Classifications

• • G—PHYSICS
  • G01—MEASURING; TESTING
  • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
  • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
  • G01N21/84—Systems specially adapted for particular applications
  • G01N21/88—Investigating the presence of flaws or contamination
  • G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
  • G01N21/892—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the flaw, defect or object feature examined

Definitions

• the present invention relates to a method for extracting feature points, a method for setting shipping standards, and an information processing system.
• Liquid crystal display devices are increasingly being used in large-screen televisions and large monitors, and as a result, there is a demand for wider films to be used on the display surfaces of liquid crystal display devices. For example, there is a demand for wider films of 2000 mm or more. Also, in order to anticipate substrate loss (film loss) and reduce transportation costs, there is a demand for the production of long film rolls with winding lengths of 1000 m or more, and even 3000 m or more.
• Patent Document 1 A quality monitoring system that performs quality control by selecting defects that occurred in the latest process from the inspection information of the upstream process and the latest process, even if a part of the product roll is cut off due to an abnormality occurring between the upstream process and the latest process in a manufacturing process of roll-shaped anti-reflection film consisting of multiple processes,
• An inspection machine provided at each step in the manufacturing process; an inspection information management database that stores and manages the inspection information obtained from the inspection machine;
• a production information management database that manages quality information and performance information for each process of the product roll; a defect selection means for selecting defects occurring in the latest process by correcting coordinates of defect detection positions in the latest process and the preceding process based on the inspection information management database and the production information management database; and a defect monitoring means for determining that the defects selected by the defect selection means are abnormal based on abnormality determination conditions and notifying the user of the abnormality.
• Patent Document 1 detects defects that occur in the latest process, identifies anomalies, and notifies the user, which can stop defects from occurring during manufacturing. However, it is insufficient for collecting information to investigate the causes of quality problems, and does not lead to the setting of appropriate product standards or process improvements.
• the present invention was made in consideration of the above circumstances, and aims to efficiently collect information that is useful for process improvements and setting shipping standards both when producing film and in the manufacturing process where post-processing is performed using the film.
• a method for extracting feature points of a film comprising the steps of: A step (a) of acquiring first inspection data in a first manufacturing process of manufacturing a film; (b) acquiring second inspection data in a second manufacturing process, which is performed after the first manufacturing process and involves performing post-processing using the manufactured film; (c) comparing first feature information of the film in the first inspection data with second feature information of the film in the second inspection data; and (d) extracting, based on a comparison result of the step (c), feature points that are present in one of the first and second inspection data but not present in the other, or that are determined to be defective in one of the inspection data but not determined to be defective in the other inspection data. Methods for extracting feature points.
• a method for extracting feature points of a film comprising the steps of: A step (a) of acquiring first inspection data in a first manufacturing process for manufacturing a film or in a second manufacturing process for performing post-processing using the film manufactured after the first manufacturing process; (b) acquiring second inspection data at an inspection position in the second manufacturing process or after a sub-process downstream of the inspection position at which the first inspection data was acquired in the second manufacturing process; (c) comparing first feature information of the film in the first inspection data with second feature information of the film in the second inspection data; and (d) extracting, based on a comparison result of the step (c), feature points that are present in one of the first and second inspection data but not present in the other, or that are determined to be defective in one of the inspection data but not determined to be defective in the other inspection data. Methods for extracting feature points.
• the one test data is the first test data, and the other test data is the second test data;
• step (d) The method for extracting feature points described in (3) above, further comprising extracting second type feature points that are present in the second inspection data and not present in the first inspection data, or that are determined to be defective in the second inspection data and not determined to be defective in the first inspection data, in step (d).
• the first inspection data and the second inspection data are inspection data obtained by processing an image of the film to extract feature point information,
• the method further includes, before the step (c), a step (e) of aligning the film in the first inspection data and the second inspection data, In the step (e), (e1) shifting the relative positions of the first test data and the second test data and/or moving position information of the feature points of the second test data; a step (e2) of calculating a distance from each of a plurality of feature points in one of the first and second test data to a nearest feature point in the other of the first and second test data;
• the method for extracting feature points according to (3) above further comprising: a step (e3) of repeating the steps (e1) and (e2) so as to minimize the distance calculated in the step (e2).
• the method for extracting feature points described in (6) above further includes, after step (e), a step (f) of calculating the distance from each of the feature points in one of the first and second test data to the closest feature point in the other test data, excluding distance values equal to or greater than a predetermined threshold, and judging whether the processing of step (e) is appropriate based on the sum or average of the distance values calculated from the distance values after excluding the distance values.
• the method further includes, before the step (c), a step (g) of aligning the film in the first inspection data and the second inspection data, In the step (g), The method for extracting feature points described in (3) above, further comprising: performing kernel density estimation on a plurality of feature points of the first inspection data and the second inspection data to calculate a probability density function of the feature points; and comparing the calculated probability density functions to align the film.
• the method further includes, before the step (c), a step (g) of aligning the film in the first inspection data and the second inspection data,
• a step (g) of aligning the film in the first inspection data and the second inspection data In the step (g), The method for extracting feature points described in (3) above, further comprising: performing kernel density estimation on a plurality of feature points in one of the first and second inspection data to calculate a probability density function of the feature points; and comparing the calculated probability density function with position information of the feature points in the other inspection data, thereby aligning the film.
• the one of the test data is the second test data, and the other of the test data is the first test data,
• the first manufacturing process and the second manufacturing process each include a plurality of sub-processes, A plurality of pieces of inspection data are acquired at a plurality of inspection positions upstream and downstream of at least one of the plurality of sub-processes; The method for extracting feature points according to (2) above, wherein one of the plurality of pieces of inspection data is used as first inspection data, and inspection data at an inspection position downstream of the first inspection data is used as second inspection data.
• An acquisition unit that acquires first inspection data in a first manufacturing process of manufacturing a film and second inspection data in a second manufacturing process of performing a post-processing using the manufactured film, the second inspection data being performed after the first manufacturing process; a comparison unit that compares first feature information of the film in the first inspection data with second feature information of the film in the second inspection data; an extraction unit that extracts, based on a comparison result from the comparison unit, a feature point that is present in one of the first and second inspection data and is not present in the other of the first and second inspection data, or a feature point that is determined to be a defect in one of the inspection data and is not determined to be a defect in the other of the inspection data, Information processing system.
• an acquisition unit that acquires first inspection data in a first manufacturing process for manufacturing a film or a second manufacturing process for performing post-processing using the manufactured film which is performed after the first manufacturing process, and second inspection data in the second manufacturing process or at an inspection position after a sub-process downstream of the inspection position where the first inspection data in the second manufacturing process is acquired; a comparison unit that compares first feature information of the film in the first inspection data with second feature information of the film in the second inspection data; an extraction unit that extracts, based on a comparison result from the comparison unit, a feature point that is present in one of the first and second inspection data and is not present in the other of the first and second inspection data, or a feature point that is determined to be a defect in one of the inspection data and is not determined to be a defect in the other of the inspection data, Information processing system.
• the feature extraction method includes a step (c) of comparing first feature information of the film in the first inspection data of the first manufacturing process with second feature information of the film in the second inspection data of the second manufacturing process, and a step (d) of extracting feature points that are present in one of the first and second inspection data but not in the other inspection data, or that are determined to be defective in one of the inspection data but not in the other inspection data, based on the comparison result of step (c).
• FIG. 1 is a schematic diagram illustrating an application example of an information processing system according to a first embodiment.
• 11 is a table for explaining extracted first to third type feature points.
• 1 is a block diagram showing a schematic configuration of an information processing system.
• 4 is an example of a user list stored in a storage unit.
