Reel components, adhesive film winding bodies

Abstract

The present invention provides a reel component that allows for winding of adhesive films of different lengths with an optimal core diameter. [Solution] The reel member comprises a circular winding core 3, a disc-shaped core ring 6 having a fitting hole 6a that fits into the winding core 3 and detachably fitted to the outer circumference of the winding core 3, and a pair of reel flanges 4A and 4B provided on both sides of the winding core 3. The outer circumference surface of the winding core 3 is provided with an engaging recess 8, and the inner circumference surface of the fitting hole 6a is provided with an engaging projection 9 that engages with the engaging recess 8. When the engaging recess 8 and the engaging projection 9 engage, the core ring 6 engages with the winding core, and the rotation of the core ring 6 is restricted.

Description

Technical Field

[0001] This technology relates to a reel member around which a tape-shaped adhesive film is wound, and an adhesive film wound body in which the tape-shaped adhesive film is wound around the reel member.

Background Art

[0002] Conventionally, a mounting method of mounting an electronic component on a substrate using an adhesive film has been used. For example, there is a connection method of mounting an electronic component such as a semiconductor component (IC chip) on a circuit board of an electronic device through an adhesive film, or connecting a tab wire serving as an interconnector to a solar cell.

[0003] The adhesive film has an adhesive layer formed on a base film serving as a support. Such an adhesive film 50 is used, for example, in the form of a wound film 51 wound around a core 53 of a reel member 54 having a pair of reel flanges 52 on both sides of the core 53 as shown in FIG. 16.

[0004] The core 53 and the reel flange 52 are formed of, for example, a thermoplastic resin or the like. The manufacturing method of the reel member 54 includes a step of creating a molded product constituting the reel member 54, and a step of producing the reel member 54 by joining the molded products together, that is, connecting two or more objects when the molded products constitute a part of the reel member 54. Specifically, the molded products constituting the reel member 54 can be produced by injection molding. Examples of the molded products include those in which the core 53 and the pair of reel flanges 52 are molded separately, those in which the core 53 and one of the reel flanges 52 are integrally molded, and those in which the other reel flange 52 is molded. Examples of the joining method between the molded products include ultrasonic welding and impulse welding (see Patent Document 1).

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

[0006] Adhesive films are available in various lengths, both short and long, depending on the application. Furthermore, the reel component preferably has a core diameter suitable for the length of the adhesive film; a small-diameter core is suitable for winding long films, while a large-diameter core is suitable for winding short films.

[0007] However, in order to prepare reel components according to the length of adhesive film to be wound, it becomes necessary to create many molds, which is inefficient.

[0008] Therefore, the objective of this technology is to provide a reel member that can wind adhesive films of different lengths with an optimal core diameter, and an adhesive film winding assembly in which adhesive films are wound on this reel member. [Means for solving the problem]

[0009] To solve the above-mentioned problems, the reel member according to this technology comprises a circular winding core, a disc-shaped core ring having a fitting hole that fits into the winding core and detachably fitted to the outer circumference of the winding core, and a pair of reel flanges provided on both sides of the winding core. The outer surface of the winding core is provided with an engaging recess, and the inner surface of the fitting hole is provided with an engaging projection that engages with the engaging recess. The engagement of the engaging recess and the engaging projection causes the core ring to engage with the winding core, thereby restricting the rotation of the core ring.

[0010] Furthermore, the adhesive film winding body according to this technology comprises a core around which a tape-shaped adhesive film is wound, a disc-shaped coring having a fitting hole and the fitting hole being detachably fitted to the outer circumference of the core, a reel member having a pair of reel flanges provided on both sides of the core, and a wound film formed by winding the adhesive film around the coring, wherein the reel member is the reel member described above. [Effects of the Invention]

[0011] According to this technology, by using a core ring having an outer diameter corresponding to the length of the adhesive film, a reel member with a core diameter suitable for the length of the adhesive film can be provided. In this reel member, the core ring engages with the winding core through the engagement of the engaging recess and the engaging protrusion, and the rotation of the core ring (circumferential movement separated from the winding core) is restricted. As a result, the core ring is prevented from free-rotating and rotates integrally with the winding core, enabling the winding and unwinding of the adhesive film. [Brief explanation of the drawing]

[0012] [Figure 1] Figure 1 is a front view showing one embodiment of a reel member. [Figure 2] Figure 2 is a cross-sectional view of the reel component. [Figure 3] Figure 3 is an exploded perspective view of the reel component. [Figure 4] Figure 4 is a plan view of the winding core. [Figure 5] Figure 5 is a cross-sectional view of the core. [Figure 6] Figure 6 is a cross-sectional view showing the process of winding the adhesive film onto the coring ring. [Figure 7] Figure 7 is a cross-sectional view showing the state when ultrasonic vibration is applied to a configuration in which there are no welded ribs on the winding core, and welded ribs are provided only on the coring. [Figure 8] Figure 8 is a plan view of the coring process. [Figure 9] Figure 9 is a perspective view showing one example of the configuration of an engagement recess formed along the thickness direction of the winding core. [Figure 10] FIG. 10 is a perspective view showing a configuration example of an engaging convex portion formed in the thickness direction of the core ring. [Figure 11] FIG. 11 is a plan view showing a state where the engaging concave portion and the engaging convex portion are engaged. [Figure 12] FIG. 12 is a cross-sectional view showing a flange rib protruding from the inner surface of the reel flange and extending from the center side to the peripheral side of the reel flange. [Figure 13] FIG. 13 is a cross-sectional view showing a manufacturing process of the reel member, (A) shows a state before fitting the core ring to the winding core of the molded product, (B) shows a state where the core ring is fitted to the winding core of the molded product, and (C) shows a state where the other reel flange is joined to the winding core of the molded product to which the core ring is fitted. [Figure 14] FIG. 14 is a cross-sectional view showing a manufacturing process of another reel member, (A) shows a process of joining one reel flange and the winding core, (B) shows a state before fitting the core ring to the winding core joined to one reel flange, (C) shows a state where the core ring is fitted to the winding core joined to one reel flange, and (D) shows a state where the other reel flange is joined to the winding core to which the core ring is fitted. [Figure 15] FIG. 15 is a cross-sectional view showing a configuration example of the adhesive film. [Figure 16] FIG. 16 is a front view showing a conventional adhesive film roll.

