Contact roller and winding device

Abstract

A contact roller (8) according to one embodiment of the present invention has a contact surface (8a) that comes into contact with a long resin film (4) when the long resin film (4) is wound around a winding shaft (6). The contact roller (8) is provided with a roller body (18), a first layer (20) disposed on the outside of the roller body in the radial direction of the roller body, and a second layer (22) having a contact surface and disposed on the outside of the first layer in the radial direction. An A Shore hardness of the second layer is less than an A Shore hardness of the first layer.

Description

[0001] This application is a divisional application of the invention patent application with the application date of April 20, 2020, application number 202010314599.1, and invention name “Contact roller and winding device”. Technical Field

[0002] The invention relates to a contact roller and a winding device. Background Art

[0003] There is a case where a long resin film is wound around a winding shaft to produce a roll-shaped blank roll. The blank roll is sold as a product or transferred to the next process and used in the next process. When the resin film is wound around the winding shaft, in order to prevent deformation defects (such as wrinkles) during winding, a contact roller is brought into contact with the resin film and the resin film is wound while applying a constant pressure (contact pressure) to the resin film.

[0004] Examples of the touch roller include touch rollers (touch drums) described in Utility Model Application Laid-Open No. 62-63248 and Utility Model Application Laid-Open No. 56-165747.

[0005] The contact roller described in Utility Model Publication No. 62-63248 is a contact roller used when winding printed film, paper, etc. The contact roller has a cylindrical core, and the core is covered with a sponge-like material. In the contact roller described in Patent Document 1, the sponge-like material contacts the film, paper, etc. to be wound.

[0006] The contact roller described in Utility Model Publication No. 56-165747 is a contact roller used when winding a magnetic tape. The contact roller comprises a circular core member, a thick elastic sponge member arranged on the periphery of the core member, and a thin elastic rubber member having a rubber hardness of 50 degrees or less arranged on the periphery of the elastic sponge member. In the contact roller described in Patent Document 2, the elastic rubber member contacts the magnetic tape to be wound. Summary of the invention

[0007] An object of the present invention is to provide a touch roller and a winding device capable of preventing deformation defects when winding a resin film.

[0008] A contact roller of one embodiment of the present invention has a contact surface that contacts the resin film when a long resin film is wound on a winding shaft, and the contact roller comprises: a roller body; a first layer, which is arranged on the outside of the roller body in the radial direction of the roller body; and a second layer, which has the contact surface and is arranged on the outside of the first layer in the radial direction, and the A Shore hardness of the second layer is smaller than the A Shore hardness of the first layer.

[0009] In this specification, the A Shore hardness is the hardness (Shore A) of the durometer type A specified in JIS K 6253.

[0010] The contact roller has a first layer and a second layer in order from the roller body side. The A Shore hardness of the second layer is smaller than the A Shore hardness of the first layer. That is, the second layer is a layer softer than the first layer. When the contact roller is brought into contact with the resin film, the second layer is in contact with the resin film. The second layer is supported by the first layer, which is harder than the second layer, so the reaction force when the contact roller is pressed against the resin film can be absorbed by the first layer. In addition, the second layer is softer than the first layer, so it can follow the surface unevenness of the resin film compared to the case where the first layer is directly in contact with the resin film. As a result, by winding the resin film while bringing the contact roller into contact with the resin film, it is easy to apply uniform pressure to the resin film in a direction orthogonal to the longitudinal direction of the resin film, and air can be prevented from being drawn in. Therefore, deformation defects when the resin film is wound can be prevented.

[0011] The Shore A hardness of the second layer may be 0 or more and 40 / 50 or less of the Shore A hardness of the first layer. In this case, it is easy to apply uniform pressure to the resin film in a direction perpendicular to the longitudinal direction of the resin film.

[0012] The first layer may have a Shore A hardness of 50 to 80, and the second layer may have a Shore A hardness of 0 to 40. In this case, the reaction force can be easily absorbed.

[0013] The second layer may be detachably mounted on the first layer, so that the second layer can be easily replaced when it is deteriorated or damaged.

[0014] The material of the surface of the roller body that is in contact with the first layer may be metal.

[0015] Alternatively, the second layer has an outer layer and an inner layer, the outer layer has the contact surface, the inner layer is arranged between the first layer and the outer layer, the A Shore hardness of the inner layer and the outer layer is smaller than the A Shore hardness of the first layer, and the A Shore hardness of the outer layer is greater than the A Shore hardness of the inner layer.

[0016] In the structure, the second layer has an outer layer which is softer than the first layer and harder than the inner layer, and the outer layer is in contact with the resin film. The outer layer can easily prevent the second layer from being deteriorated or damaged. In addition, the inner layer can follow the surface unevenness of the resin film. This makes it easy to further apply a constant pressure to the resin film.

[0017] Alternatively, the inner layer may have a Shore A hardness of 0 to 20. Alternatively, the outer layer may have a Shore A hardness of 20 to 40.

[0018] A winding device according to another embodiment of the present invention comprises: a winding shaft on which a long strip of resin film is wound; the contact roller according to one embodiment of the present invention; and a position adjustment mechanism for moving one of the winding shaft and the contact roller relative to the other so that the contact surface of the contact roller contacts the resin film with a constant pressing force.

