Glass roll manufacturing method

Abstract

The conveying process of the glass roll manufacturing method includes: an adsorption conveying process, using an adsorption conveying device located upstream of a laser irradiation device in the conveying direction to convey the glass film before the cutting process while adsorbing it; and a tension adjustment process, using a tension adjustment device arranged between the laser irradiation device and the winding device to adjust the tension acting on the glass film after the cutting process.

Description

Technical Field

[0001] The present invention relates to a method for producing a glass roll. Background Art

[0002] In recent years, the rapid spread of mobile devices such as smartphones and tablet PCs has led to a demand for thinner and lighter glass substrates. Consequently, the demand for thinner glass substrates used in these devices has also increased. In response to this situation, the development and manufacture of glass substrates thinned to film-like thicknesses (e.g., less than 300 μm), or glass films, has evolved.

[0003] The manufacturing process of a glass film sometimes includes a step of winding a ribbon-shaped base glass film, which will serve as the raw material of the glass film, into a roll to produce a glass roll. For example, Patent Document 1 discloses a method for manufacturing a glass roll that includes a forming step, an ear removal step, a first winding step, a take-out step, a cutting step, and a second winding step.

[0004] In this manufacturing method, first, in a forming step, a base glass film is continuously formed using an overflow down-draw method. Next, in an ear removal step, a laser irradiation device irradiates the base glass film with laser light to remove unnecessary ear portions located at both ends of the base glass film in the width direction, thereby forming a first glass film. In a first winding step, this first glass film is wound around a winding core to form a first glass roll.

[0005] Next, in the unloading step, the first glass film is removed from the first glass roll. In the cutting step, a laser irradiation device irradiates the first glass film with a laser. This removes the unnecessary widthwise ends of the first glass film (non-product portions), forming a second glass film. Finally, in the second winding step, the second glass film is wound around a winding core to produce a second glass roll.

[0006] Prior art literature

[0007] Patent Literature

[0008] Patent Document 1: Japanese Patent Application Publication No. 2019-48734 Summary of the Invention

[0009] Problems to be solved by the invention

[0010] In the above-described method for manufacturing a glass roll, in order to wind the second glass film around the winding core in the second winding step, tension is applied to the second glass film.

[0011] In this case, applying excessive tension to the second glass film may negatively impact the upstream cleaving process. Specifically, excessive tension on the second glass film may cause vibrations in the second glass film below the upstream laser irradiation device, potentially leading to cleavage failure.

[0012] The present invention has been made in view of the above circumstances, and a technical object of the present invention is to prevent a glass film from being cut poorly by adjusting the tension applied to the glass film.

[0013] Solutions to Problems

[0014] The present invention is used to solve the above-mentioned problems and is a method for manufacturing a glass roll, comprising: a conveying process of conveying a glass film; a cutting process of irradiating the glass film with laser from a laser irradiation device, thereby cutting a portion of the glass film; and a winding process of winding the glass film after the cutting process into a roll using a winding device. The method for manufacturing a glass roll is characterized in that the conveying process comprises: an adsorption conveying process of conveying the glass film before the cutting process while adsorbing it using an adsorption conveying device located at an upstream side of the conveying direction of the laser irradiation device; and a tension adjustment process of adjusting the tension applied to the glass film after the cutting process using a tension adjustment device arranged between the laser irradiation device and the winding device.

[0015] According to this configuration, by adjusting the tension applied to the glass film after the cutting step in the tension adjustment step, excessive tension is prevented from being applied to the glass film, thereby preventing vibration of the glass film during the cutting step and thereby preventing poor cutting of the glass film during the cutting step.

[0016] In this method, the tension adjustment device may also include: an air injection device, which is located above the glass film after the cutting process; and a supporting roller, which is located below the air injection device and supports the lower surface of the glass film after the cutting process, and the supporting roller is composed of a free roller.

[0017] According to this configuration, air is ejected downward from the air ejection device, and the air is caused to strike the glass film after the cutting process supported by the support roller, thereby pressing the glass film against the support roller.

[0018] In this method, the tension adjustment device may include a conveying roller that contacts the glass film after the cutting step at an embrace angle, and the conveying roller may be a driving roller that is driven to rotate.

[0019] According to this configuration, by adjusting the conveyance speed of the glass film after the cutting step using the conveyance rollers, it is possible to adjust the tension applied to the glass film.

[0020] In this method, the tension adjustment device may include a pair of rollers that sandwich the glass film after the cutting step.

[0021] According to this configuration, the glass film after the cutting step is sandwiched and conveyed by a pair of rollers, thereby making it possible to adjust the tension applied to the glass film.