BEST MODE FOR CARRYING OUT THE INVENTION

[0013] Hereinafter, the reel member and the adhesive film wound body to which the present technology is applied will be described in detail with reference to the drawings. Note that the present technology is not limited only to the following embodiments, and it is needless to say that various modifications are possible without departing from the gist of the present technology. The drawings are schematic, and the ratios of each dimension etc. may be different from the actual ones. Specific dimensions etc. should be determined in consideration of the following description. Needless to say, there are also portions where the relationships and ratios of the dimensions between the drawings are different from each other.

[0014] [Reel member] The reel member 1 to which the present technology is applied is shown in FIGS. 1 to 3. FIG. 1 is a front view showing an embodiment of the reel member 1, FIG. 2 is a cross-sectional view of the reel member 1, and FIG. 3 is an exploded perspective view of the reel member 1. The reel member 1 includes a core 3 around which a tape-shaped adhesive film 2 is wound, a core ring 6 fitted on the outer periphery of the core 3, and a pair of reel flanges 4A and 4B provided on both sides of the core 3.

[0015] The reel member 1 shown in FIG. 1 includes a molded product 5 in which one reel flange 4A and the core 3 are integrally formed, a core ring 6, and the other reel flange 4B. After fitting the core ring 6 toward the reel flange 4A side of the molded product 5 shown in the direction of arrow D in FIG. 3, the reel flange 4B is welded to the core 3 to form it. As will be described later, the manufacturing method of the reel member 1 is not limited to this.

[0016] [Core] As shown in FIG. 4, the core 3 is circular in plan view and is composed of an annular wall erected on the surface of one reel flange 4A. Also, the core 3 is formed with a height slightly larger than the width of the adhesive film 2 described later. The fitting hole 6a of the core ring 6 described later is fitted to the core 3. Thereby, a reel member 1 having an optimal core diameter according to the winding length of the adhesive film 2 is obtained.

[0017] The core 3 is joined to the other reel flange 4B by ultrasonic welding. As shown in Figures 4 and 5, arc-shaped welding ribs 15 are intermittently formed on the upper surface 3b of the core 3. Note that the method of joining the core 3 and the other reel flange 4B is not limited to ultrasonic welding.

[0018] Furthermore, the core 3 has a through hole 3a in its center through which a rotating device that rotates the reel member 1 is inserted. The core 3 is also provided with a pair of reel flanges 4 on both sides and rotates integrally with the reel flanges 4.

[0019] Furthermore, multiple reinforcing ribs 14 are formed radially around the insertion hole 3a. The reinforcing ribs 14 are protruding walls extending from around the insertion hole 3a to the annular wall of the core 3, and are formed at equal intervals around the insertion hole 3a. This ensures that the core 3 has sufficient strength against impacts caused by ultrasonic welding.

[0020] [Coaring] The coring 6 is disc-shaped with a fitting hole 6a formed in the center. The fitting hole 6a has an inner diameter approximately the same as the outer diameter of the winding core 3 and is detachably fitted onto the outer circumference of the winding core 3. The thickness of the coring 6 is approximately the same as the height of the winding core 3, and as shown in Figure 6, the adhesive film 2 can be wound around it in the same way as the winding core 3. A winding film 7, which is made up of multiple layers of adhesive film 2, is provided on the circumferential surface of the coring 6. The winding film 7 is supported on both sides by a pair of reel flanges 4 to prevent winding collapse.

[0021] Furthermore, the term "removable" for the core ring 6 means that during the manufacturing process of the reel member 1, the core ring 6 is not joined to the winding core 3, or that if the reel member 1 is damaged after completion, such as by peeling off the reel flange 4B of the reel member 1, the core ring 6 can be attached to or removed from the winding core 3 (it is fitted, but not joined). In other words, it refers to a state where the core ring 6 is not fixed in place, even though the opposing reel flanges 4A and 4B are integrated with the winding core 3 by welding or other means. That is, after peeling off the reel flange 4B, the core ring 6 is fitted, but it is not joined (i.e., welded or bonded). In short, "removable" can be rephrased as "fitted, but not joined."

[0022] To put it more simply, a core 3 to which one reel flange 4A is joined or integrally molded has a core ring 6 fitted into the side of the reel flange 4A. The inner diameter of the core ring 6 is slightly larger than the outer diameter of the core 3, and a clearance is created when it is fitted into place. That is, the clearance is the gap between the fitting hole 6a of the core ring 6 and the outer circumference of the core 3. This clearance allows the core ring 6 to be removed even when it is fitted into the core 3. Also, because of the clearance, the core ring 6 can rotate while sliding against the outer circumference of the core 3, or with a space between them, as will be described later. By joining the reel flange 4B in this state, it becomes a reel member 1. If the joint of the reel flange 4B is released so as not to damage the core ring 6, the core ring 6 can be removed from the core 3. This removal can be done manually because the coring 6 is simply fitted (mated) in place (a tool that can be gripped by hand may be used, taking into account any distortion in the mating). The direction of this removal is perpendicular to the surface of the reel flange 4A (direction opposite to arrow D in Figure 3). In other words, by releasing the connection of the reel flange 4B, the coring 6 can be manually moved (removed) perpendicular to the surface of the reel flange 4A. Therefore, "removable" can be rephrased as "fitted with clearance."

[0023] Alternatively, by releasing the connection of the reel flange 4B, it can be confirmed that there is clearance between the coring 6 and the winding core 3. This releases the mating. do This can be confirmed by manually moving the coring ring 6 in the circumferential direction of the winding core 3. Furthermore, the existence of this clearance can be confirmed without releasing the joint of the reel flange 4B by applying a rotational force to the coring ring 6 in the circumferential direction of the winding core 3.

[0024] In this specification, "joining" includes all means of connecting two or more objects, such as "welding," which involves creating layers by melting and mixing two objects together, and "adhesion," which involves joining them using various adhesives. However, it does not include "sticking," which occurs when objects stick together unintentionally. In the field of adhesive films, "sticking" refers to the resin overflowing from a film winding body onto the sides of the winding body or the reel flange. to Adhesion is a typical phenomenon and can also cause blocking.

