阅读说明：本技术 膜卷及其制造方法 (Film roll and its manufacturing method ) 是由 须田和哉 于 2018-05-17 设计创作，主要内容包括：本发明提供一种膜卷,其包含卷芯和缠绕在卷芯的长条的树脂膜,该树脂膜在宽度方向上的端部包含凹凸结构部,该树脂膜具有：第一区域,其包含缠绕方向上的始端部；和第二区域,其与第一区域邻接,并包含缠绕方向上的终端部,第二区域是树脂膜的凹凸结构部的凸部的高度的平均值比第一区域大1μm以上的区域,当将卷芯的直径设为R1,将缠绕在卷芯的第一区域的卷绕直径设为R2,将膜卷的直径设为R3时,3<100×(R2-R1)/R3<50,且100×(R2-R1)/R2<65。(The present invention provides a kind of film roll, and it includes the resin film of core and the strip for being wrapped in core, the end of the resin film in the direction of the width includes concaveconvex structure portion, which includes first area, and it includes the top portions on winding direction；And second area, it is adjacent with first area, it and include terminal part on winding direction, second area is 1 μm bigger than first area of the average value of the height of the protrusion in the concaveconvex structure portion of resin film or more of region, when the diameter of core is set as R1, the winding diameter for being wrapped in the first area of core is set as R2, when the diameter of film roll is set as R3,3 < 100 × (R2-R1)/R3 < 50, and 100 × (R2-R1)/R2 < 65.)

1. a kind of film roll, it includes the resin films of core and the strip for being wrapped in the core, wherein

The end of the resin film in the direction of the width includes concaveconvex structure portion,

The resin film includes first area, and it includes the top portions on winding direction；And second area, with described first Area adjacency, and include the terminal part on the winding direction,

The resin film meets formula (A), and the film roll meets formula (B)~(C),

H2-H1≥1μm(A)

3<100×(R2-R1)/R3<50(B)

100×(R2-R1)/R2<65(C)

Wherein, H1 is the average value of the height of the protrusion in the concaveconvex structure portion of the resin film in the first area,

H2 is the average value of the height of the protrusion in the concaveconvex structure portion of the resin film in the second area,

R1 is the diameter of the core,

R2 is the winding diameter for being wrapped in the first area of the core,

R3 is the diameter of the film roll.

2. film roll according to claim 1, wherein

The resin film has concaveconvex structure region in the second area,

The concaveconvex structure region is defined in the end regions from the ora terminalis of the width direction of the resin film within 20mm It is interior,

The concaveconvex structure portion that the resin film is 3 μm~25 μm with average height in the concaveconvex structure region.

3. film roll according to claim 1 or 2, wherein

It is average thick having than the region of ora terminalis 20mm more in the inner part away from width direction in at least one side of the resin film Rugosity SRa is the flat part of 5nm~25nm.

4. film roll according to any one of claim 1 to 3, wherein

Average thickness is 10 μm~100 μm.

5. a kind of manufacturing method of film roll, the film roll is film roll described in any one of Claims 1-4, wherein the film The manufacturing method of volume includes by the resin film with the winding tension of 50N/m~300N/m wound on the process of the core.

6. the manufacturing method of film roll according to claim 5, wherein

In the process for winding the resin film in the core, successively include:

First rolling step winds the first area of the resin film；With

Second rolling step winds the second area of the resin film,

Implement contact winding in first rolling step, the contact winding is will to contact the film of roller and manufacture on the way Cigarette is touched to be wound,

Implement gap winding in second rolling step, the gap winding is the institute by the contact roller and manufacture on the way State what film roll separated to be wound.

Technical field

The present invention relates to a kind of film roll and its manufacturing methods.

Background technique

When manufacturing the films such as optical film, from the viewpoint of realizing high production rate, film is usually fabricated to strip film, and will Its outer surface for being wrapped in columnar core and become film roll.

Such film roll is loaded in such as bracket disclosed in Patent Document 1 (rack) and is conveyed.In patent text The bracket disclosed in 1 for loading Wound product is offered, the Wound product includes rodlike cylinder part and volume in the rodlike cylindrical portion The sheet article of part.

