JP6671123B2 - Reel member, film container, and method of manufacturing reel member - Google Patents

Description

  The present invention relates to a reel member, a film container, and a method for manufacturing a reel member.

  For example, as disclosed in Patent Documents 1 to 3, there are known reel members on which an adhesive film can be wound. The reel member includes a core portion around which the adhesive film is wound, and flange portions provided at both ends of a rotation shaft of the core portion. Since the adhesive film is protected by the flange portion, contamination of the adhesive film can be suppressed. Further, the handleability of the reel member around which the adhesive film is wound, that is, the film container is improved.

JP 2015-86029 A JP 2014-43346 A JP 2013-216436 A

  However, conventionally, when manufacturing the reel member, no surface run-out has been considered. For this reason, the surface runout amount may become very large in some cases. Here, the surface runout means that the flange portion swings (distorts) in the rotation axis direction of the core. In the runout, the flange portion swings outward in the rotation axis direction of the winding core portion (that is, the flange portion is distorted to the outside of the reel member), and the flange portion moves in the rotation shaft inward direction of the core portion. The deflection is classified into a negative direction surface deflection (that is, the flange portion is distorted inside the reel member). In some cases, both a positive runout and a negative runout occur in one flange portion. In other words, there is a case where a surface runout in the positive direction occurs in a part of the flange portion, and a surface runout in the negative direction occurs at another part.

  When the adhesive film is wound around the reel member having a large surface run-out, the adhesive film easily falls into a gap between the flange portion and the film winding portion (the portion where the adhesive film is wound). Although details will be described later, the reason is that the gap between the flange portion and the film winding portion is widened. The detachment of the adhesive film may occur not only when the adhesive film is wound but also when the adhesive film is pulled out.

  Then, the dropped adhesive film may cause poor appearance of the film container and may cause blocking. Here, the blocking of the adhesive film means that the adhesive film is fixed to a component (for example, a flange portion, an adhesive film, or the like) in the film container. Blocking of the adhesive film causes draw-out failure, lack of an adhesive layer, and the like.

  Particularly, from the viewpoint of suppressing blocking, a large tension cannot be applied to the adhesive film when winding the adhesive film. This is because if a large tension is applied to the adhesive film during winding of the adhesive film, the adhesive layer protrudes from the adhesive film and is fixed to another adhesive film or a flange portion (that is, blocking occurs). Therefore, in the conventional reel member, the adhesive film easily moves in the film winding portion. Also in such a point, the adhesive film is likely to fall off.

  Further, in recent years, from the viewpoint of cost reduction and the like, there is a need to make the adhesive film wound around the reel member as long as possible. However, it is necessary to increase the outer diameter of the flange portion as the adhesive film becomes longer. And, the larger the outer diameter of the flange portion, the more easily the surface run-out occurs, and the larger the surface run-out amount tends to be. For this reason, as the adhesive film becomes longer, the adhesive film is more likely to fall off.

  In order to lengthen the adhesive film wound around the reel member while suppressing an increase in the outer diameter of the flange portion, it has been proposed to traverse the adhesive film around the core portion. However, in the technique in which the adhesive film is traversed around the core, the adhesive film easily falls off at the end of the film winding portion. Therefore, the problem of falling off of the adhesive film cannot be fundamentally solved.

  Further, as a method of suppressing the falling off of the adhesive film, there has been proposed a method of winding the adhesive film around a core portion and then attaching a flange portion to the core portion. However, this method increases the manufacturing cost of the film container. Further, since the structure of the film container itself becomes complicated, the handleability of the film container decreases. Furthermore, even with this method, it is not possible to prevent the adhesive film from falling off when the adhesive film is pulled out. Therefore, this method does not fundamentally solve the problem of the adhesive film falling off.

  As described above, the conventional reel member has a problem that the amount of surface runout may increase. Then, when the adhesive film is wound around the reel member having a large surface runout, there is a problem that the adhesive film easily falls off. For this reason, conventionally, in order to prevent the adhesive film from falling off, it has been necessary to very carefully perform winding and drawing of the adhesive film. Therefore, there is another problem that the operability of winding and drawing out the adhesive film is reduced.

  Therefore, the present invention has been made in view of the above-described problems, and an object of the present invention is to provide a new and improved method capable of suppressing surface runout, and thus, preventing the adhesive film from falling off. To provide a method for manufacturing a reel member, a film container, and a reel member.

In order to solve the above problems, according to one aspect of the present invention, a core portion capable of winding an adhesive film, and a flange portion provided at both ends in the rotation axis direction of the core portion, At least one or more of the core and the two flanges is a molded product, and the diameter of the core and the diameter of the flange satisfy the following expression (1). A reel member having a value in the range of ± 0.2 mm is provided.
D / F ≧ 0.005 * F−0.38 (1)
In Equation (1), D is the diameter of the core (unit: mm), and F is the diameter of the flange (unit: mm).

  Here, at least one of the two flanges may be integrally formed with the core.

  Also, a concave portion may be provided at both ends of the winding core in the rotation axis direction.

  Further, a rib extending radially from the rotation axis of the core may be formed on the bottom surface of the concave portion.

  Further, the ribs may be arranged at symmetrical positions with respect to the rotation axis of the core.

  Further, the distance between the flange portions may be 10 mm or more.

  Further, the diameter of the core portion may be 40 mm or more.

  Further, the diameter of the flange portion may be 135 mm or more.

  Further, the core portion may have a plurality of divided core portions connected in the rotation axis direction of the core portion.

  According to another aspect of the present invention, there is provided a film container including the above-mentioned reel member and an adhesive film wound around a core.

According to another aspect of the present invention, there is provided a molded product constituting a part or the whole of a reel member including a core part on which an adhesive film can be wound, and flange parts provided at both ends of the core part. One or more steps of manufacturing, and when the molded product forms a part of the reel member, fixing the molded products to each other, thereby producing a reel member. the diameter of the section is to satisfy the following equation (1), surface deflection amount of the flange portion is a value within a range of ± 0.2 mm, the manufacturing method of the reel member.
D / F ≧ 0.005 * F−0.38 (1)
In Equation (1), D is the diameter of the core (unit: mm), and F is the diameter of the flange (unit: mm).

