KR102407185B1 - The linear type roll-to-roll winding apparatus and adjusting method for optimizing the same - Google Patents

Abstract

The present invention is an unwinding winder for unwinding a roll formed by winding a film to be wound; a winding winder disposed on the opposite side of the unwinding winder to wind a roll; and a tension control mechanism for controlling the tensile force of the film transferred between the unwinding winder and the take-up winder, wherein the take-up winder is a linear roll-to-roll winding mechanism including a core enlarged portion for enlarging the outer diameter of the core portion and optimizing the same how to control it.

Description

The LINEAR TYPE ROLL-TO-ROLL WINDING APPARATUS AND ADJUSTING METHOD FOR OPTIMIZING THE SAME

The present invention relates to a linear roll-to-roll winding mechanism and an adjustment method for optimizing such a linear roll-to-roll winding mechanism, and specifically, a defect phenomenon occurring in the core of a film roll wound through the linear roll-to-roll winding mechanism It relates to a linear roll-to-roll winding mechanism that can prevent

In general, a roll-to-roll system refers to a system in which a web of a material having a very large width and transport length compared to the thickness, such as a plastic film, passes through rollers and continuously performs various processes. .

The winding process is very important in the transport process of the target product of the roll-to-roll system, and has a great influence on efficiency, storage space, and high-speed operation in the entire process.

However, the non-uniform stress inside the roll of the product to be wound may cause a wrinkle-shaped defect at the core of the roll, which may cause damage to the roll.

Therefore, there is a need for a winding mechanism that avoids the generation of unnecessary internal stress and induces a stable stress distribution.

Registered Patent Publication No. 10-0923541 Registered Patent Publication No. 10-1447045 Laid-open Patent Publication No. 10-2019-0138597

Therefore, the present invention enlarges the outer diameter of the take-up winder without changing the existing linear roll-to-roll equipment and adjusts the tensile force of the film to be wound acting in the take-up winder to match the ideal value. An object of the present invention is to provide a linear roll-to-roll winding mechanism and a method for adjusting the same, which can prevent the sagging of the roll after winding has been completed.

In order to achieve the above-mentioned technical problem, the present invention is a winding winder for unwinding a roll formed by winding a film to be wound; a winding winder disposed on the opposite side of the unwinding winder to wind a roll; and a tension control mechanism for adjusting the tensile force of the film transferred between the unwinding winder and the take-up winder, wherein the take-up winder can provide a linear roll-to-roll winding mechanism including a core enlarged portion for enlarging the outer diameter of the core portion have.

In addition, the core enlarged portion of the present invention may be integrally formed with the core portion, or the core enlarged portion may be a cylindrical shell, and the core portion may be inserted and coupled to the core enlarged portion.

In addition, the ratio of the outer diameter of the core enlarged portion to the outer diameter of the core portion of the present invention may be 1.7 or more and 2.5 or less.

In addition, the axial width of the core enlarged portion of the present invention may be smaller than the axial width of the core portion and larger than the width of the film to be wound.

In addition, the present invention is a method for optimizing a linear roll-to-roll winding mechanism, wherein when the torque applied during winding of the film to be wound in the winding winder is maintained constant, the tensile force acting on the film to be wound according to the outer diameter of the core part calculating an ideal value; Calculating the actual value of the tensile force acting on the film to be wound according to the outer diameter of the core by operating the above-described linear roll-to-roll winding mechanism; Comparing the ideal value of the tensile force with the actual value of the tensile force, determining excessive or insufficient tensile force acting on the film to be wound; and when it is determined that the magnitude of the tensile force is greater than the ideal value of the tensile force, adjusting the taper value of the tensile force acting on the film to be wound in the take-up winder to match the actual value of the tensile force to the ideal value of the tensile force; It is possible to provide a method for optimizing the type roll-to-roll winding mechanism.

In addition, in the present invention, before calculating the actual value of the tensile force acting on the film to be wound, at the time of starting the winding of the film to be wound in the winding winder, wrinkles do not occur in the core of the film to be wound, and the winding is The method may further include calculating a minimum value of the initial tensile force at which sagging of the completed roll does not occur.

In addition, the minimum value of the initial tensile force of the present invention may be greater than 200N.

According to the present invention, by adding a core enlarged portion to the core portion of the winding winder, it is possible to prevent a defect in the roll core portion.

