Method for manufacturing film material and method for manufacturing resin molded product

Abstract

The present invention provides a method for manufacturing a film material that can detect foreign matter contained in recycled materials. [Solution] The method comprises a film material production step of producing a film material 20 of a predetermined thickness T1 by heating and pressing a recycled material 11 containing a thermoplastic resin; a foreign matter detection step of detecting foreign matter 30 contained in the film material 20 by detecting whether or not there are any parts on the surface of the film material 20 that protrude more than the surrounding parts; and a foreign matter removal step of removing the foreign matter 30 if foreign matter 30 is detected in the foreign matter detection step.

Description

Technical Field

[0004] ,

[0005] , ,

[0001] The technology disclosed in this specification relates to a method for manufacturing a film material and a method for manufacturing a resin molded product.

Background Art

[0002] Conventionally, products containing thermoplastic resins have been recovered and reused as recycled materials. As a method for recovering recycled materials, the method described in Patent Document 1 below is known. Patent Document 1 below describes a method of recovering plastic by crushing a used product and then removing crushed materials other than plastic from the crushed product, and utilizing it as a recycled material.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The recycled material recovered by the above method may contain foreign matters (for example, fragments of crushed materials that could not be completely removed, etc.). If foreign matters混入 the product, there is a concern that the strength may decrease. Also, if foreign matters are exposed on the surface of the product, there is a concern that the design quality may decrease. Therefore, it is required to detect and remove foreign matters contained in the recycled material. As a method for detecting foreign matters, for example, a method of photographing the recycled material and analyzing the photographed image can be considered. However, when the color of the foreign matter is close to the color of the recycled material, detection by image analysis is difficult. For this reason, a method for detecting foreign matters by means different from image analysis is required.

[0005] The technology disclosed herein was developed based on the circumstances described above, and aims to provide a method for manufacturing a film material and a method for manufacturing a resin molded product that can detect foreign matter contained in recycled materials. [Means for solving the problem]

[0006] As a means to solve the above problems, the method for manufacturing a film material disclosed herein is characterized by comprising: a film material production step of producing a film material of a predetermined thickness by heating and pressing a recycled material containing a thermoplastic resin; a foreign matter detection step of detecting foreign matter contained in the film material by detecting whether or not there is a portion on the surface of the film material that protrudes more than the surrounding portion; and a foreign matter removal step of removing the foreign matter when the foreign matter is detected in the foreign matter detection step.

[0007] When recycled materials are heat-pressed, recycled materials containing thermoplastic resin can be easily made to a predetermined thickness. In contrast, foreign materials do not necessarily possess thermoplastic properties, making it difficult to make them to a predetermined thickness by heat-pressing. Therefore, in film materials, the parts containing foreign materials are thicker than the parts without foreign materials. This makes it possible to detect foreign materials by detecting whether or not there are areas on the surface of the film material that protrude more than the surrounding areas, and to remove the detected foreign materials more reliably.

[0008] Furthermore, the foreign matter detection step can be performed by measuring the thickness of the film material to detect the foreign matter. By measuring the thickness of the film material, it is possible to detect whether or not there are any parts on the surface of the film material that protrude more than the surrounding parts.

[0009] Furthermore, in the film material production process, the recycled material supported on the upper surface of the support is pressed from above by a roller, and the roller is moved relative to the recycled material to form the film material. In the foreign matter detection process, the foreign matter is detected by measuring the pressure acting on the upper surface when the recycled material is pressed by the roller.

[0010] If there are parts on the surface of the film material that protrude more than the surrounding areas, the pressure acting on the upper surface of the support when that part is pressed by a roller will be greater than the pressure acting on the upper surface of the support when the surrounding area is pressed by the roller. Therefore, foreign matter can be detected by measuring the pressure acting on the upper surface of the support when recycled material is pressed by a roller.

[0011] Furthermore, in the film material production process, the recycled material is pressed with a roller while the roller is moved relative to the recycled material to form the film material, and in the foreign matter detection process, the foreign matter is detected by measuring the reaction force acting on the roller when the recycled material is pressed with the roller.

[0012] If there are parts on the surface of the film material that protrude more than the surrounding area, the reaction force acting on the roller when pressing on those parts will be greater than the reaction force acting on the roller when pressing on the surrounding area. Therefore, foreign matter can be detected by measuring the reaction force acting on the roller when recycled material is pressed by the roller.

