Method for manufacturing roll body and roll body

Abstract

To provide a method for manufacturing a roll body capable of effectively alleviating a step caused by a winding start end of a sheet, and such a roll body.SOLUTION: According to an aspect of the present invention, there is provided a method for manufacturing a roll body 10 including a winding core 11 and a long sheet 12 wound around an outer peripheral surface 11A of the winding core 11, including: applying a coating material 18 to the outer peripheral surface 11A of the winding core 11 along a width direction DR1 of the winding core 11; arranging a winding start end 12A of the sheet 12 in a longitudinal direction DR2 on the outer peripheral surface 11A; and winding the sheet 12 around the winding core 11 and filling at least a first gap 13 with the coating material 18, in which coating of the coating material 18 or the arrangement of the winding start end 12A is performed so that the coating material 18 is in contact with or close to a tip surface 12A1 located in the longitudinal direction DR2 of the winding start end 12A, and the first gap 13 is a gap located between the winding core 11 and the sheet 12 on a first lap and in contact with the tip surface 12A1.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a method for producing a roll body and a roll body. [Background technology]

[0002] From the viewpoint of manufacturing efficiency, a certain amount of sheets such as films are often manufactured at once, wound around a core, and stored as a roll. In such rolls, a step occurs due to the winding start end of the sheet. Specifically, a step occurs when the first turn of the sheet moves to the second turn, and the step appears in the second turn and thereafter. Note that, depending on the type of sheet, when this step occurs, the sheet may deform and may not return to its original shape.

[0003] Currently, the following techniques have been proposed to reduce the above-mentioned difference in level: a cushion tape with high cushioning properties, such as urethane resin, is attached to or embedded in the outer peripheral surface of the winding core and then the sheet is embedded in the cushion tape (see, for example, Patent Document 1); a technique in which a winding core having rubber on its outer peripheral surface is used and the sheet is embedded in the rubber to reduce the difference in level; and a technique in which a resilient cushioning material is provided on the outer peripheral surface of the winding core along the tip of the starting end of the sheet (see, for example, Patent Document 2). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2005-75521 A [Patent Document 2] JP 2013-199355 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, under the current circumstances, none of the above techniques can effectively reduce the step.

[0006] In addition, when winding a sheet around a core, a fixing member such as double-sided tape is first attached to the outer peripheral surface of the core to fix a part of the sheet (for example, the winding start end). However, this fixing member can sometimes cause a step.

[0007] The present invention has been made to solve the above problems. That is, an object of the present invention is to provide a method for manufacturing a roll body that can effectively reduce the step caused by the winding start end of a sheet, and to provide such a roll body. Another object of the present invention is to provide a method for manufacturing a roll body that can effectively reduce the step caused by a fixing member, and to provide such a roll body. [Means for solving the problem]

[0008] The present invention includes the following inventions. [1] A method for manufacturing a roll body including a winding core and a long sheet wound around an outer peripheral surface of the winding core, the method comprising the steps of: applying a coating material to the outer peripheral surface of the winding core along the width direction of the winding core; arranging a longitudinal winding start end of the sheet on the outer peripheral surface; and winding the sheet around the winding core to fill at least a first gap with the coating material, wherein the application of the coating material or the arrangement of the winding start end is performed so that the coating material is in contact with or close to a tip surface located in the longitudinal direction of the winding start end, and the first gap is a gap located between the winding core and a first turn of the sheet and in contact with the tip surface.

[0009] [2] A method for manufacturing a roll body including a core and a long sheet wound around an outer peripheral surface of the core, the method comprising the steps of: arranging a winding start end of the sheet in the longitudinal direction on the outer peripheral surface; winding the sheet around the core at least one revolution to obtain an intermediate roll body having a first gap; applying a coating material to a surface of the sheet that constitutes the outer peripheral surface of the intermediate roll body along the width direction of the core; and, after applying the coating material, winding the sheet again around the core to interpose the coating material between the sheets, wherein the first gap is a gap that is located between the core and the sheet in the first revolution and that is in contact with a tip surface located in the longitudinal direction at the winding start end, and the coating material is applied to a first region on the surface of the sheet that constitutes the outer peripheral surface of the intermediate roll body, the first gap corresponding to the first gap.

[0010] [3] A method for manufacturing a roll body including a core and a long sheet wound around an outer peripheral surface of the core, the method including the steps of: arranging a fixing member having a first end face extending in the width direction of the core and a second end face opposite to the first end face, on the outer peripheral surface of the core along the width direction of the core, for fixing a portion of the sheet to the core; applying a coating material to the outer peripheral surface of the core along the width direction of the core; fixing a portion of the sheet to the core via the fixing member; and winding the sheet around the core after applying the coating material and fixing a portion of the sheet to the core, the method including the steps of: filling the coating material, wherein the coating material is applied or the fixing member is arranged so that the coating material is located on the first end face side or the second end face side and is in contact with or close to the first end face or the second end face, or the coating material is located on each of the first end face side and the second end face side and is in contact with or close to the first end face and the second end face, the second gap is a gap located between the winding core and the first turn of the sheet and in contact with the first end face, and the third gap is a gap located between the winding core and the first turn of the sheet and in contact with the second end face.

[0011] [4] A method for manufacturing a roll body including a core and a long sheet wound around an outer peripheral surface of the core, the method comprising the steps of: arranging a fixing member having a first end face extending in the width direction of the core and a second end face opposite to the first end face, on the outer peripheral surface of the core along the width direction of the core, for fixing a portion of the sheet to the core; fixing a portion of the sheet to the core via the fixing member; winding the sheet around the core at least one turn to obtain an intermediate roll body having a second gap and a third gap; and applying a second gap to a surface of the sheet constituting the outer peripheral surface of the intermediate roll body. a step of applying a coating material along a width direction; and a step of rewinding the sheet around the core after applying the coating material, wherein the second gap is a gap located between the core and a first turn of the sheet and in contact with the first end face of the fixed member, and the third gap is a gap located between the core and a first turn of the sheet and in contact with the second end face of the fixed member, and the coating material is applied to at least one of a second region corresponding to the second gap and a third region corresponding to the third gap on the surface of the sheet constituting the outer circumferential surface of the intermediate roll body.

[0012] [5] The method for producing a coating material according to any one of [1] to [4] above, wherein the coating material has fluidity.

[0013] [6] The method according to any one of [1] to [5] above, wherein the coating material is a curable polymer composition.

[0014] [7] The method according to any one of [1] to [6] above, wherein the coating material contains a coloring material or a luminescent material.

[0015] [8] The method for producing a sheet according to any one of [1] to [6] above, wherein the sheet has a resin film.

[0016] [9] The manufacturing method according to any one of [1] to [7] above, wherein the sheet contains an acrylic resin, a polyester resin, or a cycloolefin polymer resin.

[0017]

[10] The manufacturing method described in [8] or [9] above, wherein the thickness of the sheet is 15 μm or more and 300 μm or less.

[0018]

[11] The manufacturing method described in any one of [1] to

[10] above, wherein the sheet is a laminate having a substrate and one or more functional layers laminated on the substrate.

[0019]

[12] The method according to any one of [1] to

[11] above, wherein the sheet is used for an optical film, a polarizing plate, or a display device.

[0020]

[13] A roll body including a winding core and a long sheet wound around the outer peripheral surface of the winding core, the roll body including: a first gap located between the winding core and a first turn of the sheet and in contact with a tip surface located in the longitudinal direction at a longitudinal winding start end of the sheet of the first turn; and a first filling portion filling the first gap and extending in the width direction of the winding core.

[0021]

[14] The roll body described in

[11] above, further comprising: a fixing member provided between the winding core and the first turn of the sheet, the fixing member having a first end face extending in the width direction of the winding core and a second end face opposite to the first end face, and fixing a part of the sheet to the winding core; a second gap positioned between the winding core and the first turn of the sheet and in contact with the first end face of the fixing member; a third gap positioned between the winding core and the first turn of the sheet and in contact with the second end face of the fixing member; and at least one of a second filling portion filled in the second gap and extending in the width direction of the winding core, and a third filling portion filled in the third gap and extending in the width direction of the winding core.

[0022]

[15] A roll body including a winding core and a long sheet wound around an outer peripheral surface of the winding core, the roll body including: a first gap located between the winding core and the sheet in a first turn and in contact with a tip surface located in the longitudinal direction at a winding start end of the sheet in the longitudinal direction of the first turn; and a first intermediate portion provided in a first region corresponding to at least the first gap between the sheets in the first turn and thereafter and extending in the width direction of the winding core.

[0023]

[16] A roll body including a winding core and a long sheet wound around an outer peripheral surface of the winding core, the roll body including: a fixing member provided between the winding core and a first turn of the sheet, the fixing member having a first end face extending in a width direction of the winding core and a second end face opposite the first end face, the fixing member fixing a part of the sheet to the winding core; a second gap located between the winding core and the first turn of the sheet and in contact with the first end face of the fixing member; a third gap located between the winding core and the first turn of the sheet and in contact with the second end face of the fixing member; and at least one of a second filling portion filled in the second gap and extending in the width direction of the winding core, and a third filling portion filled in the third gap and extending in the width direction of the winding core.

[0024]

[17] A roll body including a winding core and a long sheet wound around an outer peripheral surface of the winding core, the roll body including at least one of: a fixing member provided between the winding core and the sheet in a first turn, the fixing member having a first end face extending in a width direction of the winding core and a second end face opposite the first end face, and fixing a part of the sheet to the winding core; a second gap located between the winding core and the sheet in the first turn and in contact with the first end face of the fixing member; a third gap located between the winding core and the sheet in the first turn and in contact with the second end face of the fixing member; a second intermediate portion provided in a second region between the sheets in the first turn or later corresponding to the second gap and extending in the width direction of the winding core; and a third intermediate portion provided in a third region between the sheets in the first turn or later corresponding to the third gap and extending in the width direction of the winding core.

[0025]

[18] The roll body described in

[13] or

[14] above, further comprising a fourth intermediate section connected to the first filling section and interposed between the first turn of the sheet and the second turn of the sheet.

[0026]

[19] A roll body according to any one of

[13] or

[14] above, wherein, when there is no fourth intervening portion connected to the first filling portion and interposed between the sheet of a first turn and the sheet of a second turn, a ratio of a length L1 along the longitudinal direction of the sheet in the first filling portion to a thickness T2 at a position contacting the tip surface in the first filling portion is 90 or more, and when the fourth intervening portion is present, a ratio of the sum of a length L1 along the longitudinal direction of the sheet in the first filling portion and a length L2 along the longitudinal direction of the sheet in the fourth intervening portion to a thickness T2 at a position contacting the tip surface in the first filling portion is 90 or more.

[0027]

[20] The roll body described in

[19] above, wherein, when the fourth intermediate portion is not present, a ratio of an area S1 of a region sandwiched between the outer peripheral surface of the winding core and the surface of the first filling portion in a plane including the longitudinal direction of the sheet and the radial direction of the winding core to the thickness T2 of the first filling portion is 3.0 or more, and when the fourth intermediate portion is present, a ratio of the sum of an area S1 of a region sandwiched between the outer peripheral surface of the winding core and the surface of the first filling portion and an area S2 of a region sandwiched between the outer peripheral surface of the winding core and the surface of the fourth intermediate portion in a plane including the longitudinal direction of the sheet and the radial direction of the winding core to the thickness T2 of the first filling portion is 3.0 or more.

[0028]

[21] The roll body described in

[17] above, wherein, when the thickness of the second intermediate portion is measured along the longitudinal direction of the sheet, the ratio of a length L4 from a second end of the second intermediate portion opposite to a first end of the second intermediate portion on the fixing member side in the longitudinal direction to a position at which the second intermediate portion has the maximum thickness T6 is 12 or more to a maximum thickness T6 of the second intermediate portion.

[0029]

[22] The roll body described in

[21] above, wherein a ratio of a cross-sectional area S3 of the second intermediate portion from the second tip of the second intermediate portion to a position of the maximum thickness T6 in a plane including the longitudinal direction of the sheet and the radial direction of the winding core to a maximum thickness T6 of the second intermediate portion is 2.5 or more.

[0030]

[23] The roll body according to

[15] or

[17] above, wherein the sheet has a protrusion protruding in a radial direction of the core at each of both ends extending along the longitudinal direction of the sheet.

[0031]

[24] The roll body according to any one of

[13] to

[23] above, wherein the sheet has a resin film.

[0032]

[25] The roll body according to any one of

[13] to

[23] above, wherein the sheet contains an acrylic resin, a polyester resin, or a cycloolefin polymer resin.

[0033]

[26] The roll body according to

[24] or

[25] above, wherein the thickness of the sheet is 15 μm or more and 300 μm or less.

[0034]

[27] The roll body according to

[13] above, wherein the first filling section contains a coloring material or a luminescent material.

[0035]

[28] The roll body according to

[14] or

[16] above, wherein the second filling section and the third filling section each contain a coloring material or a luminescent material.

[0036]

[29] The roll body according to

[15] above, wherein the first intermediate portion contains a coloring material or a luminescent material.

[0037]

[30] The roll body according to

[17] above, wherein the second intermediate portion and the third intermediate portion each contain a coloring material or a light-emitting material.

[0038]

[31] The roll body according to

[13] above, wherein the first filling section contains a cured product of a curable polymer composition.

[0039]

[32] The roll body according to the above

[14] or

[17] , wherein the second filling section and the third filling section each contain a cured product of a curable polymer composition.

[0040]

[33] The roll body according to the above

[15] , wherein the first intermediate portion includes a cured product of a curable polymer composition.

[0041]

[34] The roll body according to

[17] above, wherein the second intermediate portion and the third intermediate portion each contain a cured product of a curable polymer composition.

[0042]

[35] The manufacturing method described in any one of

[13] to

[34] above, wherein the sheet is a laminate having a substrate and one or more functional layers laminated on the substrate.

[0043]

[36] The method according to any one of

[13] to

[35] above, wherein the sheet is used for an optical film, a polarizing plate, or a display device. Effect of the Invention

[0044] According to one aspect of the present invention, it is possible to provide a method for manufacturing a roll body that can effectively reduce a step caused by the winding start end of a sheet, and such a roll body. According to another aspect of the present invention, it is possible to provide a method for manufacturing a roll body that can effectively reduce a step caused by a fixing member, and such a roll body. [Brief description of the drawings]

[0045] [Figure 1] FIG. 1 is a perspective view of a roll body according to a first embodiment. [Diagram 2] FIG. 2 is a plan view of a sample for identifying a position for measuring an in-plane retardation. [Diagram 3] FIG. 3 is an enlarged view of a portion of the roll body in FIG. [Figure 4] FIG. 4 is a diagram for explaining the dimensions of each component of the roll body in FIG. [Diagram 5] FIG. 5 is an enlarged view of the vicinity of the tip of the first filling section of the roll body of FIG. [Figure 6] FIG. 6 is a diagram showing regions R1 and R2 in the roll body of FIG. [Figure 7] FIG. 7 is an enlarged view of a part of another roll body according to the first embodiment. [Figure 8] FIG. 8 is an enlarged view of a part of another roll body according to the first embodiment. [Figure 9] FIG. 9 is a plan view of a roll body for identifying a measurement position by a laser displacement meter. [Figure 10] FIG. 10 is an image graph of the amount of displacement versus position created based on the measurement of a laser displacement meter. [Figure 11] FIG. 11 is an enlarged view of a part of the image graph of FIG. 10 for determining the areas S1 and S2. [Figure 12] FIG. 12 is an enlarged view of a part of another roll body according to the first embodiment. [Figure 13] FIG. 13 is an enlarged view of a part of another roll body according to the first embodiment. [Figure 14] FIG. 14 is an enlarged view of a part of another roll body according to the first embodiment. [Figure 15] FIG. 15 is an enlarged view of a part of another roll body according to the first embodiment. [Figure 16] FIG. 16 is an enlarged view of a part of another roll body according to the first embodiment. [Figure 17] 17(A) and 17(B) are diagrams that diagrammatically show the manufacturing process of the roll body according to the first embodiment. [Figure 18] 18(A) and 18(B) are diagrams that diagrammatically show the manufacturing process of the roll body according to the first embodiment. [Figure 19] 19(A) to 19(C) are diagrams illustrating a manufacturing process of another roll body according to the first embodiment. [Figure 20]20(A) and 20(B) are diagrams illustrating another manufacturing process for the roll body according to the first embodiment. [Figure 21] 21(A) and 21(B) are diagrams illustrating another manufacturing process for the roll body according to the first embodiment. [Figure 22] 22(A) to 22(D) are diagrams illustrating schematic diagrams of other manufacturing processes for the roll body according to the first embodiment. [Figure 23] 23(A) to 23(C) are diagrams illustrating schematic diagrams of other manufacturing processes for the roll body according to the first embodiment. [Figure 24] 24(A) and 24(B) are diagrams illustrating another manufacturing process for the roll body according to the first embodiment. [Diagram 25] FIG. 25 is a perspective view of a roll body according to the second embodiment. [Figure 26] FIG. 26 is an enlarged view of a portion of the roll body in FIG. [Figure 27] FIG. 27 is a diagram for explaining the dimensions of each component of the roll body in FIG. [Figure 28] FIG. 28 is a diagram showing the measurement of the maximum thickness and length of the second intermediate portion shown in FIG. [Figure 29] FIG. 29 is a diagram showing the cross-sectional area S3. [Diagram 30] FIG. 30 is an enlarged view of a part of another roll body according to the second embodiment. [Diagram 31] FIG. 31 is an enlarged view of a part of another roll body according to the second embodiment. [Diagram 32] FIG. 32 is an enlarged view of a portion of another roll body according to the second embodiment. [Diagram 33] FIG. 33 is an enlarged view of a part of another roll body according to the second embodiment. [Diagram 34] FIG. 34 is an enlarged view of a part of another roll body according to the second embodiment. [Diagram 35] FIG. 35 is an enlarged view of a portion of another roll body according to the second embodiment. [Diagram 36] FIG. 36 is an enlarged view of a portion of another roll body according to the second embodiment. [Figure 37] FIG. 37 is an enlarged view of a part of another roll body according to the second embodiment. [Figure 38] 38(A) to 38(C) are diagrams illustrating a manufacturing process of the roll body according to the second embodiment. [Figure 39] 39(A) and 39(B) are diagrams illustrating a manufacturing process of the roll body according to the second embodiment. [Diagram 40] Figure 40(A) is a graph showing the amount of displacement versus position around the first filling section of a roll body of Example 7, Figure 40(B) is a graph showing the amount of displacement versus position around the first filling section of a roll body of Example 8, and Figure 40(C) is a graph showing the amount of displacement versus position around the first filling section of a roll body of Example 9. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0046] [First embodiment] Hereinafter, the roll body according to the first embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view of the roll body according to this embodiment, FIG. 2 is a plan view of a sample for identifying a position for measuring an in-plane retardation, FIG. 3 is an enlarged view of a part of the roll body in FIG. 1, FIG. 4 is a view for explaining the dimensions of each component of the roll body in FIG. 1, and FIG. 5 is an enlarged view of the vicinity of the tip of the first filling part of the roll body in FIG. 1. FIG. 6 is a view showing the region R1 and the region R2 in the roll body in FIG. 1, FIG. 9 is a plan view of the roll body for identifying a measurement position by a laser displacement meter, FIG. 10 is an image graph of the displacement amount with respect to the position created based on the measurement of the laser displacement meter, and FIG. 11 is an enlarged view of a part of the image graph in FIG. 10 for determining areas S1 and S2. FIG. 7, FIG. 8, and FIG. 12 to FIG. 16 are enlarged views of parts of other roll bodies according to this embodiment. FIG. 17 to FIG. 19 are views that typically show the manufacturing process of the roll body according to this embodiment. 20 to 24 are diagrams illustrating another manufacturing process for the roll body according to the present embodiment.

[0047] <<<Roll body>>> The roll body 10 shown in FIG. 1 includes a winding core 11 and a long sheet 12 wound around the outer peripheral surface 11A of the winding core 11. As shown in FIG. 3, the roll body 10 further includes a first filling portion 14 filled in a first gap 13 located between the winding core 11 and the sheet 12, a second filling portion 16 filled in a second gap 15 located between the winding core 11 and the sheet 12, and a fixing member 17 for fixing a part of the sheet 12 to the winding core 11. The roll body 10 further includes a fourth intermediate portion 18 connected to the first filling portion 14 and interposed between the first turn of the sheet 12 and the second turn of the sheet 12. The roll body 10 shown in FIG. 3 includes the fourth intermediate portion 18, but does not necessarily include the fourth intermediate portion as in the roll body 10 shown in FIG. 7. The sheet 12 is wound around the winding core 11 multiple times or more, for example, two or more times.

[0048] <<Core>> The shape of the winding core 11 is not particularly limited, but is preferably columnar or cylindrical in order to easily wind the sheet 12. The winding core 11 shown in Fig. 1 is cylindrical. When the winding core is cylindrical, the roll body 10 can be held by inserting a chuck member of a winding device into a hole 11B in the width direction DR1 of the winding core 11. When the winding core is cylindrical, the winding core has a shaft member that penetrates the winding core, and the roll body can be held by the winding device by attaching the shaft member to the winding device.

[0049] The width W1 of the winding core 11 (see FIG. 1) is not particularly limited, and may be, for example, 0.1 m or more and 50 m or less. The lower limit of the width W1 of the winding core 11 may be 0.2 m or more, 0.3 m or more, 0.7 m or more, 1.0 m or more, 1.5 m or more, or 2 m or more, and the upper limit may be 30 m or less, 20 m or less, 10 m or less, 7 m or less, 5 m or less, 3.5 m or less, 3 m or less, or 2.5 m or less. The width of the winding core can be found by measuring the width of the winding core at 10 points and finding the arithmetic average value of 8 widths excluding the maximum and minimum values ​​among the 10 measured widths.

[0050] The outer diameter of the winding core 11 is not particularly limited, and may be, for example, 30 mm or more and 8000 mm or less. The lower limit of the outer diameter of the winding core 11 may be 90 mm or more or 100 mm or more, and the upper limit may be 5000 mm or less, 3500 mm or less, 2000 mm or less, 1000 mm or less, 700 mm or less, 500 mm or less, 350 mm or less, or 300 mm or less. The outer diameter of the winding core can be obtained by measuring the outer diameter of the winding core at 10 points and calculating the arithmetic average value of the outer diameters at 8 points excluding the maximum and minimum values ​​among the 10 measured outer diameters.

[0051] When the winding core 11 is cylindrical, the inner diameter of the winding core 11 is not particularly limited, and may be 20 mm or more and 7500 mm or less. The lower limit of the inner diameter of the winding core 11 may be 50 mm or more, 80 mm or more, 120 mm or more, or 150 mm or more, and the upper limit may be 4500 mm or less, 3000 mm or less, 1500 mm or less, 900 mm or less, 600 mm or less, 400 mm or less, 250 mm or less, or 200 mm or less. The inner diameter of the winding core can be obtained by measuring the inner diameter of the winding core at 10 points and calculating the arithmetic average value of the inner diameters at 8 points excluding the maximum and minimum values ​​among the 10 measured inner diameters.

[0052] In order to reduce the step caused by the winding start end of the sheet, a step may be formed at the portion of the outer peripheral surface of the winding core where the sheet contacts so that the position of the winding start end of the sheet is lower by the thickness of the sheet, but such a step is not formed at the portion of the outer peripheral surface 11A of the winding core 11 where the sheet 12 contacts. By using a winding core 11 that does not have a step at the above-mentioned portion of the outer peripheral surface 11A, it is possible to accommodate sheets 12 of various thicknesses. In this specification, "no step is formed at the portion of the outer peripheral surface of the winding core where the sheet contacts" means that there are no parts with a height difference of 3 μm or more at the center of the winding core and at each periphery of the portion 100 mm or more away from the center in the width direction of the winding core. Note that a step with a height difference of less than 3 μm may be formed at the portion of the outer peripheral surface 11A of the winding core 11 where the sheet 12 contacts.

[0053] The material constituting the winding core 11 is not particularly limited. Examples of the material constituting the winding core 11 include paper, plastic, and metal. Paper includes paper impregnated with resin. Examples of plastic include fiber reinforced plastics (FRP / Fiber Reinforced Plastics), polyolefins such as polyethylene (PE) and polypropylene (PP), polyvinyl chloride (PVC), polystyrene (PS), acrylonitrile-butadiene-styrene copolymer (ABS), phenolic resin, nylon, and the like. Among these, for example, when performing optical coating processing, fiber reinforced plastics (FRP) are preferred from the viewpoints of weight, processability, and strength. Examples of fiber reinforced plastics include those made of a hybrid of a main body made of epoxy resin or phenolic resin with fibers such as glass, epoxy, polyester, carbon, and aramid. Examples of metals include iron, stainless steel (SUS), and aluminum.

[0054] <<Sheet>> The sheet 12 is long. Specifically, the sheet 12 has a sufficiently small thickness relative to its width and a sufficiently long length.