[0025] In this technology, core rings 6 of various outer diameters are formed, each having a fitting hole 6a with an inner diameter approximately the same as the outer diameter of the core 3. The reel member 1 then fits the core ring 6 having the optimal outer diameter according to the length of the film onto the core 3. This makes it possible to easily and inexpensively form a reel member 1 with the optimal core diameter according to the length of the adhesive film 2.

[0026] In other words, adhesive films 2 are available on the market in various lengths, and it is preferable to prepare a reel member with a core diameter suitable for the length of the adhesive film 2. Furthermore, while standardizing the outer diameter of the reel member (i.e., the outer diameter of the reel flange) allows for the commonality of the reel flange, a smaller diameter core is suitable for winding long films, and a larger diameter core is suitable for winding short films.

[0027] However, in order to prepare reel components with different core diameters depending on the length of adhesive film to be wound, it becomes necessary to create many molds, resulting in poor production efficiency and being uneconomical.

[0028] Therefore, in this technology, a reel member 1 with a core diameter suitable for the length of the adhesive film 2 is obtained by forming core rings 6 with various outer diameters and selecting a core ring 6 with an outer diameter corresponding to the length of the adhesive film 2. Furthermore, in this technology, since a suitable core diameter can be selected by changing the core ring 6 according to the length of the adhesive film 2, the amount of material used in the reel member 1 (such as thermoplastic resin described later) can be minimized, thus contributing to economic efficiency and a reduction in environmental impact.

[0029] The material of the coring 6 can be, for example, a thermoplastic resin. Here, thermoplastic resins can include general-purpose resins, general-purpose engineering plastics, and super engineering plastics. The thermoplastic resin may be crystalline or amorphous. Examples of general-purpose resins include polyethylene, polypropylene, and polystyrene. Examples of general-purpose engineering plastics include polycarbonate and polyamide. Examples of super engineering plastics include polyimide and polyamideimide. size From the perspective of achieving high accuracy with good reproducibility, amorphous resins are preferred. Furthermore, from an economic standpoint, it is preferable to use general-purpose resins.

[0030] The method for manufacturing the coring 6 is not particularly limited, but these plastic materials can be used to form them simply and relatively inexpensively by known processing methods such as molding and cutting. In particular, melt molding using a mold is preferable because it minimizes material loss and reduces the generation of processing waste, thus reducing the environmental impact.

[0031] Furthermore, since each of the coring rings 6 can be fitted onto the winding core 3, it is possible to standardize components other than the coring ring 6. In addition, since the coring ring 6 can be detachably fitted onto the winding core 3, it is also possible to wind a long length of adhesive film 2 directly onto the winding core 3 without using the coring ring 6.

[0032] Thus, this technology makes it possible to provide a reel component that can wind adhesive films of different lengths with an optimal core diameter.

[0033] The lower limit of the diameter φ of the coring 6 is not particularly limited, but it is preferably 65 mm or more, and more preferably 70 mm or more. Similarly, the upper limit of the diameter φ of the coring 6 is not particularly limited, but it is preferably 120 mm or less, and more preferably 90 mm or less. As an example, it can be 40 mm or more and 160 mm or less.

[0034] Furthermore, it is preferable not to provide welding ribs 15 for joining with the reel flange 4B on the coring 6. As shown in Figure 7, if the winding core 3 does not have welding ribs 15, and if welding ribs 15 are provided only on the coring 6, applying ultrasonic vibration to melt the welding ribs 15 on the coring 6 will push in the relatively weaker part of the reel flange 4A from the center to the outer edge, which may cause the reel flange 4A to warp. As a result, it becomes impossible to maintain the specified width across the inner and outer circumference of the reel flange 4A, which increases the risk of the adhesive film 2 falling off and may also impair marketability.

[0035] Therefore, it is preferable that the reel member 1 has welding ribs 15 on the winding core 3, but does not have welding ribs 15 on the coring 6. The welding ribs 15 on the winding core 3 are formed inside the area where the adhesive film 2 is wound, and this area is a relatively strong area near the center of the reel flange 4A, so there is no risk of warping occurring in the reel flange 4A.

[0036] [Engaging portion (engaging recess 8 / engaging protrusion 9)] An engaging recess 8 is provided on the outer circumferential surface of the winding core 3. Furthermore, an engaging projection 9 that engages with the engaging recess 8 is provided on the inner circumferential surface of the fitting hole 6a of the coring ring 6. When these engaging recess 8 and engaging projection 9 engage, the coring ring 6 engages with the winding core 3, restricting the rotation of the coring ring 6. As a result, while the coring ring 6 and the winding core 3 are detachably fitted together, the coring ring 6 is prevented from free-rotating (unnecessary movement on the circumference separated from the winding core 3) and rotates integrally with the winding core 3, enabling the winding and unwinding of the adhesive film 2.

[0037] Furthermore, by providing an engaging recess 8 on the core 3, the adhesive film 2 can be wound onto the core 3 even when the coring 6 is not used. If a protrusion were provided on the core 3, problems such as the winding pressure of the adhesive film 2 being concentrated when winding the adhesive film 2 would occur.

[0038] As shown in Figure 4, the engaging recess 8 is preferably formed as an arc-shaped groove that curves in the circumferential direction of the core 3 in a plan view. Also, as shown in Figure 8, the engaging projection 9 is preferably formed as an arc-shaped projection that curves in the circumferential direction of the inner surface of the core ring 6 in a plan view. Since the inner diameter of the fitting hole 6a of the core ring 6 is slightly larger than the outer diameter of the core 3, the engaging projection 9 can be smoothly engaged with the engaging recess 8 while the core ring 6 is rotated around the outer circumference of the core 3.

[0039] Furthermore, as shown in Figure 9, it is preferable that the engaging recess 8 be formed as a groove formed in the thickness direction of the winding core 3. Also, as shown in Figure 10, it is preferable that the engaging projection 9 be formed as a protruding portion formed in the thickness direction of the coring 6. As a result, the engaging recess 8 and the engaging projection 9 engage in both the thickness directions of the winding core 3 and the coring 6, making it possible to more reliably prevent the coring 6 from rotating freely.

