CN111971158A

CN111971158A - Film forming device

Info

Publication number: CN111971158A
Application number: CN201980024275.XA
Authority: CN
Inventors: 日置一弥; 八若佐知
Original assignee: Sumitomo Heavy Industries Ltd
Current assignee: Sumitomo Heavy Industries Ltd
Priority date: 2018-03-30
Filing date: 2019-03-18
Publication date: 2020-11-20
Also published as: TW201941910A; WO2019188478A1; JP6948281B2; TWI711526B; JP2019177508A

Abstract

The film forming apparatus of the present invention forms a film by extruding a molten resin from a die and solidifying the resin, and forms a film roll by winding the formed film. The film forming apparatus is provided with a determination unit (52) for determining whether or not there is an abnormality in the roll attitude based on the change in the axial direction of the radius of the film roll body.

Description

Film forming device

Technical Field

The invention relates to a film forming device.

Background

There is known a film forming apparatus for forming a film by extruding a molten resin from a die and solidifying the resin. Conventionally, a film forming apparatus has been proposed which reduces unevenness in film thickness (hereinafter referred to as "film thickness") by changing the width of a discharge port (patent document 1).

Prior art documents

Patent document

Patent document 1: japanese laid-open patent publication No. 6-99472

Disclosure of Invention

Technical problem to be solved by the invention

According to the conventional thin film forming apparatus described in patent document 1, the film thickness unevenness can be reduced to some extent, and the accuracy as a thin film can be satisfied. However, in general, film thickness unevenness is left to some extent. Even if the unevenness satisfies the unevenness as the precision of the film, if the unevenness is accumulated when the film is wound to form the film roll, more specifically, if thick portions or thin portions are stacked, the film roll may be protruded or dented. The protrusions or depressions of the film roll become a cause of film strain.

The present invention has been made in view of such circumstances, and an object thereof is to provide a film forming apparatus capable of forming a film roll body having relatively few or small projections and depressions.

Means for solving the technical problem

In order to solve the above problems, a film forming apparatus according to an aspect of the present invention includes a determination unit configured to determine whether or not an abnormality exists in a roll posture based on a change in a radius of a film roll in an axial direction, the determination unit being configured to extrude a molten resin from a die and solidify the resin to form a film, and to roll up the formed film to form the film roll.

In addition, any combination of the above-described constituent elements or the constituent elements and expressions of the present invention may be replaced with each other in a method, an apparatus, a system, or the like.

Effects of the invention

According to the present invention, a film roll body having relatively few or small protrusions or depressions can be formed.

Drawings

Fig. 1 is a diagram showing a schematic configuration of a film forming apparatus according to an embodiment.

Fig. 2 is a sectional view showing the mold and the film thickness adjusting section shown in fig. 1.

Fig. 3 is a plan view showing the mold and the film thickness adjusting section.

Fig. 4 is a plan view showing the mold and the film thickness adjusting section.

Fig. 5 is a block diagram showing the function and structure of the control device of fig. 1.

Fig. 6 is a diagram for explaining the processing of the determination unit for determining whether or not there is an abnormality in the roll attitude.

Fig. 7 is a drawing machine of a film forming apparatus according to a modification and a drawing machine of the film forming apparatus according to the modification and its periphery.

Fig. 8 is a block diagram showing the function and configuration of a control device of the film forming apparatus according to the modified example.

Detailed Description

Hereinafter, a mode for carrying out the present invention will be described in detail with reference to the drawings. In the description of the drawings, the same elements are denoted by the same reference numerals, and the redundant description is appropriately omitted.

Fig. 1 shows a schematic configuration of a film forming apparatus 1 according to an embodiment. The film forming apparatus 1 forms a tubular film. The film forming apparatus 1 includes a die 2, a film thickness adjusting section 15, a pair of stabilizing plates 4, a tractor 5, a thickness measuring sensor 6, a winder 20, a winding posture measuring sensor 22, and a control device 7.