• 4 is an example of a lot list stored in a storage unit.
• 4 is an example of an inspection data DB stored in a storage unit.
• 4 is an example of an inspection data DB stored in a storage unit.
• 11 is a flowchart showing a process of generating first inspection data, which is performed in a first manufacturing process.
• FIG. 2 is a schematic diagram showing a configuration of an inspection device.
• FIG. 1 is a schematic diagram illustrating an application example of an information processing system according to a first embodiment.
• 11 is a table for explaining extracted first to third type feature points.
• 1 is a block diagram showing a schematic configuration of an information processing system.
• 4 is an example of
• FIG. 2 is a schematic diagram showing a configuration of an inspection device.
• FIG. 2 is a schematic diagram showing a configuration of an inspection device.
• 13 is a flowchart showing a process of generating second inspection data performed in a second manufacturing process.
• 11 is a flowchart showing a feature point extraction process executed in the information processing system.
• FIG. 11 is a schematic diagram for explaining a process of extracting feature points.
• 13 is a subroutine flowchart showing the alignment process in step S34.
• 13 is a flowchart showing a process for setting shipping standards in a first manufacturing process.
• 13 is a subroutine flowchart showing the alignment process in step S34 in the second embodiment.
• 13 is an example of a probability density function indicating the positions and intensities of feature points calculated by kernel density estimation.
• FIG. 13 is a schematic diagram showing an application example of an information processing system according to a third embodiment.
• 1 is a table showing inspection devices and inspection positions. 13 is a table explaining selected test data and knowledge obtained from the extraction results. 11 is a table for explaining extracted first to third type feature points.
• 3A to 3C are schematic diagrams illustrating a manufacturing process for a film roll and an inspection position of an inspection unit for first inspection data.
• FIG. 19 is an enlarged schematic view of the periphery of the winding device in the manufacturing process of FIG. 18 .
• 11 is a schematic diagram showing a manufacturing process for a product using a film roll and an inspection position of an inspection device for second inspection data.
• FIG. 1 is a schematic diagram showing an application example of an information processing system 50 according to a first embodiment.
• the information processing system 50 is communicatively connected to terminal devices 70 and the like in factories A and B via a network.
• the network is a communication line such as a data communication network.
• Some networks may use a wired LAN, a wireless LAN, or the like (for example, a LAN conforming to the IEEE 802.11 standard).
• the terminal device 70 is, for example, a PC (personal computer).
• the terminal device 70 is a PC used by an employee of a manufacturing company that operates Factory A and Factory B.
• Factory A is provided with a film roll manufacturing device 1000.
• Factory A is operated or managed by, for example, a film manufacturer.
• Factory A carries out a first manufacturing process for manufacturing a film roll 80.
• the film surface of the film roll 80 is inspected by an inspection device 90.
• the inspection device 90 is, for example, a camera.
• the film is, for example, an optical film, and its width is, for example, in the range of 1000 mm to 3000 mm.
• the thickness of the film is set in the range of 15 ⁇ m to 80 ⁇ m, taking into consideration quality, handling, etc.
• the length of the film roll 80 wound around the winding shaft is, for example, in the range of 2000 m to 10000 m.
• the film here includes a web.
• the web is a sheet-like material, and includes a resin film and a metal film.
• Factory B is provided with a product manufacturing device 2000.
• Factory B is operated or managed, for example, by a coating manufacturer or the like (hereinafter also referred to as a user company or user). There are multiple user companies that operate each factory B.
• factory B products are manufactured using film roll 80 shipped and transported from factory A.
• factory B a film (film F8 described below) is unwound from film roll 80, and a second manufacturing process, which is a post-processing process such as coating, is carried out.
• a coating process is carried out to apply a functional layer to the surface.
• the film surface of film roll 80 is inspected by inspection device 90. Inspection device 90 is, for example, a camera.
• inspection data also called failure data or defect data
• first inspection data containing feature information (feature points, positions, and strength) is generated by analyzing image data obtained by photographing the surface of the film.
• the information processing system 50 acquires the first inspection data from the terminal device 70 at factory A (step S1).
• the feature points are defects on the film, and are generated by analyzing image data.
• Image analysis may be performed by using a known technique to extract pixels whose pixel values deviate from the surrounding average value by a specified amount (the difference is specified or more) from image data obtained by photographing the film surface as feature points, or the feature points may be calculated using the "image processing for generating feature points" method described below.
• dozens to hundreds of feature points are generated from one or more image data obtained by photographing one film roll 80 (total length of several km).
• Defects include both defects that may lead to product defects and minor defects that do not lead to product defects.
• Feature points include defects related to poor adhesion when films are bonded together midway (by ultrasonic welding, etc.), axial unevenness, etc.
• Feature point information includes size and position (x, y coordinates).
• feature point information may be obtained by grouping (clustering) multiple adjacent feature points into one. The image processing for generating feature points will be described later.
• the film roll 80 manufactured in factory A is transported to factory B.
• the film roll 80 is optically inspected by the inspection device 90 during product inspection, and inspection data is generated.
• inspection data By analyzing image data obtained by photographing the surface of the film, inspection data including feature points (hereinafter referred to as second inspection data) is generated.
• the information processing system 50 acquires the second inspection data from the terminal device 70 in factory B (step S2). It is preferable that the inspection device 90 in factory A (first manufacturing process) and the inspection device 90 in factory B (second manufacturing process) are the same, that is, have the same measurement system and the same measurement conditions, but this is not limited to this.
• the desired performance, quality, and product standards (hereinafter referred to as product standards, etc.) may differ between factories A and B, and an inspection device 90 with an appropriate measurement system and measurement conditions may be used according to each product standard, etc.
• the information processing system 50 performs a feature point extraction process by comparing the first and second inspection data for the same film roll 80 (step S3). Specifically, the information processing system 50 performs a feature point extraction process by comparing feature points at corresponding positions on the film surface in the first and second inspection data.
• detecting feature points from image data is referred to as "generating feature points.”
• Comparing the first and second inspection data and classifying the feature points into one of the following first to third type feature points is referred to as "extracting feature points.”
• FIG. 2 is a table for explaining the first to third type feature points extracted by the feature point extraction process.
• a number of feature points generated from the inspection data of one film roll 80 may be classified into the first to third type feature points. For example, some of the several hundred feature points are extracted as first type feature points, some as second type feature points, and the rest as third type feature points.
• the first type feature points are feature points that are present in the first inspection data but not present in the second inspection data.
• the first type feature points are feature points that disappear in the second manufacturing process (e.g., a coating process). These first type feature points are feature points that do not need to be managed in the first manufacturing process. In this case, the manufacturing conditions that cause the first type feature points to occur may be subject to relaxation of standards in the first manufacturing process.
• the second type feature points are feature points that are not present in the first inspection data but are present in the second inspection data.
• the second type feature points are feature points that newly appear in the second manufacturing process. Since the second type feature points are feature points caused by the second manufacturing process, they can be used to improve the second manufacturing process.
• the third type feature point is a feature point that exists in both the first inspection data and the second inspection data.
• This third type feature point is a feature point caused by the first manufacturing process and is a feature point that needs to be managed. Since this third type feature point is a feature point caused by the first manufacturing process, it can be used to improve the first manufacturing process.
• the information processing system 50 feeds back the feature point extraction results to the users at Factory A and Factory B (Step S4).
• the extraction results are sent to the terminal device 70 in response to access from the terminal device 70 of the user of the manufacturer of the target film roll 80 and the terminal device 70 of the user to whom the film roll 80 was delivered.
• Fig. 3 is a block diagram showing a schematic configuration of the information processing system 50.
