Roll body and roll body manufacturing method

Abstract

The invention relates to a roll and a roll manufacturing method. A roll (1) is provided with: a winding core (2); a long first film (10) wound around the winding core (2); and a joining member (3) that joins one end of the first film (10) in the longitudinal direction to the winding core (2). The joining member (3) is disposed between the winding core (2) and one end of the first film (10) in the longitudinal direction in the thickness direction of the first film (10). Furthermore, in the radial direction of the winding body (1), the distance from the outer peripheral surface of the winding core (2) to the radial inner side surface of one end of the first film (10) in the longitudinal direction is the shortest in at least one end in the width direction with respect to the distance in the entire region in the width direction.

Description

TECHNICAL FIELD

[0001] The present application relates to a roll and a method for manufacturing a roll. BACKGROUND

[0002] Conventionally, a roll in which a long sheet such as a film is wound around a core is known. In the case of manufacturing such a roll, first, with respect to the sheet, an end portion (winding start end portion) of the sheet is fixed to an outer peripheral surface of the core using a fixing member such as a double-sided tape. However, if the sheet is fixed to the outer peripheral surface of the core using the fixing member, sometimes, a step is generated due to the thickness of the sheet and the thickness of the fixing member, and when the roll is manufactured in this state, a step trace is generated.

[0003] In order to suppress such a step trace, it is proposed to fill in the step due to the thickness of the sheet and the thickness of the fixing member (for example, refer to Patent Literature 1).

[0004] PRIOR ART DOCUMENTS

[0005] PATENT LITERATURE

[0006] Patent Literature 1: Japanese Patent Application Laid-Open No. 2021-107286

[0007] However, in the roll described in Patent Literature 1, a step trace due to deformation of the sheet caused by heating cannot be suppressed. Specifically, in the manufacturing process, when the sheet is heated, the sheet stretched by the heating shrinks over time after being wound. Due to this shrinkage, a difference in stress in the radial direction of the roll occurs in the width direction of the roll, and thus sometimes, a step trace is generated. SUMMARY

[0008] The present application provides a roll and a method for manufacturing a roll in which a step trace can be reduced.

[0009] The present application [1] includes a roll including: a core; a long first film wound around the core; and a joining member joining one end portion of the first film in a long dimension direction to the core, the joining member being disposed between the core and the one end portion in a thickness direction of the first film, and in a radial direction of the roll, a distance from an outer peripheral surface of the core to a radial inner side surface up to the one end portion is shortest at an end portion of at least one of a width direction orthogonal to both the long dimension direction and the thickness direction, with respect to the distance in the entire region of the width direction.

[0010] The present application [2] includes a roll body which is a roll body in which a film is wound, the film including: a first film which is a long strip; a second film which is a long strip; and a joining member which joins one end portion in a long dimension direction of the first film and the other end portion in the long dimension direction of the second film, in the roll body, the first film is positioned on the radially outer side of the roll body, the second film is positioned on the radially inner side of the roll body, and the joining member is positioned between the one end portion and the other end portion in the thickness direction of the first film, and in the radial direction of the roll body, the distance from the radially outer side surface of the other end portion to the radially inner side surface of the one end portion is shortest at the end portion of at least one of the width directions orthogonal to the two directions of the long dimension direction and the thickness direction, among the distance in the entire region of the width direction.

[0011] The present application [3] includes the roll body described in the above [1] or [2], in which the joining member is further positioned in the entire region of the width direction of the one end portion, and the thickness of the joining member at the end portion of at least one of the width directions of the one end portion is thinner than the thickness of the joining member at the central portion of the width direction of the one end portion.

[0012] The present application [4] includes the roll body described in the above [3], in which the thickness of the joining member at both end portions of the width direction of the one end portion is thinner than the thickness of the joining member at the central portion of the width direction of the one end portion.

[0013] The present application [5] includes the roll body described in the above [1] or [2], in which the joining member is not positioned at the end portion of at least one of the width directions of the one end portion.

[0014] The present application [6] includes the roll body described in the above [5], in which the joining member is not positioned at both end portions of the width direction of the one end portion.

[0015] The present application [7] includes a roll body manufacturing method which is a method of manufacturing the roll body described in the above [1] or [2], the roll body manufacturing method including a process of winding a working film including at least the first film in a vacuum atmosphere.

[0016] The present application [8] includes the roll body manufacturing method described in the above [7], further including a process of heating the working film.

[0017] Effects of Invention

[0018] In the roll of the present application, in the radial direction of the roll, the distance from the outer circumferential surface of the core to the radial inner side surface of the one end portion of the first film in the longitudinal direction is shortest at the end portion of at least one of the width direction, relative to the distance in the entire region of the width direction. Thus, the unevenness in height can be reduced.

[0019] Further, in the roll of the present application, in the radial direction of the roll, the distance from the outer circumferential surface of the core to the radial inner side surface of the one end portion of the first film in the longitudinal direction is shortest at the end portion of at least one of the width direction, relative to the distance in the entire region of the width direction. Thus, the unevenness in height can be reduced.

[0020] Further, the manufacturing method of the roll of the present application is a method of manufacturing the above-described roll, and includes a step of winding a work film including at least a first film in a vacuum atmosphere. Thus, even in a vacuum atmosphere, a roll having reduced unevenness in height can be manufactured. BRIEF DESCRIPTION OF DRAWINGS

[0021] Figure 1 is a cross-sectional view along the radial direction of the joint portion of the core and the first film in the first embodiment of the roll of the present application.

[0022] Figure 2 is a cross-sectional view along the width direction of the joint portion of the core and the first film in the first embodiment of the roll shown in Figure 1

[0023] Figure 3 is a cross-sectional view along the radial direction of the joint portion of the first film and the second film in the second embodiment of the roll of the present application.

[0024] Figure 4 is a cross-sectional view along the width direction of the joint portion of the first film and the second film in the second embodiment of the roll shown in Figure 3

[0025] Figure 5 is a schematic view of one embodiment of a roll manufacturing apparatus used in the manufacturing method of the roll of the present application.

[0026] Figure 6 is a cross-sectional view along the width direction of the joint portion of the core and the first film in the first modification of the roll of the present application.

[0027] Figure 7 is a cross-sectional view along the width direction of the joint portion of the core and the first film in the second modification of the roll of the present application.

[0028] Figure 8 ​​is a sectional view along the width direction of the joint portion of the winding core and the first film in the third modification of the roll body of the present application.

[0029] Figure 9 is a sectional view along the width direction of the joint portion of the winding core and the first film in the fourth modification of the roll body of the present application.

[0030] Explanation of Reference Signs

[0031] 1: roll body; 2: winding core; 3: joint member; 10: first film; 20: second film. DETAILED DESCRIPTION

[0032] 1. Roll body

[0033] (First Embodiment)

[0034] Reference Figure 1 and Figure 2 , a first embodiment of the roll body 1 of the present application will be described.

[0035] The roll body 1 is provided with: a winding core 2; and a long first film 10 wound around the winding core 2. The first film 10 is wound around the winding core 2 by a plurality of turns.

[0036] The shape of the winding core 2 is not particularly limited. From the viewpoint of being able to easily wind the first film 10, the shape of the winding core 2 can be exemplified by, for example, a cylindrical shape and a circular cylindrical shape. A cylindrical shape is preferable.

[0037] The material of the winding core 2 is not particularly limited. As the material of the winding core 2, for example, a high molecular material, a paper material, and a metal material can be exemplified. A metal material is preferable.

[0038] As the high molecular material of the winding core 2, for example, acrylonitrile-butadiene-styrene copolymer (ABS), polyethylene, polypropylene, polyvinyl chloride, polystyrene, ethylene-propylene copolymer, and ethylene-vinyl acetate copolymer can be exemplified.

[0039] As the metal material of the winding core 2, for example, iron, stainless steel, and aluminum can be exemplified. Aluminum is preferable.

[0040] The diameter of the winding core 2 is not particularly limited. As the diameter of the winding core 2, for example, 5 cm or more, preferably 10 cm or more, and furthermore, for example, 100 cm or less, preferably 50 cm or less. Note that the diameter of the winding core 2 refers to the average diameter of the winding core 2 in the width direction. Furthermore, it refers to the outer diameter in the case where the winding core 2 is a circular cylindrical shape.

[0041] In the first embodiment, as shown in Figure 2 , the diameter of the winding core 2 is substantially the same in the entire region in the width direction orthogonal to the radial direction.

[0042] The length in the width direction of the roll core 2 is not particularly limited as long as it is equal to or greater than the length in the width direction of the first film 10 described later. The length in the width direction of the roll core 2 is, for example, 300 mm or more, preferably 500 mm or more, and, on the other hand, for example, 10,000 mm or less, preferably 8,000 mm or less. Note that the length in the width direction of the roll core 2 refers to the average length in the width direction of the roll core 2.

[0043] The first film 10 has a shape that extends in a planar direction orthogonal to a thickness direction. The first film 10 is a film that is long in a long dimension direction and short in a width direction orthogonal to the long dimension direction in the planar direction. That is, the width direction is orthogonal to the two directions of the long dimension direction and the thickness direction.

[0044] As the first film 10, for example, a base film can be cited.

[0045] As the base film, for example, a resin film and a functional layer are provided.

[0046] The resin film supports the first film 10. The resin film has a film shape (including a sheet shape). The resin film has flexibility.

[0047] As the material of the resin film, for example, a cellulose resin, a polyester resin, a (meth)acrylic resin (an acrylic resin and / or a methacrylic resin), an olefin resin, a polycarbonate resin, a polyether sulfone resin, a polyarylate resin, a melamine resin, a polyamide resin, a polyimide resin, a polystyrene resin, a norbornene resin, and a polyvinyl alcohol resin can be cited. As the polyester resin, for example, polyethylene terephthalate (PET), polybutylene terephthalate, and polyethylene naphthalate can be cited. As the polyolefin resin, for example, polyethylene, polypropylene, and a cyclic olefin polymer (COP) can be cited. As the cellulose resin, for example, triacetyl cellulose (TAC) can be cited. The material of the resin film can be used alone or in combination with two or more.

[0048] From the viewpoints of transparency, heat resistance, mechanical strength, and the like, the resin film is preferably a polyolefin resin film formed of a polyolefin resin. More preferably, a COP film can be cited.

[0049] The thickness of the resin film is not particularly limited, and from the viewpoints of strength and workability, for example, 10 μm or more, preferably 30 μm or more, more preferably 50 μm or more, and, on the other hand, for example, 500 μm or less, preferably 300 μm or less, more preferably 200 μm or less. Note that the thickness of the resin film can be measured, for example, using a film thickness gauge.

[0050] The functional layer improves mechanical properties and optical properties. The functional layer can be provided on only one side in the thickness direction of the resin film, or can be provided on both sides in the thickness direction. The functional layer is preferably provided on the other side in the thickness direction of the resin film.

[0051] There is no particular limitation on the functional layer. As the functional layer, for example, a hard coat layer, an optical adjustment layer, and an anti-blocking layer can be cited. The hard coat layer, for example, makes the exposed surface of the resin film less likely to be scratched. The optical adjustment layer, for example, adjusts the optical properties (e.g., refractive index) of the layered film. The anti-blocking layer, for example, imparts anti-blocking properties to the respective surfaces of a plurality of layered films that contact each other in the case where the layered films are layered in the thickness direction, and the like.

