CN106886070B - Optical film manufacturing apparatus and optical film manufacturing method - Google Patents
Optical film manufacturing apparatus and optical film manufacturing method Download PDFInfo
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- CN106886070B CN106886070B CN201610891824.1A CN201610891824A CN106886070B CN 106886070 B CN106886070 B CN 106886070B CN 201610891824 A CN201610891824 A CN 201610891824A CN 106886070 B CN106886070 B CN 106886070B
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
- G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
- G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
- G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
- G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
- G02B5/3041—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid comprising multiple thin layers, e.g. multilayer stacks
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
- G01N21/892—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the flaw, defect or object feature examined
- G01N21/894—Pinholes
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
- G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
Abstract
The invention aims to provide an optical film manufacturing device and an optical film manufacturing method, which can easily determine a roller set which can cause defects. The apparatus for manufacturing an optical film includes a plurality of rollers in contact with the film, the rollers being divided into a plurality of groups according to intrinsic values of the rollers, and the intrinsic values are determined so as to correspond to pitches of marks on the processed film when the marks are transferred to the film at one point in a circumferential direction of the rollers.
Description
Technical Field
The present invention relates to an apparatus and a method for manufacturing an optical film.
Background
In an optical device such as an image display device (a liquid crystal display device, an organic E L display device, or the like), various optical films are used, and a typical example thereof is a polarizing plate used for a liquid crystal display device or the like.
The method for manufacturing an optical film includes a transport step of transporting a film (including a raw material film and an optical film manufactured by subjecting the raw material film to various processes). The method for manufacturing a polarizing plate includes a conveying step of a polarizing film, a protective film, and a laminated optical film formed by laminating them, and various processes (for example, a laminating process) are performed along a conveying path simultaneously with the conveying step.
However, in the film transport step as described above, defects such as damage, contamination, pinholes, and the like may occur on the surface of the film. Various methods for detecting such defects have been proposed (e.g., japanese patent laid-open nos. 11-223608 and 2003-344301). Such defects reduce the quality of the optical device and should be removed, and it is preferable to suppress the occurrence of defects so as not to reduce the yield.
Prior art documents
Patent document 1: japanese laid-open patent publication No. 11-223608
Patent document 2: japanese patent laid-open publication No. 2003-344301
A manufacturing apparatus for manufacturing an optical film by processing a conveyed film includes various rollers (a guide roller, a bonding roller, a cooling roller, a heating roller, and the like) with which the film comes into contact. In such a roller, if the surface is contaminated, the contamination is transferred to the film, and damage or contamination occurs on the surface of the film. An adhesive for bonding a film is adhered to the surface of a roller used in an optical film manufacturing apparatus, or a salt of a treatment liquid for treating a film is deposited, and thus contamination is likely to occur. Although the contamination on the surface of the roller can be removed by a simple method such as cleaning with a cleaning liquid, it is difficult to visually identify the contaminated roller, and it is difficult to identify the contaminated roller and clean all the rollers as targets.
Disclosure of Invention
The present inventors considered that, when a defect occurs in an optical film in a process of manufacturing the optical film, it is useful to simply identify a roller group that may cause the defect. This is because, by identifying the roller group that may cause a defect, maintenance such as cleaning can be performed on the identified roller group, and the occurrence of a defect can be effectively and easily suppressed. Accordingly, an object of the present invention is to provide an optical film manufacturing apparatus and an optical film manufacturing method capable of easily identifying a roller group that may cause a defect.
The present invention provides an apparatus and a method for manufacturing an optical film, which are described below.
[1] An optical film manufacturing apparatus that performs a process on a conveyed film to manufacture an optical film, wherein the optical film manufacturing apparatus includes a plurality of rollers that come into contact with the film, the plurality of rollers are divided into a plurality of groups according to an intrinsic value of each roller, and when a mark at one point in a circumferential direction of each roller is transferred onto the film, the intrinsic value is determined so as to correspond to a pitch of the mark on the processed film.
[2] The apparatus according to [1], wherein the pitch of the marks is calculated based on a circumferential length of the roller and a magnification of stretching applied to the film from a passing point of the roller to completion of the processing.
[3] The apparatus according to [1], wherein the pitch of the marks is measured in advance by transferring the marks to the film at one point in the circumferential direction of the roller.
