200906698 九、發明說明： 【發明所屬之技術領域】 本發明係關於用於捲繞聚合薄膜以形成一捲繞捲之系统 及方法。更特定而言’本發明係關於用於使在捲繞聚合薄 膜（例如捲繞如光學等級低模數聚丙烯薄膜之低模數薄犋） 時捲繞相關瑕疯之出現最少化的系統及方法。 【先前技術】 聚合薄膜通常以捲形式製造。不管薄媒之具體組“ 何，大規模生產通常需要形成薄膜之一連續長度或拉幅， 並隨後將如此形成之拉幅捲繞於—旋轉圓筒上（或於一安 裝至該圓筒之一核芯上）。舉例而言，可接受聚合薄膜形 成技術包括擠出一熔融或熔化樹脂（原本由所期望之材料 形成）以形成-鑄造片或拉幅。例如使用一長度取向裝置 及7或拉幅機來拉㈣1，單車由或雙軸拉伸）該鑄造拉幅， 以在一捲繞站捲繞之前賦予薄膜所期望之拉伸屬性。可將 ㈣薄膜修剪或切割成多於—個寬度並將其捲繞成至少一 樣多的捲。視需要，可允許捲繞薄膜硬化或老化從而需 要在視需要—第二捲繞站處退繞並隨後重新捲繞該薄膜。 在其h需要使薄膜老化之彼等情形中’將最初形成之薄 膜捲繞成所謂乳捲；隨後，執行一可選第二切割作業以將 該：捲切割或切削成更小寬度之薄膜長度，該等更小寬度 之^長度又在—單獨的捲繞站處捲繞成成品或切割捲。 1@ J 、作為連續並行製造系統之一部分時，標準薄膜 捲繞震置容易能夠滿足所期望之生產速度。更•刀地說， 131294.doc 200906698 上面捲繞有薄臈之圓筒/ “』以回迷鉍轉，從而產生一 緊么捲繞捲以供隨後配送及/ if ^ 1U ^ ^ ^ ^ ^ 次处理（例如，切割並重繞一 軋捲场成兩個或兩個以上g 古)…、而’遺憾的是， 间捲繞速度連同各種薄骐屬 β Φ Μ r-版 了在捲、、堯期間往薄膜之捲繞 層中賦予瑕疵。舉例而言， ^ ^ . f㊉因各種因素在捲繞期間賦 …… 飞整力（例如，在最外部捲繞層上）， 例如，捲繞裝置中之容限偏# 偏差（例如，捲繞圓筒中之容限 偏擺）、捲繞裝置處之薄膜稃 ^ _ 胰穩疋性、溥膜之測徑器控制 等。該兩個捲繞層（例如，最 取卜|捲繞層與一直接下伏捲 繞層）之間的所得不均勻度可吝& . 个』』度了產生一個（多個）捲繞内瑕疵， 該一個（多個）捲繞内瑕庇然後隨著該薄模之多個連續捲繞 層捲繞於該（該等）瑕庇之頂上而，，生長"。此等捲繞誘發瑕 疯可包括錫罐形瑕峨如，薄膜捲呈現一系列隆起環形 帶從而類似於-錫罐之側）、滑動節及卡規帶類型之瑕 疮。就此而言，儘管努力針對大薄膜寬度捲繞應用(例 如，約2米或更大）精確設計並構造捲繞裝置之機械組件， 然而不可避免的精度偏㈣然地在I繞期間產生不均句張 力’在其中文至,J影響之薄膜層不能容易地相對於直接下伏 層移動（或鬆弛）（例如，因磨擦）之情形中，可出現一個或 多個上文所提及之捲繞誘發瑕疵。當薄膜很薄時，通常更 頻繁地觀察到捲繞瑕疵。 人們已使用多種技術來幫助捲繞。舉例而言，已知添加 滑動粒子或添加劑可減少捲繞瑕疵。然而，既定用於光學 應用之薄膜可有需要最小之混濁度，而混濁度可隨著滑動 131294.doc 200906698 粒子或添加劑之使用而增大。而且，此等光學等級薄膜中 之捲繞瑕庇可隨著其他既定光學屬性之改變而顯現。一個 實例可能係形成局部拉伸薄膜或改變其厚度之硬帶。此 外，若薄膜之所期望之光學屬性包括光學相位延遲，如在 補償薄膜之情況下’則硬帶及其他捲繞瑕崎低製造商 之製造產量及/或用戶之產品品質。 除構建嚴格的製㈣料^卜，—㈣於使捲繞誘發 瑕疲最少化之長期實踐之技術係在捲繞之前视鄰薄膜之對 置邊緣（沿機器方向）賦卜滾花。該等滾花實體形成，且 理論上禁止捲繞層彼此相對明顯移動或"滑動"，如（舉例而 言）第3,502,765號及4,021，179號美國專利中所述。另外及/ 或另-選擇係’可對薄膜組成添加各種成分以促進所期望 之捲繞屬f生’例如-滑動添加劑及，或二氧化石夕或其他”夹 緊"材料。 儘管已發現上述技術對於諸多類型之薄膜而言顯著減少 捲繞誘發瑕疲之出現1而其表示更多的製造成本，而對 於其他薄膜構造而f，其不提供令人滿意的結果或完全不 可用。舉例而t，呈現相對低的拉伸模數之薄膜以及相對 薄的薄膜可能不適合於形成並保持實體賦予之滾花。因 此，舉例而言’已發現實體滾花薄低模數聚丙稀薄膜不消 :捲繞誘發瑕疵。此外，不管薄膜構造如肖，滾花裝置可 隨著時間而累積污染物(例如，污垢），而此等污染物不利 地轉移至隨後處理之薄膜。另外，最終用途要求可能阻止 併入π動劑、—氧化石夕、或通常存在用於改進捲繞屬性 131294.doc 200906698 其他材判'。舉例而ts學等、級薄媒（例如，如適用於 進顯示器（例如液晶顯示器）之觀看特性之同時雙軸定向 7忒烯垃薄膜之雙折射光學薄膜）必須滿足原本受上文所 提及之材料不利影響之嚴格的光學清晰度要求。 、儘管也許可設計並構造達到更苛求容限之捲繞裝置組件 、努力希望減少或消除捲繞誘發瑕疵，然而所得裝置可能 成本间侍令人不敢問津且因此不可能得到商業應用，尤其 * 、生產線製造商所期望之越來越大的軋捲寬度情況 下鑒於此約束條件，一更合意之解決方案將需要修改現 有並行4膜製造/捲繞系統。遺憾的{，當前不存在此類 解決方案。 習用薄臈生產線製造設備對捲繞誘發瑕疵敏感，且此問 題之可接<解決方案代價高昂且可能不適用於各種薄膜構 ^因此萬要改進之薄膜製造及捲繞系統及方法。 【發明内容】 本申凊案尤其揭示一種用於捲繞聚合薄臈之方法。該方 法〇括提供聚合薄膜之—長度連同至少—個與該聚合薄膜 ^丨直心'束條。該薄膜及該束條同時捲繞在一圓筒上 以形成一具有薄膜之連續捲繞層之捲繞捲。就此而言，相 對於該捲繞捲，將該束條連續插置於薄膜之連續捲繞層之 間，其中該束條在一最外冑薄膜㈣層肖一直接下伏薄膜 捲、:層之間建立一空隙。根據此方法，該間隙方便該最外 部捲繞層相對於該直接下伏捲繞層自然移動（例如，鬆 弛）從而補償該圓筒及/或其他與該捲繞裝置相關聯之組 131294.doc 200906698 件之任何固有不均勻度。在某些實施例中，該束條隨著連 續捲繞而相對於該薄膜之一寬度側向移動（例如，振盪）， 從而使該捲繞捲中之明顯凸出部最少化。在其他實施例 複數個小直徑束條經設置，以使該等束條相對於該薄 臈之寬度彼此間隔開。在再其他實施例中，該薄膜具有一 至少4米之寬度，且複數個小直徑束條經設置以使該等 束條相對於該薄膜之寬度彼此間隔開，該等束條位於其中 預期要在-個或多個附加或下游製程中使用該薄膜之區域 外部。附加製程可包括諸如切割或轉化、表面處理、塗 佈、壓層之類的作業。在再其他實施例中，該聚合薄膜係 :低模數光學等級薄膜’例如適合用作—液晶顯示器補償 器之低模數聚丙稀薄膜。 本申請案亦闡述一種用於製造一聚合薄膜捲繞捲之系 統。該系統包括一聚合薄膜供應裝置、—捲繞裝置及一薄 膜間隔器。該聚合薄膜供應裝置自其一出口提供一聚合薄 ❹幅。該捲繞裂置包括—可旋轉圓冑，該可旋轉圓筒經 疋位以在-原本相對於該圓筒界定之捲繞介面處自該薄膜 供應裝置接收該聚合薄膜拉幅。該薄膜㈣ϋ適㈣小直 徑束條之-連續長度供應至該捲繞介面。#於此，該系統 經組態以同時將來自該薄膜供應裝置之該聚合薄膜及來自 該薄膜間隔器之該束條捲繞於該圓筒上以將該束條連續插 之連續捲繞層之間。在某些實施例中，該薄膜間 條之—源及一用於相對於該圓筒側向移動該 -之、’f。在其他實施例中’該聚合薄膜供應裝置 131294.doc 200906698 薄膜之擠出機。鑒於此， ，且該薄膜間隔器定位於 包括一用於自一熔化樹脂擠出一 該擠出機與該捲繞裝置成一直線 δ亥拉幅機與該捲繞裝置之間。 本申請案之該等及其它態樣可藉由下文詳細描述而更加 明瞭。然@ ’在任何情況下均不應將上述概要内容視為： 本發明所主張標的物之限制’本發明所主張標的物僅由隨 附申請專利範圍來界定’且該等巾請專利範圍可在執行期 間加以修正。200906698 IX. Description of the Invention: [Technical Field of the Invention] The present invention relates to a system and method for winding a polymeric film to form a wound roll. More particularly, the present invention relates to systems for minimizing the occurrence of winding-related madness in winding a polymeric film (eg, winding a low modulus 犋 of an optical grade low modulus polypropylene film) and method. [Prior Art] The polymeric film is usually produced in the form of a roll. Regardless of the specific group of thin media, "large-scale production usually requires the formation of one continuous length or tenter of the film, and then the tenter thus formed is wound onto a rotating cylinder (or mounted to the cylinder) For example, acceptable polymeric film forming techniques include extruding a molten or molten resin (formed from the desired material) to form a cast sheet or tenter. For example, using a length orientation device and Or a tenter to pull (4) 1, bicycle or biaxially stretched) the cast tenter to impart the desired stretch properties to the film prior to winding at a winding station. The film can be trimmed or cut into more than - Width and wind it into at least as many rolls. If desired, the wound film may be allowed to harden or age so that it needs to be unwound at the second winding station and then re-wound the film as needed. In the case where the film is aged, 'the initially formed film is wound into a so-called milk roll; subsequently, an optional second cutting operation is performed to cut or cut the roll into a film width of a smaller width, such Smaller width The length is then wound into a finished product or a cut roll at a separate winding station. 1@ J As a part of a continuous parallel manufacturing system, the standard film winding is easily positioned to meet the desired production speed. Knife said, 131294.doc 200906698 The top of the cylinder / "" is wound up to reproduce the entanglement, resulting in a tight winding for subsequent delivery and / if ^ 1U ^ ^ ^ ^ ^ times (for example, cutting and rewinding a rolling field into two or more g ancient)... and 'unfortunately, the inter-winding speed together with various thin ββ Φ Μ r- editions during the roll, 尧A crucible is imparted to the wound layer of the film. For example, ^ ^ . f ten is given during winding due to various factors... flying force (for example, on the outermost wound layer), for example, tolerance in the winding device # deviation (for example, winding The tolerance in the cylinder is yaw), the film at the winding device 稃^ _ pancreas stability, caliper caliper control, etc. The resulting unevenness between the two wound layers (for example, the most taken-up | wound layer and a direct underlying wound layer) can be 吝 & Internally, the one or more windings are entangled and then grown as a plurality of successively wound layers of the thin mold are wound on top of the shelter. Such winding-induced madness can include tin cans, such as a roll of film that exhibits a series of raised loops that resemble the side of a tin can, sliding joints, and shackle type acne. In this regard, while efforts have been made to accurately design and construct mechanical components of the winding device for large film width winding applications (eg, about 2 meters or more), the inevitable precision bias (4) is uneven during I winding. Sentence tension 'in the Chinese to J, the film layer affected by J cannot easily move (or relax) relative to the direct underlying layer (for example, due to friction), one or more of the above