Method for identifying defects in a film, method and apparatus for producing a film

Abstract

A method for identifying defects in a wet film includes conveying the wet film (20) in a wet state on a conveyor (10), providing a laser projection (1511) onto the wet film, acquiring a series of images each representing an area of ​​the wet film, where at least a portion of the laser projection is visible, and identifying the defects using at least some of the images. A method and apparatus for producing the film is also disclosed.

Description

[Technical Field]

[0001] The present disclosure relates to a method for identifying defects in a film. The disclosure also relates to a method and apparatus for producing a film. The method finds particular application in the production of microfibrillated cellulose films. [Background technology]

[0002] Microfibrillated cellulose ("MFC"), or "nanocellulose," is a material composed of cellulose microfibrils that can be separated from the cellulose fiber wall.

[0003] Nanocellulose contains partially or fully fibrillated cellulose or lignocellulose fibers. The diameter of the liberated fibrils is less than 1000 nm, but the actual fibril diameter or particle size distribution and / or aspect ratio (length / width) vary depending on the source and production method. The smallest fibrils, called elementary fibrils, may be approximately 2–4 nm in diameter, but aggregated forms of elementary fibrils, also defined as microfibrils, are typically the primary product obtained when manufacturing MFCs, for example, using an expanded purification process or a pressure-drop cracking process. Depending on the source and production process, fibril lengths can vary from approximately 1 to 10 micrometers or more. Coarse nanocellulose grades may contain a significant portion of fibrillated fibers, i.e., fibrils protruding from the tracheids (cellulose fibers), as well as a certain amount of fibrils liberated from the tracheids (cellulose fibers).

[0004] Nanocellulose can also be characterized by various physical or physicochemical properties, such as its large surface area, or its ability to form a gel-like material at low solids content (1-5 wt%) when dispersed in water. The cellulose fibers preferably have a final specific surface area of ​​about 1 to about 500 m2, as determined for solvent-exchanged and freeze-dried material by the BET method. 2 / g, for example, about 1 to about 200 m2 / g, or more preferably 50 to 200 m 2 / g.

[0005] Various methods exist for producing nanocellulose, including single-pass or multi-pass purification, prehydrolysis or enzymatic treatment followed by purification or high-shear degradation or fibril liberation. Nanocellulose can be produced from wood cellulose fibers, both hardwood and softwood. It can also be made from microbial sources, agricultural fibers (such as straw pulp, bamboo, and bagasse), or other non-wood fiber sources. It is preferably made from pulp (e.g., mechanical, chemical, and / or thermomechanical pulp), including pulp from virgin fibers. It can also be made from broken or recycled paper. The term nanocellulose includes parenchyma nanocellulose and BNC (bacterial nanocellulose). Nanocellulose can also be obtained from plant fibers (e.g., sugar beet- or potato-based nanocellulose).

[0006] The above definition of nanocellulose includes, but is not limited to, the definition of nanocellulose in the ISO / TS 20477:2017 standard.

[0007] Further synonyms for nanocellulose / MFC include cellulose microfibrils, fibrillated cellulose, nanofibrillated cellulose (NFC), fibril aggregates, nanoscale cellulose fibrils, cellulose nanofibers, cellulose nanofibrils, nanocrystalline cellulose, cellulose microfibers, cellulose fibrils, cellulose nanofilaments, microfibril cellulose, microfibril aggregates, and cellulose microfibril aggregates.

[0008] Current research indicates that MFC may be a suitable material for packaging and packaging coatings due to its strength and barrier properties. Therefore, MFC has the potential to replace or complement currently used barrier films, including polymeric and metallic films.

[0009] Formation of MFC films can be achieved by solvent casting of a viscous or gel-like fluid material onto a continuous conveyor belt, followed by dehydration / drying (e.g., evaporation) of the solvent.

[0010] The term "solvent casting" is a known term that refers to a method in which a film is produced by applying a wet film containing film-forming ingredients distributed in a medium that is to be essentially removed, for example, by dehydration and / or evaporation. The film-forming ingredients can be dispersed in a carrier fluid or dissolved in a solvent, hence the term "solvent casting."

