KR20200011418A - Film rolls and their manufacturing method - Google Patents

Abstract

The core and the long resin film wound by the core are included, The resin film contains the uneven structure part at the edge part of the width direction, The resin film is the 1st area | region including the start part in a winding direction, and a 1st It has a 2nd area | region adjacent to an area | region and including the terminal part in a winding direction, and a 2nd area | region is an area | region where the average value of the height of the convex part of the uneven structure part of a resin film is larger 1 micrometer or more than a 1st area, When the diameter is R1, the winding diameter of the first region wound around the core is R2, and the diameter of the film roll is R3, 3 <100 x (R2-R1) / R3 <50, and 100 x (R2-R1) Film roll, with / R2 <65.

Description

Film rolls and their manufacturing method

This invention relates to a film roll and its manufacturing method.

At the time of manufacture of films, such as an optical film, from a viewpoint of realizing high productivity, it is common to manufacture a film as a elongate film, and to wind this to the outer surface of a cylindrical core to make a film roll.

Such a film roll is mounted, for example, conveyed by the rack etc. which are disclosed by patent document 1, and the like. In patent document 1, the rack for loading the rolled product containing a rod-shaped cylindrical member and the sheet-like article wound by the said rod-shaped cylindrical member is disclosed.

Japanese Laid-Open Patent Publication 2005-335747

Here, when the sheet-like article wound by a rod-shaped cylindrical member is an optical film, an optical film is easy to be damaged by a thin film normally. If scratches occur in the optical film, the optical properties of the optical film are impaired. However, when a roll product, such as an optical film, is loaded in a conventional rack and conveyed to a destination, a scratch may arise in an optical film due to the vibration etc. which arise during conveyance. In particular, the above-mentioned flaws were easy to occur at the position of the gravity direction upper part in the axial direction center part of a film roll, and only the measures at the time of conveyance were insufficient.

As a result of examining in order to solve the said problem, it discovered that the generation | occurrence | production of a scratch can be suppressed by manufacturing a film roll using the film which does not have an uneven structure part in the whole region of the longitudinal direction. However, in the film roll obtained by winding the film which does not have the uneven structure part in the whole area | region of the longitudinal direction, the band-shaped recessed part or convex part (also called a gauge band) extended in the circumferential direction may arise in the surface. there was.

This invention is made | formed in view of the subject mentioned above, The objective is to provide the film roll which can suppress generation | occurrence | production of a scratch and generation | occurrence | production of a gauge band, and its manufacturing method.

As a result of examination to solve the said subject, as a result, the 1st area | region containing the start end part of a winding direction, and the 2nd area | region containing the end part of a winding direction in which the average height of the convex part of an uneven structure part is 1 micrometer or more larger than a 1st area | region In the film roll manufactured so that the diameter of the core, the winding diameter of a 1st area | region, and the diameter of a film roll satisfy | fill predetermined conditions using the elongate resin film which has an adjoining thing, both the generation of a scratch and the generation of a gauge band Knowledge was obtained that could be suppressed. That is, this invention is as showing below.

[1] A film roll comprising a core and a long resin film wound on the core,

The said resin film contains an uneven structure part at the edge part of the width direction,

The said resin film has a 1st area | region including the start end part in a winding direction, and a 2nd area | region which is adjacent to the said 1st area | region, and includes the termination part in the said winding direction,

The said resin film satisfies Formula (A), and the said film roll satisfies Formula (B)-(C),

H2-H1 ≥ 1 μm (A)

3 <100 × (R2-R1) / R3 <50 (B)

100 × (R2-R1) / R2 <65 (C)

However, H1 is an average value of the height of the convex part of the said uneven structure part of the said resin film in a said 1st area | region,

H2 is the average value of the height of the convex part of the said uneven structure part of the said resin film in a said 2nd area | region,

R1 is the diameter of the winding core,

R2 is the winding diameter of the first region wound around the core,

R3 is the diameter of the film roll,

Film roll.

[2] The resin film has an uneven structure region in the second region,

The said uneven structure area | region is prescribed | regulated in the edge area within 20 mm from the edge of the width direction of the said resin film,

The said resin film has the said uneven structure part whose average height is 3 micrometers-25 micrometers in the said uneven structure area | region,

The film roll as described in [1].

[3] The resin film described in [1] or [2], wherein the resin film has, on at least one surface, a flat portion having an average roughness SRa of 5 nm to 25 nm in a region of 20 mm from the edge in the width direction. Film roll.

[4] The film roll according to any one of [1] to [3], wherein the average thickness is 10 μm to 100 μm.

[5] As a method for producing a film roll according to any one of [1] to [4],

The manufacturing method of the film roll which includes the process of winding up the said resin film in the said core by the winding tension of 50N / m-300N / m.

[6] The step of winding the resin film on the core,

A first winding step of winding up the first region of the resin film,

Including a second winding step of winding the second region of the resin film in order;

In the said 1st winding process, the touch winding which presses and winds a touch roll to the said film roll in the middle of manufacture is performed,

In the said 2nd winding process, the manufacturing method of the film roll as described in [5] which performs the gap winding which falls and winds up the said touch roll from the said film roll in the middle of manufacture.

According to this invention, the film roll which can suppress generation | occurrence | production of a scratch and generation | occurrence | production of a gauge band, and its manufacturing method can be provided.

1 is a perspective view showing a film roll according to one embodiment of the present invention.
2 is a side view schematically showing a film roll according to one embodiment of the present invention.
It is a top view which shows typically the state which expanded the resin film of the film roll which concerns on one Embodiment of this invention on the plane.
It is sectional drawing in the YY line in FIG.
It is a schematic diagram which shows typically the winding apparatus used in the manufacturing method of the film roll which concerns on one Embodiment of this invention.
It is a schematic diagram which shows typically the winding apparatus used in the manufacturing method of the film roll which concerns on one Embodiment of this invention.
It is a top view which shows typically the planar shape of the uneven structure part formed in the film roll which concerns on Example 1. FIG.
It is a front view which shows the structure of the rack used by the evaluation test of the film roll of an Example.
9 is a side view of the rack of FIG. 8.

