REEL MEMBER AND FILM ACCOMMODATING BODY

Abstract

 The reel member of the present invention includes a core portion 2, which is in the form of a cylinder and is capable of traverse winding an adhesive film, where the adhesive film contains a base film and an adhesive layer disposed on the base film, first and second flange portions 11 and 12 respectively provided at both edges of the core portion 2, and first and second guide portions 21 and 22, which are respectively provided at inner sides of the first and second flange portions 11 and 12 over entire circumferences thereof and are configured to guide the adhesive film. The first and second guide portions 21 and 22 each have a tapered shape, a width of which increases along a direction from the core portion 2 towards a rim of the first or second flange portion 11 or 12.

Description

Technical Field

[0001] The present invention relates to a technology of reel members for winding and drawing a series of a long adhesive film for connecting a tab line of a solar battery.

Background Art

[0002] Conventionally, long adhesive films for bonding various electronic parts have been known.

[0003] Such an adhesive film is formed on a narrow and long base film, and is shipped in a state where the adhesive film is round around a reel member in the form of a roll.

[0004] In recent years, there is a desire for an elongation of the aforementioned adhesive film. When the adhesive film is made long, however, a diameter of a film roll increases to thereby increase stress applied on the adhesive film, especially at the core. Therefore, there is a problem that the adhesive inside the adhesive film may be projected from the adhesive film, and may be deposited on the flange portions.

[0005] It may be possible to solve the aforementioned problem by forming a core portion of a reel member to have a wide width, and an adhesive film is wound with so-called traverse winding.

[0006] When the adhesive film is wound with traverse winding, however, the adhesive projected from the adhesive film may be deposited on the both sides of the flanges, and so-called blocking, where the adhesive film cannot be pulled out regularly, may be caused.

[0007] When a gap between a flange and an adhesive film roll is made large not to deposit an adhesive projected from the adhesive film on the flange, on the other hand, a so-called collapse of the adhesive film, where the adhesive film is moved into a space between the flange and the adhesive film roll when the adhesive film is wound, may be caused.

[0008] Note that, the technical literature related to the present invention is, for example, as follows.

Citation List

Patent Literature

[0009] PTL 1: Japanese Patent Application Laid-Open (JP-A) No. 2011-11792

Summary of Invention

Technical Problem

[0010] The present invention aims to solve the aforementioned various problems in the art, and to achieve the following object. Namely, the object of the present invention is to provide a technology which can smoothly wind a long adhesive film around a reel member, and can smoothly pull out the adhesive film from the reel member.

Solution to Problem

[0011] The means for solving the aforementioned problems are as follows.

<1> A reel member, including:

a core portion, which is in the form of a cylinder and is capable of traverse winding an adhesive film, where the adhesive film contains a base film, and an adhesive layer disposed on the base film;

a pair of flange portions, respectively provided at both edges of the core portion; and

a pair of guide portions, which are respectively provided at inner sides of the flange portions over entire circumferences thereof and are configured to guide the adhesive film,

wherein the guide portions each have a tapered shape, a width of which increases along a direction from the core portion towards a rim of the flange portion.

<2> The reel member according to <1>, wherein an angle θ of a surface of each of the guide portions with a rotational axis direction of the core portion satisfies the following relationship:

where X is a distance of the adhesive layer projected from the adhesive film in the rotational axis direction of the core portion when the adhesive film is wound around the reel member, and Y is a thickness of the base film of the adhesive film.

<3> A film accommodating body, including:

the reel member according to <1> or <2>; and

an adhesive film roll, which is the adhesive film wound around the core portion of the reel member with traverse winding,

wherein the adhesive films respectively provided at both edges of each layer of the adhesive film roll are supported in a state where the base film of each adhesive film is in contact with a surface of the guide portion.