[0011] However, to achieve uniform film properties and a film with attractive visual characteristics, it is important to identify film defects early so that measures can be taken to prevent further defects from occurring. Non-limiting examples of such defects can include air bubbles, holes, streaks, thickness variations, or stains, which may be caused by clogged feed nozzles, air entrapment, or otherwise uneven distribution of the casting suspension / solution on the belt.

[0012] Prior art methods of detecting defects are directed at the finished dry film, which means there is a substantial delay between the occurrence of a defect and its detection, and therefore it is also difficult to identify the origin of the defect.

[0013] Therefore, there is a need for improved methods for identifying defects in films. Summary of the Invention [Problem to be solved by the invention]

[0014] A general objective of the present disclosure is to provide an improved method and apparatus for identifying defects in wet films, which may be nanocellulose or other cellulose films. In particular, the present disclosure aims to provide a method and apparatus that can more accurately identify defects in the film. [Means for solving the problem]

[0015] The invention is defined by the accompanying independent claims, and embodiments are set out in the dependent claims in the following description of the accompanying drawings.

[0016] According to a first aspect, there is provided a method of identifying defects in a wet film, the method comprising the steps of conveying the wet film in a wet state on a conveyor, providing a laser projection onto the wet film, acquiring a series of images each representing an area of ​​the wet film, where at least a portion of the laser projection is visible, and identifying the defects using at least some of the images.

[0017] This method allows early and real-time identification of film defects. Optionally, film sections can be delivered with defect-indicating data, meaning the method can be performed online while the film is wet, facilitating identification of the cause of the defects.

[0018] This method can be used to detect any type of localized thickness variation, in the sense that the defect extends a shorter distance along the direction of conveyor travel. For example, depending on how the laser is angled relative to the surface, it is possible to identify defects having a range of up to about 5-10 microns in the direction of conveyor travel.

[0019] This method is useful for wet films having thicknesses of 10 to 10,000 microns, preferably 10 to 5,000 microns, 10 to 1,000 microns, 50 to 10,000 microns, 50 to 5,000 microns, 50 to 1,500 microns, 50 to 1,000 microns, or 50 to 500 microns.

[0020] This method is useful for wet films that have an optical transmittance of less than 80%, preferably less than 70%, at the wavelength of the laser.

[0021] In the context of this application, a wet film is a film having a solids content of less than 50 wt%, preferably 1-50 wt%, 3-50 wt%, 3-20 wt%, 3-15 wt%, or 3-6 wt%.

[0022] The wet film is applied as a continuous layer across a significant portion of the conveyor width and in the direction of conveyor movement.

[0023] It is possible to apply one or more pre-drying or dehydration steps upstream of the area where the image is captured.

[0024] For example, the pre-drying step can include forced evaporation, which can be achieved by radiation, for example, in the form of IR and / or microwaves, to reach a particular desired solids content.

[0025] As another example, a dewatering step (eg, press dewatering, or dewatering by capillary effect through a porous substrate, driven by gravity or assisted by vacuum) can be applied.

[0026] Dehydration and / or subsequent drying can also be assisted by radiation (IR, microwave), steam, or hot air impingement.

[0027] The laser projection can be a line or any predetermined pattern.

[0028] The laser projection can extend beyond the wet film edge, and the image can also represent a portion of the exposed conveyor surface.

[0029] Wet film thickness can be determined as the difference between the measured distance to the conveyor surface laterally outside the wet film and the measured distance to the wet film surface.

[0030] The average wet film thickness can be determined as the difference between the measured distance to the conveyor surface laterally outside the wet film and multiple measured distances to the wet film surface within the wet film width.

[0031] For example, the laser projection can extend over a width greater than the width of the wet film.

[0032] A wet film contains film-forming components distributed in a medium that must be essentially removed by separation methods such as dehydration and / or evaporation to reach a dry film. In the context of this application, a dry film is a film with a moderate content of 0.1 to 15 wt.%.

[0033] The film-forming ingredients can be dispersed in a carrier fluid, which should then be essentially removed. Alternatively, the film-forming ingredients can be dissolved in a solvent, which should then be essentially removed. In either case, the medium is in the liquid phase when casting occurs.

[0034] The film-forming component can include MFC and one or more property-modifying additives and / or fillers. Preferably, the film-forming component includes at least 50% by weight of MFC, preferably at least 60%, at least 70%, or at least 80% of MFC. For example, the film-forming component can also include other natural fiber materials, such as wood materials, in addition to MFC.

