Patent Publication Number: US-2022227655-A1

Title: Manufacturing method and manufacturing device of glass roll

Description:
TECHNICAL FIELD 
     The present invention relates to a method and a device for manufacturing a glass roll by winding a glass film on which a functional film is formed. 
     BACKGROUND ART 
     There have been known techniques for forming a functional film on a glass film while unwinding the glass film from a base glass roll and transporting the glass film in a predetermined direction using a roll-to-roll method. 
     For example, Patent Document 1 discloses a manufacturing method of a glass roll, the method including a glass film supply step of feeding a first glass film unwound from a base glass roll in a predetermined direction, a film formation step of forming a functional film (transparent conductive film) with heat on the first glass film to form a second glass film, a protective film supply step of layering a protective film on the second glass film to form a third glass film, and a winding step of winding the third glass film into a roll shape to form the glass roll. 
     When the glass film (third glass film) on which the functional film is formed is wound into the roll shape as described above, the glass film needs to be coupled to a winding core. Patent Document 2, for example, discloses a technique of coupling the winding core and the glass film by using a resin lead film (leader) to prevent damage to the glass film. 
     CITATION LIST 
     Patent Literature 
     Patent Document 1: JP 2018-188320 A 
     Patent Document 2: JP 2017-109850 A 
     SUMMARY OF INVENTION 
     Technical Problem 
     When the functional film is formed on the glass film by the roll-to-roll method as in the related art, since the resin lead film has a heat resistance lower than that of the glass film, there is a possibility of deformation or breakage of the resin lead film due to heat emitted from the film formation device when transitioning through the film formation step. Further, since the glass film and the lead film are coupled by an adhesive tape or the like, an adhesive component or the like of the adhesive tape may be altered by the heat emitted from the film formation device, causing the glass film and the lead film to separate at the coupling portion. 
     In light of the circumstances described above, the technical problem addressed by the present invention is to form a film with heat on a glass film without causing deformation or breakage of a lead film. Further, the technical problem addressed by the present invention is to form a film with heat on a glass film without causing separation of a lead film and a glass film at a coupling portion. 
     Solution to Problem 
     To solve the above-described problems, a manufacturing method of a glass roll according to the present invention includes forming a functional film on a glass film transported by a transport device while heating the glass film in a state where the glass film is in contact with a heating roller and winding the glass film on which the functional film is formed into a roll shape. The glass film is coupled to a lead film via a coupling portion, and the transport device is configured to separate the lead film and/or the coupling portion from the heating roller when the lead film and/or the coupling portion pass by the heating roller. 
     According to such a configuration, the lead film is separated from the heating roller and transported by the transport device without being brought into contact with the heating roller, thereby making it possible to prevent alteration or melt of the lead film caused by heat of the heating roller. As a result, a film can be formed with heat on the glass film without causing deformation or breakage of the lead film. Further, the coupling portion is separated from the heating roller and transported by the transport device without being brought into contact with the heating roller, thereby making it possible to prevent alteration and melt of a coupling member (adhesive tape or the like) of the coupling portion. As a result, a film can be formed with heat on the glass film without causing separation of the lead film and the glass film at the coupling portion. 
     The transport device may include a transport roller configured to transport the lead film and the glass film, the transport roller may be configured to be movable close to and away from the heating roller, and the transport roller may be configured to separate the lead film and/or the coupling portion from the heating roller when the lead film and/or the coupling portion pass by the heating roller. Thus, the lead film is separated from the heating roller by the transport roller, thereby making it possible to suitably transport the lead film without causing deformation or breakage of the lead film. Further, the coupling portion is separated from the heating roller by the transport roller, thereby making it possible to suitably transport the coupling portion without causing separation of the lead film and the glass film. 
     The transport roller may include a pair of transport rollers configured to sandwich the lead film. With this configuration, the transport roller can adjust tension acting on the lead film. Accordingly, the transport roller can suitably transport the lead film and/or the coupling portion with the lead film and/or the coupling portion separated from the heating roller. 
     The transport device may include a separation member configured to separate the lead film and/or the coupling portion from the heating roller when the lead film and/or the coupling portion pass by the heating roller. As a result, the lead film and/or the coupling portion can be reliably separated from the heating roller. 
     The separation member may be a roller. As a result, the lead film and/or the coupling portion can be suitably transported while separated from the heating roller. 
     Further, the transport device may include a heat-blocking member configured to be interposed between the heating roller and the lead film and/or the coupling portion. Since the heat from the heating roller is blocked by the heat-blocking member, alteration or melt of the lead film or alteration or melt of the coupling member (adhesive tape or the like) can be reliably prevented. 
     To solve the above-described problems, a manufacturing device for a glass roll according to the present invention includes a transport device configured to transport a glass film coupled to a lead film via a coupling portion and a heating film formation device configured to form a functional film on the glass film. The heating film formation device includes a heating roller configured to come into contact with and heat the glass film, and the transport device includes an unwinding device configured to feed out the glass film, a winding device configured to wind the glass film on which the functional film is formed into a roll shape, a transport roller disposed between the unwinding device and the winding device and configured to transport the glass film, and a separation member configured to separate the lead film and/or the coupling portion from the heating roller when the lead film and/or the coupling portion pass by the heating roller. 
     According to such a configuration, when the lead film passes by the heating roller, the lead film can be separated from the heating roller by the separation member of the transport device. As a result, alteration or melt of the lead film caused by the heat of the heating roller can be prevented. Accordingly, a film can be formed with heat on the glass film without causing deformation or breakage of the lead film. Further, when the coupling portion between the lead film and the glass film passes by the heating roller, the coupling portion can be separated from the heating roller by the separation member. As a result, alteration or melt of a coupling member (adhesive tape or the like) of the coupling portion can be prevented. Accordingly, a film can be formed with heat on the glass film without causing separation of the lead film and the glass film at the coupling portion. 
     To solve the problems described above, a manufacturing method of a glass roll according to the present invention includes forming a functional film on a glass film transported by a transport device while heating the glass film in a state where the glass film is in contact with a heating roller and winding the glass film on which the functional film is formed into a roll shape. The glass film is coupled to a lead film via a coupling portion, and the heating roller includes a roller main body configured to come into contact with and heat the glass film and a separation member configured to separate the lead film and/or the coupling portion from the roller main body when the lead film and/or the coupling portion pass by the roller main body. 