EMBODIMENT OF THE INVENTION Hereinafter, although an Example and an example are shown and this invention is demonstrated in detail, this invention is not limited to embodiment and the Example shown below, The range which does not deviate from the Claim of this invention, and its equal range. It can change arbitrarily and can carry out.

In the following description, the film "long" refers to a film having a length of 5 times or more with respect to the width, and preferably has a length of 10 times or more, and specifically, a degree of being wound and stored or transported in a roll shape. Refers to a film having a length of. There is no restriction | limiting in particular in the upper limit of the length of a long film, For example, it can be 100,000 times or less with respect to width.

Embodiment 1

The film roll which concerns on one Embodiment of this invention is demonstrated, referring FIGS.

〔One. Film roll]

FIG. 1: is a perspective view which shows schematically the state which partially unwound the resin film 100 of the terminal part side in the winding direction from the film roll 10 of this embodiment. As shown in FIG. 1, the film roll 10 of this embodiment contains the cylindrical core 11 and the elongate resin film 100 wound by the core 11.

2 is a side view schematically showing the film roll 10 of the present embodiment. The film roll 10 is a cylindrical shape centering on the point 11C, and is provided with the cylindrical core 11 and the film part 12A, 12B by which the resin film was wound on the outer side. In FIG. 2, 12A is the 1st film part to which the 1st area | region 100A containing the start end part in the winding direction of the film 100 was wound, and 12B is the termination in the winding direction of the film 100. In FIG. The 2nd area | region 100B containing a part is the 2nd film part wound up. In FIG. 2, 12P is an end portion of the first film portion 12A (first region 100A), and is connected to the second film portion 12B (second region 100B) at the end portion 12P. have. In FIG. 2, R1 is the diameter of the core 11, R2 is the winding diameter of the first region 100A wound around the core 11, and R3 is the diameter of the film roll 10.

In the following description, "resin film" may be called "film".

〔2. Resin film]

FIG. 3: is a top view which shows typically the mode which looked at the resin film 100 used for the film roll 10 of this embodiment from the upper surface 100U side. The left-right direction in FIG. 3 is a winding direction, the left side is the start end side in the winding direction, and the right side is the end side in the winding direction. As shown in FIG. 3, the resin film 100 is adjacent to the 1st area | region 100A containing the start end part in the winding direction, and the 1st area | region 100A, and includes the termination part in the winding direction. It has a second region 100B. The edge part 12P of the 1st area | region 100A is also the edge part of the start end side in the winding direction of the 2nd area | region 100B. The first region 100A is the region from the start end to the end portion 12P in the winding direction of the film 100, and the second region 100B is the end region in the winding direction from the end portion 12P. Area. The resin film 100 drawn out from the film roll 10 shown in FIG. 1 is a 2nd area | region 100B including the terminal part in a winding direction.

As shown in FIG. 3, the resin film 100 includes the uneven structure 120. In the present embodiment, the uneven structure 120 is not formed in the first region 100A, but the uneven structure 120 having the same shape is formed in both ends of the width direction (up and down direction) in the second region 100B. Is formed. In this invention, the area | region in which the uneven structure part 120 is formed is called uneven structure area | region 120R, 120L (refer FIG. 1). The region where the uneven structure between the two uneven structure regions 120R and 120L is not formed is the flat portion 110.

In this embodiment, it is preferable that the flat part 110 is formed in the area inside 20 mm from the edge of the width direction of the film 100 inside, and is formed in the area inside 18 mm from the edge. It is more preferable, It is more preferable to be formed in the area | region inner side than 15 mm from the edge, It is still more preferable to be formed in the area | region inside 12 mm from the edge.

In this embodiment, the average roughness SRa of the flat part 110 becomes like this. Preferably it is 5 nm or more, More preferably, it is 7 nm or more, More preferably, it is 9 nm or more, Preferably it is 25 nm or less, More preferably 20 nm or less, more preferably 10 nm or less. By setting average roughness SRa of the flat part 110 to below the said upper limit, generation | occurrence | production of the winding shift | offset | difference by which a film slips can be suppressed, and films are made by making average roughness SRa of the flat part 110 more than the said lower limit. It is possible to suppress the occurrence of scratches due to the easily contacting. Here, the surface roughness SRa of the flat part 110 of the film 100 uses a commercially available surface roughness measuring instrument, for example, a surface roughness measuring instrument "Surfcorder ET4000AK" manufactured by Kosaka Laboratory Co., Ltd. It can measure on conditions of 1 mm square and cutoff 0.8 mm.

[3. Uneven structure]

In this embodiment, the uneven structure part 120 which exists in uneven structure area | region 120R and 120L is formed in the position spaced apart from the edge of the width direction of the film 100, as shown in FIG. have. In the present embodiment, the width dimensions A1 of the two uneven structure regions 120R and 120L are substantially the same, and the width dimensions A1 are from the beginning (end portion 12P) of the second region 100B. It becomes constant value until end.

It is preferable that the uneven structure part 120 is formed in the edge area within 20 mm from the edge of the width direction of the film 100, It is more preferable to form in the edge area within 18 mm from the edge, The More preferably, it is formed in the end region within 15 mm from the edge. The width dimension A1 of the uneven structure region where the uneven structure portion is formed is preferably 3 mm or more, more preferably 5 mm or more, and even more preferably 7 mm or more. By making the area | region in which the uneven structure part is formed in the said range, generation | occurrence | production of buckling, winding shift | offset | difference, etc. can be suppressed.