[0012] In the present invention, a pair of the guide portions are respectively provided at inner sides of a pair of the flange portions over entire circumferences thereof and are configured to guide the adhesive film, and the guide portions each have a tapered shape, a width of which increases along a direction from the core portion towards a rim of the flange portion. Therefore, the adhesive film present both edges of each layer of the adhesive film roll is aligned and supported surfaces of the guide portions in the state where the base film is in contact with the surfaces of the guide portion, when the adhesive film is wound around the core portion of the reel member with traverse winding.

[0013] As a result, according to the present invention, the projected parts of the adhesive layer of the adhesive film are not in contact with the surface of each guide portion, and blocking can be prevented when the adhesive film is pulled out.

[0014] Since there is no gap between the adhesive film present at both edges of the adhesive film roll and each flange portion, moreover, a so-called collapse of the adhesive film, where the adhesive film is moved into a space between each flange portion and the adhesive film roll at the time of winding the adhesive film, can be prevented.

[0015] In the present invention, an angle θ of a surface of each of the guide portions with a rotational axis direction of the core portion is set to satisfy the following relationship:

[0016] In the formula above, X is a distance of the adhesive layer projected from the adhesive film in the rotational axis direction of the core portion when the adhesive film is wound around the reel member, and Y is a thickness of the base film of the adhesive film. Therefore, the projected parts of the adhesive layer of the adhesive film is more surely prevented from being in contact with the surface of each guide portion.

Advantageous Effects of the Invention

[0017] The present invention can solve the aforementioned various problems in the art, achieve the aforementioned object, and provide a technology which can smoothly wind a long adhesive film around a reel member, and can smoothly pull out the adhesive film from the reel member.

[0018] According to the present invention, it is not necessary to replace a reel member often in a process for bonding an adhesive film, and therefore production efficiency can be significantly improved.

Brief Description of Drawings

[0019] 

FIG. 1A is a side view illustrating a structure of an embodiment of the reel member of the present invention.

FIG. 1B is a front view of the reel member of FIG. 1A.

FIG. 2A is a cross-sectional view cut along the line A-A in FIG. 1A.

FIG. 2B is an explanatory view schematically illustrating the dimensional relationship of the reel member of the present invention.

FIG. 3A is a front view illustrating a structure of an embodiment of the film accommodating body of the present invention.

FIG. 3B is a view illustrating the cross-section of the adhesive film in the film accommodating body of the present invention.

FIG. 4A is an explanatory view illustrating a gap between the adhesive film wound around the core portion of the reel member of the present invention.

FIG. 4B is an explanatory view illustrating a gap between the adhesive film wound around the core portion of the reel member of the present invention.

FIG. 5A is a schematic view for explaining the problems to be solved by the present invention.

FIG. 5B is a schematic view for explaining the problems to be solved by the present invention.

FIG. 6A is a schematic view for explaining the principle of the present invention.

FIG. 6B is a schematic view for explaining the principle of the present invention.

FIG. 7 is a view illustrating one example of a production method of the film accommodating body of the present invention (part 1).

FIG. 8A is a view illustrating one example of a production method of the film accommodating body of the present invention (part 2).

FIG. 8B is a view illustrating one example of a production method of the film accommodating body of the present invention (part 2).

FIG. 9A is a side view illustrating a structure of another embodiment of the present invention.

FIG. 9B is a front view of the reel member of FIG. 9A.

FIG. 10A is a cross-sectional view cut along the line C-C of FIG. 9B.

FIG. 10B is a cross-sectional view cut along the line B-B of FIG. 9A.

FIG. 11 is an explanatory side view illustrating the dimensional relationship of the reel member of the present embodiment.

Description of Embodiments

[0020] The preferred embodiments of the present invention are explained in details with reference to drawings, hereinafter.

[0021] The present invention is not particularly limited, but the present invention is suitably used with a long adhesive film.

[0022] As for the adhesive film, the width thereof is preferably in the range of 0.6 mm to 3.0 mm, and a thickness of an adhesive layer formed on a base film is preferably in the range of 10 µm to 50 µm.

[0023] Moreover, the minimum melt viscosity of the adhesive is preferably 1 × 10³ Pa·s to 5.0 × 10⁵ Pa·s.

[0024] Note that, a thickness of the base film is described later.