mentioned volumes may occur Winding induced sputum. When the film is very thin, the winding turns are usually observed more frequently. Various techniques have been used to aid winding. For example, it is known that the addition of sliding particles or additives reduces the winding enthalpy. However, films intended for optical applications may require minimal turbidity, while turbidity may increase with the use of particles or additives. Moreover, the winding shields in such optical grade films can be visualized as other predetermined optical properties change. An example may be a hard band that forms a partially stretched film or changes its thickness. In addition, if the desired optical properties of the film include optical phase retardation, such as in the case of a compensating film, the hardband and other manufacturing yields of the low-selling manufacturer and/or the quality of the user's product. In addition to constructing a rigorous system (4), the technique of long-term practice of minimizing winding-induced fatigue is to knurl the opposite edge of the adjacent film (in the machine direction) prior to winding. The knurling entities are formed, and the winding layers are theoretically inhibited from moving relative to each other or "sliding" as described in U.S. Patent Nos. 3,502,765 and 4,021,179. Additionally and / or alternatively - the choice ' can add various ingredients to the film composition to promote the desired winding of the 'sliding additive' and/or the dioxide dioxide or other "clamping" material. The above technique significantly reduces the occurrence of winding induced fatigue for many types of films 1 which represents more manufacturing costs, while for other film constructions f, it does not provide satisfactory results or is completely unusable. While t, a film exhibiting a relatively low tensile modulus and a relatively thin film may not be suitable for forming and retaining the knurling imparted by the entity. Thus, for example, it has been found that a solid knurled thin low modulus polypropylene film does not: Winding induces enthalpy. Furthermore, regardless of the film construction, the knurling device can accumulate contaminants (e.g., dirt) over time, and such contaminants are disadvantageously transferred to the subsequently treated film. Additionally, end use requirements may Prevent the incorporation of π-actuators, - oxidized stone, or usually exist to improve the winding properties 131294.doc 200906698 Other materials judged. For example, ts, etc., grade thin media (example For example, a birefringent optical film that is biaxially oriented with a 7-decene film when applied to the viewing characteristics of a display (such as a liquid crystal display) must satisfy the strict optical clarity that would otherwise be adversely affected by the materials mentioned above. Requirements. Although it may be possible to design and construct a winding device assembly that meets more stringent tolerances, and strive to reduce or eliminate winding induced imperfections, the resulting device may be costly and therefore unlikely to be commercially available. In particular, the increasing roll width expected by the line manufacturer, given this constraint, a more desirable solution would require modification of the existing parallel 4 film manufacturing/winding system. Unfortunately, { does not currently exist. Such a solution. The manufacturing equipment of the conventional tanning production line is sensitive to the winding induced enthalpy, and the problem is that the solution is expensive and may not be suitable for various film structures, so the film manufacturing and winding system is improved. SUMMARY OF THE INVENTION The present invention discloses, inter alia, a method for winding a polymeric thin crucible. Providing a length of the polymeric film along with at least one of the straight lines of the polymeric film. The film and the strand are simultaneously wound onto a cylinder to form a wound roll having a continuous wound layer of film. In contrast, the bundle is continuously interposed between the continuous wound layers of the film with respect to the wound roll, wherein the bundle is directly on the outermost film (four) layer and directly under the film roll, layer: Establishing a gap therebetween. According to the method, the gap facilitates natural movement (eg, slack) of the outermost wound layer relative to the direct underlying wound layer to compensate for the cylinder and/or other associated with the winding device Any inherent unevenness of the set 131294.doc 200906698. In some embodiments, the bundle moves laterally (e.g., oscillates) relative to one of the widths of the film as it is continuously wound, thereby causing the roll The obvious projections in the winding are minimized. In other embodiments, a plurality of small diameter bundles are provided such that the bundles are spaced apart from one another relative to the width of the liner. In still other embodiments, the film has a width of at least 4 meters, and the plurality of small diameter bundles are disposed such that the bundles are spaced apart from each other with respect to a width of the film, wherein the bundles are located therein The outside of the area where the film is used in one or more additional or downstream processes. Additional processes may include operations such as cutting or converting, surface treatment, coating, lamination. In still other embodiments, the polymeric film is: a low modulus optical grade film', for example, suitable for use as a low modulus polypropylene film of a liquid crystal display compensator. The present application also describes a system for making a polymeric film wound roll. The system includes a polymeric film supply device, a winding device, and a film spacer. The polymeric film supply unit provides a polymeric thin web from an outlet thereof. The winding split includes a rotatable cylinder that is clamped to receive the polymeric film tenter from the film supply at a winding interface that is originally defined relative to the cylinder. The film (4) is supplied to the winding interface in a continuous length of (4) small diameter bundles. In this case, the system is configured to simultaneously wind the polymeric film from the film supply device and the bundle from the film spacer onto the cylinder to continuously insert the bundle into the continuous winding layer. between. In some embodiments, the film strip source and one are used to laterally move the -f relative to the cylinder. In other embodiments, the polymeric film supply device 131294.doc 200906698 film extruder. In view of this, and the film spacer is positioned to include an extruder for extruding from a molten resin, the extruder is in line with the winding device and the winding device. These and other aspects of the present application will be apparent from the following detailed description. However, the above summary should not be considered as a limitation of the subject matter claimed in the present invention. The subject matter claimed in the present invention is defined only by the scope of the accompanying patent application. Corrected during execution.