[0022] In the present method, it may also be that the tension adjustment process includes a first tension adjustment process, a second tension adjustment process performed after the first tension adjustment process, and a third tension adjustment process performed after the second tension adjustment process, the tension adjustment device includes a first tension adjustment device for performing the first tension adjustment process, a second tension adjustment device for performing the second tension adjustment process, and a third tension adjustment device for performing the third tension adjustment process, the first tension adjustment device includes: an air injection device, which is located above the glass film after the cutting process; and a supporting roller, which is located below the air injection device and supports the lower surface of the glass film after the cutting process, the supporting roller is a free roller, the second tension adjustment device includes a conveying roller that contacts the glass film after the cutting process at a hugging angle, the conveying roller is a driving roller driven to rotate, and the third tension adjustment device includes a pair of rollers that clamp the glass film after the cutting process.

[0023] According to this structure, by using the first tension adjustment process (first tension adjustment device), the second tension adjustment process (second tension adjustment device) and the third tension adjustment process (third tension adjustment device) to adjust the tension of the glass film after the cutting process, it is possible to prevent excessive tension from acting on the glass film and prevent the generation of vibration of the glass film during the cutting process.

[0024] Effects of the Invention

[0025] According to the present invention, by adjusting the tension applied to the glass film, it is possible to prevent a cutting defect of the glass film. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a side view showing the glass roll manufacturing apparatus according to the first embodiment.

[0027] Figure 2 It is a top view of the first tension adjustment device and the second cutting unit.

[0028] Figure 3 yes Figure 2 Cross-sectional view along line III-III.

[0029] Figure 4 This is a flowchart showing a method for manufacturing a glass roll.

[0030] Figure 5 Flowchart showing the tension adjustment process.

[0031] Figure 6 This is a side view showing a glass roll manufacturing apparatus according to a second embodiment.

[0032] Figure 7 It is a top view of the first tension adjustment device and the second cutting unit. DETAILED DESCRIPTION

[0033] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. Figures 1 to 5 A first embodiment of the glass roll manufacturing method of the present invention will be described.

[0034] Figure 1 The glass roll manufacturing apparatus used in this method is shown. The manufacturing apparatus 1 includes: a forming unit 2 for forming a strip of base glass film G; a direction-changing unit 3 for changing the direction of the base glass film G from a vertical downward direction to a horizontal direction; a first conveying unit 4 for conveying the base glass film G in the horizontal direction after the direction change; a first cutting unit 5 for cutting both widthwise ends of the base glass film G to form a first glass film G1; and a first winding device 6 for winding the first glass film G1 into a roll to produce a first glass roll GRL1.

[0035] In addition, the manufacturing device 1 also includes: a reeling device 7, which feeds out the first glass film G1 from the first glass roll GRL1; a second conveying portion 8, which conveys the first glass film G1 supplied from the reeling device 7; a second cutting portion 9, which cuts a portion of the first glass film G1 to form a second glass film G2; and a second winding device 10, which winds the second glass film G2 into a roll to obtain a second glass roll GRL2.

[0036] The forming section 2 includes: a forming body 11 having a generally wedge-shaped cross section and having an overflow groove 11a formed at its upper end; an edge roller 12 disposed directly below the forming body 11 and holding the molten glass GM formed by the forming body 11 from both the front and back sides; and an annealing furnace 13 disposed directly below the edge roller 12.

[0037] The forming section 2 causes the molten glass GM overflowing from the overflow trough 11a of the forming body 11 to flow down along the two side surfaces of the forming body 11, and the molten glass GM is merged at its lower end to form a film. The edge rollers 12 limit the widthwise contraction of the molten glass GM and adjust the widthwise dimension of the base material glass film G. The annealing furnace 13 is used to perform strain removal treatment on the base material glass film G. The annealing furnace 13 has annealing rollers 14 arranged in multiple stages in the vertical direction.

[0038] Support rollers 15 are provided below the annealing furnace 13 to sandwich the base glass film G from both the front and back sides. Tension is applied to the base glass film G between the support rollers 15 and the edge rollers 12 or between the support rollers 15 and any of the annealing rollers 14 to help thin the base glass film G.

[0039] The direction-changing unit 3 is provided below the support roller 15. A plurality of guide rollers 16 are arranged in a curved shape in the direction-changing unit 3 to guide the base glass film G. These guide rollers 16 guide the base glass film G conveyed in the vertical direction in a lateral direction.

[0040] The first conveying unit 4 is disposed in front of (on the downstream side of) the direction-changing unit 3. The first conveying unit 4 conveys the base material glass film G having passed through the direction-changing unit 3 toward the downstream side along the transverse conveying direction X1.

[0041] It should be noted that the first conveyor unit 4 can adopt any structure, for example, it can be composed of one or more belt conveyors. In this case, the first conveyor unit 4 includes a conveyor belt 17, and the base material glass film G is conveyed by driving the conveyor belt 17. The first conveyor unit 4 is not limited to this structure and can also use a roller conveyor or other various conveying devices.

