WO2013103074A1

WO2013103074A1 - Packaging body for polyvinyl alcohol film roll

Info

Publication number: WO2013103074A1
Application number: PCT/JP2012/082132
Authority: WO
Inventors: 秀朝田; 日笠　慎太郎; 磯▲ざき▼　孝徳
Original assignee: 株式会社クラレ
Priority date: 2012-01-04
Filing date: 2012-12-12
Publication date: 2013-07-11
Also published as: JP6077442B2; CN104024127A; JPWO2013103074A1; JP2016210509A; CN104024127B; CN106927139A; CN106927139B; TW201339065A; KR102038164B1; JP6246874B2; KR20140109931A; TWI598277B

Abstract

The present invention is a packaging body in which a roll of a PVA film (2) is packaged in a packaging film (4). Two ends (5) of the packaging body have a structure in which a foam cushioning (7), the packaging film (4), and a protective pad (9) are arranged in that order from the interior of the packaging body toward the outside. This structure makes it possible to fully prevent damage to the PVA film roll during storage and transportation, and makes it possible to reduce breakage when the film is uniaxially stretched.

Description

Package of polyvinyl alcohol film roll

The present invention relates to a package formed by packaging a roll formed by winding a polyvinyl alcohol film with a packaging film, a method for producing the package, and a method for storing or transporting the roll.

A polarizing plate having a light transmission and shielding function is a basic component of a liquid crystal display (LCD) together with a liquid crystal having a light switching function. This LCD is used in small devices such as calculators and wristwatches in the early stages of development, and in recent years, used in notebook computers, liquid crystal monitors, liquid crystal color projectors, liquid crystal televisions, in-vehicle navigation systems, mobile phones, and indoors and outdoors. It is expanding to various fields such as measuring instruments. On the other hand, particularly in the field of liquid crystal televisions, prices are rapidly decreasing, and improvement in yield (product yield) at the time of manufacturing polarizing plates is required.

The polarizing plate is generally a polarizing film obtained by subjecting a film of polyvinyl alcohol (hereinafter, “polyvinyl alcohol” may be abbreviated as “PVA”) to dyeing, uniaxial stretching, and, if necessary, fixing treatment with a boron compound or the like. Is manufactured by bonding a protective film such as a cellulose triacetate (TAC) film on the surface of the polarizing film.

By the way, in the uniaxial stretching described above, generally, the higher the stretching ratio, the higher the performance of the obtained polarizing film. Therefore, stretching is often performed near the limit where the PVA film breaks. For this reason, if there is even a slight scratch on the PVA film, there is a problem that cutting occurs from that point and the yield (product yield) and productivity of the polarizing film and thus the polarizing plate are likely to be lowered. In particular, the PVA film is usually stored or transported in the form of a roll in which a long PVA film is wound. If there is a scratch on the end face of the roll, the PVA film is likely to be cut during uniaxial stretching of the PVA film. There was a problem. Therefore, it is important to reduce scratches on the PVA film, but the scratches often occur during storage or transportation rather than during production of the PVA film.

With respect to such a problem, for the purpose of preventing the end face from being scratched during storage or transportation of the roll wound with the PVA film, and making it possible to stably stretch the PVA film, etc. A method is known in which the length of the core is made longer than the width of the film and is wrapped with a specific packaging film (see Patent Document 1).

In addition, a roll formed by winding a PVA film around a core tube longer than the film width is packaged with a water vapor barrier resin packaging film, and is then packaged with a packaging film made of an aluminum material for storage or transportation. It is known that a polarizing film with less variation in optical performance can be obtained from the winding outer periphery to the core of the roll, which can prevent roll roll misalignment, film scratches and blocking due to blocking. (See Patent Document 2). Patent Document 2 discloses that a protective pad having a core tube through-hole can be attached to both ends of a roll directly or after packaging in order to prevent scratches at the end and adhesion of foreign matters such as dust. Is described.

JP 2001-315895 A JP 2005-306483 A

All of the above-described conventional packaging forms have a certain degree of damage prevention effect, and the cutting at the time of stretching is reduced. However, the cutting still occurs and there is room for further improvement. In particular, in recent years, the level of cleanliness when manufacturing polarizing plates has become stricter, and PVA films are often used in clean rooms. In such cases, PVA films are brought into clean rooms. In many cases, the packaging film that is likely to have dust attached to it in advance is often removed in advance, and the protective pad attached to the outside of the packaging film is also removed at that time, so the damage to the roll is sufficiently suppressed. I couldn't. In order to suppress such damage to the roll, it is conceivable that a protective pad is attached to the inside of the packaging film as described in Patent Document 2, but simply adopting the above configuration on the roll end surface. There was a problem that the protective pad which was in direct contact was more likely to be damaged.

The present invention can sufficiently prevent damage to the roll during storage and transportation, and can suppress damage to the roll even when the roll is used in a clean room. When the PVA film is uniaxially stretched It aims at providing the package of the roll of a PVA film which can reduce cutting | disconnection of this, the manufacturing method, and the storage or transportation method of a roll.

The present inventors have studied to achieve the above object, and after attaching foam cushioning materials to both ends of the roll of the PVA film, the roll is wrapped with a packaging film, and further, both ends from above. The inventors have found that the above-mentioned object can be achieved by attaching a protective pad to the present invention, and have further studied based on the findings to complete the present invention.

That is, the present invention
[1] A package formed by wrapping a roll formed by winding a PVA film with a packaging film, the foam cushioning material, the packaging film, and protection at both ends of the package from the inside to the outside of the package A package having a structure in which pads are arranged in this order;
[2] The package according to [1], wherein the foam cushioning material is formed of closed-cell foamed plastic.
[3] The package according to [1] or [2] above, wherein the foam cushioning material is formed of foamed polyethylene.
[4] The package according to any one of the above [1] to [3], wherein the foam cushioning material has a thickness of 2 mm or more.
[5] The package according to any one of the above [1] to [4], wherein the foam cushioning material has a water absorption rate of 0.05 g / cm ² or less.
[6] The package according to any one of the above [1] to [5], wherein the roll is packaged with an aluminum film.
[7] The package according to [6] above, wherein the roll is packaged with an aluminum film and then further wrapped with a polyethylene film.
[8] The package according to [6] or [7] above, wherein the aluminum-based film is a multilayer film having a structure in which a polyethylene film or a stretched polypropylene film is laminated on both surfaces of an aluminum foil,
[9] The package according to any one of [6] to [8] above, wherein the aluminum-based film is a multilayer film having a structure in which an aluminum foil and a nylon film are laminated.
[10] The package according to any one of the above [1] to [9], wherein the 25% compressive stress of the protective pad is 50 kPa or more,
[11] A method for producing a package according to any one of [1] to [10] above, wherein the foam cushioning material is attached to both ends of the roll, and the roll with the foam cushioning material is packaged with a packaging film And a manufacturing method comprising a step of attaching a protective pad from above the packaging film,
[12] A method for storing or transporting a roll, wherein the roll is stored or transported in the form of a package of any one of [1] to [10] above,
About.