[0025] Moreover, the present invention can be applied for a so-called two-layer adhesive film, which does not have a release film on an adhesive layer. In view of a prevention of blocking at the time of pulling the film out, the present invention is particularly effective for a so-called three-layer adhesive film, in which a release film is disposed on an adhesive layer.

[0026] FIG. 1A is a side view illustrating a structure of an embodiment of the reel member of the present invention. FIG. 1B is a front view of the same reel member.

[0027] Moreover, FIG. 2A is a cross-sectional view cut along the line A-A in FIG. 1A. FIG. 2B is an explanatory view schematically illustrating the dimensional relationship of the reel member of the present invention.

[0028] The reel member 1 of the present embodiment is an integral member formed of a resin, such as polystyrene, and polycarbonate, and is mounted on a driving shaft of a film winding device or a film drawing device, which is not illustrated.

[0029] The reel member 1 contains a cylindrical core portion 2, around which an adhesive film is wound.

[0030] At the both edges of the core portion 2, first and second flange portions 11, and 12, which are a pair of flange portions, are disposed.

[0031] In case of the present embodiment, the first and second flange portions 11, and 12 are formed into identical circular plate shapes, and are disposed concentrically in a manner that the each flange portion is placed orthogonally relative to a rotational axis line O of the core portion 2.

[0032] First and second guide portions 21 and 22, which are a pair of guide portions configured to guide an adhesive film, are disposed at areas of the first and second flange portions 11, and 12, along the entire circumferences thereof.

[0033] The first and second guide portions 21 and 22 are each formed into a tapered shape (e.g., a reverse tapered shape, and a truncated cone shape), a width of which increases along the direction from the core portion 2 towards a rim of the first or second flange portion 11 or 12.

[0034] In case of the present embodiment, the first and second guide portions 21 and 22 are formed into the same shapes, and the same sizes.

[0035] The bottom surface of the first guide portion 21 is formed into the same shape and the same size to the first flange portion 11, and the top surface of the first guide portion 21 is formed into the same shape and the same size to the core portion 2.

[0036] Moreover, the bottom surface of the second guide portion 22 is formed into the shame shape and the same size to the second flange portion 12, and the top surface of the second guide portion 22 is formed into the same shape and the same size to the core portion 2.

[0037] The first and second guide portions 21 and 22 are formed to have the same height (thickness) to each other.

[0038] Moreover, a hole 3 is provided in a manner that the hole is threaded through the first flange portion 11, the first guide portion 21, the core portion 2, the second guide portion 22, and the second flange portion 12.

[0039] The reel member 1 is mounted on a driving shaft by inserting the driving shaft (not illustrated) of a film winding device or film drawing device into the hole 3.

[0040] In the present specification, a diameter (outer diameter) of each of the first and second flange portions 11 and 12 of the reel member 1 is determined as D, and thicknesses (widths) of the first and second flange portions 11 and 12 are respectively determined as W1 and W2, as illustrated in FIG. 2B.

[0041] Moreover, a diameter (outer diameter) of the core portion 2 is determined as d, and a thickness (width) of the core portion 2 is determined as T.

[0042] Furthermore, a thickness of each of the first and second guide portions 21 and 22 is determined as t.

[0043] In case of the present invention, the diameter D of each of the first and second flange portions 11 and 12 is preferably set to the range of 125 mm to 190 mm in view of space saving when a reel is mounted, but D is not particularly limited.

[0044] In case of the present invention, moreover, the thicknesses W1 and W2 of the first and second flange portions 11 and 12 are both preferably set to the range of 2 mm to 5 mm in view of space saving when a reel is mounted, but W1 and W2 are not particularly limited.

[0045] In case of the present invention, the thickness T of the core portion 2 is preferably set to the range of 10 mm to 30 mm in view of prevention of collapse of a wound roll, but T is not particularly limited.

[0046] Meanwhile, in case of the present invention, the thickness (width) t of each of the first and second guide portions 11 and 12 is set considering an angle (tapered angle) θ of a surface of each of the first and second guide portions 21 and 22 with the direction of the rotational axis line O of the core portion 2, as described later.

