WO2022107756A1

WO2022107756A1 - Sheet-like product manufacturing method, sheet-like product, original fabric, and intermediate body

Info

Publication number: WO2022107756A1
Application number: PCT/JP2021/042051
Authority: WO
Inventors: 裕司山下; 剛神丸
Original assignee: 日東電工株式会社
Priority date: 2020-11-18
Filing date: 2021-11-16
Publication date: 2022-05-27
Also published as: KR20230104169A; TW202228098A; JPWO2022107756A1; CN116507572A

Abstract

[Problem] To provide a sheet-like product manufacturing method which can contribute to investigating the cause of an abnormality in the sheet-like product and to an improvement in the yield of the sheet-like product. [Solution] The present invention is a method for manufacturing a plurality of sheet-like products S2 by feeding out, conveying, and cutting an elongated original fabric S1 wound in a roll shape, or feeding out and conveying the elongated original fabric S1 wound in the roll shape, and cutting out large sheet-shaped intermediate bodies from the original fabric S1, and cutting the intermediate bodies, the method comprising: a first marking step ST1 for marking the original fabric with first marks M1 at positions where defects F detected by inspecting the original fabric are present; and a second marking step ST2 for marking the original fabric or plurality of sheet-like products with second marks M2 representing location information on the original fabric, wherein, in the second marking step, the original fabric is marked with the second marks such that a plurality of the second marks are present on each of the plurality of sheet-like products after cutting.

Description

Manufacturing method of sheet-shaped products, sheet-shaped products, raw fabrics and intermediates

The present invention relates to a method for manufacturing a sheet-shaped product such as a polarizing film or a retardation film, a sheet-shaped product manufactured by using this manufacturing method, and an original fabric and an intermediate for manufacturing the sheet-shaped product. In particular, the present invention relates to a method for manufacturing a sheet-shaped product, a method for manufacturing the sheet-shaped product, a raw material, which can contribute to the investigation of the cause when an abnormality such as a defect occurs in the sheet-shaped product and the improvement of the yield of the sheet-shaped product. Regarding anti- and intermediates.

Conventionally, sheet-shaped products such as polarizing films and retardation films have long roll-shaped raw fabrics that are unwound, conveyed and cut, or rolled-shaped long raw materials. A large sheet-shaped intermediate is cut out by feeding and transporting the reverse, and the intermediate is cut to produce a plurality of sheet-shaped products. Then, each of the manufactured sheet-shaped products is bonded to an optical display unit such as a liquid crystal panel to manufacture an optical display device such as a liquid crystal display device.

Here, if it is known at which position the sheet-shaped product after being bonded to the optical display unit was the original fabric before cutting or the original fabric before cutting out the intermediate, a defect occurs in the sheet-shaped product. It is possible to contribute to the investigation of the cause when an abnormality such as optics occurs and the improvement of the yield of sheet-shaped products.
Therefore, for example, Patent Document 1 proposes a method of marking a mark indicating position information on the original fabric on the original fabric before cutting.
Specifically, in Patent Document 1, the original fabric of the sheet-shaped product (in the patent document 1, the roll original fabric) before being cut into the sheet-shaped product (in the patent document 1, the optical film) is compared with the original fabric of the sheet-shaped product. A method of marking a mark (roll information holding means in Patent Document 1) representing the position information (roll information in Patent Document 1) has been proposed (see, for example, paragraphs 0131 to 0133 of Patent Document 1).
According to the method described in Patent Document 1, it is considered possible to contribute to the investigation of the cause when an abnormality occurs in the sheet-shaped product and the improvement of the yield of the sheet-shaped product.

On the other hand, as described in Patent Document 2, a method of marking a mark on a raw fabric before cutting at a position where a defect detected by inspecting the raw fabric exists is also widely practiced (as described in Patent Document 2). For example, see paragraphs 0051 to 0053 of Patent Document 2).

Detected by a method of marking a mark indicating position information on the original fabric of a sheet-shaped product on the original fabric as described in Patent Document 1 and by inspecting the original fabric as described in Patent Document 2. If the method of marking the mark at the position where the defect exists is used in combination, the position where the defect exists cannot be controlled, so that both marks may overlap and be marked on the original fabric. If both marks overlap, it becomes impossible to read the mark indicating the position information, and it may not be possible to contribute to the investigation of the cause when an abnormality occurs in the sheet-shaped product and the improvement of the yield of the sheet-shaped product.
This problem is a method of marking a mark indicating position information on the raw fabric on a sheet-like product after cutting, and a method of marking a mark on a position where a defect detected by inspecting the raw fabric exists. The same can occur when used in combination.

Japanese Unexamined Patent Publication No. 2009-294645 Japanese Unexamined Patent Publication No. 2005-114624

The present invention has been made to solve the above-mentioned problems of the prior art, and the original fabric is used as opposed to the original fabric before cutting into a sheet-shaped product or the original fabric before cutting out an intermediate. For the process of marking the position where the defect detected by inspection exists, and the raw fabric before cutting into a sheet-shaped product, the raw fabric before cutting out the intermediate, or the sheet-shaped product after cutting. Even when used in combination with the marking process that marks the mark indicating the position information on the original fabric, it is possible to contribute to the investigation of the cause when an abnormality occurs in the sheet-shaped product and the improvement of the yield of the sheet-shaped product. It is an object of the present invention to provide a method for manufacturing a sheet-shaped product, a sheet-shaped product, a raw fabric and an intermediate.