  As described above, according to the present invention, the amount of surface runout is a value within the range of ± 0.2 mm, so that it is possible to suppress the surface runout and, consequently, to prevent the adhesive film from falling off.

FIG. 3 is a side view illustrating a configuration of a reel member according to the embodiment of the present invention. It is a front view of the reel member concerning the embodiment. It is a plane sectional view of a reel member. It is a front view of a film container (what wound the film around the reel member). It is explanatory drawing which shows the outline | summary of the manufacturing method of the reel member which concerns on this embodiment. It is explanatory drawing which shows the metal mold | die for producing an integral molded body (so-called one-piece molded body) of the whole reel member. It is explanatory drawing which shows the metal mold | die for producing the molded object (what is called a two-piece molded object) used as a part of a reel member. It is explanatory drawing which shows the uneven | corrugated part formed in the surface of a division | segmentation core part. It is a graph which shows the correspondence (D / F) of the diameter (D) of a core part and the diameter (F) of a flange part, and the outer diameter (F) of a flange part. It is a sectional side view which shows an example of surface runout of a positive direction. It is a side sectional view showing an example of surface run in the negative direction.

  Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the specification and the drawings, components having substantially the same functional configuration are denoted by the same reference numerals, and redundant description is omitted.

<1. Study by the Inventor>
(1-1. Run-out)
The inventor of the present invention has intensively studied a technique for suppressing surface runout, and as a result, has arrived at the reel member 1 according to the present embodiment. Therefore, first, the surface runout will be described in detail. As described above, the surface runout means that the flange portion swings (distorts) in the rotation axis direction of the core. The surface runout is classified into a positive direction surface runout and a negative direction surface runout.

  FIG. 10 shows an example of surface runout in the positive direction. In this example, the flange portion 102 of the reel member 100 has a surface runout in the positive direction. The reel member 100 is an example of a conventional reel member, and includes a core 101 and a flange 102. Further, a film winding portion 150 is formed by winding the adhesive film around the core portion 101 in a traverse shape. The degree of surface runout is indicated, for example, as the surface runout amount d. The surface runout amount d is defined (measured) as follows. First, a perpendicular line passing through the contact point 102b between the flange portion 102 and the core portion 101 and perpendicular to the rotation axis of the core portion 101 is drawn. This is set as a reference line. Next, a perpendicular line is drawn from the reference line to the outer edge portion 102c of the inner peripheral surface 102a of the flange portion 102. The length of the perpendicular is referred to as a surface runout d. The surface runout d in the positive direction has a positive value, and the surface runout d in the negative direction has a negative value.

  In the case where the flange portion 102 has a surface runout in the positive direction, the film winding portion 150 and the flange portion 102 are formed to be thicker as the film winding portion 150 becomes thicker (that is, the amount of winding of the adhesive film around the core 101 increases). The gap becomes wider. Therefore, as the film winding portion 150 becomes thicker, the adhesive film is more likely to fall off.

  As a method for solving this problem, it is conceivable to increase the width w of the film winding portion 150 as the film winding portion 150 becomes thicker. However, in this method, the adhesive film wound around both ends in the width direction of the film winding section 150 becomes unstable. Therefore, since the adhesive film still tends to fall off, this method cannot fundamentally solve the above problem.

  Then, the adhesive film may fall off both when the adhesive film is wound and when the adhesive film is pulled out. For example, when winding the adhesive film, the longer the time from the start of the winding (that is, the larger the amount of winding), the more likely the adhesive film to fall off. On the other hand, at the time of pulling out the adhesive film, the shorter the time from the start of pulling out (that is, the smaller the amount of pulling out), the more easily the adhesive film falls off. As described above, when the flange portion 102 has a surface runout in the forward direction, the adhesive film is likely to fall off.

  FIG. 11 shows an example of the surface runout in the negative direction. In this example, the flange portion 102 of the reel member 100 has a surface runout in the negative direction. Even in the case where the flange portion 102 has a surface runout in the negative direction, the adhesive film is likely to fall off.

  Specifically, the width w of the film winding portion 150 needs to be smaller than the minimum value of the distance L between the flange portions 102 (here, the distance between the outer edge portions 102c). This is because if the adhesive film contacts the flange portion 102, the adhesive film may cause blocking.

  Therefore, when the film winding portion 150 is thin (that is, when the amount of the adhesive film wound around the core portion is small), the gap between the film winding portion 105 and the flange portion 102 becomes large. In addition, the gap between the film winding portion 150 and the flange portion becomes smaller as the film winding portion 150 becomes thicker. This is because the flange portion 102 is distorted inward in the axial direction of the core portion 101. Therefore, when the film winding portion 150 is thin, the adhesive film is likely to fall off. Further, in this case, the width w of the film winding portion 150 is reduced (that is, the effective use area of the winding core portion 101 is reduced), so that another problem that the amount of the adhesive film that can be wound on the reel member 100 is reduced. Also occurs.

  Then, the adhesive film may fall off both when the adhesive film is wound and when the adhesive film is pulled out. For example, at the time of winding the adhesive film, the shorter the time from the start of winding (that is, the smaller the winding amount), the more likely the adhesive film falls off. On the other hand, at the time of pulling out the adhesive film, the longer the time from the start of pulling out (that is, the larger the amount of pulling out), the more easily the adhesive film falls off. As described above, when the flange portion 102 has a surface runout in the negative direction, the adhesive film is likely to fall off.

  However, as described above, in the related art, when the reel member is manufactured, the runout has not been considered at all. For this reason, the surface runout amount may become very large in some cases. Therefore, in the conventional technique, the adhesive film was easily dropped. Therefore, the present inventors have earnestly studied a technique for reducing the amount of surface runout, and as a result, have arrived at the reel member 1 according to the present embodiment. In the reel member 1 according to the present embodiment, the surface runout can be suppressed to ± 0.2 mm or less. Hereinafter, the present embodiment will be described.