The die 2 molds a molten resin supplied from an extruder (not shown) into a tubular shape. In particular, the die 2 extrudes molten resin from an annular slit 18 (described later in fig. 2) to mold the molten resin into a tubular shape.

The film thickness adjusting section 15 adjusts the film thickness of the molten resin extruded from the die 2 and cools the resin. The molten resin is cooled and formed into a film.

The pair of stabilizing plates 4 is disposed above the cooling device 3, and guides the formed film to the tractor 5. The tractor 5 is disposed above the stabilizer plate 4. The tractor 5 includes a pair of pinch rollers 38. The pair of pinch rollers 38 is driven to rotate by a motor not shown, and lifts up the guided film to fold it flat. The winder 20 winds the folded film having a predetermined width to form a film roll 11.

The thickness measuring sensor 6 is disposed between the film thickness adjusting portion 15 and the stabilizing plate 4. The thickness measuring sensor 6 measures the film thickness at each position in the circumferential direction while rotating around the tubular thin film. The thickness measurement sensor 6 measures the film thickness at each position in the circumferential direction at a predetermined cycle. The measurement value based on the thickness measurement sensor 6 is sent to the control device 7.

The roll posture measuring sensor 22 is disposed adjacent to the film roll body 11. The roll posture measuring sensor 22 measures information on the radii of the respective positions of the film roll body 11 in the axial direction, that is, information on the axial direction change of the radius of the film roll body 11 at a predetermined cycle. The roll posture measuring sensor 22 specifies the radius itself as the information on the radius in the present embodiment, but may measure the diameter at each position in the axial direction as the information on the radius, and may specify a certain axis parallel to the center axis of the film roll body 11 and the distance between the positions in the axial direction of the film roll body 11, for example.

The roll posture measuring sensor 22 is, for example, a laser displacement meter, and measures each position in the axial direction while moving along the central axis of the film roll body 11, specifically, the radius of the film roll body 11 at n positions from the 1 st position to the n (n is a natural number) th position arranged at a constant interval in the axial direction. The 1 st position and the n-th position correspond to one end and the other end of the film roll body 11 in the axial direction, respectively. The measurement value by the roll attitude measurement sensor 22 is sent to the control device 7.

The control device 7 transmits a control command corresponding to the measurement value received from the thickness measurement sensor 6 or the roll posture measurement sensor 22 to the film thickness adjusting section 15. The film thickness adjusting section 15 receives the control command, and adjusts the width of the slit 18 (particularly, the discharge port thereof) or the volume of the cooling air so as to reduce the thickness unevenness.

Fig. 2 is a cross-sectional view showing the mold 2 and the film thickness adjusting section 15. Fig. 3 and 4 are plan views showing the mold 2 and the film thickness adjusting section 15. Fig. 3 shows a state in which the inside of the cooling device 3 is seen through. In fig. 4, the cooling device 3 is not shown.

The mold 2 includes a mold body 10, an inner peripheral member 12, and an outer peripheral member 14. The inner peripheral member 12 is a substantially columnar member placed on the upper surface of the die main body 10. The outer peripheral member 14 is an annular member, and surrounds the inner peripheral member 12. A slit 18 extending in the vertical direction is formed in an annular shape between the inner peripheral member 12 and the outer peripheral member 14. The molten resin flows upward through the slit 18, and the molten resin is extruded from the discharge port (i.e., upper end opening) 18a of the slit 18, thereby forming a thin film having a thickness corresponding to the width of the discharge port 18 a.

The film thickness adjusting section 15 includes a cooling device 3 and a plurality of (here, 32) adjusting units 16.

The cooling device 3 is disposed above the mold 2. The cooling device 3 includes an air-cooling ring 8, and a plurality of (20 in fig. 3) valve devices 9 provided in the air-cooling ring 8 and configured to adjust the volume of cooling air blown out from the air-cooling ring 8. The air cooling ring 8 is an annular housing having an inner peripheral portion recessed downward. An annular outlet 8a opened at the upper side is formed in the inner periphery of the air cooling ring 8. In particular, the outlet 8a is formed concentrically with the annular slit 18.