In order to solve the above-mentioned problems, in the present invention, a long roll-shaped original fabric is unwound and conveyed and cut, or a long roll-shaped original fabric is unwound and conveyed. Then, a large sheet-shaped intermediate is cut out, and the intermediate is cut to produce a plurality of sheet-shaped products. The raw fabric before cutting, the raw fabric before cutting out the intermediate, and the like. Alternatively, the first marking step of marking the first mark on the intermediate at the position where the defect detected by inspecting the raw fabric exists, and the raw fabric before cutting and the intermediate are cut out. 2. 2 In the marking step, the raw fabric before cutting, the raw fabric before cutting out the intermediate, and the intermediate so that each of the plurality of sheet-shaped products after cutting has a plurality of the second marks. Alternatively, the present invention provides a method for manufacturing a sheet-shaped product, which marks the second mark on the plurality of sheet-shaped products after cutting.

According to the present invention, the first mark is marked on the raw fabric before cutting, the raw fabric before cutting out the intermediate, or the intermediate, at the position where the defect detected by inspecting the raw fabric exists. The first marking step and the second mark indicating the position information in the raw fabric are applied to the raw fabric before cutting, the raw fabric before cutting the intermediate, the intermediate, or a plurality of sheet-shaped products after cutting. Although it is used in combination with the second marking step for marking, in the second marking step, a plurality of second marks are present in each of the plurality of sheet-shaped products after cutting (that is, each sheet-shaped product is not singular, but is present. Mark so that there are multiple second marks). Therefore, the possibility that the first mark and all the plurality of second marks overlap is greatly reduced. Therefore, by reading the second mark (the second mark that does not overlap with the first mark) marked on each sheet-shaped product after cutting, the cause of an abnormality in the sheet-shaped product can be investigated and the sheet-shaped product can be detected. It is possible to contribute to the improvement of the yield.

In the present invention, the "position information in the original fabric" represented by the second mark means information including at least the position in the transport direction of the original fabric. The position of the original fabric in the transport direction may be represented by the distance from the tip of the original fabric in the transport direction (downstream end in the transport direction), or serially numbered according to the distance from the tip of the original fabric in the transport direction. It may be represented by the number given. The "position information in the original fabric" represented by the second mark may include the position in the width direction of the original fabric (the direction orthogonal to the transport direction) in addition to the position in the transport direction of the original fabric. .. Further, the second mark may represent information on the original fabric for distinguishing a plurality of original fabrics from each other. Further, the second mark may represent other incidental information.
Further, in the present invention, the position information represented by the plurality of second marks marked on each sheet-shaped product may be the same position information (for example, information on the center position of each sheet-shaped product) or different. It may be position information (for example, information on the position where each second mark is marked).
Further, in the present invention, the first mark and the second mark may be marked using ordinary colored ink or a transparent ink described later, or may be marked by laser engraving.

Preferably, in the second marking step, the second mark is marked so that the positions of the plurality of second marks in the plurality of sheet-shaped products after cutting include those different from each other in the width direction of the original fabric. do.

According to the above preferred method, for example, defects occur periodically along the transport direction of the raw fabric due to defects such as a nip roller for transporting the raw fabric (the first mark is the transport of the raw fabric). Even in the case of (marked periodically along the direction), the positions of the plurality of second marks in each sheet-shaped product include those that are different from each other in the width direction (direction orthogonal to the transport direction) of the original fabric. , The possibility that the first mark and all the plurality of second marks overlap is greatly reduced.

As the second mark, a one-dimensional code (bar code) or a two-dimensional code can be exemplified. Examples of the two-dimensional code include DataMatrix (registered trademark) and QR code (registered trademark).

Preferably, in the second marking step, when the second mark is marked on the original fabric before cutting or the original fabric before cutting out the intermediate, the original fabric is predetermined. The second mark is marked so as not to overlap the planned cutting line.

According to the above preferred method, it is possible to ensure that a plurality of second marks are marked on each sheet-shaped product after cutting.

Preferably, in the first marking step, the first mark is marked with transparent ink and / or, in the second marking step, the second mark is marked with transparent ink.

In the above preferred method, the "transparent ink" is an ink that cannot be visually recognized by the human eye under normal lighting, but is fluorescently emitted by irradiating with light of a specific wavelength so that the ink can be visually recognized. Examples of the transparent ink include UV inks that emit fluorescent light when irradiated with ultraviolet rays.
According to the above preferred method, since the first mark and / or the second mark is marked with the transparent ink, the first mark and / or the second mark becomes invisible under normal lighting, and the sheet-like product is manufactured. It has the advantage of not spoiling the appearance.

Preferably, in the second marking step, the second mark is marked so as to include those in which the positions of the second marks on the plurality of sheet-shaped products after cutting with respect to the planned cutting line are different from each other.

In the above preferred method, "including those having different positions of the second marks on the plurality of sheet-shaped products after cutting with respect to the planned cutting line" means that the plurality of sheet-shaped products after cutting are different from each other. The position of the plurality of second marks on any one sheet-shaped product selected from the above (position based on the planned cutting line) and the position of the plurality of second marks on any other sheet-shaped product (planned cutting line). When compared with the position based on), the second mark on another sheet-shaped product may not exist at the same position as any of the plurality of second marks on one sheet-shaped product. Means.
According to the above preferred method, for example, when a plurality of sheet-shaped products are laminated and used, it is possible to reduce the possibility that dents are generated in the overlapped portion due to the overlapping of the second marks in the sheet-shaped products. Has advantages.

In the present invention, for example, the first mark is composed of a plurality of dot-shaped marks arranged in the transport direction of the original fabric.
Then, for example, at least one of the plurality of dot-shaped marks constituting the first mark is referred to as the second mark. In particular, when all of the plurality of dot-shaped marks constituting the first mark are used as the second mark, the marking device for executing the first marking step is used as the marking device for executing the second marking step. It can also be used for both purposes.

Further, in order to solve the above-mentioned problems, in the present invention, the long raw fabric wound in a roll shape is unwound, conveyed and cut, or the long raw fabric wound in a roll shape is wound. A large sheet-shaped intermediate is cut out by feeding and transporting the intermediate, and the intermediate is cut to produce a plurality of sheet-like products, and there are defects detected by inspecting the raw fabric. It is also provided as a sheet-like product in which a first mark is marked at a position and a plurality of second marks indicating position information on the original fabric are marked.

