DESCRIPTION SYSTEM FOR AND METHOD OF MANUFACTURING FILM CASE

Technical Field The present invention relates to a system for and a method of manufacturing a film case such as an instant film pack.

Background Art Various types of instant film packs each having a plurality of mono-sheet type instant films (hereinafter referred to as "sheet-like films") housed in a box-shaped film case of plastics are presently commercially available. Such instant film packs are designed for use in instant cameras, printers, etc.

The film case of the instant film pack comprises a case body for accommodating the sheet-like film therein and a lid closing the case body. The case body has an exposure opening through which the exposure surface of the sheet-like film is exposed, a film cover disposed over the exposure opening, a film discharge slot defined in an end of the case body, and a groove defined in an opposite end of the case body for inserting a finger therein to discharge the sheet- like film and the film cover through the film discharge slot. The lid has a film presser for pressing the sheet- like film toward the exposure opening. For details, reference should be made to Japanese Laid-Open Patent

Publication No. 2002-116526.

When the film case is not in use, the interior space within the film case is shielded against entry of light by the film cover, a first light-shielding sheet applied to the film cover and disposed over the groove, and a second light- shielding sheet applied to an end of the case body and keeping the film discharge slot shielded against entry of light. When the film case is in use, the finger is inserted into the groove to remove the film cover through the film discharge slot. As a result, the sheet-like film is exposed to light, and the exposed sheet-like film is discharged out of the film case through the film discharge slot. The sheet-like film in the film case is normally pressed against the exposure opening by the film presser. Recently, film cases which are free of the exposure opening are also available on the market . When such a film case is in use, the insertion of the finger into the groove discharges the sheet-like film out of the film case through the film discharge slot, and the discharged sheet-like film is exposed to light outside.

Japanese Laid-Open Patent Publication No. 2002-116526 referred to above discloses a system for and a method of manufacturing a film case for exposing a sheet-like film to light while the sheet-like film is being accommodated in the film case. It is difficult to manufacture film cases which are free of the exposure opening with the disclosed manufacturing system and method.

Disclosure of Invention

It is an object of the present invention to provide a system for and a method of manufacturing, efficiently with high precision, a film case for exposing a sheet-like film to light by discharging the sheet-like film through a film discharge slot .

According to the present invention, there is provided a system for manufacturing a film case having a case body for housing a plurality of sheet-like films, the case body having a film discharge slot defined in one end thereof and a slit defined in another end thereof for discharging the sheet-like films, a lid closing the case body, a film presser mounted on the lid for pressing the sheet-like films , a light shielding sheet applied to the one end of the case body for shielding the film discharge slot against entry of light, a light shielding member covering the slit for shielding an interior of the case body against entry of light, a presser sheet applied to the case body and pressing the light shielding member to keep the light shielding member shielding the interior of the case body against entry of light, and discharge prevention sheets applied to the case body for preventing the sheet-like films from being discharged through the film discharge slot when the film case is not in use, wherein when the film case is in use, the sheet-like films are discharged through the film discharge slot for exposure outside of the film case, the system comprising a light shielding member supply line for

supplying the light shielding member, a presser sheet supply apparatus for supplying the presser sheet, a light shielding sheet supply apparatus for supplying the light shielding sheet, a discharge prevention sheet supply apparatus for supplying the discharge prevention sheets, a film presser supply line for supplying the film presser, and a main assembling line for assembling the light shielding member, the presser sheet, the light shielding sheet, and the discharge prevention sheets which have been supplied, into the case body, and assembling the film presser which has been supplied, onto the lid.

According to the present invention, there is also provided a method of manufacturing a film case having a case body for housing a plurality of sheet-like films, the case body having a film discharge slot defined in one end thereof and a slit defined in another end thereof for discharging the sheet-like films, a lid closing the case body, a film presser mounted on the lid for pressing the sheet-like films , a light shielding sheet applied to the one end of the case body for shielding the film discharge slot against entry of light, a light shielding member covering the slit for shielding an interior of the case body against entry of light, a presser sheet applied to the case body and pressing the light shielding member to keep the light shielding member shielding the interior of the case body against entry of light, and discharge prevention sheets applied to the case body for preventing the sheet-like films from being

discharged through the film discharge slot when the film case is not in use, wherein when the film case is in use, the sheet-like films are discharged through the film discharge slot for exposure outside of the film case, the method comprising the steps of feeding the case body and the lid onto a main assembling line, supplying the light shielding member from a light shielding member supply line to the main assembling line and assembling the light shielding member which has been supplied, into the case body, supplying the presser sheet from a presser sheet supply apparatus to the main assembling line and assembling the presser sheet which has been supplied, into the case body, supplying the light shielding sheet from a light shielding sheet supply apparatus to the main assembling line and assembling the light shielding sheet which has been supplied, into the case body, supplying the discharge prevention sheets from discharge prevention sheet supply apparatus to the main assembling line and assembling the discharge prevention sheets which has been supplied, into the case body, and supplying the film presser from a film presser supply line to the main assembling line and assembling the film presser which has been supplied, onto the lid.

With the above arrangement, the main assembling line is supplied with the light shielding member, the presser sheet, the light shielding sheet, the discharge prevention sheets, and the film presser. The main assembling line assembles

the light shielding member, the presser sheet, the light shielding sheet, and the discharge prevention sheets which have been supplied, into the case body, and also assembles the film presser onto the lid. Since film cases can automatically be manufactured without manual intervention, film cases of accurate dimensions and same quality can be mass-produced highly efficiently.

Preferably, the main assembling line comprises an assembling preparation line for receiving the case body and the lid supplied from a case body/lid supply apparatus and checking the case body and the lid which have been received, for their shape and orientation, and an assembling line for receiving the case body and the lid from the assembling preparation line, assembling the light shielding member, the presser sheet, the light shielding sheet, and the discharge prevention sheets into the case body which has been received, and assembling the film presser onto the lid which has been received.

Since case bodies and lids are checked in advance on the assembling preparation line, the assembling line is supplied with only those case bodies and lids which have been judged as acceptable. As a result, the accuracy and yield of film cases are increased.

Preferably, the assembling preparation line has a reception conveyor for receiving the case body and the lid as combined with each other from a supply conveyor of the case body/lid supply apparatus, and feeding the case body

and the lid which have been received, to the assembling line, and the reception conveyor is disposed between two conveyors of the supply conveyor, for feeding the case body and the lid to the assembling line while central areas of the case body and the lid are being placed on the reception conveyor .

At a location for receiving case bodies and lids , the reception conveyor is disposed between the two conveyors of the supply conveyor. Therefore, when the reception conveyor receives a case body and a lid, the central area of the case body is supported by the reception conveyor, and the opposite sides of the case body are supported by the two conveyors . As a result , the case body and the lid are prevented from being positionally displaced at the receiving location, and can be fed to the assembling line without being positionally corrected.

The assembling line preferably comprises a case body assembling line for assembling the light shielding member, the presser sheet, the light shielding sheet, and the discharge prevention sheets into the case body, a lid assembling line disposed parallel to the case body assembling line, for assembling the film presser on the lid, and a rod feed mechanism for successively feeding case bodies on the case body assembling line and lids on the lid assembling line at given intervals.

Since the assembling line is constructed of the case body assembling line and the lid assembling line, the

components (the light shielding member, the presser sheet, the light shielding sheet, the discharge prevention sheets, and the film presser) can be assembled on the case body and the lid independently of each other. Therefore, the components can be assembled highly efficiently.

Furthermore, the rod feed mechanism is used to successively feed case bodies and lids at the same speed on the assembling line. As a consequence, the components can be assembled into the case bodies and onto lids with higher efficiency in synchronism with the operation of the rod feed mechanism.