Summary of the invention

Problems to be solved by the invention

Here, optical film is usually film, is held in volume in the case where the sheet article of rodlike cylinder part is optical film Vulnerable to damage.When optical film generates scratch, the optical characteristics of optical film can be damaged.However, being loaded when in previous bracket The Wound products such as optical film and to destination convey when, sometimes due to vibration occurred during transportation etc. and cause optical film to produce Raw scratch.It especially is easy to produce above-mentioned damage at the position on gravity direction top in the axial central portion of film roll, needle Countermeasure when to conveying is inadequate.

Therefore, it is studied to solve the above-mentioned problems, as a result, it has been found that by using in the universe of longitudinal direction Film without concaveconvex structure portion manufactures film roll, it will be able to inhibit abrasive generation.But in the universe by longitudinal direction In film roll obtained from film without concaveconvex structure portion is wound, sometimes its surface generate extend in the circumferential it is band-like Recess portion or protrusion (also referred to as sudden and violent muscle (ゲ ー ジ バ Application De)).

The present invention is to complete in view of the above problems, and its purpose is to provide a kind of hairs to abrasive generation and sudden and violent muscle The film roll and its manufacturing method that life can be inhibited.

The solution to the problem

It is studied to solve the above-mentioned problems, as a result obtains following opinion: using adjacently with first area With the resin film of the strip of second area, and all met with the diameter of core diameter, the winding diameter of first area and film roll The mode of rated condition makes film roll, which can inhibit the generation of abrasive generation and sudden and violent muscle, wherein this first Region includes the top portion on winding direction, which includes the terminal part on winding direction, the bumps of the second area Big 1 μm of mean height ratio first area of the protrusion of structural portion or more.That is, the present invention is as described below.

(1) a kind of film roll, it includes the resin films of core and the strip for being wrapped in the core, wherein

The end of the resin film in the direction of the width includes concaveconvex structure portion,

The resin film includes first area, and it includes the top portions on winding direction；And second area, and it is described First area is adjacent, and includes the terminal part on the winding direction,

The resin film meets formula (A), and the film roll meets formula (B)~(C),

H2-H1≥1μm(A)

3<100×(R2-R1)/R3<50(B)

100×(R2-R1)/R2<65(C)

Wherein, H1 is being averaged for the height of the protrusion in the concaveconvex structure portion of the resin film in the first area Value,

H2 is the average value of the height of the protrusion in the concaveconvex structure portion of the resin film in the second area,

R1 is the diameter of the core,

R2 is the winding diameter for being wrapped in the first area of the core,

R3 is the diameter of the film roll.

(2) film roll according to (1), wherein

The resin film has concaveconvex structure region in the second area,

The concaveconvex structure region is defined in the end from the ora terminalis of the width direction of the resin film within 20mm In region,

The concaveconvex structure that the resin film is 3 μm~25 μm with average height in the concaveconvex structure region Portion.

(3) film roll according to (1) or (2), wherein

It is flat having than the region of ora terminalis 20mm more in the inner part away from width direction in at least one side of the resin film The flat part that equal roughness SRa is 5nm~25nm.

(4) film roll according to any one of (1) to (3), wherein

Average thickness is 10 μm~100 μm.

(5) a kind of manufacturing method of film roll, the film roll are film rolls described in any one of (1)~(4), wherein institute The manufacturing method for stating film roll includes the work with the winding tension of 50N/m~300N/m by the resin film wound on the core Sequence.

(6) manufacturing method of the film roll according to (5), wherein

The process that the resin film is wound in the core successively includes:

First rolling step winds the first area of the resin film；With

Second rolling step winds the second area of the resin film,

Implement contact winding in first rolling step, the contact winding is will to contact the institute of roller and manufacture on the way Film roll contact is stated to be wound,

Implement gap winding in second rolling step, the gap winding is by the contact roller and to manufacture on the way The film roll separate to be wound.

Invention effect

In accordance with the invention it is possible to provide a kind of film roll that can be inhibited of generation to abrasive generation and sudden and violent muscle and its Manufacturing method.

Detailed description of the invention

Fig. 1 is the perspective view for indicating the film roll of one embodiment of the present invention.

Fig. 2 is the side view that outlined the film roll of one embodiment of the present invention.

Fig. 3 is the state for showing schematically the resin film by the film roll of one embodiment of the present invention and being unfolded in the plane Top view.

Fig. 4 is the cross-sectional view at the Y-Y line of Fig. 3.