In addition, in the present invention, by adjusting the initial value and the taper value of the tensile force acting on the film to be wound in the winding winder, it is possible to prevent the defect of the roll core and the sagging of the rolled roll.

1 schematically shows the configuration of a linear roll-to-roll winding mechanism according to an embodiment of the present invention.
2 schematically shows that a film to be wound is wound on a winder according to an embodiment of the present invention.
3 schematically shows a cross-section of a core portion and a core enlarged portion of a winding winder according to an embodiment of the present invention.
Figure 4 schematically shows the coupling of the core part and the core expansion part of the winding winder according to an embodiment of the present invention.
5 schematically shows the tensile force acting upon winding a film to be wound in the winding winder according to an embodiment of the present invention.
6 is a graph showing the theoretically ideal value of the tensile force acting on the film to be wound in the winding winder of the linear roll-to-roll winding mechanism and the tensile force according to the actual outer diameter to which the present invention is applied.
7 is a graph showing the tensile force according to the actual outer diameter after applying the adjustment method of the linear roll-to-roll winding mechanism according to an embodiment of the present invention.

Hereinafter, a linear roll-to-roll winding mechanism 100 according to an embodiment of the present invention and specific examples thereof will be described with reference to the accompanying drawings through preferred embodiments of the present invention.

Prior to the description, when a part "includes" a certain component, this does not exclude other components unless otherwise stated, meaning that other components may be further included.

In addition, although embodiments of the present invention have been described with reference to the accompanying drawings, these are described for purposes of illustration, and the technical spirit of the present invention and its configuration and application are not limited thereby.

1 schematically shows the configuration of a linear roll-to-roll winding mechanism 100 according to an embodiment of the present invention.

As shown in Figure 1, the linear roll-to-roll winding mechanism 100 according to an embodiment of the present invention is an unwinding winder 10, unwinding winder 10 for unwinding a roll formed by winding a film to be wound. on the opposite side of, that is, the winding winder 20 disposed in the direction in which the film to be wound is transported to wind the roll and the tension controlling the tension of the film transferred between the unwinding winder 10 and the winding winder 20 and an adjustment mechanism (30).

As described above, it is necessary to control the internal stress distribution of the wound roll for quality control of the wound roll produced in the winding process, which is the final step in the roll-to-roll process, and the shape or size of the stress distribution inside the winding roll. Since it may cause damage and defects of the material to be wound depending on the degree of , the stress of the material to be wound may be controlled through the tension control mechanism 30 .

For example, in the roll-to-roll process, the tension control mechanism 30 for optimizing the winding takes into account the material to be used for the initial operation, the operating tension, the speed, and the outer diameter of the currently wound roll through the control unit (not shown). It is possible to control the tensile force of the target film.

On the other hand, in the roll-to-roll process, a form in which the tensile force is reduced by a predetermined increase as the outer diameter of the roll increases is called a taper tension profile. Accordingly, it can be classified into a hyperbolic taper tension profile that changes the rate of decrease in tensile force. A detailed description thereof will be described in more detail through the following examples of the present invention.

The type of film to be wound that can be used in the present invention is applicable to all types of film work without distinction between metal films and non-metal films. For example, as the non-metal film, a PET film, a nylon film, and a casting polypropylene (CPP) film may be used.

In the case of a metal film, a thickness of 20 μm to 200 μm, and in the case of a non-metal film, a thickness of 10 μm to 200 μm can be used. In the examples below, a composite film in which a metal film and a non-metal film are used together was used, and for this composite film, a metal film having a thickness of 20 μm to 80 μm and a non-metal film having a thickness of 7 μm to 50 μm were used together.

Figure 2 schematically shows that the winding target film (S) is wound on the winding winder 20 according to an embodiment of the present invention.

As shown in FIG. 2 , in the linear roll-to-roll process, the width of the core part 21 of the winding winder 20 can be changed in size according to available equipment, and the winding portion is also the width of the film to be wound. It is preferable to adjust according to (Ws). In the example below, the width of the core part 21 was 1100 mm.

On the other hand, the axial width W of the core expanded part 22 can be adjusted according to the specifications of the entire facility and the width of the film to be wound (S), but the core expanded part up to the entire axial width of the core part 21 . In the case of expanding (22), it is preferable that the axial width (W) of the core enlarged part 22 is smaller than the axial width of the core (21), since a large-scale modification of the equipment and cost are large.

