[Technical Field]
[0001] The present invention relates to a roll body.
[Background Art]
[0002] Transfer foils include sheets having a pattern layer in a predetermined shape and
a support layer supporting the pattern layer, for example, and may be manufactured
by a roll-to-roll method (see, for example, PTL 1). In the manufacture process of
transfer foil, a sheet of transfer foil or an intermediate is wound on a core so that,
during the manufacture of the transfer foil or at the completion of the transfer foil,
the transfer foil can be kept in storage or the intermediate of the transfer foil
can be transferred between equipment.
[Citation List]
[Patent Literature]
[Summary of the Invention]
[Technical Problem]
[0004] The sheet has a belt-like shape extending along the extending direction and is wound
on a core along the circumferential direction of the core. The pattern layer on the
sheet may have first regions that extend linearly along the extending direction and
second regions that extend linearly along the extending direction and are thinner
than the first regions. When the sheet is wound on the core, portions of the core
on which the first regions are wound and portions of the core on which the second
regions are wound do not vary, that is, do not change in the axial direction. Accordingly,
the roll body has thicker portions and thinner portions along the radial direction
of the core in the axial direction of the core. As a result, the sheet has wrinkles
caused by the difference in thickness between the different portions in the axial
direction, which leads to reduction in the yield of the transfer foil.
[0005] The above problem is not limited to sheets of transfer foils but is in common among
roll bodies including a core and a sheet wound on the outer peripheral surface of
the core along the circumferential direction of the core and roll bodies in which
a sheet is wound on a core and then the core is removed.
[0006] An object of the present disclosure is to provide a roll body that suppresses wrinkles
in a sheet wound on a core.
[Solution to Problem]
[0007] A roll body to solve the above problem includes a sheet as a multi-layer body that
is rolled in a cylindrical shape extending along an axial direction. When unrolled,
the sheet has a belt-like shape extending along an extending direction. A direction
orthogonal to the extending direction is a width direction, and the sheet includes
a pattern section region formed from a plurality of first regions and a plurality
of second regions. The first regions and second regions each have a belt-like shape
extending along a first direction and include an edge along the first direction, and
the edge has a shape extending along a direction crossing both the extending direction
and the width direction. In the pattern section region, the first regions and the
second regions are alternately arranged adjacent to each other. The sheet is formed
from a support layer and a pattern structure supported by the support layer. The roll
body satisfies at least one of a condition that the density of element pattern structures
in the first regions is different from the density of element pattern structures in
the second regions and a condition that the arrangement of the element pattern structures
in the first regions is different from the arrangement of the element pattern structures
in the second regions.
[0008] According to the above configuration, the edges of the first regions and the edges
of the second regions extend along the direction crossing both the extending direction
and the width direction and the first regions and the second regions are alternately
arranged, so that the portions of the core on which the edges of the first regions
are wound and the portions of the core on which the edges of the second regions are
wound vary in the axial direction. Therefore, the difference in thickness at the boundaries
between the first regions and the second regions along the radial direction of the
core is likely to be reduced, thereby suppressing an abrupt change in the thickness
of the roll body along the radial direction in the axial direction of the core. As
a result, it is possible to suppress wrinkles in the sheet wound on the core.
[0009] A roll body to solve the above problem includes a sheet as a multi-layer body that
is rolled in a cylindrical shape extending along an axial direction. When unrolled,
the sheet has a belt-like shape extending along an extending direction. The sheet
includes a pattern section region formed from a plurality of first regions and a plurality
of second regions, and each of the first regions and each of the second regions have
a shape extending along a first direction. In the pattern section region, the first
regions and the second regions are alternately arranged adjacent to each other. Each
of the first regions includes an edge along the first direction, and the position
of the edge of each of the first regions in a circumferential direction of the sheet
changes continuously along the axial direction. The sheet is formed from a support
layer and a pattern structure supported by the support layer, and the pattern structure
includes a plurality of element pattern structures that form convex portions on a
surface of the sheet. The roll body satisfies at least one of a condition that the
density of element pattern structures in the first regions is different from the density
of element pattern structures in the second regions and a condition that the arrangement
of the element pattern structures in the first regions is different from the arrangement
of the element pattern structures in the second regions.
[0010] According to the above configuration, the positions of the edges of the first regions
in the circumferential direction of the core change continuously, in other words,
the portions of the core on which the edges of the first regions are wound and the
portions of the core on which the edges of the second regions are wound vary in the
axial direction. Therefore, the difference in thickness at the boundaries between
the first regions and the second regions along the radial direction of the core is
likely to be reduced, thereby suppressing an abrupt change in the thickness of the
roll body along the radial direction of the core in the axial direction of the core.
As a result, it is possible to suppress wrinkles in the sheet wound on the core.
[0011] The roll body may further include a core that extends along the axial direction and
has an outer peripheral surface, and the sheet may be wound along the outer peripheral
surface of the core. According to the above configuration, the sheet is supported
by the core and thus the shape of the sheet is less prone to change.
[0012] In the roll body, the first direction may cross both the extending direction and
the width direction.
[0013] According to the above configuration, the first regions and the second regions extend
along the first direction crossing both the extending direction and the width direction
and the first regions and the second regions are alternately arranged, so that the
portions of the core on which the edges of the first regions are wound and the portions
of the core on which the edges of the second regions are wound vary in the axial direction.
Therefore, it is possible to suppress variations in the thickness along the radial
direction of the core in the axial direction of the core. As a result, it is possible
to suppress wrinkles in the sheet wound on the core.
[0014] In the roll body, the position of the first regions in the circumferential direction
of the core may change continuously along the axial direction.
[0015] According to the above configuration, the positions of the first regions in the circumferential
direction continuously changes along the axial direction. In other words, the portions
of the core on which the edges of the first regions are wound and the portions of
the core on which the edges of the second regions are wound vary in the axial direction.
Accordingly, it is possible to suppress variations in the thickness along the radial
direction of the core between the first regions and the second regions in the axial
direction of the core. As a result, it is possible to suppress wrinkles in the sheet
wound on the core.
[0016] In the roll body, the element pattern structures may be positioned only in the first
regions. According to the above configuration, it is possible to suppress wrinkles
in the sheet wound on the core because the density of the element pattern structures
in the second regions is a minimum.
[0017] In the above roll body, each of the element pattern structures may have a belt-like
shape extending all over a corresponding one of the first regions and having a predetermined
thickness.
[0018] According to the above configuration, it is possible to suppress wrinkles in the
sheet wound on the core because the element pattern structures that form convex portions
are spaced in an arrangement direction.
[0019] The above roll body may include a pattern layer as a concave-convex structure body
that has the pattern structure and is supported by the support layer, the first regions
may be thicker portions of the pattern layer including the element pattern structures,
and the second regions may be thinner portions of the pattern layer not including
the element pattern structures.
[0020] According to the above configuration, it is possible to suppress wrinkles in the
sheet wound on the core in the configuration both the first regions and the second
regions include portions of the pattern layer with the predetermined thickness.
[0021] In the above roll body, the pattern structure may include two or more kinds of the
element pattern structures different in shape in plan view of the sheet.
[0022] According to the above configuration, the shape of the pattern structure can be made
more complicated compared to the configuration in which all the element pattern structures
have the same shape.
[0023] In the above roll body, the plurality of element pattern structures may each have
the same shape in plan view of the sheet.
[0024] According to the above configuration, it is possible to suppress wrinkles in the
sheet wound on the core even if all the element pattern structures have the same shape.
[0025] In the above roll body, the pattern structure may include a plurality of element
pattern structure groups; each of the element pattern structure groups may be formed
from the plurality of element pattern structures; each of the first regions and each
of the second regions may include the element pattern structure groups, and the number
of the element pattern structures belonging to each of the first regions and the number
of the element pattern structures belonging to each of the second regions may be different.
[0026] According to the above configuration, not only the first regions but also the second
regions include the element pattern structure groups, and thus the shape of the pattern
structure can be made more complicated in plan view of the sheet as compared to the
configuration in which only the first regions include the element pattern structure
groups.
[0027] A roll body to solve the above problem includes a sheet as a multi-layer body that
is rolled in a cylindrical shape extending along an axial direction, and when the
sheet is unrolled, the sheet has a belt-like shape extending along an extending direction.
The sheet includes a support layer and a plurality of element pattern structure groups
that are formed on a surface of the sheet and are arranged cyclically along the extending
direction. Each of the element pattern structure groups includes a plurality of element
pattern structures that are supported by the support layer and form convex portions
on the surface of the sheet. In plan view of the sheet, a region defined by surrounding
an aggregate of the plurality of element pattern structures constituting one element
pattern structure group with an envelope contour line in contact with a portion of
an edge of each of the element pattern structures constitutes an element pattern structure
group region. A line parallel to the extending direction is a reference line, and
a direction orthogonal to the extending direction is a width direction. A distance
from one end portion of the element pattern structure group region in the width direction
to the reference line changes cyclically along the extending direction.
