TW202136140A - Touch roller, winder, film roll manufacturing system, and film roll manufacturing method - Google Patents

Abstract

A touch roller 12 provided on a winder 7 that winds up a film F which has a first knurl K1 formed at one end in the width direction TD and a second knurl K2 formed at the other end in the width direction TD, wherein a contact portion 123 that makes contact with a film roll R is disposed between the first knurl K1 and the second knurl K2 in the width direction TD.

Description

Contact roller, coiler, film coil manufacturing system, and film coil manufacturing method

The present invention relates to a contact roller, a coiler, a manufacturing system of a film coil, and a method of manufacturing a film coil.

Conventionally, there has been known a reeling machine provided with a roller (lay-on roller) that is in contact with a film roll (for example, refer to Patent Document 1). Prior art literature Patent literature

Patent Document 1: Japanese Patent Laid-Open No. 2006-193327

The problem to be solved by the invention In the coiler described in Patent Document 1, the contact pressure between the roller and the film roll may be uneven in the film width direction.

If the contact pressure between the roller and the film roll is not uniform in the width direction of the film, it may cause wrinkles and other defects in the film roll.

The present invention provides a contact roller, a winder, a manufacturing system for a film coil, and a method for manufacturing a film coil that can suppress the occurrence of wrinkles and other defects in the film coil.

Means to solve the problem The present invention [1] includes a contact roller, which is provided in a winding machine for winding a film to manufacture a film roll, the film has a first knurl and a second knurl, and the first knurl is formed in On one end of the film in the width direction orthogonal to the direction of travel, the second knurl is formed on the other end of the width direction; and, the contact roller has the same function as the film when the film is wound by the winder. The contact portion of the web contacted, and the contact portion is arranged between the first knurl and the second knurl in the width direction.

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

Thereby, it is possible to prevent the contact roller from excessively pressing the two ends of the film roll.

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

As a result, it is possible to suppress the occurrence of defects such as wrinkles in the film roll.

The present invention [2] includes the contact roller as described in [1] above, which is provided with: a roller body extending in the width direction and a shaft rotatable with the roller body; the roller body has: a first tapered portion, arranged At one end of the roller body in the width direction; a second taper portion is arranged at the other end of the roller body in the width direction; and the contact portion is arranged at the first taper in the width direction Between the portion and the second tapered portion, and extend in the width direction.

According to the above configuration, the first tapered portion is formed at one end portion in the width direction of the roller body. Therefore, the contact pressure on the film roll can be reduced at one end in the width direction of the roller body.

In addition, a second tapered portion is formed at the other end portion in the width direction of the roller body. Therefore, the contact pressure on the film roll can be reduced at the other end in the width direction of the roller body.

In summary, the first taper and the second taper can reduce the contact pressure on the film roll at the two ends of the roller body in the width direction.

Therefore, it is possible to prevent the contact roller from excessively pressing both ends of the film roll, and it is possible to make the contact roller contact the film roll with a more uniform pressing force in the entire width direction.

As a result, it is possible to more suppress the occurrence of defects such as wrinkles in the film roll.

The present invention [3] includes the contact roller as described in [2] above, wherein the shaft is arranged in the center of the roller body in the diameter direction of the roller body and extends in the width direction; the roller body is in the diameter direction It has a first layer in contact with the film roll and a second layer arranged between the first layer and the shaft; the first layer is composed of a first elastic material, and the second layer is composed of The first elastic material is made of a softer second elastic material.

According to the above configuration, the second elastic material is softer than the first elastic material, and thereby the second layer can be deformed by following the deformation of the first layer.

Therefore, the first layer can be allowed to deform in response to the surface of the film roll when the contact roller is in contact with the film roll.

Thereby, the contact roller can be brought into contact with the film roll with a uniform pressing force in the entire width direction.

As a result, it is possible to more suppress the occurrence of defects such as wrinkles in the film roll.

The present invention [4] includes a winding machine including: a winding part for winding the film to manufacture the film roll; and the contact roller according to any one of [1] to [3] above.

According to the above configuration, since the contact roller is provided, it is possible to suppress the occurrence of defects such as wrinkles in the film roll.

The present invention [5] includes a manufacturing system of a film roll material, comprising: a knurl forming machine for forming the first knurl and the second knurl on the film; and the winding machine as described in [4] above.

According to the above-mentioned configuration, since the winding machine described above is provided, it is possible to suppress the occurrence of defects such as wrinkles in the film roll.