In this embodiment, as shown in FIG. 3, the uneven structure part 120 uses the shape unit to which four rhombuses were connected as one unit, and this is a shape repeated in the film longitudinal direction (winding direction). It is preferable that the uneven structure part 120 repeats a predetermined shape unit from the viewpoint of easy adjustment of the ratio of the uneven structure area and the like.

4: is a figure which shows typically the cross section (Y-Y cross section in FIG. 3) which cut | disconnected the uneven structure part 120 of the 2nd area | region 100B in the surface perpendicular | vertical to an extending direction. The uneven structure 120 includes a concave portion 122 and a convex portion 121. Usually, the recessed part 122 corresponds to the part from which resin was removed by heat melting or ablation by laser beam irradiation, and the convex part 121 is heated and fluidized by irradiation of said laser beam. It corresponds to the part which the resin which rose. Since the convex part 121 protrudes more than the surface 100U of the surrounding film 100, in this uneven structure part 120, the substantial thickness of the film 100 becomes thick.

In FIG. 4, 100L is the bottom surface of the film 100, 122B is the bottom of the recess 122, 121T is the top of the convex portion 121, and H is the height of the convex portion 121. In the present invention, the height H of the convex portion 121 of the concave-convex structure portion 120 means the height from the upper surface 100U of the film 100 where the concave-convex structure is not formed to the top portion 121T of the convex portion. Say. The height of the convex part of the uneven structure part 120 may be uniform or nonuniform. The height of the convex part in the uneven structure part 120 of a 2nd area | region can be measured, for example using a three-dimensional surface profiler ("NewView5000" by Zayago Co., Ltd.).

In this embodiment, the average value H2 of the height H of the convex part 121 of the uneven structure part 120 in the 2nd area | region 100B of the film 100 is a value within a specific range. H2 is prescribed | regulated relatively with the average value H1 of the height H of the height H of the convex part of the uneven structure part in 1st area | region 100A of the film 100. FIG. H1 and H2 satisfy the following formula (A).

Formula (A): H2-H1 ≥ 1 μm

In this embodiment, since the uneven structure part is not formed in 100 A of 1st area | regions, the average value H1 of the height H of the height H of the convex part of the uneven structure part in 1st area | region 100A is zero. Therefore, in this embodiment, when the average value of the height H of the convex part 121 of the uneven structure part 120 of the 2nd area | region 100B is 1 micrometer or more, the said 2nd area | region 100B is a 1st area | region The average value of the height H of the height H of the convex portion 121 of the uneven structure 120 is larger than 100A. In the following description, "the average value of the height of a convex part" may be called "the average height of a convex part." The value of H2-H1 is preferably 3 µm or more, and more preferably 5 µm or more. Although the upper limit of the value of H2-H1 is not specifically limited, For example, it can be 25 micrometers or less.

In this embodiment, the average value H2 of the height H of the height H of the convex part 121 of the uneven structure part 120 of the 2nd area | region 100B is 1 micrometer or more, Preferably it is 3 micrometers or more, More preferably, it is 5 It is μm or more, more preferably 7 μm or more, while preferably 25 μm or less, more preferably 20 μm or less, even more preferably 15 μm or less. By making the average value H2 of the height H of the height H of the convex part 121 of the uneven structure part 120 in the 2nd area | region 100B more than the said lower limit, winding shift at the time of winding of a film can be suppressed, and the said height By making average value H2 of (H) into below the said upper limit, the deformation | transformation of the film resulting from the difference of the winding diameter in the part in which the uneven structure part was formed in the roll wound and the other part can be suppressed.

In this embodiment, the width | variety of the uneven structure part 120 becomes like this. Preferably it is 0.1 micrometer or more, More preferably, it is 0.15 micrometer or more, Especially preferably, it is 0.2 micrometer or more, Preferably it is 1 micrometer or less, More preferably, it is 0.75. μm or less, particularly preferably 0.5 μm or less. When the width | variety of the uneven structure 120 is more than the lower limit of the said range, winding shift | offset | difference can be suppressed at the time of winding of the film 100. FIG. In addition, when the width of the uneven structure 120 is less than or equal to the upper limit of the above range, the uneven structure 120 can be formed without collapse of the shape.

〔4. Film thickness]

The average thickness of the film 100 is preferably 10 μm or more, more preferably 20 μm or more, even more preferably 30 μm or more, preferably 100 μm or less, more preferably 80 μm or less, even more preferably. Preferably 60 μm or less. Even if it is a thin film whose average thickness is below an upper limit, generation | occurrence | production of a scratch can be suppressed effectively, and the effect of this invention is acquired. The thickness of a film can be measured using a commercially available measuring instrument, for example, "F20-NIR" by a film matrix company.

[5. Material of resin film]

The material of the resin film which comprises the film roll of this embodiment is not specifically limited, Various thermoplastic resins can be employ | adopted. The resin film may be a single layer film or may be a multilayer film having a plurality of layers. The resin film may be a stretched film or may be a film that is not stretched.

[6. Manufacturing Method of Film Roll]

The film roll of this embodiment can be manufactured by the manufacturing method including the preparation process which prepares a resin film, and the process (winding process) which winds up the prepared resin film in the core.

[6.1. Resin Film Preparation Step]

The method of providing an uneven structure part to the film before giving an uneven structure part at the time of preparation of a resin film is not specifically limited, The well-known method for forming an uneven structure can be employ | adopted. As an example of such a method, the uneven structure provision method using a laser and the uneven structure provision method using an embossing roll are mentioned. In the uneven structure provision method using a laser, a specific pattern is drawn by the laser on the surface in the uneven structure area | region of the film conveyed continuously. Thereby, the surface of the film can be partially heated with a laser, and the surface of the film can be deformed by such heating, and as a result, an uneven structure having a specific pattern can be formed. In the method of applying the uneven structure using the emboss roll, an emboss roll having a uneven structure having a specific pattern is prepared on the circumferential surface, and the uneven structure of the embossed roll is transferred to the surface in the uneven structure region of the film to be conveyed continuously. As a result, an uneven structure having a specific pattern can be formed.