[0052] The functional layer can be composed of a single layer or can be composed of multiple layers. It is preferable that the functional layer be composed of multiple layers. Furthermore, in the case where the functional layer is composed of multiple layers, it can be composed of multiple layers having different functions. The functional layer preferably has, in order toward the other side in the thickness direction, a hard coat layer and an optical adjustment layer.

[0053] The functional layer is, for example, a cured product of a curable resin composition. That is, the functional layer is a cured resin layer. Specifically, the functional layer can be formed by applying a curable resin composition on one side or both sides in the thickness direction of the resin film, drying as necessary, and then curing. The functional layer can contain particles as necessary.

[0054] The curable resin composition contains a curable resin. As the curable resin, for example, a polyester resin, an acrylic urethane resin, an acrylic resin (excluding the acrylic urethane resin), a urethane resin (excluding the acrylic urethane resin), an amide resin, a silicone resin, an epoxy resin, and a melamine resin can be cited. It is preferable that an acrylic urethane resin be cited. The curable resin can be used alone or in combination with two or more kinds.

[0055] Furthermore, as the curable resin composition, for example, an ultraviolet curing type resin composition and a thermal curing type resin composition can be cited. From the viewpoint of manufacturing efficiency, it is preferable to use an ultraviolet curing type resin composition as the curable resin composition. As a specific example of the ultraviolet curing type resin composition, the ultraviolet absorbing resin composition described in Japanese Patent Application Publication No. 2020-066153 can be cited.

[0056] From the viewpoint of adjustment of the hardness, adjustment of the surface roughness, adjustment of the refractive index, and imparting of the anti-glare property in the functional layer, the curable resin composition preferably contains particles. As the particles, for example, organic particles and inorganic particles can be cited. It is preferable that organic particles be cited.

[0057] As the organic particles, for example, acrylic resin particles, urethane resin particles, melamine resin particles, polystyrene resin particles, acrylic / styrene copolymer resin particles, and polycarbonate resin particles can be exemplified. Preferably, acrylic resin particles can be exemplified.

[0058] As the inorganic particles, for example, inorganic oxide particles such as silicon dioxide, aluminum oxide, titanium oxide, zirconium oxide, calcium oxide, tin oxide, indium oxide, cadmium oxide, and antimony oxide; and inorganic carbonate particles such as calcium carbonate can be exemplified. Preferably, inorganic oxide particles can be exemplified. More preferably, zirconium oxide particles can be exemplified.

[0059] The average particle diameter of the particles is, for example, 0.1 μm or more, preferably 0.5 μm or more, and more preferably 1.0 μm or more, and, on the other hand, for example, 5.0 μm or less, preferably 4.0 μm or less, and more preferably 3.0 μm or less.

[0060] In the curable resin composition, the blending amount of the particles is, for example, 0.01 parts by mass or more, and preferably 0.10 parts by mass or more, with respect to 100 parts by mass of the curable resin (solid content), and, on the other hand, for example, 5 parts by mass or less, and preferably 3 parts by mass or less.

[0061] The curable resin composition can contain, for example, a photopolymerization initiator, a solvent, a leveling agent, a thixotropic agent, an antistatic agent, and the like. In addition, the curable resin composition can contain the durability-improving additive described in Japanese Patent Application Publication No. 2020-066153.

[0062] The thickness (total thickness) of the functional layer is, for example, 0.1 μm or more, preferably 0.5 μm or more, and more preferably 1 μm or more, and, on the other hand, for example, 10 μm or less, preferably 5 μm or less, and more preferably 3 μm or less.

[0063] The length in the width direction of the base film is not particularly limited as long as it is equal to or less than the length in the width direction of the core 2. The length in the width direction of the base film is, for example, 300 mm or more, and preferably 500 mm or more, and, on the other hand, for example, 4000 mm or less, and preferably 3000 mm or less. Note that the length in the width direction of the base film is the length W in the width direction of the first film 10. That is, the length W in the width direction of the first film 10 is equal to or less than the length in the width direction of the core 2.

[0064] The thickness of the base film is, for example, 10 μm or more, preferably 30 μm or more, and more preferably 50 μm or more, and, on the other hand, for example, 500 μm or less, preferably 300 μm or less, and more preferably 200 μm or less.

[0065] In addition, as the first film 10, a laminated film in which an inorganic layer is laminated on one side or both sides in the thickness direction of the base film can be used.

[0066] The inorganic layer is preferably provided on the side of the base film (functional layer) opposite the side on which the functional layer is provided.

[0067] The material of the inorganic layer can be, for example, a metal, a metal oxide, or a metal nitride.

[0068] As the metal, for example, nickel, chromium, indium, aluminum, tin, gold, silver, copper, platinum, zinc, titanium, tungsten, zirconium, palladium, and an alloy of two or more of these metals can be given. Copper is preferable.

[0069] As the metal oxide, for example, an indium-containing conductive oxide, an antimony-containing conductive oxide, and a zinc-containing conductive oxide can be given. An indium-containing conductive oxide is preferable.

[0070] As the indium-containing conductive oxide, for example, indium tin composite oxide (ITO), indium zinc composite oxide (IZO), indium gallium composite oxide (IGO), and indium gallium zinc composite oxide (IGZO) can be given. ITO is preferable. As the antimony-containing conductive oxide, for example, antimony tin composite oxide (ATO) can be given. As the zinc-containing conductive oxide, for example, zinc aluminum composite oxide (AZO) can be given.

[0071] As the metal nitride, for example, aluminum nitride, titanium nitride, tantalum nitride, chromium nitride, gallium nitride, and a composite nitride thereof can be given.

[0072] The inorganic layer can be composed of a single layer or a plurality of layers.

[0073] The thickness (total thickness) of the inorganic layer is, for example, 10 nm or more, preferably 30 nm or more, and, on the other hand, for example, 300 nm or less, preferably 200 nm or less.

[0074] The thickness of the laminated film is, for example, 10 μm or more, preferably 30 μm or more, and more preferably 50 μm or more, and, on the other hand, for example, 500 μm or less, preferably 300 μm or less, and more preferably 200 μm or less.

[0075] In the roll 1, one end portion of the first film 10 in the long dimension direction is joined to the core 2. More specifically, one end portion of the first film 10 in the long dimension direction is joined to the core 2 in such a manner that the central portion in the width direction of the first film 10 and the central portion in the width direction of the core 2 substantially coincide. Further, the joining is performed in such a manner that the width direction of the core 2 and the width direction of the first film 10 are substantially parallel.

[0076] The roll 1 has a joining member 3 between the core 2 and one end portion of the first film 10 in the long dimension direction. The joining member 3 joins the core 2 and one end portion of the first film 10 in the long dimension direction.

[0077] As for the joining member 3, there are no particular limitations as long as it can join the core 2 to the first film 10. Examples of joining members 3 include adhesives and double-sided tape. Double-sided tape is preferred.

[0078] As for the adhesive, there are no particular limitations as long as it is an adhesive commonly used to bond the core 2 to the first film 10 or to the first film 10 and the second film 20. Furthermore, there are no particular limitations as for the double-sided tape, as long as it is a double-sided tape commonly used to bond the core 2 to the first film 10 or to the first film 10 and the second film 20.

[0079] The connecting component 3 can be used alone or in combination with two or more.

[0080] The joining member 3 is configured, for example, such that, in a cross-section along the longitudinal direction, one end of the joining member 3 in the longitudinal direction does not protrude relative to one end of the first membrane 10 in the longitudinal direction. Preferably, it is configured such that, in a cross-section along the longitudinal direction, one end face of the first membrane 10 in the longitudinal direction and one end face of the joining member 3 in the longitudinal direction are substantially in the same plane.

[0081] like Figure 2 As shown, in the first embodiment, the joining member 3 is disposed over the entire width direction of the first membrane 10. Furthermore, the joining member 3 is configured, for example, such that in a cross-section along the longitudinal direction, both ends of the joining member 3 in the width direction do not protrude relative to both ends of the first membrane 10 in the width direction. Preferably, it is configured such that in a cross-section along the longitudinal direction, one end face of the first membrane 10 in the width direction is substantially coplanar with one end face of the joining member 3 in the width direction, and the other end face of the first membrane 10 in the width direction is substantially coplanar with the other end face of the joining member 3 in the width direction.

[0082] In the first embodiment, the joining member 3 is joined using two or more double-sided tapes of different thicknesses. Specifically, two first double-sided tapes 31 are disposed in certain areas covering both ends in the width direction, and one second double-sided tape 32 is disposed in a certain area covering the central portion in the width direction.

[0083] In the first embodiment, two pieces of the first double-sided tape 31 are attached to one end portion in the width direction and the other end portion in the width direction of the first film 10, respectively. The two pieces of the first double-sided tape 31 after the attachment are spaced apart from each other in the width direction in a manner so as to avoid the central portion in the width direction of the first film 10. The one end portion in the width direction of the first double-sided tape 31 attached to the one end portion in the width direction of the first film 10 is substantially identical to the one end portion in the width direction of the first film 10, and the other end portion in the width direction of the first double-sided tape 31 attached to the other end portion in the width direction of the first film 10 is substantially identical to the other end portion in the width direction of the first film 10. Further, the central portion in the width direction of the second double-sided tape 32 is configured to be substantially identical to the central portion in the width direction of the first film 10. Furthermore, the other end portion in the width direction of the first double-sided tape attached to the one end portion in the width direction of the first film 10 contacts the one end portion in the width direction of the second double-sided tape 32 in a non-overlapping manner, and the one end portion in the width direction of the first double-sided tape 31 attached to the other end portion in the width direction of the first film 10 contacts the other end portion in the width direction of the second double-sided tape 32 in a non-overlapping manner.

[0084] The thickness 31 of the first double-sided tape is, for example, greater than 0 μm, preferably 1 μm or greater, more preferably 2 μm or greater, and, for example, less than 10 μm, preferably 8 μm or less.

[0085] The thickness 32 of the second double-sided tape is, for example, 10 μm or greater, preferably 15 μm or greater, more preferably 20 μm or greater, and, for example, 100 μm or less, preferably 80 μm or less, more preferably 50 μm or less.

[0086] The thickness 31 of the first double-sided tape is preferably thinner than the thickness of the second double-sided tape 32. That is, the thickness of the two end portions in the width direction of the joining member 3 is thinner than the thickness of the central portion in the width direction of the joining member 3.

[0087] If the thickness of the two end portions in the width direction of the joining member 3 is thinner than the thickness of the central portion in the width direction of the joining member 3, the unevenness mark of the roll 1 can be suppressed.

[0088] The range of the certain region including the central portion in the width direction and the certain regions including the two end portions in the width direction, respectively, is not particularly limited and can be appropriately set based on the stress applied to the roll 1 in the radial direction.