[4] The apparatus for manufacturing an optical film according to any one of [1] to [3], further comprising: an inspection unit that measures a pitch of periodic defects on the film after the treatment is completed; and a determination section that determines the group to which the roller that is likely to cause a defect belongs, based on the pitch of the defect and the intrinsic value.
[5] The apparatus for manufacturing an optical film according to any one of [1] to [3], further comprising a maintenance unit configured to perform maintenance on the rollers belonging to the group specified by the specifying unit.
[6] The apparatus for manufacturing an optical film according to [4], further comprising a maintenance unit configured to perform maintenance on the rollers belonging to the group specified by the specifying unit.
[7] The apparatus for manufacturing an optical film according to [5], wherein the maintenance unit includes a cleaning unit that cleans the roller.
[8] The apparatus for manufacturing an optical film according to [6], wherein the maintenance unit includes a cleaning unit that cleans the roller.
[9] A method for manufacturing an optical film by processing a film to be conveyed, wherein the method for manufacturing an optical film includes a conveying step of conveying the film while bringing the film into contact with a plurality of rollers, the plurality of rollers are divided into a plurality of groups according to intrinsic values of the rollers, and when a mark at one point in a circumferential direction of each roller is transferred to the film, the intrinsic value is determined so as to correspond to a pitch of the mark on the film after the processing.
[10] The method of manufacturing an optical film according to [9], wherein the pitch of the mark is calculated based on a circumferential length of the roller and a magnification of stretching of the film from a passing point of the roller to completion of the processing.
[11] The method of manufacturing an optical film according to [9], wherein the pitch of the marks is measured in advance by transferring the marks to the film at one point in the circumferential direction of the roller.
[12] The method of manufacturing an optical film according to any one of [9] to [11], further comprising: an inspection step of measuring a pitch of periodic defects on the film after the treatment is completed; and a determination process of determining the group to which the roller that is likely to cause a defect belongs, based on the pitch of the defect and the intrinsic value.
[13] The method of manufacturing an optical film according to any one of [9] to [11], further comprising a maintenance step of performing maintenance on the roller belonging to the group specified by the specification step.
[14] The method of manufacturing an optical film according to [12], further comprising a maintenance step of performing maintenance on the rollers belonging to the group identified by the identification step.
[15] The method of manufacturing an optical film according to [13], wherein the maintenance step includes a step of cleaning the roller.
[16] The method of manufacturing an optical film according to [14], wherein the maintenance step includes a step of cleaning the roller.
Effects of the invention
According to the present invention, in the optical film manufacturing apparatus and the optical film manufacturing method, the roller group which may cause a defect can be easily specified.
Drawings
Fig. 1 is a cross-sectional view showing an example of an apparatus for producing an optical film (polarizing film) of the present invention.
Fig. 2 is a cross-sectional view showing an example of an apparatus for producing an optical film (polarizing plate) of the present invention.
Fig. 3 (a) and (b) are cross-sectional views showing an apparatus for manufacturing an optical film for explaining a method of determining an intrinsic value of a roll.
Fig. 4 is a cross-sectional view showing an apparatus for manufacturing an optical film for explaining a method of determining an intrinsic value of a roll.
Fig. 5 is a cross-sectional view showing an example of the apparatus for producing an optical film of the present invention.
Description of the reference numerals
1. 1 ', 1' roller
2. 2 ', 2' roller
3 film
4a, 4b processing part
5 inspection part
10 blank film
11 blank roller
13 swelling bath
15 dyeing bath
17 Cross-linking bath
19 cleaning bath
21-35 guide roller
50-55 pinching roller
60 polarizing film
61. 62 protective film
63. 70 drying furnace
64 polarizing plate
65. 81 inspection part
71-73 heating roller
Detailed Description
[ apparatus and method for producing optical film ]
The present invention relates to an optical film manufacturing apparatus and an optical film manufacturing method for manufacturing an optical film by processing a conveyed film. The apparatus for manufacturing an optical film of the present invention includes a plurality of rollers in contact with the film, and the plurality of rollers are divided into a plurality of groups according to the intrinsic values of the rollers. When a mark at one point in the circumferential direction of each roller is transferred to the film, the intrinsic value of each roller is determined so as to correspond to the pitch of the mark on the film after the treatment.