Fig. 5 is winding device used in the manufacturing method for the film roll for being schematically illustrated at one embodiment of the present invention Schematic diagram.

Fig. 6 is winding device used in the manufacturing method for the film roll for being schematically illustrated at one embodiment of the present invention Schematic diagram.

Fig. 7 is the top view of the flat shape in the concaveconvex structure portion formed in the film roll for be schematically illustrated at embodiment 1.

Fig. 8 is the main view for indicating the structure of the bracket used in the evaluation test of the film roll of embodiment.

Fig. 9 is the side view of the bracket of Fig. 8.

Specific embodiment

Hereinafter, showing embodiment and illustrative material, the present invention is described in detail, but the present invention is not limited to following The embodiment and illustrative material shown, can be in the range of not departing from the range and its equivalency range of Patent request of the invention It arbitrarily changes to implement.

In the following description, the film of " strip " refers to the film for the length for being 5 times or more relative to width, preferably has There are 10 times or the length more than it, specifically refers to wound into rolls and carry out the length of keeping or the degree carried Film.The upper limit of the length of the film of strip is not particularly limited, such as can be set as relative to width being 100,000 times or less.

[embodiment 1]

Referring to Fig.1~Fig. 6 on one side, is on one side illustrated the film roll of one embodiment of the present invention.

(1. film roll)

Fig. 1 is outlined the resin film 100 of the terminal part side on winding direction from the film roll 10 of present embodiment The perspective view of the state of a part is unreeled.As shown in Figure 1, the film roll 10 of present embodiment includes cylindric core 11 and twines It is wound on the resin film 100 of the strip of core 11.

Fig. 2 is the side view that outlined the film roll 10 of present embodiment.Film roll 10 is the circle centered on point 11C Tubular has the core 11 of cylindrical shape and is wound with film portion 12A, 12B of resin film on the outside.In Fig. 2,12A is to film The first film portion that the 100 first area 100A comprising the top portion on winding direction is wound, 12B are to film 100 The second film portion that second area 100B comprising the terminal part on winding direction is wound.In Fig. 2,12P is the first film The end of portion 12A (first area 100A), and be connected at the 12P of the end with the second film portion 12B (second area 100B).Scheming In 2, R1 is the diameter of core 11, and R2 is the winding diameter for being wrapped in the first area 100A of core 11, and R3 is the straight of film roll 10 Diameter.

In the following description, " resin film " is known as " film " sometimes.

(2. resin film)

Fig. 3 is to show schematically the resin film 100 used in the film roll 10 of present embodiment from the side 100U of upper surface The case where top view.The left and right directions of Fig. 3 is winding direction, and left side is the beginning side on winding direction, and right side is winding side Upward terminal side.As shown in figure 3, resin film 100 have the first area 100A comprising the top portion on winding direction and with First area 100A is adjacent and includes the second area 100B of the terminal part on winding direction.The end 12P of first area 100A It also is the end of the beginning side on the winding direction of second area 100B.First area 100A is from the winding direction of film 100 Top portion to the region of end 12P, second area 100B be from end 12P to winding direction on terminal part region.Fig. 1 Shown in from film roll 10 pull out resin film 100 be the second area 100B comprising the terminal part on winding direction.

As shown in figure 3, resin film 100 includes concaveconvex structure portion 120.In the present embodiment, in first area, 100A does not have There is setting concaveconvex structure portion 120, but the both ends in the width direction of second area 100B (diagram up and down direction) are provided with The concaveconvex structure portion 120 of same shape.In the present invention, the region for being provided with concaveconvex structure portion 120 is known as concaveconvex structure area Domain 120R, 120L (referring to Fig.1).The region for being not provided with concaveconvex structure between two concaveconvex structure regions 120R, 120L is Flat part 110.

In the present embodiment, flat part 110 is preferably provided at more leans on than the ora terminalis 20mm in the width direction away from film 100 The region of inside is more preferably disposed at than the region away from ora terminalis 18mm more in the inner part, is further preferably arranged than away from the end The region of edge 15mm more in the inner part is even more preferably arranged in than the region away from ora terminalis 12mm more in the inner part.

