Resin film manufacturing apparatus and method for controlling the same

Abstract

The present invention relates to a resin film manufacturing apparatus and a control method thereof, the resin film manufacturing apparatus according to an embodiment includes a film passage sensor for winding, which is provided on an inlet side of a winder and is designed to detect passage of a conveyed resin film. When manufacturing of the resin film is started, driving of the reeling machine is started after the film passing sensor for reeling detects that the resin film has passed.

Description

Technical Field

[0001] The present disclosure relates to a resin thin film manufacturing apparatus and a control method thereof. Background Art

[0002] As disclosed in Patent Documents 1 and 2, the inventors of the present application have developed a resin thin film manufacturing apparatus and a control method thereof.

[0003] Patent Document 1: Unexamined Japanese Patent Application Publication No. JP 2022-092768

[0004] Patent Document 2: Japanese Unexamined Patent Application Publication No. JP 2023-082321. Summary of the Invention

[0005] For example, when winding of the resin film by the winder starts at the start of production of the resin film, the operator manually fixes the end of the resin film fed to the winder from the upstream side and then manually starts driving the winder.

[0006] Therefore, the inventors of the present application aimed to develop a technology for automatically starting to wind up a resin film by a winder when production of the resin film is started.

[0007] Other problems and novel features will become apparent from the description in this specification and the accompanying drawings.

[0008] The resin film production apparatus according to an embodiment includes a film passage sensor for winding, which is provided on the inlet side of the winder and is designed to detect the passage of the fed resin film. When resin film production begins, the winder is driven after the film passage sensor detects that the resin film has passed.

[0009] In the control method of the lipid film manufacturing device according to the embodiment, when the manufacture of the resin film starts, after the film passing sensor for winding arranged on the inlet side of the winder detects that the resin film has passed, the computer executes (a) to start driving the winder.

[0010] According to the above-described embodiment, it is possible to provide a resin film production apparatus capable of automatically starting to wind up the resin film by the winder when starting to produce the resin film.

[0011] The above and other objects, features and advantages of the present disclosure will be more fully understood through the detailed description and accompanying drawings given below. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 is a schematic perspective view showing the entire configuration of a resin thin film production apparatus according to a first embodiment;

[0013] Figure 2 is a schematic cross-sectional view showing the entire configuration of a resin thin film production apparatus according to a first embodiment;

[0014] Figure 3 is a cross-sectional view of the T-die 20;

[0015] Figure 4 It is a partial perspective view of the lower side (lip side) of the T-die 20;

[0016] Figure 5 is a flowchart showing the overall process of a method for controlling the resin thin film manufacturing apparatus according to the first embodiment, which is performed when manufacturing a resin thin film is started;

[0017] Figure 6 Is shown in Figure 5 Schematic cross-sectional view of a resin thin film manufacturing apparatus in control mode MD1.

[0018] Figure 7 Is shown in Figure 5 A schematic cross-sectional view of a resin thin film manufacturing apparatus in control mode MD2;

[0019] Figure 8 Is shown in Figure 5 A schematic cross-sectional view of a resin thin film manufacturing apparatus in control mode MD3.

[0020] Figure 9 It shows that Figure 5 A schematic cross-sectional view of a resin thin film manufacturing apparatus in control mode MD4.

[0021] Figure 10 It shows Figure 5 Flowchart of details of control mode MD1;

[0022] Figure 11 It shows Figure 5 Flowchart of details of control mode MD2;

[0023] Figure 12 It shows Figure 11 A schematic cross-sectional view of the casting machine 30 in step S21;

[0024] Figure 13 It shows Figure 5 Flowchart of details of control mode MD3;

[0025] Figure 14 It shows Figure 13 A schematic cross-sectional view of the casting machine 30 and the winder 40 in step S31;

[0026] Figure 15 It shows Figure 5 Flowchart of details of control mode MD4;

[0027] Figure 16 It shows Figure 5 Flowchart of the details of the control mode MD5;

[0028] Figure 17 is a schematic perspective view showing the entire configuration of a resin thin film production apparatus according to a second embodiment;

[0029] Figure 18 It is a schematic cross-sectional view showing the entire structure of a resin thin film production apparatus according to a second embodiment.

[0030] Figure 19 is a flowchart showing the overall process of a method for controlling the resin thin film manufacturing apparatus according to the second embodiment, which is performed when manufacturing a resin thin film is started;

[0031] Figure 20 Is shown in Figure 19 A schematic cross-sectional view of a resin thin film manufacturing apparatus in control mode MD6;

[0032] Figure 21 Is shown in Figure 19 A schematic cross-sectional view of a resin thin film manufacturing apparatus in control mode MD7;

[0033] Figure 22 Is shown in Figure 19 A schematic cross-sectional view of a resin thin film manufacturing apparatus in control mode MD3.

[0034] Figure 23 Is shown in Figure 19 A schematic cross-sectional view of a resin thin film manufacturing apparatus in control mode MD4.

[0035] Figure 24 It shows Figure 19 Flowchart of details of control mode MD6;

[0036] Figure 25 It shows Figure 24 A schematic cross-sectional view of the casting machine 30 and the longitudinal stretching machine 60 in step S61;

[0037] Figure 26 It shows Figure 19 Flowchart of details of control mode MD7;

[0038] Figure 27 It shows Figure 26 A schematic cross-sectional view of the longitudinal stretching machine 60 and the transverse stretching machine 70 in step S71; and

[0039] Figure 28 The second embodiment shows Figure 13 Schematic cross-sectional view of the transverse stretching machine 70 and the coiler 40 in step S31. DETAILED DESCRIPTION

[0040] Specific embodiments are described in detail below with reference to the accompanying drawings. However, the present disclosure is not limited to the embodiments shown below. In addition, for the sake of clarity, the following description and drawings are appropriately simplified.

[0041] (First embodiment)

[0042] <Overall Structure of Resin Thin Film Manufacturing Apparatus>

[0043] First, refer to Figure 1 and Figure 2 The overall structure of the resin thin film production apparatus according to the first embodiment will be described. Figure 1 It is a schematic perspective view showing the entire configuration of the resin thin film production apparatus according to the first embodiment. Figure 2 1 is a schematic cross-sectional view showing the entire configuration of the resin thin film production apparatus according to the first embodiment.

[0044] Note that, needless to say, in order to facilitate the description of the positional relationship between the components, Figure 1 and the right-handed xyz orthogonal coordinates shown in the other figures. Generally, in all figures, the positive z-axis direction is the vertical upward direction, and the xy plane is the horizontal plane.

[0045] Furthermore, in this specification, the term "resin film" includes a resin sheet.

[0046] like Figure 1 and Figure 2 As shown, the resin film manufacturing apparatus according to the first embodiment includes an extruder 10, a T-die 20, a casting machine 30, a winder 40, and a controller 50. The resin film manufacturing apparatus according to the first embodiment is an extrusion molding type resin film manufacturing apparatus in which a film-like molten resin 82a is extruded from a gap between the lips of the T-die 20 connected to the extruder 10. Note that in Figure 1 The controller 50 is omitted.

[0047] Figure 1 and Figure 2 The extruder 10 shown is a screw type extruder. Figure 2 As shown, in the extruder 10 , a screw 12 extending in the x-axis direction is accommodated in a barrel 11 extending in the x-axis direction.

[0048] The screw motor SM is connected to the base of the screw 12 . The screw motor SM is a driving source for driving the screw 12 , and is controlled by the controller 50 .

[0049] Note that only one screw 12 may be provided, or a plurality of screws 12 may be provided. For example, an extruder 10 having one screw 12 is referred to as a single-screw extruder, and an extruder 10 having two screws 12 is referred to as a twin-screw extruder.

[0050] A hopper 13 for loading a resin raw material 81, which serves as the raw material for the resin film 83, is provided above the end portion on the negative side in the x-axis direction of the barrel 11. The resin raw material 81 is, for example, resin pellets or resin powder. Furthermore, a raw material feeder 14 for supplying the resin raw material 81 into the barrel 11 is provided above the hopper 13. The raw material feeder 14 is a screw feeder and includes a feeder hopper FH, a feeder screw FS, and a feeder motor FM.

[0051] Note that the method for driving the raw material feeder 14 is not limited to any specific method, and may be a belt method, or a combination of a screw method and a belt method.