[0047] The reel member 1 of the present invention can be produced by various methods.

[0048] For example, the reel member 1 can be produced by preparing each of a first flange portion 11, a second flange portion 12, a core portion 2, a first guide portion 21, and a second guide portion 22 through injection molding, and adhering these parts through welding (e.g., heat, and ultrasonic wave).

[0049] Moreover, the aforementioned reel member 1 can be also produced by monolithic molding.

[0050] FIG. 3A is a front view illustrating a structure of an embodiment of the film accommodating body of the present invention. FIG. 3B is a view illustrating the cross-section of the adhesive film in the same film accommodating body.

[0051] The film accommodating body 7 of the present embodiment is a body, in which an adhesive film 10 is wound around the core portion 2 of the aforementioned reel member 1 with traverse winding.

[0052] The term "traverse winding" means to wind a long film around a core spirally with the predetermined pitch (gap) to thereby give a plurality of layers.

[0053] FIGs. 4A and 4B are explanatory views illustrating a gap between the adhesive film wound around the core portion of the reel member of the present invention.

[0054] In the present invention, the adhesive film 10 is wound around the core portion 2 of the reel member 1 in a manner that the gap between adjacent adhesive films 10 is to be the predetermined value p (see FIG. 4A). Moreover, the adhesive film 10 is wound over the adhesive film 10 in a manner that the gap between adjacent adhesive films 10 is to be the predetermined value p (see FIG. 4B).

[0055] In this case, the gap p between the adjacent adhesive films 10 is not particularly limited, but is preferably set to the range of 0.05 mm to 0.1 mm.

[0056] When the gap p of the adjacent adhesive films 10 is smaller than 0.05 mm, the adjacent adhesive films 10 may be bonded together with the adhesive projected in the film width direction. When the gap p is greater than 0.1 mm, on the other hand, collapse of a round roll may occur when the adhesive film 10 is wound. In case of a two-layer adhesive film, moreover, the upper layer and the bottom layer of the adhesive films 10 may be brought into contact with each other through a gap between the adjacent adhesive films 10, to thereby cause blocking.

[0057] FIGs. 5A and 5B are schematic views for explaining the problems to be solved by the present invention.

[0058] An example of a so-called three-layer adhesive film 10, in which an adhesive layer 16 and a release film 17 are disposed on a base film 15, is explained here.

[0059] In the case where the aforementioned adhesive film 10 is wound around a reel member with traverse winding in the related art, a film transportation is controlled not to bring the adhesive film 10A present at the edges of each layer of the adhesive film roll 20 into contact with the flange portion 13, considering projections of the adhesive layer 16 in the width direction of the adhesive film 10.

[0060] It is however difficult to accurately control the film transportation. As the position of each adhesive film 10 in the adhesive film roll 20 varies, the film transportation is controlled considering these variations.

[0061] If a gap between the adhesive film 10A present at the edge of the adhesive film roll 20 and the flange portion 13 is small, for example as illustrated in FIG. 5A, in this case, the adhesive layer 16 projected from the adhesive film 10A is brought into contact with the flange portion 13 to deposit the adhesive, and the adhesive film 10 cannot be pulled out regularly, to thereby cause so-called blocking.

[0062] If the gap between the adhesive film 10A present at the edge of the adhesive film roll 20 and the flange portion 13 is made large, for example as illustrated in FIG. 5B, in order not to bring the adhesive layer 16 projected from the adhesive film 10A present at the edge of the adhesive film roll 20 into contact with the flange portion 13, the adhesive film 10A present at the edge is moved into the space between the flange portion 13 and the adhesive film roll 20 when the adhesive film 10 is wound, to thereby cause a so-called collapse of the film.

[0063] Since the present invention has the structure described below, the aforementioned problems can be solved.

[0064] FIGs. 6A and 6B are schematic views for explaining the principle of the present invention.

