KR20130029715A - Metal drum, casting apparatus, method for forming casting film, and solution film forming method - Google Patents

Abstract

PURPOSE: A metal drum, a flexible device, a forming method of flexible membrane, and a solution unveiling method are provided to reduce cutting scrap malfunction and non-uniform thickness malfunction caused by a welding unit and to efficiently manufacture film of wide band shape. CONSTITUTION: A flexible device comprises a pair of metal drums(124,125), an endless band(91), a flexible die(142), and a film drier(151). The endless band is rolled in the pair of metal drums for locating a welding unit(91w) in a groove and moves to a longitudinal direction by rotating of the metal drum. The flexible die discharges polymer and dope including solvent to surface of the endless band. The film drier is made of the discharged dope, shoots heating wind to flexible membrane which is formed on the surface, and evaporates the solvent from the flexible membrane. [Reference numerals] (91) Band

Description

METAL DRUM, CASTING APPARATUS, METHOD FOR FORMING CASTING FILM, AND SOLUTION FILM FORMING METHOD}

TECHNICAL FIELD This invention relates to the formation method of a metal drum, a casting apparatus, a casting film, and a solution film forming method.

With large screens of liquid crystal displays (LCDs), large areas are also required for optical films used in LCDs. The optical film is produced at a long length and then cut to a predetermined size according to the dimensions of the LCD. Therefore, in order to manufacture an optical film of a larger area, 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. The solution film forming method is, as is well known, a dope in which a polymer is dissolved in a solvent, is cast on a flexible support to be moved, a cast film made of dope is formed on the cast, and the cast film is peeled off from the cast to dry the film. It is a method of manufacturing.

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

Then, in patent document 1, the endless band of larger width | variety than before is obtained by welding the center part band used as the center part of the width direction, and the pair of side bands used as each side part in the longitudinal direction.

Korean Patent Publication No. 2009-0110082

By the way, when the solution film-forming method was performed continuously for a long time (for example, 700 hours or more) using the endless band as described in patent document 1, cutting powder failure and thickness nonuniformity failure generate | occur | produced. As a result of examination by the inventors, it was found that the cutting powder failure and the thickness nonuniformity failure are caused by the projections and the residual stress of the welded portion.

Moreover, as a result of the earnest examination of the inventors, it turned out that the endless band as described in patent document 1 originates in the welding part extended in a longitudinal direction, and it is easy to produce curvature in the width direction. In particular, warpage tends to occur from the widthwise end of the endless band, that is, from the central band to the side band. When the width direction edge part implements the solution film forming method using the fin endless band, it originates in this curvature and the thickness nonuniformity of a flexible film | membrane arises. Even if the flexible film which generate | occur | produced such thickness nonuniformity dries, it will become a film which thickness nonuniformity generate | occur | produced (henceforth a thickness nonuniformity failure).

In addition, in the case where the endless band spans the metal drum such that the inner surface of the endless band curved by bending is in contact with the circumferential surface of the metal drum, at the side of the endless band, the band end is locally circumferential surface of the metal drum. Will come in contact with When the state in which the band end locally contacts the peripheral surface of the metal drum continues, the deformation of the endless band side portion is increased, so that the above-described thickness nonuniformity failure easily occurs.

In addition, when peeling off the flexible film | membrane which a thickness nonuniformity generate | occur | produced, the malfunction which remained without peeling easily occurs, and foaming tends to occur when drying the flexible film | membrane which a thickness nonuniformity generate | occur | produced.

In order to correct the deflection of the endless band, it is also possible to shift the metal drum so that the interval of the metal drum is increased while the endless band is wound, thereby increasing the moving tension applied to the endless band. However, when the solution film forming method is carried out in a state where the moving tension applied to the endless band is increased, the film thickness irregularity failure and the cutting powder failure caused by the welded portion are likely to occur.

This invention solves such a subject and an object of this invention is to provide a metal drum, a casting apparatus, the formation method of a casting film, and the solution film forming method.

The metal drum of the present invention is a groove which is supported so as to be free to rotate and supports a metal endless band having a weld extending in the longitudinal direction at a circumferential surface, and extending in the circumferential direction at a region where the weld is located on the circumferential surface. Characterized in having a.

It is preferable that the groove is annular. It is also preferable that the bottom of the groove has a flat surface.

The flexible device of the present invention includes a pair of metal drums, an endless band wound on a pair of metal drums so that the welded portion is located on the groove, and moved in the longitudinal direction by rotation of the metal drum, a polymer and a solvent. And a film dryer for flowing a heating air to a flexible film made of the dope which flows out the dope toward the surface of the endless band, and a flexible film formed on the surface of the dope, and evaporating the solvent from the flexible film.

It is preferable that a casting apparatus is equipped with the peeler which peels a casting film from an endless band and obtains a wet film.

Of the pair of metal drums, the metal drum facing the peeler is a peeling metal drum, and the flexible film is peeled at a portion supported by the peeling metal drum of the endless band, and a peeling drum cooler for cooling the peeling metal drum, and peeling. It is preferable to provide the band back surface cooler which cools the welding part of the endless band which moves in the direction approaching the metal drum from the back surface side.

Among the pair of metal drums, the metal drum facing the casting die is a casting metal drum, and the dope flowing out of the casting die reaches a portion supported by the casting metal drum in the endless band, and cools the casting metal drum. And a band surface cooler which is formed between the endless band between the end of the endless band and the position where the dope reaches, and the position where the flexible membrane is peeled off, and which cools the weld supported by the metal drum for casting from the surface side. It is preferable.

The formation method of the flexible film of this invention is characterized by forming a flexible film on the surface of an endless band using the said flexible device.

The solution film forming method of the present invention is characterized in that a film is produced by forming a flexible film on the surface of an endless band using the above flexible device, and peeling the flexible film from the endless band.

According to this invention, the strip | belt-shaped film which is wider than before can be manufactured efficiently, suppressing the thickness nonuniformity breakdown and the cutting powder breakdown resulting from a welding part.

Although the weld part existed also in the conventional endless band (thing whose width is 2 m or less), this weld part extends in the width direction. In the film obtained using such an endless band, the part which bad influences, such as the thickness nonuniformity resulting from a weld part, extends in the width direction similarly to a weld part. Therefore, by cutting the obtained strip-shaped film in the width direction, it was easy to remove the bad influence part from the product film. On the other hand, in the case of using an endless band having a welded portion extending in the longitudinal direction, it is not easy to remove a portion which is different from the conventional endless band and which is caused by the welded portion and has an adverse effect. According to this invention, the part formed on the weld part among the flexible films can be included in the film for products.

According to the present invention, even in such a case, a band-like film having a wider width than in the prior art can be efficiently produced while suppressing thickness nonuniformity failure and cutting powder failure caused by the weld portion.

1 is a side view showing an outline of a band manufacturing 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.
5 is a VV line cross-sectional view showing an outline of a welding support roller.
6 is an explanatory diagram of a weld bead and its surroundings.
7 is a schematic view of a tapered 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.
It is a side view which shows the outline | summary of a flexible apparatus.
It is a perspective view which shows the outline of a flexible apparatus main body.
It is a perspective view which shows the outline of a horizontal drum.
14 is a cross-sectional view taken along line P1-P1 of the band.
15 is a perspective view showing an outline of the band backside cooler.
16 is a cross-sectional view taken along line P2-P2 of the band.

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 formed 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 member 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 be formed through the same raw material and a formation process with each other. For example, as the side member 11 and the center member 12, it is preferable to use what was formed from stainless steel.