According to the present invention, it is possible to sufficiently prevent damage to the roll during storage or transportation, and even when the roll is used in a clean room, the damage to the roll can be suppressed, and the PVA film is uniaxially stretched. The package of the roll of a PVA film which can reduce the cutting | disconnection at the time of performing, its manufacturing method, and the storage or transportation method of a roll are provided.

It is the schematic which shows an example of the cross section of one edge part of the package of this invention. It is the schematic which shows an example of the roll in this invention.

The present invention is described in detail below.
The package of the present invention is obtained by packaging a roll formed by winding a PVA film with a packaging film. And in the both ends (near the both end surfaces of a roll) of the said package, it has the structure where the foam cushioning material, the packaging film, and the protection pad are arrange | positioned in this order toward the outer side from the inside of the package.

As described above, the package of the present invention has a structure in which the foam cushioning material, the packaging film, and the protective pad are arranged in this order from the inside to the outside of the package at both ends. The specific aspect of the package is not particularly limited, and, for example, at each end, from the inside of the package to the outside, (roll end surface) / foam cushioning material / packaging film / protective pad / (outside of the package) ) Arranged in this order; (roll end face) / foam cushioning material / packaging film / protective pad / packaging film / (outside of packaging) arranged in order: (roll end face) / foam cushioning material / packaging film / protection Pad / packaging film / protective pad / aspects arranged in the order of (outside of package); (roll end surface) / foam cushioning material / packaging film / protective pad / packaging film / protective pad / packaging film / (outside of package) Examples of the arrangement are as follows. In the above examples, members (foam cushioning material, packaging film or protective pad) belonging to the same category may have a multilayer structure. For example, “/ packaging film /” means one type of packaging film. There may be only one layer, one type of packaging film may be present in two or more layers, or two or more types of packaging films may be present in one or more layers, respectively. means.
Among the specific embodiments of the packaging body, since the production of the packaging body is easy and the like, (roll end face) / foam cushioning material / packaging film / protection from the inside to the outside of the packaging body at each end. An embodiment arranged in the order of pad / (outside of package) and an embodiment arranged in the order of (roll end surface) / foam cushioning material / packaging film / protective pad / wrapping film / (outside of package) are preferred, (roll end surface) The aspect which arranged in order of / foam cushioning material / packaging film / protection pad / (outside of the package) is more preferable.

FIG. 1 is a schematic view showing an example of a cross section of one end of the package of the present invention. In FIG. 1, a PVA film 2 is wound around a cylindrical core 1 described later to form a roll. And this roll is packaged by the

packaging films

4a and 4b, and forms the package. An arrow A in FIG. 1 indicates a direction from the inside of the package toward the outside, and in the schematic diagram of FIG. 1, (roll end surface 6) / foam cushioning material 7 from the inside of the package to the outside. /

Packaging films

4a and 4b / protective pad 9 / (outside of package) are arranged in this order.

The roll in the package of the present invention is formed by winding a PVA film, for example, a PVA film is wound around a cylindrical core. When the roll is formed by winding a PVA film around a cylindrical core, it is preferable that both ends of the core form protrusions that protrude from the end face of the roll. FIG. 2 is a schematic view showing an example of a roll in the present invention. In FIG. 2, a roll 11 is formed by winding a PVA film 13 around a cylindrical core 12. Each of both end portions of the cylindrical core 12 (only one end portion 16 is shown in FIG. 2) forms a protruding portion that protrudes outward from the end surface 14 of the roll in the length direction of the core. When the both ends of the core form protrusions, it is easy to attach the foam cushioning material and the protective pad, and it is easy to store or transport the roll and the package.

There is no particular limitation on the type of the above-described cylindrical core, and examples thereof include a metal one, a plastic one, a paper one, and a wooden one. It is also possible to use a core in the form of a composite, such as one using both metal and plastic, one using both metal and paper, and one using both plastic and paper. Among these, a metal and / or plastic core is preferable because it has high strength and the effects of the present invention are more prominent, and is not easily affected by wear or the like even when used repeatedly. The core is more preferable. The proportion of the mass of the metal and plastic with respect to the total mass of the cylindrical core is preferably 50% by mass or more, more preferably 80% by mass or more, and further preferably 95% by mass or more. The amount is preferably 100% by mass.

Examples of the metal include iron, stainless steel, and aluminum. One of these may be used alone, or two or more may be used in combination. Among these, aluminum is preferable from the viewpoint of strength, lightness, price, and the like.

Examples of the plastic include polyvinyl chloride, polyvinylidene chloride, polyester, polycarbonate, polyamide, epoxy resin, polyurethane, polyurea, and silicone resin. One of these is used alone. Moreover, you may use 2 or more types together. Of these, polyvinyl chloride is preferred. The plastic is also preferably a fiber reinforced plastic (FRP) such as a carbon fiber reinforced plastic from the viewpoint of strength and the like.

The diameter of the cylindrical core is not particularly limited, but the outer diameter is preferably in the range of 50 to 800 mm, more preferably in the range of 80 to 500 mm, from the viewpoint of strength, handleability, and the like. A range of 100 to 300 mm is more preferable, and a range of 150 to 250 mm is particularly preferable.
The thickness of the cylindrical core is preferably in the range of 2 to 50 mm, more preferably in the range of 3 to 20 mm, and more preferably in the range of 4 to 10 mm from the viewpoints of strength, handleability, and the like. More preferably, it is within.

Examples of PVA constituting the PVA film include PVA obtained by saponifying polyvinyl ester obtained by polymerizing vinyl ester (unmodified PVA); modified PVA obtained by graft copolymerizing a comonomer with the main chain of PVA; Modified PVA produced by saponifying modified polyvinyl ester obtained by copolymerizing vinyl ester and comonomer; a part of hydroxyl group of unmodified PVA or modified PVA was crosslinked with aldehydes such as formalin, butyraldehyde, benzaldehyde, Examples include so-called polyvinyl acetal resins.

Examples of the vinyl ester used in the production of PVA include vinyl acetate, vinyl formate, vinyl propionate, vinyl butyrate, vinyl pivalate, vinyl versatate, vinyl laurate, vinyl stearate, and vinyl benzoate. Can be mentioned. Among these, vinyl acetate is preferable from the viewpoint of ease of production, availability, and cost of PVA.