[0065] In the present invention, as described earlier, the first and second guide portions 21 and 22 are respectively provided at the inner sides of the first and second flange portions 11 and 12 along the entire circumferences thereof. The first and second guide portions 21 and 22 are each formed into a tapered shape, a width of which increases along the direction from the core portion 2 towards the rim of the first or second flange portion 11 or 12.

[0066] When the adhesive film 10 is wound around the reel member 1 with traverse winding, moreover, the adhesive film 10A present at the both edges of each layer of the wound adhesive film roll 20 is supported by the first or second guide portion 21 or 22, by bringing the bottom edge 15a of the outer side of the base film 15 is into contact with a surface 26 of the first or second guide portion 21 or 22 (see FIG. 6B).

[0067] In the present invention, an angle (tapered angle) θ of the surface 26 of the first or second guide portion 21 or 22 with the direction of the rotational axis line O of the core portion 2 is, for example, set as follows.

[0068] In the embodiment illustrated in FIG. 6B, specifically, a distance of the adhesive layer 16 projected in the width direction of the adhesive film 10 (the direction of the rotational axis line O of the core portion 2), when the adhesive film 10 is wound around the reel member 1, is determined as X, and the thickness of the base film 15 of the adhesive film 10 is determined as Y. The angle θ is set to satisfy the following relationship.

[0069] In this case, the thickness Y of the base film 15 of the adhesive film 10 is predetermined, and is known in advance.

[0070] Moreover, the distance X of the adhesive layer 16 projected in the width direction of the adhesive film 10 (projected distance of the adhesive), when the adhesive film 10 is wound around the reel member 1, can be determined by measuring in advance.

[0071] When the distance X of the projected adhesive is not constant, and has a range, the maximum value is taken as the distance X of the projected adhesive.

[0072] According to the present embodiment having the aforementioned structure, the adhesive film 10A present at the both edges of the adhesive film roll 20 is supported by the surface 26 of the first or second guide portion 21 or 22, and is aligned along the surface 26 in the state where the adhesive film 10 is wound around the reel member 1. As the projected distance X of the adhesive is smaller than Y/tanθ according to the formula (1), the projected parts of the adhesive layer 16 are not in contact with the surface 26 of the first or second guide portion 21 or 22.

[0073] As a result, according to the present embodiment, the projected parts of the adhesive layer 16 of the adhesive film 10 is not in contact with the surface 26 of the first or second guide portion 21 or 22, and blocking can be prevented when the adhesive film 10 is pulled out.

[0074] Since there is no space between the adhesive film 10A present at the both edges of the adhesive film roll 20 and the first or second guide portion 21 or 22, moreover, a so-called collapse of the adhesive film, where the adhesive film is moved into a space between the first or second guide portion 21 or 22, and the adhesive film roll 20 when the adhesive film 10 is wound, can be prevented.

[0075] In the case where the aforementioned adhesive is used, the thickness Y of the base film 15 is specifically in the range of 35 µm to 80 µm, and the projected distance X of the adhesive is specifically in the range of 30 µm to 50 µm.

[0076] In the case where such the adhesive film 10 is wound around the aforementioned reel member 1, the tapered angle θ of each of the first and second guide portions 21 and 22 is preferably set to be smaller than 60°.

[0077] In view of reductions in the weight and size of the reel member 1, however, the tapered angle θ of each of the first and second guide portions 21 and 22 is preferably set to 50° or greater.

[0078] In view of the aforementioned points, the thickness t of each of the first and second guide portions 21 and 22 is specifically, preferably set to the range of 2 mm to 5 mm.

[0079] FIGs. 7, 8A, and 8B illustrate an example of a production method of the film accommodating body of the present invention.

[0080] In order to produce the aforementioned film accommodating body, for example, the film winding device illustrated in FIGs. 7, 8A, and 8B can be used.

[0081] The film winding device contains a wind-up driving shaft 30 connected to a driving system that is not illustrated, and is constructed in a manner that the aforementioned reel member 1 is mounted on the wind-up driving shaft 30.