The mark here is a concept for determining the intrinsic value of the roller, and is assumed when the intrinsic value is determined by the following method [ a ], and is actually given to the roller at the time of the preliminary test when the intrinsic value is determined by the following method [ b ]. When the intrinsic value is determined by the method [ b ], the mark to be applied to the roller in the preliminary test is not particularly limited as long as it can be transferred to the film, and may be a convex object capable of transferring a shape to the film or a colored mark capable of transferring a color to the film. The pitch of the marks for determining the intrinsic value of the roller coincides with the pitch of periodic defects derived from the roller detected on the film in the film manufacturing process. As the periodic defects derived from the roller, defects such as damage, contamination, and pinholes are generated on the surface of the roller, and these defects are transferred to the film. The stains occurring on the surface of the roller are assumed to be those caused by adhesion of an adhesive used for bonding a film, and those caused by precipitation of salts of a treatment liquid used for treatment of a film.
(determination of intrinsic value)
The intrinsic value of each roll can be determined by the following method [ a ] or method [ b ].
The circumferential length of the roller is L, the magnification of stretching the film from the point of passage of the roller to completion of the treatment is n, and the value corresponding to n ×L is defined as the roll proper value, for example, n ×L is defined as the proper value.
In the preliminary test, a mark transferable to the film is applied to one point in the circumferential direction of the roll, the pitch of the mark on the processed film is measured, and a value corresponding to the measured value is defined as a roll proper value. For example, the measurement value is defined as an intrinsic value.
Depending on the processing contents in the optical film manufacturing apparatus, the magnification n of the accurate stretching may be unclear. In this case, the intrinsic value of the roll is preferably determined by the above-described method [ b ].
A method of determining the intrinsic value of each roller in the optical film manufacturing apparatus will be specifically described with reference to (a) and (b) of fig. 3, the manufacturing apparatus shown in (a) and (b) of fig. 3 includes two rollers 1 and 2 having different circumferential lengths and a processing section 4a, and is an apparatus for manufacturing an optical film by processing a conveyed film 3 by the processing section 4a, the circumferential length of the roller 1 is L1, the circumferential length of the roller 2 is L2, and the roller 1 has a smaller diameter than the roller 2, so the circumferential length L1 < the circumferential length L2.
As shown in fig. 3 (a), when a mark 1a is provided at one point in the circumferential direction of the roll 1, the mark 1a is transferred to the film 3, and when the pitch of the mark 1a 'transferred to the film 3 after passing through the roll 1 is P1, the pitch P1 matches the circumferential length L1 of the roll 1, and then the film 3 is subjected to a treatment by the treatment section 4a, the pitch of the mark 1 a' transferred to the film 3 after passing through the treatment section 4a is P11, and when the film 3 is extended n times in the longitudinal direction in the treatment section 4a, P11 n × P1 n ×L 1, and fig. 3 (a) shows a case where the extension magnification n times at the treatment section 4 is 1.
In the apparatus shown in fig. 3 (a), the intrinsic value of the roll 1 is determined so as to correspond to the pitch P11, and the pitch P11 may be a value measured in a preliminary test (method [ b ]), or a value calculated from n ×L 1 (method [ a ]).
As shown in fig. 3 (b), when the mark 2a is provided at one point in the circumferential direction of the roll 2, the mark 2a is transferred to the film 3, and when the pitch of the mark 2a 'transferred to the film 3 after passing through the roll 2 is P2, the pitch P2 matches the circumferential length L2 of the roll 2, and then the film 3 is processed by the processing section 4a, the pitch of the mark 2 a' transferred to the film 3 after passing through the processing section 4a is P21, and when the film 3 is extended n times in the longitudinal direction in the processing section 4a, P21 n × P2 n ×L 2, and fig. 3 (b) shows a case where the extension magnification n times of the processing section 4a is 1.
In the apparatus shown in fig. 3 (b), the intrinsic value of the roll 2 is determined so as to correspond to the pitch P21, and the pitch P21 may be a value measured in a preliminary test (method [ b ]), or a value calculated from n ×L 2 (method [ a ]).
Fig. 4 shows a case where the total draw ratio n of the processing section 4b is larger than 1, in fig. 4, the pitch of the mark 1 a' transferred to the film 3 after passing through the processing section 4b is P12, and if the total draw ratio of the processing section 4b is n, P12 is n × P1 is n ×L 1, and P12 is different from P11 in the apparatus shown in fig. 3 (a) where n is 1.
