Roll Laminate Core Conformability and Tunneling Prevention
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Solution Overview
Problem
Tunneling occurs in rolls with a laminate structure due to poor conformability between the core and the laminate, which expands or shrinks with environmental temperature and humidity changes, leading to delamination and undesirable surface marks on the adhesive layer.
Innovation Solution
A roll configuration featuring a tubular core made from acrylonitrile-butadiene-styrene copolymer resin (ABS) or polypropylene (PP) with a laminate structure comprising a process film, a surface coat layer formed from fluorine resin, a substrate layer, and a release liner, where the process film is made from polyethylene terephthalate (PET), polyolefins, or polyvinyl chloride (PVC), enhancing conformability and preventing tunneling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a process film is disposed on the surface coat layer to prevent surface irregularities and blocking, then the formation of surface irregularities and blocking is prevented, but the conformability between the laminate and the core deteriorates, causing tunneling
Solution Approach 1:
A release film is introduced as an intermediary layer between the process film and the core. This release film has specific material properties (formed from rubber resin, polyurethane resin, or polyethylene resin) that enable it to conform to the core's shape while the process film maintains surface smoothness. The release film acts as a mediator that transmits conforming forces without transmitting blocking forces, thus resolving the contradiction between surface quality and conformability.
Solution Approach 2:
The invention changes the material parameters of the layer adjacent to the core by specifying that it be formed from rubber resin, polyurethane resin, or polyethylene resin. These materials have specific elasticity and conformability parameters that allow the laminate to adapt to environmental temperature and humidity changes. By adjusting the material parameters rather than removing the process film, both surface smoothness and conformability are maintained.
2Reliability
If the laminate structure includes multiple layers (process film, surface coat layer, substrate layer) to improve functionality, then stain resistance and surface quality are improved, but the conformability between the laminate and core deteriorates, leading to tunneling
Solution Approach 1:
Different layers of the laminate are assigned different material qualities and functions. The process film provides surface smoothness and stain resistance, while the release film (adjacent to the core) provides conformability. The substrate layer provides structural support. By localizing the conformability function to the release film layer and the protective function to the process film layer, the contradiction between functionality and conformability is resolved through spatial differentiation of material properties.
Solution Approach 2:
The laminate is constructed as a composite structure with multiple layers having different material properties. The combination of process film (for surface quality), release film (for conformability), and substrate layer (for strength) creates a composite material system that exhibits both stain resistance and conformability. The synergistic effect of these different materials resolves the technical contradiction by distributing functions across layers.
3Adaptability or versatility
If the core and laminate are allowed to expand and shrink with environmental changes, then adaptability to environmental conditions is improved, but conformability deteriorates due to differential expansion, causing tunneling
Solution Approach 1:
The invention explicitly addresses thermal expansion by selecting materials for the release film (rubber resin, polyurethane resin, or polyethylene resin) that have appropriate expansion coefficients. These materials are chosen to match or complement the expansion characteristics of the core, allowing both to expand and shrink together with environmental temperature changes. This proactive design for thermal expansion prevents differential expansion that would cause tunneling, thus maintaining conformability while achieving environmental adaptability.
Data Source
AI summary
A roll and a method for producing a roll which are capable of effectively preventing tunneling are provided. A roll includes a core having a tubular shape and a laminate wound around the core. The laminate includes a process film, a surface coat layer, a substrate layer, an adhesive layer, and a release liner, in this order, in a laminating direction. The process film is formed from at least one member selected from polyethylene terephthalate (PET), polyolefins, and polyvinyl chloride (PVC). The surface coat layer is formed from a fluorine resin. The release liner is formed from polyethylene terephthalate (PET). The core is formed from an acrylonitrile-butadiene-styrene copolymer resin (ABS) or polypropylene (PP).