[0040] As shown in Figure 11, it is preferable that a space is formed in the circumferential direction of the coring 6 between the engaging recess 8 and the engaging protrusion 9. This allows, AdhesionWhen a circumferential force is applied to the coring 6, such as when the film 2 is pulled out, the engaging projection 9 abuts against the side wall of the engaging recess 8. The impact or vibration of this contact of the engaging projection 9 is Adhesion The information is transmitted to the worker's hand as he grasps and pulls out film 2. As a result, the worker, Adhesion The tension applied to the rolled film 7 when film 2 is pulled out can be sensed. Adhesion The tension required to pull out film 2 can be adjusted.

[0041] In other words, Adhesion In order to attach film 2 to a transport device, Adhesion The film 2 is pulled out from the reel member 1 and routed to the transport device. At this time, with strong force Adhesion When film 2 is pulled out, a stronger tightening force is applied to the center of the wound film 7 around the coring 6, which may cause problems such as adhesive overflow and resulting blocking.

[0042] In the reel member 1, a space is formed in the circumferential direction of the coring 6 between the engaging projection 9 of the coring 6 and the engaging recess 8 of the winding core 3. Therefore, the impact of the engaging projection 9 striking the side wall of the engaging recess 8 changes depending on the force applied to pull out the adhesive film 2. As a result, the worker, Adhesion The tension applied to the rolled film 7 when film 2 is pulled out can be sensed. Adhesion The tension used to pull out the film 2 can be adjusted. Therefore, the reel member 1 can prevent problems such as adhesive overflow and resulting blocking throughout the entire length of the wound film 7.

[0043] Generally, in order to wind a long adhesive film 2, such as one exceeding 200m in length, within the outer diameter of the reel flanges 4A and 4B, the outer diameter of the coring ring 6 must also be reduced. As the length of the adhesive film 2 increases, and as the diameter of the coring ring 6 around which the adhesive film 2 is wound decreases, the load on the wound film 7 due to winding tightness increases near the center close to the coring ring 6. If excessive tension is applied when pulling out the adhesive film 2, there is a risk of the adhesive layer overflowing, blocking which occurs when the overflowing adhesive layer unintentionally adheres to the reel flange, or the pulled-out adhesive film 2 detaching from the wound film 7.

[0044] In this regard, according to this technology, in the reel member 1, a space is formed in the circumferential direction of the coring 6 between the engaging projection 9 of the coring 6 and the engaging recess 8 of the winding core 3. Adhesion The tension adjustment when pulling out the film 2 works more effectively. In addition, even when the adhesive film winding body 10 using the reel member 1 is subjected to changes in temperature and humidity, vibrations and shocks during transport, the tension on the winding film 7 can be absorbed by this space, preventing overhang and other issues.

[0045] The maximum circumferential width of the engaging projection 9 on the inner surface of the coring 6 is not particularly limited, but it is preferably 0.05 mm or more and 0.5 mm or less, and more preferably about 0.2 mm.

[0046] As shown in Figure 11, the circumferential space on the inner surface of the coring 6 between the engaging recess 8 and the engaging projection 9 is defined as space S1. Space S1 is defined as the difference (S1:W1-W2) between the opening width W1 of the engaging recess 8 in the circumferential direction of the core 3 and the base width W2 of the engaging projection 9 in the circumferential direction of the inner surface of the coring 6. There is no particular upper limit to this space S1, but it is preferably 300 μm or less, and more preferably 250 μm or less. There is also no particular lower limit to the space S1, but it is preferably 50 μm or more, and more preferably 150 μm or more. It is particularly preferable that space S1 be in the range of 200 μm ± 30 μm. This space S1 defines the allowable amount of tension adjustment to the wound film 7 even when the magnitude of the impact when the engaging projection 9 abuts the side wall of the engaging recess 8, or when temperature and humidity changes, vibrations and shocks are applied during the transport of the adhesive film winding body 10.

[0047] Space S2 is defined as the space between the engaging recess 8 and the engaging projection 9 when the engaging recess 8 and the engaging projection 9 are engaged. There is no particular upper limit to this space S2, but it is preferably 70 μm or less, and more preferably 60 μm or less. There is also no particular lower limit to the space S2, but it is preferably 20 μm or more, and more preferably 40 μm or more. It is particularly preferable that space S2 be 50 μm. This space S2 defines the engagement force between the engaging recess 8 and the engaging projection 9, and together with space S1, defines the allowable amount of tension adjustment to the winding film 7.

[0048] The clearance mentioned above refers to the gap between the fitting hole 6a of the core ring 6 and the outer circumference of the winding core 3, and is defined as a configuration that allows the core ring 6 to be attached to and removed from the winding core 3. On the other hand, the space refers to the space between the engaging recess 8 provided on the outer circumference of the winding core 3 and the engaging protrusion 9 of the core ring 6, and is defined as a configuration for adjusting the tension on the winding film 7.

[0049] The engaging recess 8 is preferably formed on the extension of the portion of the core 3 where the reinforcing rib 14 is provided. The portion of the core 3 where the reinforcing rib 14 is provided has high strength, so even if the engaging recess 8 is provided, problems such as insufficient strength will not occur.

[0050] [Parts of use] It is preferable that there are multiple engagement points between the engagement recess 8 and the engagement projection 9. Furthermore, it is preferable that each engagement point is formed at non-equal intervals across the circumferential direction of the core ring 6 in a plan view. For example, if there are two engagement points, the other engagement point is provided at a position other than that rotated 180° from the other engagement point in the circumferential direction of the fitting hole 6a of the winding core 3 and the core ring 6. If there are three engagement points, as shown in Figures 4 and 8, a pair of engagement points are provided at positions rotated 180° relative to each other in the circumferential direction of the fitting hole 6a of the winding core 3 and the core ring 6, and the third engagement point is provided at a position non-equal to each of the pair of engagement points. This makes it possible to uniquely determine the fitting surface of the core ring 6 to the molded product 5 in which one reel flange 4A and the winding core 3 are integrally molded, and for example, if there is a marking printed on one side of the core ring 6, the marking can be fitted in a predetermined orientation.

[0051] Furthermore, the number of engagement points with the engagement recess 8 and engagement projection 9 is not limited to two or three locations, but may be four or more. Additionally, the engagement points may be spaced at equal intervals to allow the core 3 to be fitted regardless of the fitting surface of the coring ring 6, thereby improving workability and productivity.