• the information processing system 50 is, for example, a server.
• the information processing system 50 includes a control unit 51, a storage unit 52, and a communication unit 53.
• the control unit 51 has a CPU and memories such as RAM, ROM, etc.
• the CPU is a control circuit composed of a multi-core processor or the like that controls each of the above-mentioned units and executes various arithmetic processing according to a program, and each function of the information processing system 50 is realized by the CPU executing the corresponding program.
• the control unit 51 functions as an acquisition unit 511 by working with the communication unit 53.
• the control unit 51 also functions as an alignment unit 512, a comparison extraction unit 513, and an output unit 514.
• the acquisition unit 511 acquires the first and second inspection data obtained by inspection in the first and second manufacturing processes.
• the alignment unit 512 aligns the coordinates of the first and second inspection data by shifting the relative positions of the feature points of the first and second inspection data, or by moving (shifting) the position information of the second inspection data.
• the comparison extraction unit 513 corresponds to the comparison unit and the extraction unit.
• the comparison extraction unit 513 compares the feature points of the first and second inspection data after the alignment process, and extracts the first to third type feature points shown in FIG. 2.
• the output unit 514 transmits the extraction results of the feature points to the terminal device 70 or displays them on a display unit (not shown) in response to a request from the terminal device 70.
• the memory unit 52 is a large-capacity auxiliary storage device that stores various programs including an operating system and various data. For example, a hard disk, a solid state drive, a flash memory, a ROM, etc. are used as the storage. A user list, a lot list, an inspection data DB, etc. are stored in the memory unit 52. Of these, the user list and the lot list are managed and registered by an administrator accessing the terminal device 70. For example, this administrator is a person in charge of the relevant department of the manufacturer that operates factory A.
• (User List) 4A is an example of a user list stored in the storage unit.
• the user list stores user IDs, user names, contact information, etc.
• each user is assigned an access right to a search data DB (inspection database), and is given an access right to various data (inspection data, extracted data, etc.) related to the film roll 80 (identified by a lot ID) that the user is involved in.
• search data DB inspection database
• (Lot list) 4B is an example of a lot list stored in the storage unit, which records a lot ID given to each film roll, a product name (also called a type), a delivery destination user ID (orderer), and multiple manufacturing conditions, sizes (width, length, thickness), manufacturing date, etc.
• the inspection data DB stores data related to various inspections of the film roll 80, such as the first and second inspection data and the feature point extraction results as shown in Figures 5A to 5C.
• the first inspection data is data obtained from the inspection in the first manufacturing process.
• the second inspection data is data obtained from the inspection in the second manufacturing process.
• the feature point extraction results are data generated by the information processing system 50 using the first and second inspection data.
• FIG. 5A is an example of an inspection list registered in the inspection data DB.
• the inspection list stores the inspection ID, lot ID, inspection device ID, inspection data, inspection date and time, etc.
• FIG. 5B shows an example of the contents of inspection data (inspection ID: i0101) in the inspection list.
• the inspection data records the feature point ID, which is automatically assigned a consecutive number to each feature point, and for each feature point ID, its XY coordinate position and intensity.
• the intensity is the rank of the feature point, which will be described later.
• the intensity information may also include information on the size (diameter, area) of the feature point.
• the XY coordinate position is based on the origin of the film surface (e.g., the left end of the leading edge).
• X is the coordinate in the width direction of the film, and can range from 0 to 3000 mm, for example, depending on the film size (see FIG. 4B).
• Y is the coordinate in the length direction of the film, and can range from 0 to 10000 m, for example, depending on the film size.
• Figure 5C is an example of extraction result data (hereinafter simply referred to as extracted data).
• the extracted data records the inspection IDs of the original first and second inspection data, and the extraction results for each feature point.
• the extraction results (first to third types) are classified as shown in Figure 2 above.
• the integrated feature point IDs are automatically assigned consecutive numbers, and integrated feature points are generated corresponding to feature points that are present in either or both of the first and second inspection data.
• the number of integrated feature point IDs is greater than or equal to the number of first inspection and second inspection feature point IDs.
• multiple first and second inspection data may be generated for one lot ID by multiple inspection devices.
• the film roll 80 in its original wound state is inspected (photographed), and multiple second inspection data are generated by inspection in several downstream processes.
• the information processing system 50 may generate multiple feature point extraction result data for one piece of first inspection data in relation to multiple pieces of second inspection data (one-to-many). The user may be able to select which second inspection data to associate with.
• the communication unit 59 also serves as an interface for network connection with an external device such as a PC.
• Figure 6 is a flow chart showing the process of generating the first inspection data performed in the first manufacturing step.
• Step S11 the film roll 80 is manufactured by the film roll manufacturing apparatus 1000. At this time, the film roll is manufactured according to shipping standard z.
• Step S12 The inspection device 90 photographs the film and stores the image data.
• the configuration of the inspection device 90 will be described below with reference to FIG.
• the following types of devices are available for detecting irregularities on the surface of a transparent body such as film F8 as an object to be inspected, as well as bubbles, cracks, distortions in the internal structure, and the like present inside the transparent body.
• a transmission type inspection device that detects defects in an object to be inspected by irradiating the object with light and receiving the light that has passed through the object to be inspected.
• a reflection type inspection device that detects defects in an object by receiving light reflected from the object.
• the transmissive and reflective types there are bright-field inspection devices that receive non-scattered light from the surface and dark-field inspection devices that receive scattered light, depending on the positional relationship between the optical axis of the camera, the light source, and the object to be inspected.
• a bright-field inspection device if there is no defect, there is no scattering of light, so the light from the light source enters the light detection means without being blocked, and if there is a defect, the light is blocked by the defect and does not enter the light detection means. Therefore, the defect is observed as a dark dot or streak against a bright background.
• the inspection device 90 in this embodiment, any type of inspection device may be used. It is preferable, but not limited to, that the first inspection data and the second inspection data are acquired by the same type of inspection device.
• FIG. 7A is a schematic diagram showing the configuration of a reflection-type inspection device 90 as viewed from the width direction (Y direction).
• FIG. 7B is a schematic diagram showing the configuration of the inspection device 90 as viewed from the transport direction (X direction).
• the inspection device 90 includes a light source 91, a camera 92 as an optical sensor, an analysis unit 93 as a data processing device, and a storage unit 94.
• the inspection device 90 optically inspects feature points (hereinafter, simply referred to as defects) that occur on the film F8 during transport.
• the camera 92 optically inspects the film F8 of the film roll 80 and generates image data as inspection data.
• the number of cameras, the angle of view, and the distance to the film surface of the camera 92 are set so that the entire width of the film F8 becomes the inspection area (photographing range).
• the number of cameras is for arranging multiple cameras in the width direction when the entire width of the film cannot be properly photographed with one camera.
• FIG. 7B is a diagram showing a state in which two cameras 92 are arranged in the width direction (Y direction) as an example.
• the analysis unit 93 may combine multiple images obtained by continuous shooting of one camera 92 to generate one piece of image data including the entire film surface of the film roll 80, or may store multiple pieces of image data in the storage unit 94 in association with the shooting time. Also, similar image data obtained by multiple cameras 92 arranged in the width direction may be combined.
• the analysis unit 93 can determine the position in the longitudinal direction of the film F8 by the shooting time associated with the image data by referring to the stored transport speed (winding speed or sending speed). In the following description, it is assumed that multiple pieces of image data obtained by continuous shooting are stored in association with the shooting time for one film roll 80.
• the analysis unit 93 generates defect information by analyzing the image data.
• the inspection device 90 inspects defects that occur during the manufacturing process, such as during winding of the long film F8.
