Glass roll manufacturing method

Abstract

A method for manufacturing a glass roll (GR) includes a conveying step of conveying a strip-shaped glass film (G2) in a transverse conveying direction by a conveying device (4) and a winding step of winding the glass film (G2) in a roll shape. The conveying step includes an inspection step of measuring the state of each end portion (Gd, Ge) in the width direction of the glass film (G2) by a detection unit (19a, 19b) in a state where a tension is applied to the glass film (G2) passing through an intermediate conveying region (MS) of the conveying device (4) by a tension applying unit.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a glass roll by winding a glass film in a roll shape. Background Art

[0002] In recent years, mobile terminals such as smart phones and tablet PCs have been rapidly popularized and are required to be thin and lightweight. Therefore, the demand for thinner glass substrates assembled in these terminals is also increasing. Under this situation, it has reached the stage of developing and manufacturing glass substrates thinned to a film-like shape (for example, a thickness of less than 300 μm), that is, glass films.

[0003] The manufacturing process of a glass film may include a step of winding a glass ribbon, which is a raw material of the glass film, into a roll to manufacture a glass roll. For example, Patent Document 1 discloses a method of continuously manufacturing a glass ribbon formed into a plate-like shape from molten glass by a down-draw method using two rollers (pulling rollers), and winding the glass ribbon using a winding device to manufacture a glass roll (see Patent Document 1). Figure 4 as well as Figure 6 ).

[0004] In the manufacturing method of the glass roll, measures are taken to reduce the so-called bowing defect generated during the manufacturing of the glass ribbon. Specifically, as described in Patent Document 1, Figure 6 As disclosed, a measuring device for measuring bow-shaped bending defects is arranged before the winding device.

[0005] The measuring device comprises two pairs of rollers arranged at intervals in the longitudinal direction of the glass ribbon and two distance sensors arranged between the two pairs of rollers. The two pairs of rollers convey the glass ribbon in a state where the glass ribbon is relaxed downward in the region between the two pairs of rollers. The two distance sensors measure the distance between each distance sensor and each end in order to measure the length of each end in the width direction of the relaxed glass ribbon.

[0006] According to this method, the degree of the bow defect based on the difference between the length of one end portion and the length of the other end portion of the glass ribbon can be measured based on the distances measured by the two distance sensors.

[0007] Prior art literature

[0008] Patent Literature

[0009] Patent Document 1: Japanese Patent Application No. 2017-514785 Summary of the invention

[0010] Problems to be solved by the invention

[0011] However, in the above-mentioned method for manufacturing a glass roll, since the distance sensor is used to perform measurement while a portion of the glass film (glass ribbon) is slackened, accurate measurement cannot be performed when the slackened portion vibrates due to vibrations during transportation.

[0012] Therefore, a technical problem of the present invention is to measure the state of each end portion in the width direction of a glass film constituting a glass roll with high accuracy.

[0013] Solutions to Solve Problems

[0014] The present invention is a solution for solving the above-mentioned problems, and is a method for manufacturing a glass roll, comprising a conveying step of conveying a strip of glass film along a horizontal conveying direction by using a conveying device and a winding step of winding the glass film in a roll shape, wherein the conveying device comprises: a first support portion and a second support portion, which are arranged at intervals along the horizontal conveying direction and support the glass film; an intermediate conveying area, which is arranged between the first support portion and the second support portion; a tension applying portion, which applies tension to the glass film passing through the intermediate conveying area; and a detection portion, which measures the state of each end portion in the width direction of the glass film passing through the intermediate conveying area, wherein the conveying step includes an inspection step of measuring the state of each end portion of the glass film by using the detection portion in a state in which the tension of the tension applying portion is applied to the glass film passing through the intermediate conveying area.

[0015] According to this configuration, by applying tension to the glass film, the glass film can be conveyed in a stable posture. By performing the inspection step in this state, the state of each end portion in the width direction of the glass film can be measured with high accuracy by the detection unit.

[0016] The detection unit may include: a first detection unit that measures a distance from one end portion in the width direction of the glass film passing through the intermediate transfer region; and a second detection unit that measures a distance from the other end portion in the width direction of the glass film.

