TW201302417A - Method and apparatus for inspecting endless belt - Google Patents

Abstract

External force at a predetermined level is applied to a rotary shaft of an inspection roller by a driver. Tension is applied to a belt wound around the inspection roller. A sensor unit measures a distance A from a measurement position MP1 to a measuring window. The sensor unit measures a distance B from a measurement position MP2 to the measuring window. A controller calculates a curving level CL by using the distance A, the distance B, and a band width D read from a memory. The controller judges the belt as an inspection target to be ''an acceptable product'' when all the curving levels CL of the belt are equal to or less than a threshold value TH1. The controller judges the belt as the inspection target to be ''a disqualified product'' when any one of the curving levels CL of the belt exceeds the threshold value TH1.

Description

Endless belt inspection method and device

The present invention relates to an inspection method and apparatus for an endless belt.

With the large screen of a liquid crystal display (LCD), an optical film used on an LCD is also required to have a large area. After the optical film is formed into a shape, it is cut into a predetermined size according to the size of the LCD. Therefore, in order to manufacture a larger area optical film, it is required to manufacture a long optical film having a larger width than conventional ones.

As a representative manufacturing method of the elongated optical film, there is a continuous method of forming a solution. It is generally known that a continuous mode solution film forming method is a method in which a dope in which a polymer is dissolved in a solvent is cast on a moving casting support, and a flow composed of a dope is formed on the casting support. The film is stretched, the cast film is peeled off from the casting support, and dried to produce a film.

As the casting support, a metal belt wound around a driving roller is used. The maximum width of a film that can be manufactured is limited by the width of the tape. Therefore, a tape of a larger width is required when manufacturing a film of a larger width. However, only belts having a width of at most about 2 m have been obtained so far.

Therefore, in the Korean Patent Laid-Open Publication No. 2009-0110082, the center portion of the center portion in the width direction and the pair of side portions of the side portions of the belt are welded to each other in the longitudinal direction. The width of the belt.

However, the belt described in Korean Patent Laid-Open Publication No. 2009-0110082 is likely to be warped in the width direction due to the welding line extending in the longitudinal direction. In particular, warpage is likely to occur at the end portion in the width direction of the belt, that is, from the center portion to the side belt. When the solution film forming method is performed by the belt in which the end portion is warped in the width direction, the thickness of the cast film is uneven due to the warpage. Uneven thickness means uneven thickness. Even if such a cast film having uneven thickness is produced by drying, a film having uneven thickness is produced. Further, when a cast film having uneven thickness is peeled off, a peeling residual failure is liable to occur. The peeling residual failure means that the cast film is not completely peeled off from the belt and a part of the cast film remains on the belt. Further, when a cast film having uneven thickness is produced by drying, foaming easily occurs on the cast film. In addition, when the inner side surface of the belt which is bent due to the warpage (the belt surface on the side opposite to the belt surface on which one of the casting films is formed) is in contact with the circumferential surface of the driving roller, the tape is hung When the roller is driven, the belt end partially contacts the peripheral surface of the driving roller at the side of the belt. If the belt end is partially in contact with the peripheral surface of the driving roller, the deformation of the side portion of the belt is increased, so that the problem of uneven thickness is likely to occur.

Further, with the development of technology, when a belt exceeding the current manufacturing limit width can be manufactured, since the belt is used, warpage due to the welding line disappears. However, there is a problem of warpage in the width direction due to an increase in bandwidth.

Thus, regardless of the presence or absence of the weld line, when the width is wider than that of the conventional belt, the problem of warpage in the width direction occurs.

An object of the present invention is to provide an inspection method and apparatus for detecting a warped endless belt without performing a solution film forming method when the manufacturing width is wider than that of the conventional belt.

In the method for inspecting a metal endless belt according to the present invention, the endless belt has a front surface and a back surface. The arrival position reached from the dope under the casting die flow is set on the aforementioned surface, and a casting film composed of the aforementioned concentrated liquid is formed. When the endless belt is cyclically moved, the inside is supported by a film forming roller. The inspection method of the endless belt includes a distance calculation step (A step), a floating amount calculation step (B step), and a determination step (C step). The step A calculates the distance H from the measurement position on the aforementioned surface to the support surface of the inspection roller. The aforementioned measurement position corresponds to the aforementioned arrival position. The aforementioned distance H is calculated for the aforementioned endless belt in which the aforementioned inspection roller is supported and the moving tension is applied. In the step B, the amount of floating CL from the support surface to the inside is calculated according to the formula (1). The above formula (1) is CL=H-D. The aforementioned D is the thickness of the endless belt at the measurement position. The C step determines whether or not the aforementioned calculated floating amount CL is below the threshold.

In the above-described method for inspecting an endless belt, the inspection roller supports the endless belt at a central portion in the axial direction so as to be exposed at an axial end portion, and measures the measurement from the measurement position to the aforementioned measurement by the distance measuring unit in the step A. The distance A from the unit and the distance B from the aforementioned axial end portion to the aforementioned distance measuring unit are preferably calculated from the equation (2).

Formula (2) is H=B-A.

In the above-described step B, it is preferable to read the thickness D of the endless belt from the storage portion and calculate the floating amount CL by the thickness D of the endless belt read from the storage portion. The storage unit stores, in association with the position information set at the reference position on the endless belt to the measurement position, and the thickness D of the endless belt at the measurement position.

It is preferable that the endless belt is composed of a first mesh made of metal and a second mesh made of metal welded to one side in the width direction of the first net.

It is preferable that the film forming roller and the inspection roller are the same roller.

The moving tension is 60 N/mm ² , and the threshold is preferably 0.1 mm or less.

In the inspection apparatus for a metal endless belt according to the present invention, the endless belt has a front surface and a back surface. The arrival position reached from the dope under the casting die flow is set on the aforementioned surface, and a casting film composed of the aforementioned concentrated liquid is formed. When the endless belt is cyclically moved, the inside is supported by a film forming roller. An inspection apparatus for an endless belt according to the present invention includes a distance calculation unit, a floating amount calculation unit, and a determination unit. The distance calculating unit calculates the distance H from the measurement position on the surface to the support surface of the inspection roller. The aforementioned measurement position corresponds to the aforementioned arrival position. The distance H is calculated for the aforementioned endless belt in which the above-described inspection roller is supported and the moving tension is applied. The floating amount calculation unit calculates the floating amount CL from the support surface to the inside at the measurement position according to the formula (1). The above formula (1) is CL=H-D. The aforementioned D is the thickness of the endless belt at the measurement position. The determination unit determines whether or not the calculated floating amount CL is equal to or less than a threshold.

It is preferable that the above-described inspection device for the endless belt includes a distance measuring unit that measures the distance A and the distance B. The aforementioned distance A is the distance from the aforementioned distance measuring unit to the aforementioned measurement position. The distance B is a distance from the distance measuring unit to an axial end portion of the endless belt that is exposed by the inspection roller in the axial center portion. The distance calculating unit calculates the aforementioned distance H based on the equation (2).

Formula (2) is H=B-A.

The inspection device for the endless belt has a storage portion, and the floating amount calculation unit preferably calculates the floating amount CL by the thickness D of the endless belt stored in the storage portion. The storage unit stores, in association with the position information set at the reference position on the endless belt to the measurement position, and the thickness D of the endless belt at the measurement position.

It is preferable that the film forming roller and the inspection roller are the same roller.

According to the present invention, the warpage of the tape can be detected without performing the solution film forming method.

The belt manufacturing apparatus 10 shown in Figs. 1 and 2 is formed of an elongated belt member 13 composed of an elongated central member 12 and side members 11 provided on both sides in the width direction of the center member 12.

The side member 11 and the center member 12 are respectively made of a metal sheet material. The side members 11 are narrow web materials of relatively narrow width. The side member 11 and the center member 12 are preferably formed of the same material as each other, and are preferably formed of the same raw material and a forming process. For example, it is preferable to use a stainless steel as the side member 11 and the center member 12.

As the center member 12, a belt which has been conventionally used as a casting support may be used. The central member 12 is wider than the side members 11. In the present embodiment, the width of the center member 12 is constant within a range of 1500 mm or more and 2100 mm or less, and the width of the side member 11 is constant within a range of 50 mm or more and 500 mm or less.

The tape manufacturing apparatus 10 includes a delivery unit 16 , a butt portion 17 , a welding unit 18 , a heating unit 19 , and a winding device 20 .

The delivery unit 16 has a first delivery device 23 that feeds the side members 11 and a second delivery device 24 that sends out the central member 12. The delivery unit 16 separately sends the side member 11 and the central member 12 to the abutting portion 17, respectively. The side member 11 wound in a roll shape is provided in the first delivery device 23, and the side member 11 is wound up and sent to the abutting portion 17. The second delivery device 24 is provided with a central member 12 wound in a roll shape, and the central member 12 is wound up and sent to the abutting portion 17.

The abutting portion 17 abuts the independently guided side member 11 and the center member 12 such that the side edge 11e of the side member 11 and the side edge 12e of the center member 12 are in contact with each other. The butt portion 17 preferably has the first roller 26 and the second roller 27, the third roller 28, and the fourth roller 29. The first roller 26 and the second roller 27 are disposed in this order from the upstream side on the conveyance path of the center member 12. A third roller 28 is disposed on the conveying path of the side member 11. The fourth roller 29 is disposed to support both the side member 11 and the center member 12 on the conveying path.

The fourth roller 29 supports the butted support roller of the side member 11 and the center member 12 that are fed at the butt position Ph. The side edge 11e of one of the butt position Ph-side members 11 and the side edge 12e of one of the center members 12 come into contact with each other.

The second roller 27 and the third roller 28 respectively adjust the conveying path of the center member 12 and the conveying path of the side member 11 so that the center member 12 and the side member 11 are in contact with each other on the circumferential surface of the fourth roller 29.

The second roller 27 adjusts the conveying path of the center member 12, and controls the passage path of the side edge 12e to be welded to the side member 11 toward the butting position Ph. The second roller 27 is movable in the width direction Y of the center member 12. The displacement mechanism 32 moves the second roller 27 in the width direction Y.

A position detecting means 34 is disposed between the second roller 27 and the fourth roller 29. The position detecting means 34 detects the passing position of one of the side edges 12e of the center member 12, and sends the detected passing position signal to the controller 33. The controller 33 obtains the amount of displacement of the second roller 27 in the width direction Y based on the transmitted position signal, and sends the displacement amount signal to the displacement mechanism 32. The displacement mechanism 32 changes the inclination of the second roller 27 or the position of the second roller 27 in the width direction Y of the center member 12 based on the transmitted displacement amount signal. Thus, the center member 12 is displaced in the width direction Y by changing the inclination or position of the second roller 27.

It is preferable to provide the displacement mechanism 37 on the first roller 26. The first roller 26 is pressed toward the center member 12 of the second roller 27 from the one member surface by the displacement mechanism 37. The pressing pressure of the first roller 26 with respect to the center member 12 is changed according to the displacement amount of the first roller 26, and the pressing pressure is adjusted. Thereby, the winding center angle of the center member 12 wound around the second roller 27 can be controlled. According to the control of the winding center angle, the amount of displacement of the center member 12 in the width direction Y according to the second roller 27 can be controlled more accurately.