<2. Overall Structure of Reel Member>
Next, an overall configuration of the reel member 1 according to the present embodiment will be described with reference to FIGS.

  The reel member 1 includes a core part 2, a flange part 3, and a rib 24c. The core 2 is a member on which the adhesive film can be wound. Specifically, the adhesive film is wound around the peripheral surface 21 of the core 2. The cross-sectional shape of the core 2 perpendicular to the rotation axis P is circular.

  A fixing surface 22 and a concave portion 23 are formed at both ends of the core 2 in the direction of the rotation axis P. The fixing surface 22 is a plane substantially perpendicular to the rotation axis P. In the present embodiment, at least one or more of the core 2 and the two flanges 3 is a molded product. Here, it is more preferable that all are molded products. More preferably, at least one of the two flanges 3 is integrally formed with the core 2. When the flange portion 3 and the core portion 2 are integrally formed, the fixing surface 22 is defined as a boundary surface between the core portion 2 and the flange portion 3. When the core part 2 and the flange part 3 are integrally molded, the core part 2 and the flange part 3 are molded by injection molding using a mold as described later, so that the shape of the flange part 3 is stabilized. . That is, it can be expected that the amount of runout of the flange portion 3 is reduced. On the other hand, when the core 2 is separate from the flange 3, the fixing surface 22 is defined as a surface to which the flange 3 is fixed. When the winding core 2 is separate from the flange 3, the surface of the flange 3 easily follows the fixing surface 22. Therefore, as the fixing surface 22 is smoother (that is, as there is no unevenness or inclination), the flange portion 3 is more likely to be smoother. For example, even if the flange 3 is distorted in the thickness direction, the distortion is likely to be reduced when the flange 3 is fixed to the fixing surface 22. As a result, it can be expected that the amount of runout of the flange portion 3 is reduced.

  For this reason, it is preferable that the fixing surface 22 is subjected to a smoothing process. Here, the smoothing process is a process for smoothing the fixing surface 22 as much as possible. Examples of the smoothing process include a polishing process using a lathe or the like, an aging process (thermal annealing process), and the like.

  Note that there is no particular limitation on how much the smoothing process is performed. That is, by setting each dimension of the reel member 1 to a value within a predetermined range and performing appropriate smoothing processing, the surface runout of the flange portion 3 can be set to a value within a range of ± 0.2 mm. . That is, the smoothing process may be appropriately performed so that the surface runout has a value within the range of ± 0.2 mm. Note that the surface runout amount in the present embodiment is also defined in the same manner as in FIGS. That is, a perpendicular line that passes through the contact point 3 b between the flange portion 3 and the core portion 2 and that is perpendicular to the rotation axis of the core portion 2 is drawn. Next, a perpendicular is drawn from the outer edge 3c of the inner peripheral surface 3a of the flange 3 to the reference line. Then, the length of the perpendicular is defined as the surface runout. In the present embodiment, the surface runout in the positive direction has a positive value, and the surface runout in the negative direction has a negative value.

  The method of fixing the flange portion 3 to the core 2 is not particularly limited, but for example, ultrasonic welding or impulse welding is preferable, and ultrasonic welding is more preferable. According to these methods, the flange portion 3 can be firmly fixed to the core 2 while suppressing the amount of runout of the flange portion 3. The impulse welding is performed, for example, by the following method. That is, a plurality of protruding portions (male portions) are provided on the fixing surface 22 (corresponding through holes are provided on the flange portion 3). Here, the protrusion is longer than the thickness of the flange 3. Further, it is preferable that the protrusion is provided at a position symmetrical with respect to the rotation axis P of the core 2. Specifically, the protrusions are preferably provided at equal intervals along the circumferential direction of the fixing surface 22. Thereby, welding spots (spots in which the protruding portions and the through holes are integrated) are provided at equal intervals along the circumferential direction of the fixing surface 22, so that the shape of the reel member 1 can be further stabilized. Further, fluctuation of the pull-out tension can be suppressed.

  On the other hand, a portion of the inner peripheral surface 3 a of the flange portion 3 that contacts the fixing surface 22 is formed with a through hole. The through hole penetrates through the flange 3 in the thickness direction. The through hole is provided at a position facing the protruding portion. Then, the protrusion is passed through the through hole. Then, a part of the protrusion protruding from the through hole is melted and solidified. At this time, the molten material not only fills the through hole but also spreads slightly on the outer peripheral surface 3d of the flange portion 3, thereby almost completely closing the through hole. Thereby, the protrusion and the through hole are integrated. Through the above steps, the flange 3 is fixed to the core 2.

  The concave portions 23 are formed at both ends of the core 2 in the direction of the rotation axis P. The recess 23 has a cylindrical shape, and the central axis of the recess 23 is coaxial with the rotation axis P of the reel member 1. The fixing surface 22 is formed around the recess 23. By forming the concave portion 23 in the core 2, the weight of the reel member 1 can be reduced. Here, in the process of pulling out the adhesive film from the film container 50 (see FIG. 4) (drawing process), the reel member 1 is frequently stopped and rotated again. In particular, when a long (for example, 600 m or longer) adhesive film is wound around the reel member 1, the number of stops and re-rotations becomes extremely large. Therefore, if it takes time to stop and re-rotate the reel member 1, the working efficiency is significantly reduced. In this regard, in the present embodiment, by reducing the weight of the reel member 1, the inertia force when stopping or re-rotating the reel member 1 can be reduced. Therefore, the stop and re-rotation of the reel member 1 can be performed in a short time. Therefore, the extraction process can be performed stably and efficiently. Further, since the reel member 1 is reduced in weight, it is possible to reduce the pull-out tension (tension) applied to the adhesive film during the pull-out process. Also in this respect, the extraction processing can be performed stably and efficiently.

  Further, a through hole 24b for a shaft and a rib 24c are formed in the bottom surface 24 of the concave portion 23. The shaft body through hole 24b is a through hole through which a shaft body for rotating the reel member 1 passes and is fixed.