【實施方式】 一用於捲繞一聚合薄膜之捲繞系統2〇在圖i中顯示為— 聚合溥膜製造生產線22之一部分。如下文更詳細闡述，捲 繞系統20適於將聚合薄膜捲繞成捲形式，其中該聚合薄膜 最初由一聚合薄膜供應裝置24提供或產生。就此而言，薄 臈供應裝置24可呈各種形式，並產生一聚合薄膜拉幅（例 如’一連續拉幅）26(其通常顯示於圖1中）或將其提供至捲 繞系統2 0。捲繞系統2 0通常包括一捲繞裝置2 8及一薄膜間 隔器30。捲繞裝置28通常經確定尺寸且適於實現將薄膜拉 幅26捲繞成一捲繞捲，其中薄膜間隔器3〇在捲繞期間在薄 膜之至少一最外部捲繞層與一直接下伏捲繞層之間形成一 微小間隙，其中此（此等）間隙方便該最外部捲繞層相對於 該直接下伏捲繞層以一減少該捲繞捲中之捲繞誘發瑕疵之 出現之方式移動（例如，鬆弛）。 如上所示，製造生產線22(且特定而言聚合薄膜裝置24) 可與通常用於製造聚合薄膜之習用薄膜生產線製造裝置類 131294.doc -10- 200906698 似。舉例而言，聚合薄膜供應裝置24可包括一樹脂處理/ 儲存站4〇、一擠出機42、-壓模/鑄造站44及一拉幅機 46概括地說，所期望之樹脂成分保持及/或組合於樹脂 處理站4G内並隨後供應至擠出機42。擠出機a炫化該樹 脂’並隨後將炼融樹脂擠出至麼模/鑄造站44。壓模/禱造 站44實現對所擠出鑄造㈣之所期望之硬化以產生一禱= 片。然後，拉伸(例如，沿縱向及橫向方向雙軸拉物鑄 造片以形成聚合薄膜拉幅26。然後，可使拉伸式薄膜拉幅 26經受各種其他製程以實現所期望之薄膜特性。另一選擇 係’薄膜拉幅26可由-後面沒有拉伸、順序拉伸、或順序 或同時雙軸拉伸之鑄膜製程產生。亦可採用其他薄膜形成 技術，例如（舉例而言）吹膜製程。無論如何，所得薄臈拉 幅26經產生並自其一出口 48(通常所參考）供應至播繞系統 20。然而，應瞭解，此僅僅係一種用於將薄膜拉幅％供應 至捲繞系統20之可接受系統或技術。在其他實施例中，舉 例而言，薄膜拉幅26可相對於捲繞系統2〇離線形成（例 如，薄膜拉幅26可在初始製造之後經受其他處理並隨後提 供至捲繞系統20)。 作為一參考點，本文所述捲繞系統2〇適用於各種不同聚 合薄膜構造。因此，捲繞系統20可用於形成具有不同材料 構造、厚度、物理屬性（例如拉伸模數）、光學屬性等之薄 膜之捲繞捲。然而，在某些實施例中，捲繞系統2〇非常適 於捲繞或處理聚合薄膜，該等聚合薄膜原本可能經歷使用 習用捲繞裝置（例如捲繞裝置28)之捲繞誘發瑕疵及/或不適 131294.doc 200906698 合於使用原本已發現改進捲繞屬性之樹脂添加劑。舉例而 言，捲繞系統20非常適用於薄的薄膜（具有一小於約咒微 米之厚度之4膜，且包括具有一小於約25微米之厚度之極 薄的薄膜）。同樣地，捲繞系統20非常適用於捲繞具有一 低拉伸模數（例如，一小於約2.0_2 75 GPa之模數，如包括 聚丙烯之聚烯烴薄膜)之薄膜。如先前所述，呈現此等屬 性中之一者或兩者之薄膜無法適當地滾花及/或在滚花之 後繼續經歷捲繞誘發瑕疵。同樣地，針對光學應用(例如 2學顯示器或顯示器（例如，液晶顯示器）之光學補償器）所 定製之薄膜無法包括通常理解為改進捲繞屬性之習用改良 β ’例如滑動劑或二氧化石夕。捲繞系統2G非常適於捲繞此 等光學等級薄膜，其中將相位"光學等級薄膜”界定為一沒 有表面瑕疵及/或可導致例如薄膜之雙折射率、透明度或 混濁度之定域變化之非合意之光學假像。作為一參考點， 適用於捲繞系統20之可接受聚合光學等級薄膜閣述（例如） 於第M65,474號美國專利及第2〇〇4/〇156_號美國公開申 請案中，上述美國專利及公開申請案之教示内容以引用方 -U 幷入本文中且原本闌述同時雙軸拉伸式光學等級聚合薄 膜。因此，舉例而言，在某些實施例中，捲繞系統20連同 本文所述之對應捲繞方法與一非常薄（例如，約15職米） 的低模數光學等級聚丙烯薄膜結合使用。 鑒於上述背景，根據切請案之某些態樣之薄膜間隔器 30連同原本顯不呈方塊形式之捲繞裝置以顯示於圖μ中。 為參考點，捲繞裝置28可與_習用薄膜捲繞機⑼ 13I294.doc 200906698 如可自南卡羅來納州Greenville之Bruckner公司購得之薄 膜捲繞機）類似，且通常包括一將薄膜拉幅26(圖1)捲繞於 其上之圓筒50。圓筒50經驅動以實現對薄膜％之捲繞，且 因此具有一對應於（亦即，略微大於）薄膜26之一橫向拉幅 寬度之縱向長度。在某些實施例中，舉例而言，薄膜26可 具有一至少4米之寬度，且在某些實施例中一大於6米之寬 度，且在再其他實施例中一大於10米之寬度；因此，圓筒 50具有—對應縱向長度❶此外，捲繞裝置28可包括附加組 (未，、、員示）且可經組態以便將一核心（未顯示）裝配於圓筒 50上並將薄膜26捲繞於其上。 不s捲繞裝置28之具體構造如何，圖2A之薄膜間隔器3〇 皆包括一由一束條源62供應之束條60。束條60自束條源62 延伸，且受到一張力裝置64及一導軌裝置66作用，如下文 所述。張力裝置64及導軌裝置66實現當將束條6〇饋送至捲 繞裝置28(且特定而言圓筒50)時束條60之所期望之張力及 位置。概括地說’束條6〇與薄膜26(圖υ同時捲繞於圓筒^ 上且用來使所得捲繞捲（未顯示）中之隨機捲繞誘發瑕疵 之出現最少化。 束條60可呈各種形式，且與薄膜％分開地（圖〇提供。 束條60可係一單絲或複絲材料（例如，一複絲紗，如一 絲膨體奈龍紗，其可在商標名稱1兼7:S撚：奈龍6下自北 卡，來納州Raleigh之Texfi Industries購得以識別僅—種可 接受柯料）。束條60經選擇以與薄膜26相容（例如，當被置 放成與薄臈26密切接觸時不會使薄膜26之品質惡化），且 131294.doc -13· 200906698 ’、有丄與薄臈26之一厚度相比相對小的直徑或主尺寸 例而。，束條60之直徑&主尺寸小於薄膜％之厚 小於薄膜之厚度之观；且更佳小於薄膜之厚度之1〇%佳 在其他實施例中，將束條6〇之相對小的直徑或主尺 為不超過50旦尼爾；在其他實施例中不超過〜 在再其他實施例中不超過5旦尼爾。根據此構造-，：束： 將直接緊密接觸捲繞薄膜之僅一極小側向段，而且實現 捲繞層之間所期望之間隔，如下文所述。 張力裝置64視需要提供為間隔器總成3()之—部分，且適 於隨著束條60自源62延伸至導軌裝置66而在束條的中形成 級別的張力。更特定而言，當自導軌裝置Μ連續拉動束 條60夺（例如’在將束條6()連續捲繞於圓筒％上時），張力 裝置64在導執裝置“與源62之間的束條6〇中保持少量張力 以防止在束條6〇中形成鬆弛。因此，張力裝置64可呈各種 適用於束條60之特定構造之形式。舉例而言，張力裝置μ i 可包括或需要—本體’該本體隨著自導軌裝置66且因此自 ^62連續拉動（經由捲繞裝置28)束條6G而將—小的重量或 貝量施加至束條6〇上。作為一參考點由張力裝置以形成 或把加之張力只需要足以避免在束條6〇中形成鬆弛，而不 心、原本可龅致使束條60斷開或磨損之方式超過束條6〇 之拉伸長度。在再其他實施例中，可能不需要張力裝置 64 〇 導軌或導軌裂置66亦可呈各種形式，且通常經構造以將 束條60相對於圓筒5〇定位於一所期望之側向位置處以便隨 131294.doc -14- 200906698 後與薄膜26(圖1) 一起捲繞。舉例而言， 里啊茶見圖 2B，導軌裝置66可包括一終止於一由束條6〇穿過且貫穿之 眼孔或其他開口 70處之臂68。在其他實施例中，導執裝置 66進一步經組態以實現束條6〇相對於圓筒5〇(且因此在同 時捲繞薄膜26/束條60時相對於薄膜26)以一所期望之方弋 側向或左右移動。舉例而言，臂68之一基座72以可滑動^ 式裝配於一框架76之一狹槽74内，將進一步藉由一電動連 接78(通常所參考）驅動或移動於狹槽74内。根據此組熊， 電動連接78可運作以相對於圓筒5〇以一橫向或側向方式鉸 接臂68，且因此貫穿其之束條6〇。另一選擇係，各種能夠 實現束條60之側向移動之其他組態亦接受包括搖動、捃 盪或原本改變該束條之側向位置。如下文所述，導執裝置 66可以-振盈方式運作，從而以—相對慢的振|速率（例 如，約0.5-2.0個循環每分鐘）在一小距離（例如，不超過*英 吋；或者不超過3英吋；或者不超過2英吋）上側向移動或 改變束條60之位置。 捲繞裝置28及薄臈間隔器3〇之佈置可參照圖3八及3B來 加以說明。特定而言’圖从及化顯示性圖解闡釋原本提 供為捲繞裝置28(圆1)之一部分之圓筒5〇，連同包括貫穿其 之束條60之薄膜間隔器3〇(通常所參考）。此外，薄膜拉幅 26亦顯示處於-在捲繞於圓筒5〇上之前之狀態下(為了便 於闡釋，在圖3A之視圖中放大薄膜26之寬度，而縮減圓筒 5〇之直徑）。鑒於此等慣例，薄膜間隔器30通常與圓筒 5〇(且因此薄膜26)空間對準以便當薄膜26及束條60接近圓 131294.doc -15- 200906698 筒50(例如在一原本相對於圓筒5〇所建立之捲繞介面】處） 時，束條60將接收薄膜26之一主表面9〇。儘管圖3八之佈置 反映束條60與薄膜之一”下部"表面9〇介接，然而薄膜間隔 器30/束條60亦可經定位以與薄臈26之一對置"上部"表面92 介面。 如圖3B中所示，束條6〇被引導至薄膜％之對置邊緣％、 96之間的一側向或橫向位置（應瞭解，在圖邛之俯視圖 中，束條60位於薄臈26"後面”或下面以便圖沾一般地說反 映或表示一在此束條60將最初接觸薄膜26之點p根據此 疋向貝j在同日7將薄膜26及束條6G拉動或引導至圓筒5〇以 便隨後捲繞時’確保在一沿薄膜26之一寬❹之點處之束 條6〇之間的接觸。根據圖3B之組態，該單個束條60顯示為 相對於薄膜26之橫向寬度w(亦即，薄膜％之橫向拉幅寬 度）大致居中。然而，另一選擇係，束條60可經定位以在 任：相對於薄膜26之寬度之側向位置處接觸薄㈣。舉例 而吕，束條60可經設置以在對置邊緣94或96中之一者處或 附近與薄膜26介接。在再其他實施例中，薄膜間隔界 川⑻）可包括複數個分域位之束㈣。—種這樣的佈置 在圖3C中不意性地顯示為包括束條60a-60d °第_束條6〇a[Embodiment] A winding system 2 for winding a polymeric film is shown in Figure i as part of a polymeric film manufacturing line 22. As explained in more detail below, the winding system 20 is adapted to wind a polymeric film into a roll form wherein the polymeric film is initially provided or produced by a polymeric film supply unit 24. In this regard, the web supply device 24 can take a variety of forms and produce a polymeric film tenter (e.g., 'one continuous tenter) 26 (which is generally shown in Figure 1) or provided to the winding system 20. Winding system 20 typically includes a winding device 28 and a membrane separator 30. The winding device 28 is generally sized and adapted to effect winding the film tenter 26 into a wound roll, wherein the film spacer 3 is at least one outermost wound layer of the film and a direct underlying roll during winding Forming a slight gap between the layers, wherein the (the) gap facilitates movement of the outermost wound layer relative to the direct underlying wound layer in a manner that reduces the occurrence of winding induced imperfections in the wound coil (for example, slack). As indicated above, the manufacturing line 22 (and in particular the polymeric film unit 24) can be similar to the conventional film line manufacturing apparatus of the type commonly used in the manufacture of polymeric films 131294.doc -10- 200906698. For example, the polymeric film supply device 24 can include a resin processing/storage station 4A, an extruder 42, a stamper/casting station 44, and a tenter 46. In summary, the desired resin composition is maintained and / or combined in the resin processing station 4G and then supplied to the extruder 42. The extruder a stuns the resin and then extrudes the smelting resin to the mold/casting station 44. The stamper/pray station 44 achieves the desired hardening of the extruded casting (4) to produce a prayer = sheet. The sheet is then stretched (e.g., biaxially drawn in the machine direction and transverse direction to form a polymeric film tenter 26. The stretched film tenter 26 can then be subjected to various other processes to achieve the desired film characteristics. A selective system 'film stretcher 26 can be produced by a cast film process