(division of groups)
In the apparatus for manufacturing an optical film according to the present invention, a plurality of rollers are divided into a plurality of groups according to the intrinsic values, and a specific example of how the plurality of rollers are divided into groups according to the intrinsic values is shown by using fig. 5, the apparatus for manufacturing an optical film shown in fig. 5 is an apparatus further including rollers 1 ', 1 ″ having the same diameter as the roller 1, that is, the same circumferential length L, and further including rollers 2', 2 ″ having the same diameter as the roller 2, that is, the same circumferential length L2, in the apparatus shown in (a) and (b) of fig. 3, and the film 3 passing through the rollers 1, 1 ', 1 ″ is subjected to a treatment by using the same treatment section 4a and thus has the same intrinsic value, the elongation of the treatment section 4a is 1 times, and thus the intrinsic value of the rollers 1, 1', 1 ″ is set to the circumferential length L1, the rollers having the intrinsic value L is divided into groups G1. ', and the film 3 passing through the rollers 2, 2 ″ is subjected to the same treatment by the treatment section 4a, and thus the intrinsic value of the rollers is set to the elongation of the group 3892', 2, and thus the intrinsic value of the rollers is set to the intrinsic elongation of the group L.
[ Table 1]
| Group name | Intrinsic value of the roll | Rolls belonging to a group | ||
| Group G1 | L1 | Roller 1, 1' | ||
| Group | L2 | Rollers | 2, 2', 2 " |
(inspection step)
The apparatus for manufacturing an optical film shown in fig. 5 includes an inspection unit 5 for measuring the pitch of periodic defects on the film 3 after passing through the processing unit 4 a. The inspection unit 5 is not particularly limited as long as it can detect a defect on the surface of the film 3, and for example, detects an optical image on the surface of the film 3, and detects a defect by performing image processing such as smoothing, secondary differentiation, binarization, and the like on the detected image. Then, among the detected defects, the pitch is calculated for the periodically generated defects.
(determination procedure)
The apparatus for manufacturing an optical film shown in fig. 5 includes a determination unit, not shown, which performs a determination step of determining a group of rollers that may cause a defect having a measured pitch based on data of group division shown in table 1, or a person may perform the determination step based on data of group division shown in table 1 instead of the determination unit, and in the case where the pitch of a periodic defect measured by the inspection unit 5 is, for example, L1, the group G1 including the same intrinsic value as the pitch L1 is determined as the group of rollers that may cause a defect, and in the case where the pitch of a periodic defect measured by the inspection unit 5 is, for example, L2, the group G2 including the same intrinsic value as the pitch L2 is determined as the group of rollers that may cause a defect.
Since there may be a deviation between the intrinsic value of the defect-causing roll and the pitch of the periodic defect measured by the inspection unit 5, the determination unit preferably determines the defect-causing group in consideration of the deviation. In addition, although the above description has been made on the case where the group division is performed such that one group corresponds to one unique value, the group division may be performed such that one group corresponds to unique values included in a certain numerical range. The number of rollers belonging to each group may be one or more.
(maintenance step)
The maintenance process is preferably performed after the determination process. In the maintenance step, the rollers belonging to the group identified in the identification step are cleaned, repaired, replaced, and the like in accordance with the defective condition. The state of the specified roller may be visually checked to determine which maintenance is appropriate. Alternatively, the cleaning may be performed first, and then the next maintenance may be performed when the defect is detected in the inspection step. It is also possible to further determine which roller causes a defect among the rollers belonging to the group, and then perform maintenance only on that roller. The maintenance step may be performed without stopping the film conveyance when the roll or the like is cleaned by spraying, without stopping the film conveyance, or may be performed by stopping the film conveyance when repair, replacement, or the like is necessary.
The method of dividing the group of the plurality of rollers may be divided so that the rollers that can be shared by the maintenance method belong to the same group. For example, a method of easily performing maintenance of rollers that can be cleaned with the same cleaning liquid is common. Further, the rollers made of the same material can be easily maintained in common. The circumference (or diameter) of the rollers disposed in each process may be selected so that the rollers are divided into desired groups. According to the present invention, it is possible to easily determine a group of rollers that may cause a defect. In addition, by performing maintenance based on the determination, it is possible to effectively and easily suppress the generation of periodic defects of the film.
The optical film produced by the production apparatus and the production method of the present invention is an optical member used as one member of an optical device such as an image display device (e.g., a liquid crystal display device), and examples thereof include a polarizing film, a protective film having a surface treatment layer, a protective film having a retardation property (a retardation film), and a polarizing plate in which a protective film is bonded to at least one surface of a polarizing film. Examples of the surface treatment layer provided on the surface of the protective film include a hard coat layer, an antiglare layer, an antistatic layer, an antireflection layer, and an antifouling layer. In the present specification, the optical film may be a multilayer body or a single-layer body.