     According to such a configuration, when the lead film passes by the roller main body of the heating roller, the lead film can be separated from the roller main body by the separation member. As a result, alteration or melt of the lead film caused by heat of the roller main body can be prevented. Accordingly, a film can be formed with heat on the glass film without causing deformation or breakage of the lead film. Further, when the coupling portion between the lead film and the glass film passes by the roller main body, the coupling portion can be separated from the roller main body by the separation member. As a result, alteration or melt of a coupling member (adhesive tape or the like) of the coupling portion can be prevented. Accordingly, a film can be formed with heat on the glass film without causing separation of the lead film and the glass film at the coupling portion. 
     To solve the above-described problems, a manufacturing device for a glass roll according to the present invention includes a transport device configured to transport a glass film coupled to a lead film via a coupling portion and a heating film formation device configured to form a functional film on the glass film. The heating film formation device includes a heating roller configured to come into contact with and heat the glass film, and the heating roller includes a roller main body configured to come into contact with and heat the glass film and a separation member configured to separate the lead film and/or the coupling portion from the roller main body when the lead film and/or the coupling portion pass by the roller main body. 
     According to such a configuration, when the lead film passes by the roller main body of the heating roller, the lead film can be separated from the roller main body by the separation member. As a result, alteration or melt of the lead film caused by heat of the roller main body can be prevented. Accordingly, a film can be formed with heat on the glass film without causing deformation or breakage of the lead film. Further, when the coupling portion between the lead film and the glass film passes by the roller main body, the coupling portion can be separated from the roller main body by the separation member. As a result, alteration or melt of a coupling member (adhesive tape or the like) of the coupling portion can be prevented. Accordingly, a film can be formed with heat on the glass film without causing separation of the lead film and the glass film at the coupling portion. 
     Advantageous Effects of Invention 
     According to the present invention, a film can be formed with heat on a glass film without causing deformation or breakage of a lead film. Further, a film can be formed with heat on a glass film without causing separation of a lead film and a glass film at a coupling portion. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a cross-sectional view illustrating a manufacturing device for a glass roll according to a first embodiment. 
         FIG. 2  is a flowchart illustrating a manufacturing method of a glass roll. 
         FIG. 3  is a cross-sectional view illustrating one step of the manufacturing method of a glass roll. 
         FIG. 4  is a cross-sectional view illustrating one step of the manufacturing method of a glass roll. 
         FIG. 5  is a cross-sectional view illustrating a manufacturing device for a glass roll according to a second embodiment. 
         FIG. 6  is a cross-sectional view illustrating one step of a manufacturing method of a glass roll. 
         FIG. 7  is a cross-sectional view illustrating a manufacturing device for a glass roll according to a third embodiment. 
         FIG. 8  is a side view illustrating a main portion of the manufacturing device for a glass roll. 
         FIG. 9  is a cross-sectional view illustrating one step of a manufacturing method of a glass roll. 
         FIG. 10  is a cross-sectional view illustrating a manufacturing device for a glass roll according to a fourth embodiment. 
         FIG. 11  is a side view of a heating roller. 
         FIG. 12  is a bottom view of the heating roller. 
         FIG. 13  is a cross-sectional view illustrating one step of a manufacturing method of a glass roll. 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     Hereinafter, embodiments for implementing the present invention will be described with reference to the drawings.  FIGS. 1 to 4  illustrate a first embodiment of a manufacturing method and a manufacturing device for a glass roll according to the present invention. 
     The manufacturing device used in this method adopts a roll-to-roll method, and is configured to manufacture a glass roll by forming a functional film on a transparent glass film unwound from a base glass roll, and winding the glass film on which the functional film is formed into a roll shape. Hereinafter, the glass film to be unwound from the base glass roll is referred to as a first glass film, and the glass film after the functional film has been formed thereon is referred to as a second glass film. 
     As illustrated in  FIG. 1 , a manufacturing device  1  primarily includes a vacuum chamber  2 , a transport device  3 , a film formation device  4 , and a control device  5  that controls the transport device  3  and the film formation device  4 . 
     The vacuum chamber  2  houses the transport device  3  and the film formation device  4  in an interior of the vacuum chamber  2 . An internal space of the vacuum chamber  2  is set to a predetermined degree of vacuum by a vacuum pump. An inert gas, such as argon gas, can be supplied into the vacuum chamber  2 . 
     The transport device  3  includes an unwinding device  6 , a winding device  7 , transport rollers  8   a  to  8   d  disposed between the unwinding device  6  and the winding device  7 , and sensors  9 ,  10 . 
     The unwinding device  6  rotatably supports a base glass roll GR 1  and unwinds a first glass film GF 1  from the base glass roll GR 1  to feed the first glass film GF 1  to the film formation device  4 . The unwinding device  6  can change a rotational speed of the base glass roll GR 1  (feeding rate of the first glass film GF 1 ) according to the control of the control device  5 . 
     The base glass roll GR 1  mounted to the unwinding device  6  includes the first glass film GF 1 , a first lead film LF 1  coupled to a starting end portion GFa of the first glass film GF 1 , a second lead film LF 2  coupled to a terminating end portion GFb of the first glass film GF 1 , a protective film PF 1  layered on the first glass film GF 1 , and a winding core WC 1 . 
     The first glass film GF 1  and each of the lead films LF 1 , LF 2  are coupled by a coupling member such as an adhesive tape. Hereinafter, a coupling portion between the starting end portion GFa of the first glass film GF 1  and the first lead film LF 1  is referred to as a first coupling portion  11 , and a coupling portion between the terminating end portion GFb of the first glass film GF 1  and the second lead film LF 2  is referred to as a second coupling portion  12 . A first end portion (starting end portion) of the second lead film LF 2  is coupled, via the second coupling portion  12 , to the terminating end portion GFb of the first glass film GF 1 , and a second end portion (terminating end portion) of the second lead film F 2  is coupled to the winding core WC 1 . 
     A thickness of the first glass film GF 1  is 500 μm or less, preferably from 10 μm to 300 μm, and most preferably from 30 μm to 200 μm. 
