Film roll, laminated metal strip, method for manufacturing film, and method for manufacturing laminated metal strip

Abstract

To provide a film roll, a laminated metal strip, a method for manufacturing a film, and a method for manufacturing a laminated metal strip, capable of suppressing exposure of a double-sided adhesive tape by a simple method when films are bonded to each other or when the laminated metal strip is manufactured, and capable of suppressing exposure of the double-sided adhesive tape by a simple method even if the film is broken.SOLUTION: In a film roll 10 in which a film 10a bonded to another film 9a through a double-sided adhesive tape 11 is wound in a roll shape, the double-sided adhesive tape 11 stuck to an outer peripheral surface is stuck separately from a tip portion 10at of the film 10 on the outer peripheral surface.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to a film roll, a laminated metal strip, a method for manufacturing a film, and a method for manufacturing a laminated metal strip. [Background technology]

[0002] Conventionally, there are known devices and methods for continuously supplying and bonding a web, including a film or paper, to a continuously conveyed metal strip or electronic component. The web is wound in a roll (hereinafter referred to as a leading roll). The web is unwound from the leading roll and continuously supplied to the metal strip or electronic component, where it is pressed against the metal strip or electronic component. When the remaining length of the web on the leading roll becomes short, the web supply source is switched from the leading roll to a new roll (hereinafter referred to as a trailing roll). In order to supply the web to the metal strip or electronic component without interruption during the roll switching, a web splicing method known as a splice is known, in which the web on the leading roll is spliced ​​with the web on the trailing roll (see, for example, Patent Document 1).

[0003] In the above-described web joining method, double-sided adhesive tape is affixed to the leading edge of the web on the trailing roll, and the leading edge of the web on the trailing roll is joined to the leading edge of the web on the leading roll via the double-sided adhesive tape. Specifically, the leading edge of the web on the trailing roll is fixed to the outer peripheral surface of the trailing roll by a fixed label that prevents the web on the trailing roll from unwinding. The double-sided adhesive tape is then adhered to at least a portion of the fixed label so as to overlap the fixed label. The trailing roll is rotated, and the peripheral speed of the outermost portion of the trailing roll is made to approximately match the feed speed of the web on the leading roll relative to the metal strip. When the peripheral speed of the outermost portion of the trailing roll and the feed speed of the web on the leading roll relative to the metal strip or electronic components are approximately matched, the double-sided adhesive tape affixed to the leading edge of the web on the trailing roll is pressed against the web on the leading roll. In this way, the web on the trailing roll is joined to the web on the leading roll via the double-sided adhesive tape. Thereafter, the upstream portion of the double-sided adhesive tape on the web of the leading roll in the feeding direction of the web to the metal strip is cut, thereby switching the web supply source from the leading roll to the trailing roll.

[0004] In the above-described web joining method, the leading roll and the trailing roll are joined via a double-sided adhesive tape, so it is preferable that the adhesive strength of the double-sided adhesive tape be high. However, Patent Document 1 points out that an increase in adhesive strength is accompanied by an increase in the fluidity of the adhesive. Therefore, if a double-sided adhesive tape with high adhesive strength is used, the high fluidity of the adhesive may cause the adhesive to be extruded from the intended joining locations of the webs, resulting in failure of joining the webs via the double-sided adhesive tape or exposure of the adhesive.

[0005] Furthermore, when manufacturing a laminated metal strip by attaching a web to a metal strip, for example, the metal strip is heated to a predetermined temperature, and the metal strip and web are pressed together by a pressure roll to press the web onto the metal strip. The joint between the webs via the double-sided adhesive tape has a four-layer structure consisting of the web unwound from the preceding roll, the double-sided adhesive tape, the fixed label, and the web unwound from the following roll. Alternatively, it has a three-layer structure consisting of the web unwound from the preceding roll, the double-sided adhesive tape, and the web unwound from the following roll. In either case, the joint is thicker than its surrounding areas. Therefore, when the metal strip and web are pressed together by the pressure roll to press the web onto the metal strip, the difference in thickness between the joint and its surrounding areas causes shear forces to occur between them. Furthermore, the web is softened by heat from the metal strip, making it prone to deformation and shear. These factors can cause breakage in the film on the opposite side of the metal strip when sandwiching the film directly in contact with the metal strip. In addition, the film in direct contact with the metal strip is pressed against the metal strip by the pressure roll, and the above-mentioned thickness-related slippage (shear) is unlikely to occur. If the above-mentioned situation occurs, for example, the adhesive of the double-sided adhesive tape may be exposed from the broken part of the film, and the adhesive may adhere to the laminated metal strip production line and contaminate the production line.

