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Laminate sheet, laminate sheet roll, and producing method thereforRelated Patent Categories: Stock Material Or Miscellaneous Articles, Layer Or Component Removable To Expose AdhesiveLaminate sheet, laminate sheet roll, and producing method therefor description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070036931, Laminate sheet, laminate sheet roll, and producing method therefor. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to a laminate sheet constituted by an adhesive sheet having a predetermined form which is laminated onto a release sheet, and more particularly to a laminate sheet which is capable of reducing defects that may be formed on the adhesive sheet when the laminate sheet is wound into a roll. [0003] 2. Description of the Related Art [0004] A conventional laminate sheet in which adhesive labels are laminated onto a release sheet is shown in FIG. 20 (Publication of Examined Utility Model Application No. H6-18383 (FIG. 1), Publication of patent application Ser. No. H8-316175 (FIGS. 3 through 6)). In recent years, such laminate sheets have come to be used in the manufacture of optical discs in order to laminate a cover sheet onto the light-receiving surface of the optical disc. As shown in FIG. 20, a conventional laminate sheet 1P is constituted by a long release sheet 2P and cover sheet portions 301P (adhesive sheets) provided continuously in the longitudinal direction of the release sheet 2P. The cover sheet portion 301P is constituted by an adhesive layer 31P and a light-transmitting base material 32P and has an identical form to an optical disc. [0005] The laminate sheet 1P is wound into a roll form, transported and stored in a rolled state, and used by being pulled from the roll. When the laminate sheet 1P is wound into a roll in this manner, the cover sheet portions 301P are wound over other cover sheet portions 301P, and at this time, as shown in FIG. 21, traces (arc-form traces) of the contours of the cover sheet portions 301P are formed on the other cover sheet portions 301P due to winding pressure. [0006] In order to prevent such arc-form traces from forming on the cover sheet portions 301P, the laminate sheet 1P may be wound at a reduced winding pressure, but the problem with a roll which has been wound at a reduced winding pressure is that the roll is likely to collapse. [0007] Further, when the laminate sheet 1P is wound, foreign matter such as minute dust particles (normally with a diameter of 5 to 50 .mu.m) may become trapped between the wound layers of the laminate sheet 1P. If the laminate sheet 1P is wound with foreign matter trapped in this manner, depressions caused by the foreign matter are formed in the cover sheet portions 301P. [0008] Such arc-form traces and depressions formed in the cover sheet portions 301P as described above do not cause great problems in conventional optical discs, but in next-generation high capacity/high recording density optical discs (Blu-ray Discs), these arc-form traces and depressions become defects which may cause errors when data are read. SUMMARY OF THE INVENTION [0009] The present invention has been designed in consideration of such circumstances, and it is an object thereof to provide a laminate sheet which is capable of preventing the formation of defects on an adhesive sheet when the laminate sheet is wound into a roll and a producing method therefor, and a laminate sheet roll which is capable of preventing the formation of defects on an adhesive sheet and a producing method therefor. [0010] In order to achieve this object, a first aspect of the present invention is the provision of a laminate sheet formed by laminating an adhesive sheet having a predetermined form and a protective member in different positions on a long release sheet, wherein the protective member is thicker than the adhesive sheet and is provided so as not to overlap the adhesive sheet when the laminate sheet is wound into a roll. The protective member is preferably laminated onto the same side of the release sheet as the adhesive sheet, but all of or one part of the protective member may be laminated onto the opposite side to the adhesive sheet. [0011] In the invention described above, the protective member which is thicker than the thickness of the adhesive sheet is provided on the laminate sheet, and thus when the laminate sheet is wound into a roll, a gap is produced between the surface of the adhesive sheet and the back surface of the release sheet which is wound thereon. Moreover, the protective member is provided so as not to overlap the adhesive sheet when the laminate sheet is wound into a roll. Thus when the laminate sheet is wound into a roll, the contour parts of other adhesive sheets and the protective member do not press forcefully upon the adhesive sheet, and as a result, traces caused by winding pressure can be reliably prevented from forming on the adhesive sheet. [0012] Further, even when foreign matter such as minute dust particles becomes trapped between the layers of the wound laminate sheet during the winding of the laminate sheet, the gap exists between the surface of the adhesive sheet and the back surface of the release sheet, and thus the formation of depressions on the adhesive sheet caused by the foreign matter can be suppressed. [0013] According to the