  The plurality of ribs 24 c are provided on the bottom surface 24 of the recess 23. By providing a plurality of ribs 24c on the core part 2, the shape of the reel member 1 can be stabilized, and the amount of runout can be reduced.

  The rib 24 c is a plate-like member extending radially from the rotation axis P of the core 2, and is integrally formed with the core 2. The upper end surface of the rib 24c is inclined, and connects the through hole 24b for the shaft body and the inner edge of the flange portion 3.

  The installation position of the rib 24c is not particularly limited, but is preferably provided at a position symmetrical with respect to the rotation axis P of the core 2 as shown in FIG. More specifically, the ribs 24c are preferably provided at equal intervals along a circumferential direction around the rotation axis P. Thereby, the shape of the reel member 1 can be further stabilized. Further, fluctuation of the pull-out tension can be suppressed. That is, when the rib 24c is provided at an asymmetric position with respect to the rotation axis P, there is a possibility that the pull-out tension varies according to the rotation angle of the reel member 1. However, by providing the rib 24c at a position symmetrical with respect to the rotation axis P, it is possible to suppress such a change in the pull-out tension.

  The number of the ribs 24c is not particularly limited, but if the number of the ribs 24c is too small, the effect of stabilizing the shape of the reel member 1 cannot be sufficiently obtained. On the other hand, if the number of the ribs 24c is too large, the mold may not be easily removed from the core 2 at the time of molding. Further, the heat storage amount of the rib 24c may increase after molding. In this case, when the ribs 24c are radiated, the shape of the ribs 24c may be distorted. Such shape distortion may cause an increase in surface runout. From these viewpoints, the number of the ribs 24c is preferably about 3 to 16, more preferably about 5 to 8.

  In addition, the above-mentioned recessed part 23 and rib 24c may not be provided in the core part 2. However, from the viewpoint of weight reduction and stabilization of the shape of the reel member 1, it is preferable that the concave portion 23 and the rib 24 c are provided in the core 2.

  On the other hand, a lightened portion may be formed on the bottom surface 24 of the concave portion 23 from the viewpoint of further reducing the weight. The lightening portion is, for example, a through hole penetrating between the bottom surfaces 24 or a recess formed in the bottom surface 24. By providing the core portion 2 with a lightening portion, the weight of the reel member 1 can be further reduced.

  Here, the position where the lightening portion is provided is not particularly limited, but is preferably provided at a position symmetrical with respect to the rotation axis P of the core 2. More specifically, it is preferable that the lightening portions are provided at equal intervals along a circumferential direction around the rotation axis P. Thereby, the fluctuation of the pull-out tension can be suppressed. That is, when the lightening portion is provided at an asymmetric position with respect to the rotation axis P, there is a possibility that the pull-out tension varies according to the rotation angle of the reel member 1. However, by providing the lightening portion at a position symmetrical with respect to the rotation axis P, it is possible to suppress such fluctuation in the pull-out tension.

  The flange portion 3 is a ring-shaped and plate-shaped member. The flange portions 3 are provided at both ends of the core 2 in the direction of the rotation axis P. It is preferable that at least one of the two flanges 3 is formed integrally with the core 2. In the present embodiment, since the flange portion 3 is integrally molded with the core portion 2 and each dimension has a value within a predetermined range as described later, the runout of the flange portion 3 is ± 0.2 mm. Value within the range. Of course, even if both of the two flange portions 3 are separate from the core 2, the surface runout of the flange portion 3 can be set to a value within a range of ± 0.2 mm as described later.

  On the other hand, when the flange portion 3 is separate from the core portion 2, the flange portion 3 is fixed to the core portion 2 by some fixing method (for example, ultrasonic welding).

  In the present embodiment, the fixed surface 22 is smoothed, and since the dimensions are within a predetermined range as described later, the flange 3 has a surface runout of ± 0.2 mm. Value. The runout of the flange portion 3 is preferably a value within a range of ± 0.15 mm, and more preferably a value within a range of ± 0.1 mm.

  The flange 3 may be fixed to the core 2 with an adhesive. However, it is preferable that the adhesive is applied evenly on the fixing surface 22 as much as possible. This is because if the thickness of the coating layer varies, the amount of runout of the flange portion 3 may increase.

<3. Preferred numerical range of each dimension>
In the present embodiment, it is preferable that each dimension of the reel member 1 has a value within a predetermined range. Hereinafter, each dimension and a preferable numerical range will be described with reference to FIG.

First, it is preferable that the diameter D of the core part 2 and the diameter F of the flange part 3 satisfy the following expression (1).
D / F ≧ 0.005 * F−0.38 (1)

  When the diameter D of the core part 2 and the diameter F of the flange part 3 satisfy Expression (1), the surface runout of the flange part 3 can be set to a value within a range of ± 0.2 mm.

Here, it is more preferable that the diameter D of the core part 2 and the diameter F of the flange part 3 satisfy the following expression (2).
D / F ≧ 0.005 * F−0.27 (2)

  When the diameter D of the core part 2 and the diameter F of the flange part 3 satisfy Expression (2), the surface runout of the flange part 3 can be set to a value within a range of ± 0.15 mm.

Further, the diameter D of the core 2 and the diameter F of the flange 3 more preferably satisfy the following expression (1).
D / F ≧ 0.005 * F−0.14 (3)

  When the diameter D of the core part 2 and the diameter F of the flange part 3 satisfy Expression (3), the surface runout of the flange part 3 can be set to a value within a range of ± 0.1 mm. In addition, as a reason which Formulas (1)-(3) are materialized, the following are considered, for example. That is, as the diameter F of the flange portion 3 increases, the amount of surface run-out tends to increase. Therefore, the diameter D of the winding core portion 2 needs to be increased accordingly. That is, as the diameter F of the flange portion 3 increases, the D / F needs to be increased. Therefore, equations (1) to (3) hold.

  The value of the diameter D of the core 2 is not particularly limited, but is preferably 40 mm or more. This is to secure an area around which the adhesive film is wound, and to lengthen the adhesive film wound around the reel member 1. Further, the value of the diameter F itself of the flange portion 3 is not particularly limited, but is preferably 135 mm or more. This is because the film winding portion 50a (see FIG. 4) can be made thicker, and the adhesive film wound around the reel member 1 can be made longer.