< first embodiment >
In the first embodiment, the apparatus and method for manufacturing an optical film according to the present invention will be described in detail while illustrating embodiments of the apparatus and method for manufacturing a polarizing film.
(conveying Process)
Fig. 1 is a cross-sectional view schematically showing an example of a manufacturing apparatus used in a method for manufacturing a polarizing film. The polarizing film manufacturing apparatus shown in fig. 1 is configured as follows: the film 10 made of a polyvinyl alcohol resin is conveyed along a film conveying path while being continuously unwound from a stock roll 11, and the film 10 passes through a swelling bath 13, a dyeing bath 15, a crosslinking bath 17, and a cleaning bath 19 provided in the film conveying path in this order, and then passes through a drying furnace 70 (conveying step). The obtained polarizing film 60 can be directly conveyed to the next polarizing plate manufacturing step (step of bonding a protective film to one or both surfaces of the polarizing film 60) after the defect inspection by the inspection section 81. The arrows in fig. 1 show the transport direction of the film. Baths such as the swelling bath 13, the dyeing bath 15, the crosslinking bath 17, and the cleaning bath 19 in fig. 1, which are provided in the film transport path and contain a treatment liquid for treating a polyvinyl alcohol resin film, are also collectively referred to as "treatment baths".
The polarizing film manufacturing apparatus includes a plurality of rollers for supporting and/or processing the transported film, in addition to the processing baths and the drying furnace 70. In fig. 1, guide rollers 21 to 35 for supporting a film to be conveyed or further changing the film conveying direction, pinch rollers 50 to 55 for applying a driving force to the film by rotating the film to be conveyed or further changing the film conveying direction by pressing or nipping the film to be conveyed, and heating rollers 71 to 73 for promoting drying of the film in a drying furnace 70 are disposed at appropriate positions as rollers.
The guide rolls and the nip rolls can be disposed before and after each treatment bath and the drying furnace and in the treatment bath, whereby the film can be introduced into the treatment bath, immersed therein, and discharged therefrom (see fig. 1). For example, one or more guide rollers are provided in each treatment bath, and the film is transported along the guide rollers, whereby the film can be immersed in each treatment bath. The rollers in the present specification are not limited to the above-described guide rollers, nip rollers, and heating rollers, but include all rollers that rotate when coming into contact with a conveyed film, and include, for example, rollers for forming a film surface, cooling rollers for cooling a film, and the like. The roller may be a driven roller or a free roller.
In the polarizing film production apparatus shown in fig. 1, nip rollers (nip rollers 50 to 54) are arranged before and after each treatment bath, so that the inter-roller extension in which the longitudinal uniaxial extension is performed by applying a circumferential speed difference between the nip rollers arranged before and after the treatment bath can be performed in any one or more treatment baths.
(division of groups)
The rollers (guide rollers 21 to 35, nip rollers 50 to 55, and heating rollers 71 to 73) included in the manufacturing apparatus of fig. 1 are divided into groups by determining the intrinsic values of the rollers depending on the circumferential lengths of the rollers and the magnification of the film stretching from the passing point of the rollers to the inspection section 81, and in fig. 1, rollers having three circumferential lengths (referred to as "small diameter roller", "medium diameter roller", and "large diameter roller") are used, and the circumferential length of the small diameter roller is L3, the circumferential length of the medium diameter roller is L4, and the circumferential length of the large diameter roller is L5.
An example of a group division method in the case where the film 10 wound out from the stock roll 11 is a stretched film and the film is not stretched from the stock roll 11 to the inspection section 81, that is, in the case where the stretch magnification n times of the film from the passing point of each roll to the inspection section 81 is 1 time, will be described. The intrinsic value of each roll is calculated based on the circumferential length and the draw ratio. Table 2 shows an example of group division based on the above-described eigenvalues.