The present invention [6] includes a method for manufacturing a film roll material, which includes the steps of: forming the first knurl and the second knurl on the film: and winding up as described in [4] above The winding step of the machine winding the aforementioned film.

According to the method, since the film is wound by the above-mentioned winding machine, it is possible to suppress the occurrence of defects such as wrinkles in the film roll.

Invention effect According to the contact roller, the coiler, the film coil manufacturing system, and the film coil manufacturing method of the present invention, it is possible to suppress the occurrence of defects such as wrinkles in the film coil.

1. The manufacturing system of film coils As shown in FIG. 1, the film F includes a substrate S and a film C. The substrate S has a first surface S1 and a second surface S2 in the thickness direction of the substrate S. The film C is arranged on the first surface S1 of the base S. The film C covers the first surface S1 of the base S. The film C may also be an easy-to-bond layer. When the film C is an easy-adhesive layer, the film F is an easy-adhesive film. The easy-to-bond film is, for example, a polarizing plate used in image display devices such as mobile devices, car navigation devices, personal computer screens, and televisions. Specifically, the easy-to-bond film is used as a protective film for protecting the polarizer of the polarizer. The easy-to-bond film is bonded to the polarizer through the adhesive layer. The easy-adhesive film is attached to the polarizer by the easy-adhesive layer.

As shown in FIG. 2, the manufacturing system 1 of the film roll R includes: an extrusion machine 2, a first stretching machine 4A, a coating machine 3, a second stretching machine 4B, a slit processing machine 5, and a knurling machine. Processing machine 6 and coiling machine 7.

(1) Extrusion forming machine The extrusion molding machine 2 is used to extrude the substrate S (extrusion forming step). The substrate S extruded from the extrusion molding machine 2 has a sheet shape.

The base material S is made of thermoplastic resin. Thermoplastic resins include, for example, acrylic resins, polyolefin resins, cyclic polyolefin resins, polyester resins, polycarbonate resins, polystyrene resins, polyamide resins, polyimide resins, and acetate resins (diacetic acid resins). Cellulose, cellulose triacetate, etc.) and so on.

When manufacturing an easy-to-bond film used as a protective film for polarizers, the material of the substrate S is preferably acrylic resin.

In addition, when manufacturing an easy-to-bond film used as a protective film for a polarizer, the acrylic resin may also be an acrylic resin having a glutaric anhydride structure or an acrylic resin having a lactone ring structure. Acrylic resins with a glutaric anhydride structure and acrylic resins with a lactone ring structure have high heat resistance, high transparency and high mechanical strength, so they are suitable for manufacturing polarizing plates with high polarization and excellent durability. The acrylic resin having a glutaric anhydride structure is described in Japanese Patent Laid-Open No. 2006-283013, Japanese Patent Laid-Open No. 2006-335902, and Japanese Patent Laid-Open No. 2006-274118. Acrylic resins having a lactone ring structure are described in Japanese Patent Laid-Open No. 2000-230016, Japanese Patent Laid-Open No. 2001-151814, Japanese Patent Laid-Open No. 2002-120326, Japanese Patent Laid-Open No. 2002-254544, In Japanese Patent Laid-Open No. 2005-146084.

In addition, the base material S may contain other thermoplastic resins other than acrylic resins in addition to acrylic resins. By containing other thermoplastic resins, the birefringence of acrylic resins can be eliminated and an easy-to-bond film with excellent optical isotropy can be obtained. And it can also improve the mechanical strength of the easy-to-bond film.

In addition, the substrate S may also contain additives such as antioxidants, stabilizers, reinforcing materials, ultraviolet absorbers, flame retardants, antistatic agents, colorants, fillers, plasticizers, lubricants, and fillers.

(2) The first extension machine The first stretching machine 4A stretches the substrate S obtained by the extrusion step in the traveling direction MD of the substrate S after heating (first stretching step).

(3) Coating machine The coater 3 coats the coating liquid on the first surface S1 of the substrate S extruded through the extrusion step (coating step). In addition, the first surface S1 of the substrate S may be subjected to surface treatments such as corona treatment and plasma treatment after the extrusion step and before the coating step.

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

When manufacturing the easy-adhesive film, the coating liquid is used to form the easy-adhesive composition of the easy-adhesive layer.

The easy bonding layer contains binder resin and fine particles.

Examples of the binder resin include thermosetting resins such as urethane resins and epoxy resins, and examples include thermoplastic resins such as acrylic resins and polyester resins. When the easy-to-bond film is used as a protective film for polarizers, the binder resin is preferably a thermosetting resin. Multiple binder resins can be used in combination.

