TWI696005B - Winding structure and a method for forming the same - Google Patents

Abstract

A winding structure and a method for forming the same are provided. The winding structure includes a winding core, a pad sheet and a pad sheet. The pad sheet winds on the winding core. The pad sheet includes a (N-1)^th winding layer and a N^th winding layer. The Nth winding layer is the most outer winding layer of the pad sheet winding on the (N-1)^th winding layer. The (N-1)^th winding layer has a first outer pad surface. The N^th winding layer has a second outer pad surface. The pad sheet winds on the pad sheet. The pad sheet has an end portion disposed on the first outer pad surface of the pad sheet. The pad sheet winds onto the end portion with crossing a gap smaller than a thickness of the pad sheet from the second outer pad surface of the pad sheet.

Description

Winding structure and its forming method

The present invention relates to a winding structure and a method of forming the same, and particularly to a winding structure and a method of forming the same that reduces the difference in winding height.

In the manufacturing method of the optical film, generally, a large-area sheet is manufactured first, and then the sheet is cut into a sheet with a smaller area as an application. The final step in sheet production is to wind the sheet. The sheet can be stored in a manufacturing plant or shipped in a rolled state until it is taken out for processing. And the processing method can also use the roller to unwind the sheet and continuous transmission for processing. The winding method and winding structure of the sheet will affect the properties of the sheet.

The invention relates to a winding structure and a forming method thereof.

According to one aspect of the present invention, a winding structure is proposed, which includes a core, a substrate sheet, and a main sheet. The substrate sheet is wound on the core and includes the N-1th roll layer and the Nth roll layer. The Nth roll layer is the outermost roll layer wound on the N-1 roll layer. The N-1 roll layer has a first outer liner surface. The Nth roll layer has a second outer liner surface. The main sheet is wound on the substrate sheet and has an end portion provided on the substrate sheet The first outer lining surface. The main sheet is wound onto the end portion across a height difference smaller than the thickness of the main sheet on the second outer liner surface of the substrate sheet.

According to another aspect of the present invention, a winding structure is proposed, which includes a core, a backing sheet, and a main sheet. The substrate sheet is wound on the core and has a notch. The notch is defined by the non-parallel first and second planes of the substrate sheet. The main sheet is wound on the substrate sheet. The main sheet has an end portion disposed in the recess of the substrate sheet.

According to yet another aspect of the present invention, a method for forming a wound structure is proposed, which includes the following steps. The substrate sheet is wound on the core. The substrate sheet is subjected to a cutting step to form a notch. One end portion of the main sheet is placed in the recess of the substrate sheet, and then the remaining portion of the substrate sheet is wound.

In order to have a better understanding of the above and other aspects of the present invention, the following examples are specifically described in conjunction with the accompanying drawings as follows:

102, 502, 802, 902: winding structure

104, 304, 904: substrate sheet

104': Volume 1

104": Volume 2

104S': the first outer lining surface

104S": Second outer lining surface

104W': first side lining surface

104W": Second side lining surface

105: polarizer sheet

106: Core

116: Double-sided tape

161: release film

163: Protective film

167: polarizer

169: Protective film

171: Surface protective film

218: Main sheet

218': first class

218": Second class

218E': end part

218W': side sheet surface

304A: First substrate sheet

304B: Second substrate sheet

350: first plane

352: Second plane

354, 954: notch

G1, G2: height difference

FIGS. 1A to 1C illustrate a method of forming a winding structure according to an embodiment.

2A to 2D illustrate a method of forming a winding structure according to another embodiment.

FIG. 3 illustrates the winding structure of an embodiment.

4A to 4B illustrate a method of forming a winding structure according to another embodiment.

The following is a description with some embodiments. It should be noted that this disclosure does not show all possible embodiments, and other implementations not proposed in this disclosure may also be applicable. Furthermore, the size ratios in the drawings are not drawn according to the actual products. Therefore, the description and illustrations are only used to describe the embodiments, not to limit the scope of disclosure of the present disclosure. In addition, the descriptions in the embodiments, such as the detailed structure, process steps and material application, etc., are for illustrative purposes only, and do not limit the scope of the disclosure to be protected. The details of the steps and structure of the embodiments can be changed and modified according to the needs of the actual application process without departing from the spirit and scope of the present disclosure. The following description uses the same/similar symbols to indicate the same/similar components.