Preferably, the system further comprises a light shielding member assembling apparatus for assembling the light shielding member supplied from the light shielding member supply line, into the case body, a presser sheet assembling apparatus for assembling the presser sheet supplied from the presser sheet supply apparatus, into the case body, a light shielding sheet assembling apparatus for assembling the light shielding sheet supplied from the light shielding sheet supply apparatus, into the case body, a discharge prevention sheet assembling apparatus for assembling the discharge prevention sheets supplied from the discharge prevention sheet supply apparatus, into the case body, and a film presser assembling apparatus for assembling the film presser supplied from the film presser supply line, onto the lid, wherein the light shielding member assembling apparatus, the presser sheet assembling apparatus, the light

shielding sheet assembling apparatus, the discharge prevention sheet preassembling apparatus, and the film presser assembling apparatus are disposed, without facing to each other on both sides of the case body assembling line and the lid assembling line along a direction in which the case body and the lid are fed on the case body assembling line and the lid assembling line.

Because one station has only one assembling apparatus, no physical interference occurs between the assembling apparatus installed in the respective stations. As a space required for maintenance is provided for each of the apparatus, each of the apparatus can easily be serviced for maintenance .

Preferably, the presser sheet assembling apparatus has a presser sheet suction assembly for attracting the presser sheet, and a presser sheet applicator for applying a portion of the presser sheet which has been attracted, to the case body.

Since the presser sheet is applied to the case body while the presser sheet is being attracted, the light shielding member, as it is pressed by the presser sheet, is placed onto the bottom of the case body. Accordingly, the slit remains covered with the light shielding member to shield the interior of the case body against entry of light. The presser sheet suction assembly preferably comprises a plurality of suction ports defined in a distal end of a tapered block and arrayed in a longitudinal direction of the

presser sheet, and a plurality of suction passages defined in the tapered block in communication with the suction ports, wherein the presser sheet applicator projects from the distal end of the tapered block for applying the portion of the presser sheet to the case body with ultrasonic seal. While the presser sheet is being attracted through the suction ports and the suction passages, the presser sheet is applied to the case body by the ultrasonic seal produced by the presser seal applicator, so that the light shielding member is reliably pressed by the presser sheet and held on the bottom of the case body. Therefore, the slit reliably remains covered with the light shielding member.

Preferably, the suction ports extend away from the presser sheet applicator so as to provide a larger suction area for the presser sheet. The presser sheet can be thus applied while it is being reliably attracted through the suction ports.

The presser sheet applicator preferably has a plurality of pins arrayed in the longitudinal direction of the presser sheet. When the presser sheet is attracted under suction through the suction ports, the protruding pins bite into the presser sheet. Therefore, the presser sheet can be applied while it is being reliably attracted through the suction ports . Preferably, the discharge prevention sheet assembling apparatus comprises a discharge prevention sheet preassembling mechanism for temporarily assembling the

discharge prevention sheets into the case body, a discharge prevention sheet assembling mechanism for applying the discharge prevention sheets which have temporarily been assembled, and a discharge prevention sheet checking mechanism for checking the discharge prevention sheets for their shape and applied position on the case body.

The discharge prevention sheet checking mechanism checks the discharge prevention sheets for their shapes and applied positions. Accordingly, film cases can be manufactured highly accurately.

Preferably, the light shielding sheet supply apparatus has a feed interval control mechanism for feeding a light shielding sheet ribbon from a roll thereof by a predetermined length before the light shielding sheet ribbon is cut into the light shielding sheet and the light shielding sheet is supplied to the main assembling line, wherein the feed interval control mechanism comprises a motor for feeding the light shielding sheet ribbon, a camera for capturing an image of the light shielding sheet ribbon which has been fed and outputting the captured image, a feed interval calculator for calculating a feed interval required t to feed the light shielding sheet ribbon by the predetermined length, based on the image captured by the camera, and a motor controller for controlling the motor based on the feed interval which has been calculated.

Inasmuch as a feed interval for the light shielding sheet ribbon is controlled based on the image, light

shielding sheets of the predetermined length can be supplied to the main assembling line at all times .

Preferably, the light shielding sheet ribbon has a plurality of hot-melt seal members each capable of bonding the light shielding sheet to the one end of the case body, the hot-melt seal members being disposed at predetermined spaced intervals along a direction in which the light shielding sheet ribbon is fed, wherein the camera outputs an image of the light shielding sheet ribbon including one of the hot-melt seal members to the feed interval calculator, and the feed interval calculator calculates the difference between the present position of the hot-melt seal member and the position of the hot-melt seal member at a position in which the light shielding sheet ribbon is cut into the light shielding sheet, based on the image, and outputs the calculated difference as the feed interval to the motor controller.

Inasmuch as a feed interval for the light shielding sheet ribbon is controlled based on the image including the hot-melt seal member, light shielding sheets can highly accurately be supplied to the main assembling line.

Preferably, an application reference piece indicative of the position of the hot-melt seal member with respect to the position in which the light shielding sheet ribbon is cut into the light shielding sheet, is placed in the vicinity of the light shielding sheet ribbon which is fed so as to be included in the field of vision of the camera.

wherein the camera outputs an image of the application reference piece and the light shielding sheet ribbon including the hot-melt seal member to the feed interval calculator, and the feed interval calculator calculates the difference between the present position of the hot-melt seal member and the position of the application reference piece, based on the image, and outputs the calculated difference as the feed interval to the motor controller.

Inasmuch as a feed interval for the light shielding sheet ribbon is controlled based on the image including the hot-melt seal member and the application reference piece, light shielding sheets can highly accurately be supplied to the main assembling line.

Instead of the above arrangement for controlling the feed interval based on the image, the light shielding sheet supply apparatus may have a feed interval control mechanism for feeding a light shielding sheet ribbon from a roll thereof by a predetermined length, the light shielding sheet ribbon having a plurality of hot-melt seal members each capable of bonding the light shielding sheet to the one end of the case body, the hot-melt seal members being disposed at predetermined spaced intervals along a direction in which the light shielding sheet ribbon is fed, before the light shielding sheet ribbon is cut into the light shielding sheet and the light shielding sheet is supplied to the main assembling line, wherein the feed interval control mechanism comprises a motor for feeding the light shielding sheet

ribbon, a sensor for detecting a position on the light shielding sheet ribbon where the amount of reflected light changes sharply, as a position where a hot-melt seal member is present, a feed interval calculator for calculating a feed interval required to feed the light shielding sheet ribbon by the predetermined length, based on the positioned detected by the sensor, and a motor controller for controlling the motor based on the feed interval which has been calculated. The sensor detects a change in the amount of reflected light based on different component concentrations in the light shielding sheet ribbon and the seal members . Thus , the feed interval can be controlled more accurately for supplying highly accurate light shielding sheets to the main assembling line.

Preferably, the light shielding member comprises a displacement member locally covering the slit and movable along the slit, and a light shielding sheet strip applied to the displacement member and covering the slit to shield the interior of the case body against entry of light, wherein the light shielding member supply line comprises a displacement member supply mechanism for supplying the displacement member, a light shielding sheet strip supply mechanism for supplying the light shielding sheet strip, and a light shielding member assembling line for applying the light shielding sheet strip supplied by the light shielding sheet strip supply mechanism to the displacement member

supplied by the displacement member supply mechanism.

The light shielding sheet strip and the displacement member are applied to each other independently of the process of assembling the case body and the lid, on the light shielding member supply line separate from the main assembling line. Consequently, the light shielding member is assembled and the case body is assembled highly accurately.

Preferably, the displacement member supply mechanism comprises a reservoir for reserving displacement members, a feeder unit for arranging the displacement members supplied from the reservoir along a predetermined direction and thereafter feeding the displacement members , and a separator for holding and processing, one by one, the displacement members fed from the feeder unit into a predetermined shape, and delivering the processed displacement members, wherein the separator has a plurality of slots which are open toward the feeder unit for housing the displacement members therein, and when one of the displacement members is inserted into one of the slots which confronts the feeder unit, the separator is moved along a substantially arc path perpendicular to the direction in which the displacement member is inserted into the one of the slots to cause another of the slots to confront the feeder unit. Each time a displacement member is inserted into one slot in the separator by the feeder unit, the separator is moved to bring another slot in the separator into

confronting relation to the feeder unit. Accordingly, many displacement members can be separated within a short period of time, and hence the separator operates highly efficiently. Since the separator is moved along a substantially arc path perpendicular to the direction in which the displacement member is inserted, even if the displacement member projects from the feeder unit while the separator is in motion, the projecting displacement member does not interfere with the separator. Therefore, the yield of displacement members can be higher.