[0019] The winding device includes the touch roller according to one aspect of the present invention. Therefore, the resin film can be wound around the winding shaft while preventing deformation defects when the resin film is wound.

[0020] According to the present invention, it is possible to provide a touch roller and a winding device that can prevent deformation defects when winding a resin film. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 This is a schematic configuration diagram of a winding device using a touch roller according to an embodiment.

[0022] Figure 2 yes Figure 1 A schematic perspective view of a portion of a winding device is shown.

[0023] Figure 3 This is a schematic structural diagram of an example of an optical laminate (resin film).

[0024] Figure 4 This is a perspective view of an example of a touch roller.

[0025] Figure 5 It is a figure for demonstrating the contact state of a touch roller and a resin film.

[0026] Figure 6 It is a figure for demonstrating the contact state of a touch roller and a resin film.

[0027] Figure 7 The following is a drawing for explaining a method for inspecting a blank roll.

[0028] Figure 8 It is a figure for demonstrating another example of a touch roller.

[0029] Fig. 9 This is a diagram for explaining still another example of the touch roller.

[0030] Fig.10 It is a figure for demonstrating the modification of the arrangement position of a touch roller.

[0031] Description of reference numerals:

[0032] 2…winding device, 4…resin film, 6…winding shaft, 8…contact roller, 8a…contact surface, 20…first layer, 22…second layer, 30…contact roller, 32…second layer, 34…inner layer, 36…outer layer. DETAILED DESCRIPTION

[0033] The embodiments of the present invention are described below with reference to the drawings. The same or corresponding parts in the drawings are denoted by the same reference numerals and repeated descriptions are omitted. The dimensional ratios in the drawings are not necessarily the same as those in the description.

[0034] Figure 1 This is a diagram showing a schematic configuration of a winding device using a touch roller according to an embodiment. Figure 2 yes Figure 1 The schematic perspective view of a part of the winding device shown is a diagram for explaining the contact area between the touch roller and the resin film.

[0035] The winding device 2 is a device for winding a long resin film 4. The resin film 4 can be manufactured by, for example, extrusion molding. The length of the longitudinal direction of the resin film 4 is not particularly limited, for example, it is more than 1000m and less than 10000m, preferably more than 1000m and less than 6000m. The length of the width direction of the resin film 4 is not particularly limited, for example, it can also be less than 2.5m.

[0036] Examples of the resin film 4 are the following optical films. The optical film may be a single layer or an optical laminated body in which two or more layers are laminated. Examples of the single layer optical film include the thermoplastic resin film described below.

[0037] Examples of the layers constituting the optical laminate include a polarizing plate, a thermoplastic resin film, an optical functional layer, an adhesive layer, a pressure-sensitive adhesive layer, a separator, a protective film, and a touch sensor panel.

[0038] Figure 3 It is a schematic diagram showing an example of an optical layered body. Figure 3 The optical laminate 100 shown includes a polarizing plate 102 , a first adhesive layer 104 , a first optical functional layer 106 , an adhesive layer 108 , a second optical functional layer 110 , a second adhesive layer 112 , and a separator 114 .

[0039] The first adhesive layer 104, the first optical function layer 106, the adhesive layer 108, the second optical function layer 110, the second adhesive layer 112, and the separator 114 are sequentially laminated on the polarizing plate 102. Each layer of the optical laminate 100 will be described in detail below.

[0040] [Polarizing plate]

[0041] The polarizing plate 102 includes a polarizing plate 102 a and a thermoplastic resin film 102 b laminated on one or both sides of the polarizing plate 102 a .

[0042] (Polarizer)

[0043] The polarizer 102a is a layer having linear polarization characteristics. The material and manufacturing method of the polarizer 102a may also be methods known in the art. The thickness of the polarizer 102a is usually 30 μm or less, preferably 18 μm or less, and more preferably 15 μm or less. Reducing the thickness of the polarizer 102a is conducive to the thin film of the polarizing plate 102. The thickness of the polarizer 102a is usually 1 μm or more, for example, 5 μm or more.

[0044] (Thermoplastic resin film)

[0045] Examples of the thermoplastic resin film 102 b include cyclic polyolefin resin films, cellulose acetate resin films composed of resins such as cellulose triacetate and diacetyl cellulose, polyester resin films composed of resins such as polyethylene terephthalate, polyethylene naphthalate, and polybutylene terephthalate, polycarbonate resin films, (meth) acrylic resin films, polypropylene resin films, and other films known in the art.

[0046] The thickness of the thermoplastic resin film 102b is preferably thin from the viewpoint of thinning the polarizing plate 102, but if it is too thin, there is a tendency for strength to decrease and processability to deteriorate. Therefore, it is preferably 5 μm or more and 150 μm or less, more preferably 5 μm or more and 100 μm or less, and further preferably 10 μm or more and 50 μm or less.

[0047] [First adhesive layer]

[0048] The first adhesive layer 104 is a layer sandwiched between the polarizing plate 102 and the first optical functional layer 106 and bonding the two. The first adhesive layer 104 can be composed of an adhesive composition mainly composed of (meth) acrylic resin, rubber resin, polyurethane resin, ester resin, silicone resin, polyvinyl ether resin, etc. Among them, an adhesive composition based on a (meth) acrylic resin with excellent transparency, weather resistance, heat resistance, etc. is preferred. The adhesive composition can also be an active energy ray curing type or a heat curing type. The first adhesive layer 104 can be formed by a method known in the art.