[0006] Various methods have been studied to prevent such failures during web joining or during the production of laminated metal strips. For example, the adhesive tape described in Patent Document 1 contains a natural rubber adhesive compound in the adhesive of the adhesive tape. This prevents the flowability of the adhesive while maintaining high adhesiveness even at high temperatures of 160°C.

[0007] In the web joining method described in Patent Document 2, the trailing end of a leading web being continuously fed is butted against the leading end of a trailing web, and the butted portions of the webs are joined together with a splicing tape. Then, ultrasonic welding is performed across the width of the web at the leading and trailing ends of the splicing tape in the web feed direction. This creates a sloped area where the ultrasonic welding is performed, thereby preventing discontinuous steps. It is also said that this can prevent the exposure of the adhesive in the splicing tape and the occurrence of application defects such as vertical streaks and bubbles. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] Japanese Patent Application Laid-Open No. 2017-122210 [Patent Document 2] Japanese Patent Application Publication No. 4-145436 Summary of the Invention [Problem to be solved by the invention]

[0009] When manufacturing a laminated metal strip in which a web is attached to a metal strip, the metal strip and / or the web may be heated to 200°C or higher. Therefore, even if the adhesive tape described in Patent Document 1 is used to bond the webs together in the manufacture of the laminated metal strip, there is a possibility that the adhesive will flow due to heat. In other words, there is a possibility that the exposure of the adhesive will not be suppressed. Furthermore, the web bonding method described in Patent Document 2 requires an ultrasonic welding device, which may increase the overall size of the device. Furthermore, ultrasonic welding is performed after the butt joints are bonded using a splicing tape, which may increase the working time required to bond the webs together.

[0010] The present invention has been made to solve the above-mentioned problems, and aims to provide a film roll, a laminated metal strip, a method for manufacturing a film, and a method for manufacturing a laminated metal strip that can suppress exposure of double-sided adhesive tape in a simple manner when joining films together or when manufacturing a laminated metal strip, and that can suppress exposure of the double-sided adhesive tape even if the film breaks. [Means for solving the problem]

[0011] The means for solving the above problems are as follows. (1) A film roll in which a film to be joined to another film via a double-sided adhesive tape is wound into a roll, and the double-sided adhesive tape is attached to the outer peripheral surface at a distance from the tip of the film on the outer peripheral surface. (2) The film roll according to (1), wherein the distance between the double-sided adhesive tape and the leading end of the film in the unwinding direction of the film is 1.0 mm or more. (3) The film roll according to (1) or (2), wherein the distance between the double-sided adhesive tape and the leading end of the film in the unwinding direction of the film is 20.0 mm or less. (4) A laminated metal strip in which a film unwound from the film roll described in (1) or (2) is attached to at least one of the two surfaces of a metal strip, and which has a leading film attached to the metal strip prior to the film, and a joint where the film is joined to the leading film via the double-sided adhesive tape, and the leading end of the film is attached to one surface of the metal strip. (5) A laminated metal strip in which the film unwound from the film roll described in (3) is attached to at least one of the two surfaces of a metal strip, and which has a leading film attached to the metal strip prior to the film, and a joint in which the film is joined to the leading film via the double-sided adhesive tape, and the leading end of the film is attached to one surface of the metal strip. (6) A method for manufacturing a film that is continuously supplied and attached to at least one of the two surfaces of a metal strip, the method comprising: a first step of attaching a double-sided adhesive tape to the outer peripheral surface of a trailing film roll on which the trailing film is wound in a roll, at a distance from the leading end of the trailing film; a second step of synchronizing the supply speed of a leading film that is supplied to the metal strip ahead of the trailing film with the rotation speed at the outermost peripheral part of the roll-shaped trailing film roll; a third step of joining the leading film and the trailing film, whose supply speed and rotation speed have been synchronized, via the double-sided adhesive tape; and a fourth step of cutting the leading film at a portion of the leading film that is upstream of the double-sided adhesive tape in the direction in which the film is supplied to the metal strip. (7) The method for producing a film according to (6), wherein in the first step, the distance between the double-sided adhesive tape and the leading end of the following film is set to 1.0 mm or more and 20.0 mm or less. (8) A method for producing a laminated metal strip, comprising attaching a film produced by the method for producing a film according to (6) or (7) to one side of the metal strip to produce a laminated metal strip. [Effects of the Invention]

