Optical film automatic inspection device and optical film production line

Abstract

The utility model discloses an automatic inspection device for an optical film, which is arranged between a UV (ultraviolet) immobilization mechanism and a film covering mechanism and comprises a frame body, a conveying unit, a lens and a light source, the conveying unit is arranged in the middle of the frame body, and the conveying surface of the conveying unit and the output surface of the UV immobilization mechanism are in a non-flush state; the lens is arranged at the top of the frame body and is used for performing defect detection on a target film on a conveying surface; the light source is arranged at the bottom of the frame body and used for conducting auxiliary light supplementing on the target film on the conveying face. The automatic inspection device for the optical film can monitor the surface defect state of the optical film on line in real time, the defect detection rate is as high as more than 95%, and the automatic inspection device has the advantages of high efficiency, accuracy, low omission ratio and the like; the height difference design between the detection process and the previous process can reduce the jumping of the optical film in the vertical direction, so that the detection structure is more accurate, the heat dissipation of the optical film is facilitated, and the warping problem of the product is avoided.

Description

Technical Field

[0001] This utility model relates to the field of optical film production technology, and in particular to an automatic inspection device for optical films and an optical film production line. Background Technology

[0002] Currently, the detection method for surface defects of optical films is to stop the machine for first and last piece inspection. The first inspection is to cut a certain length of optical film from the beginning of the continuous production process and stop the machine to manually inspect the surface defects. After the first inspection is OK, the machine is restarted to rewind. When the rewinding is about to be completed, the machine is stopped for last inspection. A certain length of optical film from the end is cut to inspect the surface defects. After the inspection is OK, the rewinding operation is completed.

[0003] Among the above-mentioned testing methods, manual testing is prone to problems such as misjudgment and missed detection, making it difficult to guarantee the quality of the produced optical film. Furthermore, it cannot be monitored in real time during the production process, resulting in excessively long testing time and low production efficiency, which affects the production progress of optical films. Utility Model Content

[0004] The purpose of this invention is to provide an automatic inspection device for optical films. This device is positioned after the manufacturing process and before the protective film is applied. It has a defect detection rate of over 95% and a false detection rate of less than 1%, effectively detecting defects within its accuracy range. Furthermore, online real-time detection avoids downtime, facilitates timely judgment of defect types and adjustment of production line status, enabling continuous operation of the equipment and improving the production efficiency and product quality of optical films.

[0005] The objective of this utility model is achieved through the following technical solution:

[0006] An automatic inspection device for optical films, disposed between a UV immobilization mechanism and a coating mechanism, is characterized by comprising:

[0007] Frame;

[0008] A conveying unit is located in the middle of the frame, and the conveying surface of the conveying unit is not flush with the output surface of the UV curing mechanism.

[0009] A lens is mounted on the top of the frame, and the lens is used to detect defects in the target film on the conveying surface.

[0010] A light source is located at the bottom of the frame, and the light source is used to provide supplementary lighting for the target film on the conveying surface.

[0011] In some embodiments, the conveying surface of the conveying unit is 50cm-60cm higher or lower than the output surface of the immobilization mechanism.

[0012] In some embodiments, the conveying unit includes:

[0013] The horizontal shafts are evenly spaced along the conveying direction, and both ends of the horizontal shafts are provided with retaining edges that are connected to the frame.

[0014] Guide wheels are evenly distributed on each of the horizontal axes, and the guide wheels are soft rubber wheels.

[0015] In some embodiments, the number of guide wheels on each horizontal axis is 6-8, and the distance between adjacent guide wheels is 1.2m-1.6m.

[0016] In some embodiments, the delivery unit is grounded.

[0017] In some embodiments, the lens is 5cm-20cm away from the target film.

[0018] In some embodiments, the lens is a high-speed lens.

[0019] In some embodiments, the automatic optical film inspection device further includes a computer with a built-in defect detection system, the computer being electrically connected to the lens.

[0020] In some embodiments, the light source is a yellow light source.

[0021] An optical film production line includes the aforementioned automatic optical film inspection device.

[0022] In some embodiments, the optical film production line further includes an unwinding mechanism, a transfer mechanism, a UV fixation mechanism, a coating mechanism, and a rewinding mechanism arranged in sequence; wherein the automatic optical film inspection device is disposed between the UV fixation mechanism and the coating mechanism.

[0023] Compared with the prior art, the beneficial effects of this utility model include at least the following:

[0024] 1. It can monitor the surface defects of optical films online in real time, with a defect detection rate of over 95%, and has the advantages of high efficiency, accuracy and low false negative rate.