without subsequent stretching, sequential stretching, or sequential or simultaneous biaxial stretching. Other film forming techniques can also be employed, such as, for example, a blown film process. In any event, the resulting thin tenter web 26 is produced and supplied to the broadcast system 20 from an outlet 48 (generally referenced). However, it should be understood that this is merely one for supplying the film tenter % to the winding. An acceptable system or technique for system 20. In other embodiments, for example, film tenter 26 can be formed off-line relative to winding system 2 (eg, film tenter 26 can be subjected to other processing after initial fabrication and subsequently Provided to the winding system 20). As a point of reference, the winding system 2 described herein is suitable for use in a variety of different polymeric film configurations. Accordingly, the winding system 20 can be used to form different material configurations, Winding rolls of film of thickness, physical properties (e.g., tensile modulus), optical properties, etc. However, in certain embodiments, the winding system 2 is well suited for winding or processing polymeric films, such polymeric films It is possible to experience a winding induced enthalpy and/or discomfort using a conventional winding device (e.g., winding device 28) 131294.doc 200906698 in conjunction with the use of a resin additive that has been found to improve winding properties. For example, winding system 20 Very suitable for thin films (having a film of less than about 4 microns thick and comprising an extremely thin film having a thickness of less than about 25 microns). Likewise, the winding system 20 is well suited for winding with one A film having a low tensile modulus (for example, a modulus of less than about 2.0 to 75 GPa, such as a polyolefin film comprising polypropylene). As described previously, a film exhibiting one or both of these properties cannot Properly knurling and/or continuing to experience winding-induced enthalpy after knurling. Similarly, for optical applications (eg, optical compensators for 2-scientific displays or displays (eg, liquid crystal displays)) The film cannot include conventionally modified β' such as slip or sulphur dioxide, which is generally understood to improve the winding properties. The winding system 2G is well suited for winding such optical grade films, wherein the phase "optical grade film" An undesired optical artifact without surface imperfections and/or which may result in a localized change in birefringence, transparency or haze, for example, as a reference point, suitable for acceptable optical level of the winding system 20. The teachings of the above-mentioned U.S. Patent Nos. 5,474, the disclosure of which is incorporated herein by reference. And a simultaneous biaxially stretched optical grade polymeric film is described as such. Thus, by way of example, in certain embodiments, the winding system 20, along with the corresponding winding method described herein, is very thin (eg, about 15 The low modulus optical grade polypropylene film of the job meter is used in combination. In view of the above background, a film spacer 30 according to some aspects of the cleavage case is shown in Fig. 5 together with a winding device which is originally shown in the form of a block. For reference, the winding device 28 can be similar to a conventional film winder (9) 13I294.doc 200906698, such as a film winder available from Bruckner, Inc. of Greenville, South Carolina, and typically includes a film tenter 26 (Fig. 1) A cylinder 50 wound thereon. The cylinder 50 is driven to achieve a winding of the film % and thus has a longitudinal length corresponding to (i.e., slightly greater than) the transverse tenter width of the film 26. In some embodiments, for example, film 26 can have a width of at least 4 meters, and in some embodiments a width greater than 6 meters, and in still other embodiments a width greater than 10 meters; Thus, the cylinder 50 has a corresponding longitudinal length. Further, the winding device 28 can include an additional set (not, ,,) and can be configured to fit a core (not shown) to the cylinder 50 and The film 26 is wound thereon. Regardless of the specific configuration of the s-winding device 28, the film spacers 3A of Fig. 2A each include a bundle 60 that is supplied by a bundle of source 62. The bundle 60 extends from the bundle source 62 and is acted upon by a force device 64 and a rail assembly 66, as described below. The tensioning device 64 and the rail assembly 66 achieve the desired tension and position of the strap 60 when the bundle 6 is fed to the winding device 28 (and in particular the cylinder 50). In summary, the bundle 6 and the film 26 (which are simultaneously wound on the cylinder and used to minimize the occurrence of random winding induced flaws in the resulting wound coil (not shown). Available in various forms and separately from the film (Figure 〇 provided. The bundle 60 can be a monofilament or multifilament material (for example, a multifilament yarn, such as a skein of Nailong yarn, which can be used in the trade name 1 7: S捻: Nailong 6 from North Carolina, Texfi Industries of Raleigh, Latvia, was able to identify only one acceptable type of material. The bundle 60 was selected to be compatible with the film 26 (eg, when placed) When the contact with the thin crucible 26 is in close contact with the thin crucible 26, the quality of the film 26 is not deteriorated, and 131294.doc -13·200906698' has a diameter which is relatively small compared to the thickness of one of the crucibles 26 or a main dimension. The diameter of the bundle 60 & the main dimension is less than the thickness of the film is less than the thickness of the film; and more preferably less than 1% of the thickness of the film. In other embodiments, the bundle 6 is relatively small in diameter or The main ruler is no more than 50 denier; in other embodiments no more than ~ in other embodiments no more than 5 denier According to this configuration -, the bundle: will directly contact the only one small lateral section of the wound film, and achieve the desired spacing between the wound layers, as described below. The tensioning device 64 is provided as needed A portion of the spacer assembly 3() is adapted to form a level of tension in the bundle as the bundle 60 extends from the source 62 to the rail assembly 66. More specifically, when continuously pulled from the rail assembly The bundle 60 is (eg, 'when the bundle 6 () is continuously wound on the cylinder %), the tensioning device 64 maintains a small amount of tension in the bundle 6 之间 between the guide device and the source 62 to prevent The sliver 6 is formed to be slack. Thus, the tensioning device 64 can take a variety of forms suitable for the particular configuration