[0012] According to the present invention, when joining films together or when manufacturing a laminated metal strip, it is possible to suppress exposure of the double-sided adhesive tape by a simple method. Furthermore, even if the film breaks, exposure of the double-sided adhesive tape can be suppressed. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 is a diagram illustrating an example of a laminating device. [Figure 2] FIG. 1 is a diagram illustrating bonding of films together. [Figure 3] FIG. 2 is a cross-sectional view of a joint between films. [Figure 4] FIG. 2 is a cross-sectional view of a joint between films in a laminated metal strip. DETAILED DESCRIPTION OF THE INVENTION

[0014] An example of an embodiment of the present invention (hereinafter referred to as the present embodiment) will be described below. The film according to this embodiment is a film that is attached to a metal strip to produce a laminated metal strip. Examples of the film include a film primarily composed of a polymer. Examples of the polymer include polyolefins such as PP (Poly Propylene) and PE (Poly Ethylene), polyesters such as PET (Poly Ethylene Terephthalate) and PBT (Poly Butylene Terephthalate), and blends thereof. In addition to the polymer that is the main component of the film, the film may contain, as needed, pigments, antiblocking agents, waxes, antioxidants, stabilizers, and the like. Furthermore, the film may contain, as needed, a primer for improving adhesive strength or coloring. The thickness of the film is not limited in this embodiment; the present embodiment is applicable regardless of the film thickness.

[0015] The metal strip according to this embodiment may be an aluminum strip, a steel strip, a copper strip, or the like, and the surface of these strips may be plated or chemically treated. The thickness of the metal strip is preferably 0.05 mm or more and 4.00 mm or less, and the width is preferably 100 mm or more and 2000 mm or less.

[0016] The film according to this embodiment is laminated onto a metal strip, for example, by a laminating device. FIG. 1 is a diagram showing an example of a laminating device. The laminating device 1 shown in FIG. 1 has a heating device 3 for a metal strip 2. The metal strip 2 is transported to the heating device 3 by a transport device (not shown), and the heating device 3 heats the metal strip 2 to a preset temperature. The film 4 is wound into a roll (hereinafter referred to as a film roll). The film 4 is unwound from the film roll and transported onto one of the two surfaces of the metal strip 2 by a transport device. The film 4 is then pressed onto one surface of the metal strip 2 by a laminating roll 5 shown in FIG. 1, and the film 4 is heat-sealed to the one surface of the metal strip 2. In other words, the film 4 is thermocompression-bonded to the metal strip 2. In this manner, a laminated metal strip 6 is produced. In the laminating apparatus 1 shown in FIG. 1, a film 4 is supplied to each of both sides of the metal strip 2, and the film 4 is pressure-bonded to each of the two sides of the metal strip 2 by a laminating roll 5. However, instead of this, the film 4 may be supplied to one of the two sides of the metal strip 2 and bonded thereto. In the example shown in FIG. 1, a metal strip pass line roll 7 is provided on the outlet side of the heating device 3. A film pass line roll 8 is provided between the film roll and the laminating roll 5.

[0017] To improve the production efficiency and yield of the laminated metal strip 6, it is preferable to operate the laminating device 1 continuously without stopping. Therefore, in this embodiment, when the remaining length of the film 4 in the above-mentioned film roll becomes short, a film unwound from a newly prepared film roll is spliced ​​to the film 4 unwound from the film roll. Then, the film 4 is cut at a portion of the film 4 upstream of the splice between the film 4 and the film unwound from the newly prepared film roll. In this way, the film supply source for the metal strip 2 is switched to the newly prepared film roll.