[0028] According to the above configuration, the distance from at least one end portion
of the element pattern structure group region in the width direction to the reference
line parallel to the extending direction changes cyclically along the extending direction,
and thus out of end portions of the element pattern structure group region in the
width direction, the end portion where the distance to the reference line changes
cyclically changes cyclically in position in the axial direction of the core. Therefore,
it is possible to suppress wrinkles in the sheet wound on the core as compared to
the configuration in which the position of the end portion of the sheet in the axial
direction of the core does not change.
[0029] In the above roll body, each of the convex portions may include at least one prism
group in which a plurality of linear or arc-shaped prisms are aligned along one direction
in plan view of the sheet, and each of the prisms is an asymmetrical prism with inclination
angles different between both sides of an apex in a cross section as seen in the width
direction of the sheet.
[0030] According to the above configuration, the portions of the core on which the first
regions are wound and the portions of the core on which the second regions are wound
vary in the axial direction, and thus even when the element pattern structures positioned
in the first regions include a plurality of prisms, it is possible to suppress deformation
of the prisms caused by winding the sheet on the core.
[Advantageous Effects of the Invention]
[0031] According to the present disclosure, it is possible to suppress wrinkles in the sheet
wound on the core.
[Brief Description of the Drawings]
[0032]
Fig. 1 is a perspective view of a structure of a roll body in a first embodiment.
Fig. 2 is a partial planer view of a structure of a sheet included in the roll body.
Fig. 3 is a cross-sectional view of the structure illustrated in Fig. 2 taken along
line II-II.
Fig. 4 is a cross-sectional view of a structure of a core orthogonal to an axial direction.
Fig. 5 is a cross-sectional view of the structure of the core orthogonal to the axial
direction.
Fig. 6 is a cross-sectional view of the structure of the core orthogonal to the axial
direction.
Fig. 7 is a cross-sectional view of the structure illustrated in Fig. 1 taken along
line I-I.
Fig. 8 is a perspective view of a structure of a roll body in a comparative example.
Fig. 9 is a partial planar view of a structure of a sheet included in the roll body
in the comparative example.
Fig. 10 is a cross-sectional view of the structure illustrated in Fig. 8 taken along
line III-III.
Fig. 11 is a cross-sectional view of a structure of a sheet in a modification example.
Fig. 12 is a partial planar view of the structure of the sheet in the modification
example.
Fig. 13 is a partial enlarged planar view of a structure of a sheet in a modification
example.
Fig. 14 is a partial enlarged cross-sectional view of a structure of an element pattern
structure in the modification example.
Fig. 15 is a partial enlarged planar view of a structure of a sheet in a modification
example.
Fig. 16 is a partial enlarged cross-sectional view of a structure of an element pattern
structure in the modification example.
Fig. 17 is a partial enlarged planar view of a structure of a sheet in a modification
example.
Fig.18 is a partial enlarged planar view of a structure of an element pattern structure
in the modification example.
Fig.19 is a partial planar view of a structure of a sheet included in a first example
of the roll body in the second embodiment.
Fig. 20 is a partial planar view of a structure in the sheet included in a second
example of the roll body.
Fig. 21 is a partial planar view of a structure of a sheet included in a third example
of the roll body.
Fig. 22 is a partial planar view of a structure of a sheet included in a fourth example
of the roll body.
Fig. 23 is a partial planar view of a structure of a sheet included in the fourth
example of the roll body.
Fig. 24 is a partial planar view of a structure of a sheet included in a fifth example
of the roll body.
[Description of Embodiments]
[First embodiment]
[0033] A first embodiment of a roll body will be described with reference to Figs. 1 to
10. Hereinafter, a configuration of the roll body, operations of the roll body, and
a roll body in a comparative example will be described in sequence.
[Configuration of the roll body]
[0034] A configuration of the roll body will be described with reference to Figs. 1 to 6.
In Figs. 1 and 2, first regions are shown dotted for the ease of discriminating the
first regions from second regions.
[0035] As illustrated in Fig. 1, the roll body 10 includes a core 11 and a sheet 12. The
core 11 extends along an axial direction and has an outer peripheral surface 11S.
The sheet 12 has a belt-like shape extending along an extending direction D1 and is
wound on the outer peripheral surface 11S of the core 11 along a circumferential direction
DC. In the roll body 10, the sheet 12 is supported by the core 11 and thus is less
prone to change in shape.
[0036] In other words, the sheet 12 is a multi-layer body that is rolled in a cylindrical
shape extending along the axial direction. The roll body 10 is formed from the core
11 and the sheet 12 but may be formed only form the sheet 12. In this case, the core
11 is removed from the sheet 12 after the sheet 12 is wound. The space defined by
the sheet 12 is a core space.
[0037] The core 11 has a cylindrical shape and is rotatable around a rotation axis A. The
direction in which the rotation axis A extends is the axial direction. The axial direction
is also the direction in which the cylindrical sheet 12 extends. The direction of
the rotation of the core 11 around the rotation axis A along the outer peripheral
surface 11S of the core 11 is the circumferential direction DC of the core 11. The
circumferential direction DC is also the direction along the outer peripheral surface
of the sheet 12. The sheet 12 is rolled a plurality of times on the outer peripheral
surface 11S of the core 11.
[0038] As illustrated in Fig. 2, the direction orthogonal to the extending direction D1
is a width direction D2. When unrolled, the sheet 12 has a belt-like shape that extends
along the extending direction D1 and the width direction D2, and the length of the
sheet 12 along the extending direction D1 is significantly longer than the length
of the sheet 12 along the width direction D2.
[0039] The sheet 12 includes a pattern section region 12P formed from a plurality of first
regions 12A and a plurality of second regions 12B. The first regions 12A and the second
regions 12B are belt-like regions extending along the first direction, and each of
the belt-like regions has a shape extending along a direction crossing both the extending
direction D1 and the width direction D2. In other words, each of the belt-like regions
has a linear shape extending along a direction crossing both the extending direction
D1 and the width direction D2 at an angle other than the right angle. The extending
direction of each of the belt-like regions is a direction in which a straight line
connecting start and end points of the belt-like region extends. The first direction
crosses the extending direction D1 and the width direction D2.
[0040] In the plurality of belt-like regions, the first regions 12A and the second regions
12B are alternately arranged adjacent to each other along the arrangement direction.
The first regions 12A and the second regions 12B are in contact with each other in
the arrangement direction. The direction in which the first regions 12A and the second
regions 12B are arranged is one direction in the plane of the sheet 12.
[0041] In plan view of the sheet 12, the length of the first regions 12A along the direction
orthogonal to the extending direction of the first regions 12A constitutes the width
of the first regions 12A. In plan view of the sheet 12, the length of the second regions
12B along the direction orthogonal to the extending direction of the second regions
12B constitutes the width of the second regions 12B. The width of the first regions
12A is smaller than the width of the second regions 12B, but the width of the first
regions 12A may be larger than the width of the second regions 12B or the width of
the first regions 12A and the width of the second regions 12B may be equal.
[0042] As illustrated in Fig. 3, the sheet 12 is formed from a support layer 21 and a pattern
structure 22. The pattern structure 22 is supported by the support layer 21, and the
pattern structure 22 includes a plurality of element pattern structures 22a that form
convex portions on a surface 12S of the sheet 12. In the sheet 12, the density of
the element pattern structures 22a in the first regions 12A is different from the
density of the element pattern structures 22a in the second regions 12B.
[0043] The surface 12S of the sheet 12 as a concave-convex surface is formed by the surfaces
of the element pattern structures 22a and the portions of the surface of the support
layer 21 not covered with the element pattern structures 22a. In plan view of the
sheet 12, the ratio of the area of the element pattern structures 22a belonging to
each of the first regions 12A to the area of the first region 12A constitutes the
density of the element pattern structures 22a in the first region 12A. In addition,
in plan view of the sheet 12, the ratio of the area of the element pattern structures
22a belonging to each of the second regions 12B to the area of the second region 12B
constitutes the density of the element pattern structures 22a in the second region
12B.
[0044] The pattern structure 22 includes the plurality of element pattern structures 22a,
and each of the first regions 12A includes, out of the plurality of element pattern
structures 22a, an element pattern structure 22a different from the element pattern
structures 22a constituting the other first regions 12A. The support layer 21 includes
a plurality of support portions 21a, and each of the belt-like regions includes, out
of the plurality of support portions 21a, a support portion 21a different from the
support portions 21a constituting the other belt-like regions.
[0045] Since each of the first regions 12A and the second regions 12B extends along a direction
crossing both the extending direction D1 and the width direction D2 and the first
regions 12A and the second regions 12B are alternately arranged, the portions of the
core 11 on which the first regions 12A are wound and the portions of the core 11 on
which the second regions 12B are wound vary, that is, change in the axial direction.
Therefore, even if the density of the element pattern structures 22a is different
between the first regions 12A and the second regions 12B, it is possible to suppress
variations in the thickness of the sheet 12 along the radial direction of the core
11 in the axial direction of the core 11. This makes it possible to suppress wrinkles
in the sheet 12 wound on the core 11.
[0046] Each of the support layer 21 and the pattern structure 22 may have a single-layer
structure formed from one layer or may have a multi-layer structure formed from a
plurality of layers. When each of the support layer 21 and the pattern structure 22
has a multi-layer structure, the plurality of layers constituting the multi-layer
structure may include layers formed from different materials. In other words, each
of the element pattern structures 22a constituting the pattern structure 22 may have
a single-layer structure formed from one layer or a multi-layer structure formed from
a plurality of layers.