of the strap 60. For example, the tensioning device μ can include or require a body that follows the self-railing device 66 And therefore, a small weight or a bar amount is applied to the bundle 6 from the continuous pulling (via the winding device 28) bundle 6G. As a reference point by the tension device to form or to apply the tension only needs to be sufficient Avoid slack in the bundle 6〇, not careless, originally The manner in which the bundle 60 is broken or worn exceeds the stretched length of the bundle 6〇. In still other embodiments, the tensioning device 64 may not be required. The guide rail or rail split 66 may also take a variety of forms, and typically Constructed to position the bundle 60 relative to the cylinder 5 at a desired lateral position for winding with the film 26 (Fig. 1) after 131294.doc -14-200906698. For example, 2B, the rail assembly 66 can include an arm 68 that terminates in an eyelet or other opening 70 that passes through the bundle 6 and through. In other embodiments, the guide 66 is further configured to achieve The bundle 6 is moved laterally or to the left and right with respect to the cylinder 5 (and thus relative to the film 26 when the film 26/strip 60 is simultaneously wound). For example, a base 72 of the arm 68 is slidably fitted within a slot 74 of a frame 76 and is further driven or moved within the slot 74 by an electrically coupled connection 78 (generally referred to). According to the group of bears, the motorized connection 78 is operable to reorient the arm 68 in a lateral or lateral manner relative to the cylinder 5, and thus the bundle 6〇 therethrough. Alternatively, various other configurations that enable lateral movement of the bundle 60 may also include shaking, swaying, or otherwise changing the lateral position of the bundle. As described below, the pilot device 66 can operate in a vibrating manner such that at a relatively slow vibration rate (eg, about 0.5-2.0 cycles per minute) at a small distance (eg, no more than * inches; Or no more than 3 inches; or no more than 2 inches) to move laterally or change the position of the bundle 60. The arrangement of the winding device 28 and the thin spacer 3 can be explained with reference to Figs. 3 and 3B. In particular, the figure shows a cylinder 5 that is originally provided as part of the winding device 28 (circle 1), together with a film spacer 3 (including a reference) including a bundle 60 therethrough. . Further, the film tenter 26 is also shown in a state before being wound on the cylinder 5 (for convenience of explanation, the width of the film 26 is enlarged in the view of Fig. 3A, and the diameter of the cylinder 5 is reduced). In view of these conventions, the film spacer 30 is generally spatially aligned with the cylinder 5 (and thus the film 26) so that when the film 26 and the bundle 60 are close to the circle 131294.doc -15-200906698 the cartridge 50 (eg, in an original relative to When the winding interface of the cylinder 5 is established, the bundle 60 will receive one of the major surfaces 9 of the film 26. Although the arrangement of FIG. 3 reflects that the bundle 60 is in contact with one of the "lower" surfaces of the film, the film spacer 30/strip 60 can also be positioned to oppose one of the thin cymbals 26 "upper" Surface 92 interface. As shown in Figure 3B, the bundle 6〇 is guided to the lateral or lateral position between the opposite edges %, 96 of the film (should be understood, in the top view of the figure, the bundle 60 is located at or behind the tweezers 26" in order to generally reflect or indicate that a point p at which the bundle 60 will initially contact the film 26 pulls the film 26 and the bundle 6G on the same day 7 according to this direction. Or guiding to the cylinder 5 〇 for subsequent winding to ensure contact between the bundles 6 在一 at a point along the width of one of the membranes 26. According to the configuration of Figure 3B, the single bundle 60 is shown as The lateral width w relative to the film 26 (i.e., the transverse tenter width of the film %) is substantially centered. However, in another option, the bundle 60 can be positioned at any lateral position relative to the width of the film 26. Contact thin (4). For example, the bundle 60 can be configured to be at one of the opposing edges 94 or 96 Close to the film 26 interfaced. In still other embodiments, the film spacer bound ⑻ River) (iv) may comprise a plurality of sub-beams of the domain bits. Such an arrangement is shown in FIG. 3C as being unintentionally shown to include bundles 60a-60d° _ bundles 6〇a
同時捲繞於圓筒5。上時在第一邊㈣處或附J =6,而第二束條_經設置以在第二邊緣96處或 附妾觸溥膜26。針對其中薄膜26具有-相對大知 幅寬度W(例如，…丄… ㈣大的榼向拉 ⑴如：大於4米)之應用’可提供一個或多個附加 ' '歹如所不之束條6〇(；及60d。概括地說，束條60a· 131294.doc -16- 200906698 60d彼此分立隔開，其中第三及第四束條6〇c、更靠近 薄膜26之縱向中心線橫向定位。在其他實施例中，可提 供五個或更多個束條6〇，其中每一個束條6〇同樣相對於薄 臈26之寬度倾此分立隔開。不管具體數量如何，用於相 對於圓筒50引導或設置對應束條6()之設備在某些實施例中 適於實現該（該等）束條60相對於拉幅26之某一局部側向移 動(例如’圖3C中之束條6〇a_6〇d中之每一者皆貫穿一在側 向上可用言語表達之導軌裝置，例如圖⑼之導轨裝置 66)。 同時將束條60及薄臈26捲繞於圓筒5〇上可參照圖4A_4C 來加以說明。為清晰起見，在該視圖中放大薄膜％之厚 度’而縮減圓筒50之直徑。#於此，同時捲繞薄膜26及束 條60始於圖4A處（應注意，儘管僅顯示一個束條⑽，然而 亦可採用兩個或兩個以上分立定位之束條6〇，如先前所 述）。特定而言，將薄膜26之一前端96連同束條6〇之一前 端100朝圓筒50方向拉動。就此而言，可手動將薄膜26及， 或束條60中之一者或兩者朝圓筒5〇方向引導，或者可採用 機械裝置（未顯示），等等。無論如何，將束條6〇(其原本最 =遠離薄膜26提供）緊固至薄膜26之表面9〇以使束條的之 月il鳊1 00毗鄰溥膜26之前端98。舉例而言，可使用膠帶膠 帶（例如，一壓敏黏結帶束條）、黏結劑等來將前端處之 束條60耦合至薄臈26之前端98。最初將束條6〇黏結至薄膜 26之另一實例利用束條60及薄膜26之一自然吸引力（例如 黏生或靜力），S玄自然吸引力至少部分地取決於對束條及 131294.doc 200906698 薄膜之㈣及製程之選擇。另—選擇係、，可例如藉由首先 開始將薄膜26捲繞於圓筒5〇上並隨後將束條㈣合至表面 9〇來將束條6〇之前端1〇〇與薄旗26之前端％隔開（相對於薄 膜26之縱向長度），如所示。在這兩種情況下將薄膜 束條60朝圓筒50方向導引並開始同時捲繞薄膜W束條 60 ° 在圖4B之視圖+，薄膜26/束條6〇部分地捲繞在圓筒5〇 上。作為一參考點，儘管該等圖式反映薄膜26/束條⑼被 置放成與圓筒5G之-表面直接接觸，’然而，在其他實施例 中’-管狀核芯被置放於圓筒5〇上方，其中薄膜26/束條 60被置放成與該核怒接觸，且因此捲繞在該核芯上。無論 如何，圖4B圖解闡釋理論上由相對與薄膜26/束條 60界定之捲繞介面I。如本說明書通篇使用，捲繞介面1界 定為在此開始將薄膜26捲繞於圓筒5〇上之點，且因此亦視 為圓筒50之"入口”。鑒於此等慣例’則圖仙反向相對於捲 繞介面I，薄膜26由捲繞介面丨下游之一捲繞段11〇與捲繞介 面I上游之一退繞段112界定。在圓筒5〇連續旋轉（例如，相 對於圖4A-4C之視圖順時針方向）時，薄膜％及束條6〇隨著 薄膜26之捲繞段110在縱向長度上連續增大而連續及同時 捲繞在圓筒50上。 如圖4C中所示，薄膜26/束條60連續捲繞在圓筒5〇上從 而界定一捲繞捲114。就此而言，薄膜26繼續界定捲繞及 退繞段110、112，其中薄膜26之捲繞段110具有多個捲繞 層或纏繞116(通常所參考）。為清晰起見，在圖4C中以剖 131294.doc 18 200906698 面線來顯示薄膜26以更好地辨別捲繞層1丨6中之每一者， 但應瞭解，捲繞層11 6係薄膜2 6之一奇異延伸部之—分 部。特定而言，作為捲繞捲11 4形式之一部分，薄膜26包 括一最外部捲繞層116a、一直接下伏捲繞層丨丨补及附加依 序内部捲繞層11 6c、1 16d。就此而言，退繞段112在捲繞 介面I處過渡為最外部捲繞層116a，且直接下伏捲繞層116 界定為相對於最外部捲繞層116a之下一次連續捲繞。因 此’附加捲繞層116(如捲繞層116c、li6d)界定為薄膜26相 對於直接下伏捲繞層116b之連續回轉。圖4(：進一步圖解闡 釋在同時捲繞薄膜26/束條60時，束條60連續插置於薄膜 2 6之捲繞層116中之連續®比鄰者之間。因此，舉例而言， 束條60連續延伸於薄膜之最外部與直接下伏捲繞層丨丨&、 116b之間。作為一參考點，束條6〇在圖4(：中顯示為不與捲 繞介面I上游之薄膜26接觸或原本擺脫捲繞介面1上游之薄 膜26。此指示一種其中束條6〇僅需在開始該捲繞變作之前 實體附接至薄膜2 6之技術（亦即，如上文參照圖4 a所述）。 當薄膜26/束條60同時繚繞於圓筒50上時，一由捲繞薄膜 26建立之徑向壓縮力阻止束條6〇側向移動（亦即，進入或 退出圖4C之平面）。然而，在捲繞介面j上游，束條6〇可相 對於薄膜26(且因此相對於圓筒）側向操縱，如下文所述。 當連續捲繞薄膜26/束條60時，束條6〇在薄膜之至少該 最外。卩與直接下伏捲繞層1丨6a、〖丨之間建立一微小間 隙。此關係進一步圖解闡釋於圖5中，藉助此關係第一及 第二束條60a、60b分立定位且連續延伸於薄膜之捲繞層 131294.doc -19- 200906698 116(通常所參考）中之毗鄰捲繞層之間。