[ Table 2]
| Group name | Intrinsic value of the roll | Rolls belonging to a group |
| Group G3 | L3 | Guide rollers 21 to 35 |
| Group G4 | L4 | Nip roll 50-55 |
| Group G5 | L5 | Heating rollers 71 to 73 |
The guide rollers 21 to 35 are divided into a group G3 of small diameter rollers, the pinch rollers 50 to 55 are divided into a group G4 of medium diameter rollers, and the heating rollers 71 to 73 are divided into a group G5 of large diameter rollers. The information of the group division is held in a determination unit, not shown, or an external determination unit, for example. According to the group division method shown in table 2, since the rollers of the same kind (the guide roller, the nip roller, and the heating roller) are divided so as to belong to the same group, the maintenance method can be made common, which is preferable. The method of dividing the groups shown in table 2 is not limited, and the manufacturing apparatus may be designed as follows: the roll set to which contamination from the swelling bath easily adheres, the roll set to which contamination from the dyeing bath easily adheres, the roll set to which contamination from the crosslinking bath easily adheres, and the roll set to which contamination from the cleaning bath easily adheres are divided into the same group. In this case, it is preferable that the rollers of each group be cleaned by using a solution in the treatment bath, which is a cause of contamination, as a cleaning solution, and the maintenance method be shared.
In the present embodiment, the number of groups is 3, but is not particularly limited as long as it is 2 or more. In the determination section of the manufacturing apparatus of the present invention, determination of a roller that may cause a defect is performed by determining a group to which the roller belongs. When the type of the circumferential length of the roller is limited, the type of the unique value of the roller is also limited, and therefore, it is preferable to group the rollers into different groups so that the groups are formed by the unique values. However, when the circumferential length of the roller is of a large variety, or when the stretching process is performed at various magnifications in the optical film manufacturing process, that is, when the intrinsic values are of a large variety, the groups may be divided by defining the range of the intrinsic values belonging to each group.
In the case where the range of the intrinsic values belonging to each group is defined to divide the group, the number of rollers belonging to each group can be reduced by increasing the number of groups. Therefore, when the maintenance step for maintaining the rollers in the specified group is provided in the subsequent stage, the number of rollers to be maintained can be reduced, and the complexity of the maintenance step can be reduced. The number of rolls belonging to each group may also be one.
In the group division, the group division may be performed appropriately according to the eigenvalue for the rollers provided in the apparatus regardless of the group, or the group division may be performed by calculating the arranged eigenvalue in advance, selecting a roller that becomes a desired eigenvalue, and arranging the roller at each position. When the eigenvalues after arrangement are calculated in advance and the rollers that become the desired eigenvalues are selected and arranged at each position, for example, the rollers can be selected so as to belong to different groups by region. In this case, since the area in which the roller that may cause a defect is arranged can be specified in the specifying step and the roller to be maintained is arranged in the same area, there is an advantage that maintenance in the maintenance step is easily performed.
(inspection step)
The manufacturing apparatus of the present invention includes an inspection unit 81 that performs an inspection process for detecting defects on the surface of the polarizing film 60. The inspection unit 81 is not particularly limited as long as it can detect a defect on the surface of the polarizing film 60, and for example, detects an optical image on the surface of the polarizing film 60, and detects a defect by performing image processing such as smoothing, secondary differentiation, binarization, and the like on the detected image. Then, among the detected defects, the pitch is calculated for the periodically generated defects.
In the manufacturing apparatus shown in fig. 1, the position of the inspection unit 81 is set to the rear stage of the drying furnace 70, but the position of the inspection unit 81 is not limited to the above position, and may be set to the front stage of the drying furnace 70. In the subsequent determination step, a group of rollers that may cause a defect can be determined for only the rollers at the front stage of the inspection unit 81, based on the position of the inspection unit 81. In the manufacturing apparatus and the manufacturing method of the present embodiment, instead of the inspection unit 81 for detecting defects, an inspection step of visually detecting defects on the surface of the polarizing film 60 may be employed. In this case, the pitch is also determined for the periodically generated defects. The inspection step may be performed on the film transport path as shown in fig. 1, or may be performed as follows: the polarizing film thus produced was partially cut out to produce a sample as an inspection object, and the sample was examined for the presence or absence of the occurrence of periodic defects and, if any, the pitch of defects.
(determination procedure)
Then, in a determination unit, not shown, a determination step of determining a group including the eigenvalue corresponding to the measured pitch of the defect is performed based on the stored data of the eigenvalue for group division. The determination process may be performed by a person based on data of group division managed.