[0052] [Reel flange] The pair of reel flanges 4A and 4B support the wound film 7, in which the adhesive film 2 is wound multiple times around the core ring 6, and are formed in a disc shape using, for example, a plastic material. Furthermore, it is preferable that the reel flange 4 is transparent enough so that the flange ribs 20, described later, can be seen from the outside. The surface of the reel flange 4 that contacts the wound film 7 may also be subjected to electrostatic treatment. A method for performing electrostatic treatment includes, for example, applying a compound such as polythiophene. The diameter of the reel flange 4 can be appropriately designed according to the diameter of the core 3 and the length of the adhesive film 2, and is not particularly limited, but as an example, it can be 90 to 300 mm, preferably 120 to 250 mm, and more preferably 180 to 200 mm.

[0053] [Flange Rib] As shown in Figures 1 and 12, multiple flange ribs 20 may be formed on the inner surfaces of the reel flanges 4A and 4B, protruding from the inner surfaces and extending from the center to the periphery of the reel flanges 4A and 4B. This makes it easier to avoid direct contact between the sides of the adhesive film 2 and the inner surfaces of the reel flanges 4A and 4B, thereby preventing blocking. In addition, the flange ribs 20 can support the sides of the wound film 7, preventing the adhesive film 2 from unraveling.

[0054] The flange ribs 20 extend from the joint with the winding core 3 on the inner surface of the reel flanges 4A and 4B to the periphery, and are provided in groups of 12, for example, at equal intervals of 30°. The shape of the flange ribs 20 is not particularly limited and may be straight, wavy, rectangular, etc., but a straight shape is preferred. It is also preferable that the flange ribs 20 extend radially from the center to the periphery of the reel flanges 4A and 4B. The length of the flange ribs 20 can be appropriately designed according to the diameter of the reel flanges 4A and 4B and the diameter of the winding core 3. It is preferable that the flange ribs 20 reach the winding core 3 on the inner surface of 4A and 4B (the surface facing the winding adhesive film 7) so that the winding of the adhesive film 2 can be carried out under the same conditions from start to finish.

[0055] In Figure 12, the flange rib 20 has a cross-sectional view in which the width of the top portion that contacts the adhesive film 2 is narrower than the width of the base portion that contacts the inner surfaces of the reel flanges 4A and 4B. The upper limit of the height of the flange rib 20, i.e., the amount of protrusion from the inner surfaces of the reel flanges 4A and 4B to the top of the flange rib 20 in a cross-sectional view, is preferably less than 0.10 mm, more preferably 0.08 mm or less, and even more preferably 0.05 mm or less. If the height of the flange rib 20 is 0.10 mm or more, the space between the two reel flanges 4A and 4B widens relative to the width of the adhesive film 2, making detachment more likely. The lower limit of the height of the flange rib 20 is preferably 0.01 mm or more, more preferably 0.015 mm or more, and even more preferably 0.02 mm or more. If the height of the flange rib 20 is less than 0.01 mm, it becomes difficult to suppress adhesion and blocking of the adhesive layer.

[0056] In the cross-sectional view shown in Figure 12, the portion that contacts the winding film 7 is called the top of the flange rib 20, and the distance at the top of the flange rib 20 in a direction perpendicular to the extending direction of the flange rib 20 is called the top width W1.

[0057] The top of the flange rib 20 is a portion that may come into contact with the winding film 7. In order to suppress adhesion of the adhesive layer when winding the adhesive film 2 onto the reel member 1 and blocking when pulling out the adhesive film 2, it is preferable that the width W1 of the rib top be short. Specifically, the upper limit of the rib top width W1 is preferably 0.80 mm or less, and more preferably 0.60 mm or less, which effectively suppresses adhesion and blocking.

[0058] On the other hand, the top of the flange rib 20 contacts the side surface of the rolled film 7, preventing the adhesive film 2 from falling off the rolled film 7 when the adhesive film 2 is pulled out. Therefore, if the width W1 of the rib top is too short, the risk of detachment increases. For this reason, the lower limit of the width W1 of the rib top is preferably 0.10 mm or more, and more preferably 0.20 mm or more, to effectively suppress detachment.

[0059] Also, in the cross-sectional view shown in FIG. 12, the portion between both ends of the flange rib 20 that contacts the inner surface 4a of the reel flange 4 is referred to as the base of the flange rib 20, and the distance in the direction orthogonal to the extending direction of the flange rib 20 at the base of the flange rib 20 is referred to as the rib base width W2. The rib base width W2 of the flange rib 20 is wider than the top width W1 and is defined by the height and inclination angle θ of the flange rib 20. If the rib height and the rib top width W1 are constant, the larger the inclination angle θ, the shorter the rib base width W2 of the flange rib 20, and the smaller the inclination angle θ, the longer the rib base width W2 of the flange rib 20. Also, if the inclination angle θ and the rib top width W1 of the flange rib 20 are constant, the higher the rib height, the longer the rib base width W2 of the flange rib 20, and the lower the rib height, the shorter the rib base width W2 of the flange rib 20.

[0060] Specifically, the rib base width W2 can be determined from the above-described upper limit and lower limit of the rib top width W1 and the upper limit and lower limit of the inclination angle θ. As an example, on the condition that W1 < W2 is satisfied, if the rib base width W2 is too large, it becomes difficult to increase the number of ribs. Therefore, the upper limit of the rib base width W2 can be set to 5 mm or less, preferably 4 mm or less, more preferably 3 mm or less, and even more preferably 2.5 mm or less. Also, if the rib base width W2 is too small, it becomes difficult to reproduce the dimensional accuracy. Therefore, the lower limit of the rib base width W2 is 0.6 mm or more, preferably 0.8 mm or more, and more preferably 1 mm or more. In order to fully exhibit the effects of the present technology, it is preferable that all of these conditions are satisfied.