In this embodiment, provision of an uneven structure is provided only to the area | region corresponded to the 2nd area | region 100B of the resin film 100. FIG.

[6.2. Winding process]

The process of winding up a resin film in a core includes the 1st winding process which winds up the 1st area | region of a resin film, and the 2nd winding process which winds up the 2nd area | region of a resin film in order. In this embodiment, in the 1st winding process, the touch winding which presses and winds a touch roll to the film roll in the middle of manufacture is performed, and in a 2nd winding process, the touch roll is rolled off from the film roll in the middle of manufacture Gap winding is performed. When winding up the resin film which has the area | region which does not contain an uneven structure part, it is preferable to perform touch winding from a viewpoint of preventing generation of a scratch more effectively. In this embodiment, it is possible to more effectively prevent the occurrence of scratches by winding up the first region not including the uneven structure by touch winding.

FIG. 5: is a figure which shows typically the winding apparatus 200 used at a 1st winding process. The winding apparatus 200 winds up the 1st area | region 100A of the elongate film 100, and has the film roll (1st film part 12A) which wound the 1st area | region 100A on the core 11. As a winding device for obtaining a film roll), a winding core 11, a winding motor 210 as a rotation drive device for the winding core 11, a touch roll 220, and a position adjusting device for the touch roll 220. Arm 230 as an arm.

In a 1st winding process, the film 100 is continuously conveyed in the longitudinal direction of the said long film 100, and it supplies to the touch roll 220. FIG. At this time, the conveyance speed of the film 100 is equal to the winding speed at the time of winding the film 100 by the core 11 normally. Therefore, it is preferable to set the conveyance speed of the film 100 so that a desired winding speed can be implement | achieved.

The film 100 supplied to the touch roll 220 is wound around the touch roll 220. At this time, since the touch roll 220 is provided so as to be rotatable freely, the touch roll 220 rotates in the circumferential direction by the frictional force given from the wound long film 100. And the long film 100 is guide | induced to the core 11 by the touch roll 220 which rotates in this way. As needed, the touch roll 220 may be given the driving force for rotating the said touch roll 220. As shown in FIG.

The core 11 is rotated in the circumferential direction by the driving force given from the core motor 210. Therefore, the film 100 guided by the core 11 in the state wound around the touch roll 220 is wound up by the core 11. And the film roll which has 12 A of 1st film parts is formed by the film 100 wound up by the core 11. At this time, the position of the touch roll 220 is adjusted by the arm 230 so that the touch roll 220 may be wound up by the core 11, and may contact the film 100 which became a part of the film roll in manufacture.

When winding the film 100 in the core 11, the touch roll 220 receives a predetermined load in the radial direction of the core 11 by the pressing force given from an air cylinder (not shown). Press and hold Thereby, the film 100 (that is, the film contained in the film roll in the middle of manufacture) wound up to the core 11 is pressed by predetermined load toward the center of the core 11. Therefore, mixing of the air between the circumferential surface of the film roll and the film 100 in the middle of manufacture during the winding of the film 100 is suppressed.

The magnitude | size of the load which the touch roll 220 presses the film roll at the time of manufacture is 20 N / m or more normally, Preferably it is 50 N / m or more, More preferably, it is 100 N / m or more, Usually 500 N / m Hereinafter, Preferably it is 400 N / m or less, More preferably, it is 300 N / m or less. The magnitude | size of the load which the touch roll 220 presses the film roll in manufacture may change a value arbitrarily according to the winding diameter of the film roll in manufacture in the said range.

In the 1st winding process, the winding tension of the film 100 at the time of winding the film 100 to the core 11 becomes like this. Preferably it is 50 N / m or more, More preferably, it is 70 N / m or more, More Preferably it is 90 N / m or more, Preferably it is 300 N / m or less, More preferably, it is 250 N / m or less, More preferably, it is 200 N / m or less. The unit "N / m" of said winding tension shows the magnitude | size of the force added per 1 m of width of a film. By making the winding tension of the film 100 into the said range, generation | occurrence | production of the scratches in a film roll can be suppressed effectively. The winding tension of the film 100 may change a value arbitrarily according to the winding diameter of the film roll 10 in the middle of the said range. In this case, for example, the above-mentioned winding tension may be changed to become smaller, may be changed to become larger, or a combination thereof may be used.

FIG. 6: is a figure which shows typically the winding apparatus 300 used at a 2nd winding process. The winding device 300 winds up the 2nd area | region 100B of the elongate film 100, and the film roll which further wound the 2nd area | region 100B to the winding body by which the 1st area | region 100A was wound ( It is a winding device for obtaining 10). The winding device 300 includes the winding core 11, the winding core motor 310 as the rotation drive device for the winding core 11, the free roll 320, and the arm as the position adjustment device for the free roll 320 ( 330.

The free roll 320 is positioned by the arm 330 so that the touch roll 220 of the winding apparatus 200 used in the 1st winding process does not contact the core 11 and the film roll 10 during manufacture. It is adjusted. When the 2nd winding process is performed using this winding apparatus 300, after winding the film 100 to the free roll 320, the film 100 is wound up to the winding core 11, and the film roll 10 is wound up. Get At this time, the film 100 wound around the free roll 320 is wound around the core 11 after being separated from the free roll 320 to form the film roll 10.