     As the material of the first glass film GF 1 , silicate glass or silica glass is used, preferably borosilicate glass, soda-lime glass, aluminosilicate glass, or chemically strengthened glass is used, and most preferably alkali-free glass is used. Here, alkali-free glass refers to a glass that is substantially free of alkali components (alkali metal oxides), and specifically a glass with an alkali component having a weight ratio of 3000 ppm or less. The weight ratio of the alkali component in the present invention is preferably 1000 ppm or less, more preferably 500 ppm or less, and most preferably 300 ppm or less. 
     A film made of a resin is used for each of the lead films LF 1 , LF 2 . Specifically, as each of the lead films LF 1 , LF 2 , an organic resin film (synthetic resin film) such as a polyethylene terephthalate film, an ionomer film, a polyethylene film, a polypropylene film, a polyvinyl chloride film, a polyvinylidene chloride film, a polyvinyl alcohol film, a polyester film, a polycarbonate film, a polystyrene film, a polyacrylonitrile film, an ethylene-vinyl acetate copolymer film, an ethylene-vinyl alcohol copolymer film, an ethylene-methacrylic acid copolymer film, a nylon (trade name) film (polyamide film), a polyimide film, or cellophane, for example, can be used. 
     The unwinding device  6  includes a protective film recovery unit  13  configured to wind the protective film PF 1  included in the base glass roll GR 1 . The protective film recovery unit  13  is disposed at a position above the winding device  7 , but is not limited to this position. The protective film recovery unit  13  recovers the protective film PF 1  by peeling off the protective film PF 1  from the first glass film GF 1  on which the protective film PF 1  is layered and winding the protective film PF 1  into a roll shape. 
     The transport rollers  8   a  to  8   d  include the first transport roller  8   a  and the second transport roller  8   b  that transport the first glass film GF 1 , and the third transport roller  8   c  and the fourth transport roller  8   d  that transport a second glass film GF 2 . The number of the transport rollers  8   a  to  8   d  is not limited to that in this embodiment, and can be appropriately set according to the size of the manufacturing device  1 . Each of the transport rollers  8   a  to  8   d  is rotationally driven by a drive device such as an electric motor. 
     The first transport roller  8   a  and the second transport roller  8   b  are disposed at an interval between the unwinding device  6  and the film formation device  4 . The third transport roller  8   c  and the fourth transport roller  8   d  are disposed at an interval between the film formation device  4  and the winding device  7 . 
     The first transport roller  8   a  and the fourth transport roller  8   d  are each constituted by a single roller that comes into contact with one surface of each of the lead films LF 1 , LF 2  and the glass films GF 1 , GF 2 . The second transport roller  8   b  and the third transport roller  8   c  are constituted by a pair of (two) rollers that come into contact with both surfaces of each of the lead films LF 1 , LF 2  and the glass films GF 1 , GF 2 . 
     The second transport roller  8   b  and the third transport roller  8   c  are configured to be movable close to and away from the film formation device  4  by a movement device (not illustrated). The second transport roller  8   b  and the third transport roller  8   c  can move to a first position (lead film transport position, position indicated by a solid line in  FIG. 1 ) away from the film formation device  4  for transporting the lead films LF 1 , LF 2 , and to a second position (glass film transport position, position indicated by a two-dot chain line in  FIG. 1 ) close to the film formation device  4  for transporting the glass films GF 1 , GF 2 . 
     The second transport roller  8   b  and the third transport roller  8   c  cause the lead films LF 1 , LF 2  to pass therethrough without coming into contact with the film formation device  4 . That is, the second transport roller  8   b  and the third transport roller  8   c,  and the movement device thereof, also function as a separation device that separates the lead films LF 1 , LF 2  from the film formation device  4  when the lead films LF 1 , LF 2  pass through the film formation device  4 . In particular, the second transport roller  8   b  and the third transport roller  8   c  function as a separation member that separates the lead films LF 1 , LF 2  from the film formation device  4  by rotational control performed by the control device  5 . 
     The sensors  9 ,  10  include the first sensor  9  disposed downstream of the film formation device  4  (between the film formation device  4  and the winding device  7 ), and the second sensor  10  disposed upstream of the film formation device  4  (between the unwinding device  6  and the film formation device  4 ). Each of the sensors  9 ,  10  is constituted by a non-contact sensor, such as a transmission laser sensor, but is not limited to this configuration. 
     The first sensor  9  detects the first coupling portion  11  and the starting end portion GFa of the first glass film GF 1 , and transmits a detection signal to the control device  5 . The second sensor  10  detects the second coupling portion  12  and the terminating end portion GFb of the first glass film GF 1 , and transmits a detection signal to the control device  5 . 
     The winding device  7  forms a glass roll by layering a protective film PF 2  on the second glass film and winding the film around a winding core WC 2 . The winding device  7  can change a rotational speed of the winding core WC 2  by the control of the control device  5 . 
     The winding device  7  includes a protective film supply unit  14  that supplies the protective film PF 2  to the second glass film to be wound around the winding core WC 2 . The protective film supply unit  14  is disposed at a position above the winding device  7 , but is not limited to this position. The protective film supply unit  14  includes a protective film roll PFR, and supplies the protective film PF 2  unwound from the protective film roll PFR to the second glass film. 
     The film formation device  4  is constituted by a heating film formation device that transports the first glass film GF 1  while heating the first glass film GF 1 , and forms a functional film on the first glass film GF 1 . The film formation device  4  can form the functional film on the first glass film GF 1  by various film formation methods such as sputtering, vapor deposition, and chemical vapor deposition (CVD). In this embodiment, a case in which a transparent conductive film, such as an indium tin oxide (ITO) film, is formed as the functional film by sputtering will be described. 
     The film formation device  4  is constituted by an ion beam sputtering device, a magnetron sputtering device, or the like. When the film formation device  4  is a sputtering device, the film formation device  4  primarily includes a plurality of sputtering sources  15  including a target, and a heating roller  16  that heats the first glass film GF 1 . 
     Each sputtering source  15  is disposed at a constant interval from the heating roller  16  such that sputtered particles (ITO particles) that scatter from the target adhere to one surface of the first glass film GF 1 . 
     The heating roller  16  is a rotatable roller (a can-roller) that heats while coming into contact with the first glass film GF 1 . The heating roller  16  includes a roller main body  17  having a cylindrical shape and configured to support the first glass film GF 1 , and a heater  18  that heats the roller main body  17 . 