The size of the defect that reduces the yield in the optical film such as the polarizing film 60 is usually about 10 μm to 50 μm. Since the optical film is used as a member of an optical device, the size of a defect in the visual observation of the optical film may be larger than the size of a defect (foreign matter, damage, or the like) that causes the defect in the roller due to scattering, refraction, diffraction, or the like at the time of light incidence. Therefore, it is sometimes difficult to identify a roll having a defect (foreign matter, damage, or the like) that causes a defect, simply by visually checking the state of the roll. Even in such a case, according to the apparatus and method of the present invention, it is possible to identify the group to which the roller that may cause the defect belongs, and it is possible to effectively and easily suppress the occurrence of the defect by performing the maintenance process on the rollers in the group.
(maintenance step)
The maintenance process is preferably performed after the determination process. In the maintenance step, the rollers belonging to the group identified in the identification step are cleaned, repaired, replaced, and the like in accordance with the failure conditions thereof. The state of the specified roller may be visually checked to determine which maintenance is appropriate. Alternatively, the cleaning may be performed first, and then the next maintenance may be performed when the defect is detected in the inspection step. It is also possible to further determine which roller causes a defect among the rollers belonging to the group, and then perform maintenance only on that roller. The maintenance step may be performed without stopping the film conveyance when the roll or the like is cleaned by spraying, without stopping the film conveyance, or may be performed by stopping the film conveyance when repair, replacement, or the like is necessary.
< second embodiment >
In the second embodiment, the group division of the apparatus and the method for manufacturing an optical film according to the present invention will be described in detail while illustrating the embodiments of the apparatus and the method for manufacturing a polarizing plate. Fig. 2 is a cross-sectional view schematically showing an example of a manufacturing apparatus used in the method for manufacturing a polarizing plate. In the polarizing plate manufacturing apparatus shown in fig. 2, protective films 61 and 62 are conveyed in parallel with a polarizing film 60 in the upper and lower directions, and a laminate in which three films (polarizing film 60, protective films 61 and 62) are laminated with an adhesive (not shown) interposed therebetween is passed between a pair of laminating rollers 39. Then, the adhesive is dried in a drying oven 63, and a polarizing plate 64 in which protective films 61 and 62 are attached to both surfaces of a polarizing film 60 is manufactured. The polarizing plate 64 is inspected by the inspection unit 65 and then wound.
In the manufacturing apparatus shown in fig. 2, guide rollers 91 and 92 for conveying the polarizing film 60, guide rollers 93 and 94 for conveying the protective film 61, and guide rollers 95 and 96 for conveying the protective film 62 are divided into groups having different circumferential lengths. By selecting and arranging the rollers so as to belong to different groups by regions (the transport region of the polarizing film 60, the transport region of the protective film 61, and the transport region of the protective film 62), the region (group) in which the roller that may cause a defect is arranged can be identified in the identifying step, and therefore the rollers that are the maintenance target are arranged in the same region, which is advantageous in that maintenance in the maintenance step is easily performed.
The details of the inspection step, the specification step, and the maintenance step in the present embodiment are as described above in the first embodiment.
Claims (6)
1. A method for manufacturing an optical film by treating a film being conveyed,
the method for manufacturing an optical film is characterized in that,
the method for manufacturing the optical film comprises a conveying step of conveying the film while contacting the film with a plurality of rollers,
the plurality of rollers are divided into a plurality of groups according to the intrinsic values of the respective rollers,
when a mark at one point in the circumferential direction of each roller is transferred to the film, the intrinsic value is determined so as to correspond to the pitch of the mark on the film after the treatment.
2. The method for manufacturing an optical film according to claim 1,
the pitch of the mark is calculated based on the circumferential length of the roller and the magnification of the stretching of the film from the passing point of the roller to the completion of the processing.
3. The method for manufacturing an optical film according to claim 1,
the pitch of the marks is measured in advance by transferring the marks to the film at one point in the circumferential direction of the roller.
4. The method for manufacturing an optical film according to any one of claims 1 to 3,
the method of manufacturing the optical film further includes:
an inspection step of measuring a pitch of periodic defects on the film after the treatment is completed; and
a determination process in which the group to which the roller that is likely to cause a defect belongs is determined based on the pitch of the defect and the intrinsic value.
5. The method for manufacturing an optical film according to claim 4,
the method of manufacturing an optical film further includes a maintenance step of performing maintenance on the rollers belonging to the group determined by the determination step.
