, a composite film having an inner layer portion and a surface layer portion, which is substantially free of particles in the inner layer portion, and provided with a layer containing particles in the surface layer portion. The inner layer portion and the surface layer portion may be chemically different polymers or the same type of polymers. In particular, for display substrate applications, it is preferable in terms of optical properties such as transparency that the resin film does not contain particles.

  The thickness of the resin film is not particularly limited and is appropriately selected depending on the application, but a preferable range is 10 to 500 μm, more preferably 20 to 300 μm, and particularly preferably 38 to 250 μm. The resin film may be either an unstretched film or a stretched film, and the stretching direction may be a uniaxially stretched film that has been stretched in one direction or a biaxially stretched film that has been stretched in two directions, and is not particularly limited. . In addition, when using as a base material, such as a flat panel display, a touch panel, a surface protection film, and a decorative film, it is preferable to use a biaxially stretched film from the mechanical characteristics, thermal characteristics, thickness uniformity, and the like.

  The surface roughness (SRa) of the resin film is preferably 5 nm or less, and the ten-point average roughness (SRz) is preferably 300 nm or less. Here, the surface roughness (SRa) and the ten-point average roughness (SRz) are average values when the both surfaces of the resin film are measured. It is preferable to make the surface roughness of the resin film within the above range because a very clear and transparent appearance can be obtained. When making such an ultra-smooth surface state, it is necessary to contain no lubricant such as inorganic particles or organic particles in the resin film, or to make it extremely small amount. Workability may deteriorate. As a method for solving these problems, for example, a method in which a thin coating layer is provided on the surface of a resin film not containing easy-sliding particles and fine particles are contained in the coating layer maintains transparency and a clear appearance. Therefore, it is preferable because slipperiness can be imparted.

  The fine particles contained in the coating layer are not particularly limited, but inorganic particles such as colloidal silica, titanium oxide, aluminum oxide, zirconium oxide, calcium carbonate, carbon black, zeolite particles, acrylic particles, silicone particles, polyimide particles, “ Organic particles such as Teflon "(registered trademark) particles, crosslinked polyester particles, crosslinked polystyrene particles, crosslinked polymer particles, and core-shell particles may be used. Any of these particles may be used, or a plurality of types may be used in combination. The number average primary particle size of these particles is preferably in the range of 10 to 300 nm, and more preferably in the range of 40 to 150 nm. Here, the average primary particle size is an average of the particle sizes of primary particles defined as particles generated by growth of a single crystal nucleus in JIS-H7008 (2002). The particles may be monodispersed particles or aggregated particles in which a plurality of particles are aggregated. In some cases, a plurality of types of particles having different average primary particle sizes may be used in combination.

  The resin constituting the coating layer is not particularly limited, and examples thereof include polyester resins, acrylic resins, urethane resins, and the like, and are typified by melamine resins, oxazoline resins, epoxy resins, and the like. You may contain the antistatic agent represented by the crosslinking agent, the resin containing ammonium ion and a sulfonate ion, polythiophene, etc. Although it does not specifically limit about the thickness of an application layer, It is preferable that it is the range of 10-500 nm, and it is more preferable that it is 20-200 nm. In addition, as a method of forming the coating layer, any of a so-called in-line coating method in which coating is performed with a coating apparatus in the resin film manufacturing process and an offline coating method in which the film is once wound on a film roll and then coated again with an unwinding coating apparatus. May be used. The coating method is not particularly limited, and a known method such as a bar coating method, a gravure coating method, or a die coating method can be used.

  Next, the method for producing a resin film will be described by taking as an example the case of using a polyethylene terephthalate (hereinafter abbreviated as PET) film resin, but the present invention is not limited to this.

