KR102658145B1 - Touch roller, winder, film roll manufacturing system, and film roll manufacturing method - Google Patents

Abstract

Equipped with a winder (7) for winding the film (F) having a first knurl (K1) formed at one end in the width direction (TD) and a second knurl (K2) formed at the other end in the width direction (TD). In the touch roller 12, a contact portion 123 in contact with the film roll R is disposed between the first knurl K1 and the second knurl K2 in the width direction TD.

Description

Touch roller, winder, film roll manufacturing system, and film roll manufacturing method

The present invention relates to a touch roller, a winder, a film roll manufacturing system, and a film roll manufacturing method.

Conventionally, a winding machine provided with a roller (ray-on roll) in contact with a film roll is known (for example, see Patent Document 1).

Japanese Patent Publication No. 2006-193327

In a winder as described in Patent Document 1 mentioned above, the contact pressure between the roller and the film roll may become non-uniform in the width direction of the film.

If the contact pressure between the roller and the film roll is uneven in the width direction of the film, problems such as wrinkles in the film roll may occur.

The present invention provides a touch roller, a winder, a film roll manufacturing system, and a film roll manufacturing method that can prevent problems such as wrinkles forming in the film roll.

The present invention [1] is a winding method for manufacturing a film roll by winding the film having a first knurl formed on one end in the width direction orthogonal to the flow direction of the film and a second knurl formed on the other end in the width direction. It is a touch roller provided in a device, and has a contact portion that contacts the film roll when the winder is winding the film, and the contact portion is disposed between the first knurl and the second knurl in the width direction. Includes a touch roller.

According to this configuration, the contact portion does not contact the first knurl and the second knurl.

Accordingly, it is possible to prevent the touch roller from excessively pressing both ends of the film roll.

Therefore, the touch roller can be brought into contact with the film roll with a uniform pressing force across the width direction.

As a result, problems such as wrinkles forming on the film roll can be prevented from occurring.

The present invention [2] includes a roller body extending in the width direction, a shaft rotatable together with the roller body, and a first taper where the roller body is disposed at one end of the roller body in the width direction. and a second taper disposed at the other end of the roller body in the width direction, and the contact portion disposed between the first taper and the second taper in the width direction and extending in the width direction. It includes the touch roller of [1] above.

According to this configuration, a first taper is formed at one end of the roller body in the width direction. Therefore, the contact pressure against the film roll at one end of the roller body in the width direction can be reduced.

Additionally, a second taper is formed at the other end of the roller body in the width direction. Therefore, the contact pressure against the film roll at the other end of the roller body in the width direction can be reduced.

In general, the first taper and the second taper can reduce the contact pressure against the film roll at both ends of the roller main body in the width direction.

Therefore, the touch roller can be prevented from excessively pressing both ends of the film roll, and the touch roller can be brought into contact with the film roll with a more uniform pressure across the width direction.

As a result, the occurrence of problems such as wrinkles in the film roll can be further suppressed.

In the present invention [3], the shaft is disposed at the center of the roller body in the radial direction of the roller body, extends in the width direction, and the roller body is in contact with the film roll in the radial direction. a layer and a second layer disposed between the first layer and the shaft, wherein the first layer is made of a first elastic material, and the second layer is made of a second elastic material that is softer than the first elastic material. It includes the touch roller of [2] above.

According to this configuration, the second elastic material is more flexible than the first elastic material, so that the second layer can also deform along with the deformation of the first layer.

Therefore, it is possible to allow the first layer to be deformed along the surface of the film roll while the touch roller is in contact with the film roll.

Accordingly, the touch roller can be brought into contact with the film roll with uniform pressure across the width direction.

As a result, the occurrence of problems such as wrinkles in the film roll can be further suppressed.

The present invention [4] includes a winder including a winding unit for winding the film and manufacturing the film roll, and the touch roller of any one of the above [1] to [3].

According to this configuration, since the above-described touch roller is provided, problems such as wrinkles forming on the film roll can be suppressed.

The present invention [5] includes a film roll manufacturing system including a knurling machine for forming the first knurl and the second knurl on the film, and the winder of the above [4].

According to this configuration, since the above-described winder is provided, problems such as wrinkles forming on the film roll can be suppressed.

The present invention [6] includes a knurling process of forming the first knurl and the second knurl on the film, and a winding process of winding the film in the winder of [4]. It includes a method for manufacturing a film roll. do.

According to this method, since the film is wound in the above-described winder, problems such as wrinkles forming in the film roll can be suppressed.

According to the touch roller, winder, film roll manufacturing system, and film roll manufacturing method of the present invention, the occurrence of problems such as wrinkles in the film roll can be suppressed.

