U.S. patent application number 12/443223 was filed with the patent office on 2010-06-24 for automatic film winding device, sliting and winding system, and method of producing rolled film.
Invention is credited to Kei Arimitsu, Toshio Ishikawa, Kenji Ogawa.
Application Number | 20100155522 12/443223 |
Document ID | / |
Family ID | 39313793 |
Filed Date | 2010-06-24 |
United States Patent
Application |
20100155522 |
Kind Code |
A1 |
Arimitsu; Kei ; et
al. |
June 24, 2010 |
AUTOMATIC FILM WINDING DEVICE, SLITING AND WINDING SYSTEM, AND
METHOD OF PRODUCING ROLLED FILM
Abstract
To provide an automatic film winding apparatus, a slit winding
system and a method for producing a rolled film which can improve
winding quality, is reduced in size and enables winding mechanisms
to be arranged in multiple stages. The automatic film winding
apparatus includes winding shafts 21 and 22 for winding a film
around a winding core 12, a turret 20 for pivotably supporting the
winding shafts 21 and 22 in a rotatable manner, a touch roller 23
which presses the film to the winding shaft 22 when a predetermined
amount of the film is wound by the winding shaft 21, and the turret
20 is rotated by a predetermined angle to allow the film to be hung
on the winding shaft 22, a cutter 241 which cuts the film between
the winding shaft 21 and the winding shaft 22, and a film affixing
roller 25 which presses the film which has been cut to the winding
shaft 22, and moves to the front end of the film while winding the
film around the winding core 12 with the film being pressed.
Inventors: |
Arimitsu; Kei; (Ibaraki,
JP) ; Ishikawa; Toshio; (Ibaraki, JP) ; Ogawa;
Kenji; (Ibaraki, JP) |
Correspondence
Address: |
ANTONELLI, TERRY, STOUT & KRAUS, LLP
1300 NORTH SEVENTEENTH STREET, SUITE 1800
ARLINGTON
VA
22209-3873
US
|
Family ID: |
39313793 |
Appl. No.: |
12/443223 |
Filed: |
September 27, 2007 |
PCT Filed: |
September 27, 2007 |
PCT NO: |
PCT/JP2007/068770 |
371 Date: |
March 5, 2010 |
Current U.S.
Class: |
242/412 ;
242/525; 242/526; 242/527 |
Current CPC
Class: |
B65H 2404/5391 20130101;
B65H 2404/43 20130101; B65H 19/2215 20130101; B65H 23/048 20130101;
B65H 2301/41486 20130101; B65H 35/02 20130101; B65H 2301/4148
20130101; B65H 2301/41425 20130101; B65H 2404/539 20130101; B65H
2408/231 20130101; B65H 2301/41487 20130101; B65H 2301/414222
20130101; B65H 19/28 20130101; B65H 2701/1752 20130101; B65H
2408/23152 20130101; B65H 19/26 20130101; B65H 19/305 20130101;
B65H 2301/41829 20130101 |
Class at
Publication: |
242/412 ;
242/526; 242/527; 242/525 |
International
Class: |
B65H 19/26 20060101
B65H019/26; B65H 18/08 20060101 B65H018/08; B65H 23/195 20060101
B65H023/195; B65H 35/02 20060101 B65H035/02; B65H 19/28 20060101
B65H019/28; B65H 35/06 20060101 B65H035/06 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 29, 2006 |
JP |
2006-267303 |
May 24, 2007 |
JP |
2007-137660 |
Claims
1. (canceled)
2. (canceled)
3. An automatic film winding apparatus comprising two or more
winding shafts for winding a film around a winding core, a turret
which moves the two or more winding shafts to a film winding
position and a waiting position, and a cutter for cutting the film,
which further comprises: a touch roller which presses the film to
the winding core of a second winding shaft of the two or more
winding shafts when a predetermined amount of the film is wound by
a first winding shaft at the film winding position of the two or
more winding shafts, the turret is rotated by a predetermined angle
and, the film is hung on the winding core of the second winding
shaft of the two or more winding shafts which has moved to the film
winding position; the cutter which cuts, between the first winding
shaft and the second winding shaft, the film which has been pressed
to the winding core of the second winding shaft by the touch
roller; and a film affixing roller which presses the film which has
been cut to the winding core of the second winding shaft at a
position on the downstream side of the touch roller and moves to
the front end of the film which has been cut while winding the film
with the film being pressed.
4. The automatic film winding apparatus according to claim 3, which
is capable of removing the rolled film from the first winding shaft
which is at the waiting position and setting the winding core to
the first winding shaft while winding a film by the second winding
shaft.
5. The automatic film winding apparatus according to claim 3,
further comprising two or more winding mechanisms which have the
touch roller and the film affixing roller.
6. The automatic film winding apparatus according to claim 3,
wherein the touch roller has arms for a touch roller which
rotatably support the touch roller, the cutter has a pair of arms
for a cutter which rotatably supports the cutter, the film affixing
roller has a pair of arms for a film affixing roller which
rotatably supports the film affixing roller, the pair of arms for a
film affixing roller are located between the pair of arms for the
cutter, and the two or more arms for a touch roller are located
between the pair of arms for a film affixing roller.
7. The automatic film winding apparatus according to claim 3,
further comprising an air bleeding mechanism.
8. The automatic film winding apparatus according to claim 7,
wherein the air bleeding mechanism is a touch roller.
9. The automatic film winding apparatus according to claim 3,
further comprising a film carrier roller for supplying the film to
the winding shaft.
10. The automatic film winding apparatus according to claim 9,
further comprising a holding means which holds the film by pressing
the film to the film carrier roller.
11. The automatic film winding apparatus according to claim 10,
wherein the holding means is a nip bar for pressing the film to the
film carrier roller.
12. The automatic film winding apparatus according to claim 9,
wherein the angle of the contact surface of the film carrier roller
and the film (film holding angle) is 90 to 160.degree..
13. The automatic film winding apparatus according to claim 9,
wherein the film contact surface of the film carrier roller is
composed of a porous material or a slightly adhesive material.
14. The automatic film winding apparatus according to claim 3,
further comprising a winding core positioning mechanism for
positioning the winding core in the width direction of the
film.
15. The automatic film winding apparatus according to claim 14,
wherein the winding core positioning mechanism is provided with a
bar material mounted such that it can move freely between the
positioning position and the waiting position and a stopper mounted
on the bar material such that it can move freely.
16. The automatic film winding apparatus according to claim 3,
wherein the winding shaft has a film tension control system.
17. The automatic film winding apparatus according to claim 16,
wherein the winding shaft is a friction shaft which functions as
the film tension control system and the winding shaft is rotated in
the winding direction with such a torque that enables the winding
core to slide against the film which has been pressed by the touch
roller in the state where the film affixing roller is pressing the
front end of the film.
18. The automatic film winding apparatus according to claim 3,
wherein the cutter is provided with a guide member and a cutting
blade which moves along the guide member, and the film which is
imparted with tension by the abutment of the guide member is cut by
the cutting blade.
19. The automatic film winding apparatus according to claim 3,
further comprising a retaining mechanism which retains the film
which has been wound around the winding core by the film affixing
roller to the surface of the winding core.
20. The automatic film winding apparatus according to claim 3,
wherein the film affixing roller is provided with a rotating shaft
which is rotatably provided, a pair of arms provided such that they
oppose to the rotating shaft, a pair of urging arms which are
respectively connected rotatably to the front end of each of the
pair of arms and urged in the direction of the rotating shaft, and
a roller which is pivotably installed on the front end of each of
the pair of urging arms in a rotatable manner.
21. A slit winding system comprising: a slitter which cuts a film
into a predetermined width; and the automatic film winding
apparatus according to claim 3 for winding the film which has been
supplied from the slitter.
22. The slit winding system according to claim 21, wherein at least
one of the slitter and the automatic winding apparatus is movably
provided.
23. (canceled)
24. A method for producing a rolled film in which a film is wound
around a plurality of winding shafts by turns, comprising: a step
in which a first winding shaft stops rotating when a predetermined
amount of the film is wound around a winding core of a first
winding shaft; a step in which a turret holding the plurality of
winding shafts rotates by a predetermined angle, allowing the film
to be hung on the winding core of a second winding shaft, with the
film being held by a carrier roller; a step in which the touch
roller presses the film to the winding core of the second winding
shaft, and the cutter cuts the film between the first winding shaft
and the second winding shaft; a step in which the film affixing
roller presses the film to the winding core of the second winding
shaft at a position on the downstream side of the touch roller; and
a step in which the film affixing roller moves to the front end of
the film with the film being pressed.