In the winding apparatus 300, since the free roll 320 is used instead of the touch roll 220, air flows in between the circumferential surface of the film roll in manufacture and the film 100, and the 2nd film In the portion 12B, more air is contained than the first film portion 12A.

In a 2nd winding process, the winding tension of the film 100 at the time of winding up the film 100 to the core 11 is made smaller than a 1st winding process. The winding tension of the film 100 in the second winding step is preferably 50 N / m or more, more preferably 70 N / m or more, still more preferably 90 N / m or more, preferably 300 N / m or less, More preferably, it is 200 N / m or less, More preferably, it is 150 N / m or less. The unit "N / m" of said winding tension shows the magnitude | size of the force added per 1 m of width of a film. By making the winding tension of the film 100 into the said range, generation | occurrence | production of buckling, winding shift | offset | difference, etc. in a film roll can be suppressed effectively. The winding tension of the film 100 may change a value arbitrarily according to the winding diameter of the film roll 10 in the middle of the said range. In this case, for example, the above-mentioned winding tension may be changed to become smaller, may be changed to become larger, or a combination thereof may be used.

[7. Effects and Effects of the Present Embodiment]

In the present embodiment, the resin film 100 satisfies the requirements of the formula (A) (requirement (A)). In addition, in this embodiment, a film roll meets the requirements (requirements (B) and (C)) of the following formula (B) and formula (C).

Formula (B): 3 <100 × (R2-R1) / R3 <50

Formula (C): 100 × (R2-R1) / R2 <65

In formula (B)-(C), R1 is a diameter of the core 11, R2 is a winding diameter of the 1st area | region 100A wound by the core 11, and R3 is a film roll 10 ) Is the diameter.

In requirement (B), 100 * (R2-R1) / R3 becomes like this. Preferably it is four or more, More preferably, it is six or more, More preferably, it is eight or more, Preferably it is 45 or less, More preferably, it is 40 or less More preferably, it is 35 or less.

In requirement (C), 100 * (R2-R1) / R2 becomes like this. Preferably it is three or more, More preferably, it is five or more, More preferably, it is seven or more, Preferably it is 60 or less, More preferably, it is 40 or less to be.

The effect of requirements (A)-(C) is demonstrated.

In this embodiment, since the film 100 has the 1st area | region 100A in which the uneven structure part 120 is not formed in the start end part side of the winding direction, the 1st area | region 100A of the film 100 is In 12 A of wound 1st film parts, there is no film lifting, it is wound tightly, and it becomes difficult to generate friction.

Here, in the film roll obtained by winding the resin film in which the uneven structure part is not formed over the whole area, the problem that the gauge band resulting from a film thickness tends to generate | occur | produce in the outer side (part with a large winding diameter) of a film roll is a problem. have. However, in this embodiment, the 2nd area | region 100B in which the average value of the height of the height of the convex part of the uneven structure part 120 is 1 micrometer or more than the 1st area | region 100A outside the 1st film part 12A is wound up. The second film portion 12B is formed, and the second film portion 12B is wound so that the resin film 100 contains more air than the first film portion 12A.

That is, the film roll 10 of this embodiment has 12 A of 1st film parts in which friction is hard to generate | occur | produce in the part (part with a small winding diameter) near the core 11 by providing requirement (A). On the outer side (part with a large winding diameter), it has the 2nd film part 12B which contains air and is hard to be influenced by a film thickness.

When the winding diameter R2 of the 1st area | region 100A wound by the winding core 11 is large, generation | occurrence | production of a scratch is suppressed but generation | occurrence | production of a gauge band becomes easy to generate | occur | produce. As a result of examining this problem, the ratio (100 * (R2-R1) / R3) of the winding part R2-R1 of the 1st area | region 100A with respect to the diameter R3 of a film roll, and the 1st area | region ( The generation of the gauge band can be suppressed by setting the ratio of the wound portions R2-R1 of the first region 100A to the winding diameter R2 of 100A within a range that satisfies the requirements (B) and (C). I found out.

That is, according to this embodiment, since a resin film meets requirement (A) and a film roll meets requirements (B) and (C), the film which can suppress the generation of a scratch and the generation of a gauge band is suppressed. A roll and its manufacturing method can be provided.

〔8. Use of film]

The film roll of this embodiment can handle preservation, conveyance, a trade, etc. in the state of a film roll. The film unwound from the film roll of this invention can be used for a wide range of uses, and it is preferable to use it as an optical film especially. As a specific example of an optical film, a retardation film, a polarizing plate protective film, an optical compensation film, etc. are mentioned.

EXAMPLE

Hereinafter, an embodiment according to the present invention will be described. However, this invention is not limited to a following example, It can change and implement arbitrarily in the range which does not deviate from the Claim of this invention, and its equal range. Operation described below was performed under the conditions of normal temperature and normal pressure unless otherwise stated.

[Assessment Methods]

〔One. Gauge band and degree of cold wrinkles]

The film was unrolled from the film roll manufactured in the Example and the comparative example (henceforth "each example") to the winding diameter R2 of a 1st area | region, the external appearance was observed, and the presence or absence of the gauge band on a film roll was observed. When the gauge band was seen, the part corresponding to the position where the gauge band was was visually observed, and the gauge band and the degree of winding wrinkles were evaluated based on the following evaluation criteria.

(Evaluation standard)

A: A nonuniformity is not seen in the position where a gauge band existed, or a gauge band is not seen in observation of a film roll.

B: Non-uniformity is seen where the gauge band was.

〔2. Scratch Occurrence]

[2-1. Vibration test]

(2-1-1) rack

The rack used at the time of a vibration test is demonstrated briefly. 8 is a front view of a rack in a state in which the film rolls manufactured in each example are stacked, and FIG. 9 is a side view of the rack.