  The diameter A of the concave portion 23 is preferably about 100 to 130 mm in order to stably perform molding. Further, the width B of the fixing surface 22 is preferably about 1 to 4 mm in order to stably perform molding. Here, the width B of the fixing surface 22 means the length from the end of the fixing surface 22 on the concave portion 23 side to the end of the core 2 on the peripheral surface 21 side. The depth H of the recess 23 is preferably about 15 to 30 mm in order to stably provide the rib. Further, the distance C between the bottom surfaces 24 is preferably about 5 to 15 mm in order to stably perform molding. The distance L (= 2 * H + C) between the flanges 3 is not particularly limited, but is preferably 10 mm or more, and more preferably 50 mm or more. This is to secure an area around which the adhesive film is wound, and to lengthen the adhesive film wound around the reel member 1.

  When the ratio (t / F) between the thickness t of the flange portion 3 and the diameter F of the flange portion 3 is 0.05 or less, the surface runout is set to a value within a range of ± 0.2 mm or less. When it is 0.025 or less, it is more preferable because the surface runout can be set to a value within a range of ± 0.15 mm or less. Further, from the viewpoint of strength and durability, t / F is preferably 0.01 or more.

<4. Material of core part and flange part>
Examples of the material of the core part 2 and the flange part 3 include a thermoplastic resin and the like. Here, examples of the thermoplastic resin include general-purpose engineering plastics, super engineering plastics, and the like in addition to general-purpose resins. The thermoplastic resin may be crystalline or non-crystalline. Examples of general-purpose resins include polyethylene, polypropylene, and polystyrene. Examples of general-purpose engineering plastics include polycarbonate and polyamide. Examples of super engineering plastics include polyimide and polyamide imide. A non-crystalline resin is preferable in that the step accuracy can be obtained with good reproducibility.

  Note that a reel member capable of winding the adhesive film in a traverse shape requires high dimensional accuracy and the like, and thus tends to increase the manufacturing cost. For this reason, such reel members are required to be recyclable. The reel member 1 according to the present embodiment is also a reel member capable of winding the adhesive film in a traverse shape. Therefore, it is preferable that the reel member 1 has high recyclability. For this reason, it is preferable that the material of the core part 2 and the flange part 3 is polycarbonate. Polycarbonate has high solvent resistance, especially resistance to ethanol. Polycarbonate also has excellent impact resistance. Therefore, the reel member 1 made of polycarbonate can be washed with ethanol after use, and is hardly damaged during transportation. Therefore, the reel member 1 made of polycarbonate has high recyclability. The core portion 2 and the flange portion 3 may be made of a resin having the same solvent resistance, impact resistance, and specific gravity as polycarbonate. In this case, the same effect can be obtained.

<5. Structure of film container>
Next, a configuration of the film container 50 using the reel member 1 will be described with reference to FIG. The film container 50 includes the reel member 1 and a film winding portion 50a. The film winding portion 50a is formed by winding the adhesive film around the peripheral surface 21 of the winding core 2 in a traverse shape. Note that the adhesive film may not be wound in a traverse shape. In the present embodiment, since the surface runout of the flange portion 3 is a value within the range of ± 0.2 mm, the adhesive film does not easily fall off both when winding and drawing out the adhesive film.

  The adhesive film applicable to the present embodiment is not particularly limited. The adhesive film is composed of, for example, a base film and an adhesive layer laminated in a base film shape. The material of the base film is not particularly limited, and may be appropriately determined according to the use of the adhesive film. Examples of the material constituting the base film include, for example, silicone (Polyethylene terephthalate), OPP (Oriented Polypropylene), PMP (Poly-4-methylpentene-1), and PTFE (Polytetrafluoroethylene) coated with a release agent such as silicone. Things. These base films can prevent the adhesive film from drying and maintain the shape of the adhesive film.

The adhesive layer is a layer having adhesiveness and is formed on the base film. The material of the adhesive layer is not particularly limited, and may be appropriately determined depending on the use of the adhesive film. For example, the adhesive layer may be an anisotropic conductive material. However, the minimum melt viscosity of the adhesive layer is preferably from 1 × 10 ^{3 to} 5.0 × 10 ⁵ Pa · s. Further, the width of the adhesive film is preferably 0.6 to 3.0 mm, and the thickness of the adhesive layer is preferably 10 to 50 μm. In addition, from the viewpoint of preventing blocking when the adhesive film is pulled out, a release film may be further provided on the adhesive layer. The application of the adhesive film according to the present embodiment is not particularly limited, but may be used, for example, for manufacturing a solar panel or the like.

  Further, the range of the ratio of the distance L between the flange portions 3 to the width of the adhesive film (L / width of the adhesive film) is not particularly limited, but is preferably 3 or more, more preferably 5 or more, More preferably, it is 30 or more. The upper limit is not particularly limited, and may be appropriately set depending on the use of the reel member 1 and the like. The length of the adhesive film is not particularly limited, but by winding the adhesive film around the reel member 1 in a traverse shape, a longer adhesive film can be wound around the reel member 1. The length of the adhesive film may be, for example, 600 m or more. As a method for producing such a long adhesive film, for example, there is a method of producing a plurality of short adhesive films (for example, about 100 m) and connecting them.

<6. Manufacturing method of reel member>
Next, a method for manufacturing the reel member 1 will be described. The method of manufacturing the reel member 1 is generally composed of a step of producing a molded product constituting a part or the whole of the reel member 1, and a case where the molded product constitutes a part of the reel member 1. Fixing the members to each other to produce the reel member 1. Specifically, the reel member 1 is manufactured by injection molding using a mold. Hereinafter, each example of the injection molding will be described with reference to FIG.