  PET pellets having an intrinsic viscosity of 0.5 to 0.8 dl / g constituting the resin film are vacuum-dried, then supplied to an extruder, melted at 260 to 300 ° C., extruded into a sheet form from a T-shaped die, and electrostatic It is wound around a mirror casting drum having a surface temperature of 10 to 60 ° C. using an applied casting method, and is cooled and solidified to produce an unstretched PET film. This unstretched film is stretched 2.5 to 5.0 times in the longitudinal direction (referring to the traveling direction of the film and also referred to as “longitudinal direction”) between rolls heated to 70 to 100 ° C. At least one surface of this film is subjected to corona discharge treatment in air, the wet tension of the surface is set to 47 mN / m or more, and an aqueous coating containing fine particles constituting the coating layer is applied to the treated surface. The coated laminated polyester film is gripped with a clip and guided to a drying zone. After the coating layer is dried, heating is performed at a temperature of 70 to 150 ° C., and then continuously in the heating zone of 70 to 150 ° C. in the transverse direction. The film is stretched 2.5 to 5.0 times in the direction perpendicular to the direction of travel of the film (also referred to as the “width direction”), and then subjected to heat treatment for 5 to 40 seconds in a heating zone of 200 to 240 ° C. A resin film having crystal orientation completed is obtained through a cooling zone of ˜200 ° C. In addition, you may perform a 3-12% relaxation process as needed during the said heat processing. Biaxial stretching may be longitudinal, transverse sequential stretching, or simultaneous biaxial stretching, and may be re-stretched in either the longitudinal or transverse direction after longitudinal and transverse stretching. After the end of the obtained biaxially oriented laminated polyester film is cut, it is wound up as an intermediate product. Thereafter, it is cut into a desired width using a slitter, and then wound around a cylindrical core to obtain a polyester film roll having a desired length. In this slit process, the protrusion-imparting roll is pressed against the film surface during winding to form a protrusion band. At this time, by periodically changing the position in the width direction of the pressing roll with the amplitude b [mm], it is possible to obtain a resin film in which the position in the width direction of the protrusion band changes periodically. Further, by periodically changing the position in the width direction with an amplitude c [mm] at the unwinding position, the cutting position and the winding position of the film can be changed with respect to the original film.

[Measurement method of physical properties]
Hereinafter, the configuration and effects of the present invention will be described more specifically with reference to examples. In addition, this invention is not limited to the following Example. Prior to describing each example, a method for measuring various physical properties will be described.

(1) Width and position of protrusion band (See Fig. 2 and Fig. 3)
In a film sample cut out from a resin film roll, a tangent line in contact with the protrusions on both ends in the width direction of the protrusion band is drawn in the longitudinal direction, and the interval between the tangent lines is set at 50 mm intervals in the longitudinal direction with a JIS class 1 metal ruler. Five points were measured, and the average value of the five points was defined as the width of the protrusion band.

  In addition, the width direction position of the protrusion band is the width direction end of the resin film and the end of the protrusion band on the product center side (the tangent line drawn on both ends of the protrusion band that is closer to the product center). The distance was measured with a JIS Class 1 metal scale. The amount of change in the width direction of the protrusion band was the difference between the position in the width direction of the protrusion band closest to the product end and the position farthest from the product end.

(2) High amount of film roll helicopter (see Fig. 1)
The difference between the maximum height in the range of 100 mm from the width direction endmost part of the film roll and the height of the part 200 mm inside from the width direction endmost part was defined as the amount of edge of the film roll. A dial gauge (manufactured by Mitutoyo Co., Ltd.) can be equilibrated on a film roll and attached to a slidable base. First, place the dial gauge touch point on the inner part 200mm from the end, and set the scale to 0. Adjusted. Next, the touch point was moved from the innermost part 100 mm from the outermost part to the outermost part while being in contact with the film roll, and the scale at the point where the value was maximum was read. A total of 10 locations of 5 locations on one side x both ends at an arbitrary position were measured, and the average value of 10 locations was defined as the amount of edge of the film roll.

(3) Average area and total area ratio of deformed portion of projection band The projection band of the film was observed at a magnification of 50 times using a digital microscope DG-2A manufactured by SCARA Co., Ltd. The area of ten irregularities of the protrusion band was determined, and the average value was taken as the average area of the protrusion. In addition, each area of the deformed portion was approximated by a quadrangle, and the area was obtained from the product by actually measuring the vertical and horizontal lengths. However, when the shape of the deformed portion was an ellipse or an indeterminate shape, the area was calculated as a circle with the average of the major axis and the minor axis as the diameter. Further, the total area ratio of the deformed portion of the protrusion band was calculated by observing 10 visual fields with a digital microscope in the same manner as described above, dividing the area of the deformed portion by the measured visual field area, and multiplying by 100.