The rack 1 is made of steel and, as shown in Figs. 8 and 9, a pallet 4 at the bottom and a pair of support frames 3 and 3 which are installed upright from the pallet 4 and installed upward. And connecting rods 5 and 5 connecting the pair of support frames 3 and 3 on the upper side of the rack 1. The film roll 10 manufactured by each case is mounted in the upper surface of the pallet 4, the pair of support frames 3 and 3, and the accommodation space enclosed by the connecting rods 5 and 5. As shown in FIG. The pallet 4 forms the hollow rectangular parallelepiped containing the said accommodation space, and functions as a base which receives the load applied to the rack 1. 8 in FIG. 8 and FIG. 9 is a bottom plate of the pallet 4.

As shown in FIG. 9, the rack 1 has the cylindrical member receiving part 2 which accommodates the edge part of the core 11 of the film roll 10, and the opening / closing member which opens and closes the said cylindrical member receiving part 2 ( 7). After accommodating the end of the core 11 in the cylindrical member receiving part 2, the end of the core 11 is closed by the closing member 7 so as to engage the locking bracket 7A. WHEREIN: It is hold | maintained by the pressing member 9 and the rubber member 9A, and movement is regulated.

The rack 1 has an adder plate portion 6, and the adder plate portion 6 has an adder plate 6A having a support surface for supporting the side surface of the film roll 10, and a support surface of the adder plate 6A. The base plate 6B has a base plate 6B installed vertically from the rear surface on the opposite side, and a nut 6C that spirally engages with a threaded portion of a threaded bolt (not shown). After passing the threaded bolt through the bolt hole formed in the base plate 6B, the nut 6C is screwed together so that the lid plate part 6 can be fixed to the opening / closing member 7. In this evaluation test, the backing plate 6A functions as a member which clamps the side surface of the film roll 10. The weight of the rack 1 unit which does not load the film roll 10 is 100 kg.

(2-1-2) vibration test

The film roll manufactured by each example was mounted in the rack demonstrated by (2-1-1), and the random vibration test was done using the commercial random tester (made by IMF Corporation, brand name "EMK1252 / H15"). When performing the random vibration test, the base plate 6B was fixed by arranging the backing plate 6A to abut on the side surface of the film roll 10. As a condition of the random vibration test, the condition which the maximum acceleration Ga applied to the rack which mounted the film roll becomes 3.0 G was employ | adopted. Specifically, in the random vibration test, the power spectral density was excited at a power spectral density of 0.4 G ² / Hz over a total of 3 hours, 1 hour in the X-axis direction, 1 hour in the Y-axis direction, and 1 hour in the Z-axis direction. During the random vibration test, the maximum acceleration Gb applied to the core of the film roll was measured and found to be 2.0 G. The maximum acceleration Gb was measured using an acceleration sensor (gravity shock recorder "G-MEN DR 20" made by Srix Corporation) attached to the core 11 of the film roll mounted in the rack.

[2-2. Deconstruction Inspection]

The resin film was unwound every 100 m from the film roll after the vibration test, and a 10 m long resin film was sampled, and the sampled film was inspected over the entire surface by reflection inspection with high brightness light in a dark room to check for the presence of scratches. It observed and evaluated according to the following criteria.

A: No scratch

B: Scratch Occurred

<Example 1>

(1-1) Production of Resin Film

The uneven structure part was formed by the following method using the elongate optical film of 50 micrometers in average thickness in which the easily bonding layer which consists of urethane resin was formed in one surface of the film formed of cycloolefin resin.

The uneven structure part shown in FIG. 7 was formed by irradiating a laser beam to the part corresponded to the 2nd area | region of the optical film before the said process. In detail, the uneven structure part was formed in the area | region separated from 1 mm-2 mm from the edge as an area | region whose distance from the edge of the film width direction of the surface of the resin layer side of an optical film is 11.5 mm. Here, the width dimension A1 of the uneven structure region is 9.5 mm to 10.5 mm. As a laser beam irradiation apparatus, a CO ₂ laser beam irradiation apparatus ("LP-430U" manufactured by Panasonic Sunks Corporation, laser wavelength 10.6 µm) was used. In addition, the irradiation output of laser beam was made into 90% of output.

FIG. 7: is a top view which shows typically the planar shape of the uneven structure part 120 formed in Example 1. As shown in FIG. In FIG. 7, in order to show the dimension of the uneven structure 120, the coordinate of the longitudinal direction and the width direction of a resin film is shown. The numerical unit of this coordinate is millimeters. The average value of the height of the convex part of the uneven structure part 120 was 10 micrometers.

Irradiation of the laser beam was performed while moving a laser beam irradiation point at the movement speed of 2000 mm / s so that the planar shape of the uneven structure part 120 shown in FIG. In the planar shape of the uneven structure part 120 shown in FIG. 7, all the angle | corners A enclosed by the dashed-dotted line were 90 degrees in all. In addition, in the planar shape of the uneven structure part 120, the angle of nonlinear part (nonlinear part shown by dashed line in FIG. 7) other than corner | angular part A was 135 degrees. By irradiation of said laser beam, the some uneven structure part which has a planar shape shown in FIG. 7 made by the linear convex part lined up by 4.2 mm pitch in the film long direction to the surface of the resin layer side of the optical film before a process 120 was formed. This obtained the elongate resin film which has a base material layer and a resin layer, and has the uneven structure part 120 which consists of linear convex parts in the surface on the resin layer side. This elongate resin film is a resin film which has a 1st area | region in which the uneven structure part is not formed, and the 2nd area | region where the uneven structure part 120 of the shape shown in FIG. 7 was formed in the both ends of the width direction, respectively, and a 2nd area | region The average roughness SRa of the surface of the flat part between the two uneven structure regions is 10 µm. In this resin film, the length of a 1st area | region is 300 m.