  FIG. 5A shows an example in which the entire reel member 1 is integrally molded using a mold. In this example, an integrally molded product (so-called one-piece molded body) of the entire reel member 1 is produced. FIG. 6 shows an example of the mold. In the example shown in FIG. 6, the reel member 1 is molded by dies 200a to 200d. The dies 200 a and 200 b are dies for molding at least the inner peripheral surface 3 a of the core part 2 and the flange part 3, and have shapes symmetrical with respect to the rotation axis P of the core part 2. The dies 200 a and 200 b are movable in a direction perpendicular to the rotation axis P of the core 2. However, a space 210 is slightly formed between the molds 200a and 200b. This space 210 contacts the inner peripheral surface 3 a of the flange portion 3. The molds 200c and 200d are molds for molding at least the outer peripheral surface 3d of the flange portion 3, and are movable in the direction of the rotation axis P. At the time of molding the reel member 1, the molds 200a to 200d are connected to each other, and then the molten resin is injected into the internal space formed by the molds 200a to 200d. Then, after the molten resin is cured (that is, the reel member 1 is molded), the dies 200a to 200d are separated from each other (that is, the reel member 1 is released from the dies 200a to 200d).

  In this example, a large number of molds 200a to 200d are used, and the shapes of the molds 200a and 200b are complicated, so that the mold releasability of the molds 200a to 200d is deteriorated. The space 210 formed at the boundary between the molds 200 a and 200 b contacts the inner peripheral surface 3 a of the flange 3. When the molten resin is injected, the molten resin slightly enters this space 210. The molten resin that has entered the space 210 becomes burrs when cured. Therefore, burrs may be formed on the inner peripheral surface 3 a of the flange portion 3. Such burrs can cause a similar problem as negative runout.

  Thus, the example shown in FIG. 5A is less preferable than the other examples from the viewpoint of the accuracy of the reel member 1 and the manufacturing cost. Of course, the reel member 1 can also be manufactured sufficiently by this example.

  In the example shown in FIG. 5 (b), two reels 1a are formed by molding two molded articles 1a and fixing them. The molded product 1a has a divided core part 2a on which an adhesive film can be wound, and a flange part 3 integrally molded at one end of the divided core part 2a in the rotation axis Q direction. The rotation axis Q coincides with the rotation axis P of the core 2. The divided core 2a has a shape in which the core 2 is equally divided into two in a direction perpendicular to the rotation axis P. Therefore, the above-described concave portion 23, the through hole 24b for the shaft body, and the rib 24c are formed in the divided core portion 2a. Further, in the reel member 1 manufactured by this manufacturing method, the core part 2 is constituted by a plurality of divided core parts 2a connected in the rotation axis P direction.

  FIG. 7 shows an example of the mold. In the example shown in FIG. 7, the molded product 1a is molded by dies 300a and 300b. The mold 300a is a mold for molding at least the divided core portion 2a and the inner peripheral surface 3a of the flange portion 3. The mold 300a is movable in the direction of the rotation axis P of the core 2. The mold 300b is a mold for molding at least the outer peripheral surface 3d of the flange portion 3, and is movable in the rotation axis P direction. At the time of molding the reel member 1, the molds 300a and 300b are connected to each other, and thereafter, the molten resin is injected into an internal space formed by the molds 300a and 300b. Then, after the molten resin is cured (that is, the molded product 1a is molded), the dies 300a and 300b are separated from each other (that is, the molded product 1a is released from the dies 300a and 300b).

  In this example, fewer molds 300a and 300b are used than in FIG. 5A, and the shapes of the molds 300a and 300b are not so complicated, so that the mold releasability of the molds 300a and 300b is good. . In addition, in order to improve the releasability of the mold 300a, a tapered portion may be formed in the divided core portion 2a. This taper is inclined toward the rotation axis Q as the distance from the flange portion 3 increases. From the viewpoint of the winding accuracy of the adhesive film, the inclination of the taper is preferably as small as possible. Further, since the space 310 formed at the boundary between the molds 300 a and 300 b does not contact the inner peripheral surface 3 a of the flange 3, no burr is formed on the inner peripheral surface 3 a of the flange 3. Also, the number of parts that need to be fixed is as small as two.

  Thus, the example shown in FIG. 5B is the most preferable example among the examples shown in FIG. 5 from the viewpoint of the accuracy of the reel member 1 and the manufacturing cost.

  In this example, it is necessary to fix the molded products 1a to each other. This fixing is performed by, for example, impulse welding. Hereinafter, a method of the impulse welding will be described with reference to FIG. In this example, a plurality of protruding portions 40a and through holes 40b are formed on the distal end surface of the divided core 2a in the direction of the rotation axis Q. The length of the protruding portion 40a is larger than the length of the through hole 40b. The through hole 40 b is a hole that penetrates from the tip end surface of the divided core part 2 a to the bottom surface 24 of the concave part 23. The protruding portions 40a and the through holes 40b are provided alternately at symmetrical positions with respect to the rotation axis Q. That is, the protruding portions 40a and the through holes 40b are provided alternately and at equal intervals along the circumferential direction of the distal end surface of the divided core part 2a. The same number of protrusions 40a and through holes 40b are provided. The protruding portion 40a and the through hole 40b may be provided on the distal end surface of the divided core 2a by injection molding using the above-described molds 300a and 300b. The protrusion 40a provided on one of the split cores 2a is made to pass through the through hole 40b provided on the other split core 2a, while the protrusion provided on the other split core 2a. 40a is passed through a through hole 40b provided in one of the divided core portions 2a. Thereafter, a part of the protruding portion 40a protruding from the through hole 40b is melted and solidified. At this time, the molten material not only fills the through hole 40b but also spreads slightly on the bottom surface 24 of the concave portion 23, thereby almost completely closing the through hole 40b. As a result, the protrusion 40a and the through hole 40b are integrated. Through the above steps, the divided core portions 2a are fixed to each other. In this example, the protruding portions after solidification slightly protrude from the bottom surface 24 of the concave portion 23. Therefore, the mass balance of the reel member 1 can be equalized. Of course, the arrangement of the protruding portion 40a and the through hole 40b is not limited to this example. For example, the protruding portion 40a may be provided on one divided core portion 2a, and the through hole 40b may be provided on the other divided core portion 2a. However, from the viewpoint of equalizing the mass balance, the above-described example is more preferable.