Examples of fine particles include oxides such as silica, titania, alumina, and zirconia; examples include carbonates such as calcium carbonate; examples include calcium silicate and aluminum silicate. Silicates such as magnesium silicate; silicate minerals such as talc and kaolin; and phosphates such as calcium phosphate. When the easy-to-bond film is used as a protective film for polarizers, the fine particles are preferably oxides, more preferably silicon oxide. Multiple types of fine particles can be used in combination.

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

The resin component forms the coating film (easy bonding layer) of the above-mentioned binder resin by the extension process mentioned later. When the binder resin is a urethane resin, the resin component includes, for example, an aqueous urethane resin. Examples of the water-based urethane resin include non-reactive water-based urethane resins which are emulsions of urethane resins, and examples include the emulsions of urethane resins with isocyanate groups protected by blocking agents. The reactive water-based urethane resin, etc. When the binder resin is a urethane resin, the coating liquid may contain a urethane curing catalyst (triethylamine, etc.) and an isocyanate monomer.

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

(4) The second extension machine The second stretching machine 4B dries the coating liquid applied in the coating step. Thereby, the coating liquid becomes the above-mentioned film C. In addition, the second stretching machine 4B stretches the substrate S on which the film C is formed in the width direction TD of the substrate S after heating (the second stretching step). The width direction TD is orthogonal to the traveling direction MD. In the second stretching step, the substrate S on which the film C is formed is stretched, and the above-mentioned thin film F can be obtained.

(5) Slit processing machine The cutting machine 5 cuts the film F stretched in the stretching step to a predetermined width (cutting step).

(6) Knurling forming machine The knurl forming machine 6 forms knurls at both ends in the width direction of the film F cut to a predetermined width by the cutting step (knurl forming step). In addition, "knurling" refers to the unevenness formed on both ends of the film F in the width direction. Since both ends of the film F in the width direction are formed with "knurling", when the film F is rolled, a small gap can be formed between the overlapping films F in the diameter direction of the film roll R. Specifically, the knurl forming machine 6 forms the first knurl K1 (refer to FIG. 3) and the second knurl K2 (refer to FIG. 3) on the film F.

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

The first knurl K1 and the second knurl K2 are formed by laser. The first knurl K1 and the second knurl K2 can also be formed by a heated embossing roller.

(7) Coiler As shown in FIG. 1, the winding machine 7 winds up the film F formed with the knurling through the knurling forming step (winding step). By completing the winding step, the film roll R can be obtained. That is, the winding machine 7 winds the film F having the first knurl K1 and the second knurl K2 to manufacture the film roll R.

The type of coiler 7 is not limited. The coiler 7 may be, for example, a turntable coiler or the like.

2. Details of the coiler The winder 7 includes a winder 11 and a contact roller 12.

(1) Coiling section The winding part 11 winds up the film F to produce a film roll R. The winding part 11 holds the winding core W. The winding section 11 rotates the winding core W. The film F will be taken up by the rotating core W.

(2) Contact roller 12 As shown in FIG. 3, the contact roller 12 includes a shaft 12A and a roller body 12B.

(2-1) Shaft The shaft 12A is arranged at the center of the roller body 12B in the diameter direction of the roller body 12B. The shaft 12A extends in the width direction TD. The shaft 12A has a cylindrical shape. The shaft 12A is made of metal. In addition, the shaft 12A may have a cylindrical shape with a through hole penetrating in the width direction TD. In addition, the outer peripheral surface of the shaft 12A may have a polygonal shape.

(2-1) Roller body The roller body 12B can rotate together with the shaft 12A. The roller body 12B is arranged on the outer peripheral surface of the shaft 12A. The roller body 12B covers the shaft 12A. The roller body 12B extends in the width direction TD. The roller body 12B has a cylindrical shape. The diameter of the roller body 12B is larger than the diameter of the shaft 12A.

(2-1-2) The shape of the roller body The roller body 12B has a first tapered portion 121, a second tapered portion 122 and a contact portion 123.

The first taper portion 121 is arranged at one end portion in the width direction TD of the roller body 12B. The first tapered portion 121 is inclined in a direction approaching the shaft 12A as it goes to the width direction TD side. The first tapered portion 121 is inclined in a direction away from the film roll R as it goes to the width direction TD side. In addition, the first tapered portion 121 may not extend to the shaft 12A. The first tapered portion 121 is in a state away from the first knurl K1. The first tapered portion 121 may also face the first knurl K1 in the diameter direction of the roller body 12B. Since the first taper 121 is formed at one end in the width direction TD of the roller body 12B, the contact pressure to the film roll R can be reduced at one end in the width direction TD of the roller body 12B.