The third roller 28 adjusts the transport path of the side member 11, and adjusts the passage path of the side edge 11e to be welded to the central member 12 toward the docking position Ph. The third roller 28 is provided with a controller 38 that controls the orientation in the longitudinal direction. The controller 38 changes the longitudinal direction of the third roller 28, for example, along the member faces of the side members 11, so as to be at an angle of the circumferential direction in the contact region during contact with the side members 11 and the conveying direction X of the center member 12. Θ1 changes.

It is preferable to control the first roller 26 to the third roller 28 so that the butting position Ph is located on the fourth roller 29 as described above. It is preferable that each of the first roller 26 to the third roller 28 is a driving roller that rotates in the circumferential direction. By rotating in the circumferential direction, the first roller 26 and the second roller 27 also function as a conveying means of the center member 12, and the third roller 28 also functions as a conveying means of the side member 11. By setting the first roller 26 to the third roller 28 as the driving roller, the control of the conveying path of the side member 11 and the center member 12 becomes more reliable, and by preventing the side member 11 and the center member 12 from being in the first roller 26 The sliding on the third roller 28 prevents the surface of the member from being scratched.

The welding unit 18 welds the side member 11 and the center member 12 supplied from the butting portion 17 in contact with each other with the side edges 11e, 12e. By continuously supplying from the butting portion 17, the long side 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 provided with a welding device 42. As the welding device 42, for example, a laser welding device can be cited. As the laser welding device, for example, a CO ₂ laser welding device or a yttrium aluminum garnet (YAG) laser welding device can be used. In the present embodiment, a case where a CO ₂ laser welding device is used as the welding device 42 will be described.

The welding device 42 emits a concentrated laser beam, and the side member 11 and the center member 12 are irradiated with a laser to illuminate and fuse the side member 11 and the center member 12. The welding device 42 includes a laser oscillator 43, a welding device main body 46 that condenses and emits a laser beam guided from the laser oscillator 43, and a gas supply unit that supplies CO ₂ gas every time the laser is irradiated (not Graphic). The CO ₂ gas prevents oxidation of the side member 11 and the center member 12. Further, in FIG. 2, the illustration of the laser oscillator 43 is omitted in order to avoid complication of the drawing.

Instead of a laser welding device, a tungsten inert gas welding (Tungsten Inert Gas (TIG) welding) device can be used. It is well known that TIG welding is one of arc welding in which an electric arc is used as a heat source. TIG welding is one in which an inert gas (inactive gas) is used as a shielding gas and an inert gas arc welding using tungsten or a tungsten alloy is used for the electrode. Laser welding is better than TIG welding. Moreover, it can also be used as a hybrid welding combining TIG welding and laser welding.

A welding support roller 41 that supports the side member 11 and the center member 12 by the circumferential surface is provided on the conveyance path of the side member 11 and the center member 12 so as to face the discharge port of the laser of the welding device main body 46. 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. It is preferable to set the support position of the side member 11 and the center member 12 in accordance with the welding support roller 41 so that the side member 11 and the center member 12 are irradiated with laser light during the support by the circumferential surface of the welding support roller 41. That is, it is preferable to perform welding on the welding support roll 41. Thereby, the side member 11 and the center member 12 are stabilized in a state in which the side edges 11e and 12e are in contact with each other, and the laser beam can be reliably irradiated corresponding to the irradiated portion.

It is preferable that the welding device main body 46 is provided with a displacement mechanism 50 for displacing in the width direction Y. On the upstream side of the welding device 42, a position detecting means 47 for detecting the contact position Ps (refer to FIG. 5) where the side edge 11e of the side member 11 and the side edge 12e of the center member 12 are in contact with each other is detected, and will be detected. The signal of the contact position Ps (refer to FIG. 5) is sent to the controller 51. The position detecting means 47 may be disposed in the vicinity of the transfer path from the docking position Ph to the welding device 42 (for example, the welding position Pw).

The controller 51 determines the amount of displacement of the welding device main body 46 in the width direction Y based on the signal of the contact position Ps (refer to FIG. 5), and sends a signal of the displacement amount to the displacement mechanism 50. When the signal of the conveyance speed of the input side member 11 and the center member 12 is input, the controller 51 sends the signal of the displacement timing to the displacement mechanism 50 together with the signal of the displacement amount at which the welding device main body 46 is displaced. The displacement mechanism 50 changes the position of the welding device main body 46 at a predetermined timing based on the transmitted displacement amount and the signal of the displacement timing. Thus, by changing the position of the welding device main body 46 in the width direction Y, the irradiation position of the laser is more precisely controlled, and the side member 11 and the center member 12 are welded more reliably. Further, in the present embodiment, the conveying speed of the side member 11 and the center member 12 to the welding device 42 is in a range of 0.15 m/min or more and 20 m/min or less.

As shown in Fig. 1, it is more preferable to provide the chamber 52 and the cleaning device 55 on the welding unit 18. The chamber 52 separates the welding device main body 46 and the welding support roller 41 into an external space. The cleaning device 55 cleans the gas. Further, in FIG. 2, the illustration of the chamber 52 and the cleaning device 55 is omitted in order to avoid complication of the drawings. The chamber 52 is provided with a first opening (not shown) for sending the internal gas to the outside, and a second opening (not shown) for guiding the gas cleaned in the cleaning device 55 to the 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 from the first opening to the cleaning device 55, and the cleaning device 55 cleans the gas guided from the chamber 52 and sends it to the chamber 52 through the second opening. As such, the internal gas of chamber 52 circulates with cleaning device 55.

By cleaning the internal gas of the chamber 52, the welding position Pw and its periphery are cleaned, and foreign matter or the like is prevented from entering the welded portion 13w. Further, by maintaining the internal pressure of the chamber 52 higher than the pressure of the external space, it is possible to more reliably maintain the state in which the inside of the chamber 52 is cleaned. Further, by setting the welding position Pw to a position higher than the delivery portion 16, the abutting portion 17, the heating portion 19, and the winding device 20, it is possible to further prevent introduction of foreign matter from these members.

The internal cleanliness of the chamber 52 is, for example, 1000 or less as defined in the U.S. Federal Regulation FED-STD-209D, and more preferably 100 or less.

It is preferable that the heating portion 19 is provided on the downstream side of the welding unit 18. The heating unit 19 is not particularly limited as long as it heats the welded portion 13w of the belt member 13 obtained by welding to a constant temperature range. In the welded portion 13w and its periphery, the stress due to the strain caused by the welding sometimes remains inside. The welded portion 13w and its periphery can be heated by the heating portion 19 to remove stress. By removing this stress, deformation of the welded portion 13w can be suppressed even when the solution film forming method is continuously performed for a long period of time.

The temperature of the heating of the welded portion 13w based on the heating portion 19 is not particularly limited as long as it is a temperature at which stress can be removed. For example, when the belt member 13 is made of stainless steel, the temperature of the heating of the welded portion 13w based on the heating portion 19 is preferably 100 ° C or more and 200 ° C or less, more preferably 120 ° C or more and 180 ° C or less.

As the heating unit 19, for example, there is a blowing means. As shown in FIG. 1, the air blowing means of the heating unit 19 includes a duct 56 and a blower 57. The conduit 56 blows a constant temperature of gas. The blower 57 supplies the gas to the conduit 56 based on the temperature of the control gas. In addition, in FIG. 2, the illustration of the duct 56 and the blower 57 is abbreviate|omitted in order to avoid the complication of a drawing.

The heating portion 19 may be provided on the conveying path of the belt member 13 on the opposite side of the welding support roller 41 as shown in FIG. 1 or on the same side of the welding support roller 41.

The stress-removed belt member 13 is sent to the winding device 20 downstream of the heating portion 19, and is wound into a roll shape. The winding device 20 is provided with a winding core of the take-up belt member 13, and is provided with a driving means for rotating the winding core in the circumferential direction.

The winding device 20 also functions as a welding tension control means for controlling the tension of the belt member 13 and the side members 11 and the center member 12 at the welding position Pw. Here, it is preferable to control the torque of the winding device 20 so that the tension of the belt member 13 and the side members 11 and the center member 12 at the welding position Pw is kept constant. Thereby, the welded portion 13w can be set to a constant state in the longitudinal direction.

When the welding is started, it is preferably carried out, for example, by using the winding device 20 as follows. First, the side member 11 and the center member 12 are provided in the transfer path from the delivery portion 16 to the winding device 20, and the respective ends of the side member 11 and the center member 12 are wound around the winding core of the winding device 20. The winding side member 11 and the center member 12 are started to be wound. The winding is started, the conveying path of the side member 11 and the center member 12 is controlled, and the docking position Ph is maintained at a predetermined position. After the butting position Ph of the side member 11 and the center member 12 is kept constant, the welding is started by the welding device 42.

It is preferable to perform welding while suppressing the positional deviation of the side member 11, the center member 12, and the belt member 13. For example, instead of the welding unit 18, a welding unit 61 as shown in FIGS. 3 and 4 including a pressing device can be used. In the welding unit 61, the welding unit 18 shown in FIGS. 1 and 2 further includes a pressing device 62. Although the displacement mechanism 50, the controller 51, the chamber 52, and the cleaning device 55 are provided in the same manner as the welding unit 18, in order to avoid attachment The complication of the drawings is omitted in FIGS. 3 and 4 . The same components and members as those in FIGS. 1 and 2 are denoted by the same reference numerals as those in FIGS. 1 and 2, and description thereof will be omitted. Further, in the welding unit 61, the chamber 52 surrounds the pressing member 62 and the welding support roller 41 in a manner spaced apart from the external space.

The pressing device 62 suppresses the positional deviation of the side member 11, the center member 12, and the belt member 13 at the welding position Pw. The pressing device 62 presses the side member 11, the center member 12, and the belt member 13 on the welding support roller 41 against the conveyor belt by one of the first conveyor belt 63 and the second conveyor belt 64.

The first conveyor belt 63 and the second conveyor belt 64 are formed as endless belts in a ring shape. The first conveyor belt 63 and the second conveyor belt 64 are wound around the circumferential surfaces of the fifth roller 67 to the seventh roller 69 so as to be aligned in the longitudinal direction of the fifth roller 67 to the seventh roller 69. At least one of the fifth roller 67 to the seventh roller 69 is a driving roller that rotates in the circumferential direction. The first conveyor belt 63 and the second conveyor belt 64 are conveyed while maintaining the conveying path sides parallel to each other by the rotation of the driving roller.

The fifth roller 67 to the seventh roller 69 are disposed such that the rotation axis is parallel to the rotation axis of the welding support roller 41.

The fifth roller 67 to the seventh roller 69 are disposed on the conveying path of the side member 11 and the center member 12 on the side opposite to the side on which the fourth roller 29 and the welding support roller 41 are disposed. The fifth roller 67 is disposed to face the transport path from the fourth roller 29 toward the side member 11 of the welding support roller 41 and the center member 12. The sixth roller 68 is disposed to face the transport path from the welding support roller 41 toward the side member 11 of the heating portion 19 and the center member 12. The seventh blend 69 is appropriately disposed to define a transport path from the sixth roller 68 toward the first conveyor 63 and the second conveyor 64 of the fifth roller 67.