[0052] The resin raw material 81 is loaded into and stored in the feeder hopper FH. When the feed screw FS is driven and rotated by the feed motor FM, the resin raw material 81 stored in the feeder hopper FH is supplied to the barrel 11 through the hopper 13. For example, the controller 50 monitors the mass change of the resin raw material 81 stored in the feeder hopper FH while performing feedback control on the rotation of the feed motor FM. This configuration allows the amount of resin raw material 81 supplied from the raw material feeder 14 to the extruder 10 to be controlled.

[0053] Note that a plurality of raw material feeders 14 may be provided.

[0054] The resin raw material 81 supplied from the hopper 13 into the barrel 11 is conveyed from the base to the top of the rotating screw 12, that is, in the positive x-axis direction. Note that, although not shown in the figure, a heater for heating the interior of the barrel 11 is provided on the outer peripheral surface of the barrel 11 substantially over its entire longitudinal area, so that the resin raw material 81 loaded into the barrel 11 is heated. Thus, the resin raw material 81 is sheared and melted by the rotating screw 12 within the barrel 11 while being heated, and is converted into molten resin 82.

[0055] like Figure 1 As shown in FIG. 1 , the T-die 20 is connected to the lower side of the top (the end portion on the positive side in the x-axis direction) of the extruder 10. More specifically, as shown in FIG. Figure 2As shown, the T-die 20 is connected to the lower end of an L-shaped tube, which extends from the top of the extruder 10 in the positive x-axis direction (the end on the positive side in the x-axis direction) and then extends downward (in the negative z-axis direction). The film-like molten resin 82a is extruded downward (in the negative z-axis direction) from the gap between the lips of the T-die 20 located at its lower end. Note that the distance between the lips of the T-die 20 (hereinafter also referred to as the lip distance) is adjustable. As will be described in detail later, the lip distance of the T-die 20 can be adjusted at multiple positions along the longitudinal direction of the lips (y-axis direction) so that the thickness of the manufactured resin film 83 becomes uniform in the width direction (y-axis direction).

[0056] Note that Figure 2 As shown, a gear pump GP is provided in a horizontal portion of a pipeline that connects the extruder 10 with the T-die 20. The gear pump GP sucks (i.e., draws) the molten resin extruded from the extruder 10 and discharges the sucked molten resin to the T-die 20. The gear pump GP is composed of, for example, a pair of gears meshing with each other. One of the gears of the gear pump GP is driven by a motor (not shown).

[0057] Note that the pump that sucks the molten resin extruded from the extruder 10 and discharges it to the T-die 20 is not limited to a gear pump and may be any other type of pump. In addition, a plurality of extruders 10 and / or a plurality of gear pumps GP may be provided to supply the molten resin 82 to the T-die 20.

[0058] like Figure 1 As shown, a pressure sensor PS is provided on the suction side of the gear pump GP in the pipeline connecting the extruder 10 and the T-die 20. The pressure sensor PS measures the pressure of the molten resin on the suction side of the gear pump GP. The pressure measured by the pressure sensor PS is input to the controller 50.

[0059] like Figure 1 and Figure 2 As shown, the casting machine 30 includes a casting roll CS and a cooling roll CL.

[0060] The casting roll CS cools the film-like molten resin 82 a while discharging the resin thin film 83 formed when the film-like molten resin 82 a extruded from the T-die 20 is solidified onto the cooling roll CL.

[0061] Then, if Figure 1 and Figure 2 As shown, the cooling roller CL cools the resin film 83 while conveying the resin film 83. The casting roller CS and the cooling roller CL are drive rollers driven by respective drive sources (not shown). The drive source is, for example, a variable speed motor such as a servo motor.

[0062] Note that each of the casting roll CS and the cooling roll CL may be equipped with a cooling mechanism for cooling the resin film 83. Furthermore, each of the casting roll CS and the cooling roll CL may be equipped with a heating mechanism for heating the resin film 83.

[0063] In addition, the casting machine 30 may include a plurality of casting rolls CS and a plurality of cooling rolls CL.

[0064] In the resin film production apparatus according to the present embodiment, the resin film 83 discharged from the casting machine 30 is wound up by the winder 40. The winder 40 is a driving roller driven by a driving source (not shown).

[0065] Note that the reel 40 may include a plurality of drive rollers driven by a drive source(s). In addition, a plurality of reels 40 may be provided.

[0066] The film thickness sensor FTS is, for example, a non-contact type thickness sensor, and measures the thickness distribution (hereinafter also referred to as thickness distribution) of the resin film 83 discharged and conveyed from the casting machine 30 in its width direction. Figure 2 In the illustrated example, the film thickness sensor FTS is arranged so as to vertically sandwich the resin film 83, which is being conveyed horizontally, between the cooling roll CL and the winder 40. Since the film thickness sensor FTS is a non-contact sensor, it can scan (i.e., move) across the width (y-axis) of the resin film 83. Therefore, using the compact film thickness sensor FTS, the thickness distribution of the resin film 83 across its width can be measured. Furthermore, since the resin film 83 is conveyed horizontally, the thickness distribution can be accurately measured even when the film thickness sensor FTS is scanning (i.e., moving).

[0067] <Structure and Operation of Controller 50>

[0068] The controller 50 controls the extruder 10, the T-die 20, the casting machine 30, and the winder 40. Specifically, the controller 50 controls the entire resin film production apparatus according to this embodiment, thereby controlling the production of the resin film 83. The controller 50 is not limited to any specific controller, such as a PLC (Programmable Logic Controller). The controller 50 may be, for example, a PC (Personal Computer).

[0069] Although not shown in the figure, the controller 50 includes, for example, a computing unit such as a CPU (Central Processing Unit) and one or more memories such as RAM (Random Access Memory) and ROM (Read Only Memory), and various programs and data are stored in the memories. Specifically, the controller 50 functions as a computer and controls the extruder 10, the T-die 20, the casting machine 30, and the winder 40 based on the various programs described above.

[0070] Therefore, when formed into hardware, Figure 2 The controller 50 shown may be formed by the aforementioned CPU, memory, and other circuits. Alternatively, when implemented as software, the controller 50 may be implemented by a program stored in a memory, etc. That is, the controller 50 may be implemented in various forms by hardware, software, or a combination thereof.

[0071] Regarding the control of the extruder 10, the controller 50 controls the extruder 10 so that the pressure of the molten resin 82 on the suction side of the gear pump GP, as measured by the pressure sensor PS, is maintained at a target pressure. Specifically, the controller 50 performs feedback control on the amount of the resin raw material 81 supplied from the raw material feeder 14 and the rotational speeds of the screw 12 and the gear pump GP based on the pressure of the molten resin 82 measured by the pressure sensor PS.

[0072] That is, Figure 2 As shown, the controller 50 performs feedback control on the feeder motor FM, the screw motor SM, and the gear pump GP based on the pressure of the molten resin 82 measured by the pressure sensor PS. By maintaining the pressure of the molten resin 82 on the suction side of the gear pump GP at a target pressure, the amount of molten resin 82 flowing into the T-die 20 can be kept constant.

[0073] Note that, when production of the resin film 83 starts, the controller 50 performs feedback control on the rotation speed of the gear pump GP so as to maintain the pressure of the molten resin 82 on the suction side of the gear pump GP at a target pressure.

[0074] When the speed of the gear pump GP increases, the amount of molten resin 82 sucked into the gear pump GP increases, causing the pressure of the molten resin 82 on the suction side of the gear pump GP to decrease. Conversely, when the speed of the gear pump GP decreases, the amount of molten resin 82 sucked into the gear pump GP decreases, causing the pressure of the molten resin 82 on the suction side of the gear pump GP to increase.

[0075] Therefore, when the controller 50 performs feedback control on the rotation speed of the gear pump GP, if the pressure measured by the pressure sensor PS is lower than the target pressure, the rotation speed of the gear pump GP is reduced. Conversely, if the measured pressure is higher than the target pressure, the rotation speed of the gear pump GP is increased.

[0076] Meanwhile, when the resin film 83 is manufactured as a product, the controller 50 performs feedback control on the amount of the resin raw material 81 supplied from the raw material feeder 14 and the rotational speed of the screw 12 to maintain the pressure of the molten resin 82 on the suction side of the gear pump GP at the target pressure. That is, when the product is manufactured, the rotational speed of the gear pump GP is fixed.