25. The method for producing a would film according to claim 24,
further comprising a step in which the second winding shaft formed
of a friction shaft rotates in the winding direction with a torque
sufficient to remove slackening of the film which has been pressed
by the touch roller in the state where the film affixing roller is
pressing the front end of the film.
26. The method for producing a rolled film according to claim 24,
comprising: a step in which the touch roller and the film affixing
roller stop pressing the film when the carrier roller stops holding
the film, the second winding shafts rotates in the winding
direction at a predetermined winding up torque, the film is wound
around the winding core of the second winding shaft, and the front
end of the film approaches an overlapping position, and a step in
which the touch roller presses the film to the winding core of the
second winding shaft and the second winding shaft rotates in the
winding direction at a predetermined torque when the front end of
the film passes the overlapping position.
Description
TECHNICAL FIELD
[0001] The invention relates to an automatic film winding
apparatus, a slit winding system, and a method for producing a
rolled film. According to the automatic film winding apparatus, the
slit winding system, and the method for producing a rolled film, it
is possible to wind around a winding core, automatically or
semi-automatically, a film which has been multiply slitted by a
slitter or the like or a single wide film.
BACKGROUND ART
[0002] A plurality of films obtained by subjecting a long film to
multiple slitting or a wide single film is wound around a winding
core in a specified product length. In this case, in addition to
the winding operation by means of an apparatus, additional
operations are required. Examples of such additional operations
include a lot of troublesome tasks such as installation of a
winding core to a winding shaft, winding, cutting after the winding
and removal of a rolled film from the winding shaft. Manual
operation of these complicated works takes a prolonged period of
time, and makes winding at an accurate position difficult. In
addition, if a film winding apparatus does not have a turret
mechanism, the above-mentioned additional tasks are performed while
the winding apparatus is in the idling state. Under such
circumstances, various turret-type automatic film winding
apparatuses have heretofore been proposed to allow the additional
tasks to be performed quickly and accurately.
[0003] For example, Patent Document 1 discloses a turret-type
automatic film cutting and winding apparatus. This automatic
cutting and winding apparatus is provided with an electrostatic
charge-imparting means, a cutter (saw blade) and a pair of pressing
means which enter the front and back of the cutter.
[0004] Patent Document 2 discloses a technology of an end-free
winding apparatus for sheets. This end-free winding apparatus is
provided with an endless belt, a pressing roller, and a front guide
part or the like.
[0005] Furthermore, Patent Document 3 discloses a technology of a
turret winding apparatus. This turret winding apparatus has a
plurality of winding shafts with a cantilever structure and a fixed
beam. The fixing and supporting member of this fixed beam supports
the winding shaft at the winding operation position, thus allowing
this turret winding apparatus to have an inboard structure.
[0006] Patent Document 1: JP-A-S62-215452
[0007] Patent Document 2: JP-A-H09-104550
[0008] Patent Document 3: JP-A-2001-97616
DISCLOSURE OF THE INVENTION
Problems to be Solved by the Invention
[0009] However, the technology using a saw blade as disclosed in
Patent Document 1 has a problem that the cut surface cannot be
linear. In addition, when cross cutting is performed by using a
cutter such as a razor, the cutter is normally moved only in the
film width direction. This cutting method has a problem that a film
is cut curvedly at a position where the cutting blade is entered or
removed.
[0010] In the technology disclosed in Patent Document 2, a belt or
a plurality of rollers are used. By using them, a film which has
once become in the free state is caught between a core (winding
core) and a belt. Therefore, unless the position of the film in the
free state is stable, a problem arises in which the film of the
first layer tends to shift during film winding.
[0011] In the technology disclosed in Patent Document 3, although
productivity increases due to the off-line set up, the apparatus is
disadvantageous for the complicated structure thereof. In addition,
further improvement of operability is required for automation.
[0012] That is, in the field of the automatic film winding
apparatus, there is an increasing demand for realizing a reliable
winding technology by further improving winding quality and
reasonably solving the disadvantages associated with the
apparatus.
[0013] In addition, if various functions are added to improve
quality or productivity, a problem arises that an apparatus
increases in size.
[0014] Furthermore, in order to efficiently wind a plurality of
films which are obtained by multiply slitting by means of a
slitter, it is required to provide a turret-type winding mechanism
in multiple stages. Realizing a multiple-stage mechanism is
difficult for an increased apparatus size or for other reasons.
[0015] For manufactures of an apparatus, it is required to further
improve productivity, operability or the like of the automatic film
winding apparatus, thereby enhancing the added value of the
apparatus.
[0016] In view of the above-mentioned problems in conventional
technologies, the object of the invention is to further improve
winding quality and establish a highly reliable winding technology
by reasonably solving the disadvantages associated with the
conventional technologies, as well as to provide an automatic film
winding apparatus and a slitting and winding system which can be
reduced in size and arranged in multiple stages, and a method for
producing a rolled film.
Means for Solving the Problem
[0017] To solve the above-mentioned problem, the automatic film
winding apparatus of the invention comprises:
[0018] a winding shaft for winding a film around a winding
core;
[0019] a touch roller for pressing the film which has been hung on
the winding core to the winding core; and
[0020] a film affixing roller which presses the film to the winding
core at a position on the downstream side of the touch roller, and
moves to the front end of the film while winding the film with the
film being pressed.
[0021] By this configuration, the film is effectively prevented
from being slackened between the position of pressing by means of
the touch roller and the front end of the film. As a result, the
film can be wound with the film being closely adhered to the
predetermined position of the winding core, whereby the winding
quality is significantly improved.
[0022] Meanwhile, the above configuration can be applied to various
automatic film winding apparatuses.
[0023] It is preferred that the automatic film winding apparatus
have a cutter for cutting the film.
[0024] Furthermore, the automatic film winding apparatus of the
invention comprises two or more winding shafts for winding a film
around a winding core, a turret which moves the two or more winding
shafts to a film winding position and a waiting position, and a
cutter for cutting the film, which further comprises:
[0025] a touch roller which presses the film to the winding core of
a second winding shaft of the two or more winding shafts when a
predetermined amount of the film is wound by a first winding shaft
at the film winding position of the two or more winding shafts, the
turret is rotated by a predetermined angle and, the film is hung on
the winding core of the second winding shaft of the two or more
winding shafts which has moved to the film winding position;
[0026] the cutter which cuts, between the first winding shaft and
the second winding shaft, the film which has been pressed by the
touch roller; and
[0027] a film affixing roller which presses the film which has been
cut to the winding core of the second winding shaft at a position
on the downstream side of the touch roller, and moves to the front
end of the film which has been cut while winding the film with the
film being pressed.
[0028] By this configuration, the film is effectively prevented
from being slackened between the position of pressing by means of
the touch roller and the front end of the film. As a result, the
film can be wound in the state where it is closely adhered to the
predetermined position of the winding core, whereby the winding
quality is significantly improved.
[0029] In the invention, the "front end" means not only the front
end surface of the film which has been cut but also the area
including the vicinity of the front end surface.
[0030] In the invention, the "winding quality" means a disadvantage
that the winding start position (front end portion) is shifted in
the direction to the shaft core of the winding shaft (hereinafter
appropriately referred to as the "bad start"), wrinkles in the film
or folded film corners and the like which occur during film
winding.
[0031] Further, it is preferred that the automatic film winding
apparatus be capable of removing the rolled film from the first
winding shaft which is at the waiting position and setting the
winding core to the first winding shaft while winding a film by the
second winding shaft.
[0032] Due to such a configuration, removal of the rolled film or
installation of a new winding core can be performed during film
winding operation. As a result, operation rate of the apparatus can
be improved.
[0033] Further, it is preferred that the automatic winding
apparatus comprise two or more winding mechanisms which have the
touch roller and the film affixing roller.
[0034] Due to such a configuration, production capacity can be
enhanced effectively, and adaptation to various specifications
becomes possible. As a result, the additional value of the
apparatus can be improved.
[0035] Normally, the winding mechanisms are respectively provided
with a cutter, but the configuration is not limited thereto. For
example, a configuration in which a plurality of winding mechanisms
shares a common cutter may be possible.
[0036] In addition, each winding mechanism normally has a turret.
However, the configuration is not limited thereto.
