Patent Application
20130327869
The present invention relates to a method for manufacturing a roll which is a long element such as adhesive tape rolled up, and relates to such a roll.
In some cases, a roll having a predetermined width is made through a manufacturing method in which a wide sheet is rolled up on a winding unit, and then cut at every predetermined width by using a cutter. However, in this manufacturing method, the thickness of the cutter and the angle of the blade edge are easily variable, and for this reason, dimensional error relative to the width direction easily becomes large at the center side of the roll where the blade edge is deeply inserted. In view of this problem, in some cases, there is adopted a manufacturing method in which a wide sheet is cut before it is rolled up on the winding unit, thereby forming long elements having a predetermined width, and then winding these long elements on the winding unit while restricting the position in the width direction.
More specifically, PTL 1 discloses the following manufacturing method. Namely, an edge regulating roller is prepared which has a pair of flanges at both ends of the roller relative to the width direction. The flanges are tilted outwardly so that the distance between the flanges increases towards outside. This edge regulating roller is rotatably disposed at a reaching position of each long element to the roll. The long element is then rolled up while its positions relative to the width direction is regulated by having its ends relative to the width direction abut the flanges of the edge regulating roller.
Further, PTL 2 discloses the following manufacturing method. Namely, a guide block is prepared which has a pair of flanges at both ends of the guide block relative to the width direction. The flanges are tilted from the both ends by 0 to 20 degrees. This guide block is fixed to a reaching position of each long element to the roll. The long element is then rolled up while regulating its position relative to the width direction by having its ends abut the flanges of the guide block.
However, in the above traditional structure in which the flanges of the edge regulating roller or those of the guide block are tilted towards outside from the both ends relative to the width direction, the distance between the flanges increases from the base side towards the leading end side. For this reason, to prevent deterioration in the accuracy of positional regulation of the long element relative to the width direction, the base parts of the flanges on the edge regulating roller or those of the guide block need to be approximated to the roll surface to the extent that the base parts of the flanges contact the roll surface. When the long element has an adhesive agent, the adhesive agent oozing out from the long element may adhere to the flanges. This oozing-out adhesive agent causes an unstable braking force, between the roll and the flanges, consequently making the tension of the long element in process of being rolled up unstable; i.e., causes excessive tension or insufficient tension. This unstable tension may serve as a cause of significant variation in the width of the long element, leading to significant irregularity in the roll of the long element in the width direction.
Particularly, in PTL 2 where the guide block is fixed, a part where the adhesive agent has adhered causes adhesion of more adhesive agent, accumulating a large amount of adhesive agent in a short period of time. This leads to a significant amount of irregularity in the roll of the long element, relative to the width direction. Further, in cases of winding a narrow long element on a roll of a large roll diameter, the accuracy of the position regulation of the long element is easily deteriorated, increasing the swinging range of the roll surface. To add this, width of the long element is easily affected by the tension. As the result, irregularity in the roll of long element becomes significant.
In view of the above problem, the present invention is made, and it is an object of the present invention to provide a method of manufacturing a roll, in which amount of irregularity in the roll of a long element is sufficiently reduced, even in cases of winding a narrow long element having an adhesive agent on a roll having a large diameter.
An aspect of the present invention is a method of manufacturing a roll in which a long element having an adhesive agent and a predetermined width is wound by a winding unit so that the long element forms a plurality of wound layers in a radial direction from the winding unit to a roll surface, the method including: arranging, in a position distant from the roll surface, an alignment groove having a pair of groove side surfaces configured to contact both ends of the long element relative to the width direction; causing each of the pair of groove side surfaces to be on the same plane as the corresponding one of a pair of wound end surfaces formed by both ends of the wound layers relative to the width direction; and placing the long element on the alignment groove and winding the long element on the roll.
In the above structure, when the long element is wound by the winding unit, the alignment groove is positioned so that each of the pair of groove side surfaces is on the same plane as the corresponding one of the pair of wound end surfaces formed by both ends of the wound layers relative to the width direction. Since the forwarding direction of the long element from the alignment groove to the roll surface matches with the winding direction of the roll, winding is carried out while the long element is positioned relative to the width direction by the alignment groove. At this time, even when the adhesive agent on the long element adheres to the alignment groove, the adhesive agent having adhered does not generate a braking force between the alignment groove and the roll surface, because the alignment groove is in a position distant from the roll surface.