FIGS. 1A to 1C illustrate a method of forming the winding structure 102 according to an embodiment.

Referring to FIG. 1A, the substrate sheet 104 is wound on the core 106, wherein the substrate sheet 104 includes a first roll layer 104' and a second roll layer 104" in order from the inside to the outside. The first roll layer 104' It has a first outer liner surface 104S' and a first side liner surface 104W'. The second roll layer 104" is the substrate sheet 104 that crosses the first side liner surface 104W' of the first roll layer 104' and is adjacent to the first The portion on the outer surface 104S'. The second roll layer 104" located on the outermost side of the substrate sheet 104 has a second outer liner surface 104S" and a second side liner surface 104W". The second side liner surface 104W" is adjacent to the first outer liner surface 104S' and the first Between the two outer lining surfaces 104S".

In one embodiment, the material of the core 106 includes polyvinyl chloride (PVC), glass fiber, or other suitable materials. The core 106 may have a solid cylindrical shape, a hollow cylindrical shape, or other suitable long cylindrical shapes.

In one embodiment, the substrate sheet 104 may be foam plastic, foam, or air cushion film. The foam plastic is any one of polystyrene foam plastic, polyethylene foam plastic, polyurethane foam plastic, and polyvinyl chloride foam plastic. The substrate sheet 104 may also be a single-layer or multi-layer optical film sheet. In one embodiment, the thickness of the substrate sheet 104 is between 100 μm and 500 μm.

In one embodiment, the substrate sheet 104 is fixed on the core 106 with a double-sided adhesive tape (not shown).

In a preferred embodiment, the substrate sheet 104 may be a polarizing plate sheet and have a uniform thickness. In one embodiment, recycled or out-of-spec polarizer sheet material can be used, as shown in FIG. 1B, the polarizer sheet material 105 includes a substrate sheet 104 and a release film 161, and the substrate sheet 104 includes a protective film 163 , The polarizer 167, the protective film 169, and the surface protective film 171, after tearing off the release film 161, the substrate sheet 104 is directly attached to the core 106.

The polarizer 167 may be a polyvinyl alcohol (PVA) film and may be made by saponifying polyvinyl acetate resin. Examples of polyvinyl acetate resins include single polymers of vinyl acetate, that is, polyvinyl acetate, and copolymers of vinyl acetate and other monomers that can be copolymerized with vinyl acetate. Examples of other monomers copolymerizable with vinyl acetate include unsaturated carboxylic acids (e.g. acrylic acid, methacrylic acid, ethyl acrylate, propyl n-acrylate, methyl methacrylate), olefins (e.g. ethylene, propylene, 1 -Butene, 2-Methylpropene), vinyl ether (e.g. ethyl vinyl ether, methyl vinyl ether, n-propyl vinyl ether, isopropyl vinyl ether), unsaturated sulfonic acid (e.g. vinyl sulfonic acid, sodium vinyl sulfonate) and many more.

The materials of the protective films 163 and 169 may be selected from cellulose-based resins, acrylic-based resins, non-crystalline polyolefin-based resins, polyester-based resins, polycarbonate-based resins, and combinations thereof, and may specifically include polymethacrylate Polymethylmethacrylate (PMMA) and cellulose-based resins refer to resins in which part of the hydroxyl groups in cellulose are esterified with acetate, or mixed esters in which some are esterified with acetate and some are esterified with other esters. The cellulose-based resin is preferably a cellulose ester-based resin, more preferably an acetyl cellulose-based resin, such as triethyl acetyl cellulose, diethyl acetyl cellulose, cellulose acetate propionate, cellulose Acetate butyrate, etc., cellulose that is fully esterified is called triacetate cellulose (TAC), acrylic resin film, polyaromatic hydroxy resin film, polyether resin film, cyclic polyolefin resin film (such as polyacrylic acid). (Norbornene resin film), polycarbonate resin such as polyester formed from carbonic acid and diol or bisphenol, such as: polyethylene terephthalate (Polyethylene Terephthalate, PET), polypropylene (Polypropylene, PP ), polyethylene (PE), non-crystalline polyolefin resins such as cyclo olefin (co) polymers (COC/COP), composed of norbornene and cyclopentadiene , Dicyclopentadiene, tetracyclododecene and other ring-opening polymers, or copolymers with olefins, polycarbonate (Polycarbonate, PC) and any combination of the above groups. In addition, the materials of the protective films 163 and 169 may be, for example, (meth)acrylic, urethane, acrylic urethane, epoxy, polysiloxane Thermosetting resin or ultraviolet curing resin. In addition, the protective films 163 and 169 may be further subjected to surface treatment, for example, anti-glare treatment, anti-reflection treatment, hard coating treatment, anti-static treatment or anti-fouling treatment.