Further, in order to solve the above-mentioned problems, the present invention is a long raw fabric wound in a roll shape for manufacturing a plurality of sheet-shaped products by feeding, transporting and cutting. The first mark is marked at the position where the defect detected by inspecting the fabric exists, and the second mark indicating the position information on the original fabric is marked, and the plurality of sheet-like products after cutting are marked. It is also provided as an original fabric in which the second mark is marked so that a plurality of the second marks are present in each of the above.

Further, in order to solve the above-mentioned problems, the present invention is a large sheet for manufacturing a plurality of sheet-shaped products by feeding out, transporting and cutting out a long raw fabric wound in a roll shape and cutting the raw fabric. The first mark is marked at the position where the defect detected by inspecting the original fabric exists, and the second mark indicating the position information on the original fabric is marked. It is also provided as an intermediate in which the second mark is marked so that the plurality of second marks are present in each of the plurality of sheet-shaped products after cutting.

According to the present invention, a step of marking a mark on a raw fabric before cutting into a sheet-shaped product or a raw fabric before cutting out an intermediate at a position where a defect detected by inspecting the raw fabric exists. Even when the marking process for marking the mark indicating the position information on the original fabric is used in combination, it is possible to contribute to the investigation of the cause when an abnormality occurs in the sheet-shaped product and the improvement of the yield of the sheet-shaped product. Is.

It is a figure which shows the schematic structure of the manufacturing apparatus for carrying out the manufacturing method of the sheet-shaped product which concerns on one Embodiment of this invention. It is a flow figure which shows the schematic procedure of the manufacturing method which concerns on one Embodiment of this invention. It is explanatory drawing explaining the state of the original fabric and the sheet-like product in the manufacturing method which concerns on one Embodiment of this invention. It is a figure explaining the modification of the 2nd marking process ST2 shown in FIG. It is a figure explaining the modification of the 1st marking process ST1 shown in FIG. It is a figure which shows the schematic structure of the manufacturing apparatus for carrying out the manufacturing method of the sheet-shaped product which concerns on the modification of this invention.

Hereinafter, with reference to the attached drawings as appropriate, regarding the method for manufacturing a sheet-shaped product according to an embodiment of the present invention, the first mark is marked on the raw fabric before cutting, and the raw fabric before cutting is marked with the first mark. The case of marking the two marks will be described as an example.
Examples of the sheet-shaped product manufactured by the manufacturing method according to the present embodiment include a polarizing film, a retardation film, a visual compensation film, a luminance improving film, and a laminated film in which two or more of these films are laminated. .. Since the composition of each film is known, detailed description thereof will be omitted here.

FIG. 1 is a diagram showing a schematic configuration of a manufacturing apparatus for executing the method for manufacturing a sheet-shaped product according to the present embodiment. In FIG. 1, the arrow X indicates the transport direction (horizontal direction) of the original fabric S1 for manufacturing the sheet-shaped product S2, and the arrow Y indicates the width direction (horizontal direction orthogonal to the transport direction) of the original fabric S1. The arrow Z means the normal direction (vertical direction) of the surface of the original fabric S1, respectively.
As shown in FIG. 1, the manufacturing device 100 of the present embodiment includes an inspection device 1, a first marking device 2, a second marking device 3, a cutting device 4, and a control device 5. The control device 5 is electrically connected to the inspection device 1, the first marking device 2, the second marking device 3, and the cutting device 4. Further, the manufacturing apparatus 100 of the present embodiment includes a feeding roller R1, a nip roller R2, and a conveyor R3.
The manufacturing apparatus 100 of the present embodiment feeds out a long raw fabric S1 wound in a roll shape on a feeding roller R1, conveys it in the X direction by a nip roller R2, a conveyor R3, or the like, and cuts it by a cutting device 4. , An apparatus for manufacturing a plurality of sheet-shaped products S2.

The inspection device 1 is a device that detects defects existing in the raw fabric S1 by inspecting the raw fabric S1 before cutting. The inspection device 1 shown in FIG. 1 is arranged on one side in the Z direction with respect to the original fabric S1 (below the original fabric S1 in the example shown in FIG. 1), and has a light source 11 that emits light toward the original fabric S1. , It is arranged on the other side in the Z direction with respect to the original fabric S1 (above the original fabric S1 in the example shown in FIG. 1), and a transmitted image is formed by receiving light transmitted through the original fabric S1 and forming an image (imaging). By applying known image processing such as binarization to extract a pixel region having a brightness value different from that of other pixel regions to the image pickup means 12 and the transmission image input from the image pickup means 12. An image processing means 13 for detecting defects is provided. In the present embodiment, the control device 5 also functions as the image processing means 13 of the inspection device 1, but it is also possible to provide the image processing means 13 separately from the control device 5.

The inspection device 1 is not limited to the configuration of detecting defects based on the transmitted image as described above, but is generated by arranging a light source and an image pickup means on one side in the Z direction with respect to the original fabric S1. It is also possible to adopt a configuration that detects defects based on the reflected image.
When the raw fabric S1 (sheet-shaped product S2) is a polarizing film, a light source and a polarizing filter for inspection are arranged on one side in the Z direction with respect to the raw fabric S1 as the inspection device 1, and the raw fabric S1 The imaging means is arranged on the other side in the Z direction with respect to the original fabric S1, or the light source is arranged on one side in the Z direction with respect to the original fabric S1 and the inspection polarization is arranged on the other side in the Z direction with respect to the original fabric S1. It is also possible to adopt a configuration in which defects are detected based on the cross Nicol image generated by arranging the filter and the imaging means.
Further, as the inspection device 1, it is also possible to adopt a configuration for detecting defects by combining two or more images of a transmission image, a reflection image, and a cross Nicol image.

