KR101317970B1 - Solution film forming method and solution film forming facility - Google Patents

Abstract

The band 91 circulates in the longitudinal direction by the rotation of the roller 131. The ranging sensor 180 detects a distance Cx from the band 91. The control unit 198 reads the interval Cx from the ranging sensor 180. Thereafter, the control unit 198 calculates the floating amount CL of the band 91 and the roller 131 in the width direction from the read interval Cx. The control unit 198 determines the critical position Pr of the flexible area A1 in the width direction based on the flotation amount CL. Based on the critical position Pr, the length L0 of the outlet port 131a in the width direction is adjusted. The dope is made to flow out to the band 91 using the flexible die by which the length L0 of the outlet 131a was adjusted.

Description

SOLUTION FILM FORMING METHOD AND SOLUTION FILM FORMING FACILITY

The present invention relates to a solution film production method and a solution film production facility.

With large screens of liquid crystal displays (LCDs), large areas are also required for optical films used in LCDs. The optical film is manufactured to a long length, and then cut to a predetermined size according to the dimensions of the LCD. Therefore, in order to manufacture a larger area optical film, it is necessary to manufacture a long optical film with a larger width than before.

As a typical manufacturing method of a long optical film, there exists a solution film forming method of a continuous system. As is well known, the continuous film forming method of a continuous system forms a dope in which a polymer is dissolved in a solvent on a moving flexible support, and forms a cast film made of dope on a flexible support. In this method, a film is manufactured by peeling a casting film from a casting support and drying.

As the flexible support, a metal band spanning the drive roller is used. The maximum width of the film that can be produced is constrained by the width of this band. Therefore, in order to manufacture a film of larger width, a band of larger width is required. However, so far, only bands up to about 2 m wide have been obtained.

Therefore, in Korean Patent Laid-Open Publication No. 2009-0110082, a band having a larger width than the conventional one is obtained by welding a central band serving as the center portion in the width direction and a pair of side bands serving as each side portion of the band in the longitudinal direction. Is getting.

By the way, when the solution film-forming method was performed using the band of Unexamined-Japanese-Patent No. 2009-0110082, foaming failure, peeling residual failure, and film thickness nonuniformity arose. Foam failure is a phenomenon in which a flexible membrane is foamed. Peeling residual failure is a phenomenon in which a part of the flexible film remains on the flexible support without being peeled off. Thickness nonuniformity means that thickness is nonuniform. As a result of earnestly examining the inventors, the followings were found.

The band described in Korean Patent Laid-Open No. 2009-0110082 tends to bend in the width direction due to the welding line extending in the longitudinal direction. In particular, warpage tends to occur from an end portion (hereinafter referred to as a width direction end portion) in the width direction of the band, that is, from the center band to the side band. When the solution film forming method is performed using a band in which the widthwise end is bent, the thickness unevenness of the cast film occurs due to the bending. Even if the flexible film which generate | occur | produced such thickness nonuniformity dries, it will become the film which thickness nonuniformity produced. In addition, when peeling the flexible film which the thickness nonuniformity generate | occur | produced, peeling residual failure easily arises. Moreover, when drying the casting film which the thickness nonuniformity generate | occur | produced, foaming becomes easy to occur. When the band spans the drive rollers such that the inner surface of the band curved by bending contacts the circumferential surface of the drive roller, at the side of the band, the band end locally contacts the circumferential surface of the drive roller. When the state where the band end locally contacts the circumferential surface of the drive roller continues, the deformation of the side portion of the band is increased, so that the problem caused by the above-mentioned thickness nonuniformity tends to occur.

In the band described in Korean Patent Laid-Open Publication No. 2009-0110082, a welding line is exposed on a surface on which dope is cast. In the welding line, there is a pinhole having a larger diameter than other portions. For this reason, in the part formed on the welding line among the flexible films, peeling residue tends to arise due to the presence of a pinhole.

An object of this invention is to provide the solution film forming method which can manufacture a film efficiently, suppressing thickness nonuniformity using a wider band than before.

In order to solve the said subject, the solution film forming method of this invention is equipped with a film formation step (A step), a film drying step (B step), and a peeling step (C step). A-step forms the casting film which consists of dope on the casting area of the movement band which moves to a longitudinal direction. The moving band includes a metal center web and a metal side web welded to both sides in the width direction of the center web. The moving band spans the rollers with the welding line exposed to the surface. The welding line includes pinholes having a diameter of less than 70 μm. The said dope flows out from the outlet of a casting die toward the part supported by the said roller among the said moving bands. The said dope contains a polymer and a solvent. The flexible area is set on the surface. The flexible area includes the welding line. The flexible floating amount of the said moving band from the said roller in the said flexible area is 0.1 mm or less. Step B evaporates the solvent from the cast film by heating the moving band. C step peels the said flexible film which passed through said B step from the said moving band, and makes it a film.

The solution film forming method of the present invention includes a film forming step (D step), a film drying step (B step), a peeling step (C step), and a decompression step (E step). D-step forms the casting film which consists of dope on the casting area of the movement band which moves to a longitudinal direction. The movable band includes a metal center web and a metal side web welded to both sides in the width direction of the center web. The moving band spans the rollers with the welding line exposed to the surface. The said dope flows out from the outlet of a casting die toward the part supported by the said roller of the said moving band. The said dope contains a polymer and a solvent. The flexible area is set on the surface. The said flexible area contains the said welding line. Step B evaporates the solvent from the cast film by heating the moving band. C step peels the said flexible film which passed through said B step from the said moving band, and makes it a film. E-step depressurizes the said moving direction upstream of the bead formed by the said dope from the said outlet to the surface of the said moving band by a decompression chamber. The decompression chamber is disposed above the flow direction upstream from the outlet. The decompression chamber has an inlet opening that opens toward the surface of the moving band. The amount of decompression floating from the roller in the portion covered by the decompression chamber in the moving band is 0.1 mm or less. The said welding line may contain the pinhole of less than 70 micrometers in diameter.

It is preferable that a solution film forming method further includes a floating amount detection step (F step). The F step detects the floating amount of the moving band from the roller before the A step.

It is preferable that a solution film forming method further comprises a casting | flow_spread area setting step (G step). The G step is performed between the F step and the A step. The G step sets the flexible area so that the flexible floating amount becomes 0.1 mm or less. The setting is made based on the detected flotation amount.

It is preferable that a solution film forming method further comprises a pressure reduction area adjustment step (H step). The H step is performed between the F step and the A step. The H step adjusts the length of the intake port in the width direction of the movable band so that the decompression floating amount is 0.1 mm or less. The adjustment is made based on the detected flotation amount.

It is preferable that the solution film forming method further includes a floating amount reduction step (I step). In step I, the flotation amount is reduced after the step F.

In the step I, it is preferable to increase the movement tension.

In the said I-step, it is preferable to cool the band part which extends in the longitudinal direction among the said moving bands when the said floating amount is supported by the said roller and contains the part larger than zero.

It is preferable to cool the part except the said flexible area among the said moving bands at the said I step.

It is preferable that the range in which the said moving band is cooled is the moving direction downstream of the said moving band rather than the said flexible area.

It is preferable to cool the said welding line from the position which the said spilled dope reaches the said moving band to the foam limit position in the said flexible film in the said B step.

It is preferable to cool the welding line after the C step and before the next A step.

The solution film-forming installation of this invention is equipped with a moving band, a roller, a casting die, a heating part, and a peeling part. The movable band moves in the longitudinal direction. The movable band includes a metal center web and a metal side web welded to both sides in the width direction of the center web. In the movable band, a welding line is exposed on the surface. The welding line includes a pinhole less than 70 μm in diameter. The said moving band hangs over the said roller. The said casting die forms the casting film which consists of dope on a casting area. The flexible area is set on the surface and includes the welding line. The flexible die has an outlet for continuously discharging dope toward the moving band supported by the roller. The said dope contains a polymer and a solvent. The flexible floating amount of the said moving band from the said roller in the said flexible area is 0.1 mm or less. The said heating part heats the said moving band, and evaporates the said solvent from the said flexible film. The said heating part is arrange | positioned rather than the said flexible die | dye in the movement direction downstream of the said moving band. The said peeling part peels the said flexible film from the said moving band. The said peeling part is arrange | positioned rather than the said heating part in the said moving direction downstream.

The solution film-forming installation of this invention is equipped with a moving band, a roller, a casting die, a pressure reduction chamber, a heating part, and a peeling part. The movable band moves in the longitudinal direction. The movable band includes a metal center web and a metal side web welded to both sides in the width direction of the center web. The movable band is exposed to the welding line surface. The said moving band hangs over the said roller. The said casting die forms the casting film which consists of dope on a casting area. The flexible area is set on the surface and includes the welding line. The flexible die has an outlet for continuously discharging dope toward the moving band supported by the roller. The said dope contains a polymer and a solvent. The decompression chamber depressurizes the beads in the moving direction upstream. The beads are formed from the outlet by the dope over the surface of the moving band. The decompression chamber is disposed above the flow direction upstream from the outlet. The decompression chamber has an inlet opening that opens toward the surface of the moving band. The amount of decompression floatation from the roller in the portion covered by the decompression chamber in the moving band is 0.1 mm or less. The said heating part heats the said moving band, and evaporates the said solvent from the said flexible film. The said heating part is arrange | positioned rather than the said flexible die | dye in the movement direction downstream of the said moving band. The said peeling part peels the said flexible film from the said moving band. The said peeling part is arrange | positioned rather than the said heating part in the said moving direction downstream. In this solution film-forming equipment, the said welding line may contain the pinhole of less than 70 micrometers in diameter.

It is preferable that a solution film forming facility further includes a moving tension application part and a moving tension control part. The moving tension applying unit adds the moving tension in the longitudinal direction to the moving band. The moving tension control unit adjusts the size of the moving tension. The moving tension control unit reduces the floating amount as the moving tension increases.

It is preferable that the said moving tension application part has a roller moving mechanism which can move the said roller which supported the said moving band.

It is preferable that a solution film forming facility further comprises a band cooling part. The band cooling part cools the band part which extends in the longitudinal direction among the said moving bands, when it is supported by the said roller and contains the part with the said floating amount larger than zero.

It is preferable that the said band cooling part is provided in the said moving direction downstream from the said flexible area.

It is preferable that a solution film forming facility further includes a welding line cooling part. The welding line cooling unit cools the welding line.

The solution film forming method of the present invention includes a film forming step (D step), a film drying step (B step), a peeling step (C step), and a welding line cooling step (J step). D-step forms the casting film which consists of dope on the casting area of the movement band which moves to a longitudinal direction. The movable band includes a metal center web and a metal side web welded to both sides in the width direction of the center web. The moving band spans the rollers with the welding line exposed to the surface. The said dope flows out from the outlet of a casting die toward the part supported by the said roller of the said moving band. The said dope contains a polymer and a solvent. The flexible area is set on the surface. The said flexible area contains the said welding line. Step B evaporates the solvent from the cast film by heating the moving band. C step peels the said flexible film which passed through said B step from the said moving band, and makes it a film. J-step cools the said welding line.

According to the present invention, a long film having a wider width than the conventional one can be efficiently produced while suppressing thickness unevenness.

Although the welding line existed also in the conventional moving band (thing whose width is 2 m or less), this welding line is extended in the width direction. In the film obtained using such a moving band, the part which bad influences, such as thickness nonuniformity resulting from a welding line, extended in the width direction similarly to a welding line. Therefore, by cutting the obtained strip | belt-shaped film in the width direction, it was easy to remove the part which had a bad influence from a product film. On the other hand, in the case of using a moving band having a welding line extending in the longitudinal direction, unlike the conventional moving band, it is not easy to remove a portion affected by the welding line. According to this invention, the part formed on the welding line among the flexible films can be included in the film for products.

The above objects and advantages will be readily understood by those skilled in the art by reading the detailed description of the preferred embodiments with reference to the accompanying drawings.
1 is a side view showing an outline of a band production facility.
2 is a plan view showing an outline of a band manufacturing facility.
3 is a side view showing an outline of a welding unit.
4 is a plan view showing an outline of a welding unit.
FIG. 5 is a cross-sectional view taken along a line VV in FIG. 4.
6 is an explanatory diagram of a weld bead and its surroundings.
7 is a schematic view of a taper roller.
8 is a schematic view of a clip.
9 is a schematic diagram of a band.
It is a side view which shows the outline | summary of a solution film forming installation.
11 is a plan view showing an outline of a band.
It is a perspective view which shows the outline | summary of a casting die.
It is an exploded perspective view which shows the outline | summary of a casting die.
It is a perspective view which shows the outline | summary of the flow path of a casting die.
It is a perspective view which shows the outline | summary of the outlet of a casting die.
16 is a perspective view showing an outline of a band.
17 is a side view showing an outline of a band spanning two rollers.
FIG. 18 is a cross-sectional view of the band on the measurement line L1 of FIG. 16.
19 is a plan view showing an outline of a slitter.
It is a perspective view which shows the outline | summary of a band, a casting die, and a pressure reduction chamber.
It is a perspective view of the band which shows the outline | summary of a pressure reduction area.
22 is a cross-sectional view of the band on the measurement line L1.
23 is a cross-sectional view of the band on the measurement line L1.
24 is a side view showing an outline of a band spanning three rollers.
25 is a side view illustrating an outline of a band spanning three rollers.
It is a side view which shows the outline | summary of the film forming apparatus provided with the casting die provided above the support roller.
It is a side view which shows the outline | summary of a cooling roll apparatus and an air cooling apparatus.
It is sectional drawing of the band pressurized by the cooling roll.
It is a side view which shows the outline | summary of an air cooling apparatus.
30 is a plan view schematically illustrating a band in which a temperature distribution occurs.