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, and the width of the center member 12 in the present 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, The side member 11 and the center member (12) is independently sent to the butting part 17, respectively. The side member 11 wound in 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 in 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 The butt | matching part 17 is the 3rd arrange | positioned at the conveyance path of the 1st roller 26, the 2nd roller 27, and the side member 11 which are arrange | positioned in order from the upstream side to the conveyance path of the center member 12. As shown in FIG. It is preferable to have the 4th roller 29 arrange | positioned at a conveyance path so that both the roller 28, the side member 11, and the center member 12 may be supported.

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

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

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 second roller 27 is able to move freely in the width direction Y of the center member 12. The shift mechanism 32 moves the 2nd roller 27 to the width direction Y.

Between the 2nd roller 27 and the 4th roller 29, one pass position is detected in each side edge 12e of the center member 12, and a signal of the detected pass position is sent to the controller 33. As shown in FIG. Position detecting means 34 is disposed. The controller 33 calculates the displacement amount of the second roller 27 in the width direction Y based on the signal of the passed position, and sends the displacement amount signal to the shift mechanism 32. The shift mechanism 32 changes the inclination of the 2nd roller 27 and the position of the 2nd roller 27 in the width direction Y of the center member 12 based on the signal of the displacement amount sent. 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 formed in the 1st roller 26. 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 pressurization with respect to the center member 12 of the 1st roller 26 changes, and by adjusting the pressurization, of the center member 12 wound around the 2nd roller 27 You can control the center angle of the winding. By this control of the winding center angle, the amount of displacement in the width direction Y of the center member 12 by the second roller 27 can be more precisely and precisely controlled.

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. The controller 38 has a third roller such that the angle θ1 formed between the circumferential direction in the contact area and the conveyance direction X of the center member 12 is changed, for example, while being in contact with the side member 11. The longitudinal direction of the 28 is changed along the member surface of the side member 11.

As mentioned above, it is preferable to control so that the 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 all the 1st rollers 26 thru | or 3rd roller 28 are 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 the side member 11 of the means. Also works. By using the first rollers 26 to the third rollers 28 as driving rollers, the control of the conveying paths of the side member 11 and the center member 12 becomes more secure, and the side member 11 and the center member Slip on the 1st rollers 26-3rd roller 28 of (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. With a laser welding device, for example, it may be used a CO ₂ laser welding apparatus and, YAG laser welding device. In this embodiment, the case where a CO ₂ laser welding device is used as the welding device 42 is described.

The welding device 42 emits the focused laser light, and irradiates the side member 11 and the center member 12 as laser beams to melt the side member 11 and the center member 12. Bond. The welding device 42 includes a laser oscillator 43, a welding device main body 46 for condensing and injecting the laser light guided from the laser oscillator 43, and a CO ₂ gas in irradiating the laser light. It is provided with a gas supply part (not shown) which supplies a. 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 TIGsten Inert Gas welding device may be used. As is well known, TIG welding is one of arc welding as a heat source, which uses an inert gas (inert gas) as a shield gas, and a tungsten or tungsten alloy as an electrode. It is a kind. 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 which supports the side member 11 and the center member 12 in the circumferential surface 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. 41 is provided. 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 where the side edges 11e and 12e contacted each other, and laser beam can be reliably irradiated to the point which should be irradiated.

It is preferable that the welding apparatus main body 46 is equipped with the shift mechanism 50 for displacement 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 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 which reaches the welding apparatus 42 (for example, welding position Pw) from the butt position Ph.

The controller 51 calculates the displacement amount of the welding apparatus main body 46 in the width direction Y based on the signal of the contact position Ps (refer FIG. 5) sent, and transmits the signal of the displacement amount to the shift mechanism 50. send. 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 a shift mechanism ( To 50). The shift mechanism 50 changes the position of the welding apparatus main body 46 to 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 way, the irradiation position of the laser beam is more precisely and tightly controlled, and the side member 11 and the center member 12 are welded more reliably. Moreover, the conveyance speeds of the side member 11 and the center member 12 with respect to the welding apparatus 42 in this embodiment are 0.15 m / min or more and 20 m / min or less.

In the welding unit 18, as shown in FIG. 1, the chamber 52 which distinguishes the welding apparatus main body 46 and the welding support roller 41 from an external space, and the cleaning apparatus 55 which purifies a gas are provided. It is more preferable to do. 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 takes out an internal gas to the outside, and a 2nd opening (not shown) which guides the gas cleaned by the cleaning device 55 inside. The first opening and the second 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 and 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 matter etc. are prevented from mixing in the welding part 13w. Moreover, since the internal pressure of the chamber 52 is maintained higher than the pressure of an external space, the inside of the chamber 52 can be maintained more reliably in the state which cleaned. Further, by setting the welding position Pw to a position relatively high relative to the delivery section 16, the butting section 17, the heating section 19, and the winding device 20, the foreign matter is prevented from being guided therefrom. can do.

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

(Heating part)

It is preferable that the heating part 19 is formed downstream from the welding unit 18. The heating unit 19 is not particularly limited as long as it heats the welded portion 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 | transformation 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 the solution film forming method is continuously performed for a long time, the deformation of the weld portion 13w can be suppressed.

Although 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, For example, when the band member 13 consists of stainless steel, the temperature of the welding part 13w is sufficient. It is preferable that they are 100 degreeC or more and 200 degrees C or less, and it is more preferable that they are 120 degreeC or more and 180 degrees C or less.

As the heating part 19, there are a ventilation means, for example. As shown in FIG. 1, the blowing means as the heating part 19 is the duct 56 which blows off gas of a fixed temperature, and the blower 57 which sends this gas to the duct 56 after controlling the temperature of a gas. There is. 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 may be formed in the opposite side to the welding support roller 41 about FIG. 1 about the conveyance path of the band member 13, and may be formed in the same side as the welding support roller 41. 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 driving means for rotating the winding core in the circumferential direction is formed.

The winding device 20 also functions as welding tension control means for controlling the tension of 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 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 the conveyance path which reaches the winding apparatus 20 from the sending part 16, and each tip of the side member 11 and the center member 12 is wound up. It winds around the core of the apparatus 20. Winding of the side member 11 and the center member 12 is started. Winding is started and the conveyance path | route 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 between 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 shown in FIG. 3 and FIG. 4 provided with a pressurization apparatus. The welding unit 61 is further equipped with the pressurization apparatus 62 in the welding unit 18 shown to FIG. 1 and FIG. 2, The shift mechanism 50, the controller 51, the chamber 52, and clean The apparatus 55 is provided in the same manner as the welding unit 18, but their illustration is omitted in Figs. In addition, about the apparatus and member similar to FIG. 1 and FIG. 2, the code | symbol same as FIG. 1 and FIG. 2 is attached | subjected, and description is abbreviate | omitted. In the welding unit 61, the chamber 52 surrounds the pressurizing device 62 and the welding support roller 41 so as to be distinguished from the external space.

The pressurizing apparatus 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 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 the pair of belts made of 64.

The first belt 63 and the second belt 64 are endless belts formed in an annular shape. The 1st belt 63 and the 2nd belt 64 are each longitudinal direction of the 5th roller 67-the 7th roller 69 on the peripheral surface of the 5th roller 67-the 7th roller 69. As shown in FIG. Walk around to be listed. 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 are provided with the fourth roller 29 and the welding support roller 41 in the conveying 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 formed 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 formed. The sixth roller 68 is formed so as to face the conveying path of the side member 11 and the center member 12 that face the heating portion 19 from the welding support roller 41. The seventh roller 69 is appropriately arranged to determine the conveyance paths of the first belt 63 and the second belt 64 from the sixth roller 68 to the fifth roller 67.