[0035] The film-forming component also optionally comprises a water-soluble polymer capable of forming a film and / or improving the bonding between cellulose fibrils. Typical examples of such polymers are, for example, natural gums or polysaccharides or their derivatives, such as CMC, starch, etc.

[0036] The film essentially comprises film-forming components distributed in a medium to be removed, and the medium content of the wet film at the time of image capture is at least 75% by weight, preferably greater than 80%, 85%, 90%, or 95% by weight.

[0037] The film can be a cellulose-based film, particularly a microfibrillated cellulose film ("MFC").

[0038] The MFC can be unmodified MFC or chemically modified MFC, or a mixture thereof. Unmodified MFC refers to MFC made from unmodified or native cellulose fibers. The unmodified MFC can be a single type of MFC, or it can comprise a mixture of two or more types of MFC that differ (e.g., in the selection of cellulose feedstock or manufacturing method). Chemically modified MFC refers to MFC made from cellulose fibers that have undergone chemical modification before, during, or after fibrillation. The chemically modified MFC can be a single type of chemically modified MFC, or it can comprise a mixture of two or more types of chemically modified MFC that differ (e.g., in the type of chemical modification, the selection of cellulose feedstock, or the manufacturing method).

[0039] The laser projection may be applied between the casting device and the first drying device, preferably closer to the casting device than the drying device.

[0040] That is, the laser projection is applied to the wet film while the film is still in a wet state.

[0041] The laser projection can be applied to a location along the forward direction of the conveyor where the belt support is located.

[0042] Thus, the laser projection is applied to a portion of the belt that experiences relatively little vertical variation due to the belt support.

[0043] The conveyor can be a metal belt conveyor, such as a steel belt conveyor, a polymer conveyor, or a paper conveyor.

[0044] The conveyor may extend laterally beyond the wet film edges on both lateral sides of the wet film.

[0045] To effectively present the pattern, the laser projection can be applied as a fixed pattern, or the laser can be scanned at a frequency higher than the image capture frequency.

[0046] The laser projection can be applied in a vertical plane containing the conveyor's direction of travel, with the laser direction extending at an angle to said direction of travel, said angle being between 5 and 80 degrees, preferably between 10 and 60 degrees or between 15 and 40 degrees.

[0047] Alternatively, the laser projection can be applied in a vertical plane containing the conveyor's direction of travel, with the laser direction extending at an angle to said direction of travel, said angle being between 100 and 175 degrees, preferably between 100 and 150 degrees or between 105 and 130 degrees.

[0048] The image can be captured so that the image plane of the image capture device is perpendicular to a line extending in the vertical plane and at an angle of 30 to 150 degrees, preferably 40 to 90 degrees, to the laser direction.

[0049] The direction of the laser and the line normal to the image plane are in the same plane, which may be vertical and parallel to the direction of conveyor travel.

[0050] Defects can be identified by comparing the actual pattern provided by the laser projection with an expected pattern, as derived based on the image.

[0051] At the defect point, laser light scattering and / or reflection varies depending on the defect, e.g., a bubble or air inclusion, or a stain, which has different light scattering and / or reflection properties at the laser wavelength. Due to the different scattering and / or reflection, the defect appears differently in the captured image of the laser projection than its neighboring areas, thus indicating a defect. Another possibility is that the surface level of the wet film is locally lower than the average surface level of the wet film or the level of neighboring film areas, such as a hole, streak, or groove, and the difference in the captured image of the laser projection reveals the defect.

[0052] According to a second aspect, there is provided a method of manufacturing a film, the method comprising the steps of: providing a continuous conveyor having a conveyor width; using a casting device to apply a film onto the conveyor, the film comprising film-forming ingredients distributed in a medium to be essentially removed, to solvent cast the film; identifying defects in the wet film according to any one of the methods described above; and providing an indication of said defects.

[0053] The method may further include adjusting at least one casting parameter based on the indicator and / or based on the image.

[0054] Casting devices suitable for applying a liquid to a continuous conveyor belt are known per se and typically comprise an elongated nozzle extending along the width direction and having a length corresponding to the width of the film layer to be formed.