• the light source 91 irradiates light onto the inspection area of the film F8.
• the light source 91 irradiates light uniformly across the width of the rolled film F8 (a direction perpendicular to the longitudinal direction of the film F8 and parallel to the film surface).
• uniform means that the illuminance on the film F8 is approximately the same across the width of the film F8 (e.g., the difference between the maximum and minimum values is less than a predetermined value).
• Camera 92 is an optical sensor that optically reads the inspection area of film F8.
• Camera 92 is equipped with imaging elements such as a CCD (Charge Coupled Device) or a CMOS (Complementary Metal Oxide Semiconductor), lenses, etc.
• Camera 92 is an area sensor that generates two-dimensional image data from the output signals of each imaging element.
• Camera 92 detects diffuse light from the light that is irradiated by light source 91 and reflected in the inspection area of film F8.
• either a color camera or a black and white camera (monochrome camera) may be used as camera 92.
• Camera 92 has a shooting range that spans the entire width of film F8, and in one shooting session, it simultaneously reads the entire range in the width of film F8. Camera 92 may detect light in the visible light range, or it may detect light in the infrared range.
• the contrast between the signal value corresponding to the irradiated portion on the film F8 where light is irradiated by the light source 91 and the signal value corresponding to the non-irradiated portion where light is not irradiated by the light source 91 is equal to or greater than a predetermined value. In other words, it is desirable that only the portions on the film F8 where light from the light source 91 is irradiated (irradiated portions) appear bright.
• the contrast is expressed as the difference or ratio between two values to be processed (here, the signal value corresponding to the irradiated area and the signal value corresponding to the non-irradiated area), and the greater the difference between the two values, the greater the contrast.
• a light source 91 that is powerful and highly directional.
• strong means that when the illuminance at an irradiation distance of 50 mm is E50, the illuminance E50 is 50,000 lx or more.
• highly linear means that when the illuminance at an irradiation distance of 50 mm is E50 and the illuminance at an irradiation distance of 100 mm is E100, the condition (E50-E100)/E50 ⁇ 0.5 is satisfied.
• the analysis unit 93 is composed of a CPU, RAM, etc., and reads out various processing programs stored in the storage unit 94, expands them into the RAM, and performs various processes in cooperation with the programs.
• the storage unit 94 is composed of a HDD, SSD (Solid State Drive), etc., and stores various processing programs, data required to execute the programs, etc.
• the storage unit 94 also stores captured image data (inspection data) in association with the time of capture.
• the storage unit 94 stores the winding speed (e.g., 100 m/min) in the film roll manufacturing device 1000, or the payout conditions (e.g., 30 m/min) of the film F8 in the product manufacturing device 2000. These winding speeds and payout conditions may be included in the inspection list of the inspection DB (see Figure 5A).
• the analysis unit 93 detects defects (position and strength) in the film F8 by performing data processing on the output signal of the camera 92 (optical sensor).
• the data processing includes image processing of image data obtained from the output signal of the camera 92, defect determination processing that determines defects based on the data after the image processing, and quantitative evaluation processing that quantitatively evaluates the defects based on the data after the image processing.
• the camera 92 may be disposed at a position where it receives specularly reflected light emitted from the light source 91 (in the case of a bright-field inspection method that receives non-scattered light).
• the camera 92 may be positioned to avoid receiving specularly reflected light from the light source 91 (in the case of a dark-field inspection method that receives scattered light). In other words, it is preferable to position the camera 92 in a position that receives diffuse light reflected from the object to be inspected.
• Transmission type inspection device 7C shows an example of a transmission type inspection device 90.
• a transmission type inspection device 90 in which the light source 92 is disposed facing the camera 92 with the film F8 interposed therebetween may be employed.
• Step S13 The analysis unit 93 performs image processing, which will be described below, on the image data to generate a plurality of feature points.
• the analysis unit 93 acquires two-dimensional image data generated by the camera 92 and stored in the storage unit 94 .
• the analysis unit 93 performs data processing on the image data (test data) acquired from the camera 92.
• the analysis unit 93 divides the image data into multiple regions. For example, the analysis unit 93 divides the image data into n regions (e.g., several to several tens of regions) in the width direction (hereinafter referred to as regions a1 to an).
• the analysis unit 93 acquires image data of one area a1 and performs mathematical processing on the image data of area a1 (step S103). Appropriate mathematical processing is prepared depending on the type of defect to be detected (gauge band, vertical wrinkles, diagonal wrinkles, etc.).
• Mathematical processing includes preprocessing, enhancement processing, signal processing, image feature extraction, etc.
• Pretreatment includes the following: - Image cropping, ⁇ Low pass filter, high pass filter, Gaussian filter, median filter, bilateral filter, -Morphological transformation, color transformation (L*a*b*, sRGB, HSV, HSL), contrast adjustment, noise removal, restoration of blurred and shaken images, mask processing, Hough transform, projection transformation, etc.
• enhancement processing examples include the Sobel filter, Scharr filter, Laplacian filter, Gabor filter, and Canny method.
• the signal processing includes the following: - Basic statistics (maximum, minimum, average, median, standard deviation, variance, quartile), square root of sum of squares, difference, sum, product, ratio, distance matrix calculation, differential and integral calculus, threshold processing (binarization, adaptive binarization, etc.), -Fourier transform, wavelet transform, peak detection (peak value, number of peaks, half-width, etc.), etc.
• image feature extraction examples include template matching and SIFT features.
• Threshold processing is a process that determines whether or not the defect is the target of detection based on a predetermined threshold, and also determines the rank (intensity) of the defect.
• determining the presence and type of defect corresponds to the "defect determination processing.” Also, in the threshold processing of step S104, classifying defects into multiple ranks according to the threshold corresponds to the "quantitative evaluation processing.”
• defects are classified into multiple ranks for a parameter (feature) that ranges from 1 to 100.
• ranks are classified according to the size (diameter or area) of the defect. Ranks classified by size may also be further subdivided according to the parameter value.
• the analysis unit 93 performs similar processing on areas other than area a1.
• the analysis unit 93 After processing each of the regions a1-an, the analysis unit 93 integrates the results for each of the regions a1-an, and data processing ends. Specifically, the analysis unit 93 generates data that associates the rank of the detected defects and their occurrence position (x-y coordinates) for each region (each position in the width direction of the film F8).
• the analysis unit 93 stores the results of the data processing in the storage unit 94.
• the analysis unit 93 performs such data processing on each of the multiple image data obtained by inspecting one film roll 80 to obtain the processing results. By aggregating these processing results, inspection data such as that shown in FIG. 5B is generated.
• Step S14 The terminal device 70 in the first manufacturing process sends the inspection data including the plurality of pieces of feature point information obtained in the processes up to step S13 to the information processing system 50.
• the acquisition unit 511 of the information processing system 50 stores the acquired inspection data in the inspection data DB of the storage unit 52 as first inspection data.
• FIG. 8 is a flowchart showing a process for generating second inspection data performed in the second manufacturing process.
• Step S21 In the second manufacturing process, the product manufacturing apparatus 2000 performs post-processing using the film roll 80 to manufacture a product using the film F8.
• the inspection device 90 photographs the surface of the film F8 before post-processing or during or after post-processing, and stores the image data.
• the inspection device 90 is composed of, for example, a light source 91, a camera 92, an analysis unit 93, a storage unit 94, and the like, as shown in FIG.
• Step S23 The analysis unit 93 stores the generated inspection data including the feature point information of the multiple feature points in the storage unit 94 by the same process as in step S13.
• Step S24 The terminal device 70 in the second manufacturing process sends the inspection data including the plurality of pieces of feature point information obtained in the processes up to step S23 to the information processing system 50.