[0089] Specifically, in the first embodiment, the certain region including both end portions in the width direction is, for example, a region in which a range from one end portion in the width direction to a position 1 / 6 of W inward from the one end portion in the width direction and a range from the other end portion in the width direction to a position 1 / 6 of W inward from the other end portion in the width direction are combined. For example, in a case where the length W in the width direction of the first film 10 is 1500 mm, the certain region including both end portions in the width direction is a region in which a range from the one end portion in the width direction to a position 250 mm inward from the one end portion in the width direction (a range of 0 mm to 250 mm in a case where the one end portion in the width direction is set to a position of 0 mm and the other end portion in the width direction is set to a position of 1500 mm) and a range from the other end portion in the width direction to a position 250 mm inward from the other end portion in the width direction (a range of 1250 mm to 1500 mm in a case where the one end portion in the width direction is set to a position of 0 mm and the other end portion in the width direction is set to a position of 1500 mm) are combined.

[0090] Further, in the first embodiment, the certain region including the central portion in the width direction is a region of a range from a position 1 / 6 of W inward from the one end portion in the width direction to a position 1 / 6 of W inward from the other end portion in the width direction, other than the certain regions including both end portions in the width direction described above. For example, in a case where the length W in the width direction of the first film 10 is 1500 mm, the certain region including the central portion in the width direction is a region of a range from a position 250 mm inward from the one end portion in the width direction to a position 250 mm inward from the other end portion in the width direction (a range of 250 mm to 1250 mm in a case where the one end portion in the width direction is set to a position of 0 mm and the other end portion in the width direction is set to a position of 1500 mm).

[0091] Note that, in the joining of the winding core 2 and the one end portion of the first film 10 in the longitudinal direction, in a case where the joining member 3 having a constant thickness is used in the entire region in the width direction, depending on the manufacturing process of the roll, the shape of the winding core 2, and the like, a difference in stress in the radial direction of the roll 1 occurs in the width direction at the one end portion of the first film 10. Specifically, in a case where the winding core 2 having a diameter that is substantially constant in the entire region in the width direction is joined to the one end portion of the first film 10 in the longitudinal direction using the joining member 3 having a constant thickness in the entire region in the width direction, in a case where the first film 10 is heated by heat due to sputtering or the like in the manufacturing process of the roll, the first film 10 that is stretched by heating after winding shrinks (becomes a heat-shrunk state), and thus the stress in the radial direction of the roll 1 tends to increase from the central portion in the width direction to the both end portions in the width direction at the one end portion of the first film 10. That is, in a case where the winding core 2 having a diameter that is substantially constant in the entire region in the width direction is joined to the one end portion of the first film 10 in the longitudinal direction using the joining member 3 having a constant thickness in the entire region in the width direction, and the first film becomes a heat-shrunk state after winding, the stress in the radial direction of the roll 1 is the smallest at the central portion in the width direction and is the largest at the both end portions in the width direction at the one end portion of the first film 10. Thus, a step mark can sometimes occur due to the difference in stress in the width direction at the one end portion of the first film 10 in the longitudinal direction.

[0092] The length in the longitudinal direction of the joining member 3 is not particularly limited as long as it has a length sufficient to join the winding core 2 and the first film 10. The length in the longitudinal direction of the joining member 3 is, for example, 10 mm or more, preferably 30 mm or more, and, for example, 500 mm or less, preferably 300 mm or less.

[0093] The length in the width direction (total length) of the joining member 3 is not particularly limited as long as it has a length sufficient to join the winding core 2 and the first film 10.

[0094] Further, in the radial direction of the roll 1, the distance T from the outer circumferential surface of the winding core 2 to the radially inner surface of the one end portion of the first film 10 in the longitudinal direction is set. At this time, the distance T1 at the end portion of at least one side in the width direction at the one end portion of the first film 10 in the longitudinal direction is the shortest with respect to the distance T in the entire region in the width direction. When the portion having the shortest distance T1 with respect to the distance T in the entire region in the width direction is set as the shortest portion at the one end portion of the first film 10 in the longitudinal direction, the end portion of at least one side in the width direction is the shortest portion at the one end portion of the first film 10 in the longitudinal direction.

[0095] If the distance T1 at the end portion of at least one of the width directions at the one end portion of the first film 10 in the longitudinal direction is the shortest with respect to the distance T in the entire region in the width direction, the unevenness trace of the roll 1 can be suppressed.

[0096] In the first embodiment, the distance T1 in a certain region including both end portions in the width direction at the one end portion of the first film 10 in the longitudinal direction is the shortest with respect to the distance T in the entire region in the width direction. That is, the certain region including both end portions in the width direction at the one end portion of the first film 10 in the longitudinal direction is the shortest portion. Further, the distance T2 in a certain region including the central portion in the width direction at the one end portion of the first film 10 in the longitudinal direction is the longest with respect to the distance T in the entire region in the width direction. That is, when the portion having the longest distance T2 with respect to the distance T in the entire region in the width direction is set as the longest portion at the one end portion of the first film 10 in the longitudinal direction, the certain region including the central portion in the width direction at the one end portion of the first film 10 in the longitudinal direction is the longest portion.

[0097] The distance T1 at the shortest portion (the end portion of at least one of the width directions at the one end portion of the first film 10 in the longitudinal direction) is, for example, 0 μm or more, and further, for example, less than 10 μm, preferably 8 μm or less.

[0098] The distance T2 at the longest portion at the one end portion of the first film 10 in the longitudinal direction is, for example, 10 μm or more, preferably 15 μm or more, more preferably 20 μm or more, and further, for example, 100 μm or less, preferably 80 μm or less, more preferably 50 μm or less.

[0099] The ratio (T1 / T2) of the distance T1 at the shortest portion at the one end portion of the first film 10 in the longitudinal direction with respect to the distance T2 at the longest portion at the one end portion of the first film 10 in the longitudinal direction is, for example, 0 or more, and further, for example, less than 1, preferably 0.8 or less, more preferably 0.5 or less, further preferably 0.3 or less.

[0100] [Effects]

[0101] In the roll 1 of the first embodiment of the present application, in the radial direction of the roll 1, the distance T1 at the end portion of at least one of the width directions is the shortest with respect to the distance T in the entire region in the width direction as the distance T from the outer peripheral surface of the core 2 to the radially inner side surface of the one end portion of the first film 10 in the longitudinal direction. Therefore, the unevenness trace can be reduced.

[0102] Specifically, in the case of forming the roll 1, when the first film 10 is heated, the first film 10 stretched by the heating shrinks after being wound on the core 2. At this time, the both end portions in the width direction of the first film 10 are more affected than the central portion in the width direction, and further shrink. In this way, in the joining of the core 2 and the one end portion in the long dimension direction of the first film 10, in the case where the manufacturing process of the roll includes the process of heating the first film 10, the stress in the radial direction of the roll 1 increases from the central portion in the width direction toward the both end portions in the width direction at the one end portion in the long dimension direction of the first film 10. However, the thickness of the first double-sided tape 31 attached to the both end portions in the width direction is thinner than the thickness of the second double-sided tape 32 attached to the central portion in the width direction. In other words, in the radial direction of the roll 1, the distance T1 at the at least one end portion in the width direction is the shortest with respect to the distance T in the entire region in the width direction, as the distance from the outer peripheral surface of the core 2 to the inner radial surface up to the one end portion in the long dimension direction of the first film 10. Therefore, the stress in the radial direction of the roll 1 can be mitigated in correspondence with the difference in the thickness (distance). As a result, the unevenness trace can be reduced.

[0103] (Second Embodiment)

[0104] Reference Figure 3 and Figure 4 The second embodiment of the roll of the present application will be described.

[0105] In the second embodiment, the same reference numerals are assigned to the same members as those of the first embodiment of the roll 1, and detailed description thereof will be omitted. Furthermore, the second embodiment can be appropriately combined with the first embodiment of the roll 1 and the modified example described later.

[0106] As shown in Figure 3 , a film is wound on the roll 1, the film including: the long first film 10; and the long second film 20 joined to the one end portion in the long dimension direction of the first film 10. In addition, in the roll 1, the first film 10 is disposed on the outer side in the radial direction of the roll 1, and the second film 20 is disposed on the inner side in the radial direction of the roll 1. More specifically, in the roll 1, the second film 20 is wound on the core 2 first, and then the first film 10 is wound.

[0107] The first film 10 can be the same film as the first film 10 described in the first embodiment of the roll 1. The description of the first film 10 in the second embodiment is the same as the description of the first film 10 described in the first embodiment of the roll 1.

[0108] The second film 20 can be exemplified by the same film as the first film 10 described in the first embodiment of the roll 1. The description of the second film 20 in the second embodiment is the same as the description of the first film 10 described in the first embodiment of the roll 1.

[0109] In the second embodiment, the first film 10 and the second film 20 can be the same or different. It is preferable that the first film 10 and the second film 20 are the same.

[0110] In the roll 1, one end portion of the first film 10 in the long dimension direction is joined to the second film 20. More specifically, one end portion of the first film 10 in the long dimension direction is joined to the other end portion of the second film 20 in the long dimension direction in such a manner that the central portion in the width direction of the first film 10 and the central portion in the width direction of the second film 20 are substantially coincident. Further, the joining is performed in such a manner that the width direction of the first film 10 and the width direction of the second film 20 are substantially parallel.

[0111] The roll 1 has the joining member 3 between one end portion of the first film 10 in the long dimension direction and the other end portion of the second film 20 in the long dimension direction. The joining member 3 joins one end portion of the first film 10 in the long dimension direction and the other end portion of the second film 20 in the long dimension direction.

[0112] As the joining member 3 of the second embodiment, the same joining member as the joining member 3 described in the first embodiment of the roll 1 can be exemplified. The description of the joining member 3 in the second embodiment is the same as the description of the joining member 3 described in the first embodiment of the roll 1.

[0113] The joining member 3 is configured, for example, such that one end portion of the joining member 3 in the long dimension direction does not protrude with respect to one end portion of the first film 10 in the long dimension direction in a cross section along the long dimension direction. It is preferable that the joining member 3 is configured such that one end surface of the first film 10 in the long dimension direction and one end surface of the joining member 3 are in substantially the same plane in a cross section along the long dimension direction.

[0114] Further, the joining member 3 is configured, for example, such that the other end portion of the joining member 3 in the long dimension direction does not protrude with respect to the other end portion of the second film 20 in the long dimension direction in a cross section along the long dimension direction. It is preferable that the joining member 3 is configured such that the other end surface of the second film 20 in the long dimension direction and the other end surface of the joining member 3 are in substantially the same plane in a cross section along the long dimension direction.

[0115] As Figure 4In the second embodiment, the joining member 3 is disposed over the entire region in the width direction of the first film 10. Further, the joining member 3 is configured so that, in a cross section along the long dimension direction, the both end portions in the width direction of the joining member 3 do not protrude with respect to the both end portions in the width direction of the first film 10. It is preferable to be configured so that, in a cross section along the long dimension direction, one end surface in the width direction of the first film 10 and one end surface in the width direction of the joining member 3 are in substantially the same plane, and the other end surface in the width direction of the first film 10 and the other end surface in the width direction of the joining member 3 are in substantially the same plane.

[0116] Further, in the second embodiment, the joining member 3 uses two or more double-sided tapes having different thicknesses in combination. Specifically, two pieces of the first double-sided tape 31 disposed in regions including both end portions in the width direction, and one piece of the second double-sided tape 32 disposed in a region including a central portion in the width direction are used in combination.