[0037] Further, it is preferred that the automatic film winding
apparatus have a configuration in which the touch roller has arms
for a touch roller which rotatably support the touch roller, the
cutter has a pair of arms for a cutter which rotatably supports the
cutter, the film affixing roller has a pair of arms for a film
affixing roller which rotatably supports the film affixing roller,
the pair of arms for a film affixing roller are located between the
pair of arms for the cutter, and the two or more arms for a touch
roller are located between the pair of arms for a film affixing
roller.
[0038] Due to such a configuration, the apparatus can have a
reduced size since the arms do not interfere with each other.
[0039] It is preferred that the apparatus have an air bleeding
mechanism.
[0040] Due to such a configuration, a disadvantage that air enters
between the films can be prevented. As a result, the apparatus can
be reduced in size.
[0041] It is preferred that the air bleeding mechanism be a touch
roller.
[0042] Due to such a configuration, since the touch roller also
functions as the air bleeding mechanism, separate provision of an
air bleeding mechanism will be unnecessary.
[0043] It is preferred that the automatic film winding apparatus
have a film carrier roller for supplying the film to the winding
shaft.
[0044] Due to such a configuration, the film can be carried
smoothly.
[0045] Furthermore, it is preferred that the automatic film winding
apparatus have a holding means which holds the film by pressing the
film to the film carrier roller.
[0046] Due to such a configuration, occurrence of any further bad
starts can be suppressed reliably.
[0047] It is preferred that the holding means be a nip bar for
pressing the film to the film carrier roller.
[0048] Due to such a configuration, the film can be held reliably
and the apparatus can have a simple structure.
[0049] It is preferred that the angle of the contact surface of the
film carrier roller and the film (film holding angle) be 90.degree.
to 160.degree..
[0050] Due to such a configuration, the film carrier roller can be
rotated smoothly with the film.
[0051] It is preferred that the film contact surface of the film
carrier roller be formed of a porous material or a slightly
adhesive material.
[0052] Due to such a configuration, it is possible to eliminate
weaving at the end surface of a wound product which is caused by
the shift of the film in the lateral direction.
[0053] It is preferred that the automatic film winding apparatus be
provided with a winding core positioning mechanism for positioning
the winding core in the width direction of the film.
[0054] Due to such a configuration, it is possible to perform
positioning of the winding core accurately within a short period of
time. As a result, productivity or quality (center winding
accuracy) can be improved.
[0055] The "center winding accuracy" means the degree of
coincidence of the center of the winding core in the central axis
direction thereof and the center of the widthwise direction of the
rolled film.
[0056] It is preferred that the winding core positioning mechanism
be provided with a bar material mounted such that it can move
freely between the positioning position and the waiting position
and a stopper movably mounted on the bar material.
[0057] Due to such a configuration, the automatic winding apparatus
can be operated easily and can have a simple structure.
[0058] It is preferred that the automatic winding apparatus have a
film tension control system.
[0059] Due to such a configuration, the tension of the film can be
adjusted easily.
[0060] Furthermore, in the film tension control system, it is
preferred that the winding shaft be a friction shaft and that the
winding shaft be rotated in the winding direction with such a
torque that enables the winding core to slide against the film
which is pressed by the touch roller in the state where the film
affixing roller is pressing the front end of the film.
[0061] Due to such a configuration, if a slight degree of film
slackening remains between the touch roller and the film affixing
roller, the slackening can be eliminated. As a result, the winding
quality can be further improved.
[0062] Furthermore, it is preferred that the cutter be provided
with a guide member and a cutting blade which moves along the guide
member and that the film which has been imparted with tension by
the abutment of the guide member be cut by the cutting blade.
[0063] Due to such a configuration, a disadvantage that the film is
cut curvedly at the side where the cutting blade is entered or
removed can be eliminated, and linear cutting can be realized. In
addition, a trouble such as adherence of resist chips can be
eliminated.
[0064] It is preferred that the automatic film winding apparatus be
provided with a retaining mechanism which retains the film which
has been wound around the winding core by the film affixing roller
to the surface of the winding core.
[0065] Due to such a configuration, a trouble that the front end of
the film peels off from the surface of the winding core before the
films overlap one on another can be avoided reliably.
[0066] The retaining means include adsorption by static
electricity, air spraying, adhesion by a double coated adhesive
tape, an adhesive or the like.
[0067] It is preferred that the film affixing roller be provided
with a rotating shaft which is rotatably provided, a pair of arms
provided such that they oppose to the rotating shaft, a pair of
urging arms which are respectively connected rotatably to the front
end of the pair of arms and urged in the direction of the rotating
shaft, and a roller which is pivotably installed on the front end
of the pair of urging arms in a rotatable manner.
[0068] Due to such a configuration, the apparatus can be reduced in
size and can have a simple structure.
[0069] In order to attain the object of the invention, the slit
winding system of the invention is provided with a slitter which
cuts a film into a predetermined width and the automatic film
winding apparatus according to any one of the above-mentioned
claims 1 to 20 for winding up the film which has been supplied from
the slitter.
[0070] As mentioned above, the invention is effective as the slit
winding system, and can improve both quality and productivity.
[0071] It is preferred that at least one of the slitter and the
automatic winding apparatus be movably provided.
[0072] Due to such a configuration, for example, during
maintenance, the automatic film winding apparatus can be moved
easily. In addition, during production, it is possible to shorten
the distance between the slitter and the automatic film winding
apparatus. Due to the reduction in distance, the carrying span is
reduced, thus eliminating defects such as step-like irregularities
of a rolled film.
[0073] In the invention, the "step-like irregularities" means
unevenness on the end surface of a rolled film in the form of steps
or convexes and concaves.
[0074] In order to attain the above-mentioned object, the method
for producing a rolled film of the invention, in which a film is
wound around a winding shaft, comprises:
[0075] a step in which the film is hung on a winding core of the
winding shaft;
[0076] a step in which a touch roller presses the film to the
winding core of the winding shaft; and
[0077] a step in which a film affixing roller presses the film to
the winding core at a position on the downstream side of the touch
roller, and moves to the front end of the film while winding the
film with the film being pressed.
[0078] As mentioned above, the invention is advantageous as a
method for producing a rolled film, and slackening of a film
between the pressing position by a touch roller and the front end
of the film can be effectively prevented. Due to such a
configuration, winding can be performed with the film being closely
adhered to a predetermined position of the winding core. As a
result, winding quality can be significantly improved.
[0079] In order to attain the above-mentioned object, the method
for producing a rolled film of the invention, in which a film is
wound around a plurality of winding shafts by turns, comprises:
[0080] a step in which a first winding shaft stops rotating when a
predetermined amount of the film is wound around the winding core
of a first winding shaft;
[0081] a step in which a turret holding the plurality of winding
shafts rotates by a predetermined angle, allowing the film to be
hung on the winding core of a second winding shaft, with the film
being held by a carrier roller;
[0082] a step in which the touch roller presses the film to the
winding core of the second winding shaft, and the cutter cuts the
film between the first winding shaft and the second winding
shaft;
[0083] a step in which the film affixing roller presses the film to
the winding core of the second winding shaft at a position on the
downstream side of the touch roller; and
[0084] a step in which the film affixing roller moves to the front
end of the film with the film being pressed.
[0085] As mentioned above, the invention is advantageous as a
method for producing a rolled film, and slackening of a film
between the pressing position by a touch roller and the front end
of the film can be effectively prevented. Due to such a
configuration, winding can be performed with the film being closely
adhered to a predetermined position of the film. As a result,
winding quality can be significantly improved.
[0086] It is further preferred that the second winding shaft formed
of a friction shaft rotate in the winding direction with a torque
sufficient to remove slackening of the film which has been pressed
by the touch roller in the state where the film affixing roller is
pressing the front end of the film.
[0087] Provision of this step leads to further improvement in
quality.
[0088] Further, it is preferred that the method for producing a
rolled film of the invention be provided with a step in which the
touch roller and the film affixing roller stop pressing the film
when the carrier roller stops holding the film, the second winding
shafts rotates in the winding direction at a predetermined winding
torque, the film is wound around the winding core of the second
winding shaft, and the front end of the film approaches an
overlapping position, and
[0089] a step in which the touch roller presses the film to the
winding core of the second winding shaft and the second winding
shaft rotates in the winding direction at a predetermined winding
up torque when the front end of the film passes the overlapping
position.
[0090] Due to the provision of this step, occurrence of a
disadvantage such as a bad start can be prevented more
reliably.