The band manufacturing equipment 10 shown in FIG. 1 and FIG. 2 is a long band member 13 which consists of a long center member 12 and the side member 11 provided in the width direction both sides of the center member 12. To make.

The side member 11 and the center member 12 are metal sheet materials, respectively. The side member 11 is a sheet material of a relatively narrow width narrow. It is preferable that the side member 11 and the center member 12 are formed of the same raw material, and it is more preferable to form through the same raw material and a formation process with each other. For example, it is preferable to use those formed of stainless steel as the side member 11 and the center member 12.

As the center member 12, you may use the band used as a conventional flexible support body. The center member 12 is wider than the side member 11. The width | variety of the center member 12 in this embodiment is constant in the range of 1500 mm or more and 2100 mm or less, and the width of the side member 11 is constant in the range of 50 mm or more and 500 mm or less.

The band manufacturing equipment 10 includes a delivery section 16, a butting section 17, a welding unit 18, a heating section 19, and a winding device 20.

(Sending part)

The sending part 16 has the 1st sending apparatus 23 which sends out the side member 11, and the 2nd sending apparatus 24 which sends out the center member 12. As shown in FIG. Thereby, the sending part 16 sends the side member 11 and the center member 12 independently to the butt | matching part 17, respectively. The side member 11 wound by roll shape is set to the 1st delivery apparatus 23, and the side member 11 is unwound and sent to the butt part 17. FIG. The center member 12 wound by roll shape is set to the 2nd delivery apparatus 24, and the center member 12 is unwound and sent to the butt part 17. FIG.

The butting part 17 is the side member 11 and the center member 12 guided independently so that the side edge 11e of the side member 11 and the side edge 12e of the center member 12 may contact each other. Back to It is preferable that the butting part 17 has the 1st roller 26, the 2nd roller 27, the 3rd roller 28, and the 4th roller 29. As shown in FIG. The 1st roller 26 and the 2nd roller 27 are arrange | positioned in this order from the upstream side to the conveyance path of the center member 12. As shown in FIG. The 3rd roller 28 is arrange | positioned at the conveyance path of the side member 11. The 4th roller 29 is arrange | positioned at the conveyance path so that both the side member 11 and the center member 12 may be supported.

The 4th roller 29 is a butt support roller which supports the side member 11 and the center member 12 which were sent in the butt position Ph. The abutting position Ph is a position where one side edge of the side member 11 and one side edge of the center member 12 start contact.

The 2nd roller 27 and the 3rd roller 28 are the conveyance path | route and side of the center member 12 so that the center member 12 and the side member 11 may contact the peripheral surface of the 4th roller 29. As shown in FIG. The conveyance path | route of the member 11 is adjusted, respectively.

The 2nd roller 27 adjusts the conveyance path | route of the center member 12, and controls the passage path of the side edge 12e which should be welded with the side member 11 toward the butt position Ph. The passage path of the side edge 12e is a path through which the side edge 12e passes. The second roller 27 is movable in the width direction Y of the center member 12. The shift mechanism 32 moves the 2nd roller 27 to the width direction Y. As shown in FIG.

The position detection means 34 is arrange | positioned between the 2nd roller 27 and the 4th roller 29. As shown in FIG. The position detection means 34 detects one passage position among each side edge 12e of the center member 12, and sends the signal (detection signal) of the detected passage position to the controller 33. As shown in FIG. The controller 33 calculates the displacement amount of the second roller 27 in the width direction Y based on the signal of the passing position sent, and sends the displacement amount signal to the shift mechanism 32. When the shift mechanism 32 receives a signal of the displacement amount sent, the shift mechanism 32 is based on this signal, and the second roller 27 in the inclination of the second roller 27 and the width direction Y of the central member 12 ( 27) change position. In this way, the center member 12 is displaced in the width direction Y by changing the inclination and the position of the second roller 27.

It is preferable that the shift mechanism 37 is provided in the 1st roller 26. As shown in FIG. By this shift mechanism 37, the 1st roller 26 presses the center member 12 which faces the 2nd roller 27 from one member surface. According to the displacement amount of this 1st roller 26, the pressing pressure with respect to the center member 12 of the 1st roller 26 changes. By adjusting the pressing pressure, the winding center angle of the center member 12 wound around the second roller 27 can be controlled. By control of this winding center angle, the displacement amount in the width direction Y of the center member 12 by the 2nd roller 27 can be controlled more precisely.

The 3rd roller 28 adjusts the conveyance path | route of the side member 11, and adjusts the passage path | route of one side edge 11e which should be welded with the center member 12 toward the butt position Ph. . The 3rd roller 28 is equipped with the controller 38 which controls the direction of a longitudinal direction. For example, the controller 38 changes the angle θ1 formed between the circumferential direction and the conveyance direction X of the center member 12 in the contact area while being in contact with the side member 11. The longitudinal direction of the third roller 28 is changed along the member surface of the side member 11.

As mentioned above, it is preferable to control so that abutment position Ph may become on the 4th roller 29 using the 1st roller 26-the 3rd roller 28. As shown in FIG. It is preferable that the 1st roller 26-the 3rd roller 28 are all the drive rollers which rotate in a circumferential direction. By rotating in the circumferential direction, the 1st roller 26 and the 2nd roller 27 act also as a conveying means of the center member 12, and the 3rd roller 28 conveys of the side member 11 It also acts as a means. By using the 1st roller 26-the 3rd roller 28 as a drive roller, while the control of the conveyance path of the side member 11 and the center member 12 becomes more reliable, the side member 11 and the center Slip on the 1st roller 26-the 3rd roller 28 of the member 12 is prevented, and a flaw is prevented on a member surface.

(Welding unit)

The welding unit 18 welds the side member 11 and the center member 12 supplied from the butting part 17 in the state which the side edge 11e, 12e of each other contacted. By continuously supplying from the butting part 17, the length welding process of welding the side member 11 and the center member 12 in the longitudinal direction can be performed. The welding unit 18 is equipped with the welding apparatus 42. As the welding apparatus 42, a laser welding apparatus is mentioned, for example. As the laser welding apparatus can be used, for example, a CO ₂ laser welding apparatus and, YAG laser welding device. In this embodiment, the case where the CO ₂ laser welding device is used as the welding device 42 will be described.

The welding device 42 emits the focused laser light and irradiates the side member 11 and the center member 12 as laser irradiation to the side member 11 and the center member 12. Melt and join. The welding apparatus 42 is equipped with the laser oscillator 43, the welding apparatus main body 46, and a gas supply part (not shown). The welding apparatus main body 46 condenses and injects the laser beam guided from the laser oscillator 43. The gas supply part supplies CO ₂ gas when irradiating laser light. The CO ₂ gas prevents oxidation of the side member 11 and the center member 12. In addition, in FIG. 2, illustration of the laser oscillator 43 is abbreviate | omitted in order to avoid the trouble of drawing.

Instead of a laser welding device, a Tungsten Inert Gas welding device may be used. As is well known, TIG welding is one of arc welding using an arc as a heat source. TIG welding is a kind of inert gas arc welding in which an inert gas (inert gas) is used as a shield gas and tungsten or a tungsten alloy is used for an electrode. Laser welding is more preferable than TIG welding. Moreover, it is good also as hybrid welding which combined TIG welding and laser welding.

The welding support roller 41 is provided in the conveyance path of the side member 11 and the center member 12 so that the injection hole of the laser beam of the welding apparatus main body 46 may be opposed. The welding support roller 41 supports the side member 11 and the center member 12 on the circumferential surface. The rotation axis of the welding support roller 41 is parallel to the width direction Y of the side member 11 and the center member 12. The side member 11 and the center member by the welding support roller 41 so that the laser beam is irradiated to the side member 11 and the center member 12 while being supported on the circumferential surface of the welding support roller 41 ( It is preferable to set the support position of 12). That is, it is preferable to perform welding on the welding support roller 41. Thereby, the side member 11 and the center member 12 are stabilized in the state which the side edge 11e, 12e contacted each other, and a laser beam can be reliably irradiated to the place which should be irradiated.

It is preferable that the welding apparatus main body 46 is equipped with the shift mechanism 50 for displacing in the width direction Y. The upstream side of the welding apparatus 42 detects the contact position Ps (refer FIG. 5) which the side edge 11e of the side member 11 and the side edge 12e of the center member 12 contact, and detects it. The position detection means 47 which transmits the signal (detection signal) of one contact position Ps (refer FIG. 5) to the controller 51 is provided. The position detection means 47 should just be arrange | positioned in the vicinity of the conveyance path from the butt position Ph to the welding apparatus 42 (for example, welding position Pw).

When the signal of the contact position Ps (refer FIG. 5) sent from the position detector 47 is input, the controller 51, the welding apparatus main body 46 in the width direction Y based on this signal. The displacement amount is calculated, and a signal of the displacement amount is sent to the shift mechanism 50. When the signal of the conveyance speed of the side member 11 and the center member 12 is input, the controller 51 will shift the signal of the timing which will displace the welding apparatus main body 46 with the signal of the displacement amount which should be displaced, and the shift mechanism ( 50). The shift mechanism 50 changes the position of the welding apparatus main body 46 at predetermined timing based on the sent displacement amount and the signal of the displacement timing. By changing the position of the welding device main body 46 in the width direction Y in this manner, the irradiation position of the laser beam is more precisely controlled, and the side member 11 and the center member 12 are welded more reliably. In addition, the conveyance speeds of the side member 11 and the center member 12 to the welding apparatus 42 in this embodiment are made into the range of 0.15 m / min or more and 20 m / min or less.

As shown in FIG. 1, the welding unit 18 is more preferably provided with a chamber 52 and a cleaning device 55. The chamber 52 accommodates the welding apparatus main body 46 and the welding support roller 41, and distinguishes an internal space from an external space. The cleaning device 55 purifies the gas. In addition, in FIG. 2, illustration of the chamber 52 and the cleaning apparatus 55 is abbreviate | omitted in order to avoid the trouble of drawing. The chamber 52 is provided with a 1st opening (not shown) which sends an internal gas to the outside, and a 2nd opening (not shown) which guides the gas cleaned | cleaned by the cleaning device 55 inside. The 1st opening and the 2nd opening are connected to the cleaning device 55, respectively. The internal gas of the chamber 52 is guided to the cleaning device 55 from the first opening, and the cleaning device 55 cleans the gas guided from the chamber 52 to the chamber 52 through the second opening. send. In this way, the internal gas of the chamber 52 is circulated between the cleaning device 55.

By cleaning the internal gas of the chamber 52, the welding position Pw and its periphery are cleaned, and the foreign material etc. are mixed in the welding part 13w. In addition, by maintaining the pressure inside the chamber 52 higher than the pressure in the external space, the inside of the chamber 52 can be reliably supported by a state in which the inside of the chamber 52 is cleaned. Moreover, welding position Pw is made into the position relatively high with respect to the sending part 16, the butt | matching part 17, the heating part 19, and the winding-up apparatus 20, and it is the welding position Pw from these. The foreign material can be more surely prevented from being guided.

The cleanliness of the interior of the chamber 52 is preferably, for example, class 1000 or less and more preferably class 100 or less in the US Federal Standard FED-STD-209D.

(Heating section)

It is preferable that the heating part 19 is provided downstream from the welding unit 18. The heating unit 19 is not particularly limited as long as it heats the weld 13w of the band member 13 obtained by welding so as to be within a constant temperature range. In the weld part 13w and its periphery, the stress resulting from the deformation which arose by welding may remain inside. The stress can be removed by heating such a weld part 13w or its periphery with the heating part 19. FIG. By removing this stress, even if it carries out a solution film forming method continuously for a long time, the deformation of the weld part 13w can be suppressed.

The temperature of the welding part 13w by the heating of the heating part 19 will not be specifically limited if it is the temperature from which a stress is removed. However, when the band member 13 consists of stainless steel, for example, it is preferable that the temperature of the welding part 13w is 100 degreeC or more and 200 degrees C or less, and it is more preferable that it is 120 degreeC or more and 180 degrees C or less.

As the heating unit 19, for example, there is a blowing unit, and FIG. 1 illustrates a case where the heating unit 19 is a blowing unit. The blowing unit as the heating unit 19 has a duct 56 and a blower 57 as shown in FIG. 1. The duct 56 injects gas of a constant temperature. The blower 57 controls the temperature of the gas, and then sends the gas to the duct 56. In addition, in FIG. 2, illustration of the duct 56 and the blower 57 is abbreviate | omitted in order to avoid the trouble of drawing.

The heating part 19 relates to the conveyance path of the band member 13, and may be provided on the opposite side to the welding support roller 41 as shown in FIG. 1, or may be provided on the same side as the welding support roller 41. As shown in FIG.

The band member 13 from which the stress was removed is sent to the winding-up apparatus 20 downstream of the heating part 19, and wound up in roll shape. In the winding device 20, a winding core for winding the band member 13 is set, and a drive mechanism for rotating the winding core in the circumferential direction is provided.

The winding device 20 also functions as welding tension control means for controlling the tension between the band member 13, the side member 11, and the center member 12 in the welding position Pw. Therefore, it is preferable to control the torque of the winding apparatus 20 so that the tension | tensile_strength of the band member 13, the side member 11, and the center member 12 in the welding position Pw is kept constant. Thereby, the welding part 13w can be made constant in the longitudinal direction.

When starting welding, it is preferable to carry out as follows using the winding apparatus 20, for example. First, the side member 11 and the center member 12 are set in a conveyance path from the delivery section 16 to the winding apparatus 20, and the respective ends of the side member 11 and the center member 12 are wound up. We wind up in winding feeling of (20). Winding of the side member 11 and the center member 12 is started. Winding is started and the path | route of the conveyance of the side member 11 and the center member 12 is controlled, and the joining position Ph is hold | maintained at a predetermined position. After the abutment position Ph of the side member 11 and the center member 12 is kept constant, welding is started by the welding device 42.