[0117] In the second embodiment, the two pieces of the first double-sided tape 31 are attached to one end portion in the width direction and the other end portion in the width direction of the first film 10, respectively. The two pieces of the first double-sided tape 31 after attachment are spaced apart from each other in the width direction so as to avoid the central portion in the width direction of the first film 10. The one end portion in the width direction of the first double-sided tape 31 attached to the one end portion in the width direction of the first film 10 is substantially coincident with the one end portion in the width direction of the first film 10, and the other end portion in the width direction of the first double-sided tape 31 attached to the other end portion in the width direction of the first film 10 is substantially coincident with the other end portion in the width direction of the first film 10. Further, the central portion in the width direction of the second double-sided tape 32 is disposed so as to be substantially coincident with the central portion in the width direction of the first film 10. Furthermore, the other end portion in the width direction of the first double-sided tape 31 attached to the one end portion in the width direction of the first film 10 contacts the one end portion in the width direction of the second double-sided tape 32 without overlapping, and the one end portion in the width direction of the first double-sided tape 31 attached to the other end portion in the width direction of the first film 10 contacts the other end portion in the width direction of the second double-sided tape 32 without overlapping.

[0118] The thickness 31 of the first double-sided tape and the thickness 32 of the second double-sided tape are the same as the thickness 31 of the first double-sided tape and the thickness 32 of the second double-sided tape described in the first embodiment of the roll 1.

[0119] The thickness of the first double-sided tape 31 is preferably thinner than the thickness of the second double-sided tape 32. That is, the thickness of the both end portions in the width direction of the joining member 3 is thinner than the thickness of the central portion in the width direction of the joining member 3.

[0120] If the thickness of the both end portions in the width direction of the joining member 3 is thinner than the thickness at the central portion in the width direction of the joining member 3, the unevenness trace of the roll body 1 can be suppressed.

[0121] The ranges of the certain regions including the both end portions in the width direction and the certain region including the central portion in the width direction are the same as those described in the first embodiment of the roll body 1.

[0122] Note that, in the joining of the one end portion in the long dimension direction of the first film 10 and the other end portion in the long dimension direction of the second film 20, in a case where the joining member 3 of constant thickness is used in the entire region in the width direction, depending on the manufacturing process of the roll body, the shape of the roll core 2, and the like, a difference in stress in the width direction at the one end portion in the long dimension direction of the first film 10 with respect to the radial direction of the roll body 1 occurs. Specifically, in the case where the joining member 3 of constant thickness is used in the entire region in the width direction to join the one end portion in the long dimension direction of the first film 10 and the other end portion in the long dimension direction of the second film 20, in a case where the film including at least one selected from the group consisting of the first film 10 and the second film 20 is heated in the manufacturing process of the roll body, the film including at least one selected from the group consisting of the first film 10 and the second film 20 that is stretched by heating after winding is contracted (becomes a heat-shrunk state), and thus the stress in the radial direction of the roll body 1 at the one end portion in the long dimension direction of the first film 10 tends to increase from the central portion in the width direction to the both end portions in the width direction. That is, when the one end portion in the long dimension direction of the first film 10 and the other end portion in the long dimension direction of the second film 20 are joined using the joining member 3 of constant thickness in the entire region in the width direction, and the film including at least one selected from the group consisting of the first film 10 and the second film 20 after winding becomes a heat-shrunk state, the stress in the radial direction of the roll body 1 at the central portion in the width direction is the smallest, and the stress in the radial direction of the roll body 1 at the both end portions in the width direction is the largest at the one end portion in the long dimension direction of the first film 10. Thus, the unevenness trace can sometimes occur due to the difference in stress in the width direction at the one end portion in the long dimension direction of the first film 10.

[0123] The length in the long dimension direction and the length in the width direction (total length) of the joining member 3 are the same as those described in the first embodiment of the roll body 1.

[0124] Further, in the radial direction of the roll 1, a distance T' is provided from the radially outer side of the other end portion in the longitudinal direction of the second film 20 to the radially inner side of the one end portion in the longitudinal direction of the first film 10. At this time, the distance T'1 at the end portion of at least one of the width directions at the one end portion in the longitudinal direction of the first film 10 is the shortest with respect to the distance T' in the entire region in the width direction. When the portion having the shortest distance T'1 with respect to the distance T' in the entire region in the width direction is provided as the shortest portion at the one end portion in the longitudinal direction of the first film 10, the end portion of at least one of the width directions is the shortest portion at the one end portion in the longitudinal direction of the first film 10.

[0125] If the distance T'1 at the end portion of at least one of the width directions at the one end portion in the longitudinal direction of the first film 10 is the shortest with respect to the distance T' in the entire region in the width direction, the unevenness trace of the roll 1 can be suppressed.

[0126] Note that, in the second embodiment, the distance T'1 in a certain region including both end portions in the width direction is the shortest with respect to the distance T' in the entire region in the width direction at the one end portion in the longitudinal direction of the first film 10. That is, the certain region including both end portions in the width direction is the shortest portion at the one end portion in the longitudinal direction of the first film 10. Further, the distance T'2 in a certain region including the central portion in the width direction is the longest with respect to the distance T' in the entire region in the width direction at the one end portion in the longitudinal direction of the first film 10. That is, when the portion having the longest distance T'2 with respect to the distance T' in the entire region in the width direction is provided as the longest portion at the one end portion in the longitudinal direction of the first film 10, the certain region including the central portion in the width direction is the longest portion at the one end portion in the longitudinal direction of the first film 10.

[0127] The distance T'1 at the shortest portion (the end portion of at least one of the width directions at the one end portion in the longitudinal direction of the first film 10) is, for example, 0 μm or more, and further, for example, less than 10 μm, preferably 8 μm or less, at the one end portion in the longitudinal direction of the first film 10.

[0128] The distance T'2 at the longest portion at the one end portion in the longitudinal direction of the first film 10 is, for example, 10 μm or more, preferably 15 μm or more, more preferably 20 μm or more, and further, for example, 100 μm or less, preferably 80 μm or less, more preferably 50 μm or less.

[0129] The ratio (T'1 / T'2) of the distance T'1 at the shortest portion at the one end portion in the longitudinal direction of the first film 10 to the distance T'2 at the longest portion at the one end portion in the longitudinal direction of the first film 10 is, for example, 0 or more, and further, for example, less than 1, preferably 0.8 or less, more preferably 0.5 or less, and further preferably 0.3 or less.

[0130] [Effects]

[0131] As for the roll 1 of the second embodiment of the present application, in the radial direction of the roll 1, the distance T' from the radially outer side surface of the other end portion in the long dimension direction of the second film 20 to the radially inner side surface of one end portion in the long dimension direction of the first film 10 is shortest at the end portion of at least one of the width direction. Therefore, the unevenness trace can be reduced.

[0132] 2. Roll manufacturing apparatus

[0133] Reference Figure 5 One embodiment of a roll manufacturing apparatus 100 used in the manufacturing method of the roll of the present application will be described.

[0134] In Figure 5 , the paper face left-right direction is the long dimension direction, the paper face right side is the one side in the long dimension direction, and the paper face left side is the other side in the long dimension direction. The paper thickness direction is the width direction, the paper face surface side is the one side in the width direction, and the paper face inner side is the other side in the width direction. The paper face up-down direction is the up-down direction, the paper face upper side is the upper side, and the paper face lower side is the lower side.

[0135] The roll manufacturing apparatus 100 is, for example, an apparatus that manufactures the roll 1 by a roll-to-roll method under a vacuum atmosphere. The roll manufacturing apparatus 100 is, for example, provided with, in order toward the one side in the long dimension direction, a feeding chamber R1, a film forming chamber R2, and a winding chamber R3. Note that the roll manufacturing apparatus 100 can not be provided with the film forming chamber R2.

[0136] The feeding chamber R1 is configured to be adjacent to the film forming chamber R2 on the other side in the long dimension direction of the film forming chamber R2. The feeding chamber R1 is, for example, provided with a feeding roller 51 and a first guide roller 52.

[0137] The feeding roller 51 is, for example, to feed a base film that is a work film. The feeding roller 51 is a cylindrical member (a winding core) having a rotation axis. A first drive source (not shown) for rotating the feeding roller 51 is connected to the feeding roller 51. The feeding roller 51 can be rotated by a prescribed driving force from the first drive source.

[0138] Note that the work film includes at least the first film 10. The work film can further include the second film 20. In Figure 5 , the work film is the first film 10.

[0139] The first guide roller 52 is a rotating member that guides the work film fed from the feeding roller 51 toward the film forming chamber R2. The first guide roller 52 is disposed on the upper side of the feeding roller 51 and on the other side in the long dimension direction of the second guide roller 61 (to be described later).

[0140] The delivery chamber R1 is a housing that accommodates the delivery roller 51 and the first guide roller 52. The delivery chamber R1 is provided with a vacuum unit (not shown) that can make the inside vacuum.

[0141] The film formation chamber R2 is configured to be contiguous with the delivery chamber R1 on the one side in the longitudinal direction of the delivery chamber R1 and the winding chamber R3 on the other side in the longitudinal direction of the winding chamber R3. The film formation chamber R2 is provided with a second guide roller 61, a third guide roller 62, a film formation roller 63, a target 64, a fourth guide roller 65, and a fifth guide roller 66.

[0142] The second guide roller 61 is a rotating member that guides the work film delivered from the delivery chamber R1 (the first guide roller 52) toward the third guide roller 62. The second guide roller 61 is configured on the one side in the longitudinal direction of the first guide roller 52 and on the other side in the longitudinal direction of the third guide roller 62.

[0143] The third guide roller 62 is a rotating member that guides the work film delivered from the second guide roller 61 toward the film formation roller 63. The third guide roller 62 is configured on the one side in the longitudinal direction of the second guide roller 61 and on the upper side of the film formation roller 63.

[0144] The film formation roller 63 forms an inorganic layer on the face (lower side) on the other side in the thickness direction of the base film that is the work film. The film formation roller 63 is a cylindrical member having a rotation axis. The film formation roller 63 delivers the work film along the circumferential surface of the film formation roller 63. The film formation roller 63 is configured on the lower side of the third guide roller 62 and on the lower side of the fourth guide roller 65.

[0145] The target 64 is configured to be opposed to the film formation roller 63 with a space on the lower side of the film formation roller 63. In addition, in the case where the inorganic layer is formed in multiple layers, a plurality of targets 64 can be configured. In the case where a plurality of targets 64 are configured, the targets 64 are configured to be spaced apart from each other in order along the circumferential direction of the film formation roller 63. The target 64 is formed of a material of the inorganic layer.

[0146] The fourth guide roller 65 is a rotating member that guides the laminated film that is the work film delivered from the film formation roller 63 toward the fifth guide roller 66. The fourth guide roller 65 is configured on the upper side of the film formation roller 63 and on the other side in the longitudinal direction of the fifth guide roller 66.

[0147] The fifth guide roller 66 is a rotating member that guides the laminated film that is the work film delivered from the fourth guide roller 65 toward the sixth guide roller 71. The fifth guide roller 66 is configured on the one side in the longitudinal direction of the fourth guide roller 65 and on the other side in the longitudinal direction of the sixth guide roller 71.

[0148] The film formation chamber R2 is a housing that accommodates the second guide roller 61, the third guide roller 62, the film formation roller 63, the target 64, the fourth guide roller 65, and the fifth guide roller 66. The film formation chamber R2 is provided with a vacuum unit (not shown) that can make the inside vacuum.