As for the 5th roller 67 and the 6th roller 68, the 1st belt 63 and the 2nd belt 64 which face the 6th roller 68 from the 5th roller 67 are the welding support roller 41 It is arrange | positioned so that it may convey so that the side member 11, the center member 12, and the band member 13 on () may be pressed. For example, when welding the side member 11 and the center member 12 on the welding support roller 41 from above, the fifth roller 67 and the sixth roller 68 have their respective lower ends. And the position lower than the upper end of the welding support roller 41.

The 5th roller 67 and the 6th roller 68 have the conveyance path of the 1st belt 63 of the side part 13s of the band member 13 from which the side member 11 and the side member 11 were formed. It is formed so that the conveyance path of the 2nd belt 64 may face the conveyance path of the center part 13c of the band member 13 formed from the center member 12 and the center member 12 so that it may oppose a conveyance path. . Thereby, the 1st belt 63 attaches the side member 11 and the side part 13s, and the 2nd belt 64 attaches the center member 12 and the center part 13c to the welding support roller 41, respectively. Pressurize.

As described above, the first belt 63 and the second belt 64 are respectively formed to face the welding support rollers 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. As shown in 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 a longitudinal direction, and welding is performed more reliably. can do.

5 and 6, the length welding step 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 made into the 1st belt 63 and FIG. It passes through the gap of 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 of the first belt 63, and the contact position Ps and the second belt ( It is preferable to make distance D3 of 64 into the range of 3 mm or more and less than 6 mm, respectively.

Instead of the pressurizing device 62, a roller (not shown) having 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 11 and the center member 12 are pressed by the upstream one roller, and the band member 13 is pressed by the other side of the downstream, and the side member 11 in the welding position Pw and The central member 12 can be pressed.

As shown in FIG. 6, in the contact position Ps and its periphery, it melt | dissolves 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, and a heat affected zone 73 is affected by heat by welding in each of the side member 11 and the central member 12. The heat affected zone 73 may immediately exhibit a property different from that of other zones not affected by heat, or may appear over time. For example, when a wide support is used as the 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 whose heat conductivity is higher 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 zone 73 of the side member 11 and the center member 12 is made smaller or the depth of the heat affected zone 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 thermally conductive part which consists of a material whose heat conductivity is higher 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. As shown in FIG. 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 welding position Pw. 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 welds continuously in the longitudinal direction of the side member 11 and the center member 12, In addition, 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, in the intermittent welding step, first, the side member 11 and the center member 12 may be temporarily bonded, and then, the continuous welding step may be performed over the entire longitudinal direction.

In the case of temporary joining in the intermittent welding step, and then joining in the continuous welding step, the side member 11 and the center member (from the butt portion 17 (see FIGS. 1 and 2) to the welding unit 18 ( 12) Guide and weld intermittently. In addition, when the surface corresponding to the flexible surface at the time of using it as a later flexible support body, and the back surface corresponding to the non-flexible surface are set to the side member 11 and the center member 12, welding in an intermittent welding process will be performed. It is preferable to implement about the back surface. Therefore, the side member 11 and the center member 12 are conveyed so that a back surface may pass through the welding apparatus main body 46 (refer FIG. 1).

After performing an intermittent welding process, it guides and winds up to the winding-up apparatus 20. Moreover, you may heat with the heating part 19 with respect to a welding part before winding up. The temporary joining 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 device (not shown), and is sent back to the welding unit 18. This delivery is performed so that the surface of the temporary welding member may pass 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 downstream welding unit 18 is arranged. You may perform a continuous welding with ().

When welding is performed, the welding bead 72 may protrude more than the side member 11 and the center member 12 in some cases. Therefore, in the welding support roller 41 used when 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, it 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 protruded in the 1st process may pass through this groove | channel 76. Thereby, the band member 13 which is more smooth and has less residual stress can be obtained. Therefore, even if it is used as a 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 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, although the 3rd roller 28 is used as a means of adjusting the conveyance path | route of the side member 11 in the butt part 17, it replaces the 3rd roller 28 as shown in FIG. You may use the taper roller 81. The taper roller 81 is a roller of a circular cross section formed such 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 arrange | positioned.

By being in contact with this taper roller 81, the conveyed side member 11 changes the conveyance path | route in the direction of the arrow line A toward the center member 12, and approaches the center member 12. As shown in FIG. 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 provided with the drive means 82 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 drive means 82, the side member approaches 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 which spread out in the shape of co, and a pair of clamping pins 87 formed in each front-end | tip part of the clip main body 86, and clamps the side member 11. The pinching pins 87 are formed so as to be able to move freely between a pinching position for pinching the side member 11 and a retracting position for retracting from the pinching position. The clip 85 is provided with the movement mechanism 88, and is able to move freely between the holding | grip start position which starts holding | grip, and the holding | gripping release position which releases a grip. Moreover, the clip 85 can move freely also in the width direction Y. FIG.

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 is conveyed downstream, approaching 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 to the side member 11 in addition to using the side member 11 to the center 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 said embodiment, although the both side member 11 is welded to the center member 12 simultaneously, after welding one side member 11 to the center member 12, the other side member 11 is welded. You may weld to the center member 12.

(band)

As shown in FIG. 9, the band 91 (endless band) used as a flexible support body is an cyclic | 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. Moreover, the band member 13 for making the band 91 may cut to predetermined length, and the band member 13 was made from the side member 11 and the center member 12 which were cut to predetermined length previously. In this case, the band 91 may be formed as it is without cutting. It is preferable that the diameter of the pinhole in the said weld part is less than 40 micrometers.

It is preferable to cut the band member 13 in the direction crossing with the width direction Y. As for the direction of a cut, it is more preferable to cut so that the angle formed with the width direction Y may be in the range of 5 degrees or more and 15 degrees or less. Thus, the angle (theta) 2 which the welding part 91v which welded the front-end | tip and the front-end | tip in the longitudinal direction of the cut band member 13, and the width direction Y is in the range of about 5 degrees or more and 15 degrees or less. 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 other well-known welding apparatus may be used.

The band 91 produced by welding has a side portion 91s formed from the side member 11 (see FIGS. 1 to 8) and a center portion 91c formed from the center member 12 (see FIGS. 1 to 8). ), And 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. The linear welded portion 91w is preferably formed to be parallel to the longitudinal direction of the band 91. 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, What is necessary is just to use the well-known polymer which can be used as a film for 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 in FIG. 10, the solution film forming facility 110 includes a casting device 115 that produces the wet film 113 from the dope 112, and a clip that obtains the film 116 by drying the wet film 113. It has the tenter 117, the film drying apparatus 118 which performs the drying of the wet film 113, and the winding-up apparatus 119 which winds up the film 116 at the core.

(Flexible device)

As shown to FIG. 10 and FIG. 11, the flexible apparatus 115 has the casing 121 and the flexible apparatus main body arrange | positioned in the casing 121. The flexible apparatus main body has a flexible support unit, a division unit, a flexible unit, a film drying unit, and the peeling roller 122 (peeling).

The flexible support unit includes a pair of horizontal drums 124 and 125, a band 91 spanning the horizontal drums 124 and 125, and a band movement control unit 128 (see FIG. 12).

The horizontal drum 124 is provided with the drive shaft 124a and the drum main body 124b made from stainless steel which was condensed to the drive shaft 124a. The horizontal drum 125 is equipped with the shaft 125a and the drum main body 125b made from stainless steel condensed to the shaft 125a. The peripheral surfaces of the drum main bodies 124b and 125b are formed flat.

The band 91 is obtained by connecting both ends of a strip | belt-shaped sheet material. The band 91 can be manufactured by the above-mentioned band manufacturing facility 10 (refer FIG. 1).