(1-2) Production of Film Roll

In the long core resin film obtained in (1-1), the winding diameter R2 of the 1st area wound by the core was 220 mm, and the diameter R3 of the film roll was 610 in the core with the diameter R1 of 168 mm. It wound up to mm, and the film roll was produced. The evaluation test was done about the obtained film roll, and the result was shown in Table 1.

The winding of the 1st area | region was performed so that the magnitude | size of the load which the winding tension 300 N / m and the touch roll press the film roll in the middle of manufacture may be 200 N / m using the winding apparatus shown in FIG.

The winding of the 2nd area | region was performed by winding tension of 150 N / m using the apparatus (refer FIG. 6) which dropped the touch roll from the film roll in manufacture by the arm in the winding apparatus of FIG.

<Example 2>

(2-1) Production of Resin Film

A long resin film was obtained in the same manner as in (1-1) of Example 1 except that the length of the first region was 500 m.

(2-2) Preparation of Film Roll

A film roll was produced in the same manner as in (1-2) of Example 1 except that the resin film prepared in (2-1) was used and the core was wound so that R2 was 250 mm. The results are shown in Table 1.

<Example 3>

(3-1) Production of Resin Film

A long resin film was obtained in the same manner as (1-1) except that the length of the first region was set to 1000 m.

(3-2) Preparation of Film Roll

A film roll was produced in the same manner as in (1-2) of Example 1 except that the resin film prepared in (3-1) was used and R2 was wound to the core so as to be 310 mm, and an evaluation test was performed. The results are shown in Table 1.

<Example 4>

(4-1) Production of Resin Film

A long resin film was obtained in the same manner as (1-1) except that the length of the first region was 2600 m.

(4-2) Preparation of Film Roll

A film roll was produced in the same manner as in (1-2) of Example 1 except that the resin film prepared in (4-1) was used and R2 was wound to the core so that it was 450 mm. The results are shown in Table 1.

Example 5

(5-2) Preparation of Film Roll

Same as Example (1-2) except for using the winding core having a diameter R1 of 350 mm, winding the resin film around the winding core so that R2 was 375 mm, and the diameter R3 of the film roll was 685 mm. It was made, the film roll was produced, the evaluation test was done, and the result was shown in Table 1.

<Example 6>

(6-1) Production of Resin Film

A long resin film was obtained in the same manner as (1-1) except that the length of the first region was 500 m.

(6-2) Preparation of Film Roll

Using a resin film prepared in (6-1), using a winding core having a diameter (R1) of 350 mm, winding a resin film around the winding core so that R2 is 395 mm and the diameter (R3) of the film roll is 685 mm. A film roll was produced and the evaluation test was done similarly to (1-2) of Example 1 except having remarked, and the result was shown in Table 1.

<Example 7>

(7-1) Production of Resin Film

A long resin film was obtained in the same manner as (1-1) except that the length of the first region was set to 1000 m.

(7-2) Preparation of Film Roll

Using a resin film prepared in (7-1), using a winding core having a diameter (R1) of 350 mm, winding a resin film to the winding core so that R2 is 435 mm and the diameter (R3) of the film roll is 685 mm. A film roll was produced and the evaluation test was done similarly to (1-2) of Example 1 except having remarked, and the result was shown in Table 1.

<Example 8>

(8-1) Production of Resin Film

A long resin film was obtained in the same manner as (1-1) except that the length of the first region was 2600 m.

(8-2) Preparation of Film Roll

Using the resin film produced in (8-1), using the winding core having a diameter (R1) of 350 mm, winding the resin film to the winding core so that R2 is 545 mm and the diameter (R3) of the film roll is 685 mm. A film roll was produced and the evaluation test was done similarly to (1-2) of Example 1 except having remarked, and the result was shown in Table 1.

Comparative Example 1

(C1-1) Production of Resin Film

A long resin film was obtained in the same manner as (1-1) except that the length of the first region was 100 m.

(C1-2) Preparation of Film Roll

A film roll was manufactured in the same manner as in (1-2) of Example 1, except that the resin film produced in (C1-1) was used and the resin film was wound around a core so that R2 became 180 mm. The evaluation test was done and the result was shown in Table 2.

Comparative Example 2

(C2-1) Production of Resin Film

A long resin film was obtained in the same manner as (1-1) except that the length of the first region was 100 m.

(C2-2) Preparation of Film Roll

Except for using the resin film produced in (C2-1), using a winding core having a diameter (R1) of 350 mm, and winding the resin film around the winding core so that R2 was 360 mm, (1-2 in Example 1). ), A film roll was manufactured, the evaluation test was done, and the result was shown in Table 2.

Comparative Example 3

(C3-1) Production of Resin Film

A long resin film was obtained in the same manner as (1-1) except that the length of the first region was set to 1000 m.

(C3-2) Preparation of Film Roll

Using a resin film prepared in (C3-1), using a winding core having a diameter (R1) of 100 mm, winding a resin film around the winding core so that R2 is 280 mm and the diameter (R3) of the film roll is 330 mm. A film roll was produced and the evaluation test was done similarly to (1-2) of Example 1 except having remarked, and the result was shown in Table 2.

<Comparative Example 4>

(C4-1) Production of Resin Film

A long resin film was obtained in the same manner as (1-1) except that the length of the first region was 3900 m.

(C4-2) Preparation of Film Roll

A film roll was manufactured and evaluated in the same manner as in (1-2) of Example 1, except that the resin film produced in (C4-1) was used and the resin film was wound around the core so that R2 became 535 mm. The test was done and the result was shown in Table 2.

Comparative Example 5

(C5-1) Production of Resin Film

A long resin film was obtained in the same manner as (1-1) except that the length of the first region was 5200 m.