The first marking device 2 is a device that marks a mark (first mark) on the original fabric S1 before cutting at a position where a defect detected by inspecting the original fabric S1 by an inspection device 1 or the like exists. be. Specifically, the control device 5 recognizes the position where the defect detected by inspecting the original fabric S1 by the inspection device 1 or the like is recognized by the control device 5, and the control device 5 controls the first marking device 2. The first mark is marked at the position where.
The first marking device 2 of the present embodiment is an inkjet marking device using transparent ink (specifically, UV ink), and ejects transparent ink from a large number of nozzles arranged along the Y direction. This is a configuration for marking the first mark. However, as the first marking device 2, it is also possible to adopt a configuration in which marking is performed by an inkjet method using ordinary colored ink, or a configuration in which marking is performed by laser engraving. Further, when ink is used, it is possible to adopt a configuration in which marking is performed not only by the inkjet method but also by the pen method. Since the specific configurations of these marking devices are known, detailed description thereof will be omitted here.

The second marking device 3 is a device that marks a mark (second mark) representing position information on the original fabric S1 on the original fabric S1 before cutting. Specifically, when the control device 5 controls the second marking device 3, the second mark is marked so that each of the plurality of sheet-shaped products S2 after cutting has a plurality of second marks. ..
The second marking device 3 of the present embodiment is an inkjet marking device using transparent ink (specifically, UV ink) like the first marking device 2, and is arranged along the Y direction. The second mark is marked by ejecting transparent ink from a large number of nozzles. However, as the second marking device 3, it is also possible to adopt a configuration in which marking is performed by an inkjet method using ordinary colored ink, or a configuration in which marking is performed by laser engraving.

The cutting device 4 is a device that manufactures a plurality of sheet-shaped products S2 by cutting the raw fabric S1 by a known processing method such as punching or laser processing. Specifically, the control device 5 controls the cutting device 4, so that the original fabric S1 is cut along a predetermined cutting scheduled line.

Hereinafter, a manufacturing method according to the present embodiment using the manufacturing apparatus 100 having the above configuration will be described.
FIG. 2 is a flow chart showing a schematic procedure of the manufacturing method according to the present embodiment. As shown in FIG. 2, the manufacturing method according to the present embodiment includes a first marking step ST1 and a second marking step ST2. Further, the manufacturing method according to the present embodiment includes a cutting step ST3 and a recovery step ST4.
FIG. 3 is an explanatory diagram illustrating a state of the original fabric S1 and the sheet-shaped product S2 in the manufacturing method according to the present embodiment. FIG. 3A is a diagram schematically showing a state of the original fabric S1 immediately after the first marking step ST1 is executed. FIG. 3B is a diagram schematically showing the state of the original fabric S1 immediately after the second marking step ST2 is executed. FIG. 3C is a diagram schematically showing the state of the raw fabric S1 (sheet-shaped product S2) immediately after the cutting step ST3 is executed. FIG. 3D is a diagram schematically showing a state of the sheet-shaped product S2 in the process of executing the recovery step ST4.
Hereinafter, each process ST1 to ST4 will be described in order.

<First marking process ST1>
As shown in FIG. 3A, in the first marking step ST1, the defect F detected by inspecting the raw fabric S1 with respect to the raw fabric S1 before cutting (in FIG. 3A, for convenience, for convenience). The first mark M1 is marked by the first marking device 2 at the position where each defect F is shown in the star shape). The first mark M1 of the present embodiment is a plurality of circular dot-shaped marks arranged in the transport direction (X direction) of the original fabric S1. More specifically, in the first mark M1 of the present embodiment, a pattern consisting of a plurality of circular dot-shaped marks arranged in the transport direction (X direction) of the original fabric S1 has a defect F sandwiched between the original fabric S1. A pair is lined up in the width direction (Y direction). The length of each pattern (dimension in the X direction) determined by the number of dot-shaped marks is determined according to, for example, the length of the defect F (dimension in the X direction). However, the present invention is not limited to this, and various forms of marks can be adopted as the first mark M1 as long as it is marked at the position where the defect F exists.

When the first mark M1 is marked with respect to the defect F detected by the inspection by the inspection device 1, the control device 5 (image processing means 13) constituting the inspection device 1 has the defect F in the transmitted image. The position (XY coordinates) of is recognizable. Therefore, for example, the control device 5 has the position (X coordinate) of the defect F in the recognized transmission image, the separation distance L1 in the X direction of the inspection device 1 and the first marking device 2, and the encoder attached to the nip roller R2. It is possible to calculate the timing at which the detected defect F reaches the first marking device 2 based on the amount of the original fabric S1 measured by (not shown) or the like. Then, for example, the control device 5 has a nozzle of the first marking device 2 corresponding to the position (Y coordinate) of the defect F in the recognized transmission image at the timing when the detected defect F reaches the first marking device 2. The first marking device 2 is controlled so as to eject the transparent ink from the surface. As a result, the first mark M1 is marked at the position where the defect F exists.

