Film transport machine, film transport method, and film manufacturing device

Abstract

The present invention can provide a film transport machine and the like that feed a film safely and efficiently. The film transport machine feeds a film (83) from an upstream side toward a downstream side. The film transport machine comprises a feed mechanism (70) including attraction-type conveyors (711), (731) that can move between a retracted position and a transporting position and, at the transporting position, feed a film to the downstream side while attracting the film. The attraction-type conveyors feed the film while attracting the film to the surfaces of the attraction-type conveyors by means of a negative pressure or an electrostatic force. The film transport machine may be provided between a longitudinal extension region and a lateral extension region.

Description

Film conveying machine, film conveying method, and film manufacturing device

[0001] The present invention relates to a film transporting machine, a film transporting method, and a film manufacturing apparatus.

[0002] Patent Document 1 discloses a stretching machine that conveys an extruded film and stretches the film, and a clipping device that grips the film with clips.

[0003] JP 2012-187788 A

[0004] Until now, because it was not possible to feed the film between the longitudinal stretching region and the transverse stretching region, the film had to be fed manually by multiple people. This manual work is tedious and inefficient. Furthermore, when the film is fed entirely by hand, there is a possibility that the hands may come into contact with the clip closer or the conveyor. Furthermore, especially when the film is thin, if the contact area between the conveyor table on which the film is placed exceeds a certain level, the film may buckle due to friction, making it impossible to convey.

[0005] The present disclosure has been made to solve such problems, and has an object to provide a film transport device and the like that can feed a film safely and efficiently.

[0006] In one embodiment, the film transport device is a film transport device that transports a film from upstream to downstream, and is equipped with a feed mechanism including a suction conveyor that is movable between a retracted position and a transport position, and that sucks the film at the transport position while transporting the film downstream.

[0007] In one embodiment, a film transport method is a method of transporting a film from upstream to downstream using a suction conveyor that is movable between a retracted position and a transport position, in which the suction conveyor is moved to the transport position, and the film is transported downstream by driving the suction conveyor while the film is sucked by the suction conveyor.

[0008] In one embodiment, the film manufacturing apparatus includes: an extruder that melts and extrudes an input resin raw material; a die connected to the extruder that forms the molten resin into a film; a cooling roll that cools the film-like molten resin extruded from the die and conveys a resin film in which the molten resin has solidified; a longitudinal stretching machine that is located downstream of the cooling roll and longitudinally stretches the film and sends it downstream; a feed mechanism that includes a suction conveyor that is movable between a retracted position and a transport position and that, at the transport position, sucks the film and sends it downstream; and a transverse stretching machine that is located downstream of the feed mechanism and transversely stretches the film and sends it downstream.

[0009] According to one embodiment of the present disclosure, a film transport device or the like that can safely and efficiently transport a film can be provided.

[0010] FIG. 1 is a schematic perspective view showing the overall configuration of a film conveying machine and a film manufacturing apparatus according to a first embodiment. FIG. 2 is a schematic perspective view showing the configuration of a film feed mechanism according to the first embodiment. FIG. 3 is a schematic perspective view showing the overall configuration of a film conveying machine and a film manufacturing apparatus according to a second embodiment. FIG. 4 is a schematic perspective view showing the configuration of a film feed mechanism according to the second embodiment. FIG. 5 is a schematic perspective view showing the operation of a film feed mechanism according to a third embodiment. FIG. 6 is a schematic perspective view showing the operation of a film feed mechanism according to the third embodiment. FIG. 7 is a schematic perspective view showing a film feed mechanism and a clip device according to another embodiment. FIG. 8 is a top view illustrating the wrinkle-smoothing operation by a belt conveyor. FIG. 9 is a top view illustrating the wrinkle-smoothing operation by a belt conveyor.

[0011] Hereinafter, specific embodiments will be described in detail with reference to the drawings. However, the present invention is not limited to the following embodiments. In addition, the following description and drawings have been simplified appropriately for clarity.

[0012] First Embodiment <Overall Configuration of Film Manufacturing Apparatus> First, the overall configuration of a film manufacturing apparatus including a resin film conveying device according to a first embodiment will be described with reference to Fig. 1. Fig. 1 is a schematic perspective view showing the overall configuration of the film manufacturing apparatus according to the first embodiment.

[0013] The xyz Cartesian coordinate system shown in Figure 1 and other drawings is for the convenience of explaining the positional relationship of the components. Typically, the positive z-axis direction is vertically upward, and the xy plane is a horizontal plane, which is common to all drawings. In this specification, the film may be a resin film and may include a resin sheet.

[0014] As shown in Figure 1, the film production apparatus 1 includes an extruder 10, a T-die 20, a cooler 30, a longitudinal stretching machine 40, a feed mechanism 70, a transverse stretching machine 50, and a winder 60. The film production apparatus according to the first embodiment is an extrusion molding type film production apparatus that extrudes a film-like molten resin 82a from a gap between the lips of the T-die 20 connected to the extruder 10. Note that detailed portions of the feed mechanism 70 having a belt conveyor 731 are omitted from Figure 1.

