Web butt-joining apparatus and method

1 . A web butt-joining apparatus, comprising:

a turret device that supports an old roll and a new roll on which band-shaped flexible base materials are wound to be capable of being unwound, and is rotatable at every predetermined angle;

a cutting drum including a cutting member, which is provided at a cylindrical portion of a peripheral surface with its tip end protruded, forms an inclined angle of 0.5 degrees to 5 degrees with respect to an axial direction of the cylindrical portion, and has substantially the same length as a width of the band-shaped flexible base material, and a holding device that holds a tip end portion of the band-shaped flexible base material of the new roll, and capable of rotating at the same speed as conveyance speed of the band-shaped flexible base material at a time of joining the band-shaped flexible base materials;

a cutting and joining drum which includes a cutting receiving member of substantially the same length as the width of the band-shaped flexible base material, and a holding device which holds a portion in the vicinity of a tail end portion of the band-shaped flexible base material of the old roll, and is capable of rotating at the same speed as a conveyance speed of the band-shaped flexible base material at a time of joining the band-shaped flexible base materials; and

a joining drum which holds a bonding tape to be separable and is capable of rotating at the same speed as the conveyance speed of the band-shaped flexible base material at a time of joining the band-shaped flexible base materials,

wherein while conveying the band-shaped flexible base material, the web butt-joining apparatus performs cutting and butt-joining of the tail end of the band-shaped flexible base material of the old roll and the tip end of the band-shaped flexible base material of the new roll.

2 . A web butt-joining apparatus, comprising:

a turret device that supports an old roll and a new roll on which band-shaped flexible base materials are wound to be capable of being unwound, and is rotatable at every predetermined angle;

a cutting drum including a cutting member, which is provided at a cylindrical portion with a radius R of a peripheral surface with its tip end protruded with a protruded amount h, forms an inclined angle θ with respect to a radius direction of the cylindrical portion, and has substantially the same length as a width of the band-shaped flexible base material, a cushioning member composed of foaming rubber provided at both sides of the cutting member, and a holding device that holds a tip end portion of the band-shaped flexible base material of the new roll, with the inclined angle θ in the relationship of 20 degrees≧θ≧cos −1 (R/(R+h)), and capable of rotating at the same speed as conveyance speed of the band-shaped flexible base material at a time of joining the band-shaped flexible base materials;

a cutting and joining drum which includes a cutting receiving member of substantially the same length as the width of the band-shaped flexible base material, and a holding device which holds a portion in the vicinity of a tail end portion of the band-shaped flexible base material of the old roll, and is capable of rotating at the same speed as conveyance speed of the band-shaped flexible base material at a time of joining the band-shaped flexible base materials; and

a joining drum which holds a bonding tape to be separable and is capable of rotating at the same speed of the conveyance speed of the band-shaped flexible base material at a time of joining the band-shaped flexible base materials,

wherein while transferring the band-shaped flexible base material, the web butt-joining apparatus performs cutting and butt-joining of the tail end of the band-shaped flexible base material of the old roll and the tip end of the band-shaped flexible base material of the new roll.

3 . A web butt-joining apparatus, comprising:

a turret device that supports an old roll and a new roll on which band-shaped flexible base materials are wound to be capable of being unwound, and is rotatable at every predetermined angle;

a cutting drum including a cutting member block, which is provided at a front surface of a block with its tip end protruded, with a cutting member of substantially the same length as the width of the band-shaped flexible base material embedded therein, a cylindrical portion having a peripheral surface capable of fitting the cutting member block in a recessed portion formed on a front surface to be flush with each other, and a holding device holding a tip end portion of the band-shaped flexible base material of the new roll, and capable of rotating at the same speed as conveyance speed of the band-shaped flexible base material at a time of joining the band-shaped flexible base materials;

a cutting and joining drum which includes a cutting receiving member of substantially the same length as the width of the band-shaped flexible base material, and a holding device which holds a portion in the vicinity of a tail end portion of the band-shaped flexible base material of the old roll, and is capable of rotating at the same speed as conveyance speed of the band-shaped flexible base material at a time -of joining the band-shaped flexible base materials; and

a joining drum which holds a bonding tape to be separable and is capable of rotating at the same speed as the conveyance speed of the band-shaped flexible base material at a time of joining the band-shaped flexible base materials, wherein while transferring the band-shaped flexible base material, the web

butt-joining apparatus performs cutting and butt-joining of the tail end of the band-shaped flexible base material of the old roll and the tip end of the band-shaped flexible base material of the new roll.

4 . The web butt-joining apparatus according to claim 1 , wherein

Vickers hardness of the cutting receiving member is 1000 or more.

5 . The web butt-joining apparatus according to claim 2 wherein

Vickers hardness of the cutting receiving member is 1000 or more.

6 . The web butt-joining apparatus according to claim 3 , wherein

Vickers hardness of the cutting receiving member is 1000 or more.