[0049] [First optical functional layer]

[0050] The first optical functional layer 106 is a layer having other optical functions other than the polarizer 102a for imparting the desired optical function. A preferred example of the first optical functional layer 106 is a phase difference layer. As the phase difference layer, for example, a layer imparting a phase difference of λ / 2, a layer imparting a phase difference of λ / 4 (positive A plate) and a positive C plate can be cited. The phase difference layer may include an orientation layer and a substrate, or may have a liquid crystal layer, an orientation layer and a substrate each having two or more layers. The thickness of the phase difference layer may be the same as that of the polarizer 102a. The material and manufacturing method of the phase difference layer may be those known in the art.

[0051] Other examples of the first optical function layer 106 include a focusing plate, a brightness enhancement film, a reflective layer (reflective film), a semi-transmitting reflective layer (semi-transmitting reflective film), a light diffusion layer (light diffusion film), etc. The materials and manufacturing methods of each of the other examples may be known in the art.

[0052] [Adhesive layer]

[0053] The adhesive layer 108 is a layer that is sandwiched between the first optical functional layer 106 and the second optical functional layer 110 and bonds the two. The adhesive layer 108 is composed of a known aqueous composition (including an aqueous adhesive) in which a curable resin component is dissolved or dispersed in water, a known active energy ray-curable composition (including an active energy ray-curable adhesive) containing an active energy ray-curable compound, and the like.

[0054] [Second optical functional layer]

[0055] The second optical functional layer 110 is a layer having other optical functions other than the polarizing plate 102a for imparting a desired optical function. Examples of the second optical functional layer 110 include examples of the first optical functional layer 106. Thus, the description of the first optical functional layer 106 can be cited as the second optical functional layer 110. Usually, the second optical functional layer 110 has an optical function different from that of the first optical functional layer 106. For example, in the case where one of the first optical functional layer 106 and the second optical functional layer 110 is a layer imparting a phase difference of λ / 2, the other is a layer imparting a phase difference of λ / 4.

[0056] The second optical function layer 110 may be bonded to the first optical function layer 106 via a pressure-sensitive adhesive layer instead of the adhesive layer 108. As the pressure-sensitive adhesive layer used here, the description of the first pressure-sensitive adhesive layer 104 can be cited.

[0057] [Second adhesive layer]

[0058] The second adhesive layer 112 is a layer for bonding the optical laminate 100 to an image display device or other optical members. The adhesive, adhesive composition, thickness, and preparation method used as the second adhesive layer 112 are similar to those described above for the first adhesive layer 104 .

[0059] [Isolation film]

[0060] The separator 114 is provided on the second adhesive layer 112 (on the opposite side to the second optical functional layer 110) to prevent dirt and the like from adhering to the second adhesive layer 112 and to prevent the second adhesive layer 112 from being attached to other parts of the optical laminate 100 (resin film 4) when being rolled up. The separator 114 may be a film made of polyethylene resins such as polyethylene, polypropylene resins such as polypropylene, polyester resins such as polyethylene terephthalate, etc. Among them, a stretched film of polyethylene terephthalate is preferred. The separator 114 is peeled off and removed when the optical laminate 100 is attached to an image display element or other optical components.

[0061] The optical laminate 100 may include a protective film for protecting its surface (typically, the surface of the thermoplastic resin film 102b of the polarizing plate 102). The protective film is peeled off together with the adhesive layer of the protective film after the polarizing plate 102 is bonded to an image display element or other optical member.

[0062] The protective film is composed of, for example, a base film and an adhesive layer laminated thereon. The adhesive layer is described above. The resin constituting the base film may be a polyethylene resin such as polyethylene, a polypropylene resin such as polypropylene, a polyester resin such as polyethylene terephthalate and polyethylene naphthalate, a polycarbonate resin, or a thermoplastic resin such as a poly(meth)acrylic resin.

[0063] Polyester resins such as polyethylene terephthalate are preferred.

[0064] The thickness of the protective film is not particularly limited, but is preferably in the range of 20 μm or more and 200 μm or less. When the thickness of the protective film is 20 μm or more, it tends to be easy to provide strength to the optical layered body 100 .

[0065] In the optical laminate 100, for example, the thermoplastic resin film 102b may also have the optical function of the first optical functional layer 106 or the second optical functional layer 110. In this case, the optical laminate 100 may not have a layer having the same optical function as the thermoplastic resin film 102b in the first optical functional layer 106 or the second optical functional layer 110. The thermoplastic resin film 102b may also have a function as a protective film, for example. In this case, the optical laminate 100 does not have a protective film on the side opposite to the first adhesive layer 104 when viewed from the polarizing plate 102.

[0066] Resin film 4 Figure 1 As shown, the resin film 4 is transported by a transport roller R as a part of the transport mechanism and is wound using a winding device 2. The roll-shaped resin film 4 wound using the winding device 2 is also referred to as a blank roll WR. For convenience of explanation, the roll-shaped resin film 4 being wound is sometimes referred to as a blank roll WR.

[0067] The winding device 2 includes a winding shaft 6 , a contact roller 8 , and a position adjustment mechanism 10 .