[0015] 1 is a screw-type extruder. In the extruder 10, a screw extending in the x-axis direction is housed inside a cylinder 11 extending in the x-axis direction. A hopper 13 for feeding resin pellets, which are the raw material for the resin film 83, is provided above the end of the cylinder 11 on the negative x-axis direction side.

[0016] The resin pellets supplied from the hopper 13 are transported from the base to the tip of the rotating screw, i.e., in the positive direction of the x-axis. The resin pellets are heated inside the cylinder 11 and are sheared and melted by the rotating screw, turning into molten resin 82.

[0017] Although not shown, the screw is connected to a motor as a drive source via a reducer, for example. A heater for heating the inside of the cylinder 11 is provided on the outer circumferential surface of the cylinder 11 over substantially the entire longitudinal area, and the resin pellets introduced into the cylinder 11 are heated.

[0018] As shown in FIG. 1 , the T-die 20 is connected to the lower side of the tip end (the end on the positive x-axis direction) of the extruder 10. A film-like molten resin 82a is extruded downward (in the negative z-axis direction) through a gap in a lip located at the lower end of the T-die 20. The lip spacing of the T-die 20 can be adjusted. The lip spacing of the T-die 20 can be adjusted at multiple locations along the longitudinal direction of the lip (in the y-axis direction) so that the thickness of the produced resin film 83 in the width direction (in the y-axis direction) is uniform.

[0019] 1, the cooler 30 includes cooling rolls CR1 to CR4. The cooling roll CR1 cools the film-like molten resin 82a extruded from the T-die 20, and delivers the resin film 83 formed by solidifying the film-like molten resin 82a to the cooling roll CR2. The cooling roll CR1 is also called a cast roll.

[0020] 1, the cooling rolls CR2 to CR4 transport the resin film 83 in this order while cooling it. Each of the cooling rolls CR1 to CR4 may be a drive roll driven by a drive source (not shown). The drive source is, for example, a variable speed motor such as a servo motor.

[0021] Each of the cooling rolls CR1 to CR4 may be provided with a cooling mechanism for cooling the resin film 83. Each of the cooling rolls CR1 to CR4 may be provided with a heating mechanism for heating the resin film 83. The cooling device 30 includes a plurality of drive rolls for transporting the resin film 83, and therefore can be one form of the film transport device according to this embodiment.

[0022] As shown in Fig. 1, the longitudinal stretching machine 40 stretches the resin film 83 carried out from the cooling machine 30 in the longitudinal direction while transporting the film. The longitudinal stretching machine 40 shown in Fig. 1 includes eleven rolls R1 to R11. Each of the rolls R1 to R11 is a drive roll driven by a drive source (not shown). The drive source is, for example, a variable speed motor such as a servo motor. The longitudinal stretching machine 40 is one form of a film transporting machine according to this embodiment.

[0023] The longitudinal stretching machine 40 may be provided with a plurality of drive rolls for transporting the resin film 83, and the number and arrangement of the drive rolls provided in the longitudinal stretching machine 40 may be determined appropriately. Each of the rolls R1 to R11 may be provided with at least one of a cooling mechanism for cooling the resin film 83 and a heating mechanism for heating the resin film 83. Furthermore, the longitudinal stretching machine 40 may be provided with one or more nip rolls for pressing the resin film 83 against any of the rolls R1 to R11. The nip rolls are not drive rolls. In addition, the region in the film transport path where the film is longitudinally stretched by the longitudinal stretching machine 40 is also called the longitudinal stretching region.

[0024] The feeding mechanism 70 assists in feeding the resin film 83 discharged from the longitudinal stretching machine 40 to the subsequent transverse stretching machine 50 (particularly, the clip closer 501 in FIG. 7 ). Previously, the film was placed on a conveying table and manually fed downstream. However, there was a risk of the hand coming into contact with the clip closer or conveying machine. Furthermore, particularly for thin films (e.g., 50 microns or less), if the contact area between the film and the conveying table exceeds a certain level, the film may buckle and become difficult to convey. Therefore, the present disclosure provides a new film feeding mechanism 70 with the functions of suctioning and feeding the film (although manual labor may be required in some cases). Details of this feeding mechanism 70 will be described later. The feeding mechanism 70 can be one form of a film conveying device according to this embodiment.

[0025] The transverse stretching machine 50 stretches the resin film 83 delivered from the feed mechanism 70 in its width direction (y-axis direction). More specifically, the transverse stretching machine 50 includes a pair of rails RL1 and RL2. A large number of clips (not shown) are slidably arranged in parallel along the entire length of the rails RL1 and RL2.