The above-mentioned comonomer used for the production of the modified PVA is copolymerized mainly for the purpose of modifying the PVA, and is used within a range not impairing the gist of the present invention. Examples of such a comonomer include olefins such as ethylene, propylene, 1-butene, and isobutene; acrylic acid or a salt thereof; methyl acrylate, ethyl acrylate, n-propyl acrylate, i-propyl acrylate, acrylic Acrylic acid esters such as n-butyl acrylate, i-butyl acrylate, t-butyl acrylate, 2-ethylhexyl acrylate, dodecyl acrylate, octadecyl acrylate; methacrylic acid or salts thereof; methyl methacrylate, methacryl Such as ethyl acetate, n-propyl methacrylate, i-propyl methacrylate, n-butyl methacrylate, i-butyl methacrylate, t-butyl methacrylate, 2-ethylhexyl methacrylate, dodecyl methacrylate, octadecyl methacrylate, etc. Methacrylic acid esters Acrylamide derivatives such as acrylamide, N-methyl acrylamide, N-ethyl acrylamide, N, N-dimethyl acrylamide, diacetone acrylamide, acrylamide propane sulfonic acid or its salt, acrylamide propyl dimethylamine or its salt, N-methylol acrylamide or its derivative Methacrylamide derivatives such as methacrylamide, N-methyl methacrylamide, N-ethyl methacrylamide, methacrylamide propanesulfonic acid or salts thereof, methacrylamide propyldimethylamine or salts thereof, N-methylol methacrylamide or derivatives thereof; N-vinylamides such as vinylformamide, N-vinylacetamide, N-vinylpyrrolidone; methyl vinyl ether, ethyl vinyl Vinyl ethers such as ether, n-propyl vinyl ether, i-propyl vinyl ether, n-butyl vinyl ether, i-butyl vinyl ether, t-butyl vinyl ether, dodecyl vinyl ether, stearyl vinyl ether; nitriles such as acrylonitrile and methacrylonitrile; vinyl chloride, Vinyl halides such as vinylidene chloride, vinyl fluoride, and vinylidene fluoride; allyl compounds such as allyl acetate and allyl chloride; maleic acid or a salt or ester thereof; itaconic acid or a salt or ester thereof; vinylsilyl such as vinyltrimethoxysilane Compound; isopropenyl acetate and the like. Among these, α-olefins (eg, α-olefins having 2 to 30 carbon atoms), unsaturated carboxylic acids or derivatives thereof, unsaturated sulfonic acids or derivatives thereof are preferable, α-olefins are more preferable, and ethylene is particularly preferable. .
In the modified PVA, the amount of modification with a comonomer is preferably 15 mol% or less, and more preferably 5 mol% or less, based on the number of moles of all structural units constituting the modified PVA.

The polymerization degree of PVA is not particularly limited, but is preferably 2000 or more, more preferably 2300 or more from the viewpoint of polarization performance and durability when uniaxially stretched into a polarizing film and further a polarizing plate. preferable. Further, from the viewpoint of easy production of a homogeneous PVA film, stretchability, etc., the degree of polymerization of PVA is preferably 8000 or less, and more preferably 6000 or less. The degree of polymerization of PVA in the present specification means an average degree of polymerization measured according to the description of JIS K6726-1994, and the intrinsic viscosity measured in water at 30 ° C. after re-saponifying and purifying PVA. Can be obtained from

The degree of saponification of PVA is not particularly limited, but it is preferably 99 mol% or more from the viewpoint of polarization performance and durability when uniaxially stretched into a polarizing film and further a polarizing plate, and is 99.3 mol%. More preferably, it is more preferably 99.8 mol% or more. In this specification, the “degree of saponification” of PVA refers to the total number of moles of structural units (typically vinyl ester units) that can be converted to vinyl alcohol units by saponification and the vinyl alcohol units of PVA. The percentage of the number of moles of the vinyl alcohol unit (mol%). The degree of saponification can be measured by the method described in JIS K6726-1994.

The PVA film preferably contains a plasticizer. When the PVA film contains a plasticizer, the dyeability and stretchability are improved, and the process passability during the production of the PVA film is also improved. The plasticizer is preferably a polyhydric alcohol, and examples thereof include ethylene glycol, glycerin, diglycerin, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, trimethylolpropane and the like. Species can be used alone or in combination of two or more. Among these, glycerin, diglycerin, or ethylene glycol is more preferably used from the viewpoint of excellent stretchability improvement effect.

The content of the plasticizer in the PVA film is preferably 1 to 30 parts by mass, more preferably 3 to 25 parts by mass, and further preferably 5 to 20 parts by mass with respect to 100 parts by mass of PVA. When the content is less than 1 part by mass, the dyeability and stretchability may be reduced. When the content is more than 30 parts by mass, the PVA film becomes too flexible and the handleability may be reduced.

It is preferable that a PVA film contains surfactant from points, such as the improvement of the peelability from the drying roll used for the manufacture, and the improvement of the handleability of a PVA film. Although there is no restriction | limiting in particular in the kind of surfactant, Anionic or nonionic surfactant is used preferably.
Examples of the anionic surfactant include carboxylic acid types such as potassium laurate, sulfate ester types such as octyl sulfate, and sulfonic acid types such as dodecylbenzene sulfonate.
Nonionic surfactants include, for example, alkyl ether types such as polyoxyethylene oleyl ether, alkylphenyl ether types such as polyoxyethylene octylphenyl ether, alkyl ester types such as polyoxyethylene laurate, and polyoxyethylene laurylamino. Alkylamine type such as ether, alkylamide type such as polyoxyethylene lauric acid amide, polypropylene glycol ether type such as polyoxyethylene polyoxypropylene ether, alkanolamide type such as oleic acid diethanolamide, polyoxyalkylene allyl phenyl ether, etc. And allyl phenyl ether type.
These surfactants can be used individually by 1 type or in combination of 2 or more types.

The content of the surfactant in the PVA film is preferably 0.01 to 1 part by mass, more preferably 0.02 to 0.5 part by mass, and 0.05 to 0.3 part by mass with respect to 100 parts by mass of PVA. Is particularly preferred. When the content is less than 0.01 parts by mass, the effect of improving the peelability and the handleability may be difficult to appear. On the other hand, when the content is more than 1 part by mass, the surfactant is eluted on the surface of the PVA film and causes blocking. And the handleability may be reduced.

The PVA film is composed of other components other than PVA, plasticizer, and surfactant, such as stabilizers (antioxidants, ultraviolet absorbers, heat stabilizers, etc.), compatibilizers, antiblocking agents, flame retardants, It may contain an antistatic agent, a lubricant, a dispersant, a fluidizing agent, an antibacterial agent, and the like. These additives can be used alone or in combination of two or more.
The content of PVA in the PVA film is preferably 50% by mass or more, more preferably 70% by mass or more, and further preferably 85% by mass or more.

The PVA film is made up of a PVA and, if necessary, a film-forming stock solution in which a plasticizer, a surfactant, and other components other than those described above are dissolved in a liquid medium, a PVA, a liquid medium, and a plastic as needed. Can be produced using a film-forming stock solution in which the PVA is melted containing other agents, surfactants, and other components described above. Specifically, for example, PVA and, if necessary, a plasticizer, Surfactant, film-forming stock solution prepared by mixing liquid medium with other components described above other than these, and PVA pellets containing liquid medium as needed, plasticizer, surface active It can be produced using a film-forming stock solution that is melted in the presence of an agent and other components described above other than these. In preparing the film-forming stock solution, a stirring mixer, a melt extruder, or the like can be used.

Examples of the liquid medium used for the preparation of the membrane forming stock solution include water, dimethyl sulfoxide, dimethylformamide, dimethylacetamide, N-methylpyrrolidone, and the like. One or more of these can be used. Can be used. Among these, water is preferable from the viewpoint of environmental load and recoverability.

The volatile fraction of the film-forming stock solution (content ratio of volatile components such as solvents removed by volatilization or evaporation during film formation in the film-forming stock solution) varies depending on the film-forming conditions, but is 50 to 95% by mass It is preferable to be within the range. When the volatile fraction of the film-forming stock solution is 50% by mass or more, the viscosity of the film-forming stock solution does not become too high, and filtration and defoaming are smoothly performed during preparation of the film-forming stock solution, and there are few foreign matters and defects. Film production is facilitated. On the other hand, when the volatile fraction of the film-forming stock solution is 95% by mass or less, the concentration of the film-forming stock solution does not become too low, and industrial production of the PVA film becomes easy.