[0091] As mentioned above, according to the automatic film winding
apparatus, the slit winding system and the method for producing a
rolled film of the invention, not only the winding quality can be
improved but also the apparatus can be reduced in size and can be
arranged in multiple stages.
BRIEF DESCRIPTION OF THE DRAWINGS
[0092] FIG. 1 is a schematic cross sectional view of a slit winding
system according to one embodiment of the invention as viewed from
the lateral direction;
[0093] FIG. 2 is a schematic front view of an automatic film
winding apparatus according to one embodiment of the invention;
[0094] FIG. 3 is a schematic view of a film affixing roller of an
automatic film winding apparatus according to one embodiment of the
invention, in which (a) is a front view and (b) is a
cross-sectional view taken along the line A-A;
[0095] FIG. 4 is a schematic view of a touch roller of an automatic
film winding apparatus according to one embodiment of the
invention, in which (a) is a front view and (b) is a
cross-sectional view taken along the line B-B;
[0096] FIG. 5 is a schematic view of a cutter provided with a guide
of the automatic film winding apparatus according to one embodiment
of the invention, in which (a) is a front view and (b) is a
cross-sectional view taken along the line C-C;
[0097] FIG. 6 is a schematic view of a winding core positioning
means of the automatic film winding apparatus according to one
embodiment of the invention, in which (a) is a front view and (b)
is a cross-sectional view taken along the line D-D;
[0098] FIG. 7 is a schematic enlarged cross sectional view of the
film carrier roller in the automatic film winding apparatus
according to one embodiment of the invention for explaining the
holding angle;
[0099] FIG. 8 is a schematic cross sectional view of the essential
parts of the automatic film winding apparatus according to one
embodiment of the invention as viewed from the lateral direction
for explaining each operation;
[0100] FIG. 9 is a schematic enlarged cross sectional view of the
essential parts of the automatic film winding apparatus according
to one embodiment of the invention as viewed from the lateral
direction for explaining the effects of the film affixing
roller;
[0101] FIG. 10 is an enlarged view of the essential parts of the
automatic film winding apparatus according to one embodiment of the
invention as viewed from the lateral direction for explaining the
effects of the low-speed rotation with a torque sufficient to
remove slackening; in which (a) is a cross-sectional view before
removal of slackening and (b) is a cross-sectional view after
removal of slackening; and
[0102] FIG. 11 is a schematic flow chart for explaining the method
for producing a rolled film according to one embodiment of the
invention.
BEST MODE FOR CARRYING OUT THE INVENTION
[0103] An explanation is made on one embodiment of the slit winding
system and the automatic film winding apparatus according to the
invention.
(Slit Winding System)
[0104] FIG. 1 shows a schematic cross sectional view of the slit
winding system according to one embodiment of the invention as
viewed from the lateral direction.
[0105] In FIG. 1, a slit winding system 1 is formed of an automatic
film winding apparatus 2 and a slitter 3. The automatic film
winding apparatus 2 is connected to a web feeding apparatus 4.
[0106] The web feeding apparatus 4 has a feeding shaft 41 on which
a web 11 is installed, and supplies a film 10 to the slitter 3. The
slitter 3 has a slitting part 31 which cuts the film 10 which has
been supplied from the web feeding apparatus 4, and an edge winding
part 32 which winds the edge portion of the film 10. This slitter 3
supplies the films 10 which have been cut to the automatic winding
apparatus 2. This automatic film winding apparatus 2 simultaneously
winds the films 10 which have been cut and supplied from the
slitter 3 (two films in this embodiment).
[0107] In this embodiment, the automatic film winding apparatus 2
and the slitter 3 are separately provided. However, the invention
is not limited to this configuration. For example, the film
automatic winding apparatus 2 may be incorporated into the slitter
3 as part of the slitter 3.
[0108] Although not shown, the slit winding system 1 has a winding
apparatus moving mechanism which allows the automatic film winding
apparatus 2 to be movable. In addition, the winding apparatus
moving mechanism has an LM guide, a motor, a gear, a chain or the
like, and allows the automatic film winding apparatus 2 to move
freely. Due to the provision of the winding apparatus moving
mechanism, it is possible to move the automatic film winding
apparatus 2 freely during maintenance. Furthermore, during
production, the distance between the slitter 3 and the automatic
film winding apparatus 2 can be shortened. Due to the shortened
distance, the carrying span is reduced. As a result, step-like
irregularities or other disadvantages can be suppressed. In
addition, connection to other slitters or modification of the slit
constant can be performed easily.
[0109] The configuration of the winding apparatus moving mechanism
is not limited to that mentioned above. The winding mechanism
moving mechanism can have various configurations. For example, it
may have a configuration in which a guide, a ball screw, a motor or
the like is used, or a cylinder is used instead of a motor.
Furthermore, it may have a configuration in which a guide, a ball
screw or the like is provided, and the ball screw is manually
turned. In respect of operability or safety, a configuration using
a guide, a ball screw, a motor or the like is preferable.
(Film Automatic Winding Apparatus)
[0110] FIG. 2 is a schematic front view of an automatic film
winding apparatus according to one embodiment of the invention.
[0111] In FIG. 2, for the convenience of easy understanding of the
condition of the film 10 which is being wound, a cutter 24 provided
with a guide, a film affixing roller 25, a winding core positioning
means 29 or the like, which will be mentioned later, are not
shown.
[0112] The automatic film winding apparatus 2 is provided with a
turret 20, a first winding shaft 21, a second winding shaft 22, a
touch roller 23, a cutter 24 provided with a guide, a film affixing
roller 25, a nip bar 26, a first film carrier roller 27, a second
film carrier roller 28, a winding core positioning means 29 or the
like.
[0113] When winding a single film or a plurality of films which are
adjacent to each other, only one set of the winding mechanism is
provided. This winding mechanism has a pair of the opposing turrets
20, the touch roller 23, the cutter 24 provided with a guide as a
cutting means, the film affixing roller 25 or the like. The
above-mentioned winding mechanism is provided at two locations if
the films are wound alternatively in two separated groups. Due to
such a configuration, troubles that the edge of each of the
multiply slitted films gets scratches or the film gets caught in
adjacent winding rolls can be avoided.
[0114] The automatic film winding apparatus 2 of this embodiment
has the two-stage winding mechanisms which are provided in the
vertical direction. This winding mechanism has a pair of the
opposing turrets 20, the touch roller 23, the cutter 24 provided
with a guide as a cutting means, the film affixing roller 25 or the
like. Due to such a configuration, the film 10 can be wound
simultaneously in each of the winding mechanisms, whereby
production ability can be enhanced effectively. In addition, due to
the adaptability to various specifications, the added value of the
apparatus can be improved.
[0115] Though not shown, the automatic film winding apparatus 2
has, on the both sides thereof, a motor for driving, a gear box, a
pulley or the like for driving are provided to allow the first
winding shaft 21, the second winding shaft 22 and the turret 20 to
rotate. On the left side thereof, a display panel 202, an operation
panel 203, and a control device (not shown) for controlling each of
the driving means are provided.
<Turret>
[0116] The turret 20 is in the form of a pair of opposing discs,
and each turret is rotatably secured to a pivotable support plate
201. Between the pair of turrets 20, the first winding shaft 21 and
the second winding shaft 22 are pivotably installed. Due to such a
configuration, for example, if the turret 20 is rotated by
180.degree., the first winding shaft 21 at the film winding
position is moved to the waiting position, and the second winding
shaft 22 at the waiting position is moved to the film winding
position.
[0117] Further, it is preferred that the turrets have a
configuration in which the rolled film 10 is removed from the first
winding shaft 21 at the waiting position while the film is wound
around the second winding shaft 22 and the winding core 12 is
installed in the first winding shaft 21. Specifically, the right
end of each of the first winding shaft 21 and the second winding
shaft 22 is supported by the turret 20 on the right through a
rotatable bearing 212, and the left end of each of the first
winding shaft 21 and the second winding shaft 22 is rotatably
supported by the turret 20 on the left by a switching bearing 213
provided at a position corresponding to the rotatable bearing 212.
The switching bearing 213 stops supporting the left end of each of
the first winding shaft 21 or the second winding shaft 22 when
these shafts are caused to rotate in the front direction. Due to
such a configuration, removal of the rolled film 10 or the
installation of a new winding core 12 can be performed easily
during the film winding operation. As a result, the operation rate
of the apparatus can be improved.