(4) Average height of protrusion band Using a digital micrometer μ-Mate M-30 manufactured by Sony Precision Technology Co., Ltd., the thickness of the central part in the width direction of the protrusion band and the thickness of the part without the protrusion band are 20 points each. Measurement was averaged, and the difference was taken as the height of the protrusion.

(5) Film surface roughness (SRa), Ten-point average roughness (SRz)
Using a three-dimensional surface roughness meter (manufactured by Kosaka Laboratory, ET4000AK), measurement was performed by the stylus method under the following conditions. The surface roughness (SRa) is the difference between the height of the roughness curved surface and the height of the center surface of the roughness curved surface, and represents the average value of the absolute values. The ten-point average roughness (SRz) ) Represents the difference between the average value of the height of the top of the roughness surface from the 1st to the 5th and the average height of the valley from the 1st to the 5th. It is a thing. In addition, the surface roughness (SRa) and the ten-point average roughness (SRz) in the present invention were average values obtained by measuring both surfaces of the film.
Needle diameter 2 (μmR)
Needle pressure 10 (mg)
Measurement length 500 (μm)
Vertical magnification 20000 (times)
CUT OFF 250 (μm)
Measurement speed 100 (μm / s)
Measurement interval 5 (μm)
Number of recordings 80 Hysteresis width ± 6.25 (nm)
Standard area 0.1 (mm ² )

(6) Flatness After winding up the resin film roll, it was aged for 72 hours in an environment of 23 ° C. and 60 RH%. Next, one roll outermost layer was discarded, and a sample having a length of 3 m in the longitudinal direction was taken from the inside. The collected film sample was placed on a flat table, and the end sagging was confirmed by reflection from a fluorescent lamp. In addition, the slack of the both ends of the width direction was confirmed, and it judged with the worse result.
A: No sagging is observed.
○: The height of the sag in the end in the width direction is less than 2 mm.
(Triangle | delta): The height of slack at the end of the width direction is less than 3 mm.
X: The height of the sag in the end in the width direction exceeds 3 mm.
In addition, (double-circle), (circle), (triangle | delta) is a pass range.

(7) Processing characteristics Actinic ray curable resin (purchased UV-1700B [refractive index: 1.50 to 1.51] manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) constituting the hard coat layer on the surface of the resin film film Using a gravure coater, it was uniformly coated so that the film thickness after curing was 2.0 μm. At this time, the coating width was adjusted so that the hard coat layer did not cover the protrusion band. Next, the integrated irradiation intensity was 300 mJ / cm ² with a concentrating high-pressure mercury lamp (H03-L31 manufactured by Eye Graphics Co., Ltd.) having an irradiation intensity of 120 W / cm set at a height of 9 cm from the surface of the hard coat layer. After being cured by irradiating ultraviolet rays so as to become, an optical laminated film having a hard coat layer laminated on the film was obtained by winding at a tension of 100 N / m. From the appearance and winding shape of the obtained hard coat film, workability was determined as follows.
(Double-circle): It is favorable without the generation | occurrence | production of a new surface flaw and a roll shift | offset | difference.
◯: There is no scratch of 1 mm or more that can be visually recognized by halogen light (100 W) reflection, and the amount of deviation of the roll is 1 mm or less.
(Triangle | delta): There is no crack of 1 mm or more which can be visually recognized by three wavelength fluorescent lamp (30W) reflection, and the deviation | shift amount of a roll is 2 mm or less.
X: Scratch generation of 1 mm or more that can be visually recognized by the reflection of the three-wavelength fluorescent lamp (30 W), or the deviation amount of the roll exceeds 2 mm.
In addition, (double-circle), (circle), (triangle | delta) is a pass range.

[Reference Example 1] Preparation of polyethylene terephthalate (PET) pellets Using terephthalic acid as the acid component and ethylene glycol as the glycol component, the amount is 300 ppm in terms of antimony atoms with respect to the polyester pellets from which antimony trioxide (polymerization catalyst) can be obtained. And a polycondensation reaction was performed to obtain polyethylene terephthalate (PET) pellets having an intrinsic viscosity of 0.63 dl / g, a carboxyl end group amount of 40 equivalents / ton, and a melting point of 256 ° C.