[0042] The first cutting unit 5 is disposed above the first conveying unit 4. In this embodiment, the first cutting unit 5 is configured to cut the base material glass film G using laser cleavage. Specifically, the first cutting unit 5 includes a pair of laser irradiation devices (hereinafter referred to as "first laser irradiation devices") 18 and a pair of cooling devices (hereinafter referred to as "first cooling devices") 19 disposed downstream of the first laser irradiation devices 18.

[0043] The first cutting unit 5 irradiates a predetermined portion of the conveyed base material glass film G with laser light L from each first laser irradiation device 18 to heat it, and then releases the refrigerant R from the first cooling device 19 to cool the heated portion.

[0044] The first winding device 6 is provided downstream of the first conveying unit 4 and the first cutting unit 5. The first winding device 6 rotates the winding core 20 and winds the first glass film G1 into a roll to form a first glass roll GRL1. The first glass roll GRL1 is conveyed to the position of the unwinding device 7.

[0045] The unwinding device 7 functions as a supply unit for supplying the first glass film G1 to the second conveying unit 8 and the second cutting unit 9. The unwinding device 7 is loaded with the first glass roll GRL1 transferred from the first winding device 6, and unwinds the first glass film G1 from the first glass roll GRL1 and supplies it to the second conveying unit 8.

[0046] The second conveying unit 8 conveys the first glass film G1 and the second glass film G2 using a roll-to-roll method. The second conveying unit 8 conveys the first glass film G1, which has been fed from the first glass roll GRL1 by the unwinding device 7, upward in the horizontal conveying direction Z1 and then along the horizontal conveying direction X2. The second conveying unit 8 conveys the second glass film G2 formed by the second cutting unit 9 along the horizontal conveying direction X2 and then downward in the horizontal conveying direction Z2 toward the second winding device 10.

[0047] Specifically, if Figure 1 As shown, the second conveying section 8 includes: conveying rollers 21a, 21b, which are arranged at various positions in the conveying path of these glass films in order to convey the first glass film G1 and the second glass film G2; an upstream conveyor 22a, which is located on the upstream side of the second cutting section 9; a downstream conveyor 22b, which is located on the downstream side of the second cutting section 9; a separating device 23, which separates the non-product portion Gs formed by cutting the first glass film G1 using the second cutting section 9 from the second glass film G2; and tension adjusting devices 24 to 26, which adjust the tension applied to the second glass film G2.

[0048] The upstream conveyor 22a is comprised of a belt conveyor, but is not limited to this structure. In this embodiment, the upstream conveyor 22a includes a plurality of belts (hereinafter referred to as "first belts") 27. The first belts 27 contact the lower surface of the first glass film G1 and support the first glass film G1 in a horizontal position. The first belts 27 are configured to convey the first glass film G1 toward the second cutting unit 9 on the downstream side.

[0049] Each first belt 27 is composed of, for example, an endless belt. Figure 2 As shown, the first belt located in the center of the width direction of the plurality of first belts 27 is composed of a suction belt. This first belt (suction belt) 27 has a plurality of suction holes 27a extending through the belt in the thickness direction. The suction holes 27a are connected to a suction device (not shown). With this structure, the upstream conveyor 22a functions as a suction transport device that suctions the first glass film G1 and transports it to the second cutting section 9.

[0050] The downstream conveyor 22b is composed of a suction belt conveyor and other suction transport devices. The downstream conveyor 22b includes multiple belts (hereinafter referred to as "second belts") 28. The second belts 28 contact the lower surface of the second glass film G2 and support the second glass film G2 in a horizontal position. The second belts 28 are configured to transport the second glass film G2 toward the downstream separation device 23.

[0051] Each second tape 28 is composed of, for example, an endless tape. The second tape 28 is composed of, for example, an adsorption tape that adsorbs the second glass film G2. Figure 2 As shown, the second belt 28 has a plurality of suction holes 28a extending through the belt in the thickness direction. The suction holes 28a are connected to a suction device (not shown).

[0052] like Figure 2 as well as Figure 3 As shown, the separation device 23 is positioned downstream of the downstream conveyor 22b. The separation device 23 includes a first support roller 23a and a second support roller 23b that support the second glass film G2; a third support roller 23c that supports the non-product portion Gs; a first air injection device 29a that injects air A toward the second glass film G2; and a second air injection device 29b that injects air B toward the second glass film G2.

[0053] The first support rollers 23a include two support rollers. Each first support roller 23a supports the end portions Ga and Gb of the second glass film G2 in the width direction Y from the lower surface of the second glass film G2. The second support roller 23b is positioned between the two first support rollers 23a. The outer diameter of the second support roller 23b is larger than that of the first support roller 23a. The first and second support rollers 23a, 23b, are, for example, free rollers and rotate due to friction with the second glass film G2.