[0013] Furthermore, as a means to solve the above problems, the method for manufacturing a resin molded product disclosed herein comprises a roll material forming step of winding the film material into a roll shape to form a roll material, a cutting step of cutting the roll material at multiple locations in the axial direction to form multiple resin members, and a molding step of molding a resin molded product from the multiple resin members using an injection molding machine.

[0014] By cutting the roll material into sections during the cutting process, it can be made into multiple resin components. By dividing the film material into multiple resin components, it can be easily transported. Furthermore, by dividing the material to be fed into the injection molding machine into multiple resin components, it can be fed into the injection molding machine more easily compared to when the film material is fed into the machine. [Effects of the Invention]

[0015] According to the present invention, it is possible to provide a method for manufacturing a film material and a method for manufacturing a resin molded product that can detect foreign matter contained in recycled materials. [Brief explanation of the drawing]

[0016] [Figure 1] Diagram showing recycled material being heated by a heating device. [Figure 2] Diagram showing the foreign object detection process. [Figure 3] Diagram showing the foreign matter removal process. [Figure 4] Diagram showing a modified example of the foreign matter removal process. [Figure 5] Diagram showing a modified example of the foreign matter removal process. [Figure 6] Diagram showing the roll material formation process and cutting process. [Figure 7] Diagram showing the molding process [Figure 8] Cross-sectional view showing the inside of the hopper [Figure 9] Figure showing the foreign object detection process according to Embodiment 2 of the present invention. [Figure 10] This figure shows a foreign object detection process according to Embodiment 3 of the present invention. [Figure 11]Figure showing the foreign object detection process according to Embodiment 4 of the present invention [Figure 12] Figure showing a state in which a foreign object is detected in the foreign object detection process according to Embodiment 4 of the present invention

Mode for Carrying Out the Invention

[0017] <Embodiment 1> Embodiment 1 of the present invention will be described with reference to FIGS. 1 to 8. In the present embodiment, a method for manufacturing a film material for manufacturing a film material from recycled materials and a method for manufacturing a resin molded product for manufacturing a resin molded product from the film material will be exemplified.

[0018] The recycled material 11 of the present embodiment is in the form of pellets (for example, cylindrical) as shown in FIG. 1. The recycled material 11 is made of a thermoplastic resin (for example, polypropylene or the like). The recycled material 11 is obtained by crushing a recovered product (such as an interior material for a vehicle) or a scrap material generated during the production of a product, then selecting a specific material (a thermoplastic resin material), and heating the material to form it into pellets. In addition, additives or the like may be added to the selected material as necessary.

[0019] The recycled material 11 exhibits a color such as black or close to black. In addition, the color of the recycled material 11 tends to be black. The reason for this is that in interior materials for vehicles, generally, black interior materials are popular, the shipment volume of such interior materials is large, and various colored interior materials are mixed, approaching black. In addition, the recycled material 11 includes those obtained by recovering products used in the market (so-called PCR materials) and those obtained by reusing materials generated in the manufacturing process of products (so-called PIR materials).

[0020] The method for manufacturing the film material of the present embodiment includes a film material generation step of generating a film material 20 by hot pressing the recycled material 11, a foreign object detection step of detecting a foreign object 30 contained in the film material 20, and a foreign object removal step of removing the foreign object 30 when the foreign object 30 is detected in the foreign object detection step.

[0021] During the process of collecting products and molding recycled material 11, foreign matter 30 may be mixed in, and any foreign matter 30 that cannot be completely removed may be mixed with multiple recycled materials 11, as shown in Figure 1. Foreign matter 30 is composed of materials other than thermoplastic resin, for example. Examples of foreign matter 30 include those composed of thermosetting resin (e.g., polyurethane), but the material is not limited to this.

[0022] In the process of molding the recycled material 11, the collected product is crushed, and then the crushed pieces are passed through a mesh with a predetermined size to remove pieces larger than the predetermined size. If the foreign matter 30 is elastic, it may pass through the mesh due to elastic deformation, making it particularly difficult to remove.

[0023] (Film material production process) In the film material production process, as shown in Figure 1, multiple recycled materials 11 are placed on a conveyor belt 50. The conveyor belt 50 is driven by a drive device (e.g., a drive roller, etc.) not shown, and is capable of transporting the recycled materials 11 horizontally. In this embodiment, the conveyor belt 50 is used to transport the recycled materials 11 from left to right in each figure.

[0024] Next, the recycled material 11 is transported by the conveyor belt 50, and the recycled material 11 is heated by a heating device 51 (infrared heater, etc.) positioned above it. At this time, the heating temperature of the recycled material 11 is set to a temperature higher than the melting point of the thermoplastic resin that makes up the recycled material 11. As a result, the recycled material 11 becomes molten.

