JP2012149897A - Total number appearance inspection device of laminated body and total number appearance inspecting method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a device and a method enabling a total number appearance inspection of a plastic laminated body, especially a device and a method enabling a total number appearance inspection of an optical laminated body of a sheet which is machined to be an eyewear, and furthermore, a laminated body which is advantageous in a final machining step.SOLUTION: A device is composed of (1) means for continuously carrying a laminated body; (2) means for inspecting a defect of the laminated body; (3) means for pasting a protection film to the laminated body; and (4) means for marking a defect part of the laminated body.

Description

  The present invention relates to an apparatus and a method for enabling a total appearance inspection of a laminate, and a laminate on which defects are marked.

  Plastic laminates such as polarizing laminates and dimming laminates for optical applications are provided in a predetermined size for final processing steps such as cutting, bending, and drilling. Usually, before supplying to the final processing step, check the board for defects such as bubbles, dust, dents, etc., and a plate that can be supplied to the final processing step (accepted product) and a plate that cannot be supplied ( It passes through the process of sorting into rejected products. In the inspection of such a plastic laminate, the number of target articles is large, and the articles are continuously produced. Therefore, the accepted product and the rejected product are selected by sampling inspection.

  Since there are defects caused by bonding, the process of selecting acceptable and unacceptable products is the state of the plate provided in the final processing step (on the front and back of the laminate to protect against stresses such as storage and transportation) The protective film on the protective film is peeled off, the defects are visually detected, and the acceptable product or defective product is selected according to the number of defects, the degree of distribution, and the size.

  In the sampling inspection performed in this way, products are randomly extracted for each manufacturing lot and the inspection is performed. After such inspection, the sequence of rejected products (part where the rejected products are distributed) is specified, and the rejected products are removed from the product group provided for the final processing step.

  In such a conventional sampling inspection, the defect detection process depends on human experience. Therefore, there is a problem in that the inspection accuracy is kept constant and the inspection processing amount. Furthermore, even if the product peeled off the protective film and used visually is a pass product, it cannot be provided to the final processing step. Further, when the sequence of rejected products is specified, even if there is one acceptable product, it has been discarded as a rejected product. Therefore, the conventional sampling inspection has room for improvement in the product yield.

  In the roll-shaped laminated body, it is possible to provide an inspection site upstream of the winding process and mechanically inspect the whole. In addition, by processing information on the inspection result at this time, it has been possible to manufacture a single sheet so as to eliminate a sheet including a defective portion when cutting into a single sheet.

  In addition, protective films have been developed that can be visually inspected without changing the permeability and removing them.

  However, the present condition is that the laminated body which attached the information for every sheet | seat sheet is not provided to the final processing user.

  The optical laminate used for eyewear such as glasses, sunglasses, goggles, etc. has a color distribution in the form of a single sheet. Therefore, the final processing user of eyewear, in particular, a lens for sunglasses, needs to perform color matching of the punched lens.

Cited Document 1 JP 2008-116438 A
Cited Document 2 JP 2008-116437 A
Cited Document 3 JP2009-61498

  If it becomes possible to provide the final processing user with a laminated body that has undergone all appearance inspections and is provided with processing information, the manufacturing cost of the final processing user will be reduced, and the manufacturing yield will be improved. Inspection accuracy and product yield will be improved if all products can be inspected, but all the laminates will be inspected until the protective film of the laminated body once peeled off, and the information will be put on the product. No specific method has been proposed for this purpose.

  The present invention provides an apparatus and method that allows 100% visual inspection of plastic laminates. In particular, the present invention provides an apparatus and method that allows for a full visual inspection of single-sheet optical laminates that are processed into eyewear. Furthermore, the present invention provides an advantageous laminate in the final processing step.

  Specific examples of what can be visually inspected by the apparatus and method of the present invention include an optical sheet for display, an optical sheet for glasses or sunglasses, a polarizing sheet, a light control sheet, and a light control polarizing sheet.

  The optical laminate obtained by the present invention is advantageous for the production of glasses, sunglasses, goggles, helmet shields and the like.

  The apparatus of the present invention includes (1) means for continuously carrying the laminate (means 01), (2) means for inspecting defects in the laminate (means 02), and (3) means for marking defective portions of the laminate. (Means 03) and (4) Means (Means 04) for classifying acceptable products and rejected products according to the number of defective portions of the laminate.

  The apparatus of the present invention further includes (1) means for automatically peeling the protective film on the laminate (means 11) after (1) means for continuously conveying the laminate, and (2) of the laminate. It also relates to an apparatus comprising (22) means for bonding a protective film on the laminate (means 22) after the means for inspecting defects.