In the first marking step ST1, the first mark M1 is used for the defect F detected by inspecting the raw fabric S1 with another inspection device (not shown) before the inspection by the inspection device 1. It is also possible to mark. In this case, the position of the defect F detected by another inspection device (for example, the XY coordinates with respect to the tip in the transport direction of the original fabric S1) is input to the control device 5 in advance. Then, for example, the control device 5 has the input position (X coordinate) of the defect F, the separation distance L2 in the X direction of the feeding roller R1 and the first marking device 2, and the encoder attached to the nip roller R2 (not shown). ) And the like, it is possible to calculate the timing at which the defect F detected by another inspection device reaches the first marking device 2. Then, for example, the control device 5 of the first marking device 2 corresponding to the position (Y coordinate) of the defect F detected by another inspection device at the timing when the detected defect F reaches the first marking device 2. The first marking device 2 is controlled so as to eject the transparent ink from the nozzle. As a result, the first mark M1 is marked at the position where the defect F exists.
Further, in order to calculate the timing at which the defect F detected by another inspection device reaches the first marking device 2, for example, as described in Patent Document 2, the width direction (Y direction) end of the original fabric S1 is used. By recording the identification information indicating the position of the raw fabric S1 in the transport direction in the portion (the end portion not used as the sheet-shaped product S2), and reading this identification information and inputting it to the control device 5, the above-mentioned It is also possible to adopt a configuration that calculates the timing.

<Second marking process ST2>
As shown in FIG. 3B, in the second marking step ST2, the second marking device 3 marks the original fabric S1 before cutting with the second mark M2 representing the position information in the original fabric S1. The position information represented by the second mark M2 means information including at least the position of the original fabric S1 in the transport direction (X direction). The position of the original fabric S1 in the transport direction may be represented by the distance from the tip of the original fabric S1 in the transport direction, or a number assigned serially according to the distance from the tip of the original fabric S1 in the transport direction. It may be represented by. The position information represented by the second mark M2 may include a position in the width direction (Y direction) of the original fabric S1 in addition to the position in the transport direction of the original fabric S1. Further, the second mark M2 may represent information about the original fabric S1 for distinguishing a plurality of original fabrics S1 from each other.
The second mark M2 of the present embodiment is DataMatrix (registered trademark) which is a kind of two-dimensional code. However, the present invention is not limited to this, as long as it can represent other two-dimensional codes such as QR code (registered trademark), one-dimensional code (bar code), and position information on the original fabric S1. As the second mark M2, various forms of marks can be adopted.

In the second marking step ST2, the second marking device 3 makes the second mark with respect to the original fabric S1 before cutting so that a plurality of second marks M2 exist in each of the plurality of sheet-shaped products S2 after cutting. Mark M2. Specifically, the planned cutting line CL shown by the broken line in FIG. 3B is determined in advance according to the dimensions and shape of the sheet-shaped product S2, and is stored in the control device 5. The planned cutting line CL is not actually drawn on the original fabric S1, but is stored, for example, in XY coordinates with respect to the tip of the original fabric S1 in the transport direction. In the example shown in FIG. 3B, the planned cutting line CL is in a grid pattern, and is within each rectangle partitioned by the planned cutting line CL (18 rectangles are shown in FIG. 3B). The portion of the original fabric S1 located becomes the sheet-shaped product S2 after cutting. Therefore, in the second marking step ST2, a plurality of second marks M2 are present in each rectangle partitioned by the planned cutting line CL by the second marking device 3, and are not overlapped with the planned cutting line CL. The second mark M2 is marked on the surface. In the example shown in FIG. 3B, four second marks M2 are marked in each rectangle, and the positions of the four second marks M2 with respect to the planned cutting line CL are the same for all the rectangles. Is set to. Specifically, in FIG. 3B, the positions of the four second marks M2 existing in each rectangle are located near the upper left vertex, near the upper right vertex, and near the lower left vertex of each rectangle. And near the lower right vertex. The position of the second mark M2 located near the upper left apex of the rectangle and the position of the second mark M2 located near the upper right apex are different from each other in the width direction (Y direction) of the original fabric S1. Further, the position of the second mark M2 located near the lower left apex of the rectangle and the position of the second mark M2 located near the lower right apex are different from each other in the width direction (Y direction) of the original fabric S1.

When the second marking step ST2 is executed, for example, the control device 5 is measured by the separation distance L3 in the X direction of the feeding roller R1 and the second marking device 3 and an encoder (not shown) attached to the nip roller R2. It is possible to calculate the timing at which a predetermined portion of the original fabric S1 reaches the second marking device 3 based on the amount of the original fabric S1 conveyed. Then, for example, in the control device 5, a portion having predetermined XY coordinates with respect to the planned cutting line CL (a portion marking each of the four second marks M2 in each rectangle) reaches the second marking device 3. At the timing, the second marking device 3 is controlled so that the transparent ink is ejected from the nozzle of the second marking device 3 corresponding to the Y coordinate of the predetermined XY coordinate. As a result, the second mark M2 is marked on each of the four portions in each rectangle.

<Cutting process ST3>
As shown in FIG. 3C, in the cutting step ST3, the original fabric S1 marked with the first mark M1 and the second mark M2 is cut along the planned cutting line CL (see FIG. 3B) by the cutting device 4. To produce a plurality of sheet-shaped products S2. When a punching device is applied as the cutting device 4, the transport of the raw fabric S1 is temporarily stopped at the timing when the planned cutting line CL of the raw fabric S1 reaches the cutting device 4, and the raw fabric S1 is cut. It will be. When a laser processing device is applied as the cutting device 4, it is possible to cut while transporting the raw fabric S1 without stopping the transport of the raw fabric S1.
When executing the cutting step ST3, for example, the control device 5 uses the feeding roller R1 and the cutting device 4 to have a separation distance L4 in the X direction, and an original fabric S1 measured by an encoder (not shown) attached to the nip roller R2. It is possible to calculate the timing at which the scheduled cutting line CL of the original fabric S1 stored in the control device 5 reaches the cutting device 4 based on the transport amount. Then, the control device 5 controls and drives the cutting device 4 at the timing when the planned cutting line of the original fabric S1 reaches the cutting device 4. As a result, the raw fabric S1 is cut along the planned cutting line CL, and a plurality of sheet-shaped products S2 are manufactured.