A plurality of hose ports 8b are formed at equal intervals in the circumferential direction on the outer peripheral portion of the air-cooling ring 8. A hose (not shown) is connected to each of the plurality of hose ports 8b, and cooling air is sent from a blower (not shown) into the air cooling ring 8 through the hose. The cooling air sent into the air-cooling ring 8 is blown out from the blow-out port 8a and blown onto the molten resin.

The plurality of valve devices 9 are disposed in the ventilation path between the outlet 8a and the hose port 8b without a gap in the circumferential direction. By adjusting the respective opening degrees of the plurality of valve devices 9, the volume of the cooling air blown out from the air outlet 8a can be adjusted. For example, by setting the opening degrees of all the valve devices 9 to be the same, the volume of the cooling air blown out from the air outlet 8a can be made uniform in the circumferential direction. For example, by setting the opening degree of at least one valve device 9 to be different from the opening degrees of the other valve devices 9, the volume of the cooling air blown out from the air outlet 8a can be changed in the circumferential direction. When the thickness unevenness occurs in the film, for example, the opening degree of the valve device 9 corresponding to the thin portion (for example, located below the thin portion) is increased, and the amount of the molten resin blown to the lower side of the thin portion is increased. This reduces the thickness unevenness of the film to be formed later.

The plurality of adjustment units 16 are arranged so as to surround the upper end side of the outer peripheral member 14 with almost no gap in the circumferential direction. In particular, the adjustment unit 16 is mounted to the outer peripheral member 14 in a cantilever manner. A cooling device 3 is fixed above the plurality of adjusting units 16. Each of the plurality of adjustment units 16 is configured to be able to apply a pressing load directed radially inward or a tensile load directed radially outward to the outer peripheral member 14. The outer peripheral member 14 is elastically deformed by being applied with a pressing load or a tensile load. Therefore, by adjusting the plurality of adjustment units 16, the width of the discharge port 18a can be locally adjusted in the circumferential direction, and the film thickness can be locally controlled in the circumferential direction. When the film thickness varies in the circumferential direction, for example, a tensile load is applied to the outer peripheral member 14 from the adjusting means 16 corresponding to the thin-walled portion (for example, located below the thin-walled portion), and the gap of the discharge port 18a below the thin-walled portion is increased. This reduces film thickness unevenness.

As shown in fig. 2, the adjustment unit 16 includes, as an example: an actuator 24 that is driven in accordance with a control command from the control device 7; a lever 34 supported by the pivot shaft 32 and receiving the rotational force of the actuator 24; and an operating rod 36 supported by the outer peripheral member 14 so as to be displaceable in the axial direction and supported at the point of action of the lever 34. The rotational force of the lever 34 is converted into a force in the axial direction of the operating rod 36, the force in the axial direction becomes a load to the inner peripheral member 12 or the outer peripheral member 14, and the lever 34 directly applies a force to the operating rod 36 at a point of action of the lever 34.

Fig. 5 is a block diagram showing the function and structure of the control device 7. Each block shown here can be realized by a component or a mechanical device represented by a CPU of a computer in hardware, and can be realized by a computer program or the like in software. Accordingly, those skilled in the art will appreciate that these functional blocks can be implemented in various forms by a combination of hardware and software.

The control device 7 includes: a communication unit 40 that performs communication processing with the thickness measurement sensor in accordance with various communication protocols; a U/I unit 42 for receiving operation input from a user and displaying various screens on the display unit; a data processing unit 46 for executing various data processing based on the data acquired from the communication unit 40 and the U/I unit 42; and a storage unit 48 for storing the data referred to and updated by the data processing unit 46.