Preferably, the light shielding member supply line further comprises a displacement member checking line for checking the displacement member supplied by the displacement member supply mechanism, for its shape and orientation, and thereafter supplying the displacement member which has been checked, to the light shielding member assembling line.

As the displacement member check line checks displacement members in advance, the light shielding member assembling line is supplied with only displacement members that have been judged as acceptable in the checking process. Therefore , the accuracy and yield of the light shielding members can be higher.

Preferably, the light shielding member assembling line comprises a light shielding sheet strip preassembling mechanism for temporarily applying the light shielding sheet strip to the upper surface of the displacement member such

that the light shielding sheet strip projects from the displacement member as viewed in plan, a light shielding sheet strip presealing mechanism for presealing the light shielding sheet strip which has been temporarily applied, and a light shielding sheet strip assembling mechanism for finally applying the light shielding sheet strip which has been presealed.

A light shielding sheet strip is temporarily applied to the upper surface of a displacement member such that the light shielding sheet strip partly projects from the displacement member and is presealed and applied. When the light shielding member is placed over the slit, the projecting portion of the light shielding sheet strip covers the boundary between the displacement member and the slit, thus shielding the interior of the case body more securely against entry of light.

Preferably, the slit extends from a side of the case body at the other end to a bottom thereof, and the light shielding member assembling line comprises an incision forming mechanism for forming an incision in a longer side of the light shielding sheet strip near a corner of the displacement member, a longer side folding mechanism for inwardly folding a longer side portion near the incision of the light shielding sheet strip with the incision formed therein, toward the light shielding sheet strip, and a shorter side folding mechanism for inwardly folding a shorter side portion near the incision of the light

shielding sheet strip with the incision formed therein, at the incision toward the light shielding sheet strip .

The slit is covered with the light shielding member where the light shielding sheet strip is partly folded by folding the longer side portion on the incision side and the shorter side portion on the incision side. The shorter side portion covers the portion of the slit which is defined in the other end of the case body, and the longer side portion on the incision side covers the portion of the slit which is defined in the bottom of the case body. As a result, the interior of the case body is shielded more securely against entry of light when it is not in use. The incision allows the position to be folded of the shorter side portion to be easily identified and hence allow the shorter side portion to be easily folded. Accordingly, the process of folding the light shielding sheet strip can be made highly efficient .

Preferably, the shorter side folding mechanism inwardly folds the shorter side portion such that a segment of the inwardly folded longer side portion which extends from the incision and is on the side of the shorter side portion is positioned more inwardly of the case body than another segment of the inwardly folded longer side portion.

When the slit is covered with the light shielding member, the segment of the inwardly folded longer side portion which extends from the incision and is on the side of the shorter side portion is positioned more inwardly of

the case body than the other segment of the inwardly folded longer side portion. The portion of the slit which is close to the other end of the case body can be higher.

Preferably, the longer side folding mechanism comprises a longer side folding die for inwardly folding the longer side portion near the incision, and a first holding die for holding the portion of the light shielding sheet strip which is applied to the displacement member and a portion of the shorter side portion. The longer side portion can thus be folded reliably.

Preferably, the first holding die has a recess defined therein for locally lowering the amount of folding of the longer side portion folded by the longer side folding die, the recess being disposed in confronting relation to a portion of the longer side portion which extends from the incision to a central area of the longer side portion.

When the shorter side portion is folded, the segment of the inwardly folded longer side portion which is joined to the shorter side portion is inwardly folded more toward the light shielding sheet strip than the other segment of the inwardly folded longer side portion. When the slit is t covered with the light shielding member having the inwardly folded light shielding sheet strip, because the segment of the inwardly folded longer side portion which is joined to the shorter side portion is disposed ^' more inwardly of the case body than the other segment of the longer side portion, the portion of the slit which is defined in the other end of

the case body can be shielded more securely against entry of light .

Preferably, the shorter side folding mechanism comprises a shorter side folding die for folding the shorter side portion, and a second holding die for holding the portion of the light shielding sheet strip which is applied to the displacement member. The shorter side portion can thus be folded reliably.

Preferably, the second holding die has a projection for abutting a portion of the light shielding sheet strip which extends from the incision to a central area of the longer side portion to locally lower the amount of folding of the longer side portion when the shorter side folding die folds the shorter side portion. The projection is effective to locally reduce the amount of folding of the longer side portion. Therefore, when the light shielding member covers the slit, the segment of the longer side portion which is joined to the shorter side portion can be folded more inwardly of the case body than the other segment of the longer side portion.

Therefore, the portion of the slit which is defined in the other end of the case body can be shielded more securely against entry of light.

Preferably, the light shielding member assembling line further comprises a plurality of first suction mechanisms for attracting the displacement member, a plurality of second suction mechanisms for attracting the light shielding

sheet strip finally applied to the displacement member, and a placement rail for placing the displacement member thereon, the placement rail being disposed on a portion of the light shielding member assembling line which extends from an upstream side thereof to the light shielding sheet strip presealing mechanism, wherein each of the first suction mechanisms attracts and feeds the displacement member from a present position on the placement rail by a predetermined distance downstream of the placement rail, wherein the first suction mechanisms are disposed at predetermined spaced intervals downstream of the light shielding sheet strip presealing mechanism, and each of the second suction mechanisms attracts the light shielding sheet strip which has been presealed or finally applied, and feeds the light shielding sheet strip and the displacement member to which the light shielding sheet strip is applied from the present position to the first suction mechanism positioned downstream thereof.

The light shielding sheet strip or the displacement member is fed while the upper surface of the light shielding sheet strip is being attracted by first suction mechanism or the lower surface of the displacement member is being attracted by the second suction mechanism. Consequently, when the light shielding member or the displacement member is to be processed, it can easily be positioned in the feeding direction and the direction perpendicular to the feeding direction. As a result, the light shielding member

or the displacement member can be processed highly efficiently. As light shielding sheet strips and displacement members are successively fed, the light shielding members can efficiently be assembled by operating the apparatus disposed along the light shielding member assembling line in synchronism with the feeding timing. Preferably, the case body with the light shielding member, the presser sheet, the light shielding sheet, and the discharge prevention sheets being assembled therein, and the lid with the film presser assembled thereon are integrally assembled together on a downstream side of the main assembling line, and the system further comprises a sample pickup line disposed downstream of the main assembling line, for picking up the case body and the lid which have been integrally assembled together as a sample film case from the main assembling line. Consequently, sample film cases can efficiently be picked up from the main assembling line.

Preferably, the sample pickup line has a sample pickup chute for placing thereon the sample film case picked up from the main assembling line, the sample pickup chute having a plurality of recesses defined therein at predetermined spaced intervals for receiving a protrusion disposed on the one end of the film case near the film discharge slot.

Since the protrusion is housed in recesses, sample film cases can reliably be picked up from the main assembling

line through the sample pickup chute.

Preferably, each of the recesses has a depth progressively smaller along a direction in which the sample film case is fed on the sample pickup chute. The recesses are deepest at their ends closer to the main assembling line. Therefore, the sample film cases placed on the sample pickup chute are prevented from being delivered back toward the main assembling line. The depth of each of the recesses is progressively smaller along the feeding direction. Consequently, when a sample film case is transferred from the main assembling line onto the sample pickup chute, those sample film cases which have already been placed on the sample pickup chute are pushed along the feeding direction. As a result, the sample film cases can easily be picked up.

Preferably, the light shielding member supply line, the film presser supply line, or the main assembling line has a positioning member for positioning a side or upper portion of the case body, the lid, the light shielding member, or the film presser when the case body, the lid, the light shielding member, or the film presser is assembled or checked.

Since the case body, the lid, the light shielding member, or the film presser is highly accurately positioned, the case body, the lid, the light shielding member, or the film presser can be assembled or checked with high accuracy. As a result, the yield of film cases can be higher.

The above and other objects, features, and advantages of the present invention will become more apparent from the following description when taken in conjunction with the accompanying drawings in which preferred embodiments of the present invention are shown by way of illustrative example.