[0017] According to this configuration, the length of one end and the length of the other end of the glass film can be obtained based on the data of the distance of one end of the glass film measured by the first detection unit and the data of the distance of the other end of the glass film measured by the second detection unit. The quality of the glass film (glass roll) can be determined based on the difference in their lengths.

[0018] The tension applying unit may include an unwinding device for delivering the glass film and a winding device for winding the glass film in a roll. By performing the inspection process with tension applied to the glass film by the unwinding device and the winding device, the detection unit can perform measurement with high accuracy.

[0019] Alternatively, the method for manufacturing a glass roll of the present invention includes a forming step of forming molten glass using a forming device to form the glass film before the conveying step, and the tension-applying portion may include a fixed conveying portion for conveying the glass film in a fixed and maintained state and a winding device for winding the glass film into a roll.

[0020] By performing the inspection step in a state where tension is applied to the glass film by the fixed conveying unit and the winding device, the glass film after the forming step can be measured with high accuracy by the detection unit.

[0021] The fixed conveying unit may include a suction conveyor. Thus, the glass film can be conveyed while appropriately applying tension to the glass film.

[0022] The conveying device may include an auxiliary conveying device that is disposed in the intermediate conveying region and conveys the glass film. The detection unit may be disposed above the auxiliary conveying device.

[0023] In the forming step, the forming device may adjust the tension applied to the glass film according to the state of each end of the glass film detected by the detection unit. Thus, a glass film with high dimensional accuracy can be manufactured, and a high-quality glass roll can be manufactured.

[0024] Furthermore, in the method for manufacturing a glass roll of the present invention, the winding device may apply tension to the glass film passing through the intermediate conveyance region by using its winding force.

[0025] Effects of the Invention

[0026] According to the present invention, the state of each end portion in the width direction of a glass film constituting a glass roll can be measured with high accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 This is a side view showing one embodiment of the method for producing a glass roll of the present invention.

[0028] Figure 2 This is a front view showing a forming step in the method for manufacturing a glass roll.

[0029] Figure 3 This is a plan view showing a conveying step in the method for producing a glass roll.

[0030] Figure 4 It is a perspective view showing an inspection process in the conveying process.

[0031] Figure 5 This is a side view showing a preparation step in the method for manufacturing a glass roll.

[0032] Figure 6 It is a graph showing an example of measurement data in the inspection process.

[0033] Figure 7 This is a side view showing another example of the conveying step in the method for producing a glass roll. DETAILED DESCRIPTION

[0034] Hereinafter, specific embodiments of the present invention will be described with reference to the accompanying drawings. Figures 1 to 7 One embodiment of the method for producing a glass roll of the present invention is described.

[0035] Figures 1 to 3 The overall structure of the manufacturing device of the glass roll used in the present method is shown. The manufacturing device 1 includes: a forming device 2 that forms a ribbon-shaped base glass film (glass ribbon) G1 from molten glass; a direction conversion device 3 that converts the traveling direction of the base glass film G1; a lateral conveying device 4 that conveys the base glass film G1 along the lateral conveying direction GX; a winding device 5 that winds the product glass film G2 formed by removing unnecessary parts (ears) of the width direction ends Ga and Gb of the base glass film G1 into a roll to form a glass roll GR; and a control device 6 that performs various controls of each device 2 to 5.

[0036] It should be noted that, in the present embodiment, the thickness of the product glass film G2 is 300 μm or less, and preferably 100 μm or less.

[0037] like Figure 1 as well as Figure 2 As shown, the forming device 2 comprises: a forming body 7 which is roughly wedge-shaped in cross section and has an overflow groove 7a formed at the upper end; an edge roller 8 which is arranged directly below the forming body 7 and clamps the molten glass overflowing from the forming body 7 from both the front and back sides; and an annealing piece 9 which is arranged directly below the edge roller 8.

[0038] The forming device 2 makes the molten glass overflowing from the overflow groove 7a of the forming body 7 flow down along the two side surfaces respectively, and merge at the lower end to form a film-shaped molten glass. The edge roller 8 limits the widthwise contraction of the molten glass to form a mother glass film G1 of a specified width. The annealing piece 9 is used to perform strain removal treatment on the mother glass film G1. The annealing piece 9 has annealing rollers 10 arranged in multiple stages in the vertical direction.

