JP6776856B2 - Pressure contact roller - Google Patents

Description

The present invention relates to a pressure contact roller.

In the film manufacturing process and processing process, the film may be conveyed by various rollers and wound into a roll. Since the film is generally an insulator, the film roll may have a charging defect due to friction with a roller or the like. This charging defect can be solved by arranging a static elimination device with needle-shaped electrodes during the process to neutralize the charging, but it is difficult to eliminate static electricity from the locally charged part of the film, and during the coating process in the subsequent process. Problems such as uneven application of the solution and loss of the metal vapor deposition film during the vapor deposition process occur.

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

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

Japanese Unexamined Patent Publication No. 2008-81239 Japanese Unexamined Patent Publication No. 2006-151569

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

Therefore, an object of the present invention is to provide a pressure contact roller capable of suppressing charging defects even in a smooth film.

In order to achieve the above object, the roller of the present invention is a substantially cylindrical core member and a rubber layer coated on the surface of the core member, and the average particle size in the rubber layer is 1 μm or more and 100 μm or less. A pressure-contact roller containing a rubber layer containing a substantially spherical filler having a volume content of 30% or more and 50% or less with respect to the rubber layer. The rubber layer contains the filler on the surface of the rubber layer. There is a portion exposed from the surface and / or a portion where the surface of the rubber layer is raised including the filler inside, and the outer diameter of the roller is 25 mm or more and 130 mm or less.

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

The "average particle size" refers to the particle size (median diameter) at a point where the cumulative curve is 50% when the cumulative curve is obtained with the total product as 100% in the particle size distribution.

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

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

The "amorphous carbon-like film" refers to an amorphous carbon or a hard film of carbon having amorphousness as a laminate of crystals.

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

Further, according to a preferred embodiment of the present invention, the hardness of the rubber layer is more than 55 ° and 70 ° or less in JIS-A.

According to the present invention, when the film is wound, by using a pressure contact roller that can physically and chemically suppress the charge due to contact and friction with the film, the charge defect of the film is suppressed and the quality of the rolled film is improved. A good film roll body can be obtained.

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

Hereinafter, preferred embodiments of the pressure contact rollers according to the present invention will be described in detail with reference to the accompanying drawings.

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

Each roller is rotationally supported by a bearing, and the bearing is appropriately supported by a frame or the like. The pressure contact roller 5, the guide roller 7, and the lower blade roller 8 may be a driven roller that rotates by a frictional force with the film 10, or may be a drive roller using a motor or the like. When driven by a motor or the like, it is preferable that the rotation speed of the rollers is substantially the same as the transport speed of the film 10 so that the rollers and the film 10 do not slip and cause triboelectric charging on the film 10. It is preferable that the core 11 is gripped by a chuck supported by a bearing and rotationally driven by a motor or the like. Further, the electric potential of the film roll 12 can be suppressed low by the static eliminator 13 installed toward the film roll 12. The static eliminator 13 is a device that generates ions in the air and neutralizes the charged charge of the film 10 by the ions, and is used for the purpose of assisting the charge suppressing effect of the pressure contact roller 5 of the present invention. Further, as appropriate, a nip roller or suction roller for gripping the film 10 and accurately controlling tension and speed, a wrinkle smoothing roller for widening the film 10 in the width direction, and the like may be arranged in the slit process.