[0055] The width W2 of the sheet 12 (see FIG. 1) is not particularly limited, and may be, for example, 0.1 m or more and 50 m or less. In this specification, the "width of the sheet" means the length of the sheet in the short direction (width direction of the core). The lower limit of the width W2 of the sheet 12 may be 0.2 m or more, 0.3 m or more, 0.5 m or more, 1.0 m or more, or 2.0 m or more, and the upper limit may be 30 m or less, 20 m or less, 10 m or less, 7 m or less, 5 m or less, 3.5 m or less, or 3 m or less. The width of the sheet can be obtained by measuring the width of the sheet at 10 points and calculating the arithmetic average value of the widths at 8 points excluding the maximum and minimum values ​​among the 10 measured widths.

[0056] It is preferable that the width W2 of the sheet 12 is smaller than the width W1 of the core 11. This allows the sheet 12 to be securely held by the core 11.

[0057] The length of the sheet 12 may be, for example, 20 m or more and 10,000 m or less. In this specification, the "length of the sheet" refers to the length of the sheet in the longitudinal direction. The lower limit of the length of the sheet 12 may be 30 m or more, 40 m or more, or 50 m or more, and the upper limit may be 9,000 m or less or 8,000 m or less.

[0058] The thickness of the sheet 12 is not particularly limited, but may be, for example, 3 μm or more and 600 μm or less. The lower limit of the thickness of the sheet 12 may be 10 μm or more, 15 μm or more, 20 μm or more, or 30 μm or more, and the upper limit may be 500 μm or less, 400 μm or less, 300 μm or less, 200 μm or less, 110 μm or less, or 80 μm or less. This is not limited when a thin film is preferred depending on the application, and 3 μm or more and less than 50 μm, and further 40 μm or less are preferable. The thickness of the sheet can be obtained by measuring the thickness of the sheet at 10 points and calculating the arithmetic average value of the thicknesses at 8 points excluding the maximum and minimum values ​​among the thicknesses measured at 10 points. Note that the above-mentioned step is unlikely to occur when the sheet is thick, but becomes more noticeable as the thickness becomes thinner. The present invention is particularly effective when the sheet is thin (80 μm or less, less than 50 μm, and further 40 μm or less).

[0059] When the sheet 12 contains, for example, an acrylic resin, a polyester resin (particularly, polyethylene terephthalate), or a cycloolefin polymer resin, the thickness of the sheet 12 is preferably 15 μm or more and 300 μm or less. When the sheet 12 contains any of these resins, the step becomes more prominent as the sheet becomes thinner, but when the sheet is made extremely thin, the step tends to become smaller. For example, when a heating process of 50° C. or more is performed in the subsequent process, the deformation due to the step may be eliminated if the sheet is thin. However, when the sheet has a certain thickness (for example, 15 μm or more), the deformation may not be eliminated even if the heating process is performed. For this reason, it is particularly effective when the thickness of the sheet 12 is 15 μm or more. Also, when the sheet 12 contains any of these resins, if the sheet is too thick, a large amount of coating material is required. For this reason, from the viewpoint of cost reduction, the thickness of the sheet 12 is preferably 300 μm or less. Furthermore, when any of these resins is included, a step may not easily occur if the thickness exceeds 300 μm. When the sheet 12 includes any of these resins, the lower limit of the thickness of the sheet 12 is more preferably 20 μm or more, 35 μm or more, or 50 μm or more, and the upper limit of the thickness of the sheet 12 is more preferably 250 μm or less, 200 μm or less, 150 μm or less, or 100 μm or less. When any of these resins is included, it is particularly effective when the thickness is neither too thin nor too thick.

[0060] Furthermore, when the fixing member 17 is provided, the sheet 12 is disposed on the fixing member 17, and the total thickness of the sheet 12 and the fixing member 17 affects the step caused by the roll start end of the sheet. Therefore, for example, assuming that the thickness of the fixing member 17 is 3 μm or more and 10 μm or less, the thickness of the sheet 12 is preferably thin, and therefore the upper limit is preferably 130 μm or less, and further preferably 90 μm or less. Furthermore, when the fixing member is an adhesive tape, if the thickness of the fixing member exceeds 15% of the thickness of the sheet, the effect on the step is more likely to occur. Therefore, it is better that the thickness of the sheet 12 is not too thin, and the lower limit of the thickness of the sheet 12 is preferably, for example, 20 μm or more or 35 μm or more.

[0061] Examples of the sheet include films, metal foils, and papers. The film may be, for example, a resin film. When the resin film is used for applications requiring light transmittance (for example, optical film applications), the resin film is preferably light transmittance. The resin constituting such a resin film is not particularly limited as long as it has light transmittance, and examples thereof include acrylic resins, polyolefin resins (polyethylene resins, polypropylene resins, cycloolefin polymer resins), polycarbonate resins, polyacrylate resins, polyester resins (polyethylene terephthalate, polyethylene naphthalate, etc.), aromatic polyether ketone resins, polyether sulfone resins, acetyl cellulose resins (for example, triacetyl cellulose resins), polyimide resins, polyamideimide resins, polyamide resins, or mixtures of two or more of these resins. Among these, resin films with relatively high flexibility, such as resin films containing acrylic resins, polyolefin resins, polyester resins, acetyl cellulose resins, polyimide resins, polyamideimide resins, or polyamide resins, are easily deformed due to steps caused by the beginning end of the sheet or steps caused by the fixing member, so the technology of the present invention is effective. Furthermore, in recent years, low moisture permeable resins with little distortion and low moisture permeability have been preferred for use in large displays. In the case of large displays, the entire width of the sheet is often the product, so if even a part of the sheet is deformed due to steps, the entire sheet must be discarded. For example, acrylic resins, polyester resins, and cycloolefin polymer resins are preferably used in large displays, but the technology of the present invention can effectively prevent deformation due to steps and improve mass productivity, so the technology of the present invention is particularly effective for sheets made of these resins. Furthermore, when thinness is required in the final product, for example, when a film with a thickness of less than 50 μm is used, the technology of the present invention is suitable for films of any material.

[0062] When the sheet 12 is used as an optical film, and particularly when it contains an acrylic resin or a cycloolefin polymer resin, the in-plane phase difference (retardation: Re) of the sheet 12 is preferably 10 nm or less. The in-plane phase difference Re of the sheet 12 being 10 nm or less means that the optical distortion is small, and it can be said that there is almost no residual stress during the manufacture of the sheet 12. In other words, the in-plane phase difference Re of the sheet 12 being 10 nm or less is preferable because the polymer in the sheet 12 is uniform, and when the sheet 12 is rolled into a long length roll, any step is unlikely to cause a new step due to the polymer state inside the sheet 12. The upper limit of the in-plane phase difference Re of the sheet 12 is more preferably 8 nm or less, or 4 nm or less, from the viewpoint of preventing color unevenness and blackout, which are issues when used in combination with a polarizer in display applications. Furthermore, in the case of acrylic resins, if they are used for optical purposes, the phenomenon of turning white when bent, as occurs with conventional acrylic resin films, does not occur, and it is preferable that the haze value (total haze value) is small, at 1% or less or 0.5% or less.

[0063] In addition, when the sheet 12 is used as an optical film and contains a polyester resin, it is preferable that the polymer in the sheet 12 is uniform, as described above, because new steps are less likely to occur due to the internal polymer state. When the sheet 12 contains a polyester resin, stretching is essential to obtain physical strength, so in order to make the polymer state as uniform as possible, it is preferable to manufacture the sheet by sequential or simultaneous biaxial stretching at approximately the same magnification in the length and width directions. As a result, a sheet containing a polyester resin with a smaller in-plane retardation than conventional sheets is obtained. This small in-plane retardation means that the sheet has a thickness of 10 μm to 90 μm and an in-plane retardation of 1500 nm or less, preferably 1200 nm or less, more preferably 1000 nm or less, and even more preferably 800 nm or less. In order to improve the physical properties such as the elastic modulus and tear strength of the biaxially stretched polyester as a plastic film, it is better that the in-plane retardation is not too small, and it is preferably 200 nm or more, and more preferably 400 nm or more.

[0064] In order to further improve the physical properties, it is better to consider the balance between the birefringence in the in-plane direction and the birefringence in the thickness direction. The Nz coefficient is an index of this. The Nz coefficient is affected by the crystallinity and orientation inside the film, and is therefore related to the properties of the entire sheet. For example, in the case of polyethylene terephthalate, the Nz coefficient is usually 2 to 4, but in particular when it is made into a long roll, it is preferably 5 or more, more preferably 8 or more, and most preferably 10 or more, in that new steps are unlikely to occur due to the polymer state in the sheet due to some steps. The upper limit of the Nz coefficient is about 80, preferably 70 or less, and most preferably 50 or less.

[0065] The in-plane retardation (Re) is expressed by the following formula (1) using the refractive index nx in the slow axis direction, which is the direction in the sheet that has the largest refractive index in the plane, the refractive index ny in the fast axis direction, which is the direction perpendicular to the slow axis direction in the plane, and the thickness t (nm) of the sheet. From the following formula (1), it can be seen that a small in-plane retardation tends to improve bending resistance because of a low degree of orientation. The in-plane retardation (Re) can be measured, for example, by using a product name "RETS-100" manufactured by Otsuka Electronics Co., Ltd., or a product name "KOBRA-WR" or "PAM-UHR100" manufactured by Oji Scientific Instruments Co., Ltd. In-plane phase difference (Re)=(nx-ny)×t…(1)

[0066] The Nz coefficient is expressed by the following formula (2) using the refractive index nz in the thickness direction of the sheet, the above nx, and the above ny. Nz coefficient=(nx-nz) / (nx-ny) …(2)

[0067] When measuring the above Re using the RETS-100, the following procedure can be followed. First, in order to stabilize the RETS-100 light source, leave it for 60 minutes or more after turning on the light source. After that, select the rotating analyzer method and the θ mode (angle direction phase difference measurement mode). By selecting this θ mode, the stage becomes a tilted rotating stage.

[0068] Next, the following measurement conditions are entered into the RETS-100. (Measurement conditions) Retardation measurement range: Rotating analyzer method Measurement spot diameter: φ5mm Tilt angle range: -40°~40° Measurement wavelength range: 400nm~800nm The average refractive index of the sample (for example, N=1.617 for PET, and 1.5 for acrylic resin film). Thickness: Thickness measured separately using SEM or optical microscope

[0069] Background data is then obtained without placing a sample in the instrument, the instrument is closed, and this is done every time the light source is turned on.

[0070] Thereafter, a sample is placed on a stage in the apparatus. The shape of the sample may be any shape, for example, rectangular. The size of the sample may be 50 mm x 50 mm. When there are multiple samples, they must all be placed in the same orientation. For example, it is preferable to mark all the samples in advance so that they are all placed in the same orientation.

[0071] After placing the sample, rotate the stage 360° on the XY plane in an environment with a temperature of 23±5°C and a relative humidity of 50±20% to measure the fast axis and slow axis. After the measurement is completed, select the slow axis. Then, the measurement is performed while the stage is tilted in a set angle range around the slow axis, and data (Re) is obtained in 10° increments for the set tilt angle range and set wavelength range. The in-plane retardation Re is the value measured with an incident angle of 0° and light with a wavelength of 589 nm. The in-plane retardation Re is measured at five different points. Specifically, first, draw two orthogonal imaginary lines IL1 and IL2 passing through the center A1 of the sample SA as shown in FIG. 2. When these imaginary lines IL1 and IL2 are drawn, the sample is divided into four sections. Then, set one point equidistant from the center A1 in each section, a total of four points A2 to A4, and measure the center A1 and the points A2 to A4 in total of five points. Of the five measured values, the arithmetic average value of three values ​​excluding the maximum and minimum values ​​is determined as the in-plane retardation Re.

[0072] The sheet 12 may have a single layer structure, or may have a laminate structure in which two or more layers are laminated. Specifically, the sheet 12 may be a substrate alone or a functional layer alone, or may be, for example, a laminate in which one or more functional layers are formed on a substrate (for example, an optical laminate). In this specification, the term "functional layer" refers to a layer intended to exert some function in the laminate. Specifically, examples of the functional layer include a base layer, a hard coat layer, an impact absorbing layer, an antiglare layer, an antistatic layer, a conductive layer, a heat dissipation layer, an ultraviolet absorbing layer, a special wavelength absorbing layer, a special wavelength transmitting layer, a color reproducibility improving layer, a liquid crystal layer, a retardation adjusting layer, a viewing angle adjusting layer, a reflective layer, a colored layer, an anti-reflection layer (a high refractive index layer, a low refractive index layer), an antifouling layer, a water repellent layer, an oil repellent layer, and the like, or a combination thereof. In this specification, the "functional layer" may have a single layer structure, or may have a laminate structure. However, in this specification, the "functional layer" refers to a layer that exists even when the sheet 12 is used, and does not include a release liner that is peeled off when used. If a release liner is present in the sheet, defects are likely to occur and new steps different from the steps described above are likely to occur. If a release liner is provided on the sheet 12, the sheet is wound around the core 11 with the release liner peeled off.

[0073] The uses of the sheet 12 are not particularly limited, and examples thereof include optical uses (optical film uses, polarizing plate uses, display device uses), fittings uses, automobile interior decoration uses, battery component uses, food packaging uses, etc. Among these, if there is a step due to the roll start end of the sheet or a step due to a fixing member, not only the appearance but also the light transmittance may be affected, so the technology of the present invention is particularly effective for optical uses.

[0074] The sheet 12 has a winding start end 12A (see FIG. 3) and a winding end 12B (see FIG. 1). In the roll body 10, the winding start end 12A is located on the inner side (winding core 11) of the winding end 12B. In the roll body 10, as shown in FIG. 3, a tip surface 12A1 located in the longitudinal direction DR2 of the winding start end 12A is substantially aligned with a second end surface 17B (described later) of the fixing member 17 in a cross section along the longitudinal direction DR2 of the sheet 12 and the radial direction DR3 of the winding core 11. In this specification, "substantially aligned" means that the distance between the tip surface 12A1 and the second end surface 17B in the longitudinal direction DR2 of the winding start end 12A is within ±20% of the width W3 (see FIG. 4) of the fixing member 17. Note that the above "+" means that the tip face 12A1 protrudes further than the second end face 17B, and the above "-" means that the tip face 12A1 is recessed further than the second end face 17B (i.e., the second end face 17B protrudes further than the tip face 12A1).

[0075] <<Fixing parts>> The fixing member 17 is for fixing a part of the sheet 12 to the outer peripheral surface 11A of the winding core 11. The fixing member 17 extends in the width direction DR1 of the winding core 11. This allows a part of the sheet 12 to be fixed to the outer peripheral surface 11A of the winding core 11 along the width direction DR1 of the winding core 11.

[0076] The fixing member 17 has a second end face 17B opposite to the first end face 17A. The first end face 17A and the second end face 17B both extend in the width direction DR1 of the winding core 11.

[0077] In Fig. 3, the fixing member 17 is in close contact with the outer peripheral surface 11A of the winding core 11 and the winding start end 12A of the sheet 12, and fixes the winding start end 12A of the sheet 12 to the outer peripheral surface 11A of the winding core 11. Note that, in the first turn of the sheet 12, the sheet 12 may be fixed at a portion other than the winding start end 12A. In Fig. 3, the entire surface of the fixing member 17 is in close contact with the winding start end 12A, but as shown in Fig. 8, the first filling section 14 may be inserted between the winding start end 12A and the fixing member 17 as long as the winding start end 12A is fixed to the fixing member 17 to an extent that does not cause problems during winding, for example, so ... that the winding start end 12A does not peel off from the fixing member 17 during winding.

[0078] The fixing member 17 is not particularly limited, but examples thereof include an adhesive member and a pressure sensitive adhesive member such as a double-sided tape. The fixing member 17 may have elasticity (cushioning properties). The pressure sensitive adhesive member has pressure sensitive adhesive properties on both sides.

[0079] The width W3 of the fixing member 17 (see FIG. 4) is preferably 5 mm or more and 100 mm or less. If the width W3 of the fixing member 17 is 5 mm or more, a part of the sheet 12 can be reliably fixed to the outer peripheral surface 11A of the winding core 11, and if it is 100 mm or less, the sheet 12 can be wound without causing wrinkles in the sheet 12. In this specification, the "width of the fixing member" means the distance from the first end face to the second end face. The lower limit of the width W3 of the fixing member 17 is preferably 10 mm or more, 20 mm or more, or 30 mm or more, and the upper limit is preferably 50 mm or less or 40 mm or less.

[0080] The thickness of the fixing member 17 is preferably 3 μm or more and 600 μm or less. If the thickness of the fixing member 17 is 3 μm or more, it is possible to reliably fix a part of the outer peripheral surface 11A of the winding core 11, and if it is 600 μm or less, it is possible to further suppress deformation of the sheet 12. The lower limit of the thickness of the fixing member 17 is preferably 5 μm or more, 10 μm or more, or 20 μm or more, and the upper limit is preferably 200 μm or less, 100 μm or less, or 50 μm or less. The thickness of the fixing member can be found by measuring the thickness of the fixing member at 10 points and calculating the arithmetic average value of the thicknesses at the 10 points.

[0081] <First Gap> The first gap 13 is a gap in contact with the leading end surface 12A1 located in the longitudinal direction DR2 (see FIG. 3) of the winding starting end 12A. Specifically, the first gap 13 shown in FIG. 3 is a gap surrounded by the outer peripheral surface 11A of the winding core 11, the back surface 12C of the first turn of the sheet 12, the leading end surface 12A1 of the winding starting end 12A, and the second end surface 17B of the fixing member 17. If the fixing member 17 is not provided, the first gap is a gap surrounded by the outer peripheral surface of the winding core, the back surface of the first turn of the sheet, and the leading end surface of the winding starting end.

[0082] The first gap 13 is a gap that contacts the tip end surface 12A1, is located between the winding core 11 and the first turn of the sheet 12, and is also a gap that contacts the second end surface 17B, and is therefore also a third gap, which will be described later.

[0083] <Second gap> The second gap 15 is a gap in contact with the first end surface 17A of the fixing member 17. Specifically, the second gap 15 shown in FIG.

[0084] <First filling section> The first filling portion 14 is filled in the first gap 13. That is, the first filling portion 14 contacts the outer peripheral surface 11A of the winding core 11, the back surface 12C of the first turn of the sheet 12, the tip surface 12A1 of the winding start end 12A, and the second end surface 17B of the fixing member 17. If the fixing member 17 is not provided, the first filling portion contacts the outer peripheral surface of the winding core, the back surface of the first turn of the sheet, and the tip surface of the winding start end. In this specification, "filled" means that the gap is generally filled with the material constituting the filling portion. However, the filling portion may have voids (e.g., air bubbles) inside.

[0085] The sheet 12 has an effective region used as a product and non-effective regions located on both sides of the effective region in the short-side direction of the sheet 12 and not used as a product, and the first filling portion 14 is present at least in the effective region. Since the effective region is the region used as a product, it is preferable that the first filling portion 14 is present across the entire width of the effective region in the width direction DR1 of the core 11. The first filling portion 14 may be present in the non-effective region as long as it is present in the effective region, but if the first filling portion 14 is present in the non-effective region, there is a risk that the first filling portion 14 will protrude from the sheet 12, and since the non-effective region is not used as a product in the first place and there is no need to reduce the step, the first filling portion 14 does not have to be present in the non-effective region. The non-effective region varies depending on the use of the sheet and the width of the sheet, but is usually a region within 10 mm to 30 mm inward from both ends in the short-side direction of the sheet. When the first filling portion 14 is present in a non-effective area, the first filling portion 14 may be present at both ends of the short side of the sheet, but from the viewpoint of suppressing protrusion, it is preferable that the first filling portion 14 is present at a location at least 1 mm, preferably at least 5 mm, and more preferably at least 10 mm away from each of these ends toward the center of the sheet.

[0086] The edge thickness T1 (see Figs. 4 and 5) of the tip 14A on the side of the separation position P1 where the first round sheet 12 separates from the winding core 11 in the first filling section 14 is preferably thin because a thicker thickness may cause a new step to be formed due to this thickness. As will be described later, depending on the purpose, it may be better for the edge thickness T1 to exist to some extent rather than not to exist at all. The edge thickness T1 is preferably, for example, 50 µm or less. The edge thickness T1 is preferably 30 µm or less, 20 µm or less, 10 µm or less, 5 µm or less, or even 2 µm or less in order to shorten the deformation relaxation length, which is the distance from the winding start end 12A to the point where the deformation due to the step at the winding start end 12A becomes unnoticeable. The more the step due to the winding start end is relaxed, the more the deformation of the sheet due to this step is relaxed, and therefore the deformation relaxation length becomes shorter. In this specification, the term "deformation relaxation length" may refer to the length until the sheet deformation due to the step caused by the winding start end is relaxed, and may also refer to the length until the sheet deformation due to the step caused by the fixing member is no longer visible. When the deformation relaxation length is used to mean the length until the sheet deformation due to the step caused by the fixing member is no longer visible, the deformation relaxation length is the distance from the winding start end 12A to the point where the deformation due to the step of the fixing member 17 is no longer visible. The deformation relaxation length is preferably short, and specifically, it is preferably 100 m or less, 75 m or less, 60 m or less, 50 m or less, or 35 m or less, 20 m or less, or 15 m or less. Note that if the deformation relaxation length is 75 m or less, it is favorable because the sheet deformation is not visible in more areas. As described above, the deformation relaxation length is the length until the sheet deformation due to the step is no longer visible, but whether or not a step exists is determined as follows. First, in an indoor environment of 800 Lux to 2000 Lux, a white light source tube (white LED lamp, white fluorescent lamp, etc.) is reflected onto a long sheet, and if there are any parts where the outline of the white light source tube reflected on the sheet is distorted compared to other parts of the sheet, it is determined that a step exists. Meanwhile, if there are any parts around the step where the outline of the white light source tube reflected on the sheet can be determined to be the same as the other parts of the sheet, it is determined that no step exists.The white light source tube is arranged so that its longitudinal direction is along the longitudinal direction of the sheet. The length of the white light source tube can be changed depending on the width and length of the sheet. Specifically, the length of the white light source tube is preferably set to a length that spans the portion of the sheet where the step exists and the portion where the step does not exist. This makes it easier to see the portion where the step exists. In addition, if the observation environment has the above-mentioned brightness, the white light source tube itself may be turned on or off. During observation, it is important that the white light source tube is reflected in the sheet and its contour line is visible. For this reason, as the observation condition, the one where the contour line of the white light source tube is clearly visible is appropriately selected. For example, if the contour line of the white light source tube is easier to see on the back side of the sheet than on the front side of the sheet, the white light source tube may be reflected on the back side of the sheet to check whether there is a step. Specifically, for example, in the case of a laminate in which a functional layer in which the white light source tube is not easily reflected, such as an antiglare layer, is laminated on the front side of the substrate, it may be difficult to check whether there is a step when observed from the antiglare layer side. Therefore, in this case, it is advisable to project a white light source tube onto the back side of the substrate on which the antiglare layer is not laminated, and check whether there is a step. This judgment can also be used for roll bodies for various applications, such as a laminate in which one or more functional layers are laminated on a substrate, or a laminate in which the laminate is attached to a polarizer. For example, when an antiglare layer is laminated on a substrate as a functional layer, it is possible to judge whether there is a step by checking that the uneven shape that exerts the antiglare function is crushed by pressure and appears colored, such as a shadow. In addition, when various functional layers are laminated and it is difficult to project a white light source tube onto the visible side or the opposite side of the roll body, it is possible to judge whether there is a step by checking that a color different from other parts is visible due to a shadow or the like caused by a change in shape as described above.

[0087] Furthermore, when sheet 12 is a thin film having a thickness of 3 μm or more and less than 50 μm, it is more susceptible to the effects of steps caused by winding starting end 12A than when the thickness is thicker. Therefore, when such a thin film is used, edge thickness T1 is preferably 10 μm or less, and from the viewpoint of shortening the deformation relaxation length, it is more preferably 7 μm or less, 5 μm or less, or even 1 μm or less.

[0088] From the viewpoint of minimizing the deformation relaxation length, the edge thickness T1 is preferably the above-mentioned thickness, but the surface of the winding core may be surface-finished and have unevenness. At the tip of the first filling part, the material constituting the first filling part is embedded along the unevenness, so there may be parts where the edge thickness T1 exists and parts where it does not exist, which may cause unevenness. However, if the edge thickness T1 is thin, even if such unevenness occurs, there is no real harm. For this reason, when unevenness exists and causes unevenness, it is preferable that the edge thickness T1 is thin, and specifically, for example, the edge thickness T1 is preferably 15 μm or less, 10 μm or less, 5 μm or less, or even 1 μm or less.