[0077] When the rotation speed of the screw 12 increases, the amount of the molten resin 82 extruded (i.e., pushed) toward the gear pump GP increases, causing the pressure of the molten resin 82 on the suction side of the gear pump GP to rise. Conversely, when the rotation speed of the screw 12 decreases, the amount of the molten resin 82 extruded (i.e., pushed) toward the gear pump GP decreases, causing the pressure of the molten resin 82 on the suction side of the gear pump GP to decrease.

[0078] Therefore, when the controller 50 performs feedback control on the rotational speed of the screw 12, if the pressure measured by the pressure sensor PS is lower than the target pressure, the rotational speed of the screw 12 is increased. In this case, the amount of the resin raw material 81 supplied from the raw material feeder 14 is also increased. Conversely, if the measured pressure is higher than the target pressure, the rotational speed of the screw 12 is reduced. In this case, the amount of the resin raw material 81 supplied from the raw material feeder 14 is also reduced.

[0079] In addition, if Figure 2 As shown, in order to control the T-die 20, the controller 50 performs feedback control on the lip distance of the T-die 20 based on the thickness distribution of the resin film 83 obtained from the film thickness sensor FTS. More specifically, the controller 50 controls the lip distance of the T-die 20 so that the thickness of the resin film 83 becomes uniform in its width direction.

[0080] In addition, if Figure 2 As shown, in order to control the casting machine 30 and the winder 40, the controller 50 controls the rotation speeds of the casting roll CS, the cooling roll CL, and a driving source (e.g., a motor (not shown)) for driving the winder 40. For example, the controller 50 controls the rotation speed of the driving source for driving the winder 40 to maintain the tension of the resin film 83 at a constant tension in the winder 40.

[0081] Furthermore, when the resin film 83 is first produced, Figure 2After a predetermined timing when the resin film 83 has passed through the film passing sensor S1, the controller 50 starts driving the winder 40. That is, the winding of the resin film 83 by the winder 40 starts.

[0082] Note that the film passing sensor S1 is a film passing sensor for winding provided on the inlet side of the winder 40, and detects the passage of the resin film 83 being conveyed when manufacturing starts. Also, in this embodiment, it can also be said that the film passing sensor S1 is provided on the outlet side of the casting machine 30 and can detect that the resin film 83 has passed through the casting machine 30 when manufacturing starts. The film passing sensor S1 is not limited to any specific sensor as long as it can detect the passage of the resin film 83. For example, the film passing sensor S1 is a photoelectric sensor or a temperature sensor.

[0083] Note that although in Figure 2 the film thickness sensor FTS is arranged between the film passing sensor S1 and the winder 40, the film passing sensor S1 can be arranged between the film thickness sensor FTS and the winder 40.

[0084] Alternatively, the film passing sensor can be provided at each of the outlet side of the casting machine 30 and the inlet side of the winder 40.

[0085] As described above, the resin film manufacturing apparatus according to this embodiment includes a film passing sensor S1 provided on the inlet side of the winder 40 and detects the passage of the conveyed resin film 83. In addition, when starting the manufacture of the resin film 83, after detecting that the resin film 83 has passed through the winder 40 by the film passing sensor S1, the winder 40 is started to be driven. Therefore, in the resin film manufacturing apparatus according to this embodiment, when starting the manufacture of the resin film, the winding of the resin film can be automatically started by the winder.

[0086] <Structure of the T-die 20>

[0087] Hereinafter, the structure of the T-die 20 will be described in more detail with reference to Figure 3 and Figure 4 in a more detailed manner. Figure 3 is a cross-sectional view of the T-die 20. In addition, Figure 4 is a partial perspective view of the lower side (lip side) of the T-die 20.

[0088] As Figure 3 and Figure 4As shown, the T-die 20 is composed of a pair of die blocks 21 and 22 arranged to abut against each other. Each of the pair of die blocks 21 and 22 arranged to abut against each other is formed with a tapered portion that slopes downward from the outer surface toward the inner surface (abutment surface). Specifically, thin lips 21a and 22a are provided at the lower ends of the abutment surfaces of the die blocks 21 and 22, respectively.

[0089] Inlet 20a, manifold 20b, and slit 20c are formed in the abutting surfaces of a pair of mold blocks 21 and 22. Inlet 20a extends downward (in the negative z-axis direction) from the upper surface of T-die 20. Manifold 20b extends from the lower end of inlet 20a in both the positive and negative y-axis directions. Thus, inlet 20a and manifold 20b form a T-shape in T-die 20.

[0090] Furthermore, a slit 20c extending from the bottom surface of the manifold 20b to the lower surface of the T-die 20 extends in the y-axis direction. The molten resin 82 is extruded downward from the slit 20c (ie, from the gap between the lips 21a and 22a) through the inlet 20a and the manifold 20b.

[0091] Note that while lip 21a is a fixed, stationary lip, lip 22a is a movable lip connected to adjustment bolt 23. A cutout groove 22b is formed in lip 22a, extending obliquely upward from the outer surface toward the abutment surface. Lip 22a is pushed and pulled by adjustment bolt 23, allowing it to move using the bottom of cutout groove 22b as a fulcrum. As described above, only lip 22a is formed as a movable lip, making it easy to adjust the lip distance with a simple structure.

[0092] like Figure 3 and Figure 4 As shown, the adjustment bolts 23 extend obliquely upward along the tapered portion of the mold block 22. The adjustment bolts 23 are supported by retainers 25a and 25b fixed to the mold block 22. More specifically, the adjustment bolts 23 are screwed into threaded holes formed in the retainer 25a. On the other hand, although the adjustment bolts 23 are inserted through through holes formed in the retainer 25b, they are not screwed into the retainer 25b.

[0093] Note that the holders 25a and 25b do not necessarily need to be formed as components provided separately from the mold block 22. That is, they may be formed integrally with the mold block 22. Furthermore, the adjustment bolt 23 may be screwed into the holder 25b.

[0094] Note that Figure 4 As shown, a plurality of adjustment bolts 23 are arranged along the longitudinal direction of the lips 21a and 22a (along the y-axis direction). The longitudinal direction of the lips 21a and 22a corresponds to (i.e., is substantially parallel to) the width direction of the resin film. Although the drawings are simplified in Figure 4 In the example shown, only three adjusting screws 23 are provided, but the number of adjusting screws 23 provided in a mold block is usually greater than three.

[0095] A motor 24 is provided for each adjusting bolt 23 to adjust the tightening amount (tightening strength) of the adjusting bolt 23. Figure 3 and Figure 4 In the illustrated example, a motor 24 is connected to the upper end of each adjusting bolt 23 via a connecting member 27. By tightening (i.e., screwing) the adjusting bolt 23 by the motor 24, the lip 22a is pushed by the lower end surface of the adjusting bolt 23. Furthermore, the lower end of the adjusting bolt 23 is connected to the lip 22a via a connecting member 26 having a U-shaped cross-section and fixed to the lip 22a. Therefore, by loosening (i.e., unscrewing) the adjusting bolt 23 by the motor 24, the lip 22a is pulled by the connecting member 26.

[0096] The distance between lips 21a and 22a can be adjusted by adjusting the tightening amount of adjusting bolt 23. Specifically, as the tightening amount of adjusting bolt 23 increases, adjusting bolt 23 pushes lip 22a, reducing the distance between lips 21a and 22a. On the other hand, as the tightening amount of adjusting bolt 23 decreases, the distance between lips 21a and 22a increases. The tightening amount (or tightening intensity) of each adjusting bolt 23, i.e., the rotation amount of each motor 24, is also controlled by controller 50.

[0097] Note that a technique is known in which each adjusting bolt 23 is heated by a heater provided therein, and the lip gap is finely adjusted based on its thermal expansion. Specifically, as the heating temperature of the adjusting bolt 23 increases, its thermal expansion increases, causing the adjusting bolt 23 to push against the lip 22a, thereby reducing the lip gap. Conversely, as the heating temperature of the adjusting bolt 23 decreases, its thermal expansion decreases, increasing the lip gap. In this technique, the heating of each heater is also controlled by the controller 50.

[0098] <Overall Process of Control Method for Resin Thin Film Manufacturing Apparatus>

[0099] Next, we will refer to Figure 2 and Figures 5 to 9 The entire process of the method for controlling the resin thin film manufacturing apparatus according to the first embodiment, which is performed when manufacturing the resin thin film is started, will be described. Figure 5 1 is a flowchart showing the entire process of the method for controlling the resin thin film manufacturing apparatus according to the first embodiment, which is performed when manufacturing the resin thin film starts.