相對於薄膜之最外 部與直接下伏捲繞層116a、116b，束條6〇a、60b個別地或 共同地界定一個或多個間隙12〇(通常所參考），其中該（該 等）間隙120最普遍位於捲繞介面I處（如圖4C,中最為顯見）。 特定而言，當薄膜60連續捲繞在圓筒50上時，最外部捲繞 層116a中所固有之張力將最外部捲繞層116a壓縮抵靠在直 接下伏捲繞層116b上。然而’至少在捲繞介面I處，束條 60a、60b有效地隔開最外部與直接下伏捲繞層i 16&、 116b(經由該（該等）間隙120)。此又使最外部捲繞層丨丨以獲 得一相對於直接下伏捲繞層116b之自由度從而使最外部捲 繞層116a能夠相對於直接下伏捲繞層U6b鬆弛（或者移 動），從而釋放或克服任何原本可能因圓筒5〇(或捲繞裝置 28(圖1)之其他組件）所固有之容限偏差而引起之自然誘發 應力。因此，捲繞誘發瑕疵之出現顯著減少，甚至消除。 如圖5中所示，在薄膜116之毗鄰捲繞層之間的該（該等）間 隙1 2 0隨著薄膜2 6之多次捲繞而減小且最終消除（例如，相 對於薄膜之捲繞層116c、116d ’該（該等）間隙12〇因捲繞捲 114所固有之徑向壓縮力而不復存在 圖5進一步反映在某些實施例中，束條6〇a、6〇b之—側 向位置（亦即，相對於薄膜26之邊緣94、96且因此相對於 圓筒50)隨著每一次連續捲繞而略微變化。就此而言，且 如先前所述，在某些實施例中，薄膜間隔器3〇(圖2八及2” 經組態以在捲繞於圓筒5 0上之前於一點處賦予對應束條 60a、60b —侧向移動。舉例而言，且參見圖6A，束條 131294.doc -20- 200906698 6〇a、60b顯示相對於薄膜26，且特定而言其退繞段112及 敢外。卩捲繞層116 a。在捲繞介面I (通常所參考）上游之一點 P處’束條60a、6〇b可相對薄膜26之對應邊緣94、96自由 地側向移動。一旦開始將薄膜26/束條捲繞於圓 筒5〇上（亦即，在捲繞介面I處），則基本固定束條60a、00b 相對於捲繞薄膜段11 0之側向位置。 在某些實施例中，為了避免在捲繞捲丨丨4(圖4C)中形成 原本可能因要與連續捲繞連續對準之束條6〇a、6〇b而引起 之明顯突出部，束條6〇a、6〇b在捲繞介面丨上游之點p處沿 一側向方向（由圖6A中之箭頭表示）移動。同樣，此側向移 動界定相對於薄膜26之寬度W或橫向方向。根據其中束條 、60b具有小直徑之實施例中，一與束條6〇&、6此相關 聯之行進距離或週期D可相對較小，不超過6英吋；或者不 超過4英尺，或者在丨_3英吋這範圍内；或者在ι·5 英吋 範圍内相對於薄膜26之橫向拉幅寬度w，側向行進距離 D亦可拖述為不超過該橫向拉幅寬度之百分之十；或者不 超過百分之五；或者不超過百分之三。在某些實施例中， 束條60a、60b之側向移動係在振盪基礎上執行，其中該振 盪頻率不超過5個循環每分鐘；或者不超過3個循環每分 釦，或者在0.5-2個循環/分鐘之範圍内。其他振盪週期及/ 或頻率亦可接受，且該（該等）束條60a、及/或60b可以不振 盪（例如，不均勻）方式側向移動。如由圖6 A中之虛線所 不，側束條60a、60b相對於薄膜26之對應邊緣94、96之路 仅由一變化之側向分量表徵。圖6B進一步圖解闡釋此關 131294.doc 21 200906698 係，藉此薄膜26顯示為自圓筒5〇退繞且束條6〇a、6〇b具有 一沿薄膜26之一縱向長度側向變化之路徑。 作為一參考點，已發現可藉由在捲繞期間控制振盪該 (該等）束條60之距離或寬度（例如，行進距離D)來在捲繞期 間控制薄膜之連續層之間的有效間隔或間隙（因該（該等）束 條60之存在而引起之）。就此而言，可以兩種方式中之至 少-種方式來控制振i距離或寬度。首先，可控制機械振 盪裝置之實際行進距離。另一選擇係，可控制振盪速度。 為此目的，已發現可藉由增大振盪速度來使束條佈置（相 對於薄膜26)之距離或寬度變窄，並可藉由減小振盪速度 來使其變寬。 圖7圖解闡釋由上述系統及方法所產生之捲繞捲ιΐ4之一 個實施。捲繞捲丨14係由兩個分別具有周向凸出部13以原 本因對應束條60a、60b(圖5)之存在而產生）之帶狀區 130a、13Ob及至少一個基本上沒有周向凸出部或任何捲繞 誘發瑕疵之非帶狀或有效區134表徵。應瞭解，當採用僅 一個束條60時，將產生僅一個帶狀區13〇&或l3〇b ;相反 地，當採用許多個束條60時，將產生一對應數量之帶狀區 130a、130b。無論如何，該（該等）有效區134代表一具有最 少捲繞誘發瑕疵之薄膜26之捲繞捲。接著，可將捲繞捲 114提供至一使用者，該使用者隨後利用來自有效區之 薄臈26。另一選擇係，可使捲繞捲U4經受其中移動該（該 等）帶狀區130a、130b(且特定而言，與其相關聯之該（該 等）束條60)之進一步處理。 131294.doc -22- 200906698 本申請案之聚合薄膜捲繞及製造方法及系統提供一相對 於用於產生一具有最少或沒有捲繞誘發瑕疵之薄膜之捲繞 捲之習用技術之顯著改進。薄膜之最外部與直接下伏捲繞 層之間的所期望之間隔由一單獨提供之束條形成，而此方 法代表一代替滾花之低成本。此尤其有利於某些原本不適 δ於滾花或採用原本可能改進捲繞屬性之樹脂添加劑之薄 膜（例如，諸如光學等級聚丙烯薄膜之低模數薄光學等級 薄膜）。 可藉助附加組件或步驟來增強本文所述之捲繞系統及方 法。在某些實施例中，一個（多個）包裝或接觸捲與捲繞薄 膜（低及咼模數薄膜兩者）結合使用。作為一參考點，使用 該（該等）包裝或接觸捲通常稱作接觸捲動，且使捲繞能夠 藉助極低捲繞心軸張力或扭矩進行，此乃因該（該等）捲有 助於迫使過剩空氣從連續捲繞層之間退出。此又可增強捲 繞捲中層-層穩定性。 儘管本文已參照較佳實施例對本發明予以闡述，但熟習 此項技術者可認識到，可在形式及具體細節上作出改變， 此並不背離本發明之主旨及範疇。 【圖式簡單說明】 包括附圖以幫助說明本發明。附圖中之元件未必相互成 比例。相同之參考編號標示相同之零件。 圖1係一用於捲繞一提供為一聚合薄臈生產線之一部分 之聚合薄膜之系統之方塊圖； 圖2Α係一適用於圖i之捲繞系統之薄臈間隔器之方塊 131294.doc -23· 200906698 圖； 圖2B係圖2A之薄膜間隔器之一示意圖； 圖3A係圖1及2A之捲繞系統之部分結合一聚合薄膜拉幅 之一示意性側視圖； 圖3B係圖3A之佈置之一示意性俯視圖； ' 圖3C係另一捲繞系統佈置結合一聚合薄膜拉幅之一示意 •性俯視圖； 圖4A-4C示意性地圖解闡釋同時捲繞一聚合薄膜及一束 ’條； 圖5係在一捲繞作業期間聚合薄膜及束條之一簡化剖視 圖； 圖6A係在捲繞期間聚合薄膜及束條之一示意性俯視圖； 圖6B示意性圖解闡釋處於退繞狀態下之圖6A之薄膜及 束條；及 圖7係一在由圖1之系統處理之後捲繞捲之側視圖。 【主要元件符號說明】 I 捲繞介面 D 行進距離或週期 P 點 W 寬度 20 捲繞系統 22 聚合薄膜製造生產線 24 聚合薄膜供應裝置 26 薄膜 131294.doc -24- 200906698 28 捲繞裝置 30 薄膜間隔器 40 樹脂處理/儲存站 42 擠出機 44 壓模/鑄造站 46 拉幅機 48 出口 50 圓筒 60a 束條 60 束條 60b 束條 60c 束條 60d 束條 62 束條源 64 張力裝置 66 導軌裝置 68 臂 70 開口 72 基座 74 狹槽 76 框架 78 電動連接 90 主表面（”下部”表 92 對置''上部”表面 131294.doc •25- 200906698 94 第一邊緣 96 第二邊緣 98 前端 100 前端 110 捲繞段 112 退繞段 114 捲繞捲 116a 最外部捲繞層 116b 直接下伏捲繞層 116c 内部捲繞層 116d 内部捲繞層 116 捲繞層 120 間隙 130a 帶狀區 130b 帶狀區 132 周向凸出部 134 非黏接或有效區 131294.doc -26-It is wound around the cylinder 5 at the same time. The upper side is at the first side (four) or attached with J = 6, and the second strip _ is arranged to be at the second edge 96 or attached to the haptic film 26. For applications in which the film 26 has a relatively large width W (for example, ... 丄 ... (4) large 拉 pull (1) such as: greater than 4 meters) 'may provide one or more additional ' ' 6〇(; and 60d. In summary, the bundles 60a·131294.doc-16-200906698 60d are spaced apart from each other, wherein the third and fourth bundles 6〇c are positioned closer to the longitudinal centerline of the film 26 In other embodiments, five or more bundles 6〇 may be provided, each of which is also spaced apart from the width of the thin web 26. Regardless of the specific number, The apparatus for guiding or arranging the corresponding bundle 6() of the cylinder 50 is suitable in some embodiments to effect some partial lateral movement of the bundle 60 relative to the tenter 26 (eg, 'Fig. 3C) Each of the bundles 6〇a_6〇d extends through a rail device that can be expressed in the lateral direction, such as the rail device 66 of Fig. 9). At the same time, the bundle 60 and the thin bundle 26 are wound around the cylinder 5. The crucible can be described with reference to Figures 4A-4C. For the sake of clarity, the thickness of the film % is enlarged in this view and the circle is reduced. The diameter of the cartridge 50. Here, the winding of the film 26 and the bundle 60 at the same time begins at Figure 4A (it should be noted that although only one bundle (10) is shown, two or more separately positioned bundles may be used. 6〇, as previously described. In particular, one of the front ends 96 of the film 26 is pulled along with the front end 100 of one of the bundles 6〇 toward the cylinder 50. In this regard, the film 26 and/or the bundle can be manually removed. One or both of 60 are directed toward the cylinder 5 ,, or a mechanical device (not shown) can be used, etc. In any event, the bundle 6 〇 (which is originally provided at most = away from the film 26) is fastened to The surface of the film 26 is 9 〇 so that the month il鳊1 00 of the bundle is adjacent to the front end 98 of the ruthenium film 26. For example, a tape tape (for example, a pressure-sensitive adhesive tape bundle), a binder, or the like can be used. The strap 60 at the front end is coupled to the front end 98 of the cassette 26. Another example of initially bonding the strip 6 to the film 26 utilizes one of the strip 60 and the film 26 to have a natural attraction (e.g., adhesion or static), The natural attraction of S Xu depends, at least in part, on the bundle and the film (131) and process Alternatively, the selection system can be used, for example, by first winding the film 26 onto the cylinder 5 and then joining the bundle (4) to the surface 9〇 to tie the front end of the bundle 6 to the thin flag. The front end of the 26 is spaced apart (relative to the longitudinal length of the film 26) as shown. In both cases, the film bundle 60 is guided toward the cylinder 50 and begins to wind the film W bundle 60° simultaneously. 