invention as described above, defects which may be formed on the adhesive sheet when the laminate sheet is wound into a roll can be dramatically reduced. [0014] In the invention described above, the adhesive sheet is preferably provided continuously in a central portion in the direction of width of the release sheet, and the protective member is preferably provided on both side portions in the direction of width of the release sheet. By constituting the laminate sheet in this manner, defects which maybe formed on the adhesive sheet when the laminate sheet is wound into a roll can be effectively reduced. [0015] A second aspect of the present invention is the provision of a laminate sheet formed by laminating an adhesive sheet having a predetermined form and a protective member in different positions on a long release sheet, wherein the protective member is thicker than the adhesive sheet and is provided so as to partially overlap the adhesive sheet when the laminate sheet is wound into a roll. Here, overlap of the protective member and adhesive sheet indicates that the protective member and adhesive sheet overlap in the radial direction of the roll, and includes both indirect overlap (with the release sheet interposed therebetween) and direct overlap (when the release sheet is not interposed therebewteen). Note that the protective member is preferably laminated onto the same side of the release sheet as the adhesive sheet, but all of or one part of the protective member may be laminated onto the opposite side to the adhesive sheet. [0016] In the invention described above, the protective member which is thicker than the thickness of the adhesive sheet is provided on the laminate sheet, and thus when the laminate sheet is wound into a roll, a gap is produced between the surface of the adhesive sheet and the back surface of the release sheet which is wound thereon. Thus the contour parts of other adhesive sheets do not press forcefully upon the adhesive sheet, and as a result traces caused by winding pressure are prevented from forming on the adhesive sheet. [0017] Further, even when foreign matter such as minute dust particles becomes trapped between the layers of the wound laminate sheet during the winding of the laminate sheet, the gap exists between the surface of the adhesive sheet and the back surface of the release sheet, and thus the formation of depressions on the adhesive sheet caused by the foreign matter can be suppressed. Hence according to the invention, defects which maybe formed on the adhesive sheet when the laminate sheet is wound into a roll can be dramatically reduced. [0018] Further, by having the protective member partially overlap the adhesive sheet when the laminate sheet is wound into a roll, the surface contact area between the surfaces of the protective member and release sheet is ensured to a certain degree and the part of the roll at which protective members overlap bears the greatest winding pressure. Hence stability as a roll is high and the roll is unlikely to collapse during use, transportation, and so on. [0019] In the invention described above, the adhesive sheet is preferably provided in a continuous plurality in a central portion in the direction of width of the release sheet such that gaps are formed at least in the vicinity of the both side portions in the direction of width of the release sheet, and the protective member is preferably provided on both side portions in the direction of width of the release sheet and in the gaps between the plurality of adhesive sheets. By constituting the laminate sheet in this manner, defects which maybe formed in the adhesive sheet can be effectively reduced, and stability as a roll can be effectively improved. [0020] In the inventions described above, the thickness of the protective member is preferably greater than the thickness of the adhesive sheet by 5 to 100 .mu.m. By setting the thickness of the protective member thus, an effect of preventing traces caused by winding pressure and depressions caused by foreign matter from forming on the adhesive sheet can be sufficiently obtained, and excessive increases in the diameter (volume) of the roll can be avoided. [0021] In the invention described above, the surface area of the overlapping part between the protective member and adhesive sheet is preferably not more than 50% of the surface area of the adhesive sheet. According to this invention, the surface area of the laminate sheet occupied by the protective member is suppressed, and thus anumber of formed adhesive sheets can be ensured. Note that "the overlapping part between the protective member and adhesive sheet" in this specification corresponds to a part of the protective member which exists further inside in the direction of width than a virtual straight line which connects the outermost edge of adjacent adhesive sheets in the direction of width of the release sheet. [0022] In the inventions described above, the adhesive sheet may comprise a base material constituted by a resin sheet, and an adhesive layer. When the adhesive sheet is constituted in such a manner, traces caused by winding pressure and depressions caused by foreign matter are likely to form on the adhesive sheet, but by means of the present invention, these defects can be effectively reduced. 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