[0118] In this embodiment, two winding shafts are provided in the
turret. The number of the winding shafts is, however, not limited
to two. Three or more winding shafts may be provided, for example.
If four winding shafts are provided in the turret, the turret is
rotated by 90.degree.. Due to this rotation, each winding shaft
moves, and the winding shaft, which has moved to the film winding
position, winds up the film. As a result, the film can be wound
continuously.
[0119] The turret cannot be necessarily provided if only one
winding shaft is used.
<Winding Shaft>
[0120] The first winding shaft 21 and the second winding shaft 22
wind the film 10 around the winding core 12. A film tension control
system may preferably be provided. By the provision of the film
tension control system, the tension of the film 10 can be adjusted
easily.
[0121] The first winding shaft 21 and the second winding shaft 22
are friction shafts each having an expanded packing 211. Due to
such a configuration, a rotation torque to be transmitted to the
winding core 12 can be controlled. In addition, as mentioned later,
if a slight degree of film slackening remains between the touch
roller 23 and the film affixing roller 25, such slackening can be
removed.
[0122] Normally, it is preferred that the winding speed of the film
10 be 50 m/min or more. The winding speed is, however, not limited
thereto.
[0123] The film tension control system used is not limited to the
above-mentioned expanded packing 211. For example, a simple air
shaft or air friction shaft can be used. Other expansion shafts may
also be used.
[0124] The maximum width dimension which allows the winding core 12
to be installed is set as L. Therefore, the automatic film winding
apparatus 2 can wind the film 10 of which the maximum width
dimension is L.
[0125] In this embodiment, the film 10 is wound by the right side
portion of the first winding shaft 21 (second winding shaft 22) in
the upper stage and the left side portion of the first winding
shaft 21 (second winding shaft 22) in the lower stage. The manner
of winding is, however, not limited thereto. For example, although
not shown, three films 10 can be simultaneously wound by the right
side portion and the left side portion of the first winding shaft
21 (second winding shaft 22) in the upper stage and the central
portion of the first winding shaft 21 (second winding shaft 22) in
the lower stage. That is, the quantity of the winding core 12, the
installation position of the winding core 12, and the film width
can be set freely within the maximum dimension L.
<Film Affixing Roller>
[0126] FIG. 3 is a schematic view of a film affixing roller of the
automatic film winding apparatus according to one embodiment of the
invention, in which (a) is a front view and (b) is a
cross-sectional view taken along the line A-A.
[0127] In FIG. 3, the film affixing roller 25 is provided with a
roller 251, an urging arm 252, an arm 253, an air cylinder 254, a
rotating shaft 255 and a driving arm 256.
[0128] The both ends of the rotating shaft 255 are rotatably
supported by the opposing pivotable support plates 201, and the
driving arm 256 is fixed to the front end on the right side. The
front end of this driving arm 256 is connected to an air cylinder
for rotating (not shown).
[0129] The pair of the arms 253 is a hook-shaped plate. In the
opposing state, the roots thereof are fixed to the rotating shaft
255. This arm 253 and the urging arm 252 are the arms for the
affixing roller as the film affixing roller moving mechanism, and
rotatably support the film affixing roller 25.
[0130] To the front end of the arm 253, the urging arm 252, which
is in the concave shape with the both ends thereof being curved, is
rotatably connected, and is urged towards the rotating shaft 255 by
the air cylinder 254. The waiting position of this urging arm 252
is a position at which it is almost perpendicular to the arm 253.
The roller 251 which has been secured to the urging arm 252 presses
the film 10 on the winding core 12 when the arm 253 rotates in the
affixing direction.
[0131] The roller 251 is a free-roller having a length of L, with
the top surface being formed of a resin, rubber or the like. This
roller 251 is rotatably secured to the front end of the opposing
pair of urging arms 252.
[0132] By allowing the film affixing roller 25 to have the
above-mentioned configuration, the apparatus can have a reduced
size and a simple structure, leading to the reduction in
manufacturing cost.
[0133] This film affixing roller 25 presses the cut film 10 to the
winding core 12 of the second winding shaft 22 at a position on the
downstream side of the touch roller 23, for example. The film
affixing roller 25 moves to the front end of the film 10 which has
been cut, while winding the film 10 which has been cut around the
winding core 12 with the film being pressed.
<Touch Roller>
[0134] FIG. 4 is a schematic view of a touch roller of the
automatic film winding apparatus according to one embodiment of the
invention, in which (a) is a front view and (b) is a
cross-sectional view taken along the line B-B.
[0135] In FIG. 4, the touch roller 23 is provided with a roller
231, an arm 232, a rotating shaft 233 and a driving arm 234.
[0136] The rotating shaft 233 is a shaft in which a key way is
formed. The both ends of the rotating shaft, 233 are rotatably
supported by the opposing pivotably support plates 201. The driving
arm 234 is fixed to the front end on the right side of the rotating
shaft 233. The front end of this driving arm 234 is connected to an
air cylinder for driving (not shown). The roots of the pair of the
arms 232, which are in the opposing state, are fixed to the
rotating shaft 233 through a key (not shown). The roller 231 is a
free-roller with the top surface being formed of a resin, rubber or
the like. This roller 231 is rotatably secured to the front end of
the opposing pair of arms 232.
[0137] The length of the roller 231 corresponds to the width of the
film 10 to be wound. In addition, the roller 231 is installed at a
position corresponding to the film 10 to be wound by the arm
232.
[0138] If the film 10 having a different width is wound with a
product change, the position of the arm 232 is adjusted by means of
the roller 231 having a length corresponding to the width of the
film. By doing this, it is possible to meet the product change
easily. The length of the roller 231 can be appropriately adjusted
according to the width of the film 10 to be wound. The length of
the roller 231 may be slightly longer or shorter than the width of
the film 10. In respect of air bleeding, it is preferred that the
length of the roller 231 be slightly longer than the width of the
film 10. In respect of prevention of weaving, it is preferred that
the length of the roller 231 be slightly shorter than the width of
the film 10. That is, the length of the roller 231 can be
appropriately selected according to the type or thickness of the
film 10 to be wound.
[0139] The touch roller 23 presses the film 10, which has been hung
on the winding core 12 of the second winding shaft 22, to the
winding core 12 of the second winding shaft 22, when, for example,
the winding of the film 10 by the first winding shaft 21 is
completed and the turret 20 is rotated by a predetermined angle
(180.degree.).
[0140] Furthermore, it is preferred that the automatic film winding
apparatus 2 have an air bleeding mechanism. Due to the provision of
the air bleeding mechanism, a trouble that air enters between the
films 10 can be prevented.
[0141] In the automatic film winding apparatus 2 in this
embodiment, the touch roller 23 is used as the air bleeding
mechanism. Due to such a configuration, since the touch roller 23
functions also as the air bleeding mechanism, the need for
providing a bleeding mechanism can be eliminated. As a result,
reduction in size of the apparatus can be realized.
[0142] The air bleeding mechanism is not limited to the
above-mentioned mechanism. Any mechanism can be used insofar as it
can perform air bleeding. For example, the near roll winding method
in which winding is performed with the roller being in the vicinity
of, not in contact with, the film, or the touch roll winding method
in which winding is performed with the touch roller 23 being
completely in contact with the film.
[0143] If the film 10 has no problems in its properties, it is
preferable to select the touch rolling method in which the touch
roller 23 is used since it is an effective way to prevent air
entertainment. The touch roller 23 is particularly preferable
since, in addition to air bleeding, the touch roller 23 has a
function of pressing the film, and is capable of preventing the
film 10 from shifting during cutting.
<Cutter Provided with a Guide>
[0144] FIG. 5 is a schematic view of a cutter provided with a guide
of the automatic film winding apparatus according to one embodiment
of the invention, in which (a) is a front view and (b) is a
cross-sectional view taken along the line C-C.
[0145] In FIG. 5, the cutter 24 provided with a guide is provided
with a cutting blade 241, a rodless cylinder 242, a holding member
243, a guide bar 244, an arm 245, a rotating shaft 246 and a
driving arm 247.
[0146] The both ends of the rotating shaft 246 are rotatably
supported by the pivotable support plate 201 which are opposing,
and the driving arm 247 is fixed to the front end on the right side
of the rotating shaft. The front end of the driving arm 247 is
connected to an air cylinder for rotating (not shown).