This way, from the beginning to the end of winding the long element, the long element is wound with a stable tension while being positioned relative to the width direction. Therefore, the amount of irregularity in the layers of the long element is sufficiently reduced, even in cases of winding a narrow long element having an adhesive agent on a roll having a large diameter.
The aspect of the present invention may be adapted so that the alignment groove has a groove depth greater than the thickness of the long element.
The above structure in which the groove depth is greater than the thickness of the long element causes the both ends of the long element relative to the width direction, having departed from the alignment groove to contact the groove side surfaces of the alignment groove longer than a case where the groove depth is smaller. Therefore, the groove side surfaces in contact with the both ends of the long element relative to the width direction improve the positional regulation of the long element relative to the width direction. It is therefore possible to further sufficiently reduce the irregularity in the layers of long element.
The aspect of the present invention may be adapted so that the winding is carried out while the alignment groove is moved in a forwarding direction of the long element.
In the structure, the adhesive agent is less likely collected, as compared with a case where the adhesive agent is accumulated in a position where adhesion of the adhesive agent has occurred, because even when the adhesive agent adheres to the alignment groove, the adhesive agent having adhered moves in the forwarding direction of the long element, along with the alignment groove. Since a rapid increase in the amount of adhesive agent on the alignment groove is prevented, it is possible to reduce variation in the tension of the long element caused by the adhesive agent staying in the alignment groove generating a braking force to forwarding of the long element. As the result, the width of the long element is stabilized from the beginning to the end of winding. Therefore, the amount of irregularity in the layers of the long element is made sufficiently small, even in cases of winding a narrow long element having an adhesive agent on a roll having a large diameter.
The aspect of the present invention may be adapted so that the alignment roller having the alignment groove around its circumference is rotated about the axis of the alignment roller, thereby moving the alignment groove in the forwarding direction of the long element.
The above structure enables adjustment of the relative position relation and the speed difference between the groove side surfaces of the alignment groove and the long element, by raising or reducing the rotation speed of the alignment roller. This facilitates adjustment of the bonding force amongst the wound layers on the roll to a desirable value.
Another aspect of the present invention is a roll manufactured by the above described manufacturing method such that a maximum amount of irregularity in the both ends of the wound layers of the long element relative to the width direction is 0 mm to 1.0 mm, preferably, 0 mm to 0.7 mm, and more preferably 0 mm to not more than 0.5 mm.
The above structure makes it easy to confirm that the roll is manufactured by the method of the present invention for manufacturing a roll.
The present invention yields a roll having sufficiently small amount of irregularity in the layers of a long element on the roll.
The following describes a preferable embodiment of the present invention, with reference to attached drawings.
A roll manufacturing method of present embodiment, as shown in
An alignment roller preparation process is a process of selecting a desirable alignment roller 6 from a plurality of types of alignment rollers 6, and mounting the alignment roller 6 to an alignment device 2. Specifically, as shown in
A long element setting process is a process carried out subsequent to the alignment roller preparation process, and is a process for enabling winding of a long element 72 corresponding to the roll 73 to be produced. Specifically, a plurality of winding units 8 each corresponding to the width of the wound layer 73b (long elements 72) of the roll 73 are mounted to a winding roller 51. Each of the winding units 8 is movable in the width direction of the winding roller 51.
After the above, the intervals between the winding units 8 are adjusted so that the position of each of the winding unit 8 and the position of each alignment groove 62 of the corresponding alignment roller 6 relative to the vertical direction match with each other. Specifically, the positional relationship is adjusted as follows. When the distance between the winding unit 8 and the alignment roller 6 can be increased or decreased, the distance between the winding unit 8 and the alignment roller 6 is reduced to the extent that the alignment roller 6 is close to the circumference of the winding roller 51. Then, while the distance between the winding unit 8 and the alignment roller 6 is increased as needed by a worker, the winding unit 8 is engaged with the alignment groove 62 of the alignment roller 6. This way, the alignment groove 62 of the alignment roller 6 and the winding unit 8 are positioned to match each other, relative to the vertical direction.