[0039] Support rolls 11 are provided below the annealing material 9 to sandwich the base glass film G1 from both the front and back sides. Tension is applied between the support rolls 11 and the edge rolls 8 or between the support rolls 11 and any annealing roll 10 to promote thinning of the base glass film G1.

[0040] The direction conversion device 3 converts the traveling direction of the base glass film G1 from the vertical downward direction to the horizontal conveying direction GX. The direction conversion device 3 is provided below the support roller 11. A plurality of guide rollers 12 for guiding the base glass film G1 are arranged in a curved shape in the direction conversion device 3. These guide rollers 12 guide the base glass film G1 conveyed in the vertical direction in the horizontal direction.

[0041] The lateral transport device 4 is arranged in front of the direction of travel (downstream side) of the direction change device 3. The lateral transport device 4 includes a first transport device 13, a second transport device 14, and a third transport device 15. The first transport device 13 is arranged on the downstream side of the direction change device 3. The second transport device 14 is arranged on the downstream side of the first transport device 13. The third transport device 15 is arranged on the downstream side of the second transport device 14.

[0042] The first conveying device 13 and the second conveying device 14 are constituted by, for example, belt conveyors, but are not limited thereto, and may be constituted by roller conveyors or other various conveyors. The first conveying device 13 conveys the base glass film G1 that has passed through the direction changing device 3 continuously toward the downstream side in the lateral conveying direction GX.

[0043] like Figure 1 as well as Figure 3 As shown, the second conveying device 14 includes a cutting unit 16 for cutting the width direction ends (ears) Ga and Gb of the base glass film G1 into non-product parts Gc. The cutting unit 16 cuts the base glass film G1 by laser cutting, for example, but is not limited to this cutting method. The cutting unit 16 includes a pair of laser irradiation devices 17a and a pair of cooling devices 17b arranged on the downstream side of the laser irradiation device 17a. After the cutting unit 16 irradiates the laser from each laser irradiation device 17a to a predetermined part of the conveyed base glass film G1 and heats it, the cooling medium is released from the cooling device 17b to cool the heated part.

[0044] The third conveying device 15 includes a conveying unit 18 that conveys the product glass film G2 in the lateral conveying direction GX, detection units 19 a and 19 b that measure the distance to the product glass film G2 , and an auxiliary conveying device 20 .

[0045] The conveying unit 18 includes a fixing conveying unit 21 that conveys the product glass film G2 toward the downstream side while being fixed and held, and a first supporting unit 22 and a second supporting unit 23 that support the product glass film G2 .

[0046] The fixed conveying unit 21 not only conveys the product glass film G2 but also functions as a tension applying unit that applies tension to the product glass film G2. The fixed conveying unit 21 is connected to the control device 6. The fixed conveying unit 21 is composed of a suction conveyor having a conveyor belt 24, for example.

[0047] In this embodiment, "fixed holding" means that the conveyor belt 24 and the part of the product glass film G2 being transported do not move relative to each other during the process of transporting the product glass film G2 by the fixed transport unit 21. That is, in a state where the product glass film G2 is fixedly held, the surface of the conveyor belt 24 and the part of the lower surface of the product glass film G2 in contact with the surface do not move relative to each other during transport.

[0048] A plurality of adsorption holes (not shown) penetrating the conveyor belt 24 in the thickness direction are formed in the conveyor belt 24. In addition, a negative pressure generating device (not shown) connected to a vacuum pump or the like is arranged on the inner peripheral side of the conveyor belt 24. The negative pressure generating device generates negative pressure for adsorbing the product glass film G2 through the adsorption holes.

[0049] Thus, the surface of the conveyor belt 24 fixes and holds the lower surface of the product glass film G2 by adsorption. The product glass film G2 adsorbed on the conveyor belt 24 is conveyed to the downstream side of the conveying path at the same conveying speed as the conveying speed of the conveyor belt 24. It should be noted that the conveyor belt 24 may be a structure that adsorbs the entire width of the product glass film G2 in the width direction, or may be a structure that adsorbs only a portion of the width direction.