Brief Description of Drawings

FIG. 1 is a perspective view, as viewed from above, of a film case manufactured by a film case manufacturing system according to an embodiment of the present invention;

FIG. 2 is a perspective view, as viewed from below, the film case shown in FIG. 1 ;

FIG. 3 is an exploded perspective view of the film case shown in FIGS. 1 and 2; FIG. 4 is a perspective view of a case body of the film case shown in FIGS . 1 through 3 ;

FIG. 5 is an enlarged perspective view of a light shielding member mounted in the case body shown in FIG. 4;

FIG. 6 is a plan view of the film case manufacturing system according to the embodiment of the present invention;

FIG. 7 is a fragmentary perspective view of an assembling line;

FIG. 8 is a fragmentary perspective view illustrating the manner in which a case body and a lid are transferred from a case body/lid supplying apparatus to an assembling preparation line,-

FIG. 9 is a perspective view of a light shielding

member assembling apparatus;

FIG. 10 is a perspective view showing the manner in which a presser of the light shielding member assembling apparatus operates ; FIGS. HA through HE are fragmentary cross-sectional views showing a sequence of operation for placing a light shielding member into a case body;

FIG. 12 is a perspective view of a light shielding sheet strip applying mechanism of the light shielding member assembling apparatus;

FIGS. 13A through 13C are fragmentary cross-sectional views showing a sequence of operation for applying a light shielding sheet strip to an end of a case body;

FIG. 14 is a fragmentary perspective view of a presser sheet applying block of a presser sheet assembling apparatus ;

FIGS. 15A through 15C are fragmentary cross-sectional views showing the manner in which a presser sheet is applied by the presser sheet applying block; FIG. 16 is a block diagram of major components of a feed interval control mechanism;

FIG. 17 is a plan view showing an image that is supplied from a camera to an image checker of the feed interval control mechanism shown in FIG. 16; FIG. 18 is a side elevational view, partly in cross section, of a light shielding sheet assembling mechanism and a case body pressing mechanism;

FIG. 19 is a cross-sectional view of pressers of the case body pressing mechanism shown in FIG. 18;

FIG. 2OA is a plan view showing the shape of a heater in a conventional film case manufacturing system; FIG. 2OB is a plan view showing the shape of an applied seal formed by the heater shown in FIG. 2OA;

FIG. 2OC is a fragmentary cross-sectional view showing how a light shielding sheet attached to the case body by the applied seal shown in FIG. 2OB shields light; FIG. 21A is a plan view showing the shape of another heater in a conventional film case manufacturing system;

FIG. 2IB is a plan view showing the shape of an applied seal formed by the heater shown in FIG. 2IA;

FIG. 21C is a fragmentary cross-sectional view showing how a light shielding sheet attached to the case body by the applied seal shown in FIG. 21B shields light;

FIG. 22A is a plan view showing the shape of a heater in the film case manufacturing system according to the embodiment of the present invention; FIG. 22B is a plan view showing the shape of an applied seal formed by the heater shown in FIG. 22A;

FIG. 22C is a fragmentary cross-sectional view showing how a light shielding sheet attached to the case body by the applied seal shown in FIG. 22B shields light; FIGS. 23A through 23C are fragmentary cross-sectional views of a light shielding sheet assembling apparatus according to a first modification;

FIG. 24 is a fragmentary cross-sectional view of a light shielding sheet assembling apparatus according to a second modification;

FIG. 25 is a fragmentary cross-sectional view of a light shielding sheet assembling apparatus according to a third modification;

FIG. 26 is a fragmentary perspective view of a sample pickup line ;

FIGS. 27A and 27B are plan views showing an arc movement pattern of a separator;

FIG. 28 is a vertical cross-sectional view of a first suction mechanism;

FIG. 29 is a vertical cross-sectional view of first suction mechanisms; FIG. 30 is a vertical cross-sectional view of first and second suction mechanisms;

FIG. 31 is a perspective view of an image checking apparatus ;

FIG. 32 is a perspective view of a positioning mechanism and its actuating mechanism of the image checking apparatus shown in FIG. 31;

FIG. 33 is a perspective view of a positioning mechanism and its actuating mechanism of the image checking apparatus shown in FIG. 31; FIGS. 34A and 34B are plan views showing how the position in which a light shielding sheet strip is applied to a displacing member is checked;

FIG. 35 is a fragmentary perspective view showing the manner in which a light shielding sheet strip is bent by a longer side bending mechanism and a shorter side bending mechanism; FIG. 36 is a perspective view of major components of a bending action actuating mechanism for actuating the longer side bending mechanism and the shorter side bending mechanism;

FIG. 37 is a flowchart of an operation sequence of the assembling preparation line;

FIG. 38 is a flowchart of an operation sequence of a main assembling line;

FIG. 39 is a flowchart of an operation sequence of a case body assembling line; FIG. 40 is a flowchart of an operation sequence of assembling a light shielding member in a case body;

FIGS. 41 and 42 are a flowchart of an operation sequence of a light shielding member supply line;

FIG. 43 is a flowchart of an operation sequence of the light shielding member supply line;

FIG. 44 is a flowchart of an operation sequence of assembling a presser sheet in a case body;

FIG. 45 is a flowchart of an operation sequence of assembling a light shielding sheet in a case body; FIG. 46 is a flowchart of an operation sequence of assembling first and second discharge prevention sheets in a case body;

FIG. 47 is a flowchart of an operation sequence of a lid assembling line; and

FIG. 48 is a flowchart of an operation sequence of a film presser supply line.

Best Mode for Carrying Out the Invention

FIGS. 1 and 2 show in perspective a film case 10 manufactured by a film case manufacturing system according to an embodiment of the present invention. FIG. 3 shows in exploded perspective the film case 10 shown in FIGS. 1 and 2, and FIG. 4 shows in perspective a case body 14 of the film case 10. A sheet-like film 12 is made of a self- development photosensitive material, and is exposed to light when it is discharged out of the film case 10. As shown in FIGS. 1 through 4, the film case 10 basically comprises a substantially rectangular case body 14 that is capable of holding therein a plurality of sheet-like films 12, and a lid 16 closing the case body 14.

A film discharge slot 20 is defined in an end 18 of the case body 14 for discharging a sheet-like film out of the case body 14. A light shielding sheet 22 is applied to an outer side (a surface 19a) of the end 18 in covering relation to the film discharge slot 20.

Sides and a bottom (protrusion) 24 of the end 18 project outwardly to make rigid the end 18 in which the film discharge slot 20 is defined. The light shielding sheet 22 is mounted in a recess 28 that is defined in the end 18 and

is concave toward an opposite end 26 of the case body 14. The recess 28 is surrounded by an outer protrusive edge 30 made up of the sides, the bottom 24, and an upper face of the end 18. When the light shielding sheet 22 is mounted in the recess 28, the light shielding sheet 22 and the outer protrusive edge 30 coact to keep the film discharge slot 20 against entry of light or resistant to entry of light . The recess 28 has upper corners on its surface and the film discharge slot 20 has side and bottom surfaces. These upper corners and side and bottom surfaces are grained for a rougher finish than the other areas of the recess 28. When the light shielding sheet 22 is mounted in the recess 28, the grained corners and surfaces cooperate with the light shielding sheet 22 in making the film discharge slot 20 more resistant to entry of light.

The light shielding sheet 22 is applied in a cantilevered fashion to the portion of the recess 28 closer to the lid 16. The light shielding sheet 22 is applied to the case body 14 by an applied seal 32 having an irregularly shaped edge including a plurality of teeth projecting toward the film discharge slot 20 (see FIGS. 1 and 4). Specifically, the applied seal 32 comprises a base 32a extending on the light shielding sheet 22 in the longitudinal direction of the film discharge slot 20, first teeth 32b projecting from respective opposite ends of the base 32a toward the film discharge slot 20, a plurality of second teeth 32c arrayed between the first teeth 32b and

projecting toward the film discharge slot 20, and a third tooth 32d projecting from the center of the base 32a toward the film discharge slot 20.

The first teeth 32b and the third tooth 32d project longer than the second teeth 32c toward the film discharge slot 20. The second teeth 32c are arranged at given regular intervals between the first teeth 32b and the third tooth 32d. The protrusion distances that the teeth 32b, 32c, 32d project from the base 32a toward the film discharge slot 20 are progressively smaller in the order of the first teeth 32b, the third tooth 32d, and the second teeth 32c (first teeth 32b > third tooth 32d > second teeth 32c).