[0149] The take-up chamber R3 is configured to be contiguous to the film formation chamber R2 on the one side in the long dimension direction of the film formation chamber R2. The take-up chamber R3 is provided with, for example, the sixth guide roller 71 and the take-up roller 72.

[0150] The sixth guide roller 71 is a rotating member that guides the work film delivered from the fifth guide roller 66 toward the take-up chamber R3. The sixth guide roller 71 is disposed on the one side in the long dimension direction of the fifth guide roller 66 and on the upper side of the take-up roller 72.

[0151] The take-up roller 72 takes up the work film. The take-up roller 72 is a cylindrical member (core) having a rotation axis. The take-up roller 72 is connected to a second drive source (not shown) for rotating the take-up roller 72. The take-up roller 72 can be rotated by a prescribed driving force from the second drive source.

[0152] The take-up chamber R3 is a housing that accommodates the sixth guide roller 71 and the take-up roller 72. The take-up chamber R3 is provided with a vacuum unit (not shown) that can make the inside vacuum.

[0153] 3. Method for manufacturing roll

[0154] (First embodiment)

[0155] A first embodiment of the method for manufacturing the roll of the present application will be described using the roll manufacturing apparatus 100 described above. Note that the method of the first embodiment for manufacturing the roll 1 described above is the first embodiment of the method for manufacturing the roll.

[0156] The method for manufacturing the roll manufactures the roll 1 in a vacuum atmosphere. Specifically, the method for manufacturing the roll manufactures the roll 1 in a vacuum atmosphere by a roll-to-roll method. The method for manufacturing the roll includes a process of taking up the work film including the first film 10 in a vacuum atmosphere (take-up process). The method for manufacturing the roll preferably includes a process of heating the work film including the first film 10 (heating process).

[0157] To manufacture the roll 1, first, the base material film is disposed on the delivery roller 51. Specifically, a roll (base material roll) in which a long base material film is wound in a roll shape is attached to the delivery roller 51.

[0158] The base material film includes the first film 10 and is a film delivered from the delivery roller 51 of the delivery chamber R1.

[0159] Next, one end portion of the first film 10 (base material film) in the long dimension direction is joined to the take-up roller 72 (core 2).

[0160] Specifically, first, the winding core 2 as the winding roll 72 is prepared. Then, at one end portion in the long dimension direction of the first film 10, the first film 10 is joined to the winding core 2 by the joining member 3.

[0161] Specifically, at one end portion in the long dimension direction of the first film 10, the first double-sided tape 31 is attached to a certain region including both end portions in the width direction, and the second double-sided tape 32 is attached to a certain region including the central portion in the width direction. The first double-sided tape 31 and the second double-sided tape 32 are attached to the radially inner side of the first film 10, respectively. Then, the face of each of the first double-sided tape 31 and the second double-sided tape 32, which is opposite to the face attached to the first film 10, is attached to the winding core 2.

[0162] At this time, the central portion in the width direction of the first film 10 substantially coincides with the central portion in the width direction of the winding core 2. Further, the joining is performed in such a manner that the width direction of the first film 10 substantially coincides with the width direction of the winding core 2.

[0163] Thus, at one end portion in the long dimension direction of the first film 10, the first film 10 is joined to the winding core 2 by the joining member 3.

[0164] Next, the base film as the first film 10 (working film) is transported (transporting step).

[0165] Specifically, the first driving source and the second driving source are driven to rotate the feed roll 51 and the winding roll 72 (winding core 2), whereby the first film 10 is fed from the feed roll 51 and is sequentially transported to the first guide roll 52, the second guide roll 61, the third guide roll 62, the film-forming roll 63, the fourth guide roll 65, the fifth guide roll 66, the sixth guide roll 71, and is wound by the winding roll 72 (winding core 2).

[0166] Thus, the first film 10 (working film) is transported from the feed roll 51 to the winding roll 72 by the roll-to-roll method.

[0167] The transport speed of the working film is, for example, 3 m / min or more, and further, for example, 20 m / min or less. Further, the transport tension of the working film is, for example, 50 N or more, and further, for example, 1000 N or less.

[0168] The transporting step can include a heating step. As the heating step, there is no particular limitation as long as it is a step of heating the working film including the first film 10. As the heating step, for example, the film-forming step can be cited.

[0169] The film-forming step is a step of forming an inorganic layer on the face on the other side of the thickness direction of the base film as the first film 10 (working film) while transporting the base film.

[0170] Specifically, the base material film as the first film 10 is transported while film formation is performed in the film formation chamber R2. As the film formation method, there is no particular limitation as long as it is a method capable of film formation with heating in a vacuum atmosphere. As the film formation method, for example, a dry coating method can be cited. As the dry coating method, for example, a vacuum evaporation method and a sputtering method can be cited. The sputtering method is preferable.

[0171] As the sputtering method, for example, a diode sputtering method, an ECR (electron cyclotron resonance) sputtering method, a magnetron sputtering method, and an ion beam sputtering method can be cited. The magnetron sputtering method is preferable.

[0172] In the sputtering method, a gas (an inert gas such as argon) is supplied to the inside of the film formation chamber R2 in a vacuum atmosphere, and a negative voltage is applied to a target 64 provided on a cathode in the film formation chamber R2. Thereby, glow discharge is generated, gas atoms are ionized, and the gas ions collide with the target surface at high speed, and the target material is ejected from the target surface. As a result, the target material ejected from the target 64 is attached to the surface (lower surface) on the other side of the thickness direction of the base material film on the lower side of the film formation roller 63, and an inorganic layer is formed.

[0173] In the sputtering method, the inorganic layer is formed by sputtering while the base material film is transported along the circumferential surface of the film formation roller 63. That is, the inorganic layer is a sputtered layer.

[0174] At this time, the base material film is preferably bonded over 180° in the circumferential direction of the film formation roller 63.

[0175] As the sputtering gas, for example, argon, krypton, xenon, and a mixed gas thereof can be cited. Argon is preferable. In addition, a reactive gas (for example, oxygen) can also be used in combination. Note that in the case of using the reactive gas in combination, the amount of introduction thereof is set in a manner to satisfy the partial pressure of the reactive gas described later.

[0176] The gas pressure in the film formation chamber R2 in the film formation by the sputtering method (the gas pressure in the film formation chamber R2 at the time of introduction of the sputtering gas, or the sputtering gas and the reactive gas) is, for example, 0.02 Pa to 1 Pa, and is preferably 0.1 Pa to 0.6 Pa.

[0177] In the case of using the reactive gas in combination, the partial pressure of the reactive gas in the film formation chamber R2 is, for example, 1.0 x 10 － 4 Pa to 1.0 x 10 －2 Pa.

[0178] As the power source for applying a voltage to the target, for example, a DC power source, an AC power source, an MF power source, and an RF power source can be cited. The DC power source is preferable.

[0179] The film deposition temperature (temperature of the film deposition roll at the time of film deposition) is, for example, 0°C or higher, preferably 10°C or higher, and more preferably 20°C or higher, and is, for example, 150°C or lower, preferably 80°C or lower.

[0180] The material of the target 64, that is, the material of the inorganic layer, can be exemplified by the above-mentioned metal, metal oxide, and metal nitride.

[0181] Thus, the laminated film as the first film is obtained on the lower side of the film deposition roll 63, and has the substrate film and the inorganic layer laminated on the other side (lower surface) of the substrate film in the thickness direction.

[0182] The laminated film as the first film 10 manufactured as described above is transported to the winding roll 72 (winding core 2) on the other side in the longitudinal direction by the film deposition roll 63, the fourth guide roll 65, and the fifth guide roll 66.

[0183] Then, the work film including the first film 10 is wound by the winding roll 72 (winding core 2) under a vacuum atmosphere (winding process), and thus the roll 1 is manufactured.

[0184] Note that the roll 1 manufactured as such can be attached to the feeding roll 51. That is, the winding core 2 can be either the winding roll 72 or the feeding roll 51.

[0185] The roll diameter of the roll is, for example, 0.1 m or higher, preferably 0.3 m or higher, and is, for example, 0.7 m or lower, preferably 1.0 m or lower.

[0186] [Effects]

[0187] The method of manufacturing the roll of the first embodiment of the present application is a method of manufacturing the above-described roll 1, and includes a process of winding a work film including at least the first film 10 under a vacuum atmosphere. Thus, even under a vacuum atmosphere, the roll 1 capable of reducing the unevenness trace can be manufactured.

[0188] (Second Embodiment)

[0189] A second embodiment of a method of manufacturing the roll of the present application using the above-described roll manufacturing apparatus 100 will be described. Note that the method of manufacturing the above-described roll 1 of the second embodiment is a second embodiment of the method of manufacturing the roll.

[0190] In the second embodiment, the same reference numerals are assigned to the same members and processes as those of the first embodiment of the method of manufacturing the roll, and detailed description thereof is omitted. Moreover, the second embodiment can be appropriately combined with the first embodiment of the method of manufacturing the roll and the modified example described later.

[0191] The method for manufacturing the roll body manufactures the roll body 1 in a vacuum atmosphere. Specifically, the method for manufacturing the roll body manufactures the roll body 1 in a vacuum atmosphere by a roll-to-roll method. The method for manufacturing the roll body includes a process of winding a work film including the first film 10 and the second film 20 in a vacuum atmosphere (winding process). The method for manufacturing the roll body preferably includes a process of heating the work film including the first film 10 and the second film 20 (heating process).

[0192] For manufacturing the roll body 1, first, a base film as the first film 10 and a base film as the second film 20 are prepared.

[0193] Next, one end portion of the first film 10 in the longitudinal direction is joined to the other end portion of the second film 20 in the longitudinal direction.

[0194] Specifically, at one end portion of the first film 10 in the longitudinal direction, a first double-sided tape 31 is attached to a certain region including both end portions in the width direction, and a second double-sided tape 32 is attached to a certain region including a central portion in the width direction. The first double-sided tape 31 and the second double-sided tape 32 are attached to the inner side in the radial direction of the first film 10. Then, the faces of the first double-sided tape 31 and the second double-sided tape 32, which are opposite to the faces attached to the first film 10, are attached to the outer side in the radial direction of the second film 20.

[0195] At this time, the central portion in the width direction of the first film 10 and the central portion in the width direction of the second film 20 substantially coincide. In addition, the first film 10 and the second film 20 are joined in such a manner that the width direction of the first film 10 and the width direction of the second film 20 substantially parallel.

[0196] Thus, at one end portion of the first film 10 in the longitudinal direction, the first film 10 and the second film 20 are joined by the joining member 3.

[0197] Next, a base roll including the first film 10 and the second film 20 joined by the joining member 3 is prepared. In the base roll, the first film 10 is disposed on the inner side in the radial direction, and the second film is disposed on the outer side in the radial direction. The base roll including the first film 10 and the second film 20 is attached to a feed-out roll 51, and a work film including the first film 10 and the second film 20 is transported (transporting process). The transporting process is the same as the transporting process described in the first embodiment of the method for manufacturing the roll body.

[0198] In addition, the transporting process can include a heating process, like the first embodiment of the method for manufacturing the roll body.