  Further, it is preferable that the adhesive film is not directly wound around the boundary portion 2b between the divided core portions 2a. For example, it is preferable to first wind a lead tape around this portion, and then wind an adhesive film on the lead tape.

  In the example shown in FIG. 5C, the reel member 1 is manufactured by molding the molded product 1b and the flange portion 3 and fixing them. The molded product 1b has a core part 2 and a flange part 3 integrally molded at one end of the core part 2 in the direction of the rotation axis P. The molded article 1b may be molded by a mold similar to the mold shown in FIG. In addition, it is preferable to form the same taper in the core part 2 as the divided core part 2a. Further, the fixing between the flange portion 3 and the core portion 2 may be performed by ultrasonic welding. A specific method is as described above. In this example, burrs do not occur on the inner peripheral surface 3a of the flange portion 3, and the number of dies for molding the molded product 1b can be reduced. Furthermore, the number of parts that need to be fixed is as small as two. However, since it takes some time to release the molded product 1b from the mold, the accuracy is slightly inferior to the example shown in FIG. 5B.

  In the example shown in FIG. 5D, the reel member 1 is manufactured by separately molding the two flange portions 3 and the core 2 and fixing them. In this example, since the two flanges 3 and the core 2 are individually molded, the two flanges 3 and the core 2 can be molded with high precision. Further, no burr is generated on the inner peripheral surface 3a of the flange portion 3. However, since the number of parts that need to be fixed is as large as three, the cost is higher than the example shown in FIG.

<1. Example 1>
Next, examples of the present invention will be described. In Example 1, the following experiment was performed.

(1-1. Preparation of adhesive film)
It has a base film made of PET having a width of 1 mm and a thickness of 38 μm, an adhesive layer having a thickness of 20 μm formed on the base film, and a peelable PET film having a thickness of 12 μm formed on the adhesive layer. An adhesive film was prepared. The length of the adhesive film was 5,000 m. Specifically, a plurality of adhesive films having a thickness of about 100 m were prepared, and these were connected to prepare a 5,000 m adhesive film.

  Here, the adhesive layer was produced by the following steps. Specifically, 30 parts by mass of a phenoxy resin (YP-50 manufactured by Nippon Steel Chemical Co., Ltd.), 20 parts by mass of a liquid epoxy resin (JER828 manufactured by Mitsubishi Chemical Co., Ltd.), 10 parts by mass of a rubber component (SG80H manufactured by Nagase Chemtech Co., Ltd.), An adhesive composition containing 40 parts by mass of a curing agent (NOVACURE 3941HP manufactured by Asahi Kasei Corporation) and 1 part by mass of a silane coupling agent (A-187 manufactured by Momentive Performance Materials) was prepared.

  Then, a coating liquid was prepared by dissolving the adhesive composition in a solvent toluene, and the coating liquid was coated on a base film. And the solvent was volatilized by heating the coating layer at 50 degreeC for 10 minutes. Through the above steps, an adhesive layer was produced. The adhesive layer had a minimum melt viscosity of 7.0 × 103 Pa · s. The minimum melt viscosity of the adhesive layer is a value measured using a rotary rheometer (manufactured by TA instrument). The measurement was performed using a measurement plate having a diameter of 8 mm, with the temperature rising rate being 10 ° C./min and the force at the time of measurement being constant at 1 N.

(1-2. Production of Reel Member)
The reel member 1 was molded by the manufacturing method shown in FIG. Here, an S-2000i, 300t type manufactured by Mitsubishi Heavy Industries Plastic Technology was used as a molding device, and a general-purpose slide core type die was used as a die. Injection molding was performed in the following steps. That is, the polycarbonate resin melted by heating to about 300 ° C. was injected into a mold and held at a holding pressure of about 1200 kg / cm ² . Then, the resin was solidified by cooling for 30 seconds. Injection molding was performed by the above steps.

  The divided core portions 2a were fixed to each other by the impulse welding described above. The arrangement of the protruding portion 40a and the through hole 40b was as shown in FIG. 8, and an impulse welding machine manufactured by Munekata Industrial Machinery Co., Ltd. was used as the impulse welding machine. The conditions for impulse welding were as follows: energization time: 0.5 seconds; cooling time: 2 seconds. The reel member 1 was manufactured by the above steps. The dimensions of the reel member 1 are as follows. Diameter D of core part 2 = 120 mm, diameter F of flange part 3 = 170 mm, D / F = 0.706, thickness t of flange part 3 = 3 mm, width B of fixing surface 22 = 2 mm, diameter of concave part 23 A = 116 mm, B / A = 0.017, depth H of the concave portion 23 = 23 mm, distance C between the bottom surfaces 24 = 10 mm, H / C = 2.3, distance L between the flange portions 3 = 50 mm.

(1-3. Measurement of runout amount)
Next, the surface runout of the flange portion 3 was measured as follows. First, four contact points 3b between one flange portion 3 and the core portion 2 were set at 90 ° intervals along the circumferential direction of the core portion 2. The surface runout was measured using these contact points 3b. Specifically, the other flange portion 3 of the reel member 1 was installed on a pedestal prepared in advance, and the surface runout was measured using a tracing indicator TI-113HR (513-474) manufactured by Mitutoyo Corporation. The surface runout of the other flange 3 was measured in the same manner. Then, the maximum amount of positive and negative maximum runout in a total of eight measured values was defined as the surface runout of the flange portion 3.