[0026] In Fig. 1, the arrows on the rails RL1 and RL2 indicate the movement direction of the clips. As shown in Fig. 1, the rails RL1 and RL2 have a loop structure with an outgoing path along which the clips move in the conveying direction of the resin film 83 (positive direction of the x-axis) and a returning path along which the clips move in the opposite direction (negative direction of the x-axis). That is, in the transverse stretching machine 50, the clips revolve around the rails RL1 and RL2 having the loop structure. Although not shown in Fig. 1, a clip closer (501 in Fig. 7) closes the tenter clips on the film. As shown in Fig. 1, the rails RL1 and RL2 have a symmetrical configuration with respect to a plane parallel to the xz plane.

[0027] 1, rails RL1 and RL2 are both arranged substantially parallel to each other on the outgoing path that advances in the conveyance direction (positive direction of the x-axis) and the returning path that advances in the opposite direction (negative direction of the x-axis). The returning path of rail RL1 is arranged on the outer side in the width direction of the resin film 83 (negative direction of the y-axis). The returning path of rail RL2 is also arranged on the outer side in the width direction of the resin film 83 (positive direction of the y-axis).

[0028] As shown in Figure 1, the outgoing paths of rails RL1 and RL2 have a pair of parallel portions parallel to the x-axis at both ends in the longitudinal direction (x-axis direction), and a slanted portion slanting in the y-axis direction between the parallel portions. The slanted portion of rail RL1 is slanted in the negative y-axis direction, and the slanted portion of rail RL2 is slanted in the positive y-axis direction. That is, in the slanted portions of the outgoing paths of rails RL1 and RL2, the distance between rails RL1 and RL2 in the y-axis direction increases as the rails progress in the positive x-axis direction.

[0029] 1 , in the portions of the rails RL1 and RL2 that come into contact with the resin film 83, the clips grip both ends of the resin film 83 in the width direction (y-axis direction) and move in the positive x-axis direction along the rails RL1 and RL2. Therefore, as shown in FIG. 1 , in the oblique portions of the rails RL1 and RL2 that come into contact with the resin film 83, the resin film 83 is transported in the positive x-axis direction and stretched in the width direction (y-axis direction). On the other hand, in the parallel portions of the rails RL1 and RL2 that come into contact with the resin film 83, the resin film 83 is only transported in the positive x-axis direction and is not stretched in the width direction (y-axis direction).

[0030] The transverse stretching machine 50 shown in Fig. 1 has a drive source that drives clips for transporting the resin film 83. The drive source is, for example, a variable speed motor such as a servo motor. The transverse stretching machine 50 can be one form of the film transport machine according to this embodiment.

[0031] The resin film 83 discharged from the transverse stretching machine 50 is taken up by the winder 60. The winder 60 is a drive roll driven by a drive source (not shown). The winder 60 may include a plurality of drive rolls driven by a drive source. In this case, the winder 60 can be one form of the film transport device according to this embodiment. In addition, the region in the film transport path where the film is transversely stretched by the transverse stretching machine 50 is also called the transverse stretching region.

[0032] As described above, in the film conveying machine of this embodiment, some or all of the cooling machine 30, the longitudinal stretching machine 40, the feed mechanism 70, the transverse stretching machine 50, and the winding machine 60 can be one aspect of the film conveying machine of this embodiment.

[0033] <Overall Configuration of Feeding Mechanism> Fig. 2 is a schematic perspective view showing the configuration of the film feeding mechanism. As an example, the feeding mechanism 70 can be provided downstream of the longitudinal stretching machine 40 and upstream of the transverse stretching machine 50 in the film transport path.

[0034] The feed mechanism 70 includes a liftable lower platform 730 having a belt conveyor 731. The belt conveyor 731 includes a plurality of rolls 731R, 731R provided at both ends, and a belt 7311 wound around the plurality of rolls. The roll 731R is a roll with a built-in motor. The belt conveyor may be any of various known belt conveyors.

[0035] The lower table 730 can be raised and lowered vertically by an elevating mechanism 735. When a sensor detects the film fed from the longitudinal stretching machine 40, the lower table 730 is raised vertically from the retracted position (downward along the vertical arrow from the position in Figure 2 ) to the conveying position (position in Figure 2 ) by the elevating mechanism 735. The lower table 730 is normally in the retracted position to prevent contact with the film and damage to the film, and is raised to the conveying position ( Figure 2 ) when the film is conveyed between the longitudinal stretching region and the transverse stretching region and when clips are attached (chucking). Thereafter, after chucking is completed, the lower roll table 720 descends to the retracted position.

[0036] The surface of the belt conveyor 731 of the lower platform 730 is provided with one or more suction sections 733 that attract the film. The suction sections 733 can attract the film by, for example, electrostatic force or negative pressure. The electrostatic attraction sections 733 can be electrode films laminated at predetermined intervals on the back surface of the belt. A charge supply section can be provided slightly upstream in the direction of movement of the belt 7311, and this charge supply section can apply a positive charge to the surface of the belt 7311 and a negative charge to the surface of the electrode film. In other embodiments, the belt 7311 can be porous or sponge. Visible holes can also be formed in the belt 7311. The negative pressure attraction sections 733 can be suction ports. The film can be sucked from these suction ports by a pump via a hose. Note that the configuration of the suction-type belt conveyor is not limited to these, and various known types can be used.