[0199] As the heating process, there is no particular limitation as long as it is a process of heating the work film including the first film 10. In addition, the work film including the first film 10 and the second film 20 can be heated. As the heating process, for example, a film formation process can be cited.

[0200] The film-forming process is the same as the film-forming process described in the first embodiment of the method for manufacturing the roll.

[0201] After the film-forming process, the laminated film, which is the first film 10 and the second film 20, is conveyed to the winding roller 72 (core 2) via the film-forming roller 63, the fourth guide roller 65 and the fifth guide roller 66.

[0202] Then, under a vacuum atmosphere, the working film, including the first film 10 and the second film 20, is wound up by the winding roller 72 (winding process) to produce the roll 1.

[0203] [Effects]

[0204] The second embodiment of the present invention provides a method for manufacturing the roll 1 described above, comprising a step of winding a working film, including at least a first film 10, under a vacuum atmosphere. Therefore, even under a vacuum atmosphere, a roll 1 with reduced height difference marks can be manufactured.

[0205] 4. Variations

[0206] Reference Figure 6-9 The following describes a modified example of the scroll body of the present invention. It should be noted that the fifth modified example is not illustrated.

[0207] In the modified examples, the same reference numerals are used to label the same components as in the first embodiment of scroll 1, and detailed descriptions are omitted. Furthermore, the first embodiment of scroll 1, the second embodiment of scroll 1, and the modified examples can be appropriately combined.

[0208] (First variation)

[0209] In the first embodiment of the roll 1 described above, the bonding member 3 is disposed over the entire area of ​​the width direction of the first film 10, and the bonding member 3 is made of two or more double-sided adhesive tapes of different thicknesses, but is not limited thereto.

[0210] Specifically, in the first variation, such as Figure 6 As shown, the first double-sided tape 31 (joining member 3) is not disposed in a certain area including both ends in the width direction, and a second double-sided tape 32 is disposed only in a certain area including the central portion in the width direction. In the first modified example, the central portion of the second double-sided tape 32 in the width direction is disposed approximately at the same level as the central portion of the first film 10 in the width direction.

[0211] It should be noted that, in the first modified example, the distance T1 in a certain region at one end of the first membrane 10 in the longitudinal direction, including both ends in the width direction, is the shortest relative to the distance T in the entire width direction. That is, when the portion at one end of the first membrane 10 in the longitudinal direction that has the shortest distance T1 relative to the entire width direction is defined as the shortest part, the certain region at one end of the first membrane 10 in the longitudinal direction, including both ends in the width direction, is the shortest part. Furthermore, the distance T2 in a certain region at one end of the first membrane 10 in the longitudinal direction, including the central portion in the width direction, is the longest relative to the distance T in the entire width direction. That is, when the portion at one end of the first membrane 10 in the longitudinal direction that has the longest distance T2 relative to the entire width direction is defined as the longest part, the certain region at one end of the first membrane 10 in the longitudinal direction, including the central portion in the width direction, is the longest part.

[0212] At one end of the first membrane 10 along its longitudinal direction, the distance T1 at the shortest point is 0 μm. That is, the outer peripheral surface of the core 2 contacts the radially inner surface of the shortest point. In the first modified example, at one end of the first membrane 10 along its longitudinal direction, the distance T1 at the shortest point is 0 μm, therefore... Figure 6 The distance T1 is not shown in the diagram.

[0213] That is, the distance T1 at at least one end in the longitudinal direction and the width direction of the first membrane 10 is the shortest relative to the distance T over the entire region in the width direction. Therefore, it is possible to suppress the height difference marks on the roll 1.

[0214] (Second variation)

[0215] In the first embodiment of the roll body 1 described above, the core 2 is cylindrical in shape, and the diameter of the core 2 is approximately the same throughout the width direction orthogonal to the radial direction, but is not limited thereto.

[0216] Specifically, in the second variation, such as Figure 7 As shown, the diameter of the core 2 is smallest at its central part in the width direction, and the diameter tends to increase towards both ends in the width direction of the core 2. That is, the diameter of the core 2 is largest at both ends in the width direction.

[0217] In the second variation, the maximum and minimum diameters of the core 2 are not particularly limited as long as they fall within the range of the diameters of the core 2 described in the first embodiment of the roll body 1.

[0218] In the second variation, the joining member 3 can be disposed over the entire width direction of the first membrane 10, or only over a certain area including the central portion in the width direction. Figure 7In this case, the joining member 3 is disposed in the entire region in the width direction, including both ends in the width direction and the central part in the width direction.

[0219] It should be noted that in the second variation, the distance T1 in a certain region at one end of the first membrane 10 in the longitudinal direction, including both ends in the width direction, is the shortest relative to the distance T in the entire width direction. That is, when the portion at one end of the first membrane 10 in the longitudinal direction that has the shortest distance T1 relative to the entire width direction is defined as the shortest portion, the certain region at one end of the first membrane 10 in the longitudinal direction, including both ends in the width direction, is the shortest portion. Furthermore, the distance T2 in a certain region at one end of the first membrane 10 in the longitudinal direction, including the central portion in the width direction, is the longest relative to the distance T in the entire width direction. That is, when the portion at one end of the first membrane 10 in the longitudinal direction that has the longest distance T2 relative to the entire width direction is defined as the longest portion, the certain region at one end of the first membrane 10 in the longitudinal direction, including the central portion in the width direction, is the longest portion.

[0220] (Third variation)

[0221] In the first embodiment of the roll 1 described above, the bonding member 3 is disposed over the entire area of ​​the width direction of the first film 10. Specifically, two first double-sided tapes 31 are disposed at one end of the first film in the length direction and at both ends in the width direction, and a second double-sided tape 32 is disposed at the center in the width direction, but this is not a limitation.

[0222] Specifically, at one end of the first membrane 10 in the longitudinal direction, the arrangement of the connecting member 3 is not particularly limited as long as the distance T1 at at least one end in the width direction is the shortest relative to the distance T in the entire region in the width direction.

[0223] In the third variation, such as Figure 8 As shown, the bonding member 3 is disposed over the entire width direction of the first film 10. Furthermore, the bonding member 3 is made using two or more double-sided adhesive tapes of different thicknesses. Specifically, a first double-sided adhesive tape 31 is disposed over a certain area including one end in the width direction, and a second double-sided adhesive tape 32 is disposed over a certain area including the other end in the width direction.

[0224] In the third modification, the first double-sided tape 31 is attached to one end portion in the width direction of the first film 10. The one end portion in the width direction of the first double-sided tape 31 substantially coincides with the one end portion in the width direction of the first film 10. Further, the second double-sided tape 32 is attached to the other end portion in the width direction of the first film 10. The other end portion in the width direction of the second double-sided tape 32 substantially coincides with the other end portion in the width direction of the first film 10. Furthermore, the other end portion in the width direction of the first double-sided tape 31 contacts the one end portion in the width direction of the second double-sided tape 32 in a non-overlapping manner.

[0225] The range of the certain region including the one end portion in the width direction and the certain region including the other end portion in the width direction is not particularly limited and can be appropriately set based on the stress applied to the roll 1 in the radial direction.

[0226] In the third modification, the certain region including the one end portion in the width direction refers to a region from the central portion in the width direction to the one end portion in the width direction. Specifically, in the case where the length W in the width direction of the first film 10 is 1500 mm, the certain region including the one end portion in the width direction is a region in the range of 0 mm to 750 mm (in the case where the one end portion in the width direction is set to the position of 0 mm and the other end portion in the width direction is set to the position of 1500 mm) from the one end portion in the width direction to the position 750 mm inward in the width direction from the one end portion in the width direction.

[0227] In the third modification, the certain region including the other end portion in the width direction refers to a region from the central portion in the width direction to the other end portion in the width direction. Specifically, in the case where the length W in the width direction of the first film 10 is 1500 mm, the certain region including the other end portion in the width direction is a region in the range of 750 mm to 1500 mm (in the case where the one end portion in the width direction is set to the position of 0 mm and the other end portion in the width direction is set to the position of 1500 mm) from the other end portion in the width direction to the position 750 mm inward in the width direction from the other end portion in the width direction.

[0228] It should be noted that, in the third variation, the distance T1 in a certain region of one end of the first membrane 10 in the longitudinal direction, including the end in the width direction, is the shortest relative to the distance T in the entire region in the width direction. That is, when the portion of the first membrane 10 at one end in the longitudinal direction that has the shortest distance T1 relative to the entire region in the width direction is defined as the shortest portion, then the certain region of the first membrane 10 at one end in the longitudinal direction, including the end in the width direction, is the shortest portion. Furthermore, the distance T2 in a certain region of one end of the first membrane 10 in the longitudinal direction, including the other end in the width direction, is the longest relative to the distance T in the entire region in the width direction. That is, when the portion of the first membrane 10 at one end in the longitudinal direction that has the longest distance T2 relative to the entire region in the width direction is defined as the longest portion, then the certain region of the first membrane 10 at one end in the longitudinal direction, including the other end in the width direction, is the longest portion.

[0229] (Fourth variation)

[0230] In the first embodiment of the roll 1 described above, the joining member 3 is disposed over the entire area of ​​the width direction of the first film 10, but is not limited thereto.

[0231] Specifically, in the fourth variation, such as Figure 9 As shown, the first double-sided tape 31 is not disposed in a certain area that includes both ends in the width direction, but the second double-sided tape 32 is disposed in a certain area that includes the central part in the width direction. Furthermore, the first double-sided tape 31 is disposed in a certain area between the certain areas that include both ends in the width direction and the certain area that includes the central part in the width direction.

[0232] In the fourth variation, the central portion of the second double-sided tape 32 in the width direction is configured to substantially coincide with the central portion of the first film 10 in the width direction. Two first double-sided tapes 31 are respectively attached to one end and the other end of the second double-sided tape 32 in the width direction. More specifically, the other end of the first double-sided tape 31 attached to one end of the second double-sided tape 32 in the width direction contacts the first end of the second double-sided tape 32 in a non-overlapping manner, and the first end of the first double-sided tape 31 attached to one end of the second double-sided tape 32 in the width direction is spaced apart from the first end of the first film 10 in the width direction. Furthermore, one end of the first double-sided tape 31 in the width direction, which is attached to the other end of the second double-sided tape 32 in the width direction, contacts the other end of the second double-sided tape 32 in the width direction in a non-overlapping manner, and the other end of the first double-sided tape 31 in the width direction, which is attached to the other end of the second double-sided tape 32 in the width direction, is spaced apart from the other end of the first film 10 in the width direction.

[0233] The range of the certain region including the central portion in the width direction, the certain region including the central portion in the width direction, and the certain region between the certain regions including the both end portions in the width direction and the certain region including the central portion in the width direction is not particularly limited and can be appropriately set based on the stress applied to the roll body 1 in the radial direction.

[0234] In the fourth modification, the certain region including the both end portions in the width direction is, for example, a region in which a range from the one end portion in the width direction to a position 1 / 10 of W inward in the width direction from the one end portion in the width direction and a range from the other end portion in the width direction to a position 1 / 10 of W inward in the width direction from the other end portion in the width direction are combined. For example, in a case where the length W in the width direction of the first film 10 is 1500 mm, the certain region including the both end portions in the width direction is a region in which a range from the one end portion in the width direction to a position 150 mm inward in the width direction from the one end portion in the width direction (a range of 0 mm to 150 mm in a case where the one end portion in the width direction is set to a position of 0 mm and the other end portion in the width direction is set to a position of 1500 mm) and a range from the other end portion in the width direction to a position 150 mm inward in the width direction from the other end portion in the width direction (a range of 1350 mm to 1500 mm in a case where the one end portion in the width direction is set to a position of 0 mm and the other end portion in the width direction is set to a position of 1500 mm) are combined.