(1-4. Production of film container (adhesive film winding test))
A film container 50 was produced by winding an adhesive film around the reel member 1. Here, the width w of the film winding portion 50a was 49.5 mm. The winding of the adhesive film was performed according to the method disclosed in Patent Document 1. The traverse pitch was 1 mm, and the line speed was 25 M / min. Further, the location of the drop was visually measured, and based on the location of the drop, the film container 50 was evaluated as follows.
A: No dropout B: Dropout occurred but mild (no problem in practical use)
C 1-5 locations of falling out of 5,000 m of adhesive film D 6 or more locations of falling out of 5,000 m of adhesive film

(1-5. Pull-out test of adhesive film)
A self-made draw-out tester prepared with reference to a commercially available film pasting and pasting device such as a film pasting device (model number TTO-1794M) manufactured by Shibaura Mechatronics Co., Ltd. was prepared. Then, using this pull-out tester, the operation was performed until all the adhesive films were pulled out from the film container 50 at a reel housing temperature of 30 ° C., a pulling speed of 500 mm / sec, a pull-out tension of 50 g, and a stroke of 250 mm. The number of times was visually measured, and based on the number of times of dropping, the film container 50 was evaluated as follows.
A: No dropout B: Dropout occurred but mild (no problem in practical use)
C The number of times of falling off is 1 to 5 times in 5000 m of the adhesive film.

  Table 1 summarizes the diameter D of the core 2, the diameter F / D / F of the flange 3, the amount of runout, and the evaluation of dropout.

<2. Examples 2 to 9, Comparative Example 1>
The same processing as in Example 1 was performed except that the diameter D of the core 2 and the diameter F of the flange 3 were changed as shown in Table 1. Table 1 collectively shows the dimensions (diameter D of the core part 2, diameter F of the flange part 3, D / F), surface runout, and dropout evaluation of each example.

<3. Examination of evaluation results>
As shown in Table 1, it was found that the smaller the amount of surface run-out was, the more difficult it was to drop out. That is, according to the present embodiment, the surface runout can be set to a value within the range of ± 0.2 mm. Further, the surface runout amount is preferably a value within a range of ± 0.15 mm, and more preferably a value within a range of ± 0.1 mm.

  Further, as shown in FIG. 5, the results of Examples 1 to 9 are plotted on an xy plane where the horizontal axis is the diameter F of the flange portion 3 and the vertical axis is D / F. Further, the type of each point was changed according to the amount of surface runout. As a result, it was found that a straight line connecting points of the same type could be drawn. That is, the straight line L1 is a straight line connecting points at which the surface runout is within the range of ± 0.2, and the straight line L2 is a straight line connecting the points at which the plane runout is within the range of ± 0.15. The straight line L3 is a straight line connecting points at which the surface runout is within the range of ± 0.1.

Then, the straight line L1 is represented by the following equation (1 ′).
D / F = 0.005 * F−0.38 (1 ′)
The straight line L2 is represented by the following equation (2 ′).
D / F = 0.005 * F−0.27 (2 ′)
The straight line L3 is represented by the following equation (3 ′).
D / F = 0.005 * F−0.14 (3 ′)

  As a result, when the diameter D of the core part 2 and the diameter F of the flange part 3 satisfy the above-described formula (1), it can be said that the surface runout is a value within the range of ± 0.2. When the diameter D of the core part 2 and the diameter F of the flange part 3 satisfy the above-described formula (2), it can be said that the amount of surface runout is a value within the range of ± 0.15. In addition, when the diameter D of the core 2 and the diameter F of the flange 3 satisfy the above-described formula (3), it can be said that the surface runout has a value within a range of ± 0.1. For example, Comparative Example 1 does not satisfy Expression (1), and thus the surface runout amount is −0.3 or less.

  As described above, the preferred embodiments of the present invention have been described in detail with reference to the accompanying drawings, but the present invention is not limited to such examples. It is obvious that those skilled in the art to which the present invention pertains can conceive various changes or modifications within the scope of the technical idea described in the claims. It is understood that these also belong to the technical scope of the present invention.

DESCRIPTION OF SYMBOLS 1 Reel member 2 Core part 3 Flange part 21 Peripheral surface 22 Fixed surface 23 Concave part 24 Bottom surface 24b Shaft through-hole 24c Rib 50 Film container 50a Film winding part

Claims (12)

A core part around which an adhesive film can be wound;
And flange portions provided at both ends in the rotation axis direction of the core portion,
At least one or more of the core portion and the two flange portions are molded products,
The diameter of the core portion and the diameter of the flange portion satisfy the following equation (1):
The reel member, wherein a surface runout of the flange portion is a value within a range of ± 0.2 mm.
D / F ≧ 0.005 * F−0.38 (1)
In the formula (1), D is the diameter (unit: mm) of the core portion, and F is the diameter (unit: mm) of the flange portion. The diameter D of the core is 40 mm or more,
The reel member according to claim 1, wherein a diameter F of the flange portion is 135 mm or more. The reel member according to claim 2, wherein the diameter D of the core portion is 120 mm or less. The reel member according to claim 2, wherein the diameter (F) of the flange portion is less than 250mm. The reel member according to any one of claims 1 to 4 , wherein at least one of the two flange portions is integrally formed with the core. The reel member according to any one of claims 1 to 5 , further comprising concave portions formed at both ends in the rotation axis direction of the core portion. The reel member according to claim 6 , wherein a rib extending radially from a rotation axis of the core portion is formed on a bottom surface of the concave portion. The reel member according to claim 7 , wherein the rib is disposed at a position symmetrical with respect to a rotation axis of the core. The reel member according to any one of claims 1 to 8 , wherein a distance between the flange portions is 10 mm or more. The reel member according to any one of claims 1 to 9 , wherein the core has a plurality of divided cores connected in a rotation axis direction of the core. A reel member according to any one of claims 1 to 10 ,
A film container comprising: an adhesive film wound around the core portion. A step of producing one or more molded products constituting a part or the whole of a reel member including a core portion capable of winding an adhesive film and flange portions provided at both ends of the core portion,
When the molded product constitutes a part of the reel member, by fixing the molded products to each other, including the step of producing the reel member,
The diameter and the diameter of the flange portion of the winding core portion is to satisfy the following equation (1),
The method of manufacturing a reel member, wherein a surface runout of the flange portion is a value within a range of ± 0.2 mm .
D / F ≧ 0.005 * F−0.38 (1)
In the formula (1), D is the diameter (unit: mm) of the core portion, and F is the diameter (unit: mm) of the flange portion.

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