[0054] The third support roller 23c conveys the non-product portion Gs, created by cutting off the ends Ga and Gb in the width direction Y of the first glass film G1, toward the downstream side. The outer diameter of the third support roller 23c is approximately the same as that of the first support roller 23a, and smaller than that of the second support roller 23b. This structure allows the second support roller 23b to lift the second glass film G2, creating a gap between the second glass film G2 (ends Ga and Gb) supported by the first support roller 23a and the non-product portion Gs supported by the third support roller 23c. This makes it easier to prevent contact between the second glass film G2 (ends Ga and Gb) and the non-product portion Gs.

[0055] The first air jet device 29a and the second air jet device 29b are arranged above the second glass film G2. The first air jet device 29a jets air A toward the center of the second glass film G2 in the width direction Y. The second air jet device 29b jets air B toward the ends Ga and Gb of the second glass film G2. The air B has a relatively high jet pressure because it needs to press the ends Ga and Gb downward. The air A has a relatively low jet pressure because it only prevents the second glass film G2 from floating. Figure 2 In FIG. 1 , a portion (cross-hatched portion) denoted by reference symbol AP so as to overlap with the second support roller 23 b shows an area where the air A and B are blown onto the second glass film G2 by the air injection devices 29 a and 29 b .

[0056] like Figure 1 as well as Figure 2 As shown, the second cutting unit 9 is located in the area between the upstream conveyor 22a and the downstream conveyor 22b of the second conveyor 8. The second cutting unit 9 is configured to cut the widthwise ends Ga and Gb of the first glass film G1 using laser cutting. The second cutting unit 9 includes a pair of laser irradiation devices (hereinafter referred to as "second laser irradiation devices") 30 and a pair of cooling devices (hereinafter referred to as "second cooling devices") 31, which are located downstream of each second laser irradiation device 30.

[0057] like Figure 1 As shown in FIG. 1 , a platform 32 is provided below the second laser irradiation device 30 and the second cooling device 31 so as to contact the lower surface of the first glass film G1. Figure 2 As shown, since the first glass film G1 is cut at two locations in the width direction, the stage 32 is disposed at two locations corresponding to the pair of second laser irradiation devices 30 and the second cooling device 31 .

[0058] The platform 32 is fixed to the floor and is always stationary, which is not shown in the figure. The platform 32 has a plurality of suction ports 33 for sucking the first glass film G1. The suction ports 33 are connected to a suction device (not shown).

[0059] like Figure 1 As shown, the tension adjustment devices 24 to 26 are arranged between the upstream conveyor 22a and the second winding device 10. The tension adjustment devices 24 to 26 include a first tension adjustment device 24 located downstream of the second cutting section 9, a second tension adjustment device 25 located downstream of the first tension adjustment device 24, and a third tension adjustment device 26 located downstream of the second tension adjustment device 25.

[0060] The first tension adjustment device 24 includes an air injection device 34 located above the second glass film G2 and a support roller 35 located below the air injection device 34 and supporting the lower surface of the second glass film G2 .

[0061] The air injection device 34 is configured to inject air A downward. Figure 2 In FIG. 1 , a portion (a cross-hatched portion) denoted by reference symbol AP so as to overlap with the support roller 35 shows a region where the air A is blown toward the second glass film G2 by the air injection device 34 .

[0062] The air injection device 34 blows air A across the entire width of the second glass film G2 in the width direction Y. However, the method of blowing air A is not limited to this embodiment. The air injection device 34 may also inject air so that the air A contacts the center portion of the second glass film G2 in the width direction Y, thereby preventing the air A from contacting the end portions Ga and Gb of the second glass film G2.

[0063] The support roller 35 is, for example, a free roller. The outer diameter of the support roller 35 is 100 to 200 mm, but is not limited to this range. The outer peripheral surface of the support roller 35 is made of resin, but is not limited to this material. The support roller 35 supports the second glass film G2 from below over its entire width in the width direction Y.

[0064] The second tension adjustment device 25 includes a conveying roller 36 that contacts the second glass film G2 at an angle. In this embodiment, the conveying roller 36 is a drive roller that is driven by a drive motor (not shown). The angle (center angle) of the conveying roller 36 with respect to the second glass film G2 is preferably 40° to 50°, but is not limited to this range. The outer peripheral surface of the conveying roller 36 is made of resin, but is not limited to this material.

[0065] The second tension adjustment device 25 (the conveyance roller 36 ) also functions as a direction changing unit that changes the conveyance direction of the second glass film G2 from the lateral conveyance direction X2 to the downward direction Z2 .

[0066] The third tensioning device 26 is located downstream of the second tensioning device 25 and below the second tensioning device 25. The third tensioning device 26 includes a pair of rollers 37 and 38 that sandwich the second glass film G2. The pair of rollers 37 and 38 includes a first roller 37 that contacts one surface of the second glass film G2 and a second roller 38 that contacts the other surface of the second glass film G2.