[0100] Figures 6 to 9 are respectively shown in Figure 5Schematic cross-sectional view of a resin thin film manufacturing apparatus in control modes MD1 to MD4. Figure 2 Shows the Figure 5 A resin thin film manufacturing device in control mode MD5.

[0101] Notice, Figure 5 The resin thin film manufacturing apparatus shown is controlled by a controller 50 which is a computer. Figure 5 The details of each of the control modes MD1 to MD5 will be described later.

[0102] First, if Figure 5 and Figure 6 As shown, the driving of the extruder 10 is started, and the film-shaped molten resin 82a is extruded from the T-die 20 at a predetermined pressure (control mode MD1).

[0103] Then, if Figure 5 and Figure 7 As shown, the casting machine 30 starts to be driven, and while the film-like molten resin 82a is supplied to the casting roll CS, the resin film 83 is discharged from the cooling roll CL (control mode MD2).

[0104] Then, if Figure 5 and Figure 8 As shown, the winder 40 is driven to allow the resin film 83 to pass through and be wound on the winder 40 (control mode MD3). Figure 8 At a predetermined timing after the film passage sensor S1 shown detects that the resin film 83 has passed, the controller 50 starts driving the winder 40 .

[0105] Then, if Figure 5 and Figure 9 As shown, the film thickness of the resin film 83 is adjusted (control mode MD4). Specifically, the controller 50 adjusts the film thickness of the resin film 83 based on the control mode MD4. Figure 9 The film thickness sensor FTS shown acquires the thickness distribution of the resin film 83 and performs feedback control on the lip distance of the T-die 20.

[0106] Then, if Figure 2 and Figure 5 As shown, after completing the control mode MD4 for adjusting the film thickness of the resin film 83, the controller 50 switches the control mode to the control mode MD5 for manufacturing a product. That is, the production of the resin film 83 as a product begins.

[0107] <Details of Control Method MD1>

[0108] Next, we will refer to Figure 6 and Figure 10 illustrate Figure 5 Details of control mode MD1. Figure 10 It shows Figure 5 Flowchart of the details of the control mode MD1.

[0109] Notice, Figure 10 The control shown is performed by the controller 50 which is a computer. Note that Figure 10 The "Start Control Mode MD1" in Figure 5 For example, the control mode MD1 is started by an operator through an operation on the controller 50 , and the controller 50 performs subsequent control.

[0110] First, if Figure 10 As shown, Figure 6 The gear pump GP shown is started and operated at the lowest rotational speed (step S11).

[0111] Then, if Figure 10 As shown, start Figure 6 The screw 12 shown, ie, the screw motor SM, is started and its rotation speed is increased to a target rotation speed (step S12).

[0112] Next, if Figure 10 As shown, start Figure 6 The raw material feeder 14 shown, ie, the feeder motor FM, increases the amount of the resin raw material 81 as the raw material supplied to the drum 11 to a target supply amount (step S13).

[0113] Then, when the pressure of the molten resin 82 reaches the target pressure, control is performed to maintain the target pressure (step S14). Specifically, the controller 50 performs feedback control on the rotation speed of the gear pump GP to convert the rotation speed of the gear pump GP to the target pressure. Figure 6 The pressure of the molten resin 82 on the suction side of the gear pump GP measured by the illustrated pressure sensor PS is maintained at a predetermined target pressure.

[0114] Through the above series of processing, the control mode MD1 is completed. Note that, needless to say, there may be a passage of a predetermined time (eg, waiting) by a timer etc. between each step and the next step of the step. The same applies to the following description.

[0115] Note that steps S12 to S14 may be repeated while increasing each (or at least one) of the target rotation speed of the screw in step S12 , the target amount of raw material to be supplied in step S13 , and the target pressure in step S14 in a stepwise manner.

[0116] <Details of Control Method MD2>

[0117] Next, we will refer to Figure 11 and Figure 12 illustrate Figure 5Details of control mode MD2. Figure 11 It shows Figure 5 Flowchart of the details of control mode MD2. Figure 12 It shows Figure 11 Schematic cross-sectional view of the casting machine 30 in step S21 in FIG.

[0118] Notice, Figure 11 The control shown is also performed by the controller 50 which is a computer.

[0119] First, if Figure 11 As shown, the casting machine 30 is started, and the film-like molten resin 82a is supplied to the casting roll CS, thereby starting to discharge the resin film 83 from the cooling roll CL (step S21).

[0120] The following will refer to Figure 12 An example of step S21 is described below. Figure 12 In the example shown, except Figure 2 In addition to the shown casting roll CS and cooling roll CL, the casting machine 30 includes a dummy film feeder FF, a dummy film cutter FC, nip rolls NR1 and NR2, and a temperature sensor TS.

[0121] exist Figure 12 In the example shown, before the casting machine 30 is started, the dummy film DF1 to be cast is passed through the casting roll CS and the cooling roll CL. Specifically, the dummy film DF1 supplied from the dummy film feeder FF passes through the casting roll CS and the cooling roll CL, and the leading end of the dummy film DF1 is sandwiched between the cooling roll CL and the nip roll NR2. These operations are performed manually, for example, but can also be performed by a robot or the like.

[0122] Then, when the temperature sensor TS detects the film-like molten resin 82a, the casting machine 30, specifically the casting roll CS and the cooling roll CL, is driven and rotated at a low speed. As this is done, the film-like molten resin 82a is pressed against and adheres to the dummy film DF1 on the casting roll CS by the nip roll NR1. As the casting roll CS and the cooling roll CL rotate, the dummy film DF1 is fed from the dummy film feeder FF.

[0123] Note that the driving of the casting roll CS and the cooling roll CL may be started at a predetermined timing after starting the control mode MD2 (ie, after completing the control mode MD1) without detecting the film-like molten resin 82a by the temperature sensor TS. That is, the temperature sensor TS is not indispensable.

[0124] Afterwards, when Figure 12When the film passing sensor S1 detects the resin film 83 discharged from the cooling roller CL, the dummy film DF1 is cut by the dummy film cutter FC. Note that, for example, the width of the dummy film DF1 is different from the width of the resin film 83, and Figure 12 In the diagram shown, a plurality of film passage sensors S1 are arranged in the depth direction. Therefore, the resin film 83 can be detected by the film passage sensor S1 (ie, a plurality of film passage sensors S1) while being distinguished from the dummy film DF1.

[0125] Then, if Figure 11 As shown, the amount of the supplied molten resin 82 is increased to a target value (step S22). Through the above series of processing, the control mode MD2 is completed.

[0126] <Details of Control Method MD3>

[0127] Next, we will refer to Figure 13 and Figure 14 illustrate Figure 5 Details of control mode MD3. Figure 13 It shows Figure 5 Flowchart of the details of the control mode MD3. Figure 14 It shows Figure 13 Schematic cross-sectional view of the casting machine 30 and the winder 40 in step S31 in FIG.

[0128] Notice, Figure 13 The control shown is also performed by the controller 50 which is a computer.

[0129] First, if Figure 13 As shown, the winder 40 is started and the winding of the resin film 83 is started under constant rotation control (step S31). Specifically, the resin film 83 is detected by the film passing sensor S1 and Figure 11 The coiler 40 is started at a predetermined timing after step S22 in the process.

[0130] The following will refer to Figure 14 An example of step S31 is described below. Figure 14 In the illustrated example, a film connecting device FW1 for winding is provided between the film passing sensor S1 and the winder 40. The film connecting device FW1 connects the films to each other. For example, the film connecting device FW1 welds the resin films to each other.

[0131] Before starting the winder 40 in step S31, the leading end of the dummy film DF2 to be wound is fixed to the winder 40. At the same time, the trailing end of the dummy film DF2 is pre-placed in the film connecting device FW1. These operations are performed manually, but can also be performed by a robot or the like.

[0132] Then, after the resin film 83 discharged from the casting machine 30 is detected by the film passing sensor S1, the resin film 83 and the dummy film DF2 are connected to each other by the film connecting device FW1 at a predetermined timing, and then the winder 40 is started. Through this series of operations, the resin film 83 is automatically passed through the winder 40, thereby automatically starting the winding of the resin film 83.