     The roller main body  17  is formed from glass, ceramic, or metal. The roller main body  17  is rotatably supported by a shaft portion  19 . 
     The heater  18  is disposed inside the roller main body  17  to heat the roller main body  17 . The heater  18  is constituted by, for example, an oil heater, an infrared heater, or a near infrared heater, but is not limited to this configuration. 
     The control device  5  includes a computer (for example, a personal computer (PC)) that implements various hardware such as a central processing unit (CPU), a read only memory (ROM), a random access memory (RAM), a hard-disk drive (HDD), an input/output interface, and a display. The control device  5  is communicably connected to the film formation device  4 , the unwinding device  6 , the winding device  7 , the transport rollers  8   a  to  8   d,  the movement device of the second transport roller  8   b  and the third transport roller  8   c,  and the sensors  9 ,  10 . The control device  5  executes control related to the heating temperature, film formation, and transport of the film formation device  4 , control of the unwinding device  6 , control of the winding device  7 , rotational control of the transport rollers  8   a  to  8   d,  repositioning control of the second transport roller  8   b  and the third transport roller  8   c,  and the like. 
     Hereafter, a method of manufacturing a glass roll using the manufacturing device  1  having the above-described configuration will be described. As illustrated in  FIG. 2 , this method includes a start preparation step S 1 , a film formation step S 2 , and an end preparation step S 3 . 
     In the start preparation step S 1 , the base glass roll GR 1  is mounted on the unwinding device  6 , the first lead film LF 1  is unwound from the base glass roll GR 1 , and the starting end portion of the first lead film LF 1  is coupled to the winding core WC 2  of the winding device  7 . In this case, the transport device  3  places the second transport roller  8   b  and the third transport roller  8   c  at the first position (lead film transport position). As illustrated in  FIG. 1 , a portion of the first lead film LF 1  positioned between the second transport roller  8   b  and the third transport roller  8   c  is in a state of being separated from the heating roller  16  of the film formation device  4 . The second transport roller  8   b  and the third transport roller  8   c  sandwich the first lead film LF 1 , making it possible to apply appropriate tension to the first lead film LF 1  in a region from the unwinding device  6  to the second transport roller  8   b  and a region from the third transport roller  8   c  to the winding device  7  while maintaining a state of the first lead film LF 1  being separated from the heating roller  16  as described above. 
     Subsequently, the vacuum chamber  2  is closed and the internal space thereof is set to a predetermined degree of vacuum. Further, the vacuum chamber  2  is filled with an inert gas. 
     Subsequently, the control device  5  synchronously activates the unwinding device  6 , the transport rollers  8   a  to  8   d,  the roller main body  17  of the heating roller  16 , and the winding device  7  and transports the first lead film LF 1  from the unwinding device  6  on the upstream side to the winding device  7  on the downstream side at a predetermined speed. Further, the control device  5  starts the heater  18  of the film formation device  4 , and starts heating the roller main body  17  (temperature increase step). 
     In the temperature increase step, the roller main body  17  is heated by the heater  18  to a predetermined film formation temperature or higher. The temperature of the roller main body  17  to be heated is set to from 200° C. to 500° C., for example, but the temperature is not limited to this range. Note that, during execution of the temperature increase step, the sputtering sources  15  are not activated and do not emit sputtered particles. 
     The control device  5  controls rotational speeds of the second transport roller  8   b  and the third transport roller  8   c,  and maintains the state in which the first lead film LF 1  is separated from the heating roller  16  of the film formation device  4  in a region between the second transport roller  8   b  and the third transport roller  8   c.  The first lead film LF 1  that bypasses the heating roller  16  is wound onto the winding device  7  via the third transport roller  8   c  and the fourth transport roller  8   d.    
     In the start preparation step S 1 , the first lead film LF 1  having passed through the film formation device  4  is wound onto the winding device  7 , thereby unwinding the first glass film GF 1  included in the base glass roll GR 1  from the base glass roll GR 1 .The first glass film GF 1  is transported to the winding device  7  via the film formation device  4  together with the first lead film LF 1 . 
     As illustrated in  FIG. 3 , when the first coupling portion  11  has passed through the film formation device  4 , the first sensor  9  detects the first coupling portion  11  and the starting end portion GFa of the first glass film GF 1 , and transmits a detection signal to the control device  5 . Upon receiving the detection signal from the first sensor  9 , the control device  5  determines whether or not the roller main body  17  is heated to a predetermined film formation temperature. In a case in which the roller main body  17  has not reached the film formation temperature, the control device  5  continues the temperature increase step. In a case in which the roller main body  17  has reached the film formation temperature, the control device  5  ends the start preparation step S 1  and starts the next film formation step S 2 . 
     In the film formation step S 2 , the control device  5  transmits a control signal to the transport device  3 , and moves the second transport roller  8   b  and the third transport roller  8   c  in a first position (position indicated by a two-dot chain line in  FIG. 3 ) to a second position (position indicated by a solid line in  FIG. 3 ). Furthermore, the control device  5  controls a transport speed of the first glass film GF 1  by the transport device  3 , and brings the first glass film GF 1  into contact with the heating roller  16  of the film formation device  4 . In this embodiment, the second transport roller  8   b  and the third transport roller  8   c  are moved to the second position (brought close to the heating roller  16 ), making it possible to secure, to the extent possible, a large holding angle of the first glass film GF 1  on the heating roller  16 . 
     In the film formation step S 2 , the roller main body  17  guides, by the rotation of the roller main body  17 , the first glass film GF 1  downstream while heating the first glass film GF 1 . The first glass film GF 1  is heated to 150° C. or higher by the roller main body  17 . In a case in which the sputtered particles are ITO, the first glass film GF 1  is desirably heated to 200° C. or higher, more desirably heated to 250° C. or higher, and most desirably heated to 300° C. or higher. 
     By the control of the control device  5 , the film formation device  4  causes the sputtered particles (ITO particles, for example) to scatter from the plurality of sputtering sources  15  and sequentially adhere to the first glass film GF 1  transported by the roller main body  17 . 