In the present embodiment, the mean roughness SRa of flat part 110 is preferably 5nm or more, more preferably 7nm or more, Further preferably 9nm or more, preferably 25nm hereinafter, more preferably 20nm hereinafter, further preferably 10nm or less.Pass through Make the above-mentioned upper limit value of mean roughness SRa of flat part 110 hereinafter, be able to suppress as film is slided and caused by volume it is inclined The generation of shifting, it is more than the above-mentioned lower limit value of mean roughness SRa by making flat part 110, be able to suppress due to film each other it Between be easy contact and caused by abrasive generation.Here, the surface roughness SRa of the flat part 110 of film 100 be able to use it is commercially available Surfagauge, such as little Ban research institute corporation surfagauge " Surfcorder ET4000AK " is measured with 50 μ N of contact pilotage load, measurement length 1mm square, the condition of cutoff value 0.8mm.

(3. concaveconvex structure portion)

In the present embodiment, as shown in Figures 1 and 3, the concaveconvex structure being present in concaveconvex structure region 120R, 120L Portion 120, which is arranged in from the ora terminalis in the width direction of film 100, to be positioned away from.In the present embodiment, Liang Ge concaveconvex structure area The width dimensions A1 of domain 120R, 120L are roughly the same, and width dimensions A1 is set as from the beginning (end 12P) of second area 100B It is constant value to terminal.

Concaveconvex structure portion 120 is preferably provided at the end regions from the ora terminalis in the width direction of film 100 within 20mm, The end regions from the ora terminalis within 18mm are more preferably disposed at, within being further preferably arranged in from ora terminalis 15mm End regions.In addition, the width dimensions A1 for being formed with the concaveconvex structure region in concaveconvex structure portion is preferably 3mm or more, more preferably For 5mm or more, further preferably 7mm or more.It, can by the way that the region for being provided with concaveconvex structure portion to be set as in above range Inhibit the generation buckled, roll up offset etc..

In the present embodiment, as shown in figure 3, concaveconvex structure portion 120 is to have linked the shaped unit of four diamond shapes and make The shape of the shaped unit is repeated for a unit and on film longitudinal direction (winding direction).From being easily adjusted concave-convex knot The viewpoints such as the ratio of structure area are set out, and concaveconvex structure portion 120 is preferably the shape for repeating defined shaped unit.

Fig. 4 is to show schematically to carry out the concaveconvex structure portion 120 of second area 100B with the face vertical with extending direction The figure of the section (the Y-Y section of Fig. 3) of cutting.Concaveconvex structure portion 120 has recess portion 122 and protrusion 121.In general, recess portion 122 It is equivalent to through heat fusing caused by the irradiation using laser or ablation and eliminates the part of resin, in addition, 121 phase of protrusion When in the part for the resin protuberance that the irradiation by above-mentioned laser is heated and is flowed.Film 100 due to protrusion 121 than surrounding Face 100U it is more prominent, so the actual (real) thickness of film 100 thickens in the concaveconvex structure portion 120.

In Fig. 4,100L is the lower surface of film 100, and 122B is the bottom of recess portion 122, and 121T is the top of protrusion 121, H For the height of protrusion 121.In the present invention, the height H of the protrusion 121 in concaveconvex structure portion 120 refers to the concave-convex knot of never setting The upper surface 100U of the film 100 of structure plays the height of the top 121T of protrusion.The height of the protrusion in concaveconvex structure portion 120 can be equal It is even, it can also be uneven.The height of protrusion in the concaveconvex structure portion 120 of second area is able to use such as three-dimensional surface profile Instrument (ZYGO corporation " NewView5000 ") measures.

In the present embodiment, the height H of the protrusion 121 in the concaveconvex structure portion 120 in the second area 100B of film 100 Average value H2 is the value in specific range.H2 is the height of the protrusion in the concaveconvex structure portion in the first area 100A with film 100 As defined in the average value H1 of degree H is relatively carried out.H1, H2 meet following formula (A).

Formula (A): H2-H1 >=1 μm

In the present embodiment, because being not provided with concaveconvex structure portion, first area in the 100A of first area The average value H1 of the height H of the protrusion in the concaveconvex structure portion in 100A is 0.Thus, in the present embodiment, if second area The average value of the height H of the protrusion 121 in the concaveconvex structure portion 120 of 100B is 1 μm or more, then second area 100B is concave-convex knot 1 μm bigger than first area 100A of the average value of the height H of the protrusion 121 in structure portion 120 or more of region.In the following description, Sometimes " average value of the height of protrusion " is known as " average height of protrusion ".The value of H2-H1 is preferably 3 μm or more, more preferably It is 5 μm or more.The upper limit of the value of H2-H1 is not particularly limited, such as can be set as 25 μm or less.