(Shift prevention)

It is preferable to perform welding, suppressing the position shift of the side member 11, the center member 12, and the band member 13. As shown in FIG. For example, instead of the welding unit 18, you may use the welding unit 61 as shown in FIG. 3 and FIG. 4 provided with a pressurization apparatus. The welding unit 61 has the structure which added the pressurization apparatus 62 to the welding unit 18 shown to FIG. 1 and FIG. 2 further. That is, the welding unit 61 is equipped with the shift mechanism 50, the controller 51, the chamber 52, and the cleaning device 55 similarly to the welding unit 18. As shown in FIG. However, in order to avoid the congestion of the city, such illustration is omitted in FIGS. 3 and 4. In addition, about the apparatus, member, etc. which are the same as FIG. 1 and FIG. 2, the code | symbol same as FIG. 1 and FIG. 2 is attached | subjected, and description is abbreviate | omitted. Moreover, in the welding unit 61, the chamber 52 surrounds the pressurizing device 62 and the welding support roller 41 so that it may distinguish from an external space, and distinguishes an internal space from an external space.

The pressurizing device 62 suppresses the positional shift of the side member 11, the center member 12, and the band member 13 in the welding position Pw, and is the 1st belt 63 and the 2nd belt. The side member 11, the center member 12, and the band member 13 on the welding support roller 41 are pressed by a pair of belts consisting of 64.

The first belt 63 and the second belt 64 are endless belts formed in an annular shape. The first belt 63 and the second belt 64 are wound around the circumferential surfaces of the fifth roller 67 to the seventh roller 69. The 1st belt 63 and the 2nd belt 64 are wound so that they may line up in each longitudinal direction of the 5th roller 67-the 7th roller 69. As shown in FIG. At least one of the fifth rollers 67 to seventh rollers 69 is a driving roller that rotates in the circumferential direction. By rotation of this drive roller, the 1st belt 63 and the 2nd belt 64 are conveyed, maintaining the conveyance path parallel to each other.

The fifth rollers 67 to seventh rollers 69 are disposed such that the rotating shaft is parallel to the rotating shaft of the welding support roller 41.

The fifth rollers 67 to seventh rollers 69 have the side where the fourth roller 29 and the welding support roller 41 are disposed with respect to the conveyance path between the side member 11 and the center member 12. Is arranged in the region on the opposite side. The 5th roller 67 is provided so that the conveyance path of the side member 11 and the center member 12 which may face the welding support roller 41 from the 4th roller 29 may be provided. The 6th roller 68 is provided so as to oppose the conveyance path of the side member 11 and the center member 12 which face the heating part 19 from the welding support roller 41. FIG. 7th roller 69 is suitably arrange | positioned so that the conveyance path of the 1st belt 63 and the 2nd belt 64 which may face the 6th roller 68 from the 6th roller 68 may be determined.

The first belt 63 and the second belt 64 from the fifth roller 67 to the sixth roller 68 have the side member 11, the central member 12, and the band on the welding support roller 41. The fifth roller 67 and the sixth roller 68 are disposed so as to be conveyed while pressing the member 13. For example, when welding the side member 11 and the center member 12 on the welding support roller 41 from above, the 5th roller 67 and the 6th roller 68 have these lower ends, respectively. It is arrange | positioned so that it may become a position lower than the upper end of the welding support roller 41. FIG.

The 5th roller 67 and the 6th roller 68 are the side parts of the band member 13 by which the conveyance path of the 1st belt 63 is formed from the conveyance path of the side member 11, and the side member 11 ( 13s) is provided so as to face the conveying path. The 5th roller 67 and the 6th roller 68 are the center part of the band member 13 by which the conveyance path of the 2nd belt 64 is formed by the conveyance path of the center member 12 and the center member 12 further. It is provided so as to oppose the conveyance path of 13c. Thereby, the 1st belt 63 presses the side member 11 and the side part 13s to the welding support roller 41, and the 2nd belt 64 presses the center member 12 and the center part 13c. Pressurizes to the welding support roller 41.

As described above, the first belt 63 and the second belt 64 are provided to face the welding support roller 41, respectively, and the side member 11 and the center member 12 at the welding position Pw. ) To the same height. The height of the side member 11 and the center member 12 is the height of the surface of each member 11 and 12. FIG. Thus, by pressing the side member 11 and the center member 12 so that height may become the same, and welding in this state, the aspect of the welding part 13w becomes more uniform in the longitudinal direction, and welding is performed more. It can be done surely.

5 and 6, the length welding process will be described in more detail. The 1st belt 63 and the 2nd belt 64 are conveyed in the state separated from each other. As for the 1st belt 63 and the 2nd belt 64, a conveyance path is set so that the welding position Pw may pass through the clearance gap between the 1st belt 63 and the 2nd belt 64. As shown in FIG. Thereby, the contact position Ps which the side edge 11e of the side member 11 and the side edge 12e of the center member 12 contact | connects is 1st belt 63, as shown in FIG. It passes through the gap with the 2nd belt 64, and is welded between the 1st belt 63 and the 2nd belt 64. As shown in FIG. In addition, illustration of the welding apparatus main body 46 is abbreviate | omitted in FIG.

It is preferable to make the space | interval D1 of the 1st belt 63 and the 2nd belt 64 into the range of 6 mm or more and 12 mm or less. In the cross section in the width direction Y of the side member 11 and the center member 12, the contact position Ps and the distance D2 between the first belt 63 and the contact position Ps It is preferable to make distance D3 with the 2nd belt 64 into 3 mm or more and less than 6 mm, respectively.

Instead of the pressurizing device 62, rollers (not shown) which have a rotating shaft parallel to the rotating shaft of the welding support roller 41 may be disposed upstream and downstream of the welding device main body 46, respectively. In this case, the side member in the welding position Pw is pushed by pushing the side member 11 and the center member 12 with the upstream one roller, and pressing the band member 13 with the other roller downstream. 11 and the center member 12 can be pressurized.

As shown in FIG. 6, the contact position Ps and its periphery are melt | dissolved by the heat of the welding apparatus 42, and the welding bead 72 is formed. Heat is transmitted from the welding bead 72 to both sides, so that each of the side member 11 and the central member 12 has a heat affected area 73 which is affected by the heat in the welding. The heat affected zone 73 may immediately exhibit a property different from other areas not affected by heat, or may be displayed over time. For example, when a widespread heat influence is used as a flexible support body, when the solution film forming method is continuously performed for a long time, damage such as deformation of the weld portion 13w or foaming of the flexible film occurs.

Therefore, as shown in FIG. 5, in the passage area | region through which the contact position Ps passes among the circumferential surfaces of the welding support roller 41, it consists of a material with a higher thermal conductivity than the side member 11 and the center member 12. As shown in FIG. It is preferable that the high thermally conductive portion 71 is formed. Thereby, the heat from the welding apparatus 42 (refer FIG. 3, FIG. 4) can be spread | diffused more quickly. In order to diffuse heat faster on the welding support roller 41 side, the width of the heat affected area 73 between the side member 11 and the center member 12 is made smaller or the depth of the heat affected area 73 is also shallower. can do.

It is preferable that the width | variety D4 of the passage area | region used as the high thermally conductive part 71 is the range of 26 mm or more and 32 mm or less.

Moreover, it is more preferable that the high heat conduction part (not shown) which consists of a material with a higher thermal conductivity than the side member 11 and the center member 12 is also formed in both surfaces of the 1st belt 63 and the 2nd belt 64. desirable. Thereby, the magnitude | size of the heat affected area | region 73 can be made small in the width direction or the thickness direction.

The side edge 11e of the side member 11 and the side edge 12e of the center member 12 are preferably in a state of being in close contact with each other so that the gap becomes 0 (zero) at the contact position Ps. Therefore, it is preferable that the side member 11 and the center member 12 are previously formed in the shape which does not produce a gap when abutting each edge 11e and 12e. Thereby, the band member without a space | gap in a welding part can be manufactured more reliably.

Said length welding process may be only the continuous welding process which continuously welds in the longitudinal direction of the side member 11 and the center member 12, In addition, it performs the intermittent welding process which performs welding intermittently. You may also When welding intermittently, the side member 11 and the center member 12 which are continuously sent to the welding apparatus 42 are welded intermittently. It is preferable to perform such an interruption welding process before a continuous welding process. In this case, first, in the intermittent welding step, the side member 11 and the center member 12 may be temporarily joined, and thereafter, the joint may be joined over the entire longitudinal direction in the continuous welding step.

In the case of temporarily joining in the intermittent welding step, and then joining in the continuous welding step, the side member 11 and the center member 12 from the butt portion 17 (see FIGS. 1 and 2) to the welding unit 18. ) To weld intermittently. In addition, when setting the surface corresponding to the flexible surface and the back surface corresponding to a non-flexible surface to the side member 11 and the center member 12 when using it as a subsequent flexible support body, welding in an intermittent welding process, It is preferable to carry out about the back surface. Therefore, the side member 11 and the center member 12 are conveyed so that the back surface may face the welding apparatus main body 46 (refer FIG. 1).

After performing the intermittent welding step, the winding device 20 is guided and wound up. In addition, you may heat the welding part 13w by the heating part 19 before winding up. The provisional joint member (not shown) which consists of the side member 11 and the center member 12 wound up through the intermittent welding process is unwound by a delivery apparatus (not shown), and is sent back to the welding unit 18. FIG. This feeding is performed so that the surface of the provisional joining member passes through the welding apparatus main body 46 (refer FIG. 1). In the welding unit 18, continuous welding is performed and the band member 13 is obtained. In addition, instead of this method, two welding units 18 are arranged in a relatively upstream and downstream manner, intermittent welding is performed by one upstream welding unit 18, and the other welding unit 18 downstream. You may perform a continuous welding by this.

When welding is performed, the welding bead 72 may be formed more convexly than the side member 11 and the center member 12. Therefore, the welding support roller 41 used in the case of performing the 1st process of welding one surface in the longitudinal direction and the 2nd process of welding the other surface in the longitudinal direction as mentioned above is shown in FIG. As described above, it is preferable that the groove 76 is formed in a passage region through which the contact position Ps passes among the peripheral surfaces of the welding support roller 41. What is necessary is just to convey the side member 11 and the center member 12, and to perform a 2nd process so that the weld part formed from the welding bead 72 which convex at the 1st process may pass through this groove | channel 76. Thereby, the band member 13 with less residual stress can be obtained more smoothly. Therefore, even if it is used in solution film forming, the film | membrane which has less deformation | transformation and a change in a characteristic as a band as a flexible support body does not foam, and a flexible film can be manufactured more reliably without thickness nonuniformity.

It is preferable that the width | variety D5 of the groove | channel 76 is the range of 6 mm or more and 12 mm or less, and the depth D6 of the groove | channel should just be about 1 mm.

In the above embodiment, the 3rd roller 28 is used as a means to adjust the conveyance path | route of the side member 11 in the butt | matching part 17. FIG. However, you may use the taper roller 81 as shown in FIG. 7 instead of the 3rd roller 28. The taper roller 81 is a roller of a circular cross section formed so that the diameter d continuously decreases from one end to the other end. The diameter d continuously decreases at a constant ratio from one end to the other end. The taper is provided so that one end of the large diameter d faces the conveying path of the central member 12 and the other end of the small diameter d faces the opposite side to the central member 12 (the conveying path side of the side member 11). The roller 81 is arranged.

By being in contact with this taper roller 81, the conveyed side member 11 changes the conveyance path to the direction of the arrow line A toward the center member 12, and is close to the center member 12. As shown in FIG. You lose. Thereby, the side member 11 is reliably conveyed toward the abutting position Ph (refer FIG. 1, FIG. 2).

It is preferable that the taper roller 81 is equipped with the motor 82 as a drive means which rotates in a circumferential direction. The rotating shaft is formed by inserting the center of one end face and the center of the other end face. By conveying the side member 11 by the taper roller 81 which rotates by the motor 82, a side member becomes closer to the center member 12 more effectively.

Instead of the third roller 28, a clip 85 as a gripping means as shown in FIG. 8 may be used. The clip 85 is provided with the clip main body 86 opened in the U shape, and a pair of clamping pins 87 provided in each front-end | tip part of the clip main body 86, and clamps the side member 11, and grips it. . The clamping pin 87 is provided so that a movement is possible between the clamping position which clamps the side member 11, and the retracted position which retracts from a clamping position. The clip 85 is provided with the movement mechanism 88, and becomes movable between the holding start position (not shown) which starts holding | grip, and the holding | grip release position (not shown) which release | releases a holding | gripping. Moreover, the clip 85 becomes movable also in the width direction Y.

The clip 85 grips the side member 11 by moving the clamping pin 87 to the clamping position at the grip start position. The clip 85 conveys downstream, nearing the direction A toward the center member 12 in a state where the side member 11 is held.

The taper roller 81 and the clip 85 may be used to bring the center member 12 closer to the side member 11 in addition to using the side member 11 close to the central member 12. . In this case, what is necessary is just to support or convey the center member 12 with the taper roller 81 and the clip 85.

In the above embodiment, both side members 11 are welded to the center member 12 at the same time. However, after welding one side member 11 to the center member 12, the other side member 11 may be welded to the center member 12.

(band)

As shown in FIG. 9, the band 91 used as a flexible support body is an annular endless band. The band 91 is made by welding one end and the other end in the longitudinal direction of the band member 13. In addition, the band member 13 for making the band 91 may be cut to predetermined length. When the band member 13 is made of the side member 11 and the center member 12 which were cut to a predetermined length in advance, the band 91 may be made as it is without being cut. It is preferable that the diameter of the pinhole in the weld part 13w is less than 40 micrometers.