The band 91 is preferably made of SUS316 having sufficient corrosion resistance and strength. It is preferable that the width | variety of the band 91 is 1.1 times or more and 2.0 times or less of the flexible width of the dope 112, for example. It is preferable that the length of the band 91 is 20 m or more and 200 m or less, for example. It is preferable that the thickness of the band 91 is 0.5 mm or more and 2.5 mm or less, for example. Moreover, as for the thickness nonuniformity of the band 91, it is preferable to use that which is 0.5% or less with respect to the whole thickness. Moreover, the surface (henceforth flexible surface) 91a in which a casting film is formed, and the back surface 91b which contact | connects the drum main bodies 124b and 125b are formed flat. In particular, it is preferable that the flexible surface 91a is polished, and it is preferable that the surface roughness of the flexible surface 91a is 0.05 micrometer or less.

As shown in FIG. 12, the band movement control unit 128 is for controlling the movement and temperature of the band 91, The drive motor 128m, the shaft shift part 128s, and the load cell 128lc And a drum temperature control unit 128d (peelable drum cooler, flexible drum cooler), a band temperature control unit 128b, and a controller 128c.

The drive motor 128m is connected to the drive shaft 124a. The controller 128c controls the drive motor 128m to rotate the drum body 124b at a predetermined speed. The band 91 circulates in a predetermined direction as the drum body 124b rotates, and the drum body 125b rotates in accordance with the movement of the band 91. Hereinafter, the moving direction of the band 91 is called the Z1 direction, the width direction of the band 91 is called the Z2 direction, and the vertical direction is called the Z3 direction.

The moving speed of the flexible surface (91a) of the band (91) (V _91a) is preferably not more than 150 m / min. When the moving speed V _91a exceeds 150 m / min, it becomes difficult to stably form the beads. What is necessary is just to consider the productivity of the film made into the lower limit of the moving speed _V91a . The lower limit of the movement speed V _91a is 10 m / min, for example.

The drive shaft 124a has a tension application position at which a predetermined movement tension is applied to the band 91 spanning the drum bodies 124b and 125b, and a deflection position at which the band 91 spanning the drum bodies 124b and 125b is loosened. Freely move between. The axis shift part 128s can change the drive shaft 124a between the tension application position and the deflection position under the control of the controller 128c. It is preferable that the axis shift part 128s changes the drive shaft 124a, maintaining the state parallel to the axis 125a.

The load cell 128lc is attached to the drive shaft 124a. The load cell 128lc detects the external force which the drive shaft 124a receives. The controller 128c reads the external force which the drive shaft 124a receives from the load cell 128lc. Next, the controller 128c controls the axis shift unit 128s so that the movement tension applied to the band 91 is predetermined based on the read external force and the value of the cross-sectional area of the built-in band 91. do. In this way, a uniform moving tension in the Z2 direction can be applied to the band 91.

The drum temperature control unit 128d includes a drum temperature control unit 128da attached to the horizontal drum 124, and a drum temperature control unit 128db attached to the horizontal drum 125. The drum temperature adjusting units 128da and 128db respectively circulate the heat transfer medium adjusted to the desired temperature under the control of the controller 128c in the flow paths formed in the drum bodies 124b and 125b. By circulation of this heat transfer medium, the temperature of the drum main bodies 124b and 125b can be maintained at a desired temperature. It is preferable that the temperature of the flexible surface 91a of the band 91, especially the part where a flexible film is formed, is adjusted substantially constant within the range of 10 to 40 degreeC.

The band temperature adjusting part 128b will be described later.

The division unit is equipped with the 1st-3rd sealing member 131-133, as shown in FIG. The first to third sealing members 131 to 133 are sequentially disposed in the casing 121 from the upstream side in the Z1 direction toward the downstream side. The first to third seal members 131 to 133 protrude from the inner wall surface of the casing 121, respectively, and are formed so that the protruding end is close to the flexible surface 91a of the band 91. The area enclosed by the first to third seal members 131 to 133 in the casing 121, that is, the inner wall surface of the casing 121 and the flexible surface 91a, moves from the upstream side in the Z1 direction to the downstream side. It is divided into the flexible chamber 121a, the drying chamber 121b, and the peeling chamber 121c. And the airtightness of the flexible chamber 121a is hold | maintained by the 1st-2nd sealing member 131-132. In addition, the airtightness of the drying chamber 121b is hold | maintained by the 2nd-3rd sealing member 132-133. The space | interval of the 1st-3rd sealing members 131-133 and the flexible surface 91a is 1.5 mm or more and 2.0 mm or less, for example.

(Flexible room)

In the casting chamber 121a, a casting unit for forming the casting film 141 from the dope 112 is disposed. The flexible unit includes a flexible die 142 and a pressure reducer 143. The casting die 142 has the dope outlet 142a which flows out the dope 112, and is arrange | positioned above the horizontal drum 124 so that the dope outlet 142a may be close to the band 91.

The casting die 142 flows out the dope 112 toward the band 91 from the dope outlet 142a. The dope 112 until it flows out from the dope outlet 142a and reaches the flexible surface 91a forms a bead. The dope 112 which reached the flexible surface 91a forms the strip | belt-shaped flexible film 141 as a result of flowing in the Z1 direction.

The pressure reducer 143 is for depressurizing the upstream side of the bead in the Z1 direction, and the decompression chamber 143a and the decompression chamber disposed at an upstream side in the Z1 direction than the dope outlet 142a of the casting die 142. A pressure reducing fan (not shown) for sucking gas in 143a and a suction pipe (not shown) for connecting the pressure reducing fan and the pressure reduction chamber 143a are provided.

(Drying room)

In the drying chamber 121b, a film drying unit for drying the cast film is disposed. The membrane drying unit includes a first dryer 151 and a second dryer 153 as a membrane dryer for supplying predetermined drying air to the flexible membrane 141, and a drying controller (not shown). The first dryer 151 and the second dryer 153 are sequentially formed in the drying chamber 121b from the upstream side in the Z1 direction toward the downstream side. The first dryer 151 is disposed above the band 91 that spans the horizontal drums 124 and 125. The second dryer 153 is disposed below the band 91 that spans the horizontal drums 124 and 125.

The 1st dryer 151 is equipped with the 1st air supply duct 151a and the 1st exhaust duct 151b. The first air supply duct 151a and the first exhaust duct 151b are sequentially formed from the upstream side in the Z1 direction toward the downstream side. The 1st air supply duct 151a and the 1st exhaust duct 151b are respectively spaced apart from the band 91. The first air supply duct 151b is formed with a first air supply port through which the first drying wind 151da is sent out. The first air supply opening opened toward the downstream side in the Z1 direction extends from one end of the flexible membrane 141 to the other end. The 1st exhaust port which exhausts the 1st dry wind 151da is formed in the 1st exhaust duct 151a. The first exhaust port opened toward the upstream side in the Z1 direction extends from one end of the flexible membrane 141 to the other end.

The 2nd dryer 153 is equipped with the 2nd exhaust duct 153a and the 2nd air supply duct 153b. The second exhaust duct 153a and the second air supply duct 153b are sequentially formed from the upstream side in the Z1 direction toward the downstream side. The 2nd exhaust duct 153a and the 2nd air supply duct 153b are respectively spaced apart from the band 91. A second exhaust port for exhausting the second drying wind 153da is formed in the second exhaust duct 153a. The second exhaust port that is opened toward the downstream side in the Z1 direction extends from one end of the flexible membrane 141 to the other end. The second air supply duct 153b is provided with a second air supply mechanism through which the second drying wind 153da is sent out. The second air supply opening, which is open toward the upstream side in the Z1 direction, extends from one end of the flexible membrane 141 to the other end.