[0147] The pair of arms 245 is a plate with the front end being
curved. In the opposing state, the roots thereof are fixed to the
rotating shaft 246. The rodless cylinder 242 is installed on the
front end of the arms 245 through a supporting member. A connecting
member is installed on the front end of each of the arms 245
through the supporting member. Two guide bars 244 are installed on
each of the connecting member in such a manner that they are
opposing with a prescribed interval.
[0148] A cutting blade 241 is installed on the rodless cylinder 242
through the holding member 243. This cutting blade 241 can cut the
film 10 having a maximum width dimension of L. Furthermore, the
cutting blade 241 moves through a predetermined gap between the two
guide bars 244. That is, when the arms 245 are rotated, the two
guide bars 244 abut the film 10, and by this abutment, the film 10
is imparted with an appropriate tension. The cutting blade 241 cuts
the film 10 which has been imparted with an appropriate tension. By
doing this, a trouble can be avoided that the film is cut in a
curved manner at a position where the blade 241 is entered or
removed, thus realizing linear cutting. In addition, a trouble such
as adherence of resist chips can be avoided.
[0149] This cutter 24 provided with a guide cuts the film 10 which
has been hung on the first winding shaft 21 and the second winding
shaft 22 between the first winding shaft 21 and the second winding
shaft 22.
[0150] As mentioned above, the cutter 24 provided with a guide has
a pair of arms 245 which are rotatably supported, and the distance
between the pair of arms is taken as L.sub.0 (see FIG. 5).
[0151] Here, the film affixing roller 25 has a pair of arms 253
which are rotatably supported, and the maximum external dimension
of the arms 253 including the air cylinder 254 is L.sub.1 (see FIG.
3), and L.sub.0 is larger than L.sub.1. Therefore, the pair of arms
253 of the film affixing roller 25 is accommodated between the pair
of arms 245 of the cutter 24 provided with a guide.
[0152] The distance between the arms 253 is L.sub.2 (see FIG. 3),
and the distance between the pair of arms 232 which pivotably
supports the touch roller 23 is shorter than the distance between
the pair of arms 253 (L.sub.2). Therefore, the pair of arms 232 of
the touch roller 23 is accommodated between the pair of arms 253
(see FIG. 4).
[0153] Therefore, due to the above-mentioned configuration, the
automatic film winding apparatus 2 of this embodiment can be
reduced in size since the arms 245, 253 and 232 do not interfere
with each other.
<Winding Core Positioning Means>
[0154] FIG. 6 is a schematic view of a winding core positioning
means of the automatic film winding apparatus according to one
embodiment of the invention, in which (a) is a front view and (b)
is a cross-sectional view taken along the line D-D.
[0155] In FIG. 6, the winding core positioning means 29 is provided
with a stopper 291, a knob 292, a sliding bar 293, a connecting
plate 294 and a bearing 295.
[0156] The stopper 291 is in an approximate rectangular cylindrical
shape, and is slidably installed on the sliding bar 293. The knob
292 with a male screw being projectably provided at the lower part
thereof penetrates the stopper 291. The stopper 291 is fixed to the
sliding bar 293 when the knob 292 is tightened, and becomes
slidable when the knob 292 is loosened.
[0157] The both ends of the sliding bar 293 are connected to the
bearing 295 through the connecting plate 294. Each of the pair of
the bearings 295 is screwed to the pivotable support plate 201. The
bearing 295 has a rotating angle of about 180.degree., and can be
freely rotated within this range. An operator rotates the sliding
bar 293 between the waiting position (the position which is
obliquely below as viewed from the front side) and the positioning
position (the position which is obliquely above as viewed from the
back side).
[0158] The stopper 291 of the winding core positioning means 29 is
normally in the waiting position, and avoids a trouble that it
contacts the rolled film 10. When positioning of the winding core
12 is performed, the stopper 291 is rotated to the positioning
position, where the end surface of the winding core 12 abuts the
stopper 291, whereby the winding core 12 can be positioned. In this
embodiment, the abutting surface of the stopper 291 is set at a
position which is away from the center of the shaft with a distance
of L.sub.3 (see FIG. 2).
[0159] By doing this, it is possible to position the winding core
12 accurately in a short period of time, whereby the productivity
or quality (winding accuracy in center) can be improved. By
allowing the winding core positioning means 29 to have the
above-mentioned configuration, it can be operated easily and can
have a simplified structure. As a result, the manufacturing cost
can be reduced.
[0160] In the configuration of this embodiment, an operator sets
the winding core 12. The configuration is, however, not limited to
this. For example, the winding core 12 may be automatically set at
a predetermined position above the winding shafts 21 and 22 by
means of a winding core positioning mechanism (not shown).
<Film Carrier Roller>
[0161] It is preferred that the automatic film winding apparatus
have a film carrier roller which supplies the film 10 to the
winding shafts 21 and 22. Due to the provision of the film carrier
roller, the film 10 can be carried smoothly.
[0162] As shown in FIG. 1, the automatic film winding apparatus 2
of this embodiment is provided with a first film carrier roller 27
and a second film carrier roller 28 for each of the pair of the
turrets 20. The first film carrier roller 27 and the second film
carrier roller 28 supply the film 10 to the first winding shaft 21
or the second winding shaft 22.
[0163] The journal diameter of the film carrier rollers 27 and 28
is 10 to 25 mm. The journal diameter means the axial diameter of
the roller. The optimum journal diameter is about 10 to 25 mm for
decreasing the rotation resistance with the bearing. If the journal
diameter is too large, the rotation resistance increases, making
the rotation of a free roller difficult. If the journal diameter is
too small, the roller has an insufficient strength. More
preferably, the journal diameter is about 10 to 15 mm. In this
embodiment, a journal diameter of 15 mm is selected. The journal
diameter is not limited to this range. Normally, a slide caliper is
used to measure the journal diameter.
[0164] It is preferred that the angle of the contact surface of the
film carrier roller and the film (film holding angle) be 90 to
160.degree.. Specifically, as shown in FIG. 7, the holding angle of
the last two rollers (the film carrier rollers 27 and 28) is
preferably within the range of 90 to 160.degree. at least as viewed
from the winding shaft. The reason therefor is as follows. If the
holding angle is too small, the roller does not rotate, causing the
film to meander or causing the film to have scratches. If the
holding angle is too large, the film tension is decreased. As a
result, the holding tension of the wound product cannot be
controlled, and a trouble occurs that winding is too tight or the
like.
[0165] It is preferred that the film contact surface of the film
carrier rollers 27 and 28 be formed of a porous material or a
slightly adhesive material. The reason for using a porous material
in the above-mentioned film contact surface is as follows. By using
a porous material, weaving of the end surface of a rolled film
product (step-like irregularities) caused by lateral shift of the
film due to the air which has entered between the film 10 and the
film carrier rollers 27 and 28 can be effectively prevented.
Examples of the porous material include foaming materials. Of them,
rubber materials are preferable since they do not get scratches,
they exhibit excellent durability or for other reasons. When an
adhesive material is used in the above-mentioned film contact
surface, it is preferable to use a slightly adhesive rubber
material in order not to adversely affect the holding tension
(winding tightness) of a wound product. Depending largely on the
properties of a wound product, a rubber material having a friction
coefficient of 0.7 to 0.8 and a rubber hardness of 40 to 80.degree.
is preferable.
<Nip Bar>
[0166] In the automatic film winding apparatus 2 of this
embodiment, as a holding means which holds the film 10 which has
stopped, a nip bar 26 is provided below the first film carrier
roller 27.
[0167] This nip bar 26 is a metal bar of which the top surface is
formed of a resin or rubber, and has almost the same length as that
of the first film carrier roller 27. The nip bar 26 reciprocates up
and down by a reciprocating driving means such as an air cylinder.
The nip bar 26, when moved upwardly, presses the film 10 which has
stopped to the first film carrier roller 27 and holds so that it
does not move.
[0168] Due to the provision of the nip bar 26, the film 10 which
has stopped is effectively prevented from shifting in the lateral
direction, ensuring further suppression of a bad start. By the
above-mentioned structure, the film 10 can be held reliably. In
addition, due to the simplified structure, manufacturing cost can
be reduced.
[0169] Next, the action and effect of the automatic film winding
apparatus 2 having the above-mentioned configuration will be
described with reference to the drawings.
[0170] FIG. 8 is a schematic cross sectional view of the essential
parts of the automatic film winding apparatus according to one
embodiment of the invention as viewed from the lateral direction
for explaining each operation.