It is preferable to cut the band member 13 in the direction crossing the width direction Y. As shown in FIG. As for the direction of a cut, it is more preferable to cut so that the angle formed with the width direction Y may become 5 degrees or more and 15 degrees or less in general. Thus, the angle (theta) 2 which the weld part 91v which welded the one end and the other end in the longitudinal direction of the cut band member 13, and the width direction Y is generally 5 degrees or more and 15 degrees or less. Becomes Thus, in the annular welding process which makes the elongate band member 13 annular, the welding apparatus 42 used in the length welding process may be used, and another well-known welding apparatus may be used.

The band 91 manufactured by welding has a side portion 91s formed of the side member 11 (see FIGS. 1 to 8) and a central portion 91c formed of the center member 12 (see FIGS. 1 to 8). ) The weld part 91w of the side part 91s and the center part 91c is exposed to the surface 91a or the back surface 91b. The weld part 91w is a part corresponded to the weld part 13w. It is preferable that the linear weld part 91w is provided so that it may become parallel to the longitudinal direction of the band 91. FIG. The width | variety of the band 91 obtained in this way is 2000 mm or more and 3000 mm or less.

The obtained band 91 is used for a solution film forming facility, after polishing the surface to make it a mirror surface. Next, the method of manufacturing a film in a solution film forming facility is demonstrated below. The kind of polymer is not specifically limited, You may use the well-known polymer which can be used as a film in solution film forming. In the following embodiment, the case where cellulose acylate is used as a polymer is demonstrated as an example.

(Solution film production facility)

As shown to FIG. 10 and FIG. 11, the solution film forming installation 110 is a film forming apparatus 117, the 1st tenter 120, the roller drying apparatus 124, the 2nd tenter 125, The slitter 126 and the winding device 127 are provided in order from an upstream side. In the film forming apparatus 117, the film 116 is formed of the dope 113 in which the cellulose acylate 111 is dissolved in the solvent 112. The first tenter 120 advances drying while supporting each side of the film 116 with the support means 119. The roller drying apparatus 124 dries, supporting the film 116 with the some roller 122. As shown in FIG. The 2nd tenter 125 supports each side part of the film 116 with a support means, and gives tension to the film 116 in the width direction. The slitter 126 cuts off each edge portion supported by the supporting means of the second tenter 125. The winding device 127 winds the film 116 in which the edge part was cut off to the winding core, and makes it roll shape.

(Film forming device)

The film forming apparatus 117 includes a pair of rollers 131 and 132 rotating in the circumferential direction. The pair of rollers 131 and 132 are arranged so as to be parallel to each other on the horizontal plane. The band 91 is wound around the circumferential surface between the roller 131 and the roller 132. The roller 131 is a drive roller (drive roller), and the roller 132 is a free roller (non-drive roller).

The rollers 131 and 132 are provided with a 1st controller (not shown) and a 2nd controller (not shown) which control circumferential surface temperature to predetermined temperature, respectively.

In the film forming apparatus 117, the casting die 133, the film drying apparatus 134, and the peeling roller 135 which let the dope 113 flow out toward the downstream side from the moving direction upstream of the band 91 are carried out. Are installed sequentially.

(Flexible die)

The flexible die 133 flows out the dope 113 with respect to the surface 91a of the band 91 supported by the roller 131, and is provided with the outflow port 133a which flows out the dope 113 at the front-end | tip. . The casting die 133 is disposed so that the outlet port 133a faces the surface 91a of the band 91. As shown in the figure, the casting die 133 is preferably provided above the band 91 so as to be directly above the roller 131. The dope 113 which flowed out from the outlet port 133a is cast on the surface of the band 91. As a result, the flexible film 136 which consists of the dope 113 which flowed out from the outflow opening 133a is formed on the surface of the band 91. As shown in FIG. In addition, the detail of the casting die 133 is mentioned later.

The film drying apparatus 134 has the 1st duct 141-the 3rd duct 143. As shown in FIG. The 1st duct 141-the 3rd duct 143 which send dry air toward the casting film 136 are arrange | positioned in order from the upstream along the movement path of the band 91. FIG. The first duct 141 is provided on the surface 91a side and the rear surface side of the band 91 moving from the roller 131 toward the roller 132. The second duct 142 is provided on the surface 91a side of the band 91 supported by the roller 132. The third duct 143 is provided on the front surface 91a side and the rear surface side of the band 91 moving from the roller 132 toward the roller 131.

The first to third ducts 141 to 143 are respectively connected to a blower (not shown). A blower controller (not shown) that independently controls the temperature, humidity, and flow rate of the gas supplied to each of the first to third ducts 141 to 143 is connected to the blower. In the 1st duct-the 3rd duct 141-143, the discharge port which delivers the gas supplied from the blower as dry air is provided. The outlet port provided in the 1st-3rd ducts 141-143 is formed so as to oppose the surface 91a and the back surface.

The discharge port provided in the 1st duct 141-the 3rd duct 143 is formed in the slit shape, and is extended and installed over one side part 91s from the other side part 91s. As for the length of each discharge port in the width direction of the band 91, dry air should just touch the whole cast film 136 or the band 91 whole.

The temperature of the drying wind is preferably lowered from the upstream side to the downstream side of the movement path of the band 91. It is preferable that the temperature of the drying wind from the 1st duct 141 is 50 degreeC or more and 140 degrees C or less, It is preferable that the temperature of the drying wind from the 2nd duct 142 is 50 degreeC or more and 140 degrees C or less, and the 3rd duct ( It is preferable that the temperature of the drying wind from 143) is 40 degreeC or more and 100 degrees C or less.

A blower (not shown) may be disposed in the transport path between the film forming apparatus 117 and the first tenter 120. Drying of the film 116 can be advanced by blowing from this blower.

(1st tenter)

The 1st tenter 120 uses the support means 119, supports both edge parts of the film 116, conveys it in a longitudinal direction, gives tension in the width direction, and widens the width of the film 116. FIG. In the 1st tenter 120, a preheating area, an extending area, and a relaxation area are formed in the conveyance path of the film 116 mentioned later in order from an upstream side. In addition, the relaxation area may be omitted.

The first tenter 120 includes a pair of rails (not shown) and a chain (not shown). Rails are provided on both sides of the conveyance path of the film 116, and a pair of rails are spaced apart at predetermined intervals. This rail space | interval is constant in a preheating area, becomes gradually wider toward downstream in an extending | stretching area, and is constant in a relaxation area. In addition, you may make it rail gradually narrower as it goes downstream.

The chain is attached to the primary sprocket and the driven sprocket (not shown) so as to be movable along the rail. The plurality of supporting means 119 is attached to the chain at predetermined intervals. By rotation of the prime sprocket, the support means 119 circulates along the rail.

The support means 119 starts the support of the guided film 116 in the vicinity of the inlet of the first tenter 120, moves to the outlet, and releases the support in the vicinity of the outlet. The support means 119 which release | released support moves to the vicinity of an entrance again, and supports the newly guided film 116. FIG.

The duct 155 is provided above the conveyance path of the film 116. The duct 155 has a slit for sending dry air and is supplied from a blower (not shown). The blower sends the drying air adjusted to a predetermined temperature and humidity to the duct 155. The duct 155 is disposed so that the slits face the conveying path of the film 116. Each slit is a shape extended in the width direction of the film 116, and is formed in a conveyance direction at predetermined intervals from each other. In addition, the duct which has the same structure may be provided below the conveyance path of the film 116, and may be provided both above and below the conveyance path of the film 116. FIG.

In this 1st tenter 120, while a film is conveyed, it is dried by the drying wind from the duct 155, and the width | variety can be changed by the support means 119 at predetermined timing.

The solvent content rate of the film 116 in an extending | stretching area is 2 mass% D.B. 250 mass% or more It is preferable that it is the following and 2 mass% D.B. 100 mass% or more D.B. It is more preferable that it is the following. Elongation rate ER1 (= {(width after extending | stretching) / (width before extending | stretching)) * 100) in an extending | stretching process is more than 100%, and it is preferable that it is 140% or less. It is preferable that the temperature of the film 116 in an extending | stretching process is 95 degreeC or more and 150 degrees C or less.

In addition, in this specification, a solvent content rate (unit: mass% DB) is a dry basis value, and specifically, when the mass of a solvent makes x and the mass of the cast film 136 or the film 116 y, , {x / (yx)} × 100.

(Roller drying device)

The atmosphere inside the roller drying apparatus 124 is adjusted by the air conditioner which temperature, humidity, etc. are not shown in figure. Many rollers 122 are provided in the roller drying apparatus 124, and the film 116 is wound up and conveyed by these. In the roller drying apparatus 124, the solvent is evaporated from the film 116. In the roller drying apparatus 124, a solvent content rate is 5 mass% D.B. It is preferable to perform a drying process until it becomes below.

In addition, when the film 116 which came out from the roller drying apparatus 124 is curled, the curl is correct | amended between the roller drying apparatus 124 and the 2nd tenter 125, and the film 116 is flattened. A curl straightening device (not shown) may be provided.

(Second tenter)

The second tenter 125 extends the film 116. By this stretching, a film 116 having desired optical properties is obtained. The film 116 obtained can be used as a retardation film. The second tenter 125 has the same structure as the first tenter 120. In addition, the duct 157 provided in the second tenter 125 flows out the drying air heated to a predetermined temperature from the slit (not shown) and flows toward the film 116.

The elongation rate ER2 (= {(width after stretching) / (width before stretching)) × 100) in the stretching in the second tenter 125 is preferably greater than 105% and 200% or less, and 110% or more. It is more preferable that it is 160% or less. The solvent content rate of the film 116 at the time of extending | stretching start is 5 mass% D.B. It is preferable that it is the following and it is 3 mass% D.B. It is more preferable that it is the following. It is preferable that the temperature of the film 116 in extending | stretching is 100 degreeC or more and 200 degrees C or less.

A cooling device (not shown) may be provided between the second tenter 125 and the slitter 126 to cool and lower the film 116 from the second tenter 125.

Depending on the optical characteristics of the film 116 to be manufactured, the second tenter 125 may be omitted.

Next, the detail of the casting die 133 is demonstrated. As shown in FIG. 12 and FIG. 13, the flexible die 133 has a pair of side plates 161 and a pair of lip plates 162. Each pair of lip plate 162 has the flow path formation surface 162b provided with the flow path formation part 162a which comprises the flow path 163, respectively. The pair of lip plates 162 extend in the width direction of the band 91 (see FIG. 11), and are arranged in the moving direction of the band 91 so that the flow path forming surfaces 162b are in close contact with each other. In the pair of lip plates 162 in which the flow path forming surfaces 162b are in close contact, a gap formed by the flow path forming surfaces 162b is opened in both end surfaces in the width direction.

The pair of side plates 161 each have an inner surface 161a, and are arranged spaced apart in the width direction of the band 91 (refer FIG. 11) so that inner surfaces 161a may face. The pair of side plates 161 are arranged to close the gap formed by the flow path forming surface 162b. In this way, a die main body is formed of a pair of side plates 161 and a pair of lip plates 162, and the flow path 163 of the dope 113 penetrating the die main body is a pair of side plates 161 and 1. It is surrounded by a pair of lip plates 162 (see FIG. 14).

As shown in FIG. 15, the outlet port 133a used as the exit of the flow path 163 is formed in the slit shape. By providing the inner deceleration plate 165 of a predetermined dimension in the outlet 133a, the length L0 of the outlet 133a in the width direction of the band 91 can be adjusted appropriately.

As shown to FIG. 16 and FIG. 17, the roller 131 has the roller main body 131a which supports the back surface 91b of the band 91 in the circumferential surface, and the rotating shaft 131b which axially supports the roller main body 131a. ) The roller 132 consists of the roller main body 132a which supports the back surface 91b of the band 91 in the circumferential surface, and the rotating shaft 132b which axially supports the roller main body 132a.

The rotating shaft 131b is connected to the motor 171 and the drive unit 172. By the motor 171, the roller main body 131a rotates about the rotating shaft 131b. The band 91 circulates by the rotation of the roller main body 131a. Moreover, the rotating shaft 131b is movable between the tension application position Pw and the release position Pu. The tension application position Pw is a position at which a predetermined tension is applied to the band 91 across the rollers 131 and 132. The release position Pu is a position where the band 91 across the rollers 131, 132 is loosened. The drive part 172 can change the rotating shaft 131b between the tension application position Pw and the release position Pu under the control of the control part 198. FIG. It is preferable that the drive part 172 shifts the rotating shaft 132b, maintaining the state parallel to the rotating shaft 131b. In addition, a load cell 173 is attached to the rotation shaft 131b. The load cell 173 detects the external force which the rotation shaft 131b receives.

As shown to FIG. 10 and FIG. 17, the range forming sensor 180 is provided in the film forming apparatus 117. FIG. The ranging sensor 180 measures the distance Cx from the surface 91a of the band 91 in the measurement line L1 (see FIG. 16) set in the band 91. The measuring line L1 extends from one end to the other end in the width direction of the band 91. The measurement line L1 is appropriately set from the position P1 where the dope 113 which flowed out from the casting die 133 lands, from the position P1 to which the casting film 136 is peeled off by the peeling roller 135. . As the space | interval Cx is shown in FIG. 18, space | interval Cx (0), Cx (1), Cx (2), ... in arbitrary positions on the measurement line L1. Cx (n-1) and Cx (n) are shown. The range sensor 180 is arrange | positioned at the position spaced apart by the distance Cy above the roller 131 on the movement direction downstream side than the peeling roller 135, and the movement direction upstream side than the casting die 133. As shown in FIG.

As the range sensor 180, a well-known thing, such as an eddy current displacement sensor, can be used.

As shown in FIG. 19, the slitter 126 is equipped with a pair of cutter 190 which cut | disconnects the edge part 116a of the film 116. As shown in FIG. The pair of cutters 190 are each movable in the width direction of the film 116. The shift unit 194 individually moves the pair of cutters 190 to a predetermined position.

