Conveying roll, thin material manufacturing device, and manufacturing method of conveying roll

Abstract

To provide a conveying roll 1 having no burr in a top cut part, and a thin material manufacturing device 20 equipped with the conveying roll 1.SOLUTION: There is provided a conveying roll 1 having a satin-finished part 2a on the surface of a roll base material 2, in which the satin-finished part has a recess and a protrusion 2c which are nonuniformly formed. The protrusion 2c is top-cut, and the shape of the peripheral edge of the top-cut portion is formed in a curved shape. A thin material manufacturing device 20 is used for manufacturing a thin material X such as a resin film or a metal foil, and is equipped with the conveying roll 1.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a conveying roll mounted in a manufacturing device for thin materials such as resin films and metal foils (hereinafter, these will be referred to as "thin materials"), and a thin material manufacturing device equipped with the conveying roll. and a method for manufacturing the transport roll. Regarding. [Background technology]

[0002] Plastic films and metal foils are used in smartphones and LCD TVs. Plastic films include PET film and TAC film, while metal foils include copper foil and aluminum foil. These films and metal foils are used not only in smartphones and LCD TVs, but also as curved current collectors for batteries in hybrid cars and electrodes for fuel cells.

[0003] The plastic films and metal foils used in such equipment cannot be permitted to have surface scratches, spots, or other defects that could cause product defects.For this reason, in the manufacturing equipment for plastic films and metal foils, it is desirable for the roughness of the rolls that come into contact with the plastic films and metal foils to be 0.2S or less.

[0004] However, if the roll surface is too smooth, a vacuum forms between the roll and the film, making it difficult for the film to be separated from the roll (the so-called blocking phenomenon) (see Figures 12(a) and (b)). When the blocking phenomenon occurs, other problems such as wrinkles appearing in the resin film or metal foil occur.

[0005] As a countermeasure to this, a textured roll is sometimes used in which an uneven shape is formed on the roll surface by blasting (for example, Patent Document 1). As shown in Figures 13(a) to (c), the textured roll has an uneven surface, which reduces the contact area between the resin film or metal foil and the roll, preventing a vacuum from forming between the roll and the film, thereby suppressing the blocking phenomenon.

[0006] However, since the unevenness of the matte roll is formed by blasting, the height of the top of the protrusions is non-uniform (see Figure 14). This unevenness in height can cause scratches on the mating material, such as a resin film or metal foil (see Figures 15(a) and (b)).

[0007] In order to solve such problems, a so-called top-cut process (hereinafter simply referred to as "top-cut") is carried out, in which the tops of the convex portions are cut off using a mechanical tool such as a buff or a grindstone. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] Japanese Utility Model Application Publication No. 3-23148 [Patent Document 2] Japanese Utility Model Application Publication No. 7-43645 Summary of the Invention [Problem to be solved by the invention]

[0009] However, when top cutting is performed using a mechanical tool, burrs are generated in the cut area, which can cause scratches on the mating material, such as resin film or metal foil, and the reality is that this problem has not yet been solved.

[0010] The present invention has been made in view of the above circumstances, and the problem to be solved is to provide a conveying roll having no burrs in the top cut portion, and a thin material manufacturing apparatus having the conveying roll. and a method for manufacturing the transport roll. The purpose of this invention is to provide [Means for solving the problem]

[0011] The transport roll of the present invention is a transport roll having a matte surface on a surface of a roll base material, Pear-textured part Convex but Top cut, top cut Convex Around The edges are free of edges and burrs caused by top cutting. It is formed into a curved surface. The thin material manufacturing apparatus of the present invention is an apparatus for manufacturing thin materials such as resin films and metal foils, and is equipped with the transport roll of the present invention as a transport roll.

[0012] The conveying roll manufacturing method of the present invention is a method for manufacturing a conveying roll having a matte portion on the surface of a roll base material, in which the convex portions of the matte portion are top-cut, and edges and burrs generated during the top-cutting are removed from the peripheral edges of the top-cut convex portions to curve the peripheral edges of the convex portions. Effect of the Invention

[0013] The conveying roll of the present invention has no burrs in the top-cut portion, and therefore is less likely to cause defects such as scratches or spots on the mating material. The thin material manufacturing device of the present invention is equipped with a conveying roll that provides the above-mentioned effects, and therefore provides the same effects as the conveying roll. [Brief description of the drawings]