[0067] At least one of the first roller 37 and the second roller 38 is a drive roller that is driven and rotated by a motor (not shown). The outer diameter of the first roller 37 and the outer diameter of the second roller 38 may be the same or different. The outer peripheral surface of each roller 37 and 38 is made of resin, but this material is not limited to this.

[0068] The second winding device 10 is located downstream of the third tension adjusting device 26 and below the third tension adjusting device 26. The second winding device 10 winds up the second glass film G2 that has passed through the third tension adjusting device 26 using a winding core 39 to form a second glass roll GRL2.

[0069] The second glass film G2 (first glass film G1) produced by the manufacturing apparatus 1 having the above-described structure is made of silicate glass or silica glass, preferably borosilicate glass, soda-lime glass, aluminosilicate glass, or chemically strengthened glass, with alkali-free glass being most preferred. Alkali-free glass refers to glass that contains substantially no alkali (alkali metal oxides), specifically, glass containing an alkali content of 3000 ppm by weight or less. The alkali content in the present invention is preferably 1000 ppm by weight or less, more preferably 500 ppm or less, and most preferably 300 ppm or less.

[0070] The thickness of the second glass film G2 (first glass film G1 ) is 10 μm to 300 μm, preferably 30 μm to 200 μm, and most preferably 30 μm to 100 μm.

[0071] Hereinafter, a method for manufacturing the second glass roll GRL2 using the manufacturing apparatus 1 having the above-described configuration will be described.

[0072] This method includes a first conveying step of conveying the base glass film G and the first glass film G1 and a second conveying step of conveying the first glass film G1 and the second glass film G2 between the unwinding device 7 and the second winding device 10 .

[0073] In the first conveying step, the base material glass film G is conveyed to the first cutting section 5 by the annealing rollers 14 and support rollers 15 of the annealing furnace 13, the direction-changing section 3, and the first conveying section 4. In the first conveying step, the first glass film G1 formed in the first cutting section 5 is conveyed to the first winding device 6 by the first conveying section 4.

[0074] In the second conveying step, the first glass film G1 is conveyed from the unwinding device 7 to the second cutting unit 9 by the second conveying unit 8. In the second conveying step, the second glass film G2 formed in the second cutting unit 9 is conveyed to the second winding device 10 by the second conveying unit 8.

[0075] like Figure 4As shown, the method includes a forming step S1, a first cutting step S2, a first winding step S3, a feeding step S4, an upstream conveying step S5, a second cutting step S6, a downstream conveying step S7, a tension adjustment step S8, and a second winding step S9. The upstream conveying step S5, the downstream conveying step S7, and the tension adjustment step S8 constitute part of the second conveying step.

[0076] In the forming step S1 , the molten glass GM overflowing from the overflow channel 11 a of the forming body 11 in the forming part 2 flows down along both side surfaces of the forming body 11 , and the molten glass is merged at the lower end to be formed into a film shape.

[0077] At this time, the edge rollers 12 restrict the widthwise contraction of the molten glass GM to form a predetermined width of the base glass film G. Subsequently, the base glass film G is subjected to a strain removal treatment (annealing step) in the annealing furnace 13. Under the tension of the support rollers 15, the base glass film G is formed to a predetermined thickness.

[0078] The first cutting step S2 is to cut off both widthwise end portions of the base material glass film G while continuously conveying the base material glass film G through the first conveying step. Specifically, in the first cutting step S2, while the base material glass film G is conveyed along the transverse conveying direction X1 by the first conveying unit 4, a portion of the base material glass film G is irradiated with the laser light L from the first laser irradiation device 18 in the first cutting unit 5.

[0079] The base glass film G is heated by the irradiation of the laser light L. Then, when the heated portion of the base glass film G reaches directly below the first cooling device 19 , it is cooled by the coolant R ejected downward from the first cooling device 19 .

[0080] The expansion caused by localized heating by the first laser irradiation device 18 and the contraction caused by cooling by the first cooling device 19 generate thermal stress in the base glass film G. Initial cracks are already formed in the base glass film G, and these cracks are propagated by the thermal stress. As a result, the widthwise ends (ears) of the base glass film G are separated from the base glass film G as non-product portions Gs, forming the first glass film G1.

[0081] In the first winding step S3 , the first glass film G1 is wound around the core 20 in the first winding device 6 to form a first glass roll GRL1 . Thereafter, the first glass roll GRL1 is removed from the first winding device 6 and transferred to the unwinding device 7 .

[0082] In the supply process S4, the first glass film G1 is fed out from the first glass roll GRL1 attached to the unwinding device 7. The first glass film G1 is conveyed upward Z1 by the conveying rollers 21a of the second conveying unit 8.