[0018] Figure 2 is a diagram illustrating the joining of films. Figure 2(A) shows an example of a leading film roll (hereinafter referred to as leading roll) 9 that is currently supplying a film 9a (hereinafter referred to as leading film 9a) to a metal strip 2. When the remaining length of the leading film 9a on the leading roll 9 becomes short, a new trailing film roll (hereinafter referred to as trailing roll) 10 is prepared. The trailing roll 10 is a roll of trailing film 10a that has the same structure as the leading film 9a.

[0019] Of both ends of the trailing film 10a, one end (referred to as the leading end) 10at is located on the outer circumferential surface of the trailing roll 10. The leading end 10at of the trailing film 10a may be fixed to the outer circumferential surface of the trailing roll 10 by a fixed label (not shown) that prevents the trailing film 10a from unwinding. In Figure 2, the fixed label is omitted to simplify the drawing.

[0020] Double-sided adhesive tape 11 is applied to the outer peripheral surface of the following roll 10, upstream of the leading end 10at of the following film 10a in the unwinding direction of the film 10a (the film supply direction in FIG. 2), at a predetermined distance from the leading end 10at of the following film 10a. FIG. 2(B) shows this state. The work of applying the double-sided adhesive tape 11 to the outer peripheral surface of the following roll 10 may be performed manually, or may be automated using a double-sided adhesive tape 11 applying device (not shown). The above-mentioned step of applying the double-sided adhesive tape 11 to the following roll 10 corresponds to the first step of this embodiment.

[0021] The double-sided adhesive tape 11 may be formed by applying a silicone-based, acrylic-based, or urethane-based adhesive to both sides of a substrate made of, for example, PET, cellulose, or nonwoven fabric. The double-sided adhesive tape 11 may also be a so-called substrate-less double-sided adhesive tape, which does not have the above-mentioned substrate and is formed only by an adhesive.

[0022] The double-sided adhesive tape 11 may be colored to make it easier to detect the joints between the films 9a, 10a via the double-sided adhesive tape 11. The width of the double-sided adhesive tape 11 in the feeding direction of the films 9a, 10a is preferably 15 mm or more and 100 mm or less, and more preferably 30 mm or more and 70 mm or less, from the viewpoint of ensuring adhesive strength and from an economical viewpoint.

[0023] Here, the distance between the leading end 10at of the following film 10a and the double-sided adhesive tape 11 will be described. In this embodiment, when attaching the double-sided adhesive tape 11 to the following film 10, the distance d between the leading end 10at of the following film 10a and the double-sided adhesive tape 11 is preferably set to 1.0 mm or more and 20.0 mm or less. Furthermore, the distance d is more preferably set to 1.5 mm or more and 10.0 mm or less, and even more preferably set to 1.8 mm or more and 3.0 mm or less. If the distance d is less than 1.0 mm, as described below, the preceding film 9a may break at the step around the double-sided adhesive tape 11, exposing the double-sided adhesive tape 11 to the outside, i.e., to the air. Furthermore, the adhesive surface of the double-sided adhesive tape 11 may be exposed, and the adhesive of the double-sided adhesive tape 11 may adhere to the line roll (not shown) of the laminating device 1. Alternatively, when the laminated metal strip is wound into a roll, the adhesive may adhere to the films that are in contact with each other. If the gap d exceeds 20.0 mm, the trailing film 10a may be turned up by the wind when the joined films 9a, 10a are transported at high speed relative to the metal strip 2, deteriorating the appearance of the laminated metal strip. Furthermore, if the turned-up trailing film 10a enters the laminating device 1 while overlapping the joined portion and the laminated metal strip is produced, there is a possibility that scratches may occur on the laminated metal strip.

[0024] Since the double-sided adhesive tape 11 is used to bond the films 9a, 10a together, the above-mentioned gap is substantially maintained when and after the films 9a, 10a are bonded together via the double-sided adhesive tape 11. The above-mentioned gap can be confirmed by observing the bonded portion after the films 9a, 10a are bonded together via the double-sided adhesive tape 11.

[0025] Although there are no restrictions on the distance between both ends of the following film 10a in the width direction and the double-sided adhesive tape 11, it is preferable that there is a slight gap, and the gap in the width direction is preferably 50.0 mm or less, and more preferably 1.0 mm or more and 20.0 mm or less. This makes it possible to prevent the double-sided adhesive tape 11 and the adhesive from being exposed to the outside of the following roll 10 in the width direction of the following film 10a.