[0050] The first support part 22 and the second support part 23 are composed of rollers that support the lower surface of the product glass film G2. Each support part 22, 23 can be a free roller or can be driven to rotate by a driving device such as a motor. The first support part 22 and the second support part 23 are separated in the horizontal conveying direction GX. The first support part 22 is arranged on the downstream side of the fixed conveying part 21. The second support part 23 is arranged on the downstream side of the first support part 22.

[0051] An intermediate conveyance region MS through which the product glass film G2 to which tension is applied passes is formed between the first support portion 22 and the second support portion 23 .

[0052] The detection units 19a and 19b are arranged above the auxiliary transport device 20 in the intermediate transport area MS. In addition, the detection units 19a and 19b are located above the product glass film G2 passing through the intermediate transport area MS. The detection units 19a and 19b are composed of, for example, ultrasonic distance sensors, but may also be composed of various other distance sensors. The detection units 19a and 19b include a first detection unit 19a that measures the distance to one end Gd in the width direction of the product glass film G2 and a second detection unit 19b that measures the distance to the other end Ge in the width direction of the product glass film G2. Figure 3 as well as Figure 4 As shown, the first detection unit 19a and the second detection unit 19b are separated in the width direction of the product glass film G2 (horizontal direction orthogonal to the transverse transport direction GX).

[0053] The auxiliary conveying device 20 is arranged in the middle conveying area MS. The auxiliary conveying device 20 includes an auxiliary conveying unit 25 that can contact the lower surface of the product glass film G2 and a lifting device 26 that lifts and lowers the auxiliary conveying unit 25. The auxiliary conveying unit 25 is composed of, for example, a belt conveyor, but is not limited to this structure and may also be composed of other conveying mechanisms. The lifting device 26 moves the auxiliary conveying unit 25 from a standby position (see FIG. 2 ) to a standby position (see FIG. 2 ) in the initial stage of manufacturing the glass roll GR. Figure 1 ) rises and contacts the lower surface of the product glass film G2.

[0054] The winding device 5 is provided on the downstream side of the third conveying device 15. The winding device 5 includes a winding roller 27, a motor (not shown) for driving the winding roller 27 to rotate, and a protection sheet supply unit 28 for supplying the protection sheet PS to the winding roller 27. The winding device 5 overlaps the protection sheet PS with the product glass film G2 from the protection sheet supply unit 28, and rotates the winding roller 27 by the motor, thereby winding the product glass film G2 in a roll. The wound product glass film G2 is constituted as a glass roll GR.

[0055] The winding device 5 applies tension to the product glass film G2 passing through the intermediate conveyance region MS of the third conveyance device 15 by its winding force. That is, the winding device 5 also functions as a tension applying unit that applies tension to the product glass film G2 together with the fixed conveyance unit 21 of the third conveyance device 15.

[0056] The control device 6 includes, for example, a computer (eg, PC) equipped with various hardware such as a CPU, ROM, RAM, HDD, monitor, and input / output interface, etc. The control device 6 is communicatively connected to the forming device 2, the lateral transport device 4, and the winding device 5.

[0057] The control device 6 includes a calculation processing unit that executes various calculations, and a storage unit that stores data and various programs necessary for manufacturing the glass roll GR.

[0058] The calculation processing unit can, for example, perform calculation processing for controlling the rotation speed of the support roller 11 in the forming device 2 and the pressing force of the support roller 11 on the base glass film G1. The calculation processing unit can perform calculation processing for operating the detection units 19a and 19b. The calculation processing unit can perform calculation processing for calculating the lengths of the ends Gd and Ge of the product glass film G2 based on the data measured by the detection units 19a and 19b. In addition, the calculation processing unit can perform calculation processing for adjusting the tension applied to the base glass film G1 in the forming device 2 (support roller 11) based on the difference in the calculated lengths of the ends Gd and Ge.