[0235] In the fourth modification, the certain region including the central portion in the width direction is, for example, a region of a range from a position 1 / 5 of W inward in the width direction from the one end portion in the width direction to a position 1 / 5 of W inward in the width direction from the other end portion in the width direction. Specifically, in a case where the length W in the width direction of the first film 10 is 1500 mm, the certain region including the central portion in the width direction is a region of a range from a position 300 mm inward in the width direction from the one end portion in the width direction to a position 300 mm inward in the width direction from the other end portion in the width direction (a range of 300 mm to 1200 mm in a case where the one end portion in the width direction is set to a position of 0 mm and the other end portion in the width direction is set to a position of 1500 mm).

[0236] In the fourth modification, the certain region between the certain region including both end portions in the width direction and the certain region including the central portion in the width direction is a certain region not including both the end portions in the width direction and the central portion in the width direction. The certain region between the certain region including both end portions in the width direction and the certain region including the central portion in the width direction is, for example, a region in which a range from a position at which W x 1 / 10 has advanced from one end portion in the width direction toward the inside in the width direction to a position at which W x 1 / 5 has advanced from one end portion in the width direction toward the inside in the width direction and a range from a position at which W x 1 / 10 has advanced from the other end portion in the width direction toward the inside in the width direction to a position at which W x 1 / 5 has advanced from the other end portion in the width direction toward the inside in the width direction are combined. For example, in a case where the length W in the width direction of the first film 10 is 1500 mm, the certain region between the certain region including both end portions in the width direction and the certain region including the central portion in the width direction is a region in which a range from a position at which 150 mm has advanced from one end portion in the width direction toward the inside in the width direction to a position at which 300 mm has advanced from one end portion in the width direction toward the inside in the width direction (a range of 150 mm to 300 mm in a case where the position of one end portion in the width direction is set to 0 mm and the position of the other end portion in the width direction is set to 1500 mm) and a range from a position at which 150 mm has advanced from the other end portion in the width direction toward the inside in the width direction to a position at which 300 mm has advanced from the other end portion in the width direction toward the inside in the width direction (a range of 1200 mm to 1350 mm in a case where the position of one end portion in the width direction is set to 0 mm and the position of the other end portion in the width direction is set to 1500 mm) are combined.

[0237] Note that, in the fourth modification, at one end portion in the longitudinal direction of the first film 10, the distance T1 in the certain region including both end portions in the width direction is the shortest among distances T in the entire region in the width direction. That is, at one end portion in the longitudinal direction of the first film 10, the certain region including both end portions in the width direction is the shortest portion when a portion having the shortest distance T1 among distances T in the entire region in the width direction is set as the shortest portion. Further, at one end portion in the longitudinal direction of the first film 10, the distance T2 in the certain region including the central portion in the width direction is the longest among distances T in the entire region in the width direction. That is, at one end portion in the longitudinal direction of the first film 10, the certain region including the central portion in the width direction is the longest portion when a portion having the longest distance T2 among distances T in the entire region in the width direction is set as the longest portion.

[0238] Note that the distance T1 at the shortest portion at one end portion in the long dimension direction of the first film 10 is 0 μm. That is, the outer peripheral surface of the core 2 is in contact with the radially inner surface of the shortest portion. In the fourth modification example, the distance T1 at the shortest portion at one end portion in the long dimension direction of the first film 10 is 0 μm, and thus the distance T1 is not illustrated in FIG. 6. Figure 9

[0239] That is, the distance T1 in a certain region including both end portions in the width direction at one end portion in the long dimension direction of the first film 10 is the shortest with respect to the distance T in the entire region in the width direction. Specifically, in the radial direction of the roll 1, the distance T from the outer peripheral surface of the core 2 to the radially inner surface of one end portion in the long dimension direction of the first film 10 is gradually shortened from both end portions in the width direction to the central portion in the width direction. Thus, the unevenness trace of the roll 1 can be further suppressed.

[0240] (Fifth Modification Example)

[0241] In the first embodiment of the roll 1 described above, the one end surface of the joint member 3 in the long dimension direction is arranged on substantially the same plane as the one end surface of the first film 10 in the long dimension direction, but is not limited thereto.

[0242] Specifically, in the fifth modification example, the joint member 3 is arranged such that one end portion in the long dimension direction of the first film 10 protrudes with respect to one end portion in the long dimension direction of the joint member 3. That is, the joint member 3 is arranged on the inner side in the long dimension direction of the first film 10.

[0243] Example

[0244] Examples, comparative examples, and reference examples are shown below to further specifically describe the present application. Note that the present application is not limited to any of the examples, comparative examples, and reference examples. Further, in the following description, specific numerical values of compounding ratios (containing ratios), physical property values, parameters, and the like used can be replaced with upper limits (numerical values defined as "or less," "less than") or lower limits (numerical values defined as "or more," "more than") of the corresponding compounding ratios (containing ratios), physical property values, parameters, and the like described in the above "DETAILED DESCRIPTION" in place of the corresponding descriptions.

[0245] Comparative Example 1

[0246] ​First, a cyclic olefin polymer (COP) film (trade name: ZEONOR, thickness 100 μm, width 1500 mm, manufactured by ZEON Corporation) was prepared as a long, transparent resin film. A hard coating was formed on the side of the COP film opposite to its thickness direction. The hard coating was formed in the following order. Then, an optical adjustment composition (a UV-curable composition containing zirconia particles with a refractive index of 1.64) was coated on the side of the hard coating opposite to its thickness direction, and cured by UV irradiation to form an optical adjustment layer with a thickness of 100 nm. Thus, a long, narrow substrate film was obtained.

[0247] A UV-absorbing resin composition solution was prepared by mixing 3.3 parts by mass of compound C2 disclosed in Japanese Patent Application Publication No. 2020-066153, 24 parts by mass of a UV-curable resin composition solution (a mixed solution of 80% by mass of "UNIDIC ICELS-888 (50% by mass solids)" manufactured by DIC Corporation and 20% by mass of "UNIDIC RS-605 (60% by mass solids)"), 0.49 parts by mass of hydroxycyclohexylphenyl ketone (photopolymerization initiator, trade name: Irgacure 184, manufactured by Ciba-Geigy Corporation), 0.049 parts by mass of monodisperse acrylic acid particles (trade name: MX-180TAN, average particle size 1.8 μm, manufactured by Soken Chemical Co., Ltd.), and 75 parts by mass of ethyl acetate (solvent). The UV-absorbing resin composition solution was coated onto the side opposite to the thickness direction of a COP film, dried at 80°C for 1 minute, and then cured by UV irradiation with an ozone-type high-pressure mercury lamp. As a result, a hard coating with a thickness of 1.3 μm was formed.

[0248] Next, the substrate film is disposed on Figure 5 The feed roller is shown in the roll-forming apparatus (DC magnetron sputtering film forming apparatus). Specifically, a substrate roll formed by winding a substrate film into a roll is attached to the feed roller. Thus, a substrate film is prepared as a first film in a long strip. It should be noted that in the substrate roll, the substrate film is wound with its radial outer side facing outwards, in the thickness direction of the substrate film, and then attached to the feed roller.

[0249] Next, one end of the first film (substrate film) in the long dimension direction is joined to the core (winding roller).

[0250] Specifically, firstly, an aluminum core with a diameter of 15.24 cm was prepared as the core. Next, the radially inner surface of the first film at one end in the longitudinal direction was joined to the outer peripheral surface of the core using double-sided adhesive tape (jointing member).

[0251] As the double-sided tape, a second double-sided tape (thickness 30 μm, length 100 mm in the long dimension direction) was used, and one face of the second double-sided tape in the thickness direction was attached to the entire region (1500 mm) in the width direction of the first film, and the other face of the second double-sided tape in the thickness direction was attached to the outer peripheral surface of the core, whereby the first film was joined to the core.

[0252] At this time, the second double-sided tape was configured such that one end face in the long dimension direction of the second double-sided tape and one end face in the long dimension direction of the first film were in substantially the same plane, and further configured such that one end face in the width direction of the second double-sided tape and one end face in the width direction of the first film were in substantially the same plane, and one end face in the width direction of the second double-sided tape and the other end face in the width direction of the first film were in substantially the same plane.

[0253] (Transportation step)

[0254] In the transportation step, first, the base film as the first film (working film) was transported under a vacuum atmosphere.

[0255] Specifically, in order to transport the first film (working film), the first drive source and the second drive source (specifically, a motor) were driven to rotate the feed roll and the take-up roll, and the first film was transported. The transportation speed was set to 13 m / min.

[0256] Next, while the base film as the first film was being transported, sputtering (reactive sputtering) was performed under a vacuum atmosphere. Specifically, in the film formation chamber, a copper layer (thickness: 60 nm) as an inorganic layer was formed on the other face in the thickness direction of the base film (the other face in the thickness direction of the optical adjustment layer) by a magnetron sputtering method. Details of the sputtering conditions of the copper layer are shown below.

[0257] In the film formation of the copper layer, after vacuum exhaust was performed in the sputtering film formation device, argon (Ar) as a sputtering gas was introduced into the film formation chamber, and the gas pressure in the film formation chamber was set to 0.3 Pa. As the target, copper (Cu) (manufactured by Sumitomo Metal Industries, Ltd.) was used. As the power source for applying voltage to the target, a DC power source was used. The film formation temperature (temperature of the film formation roll at the time of film formation) was set to 40°C.

[0258] After the film formation of the copper layer, the laminated film as the first film was taken up with the take-up roll (core). Note that the length of the working film in the long dimension direction to which it was taken up was about 4000 m.

[0259] Note that the transportation tension of the working film in the transportation step was set to 500 N.

[0260] Thus, the roll of Comparative Example 1 was produced.

[0261] Note that in the roll body of Comparative Example 1, the distance T from the outer peripheral surface of the roll core 2 to the radially inner side surface of the one end portion in the long dimension direction of the first film is constant in the entire region in the width direction. That is, in the case of Comparative Example 1, the one end portion in the long dimension direction of the first film does not have a portion (shortest portion) having the shortest distance T1 among the distances T in the entire region in the width direction.

[0262] Example 1

[0263] The double-sided tape (joining member) for joining the one end portion in the long dimension direction of the first film (base film) to the roll core (roll-up roller) was changed as described below, and otherwise, the roll body of Example 1 was manufactured in the same manner as in Comparative Example 1.