[0026] After the double-sided adhesive tape 11 is applied to the trailing roll 10, the trailing roll 10 is rotated, and the rotational speed, i.e., peripheral speed, of the outermost peripheral portion of the trailing roll 10 is synchronized with the feed speed of the leading film 9a relative to the metal strip 2. When these speeds are approximately equal, as shown in FIG. 2(C), the trailing roll 10 is brought close to the leading film 9a, and the double-sided adhesive tape 11 is pressed against the leading film 9a together with the trailing roll 10 to pressure-bond the film 9a. In this way, the trailing film 10a is bonded to the leading film 9a via the double-sided adhesive tape 11. The process of synchronizing the rotational speed of the outermost peripheral portion of the trailing roll 10 with the feed speed of the leading film 9a relative to the metal strip 2 corresponds to the second process of this embodiment, and the process of bonding the trailing film 10a to the leading film 9a via the double-sided adhesive tape 11 corresponds to the third process of this embodiment.

[0027] 2(D), the upstream portion of the leading film 9a relative to the double-sided adhesive tape 11 in the supply direction of each film 9a, 10a relative to the metal strip 2 is cut using a cutter, scissors, a laser, or other method. In this way, the following film 10a is joined to the leading film 9a, and the film supply source relative to the metal strip 2 is switched from the leading roll 9 to the following roll 10 in the laminating apparatus 1 shown in FIG. 1. The above-mentioned step of cutting the upstream portion of the leading film 9a relative to the double-sided adhesive tape 11 in the supply direction of each film 9a, 10a relative to the metal strip 2 corresponds to the fourth step of this embodiment. The method of joining the leading film 9a and the following film 10a as described above corresponds to the film manufacturing method of this embodiment.

[0028] FIG. 3 is a cross-sectional view showing a joint 12 between the leading film 9a and the trailing film 10a joined via the double-sided adhesive tape 11 as described above. In the joint 12 shown in FIG. 3, there is a gap d between the double-sided adhesive tape 11 and the leading end 10at of the trailing film 10a. The laminated portion between the leading film 9a and the leading end 10at of the trailing film 10a forms a step 13. The thickness of the step 13 increases by the amount of the trailing film 10a. Therefore, as described below, when the film is bonded to the metal strip 2, the increased film thickness at the step 13 may cause the film to break. The film formed by bonding the leading film 9a and the trailing film 10a as described above corresponds to the film 4 shown in FIG. 1 and the film of this embodiment. This film 4 is fed to the laminating device 1 shown in FIG. 1 and pressed onto the metal strip 2 to produce a laminated metal strip 6. The method of manufacturing a laminated metal strip 6 by pressing a film 4 onto a metal strip 2 using a laminating device 1 shown in FIG. 1 corresponds to the method of manufacturing a laminated metal strip of this embodiment.

[0029] 4 is a cross-sectional view of a joint 12 between films 9a and 10a in laminated metal strip 6. In the example shown in FIG.

[0030] (Actions and Effects) 1, a film 4 formed by bonding films 9a, 10a together is supplied to and pressure-bonded to a metal strip 2. At the bonding portion 12 and the stepped portion 13 of the film 4, the trailing film 10a is positioned on the metal strip 2 side, and a leading end 10at of the trailing film 10a is directly pressure-bonded to the metal strip 2 by a laminating roll 5.

[0031] Specifically, when the stepped portion 13 of the film 4 is pressed against the metal strip 2, as shown in FIG. 4 , the leading film 9a is laminated on the opposite side of the metal strip 2, sandwiching the trailing film 10a, at the stepped portion 13. That is, the thickness of the film 4 is increased at the stepped portion 13 by the amount of the trailing film 10a. Therefore, when the laminating roll 5 presses the stepped portion 13 against the metal strip 2, the load pressing the film 4 toward the metal strip 2 increases by the amount of the trailing film 10a. Furthermore, the film 4 may be softened by the heat of the metal strip 2. As a result, shear force may be generated in the leading film 9a, located on the opposite side of the stepped portion 13 from the metal strip 2, potentially causing a portion of the film to break. The trailing film 10a is in direct contact with and pressed against the metal strip 2. Therefore, shear force due to the increased thickness of the film 4 is unlikely to be generated in the trailing film 10a, making it unlikely for the trailing film 10a to break.