[0025] Next, as shown in Figure 2, the conveyor belt 50 transports the recycled materials 11 while pressing them from above with the rollers 52, with the rollers 52 supporting the multiple recycled materials 11 supported on the upper surface of the conveyor belt 50 (support section) (moving the rollers relative to the recycled materials). As a result, the multiple recycled materials 11, which are in a molten state, are pressed together by the rollers 52 and become one, forming a film material 20 with a predetermined thickness T1. The thickness T1 is set to a value smaller than the dimensions of the foreign matter 30. The thickness T1 can be determined by measuring the dimensions of various foreign matter that were actually mixed in and using those measurements as a reference. The thickness T1 is, for example, 0.2 mm, but is not limited to this value. The rollers 52 have a length that allows them to press the multiple recycled materials 11 over the entire length in the horizontal direction perpendicular to the transport direction of the film material 20 (the direction through the paper in Figure 2).

[0026] When the film material 20 is formed by the roller 52, the foreign matter 30 is also pressed by the roller 52. However, since the foreign matter 30 is not in a molten state, it is difficult to crush it easily. As a result, in the film material 20, the portion containing the foreign matter 30 has a thickness T2 that is greater than the thickness T1 of the other portions. In other words, on the surface of the film material 20, the portion containing the foreign matter 30 becomes a protruding portion 21 that stands out from the surrounding portion.

[0027] (Foreign object detection process) In the foreign matter detection process, foreign matter 30 contained in the film material 20 is detected by detecting whether or not there are protrusions 21 (parts on the surface of the film material 20 that protrude from the surrounding area). As shown in Figure 2, the thickness T2 of the film material 20 in the part with protrusions 21 is greater than the thickness T1 of the film material 20 in the part without protrusions 21. In the foreign matter detection process, the presence or absence of protrusions 21, and thus the foreign matter 30, is detected by measuring the thickness of the film material 20 with a measuring device 53.

[0028] Specifically, as shown in Figure 2, a measuring device 53, such as a laser displacement meter, is used to measure the distance L1 from the measuring device 53 to the surface of the film material 20. The thickness of the film material 20 can be determined by subtracting distance L1 from the distance L2 from the measuring device 53 to the upper surface 50A of the conveyor belt 50. Therefore, while the film material 20 is being transported, the measuring device 53 measures distance L1, and if there is a place where the thickness of the film material 20 is larger (in other words, a place where distance L1 is smaller), it can be determined that there is a protrusion 21 (and thus a foreign object 30). Note that in Figure 2, the measurement device 53 is used to detect foreign objects while the recycled material 11 is being formed into film material 20 by the roller 52, but foreign object detection may be performed by the measuring device 53 after all of the multiple recycled materials 11 have been formed into film material 20.

[0029] When using a laser displacement meter as the measuring device 53, multiple laser displacement meters are arranged in a line across the entire width of the film material 20 (horizontal direction and direction perpendicular to the transport direction of the film material 20, the direction through the plane of the paper in Figure 2). This makes it possible to detect foreign matter 30 across the entire width of the film material 20.

[0030] (Foreign matter removal process) In the foreign matter removal process, as shown in Figure 3, the surrounding portion of the foreign matter 30 in the film material 20 is cut using a blade 54 to remove the foreign matter 30. However, the method of removing the foreign matter 30 is not limited to using a blade 54. For example, in the foreign matter removal process, as shown in Figure 4, a punch 55 may be used to punch out the portion of the film material 20 containing the foreign matter 30 (protruding portion 21). When using a punch 55, the punching operation can be performed while applying fine vibrations (such as ultrasonic vibrations) to the punch 55 to prevent the film material 20 from adhering to the punch 55.

[0031] Furthermore, in the foreign matter removal process, as shown in Figure 5, the foreign matter 30 may be removed by irradiating the portion of the film material 20 containing the foreign matter 30 (protruding portion 21) with a laser using a laser irradiation device 56. In addition, in the foreign matter detection process, the position of the protruding portion 21 in the longitudinal direction of the film material 20 (the direction along the conveying direction of the conveyor belt 50, the left and right direction in Figure 2) may be stored, and the position of each foreign matter removal device (blade 54, punch 55, laser irradiation device 56) with the protruding portion 21 may be adjusted based on the stored position information of the protruding portion 21.