[0083] Then, in the upstream transport step S5, the upstream conveyor 22a transports the first glass film G1 along the transverse transport direction X2 while sucking it, and supplies it to the second cutting section 9 (suction transport step). Thus, the upstream conveyor 22a can transport the first glass film G1 to the second cutting section 9 without causing positional displacement of the first glass film G1.

[0084] In the second cutting step S6 , the second laser irradiation device 30 irradiates a portion of the first glass film G1 continuously supplied from the upstream conveyor 22 a with the laser beam L.

[0085] The first glass film G1 is heated by the irradiation of the laser light L. Then, when the heated portion of the first glass film G1 reaches directly below the second cooling device 31 , it is cooled by the coolant R ejected downward from the second cooling device 31 .

[0086] Thermal stress is generated in the first glass film G1 by expansion caused by localized heating by the second laser irradiation device 30 and contraction caused by cooling by the second cooling device 31. Initial cracks are already formed in the first glass film G1, and these cracks are propagated by the thermal stress. As a result, the two end portions Ga and Gb of the first glass film G1 in the width direction Y are separated from the first glass film G1 as non-product portions Gs, forming the second glass film G2.

[0087] In the downstream conveying step S7, the downstream conveyor 22b conveys the second glass film G2 to the downstream side while adsorbing it with a weak adsorption force using the second belt 28. This can prevent the second glass film G2 from flapping after being cut.

[0088] The separator 23 ejects air A from the first air ejection device 29a and ejects air B from the second air ejection device 29b, and supports the second glass film G2 conveyed by the downstream conveyor 22b with the first support roller 23a and the second support roller 23b.

[0089] like Figure 3 As shown, the separating device 23 lifts the second glass film G2 with the second support roller 23 b and presses the end portions Ga and Gb of the second glass film G2 from above with the air B ejected from the second air ejecting device 29 b .

[0090] Thereby, the second glass film G2 can be forcibly bent and deformed along the width direction Y. In this case, the second supporting roller 23 b supports the lower surface of the bent and deformed second glass film G2 .

[0091] Due to this bending, the separating device 23 separates the second glass film G2 and the non-product portion Gs in the width direction thereof. The third support roller 23 c conveys the non-product portion Gs separated from the second glass film G2 to the downstream collecting portion.

[0092] In the tension adjustment step S8, the tension of the second glass film G2 is adjusted while the second glass film G2 is conveyed by the conveying rollers 21b of the second conveying section 8 and the tension adjustment devices 24 to 26 between the downstream conveyor 22b and the second winding device 10. Figure 5 As shown, the tension adjustment step S8 includes a first tension adjustment step S81 , a second tension adjustment step S82 and a third tension adjustment step S83 .

[0093] In the first tension adjustment step S81, air A ejected from the air ejection device 34 of the first tension adjustment device 24 is brought into contact with the upper surface of the second glass film G2, which has been conveyed downstream by the downstream conveyor 22b. The second glass film G2 is pressed against the support roller 35 by the air A. This prevents excessive tension from being applied to the portion of the second glass film G2 located upstream of the support roller 35.

[0094] In the second tension adjustment step S82, the conveying rollers 36 are driven by a motor to convey the second glass film G2. In this case, it is desirable that the conveying speed of the second glass film G2 by the conveying rollers 36 is slower than the conveying speed of the second glass film G2 by the downstream conveyor 22b. Thus, the tension of the second glass film G2 is adjusted within the range from the downstream conveyor 22b to the second tension adjustment device 25 so as not to be excessively high. Furthermore, in the second tension adjustment step S82, the conveying rollers 36 change the conveying direction of the second glass film G2 from the horizontal conveying direction X2 to the downward direction Z2.

[0095] In the third tension adjustment step S83, the second glass film G2, which has been moved downward Z2 by the second tension adjustment device 25, is further conveyed downward while being sandwiched between the first roller 37 and the second roller 38 of the third tension adjustment device 26. In this manner, by sandwiching and conveying the second glass film G2 between the first roller 37 and the second roller 38, the tension of the second glass film G2 upstream of the third tension adjustment device 26 is adjusted.

[0096] In the second winding step S9, the second glass film G2 is wound around the winding core 39 in the second winding device 10. The second winding device 10 rotates the winding core 39 to apply tension to the second glass film G2. By winding the second glass film G2 to a predetermined length, the second glass roll GRL2 is formed in the second winding device 10.

[0097] According to the method for manufacturing the second glass roll GRL2 of the present embodiment described above, the tension applied to the second glass film G2 is adjusted in the tension adjustment step S8 (tension adjustment devices 24 to 26), thereby preventing excessive tension from acting on the second glass film G2. This prevents vibration of the second glass film G2 in the second cutting step S6 and prevents poor cutting of the second glass film G2.