[0055] After image capture, the film passes through one or more dehydration and / or drying zones where the wet film medium is removed to yield a dry film.

[0056] Films formed by the method of the present invention, when dried, may have a thickness of 10 to 100 microns, preferably 15 to 60 microns.

[0057] The film can be a barrier film, a membrane film, or a nanopaper.

[0058] Adjusting at least one casting parameter can include adjusting a feed rate and / or a feed distribution of the wet film.

[0059] Adjusting at least one casting parameter can include adjusting a doctor blade configured to control wet film thickness and / or wet film thickness distribution.

[0060] The step of adjusting at least one casting parameter can include adjusting a lip of a slot die-type casting unit.

[0061] The method includes the steps of providing an alarm directed to an operator; The method may further include at least one of recording a location corresponding to the defect and stopping at least one of the casting apparatus and the conveyor.

[0062] For example, the method may include recording location and optionally type data on a quality control system or carrier associated with the film so that the location of the defect can be derived at a later time, thereby allowing the user of the film to avoid using that portion of the film.

[0063] Storing information about the detected defects in a production log or quality control system may include indicating the time and location of the detected defects.

[0064] According to a third aspect, there is provided an apparatus for producing a film, the apparatus comprising: a continuous conveyor having a conveyor width; a casting apparatus for applying a wet film onto the conveyor, the wet film comprising film-forming components distributed in a medium to be removed essentially, the casting apparatus for solvent-casting the film to provide a wet film width smaller than the conveyor width; a laser projection apparatus configured to provide a laser projection onto the wet film; an image capture apparatus configured to acquire a series of images each representing an area of ​​the wet film, wherein at least a portion of the laser projection is visible; and a processing apparatus configured to use at least some of the images to identify defects in the wet film.

[0065] The apparatus can further include an adjustable device configured to adjust the casting device based on the identified defects in the wet film. [Brief explanation of the drawings]

[0066] [Figure 1] 1 shows a schematic side view of an apparatus for solvent casting a film. [Figure 2] 2 shows a schematic top view of the device of FIG. 1. [Figure 3] 3 shows a schematic top view of a detail of the apparatus of FIG. 2; [Figure 4] 2 shows a detailed schematic view of the laser projection device of FIG. 1; DETAILED DESCRIPTION OF THE INVENTION

[0067] The drawings show diagrammatically an apparatus in which the invention can be implemented. Apparatus for use in belt casting is known per se and will therefore only be briefly described with reference to the drawings.

[0068] A belt casting machine typically includes a conveyor belt 10, which may be a solid steel belt or a continuous smooth belt of polymer or paper material.

[0069] The steel belt can be ground or polished to provide a smooth film surface. For very smooth film surfaces, mirror-quality polished steel belts can be used.

[0070] The polymer or paper belt may have a surface coating to provide a sufficiently smooth surface.

[0071] The conveyor belt may be a continuous or endless conveyor belt such as a metal belt, especially a steel belt.

[0072] The conveyor belt is arranged to run over at least one pair of conveyor belt pulleys 11, 12, at least one of which may be a drive pulley. Additional support pulleys may be provided, but need not be. Typically, the belt speed may be of the order of at least 10 m / min, perhaps at least 50 m / min or at least 75 m / min.

[0073] The belt width can be on the order of 0.3 to 8 m, typically 0.5 to 6 m or 1 to 5 m.

[0074] A drying chamber 13 may be provided over a portion of the belt. Such a drying chamber may be positioned to completely surround the belt as viewed in cross section perpendicular to the belt's direction of travel. The drying chamber may include one or more zones in which controlled temperature, gas atmosphere, and airflow may be provided. For example, it may be desirable to provide high temperatures to promote solvent evaporation and low humidity air to maximize the air's ability to accept evaporated solvent. The exhaust airflow may be connected to a solvent recovery or destruction device.

[0075] The drying chamber may be preceded by one or more pre-drying or dewatering zones (not shown).

[0076] One or more pre-drying or dehydration steps may be provided upstream of the area where the image is captured.

[0077] Alternatively, or as a supplement, one or more pre-drying or dehydration steps may be provided downstream of the area where the image is captured, but upstream of the drying chamber 13 .