[0032] Next, a method for manufacturing a resin molded product will be described. The method for manufacturing a resin molded product according to this embodiment comprises a roll material forming step of forming a roll material 31 from a film material 20 manufactured by the above-described method for manufacturing a film material, a cutting step of forming a plurality of resin members 32 from the roll material 31, and a molding step of forming a resin molded product 70 from the plurality of resin members 32 using an injection molding machine.

[0033] (Roll material formation process) In the roll material formation process, as shown in Figure 6, the film material 20 is wound into a roll shape to form the roll material 31. In the film material production process described above, the film material 20 is heated by the heating device 51. In this process, the residual heat from the film material 20 heated in the film material production process softens the surface of the film material 20. By winding the film material 20 in this state, the surfaces of the film material 20 that come into contact during winding can be bonded together, preventing the winding from unraveling and the film material 20 from returning to its original state after being formed into the roll material 31. In other words, by using the residual heat from the film material 20 heated by the heating device 51, the film material 20 can be formed into the roll material 31 without heating it in the roll material formation process. Alternatively, the film material 20 may be heated before being formed into the roll material 31 in the roll material formation process.

[0034] (cutting process) In the cutting process, as shown in Figure 6, the roll material 31 is cut at multiple points in the axial direction (the longitudinal direction of the roll material 31, the left-right direction in Figure 6) using a cutting blade 57 to form multiple resin members 32. The resin members 32 are obtained by slicing the roll material 31 and are disc-shaped.

[0035] (molding process) In the molding process, injection molding is performed using the injection molding machine 60 shown in Figure 7. The injection molding machine 60 comprises a hopper 61 which constitutes the material input port, a cylinder 62, a nozzle 63, and a pair of molds 64 and 65 which can move closer to and further apart from each other. A molding space S1 with a shape that conforms to the shape of the product is formed between the pair of molds 64 and 65.

[0036] In the molding process, as shown in Figure 7, multiple resin members 32 are placed into the hopper 61. The placed resin members 32 are heated (not shown) in the cylinder 62 by a heater and become molten, and then injected into the molding space S1 from the tip of the nozzle 63. Subsequently, the molten resin filling the molding space S1 cools and solidifies to form a resin molded product 70. The resin molded product 70 can be exemplified, for example, interior materials for vehicles such as cars, but is not limited to this.

[0037] Next, the effects of this embodiment will be described. The method for manufacturing the film material of this embodiment comprises: a film material production step of generating a film material 20 of a predetermined thickness T1 by heating and pressing a recycled material 11 containing a thermoplastic resin; a foreign matter detection step of detecting whether or not there are any parts (protrusions 21) on the surface of the film material 20 that protrude more than the surrounding parts, thereby detecting foreign matter 30 contained in the film material 20; and a foreign matter removal step of removing the foreign matter 30 if foreign matter 30 is detected in the foreign matter detection step.

[0038] When recycled material 11 is heat-pressed, recycled material 11 containing thermoplastic resin can be easily made to a predetermined thickness. In contrast, foreign matter 30 does not necessarily have thermoplastic properties, making it difficult to make it to a predetermined thickness T1 by heat-pressing. Therefore, the portion of the film material 20 containing foreign matter 30 is thicker than the portion without foreign matter 30. This makes it possible to detect foreign matter 30 by detecting whether or not there are any parts on the surface of the film material 20 that protrude more than the surrounding area, and the detected foreign matter 30 can be removed more reliably.

[0039] Furthermore, in the foreign object detection process, foreign objects 30 are detected by measuring the thickness of the film material 20. By measuring the thickness of the film material 20, it is possible to detect whether or not there are any parts on the surface of the film material 20 that protrude more than the surrounding parts.

[0040] Furthermore, the method for manufacturing a resin molded product according to this embodiment comprises a roll material formation step of winding a film material 20 into a roll shape to form a roll material 31, a cutting step of cutting the roll material 31 at multiple locations in the axial direction to form multiple resin members 32, and a molding step of molding a resin molded product 70 from the multiple resin members 32 using an injection molding machine 60.

[0041] In the cutting process, the roll material 31 can be cut into multiple resin components 32. By dividing the film material 20 into multiple resin components 32, it can be easily transported. Furthermore, by dividing the material to be fed into the injection molding machine 60 into multiple resin components 32, it can be fed into the injection molding machine 60 more easily than when the film material 20 is fed into the injection molding machine 60.

[0042] If, as shown in Figure 8, the film material 20 is fed into the hopper 61 of the injection molding machine 60, there is a concern that the film material 20 may get caught on the inner surface of the hopper 61 and cause a blockage. In contrast, the disc-shaped resin member 32 is suitable because it is less likely to get caught on the inner surface of the hopper 61.