• the acquisition unit 511 of the information processing system 50 stores the acquired inspection data in the inspection data DB of the storage unit 52 as second inspection data.
• Feature point extraction process The feature point extraction process executed by the information processing system 50 will be described below with reference to Fig. 9 to Fig. 11.
• Fig. 9 is a flowchart showing the feature point extraction process.
• Fig. 10 is a schematic diagram for explaining the feature point extraction process.
• Fig. 11 is a subroutine flowchart showing the alignment process in step S34.
• Step S31 The information processing system 50 starts the processing from step S31 onwards in response to a start instruction from the user via the terminal device 70, or when the second test data is registered in the test data DB of the memory unit 52 and a pair of first and second test data is obtained.
• the acquisition unit 511 acquires the same lot, i.e., a pair of first and second inspection data, from the inspection data DB.
• the alignment unit 512 performs preprocessing on the first test data under a first condition, and performs preprocessing on the second test data under a second condition.
• the XY coordinate system of each feature point in the second test data is aligned with the XY coordinate system of the first test data.
• this is not limited to this, and the XY coordinate system of the first test data may be aligned with the XY coordinate system of the second test data.
• the alignment unit 512 performs preprocessing of the second condition by inverting the Y coordinate (up and down) of the second inspection data to match the difference between winding (first manufacturing process) and unwinding (second manufacturing process).
• the alignment unit 512 performs preprocessing of inverting the X coordinate (left and right) of the second inspection data (or the first inspection data).
• the second inspection data may be coordinate-converted using that expansion/contraction rate.
• the alignment unit 512 executes at least one of the following noise removal processes for the first inspection data and the second inspection data as included in the first and second conditions.
• Step S34 The position alignment unit 512 executes a process of aligning the coordinate systems.
• Fig. 11 is a subroutine flowchart showing the position alignment process in step S34.
• the alignment unit 512 performs coarse adjustment in steps S401 to S403.
• the alignment unit 512 performs a process of shifting the coordinate position of the second test data by a predetermined amount in the XY direction, calculates the distances L1 to Lm between the corresponding feature points at that time, and selects the shift amount (x1, y1) whose sum is the smallest.
• an average value may be used instead of the sum.
• the corresponding feature points are extracted as the closest feature points.
• the distance may become a value at infinity.
• the alignment unit 512 may exclude distance values equal to or greater than a predetermined threshold value, and use the sum or average value of the distance values after the exclusion.
• the alignment unit 512 sequentially shifts the coordinate position of the second inspection data from (-shift_x, -shift_y) to (+shift_x, +shift_y) around the central shift amount (0, 0) in increments of a fixed coarse adjustment shift amount a. Then, for each of feature points 1 to m of the first inspection data at that time, it calculates distances L1 to Lm to the adjacent feature points in the second inspection data. Then, from (-shift_x, -shift_y) to (+shift_x, +shift_y), it selects the shift amount (x1, y1) with the smallest total distance.
• steps S404 to S406 the alignment unit 512 performs fine adjustment and selects a shift amount (x2, y2).
• the processing here is similar to that in steps S401 to S403, but differs from the coarse adjustment in steps S401 to S403 in the following respects.
• the fine adjustment shift amount b is smaller than the coarse adjustment shift amount a, and the central shift amount is not (0, 0), but the shift amount (x1, y1) selected in step S403 is set as the central shift amount.
• the fine adjustment shift amount b is sufficiently smaller than the coarse adjustment shift amount a, for example, 0.1 mm, which is one order of magnitude smaller.
• Step S407 The alignment unit 512 performs coordinate conversion processing on the second inspection data using the shift amount (x2, y2) selected in step S406.
• Step S408 After the coordinate transformation, the alignment unit 512 calculates the distances L1 to Lm and checks whether the sum is less than a predetermined threshold value. If the sum is equal to or greater than the predetermined threshold value, the alignment unit 512 may determine that the alignment in step S407 is inappropriate.
• Step S409 If the alignment is inappropriate (YES), the control unit 51 ends the process (END). If the alignment is inappropriate, an error message may be displayed, or a record may be made in the test data DB to the effect that the calculation cannot be performed. On the other hand, if the alignment is appropriate (NO), the control unit 51 ends the process of FIG. 11, returns to the process of FIG. 9 (RETURN), and executes the processes from step S35 onward.
• the comparison extraction unit 513 compares the feature point information of the first inspection data and the second inspection data.
• the second inspection data here is the data after the alignment process in step S34.
• the comparison extraction unit 513 extracts feature points that are present in only one of the first and second inspection data and not in the other.
• the comparison extraction unit 513 also extracts feature points that are present in both data. Through this process, the comparison extraction unit 513 generates extracted data in which the feature points are classified into first to third type feature points (see FIGS. 2 and 5C).
• Step S37 The output unit 514 registers the extraction result (extracted data) generated in step S36 in the test data DB, or transmits the extraction result to the terminal device 70. This ends the feature point extraction process shown in Fig. 9 (END).
• the first feature information of the film in the first inspection data is compared with the second feature information of the film in the second inspection data. Based on the comparison result, feature points that are present in one of the first and second inspection data but not in the other, or feature points that are determined to be defective in one of the inspection data but not in the other, are extracted. This makes it possible to efficiently collect information that is useful for process improvement and shipping specification setting both when manufacturing the film for the film roll and in the manufacturing process where post-processing is performed using the film.
• FIG. 12 is a flowchart showing the process of setting the shipping specifications in the first manufacturing process.
• Step S51 A user such as a manager who manages the first manufacturing process refers to the extraction result through the terminal device 70 of the first manufacturing process.
• the process here corresponds to step S37 in FIG.
• Step S52 The user can review the shipping standard z of the first manufacturing process by referring to the first type feature points, i.e., feature points that are present in the first inspection data but not present in the second inspection data. For example, by reviewing the shipping standard z regarding the first type feature points in the first manufacturing process, an improvement in yield can be expected.
• first type feature points i.e., feature points that are present in the first inspection data but not present in the second inspection data.
• an information processing system 50 according to the second embodiment will be described with reference to Figures 13 and 14.
• kernel density estimation is used for the alignment process of the coordinate system.
• it differs from the alignment process of the first embodiment ( Figures 10 and 11), but the configuration examples of the first embodiment shown in Figures 1 to 9 can be commonly applied to the other configurations.
• Figure 13 is a subroutine flowchart showing the alignment process of step S34 in the second embodiment.
• the alignment unit 512 obtains a probability density function by performing kernel density estimation on the first inspection data.
• the kernel density estimation is performed in two dimensions, and a Gaussian kernel is used as the kernel function.
• a predetermined value is used as the bandwidth. For example, a table in which each product name (type) is associated with a bandwidth may be stored in the storage unit 52, and a bandwidth value for each product name may be used, or different bandwidth values may be used depending on the number of feature points.
• the alignment unit 512 calculates density for each feature point data by taking into account surrounding data. Then, the alignment unit 512 adds up the densities calculated for each data to obtain a probability density function. FIG.
• FIG. 14 is an example of a probability density function indicating the position and intensity (density) of a feature point calculated by kernel density estimation.
• the vertical and horizontal axes are XY coordinates, and it is shown that the higher the concentration, the higher the density.
• Step S452 The alignment unit 512 performs kernel density estimation on the second inspection data in the same manner as in step S451 to obtain a probability density function.
• Steps S453 to S455 The position matching unit 512 compares the two obtained probability density functions and performs correspondence based on density distribution (position and intensity information). The position matching unit 512 then calculates a conversion matrix based on the correspondence result and performs coordinate conversion of the XY coordinates on the second inspection data.