In the present embodiment, the average value H2 of the height H of the protrusion 121 in the concaveconvex structure portion 120 of second area 100B It is 1 μm or more, preferably 3 μm or more, more preferably 5 μm or more, further preferably 7 μm or more, on the other hand, preferably 25 μm hereinafter, more preferably 20 μm hereinafter, further preferably 15 μm or less.By making the concaveconvex structure portion in second area 100B The average value H2 of the height H of 120 protrusion 121 is above-mentioned lower limit value or more, volume offset when wound film is able to suppress, by making The average value H2 of height H be above-mentioned upper limit value hereinafter, be able to suppress in the volume being wound into due to being formed with concaveconvex structure The deformation of film caused by difference of the part in portion with the winding diameter of the part other than it.

In the present embodiment, the width in concaveconvex structure portion 120 is preferably 0.1 μm or more, and more preferably 0.15 μm or more, Particularly preferably 0.2 μm or more, preferably 1 μm hereinafter, more preferably 0.75 μm hereinafter, particularly preferably 0.5 μm or less.Pass through The width in concaveconvex structure portion 120 is the lower limit value of above range or more, is able to suppress the volume offset when film 100 is wound.In addition, Width by concaveconvex structure portion 120 is the upper limit value of above range hereinafter, concaveconvex structure portion can not be formed to failure mode 120。

(thickness of 4. films)

The average thickness of film 100 is preferably 10 μm or more, more preferably 20 μm or more, further preferably 30 μm or more, Preferably 100 μm hereinafter, more preferably 80 μm hereinafter, further preferably 60 μm or less.Even average thickness is upper limit value Relatively thin film below, can also effectively inhibit abrasive generation, can obtain effect of the invention.The thickness of film can make It is measured with " F20-NIR " of commercially available measuring instrument, such as Filmetrics corporation.

(materials of 5. resin films)

The material for constituting the resin film of the film roll of present embodiment is not particularly limited, and can use various thermoplastic resins Rouge.Resin film can be monofilm, be also possible to the multilayer film with multiple layers.Resin film can be stretched film, be also possible to Non-stretched film.

(manufacturing methods of 6. film rolls)

The film roll of present embodiment can be by the inclusion of the preparation section for preparing resin film and the resin film roll that will have been prepared It is manufactured around the manufacturing method of the process (rolling step) of core.

(6.1. resin film preparation section)

When preparing resin film, the method for assigning concaveconvex structure portion to the film before assigning concaveconvex structure portion is not limited especially It is fixed, the known method of concaveconvex structure can be used to form.As the example of such method, can enumerate using laser Concaveconvex structure adding method and the concaveconvex structure adding method for using knurling rolls.In the concaveconvex structure imparting side using laser In method, surface in the concaveconvex structure region for the film being fed continuously utilizes laser to describe specific pattern.Make as a result, It is locally heated with surface of the laser to film, the surface deformation of film can be made by the heating, as a result, being capable of forming Concaveconvex structure portion with specific pattern.In the concaveconvex structure adding method using knurling rolls, prepare to have in circumferential surface specific The knurling rolls of the concaveconvex structure of pattern, the surface transfer knurling rolls in the concaveconvex structure region for the film being fed continuously it is recessed Male structure, thus, it is possible to form the concaveconvex structure with specific pattern.

In the present embodiment, the imparting of concaveconvex structure is the only area to the second area 100B for being equivalent to resin film 100 Domain assigns.

(6.2. rolling step)

Resin film be wound up into the process of core successively include the first rolling step for winding the first area of resin film and Wind the second rolling step of the second area of resin film.In the present embodiment, implement contact volume in the first rolling step Around contact winding is will to contact roller to be contacted with the film roll of manufacture on the way to be wound；Implement in the second rolling step Gap winding, gap winding are will to contact the film roll of roller and manufacture on the way to separate to be wound.To have do not include In the case that the resin film in the region in concaveconvex structure portion is wound, from the viewpoint of more efficiently preventing from abrasive generation, Contact winding is preferably implemented.In the present embodiment, in the way of contacting winding to not including the of concaveconvex structure portion One region is wound, and can more efficiently prevent from abrasive generation.