 The drying controller independently adjusts the temperature or the wind speed of the first drying wind 151da and the second drying wind 153da, and controls the temperature of the first drying wind 151da and the second drying wind 153da. First to second temperature controllers (not shown), first to second blowing fans (not shown) for adjusting the air volume of the first drying wind 151da and the second drying wind 153da, and a controller ( Not shown). The 1st-2nd temperature controller and the 1st-2nd blowing fan are formed in the duct of 1st dryer 151-2nd dryer 153. FIG. The controller controls the first to second temperature controllers and the first to second blowing fans to independently adjust the temperature and the wind speed for the first drying wind 151da and the second drying wind 153da.

(Peeling room)

The peeling roller 122 is arrange | positioned at the peeling chamber 121c. The peeling roller 122 peels the flexible film 141 which became the peelable state from the band 91, and sets it as the wet film 113, and carries out the wet film 113 from the outlet 121co formed in the peeling chamber 121c. Send it out. In this way, the horizontal drum 124 becomes a metal drum for casting and peeling.

You may provide the condensation apparatus 115 which condenses the solvent contained in the atmosphere in the casing 121, and the collection | recovery apparatus which collect | recovers the condensed solvent in the casting apparatus 115. Thereby, the density | concentration of the solvent contained in the atmosphere in the casing 121 can be maintained in a fixed range.

As shown in FIG. 13, the band support surface 124bs which supports the back surface 91b of the band 91 is formed in the outer peripheral part of the drum main body 124b. The band support surface 124bs is formed with a groove extending in the circumferential direction, that is, a relief groove 124bd, in a region where the weld portion 91w is located. The relief groove 124bd extends in the circumferential direction and is formed in an annular shape. Similarly, the band support surface 125bs which supports the back surface 91b of the band 91 is formed in the outer peripheral part of the drum main body 125b. A relief groove 125bd is formed in the band support surface 125bs. The relief groove 125bd is formed in the same shape as the relief groove 124bd, extends in the circumferential direction, and is formed in an annular shape. The relief grooves 124bd and 125bd formed extending in the circumferential direction may not be annular as long as the thickness nonuniformity failure and the cutting powder failure caused by the welded portion are suppressed, that is, the ends thereof may be separated. .

As shown in FIG. 14, the band 91 is wound around the drum main body 124b so that the welding part 91w may become on the relief groove 124bd. Similarly, the band 91 spans the drum body 125b so that the weld portion 91w is on the relief groove 125bd.

The width W _124bd of the relief groove 124bd may be the width of the welded portion 91w to be added to the meander width of the band 91 when moved while being wound around the drums 124 and 125, For example, they are 20 mm or more and 40 mm or less. The depth D _124bd of the relief groove 124bd may be such that the distance CL1 from the bottom of the relief groove 124bd to the back surface 91b of the band 91 is within 0.2 mm, for example, 0.03 mm. 0.2 mm or less. Moreover, it is preferable that the edge part 124bE of the relief groove 124bd is chamfered.

When the band 91 meanders, when the interval between the bottom portion 124bb of the relief groove 124bd and the band 91 is increased, poor heat transfer to the band 91 occurs, and the bottom portion 124bb and the band 91 are formed. If the spacing decreases, the problem of contact with the weld portion 91w occurs. Therefore, it is preferable that the bottom part 124bb of the relief groove 124bd is flat and has a flat surface. That is, it is preferable that the bottom part 124bb of the relief groove 124bd is parallel to the band support surface 124bs. Since the bottom portion 124bb of the relief groove 124bd is parallel to the band supporting surface 124bs, even when the band 91 meanders, it is necessary to keep the interval between the bottom portion 124bb and the band 91 constant. It becomes possible.

(Band temperature control part)

As shown to FIG. 11 and FIG. 12, the band temperature control part 128b is equipped with the band surface cooler 161 arrange | positioned at the peeling chamber 121c, and the band back surface cooler 162 arrange | positioned at the drying chamber 121b. do.

As shown in FIGS. 14 and 15, the band surface cooler 161 is downstream from the position PP where the flexible film 141 is peeled off (hereinafter, referred to as a peeling position), and is a relief groove in the Z2 direction. It forms in the part which opposes 124bd, ie, the vicinity of the welding part 91w. Here, the peeling position PP is set in the part supported by the metal drum for peeling, ie, the horizontal drum 124, among the bands 91. As shown in FIG.

The band surface cooler 161 is a temperature control part 161t for adjusting the temperature of the cooling gas 161a, a cooling nozzle 161n for sending the cooling gas 161a, and cooling sent from the cooling nozzle 161n. The cooling nozzle position adjustment part 161s which adjusts the position of the cooling nozzle 161n so that the gas 161a may contact the welding part 91w by the side of the flexible surface 91a is provided.

As shown in FIG. 15 and FIG. 16, the band back surface cooler 162 is a portion of the band 91 moving to approach the horizontal drum 124 in the Z1 direction, and the relief groove 124bd in the Z2 direction. It forms in the part which opposes, ie, the vicinity of the welding part 91w.

The band back surface cooler 162 is similar to the band surface cooler 161, The temperature control part 162t which adjusts the temperature of the cooling gas 162a, The cooling nozzle 162n which sends out cooling gas 162a, And a cooling nozzle position adjusting portion 162s for adjusting the position of the cooling nozzle 162n so that the cooling gas 162a sent out from the cooling nozzle 162n touches the weld portion 91w on the rear surface 91b side. .

Returning to FIG. 10, the support roller 171 which supports the wet film 113 is arranged in multiple numbers by the bridge | crosslinking part between the casting apparatus 115 and the clip tenter 117. As shown in FIG. The support roller 171 rotates about an axis by the motor which is not shown in figure. The support roller 171 supports the wet film 113 sent out from the casting apparatus 115, and guides it to the clip tenter 117. Moreover, although the case where two support rollers 171 are arranged in a bridge | crosslinking part is shown, this invention is not limited to this, You may list one or three or more support rollers 171 in a bridge | crosslinking part. In addition, the support roller 171 may be a free roller.

The clip tenter 117 has many clips which hold | grip the width direction both edge part of the wet film 113, and this clip moves on an extending track | orbit. Dry air is sent to the wet film 113 held by the clip, and the wet film 113 is subjected to a drying treatment together with the stretching treatment in the width direction.

An edge cutting device 172 is formed between the clip tenter 117 and the film drying device 118. Both ends of the width direction of the film 116 sent to the edge cutting device 172 are formed with the gripping trace formed by the clip. The edge cutting device 172 cuts off both end portions which have this gripping mark. The cut out portion is sequentially sent to a blow blower (not shown) and a crusher (not shown) by blowing, finely cut, and reused as a raw material such as dope.

The film drying apparatus 118 is a casing provided with the conveyance path of the film 116, the some roller 118a which forms the conveyance path of the film 116, and the air conditioner which adjusts the temperature and humidity of the atmosphere in a casing. (Not shown). The film 116 introduced into the casing is conveyed while being wound on the plurality of rollers 118a. By controlling the temperature and humidity of this atmosphere, the solvent remaining from the film 116 conveyed inside the casing evaporates. Moreover, the adsorption | recovery | recovery apparatus which collect | recovers the solvent evaporated from the film 116 by adsorption to the film drying apparatus 118 is connected.