Further, when the distance between the winding unit 8 and the alignment roller 6 is fixed, a plate-like or a belt-like position adjusting member is placed in the vertical direction. Using this position adjusting member as the reference, the positions of the winding unit 8 and that of the alignment groove 62 of the alignment roller 6 are adjusted. Note that a laser beam may be used as the position adjusting member. When the position adjustment is completed as described above, all the winding units 8 are fixed to the winding roller 51.
Next, a sheet roll 7 formed by a sheet 71 whose thickness is the same as the thickness of the wound layer 73b (long elements 72) of the roll 73. The sheet roll 7 is taken out from a not-shown roll storage and is conveyed to the unwind device 3 by a suspending device 91 of the roll conveyance device 9. Note that the sheet roll 7 has a thickness which is at least the thickness of the long element 72, and has a width which is two or more times the width of the long element 72. The sheet roll 7 is then set to the unwind device 3.
After that, the leading end portion of the sheet 71 positioned on the outer surface of sheet roll 7 is unwound by an operator and is forwarded to a cutting apparatus 4, through a conveyance path formed by guide rollers or the like. The sheet 71 is cut into a plurality of long elements 72 each having the roll width, by the cutting apparatus 4. Of these long elements 72, odd-number th long elements 72 when counted in a width direction are directed downward, while even-number th long elements 72 when counted in the width direction are directed upward. The long elements 72 directed downwards are each placed on an alignment groove 62 of the corresponding alignment roller 6 on the lower side as is the case of placing a belt on a pulley, and are brought into a setting-standby state during which the leading end portion is the free end. On the other hand, the long elements 72 directed upwards are each placed on the alignment groove 62 of the corresponding alignment roller 6 on the upper side, and are brought into the setting-standby state during which the leading end portion is the free end.
After that, the leading end portion of each long element 72 is fixed to the corresponding winding unit 8 disposed immediately below or immediately above. That is, a pair of groove side surfaces 62a of the alignment groove 62 and a pair of wound end surfaces 73c formed by both ends of the wound layer 73b relative to the width direction are disposed so that each groove side surface 62a and the corresponding end of the wound layer 73b are present on the same plane. At this time, the positions of the long element 72 and the winding unit 8 match with each other relative to the vertical direction, therefore the length of the long element 72 easily directed and fixed to the winding direction of the winding unit 8. This operation of fixing may be done by adhering the adhesive agent on the long elements 72 to the winding unit 8.
When the distance between the winding unit 8 and the alignment roller 6 can be increased or reduced, the distance between the winding unit 8 and the alignment roller 6 is reduced to the extent that the alignment roller 6 is nearby the circumference of the winding roller 51. This way, the winding unit 8 is engaged with the alignment groove 62, and the groove bottom surface 62b of the alignment groove 62 is pressed against the long element 72 in the direction of the winding unit 8. Then, the fixed state of the winding roller 51 and the winding unit 8 is temporarily released. As the result, as shown in
The unwinding process, the cutting process, and the aligning and winding process are carried out at the same time after the long element setting process. The unwinding process is a process of unwinding the sheet 71 of the sheet roll 7 set to the unwind device 3, at a predetermined forwarding speed. The cutting process is a process for cutting the sheet 71 unwound from the unwind device 3 into a plurality of long elements 72 having a predetermined width. The aligning and winding process is a process for winding the long elements 72 to the winding units 8, at the same time.
Specifically, rotation of the winding units 8 on the wind device 5 and rotation of the sheet roll 7 on the unwind device 3 are started at the same time. The rotation speed of the wind device 5 and that of the unwind device 3 are adjusted to keep the constant tension of the sheet 71 and the long elements 72 being conveyed. This way, cutting width by the cutting apparatus 4 is stabilized, thus highly accurately forming the long elements 72 each having a predetermined width. Then, aligning and winding process takes place at the wind device 5 at a stable operation.