The fifth roller 67 and the sixth roller 68 are disposed so as to press the first conveyor belt 63 and the second conveyor belt 64 from the fifth roller 67 toward the sixth roller 68 to press the side member 11, the center member 12, and the belt member on the welding support roller 41. 13 way to transfer. For example, when the side member 11 and the center member 12 on the welding support roller 41 are welded from above, the fifth roller 67 and the sixth roller 68 are disposed such that their lower ends become lower than the upper end of the welding support roller 41.

The fifth roller 67 and the sixth roller 68 are disposed such that the conveying path of the first conveyor belt 63 faces the conveying path of the side member 11 and the side portion 13s of the belt member 13 formed by the side member 11, and the second conveyor belt 64 The conveying path faces the conveying path of the center member 12 and the center portion 13c of the belt member 13 formed by the center member 12. Thereby, the first conveyor belt 63 presses the side member 11 and the side portion 13s to the welding support roller 41, and the second conveyor belt 64 presses the center member 12 and the center portion 13c to the welding support roller 41.

As described above, the first conveyor belt 63 and the second conveyor belt 64 are respectively disposed to face the welding support roller 41, and are pressed such that the heights of the side members 11 and the center member 12 at the welding position Pw are equal. The height of the side members 11 and the center member 12 is the height of the surface of each of the members 11, 12. Thus, the side member 11 and the center member 12 are pressed so that the height becomes equal, and welding is performed in this state, so that the aspect of the welded portion 13w becomes more uniform in the longitudinal direction, and welding can be further reliably performed.

The long side welding process will be described in further detail with reference to FIGS. 5 and 6. The first conveyor belt 63 and the second conveyor belt 64 are conveyed in a state of being separated from each other. The first conveyor 63 and the second conveyor 64 set the transmission path so that the gap between the first conveyor 63 and the second conveyor 64 is at the welding position Pw. Thereby, the contact position Ps at which the side edge 11e of the side member 11 and the side edge 12e of the center member 12 contact each other passes through the gap between the first conveyor belt 63 and the second conveyor belt 64 as shown in FIG. 5, and is in the first conveyor belt 63 and the 2 Welding between the conveyor belts 64. In addition, the illustration of the welding apparatus main body 46 is abbreviate|omitted by FIG.

The interval D1 between the first conveyor belt 63 and the second conveyor belt 64 is preferably in 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 distance D2 between the contact position Ps and the first conveyor 63, and the distance D3 between the contact position Ps and the second conveyor 64 are set to be 3 mm or more and less than 6 mm, respectively. Preferably.

Instead of the pressing device 62, a roller (not shown) having a rotation axis parallel to the rotation axis of the welding support roller 41 may be disposed upstream and downstream of the welding device main body 46, respectively. At this time, the side member 11 and the center member 12 at the welding position Pw can be pressed by pressing the side member 11 and the center member 12 by one of the upstream rollers and pressing the belt member 13 by the other downstream roller.

As shown in FIG. 6, the welding bead 72 is formed at the contact position Ps and its periphery due to the heat of the welding device 42 being dissolved. Heat is transferred from the welding bead 72 to both sides, and a heat-affected zone 73 which is affected by heat during welding is generated in the side member 11 and the center member 12, respectively. The heat-affected zone 73 sometimes exhibits traits that are different from other zones that are not affected by heat, either immediately or over time. For example, when a heat-affected person is used as a casting support in such a wide range, when the solution film forming method is continuously performed for a long period of time, disadvantages such as deformation of the welded portion 13w or foaming of the cast film occur.

Therefore, as shown in FIG. 5, it is preferable to form the high heat conduction portion 71 composed of a material having a higher thermal conductivity than the side member 11 and the center member 12 in the passing region through which the contact position Ps passes in the circumferential surface of the welding support roller 41. Thereby, the heat from the welding device 42 (refer to FIGS. 3 and 4) can be diffused more quickly. In order to spread heat more quickly on the side of the welding support roller 41, the width of the heat-affected zone 73 of the side member 11 and the center member 12 can be further reduced, or the depth of the heat-affected zone 73 can be made shallower.

It is preferable that the width D4 of the passage region of the high heat conduction portion 71 is in the range of 26 mm or more and 32 mm or less.

Further, it is preferable that both surfaces of the first conveyor belt 63 and the second conveyor belt 64 have a high heat conduction portion having a higher thermal conductivity than the materials of the side members 11 and the center member 12. Thereby, the size of the heat-affected zone 73 can be reduced in the width direction or the thickness direction.

It is preferable that the side edge 11e of the side member 11 and the side edge 12e of the center member 12 are adhered to a gap of 0 (zero) at the welding position Pw. Therefore, it is preferable that the side member 11 and the center member 12 are formed in advance so as not to form a gap when the side edges 11e and 12e are butted. Thereby, it is possible to more reliably manufacture the belt member having no gap in the welded portion.

The above-described long-side welding process may be a continuous welding process in which welding is continuously performed only in the longitudinal direction of the side members 11 and the center member 12. In addition, a intermittent welding process of intermittent welding may be performed. If the welding is intermittent, the side member 11 and the center member 12 continuously fed to the welding device 42 are intermittently welded. This intermittent soldering process is preferably performed prior to the continuous soldering process. At this time, in the intermittent welding process, first, the side member 11 and the center member 12 are temporarily joined, and then the entire area in the longitudinal direction is joined in the continuous welding process.

When the joining is performed in the continuous welding process after the temporary joining in the intermittent welding process, the side member 11 and the center member 12 are guided from the butting portion 17 (refer to Figs. 1, 2) to the welding unit 18 and intermittently welded. Further, when the opposite side member 11 and the center member 12 are set to the surface corresponding to the casting surface when used as the rear casting support and the inner surface corresponding to the non-casting surface, the welding in the intermittent welding process is performed for the inside. It is better. Therefore, the side member 11 and the center member 12 are conveyed in such a manner that the inside faces the welding device main body 46 (refer to FIG. 1).

After the intermittent welding process, the winding device 20 is guided and taken up. Further, the welded portion may be heated by the heating portion 19 before winding. A temporary joining member (not shown) composed of the side member 11 and the center member 12 wound by the intermittent welding process is wound up by a feeding device (not shown), and sent to the welding unit 18 again. This delivery is performed such that the surface of the temporary welding member faces the welding device main body 46 (refer to FIG. 1). Continuous welding is performed in the welding unit 18 to obtain the belt member 13. Further, instead of this method, two welding units 18 may be arranged in the upstream and downstream directions, and intermittent welding may be performed by one of the upstream welding units 18, and continuous welding may be performed by the other welding unit 18 downstream.

When welding is performed, the welding bead 72 may be formed more convex than the side member 11 and the center member 12. Therefore, the welding support roller 41 used in the first process of welding one of the faces in the longitudinal direction and the second process of welding the other face in the longitudinal direction is as shown in FIG. It is preferable that a groove 76 is formed in the peripheral surface of the roller 41 at a passing region through which the contact position Ps passes. The second process may be carried out by transporting the side member 11 and the center member 12 so that the welded portion formed by the welding bead 72 raised in the first process passes through the groove 76. Thereby, the belt member 13 which is smoother and has less residual stress can be obtained. As a result, even if it is used for film formation in a solution, deformation or shape change is less in the belt as the casting support, and the cast film is not foamed, and a film having no thickness unevenness can be more reliably produced.

The width D5 of the groove 76 is preferably in the range of 6 mm or more and 12 mm or less, and the depth D6 of the groove may be about 1 mm.

In the above embodiment, the third roller 28 is used as a means for adjusting the conveying path of the side member 11 on the abutting portion 17, but the third roller 28 may be replaced by a tapered roller 81 as shown in FIG. The tapered roller 81 is a cross-sectional circular roller formed in such a manner that the diameter d continuously decreases from one end toward the other end. The diameter d is continuously decreased in a constant ratio from one end toward the other end. The tapered roller 81 is disposed such that the one end having the larger diameter d faces the conveying path of the center member 12 and the other end having the smaller diameter d faces the opposite side of the center member 12 (the conveying path side of the side member 11).

The side member 11 during conveyance changes the conveyance path toward the center member 12 by the contact with the tapered roller 81, and approaches the center member 12. Thereby, the side member 11 is reliably conveyed toward the docking position Ph (refer to FIGS. 1 and 2).

It is preferable that the tapered roller 81 is provided with a driving means 82 that rotates in the circumferential direction. The rotating shaft is inserted through the center of one end surface and the center of the other end surface. The side member 11 is conveyed by the tapered roller 81 rotated by the driving means 82, so that the side member is more effectively approached to the central member 12.

Instead of the third roller 28, a clip 85 as a holding means as shown in Fig. 8 can be used. The clip 85 has an opening The clip-shaped main body 86 and the pair of gripping fingers 87 provided at the respective distal end portions of the clip main body 86 grip the grip side member 11. The gripping needle 87 is movably disposed between the gripping position of the grip side member 11 and the retracted position retracted from the gripping position. The clip 85 is provided with a moving mechanism 88 that is movable between a grip start position at which gripping is started and a grip release position at which gripping is released. Further, the clip 85 is also freely movable in the width direction Y.

As the gripping needle 87 moves toward the gripping position, the clip 85 grips the side member 11 at the gripping start position. The clip 85 approaches the direction A of the holding side member 11 toward the center member 12, and is conveyed downstream.

The tapered roller 81 and the clip 85 are used to bring the side member 11 toward the center member 12, and may be used in order to bring the center member 12 closer to the side member 11. At this time, the central member 12 may be supported or conveyed by the tapered roller 81 and the clip 85.

In the above embodiment, the two side members 11 are simultaneously welded to the center member 12. However, one of the side members 11 may be welded to the center member 12, and the other side member 11 may be welded to the center member 12.

As shown in Fig. 9, the belt 91 used as the casting support is a ring-shaped endless belt. One end and the other end in the longitudinal direction of the 91-series welded belt member 13 are formed. Further, the belt member 13 for producing the belt 91 can be cut to a predetermined length, and when the belt member 13 is produced from the side member 11 and the center member 12 which are previously cut to a predetermined length, the belt 91 can be produced in an unsheared state. The pinhole diameter in the welded portion is preferably less than 40 μm.

It is preferable to cut the belt member 13 in a direction crossing the width direction Y. It is more preferable that the tape member 13 is cut so that the angle formed by the shear direction and the width direction Y is approximately 5 or more and 15 or less. An angle θ2 between one end in the longitudinal direction of the strip member 13 to be welded and the welded portion 91v and the width direction Y at the other end is in a range of approximately 5° or more and 15° or less. In the annular welding process in which the elongated belt member 13 is formed into a ring shape, the welding device 42 used in the long-side welding process can be used, and other known welding devices can be used.

The belt 91 manufactured by welding includes a side portion 91s formed by the side members 11 (refer to Figs. 1 to 8) and a central portion 91c formed by the center member 12 (refer to Figs. 1 to 8), a side portion 91s and a central portion The welded portion 91w of the 91c is exposed on the surface 91a or the inner surface 91b of the belt. The welded portion 91w corresponds to a portion of the welded portion 13w. It is preferable that the linear welded portion 91w is provided in parallel with the longitudinal direction of the belt 91. The width of the belt 91 thus obtained is in the range of 2000 mm or more and 3000 mm or less.