[0059] The storage unit stores a program for controlling the rotation speed of the support roller 11 in the forming device 2 and the pressing force (clamping force) of the support roller 11 on the base glass film G1, a program for controlling the conveying speed of each glass film G1 and G2 in the horizontal conveying device 4, a program for controlling the adsorption force of the fixed conveying unit 21 on the product glass film G2, and the winding speed and winding force of the product glass film G2 in the winding device 5, etc.

[0060] The storage unit stores a program for calculating the lengths of the ends Gd and Ge of the product glass film G2 and their differences based on the data measured by the detectors 19a and 19b of the third conveying device 15. The storage unit can also store the data measured by the detectors 19a and 19b of the third conveying device 15.

[0061] Hereinafter, a method for manufacturing a glass roll GR using the manufacturing apparatus 1 having the above configuration will be described. This method includes a forming step of forming a base material glass film G1, a conveying step of conveying each glass film G1, G2, and a winding step of winding the product glass film G2 into a roll.

[0062] In the forming process, the molten glass overflowing from the overflow trough 7a of the forming body 7 in the forming device 2 is made to flow down along both sides and merge at the lower end to form the molten glass into a film. At this time, the edge roller 8 is used to limit the width direction contraction of the molten glass to form a mother glass film G1 of a specified width. After that, the mother glass film G1 is subjected to strain removal treatment by the annealing piece 9. The mother glass film G1 is formed into a specified thickness under the action of the tension given by the support roller 11.

[0063] In the conveying process, the conveying direction of the base glass film G1 formed in the forming process is converted from the longitudinal direction to the lateral conveying direction GX by the direction converting device 3. In the conveying process, the base glass film G1 is conveyed by the first conveying device 13 and the second conveying device 14, and the product glass film G2 is conveyed by the second conveying device 14 and the third conveying device 15.

[0064] The conveying step includes a cutting step of dividing the base glass film G1 into the non-product portion Gc and the product glass film G2 and an inspection step of inspecting the product glass film G2.

[0065] In the cutting process, the base glass film G1 is transported to the downstream side by the second conveying device 14, and a portion of the base glass film G1 is heated by irradiating a laser from the laser irradiation device 17a in the cutting section 16. After that, a cooling medium is blown to the heated portion by the cooling device 17b. Thus, thermal stress is generated in the base glass film G1. An initial crack is formed in the base glass film G1 in advance, and the crack is developed under the action of the thermal stress. Thus, the non-product portion Gc and the product glass film G2 are formed from the base glass film G1.

[0066] It should be noted that, at the start of the production of the glass films G1 and G2, a preparation step is performed to connect the leading end Gf of the product glass film G2 to the winding device 5. Figure 5 As shown, in this preparation process, the auxiliary transport device 20 in the third transport device 15 is in operation.

[0067] That is, the auxiliary transport device 20 operates the lifting device 26 to move the auxiliary transport section 25 from the standby position (see Figure 1 The auxiliary conveying portion 25 is arranged such that its upper surface is at the same height as the first supporting portion 22 and the second supporting portion 23. Thus, the auxiliary conveying portion 25 is in a state capable of supporting the lower surface of the product glass film G2.

[0068] The starting end Gf of the product glass film G2 conveyed by the second conveying device 14 moves from the auxiliary conveying portion 25 to the second supporting portion 23. The starting end Gf is further conveyed to the downstream side and connected to the winding roller 27 of the winding device 5. When the connection (preparation process) of the product glass film G2 to the winding device 5 is completed, the auxiliary conveying device 20 operates the lifting device 26 to lower the auxiliary conveying portion 25 to the standby position.

[0069] In the inspection process, the tension applying unit (fixed conveying unit 21 and winding device 5) applies tension in the longitudinal direction to the product glass film G2 that passes through the intermediate conveying area MS after the preparation process. The product glass film G2 passes under each detection unit 19a, 19b while being pulled by the fixed conveying unit 21 and the winding device 5.

[0070] The first detection unit 19a and the second detection unit 19b measure the distance (displacement) between each detection unit 19a, 19b and the upper surface of the product glass film G2 passing through the intermediate transport region MS. The measured data is sent to the control device 6 and stored in the storage unit.