[0047] The element pattern structures 22a are positioned only in the first regions 12A.
Accordingly, it is possible to suppress variations in the thickness of the sheet 12
along the radial direction of the core 11 when the density of the element pattern
structures 22a in the second regions 12B is a minimum.
[0048] In each of the first regions 12A, each of the element pattern structures 22a has
a belt-like shape extending all over a corresponding one of the first regions and
having a predetermined thickness. Accordingly, it is possible to suppress wrinkles
in the sheet 12 wound on the core 11 when the element pattern structures 22a that
form the convex portions are spaced in the arrangement direction.
[0049] More specifically, each of the element pattern structures 22a has a linear shape
extending along the same direction as the first region 12A to which the element pattern
structure 22a belongs, that is, the direction crossing both the extending direction
D1 and the width direction D2. The element pattern structures 22a each extend all
over a corresponding first region 12A and have substantially the same thickness.
[0050] A recess 22b is formed between two element pattern structures 22a adjacent to each
other in the arrangement direction so as to extend all over a second region 12B. Each
of the recesses 22b has a linear shape extending along the same direction as the second
regions 12B, that is, the direction crossing both the extending direction D1 and the
width direction D2. Thus, out of the first regions 12A and the second regions 12B,
the first regions 12A have the element pattern structures 22a but the second regions
12B do not have the element pattern structures 22a. Accordingly, the density of the
element pattern structures 22a is different between the first regions 12A and the
second regions 12B.
[0051] Figs. 4 to 6 illustrate examples of a cross-sectional structure of the roll body
10 orthogonal to the axial direction of the core 11. The cross-sectional structures
of the roll body 10 illustrated in Figs. 4 to 6 are different in the axial position.
The cross-sectional structures illustrated in Figs. 4 to 6 include mutually different
portions of the same first region 12A. For the sake of illustration, each of Figs.
4 to 6 illustrates the sheet 12 as one circle in which one first region 12A is positioned
on the foremost layer of the sheet 12 wound on the core 11.
[0052] The sheet 12 of the roll body 10 described above is also configured as described
below. That is, the sheet 12 includes the pattern section region 12P formed from the
plurality of first regions 12A and the plurality of second regions 12B, and each of
the first regions 12A and each of the second regions 12B are shaped to extend along
the first direction. In the pattern section region 12P, the first regions 12A and
the second regions 12B are alternately arranged adjacent to each other. The positions
of the first regions 12A in the circumferential direction DC of the core 11 change
continuously along the axial direction.
[0053] Fig. 4 illustrates the cross-sectional structure of the roll body 10 at a first position
in the axial direction.
[0054] As illustrated in Fig. 4, a first portion 12A1 of the first region 12A is located
at the first position on the roll body 10 in the axial direction. The first portion
12A1 is located at a predetermined position in the sheet 12 in the circumferential
direction DC of the core 11. The first portion 12A1 is located, for example, directly
above the rotation axis A at the first position in the axial direction.
[0055] In the circumferential direction DC of the core 11, a point positioned on the outer
peripheral surface 11S of the core 11 directly above the rotation axis A is set as
a reference point P, and a straight line extending from the rotation axis A as the
center of the core 11 to the reference point P is set as a reference line LB. The
angle formed by the reference line LB and a straight line L connecting the given point
on the outer peripheral surface 11S of the core 11 and the rotation axis A is a phase.
The phase is 0° at the first portion 12A1.
[0056] Fig. 5 illustrates the cross-sectional structure of the roll body 10 at a second
position in the axial direction different from the first position.
[0057] As illustrated in Fig. 5, a second portion 12A2 of the first region 12A is located
at the second position on the roll body 10 in the axial direction. The second portion
12A2 is a predetermined portion of the sheet 12 in the circumferential direction DC
of the core 11, which is located at the position different from the position of the
first portion 12A1. That is, the first portion 12A1 and the second portion 12A2 are
different in phase in the circumferential direction DC. The phase of the second portion
12A2 is α° different from the phase of the first portion 12A1.
[0058] Fig. 6 illustrates the cross-sectional structure of the roll body 10 at a third position
in the axial direction different from the first position and the second position.
As seen in the axial direction, the second position is sandwiched between the first
position and the third position.
[0059] As illustrated in Fig. 6, a third portion 12A3 of the first regions 12A is located
at the third position on the roll body 10 as seen in the axial direction. The third
portion 12A3 is a predetermined portion of the sheet 12 in the circumferential direction
DC of the core 11, which is located at the position different from the position of
the first portion 12A1 and the position of the second portion 12A2.
[0060] That is, the phase of the third portion 12A3 is different from both the phase of
the first portion 12A1 and the phase of the second portion 12A2. The phase of the
third portion 12A3 is an angle of β° different from the phase of the first portion
12A1, and is also different from the phase α° of the second portion 12A2.
[0061] The first regions 12A of the sheet 12 are wound in a spiral form on the outer peripheral
surface 11S of the core 11, and thus the phases of the first regions 12A in the circumferential
direction of the core 11 change continuously along the axial direction. In other words,
the portions of the core 11 on which the first regions 12A are wound and the portions
of the core 11 on which the second regions 12B are wound vary in the axial direction.
[0062] Accordingly, even if the density of the element pattern structures 22a in the first
regions 12A and the density of the element pattern structures 22a in the second regions
12B are different, it is possible to suppress variations in the thickness of the roll
body 10 in the radial direction of the core 11, along the axial direction of the core
11. Therefore, it is possible to suppress wrinkles in the sheet 12 wound on the core
11.
[Operations of the roll body]
[0063] Operations of the roll body 10 will be described with reference to Fig. 7.
[0064] Fig. 7 illustrates a cross-sectional view of the roll body 10 along the rotation
axis A of the core 11. For the sake of illustration, Fig. 7 illustrates the thickness
of the support layer 21 and the thickness of the element pattern structures 22a included
in the pattern structure 22 in an exaggerated manner.
[0065] As illustrated in Fig. 7, when the sheet 12 is wound on the core 11, the portions
of the sheet 12 where the first regions 12A are positioned in an axial direction DA
of the core 11 shift continuously along with changes in the positions of portions
of the sheet 12 where the first regions 12A are positioned in the radial direction
DR of the core 11. In addition, the portions of the sheet 12 where the second regions
12B are positioned in the axial direction DA of the core 11 shift continuously along
with changes in the positions of portions of the sheet 12 where the first regions
12A are positioned in the radial direction DR of the core 11.
[0066] Accordingly, the portions of the roll body 10 where the first regions 12A are positioned
in the axial direction DA and the portions of the roll body 10 where the second regions
12B are positioned in the axial direction DA vary. Therefore, even when the first
regions 12A and the second regions 12B are different in thickness, the difference
in thickness between the first regions 12A and the second regions 12B is not fixed
in the axial direction DA. This suppresses variations in the thickness of the roll
body 10 along the radial direction DR in the axial direction DA, to thereby suppress
wrinkles in the sheet 12 caused by such variations in thickness.
[0067] As illustrated in Fig. 7, the sheet 12 may be wound on the core 11 such that each
of the element pattern structures 22a is positioned in the support layer 21 closer
to the outer peripheral surface 11S of the core 11 than the succeeding element pattern
structures 22a are. That is, the sheet 12 may be wound on the core 11 such that each
of the element pattern structures 22a is positioned on the surface of the sheet 12
closer to the core. Alternatively, the sheet 12 may be wound on the core 11 such that
each of the element pattern structures 22a is positioned in the support layer 21 away
from the outer peripheral surface 11S of the core 11 than the preceding element pattern
structures 22a. That is, the sheet 12 may be wound on the core 11 such that each of
the element pattern structures 22a is positioned on the surface of the sheet 12 opposite
to the surface closer to the core.
[Roll body in a comparative example]
[0068] A configuration of a roll body in a comparative example will be described with reference
to Figs. 8 to 10.
[0069] As illustrated in Fig. 8, similarly to the roll body 10 in the first embodiment described
above, the roll body R includes a core R1 extending in the axial direction and the
core R1 has an outer peripheral surface R1S. A sheet R2 is wound on the outer peripheral
surface R1S of the core R1 along a circumferential direction DC of the core R1.
[0070] As illustrated in Fig. 9, the sheet R2 includes a plurality of first regions R2A
and a plurality of second regions R2B. In plan view of the sheet R2, each of the first
regions R2A and the second regions R2B has a linear shape extending along the extending
direction D1, and the first regions R2A and the second regions R2B are alternately
arranged along a width direction D2.
[0071] As illustrated in Fig. 10, the sheet R2 is formed from a support layer R21 and a
pattern structure R22. Each of the first regions R2A is formed from a portion of the
support layer R21 and element pattern structures R22a, whereas each of the second
regions R2B is formed only from a portion of the support layer R21.
[0072] Therefore, in the roll body R, similarly to the roll body 10 in the first embodiment,
the density of the element pattern structures R22a in the first regions R2A is larger
than the density of the element pattern structures R22a in the second regions R2B.