[0061] The fewer the number of flange ribs 20 on the reel member 1, the smaller the contact area between the flange ribs 20 and the side surface of the winding film 7, which is advantageous in preventing sticking during winding and blocking during unwinding. However, the spacing between the flange ribs 20 widens, increasing the risk of them falling off. Therefore, it is preferable to have 6 or more flange ribs 20, and more preferably 12 or more. While increasing the number of flange ribs 20 increases the difficulty of manufacturing, the narrower spacing between the flange ribs 20 reduces the amount of room for the adhesive film 2 to shift between them. Therefore, the number of flange ribs 20 should be selected considering a combination of factors such as the film width and length, and the tendency of the binder resin to overflow. The same applies to other design factors besides the number of ribs on the reel member 1. If there are too many ribs, the ease of manufacturing may be impaired, so it is preferable to have 36 or fewer ribs, and more preferably 24 or fewer ribs.

[0062] Furthermore, in order to uniformly reduce the risk of detachment over the entire circumference, it is preferable that each flange rib 20 is provided at equal intervals in the circumferential direction.

[0063] The flange ribs 20 provided on the inner surface of the side plate portion 2 are provided as convex ridges formed continuously from the inner circumference to the outer circumference of the reel flanges 4A and 4B, but the flange ribs 20 may be formed intermittently. In addition, the flange ribs 20 may be formed in a straight line or in a curved, undulating shape.

[0064] Furthermore, when the flange ribs 20 are arranged radially, it is preferable that their radial centers coincide with the centers of the reel flanges 4A and 4B, but they can be made to not coincide if necessary. In addition, the flange ribs 20 can be arranged so that they radiate outwards from each of several different radial centers.

[0065] The flange rib 20 is formed in a trapezoidal shape. The flange rib 20 may be symmetrical or asymmetrical, as shown in Figure 12. Furthermore, the flange rib 20 may have a mixture of symmetrical and asymmetrical regions in the longitudinal direction. In addition, the flange rib 20 may be rectangular in cross-section, rectangular with chamfered corners, or arc-shaped or semi-circular. Thus, the specific details of the flange rib 20 provided on the inner surface of the reel flanges 4A and 4B, such as the number and shape, are not particularly limited as long as they prevent adhesive from adhering to the inner surface of the reel flanges 4A and 4B. Reel flanges 4A and 4B equipped with such flange ribs 20 can be formed by molding methods such as injection molding and extrusion molding, or by known manufacturing methods such as machining.

[0066] Here, the coring 6 is provided with concave portions 21 that avoid interference with the flange ribs 20, depending on the position where the flange ribs 20 are formed. The concave portions 21 are formed radially on the plate surface of the coring 6, and when the coring 6 is fitted into a predetermined position where the engaging protrusions 9 and engaging recesses 8 engage, the flange ribs 20 are positioned.

[0067] The flange ribs 20 are located on the inner surfaces of the opposing reel flanges 4A and 4B via the winding core 3. While flange ribs 20 may also be formed on the outer surfaces of the reel flanges 4A and 4B on the side where the winding core 3 is not present, forming them only on the inner surfaces is preferable because it reduces the amount of material used. Furthermore, the flange ribs 20 support the sides of the wound film 7 and are not reinforcing materials (e.g., spokes or similar) that are located inside the winding core 3 or the reel flanges 4A and 4B and reinforce the reel flanges 4A and 4B themselves. This does not exclude the case where the reinforcing material is exposed on the inner surface of the reel flanges 4A and 4B (i.e., the reinforcing material and the flange ribs 20 are the same object), but in this case, the reinforcing material and the flange ribs 20 would be different components from the winding core 3 and the reel flanges 4A and 4B. Therefore, there remains a concern that the manufacturing difficulty and cost will increase. Accordingly, it is preferable that the reel flanges 4A and 4B, the flange ribs 20, and the winding core 3 are all made of the same material (resin).

[0068] The core 3 and the pair of reel flanges 4A and 4B can be formed using the same material as the coring 6 described above.

[0069] [Manufacturing method for reel components] The manufacturing process for the reel member 1 includes the steps of: manufacturing a molded product 5 in which one reel flange 4A and the winding core 3 constituting the reel member 1 are integrally molded, the other reel flange 4B and the coring ring 6; fitting the winding core 3 of the molded product 5 with the coring ring 6; and joining the other reel flange 4B to the winding core 3 of the molded product 5 in which the coring ring 6 is fitted. Figure 13 is a cross-sectional view showing the manufacturing process for the reel member 1, where (A) shows the state before the coring ring 6 is fitted to the winding core 3 of the molded product 5, (B) shows the state after the coring ring 6 is fitted to the winding core 3 of the molded product 5, and (C) shows the state after the other reel flange 4B is joined to the winding core 3 of the molded product 5 in which the coring ring 6 is fitted.

[0070] Here, as described above, no welding ribs are formed on the coring 6, and the joining with the other reel flange 4B is performed solely by applying ultrasonic vibration to the welding ribs 15 formed on the upper surface 3b of one of the winding cores 3. Therefore, the specified width can be maintained across the inner and outer circumferences of the reel flange 4A, without causing the risk of the adhesive film 2 falling off or compromising marketability.

[0071] Alternatively, the reel member 1 may be manufactured without producing a molded product 5 by joining one reel flange 4A and the winding core 3 by ultrasonic welding or the like, fitting the winding core 3 and the coring ring 6, and then joining the other reel flange 4B and the winding core 3 by ultrasonic welding or the like. Figure 14 is a cross-sectional view showing the manufacturing process of another reel member 1, where (A) shows the process of joining one reel flange 4A and the winding core 3, (B) shows the state before fitting the coring ring 6 to the winding core 3 joined to one reel flange 4A, (C) shows the state after fitting the coring ring 6 to the winding core 3 joined to one reel flange 4A, and (D) shows the state after joining the other reel flange 4B to the winding core 3 with the coring ring 6 fitted.

[0072] Furthermore, in the manufacturing process of the reel member 1 related to this technology, the method of joining the winding core 3 and the reel flange 4B or reel flanges 4A, 4B is not particularly limited, and in addition to ultrasonic welding, impulse welding or the like may be used, or adhesive tape (adhesive) may be used.

[0073] [Adhesive film winding assembly] The adhesive film winding body 10 comprises the reel member 1 described above and a winding film 7 in which the adhesive film 2 is wound around the coring 6.

[0074] [Adhesive film] As shown in Figure 15, the adhesive film 2 wound around the coring 6 has a base film 11 and an adhesive layer 12 consisting of an insulating binder supported by the base film 11.