[0014] [Figure 1] FIG. 2A is a cross-sectional view showing an example of a transport roll of the present invention, and FIG. 2B is a conceptual diagram of the surface shape of the transport roll of the present invention. [Diagram 2] This shows an example of a device used for processing the cut convex portion into a curved surface. [Diagram 3] Ideal transport roll surface shape profile after top cutting. [Figure 4] 1A shows an example of a CCD observation image of the transport roll of the present invention, and FIG. 1B shows an example of a 3D observation image of the transport roll of the present invention. [Diagram 5] 1 shows the state of the surface of a film transported using the transport roll of the present invention. [Figure 6] 1A shows an example in which a crown roll is used as the roll substrate, and FIG. 1B shows an example in which an inverted crown roll is used as the roll substrate. [Figure 7] 1A shows an example of a roll substrate having a matte finish portion in the center of the long face and flat portions on both outside sides thereof, and FIG. 1B shows an example of a roll substrate having a flat portion in the center of the long face and matte finish portions on both outside sides thereof. [Figure 8] FIG. 1( a ) is a partial enlarged view showing an example of a roll substrate in which the matte finish portion and the flat portion are the same height, FIG. 1( b ) is a partial enlarged view showing an example of a roll substrate in which the matte finish portion is one step higher than the flat portion, and FIG. 1( c ) is a partial enlarged view showing an example of a roll substrate in which the matte finish portion is one step lower than the flat portion. [Figure 9]FIG. 1( a ) shows an example of a roll substrate having a flat portion with spiral grooves on both longitudinal outer sides of a matte finish portion, FIG. 1( b ) is a conceptual diagram showing an example of the surface shape of the spiral groove, and FIG. 1( c ) is a conceptual diagram showing another example of the surface shape of the spiral groove. [Figure 10] FIG. 2A is a cross-sectional view showing an example of a transport roll having a hard coating on the surface of a roll substrate, and FIG. 2B is a partially enlarged view of FIG. [Figure 11] 1 shows an example of a thin material manufacturing device equipped with a conveying roll of the present invention. [Figure 12] (a)(b) is an explanatory diagram of the blocking phenomenon. [Figure 13] (a) is a conceptual diagram of the surface shape of a conventional transport roll, (b) shows an example of a CCD observation image of a conventional transport roll, and (c) shows an example of a 3D observation image of a conventional transport roll. [Figure 14] Profile of the surface shape of a conventional textured roll. [Figure 15] (a) shows the state of the film surface before the film is transported, and (b) shows the state of the film surface after it has been transported using a conventional matte roll. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] (Embodiment of Transport Roll) An example of the transport roll 1 of the present invention will be described with reference to the drawings. The transport roll 1 of the present invention is mounted and used in a manufacturing device for various thin materials X including resin films and metal foils.

[0016] 1(a)(b) shows an example of a transport roll 1, which is a so-called matte roll having a matte part 2a that is formed by blasting (e.g., sandblasting) on ​​the surface of a roll substrate 2. The roll substrate 2 in this embodiment is mounted on the outer periphery of a shaft 3. The roll substrate 2 can also be mounted via a bearing attached to a flange.

[0017] For example, metal rolls, stainless steel rolls, carbon steel rolls, plated rolls, resin rolls, thermal spray rolls, aluminum alloy rolls, etc. can be used for the roll substrate 2. For example, SS400 can be used as the metal roll, SUS304 or SUS440C can be used as the stainless steel roll, STKM13A or S25C can be used as the carbon steel roll, HCr plated rolls or Ni plated rolls can be used as the plated roll, MC nylon or PEEK can be used as the resin roll, and WC thermal spray rolls can be used as the thermal spray roll. In addition, DLC films and SiO 2 It is also possible to use a material having an amorphous film formed thereon, such as HCr plating.

[0018] The surface roughness of the roll substrate 2 is set in the range of 0.2 μm to 10.0 μm, preferably 0.5 μm to 8.0 μm, more preferably 0.8 μm to 7.0 μm, and further preferably 1.0 μm to 5.0 μm, in terms of the root mean square height (Rq).

[0019] As shown in Fig. 1(b), in the transport roll 1 of this embodiment, the tops of the convex parts 2c on the surface (matte surface) of the roll substrate 2 are cut. The convex parts with cut tops (hereinafter referred to as "cut convex parts") are formed into curved shapes by removing edges and burrs. The curved surface treatment of the cut convex parts can be performed by electrolytic polishing using an electrolyte or etching using plasma.

[0020] For example, when forming a curved cut convex portion by etching using plasma, an apparatus as shown in Fig. 2 can be used. In Fig. 2, 5 is a vacuum chamber, 6 is an RF high-frequency power supply, 7 is an RF electrode, 8 is a high-voltage pulse power supply, and 9 is a gas inlet. Instead of the RF high-frequency power supply 6 and the RF electrode 7, an ICP plasma source (ICP power supply) can also be used.