There is no particular limitation on the film forming method when forming the PVA film using the film forming stock solution. For example, a wet film forming method, a gel film forming method, a cast film forming method, an extrusion film forming method, etc. may be adopted. it can. These film forming methods may be employed alone or in combination of two or more. Among the above film forming methods, a cast film forming method or an extrusion film forming method using a known film discharge device (film casting device) such as a T-shaped slit die, a hopper plate, an I-die, a lip coater die, etc. Is preferred. As a specific method of the cast film forming method or the extrusion film forming method, for example, the film forming stock solution is discharged in a film shape on the peripheral surface of a rotating heated roll (or belt) positioned on the most upstream side. Hot air (preferably on the entire surface (non-contact surface) that is not in contact with the roll (or belt) of the film that is cast and discharged or cast on the peripheral surface of the roll (or belt) as necessary 50 to 150 ° C., more preferably 70 to 120 ° C.), for example, by blowing volatile components from the non-contact surface, and the film preferably has a volatile fraction of 15 to 30 mass. %, And then dry further on the peripheral surface of one or a plurality of drying rolls whose rotating shafts are arranged in parallel to each other on the downstream side, or hot air drying such as a hot air oven type Let it pass through the device. After drying, a method of winding the winding device can be preferably employed. The drying by the drying roll and the drying by the hot air drying device may be appropriately combined. Moreover, the film forming apparatus to be used may have a heat processing apparatus, a humidity control apparatus, etc. as needed.

Even if the PVA film wound up by the winding device as described above is used as it is in the packaging body of the present invention as it is, the PVA film is unwound and then rewound again to form a roll. Either can be used.

The width of the PVA film used in the present invention is not particularly limited, but since the liquid crystal television and the liquid crystal monitor have recently been enlarged in size, the width of the PVA film is 3 m or more so that it can be used effectively. Is preferably 4 m or more, more preferably 5 m or more. On the other hand, when producing a polarizing film with an industrial production machine, if the width of the PVA film is too wide, uniform uniaxial stretching may be difficult. Therefore, the width of the PVA film is preferably 6 m or less. .

The thickness of the PVA film is preferably in the range of 5 to 80 μm, preferably in the range of 10 to 60 μm, from the viewpoints of practicality, ease of production of the PVA film, and ease of uniaxial stretching. More preferably, it is more preferably in the range of 20 to 50 μm. When the thickness of the PVA film is less than 5 μm, the PVA film tends to break during uniaxial stretching for producing a polarizing film. On the other hand, when the thickness of the PVA film exceeds 80 μm, stretch spots tend to occur during uniaxial stretching for producing a polarizing film.

The foam cushioning material used in the present invention is not particularly limited as long as it has a foaming structure and exhibits a buffering action, and even if it is formed of closed-cell foamed plastic, continuous Either of them may be formed of foamed foam plastic, but when a foam cushioning material formed of open-cell foamed plastic is used, the foam cushioning material may have a large water absorption rate. In many cases, the foam cushioning material absorbs the moisture in the PVA film in the package and generates moisture spots on the PVA film, and tends to be cut when the PVA film is uniaxially stretched. It is preferably formed of foamed plastic.

There is no particular limitation on the material of the foam cushioning material. For example, a foam cushioning material formed of foamed plastic such as foamed polyethylene, foamed polystyrene, foamed polyurethane, or foamed polyvinyl chloride can be used, but the water absorption rate tends to increase. When foam cushioning material is used, the moisture content of the PVA film is generated in the package, and cutting tends to occur when the PVA film is uniaxially stretched. It is preferable to use a foam cushioning material formed of easily foamed polyethylene.

The thickness of the foam cushioning material is preferably 2 mm or more, more preferably 3 mm or more, further preferably 5 mm or more, and particularly preferably 7 mm or more. When the thickness is 2 mm or more, the end face of the roll can be more effectively prevented from being damaged. Although there is no restriction | limiting in particular in the upper limit of the thickness of a foam cushioning material, From the point of handleability, it is preferable that the said thickness is 15 mm or less. In addition, when it is difficult to ensure the thickness with one foam cushioning material, a plurality of foam cushioning materials may be stacked to secure the thickness as a total thickness.

The 25% compressive stress of the foam cushioning material is preferably 50 kPa or more, more preferably 70 kPa or more, and further preferably 100 kPa or more. When the 25% compressive stress is 50 kPa or more, damage to the roll end face can be more effectively prevented. If the foam cushioning material has a too large 25% compressive stress, the foam cushioning material may damage the roll end face. Therefore, the 25% compressive stress is preferably 300 kPa or less, more preferably 250 kPa or less, and 200 kPa. It is particularly preferred that
The 25% compressive stress of the foam cushioning material can be measured according to JIS K7220: 2006.

Water absorption of the foam cushioning material is preferably at 0.05 g / cm ² or less, more preferably 0.03 g / cm ² or less, and more preferably 0.01 g / cm ² or less. When the water absorption exceeds 0.05 g / cm ² , the foam cushioning material absorbs the moisture in the PVA film in the package to generate moisture spots on the PVA film, and is likely to be cut during uniaxial stretching of the PVA film. Tend to be. Although there is no restriction | limiting in particular in the lower limit of a water absorption rate, since it becomes hard and a buffer function tends to fall, so that a water absorption rate is low, a water absorption rate is 0.0002 g / cm < ² > or more, for example. In addition, the water absorption rate in this specification means the amount of water absorption by the measuring method described in JIS A9511: 2006R.

The package of the present invention is formed by packaging a roll with a packaging film. The type of the packaging film used in the present invention is not particularly limited, and an aluminum-based film, a polyethylene film, a polyester film, a nylon film, or the like can be used. In at least one of the packaging films used, an aluminum-based film is used. Is preferably used. When the roll is formed by packaging the roll with an aluminum-based film, when the roll is stored or transported in the form of the pack of the present invention, the penetration of moisture into the pack is effectively suppressed. can do.

In the packaging body of the present invention, the roll may be packaged with one type of packaging film or with two or more types of packaging film, but both of the characteristics of each packaging film should be provided. Therefore, it is preferable that the film is packaged with two or more types of packaging films. In particular, it is preferable to arrange the packaging film having excellent water vapor barrier properties on the inside and the packaging film having excellent mechanical properties on the outside.

In the case where the package is formed by packaging a roll with an aluminum film, the package is preferably formed by further packaging with a polyethylene film after the roll is packaged with an aluminum film. Aluminum film may cause pinholes to open and water vapor barrier properties to deteriorate, but by placing a polyethylene film on the outside of the aluminum film, pinholes are less likely to open in the aluminum film, resulting in water vapor barrier properties. The decrease is less likely to occur.

As the above-mentioned aluminum film, those having excellent water vapor barrier properties are preferable. For example, aluminum foil and plastic film laminated or aluminum vapor deposition film can be mentioned. Are preferably laminated.