1 is a cross-sectional view of a film wound by a winder according to an embodiment of the present invention.
Figure 2 is a schematic configuration diagram of a film roll manufacturing system according to an embodiment of the present invention.
Figure 3 is a cross-sectional view of a touch roll according to an embodiment of the present invention.

1. Manufacturing system of film roll

As shown in FIG. 1, the film (F) includes a base material (S) and a coating film (C). The base material S has a first surface S1 and a second surface S2 in the thickness direction of the base material S. The coating (C) is disposed on the first side (S1) of the substrate (S). The coating (C) covers the first surface (S1) of the substrate (S). The coating C may be an easily adhesive layer. When the coating (C) is an easily adhesive layer, the film (F) is an easily adhesive film. Easily adhesive films are used for polarizing plates in image display devices such as mobile devices, car navigation devices, PC monitors, and televisions, for example. In detail, the easily adhesive film is used as a protective film that protects the polarizer of the polarizing plate. The easily adhesive film is bonded to the polarizer through an adhesive layer. The easily adhesive film is bonded to the polarizer in the easily adhesive layer.

As shown in FIG. 2, the production system 1 for the film roll R includes an extrusion molding machine 2, a first stretching machine 4A, an applicator 3, and a second stretching machine 4B, It is provided with a slitting machine (5), a knurling machine (6), and a winding machine (7).

(1) Extrusion molding machine

The extrusion molding machine 2 extrudes the substrate S (extrusion molding process). The base material S extruded from the extrusion molding machine 2 has a sheet shape.

The base material (S) is made of thermoplastic resin. Thermoplastic resins include, for example, acrylic resins, polyolefin resins, cyclic polyolefin resins, polyester resins, polycarbonate resins, polystyrene resins, polyamide resins, polyimide resins, acetate resins (diacetylcellulose, triacetylcellulose, etc.). I can hear it.

When manufacturing an easily adhesive film used as a protective film for a polarizer, acrylic resin is preferably used as a material for the base material (S).

Additionally, when manufacturing an easily adhesive film used as a protective film for a polarizer, the acrylic resin may be an acrylic resin having a glutaric anhydride structure or an acrylic resin having a lactone ring structure. Acrylic resins with a glutaric anhydride structure and acrylic resins with a lactone ring structure have high heat resistance, high transparency, and high mechanical strength, and are therefore suitable for producing a polarizing plate with a high degree of polarization and excellent durability. Acrylic resins having a glutaric anhydride structure are described in JP-A-2006-283013, JP-A-2006-335902, and JP-A-2006-274118. Acrylic resins having a lactone ring structure are disclosed in Japanese Patent Application Laid-open No. 2000-230016, Japanese Patent Application Laid-Open No. 2001-151814, Japanese Patent Application Laid-Open No. 2002-120326, Japanese Patent Application Laid-Open No. 2002-254544, and Japanese Patent Application Laid-Open No. 2005-146084. It is described in the gazette no.

Additionally, the base material (S) may contain a thermoplastic resin other than the acrylic resin in addition to the acrylic resin. By containing another thermoplastic resin, the birefringence of the acrylic resin can be offset to obtain an easily adhesive film with excellent optical isotropy. Additionally, the mechanical strength of the easily adhesive film can be improved.

Additionally, the base material (S) may contain additives such as antioxidants, stabilizers, reinforcing materials, ultraviolet absorbers, flame retardants, antistatic agents, colorants, fillers, plasticizers, lubricants, and fillers.

(2) First stretching machine

The first stretching machine 4A heats the substrate S obtained through the extrusion molding process and then stretches the substrate S in the flow direction MD (first stretching process).

(3) Applicator

The applicator 3 applies the coating liquid to the first surface S1 of the base material S extruded by the extrusion molding process (application process). Additionally, the first surface S1 of the substrate S may be subjected to surface treatment such as corona treatment or plasma treatment after the extrusion molding process and before the coating process.

Examples of the applicator 3 include a bar coater, a gravure coater, and a kiss coater.

When manufacturing an easily adhesive film, the coating liquid is an easily adhesive composition for forming an easily adhesive layer.

The easily adhesive layer contains binder resin and fine particles.

Examples of the binder resin include thermosetting resins such as urethane resins and epoxy resins, and thermoplastic resins such as acrylic resins and polyester resins. When the easily adhesive film is used as a protective film for a polarizer, the binder resin is preferably a thermosetting resin. Multiple types of binder resin can be used together.