[0071] The calculation processing unit of the control device 6 graphs the displacement data of the end portions Gd and Ge of the product glass film G2 measured by the detection units 19 a and 19 b , and displays the graph on a monitor.

[0072] Figure 6 An example of a graph displayed on a monitor is shown. The horizontal axis of the graph shows the conveying distance (m) of the product glass film G2, and the vertical axis shows the displacement (mm) of the measurement position. The graph measures the distance between each end Gd, Ge of the product glass film G2 and each detection part 19a, 19b when the product glass film G2 passes under the detection parts 19a, 19b for a certain period of time, and shows the change of the distance as the displacement amount.

[0073] In the curve graph, the displacement data of one end Gd of the product glass film G2 measured by the first detection unit 19a is displayed in a straight line. In addition, in the curve graph, the data of the other end Ge of the product glass film G2 measured by the second detection unit 19b is displayed in a broken line. Therefore, the curve graph shows that the other end Ge of the product glass film G2 is longer than the one end Gd. In addition, in the curve graph, the displacement of the one end Gd of the product glass film G2 is substantially zero, and the displacement of the other end Ge is negative relative to this. This means that the other end Ge of the product glass film G2 is looser downward than the one end Gd.

[0074] In addition, in the graph, the measured data of the other end Ge of the product glass film G2 is displayed in a broken line shape, which means that the second detection unit 19b detects the wrinkle W remaining at the other end Ge of the product glass film G2 (see Figure 3 as well as Figure 4 When the base glass film G1 is produced, the wrinkles W appear at the ends Ga and Gb of the base glass film G1. Even when the product glass film G2 is formed by the cut portion 16, a part of the wrinkles W may remain at the ends Gd and Ge of the product glass film G2.

[0075] The calculation processing unit of the control device 6 calculates the lengths of the ends Gd and Ge in the width direction of the product glass film G2 that has passed through the intermediate conveying area MS for a certain period of time based on the displacement data (the data of the distances between the detection units 19a and 19b and the upper surface of the product glass film G2) measured by the first detection unit 19a and the second detection unit 19b. Then, the calculation processing unit calculates the difference between the length of one end Gd in the width direction of the product glass film G2 and the length of the other end Ge.

[0076] The calculation processing unit compares the calculated length difference with the reference value stored in the storage unit. When the calculated length difference exceeds the reference value, the calculation processing unit sends a control signal to the forming device 2 to reduce the length difference. The forming device 2 adjusts, for example, the rotation speed of the support roller 11 or the pressing force (clamping force) of the support roller 11 on the base material glass film G1 based on the received control signal.

[0077] It should be noted that, in the conveying process, in the area between the second conveying device 14 and the third conveying device 15 (fixed conveying unit 21), the product glass film G2 is conveyed in a loose state (see Figure 1 In this case, no tension is applied to the base material glass film G1 cut by the cutting unit 16. Thus, it is possible to prevent the cut portion of the base material glass film G1 from being damaged by the action of tension.

[0078] In the winding process, the protective sheet PS is supplied to the product glass film G2 from the protective sheet supply unit 28, and the product glass film G2 conveyed by the third conveying device 15 is rolled up by the winding roller 27 of the winding device 5. By winding up the product glass film G2 of a predetermined length by the winding roller 27, the glass roll GR is completed.

[0079] The glass roll GR manufactured as described above may be transported by roll-to-roll. Figure 7 As shown, during the roll-to-roll conveyance, the product glass film G2 is pulled out from the first glass roll GR1 mounted on the unwinding device 29, and the product glass film G2 is rolled up by the winding device 5 arranged at a position separated from the unwinding device 29 to form a second glass roll GR2.

[0080] The roll-to-roll conveying device (manufacturing device) includes, in addition to the above-mentioned unwinding device 29 and winding device 5, a first supporting portion 22 and a second supporting portion 23, which are arranged between the unwinding device 29 and the winding device 5; and detection portions 19a, 19b, which are arranged in the intermediate conveying area MS between the first supporting portion 22 and the second supporting portion 23.

[0081] The unwinding device 29 includes a unwinding roller 30, a motor (not shown) for driving the unwinding roller 30 to rotate, and a protection sheet winding unit 31 for collecting the protection sheet PS pulled out from the first glass roll GR1. Figure 1 The winding device 5 of the manufacturing device 1 has the same structure.