In some embodiments, the material of the release film 161 and the surface protective film 171 may be the same as or different from the protective films 163 and 169, and the material may be selected from the group consisting of cellulose resin, acrylic resin, and amorphous polyolefin resin. , Polyester resin, polycarbonate resin and their combination. The release film 161 and the surface protection film 171 may still include a photocurable adhesive material, or other suitable materials. The photocurable adhesive material is selected from the group consisting of acrylic resin, polyester resin, polycarbonate resin, and amorphous polyolefin resin. The photocurable adhesive material may include a photopolymerizable compound, among which the photocurable adhesive material The photopolymerizable compound used is not particularly limited, and examples thereof include acrylic monomers such as polyester acrylate, urethane acrylate, polybutadiene acrylate, silicone acrylate, and epoxy acrylate; hydrogenated epoxy Monomers, alicyclic epoxy monomers, aliphatic epoxy monomers and other epoxy monomers, epoxy acrylate prepolymers, acrylate prepolymers, urethane acrylate prepolymers, aliphatic The urethane acrylate prepolymer, aromatic urethane acrylate prepolymer, polyester acrylate prepolymer and the like can be used alone or in combination of two or more of the above materials.

Next, referring to FIG. 1C, a double-sided adhesive tape 116 is provided, and an adhesive surface is adhered to the first outer surface 104S' of the first roll layer 104' of the substrate sheet 104. In one embodiment, the double-sided tape 116 may have a uniform thickness, which is smaller than the thickness of the substrate sheet 104.

The end portion 218E' of the first layer 218 of the main sheet 218 can be adhered and fixed on the first roll layer 104' of the substrate sheet 104 by double-sided tape 116, and the rest is wound according to the winding and conforms to the roll. In general, the end portion 218E' of the main sheet 218 is disposed as close as possible to the second roll layer 104" of the substrate sheet 104. For example, in one embodiment, the end portion 218E' of the main sheet 218 has side panels The sheet surface 218W' is the second side liner surface 104W" facing the second roll layer 104" of the substrate sheet 104. In one embodiment, the side sheet surface 218W' may abut the second side liner surface 104W".

As shown in FIG. 1C, the first layer 218' of the main sheet 218 is conformally rolled from the end portion 218E' on the first roll layer 104' of the substrate sheet 104, and then rolled on the first sheet layer 104 of the substrate sheet 104. On the second roll layer 104", then the main sheet 218 crosses the side sheet surface 218W' of the end portion 218E' and the portion rolled on the end portion 218E' (or the first level 218') is the second level 218", the third, fourth, or higher layer winding structure of the main sheet 218 can be deduced by analogy. In one embodiment, the main sheet 218 is a polarizing plate sheet. The main sheet 218 may also include other materials, or other optical sheets. In one embodiment, the main sheet 218 may be a single-layer or multi-layer optical sheet. In one embodiment, the main sheet 218 may have a uniform thickness, ranging from 100 μm to 500 μm, and may be greater than or equal to the thickness of the substrate sheet 104. Since the side sheet surface 218W' of the end portion 218E' is shielded by the second roll layer 104" of the backing sheet 104, the main sheet 218 is stacked from the second roll layer 104" of the backing sheet 104 to the end section 218E' The height difference G1 to be spanned may be smaller than the thickness of the main sheet 218 (or the end portion 218E′). The height difference G1 is the height difference between the top edge of the side sheet surface 218W' and the top edge of the second side liner surface 104W". In one embodiment, the height difference G1 may approach zero.