Among the aluminum-based films in which aluminum foil and plastic film are laminated, a multilayer film having a structure in which polyethylene film or stretched polypropylene film is laminated on both sides of aluminum foil has moderate flexibility and pinholes. It is preferable because it is difficult to open. In a multilayer film having a structure in which polyethylene films are laminated on both sides of an aluminum foil, when a polyethylene film layer is disposed on at least one surface of the multilayer film, a roll is wrapped with the packaging film at the time of packaging, and then heat sealing, etc. This method is preferable because the roll can be sealed in a substantially tubular shape by this method, and water intrusion into the package can be more effectively suppressed.

Further, the aluminum film in which the aluminum foil and the plastic film are laminated is preferably a multilayer film having a structure in which the aluminum foil and the nylon film are laminated. Nylon film has high strength and is excellent in scratch resistance. The multilayer film is preferably one in which a nylon film is laminated on one or both sides of an aluminum foil, or one in which a polyethylene film or a stretched polypropylene film is laminated on one or both sides of an aluminum foil.

In the packaging body of the present invention, the number of windings when the roll is wrapped with each packaging film is not particularly limited, and may be single winding, or may be double winding or multiple winding of three or more windings. Good. Here, the single winding, the double winding, and the triple winding or more mean that the packaging film has one layer or two layers in most of the outer peripheral surface of the roll (for example, 50% or more of the area of the outer peripheral surface of the roll). , And 3 or more layers, respectively.

The material and structure of the protective pad used in the present invention are not particularly limited, and conventionally known protective pads can be used. Examples of the material of the protective pad include celluloses such as polystyrene, polyethylene, polypropylene, polyester, polyvinyl chloride and paper, and polyethylene is particularly preferable from the viewpoint of water absorption. Moreover, also about a structure, the protective pad which shows a buffer action, such as a nonwoven fabric, a foam, and those which combined, can be used, and a foam is especially preferable from the point of a buffer effect.

The thickness of the protective pad is preferably 3 mm or more, more preferably 5 mm or more, further preferably 10 mm or more, and particularly preferably 15 mm or more. When the thickness is 3 mm or more, the end face of the roll can be more effectively prevented from being damaged. Although there is no restriction | limiting in particular in the upper limit of the thickness of a protective pad, From the point of handling property, it is preferable that the said thickness is 20 mm or less. In addition, when it is difficult to ensure the thickness with one protective pad, the thickness may be secured as a total thickness by stacking a plurality of protective pads.

The 25% compressive stress of the protective pad is preferably 50 kPa or more, more preferably 70 kPa or more, and further preferably 100 kPa or more. When the 25% compressive stress is 50 kPa or more, damage to the roll end face can be more effectively prevented. Although there is no restriction | limiting in particular in the upper limit of 25% compressive stress of a protective pad, Since a protective function will fall when 25% compressive stress is too large, the said 25% compressive stress is 300 kPa or less, for example.
The 25% compressive stress of the protective pad can be measured according to JIS K7220: 2006.

There is no restriction | limiting in particular in the manufacturing method of the package of this invention, Although you may manufacture with what kind of manufacturing method, Since a roll can be packaged efficiently and smoothly, a foam cushioning material is attached to the both ends of a roll. A method having at least a step, a step of packaging the roll to which the foam cushioning material is attached with a packaging film, and a step of attaching a protective pad from above the packaging film can be preferably employed.

According to the package of the present invention, as described above, it is possible to sufficiently prevent damage to the roll during storage and transportation, and to suppress damage to the roll even when the roll is used in a clean room. it can. Therefore, the present invention includes a roll storage or transport method in which the roll is stored or transported in the form of the package of the present invention described above.

The storage conditions for storing the roll are not particularly limited, but the storage temperature is preferably in the range of −20 to 50 ° C., more preferably in the range of −10 to 40 ° C., More preferably, it is within the range of 5 to 30 ° C. In addition, the storage humidity is preferably 80% RH or less, and more preferably 50% RH or less.

There is no particular limitation on the storage period when the package is stored. For example, it is preferably within a range of 1 day to 1 year, and more preferably within a range of 2 days to 6 months.

Thus, according to the package of the present invention, damage to the roll during storage or transportation can be sufficiently prevented, and damage to the roll can be suppressed even when the roll is used in a clean room. Therefore, cutting when the PVA film is uniaxially stretched can be reduced. Therefore, the PVA film packaged in the form of the package of the present invention can be preferably used as a PVA film for producing an optical film such as a polarizing film that is uniaxially stretched when used.

A method for producing a polarizing film using a PVA film packaged in the form of the package of the present invention as a raw material is not particularly limited, and a conventionally known method can be employed. For example, the present invention After removing the roll by removing the packaging film from the packaging body, the PVA film unwound from the roll is dyed, uniaxially stretched, and further fixed, dried, and heat treated as necessary. A polarizing film can be manufactured by performing etc. In that case, the order of operations such as dyeing, uniaxial stretching, and fixing is not particularly limited. Further, if necessary, one or more of the above-described processes can be performed twice or more.

There is no particular limitation on the take-out method when taking out the roll from the package, but when the roll is used in a clean room, the effect of the present invention is more prominent. Therefore, the protective pad is removed from the package outside the clean room. After removing the packaging film, a method of removing the foam cushioning material in the clean room can be preferably employed. Here, it is preferable to remove the foam cushioning material after setting the roll in a polarizing film manufacturing apparatus such as a stretching machine.

The dyeing process in the production of the polarizing film may be performed at any stage before the uniaxial stretching process, simultaneously with the uniaxial stretching process, or after the uniaxial stretching process. Examples of the dye used for the dyeing treatment include iodine-potassium iodide; direct black 17, 19, 154; direct brown 44, 106, 195, 210, 223; direct red 2, 23, 28, 31, 37, 39, 79. 81, 240, 242, 247;

Direct Blue

1, 15, 22, 78, 90, 98, 151, 168, 202, 236, 249, 270;

Direct Violet

9, 12, 51, 98; Direct Green 1, 85 Direct yellow 8, 12, 44, 86, 87; dichroic dyes such as direct orange 26, 39, 106, 107, etc., which may be used alone or in combination of two or more May be used.
The dyeing treatment is generally performed by immersing the PVA film in a solution containing the dye, but is not limited thereto, for example, a method of applying a dye on the PVA film, for producing a PVA film It is also possible to employ a method in which a dye is added in advance to the film-forming stock solution and a dyed PVA film is directly produced by film formation. There are no particular limitations on the processing conditions and specific processing method during the dyeing process.