[0043] <Embodiment 2> Embodiment 2 will be described with reference to Figure 9. The same reference numerals are used for parts identical to those in the above embodiment, and redundant descriptions are omitted. In this embodiment, the content of the foreign object detection process differs from that of the above embodiment. In the foreign object detection process of this embodiment, as shown in Figure 9, a load cell 150 is used to detect foreign objects 30.

[0044] The load cell 150 is positioned below the conveyor belt 50. When pressure is applied to the location corresponding to the load cell 150 on the upper surface 50A of the conveyor belt 50, the pressure is transmitted to the load cell 150 via the conveyor belt 50. The load cell 150 is positioned opposite the roller 52, with the conveyor belt 50 in between. This makes it possible for the load cell 150 to measure the pressure acting on the upper surface 50A of the conveyor belt 50 when the recycled material 11 (and consequently the film material 20) is pressed by the roller 52. In the foreign object detection process of this embodiment, foreign objects 30 are detected by measuring the pressure acting on the upper surface 50A when the recycled material 11 is pressed by the roller 52 using the load cell 150.

[0045] In the foreign object detection process, if there is a portion (protrusion 21) on the surface of the film material 20 that protrudes more than the surrounding portion, the pressure acting on the upper surface 50A of the conveyor belt 50 when that portion is pressed by the roller 52 will be greater than the pressure acting on the upper surface 50A of the conveyor belt 50 when the surrounding portion is pressed by the roller 52. Therefore, by measuring the pressure acting on the upper surface 50A of the conveyor belt 50 when the recycled material 11 is pressed by the roller 52 using the load cell 150, foreign objects 30 can be detected. In other words, if the pressure measured by the load cell 150 temporarily increases during the process of generating the film material 20 with the roller 52 (the process of moving the roller 52 relative to the film material 20), it can be determined that there is a protrusion 21 (and thus foreign object 30). The load cells 150 are arranged in a row across the entire width direction of the film material 20 (the direction through the paper in Figure 9). This makes it possible to detect foreign objects 30 across the entire width direction of the film material 20.

[0046] <Embodiment 3> Embodiment 3 will be described with reference to Figure 10. The same reference numerals are used for parts identical to those in the above embodiments, and redundant descriptions are omitted. In this embodiment, the content of the foreign object detection process differs from that of the above embodiments. In the foreign object detection process of this embodiment, as shown in Figure 10, a pressure-sensitive sensor sheet 250 is used to detect foreign objects 30.

[0047] In this embodiment, a pressure-sensitive sensor sheet 250 is interposed between the conveyor belt 50 and the recycled material 11. That is, the recycled material 11 is supported on the upper surface 250A of the pressure-sensitive sensor sheet 250 (support portion). This makes it possible for the pressure-sensitive sensor sheet 250 to measure the pressure acting on the upper surface 250A of the pressure-sensitive sensor sheet 250 when the recycled material 11 (and thus the film material 20) is pressed by the roller 52. In the foreign object detection process of this embodiment, foreign objects 30 are detected by measuring the pressure acting on the upper surface 250A when the recycled material 11 is pressed by the roller 52.

[0048] In the foreign object detection process, if there is a portion (protrusion 21) on the surface of the film material 20 that protrudes more than the surrounding area, the pressure acting on the upper surface 250A of the pressure-sensitive sensor sheet 250 when that portion is pressed by the roller 52 will be greater than the pressure acting on the upper surface 250A when the surrounding area is pressed by the roller 52. Therefore, by measuring the pressure acting on the upper surface 250A of the pressure-sensitive sensor sheet 250 when the recycled material 11 is pressed by the roller 52, the foreign object 30 can be detected. In other words, if the pressure measured by the pressure-sensitive sensor sheet 250 temporarily increases during the process of generating the film material 20 with the roller 52, it can be determined that there is a protrusion 21 (and thus a foreign object 30). The pressure-sensitive sensor sheet 250 is placed over the entire surface of the film material 20. This makes it possible to detect foreign objects 30 over the entire surface of the film material 20.

[0049] <Embodiment 4> Embodiment 4 will be described with reference to Figures 11 and 12. Parts identical to those in the above embodiments are denoted by the same reference numerals, and redundant descriptions are omitted. In this embodiment, the content of the foreign object detection process differs from that of the above embodiments. In the foreign object detection process of this embodiment, as shown in Figure 11, a load cell 350 is used to detect foreign objects 30.