[0082] A guide roller 32 having a guide groove 31 on a surface thereof (see FIGs. 8A and 8B) is disposed adjacent to the wind-up driving shaft 30.

[0083] The guide roller 32 is disposed parallel to the wind-up driving shaft 30, and is configured to be driven by a guide roller driving shaft 33, which is movable in the axial direction of the wind-up driving shaft 30.

[0084] In the case where the adhesive film 10 is wound around the reel member 1 using the aforementioned film winding device, the adhesive film 10 pulled out from a film supply, which is not illustrated, is placed over the guide groove 31 of the guide roller 32, and a tip of the adhesive film 10 is attached to one of the edges of the core portion 2.

[0085] In this state, the wind-up driving shaft 30 is rotated in the winding up direction.

[0086] As illustrated in FIGs. 8A and 8B, in this case, the adhesive film 10 is moved between the first and second guide portions 21 and 22 in the direction of the wind-up driving shaft 30 by moving the guide roller driving shaft 33 in the axial direction thereof.

[0087] The adhesive film 10 is wound around the core portion 2 of the reel member 1 with traverse winding in the state where the outer edges of the base film 15 of the adhesive film 10 are in contact with the first or second guide portion 21 or 22, by repeating the aforementioned operation. As a result, the desired film accommodating body 7 is attained.

[0088] FIGs. 9 to 11 illustrate another embodiment of the present invention. FIG. 9A is a side view illustrating a structure of the embodiment, and FIG. 9B is a front view of the same reel member.

[0089] Moreover, FIG. 10A is a cross-sectional view cut along the line C-C of FIG. 9B, and FIG. 10B is a cross-sectional view cut along the line B-B of FIG. 9A.

[0090] The parts corresponding to the aforementioned embodiments are given with the identical references, and descriptions thereof are omitted, hereinafter.

[0091] The reel member 1A of the present embodiment contains a cylindrical core portion 2A, which is thinner than the core portion 2 of the aforementioned embodiment.

[0092] A cylindrical shaft portion 5 is disposed in the inner space 4 of the core portion 2A.

[0093] The shaft portion 5 has the smaller diameter than the diameter of the core portion 2A, and is arranged concentrically with the core portion 2A and secured to the inner walls of the first and second guide portions 21 and 22.

[0094] Moreover, the aforementioned hole 3 is disposed to correspond to the driving shaft support 5a, which is an inner wall area of the shaft portion 5. The driving shaft is inserted into the hole 3, and is supported with the driving shaft support 5a. In this manner, the reel member 1A is constructed to be mounted to the driving shaft.

[0095] FIG. 11 is an explanatory side view that schematically illustrates the dimensional relationship of the reel member of the present embodiment.

[0096] In case of the present embodiment, the diameter (outer diameter) of the core portion 2A is determined as d1, and the thickness (width) thereof is determined as w1.

[0097] Moreover, the diameter (inner diameter) of the driving shaft support 5a of the shaft portion 5 is determined as d2, and the thickness thereof is determined as w2.

[0098] In case of the present embodiment, the diameter d1 of the core portion 2A of the reel member 1A is preferably set to the range of 50 mm to 130 mm, and the thickness w1 of the core portion 2A is preferably set to the range of 1.5 mm to 5.0 mm for securing the rigidness required when the long adhesive film 10 is wound or drawn, but the diameter d1 and the thickness w1 are not particularly limited.

[0099] In case of the present embodiment, moreover, the diameter d2 of the driving shaft support 5a of the shaft portion 5 of the reel member 1A is preferably set to the range of 18.0 mm to 26.0 mm, and the thickness w2 of the shaft portion 5 is preferably set to the range of 1.0 mm to 2.5 mm for securing the rigidness required when the long adhesive film 10 is wound or drawn, but the diameter d2 and the thickness w2 are not particularly limited.

[0100] In addition to the embodiment already described, the aforementioned present embodiment exhibits the following effects.