The cutter 190 consists of a redemption blade and a lowered blade. The repayment blade is located above the conveyance path of the film 116. The lower ring is located below the conveyance path of the film 116. The edge part 116a is cut | disconnected by sending the film 116 between these redemption blades and a lower ring blade. The film 116 from which the edge portion 116a is cut is sent to the winding device 127. Moreover, the edge part 116a is sent to the air conveying apparatus 192.

(Control unit)

16-19, the control part 198 is connected with the motor 171, the drive part 172, the load cell 173, the range sensor 180, and the shift part 194. As shown in FIG.

As shown in FIG. 16 and FIG. 17, the control unit 198 circulates the band 91 wound on the rollers 131 and 132 via the motor 171. In addition, the control unit 198 applies the external force F1 to the rotation shaft 131b of the roller 131 through the driving unit 172. The control unit 198 reads the external force applied to the rotation shaft 131b from the load cell 173. The control unit 198 divides the external force F1 by the value BS, and makes the share a conveyance tension. Here, the value BS is multiplied by the average cross-sectional area Sav of the band 91, and is stored in the internal memory of the controller 198. And when the calculated conveyance tension is larger than a target value, the control part 198 controls the drive part 172 so that the external force F1 may reduce. Moreover, when the calculated conveyance tension is smaller than the target value, the control part 198 controls the drive part 172 so that the external force F1 may increase. In this way, the control part 198 can adjust the magnitude | size of the conveyance tension applied to the band 91 through the drive part 172 and the load cell 173 to a predetermined thing.

Next, the operation of the present invention will be described.

(Injury quantity detection process)

As shown in FIG. 16, under the control of the control part 198, the roller 131 rotates. The band 91 circulates in the longitudinal direction by the rotation of the roller 131. The movement speed of the band 91 is 20 m / min or more and 100 m / min or less, for example. As shown in FIG. 18, the range sensor 180 measures the space | interval Cx in the measurement line L1 (refer FIG. 16). The control unit 198 reads the interval Cx from the ranging sensor 180. Thereafter, the control unit 198 subtracts the sum of the thicknesses of the intervals Cx and the band 91 read from the interval Cy between the roller 131 and the sensor 150 in the width direction. The floating amount CL of the band 91 from the roller 131 is calculated. As a representative example of the floating amount CL, in FIG. 18, the floating amount CL (0) calculated from the interval Cx (0) and the floating amount CL (1) calculated from the interval Cx (1). Indicates. In addition, it is preferable to measure the thickness and space | interval CLy of the band 91 beforehand, and to store it in the internal memory of the control part 198, etc.

(Flexible Area Setting Process)

Next, the control part 198 determines the critical position Pr of the flexible area A1 in the width direction of the band 91 based on the floating amount CL. That is, in the band 91 to which the predetermined movement tension is applied, the control unit 198 controls the flexible area so that the floating amount CL in the entire flexible area A1 becomes equal to or less than the reference floating amount CLj. The threshold position Pr of A1) is determined. The reference flotation amount CLj is, for example, preferably 0.1 mm or less when the moving tension of the band 91 is 60 N / mm ² . In addition, the flexible area A1 is an area used as the object to form the flexible film 136. The flexible film 136 may be formed in the whole width direction of the flexible area A1, and may be formed in a part of the width direction. The critical position Pr is the side edge of the flexible area A1, and is set in both sides of the band 91, respectively.

In addition, although the upper limit of the reference flotation amount CLj was made into 0.1 mm, the upper limit of the reference flotation amount CLj may be determined according to the quality level made into the manufacturing objective. In addition, the determination of whether or not the floating amount CL exceeds the upper limit of the reference floating amount CLj is performed under the condition of setting the movement tension applied to the band 91 to a predetermined value. In the judgment, the moving tension applied to the band 91 may be appropriately set, such as the moving tension applied to the band 91 at the time of actual manufacture.

Based on the critical position Pr of the flexible area A1, it replaces with the inner decal plate 165 of a predetermined dimension. By replacing the inner decelerating plate 165, the length L0 (see FIG. 15) of the outlet 131a in the width direction is adjusted.

(Film forming step)

As shown in FIG. 11, the casting die 133 (see FIG. 10) continuously flows the dope 113 out onto the surface 91a of the band 91. The dope 113 is flexible on the band 91. As a result, in the flexible area A1 on the band 91, the welding part 91w exposed to the surface 91a is covered, and the flexible film 136 is formed.

As shown in FIG. 10, the 1st duct 141 sends dry air toward the flexible film 136 and the back surface 91b (refer FIG. 17) of the band 91. As shown in FIG. When dry air from the first duct 141 contacts the flexible membrane 136, the solvent evaporates from the flexible membrane 136. Moreover, as a result of the back surface 91b (refer FIG. 17) of the band 91 being heated by the contact of dry wind, evaporation of the solvent in the casting film 136 is accelerated | stimulated.

The second duct 142 sends dry air toward the flexible membrane 136. When dry air from the second duct 142 contacts the flexible membrane 136, the solvent evaporates from the flexible membrane 136. Moreover, the temperature of the circumferential surface of the roller 132 is adjusted by the 2nd controller so that it may become higher temperature than the temperature of the casting film 136. FIG. As a result of the band 91 being heated from the back surface 91b (refer to FIG. 17) by the contact with the roller 132, heat from the roller 132 is transmitted to the flexible film 136. In this way, evaporation of the solvent in the casting film 136 is promoted.

The third duct 143 sends the drying wind toward the rear face 91b of the flexible film 136 and the band 91. When dry air from the third duct 143 contacts the flexible membrane 136, the solvent evaporates from the flexible membrane 136. Moreover, as a result of the band 91 being heated from the back surface 91b (refer FIG. 17) side by contact of dry wind, evaporation of the solvent in the casting film 136 is accelerated | stimulated.

By the evaporation of the solvent, the flexible film 136 which becomes the grade which can be conveyed to the 1st tenter 120 is peeled off from the band 91 in the state containing a solvent. At the time of peeling, the film 116 is supported by the peeling roller (henceforth a peeling roller) 137, and the peeling position P2 which the flexible film 136 peels from the band 91 is kept constant. In addition, the peeling roller 135 may be a drive roller provided with a drive means and rotating in a circumferential direction.

The band 91 from which the cast film 136 has been peeled off is made hotter than the dope 113 flowing out of the cast die 133 by the film drying apparatus 134. When the dope 113 flows out as it is about such a band 91, foaming of the dope 113 will arise. Therefore, the temperature of the peripheral surface of the roller 131 is adjusted to be lower than the dope 113 which flows out from the casting die 133 using a 1st controller. Thereby, since the band 91 supported by the roller 131 becomes lower than the dope 113 which flows out from the casting die 133, foaming of the dope 113 can be prevented.

The exfoliated cast film 136, that is, the film 116, is sequentially guided to the first tenter 120, the roller drying apparatus 124, and the second tenter 125.

(Slitter)

As shown in FIG. 18, the control unit 198 displaces the cutter 190 to a predetermined position. By the cutter 190, the edge portion 116a of the film 116 is cut off. The film 116 in which the edge part 116a was cut off is roll-shaped by the winding device 127. FIG.

According to this invention, since the floating amount of the band 91 from the roller 131 in the flexible area A1 in which the flexible film 136 is formed is small, the thickness nonuniformity of the flexible film 136 can be suppressed. Therefore, according to this invention, the problem (thickness nonuniformity of a film, peeling residual failure, and foaming) resulting from the thickness nonuniformity of the flexible film 136 can be prevented.

In addition, since the drying of the dope 113 is less likely to proceed on the welded portion 91w including the pinhole of less than 70 μm in diameter, the peeling residual failure is not observed in the portion on the welded portion 91w of the flexible film 136. It is easy to occur. In the present invention, since the floating amount of the band 91 in the flexible area A1 is small, drying of the portion on the weld portion 91w of the flexible film 136 can be reliably performed. Therefore, according to this invention, peeling residual failure resulting from the welding part 91w can be prevented.

Although it is most preferable that a pinhole is not contained in the weld part 91w, when it arises unavoidably in a manufacturing process, it is preferable that the diameter of a pinhole is suppressed to less than 70 micrometers. It is preferable that the pinholes of less than 70 micrometers in diameter included in the weld part 91w are 5 pieces / m or less, and it is preferable that the pinholes of less than 70 micrometers in diameter are 1 piece / mm or less. Here, "piece / m" is the number of pinholes contained in the weld part 91w in the range of 1 m in the longitudinal direction of the band 91, and "piece / mm" is 1 mm in the longitudinal direction of the band 91. It is the number of pinholes contained in the weld part 91w in the range.

In addition, as shown in FIG. 20, you may provide the pressure reduction unit which pressure-reduces the back side of the bead (moving direction upstream of the band 91), and the moving direction upstream of the casting die 133. As shown in FIG. Here, the beads are formed from the outlet 133a (see FIG. 15) over the surface 91a of the band 91 by the dope flowing out from the casting die 133. By the pressure reduction unit, the vibration of the beads generated near the surface 91a in accordance with the movement of the band 91 and flowing due to the accompanying air flowing in the movement direction of the band 91 is suppressed. Thickness nonuniformity etc. can be prevented. Vibration of the beads caused by the accompanying wind is a problem when the movement speed of the band 91 exceeds 30 m / min. Therefore, when the moving speed of the band 91 exceeds 30 m / min, it is preferable to provide the decompression unit 205.

The pressure reduction unit has a pressure reduction chamber 207, a pressure reduction fan (not shown) for sucking gas in the pressure reduction chamber 207, and a suction pipe (not shown) connecting the pressure reduction fan and the pressure reduction chamber 207. .

(Decompression chamber)

The pressure reduction chamber 207 is arrange | positioned so that it may be adjacent to the surface 91a in the normal direction of the surface 91a in the upstream side rather than the casting die 133 in the moving direction of the band 91. As shown in FIG. The space | interval of the pressure reduction chamber 207 and the surface 91a is 0.7 mm or less, for example.

The pressure reduction chamber 207 consists of a box-shaped chamber main body, a sealing member, and a rectifying member. The sealing member raises the sealing property in the chamber main body 210. The rectifying member adjusts the flow of gas in the decompression chamber 207 to be in a predetermined direction. The chamber main body is for surrounding the back side of the bead. The chamber main body has an upstream side wind shield plate 213, a pair of side wind shield plates 214, a top plate 215, and a front plate. The upstream side wind block 213 is in a posture standing up with respect to the surface 91a on the upstream side of the band 91 in the moving direction upstream of the band 91 than the outlet port 133a (see FIG. 15). In order to be close to the surface 91a. The upstream wind shield plate 213 extends from one side portion 91s of the band 91 over the other side portion 91s. Both ends of the upstream wind shield plate 213 are abutted with the side part 91s, respectively. The pair of side wind shield plates 214 are each standing upright with respect to the surface of the side portion 91s, and are directed from both ends of the upstream wind shield plate 213 toward the downstream in the movement direction of the band 91. It is installed to be extended. The top plate 215 and the front plate hang on the pair of side wind shield plates 214.

The decompression chamber 207 is formed by being surrounded by an upstream side wind block 213, a pair of side wind block 214, a top plate 215, and a front plate, and a suction port opened toward the surface 91a. (Not shown). By the pressure reduction fan (not shown), the pressure reduction chamber 207 sucks the gas upstream of the bead from the suction port. As a result of the suction of the gas on the upstream side of the bead, the air pressure on the upstream side of the bead decreases, and a pressure difference ΔP on the upstream side and the downstream side of the bead can be generated. By this pressure difference (DELTA) P, the vibration of the beads which generate | occur | produces in the vicinity of the surface 91a according to the movement of the band 91, and flows in the accompanying wind which flows in the moving direction of the band 91 is suppressed, The thickness nonuniformity of a cast film and a film can be prevented.

As shown in FIG. 21, on the surface 91a of the band 91, the pressure reduction area A2 is formed. The pressure reduction area A2 is a part of the surface 91a covered by the pressure reduction chamber 207.

(Injury quantity detection process)

The range sensor 180 measures the space | interval Cx in the measurement line L1 (refer FIG. 16). As shown in FIG. 17, the control unit 198 reads the interval Cx from the ranging sensor 180. Then, the control part 198 subtracts the sum of the thickness of the interval Cx and the band 91 which were read from the space Cy between the roller 131 and the sensor 150 in the width direction. The floating amount CL of the band 91 from the roller 131 is calculated.

(Decompression area adjustment process)

The control unit 198 determines the critical position of the decompression area A2 in the width direction based on the flotation amount CL. The critical position of the decompression area A2 is set so that in the band 91 to which predetermined | prescribed conveyance tension is applied, the floating amount CL in the whole decompression area A2 will be below the reference floating amount CLj. In this way, the reduced pressure area A2 is set. By providing the pressure reduction chamber 207 of the dimension which covers only the pressure reduction area A2 obtained in this way, in the width direction of the band 91, the pressure reduction chamber 207 and the surface 91a of the band 91 are provided. The variation of the interval can be suppressed. As a result, the pressure difference ΔP can be made uniform in the width direction of the band 91. Therefore, according to this invention, the thickness nonuniformity of the flexible film 136 resulting from the deviation of the pressure difference (DELTA) P can be prevented. Moreover, in the width direction of the band 91, the pressure reduction area A2 contains the flexible area A1. For this reason, the floating amount CL in the flexible area A1 becomes the reference floating amount CLj by making the floating amount CL in the whole of the decompression area A2 below the reference floating amount CLj. It becomes as follows.

In the case of performing the reduced pressure area adjusting step, the flexible area setting step may be omitted.