[0171] As shown in FIG. 8(a), in the automatic film winding
apparatus 2, when a predetermined amount of the film 10 is wound
around the winding core 12 of the first winding shaft 21, the first
winding shaft 21 stops rotating (Step S1).
[0172] At this time, the first winding shaft 21 and the second
winding shaft 22 are not rotating, the touch roller 23 is pressing,
the film affixing roller 25, the cutter 24 provided with a guide
and the nip bar 26 are waiting, and the winding core positioning
means 29 is at the positioning position. The first winding shaft 21
is at the film winding position and the second winding shaft 22 is
at the waiting position.
[0173] When winding the film 10, the touch roller 23 presses the
film 10 to be wound around the winding core 12. As a result, the
touch roller 23 functions as an air bleeding mechanism between the
films 10 to be wound. If the first winding shaft 21 stops rotating,
the touch roller 23 keeps on pressing.
[0174] During winding the film 10, the contact angle (film holding
angle) of the carrier rollers 27 and 28 and the film 10 is
preferably 90.degree. to 160.degree.. If the holding angle is
smaller than 90.degree., the rotation of the carrier roller becomes
insufficient, causing the film to meander. When the holding angle
is larger than 160.degree., film tension becomes too strong,
causing difficulty in the adjustment of the film tension on the
winding shaft.
[0175] When winding the film 10, a pressure control mechanism
(expanded packing 211) adjusts the pressure applied on the winding
core 12, whereby a tension suitable for film winding can be
ensured.
[0176] Next, as shown in FIG. 8(b), the film 10 which is hung on
the first film carrier roller 27 is held by the nip bar 26.
Subsequently, the touch roller 23 rotates upward, and the turret 20
rotates by 180.degree., and the film 10 is hung on the second
winding shaft 22 (Step S2).
[0177] At this time, the first winding shaft 21 moves to the
waiting position and the second winding shaft 22 moves to the
winding position.
[0178] At this time, the first winding shaft 21 and the second
winding shaft 22 are not rotating, the nip bar 26 is holding, and
the touch roller 23, the film affixing roller 25, the cutter 24
provided with a guide and the winding core positioning means 29 are
waiting.
[0179] Due to the holding of the film 10 by the nip bar 26,
occurrence of a bad start can be prevented more reliably.
[0180] Before the turret 20 starts to rotate, an operator applies
an adhesive to part of the surface of the winding core 12 of the
second winding shaft 22, positions this winding core 12 on the
second winding shaft 22 by means of the winding core positioning
means 29, and the winding core positioning means 29 are rotated to
the waiting position.
[0181] If the turret 20 rotates, the winding core 12 of the first
winding shaft 21 is returned in the counterclockwise direction.
However, due to the holding torque of the expanded packing 211, the
film 10 is in the tensed state. That is it keeps the tension
suitable for film cutting.
[0182] Next, as shown in FIG. 8(c), the touch roller 23 rotates
downward and presses the film 10 to the winding core 12 of the
second winding shaft 22. Subsequently, the cutter 24 provided with
a guide rotates downward, and cuts the film 10 linearly between the
first winding shaft 21 and the second winding shaft 22 (Step
S3).
[0183] At this time, the first winding shaft 21 and the second
winding shaft 22 are not rotating, the nip bar 26 is holding, the
touch roller 23 is pressing, the cutter 24 provided with a guide is
cutting, and the film affixing roller 25 and the winding core
positioning means 29 are waiting.
[0184] In this embodiment, when cutting the film 10, the first
winding shaft 21 stops rotating. The configuration is, however, not
limited thereto. For example, when cutting the film 10, the first
winding shaft 21 may be rotated at a speed of 15 m/min or less (a
small rpm corresponding to the winding speed of 15 m/min or less).
By doing this, the tension of the cut surface of the film can be
ensured.
[0185] Then, as shown in FIG. 8(d), the cutter 24 provided with a
guide rotates upward, the film affixing roller 25 rotates downward,
and presses the film 10 which has been cut to the winding core 12
of the second winding shaft 22 at a position on the downstream side
of the touch roller 23 (Step S4).
[0186] At this time, the first winding shaft 21 and the second
winding shaft 22 are not rotating, the nip bar 26 is holding, the
touch roller 23 is pressing, the film affixing roller 25 is
pressing, and the cutter 24 provided with a guide and the winding
core positioning means 29 are waiting.
[0187] Then, as shown in FIG. 8(e), the film affixing roller 25
further rotates downward, and moves to the front end of the film 10
which has been cut while winding the film 10 around the winding
core 12 with the film 10 being pressed to the winding core 12 (Step
S5).
[0188] At this time, the first winding shaft 21 and the second
winding shaft 22 are not rotating, the nip bar 26 is holding, the
touch roller 23 is pressing, the film affixing roller 25 is
pressing, and the cutter 24 provided with a guide and the winding
core positioning means 29 are waiting.
[0189] The front end of the film 10 which has been cut is away from
the film cutting position within a range of several millimeters
below the decimal point to several tens of millimeters.
[0190] In this embodiment, as shown in FIG. 9, a roller 251 of the
film affixing roller 25, which is indicated by a dotted line, abuts
the film 10 from the obliquely above as view from the front side,
and presses the film 10 to the winding core 12 (Step S4). In the
above step S5, the roller 251 moves by about 100.degree. with the
film 10 being pressed to the winding core 12, and maintains its
pressed state (this roller 251 is indicated by a solid line). As a
result, the film 10 between the roller 231 and the roller 251
indicated by a dotted line adheres to the winding core 12. In
particular, the film 10 between the roller 251 indicated by a
dotted line and the roller 251 indicated by a solid line is
forcibly adhered to the winding core 12 by the roller 251. That is,
slackening of the film 10 between the pressing position by the
roller 231 of the touch roller 23 and the front end of the film 10
which has been cut can be effectively prevented, whereby the film
10 can be wound while maintaining the state in which the film 10 is
adhered to a predetermined position of the winding core. As a
result, troubles such as a bad start, wrinkles of the film or
folded film corners which occur during film winding can be
reasonably prevented.
[0191] The distance (angle) for which the roller 251 moves with the
film 10 being pressed to the winding core 12 is not limited to
100.degree. as mentioned above, and can be within the range of
about 60.degree. to 130.degree. according to the kind (adhesive
strength) of the film or the like.
[0192] It is preferred that, as shown in FIG. 9, the angle at which
the film 10 is wound around the winding core 12 (winding angle) be
within the range of 30.degree. to 90.degree., more preferably, a
larger angle within the above-mentioned range. By this angle, the
front end of the film 10 which has been cut can be inserted between
the film 10 to be supplied and the winding core 12 with a shorter
distance. As a result, winding quality (in particular, prevention
of folded film corners) can be improved.
[0193] The winding angle refers to an angle formed by the position
right above the winding core 12 and the position at which the film
10 to be supplied is brought into contact with the winding core
12.
[0194] Next, as shown in FIG. 8(f), while keeping the state where
the film affixing roller 25 is pressing the front end of the film
10 which is being pressed to the winding core 12 by the film
affixing roller 25, the second winding shaft 22, which is a
friction shaft, rotates in the winding direction at a predetermined
torque which is enough to remove slackening (Step S6).
[0195] At this time, the first winding shaft 21 is not rotating,
the second winding shaft 22 is rotating at a low speed, the nip bar
26 is holding, the touch roller 23 is pressing, the film affixing
roller 25 is pressing, and the cutter 24 with a guide and the
winding core positioning means 29 are waiting.
[0196] In addition, slackening can be completely removed by a
low-speed operation at the above-mentioned predetermined torque
which is sufficient to remove the slackening. That is, as shown in
FIG. 10(a), for example, a slight degree of slackening may remain
between the roller 231 of the touch roller 23 and the roller 251 of
the film affixing roller 25. In this case, such slackening can be
completely removed by allowing the winding core 12 to rotate by a
small angle (from the X position to the X.sub.1 position) according
to the amount of slackening without allowing the film 10 on the
upstream side of the touch roller 23 to advance. As a result,
troubles such as a bad start, wrinkles of the film or folded film
corners which occur during film winding can be reasonably avoided,
thus realizing a reliable winding technology.
[0197] The low-speed rotation of the second winding shaft 22 in the
step S6 is normally performed at an rpm corresponding to a speed
which is 50% or less of the film winding speed. Specifically, when
the film winding speed is 50 m/min, the second winding shaft 22
rotates at a small rpm which corresponds to the winding speed of 25
m/min or less.