The obtained belt 91 is used for a solution film forming apparatus after being surface-ground and mirror-finished. Next, a method of producing a film in a solution film forming apparatus will be described below. The type of the polymer is not particularly limited, and a known polymer which can form a film in a solution film formation may be used. In the following embodiments, a case where a cellulose halide is used as a polymer will be described as an example.

As shown in FIG. 10, the solution film forming apparatus 110 includes a film forming apparatus 117, a first tenter 120, a roll drying device 124, a second tenter 125, a slitter 126, and a winding device 127 in this order from the upstream side. The film forming apparatus 117 forms a film 116 from the dope 113 obtained by dissolving the cellulose halide 111 in the solvent 112. The first tenter 120 is dried while holding the side portions of the film 116 by the holding member 120a. The roll drying device 124 is dried while supporting the film 116 by a plurality of rolls 122. The second tenter 125 holds the side portions of the film 116 by the holding member 125a, and applies tension to the film 116 in the width direction. The slitter 126 cuts off the edges held by the holding members 125a of the second tenter 125. The winding device 127 rolls the film 116 on the cut edge onto the core to form a roll.

The film forming apparatus 117 includes a pair of film forming rollers 131 and 132 that rotate in the circumferential direction. The pair of film forming rollers 131 and 132 are arranged in parallel with each other on the horizontal surface, and the film forming roller 131 and the film forming roller 132 are formed. The upper belt 91 is wound. The film forming roller 131 is a driving roller (driving roller), and the film forming roller 132 is a free roller. Each of the film forming rollers 131 and 132 includes a first controller (not shown) and a second controller (not shown) that control the peripheral surface temperature within a predetermined temperature.

In the film forming apparatus 117, a casting die 133 that discharges the dope 113, a film drying device 134, and a peeling roller 135 are sequentially disposed from the upstream side toward the downstream side in the moving direction of the belt 91.

As shown in FIG. 11 and FIG. 12, the casting die 133 is configured such that the dope 113 (see FIG. 10) flows toward the surface 91a of the belt 91 supported by the film forming roller 131. The casting die 133 is provided at the front end with an outflow port 133a through which the dope 113 (refer to Fig. 10) flows. The casting die 133 is disposed such that the outflow port 133a faces the surface 91a of the belt 91.

The dope 113 (refer to FIG. 10) flowing down from the casting die 133 falls on the arrival position DP on the surface 91a of the belt 91. Since the belt 91 is in a moving state, the dope 113 (refer to FIG. 10) that has fallen on the reaching position DP flows and extends in the casting zone CA set on the surface 91a of the belt 91. Thus, a casting film 136 composed of the dope 113 (refer to FIG. 10) and having a casting width CW is formed in the casting zone CA.

The casting die 133 is disposed such that the arrival position DP becomes a position as described below. As shown in FIGS. 11 and 13, the arrival position DP is set to a portion of the surface 91a of the belt 91 that is supported by the film forming roller 131. It is preferable that the arrival position DP is set to be on the upstream side in the moving direction of the feed belt 91 from the top TP of the film forming roller 131. Further, the direction from the rotation center O _131a rotating shaft 131a of the plane L _TP extending the top TP angle L _DP by an angle of orientation reaches surface extending the position DP from the rotation center O _131a rotating shaft 131a of φ1 less than 0 ° 45 ° The following are preferred.

As shown in FIG. 10, the membrane drying device 134 has a first duct 141 to a third duct 143. The first duct 141 to the third duct 143 that send dry air toward the casting film 136 are sequentially disposed from the upstream side along the movement path of the belt 91. The first duct 141 is provided on the surface 91a side and the inner surface 91b side of the belt 91 that moves from the film forming roller 131 to the film forming roller 132. The second duct 142 is provided on the surface 91a side of the belt 91 supported by the film forming roller 132. The third duct 143 is provided on the surface 91a side and the inner surface 91b side of the belt 91 that moves from the film forming roller 132 toward the film forming roller 131.

Each of the first to third conduits 141 to 143 is connected to a blower (not shown). A blower controller (not shown) that independently controls the temperature, humidity, and flow rate of the gas supplied to the first to third conduits 141 to 143 is connected to the blower. The first to third conduits 141 to 143 are provided with a delivery port that sends the gas supplied from the blower as dry air. The delivery ports provided in the first to third conduits 141 to 143 are formed to face the surface 91a and the inner surface 91b of the belt 91.

The outflow ports provided in the first duct 141 to the third duct 143 are formed in a slit shape, and are extended from one end of the belt 91 to the other end. The length of each of the outflow ports in the width direction of the belt 91 may be such that the dry air contacts the entire casting film 136.

The temperature of the dry wind is preferably lowered as it goes from the upstream side to the downstream side of the moving path of the belt 91. The temperature of the dry air from the first duct 141 is preferably 50° C. or higher and 140° C. or lower, and the temperature of the dry air from the second duct 142 is preferably 50° C. or higher and 140° C. or lower, and the dry air from the third duct 143 is preferably used. The temperature is preferably from 40 ° C to 100 ° C.

As shown in Fig. 11, the film forming roller 131 is composed of a rotating shaft 131a and a roller main body 131b fixed to the rotating shaft 131a. The structure of the film forming roller 132 is the same as that of the film forming roller 131. As shown in FIG. 12, the motor 171 and the driving portion 172 are connected to the rotating shaft 131a. The film forming roller 131 is rotated about the rotating shaft 131a by the motor 171. The driving unit 172 applies an external force from the film forming roller 132 (refer to FIG. 10) toward the film forming roller 131 to the rotating shaft 131a. The external force F1 is applied to the rotating shaft 131a, and the moving tension T1 is applied to the belt 91. Further, a force sensor 173 is attached to the rotating shaft 131a. The force sensor 173 detects the magnitude of the external force F1 that the rotating shaft 131a receives. The control unit (not shown) calculates the movement tension T1 by the force sensor 173 detecting the external force F1 with the value stored in the internal memory. The magnitude of the moving tension T1 may be determined according to the size of the belt 91 or the moving path, for example, 60 N/mm ² .

Next, a solution film forming method by the solution film forming apparatus 110 will be described. In the solution film forming method, a film forming process, a film drying process, a peeling process, and a film drying process are sequentially performed. Further, "film" means a film located on the belt 91, and "film" means a film peeled off from the belt 91.

As shown in Fig. 11, in the film forming process, the casting die 133 continuously flows out of the dope 113 to the surface 91a of the belt 91 (refer to Fig. 10). A casting film 136 composed of the dope 113 and having a casting width CW (refer to FIG. 12) is formed in the casting zone CA (refer to FIG. 12) by a film forming process.

As shown in FIGS. 10 and 11, in the film forming process, the first duct 141 sends dry air toward the casting film 136 and the inner surface 91b of the belt 91, and the second duct 142 sends dry air toward the casting film 136, and the third duct 143 Dry air is sent toward the casting film 136 and the inner surface 91b of the belt 91. If the dry wind contacts the casting film 136, the solvent 112 evaporates from the casting film 136. Further, the inner surface 91b of the belt 91 is heated by the contact of the dry air, and as a result, the evaporation of the solvent from the casting film 136 is promoted. Further, the peripheral surface temperature of the film forming roller 132 is adjusted to be higher than the temperature of the casting film 136 by the second controller. The heat of the film forming roller 132 is transferred to the casting film 136 by the contact with the film forming roller 132, and the belt 91 is heated from the inner surface 91b side. In this way, evaporation of the solvent from the casting film 136 is promoted.

In the peeling process, the casting film 136 which is peeled off from the belt 91 in a state containing a solvent to the extent that it can be conveyed to the first tenter 120 is removed by evaporation of the solvent. At the time of peeling, the film 116 is supported by the peeling roller 135, and the peeling position PP at which the casting film 136 is peeled off from the belt 91 is kept constant. Further, the peeling roller 135 may be a driving roller that is provided with a driving means and that rotates in the circumferential direction.

The temperature of the belt 91 of the peeled casting film 136 becomes higher than the temperature of the concentrated liquid 113 flowing out from the casting die 133 by the film drying device 134. If the concentrated liquid 113 is directly discharged from the belt 91, foaming of the concentrated liquid 113 is caused. Therefore, the temperature of the peripheral surface of the film forming roller 131 is adjusted to be lower than the temperature of the concentrated liquid 113 flowing out from the casting die 133 by the first controller. Thereby, the temperature of the belt 91 supported by the film forming roller 131 becomes lower than the temperature of the concentrated liquid 113 flowing out from the casting die 133, so that the foaming of the dope 113 can be prevented.

The peeled cast film 136, that is, the film 116 is sequentially guided to the first tenter 120, the roll drying device 124, and the second tenter 125. A film drying process in which the film 116 is brought into contact with a predetermined dry gas is performed in the first tenter 120, the roll drying device 124, and the second tenter 125. Drying of film 116 is carried out by a film drying process.

The slitter 126 performs a trimming process for cutting the edges of the film 116. The film 116 of the cut edge is wound into a roll shape by the winding device 127.

(with inspection device)

Next, a tape inspection device for inspecting whether or not the thickness of the tape 91 is caused by the warpage of the tape 91 when the tape 91 manufactured by the tape manufacturing apparatus 10 (refer to FIG. 1) is used in the solution film forming method will be described.

As shown in FIGS. 14 and 15, the tape inspection device 200 includes a pair of inspection rollers 201 and 202, a displacement unit 203, a motor 205, a driving unit 206, a force sensor 207, a sensor unit 208, and a control unit 210 ( Refer to Figure 16).

The pair of inspection rollers 201 and 202 are used to wind the belt 91 to be inspected, and are arranged in parallel on the horizontal plane. The inspection roller 201 is a driving roller, and the inspection roller 202 is a free roller. The shape and size of the inspection rollers 201 and 202 are preferably the same as those of the film forming rollers 131 and 132. For example, it is preferable that the diameters of the inspection rollers 201 and 202 are the same as the diameters of the film forming members 131 and 132.

In addition, even when the diameters of the inspection rollers 201 and 202 are different from the diameters of the film forming rollers 131 and 132, the vertical stress acting on the belt 91 wound around the inspection rollers 201 and 202 acts on the winding. The present invention can be applied to the condition that the vertical stress of the belt 91 of the film forming rolls 131 and 132 is equal. The vertical stress N acting on the belt 91 wound on the roller of the diameter Dr can be expressed by the following formula. Among them, T1 is the moving tension of the belt 91, and THb is the thickness of the belt 91.

N=THb×T1/0.5Dr

The inspection roller 201 is composed of a rotating shaft 201a and a roller main body 201b that is axially coupled to the rotating shaft 201a. The inspection roller 202 is composed of a rotating shaft 202a and a roller main body 202b that is axially coupled to the rotating shaft 202a.