[0032] Furthermore, in this embodiment, the double-sided adhesive tape 11 and the leading end 10at of the following film 10a are spaced apart from each other in the feeding direction of the film 4. That is, the stepped portion 13 where the above-described breakage may occur and the double-sided adhesive tape 11 are spaced apart from each other. Therefore, even if a breakage occurs in a portion of the preceding film 9a at the stepped portion 13 as described above, the double-sided adhesive tape 11 is unlikely to be exposed from the broken portion of the preceding film 9a. This prevents contamination caused by the adhesive of the double-sided adhesive tape 11 being exposed and adhering to the production line (not shown) of the laminating apparatus 1 or to a line roller (not shown).

[0033] The film manufacturing method of this embodiment is primarily implemented in processes for manufacturing laminated metal strips 6 and electronic components (not shown). However, the film manufacturing method of this embodiment may also be applied when joining together multiple rolls of film whose outer diameter has become smaller than the designed outer diameter due to manufacturing problems or other reasons to manufacture a single large-diameter roll. Even when film is unwound from such a large-diameter roll and laminated onto a metal strip, substantially the same effects and advantages as those of the above-described embodiment can be obtained. That is, when laminating a film onto a metal strip in a laminating device, exposure of the adhesive from the double-sided adhesive tape and the resulting contamination of the production line can be suppressed. Furthermore, exposure of the adhesive from the double-sided adhesive tape can be suppressed during transportation and storage of the large-diameter roll.

[0034] The remaining length of the leading roll 9 from which the leading film 9a is being unwound can be estimated by at least one of visual inspection, rotation speed, cumulative number of rotations, cumulative length, and weight. Furthermore, the timing for splicing the leading film 9a and the following film 10a may be determined by an operator or by a control device (not shown).

[0035] The aforementioned case where the remaining length of the leading roll 9 becomes short can be exemplified by a case where there is a risk of the leading film 9a slipping out if the trailing film 10a is not joined to the leading film 9a. The trailing film 9a slipping out means that the trailing film 10a is not joined to the leading film 9a, and the tail end of the leading film 9a enters the laminating device 1, causing the laminating device 1 to stop. The film manufacturing method of this embodiment and the laminated metal strip manufacturing method of this embodiment can also be applied when switching from a film currently being used in a laminating device to another film. They can also be applied when switching the type of film in conjunction with switching the type of metal strip used in the laminating device. [Example]

[0036] Below, we will explain examples that were conducted to investigate the exposure state of the adhesive of the double-sided adhesive tape in a production line of a laminating device that press-bonds the film according to this embodiment to a metal strip. Note that this example is merely intended to explain the effects of this embodiment and is not intended to limit this embodiment. In Examples 1 to 14 and Comparative Examples 1 and 2 described below, a chromium-plated steel strip (TFS) having a thickness of 0.22 mm or more and 0.32 mm or less was used as the metal strip.

[0037] Example 1 A strip-shaped film made of block polypropylene with a thickness of 50 μm (corresponding to the trailing film described above; hereinafter referred to as the trailing film) was prepared. A 50 μm thick acrylic substrate-less double-sided adhesive tape was attached to the leading edge of the trailing film, spaced apart from the leading edge, in the feeding direction of the trailing film in the laminating device described below. The distance between the leading edge of the trailing film and the double-sided adhesive tape was set to 1.0 mm. Separately, another strip-shaped film made of block polypropylene with a thickness of 50 μm (corresponding to the leading film described above; hereinafter referred to as the leading film) was prepared. The leading edge of the trailing film was joined to the tail edge of the leading film via the double-sided adhesive tape in the feeding direction of the leading film in the laminating device described below. In this way, a film in which the leading film and the trailing film were joined was produced. The joint between the leading film and the trailing film via the double-sided adhesive tape in this film corresponds to the joint 12 described above, and the laminated portion between the leading film and the leading edge of the trailing film corresponds to the step 13 described above.

[0038] The above-mentioned film was loaded into a laminating machine configured to dispense the film in synchronization with a metal strip transported at 40 m / min. The leading edge of the trailing film at the joint was directly contacted with one side of the metal strip heated to a predetermined temperature, and the two were sandwiched between a pair of pressure rolls to press the film onto one side of the metal strip. Another seamless film made of block polypropylene with a thickness of 50 μm was contacted with the other side of the metal strip, and the other film was pressed onto the other side of the metal strip by sandwiching the two pressure rolls.