In the aligning and winding process, the rolls 73 are manufactured as follows. Namely, as shown in
The distance in the above description that the alignment groove 62 is disposed in a position distant from the roll surface 73a is preferably set so that the length of the long element 72 with respect to the groove depth of the alignment groove 62 is such that (1) the possibility of having the alignment roller 6 contact the roll surface 73a due to mechanical vibration or the like is prevented, and (2) an oscillation errors of the long elements 72 relative to the width direction is an insignificant level.
In the above described winding method, when the long element 72 is wound on the winding unit 8, the alignment groove 62 is positioned so that each of a pair of wound end surfaces 73c formed by the both ends of the wound layers 73b relative to the width direction is on the same plane as the corresponding one of a pair of groove side surfaces 62a. Since the forwarding direction of the long element 72 from the alignment groove 62 to the roll surface 73a matches with the winding direction on the roll 73, the long element 72 is wound while being positioned relative to the width direction by the alignment groove 62. Even when an adhesive agent on the long element 72 adheres to the alignment grooves 62, this adhesive agent having adhered does not generate a braking force between the alignment grooves 62 and the roll surface 73a, because the alignment groove 62 is positioned distant from the roll surface 73a. This way, from the beginning to the end of winding the long element 72, the long element 72 is wound at a stable tension while being positioned relative to the width direction. Therefore, even when a narrow long element 72 having an adhesive agent is wound on a roll having a large diameter, the amount of irregularity in the roll of the long element 72 relative to the width direction is sufficiently reduced.
Further, the alignment groove 62 having a groove depth greater than the thickness of the long element 72 causes the both ends of the long element 72 relative to the width direction having departed the alignment groove 62 to be in contact with the groove side surfaces 62a of the alignment groove 62 longer than a case where the groove depth is smaller. These groove side surfaces 62a in contact with the both ends of the long element 72 relative to the width direction improves the accuracy in position regulation relative to the width direction. Thus, the irregularity in the roll of long element 72 is further sufficiently reduced.
Further, the following effects are also achievable by winding the long element 72 while moving the alignment groove 62 in the forwarding direction of the long element 72.
Specifically, when the long element 72 is wound while its position relative to the width direction is regulated by the alignment groove 62, the adhesive agent oozing out from the both ends of the long element 72 may adhere to the alignment groove 62. When the alignment groove 62 is fixed, the adhesive agent once adhered to the alignment groove 62 induces collection of more adhesive agent to the alignment groove 62. This way, a large quantity of adhesive agent accumulates in the alignment groove 62 in a short period of time. The adhesive agent accumulated in the alignment groove 62 sticks the adhesive agent on the long element 72 of each wound layer 73b, and generates a braking force between the alignment groove 62 and the long element 72 during the winding. Rapid increase in the amount of accumulated adhesive agent causes an excessively large tension to the long element 72 being wound. The rapidly increased tension causes a change in the width of the long element 72, which may cause an increase in the amount of irregularity relative to the width direction, amongst the wound layers 73b of the long element.
To the contrary, when the long element 72 is wound while the alignment groove 62 is moved in the forwarding direction of the long element 72, even when the adhesive agent adheres to the alignment groove 62, the adhesive agent having adhered moves in the forwarding direction of the long element 72 along with the alignment groove 62. This way, adhesion of the adhesive agent is less likely be promoted as compared with a case where the adhesive agent is accumulated in a position where the adhesion has occurred. Since a rapid increase in the amount of accumulated adhesive agent in the alignment groove 62 is prevented, it is possible to reduce variation in the tension of the long element 72 caused by the adhesive agent having been accumulated in the alignment groove 62 acting as a brake force for forwarding the long element 72. The width of the long element 72 therefore is stabilized from the beginning to the end of winding, which enables sufficient reduction of the amount of irregularity relative to the width direction of each wound layer 73b in the roll of the long element 72, even when winding a narrow long element 72 to a roll having a large diameter.