[0050] In this embodiment, the roller 52 is attached to the fixing member 353 via a connecting member 351. The roller 52 is rotatably mounted to the connecting member 351. The load cell 350 is positioned above the connecting member 351 and is in contact with the upper surface of the connecting member 351. With this configuration, the reaction force acting on the roller 52 when the recycled material 11 is pressed by the roller 52 acts on the load cell 350 via the connecting member 351. In other words, it is possible to measure the reaction force acting on the roller 52 when the recycled material 11 is pressed by the roller 52 using the load cell 350 via the connecting member 351. In the foreign matter detection process, foreign matter is detected by measuring the reaction force acting on the roller 52 when the recycled material 11 is pressed by the roller 52 using the load cell 350.

[0051] As shown in Figure 11, when the roller 52 presses a portion of the film material 20 that does not contain foreign matter 30, the reaction force acting on the roller 52 is relatively small because the film material 20 is in a molten state. In contrast, as shown in Figure 12, when the roller 52 presses a portion of the film material 20 that contains foreign matter 30 (protrusion 21), it becomes difficult to crush that portion with the roller 52. For this reason, a higher reaction force acts on the roller 52 than the reaction force when pressing a portion that does not contain foreign matter 30.

[0052] Thus, if there is a part on the surface of the film material 20 that protrudes more than the surrounding part, the reaction force acting on the roller 52 when pressing that part will be greater than the reaction force acting on the roller 52 when pressing the surrounding part. For this reason, foreign matter 30 can be detected by measuring the reaction force acting on the roller 52 when the recycled material 11 is pressed by the roller 52 using the load cell 350. In other words, if the measurement value by the load cell 350 temporarily increases during the process of generating the film material 20 with the roller 52, it can be determined that there is a protrusion 21 (and therefore foreign matter 30).

[0053] <Other Embodiments> The technologies disclosed herein are not limited to the embodiments described above in the description and drawings, but also include, for example, the following embodiments. (1) In the above embodiment, a plurality of pelletized recycled materials 11 were given as examples of recycled materials, but the shape of the recycled material is not limited thereto. For example, the recycled material may be a single mass of resin. (2) In the above embodiment, a film material 20 is generated by conveying a plurality of recycled materials 11 and pressing them with a fixed roller 52. However, the film material 20 may also be generated by pressing the recycled materials 11 with the roller 52 and displacing the roller 52. [Explanation of symbols]

[0054] 11…Recycled material, 20…Film material, 21…Protrusion (part on the surface of the film material that protrudes more than the surrounding area), 30…Foreign matter, 31…Roll material, 32…Resin component, 50…Conveyor belt (support part), 50A…Upper surface of conveyor belt (upper surface of support part), 60…Injection molding machine, 70…Resin molded product, 250…Pressure sensor (support part), 250A…Upper surface of pressure sensor (upper surface of support part)

Claims

1. A film material production process that generates a film material of a predetermined thickness by heating and pressing recycled material containing thermoplastic resin, A foreign matter detection step for detecting foreign matter contained in the film material by detecting whether or not there is a portion on the surface of the film material that protrudes more than the surrounding portion, A method for manufacturing a film material, comprising: a foreign matter removal step, in which a foreign matter is removed when the foreign matter is detected in the foreign matter detection step.

2. The method for manufacturing a film material according to claim 1, wherein the foreign matter is detected in the foreign matter detection step by measuring the thickness of the film material.

3. In the film material production process, the recycled material supported on the upper surface of the support is pressed from above by a roller, and the roller is moved relative to the recycled material, thereby transforming the recycled material into the film material. The method for manufacturing a film material according to claim 1, wherein the foreign matter detection step involves detecting the foreign matter by measuring the pressure acting on the upper surface when the recycled material is pressed by the roller.

4. In the aforementioned film material production process, the recycled material is pressed with a roller while the roller is moved relative to the recycled material, thereby transforming the recycled material into the film material. The method for manufacturing a film material according to claim 1, wherein the foreign matter detection step involves detecting the foreign matter by measuring the reaction force acting on the roller when the recycled material is pressed by the roller.

5. A roll material forming step, which involves winding a film material manufactured by the method for manufacturing a film material according to any one of claims 1 to 4 into a roll shape, A cutting step to obtain multiple resin members by cutting the roll material at multiple locations in the axial direction, A method for manufacturing a resin molded product, comprising a molding step of molding a resin molded product from a plurality of resin members using an injection molding machine.

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