[0101] In the present embodiment, specifically, any distortion is not applied to the shaft portion 5, even when a large force is applied to the core portion 2A due to the stress of the adhesive film 10 generated by winding the adhesive film 10 around the core portion 2A, because the shaft portion 5 having the driving shaft support 5a is secured to the first and second flange portions 11 and 12 in the inner space 4 of the core portion 2A.

[0102] As a result, according to the present embodiment, the reel member 1A is smoothly mounted without any difficulty, when the reel member 1A, around which the adhesive film 10 is wound with traverse winding, is mounted on the driving shaft of the drawing device, and thus the film accommodating body 7, in which the longer adhesive film 10 has been wound, can be provided.

[0103] Note that, the present invention is not limited to the aforementioned embodiments, and various changes can be made.

[0104] In the embodiment above, for example, surfaces of the first and second guide portions 21 and 22 are each formed linearly in the cross-section thereof (see FIG. 2), but the present invention is not limited to this embodiment. The surfaces of the first and second guide portions 21 and 22 may be each formed into a curve in the cross-section thereof.

[0105] In this case, the projected parts of the adhesive layer 16 of the adhesive film 10 are surely prevented from being in contact with the surface of the first or second guide portion 21 or 22, as long as the surfaces of the first and second guide portions 21 and 22 are configured to satisfy the relationship of θ < tan^-1 (Y/X).

Examples

[0106] The present invention is specifically explained through examples and comparative example thereof, hereinafter. These examples shall not be construed as to limit the scope of the present invention in any way.

[Preparation of Adhesive Film]

[0107] An adhesive layer having a thickness of 25 µm was formed on a base film, which was formed of PET having a width of 1 mm, and had a thickness of 38 µm, and a PET release film having a thickness of 12 µm was further applied on the adhesive layer. The resultant was used as an adhesive film.

[0108] The composition of the adhesive contained 30 parts by weight of a phenoxy resin (YP-50, manufactured by Nippon Steel & Sumikin Chemical Co., Ltd.), 20 parts by weight of a liquid epoxy resin (JER828, manufactured by Mitsubishi Chemical Corporation), 10 parts by weight of a rubber component (SG80H, manufactured by Nagase ChemteX Corporation), 40 parts by weight of a hardening agent (NOVACURE 3941HP, manufactured by Asahi Kasei Corporation), and 1 part by weight of a silane coupling agent (A-187, manufactured by Momentive Performance Materials, Inc.).

[0109] The aforementioned adhesive composition was dissolved in a toluene solvent, followed by applying the resulting solution onto the base film. The applied solution was heated for 10 minutes at the atmospheric temperature of 50°C to evaporate the solvent, to thereby form the adhesive layer.

[0110] The minimum melt viscosity of the adhesive was 7.0 × 10³ Pa·s.

[0111] The minimum melt viscosity of the adhesive is a value measured by means of a rotary rheometer (manufactured by TA instruments) at the heating speed of 10 °C/min, with maintaining the measuring pressure constant to 5 g, using a measuring plate having a diameter of 8 mm.

(Example 1)

[0112] As for a reel member, a reel member, which was formed of a polystyrene resin, and had a structure illustrated in FIGs. 9A and 9B, was used.

[0113] The used reel member had the core portion having a width of 50 mm, a diameter of 65 mm, and a thickness of 5 mm, the shaft portion having a diameter of 25 mm, and a thickness of 5 mm, and a pair of flange portions each having the diameter of 135 mm.

[0114] Moreover, a pair of guide portions were provided to give a tapered angle θ of 56°.

[0115] An adhesive film of 5,000 m was wound around the reel member with traverse winding in accordance with the method illustrated in FIGs. 7, 8A, and 8B.

[0116] The projected distance X of the adhesive was measured by observing the adhesive film adjacent the core portion under a microscope, and was 25 µm.

[0117] In Example 1, therefore, the value of tan^-1 [thickness of base film (Y)/ projected distance of adhesive (X)] was 56.66.

(Example 2)

[0118] The aforementioned adhesive film of 5,000 m was wound with traverse winding under the same conditions as in Example 1, provided that the tapered angle θ of the guide portion was set to 60°.