The rotating shaft 202a is freely movable between the tension applied position Pt and the slack position Pr (refer to FIG. 17). The tension applied position Pt is a position at which a predetermined tension is applied to the belt 91 wound around the inspection rollers 201, 202. The slack position Pr is a position where the belt 91 wound around the inspection rollers 201 and 202 is slack. The driving unit 206 applies a force F2 from the roller main body 202b toward the roller main body 201b to the rotating shaft 201a. By applying an external force F2 to the rotating shaft 201a, a moving tension T2 is applied to the belt 91 wound around the inspection rollers 202, 201. The force sensor 207 detects the magnitude of the external force F2 that the rotating shaft 201a receives.

The measurement position MP1 extending in the width direction of the belt 91 is set on the surface 91a of the belt 91 supported on the inspection roller 201. The measurement position MP1 corresponds to the arrival position DP (refer to FIG. 11). That is, the angle of the face direction measurement position M of MP1 _MP1 extends and an angle from the rotation axis center O of surfaces _201a 201a extends M _TP TP of the top roller 201 φ2 from the rotation center O of the rotating shaft 201a _201a toward the inspection Equal to the angle φ1 (refer to Figure 11).

The measurement position MP2 is set on the circumferential surface 201bx. The measurement position MP2 is the intersection of the surface M _MP1 and the axial end portion 201be.

The sensor unit 208 is disposed on the side of the surface 91a of the belt 91, that is, on the surface M _MP1 . The sensor unit 208 includes a measurement window 208a that is opposite to the measurement position MP1. The measurement window 208a extends from one end in the axial direction of the roller main body 201b of the support belt 91 to the width direction of the belt 91 over the other end.

Also, the sensor unit 208 is provided with a distance sensor 208x and a reference position detecting sensor 208y. The distance sensor 208x measures the distance from the measurement window 208a to the measurement position MP1 or the distance from the measurement window 208a to the measurement position MP2. The reference position detecting sensor 208y detects whether or not the reference position set on the surface 91a of the belt 91 is at the measuring position MP1. The distance sensor 208x has a sensing device (not shown), a built-in CPU (not shown), and a built-in memory (not shown). As the reference position detecting sensor 208y, for example, a reflective photo sensor can be utilized. The reference position set on the surface 91a of the belt 91 will be described later.

The thickness measurement lines ST(j) [j = 1, 2, 3, ..., n) extending in the width direction of the belt 91 are set to be aligned in the longitudinal direction of the belt 91. Further, the thickness measurement lines SM(i) [i = 1, 2, 3, ..., m) extending in the longitudinal direction of the belt 91 are set to be aligned in the width direction of the belt 91. Further, the interval between the adjacent thickness measurement lines ST and the interval between the adjacent thickness measurement lines SM are set to a predetermined value in advance.

As shown in FIG. 16 , the control unit 210 includes a CPU 211 , a storage unit 212 , a distance calculation unit 216 , a floating amount calculation unit 217 , and a determination unit 218 .

The CPU 211 is electrically connected to the storage unit 212 or the respective units 216 to 218 via the bus 222. A program or each material is stored in the storage unit 212. As a program stored in the storage unit 212, there is a check program for the tape or the like. Further, as the data stored in the storage unit 212, the tape thickness information 225 (refer to FIG. 18), the threshold value TH1, the movement tension T1, and the like are included.

As shown in FIG. 18, the tape thickness information 225 is composed of the position information MD of each thickness measurement line ST (refer to FIG. 15) and the thickness distribution information DB of the belt 91 on each thickness measurement line ST (refer to FIG. 15). The positional information MD indicates the distance L(j) from the reference position B1 (refer to FIG. 15) to the arbitrary thickness measurement line ST(j) in the longitudinal direction of the belt 91 (refer to FIG. 15). Here, the reference position B1 is exposed to the welded portion 91v of the surface 91a of the belt 91 (refer to FIG. 15).

The thickness distribution information DB is composed of the thickness measurement value D of the belt 91 at each intersection P of the thickness measurement line ST and the thickness measurement line SM, and the measurement value D is grouped for each thickness measurement line ST. For example, when the measured value of the thickness of the belt 91 on the intersection P(i, j) of the arbitrary thickness measurement line ST(j) and the arbitrary thickness measurement line SM(i) is expressed as D(i, j), any The thickness distribution information DB(j) of the thickness measurement line ST(j) includes D(1, j), D(2, j), D(3, j), ..., D(i-1). , j), D(i, j), D(i+1, j), ..., D(m, j). Further, the measured value D(i, j) can be obtained in advance by an ultrasonic sensor or the like.

As shown in FIG. 16, the distance calculating unit 216 calculates the distance H from the circumferential surface 201bx of the roller main body 201b to the surface 91a of the belt 91 according to the formula (2) (refer to FIG. 19).

Formula (2) is H=B-A.

A is the distance from the measurement window 208a to the measurement position MP1 (refer to FIG. 19), and B is the distance from the measurement window 208a to the measurement position MP2 (refer to FIG. 19).

The floating amount calculation unit 217 calculates the floating amount CL from the circumferential surface 201bx to the inner surface 91b of the belt 91 according to the formula (1) (refer to FIG. 20).

Formula (1) is CL=H-D.

The determination unit 218 determines whether or not all of the CLs calculated by the floating amount calculation unit 217 are equal to or smaller than the threshold TH1. The threshold TH1 is stored in the storage unit 212. The threshold TH1 may be determined according to the target quality of the belt 91. In the solution film forming method, in order to suppress the thickness unevenness failure or the peeling residual failure or foaming due to the thickness unevenness failure, it is preferable to set the threshold TH1 to 0.1 mm or less.

Next, a tape inspection process 230 (refer to FIG. 21) in the tape inspection apparatus 200 shown in FIG. 14 will be described.

First, the displacement portion 203 sets the rotation shaft 202a at the slack position Pr (refer to FIG. 17). The tape 91 to be inspected is hung on the inspection rollers 201 and 202. Thereafter, the displacement portion 203 sets the rotation shaft 202a at the tension application position Pt (S10 of Fig. 21).

As shown in FIGS. 15 and 16, the drive unit 206 applies an external force F2 to the rotating shaft 201a under the control of the control unit 210. The force sensor 207 detects the external force F2. The control unit 210 reads the external force F2 from the force sensor 207 and reads the value BS from the storage unit 212. The average cross-sectional area Sav of the value BS strap 91 is multiplied by 2 to obtain. Next, the control unit 210 divides the external force F2 by the value BS to calculate the movement tension T2. Moreover, the control unit 210 adjusts the magnitude of the external force F2 so that the calculated movement tension T2 becomes the same as the movement tension T1 read from the storage unit 212. Thus, the same movement tension as that at the time of film formation is applied to the belt 91 (S11 of Fig. 21).

As shown in FIGS. 14 and 15, when the motor 205 rotates the rotating shaft 201a, the belt 91 moves in the longitudinal direction. The reference position detecting sensor 208y emits test light to the measurement position MP1 using the light source. The test light emitted from the reference position detecting sensor 208y is reflected at the measurement position MP1 and becomes reflected light incident on the measurement window 208a. The reference position detecting sensor 208y detects the amount of reflected light incident from the measuring window 208a. When the amount of reflected light detected is less than the reference amount, the built-in CPU transmits a reference position detection signal to the CPU 211. Here, the reference amount is the amount of reflected light on the surface 91a of the belt 91 other than the reference position B1 when the test light is irradiated on the measurement position MP1. In this way, the reference position detecting sensor 208y performs the detection of the reference position B1 at the measurement position MP1 (S12 of Fig. 21).

The CPU 211 rotates the inspection roller 201 through the motor 205 only for a predetermined time t1 from the timing of receiving the reference position detection signal. By the rotation of the inspection roller 201, the belt 91 of the distance L corresponding to the time t1 is sent in the longitudinal direction. For example, when only the belt 91 having the distance L(j) is sent from the reference position B1, the thickness measurement line ST(j) is located at the measurement position MP1 (S13 in Fig. 21).

As shown in FIG. 19, the sensor unit 208 measures the distance from the surface 91a of the belt 91 to the measurement window 208a at the intersection point P (refer to FIG. 15) at each measurement position MP1 by the distance sensor 208x (refer to FIG. 16). A (S14 of Fig. 21). For example, when the thickness measurement line ST(j) is located at the measurement position MP1 (refer to FIG. 15), the distance sensor 208x (refer to FIG. 16) measures the intersection P(i, j) on the thickness measurement line ST(j) [ The distance A(i,j)[i=1,2,3,...m] on i=1, 2, 3, ... m].

Further, the sensor unit 208 measures the distance B from the axial end portion 201be to the measurement window 208a at the measurement position MP2 (refer to FIG. 15) by the distance sensor 208x (refer to FIG. 16). When the thickness measurement line ST(j) is located at the measurement position MP1, the distance sensor 208x (refer to FIG. 16) measures the distance B(j) from the axial end portion 201be to the measurement window 208a (S15 of FIG. 21). Further, if the measurement point of the distance B(j) is a point set at the measurement position MP2, it may be one point or a plurality of points. When the measurement point of the distance B (j) is set to one point, the measured value at the measurement point may be set to the distance B (j). Further, when the measurement point of the distance B(j) is set to a plurality of points, the average value of the measured values at the respective measurement points can be set to the distance B (j).

The measured values of the distance A and the distance B are stored in the storage unit 212 (refer to FIG. 16) (S16 of FIG. 21).

The CPU 211 determines whether or not the measurement of all the thickness measurement lines ST is completed (S17 of Fig. 21). When it is determined that the measurement regarding all the thickness measurement lines ST is ended, the process proceeds to the next process (S20 of Fig. 21). On the other hand, when it is determined that the measurement of all the thickness measurement lines ST has not been completed, the step of moving the belt 91 to the next thickness measurement line ST to the measurement position MP1 (S18 of FIG. 21) and the thickness measurement are repeatedly performed. The line ST performs a series of steps (S14 to S16).

The distance calculating unit 216 calculates the distance H from the axial end portion 201be to the surface 91a of the belt 91 (refer to FIG. 20) according to the formula (2) (S20 of FIG. 21). The calculated distance H is stored in the storage unit 212 (refer to 16).

Equation (2) is H(i,j)=B(j)-A(i,j).

[j=1,2,3,...n][i=1,2,3,...m]

The floating amount calculation unit 217 reads the thickness information 225 of the tape from the storage unit 212, and calculates the floating amount CL(i, j) (refer to FIG. 21) according to the formula (1) (S21 of FIG. 21). The calculated floating amount CL is stored in the storage unit 212 (refer to FIG. 16).

Equation (1) is CL(i,j)=H(i,j)-D(i,j).

[j=1,2,3,...n][i=1,2,3,...m]

The determination unit 218 determines whether or not all the floating amounts CL(i, j) of the belt 91 are equal to or smaller than the threshold TH1 (S22 in Fig. 21). When it is determined that all the floating amounts CL(i, j) are equal to or less than the threshold TH1, it is determined that the belt 91 is "good product" (S23 of Fig. 21). On the other hand, it is determined that the belt 91 outside the allowable range is judged as "non-conforming product" (S24 of Fig. 21). Outside the allowable range means that at least one of the floating amounts CL(i, j) is greater than the threshold TH1.