[0037] Furthermore, when a sensor detects that the film 83 fed (for example, manually) has reached a sufficient contact area on the belt conveyor 731, film transport may be stopped and the suction unit 733 may be activated to suck the film. In other words, the stopped film can be reliably sucked by the suction unit 733. After suction, the belt conveyor 731 may be driven to feed the film.

[0038] In this way, belt conveyor 731 is a suction belt conveyor that can suck the film being transported while sending the film downstream, reducing the labor required for manual transport and preventing buckling even for thin films.

[0039] Guide rolls 729, 729 are provided to guide the film sent from the longitudinal stretching machine 40. Two meandering detection units 90 are provided after the guide rolls 729, 729. One or more meandering detection units 90 can be disposed immediately after the longitudinal stretching machine 40 or between the longitudinal stretching machine 40 and the transverse stretching machine 50.

[0040] In the first embodiment described above, the use of a suction-type belt conveyor assists manual film transport and allows even thin films to be transported without buckling (particularly to the clip closer 501 shown in FIG. 7 ), allowing the clip closer to safely attach (chucking) the clip.

[0041] Second Embodiment <Overall Configuration of Film Manufacturing Apparatus> First, the overall configuration of a film manufacturing apparatus including a resin film conveying device according to a second embodiment will be described with reference to Fig. 3. Fig. 3 is a schematic perspective view showing the overall configuration of the film manufacturing apparatus according to the first embodiment. In Fig. 3, the same components as those in the first embodiment are designated by the same reference numerals as those in Fig. 1, and descriptions thereof will be omitted where appropriate.

[0042] The xyz Cartesian coordinate system shown in Figure 3 and other drawings is for the convenience of explaining the positional relationship of the components. Typically, the positive z-axis direction is vertically upward, and the xy plane is a horizontal plane, which is common to all drawings. In this specification, the film may be a resin film and may include a resin sheet.

[0043] As shown in Figure 3, the film production apparatus 1 includes an extruder 10, a T-die 20, a cooler 30, a longitudinal stretching machine 40, a feed mechanism 70, a transverse stretching machine 50, and a winder 60. The film production apparatus according to the first embodiment is an extrusion molding type film production apparatus that extrudes a film-like molten resin 82a from a gap between the lips of the T-die 20 connected to the extruder 10. Note that detailed portions of the robot mechanism 71 and the lower roll mechanism 72 are omitted from Figure 3.

[0044] The feeding mechanism 70 automatically feeds the resin film 83 discharged from the longitudinal stretching machine 40 to the subsequent transverse stretching machine 50. Until now, because the longitudinal stretching machine 40 and the transverse stretching machine 50 have different feeding mechanisms, manual work by multiple people was required to feed the resin film 83 discharged from the longitudinal stretching machine 40 to the subsequent transverse stretching machine 50. However, since this work is tedious and inefficient, the present disclosure provides a new film feeding mechanism 70 having the functions of sucking and gripping the film and feeding it. Details of this feeding mechanism 70 will be described later. The feeding mechanism 70 can be one form of a film transport device according to this embodiment. The feeding mechanism 70 has a belt conveyor 711, the surface of which is provided with a suction section 713 for sucking the film.

[0045] In the film transporting machine according to this embodiment, some or all of the cooling machine 30, the longitudinal stretching machine 40, the feed mechanism 70, the transverse stretching machine 50, and the winding machine 60 may be one aspect of the film transporting machine according to this embodiment.

[0046] <Overall Configuration of Feeding Mechanism> Fig. 4 is a schematic perspective view showing the configuration of the film feeding mechanism. As an example, the feeding mechanism 70 may be provided downstream of the longitudinal stretching machine 40 and upstream of the transverse stretching machine 50 in the film transport path.

[0047] The feed mechanism 70 includes a robot arm 715 having a belt conveyor 711 below its tip, and a lower roll platform 720 that is provided below the belt conveyor 711 and is capable of moving up and down and has multiple rolls UR. The lower roll platform 720 can be raised and lowered vertically by a lifting mechanism 725. In FIG. 4 , the lifting mechanism 725 includes three lifting units that can be raised and lowered synchronously. The lower roll platform 720 is normally in a retracted position (downward along the vertical arrow from the position in FIG. 4 ) to prevent contact with the film and damage to the film. It rises to the transport position ( FIG. 4 ) when the film is transported between the longitudinal stretching zone and the transverse stretching zone and when clips are attached (chucking). After chucking is complete, the lower roll platform 720 descends to the retracted position.

[0048] The robot arm 715 may be a six-axis vertical articulated robot arm. The robot arm 715 includes a base 7150 fixed to the floor, a first link 7151 rotatably and tiltably attached to the base 7150, a second link 7152 tiltably and tiltably attached to the tip of the first link 7151, and a wrist 7153 tiltably attached to the tip of the second link 7152. Various known robot arms may be used as the robot arm.