  Means 01 is means for transporting the laminate to the region of means 02 to means 04. It is a means which can carry out line transportation of a laminated body continuously, and a drive roller or a belt conveyor, or these combination is preferable. The laminate to be inspected is first installed on the means, and the appearance inspection is started continuously. Specifically, the stacked body stacked in the magazine portion is taken out by a vacuum chunk, placed in the main line, and transported by a driving roller or the like.

  Means 02 performs an appearance inspection on the front and back of the sheet. The defect of the laminated body is that a light beam from a light source is incident on the laminated body (laminated body from which the protective film is peeled off) on the inspection stage, and the image at this time is received by a CCD camera or the like and transmitted to the image processing apparatus. As the light beam, any light beam from ultraviolet rays to infrared rays can be used. A CCD camera is placed on the top of the laminate to be inspected, and a light source is installed on the bottom of the laminate to receive transmitted light. It is also possible to install a reflector at the bottom of the laminate and install the light source and CCD camera above the transport surface to receive the reflected light. Defects outside and inside the stack can be detected by selecting the light source and the CCD camera. The information read by the CCD camera is, for example, converted from light and dark into waveform information and sent to means 03 located downstream. It is possible to install a plurality of means 02 upstream of means 03 and inspect a plurality of parameters.

  Means 03 is means for recording processing information. The laminated body is received, a predetermined marking is made on the defect location based on the inspection result, and the result is delivered to the means 04. The processing information includes not only defects in the laminate but also information advantageous for punching and information advantageous for color matching. For example, in the case of a polarizing laminate, it is possible to record a guideline for color matching that divides the width of the laminate into three equal parts or four equal parts in parallel with the stretching direction of the polarizing film. In addition, it is possible to record a guideline that matches the size of the lens to be punched into a defect-free area. With this device, the presence or absence of defects on all laminates is clearly recorded on the article. In one embodiment, the marking is printed on the protective film by an inkjet method. In other embodiments, the marking may be laser, sealing, etc. Any marking method may be used as long as it does not affect the product.

  Means 04 is an apparatus that distributes the board to be provided to the final processing step and the board not to be provided according to the inspection result in means 02. In response to a command from this inspection device, the stacked body on the transport surface is stacked in a box of acceptable and unacceptable items by a vacuum chunk. With the means 04, it is also possible to pile up only acceptable products. The use of the vacuum chunk is a typical aspect, and any means can be used as long as it does not affect the quality of the laminate.

  Means 11 is means for automatically peeling off the protective film of the laminate. The adhesive tape is brought into contact with the protective film of the laminate which is located downstream of the means 01 and sent by the means 01, and the protective film is peeled off by winding up the adhesive tape. The use of the adhesive tape is a typical embodiment, and any means can be used as long as it does not affect the quality of the laminate.

  The means 22 is a means for attaching a protective film. Located downstream of the means 02. The protective film is pulled out from the two protective film rollers set on the transport surface, and attached to the laminate by a guide roll. When a film is attached to the rear end of the laminate, a movable cutter knife installed in the vicinity moves to cut the protective film. Here, the protective film is again bonded to the laminate subjected to the inspection, and transported to the means 03 for marking defects by means 01.

  Further, according to the inspection result of the means 02, it is possible to discard the protective film without attaching the protective film by the means 22.

  The size of the sheet that can be inspected by the apparatus of the present invention is 50 mm to 2000 mm in width, 50 mm to 2000 mm in length, and 0.1 mm to 3 mm in thickness. A laminate having a width of 500 mm, a length of 500 mm to 1000 mm, and a thickness of 0.3 to 2 mm is more preferable.

  Specific types of the laminate include an optical laminate for glasses, a polarization laminate, a light control laminate, and a light control polarization laminate.

  The invention also relates to a method that allows 100% inspection of the (optical) laminate. The method includes (A) a step of continuously carrying the laminate, (B) a step of inspecting defects in the laminate, (C) a step of marking defective portions of the laminate, and (D) the number of defective portions. It includes a step of classifying the accepted product and the rejected product accordingly. Steps (A), (B), (C), and (D) are respectively performed by means 01, means 02, means 03, and means 04 in the above-described apparatus of the present invention.

  The method of the present invention further includes (A) a step of automatically peeling the protective film on the laminate (step a) after the step of continuously carrying the laminate (A), and (B) of the laminate. The present invention also relates to a method including (b) a step of attaching a protective film on the laminate (means b) after the step of inspecting for defects. Steps (a) and (b) are performed by means 11 and 22 in the apparatus of the present invention described above.