In a comparative example, the main sheet 218 of the winding structure is directly wound on the core 106, and the main sheet 218 needs to span a height difference equal to the entire thickness of its single layer, so the portion corresponding to the height difference is prone to obvious compression Mark transfer problem, in which the second-level 218" closest to the first-level 218' is the most serious transfer problem, and may even be judged as a bad part and cannot be applied to the product. In another comparative example, if the main sheet 218 It is fixed by double-sided tape and then wound on the core 106, which will cause a greater height difference. In contrast, the embodiment of the present disclosure uses the substrate sheet 104 to enable the main sheet 218 to be removed from the first level 218' A higher level of winding is performed across the height difference G1 that is less than its own thickness, so it can improve the indentation transfer phenomenon, avoid the problem of the main sheet 218 because the indentation becomes a defective product, and increase the main sheet 218 to be applied to the product. Available parts.

The embodiment shown in FIGS. 1A and 1C is described with a substrate sheet 104 with a two-roll layer structure, in which the first roll layer 104' can be regarded as the N-1 roll layer, and the second roll layer 104" can be regarded as the first N roll layer, N=2. However, according to the present disclosure, it is not limited to this. In other embodiments, other N roll layer structure substrate sheets may be used, wherein the outermost roll layer is the Nth roll layer, adjacent to it The lower roll layer is the N-1 roll layer, and so on, and other lower roll layers that are closer to the core 106 in sequence, such as the N-2 roll layer, etc., N=3, 4, 5, or a larger integer. Similar to the embodiment concept described with reference to FIGS. 1A and 1C, the N-1 roll layer has a first outer liner surface 104S′, the Nth roll layer has a second outer liner surface 104S′, and the main sheet 218 is formed by The end portion 218E' is configured to be wound on the first outer liner surface 104S', and with the Nth roll layer, the main sheet 218 is able to span less than the end portion The height difference G1 of the entire thickness of 218E' is wound onto the end portion 218E' and then conforms to the winding.

2A to 2D illustrate a method of forming the winding structure 502 according to another embodiment.

Referring to FIG. 2A, the first substrate sheet 304A is wound on the core 106. In one embodiment, the first substrate sheet 304A has a uniform thickness. The two opposite side liner surfaces of the first substrate sheet 304A of the single roll layer may be as close as possible, for example, the two opposite side liner surfaces may face each other with a slit or adjacent to each other. In one embodiment, the first substrate sheet 304A is a polarizing plate sheet. In other embodiments, the first substrate sheet 304A may include other materials or other optical sheets. In one embodiment, the first substrate sheet 304A may be a single-layer or multi-layer optical sheet.

Referring to FIG. 2B, the second substrate sheet 304B is wound on the first substrate sheet 304A. In one embodiment, the second substrate sheet 304B has a uniform thickness, and may be larger than the thickness of the first substrate sheet 304A. The two opposite side liner surfaces of the second substrate sheet 304B of the single roll layer may be as close as possible, for example, the two opposite side liner surfaces may face each other with a slit or adjacent to each other. In one embodiment, the second substrate sheet 304B is a polarizing plate sheet. In other embodiments, the second substrate sheet 304B may include other materials or other optical sheets. In one embodiment, the second substrate sheet 304B may be a single-layer or multi-layer optical sheet. The substrate sheet 304 includes a first substrate sheet 304A and a second substrate sheet 304B in different roll layers, respectively.

In one embodiment, the material and thickness of the first substrate sheet 304A and the second substrate sheet 304B are similar to those of the substrate sheet 104, and will not be repeated here. One implementation In the example, the thickness of the first substrate sheet 304A and the second substrate sheet 304B are different, for example, the thickness of the first substrate sheet 304A is smaller than the thickness of the second substrate sheet 304B. In one embodiment, the thickness of the first substrate sheet 304A is between 40-130 μm, and the thickness of the second substrate sheet 304B is between 100 μm-500 μm.