In addition, the control part 198 may determine cutting | disconnection position Pc so that the floating amount CL may be below the reference floating amount CLk in the flexible area A1. The reference flotation amount CLk is preferably, for example, 0.02 mm or less when the moving tension of the band 91 is 60 N / mm ² . In this case, the cutter 190 may be displaced to the cutting position Pc (see FIG. 19).

In addition, although the upper limit of the reference flotation amount CLk was made 0.02 mm, the upper limit of the reference flotation amount CLk may be determined according to the quality level made into the manufacturing objective. In addition, the determination of whether or not the floating amount CL exceeds the upper limit of the reference floating amount CLk is performed under the condition of setting the movement tension applied to the band 91 to a predetermined value. In the judgment, the moving tension applied to the band 91 may be appropriately set, such as the moving tension applied to the band 91 at the time of actual manufacture.

When judging whether or not the floating amount CL exceeds the upper limit of the reference floating amount CLj or determining whether the floating amount CL exceeds the upper limit of the reference floating amount CLk, the band 91 is performed. moving the tension applied to, for example, is ^{50N / mm 2 ~ 70N / mm} 2.

When the floating amount CL at the cutting position Pc is set to CL (Pc), and the distance between the contact critical position Pt and the cutting position Pc is L _{Pt - Pc} , {CL (Pc) / L _{Pt -} the value of _Pc}, 10 ^- is preferably ⁵ or less. In addition, the contact critical position Pt says the position in which the band 91 floats from the roller 131, ie, the position in the width direction center side among the parts where the floating amount CL is larger than zero.

In the said embodiment, cutting position Pc is set on the side part 91s. However, this invention is not limited to this, As shown in FIG. 22, you may set cutting position Pc on the center part 91c.

In the above embodiment, the outer surface of the bent band 91 is supported by the roller 131. However, the present invention is not limited to this, and as shown in FIG. 23, the inner surface of the bent band 91 may be supported by the roller 131. Here, when the maximum value among the measured floating amount CL, ie, the floating amount CL (w) in the weld portion 91w is equal to or less than the reference floating amount CLj, as shown in the drawing, the critical position Pr ) Can be set on the side portion 91s side. On the other hand, when the floating amount CL (w) in the welding part 91w exceeds the reference floating amount CLj, the critical position Pr is the center part 91c side, and the floating amount CL is a reference | standard. What is necessary is just to set it to the position below floating level CLj.

In the said embodiment, in order to apply the movement tension to the band 91, the rotating shaft 132b of the roller 132 is fixed, and the rotating shaft 131b of the roller 131 is tension-positioned using the drive part 172 ( Pw) is shifted between the release position Pu. However, the present invention is not limited to this. For example, the rotation shaft 131b of the roller 131 is fixed, and the drive shaft 132 is used to shift the rotation shaft 132b of the roller 132 between the tension application position Pw and the release position Pu. You can also do it. Moreover, you may change the rotation shaft 131a, 131b, respectively.

In addition, as shown in FIG. 24 and FIG. 25, a support roller 225 supporting the band 91 may be provided between the rollers 131 and 132. In this case, the desired moving tension can be applied to the band 91 by shifting the support roller 225 between the tension application position Pw and the release position Pu using the drive unit 172. have.

In the said embodiment, the width of the center member 12 is made wider than the width of the side member 11. However, the present invention is not limited to this, and the width of the center member 12 may be the same as the width of the side member 11 or may be narrower than the width of the side member 11. The number of constituent members (center member or side member) constituting the band 91 is not limited to three, but may be two or four or more.

In the said embodiment, the roller 131 is made into the drive roller, and the roller 132 is made into the free roller. However, the present invention is not limited to this, and the roller 131 may be a free roller, and the roller 132 may be a drive roller.

In the said embodiment, the casting die 133 is arrange | positioned immediately above one roller 131. As shown in FIG. However, this invention is not limited to this, You may arrange | position the casting die 133 between one roller 131 and the other roller 132, as shown in FIG. In addition, in this case, the support roller 225 may be arrange | positioned in the position which opposes the casting die 133 via the band 91, and the support roller 225 may support the band 91. FIG. In this case, the desired moving tension can be applied to the band 91 by shifting at least one of the rollers 131, 132, and 225 between the tension application position Pw and the release position Pu.

(Injury Reduction Process)

The floating amount CL becomes small as the vertical stress N acting on the band wound around the roller becomes larger. Using this property, the flotation amount reduction step of increasing the vertical stress N to reduce the flotation amount CL may be performed. It is preferable to perform a floating amount reduction process between a floating amount detection process and a film formation process. In addition, you may perform a floating amount detection process again after performing a floating amount detection process and a floating amount reduction process in order, and before a film formation process. In addition, you may perform the floating amount reduction process again after the floating amount detection process again before the film formation process.

Here, Dr is the diameter of the roller, T1 is the moving tension of the band, and THb is the thickness of the band. The vertical stress N acting on the band wound around the roller is represented by the following equation.

N = THb × T1 / 0.5Dr

Therefore, the floating amount CL can be reduced by increasing the moving tension T1.

In addition, when the diameter Dr of the rollers 131 and 132 is 2000 mm and the thickness THb of the band is 1.6 mm, the moving tension applied to the band 91 is, for example, 50 N / mm ² to 70 N /. mm ² .

As shown in FIG. 27, you may provide the cooling roller apparatus 230 and the air cooling apparatus 231 to the film forming apparatus 117. The cooling roller device 230 is provided between the peeling roller 135 and the casting die 133 in the moving direction of the band 91. In addition, when the pressure reduction chamber 207 (refer FIG. 20) is provided, when the cooling roller apparatus 230 is provided between the peeling roller 135 and the pressure reduction chamber 207 in the moving direction of the band 91, do.

The cooling roller apparatus 230 is equipped with the cooling roller 230a, the roller warmer 230b, and the mounting member 230c. The cooling roller 230a rotates with the movement of the band 91 in the state which contacted the surface 91a of the band 91. FIG. The roller temperature controller 230b adjusts the temperature of the cooling roller 230a. The mounting member 230c mounts the cooling roller 230a. The cooling roller 230a consists of a cooling roller main body 230aa and the rotating shaft 230ab, as shown in FIG. The rotating shaft 230ab axially supports the cooling roller main body 230aa. The rotating shaft 230ab is arrange | positioned so that the circumferential surface of the cooling roller main body 230aa may contact the floating part 91f in which the floating amount CL is larger than zero among the surface 91a of the band 91. As shown in FIG. The mounting member 230c includes a base member 230cb and a biasing member 230cs. The base member 230cb is disposed to face the band 91 via the cooling roller 230a. The biasing member 230cs connects the base member 230cb and the rotary shaft 230ab, and biases the rotary shaft 230ab toward the band 91 side. As the biasing member 230cs, for example, a spring can be used. The biasing member 230cs can prevent the excessive load from being applied to the band 91.

The roller temperature controller 230b adjusts the temperature of the cooling roller 230a in the range of -10 degreeC or more and 10 degrees C or less, for example.

As shown in FIG. 27 and FIG. 29, the air cooling device 231 is provided between the flexible die 133 and the first duct 141 in the moving direction of the band 91. The air cooling apparatus 231 is provided with the duct 231b provided with the nozzle 231a which injects cooling gas into the back surface 91b of the band 91. The air cooling device 231 further includes a blower 231c and a gas temperature controller 231d. The blower 231c sends a cooling gas to the duct 231b. The gas temperature controller 231d adjusts the temperature of the cooling gas sent to the duct 231b. The cooling gas sent to the duct 231b by the blower 231c and the gas heater 231d is injected from the nozzle 231a toward the rear surface 91b of the band 91.

Floating amount reduction process can be performed by cooling a part of band 91 using the cooling roller apparatus 230 or the air cooling apparatus 231. FIG.

By cooling of the band 91 which used the cooling roller apparatus 230 and the air cooling apparatus 231, the high temperature part 91H and the low temperature part 91L arise in the band 91. The band 91 having such a temperature distribution can be divided into a low temperature band portion 91LB including a low temperature portion 91L and a high temperature band portion 91HB including only the high temperature portion 91H. 30). When the tension in the longitudinal direction is uniformly applied to the band 91 having such a temperature distribution in the width direction, the stress in the entire low temperature band portion 91LB including the low temperature portion 91L is high temperature portion 91H. It is larger than the stress in the whole high temperature band part 91HB which consists of). As a result, the moving tension applied to the low temperature band section 91LB becomes larger than the moving tension applied to the high temperature band section 91HB. In this invention, the floating part 91f is made into the low temperature part 91L using the cooling roller apparatus 230 and the air cooling apparatus 231. FIG. For this reason, the movement tension applied to the low temperature band part 91LB including the floating part 91f becomes larger than other parts. Therefore, according to the present invention, the floating amount reduction step is selectively performed on the floating portion 91f.

It is preferable to determine the range which cools the band 91 in a floating amount reduction process as follows. In the direction orthogonal to the moving tension, that is, in the width direction of the band 91, the cooling range may be set to the floating portion 91f serving as the flexible area or the reduced pressure area. In addition, it is preferable to cool the position where the floating amount CL becomes the maximum among the floating portions 91f.

In the movement tension direction, ie, the longitudinal direction of the band 91, when reducing the floating amount CL simply, you may set a cooling range in any part. However, when the whole low temperature band part 91LB is cooled, the elasticity modulus of the band 91 will increase in the flexible area A1 or the pressure reduction area A2, and the upstream of the movement direction of each area A1, A2, and consequently, As a result, the capability of correcting the floating amount CL in the flexible area A1, the reduced pressure area A2, or the like decreases. Therefore, it is preferable to cool in the part of the low temperature band part 91LB of the movement direction downstream from the casting area A1 or the pressure reduction area A2. Thereby, the ability to correct the floating amount CL in the flexible area A1, the reduced pressure area A2, or the like can be maintained while improving the stress applied to the entire low temperature band portion 91LB.

Moreover, in the said embodiment, the cooling roller apparatus 230 is provided between the peeling roller 135 and the casting die 133 in the moving direction of the band 91. As shown in FIG. However, instead of this, the air cooling device 231 may be provided between the peeling roller 135 and the casting die 133. Moreover, in the said embodiment, the air cooling apparatus 231 is provided between the casting die 133 and the 1st duct 141 in the moving direction of the band 91. FIG. However, instead of this, the cooling roller device 230 may be provided between the casting die 133 and the first duct 141.

In addition, instead of the cooling roller 230a, you may use the cooling tool which rotates with the movement of the band 91 in the state which contacted the surface 91a of the band 91. FIG.

In addition, a flotation detection process and a flotation reduction process may be performed when starting a solution film forming method, and may be performed in a solution film forming method. By such a floating amount detection process or a floating amount reduction process, the warpage generated in the band 91 when not in use and the warpage generated by the use of the solution film forming method are corrected.

(Foam prevention process)

Moreover, it is preferable to perform the foaming prevention process which cools the weld part 91w. As a method of cooling the weld part 91w, the cooling roller apparatus 230 and the air cooling apparatus 231 mentioned above may be used. By cooling the weld part 91w using the cooling roller apparatus 230 or the air cooling apparatus 231, foaming in the weld part 91w is suppressed. It is preferable to perform a foaming prevention process from the arrival position which dope reaches | attains the surface of the band 91 to a foam limit position. The foam limit position is determined by the solvent content of the flexible membrane 136 and the temperature of the flexible membrane 136, and can be determined according to the drying conditions of the flexible membrane 136.

In addition, a foaming prevention process can be performed independently from the above-mentioned floating amount detection process, a flexible area setting process, a reduced pressure area adjustment process, and a floating amount reduction process. In particular, when performing a solution film forming method using the band 91 provided with the weld part 91w extended in a longitudinal direction, when foam prevention is the main focus, you may perform only a foam prevention process.

In this embodiment, the air cooling device 230 is used to cool the band 91. However, instead of the air cooling apparatus 230, you may use the solvent coating apparatus which apply | coats a solvent to the back surface 91b of the band 91. By the solvent coating apparatus, the predetermined part of the band 91 can be cooled using the heat of vaporization of the apply | coated solvent.

The film 116 obtained by this invention can be used especially for a retardation film and a polarizing plate protective film.

It is preferable that they are 600 mm or more and 3000 mm or less, and, as for the width | variety of the film 116, it is more preferable that they are 2000 mm or more and 3000 mm or less. Moreover, even if the width | variety of the film 116 exceeds 3000 mm, this invention can be applied. It is preferable that the film thickness of the film 116 is 30 micrometers or more and 120 micrometers or less.

(Polymer)

The polymer which can be used for this invention will not be specifically limited if it is a thermoplastic resin, For example, a cellulose acylate, a lactone ring containing polymer, a cyclic olefin, a polycarbonate etc. are mentioned. Among them, preferred are cellulose acylate and cyclic olefin, and preferred among them are cellulose acylate including acetate group and propionate group and cyclic olefin obtained by addition polymerization.

(Cellulose acylate)

As cellulose acylate, it is preferable that substitution degree of the acyl group to the hydroxyl group of a cellulose satisfy | fills following formula (I)-(III). In following formula (I)-(III), A and B show the substitution degree of the acyl group with respect to the hydrogen atom in the hydroxyl group of a cellulose, A is the substitution degree of an acetyl group, B is C2-C22 It is substitution degree of phosphorus acyl group. It is preferable that 90 mass% or more of cellulose acylate is 0.1-4 mm particle | grains. Especially, this invention has a big effect especially when cellulose diacetate (DAC) is used as a cellulose acylate.

(I) 2.0≤A + B≤3.0

(II) 0≤A≤3.0

(III) 0≤B≤2.9

The glucose units which bind β-1,4 constituting cellulose have free hydroxyl groups in the second, third and sixth positions. The cellulose acylate is a polymer (polymer) in which part or all of these hydroxyl groups are esterified with an acyl group having 2 or more carbon atoms. Acyl substitution degree means the ratio (the case of 100% esterification is substitution degree 1) which the hydroxyl group of a cellulose esterifies in 2nd, 3rd, and 6th positions, respectively.