The second tapered portion 122 is arranged at the other end portion in the width direction TD of the roller body 12B. The second tapered portion 122 is inclined in a direction approaching the shaft 12A as it goes to the other side in the width direction TD. The second tapered portion 122 is inclined in a direction away from the film roll R as it goes to the other side in the width direction TD. In addition, the second tapered portion 122 may not extend to the shaft 12A. The second tapered portion 122 is in a state away from the second knurl K2. The second tapered portion 122 may also face the second knurl K2 in the diameter direction of the roller body 12B. Since the second taper 122 is formed at the other end of the roller body 12B in the width direction TD, the contact pressure on the film roll R can be reduced at the other end of the roller body 12B in the width direction TD.

The contact portion 123 is arranged between the first tapered portion 121 and the second tapered portion 122 in the width direction TD. The contact portion 123 extends from the first tapered portion 121 to the second tapered portion 122 in the width direction TD. When the winder 7 winds up the film F, the contact portion 123 comes into contact with the film roll R.

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

The angle θ2 between the surface S11 of the contact portion 123 and the surface S13 of the second taper portion 122 is greater than 90°. The angle θ2 is preferably 100° or more. The angle θ2 is preferably the same as the angle θ1. Since the angle θ2 is greater than the above-mentioned lower limit, the contact pressure on the film roll R at the other end in the width direction TD of the roller body 12B can be reduced. In addition, the angle θ2 is less than 180°, preferably 160° or less.

In the state where the contact roller 12 is in contact with the film roll R, the contact portion 123 is arranged between the first knurl K1 and the second knurl K2 in the width direction TD. In the state where the contact roller 12 has been in contact with the film roll R, the contact portion 123 is in a state away from the first knurl K1 and in a state away from the second knurl K2 in the width direction. In other words, the contact roller 12 does not contact the first knurl K1 and the second knurl K2.

Thereby, it is possible to prevent the contact roller 12 from excessively pressing the both ends of the film roll R. Therefore, the contact roller 12 can be brought into contact with the film roll R with a uniform pressing force in the entire width direction. As a result, it is possible to suppress the occurrence of defects such as wrinkles in the film roll material R in the winding step.

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

Therefore, it is possible to suppress the contact roller 12 from excessively pressing both ends of the film roll R, and it is possible to make the contact roller 12 contact the film roll R with a more uniform pressing force in the entire width direction TD.

As a result, it is possible to more suppress the occurrence of defects such as wrinkles in the film roll R.

(2-2-2) The layer structure of the roller body The roller body 12B has a first layer L1 and a second layer L2 in the diameter direction. In other words, the roller body 12B has a plurality of layers in the diameter direction.

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

Examples of the first elastic material include rubber such as acrylonitrile-butadiene rubber (NBR), silicone rubber, fluororubber, chloroprene rubber, urethane rubber (polyurethane elastomer), etc. ; For example: acrylonitrile-butadiene rubber (NBR) sponge, silicone rubber sponge, fluororubber sponge, chloroprene rubber sponge, urethane sponge (polyurethane foam), etc.的foams.

The hardness of the first elastic material is, for example, A60 or more, preferably A70 or more, and for example, A90 or less, preferably A80 or less.

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

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

The second layer L2 is arranged between the first layer L1 and the shaft 12A in the diameter direction. The second layer L2 is in contact with the first layer L1. In this embodiment, the second layer L2 is also in contact with the shaft 12A. The second layer L2 is composed of a second elastic material.

As the second elastic material, for example, the same material as the above-mentioned first elastic material can be mentioned.

The second elastic material is softer than the first elastic material. The second elastic material is softer than the first elastic material, thereby following the deformation of the first layer L1, the second layer L2 can also be deformed. Therefore, it is possible to allow the first layer L1 to deform in response to the surface of the film roll R in a state where the contact roller 12 is in contact with the film roll R. Thereby, the contact roller 12 can be brought into contact with the film roll R with a uniform pressing force in the entire width direction. As a result, it is possible to more suppress the occurrence of defects such as wrinkles in the film roll R.

The hardness of the second elastic material is, for example, A15 or more, preferably A20 degrees or more, and for example, A50 or less, preferably A40 degrees or less.