[0075] The length of the adhesive film 2 is not particularly limited, but as the required film length for the adhesive film winding body 10 product, the lower limit of the length of the adhesive film 2 can preferably be 5m or more, preferably 10m or more, more preferably 50m or more, and it may also be 100m or more, or longer than 200m. On the other hand, as the film length increases, the pressure due to winding tightening applied to the adhesive film 2 near the coring 6 increases, increasing the risk of blocking due to the overflow of the adhesive layer. Therefore, the upper limit of the length can preferably be 500m or less, 400m or less, or 300m or less. By making the length of the adhesive film 2 less than 200m, the risk of adhesive overflow and blocking due to winding tightening can be reduced. Also, by making the length of the adhesive film 2 200m or more, preferably 250m or more, the demand for longer lengths can be met, reducing the frequency of replacement of the reel member 1 and improving workability. The lower and upper limits of the length of the adhesive film 2 can be appropriately selected according to the purpose.

[0076] Furthermore, while the width of the adhesive film 2 is not particularly limited, the increasing diversification and miniaturization of electronic devices in recent years has led to a reduction in the mounting area, and consequently, a demand for narrower adhesive films. In response to this demand for narrower films, the adhesive film 2 can preferably have an upper limit width of, for example, 50 mm or less, 32 mm or less, 16 mm or less, 5.0 mm or less, preferably 4.0 mm or less, 2.0 mm or less, 1.5 mm or less, 1.2 mm or less, 0.6 mm or less, 0.5 mm or less, or 0.4 mm or less, and a lower limit width of 0.1 mm or more, preferably 0.3 mm or more.

[0077] An example of an adhesive film 2 that can accommodate such narrowing and lengthening is one with a width of 0.5 mm and a length of 350 m. One method for producing a long adhesive film is to produce multiple short adhesive films (for example, about 100 m each) and connect them. The coring 6 and the adhesive film 2 may also be fixed using leads and connecting tapes (not shown).

[0078] Furthermore, when the adhesive film 2 is made long and narrow, such as with a length of 150m to 200m or more and a width of 1.2mm to 0.8mm or less, there is a risk of overflow due to winding tightness. However, with the reel member 1 of this technology, even when the outer diameter of the coring 6 is relatively small, such as 85mm, the tension during winding of the adhesive film 2 can be controlled, thereby reducing such risks.

[0079] The base film 11 is a support film molded into a tape shape that supports the adhesive layer 12. Examples of base films 11 include PET (Poly Ethylene Terephthalate), OPP (Oriented Polypropylene), PMP (Poly-4-methylpentene-1), and PTFE (Polytetrafluoroethylene). Furthermore, it is preferable to use a base film 11 in which at least the surface facing the adhesive layer 12 has been treated with, for example, a silicone resin.

[0080] This technology assumes an adhesive film 2 in which the base film 11 and adhesive layer 12 are separable, but it can also be applied to adhesive films in which the adhesive layer is inseparable from the base film. Therefore, the adhesive layer may be a layer that only provides adhesion.

[0081] The thickness of the base film 11 is not particularly limited. The lower limit of the thickness of the base film 11 is 3 μm or more for practical purposes, preferably 10 μm or more, more preferably 25 μm or more, and even more preferably 38 μm or more for stable separation. The upper limit of the thickness of the base film 11 is preferably 200 μm or less, more preferably 100 μm or less, and even more preferably 75 μm or less, because if it is too thick, there is a concern that excessive pressure will be applied to the adhesive layer 12. It may also be 50 μm or less.

[0082] On the other hand, the insulating binder (resin composition) that forms the adhesive layer 12 can be a known insulating binder, and can be appropriately selected depending on the application of the adhesive film 2, the presence or absence of fillers, etc., and can be formed from a thermoplastic resin composition, a high-viscosity adhesive resin composition, or a curable resin composition. For example, if the adhesive film 2 is to be used as an adhesive for mounting electronic components, it can be the same as the resin composition that forms the insulating resin layer etc. described in WO2018 / 074318A1. In addition, multiple insulating resin layers may be laminated. Furthermore, in a laminate in which multiple insulating resin layers are laminated, it is not necessary for all layers to have the same composition.

[0083] For example, a thermal polymerization initiator may be used as the polymerization initiator for the curable resin composition, a photopolymerization initiator may be used, or both may be used in combination. For example, a thermal cationic polymerization initiator may be used as the thermal polymerization initiator and an epoxy resin as the thermally polymerizable compound, and a photoradical polymerization initiator may be used as the photopolymerization initiator and an acrylate compound as the photopolymerizable compound. A thermal anionic polymerization initiator may also be used as the thermal polymerization initiator. As a thermal anionic polymerization initiator, it is preferable to use a microencapsulated latent curing agent having an imidazole modified material as a nucleus and its surface coated with polyurethane.

[0084] The melt viscosity at a predetermined temperature and the minimum melt viscosity of the adhesive layer formed from the curable resin composition are not particularly limited. For example, they may conform to the insulating resin layer described in WO2018 / 074318A1, but are not limited to this. Melt viscosity is considered to be the dominant factor in the occurrence of overflow at storage temperature, ambient temperature during use, etc. If the minimum melt viscosity is too high, concerns may arise regarding indentation and flow when used under pressure, so it should be adjusted depending on the object. This minimum melt viscosity can be determined, for example, using a rotary rheometer (manufactured by TA instrument), maintaining a constant measurement pressure of 5g, and using an 8mm diameter measurement plate. More specifically, it can be determined by setting the temperature range to 30-200°C, the heating rate to 10°C / min, the measurement frequency to 10Hz, and the load variation on the measurement plate to 5g. The melt viscosity at a predetermined temperature can be measured in the same way as the minimum melt viscosity by fixing the temperature. Alternatively, the melt viscosity may be measured by tensile measurement using TMA (Thermomechanical Analysis). The minimum melt viscosity can be adjusted by changing the type and amount of melt viscosity modifiers and thixotropic agents used, as well as the preparation conditions of the resin composition.