[0068] The winding shaft 6 is a core for winding the resin film 4. In the present embodiment, the winding shaft 6 is driven to rotate by a motor or the like, so that the resin film 4 is wound around the winding shaft 6. Unless otherwise specified, the winding device 2 of the present embodiment adopts a center-driven winding method (center-driven method) for winding the resin film 4 by rotating the winding shaft 6.

[0069] The contact roller 8 is a roller for pressing the resin film 4 wound using the winding shaft 6 and applying a constant pressure (hereinafter also referred to as "contact pressure"). The contact pressure on the resin film 4 is, for example, 500 N / m or less, preferably 400 N / m or less, and more preferably 330 N / m or less. The lower limit of the contact pressure is usually 10 N / m, preferably 100 N / m, etc. The contact roller 8 has a contact surface 8a that contacts the resin film 4. The contact surface 8a is the outermost surface of the contact roller 8. The width of the contact surface 8a (the length in the direction of the rotation axis of the contact roller 8) is usually greater than the width of the resin film 4 (the length in the direction orthogonal to the length direction of the resin film 4). An example of the radial length (diameter) of the contact roller 8 is 30 mm to 300 mm, preferably 50 mm to 200 mm, and more preferably 120 mm to 160 mm. The contact roller 8 is sometimes also called a clamping roller, a contact rubber roller, a pressure roller, etc.

[0070] The contact roller 8 is supported by a pair of supporting members 12 (see Figure 2 ) is supported in a rotatable manner. The supporting member 12 may be in the form of a plate or a rod.

[0071] The position adjustment mechanism 10 is to Figure 1 The blank arrow in the figure indicates a mechanism for moving one of the winding shaft 6 and the touch roller 8 relative to the other by bringing the contact surface 8 a of the touch roller 8 into contact with the resin film 4 with a pressing force that applies a constant contact pressure.

[0072] exist Figure 1 In the illustrated embodiment, the contact roller 8 is moved relative to the winding shaft 6. Figure 1In the illustrated embodiment, the position adjustment mechanism 10 is a working cylinder. The position adjustment mechanism 10 has a working cylinder body 14 and a working cylinder rod 16 that can be extended and retracted relative to the working cylinder body 14. The working cylinder rod 16 is connected to the supporting member 12. Examples of working cylinders of the position adjustment mechanism 10 include hydraulic cylinders and air cylinders. The position adjustment mechanism 10 can also be an actuator. The position adjustment mechanism 10 can also be a swing type, for example. For example, the end of a pair of supporting members 12 on the opposite side of the contact roller 8 can also be mounted on the supporting shaft in a swingable manner. In this case, the supporting shaft functions as the position adjustment mechanism 10. The pair of supporting members 12 can also be part of the position adjustment mechanism 10.

[0073] The position adjustment mechanism 10 may include, for example, a control unit that controls the cylinder to adjust the position of the touch roller 8 so as to apply a constant contact pressure to the resin film 4 according to the amount of the resin film 4 wound around the winding shaft 6. The control unit may be provided by the cylinder, for example.

[0074] Under the action of the position adjustment mechanism 10, even if the diameter of the blank roll WR changes due to the continuous winding of the resin film 4 around the winding shaft 6, the contact roller 8 retreats accordingly. As a result, the contact area A ( Figure 2 A constant contact pressure is applied to the area (an area surrounded by a dashed line and shown by hatching in FIG. 4 ). The contact area A has a rectangular shape extending in the width direction of the resin film 4.

[0075] Next, use Figure 4 The touch roller 8 will be described in detail. The touch roller 8 includes a roller body 18 , a first layer 20 , and a second layer 22 .

[0076] The roller body 18 is the core material of the contact roller 8. The roller body 18 has a cylinder 24, a pair of end walls 25 and a pair of shaft portions 26. Examples of materials of the cylinder 24 include metal, carbon and CFRP (carbon fiber reinforced plastic). Examples of metals include iron, stainless steel, aluminum, etc. The surface of the cylinder 24 is the surface of the roller body 18 that contacts the first layer 20. The pair of end walls 25 close the openings at both ends of the cylinder 24. The cylinder 24 and the pair of end walls 25 form a hollow main body. The pair of shaft portions 26 and the pair of end walls 25 are arranged concentrically with the axis of the cylinder 24. Figure 2 The middle figure shows one end wall 25 and one shaft portion 26 of a pair of end walls 25 and a pair of shaft portions 26. The pair of shaft portions 26 are rotatably supported by a pair of support members 12. The roller body 18 may include one shaft portion penetrating the pair of end walls 25.

[0077] In the present embodiment, the first layer 20 is arranged outside the roller body 18 (specifically, outside the cylinder 24) in the radial direction of the roller body 18. The first layer 20 covers the surface of the cylinder 24 of the roller body 18. In the present embodiment, the first layer 20 is an elastic layer. The first layer 20 is a base layer for the second layer 22. An example of the material of the first layer 20 is rubber. The first layer 20 can be formed by winding a rubber sheet in the circumferential direction of the cylinder 24, or by forming a cylinder portion in advance with the rubber sheet and attaching the cylinder portion to the roller body 18.