Between the film drying apparatus 118 and the winding apparatus 119, the cooling chamber 173, the antistatic bar (not shown), the knurling provision roller 174, and the edge cutting apparatus (not shown) in order from the upstream side in order. ) Is formed. The cooling chamber 173 cools the film 116 until the temperature of the film 116 becomes substantially room temperature. The antistatic bar is sent out from the cooling chamber 173 and performs an antistatic treatment for removing electricity from the charged film 116. The knurling imparting roller 174 imparts knurling for winding to both ends in the width direction of the film 116. The edge cutting device cut | disconnects the width direction both ends of the film 116 so that knurling may remain in the width direction both ends of the film 116 after cutting.

The winding device 119 has a press roller 119a and a winding core 119b. The film 116 sent to the winding apparatus 119 is wound up by the winding core 119b, being pressed by the press roller 119a, and becomes a roll shape.

Next, the operation of the present invention will be described. As shown in FIG. 11, the controller 128c rotates the horizontal drum 124 through the drive motor 128m. Thereby, the band 91 circulates through each thread 121a-121c sequentially.

(Film forming step)

In the casting chamber 121a, a casting step of forming the casting film 141 made of the dope 112 is performed on the band 91. The casting die 142 continuously flows the dope 112 out of the dope outlet 142a. The dope 112 which flowed out forms the beads from the casting die 142 over the band 91, and flows on the band 91. In this way, the flexible film 141 which consists of the dope 112 is formed on the band 91.

The pressure reducer 143 can make the state in which the pressure of the bead upstream Z1 direction is lower than the pressure of the bead Z1 direction downstream side. It is preferable that the pressure difference (DELTA) P of the Z1 direction upstream and Z1 direction downstream of a bead is 10 Pa or more and 2000 Pa or less.

(Film drying process)

In the drying chamber 121b, predetermined drying air is made to flow to the casting film 141, and the drying process which evaporates a solvent from the casting film 141 is performed. The film drying process is performed until the flexible film 141 becomes a state capable of being self-supporting and conveying. In a film drying process, a 1st film drying process and a 2nd film drying process are performed sequentially.

In the first film drying step, the solvent is evaporated from the flexible film 141 until a dry layer is formed on the surface layer of the flexible film 141. The first dryer 151 sends the first drying wind 151da from the first air supply mechanism.

By this 1st film drying process, the casting film 141 will have a dry layer and a wet layer. The dry layer is formed on the surface side of the cast film 141 and is a portion where drying has advanced compared to the wet layer located on the band 91 side than the dry layer. That is, the content rate of the solvent of a dry layer is low compared with a wet layer. In addition, the surface of a dry layer is formed smoothly. When a predetermined drying process is performed with respect to the flexible film 141 which has a dry layer, the surface of a dry layer becomes the surface of the obtained flexible film 141. Therefore, by forming a dry layer in the flexible film 141 immediately after formation, the flexible film 141 with a smooth surface can be obtained.

Here, the content rate of a solvent shows the quantity of the solvent contained in a casting film or each film on a dry weight basis, and takes a sample from the target film, x the mass of this sample, and the mass after drying a sample When it is set to y, it is represented by {(xy) / y} × 100 mass%.

It is preferable that the temperature of the 1st drying wind 151da is 30 degreeC or more and 80 degrees C or less. Moreover, it is preferable that the wind speed of the 1st dry wind 151da is 5 m / sec or more and 25 m / sec or less.

The 2nd film | membrane drying process evaporates a solvent from the casting film 141 until it becomes the state which can be conveyed independently using the 2nd dry wind 153da. The 2nd dryer 153 flows the 2nd drying air 153da along the membrane surface of the casting film 141 toward the upstream side from the downstream side in the Z1 direction. Thus, by flowing the 2nd drying wind 153da to the direction opposite to Z1 direction, evaporation of a solvent is accelerated | stimulated compared with the case where it flows in Z1 direction. It is preferable to perform a 2nd film drying process with respect to the casting film 141 whose content rate of a solvent is 20 mass% or more and 150 mass% or less. It is preferable that the temperature of the 2nd dry wind 153da is 40 degreeC or more and 80 degrees C or less. Moreover, it is preferable that the wind speed of the 2nd drying wind 153da is 5 m / sec or more and 20 m / sec or less.

(Peeling process)

In the peeling chamber 121c, the peeling process which peels the flexible film 141 which became the peelable state from the band 91 is performed. The peeling roller 122 peels the flexible film 141 which became the peelable state from the band 91 as the wet film 113, and makes the wet film 113 from the outlet 121co formed in the peeling chamber 121c. Send it out. It is preferable to perform a peeling process with respect to the flexible film 141 whose solvent content is 20 mass% or more and 80 mass% or less.

The band 91 is fed from the peeling chamber 121c and then introduced into the casting chamber 121a again.

The band 91 which has the weld part 91w is easy to bend over the side part 91s (refer FIG. 9) from the center part 91c (refer FIG. 9). When the band 91 is warped, a portion of the band 91 is lifted from the horizontal drums 124 and 125, resulting in foaming failure, failure remaining without peeling, and thickness nonuniformity failure of the film. The lifting amount of the band 91 in the horizontal drums 124 and 125 decreases as the vertical stress N acting on the band 91 wound around the horizontal drums 124 and 125 increases. You may use this property, and you may perform the lifting amount reduction process which reduces the lifting amount CL by increasing normal stress (N).

Here, if Dr is the radius of the horizontal drum, T is the moving tension of the band, and TH is the thickness of the band, the vertical stress (N) acting on the band wound around the horizontal drum is represented by the following equation.

N = TH × T / Dr

Moreover, when the radius Dr of the horizontal drums 124 and 125 is 1000 mm and the thickness TH 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.

When the solution film forming method using the band 91 having the weld portion 91w is continuously performed for a long time, cutting powder failure and thickness non-uniformity failure caused by the weld portion 91w occur. When the solution film forming method is continuously performed for a long time, the weld portion 91w protrudes from the back surface 91b.

Here, when the solution film-forming method is performed continuously for a long time, it is estimated that the cause which the welding part 91w protrudes from the back surface 91b is a phase transformation which arises by the residual stress of the welding part 91w.

And when the band 91 is moved in the state which the welding part 91w protruded from the back surface 91b, the outer peripheral part of the welding part 91w and the drum main bodies 124b and 125b will contact. If this contact is repeated on the back surface 91b, the weld part 91w in the flexible surface 91a deforms into a concave shape with time. When the solution film-forming method is performed in this state, the mark of the weld part 91w will remain in thickness nonuniformity in the film 116. When the film 116 having the thickness nonuniformity is wound on the core 119b as it is, the marks of the weld portions 91w overlap and become black bands and appear on the film roll (hereinafter referred to as black band failure). Moreover, when the solution film forming method is performed in the state where the welding part 91w protruded from the back surface 91b, the cutting powder failure will generate | occur | produce by the grazing of the welding part 91w and the outer peripheral parts of the drum main bodies 124b and 125b.

In the present invention, the relief groove 124bd is formed in the band support surface 124bs of the drum main body 124b, and the band 91 is placed in the drum main body 124b so that the welded part 91w is located on the relief groove 124bd. ), The weld part 91w does not contact the drum main body 124b. Similarly, since the band 91 is wound around the drum main body 125b so that the weld part 91w is located on the relief groove 125bd, the welding part 91w does not contact the drum main body 125b. For this reason, it becomes possible to suppress thickness nonuniform failure and cutting powder failure.

Moreover, the temperature of the band 91 which passed through the film drying process is high compared with before introduction of a film drying process by contact with each dry wind. When the film forming step is performed using the band 91 in a high temperature state, foaming of the dope may occur. According to the drum temperature control part 128da, it becomes possible to cool the drum main body 124b so that the band 91 may become lower than foaming temperature of dope. And by cooling the drum main body 124b, the temperature of the part which directly contacts the drum main body 124b in the band 91 can be made lower than foaming temperature of dope.