[0073] As described above, the first regions R2A and the second regions R2B extend along
the extending direction D1, and the first regions R2A and the second regions R2B are
alternately arranged along the width direction D2. Thus, when the sheet R2 is wound
on the core R1, the portions of the core R1 on which the first regions R2A are wound
and the portions of the core R1 on which the second regions R2B are wound do not vary
in the axial direction DA of the core R1. Accordingly, the portions of the roll body
R where the first regions R2A overlap are thicker along the radial direction DR of
the core R1, whereas the portions of the roll body R where the second regions R2B
overlap are thinner along the radial direction DR.
[0074] Accordingly, the roll body R in the comparative example has variations in the thickness
along the radial direction DR in the axial direction of the roll body R, which causes
wrinkles in the sheet R2 wound on the core R1.
[0075] As described above, according to the first embodiment of the roll body, the following
advantageous effects can be obtained.
- (1) The portions of the core 11 on which the first regions 12A are wound and the portions
of the core 11 on which the second regions 12B are wound vary in the axial direction
DA. This suppresses variations in the thickness of the roll body 10 along the radial
direction DA of the core 11 in the axial direction DA of the core 11. Therefore, it
is possible to suppress wrinkles in the sheet 12 wound on the core 11.
- (2) It is possible to suppress variations in the thickness of the sheet 12 along the
radial direction DR of the core 11 when the density of the element pattern structures
22a in the second regions 12B is a minimum.
- (3) It is possible to suppress wrinkles in the sheet 12 wound on the core 11 when
the element pattern structures 22a forming the convex portions are spaced in the arrangement
direction.
The first embodiment described above can be appropriately modified as described below.
The first regions 12A and the second regions 12B are not limited to a linear shape
but may have a folded shape with at least one bend or may have a curved shape with
at least one bend. Even in this configuration, the advantageous effect equivalent
to (3) described above can be obtained if the element pattern structures 22a are positioned
in the entire first regions 12A and have a predetermined thickness. In addition, the
advantageous effect equivalent to (2) described above can be obtained if the element
pattern structures 22a are positioned only in the first regions 12A. Further, the
advantageous effect equivalent to (1) described above can be obtained if the first
regions 12A and the second regions 12B extend along the direction crossing both the
extending direction D1 and the width direction D2 and are alternately arranged along
the arrangement direction.
The element pattern structures 22a may be repeatedly provided in a predetermined cycle
along the extending direction D1. Specifically, each of the element pattern structures
22a may have a linear shape extending along the direction crossing both the extending
direction D1 and the width direction D2 and its length in the extending direction
D1 may be shorter than the length of the sheet 12 in the extending direction D1.
As illustrated in Fig. 11, the sheet 12 may include a pattern layer 23. The pattern
layer 23 may be a concave-convex structure body supported by the support layer 21;
the first regions 12A may be thicker portions of the pattern layer 23 including the
element pattern structures 22a; and the second regions 12B may be thin portions of
the pattern layer 23 not including the element pattern structures 22a. Specifically,
the pattern layer 23 may have first parts 23a included in the first regions 12A and
second parts 23b included in the second regions 12B, and portions of the first parts
23a protruding more than the second parts 23b may be the element pattern structures
22a. In this configuration, the pattern structure 22 is formed from the portions of
the first parts 23a protruding more than the second parts 23b, and the concave-convex
surface of the pattern layer 23 is an example of the surface 12S of the sheet 12.
According to the above configuration, the following advantageous effects can be obtained.
- (4) It is possible to suppress wrinkles in the sheet 12 wound on the core 11 when
the portions of the pattern layer 23 are formed from the first regions 12A and the
second regions 12B which are different in thickness.
The first regions 12A and the second regions 12B may not necessarily extend along
the direction crossing both the extending direction D1 and the width direction D2.
That is, the first regions 12A and the second regions 12B may extend along the extending
direction D1 or may extend along the width direction D2. In this configuration, the
edge of each of the first regions 12A and the second regions 12B, that is, the edge
of each of the belt-like regions along the extending direction of the belt-like region
extend at least partially along a direction crossing both the extending direction
D1 and the width direction D2. In other words, the edge of each of the belt-like regions
includes a portion not extending along the extending direction D1 and not extending
along the width direction D2.
For example, as illustrated in Fig. 12, in a sheet 12a, first regions 12Aa have a
shape extending along the extending direction D1 and include edges 12Ae extending
along the extending direction of the first regions 12Aa. Each of the edges 12Ae has
a wave-line shape with a plurality of bends arranged along the extending direction
D1 so that the edge 12Ae extends along a direction crossing both the extending direction
D1 and the width direction D2. That is, each of the edges 12Ae includes portions not
extending along the extending direction and not extending along the width direction
D2.
The edges 12Ae of the first regions 12Aa are also edges 12Be of the second regions
12Ba adjacent to the first regions 12Aa. That is, each of the edges 12Be of the second
regions 12Ba has a wave-line shape with a plurality of bends arranged along the extending
direction D1 so that the edge 12Be extends along a direction crossing both the extending
direction D1 and the width direction D2. That is, each of the edges 12Be includes
portions not extending along the extending direction and not extending along the width
direction D2.
In other words, the positions of the edges 12Ae of the first regions 12Aa in the circumferential
direction of the core 11 change continuously along the axial direction.
According to this configuration, the following advantageous effects can be obtained.
- (5) The portions of the core 11 on which the edges 12Ae of the first regions 12Aa
are wound and the portions of the core 11 on which the edges 12Be of the second regions
12Ba are wound vary in the axial direction. Therefore, the difference in thickness
at the boundaries between the first regions 12Aa and the second regions 12Ba is likely
to be reduced along the radial direction of the core 11. Accordingly, even when the
density of the element pattern structures is different between these regions, it is
possible to suppress an abrupt change in the thickness of the roll body along the
radial direction of the core 11 in the axial direction of the core 11. This suppresses
wrinkles in the sheet 12a wound on the core 11.
[0076] In the configuration described above with reference to Fig. 12, the edges 12Ae of
the first regions 12Aa and the edges 12Be of the second regions 12Ba may have a folded
shape with a plurality of bends arranged along the extending direction D1 or may have
a folded shape with one bend, or may have an arc shape.
[0077] Each of the element pattern structures may include a plurality of prism groups. Fig.
13 referred to later illustrates an enlarged portion of a planar structure of a sheet
12b in plan view of the sheet 12b.
[0078] As illustrated in Fig. 13, one first region 12Ab is sandwiched between two second
regions 12Bb in the width direction D2 in plan view of the sheet 12b. The first regions
12Ab have a plurality of cells C. In other words, an element pattern structure 22p
positioned in the first region 12Ab has a plurality of cells C. The plurality of cells
C include triangular cells C and quadrilateral cells C in plan view of the plane of
the sheet 12b. As described above, the plurality of cells C may include cells C different
in shape in plan view of the sheet 12b or all the cells C may be equal in shape in
plan view of the sheet 12b.
[0079] Each of the cells C has a prism group formed from a plurality of prisms Pr. In each
of the prism groups, the plurality of arc-shaped prisms Pr are aligned along one direction
in plan view of the sheet 12b. The plurality of prism groups include prism groups
different in the direction in which the prisms Pr are aligned. In addition, the plurality
of prism groups include prism groups different in the number of prisms Pr belonging
to one prism group or prism groups different in the pitch of the prisms Pr in the
direction in which the plurality of prisms Pr are aligned. All the prism groups may
be equal in the direction in which the prisms Pr are aligned, or all the prism groups
may be equal in the number of prisms Pr included in the prism group or may be equal
in the pitch of the prisms Pr in the direction in which the plurality of prisms Pr
are aligned.
[0080] In each of the element pattern structures 22p, the plurality of prism groups are
arranged along the extending direction D1 and the plurality of prism groups are arranged
along the width direction D2. Each of the element pattern structures 22p may be configured
such that only one prism group is positioned in the extending direction D1 and the
plurality of prism groups are arranged along the width direction D2 or may be configured
such that only one prism group is positioned in the width direction D2 and the plurality
of prism groups are arranged along the extending direction D1. Alternatively, each
of the element pattern structures 22p may be formed from only one prism group.
[0081] The prisms Pr have an arc shape in plan view of the sheet 12b but may have a linear
shape. The plurality of prism groups may include both prism groups formed from arc-shaped
prisms Pr and prism groups formed from linear-shaped prisms Pr, or all the prism groups
may have linear-shaped prisms Pr.
[0082] Fig. 14 illustrates an example of a cross-sectional structure of the sheet 12b in
the thickness direction and orthogonal to the direction in which the plurality of
prisms Pr extend, in other words, a cross-sectional structure in the width direction
D2 as an example of a cross-sectional structure corresponding to one prism group included
in the element pattern structure 22p. In the example of Fig. 14, the pitch of the
prisms Pr gradually decreases along the direction in which the plurality of prisms
Pr are aligned, that is, one of two inclination angles sandwiching an apex gradually
decreases in the cross sections of the prisms Pr. However, in the direction in which
the plurality of prisms Pr are aligned, the pitch of the prisms Pr may be constant
as illustrated in Fig. 13 referred to earlier or both the two inclination angles sandwiching
the apex may be constant in the direction in which the plurality of prisms are aligned.
