Reel member, and adhesive film wound body

Abstract

Provided is a reel member which can be wound at an optimum winding core diameter even when adhesive films having different lengths are wound thereon.　A reel member comprises: a circular winding core 3; a disk-like core ring 6 that is detachably fitted to the outer circumference of the winding core 3 and that has a fitting hole 6a to which the winding core 3 fits; and a pair of reel flanges 4A, 4B provided on both sides of the winding core 3. An engagement recess 8 is provided to the outer circumferential surface of the winding core 3. An engagement projection 9 that is to be engaged with the engagement recess 8 is provided on the inner circumferential surface of the fitting hole 6a. By engaging the engagement recess 8 with the engagement projection 9, the core ring 6 is engaged with the winding core and rotation of the core ring 6 becomes restricted.

Description

Reel member, Adhesive film wound body

[0001] This technology relates to a reel member around which a tape-shaped adhesive film is wound, and an adhesive film wound body in which a tape-shaped adhesive film is wound around the reel member. This application claims priority based on Japanese Patent Application No. 2024 - 159612, which was filed in Japan on September 13, 2024, and this application is incorporated herein by reference.

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

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

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

[0005] Japanese Patent Application Laid-Open No. 2021 - 80098

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

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

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

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

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

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

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

[0013] The reel components and adhesive film winding bodies to which this technology is applied will be described in detail below with reference to the drawings. It should be noted that this technology is not limited to the embodiments described below, and various modifications are possible within the scope of the gist of this technology. Furthermore, the drawings are schematic, and the proportions of dimensions may differ from those of reality. Specific dimensions should be determined by referring to the following explanation. It should also be noted that there may be differences in the relationships and proportions of dimensions between different drawings.

[0014] [Reel Member] Figures 1 to 3 show a reel member 1 to which this technology is applied. Figure 1 is a front view showing one embodiment of the reel member 1, Figure 2 is a cross-sectional view of the reel member 1, and Figure 3 is an exploded perspective view of the reel member 1. The reel member 1 comprises a winding core 3 on which a tape-shaped adhesive film 2 is wound, a coring 6 fitted to the outer circumference of the winding core 3, and a pair of reel flanges 4A and 4B provided on both sides of the winding core 3.

[0015] The reel member 1 shown in Figure 1 comprises a molded product 5 in which one reel flange 4A and a winding core 3 are integrally molded, a coring 6, and the other reel flange 4B. The coring 6 is fitted to the reel flange 4A side of the molded product 5, as shown by arrow D in Figure 3, and then the reel flange 4B is welded to the winding core 3. As will be described later, the manufacturing method of the reel member 1 is not limited to this.

[0016] [Core] As shown in Figure 4, the core 3 is circular in plan view and consists of an annular wall erected on the surface of one of the reel flanges 4A. The core 3 is also formed to be slightly larger in height than the width of the adhesive film 2, which will be described later. The fitting hole 6a of the coring 6, which will be described later, is fitted into the core 3. This provides a reel member 1 having an optimal core diameter according to the winding length of the adhesive film 2.

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

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

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

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

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

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

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

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

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

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

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

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

[0029] The material of the coring 6 can be, for example, a thermoplastic resin. Here, examples of thermoplastic resins include general-purpose resins, general-purpose engineering plastics, and super engineering plastics. The thermoplastic resin may be crystalline or amorphous. Examples of general-purpose resins include polyethylene, polypropylene, and polystyrene. Examples of general-purpose engineering plastics include polycarbonate and polyamide. Examples of super engineering plastics include polyimide and polyamideimide. From the viewpoint of obtaining dimensional accuracy with good reproducibility, amorphous resins are preferred. Also, from the viewpoint of economy, it is preferable to use general-purpose resins.

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

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

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

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

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

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

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

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

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

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

[0040] As shown in Figure 11, it is preferable that a space is formed in the circumferential direction of the coring 6 between the engaging recess 8 and the engaging projection 9. This allows the engaging projection 9 to strike the side wall of the engaging recess 8 when a circumferential force is applied to the coring 6, such as when the adhesive film 2 is pulled out. The impact or vibration of this contact by the engaging projection 9 is transmitted to the hand of the worker who is gripping and pulling out the adhesive film 2. This allows the worker to sense the tension applied to the winding film 7 when the adhesive film 2 is pulled out and to adjust the tension for pulling out the adhesive film 2.

[0041] In other words, in order to attach the adhesive film 2 to a conveying device, the adhesive film 2 is pulled out from the reel member 1 and routed to the conveying device. If the adhesive film 2 is pulled out with too much force at this time, the winding force will be stronger near the center of the wound film 7 that is wound around the coring 6, which may cause problems such as adhesive overflow and blocking.

[0042] In the reel member 1, a space is formed in the circumferential direction of the core ring 6 between the engaging convex portion 9 of the core ring 6 and the engaging concave portion 8 of the core 3. Therefore, according to the force applied to pull out the adhesive film 2, the impact that the engaging convex portion 9 hits against the side wall of the engaging concave portion 8 changes. Thereby, an operator can sense the tension applied to the wound film 7 when pulling out the adhesive film 2, and can adjust the tension for pulling out the adhesive film 2. Therefore, the reel member 1 can prevent problems such as the protrusion of the adhesive and the blocking caused thereby over the entire area of the wound film 7.