• Steps S456 to S457 The process here is the same as steps S406 to S407 in Fig. 11.
• the alignment unit 512 uses the coordinate-converted inspection data to calculate distances L1 to Lm from feature points 1 to m in one inspection data to the corresponding feature points in the other inspection data, and checks whether the sum is less than a predetermined threshold. If the sum is equal to or greater than the predetermined threshold, the alignment unit 512 ends the process (END) if it determines that the alignment in step S455 is inappropriate. On the other hand, if the alignment is appropriate (NO), the control unit 51 ends the process in Fig. 13, returns to the process in Fig. 9 (RETURN), and executes the process from step S35 onward.
• the film is aligned by calculating the probability density function of the feature points using kernel density estimation and comparing the calculated probability density functions. This also provides the same effect as the first embodiment.
• kernel density estimation is performed on both the first and second inspection data to calculate the probability density function of the feature points, but this is not limiting.
• kernel density estimation may be performed on only one of the inspection data (e.g., the second inspection data), and the obtained probability density function may be compared with the feature point information of the other inspection data to align the film.
• FIG. 15 is a schematic diagram showing an application example of the information processing system 50 according to the third embodiment.
• FIG. 16 is a table showing the relationship between the multiple inspection devices 90a1 to 90b3 in FIG. 15 and the inspection positions.
• FIG. 15 is a diagram corresponding to FIG. 1, but the description of some configurations such as the terminal device 70 is omitted.
• an example was shown in which the first inspection data is acquired in the first manufacturing process, and the second inspection data is acquired in the second manufacturing process.
• inspection data is acquired at multiple inspection positions in each of the first and second manufacturing processes, and a combination of the first and second inspection data is selected from the multiple inspection data obtained.
• the inspection data at the upstream inspection position in the process flow direction is referred to as first inspection data
• the inspection data at the downstream inspection position is referred to as second inspection data.
• the inspection device 90 may be made up of multiple inspection units. For example, it may be made up of an inspection unit (camera) for detecting scratches on the surface of the film F8 and an inspection unit (camera) for detecting foreign objects inside the film F8. In this case, one of the analysis results obtained by analyzing the photographed data obtained from the two inspection units may be used, or a combination of these two analysis results (arithmetic processing such as addition) may be used as the inspection data.
• the inspection device 90a1 is placed at the final stage of the first manufacturing process 1000 (immediately upstream of the winding process).
• the first manufacturing process there is a storage process or a transport process for the film roll 80.
• the first to third sub-processes are the first to third coating processes, respectively.
• the first and second layers are applied to the original film F8, respectively (see the enlarged cross-sectional view of the blown-out in FIG. 15).
• Each sub-process may include not only a coating process in which a coating liquid is applied, but also other auxiliary processes such as a drying process.
• each sub-process is not limited to a coating process, and may be an adhesion process (lamination process) in which another film is adhered and attached, as in the embodiment described later.
• 17A is a diagram showing findings obtained by an extraction process when any two combinations are selected from the multiple test data (data A to data B3) shown in FIG. 16 and used as the first and second test data.
• This extraction process is executed by the information processing system 50, and any of the extraction processes described in the first and second embodiments may be applied. This selection may be made by a user via the terminal device 70, or the information processing system 50 may perform the extraction process for all combinations and output the results.
• FIG. 17B is a table for explaining the first to third types of feature points extracted by the feature point extraction process in the third embodiment.
• the first type of feature point is a feature point that has disappeared by the time the second inspection data is acquired (hereinafter referred to as the second inspection position). It can be subject to relaxation of standards for the manufacturing process or sub-manufacturing process upstream of the inspection position where the first inspection data is acquired (hereinafter referred to as the first inspection position).
• the second type of feature point is a feature point caused by an intermediate process (manufacturing process or sub-process) between the first inspection position and the second inspection position. This second type of feature point can be used to improve the intermediate process.
• the third type of feature point is a feature point caused by an upstream process (manufacturing process or sub-process) upstream of the first inspection position, and is also a feature point that requires management. This third type of feature point can be used to improve the upstream process.
• the information processing system 50 can feed back the extraction results of feature points obtained from such multiple combinations to users at Factory A and Factory B.
• first inspection data is obtained in the first manufacturing process for manufacturing a film or in the second manufacturing process for performing post-processing using the manufactured film after the first manufacturing process.
• Second inspection data is obtained in the second manufacturing process or at an inspection position after a sub-process downstream from the inspection position where the first inspection data was obtained in the second manufacturing process. That is, two inspection data are selected from the multiple inspection data obtained in the first and second manufacturing processes, and the inspection data from the upstream process is used as the first inspection data and the inspection data from the downstream process is used as the second inspection data. Then, the first feature point information of the film in the first inspection data is compared with the second feature point information of the film in the second inspection data.
• (First film roll manufacturing process) 18 produces an optical film by a solution casting method.
• a film roll 80 of the produced optical film is inspected by an inspection device 90 during product inspection.
• the raw resin is dissolved in a solvent, and various additives such as plasticizers, UV absorbers, anti-degradation agents, slip agents, and peeling promoters are added as necessary to prepare a dope, which is then extruded from a die onto an endless metal support (such as a belt or drum) that moves indefinitely.
• an endless metal support such as a belt or drum
• the solvent is removed to a certain extent on the endless support, and the film is peeled off from the endless support, then passed through a drying section by various conveying means to remove the solvent, and wound onto a winding shaft for production.
• the film roll manufacturing apparatus 1000 has a casting section 01, a first drying section 02, a stretching section 03, a second drying section 04, a knurling forming section 05, and a winding and recovery section 06 (also called a winding device).
• an inspection device 90 is disposed in the winding and recovery section 06.
• the inspection device 90 optically inspects the film surface side of the film roll 80 and generates first inspection data.
• the configuration of the inspection device 90 is as described above (FIG. 7, etc.).
• the casting section 01 has a mirror-finished, strip-shaped metal casting belt (hereinafter referred to as the belt) 01a, which is an endless support that runs endlessly (in the direction of the arrow in the figure), and a die 01b that casts a dope, which is a resin dissolved in a solvent, onto the belt 01a.
• a decompression chamber (not shown) may be provided upstream of the die 01b in the belt transport direction, and a pressurization chamber (not shown) may be provided downstream.
• the casting section 01 has a peeling roll 01d.
• the peeling roll 01d peels off the casting film 01c formed by casting onto the belt 01a.
• the casting film 01c peeled off by the peeling roll 01d constitutes the unstretched film F8a.
• the first drying section 02 (first drying process) has a drying box 02a with a dry air intake 02b and an exhaust 02c, and a conveying roll 02d made up of multiple sets of upper and lower pairs for conveying the unstretched film F8a.
• the first drying section 02 is capable of adjusting the amount of solvent contained in the unstretched film F8a before it enters the stretching section 03 (stretching process), and can be installed as needed.
• the stretching section 03 has an MD (machine direction) stretching section 03a and a TD (transverse direction) stretching section 03b.
• the stretching section 03 stretches the unstretched film F8a transported from the first drying section 02.
• the second drying section 04 (second drying process) has the same basic configuration as the first drying section 02, so a detailed explanation will be omitted.
• the knurling forming section 05 forms knurling on both ends of the stretched film F8 conveyed from the second drying section 04 before the stretched film F8 is wound around a winding shaft in the winding and recovery section 06 (winding and recovery process). Regarding the position at which the knurling is formed, it is preferable to cut off both ends of the stretched film F8 held by the TD stretching section 03b arranged upstream of the knurling forming section 05, and then form knurling on both ends of the stretched film F8.