[0083] As illustrated in Fig. 14, each of the prisms Pr is an asymmetrical prism with inclination
angles different between both sides of an apex in a cross section of the sheet 12b
along the thickness direction. More specifically, each of the prisms Pr has an apex
Pra, and, in the cross section along the thickness direction of the sheet 12b, one
of the inclination angles on one side of the apex Pra is a first inclination angle
θ1 and the other inclination angle is a second inclination angle θ2. Each of the first
inclination angle θ1 and the second inclination angle θ2 is an angle formed by the
surface of the support layer 21 on which the element pattern structure 22p is positioned
and the inclination surface of the prism Pr. The first inclination angle θ1 and the
second inclination angle θ2 are different, and the first inclination angle θ1 is an
acute angle and the second inclination angle θ2 is a right angle. Alternatively, the
first inclination angle θ1 and the second inclination angle θ2 may be both acute angles.
[0084] The first inclination angle θ1 of the prisms Pr gradually decreases along the direction
in which the plurality of prisms Pr are aligned. That is, the pitch of the prisms
Pr gradually increases in the direction in which the plurality of prisms Pr are aligned.
In contrast to this, the second inclination angle θ2 is constant in the direction
in which the plurality of prisms Pr are aligned. Alternatively, both the first inclination
angle θ1 and the second inclination angle θ2 may change continuously along the direction
in which the plurality of prisms Pr are aligned.
[0085] Each of the element pattern structures 22p has a support portion 22p1 positioned
between each of the prisms Pr and the support layer 21 in the thickness direction
of the sheet 12b. Each of the prisms Pr protrudes from the support portion 22p1 to
the opposite side of the support portion 22p1 from the support layer 21. The plurality
of prisms Pr are connected together via the support portion 22p1. The element pattern
structure 22p may not necessarily have the support portion 22p1.
[0086] The material for the element pattern structures 22p may be a light transmissive material
or a material that has a property of reflecting most of light incident on the element
pattern structures 22p. When the material for the element pattern structures 22p is
to be a light transmissive material, the material for the element pattern structures
22p may be any of various light-transmissive resins and dielectric substances, for
instance. When the material for the element pattern structure 22p is to be a material
that has a property of reflecting most of light incident on the element pattern structures
22p, the material for the element pattern structures 22p may be a metal, for example.
The element pattern structures 22p may include both a layer formed from a light transmissive
material and a layer formed from a light reflecting material.
[0087] Each of the element pattern structures 22p includes cells C different in the direction
in which the plurality of prisms Pr are aligned and cells C different in the number
of prisms Pr included in one prism group. This makes it possible to change the property
of transmitting light and the property of reflecting light between the cells C different
in the direction in which the plurality of prisms Pr are arranged and between the
cells C different in the number of prisms Pr included in one prism group.
[0088] According to this configuration, the following advantageous effects can be obtained.
[0089] (6) The portions of the core 11 on which the first regions 12Ab are wound and the
portions of the core 11 on which the second regions 12Bb are wound vary in the axial
direction. Therefore, even when the element pattern structures 22p positioned in the
first regions 12Ab include the plurality of prisms Pr, it is possible to suppress
deformation of the prisms Pr caused by winding the sheet 12b on the core 11.
[0090] The configuration described above with reference to Figs. 13 and 14 can be further
modified as described below. That is, a portion of each of the first regions including
the plurality of prisms Pr may be a prism portion, and each of the first regions may
include buffer portions sandwiching the prism portion in the width direction D2. The
height of the buffer portions is smaller than the height of the prism portion, and
the buffer portions include a concave-convex surface opposite to the surface in contact
with the support layer 21. Each of the first regions may further include transition
portions between the prism portion and the buffer portions in the width direction
D2. The height of the transition portions is a dimension between the height of the
prism portion and the height of the buffer portions, for example. The heights of the
prism portion, the buffer portions, and the transition portions take the respective
maximum values of these portions. This sheet will be described in detail with reference
to Figs. 15 and 16.
[0091] Fig. 15 illustrates an enlarged portion of a planar structure of a sheet 12c in plan
view of the sheet 12c. Fig. 16 illustrates a cross-sectional structure of the sheet
12c along the thickness direction and orthogonal to the direction in which the plurality
of prisms Pr extend.
[0092] As illustrated in Fig. 15, in plan view of the sheet 12c, one first region 12Ac is
sandwiched between two second regions 12Bc in the width direction D2. The first region
12Ab includes a prism portion Ac1 extending along a direction crossing the extending
direction D1 and the width direction D2, two buffer portions Ac2, and two transition
portions Ac3. The two buffer portions Ac2 sandwich the prism portion Ac1 therebetween
in the width direction D2. Each of the transition portions Ac3 is positioned between
the prism portion Ac1 and a corresponding buffer portion Ac2. The buffer portions
Ac2 and the transition portions Ac3 extend along the extending direction of the prism
portion Ac1.
[0093] In plan view of the sheet 12c, the total area of the buffer portions Ac2 is preferably
larger than the area of the prism portion Ac1, and more preferably, the area of each
of the buffer portions Ac2 is larger than the area of the prism portion Ac1. In other
words, in the width direction D2, the total width of the buffer portions Ac2 is preferably
larger than the width of the prism portion Ac1, and more preferably, the width of
each of the buffer portions Ac2 is larger than the width of the prism portion Ac1.
[0094] As illustrated in Fig. 16, in the first region 12Ac, the prism portion Ac1 is highest
and the buffer portions Ac2 are lowest. Each of the buffer portions Ac2 includes a
concave-convex surface on the side opposite to the surface in contact with the support
layer 21. The concave-convex surface can be a concave-convex surface with the function
to diffract light, the function to prevent reflection of light, the function to scatter
light, and the function to interfere with light. The concave-convex surface can also
include a plurality of portions having different functions.
[0095] Each of the transition portions Ac3 can include a concave-convex surface on the side
opposite to the surface in contact with the support layer 21 similarly to the buffer
portions Ac2. The concave-convex surface of each of the transition portions Ac3 can
be configured in the same manner as that of each of the buffer portions Ac2. Alternatively,
the surface of each of the transition portions Ac3 on the side opposite to the surface
in contact with the support layer 21 may be an inclined surface. The inclined surface
has an inclination so that the height of the transition portion Ac3 gradually decreases
along the direction from the prism portion Ac1 to the buffer portion Ac2.
[0096] The prism portion Ac1, the buffer portions Ac2, and the transition portions Ac3 can
be integrated as one layer. Accordingly, it is possible to suppress misalignment among
the prism portion Ac1, the buffer portions Ac2, and the transition portions Ac3. The
first regions 12Ac may be formed by using one original plate, and this original plate
may be obtained by connecting together an original plate for the prism portion, an
original plate for the buffer portions, and an original plate for the transition portions.
[0097] When the sheet 12c is rolled on the core, the buffer portions Ac2 included in the
first region 12Ac are subjected to a pressure of a magnitude between the pressure
on the prism portion Ac1 and the pressure on the second region 12Bc. Accordingly,
it is possible to suppress an abrupt change in the pressure between the pressure on
the prism portion Ac1 and the pressure on the second region 12Bc. This further suppresses
the deformation of the prism portion Ac1 when the sheet 12c is wound.
[0098] In addition, the transition portions Ac3 included in each of the first regions 12Ac
can reduce the difference in height between the prism portion Ac1 and the buffer portions
Ac2. This further suppresses the deformation of the prism portion Ac1.
[0099] Each of the first regions 12Ab may include the prism portion Ac1 extending along
a direction crossing the extending direction D1 and the width direction D2, one buffer
portion Ac2 on one side of the prism portion Ac1 in the width direction D2, and one
transition portion Ac3 between the prism portion Ac1 and the buffer portion Ac2. Each
of the first regions 12Ab may include the prism portion Ac1 extending along a direction
crossing the extending direction D1 and the width direction D2 and only one buffer
portion Ac2 adjacent to the prism portion Ac1.
[0100] Each of the first regions 12Ab may include the prism portion Ac1 extending along
a direction crossing the extending direction D1 and the width direction D2 and only
two buffer portions Ac2 sandwiching the prism portion Ac1 in the width direction D2.
Each of the first regions 12Ab may include the prism portion Ac1 extending along a
direction crossing the extending direction D1 and the width direction D2, the two
buffer portions Ac2 sandwiching the prism portion Ac1, and one transition portion
Ac3 between any one of the two buffer portions Ac2 and the prism portion Ac1, with
the other buffer portion Ac2 and the prism portion Ac1 being adjacent to each other.
[0101] The configuration described above with reference to Figs. 13 and 14 can be further
modified as described below. That is, the configuration described above with reference
to Figs. 13 and 14 can be carried out in combination with the configuration described
above with reference to Fig. 11.
[0102] In plan view of a sheet 12d, one first region 12Ad is sandwiched between two second
regions 12Bd in the width direction D2 as illustrated in Fig. 17. The first region
12Ad has a plurality of cells C similarly to the first region 12Ab described above.
[0103] Each of the second regions 12Bd includes linear projections Bd1 extending along the
extending direction D1. Each of the second regions 12Bd includes a plurality of linear
projections Bd1, and the plurality of projecting streaks Bd1 are spaced along the
width direction D2. Each of the second regions 12Bd may include only one linear projection
Bd1.