[0078] The A Shore hardness of the first layer 20 is generally 50 to 80. The first layer 20 is a layer for absorbing the reaction force (or contact) of the pressing force when the contact roller 8 is pressed against the resin film 4. For example, from the point of view of preventing the contact roller 8 itself from bending by utilizing its own weight, it is preferable to avoid the first layer 20 being too thick. By preventing the bending of the contact roller 8 itself, it is easy to apply the contact pressure evenly along the width direction of the resin film 4. On the other hand, from the point of view of the easy dispersion of the reaction force, it is preferable to avoid the first layer 20 being too thin. By dispersing the reaction force, it is easy to apply the contact pressure evenly along the width direction of the resin film 4. Therefore, the thickness of the first layer 20 is generally 2 mm to 15 mm, preferably 3 mm to 15 mm, and the more preferred range is 3 mm to 12 mm.

[0079] The Shore A hardness of the first layer 20 is a hardness obtained by testing a test piece having a thickness of 6 mm and formed of the same material as the first layer 20 with a hardness (Shore A) of a durometer type A in accordance with JIS K 6253.

[0080] The first layer 20 may be formed, for example, by winding a sheet to be the first layer 20 around the roller body 18 , or may be formed by inserting the roller body 18 into a cylindrical sheet to be the first layer 20 .

[0081] The second layer 22 is arranged outside the first layer 20 in the radial direction. The surface of the second layer 22 is the contact surface 8a. The A Shore hardness of the second layer 22 is less than the A Shore hardness of the first layer 20. That is, the second layer 22 is a layer softer than the first layer 20. An example of the A Shore hardness of the second layer 22 is 0 or more and 40 / 50 or less of the A Shore hardness of the first layer 20. For example, when the A Shore hardness of the first layer 20 is 50 to 80, the A Shore hardness of the second layer 22 is 0 to 40.

[0082] The thickness of the second layer 22 is not particularly limited, and is, for example, 0.5 mm to 10 mm, preferably 1 mm to 10 mm, and more preferably 1 mm to 7 mm.

[0083] In this embodiment, the second layer 22 is a porous layer. The porous layer is not particularly limited, and a foamed material (so-called foam) composed of a resin can be cited. The resin constituting the porous layer can be cited as polyethylene, polyurethane, etc.

[0084] The second layer 22 may be formed, for example, by winding a sheet of foam material along the circumferential direction of the first layer 20, or by using a plurality of rectangular (or long strip) foam materials to cover the outer surface of the first layer 20 without forming a gap. When using a plurality of rectangular (or long strip) foam materials to cover the outer surface of the first layer 20, for example, the plurality of rectangular (or long strip) foam materials may be arranged in a manner such that the length direction of the plurality of rectangular (or long strip) foam materials coincides with the direction of the rotation axis of the touch roller 8 and a plurality of them may be arranged in the circumferential direction, or the plurality of rectangular (or long strip) foam materials may be wound around the first layer 20 in a manner such that the length direction of the plurality of rectangular (or long strip) foam materials crosses the direction of the rotation axis of the touch roller 8 (or in a spiral shape).

[0085] The second layer 22 can be detachably mounted on the first layer 20. For example, the foam material or a plurality of rectangular (or long strip) foam materials can be attached to the outer surface of the first layer 20 by double-sided tape, peelable adhesive, etc.

[0086] The second layer 22 may have a plurality of stacked structures in the radial direction, for example, if it has the above-mentioned Shore A hardness relationship with the first layer 20. When the second layer 22 has a stacked structure having a plurality of layers, the materials of the layers may be different if the second layer 22 having a stacked structure satisfies the above-mentioned Shore A hardness range.

[0087] The Shore A hardness of the second layer 22 is the hardness obtained by preparing a test piece with a thickness of 6 mm formed by the same material as the second layer 22 and testing it using a type A durometer in accordance with JIS K6253. Alternatively, when the second layer 22 has a laminated structure including a plurality of layers, the Shore A hardness of each layer of the second layer 22 may be the hardness (Shore A) of the durometer type A specified in JIS K 6253 of each test piece with a thickness of 6 mm formed by the same material as the respective layers.

[0088] For example, in an embodiment where the first layer 20 is a rubber layer and the second layer 22 is a sponge layer, the touch roller 8 corresponds to a surface roller in which a rubber layer is provided on the outer surface of the roller body 18 and covered with a sponge layer.

[0089] The touch roller 8 includes a first layer 20 and a second layer 22 arranged in this order from the roller body 18. The A Shore hardness of the second layer 22 is lower than that of the first layer 20. In other words, the touch roller 8 includes a relatively hard first layer 20 (base layer) and a relatively soft second layer 22 on the outer side of the roller body 18. The effect of having the relatively hard first layer 20 and the relatively soft second layer 22 on the outer side of the roller body 18 in this way will be described by comparing with a case where the second layer 22 is not provided and a case where the first layer 20 is not provided.

[0090] The contact roller 8 is Figure 1 and Figure 2 As shown in FIG. 1 , a constant contact pressure acts on the surface of the resin film 4 wound around the winding shaft 6. Figure 5 As shown, there is a case where irregularities are generated on the surface of the resin film 4 pressed by the touch roller 8 . Figure 5 For the purpose of description, a state before the touch roller 8 comes into contact with the resin film 4 is shown.