[0133] Then, if Figure 13 As shown, after the tension caused by the resin film 83 is detected in the winder 40, the control of the winder 40 is switched from the constant rotation control to the constant tension control (step S32).

[0134] Then, if Figure 13 As shown, the production line operating conditions are changed to the set value of the control mode MD3 (step S33). For example, the production line speed is increased to the set value of the control mode MD3. Through the above series of processes, the control mode MD3 is completed.

[0135] <Details of Control Method MD4>

[0136] Next, we will refer to Figure 15 illustrate Figure 5 Details of the control mode MD4. Figure 15 It shows Figure 5 Flowchart of the details of the control mode MD4.

[0137] Notice, Figure 15 The control shown is also performed by the controller 50 which is a computer.

[0138] First, if Figure 15 As shown, the production line operating conditions are changed to the set value for film thickness adjustment (step S41). For example, the production line speed is increased to the set value for film thickness adjustment.

[0139] Then, if Figure 15 As shown, the film thickness is adjusted (step S42). Specifically, the controller 50 adjusts the film thickness based on the Figure 9 The film thickness sensor FTS shown acquires the thickness distribution of the resin film 83 and performs feedback control on the lip distance of the T-die 20.

[0140] Then, if Figure 15 As shown, when the thickness of the resin film 83 is not within the predetermined range ("No" at step S43), the film thickness adjustment in step S42 is continued. On the other hand, when the thickness of the resin film 83 is within the predetermined range ("Yes" at step S43), the control mode MD4, i.e., the film thickness adjustment, is completed.

[0141] Note that steps S41 to S43 may be repeated while increasing the line speed to the set value for film thickness adjustment in a stepwise manner.

[0142] <Details of control method MD5>

[0143] Next, we will refer to Figure 16 illustrate Figure 5 Details of the control mode MD5 in. Figure 16 It shows Figure 5 Flowchart of the details of the control mode MD5.

[0144] Notice, Figure 16 The control shown is also performed by the controller 50 which is a computer.

[0145] First, if Figure 16 As shown, the production line operating conditions are changed to the set values ​​for product manufacturing (step S51). For example, the production line speed is increased to the set value for product manufacturing.

[0146] Then, if Figure 16 As shown, the control mode of the extruder 10 is switched from the control mode used after the start of production to the control mode for product production (step S52). Through the above series of processing, the control mode MD5 is completed.

[0147] As described above, in the control mode of the extruder 10 at the start of production, the rotational speed of the gear pump GP is feedback-controlled to maintain the pressure of the molten resin 82 on the suction side of the gear pump GP at the target pressure. Simultaneously, in the control mode of the extruder 10 during product production, the amount of the resin raw material 81 supplied from the raw material feeder 14 and the rotational speed of the screw 12 are feedback-controlled to maintain the pressure of the molten resin 82 on the suction side of the gear pump GP at the target pressure. During these processes, the rotational speed of the gear pump GP is fixed.

[0148] Note that in Figure 16 In the process, the completion of control mode MD5 means the continuation of product manufacturing.

[0149] (Second embodiment)

[0150] <Overall Structure of Resin Thin Film Manufacturing Apparatus>

[0151] Next, we will refer to Figure 17 and Figure 18 The entire structure of a resin thin film production apparatus according to the second embodiment will be described. Figure 17 It is a schematic perspective view showing the entire configuration of a resin thin film production apparatus according to a second embodiment. Figure 18 It is a schematic cross-sectional view showing the entire structure of a resin thin film production apparatus according to a second embodiment.

[0152] like Figure 17 and Figure 18 As shown, the resin film manufacturing device according to this embodiment further includes a Figure 1 and Figure 2 A longitudinal stretching machine 60 and a transverse stretching machine 70 are shown between the casting machine 30 and the winder 40. Specifically, the longitudinal stretching machine 60 is provided after the casting machine 30 (ie, on the outlet side thereof), and the transverse stretching machine 70 is provided after the longitudinal stretching machine 60.

[0153] like Figure 17 and Figure 18 As shown, the longitudinal stretching machine 60 stretches the resin film 83 discharged from the casting machine 30 in the longitudinal direction while conveying the resin film 83. Figure 17 and Figure 18 The longitudinal stretching machine 60 shown includes five rollers R1 to R5. Each of the rollers R1 to R5 is a drive roller driven by a drive source (not shown). The drive source is, for example, a variable speed motor such as a servo motor.

[0154] Note that the longitudinal stretching machine 60 only needs to include a plurality of drive rollers for conveying the resin film 83 , and the number and arrangement of the drive rollers provided in the longitudinal stretching machine 60 can be appropriately determined.

[0155] Furthermore, each of the rollers R1 to R5 may include at least one of a cooling mechanism for cooling the resin film 83 and a heating mechanism for heating the resin film 83 .

[0156] Furthermore, the longitudinal stretching machine 60 may include one or more nip rollers for pressing the resin film 83 against one of the rollers R1 to R5. The nip rollers are not drive rollers.

[0157] like Figure 17 As shown, the transverse stretching machine 70 stretches the resin film 83 discharged from the longitudinal stretching machine 60 in its width direction (y-axis direction). More specifically, the transverse stretching machine 70 includes a pair of rails RL1 and RL2. In addition, a large number of clips (not shown) are slidably arranged side by side across the rails RL1 and RL2.

[0158] exist Figure 17 In FIG, the arrows shown for rails RL1 and RL2 show the direction in which the clamp moves. Figure 17As shown, each of the rails RL1 and RL2 has an endless configuration including an outward path along which the gripper moves in the direction in which the resin film 83 is conveyed (i.e., the positive x-axis direction); and a return path along which the gripper moves in the direction opposite to the outward path (i.e., the negative x-axis direction). That is, in the transverse stretching machine 70, the gripper circulates along the respective rails RL1 and RL2, each having an endless configuration.

[0159] like Figure 17 As shown, the rails RL1 and RL2 have a symmetrical configuration with respect to a plane parallel to the xz plane.

[0160] like Figure 17 As shown, in the rails RL1 and RL2, the outward path along which the gripper moves in the conveying direction (i.e., the positive x-axis direction) and the return path along which the gripper moves in the direction opposite to the conveying direction (i.e., the negative x-axis direction) are arranged approximately parallel to each other. The return path of the rail RL1 is arranged outside the width direction of the resin film 83 (i.e., on the negative side in the y-axis direction). The return path of the rail RL2 is also arranged outside the width direction of the resin film 83 (i.e., on the positive side in the y-axis direction).

[0161] like Figure 17 As shown, in the outward path of each of rails RL1 and RL2, a pair of parallel portions parallel to the x-axis are provided at both ends of the rail in the longitudinal direction (x-axis direction), and an inclined portion inclined relative to the y-axis direction is provided between these parallel portions. The inclined portion of rail RL1 is inclined in the negative y-axis direction, while the inclined portion of rail RL2 is inclined in the positive y-axis direction. In other words, in the inclined portions of the outward paths of rails RL1 and RL2, the distance between rails RL1 and RL2 in the y-axis direction increases as the distance from the negative x-axis end of the rail increases in the positive x-axis direction.

[0162] Note that in Figure 17 In the outward path of the rails RL1 and RL2 shown, the clamps move in the positive x-axis direction along the rails RL1 and RL2 while holding both ends of the resin film 83 in the width direction (y-axis direction) at the portions where they come into contact with the resin film 83. Figure 17 As shown, in the inclined portion of the outward path of the rails RL1 and RL2, the resin film 83 is conveyed in the positive x-axis direction while being stretched in the width direction (y-axis direction).

[0163] Note that in Figure 17In the illustrated rails RL1 and RL2, at portions where the clamps do not contact the resin film 83, the clamps move along the rails RL1 and RL2 without holding the resin film 83. More specifically, the clamps hold the resin film 83 at the entrance to the transverse stretcher 70, i.e., at the rear ends of the rails RL1 and RL2 (the negative ends in the x-axis direction), and then move along the rails RL1 and RL2 in the positive x-axis direction while holding the resin film 83. The clamps then release the resin film 83 at the exit of the transverse stretcher 70, i.e., at the front ends of the rails RL1 and RL2 (the positive ends in the x-axis direction).

[0164] also, Figure 1 The illustrated transverse stretching machine 70 includes a drive source(s) for driving the grippers that convey the resin film 83. The drive source is, for example, a variable speed motor such as a servo motor.