[Reference Example 2] Preparation of polyethylene naphthalate (PEN) pellets 100 parts by weight of 2,6-naphthalenedicarboxylic acid dimethyl ester and 60 parts by weight of ethylene glycol, 0.03 parts by weight of cobalt acetate tetrahydrate as a transesterification catalyst After use and transesterification according to a conventional method, 0.023 part by weight of trimethyl phosphate was added to substantially complete the transesterification reaction. Further, after adding 0.024 part (0.82 mol) of antimony trioxide, the polycondensation reaction was carried out in the usual manner under high temperature and high vacuum, and the intrinsic viscosity (measured in a phenol / tetrachloroethane mixed solvent at 35 ° C.) Polyethylene naphthalate (PEN) pellets having 0.62 dl / g and a melting point of 269 ° C. were obtained.

[Reference Example 3] Preparation of polyphenylene sulfide (PPS) pellets In an autoclave vessel, 56.25 mol parts of sodium hydrosulfide (NaSH), 54.8 mol parts of sodium hydroxide, 16 mol parts of sodium acetate, and N-methylpyrrolidone (NMP) ) 170 mol parts were charged. Next, dehydration was performed by raising the internal temperature to 220 ° C. while stirring under a nitrogen gas stream. After dehydration, the system was cooled to 170 ° C., and then 55 mol parts of p-dichlorobenzene (p-DCB) and 0.055 mol parts of 1,2,4-trichlorobenzene (TCB) were added to 25 mol parts of NMP. The system was pressurized and sealed to 2.0 kg / cm ² under a nitrogen stream. After heating at 235 ° C. for 1 hour and further at 270 ° C. for 3 hours with stirring, the system was cooled to room temperature, and the resulting polymer slurry was poured into 200 mol of water, and stirred at 70 ° C. for 30 minutes. Separated. The polymer was further washed five times with stirring at about 70 ° C. ion-exchanged water (9 times the polymer weight), and then stirred for about 1 hour under a nitrogen stream with a 5% by weight aqueous solution of lithium acetate at about 70 ° C. . Further, after washing with ion-exchanged water at about 70 ° C. three times, it was separated and dried in an atmosphere of 120 ° C. and 1 torr for 20 hours to obtain white polyphenylene sulfide powder. Next, the polyphenylene sulfide powder was stirred twice for 30 minutes with NMP (three times the weight of the polyphenylene sulfide polymer) at 70 ° C. in a commercially available nitrogen gas atmosphere. This polyphenylene sulfide powder was further washed four times with ion-exchanged water at about 70 ° C., separated, and dried as described above to obtain white polyphenylene sulfide powder. The polyphenylene sulfide powder had a melt viscosity of 5000 poise at 300 ° C. and a melting point of 285 ° C. Next, a slurry in which spherical calcite-type calcium carbonate having an average particle diameter of 1.0 μm is finely dispersed in ethylene glycol by 50% by weight is prepared, and this slurry is filtered through a 1 μm cut filter, and then the polyphenylene sulfide powder is added to Henschel. Mixing was performed using a mixer so that the calcium carbonate would be 0.05% by weight. Next, it is supplied to a twin-screw extruder having two vent holes, and at the same time as melt kneading, ethylene glycol is removed from the vent holes, extruded into a gut shape, cooled in water, cut and then cut into calcium carbonate particle-containing polyphenylene sulfide (PPS). ) Pellet.

Reference Example 4 Preparation of Polyester Resin (A) 60 mol parts of terephthalic acid, 30 mol parts of 2,6-naphthalenedicarboxylic acid, 5 mol parts of sodium 5-sulfoisophthalate, glycol component as dicarboxylic acid component under nitrogen gas atmosphere 100 parts by weight of ethylene glycol was charged into a transesterification reactor, and 100 parts by weight of tetrabutyl titanate (catalyst) was added to 1 million parts by weight of the total dicarboxylic acid component, followed by esterification at 160 to 240 ° C. for 5 hours. After the reaction, the distillate was removed.

  Thereafter, 5 parts by weight of 1,3,5-trimellitic acid, which is a trivalent or higher polyvalent carboxylic acid component, and 100 parts by weight of tetrabutyl titanate are further added to 1 million parts by weight of the total dicarboxylic acid. After removing the distillate at 0 ° C. until the reaction product became transparent, a polycondensation reaction was performed under reduced pressure at 220 to 280 ° C. to obtain a polyester resin (A). The Tg of the polyester resin was 120 ° C.