[0039] The metal strip with the film bonded thereto was then immediately immersed in cooling water to rapidly cool it, yielding a laminated metal strip. The laminated metal strip was then wound into a coil. This process of producing laminated metal strips was repeated several times, and the state of exposure of the adhesive of the double-sided adhesive tape and the presence or absence of curling at the leading edge of the trailing film during the production of the laminated metal strip were checked for each case.

[0040] The state of adhesive exposure of the double-sided adhesive tape on the laminated metal strip and whether or not the trailing film had curled up were determined by observing the joints between the films when the coiled laminated metal strip was unwound under almost no tension. The results are summarized in Table 1. Unwound laminated metal strip under no tension refers to a state in which the laminated metal strip was unwound from the coil with almost no tension.

[0041] [Table 1]

[0042] In Table 1, if the adhesive of the double-sided adhesive tape is exposed due to a break in the leading film at the step, i.e., the leading edge of the trailing film, an "X" is entered in the "Exposed adhesive" column. If there is no exposed adhesive at the same position, an "O" is entered in the "Exposed adhesive" column. Also, if the leading edge of the trailing film is curled up at the joint, an "X" is entered in the "Curling of leading edge of trailing film" column. If there is no curling of the leading edge of the trailing film, an "O" is entered in the "Curling of leading edge of trailing film" column.

[0043] (Examples 2 to 9, Comparative Example 1) Laminated metal strips were obtained in the same manner as in Example 1, except that the type of double-sided adhesive tape and the distance between the leading end of the trailing film and the double-sided adhesive tape were changed as shown in Table 1.

[0044] Example 10 A 50 μm thick film made of block polypropylene was wound into a roll, and a double-sided adhesive tape was attached at a predetermined distance from the leading edge of the film (hereinafter referred to as the trailing film) located on the outer peripheral surface of the roll (corresponding to the trailing roll described above; hereinafter referred to as the trailing roll). The double-sided adhesive tape used was a substrateless double-sided adhesive tape with a thickness of 50 μm and made of an acrylic adhesive. The distance between the leading edge of the trailing film and the double-sided adhesive tape was set to 1.0 mm.

[0045] In a laminated metal strip production line, a trailing roll with double-sided adhesive tape attached was placed on the standby side of a splicing device that splices films together. Then, when the remaining length of the operating roll (corresponding to the aforementioned leading roll, hereinafter referred to as the leading roll) that was unwinding a film (hereinafter referred to as the leading film) in synchronization with the metal strip being transported at 200 m / min became short, the standby trailing roll was rotated. A 50 μm-thick film made of block polypropylene was used as the leading film. After the rotational speed of the trailing roll reached approximately the same speed as the metal strip transport speed, the trailing roll was pressed against the leading film being unwound from the leading roll, splicing the leading film and the trailing film via the double-sided adhesive tape. With the films spliced ​​together, the trailing roll made one rotation, and then a cutter was used to cut the leading film upstream of the double-sided adhesive tape in the film feed direction relative to the metal strip.

[0046] The leading edge of the trailing film at the joint of the above-mentioned film was then directly contacted with one side of a metal strip heated to a predetermined temperature, and the two were clamped and pressed together by a pair of pressure rollers. Another seamless film made of block polypropylene with a thickness of 50 μm was contacted with the other side of the metal strip, and the two were clamped and pressed together by a pair of pressure rollers. After the film was pressed onto the metal strip, it was immediately immersed in cooling water for rapid cooling to obtain a laminated metal strip. The laminated metal strip was wound into a coil. This laminated metal strip was produced multiple times, and the exposure of the adhesive on the double-sided adhesive tape and the presence or absence of curling at the leading edge of the trailing film were confirmed in the same manner as in Example 1. The results are summarized in Table 2.

[0047] [Table 2]

[0048] (Examples 11 to 18, Comparative Example 2) A laminated metal strip was obtained in the same manner as in Example 8, except that the thicknesses of the leading film and trailing film, the type of double-sided adhesive tape, and the distance between the leading end of the trailing film and the double-sided adhesive tape were changed as shown in Table 2.