[0091] When the touch roller 8 does not have the second layer 22, the first layer 20 contacts the surface of the resin film 4. In this case, when the first layer 20 has, for example, the Shore A hardness, the first layer 20 cannot follow the unevenness of the resin film 4. As a result, there is a problem of Figure 2 In the contact area A shown in FIG. 1 , a gap is formed between the contact roller 8 and the resin film 4. As a result, the contact pressure is unevenly applied to the contact area A along, for example, its width direction (the direction of the rotation axis of the contact roller 8). On the other hand, in the case where the contact roller 8 does not have the first layer 20, that is, in the case where the second layer 22 is directly provided on the roller body 18, the convex portion on the surface of the resin film 4 is easily subjected to a contact pressure stronger than the designed contact pressure due to the influence of the roller body 18. Therefore, in this case, the contact pressure is also uneven. Figure 2 The contact area A shown in the figure has a contact pressure applied unevenly along its width direction. As described above, if the contact pressure is applied unevenly in the width direction of the contact area A, air is drawn in when the resin film 4 is wound around the winding shaft 6. The resin film 4 is not easy to allow air to pass through, and is therefore easily affected by the air being drawn in. Therefore, if air is drawn in, the resin film 4 is likely to have a deformation defect such as wrinkles.

[0092] On the other hand, when the outer side of the roller body 18 has a relatively hard first layer 20 and a relatively soft second layer 22, as shown in FIG. Figure 6 The second layer 22 follows the surface irregularities of the resin film 4 , and the first layer 20 is interposed between the roller body 18 and the second layer 22 . The hardness (or elasticity) of the first layer 20 can absorb strong pressure generated on the convex portion of the resin film 4 .

[0093] As a result, the contact pressure can be uniformly applied to the contact area A along the width direction thereof. Therefore, the above-mentioned deformation defect in the resin film 4 wound on the winding shaft 6 can be prevented. As a result, when the resin film 4 is unwound from the blank roll WR obtained by winding the resin film 4 on the winding shaft 6 again and a product is manufactured using the unwound resin film 4, it is easy to manufacture a qualified product.

[0094] If the A Shore hardness of the second layer 22 is 0 or more and 40 / 50 or less of the A Shore hardness of the first layer 20, it is easy to make the contact pressure uniform in the width direction of the contact area A. Similarly, if the A Shore hardness of the first layer 20 is 50 to 80 and the A Shore hardness of the second layer 22 is 0 to 40, it is easy to make the contact pressure uniform in the width direction of the contact area A.

[0095] As described above, in the touch roller 8, the first layer 20 absorbs the strong pressure generated in the convex part of the resin film 4, while the second layer 22 follows the concavoconvex of the surface of the resin film 4. Therefore, the thickness of the second layer 22 can be appropriately selected according to the A Shore hardness of the first layer 20 and the second layer 22 and the contact pressure of the contact area A. As shown in the example, if the thickness of the second layer 22 is 10 mm or less (or 7 mm or less), the first layer 21 can be used more effectively.

[0096] In the embodiment in which the second layer 22 is detachable from the first layer 20, the manufacturing cost of the blank roll WR can be reduced. For example, the second layer 22 is pressed against the resin film 4, so there is a case where the second layer 22 is deteriorated or damaged (cutting, wear, etc.). Even in such a case, if the second layer 22 is detachable from the first layer 20, only the second layer 22 needs to be replaced. As a result, the cost can be reduced compared to the case of replacing the entire touch roller 8.

[0097] Next, a specific example will be described. In the specific example, three touch rollers are prepared. In order to distinguish the three touch rollers, the three touch rollers are referred to as touch roller TR1, touch roller TR2, and touch roller TR3. The touch roller TR1 is a touch roller used for a comparative experiment.

[0098] For the sake of convenience, in the description of the specific example, the case where the touch roller TR1 used in the comparative specific example is used is also described together with the case where the touch roller TR2 and the touch roller TR3 are used. Figure 1 The same elements as those in the description of the winding device 2 are denoted by the same reference numerals, and duplicate descriptions are omitted.

[0099] (Contact roller TR1)

[0100] The contact roller TR1 has a roller body 18 and a rubber layer provided on the outer surface of the roller body 18. In the contact roller TR1, the rubber layer corresponds to the first layer 20. The outermost surface of the contact roller TR1 (corresponding to the contact surface 8a) is the surface of the rubber layer. That is, the contact roller TR1 is a contact roller without the second layer 22. The width direction length of the contact roller TR1 is 2m to 2.5m. The roller body 18 is made of metal. The thickness of the rubber layer is 10mm. The A Shore hardness of the rubber layer is 65.

[0101] (Contact roller TR2)

[0102] The contact roller TR2 has a structure in which the surface of the rubber layer (first layer 20) of the contact roller TR1 is further covered with a sponge sheet. Therefore, the contact roller TR2 has a roller body 18, a rubber layer provided on the outer surface of the roller body 18, and a sponge layer provided on the outer surface of the rubber layer. In the contact roller TR2, the sponge layer corresponds to the second layer 22. The thickness of the sponge layer (second layer 22; sponge sheet) is 2 mm, and the width direction length is the same as the width direction length of the contact roller TR1. The A Shore hardness of the sponge layer (second layer 22), that is, the A Shore hardness of the sponge sheet used for the contact roller TR2 is 8.