  531.6 parts by weight of water, 2.0 parts by weight of 25% by weight ammonia water and 33.4 parts by weight of butyl cellosolve are added to 100.0 parts by weight of the polyester resin (A), and dissolved at 40 ° C. It was. Subsequently, the reaction vessel was sealed, and the internal temperature of the vessel was raised to 120 ° C. and heated for 2 hours to obtain an aqueous dispersion of the polyester resin (A).

<Composition of polyester resin (A)>
(Dicarboxylic acid component and polycarboxylic acid component)
・ 60 mol parts of terephthalic acid ・ 30 mol parts of 2,6-naphthalenedicarboxylic acid ・ 5 mol parts of sodium 5-sulfoisophthalate ・ 5 mol parts of 1,3,5-trimellitic acid (glycol component)
・ 100 mol parts of ethylene glycol

[Example 1]
The polyethylene terephthalate pellets (intrinsic viscosity 0.63 dl / g) obtained by the method of Reference Example 1 were dried in a vacuum at 160 ° C. for 4 hours, then supplied to an extruder and melt-extruded at 285 ° C. A stainless steel fiber is sintered and compressed with a filter having an average opening of 5 μm, and then a stainless steel powder with an average opening of 14 μm is filtered through a sintered filter, and then extruded into a sheet form from a T-shaped die and cast by applying electrostatic force. Using a method, it was wound around a mirror casting drum having a surface temperature of 20 ° C. and solidified by cooling. This unstretched film is preheated to 70 ° C. with a preheating roll, and then stretched 3.1 times in the longitudinal direction using the difference in peripheral speed between the rolls while heating up to 90 ° C. using a radiation heater from the top and bottom. It cooled to 25 degreeC with the cooling roll, and was set as the uniaxially oriented (uniaxial stretching) film. Both surfaces of the film were subjected to corona discharge treatment in air, and the surface tension of the film was 55 mN / m.

Next, the following coating liquid (A) was applied to both surfaces of the uniaxially stretched film using a bar coater.
<Composition of coating liquid (A)>
The used coating liquid is an aqueous solution containing the following components when the polyester resin solid content is 100 parts by weight and having a concentration in terms of polyester resin solid content of 5.0%.
Polyester resin (A): 100 parts by weight Melamine-based crosslinking agent (“Nikarak” MW12LF manufactured by Sanwa Chemical Co., Ltd.): 40 parts by weight (solid content conversion)
Colloidal silica with a particle size of 140 nm: 1.5 parts by weight

  The uniaxially stretched film coated with the coating liquid was held with a clip, dried and preheated in an oven at an ambient temperature of 120 ° C., and continuously stretched 3.7 times in the width direction in a 120 ° C. stretching zone. The obtained biaxially oriented (biaxially stretched) film was heat-treated in a heating zone at 230 ° C. for 10 seconds, then subjected to 5% relaxation treatment while being cooled from 230 ° C. to 120 ° C., and then cooled to 50 ° C. . Next, after removing both ends in the width direction, the film was wound up, and a coating layer having a thickness of 90 nm was laminated on both sides of the base polyester film. The thickness was 125 μm, the haze was 0.8% (JIS K7105 (1981)), and the surface was rough. An intermediate product of a laminated polyester film having an SRa of 3.0 nm, a ten-point average roughness (SRz) of 150 nm, and a width of 4 m was obtained.

  The obtained intermediate product is unwound in a slitting process shown in the schematic diagram of FIG. 7 with an unwinding tension of 900 N / 4 m, cut into three 1200 mm wide products and ears at both ends, and the cut film is A resin film roll is wound up on a fiber reinforced plastic core having an inner diameter of 6 inches under the conditions of a winding tension of 250 N / m and a pressing force of 50 N / m by a pressing roll having a diameter of 130 mm, a width of 1200 mm, a product length of 1700 m, and a winding core surplus A film roll having a length of 50 m (total film length of 1750 m) was obtained. The product outer diameter of the film roll was 568 mm. It should be noted that the protrusion band is formed at a temperature of 260 ° C. and a pressing force of 1000 N using a protrusion applying roll having a diameter of 127 mm so that the protrusion band is within a range of 45 mm from both ends in the width direction of each product before the film is cut into the product width. The film was pressed against one side of the film surface (the outer surface side of the film roll) to form the protrusion bands shown in Table 1. At this time, the intermediate product unwinding device causes the cutting device and the winding device to oscillate in a straight line with a period of 500 m in the range of 150 mm in the film width direction. A range of 20 mm in the film width direction was linearly oscillated with a period of 100 m with respect to the winding device.