[0021] When using the device of FIG. 2, the cut convex portion can be curved, for example, by the following procedure. (1) The top-cut roll substrate 2 is set within the RF electrode 7 in the vacuum chamber 5, and the inside of the vacuum chamber 5 is brought to room temperature and into a vacuum state. (2) In the state of (1) above, a high-frequency voltage is applied by the RF high-frequency power supply 6 to generate plasma around the roll substrate 2 (specifically, around the RF electrode 7 in the vacuum chamber 5), and a negative high-voltage pulse is applied to the roll substrate 2 by the high-voltage pulse power supply 8. (3) In the state of (2) above, Ar gas is injected into vacuum chamber 5 from gas injection port 9, and the Ar gas is reacted in vacuum chamber 5, thereby making the cut convex portion into a curved surface shape.

[0022] When performing the curved surface processing using this method, the processing can be performed under the following conditions, for example. Gas used: Ar, H 2 , Ga Negative pulse voltage: -50 to -15000V RF output: 100~3000W

[0023] The method for forming a curved surface of the cut convex portion described here is only an example, and the cut convex portion can be formed into a curved surface by other methods. Also, the curved surface treatment of the cut convex portion can be performed using an apparatus other than the apparatus shown in FIG.

[0024] Figure 3 shows the profile of the ideal surface shape of the matte roll after the top cut. The transport roll of this embodiment has no protrusions on the roll surface by curving the periphery of the cut part through plasma etching.

[0025] Fig. 4(a) shows an example of a CCD observation image of the transport roll 1 of the present invention, and Fig. 4(b) shows an example of a 3D observation image. From Fig. 4(a) and (b), it can be seen that the shape of the periphery of the cut part in the transport roll 1 of the present invention is curved compared to Fig. 13(b) and (c).

[0026] Figure 5 shows an image of a film transported using the transport roll 1 of the present invention. When a conventional transport roll was used, scratches were generated on the film surface as shown in Figure 15(b), but when the transport roll 1 of the present invention was used, scratches like those in Figure 15(b) were not generated.

[0027] (Other embodiments of the transport roll) The roll substrate 2 in the above embodiment is a so-called straight roll (flat roll), but the roll substrate 2 may be a crown roll as shown in FIG. 6(a) or an inverted crown roll as shown in FIG. 6(b).

[0028] In addition, the roll substrate 2 in the embodiment has the matte finish portion 2a on the entire long surface with which the thin material X such as a film comes into contact, but the roll substrate 2 may have the matte finish portion 2a on a part of the long surface. Specifically, as shown in Fig. 7(a), the roll substrate 2 may have the matte finish portion 2a in the center of the long surface and the flat portions 2b on both outsides thereof, or as shown in Fig. 7(b), the roll substrate 2 may have the flat portion 2b in the center of the long surface and the matte finish portion 2a on both outsides thereof.

[0029] When using a roll substrate 2 having a matte finish portion 2a and a flat portion 2b, in addition to the matte finish portion 2a and the flat portion 2b having the same height as shown in Fig. 8(a), the matte finish portion 2a may be one step higher than the flat portion 2b as shown in Fig. 8(b), or the matte finish portion 2a may be one step lower than the flat portion 2b as shown in Fig. 8(c). When there is a step at the boundary between the matte finish portion 2a and the flat portion 2b as shown in Fig. 8(b) and (c), a taper may be provided from the matte finish portion 2a toward the flat portion 2b so that the matte finish portion 2a and the flat portion 2b are smoothly connected.

[0030] The flat portion 2b of the roll substrate 2 may be provided with a spiral groove 2d in a direction extending the ends of the thin material X toward both ends as shown in Fig. 9(a). There are no particular restrictions on the depth, pitch, or other shape of the spiral groove 2d, but as an example of the shape, it may be a flat-top shape as shown in Fig. 9(b) or a sharp-top shape as shown in Fig. 9(c). By forming the spiral groove 2d in the flat portion 2b, it is possible to prevent the thin material X from wrinkling or meandering as it is being conveyed.

[0031] Although not described in the above embodiment, the transport roll 1 of the present invention may have a hard coating 4 on the surface of the roll substrate 2 as shown in Fig. 10(a) and (b). The hard coating 4 may be formed by an existing method such as a method using plasma.

[0032] The hard coating 4 may have a hardness of, for example, 500 HV or more, preferably 800 HV or more, more preferably 1000 HV or more, and even more preferably 1100 HV or more, as measured by a Vickers hardness tester. However, the hardness of the hard coating 4 may be higher or lower.