Examples of fine particles include oxides such as silicon oxide (silica), titanium oxide (titania), aluminum oxide (alumina), and zirconium oxide (zirconia), carbonates such as calcium carbonate, such as calcium silicate and aluminum silicate. , silicates such as magnesium silicate, silicate minerals such as talc and kaolin, and phosphates such as calcium phosphate. When an easily adhesive film is used as a protective film for a polarizer, the fine particles are preferably oxide, more preferably silicon oxide. Multiple types of fine particles can be used together.

The coating liquid (easy-adhesion composition) contains a resin component, the above-mentioned fine particles, and a dispersion medium.

The resin component forms a film (easily adhesive layer) of the binder resin described above through a stretching process described later. When the binder resin is a urethane resin, examples of the resin component include water-based urethane resin. Examples of the water-based urethane resin include non-reactive water-based urethane resins that are emulsions of urethane resins, and reactive water-based urethane resins that are emulsions of urethane resins in which an isocyanate group is protected by a blocking agent. When the binder resin is a urethane resin, the coating liquid may contain a urethane curing catalyst (triethylamine, etc.) and an isocyanate monomer.

Examples of the dispersion medium include water, alcohols such as methanol and ethanol, and ketones such as acetone and methyl ethyl ketone.

(4) Second stretching machine

The second stretching machine 4B dries the coating liquid applied through the coating process. Accordingly, the coating liquid becomes the film C described above. Additionally, the second stretching machine 4B heats the substrate S on which the coating C is formed and then stretches the substrate S in the width direction TD (second stretching process). The width direction (TD) is perpendicular to the flow direction (MD). Through the second stretching process, the base material (S) on which the film (C) has been formed is stretched to obtain the above-described film (F).

(5) Slit processing machine

The slitting machine 5 cuts the film F stretched through the stretching process to a predetermined width (slit process).

(6) Knurled processing machine

The knurling machine 6 forms knurls at both ends in the width direction of the film F cut to a predetermined width by a slit process (knurling process). In addition, “null” refers to irregularities formed on both ends of the film F in the width direction. By forming "nulls" at both ends of the film F in the width direction, a slight gap can be formed between the overlapping films F in the radial direction of the film roll R when winding the film F. . In detail, the knurling machine 6 forms a first knurl K1 (see FIG. 3) and a second knurl K2 (see FIG. 3) in the film F.

As shown in FIG. 3, the first knurl K1 is formed at one end of the film F in the width direction TD. The second knurl K2 is formed at the other end of the film F in the width direction TD.

The first null K1 and the second null K2 are formed by a laser. The first knurl K1 and the second knurl K2 may be formed by a heated emboss roll.

(7) Winder

As shown in FIG. 1, the winder 7 winds the film F in which knurls were formed by the knurling process (winding process). When the winding process is completed, a film roll R can be obtained. That is, the winder 7 winds the film F having the first knurl K1 and the second knurl K2 and manufactures the film roll R.

The type of winder 7 is not limited. Examples of the winding machine 7 include a turret winding machine.

2. Details of winder

The winder 7 includes a winder 11 and a touch roller 12.

(1) Winding part

The winding unit 11 winds the film F and produces a film roll R. The winding portion 11 holds the winding core W. The winding unit 11 rotates the winding core (W). The film (F) is wound on a rotating winding core (W).

(2) Touch roller (12)

As shown in FIG. 3, the touch roller 12 includes a shaft 12A and a roller body 12B.

(2-1) Shaft

The shaft 12A is disposed at the center of the roller body 12B in the radial direction of the roller body 12B. Shaft 12A extends in the width direction TD. The shaft 12A has a cylindrical shape. Shaft 12A is made of metal. Additionally, the shaft 12A may have a cylindrical shape with a through hole penetrating in the width direction (TD). Additionally, the outer peripheral surface of the shaft 12A may have a polygonal shape.

(2-1) Roller body

The roller body 12B is rotatable together with the shaft 12A. The roller body 12B is disposed on the outer peripheral surface of the shaft 12A. The roller body 12B covers the shaft 12A. The roller body 12B extends in the width direction TD. The roller body 12B has a cylindrical shape. The diameter of the roller body 12B is larger than the diameter of the shaft 12A.

(2-1-2) Shape of roller body

The roller body 12B has a first taper 121, a second taper 122, and a contact portion 123.

The first taper 121 is disposed at one end of the roller body 12B in the width direction TD. The first taper 121 is inclined toward one side of the width direction TD in a direction closer to the shaft 12A. The first taper 121 is inclined in a direction away from the film roll R as it faces one side of the width direction TD. Additionally, the first taper 121 does not need to extend to the shaft 12A. The first taper 121 is spaced apart from the first knurl K1. The first taper 121 may face the first knurl K1 in the radial direction of the roller body 12B. A first taper 121 is formed at one end of the roller body 12B in the width direction TD, so that the film roll R ) can reduce the contact pressure.