[0198] Next, as shown in FIG. 8(g), the nip bar 26 moves downward,
and the first film carrier roller 27 stops holding the film 10.
Subsequently, the second winding shaft 22 rotates at a low speed in
the winding direction at a predetermined winding torque, and the
film 10 is wound around the winding core 12 of the second winding
shaft 22. Furthermore, when the front end of the film 10 which has
been cut approaches the position where the films 10 overlap one on
another, the touch roller 23 and the film affixing roller 25 rotate
upward, and stop pressing the film 10 (Step S7).
[0199] At this time, the first winding shaft 21 is not rotating,
the second winding shaft 22 is rotating at a low speed, and the nib
bar 26, the touch roller 23, the film affixing roller 25, the
cutter 24 with a guide and the winding core positioning means 29
are waiting. Normally, the second winding shaft 22 rotates half to
several times at the above-mentioned low speed, whereby the films
10 overlap one on another accurately.
[0200] The low-speed rotation of the second winding shaft 22 in the
step S7 is normally performed at an rpm corresponding to a speed
which is 50% or less of the film winding speed. Specifically, when
the film winding speed is 50 m/min, the second winding shaft 22
rotates at a low speed with a small rpm which corresponds to the
winding speed of 25 m/min or less.
[0201] Next, as shown in FIG. 8(h), when the front end of the film
10 which has been cut passes the position at which the films 10
overlap one on another, the touch roller 23 rotates downward again,
and presses the film 10 to the winding core 12 of the second
winding shaft 22. Subsequently, the second winding shaft 22 rotates
in the winding direction at a predetermined winding up torque (Step
S8).
[0202] At this time, the first winding shaft 21 is not rotating,
the second winding shaft 22 is rotating at a predetermined winding
speed, the touch roller 23 is pressing, and the nip bar 26, the
film affixing roller 25, the cutter 24 provided with a guide and
the winding core positioning means 29 are waiting.
[0203] Next, although not shown, an operator removes from the first
winding shaft 21 the winding core 12 around which the film 10 has
been wound in advance from the first winding shaft 21, and then
inserts a new winding core 12 into the first winding shaft 21 (Step
S9).
[0204] As mentioned hereinabove, according to the automatic film
winding apparatus 2 of this embodiment, slackening of the film 10
between the pressing position by the touch roller 23 and the front
end of the film 10 which has been cut is effectively suppressed,
and therefore, the film 10 can be wound with the film 10 being
closely adhered to the predetermined position of the winding core
12. As a result, troubles such as a bad start, wrinkles of the film
or folded film corners which occur during film winding can be
prevented, whereby winding quality can be significantly
improved.
[0205] By allowing the winding shafts 21 and 22 to rotate at a low
speed with a torque sufficient to remove slackening, a slight
degree of slackening can be removed to improve winding quality.
[0206] The invention is effective also as the invention of the slit
winding system 1. That is, due to the provision of the automatic
film winding apparatus 2, both quality and productivity can be
improved.
[0207] Next, one embodiment of the method for producing a rolled
film will, be explained.
[0208] First, as shown in FIG. 11, the first winding shaft 21 stops
rotating when a predetermined amount of the film 10 is wound around
the winding core 12 of the first winding shaft 21 (Step S1).
[0209] Next, the nip bar 26 allows the film 10 which has stopped to
be held by the first film carrier roller 27, the touch roller 23
stops pressing the film 10, the turret 20 rotates by 180.degree. to
allow the film 10 to be hung on the winding core 12 of the second
winding shaft 22 (Step S2).
[0210] Subsequently, the touch roller 23 presses the film 10 to the
winding core 12 of the second winding shaft 22, and the cutter 24
provided with a guide cuts the film 10 (Step S3).
[0211] Next, at a position on the downstream side of the touch
roller 23, the film affixing roller 25 presses the film 10 which
has been cut to the winding core 12 of the second winding shaft 22
(Step S4).
[0212] Subsequently, the film affixing roller 25 moves to the front
end of the film 10 which has been cut while winding the film 10
with the film 10 being pressed (Step S5).
[0213] Then, the second winding shaft 22, which is a friction
shaft, rotates at a low speed in the winding direction at a
predetermined torque which is sufficient to remove slackening (Step
S6).
[0214] Then, the nip bar 26 stops holding the film 10, and the
second winding shaft 22 rotates at a low speed in the winding
direction at a predetermined winding torque. When the film 10 is
wound around the winding core 12 of the second winding shaft 22,
and the front end of the film 10 which has been cut approaches to
the position where the films 10 overlap one on another, the touch
roller 23 and the film affixing roller 25 stop pressing (Step
S7).
[0215] Subsequently, when the front end of the film 10 which has
been cut passes the position where the films 10 overlap one on
another, the touch roller 23 presses the film 10 to the winding
core 12 of the second winding shaft 22, and the second winding
shaft 22 rotates in the winding direction at a predetermined
winding up torque (Step S8).
[0216] Then, the winding core 12 around which the film 10 has been
wound in advance is removed from the first winding shaft 21, and a
new winding core 12 is inserted into the first winding shaft 21
(Step S9).
[0217] As mentioned hereinabove, the invention is effective as a
method for producing a rolled film, and can improve both quality
and productivity.
[0218] In the slit winding system 1, the automatic film winding
apparatus 2 and the method for producing a rolled film of the
above-mentioned embodiment, the automatic film winding apparatus 2
has a configuration in which the automatic winding apparatus 2 is
provided with the turret 20, the cutter 24 provided with a guide,
the nip bar 26, the winding core positioning means 29 or the like.
The invention is, however, not limited thereto.
[0219] For example, as shown in FIG. 9, the automatic film winding
apparatus of the invention may have a simple configuration in which
it is provided with only one winding shaft 22, the touch roller 23
(the roller 231) and the film affixing roller 25 (the roller 251).
That is, this automatic film winding apparatus is not necessarily
provided with the turret 20, the cutter 24 provided with a guide,
the nip bar 26 and the winding core positioning means 29 or the
like.
[0220] In this case, an operator cuts the film 10 which has been
wound around the winding core 12, and removes the rolled film 10
and the winding core 12, sets a new winding core 12 and hangs the
film 10 on a new winding core 12. By doing this, in this automatic
film winding apparatus, the touch roller 23 and the film affixing
roller 25 effectively suppress slackening of the film 10 between
the pressing position by the touch roller 23 and the front end of
the film 10. Specifically, in this automatic film winding
apparatus, since it is possible to wind the film 10 with the film
10 being closely adhered to a predetermined position of the winding
core 12, winding quality is significantly improved.
[0221] The automatic film winding apparatus with the
above-mentioned simple configuration may optionally have various
functions or structures (for example, an automatic cutter, a
plurality of winding mechanisms, rotatable touch rollers or film
affixing rollers).
[0222] In addition, this automatic film winding apparatus with this
simple configuration is effective when used in producing a rolled
film. By using this automatic film winding apparatus in producing a
rolled film, winding quality is significantly improved. Further,
this method for producing a rolled film may have a step of allowing
the shaft to rotate in the winding direction with a torque which is
sufficient to remove slackening, or other steps.
[0223] The automatic film winding apparatus, the slit winding
system and the method for producing a rolled film are explained
hereinabove with reference to preferred embodiments. However, the
invention is not limited to the above-mentioned embodiments, and it
is needless to say that various modifications are possible within
the scope of the invention.
[0224] For example, an adhesive such as glue is used as the
retaining means which retains the film 10 which has been wound
around the winding core 12 by the film affixing roller 25 on the
surface of the winding core 12. The retaining means is, however,
not limited to an adhesive. For example, depending on the
properties of the film 10, adsorption by static electricity, air
spraying, adhesion by a double coated adhesive tape or the like may
be used. By using these methods, a trouble that the front end of
the film 10 peels off from the surface of the winding core 12
before the films 10 overlap one on another can be avoided
reliably.
[0225] In addition, as mentioned hereinabove, by using the
apparatus of the invention, to say nothing of the semi-automatic
winding, fully automatic winding can be realized easily.
INDUSTRIAL APPLICABILITY
[0226] Although the invention relates to the automatic film winding
apparatus for winding a film, the slit winding system and a method
for producing a rolled film, the materials or structures of the
film are not particularly limited. Examples of the materials of the
film include a resin, a metal, a cloth, paper or the like, and a
mixture thereof. As for the structure of the film, a laminate
structure obtained by stacking layers of different materials or the
like may be used.
* * * * *