[0049] The belt conveyor 711 is connected to the tip of a robot arm 715 via a mounting part 712. The belt conveyor 711 includes a plurality of rolls 711R, 711R provided at both ends, and a belt 7111 wound around the plurality of rolls. The roll 711R is a roll with a built-in motor. Various known belt conveyors can also be used as the belt conveyor.

[0050] The surface of the belt conveyor 711 of the robot arm 715 is provided with a suction unit 713 that sucks the film. The suction unit 713 can suck the film by, for example, electrostatic force or negative pressure. The electrostatic suction unit 713 can be an electrode film laminated at predetermined intervals on the back surface of the belt. A charge supply unit can be provided slightly upstream in the direction of movement of the belt 7111, and this charge supply unit can apply a positive charge to the surface of the belt 7111 and a negative charge to the surface of the electrode film. In other embodiments, the belt 7311 can be porous or sponge. Visible holes can also be formed in the belt 7311. The negative pressure suction unit 713 can be a suction port. A pump can suck the film 83 from this suction port via a hose. Note that the configuration of the suction-type belt conveyor is not limited to these, and various known types can be used.

[0051] Furthermore, when a sensor detects that the film 83 being fed (for example, by a film feeder) has reached a sufficient contact area with the belt conveyor 711, the film feed may be stopped and the suction unit 713 may be activated to suck the film. In other words, the stopped film can be reliably sucked by the suction unit 713. After suction, the belt conveyor 711 may be driven to feed the film.

[0052] In this way, the belt conveyor 711 is a suction belt conveyor that can suck the film being conveyed while sending the film downstream. As a result, even if the belt conveyor 711 and the lower roll base 720 are not in parallel contact with each other and do not grip the thin film with a sufficient contact surface, the suction function and feeding function can prevent buckling and allow the film to be conveyed.

[0053] Guide rolls 729, 729 are provided to guide the film sent from the longitudinal stretching machine 40. Two meandering detection units 90 are provided after the guide rolls 729, 729. One or more meandering detection units 90 can be disposed immediately after the longitudinal stretching machine 40 or between the longitudinal stretching machine 40 and the transverse stretching machine 50.

[0054] <Overall Configuration of Feeding Mechanism> Fig. 5 is a schematic perspective view showing the configuration of the film feeding mechanism. As an example, the feeding mechanism 70 can be provided downstream of the longitudinal stretching machine 40 and upstream of the transverse stretching machine 50 in the film transport path.

[0055] The feeding mechanism 70 includes a robot arm 715 having a belt conveyor 711 below its tip, and a lower roll platform 720 that is provided below the belt conveyor 711 and has multiple rolls and can be raised and lowered. The lower roll platform 720 can be raised and lowered vertically by a lifting mechanism 725. In FIG. 5 , the lifting mechanism 725 includes three lifting units that can be raised and lowered synchronously. The lower roll platform 720 is normally located in a retracted position (downward along the vertical arrow from the position in FIG. 5 ) to prevent contact with the film and damage it. It rises to the conveying position ( FIG. 5 ) when the film is conveyed and chucked between the longitudinal stretching zone and the transverse stretching zone. The lower roll platform 720 includes multiple lower right rolls RUR and lower left rolls LUR arranged in two rows so that the film can be loaded and fed. The belt conveyor 711 shown in FIG. 5 is provided facing the lower left roll LUR, but it may also be provided facing the lower right roll RUR.

[0056] The robot arm 715 may be a six-axis vertical articulated robot arm. The robot arm 715 includes a base 7150 fixed to the floor, a first link 7151 rotatably and tiltably attached to the base 7150, a second link 7152 tiltably and tiltably attached to the tip of the first link 7151, and a wrist 7153 tiltably attached to the tip of the second link 7152. Various known robot arms may be used as the robot arm.

[0057] The belt conveyor 711 is connected to the tip of a robot arm 715 via a mounting part 712. The belt conveyor 711 includes a plurality of rolls 711R, 711R provided at both ends, and a belt 7111 wound around the plurality of rolls. The roll 711R is a roll with a built-in motor. Various known belt conveyors can also be used as the belt conveyor.

[0058] The surface of the belt conveyor 711 of the robot arm 715 is provided with one or more suction sections 713 that suck the film. The suction sections 713 can suck the film by, for example, electrostatic force or negative pressure. The electrostatic suction sections 713 can be electrode films laminated at predetermined intervals over the entire surface of the belt. A charge supply section can be provided slightly upstream in the direction of movement of the belt 7111, and this charge supply section can apply a positive charge to the surface of the belt 7111 and a negative charge to the surface of the electrode film. In other embodiments, the belt 7311 can be porous or sponge. Visible holes can also be formed in the belt 7311. The negative pressure suction section 713 can be one or more suction ports. A pump can suck the film 83 from these suction ports via a hose. Note that the configuration of the suction-type belt conveyor is not limited to these, and various known types can be used.