[0078] For example, the pre-drying step can include forced evaporation, which can be achieved by radiation, for example, in the form of IR and / or microwaves, to reach a particular desired solids content.

[0079] As another example, a dewatering step (eg, press dewatering, or dewatering by capillary effect through a porous substrate, driven by gravity or assisted by vacuum) can be applied.

[0080] Dehydration and / or subsequent drying can also be assisted by radiation (IR, microwave), steam, or hot air impingement.

[0081] For example, a film applicator 14 may be provided at one end of the conveyor 10 by a first belt pulley 11. The film applicator 14 may have one or more feeders 141 and / or doctor blades 142, which may be used to control the thickness and / or thickness distribution of the film across the belt width.

[0082] The controller 15 can be configured to control the feeder 141, an external feed pump (not shown), the lip of a slot die-type casting unit, and / or the doctor blade 142 via drive motors or actuators (not shown).

[0083] The laser projection device 15 includes a laser source 151 and an image capture device 152, such as a camera.

[0084] A laser projection device 151 provides a laser projection 1511 across the film width, and an image capture device 152 acquires an image of at least a portion of the laser projection 1511 .

[0085] On a flat surface, the laser projection 1511 will provide a predetermined pattern, such as, but not limited to, a straight line extending across the conveyor 10 perpendicular to its direction of travel.

[0086] The laser may operate at a wavelength of about 380-900 nm, preferably 380-750 nm, more preferably 625-740 nm.

[0087] The laser projection device 151 can be formed from one or more laser sources 151, which can be adjusted to provide different portions of the laser projection 1511 and / or to reinforce each other to increase the intensity of the projection 1511.

[0088] Laser projection devices can operate by scanning a laser dot or with a fanning filter to provide a stationary projection.

[0089] In use, the conveyor belt is driven at a predetermined speed in a forward direction, shown in the drawings as the "X" direction, while film solution 20 is dispensed onto the belt surface. In a region downstream of the film coater, a laser projection 1511 is applied across the film while simultaneously acquiring images using image capture device 152, each image showing the laser projection, the film surface, and the exposed belt surface laterally outward of the film surface.

[0090] 4, the laser source 151 may be directed along a direction D151 at an angle a of 5 to 80 degrees, preferably 10 to 60 degrees, or 15 to 40 degrees relative to the conveyor surface as viewed in a vertical plane XZ parallel to the direction of travel of the conveyor. As specific examples, the laser source may be directed to the conveyor surface at an angle of 10 to 20 degrees, 20 to 30 degrees, 30 to 40 degrees, 40 to 50 degrees, 50 to 60 degrees, 60 to 70 degrees, or 70 to 80 degrees.

[0091] Alternatively, if the laser projection is applied along a direction opposite to the forward direction, the angle may be 100 to 175 degrees, preferably 100 to 150 degrees or 105 to 130 degrees.

[0092] The image capture device 152 may be oriented along a direction D152 at an angle b of 30 to 150 degrees, preferably 40 to 90 degrees, relative to the laser source direction D151, as seen in said vertical plane XZ.

[0093] A filter 153 can be placed in the optical path of the laser light between the conveyor and the image capture device 152. The filter can be matched to the associated laser wavelength(s).

[0094] The thickness direction of the film is designated in the drawings as the "Z" direction, and the width direction of the film is designated in the drawings as the "Y" direction.

[0095] Below, as an illustrative example, a method for determining film thickness is described.

[0096] The controller 15 receives the images and performs image processing to determine the thickness of the film and / or the thickness distribution of the film across the width of the film.

[0097] When the controller 15 determines that the film thickness and / or film thickness distribution is outside of the acceptable range, it can adjust the feeder 141, the external feed pump (not shown), the lip of a slot die-type casting unit, and / or the doctor blade 142 based on the determined film thickness and / or film thickness distribution to adjust the film thickness.

[0098] When the film is applied in its wet state, it may have a solids content of 1-25% by weight or 3-20% by weight, with the remainder being solvent(s) or dispersion medium(s), preferably the solids content may be 1-3%, 3-6%, 6-9%, 9-12%, 12-15%, 15-18%, 18-21%, 21-24%, or 24-25% (by weight).

[0099] The solid portion can include a primary material, such as an MFC, and one or more additives. The primary material can be present at least 50% by weight of the solid portion, preferably at least 60, 70, 80, or 90% by weight.