[0025] 2. It can mark and analyze defects on the surface of optical films, making it easy to quickly adjust the product production status, thereby reducing raw material loss and improving product production efficiency.

[0026] 3. The height difference design between the testing process and the previous process can reduce the vertical movement of the optical film, resulting in a more accurate testing structure. It also facilitates heat dissipation of the optical film and avoids product warping. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of the automatic optical film inspection device of this utility model.

[0028] Figure 2 This is a schematic diagram of the optical film production line of this utility model.

[0029] In the diagram: 1. Frame; 2. Conveying unit; 21. Horizontal axis; 22. Guide wheel; 23. Edge guard; 3. Lens; 4. Light source; 5. Unwinding mechanism; 6. Transfer mechanism; 7. UV curing mechanism; 8. Coating mechanism; 9. Rewinding mechanism. Detailed Implementation

[0030] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided to make the present invention more comprehensive and complete, and to fully convey the concept of the exemplary embodiments to those skilled in the art. The same reference numerals in the drawings denote the same or similar structures, and therefore repeated descriptions of them will be omitted.

[0031] The terms used to describe position and direction in this utility model are illustrated with the accompanying drawings, but changes can be made as needed, and all such changes are included within the scope of protection of this utility model.

[0032] Benru Figure 1 and Figure 2 As shown, this utility model discloses an automatic optical film inspection device, which is set between the UV immobilization mechanism 7 and the coating mechanism 8, and includes a frame 1, a conveying unit 2, a lens 3 and a light source 4.

[0033] Among them, the frame 1 is a frame structure with open front and back, which can be welded from conductive pipes such as steel, aluminum or their alloys, so as to ensure the structural strength of the frame 1 and give it a certain static electricity conduction capability.

[0034] The conveying unit 2 is located in the middle of the frame 1 and is used to transfer the target film from the UV fixation mechanism 7 to the coating mechanism 8. In this application, the conveying unit 2 includes horizontal shafts 21 evenly spaced along the conveying direction and guide wheels 22 evenly spaced on each horizontal shaft 21. The two ends of the horizontal shafts 21 are provided with flanges 23 connecting to the frame 1, which support the horizontal shafts 21 and guide the movement of the target film. Each horizontal shaft 21 has 6-8 guide wheels 22, and the spacing between adjacent guide wheels 22 is 1.2m-1.6m, preferably 6-8 guide wheels 22 at 1.5m intervals. The array arrangement of the guide wheels 22 provides a reasonable contact point with the target film, effectively avoiding excessive contact points that could lead to friction and increased product defects. Preferably, the guide wheels 22 can be made of soft rubber to reduce frictional damage to the target film.

[0035] Furthermore, the highest points of each guide wheel 22 collectively constitute the conveying surface of the conveying unit 2, and this surface is not flush with the output surface of the UV curing mechanism 7. That is, there is a height difference between the conveying surface of the conveying unit 2 and the output surface of the UV curing mechanism 7. By adding guide wheels 22 and setting this height difference, large vertical jumps in the target film can be avoided, resulting in more accurate detection. In this application, the conveying surface of the conveying unit 2 is 50cm-60cm higher or lower than the output surface of the curing mechanism. Its main purpose is to act as a buffer, ensuring that the vertical jump of the target film during detection is less than ±0.1mm, thereby improving detection accuracy. On the other hand, the target film has a high temperature after UV curing; vertical lifting or lowering facilitates heat dissipation from the target film, thereby preventing product warping and improving finished product quality.

[0036] Lens 3 is positioned at the top of the frame 1, 5cm-20cm away from the target film, to detect defects in the target film on the conveying surface. In this application, lens 3 is preferably a high-speed lens 3, and there may be one or more lenses, which are electrically connected to a computer (not shown). The moving target film is continuously scanned and photographed at high speed. The captured images are transmitted to the computer, where its built-in defect detection system processes and analyzes the images in real time, monitors the surface defects of the target film online, promptly alarms and sends signals to the production line upon detection of defects, and marks the defect location in real time for subsequent problem identification and analysis.

[0037] Light source 4 is located at the bottom of frame 1 and is used to provide supplementary lighting for the target film on the conveying surface. In this application, the light source is preferably a yellow light source 4, and there can be one or more of them. Compared with white light, yellow light is softer and is more likely to expose the defect location when it shines on the bottom side of the target film, thereby improving the detection effect.

[0038] Compared to manual inspection, this application introduces an automatic optical film inspection device after the manufacturing process and before lamination. Through one or more lenses 3 and a light source 4 mounted on the frame 1, the moving target film is continuously scanned and photographed at high speed, and the images are processed and analyzed in real time. It can monitor the defect status of the target film surface online, and has the advantages of high efficiency and accuracy.