[0264] Specifically, as the double-sided tape, a first double-sided tape (thickness 5 μm, length in long dimension direction 100 mm) was used, and the surface of one side in the thickness direction of two pieces of the first double-sided tape was attached to the radially inner side surface of both end portions in the width direction of the first film. More specifically, two pieces of the first double-sided tape were attached to the region from the one end portion in the width direction of the first film to the position 250 mm advanced in the width direction from the one end portion in the width direction (0 mm to 250 mm in the case where the position of the one end portion in the width direction is set to 0 mm and the position of the other end portion in the width direction is set to 1500 mm) and the region from the other end portion in the width direction of the base film to the position 250 mm advanced in the width direction from the other end portion in the width direction (1250 mm to 1500 mm in the case where the position of the one end portion in the width direction is set to 0 mm and the position of the other end portion in the width direction is set to 1500 mm). Further, as the double-sided tape, a second double-sided tape (thickness 30 μm, length in long dimension direction 100 mm) was used, and the surface of one side in the thickness direction of one piece of the second double-sided tape was attached to the central portion in the width direction of the first film. More specifically, the second double-sided tape was attached to the region other than the both end portions in the width direction of the first film (250 mm to 1250 mm in the case where the position of the one end portion in the width direction is set to 0 mm and the position of the other end portion in the width direction is set to 1500 mm). Subsequently, the surface of the other side in the thickness direction of both kinds of double-sided tapes was attached to the outer peripheral surface of the roll core, whereby the first film was joined to the roll core.

[0265] Note that in the roll body of Example 1, the region (both end portions in the width direction) to which the first double-sided tape was attached was the shortest portion, and the region (central portion in the width direction) to which the second double-sided tape was attached was the longest portion, at the one end portion in the long dimension direction of the first film. The distance T1 at the shortest portion was 5 μm, and the distance T2 at the longest portion was 30 μm.

[0266] Example 2

[0267] The double-sided tape (joining member) that joins one end portion of the long dimension direction of the first film (base film) to the winding core (winding roller) was changed as described below, and otherwise, the roll of Example 2 was manufactured in the same manner as Comparative Example 1.

[0268] Specifically, the face of one side of the thickness direction of one sheet of the second double-sided tape (thickness 30 μm, length 100 mm in the long dimension direction) was attached to the radially inner side face of the central portion in the width direction of the first film. In more detail, the second double-sided tape was attached in the region other than the both end portions in the width direction of the first film described in the above Example 1 (in the case where the one end portion in the width direction is set to 0 mm and the other end portion in the width direction is set to 1500 mm, the region of 250 mm to 1250 mm). Subsequently, the face of the other side of the thickness direction of the second double-sided tape was attached to the outer peripheral surface of the winding core, whereby the first film was joined to the winding core. Note that the double-sided tape was not attached to the both end portions in the width direction of the first film.

[0269] Note that in the roll of Example 2, the region (both end portions in the width direction) where the double-sided tape (joining member) was not disposed at one end portion in the long dimension direction of the first film was the shortest portion, and the region (central portion in the width direction) where the second double-sided tape was attached was the longest portion. The distance T1 at the shortest portion was 0 μm, and the distance T2 at the longest portion was 30 μm.

[0270] Example 3

[0271] A base film was prepared as the first film in the same order as Comparative Example 1, and was disposed on the feed roller in the roll manufacturing apparatus (DC magnetron sputtering film forming apparatus) shown in FIG. 1. That is, the base film roll in which the base film was wound in a roll shape was attached to the feed roller. Figure 5

[0272] Further, a polyethylene terephthalate (PET) film having a thickness of 50 μm, a length of 1500 mm in the width direction, and a length of 150 m in the long dimension direction was prepared as the second film, and was disposed on the winding roller in the roll manufacturing apparatus (DC magnetron sputtering film forming apparatus) shown in FIG. 1. That is, the PET roll in which the PET film was wound in a roll shape was attached to the winding roller. Figure 5

[0273] Subsequently, the radially inner side face of the first film at one end portion in the long dimension direction of the first film fed out from the feed roller was joined to the radially outer side face of the second film at the other end portion in the long dimension direction of the second film by the double-sided tape (joining member).

[0274] ​​More specifically, one face of one of the first double-sided tapes (thickness 5 μm, length 100 mm in the long dimension) was attached to the radially inner side of each of the two end portions in the width direction of the first film. Specifically, one of the first double-sided tapes was attached to a region 250 mm from one end portion in the width direction of the first film toward the other end portion (0 mm to 250 mm in the case where the one end portion in the width direction is set to 0 mm and the other end portion in the width direction is set to 1500 mm) and a region 250 mm from the other end portion in the width direction of the first film toward the one end portion (1250 mm to 1500 mm in the case where the one end portion in the width direction is set to 0 mm and the other end portion in the width direction is set to 1500 mm). Further, one face of one of the second double-sided tapes (thickness 30 μm, length 100 mm in the long dimension) was attached to the radially inner side of the central portion in the width direction of the first film. Specifically, one of the second double-sided tapes was attached to a region other than the two end portions in the width direction of the first film (250 mm to 1250 mm in the case where the one end portion in the width direction is set to 0 mm and the other end portion in the width direction is set to 1500 mm). Subsequently, the other face of each of the two types of double-sided tapes was attached to the radially outer side of the second film at the other end portion in the long dimension of the second film, whereby the first film and the second film were joined.

[0275] Next, the first film was conveyed (conveying step). With respect to the conveying step, the same sequence as in Comparative Example 1 was adopted, and the roll of Example 3 was manufactured. In the roll of Example 3, the first film was disposed on the radially outer side of the roll, and the second film was disposed on the radially inner side.

[0276] Note that in the roll of Example 3, the region (both end portions in the width direction) to which the first double-sided tape was attached was the shortest portion at the one end portion in the long dimension of the first film, and the region (central portion in the width direction) to which the second double-sided tape was attached was the longest portion. The distance T'1 at the shortest portion was 5 μm, and the distance T'2 at the longest portion was 30 μm.

[0277] Example 4

[0278] The double-sided tape that joined the one end portion in the long dimension of the first film (base film) and the other end portion in the long dimension of the second film was changed as described below, and otherwise, the roll of Example 4 was manufactured in the same manner as in Example 3.

[0279] Specifically, one face of one second double-sided tape in the thickness direction was attached to the radially inner side face of the central portion in the width direction of the first film using a second double-sided tape (thickness 30 μm, length 100 mm in the long dimension direction). More specifically, the second double-sided tape was attached in a region other than both end portions in the width direction of the first film described in the above-described Example 3 (in the case where one end portion in the width direction is set to 0 mm and the other end portion in the width direction is set to 1500 mm, a region of 250 mm to 1250 mm). Subsequently, the other face of the second double-sided tape in the thickness direction was attached to the radially outer side face of the second film at the other end portion in the long dimension direction of the second film, whereby the first film and the second film were joined. Note that no double-sided tape was attached to both end portions in the width direction of the first film.

[0280] Note that in the roll of Example 4, the region (both end portions in the width direction) where no double-sided tape (joining member) was disposed at one end portion in the long dimension direction of the first film was the shortest portion, and the region (central portion in the width direction) where the second double-sided tape was attached was the longest portion. The distance T'1 at the shortest portion was 0 μm, and the distance T'2 at the longest portion was 30 μm.

[0281] < Evaluation >

[0282] [Appearance]

[0283] The first film (laminated film) serving as the working film was extracted from each roll of each example and Comparative Example 1, and the appearance of the surface of the copper layer was visually confirmed, and the presence or absence of a step trace was evaluated according to the following criteria. The results are shown in Table 1 and Table 2.

[0284] {Criteria}

[0285] A: There was no change in the color tone of the surface of the copper layer. B: There was a change in the color tone of the surface of the copper layer.

[0286] [Table 1]

[0287]

[0288] [Table 2]

[0289]

[0290] < Investigation >

[0291] In the roll manufactured by the manufacturing method of the roll of Example 1 and Example 2, in the radial direction of the roll, the distance T1 at at least one end portion in the width direction (specifically, the distance T1 at both end portions in the width direction) was the shortest relative to the distance T in the entire region in the width direction, as the distance T from the outer peripheral surface of the core to the radially inner side face of one end portion of the first film. Therefore, it was possible to reduce the step trace of the roll.

[0292] On the other hand, in the roll body manufactured by the manufacturing method of the roll body of Comparative Example 1, the distance T from the outer peripheral surface of the roll core to the radially inner side surface of the one end portion of the first film in the long dimension direction is constant in the entire region in the width direction. That is, in the case of Comparative Example 1, the portion having the shortest distance T1 with respect to the distance T in the entire region in the width direction (the shortest portion) is not present at the one end portion of the first film in the long dimension direction. Therefore, the unevenness trace of the roll body is generated.

[0293] In the roll body manufactured by the manufacturing method of the roll body of Embodiment 3, Embodiment 4, the distance T1 at the end portion of at least one of the width directions is the shortest with respect to the distance T in the entire region in the width direction as the distance T from the radially outer side surface of the other end portion of the second film to the radially inner side surface of the one end portion of the first film in the long dimension direction. Therefore, the unevenness trace of the roll body can be reduced.

[0294] Note that the above-described application is provided as an example of an embodiment of the present application, but is simply an example and is not to be construed as a limiting interpretation. Variations of the present application that are clear to those skilled in the art are included in the claims described below.

[0295] Industrial Applicability

[0296] The roll body of the present application is suitable as a film roll (for example, a base material roll and a laminated film roll) used in various industrial fields. Furthermore, the manufacturing method of the roll body of the present application is suitable for manufacturing a roll body by a roll-to-roll method in various industrial fields.

Claims

1. A roll body comprising: a core; a first film in a long strip shape wound around the core; and a joining member joining one end portion of the first film in a long dimension direction and the core, the joining member is disposed between the core and the one end portion in a thickness direction of the first film, in a radial direction of the roll body, a distance from an outer peripheral surface of the core to a radial inner side surface of the one end portion is shortest at an end portion of at least one of a width direction orthogonal to both the long dimension direction and the thickness direction, relative to the distance in an entire region of the width direction.

2. A roll body in which a film is wound, the film comprises: a first film in a long strip shape; a second film in a long strip shape; and a joining member joining one end portion of the first film in a long dimension direction and the other end portion of the second film in a long dimension direction, in the roll body, the first film is disposed on a radially outer side of the roll body, and the second film is disposed on a radially inner side of the roll body, the joining member is disposed between the one end portion and the other end portion in a thickness direction of the first film, in a radial direction of the roll body, a distance from a radially outer side surface of the other end portion to a radially inner side surface of the one end portion is shortest at an end portion of at least one of a width direction orthogonal to both the long dimension direction and the thickness direction, relative to the distance in an entire region of the width direction.

3. The roll body according to claim 1 or 2, wherein the joining member is further disposed in an entire region of the width direction of the one end portion, a thickness of the joining member at the end portion of at least one of the width direction of the one end portion is thinner than a thickness of the joining member at a central portion of the width direction of the one end portion.

4. The roll body according to claim 3, wherein thicknesses of the joining member at both end portions of the width direction of the one end portion are thinner than the thickness of the joining member at the central portion of the width direction of the one end portion.

5. The roll body according to claim 1 or 2, wherein the joining member is not disposed at the end portion of at least one of the width direction of the one end portion.

6. The roll body according to claim 5, wherein the joining member is not disposed at both end portions of the width direction of the one end portion.

7. A method of manufacturing a roll body, the method of manufacturing the roll body according to claim 1 or 2, the method of manufacturing the roll body comprises a step of winding a work film including at least the first film in a vacuum atmosphere.

8. The method of manufacturing the roll body according to claim 7, wherein the method of manufacturing the roll body further comprises a step of heating the work film.

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