Note that the alignment roller 6 of the present embodiment may be rotatably supported by the alignment device 2, or may be supported so that its rotation speed is adjustable by means of adjusting the rotation drive force of the alignment device 2. Specifically, the way of supporting to enable adjustment of rotation speed is such that the alignment groove 62 is moved in the forwarding direction of the long element 72 when the alignment roller 6 is rotated about its axis. When the support is such that the rotation speed is adjustable, it is possible to adjust the relative positional relation and the difference in the speed of the groove side surfaces 62a of alignment groove 62 and the long elements 72 simply by adjusting the rotation speed of the alignment roller 6. Therefore, the adhesive force among the wound layers 73b of the roll 73 is easily adjusted to a desirable value.
When the roll diameter of the roll 73 becomes a predetermined roll diameter, the wind device 5 and the unwind device 3 are stopped. After that, all the long elements 72 are cut between the roll 73 and the alignment roller 6, and enters the setting-standby state as shown in
In each of the rolls 73 manufactured by the manufacturing method having the above processes, the amount of irregularity in the both ends of the wound layers 73b of the long element 72 relative to the width direction is 0 mm to 1.0 mm, preferably 0 mm to 0.7 mm, and more preferably 0 mm to 0.5 mm, irrespective of the winding diameter of the roll 73 (or the width L4 of the long element 72) as shown in
Specifically, the sheet 71 includes at least a separation layer 711 and an adhesive layer 712. The sheet 71 is manufactured by applying an adhesive agent composition solution on a separation film to serve as the separation layer 711 to form an applied layer, and drying this applied layer to form the adhesive layer 712. Note that the adhesive agent composition solution may contain an inorganic filler as needed. The method of applying the adhesive agent composition solution is not particularly limited. For example, a comma coating, a fountain method, a gravure method, or the like may be adopted as the method of applying the adhesive agent. The thickness of application may be suitably set so that the thickness L3 of the adhesive layer 712 resulting at the end, after the applied layer is dried, is within a range of 0.025 mm to 5.0 mm. The viscosity of the adhesive agent composition solution is not particularly limited; however, is preferably 400 to 2500 mPa·s, and more preferably, 800 to 2000 mPa·s.
The separation film (separation layer 711) is not particularly limited and any traditionally known separation film is adoptable. Specifically, for example, the separation film is such that a separation coating layer such as a silicone layer or the like is formed on a surface of the base material of the separation film to which the adhesive layer is pasted. Further, example materials for the separation film includes: paper materials such as glassine paper and a resin film made of polyethylene, polypropylene, polyester, or the like. The thickness L2 of the separation film is set to be 0.025 mm to 0.3 mm.
Note that the present embodiment deals with a case where the long elements 72 (sheet 71) has an adhesive layer 712 as in the case of an adhesive tape or the like; however, the present invention is not limited to this, and the present invention may be applied to winding of any given long element 72 having no adhesive layer 712. For example, the long element 72 may be elastic tape used for fixing cushions or the like on a frame of a display of a laptop computer or a word processor, or a non-adhesive tape such as magnetic tape, ink ribbons, photo films, long paper tape, or the like.
Next, the following describes a roll manufacturing device 1 as shown in
The roll manufacturing device 1 includes: a roll conveyance device 9 for conveying a sheet roll 7; an unwind device 3 configured to unwind a sheet 71 from the sheet roll 7; a cutting apparatus 4 configured to cut the sheet 71 into a plurality of long elements 72 each having a predetermined width; an alignment device 2 configured to aligning the long elements 72 while regulating the positions of the long elements relative to the width direction; a wind device 5 configured to wind the long elements 72 to form rolls 73; and a take-out device configured to take out the rolls 73 formed by the wind device 5 to a subsequent process.
The roll conveyance device 9 has a function of carrying out an alignment roller setting process, and is configured to convey, to any given position, the sheet roll 7 from a not-shown previous process in which the sheet roll 7 is manufactured and stored. Specifically, the roll conveyance device 9 includes: a rail 92 disposed so as to enable trafficking above the devices for carrying out each of the processes; at least one suspending device 91 capable of moving along the rail 92; and a not-shown conveyance control device. The suspending device 91 is capable of suspending the sheet roll 7 at its core 7a and elevating the sheet roll 7. The conveyance control device is configured to manage and control the operation of the suspending device 91 based on production plan information so as to convey a sheet roll 7 for a predetermined product to a predetermined position.