Typical configurations of the pressure contact roller of the present invention are shown in FIGS. 2 to 9. FIG. 2 is a cross-sectional view schematically showing a configuration as an example of the pressure contact roller 5 of the present invention. The material of the core 1 is preferably one having rigidity and strength that can withstand high pressure, and a metal such as steel or aluminum, a carbon fiber reinforced resin, or the like is preferable. The surface of the cylindrical core 1 is coated with the rubber layer 2. The type of the rubber layer 2 is not particularly limited, and is, for example, natural rubber, nitrile rubber, chloroprene rubber, ethylene propylene rubber, silicone rubber, chlorosulfonated polyethylene rubber, urethane rubber, fluororubber, and a mixture thereof. Can be used as appropriate. In the winding portion 17 of the film 10 of FIG. 1, the inventors of the present application generate a particularly large triboelectric charge between the pressure contact roller 5 and the film 10, so that the triboelectric charge accumulates and a local discharge occurs. I thought that it would be a charging defect if it happened. As described above, the surfaces of optical films, base films for magnetic recording media, ribbon films for thermal transfer, and the like have been smoothed, and it has become impossible to suppress charging defects due to friction with the conventional pressure contact roller configuration. Therefore, in order to suppress triboelectric charging, the inventor of the present application paid attention to the contact state between the pressure contact roller 5 and the film 10. The inventor of the present application has found that even if the surface of the film 10 is smooth, triboelectric charging can be suppressed by reducing the contact area between the film 10 and the pressure roller 5. Therefore, the pressure contact roller 5 of the present invention has the following features.

In the pressure contact roller 5 of the present invention, as shown in the enlarged view of FIG. 2, the rubber layer 2 contains the filler 3, the portion where the filler 3 is exposed from the surface of the rubber layer 2, and the rubber layer. Since the surface of 2 has a raised portion containing the filler 3 inside, unevenness is formed on the surface of the pressure contact roller 5. The material of the filler 3 is not particularly limited, and examples thereof include alumina, silica, and carbon black. Further, in order to improve the dispersibility and filling property of the filler 3 in the rubber layer 2 and not to damage the surface of the film 10, a substantially spherical filler 3 can be applied.

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

The volume content of the filler 3 with respect to the rubber layer 2 is 30% or more and 50% or less. If the volume content of the filler 3 with respect to the rubber layer 2 is less than 30%, the filler 3 for effectively reducing the contact area is insufficient and the charging defect cannot be suppressed. On the other hand, when the volume content of the filler 3 with respect to the rubber layer 2 exceeds 50%, the rubber state cannot be maintained and the roller cannot be molded. Here, when the volume content of the filler 3 with respect to the rubber layer 2 is more than 40% and 50% or less, it can be molded as a roller, but the proportion of the filler 3 is rather large and the rubber connection is poor, so that the pressure contact roller 5 The filler 3 may easily fall off when used as a rubber layer, or the rubber layer 2 may crack during production. Therefore, more preferably, the volume content of the filler 3 with respect to the rubber layer 2 is 30% or more and 40% or less. Within this range, the filler 3 is less likely to fall off from the surface of the rubber layer 2, and molding can be performed without impairing the hardness of the rubber layer 2.

It has been described that when the filler 3 is in the above range, the filler 3 forms irregularities on the surface of the pressure contact roller 5 to reduce the contact area, but the rubber layer 2 between the filler 3 and the filler 3 is completely formed on the film 10. It's not that they don't touch. FIG. 3 is a cross-sectional view schematically showing a contact state between the pressure contact roller 5 and the film 10 according to the embodiment of the present invention. As shown in FIG. 3, in the pressure contact roller 5 of the present invention, the convex portion formed by exposing the filler 3 from the surface of the rubber layer 2 and the surface of the rubber layer 2 are raised including the filler 3 inside. Pressure is mainly applied to the convex portion formed by the above, but since the filler 3 is substantially spherical, the contact state between the convex portion and the film 10 becomes point contact. Further, the pressure with the film 10 is small in the concave portion formed around the convex portion formed by the exposed rubber portion, and in the vicinity of the filler 3, a part of the film 10 is not contacted. As described above, the pressure contact roller 5 of the present invention reduces the contact area and the frictional force with the film 10, and is therefore effective in suppressing the charging defects of the film 10.

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

Here, the elastic modulus E of the rubber layer 2 is as shown in the following mathematical formula 2 when the rubber hardness is S (shore A).