<Recovery process ST4>
As shown in FIG. 3D, in the recovery step ST4, an unnecessary portion S11 (see FIG. 3C) that does not become a sheet-shaped product S2 is known while the cut raw fabric S1 is conveyed by the conveyor R3. Remove with a removal device (not shown). After that, the sheet-shaped product S2 is conveyed by the conveyor R3 and dropped by gravity from the downstream end of the conveyor R3 in the conveying direction to collect the sheet-shaped product S2.

According to the manufacturing method according to the present embodiment described above, the first mark M1 is marked on the raw fabric S1 before cutting at the position where the defect F detected by inspecting the raw fabric S1 exists. Although the first marking step ST1 and the second marking step ST2 for marking the second mark M2 representing the position information in the raw fabric S1 with respect to the raw fabric S1 before cutting are used in combination, in the second marking step ST2, Mark so that each of the plurality of sheet-shaped products S2 after cutting has a plurality of second marks M2 (that is, each sheet-shaped product S2 has a plurality of second marks M2 instead of a single one). Therefore, the possibility that the first mark M1 and all the plurality of second marks M2 overlap is greatly reduced. Therefore, by reading the second mark M2 (the second mark M2 that does not overlap with the first mark M1) marked on each sheet-shaped product S2 after cutting, the cause of the abnormality in the sheet-shaped product S2 is investigated. It is also possible to contribute to improving the yield of the sheet-shaped product S2.

Further, according to the manufacturing method according to the present embodiment, in the second marking step ST2, the positions of the plurality of second marks M2 in the plurality of sheet-shaped products S2 after cutting are in the width direction (Y direction) of the original fabric S1. The second mark M2 is marked so as to include those different from each other. Specifically, the position of the second mark M2 located near the upper left apex of each rectangle partitioned by the planned cutting line CL and the position of the second mark M2 located near the upper right apex of the original fabric S1. The positions of the second mark M2 located near the lower left apex of the rectangle and the position of the second mark M2 located near the lower right apex of the rectangle are different from each other in the width direction, and are different from each other in the width direction of the original fabric S1. Therefore, for example, due to a defect in the nip roller R2 or the like, defects occur periodically along the transport direction (X direction) of the raw fabric S1 (accordingly, the first mark M1 moves in the transport direction of the raw fabric S1). Even in the case of (marked periodically along the line), since the positions of the plurality of second marks M2 in each sheet-shaped product S2 include those different from each other in the width direction of the original fabric S1, the first mark M1 and The possibility that all the plurality of second marks M2 overlap is greatly reduced.

Further, according to the manufacturing method according to the present embodiment, in the second marking step ST2, the second mark M2 is marked so as not to overlap the predetermined cutting planned line CL of the original fabric S1. Therefore, in each sheet-shaped product S2 after cutting, a plurality of second marks M2 can be reliably marked.
Further, according to the manufacturing method according to the present embodiment, the first mark M1 and the second mark M2 are marked by an inkjet method using transparent ink in each of the first marking step ST1 and the second marking step ST2. Therefore, under normal lighting, the first mark M1 and the second mark M2 are invisible, which has the advantage of not impairing the appearance of the sheet-shaped product S2.

In the present embodiment, as shown in FIG. 3B, in the second marking step ST2, four second marks M2 are marked in each rectangle partitioned by the scheduled cutting line CL, and the cutting is scheduled. Although the example in which the positions of the four second marks M2 with respect to the line CL are set to be the same for all the rectangles has been described, the present invention is not limited to this.

FIG. 4 is a diagram illustrating a modified example of the second marking step ST2. Specifically, FIG. 4 is a diagram schematically showing the state of the original fabric S1 immediately after executing the modified example of the second marking step ST2. In FIG. 4, unlike FIG. 3 (b), the defect F and the first mark M1 are not shown.
As shown in FIG. 4, also in the modified example of the second marking step ST2, four second marks M2 are marked in each rectangle partitioned by the planned cutting line CL, as in the case shown in FIG. 3 (b). For each rectangle, the second mark M2 closest to the upper left vertex of the rectangle is M21, the second mark M2 closest to the upper right vertex of the rectangle is M22, and the second mark closest to the lower left vertex of the rectangle. The mark M2 is M23, and the second mark M2 closest to the lower right vertex of the rectangle is M24. Then, the positions (XY coordinates) of the second marks M21 to M24 based on the planned cutting line CL (based on the intersecting vertices of the planned cutting line CL) are set to (X1, Y1) and (X2, Y2), respectively. , (X3, Y3), (X4, Y4).

In this case, in the second marking step ST2 shown in FIG. 3B, the positions of the four second marks M2 (corresponding to M21 to M24 shown in FIG. 4) in each rectangle are the same for all the rectangles, that is, , X1 to X4 and Y1 to Y4 are set to be the same for all rectangles. However, in the modified example of the second marking step ST2 shown in FIG. 4, the positions of the four second marks M21 to M24 in each rectangle are set to include those having different positions from each other. That is, when the positions of the four second marks M21 to M24 in any one rectangle selected from all the rectangles are compared with the positions of the four second marks M21 to M24 in any other rectangle. , The four second marks M21 to M24 in the other rectangle may not exist at the same position as any of the four second marks M21 to M24 in one rectangle. In particular, in the example shown in FIG. 4, as a preferable example, all the positions of the four second marks M21 to M24 are set so as to be different for each rectangle. That is, in the example shown in FIG. 4, the position of the second mark M21 (X1, Y1) is different for each rectangle, the position of the second mark M22 (X2, Y2) is different for each rectangle, and the position of the second mark M23 ( X3, Y3) is different for each rectangle, and the position (X4, Y4) of the second mark M24 is different for each rectangle.