4B, the film 26/strip 6〇 is partially wound on the cylinder 5〇. As a reference point, although the patterns reflect that the film 26/strip (9) is placed with the cylinder 5G - the surface is in direct contact, 'however, in other embodiments the '-tubular core is placed over the cylinder 5〇, wherein the film 26/strip 60 is placed in contact with the nuclear anger, and thus wound around On the core. In any event, Figure 4B illustrates the theoretical winding interface I defined by the opposing film 26/strip 60. As used throughout this specification, the winding interface 1 is defined as the point at which the film 26 is initially wound onto the cylinder 5, and is therefore also considered to be the "entry" of the cylinder 50. In view of these conventions, The film is oppositely opposed to the winding interface I, and the film 26 is defined by one of the winding sections 11 丨 downstream of the winding interface 〇 and one of the unwinding sections 112 upstream of the winding interface I. The cylinder 5 〇 continuously rotates (for example, With respect to the clockwise direction of the views of Figures 4A-4C, the film % and the bundle 6 连续 are continuously and simultaneously wound on the cylinder 50 as the winding section 110 of the film 26 continuously increases in the longitudinal length. As shown in Figure 4C, film 26/strip 60 is continuously wound onto cylinder 5 to define a winding roll 114. In this regard, film 26 continues to define winding and unwinding sections 110, 112, wherein film 26 The winding section 110 has a plurality of wound layers or windings 116 (generally referenced). For clarity, the film 26 is shown in section line 131294.doc 18 200906698 in Figure 4C to better distinguish the wound layer. Each of 1丨6, but it should be understood that the wound layer 116 is a sub-portion of one of the singular extensions of the film 26. As part of the form of the wound roll 114, the film 26 includes an outermost wound layer 116a, a direct underlying wound layer ridge and an additional sequential inner wound layer 11 6c, 1 16d. The unwinding section 112 transitions to the outermost wound layer 116a at the winding interface I, and the direct underlying wound layer 116 is defined as one continuous winding below the outermost wound layer 116a. Thus 'additional winding layer 116 (e.g., wound layers 116c, li6d) is defined as a continuous revolution of film 26 relative to direct underlying wound layer 116b. Figure 4 (: further illustrates that when strip 26/beam 60 is simultaneously wound, bundle 60 is continuous Inserted between successive® neighbors in the wound layer 116 of the film 26. Thus, for example, the bundle 60 extends continuously over the outermost portion of the film and directly underlying the wound layer 丨丨 & As a reference point, the bundle 6 is shown in Figure 4 (not shown as being in contact with the film 26 upstream of the winding interface I or otherwise detached from the film 26 upstream of the winding interface 1. This indicates a bundle 6 其中It is only necessary to physically attach the film to the film 26 before starting the winding change (ie, as above) Referring to Figure 4a). When the film 26/strip 60 is simultaneously wound around the cylinder 50, a radial compressive force established by the wound film 26 prevents the bundle 6 from moving laterally (i.e., into or Exiting the plane of Figure 4C. However, upstream of the winding interface j, the bundle 6〇 can be manipulated laterally relative to the film 26 (and therefore relative to the cylinder), as described below. When continuously winding the film 26/bundle At 60 o'clock, the bundle 6 is at least the outermost portion of the film. A slight gap is established between the crucible and the directly underlying wound layer 1丨6a, 丨. This relationship is further illustrated in Fig. 5, by means of this relationship. The first and second bundles 60a, 60b are positioned separately and extend continuously between adjacent wound layers in the wound layer 131294.doc -19-200906698 116 (generally referenced) of the film. The bundles 6〇a, 60b individually or collectively define one or more gaps 12〇 (generally referenced) with respect to the outermost and direct underlying wound layers 116a, 116b of the film, wherein the (the) gaps 120 is most commonly located at the winding interface I (as best seen in Figure 4C). In particular, when the film 60 is continuously wound on the cylinder 50, the tension inherent in the outermost wound layer 116a compresses the outermost wound layer 116a against the direct underlying wound layer 116b. However, at least at the winding interface I, the bundles 60a, 60b effectively separate the outermost and direct underlying winding layers i 16 & 116b (via the gap 120). This in turn causes the outermost wound layer to obtain a degree of freedom with respect to the direct underlying wound layer 116b such that the outermost wound layer 116a can relax (or move) relative to the direct underlying wound layer U6b, thereby Naturally induced stresses that would otherwise be caused by the tolerances inherent in the cylinder 5 (or other components of the winding device 28 (Fig. 1)) are released or overcome. Therefore, the occurrence of winding-induced enthalpy is significantly reduced or even eliminated. As shown in FIG. 5, the (the) gap 1 20 between the adjacent wound layers of the film 116 decreases and eventually disappears as the film 26 is wound multiple times (eg, relative to the film). The wound layers 116c, 116d 'the gaps 12 而不 are no longer present due to the radial compressive forces inherent to the coils 114. Figure 5 is further reflected in some embodiments, the bundles 6〇a, 6〇 The lateral position of b (i.e., relative to the edges 94, 96 of the film 26 and thus relative to the cylinder 50) varies slightly with each successive winding. In this regard, and as previously described, at some In some embodiments, the film spacers 3 (Figs. 2 and 2) are configured to impart lateral movement to the corresponding bundles 60a, 60b at a point prior to being wound on the cylinder 50. For example, Referring to Fig. 6A, the bundle 131294.doc -20-200906698 6〇a, 60b is shown with respect to the film 26, and in particular its unwinding section 112 and dare. The winding layer 116a is in the winding interface I. (usually referenced) at one of the upstream points P, the bundles 60a, 6〇b are free to move laterally relative to the corresponding edges 94, 96 of the membrane 26. Once started, the strips will be thin. The 26/bundle is wound on the cylinder 5 (i.e., at the winding interface I) to substantially fix the lateral position of the bundle 60a, 00b relative to the wound film segment 110. In certain embodiments In order to avoid the formation of a prominent protrusion in the winding reel 4 (Fig. 4C) which may be caused by the continuous alignment of the bundles 6〇a, 6〇b with the continuous winding, the bundle 6〇a 6〇b moves in a side direction (indicated by the arrow in Fig. 6A) at a point p upstream of the winding interface 。. Again, this lateral movement defines a width W or a transverse direction with respect to the film 26. In embodiments where the straps 60b have a small diameter, the travel distance or period D associated with the bundles 6〇&, 6 may be relatively