Two discharge prevention sheets 34a, 34b (hereinafter referred to as "first discharge prevention sheet 34a" and "second discharge prevention sheet 34b", respectively) are applied to a bottom 36 of the case body 14 near an inner side of the end 18, namely, near another surface 19b. The discharge prevention sheets 34a, 34b are bent into a substantially L-shape (see FIG. 3). The discharge prevention sheets 34a, 34b have respective proximal ends applied to the respective corners of the end 18 on the bottom 36, and respective distal ends held in contact with the other surface 19b of the end 18. The discharge prevention sheets 34a, 34b thus positioned are effective to prevent the sheet-like films 12 from being discharged through the film discharge slot 20 and also to keep the sheet-like films 12 against exposure to light in cooperation

with the light shielding sheet 22 when the film case 10 is not in use.

The case body 14 has a slit 38 defined therein and extending from a corner of the other end 26 to the bottom 36 thereof. When the film case 10 is loaded into a camera, a printer, or the like, a finger 40 (see FIG. 2) is inserted into the slit 38 for discharging a sheet-like film 12 out of the case body 14 through the film discharge slot 20.

A recess 44 is defined in the bottom 36 along a side wall 42 of the case body 14 in surrounding relation to the slit 38, and a land 46 is disposed on the bottom 36 and cooperates with the side wall 42 and the other end 26 in surrounding the recess 44 (see FIGS. 3 and 4). The recess 44 is spaced from the slit 38 by a ridge 48 that is disposed between the slit 38 and the recess 44 and surrounds the slit 38. Two teeth 50, 52 that are spaced respective certain distances from the slit 38 toward the end 18 are disposed in the recess 44.

The slit 38 is covered with a light shielding member 54 that is pressed against the bottom of the recess 44 by a presser sheet 56 applied to the land 46. The presser sheet 56 is substantially in the shape of a parallelogram. The presser sheet 56 covers a portion of the light shielding member 54 which is placed in the recess 44, or in other words, held against the bottom 36.

The light shielding member 54 comprises a substantially rectangular displacement member 58 for covering a portion of

the slit 38 which is positioned in the recess 44, and a light shielding sheet strip 60 applied to the upper surface of the displacement member 58 and bent into a substantially L-shape (see FIGS. 3 through 5). The displacement member 58 has two rails 62, 64 projecting from the lower surface thereof and extending along side edges of the ridge 48. The rails 62, 64 have respective ends, at the side of the end 18, joined to each other by an end wall 65 (see FIG. 5) which is closer to the end 18. When the displacement member 58 is placed in the case body 14 over the slit 38 and the light shielding sheet strip 60 on the displacement member 58 is pressed downwardly by the presser sheet 56 that is applied to the land 46, the rail 62 fits in the recess 44 along the side wall 42 and the other rail 64 fits in the recess 44 along the land 46, and the displacement member 58 has opposite side edges which abut the side wall 42 and a side edge of the land 46, respectively.

When the finger 40 is inserted into the slit 38 with the light shielding member 54 being thus mounted on the bottom 36 of the case body 14, the light shielding member 54 is displaced toward the end 18 under pressing forces from the finger 40 while the light shielding member 54 is being guided by the land 46, the ridge 48, and the side wall 42, until the end wall 65 moves over the tooth 50 into abutment against the tooth 52.

The displacement member 58 has a beveled edge 71 at a

corner thereof which is closer to the end 18. As shown in FIGS. 3 through 5, the light shielding sheet strip 60 is applied to the displacement member 58 such that the light shielding sheet strip 60 have portions projecting beyond the displacement member 58. Specifically, the light shielding sheet strip 60 has longitudinal side portions projecting beyond the longitudinal side edges of the displacement member 58 and an end portion projecting beyond an end of the displacement member 58, which is remote from the end wall 65, toward the other end 26 of the case body 14.

As a result, when the light shielding member 54 is placed in the case body 14, the projecting end portion (hereinafter referred to as "shorter side portion 66") of the light shielding sheet strip 60 covers the portion of the slit 38 which is defined in the other end 26, and the projecting longitudinal side portions of the light shielding sheet strip 60 cover the boundary regions between the bottom 36 and the displacement member 58.

The shorter side portion 66 is applied to the other end 26 in covering relation to the portion of the slit 38 which is defined in the other end 26. An applied seal 67 disposed on the shorter side portion 66 is substantially U-shaped so as to surround the portion of the slit 38 which is defined in the other end 26. As a consequence, the applied seal 67 on the shorter side portion 66 is effective to prevent external light from entering through the portion of the slit 38 which is defined in the other end 26 (see FIG. 4).

When the shorter side portion 66 is applied to the other end 26 with the slit 38 being covered with the light shielding member 54, the displacement member 58 covers the portion of the slit 38 which is positioned in the recess 44, and the light shielding sheet strip 60 covers the portion of the slit 38 which is defined in the other end 26 and the boundary regions between the bottom 36 and the displacement member 58. Accordingly, the light shielding member 54 prevents external light from entering through the slit 38, and cooperates with the light shielding sheet 22 and the discharge prevention sheets 34a, 34b in shielding the interior of the case body 14 against entry of light.

The portion (hereinafter referred to as "longer side portion 68") of the light shielding sheet strip 60 which projects toward the side wall 42 is folded toward the upper surface of the light shielding sheet strip 60. The longer side portion 68 has an incision 70. The shorter side portion 66 is folded toward the upper surface of the light shielding sheet strip 60 along the end of the displacement member 58 which is closer to the other end 26 (see FIGS. 4 and 5 ) .

The longer side portion 68 comprises a segment (hereinafter referred to as "first longer side segment 72") joined to the shorter side portion 66 and extending from the incision 70 toward the other end 26, and a segment

(hereinafter referred to as "second longer side segment 74") extending from the incision 70 toward the end 18 and

projecting beyond the corresponding side edge of the displacement member 58.

When the light shielding member 54 is placed in the case body 14 over the slit 38, the first longer side segment 72 and the second longer side segment 74 abut against the side wall 42, and the shorter side portion 66 joined to the first longer side segment 72 abuts against the other end 26. Since the longer side portion 68 has the incision 70, the portion of the first longer side segment 72 which is close to the incision 70 may be positioned inwardly of the portion of the second longer side segment 74 which is close to the incision 70 (see FIG. 4). As a result, the entry of external light through the slit 38 is reliably prevented. The lid 16 has two substantially oblong openings 80a, 80b defined therein. The lid 16 also has two ledges 84a, 84b disposed on a lower surface thereof for engaging respective side walls 42, 82 of the case body 14 (see FIGS. 1 and 3). A support foot 86 projects from the lower surface of the lid 16 at a position between the openings 80a, 80b. The ledges 84a, 84b and the support foot 86 serve to prevent the sheet-like films 12 held in the case body 14 from being bent toward the lid 16. Two crimp pins 88a, 88b also project from the lower surface of the lid 16 near the support foot 86. A colored foil 90 is applied to an upper surface of the lid 16. The colored foil 90 serves to indicate to the user the direction in which the film case 10 is to be loaded into a camera, a printer, or the like.

A film presser 92 is mounted on the lower surface of the lid 16. The film presser 92 has holes 94a, 94b defined centrally therein for the passage of the crimp pins 88a, 88b therethrough, and a hole 96 defined therein for the passage of the support foot 86 therethrough. The film presser 92 has a beveled corner near the slit 38, providing a cutout 92a for avoiding interference between the film presser 92 and the finger 40 that is inserted into the slit 38. After the crimp pins 88a, 88b are inserted respectively through the holes 94a, 94b, tip ends thereof are crimped to secure the film presser 92 to the lid 16. The film presser 92 also has a plurality of perforations 98 near the holes 94a, 94b, 96, for making the film presser 92 flexible.