[0089] On the other hand, there is also an effect due to the presence of the edge thickness T1. For example, the winding core is often reused after the use of the roll body. For this reason, the winding core is required to have reworkability, in which the filling part in contact with the winding core, such as the first filling part, is peeled off from the winding core or removed by cleaning or wiping to reuse the winding core. For this reason, for example, the first filling part 14 is preferably not bonded to the winding core 11, as described later. In addition, in the portion where the first filling part 14 is in contact with the winding core 11 and the sheet 12, it is preferable that the sheet 12 can be peeled off cleanly from the first filling part 14. If the first filling part 14 undergoes cohesive failure when the sheet 12 is peeled off from the first filling part 14, it may be difficult to peel off the entire first filling part 14 cleanly from the winding core 11. On the other hand, if the edge thickness T1 exists, it may trigger the peeling off of the sheet 12, so from the viewpoint of reworkability, it is preferable to intentionally have the edge thickness T1 exist. For example, from the viewpoint of reworkability, the edge thickness T1 is preferably 5 μm or more. The preferred thickness of this edge thickness T1 varies depending on the material of the core and the sheet, and the edge thickness T1 may be 1.5 μm or more, or even 5 μm or more. The upper limit of the edge thickness is preferably 30 μm or less, since there is a risk of new steps being formed due to the thickness.

[0090] The edge thickness T1 can be measured using a scanning optical interference surface profiler, such as the "New View" series manufactured by Zygo.

[0091] Specifically, the edge thickness T1 can be obtained using a scanning optical interference surface profiler (product name "New View7300", manufactured by Zygo) as follows. First, when the entire sheet is unwound, the first filling portion 14 may adhere to the sheet 12 side and peel off from the core. If the first filling portion 14 adheres to the unwound sheet 12 side, one or more samples having a size of 0.5 mm square or more including the tip portion 14A of the first filling portion 14 are obtained from the sheet. The sample is not limited to a square, but may be a rectangle (e.g., 2 mm x 5 mm) as long as it is 0.5 mm square or more. The sample is cut out from any location that includes the first filling portion 14 and is not stained or has fingerprints attached. Then, the edge thickness T1 of the first filling portion 14 is measured under the following measurement conditions. The edge thickness T1 can be obtained by measuring the edge thickness at 10 points and calculating the arithmetic average value of the thicknesses at 8 points excluding the maximum and minimum values ​​among the 10 measured thicknesses. (Measurement conditions) Objective lens: 10x ·Zoom: 1x ·Measurement area: 2.17mm x 2.17mm Scan Length: 5μm min mod:0.015

[0092] The thickness T2 (see FIG. 4) at the position in contact with the tip surface 12A1 of the first filling portion 14 is preferably thicker than the sum of the thicknesses of the fixing member 17 and the sheet 12 when the fixing member 17 is present, and is preferably thicker than the thickness of the sheet 12 when the fixing member 17 is not present. By setting the thickness T2 to such a thickness, the step caused by the winding start end 12A can be more effectively alleviated. However, if the thickness T2 is too thick, the step caused by the winding start end 12A can be alleviated, but it may have an adverse effect on the winding of the sheet 12. For this reason, for example, when the thickness of the sheet 12 is 50 μm or more and 200 μm or less, the thickness T2 is preferably 52 μm or more and 220 μm or less, and furthermore, 52 μm or more and 150 μm or less. Also, when the thickness of the sheet 12 is 3 μm or more and less than 50 μm, the thickness T2 is preferably 50.5 μm or more and 100 μm or less.

[0093] The thickness T2 at the position of the first filling portion 14 in contact with the tip surface 12A1 can be measured as follows. The measurement method for the thickness T2 may be different depending on whether the fourth intermediate portion 18 is present or not. When the fourth intermediate portion 18 is not present, the thickness T2 can be measured using a laser displacement meter or a stereo microscope, and when the fourth intermediate portion 18 is present, the thickness T2 can be measured using a stereo microscope. The measurement of the thickness T2 using a laser displacement meter or a stereo microscope is performed in an environment with a temperature of 23±5° C. and a relative humidity of 50±20%.

[0094] The thickness T2 can be measured by a laser displacement meter as follows. The following measurement method utilizes the reflection of laser light, and is therefore particularly effective when the sheet 12 is transparent and the first filling portion is not transparent (for example, colored). First, a jig for rotating the roll body 10 and a laser displacement meter (for example, product name "LK-G30" manufactured by Keyence Corporation) are prepared and placed at predetermined positions. The jig is inserted into the hole 11B in the width direction DR1 of the core 11 and is configured to rotatably hold the roll body 10. Note that, although the LK-G30 is given as the laser displacement meter, an equivalent laser displacement meter such as a successor model may be used instead of the LK-G30.

[0095] The laser displacement meter is equipped with a laser source and a light receiving element, and is a device that can measure displacement based on the position at which laser light is received by the light receiving element after it is irradiated from the laser source and reflected from the surface of the first filling section 14.

[0096] The laser displacement gauges are positioned above the roll body 10, and three of them are arranged so that the laser light is irradiated toward the surface of the roll body 10. The laser displacement gauges are arranged as follows. First, as shown in FIG. 9, a first position B1 and a second position B2 are determined to divide the width of the sheet 12 into thirds. The first position B1 is located on the first end 12G1 side in the short direction of the sheet 12 (the width direction DR1 of the core 11), and the second position B2 is located on the second end 12G2 side opposite to the first end 12G1. The first laser displacement gauge is arranged so that the laser light is irradiated to the midpoint C1 between the first position B1 and the first end 12G1, the second laser displacement gauge is arranged so that the laser light is irradiated to the midpoint C2 between the first position B1 and the second position B2, and the third laser displacement gauge is arranged so that the laser light is irradiated to the midpoint C3 between the second position B2 and the second end 12G2.

[0097] Then, the roll body 10 is attached to a jig, and the sheet 12 is unwound until the first filling portion 14 is exposed from the roll body 10. Thereafter, while the first filling portion 14 is exposed, the core 11 is rotated at a rotation speed of 30 mm / s, and the displacement is continuously measured with a laser displacement meter at a sampling period of 200 μs to obtain a graph (see FIG. 10) with the horizontal axis representing the position (mm) and the vertical axis representing the displacement (mm). This measurement is performed from the tip 14A of the first filling portion 14 to the position where it contacts the tip surface 12A1, and in this measurement, the reference height (0 mm displacement line) is the height of the core 11, and the difference between the reference height and the displacement of the first filling portion 14 is the thickness of the first filling portion 14. In addition, in this graph, one division on the horizontal axis is 5 mm, and one division on the vertical axis is 0.02 mm.

[0098] In this graph, the amount of displacement increases from the tip 14A where the first filling portion 14 exists, but the amount of displacement drops sharply after the position where the first filling portion 14 contacts the tip surface 12A1. Therefore, the position E1 on the position displacement curve where the amount of displacement starts to drop sharply is found in the graph. Then, the thickness T2 of the first filling portion 14 at the position where the first filling portion 14 contacts the tip surface 12A1 is found by finding the difference in the amount of displacement between the 0 mm displacement line and position E1.

[0099] The thickness T2 can be measured using a stereo microscope as follows. First, the portion including the winding start end 12A, the first filling portion 14, and the second turn of the sheet 12 is sampled and fixed so as not to crush this portion. Then, the cross section of this fixed portion is polished, and the thickness T2 of the first filling portion 14 is measured using a stereo microscope (for example, product name "Digital Microscope VHX-7000" manufactured by Keyence Corporation). Note that, although the digital microscope VHX-7000 is given as the stereo microscope, a similar stereo microscope such as a successor model may be used instead of the VHX-7000.

[0100] Since both end portions 12G (see FIG. 1) extending in the longitudinal direction DR2 of the sheet 12 are not used as a product, the length of the first filling portion 14 in the width direction DR1 of the core 11 may be smaller than the width W2 of the sheet 12 as long as it is equal to or greater than the effective area for manufacturing the product in the roll body 10.

[0101] The first filling section 14 preferably contains a coloring material or a luminescent material. When the first filling section 14 contains a coloring material or a luminescent material, it is easy to visually check if the first filling section 14 protrudes from the roll body 10. In addition, it is easy to check the thickness, length, etc. of the first filling section 14.

[0102] When the first filling section 14 is colored, the color of the first filling section 14 is not particularly limited, but from the viewpoint of ensuring that the presence of the first filling section 14 can be grasped and that any components of the first filling section 14 that adhere to the winding device are not noticeable, white, gray, or the like is preferable.

[0103] When the first filling section 14 is colored, the first filling section 14 contains a coloring material. When the first filling section 14 is a cured product of a coating material, it is preferable that the coloring material does not inhibit the curing. The coloring material may be either a pigment or a dye, and may be either an organic coloring material or an inorganic coloring material. Specific examples of the coloring material include titanium oxide, carbon black, or a mixture thereof.

[0104] When the first filling portion 14 is colored, the content of the coloring material in the first filling portion 14 is preferably 0.1% by mass or more and 50% by mass or less. If the content of the coloring material is 0.1% by mass or more, the first filling portion 14 can be visually confirmed, and if it is 50% by mass or less, good reworkability can be maintained even if the coloring material is an inorganic material or an organic material.

[0105] When the first filling section 14 contains a luminescent material, the luminescent material is not particularly limited, but may be a fluorescent material or a phosphorescent material. When the first filling section 14 contains a fluorescent material or a phosphorescent material, the fluorescent material or the phosphorescent material in the first filling section 14 can be made to emit light by irradiating the first filling section 14 with light such as ultraviolet light or visible light.

[0106] The shape of the surface 14B of the first filling portion 14 is preferably upwardly convex. If the shape of the surface 14B is upwardly convex, the sheet 12 can be lifted more than if the shape is downwardly concave, and the above-mentioned step can be alleviated. Whether the shape of the surface 14B is upwardly convex can be determined from the graph of the position displacement curve, as with the thickness T2. Specifically, first, in the above graph, the position where the first filling portion 14 exists is higher than the height of the winding core 11, so the displacement amount increases. The position E2 (see FIG. 10) that is the intersection of the displacement amount 0 mm line and the position displacement curve at the point where the displacement amount starts to increase is identified. Then, an imaginary line IL3 (see FIG. 10) that passes through the positions E1 and E2 is drawn. If the ratio of the number of peaks located above the virtual line IL3 among the number of peaks of the position displacement curve existing between the positions E1 and E2 is 50% or more, the shape of the surface 14B of the first filling portion 14 can be determined to be upwardly convex, and if the ratio of the number of peaks located below the virtual line IL3 among the number of peaks of 50% or more among the number of peaks of the position displacement curve existing between the positions E1 and E2 is less than 50%, the shape of the first filling portion 14 can be determined to be downwardly concave. Note that if the virtual line IL3 and the position displacement curve overlap, it is determined to be downwardly concave. In the graph for determining the shape of the first filling portion 14, one division on the horizontal axis is 5 mm, and one division on the vertical axis is 0.02 mm.

[0107] When the shape of the surface 14B of the first filling portion 14 is convex upward, the average distance D1 from the virtual line IL3 to the position displacement curve in the vertical direction is preferably 0.003 mm or more. If the average distance D1 is 0.003 mm or more, the sheet 12 can be effectively lifted, so that the above-mentioned step can be further alleviated. The lower limit of this average distance D1 is more preferably 0.01 mm or more. The upper limit of the average distance D1 is preferably 0.1 mm or less, and even more preferably 0.07 mm or less, because an excessively convex shape may cause a new step. The above-mentioned average distance D1 is obtained by taking the virtual line IL3 as a reference line, reading seven peaks that are convex upward from this virtual line IL3, and averaging the values ​​of the five points excluding the maximum and minimum values. The peak to be read is the mountain part, and the large part is selected.

[0108] The inclination of the virtual line IL3 with respect to the horizontal axis of the graph of the position displacement curve is preferably 0.0020 or more and 0.0130 or less, more preferably 0.0030 or more and 0.0070 or less, and even more preferably 0.0050 or more and 0.0060 or less. If this inclination is 0.0050 or more, the filling material can be filled without being depressed, and if it is 0.0060 or less, the filling material can be filled without being significantly convex. The lower limit of this inclination is preferably 0.0020 or more, 0.0030 or more, or 0.040 or more, and the upper limit is preferably 0.0130 or less, 0.0120 or less, or 0.0100 or less.

[0109] It is preferable that the thickness of the first filling portion 14 gradually increases from the vicinity of the separation position P1 toward the tip surface 12A1. By changing the thickness of the first filling portion 14 in this way, a sudden change in height of the sheet 12 in the radial direction DR3 of the winding core 11 (the normal direction of the outer circumferential surface 11A) can be suppressed, and therefore a step caused by the winding start end portion 12A can be mitigated.

[0110] If the thickness of the first filling part changes suddenly, the deformation caused by the thickness change part may remain, and the step caused by the winding start end may not be sufficiently alleviated. For this reason, it is preferable to ensure a sufficient length of the first filling part relative to the thickness of the sheet. However, if the length of the first filling part is increased, and other effects such as winding occur, the length of the first filling part may be intentionally shortened from the optimal state, so that the deformation relaxation length is longer than the state in which the first filling part has the optimal length, but the deformation relaxation length can be shorter than if the first filling part is not provided. Therefore, when the fourth intermediate part 18 is present as shown in FIG. 4, it is preferable that the ratio ((length L1 + length L2) / thickness T2) of the sum of the length L1 (see FIG. 4) of the first filling part 14 along the longitudinal direction DR2 of the sheet 12 (see FIG. 4) and the length L2 (see FIG. 4) of the fourth intermediate part 18 along the longitudinal direction DR2 of the sheet 12 to the thickness T2 at the position of the first filling part 14 in contact with the tip surface 12A1 is 90 or more. 7, when the fourth intermediate portion 18 does not exist, the ratio (length L1 / thickness T2) of the length L1 (see FIG. 7) of the first filling portion 14 along the longitudinal direction DR2 of the sheet 12 to the thickness T2 of the first filling portion 14 at the position contacting the tip surface 12A1 to the thickness T2 of the first filling portion 14 at the position contacting the tip surface 12A1 is preferably 90 or more. The lower limit of these ratios is preferably 100 or more, 110 or more, 120 or more, or 140 or more in terms of shortening the deformation relaxation length. The upper limit of these ratios is not particularly limited, and may be, for example, 1200 or less, 1000 or less, 800 or less, 500 or less, or 300 or less.

[0111] The length L1 is the length from the position where the first filling portion 14 contacts the leading end surface 12A1 along the longitudinal direction DR2 of the sheet 12 to the end on the side of the separation position P1. The length L2 is the length from the position directly above the leading end surface 12A1 along the longitudinal direction DR2 of the sheet 12 to the end on the side of the position where the first round of the sheet 12 and the second round of the sheet 12 contact each other. The lengths L1 and L2 can be obtained from the graph of the position displacement curve, as with the thickness T2. Specifically, first, the presence of the fourth intermediate portion is confirmed by a method described later. If the fourth intermediate portion exists, the positions E1 and E2 are found from the graph of the position displacement curve. Next, a virtual line IL4 (see FIG. 10) is drawn that passes through the position E2 and is perpendicular to the 0 mm displacement line. Then, if the intersection of the virtual line IL4 and the 0 mm displacement line is set to position E3, the total length of the lengths L1 and L2 can be obtained by obtaining the distance between the positions E2 and E3. Moreover, in the case where the fourth intermediate portion does not exist, the length L1 can be obtained by finding the distance between the position E2 and the position E3 using the above method.

[0112] For example, when the thickness of the sheet 12 is 50 μm or more and 200 μm or less, the length L1 is preferably 110 μm or more, and in order to further shorten the deformation relaxation length, the length L1 is preferably 1 mm or more, and further preferably 10 mm or more. However, if the length L1 is too long, it becomes difficult to form the upwardly convex first filling part in processing, and there is a risk that wavy thickness unevenness will occur in the first filling part, so the upper limit of the length L1 is preferably 100 mm or less from the viewpoint of easily obtaining the upwardly convex first filling part 14 and suppressing wavy thickness unevenness.

[0113] The above (length L1 + length L2) / thickness T2 or length L1 / thickness T2 can roughly represent the shape of the first filling section 14, but in order to more accurately represent a shape such as an upward convex shape in the first filling section 14, it is preferable to further use the area of ​​the first filling section 14 in a plane including the longitudinal direction DR2 of the sheet 12 and the radial direction DR3 of the winding core 11. Specifically, when the fourth intermediate portion 18 is present as shown in FIG. 4, the ratio ((area S1+area S2) / thickness T2) of the sum of the area S1 (see FIG. 6) of the region R1 sandwiched between the outer peripheral surface 11A of the winding core 11 and the surface 14B of the first filling portion 14 in a plane (plane shown in FIG. 4) including the longitudinal direction DR2 of the sheet 12 and the radial direction DR3 of the winding core 11 and the area S2 (see FIG. 6) of the region R2 sandwiched between the outer peripheral surface 11A of the winding core 11 and the surface 18A of the fourth intermediate portion 18 to the thickness T2 at the position in contact with the tip surface 12A1 of the first filling portion 14 is preferably 3.0 or more. The area S1 of the region R1 in FIG. 6 represents the cross-sectional area of ​​the first filling portion 14. The area S2 of the region R2 in FIG. 6 represents the sum of the cross-sectional area of ​​the fourth intermediate portion 18, the cross-sectional area of ​​the sheet 12 in the region R2, and the cross-sectional area of ​​the fixing member 17 in the region R2. In addition, FIG. 6 shows a state in which the sheet 12 on the first filling portion 14 and the fourth intermediate portion 18 is peeled off to expose the first filling portion 14 and the fourth intermediate portion 18. When the fourth intermediate portion 18 does not exist, it is preferable that the ratio (area S1 / thickness T2) of the area S1 of the region R1 sandwiched between the outer peripheral surface 11A of the winding core 11 and the surface 14B of the first filling portion 14 in a plane (plane shown in FIG. 7) including the longitudinal direction DR2 of the sheet 12 and the radial direction DR3 of the winding core 11 to the thickness T2 of the first filling portion 14 is 3.0 or more. If these ratios are 3.0 or more, the total of the area S1 and the area S2 or the area S1 is large relative to the thickness T2, so that the sheet 12 can be effectively lifted by the first filling portion 14, and thus the above-mentioned step can be further alleviated. From the viewpoint of further alleviating the above-mentioned step, the lower limit of these ratios is preferably 4.0 or more, 5.0 or more, 6.0 or more, 7.0 or more, or 8.0 or more. Furthermore, the upper limit of these ratios is not particularly limited, but may be, for example, 50.0 or less, or even 17.0 or less.

[0114] The sum of area S1 and area S2 and area S1 can be found by calculating the product of the thickness t at each measurement point MP and the width d between each pair of measurement points MP in the region from position E2 to position E3, as shown in Fig. 11, and then summing up the products. The width between the measurement points can be found from the sampling period, the rotational speed of the winding core, and the outer diameter of the winding core. Specifically, the width between the measurement points can be found from the following formula (3). In formula (3), d (μm) is the width between the measurement points, ΔT (s) is the sampling period, r (rpm) is the rotational speed of the winding core, φ (mm) is the outer diameter of the winding core, and π is the circular constant. d=ΔT×(r / 60)×φ×π×1000…(3)

[0115] As described above, the core is often reused after the roll body is used, so reworkability is required. For this reason, it is preferable that the first filling portion 14 is not bonded to the core 11. If the reworkability is good, the core can be reused after the roll body is used. In this specification, "a state in which the core can be reused" means a state in which the entire outer peripheral surface of the core is visually observed and there is no adhesion that causes a step. The removal method differs depending on the filling material used for the first filling portion. In the case of a hard coat layer for a display device that has a high crosslink density and is hard, a thinner edge thickness T1 may be easier to remove. On the other hand, in the case of a hard coat layer for a display device that has a low crosslink density and has rubber elasticity, a thicker edge thickness T1 may be easier to remove. In either case, it is sufficient that no adhesion that causes a step remains when visually observed. In addition, in this specification, "adhesion" is a concept that includes adhesion. Since the first filling portion 14 is not bonded to the core 11, the first filling portion 14 can be easily peeled off, and therefore has good reworkability. It is more preferable that the first filling portion 14 can be peeled off slowly from the winding core 11 by washing or wiping the winding core 11, or by creating an opening at the end of the first filling portion 14 with a blade-like object so as not to damage the winding core 11, using fingers, etc. It is also more preferable that the first filling portion 14 does not substantially contain an adhesive component.

[0116] When a 90° peel test is performed in which the constituent material of first filling portion 14 is peeled perpendicularly to outer peripheral surface 11A of winding core 11, it is preferable that the constituent material peels off from outer peripheral surface 11A of winding core 11 with a tensile force of less than 2.0 N. When the constituent material peels off with a tensile force of less than 2.0 N, first filling portion 14 can be easily peeled off, providing good reworkability, and when the constituent material peels off with a tensile force of 0.3 N or less, first filling portion 14 can be peeled off even more easily, providing excellent reworkability.

[0117] The 90° peel test can be performed using a sample and a spring tension gauge (manufactured by Ohba Keiki Seisakusho Co., Ltd.). Specifically, first, a mold larger than the size of the sample is prepared, and this mold is placed on the outer peripheral surface 11A of the winding core 11. Then, a coating material for forming the first filling portion 14 is poured into this mold and cured as necessary to obtain a material layer. Thereafter, the material layer is removed from the mold, and the material layer is cut into a size of 20 mm x 100 mm using a cutter or the like to obtain 10 samples provided on the outer peripheral surface 11A of the winding core 11. Then, one end of the sample is held by a spring tension gauge, and the one end is pulled up perpendicularly to the outer peripheral surface 11A of the winding core 11 while measuring the tensile force in an environment with a temperature of 25°C and a relative humidity of 30% to 70%, and the sample is peeled off at a peeling speed of 10 mm / sec. Then, of the 10 samples subjected to the 90° peel test, the arithmetic average value of the tensile strengths of the 8 samples excluding the sample with the maximum tensile strength and the sample with the minimum tensile strength is regarded as the tensile strength of the above-mentioned constituent material.

[0118] The tensile strength of the material of the first filling portion 14 is preferably 3.0 MPa or more. If the tensile strength of the material is 3.0 MPa or more, the first filling portion 14 is less likely to tear when peeled off, and good reworkability can be obtained. From the viewpoint of obtaining excellent reworkability, the lower limit of the tensile strength of the material is more preferably 3.2 MPa or more or 3.4 MPa or more. In addition, if the tensile strength of the material is too large, the cushioning property of the first filling portion is poor, so the upper limit of the tensile strength of the material is preferably 16.0 MPa or less, 8.0 MPa or less, or 5.5 MPa or less in order to obtain good cushioning property.

[0119] The tensile strength of the above-mentioned constituent materials can be measured using a sample and a Tensilon universal testing machine (product name "RTC-1310A", manufactured by A&D Co., Ltd.) in accordance with JIS K6251:2017. Specifically, first, a mold larger than the size of the sample is prepared, and this mold is placed on the outer peripheral surface 11A of the winding core 11. Then, a coating material for forming the first filling portion 14 is poured into this mold and cured as necessary to obtain a material layer. Thereafter, the material layer is removed from the mold, and the material layer is punched out to the size of the dumbbell-shaped No. 2 shape described in JIS K6251:2017 with a punching blade (for example, a tensile No. 2 dumbbell-shaped punching blade manufactured by Kobunshi Keiki Co., Ltd.) to obtain 10 samples. Thereafter, the sample is kept in an environment of 25°C for 24 hours. Then, the pair of gripping tools of the Tensilon universal testing machine grip both longitudinal ends of the sample, and a tensile test is performed under conditions of a temperature of 25°C, a relative humidity of 30% to 70%, an initial gripping tool distance of 20 mm, and a tensile speed of 100 mm / min, to measure the tensile strength of the sample. The arithmetic average value of the tensile strengths of 8 samples out of the 10 samples, excluding the maximum and minimum values, is taken as the tensile strength of the above-mentioned constituent material.

[0120] The elongation at break of the constituent material of the first filling portion 14 is preferably 200% or more. If the elongation at break of the constituent material is 200% or more, the first filling portion 14 is easily elongated, so that the first filling portion 14 is less likely to tear when peeled off, and good reworkability can be obtained. From the viewpoint of obtaining excellent reworkability, the lower limit of the elongation at break of the constituent material is more preferably 250% or more, 300% or more, or 350% or more. In addition, the upper limit of the elongation at break of the constituent material may be 850% or less, 600% or less, or 500% or less. The elongation at break of the constituent material can be measured in accordance with JIS K6251:2017 using a sample and a Tensilon universal testing machine (product name "RTC-1310A", manufactured by A&D Co., Ltd.) in the same manner as the measurement method of tensile strength.

[0121] The tear strength of the constituent material of the first filling portion 14 is preferably 1.0 N / mm or more. If the tear strength of the constituent material is 1.0 N / mm or more, the first filling portion 14 is less likely to tear when peeled off, and good reworkability can be obtained. From the viewpoint of obtaining excellent reworkability, the lower limit of the tear strength of the constituent material is more preferably 2.0 N / mm or more, 4.0 N / mm or more, 6.0 N / mm or more, 8.0 N / mm or more, or 10 N / mm or more. The upper limit of the tear strength of the constituent material may be 35 N / mm or less, 30 N / mm or less, or 25 N / mm or less. The tear strength of the constituent material can be measured using a sample and a Tensilon universal testing machine (product name "RTC-1310A", manufactured by A&D Co., Ltd.) in accordance with JIS K6252:2007. The sample is to be prepared by the method described in the tensile strength column.