[0104] As illustrated in Fig. 18, the sheet 12d includes a support layer 21 and a pattern
layer 23d. The first regions 12Ad and the second regions 12Bd include mutually different
portions in the pattern layer 23d. A plurality of prisms Pr included in each of the
first region 12Ad constitute an element pattern structure 22p, and the first regions
12Ad are thicker portions of the pattern layer 23d. The second regions 12Bd are thinner
portions of the pattern layer 23d not including the element pattern structures 22p.
[0105] According to this configuration, when the pattern layer 23d is formed on the support
layer 21, the following advantageous effects can be obtained. To manufacture the sheet
12d, a film coating for forming the pattern layer 23d is formed on the support layer
21, and then an original plate for forming the prisms Pr is pressed against the film
coating. The original plate has a pattern corresponding to the linear projections
Bd1 to form the linear projections Bd1 concurrently with the prisms Pr. Accordingly,
the pattern of the original plate is pressed against the portions of the film coating
for forming the pattern layer 23d corresponding to the second regions 12Bd, too. This
suppresses lift of the portions of the film coating corresponding to the second regions
12Bd from the support layer 21.
[0106] Since each of the second regions 12Bd includes the linear projections Bd1, even
if a portion of the second region 12Bd contacts another portion of the second region
12Bd when the sheet 12d is wound on the core 11, it is possible to suppress occurrence
of blocking between these portions as compared to the case in which each of the second
regions 12Bd includes no linear projections.
[0107] The configuration described above with reference to Figs. 17 and 18 can be carried
out in combination with the configuration described above with reference to Figs.
15 and 16. That is, the portion of the pattern layer 23d corresponding to each of
the first regions 12Ad may include at least one of the buffer portions Ac2 and the
transition portions Ac3.
[0108] In the first embodiment, the density of the element pattern structures in the first
regions and the density of the element pattern structures in the second regions are
different. The present invention is not limited to this but the density of the element
pattern structures in the first regions and the density of the element pattern structures
in the second regions may be equal. In this case, the arrangement of the element pattern
structures in the first regions and the arrangement of the element pattern structures
in the second regions are different. Alternatively, the density of the element pattern
structures in the first regions and the density of the element pattern structures
in the second regions may be different and the arrangement of the element pattern
structures in the first regions and the arrangement of the element pattern structures
in the second regions may be different.
[Second embodiment]
[0109] A second embodiment of a roll body will be described with reference to Figs. 19 to
24. The roll body in the second embodiment is different from the roll body in the
first embodiment in that each of the first regions includes a plurality of element
pattern structures. This difference will be described below in detail and detailed
description of components in common with the roll body in the first embodiment will
be omitted. Configurations of first to fifth examples of the roll body will be described
below in sequence.
[0110] In each of Figs. 19 to 24, in plan view of the sheet, the element pattern structures
are shown dotted for the ease of discriminating between the portions with the element
pattern structures and the portions without element pattern structures.
[First example]
[0111] The first example of the roll body in the second embodiment will be described with
reference to Fig. 19.
[0112] As illustrated in Fig. 19, in a sheet 30, each of first regions 30A and second regions
30B has a linear shape extending along a direction crossing both the extending direction
D1 and the width direction D2.
[0113] The sheet 30 is formed from a support layer 31 and a pattern structure 32. The pattern
structure 32 is formed from a plurality of element pattern structures 32a, and the
plurality of element pattern structure 32a belong to one first region 30A.
[0114] The pattern structure 32 includes two or more kinds of element pattern structures
32a different in shape in plan view of the sheet 30. Accordingly, the shape of the
pattern structures 32 can be made complicated as compared to the configuration in
which all the element pattern structures 32a have the same shape.
[0115] In the pattern structure 32, each of the element pattern structures 32a is a portion
with a predetermined thickness. The pattern structure 32 is positioned in the first
regions 30A but is not positioned in the second regions 30B. In each of the first
regions 30A, the plurality of element pattern structures 32a are separated from each
other along the extending direction of the first region 30A.
[0116] Each of the element pattern structures 32a has a shape representing one letter of
the alphabet in plan view of the sheet 30. Each of the element pattern structures
32a has a shape representing any of letters "G", "E", "N", "U", and "I" of the alphabet.
[0117] In other words, in the first example of the roll body, the sheet 30 includes the
support layer 31 and a plurality of element pattern structure groups 32b that are
formed on the surface of the sheet 30 and are arranged cyclically along the extending
direction D1. Each of the element pattern structure groups 32b is formed from a plurality
of element pattern structures 32a that are supported by the support layer 31 and form
convex portions on the surface of the sheet 30. In the first example of the roll body,
one element pattern structure group 32b is formed by element pattern structures 32a
having the shapes representing the letters "G", "E", "N", "U", "I", "N", and "E".
The plurality of element pattern structures 32a constituting one element pattern structure
group 32b are arranged along a direction crossing both the extending direction D1
and the width direction D2. The plurality of element pattern structure groups 32b
are repeatedly provided in a predetermined cycle in a belt-like region of the sheet
30 extending along the extending direction D1 and occupying a portion of the sheet
30 in the width direction.
[0118] In plan view of the sheet 30, an element pattern structure group region Gr is defined
by surrounding an aggregate of a plurality of element pattern structures 32a constituting
one element pattern structure group 32b with an envelope contour line OL in contact
with a portion of edge of each of the element pattern structures 32a. The envelope
contour line OL is in contact with all the element pattern structures 32a belonging
to one element pattern structure group 32b. The envelope contour line OL is preferably
set to include a linear line extending in a direction in which the element pattern
structures 32a are arranged.
[0119] In the first example of the roll body, a line parallel to the extending direction
D1 is a reference line LD. The reference line LD is set to overlap the sheet 30 but
may be set to be separate from the sheet 30. The distance from at least one end portion
of the element pattern structure group region GR in the width direction D2 to the
reference line LD changes cyclically along the extending direction D1. In the first
example of the roll body, the distance from each end portion of the element pattern
structure group region GR in the width direction D2 to the reference line LD changes
within one element pattern structure group region GR, and the element pattern structure
group region GR is repeated cyclically along the extending direction D1 so that the
distance from each end portion to the reference line LD changes cyclically along the
extending direction D1.
[Second example]
[0120] The second example of the roll body in the second embodiment will be described with
reference to Fig. 20.
[0121] As illustrated in Fig. 20, in a sheet 40, first regions 40A and second regions 40B
have a linear shape extending along a direction crossing both the extending direction
D1 and the width direction D2.
[0122] The sheet 40 is formed from a support layer 41 and a pattern structure 42, and the
pattern structure 42 includes a plurality of element pattern structure groups 42b.
Each of the element pattern structure groups 42b is formed from a plurality of element
pattern structures 42a. Each of the first regions 40A and each of the second regions
40B includes the element pattern structure group 42b.
[0123] In the pattern structure 42, the plurality of element pattern structures 42a belonging
to one element pattern structure group 42b are separated from each other along the
width direction D2. The plurality of element pattern structures 42a belonging to each
of the element pattern structure groups 42b are configured in the same manner as the
plurality of element pattern structures 32a in the first example.
[0124] The plurality of element pattern structure groups 42b belonging to one first region
40A are separated from each other along a direction crossing both the extending direction
D1 and the width direction D2. When a plurality of element pattern structure groups
42b belong to one second region 40B, the plurality of element pattern structure groups
42b are preferably separated from each other along a direction crossing both the extending
direction D1 and the width direction D2 similarly to the plurality of element pattern
structure groups 42b belonging to one first region 40A.
[0125] The number of the element pattern structure groups 42b belonging to one first region
40A is larger than the number of the element pattern structure groups 42b belonging
to one second region 40B. More specifically, three element pattern structure groups
42b belong to one first region 40A, and one element pattern structure group 42b belongs
to one second region 40B.
[0126] If the number of the element pattern structure groups 42b belonging to one first
region 40A is different from the number of the element pattern structure groups 42b
belonging to one second region 40B, the number of the element pattern structure groups
42b belonging to one first region 40A may be other than three and the number of the
element pattern structure groups 42b belonging to one second region 40B may be other
than one. Alternatively, the number of the element pattern structure groups 42b belonging
to each first region 40A may be smaller than the number of the element pattern structure
groups 42b belonging to each second region 40B.
[0127] According to the second example, not only the first regions 40A but also the second
regions 40B include the element pattern structure groups 42b, and thus the shape of
the pattern structure 42 becomes more complicated in plan view of the sheet 40 as
compared with a configuration in which only the first regions 40A include the element
pattern structure groups 42b.
[0128] In other words, in the second example of the roll body, the sheet 40 includes the
support layer 41 and the plurality of element pattern structure groups 42b that are
formed on the surface of the sheet 40 and are arranged cyclically along the extending
direction D1. Each of the element pattern structure groups 42b is formed from a plurality
of element pattern structures 42a that are supported by the support layer 41 and form
convex portions on the surface of the sheet 40.