(C5-2) Preparation of Film Roll

Except for using the resin film produced in (C5-1), winding the resin film around the core so that R2 is 610 mm and the diameter (R3) of the film roll is 1000 mm, In the same manner, a film roll was produced, an evaluation test was performed, and the results are shown in Table 2.

Comparative Example 6

(C6-1) Production of Resin Film

A long resin film was obtained in the same manner as (1-1) except that the length of the first region was 2600 m.

(C6-2) Preparation of Film Roll

Using a resin film prepared in (C6-1), using a winding core having a diameter (R1) of 100 mm, winding the resin film to a winding core so that R2 is 430 mm and the diameter (R3) of the film roll is 600 mm. A film roll was produced and the evaluation test was done similarly to (1-2) of Example 1 except having remarked, and the result was shown in Table 2.

The evaluation result of an Example and a comparative example was shown in Table 1 and Table 2. Table shows the lengths of R1, R2, R3, 100 × (R2-R1) / R3, 100 × (R2-R1) / R2, and the first region in the resin film in Examples and Comparative Examples. "The length of a 1st area"), the average value of the height of the convex part of a concave-convex structure part of a 1st area ("average height of a convex part of a 1st area" in a table), and the average value of the height of the convex part of a convex part of a 2nd area | region The "average height of the convex part of a 2nd area | region", the surface roughness SRa of a flat part ("SRa of a flat part" in a table), the winding tension of a 1st winding process, and the winding tension of a 2nd winding process were also shown.

From the results of Tables 1 and 2, it was found that the film rolls satisfying the requirements of the present invention can both suppress the occurrence of scratches and the generation of gauge bands.

[Other Embodiments]

This invention is not limited to embodiment described by the said technique and drawing, For example, the following embodiment may be sufficient.

(1) In the said embodiment, although the film 100 which has uneven structure area | region 120R, 120L having substantially the same width dimension was shown, the film which differs in the width dimension of two uneven structure area | region may be sufficient.

(2) In the said embodiment, although the uneven structure part 120 showed the film 100 formed in the position spaced apart from the short edge of the width direction of the film 100, the uneven structure part contact | connected the short edge of the width direction of the film. The film formed at the position may be sufficient.

(3) In the above embodiment, the concave-convex structure portion having one unit of the shape unit in which four lozenges are connected is shown.

(4) In the said embodiment, although the resin film which has the 1st area | region where the uneven structure part is not formed (the height of the convex part is 0) was shown, the resin film which has the 1st area | region in which the uneven structure part is formed may be sufficient. . In this case, the average value of the height of the convex portions of the concave and convex portions of the second region may be 1 μm or more larger than the average value of the height of the convex portions of the concave and convex portions of the first region.

(5) In the said embodiment, touch winding is performed in the 1st winding process which winds up the 1st area | region of a resin film, and the example which performs gap winding in the 2nd winding process which winds up the 2nd area | region of a resin film is given. Although shown, it is not limited to this. For example, when using the resin film in which the uneven structure part is formed in both a 1st area | region and a 2nd area | region, a gap winding may be sufficient as the winding method of the 1st area | region and the 2nd area | region of a resin film.

10... Film roll
11... Heart
11C... Center of Core
12A... First film part
12B... 2nd film part
12P... End of the first film portion
100... Resin film
100U... Top surface of resin film
100L... Bottom of resin film
100A... First area
100B... Second area
110... Flat part
120... Uneven structure
120L, 120R... Uneven structure area
121... Convex
121T... Top of convex
122... Recess
122B... Bottom of recess
200, 300... Winding device
210, 310... Winding motor
220... Touch roll
230, 330... Arm
320... Free roll
A1... Width dimension of uneven structure area
H… Height of convexity
R1... Diameter of core
R2... Winding diameter of the first region wound in the core
R3... Diameter of film roll

Claims (6)

As a film roll containing a core and a long resin film wound by the core,
The said resin film contains an uneven structure part at the edge part of the width direction,
The said resin film has a 1st area | region including the start end part in a winding direction, and a 2nd area | region which adjoins the said 1st area | region and contains the terminal part in the said winding direction,
The said resin film satisfies Formula (A), and the said film roll satisfies Formula (B)-(C),
H2-H1 ≥ 1 μm (A)
3 <100 × (R2-R1) / R3 <50 (B)
100 × (R2-R1) / R2 <65 (C)
However, H1 is an average value of the height of the convex part of the said uneven structure part of the said resin film in a said 1st area | region,
H2 is the average value of the height of the convex part of the said uneven structure part of the said resin film in a said 2nd area | region,
R1 is the diameter of the winding core,
R2 is the winding diameter of the first region wound around the core,
R3 is the diameter of the film roll,
Film roll. The method of claim 1,
The said resin film has an uneven structure area | region in the said 2nd area | region,
The uneven structure region is defined within an end region within 20 mm from the edge of the width direction of the resin film,
The said resin film has the said uneven structure part whose average height is 3 micrometers-25 micrometers in the said uneven structure area | region,
Film roll. The method according to claim 1 or 2,
The said resin film has a flat part whose average roughness SRa is 5 nm-25 nm in the area | region inside 20 mm from the edge of the width direction on at least one surface. The method according to any one of claims 1 to 3,
A film roll, with an average thickness of 10 μm to 100 μm. As a manufacturing method of the film roll in any one of Claims 1-4,
The manufacturing method of the film roll which includes the process of winding up the said resin film in the said core by the winding tension of 50N / m-300N / m. The method of claim 5,
The process of winding up the said resin film in the said core,
A first winding step of winding up the first region of the resin film,
Including a second winding step of winding the second region of the resin film in order;
In the said 1st winding process, the touch winding which presses and winds a touch roll to the said film roll in the middle of manufacture is performed,
In the second winding step, a method of producing a film roll, in which a gap winding is performed in which the touch roll is dropped and wound from the film roll in the middle of production.

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