7 . The web butt-joining apparatus according to claim 1 , wherein

a metallizing plating layer of a thickness of 10 to 30 μm is formed on a front surface of the cutting receiving member.

8 . The web butt-joining apparatus according to claim 2 , wherein

a metallizing plating layer of a thickness of 10 to 30 μm is formed on a front surface of the cutting receiving member.

9 . The web butt-joining apparatus according to claim 3 , wherein

a metallizing plating layer of a thickness of 10 to 30 μm is formed on a front surface of the cutting receiving member.

10 . The web butt-joining apparatus according to claim 4 , wherein

a metallizing plating layer of a thickness of 10 to 30 μm is formed on a front surface of the cutting receiving member.

11 . The web butt-joining apparatus according to claim 1 , wherein

Vickers hardness of the cutting member is 600 to 1000.

12 . The web butt-joining apparatus according to claim 2 , wherein

Vickers hardness of the cutting member is 600 to 1000.

13 . The web butt-joining apparatus according to claim 3 , wherein

Vickers hardness of the cutting member is 600 to 1000.

14 . The web butt-joining apparatus according to claim 4 , wherein

Vickers hardness of the cutting member is 600 to 1000.

15 . The web butt-joining apparatus according to claim 7 , wherein

Vickers hardness of the cutting member is 600 to 1000.

16 . A web butt-joining method for performing cutting and butt-joining of a tail end of a band-shaped flexible base material of an old roll and a tip end of a band-shaped flexible base material wound round a new roll while causing the band-shaped base material wound around the old roll to travel, comprising the steps of:

winding the band-shaped flexible base material of the new roll on a cutting drum, and holding a tip end portion of the band-shaped flexible base material of the new roll by a new web holding device of the cutting drum;

winding the band-shaped flexible base material of the old roll on a cutting and joining drum and holding a portion in the vicinity of a tail end portion of the band-shaped flexible base material of the old roll by an old web holding device of-the cutting and joining drum;

holding a bonding tape at a joining drum;

while rotating the cutting and joining drum at the same speed as conveyance speed of the band-shaped flexible base material, and rotating the cutting drum at the same speed as conveyance speed of the band-shaped flexible base material, cutting the band-shaped flexible base material of the old roll and the band-shaped flexible base material of the new roll in an overlapped state by a cutting member which is provided at a cylindrical portion of a peripheral surface of the cutting drum or the cutting and joining drum with its tip end protruded and which forms an inclined angle of 0.5 degrees to 5 degrees with respect to an axial direction of the cylindrical portion;

casting away a portion in the vicinity of the tail end portion of the band-shaped flexible base material of the old roll and the tip end portion of the band-shaped flexible base material of the new roll which are cut, and holding the band-shaped flexible base material of the old roll and the band-shaped flexible base material of the new roll on the peripheral surface of the cutting drum or the cutting and joining drum; and

bonding the bonding tape held at the joining drum to the band-shaped flexible base material of the old roll and the band-shaped flexible base material of the new roll held at the peripheral surface of the cutting drum or the cutting and joining drum.

17 . A web butt-joining method for performing cutting and butt-joining of a tail end of a band-shaped flexible base material of an old roll and a tip end of a band-shaped flexible base material wound around a new roll while causing the band-shaped base material wound around the old roll, comprising the steps of:

winding the band-shaped flexible base material of the new roll on a cutting drum, and holding a tip end portion of the band-shaped flexible base material of the new roll by a new web holding device of the cutting drum;

winding the band-shaped flexible base material of the old roll on a cutting and joining drum and holding a portion in the vicinity of a tail end portion of the band-shaped flexible base material of the old roll by the old web holding device of the cutting and joining drum;

holding a bonding tape at a joining drum;

while rotating the cutting and joining drum at the same speed as conveyance speed of the band-shaped flexible base material, and rotating the cutting drum at the same speed as conveyance speed of the band-shaped flexible base material, cutting the band-shaped flexible base material of the old roll and the band-shaped flexible base material of the new roll in an overlapped state by a cutting member which is provided at a cylindrical portion with a radius R of a peripheral surface of the cutting drum or the cutting and joining-drum with its tip end protruded with a protruded amount h and which forms an inclined angle θ with respect to a radius direction of the cylindrical portion, which is a cutting member with the inclined angle θ being in relationship of 20 degrees≧θ≧cos −1 (R/(R+h)), and cushioning members composed of foaming rubber provided at both sides of the cutting member;

casting away a portion in the vicinity of the tail end portion of the band-shaped flexible base material of the old roll and the tip end portion of the band-shaped flexible base material of the new roll which are cut, and holding the band-shaped flexible base material of the old roll and the band-shaped flexible base material of the new roll on the peripheral surface of the cutting drum or the cutting and joining drum; and

bonding the bonding tape held at the joining drum to the band-shaped flexible base material of the old roll and the band-shaped flexible base material of the new roll held at the peripheral surface of the cutting drum or the cutting and joining drum.