In addition, if the axial width (W) of the core enlarged portion 22 is smaller than the width (Ws) of the film to be wound (S), a defect occurs in the edge portion of the film (S) during winding, so the core enlarged portion It is preferable that the axial width W of (22) is larger than the width Ws of the film S to be wound.

3 schematically shows a cross-section of the core part 21 and the core enlarged part 22 of the winding winder 20, and FIG. 4 is the core of the winding winder 20 according to an embodiment of the present invention. It schematically shows the coupling of the part and the core enlarged part.

As shown in FIG. 3 , the core expanded part 22 surrounds the core part 21 to increase the outer diameter of the entire winding winder 20 , and the core expanded part 22 and the core part 21 . ) can be integrally molded and manufactured.

In addition, as shown in FIG. 4 , it is also possible to manufacture the core enlarged part 22 in the form of a cylindrical shell and combine it in the form of inserting the core part 21 into the opening of the core enlarged part 22 . do.

As shown in FIG. 3 , the outer diameter of the core part 21 is denoted by d, and the outer diameter of the core enlarged part 22 is denoted by D. In order to check the wrinkle defect rate (%) of the film roll that has been wound according to the ratio of D/d, the core part 21 and the core enlargement part 22 made of FRP material with the smallest deformation with a 6-inch outer diameter are used. A plurality of experiments were performed as shown in [Table 1] below.

[Table 1]

As described in [Table 1], when the ratio of D/d was 1.7 to 2.5, it was confirmed that the wrinkle defect rate (%) was significantly lowered. Specifically, when the ratio of D/d is 2.5 or more (#9 in Table 1), it was confirmed that the wrinkle defect rate (%) increased, that is, the improvement effect of the wrinkle defect decreased again, and the Even when the ratio was 1.7 or less (#3 in Table 1), it was confirmed that the improvement effect of the wrinkle defect was lowered again.

Figure 5 schematically shows the tensile force (T) acting when the winding target film (S) is wound in the winding winder 20 according to an embodiment of the present invention.

By adjusting the winding condition of the winding winder 20 at the same time as the outer diameter of the core part 21 is enlarged, the improvement effect of the wrinkle defect can be maximized.

For example, when the winding target film (S) is wound, the torque acting on the winding target film (S) may be kept constant, and the calculation of this torque may be calculated as the outer diameter x tensile force of the film roll.

Referring to [Table 2] below, theoretically, the ideal tensile force value for how the tensile force value according to the outer diameter of the film roll can be changed to maintain a constant torque is shown.

[Table 2]

6 is a graph showing the data of [Table 2], wherein the horizontal axis represents the outer diameter, and the vertical axis represents the tensile force value.

As shown in FIG. 6 , the blue dotted line is the theoretical most ideal shape when winding, and the green solid line is also the ideal shape. As such, whether to wind in the form of an ideal curve or a straight line may vary depending on the specifications of the equipment.

On the other hand, the orange dotted line is the tensile force value according to the outer diameter during actual work. As shown in FIG. 6 , it can be seen that considerably more force is acting than in the theoretical graph, and at this time, the rate of occurrence of wrinkles in the core of the film roll is also high. In an exemplary experiment, if the ideal winding defect rate (%) was measured to be 15, the actual winding defect rate (%) was measured to be 22.

Therefore, by comparing the ideal value of the above-described tensile force and the actual value of the tensile force operating the winding mechanism according to an embodiment of the present invention, it can be determined how large the tensile force acting on the film to be wound is greater than the value of the ideal tensile force, , when it is determined that the magnitude of the actual tensile force is greater than the ideal value of the tensile force, the linear taper value of the tensile force acting on the film to be wound is adjusted through the tensile control mechanism 30 to substantially match the actual value of the tensile force with the ideal value Thus, a method to reduce the incidence of wrinkles (%) in the core area can be considered.

For example, first determine the value of the initial tensile force with the least stress at the core of the film roll. It is not calculated with a formula or formula, and was found through testing while changing each initial value.

That is, it is necessary to calculate the minimum value of the initial tensile force at the time of starting the winding of the film to be wound, no wrinkles occur in the core of the film to be wound, and no sagging of the roll after the winding is completed.