Fig. 5 is the figure for being schematically illustrated at winding device 200 used in the first rolling step.Winding device 200 is to use It is wound in the first area 100A of the film 100 to strip and obtains being wound with the film roll of first area 100A in core 11 The winding device of (film roll with the first film portion 12A), the winding device have core 11, as the rotation drive for core 11 Core motor 210, contact roller 220 and the arm 230 as the position regulator for contacting roller 220 of dynamic device.

In the first rolling step, the film 100 is continuously conveyed in the longitudinal direction of strip film 100, and to contact roller 220 supplies.At this point, the conveying speed of film 100 usually with use winding speed when 11 wound film 100 of core equal.Therefore, film 100 conveying speed is set preferably in a manner of it can be realized desired winding speed.

To contact roller 220 supply film 100 by around ride over contact roller 220.At this point, contact roller 220 is configured to certainly Rotated by ground, thus by from rotated in the circumferential around the frictional force that the strip film 100 taken applies.Then, using in this way The contact roller 220 of rotation, strip film 100 are directed into core 11.Also it can according to need and apply to contact roller 220 for making this Contact the driving force that roller 220 rotates.

Core 11 is rotated in the circumferential by the driving force applied from core motor 210.Therefore, with around taking in contact The film 100 that the state of roller 220 is directed to core 11 is wound onto core 11.Then, it is formed by the film 100 wound on core 11 Film roll with the first film portion 12A.At this point, contact roller 220 adjusts position by arm 230, so that with core is had been wrapped around 11 and the film 100 that becomes a part of manufacture film roll on the way is contacted.

When using 11 wound film 100 of core, using the force applied from cylinder (not shown), roller 220 is contacted to provide Load radially push manufacture film roll on the way in core 11.As a result, wound on the film 100 of core 11 (that is, manufacture is on the way The film roll film that is included) be pushed with the center of defined load towards core 11.Therefore, in wound film 100, can press down Air processed is rolled between the circumferential surface and film 100 of the film roll of manufacture on the way.

Contacting roller 220 and pushing the payload of the film roll of manufacture on the way is usually 20N/m or more, preferably 50N/m or more, More preferably 100N/m or more, usually 500N/m hereinafter, preferably 400N/m hereinafter, more preferably 300N/m or less.Contact The payload that roller 220 pushes manufacture film roll on the way can according to the winding diameter of the film roll of manufacture on the way and within the above range Arbitrarily change numerical value.

In the first rolling step, the winding tension of the film 100 when by film 100 wound on core 11 be preferably 50N/m with On, more preferably 70N/m or more, further preferably 90N/m or more, preferably 300N/m hereinafter, more preferably 250N/m with Under, further preferably 200N/m or less.The unit [N/m] of above-mentioned winding tension indicates the power for being applied to every 1m width of film Size.By the way that the winding tension control of film 100 within the above range, can efficiently be inhibited the hair of scratch of film roll etc. It is raw.The winding tension of film 100 can arbitrarily change number according to the winding diameter of the film roll 10 of manufacture on the way within the above range Value.It in this case, can also be to become larger for example, above-mentioned winding tension can be changed in a manner of gradually smaller Mode changes, and can also combine both modes.

Fig. 6 is the figure for being schematically illustrated at winding device 300 used in the second rolling step.Winding device 300 is to use It is wound and is obtained in the winding body enterprising one for being wound with first area 100A in the second area 100B of the film 100 to strip Step is wound with the winding device of the film roll 10 of second area 100B.Winding device 300 has core 11, as core 11 Core motor 310, free roll 320 and the arm as the position regulator for free roll 320 of rotation drive device 330。

Free roll 320 is by arm 330 so that the contact roller 220 of the winding device 200 used in the first rolling step The mode not contacted with the film roll 10 of core 11 and manufacture on the way has adjusted the roller of position.When the such winding device 300 of use When executing the second rolling step, by film 100 after riding over free roll 320 by film 100 wound on core 11, obtain film roll 10. At this point, forming film roll 10 by core 11 is wound onto after leaving free roll 320 around the film 100 for riding over free roll 320.