     With the first glass film GF 1  heated by the roller main body  17 , the ITO particles adhering to the first glass film GF 1  crystallize, and a functional film FM having a low resistance (20 Ω/sq or less, for example) is formed. As a result, the second glass film GF 2  is formed as illustrated in  FIG. 4 . 
     As illustrated in  FIG. 4 , in the film formation step S 2 , while the protective film PF 2  is layered on the second glass film GF 2  by the protective film supply unit  14 , the second glass film GF 2  and the protective film PF 2  are wound around the winding core WC 2  by the winding device  7 . As a result, a glass roll GR 2  is formed around the winding core WC 2 . The outer diameter of the glass roll GR 2  expands according to the rotation of the winding core WC 2 . 
     When the film formation step S 2  is nearly completed, the first glass film GF 1  is fed out from the unwinding device  6  in its entirety. Subsequently, the second coupling portion  12  is fed out from the unwinding device  6 . When the second coupling portion  12  reaches the second sensor  10 , the second sensor  10  detects the second coupling portion  12  and the terminating end portion GFb of the first glass film GF 1 , and transmits a detection signal to the control device  5 . 
     Upon receiving the detection signal from the second sensor  10 , the control device  5  ends the film formation step S 2  and starts the end preparation step S 3 . The end preparation step S 3  includes a temperature decrease step of decreasing the temperature of the film formation device  4  in order to prevent deformation or breakage of the second lead film LF 2  and separation of the first glass film GF 1  and the second lead film LF 2  at the second coupling portion  12 . This temperature decrease step starts while the first glass film GF 1  passes through the film formation device  4  and before the terminating end portion GFb reaches the film formation device  4 . 
     In the temperature decrease step, the control device  5  stops the heating by the heating roller  16 . When the heater  18  stops, the temperature of the roller main body  17  gradually decreases. Further, the control device  5  stops the sputtering sources  15  of the film formation device  4 . 
     The control device  5  moves the second transport roller  8   b  and the third transport roller  8   c  in the second position (glass film transport position) to the first position (lead film transport position). Furthermore, the control device  5  controls the rotational speed of the winding core WC 1  of the unwinding device  6 , the transport rollers  8   a  to  8   d,  and the winding core WC 2  of the winding device  7 , and causes the second lead film LF 2  to be separated from the heating roller  16  in a region between the second transport roller  8   b  and the third transport roller  8   c.    
     The control device  5  controls the rotational speed of the second transport roller  8   b  and the third transport roller  8   c,  and maintains a state in which the second lead film LF 2  is separated from the heating roller  16  of the film formation device  4 . The second lead film LF 2  that has bypassed the heating roller  16  is wound onto the winding device  7  via the third transport roller  8   c  and the fourth transport roller  8   d.    
     When the second lead film LF 2  that has passed through the film formation device  4  is wound onto the winding device  7 , the end preparation step S 3  ends and the glass roll GR 2  is completed in a state of being supported by the winding device  7 . The glass roll GR 2  is removed from the vacuum chamber  2  and fed to the next step. 
     Note that, in the subsequent step, the second glass film GF 2  is unwound from the glass roll GR 2 , and a predetermined circuit pattern (an electrode pattern, for example) is formed in the functional film FM by a method such as photolithography. When a predetermined manufacturing-related process is performed, the protective film PF 2  is removed (peeled) from the second glass film GF 2 . 
     According to the manufacturing method and the manufacturing device  1  for the glass roll GR 2  according to the embodiment described above, in a case in which the lead films LF 1 , LF 2  are transported by the control of the transport device  3  performed by the control device  5 , the transport path (path line) can be changed to a transport path that differs from the transport path of the glass films GF 1 , GF 2 . 
     That is, in the start preparation step S 1  and the end preparation step S 3 , the lead films LF 1 , LF 2  are separated from the heating roller  16 , making it possible to cause the lead films LF 1 , LF 2  to bypass and not come into contact with the heating roller  16 . With this bypass path, the lead films LF 1 , LF 2  can be transported without alteration or melt. Accordingly, the functional film FM can be formed on the first glass film GF 1  without causing deformation or breakage of the lead films LF 1 , LF 2 . 
     Similarly, each of the coupling portions  11 ,  12  is separated from the heating roller  16  by a bypass path, making it possible to transport the coupling portions  11 ,  12  without causing alteration or melt of the coupling member such as adhesive tape. Accordingly, the functional film FM can be formed on the first glass film GF 1  without causing separation of the first glass film GF 1  and the lead films LF 1 , LF 2  at each of the coupling portions  11 ,  12 . 
     Further, in the start preparation step  51 , the temperature increase step can be performed without stopping the transport of the first lead film LF 1 , making it possible to shorten the time spent on the start preparation step  51  to the extent possible compared to a case in which the first lead film LF 1  is brought into contact with the heating roller  16  and then transported. Accordingly, the glass roll GR 2  can be efficiently manufactured. 
       FIGS. 5 and 6  illustrate a second embodiment of the present invention. In this embodiment, the configuration of the transport device of the manufacturing device differs from that of the first embodiment. 
     In addition to the unwinding device  6 , the winding device  7 , and the transport rollers  8   a  to  8   d,  the transport device  3  includes a separation device that separates the lead films LF 1 , LF 2  from the heating roller  16  of the film formation device  4 . The separation device includes separation rollers  20   a,    20   b  as a separation member, and a movement device that moves these separation rollers  20   a,    20   b.  In this embodiment, two rollers are exemplified as the separation rollers  20   a,    20   b,  but the number of the separation rollers  20   a,    20   b  is not limited thereto in this embodiment and can be set as appropriate according to the size of the manufacturing device  1 . 
     As illustrated in  FIG. 5 , the separation rollers  20   a,    20   b  are configured to be repositionable, by the movement device, between a first position (lead film separation position, position indicated by a solid line in  FIG. 5 ) at which the separation rollers  20   a,    20   b  are in contact with the lead films LF 1 , LF 2 , and a second position (standby position, position indicated by a two-dot chain line in  FIG. 5 ) at which the separation rollers  20   a,    20   b  are not in contact with the lead films LF 1 , LF 2 . The separation rollers  20   a,    20   b  include the first separation roller  20   a  that comes into contact with the lead films LF 1 , LF 2  between the second transport roller  8   b  and the heating roller  16 , and the second separation roller  20   b  that comes into contact with the lead films LF 1 , LF 2  between the third transport roller  8   c  and the heating roller  16 . 