[0122] The hardness of the material of the first filling section 14 measured by a durometer type A is preferably 95° or less. Pressure is always applied to the tip of the first filling section during winding, and pressure may also be applied due to changes over time or environmental changes (temperature, humidity, and / or pressure). In order to suppress the step caused by the tip of the first filling section, it is also effective to have a thin tip of the first filling section, but by using a soft resin whose hardness of the above-mentioned material measured by a durometer type A is 95° or less, the first filling section will deform due to the pressure when the sheet is wound, and the step caused by the tip of the first filling section can be suppressed. It is more preferable that the upper limit of the hardness is 95° or less, 80° or less, 70° or less, or 50° or less. On the other hand, when the difference in hardness between the sheet and the first filling part is large, such as when the sheet is hard and the first filling part is soft, and when the fourth intermediate part does not exist, only the first filling part is compressed by the pressure when the sheet is wound, and the step caused by the winding start end is not sufficiently alleviated, and there is a risk that the sheet may be slightly deformed. For this reason, the lower limit of the hardness is preferably 10° or more, 15° or more, 20° or more, or 25° or more.

[0123] The hardness measurement using a durometer type A is performed in accordance with JIS K6253:1997. Specifically, a mold larger than the size of the sample is prepared first, and the mold is placed on the outer peripheral surface 11A of the core 11. Then, the coating material for forming the first filling portion 14 is poured into the mold, and cured as necessary to obtain a material layer. Thereafter, the material layer is removed from the mold, and cut out by a cutter or the like to obtain 10 samples each having a size of 100 mm x 100 mm and a thickness of 10 mm. Then, the hardness is measured using a durometer type A (product name "GS-719N (TYPE A)", manufactured by Techrock Corporation) under an environment of a temperature of 25°C and a relative humidity of 30% to 70%. The arithmetic average value of the hardness of 8 samples excluding the maximum and minimum values ​​among the 10 samples is taken as the hardness of the above-mentioned constituent material.

[0124] When the sheet is wound, the coating material flows so as to reduce the step caused by the winding start end, but if the coating material is a curable polymer composition and shrinks during subsequent curing, the first filling section may not sufficiently reduce the step, and the sheet may be slightly deformed, especially when the fourth intervening section does not exist. For this reason, the linear shrinkage rate of the constituent material of the first filling section 14 is preferably 1.5% or less. If the linear shrinkage rate of the constituent material is 1.5% or less, a first filling section with excellent dimensional stability can be formed, so that the first filling section can sufficiently reduce the step. From the viewpoint of more sufficiently reducing the step, the upper limit of the linear shrinkage rate of the first filling section 14 is more preferably 1.3% or less, 1.0% or less, or 0.7% or less. The lower limit of the heat shrinkage rate may be 0% or more.

[0125] The linear shrinkage of the above-mentioned constituent material can be measured as follows. First, a mold having a thickness of 2 mm and a size of 130 mm or more square is prepared, and the coating material for forming the first filling portion 14 is poured into the mold and cured to obtain a sample (molded product). After complete curing, the dimensions of the sample are measured and compared with the inner dimensions of the mold to obtain the linear shrinkage based on JIS K6249:2003. The arithmetic average value of the linear shrinkage of 8 samples out of 10 samples, excluding the maximum and minimum values, is taken as the linear shrinkage of the above-mentioned constituent material.

[0126] The first filling portion 14 can be formed by flowing or deforming the filling material. When the filling material exhibits fluidity, it does not necessarily have to exhibit fluidity at all times as long as it exhibits fluidity before or during the rolling of the sheet. Examples of the filling material include a coating material and a filling tape.

[0127] The coating material is a coatable material, and has fluidity, for example, when applied or wound. Examples of coating materials having fluidity include not only liquids, but also materials that change from liquid to solid, solids that have fluidity when heated, or curable materials. When the coating material is a curable material, the first filling portion 14 is formed from a cured product of the curable material.

[0128] Examples of the coating material include a curable polymer composition, a thermoplastic resin, an oil, a starch, an adhesive, an adhesion agent, and a sol.

[0129] The curable polymer composition may be a curable resin composition or a curable rubber composition. When a thermoplastic resin is used as the coating material, it is necessary to heat the resin to have fluidity during coating and winding.

[0130] The filling tape is a tape that becomes the first filling portion 14 by filling the first gap 13, and has the property of spreading by capillary action due to the pressure when the sheet 12 is wound, or is a gel tape. The filling tape is used by being attached to or in close contact with the outer peripheral surface 11A of the winding core 11.

[0131] As described above, the first filling portion is required to have reworkability. If the filling material (e.g., coating material, etc.) is a sealant material, the sealant material will adhere firmly to the winding core, resulting in poor reworkability. In contrast, the molding material is intended to be removed from the mold, and therefore has excellent reworkability. For this reason, from the viewpoint of reworkability, the molding material is preferred as the filling material (e.g., coating material, etc.).

[0132] The shear viscosity of the filling material (e.g., coating material, etc.) at 25°C and a shear rate of 1 / s is preferably 500 Pa·s or less. For example, it is possible to use a spatula or the like to spread the filling material (e.g., coating material, etc.) applied to the core and adjust the shape of the filling material before winding the sheet, but spreading the filling material by such a process requires a lot of effort. In contrast, if the shear viscosity of the filling material is 500 Pa·s or less, the filling material can be spread into a desired shape by the pressure when winding the sheet, so that a special process for spreading the filling material can be omitted. The shear viscosity is more preferably 200 Pa·s or less. From the viewpoint of easily spreading the filling material, the shear viscosity is preferably 300 Pa·s or less, 100 Pa·s or less, or 50 Pa·s or less.

[0133] On the other hand, from the viewpoint of shortening the deformation relaxation length, the shear viscosity is preferably 10 Pa·s to 75 Pa·s, and more preferably 20 Pa·s to 50 Pa·s. If the shear viscosity is 10 Pa·s or more, the fluidity is not too high, so that deformation of sheet 12 can be relaxed, and if it is 75 Pa·s or less, deformation due to the tip of the first filling section can be suppressed.

[0134] Furthermore, from the viewpoint of further suppressing the filling material from squeezing out, it is preferable that the shear viscosity is 15 Pa s or more, and even more preferably 20 Pa s or more, since this can suppress the filling material from squeezing out from between the winding core 11 and the sheet 12 during application. Furthermore, it is preferable that the shear viscosity is 60 Pa s or more. If the shear viscosity is 60 Pa s or more, the fluidity of the filling material is low, and the filling material can be suppressed from squeezing out from between the winding core and the sheet during application and / or due to the pressure during winding.

[0135] The shear viscosity of the filling material can be measured using a dynamic viscoelasticity measuring device (for example, manufactured by Anton Paar Japan Co., Ltd.). Specifically, using a parallel plate with a diameter of 25 mm, the shear viscosity of the filling material is measured 10 times at a shear rate of 1 [1 / s] in an environment of a temperature of 25°C and a relative humidity of 30% to 70%, and the shear viscosity is calculated by calculating the arithmetic mean value of 8 shear viscosities excluding the maximum and minimum values ​​out of the 10 measured shear viscosities.

[0136] The filling material (for example, coating material) preferably does not contain a volatile component such as a solvent. When the filling material does not contain a volatile component, deformation such as cracking in the first filling portion 14 is small, and sheet marks are less likely to occur.

[0137] (Coating material) The coating material is preferably a material that can be applied when the first filling portion is formed, but has low fluidity in the state of the roll body 10. In this specification, "has low fluidity in the state of the roll body" means that the coating material does not overflow from the roll body during transportation or manufacturing of the roll body. When forming the first filling portion 14 in the first gap 13, the coating material needs to be applicable, but if the coating material has high fluidity in the state of the roll body 10, the first filling portion may overflow and become dirty during transportation or manufacturing. In contrast, if the coating material is a material that can be applied when the first filling portion 14 is formed and has low fluidity in the state of the roll body 10, the first filling portion 14 can be formed in the first gap 13, and overflow and contamination of the first filling portion 14 can be suppressed. An example of a material that can be applied when the first filling portion is formed, but has low fluidity in the state of the roll body 10 is a curable polymer composition.

[0138] When the coating material is a curable polymer composition, examples of the coating material that can be used include ionizing radiation curable polymer compositions (ionizing radiation curable resin compositions and ionizing radiation curable rubber compositions), thermosetting polymer compositions (thermosetting resin compositions and thermosetting rubber compositions), and room temperature curable polymer compositions (polymer compositions that cure at room temperature, around 20°C to 30°C) (room temperature curable resin compositions and room temperature curable rubber compositions).

[0139] Room temperature curable polymer compositions include, for example, two-component curable polymer compositions consisting of a base agent and a curing agent, and one-component curable polymer compositions that cure with moisture in the air. The part at the center of the sheet in the first filling part is in a nearly sealed state with the sheet rolled up, so this part is unlikely to come into contact with air and may not cure sufficiently. In contrast, two-component curable polymer compositions start reacting when the base agent and the curing agent are mixed, so they can be cured simply by time management. In addition, two-component curable polymer compositions are preferable in that they have excellent storage stability compared to one-component curable polymer compositions.

[0140] Examples of the ionizing radiation-curable polymer composition include compositions containing a compound having an ethylenically unsaturated group such as a (meth)acryloyl group, a vinyl group, an allyl group, etc. Ionizing radiation to be irradiated when curing the ionizing radiation-curable polymer composition include visible light, ultraviolet light, X-rays, electron beams, α-rays, β-rays, and γ-rays.

[0141] The ionizing radiation curable polymer composition may be, for example, an acrylic gel composition that forms an acrylic gel by irradiating with ionizing radiation. The acrylic gel composition may, for example, include ethyl (meth)acrylate, n-propyl (meth)acrylate, i-propyl (meth)acrylate, n-butyl (meth)acrylate, i-butyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, n-hexyl (meth)acrylate, n-amyl (meth)acrylate, i-amyl (meth)acrylate, octyl (meth)acrylate, i-octyl (meth)acrylate, i-myristyl (meth)acrylate, lauryl (meth)acrylate, nonyl (meth)acrylate, i-nonyl (meth)acrylate, i-decyl (meth)acrylate, tridecyl (meth)acrylate, stearyl (meth)acrylate, i-stearyl (meth)acrylate, etc. In this specification, the term "(meth)acrylate" is intended to include both "acrylate" and "methacrylate."

[0142] Examples of the thermosetting polymer composition and the room temperature curable polymer composition include a urethane resin composition, an epoxy resin composition, and a silicone composition. Among these, a silicone composition can be preferably used. Examples of the silicone composition include a silicone gel composition and a silicone rubber composition, both of which are suitable for reducing the above-mentioned step and deformation.

[0143] In this specification, the term "silicone gel cured product (silicone gel)" formed by curing a silicone gel composition refers to a cured product with a very low crosslink density, mainly composed of organopolysiloxane, and having a penetration according to JIS K2220:2013 (1 / 4 cone) of 10 to 150. This corresponds to a product with such low hardness (i.e., softness) that the measured value (rubber hardness value) is 0 in the rubber hardness measurement according to JIS K6249:2003 and does not show a valid rubber hardness value, and in this respect, it is different from so-called silicone rubber compositions and silicone rubber cured products (rubber-like elastomers).

[0144] Silicone rubber compositions include one-component curing silicone rubber compositions and two-component curing silicone rubber compositions. One-component curing silicone rubber compositions include condensation reaction curing rubber compositions that cure at room temperature and addition reactive rubber compositions that cure by heating. Two-component curing silicone rubber compositions include condensation reaction curing rubber compositions and addition reactive rubber compositions that cure at room temperature and addition reactive rubber compositions that cure by heating. It is also possible to modify the silicone rubber composition with other resins to make it an ionizing radiation curing rubber composition. In the present invention, any of the curing methods is possible, but among these, two-component curing silicone rubber compositions are preferred because they can be cured uniformly and have excellent storage stability.

[0145] An example of the silicone rubber composition is an RTV (Room Temperature Vulcanizing) silicone rubber composition. The RTV silicone rubber composition has a smaller shrinkage rate and better dimensional stability than an ionizing radiation curable polymer composition, and has excellent fluidity before curing, so that it easily penetrates into the gap between the winding core 11 and the sheet 12 or between the sheets 12, and has low fluidity after curing. Furthermore, since this RTV silicone rubber composition has deep curing properties, the curing reaction tends to proceed uniformly regardless of the thickness at the time of application. In addition, since this composition has excellent releasability, it is easy to peel off the cured product and make it into a state where it can be used again as a roll body.

[0146] The RTV silicone rubber composition includes a condensation reaction curing RTV silicone rubber composition and an addition reaction curing RTV silicone rubber composition depending on the curing reaction mechanism. Either can be preferably used in the present invention. A condensation reaction curing RTV silicone rubber composition is preferable because there is no curing inhibition, and an addition reaction curing RTV silicone rubber composition is preferable because the cure shrinkage rate is even smaller. In the present invention, the thickness of the coating material required to reduce the above-mentioned step tends to increase as the cure shrinkage of the material increases, so that an addition reaction curing RTV silicone rubber composition is preferably used, particularly for thin sheets (for example, the thickness of the sheet 12 is 3 μm to 45 μm).

[0147] The RTV silicone rubber composition is preferably a liquid silicone rubber (LSR) since it does not require special processing equipment.

[0148] The above-mentioned various compositions may contain functional components to exhibit desired functions. For example, since silicone rubber compositions are generally electrical insulators, they may become charged when in contact with the winding core 11, the sheet 12, or other substances. In this case, a conductive filler may be added to the silicone rubber composition. This can prevent the inclusion of foreign matter such as dust, thereby suppressing the above-mentioned step from being caused.

[0149] Examples of conductive fillers that can be mixed into the silicone rubber composition include carbon black (acetylene black and ketjen black), silver powder, gold-plated silica or graphite, conductive zinc oxide, etc. In recent years, ionically conductive silicone rubber has also been developed, and this ionically conductive silicone rubber can also be used.

[0150] The silicone gel composition may contain optional components within the scope of the present invention, such as reaction inhibitors, inorganic fillers, organopolysiloxanes that do not contain silicon-bonded hydrogen atoms or silicon-bonded alkenyl groups, heat resistance imparting agents, flame retardant agents, thixotropy imparting agents, pigments, dyes, etc.

[0151] The reaction inhibitor is a component for suppressing the reaction of the composition, and specific examples thereof include acetylene-based, amine-based, carboxylate-based, and phosphite-based reaction inhibitors.

[0152] Examples of inorganic fillers include inorganic fillers such as fumed silica, crystalline silica, precipitated silica, hollow filler, silsesquioxane, fumed titanium dioxide, magnesium oxide, zinc oxide, iron oxide, aluminum hydroxide, magnesium carbonate, calcium carbonate, zinc carbonate, layered mica, carbon black, diatomaceous earth, and glass fiber; and fillers obtained by subjecting these fillers to surface hydrophobic treatment with organosilicon compounds such as organoalkoxysilane compounds, organochlorosilane compounds, organosilazane compounds, and low molecular weight siloxane compounds. Silicone rubber powder, silicone resin powder, and the like may also be blended.

[0153] When the application material is an adhesive, the adhesive can be a denture adhesive. Denture adhesives can be broadly divided into denture adhesives and home reliners, and among denture adhesives, denture adhesives can be used as the adhesive. When adhesives are classified into, for example, powder type, cream type, or tape type like denture adhesives, the adhesive used as the application material is a powder type or cream type adhesive.

[0154] The adhesive may be one that exhibits adhesiveness by itself or one that exhibits adhesiveness due to moisture. A powder-type adhesive, for example, absorbs moisture when it comes into contact with moisture and exhibits adhesiveness. A cream-type adhesive, for example, is one in which an adhesive powder component is made into a cream with an ointment base and exhibits adhesiveness.

[0155] The adhesive preferably contains a water-soluble polymer. The water-soluble polymer is not particularly limited, and examples thereof include alginic acid, alginates (e.g., sodium alginate, potassium alginate, ammonium alginate, alginic acid esters, etc.), natural polymer compounds (e.g., gum arabic, gum tragacanth, locust bean gum, xanthan gum, guar gum, agar, gelatin, karaya gum, carrageenan, etc.), cellulose polymers (e.g., methylcellulose, sodium carboxymethylcellulose, hydroxyethylcellulose, hydroxypropylmethylcellulose, hydroxypropylcellulose, etc.), polyethylene glycol, polyvinylpyrrolidone, polyvinyl alcohol, methyl vinyl ether, carboxyvinyl polymer, copolymer of acrylamide and acrylic acid, sodium polyacrylate, polyethylene oxide, etc. These water-soluble polymers may be used alone or in any combination of two or more.

[0156] Among the above cellulose-based polymers, sodium carboxymethylcellulose is preferred. Sodium carboxymethylcellulose is a sodium salt of polyvalent carboxymethyl ether of cellulose, also known as sodium carmellose. Sodium carboxymethylcellulose is a powder, and when moistened, it becomes hydrated and exhibits adhesion or elasticity, thereby imparting further adhesiveness to the adhesive.

[0157] As long as the adhesive as a coating material can be coated, it can further contain an oil-based base, an aqueous base, a powder base, a gum base, an excipient, an emulsifier, a humectant, a pH adjuster, a viscosity adjuster, a plasticizer, a colorant, etc. Examples of these bases and additives include those that have been widely used in denture adhesives.

[0158] For example, oily bases are used as bases when adhesives are prepared in a paste-like form such as cream type, etc. Examples of oily bases include mineral oil components (e.g., liquid paraffin, petrolatum, gelling hydrocarbons, etc.) that are commonly used in non-aqueous adhesives (e.g., cream type).

[0159] Examples of cream-type adhesives that can be used include New Polygrip (registered trademark) S, New Polygrip (registered trademark) V, New Polygrip (registered trademark) Additive-free, Polident (registered trademark) NEO denture adhesive (all manufactured by GlaxoSmithKline Consumer Healthcare Japan), ToughGrip (registered trademark) Cream Additive-free (manufactured by Kobayashi Pharmaceutical Co., Ltd.), and Correct (registered trademark) Cream (manufactured by Shionogi & Co., Ltd.).

[0160] When the application material is an adhesive, the adhesive may be a home reliner (cushion type) of a denture adhesive. The adhesive enhances the adhesive force by improving the marginal closure effect. Such an adhesive may contain, for example, a water-insoluble polymer. The water-insoluble polymer is not particularly limited, but may be, for example, a polyvinyl resin such as a vinyl acetate resin.

[0161] Examples of adhesives that can be used include Polident (registered trademark) Cushion (manufactured by GlaxoSmithKline Consumer Healthcare Japan), ToughGrip (registered trademark) Cushion Clear, ToughGrip (registered trademark) Cushion Pink, Soft ToughGrip (registered trademark) (all manufactured by Kobayashi Pharmaceutical Co., Ltd.), Cushion Correct (registered trademark) EZ (manufactured by Shionogi & Co., Ltd.), New Liondent White, and New Liondent Pink (all manufactured by Lion Corporation).

[0162] When the coating material is a sol, examples of the sol include silica sol, alumina sol, and metal oxide sol such as zirconia sol, titanium oxide sol, cerium oxide sol, tin oxide sol, and niobium oxide sol.

[0163] In order to prevent the coating material from flowing too much while allowing the coating material to flow to the vicinity of the position (separation position) P1 where the first turn of sheet 12 separates from the outer peripheral surface 11A of core 11, it is desirable to appropriately adjust the viscosity of the coating material when applied.

[0164] The coating material is applied in a line shape, and the amount of coating material per unit width is preferably an amount that can obtain the thicknesses T1 to T3 in the above ranges in the first filling portion 14. Specifically, for example, the lower limit of the amount of coating material per unit width is 0.2 cm 3 If the amount of coating material is too small, for example, air may be trapped when coating with a syringe, making it difficult to discharge the coating material from the syringe, or the coating may be cut off when coating the sheet by running the sheet. 3 This can be prevented by setting the coating thickness to 3.5 cm / m or more. 3 If the amount of coating material applied is too large, the coating material may drip under its own weight or new steps may be created. 3 This can be prevented by applying the coating amount of 0.3 cm or less. 3 More preferably, the coating amount is 2.0 cm 3 / m or less, or 1.5cm 3 It is more preferable that the thickness is equal to or less than 1 / m.

[0165] (Filling Tape) The constituent material of the filling tape may be the adhesive, adhesive, or gel described in the above-mentioned application material section. Examples of the gel include silicone-based gels formed from the silicone gel composition, acrylic-based gels formed from the acrylic gel composition, polyolefin-based gels, polyurethane-based gels, butadiene-based gels, isoprene-based gels, butyl-based gels, styrene-butadiene-based gels, ethylene-vinyl acetate copolymer-based gels, ethylene-propylene-diene terpolymer-based gels, and fluorine-based gels. Examples of the filling tape that may be used include Touch Correct (registered trademark) II (manufactured by Shionogi & Co., Ltd.) and αGEL (registered trademark) (manufactured by Taica Corporation).

[0166] The length of the filling tape is preferably equal to or greater than the width of the effective area in the width direction DR1 of the winding core 11. By setting the length of the filling tape to such a length, the first filling section can be formed over the entire width of the effective area, and thus the step caused by the winding start end 12A of the sheet 12 can be mitigated over the entire width of the effective area. From the viewpoint of suppressing protrusion of the filling tape when the sheet 12 is wound, the filling tape is preferably arranged so as to be 1 mm or more, 10 mm or more, or 30 mm or more away from both ends of the short side of the sheet 12 in the width direction DR1 of the winding core 11. The length of the filling tape means the length of the filling tape in the width direction DR1.

[0167] The width of the filling tape is preferably 5 mm or more. By setting the width of the filling tape to such a width, the step caused by the winding start end 12A of the sheet 12 can be more effectively alleviated. The lower limit of the width of the filling tape is more preferably 6 mm or more, 7 mm or more, or 8 mm or more. From the viewpoint of suppressing overlapping of the filling tape, the upper limit of the width of the filling tape is preferably less than the outer circumferential length of the winding core 11. Note that the width of the filling tape means the length of the filling tape in the longitudinal direction DR2 of the sheet 12.

[0168] The thickness of the filling tape is preferably equal to or greater than the height of the upper surface 12A2 of the winding start end 12A. By making the filling tape thicker in this manner, the filling tape can be spread over a wide area when the sheet 12 is wound, and the step caused by the winding start end 12A of the sheet 12 can be more effectively alleviated. Specifically, the thickness of the filling tape is preferably 52 μm to 220 μm when the thickness of the sheet 12 is 50 μm to 200 μm, and is preferably 50.5 μm to 100 μm when the thickness of the sheet 12 is 3 μm to less than 50 μm.

[0169] <Second filling section> The second filling portion 16 fills the second gap 15. That is, the second filling portion 16 contacts the outer peripheral surface 11A of the winding core 11, the back surface 12C of the sheet 12, and the first end surface 17A of the fixing member 17.

[0170] The physical properties, such as tensile strength, of the constituent material of the second filling portion 16 are similar to the physical properties, such as tensile strength, of the constituent material of the first filling portion 14, and therefore a description thereof will be omitted here.

[0171] The second filling section 16 can be formed by applying or deforming a filling material. Examples of the filling material include a coating material or a filling tape. The filling material, coating material, and filling tape are similar to the filling material, coating material, and filling tape described in the first filling section 14, so the description will be omitted. The constituent material of the second filling section may be the same as the constituent material of the first filling section 14, or may be different.

[0172] It is preferable that the thickness of the second filling portion 16 gradually decreases from the first end face 17A toward the vicinity of the arrival position P2 where the first turn of the sheet 12 reaches the outer peripheral surface 11A of the winding core 11. By changing the thickness of the second filling portion 16 in this way, a sudden change in the height direction of the sheet 12 can be suppressed, and therefore the step caused by the fixing member 17 can be mitigated.

[0173] Since both end portions 12G extending in the longitudinal direction DR2 of the sheet 12 are not used as a product, the length of the second filling portion 16 in the width direction DR1 of the winding core 11 may be smaller than the width W2 of the sheet 12 as long as it is equal to or greater than the effective area for manufacturing the product in the roll body 10.

[0174] <4th intervening part> Since the first filling portion tends to be softer than the sheet, if the height of the first filling portion at the position where it contacts the tip surface of the starting end of the winding is the same as the top surface of the starting end of the winding, a step may occur at the corner of the tip surface of the starting end of the winding and the top surface when the sheet is wound. In contrast, when the fourth intermediate portion 18 is formed, the fourth intermediate portion 18 can absorb the difference in hardness between the first filling portion 14 and the sheet 12, so the step at the corner between the tip surface 12A1 of the starting end of the winding and the top surface 12A2 can be reduced. In addition, the presence of the fourth intermediate portion 18 can suppress the concentration of stress at the step caused by the starting end of the winding 12A, and the deformation of the sheet 12 from the third turn onwards can be made gentle, so this step can be alleviated.