[0100] Typical additives used to provide particular film properties may include antiblocking and antistatic compounds, chelating agents, dyes, conductive materials, pigments, and the like.

[0101] Other additives may include natural fiber materials such as wood materials.

[0102] The film passes through a drying chamber and is then released from belt 10 after which it can be packaged for shipping, such as by being wound onto reel 16.

[0103] The conveyor belt may be supported by one or more belt supports 17, which may be provided as roller or sliding supports that may extend across all or part of the width of the belt.

[0104] The laser projection can be applied to the belt surface at the contact area between the support 17 and the belt 10. Preferably, the laser projection can be provided within a distance in the X direction of 50% of the diameter of the support roller from a line of contact parallel to the Y axis between the support roller 17 and the belt 10, preferably within a distance of 25% of the diameter of such support roller.

[0105] FIG. 3 shows a schematic representation of a section of the belt 10 with the wet film 20 expanded, with an example image frame 30 shown in dashed lines and the laser projection 1511 shown in broken lines.

[0106] Preferably, the laser projection is provided at an angle a as described above from the laser direction in a vertical plane that is parallel to the forward direction X of the conveyor belt, i.e. in the XZ plane.

[0107] In the illustrated case, the laser projection 1511 on the target area presents five sections, which are displaced relative to one another in the X direction, thus indicating the thickness and / or thickness variation of the film 20 .

[0108] A first pair of laser projections 15111, 15115 strike the exposed surface portion 101 of the belt 10. These laser projections 15111, 15115 therefore indicate the zero thickness level and can be used to indicate a reference plane parallel to the XY plane.

[0109] The second pair of laser projections 15112, 15114 strike the surface of the wet film 20, closer to the projection device 141 than the first pair of laser projections and exhibiting a higher level, which may be the desired film surface.

[0110] The third laser projection portion 15113 extends laterally beyond the second pair of laser projections 15112, 15114 and therefore represents a lower level.

[0111] Therefore, the distance in the X direction between the first and second pair of laser projections 15111, 15115, 15112, 15114 indicates the film thickness, which can be calculated by knowing the projection angle and said distance in the X direction.

[0112] A third laser portion 15113 exhibiting a reduction in thickness can be identified and measured in a similar manner.

[0113] Images may be taken at a predetermined frequency that may be determined based on the belt speed.

[0114] Each image can be analyzed to identify the location of the laser projection within the image and calculate, for example, the average film thickness, maximum film thickness, minimum film thickness, or standard deviation of the thickness.

[0115] If one or more of the above parameters fall outside of a predetermined range, an alarm may be activated, stopping the feed and / or conveyor advancement.

[0116] The results can be used as input to adjust the feeder 14. Such adjustments can include adjusting the feed rate across all or part of the width of the feeder 141.

[0117] Optionally, or as a supplement, the results can be used as input for adjusting the doctor blade 142 .

[0118] Further optionally or as a supplement, the results can be used as input for adjusting the lip of a slot die type casting unit.

[0119] However, optionally, the produced film can be delivered with an animation detailing the thickness profile of the entire film or a portion of the film.

[0120] Although the disclosure herein relates to MFCs, it is understood that the methods and systems can also be used to produce other types of films, including, but not limited to, cellulose-based films such as cellulose triacetate, polymer films such as polyimides, liquid crystal polymers, or poly(vinylidene fluoride), and edible films such as sodium caseinate and calcium caseinate-based films.

[0121] To achieve accurate measurement of the film, it is possible to measure the thickness of the film with an additional belt support, as described above.

[0122] As an additional measure, a calibration run can be performed on the belt to determine the shape of the belt when empty of film.

[0123] Laser measurements such as those described above may also be simultaneously applied to the underside of the belt and the results of such measurements used to compensate for variations in belt shape and / or movement.

[0124] The above method can also be used to identify defects in wet films. Such identification can be based on deviations between the laser projection pattern as shown in one or more images and the expected laser projection pattern.

[0125] For example, holes or depressions in the film may appear as localized displacements of the lines in the laser projection pattern.

[0126] As another example, air inclusions may appear as localized disruption of lines in a laser projection pattern due to significantly increased transmission or scattering at such spots, such that the laser beam is absorbed rather than reflected.