The film case 10 thus constructed houses a plurality of sheet-like films 12 therein in a light-shielded fashion, and is loaded into a camera, a printer, or the like. Then, the finger 40 is inserted into the slit 38, pushing the light shielding sheet strip 60 to displace the shorter side portion 66 thereof away from the other end 26 of the case body 14 toward the end 18 thereof. When the finger 40 is inserted into the slit 38 again, the light shielding member 54 and the sheet-like film 12 placed on the bottom 36 are displaced toward the end 18 by the finger 40. As a result, the distal ends of the discharge prevention sheets 34a, 34b project outwardly from the film discharge slot 20 under the pressing forces of the sheet-like film 12, which is discharged out of the case body 14 through the film

discharge slot 20. The discharged sheet-like film 12 is exposed to light outside, recording a desired image thereon. During this time, the remaining sheet-like films 12 held in the film case 10 remain pressed against the bottom 36 at all times by pins (not shown) that are inserted through the openings 80a, 80b defined in the lid 16.

FIG. 6 shows in plan a film case manufacturing system 100 for manufacturing the film case 10.

The film case manufacturing system 100 comprises a case body/lid supply apparatus (not shown) for supplying a case body 14 and a lid 16 (see FIGS. 1 through 4), a light shielding member supply line 102 for supplying a light shielding member 54 (see FIGS. 3 through 5), a presser sheet supply apparatus 104 for supplying a presser sheet 56, a light shielding sheet supply apparatus 106 for supplying a light shielding sheet 22, a first discharge prevention sheet supply apparatus 108 for supplying a first discharge prevention sheet 34a, a second discharge prevention sheet supply apparatus 110 for supplying a second discharge prevention sheet 34b, a film presser supply line 112 for supplying a film presser 92, and a main assembling line 114 for assembling the light shielding member 54, the presser sheet 56, the light shielding sheet 22, and the first and second discharge prevention sheets 34a, 34b into the case body 14, and also assembling the supplied film presser 92 onto the lid 16.

The main assembling line 114 is essentially straight in

configuration, and comprises an assembling preparation line 116 for receiving the case body 14 and the lid 16 supplied from the case body/lid supply apparatus, and an assembling line 118 for assembling the above components into the received case body 14 and onto the received lid 16.

As shown in FIGS. 6 and 7, the assembling line 118 comprises a case body assembling line 120 for assembling the light shielding member 54, the presser sheet 56, the light shielding sheet 22, and the first and second discharge prevention sheets 34a, 34b into the case body 14, a lid assembling line 122 disposed parallel to the case body assembling line 120, for assembling the film presser 92 on the received lid 16, and a rod feed mechanism 124 for successively feeding case bodies 14 on the case body assembling line 120 and lids 16 on the lid assembling line 122 at given intervals.

On both sides of the case body assembling line 120 and the lid assembling line 122, there are arranged a light shielding member assembling apparatus 126 for assembling the light shielding member 54 supplied from the light shielding member supply line 102 into the case body 14, a presser sheet assembling apparatus 128 for assembling the presser sheet 56 supplied from the presser sheet supply apparatus 104 into the case body 14, a light shielding sheet assembling apparatus 130 for assembling the light shielding sheet 22 supplied from the light shielding sheet supply apparatus 106 into the case body 14, a first discharge

prevention sheet preassembling apparatus 132 for temporarily assembling the first discharge prevention sheet 34a supplied from the first discharge prevention sheet supply apparatus 108 into the case body 14, a film presser assembling apparatus 133 for assembling the film presser 92 supplied from the film presser supply line 112 onto the lid 16, and a second discharge prevention sheet preassembling apparatus 134 for temporarily assembling the second discharge prevention sheet 34b supplied from the second discharge prevention sheet supply apparatus 110 into the case body 14. These apparatus 126, 128, 130, 132, 133, 134 are disposed in sequence along the direction in which the case body 14 and the lid 16 are fed, i.e., along the direction from right to left in FIG. 6. The apparatus 126, 128, 130, 132, 133, 134 are positioned, without facing to each other, across the case body assembling line 120 and the lid assembling line 122.

FIG. 8 illustrates in fragmentary perspective the manner in which a case body 14 and a lid 16 are transferred from the case body/lid supplying apparatus to the assembling preparation line 116 (see FIG. 6).

As shown in FIG. 8, the case body/lid supplying apparatus transfers the case body 14 with the lid 16 placed thereon from a supply conveyor 138 to a reception conveyor 136 of the assembling preparation line 116. The case body 14 and the lid 16 are fed on the supply conveyor 138 with the end 18 being positioned upstream and the other end 26

downstream in the feeding direction (from left to right in FIG. 8), and then transferred to the receiving conveyor 136. The receiving conveyor 136 has a smaller width than the case body 14 in the direction perpendicular to the feeding direction.

The supply conveyor 138 comprises two parallel conveyors 140a, 140b disposed on the respective sides of an end thereof.

The supply conveyor 138 and the reception conveyor 136 operate as follows: The case body 14 has its laterally opposite sides supported respectively on the conveyors 140a, 140b of the supply conveyor 138. Rollers 144 engaging respective ends of the conveyors 140a, 140b are rotated, and a roller 142 engaging an end of the reception conveyor 136 is rotated. The case body 14 and the lid 16 that are placed on the conveyors 140a, 140b are transferred from the case body/lid supplying apparatus to the assembling preparation line 116 with the case body 14 having a central area supported on the reception conveyor 136. On the assembling preparation line 116, a plurality of sets of case bodies 14 and lids 16 are successively fed by the reception conveyor 136. One set of a case body 14 and a lid 16 is separated from the successive sets, and the case body 14 and the lid 16 are checked by a checking apparatus 146 (see FIG. 6) that is disposed in a downstream region of the assembling preparation line 116.

In the checking apparatus 146, corners of the case body

14 are positioned by a tapered positioning member 148 (see FIG. 7). With the corners of the case body 14 being thus positioned, the checking apparatus 146 checks (1) whether the case body 14 has the lid 16 or not, checks (2) the direction of the lid 16 with respect to the case body 14, and checks (3) the lifting (height) of the lid 16 with respect to the case body 14.

In the checking process (1), test pieces (not shown) complementary in shape to the openings 80a, 80b of the lid 16 (see FIGS. 1 and 3) are lowered to inspect whether the lid 16 is normally placed on the case body 14 or not. In the checking processes (2), (3), the height of the lid 16 is inspected by a laser sensor to check the lifting (height) of the lid 16 with respect to the case body 14. If a case body 14 and a lid 16 are found unacceptable in any of the checking processes (1) through (3), then they are rejected and discharged outside as defective pieces through a defective piece discharge line 150.

If a case body 14 and a lid 16 are found acceptable in all the checking processes (1) through (3), then they are turned 90° in orientation by a transfer apparatus 152 that is disposed downstream of the assembling preparation line 116, and then transferred to the case body assembling line 120 (see FIGS. 6 and 7) . Upstream of the light shielding member assembling apparatus 126 of the case body assembling line 120, there are disposed a transfer apparatus 154 for transferring only

the lid 16, of the case body 14 and the lid 16 that have been transferred thereto, to the lid assembling line 122, and a checking apparatus 156 for checking whether the case body 14 and the lid 16 are separate from each other or not downstream of the transfer apparatus 154.

The transfer apparatus 154 attracts and grips the lid 16 from above, and transfers the lid 16 from the case body assembling line 120 to the lid assembling line 122 in a direction perpendicular to the feeding direction of the assembling line 118. At this time, the transfer apparatus 154 transfers the lid 16 with its upper surface facing upwardly to the lid assembling line 122. The checking apparatus 156 confirms the separation of the case body 14 and the lid 16 from each other with a sensor, not shown. As shown in FIG. 7, the assembling line 118 includes a single elongate plate 158 extending in the feeding direction and having side walls 160a, 160b, 160c disposed on side and central regions thereof. The side walls 160a, 160b, 160c define two passages therebetween which serve as the case body assembling line 120 and the lid assembling line 122, respectively .

The case body 14 is placed between the side walls 160b, 160c with its longitudinal axis extending perpendicularly to the feeding direction. The lid 16 is placed between the side walls 160a, 160b with its longitudinal axis extending perpendicularly to the feeding direction.