[0175] The fourth intermediate portion 18 preferably contains a coloring material or a luminescent material, similar to the first filling portion 14. By containing a coloring material or a luminescent material in the fourth intermediate portion 18, it is easy to visually recognize the fourth intermediate portion 18 when it protrudes from the roll body 10. In addition, it is easy to confirm the presence of the fourth intermediate portion 18. The coloring material and the luminescent material contained in the fourth intermediate portion 18 are the same as the coloring material and the luminescent material explained in the section of the first filling portion 14, and therefore the explanation will be omitted.

[0176] When the sheet 12 is transparent and the fourth intermediate portion 18 is colored, it is easy to visually check whether the fourth intermediate portion 18 is present. Specifically, the sheet 12 is first unwound from the roll 10 until the second turn of the sheet 12 is on the surface. Then, in the roll 10 where the second turn of the sheet 12 is on the surface, the vicinity of the winding start end 12A is visually observed to see whether there is a colored portion on the winding start end 12A. When there is a colored portion on the winding start end 12A, it can be determined that the fourth intermediate portion 18 is present, and when there is no colored portion, it can be determined that the fourth intermediate portion 18 is not present.

[0177] Even when the sheet 12 is transparent and the fourth intermediate portion 18 contains a luminescent material, the presence or absence of the fourth intermediate portion 18 can be easily confirmed by visual inspection in the same manner as described above. When the luminescent material is a material that emits light when irradiated with light such as ultraviolet light or visible light, the presence or absence of the fourth intermediate portion 18 is confirmed by irradiating it with light.

[0178] When the thickness of the sheet 12 is 50 μm or more and 200 μm or less, the thickness T3 (see FIG. 4) of the fourth intermediate portion 18 is preferably 2 μm or more and 110 μm or less. If the thickness T3 of the fourth intermediate portion 18 is within this range, the deformation relaxation length can be shortened while avoiding adverse effects on the winding of the sheet 12. Note that, even when the thickness T3 of the fourth intermediate portion 18 exceeds 110 μm, the deformation relaxation length can be shortened, but adverse effects may be caused on the winding of the sheet 12.

[0179] When the thickness of sheet 12 is 3 μm or more and less than 50 μm, or even 40 μm or less, sheet 12 is more likely to deform due to the step caused by winding start end 12A than when sheet 12 is thicker. For this reason, thickness T3 of fourth intermediate portion 18 is preferably 0.5 μm or more and 50 μm or less. If thickness T3 of fourth intermediate portion 18 is within this range, the above-mentioned deformation relaxation length can be shortened while avoiding adverse effects on winding of sheet 12.

[0180] The thickness T3 of the fourth intermediate portion 18 is the maximum thickness of the fourth intermediate portion 18. The thickness T3 of the fourth intermediate portion 18 is measured as follows. First, a portion including the winding start end portion 12A, the fourth intermediate portion 18, and the second turn of the sheet 12 is sampled and fixed so as not to be crushed. Then, the cross section of this fixed portion is polished, and the thickness T3 of the fourth intermediate portion 18 is measured with a stereomicroscope (for example, product name "Digital Microscope VHX-7000", manufactured by Keyence Corporation).

[0181] The fourth intermediate portion 18 can be formed by applying or deforming a filling material. Examples of the filling material include a coating material or a filling tape. This filling material, coating material, and filling tape are similar to the filling material, coating material, and filling tape described in the first filling portion 14, so the description will be omitted. The constituent material of the fourth intermediate portion 18 may be the same as the constituent material of the first filling portion 14, or may be different.

[0182] <<Other roll bodies>> In the roll body 10, the tip surface 12A1 of the winding start end 12A of the sheet 12 and the second end surface 17B of the fixed member 17 are substantially aligned in a cross section along the longitudinal direction DR2 of the sheet 12 and the radial direction DR3 of the winding core 11, but as in the roll body 20 shown in Fig. 12, the tip surface 12A1 of the winding start end 12A of the sheet 12 may protrude beyond the second end surface 17B of the fixed member 17. In this case, the second gap 15 may be filled with a second filling portion 16, and a third filling portion 22 may be filled in a third gap 21 located between the outer circumferential surface 11A of the winding core 11 and the back surface 12C of the first turn of the sheet 12 on the side of the second end surface 17B.

[0183] <Third Gap> 12 is a gap surrounded by the outer peripheral surface 11A of the winding core 11, the back surface 12C of the first turn of the sheet 12, and the second end surface 17B of the fixing member 17.

[0184] <Third filling section> The third filling section 22 is similar to the second filling section 16 except that it fills the third gap 21, and therefore a description thereof will be omitted here.

[0185] In the roll body 10, the second gap 15 is filled with the second filling portion 16, but from the viewpoint of reducing the step caused by the winding start end portion 12A of the sheet 12, it is sufficient that the first gap 13 is filled with the first filling portion 14, so the second gap 15 does not have to be filled with the second filling portion 16 as in the roll body 30 shown in Fig. 13. In the roll body 30, the second gap 15 is hollow.

[0186] In the roll body 10, the first gap 13 is filled with the first filling portion 14, but from the viewpoint of reducing the step caused by the fixing member 17, it is sufficient that the second gap 15 is filled with the second filling portion 16, so the first gap 13 does not have to be filled with the first filling portion 14 as in the roll body 40 shown in Fig. 14. In the roll body 40, the first gap 13 is hollow.

[0187] The roll body 10 includes one fixed member 17, but may include two or more fixed members as shown in FIG. 15. In the roll body 50 shown in FIG. 15, in addition to the fixed member 17, a fixed member 51 is provided on the first end face 17A side of the fixed member 17. In the roll body 50 shown in FIG. 15, the tip face 12A1 of the winding start end 12A of the sheet 12 protrudes from the second end face 17B of the fixed member 17, so that in order to suppress the step caused by the fixed member 17, it is preferable that the second gap 15 is filled with the second filling portion 16 and the third gap 21 is filled with the third filling portion 22. Similarly, in the roll body 50 shown in FIG. 15, in order to suppress the step caused by the fixed member 51, the second gap 52 on the first end face 51A side of the fixed member 51 described later is filled with the second filling portion 53, and the third gap 54 on the second end face 51B side of the fixed member 51 described later is filled with the third filling portion 55.

[0188] <Fixing material> The fixing member 51 has a first end face 51A and a second end face 51B opposite thereto. The first end face 51A and the second end face 51B both extend in the width direction DR1 of the winding core 11. The fixing member 51 is similar to the fixing member 17, and therefore a description thereof will be omitted here.

[0189] <Second gap> 15 is a gap surrounded by the outer circumferential surface 11A of the core 11, the back surface 12C of the first turn of the sheet 12, and the first end surface 51A of the fixing member 51.

[0190] <Third Gap> 15 is a gap surrounded by the outer circumferential surface 11A of the core 11, the back surface 12C of the first turn of the sheet 12, and the second end surface 51B of the fixing member 51.

[0191] <Second filling section and third filling section> The second filling section 53 is similar to the second filling section 16 except that it fills the second gap 52, and therefore a description thereof will be omitted here. The third filling section 55 is similar to the second filling section 16 except that it fills the third gap 54, and therefore a description thereof will be omitted here.

[0192] Although the roll body 10 includes a fixing member 17, it may not include the fixing member 17 like a roll body 60 shown in FIG.

[0193] 12, 13, 15, and 16 do not show the length L1, length L2, thickness T2, thickness T3, area S1, and area S2, but in the roll bodies 20, 30, 50, and 60, the length L1, length L2, thickness T2, thickness T3, (length L1+L2) / thickness T2, and (area S1+S2) / thickness T2 are the same as in the case of the roll body 10.

[0194] Although the roll bodies 20, 30, 50, and 60 all have the fourth intermediate portion 18, they do not necessarily have to have the fourth intermediate portion. In this case, the length L1 / thickness T2 and the area S1 / thickness T2 are the same as those of the roll body 10 shown in FIG.

[0195] In Figure 13, the entire surface of the fixing member 17 is in close contact with the starting end 12A, but similar to the roll body 10 shown in Figure 8, the first filling section 14 may be inserted between the starting end 12A and the fixing member 17.

[0196] <<Roll body manufacturing method>> The roll body 10 can be manufactured, for example, by the following method: First, fixing members 17 are arranged on the outer circumferential surface 11A of the winding core 11 along the width direction DR1 of the winding core 11 as shown in Fig. 17(A).

[0197] After the fixing member 17 is placed, coating materials 201 and 202 are applied to the outer peripheral surface 11A of the winding core 11 along the width direction DR1 of the winding core 11 as shown in Fig. 17(B) using an application device such as a dispenser or a syringe. The coating material 201 is applied so as to contact the second end surface 17B of the fixing member 17, and the coating material 202 is applied so as to contact the first end surface 17A of the fixing member 17. In this case, for example, the coating materials 201 and 202 may be applied simultaneously using two application devices.

[0198] In the above, the coating material 201 is applied so as to contact the second end surface 17B, and the coating material 202 is applied so as to contact the first end surface 17A. However, if the coating material has high wettability and low viscosity, when the coating material is applied so as to contact the second end surface or the first end surface, the coating material may penetrate between the winding start end and the fixing member, and may also spread to the area between the winding start end and the back surface of the sheet. Although it is possible to control the coating material to a desirable state, excessive impregnation or spreading may result in hardening at an uncontrollable position, which may result in the formation of a new step. In addition, if the viscosity of the filling material is high (for example, a tape-like material) or the wettability of the coating material is low, when the filling material or coating material is placed, it is highly likely that it will harden in a state where it spreads only in the vicinity of the placement, so if it is not sufficiently wetted and spread by the winding in the later process, the material will harden in a thick state near the winding start end, and there is a risk that the step will become larger. For this reason, it is preferable that the coating material 201 is applied so as to be close to the second end surface 17B of the fixing member 17, and it is preferable that the coating material 202 is applied so as to be close to the first end surface 17A of the fixing member 17. In this specification, "close" means a position that is clearly separated from the winding start end or the fixing member. For example, even if the coating material is a low-viscosity material, the separation distance from the winding start end or the fixing member is preferably 0.3 mm or more. This separation distance is preferably 0.5 mm or more, and preferably 1 mm or more from the viewpoint of maximum stability. If this separation distance is too large, it is difficult to obtain the effect of reducing the step, so it is preferable to adjust the distance within a range in which the first filling portion 14 in FIG. 3 etc. can be completed. For example, the upper limit of this separation distance is preferably 10 mm or less, 7 mm or less, or even 5 mm or less. If this separation distance exceeds 10 mm, in addition to the possibility that the first gap will not be filled, there is a risk that the coating material will flow off before the sheet is wound, depending on the diameter of the winding core. If the viscosity of the coating material is low, it is recommended to apply a larger amount. The separation distance is measured at 10 points, and the arithmetic mean value of the separation distances at 8 points, excluding the maximum and minimum values, is calculated.

[0199] When the viscosity of the coating material is high, the coating material is difficult to spread, so it is preferable that the separation distance is short. When the viscosity of the coating material is low, if the separation distance is too small, there is a risk that a large amount of coating material will be present on the fixed member, and if the separation distance is too large, there is a risk that the coating material will spread in another direction and not be able to sufficiently fill the desired gap, so it is preferable that the separation distance is neither too small nor too large.

[0200] In the above, after the fixing member 17 is arranged on the outer peripheral surface 11A of the winding core 11, the coating materials 201, 202 are simultaneously applied to both sides of the fixing member 17, but the coating materials 201, 202 may be applied and the fixing member 17 may be arranged in the order of the following manufacturing methods (1) to (3). Among these, the following manufacturing method (2) is preferred. The same applies to the coating materials 204 and 205 described below.

[0201] In manufacturing method (1), after placing a fixed member 17 on the outer peripheral surface 11A of the winding core 11, a coating material 201 is applied to the second end surface 17B side of the fixed member 17 so as to maintain the above-mentioned separation distance, and then a coating material 202 is applied to the first end surface 17A side of the fixed member 17 so as to maintain the above-mentioned separation distance.

[0202] In manufacturing method (2), after coating the outer peripheral surface 11A of the winding core 11 with coating material 201, the fixed member 17 is positioned so that the distance from the coating material 201 is the above-mentioned distance, and then coating material 202 is applied to the side of the fixed member 17 opposite to coating material 201 so that the distance from the fixed member 17 is the above-mentioned distance. By applying the coating materials 201, 202 and arranging the fixed member 17 in this order, the coating materials can be arranged with a stable distance, and excess coating materials 201, 202, etc. can be prevented from being applied onto the fixed member 17, thereby preventing the occurrence of new steps on the fixed member 17.

[0203] The manufacturing method (3) is a method in which coating materials 201, 202 are applied to the outer peripheral surface 11A of the winding core 11 at a predetermined interval, and then a fixing member 17 is disposed between the coating materials 201, 202.

[0204] In addition, when the first filling section 14 is formed but the second filling section 16 is not formed, it is preferable to first apply the coating material 201 and then position the fixing member 17 so that the distance from the coating material 201 is the above-mentioned distance, and when the second filling section 16 is formed but the first filling section 14 is not formed, it is preferable to first apply the coating material 202 and then position the fixing member 17 so that the distance from the coating material 202 is the above-mentioned distance.

[0205] The coating materials 201, 202 are preferably applied to an area equal to or greater than the width of the effective area in the width direction DR1 of the core 11. By applying the coating materials 201, 202 in this manner, the coating materials 201-205 can be present over the entire width of the effective area of ​​the first filling section and the second filling section, and this makes it possible to reduce the step caused by the winding start end of the sheet 12 and the step caused by the fixing member 17 over the entire width of the effective area. From the viewpoint of suppressing the protrusion of the coating materials 201, 202 when the sheet 12 is wound, the coating materials 201, 202 are preferably applied inwardly from both ends in the short direction of the sheet 12 in the width direction DR1 of the core 11 by 1 mm or more, 10 mm or more, or 30 mm or more.

[0206] The coating material 201 is preferably applied so that the width of the coating material 201 is 5 mm or more, 10 mm or more, or 30 mm or more. By applying the coating material 201 in this manner, it is possible to more effectively reduce the step caused by the winding start end 12A of the sheet 12. The upper limit of the width of the coating material 201 is preferably less than the outer circumferential length of the winding core 11, from the viewpoint of suppressing overlapping of the coating material.

[0207] The coating material 202 is preferably applied so that the width of the coating material 202 is 0.5 mm or more, 1 mm or more, or 5 mm or more. By applying the coating material 202 in this manner, it is possible to more effectively reduce the step caused by the fixing member 17. The upper limit of the width of the coating material 202 is preferably less than the outer circumferential length of the winding core 11, from the viewpoint of suppressing overlapping of the coating material.

[0208] The coating material 201 is preferably applied so that the thickness of the coating material 201 is equal to or greater than the height of the upper surface 12A2 of the winding start end 12A. By applying the coating material 201 in this manner, a sufficient amount of the coating material 201 is applied, so that the step caused by the winding start end 12A of the sheet 12 can be more effectively alleviated. The specific thickness of the coating material 201 is preferably 52 μm to 2000 μm when the thickness of the sheet 12 is 50 μm to 200 μm, and is preferably 50.5 μm to 2000 μm when the thickness of the sheet 12 is 3 μm to 50 μm. The thickness of the coating material 201 is the thickness before the sheet 12 is wound.

[0209] The coating material 202 is preferably applied so that the thickness of the coating material 202 is equal to or greater than the height of the surface of the fixing member 17. By applying the coating material 202 in this manner, a sufficient amount of the coating material 202 is applied, so that the step caused by the fixing member 17 can be more effectively alleviated. Specifically, the lower limit of the thickness of the coating material 202 is preferably 3 μm or more and 12 μm or less when the thickness of the fixing member 17 is 3 μm or more and 10 μm or less. Note that the thickness of the coating material 202 is the thickness before the sheet 12 is wound.

[0210] 18(A), after coating materials 201, 202, starting end 12A of sheet 12 is positioned so that tip surface 12A1 of starting end 12A contacts coating material 201 and sheet 12 covers coating material 202. Specifically, starting end 12A of sheet 12 is affixed to fixing member 17, and starting end 12A is fixed to outer circumferential surface 11A of core 11 via fixing member 17.

[0211] After the winding start end 12A of the sheet 12 is fixed to the winding core 11, the sheet 12 is wound around the outer peripheral surface 11A of the winding core 11 as shown in FIG. 18(B). When the sheet 12 is wound, the coating materials 201 and 202 flow and spread, so that the first gap 13 is filled with the coating material 201 and the second gap 15 is filled with the coating material 202, forming the first filling portion 14 filled in the first gap 13 and the second filling portion 16 filled in the second gap 15. This results in a roll body 10. In order to reliably spread and fill the coating material 201 and the like in the first gap 13 and the like, when the sheet 12 exceeds 1000 m, it is preferable to wind the sheet 12 for 1000 m or more, and when the sheet 12 is less than 1000 m, it is preferable to wind the entire length of the sheet 12.

[0212] Furthermore, when the coating materials 201, 202 are curable polymer compositions, the curable polymer composition is cured after at least the second turn of the sheet 12. When the curable polymer composition is a one-component curable polymer composition (moisture-curable polymer composition), this composition reacts with the moisture in the air and cures when left at room temperature, so that it can be cured without using a special device such as a heating device or an ionizing radiation irradiation device. When the curable polymer composition is a two-component curable polymer composition, it can be cured by mixing the main agent and the curing agent.

[0213] The roll body 20 can be manufactured, for example, by the following method. First, the fixing member 17 is disposed on the outer circumferential surface 11A of the core 11 along the width direction DR1 of the core 11.

[0214] After the fixing member 17 is arranged, coating materials 203 to 205 are applied to the outer peripheral surface 11A of the winding core 11 along the width direction DR1 of the winding core 11 as shown in FIG. 19(A) using a coating device such as a dispenser or a syringe. The coating material 204 is applied so as to contact the first end face 17A of the fixing member 17, and the coating material 205 is applied so as to contact the second end face 17B of the fixing member 17. The coating material 203 is applied to a location away from the second end face 17B of the fixing member 17 and the coating material 205. Note that the coating material 203 may be applied so as to be close to the tip face 12A1 of the winding start end 12A of the sheet 12, the coating material 204 may be applied so as to be close to the first end face 17A of the fixing member 17, and the coating material 205 may be applied so as to be close to the second end face 17B of the fixing member 17. In addition, after placing the fixed member 17 on the outer peripheral surface 11A of the winding core 11, the coating materials 203-205 are applied. However, after applying the coating materials 203-205, the fixed member 17 may be placed so that the coating material 204 contacts or is close to the first end surface 17A of the fixed member 17, and so that the coating material 205 contacts or is close to the second end surface 17B of the fixed member 17.

[0215] 19(B), starting end 12A of sheet 12 is positioned so that tip surface 12A1 of starting end 12A contacts coating material 203 and sheet 12 covers coating materials 204, 205. Specifically, starting end 12A of sheet 12 is affixed to fixing member 17, and starting end 12A is fixed to outer circumferential surface 11A of core 11 via fixing member 17.

[0216] After the winding start end 12A of the sheet 12 is fixed to the winding core 11, the sheet 12 is wound around the outer peripheral surface 11A of the winding core 11 as shown in Fig. 19(C). When the sheet 12 is wound, the coating materials 203 to 205 flow and spread, so that the first gap 13 is filled with the coating material 203, the second gap 15 is filled with the coating material 204, and the third gap 21 is filled with the coating material 205, forming the first filling portion 14 filled in the first gap 13, the second filling portion 16 filled in the second gap 15, and the third filling portion 22 filled in the third gap 21. In this way, a roll body 20 is obtained. In order to reliably spread and fill the coating material 203 etc. in the first gap 13 etc., if the sheet 12 is longer than 1000 m, it is preferable to roll up the sheet 12 by 1000 m or more, and if the sheet 12 is less than 1000 m, it is preferable to roll up the entire length of the sheet 12.

[0217] In all of the above manufacturing methods, the coating materials 201 to 205 are caused to flow by rolling the sheet 12, but the coating materials 201, etc. may be caused to flow in advance before rolling the sheet 12. However, if the coating materials 201, etc. are caused to flow before rolling the sheet 12, the number of steps increases, so it is preferable to cause the coating materials 201 to 205 to flow by rolling the sheet 12.

[0218] In the above manufacturing method, the coating materials 201-205 are applied using a coating device such as a dispenser or a syringe, but the coating materials 201-205 may be applied using a mold having a slit together with the coating device. By applying the coating materials 201-205 using a mold having a slit, it is possible to reduce partial variations in the thickness, width, etc. of the coating materials 201-205. The constituent material of the mold is not particularly limited, but examples thereof include resin and metal.

[0219] Specifically, first, a mold 210 having a slit 210A is prepared as shown in Fig. 20(A). This mold 210 is used to apply the coating material 201. The length, width, and depth of the slit 210A are similar to the length, width, and thickness of the coating material 201, respectively, and therefore a description thereof will be omitted here.

[0220] After preparing the die 210, the die is placed on the outer peripheral surface 11A of the winding core 11 along the width direction DR1 of the winding core 11 as shown in Fig. 20(B). The die 210 is placed so that the inner surface on the fixing member 17 side in the width direction of the slit overlaps with or is close to the second end surface 17B of the fixing member 17 when viewed from directly above the die 210.

[0221] After the mold 210 is placed on the outer peripheral surface 11A of the winding core 11, the coating material 201 is supplied into the slit 210A as shown in FIG. 20(B) using a coating device such as a dispenser or a syringe. The coating device may be a dispenser or a syringe, but may also be a spray or a die coater. Thereafter, if necessary, excess coating material 201 present on the surface of the mold 210 is scraped off with a doctor blade or the like. Then, by removing the mold 210, the coating material 201 can be placed on the outer peripheral surface 11A of the winding core 11. The subsequent steps are the same as those for the roll bodies 10 and 20 described above. The coating materials 202 to 205 can also be placed using the mold 210 having the slit 210A in the same procedure.

[0222] Instead of applying the coating materials 201-205, a filling tape may be placed on the outer peripheral surface 11A of the winding core 11. Specifically, first, as shown in Fig. 21(A), the coating material 201 is applied in the form of a tape to the surface of the base material 221 using an application device such as a dispenser or syringe to form a laminate 220 including the base material 221 and a filling tape 222 made of the coating material 201. Note that although the filling tape 222 is formed from the coating material 201 here, it is not necessary to use the coating material 201 as long as the filling tape is made of a material that spreads due to the pressure applied when the sheet is wound.

[0223] The material of the substrate 221 is not particularly limited, and examples thereof include polyester resins such as polyethylene terephthalate, cellulose resins such as triacetyl cellulose, and acrylic resins. A known release film may be used as the substrate 221. When applying the coating material 201 to the surface of the substrate 221, it is preferable to draw an alignment line 221A on the substrate 221 in advance and apply the coating material 201 along the alignment line 221A. By drawing such an alignment line 221A on the substrate 221 in advance, it is possible to suppress misalignment of the coating material 201. When applying the coating material 201 to the surface of the substrate 221, it is preferable to unwind the substrate 221 at a constant speed using an unwinding device while keeping the coating device fixed. Uneven coating can be suppressed by unwinding the substrate 221 at a constant speed.

[0224] After forming the laminate 220, as shown in FIG. 21(B), the laminate 220 is attached or adhered to the outer peripheral surface 11A of the winding core 11 so that the filling tape 222 contacts the outer peripheral surface 11A of the winding core 11. The filling tape 222 is attached or adhered to the second end surface 17B of the fixing member 17 so that it contacts or is close to the second end surface 17B. Thereafter, the base material 221 is peeled off. This allows the filling tape 222 to be disposed on the outer peripheral surface 11A of the winding core 11. The subsequent steps are the same as those for the roll bodies 10 and 20 described above.

[0225] In the above, a laminate having one base material and a filling tape is formed, but a laminate having two base materials, a filling tape, and a thickness adjusting member may be formed. Specifically, as shown in Fig. 22(A), a coating material 201 is applied to the surface of a first base material 231 by a coating device such as a dispenser or a syringe.