[0129] The plurality of element pattern structures 42a constituting one element pattern
structure group 42b are arranged along the width direction D2. Each of the element
pattern structure groups 42b has a length along substantially the entire sheet 40
in the width direction D2 and the plurality of element pattern structure groups 42b
are repeated cyclically along the extending direction D1. Among the plurality of element
pattern structure groups 42b, the element pattern structure groups 42b of which the
center is substantially arranged with the center of the sheet 40 as seen in the width
direction D2 are alternately positioned. Between those element pattern structure groups
42b, the element pattern structure group 42b closer to one end portion and the element
pattern structure group 42b closer to the other end portion are alternately positioned
in the width direction D2.
[0130] The envelope contour line OL is in contact with all the element pattern structures
42a belonging to one element pattern structure group 42b. The envelope contour line
OL is preferably set to include a straight line extending along the direction in which
the element pattern structures 42a are arranged. In the second example of the roll
body, the distance from each end portion of the element pattern structure group region
GR in the width direction D2 to the reference line LD changes cyclically along the
extending direction D1 among the element pattern structure group regions GR.
[Third example]
[0131] A third example of the roll body in the second embodiment will be described with
reference to Fig. 21.
[0132] As illustrated in Fig. 21, in a sheet 50, first regions 50A and second regions 50B
extend along a direction crossing both the extending direction D1 and the width direction
D2, and the edge of each of the first regions 50A and the second regions 50B along
the extending direction of the regions has a folded shape with a plurality of bends.
Each of the first regions 50A and the second regions 50B has a belt-like shape with
a plurality of constricted portions along the extending direction of the regions.
The first regions 50A and the second regions 50B are substantially equal in width.
[0133] The sheet 50 is formed from a support layer 51 and a pattern structure 52, and a
plurality of element pattern structures 52a belong to one first region 50A. In each
of the first regions 50A, the plurality of element pattern structures 52a are separated
from each other along the extending direction of the first region 50A. In plan view
of the sheet 50, each of the element pattern structures 52a has a hexagonal shape,
and out of the six sides of the element pattern structure 52a, two parallel sides
extend along the width direction D2.
[0134] On the other hand, one element pattern structure 52a belongs to one second region
50B. In each of the second regions 50B, the element pattern structure 52a is positioned
in the center in the width direction D2, and the position of the element pattern structure
52a in the second region 50B in the width direction D2 is equal to the position of
one element pattern structure 52a in each of the first regions 50A in the width direction
D2. Accordingly, in the pattern structure 52, the plurality of element pattern structures
52a including the element pattern structures 52a belonging to the second regions 50B
are aligned along the extending direction D1. All the element pattern structures 52a
have the same shape.
[0135] According to the third example, even if all the element pattern structures have
the same shape, it is possible to suppress continuous winding of the element pattern
structures at a predetermined position in the axial direction of the core 11, thereby
suppressing variations in the thickness of the sheet 50 along the radial direction
of the core 11.
[0136] In other words, in the third example of the roll body, the sheet 50 includes the
support layer 51 and the plurality of element pattern structure groups 52b that are
formed on the surface of the sheet 50 and arranged cyclically along the extending
direction D1. Each of the element pattern structure groups 52b is formed from a plurality
of element pattern structures 52a that are supported by the support layer 51 and form
convex portions on the surface of the sheet 50.
[0137] In the third example of the roll body, one element pattern structure group 52b is
formed from the plurality of hexagonal element pattern structures 52a. The plurality
of element pattern structures 52a constituting one element pattern structure group
52b are arranged along a direction crossing the extending direction D1. The plurality
of element pattern structure groups 52b are separated from each other in the extending
direction D1, and one element pattern structure 52a is positioned between two element
pattern structure groups 52b in the extending direction D1.
[0138] The envelope contour line OL is set partially along sides of each of the element
pattern structures 52a. In the fourth example of the roll body, the sides defining
the end portions of the element pattern structure group region GR in the width direction
D2 are inclined with respect to both the extending direction D1 and the width direction
D2. Accordingly, the distance from each end portion of the element pattern structure
group region GR in the width direction D2 to the reference line LD changes within
one element pattern structure group 52b, and the thus configured element pattern structure
group region GR is repeated along the extending direction D1 so that the distance
from the end portion to the reference line LD changes cyclically along the extending
direction D1.
[Fourth example]
[0139] A fourth example of the roll body in the second embodiment will be described with
reference to Figs. 22 and 23.
[0140] As illustrated in Fig. 22, in a sheet 60, first regions 60A and second regions 60B
are arranged along a direction crossing both the extending direction D1 and the width
direction D2. The edge of each of the first regions 60A along the extending direction
of the first region 60A has a folded shape with a plurality of bends, and each of
the first regions 60A has a belt-like shape with a plurality of constricted portions
along the extending direction of the first region 60A. Each of the second regions
60B has a belt-like shape with a plurality of bends. The first regions 60A are wider
than the second regions 60B.
[0141] The sheet 60 is formed from a support layer 61 and a pattern structure 62, and a
plurality of element pattern structures 62a belong to one first region 60A. The plurality
of element pattern structures 62a have the same shape in plan view of the sheet 60.
[0142] Each of the element pattern structures 62a has a hexagonal shape, and out of the
six sides of the element pattern structure 62a, two parallel sides extend along the
extending direction D1. The plurality of element pattern structures 62a belonging
to one first region 60A are spaced along the extending direction of the first regions
60A.
[0143] On the other hand, no element pattern structure 62a belongs to the second regions
60B. That is, each of the second regions 60B is formed only from a portion of the
support layer 61.
[0144] According to the fourth example, the same advantageous effects as those of the third
example can be obtained.
[0145] In other words, in the fourth example of the roll body, the sheet 60 includes the
support layer 61 and a plurality of element pattern structure groups 62b that are
formed on the surface of the sheet 60 and arranged cyclically along the extending
direction D1 as illustrated in Fig. 23. Each of the element pattern structure groups
62b is formed from a plurality of element pattern structures 62a that are supported
by the support layer 61 and form convex portions on the surface of the sheet 60.
[0146] In the fourth example of the roll body, one element pattern structure group 62b is
formed from the hexagonal element pattern structures 62a. The plurality of element
pattern structures 62a constituting one element pattern structure group 62b are arranged
along the width direction D2. The plurality of element pattern structure groups 62b
are repeated in a predetermined cycle along the extending direction D1. Among the
plurality of element pattern structure groups 62b, the number of the element pattern
structures 62a belonging to each element pattern structure group 62b is different.
Accordingly, two kinds of element pattern structure groups 62b different in the positions
of the end portions in the width direction D2 are alternately arranged along the extending
direction D1. Of the two kinds of element pattern structure groups 62b, one kind of
element pattern structure groups 62b include three element pattern structures 62a,
and the other kind of element pattern structure groups 62b include two element pattern
structures 62a.
[0147] The envelope contour line OL is set partially along sides of each of the element
pattern structures 62a. In the fourth example of the roll body, the distance from
each end portion of the element pattern structure group region GR in the width direction
D2 to the reference line LD changes cyclically along the extending direction D1 among
the element pattern structure group regions GR.
[Fifth example]
[0148] A fifth example of the roll body in the second embodiment will be described with
reference to Fig. 24.
[0149] As illustrated in Fig. 24, in a sheet 70, first regions 70A and second regions 70B
extend along a direction crossing both the extending direction D1 and the width direction
D2. Each of the first regions 70A has a belt-like shape in which a plurality of diamond-shaped
portions are aligned along the direction crossing both the extending direction D1
and the width direction D2 in plan view of the sheet 70.
[0150] Each of the second regions 70B has a belt-like shape in plan view of the sheet 70,
and the edge of each of the second regions 70B along the extending direction has a
folded shape with a plurality of bends. Each of the second regions 70B includes hexagonal
portions aligned along the extending direction of the second region 70B. Each of the
second regions 70B has a belt-like shape with a plurality of constricted portions
along the extending direction of the second region 70B.
[0151] The sheet 70 is formed from a support layer 71 and a pattern structure 72, and a
plurality of element pattern structures 72a belong to one first region 70A. Each of
the element pattern structures 72a has a diamond shape and the plurality of element
pattern structures 72a are aligned along the extending direction of the first region
70A.
[0152] On the other hand, no element pattern structure 72a belongs to each of the second
region 70B. In other words, each of the second regions 70B is formed only from a portion
of the support layer 71.
[0153] According to the fifth example, the same advantageous effects as those of the third
example can be obtained.
[0154] In other words, in the fifth example of the roll body, the sheet 70 includes the
support layer 71 and a plurality of element pattern structure groups 72b that are
formed on the surface of the sheet 70 and arranged cyclically along the extending
direction D1. Each of the element pattern structure groups 72b is formed from the
plurality of element pattern structures 72a that are supported by the support layer
71 and form convex portions on the surface of the sheet 70. In plan view of the sheet
70, one element pattern structure group 72b is formed from the diamond-shaped element
pattern structures 72a. The plurality of element pattern structures 72a constituting
one element pattern structure group 72b is arranged along a direction crossing both
the extending direction D1 and the width direction D2. Each of the element pattern
structure groups 72b has a length along substantially the entire sheet 70 in the width
direction D2 and the plurality of element pattern structure groups 72b are repeated
in a predetermined cycle along the extending direction D1.