[0165] <Configuration and Operation of Controller 50>

[0166] In this embodiment, when the resin film 83 is first manufactured, Figure 18 At a predetermined timing after the film passage sensor S2 shown detects that the resin film 83 has passed, the controller 50 starts driving the longitudinal stretching machine 60 .

[0167] Note that the film passing sensor S2 is a film passing sensor for longitudinal stretching, which is provided on the inlet side of the longitudinal stretching machine 60 and detects the passing of the resin film 83 being conveyed when manufacturing starts. Figure 2 The film passing sensor S1 in FIG. 2 and the film passing sensor S2 are provided on the exit side of the casting machine 30 and detect that the resin film 83 has passed through the casting machine 30 when production starts.

[0168] Note that a film passage sensor may be provided at each of the outlet side of the casting machine 30 and the inlet side of the longitudinal stretching machine 60 .

[0169] As described above, the resin film manufacturing apparatus according to this embodiment includes a film passage sensor S2, which is provided on the inlet side of the longitudinal stretching machine 60 and detects the passage of the fed resin film 83. Furthermore, when the production of the resin film 83 is started, the longitudinal stretching machine 60 is started after the film passage sensor S2 detects that the resin film 83 has passed. Therefore, in the resin film manufacturing apparatus according to this embodiment, when the production of the resin film is started, the longitudinal stretching machine 60 can automatically start stretching the resin film in the longitudinal direction.

[0170] In addition, in this embodiment, when the resin film 83 is first manufactured, Figure 18At a predetermined timing after the film passage sensor S3 shown detects that the resin film 83 has passed, the controller 50 starts holding the resin film 83 by the transverse stretching machine 70 .

[0171] Note that the film passage sensor S3 is a film passage sensor for transverse stretching provided on the inlet side of the transverse stretching machine 70, and detects the passage of the fed resin film 83 when production starts. It can also be said that the film passage sensor S3 is provided on the outlet side of the longitudinal stretching machine 60, and detects that the resin film 83 has passed through the longitudinal stretching machine 60 when production starts.

[0172] Note that a film passage sensor may be provided at each of the exit side of the longitudinal stretching machine 60 and the entrance side of the transverse stretching machine 70 .

[0173] As described above, the resin film manufacturing apparatus according to this embodiment includes the film passage sensor S3, which is provided on the inlet side of the transverse stretching machine 70 and detects the passage of the fed resin film 83. Then, when the production of the resin film 83 starts, after the film passage sensor S3 detects that the resin film 83 has passed, the resin film 83 begins to be held by the transverse stretching machine 70. Therefore, in the resin film manufacturing apparatus according to this embodiment, when the production of the resin film starts, the transverse stretching of the resin film can be automatically started by the transverse stretching machine.

[0174] In addition, in this embodiment, similarly to the first embodiment, when the resin film 83 is initially manufactured, Figure 18 At a predetermined timing after the film passage sensor S1 shown detects that the resin film 83 has passed, the controller 50 starts driving the winder 40. That is, the winder 40 starts winding up the resin film 83.

[0175] Note that in this embodiment, the film passage sensor S1 is also a film passage sensor for winding provided on the inlet side of the winder 40, and detects the passage of the fed resin film 83 when production starts. Meanwhile, in this embodiment, it can also be said that the film passage sensor S1 is provided on the outlet side of the transverse stretching machine 70, and detects that the resin film 83 has passed through the transverse stretching machine 70 when production starts.

[0176] Note that a film passage sensor may be provided at each of the exit side of the transverse stretching machine 70 and the entrance side of the winder 40 .

[0177] As described above, the resin film manufacturing apparatus according to this embodiment further includes a film passage sensor S1, which is provided on the inlet side of the winder 40 and detects the passage of the fed resin film 83. Furthermore, when production of the resin film 83 begins, the winder 40 is driven after the film passage sensor S1 detects that the resin film 83 has passed. Therefore, in the resin film manufacturing apparatus according to this embodiment, when production of the resin film begins, winding of the resin film by the winder can be automatically started.

[0178] As described above, the resin film production apparatus according to this embodiment includes film passage sensors S2, S3, and S1, each of which detects the passage of the fed resin film 83 at the inlet side of the longitudinal stretching machine 60, the transverse stretching machine 70, and the winder 40, respectively. Furthermore, when production of the resin film 83 is started, after the film passage sensors S2, S3, and S1 detect the passage of the resin film 83, the driving of the longitudinal stretching machine 60, the holding of the resin film 83 by the transverse stretching machine 70, and the driving of the winder 40 are sequentially started.

[0179] Therefore, in the resin film manufacturing apparatus according to this embodiment, when the resin film manufacturing starts, the longitudinal stretching, transverse stretching and winding of the resin film by the longitudinal stretching machine, transverse stretching machine and winder can be automatically and sequentially started respectively.

[0180] The rest of the structure and Figure 2 Since the resin thin film production apparatus of the first embodiment shown is the same, the description thereof will be omitted.

[0181] <Overall Flow of Control Method for Resin Thin Film Manufacturing Apparatus>

[0182] Next, we will refer to Figures 18 to 23 The overall process of the method for controlling the resin thin film manufacturing apparatus according to the second embodiment, which is performed when manufacturing the resin thin film is started, is described. Figure 19 is a flowchart showing the overall procedure of a method for controlling the resin thin film manufacturing apparatus according to the second embodiment, which is performed when manufacturing a resin thin film is started.

[0183] like Figure 19 As shown, the control method of the lipid film manufacturing device according to this embodiment also includes Figure 5 Control modes MD6 and MD7 are shown between control modes MD2 and MD3.

[0184] Figure 20 and Figure 21 are respectively shown in Figure 19 Schematic cross-sectional view of a resin thin film manufacturing apparatus in control modes MD6 and MD7. Figure 22 and Figure 23 are respectively shown in Figure 19 Schematic cross-sectional view of a resin thin film manufacturing apparatus in control modes MD3 and MD4. Figure 18 Shown in Figure 19 A resin thin film manufacturing device in control mode MD5.

[0185] in addition, Figure 19 The control of the resin thin film manufacturing apparatus shown is executed by a computer which is a controller 50. Details of each of the control modes MD6 and MD7 added in the present embodiment will be described later.

[0186] also, Figure 19 The control modes MD1 and MD2 shown are Figure 5 The control modes MD1 and MD2 shown are the same, so detailed description thereof will be omitted.

[0187] like Figure 19 and Figure 20 As shown, after the control mode MD2, the driving of the longitudinal stretching machine 60 is started, and the resin film 83 is passed through the longitudinal stretching machine 60 and stretched in the longitudinal direction (control mode MD6). Figure 20 The controller 50 starts driving the longitudinal stretching machine 60 at a predetermined timing after the film passing sensor S2 detects the resin film 83 discharged from the casting machine 30 .

[0188] Then, if Figure 19 and Figure 21 As shown, the resin film 83 is passed through the transverse stretching machine 70 and stretched in the width direction (control mode MD7). Figure 21 At a predetermined timing after the film passage sensor S3 shown detects the resin film 83 discharged from the longitudinal stretching machine 60 , the controller 50 starts holding the resin film 83 by the transverse stretching machine 70 .

[0189] Then, if Figure 19 and Figure 22 As shown, the winder 40 is started to be driven, and the resin film 83 is passed through and wound on the winder 40 (control mode MD3). Figure 22 The controller 50 starts driving the winder 40 at a predetermined timing after the film passing sensor S1 detects the resin film 83 discharged from the transverse stretching machine 70 .

[0190] Then, if Figure 19 and Figure 23 As shown, the film thickness of the resin film 83 is adjusted (control mode MD4). Specifically, the controller 50 adjusts the film thickness of the resin film 83 based on the control mode MD4. Figure 23The film thickness sensor FTS shown in the figure obtains the thickness distribution of the resin film 83 and performs feedback control on the lip distance of the T-die 20. In this embodiment, the film thickness sensor FTS measures the thickness distribution of the resin film 83 discharged and conveyed from the transverse stretching machine 70 along its width direction.

[0191] Note that a film thickness sensor may also be provided at at least one of the outlets of the casting machine 30 and the longitudinal stretching machine 60 .

[0192] In addition, if Figure 18 and Figure 19 As shown, after completing the control mode MD4 for adjusting the film thickness of the resin film 83, the controller 50 switches the control mode to the control mode MD5 for manufacturing a product. That is, the production of the resin film 83 as a product begins.