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

Here, the outer diameter of the pressure contact roller 5 is 25 mm or more and 130 mm or less. If the outer diameter of the pressure contact roller 5 is less than 25 mm, the deflection of the pressure contact roller 5 becomes too large, and it is not possible to uniformly apply pressure in the width direction of the film 10, leading to winding defects such as wrinkles. .. On the other hand, when the outer diameter of the pressure contact roller 5 exceeds 130 mm, as can be seen from Equation 1, the outer diameter D ₁ of the pressure contact roller 5 becomes large and the contact area A becomes large, so that the charging defect due to friction cannot be suppressed. More preferably, the outer diameter of the pressure contact roller 5 is 25 mm or more and 70 mm or less. Within this range, the effect of blocking the air accompanying the inner layer of the film roll 12 is higher, and the film 10 can be wound without any defects such as wrinkles, which is preferable.

The hardness of the rubber layer 2 is preferably 40 ° or more and 80 ° or less in JIS-A. When the hardness of the rubber layer 2 is less than 40 ° in JIS-A, the elastic modulus E of the rubber layer 2 is small as can be seen from the mathematical formula 2, and the contact area A is large in the mathematical formula 1. The drawbacks cannot be suppressed. On the other hand, if the hardness of the rubber layer 2 exceeds 80 ° in JIS-A, the deformation of the rubber layer 2 is hindered, pressure cannot be uniformly applied in the width direction of the film 10, and there are defects such as wrinkles. Leads to. Here, the inventor of the present application has made it possible to further reduce the contact area between the pressure contact roller 5 and the film 10 when winding a film 10 having a particularly smooth surface such as a base film for a magnetic recording medium or a ribbon film for thermal transfer. It has been found that it is preferable to increase the hardness of the rubber layer 2 to further reduce the amount of deformation of the rubber at the time of contact pressure. On the other hand, if the hardness of the rubber layer 2 is too high, the amount of deformation of the rubber cannot follow the thickness unevenness of the film 10. Therefore, preferably, the hardness of the rubber layer 2 exceeds 55 ° and 70 ° or less in JIS-A. Yes, more preferably, the hardness of the rubber layer 2 is 60 ° or more and 65 ° or less in JIS-A.

The thickness of the rubber layer 2 is preferably 2 mm or more and 6 mm or less. In Equation 1, when the thickness t of the rubber layer 2 is large, the contact area A is large, and when the thickness of the rubber layer 2 exceeds 6 mm, the charging defect due to friction cannot be suppressed. On the other hand, if the thickness of the rubber layer 2 is less than 2 mm, the rubber layer 2 is restrained at the interface with the hard core 1, so that the deformation of the rubber layer 2 is small and it becomes impossible to follow the thickness unevenness of the film 10. It is not possible to apply pressure uniformly in the width direction of the film 10, which leads to defects such as wrinkles.

The contact pressure is preferably 800 N / m or less, and more preferably 400 N / m or less. In Equation 1, by setting the contact pressure P in the above range, the contact area A becomes small, and it becomes easy to suppress the charging defect due to friction.

Further, the pressure contact roller 5 that is effective in suppressing charging defects is not limited to the configuration shown in FIG. 2, and may be the configuration of the pressure contact roller 5 shown in FIGS. 4 and 5. In the configuration of the pressure contact roller 5 of FIG. 4, as shown in the enlarged view of FIG. 4, the filler 3 is a rubber layer without forming a portion where the surface of the rubber layer 2 contains the filler 3 and is raised. It forms a portion exposed from the surface of 2. Further, in the configuration of the pressure contact roller 5 of FIG. 5, as shown in the enlarged view of FIG. 5, the filler 3 is not exposed from the surface of the rubber layer 2, and the surface of the rubber layer 2 contains the filler 3 inside. It forms a raised part. Even in these configurations, the surface of the pressure contact roller 5 can be formed with irregularities that reduce the contact area with the film 10, and thus has a sufficient effect of suppressing charge defects.