[0127] As yet another example, a speck of dirt or protrusion protruding upward from the film surface may appear as a shadow that disrupts part of the laser projection pattern.

[0128] As yet another example, a speck of dirt, a lump of gel, or an accumulation of fibril flock may protrude so as to change the local scattering of the laser beam and / or disrupt part of the laser projection pattern.

Claims

1. A method for identifying defects in a wet film, including thickness variations, wherein the wet film is a film (20) comprising film-forming components distributed essentially in a medium to be removed, the wet film being a cellulose-based barrier film containing at least 50% by weight of microfibrillated cellulose, and the content of said medium in said wet film being at least 75% by weight, comprising: conveying the wet film (20) in a wet state on a continuous conveyor (10) having a conveyor width, the continuous conveyor (10) being a metal belt conveyor, a polymer conveyor, or a paper conveyor; performing a laser projection (1511) onto the wet film, the laser projection (1511) being applied at a position along the forward direction (X) of the conveyor where a belt support (17) is located; and, acquiring a series of images, each image representing an area of ​​the wet film in which at least a portion of the laser projection is visible; identifying the defects using at least some of the images; Including, the laser projection (1511) extends beyond the wet film edge; the image also represents a portion of an exposed conveyor surface; A method in which wet film thickness is determined as the difference between a measured distance to a conveyor surface laterally outward of said wet film and a measured distance to the wet film surface.

2. 2. The method of claim 1, wherein the average wet film thickness is determined as the difference between a measured distance to a conveyor surface laterally outside the wet film and a plurality of measured distances to the wet film surface within the wet film width.

3. 2. The method of claim 1, wherein the laser projection is applied between a casting device (14) and a first drying device (13).

4. The method according to any one of claims 1 to 3, wherein the conveyor (10) extends laterally beyond the wet film edges on both lateral sides of the wet film (20).

5. 5. The method of claim 1, wherein the laser projection (1511) is applied as a fixed pattern or the laser is scanned at a frequency higher than the image capture frequency to effectively present the pattern.

6. 6. The method according to any one of claims 1 to 5, wherein the laser projection (1511) is applied in a vertical plane containing the direction of travel (X) of the conveyor, with the laser direction extending at an angle to said direction of travel, said angle being between 5 and 80 degrees.

7. 6. The method according to any one of claims 1 to 5, wherein the laser projection (1511) is applied in a vertical plane containing the direction of travel (X) of the conveyor, with the laser direction extending at an angle to said direction of travel, said angle being between 100 and 175 degrees.

8. 8. The method of claim 6 or 7, wherein the image is captured such that the image plane of an image capture device is perpendicular to a line extending in the vertical plane and at an angle of between 30 and 150 degrees relative to the laser direction.

9. 9. The method of claim 6, wherein the defects are identified by comparing an actual pattern provided by the laser projection (1511) with an expected pattern, as derived based on the image.

10. 1. A method for producing a film, wherein the film is a cellulose-based barrier film containing at least 50% by weight of a microfibrillated cellulose film, the method comprising: providing a continuous conveyor (10) having a conveyor width, said continuous conveyor (10) being a metal belt conveyor, a polymer conveyor, or a paper conveyor; using a casting device (14) for applying a film (20) onto the conveyor, the film (20) comprising film-forming components distributed in a medium to be essentially removed, to solvent-cast the film; Identifying defects in the wet film according to the method of any one of claims 1 to 9; providing an indication of the defect; A method comprising:

11. The method of claim 10 , further comprising adjusting at least one casting parameter based on the indication and / or based on the image.

12. The method of claim 11 , wherein adjusting at least one casting parameter comprises adjusting a feed rate and / or a feed distribution of the wet film.

13. 13. The method of claim 11 or 12, wherein adjusting at least one casting parameter comprises adjusting a doctor blade (142) configured to control wet film thickness and / or wet film thickness distribution.

14. The method according to any one of claims 11 to 13, wherein the step of adjusting at least one casting parameter comprises adjusting a lip of a slot-die type casting unit.

15. providing an alarm directed to an operator; recording a location corresponding to the defect; and The method of claim 10 further comprising at least one of the steps of stopping at least one of the casting apparatus and the conveyor.

Images