When the belt 91 judged to be "nonconforming product" is used in the solution film forming method, thickness unevenness occurs in the casting film 136. In the present invention, since the produced tape 91 is inspected based on the floating amount CL under the same conditions as the film forming conditions, it is possible to detect whether or not the tape is caused to cause uneven thickness of the casting film 136 without performing the solution film forming method.

Further, as shown in FIG. 11 and FIG. 12, a decompression chamber 237 that decompresses the back side of the liquid droplet (the upstream side in the moving direction of the belt 91) on the back side of the casting die 133 can be provided on the upstream side in the moving direction of the casting die 133. Among them, the liquid bead is formed by passing the concentrated liquid flowing out from the casting die 133 from the outflow port 133a over the surface 91a of the belt 91. By the decompression chamber 237, it is possible to suppress the vibration of the bead caused by the wind accompanying the movement of the belt 91 in the vicinity of the surface 91a of the belt 91 and the moving direction of the belt 91, and it is possible to prevent the thickness of the casting film or the film even. Not equal. When the moving speed of the belt 91 exceeds 30 m/min, the vibration of the liquid bead caused by the wind is a problem. Therefore, when the moving speed of the belt 91 exceeds 30 m/min, it is preferable to provide the decompression chamber 237.

The decompression chamber 237 is disposed closer to the upstream side than the casting die 133 in the moving direction of the belt 91, and is disposed closer to the surface 91a of the belt 91 in the normal direction of the surface 91a of the belt 91. The interval between the decompression chamber 237 and the surface 91a of the belt 91 is, for example, 0.7 mm or less. A decompression fan (not shown) for sucking the gas in the decompression chamber 237 is connected to the decompression chamber 237 through a suction pipe.

The decompression chamber 237 is composed of a box-shaped chamber main body, a sealing member for improving the sealing property in the chamber main body, and a rectifying member for rectifying the flow of the gas in the decompression chamber 237 in a predetermined direction. The room main system is used to surround the back side of the liquid bead, and has an upstream side windshield 237a, a pair of side windshields 237b, a top plate 237c, and a front panel. The upstream side windshield 237a is disposed in a posture that is erected with respect to the surface 91a of the belt 91, on the upstream side in the moving direction of the belt 91 than the outflow port 133a (refer to FIG. 11), in the normal direction of the surface 91a of the belt 91 Near the surface 91a of the belt 91. The upstream side windshield 237a extends from the side of one of the belts 91 to the other side, and both end portions of the upstream side windshield 237a are opposed to the side portions. Each of the pair of side windshields 237b is extended from the both end portions of the upstream side windshield 237a toward the downstream side in the moving direction of the belt 91 in a posture in which the surfaces of the opposite side portions are erected. A pair of side windshields 237b are hung around the top plate 237c and the front panel.

The decompression chamber main body is formed by the upstream side windshields 237a and 1 and the side windshield 237b, the top plate 237c, and the front panel, and has a suction port (not shown) that opens toward the surface 91a of the belt 91. The decompression chamber 237 attracts a gas located on the upstream side of the liquid droplet from the suction port by a pressure reducing fan (not shown). As a result of attracting the gas located on the upstream side of the liquid bead, the air pressure on the upstream side of the liquid bead drops, and the pressure difference ΔP between the upstream side and the downstream side of the liquid bead can be generated. By the pressure difference ΔP, it is possible to suppress the vibration of the bead which is generated in the vicinity of the surface 91a of the belt 91 in the moving direction of the belt 91 as the belt 91 moves, and even the cast film or the film can be prevented. The thickness is not uniform.

As shown in FIGS. 11 and 13, a pressure reducing area BA is formed on the surface 91a of the belt 91. The decompression zone BA is a portion of the surface 91a of the belt 91 supported by the film forming roller 131 covered by the decompression chamber 237.

At this time, the belt inspection device 200 (see FIG. 14) performs the measurement of the floating amount CL of the measurement position MP1, and also performs the floating amount CL on the measurement position MA (refer to FIG. 15) corresponding to the pressure reduction area BA. The measurement is preferably. More specifically, it is preferable to set the measurement line ML extending in the width direction at the measurement position MA set on the surface 91a of the belt 91, and perform the above-described tape inspection process 230 (refer to FIG. 21) for each of the measurement lines ML. It is preferable that the measurement line ML is arranged from the flow end in the moving direction of the belt 91 at the measurement position MA to the moving downstream end of the belt 91. Thereby, the inspection of the belt 91 can be performed over the entire area of the measurement position MA.

The measurement position MA is set on the surface 91a of the belt 91 supported on the inspection roller 201. 11 and 22, the angle and the plane surface _L BAu L _TP are angled to extend toward the area BA reduced pressure from the rotation center O _131a to the upstream end of the moving direction of the belt 91 equal _BAu φ BAu from the rotation center O _201a An angle φ _{MAu at} which the surface L _MAu extending toward the upstream end MAu of the belt 91 of the measurement position MA is at an angle with the plane L _TP . And, φ _BAd from the rotation center O _{131a BAd} orientation angle and the plane surface L L _TP extends the downstream end of the moving direction of the belt 91 BAd pressure area BA is equal to the angular position of the belt 91 toward MA measured from the rotation center O _201a The angle φ _{MAd at} which the surface M _{MAd of the} downstream end MAd of the moving direction is at an angle with the plane M _TP .

When the belt 91 in which the floating amount CL at the measurement position MA exceeds the threshold TH1 is used in the solution film forming method, the sealing property of the decompression unit varies depending on the movement of the belt 91. Further, as a result of the vibration of the liquid bead due to the variation in the sealing property of the decompression unit, uneven thickness of the cast film is caused. Therefore, the floating amount CL is measured by the measurement position MA (refer to FIG. 22) corresponding to the pressure reduction zone BA, and the tape 91 is inspected over the entire area of the measurement position MA, and it is possible to detect whether or not the solution film formation method is performed. In order to induce uneven thickness of the cast film.

Next, an example of a method of setting the thickness measurement line SM will be described. In Fig. 23, the band in which the warpage is not generated, that is, the band in which the floating amount CL is "0" indicates the distance data detected by the sensing device of the distance sensor 208x, and in Fig. 24, the warpage is generated. The strip shows the distance data detected by the sensing device of the sensor 208x. 23 and 24 show the position of the belt 91 in the width direction, and the vertical axes of Figs. 23 and 24 indicate the distance detected by the sensing device.

The sensing device of the distance sensor 208x measures the distance from the measurement window 208a to the surface 91a or the axial end portion 208be of the belt 91 from one end in the width direction to the belt 91 at the other end. The built-in CPU of the distance sensor 208x reads the data (hereinafter referred to as distance data) of the distance measured by the sensing device from the outer side in the width direction of the one side toward the center side in the width direction to the outer side in the width direction. Next, the built-in CPU determines the initial value E1 in the distance data as the end of the axial end portion 201be, and determines the peak value E2 as the end of the belt 91. The initial value E1 is an initial value portion that is initially detected by the built-in CPU that is read from the outer side in the width direction of one of the width directions to the outer side in the width direction, and the peak value E2 indicates the position of the maximum value in the distance data.

Next, the built-in CPU selects an arbitrary distance data between the position of the initial value E1 and the position which is only a predetermined amount away from the initial value E1 toward the center in the width direction. Moreover, the distance B is calculated based on the selected distance data.

Further, the built-in CPU selects an arbitrary distance data between the position of the peak E2 and the position from the peak E2 to the center side in the width direction by only a predetermined amount ε. Thus, the built-in CPU calculates the distance A based on the selected distance data.

The thickness measurement line SM is located at the extreme end in the width direction of the belt 91, that is, the thickness measurement line SM (1) or the thickness measurement line SM (m) is set at a position corresponding to the peak E2 in FIG. 23 or FIG. That is, the end of one of the belts 91 or the other end is preferred. Thereby, the built-in CPU can recognize the position of the peak E2 as the thickness measurement line SM(1) or the thickness measurement line SM(m). In addition, since the interval ε of the adjacent thickness measurement lines SM can be set in advance, the position from the peak E2 to the center in the width direction only a predetermined distance can be regarded as the thickness measurement line SM (2) or the thickness measurement line SM (m). -1).

In this manner, even if the end portion of the belt 91 in the width direction is warped, the error in the position of the thickness measurement line SM in the width direction can be minimized.

In the above embodiment, the thickness measurement line SM is set based on one end or the other end of the belt 91. However, the present invention is not limited thereto, and a portion where warpage does not occur (for example, the width direction of the belt 91) may be employed. Based on the center portion, the thickness measurement line SM is set at a position away from the portion only by a predetermined distance. Further, in the case of the belt 91 having the welded portion 91w, the thickness measurement line SM may be set at a position away from the portion by a predetermined distance from the position of the welded portion 91w. Further, the thickness measurement line SM may be set at a position away from the predetermined distance by the other mark set on the surface 91a of the belt 91 as a reference.

The tape inspection process 230 can be applied to the tape 91 having only the welded portion 91v and the tape 91 having the welded portion 91v and the welded portion 91w.

In the above-described film forming apparatus 117 (refer to FIG. 10), the arrival position DP and the peeling position PP are set on the surface 91a of the belt 91 supported by the film forming roller 131, but the present invention is not limited thereto. For example, the film forming roller 131 may be replaced by the reaching support roller and the peeling support roller. At this time, on the surface 91a of the belt 91 which is hung on the support roller and the peeling support roller, the reaching position DP is set at the portion supported by the supporting roller, and the portion supported by the peeling supporting roller is supported. Set the peeling position PP. Further, when the decompression chamber 237 is provided, the decompression zone BA is set to reach the portion supported by the support roller. The inspection process 230 of the present invention can be performed at a position corresponding to such an arrival position DP or a pressure reduction zone BA.

The reference position B1 may not be the welded portion 91v. For example, another symbol set on the surface 91a of the belt 91 can be set as the reference position B1.

It is preferable that the film forming rolls 131 and 132 and the evaluation rolls 201 and 202 are the same roll. Also, the tape inspection process 230 can be performed on the solution film forming apparatus 110.

The film 116 obtained by the solution film forming apparatus 110 shown in Fig. 10 can be used for a retardation film or a polarizing plate protective film.

The width of the film 116 is preferably 600 mm or more and 3000 mm or less, more preferably 2,000 mm or more and 3,000 mm or less. Further, the present invention can be applied even when the width of the film 116 exceeds 3,000 mm. The film thickness of the film 116 is preferably 30 μm or more and 120 μm or less.

(polymer)

The polymer which can be used in the present invention is not particularly limited as long as it is a thermoplastic resin, and examples thereof include a cellulose halide, a lactone-containing cyclic polymer, a cyclic olefin, and a polycarbonate. Among them, a cellulose halide and a cyclic olefin are preferable, and among them, a cellulose halide containing an acetate group or a propionate group and a cyclic olefin obtained by addition polymerization are preferred.

(cellulose cellulose)

As the cellulose halide, it is preferred that the degree of substitution of the thiol group to the hydroxyl group of the cellulose satisfies the following formulas (I) to (III). In the following formulae (I) to (III), A and B represent the degree of substitution of a sulfhydryl group with a hydrogen atom in a hydroxyl group of cellulose, A is a degree of substitution of an acetyl group, and B is a ruthenium having a carbon number of 3 to 22. The degree of substitution of the base. It is preferred that 90% by mass or more of the cellulose halide is 0.1 to 4 mm. Among them, the present invention has a particularly large effect when cellulose diacetate (DAC) is used as the cellulose oxime.