By the way, in the band 91, the part which does not directly contact the drum main body 124b, ie, the part which opposes the relief groove 124bd, is not enough cooling. And when cooling is inadequate, foaming of dope will arise.

As shown in FIG. 14, since the band surface cooler 161 can flow cooling gas 161a into the part which opposes the relief groove 124bd using the cooling nozzle 161n, the drum temperature control part 128da ), The lack of cooling of the drum body 124b can be compensated for. Therefore, the film 116 can be manufactured efficiently, suppressing foaming of dope more reliably.

Moreover, in terms of production efficiency, it is preferable that the timing of performing a peeling process is high in the content rate of the solvent of a cast film. However, when it is going to perform a peeling process with respect to the flexible film with a high content rate of a solvent, the malfunction which remained without peeling will likely occur. Therefore, it is preferable to cool the casting film immediately before the peeling step. By cooling the drum main body 124b using the drum temperature adjusting part 128da, cooling of the cast film immediately before a peeling process is attained. By cooling the drum main body 124b, the temperature of the part of the band 91 which directly contacts with the drum main body 124b can be made lower than foaming temperature of dope.

By the way, in the band 91, the part which does not directly contact the drum main body 124b, ie, the part which opposes the relief groove 124bd, is not enough cooling. And when cooling is inadequate, the malfunction which remains without peeling will arise.

As shown in FIG. 16, since the band back surface cooler 162 can flow cooling gas 162a into the part which opposes the relief groove 124bd using the cooling nozzle 162n, the drum temperature control part ( The lack of cooling of the drum main body 124b by 128da can be compensated for. Therefore, the film 116 can be manufactured efficiently, more reliably suppressing the malfunction which remained without peeling.

Moreover, as long as the setting position of the band surface cooler 161 in a Z1 direction is between peeling position PP and arrival position CP, any position of the peeling chamber 121c and the flexible chamber 121a may be sufficient. Here, the arrival position CP is set in the part of the band 91 supported by the flexible metal drum, ie, the horizontal drum 124 (refer FIG. 11 and FIG. 15). Thus, what is necessary is just to perform the process of cooling the band 91 which used the band surface cooler 161 between a peeling process and the following film formation process.

In the said embodiment, although the stainless band 91 was used, the metal band 91 other than stainless steel may be sufficient. Similarly, although the stainless horizontal drums 124 and 125 were used, you may use the metal horizontal drums 124 and 125 other than stainless steel.

Instead of using the band surface cooler 161 to cool the cooling gas 161a to the welded portion 91w on the flexible surface 91a side, the solvent is applied to the welded portion 91w on the flexible surface 91a side. The coated solvent may be evaporated or rolled in a state in which the cooled roller is in contact with the weld portion 91w on the side of the flexible surface 91a. Similarly, using the band back surface cooler 162, instead of letting the cooling gas 162a to the weld part 91w of the back surface 91b side, the solvent was apply | coated to the weld part 91w of the back surface 91b side. Thereafter, the applied solvent may be evaporated or rolled in a state in which the cooled roller is in contact with the weld portion 91w on the rear surface 91b side. When the band 91 is cooled using a band surface cooler or a band back surface cooler, a solvent contained in the dope may be applied to the band 91.

Although the installation position of the casting die 142 was made above the horizontal drum 124, this invention is not limited to this. When the sealing members 131 to 132 are formed to be close to the portion of the band 91 wound around the horizontal drum 125, the installation position of the casting die 142 may be above the horizontal drum 125. In this case, the horizontal drum 125 becomes a metal drum for casting, and the horizontal drum 124 becomes a metal drum for peeling.

In addition, when the support drum which supports the band 91 is formed between the horizontal drums 124 and 125, and the sealing member 131-132 is formed so that it may be adjacent to the part of the band 91 supported by the support drum, The installation position of the casting die 142 may be above the support drum. In this case, the support drum becomes a metal drum for casting, and the horizontal drum 124 becomes a metal drum for peeling.

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

It is preferable that it is 600 mm or more, and, as for the width | variety of the film 116, it is more preferable that they are 1400 mm or more and 2500 mm or less. Moreover, this invention is effective also when the width | variety of the film 116 is larger than 2500 mm. Moreover, it is preferable that the film thickness of the film 116 is 20 micrometers or more and 80 micrometers or less.

Moreover, it is preferable that in-plane retardation Re of the film 116 is 20 nm or more and 300 nm or less, and it is preferable that the thickness direction retardation Rth of the film 116 is -100 nm or more and 300 nm or less.

The measuring method of in-plane retardation Re is as follows. In-plane retardation (Re) is a retardation value measured in the vertical direction at 632.8 nm with an automatic birefringence meter (KOBRA21DH Oji Measurement Co., Ltd.) after humidifying a sample film at temperature 25 degreeC, 60% RH of humidity for 2 hours. Was used. Re is represented by the following formula.

Re = | n1-n2 | × d

n1 represents the refractive index of the slow axis, n2 represents the refractive index of the fast axis 2, and d represents the thickness (film thickness) of the film.

The measuring method of thickness direction retardation Rth is as follows. The sample film was humidified for 2 hours at a temperature of 25 ° C. and a humidity of 60% RH, and measured in the vertical direction at 632.8 nm by an ellipsometer (manufactured by M150 Nippon Spectroscopy) while measuring the same while tilting the film plane. It was computed according to the following formula from the extrapolation value of one retardation value.

Rth = {(n1 + n2) / 2-n3} × d

n3 represents the refractive index of the thickness direction.

(Polymer)

In the said embodiment, the polymer used as a raw material of a polymer film is not specifically limited, For example, a cellulose acylate, a cyclic polyolefin, etc. are mentioned.

(Cellulose acylate)

Only one kind of acyl group may be used for the cellulose acylate of the present invention, or two or more kinds of acyl groups may be used. When using two or more types of acyl groups, it is preferable that one of them is an acetyl group. It is preferable that the ratio which esterifies the hydroxyl group of a cellulose with carboxylic acid, ie, the substitution degree of an acyl group, satisfy | fills all of following formula (I)-(III). In the following formulas (I) to (III), A and B represent a degree of substitution of an acyl group, A is a degree of substitution of an acetyl group, and B is a substitution of an acyl group having 3 to 22 carbon atoms. It is also. Moreover, it is preferable that 90 weight% or more of triacetyl cellulose (TAC) is 0.1 mm-4 mm of particle | grains.

(I) 2.0 ≤ A + B ≤ 3.0

(II) 1.0 ≤ A ≤ 3.0

(III) 0 ≦ B ≦ 2.0

It is more preferable that all substitution degrees A + B of an acyl group are 2.20 or more and 2.90 or less, and it is especially preferable that they are 2.40 or more and 2.88 or less. Moreover, it is more preferable that substitution degree B of the acyl group of C3-C22 is 0.30 or more, and it is especially preferable that it is 0.5 or more.

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 of this invention, an aliphatic group or an aryl group may be sufficient, and is not specifically limited. They are alkylcarbonyl ester, alkenylcarbonyl ester, aromatic carbonyl ester, aromatic alkylcarbonyl ester, etc. of cellulose, for example, and may have a group substituted further, respectively. Preferred examples thereof include propionyl, butanoyl, pentanoyl, hexanoyl, octanoyl, decanoyl, dodecanoyl, tridecanoyl, tetradecanoyl, hexadecanoyl, octadecanoyl, iso-butanoyl, t -Butanoyl, cyclohexanecarbonyl, oleoyl, benzoyl, naphthylcarbonyl, cinnamoyl group, and the like. Among these, propionyl, butanoyl, dodecanoyl, octadecanoyl, t-butanoyl, oleyl, benzoyl, naphthylcarbonyl, cinnamoyl and the like are more preferable, and particularly preferably propionyl and butanoyl .