[0193] <Details of Control Method MD6>

[0194] Next, we will refer to Figure 24 and Figure 25 illustrate Figure 19 Details of the control mode MD6. Figure 24 It shows Figure 19 Flowchart of the details of the control mode MD6. Figure 25 It shows Figure 24 Schematic cross-sectional view of the casting machine 30 and the longitudinal stretching machine 60 in step S61 in FIG.

[0195] Notice, Figure 24 The control shown is also performed by the controller 50 which is a computer.

[0196] First, if Figure 24 As shown, the longitudinal stretching machine 60 is started and the resin film 83 is passed through the longitudinal stretching machine 60 (step S61). Specifically, after the resin film 83 discharged from the casting machine 30 is detected by the film passing sensor S2, the longitudinal stretching machine 60 is started at a predetermined time.

[0197] The following will refer to Figure 25 An example of step S61 is described below. Figure 25 In the example shown, a film connecting device FW2 for longitudinal stretching is provided between the film passing sensor S2 and the longitudinal stretching machine 60. This film connecting device FW2 connects the films to each other. For example, similar to the film connecting device FW1, the film connecting device FW2 welds the resin films to each other.

[0198] Before starting the longitudinal stretching machine 60 in step S61, the leading end of the dummy film DF3 to be longitudinally stretched is pre-clamped between roller R5 and nip roller NR3, located at the rear end of the longitudinal stretching machine 60. Simultaneously, the trailing end of the dummy film DF3 is pre-placed in the film connecting device FW2. These operations are performed manually, for example, but can also be performed by a robot or the like.

[0199] Then, after the resin film 83 is detected by the film passage sensor S2, the resin film 83 and the dummy film DF3 are connected to each other by the film connecting device FW2, and then the longitudinal stretching machine 60 is started. Through this series of operations, the resin film 83 is automatically passed through the longitudinal stretching machine 60, thereby automatically starting the longitudinal stretching of the resin film 83.

[0200] Note that in Figure 25 In the example shown, the resin film 83 discharged from the casting machine 30 is conveyed to the film connecting device FW2 by the conveyor CV1. The conveyor CV1 is driven by the conveyor motor CM1. The conveyor motor CM1 is controlled by the controller 50.

[0201] Notice, Figure 25 The conveyor CV1 shown is not indispensable. Figure 14 In the process, the resin film 83 discharged from the casting machine 30 may be conveyed to the film connecting device FW1 by a conveyor (not shown).

[0202] Then, if Figure 24 As shown, when Figure 25 When the film-passing sensor S3 detects the resin film 83 being discharged from the longitudinal stretching machine 60, the line operating conditions are changed to the set values ​​for control mode MD6 (step S62). For example, the line speed is increased to the set value for control mode MD6. The above series of processes completes control mode MD6.

[0203] <Details of Control Method MD7>

[0204] Next, we will refer to Figure 26 and Figure 27 illustrate Figure 19 Details of control mode MD7. Figure 26 It shows Figure 19 Flowchart of the details of the control mode MD7. Figure 27 It shows Figure 26 Schematic cross-sectional view of the longitudinal stretching machine 60 and the transverse stretching machine 70 in step S71 in FIG.

[0205] Notice, Figure 26 The control shown is also performed by the controller 50 which is a computer.

[0206] First, if Figure 26 As shown, the resin film 83 is held at the entrance of the transverse stretching machine 70 (step S71). Specifically, after the resin film 83 discharged from the longitudinal stretching machine 60 is detected by the film passing sensor S3, the resin film 83 is held by the transverse stretching machine 70 at a predetermined time.

[0207] Note that the transverse stretching machine 70 has already been started before step S71 , and the clips are cyclically moved along the rails RL1 and RL2 .

[0208] The following will refer to Figure 27 An example of step S71 is described below. Figure 27 In the example shown, a film connecting device FW3 for transverse stretching is provided between the film passing sensor S3 and the transverse stretching machine 70. The film connecting device FW3 connects the films to each other. For example, similar to the film connecting device FW1, the film connecting device FW3 welds the resin films to each other.

[0209] exist Figure 27 In the example shown, prior to step S71, the leading end of the dummy film DF4 for transverse stretching is positioned at the entrance of the transverse stretching machine 70. Simultaneously, the trailing end of the dummy film DF4 is positioned within the film connecting device FW3. These operations are performed manually, for example, but may also be performed by a robot or the like.

[0210] Note that in Figure 27 In the illustrated example, dummy film DF4 is arranged on a conveyor CV2 extending from a film connecting device FW3 to the entrance of a transverse stretching machine 70. Conveyor CV2 can convey dummy film DF4 while simultaneously drawing suction from it via a suction blower SB. Conveyor CV2 is driven by a conveyor motor CM2. Conveyor motor CM2 and suction blower SB are controlled by a controller 50.

[0211] Then, after the resin film 83 is detected by the film passage sensor S3, the resin film 83 and the dummy film DF4 are connected to each other by the film connecting device FW3 at a predetermined timing, and then the conveyor CV2 is started and begins to hold the resin film 83 by the transverse stretching machine 70. Through this series of operations, the resin film 83 is automatically passed through the transverse stretching machine 70, thereby automatically starting the transverse stretching of the resin film 83.

[0212] More specifically, through the above-described series of operations, while the dummy film DF4 connected to the resin film 83 is conveyed by the conveyor CV2, the leading end of the dummy film DF4 is held by the clamp at the entrance of the transverse stretching machine 70. Thereafter, when it is determined that the resin film 83 is held by the clamp, for example, based on the elapse of a predetermined time, the conveying motor CM2 and the suction blower SB are stopped.

[0213] Note that in Figure 27 In the embodiment, the resin film 83 discharged from the casting machine 30 can be conveyed to the film connecting device FW3 by a conveyor (not shown). In addition, a sensor for checking whether the resin film 83 is held by the clip can be separately provided at the entrance of the transverse stretching machine 70.

[0214] Then, if Figure 26 As shown, when the resin film 83 passes through the transverse stretching machine 70, the line speed is increased to the set value for the control mode MD7 (step S72).

[0215] Then, if Figure 26 As shown, in Figure 27 After the film passing sensor S1 detects the resin film 83 discharged from the transverse stretching machine 70 (step S73), the control mode MD7 is completed.

[0216] <Details of Control Method MD3>

[0217] Next, we will refer to Figure 13 and Figure 28 illustrate Figure 19 The details of the control mode MD3 are shown in FIG. Figure 13 Also used in the following instructions. Figure 28 The second embodiment shows Figure 13 Schematic cross-sectional view of the transverse stretching machine 70 and the winder 40 in step S31 in FIG.

[0218] First, if Figure 13 As shown in FIG. 1 , the winder 40 is started and the winding of the resin film 83 is started under constant rotation control (step S31). Specifically, Figure 26 After step S73 in which the resin film 83 is detected by the film passing sensor S1, the winder 40 is started at a predetermined timing.

[0219] Refer to the following Figure 28 An example of step S31 in this embodiment will be described. Figure 28 In the example shown, a film connecting device FW1 for winding is provided between the film passage sensor S1 and the winder 40 , and connects the films to each other.

[0220] Before starting the winder 40 in step S31, the leading end of the dummy film DF2 is fixed to the winder 40. At the same time, the trailing end of the dummy film DF2 is placed in the film connecting device FW1. These operations are performed manually, but can also be performed by a robot or the like.

[0221] Then, after the resin film 83 discharged from the transverse stretching machine 70 is detected by the film passing sensor S1, the resin film 83 and the dummy film DF2 are connected to each other by the film connecting device FW1 at a predetermined timing, and then the winder 40 is started. Through this series of operations, the resin film 83 is automatically passed through the winder 40, thereby automatically starting the winding of the resin film 83.

[0222] In this embodiment Figure 13 The subsequent steps S32 and S33 shown in FIG are also the same as those in the first embodiment, and therefore description thereof is omitted.

[0223] The details of control modes MD4 and MD5 are similar to Figure 15 and Figure 16 The details of the first embodiment are shown, and therefore a detailed description thereof will be omitted.

[0224] The remaining structure is the same as that of the first embodiment, and therefore the description thereof is omitted.

[0225] Note that, in this embodiment, only one of the longitudinal stretching machine 60 and the transverse stretching machine 70 may be provided. Alternatively, a plurality of longitudinal stretching machines 60 and / or a plurality of transverse stretching machines 70 may be provided.