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

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

4. Modifications (1) The touch scroll wheel 12 may not have the first taper portion 121 and the second taper portion 122.

(2) The use of the coiler 7 is not limited to extrusion. For example, the substrate S may be released from the roll of the substrate S, the released substrate S may be stretched, and then the winding machine 7 may be used for winding.

(3) The method of manufacturing the film roll R may not include the coating step.

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

(5) The manufacturing system 1 of the film F may not include the first stretching machine 4A. The substrate S may be stretched in the traveling direction MD and the width direction TD by the second stretcher 4B after the coating step (simultaneous biaxial stretching). In addition, although the aforementioned invention is provided as an exemplary embodiment of the present invention, it is only an example and should not be interpreted in a limited manner. Those skilled in the art in this technical field know that the modification examples of the present invention are included in the scope of the patent application described below. Industrial availability The contact roller, coiler, film coil manufacturing system, and film coil manufacturing method of the present invention can be used to manufacture film coils composed of films such as easy-to-bond films.

1: Manufacturing system 2: Extrusion forming machine 3: Coating machine 4A: The first extension machine 4B: The second extension machine 5: Cutting machine 6: Knurling forming machine 7: Coiler 11: Coiling section 12: Contact roller 12A: Shaft 12B: Roller body 121: first cone 122: 2nd cone 123: contact part C: envelope F: Film K1: 1st knurling K2: 2nd knurling L1: Layer 1 L2: Layer 2 R: Film coil S: Substrate S1: The first side of the substrate S2: The second side of the substrate S11: The surface of the contact part S12: Surface of the first cone S13: Surface of the second cone t: the thickness of the roller body W: core θ1: The angle between the surface of the contact part and the surface of the first cone θ2: The angle between the surface of the contact part and the surface of the second cone φ1: Outer diameter of contact roller φ2: The diameter of the shaft

Fig. 1 is a cross-sectional view of a film wound by a winder as an embodiment of the present invention. Fig. 2 is a schematic configuration diagram of a film roll manufacturing system as an embodiment of the present invention. Fig. 3 is a cross-sectional view of a contact roller as an embodiment of the present invention.

12: Contact roller

12A: Shaft

12B: Roller body

121: first cone

122: 2nd cone

123: contact part

F: Film

K1: 1st knurling

K2: 2nd knurling

L1: Layer 1

L2: Layer 2

R: Film coil

S11: The surface of the contact part

S12: Surface of the first cone

S13: Surface of the second cone

t: the thickness of the roller body

W: core

θ 1: The angle between the surface of the contact part and the surface of the first cone

θ 2: The angle between the surface of the contact part and the surface of the second cone

φ 1: Outer diameter of contact roller

φ 2: The diameter of the shaft

Claims (6)

A contact roller, which is provided by a winding machine used to wind a film to manufacture a film roll. The film has a first knurl and a second knurl, and the first knurl is formed perpendicular to the direction of travel of the film On one end in the width direction, the second knurl is formed on the other end in the width direction; The characteristics of the contact roller are: It has a contact portion that comes into contact with the film roll when the film is wound by the coiler, and The contact portion is arranged between the first knurl and the second knurl in the width direction. For example, the contact roller of claim 1, which has: Shaft; and A roller body that extends in the aforementioned width direction and can rotate with the aforementioned shaft; The aforementioned roller body has: The first taper is arranged at one end of the roller body in the width direction; The second taper portion is arranged at the other end portion in the width direction of the roller body; and The contact portion is arranged between the first tapered portion and the second tapered portion in the width direction, and extends in the width direction. Such as the contact roller of claim 2, wherein the shaft is arranged in the center of the roller body in the diameter direction of the roller body, and extends in the width direction; The roller body has a first layer in contact with the film roll in the diameter direction, and a second layer disposed between the first layer and the shaft; The aforementioned first layer is composed of a first elastic material, and The second layer is made of a second elastic material that is softer than the first elastic material. A coiling machine characterized by: The winding part for winding the aforementioned film to manufacture the aforementioned film roll; and Such as the contact roller of any one of claims 1 to 3. A manufacturing system for film coils, characterized by having: A knurling machine for forming the first knurl and the second knurl on the film; and Such as the coiling machine of request item 4. A method for manufacturing film coils, characterized by comprising the following steps: The knurling step of forming the first knurl and the second knurl on the film: and The winding step of winding the aforementioned film with the winding machine as in claim 4.

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