• the winding and recovery section 06 has a winder 06a that winds up the stretched film F8, both ends of which have been knurled by the knurling forming section 05, and an entrained air amount control device 06b.
• the winding and recovery section 06 also has a contact or non-contact linear encoder 06c for detecting the running speed of the stretched film F8, a winding shaft rotation speed measuring device 06d, a tension control device 06e, and a thickness measuring device 06f.
• the raw resin is dissolved in a solvent, and various additives such as plasticizers, ultraviolet absorbers, deterioration inhibitors, slipping agents, and peeling promoters are added as necessary to prepare a dope, which is extruded from a die 01b onto an endless belt 01a that moves indefinitely.
• the solvent is removed to a certain extent from the cast film formed by casting on the endless support, and then the film is peeled off from the belt.
• the film is passed through a drying section and a stretching section 03 by various conveying means to form knurlings on both ends, and then wound up on a winding shaft in a winding and collecting section 06 to produce an optical film.
• the width of the optical film produced as shown in Figures 18 and 19 is preferably 1000 mm to 2500 mm, taking into consideration productivity, quality, etc.
• the thickness is preferably 15 ⁇ m to 50 ⁇ m, taking into consideration quality, handling, etc.
• the length of the optical film F8 of the film roll 8 wound around the winding shaft 82 (see Figure 19.
• the winding shaft is also called the core) is preferably 2000 m to 8000 m, taking into consideration productivity, winding quality, etc.
• the winding length is a value calculated from the speed and time.
• Figure 19 is an enlarged schematic diagram showing the knurling forming section 05 and the winding and collecting section 06.
• the knurling forming device 05a is a pair of a knurling forming roll 501a having an uneven surface with a pressing means 501c and a receiving roll 501b.
• the stretched film F8 is sandwiched between the knurling forming roll 501a and the receiving roll 501b, so that knurling is formed on both ends of the stretched film F8.
• the knurling forming roll 501a can be moved in the vertical direction (in the direction of the arrow in the figure) by the pressing means 501c.
• the amount of movement (amount of pressure) of the pressing means 501c is controlled by the control device 07.
• the control device 07 has a memory, a CPU, and an input/output I/F.
• the control device 07 performs calculations between information input to the CPU and information previously input to the memory, determines the amount of movement (pressure) of the pressing means 501c, and determines the amount of movement (pressure) of the knurling forming roll 501a.
• the amount of movement (pressure) of the knurling forming roll 501a increases, the height of the knurling formed increases, and when the amount of movement (pressure) of the knurling forming roll 501a decreases, the height of the knurling formed decreases.
• the knurling forming section 05 has a TD stretching section (not shown) upstream of the conveying direction of the stretched film F8, it is preferable to form knurling on both ends of the stretched film F8 held by the TD stretching section (not shown) after cutting off both ends of the stretched film.
• the knurling forming device 05a is shown to use a pressure roll and a receiving roll, but other methods such as an inkjet method and a laser method can also be used.
• the knurling forming device can be of any method.
• the amount of knurling forming material discharged from the inkjet head is controlled.
• the laser output is controlled.
• the entrained air amount control device 06b has a touch roll 602a that contacts and presses the stretched film F8 being wound around the winding shaft 82, and a pressure amount control device 602b that controls the amount of pressure applied by the touch roll 602a. By adjusting the amount of pressure, it is possible to adjust the amount of entrained air.
• the pressure amount control devices 602b are disposed on both ends of the touch roll 602a.
• the material can be metal, or a metal roll wrapped with resin or rubber. It is also possible to use a crown roll with a diameter that changes from the center to the sides.
• the core material can be aluminum, iron, or CFRP (carbon fiber reinforced plastics).
• the tension control device 06e has a tension controller 605a and a moving means 605b for the tension controller 605a.
• the tension control device 06e is capable of moving the position of the tension controller 605a (in the direction of the arrow in the figure) in accordance with changes in the stretched film F8 wound around the winding shaft 82 in the recovery section 6.
• the tension is low at the beginning of winding (setting value t1), and is set so that the tension increases as the winding diameter increases (setting value t1 + ⁇ ).
• the tension setting value t1 is changed depending on the winding conditions set by the winding condition setting unit 315.
• a manufacturing process of a product (hereinafter simply referred to as a product) equipped with a film roll 80 from which second inspection data in this embodiment is obtained will be described.
• a product hereinafter simply referred to as a product
• an inspection device 90 optically inspects the film surface side of the film roll 80 and generates inspection data.
• the inspection device 90 used in this second manufacturing process is an inspection device that has substantially the same inspection performance as the first inspection device 90 used when manufacturing the film roll 80 in Fig. 18.
• Figure 20 is a schematic diagram showing the manufacturing process of a laminated polarizing film 1 equipped with a film roll 80, and the inspection position of an inspection device 90 for the second inspection data.
• the laminated polarizing film manufacturing equipment 2000 shown in Figure 20 performs a series of processes, from manufacturing the polarizer to bonding the protective film to obtain the laminated polarizing film, on a single production line.
• the product manufacturing apparatus 2000 for manufacturing the laminated polarizing film 1 having the film F8 shown in FIG. 20 has, in order from the upstream side, a wet processing apparatus 204, a drying apparatus 205, and a laminating apparatus 206.
• the product manufacturing apparatus 2000 also has a payout section 202.
• the film roll 80 manufactured by the film roll manufacturing apparatus 1000 in FIG. 18 and FIG. 19 is loaded into the third roll section 63 of this payout section 202, and the film F8 paid out from the film roll 80 is used as the second protective film 13.
• an inspection device 90 is disposed in the third roll section 63 of the payout section 202.
• the inspection device 90 optically inspects the film surface side of the film roll 80 loaded into the third roll section 63 and generates the first inspection data.
• the arrow indicates the transport direction of the film, etc. (same in FIG. 19 and FIG. 20).
• the wet treatment device 204 has a first roll section 41 around which a long strip of untreated hydrophilic polymer film 1a is wound, a transport section 42 that transports the hydrophilic polymer film 1a, and a processing section.
• the processing section is a section that processes the untreated hydrophilic polymer film 1a with a dichroic substance to change the hydrophilic polymer film 1a into a polarizer 1b.
• the drying device 205 has a transport section 501 that transports the long strip-shaped polarizer 1b, and a heating section that applies heat to the polarizer 1b to dry the polarizer 1b.
• the laminating device 206 has a transport section 61 that transports the dried polarizer 1c and protective film 12, an adhesive coating section 64, a bonding section 67, and a chamber 69 that surrounds the adhesive coating section 64 and the bonding section 67.
• the wet treatment device 204 includes a treatment section for dyeing the long strip-shaped hydrophilic polymer film 1a with a dyeing treatment liquid and stretching the film 1a.
• the wet treatment includes a treatment for stretching the hydrophilic polymer film 1a while applying a plurality of treatment liquids including the dyeing treatment liquid to the hydrophilic polymer film 1a.
• wet treatment devices are well known in the art, and the wet treatment device 204 of the present invention can also adopt a well-known configuration.
• the processing section includes, for example, from the upstream side, a swelling processing tank 4A, a dyeing processing tank 4B, a crosslinking processing tank 4C, a stretching processing tank 4D, and a cleaning processing tank 4E.
• the conveying section 42 of the wet treatment device 204 has multiple guide rolls, etc., and pulls out the long strip-shaped hydrophilic polymer film 1a wound around the first roll section 41 and conveys it to the treatment section.
• the swelling treatment tank 4A is a treatment tank that contains a swelling treatment liquid.
• the swelling treatment liquid swells the hydrophilic polymer film 1a.