  By the apparatus and method of the present invention, it is possible to efficiently perform a total appearance inspection of a large number of single-sheet laminates. The laminated body on which the processing information is marked by the apparatus of the present invention can be punched while avoiding the defective portion.

FIG. 1 is a schematic diagram illustrating an exemplary embodiment of the method of the present invention. A broken line indicates an information transmission route from the inspection device. FIG. 2 shows an example of the apparatus of the present invention. FIG. 3 shows a single wafer laminate in which defects of the present invention are marked. FIG. 4 is a sheet of a polarizing laminate in which punching information useful for pairing of binocular lenses is described.

  A laminate (polarized laminate) (width 500 mm, length 500 mm, thickness 0.6 mm) in which two sheets of polycarbonate (PC) were bonded and a polarizing film was inserted between them was used in the following examples.

  In the start unit 10 including the magazine 11 loaded with the polarization laminate, the polarization laminate is taken out by the vacuum chunk 12 and placed at the head position of the line main stream 13. The laminate is laterally pushed from the side, and is applied to the reference plane located at the end of the main line of the line to align the longitudinal direction of the laminate. The laminated body is pushed out in the longitudinal direction by a single-axis robot and moved to the downstream protective film peeling apparatus 20. Nip the non-product area at both ends of the laminate and transport it with rollers. Moreover, since it is only a drive roller, conveyance is also possible. When the laminate is delivered from the upstream means to the downstream means, it is fed from the upstream side to the downstream side by a nip roller.

  In the protective film peeling device 20, a close contact nip roller 21 and a nip roller 22 are respectively installed above and below the laminate conveyance surface, and an adhesive tape roll and a winding device are provided in the areas a and b above and below the conveyance surface. is set up. The polarizing laminate is sandwiched by the contact nip roller 21 via an adhesive tape, and the contact nip roller 21 is rotated and conveyed to peel off the front and back protective films at the same time.

  When a sensor is installed in the laminate transport unit and the laminate reaches the inspection unit 30, the inspection is automatically started. A defect inspection apparatus 31 is installed in the inspection unit. The conveyance in the inspection section is preferably carried out by holding the both ends of the sheet and transporting the belt. The laminated body after the inspection is discharged to the discharge stage 32 and slide-discharged to the next process apparatus.

  The protective film affixing device 40 is provided with protective film rolls and nip rolls in the areas c and d above and below the conveying surface. A protective film is pulled out from two protective film rolls set up and down, and is sandwiched with a laminate on a nip roller heated to 80 ° C. Rotate the nip roller and attach the protective film to the front and back of the laminate at the same time.

  The film on the front and back of the laminate is cut with a cutter knife blade (width 300 mm) attached to the region c.

  The laminated body from the previous process is conveyed to the buffer stage of the marking device 50. In the marking process, both ends of the laminate are held and conveyed by a belt. An inkjet marker 51 is installed on the upper part of the laminate conveyance surface. The sheet ID information is received together with the marking information from the defect inspection apparatus, and the ID is confirmed at the marking unit. When a sheet is removed between the inspection unit and the marking unit, it is possible to prevent erroneous marking by deleting the ID of the removed sheet. The laminated body after marking is conveyed to the finished product stocker unit 60, and the laminated body is transferred to a box of acceptable products and unacceptable products using a vacuum chunk.

(Example)
With the above-mentioned apparatus, 5,000 polarizing laminates could be inspected within 8 hours. The number of polarizing laminates classified as acceptable products was 4,455, and the number of polarizing laminates classified as unacceptable products was 545. When punching is performed by avoiding a portion marked as a defective portion from the polarizing laminate separated as an acceptable product, approximately 50,780 lenses for binocular sunglasses can be manufactured.

(Comparative example)
In a conventional sampling inspection without using an apparatus, an average of 30% (that is, approximately 1,480 sheets per 5,000 sheets per lot) is discarded as rejected products. In other words, if the number of polarizing laminates that were accepted in the conventional inspection was 3,520, 41,580 lenses for binocular sunglasses could be punched out from the accepted products. Furthermore, since the product yield after normal punching is 95%, the final number of sunglasses lenses is approximately 39,500. In other words, approximately 50,780 sunglasses lenses can be manufactured in the inspection using the apparatus, whereas the production amount is approximately 39,500 in the conventional inspection. Therefore, in the inspection using the apparatus, approximately 11, Many 280 lenses for two-lens sunglasses can be manufactured.

By the apparatus and method of the present invention, it has become possible to efficiently perform a total appearance inspection of a large number of single sheet laminates. The laminate on which the processing information is marked by the apparatus of the present invention can be punched out while avoiding the defective portion. Furthermore, the product can be easily assembled based on the processing information. Therefore, user operability is improved in the final processing step. According to the present invention, it is expected that there will be no punching of a defective portion in the final processing step. Such an effect improves the production efficiency of the product. Eventually, a reduction in product manufacturing costs is also expected.