The second taper 122 is disposed at the other end of the roller body 12B in the width direction TD. The second taper 122 is inclined toward the other side of the width direction TD in a direction closer to the shaft 12A. The second taper 122 is inclined in a direction away from the film roll R as it faces the other side of the width direction TD. Additionally, the second taper 122 does not need to extend to the shaft 12A. The second taper 122 is spaced apart from the second knurl K2. The second taper 122 may face the second knurl K2 in the radial direction of the roller body 12B. The second taper 122 is formed at the other end of the roller body 12B in the width direction TD, so that the film roll R is formed at the other end of the roller body 12B in the width direction TD. ) can reduce the contact pressure.

The contact portion 123 is disposed between the first taper 121 and the second taper 122 in the width direction TD. The contact portion 123 extends in the width direction TD from the first taper 121 to the second taper 122. When the winder 7 is winding the film F, the contact portion 123 is in contact with the film roll R.

The angle θ1 between the surface S11 of the contact portion 123 and the surface S12 of the first taper 121 is greater than 90°. The angle θ1 is preferably 100° or more. When the angle θ1 is greater than the above lower limit, the contact pressure against the film roll R at one end of the roller body 12B in the width direction TD can be reduced. Additionally, the angle θ1 is smaller than 180°, and is preferably 160° or less.

The angle θ2 between the surface S11 of the contact portion 123 and the surface S13 of the second taper 122 is greater than 90°. The angle θ2 is preferably 100° or more. The angle θ2 is preferably equal to the angle θ1. When the angle θ2 is greater than the above lower limit, the contact pressure against the film roll R at the other end of the roller body 12B in the width direction TD can be reduced. Additionally, the angle θ2 is smaller than 180°, and is preferably 160° or less.

With the touch roller 12 in contact with the film roll R, the contact portion 123 is disposed between the first knurl K1 and the second knurl K2 in the width direction TD. With the touch roller 12 in contact with the film roll R, the contact portion 123 is separated from the first knurl K1 and the second knurl K2 in the width direction. In other words, the touch roller 12 does not contact the first knurl K1 and the second knurl K2.

Accordingly, the touch roller 12 can be prevented from excessively pressing both ends of the film roll R. Therefore, the touch roller 12 can be brought into contact with the film roll R with a uniform pressing force across the width direction. As a result, it is possible to suppress problems such as wrinkles forming on the film roll R during the winding process.

In addition, as described above, the contact pressure against the film roll R can be reduced at both ends of the roller body 12B in the width direction TD by the first taper 121 and the second taper 122. You can.

Therefore, it is possible to further suppress the touch roller 12 from excessively pressing both ends of the film roll R, and to press the touch roller 12 with a more uniform pressure across the width direction TD. ) can be contacted.

As a result, problems such as wrinkles forming on the film roll R can be further prevented from occurring.

(2-2-2) Layer structure of roller body

The roller body 12B has a first layer L1 and a second layer L2 in the radial direction. In other words, the roller body 12B has a plurality of layers in the radial direction.

The first layer L1 is the skin layer of the roller body 12B in the radial direction. The first layer (L1) is disposed at least on the surface (S11) of the contact portion (123). The first layer L1 may be disposed on all of the surface S11 of the contact portion 123, the surface S12 of the first taper 121, and the surface S13 of the second taper 122. The first layer (L1) is in contact with the film roll (R). The first layer L1 is made of a first elastic material.

As the first elastic material, for example, rubber such as acrylonitrile-butadiene rubber (NBR), silicone rubber, fluororubber, chloroprene rubber, urethane rubber (polyurethane elastomer), for example, acrylonitrile-butadiene rubber (NBR) ) Foams such as sponge, silicone rubber sponge, fluorine rubber sponge, chloroprene rubber sponge, and urethane sponge (polyurethane foam) can be mentioned.

The hardness of the first elastic material is, for example, A60 or higher, preferably A70 or higher, for example, A90 or lower, preferably A80 or lower.

Additionally, hardness is measured by the method specified in JIS K 6253-3:2012.

When the outer diameter (ϕ1) of the touch roller 12 is 120 mm, the diameter (ϕ2) of the shaft 12A is 100 mm, and the thickness (t) of the roller body 12B is 10 mm, the first layer (L1) The thickness is, for example, 5 mm or less, preferably 3 mm or less, for example, 1 mm or more.