The storage unit 48 includes an allowable film thickness storage unit 60, an actual film thickness storage unit 62, and a roll attitude information storage unit 64. The allowable film thickness storage unit 60 stores the range of the allowable film thickness. The measured film thickness storage unit 62 stores the film thickness at each position in the circumferential direction of the thin film in the tubular state, measured by the thickness measuring sensor 6, and the measurement time thereof in association with each other. The roll posture information storage unit 64 stores the positions of the film roll body 11 in the axial direction, the radii of the film roll body 11 at the positions measured by the roll posture measurement sensors 22, and the measurement times thereof in association with each other. The time when the later-described acquiring unit 50 acquires the film thickness and the radius may be regarded as the measurement time.

The data processing unit 46 includes an acquisition unit 50, a determination unit 52, a determination unit 54, an operation control unit 56, and a notification unit 58. The acquisition unit 50 acquires the film thickness measured by the thickness measurement sensor 6.

The determination unit 52 determines whether or not there is an abnormality in the roll posture of the film roll body 11, in other words, whether or not there is a protrusion or a depression in the film roll body 11, from the change in the axial direction of the radius of the film roll body 11 at a predetermined cycle.

Fig. 6 is a diagram for explaining the process of determining whether or not the roll attitude is abnormal by the determination unit 52. In fig. 6, the horizontal axis represents the axial position of the film roll body 11, and the vertical axis represents the radius. That is, fig. 6 shows the radius of the film roll body 11 at each position in the axial direction, that is, the change in the axial direction of the radius of the film roll body 11.

In the present embodiment, the determination unit 52 is arranged in a range R from the i-th (i is 1, 2, … …, n-m (m is a constant of a natural number)) position to the i + m-th position in the axial direction_iMaximum value R of radius of inner film roll body_imax and minimum value R_iWhen the difference between max is equal to or greater than a predetermined difference threshold D, it is determined that the range R is within_iIf there is a protrusion or a depression, it is determined that there is an abnormality in the roll attitude.

The value of m may be determined by experiments or the like. Even if there is a difference of the difference threshold D or more in the radius as in the 2 axial positions surrounded by the broken line, the axial change in the radius is gentle when the 2 axial positions are relatively separated, and therefore, the change does not cause the film strain. If the value of m is too large, this case is also determined to be a protrusion or a depression. If the value of m is too small, it can be determined that the winding posture is abnormal only when there is a projection or a recess having a sharp change in the radius in the axial direction. Therefore, the value to be set to m needs to be determined in consideration of these.

The notification section 58 will be in the range R₁Range R₂… …, range R_n-mThe information that the range in which the protrusion or the depression is determined to be present and the winding posture are abnormal is notified by a display or a sound on the display unit.

The determination unit 54 determines the load to be applied to the outer peripheral member 14 by each of the adjustment units 16 and/or the opening degree of each of the valve devices 9. In particular, the determination unit 54 determines the load to be applied to the outer peripheral member 14 by each of the adjustment units 16 and/or the opening degree of each of the valve devices 9 so that the film thickness measured by the thickness measurement sensor 6 is within the allowable range of the film thickness at each position in the circumferential direction of the tubular thin film.

The operation controller 56 controls the operation of the film thickness adjuster 15, that is, the operation of the adjusting unit 16 and the valve device 9. Specifically, the motion control unit 56 sends a control command to the adjustment unit 16 to apply the load determined by the determination unit 54 to the outer peripheral member 14, and sends a control command indicating the opening degree determined by the determination unit 54 to the valve device 9.

The operation of the film forming apparatus 1 configured as described above will be described.

The molten resin is extruded from the outlet 18a of the die 2, and cooling air is blown from the cooling device 3 of the film thickness adjusting section 15 to solidify the molten resin to form a thin film. In the film formation, the thickness measuring sensors 6 measure the film thickness of the tubular film at each position in the circumferential direction at a predetermined cycle. In the film formation, the roll posture measuring sensor 22 measures the radius of the film roll body 11 at each position in the axial direction at a predetermined cycle. The control device 7 controls the film thickness adjusting unit 15 so that the film thickness measured by the thickness measuring sensor 6 is within the allowable range of film thickness. The control device 7 further determines whether or not there is an abnormality in the roll posture of the film roll body 11, and notifies the user of the information when it is determined that there is an abnormality. Upon receiving the notification, the user manually adjusts the film thickness adjusting section 15 so as to cancel the abnormality of the roll posture, that is, to eliminate the projection or depression.