[0082] Detection units 19a, 19b and Figure 1 The detection units 19a and 19b shown in the figure are similarly constituted by distance sensors such as ultrasonic distance sensors. Figure 4 The first detection unit 19a and the second detection unit 19b are arranged at intervals in the width direction of the product glass film G2. Each detection unit 19a, 19b can measure the distance between each end Gd, Ge in the width direction of the product glass film G2 and each detection unit 19a, 19b (displacement of each end Gd, Ge). Each detection unit 19a, 19b can be connected to Figure 1 The control device 6 can also be connected to an independent control device.

[0083] In this conveying method, the unwinding device 29 that feeds out the product glass film G2 and the winding device 5 that winds up the product glass film G2 in a roll form constitute a tension applying section.

[0084] In the conveying process of this method, the product glass film G2 and the protection sheet PS are pulled out from the first glass roll GR1 mounted on the unwinding device 29. The product glass film G2 is conveyed to the winding device 5 via the first support portion 22, the intermediate conveying area MS, and the second support portion 23. The protection sheet PS pulled out from the first glass roll GR1 together with the product glass film G2 is wound by the protection sheet winding unit 31.

[0085] In the conveying process, the product glass film G2 passing through the intermediate conveying region MS is pulled in the longitudinal direction thereof by the unwinding device 29 and the winding device 5. Thus, tension is applied to the product glass film G2.

[0086] In the inspection process, the first detection unit 19a measures the distance between the first detection unit 19a and one end Gd in the width direction of the product glass film G2 to which tension is applied. In addition, the second detection unit 19b measures the distance between the second end Ge in the width direction of the product glass film G2 and the second detection unit 19b. The data measured by the detection units 19a and 19b are sent to the control device.

[0087] The calculation processing unit of the control device calculates the length of each end Gd, Ge in the width direction of the product glass film G2 that has passed through the intermediate conveying area MS for a certain period of time based on the measurement data received from each detection unit 19a, 19b. The calculation processing unit calculates the difference between the calculated length of one end Gd and the length of the other end Ge of the product glass film G2. The calculation processing unit compares the difference in length with the reference value stored in the storage unit. When the difference in length exceeds the reference value, the calculation processing unit determines that the first glass roll GR1 (or the second glass roll GR2) is unqualified.

[0088] In the winding process of this embodiment, the product glass film G2 passing through the second support 23 is rolled up by the winding roller 27 of the winding device 5. At this time, the protection sheet PS from the protection sheet supply unit 28 is overlapped on the product glass film G2. Thus, the second glass roll GR2 is formed in the winding device 5.

[0089] According to the manufacturing method of the glass roll GR of the present embodiment described above, in the inspection process, the product glass film G2 is conveyed under tension, so that the product glass film G2 can be supported and conveyed in a stable posture. Thus, the detection units 19a and 19b can measure the state (length) of each end Gd and Ge in the width direction of the product glass film G2 with high accuracy.

[0090] In this method, the support roller 11 in the forming device 2 is controlled (feedback control) based on the information of the lengths of the ends Gd and Ge of the product glass film G2 measured in the inspection process, so that the difference in the lengths of the ends Gd and Ge can be minimized. As a result, the product glass film G2 with high dimensional accuracy can be manufactured, and thus the high-quality glass roll GR can be manufactured.

[0091] It should be noted that the present invention is not limited to the configuration of the above-described embodiment, nor is it limited to the above-described effects. The present invention can be modified in various ways without departing from the gist of the present invention.

[0092] In the above Figure 7 In the example of FIG. 1 , an example of conveying the product glass film G2 by roller-to-roll conveyance and performing the inspection process is shown, but the present invention is not limited to this structure. In the glass roll manufacturing method of the present invention, a cleaning process, a film forming process, and other manufacturing-related processing processes can be performed before and after the inspection process.

[0093] In the above-described embodiment, an example in which the base glass film G1 is formed by the overflow down-draw method is shown. However, as a modification of this embodiment, the base glass film G1 may be formed by the slit down-draw method, the re-draw method, the float method, or the like.

