Method and apparatus for manufacturing film structure

Patent metadata

Field	Value
Publication number	US-11518081-B2
Application number	US-202016792620-A
Country	US
Kind code	B2
Filing date	Feb 17, 2020
Priority date	Mar 11, 2019
Publication date	Dec 6, 2022
Grant date	Dec 6, 2022

Abstract

A method for manufacturing a film structure includes: a positional deviation amount detection process of detecting an amount of positional deviation related to a relative position of a second cured film formed on a rear surface of a film with respect to a first cured film formed on a front surface of the film; a relative position adjustment process of correcting a position or a rotation speed of a second transfer roll to adjust the relative position such that the amount of positional deviation detected in the positional deviation amount detection process is reduced; a first tensile force detection process and a second tensile force detection process of respectively detecting a tensile force of the film between a first pressurizing roll and a second pressurizing roll before and after the relative position adjustment process; and a tensile force adjustment process of adjusting the tensile force of the film such that the tensile force of the film detected in the second tensile force detection process approaches the tensile force of the film detected in the first tensile force detection process.

First claim

What is claimed is:

1. A method for manufacturing a film structure obtained by transferring a transfer material to both surfaces of a successively traveling film and curing the transfer material, the method comprising:
a first application process of applying the transfer material containing an ultraviolet curable resin to a front surface of the film;
a first curing process of pressurizing the front surface of the film against a first transfer roll with a first pressurizing roll and curing the transfer material applied to the front surface of the film with ultraviolet rays, thereby forming a first cured film;
a second application process of applying the transfer material containing an ultraviolet curable resin to a rear surface of the film;
a second curing process of pressurizing the rear surface of the film against a second transfer roll with a second pressurizing roll and curing the transfer material applied to the rear surface of the film with ultraviolet rays, thereby forming a second cured film;
a positional deviation amount detection process of detecting an amount of positional deviation related to a relative position of the second cured film with respect to the first cured film;
a relative position adjustment process of correcting a position or a rotation speed of the second transfer roll to adjust the relative position such that the amount of positional deviation detected in the positional deviation amount detection process is reduced;
a first tensile force detection process and a second tensile force detection process of respectively detecting a tensile force of the film between the first pressurizing roll and the second pressurizing roll before and after the relative position adjustment process; and
a tensile force adjustment process of adjusting the tensile force of the film such that the tensile force of the film detected in the second tensile force detection process approaches the tensile force of the film detected in the first tensile force detection process.

2. The method for manufacturing a film structure according to claim 1 ,
wherein the amount of positional deviation in a traveling direction of the film is reduced by correcting the rotation speed of the second transfer roll in the relative position adjustment process.

3. The method for manufacturing a film structure according to claim 2 ,
wherein the rotation speeds of the first transfer roll and the second transfer roll are synchronized, and
in the relative position adjustment process, the amount of positional deviation in the traveling direction of the film is reduced by correcting the rotation speed of the second transfer roll in a state in which the synchronization of the rotation speeds of the first transfer roll and the second transfer roll is released when the rotation speed of the second transfer roll is corrected.

4. The method for manufacturing a film structure according to claim 1 ,
wherein the amount of positional deviation is reduced by correcting the position of the second transfer roll in the relative position adjustment process.

5. The method for manufacturing a film structure according to claim 4 ,
wherein the amount of positional deviation in a width direction of the film is reduced by correcting the position of the second transfer roll in the width direction in the relative position adjustment process.

6. The method for manufacturing a film structure according to claim 4 ,
wherein the amount of positional deviation in the traveling direction of the film is reduced by correcting the position of the second transfer roll in a height direction and causing an outer circumferential surface of the second transfer roll to slip in the height direction relative to the transfer material applied to the rear surface of the film in the relative position adjustment process.

7. The method for manufacturing a film structure according to claim 1 ,
wherein the amount of positional deviation is reduced by causing an outer circumferential surface of the second transfer roll to slip above the transfer material applied to the rear surface of the film in the relative position adjustment process.

8. An apparatus for manufacturing a film structure obtained by transferring a transfer material to both surfaces of a successively traveling film and curing the transfer material, the apparatus comprising:
a first application unit and a second application unit that respectively apply the transfer material containing an ultraviolet curable resin to the film;
a first transfer roll and a second transfer roll that respectively have transfer shapes on front surfaces thereof;
a first pressurizing roll that pressurizes the transfer material applied to a front surface of the film by the first application unit against the first transfer roll;
a first curing section that cures the transfer material pressurized by the first pressurizing roll with ultraviolet rays, thereby forming a first cured film;
a second pressurizing roll that pressurizes the transfer material applied to a rear surface of the film by the second application unit against the second transfer roll;
a second curing section that cures the transfer material pressurized by the second pressurizing roll with ultraviolet rays, thereby forming a second cured film;
a positional deviation amount detection mechanism that detects an amount of positional deviation related to a relative position of the second cured film with respect to the first cured film;
a correction mechanism that corrects a position or a rotation speed of the second transfer roll;
a tensile force detection mechanism that detects a tensile force of the film between the first pressurizing roll and the second pressurizing roll;
a tensile force adjustment mechanism that adjusts the tensile force of the film; and
a control unit that controls the correction mechanism such that the amount of positional deviation is reduced and controls the tensile force adjustment mechanism such that the tensile force of the film detected by the tensile force detection mechanism after the correction performed by the correction mechanism approaches the tensile force of the film detected by the tensile force detection mechanism before the correction.

9. The apparatus for manufacturing a film structure according to claim 8 ,
wherein the correction mechanism corrects the rotation speed of the second transfer roll.

10. The apparatus for manufacturing a film structure according to claim 9 ,
wherein the control unit causes rotation speeds of the first transfer roll and the second transfer roll to be synchronized and releases the synchronization of the rotation speeds of the first transfer roll and the second transfer roll when the rotation speed of the second transfer roll is corrected.

11. The apparatus for manufacturing a film structure according to claim 8 ,
wherein the correction mechanism corrects the position of the second transfer roll.

12. The apparatus for manufacturing a film structure according to claim 11 ,
wherein the correction mechanism corrects the position of the second transfer roll in a width direction.

13. The apparatus for manufacturing a film structure according to claim 11 ,
wherein the correction mechanism causes an outer circumferential surface of the second transfer roll to slip in a height direction relative to the transfer material applied to the rear surface of the film by correcting the position of the second transfer roll in the height direction.

14. An apparatus for manufacturing a film structure obtained by transferring a transfer material to both surfaces of a successively traveling film and curing the transfer material, the

Assignees

• Panasonic Ip Man Co Ltd

Inventors

• Kamatani Junichi
• Yamamoto Yuji
• Kamikihara Nobuyuki

Classifications

• B29C2035/0827

  using UV radiation · CPC title

• B29C35/10

  for articles of indefinite length · CPC title

• B32B27/26

  using curing agents · CPC title

• B29C59/04 Primary

  using rollers or endless belts · CPC title

• B29C69/02 Primary

  of moulding techniques only · CPC title