Not limited to the example shown in FIG. 4, as a modification, for example, only the positions of the four second marks M2 in one rectangle are different from the positions of the four second marks M2 in the remaining rectangles, and the remaining rectangles. The positions of the four second marks M2 may be the same.
Further, as a modification, for example, only the position of one second mark M2 (for example, the second mark M24) in one rectangle is the corresponding second mark (for example, the second mark M24) of the remaining rectangle. The positions of the remaining second marks (for example, the second mark M21, the second mark M22, and the second mark M23) may be the same for all the rectangles, unlike the positions of.

As described above, in the modified example of the second marking step ST2, since the positions of the four second marks M2 in each rectangle are set to include those different from each other, in the plurality of sheet-shaped products S2 after cutting. The positions M2 of the second mark include those different from each other. Therefore, for example, when a plurality of sheet-shaped products S2 are laminated and used, there is an advantage that the possibility that the second mark M2 in each sheet-shaped product S2 overlaps and a dent is generated in the overlapped portion can be reduced. Have.

Further, in the present embodiment, in the first marking step ST1, as shown in FIG. 3A, the first marking is composed of a plurality of circular dot-shaped marks arranged in the transport direction (X direction) of the original fabric S1. Although an example of marking the mark M1 has been described, the present invention is not limited to this.

FIG. 5 is a diagram illustrating a modified example of the first marking step ST1. Specifically, FIG. 5 is a diagram schematically showing a part of the original fabric S1 immediately after the modification of the first marking step ST1 is executed.
As shown in FIG. 5, in the modified example of the first marking step ST1, at least one of the plurality of dot-shaped marks constituting the first mark M1 (all in the example shown in FIG. 5) becomes the second mark M2. ing. That is, at least one of the plurality of dot-shaped marks is not a circular mark, but a second mark M2 such as a two-dimensional code representing position information on the original fabric S1. In particular, as shown in FIG. 5, when all of the plurality of dot-shaped marks constituting the first mark M1 are used as the second mark M2, the first marking device 2 for executing the first marking step ST1 Can also be used as the second marking device 3 for executing the second marking step ST2.

Further, in the present embodiment, in the second marking step ST2, the second mark is attached to the original fabric S1 before cutting so that four second marks M2 are present in each of the plurality of sheet-shaped products S2 after cutting. Although the case of marking M2 has been described as an example, the present invention is not limited to this. As long as the second mark M2 is marked on the original fabric S1 before cutting so that a plurality of (that is, two or more) second marks M2 exist in each of the plurality of sheet-shaped products S2 after cutting. There is no limit to the number.

Further, in the present embodiment, a case where a plurality of sheet-shaped products S2 are manufactured by feeding out, transporting, and cutting a long raw fabric S1 wound in a roll shape has been described as an example, but the present invention has been described. Is not limited to this. A long roll-shaped raw fabric S1 is unwound and conveyed to mark the first mark M1 and the second mark M2, and then a large sheet-like intermediate (dimer than a plurality of sheet-like products S2). It is also possible to adopt an embodiment in which a plurality of sheet-shaped products S2 are manufactured by cutting out the large sheet-shaped intermediate) and cutting the intermediate. The intermediate may be cut by being conveyed by a conveyor R3 or the like, or may be cut while being placed on a predetermined cutting table.

Further, in the present embodiment, the case where the first mark M1 is marked on the original fabric S1 before cutting has been described as an example, but the present invention is not limited to this, and the intermediate cut out from the original fabric S1. It is also possible to mark the first mark M1 on the body. Further, in the present embodiment, the case where the second mark M2 is marked on the original fabric S1 before cutting has been described as an example, but the present invention is not limited to this, and the intermediate cut out from the original fabric S1. It is also possible to mark the second mark M2 on the body and a plurality of sheet-shaped products S2 after cutting.

FIG. 6 shows a schematic configuration of a manufacturing apparatus for executing a method for manufacturing a sheet-shaped product S2 according to a modified example of the present invention (a configuration in which a second mark M2 is marked on a plurality of sheet-shaped products S2 after cutting). It is a figure which shows. In FIG. 6, the same components as those of the manufacturing apparatus 100 shown in FIG. 1 are designated by the same reference numerals.
As shown in FIG. 6, in the modified manufacturing device 100', the second marking device 3 is arranged on the conveyor R3 on the downstream side (downstream side in the transport direction of the sheet-shaped product S2) from the cutting device 4, and is in the form of a sheet. Prior to the collection of the product S2, the second marking device 3 marks the sheet-shaped product S2 with the second mark M2.

Specifically, for example, the control device 5 is the original fabric S1 measured by the separation distance L3'in the X direction of the feeding roller R1 and the second marking device 3 and an encoder (not shown) attached to the nip roller R2. Based on the transport amount and the transport amount of the sheet-shaped product S2 measured by an encoder (not shown) or the like attached to the roller provided on the conveyor R3, a predetermined portion of the raw fabric S1 is cut into the sheet-shaped product S2. After that, the timing of reaching the second marking device 3 can be calculated. Then, for example, the control device 5 has a portion having predetermined XY coordinates with reference to the planned cutting line CL of the original fabric S1 (the cutting line that becomes the edge of the sheet-shaped product S2 after being cut into the sheet-shaped product S2). In the example shown in FIG. 3, the second marking device corresponding to the Y coordinate of the predetermined XY coordinates at the timing when the four second marks M2 in each rectangle (the portion marking each of the four second marks M2) reaches the second marking device 3. The second marking device 3 is controlled so as to eject the transparent ink from the nozzle of 3. As a result, in the example shown in FIG. 3, the second mark M2 is marked on each of the four portions in each rectangle (inside the sheet-shaped product S2).