[0059] Furthermore, when a sensor detects that the film 83 being fed (for example, by a film feeder) has reached a sufficient contact area with the belt conveyor 711, the feed may be stopped, and the suction unit 713 may be activated to suck the film. In other words, the stopped film can be reliably sucked by the suction unit 713. After suction, the belt conveyor 711 may be driven to feed the film downstream.

[0060] In this way, the belt conveyor 711 is a suction-type belt conveyor that can suck the film being conveyed while sending the film downstream. This prevents buckling and allows the film to be conveyed even if the belt conveyor 711 and the lower roll table 720 cannot be perfectly parallel and the thin film is not gripped between them by a sufficient contact surface.

[0061] Guide rolls 729, 729 are provided to guide the film sent from the longitudinal stretching machine 40. Two meandering detection units 90 are provided after the guide rolls 729, 729. One or more meandering detection units 90 can be disposed immediately after the longitudinal stretching machine 40 or between the longitudinal stretching machine 40 and the transverse stretching machine 50.

[0062] <Operation of the Feed Mechanism> Figure 6 is a schematic perspective view showing the operation of the film feed mechanism. As shown in Figure 6, the feed mechanism 70 loads the film 83 fed from upstream by raising the lower roll platform 720 (from the retracted position to the conveying position). That is, the lower roll platform 720 is movable between the retracted position and the conveying position. Next, the robot arm 715 lowers its tip, thereby gripping the film 83 between the belt conveyor 711 and the lower roll platform 720 and sucking the film with the suction unit, and conveying the film 83 downstream by rotating the belt conveyor 711. That is, the belt conveyor 711 held by the robot arm 715 is movable between the retracted position and the conveying position (gripping position).

[0063] As shown in FIG. 3 , the film 83 fed from the longitudinal stretching machine 40 is fed along guide rolls 729, 729 provided at both ends of the path to above the lower roll platform 720 of the lower roller mechanism 72. When the fed film 83 is detected by a sensor (either from the longitudinal stretching machine 40 or manually), the lifting mechanism 725 is driven, and the lower roll platform 720 is raised from the retracted position to a predetermined position (conveying position), allowing the film 83 to be placed on the lower roll platform 720. The film 83 is moved downstream on the rolls of the lower roll platform 720 by the longitudinal stretching machine 40. The rolls on the lower roll platform 720 may include a plurality of lower right rolls RUR and a plurality of lower left rolls LUR arranged in two rows. Each roll may be a drive roll driven by a drive source (not shown), or a free roll without a drive source.

[0064] When a sensor detects that the film 83 has been fed to a predetermined position on the roll of the lower roll table 720 by the longitudinal stretching machine 40 (or the drive roll), the robot arm 715 lowers the belt conveyor 711 at its tip from the retracted position to the transport position (gripping position). Specifically, as shown in FIG. 6 , the belt conveyor 711 descends substantially parallel to the multiple lower left rolls LUR of the lower roll table 720 and grips the film 83 while it is moving. The suction unit 713 of the belt conveyor 711 is then activated to suck the film 83 onto the surface of the belt conveyor 711. The belt conveyor 711 drives the multiple rolls 711R, 711R while still sucking the film 83. The film 83, gripped by the belt 7111 and the multiple lower left rolls LUR and sucked by the suction unit, is sent downstream. In addition, if the multiple lower left rolls LUR have drive sources, the multiple lower left rolls LUR may rotate in synchronization with the multiple rolls 711R of the belt conveyor 711.

[0065] Figure 6 shows one robot mechanism 71 corresponding to the multiple lower left rolls LUR shown in Figure 5, but the operation of the lower roll table 720 and robot mechanism 71 shown in Figure 4 is similar, so detailed explanation will be omitted.

[0066] 5 and 6 show one robot mechanism 71 corresponding to multiple lower left rolls LUR, but another robot mechanism corresponding to multiple lower right rolls RUR may be provided. Alternatively, the robot mechanism 71 may have two branched second links 7152, 7152 corresponding to multiple lower right rolls RUR and multiple lower left rolls LUR, respectively. In some embodiments, the lower side of the robot arm may have a first conveyor corresponding to multiple left rolls and a second conveyor corresponding to multiple right rolls. In this case, the first conveyor and the second conveyor are each configured to be rotatable about a vertical axis.

[0067] As described above, wrinkles in the film can also be smoothed out by sending the film downstream while being held between the multiple lower right rolls RUR and the belt conveyor 711.