[0226] Then, as shown in FIG. 22(B), the second substrate 233 is layered on the coating material 201 so as to sandwich the coating material 201 and the thickness adjusting member 232 having a desired thickness for adjusting the coating material 201 to a desired thickness, thereby forming a laminate 230. Examples of the thickness adjusting member 232 include spacers and particles. It is preferable that the peel strength of the second substrate 233 with respect to the coating material 201 is smaller than the peel strength of the first substrate 231 with respect to the coating material 201. By satisfying such a relationship, the second substrate 233 can be easily peeled off. The peel strength of the second substrate 233 is a value measured by the following measurement method using a tensile tester (product name "Single Column Type Material Tester STA-1150", manufactured by A&D Co., Ltd.). When measuring the peel strength, first, a double-sided tape (Teraoka Seisakusho Co., Ltd. No. 751B) is attached to a glass plate having a length of 30 cm and a width of 2.5 cm. On the other hand, the laminate 230 is cut into a size of 200 mm long x 25 mm wide, the first substrate 231 side is attached to a glass plate with double-sided tape, and the laminate 230 attached to the glass plate is held by a pair of jigs of a tensile tester. The laminate 230 attached to the glass plate is then held by a pair of jigs of a tensile tester. When the laminate 230 is held by the jigs, the second substrate 233 is slightly peeled off from the laminate 230 by hand in advance to create an opening, and the second substrate 233 is held by one of the jigs, and the glass plate and the laminate 230 are held by the other jig. In this state, the second substrate 233 is peeled off under the conditions of a peeling speed of 300 mm / min, a peeling distance of 50 mm, and a peeling angle of 180°, and the peel strength between the coating material 201 and the second substrate 233 at that time is measured. The peel strength is the arithmetic average value of values ​​measured three times. The peel strength of the first substrate 231 is measured in the same manner as the peel strength of the second substrate 233. As the first base material 231 and the second base material 233, the same material as the base material 221 can be used.

[0227] After forming the laminate 230, a predetermined pressure is applied to the laminate 230. As a result, the thickness of the coating material 201 becomes a desired thickness. Then, the laminate 230 is cut out into a tape shape. As a result, the laminate 230 having the filling tape 234 made of the coating material 201 is formed.

[0228] Then, as shown in FIG. 22(C), the second base material 233 is peeled off. In this state, the laminate 230 is attached or adhered to the outer peripheral surface 11A of the winding core 11 so that the filling tape 234 contacts the outer peripheral surface 11A of the winding core 11 as shown in FIG. 22(D). The filling tape 234 is attached or adhered to the second end surface 17B of the fixing member 17 so as to contact or be close to the second end surface 17B. Then, the first base material 231 is peeled off. This allows the filling tape 234 to be placed on the outer peripheral surface 11A of the winding core 11. The subsequent steps are the same as those for the roll bodies 10 and 20 described above. Instead of the coating materials 202 to 205, the filling tape can be placed on the outer peripheral surface 11A of the winding core 11 in the same procedure as the filling tape 234.

[0229] Also, a mold may be used to form and transfer the filling tape. By transferring the filling tape using a mold, the filling tape can be easily installed at the same time as the fixing member 17. Specifically, first, a mold 241 is prepared as shown in FIG. 23(A). The mold 241 has an opening 241A. It is preferable that the longitudinal side of the mold 241 is open so that the filling tape described later can be easily removed from the mold 241. The mold 241 is, for example, U-shaped. The mold 241 is not particularly limited, but can be formed from, for example, resin, metal, etc. The length, width, and depth of the opening 241A of the mold 241 are the same as the length, width, and thickness of the filling tape, so that the description will be omitted here.

[0230] After preparing the mold 241, as shown in Fig. 23(B), the coating material 201 is poured into the mold 241 to form the filling tape 242. Then, as shown in Fig. 23(C), the mold 241 is pressed against the outer peripheral surface 11A of the winding core 11 so that the filling tape 242 comes into contact with the outer peripheral surface 11A of the winding core 11. When pressing the mold 241, if the coating material 201 is a material that exhibits adhesiveness when wet, it is preferable to wet the surface of the filling tape 242 with water to make it viscous. By making the surface of the filling tape 242 viscous, it is possible to attach or adhere the filling tape 242 to the outer peripheral surface 11A of the winding core 11.

[0231] Thereafter, the mold 241 is removed from the filling tape 242. This allows the filling tape 242 to be arranged on the outer peripheral surface 11A of the winding core 11. The subsequent steps are the same as those described above for the roll bodies 10 and 20. Instead of the coating materials 202-205, the filling tape can be arranged on the outer peripheral surface 11A of the winding core 11 in the same procedure as for the filling tape 242.

[0232] The filling tape may be transferred to the outer peripheral surface 11A of the core 11 by offset printing. By forming and transferring the filling tape by offset printing, time management becomes easy, and the filling tape can be placed at a set time with good positional accuracy. Specifically, first, as shown in FIG. 24(A), the coating material 201 is applied to the outer peripheral surface of the intermediate transfer body 251 (for example, an intermediate transfer roll) by a coating device such as a dispenser or a syringe to form the filling tape 252. Then, as shown in FIG. 24(B), the filling tape 252 formed on the outer peripheral surface of the intermediate transfer body 251 is transferred to the outer peripheral surface 11A of the core 11 by offset printing. This allows the filling tape 252 to be placed on the outer peripheral surface 11A of the core 11. The subsequent steps are the same as the above-mentioned steps for the roll bodies 10 and 20. Instead of the coating materials 202 to 205, the filling tape can be placed on the outer peripheral surface 11A of the core 11 in the same procedure as the filling tape 252.

[0233] According to this embodiment, since the first gap 13 is filled with the first filling portion 14, the portion of the first turn of the sheet 12 on the first filling portion 14 can be gently lifted from the separation position P1 toward the tip end surface 12A1. This makes it possible to reduce the step caused by the winding start end portion 12A of the sheet 12.

[0234] According to this embodiment, since the second gap 15 is filled with the second filling portion 16, the portion of the first turn of the sheet 12 on the second filling portion 16 can be gently lowered from the first end surface 17A toward the arrival position P2. This makes it possible to effectively reduce the step caused by the fixing member 17.

[0235] In the roll body 20, since the third gap 21 is filled with the third filling portion 22, the portion of the sheet 12 in the first turn above the third filling portion 22 can be gently lifted. This makes it possible to more effectively reduce the step caused by the fixing member 17.

[0236] When the sheet is deformed, there are parts of the sheet that cannot be used as a product, so the effective length of the sheet is compensated to ensure the effective length. In other words, when the part of the sheet that cannot be used as a product becomes longer due to deformation, sheet loss increases. In contrast, according to this embodiment, the step caused by the winding start end 12A of the sheet 12 and the step caused by the fixing members 17 and 51 can be mitigated, so that the deformation of the sheet 12 can be suppressed. This reduces the sheet loss.

[0237] [Second embodiment] Hereinafter, a roll body according to a second embodiment of the present invention will be described with reference to the drawings. Fig. 25 is a perspective view of the roll body according to this embodiment, Fig. 26 is an enlarged view of a portion of the roll body in Fig. 25, Fig. 27 is a view for explaining the dimensions of each component of the roll body in Fig. 25, Fig. 28 is a view for measuring the maximum thickness and length of the second intermediate portion shown in Fig. 25, and Fig. 29 is a view showing the cross-sectional area S3. Figs. 30 to 37 are enlarged views of a portion of another roll body according to this embodiment, and Figs. 38 and 39 are views that typically show the manufacturing process of the roll body according to this embodiment.

[0238] <<<Roll body>>> The roll body 70 shown in Fig. 25 includes a winding core 11 and a long sheet 12 wound around the outer peripheral surface 11A of the winding core 11. As shown in Fig. 25, the roll body 70 further includes a first intermediate portion 71 and a second intermediate portion 72 provided between the sheets 12 in the first and subsequent turns, and a fixing member 17 for fixing a part of the sheet 12 to the winding core 11. The sheet 12 is wound around the winding core 11 for multiple turns, for example, two or more turns. In the roll body 70, the first gap 13 and the second gap 15 are hollow, so that the first gap 13 is not filled with the first filling portion 14, and the second gap 15 is not filled with the second filling portion 16.

[0239] <<First intervening part>> The first intermediate portion 71 is provided between the sheets 12 in the first or subsequent rounds. Specifically, the first intermediate portion 71 is sandwiched between a lower sheet 12 located below the first intermediate portion 71 (closer to the winding core 11) and in contact with the first intermediate portion 71, and an upper sheet 12 located above the first intermediate portion 71 and in contact with the first intermediate portion 71. Therefore, a sheet 12 is always present on the first intermediate portion 71. The first intermediate portion 71 is provided between the sheets 12 in the first or subsequent rounds. Specifically, the first intermediate portion 71 is provided at least in a first region 12D corresponding to the first gap 13 between the sheets 12 in the first or subsequent rounds. The first intermediate portion 71 extends in the width direction DR1 of the winding core 11.

[0240] The edge thickness T4 (see FIG. 27) of the end 71A on the side of the separation position P3 (see FIG. 26) where the upper sheet 12 separates from the lower sheet 12 in the first intermediate portion 71 is preferably thin because a thicker thickness may cause a new step to be formed. Specifically, for example, the edge thickness T4 is preferably 50 μm or less. In order to shorten the deformation relaxation length, the edge thickness T4 is more preferably 10 μm or less, and further preferably 2 μm or less.

[0241] Furthermore, when sheet 12 is a thin film having a thickness of 3 μm or more and less than 50 μm, it is more susceptible to the effects of steps caused by winding starting end 12A than when the thickness is thicker. Therefore, when such a thin film is used, edge thickness T4 is preferably 10 μm or less, and from the viewpoint of shortening the deformation relaxation length, it is more preferable that it be 5 μm or less, and even more preferably 1 μm or less.

[0242] The edge thickness T4 can be measured by a scanning optical interference surface profiler (product name "New View7300", manufactured by Zygo) in the same manner as the edge thickness T1. Alternatively, it can also be measured as follows. First, a portion including the end 71A and the lower sheet 12 and upper sheet 12 in contact with the end 71A is cut out, and a cross section of this portion is obtained by cutting or polishing with a blade, and observed with a stereomicroscope (for example, product name "Digital Microscope VHX-7000", manufactured by Keyence Corporation).

[0243] 26 and 27, the first intermediate portion 71 has a first portion 71B that is interposed in the first region 12D corresponding to the first gap 13, and a second portion 71C that is located on the side of arrival position P4 (see FIG. 26) where the sheet 12 above the first portion 71B reaches the sheet 12 below. Since the first intermediate portion 71 has not only the first portion 71B but also the second portion 71C, it is possible to prevent stress from concentrating on the step caused by the winding start end portion 12A, and deformation of the sheets 12 subsequent to the upper sheet 12 can be made gentler, thereby mitigating this step.

[0244] The thickness T5 of the second portion 71C (see FIG. 27) is preferably 2 μm or more and 300 μm or less. If the thickness T5 of the second portion 71C is in this range, the deformation relaxation length can be shortened while avoiding adverse effects on the winding of the sheet 12. Note that, even if the thickness T3 of the second portion 71C exceeds 300 μm, the deformation relaxation length can be shortened, but adverse effects may be caused on the winding of the sheet 12.

[0245] The thickness T5 of the second portion 71C is the maximum thickness of the second portion 71C. The thickness T5 of the second portion 71C can be measured by a scanning optical interference surface profiler (product name "New View7300", manufactured by Zygo) in the same manner as the edge thickness T1. Alternatively, it can be measured as follows. First, the portion including the lower sheet 12, the second portion 71C, and the upper sheet 12 is sampled and fixed so that this portion is not crushed. Then, the cross section of this fixed portion is polished, and the thickness T5 of the second portion 71C is measured with a stereomicroscope (for example, product name "Digital Microscope VHX-7000", manufactured by Keyence Corporation).

[0246] If the thickness of the first intermediate portion changes suddenly, deformation due to the change in thickness may remain, and the step due to the winding start end may not be sufficiently alleviated. For this reason, it is preferable to ensure that the length of the first intermediate portion is sufficient for the thickness of the sheet. However, if the length of the first intermediate portion is increased, and other effects such as winding occur, the length of the first intermediate portion may be intentionally shortened from the optimal state, so that the deformation relaxation length is longer than the state in which the first intermediate portion has the optimal length, but the deformation relaxation length can be shorter than if the first intermediate portion is not provided. Therefore, it is preferable that the ratio (length L3 / distance D2) of the length L3 from the position corresponding to the tip surface 12A1 of the first intermediate portion 71 to the end on the separation position P3 side to the distance D2 (see FIG. 27) from the outer peripheral surface 11A of the winding core 11 to the upper surface 12A2 of the winding start end 12A is 1 or more. In order to shorten the deformation relaxation length, it is preferable that this ratio is 5 or more, and further 50 or more.

[0247] The length L3 can be measured as follows. First, the lower sheet 12 and the upper sheet 12 are left, and the remaining sheet 12 is unwound. If the sheet 12 is transparent or translucent, the area where the first intervening portion 71 is present can be visually confirmed. For this reason, the sheet 12 is observed through the sheet 12 using a ruler or a tape measure to measure the distance from the tip surface 12A1 of the winding start end portion 12A to the end of the first intervening portion 71 on the side of the separation position P3, and the length L3 is calculated by averaging the distances. On the other hand, if the sheet 12 cannot be observed through the sheet 12, first, a portion including the lower sheet 12, the first intervening portion 71, and the upper sheet 12 is sampled so that this portion is not crushed. Then, this portion is fixed and polished to expose a cross section, and the distance from the position corresponding to the tip surface 12A1 of the first intervening portion to the end on the side of the separation position is measured using a stereomicroscope (for example, product name "Digital Microscope VHX-7000", manufactured by Keyence Corporation).

[0248] The longer the length L3, the better; however, for example, when the thickness of the sheet 12 is 50 μm or more and 200 μm or less, the length L3 is preferably 110 μm or more, and in order to further shorten the deformation relaxation length, it is preferable that the length L3 be 1 mm or more, and even more preferably 10 mm or more.

[0249] The physical properties, such as tensile strength, of the constituent material of the first intervening portion 71 are similar to the physical properties, such as tensile strength, of the constituent material of the first filling portion 14, and the material constituting the first intervening portion 71 is similar to the material of the first filling portion 14, so description thereof will be omitted here.

[0250] <<Second intervening part>> The second intermediate portion 72 is provided between the sheets 12 in the first turn and thereafter. Therefore, a sheet 12 is always present on the second intermediate portion 72. The second intermediate portion 72 is provided between the sheets 12 in the first turn and thereafter. Specifically, the second intermediate portion 72 is provided in at least a second region 12E corresponding to the second gap 15 between the sheets 12 in the first turn and thereafter. The second intermediate portion 72 extends in the width direction DR1 of the winding core 11.

[0251] The second intervening portion 72 is provided between the same sheets 12 as the first intervening portion 71 (for example, between the second round sheet 12 and the third round sheet 12), but the second intervening portion 72 may be provided between sheets 12 different from the first intervening portion 71.

[0252] The maximum thickness T6 of the second intermediate portion 72 (see Figs. 27 and 28) is preferably 0.01 mm or more. If the maximum thickness T6 of the second intermediate portion 72 is 0.01 mm or more, the step caused by the fixing member 17 can be effectively alleviated. From the viewpoint of more effectively alleviating the step, the maximum thickness T6 is more preferably 0.02 mm or more, 0.03 mm or more, or 0.04 mm or more. On the other hand, if the maximum thickness T6 is too thick, the step caused by the winding start end portion 12A can be alleviated, but this may have an adverse effect on the winding of the sheet 12. For this reason, the upper limit of the maximum thickness T6 is preferably 0.2 mm or less or 0.1 mm or less.

[0253] The maximum thickness T6 can be measured by the same method as the thickness T2, using a laser displacement meter or a stereo microscope. When measuring the maximum thickness T6 with a laser displacement meter, first, as in the measurement of the thickness T2, the roll body 70 is attached to a jig and three laser displacement meters are arranged at predetermined positions, and then the sheet 12 is unwound until the second intermediate portion 72 is exposed from the roll body 70. Thereafter, with the second intermediate portion 72 exposed, the core 11 is rotated at a rotation speed of 30 mm / s while the displacement amount is continuously measured with a sampling period of 200 μs using the laser displacement meter, and a graph is obtained with the horizontal axis representing the position (mm) and the vertical axis representing the displacement amount (mm). This measurement is performed from the second tip 72B on the opposite side of the first tip 72A on the fixed member 17 side of the second intermediate portion 72 to the first tip 72A. In this measurement, the reference height (0 mm displacement line) is set to the height of the winding core 11, and the difference between the reference height and the height of the second intermediate portion 72 is set to the thickness of the second intermediate portion 72. Then, the maximum thickness T6 of the second intermediate portion 72 is obtained by finding the difference between the displacement amount at the position where the displacement amount is the largest and the displacement amount at the 0 mm displacement line. The obtained graph represents a plane that substantially includes the longitudinal direction of the sheet and the radial direction of the winding core. In addition, in this graph, one scale on the horizontal axis is 5 mm, and one scale on the vertical axis is 0.02 mm. In FIG. 27, the first tip 72A is located directly above the fixed member 17.

[0254] The measurement of the maximum thickness T6 using a stereomicroscope can be performed as follows. First, a portion including the lower sheet 12, the second intermediate portion 72, and the upper sheet 12 is sampled and fixed so as not to crush this portion. Then, the cross section of this fixed portion is polished, and the maximum thickness T6 of the second intermediate portion 72 is measured using a stereomicroscope (for example, product name "Digital Microscope VHX-7000" manufactured by Keyence Corporation).

[0255] When the thickness of the second intermediate portion 72 is measured along the longitudinal direction DR2 of the sheet 12, the ratio (length L4 / maximum thickness T6) of the length L4 (see FIG. 27) from the second tip 72B of the second intermediate portion 72 to the position where the second intermediate portion 72 has the maximum thickness T6 in the longitudinal direction DR2 to the maximum thickness T6 of the second intermediate portion 72 is preferably 12 or more. If this ratio is 12 or more, it is possible to suppress deformation remaining near the second tip 72B of the second intermediate portion 72. Furthermore, if the thickness of the second intermediate portion is too thick, the winding property may be deteriorated due to deviation from a perfect circle during winding, but if this ratio is 12 or more, the second intermediate portion 72 is not too thick, so that deterioration of winding property can be suppressed. Furthermore, if the thickness of the second intermediate portion is too thick, there is a risk of new deformation caused by the second intermediate portion occurring, but if this ratio is 12 or more, it is possible to suppress such new deformation occurring. From the viewpoint of shortening the deformation relaxation length, the lower limit of this ratio is preferably 25 or more, 50 or more, 75 or more, 100 or more, 125 or more, 150 or more, 175 or more, or 200 or more. From the viewpoint of effectively reducing the step caused by the fixing member, it is preferable that the maximum thickness T6 of the second intermediate portion 72 is large, and therefore the upper limit of this ratio is preferably, for example, 2000 or less, 1000 or less, 500 or less, or 375 or less.

[0256] From the viewpoint of reducing the step, the longer the length L4, the better. For example, when the thickness of the sheet 12 is 50 μm or more and 200 μm or less, the length L4 is preferably 5.0 mm or more, and in order to further shorten the deformation reduction length, the length L4 is more preferably 7.0 mm or more, and further preferably 9.0 mm or more. However, if the length L4 is too long, in the region R3 (see FIG. 28) from the second tip 72B of the second intermediate portion to the position where the maximum thickness T6 is reached, it becomes difficult to form the second intermediate portion having a convex surface, and there is a risk that wavy thickness unevenness may occur in the second intermediate portion. Therefore, the upper limit of the length L4 is preferably 20 mm or less, from the viewpoint of making the surface 72C of the second intermediate portion 72 in the region R3 more likely to be convex and suppressing wavy thickness unevenness.

[0257] The length L4 can be obtained from the graph of the position-displacement curve, similarly to the maximum thickness T6. Specifically, first, since the presence of the second tip 72B of the second intermediate portion 72 increases the amount of displacement, a first position is found from the graph of the position-displacement curve, which is the intersection of the 0 mm displacement line and the position-displacement curve at the point where the amount of displacement starts to increase. Next, an imaginary line is drawn that passes through the position where the amount of displacement is the highest and is perpendicular to the 0 mm displacement line. Then, the intersection of this imaginary line and the 0 mm displacement line is set as the second position, and the length L4 can be obtained by finding the distance between the first position and the second position.

[0258] The above-mentioned length L4 / maximum thickness T6 can roughly represent the shape of the second intermediate portion 72, but in order to more accurately represent the shape of the surface 72C being convex, it is preferable to further use the cross-sectional area of ​​the second intermediate portion 72. Specifically, it is preferable that the ratio (cross-sectional area S3 / maximum thickness T6) of the cross-sectional area S3 (see FIG. 28) of the second intermediate portion 72 from the second tip 72B to the position of the maximum thickness T6 in a plane (plane shown in FIG. 28) including the longitudinal direction DR2 of the sheet 12 and the radial direction DR3 of the winding core 11 to the maximum thickness T6 of the second intermediate portion 72 is 2.5 or more. If this ratio is 2.5 or more, the cross-sectional area S3 of the second intermediate portion 72 is large with respect to the maximum thickness T6, so that the second intermediate portion 72 can effectively lift the sheet 12, thereby further mitigating the step. From the viewpoint of further reducing the step, the lower limit of the cross-sectional area S3 / maximum thickness T6 is preferably 3.0 or more, 3.5 or more, 4.0 or more, 5.0 or more, 5.5 or more, 6.0 or more, 6.5 or more, or 7.0 or more. The upper limit of the cross-sectional area S3 / maximum thickness T6 is not particularly limited, but may be, for example, 20.0 or less, 17.5 or less, 15.0 or less, 12.5 or less, or 10.0 or less. The cross-sectional area S3 is the cross-sectional area of ​​the region R3 of the second intermediate portion 72 (the cross-sectional area of ​​the region surrounded by the solid line in the second intermediate portion 72 in FIG. 29), and can be obtained by calculating the product of the thickness at each measurement point and the width between each measurement point in the region from the first position to the second position on the graph of the position displacement curve, and then summing up the products.

[0259] The physical properties, such as tensile strength, of the material constituting the second intermediate portion 72 are similar to the physical properties, such as tensile strength, of the material constituting the second filling portion 16, and the material constituting the second intermediate portion 72 is similar to the material constituting the second filling portion 16, so description thereof will be omitted here.

[0260] As described below, in the sheet 12 (upper sheet 12) outside the first intervening portion 71 and the second intervening portion 72 in the radial direction DR3, the step caused by the winding start end 12A of the sheet 12 and the step caused by the fixing member 17 can be suppressed, but in the sheet 12 (lower sheet 12) inside (core 11 side) the first intervening portion 71 and the second intervening portion 72 in the radial direction DR3, the step caused by the winding start end 12A of the sheet 12 and the step caused by the fixing member 17 cannot be suppressed. For this reason, it is preferable that the first intervening portion 71 and the second intervening portion 72 are provided as far inside in the radial direction DR3 as possible (for example, between the sheet 12 of the first turn and the sheet 12 of the second turn, or between the sheet 12 of the second turn and the sheet 12 of the third turn).

[0261] <<Other roll bodies>> In the roll body 70, the tip surface 12A1 of the winding start end 12A of the sheet 12 and the second end surface 17B of the fixed member 17 are substantially aligned in a cross section along the longitudinal direction DR2 of the sheet 12 and the radial direction DR3 of the winding core 11, but as in the roll body 80 shown in Fig. 30, the tip surface 12A1 of the winding start end 12A of the sheet 12 may protrude beyond the second end surface 17B of the fixed member 17. In this case, not only is the second intermediate portion 72 interposed in the second region 12E between the sheets 12, but a third intermediate portion 81 may also be interposed in a third region 12F corresponding to the third gap 21 on the side of the second end surface 17B between the sheets 12.

[0262] <Third intervening part> The third intermediate portion 81 is similar to the second intermediate portion 72 except that it is interposed in the third region 12F corresponding to the third gap 21, and therefore a description thereof will be omitted here.

[0263] In the roll body 70, the second intermediate portion 72 is provided in the second region 12E between the sheets 12, but from the viewpoint of reducing the step caused by the winding start end 12A of the sheet 12, it is sufficient that the first intermediate portion 71 is provided in the first region 12D between the sheets 12, so the second intermediate portion 72 does not have to be provided in the second region 12E between the sheets 12 as in the roll body 90 shown in Fig. 31. In the roll body 90 shown in Fig. 31, the sheets 12 are in close contact with each other in the second region 12E.

[0264] In the roll body 70, the first intermediate portion 71 is provided in the first region 12D between the sheets 12, but from the viewpoint of reducing the step caused by the fixing member 17, it is sufficient that the second intermediate portion 72 is provided in the second region 12E between the sheets 12, so that the first intermediate portion 71 does not have to be provided in the first region 12D between the sheets 12 as in the roll body 100 shown in Fig. 32. In the roll body 100 shown in Fig. 32, the sheets 12 are in close contact with each other in the first region 12D.

[0265] The roll body 70 includes a first intermediate portion 71, but a first filling portion 14 may be provided instead of the first intermediate portion 71 as in a roll body 110 shown in Fig. 33. That is, the first gap 13 may be filled with the first filling portion 14, and a second intermediate portion 72 may be provided in a second region 12E between the sheets 12.