  The properties of the obtained film roll are shown in Table 1. Despite the very smooth film, the obtained resin film roll has a good winding shape with no end sagging or misalignment, and when the hard coat was laminated on the outer surface side of the film There was no generation of scratches or air accumulation or slippage during winding of the hard coat film, and it had very good processing characteristics.

[Examples 1 to 12, Comparative Examples 1 to 5]
A film roll was obtained according to Example 1 except that the conditions of the slitting process were as shown in Table 1. The properties of the obtained film roll are shown in Table 1.

[Example 13]
A film roll having a surface roughness (SRa) of 7.0 nm and a ten-point average roughness (SRz) of 400 nm was obtained according to Example 1 except that the coating liquid was changed to the following coating liquid (B). The properties of the obtained film roll are shown in Table 1.

<Composition of coating liquid (B)>
The used coating liquid is an aqueous solution containing the following components when the polyester resin solid content is 100 parts by weight.
Polyester resin (A): 100 parts by weight Melamine-based crosslinking agent (“Nikarak” MW12LF manufactured by Sanwa Chemical Co., Ltd.): 40 parts by weight (solid content conversion)
-Colloidal silica with a particle size of 300 nm: 1.5 parts by weight

[Example 14]
The change in position in the width direction of the protrusion band was changed to a method in which the pattern shape of the protrusion-applying roll was changed by 25 mm in the width direction with a length period (0.4 m) of one roll without oscillating the protrusion-applying device. Except for the above, a film roll was obtained according to Example 1. The properties of the obtained film roll are shown in Table 1.

[Example 15]
The raw material of the resin film was changed to polyethylene naphthalate, and the film roll was obtained as follows, with the slit process conditions as shown in Table 1.

  The polyethylene naphthalate pellets described in Reference Example 2 were dried at 180 ° C. for 3 hours, then supplied to an extruder hopper, melted at a melting temperature of 300 ° C., and filtered through a filter having an average opening of 5 μm obtained by sintering and compressing stainless steel fibers. After that, the sheet was extruded from a T-shaped base into a sheet shape, wound around a mirror casting drum having a surface temperature of 40 ° C. using an electrostatic application casting method, and cooled and solidified to obtain an unstretched film. This unstretched film is preheated to 120 ° C. with a preheating roll, and then stretched 3.0 times in the longitudinal direction using the difference in peripheral speed between the rolls while being heated from above and below using a radiation heater, and subsequently used as a cooling roll. And cooled to 25 ° C. to obtain a uniaxially oriented (uniaxially stretched) film. Both surfaces of the film were subjected to corona discharge treatment in air, and the surface tension of the film was 55 mN / m.

  Next, the same coating liquid as in Example 1 was applied to both sides of the uniaxially stretched film using a bar coater, both ends of the film were held with clips, dried and preheated at an atmospheric temperature of 120 ° C. in an oven, and subsequently The film was continuously stretched 3.3 times in the width direction in a stretching zone at 140 ° C. The obtained biaxially oriented (biaxially stretched) film was heat-treated in a heating zone at 230 ° C. for 10 seconds, then subjected to 5% relaxation treatment while being cooled from 230 ° C. to 120 ° C., and then cooled to 50 ° C. . Subsequently, after removing both end portions in the width direction, the film is wound up, and a coating layer is laminated on both sides of the base polyester film with a thickness of 125 μm, a haze of 1.0% (JIS K7105 (1981)), and a surface roughness (SRa). An intermediate product of a laminated polyester film having a thickness of 0 nm, a ten-point average roughness (SRz) of 175 nm, and a width of 4 m was obtained. A product roll was obtained by processing the obtained intermediate product in the same manner as in Example 1 except that the temperature of the protrusion imparting roll was 290 ° C.

[Example 16]
The raw material of the resin film was changed to polyphenylene sulfide, and a film roll was obtained by the following method while setting the slit process conditions as shown in Table 1.