[0085] The insulating binder may contain fillers such as organic fillers, inorganic fillers, and composite fillers (organic-inorganic mixed fillers) for the purpose of imparting conductivity, viscosity modifiers, thixotropic agents, polymerization initiators, coupling agents, flame retardants, etc., depending on the application of the adhesive film 2. Examples include conductive fillers for electrical applications, insulating fillers for gap spacer applications, or fillers used for optical applications such as light scattering or matte finishes, or fillers used for coloring purposes such as pigments. These can be adjusted as appropriate according to the intended use. The applications of the fillers are not limited, and there are many known fillers for each application, so examples are not provided. The fillers are not limited to one type, and multiple types of fillers may be mixed. The size (average particle diameter) of the fillers is also not particularly limited. By including conductive fillers in the adhesive film 2 to impart conductivity, a conductive adhesive film (including anisotropic conductive adhesive film) can be made.

[0086] The above describes an adhesive film winding assembly 10 in which an adhesive film 2 is wound around a reel member 1. However, the reel member 1 can also be used to wind films other than the adhesive film 2.

[0087] [Manufacturing method for adhesive film windings] The adhesive film 2 can be manufactured by coating the binder resin composition, which is a mixture of the above-mentioned binder resin components and optionally included fillers, onto the base film 11 and then drying it. The fillers may be added after the binder resin components have been coated onto the base film 11. Furthermore, the adhesive film 2 may have a release film provided on the side opposite to the base film 11.

[0088] As shown in Figure 6, the adhesive film 2 is wound multiple times around the coring 6 of the reel member 1 while being guided by guide rollers, thereby forming a wound film 7. The wound film 7 is supported on both sides by a pair of reel flanges 4A and 4B to prevent it from unraveling. This results in an adhesive film wound body 10.

[0089] The reel member 1 can be reused. That is, after all of the adhesive film 2 has been unwound, the reel member 1 can be used to wind the adhesive film 2 onto the coring 6.

[0090] Specifically, the process involves using up all of the film 7 on the adhesive film winding casing 10, that is, unwinding all of the adhesive film 2; attaching the end of a new adhesive film 2 to the coring 6 of the reel member 1 from which the adhesive film 2 was unwinding; and winding the new adhesive film 2 onto the coring 6. This allows for the creation of another adhesive film winding casing 10. This recycled adhesive film winding casing 10 has the same configuration as a newly manufactured adhesive film winding casing 10, but may be distinguished by not having the markings that were attached to the packaging when the newly manufactured adhesive film winding casing 10 was shipped. In this way, by repeatedly using the reel member 1 instead of discarding it, it is possible to contribute to reducing the environmental burden.

[0091] As mentioned above, the core ring 6 of the reel member 1 is detachably fitted onto the winding core 3. Therefore, when reusing the reel member, the core ring 6 can be removed from the winding core 3 by releasing the joint without damaging the reel flange 4A or 4B. This removal can be done manually, as the core ring 6 is simply fitted into place (a tool that can be gripped by hand may be used, taking into account any distortion of the fit). Consequently, the reel member 1 of the refurbished adhesive film winding body 10 may be reused with the core ring 6 fitted, or it may be reused with the adhesive film 2 wound around the winding core 3 without fitting the core ring 6. [Explanation of Symbols]

[0092] 1 Reel component, 2 Adhesive film, 3 Winding core, 3a Through hole, 3b Top surface, 4A, 4B Reel flange, 5 Molded product, 6 Coring, 6a Fitting hole, 7 Winding film, 8 Engaging recess, 9 Engaging protrusion, 10 Adhesive film winding body, 11 Base film, 12 Adhesive layer, 15 Welding rib, 20 Flange rib, 21 Concave surface

Claims

1. A circular core, A disc-shaped core ring having a fitting hole for fitting into the aforementioned core, and detachably fitted to the outer circumference of the aforementioned core, The winding core is provided with a pair of reel flanges on both sides, The outer circumferential surface of the winding core is provided with an engaging recess. The inner circumferential surface of the fitting hole is provided with an engaging projection that engages with the engaging recess, The engagement recess and the engagement projection engage with the core ring, thereby restricting the rotation of the core ring. Reel components.

2. At least one of the pair of reel flanges is attached to the winding core, The reel member according to claim 1, wherein the joining surface of the winding core with the reel flange is provided with welding ribs for joining with the reel flange.

3. The reel member according to claim 2, wherein the coring is not provided with welding ribs for joining with the reel flange.

4. Multiple engagement points are provided between the engagement recess and the engagement projection. The reel member according to any one of claims 1 to 3, wherein each engaging portion is formed at non-equal intervals over the circumferential direction of the coring in a plan view.

5. Three engagement points are provided. A pair of engaging parts are provided at positions 180° apart from each other. The reel member according to claim 4, wherein one engagement portion other than the pair of engagement portions is formed at a position not equal to each of the pair of engagement portions.

6. The engagement recess is an arc-shaped groove that curves in the circumferential direction of the core in a plan view. The reel member according to any one of claims 1 to 3, wherein the engaging projection is an arc-shaped projection that curves in the circumferential direction on the inner surface of the coring in a plan view.

7. The engagement recess is a groove formed in the thickness direction of the winding core, The engaging projection is a raised ridge formed in the thickness direction of the coring, The reel member according to any one of claims 1 to 3, wherein a space is formed in the circumferential direction of the coring between the engaging recess and the engaging protrusion.

8. The reel member according to any one of claims 1 to 3, wherein a plurality of ribs are formed on the inner surface of the reel flange, protruding from the inner surface and extending from the center side to the peripheral side of the reel flange.

9. A reel member having a core around which a tape-like adhesive film is wound, a disc-shaped core ring having a fitting hole, the fitting hole being detachably fitted to the outer circumference of the core, and a pair of reel flanges provided on both sides of the core, The adhesive film is wound around the core ring to form a wound film, The reel member is the reel member described in any one of claims 1 to 3, wherein the adhesive film winding body.

10. The adhesive film winding body according to claim 9, wherein the adhesive film is a conductive adhesive film.

11. The adhesive film winding body according to claim 9 or 10, wherein the length of the adhesive film is 5 m or more.

12. The adhesive film winding body according to claim 11, wherein the diameter φ of the coring is 65 mm or more and 120 mm or less.

13. The adhesive film winding body according to claim 12, wherein the adhesive film is wound to a length of more than 200 m.

14. The adhesive film winding body according to claim 12, wherein the length of the adhesive film is 200 m or less.

Images