[0266] The second intermediate portion 72 of the roll body 110 is provided between the second round of the sheet 12 and the third round of the sheet 12, but the second intermediate portion 72 may also be provided between the first round of the sheet 12 and the second round of the sheet 12 as in the roll body 120 shown in Figure 34.

[0267] Although the roll body 70 includes the second intermediate portion 72, a second filling portion 16 may be provided instead of the second intermediate portion 72 as in a roll body 130 shown in Fig. 35. That is, the first intermediate portion 71 may be provided in the first region 12D between the sheets 12, and the second filling portion 16 may be filled in the second gap 15.

[0268] The roll body 70 includes a fixing member 17 that fixes the sheet 12 to the outer peripheral surface 11A of the core 11, but it does not necessarily have to include the fixing member 17 like a roll body 140 shown in FIG.

[0269] In the roll body 70, the thickness of the sheet 12 is uniform, but as in the roll body 150 shown in FIG. 37, a convex portion 12H protruding outward in the radial direction DR3 of the winding core 11 may be formed on both end portions 12G extending along the longitudinal direction of the sheet 12. When the viscosity of the filling material (e.g., coating material), the first intermediate portion 71, the second intermediate portion 72, or the third intermediate portion 81 is low or when the thickness of the sheet is uniform, the filling material (e.g., coating material, etc.) may protrude from between the sheets, resulting in the filling material, etc., being present in unintended locations. In response to this, by forming the convex portions 12H on both end portions 12G of the sheet 12, it is possible to suppress the filling material (e.g., coating material, etc.) from protruding from both end portions 12G after the filling material is placed, for example, after the coating material is applied. In addition, both end portions 12G of the sheet 12 are cut off and are not used in the product, so there is no problem with the product even if both end portions 12G of the sheet have such protrusions 12H. The protrusions 12H may be formed by knurling or coating, or by attaching a tape (for example, a side tape). In the case of coating, the same material as the material of the first filling portion 14 can be used.

[0270] 37, the protrusions 12H are provided on all portions of both end portions 12G of the sheet 12, but the protrusions 12H may be provided partially. For example, the protrusions 12H may be provided partially at positions sandwiching the first intermediate portions 71 at both end portions 12G extending along the longitudinal direction of the sheet 12, at positions sandwiching the second intermediate portions 72 at both end portions 12G extending along the longitudinal direction of the sheet 12, and / or at positions sandwiching the third intermediate portions 81 at both end portions 12G extending along the longitudinal direction of the sheet 12. When the convex portion 12H is located in a position sandwiching the first intervening portion 71, it is possible to suppress the filling material (e.g., coating material) and the first intervening portion 71 from spilling out, when the convex portion 12H is located in a position sandwiching the second intervening portion 72, it is possible to suppress the filling material (e.g., coating material) and the second intervening portion 72 from spilling out, and when the convex portion 12H is located in a position sandwiching the third intervening portion 81, it is possible to suppress the filling material (e.g., coating material) and the third intervening portion 81 from spilling out.

[0271] Although the distance D2, length L3, length L4, maximum thickness T6, and cross-sectional area S3 are not shown in Figures 31 to 36, when the first intermediate portion 71 is present, the distance D2, length L3, and length L3 / distance D2 are the same as in the case of the roll body 70, and when the second intermediate portion 72 is present, the length L4, length L4 / maximum thickness T6, and cross-sectional area S3 / maximum thickness T6 are the same as in the case of the roll body 70.

[0272] In addition, in Figures 33 and 34, the entire surface of the fixing member 17 is in close contact with the starting end 12A, but similar to the roll body 10 shown in Figure 8, the first filling section 14 may be inserted between the starting end 12A and the fixing member 17.

[0273] <<Roll body manufacturing method>> The roll body 70 can be manufactured, for example, by the following method: First, the fixing members 17 are arranged on the outer peripheral surface 11A of the winding core 11 along the width direction DR1 of the winding core 11 as shown in Figure 38(A).

[0274] After positioning the fixing member 17, the starting end 12A of the sheet 12 is fixed to the outer peripheral surface 11A of the winding core 11 via the fixing member 17 so that the tip surface 12A1 of the starting end 12A of the sheet 12 is approximately aligned with the second end surface 17B of the fixing member 17, as shown in Figure 38 (B).

[0275] After the winding start end 12A of the sheet 12 is fixed to the outer circumferential surface 11A of the winding core 11, as shown in Fig. 38(C), the sheet 12 is wound at least one turn around the outer circumferential surface 11A of the winding core 11. In this way, an intermediate roll body 73 having a first gap 13 and a second gap 15 is obtained.

[0276] After obtaining the intermediate roll body 73, coating materials 206, 207 are applied to the surface 12I of the sheet 12 constituting the outer circumferential surface 73A of the intermediate roll body 73 along the width direction DR1 of the winding core 11 as shown in Fig. 39(A). The coating material 206 is applied to at least the first region 12D corresponding to the first gap 13, and the coating material 207 is applied to at least the second region 12E corresponding to the second gap 15. The coating materials 74, 75 are similar to the coating materials 201, 202, and therefore a description thereof will be omitted here.

[0277] After the coating materials 206 and 207 are applied, the sheet 12 is wound again around the winding core 11 as shown in FIG. 39(B). This causes the coating materials 206 and 207 to flow and spread, so that the coating material 206 is provided in the first region 12D between the sheets 12 and the coating material 207 is provided in the second region 12E between the sheets 12, forming the first intermediate portion 71 and the second intermediate portion 72. This results in a roll body 70. Note that if at least one of the coating materials 206 and 207 is a curable material, the curable material is cured after the sheet 12 is wound again.

[0278] In the manufacturing method of the roll body 70, the coating materials 206, 207 are not applied using a mold 210 having a slit 210A, but the coating materials 206, 207 may be applied using a mold 210 having a slit 210A as in the first embodiment. Also, the first intermediate portion 71 and the second intermediate portion 72 may be formed by a filling sheet instead of the coating materials 206, 207 in a manner similar to the first embodiment.

[0279] According to this embodiment, the first intermediate portion 71 is provided in the first region 12D between the sheets 12, so that the portion of the sheet 12 on the first intermediate portion 71 can be gently lifted toward the tip surface 12A1 side. This effectively reduces the step caused by the winding start end portion 12A of the sheet 12.

[0280] According to this embodiment, since the second intermediate portion 72 is provided in the second region 12E between the sheets 12, it is possible to gently lift up the portion of the sheet 12 above the second intermediate portion 72. This makes it possible to effectively reduce the step caused by the fixing member 17.

[0281] Furthermore, since the step caused by winding start end 12A of sheet 12 and the step caused by fixing member 17 can be reduced, deformation of sheet 12 can be suppressed.

[0282] When the first gap is filled with the first filling portion and the second gap is filled with the second filling portion, the first filling portion and the second filling portion may flow to the portion where no pressure is applied. In contrast, in this embodiment, the first intermediate portion 71 and the second intermediate portion 72 are provided between the sheets 12, so that the materials constituting the first intermediate portion 71 and the second intermediate portion 72 are less likely to flow and protrude. EXAMPLES

[0283] In order to explain the present invention in detail, the following examples are given, but the present invention is not limited to these. Fig. 40(A) is a graph showing the amount of displacement relative to the position around the first filling part of the roll body according to Example 7, Fig. 40(B) is a graph showing the amount of displacement relative to the position around the first filling part of the roll body according to Example 8, and Fig. 40(C) is a graph showing the amount of displacement relative to the position around the first filling part of the roll body according to Example 9.

[0284] <Preparation of composition for hard coat layer> First, the components were mixed so as to obtain the composition shown below, thereby obtaining a composition 1 for a hard coat layer.

[0285] (Hardcoat layer composition 1) Pentaerythritol triacrylate (product name "KAYARAD-PET-30", manufactured by Nippon Kayaku Co., Ltd.): 60 parts by weight Photopolymerization initiator (1-hydroxycyclohexyl phenyl ketone, product name "Omnirad184", manufactured by IGM Resins BV): 5 parts by mass Silicone leveling agent (product name "Seikabeam 10-28", manufactured by Dainichi Seika Chemicals Mfg. Co., Ltd., solid content 10%): 0.1 parts by weight Silica particles (product name "SIRMIBK-H84", manufactured by CIK Nanotech Co., Ltd., average particle size 30 nm, solid content 30%): 3 parts by weight Methyl isobutyl ketone (MIBK): 80 parts by weight Cyclohexanone: 20 parts by weight

[0286] <Example 1> First, a rectangular double-sided tape measuring 1,380 mm in length, 20 mm in width and 10 μm in thickness was attached as a fixing member to the outer peripheral surface of a cylindrical winding core made of fiber-reinforced plastic having an inner diameter of 153 mm, an outer diameter of 167 mm and a width of 1,600 mm along the width direction of the winding core.

[0287] After the double-sided tape was applied, the core was held by a chucking member of the winding device and fixed to the winding device. Thereafter, a one-component curing silicone resin composition (product name "Hapio Seal Pro HG", manufactured by Kampe Hapio Co., Ltd.) was applied as a coating material in two rolls in an environment of 25°C so as to contact the first end face and the second end face of the double-sided tape extending along the width direction of the core. The color of this silicone resin composition was gray. The shear viscosity of this silicone resin composition when applied was 180 Pa·s, and the silicone resin composition was applied along the width direction of the core and in an amount of 1 cm per unit width. 3 Each was applied in a linear fashion so that the area was 1 / m.

[0288] Then, the winding start end in the longitudinal direction of a sheet of acrylic resin film (in-plane retardation Re: 5 nm) having a length of 3000 m, a width of 1340 mm and a thickness of 80 μm was attached to a double-sided tape along the width direction of the core, and the acrylic resin film was fixed to the outer circumferential surface of the core. The acrylic resin film was arranged so that the tip surface in the longitudinal direction of the winding start end of the acrylic resin film was in contact with the silicone resin composition and was approximately aligned with the second end surface of the double-sided tape in the radial direction of the core.

[0289] Thereafter, the entire acrylic resin film was wound around a core by a winding device, and a first gap located between the core and the first turn of the acrylic resin film and in contact with the tip surface of the winding start end of the acrylic resin film was filled with a silicone resin composition, and a second gap located between the core and the first turn of the acrylic resin film and in contact with the first end surface of the double-sided tape was filled with a silicone resin composition. In this way, a roll body was obtained. In the roll body, the silicone resin composition was cured to form a first filling part filled in the first gap with a length of 20 mm, a width of 1340 mm, and a maximum thickness of 300 μm, and a second filling part filled in the second gap with a length of 20 mm, a width of 1340 mm, and a maximum thickness of 300 μm.

[0290] The shear viscosity of the silicone resin composition was measured using a dynamic viscoelasticity measuring device manufactured by Anton Paar Japan Co., Ltd. Specifically, the shear viscosity of the silicone resin composition was determined by measuring the shear viscosity at a shear rate of 1 [1 / s] at 25°C using a parallel plate with a diameter of 25 mm. The viscosity of the silicone resin composition was determined by measuring the viscosity of the silicone resin composition 10 times and calculating the arithmetic average value of 8 shear viscosities excluding the maximum and minimum values ​​among the 10 viscosities measured. The shear viscosity of the coating material used in the following other examples was also measured in the same manner as in Example 1.

[0291] The in-plane retardation Re of the acrylic resin film was measured using a retardation film and optical material inspection device (product name "RETS-100", manufactured by Otsuka Electronics Co., Ltd.). Specifically, first, in order to stabilize the light source of the RETS-100, the light source was turned on and left for 60 minutes or more. After that, the rotating analyzer method was selected, and the θ mode (angle direction retardation measurement mode) was selected. By selecting this θ mode, the stage became an inclined rotating stage.

[0292] Next, the following measurement conditions were entered into the RETS-100. (Measurement conditions) Retardation measurement range: Rotating analyzer method Measurement spot diameter: φ5mm Tilt angle range: -40°~40° Measurement wavelength range: 400nm~800nm Average refractive index of sample: 1.5 Thickness: 80μm

[0293] Background data was then obtained without any samples placed in the instrument, the instrument was closed, and this was done every time the light source was turned on.

[0294] Then, a sample was placed on the stage in the device. The size of the sample was 50 mm × 50 mm.

[0295] After placing the sample, the stage was rotated 360° on the XY plane in an environment of 23°C temperature and 50% relative humidity to measure the fast axis and slow axis. After the measurement was completed, the slow axis was selected. Then, the measurement was performed while the stage was tilted in a set angle range around the slow axis, and data (Re) was obtained in 10° increments for the set tilt angle range and set wavelength range. The in-plane retardation Re was measured at five different positions. Specifically, as shown in FIG. 2, it was measured at a total of five points, including the center A1 of the sample and points A2 to A4. Then, the arithmetic average value of three points excluding the maximum and minimum values ​​among the five measured values ​​was taken as the in-plane retardation Re.

[0296] <Example 2> In Example 2, a roll body was obtained in the same manner as in Example 1, except that a two-component curing silicone rubber composition (product name "KE-24", manufactured by Shin-Etsu Chemical Co., Ltd.) was used instead of the silicone resin composition for forming the first and second filled portions. This silicone rubber composition was white when mixed, and had a shear viscosity of 75 Pa s when applied.

[0297] <Example 3> In Example 3, a roll body was obtained in the same manner as in Example 1, except that a two-component curing silicone rubber composition (product name "ELASTOSIL (registered trademark) M 4503", manufactured by Wacker Asahi Kasei Silicones Co., Ltd., condensation curing type) was used instead of the silicone resin composition for forming the first filled portion and the second filled portion. This silicone rubber composition was white when mixed, and had a shear viscosity of 40 Pa s when applied. Furthermore, this silicone rubber composition did not contain any volatile components or adhesive components.

[0298] When a 90° peel test was conducted in which the constituent material of the first filling section in the roll body of Example 3 was peeled perpendicularly to the outer peripheral surface of the core at a peel speed of 10 mm / min, the constituent material peeled off with a tensile force of 0.2 N.

[0299] The 90° peel test was carried out using a sample and a spring tension gauge (manufactured by Ohba Keiki Seisakusho Co., Ltd.). Specifically, a mold larger than the size of the sample was first prepared, and the mold was placed on the outer circumferential surface of the core. A two-component curing silicone rubber composition (product name "ELASTOSIL (registered trademark) M 4503", manufactured by Wacker Asahi Kasei Silicone Co., Ltd., condensation curing type) was then poured into the mold and cured to obtain a material layer. The material layer was then removed from the mold, and cut into a size of 20 mm x 100 mm using a cutter to obtain a sample provided on the outer circumferential surface of the core. One end of the sample was then held by a spring tension gauge, and the one end was pulled up perpendicularly to the outer circumferential surface of the core while measuring the tensile force in an environment of a temperature of 25°C and a relative humidity of 50%, and the sample was peeled off at a peeling speed of 10 mm / sec. Of the 10 samples subjected to the 90° peel test, the sample with the maximum tensile strength and the sample with the minimum tensile strength were excluded, and the arithmetic average value of the tensile strengths of the 8 samples was taken as the tensile strength of the above-mentioned constituent material.

[0300] The tensile strength of the material of the first filling portion in the roll body according to Example 3 was 3.5 MPa, the elongation at break was 450%, and the tear strength was 12.0 N / mm. The hardness of the material of the first filling portion measured with a durometer type A was 28°, and the linear shrinkage of the material of the first filling portion was 0.10%.

[0301] The tensile strength of the material constituting the first filling part was measured using a sample and a Tensilon universal testing machine (product name "RTC-1310A", manufactured by A&D Co., Ltd.) in accordance with JIS K6251:2017. Specifically, a mold larger than the size of the sample was first prepared, and this mold was placed on the outer peripheral surface of the winding core. Then, a two-part curing silicone rubber composition for forming the first filling part (product name "ELASTOSIL (registered trademark) M 4503", manufactured by Wacker Asahi Kasei Silicone Co., Ltd., condensation curing type) was poured into this mold and cured to obtain a material layer. Thereafter, the material layer was removed from the mold, and the material layer was punched out to the size of the dumbbell-shaped No. 2 shape described in JIS K6251:2017 with a tensile No. 2 dumbbell-shaped punching blade manufactured by Kobunshi Keiki Co., Ltd., to obtain a sample. Then, the sample was kept in an environment of 25 ° C for 24 hours. The sample was then held at both longitudinal ends by a pair of gripping tools of the Tensilon universal testing machine, and a tensile test was performed under conditions of a temperature of 25° C., a relative humidity of 50%, an initial gripping tool distance of 20 mm, and a tensile speed of 100 mm / min to measure the tensile strength of the sample. The arithmetic average value of the tensile strengths of 8 samples out of the 10 samples, excluding the maximum and minimum values, was determined as the tensile strength of the above-mentioned constituent material.

[0302] The elongation at break of the constituent material of the first filling part was measured in accordance with JIS K6251:2017 using a sample and a Tensilon universal testing machine (product name "RTC-1310A", manufactured by A&D Co., Ltd.) in the same manner as the measurement method for tensile strength. The arithmetic average value of the elongation at break of 8 samples out of 10 samples, excluding the maximum and minimum values, was taken as the elongation at break of the above constituent material.

[0303] The tear strength of the material constituting the first filling section was measured in accordance with JIS K6252:2007 using a sample and a Tensilon universal testing machine (product name "RTC-1310A", manufactured by A&D Co., Ltd.) in the same manner as the method for measuring tensile strength. The arithmetic mean value of the tear strengths of 8 samples out of 10 samples, excluding the maximum and minimum values, was taken as the tear strength of the above-mentioned material.

[0304] The hardness of the material of the first filling part was measured by a durometer type A in accordance with JIS K6253:1997. Specifically, a mold larger than the size of the sample was prepared and placed on the outer peripheral surface of the core. A two-part curable silicone rubber composition for forming the first filling part (product name "ELASTOSIL (registered trademark) M 4503", manufactured by Wacker Asahi Kasei Silicone Co., Ltd., condensation curable) was poured into the mold and cured as necessary to obtain a material layer. The material layer was then removed from the mold and cut out by a cutter or the like to obtain a sample with a size of 100 mm x 100 mm and a thickness of 10 mm. The hardness was measured using a durometer type A (product name "GS-719N (TYPE A)", manufactured by Techrock Co., Ltd.) under an environment of a temperature of 25°C and a relative humidity of 50%. The arithmetic average value of the hardness of 8 samples excluding the maximum and minimum values ​​out of the 10 samples was taken as the hardness of the above-mentioned constituent material.

[0305] The linear shrinkage of the first filling part can be measured as follows. First, a mold having a thickness of 2 mm and a size of 130 mm square is prepared, and a two-liquid curable silicone rubber composition for forming the first filling part (product name "ELASTOSIL (registered trademark) M 4503", manufactured by Wacker Asahi Kasei Silicone Co., Ltd., condensation curable) is poured into the mold and cured to obtain a sample (molded product). After completely curing, the dimensions of the sample were measured and compared with the inner dimensions of the mold to obtain the linear shrinkage based on JIS K6249:2003. The arithmetic average value of the linear shrinkage of 8 samples excluding the maximum and minimum values ​​out of 10 samples was taken as the linear shrinkage of the above-mentioned constituent material.

[0306] <Example 4> In Example 4, a roll body was obtained in the same manner as in Example 1, except that a two-component curing silicone rubber composition (product name "ELASTOSIL (registered trademark) M 4601", manufactured by Wacker Asahi Kasei Silicones Co., Ltd., addition reactive) was used instead of the silicone resin composition for forming the first and second filled portions. This silicone rubber composition was white when mixed, and the shear viscosity of this silicone rubber composition when applied was 20 Pa s.

[0307] <Example 5> In Example 5, a roll body was obtained in the same manner as in Example 1, except that a two-component curing urethane resin composition (product name "Human Skin Gel", manufactured by Exseal Corporation) was used instead of the silicone resin composition for forming the first filled portion and the second filled portion. This urethane resin composition was white when mixed, and had a shear viscosity of 6.5 Pa s when applied.

[0308] <Example 6> First, a rectangular double-sided tape measuring 1,380 mm in length, 20 mm in width and 10 μm in thickness was attached as a fixing member to the outer peripheral surface of a cylindrical winding core made of fiber-reinforced plastic having an inner diameter of 153 mm, an outer diameter of 167 mm and a width of 1,600 mm along the width direction of the winding core.

[0309] After the double-sided tape was applied, the core was held by a chucking member of the winding device and fixed to the winding device. The winding start end in the longitudinal direction of a polyethylene terephthalate film (PET film, in-plane retardation Re: 1000 nm, Nz coefficient: 20) having a length of 3000 m, a width of 1490 mm and a thickness of 80 μm as a sheet was applied to the double-sided tape along the width direction of the core, and the PET film was fixed to the outer peripheral surface of the core.

[0310] The PET film was then wound up one turn by a winding device to obtain an intermediate roll body. In the intermediate roll body, a first gap was formed between the winding core and the first turn of the PET film and in contact with the tip face of the winding start end of the PET film, and a second gap was formed between the winding core and the first turn of the PET film and in contact with the first end face of the double-sided tape.

[0311] After obtaining the intermediate roll, a one-part curable silicone resin composition (product name "Hapio Seal Pro HG", manufactured by Kampe Hapio Co., Ltd.) was applied as a coating material to the surface of the PET film constituting the outer circumferential surface of the intermediate roll along the width direction of the core in an environment of 25°C. The viscosity of the silicone resin composition when applied was 180 Pa s, and the silicone resin composition was applied along the width direction of the core at a coating amount of 1 cm per unit width. 3 / m. Specifically, the silicone resin composition was applied to a first region corresponding to the first gap and a second region corresponding to the second gap.

[0312] After the silicone resin composition was applied, the entire PET film was wound again on the core by a winding device, and the silicone resin composition was interposed in each of the first and second regions between the PET films. This resulted in a roll body. In the roll body, the silicone resin composition was cured to form a first interposed portion having a length of 20 mm, a width of 1340 mm, and a maximum thickness of 300 μm in the first region between the PET films, and a second interposed portion having a length of 20 mm, a width of 1340 mm, and a maximum thickness of 300 μm in the second region between the PET films.

[0313] The in-plane retardation Re of the PET film used in Example 6 was measured in the same manner as the in-plane retardation Re of the acrylic resin film used in Example 1. However, in this case, the average refractive index N of the sample was set to 1.617.

[0314] <Example 7> In Example 7, an acrylic resin film having a length of 3000 m, a width of 1340 mm and a thickness of 85 μm was used as a sheet, specifically, a laminate consisting of an acrylic resin film and a hard coat layer. The silicone rubber composition for forming the first and second filling parts was applied in the width direction of the core and in an amount of 0.3 cm per unit width. 3 A roll body was obtained in the same manner as in Example 3, except that the coating was applied in a linear manner so that the thickness of the coating was 1 / m.

[0315] The laminate was formed as follows. First, a continuous coater was used to send out the acrylic resin film used in Example 1, which had a length of 3000 m, a width of 1340 mm and a thickness of 80 μm, from a winding roll to the coating section of the first unit, and the hard coat layer composition 1 was applied to form a coating film. The coating film was then dried in the drying section at a temperature of 70° C. for 60 seconds to evaporate the solvent in the coating film, and ultraviolet rays were applied in the curing section at an integrated light intensity of 150 mJ / cm 2 . 2 The coating was cured by irradiating the coating so as to form a hard coat layer having a thickness of 5.0 μm and a coating width of 1300 mm, thereby obtaining a laminate having a length of 3000 m and a thickness of 85 μm.

[0316] <Example 8> In Example 8, the silicone rubber composition for forming the first and second filling sections was applied in the width direction of the core at a coating amount of 0.5 cm 3 A roll body was obtained in the same manner as in Example 7, except that the coating was applied in a linear manner so that the thickness of the coating was 1 / m.

[0317] <Example 9> In Example 9, the silicone rubber composition for forming the first and second filling sections was applied in the width direction of the core at a coating amount of 0.8 cm per unit width. 3 A roll body was obtained in the same manner as in Example 7, except that the coating was applied in a linear manner so that the thickness of the coating was 1 / m.

[0318] <Example 10> In Example 10, the silicone rubber composition for forming the first and second filling parts was applied in an amount of 1 cm per unit width. 3 A roll body was obtained in the same manner as in Example 9, except that the coating was applied in a linear manner so that the thickness of the coating was 1 / m.

[0319] <Example 11> In Example 11, the shear viscosity of the two-component curable silicone rubber composition for forming the first filled portion and the second interposed portion during application was set to 2 Pa s, and the application amount per unit width was set to 1.5 cm 3 A roll body was obtained in the same manner as in Example 9, except that the thickness was changed to / m.

[0320] <Example 12> In Example 12, the shear viscosity of the silicone rubber composition for forming the first filled portion and the second interposed portion during application was set to 6.5 Pa s, and the application amount per unit width was set to 1.2 cm 3 A roll body was obtained in the same manner as in Example 9, except that the thickness was changed to / m.