(solvent)

Examples of the solvent for preparing the dope include aromatic hydrocarbons (for example, benzene and toluene), halogenated hydrocarbons (for example, dichloromethane, chlorobenzene and the like), 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, and the like. In addition, in this invention, dope means the polymer solution and dispersion which are obtained by melt | dissolving or disperse | distributing a polymer in a solvent.

Among these, halogenated hydrocarbons having 1 to 7 carbon atoms are preferably used, and dichloromethane is most preferably used. From the viewpoints of physical properties such as solubility of the polymer, peelability from the support of the flexible membrane, mechanical strength of the film, and optical properties of the film, it is preferable to mix one or several kinds of alcohols having 1 to 5 carbon atoms in addition to dichloromethane. Do. 2 weight%-25 weight% are preferable with respect to the whole solvent, and, as for the content rate of alcohol, 5 weight%-20 weight% are more preferable. Specific examples of the alcohol include methanol, ethanol, n-propanol, isopropanol, n-butanol and the like, and methanol, ethanol, n-butanol or a mixture thereof is preferably used.

By the way, in order to minimize the effect on the environment in recent years, the examination of the solvent composition in the case of not using dichloromethane is advanced, and about this objective, the ether and carbon atom of 4-12 carbon atoms are studied. Ketones having 3 to 12 carbon atoms, esters having 3 to 12 carbon atoms and alcohols having 1 to 12 carbon atoms are preferably used. These may be mixed and used suitably. For example, the mixed solvent of methyl acetate, acetone, ethanol, n-butanol is mentioned. These ethers, ketones, esters and alcohols may have a cyclic structure. Moreover, the compound which has two or more of functional groups of ether, ketone, ester, and alcohol (namely, -O-, -CO-, -COO-, and -OH) can also be used as a solvent.

The details of the cellulose acylate are described in paragraphs [0140] to [0140] of JP 2005-104148 A. These descriptions can also be applied to the present invention. Moreover, the same applies to additives such as a solvent, a plasticizer, a deterioration inhibitor, an ultraviolet absorber (UV agent), an optically anisotropic control agent, a retardation control agent, a dye, a mat agent, a release agent, a peeling accelerator, and the like. It is described in detail in the paragraphs [0196] to [0516] of the call.

In the said embodiment, although the solution film forming method was demonstrated, this invention is applicable also to the method of apply | coating (flexible) a liquid on a support body, and forming a coating film.

(Example)

In order to confirm the effect of this invention below, experiment 1-4 was performed. The detail of each experiment is demonstrated in Experiment 1, and about Experiments 2-4, only the conditions different from Experiment 1 are shown.

(Experiment 1)

Using the band 91 which gave predetermined | prescribed grinding | polishing process to the soft surface 91a and the back surface 91b, the solution film forming installation 110 (refer FIG. 10) is performed continuously for 700 hours, and the film from dope 112 is performed. (116) was prepared. As the flexible support unit, horizontal drums 124 and 125, a band 91, and a band movement control unit 128 as shown in FIG. 12 were used. The maximum value CL1 (see FIG. 14) of the interval between the bottom of the relief groove 124bd and the back surface 91b of the band 91 was 0.1 mm. By the drum temperature adjusting units 128da and 128db, the temperature of the drum body 124b was adjusted to 10 ° C, and the temperature of the drum body 125b was adjusted to 30 ° C. The moving tension T1 applied to the band 91 was 60 N / mm 2. In addition, the band temperature control part 128b was not used.

(Experiment 2)

CL1 was the value shown in Table 1, and the film 116 was produced like Example 1 except having used the band back surface cooler 162 as the band temperature control part 128b. The temperature of the cooling gas 162a was 5 degreeC, and the wind speed of the cooling gas 162a was 20 m / sec.

Experiment 3

CL1 was the value shown in Table 1, and the film 116 was produced like Example 1 except having used the band surface cooler 161 as the band temperature control part 128b. The temperature of the cooling gas 161a was 5 degreeC, and the wind speed of the cooling gas 161a was 20 m / sec.

(Experiment 4)

Instead of the horizontal drums 124, 125, the film 116 was produced in the same manner as in Experiment 1, except that a horizontal drum was used which had no relief groove and the entire circumferential surface was flat.

(evaluation)

The following evaluation was performed about the film obtained by the experiment 1-the experiment 4.

1. Evaluation of Cutting Failure

The presence or absence of cutting powder breakdown was investigated.

A: No cutting powder failure occurred.

B: Cutting failure occurred.

2. Evaluation of thickness nonuniformity in the weld mark

In the following procedure, it was examined whether the weld tread remained as thickness nonuniformity. In the winding device 119, the sample film was cut out from the film before winding up to the core. 10 sheets of cut out sample films were stacked. And when light permeated through the 10 sheets of sample film, the shadow which appears on the surface of a sample film was visually observed. When shading was not observed in the part formed in the weld part among sample films, it was set as (A), and it was set as (B) when shading was observed in the part formed in the weld part among sample films.

Table 1 shows the evaluation results of Experiments 1 to 4. In addition, in Table 1, the number attached to the evaluation result represents the number attached to the said evaluation item.

110: solution film production equipment
115: flexible device
91: flexible band
141: flexible film
124, 125: horizontal drum
124bs, 125bs: band support surface
124bd, 125bd: Relief Home
161: Band Surface Cooler
162: Band Back Cooler

Claims (9)

Supported to rotate freely,
A metal endless band having a weld extending in the longitudinal direction is supported at the circumferential surface,
The circumferential surface has a metal drum, characterized in that it has a groove extending in the circumferential direction in the region where the weld is located. The method of claim 1,
A metal drum in which said groove is annular. 3. The method according to claim 1 or 2,
And the bottom of the groove has a flat surface. A pair of metal drums according to any one of claims 1 to 3,
The endless band is wound on the pair of metal drums so that the welding portion is located on the groove, and moved in the longitudinal direction by the rotation of the metal drum;
A flexible die for flowing a dope comprising a polymer and a solvent toward the surface of the endless band,
A flexible device comprising a membrane drier made of the dope which flows out and heating air to a flexible membrane formed on the surface, and evaporating the solvent from the flexible membrane. The method of claim 4, wherein
A flexible device having a peeler for peeling the flexible film from the endless band to obtain a wet film. The method of claim 5, wherein
The said metal drum which opposes the said peeler among the said pair of metal drums is a peeling metal drum,
The flexible film is peeled off at a portion supported by the peeling metal drum of the endless band,
A peeling drum cooler for cooling the peeling metal drum;
The flexible apparatus provided with the band back surface cooler which cools the said welding part of the said endless band moving from the back surface side closer to the said peeling metal drum. The method according to claim 5 or 6,
The metal drum facing the casting die of the pair of metal drums is a casting metal drum,
The dope flowing out of the casting die reaches a portion of the endless band supported by the casting metal drum,
A flexible drum cooler for cooling the flexible metal drum;
A band surface cooler is formed between the endless band of the endless band and the position where the flexible film is peeled off to face the endless band and cools the welded portion supported by the flexible metal drum from the surface side. One flexible device. The flexible film is formed on the surface of the endless band by using the flexible device according to claim 4. The film is produced by forming the said flexible film on the surface of the said endless band, and peeling the said flexible film from the said endless band using the flexible apparatus as described in any one of Claims 5-7. Way.

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