     The other configurations of this embodiment are the same as those of the first embodiment. In this embodiment, components common to those of the first embodiment are denoted by the same reference numerals as those of the first embodiment. 
     Hereafter, a manufacturing method of the glass roll GR 2  according to this embodiment will be described. 
     As illustrated in  FIG. 5 , in the start preparation step S 1 , each of the separation rollers  20   a,    20   b  moves from the second position to the first position. In this case, the second transport roller  8   b  and the third transport roller  8   c  are disposed in the first position (lead film transport position). The first separation roller  20   a  passes between the second transport roller  8   b  and the heating roller  16  when moving to the first position. The second separation roller  20   b  passes between the third transport roller  8   c  and the heating roller  16  when moving to the first position. 
     In the first position, each of the separation rollers  20   a,    20   b  is in contact with the first lead film LF 1  and separate the first lead film LF 1  from the heating roller  16 . By the movement of each of the separation rollers  20   a,    20   b  to the first position, a bypass path is formed that allows the first lead film LF 1  to bypass the heating roller  16 . 
     In the start preparation step S 1 , the control device  5  controls the unwinding device  6 , the transport rollers  8   a  to  8   d,  and the winding device  7 , and starts transport of the first lead film LF 1 . The control device  5  heats the roller main body  17  by the heater  18  while rotating the roller main body  17  (temperature increase step). 
     When the start preparation step S 1  progresses and the first coupling portion  11  is detected by the first sensor  9 , the control device  5  determines whether or not the heating roller  16  has reached the film formation temperature, similarly to the first embodiment. In a case in which the heating roller  16  has reached the film formation temperature, the control device  5  ends the start preparation step S 1 , and executes the next film formation step S 2 . 
     As illustrated in  FIG. 6 , in the film formation step S 2 , the separation rollers  20   a,    20   b  move from the first position to the second position, which is the standby position. The second transport roller  8   b  and the third transport roller  8   c  move from the first position (lead film transport position) to the second position (glass film transport position), and bring the first glass film GF 1  into contact with the heating roller  16 . 
     Subsequently, the control device  5  starts the sputtering sources  15  and causes sputtered particles to adhere to the first glass film GF 1  transported by the heating roller  16 . As a result, the second glass film GF 2  on which the functional film FM is formed, is formed. The second glass film GF 2  is wound around the winding core WC 2  of the winding device  7 , thereby forming the glass roll GR 2 . 
     When the film formation step S 2  progresses and the second coupling portion  12  is detected by the second sensor  10 , the control device  5  ends the film formation step S 2  and executes the next end preparation step S 3 . The control device  5  stops the heater  18  and the sputtering sources  15  while maintaining the rotation of the roller main body  17  of the film formation device  4  (temperature decrease step). 
     In the temperature decrease step, the control device  5  moves the second transport roller  8   b  and the third transport roller  8   c  in the second position (glass film transport position) to the first position (lead film transport position). Subsequently, the separation rollers  20   a,    20   b  in the second position (standby position) move to the first position (lead film separation position) before the second coupling portion  12  reaches the heating roller  16  by the control of the control device  5 . 
     The separation rollers  20   a,    20   b  that have moved to the first position separate the second lead film LF 2  to be transported by the transport device  3  transported by the heating roller  16  from the heating roller  16 . When the second lead film LF 2  that has passed through the film formation device  4  is wound by the winding device  7  in its entirety, the glass roll GR 2  is completed. 
     According to the manufacturing method and the manufacturing device  1  for the glass roll GR according to this embodiment, the lead films LF 1 , LF 2  and the coupling portions  11 ,  12  are separated from the heating roller  16  by the separation rollers  20   a,    20   b,  making it possible to maintain constant separation distances between the lead films LF 1 , LF 2  and the heating roller  16  and between the coupling portions  11 ,  12  and the heating roller  16 . 
       FIGS. 7 to 9  illustrate a third embodiment of the present invention. In addition to the unwinding device  6 , the winding device  7 , and the transport rollers  8   a  to  8   d,  the transport device  3  of the manufacturing device  1  according to this embodiment includes a separation device that separates the lead films LF 1 , LF 2  from the heating roller  16  of the film formation device  4 , and a heat-blocking device. The separation device includes the separation rollers  20   a,    20   b  as a separation member, and a movement device that moves the separation rollers  20   a,    20   b.  The heat-blocking device includes a heat-blocking plate  21  as a heat-blocking member, and a movement device that moves this heat-blocking plate  21 . 
     As illustrated in  FIGS. 7 and 8 , the heat-blocking plate  21  is configured in a flat plate shape by a heat-blocking material, but the heat-blocking plate  21  is not limited to this shape and may be configured in various shapes such as an arcuate curved plate shape. In this embodiment, three heat-blocking plates  21  are exemplified, but the number of heat-blocking plates  21  is not limited to that in this embodiment. 
     A cooling pipe  22  is provided inside the heat-blocking plate  21 . The cooling pipe  22  allows a coolant such as cooling water to circulate, thereby cooling the heat-blocking plate  21 . 
     As illustrated in  FIG. 8 , the heat-blocking plate  21  is configured to be repositionable between a first position (position indicated by a solid line) where heat-blocking is performed and a second position (position indicated by a two-dot chain line) as a standby position, by the movement device. In the first position, the heat-blocking plate  21  is interposed between the roller main body  17  of the heating roller  16  and the lead films LF 1 , LF 2 . In the second position, the heat-blocking plate  21  is in a position separated from the heating roller  16  in an axial direction of the heating roller  16 . 
     The other configurations of this embodiment are the same as those of the second embodiment. Components that are the same as those of the second embodiment in this embodiment are denoted by the same reference numerals as those of the second embodiment. 
     Hereafter, a manufacturing method for the glass roll GR 2  according to this embodiment will be described. 
     In the start preparation step S 1 , the transport device  3  lowers each of the separation rollers  20   a,    20   b  from the second position (standby position) to the first position (lead film separation position). In this case, the second transport roller  8   b  and the third transport roller  8   c  are disposed in the first position (lead film transport position). 