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

FIG. 6 is a cross-sectional view schematically showing another configuration of the pressure contact roller 5 of the present invention. In the configuration of the pressure contact roller 5 of FIG. 6, as shown in the enlarged view of FIG. 6, the portion where the filler 3 is exposed from the surface of the rubber layer 2 and the surface of the rubber layer 2 include the filler 3 inside. By having the raised portion, the amorphous carbon-like film 4 is coated on the outermost layer of the pressure contact roller 5 having an uneven shape formed on the surface. By having the amorphous carbon-like film 4 on the outermost surface layer of the pressure contact roller 5, the flexibility of the rubber layer 2 is not impaired and only the very surface layer of the pressure contact roller 5 is cured, so that the contact area is further reduced. The effect is enhanced, and since the rubber layer 2 can be prevented from being worn and a low friction coefficient can be maintained, the effect of suppressing charge defects is further enhanced. Further, since the outermost surface layer of the pressure contact roller 5 is covered with the amorphous carbon-like film 4, it is possible to prevent the filler 3 from falling off from the rubber layer 2 and becoming a foreign matter defect of the film 10. Here, the amorphous carbon-like film 4 is a hard carbon film having a specific solid structure (amorphous or amorphous as a laminate of crystals) as described above, and is, for example, methane or acetylene. If plasma CVD (chemical vapor phase film formation) or the like using a hydrocarbon-based gas such as ethylene is used, a hard carbon film can be formed on a soft layer such as rubber. This film is called a diamond-like carbon film (DLC film). As the film forming method of the amorphous carbon-like film 4, the method described in Patent Document 1 may be adopted. If the thickness of the amorphous carbon-like film 4 is too thin, it may be difficult to form a film with a uniform thickness, while if the film is too thick, the flexibility of the rubber layer 2 is impaired. Since there are cases, it is preferably 0.1 μm or more and 10 μm or less.

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

Further, the pressure contact roller 5 in which the outermost surface layer is coated with the amorphous carbon-like film 4 is not limited to the configuration shown in FIG. 6, and may have the configuration shown in FIGS. 7 and 8. The configuration of the pressure contact roller 5 in FIG. 7 is that, as shown in the enlarged view of FIG. 7, the filler 3 is made of rubber without forming a raised portion where the surface of the rubber layer 2 contains the filler 3 inside. The outermost layer of the pressure contact roller 5 on which the portion exposed from the surface of the layer 2 is formed is coated with the amorphous carbon-like film 4. Further, the configuration of the pressure contact roller 5 in FIG. 8 is that, as shown in the enlarged view of FIG. 8, the filler 3 is contained inside the surface of the rubber layer 2 without being exposed from the surface of the rubber layer 2. The outermost layer of the pressure contact roller 5 on which the raised portion is formed is coated with the amorphous carbon-like film 4. Even in these configurations, unevenness is formed on the surface of the pressure contact roller 5 to reduce the contact area with the film 10, and a low friction coefficient can be maintained on the outermost layer of the pressure contact roller 5, which is charged with the polyethylene terephthalate film. Since it forms an amorphous carbon-like film 4 having good compatibility, it has a sufficient effect of suppressing charge defects.

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

Hereinafter, the present invention will be specifically described with reference to Examples, but the present invention is not limited to these Examples.

[Example 1]
In the slitting process of the film 10 shown in FIG. 1, using the pressure contact roller 5 of FIG. 2, the width is 1000 mm, the average thickness is 5 μm, and the surface is smooth with an arithmetic mean roughness Ra = 2 nm specified in JIS B0601: 2013. A polyethylene terephthalate (PET) film was wound around a core 11 made of a glass fiber reinforced resin at a winding speed of 120 m / min and a winding length of 15,000 m to obtain a film roll 12. The pressure contact roller 5 was pressed against the core 11 by an air cylinder so that the contact pressure was 300 N / m. The contact roller 5 had a surface length of 1100 mm and an outer diameter of 70 mm, and the rubber layer 2 was made of chloroprene rubber having a thickness of 5 mm and a hardness of 50 ° (JIS-A). The filler 3 was a substantially spherical alumina having an average particle size of 4 μm, and the volume content of the filler 3 with respect to the rubber layer 2 was 33%. The material of the core 1 was STKM13A specified in JIS G3445: 2016.

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

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

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

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

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

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

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

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

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

[Comparative Example 1]
As the pressure contact roller 5, a core 1 made of STKM13A coated with chloroprene rubber having a thickness of 5 mm and a hardness of 50 ° (JIS-A) was used. The rubber layer 2 did not contain a substantially spherical filler having an average particle size of 1 μm or more and 100 μm or less, and did not form a DLC film which is an amorphous carbon-like film 4. Other conditions were the same as in Example 1.