The uniaxial stretching treatment may be performed by either a wet stretching method or a dry heat stretching method. Furthermore, the uniaxial stretching treatment may be performed in warm water containing boric acid, may be performed in a solution containing the above-described dye or in a fixing treatment bath described later, or using a PVA film after water absorption. It may be performed in the air or by other methods. The stretching temperature in the uniaxial stretching treatment is not particularly limited, but when the PVA film is stretched in warm water (wet stretching), it is in the range of 30 to 90 ° C, more preferably 40 to 70 ° C, and further preferably 45 to 65 ° C. The temperature within the range is preferably employed, and in the case of dry heat stretching, a temperature within the range of 50 to 180 ° C. is preferably employed. In addition, the stretching ratio of the uniaxial stretching treatment (total stretching ratio when performing uniaxial stretching in multiple stages) is preferably 4 times or more based on the length before stretching, preferably 5 times or more from the viewpoint of polarization performance. More preferably, it is more preferably 5.5 times or more. Although there is no particular upper limit of the draw ratio, it is preferably 8 times or less in order to perform uniform drawing. It is preferable from the viewpoint of productivity that the uniaxial stretching of the PVA film is continuously performed in the length direction (MD) of the long PVA film by using a stretching roll.

The thickness of the uniaxially stretched film (polarizing film) is preferably 3 to 75 μm, particularly 5 to 50 μm, from the viewpoints of polarizing performance, handleability, durability, and the like.

When manufacturing a polarizing film, a fixing process is often performed in order to strengthen the adsorption of the dye to the film. As the fixing treatment, a method of immersing a film (for example, a uniaxially stretched film) in a fixing treatment bath to which boric acid and / or a boron compound is added is generally widely adopted. In that case, you may add an iodine compound in a fixed treatment bath as needed.

The film subjected to uniaxial stretching treatment or uniaxial stretching treatment and fixing treatment may be further subjected to drying treatment and / or heat treatment. The temperature for the drying treatment and / or heat treatment is preferably 30 to 150 ° C., particularly 50 to 140 ° C. If the temperature of the drying treatment and / or the heat treatment is too low, the dimensional stability of the obtained polarizing film tends to be lowered, while if too high, the polarization performance tends to deteriorate due to decomposition of the dye.

A polarizing plate can be produced by attaching optically transparent protective films having mechanical strength to both surfaces or one surface of the polarizing film obtained as described above. As the protective film in that case, a cellulose triacetate (TAC) film, an acetic acid / cellulose butyrate (CAB) film, an acrylic film, a polyester film, or the like can be used. Moreover, as an adhesive for laminating a protective film, a PVA adhesive or a urethane adhesive is generally used, and among them, a PVA adhesive is preferably used.

The polarizing plate obtained as described above can be used as a component of a liquid crystal display device after being coated with an acrylic adhesive or the like and then bonded to a glass substrate. When the polarizing plate is bonded to the glass substrate, a retardation film, a viewing angle improving film, a brightness improving film, or the like may be bonded simultaneously.

Hereinafter, the present invention will be specifically described with reference to examples. However, the present invention is not limited to the following examples.

Example 1
(1) PVA film having a width of 400 cm, a thickness of 75 μm, and a length of 10,000 m (polymerization degree of PVA of 2400, saponification degree of PVA of 99.9 mol%, glycerin of 11 mass%, moisture content of 4.0 mass%) It was wound up on a cylindrical aluminum core having a diameter of 450 cm and a diameter of 6 inches to obtain a roll. At this time, it wound up so that a core might protrude 25 cm from each end surface of a roll. The diameter of the obtained roll was 115 cm. When the end surface and outer peripheral surface of this roll were visually observed, no scratches were observed.

(2) A foamed polyethylene sheet having a thickness of 5 mm cut out in accordance with the shape of the roll end face was attached to each end face of the roll as a foam cushioning material one by one. This foamed polyethylene sheet was of the closed cell type with a foaming ratio of 10 times, the water absorption was 0.01 g / cm ² , and the 25% compressive stress was 130 kPa.
The roll to which the foam cushioning material was attached was packaged with an aluminum film. At this time, it was tightly packed so that air could not enter as much as possible between the roll and the aluminum film, and was wrapped in a single layer. Here, as an aluminum film, a stretched polypropylene film (OPP film) having a thickness of 20 μm, a low density polyethylene film (LDPE film) having a thickness of 15 μm, an aluminum foil having a thickness of 7 μm, and an LDPE film having a thickness of 15 μm are laminated in this order. The OPP film side was set to the inside.
The roll packaged with the aluminum film was further packaged with a polyethylene film having a thickness of 40 μm. At this time, the aluminum film and the polyethylene film were tightly packed so as not to enter air as much as possible, and were packaged in a single layer. Here, a polyethylene film colored in red was used so that it was easy to distinguish when the roll was damaged.
Use packaging film (aluminum-based film and polyethylene film) that has a width sufficiently longer than the length of the aluminum core, and push the remaining part near both ends inside the core when packaging. It is. And after wrapping with a polyethylene film, the packaging film was fixed with the rubber band at the outer peripheral part of the protrusion part from which the core protruded from the end surface of the roll.
Furthermore, 10 mm thick protective pads having a substantially roll end face shape were attached to both ends from the top of the packaging film one by one. This protective pad was obtained by cutting a closed-cell type foamed polyethylene sheet so that the outermost diameter was about 10 mm larger than the shape of the roll end face, and the 25% compression stress was 130 kPa.
As a result of confirming the appearance of the package obtained as described above, no abnormality that was expected to be damaged was found.

(3) The above package was placed on a mount and transported to a warehouse, where it was stored for 3 months. When placing on the gantry, a band was wound around the protruding part of the core, and it was lifted with a hoist and placed on the gantry. When the appearance of the package was checked after placing it on the gantry, no abnormality was found in the roll part. The platform used has a structure that supports only the protruding portion of the core from above and below, and the frame is less likely to come into contact with the roll portion and damage the end face and outer peripheral surface of the roll.
After 3 months of storage, the package was lifted from the mount and transferred to the clean room mount. And the protective pad of the outer side of a packaging film was removed, and the packaging film was removed after that. When the foam cushioning material adhered to the outer peripheral surface of the roll and the end surface of the roll was observed, no damage was observed. Moreover, no wrinkles that absorbed moisture on the surface of the PVA film were observed.

(4) The roll with the foam cushioning material attached to the end face of the roll in close contact with the roll was placed in the clean room together with the clean room mount, and the roll was set in a stretching machine. When the foam cushioning material was removed and the end face of the roll was confirmed, no damage was observed. Moreover, when the degree of cleanliness of the surroundings was measured, it was a class 1000 level, which was the same level as before the roll was brought into the clean room.

(5) When the PVA film (8000 m) unwound from the roll was stretched uniaxially at a stretch ratio of 5 with a stretching machine, no cutting occurred.

Example 2
(1) PVA film having a width of 440 cm, a thickness of 60 μm and a length of 12,500 m (PVA polymerization degree 2400, PVA saponification degree 99.9 mol%, glycerin 11 mass% contained, moisture content 4.0 mass%) A roll was obtained by winding it around a cylindrical iron core of 480 cm and a diameter of 6 inches. At this time, it wound up so that a core might protrude 20 cm from each end surface of a roll. The diameter of the obtained roll was 122 cm. When the end surface and outer peripheral surface of this roll were visually observed, no scratches were observed.