On the downstream side of the roll conveyance device 9 relative to the forwarding direction of the sheet 71 is an unwind device 3. The unwind device 3 has a function of carrying out the long element setting process and the unwinding process, and includes a core-holder configured to detachably hold the core 7a of the sheet roll 7; a rotation drive device configured to rotate the core-holder with a given rotation speed and a given torque; a rotation control device configured to control the rotation speed of the rotation drive device. On the downstream side of the unwind device 3 is a cutting apparatus 4. The cutting apparatus 4 has a function of carrying out the long element setting process and the cutting process, and includes: a plurality of cutting blades 41; a cutting blade holder configured to hold the cutting blades 41 so that the cutting blades 41 are positioned in given positions relative to the width direction; a cutting blade drive mechanism configured to rotate the cutting blades 41 at a given rotation speed, and a cutting roller 42 to which the sheet 71 and the blade edges of the cutting blades 41 abut.
On the downstream side of the cutting apparatus 4 are two alignment devices 2. These alignment devices 2 are symmetrically arranged relative to an up/down direction. Each alignment device 2 has a function of carrying out the long element setting process and the aligning and winding process. On the downstream side of the alignment device 2 is a wind device 5. The wind device 5 has a function of carrying out the long element setting process and the aligning and winding process.
The wind device 5 detachably has the winding roller 51, and a not-shown rotation drive device configured to rotate the winding roller 51 at a given rotation speed. The winding roller 51 has a diameter that can be inserted into the winding unit 8. Further, the winding roller 51 has a plurality of pressing members capable of projecting to the outer side than the roller surface. The pressing members switch the state of the winding unit 8 and the winding roller 51 between an inserted state and a fixed state. On the downstream side of the wind device 5 is a take-out device. The take-out device is capable of taking out the products. For example, the take-out device may be a bogie capable of carrying thereon the roll 73, or a roll conveyance device 9.
As shown in
As shown in
There are a plurality of types of alignment rollers 6 having alignment grooves 62 of various groove depths A1 in combination with various groove widths A2. The groove width A2 of the alignment groove 62 substantially matches with the width L4 of the long element 72. Note that, by the groove width A2 of the alignment groove 62 substantially matching with the width L4 of the long element 72, it means that the groove width A2 matches with the width L4 so that the amount of irregularity in the roll 73 relative to the width direction is within an allowable range. In other words, the groove width A2 of the alignment groove 62 may match with the width L4 of the long element 72, or be greater or smaller than the width L4 of the long element 72, provided that the amount of irregularity in the roll 73 relative to the width direction is within the allowable range.
Further, the groove depth A1 of the alignment groove 62 is set to be twice or more the thickness L1 of the long element 72. With the groove depth A1 greater than the thickness of wound layers 73b, the alignment groove 62 enables each of the pair of groove side surfaces 62a to be on the same plane as the corresponding one of the pair of wound end surfaces 73c formed by both ends of the wound layers 73b relative to the width direction.
The width A3 of the groove side surface wall 61 may be the same as or different from the groove width A2 of the alignment groove 62. For example, in
Further, the alignment rollers 6 to be mounted to the upper or lower alignment device 2 may have different groove widths A2 of the groove side surface wall 61. In this case, by setting two different cutting widths in the cutting apparatus 4, it is possible to wind two different types of long elements 72 by the wind devices 5.
The present embodiment deals with a case where the top portion of the groove side surface wall 61 of the alignment roller 6 is flat, i.e., the top portion has a surface matching with the axial direction; however, the present invention is not limited to this. For example, as shown in
The embodiment of the present invention thus described is solely to serve as an example of the present invention, and is not to limit the present invention. Specific structures may be suitably modified. Further, the work and effects described in the embodiment of the present invention are no more than examples achieved by a preferred mode of the present invention, and the work and effects therefore shall not be limited to those described in the embodiment of the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2011-028269 | Feb 2011 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2012/052957 | 2/9/2012 | WO | 00 | 8/23/2013 |