  The calcium carbonate particle-containing polyphenylene sulfide pellets described in Reference Example 3 were dried at a temperature of 180 ° C. for 4 hours under a reduced pressure of 3 mmHg using a rotary vacuum dryer. The obtained dried chip was supplied to a single-screw extruder whose melting part was heated to 310 ° C., filtered through a filter having an average opening of 5 μm obtained by sintering and compressing stainless steel fibers, and then sheet-shaped from a T-shaped die. Then, it was wound around a mirror casting drum having a surface temperature of 25 ° C. by using an electrostatic application casting method, and cooled and solidified to obtain an unstretched film. This unstretched film was stretched by a longitudinal stretching machine at a film temperature of 101 ° C. at a magnification of 3.2 times in the longitudinal direction. Thereafter, both ends were held with clips and guided to a tenter, stretched in the width direction at a stretching temperature of 101 ° C. and a stretching ratio of 3.4 times, subsequently heat-treated at a temperature of 260 ° C. for 8 seconds, and then cooled to room temperature. Thereafter, the film edge was removed, and an intermediate product of a biaxially oriented polyphenylene sulfide film having a thickness of 100 μm, a surface roughness (SRa) of 24.0 nm, a ten-point average roughness (SRz) of 1100 nm, and a width of 2.4 m was obtained. The obtained intermediate product was unwound at a slitting step with an unwinding tension of 500 N / 2.4 m, cut into two products with a width of 1000 mm and ears at both ends, and the cut films were each wound at an unwinding tension of 250 N / m, a resin film roll is wound up on a fiber reinforced plastic core having an inner diameter of 6 inches under the condition of a pressing force of 50 N / m by a pressing roll having a diameter of 130 mm, a width of 1000 mm, a product length of 500 m, and a core length of 30 m (total film length 530 m) film roll was obtained. The product outer diameter of the film roll was 315 mm. Note that the protrusion band is formed by a protrusion applying device using a protrusion applying roll having a diameter of 127 mm at a temperature of 290.degree. The film was pressed against one side of the film surface (the outer surface side of the film roll) to form the protrusion bands shown in Table 1. At this time, the intermediate product unwinding device causes the cutting device and the winding device to oscillate in a straight line with a period of 300 m in the range of 100 mm in the film width direction. A range of 30 mm in the film width direction was oscillated with a period of 100 m with respect to the winding device.

  According to Table 1, when the width (a) of the protrusion band is in the range of 5 to 20 mm and the position in the width direction of the protrusion band is changed, the helicopter height at the end of the resin film roll is optimized. As a result, good flatness was obtained, and the workability was within the acceptable range. Further, a better result was obtained when the relationship between the change amount (b) in the width direction of the protrusion band and the width (a) of the protrusion band satisfied a ≦ b ≦ 5a.

Further, the edge of the resin film roll when the area of the deformed part in the protrusion band is 0.03 to 0.20 mm ² , the total area ratio of the deformed part is 3 to 20% by area, and the average height of the protrusion band is 4 to 10 μm. As a result, high amounts, flatness, and workability tend to be favorable (by comparison between Example 1 and Examples 9, 11, and 12). Further, the value of the width (a) of the protrusion band, the width (a) of the protrusion band, and the change amount (b) in the width direction of the protrusion band are in the above relationship, and the shape / height of the protrusion band is more preferable. The surface roughness of the film when the area of the deformed part as the range is 0.05 to 0.18 mm ² , the total area ratio of the deformed part is 3 to 10 area%, and the average height of the protrusion band is 5 to 8 μm. Even in a very smooth film having an SRa of 5 nm or less and a ten-point average roughness (SRz) of 150 nm or less, the film roll has a high edge, flatness, and workability when a functional layer is added. Good results were obtained (see Examples 1, 4, 6, 8, 10, 14, 15, 16). That is, by defining the width of the protrusion band and further changing the position in the width direction according to the longitudinal position direction, even when a high protrusion band is formed, the edge height of the protrusion band portion of the film roll is controlled to an appropriate value. It can be seen that a resin film roll excellent in winding form, flatness and workability can be obtained.