[0094] In the above embodiment, an example is shown in which the fixed conveying section 21 of the third conveying device 15 is composed of a suction conveyor, but the present invention is not limited to this structure. The fixed conveying section 21 may also be composed of, for example, a suction roll, a nip roll, or other conveying mechanism that can apply tension to the product glass film G2.

[0095] In the above-mentioned embodiment, an example is shown in which the state of each end Gd, Ge of the product glass film G2 is measured by the detection units 19a, 19b composed of distance sensors, but the present invention is not limited to this structure. The detection units 19a, 19b can also be composed of a camera that can capture each end Gd, Ge of the product glass film G2, or other measurement devices. In addition, the detection unit of the present invention can also include a third detection unit that measures the state (length) of the central portion in the width direction of the product glass film G2.

[0096] Description of Reference Numerals

[0097] 2 Forming device

[0098] 4 Horizontal transport device

[0099] 5 Winding device

[0100] 19a First Detection Unit

[0101] 19b Second detection unit

[0102] 20 Auxiliary handling device

[0103] 21 Fixed transport unit

[0104] 22 First support

[0105] 23 Second support

[0106] 29 Unwinding device

[0107] G1 Base material glass film

[0108] G2 Product Glass Film

[0109] Gd One end of the product glass film in the width direction

[0110] The other end of the Ge product glass film in the width direction

[0111] GR Glass Roll

[0112] GR1 First Glass Roll

[0113] GR2 Second Glass Volume

[0114] GX Horizontal transport direction

[0115] MS Intermediate handling area.

Claims

1. A method for manufacturing a glass roll, comprising a conveying step of conveying a strip-shaped glass film in a lateral conveying direction by a conveying device and a winding step of winding the glass film in a roll shape, The method for manufacturing the glass roll is characterized in that: The transport device comprises: a first support portion and a second support portion which are arranged at intervals along the lateral transport direction and support the glass film; an intermediate transport area disposed between the first support portion and the second support portion; a tension applying section that applies tension to the glass film passing through the intermediate conveying region; a detection unit configured to measure a state of each end portion in the width direction of the glass film passing through the intermediate conveyance region; as well as a control device that calculates the length of each end portion of the glass film based on the data measured by the detection unit, The conveying step includes an inspection step of measuring the state of each end portion of the glass film using the detection unit in a state where the tension of the tension applying unit is applied to the glass film passing through the intermediate conveying region. In the inspection step, the control device calculates the lengths of the respective ends of the glass film based on data measured by the detection unit, and then calculates a difference between the length of one end of the glass film and the length of the other end of the glass film.

2. The method for manufacturing a glass roll according to claim 1, wherein: The detection unit includes a first detection unit that measures a distance from one end portion in the width direction of the glass film passing through the intermediate transfer region, and a second detection unit that measures a distance from the other end portion in the width direction of the glass film.

3. The method for manufacturing a glass roll according to claim 1 or 2, wherein: The tension applying unit includes an unwinding device for feeding out the glass film and a winding device for winding the glass film into a roll.

4. The method for manufacturing a glass roll according to claim 1 or 2, wherein: The method for manufacturing a glass roll includes a forming step of forming the molten glass by a forming device to form the glass film before the conveying step. The tension applying unit includes a fixing and conveying unit that conveys the glass film in a fixed and held state, and a winding device that winds up the glass film in a roll shape.

5. The method for manufacturing a glass roll according to claim 4, wherein: The fixed transporting part includes a suction conveyor.

6. The method for manufacturing a glass roll according to claim 1 or 2, wherein: The conveying device includes an auxiliary conveying device, the auxiliary conveying device is disposed in the intermediate conveying area and conveys the glass film. The detection unit is arranged above the auxiliary transport device.

7. The method for manufacturing a glass roll according to claim 4, wherein: In the forming step, the forming device adjusts tension applied to the glass film according to the state of each end portion of the glass film detected by the detection unit.

8. The method for manufacturing a glass roll according to claim 3, wherein: The winding device applies tension to the glass film passing through the intermediate conveyance region by means of its winding force.

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