[0155] The envelope contour line OL is set along the outer edge of each of the element pattern
structures 72a belonging to one element pattern structure group 72b. The sides constituting
the diamond-shaped element pattern structure 72a are inclined with respect to both
the extending direction D1 and the width direction D2. Accordingly, within one element
pattern structure group region GR, the distance from each end portion of the element
pattern structure group region GR in the width direction D2 to the reference line
LD changes cyclically along the extending direction D1, so that the distance from
each end portion of the element pattern structure group region GR to the reference
line LD changes cyclically along the extending direction D1 among the element pattern
structure group regions GR.
[0156] As described above, according to the second embodiment of the roll body, the following
advantageous effects can be obtained.
(7) As in each of the first to fifth examples, according to the first regions including
the plurality of element pattern structures, it is possible to represent complicated
shapes by the plurality of element pattern structures as compared to the configuration
in which one element pattern structure is continuous over the entire first regions.
(8) According to the configuration in which a pattern structure includes two or more
kinds of element pattern structures different in shape as in each of the first and
second examples, the shape of the pattern structure can be made complicated as compared
to the configuration in which all the element pattern structures have the same shape.
(9) Even if all the element pattern structures have the same shape as in each of the
third to fifth examples, it is possible to suppress continuous winding of the element
pattern structures at a predetermined position in the axial direction of the core
11, thereby suppressing variations in the thickness of the roll of the sheet 50 along
the radial direction of the core 11.
(10) According to the configuration in which not only the first regions 40A but also
the second regions 40B include the element pattern structure groups 42b as in the
second example, the shape of the pattern structure 42 can be made more complicated
in plan view of the sheet 40 as compared to the configuration in which only the first
regions 40A include the element pattern structure groups 42b.
(11) The distance from each end portion of the element pattern structure group region
GR in the width direction D2 to the reference line LD parallel to the extending direction
D1 changes cyclically along the extending direction D1, and thus the position of each
end portion changes cyclically in the axial direction of the core. Therefore, it is
possible to suppress wrinkles in the sheet wound on the core as compared to the configuration
in which the position of each end portion in the axial direction of the core does
not change.
[0157] The second embodiment described above can be appropriately modified as described
below.
[0158] Each of the element pattern structure group regions GR may be set such that the distance
from one end portion of the element pattern structure group region GR in the width
direction D2 to the reference line LD changes cyclically, whereas the length from
the other end portion to the reference line LD is constant. According to this configuration
as well, it is possible to suppress wrinkles in the sheet at least at the end portion
of the element pattern structure group region GR where the distance from the reference
line LD changes cyclically along the extending direction D1.
[0159] Each of the first to fifth examples can be carried out in combination with the configuration
of the modification example of the first embodiment described above with reference
to Fig. 11. Specifically, in each of the examples, the sheet may include a support
layer and a pattern layer, and the pattern layer may be a concave-convex structure
body including the pattern structure. In addition, portions of the pattern layer included
in the second regions and having no element pattern structure may have a predetermined
thickness.
[0160] In the second example, the element pattern structure groups 42b belonging to the
first regions 40A and the element pattern structure groups 42b belonging to the second
regions 40B may have different shapes in plan view of the sheet 40. That is, the element
pattern structure groups belonging to the first regions 40A may be formed from a plurality
of first element pattern structures and the element pattern structure groups belonging
to the second regions 40B may be formed from second element pattern structures different
from the first element pattern structures.
[0161] The element pattern structures are not limited to the shapes described above but
may have a shape representing any one of characters, numbers, symbols, and graphics
in plan view of the sheet.
[0162] The roll body in each of the examples of the second embodiment may include a sheet
but may not include a core as in the modification example of the first embodiment.
[Examples]
[0163] A polyethylene terephthalate film with a thickness of 23 µm was prepared as a base
material, and an ink for a relief layer with the composition shown below was applied
to the base material by gravure printing such that the thickness of the dried ink
became 1 µm. Accordingly, six whole sheets with a length of 5000 m were prepared.
Each of the whole sheets was wound on a core to obtain a roll body.
[Ink for relief layer]
[0164]
Urethane acrylate: 50.0 pts. mass
Methyl ethyl ketone: 30.0 pts. mass
Ethyl acetate: 20.0 pts. mass
Photo initiator: 1.5 pts. mass
[0165] As the urethane acrylate, Hitaloid 7903 series: multifunctional (Hitaloid is a registered
trademark) produced by Hitachi Chemical Co., Ltd. was used, and as the photo initiator,
Irgacure 184 (Irgacure is a registered trademark) produced by BASF Corporation was
used.
[0166] Then, each of the whole sheets was unrolled from the core, and a roll photopolymer
method was used to press a cylindrical original plate with a concave-convex outer
peripheral surface against the coat layer formed by the ink for relief layer to process
the surface of the coat layer opposite to the surface in contact with the base material
into a concave-convex surface. The original plate was pressed against the coat film
under the conditions that the press pressure was 2 Kgf/cm
2, the press temperature was 80°C, and the press speed was 10 m/min.
[0167] Concurrently with the pressing of the original plate against the coat layer, the
base material was irradiated with ultraviolet radiation from the side opposite to
the side with the coat film to harden the coat film. The irradiation with ultraviolet
radiation was performed by using a high-pressure mercury lamp and the exposure amount
was set to 300 mJ/cm
2. Accordingly, a relief layer having a sinusoidal relief surface with a depth of 120
nm and a cycle of 700 nm was formed to obtain a support layer formed from the base
material and the relief layer. Then, the support layer was wound on a core to obtain
a roll body.
[0168] The support layer was fed out from the roll body, and a 70 nm-thick aluminum layer
was formed by a roll-type vacuum evaporation device on the entire relief surface of
the relief layer. After that, the support layer with the aluminum layer was wound
on a core to obtain a roll body.
[0169] The stacked body of the aluminum layer and the support layer was fed out from the
roll body, and a mask ink with the composition shown below was applied by gravure
printing to the aluminum layer to form a mask. At this time, masks different in shape
were formed on the six roll bodies.
[0170] A mask for forming the pattern layer described above with reference to Fig. 2 was
formed on the first roll body to obtain the roll body in the first example, and a
mask for forming the pattern layer described above with reference to Fig. 19 was formed
on the second roll body to obtain the roll body in the second example. A mask for
forming the pattern layer described above with reference to Fig. 20 was formed on
the third roll body to obtain the roll body in the third example, and a mask for forming
the pattern layer described above with reference to Fig. 21 was formed on the fourth
roll body to obtain the roll body in the fourth example.
[0171] A mask for forming the pattern layer described above with reference to Fig. 22 was
formed on the fifth roll body to obtain the roll body in the fifth example, and a
mask for forming the pattern layer described above with reference to Fig. 9 was formed
on the sixth roll body to obtain the roll body in the first comparative example. In
addition, after drying, a mask ink was applied to the aluminum layer such that each
of the masks had a thickness of 3 µm.
[Mask ink]
[0172]
Polyamide resin: 20.0 pts. mass
Ethanol: 50.0 pts. mass
Toluene: 30.0 pts. mass
[0173] The stacked body of the support layer and the aluminum layer was subjected to alkaline
etching to obtain a sheet formed from the support layer and the element pattern structures.
Then, the sheet was wound on a core to obtain a roll body.
[Evaluations]
[0174] The roll bodies in the first to fifth examples and the roll body in the first comparative
example were unrolled to check visually whether the sheets had wrinkles. It has been
revealed that the roll bodies in the first to fifth examples had no wrinkles in the
sheets, whereas the roll body in the first comparative example had wrinkles in the
sheet.
[Reference Signs List]
[0175]
- 10, R
- Roll body
- 11, R1
- Core
- 11S, R1S
- Outer peripheral surface
- 12, 12a, 12b, 12c, 12d, 30, 40, 50, 60, 70, R2
- Sheet
- 12A, 12Aa, 12Ab, 12Ac, 12Ad, 30A, 40A, 50A, 60A, 70A, R2A
- First region
- 12Ae, 12Be
- Edge
- 12A1, 23a
- First part
- 12A2, 23b
- Second part
- 12A3
- Third part
- 12B, 12Ba, 12Bb, 12Bc, 12Bd, 30B, 40B, 50B, 60B, 70B, R2B
- Second region
- 12P
- Pattern section region
- 12S
- Surface
- 21, 31 ,41, 51, 61, 71, R21
- Support layer
- 21a, 22p1
- Support portion
- 22, 32, 42, 52, 62, 72, R22
- Pattern structure
- 22a, 22p, 32a, 42a, 52a, 62a, 72a, R22a
- Element pattern structure
- 22b
- Recess
- 23, 23d
- Pattern layer
- 32b, 42b, 52b, 62b, 72b
- Element pattern structure groupA ... Rotation axis
- Ac1
- Prism portion
- Ac
- Buffer portion
- Ac3
- Transition portion
- Bd1
- Linear projection
- C
- Cell
- GR
- Element pattern structure group region
- L
- Straight line
- LB, LD
- Reference line
- OL
- Envelope contour line
- P
- Reference point
- Pr
- Prism
- Pra
- Apex