The plate 158 also has two slits 162a, 162b defined

therein respectively on the case body assembling line 120 and the lid assembling line 122 along the feeding direction. The rod feed mechanism 124 has fingers 164a, 164b inserted respectively through the slits 162a, 162b. The rod feed mechanism 124 also has a single elongate plate 166 extending along the feeding direction, and the fingers 164a, 164b project upwardly from the plate 166 at predetermined spaced intervals along the feeding direction.

Each of the spaced intervals between the fingers 164a, 164b is substantially the same as the width of the case body 14 and the lid 16. The fingers 164a, 164b are inserted through the slits 162a, 162b. On the case body assembling line 120, each of the case bodies 14 is positioned in the feeding direction by and between two fingers 164b and positioned in the direction perpendicular to the feeding direction by and between the side walls 160b, 160c. On the lid assembling line 122, each of the lids 16 is positioned in the feeding direction by and between two fingers 164a and positioned in the direction perpendicular to the feeding direction by and between the side walls 160a, 160b.

In FIG. 7, the lower surface of each of the lids 16 is shown as facing upwardly on the lid assembling line 122. However, the lower surface of each of the lids 16 may face downwardly . The rod feed mechanism 124 includes a cam and link mechanism (not shown) for moving the plate 166 a predetermined distance in the feeding direction and also

moving the plate 166 vertically thereby to feed the case bodies 14 and the lids 16 intermittently by a predetermined pitch. The predetermined distance that the rod feed mechanism 124 moves the plate 166 is the same as the interval between an upstream pair of fingers 164a, 164b and a downstream pair of fingers 164a, 164b. In FIG. 7, the rod feed mechanism 124 moves back and forth and also moves vertically, as indicated by the solid-line arrows.

For assembling the light shielding member 54, the presser sheet 56, the light shielding sheet 22, and the first and second discharge prevention sheets 34a, 34b into the case body 14 (see FIGS. 1 through 4) on the case body assembling line 120, the case body 14 is positioned by a positioning member 148. For assembling the film presser 92 onto the lid 16 on the lid assembling line 122, the lid 16 is positioned by another positioning member 148. Specifically, as shown in FIG. 7, the side wall 160c has a recess 168 defined therein, and corners of the case body 14 at the end 18 are engaged and positioned by the positioning member 148 that is inserted through the recess 168 on the case body assembling line 120. On the lid assembling line 122, the positioning member 148 is lowered to engage and position the lid 16.

Alternatively, the positioning member 148 may be lowered to engage and position the side walls 42, 82 of the case body 14 on the case body assembling line 120, and the side wall 160a may have a recess, not shown, defined therein

and corners of the lid 16 may be engaged and positioned by the positioning member 148 that is inserted through the recess defined in the side wall 160a.

FIG. 9 shows in perspective the light shielding member assembling apparatus 126. FIG. 10 shows in perspective the manner in which the light shielding member 54 supplied from the light shielding member supply line 102 is positioned by a light shielding member positioning mechanism 170 and placed in the case body 14. FIGS. HA through HE show in fragmentary cross section a sequence of operation for placing the light shielding member 54 into the case body 14. FIG. 12 shows in perspective a light shielding sheet strip applying mechanism 172 for applying the shorter side portion 66 of the light shielding sheet strip 60 to the other end 26 of the case body 14. FIGS. 13A through 13C show in fragmentary cross section a sequence of operation for applying the shorter side portion 66 to the other end 26 of the case body 14 with the light shielding sheet strip applying mechanism 172. As shown in FIGS. 9, 10, 12, the light shielding member assembling apparatus 126 comprises a positioning member (case body positioning member) 148 for positioning corners of the case body 14 at the end 18, a light shielding member positioning mechanism 170 for positioning the light shielding member 54 supplied from the light shielding member supply line 102 (see FIG. 6), a light shielding member attracting mechanism 174 for attracting under suction the

light shielding sheet strip 60 of the light shielding member 54 that has been positioned and moving the light shielding member 54 to a position near the slit 38, a guide support mechanism 176 for supporting the lower surface of the displacement member 58 through the slit 38 and guiding the light shielding member 54 into the slit 38 in coaction with the light shielding member attracting mechanism 174, a light shielding member pressing mechanism 178 for pressing the light shielding sheet strip 60 of the light shielding member 54 from above, and a light shielding sheet strip applying mechanism 172 for applying the shorter side portion 66 of the light shielding sheet strip 60 to the other end 26 of the case body 14.

The light shielding member positioning mechanism 170 has positioning members 180a through 18Od for positioning the displacement member 58 of the light shielding member 54 that is supplied from the light shielding member supply line 102 (see FIG. 6). While the lower surface of the displacement member 58 is being attracted and gripped by a suction member (not shown), longer side edges of the displacement member 58 are sandwiched by the confronting positioning members 180a, 180c and shorter side edges of the displacement member 58 are sandwiched by the confronting positioning members 180b, 18Od, thereby positioning the light shielding member 54.

The positioning members 180a through 18Od are movable by a cam mechanism (not shown) and are normally biased by

resilient members (not shown) to press the displacement member 58. One of the two confronting positioning members of each pair serves as a reference positioning member, and is biased under larger resilient forces to press the displacement member 58. The other positioning member is biased under smaller resilient forces to press the displacement member 58.

The light shielding member attracting mechanism 174 has a substantially rectangular suction block 182 for attracting under suction the light shielding sheet strip 60 of the light shielding member 54. The suction block 182 is supported on a slide block 186 by two upwardly extending support rods 184a, 184b. The suction block 182 attracts under suction a portion of the region of the light shielding sheet strip 60 which is applied to the displacement member 58. The slide block 186 is movable in the direction perpendicular to the feeding direction, i.e., in the longitudinal direction of the case body 14 in FIG. 9, along a guide rail 190 mounted on an upstanding slide table 188. The slide table 188 is vertically movable along a guide rail 194 mounted on an upstanding table 192.

The slide block 186 is operatively coupled to an end of a substantially V-shaped pivoted link 198 by a joint 196, and the other end of the link 198 is operatively coupled to a link 200. The slide table 188 is operatively coupled to an end of a substantially V-shaped pivoted link 204 by a joint 202, and the other end of the link 204 is operatively

coupled to a link 206.

When the link 200 is vertically moved by a cam mechanism, not shown, the link 198 is turned about its pivot, causing the joint 196 to move the slide block 186 and the suction block 182 in the direction perpendicular to the feeding direction while being guided by the guide rail 190. When the link 206 is vertically moved by a cam mechanism, not shown, the link 204 is turned about its pivot, causing the joint 202 to move the slide table 188, the slide block 186, and the suction block 182 in the vertical direction.

Therefore, when the links 200, 206 are vertically moved while the region of the light shielding sheet strip 60 which is applied to the displacement member 58 is being attracted from above under suction by the suction block 182, the light shielding member 54 can be moved from the light shielding member positioning mechanism 170 to a position above the slit 38 in the case body 14.

The support rods 184a, 184b coupled to the suction block 182 extend through the slide block 186 and are connected to a plate 208 placed on the upper surface of the slide block 186. The slide block 186 has a lower surface held in engagement with cylindrical sleeves 210a, 210b through which the support rods 184a, 184b extend. Helical springs 212a, 212b are disposed around the respective support rods 184a, 184b between the sleeves 210a, 210b and the suction block 182.

When the sleeves 210a, 210b are lowered, the suction

block 182 is lowered under the resiliency of the helical springs 212a, 212b.

For the suction block 182 to attract and hold the light shielding member 54 that is positioned by the light shielding member positioning mechanism 170, the slide table 188 is lowered to lower the lower surface (suction surface) of the suction block 182 to a predetermined position with respect to the light shielding sheet strip 60, so that the lower surface of the suction block 182 is pressed against the upper surface of the light shielding sheet strip 60 under the resiliency of the helical springs 212a, 212b. Then, the suction block 182 starts to attract the light shielding sheet strip 60 under suction.