The second layer L2 is disposed between the first layer L1 and the shaft 12A in the radial direction. The second layer (L2) is in contact with the first layer (L1). In this embodiment, the second layer L2 also contacts the shaft 12A. The second layer L2 is made of a second elastic material.

Examples of the second elastic material include the same material as the first elastic material described above.

The second elastic material is more flexible than the first elastic material. Since the second elastic material is more flexible than the first elastic material, the second layer (L2) can also be deformed to follow the deformation of the first layer (L1). Therefore, the first layer L1 can be allowed to deform along the surface of the film roll R while the touch roller 12 is in contact with the film roll R. Accordingly, the touch roller 12 can be brought into contact with the film roll R with uniform pressure across the width direction. As a result, problems such as wrinkles forming on the film roll R can be further prevented from occurring.

The hardness of the second elastic material is, for example, A15 or higher, preferably A20 or higher, for example, A50 or lower, preferably A40 or lower.

The thickness of the second layer (L2) is greater than or equal to the thickness of the first layer (L1). When the outer diameter (ϕ1) of the touch roller 12 is 120 mm, the diameter (ϕ2) of the shaft 12A is 100 mm, and the thickness (t) of the roller body 12B is 10 mm, the second layer (L2) The thickness is, for example, 5 mm or more, preferably 7 mm or more, for example, 9 mm or less.

The ratio of the thickness of the first layer (L1) to the thickness of the second layer (L2) (thickness of the first layer (L1) / thickness of the second layer (L2)) is preferably, for example, 1/10 or more. Typically, it is 1/8 or more, for example, 1/2 or less, preferably 1/3 or less.

4. Variation example

(1) The touch roller 12 does not need to have the first taper 121 and the second taper 122.

(2) The use of the winder 7 is not limited to extrusion molding. For example, the base material S may be fed from the roll of the base material S, the fed base material S may be stretched, and wound by the winder 7.

(3) The manufacturing method of the film roll R does not need to include an application process.

(4) The layer structure of the roller body 12B is not limited to a two-layer structure. A laminated structure of three or more layers may be used as long as deformation of the first layer (L1) can be tolerated.

(5) The production system 1 for the film F does not need to be provided with the first stretching machine 4A. After the application process, the base material S may be stretched (biaxially stretched) in the flow direction (MD) and the width direction (TD) by the second stretching machine 4B.

Additionally, although the above invention has been provided as an exemplary embodiment of the present invention, this is merely an example and should not be construed as limiting. Modifications of the present invention apparent to those skilled in the art are included in the following claims.

The touch roller, winder, film roll manufacturing system, and film roll manufacturing method of the present invention are used for manufacturing film rolls made of films such as easily adhesive films.

1: Manufacturing system
6: Knurling machine
7: Winder
11: winding part
12: touch roller
12A: Shaft
12B: Roller body
121: first taper
122: second taper
123: contact part
K1: 1st board
K2: 2nd board
L1: first floor
L2: second layer
R: film roll

Claims (6)

A touch roller provided in a winder for winding the film and manufacturing a film roll, having a first knurl formed on one end in the width direction orthogonal to the flow direction of the film and a second knurl formed on the other end in the width direction. ,
With shaft,
A roller body extending in the width direction and rotatable with the shaft,
The roller body is,
a first taper disposed at one end of the roller body in the width direction;
a second taper disposed at the other end of the roller body in the width direction;
It is disposed between the first taper and the second taper in the width direction, extends in the width direction, and has a contact portion that contacts the film roll when the winder is winding the film,
The contact portion is disposed between the first knurl and the second knurl in the width direction,
A touch roller, characterized in that the first taper and the second taper are separated from the film. According to claim 1,
The first taper faces the first knurl in the radial direction of the roller body and is away from the first knurl,
The touch roller is characterized in that the second taper faces the second knurl and is spaced apart from the second knurl in the radial direction of the roller body. According to claim 2,
The shaft is disposed at the center of the roller body in the radial direction of the roller body and extends in the width direction,
The roller body is in the radial direction,
a first layer in contact with the film roll;
having a second layer disposed between the first layer and the shaft,
the first layer is made of a first elastic material,
A touch roller, characterized in that the second layer is made of a second elastic material that is softer than the first elastic material. a winding unit for winding the film and producing the film roll;
A winder comprising the touch roller according to claim 1. a knurling machine for forming the first knurl and the second knurl on the film;
A film roll manufacturing system comprising the winding machine according to claim 4. a knurling process of forming the first knurl and the second knurl in the film;
A method for producing a film roll, comprising a winding step of winding the film with the winder according to claim 4.