• the dyeing treatment tank 4B is a treatment tank that contains a dyeing treatment liquid.
• the dyeing treatment liquid dyes the hydrophilic polymer film 1a.
• the cross-linking treatment tank 4C is a treatment tank that contains a cross-linking treatment liquid.
• the cross-linking treatment liquid cross-links the dyed hydrophilic polymer film 1a.
• the stretching treatment tank 4D is a treatment tank that contains a stretching treatment liquid.
• the stretching treatment liquid is not particularly limited, but for example, a solution containing a boron compound as an active ingredient can be used.
• the cleaning treatment tank 4E is a treatment tank that contains a cleaning treatment liquid.
• the cleaning treatment liquid cleans the hydrophilic polymer film 1a after stretching.
• the cleaning treatment liquid is a treatment liquid for cleaning treatment liquids such as the dyeing treatment liquid and the cross-linking treatment liquid that have adhered to the hydrophilic polymer film 1a.
• As the cleaning treatment liquid water such as ion-exchanged water, distilled water, and pure water is typically used.
• the drying device 205 is provided downstream of the wet treatment device 204 and upstream of the laminating device 206. In the illustrated example, the drying device 205 is provided downstream of the cleaning treatment tank 4E.
• drying device 205 There may be only one drying device 205, or two or more drying devices may be provided in line in the transport direction of the polarizer. In the illustrated example, for example, one drying device 205 is provided in the transport path of the polarizer.
• the drying device 205 has a transport section 501 having a guide roll for transporting the long strip-shaped polarizer 1b manufactured by the wet processing device 204, and a heating section for applying heat to the polarizer 1b transported in the longitudinal direction (MD direction) by the transport section 501 to dry it.
• the heating section includes, for example, a chamber 502 and a heat source (not shown).
• the chamber 502 includes a space 503 inside which the polarizer can be transported.
• the conveying unit 61 of the laminating device 206 has a guide roll and the like.
• the conveying unit 61 conveys the long strip-shaped polarizer 1c dried by the drying device 205 to the bonding unit 67.
• the conveying unit 61 also conveys the long strip-shaped protective film 12 and the like to the bonding unit 67.
• the illustrated laminated polarizing film manufacturing apparatus 2000 can laminate a first protective film 12 and a second protective film 13 on both sides of a polarizer 1c.
• This apparatus can produce a laminated polarizing film 1 having a layer structure of first protective film 12/adhesive layer 31/polarizer 11/adhesive layer 32/second protective film 13, as shown in Figure 20 (the bubble area in the lower left of Figure 20).
• the product manufacturing apparatus 2000 has a second roll section 62 around which a long strip-shaped first protective film 12 is wound, and a third roll section 63 around which a long strip-shaped second protective film 13 (film F8) is wound.
• the first protective film 12 of the second roll section 62 and the second protective film 13 of the third roll section 63 are each independently transported from each roll section 62, 63 to the bonding section 67 by the transport section 61.
• the adhesive coating unit 64 has a coating roll 641.
• the coating roll 641 of the adhesive coating unit 64 applies adhesive to the film.
• the adhesive coating unit 64 is located upstream of the lamination unit 67.
• the adhesive application section 64 is disposed on one side of the first protective film 12 and one side of the second protective film 13 (film F8).
• One adhesive coating section 64 applies adhesive to one side of the first protective film 12 to form an adhesive layer, and the other adhesive coating section 64 applies adhesive to one side of the second protective film 13 (film F8) to form an adhesive layer.
• an adhesive coating portion may be disposed on one side of the polarizer 1c and on the other side of the polarizer 1c (not shown).
• an adhesive layer can be formed by coating one side of the polarizer 1c and on the other side of the polarizer 1c, respectively.
• the adhesive coating portions arranged on one side of the polarizer 1c and on the other side of the polarizer 1c can also be used to apply the easy-adhesion composition described below.
• the adhesive coating section 64 has, for example, a gravure roll 641 which is a coating roll, a container 642 in which adhesive is stored, and a doctor blade 643.
• the adhesive coating section 64 may also have a backup roll as necessary.
• the backup roll is disposed opposite the gravure roll 641 with the film sandwiched between them.
• the gravure roll 641 has a number of cells (recesses into which adhesive is placed) formed on its surface.
• the gravure roll 641 rotates around its axis so that its surface comes into contact with the adhesive 65 stored in the container 642 (the direction of rotation of the gravure roll 641 is indicated by an arrow).
• the adhesive 65 adheres to the surface of the gravure roll 641, including the cells, and excess adhesive 65 is scraped off into the container 642 by the doctor blade 643.
• the gravure roll 641 with adhesive in its cells, comes into contact with the film, the adhesive 65 in the cells is transferred to one side of the first protective film 12 and the second protective film 13. In this way, the adhesive 65 is solidly applied from the gravure roll 641 to one side of each of the first protective film 12 and the second protective film 13.
• the adhesive for bonding the polarizer 1c to the first protective film 12 and the second protective film 13 is not particularly limited, but it is preferable to use an active energy ray curable adhesive as described above.
• an active energy ray curable adhesive a conventionally known adhesive may be used.
• the active energy ray curable adhesive generally contains an active energy ray curable component and a polymerization initiator, and contains various additives as necessary.
• the unwinding section 202 has an easy-adhesion treatment tank 21, a cleaning treatment tank 22, and a heat treatment tank 23.
• the easy-adhesion treatment tank 21 performs easy-adhesion treatment on the surface of the second protective film 13 (film F8) to which the polarizer 11 is bonded.
• the easy-adhesion treatment tank 21 performs corona discharge treatment, plasma treatment, etc.
• the corona discharge treatment is performed by applying a high voltage to a wire or sawtooth electrode arranged in a chamber facing the second protective film 13 (film F8).
• the cleaning treatment tank 22 has a configuration similar to that of the above-mentioned cleaning treatment tank 4E, and is a treatment tank in which a cleaning treatment liquid is contained.
• the cleaning treatment liquid cleans the second protective film 13 (film F8).
• the heat treatment tank 23 has a configuration similar to that of the drying device 205, and heats and dries the second protective film 13 (film F8). In addition, the drying temperature of the heat treatment tank 23 is changed according to the heat treatment conditions set by the manufacturing management system 3000.
• the information processing system 50 described above is the main configuration for explaining the features of the above embodiment, and is not limited to the above configuration, and various modifications can be made within the scope of the claims. Furthermore, configurations that are included in general information processing devices/systems are not excluded.
• the information processing system 50 may include an inspection device 90 disposed in the first manufacturing process and/or the second manufacturing process.
• the control unit 51 of the information processing system 50 may be responsible for the feature point generation function of the analysis unit 93 of the inspection device 90. In this case, image data of an image of the film surface and the shooting conditions thereof (information such as transport speed, camera direction, angle of view, etc.) are sent from the inspection device 90 to the information processing system 50, and the feature point generation process is performed on the control unit 51 side.
• the means and methods for performing various processes in the information processing system 50 according to the above-described embodiment can be realized by either a dedicated hardware circuit or a programmed computer.
• the above programs may be provided by a computer-readable recording medium such as a USB memory or a DVD (Digital Versatile Disc)-ROM, or may be provided online via a network such as the Internet.
• the programs recorded on the computer-readable recording medium are usually transferred to and stored in a storage unit such as a hard disk.
• the above programs may be provided as standalone application software, or may be incorporated into the software of the device as one of its functions.

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• 2024
  • 2024-11-25 JP JP2025546415A patent/JP7838713B2/ja active Active
  • 2024-11-25 WO PCT/JP2024/041567 patent/WO2025121178A1/ja active Pending
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