(I) 2.0 A+B 3.0

(II)0 A 3.0

(III)0 B 2.9

The glucose unit which constitutes β-1,4 linkage of cellulose has free hydroxyl groups at the 2, 3 and 6 positions. The cellulose oxime is a polymer (polymer) which esterifies a part or the whole of these hydroxyl groups by a fluorenyl group having 2 or more carbon atoms. The thiol substitution degree refers to a ratio at which the hydroxyl groups of cellulose are esterified at the 2, 3, and 6 positions, respectively (when 100% is esterified, the degree of substitution is 1).

The total degree of substitution is, that is, the value of DS2+DS3+DS6 is preferably 2.00 to 3.00, more preferably 2.22 to 2.90, and particularly preferably 2.40 to 2.88. Further, the value of DS6/(DS2+DS3+DS6) is preferably 0.28, more preferably 0.30 or more, and particularly preferably 0.31 to 0.34. Wherein DS2 is a ratio in which a hydrogen of a 2-hydroxyl group in a glucose unit is substituted by a mercapto group (hereinafter referred to as a "2-position thiol substitution degree"), and DS3 is a ratio in which a hydrogen of a 3-hydroxy group in a glucose unit is substituted by a mercapto group. (hereinafter referred to as "3-position thiol substitution degree"), and DS6 is a ratio in which hydrogen of the 6-position hydroxyl group in the glucose unit is substituted by a mercapto group (hereinafter referred to as "6-position thiol substitution degree").

The mercapto group used in the cellulose halide of the present invention may be used alone or in combination of two or more kinds. When two or more kinds of sulfhydryl groups are used, one of them is preferably an ethylidene group. When the sum of the degree of substitution of the 2, 3, and 6 hydroxyl groups by the ethyl fluorenyl group is set to DSA, and the sum of the 2, 3, and 6 hydroxyl groups is replaced by a thiol group other than the ethyl fluorenyl group, For DSB, the value of DSA+DSB is preferably 2.22 to 2.90, and particularly preferably 2.40 to 2.88.

Further, DSB is preferably 0.30 or more, and more preferably 0.7 or more. Further, a substituent of 20% or more of the DSB having a hydroxyl group of 6 is preferably 25% or more, more preferably 30% or more, and particularly preferably 33% or more. Further, a cellulose halide having a value of DSA + DSB at the 6-position of the cellulose halide of 0.75 or more, more preferably 0.80 or more, particularly preferably 0.85 or more is also preferable by using these cellulose halides. It is possible to produce a concentrated liquid which is more excellent in solubility. In particular, when a non-chlorine-based organic solvent is used, a concentrated liquid exhibiting excellent solubility and having low viscosity and excellent filterability can be produced.

The cellulose which is a raw material of the cellulose halide may be obtained from any one of cotton wool fibers and a slurry.

The fluorenyl group having 2 or more carbon atoms of the cellulose halide in the present invention may be an aliphatic group or an aryl group, and is not particularly limited. For example, an alkylcarbonyl ester, an olefinic carbonyl ester, an aromatic carbonyl ester, an aromatic alkylcarbonyl ester, or the like of cellulose may be mentioned, and each may have a further substituted group. As preferred examples thereof, a propyl group, a butyl group, a pentyl group, a hexyl group, a octyl group, a decyl group, a dodecyl group, a tridecyl fluorenyl group, a tetradecyl fluorenyl group, and a hexadecane group may be mentioned. An alkanoyl group, an octadecyl fluorenyl group, an isobutyl fluorenyl group, a tertiary butyl fluorenyl group, a cyclohexanecarbonyl group, an oil fluorenyl group, a benzamyl group, a naphthylcarbonyl group, a cinnamyl group, and the like. Among them, a propyl fluorenyl group, a butyl decyl group, a dodecyl fluorenyl group, an octadecyl fluorenyl group, a tertiary butyl fluorenyl group, an oil fluorenyl group, a benzamidine group, a naphthylcarbonyl group, a cinnamyl group, etc. are more preferable, and a propyl sulfonyl group and a butyl fluorenyl group are particularly good.

(solvent)

Examples of the solvent for preparing the dope include aromatic hydrocarbons (for example, benzene, toluene, etc.), halogenated hydrocarbons (for example, dichloromethane, chlorobenzene, etc.), and alcohols (for example, methanol, ethanol, n-propanol, n-butanol, Diethylene glycol or the like), a ketone (e.g., acetone, methyl ethyl ketone, etc.), an ester (e.g., methyl acetate, ethyl acetate, propyl acetate, etc.) and an ether (e.g., tetrahydrofuran, methyl cellosolve, etc.).

Among the above halogenated hydrocarbons, a halogenated hydrocarbon having 1 to 7 carbon atoms is preferably used, and dichloromethane is most preferred. From the viewpoint of the solubility of the cellulose halide, the peelability of the cast film from the support, the mechanical strength of the film, and the optical properties, one or several kinds of carbon atoms of 1 to 5 are mixed in addition to dichloromethane. The alcohol is preferred. The content of the alcohol is preferably 2 to 25% by mass based on the entire solvent, more preferably 5 to 20% by mass. The alcohol may, for example, be methanol, ethanol, n-propanol, isopropanol or n-butanol, but methanol, ethanol, n-butanol or a mixture thereof is preferred.

Recently, the solvent composition without using methylene chloride has also been studied for the purpose of minimizing the influence on the environment. In this case, an ether having 4 to 12 carbon atoms, a ketone having 3 to 12 carbon atoms, an ester having 3 to 12 carbon atoms, and an alcohol having 1 to 12 carbon atoms are preferred. These are also mixed as appropriate for use. For example, a mixed solvent of methyl acetate, acetone, ethanol, and n-butanol can be mentioned. These ethers, ketones, esters, and alcohols may have a cyclic structure. Further, a compound having any one of two or more ether, ketone, ester, and alcohol functional groups (that is, -O-, -CO-, -COO-, and -OH) can also be used as a solvent.

[Examples]

Hereinafter, in order to confirm the effect of the present invention, Experiments 1 to 6 were carried out. The details of each experiment are explained by Experiment 1, and the experiments 2 to 6 only show conditions different from Experiment 1.

(Experiment 1)

In the belt manufacturing apparatus 10 shown in Fig. 1, a belt (A-1) was produced from a side member 11 (width: 150 mm) made of SUS316 and a center member 12 (width: 2000 mm) made of SUS316.

The tape inspection process 230 shown in Fig. 21 is performed on the tape (A-1) by the tape inspection device 200 shown in Fig. 14. The floating amount CL at the measurement position MP1 and the floating amount CL at the measurement position MA in the inspection process 230. The maximum value of the floating quantity measurement positions MP1 CL CL of _MP and floating quantity measurement position of maximum CL _MA MA CL as shown in Table 1. When the inspection process 230 is performed, the movement tension T2 applied to the belt to be inspected is 60 N/mm ² .

In the solution film forming apparatus 110 (refer to FIG. 10), the film 116 is produced from a dope 113 containing cellulose diacetate (DAC) and a solvent. The belt (A-1) is used as the belt 91. The belt 91 has a moving speed of 40 m/min. The casting die 133 continuously flows out of the dope 113 to the belt 91 in the moving state. A casting film 136 composed of a dope 113 is formed on the surface 91a of the belt 91.

The solvent is evaporated from the casting film 136 on the belt 91 by the dry air from the respective conduits 141 to 143. The peeling roller 135 peels the casting film 136 from the belt 91 and serves as the film 116. The film 116 is sequentially sent to the first tenter 120, the roll drying device 124, the second tenter 125, and the slitter 126.

(Experiment 2 to 6)

A film 116 was produced in the same manner as in Experiment 1 except that the belts (A-2) to (A-6) obtained by the belt manufacturing equipment 10 were used as the belt 91 instead of the belt (A-1). The maximum value CL _MP of the floating amount CL and the maximum value CL _{MA of the} floating amount CL are as shown in Table 1.

The films obtained in Experiments 1 to 6 were evaluated as follows.

1. Peel residue evaluation

The presence or absence of peeling residual cast film in the belt was investigated.

A: No peeling of the cast film was caused in the belt.

B: Peeling residue of the cast film was generated in the belt.

2. Evaluation of thickness unevenness

The thickness unevenness of the cast film was evaluated in the following order. The sample film is cut out from the film before the core is taken up by the take-up device 127. When light is transmitted to the sample film, the shadow appearing on the surface of the sample film is visually observed. When the intensity of the shadow observed in the sample film is larger than that of the product film which is the thickness unevenness evaluation test as the retardation film or the polarizing plate protective film, it is judged that the thickness unevenness (B) cannot be tolerated. Further, when the scale of the shadow observed in the sample film is the same as or smaller than that of the product film as the performance test of the retardation film or the polarizing plate protective film, it is determined that the thickness unevenness can be tolerated (A) .

Table 1 shows the evaluation results of Experiments 1 to 6. In addition, the serial number attached to the evaluation result in Table 1 indicates the serial number attached to the above evaluation item.

10. . . Belt manufacturing equipment

11. . . Side member

11e, 12e. . . Side edge

12. . . Central component

13. . . Belt member

13c, 91c. . . Central department

13s, 91s. . . Side

13w, 91v, 91w. . . Welding department

16. . . Delivery department

17. . . Docking

18, 61. . . Welding unit

19. . . Heating department

20, 127. . . Winding device

twenty three. . . First delivery device

twenty four. . . Second delivery device

26. . . First roller

27. . . Second roller

28. . . Third roller

29. . . 4th roller

34, 47. . . Position detection

32, 37, 50. . . Displacement mechanism

33, 38, 51. . . Controller

41. . . Welding support roller

42. . . Welding device

43. . . Laser oscillator

46. . . Welding device body

52. . . room

55. . . Cleaning device

56, 141, 142, 143. . . catheter

57. . . Blower

62. . . Pressing member

63. . . 1st conveyor belt

64. . . 2nd conveyor belt

67. . . Fifth roller

68. . . 6th roller

69. . . 7th roller

71. . . High heat conduction section

72. . . Welding bead

73. . . Heat affected zone

76. . . groove

81. . . Cone roller

82. . . Driving means

85. . . Clip

86. . . Clip body

87. . . Holding needle

88. . . Mobile agency

91. . . band

91a. . . Belt surface

91b. . . Inside the belt

110. . . Solution film making equipment

111. . . Cellulose telluride

112. . . Solvent

113. . . Concentrate

116. . . film

117. . . Film forming device

120. . . 1st tenter

120a, 125a. . . Holding member

122. . . Roll

124. . . Roll drying device

125. . . 2nd tenter

126. . . Slitting machine

131, 132. . . Film roll

131a. . . Rotary axis

131b. . . Roller body

133, 136. . . Casting die

133a. . . Outflow

134. . . Membrane drying device

135. . . Stripping roller

171, 205. . . motor

172, 206. . . Drive department

173, 207. . . Power sensor

200. . . With inspection device

201, 202. . . Inspection roller

201a, 202a. . . Rotary axis

201b, 202b. . . Roller body

201be. . . Axial end

201bx. . . The circumference of the roller body

203. . . Displacement section

208. . . Sensor unit

208a. . . Measurement window

208x. . . Distance sensor

208y. . . Reference position detection sensor

210. . . Control department

211. . . CPU

212. . . Storage department

216. . . Distance calculation department

217. . . Floating amount calculation unit

218. . . Judgment department

222. . . bus

225. . . Thickness information

230. . . With inspection process

237. . . Decompression chamber

237a. . . Upstream side windshield

237b. . . Side shelter

237c. . . roof

A. . . arrow

A(i,j). . . Distance on the intersection P(i,j) on the thickness measurement line ST(j)