[0098] Figure 6 as well as Figure 7 A second embodiment of the present invention will be described. A manufacturing apparatus 1 of this embodiment forms two second glass films G2A and G2B from one first glass film G1 and winds these glass films to manufacture two second glass rolls GRL2A and GRL2B.

[0099] The second cutting unit 9 of the manufacturing apparatus 1 is equipped with three second laser irradiation devices 30 and three second cooling devices 31 to form two second glass films G2A and G2B from one first glass film G1. Three stages 32 are arranged below each of the second laser irradiation devices 30 to support the lower surface of the first glass film G1.

[0100] To adjust the tension applied to the two second glass films G2A and G2B, the manufacturing apparatus 1 includes two first tension adjustment devices 24A and 24B, two second tension adjustment devices 25A and 25B, and third tension adjustment devices 26A and 26B. The structures of the tension adjustment devices 24A, 24B, 25A, 25B, 26A, and 26B are similar to those of the tension adjustment devices 24 to 26 in the first embodiment. Furthermore, the manufacturing apparatus 1 includes two separation devices 23A and 23B, corresponding to the two second glass films G2A and G2B.

[0101] The manufacturing apparatus 1 includes two second winding devices 10A and 10B in order to individually wind up the two second glass films G2A and G2B formed in the second cutting portion 9 .

[0102] Hereinafter, in the method of manufacturing the second glass rolls GRL2A and GRL2B using the manufacturing apparatus 1 of the present embodiment, points different from the first embodiment will be described.

[0103] In the second cutting step S6, the second glass film G2 is irradiated with laser light L from each second laser irradiation device 30, and the second cooling device 31 sprays a coolant R toward the second glass film G2. This separates the non-product portion Gs from the first glass film G1, forming two second glass films G2A and G2B as product portions.

[0104] In the first tension adjustment step S81 of the tension adjustment process S8, the tension applied to the two second glass films G2A and G2B is individually adjusted using the two first tension adjustment devices 24A and 24B. Subsequently, in the second tension adjustment step S82, the tension of each second glass film G2A and G2B is individually adjusted using the two second tension adjustment devices 25A and 25B. Similarly, in the subsequent third tension adjustment step S83, the tension of the second glass films G2A and G2B is individually adjusted using the two third tension adjustment devices 26A and 26B.

[0105] In the second winding step S9, two second glass films G2A and G2B are individually wound by the two second winding devices 10A and 10B. Thus, second glass rolls GRL2A and GRL2B are formed in the second winding devices 10A and 10B.

[0106] The other structures of this embodiment are the same as those of the first embodiment. In this embodiment, the same components as those of the first embodiment are denoted by the same reference numerals.

[0107] It should be noted that the present invention is not limited to the configuration of the above-described embodiment, nor is it limited to the above-described effects. The present invention can be modified in various ways without departing from the spirit of the present invention.

[0108] In the above-described embodiment, the method for manufacturing the second glass roll GRL2 in which all of the first tension adjusting step S81 , the second tension adjusting step S82 , and the third tension adjusting step S83 are performed is exemplified, but the present invention is not limited to this configuration.

[0109] The present invention can adjust the tension of the second glass film G2 by executing only the first tension adjustment step S81, that is, by operating only the first tension adjustment device 24. Furthermore, the present invention can adjust the tension of the second glass film G2 by executing only the second tension adjustment step S82 (operating only the second tension adjustment device 25) or by executing only the third tension adjustment step S83 (operating only the third tension adjustment device 26). Alternatively, the tension adjustment step S8 can be performed by operating two of the tension adjustment devices 24 to 26.

[0110] In the above embodiment, the manufacturing apparatus 1 includes the first tension adjusting device 24, the second tension adjusting device 25, and the third tension adjusting device 26. However, the present invention is not limited to this configuration. The present method can also be implemented using a manufacturing apparatus 1 including only the first tension adjusting device 24, only the second tension adjusting device 25, only the third tension adjusting device 26, or a manufacturing apparatus 1 including two of these.

[0111] In the above-described embodiment, the production apparatus 1 includes the separation device 23 , but the present invention is not limited to this configuration, and the production apparatus 1 may not include the separation device 23 .

[0112] In the above embodiment, the downstream conveyor 22b includes a suction belt conveyor, but the present invention is not limited to this structure. The downstream conveyor 22b may be a normal belt conveyor without a suction mechanism.

[0113] In the above embodiment, an example is shown in which the first glass film G1 is supplied by the unwinding device 7 in the supply step S4, but the present invention is not limited to this configuration and can also be applied to a method of manufacturing the first glass roll GRL1.

[0114] That is, the first cutting section 5 of the manufacturing apparatus 1 may have the same structure as the second cutting section 9. The first conveying section 4 may have the same structure as the second conveying section 8 (upstream conveyor 22a, downstream conveyor 22b, separator 23, tension adjusting devices 24 to 26).