[0068] In some embodiments, a meandering detection unit 90 (e.g., various sensors such as a camera, laser sensor, edge sensor, etc.) may be provided above the lower roll base 720 to detect whether the film is meandering. For example, in FIG. 5 , the meandering detection unit 90 is an edge sensor that detects both ends of the film after the longitudinal stretching region. If the meandering of the film is detected by the meandering detection unit 90, the robot arm 715 may perform vertical axial rotation while pressing the belt conveyor 711 against the film 83 placed on the lower roll base 720 based on the detection result. For example, if the film is meandering to the left of the traveling direction, the robot arm 715 performs vertical axial rotation clockwise while pressing the belt conveyor 711 against the film 83 placed on the lower roll base 720. This allows the film meandering to be corrected, allowing the subsequent clip closer 501 ( FIG. 7 ) to properly close the clip and perform transverse stretching. The operation of the robot arm 715 is controlled by a control unit (not shown). The control unit receives sensor signals from various sensors such as the meandering detection unit 90, and controls various driving units related to the robot arm, etc., to operate based on the sensor signals. The control unit can execute various controls based on various programs stored in the storage unit, and is realized by a central processing unit (CPU), read-only memory (ROM), random access memory (RAM), input / output ports (I / O), etc.

[0069] 7 is a schematic perspective view showing a film feed mechanism and clip device according to another embodiment. Clip devices 500 are arranged at both ends of the film after the aforementioned feed mechanism 70. While only the clip device 500 for the left end of the film is shown in FIG. 7, the clip device 500 for the right end of the film can also be arranged in a substantially symmetrical manner.

[0070] As described above, the feed mechanism 70 uses the belt conveyor 711 and the lower roll table 720 to suck and grip the film while feeding it to the position of the clip closers 501. One clip closer 501 closes a clip on one end of the gripped film. Then, the other clip closer 501 closes a clip on the other end of the gripped film. This clip attachment operation is also called chucking. After the left and right clip closers 501, 501 close clips on both ends of the film, the film transporter can move the film downstream. In this way, the feed mechanism 70 can assist the clip closers in their clipping operation for transverse stretching. This reduces or eliminates manual work by multiple people, prevents human hands from getting caught in the clip closers, and enables safe and smooth chucking and transport of the film.

[0071] In some embodiments, a wrinkle detection unit 7121 (e.g., a camera) that detects wrinkles in the film 83 may be provided above the lower roll table 720 (e.g., below the mounting portion 712 of the robot arm 715). The wrinkle detection unit 7121 (e.g., a camera or edge sensor) may be provided in a location separate from the robot arm 715 (e.g., on the ceiling) between the longitudinal stretching machine 40 and the robot arm 715. Based on the captured image of the film, the robot arm 715 can also rotate around a vertical axis while pressing the belt conveyor 711 against the film 83 placed on the lower roll table 720, as shown in FIG. 8. This can remove localized wrinkles in the film. In another embodiment, the two suction-type belt conveyors 711, 711 can move widely to the left and right while holding down the film, as shown in FIG. 9, to remove wrinkles from the film. Note that suction of the film may be stopped during the above-described wrinkle removal operation. It is also possible to remove wrinkles from the film by leaving one of the two belt conveyors fixed near one edge of the film and moving only the other belt conveyor toward the other edge of the film. The operation of the robot arm 715 is controlled by a control unit (not shown). The control unit receives sensor signals from various sensors such as the wrinkle detection unit 7121, and can control the driving of various driving units related to the robot arm, etc., based on the sensor signals.

[0072] In some embodiments, in the film transport machine, the lower roll table includes a plurality of left rolls and a plurality of right rolls arranged left and right, and the underside of the robot arm has a first suction type conveyor corresponding to the plurality of left rolls and a second suction type conveyor corresponding to the plurality of right rolls, and the first suction type conveyor and the second suction type conveyor are each configured to be rotatable about a vertical axis.

[0073] In the above examples, the program includes instructions (or software code) that, when loaded into a computer, cause the computer to perform one or more functions described in the embodiments. The program may be stored on a non-transitory computer-readable medium or a tangible storage medium. By way of example and not limitation, computer-readable medium or tangible storage medium includes random-access memory (RAM), read-only memory (ROM), flash memory, solid-state drive (SSD) or other memory technology, CD-ROM, digital versatile disc (DVD), Blu-ray disc or other optical disk storage, magnetic cassette, magnetic tape, magnetic disk storage or other magnetic storage device. The program may also be transmitted on a transitory computer-readable medium or communication medium. By way of example and not limitation, transitory computer-readable medium or communication medium includes electrical, optical, acoustic, or other forms of propagated signals.

[0074] The invention made by the inventor has been specifically described above based on the embodiments, but it goes without saying that the present invention is not limited to the above-described embodiments and various modifications are possible within the scope of the present invention. For example, although a belt conveyor has been described in the above embodiment, a roll conveyor may also be used. From the viewpoint of smoothing out wrinkles in the film, it is more preferable to use a belt conveyor.

[0075] In some embodiments, a film transport method is provided in which a film is transported from upstream to downstream using a suction conveyor that is movable between a retracted position and a transport position, and the suction conveyor is moved to the transport position, and the film is sucked by the suction conveyor while the suction conveyor is driven to transport the film downstream.