(2) A foamed polyethylene sheet having a thickness of 10 mm cut out in accordance with the shape of the roll end face as a foam cushioning material was attached to both end faces of the roll one by one. This foamed polyethylene sheet was of the closed cell type with an expansion ratio of 20 times, the water absorption was 0.03 g / cm ² , and the 25% compression stress was 60 kPa.
The roll to which the foam cushioning material was attached was packaged with an aluminum film. At this time, it was tightly packed so that air would not enter between the roll and the aluminum-based film as much as possible, and was wrapped in a single layer. Here, as the aluminum-based film, an OPP film having a thickness of 20 μm, an LDPE film having a thickness of 15 μm, an aluminum foil having a thickness of 7 μm, an LDPE film having a thickness of 15 μm, a nylon film (Ny film) having a thickness of 15 μm, and an LDPE film having a thickness of 15 μm. The OPP film side was made inside by using the thing laminated | stacked in order.
The roll packaged with the aluminum film was further packaged with a polyethylene film having a thickness of 40 μm. At this time, the aluminum film and the polyethylene film were double-wrapped so as to be in close contact with each other so that air did not enter as much as possible. Here, a polyethylene film colored in red was used so that it was easy to distinguish when the roll was damaged.
In addition, as the packaging film (aluminum film and polyethylene film), a film having a width sufficiently longer than the length of the iron core was used, and the excess portion near both ends was pushed inside the core during packaging. . And after wrapping with a polyethylene film, the packaging film was fixed with the rubber band at the outer peripheral part of the protrusion part from which the core protruded from the end surface of the roll.
Furthermore, 10 mm thick protective pads having a substantially roll end face shape were attached to both ends from the top of the packaging film one by one. This protective pad was obtained by cutting a closed-cell type foamed polyethylene sheet so that the outermost diameter was about 10 mm larger than the shape of the roll end face, and the 25% compression stress was 130 kPa.
When the external appearance of the package obtained as described above was confirmed, no abnormality that was expected to be damaged was found.

<< Comparative Example 1 >>
(1) PVA film having a width of 400 cm, a thickness of 75 μm, and a length of 10,000 m (polymerization degree of PVA of 2400, saponification degree of PVA of 99.9 mol%, glycerin of 11 mass%, moisture content of 4.0 mass%) It was wound up on a cylindrical aluminum core having a diameter of 450 cm and a diameter of 6 inches to obtain a roll. At this time, it wound up so that a core might protrude 25 cm from each end surface of a roll. The diameter of the obtained roll was 115 cm. When the end surface and outer peripheral surface of this roll were visually observed, no scratches were observed.

(2) The roll was packaged with an aluminum film without attaching a foam cushioning material to both end faces of the roll. At this time, it was tightly packed so that air would not enter between the roll and the aluminum-based film as much as possible, and was wrapped in a single layer. Here, as the aluminum-based film, an OPP film having a thickness of 20 μm, an LDPE film having a thickness of 15 μm, an aluminum foil having a thickness of 7 μm, and an LDPE film having a thickness of 15 μm were laminated in this order, and the OPP film side was set inside.
The roll packaged with the aluminum film was further packaged with a polyethylene film having a thickness of 40 μm. At this time, the aluminum film and the polyethylene film were tightly packed so as not to enter air as much as possible, and were packaged in a single layer. Here, a polyethylene film colored in red was used so that it was easy to distinguish when the roll was damaged.
Use packaging film (aluminum-based film and polyethylene film) that has a width sufficiently longer than the length of the aluminum core, and push the remaining part near both ends into the inside of the core when packaging. It is. And after wrapping with a polyethylene film, the packaging film was fixed with the rubber band at the outer peripheral part of the protrusion part from which the core protruded from the end surface of the roll.
Furthermore, 10 mm thick protective pads having a substantially roll end face shape were attached to both ends from the top of the packaging film one by one. This protective pad was obtained by cutting a closed-cell type foamed polyethylene sheet so that the outermost diameter was about 10 mm larger than the shape of the roll end face, and the 25% compression stress was 130 kPa.
When the external appearance of the package obtained as described above was confirmed, no abnormality that was expected to be damaged was found.

(3) The above package was placed on a mount and transported to a warehouse, where it was stored for 3 months. When placing on the gantry, a band was wound around the protruding part of the core, and it was lifted with a hoist and placed on the gantry. When the appearance of the package was checked after placing it on the gantry, no abnormality was found in the roll part. The platform used has a structure that supports only the protruding portion of the core from above and below, and the frame is less likely to come into contact with the roll portion and damage the end face and outer peripheral surface of the roll.
After 3 months of storage, the package was lifted from the mount and transferred to the clean room mount. And the protective pad of the outer side of a packaging film was removed, and the packaging film was removed after that. When the appearance of the roll was observed, the outer peripheral surface and end surface of the roll were not damaged. Moreover, no wrinkles that absorbed moisture on the surface of the PVA film were observed.

(4) The roll from which the packaging film was removed was placed in a clean room together with the clean room mount, and the roll was set in a stretching machine. When the end surface of this roll was confirmed, the damage was recognized. Moreover, when the degree of cleanliness of the surroundings was measured, it was a class 1000 level, which was the same level as before the roll was brought into the clean room.

(5) When the PVA film (8000 m) unwound from the roll with a stretching machine was uniaxially stretched at a stretch ratio of 5 times, the cutting considered to be caused by scratches on the end face of the roll occurred three times.

<< Comparative Example 2 >>
(1) PVA film having a width of 400 cm, a thickness of 75 μm, and a length of 10,000 m (polymerization degree of PVA of 2400, saponification degree of PVA of 99.9 mol%, glycerin of 11 mass%, moisture content of 4.0 mass%) It was wound up on a cylindrical aluminum core having a diameter of 450 cm and a diameter of 6 inches to obtain a roll. At this time, it wound up so that a core might protrude 25 cm from each end surface of a roll. The diameter of the obtained roll was 115 cm. When the end surface and outer peripheral surface of this roll were visually observed, no scratches were observed.

(2) A foamed polyethylene sheet having a thickness of 5 mm cut out in accordance with the shape of the roll end face was attached one by one to both end faces of the roll as a foam cushioning material. This foamed polyethylene sheet was of the closed cell type with a foaming ratio of 10 times, the water absorption was 0.01 g / cm ² , and the 25% compressive stress was 130 kPa.
The roll to which the foam cushioning material was attached was packaged with an aluminum film. At this time, it was tightly packed so that air would not enter between the roll and the aluminum-based film as much as possible, and was wrapped in a single layer. Here, as the aluminum-based film, an OPP film having a thickness of 20 μm, an LDPE film having a thickness of 15 μm, an aluminum foil having a thickness of 7 μm, and an LDPE film having a thickness of 15 μm were laminated in this order, and the OPP film side was set inside.
The roll packaged with the aluminum film was further packaged with a polyethylene film having a thickness of 40 μm. At this time, the aluminum film and the polyethylene film were tightly packed so as not to enter air as much as possible, and were packaged in a single layer. Here, a polyethylene film colored in red was used so that it was easy to distinguish when the roll was damaged.
Use packaging film (aluminum-based film and polyethylene film) that has a width sufficiently longer than the length of the aluminum core, and push the remaining part near both ends into the inside of the core when packaging. It is. And after wrapping with a polyethylene film, the packaging film was fixed with the rubber band at the outer peripheral part of the protrusion part from which the core protruded from the end surface of the roll.
When the external appearance of the packaging body to which the protective pad was not attached was confirmed as described above, no abnormality that was expected to be damaged was found.