small, no more than 6 inches; or no more than 4 feet, or Within the range of 丨3 inches; or within the range of ι·5 inches relative to the transverse tenter width w of the film 26, the lateral travel distance D can also be described as not exceeding the width of the transverse tenter width Ten; or no more than five percent; or no more than three percent. In some embodiments, the lateral movement of the bundles 60a, 60b Performed on an oscillating basis, where the oscillating frequency does not exceed 5 cycles per minute; or no more than 3 cycles per decibel, or within 0.5-2 cycles/min. Other oscillation periods and/or frequencies may also Accepted, and the (s) bundles 60a, and/or 60b may move laterally without oscillation (e.g., uneven). As indicated by the dashed lines in Figure 6A, the side bundles 60a, 60b are opposed to the film. The path of the corresponding edges 94, 96 of 26 is characterized only by a varying lateral component. Figure 6B further illustrates this closure 131294.doc 21 200906698, whereby the film 26 is shown as unwinding from the cylinder 5 and the bundle 6 〇a, 6〇b have a path that varies laterally along one of the longitudinal lengths of the film 26. As a point of reference, it has been found that the effective spacing between successive layers of the film can be controlled during winding by controlling the distance or width (e.g., travel distance D) of the bundle 60 during winding. Or gap (caused by the presence of the bundle 60). In this regard, the vibration distance or width can be controlled in at least one of two ways. First, the actual travel distance of the mechanical oscillating device can be controlled. Another option is to control the oscillation speed. For this purpose, it has been found that the distance or width of the bundle arrangement (relative to the film 26) can be narrowed by increasing the oscillation speed and can be made wider by reducing the oscillation speed. Figure 7 illustrates one implementation of a wound roll ΐ4 produced by the above system and method. The winding reel 14 is composed of two strip-shaped regions 130a, 13Ob each having a circumferential projection 13 respectively due to the presence of corresponding bundles 60a, 60b (Fig. 5) and at least one substantially no circumferential direction. The embossment or any non-ribbon or active area 134 of the winding induced enthalpy is characterized. It will be appreciated that when only one bundle 60 is employed, only one ribbon region 13 〇 & or l3 〇 b will be produced; conversely, when a plurality of bundles 60 are employed, a corresponding number of ribbon regions 130a will be produced. , 130b. In any event, the (s) effective area 134 represents a wound roll of film 26 having a minimum of winding induced enthalpy. Next, the winding roll 114 can be provided to a user who then utilizes the thin raft 26 from the active area. Alternatively, the wound roll U4 can be subjected to further processing in which the strips 130a, 130b (and in particular, the bundles 60 associated therewith) are moved. 131294.doc -22- 200906698 The polymeric film winding and manufacturing process and system of the present application provides a significant improvement over conventional techniques for producing a wound roll having a film with minimal or no winding induced enthalpy. The desired spacing between the outermost portion of the film and the directly underlying wound layer is formed by a separately provided bundle of strips, and this method represents a low cost alternative to knurling. This is particularly advantageous for certain films which are not suitable for knurling or for the use of resin additives which may otherwise improve the winding properties (e.g., low modulus thin optical grade films such as optical grade polypropylene films). The winding system and method described herein can be enhanced with additional components or steps. In some embodiments, one or more packages or contact rolls are used in combination with a wound film (both low and 咼 modulus films). As a point of reference, the use of such packages or contact rolls is commonly referred to as contact rolling, and the winding can be performed with very low winding mandrel tension or torque, as this (volume) helps To force excess air to exit from the continuous winding layer. This in turn enhances layer-to-layer stability in the wound roll. Although the present invention has been described herein with reference to the preferred embodiments thereof, it will be understood that BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings are included to illustrate the invention. The elements in the figures are not necessarily to scale. The same reference numbers indicate the same parts. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a block diagram of a system for winding a polymeric film provided as part of a polymeric tantalum production line; Figure 2 is a block suitable for the thin web spacer of the winding system of Figure i 131294.doc - Figure 2B is a schematic view of one of the film spacers of Figure 2A; Figure 3A is a schematic side view of a portion of the winding system of Figures 1 and 2A combined with a polymeric film tenter; Figure 3B is a schematic view of Figure 3A A schematic top view of the arrangement; 'Fig. 3C is a schematic plan view of another winding system arrangement combined with a polymeric film tenter; Figures 4A-4C schematically illustrate the simultaneous winding of a polymeric film and a bundle of 'strips' Figure 5 is a simplified cross-sectional view of one of the polymeric film and the bundle during a winding operation; Figure 6A is a schematic top view of the polymeric film and the bundle during winding; Figure 6B is a schematic illustration of the unwound state The film and bundle of Figure 6A; and Figure 7 is a side view of the wound roll after being processed by the system of Figure 1. [Main component symbol description] I Winding interface D Travel distance or period P point W Width 20 Winding system 22 Polymer film manufacturing line 24 Polymer film supply device 26 Film 131294.doc -24- 200906698 28 Winding device 30 Film spacer 40 Resin treatment/storage station 42 Extruder 44 Die/casting station 46 Tenter 48 Outlet 50 Cylinder 60a Bundle 60 Bundle 60b Bundle 60c Bundle 60d Bundle 62 Bundle source 64 Tension device 66 Rail device 68 Arm 70 Opening 72 Base 74 Slot 76 Frame 78 Electrical connection 90 Main surface ("lower" table 92 Opposite ''upper'' surface 131294.doc •25- 200906698 94 First edge 96 Second edge 98 Front end 100 Front end 110 Winding section 112 Unwinding section 114 Winding roll 116a Outer winding layer 116b Directly underlying winding layer 116c Inner winding layer 116d Inner winding layer 116 Winding layer 120 Clearance 130a Banded zone 130b Banded zone 132 Circumferential projection 134 non-adhesive or effective area 131294.doc -26-