Next, the effects of the present embodiment will be described. According to the film forming apparatus 1 of the present embodiment, it is determined whether or not there is an abnormality in the roll posture of the film roll body 11, that is, whether or not there is a protrusion or a depression, and therefore the presence thereof can be grasped. This makes it possible to remove the abnormality of the winding position and form the film roll body having relatively few or small projections or depressions.

Further, according to the film forming apparatus 1 of the present embodiment, the roll posture measuring sensor 22 directly measures information on the radius of the film roll body 11. Therefore, the information on the radius of the film roll body 11 can be measured with high accuracy, and whether or not there is an abnormality in the roll attitude can be determined with high accuracy.

The structure and operation of the film forming apparatus according to the embodiment are explained above. These embodiments are illustrative, and those skilled in the art will understand that various modifications are possible in the combination of these respective constituent elements, and that these modifications are also within the scope of the present invention.

(modification 1)

Fig. 7 is a view showing the tractor 5 of the film forming apparatus 1 according to the modification and its periphery. The tractor 5 includes a pair of 1 st pinch rollers 138, a pair of 2

nd pinch rollers

140, and 1 st to 5 th steering rollers 142 to 150. The 1 st pinch roller 138 and the 1 st steering roller 142 to the 5 th steering roller 150 are configured to be capable of reciprocating rotation about a vertical axis. Although the configuration of the tractor 5 is well known and detailed description thereof is omitted, the film is twisted by the turning of the 1 st pinch roller 138 and the 1 st to 5 th steering rollers 142 to 150, and the position of the tubular film before being folded by the 1 st pinch roller 138 in the circumferential direction is gradually shifted relative to the position of the film stacked when the film is wound by the winding machine 20 and averaged, thereby reducing occurrence of abnormalities in the winding posture of the film.

In the present modification, it is also possible to determine whether or not there is an abnormality in the roll posture of the film roll body 11, and to notify the determination result, as in the embodiment. After receiving the notification of the determination result, the user can manually adjust the film thickness adjusting unit 15 so as to cancel the abnormality of the winding posture. The user can cancel the abnormality of the winding posture by changing the turning speed of at least one of the 1 st pinch roller 138 and the 1 st turn rollers 142 to 5 th turn rollers 150 or changing the turning timing.

(modification 2)

In the embodiment and the above-described modifications, a case where the roll posture measuring sensor 22 measures information on the radius of each position of the film roll body 11 in the axial direction is described. As a modification, information on the radius of each position of the film roll body 11 in the axial direction may be specified (estimated) from the film thickness measured by the thickness measuring sensor 6. Fig. 8 is a block diagram showing the function and structure of the control device 7 of the film forming apparatus 1 according to the modification. Fig. 8 corresponds to fig. 5. In the present modification, the data processing section 46 further includes a specification section 59. The specifying section 59 specifies the radius of each position of the film roll body 11 in the axial direction based on the film thickness at the corresponding circumferential position of the tubular film before folding. More specifically, since the film roll body 11 is a roll body formed by folding and winding a tubular film, the radius of the film roll body 11 at each position in the axial direction can be specified by summing the film thicknesses at the 2 corresponding circumferential positions of the tubular film before folding.

According to the film forming apparatus 1 of the present modification, since the information on the radius of the film roll body 11 is specified based on the measurement value of the thickness measurement sensor 6, the roll posture measurement sensor 22 is not required. This can reduce the cost of the film forming apparatus 1.