[0103] (Contact roller TR3)

[0104] The contact roller TR3 has a structure in which the surface of the sponge layer of the contact roller TR2 is further covered with the sponge sheet used in the contact roller TR2. Therefore, the contact roller TR3 has a roller body 18, a rubber layer provided on the outer surface of the roller body, and two sponge layers provided in sequence on the outer surface of the rubber layer. The two sponge layers correspond to the second layer 22. The thickness of each sponge layer is 2 mm, so when the two sponge layers are regarded as one sponge layer, the contact roller TR3 has a sponge layer (second layer 22) with a thickness of 4 mm on the outer side of the rubber layer. The two sponge layers are made of the same material, so the A Shore hardness of the second layer 22 having two sponge layers in the contact roller TR3 is 8, similar to the case of the contact roller TR2. The width direction length of the two sponge layers is the same.

[0105] Next, in Figure 1 In the winding device 2 shown, the touch roll TR1, the touch roll TR2, and the touch roll TR3 are used as the touch roll 8 to wind up the resin film 4. The resin film 4 used for winding up is a poly (meth) acrylic resin film (thickness 40 μm to 80 μm; winding length 4000 mm). When each of the touch roll TR1, the touch roll TR2, and the touch roll TR3 is used, the resin film 4 wound up is the same.

[0106] In winding the resin film 4, a center-driven winding type winder is used as the winding device 2. The winding speed is 30 m / min to 60 m / min. The winding tension (tension per unit width) when winding the resin film 4 is 150 N / m to 250 N / m. The position adjustment mechanism 10 uses an air cylinder. When the contact rollers TR1, TR2, and TR3 are pressed against the resin film 4 using the position adjustment mechanism 10, the contact pressure is 200 N / m to 300 N / m.

[0107] The structures and winding conditions of the resin film 4 and the winding device 2 are the same except that the touch roll TR1 , the touch roll TR2 , and the touch roll TR3 are respectively used as the touch roll 8 .

[0108] Appearance inspection is performed on the blank roll WR produced by winding the resin film 4 using the touch roll TR1 , the touch roll TR2 , and the touch roll TR3 , respectively.

[0109] Specifically, if Figure 7 As shown, the blank roll WR is irradiated with light from a light source 28 disposed on one side of the blank roll WR, and the transmitted light is visually observed from the side of the blank roll WR opposite to the light source 28. As the light source 28, a Purui lamp (manufactured by CSC Corporation) is used.

[0110] When the resin film 4 is wound up using the winding device 2 , for example, air is drawn in and deformation defects (wrinkles, etc.) occur in the blank roll WR, and the deformation defect portion becomes dark.

[0111] Thus, the presence or absence of a deformation defect is evaluated based on the degree of the dark shadow (darkness) caused by the deformation defect relative to the sample serving as the evaluation reference.

[0112] In the case of the blank roll WR when the touch roller TR1 is used, the dark shadow (darkness) of the deformation defect is confirmed by the appearance inspection. On the other hand, in the case of using the touch rollers TR2 and TR3, the dark shadow (darkness) of the deformation defect is not confirmed by the appearance inspection. That is, it is known that when the rubber layer is in direct contact with the resin film 4, for example, air is drawn in when the resin film 4 is wound, and deformation defects occur, while, on the other hand, when the sponge layer having a smaller Shore A hardness than the rubber layer is in contact with the resin film 4, deformation defects can be prevented.

[0113] The present invention is not limited to the above-described various embodiments, but is intended to include the scope indicated by the claims, and to include all modifications within the meaning and scope equivalent to the claims.

[0114] For example, the contact roller may also be Figure 8The touch roller 30 shown. The touch roller 30 is different from the touch roller 8 in that it includes a second layer 32 instead of the second layer 22. The second layer 32 includes an inner layer 34 and an outer layer 36. The inner layer 34 and the outer layer 36 are both porous layers (e.g., sponge layers). The A Shore hardness of the inner layer 34 and the outer layer 36 is smaller than the A Shore hardness of the first layer 20, and the A Shore hardness of the inner layer 34 is smaller than the A Shore hardness of the outer layer 36. In other words, the inner layer 34 and the outer layer 36 are softer than the first layer 20, and the outer layer 36 is harder than the inner layer 34. For example, the A Shore hardness of the inner layer 34 is 0 to 20, and the A Shore hardness of the outer layer 36 is 20 to 40. The A Shore hardness of the inner layer 34 is smaller than the A Shore hardness of the outer layer 36, so when one of the illustrated inner layer 34 and the outer layer 36 includes a region with an A Shore hardness of 20, the other does not include a region with an A Shore hardness of 20. The inner layer 34 may be detachably attached to, for example, the first layer 20. The outer layer 36 may be detachably attached to, for example, the inner layer 34.

[0115] The A Shore hardness of the outer layer 36 (or the A Shore hardness of the second layer 32) is smaller than that of the first layer 20, so the touch roller 30 has the same effect as the touch roller 8. Specifically, the inner layer 34 of the second layer 32 of the touch roller 30 is softer than the outer layer 36, so it can follow the surface unevenness of the resin film 4. The second layer 32 has an outer layer 36 that is harder than the inner layer 34, so it is possible to prevent the second layer 32 from being deteriorated or damaged (cutting, wear, etc.) compared to making the inner layer 34 directly contact the resin film 4. In addition, the length of the short side direction of the contact area A is easy to be shortened. Therefore, the surface of the resin film 4 can be reliably pressed with a constant contact pressure.