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

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

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

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

[Comparative Example 6]
The pressure contact roller 5 is a substantially spherical filler having an average particle size of 1 μm or more and 100 μm or less, although a core 1 of material STKM13A coated with chloroprene rubber having a thickness of 5 mm and a hardness of 50 ° (JIS-A) is used. The DLC film, which is an amorphous carbon-like film 4, was not formed. As the film 10, a polyethylene terephthalate (PET) film having a width of 1000 mm, an average thickness of 5 μm, and a surface surface of which the arithmetic average roughness Ra = 5 nm specified in JIS B0601: 2013, which is coarser than other conditions, was used. Other conditions were the same as in Example 1.

[Comparative Example 7]
The pressure contact roller 5 is a substantially spherical filler having an average particle size of 1 μm or more and 100 μm or less, although a core 1 of material STKM13A coated with chloroprene rubber having a thickness of 5 mm and a hardness of 50 ° (JIS-A) is used. The DLC film which does not contain 3 and is an amorphous carbon-like film 4 was not formed. As the film 10, a polypropylene (PP) film having a width of 1000 mm, an average thickness of 5 μm, and a surface having an arithmetic mean roughness Ra = 10 nm specified in JIS B0601: 2013 was used. Other conditions were the same as in Example 1.

[Electrification defect evaluation method]
After winding up, the occurrence of charging defects was confirmed. The presence or absence of charging defects was evaluated by sprinkling a copy toner on the film 10. Toner adheres to the charged part. "◎" when no charging defect is confirmed in 100 out of 100, "○" when 1 or more and 3 or less charging defects are confirmed in 100, 4 or more out of 100 charging defects 9 When this or less was confirmed, it was judged as "Δ", and when 10 or more of 100 charging defects were confirmed, it was judged as "x".

[Evaluation method of transcription trace]
After winding up, the occurrence of transfer marks was confirmed. "○" if no transfer marks are confirmed out of 100, "△" if 1 or more and 9 or less transfer marks are confirmed out of 100, and 10 or more transfer marks are confirmed. If it is, it is judged as "x".

[Wrinkle evaluation method]
After rolling up, we confirmed the occurrence of wrinkles. If 3 or less of 100 wrinkles are confirmed, "○", if 4 or more and 9 or less of 100 wrinkles are confirmed, "△", if 10 or more of 100 wrinkles are confirmed, It was judged as "x".

[Evaluation method of surface condition of pressure contact roller]
The surface condition of the pressure contact roller 5 after winding 10 film rolls 12 was confirmed. If there is no particular problem, "○", if the filler 3 is confirmed to have fallen off a part of the rubber layer 2, and if wear powder is generated on the surface of the pressure contact roller 5, "△", the pressure contact roller 5 When the rubber layer 2 was brittle and the rubber layer 2 was broken at the molding stage, it was judged as "x".

Table 1 summarizes the conditions and evaluation results of Examples 1 to 10 and Comparative Examples 1 to 7. The conditions surrounded by the cells in the thick frame in the table are the parts where the conditions are changed from the first embodiment.

In Examples 1 to 10, substantially spherical alumina particles having an average particle size of 1 μm or more and 100 μm or less are contained in the rubber layer 2 of the pressure contact roller 5 with a volume content of 30% or more and 50% or less, so that the surface has an uneven shape. Is formed, and the outer diameter of the pressure contact roller 5 is 25 mm or more and 130 mm or less, the contact area with the film roll 12 is smaller than that of the normal pressure contact roller 5, which is a good result for charging defects. Met.

In Example 2, the rubber layer 2 of the pressure contact roller 5 contained 46% of substantially spherical alumina particles having an average particle size of 4 μm, which exceeds a volume content of 40%, so that the surface of the pressure contact roller 5 was slightly covered. The filler 3 was seen to fall off, resulting in some abrasion powder of the rubber layer 2 adhering to the surface of the pressure contact roller 5.