B(j). . . Distance from axial end 201be to measurement window 208a

B1. . . Reference position

BA. . . Decompression zone

BAd. . . Downstream end

BAu. . . Upstream

CA. . . Casting zone

CL(i,j). . . Floating amount

CW. . . Cast width

d. . . diameter

D(i,j). . . Thickness measurement of strip 91 at intersection P(i,j)

D1. . . The interval between the first conveyor belt 63 and the second conveyor belt 64

D2. . . The distance between the contact position Ps and the first conveyor belt 63

D3. . . The distance between the contact position Ps and the second conveyor belt 64

D4. . . Through the width of the area

D5. . . Width of slot 76

D6. . . Depth of slot 76

DB. . . Thickness distribution information

DP. . . Arrival location

E1. . . Initial value

E2. . . Peak

H(i,j). . . Distance from the axial end 201be to the surface 91a of the belt 91

L(j). . . Distance from the reference position B1 to an arbitrary thickness measurement line ST(j)

L _BAd . . . The surface extending from the rotation center O _131a toward the downstream end BAd of the moving direction of the belt 91 of the decompression zone BA

L _BAu . . . The surface extending from the rotation center O _131a toward the upstream end BAu of the movement direction of the belt 91 of the decompression zone BA

L _DP . . . The surface extending from the rotation center O _{131a of} the rotation shaft 131a toward the arrival position DP

L _TP . . . a surface extending from the rotation center O _{131a of} the rotating shaft 131a toward the top TP

MA. . . Measuring position

MAd. . . Measuring the downstream end of the belt 91 in the moving direction of the position MA

MAu. . . Measuring the upstream end of the moving direction of the belt 91 of the position MA

MD. . . Location information

ML. . . Measuring line

M _MAd . . . The surface extending from the rotation center O _201a toward the downstream end MAd of the moving direction of the belt 91 of the measurement position MA

M _MAu . . . The surface extending from the rotation center O _201a toward the downstream end MAu of the movement direction of the belt 91 at the measurement position MA

M _MP1 . . . The surface extending from the rotation center O _{201a of} the rotating shaft 201a toward the measurement position MP1

MP1. . . Measuring position extending in the width direction of the belt

MP2. . . The intersection of the surface M _MP1 and the axial end 201be

M _TP . . . The surface extending from the rotation center O _{201a of} the rotating shaft 201a toward the top TP of the inspection roller 201

O _131a . . . The center of rotation of the rotating shaft 131a

O _201a . . . The center of rotation of the rotating shaft 201a

P(i,j). . . The intersection of the thickness measurement line ST(j) and the thickness measurement line SM(i)

Ph. . . Docking position

PP. . . Peeling position

Pr. . . Relaxed position

Ps. . . Contact position

Pt. . . Tension plus position

Pw. . . Position of welding

SM(i-1), SM(i), SM(i+1), ST(j-1), ST(j), ST(j+1). . . Thickness measurement line

S10, S11, S12, S13, S14, S15, S16, S17, S18, S20, S21, S22, S23. . . step

TP. . . top

X. . . Transfer direction

Y. . . Width direction

Θ1. . . The angle between the circumferential direction in the contact area and the conveying direction X of the central member 12

Θ2. . . The angle formed by the welded portion 91v and the width direction Y

Φ1. . . The angle between the surface L _TP and the surface L _DP

Φ2. . . Angle at which the face M _TP is at an angle to the face M _MP1

φ _BAd . . . L _BAd angle and the plane surface of the angled L _TP

φ _BAu . . . The angle between the surface L _BAu and the surface L _TP

Φ _MAd . . . Angle of the angle between the surface M _MAd and the surface M _TP

Φ _MAu . . . The angle between the surface M _MAu and the surface M _TP

Fig. 1 is a side view showing an outline of a manufacturing apparatus of a belt.

Fig. 2 is a plan view showing an outline of a belt manufacturing apparatus.

Fig. 3 is a side view showing an outline of a welding unit.

Fig. 4 is a plan view showing an outline of a welding unit.

Fig. 5 is a cross-sectional view taken along the line V-V of the outline of the welding support roller.

Fig. 6 is an explanatory view of the welding bead and its periphery.

Fig. 7 is a schematic view of a tapered roller.

Figure 8 is a schematic view of a clip.

Figure 9 is a schematic view of the strap.

Fig. 10 is a side view showing an outline of a solution film forming apparatus.

Fig. 11 is a side view showing an outline of the arrival position DP and the pressure reduction area BA.

Fig. 12 is a perspective view showing an outline of a casting die, a decompression chamber, and a film forming roller.

Fig. 13 is a perspective view showing an outline of the arrival position DP and the decompression zone BA.

Fig. 14 is a side view showing an outline of a tape inspection device when a rotary shaft is provided at a tension application position.

Fig. 15 is a perspective view showing an outline of a belt wound around an inspection roller.

Fig. 16 is a block diagram showing an outline of a tape inspection device.

Fig. 17 is a side view showing an outline of a tape inspection device when a rotary shaft is provided at a slack position.

Fig. 18 is an explanatory diagram showing an outline of thickness information.

Fig. 19 is a cross-sectional view of the belt on the thickness measurement line ST(j) provided at the measurement position MP1, showing the outlines of the distances A, B, and H.

Fig. 20 is a cross-sectional view of the belt on the thickness measurement line ST(j) provided at the measurement position MP1, and shows an outline of the distances A, H, the thickness D of the belt, and the floating amount CL.

Figure 21 is a flow chart showing an outline of the inspection process.

Fig. 22 is a side view showing an outline of a tape inspection device when a rotary shaft is provided at a tension application position.

Fig. 23 is an explanatory view showing an outline of a distance detected by a sensing device of the distance sensor when warpage does not occur on the belt.

Fig. 24 is an explanatory view showing an outline of a distance detected by a sensing device of the distance sensor when warpage occurs on the belt.

91. . . band

91a. . . Belt surface

91b. . . Inside the belt

200. . . With inspection device

201, 202. . . Inspection roller

201a, 202a. . . Rotary axis

201b, 202b. . . Roller body

201bx. . . The circumference of the roller body

203. . . Displacement section

207. . . Power sensor

208. . . Sensor unit

208a. . . Measurement window

208x. . . Distance sensor

208y. . . Reference position detection sensor

M _MP1 . . . The surface extending from the rotation center O _{201a of} the rotating shaft 201a toward the measurement position MP1

MP1. . . Measuring position extending in the width direction of the belt

MP2. . . The intersection of the surface M _MP1 and the axial end 201be

M _TP . . . The surface extending from the rotation center O _{201a of} the rotating shaft 201a toward the top TP of the inspection roller 201

O _201a . . . The center of rotation of the rotating shaft 201a

Pt. . . Tension plus position

TP. . . top

Φ2. . . Angle at which the face M _TP is at an angle to the face M _MP1

Claims (10)

A method for inspecting a metal endless belt, the endless belt having a surface and a back surface, wherein the surface is set to a position at which a concentrated liquid flowing from a casting die reaches, and a cast film composed of the aforementioned concentrated liquid is formed When the endless belt is cyclically moved, the inside is supported by a film forming roller, and the method for inspecting the endless belt includes the following steps: (A) calculating the support from the measurement position on the surface to the inspection roller The distance H of the surface, the measurement position corresponds to the arrival position, and the distance H is calculated for the endless belt in a state in which the inside of the inspection roller is supported by the inspection roller and the movement tension is applied; (B) the measurement is calculated according to the formula (1) The floating amount CL from the support surface to the inside of the position, the formula (1) is CL = HD, the D is the thickness of the endless belt at the measurement position; and (C) the above calculated Whether the floating amount CL is below the threshold. The inspection method of the endless belt according to the first aspect of the invention, wherein the inspection roller supports the endless belt at a central portion in the axial direction so that the axial end portion is exposed, and the distance measuring unit is used in the aforementioned step A. Measuring a distance A from the aforementioned measurement position to the distance measuring unit and a distance B from the aforementioned axial end portion to the aforementioned distance measuring unit, and calculating the aforementioned distance H according to the formula (2), wherein the formula (2) ) is H=BA. The method for inspecting an endless belt according to claim 1, wherein in the step B, the thickness D of the endless belt is read from the storage portion, and the ring is read from the storage portion. The thickness D of the belt is used to calculate the floating amount CL in which the positional information from the reference position set on the endless belt to the measurement position is associated with the thickness D of the endless belt at the measurement position. storage. The method for inspecting an endless belt according to claim 1, wherein the endless belt is composed of a first mesh made of metal and a second mesh made of metal welded to one side in the width direction of the first net. The method for inspecting an endless belt according to the first aspect of the invention, wherein the film forming roller and the inspection roller are the same roller. The method for inspecting an endless belt according to claim 1, wherein the moving tension is 60 N/mm ² and the threshold is 0.1 mm or less. An inspection device for a metal endless belt, wherein the endless belt has a surface and a back surface, and the surface is provided with a position reached from a concentrated liquid flowing under a casting die, and a cast film composed of the aforementioned concentrated liquid is formed. When the endless belt is circulated, the inside is supported by a film forming roller, and the inspection apparatus for the endless belt includes a distance calculating unit that calculates a support from the measurement position on the surface to the inspection roller. The distance H of the surface, the measurement position corresponds to the arrival position, and the distance H is calculated for the endless belt in a state in which the inside of the inspection roller is supported by the inspection roller and the movement tension is applied; the floating amount calculation unit according to the formula (1) Calculating the floating amount CL from the support surface to the inside at the measurement position, wherein the formula (1) is CL=HD, the D is the thickness of the endless belt at the measurement position, and the determination unit determines the foregoing It is calculated whether the floating amount CL is below the threshold. The inspection apparatus for an endless belt according to claim 7, comprising: a distance measuring unit that measures a distance A and a distance B, wherein the distance A is a distance from the distance measuring unit to the measurement position, and the distance B a distance from the distance measuring unit to an axial end portion of the annular belt that supports the inspection roller exposed at the central portion in the axial direction, wherein the distance calculating unit calculates the distance H according to the formula (2), wherein 2) is H=BA. The inspection device for an endless belt according to the seventh aspect of the invention, wherein the inspection device includes a positional information set at a reference position on the endless belt to a position of the measurement position, and a thickness of the endless belt at the measurement position. In the storage unit in which D is associated, the floating amount calculation unit calculates the floating amount CL by the thickness D of the endless belt stored in the storage unit. The inspection device for an endless belt according to claim 7, wherein the film forming roller and the inspection roller are the same roller.