[0033] The hard coating 4 may be, for example, an HCr plating layer, a Ni plating layer, a DLC layer, a thermal spray coating, a CrN coating, a fluorine-containing coating, a fluorine coating, a ceramic coating, or the like. The coatings listed here are only examples, and the hard coating 4 may be other coatings. The hard coating 4 may also have a structure made up of multiple layers. An example of a structure made up of multiple layers is one in which a DLC layer is formed on an HCr plating layer.

[0034] Generally, the matte roll has a smaller contact area than the mirror roll, and therefore is inferior to the mirror roll in terms of wear resistance. If the surface becomes rough due to wear, there is a risk of damaging the mating material, which is a resin film or metal foil. However, in the example shown in Fig. 10(a)(b), the hard coating 4 is provided on the surface of the roll substrate 2, so that the risk of wear of the protrusions 2c, the surface roughening caused by the wear, and the occurrence of damage to the mating material caused by the surface roughening can be prevented in advance.

[0035] (Embodiment of thin material manufacturing device) An example of an embodiment of a thin material manufacturing apparatus 20 of the present invention will be described with reference to the drawings. The thin material manufacturing apparatus 20 of the present invention is an apparatus for manufacturing a thin material X such as a resin film or a metal foil. Here, the case where the thin material manufacturing apparatus 20 is an apparatus for manufacturing a functional film is taken as an example.

[0036] 11, reference numeral 10 denotes a payout roll, 11 denotes a take-up roll, 12 denotes a transport roll, 13 denotes an impression roll, 14 denotes a coating liquid container, 15 denotes a gravure roll, 16 denotes a touch roll, 17 denotes a blade, and 18 denotes a drying furnace. In this embodiment, the transport roll 1 described in the embodiment of the transport roll is used as the transport roll.

[0037] In the thin material manufacturing apparatus 20 of this embodiment, the contact area between the transport roll 1 and the mating material is small, so a vacuum is not created between the transport roll 1 and the mating material, and blocking is unlikely to occur. In addition, the cut convex portion of the convex portion 2c is formed in a curved shape and has no burrs or edges, so there is little risk of damaging the mating material. [Industrial Applicability]

[0038] The conveying roll 1 of the present invention can be mounted and used in an apparatus for manufacturing thin material X such as a resin film or metal foil used in various devices, as well as an apparatus for manufacturing electrode foil used in fuel cells, etc. Also, the thin material manufacturing apparatus 20 of the present invention can be used as an apparatus for manufacturing thin material X such as a resin film or metal foil. [Explanation of symbols]

[0039] 1 Transport roll 2 Rolled substrate 2a Pear-finished part 2b Flat section 2c Convex part 2d spiral groove 3-axis 4 Hard coating 5. Vacuum Chamber 6 RF high frequency power supply 7 RF electrode 8 High voltage pulse power supply 9 Gas inlet 10. Pay-off roll 11 Take-up roll 12 Transport roll 13 Impression cylinder roll 14 Coating fluid container 15 Gravure Roll 16 Touch Roll 17 Blades 18 Drying oven 20 Thin material manufacturing equipment X Thin material

Claims

1. In a conveying roll having a matte surface on a roll base material, The matte finish portion has unevenly formed concave and convex portions, The convex portion is top cut, The peripheral shape of the top cut portion is formed into a curved surface. A transport roll characterized by the above.

2. The transport roll according to claim 1, The surface roughness of the roll substrate is 0.2 μm to 10.0 μm in root mean square height. A transport roll characterized by the above.

3. The transport roll according to claim 1 or 2, The surface of the roll base material is provided with a hard coating having a hardness of 500 HV or more. A transport roll characterized by the above.

4. The transport roll according to claim 3, The hard coating is one or more of an HCr plating layer, a Ni plating layer, a DLC layer, a thermal spray coating, a CrN coating, a fluorine-containing coating, a fluorine coating, and a ceramic coating. A transport roll characterized by the above.

5. The transport roll according to any one of claims 1 to 4, The roll base material is a flat roll, a crown roll, or an inverted crown roll; A transport roll characterized by the above.

6. The transport roll according to any one of claims 1 to 5, A matte surface portion is provided in the center of the surface of the roll substrate, and a flat portion without irregularities is provided outside the matte surface portion; or a flat portion without irregularities is provided in the center of the surface of the roll substrate, and a matte surface portion is provided outside the flat portion. A transport roll characterized by the above.

7. The transport roll according to claim 6, The flat part has a spiral groove. A transport roll characterized by the above.

8. In a thin material manufacturing apparatus equipped with a conveying roll, The transport roll is the transport roll according to any one of claims 1 to 7. A thin material manufacturing apparatus characterized by the above.

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