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

In Example 5, since the outer diameter of the pressure contact roller 5 was 120 mm, the rubber layer 2 was slightly deformed, resulting in some wrinkles.

In Example 6, since the rubber layer 2 of the pressure contact roller 5 is a high-hardness rubber having a hardness of 75 °, better results are obtained for charging defects, but the rubber layer 2 is slightly deformed. It was inhibited and resulted in some wrinkles.

In Example 7, PP was used as a raw material for the film 10. Many fibrils were formed in the PP film, which is a crystalline polymer, and the arithmetic mean roughness Ra = 10 nm, which was coarser than that of the PET film, and the result for charging defects was better than that of the PET film.

In the eighth embodiment, a DLC film is formed on the outermost layer of the pressure contact roller 5, the surface of the pressure contact roller 5 is prevented from being worn, and PET is used as the raw material of the film 10, and the surface of the pressure contact roller 5 is covered. By bringing the charged trains closer to the charged trains of the film 10, better results were obtained with respect to charging defects.

In Example 9, since the rubber layer 2 of the pressure contact roller 5 is a high-hardness rubber having a hardness of 60 °, better results are obtained for charging defects.

Further, in Example 10, the DLC film was formed on the outermost layer of the high-hardness rubber in which the rubber layer 2 had a hardness of 60 °, which was the best result for the charging defect.

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

In Comparative Example 3, the rubber layer 2 of the pressure contact roller 5 contained 62% of substantially spherical alumina particles having an average particle size of 4 μm, which exceeded 50% in volume, so that the rubber state could not be maintained and the roller was used as a roller. The result was that it could not be molded.

In Comparative Example 4, since the rubber layer 2 of the pressure contact roller 5 contained substantially spherical alumina particles having an average particle size of more than 100 μm and having a diameter of 200 μm, the surface irregularities of the pressure contact roller 5 became too large, and the generation rate of transfer marks was high. The result was.

In Comparative Example 5, although the rubber layer 2 of the pressure contact roller 5 contained substantially spherical alumina particles having an average particle size of 4 μm with a volume content of 33%, the outer diameter of the pressure contact roller 5 was 220 mm, which exceeds 130 mm, and other It is larger than the condition, and as a result, the contact area between the pressure contact roller 5 and the film 10 becomes large, the charging defect occurrence rate is high, and the effect of blocking the air accompanying the inner layer of the film roll 12 is impaired, and the film roll The result was that 12 wrinkles were generated.

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

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

As described above, according to the present invention, the film 10 is formed by using the pressure contact roller 5 in which the rubber layer 2 contains the filler 3, the uneven shape is formed on the surface, and the amount of deformation of the rubber layer 2 is small. Even when the film 10 is smooth, the charge of the film 10 is suppressed, and it is possible to provide the film roll 12 having no charge defect.

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

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

Claims (5)

Approximately cylindrical core member and
A rubber layer coated on the surface of the core member, wherein a substantially spherical filler having an average particle size of 1 μm or more and 100 μm or less is contained in the rubber layer at a volume content of 30% or more and 50% or less with respect to the rubber layer. A pressure roller that includes a rubber layer
The rubber layer has a portion where the filler is exposed from the surface of the rubber layer and / or a portion where the surface of the rubber layer contains the filler and is raised.
A pressure contact roller having an outer diameter of 25 mm or more and 130 mm or less. The pressure contact roller according to claim 1, wherein the rubber layer has a portion where the filler is exposed from the surface of the rubber layer, and the surface of the rubber layer is covered with a layer of an amorphous carbon-like film. The pressure contact roller according to claim 2, wherein a portion of the filler exposed from the surface of the rubber layer is coated with a layer of an amorphous carbon-like film. The contact pressure according to claim 1, wherein the rubber layer has a portion where the surface of the rubber layer is raised including the filler inside, and the surface of the rubber layer is covered with a layer of an amorphous carbon layered film. roller. The pressure contact roller according to any one of claims 1 to 4, wherein the hardness of the rubber layer exceeds 55 ° and is 70 ° or less in JIS-A.

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