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Method and apparatus for producing film roll, and film roll

a film roll and film technology, applied in the direction of thin material processing, instruments, optics, etc., can solve the problems of thin film or the like formed on the surface of the substrate, damage to the thin film or the like, and decline in display quality,

Inactive Publication Date: 2009-11-12
SHARP KK
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention relates to a method and apparatus for producing a film roll with non-contact surfaces and prevention of enlargement of the diameter of the film roll. The technical effects of the invention include preventing mutual contact of surfaces of a film substrate when wound and securing a non-contact state of the substrate surfaces. The method involves placing belt-like spacers at both sides of the film substrate and at a middle portion between the sides. The spacers are placed in a longitudinal direction of the film substrate and are designed to prevent enlargement of the film roll and secure the non-contact state of the substrate surfaces. The apparatus includes a roll core for winding the film substrate and the spacers are introduced from reels located at positions corresponding to the sides and middle of the film substrate. The use of the spacers does not significantly affect the film substrate and the method allows for the placement of the spacers at specific positions based on the needs of the film substrate.

Problems solved by technology

In the roll-to-roll system, for example, since a film substrate with a length of hundreds of meters is wound around a delivery roll and take-up roll, it could happen that surfaces of the film substrate contact each other or that a thin film or the like having been formed on the surfaces of the substrate is damaged by winding the substrate with foreign substances contacting or adhering to layers thereof.
When surfaces of a film substrate contact one another, damaged portions are caused in conductive elements having been formed on the surfaces of the substrate, resulting in a decline in display quality.
For example, as described in the Japanese Published Unexamined Application No. 2004-199643, placing spacers only at both sides could still result in mutual contact of substrate surfaces because of a flexure of the substrate itself to cause damage portions in conductive elements on the substrate surfaces and a decline in display quality of display panels.
However, as the spacers have larger thicknesses, the diameter of a resultant film roll of a film substrate becomes larger, and thereby a production apparatus necessarily becomes larger.
It is not preferable to use spacers having larger thicknesses since enlargement of the production apparatus has a significant problem particularly when it is a vacuum-based production apparatus.

Method used

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  • Method and apparatus for producing film roll, and film roll
  • Method and apparatus for producing film roll, and film roll
  • Method and apparatus for producing film roll, and film roll

Examples

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embodiment 1

Preferred Embodiment 1

[0040]FIG. 1 through FIG. 3 show a method and an apparatus for producing a film roll of the present invention, and Preferred Embodiment 1 of the film roll. In the present preferred embodiment, a roll-to-roll wet etching apparatus is illustrated as an apparatus for producing a film roll.

[0041]FIG. 1 is a cross-sectional view of a wet etching apparatus 30a according to the present preferred embodiment.

[0042]The wet etching apparatus 30a includes a first roll housing chamber 21 where a film roll 3a before processing is housed, an etching process chamber 22 where etching is performed, a rinsing process chamber 23 where rinsing is performed, and a second roll housing chamber 24 where a film roll 3b after processing is housed, which are arranged in numerical sequence. The wall between the first roll housing chamber 21 and the etching process chamber 22, the wall between the etching process chamber 22 and the rinsing process chamber 23, and the wall between the rinsin...

embodiment 2

Preferred Embodiment 2

[0069]FIG. 5 shows Preferred Embodiment 2 of an apparatus for producing a film roll according to the present invention. The present preferred embodiment illustrates a coating apparatus using a roll-to-roll system as an apparatus for producing a film roll. Here, in each of the following preferred embodiments, the same elements as those of FIG. 1 through FIG. 3 are denoted by the same reference numerals used in FIG. 1 through FIG. 3, and the detailed descriptions thereof will be omitted.

[0070]FIG. 5 is a cross-sectional view of a coating apparatus 30b according to the present preferred embodiment.

[0071]The coating apparatus 30b includes a first roll housing chamber 21 where a film roll before processing is housed, a coating chamber 25 where coating is performed, a heating process chamber 26 where heating is performed, and a second roll housing chamber 24 where a film roll after processing is housed, which are arranged in numerical sequence. The wall between the f...

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Abstract

A method for producing a film roll of a wound film substrate includes, a spacer placing step for placing belt-like spacers respectively at both sides of the film substrate and at a middle portion of the film substrate between the sides such that the spacers extend in a longitudinal direction of the film substrate, and a winding step for winding the film substrate together with the placed spacers.

Description

BACKGROUND OF THE INVENTION[0001]1. Field of the Invention[0002]The present invention relates to a method and an apparatus for producing a film roll, and a film roll, and in particular to a technique for winding a film substrate that is used for producing display panels such as liquid crystal displays or organic electroluminescence displays and is a constituent of a film roll.[0003]2. Description of the Related Art[0004]In recent years, flexible display panels using a flexible substrate such as a plastic substrate have been developed in the field of liquid crystal displays or organic electroluminescence displays, etc. For producing such flexible display panels, a roll-to-roll system where the flexible substrate may be continuously processed is preferred in terms of productivity.[0005]In the roll-to-roll system, for example, since a film substrate with a length of hundreds of meters is wound around a delivery roll and take-up roll, it could happen that surfaces of the film substrate ...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B65H18/08B65H18/28
CPCB65H18/00B65H18/08B65H2301/4127G02F1/133351G02F1/1303G02F1/133305B65H2301/414324
Inventor KANZAKI, YOHSUKENISHIKI, HIROHIKO
Owner SHARP KK