[0076] In some embodiments, the film manufacturing apparatus includes an extruder that melts and extrudes an input resin raw material, a die connected to the extruder that forms the molten resin into a film, a cooling roll that cools the film-like molten resin extruded from the die and conveys a resin film in which the molten resin has solidified, a longitudinal stretching machine located downstream of the cooling roll that longitudinally stretches the film and sends it downstream, a feed mechanism including a suction conveyor that is movable between a retracted position and a transport position and that, at the transport position, sucks the film and sends it downstream, and a transverse stretching machine located downstream of the feed mechanism that transversely stretches the film and sends it downstream.

[0077] This application claims priority based on Japanese Patent Application No. 2024-117635, filed on July 23, 2024, the disclosure of which is incorporated herein in its entirety by reference.

[0078] 1 Film manufacturing apparatus 10 Extruder 11 Cylinder 13 Hopper 20 T-die 30 Cooling machine 40 Longitudinal stretching machine 50 Transverse stretching machine 60 Winding machine 70 Feeding mechanism 71 Robot mechanism 72 Lower roller mechanism 82a Molten resin 83 Film 90 Meandering detection unit 500 Clip device 501 Clip closer 711 Suction type belt conveyor 712 Mounting unit 713 Suction unit 715 Robot arm 720 Lower roll base 725 Lifting mechanism 729 Guide roll 730 Lower base 731 Suction type belt conveyor 733 Suction unit CR1 to CR4 Cooling rolls R1 to R11 Rolls RL1, RL2 Rail RUR Right lower roll LUR Left lower roll

Claims

1. A film transport device that transports a film from upstream to downstream, comprising a feed mechanism including a suction conveyor that is movable between a retracted position and a transport position, and that, at the transport position, sucks the film while transporting it downstream.

2. The film transport machine according to claim 1, wherein the suction conveyor is provided below the tip of a robot arm, and a lower roll table having a plurality of rolls is provided below the suction conveyor.

3. The film transporter according to claim 1, wherein the suction type conveyor transports the film while sucking it onto the surface of the suction type conveyor by negative pressure or electrostatic force.

4. The film transport machine described in claim 2, wherein the feeding mechanism is configured to place the film being fed from upstream on the lower roll table, and the robot arm lowers the tip to grip and suck the film between the suction conveyor and the lower roll table, while rotating the suction conveyor to transport the film downstream.

5. The film transport machine according to claim 1, wherein the suction type conveyor is mounted on a lower platform that can be raised and lowered between a retracted position and a transport position.

6. The film transport machine according to claim 1, further comprising: a longitudinal stretching machine provided in a longitudinal stretching region upstream of the feed mechanism, which stretches the film longitudinally while transporting it downstream; and a transverse stretching machine provided in a transverse stretching region downstream of the feed mechanism, which stretches the film transversely while transporting it downstream.

7. A film transport machine as described in claim 2, comprising: a wrinkle detection unit that detects wrinkles in the film; and the robot arm configured to rotate about a vertical axis while pressing the suction conveyor against the film placed on the lower roll table based on an image of the film.

8. A film transport machine as described in claim 2, wherein the robot arm is configured to move the suction conveyor toward the side edge of the film while pressing the suction conveyor against the film placed on the lower roll table based on an image of the film.

9. A film transport machine as described in claim 4, comprising a meandering detection unit that detects whether the film is meandering, and when said meandering is detected, said robot arm is configured to rotate about a vertical axis while pressing said suction conveyor against the film placed on said lower roll table based on the detection result.

10. The film transport machine according to claim 2, wherein the lower roll table is connected to a drive source and configured so that the plurality of rolls rotate in synchronization with the rotation of the suction conveyor.

11. A film transport machine as described in claim 2, wherein the lower roll table includes a plurality of left rolls and a plurality of right rolls arranged left and right, and the underside of the robot arm has a first suction type conveyor corresponding to the plurality of left rolls and a second suction type conveyor corresponding to the plurality of right rolls, and the first suction type conveyor and second suction type conveyor are each configured to be rotatable about a vertical axis.

12. A film transport method for transporting a film from upstream to downstream using a suction conveyor that is movable between a retracted position and a transport position, wherein the suction conveyor is moved to the transport position, and the film is transported downstream by driving the suction conveyor while sucking the film with the suction conveyor.

13. A film manufacturing apparatus comprising: an extruder that melts and extrudes an input resin raw material; a die connected to the extruder that forms the molten resin into a film; a cooling roll that cools the molten resin film extruded from the die and carries out a resin film formed by solidifying the molten resin; a longitudinal stretching machine that is located downstream of the cooling roll and longitudinally stretches the film while sending it downstream; a feed mechanism that includes a suction conveyor that is movable between a retracted position and a transport position and that, at the transport position, sucks the film while sending it downstream; and a transverse stretching machine that is located downstream of the feed mechanism and transversely stretches the film while sending it downstream.

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