     Each of the separation rollers  20   a,    20   b  comes into contact with the first lead film LF 1 , and separates the first lead film LF 1  from the heating roller  16 . Subsequently, by the control of the control device  5 , the transport device  3  moves each of the heat-blocking plates  21  from the second position (standby position) to the first position (heat-blocking position). The heat-blocking plates  21  enter a space between the roller main body  17  of the heating roller  16  and the first lead film LF 1  supported by the separation rollers  20   a,    20   b,  and stop at the first position. Subsequently, the transport device  3  transports the first lead film LF 1  downstream. 
     As illustrated in  FIG. 9 , in the film formation step S 2 , the transport device  3  moves the heat-blocking plates  21  in the first position to the second position. Subsequently, the transport device  3  raises the separation rollers  20   a,    20   b  in the first position to the second position. Subsequently, the transport device  3  moves the second transport roller  8   b  and the third transport roller  8   c  in the first position to the second position (glass film transport position). 
     Subsequently, as illustrated in  FIG. 9 , the functional film FM is formed on the first glass film GF 1  by the film formation device  4 . In this case, since each of the heat-blocking plates  21  is in the second position (standby position) separated from the heating roller  16  in the axial direction of the heating roller  16 , the sputtered particles emitted from the sputtering sources  15  can move toward the first glass film GF 1  while the path is not obstructed by the heat-blocking plates  21 . 
     Upon completion of the film formation step S 2 , the transport device  3  moves the second transport roller  8   b  and the third transport roller  8   c  in the second position to the first position (lead film transport position) in the end preparation step S 3  (temperature decrease step). Subsequently, the transport device  3  moves the separation rollers  20   a,    20   b  in standby in the second position to the first position (lead film separation position). Subsequently, the transport device  3  moves each of the shielding plates  21  in standby in the second position to the first position (heat-blocking position). 
     According to the manufacturing method and the manufacturing device  1  for the glass roll GR 2  according to this embodiment, in the start preparation step  51  and the end preparation step S 3 , the heat-blocking plates  21  are interposed between the heating roller  16  and the lead films LF 1 , LF 2 , making it possible to block the heat radiated from the heating roller  16  so as to not transmit the heat to the lead films LF 1 , LF 2  and the coupling portions  11 ,  12 . As a result, deformation and breakage of the lead films LF 1 , LF 2  and separation of the first glass film GF 1  and the lead films LF 1 , LF 2  at the coupling portions  11 ,  12  can be effectively prevented. 
       FIGS. 10 to 13  illustrate a fourth embodiment of the present invention. In this embodiment, the configuration of the film formation device of the manufacturing device differs from that of the first embodiment. 
     As illustrated in  FIGS. 10 to 12 , the heating roller  16  of the film formation device  4  includes the roller main body  17  and a plurality of separation members  23  that separate the lead films LF 1 , LF 2  from the roller main body  17 . 
     The roller main body  17  includes a plurality of recessed portions  17   a  that accommodate the separation members  23 . As illustrated in  FIG. 11 , a hole  17   b  through which the separation member  23  is inserted is formed in the recessed portion  17   a.  As illustrated in  FIG. 12 , the recessed portion  17   a  is formed at an end portion of the roller main body  17  in a width direction. 
     The roller main body  17  includes a heater inside the roller main body  17 . The heater can heat an outer circumferential surface of the roller main body  17  that comes into contact with the first glass film GF 1 . 
     The separation member  23  is configured in a plate shape or a rod shape. The separation member  23  is configured to be retractable by an actuator built into the roller main body  17 . The separation member  23  can, by the control of the control device  5 , be changed in position between a first position (lead film support position) of protruding further outward in a radial direction of the roller main body  17  than the outer circumferential surface of the roller main body  17 , and a second position (standby position) of being retracted from the first position and accommodated in the recessed portion  17   a.  As illustrated in  FIG. 12 , the separation members  23  are disposed so as to come into contact with end portions LFa, LFb of the lead films LF 1 , LF 2  in the width direction. 
     The other configurations of this embodiment are the same as those of the first embodiment. In this embodiment, components common to those of the first embodiment are denoted by the same reference numerals as those of the first embodiment. 
     Hereafter, a manufacturing method of the glass roll GR 2  according to this embodiment will be described. 
     As illustrated in  FIG. 10 , in the start preparation step S 1 , the control device  5  places the second transport roller  8   b  and the third transport roller  8   c  in the first position (lead film transport position), and places the separation members  23  of the heating roller  16  in the first position (lead film support position). 
     In the start preparation step S 1 , the control device  5  controls the unwinding device  6 , the transport rollers  8   a  to  8   d,  and the winding device  7 , and starts transport of the first lead film LF 1 . The control device  5  heats the roller main body  17  by the heater while rotating the roller main body  17  (temperature increase step). 
     Upon reaching the heating roller  16 , the first coupling portion  11  and the first lead film LF 1  transported by the transport device  3  come into contact with the separation members  23 . End portions of the separation members  23  separate the first lead film LF 1  from the outer circumferential surface of the roller main body  17  while supporting the first lead film LF 1 . 
     With the rotation of the heating roller  16  (roller main body  17 ), the first lead film LF 1  is transported downstream of the heating roller  16  in a state of being in contact with the plurality of separation members  23  and without coming into contact with the outer circumferential surface of the roller main body  17 . 
     When the start preparation step S 1  progresses and the first coupling portion  11  is detected by the first sensor  9 , the control device  5  determines whether or not the heating roller  16  has reached the film formation temperature, similarly to the first embodiment. In a case in which the heating roller  16  has reached the film formation temperature, the control device  5  ends the start preparation step S 1 , and executes the next film formation step S 2 . 
     As illustrated in  FIG. 13 , the control device  5  moves the separation members  23  in the first position to the second position. As a result, the separation members  23  are accommodated in the recessed portions  17   a  of the roller main body  17 . 
     Subsequently, similarly to the first embodiment, the film formation device  4  forms the functional film FM on the first glass film GF 1  while heating the first glass film GF 1  by the roller main body  17 . In this case, the separation members  23  accommodated in the recessed portions  17   a  of the roller main body  17  do not come into contact with the first glass film GF 1 . 