Referring to FIG. 2C, a cutting step is performed on the substrate sheet 304 to form a first plane 350 (for example, a coplanar plane caused by cutting) and a second plane 352 on the first substrate sheet 304A and the second substrate sheet 304B. For example, another coplanarity caused by cutting), the first plane 350 and the second plane 352 may define a notch 354 with an L-profile. In one embodiment, the first plane 350 and the second plane 352 may be perpendicular to each other or form an acute or obtuse angle.

In one embodiment, the first substrate sheet 304A and the second substrate sheet 304B can be formed of a material with a hardness lower than that of the core 106, so compared to the method of forming a notch directly on the core 106, the embodiment of the present disclosure The cutting step of forming the notch 354 in the substrate sheet 304 is easier to perform, and the cutting profile of the notch 354 can be controlled more precisely. In addition, the structure of the core 106 is not destroyed, so it can be reused again to reduce the cost of consumption.

Please refer to FIG. 2D, an adhesive surface of the double-sided tape 116 may be adhered to the second plane 352. The end portion 218E′ of the main sheet 218 can be adhesively fixed into the recess 354 using the other adhesive surface opposite to the double-sided tape 116, and then the remaining portion is wound on the substrate sheet 304. In general, the end portion 218E′ of the main sheet 218 is disposed as close to the first plane 350 of the substrate sheet 304 as possible. In one embodiment, the main sheet 218 has a uniform thickness, ranging from 100 μm to 500 μm, and the thickness is greater than or equal to the second substrate Sheet 304B. The first layer 218' of the main sheet 218 is rolled from the end portion 218E' to the substrate sheet 304, and then the main sheet 218 is rolled across the end sheet portion 218E' and rolled at the end portion The part of 218E' (or the first level 218') is the second level 218", and the third, fourth, or higher level winding structure of the main sheet 218 can be deduced by analogy. Among them, the main sheet 218 The height difference G2 that needs to be spanned from the substrate sheet 304 to the end portion 218E' is smaller than the thickness of the main sheet 218 (or the end portion 218E'), so that the problem of indentation transfer at a higher level as a defective product can be avoided. In the example, the height difference G2 is the height difference between the top edge of the side sheet surface 218W' and the top edge of the first plane 350. In one embodiment, the first substrate sheet 304A and the second substrate sheet 304B The thickness sum of the double-sided tape 116 and the main sheet 218 is approximately the same, so that the height difference G2 can approach zero.

The embodiment shown in FIGS. 2A to 2D uses a substrate sheet 304 with a two-roll layer structure, and the cutting depth for forming the notch 354 is stopped on the surface of the core 106. However, according to this disclosure, it is not limited to this. In other embodiments, it is also possible to use other roll number structure or different thickness distribution substrate sheets, and use the cutting step to form a notch in the substrate sheet to accommodate the end portion 218E' of the main sheet 218 and then to the main sheet The material 218 is wound to protect the surface of the core 106 from cutting damage. The cutting depth can be adjusted appropriately to control the contour of the notch, so that when the end portion 218E' of the main sheet 218 is placed in the notch for winding, it is possible to span from the first level 218' to the end from the height difference less than its thickness Part 218E' rolls over the second layer 218" and other higher layers to avoid the problem of indentation transfer becoming a defective product.

FIG. 3 illustrates a winding structure 802 of an embodiment, which differs from the winding structure 502 of FIG. 2D in that the thickness of the first substrate sheet 304A can approach the double-sided tape 116 and the second substrate sheet The thickness of 304B may approach the main sheet 218, and the thickness of the first plane 350 (ie, the depth of the cutting notch 354) is equal to the total thickness of the first substrate sheet 304A and the second substrate sheet 304B (ie, equal to both sides The total thickness of the adhesive tape 116 and the main sheet 218), so that the height difference that the sheet 218 needs to span from the substrate sheet 304 to the end portion 218E' (refer to the concept of the height difference G2 in FIG. 2D) can approach zero.

4A to 4B illustrate a method of forming the winding structure 902 according to another embodiment. Referring to FIG. 4A, a single substrate sheet 904 is wound on the core 106 in multiple layers. In one embodiment, the substrate sheet 904 is a polarizing plate sheet. In other embodiments, the substrate sheet 904 may include other materials or other optical sheets. In one embodiment, the substrate sheet 904 may be a single-layer or multi-layer optical sheet.