(3) The above package was placed on a mount and transported to a warehouse, where it was stored for 3 months. When placing on the gantry, a band was wound around the protruding part of the core, and it was lifted with a hoist and placed on the gantry. After placing on the mount, the appearance of the package was confirmed. The platform used has a structure that supports only the protruding part of the core from above and below, and the platform is less likely to come into contact with the roll part and damage the end face and outer peripheral surface of the roll. The end face portion of the roll was found to have been hit by a band, and the packaging film was torn.
After 3 months of storage, the package was lifted from the mount and transferred to the clean room mount. And the packaging film was removed. When the foam cushioning material adhered to the outer peripheral surface of the roll and the end surface of the roll was observed, imprints were observed on the foam cushioning material adhered to the end surface of the roll. Moreover, the wrinkles which absorbed moisture were recognized by the PVA film surface of the vicinity of the roll end surface.

(4) The roll with the foam cushioning material attached to the end face of the roll in close contact with the roll was placed in the clean room together with the clean room mount, and the roll was set in a stretching machine. When the foam cushioning material was removed and the end face of the roll was confirmed, scratches were observed. Moreover, when the degree of cleanliness of the surroundings was measured, it was a class 1000 level, which was the same level as before the roll was brought into the clean room.

(5) When the PVA film (8000 m) unwound from the roll with a stretching machine was uniaxially stretched at a stretch ratio of 5 times, the cutting considered to be caused by scratches on the end face of the roll occurred 5 times.

<< Comparative Example 3 >>
(1) PVA film having a width of 400 cm, a thickness of 75 μm, and a length of 10,000 m (polymerization degree of PVA of 2400, saponification degree of PVA of 99.9 mol%, glycerin of 11 mass%, moisture content of 4.0 mass%) A cylindrical aluminum core having a diameter of 450 cm and a diameter of 6 inches was wound up to obtain a roll. At this time, it wound up so that a core might protrude 25 cm from each end surface of a roll. The diameter of the obtained roll was 115 cm. When the end surface and outer peripheral surface of this roll were visually observed, no scratches were observed.

(2) As a non-foaming buffer material, a piece of polyethylene nonwoven fabric sheet having a thickness of 5 mm cut according to the shape of the roll end face was attached to each end face of the roll one by one.
The roll to which the non-foam cushioning material was attached was packaged with an aluminum film. At this time, it was tightly packed so that air would not enter between the roll and the aluminum-based film as much as possible, and was wrapped in a single layer. Here, as the aluminum-based film, an OPP film having a thickness of 20 μm, an LDPE film having a thickness of 15 μm, an aluminum foil having a thickness of 7 μm, and an LDPE film having a thickness of 15 μm were laminated in this order, and the OPP film side was set inside.
The roll packaged with the aluminum film was further packaged with a polyethylene film having a thickness of 40 μm. At this time, the aluminum film and the polyethylene film were tightly packed so as not to enter air as much as possible, and were packaged in a single layer. Here, a polyethylene film colored in red was used so that it was easy to distinguish when the roll was damaged.
Use packaging film (aluminum-based film and polyethylene film) that has a width sufficiently longer than the length of the aluminum core, and push the remaining part near both ends into the inside of the core when packaging. It is. And after wrapping with a polyethylene film, the packaging film was fixed with the rubber band at the outer peripheral part of the protrusion part from which the core protruded from the end surface of the roll.
Furthermore, 10 mm thick protective pads having a substantially roll end face shape were attached to both ends from the top of the packaging film one by one. This protective pad was obtained by cutting a closed-cell type foamed polyethylene sheet so that the outermost diameter was about 10 mm larger than the shape of the roll end face, and the 25% compression stress was 130 kPa.
When the external appearance of the package obtained as described above was confirmed, no abnormality that was expected to be damaged was found.

(3) The above package was placed on a mount and transported to a warehouse, where it was stored for 3 months. When placing on the gantry, a band was wound around the protruding part of the core, and it was lifted with a hoist and placed on the gantry. When the appearance of the package was checked after placing it on the gantry, no abnormality was found in the roll part. The platform used has a structure that supports only the protruding portion of the core from above and below, and the frame is less likely to come into contact with the roll portion and damage the end face and outer peripheral surface of the roll.
After 3 months of storage, the package was lifted from the mount and transferred to the clean room mount. And the protective pad of the outer side of a packaging film was removed, and the packaging film was removed after that. When the non-foamed cushioning material adhered to the outer peripheral surface of the roll and the end surface of the roll was observed, no damage was observed. Moreover, no wrinkles that absorbed moisture on the surface of the PVA film were observed.

(4) The above-mentioned roll with the non-foam cushioning material adhered and attached to the end face of the roll was placed in a clean room together with the clean room mount, and the roll was set in a stretching machine. When the non-foam cushioning material was removed and the end face of the roll was confirmed, no damage was observed. Moreover, when the surrounding cleanliness was measured, it was a class 10000 level, which was a lower level than before the roll was brought into the clean room, which was a problem. Presumably, dust or the like was generated from the non-foamed cushioning material (polyethylene non-woven sheet).

The above results are summarized in Table 1.

1 cylindrical core, 2 PVA film, 3 outer peripheral surface of roll, 4a packaging film, 4b packaging film, 5 end of packaging, 6 roll end surface, 7 foam cushioning material, 8 rubber band, 9 protective pad, 11 Roll, 12 cylindrical core, 13 PVA film, 14 roll end face, 15 roll outer peripheral face, 16 core end.

Claims

A packaging body in which a roll formed by winding a polyvinyl alcohol film is wrapped with a packaging film, the foam cushioning material, the packaging film, and a protective pad at both ends of the packaging body from the inside to the outside of the packaging body A package having a structure arranged in this order.
The package according to claim 1, wherein the foam cushioning material is formed of closed-cell foamed plastic.
The package according to claim 1 or 2, wherein the foam cushioning material is formed of foamed polyethylene.
The package according to any one of claims 1 to 3, wherein the foam cushioning material has a thickness of 2 mm or more.
The package according to any one of claims 1 to 4, wherein the foam cushioning material has a water absorption of 0.05 g / cm 2 or less.
The package according to any one of claims 1 to 5, wherein the roll is packaged with an aluminum film.
7. The package according to claim 6, wherein the roll is packaged with an aluminum-based film and then further wrapped with a polyethylene film.
The package according to claim 6 or 7, wherein the aluminum-based film is a multilayer film having a structure in which a polyethylene film or a stretched polypropylene film is laminated on both surfaces of an aluminum foil.
The package according to any one of claims 6 to 8, wherein the aluminum film is a multilayer film having a structure in which an aluminum foil and a nylon film are laminated.
The package according to any one of claims 1 to 9, wherein the 25% compressive stress of the protective pad is 50 kPa or more.
A method for producing a package according to any one of claims 1 to 10, wherein a step of attaching a foam cushioning material to both ends of the roll, a step of packaging the roll having the foam cushioning material attached thereto with a packaging film, And a manufacturing method comprising attaching a protective pad from above the packaging film.
A method for storing or transporting a roll, wherein the roll is stored or transported in the form of a package according to any one of claims 1 to 10.