[0226] In the above examples, the program includes a set of instructions (or software codes) that, when read into a computer, causes the computer to perform one or more functions described in the exemplary embodiments. The program may be stored in a non-transient computer-readable medium or a physical storage medium. By way of example and not limitation, the computer-readable medium or physical storage medium may include random access memory (RAM), read-only memory (ROM), flash memory, a solid-state drive (SSD) or other memory technology, a CD-ROM, a digital versatile disc (DVD), a Blu-ray (Blu-ray, registered trademark) disc or other optical disc storage, a cassette, a magnetic tape and disk storage or other magnetic storage device. The program may be transmitted on a transient computer-readable medium or a communication medium. By way of example and not limitation, a transient computer-readable medium or a communication medium may include electrical, optical, acoustic or other forms of propagated signals.

[0227] From the disclosure thus described, it will be obvious that the disclosed embodiments may be modified in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the appended claims.

Claims

1. A resin film manufacturing device, comprising: an extruder designed to melt a resin material charged therein and then extrude the molten resin material; a die connected to the extruder and designed to mold the molten resin into a film-like shape; A casting machine including a casting roll designed to cool the film-like molten resin extruded from the die while conveying a resin film formed when the molten resin is solidified; a winder designed to wind up the manufactured resin film; a film passage sensor for winding, which is provided on the inlet side of the winder and is designed to detect the passage of the resin film being conveyed; and A controller is designed to control the production of the resin film, wherein when the production of the resin film starts, after the film passage sensor for winding detects that the resin film has passed, the controller starts driving the winder.

2. The resin thin film manufacturing apparatus according to claim 1, wherein: Also included is a film connecting device for winding, which is arranged between the film passing sensor for winding and the winding machine and is designed to connect the films to each other, wherein, When manufacturing of the resin film starts, the controller starts driving the winder after causing the film connecting device for winding to connect the resin film detected by the film passing sensor for winding with the dummy film for winding that has been fixed to the winder.

3. The resin thin film manufacturing apparatus according to claim 2, wherein: The film connecting device for winding welds the dummy film for winding to the resin film.

4. The resin thin film manufacturing apparatus according to claim 1, wherein: The controller: When starting the driving of the coiler, setting the control of the coiler to constant rotation control; and After tension is detected in the reel, control of the reel is switched to constant tension control.

5. The resin thin film manufacturing apparatus according to claim 1, wherein: Also includes: a longitudinal stretching machine, which is disposed after the casting machine and is designed to stretch the resin film in the longitudinal direction; as well as A film passing sensor for longitudinal stretching, which is arranged at the inlet side of the longitudinal stretching machine and is designed to detect the passing of the conveyed resin film, wherein When production of the resin film starts, the controller starts driving of the longitudinal stretching machine after detecting that the resin film has passed through by the film passage sensor for longitudinal stretching.

6. The resin thin film manufacturing apparatus according to claim 5, wherein: It also includes a film connecting device for longitudinal stretching, which is arranged between the film passing sensor for longitudinal stretching and the longitudinal stretching machine and is designed to connect the films to each other, wherein, When the manufacture of the resin film begins, the controller starts driving the longitudinal stretching machine after causing the film connecting device for longitudinal stretching to connect the resin film detected by the film passing sensor for longitudinal stretching with the dummy film for longitudinal stretching that has been fixed to the longitudinal stretching machine.

7. The resin thin film manufacturing apparatus according to claim 6, wherein: The film connecting device for longitudinal stretching welds the dummy film for longitudinal stretching to the resin film.

8. The resin thin film manufacturing apparatus according to claim 5, wherein: Also includes: a transverse stretching machine, which is disposed after the longitudinal stretching machine and is designed to stretch the resin film in the width direction; as well as A film passing sensor for transverse stretching is provided at the inlet side of the transverse stretching machine and is designed to detect the passage of the resin film being conveyed, wherein: When production of the resin film starts, the controller starts holding the resin film by the transverse stretching machine after detecting that the resin film has passed by using the film passage sensor for transverse stretching.

9. The resin thin film manufacturing apparatus according to claim 8, wherein: It also includes a film connecting device for transverse stretching, which is arranged between the film passing sensor for transverse stretching and the transverse stretching machine and is designed to connect the films to each other, wherein, When the manufacture of the resin film begins, the controller starts to hold the resin film through the transverse stretching machine after causing the film connecting device for transverse stretching to connect the resin film detected by the film passing sensor for transverse stretching with a dummy film for transverse stretching arranged to extend to the entrance of the transverse stretching machine.

10. The resin thin film manufacturing apparatus according to claim 9, wherein: The film connecting device for transverse stretching welds the dummy film for transverse stretching to the resin film.

11. A method for controlling a resin film manufacturing device, wherein: The resin film manufacturing device comprises: an extruder designed to melt a resin material charged therein and then extrude the molten resin material; a die connected to the extruder and designed to mold the molten resin into a film-like shape; A casting machine including a casting roll designed to cool the film-like molten resin extruded from the die while conveying a resin film formed when the molten resin is solidified; A winder designed to wind up the produced resin film, wherein When the resin film is started to be manufactured, the computer executes (a) After the passage of the resin film is detected by using a film passage sensor for winding provided on the entrance side of the winder, the driving of the winder is started.

12. The control method of a resin thin film manufacturing apparatus according to claim 11, wherein: The resin film manufacturing apparatus further includes a film connecting device for winding, which is provided between the film passing sensor for winding and the winder and is designed to connect the films to each other, and In (a), after the resin film detected by the film passing sensor for winding is connected to the dummy film for winding that has been fixed to the winder by the film connecting device for winding, the driving of the winder is started.

13. The control method of the lipid thin film manufacturing device according to claim 12, wherein: In (a), the film connecting device for winding welds the dummy film for winding to the resin film.

14. The control method of a resin thin film manufacturing apparatus according to claim 11, wherein: In (a), When the drive of the coiler is started, the control of the coiler is set to constant rotation control; and After tension is detected in the reel, control of the reel is switched to constant tension control.

15. The control method of a resin thin film manufacturing apparatus according to claim 11, wherein: The resin film manufacturing apparatus further includes a longitudinal stretching machine which is disposed after the casting machine and is designed to stretch the resin film in the longitudinal direction, and When the resin film is manufactured, the computer executes, before (a): (b) After the passage of the resin film is detected by using a film passage sensor for longitudinal stretching provided on the inlet side of the longitudinal stretching machine, driving of the longitudinal stretching machine is started.

16. The control method of a resin thin film manufacturing apparatus according to claim 15, wherein: The resin film manufacturing apparatus further includes a film connecting device for longitudinal stretching, which is provided between the film passing sensor for longitudinal stretching and the longitudinal stretching machine and is designed to connect the films to each other, and In (b), after the resin film detected by the film passing sensor for longitudinal stretching is connected to the dummy film for longitudinal stretching that has been fixed to the longitudinal stretching machine by the film connecting device for longitudinal stretching, the driving of the longitudinal stretching machine is started.

17. The control method of the lipid thin film manufacturing device according to claim 16, wherein: In (b), the film connecting device for longitudinal stretching welds the dummy film for longitudinal stretching to the resin film.

18. The control method of a resin thin film manufacturing apparatus according to claim 15, wherein: The resin film manufacturing apparatus further includes a transverse stretching machine which is disposed after the longitudinal stretching machine and is designed to stretch the resin film in the width direction, and When the production of the resin film is started, the computer executes, after (b) and before (a): (c) After detecting that the resin film has passed through by using a film passage sensor for transverse stretching provided on the inlet side of the transverse stretching machine, starting to hold the resin film by the transverse stretching machine.

19. The control method of a resin thin film manufacturing apparatus according to claim 18, wherein: The resin film manufacturing apparatus further includes a film connecting device for transverse stretching, which is provided between the film passing sensor for transverse stretching and the transverse stretching machine and is designed to connect the films to each other, and In (c), after the resin film detected by the film passage sensor for transverse stretching is connected to a dummy film for transverse stretching arranged to extend to an inlet of the transverse stretching machine, the resin film starts to be held by the transverse stretching machine.

20. The control method of the lipid thin film manufacturing apparatus according to claim 19, wherein in (c), the film connecting device for transverse stretching welds the dummy film for transverse stretching to the resin film.

Images