[0043] Generally, in order to wind a long adhesive film 2 having a length exceeding 200 m inside the outer diameters of the reel flanges 4A and 4B, the outer diameter of the core ring 6 is also reduced. As the adhesive film 2 becomes longer and the core ring 6 around which the adhesive film 2 is wound becomes smaller in diameter, the load due to winding becomes larger near the center near the core ring 6, and when excessive tension is applied when pulling out the adhesive film 2, there is a risk of inducing problems such as the protrusion of the adhesive layer, blocking in which the protruding adhesive layer unintentionally adheres to the reel flange and inhibits unwinding, and dropping in which the pulled-out adhesive film 2 detaches from the wound film 7 etc.

[0044] In this regard, according to the present technology, in the reel member 1, the tension adjustment when pulling out the adhesive film 2 due to the formation of a space in the circumferential direction of the core ring 6 between the engaging convex portion 9 of the core ring 6 and the engaging concave portion 8 of the core 3 acts more effectively. In addition, even when changes in temperature and humidity, vibration, and impact are applied during the transportation of the adhesive film wound body 10 using the reel member 1, the tension applied to the wound film 7 can be absorbed by the space, and protrusion etc. can be prevented.

[0045] The maximum width in the circumferential direction of the inner peripheral surface of the core ring 6 of the engaging convex portion 9 is not particularly limited, but it is preferably 0.05 mm or more and 0.5 mm or less, and more preferably about 0.2 mm.

[0046] As shown in Fig. 11, a circumferential space on the inner circumferential surface of the core ring 6 between the engaging recess 8 and the engaging projection 9 is defined as a space S1. The space S1 refers to the difference (S1: W1 - W2) between the opening width W1 of the engaging recess 8 in the circumferential direction of the core 3 and the base width W2 of the engaging projection 9 in the circumferential direction of the inner circumferential surface of the core ring 6. The upper limit of this space S1 is not particularly limited, but it is preferably 300 μm or less, and more preferably 250 μm or less. Also, the lower limit of the space S1 is not particularly limited, but it is preferably 50 μm or more, and more preferably 150 μm or more. It is particularly preferable that the space S1 is in the range of 200 μm ± 30 μm. This space S1 defines the magnitude of the impact when the engaging projection 9 hits the side wall of the engaging recess 8, and also defines the allowable amount of tension adjustment for the wound film 7 even when changes in temperature and humidity, vibration, and impact are applied during transportation of the adhesive film wound body 10.

[0047] A space between the engaging recess 8 and the engaging projection 9 in the state where the engaging recess 8 and the engaging projection 9 are engaged is defined as a space S2. The upper limit of this space S2 is not particularly limited, but it is preferably 70 μm or less, and more preferably 60 μm or less. Also, the lower limit of the space S2 is not particularly limited, but it is preferably 20 μm or more, and more preferably 40 μm or more. It is particularly preferable that the space S2 is 50 μm. This space S2 defines the engaging force between the engaging recess 8 and the engaging projection 9, and together with the space S1, defines the allowable amount of tension adjustment for the wound film 7.

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

[0049] The engaging recess 8 is preferably formed on the extension line of the portion where the reinforcing rib 14 of the core tube 3 is provided. The portion where the reinforcing rib 14 of the core tube 3 is provided has high strength, and no problems such as insufficient strength occur even when the engaging recess 8 is provided.

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

[0051] Furthermore, the engagement points between the engagement recess 8 and the engagement projection 9 are not limited to two or three locations, but may be four or more. In addition, the engagement points may be provided at equal intervals to allow the core 3 to be fitted regardless of the fitting surface of the coring 6, thereby improving workability and productivity.

[0052] [Reel Flanges] A pair of reel flanges 4A and 4B support the wound film 7, in which the adhesive film 2 is wound multiple times around the core ring 6, and are formed in a disc shape using, for example, a plastic material. Furthermore, it is preferable that the reel flange 4 is transparent enough so that the flange ribs 20, which will be described later, can be seen from the outside. In addition, the surface of the reel flange 4 that contacts the wound film 7 may be subjected to electrostatic treatment. A method of performing electrostatic treatment is, for example, to apply a compound such as polythiophene. The diameter of the reel flange 4 can be appropriately designed according to the diameter of the winding core 3 and the length of the adhesive film 2, and there are no particular restrictions, but as an example it can be 90 to 300 mm, preferably 120 to 250 mm, and more preferably 180 to 200 mm.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Claims

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

2. The reel member according to claim 1, wherein at least one of the pair of reel flanges is joined to the winding core, and a welding rib for joining with the reel flange is provided on the joining surface of the winding core to the reel flange.

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

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

5. The reel member according to claim 4, wherein three engagement portions are provided, a pair of engagement portions are provided at positions 180° apart from each other, and one engagement portion other than the pair of engagement portions is formed at a position not equally spaced from each of the pair of engagement portions.

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

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

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

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

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

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

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

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

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

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