When determining the initial tensile force value, it is important whether or not wrinkles occur in the core of the film roll, but there should be no sagging of the rolled roll. The results are shown in [Table 3] below.

[Table 3]

As shown in [Table 3], when the initial tensile force values were 100 and 150N, sagging of the roll occurred and it was confirmed that the state was so bad that the wrinkle generation rate could not be confirmed. In addition, it was confirmed that the higher the initial tensile force value, the higher the wrinkle rate of the film roll core part. Therefore, it was confirmed that the minimum value of the initial tensile force that does not cause sagging of the roll is 200N (#3 in Table 3), which is the optimal value for alleviating the wrinkle phenomenon of the core part.

Next, as described above, Example #3, in which roll sagging did not occur, was set as the initial tensile force value, and torque and core enlargement were applied.

First, the size of the outer diameter and theoretical tensile force according to a constant torque value of 200N is shown in [Table 4] below.

[Table 4]

In addition, the outer diameter and actual tensile force after applying the core enlarged part are shown in FIG. 7 , and as shown in FIG. 7 , the wrinkle occurrence rate was confirmed by applying the set initial tensile force value of 200N and the taper value to 75%. In this case, the ratio of D/d used was 1.9.

As a result of the test, the wrinkle defect rate was measured to be 4, and it was confirmed that the wrinkle defect rate of the core part of the roll was rapidly reduced when the core enlarged part, the initial tensile force value, and the taper value condition were applied simultaneously.

With reference to the above descriptions, those skilled in the art to which the present invention pertains will be able to understand that the present invention may be embodied in other specific forms without changing the technical spirit or essential characteristics thereof.

Therefore, it should be understood that the above-described embodiments are illustrative in all respects and are not intended to limit the present invention to the above-described embodiments, and the scope of the present invention lies in the claims to be described later rather than the detailed description described above. All changes or modifications derived from the meaning and scope of the claims and equivalent concepts should be construed as being included in the scope of the present invention.

100 Linear Roll-to-Roll Winding Mechanism
10 Unwinding Winder 20 Winding Winder
30 Tension adjustment mechanism 21 Core part
22 Core enlarged S film to be wound
Ws Width of film to be wound W Axial width of core enlarged part
d Core part outer diameter D Core enlarged part outer diameter
T tensile force

Claims (8)

As an optimization control method of a linear roll-to-roll winding mechanism,
Calculating an ideal value of the tensile force acting on the film to be wound according to the outer diameter of the core part when the torque applied during the winding of the film to be wound is kept constant in the winding winder;
calculating an actual value of the tensile force acting on the film to be wound according to the outer diameter of the core by operating the linear roll-to-roll winding mechanism;
Comparing the ideal value of the tensile force with the actual value of the tensile force, determining the excess or deficiency of the actual tensile force acting on the film to be wound; and
When it is determined that the magnitude of the actual tensile force is greater than the ideal value of the tensile force, the taper value of the tensile force acting on the film to be wound is adjusted in the take-up winder to match the actual value of the tensile force to the ideal value of the tensile force step; including;
The linear roll-to-roll winding mechanism may include: an unwinding winder for unwinding a roll formed by winding a film to be wound; a winding winder disposed on the opposite side of the unwinding winder to wind the roll and including a core enlarged portion for enlarging an outer diameter of the core portion; and a tension adjusting mechanism for adjusting the tensile force of the film transferred between the unwinding winder and the take-up winder,
The expanded core part is integrally formed with the core part, and a ratio of the outer diameter of the core expanded part to the outer diameter of the core part is 1.7 or more and 2.5 or less, and the axial width of the core expanded part is smaller than the axial width of the core part. Optimization control method of a linear roll-to-roll winding mechanism, characterized in that larger than the width of the film to be wound.
The method of claim 1,
Before calculating the actual value of the tensile force acting on the film to be wound, at the time when the winding of the film to be wound is started in the winding winder, wrinkles do not occur in the core of the film to be wound, and winding is completed Optimization control method of a linear roll-to-roll winding mechanism, characterized in that it further comprises the step of calculating the minimum value of the initial tensile force does not occur sag of the roll.
3. The method of claim 2,
Optimization control method of a linear roll-to-roll winding mechanism, characterized in that the minimum value of the initial tensile force is greater than 200N.

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