6. The method for manufacturing an optical film according to claim 5,
the maintenance process includes a process of cleaning the roller.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2015203692 | 2015-10-15 | ||
| JP2015-203692 | 2015-10-15 |
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| CN106886070A CN106886070A (en) | 2017-06-23 |
| CN106886070B true CN106886070B (en) | 2020-07-28 |
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| CN201610891824.1A Active CN106886070B (en) | 2015-10-15 | 2016-10-12 | Optical film manufacturing apparatus and optical film manufacturing method |
| CN201621116729.6U Active CN206515501U (en) | 2015-10-15 | 2016-10-12 | The manufacture device of optical film |
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| CN201621116729.6U Active CN206515501U (en) | 2015-10-15 | 2016-10-12 | The manufacture device of optical film |
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|---|---|
| JP (1) | JP2017075936A (en) |
| KR (1) | KR20170044598A (en) |
| CN (2) | CN106886070B (en) |
| TW (1) | TWI694963B (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2017075936A (en) * | 2015-10-15 | 2017-04-20 | 住友化学株式会社 | Apparatus for manufacturing optical film and method for manufacturing optical film |
| JP7079365B1 (en) * | 2021-09-28 | 2022-06-01 | 日東電工株式会社 | A method for manufacturing a stretched film, a method for manufacturing an optical laminate, and a film stretching device. |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH09109372A (en) * | 1995-10-18 | 1997-04-28 | Datsuku Eng Kk | Product inspecting apparatus and mark presence or absence inspecting means |
| CN1576828A (en) * | 2003-07-28 | 2005-02-09 | 日东电工株式会社 | Inspection method and system for sheet products |
| CN1605859A (en) * | 2003-10-09 | 2005-04-13 | 日东电工株式会社 | Lamellar product and checking method, checking system and image display device thereof |
| CN102177081A (en) * | 2008-09-10 | 2011-09-07 | 3M创新有限公司 | Multi-roller registered repeat defect detection of a web process line |
| CN206515501U (en) * | 2015-10-15 | 2017-09-22 | 住友化学株式会社 | The manufacture device of optical film |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP3881506B2 (en) * | 2000-11-24 | 2007-02-14 | 住友化学株式会社 | Method and apparatus for determining roll-induced defects |
| JP4202707B2 (en) * | 2002-09-30 | 2008-12-24 | 富士フイルム株式会社 | Method for identifying periodic defect occurrence location and inspection system |
| JP5413275B2 (en) * | 2010-03-31 | 2014-02-12 | 東レ株式会社 | Periodic defect detection method, apparatus, and sheet-like object manufacturing method |
| JP6413243B2 (en) * | 2014-01-22 | 2018-10-31 | 大日本印刷株式会社 | Quality control system, quality control method, and program |
| JP2015172527A (en) * | 2014-03-12 | 2015-10-01 | 東レ株式会社 | Defect inspection device, and estimation device of defect occurrence position |
-
2016
- 2016-09-23 JP JP2016185485A patent/JP2017075936A/en active Pending
- 2016-10-12 CN CN201610891824.1A patent/CN106886070B/en active Active
- 2016-10-12 CN CN201621116729.6U patent/CN206515501U/en active Active
- 2016-10-12 TW TW105132876A patent/TWI694963B/en active
- 2016-10-13 KR KR1020160132801A patent/KR20170044598A/en not_active Application Discontinuation
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH09109372A (en) * | 1995-10-18 | 1997-04-28 | Datsuku Eng Kk | Product inspecting apparatus and mark presence or absence inspecting means |
| CN1576828A (en) * | 2003-07-28 | 2005-02-09 | 日东电工株式会社 | Inspection method and system for sheet products |
| CN1605859A (en) * | 2003-10-09 | 2005-04-13 | 日东电工株式会社 | Lamellar product and checking method, checking system and image display device thereof |
| CN102177081A (en) * | 2008-09-10 | 2011-09-07 | 3M创新有限公司 | Multi-roller registered repeat defect detection of a web process line |
| CN206515501U (en) * | 2015-10-15 | 2017-09-22 | 住友化学株式会社 | The manufacture device of optical film |
Also Published As
| Publication number | Publication date |
|---|---|
| JP2017075936A (en) | 2017-04-20 |
| KR20170044598A (en) | 2017-04-25 |
| TW201718381A (en) | 2017-06-01 |
| CN206515501U (en) | 2017-09-22 |
| TWI694963B (en) | 2020-06-01 |
| CN106886070A (en) | 2017-06-23 |
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