[0049] In the laminated metal strips of Examples 1 to 18, as shown in Tables 1 and 2, the distance between the leading edge of the trailing film and the double-sided adhesive tape was set to 1.0 mm or more and 20.0 mm or less. Therefore, in Examples 1 to 18, even if the leading film broke at the leading edge of the trailing film, the broken portion of the leading film and the double-sided adhesive tape were spaced apart from each other, and exposure of the adhesive of the double-sided adhesive tape due to the breakage of the leading film was suppressed. As a result, contamination of the laminating device production line by the adhesive was suppressed.

[0050] On the other hand, in Examples 8, 9, 17, and 18, the distance between the leading edge of the trailing film and the double-sided adhesive tape exceeded 20.0 mm, as shown in Tables 1 and 2. Therefore, in Examples 8, 9, 17, and 18, when the film was transported toward the metal strip by the laminating device, curling of the leading edge of the trailing film was observed at the joint.

[0051] Furthermore, in Comparative Examples 1 and 2, as shown in Tables 1 and 2, there was no gap between the leading edge of the trailing film and the double-sided adhesive tape. Therefore, in Comparative Examples 1 and 2, when the leading film broke at the leading edge of the trailing film, it was observed that the adhesive of the double-sided adhesive tape was exposed from the broken portion of the leading film. Furthermore, in Comparative Examples 1 and 2, portions of the laminated metal strip wound into a coil were stuck together by the exposed adhesive. As a result, when the laminated metal strip wound into a coil was unwound under tension, it was not possible to smoothly unwound the laminated metal strip from the coil, resulting in breakage of the laminated metal strip. [Explanation of symbols]

[0052] 1. Laminating device 2 Metal Strips 3 Heating device 4 Film 5 Laminate Roll 6. Laminated metal strip 7 Pass line roll for metal strips 8 Film pass line roll 9 Leading Roll 9a Leading Film 10 Trailing Roll 10a Trailing film 10at Leading edge of trailing film 11 Double-sided adhesive tape 12 Joint between leading and trailing films 13 Step

Claims

1. A film roll in which a film to be bonded to another film via a double-sided adhesive tape is wound into a roll, the double-sided adhesive tape is attached to the outer peripheral surface at a distance from the leading end of the film on the outer peripheral surface.

2. The film roll according to claim 1 , wherein the distance between the double-sided adhesive tape and the leading end of the film in the film unwinding direction is 1.0 mm or more.

3. 3. The film roll according to claim 1, wherein the distance between the double-sided adhesive tape and the leading end of the film in the unwinding direction of the film is 20.0 mm or less.

4. A laminated metal strip in which the film unwound from the film roll according to claim 1 or 2 is attached to at least one of both surfaces of a metal strip, a leading film attached to the metal strip prior to the film; and a joining portion where the film is joined to the leading film via the double-sided adhesive tape, A laminated metal strip, in which the leading end of the film is attached to one surface of the metal strip.

5. A laminated metal strip in which the film unwound from the film roll according to claim 3 is attached to at least one of both surfaces of a metal strip, a leading film attached to the metal strip prior to the film; and a joining portion where the film is joined to the leading film via the double-sided adhesive tape, A laminated metal strip, in which the leading end of the film is attached to one surface of the metal strip.

6. A method for manufacturing a film that is continuously supplied and attached to at least one of both surfaces of a metal strip, comprising: a first step of attaching a double-sided adhesive tape to an outer peripheral surface of a trailing film roll in which the trailing film is wound in a roll shape, at a distance from the leading end of the trailing film; a second step of synchronizing the feed speed of the leading film, which is fed to the metal strip ahead of the trailing film, with the rotation speed of the outermost peripheral portion of the roll of the trailing film; a third step of joining the leading film and the trailing film, the supply speed of which is synchronized with the rotation speed, via the double-sided adhesive tape; a fourth step of cutting the preceding film at a portion of the preceding film upstream of the double-sided adhesive tape in the direction in which the film is fed relative to the metal strip.

7. The method for producing a film according to claim 6 , wherein in the first step, the distance between the double-sided adhesive tape and the leading end of the following film is set to be 1.0 mm or more and 20.0 mm or less.

8. A method for producing a laminated metal strip, comprising attaching a film produced by the method for producing a film according to claim 6 or 7 to one surface of the metal strip to produce a laminated metal strip.

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