As for the total acylation substitution degree, ie, the value of DS2 + DS3 + DS6, 2.00-3.00 are preferable, More preferably, they are 2.22-2.90, Especially preferably, they are 2.40-2.88. Moreover, as for the value of DS6 / (DS2 + DS3 + DS6), 0.28 is preferable, More preferably, it is 0.30 or more, Especially preferably, it is 0.31-0.34. Here, DS2 is the ratio (henceforth "acyl substitution degree of 2nd position") in which the hydrogen of the 2nd position hydroxyl group in a glucose unit is substituted by an acyl group, DS3 is the 3rd position in a glucose unit The hydrogen of the hydroxyl group is substituted by the acyl group (henceforth "the acyl substitution degree of 3rd position"), and DS6 is the ratio of hydrogen of the 6th hydroxyl group substituted by the acyl group in the glucose unit (hereinafter "Acyl substitution degree of 6".

Only one type of acyl group may be used for the cellulose acylate of the present invention, or two or more types of acyl groups may be used. When using two or more types of acyl groups, it is preferable that one is an acetyl group. The sum total of the degree to which the 2nd, 3rd, and 6th hydroxyl groups are substituted by the acetyl group is made into DSA, and the sum of the degree to which the 2nd, 3rd and 6th hydroxyl groups are substituted by the acyl groups other than an acetyl group When it is set as DSB, it is preferable that the value of DSA + DSB is 2.22-2.90, Especially preferably, it is 2.40-2.88.

Moreover, it is preferable that DSB is 0.30 or more, Especially preferably, it is 0.7 or more. Moreover, it is preferable that 20% or more of DSB is a substituent of the hydroxyl group of a 6th position, More preferably, it is 25% or more, More preferably, 30% or more, It is preferable that it is especially 33% or more. Moreover, the value of DSA + DSB in the 6th position of a cellulose acylate is 0.75 or more, More preferably, it is 0.80 or more, Especially the cellulose acylate which is 0.85 or more is also preferable, By using such a cellulose acylate, it is excellent in solubility more You can make dope. In particular, when a non-chlorinated organic solvent is used, dope which exhibits excellent solubility and is low in viscosity and excellent in filterability can be produced.

The cellulose which is a raw material of cellulose acylate may be obtained from any one of a linter and a pulp.

As a C2 or more acyl group of the cellulose acylate in this invention, an aliphatic group or an aryl group may be sufficient and it is not specifically limited. For example, an alkylcarbonyl ester, an alkenylcarbonyl ester, an aromatic carbonyl ester, an aromatic alkylcarbonyl ester, etc. of cellulose are mentioned, You may have group substituted further, respectively. As such a preferable example, propionyl group, butanoyl group, pentanoyl group, hexanoyl group, octanoyl group, decanoyl group, dodecanoyl group, tridecanoyl group, tetradecanoyl group, hexadecanoyl group, octadecanoyl group, iso- Butanoyl group, t-butanoyl group, cyclohexanecarbonyl group, oleoyl group, benzoyl group, naphthylcarbonyl group, cinnamoyl group, etc. are mentioned. Among these, propionyl group, butanoyl group, dodecanoyl group, octadecanoyl group, t-butanoyl group, oleoyl group, benzoyl group, naphthylcarbonyl group, cinnamoyl group, and the like are more preferable, and particularly preferably It is an onil group and a butanoyl group.

(solvent)

Examples of the solvent for preparing the dope include aromatic hydrocarbons (for example, benzene and toluene), halogenated hydrocarbons (for example, dichloromethane and chlorobenzene), alcohols (for example, methanol, ethanol, n-propanol, n Butanol, diethylene glycol, etc.), ketones (e.g., acetone, methyl ethyl ketone, etc.), esters (e.g., methyl acetate, ethyl acetate, propyl acetate, etc.) and ethers (e.g., tetrahydrofuran, Methyl cellosolve, etc.) etc. are mentioned.

Among the halogenated hydrocarbons described above, halogenated hydrocarbons having 1 to 7 carbon atoms are preferably used, and dichloromethane is most preferably used. From the viewpoint of physical properties such as solubility of the cellulose acylate, peelability from the support of the flexible membrane, mechanical strength and optical properties of the film, it is preferable to mix one or more kinds of alcohols having 1 to 5 carbon atoms in addition to dichloromethane. As for content of alcohol, 2-25 mass% is preferable with respect to the whole solvent, More preferably, it is 5-20 mass%. Examples of the alcohol include methanol, ethanol, n-propanol, isopropanol, n-butanol and the like, but methanol, ethanol, n-butanol or a mixture thereof is preferably used.

In recent years, the solvent composition which does not use dichloromethane is also examined in order to suppress the influence on the environment to the minimum. In this case, ethers of 4 to 12 carbon atoms, ketones of 3 to 12 carbon atoms, esters of 3 to 12 carbon atoms, and alcohols of 1 to 12 carbon atoms are preferable, and these are suitably mixed and used. There is also. For example, the mixed solvent of methyl acetate, acetone, ethanol, n-butanol is mentioned. Such ethers, ketones, esters and alcohols may have a cyclic structure. Moreover, the compound which has two or more of functional groups (namely, -O-, -CO-, -COO-, and -OH) of an ether, a ketone, ester, and an alcohol can also be used as a solvent.

[Example]

In order to confirm the effect of this invention below, experiment 1-8 was implemented. The detail of each experiment is demonstrated in experiment 1, and about experiment 2-8, only the conditions different from experiment 1 are shown.

(Experiment 1)

In the band manufacturing equipment 10 shown in FIG. 1, the band A was manufactured by the side member 11 made from SUS316, and the center member 12 made from SUS316. The band A was the type shown in FIG. 17, the width of the side member was 150 mm, and the width of the center member was 2000 mm. As a result of observing with an electron microscope, the maximum diameter (phi) of the pinhole which exists in the weld part 91w was as Table 1. The observation range by the electron microscope was 100 m in the longitudinal direction of the weld part 91w, and was made into the whole in the width direction.

When the moving tension was 60 N / mm ² , the floating amount CL of the band 91 was measured, and one pair of critical positions Pr and one pair of cutting positions Pc were set. When the conveyance tension was 60 N / mm ² , the maximum value CL _A1 of the floating amount CL in the flexible area A1 was as shown in Table 1. The length W1 between the pair of critical positions Pr, that is, the width of the flexible area A1, was 2200 mm, and the length W2 between the pair of cutting positions Pc was 1700 mm.

band
Classification φ
(μm) CL _A1
(mm) CL _A2
(mm) Evaluation results One 2 3 4 Experiment 1 A 68 0.10 - P B B P Experiment 2 B 40 0.05 - P B A P Experiment 3 C 72 0.10 - F B D F Experiment 4 A 68 0.12 - F B D F Experiment 5 A 68 0.09 0.10 P B B P Experiment 6 B 40 0.03 0.05 P A A P Experiment 7 A 68 0.11 0.11 F C C F Experiment 8 A 68 0.12 0.13 F D D F

In the solution film-forming installation 110 (refer FIG. 10), the film 116 was manufactured by the dope 113 containing a cellulose diacetate (DAC) and a solvent. The band A was used as the band 91. The moving speed of the band 91 was 40 m / min. The casting die 133 continuously flowed the dope 113 into the band 91 of the moving state. On the surface 91a of the band 91, the cast film 136 which consists of dope 113 was formed.

The solvent was evaporated from the flexible film 136 on the band 91 using the drying wind from each duct 141-143. The peeling roller 135 peeled the casting film 136 from the band 91, and set it as the film 116. FIG. The film 116 was sequentially sent to the first tenter 120, the roller drying apparatus 124, the second tenter 125, and the slitter 126.

(Experiment 2)

A film 116 was manufactured in the same manner as in Experiment 1 except that the band B obtained by the band production facility 10 was used instead of the band A. However, the maximum diameter CL of the pinhole which exists in the welding part 91w with respect to the band B, and the maximum value CL _A1 of the floating amount CL in the flexible area A1 are shown in Table 1, It was like

(Experiment 3)

A film 116 was manufactured in the same manner as in Experiment 1 except that the band C obtained by the band manufacturing facility 10 was used instead of the band A. However, the maximum diameter CL of the pinhole which exists in the welding part 91w with respect to the band C, and the maximum value CL _A1 of the floating amount CL in the flexible area A1 are shown in Table 1, It was like

(Experiment 4)

In Experiment 4, the film 116 was manufactured similarly to Experiment 1 except having set the maximum value CL _A1 of the floating amount CL in the casting area A1 to Table 1.

(Experiments 5-8)

In Experiments 5-8, the film 116 was manufactured like Example 1 except having provided the pressure reduction chamber 207 (refer FIG. 19). However, in Experiment 6, instead of the band A, the band B obtained by the band production facility 10 was used. With respect to the band used in the experiments 5 to 8, the maximum diameter φ of the pinhole existing in the welded portion 91w, the maximum value CL _A1 of the floating amount CL in the flexible area _A1 , and the reduced pressure area A2. The maximum value CL _A2 of the floating amount CL in) was as shown in Table 1.

The following evaluation was performed about the film obtained by the experiment 1-the experiment 8.

1. Peel residue evaluation

It investigated about the presence or absence of peeling residual of the cast film in a band.

P: No peeling residue of the cast film in the band occurred.

F: Peeling residue of the cast film in the band occurred.

2. Evaluation of Flexibility Point

The position P1 where dope lands on the band was investigated.

A: The position P1 at which dope lands on the band was constant.

B: The position P1 at which dope lands on the band was almost constant.

C: The position P1 at which dope lands on the band was intermittently changed.

D: The position P1 at which dope lands on the band was always varied.

3. Evaluation of peeling position

It investigated about the position P2 from which a flexible film is peeled from a band.

A: The position P2 at which the flexible film was separated from the band was constant in the band width direction.

B: The position P2 at which the flexible film was separated from the band was almost constant in the band width direction.

C: The failure that the peeling position P2 of the flexible film edge part becomes downstream of the movement direction of a band rather than the peeling position P2 of the flexible film center part has occurred intermittently.

D: The failure that the peeling position P2 of the flexible film edge part becomes downstream of the moving direction of a band rather than the peeling position P2 of a flexible film center part always occurred.

4. Evaluation of the presence or absence of thickness nonuniformity

In the following procedure, the presence or absence of the thickness nonuniformity of a flexible film was evaluated. In the winding-up part 127, the sample film was cut out from the film before winding up by the winding core. When light was transmitted through the sample film, the shadows appearing on the surface of the sample film were visually observed. When the intensity | strength of the shade observed with the sample film was larger than the product film which passed the evaluation test of the thickness nonuniformity as retardation film or a polarizing plate protective film, it was judged that the thickness nonuniformity was unacceptable (F). Moreover, when the magnitude | size of the shade observed by the sample film is the same as the thing of the product film which passed the performance test as a retardation film or a polarizing plate protective film, and smaller than it, the thickness nonuniformity can be judged (P). did.

About the evaluation result of experiment 1-8, it shows in Table 1. In addition, in Table 1, the number added to the evaluation result represents the number attached to the said evaluation item.

Next, to confirm the effect of the present invention, experiments 11 to 26 were performed. The details of each experiment show only the different conditions from Experiment 1.

(Experiments 11-14)

A film 116 was manufactured in the same manner as in Experiment 1, except that the band shown in Table 2 was used instead of the band (A), and each parameter shown in Table 2 was set to the value shown in Table 2. Among the parameters shown in Table 2, φ, CL _A1 , and CL _A2 are the same as those shown in Table 1. A solvent content rate is a solvent content rate in the cast film 136 at the time of peeling from the band 91. T1 is a moving tension applied to the band 91. Tb is the temperature of the weld part 91w in the softening point P1 (refer FIG. 10). Δ (Tc) is the flexible film 136 on the welded portion 91w at the softening point P1 from the foaming limit temperature TR of the flexible film 136 on the welded portion 91w at the softening point P1. Minus the temperature (Tf).

Band type Band
speed
(m / min) φ
(μm) CL _A1
(mm) CL _A2
(mm) Solvent content rate (mass% D.B.) T1
(N / mm ² ) Tb
(℃) ΔTc
(℃) ΔTh
(℃) Evaluation results One 2 3 4 5 Experiment 11 A2 40 70 0.10 - 45 55 25 10 - P B B P B Experiment 12 B2 40 40 0.05 - 45 55 25 10 - P B A P A Experiment 13 C2 40 75 0.10 - 45 55 25 10 - F B D F D Experiment 14 A2 40 70 0.12 - 45 55 25 10 - F B D F B Experiment 15 A2 40 70 0.09 0.10 45 55 25 10 - P B B P B Experiment 16 B2 40 40 0.03 0.05 45 55 25 10 - P A A P A Experiment 17 A2 40 70 0.11 0.11 45 55 25 10 - F C C F B Experiment 18 A2 40 70 0.12 0.13 45 55 25 10 - F D D F B Experiment 19 B2 70 40 0.03 0.05 70 55 28 5 - P A A P B Experiment 20 D2 70 45 0.03 0.05 70 55 28 5 - P A A P B Experiment 21 A2 70 70 0.09 0.10 70 55 28 5 - P B B P C Experiment 22 A2 70 70 0.09 0.10 70 55 23 12 - P B B P B Experiment 23 C2 70 75 0.09 0.10 70 55 23 12 - F B B P D Experiment 24 A2 70 70 0.11 0.11 70 55 23 12 3.0 F C C F B Experiment 25 A2 70 70 0.09 0.09 70 70 23 12 - P B B P B Experiment 26 A2 70 70 0.08 0.08 70 55 23 12 -3.0 P B B P B

Foam limit temperature TR was calculated | required based on the solvent content rate and temperature Tf of the cast film 136 measured in view of the table which the foam limit temperature TR, the solvent content rate, and the temperature Tf were associated with. The temperature Tf of the flexible film 136 was calculated | required by the infrared sensor. The solvent content rate of the cast film 136 was calculated based on the concentration of the polymer in the dope 114 before outflow. Each temperature (Tb) for the band, the temperature (T _91c), the temperature (T _{CL - MAX)} is a measure of the emergency stop immediately after the operation of the solution film forming equipment 10, according to the experiment. Each of the temperature of the band (Tb), a temperature (T _91c), the _{temperature-of} the measurement (T _{MAX CL),} used a contact type thermometer.