Description 10: Start unit 11: Magazine 12: Vacuum chunk 13: Main line 20: Protection film peeling device 21: Contact nip roller 22: Nip roller 30: Inspection unit 31: Defect inspection device 32: Discharge stage 40: Protection film Pasting device 50: Marking device 51: Ink jet marker 60: Finished product stocker part a: Adhesive tape roll and winding device installation area b: Adhesive tape roll and winding device installation area c: Protective film roll, nip roll, and cutter knife Blade installation area d: Protection film roll and nip roll installation area

Claims (23)

(1) means for continuously carrying the laminate,
(2) means for inspecting defects in the laminate;
(3) An apparatus for inspecting the total number of laminates including means for marking processing information on the laminate, and (4) means for classifying acceptable products and rejected products according to the inspection results of defects. (1) After means for continuously carrying the laminate, (11) After means for automatically peeling off the protective film on the laminate and (2) After means for inspecting defects in the laminate (22) On the laminate The apparatus according to claim 1, comprising means for laminating a protective film.   The apparatus according to claim 1 or 2, wherein the laminate is either a roll sheet or a sheet.   The apparatus according to claim 1, wherein the laminate is selected from the group consisting of an optical sheet for display, an optical sheet for glasses, a polarizing sheet, a light control sheet, and a light control polarizing sheet.   The apparatus according to any one of claims 1 to 4, wherein a size of the laminated body is 50 mm to 2000 mm in width, 50 mm to 2000 mm in length, and 0.1 mm to 3 mm in thickness.   The apparatus according to any one of claims 1 to 5, wherein the means for continuously carrying the laminate is a drive roller, a belt conveyor, or a combination thereof.   The apparatus of any one of Claims 2 thru | or 6 which performs the means to peel off the protective film on a laminated body automatically with an adhesive tape.   The means for inspecting a defect in the laminate is performed by reading light in the infrared region from ultraviolet light transmitted through the inspection region, or by reading reflection of the light transmitted through the inspection region, or a combination thereof. The apparatus of any one of Claims.   It is before the means for bonding the protective film to the laminate, and after the means for inspecting the defects of the laminate, includes means for discarding rejected products based on the results of the means of the laminate. 9. The apparatus according to any one of items 8.   The apparatus of any one of Claims 2 thru | or 9 including the process of cut | disconnecting a protective film after the means to affix a protective film on a laminated body.   The apparatus according to any one of claims 1 to 10, wherein means for marking processing information on the laminate is performed by an ink jet method. (A) a step of continuously carrying the laminate,
(B) Means for inspecting the stack for defects,
(C) A method of performing a total appearance inspection of a plastic laminate including a step of marking processing information on a laminate, and (D) a step of classifying acceptable products and rejected products according to the number of defective portions. (A) After the step of carrying the laminate continuously, (a) After the step of automatically removing the protective film on the laminate and (B) The step of inspecting the laminate for defects (b) On the laminate The apparatus of Claim 12 including the process of bonding a protective film to.   The method according to claim 12 or 13, wherein the laminate is either a roll sheet or a sheet. The method according to claim 12, wherein the laminate is selected from the group consisting of an optical sheet for display, an optical sheet for glasses, a polarizing sheet, a light control sheet, and a light control polarizing sheet.   The method according to any one of claims 11 to 15, wherein the laminate has a width of 50 mm to 2000 mm, a length of 50 mm to 2000 mm, and a thickness of 0.1 mm to 3 mm.   The method of any one of Claims 11 thru | or 16 which performs the process of conveying a laminated body continuously by a drive roller, a belt conveyor, or these combination.   The method of any one of Claims 13 thru | or 17 which performs the process of peeling off the protective film on a laminated body automatically with an adhesive tape.   The step of inspecting a defect in the laminate is a step of reading a light ray in an infrared region from an ultraviolet ray transmitted through an inspection region, a step of reading a reflection of the transmitted light beam, or a combination thereof. The method according to any one of the above.   20. The method according to claim 13, further comprising a step of discarding the rejected product based on a result of the step of inspecting a defect of the laminated body before the step of bonding the protective film to the laminated body. the method of.   The method according to any one of claims 11 to 20, wherein the step of marking the defective portion on the laminate is performed by an ink jet method.   A laminate in which both surfaces are masked with a protective film, wherein information for processing the laminate is described on the protective film. The laminate according to claim 22, wherein the processing information is uneven color of a product, a defect, or a combination thereof.

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