     In the end preparation step S 3 , the control device  5  moves the separation members  23  in standby in the second position to the first position, and starts the temperature decrease step. The second coupling portion  12  and the second lead film LF 2  that have reached the heating roller  16  are transported downstream in a state of being separated from the roller main body  17  by the separation members  23 . 
     According to the manufacturing method and the manufacturing device  1  for the glass roll GR 2  according to this embodiment described above, in the start preparation step S 1  and the end preparation step S 3 , the lead films LF 1 , LF 2  are separated from the roller main body  17  by the separation members  23  of the heating roller  16 , thereby making it possible to cause the lead films LF 1 , LF 2  to bypass and not be brought into contact with the roller main body  17 . With this bypass path, the lead films LF 1 , LF 2  can be transported without alteration or melt. Accordingly, the functional film FM can be formed on the first glass film GF 1  without causing deformation or breakage of the lead films LF 1 , LF 2 . 
     Similarly, each of the coupling portions  11 ,  12  is separated from the roller main body  17  by the bypass path, making it possible to transport each of the coupling portions  11 ,  12  without causing alteration or melt of the coupling member such as adhesive tape. Accordingly, the functional film FM can be formed on the first glass film GF 1  without causing separation of the first glass film GF 1  and the lead films LF 1 , LF 2  at each of the coupling portions  11 ,  12 . 
     Note that the present invention is not limited to the configurations of the embodiments described above, and is not limited to the actions and effects described above. Various modifications can be made to the present invention without departing from the spirit of the present invention. 
     In the embodiments described above, an example has been illustrated in which the second transport roller  8   b  and the third transport roller  8   c  are configured to be repositionable between the first position and the second position, but the present invention is not limited to this configuration. In the transport device  3 , the second transport roller  8   b  and the third transport roller  8   c  can be installed at positions where the lead films LF 1 , LF 2  and the glass films GF 1 , GF 2  can be suitably transported, and the lead films LF 1 , LF 2  and the glass films GF 1 , GF 2  can be transported without changing those positions. 
     In the transport device  3 , not only the second transport roller  8   b  and the third transport roller  8   c  but also the first transport roller  8   a  and the fourth transport roller  8   d  may be constituted by a pair of rollers and configured to be repositionable. 
     In the second embodiment and the third embodiment described above, the second transport roller  8   b  and the third transport roller  8   c  are constituted by a pair of rollers, but the present invention is not limited to this configuration. In a case in which the manufacturing device  1  includes the separation device (separation rollers  20   a,    20   b ), each of the second transport roller  8   b  and the third transport roller  8   c  may be constituted by a single roller. 
     In the embodiments described above, an example has been illustrated in which, in the end preparation step S 3 , a temperature decrease step in which the temperature of the heating roller  16  is decreased is executed, but the present invention is not limited to this configuration. In a case in which the second lead film LF 2  can be separated from the heating roller  16  until in a position where alteration or melt of the second lead film LF 2  does not occur, and in a case in which the second coupling portion  12  can be separated from the heating roller  16  until in a position where alteration or melt of the coupling member such as adhesive tape used in the second coupling portion  12  does not occur, the second lead film LF 2  and the second coupling portion  12  may be transported without decreasing the temperature of the heating roller  16 . Further, in a case in which heat-blocking is performed by the heat-blocking plates  21 , the second lead film LF 2  may be transported without decreasing the temperature of the heating roller  16 . 
     In the embodiments described above, an example has been illustrated in which the positions of the first coupling portion  11  and the second coupling portion  12  are detected by using the first sensor  9  and the second sensor  10 , but the present invention is not limited to this configuration. In a case in which lengths of the first glass film GF 1  and each of the lead films LF 1 , LF 2  are identified in advance, the positions of the first coupling portion  11  and the second coupling portion  12  on the transport path can be identified from an unwound distance and a wound distance. 
     In the embodiments described above, the first lead film LF 1  and the first coupling portion  11 , when transported, are separated from the heating roller  16  and, after the first coupling portion  11  passes by the heating roller  16 , the first glass film GF 1  is brought into contact with the heating roller  16 . However, the present invention is not limited to this embodiment. For example, in a case in which a polyimide film or the like having a high heat resistance is used as the first lead film LF 1 , the first lead film LF 1  can be transported in a state of being in contact with the heating roller  16 . In this case, the first coupling portion  11  may be separated from the heating roller  16  before or immediately after the first coupling portion  11  reaches the heating roller  16 . The same applies to the second lead film LF 2  and the second coupling portion  12 . In addition, in a case in which the heating temperature of the heating roller  16  has not reached the predetermined temperature and thus is in a temperature range in which the first lead film LF 1  does not undergo alteration, melt, or the like, the first lead film LF 1  may be transported in contact with the heating roller  16  and, once the heating roller  16  reaches the predetermined temperature and thus is in a temperature range in which the first lead film LF 1  may undergo alteration, melt, or the like, the first lead film LF 1  may be separated from the heating roller  16 . 
     In the third embodiment described above, an example has been illustrated in which the heat-blocking plate  21  of the heat-blocking device is configured to be movable in the axial direction of the heating roller  16  of the film formation device  4 , but the present invention is not limited to this configuration. The heat-blocking plate  21  may be moved in a circumferential direction of the heating roller  16  to reposition the heat-blocking plate  21  between a first position (heat-blocking position) and a second position (standby position) above the heating roller  16 . 
     In the third embodiment described above, a configuration in which the cooling pipe  22  is provided inside the heat-blocking plate  21  of the heat-blocking device has been illustrated as an example, but the present invention is not limited to this configuration and only the heat-blocking plate  21  may be provided without providing the cooling pipe  22 . 
     REFERENCE SIGNS LIST 
     
         
           1  Manufacturing device 
           3  Transport device 
           4  Film formation device 
           6  Unwinding device 
           7  Winding device 
           8   a  First transport roller 
           8   b  Second transport roller 
           8   c  Third transport roller 
           8   d  Fourth transport roller 
           11  First coupling portion 
           12  Second coupling portion 
           16  Heating roller 
           17  Roller main body 
           20   a  First separation roller 
           20   b  Second separation roller 
           21  Heat-blocking plate 
           23  Separation member 
         FM Functional film 
         GF 1  First glass film 
         GF 2  Second glass film 
         GR 2  Glass roll 
         LF 1  First lead film 
         LF 2  Second lead film