(Experiment 15-24)

In experiments 15-24, the pressure reduction chamber 207 (refer FIG. 19) was installed, the band shown in Table 2 was used instead of the band A, and each parameter shown in Table 2 was taken as the value shown in Table 2. A film 116 was manufactured in the same manner as in Experiment 1 except for the one.

(Experiment 25)

In Experiment 25, in a solution film-forming equipment 10 used in experiment 24 was increased to move the tension (T1), from 55N / mm ² to 70N / mm ^2. By the increase of the moving tension T1, the value CL _A1 decreased from 0.11 mm to 0.09, and the value CL _A2 decreased from 0.11 mm to 0.09. Thereafter, a film 116 was manufactured in the same manner as in Experiment 1.

(Experiment 26)

In the experiment 26, in the solution film-forming installation 10 used in the experiment 24, the air cooling apparatus 231 shown in FIG. 27 was installed between the casting die 133 and the 1st duct 141. FIG. And the cooling gas was sprayed on the back surface 91b using the air cooling apparatus 231. As shown in FIG. In the case of Experiment 24 (that is, before installing the air cooling device 231), Δ (Th) was 3.0 ° C, and Δ (Th) after injecting cooling gas using the air cooling device 231 was -3.0 ° C. . By the change of Δ (Th), the value CL _A1 decreased from 0.11 mm to 0.08, and the value CL _A2 decreased from 0.11 mm to 0.08. Thereafter, a film 116 was manufactured in the same manner as in Experiment 1. Here, Δ (Th) is the central portion 91c of the band 91 from the temperature T _{CL - MAX} at the portion where the floating amount CL is maximum between the flexible die 133 and the first duct 141. _Minus the temperature (T _91c ).

About the film obtained by experiment 11-experiment 26, the following evaluation was performed in addition to the above-mentioned peeling residual evaluation, evaluation of a softening point, evaluation of a peeling position, and evaluation of the presence or absence of thickness nonuniformity.

5. Evaluation of the presence or absence of foaming

Whether or not foaming occurred in the flexible membrane 136 was examined.

A: Foaming could not be confirmed.

B: Although foaming was confirmed slightly, it did not become a problem in conveying a film, and it did not affect also the quality (retardation, direction of slow axis, uniformity of haze) of optical characteristics.

C: Although foaming was confirmed, it did not become a problem in conveying a film. Moreover, although the influence on the quality (retardation, direction of slow axis, uniformity of haze) of the optical characteristic was found a little, it was a level which is satisfactory as a product.

D: Large-scale foaming occurred, and a breakdown in which the film broke at the peeling step or the first tenter 120 or the second tenter 125 from the foaming point occurred frequently.

About the evaluation result of experiment 11-26, it shows in Table 2. In addition, in Table 2, the number added to the evaluation result represents the number attached to the said evaluation item.

Claims (38)

A moving band consisting of a metal center web and a metal side web welded to both sides in the width direction of the center web, the welding line including only pinholes having a diameter of 70 μm or less, exposed to the surface, and moving in the longitudinal direction while covering the rollers. The dope containing a polymer and a solvent is continuously discharged from the outlet of a casting die toward the part supported by the said roller, and the casting film which consists of the said dope is formed on the casting area set to the said surface and containing the said welding line. Film forming process
A film drying step of evaporating the solvent from the flexible membrane by heating the moving band,
It has a peeling process which peels the said flexible film which passed through the said film drying process from the said moving band, and uses it as a film,
The floating amount of the said moving band from the said roller in the said flexible area is 0.1 mm or less, The solution film forming method characterized by the above-mentioned. The method of claim 1,
It has a floating amount reduction process which makes the floating amount of the said moving band from the said roller in the said flexible area small,
After the floating amount reduction step, the floating amount of the movable band in the flexible area is 0.1 mm or less. 3. The method of claim 2,
A flotation amount detecting step which is performed before the flotation amount reduction step and detects the flotation amount of the movable band from the roller;
And a flexible area setting step of setting the flexible area in a region where the floating amount of the movable band is 0.1 mm or less based on the detected floating amount, based on the detected floating amount. The method according to claim 2 or 3,
In the floating amount reduction step, the film forming method, characterized in that for increasing the moving tension applied to the moving band. The method according to claim 2 or 3,
In the floating amount reduction step, a solution film forming method comprising cooling a band portion including a portion having a larger than zero portion and extending in a longitudinal direction when supported by the roller, among the moving bands. The method according to claim 2 or 3,
In the floating amount reduction step, a solution film forming method is characterized in that the portion of the movable band is cooled except for a portion covered by the flexible area. The method according to claim 2 or 3,
In the floating amount reduction step, the film forming method of the moving band is cooled on the downstream side in the moving direction of the moving band than a portion covered by the flexible area. The method according to claim 2 or 3,
And the floating amount reducing step is performed before the first film forming step. The method according to claim 2 or 3,
The said flotation decrease process performed between the said peeling process and the following said film formation process cools the said surface side of the said moving band, The solution film forming method characterized by the above-mentioned. The method according to claim 2 or 3,
The flotation amount reduction step performed between the film forming step and the film drying step cools the back side of the moving band. A welding line consisting of a metal center web and a metal side web welded to both sides in the width direction of the center web is exposed to the surface and is flexible toward the portion supported by the roller of the moving band moving in the longitudinal direction while being spread over the roller. A film forming step of continuously flowing a dope containing a polymer and a solvent from an outlet of the die to form a flexible film made of the dope on the flexible area set on the surface and including the welding line;
The movement of the beads formed over the surface of the moving band from the outlet by the dope, using a decompression chamber disposed at the upstream side of the moving direction than the outlet and having an inlet for opening toward the surface of the moving band. A decompression step of depressurizing the upstream side of the direction;
A film drying step of evaporating the solvent from the flexible membrane by heating the moving band,
A peeling step of peeling the flexible film through the film drying step from the moving band to form a film;
It has a floating amount reduction process which makes the floating amount from the said roller small in the part covered by the said pressure reduction chamber among the said moving bands,
The maximum diameter of the pinhole included in the welding line is 70 ㎛ or less,
After the flotation reduction step, the flotation amount in the portion covered by the decompression chamber is 0.1 mm or less. The method of claim 11,
A flotation amount detecting step which is performed before the flotation amount reduction step and detects the flotation amount of the movable band from the roller;
And a reduced pressure area adjusting step of adjusting the length of the intake port in the width direction of the movable band so that the floating amount in the portion covered by the decompression chamber is 0.1 mm or less based on the detected floating amount. Solution forming method characterized by the above-mentioned. 13. The method according to claim 11 or 12,
In the floating amount reduction step, the film forming method, characterized in that for increasing the moving tension applied to the moving band. 13. The method according to claim 11 or 12,
In the floating amount reduction step, a solution film forming method comprising cooling a band portion including a portion having a larger than zero portion and extending in a longitudinal direction when supported by the roller, among the moving bands. 13. The method according to claim 11 or 12,
In the flotation reduction step, the film forming method of the moving band is cooled except for the portion covered by the flexible area or the decompression chamber. 13. The method according to claim 11 or 12,
In the floating amount reduction step, the film forming method of the moving band is cooled on the downstream side in the moving direction of the moving band than the portion covered by the flexible area or the decompression chamber. 13. The method according to claim 11 or 12,
And the floating amount reducing step is performed before the first film forming step. 13. The method according to claim 11 or 12,
The said flotation decrease process performed between the said peeling process and the following said film formation process cools the said surface side of the said moving band, The solution film forming method characterized by the above-mentioned. 13. The method according to claim 11 or 12,
The flotation amount reduction step performed between the film forming step and the film drying step cools the back side of the moving band. A moving band consisting of a metal center web and a metal side web welded to both sides in the width direction of the center web, the welding line including only pinholes having a diameter of 70 μm or less, exposed to the surface, and moving in the longitudinal direction while covering the rollers. Wow,
A flexible membrane made of the dope is formed on the flexible area including the welding line and having an outlet for continuously discharging the dope containing the polymer and the solvent toward the moving band supported by the roller. Flexible Daiwa
Heating means disposed downstream of the moving die from the casting die and heating the moving band to evaporate the solvent from the casting film;
It has a peeling means arrange | positioned below the said moving direction downstream from the said heating means, and peeling the said flexible film from the said moving band,
The floating film amount of the said moving band from the said roller in the said flexible area is 0.1 mm or less, The solution film forming equipment characterized by the above-mentioned. 21. The method of claim 20,
And a floating amount reducing means for reducing the floating amount of the movable band from the roller in the flexible area,
The floating amount reduction means,
Moving tension applying means for adding the moving tension in the longitudinal direction to the moving band;
Moving tension adjusting means for adjusting the size of the moving tension;
And a control means for controlling said moving tension adjusting means so that said moving tension is increased. 22. The method according to claim 20 or 21,
Floating amount detecting means for detecting the floating amount of the movable band from the roller;
And a flexible area setting means for setting the flexible area in a region where the floating amount of the movable band is 0.1 mm or less based on the detected floating amount. 22. The method of claim 21,
The floating amount reduction means,
Moving tension applying means for adding the moving tension in the longitudinal direction to the moving band;
Moving tension adjusting means for adjusting the size of the moving tension;
And a control means for controlling said moving tension adjusting means so that said moving tension is increased. 24. The method of claim 23,
The moving tension applying unit has a roller moving unit capable of moving the roller supporting the moving band. 25. The method according to claim 23 or 24,
The moving tension adjusting means includes band cooling means for cooling a band portion including a portion having a greater than zero and extending in a longitudinal direction when supported by the roller, among the moving bands. equipment. The method of claim 25,
The said band cooling means was formed in the said moving direction downstream rather than the part covered by the said flexible area, The solution film forming equipment characterized by the above-mentioned. The method of claim 25,
The band cooling means is formed between the peeling means and the casting die, and cools the surface side of the moving band. The method of claim 25,
The band cooling means is formed between the casting die and the heating means, and cools the back side of the moving band. The method of claim 25,
It has foam prevention means for preventing foaming in the said flexible film,
The said foam prevention means is equipped with the welding line cooling means which cools the said welding line, The solution film forming equipment characterized by the above-mentioned. A moving band, wherein the welding line is formed of a metal center web and a metal side web welded to both sides in the width direction of the center web, and is moved in the longitudinal direction while being exposed to the surface and over the roller;
A flexible membrane made of the dope is formed on the flexible area including the welding line and having an outlet for continuously discharging the dope containing the polymer and the solvent toward the moving band supported by the roller. Flexible Daiwa
It is provided in the said movement direction upstream rather than the said outlet, Comprising: It has the inlet port which opens toward the surface of the said movement band, The said dope decompress | reduces the said movement direction upstream of the bead formed from the said outlet to the surface of the said movement band. With a decompression chamber,
Heating means disposed downstream of the moving die from the casting die and heating the moving band to evaporate the solvent from the casting film;
Peeling means arranged on the downstream side in the moving direction of the moving band from the heating means and peeling the flexible film from the moving band;
And a flotation amount reducing means for reducing the flotation amount from the roller in the portion covered by the decompression chamber of the movable band,
The floating amount reduction means,
Moving tension applying means for adding the moving tension in the longitudinal direction to the moving band;
Moving tension adjusting means for adjusting the size of the moving tension;
And control means for controlling said moving tension adjusting means so that said moving tension is increased,
The decompression floatation amount from the said roller in the part covered by the said decompression chamber among the said moving bands is 0.1 mm or less,
The maximum diameter of the pinhole included in the welding line is 70 ㎛ or less solution production facility. 31. The method of claim 30,
Floating amount detecting means for detecting the floating amount of the movable band from the roller;
And a reduced pressure area setting means for setting a portion covered by the decompression chamber in a region where the floating amount of the movable band is 0.1 mm or less based on the detected floating amount. 32. The method of claim 30 or 31 wherein
The floating amount reduction means,
Moving tension applying means for adding the moving tension in the longitudinal direction to the moving band;
Moving tension adjusting means for adjusting the size of the moving tension;
And a control means for controlling said moving tension adjusting means so that said moving tension is increased. 33. The method of claim 32,
The moving tension applying unit has a roller moving unit capable of moving the roller supporting the moving band. 33. The method of claim 32,
The moving tension adjusting means includes band cooling means for cooling a band portion including a portion having a greater than zero and extending in a longitudinal direction when supported by the roller, among the moving bands. equipment. 35. The method of claim 34,
The said band cooling means is formed in the said moving direction downstream rather than the part covered by the said flexible area or the said pressure reduction chamber, The solution film forming equipment characterized by the above-mentioned. 35. The method of claim 34,
The band cooling means is formed between the peeling means and the casting die, and cools the surface side of the moving band. 35. The method of claim 34,
The band cooling means is formed between the casting die and the heating means, and cools the back side of the moving band. 35. The method of claim 34,
It has foam prevention means for preventing foaming in the said flexible film,
The said foam prevention means is equipped with the welding line cooling means which cools the said welding line, The solution film forming equipment characterized by the above-mentioned.

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