Further, as a method for marking the second mark M2, it is also possible to adopt a method using the identification information described in Patent Document 2.
Specifically, as described in Patent Document 2, the position of the original fabric S1 in the transport direction is represented at the widthwise (Y direction) end of the original fabric S1 (the end not used as the sheet-shaped product S2). The identification information is recorded, and for example, the identification information is read by a predetermined reading device arranged immediately before the cutting device 4, and is input to the control device 5. The control device 5 determines the sheet-shaped product S2 after cutting based on the read identification information and the conveyed amount of the sheet-shaped product S2 measured by an encoder (not shown) or the like attached to a roller provided in the conveyor R3. , A part having predetermined XY coordinates with respect to the edge of the sheet-shaped product S2 which recognizes the position in the transport direction in the original fabric S1 and is sequentially transported after cutting (in the example shown in FIG. 3, four parts in each rectangle). It is possible to calculate the timing at which the portion for marking the second mark M2) reaches the second marking device 3. Then, the control device 5 can also control the second marking device 3 so as to inject the transparent ink from the nozzle of the second marking device 3 corresponding to the Y coordinate of the predetermined XY coordinates at the above timing. Is.

Further, in the present embodiment, there is an example in which the first marking process ST1, the second marking process ST2, the cutting process ST3, and the recovery process ST4 are executed by a single manufacturing apparatus 100 (in other words, a single manufacturing line). However, the present invention is not limited to this. For example, after executing the first marking step ST1 and the second marking step ST2, the original fabric S1 marked with the first mark M1 and the second mark M2 is once wound on a take-up roller (not shown), and another It is also possible to adopt an embodiment in which the cutting step ST3 and the recovery step ST4 are executed by transporting the product to the production line. In other words, it is also possible to divide a series of steps of the first marking step ST1, the second marking step ST2, the cutting step ST3 and the recovery step ST4 between the second marking step ST2 and the cutting step ST3. In addition, it is possible to divide a series of processes ST1 to ST4 between any processes, such as dividing between the first marking process ST1 and the second marking process ST2.

Further, in the present embodiment, the case where the first marking step ST1 and the second marking step ST2 are executed in this order has been described as an example, but the present invention is not limited to this, and the second marking step ST2 is described first. It is also possible to adopt an embodiment in which the first marking step ST1 is executed after the execution.

1 ... Inspection device 2 ... 1st marking device 3 ... 2nd marking device 4 ... Cutting device 5 ... Control device 100 ... Manufacturing device F ... Disadvantage M1 ... No. 1 mark M2 ・・・ 2nd mark S1 ・・・ Original fabric S2 ・・・ Sheet-like product

Claims

A long roll of raw fabric wound in a roll shape is unwound and transported to be cut, or a long raw fabric wound in a roll shape is unwound and transported to cut out a large sheet-shaped intermediate. A method for producing a plurality of sheet-shaped products by cutting the intermediate.
The first mark is marked on the raw fabric before cutting, the raw fabric before cutting out the intermediate, or the intermediate, at the position where the defect detected by inspecting the raw fabric exists. First marking process and
The original fabric before cutting, the original fabric before cutting out the intermediate, the intermediate, or the plurality of sheet-like products after cutting are marked with a second mark indicating position information on the original fabric. Including the second marking step
In the second marking step, the raw fabric before cutting, the raw fabric before cutting out the intermediate, and the said material so that a plurality of the second marks are present in each of the plurality of sheet-like products after cutting. Marking the second mark on the intermediate or the plurality of sheet-like products after cutting.
Manufacturing method for sheet-shaped products.
In the second marking step, the second mark is marked so that the positions of the plurality of second marks in each of the plurality of sheet-shaped products after cutting include those having different positions in the width direction of the original fabric.
The method for manufacturing a sheet-shaped product according to claim 1.
The second mark is a one-dimensional code or a two-dimensional code.
The method for manufacturing a sheet-shaped product according to claim 1 or 2.
In the second marking step, when the second mark is marked on the original fabric before cutting or the original fabric before cutting out the intermediate, a predetermined cutting planned line of the original fabric is used. Mark the second mark so that it does not overlap with
The method for manufacturing a sheet-shaped product according to any one of claims 1 to 3.
In the first marking step, the first mark is marked with transparent ink and / or, in the second marking step, the second mark is marked with transparent ink.
The method for manufacturing a sheet-shaped product according to any one of claims 1 to 4.
In the second marking step, the second mark is marked so that the positions of the second marks on the plurality of sheet-shaped products after cutting with respect to the planned cutting line are different from each other.
The method for manufacturing a sheet-shaped product according to any one of claims 1 to 5.
The first mark is composed of a plurality of dot-shaped marks arranged in the transport direction of the original fabric.
The method for manufacturing a sheet-shaped product according to any one of claims 1 to 6.
At least one of the plurality of dot-shaped marks constituting the first mark is the second mark.
The method for manufacturing a sheet-shaped product according to claim 7.
A large sheet-shaped intermediate can be obtained by feeding out and transporting a long roll-shaped original fabric and cutting it, or by feeding out and transporting a long roll-shaped raw fabric. A sheet-like product manufactured in a plurality by cutting and cutting the intermediate.
The first mark is marked at the position where the defect detected by inspecting the original fabric exists, and a plurality of second marks indicating the position information on the original fabric are marked.
Sheet-shaped product.
It is a long raw fabric wound in a roll shape for manufacturing multiple sheet-shaped products by feeding, transporting, and cutting.
The first mark is marked at the position where the defect detected by inspecting the original fabric exists, and the second mark indicating the position information on the original fabric is marked.
The second mark is marked so that the plurality of second marks are present on each of the plurality of sheet-shaped products after cutting.
Original fabric.
It is a large sheet-shaped intermediate for manufacturing a plurality of sheet-shaped products by feeding out, transporting, cutting out, and cutting a long raw fabric wound in a roll shape.
The first mark is marked at the position where the defect detected by inspecting the original fabric exists, and the second mark indicating the position information on the original fabric is marked.
The second mark is marked so that the plurality of second marks are present on each of the plurality of sheet-shaped products after cutting.
Intermediate.