  The resin film roll according to the present invention has a very good winding shape and flatness even if it is a highly smooth film. Further, when the functional layer is laminated on the film, there is no occurrence of scratches or winding deviations, and the processability is excellent. Has characteristics. Therefore, it is suitable for flat panel displays and touch panels, surface protection films, base films for decorative films, release films, etc. that require highly transparent and highly smooth films and have severe quality requirements such as scratches and flatness. Can be used.

DESCRIPTION OF SYMBOLS 1 Resin film roll 2 Core for winding up resin film roll 3 Protrusion band 4 Helicopter amount 5 of resin film roll Width direction end part 6 of resin film Each deformation part located in the width direction end part of a protrusion band is tied Tangent line 7 Deformation part 8 in projection band Width of projection band (a)
9 Distance from the film width direction end of the protrusion band (distance between the tangent line from the center of the product and the film end of the tangent lines connecting the individual deformed portions located at the width direction end of the protrusion band)
10 Projection band width direction change (b)
11 Protrusion band width direction position change period 12 Protrusion imparting roll 13 Protrusion imparting roll whose transfer position periodically changes in the width direction 14 Counter electrode roll 15 Cutter 16 Edge processing device 17 Pressing roll 18 Conveying roll 19 Film traveling direction 20 Protrusion Unit 21 including application step, cutting step, winding step Unit width direction position change amount 22 including protrusion applying step, cutting step, winding step Projection applying step 23 Width direction position change amount 24 of protrusion applying step Intermediate product roll 25 Intermediate product roll unwinding unit 26 Width direction position change amount of intermediate product roll unwinding unit

Claims (8)

  A resin film roll formed by winding a resin film in a film longitudinal direction, and having a protrusion band made of one or a plurality of protrusions in a film region having a distance of 100 mm or less from both ends in the film width direction. The film extends in the longitudinal direction of the film, the width (a) of the protrusion band is 5 to 20 mm, and the position of the protrusion band with respect to the film width direction changes along the film longitudinal direction. Resin film roll.   The position of the protrusion band with respect to the film width direction periodically changes along the film longitudinal direction, and the amount of change (b) is not less than 1 and not more than 5 times the width (a) of the protrusion band. The resin film roll described in 1.   The resin film roll according to claim 1 or 2, wherein a roll diameter of the resin film roll is 300 to 800 mm, and an edge height in a film region having a distance from a film end on both sides within 100 mm is 200 µm to 1500 µm. . The protrusion band is composed of an assembly of independent protrusions, the average area of each deformation portion in the protrusion band is 0.03 to 0.20 mm ² , and the area ratio of the deformation portion in the protrusion band is 3 to 3. The resin film roll according to any one of claims 1 to 3, wherein the resin film roll has an area of 10% by area and an average height of the protrusion band of 4 to 10 µm.   The resin film roll in any one of Claims 1-4 in which resin which comprises the said resin film consists of a polyethylene terephthalate resin, a polyethylene naphthalate resin, or a polyphenylene sulfide resin.   The resin film roll in any one of Claims 1-5 whose surface roughness (SRa) of the said resin film is 5 nm or less, and whose ten-point average roughness (SRz) is 300 nm or less. A film region having a distance of 100 mm or less from both ends in the film width direction has a protrusion band composed of one or a plurality of protrusions, the protrusion band extends in the film longitudinal direction, and the width of the protrusion band ( a) is a method for producing a resin film roll obtained by winding a resin film having a length of 5 to 20 mm in the longitudinal direction of the film,
A protrusion applying step of providing a protrusion band with a protrusion applying roll in a film region having a distance from both ends of the resin film in the film width direction of 100 mm or less,
A cutting step of cutting the resin film at both ends in the film width direction;
A winding step of winding the resin film,
In the projection application step, the film width direction position of the projection application site in the projection application roll is periodically changed with respect to the width direction position of the film cutting site to be cut in the cutting step. Film roll manufacturing method.   The position of the film cutting portion to be cut in the cutting step with respect to the film width direction and the position of the film winding portion to be wound in the winding step with respect to the film width direction are periodically changed, and the film cutting portion and the film Both the amount of change in the position of the film winding portion relative to the film width direction is larger than the amount of change in the film width direction of the protrusion applying portion in the protrusion applying roll relative to the position of the cutting portion in the film width direction. The manufacturing method of the resin film roll of Claim 7 changed so that it may become.

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