[0321] <Example 13> First, a cylindrical winding core made of fiber-reinforced plastic with an inner diameter of 153 mm, an outer diameter of 167 mm, and a width of 1600 mm was held by a chucking member of the winding device and fixed to the winding device. Then, a two-component curing silicone rubber composition (product name "ELASTOSIL (registered trademark) M 4503", manufactured by Wacker Asahi Kasei Silicones Co., Ltd., condensation curing type) was applied as a coating material in an environment of 25°C. The viscosity of the silicone rubber composition when applied was 180 Pa s, and the silicone rubber composition was applied along the width direction of the winding core and in an amount of 1 cm per unit width. 3 / m.

[0322] Thereafter, a rectangular double-sided tape having a length of 1380 mm, a width of 20 mm, and a thickness of 10 μm was attached as a fixing member along the width direction of the core so that the distance between the double-sided tape and the two-component curing silicone rubber composition was 3 mm. The distance was measured at 10 points, and the arithmetic average value of the distances at 8 points, excluding the maximum and minimum values, was calculated from the measured distances at 10 points. In the following examples, the distance was calculated in this manner.

[0323] The start end of the winding in the longitudinal direction of the laminate, which had a length of 3000 m, a width of 1340 mm and a thickness of 85 μm similar to that of Example 7 as a sheet, was attached to the double-sided tape along the width direction of the winding core, and the laminate was fixed to the outer circumferential surface of the winding core. The laminate was arranged so that the tip surface in the longitudinal direction of the start end of the winding of the laminate was in contact with the silicone rubber composition and was approximately aligned with the second end surface of the double-sided tape in the radial direction of the winding core.

[0324] The laminate was then wound around a core using a winding device, and a silicone rubber composition was filled into a first gap located between the core and the first turn of the laminate and in contact with the tip surface of the starting end of the winding of the laminate.

[0325] The laminate was then wound up one turn by a winding device to obtain an intermediate roll body. In the intermediate roll body, a second gap was formed between the winding core and the first turn of the laminate, and in contact with the first end face of the double-sided tape.

[0326] After obtaining the intermediate roll, a two-component curing silicone rubber composition (product name "ELASTOSIL (registered trademark) M 4503", manufactured by Wacker Asahi Kasei Silicones, condensation curing type) was applied as a coating material to the surface of the laminate constituting the outer circumferential surface of the intermediate roll along the width direction of the core in an environment of 25°C. The viscosity of the silicone rubber composition when applied was 180 Pa s, and the silicone rubber composition was applied along the width direction of the core at a coating amount of 1 cm per unit width. 3 / m. Specifically, the silicone rubber composition was applied to the second region corresponding to the second gap.

[0327] After the silicone rubber composition was applied, the entire laminate was wound again on the core by the winding device to interpose the silicone rubber composition in the second region between the laminates. This resulted in a roll body. In the roll body, the silicone rubber composition was cured to form a first filling portion having a width of 1340 mm in the first gap, and a second interposing portion having a width of 1340 mm was formed in the second region between the laminates.

[0328] <Example 14> In Example 12, a roll body was obtained in the same manner as in Example 11, except that a two-component curing silicone rubber composition (product name "ELASTOSIL (registered trademark) M 4601", manufactured by Wacker Asahi Kasei Silicones, addition reactive) was used instead of the two-component curing silicone rubber composition (product name "ELASTOSIL (registered trademark) M 4503", manufactured by Wacker Asahi Kasei Silicones, condensation curing) for forming the first filled portion and the second interposed portion. The shear viscosity of the silicone rubber composition when applied was 10 Pa s.

[0329] <Example 15> In Example 15, the shear viscosity of the two-component curable silicone rubber composition for forming the first filled portion and the second interposed portion during application was 10 Pa s, and the application amount per unit width was 0.8 cm 3 A roll was obtained in the same manner as in Example 13, except that the thickness of the roll was set to 1 / m and the distance between the double-sided tape and the two-component curing silicone rubber composition was set to 3 mm.

[0330] <Example 16> In Example 16, the shear viscosity of the two-component curable silicone rubber composition for forming the first filled portion and the second interposed portion during application was set to 10 Pa s, and the application amount per unit width was set to 1.2 cm 3 A roll was obtained in the same manner as in Example 13, except that the thickness of the roll was set to 1 / m and the distance between the double-sided tape and the two-component curing silicone rubber composition was set to 3 mm.

[0331] <Comparative Example 1> In Comparative Example 1, a roll body was obtained in the same manner as in Example 1, except that no coating material was applied.

[0332] <Comparative Example 2> In Comparative Example 2, a roll body was obtained in the same manner as in Comparative Example 1, except that the laminate used in Example 7 was used instead of the acrylic resin film.

[0333] In the roll bodies according to Examples 1 to 16, the edge thickness T1 of the first filling part was measured. The edge thickness T1 was measured using a scanning optical interference surface profiler (product name "New View7300", manufactured by Zygo). Specifically, first, when a film such as an acrylic resin film or a PET film or a laminate was completely unwound, the first filling part was attached to the laminate side, and some of them were peeled off from the core. Then, one or more samples having a size of 2 mm x 5 mm including the first filling part were cut out from the laminate. The samples were cut out from any location including the tip of the first filling part and not having dirt, fingerprints, etc. attached thereto. Then, the edge thickness T1 of the first filling part was measured under the following measurement conditions. The edge thickness T1 was obtained by measuring the edge thickness at 10 points and calculating the arithmetic average value of the thicknesses at 8 points excluding the maximum and minimum values ​​among the thicknesses at the 10 measured points. (Measurement conditions) Objective lens: 10x ·Zoom: 1x ·Measurement area: 2.17mm x 2.17mm Scan Length: 5μm min mod:0.015 ·Temperature: 23℃ Relative humidity: 50%

[0334] <Deformation relaxation length measurement> In the roll bodies according to the examples and the comparative examples, the length at which the step caused by the winding start end of the film or laminate, such as an acrylic resin film or a PET film, and the step caused by the double-sided tape were alleviated was measured. Specifically, since the step becomes smaller from the winding start end to the winding end, the film or laminate was first unwound while measuring the unwound length (m) until the step was visible. Then, the film or laminate was cut out at the point where the step was visible. In a state where a polyvinyl alcohol film was attached to the cut-out part of the film or laminate, visual observation was performed by reflecting light with a white LED lamp reflected on the film or laminate in an indoor environment of 800 Lux to 2000 Lux. Then, the distance from the point where the step was no longer visible to the winding start end was measured, and this was taken as the deformation relaxation length. Here, a step was judged to exist when the outline of the white LED light reflected on the film or laminate was distorted compared to other parts of the film or laminate, and a step was judged not to exist when the outline of the white LED light reflected around the step was judged to be the same as other parts of the film or laminate. The white LED light was arranged so that the longitudinal direction of the white LED light was along the longitudinal direction of the film or laminate. The length of the white LED light was set to the length that spanned the part of the film or laminate where the step existed and the part where the step did not exist. During observation, the side where the line of the white LED light was clearly visible was appropriately selected, and the white LED light was reflected on the film or laminate so that the outline line was visible. In addition, visual observation was performed from all angles (-180° to 180°) with the normal direction of the surface of the film or laminate as the reference (0°).

[0335] <Confirmation of the presence of the fourth intervening part> In Examples 3 and 7 to 16, it was confirmed whether or not a fourth intervening portion exists on the starting end portion. Specifically, first, the laminate was unwound from the roll body until the surface became the laminate of the second round. Then, in the roll body where the laminate of the second round became the surface, the vicinity of the starting end portion was visually observed to check whether there is a colored portion on the starting end portion. And when there is a colored portion on the starting end portion, it was determined that the fourth intervening portion exists, and when there is no colored portion, it was determined that the fourth intervening portion does not exist. Fifteen observers were used, and when all the observers determined that there is a colored portion on the starting end portion, it was judged that the fourth intervening portion exists.

[0336] <Measurement of the slopes of L1, L1 + L2, T2, S1, S1 + S2, and IL3> In the roll body according to Examples 3 and 7 to 16, when the existence of the fourth intervening portion was not confirmed, the length L1, the thickness T2, and the area S1 were measured, and L1 / thickness T2 and area S1 / thickness T2 were obtained. When the existence of the fourth intervening portion was confirmed, the length L1 + length L2, the thicknesses T1 and T2, and the areas S1 + S2 were measured, and (length L1 + length L2) / thickness T2 and (area S1 + area S2) / thickness T2 were obtained. Note that the lengths L1 and L2, the thickness T2, and the areas S1 and S2 mean the portions shown in FIGS. 4 to 8.

[0337] Specifically, first, a jig for rotating the roll body and a laser displacement meter (product name "LK-G30", manufactured by Keyence Corporation) were prepared and arranged at predetermined positions. The jig was inserted into the holes in the width direction of the core and held the roll body rotatably.

[0338] The laser displacement gauges were positioned above the roll body, and three were arranged so that the laser light was irradiated toward the surface of the roll body. The locations of the laser displacement gauges were as follows. First, a first position and a second position were determined to divide the width of the laminate into thirds. The first position was located on the first end side of the short side of the laminate, and the second position was located on the second end side opposite to the first position. The first laser displacement gauge was arranged so that the laser light was irradiated to the midpoint between the first position and the first end, the second laser displacement gauge was arranged so that the laser light was irradiated to the midpoint between the first position and the second position, and the third laser displacement gauge was arranged so that the laser light was irradiated to the midpoint between the second position and the second end.

[0339] Then, the roll body was attached to a jig, and the acrylic resin film was unwound until the first filling part was exposed from the roll body. After that, in a state in which the first filling part was exposed, the core was rotated at a rotation speed of 30 mm / s in an environment of 23°C temperature and 50% relative humidity, and the displacement was continuously measured with a laser displacement meter at a sampling period of 200 μs to obtain a graph (see FIG. 40(A) to FIG. 40(C)) with the horizontal axis representing the position (mm) and the vertical axis representing the displacement (mm). This measurement was performed from the tip of the first filling part to the position contacting the tip surface, and in this measurement, the reference height (0 mm displacement line) was defined as the height of the core, and the difference in height between the core and the first filling part was defined as the thickness of the first filling part. The obtained graph represents a plane that substantially includes the longitudinal direction of the sheet and the radial direction of the core. In addition, in this graph, one division on the horizontal axis is 5 mm, and one division on the vertical axis is 0.02 mm.

[0340] In this graph, the position on the position displacement curve where the amount of displacement begins to drop rapidly was designated as position E1. When the presence of the fourth intermediate portion was not confirmed, the thickness T2 of the first filling portion at the position in contact with the tip surface was calculated by calculating the difference in the amount of displacement between the 0 mm displacement line and position E1.

[0341] When the presence of the fourth intervening portion was confirmed, the thickness T2 was measured by the following method. First, a sample of 2 cm x 2 cm including the winding start end 12A, the first filling portion 14, and the second round of the sheet 12 was taken and fixed so that the portion including this portion would not be crushed. Then, the cross section of the fixed sample was polished, and the thickness T2 of the first filling portion was measured with a stereomicroscope (product name "Digital Microscope VHX-7000", manufactured by Keyence Corporation) in an environment of a temperature of 23°C and a relative humidity of 50%. The measurement of the thickness T2 with the stereomicroscope was performed with a coaxial epi-illumination as the illumination of the digital microscope, at a magnification of 500 times, in a dark field and with reflected light.

[0342] In addition, when the presence of the fourth intermediate portion was not confirmed, the length L1 was obtained from the graph of the position-displacement curve in the same manner as the thickness T2. Specifically, first, the position E1 and the intersection of the 0 mm displacement line and the position-displacement curve at the point where the displacement starts to increase were determined as position E2 from the graph. Next, an imaginary line IL4 was drawn that passes through the position E1 and is perpendicular to the 0 mm displacement line. Then, the intersection of the imaginary line IL4 and the 0 mm displacement line was determined as position E3, and the length L1 was obtained by obtaining the distance between positions E2 and E3. The area S1 was calculated by calculating the product of the thickness at each measurement point and the width between each measurement point in the region from position E2 to position E3, and summing them up. The width between the measurement points was calculated based on the above formula (3) from the sampling period, the rotation speed of the winding core, and the outer diameter of the winding core, and was 6.24 μm. When the presence of the fourth intermediate portion was confirmed, length L1+length L2 was obtained in the same manner as length L1 when the presence of the fourth intermediate portion was not confirmed.

[0343] When the presence of the fourth intermediate portion was not confirmed, the length L1 / thickness T2 and area S1 / thickness T2 were calculated using the length L1, thickness T2, and area S1. When the presence of the fourth intermediate portion was confirmed, the sum of the length L1 and length L2, the thickness T2, and the sum of the area S1 and area S2 were used to calculate (length L1+length L2) / thickness T2 and (area S1+area S2) / thickness T2.

[0344] Further, in the above graph, a virtual line IL3 (see FIGS. 40(A) to 40(C)) passing through position E1 and position E2 was drawn, and the slope of this virtual line IL3 was obtained.

[0345] <Measurement of L4, T6, and S3> In the roll bodies according to Examples 13 to 16, the length L4, the maximum thickness T6, and the cross-sectional area S3 were measured, and L4 / maximum thickness T6 and cross-sectional area S3 / maximum thickness T6 were obtained. Note that the length L4 and the maximum thickness T6 mean the portions shown in FIG. 27, and the cross-sectional area S3 means the portion shown in FIG. 29. The length L4, the maximum thickness T6, and the cross-sectional area S3 were measured using a jig for rotating the roll body and a laser displacement meter (product name: "LK-G30", manufactured by Keyence Corporation). Specifically, first, in the same manner as the measurement of the length L1 and the like, the roll body was attached to the jig and three laser displacement meters were arranged at predetermined positions, and then the laminate was fed out until the second intervening portion was exposed from the roll body. Thereafter, in a state where the second intervening portion was exposed, while rotating the core at a rotation speed of 30 mm / s under an environment of a temperature of 23°C and a relative humidity of 50%, the displacement amount was continuously measured by the laser displacement meter at a sampling period of 200 μs, and a graph was obtained with the horizontal axis being the position (mm) and the vertical axis being the displacement amount (mm). This measurement was performed from the second tip on the opposite side of the first tip on the double-sided tape side of the second intervening portion toward the first tip. In this measurement, the reference height (displacement amount 0 mm line) was set as the height of the core, and the difference in height between the core and the second intervening portion was set as the thickness of the second intervening portion. The obtained graph represents a plane substantially including the longitudinal direction of the sheet and the radial direction of the core. Also, in this graph, one scale on the horizontal axis was 5 mm and one scale on the vertical axis was 0.02 mm.

[0346] In this graph, the position where the displacement amount was the highest was found, and the maximum thickness T6 in the second intervening portion was obtained by finding the difference between the displacement amount 0 mm line and the displacement amount at this position.

[0347] Also, from this graph, the first position was found, which was the intersection of the 0 mm displacement line and the position displacement curve at the point where the displacement started to increase. Next, an imaginary line was drawn that passed through the position where the displacement was the highest and was perpendicular to the 0 mm displacement line. Then, the intersection of this imaginary line and the 0 mm displacement line was set as the second position, and the length L4 was calculated by calculating the distance between the first position and the second position. The cross-sectional area S3 was calculated by calculating the product of the thickness at each measurement point and the width between each measurement point in the region from the first position to the second position, and then adding them up. The width between the measurement points was calculated based on the above formula (3) from the sampling period, the rotation speed of the winding core, and the outer diameter of the winding core, and was 6.24 μm.

[0348] In addition, the length L4 / maximum thickness T6 and cross-sectional area S3 / maximum thickness T6 were calculated using the length L4, maximum thickness T6, and cross-sectional area S3 / maximum thickness T6.

[0349] The results are shown in Tables 1 to 3 below. [Table 1]

[0350] [Table 2]

[0351] [Table 3]

[0352] The roll body according to Comparative Example 1 had a long deformation relaxation length at the winding start end and a long deformation relaxation length in the double-sided tape. This is believed to be because the first gap was hollow, so the step caused by the winding start end of the acrylic resin film was large, and the second gap was hollow, so the step caused by the double-sided tape was large. In contrast, the roll bodies according to Examples 1 to 12 had shorter deformation relaxation lengths at the winding start end and in the double-sided tape than the roll body according to Comparative Example 1. This is believed to be because the roll bodies according to Examples 1 to 5 and 7 to 15 had a small step caused by the winding start end of the acrylic resin film because the first filling part was filled in the first gap, and a small step caused by the double-sided tape because the second filling part was filled in the second gap or the second interposed part was interposed in the area corresponding to the second gap. In addition, in Example 6, since the first intermediate portion was interposed in the first region corresponding to the first gap, the step caused by the starting end of the winding of the PET film was small, and since the second intermediate portion was interposed in the second region corresponding to the second gap, the step caused by the double-sided tape was small.

[0353] The first filling portion of the roll bodies of Examples 3 and 8 to 16 had length L1 / thickness T2 or (length L1 + length L2) / thickness T2 of 90 or more, and / or area S1 / thickness T2 or (area S1 + area S2) / thickness T2 of 3.0 or more, so the deformation relaxation length at the winding start end was shorter than that of the roll body of Example 7, in which length L1 / thickness T2 was less than 90.

[0354] In the second intermediate portion of the roll bodies in Examples 13 to 16, the length L4 / maximum thickness T6 was 12 or more and / or the cross-sectional area S3 / maximum thickness T6 was 2.5 or more, so the deformation relaxation length of the double-sided tape was short.

[0355] In the rolls of Examples 1, 2, 6, and 13, the shear viscosity of the silicone resin composition or silicone rubber composition when applied was 60 Pa·s or more, so no overflow of the composition from between the winding core and the acrylic resin film or PET film was observed when pressure was applied during application or winding. In the rolls of Examples 3, 4, and 7 to 10, the shear viscosity of the composition when applied was less than 60 Pa·s but was 15 Pa·s or more, so no overflow occurred during application, but overflow of the composition was observed when pressure was applied during winding. In Examples 5, 11, 12, and 14 to 16, the shear viscosity of the composition when applied was less than 15 Pa·s, so overflow of the composition from between the winding core and the acrylic resin film was observed.

[0356] In addition, a reworkability test was performed on the roll body according to Example 3. Specifically, first, the acrylic resin film was unwound to expose the first filling part. Then, an edge was used to create an opening at the end of the first filling part so as not to damage the winding core, and the first filling part was slowly peeled off from the winding core with fingers. The evaluation criteria for reworkability were that the first filling part was good when it was peeled off cleanly, and that the first filling part was poor when a part of it remained on the winding core due to breakage or the like. In such an evaluation, the first filling part of the roll body according to Example 3 was good because it was peeled off cleanly. In addition, when a reworkability test was performed on roll bodies according to Examples other than Example 3, the reworkability was as good as that of the first filling part according to Example 3. The tensile strength of the material of the first filling part in the roll body according to the examples other than Example 3 was 3.0 MPa or more and 5.5 MPa or less, the elongation at break was 250% or more and 600% or less, the tear strength was 6 N / mm or more and 25 N / mm or less, the hardness of the material of the first filling part measured with a durometer type A was 10° or more and 50° or less, and the linear shrinkage rate of the material of the first filling part was in the range of 0% or more and 1.0% or less. In addition, as shown in Table 1, the edge thickness T1 of the first filling part of the roll body according to Examples 1 to 16 was in the range of 1.5 μm or more and 20 μm or less. When peeling off the first filling part or cleaning or wiping it off, the thicker the edge thickness T1, the easier it was to peel off or remove the first filling part, although slightly.

[0357] In Examples 1 to 12, the silicone resin composition or the silicone rubber composition was applied so as to contact the first end surface and the second end surface of the double-sided tape, but in Examples 1 to 12, when the silicone resin composition or the silicone rubber composition was applied or the double-sided tape was arranged so that the distance between the silicone resin composition or the silicone rubber composition and the double-sided tape was 1 mm, a roll body could be stably manufactured, and the obtained roll body was approximately the same as the above evaluation results and measurement results of the roll body of Examples 1 to 12. Similarly, in Examples 1 to 12, when the silicone resin composition or the silicone rubber composition was applied or the double-sided tape was arranged so that the distance between the silicone resin composition or the silicone rubber composition and the double-sided tape was 3 mm, a roll body could be stably manufactured, and the obtained roll body was approximately the same as the above evaluation results and measurement results of the roll body of Examples 1 to 12. In these cases, the silicone resin composition etc. was first applied linearly along the width direction of the core, then the double-sided tape was positioned so that the distance between the second end face of the double-sided tape and the silicone resin composition etc. was 1 mm or 3 mm, and further the silicone resin composition etc. was applied linearly along the width direction of the core so that the distance between the first end face of the double-sided tape and the silicone resin composition etc. was 1 mm or 3 mm.

[0358] Furthermore, in Example 2, when the silicone rubber composition was applied and the double-sided tape was arranged so that the distance between the silicone rubber and the double-sided tape was 5 mm, a roll body could be stably manufactured, and the obtained roll body was almost the same as the above evaluation results and measurement results of the roll body according to Example 2. The edge thickness T1 was 2 μm. In this case, the silicone rubber composition was first applied linearly along the width direction of the core, then the double-sided tape was arranged so that the distance between the second end face of the double-sided tape and the silicone rubber composition was 5 mm, and the silicone rubber composition was further applied linearly along the width direction of the core so that the distance between the first end face of the double-sided tape and the silicone rubber composition was 5 mm.

[0359] In Example 3, a silicone rubber composition with a shear viscosity of 40 Pa·s was used when applied, but when the shear viscosity when applied was set to 7 Pa·s and the distance between the double-sided tape and the silicone rubber composition was set to 11 mm, the silicone rubber composition located on the first end face side of the double-sided tape flowed to the opposite side to the double-sided tape. Similarly, when the shear viscosity was set to 250 Pa·s and the silicone rubber composition was placed so as to contact the first and second end faces of the double-sided tape, it was difficult to cause the composition to flow sufficiently even when the acrylic resin film was wound around it, and after curing, another step, although slight, appeared at the beginning of the winding. [Explanation of symbols]

[0360] 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150...Roll body 11...Core 11A…Outer surface 12…Sheet 12A…Start of winding end 12A1…Tip surface 12D…First area 12E…Second area 12F…Third area 12G...end 12H…Convex 13…First gap 14…First filling section 15, 52…Second gap 16, 53…Second filling section 17, 51…Fixing members 17A, 51A...1st end surface 17B, ​​51B…Second end surface 21, 54…Third gap 22, 55…Third filling section 71...First intervening part 72…Second intervening part 73...Intermediate roll body 81...Third intervening part 201~207…Coating materials

Claims

1. A method for manufacturing a roll body including a core and a long sheet wound around an outer peripheral surface of the core, comprising: A step of placing a winding start end of the sheet in a longitudinal direction on the outer circumferential surface; a step of winding the sheet around the core at least one turn to obtain an intermediate roll body having a first gap; applying a coating material to a surface of the sheet constituting the outer peripheral surface of the intermediate roll body along a width direction of the core; and after applying the coating material, rewinding the sheet around the core to interpose the coating material between the sheets. the first gap is a gap located between the winding core and the first turn of the sheet and in contact with a tip end surface located in the longitudinal direction at the winding start end, the coating material is applied to a first region on the surface of the sheet that constitutes the outer circumferential surface of the intermediate roll body, the first region corresponding to the first gap.

2. A method for manufacturing a roll body including a core and a long sheet wound around an outer peripheral surface of the core, comprising: a step of disposing a fixing member on the outer peripheral surface of the winding core along a width direction of the winding core, the fixing member having a first end surface extending in the width direction of the winding core and a second end surface opposite to the first end surface, for fixing a portion of the sheet to the winding core; fixing a portion of the sheet to the core via the fixing member; winding the sheet around the core at least one turn to obtain an intermediate roll body having a second gap and a third gap; applying a coating material to a surface of the sheet constituting an outer circumferential surface of the intermediate roll body along the width direction of the core; and rewinding the sheet around the core after applying the coating material. the second gap is a gap located between the core and the first turn of the sheet and in contact with the first end surface of the fixing member, the third gap is a gap located between the core and the first turn of the sheet and in contact with the second end surface of the fixing member, the coating material is applied to at least one of a second region corresponding to the second gap and a third region corresponding to the third gap on the surface of the sheet constituting the outer circumferential surface of the intermediate roll body.

3. The method according to claim 1 or 2, wherein the coating material has flowability.

4. The method according to claim 1 , wherein the coating material is a curable polymer composition.

5. The method according to claim 1 , wherein the coating material contains a coloring material or a luminescent material.

6. The method according to claim 1 , wherein the sheet comprises a resin film.

7. The method according to claim 1 , wherein the sheet contains an acrylic resin, a polyester resin, or a cycloolefin polymer resin.

8. The method according to claim 6 or 7, wherein the sheet has a thickness of 15 μm or more and 300 μm or less.

9. The method according to claim 1 , wherein the sheet is a laminate having a substrate and one or more functional layers laminated on the substrate.

10. The method according to claim 1 , wherein the sheet is used for an optical film, a polarizing plate, or a display device.

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