[0039] In addition, detected defects can be marked by computer and promptly alerted and fed back to the production line so that problems can be found and analyzed, thereby adjusting the production status of the fast production line, reducing raw material waste, and improving product production efficiency.

[0040] In some embodiments, the conveying unit 2 is grounded to guide static electricity on the guide wheel 22 to the ground, preventing damage to the target film and improving product quality. For example, the horizontal shaft 21 of the conveying unit 2 can guide the static electricity accumulated on the guide wheel 22 to the ground via the frame 1 or external wires.

[0041] Or as Figure 2 As shown, this utility model also discloses an optical film production line, including the aforementioned automatic optical film inspection device. Specifically, the optical film production line includes an unwinding mechanism 5, a transfer mechanism 6, a UV fixation mechanism 7, a coating mechanism 8, and a rewinding mechanism 9 arranged sequentially, wherein the automatic optical film inspection device is disposed between the UV fixation mechanism 7 and the coating mechanism 8.

[0042] The production process of the optical film production line of this application is as follows: First, the unwinding mechanism 5 releases the film material; then, the transfer mechanism 6 transfers the optical structure onto the surface of the film material, and the optical film is demolded from the mold of the transfer mechanism 6 by low-pressure UV irradiation; next, the first high-pressure UV lamp box and the second high-pressure UV lamp box of the UV fixation mechanism 7 respectively perform UV fixation on the optical film. This is the process of optical film manufacturing.

[0043] The optical film is transferred to the automatic optical film inspection device, where it is inspected for defects by the lens 3 under the illumination of the light source 4, and the production line is adjusted according to the inspection results.

[0044] The finished optical film enters the coating mechanism 8, where protective films are applied to its back and front sides in sequence. Finally, the winding mechanism 9 winds up the finished optical film.

[0045] Compared to existing optical film production lines, this application adds an automatic optical film inspection device after the manufacturing process and before back sealing, enabling a defect detection rate of over 95% for the optical film surface. This results in accurate detection, shorter processing time, and a low rate of missed detections. Furthermore, defects can be marked or coded based on their location, and the defect detection system allows for a direct visual observation of the periodic distribution of defects on the optical film surface to determine the defect type and analyze its causes. This facilitates timely adjustments to the production line, reduces raw material waste, and improves product production efficiency.

[0046] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and alterations to the above embodiments within the scope of the present invention without departing from the principles and spirit of the present invention, and all such changes should fall within the protection scope of the claims of the present invention.

Claims

1. An automatic inspection device for optical films, disposed between a UV immobilization mechanism (7) and a coating mechanism (8), characterized in that, include: Frame (1); The conveying unit (2) is located in the middle of the frame (1), and the conveying surface of the conveying unit (2) is not flush with the output surface of the UV fixation mechanism (7). A lens (3) is disposed on the top of the frame (1) and is used to detect defects in the target film on the conveying surface; A light source (4) is located at the bottom of the frame (1) and is used to provide supplementary lighting for the target film on the conveying surface.

2. The automatic inspection device for optical films according to claim 1, characterized in that, The conveying surface of the conveying unit (2) is 50 cm to 60 cm higher or lower than the output surface of the UV immobilization mechanism (7).

3. The automatic inspection device for optical films according to claim 1, characterized in that, The conveying unit (2) includes: A horizontal shaft (21) is evenly distributed along the conveying direction, and both ends of the horizontal shaft (21) are provided with baffles (23) that are connected to the frame (1). Guide wheels (22) are evenly distributed on each of the horizontal shafts (21), and the guide wheels (22) are soft rubber wheels.

4. The automatic inspection device for optical films according to claim 3, characterized in that, The number of guide wheels (22) on each horizontal axis (21) is 6-8, and the distance between adjacent guide wheels (22) is 1.2 m-1.6 m.

5. The automatic inspection device for optical films according to claim 3, characterized in that, The transmission unit (2) is grounded.

6. The automatic inspection device for optical films according to claim 1, characterized in that, The lens (3) is 5cm-20cm away from the target film.

7. The automatic inspection device for optical films according to claim 1, characterized in that, The lens (3) is a high-speed lens.

8. The automatic inspection device for optical films according to claim 1, characterized in that, It also includes a computer with a built-in defect detection system, which is electrically connected to the lens.

9. The automatic inspection device for optical films according to claim 1, characterized in that, The light source (4) is a yellow light source.

10. An optical film production line, characterized in that, Includes the automatic inspection device for optical films as described in any one of claims 1-9.

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