[0116] The contact roller can also be Fig. 9 The touch roller 38 shown. The touch roller 38 is different from the touch roller 8 in that it includes a second layer 40 instead of the second layer 22. The relationship of the A Shore hardness of the second layer 40 to the first layer 21 is the same as that of the second layer 22, and the examples of the materials of the second layer 40 are the same as those of the second layer 22. The second layer 40 will be described below with the differences from the second layer 22 as the center.

[0117] The second layer 40 has a first region 40a, a second region 40b, and a third region 40c in sequence along the width direction. The first region 40a, the second region 40b, and the third region 40c have the same thickness. The A Shore hardness of at least one of the first region 40a, the second region 40b, and the third region 40c is different from the A Shore hardness of the other regions. For example, the A Shore hardness of the first region 40a and the third region 40c is the same and is smaller than (or larger than) the A Shore hardness of the second region 40b. The difference in A Shore hardness can be achieved by using different materials.

[0118] exist Fig. 9The example in FIG. 4 shows a case where the second layer 40 has three regions in the width direction, but the number of regions is not limited to 3. The A Shore hardness of the plurality of regions in the width direction of the second layer 40 and the length of each region in the width direction can be set so as to apply a uniform contact pressure to the resin film 4 in the width direction.

[0119] The location where the touch roller 8 and the resin film 4 are brought into contact is not limited to Figure 1 and Figure 2 The contact portion (or the vicinity thereof) of the resin film 4 and the winding shaft 6 (or the roll-shaped resin film 4 wound on the winding shaft 6). Fig.10 As shown, the touch roller 8 may be arranged in the circumferential direction of the winding shaft 6 so as to come into contact with the roll-shaped resin film 4 wound around the winding shaft 6 .

[0120] The roller body 18 may not include the pair of shaft portions 26. In this case, a rotating shaft may be prepared independently of the contact roller 8, and the rotating shaft may be passed through the contact roller as the roller body 18 itself and supported by a pair of supporting members 12 in a rotatable manner. The roller body 18 may include, for example, a cylindrical main body (solid main body) and a pair of shaft portions 26. In this case, the pair of shaft portions 26 are respectively provided on both end surfaces of the main body in the axial direction concentrically with the axis of the main body. Examples of the material of the main body are metals (e.g., iron, stainless steel, aluminum, etc.). The surface of the main body is the surface of the roller body 18 that contacts the first layer 20.

[0121] The position adjustment mechanism 10 can also move the winding shaft 6. As a method of winding the resin film 4 onto the winding shaft 6, the winding device 2 can also adopt the following surface driven winding method, that is, a driving shaft (or driving roller) independent of the contact roller 8 is pressed against the resin film 4, the driving shaft is driven to rotate, and the friction force generated in the contact area A between the driving shaft and the resin film 4 is used to rotate the winding shaft 6 on which the resin film 4 is wound, thereby winding the resin film 4 around the winding shaft 6.

[0122] Alternatively, the winding device 2 may adopt a combined drive method by combining the center drive winding method illustrated in the above embodiment with the surface drive winding method. In the surface drive winding method, the contact roller 8 itself may be used instead of the drive shaft.

[0123] The second layer 22 may be any layer as long as its Shore A hardness is smaller than that of the first layer. The second layer 22 is not limited to a porous layer, and the material of the second layer 22 may be rubber.

[0124] The above-described embodiments and various modifications may be appropriately combined within the scope not departing from the gist of the present invention.

Claims

1. A contact roller having a contact surface that contacts a resin film when a long resin film is wound around a winding shaft, wherein: The contact roller comprises: Roller body; a first layer arranged outside the roller body in a radial direction of the roller body; and a second layer having the contact surface and arranged outside the first layer in the radial direction, The Shore A hardness of the second layer is less than the Shore A hardness of the first layer, The second layer has: an outer layer having the contact surface; and an inner layer disposed between the first layer and the outer layer, Both the inner layer and the outer layer are porous layers.

2. The contact roller according to claim 1, wherein: The Shore A hardness of the second layer is 0 or more and 40 / 50 or less of the Shore A hardness of the first layer.

3. The contact roller according to claim 1, wherein The first layer has a Shore A hardness of 50 to 80. The second layer has a Shore A hardness of 0-40.

4. The contact roller according to any one of claims 1 to 3, wherein The second layer is detachably mounted on the first layer.

5. The contact roller according to any one of claims 1 to 3, wherein The material of the surface of the roller body that is in contact with the first layer is metal.

6. The contact roller according to any one of claims 1 to 3, wherein The Shore A hardness of the inner layer and the outer layer is less than the Shore A hardness of the first layer, The outer layer has a Shore A hardness greater than that of the inner layer.

7. The contact roller according to claim 6, wherein: The inner layer has a Shore A hardness of 0-20.

8. The contact roller according to claim 6, wherein: The outer layer has a Shore A hardness of 20-40.

9. A winding device, wherein: The winding device comprises: A winding shaft for winding the long strip of resin film; A contact roller, which is the contact roller according to any one of claims 1 to 8; and A position adjustment mechanism moves one of the winding shaft and the touch roller relative to the other so that the contact surface of the touch roller contacts the resin film with a constant pressing force.

Images