(modification 3)

In the embodiment and the above-described modifications, the case where the control device 7 notifies the information by displaying or sounding on the display unit when it is determined that the protrusion or the depression is generated in the film roll body 11 has been described. As a modification, the control device 7 may automatically adjust the film-thickness adjusting section 15 to eliminate the protrusion or depression. At this time, the determination unit 54 further determines the load to be applied to the outer peripheral member 14 by each of the adjustment units 16 and/or the opening degree of each of the valve devices 9 so as to cancel the abnormal state when the determination unit 52 determines that there is an abnormality in the roll posture of the film roll body 11, that is, so as to cancel the protrusion or depression when it is determined that the protrusion or depression is generated in the film roll body 11.

Specifically, the determination unit 54 determines the load to be applied to the outer peripheral member 14 by each of the adjustment units 16 and/or the opening degree of each of the valve devices 9 so as to be within a certain range R when it is determined that the load is within the certain range R_iWhen the rolling posture of (2) is abnormal, the range R is set_iThe radius of each position (i-th to i + m-th positions) of (a) is close to a certain reference value. For example, the determination unit 54 determines the load to be applied to the outer peripheral member 14 by each of the adjustment units 16 and/or the opening degree of each of the valve devices 9 so that the range R is within_iThe film thickness corresponding to the portion thicker than the reference value becomes thinner within the allowable film thickness range, and the film thickness corresponding to the portion thinner than the reference value becomes thicker within the allowable film thickness range.

The reference value may be a range R measured by the roll attitude measurement sensor 22_iThe maximum value of the radius measurement values at each position in (2) may be a minimum value, an average value, an intermediate value, or a variance value. When the average value, the median value, or the variance value is used as the reference value, the abnormality of the winding posture can be resolved relatively early. The reference value may be any one of a maximum value, a minimum value, an average value, a median value, and a variance value. And, for example, in the range R_i+1Range R_i-1For example, when there is no abnormality in the winding state in a close range, the average value, the median value, or the variance value in any one of the ranges may be used as the reference value.

(modification 4)

In the embodiment and the above-described modification, the case where the discharge port 18a of the mold 2 is a ring-shaped, so-called circular mold has been described, but the present invention is not limited thereto. At least a part of the technical idea of the embodiment can be applied to a so-called T-die having a linear discharge port.

Any combination of the above-described embodiments and modifications is also useful as an embodiment of the present invention. The new embodiment generated by the combination has the effects of the combined embodiments and the modified examples.

Industrial applicability

The present invention can be applied to a film forming apparatus.

Description of the symbols

1-a film forming device, 2-a die, 6-a thickness measuring sensor, 7-a control device, 22-a winding posture measuring sensor and 52-a judging part.

Claims

1. A film forming apparatus for forming a film by extruding a molten resin from a die and solidifying the resin, and winding the formed film to form a film roll, the film forming apparatus comprising:

and a determination unit for determining whether the winding posture is abnormal or not based on the change of the radius of the film roller in the axial direction.

2. The film forming apparatus as claimed in claim 1,

the judgment unit judges that the roll posture is abnormal when the difference between the maximum value and the minimum value of the radius of the film roll body in the predetermined range of the axial direction is more than a predetermined difference threshold value.

3. The film forming apparatus according to claim 1 or 2, comprising:

and a notification unit configured to notify the user of the information when the determination unit determines that the roll posture is abnormal.

4. The film forming apparatus according to claim 1 or 2, comprising:

a film thickness adjusting section for adjusting the thickness of the formed film; and

an operation control section for controlling the operation of the film thickness adjusting section,

the operation control unit controls the film thickness adjustment unit to remove the abnormality when the determination unit determines that the roll attitude is abnormal.

5. The film forming apparatus according to any one of claims 1 to 4, comprising:

and a sensor for measuring information on the radius of the film roll body at each position in the axial direction.

6. The film forming apparatus according to any one of claims 1 to 4,

the die extrudes molten resin in a tubular shape from an annular discharge port,

the film forming apparatus includes:

a sensor for measuring the thickness of the film at each position in the circumferential direction; and

the specifying unit specifies information on the radius of the film roll body at each position in the axial direction, based on the film thickness at each position in the circumferential direction measured by the sensor.