Please refer to FIG. 4B, and then, with a concept similar to that described in FIGS. 2C and 2D, perform a cutting step on the substrate sheet 904 to form a notch 954, and use the double-sided tape 116 to place the main sheet 218 on the The end portion 218E' is adhesively fixed into the recess 954, and then the remaining portion is wound on the substrate sheet 904. In one embodiment, the depth of the notch 954 is equal to the total thickness of the double-sided tape 116 and the main sheet 218, so that the height difference that the sheet 218 needs to span from the substrate sheet 904 to the end portion 218E' (refer to the height of FIG. 2D The concept of difference G2) can approach zero.

In addition, in the present invention, if the surface of the core 106 has irregularities or foreign substances adhered, by covering the aforementioned substrate sheet, the problem of indentation transfer becoming a defective product can be further prevented and avoided.

In summary, although the present invention has been disclosed as above with examples, it is not intended to limit the present invention. Those with ordinary knowledge in the technical field to which the present invention belongs can make various modifications and retouching without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be deemed as defined by the scope of the attached patent application.

102: winding structure

104: substrate sheet

104': Volume 1

104": Volume 2

104S': the first outer lining surface

104S": Second outer lining surface

104W': first side lining surface

104W": Second side lining surface

106: Core

116: Double-sided tape

218: Main sheet

218': first class

218": Second class

218E': end part

218W': side sheet surface

G1: height difference

Claims (10)

A winding structure includes: a core; a substrate sheet wound on the core and having a notch, the notch is formed by a non-parallel first plane and a first plane of the substrate sheet Two planes are defined; and a main sheet wound on the substrate sheet, wherein the main sheet has an end portion disposed in the recess of the substrate sheet; wherein the substrate sheet includes separate rolls Layer of a first substrate sheet and a second substrate sheet, the first plane is a coplanar plane of the first substrate sheet and the second substrate sheet, the second plane is the first substrate sheet and The other coplanar of the second substrate sheet. The winding structure as described in item 1 of the patent application scope, wherein the main sheet is wound on the outer liner surface of the substrate sheet across a height difference smaller than the thickness of the main sheet to the end portion on. The winding structure as described in item 2 of the patent application scope, wherein the height difference is substantially zero. The winding structure as described in item 2 of the patent application scope, wherein the end portion of the main sheet has a side sheet surface, and the height difference is the top edge of the side sheet surface and the top edge of the first plane The difference in height. The winding structure as described in item 1 of the patent application scope further includes a double-sided adhesive tape disposed in the recess and used to adhere the end portion to the second plane of the substrate sheet. The winding structure as described in item 1 of the patent application scope, wherein the first plane and the second plane form an L shape. The winding structure as described in item 1 of the scope of the patent application further includes a double-sided tape disposed in the recess and used to adhere the end portion to the second plane of the substrate sheet, wherein the double-sided The thickness sum of the adhesive tape and the main sheet is substantially equal to the thickness sum of the first substrate sheet and the second substrate sheet. The winding structure as described in item 7 of the patent application scope, wherein the thickness of the first plane is substantially equal to the sum of the thicknesses of the double-sided tape and the main sheet, or is substantially equal to the first substrate sheet and the This thickness sum of the second substrate sheet. A method for forming a winding structure includes: winding a substrate sheet on a core; performing a cutting step on the substrate sheet to form a notch, the notch is determined by the substrate sheet A parallel first plane and a second plane are defined; and an end portion of a main sheet is placed in the recess of the substrate sheet, and then the remaining portion is wound on the substrate sheet; wherein the liner The bottom sheet includes a first substrate sheet and a second substrate sheet in different roll layers, the first plane is a coplanar plane of the first substrate sheet and the second substrate sheet, and the second plane is The other of the first substrate sheet and the second substrate sheet are coplanar. The method for forming a winding structure as described in item 9 of the patent application scope, wherein winding the substrate sheet on the core includes: winding the first substrate sheet on the core; and the The second substrate sheet is wound on the first substrate sheet, wherein the cutting step is performed on the first substrate sheet and the second substrate sheet.

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