In winding device 300, contact roller 220, therefore the circumferential surface of the film roll in manufacture on the way are replaced using free roll 320 Air is flowed between film 100, the air more than the first film portion 12A is contained in the second film portion 12B.

In the second rolling step, the winding tension of the film 100 when by film 100 wound on core 11 is than the first rolling step It is small.The winding tension of film 100 in second rolling step is preferably 50N/m or more, more preferably 70N/m or more, further excellent 90N/m or more, preferably 300N/m are selected as hereinafter, more preferably 200N/m is hereinafter, further preferably 150N/m or less.It is above-mentioned The unit [N/m] of winding tension indicates the size for being applied to the power of every 1m width of film.By by the winding tension control of film 100 Within the above range, the generation can efficiently inhibit the buckling of film roll, roll up offset etc..The winding tension of film 100 can basis It manufactures the winding diameter of film roll 10 on the way and arbitrarily changes numerical value within the above range.In this case it is possible, for example, to make Above-mentioned winding tension is changed in a manner of gradually smaller, can also be changed in a manner of becoming larger, can also be by both Mode combines.

(effects and effect of 7. present embodiments)

In the present embodiment, resin film 100 meets the condition (condition (A)) of above-mentioned formula (A).In addition, in this embodiment party In formula, film roll meets the condition (condition (B) and condition (C)) of formula below (B) and formula (C).

Formula (B): 3 < 100 × (R2-R1)/R3 < 50

Formula (C): 100 × (R2-R1)/R2 < 65

In formula (B)~(C), R1 is the diameter of core 11, and R2 is the winding for being wrapped in the first area 100A of core 11 Diameter, R3 are the diameter of film roll 10.

In condition (B), 100 × (R2-R1)/R3 is preferably 4 or more, more preferably 6 or more, further preferably 8 with On, preferably 45 hereinafter, more preferably 40 hereinafter, further preferably 35 or less.

In condition (C), 100 × (R2-R1)/R2 is preferably 3 or more, more preferably 5 or more, further preferably 7 with On, preferably 60 hereinafter, more preferably 40 or less.

Condition (A)~(C) effect is illustrated.

In the present embodiment, there is film 100 the top portion side on winding direction to be not provided with concaveconvex structure portion 120 First area 100A, therefore in the first film portion 12A for being wound with first area 100A of film 100, film will not float and close Ground winding, is not likely to produce friction.

Here, film roll obtained from being wound in the resin film that universe is not provided with concaveconvex structure portion exists in film roll Outside (winding diameter big part) the problem of being easy to happen the sudden and violent muscle due to caused by film thickness.However, in the present embodiment, It is provided on the outside of the first film portion 12A the average value of the height of the protrusion in concaveconvex structure portion 120 is bigger than first area 100A by 1 μm or more the second film portion 12B for being entwined of second area 100B, containing than the first film portion in second film portion 12B The mode of the more air of 12A is wound with resin film 100.

That is, the film roll 10 of present embodiment with condition (A), thus close to the part of core 11 due to (rolling up The part small around diameter) there is the first film portion 12A for being not likely to produce friction, (the big part of winding diameter) has and contains on the outside Air and be not easily susceptible to film thickness influence the second film portion 12B.

Be wrapped in the first area 100A of core 11 winding diameter R2 it is big in the case where, be able to suppress abrasive generation, But it is easy to happen sudden and violent muscle.It is studied for this problem, as a result, it has been found that the wound section (R2- by making first area 100A R1) relative to the ratio of the diameter R3 of film roll (100 × (R2-R1)/R3) and the wound section (R2- of first area 100A R1) become relative to the ratio of the winding diameter R2 of first area 100A and meet condition (B), the range of (C), be able to suppress sudden and violent muscle Generation.

That is, according to the present embodiment, resin film meets condition (A), and film roll meets condition (B), (C), thus It is capable of providing the film roll and its manufacturing method that can be inhibited to the generation of abrasive generation and sudden and violent muscle.

(purposes of 8. films)

The film roll of present embodiment such as can be saved with the state of film roll, carry, trade at the disposition.From film of the invention Rolling up the film unreeled out can be used in extensive purposes, wherein be preferably used as optical film.As the concrete example of optical film, can enumerate Phase difference film, polaroid protective film, optical compensation films etc..