[0119] Moreover, the projected distance X of the adhesive was measured under the same conditions as in Example 1, and the projected distance X was 25 µm. Therefore, the value of tan^-1 [thickness of base film (Y)/projected distance of adhesive (X)] was 56.66.

(Comparative Example 1)

[0120] The aforementioned adhesive film of 5,000 m was wound with traverse winding under the same conditions as in Example 1 using the reel member having the same structure as in Example 1, provided that tapered guide portions were not disposed to a pair of the flange portions.

[0121] In this case, a gap between the edge of the adhesive film roll and the flange portion was set to 0.1 mm.

[0122] Moreover, the projected distance X of the adhesive was measured under the same conditions as in Example 1, and the projected distance X was 25 µm. Therefore, the value of tan^-1 [thickness of base film (Y)/projected distance of adhesive (X)] was 56.66.

<Evaluation>

[0123] The film accommodating bodies produced in Examples 1 and 2, and Comparative Example 1 were each mounted on a driving shaft of a film drawing device, and the film was drawn under the conditions that the environmental test temperature was 30°C, the drawing speed was 4,000 mm/min, and the drawing tension was 50 g. Any abnormality caused during the drawing was observed. The results are presented in Table 1.

Table 1

	Ex. 1	Ex. 2	Comp. Ex. 1
Thickness Y of base film (µm)	38	38	38
Projected width X of adhesive layer (µm)	25	25	25
tar-1(Y/X)	56.66	56.66	56.66
Actual angle of guide surface (°)	56	60	90 (no taper)
Drawing evaluation	A	B	C

<Evaluation Results>

[0124] As it is clear from Table 1, the adhesive film could be pulled out without any problem in Example 1, in which the tapered angle θ of the guide portion was 56° that was smaller than the value of tan^-1 [the thickness of the base film (Y) / projected distance of the adhesive (X)], i.e., 56.66.

[0125] The adhesive film could be pulled out, through the adhesive film was slightly pulled back, in Example 2, in which the tapered angle θ of the guide portion was 60° that was slightly greater than the value of tan^-1 [the thickness of the base film (Y) / projected distance of the adhesive (X)], i.e., 56.66.

[0126] Meanwhile, the adhesive was attached to the flange portions, and the adhesive film could not be pulled out regularly in Comparative Example 1, in which a tapered guide portion was not disposed to each flange portion.

[0127] The effects of the present invention could be demonstrated from the results presented above.

Reference Signs List

[0128] 

1:

reel member

2:

core portion

3:

hole

7:

film accommodating body

10:

adhesive film

11:

first flange portion

12:

second flange portion

15:

base film

16:

adhesive layer

21:

first guide portion

22:

second guide portion

O:

rotational axis line

X:

projected distance of adhesive

Y:

thickness of base film

Claims

1. A reel member, comprising:

a core portion, which is in the form of a cylinder and is capable of traverse winding an adhesive film, where the adhesive film contains a base film, and an adhesive layer disposed on the base film;

a pair of flange portions, respectively provided at both edges of the core portion; and

a pair of guide portions, which are respectively provided at inner sides of the flange portions over entire circumferences thereof and are configured to guide the adhesive film,

wherein the guide portions each have a tapered shape, a width of which increases along a direction from the core portion towards a rim of the flange portion.

2. The reel member according to claim 1, wherein an angle θ of a surface of each of the guide portions with a rotational axis direction of the core portion satisfies the following relationship:

where X is a distance of the adhesive layer projected from the adhesive film in the rotational axis direction of the core portion when the adhesive film is wound around the reel member, and Y is a thickness of the base film of the adhesive film.

3. A film accommodating body, comprising:

the reel member according to claim 1 or 2; and

an adhesive film roll, which is the adhesive film wound around the core portion of the reel member with traverse winding,

wherein the adhesive films respectively provided at both edges of each layer of the adhesive film roll are supported in a state where the base film of each adhesive film is in contact with a surface of the guide portion.

Drawing