[0115] In this case, during the supply process, the base material glass film G is supplied from the forming unit 2 and the direction-changing unit 3 to the first cutting unit 5. That is, the forming unit 2 and the direction-changing unit 3 function as a supply unit for supplying the glass film (base material glass film G) to the first cutting unit 5, similarly to the unwinding device 7. The tension of the first glass film G1 formed by cutting the base material glass film G at both widthwise ends in the first cutting unit 5 is adjusted in the tension adjustment process.

[0116] Description of Reference Numerals

[0117] 6. First winding device

[0118] 10 Second winding device

[0119] 18. First laser irradiation device

[0120] 22a Upstream conveyor (adsorption transport device)

[0121] 24 First tension adjustment device

[0122] 25 Second tension adjustment device

[0123] 26 Third tension adjustment device

[0124] 30 Second laser irradiation device

[0125] 34 Air injection device

[0126] 35 support roller

[0127] 36 transport rollers

[0128] 37 First Roller

[0129] 38 Second Roller

[0130] G Base material glass film

[0131] G1 First Glass Film

[0132] G2 Second Glass Film

[0133] GRL1 First Glass Roll

[0134] GRL2 Second Glass Volume

[0135] L Laser

[0136] S2 First cutting process

[0137] S3 First winding process

[0138] S5 Upstream transport process (adsorption transport process)

[0139] S6 Second cutting process

[0140] S8 tension adjustment process

[0141] S81 First tension adjustment process

[0142] S82 Second tension adjustment process

[0143] S83 The third tension adjustment process

[0144] S9 Second winding process.

Claims

1. A method for manufacturing a glass roll, comprising: Handling process, handling glass film; a cutting step of irradiating the glass film with laser light from a laser irradiation device to cut a portion of the glass film; and a winding step of winding the glass film after the cutting step into a roll shape using a winding device, The method for manufacturing the glass roll is characterized in that: The handling process includes: a suction conveying step of conveying the glass film before the cutting step while sucking it using a suction conveying device located upstream of the laser irradiation device in the conveying direction; and a tension adjustment step of adjusting the tension applied to the glass film after the cutting step using a tension adjustment device provided between the laser irradiation device and the winding device; The tension adjustment device includes: an air jet device located above the glass film after the cutting process; and a support roller located below the air jet device and supporting the lower surface of the glass film after the cutting process. The support roller is a free roller.

2. The method for manufacturing a glass roll according to claim 1, wherein: The tension adjustment device includes a conveying roller that contacts the glass film after the cutting step at an embracing angle. The conveying roller is a driving roller that is driven to rotate.

3. The method for manufacturing a glass roll according to claim 1 or 2, wherein: The tension adjustment device includes a pair of rollers that sandwich the glass film after the cutting step.

4. A method for manufacturing a glass roll, comprising: Handling process, handling glass film; a cutting step of irradiating the glass film with laser light from a laser irradiation device to cut a portion of the glass film; and a winding step of winding the glass film after the cutting step into a roll shape using a winding device, The method for manufacturing the glass roll is characterized in that: The handling process includes: a suction conveying step of conveying the glass film before the cutting step while sucking it using a suction conveying device located upstream of the laser irradiation device in the conveying direction; and a tension adjustment step of adjusting the tension applied to the glass film after the cutting step using a tension adjustment device provided between the laser irradiation device and the winding device; The tension adjustment device includes a conveying roller that contacts the glass film after the cutting step at an embracing angle. The conveying roller is a driving roller that is driven to rotate.

5. A method for manufacturing a glass roll, comprising: Handling process, handling glass film; a cutting step of irradiating the glass film with laser light from a laser irradiation device to cut a portion of the glass film; and a winding step of winding the glass film after the cutting step into a roll shape using a winding device, The method for manufacturing the glass roll is characterized in that: The handling process includes: a suction conveying step of conveying the glass film before the cutting step while sucking it using a suction conveying device located upstream of the laser irradiation device in the conveying direction; and a tension adjustment step of adjusting the tension applied to the glass film after the cutting step using a tension adjustment device provided between the laser irradiation device and the winding device; The tension adjustment process includes a first tension adjustment process, a second tension adjustment process performed after the first tension adjustment process, and a third tension adjustment process performed after the second tension adjustment process. The tension adjustment device includes a first tension adjustment device for performing the first tension adjustment process, a second tension adjustment device for performing the second tension adjustment process, and a third tension adjustment device for performing the third tension adjustment process. The first tension adjustment device includes: an air jet device located above the glass film after the cutting process; and a support roller located below the air jet device and supporting the lower surface of the glass film after the cutting process, wherein the support roller is a free roller. The second tension adjustment device includes a conveying roller that contacts the glass film after the cutting step at an embrace angle, and the conveying roller is a driving roller that is driven to rotate. The third tension adjustment device includes a pair of rollers that sandwich the glass film after the cutting step.

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