The guide support mechanism 176 comprises a blade- shaped clamp (guide support member) 214 disposed directly below the slit 38 in the case body 14, and a support member 216 which supports the lower proximal end of the clamp 214. The support member 216 is coupled to a link 218. The clamp 214 has an upper distal end that is tapered upwardly. The clamp 214 has a width small enough to be inserted through the portion of the slit 38 that is defined in the bottom 36. When the clamp 214 is moved upwardly and inserted through the slit 38, the tapered distal end of the clamp 214 positions the lower surface of the displacement member 58 highly accurately for guiding the light shielding member 54 to the slit 38.

Specifically, when the link 218 is vertically moved by

a cam mechanism, not shown, the support member 216 moves the clamp 214 into and out of the slit 38 (see FIGS. HA through HE) . If the light shielding member 54 is positioned above the slit 38 by being attracted by the suction block 182, then the distal end of the clamp 214 inserted through the slit 38 can support the lower surface of the displacement member 58 of the light shielding member 54.

When the light shielding member 54 is guided onto the bottom 36 of the case body 14, the shorter side portion 66 of the light shielding sheet strip 60 contacts the other end 26 and the longer side portion 68 thereof contacts the side wall 42. Therefore, the other end 26 and the side wall 42 apply reactive forces to the shorter side portion 66 and longer side portion 68, tending to positionally displace the light shielding member 54 with respect to the bottom 36. According to the present invention, however, the light shielding sheet strip 60 of the light shielding member 54 is attracted and held by the suction block 182 from above and the displacement member 58 of the light shielding member 54 is supported by the clamp 214 from below. Therefore, regardless of the reactive forces from the other end 26 and the side wall 42, the light shielding member 54 is securely placed in position in the case body 14 while being vertically held by the suction block 182 and the clamp 214. The light shielding member pressing mechanism 178 has a substantially L-shaped presser 220 for pressing the light shielding sheet strip 60 of the light shielding member 54.

The presser 220 has a distal end portion 222a for pressing, from above, a portion of the region of the light shielding sheet strip 60 which is applied to the displacement member 58. The presser 220 also has a substantially rectangular proximal end portion 222b supported on a support member 226 by a presser pivot 224.

Since the upper surface of the light shielding sheet strip 60 is attracted by the suction block 182, the distal end portion 222a of the presser 220 presses a remaining portion of the applied region of the light shielding sheet strip 60 which is not attracted by the suction block 182, or stated otherwise, a portion of the light shielding sheet strip 60 which is closer to the end 18 of the case body 14. The support member 226 extends longitudinally of the case body 14 and has a central recess 228 defined therein which accommodates the proximal end portion 222b therein. The presser pivot 224 is fixed to the support member 226 at a lower surface thereof near the recess 228, and includes a turn rod 230 by which the proximal end portion 222b is pivotally supported. A substantially T-shaped angular range limiter 232 extends through the support member 226 and is mounted on the upper surface of the presser 220. A spring 234 for normally urging the presser 220 to move toward the light shielding sheet strip 60 is interposed between the support member 226 and the presser 220.

The presser 220 is movable within a range that is defined between the upper surface of the presser 220 and an

upper tip end 236 of the angular range limiter 232.

The support member 226 has a proximal end fixed to a rectangular slide block 240 by screws 238 for movement in the feeding direction and back along a guide rail 244 mounted on an upstanding slide table 242. The slide table 242 is vertically movable along two guide rails 248a, 248b mounted on an upstanding table 246. A link 250 is coupled to the slide block 240, and a link 252 is coupled to the slide table 242. When the link 250 is moved in the feeding direction by a cam mechanism, not shown, the slide block 240, the support member 226, and the presser 220 is also moved in the feeding direction. When the link 252 is vertically moved by a cam mechanism, not shown, the slide table 242, the slide block 240, the support member 226, and the presser 220 is also vertically moved.

As shown in FIGS. 10, 12, 13A through 13C, the light shielding sheet strip applying mechanism 172 has a substantially U-shaped heater 254 and a substantially L- shaped presser 256. The presser 256 has a distal end portion 258 extending through the heater 254 out of contact with its opposite sides toward the other end 26 of the case body 14 for pressing the light shielding sheet strip 60 against the bottom 36 of the case body 14. With the light shielding sheet strip 60 being pressed against the bottom 36 of the case body 14 by the presser 256, the heater 254 moves toward the other end 26 into

abutment against the shorter side portion 66 of the light shielding sheet strip 60 for applying the shorter side portion 66 to the other end 26. Specifically, the heater 254 is of the U shape surrounding the portion of the slit 38 which is defined in the other end 26. The reverse side of the shorter side portion 66 which faces the other end 26 has a hot-melt seal member, not shown, disposed thereon. When the heater 254 abuts against the shorter side portion 66 and heats the abutting region thereof, the portion of the hot- melt seal member which corresponds to the heater 254 is fused and fixed as the U-shaped applied seal 67 to the other end 26. As a result, the shorter side portion 66 is applied to the other end 26 by the U-shaped applied seal 67 (see FIG. 4). The light shielding sheet strip applying mechanism 172 monitors the heated temperature of the heater 254. If the shorter side portion 66 is applied to the other end 26 of the case body 14 at a temperature out of a predetermined temperature range, then the light shielding sheet strip applying mechanism 172 can reject the case body 14 as a defective component or can shut down the film case manufacturing system 100 in its entirety.

The heater 254 is supported by a support block 260 that is coupled to a cylinder rod 268 of an actuator 266 by a substantially L-shaped thermally insulative joint 264.

When the actuator 266 is operated to move the cylinder rod 268 back and forth at certain time intervals in the

longitudinal direction of the case body 14, the thermally insulative joint 264, the support block 260 and the heater 254 are also moved back and forth in the longitudinal direction of the case body 14. The cylinder rod 268 should preferably be moved back and forth in ganged relation to the rod feed mechanism 124 (see FIG. 7). However, if the cylinder rod 268 stops when it has moved toward the other end 26 of the case body 14 or if the cylinder rod 268 is moved back and forth at a speed lower than the rod feed mechanism 124, then the heater 254 presses the shorter side portion 66 of the light shielding sheet strip 60 for a long period of time, tending to make the case body 14 defective. To avoid such a drawback, the actuator 266 is arranged such that when the heater 254 displaced forwardly by the cylinder rod 268 has heated the shorter side portion 66 for a given period of time, the actuator 266 retracts the cylinder rod 268 to prevent the heater 254 from heating the shorter side portion 66 more than necessary. The thermally insulative joint 264 also functions to block the transfer of heat from the support block 260 and the heater 254 to the cylinder rod 268 and the actuator 266. The actuator 266 is fixed to an upstanding slide table 270, and the presser 256 is supported on the slide table 270 by a support block 262. The slide table 270 is vertically movable along a guide rail 274 mounted on an upstanding table 272.

A link 276 is coupled to the slide table 270. When the link 276 is vertically moved by a cam mechanism, not shown, the slide table 270 is vertically moved while being guided by the guide rail 274, causing the actuator 266 coupled to the slide table 270, the cylinder rod 268, the thermally insulative joint 264, and the support block 260 to move the heater 254 vertically, and also causing the support block 262 coupled to the slide table 270 to move the presser 256 vertically. The presser 256 has a proximal end portion 259 coupled to the support block 262, which has a presser displacement member 261 on its distal end portion. The presser displacement member 261 is of a structure similar to the proximal end portion 222b of the presser 220, the turn rod 230, the angular range limiter 232, and the spring 234 (see FIG. 9) described above.

Specifically, the proximal end portion 259 of the presser 256 is pivotally supported on the support block 262 by a turn rod 263, and the presser displacement member 261 has a distal end portion extending along the proximal end portion 259. A substantially T-shaped angular range limiter 265 extends through the presser displacement member 261 and is mounted on the distal end portion of the presser displacement member 261. A spring 267 for normally urging the presser 256 to move toward the light shielding sheet strip 60 is interposed between the presser 256 and the presser displacement member 261.

The presser 256 is movable within a range that is defined between the upper surface of the presser 256 and an upper tip end 269 of the angular range limiter 265.

In the light shielding member assembling apparatus 126, the respective cam mechanisms for actuating the links 200, 206, 218, 250, 252, 276 (see FIGS. 9 and 12) are operated in synchronism with the cam and link mechanism (not shown) for actuating the rod feed mechanism 124, and the light shielding member positioning mechanism 170 is also operated in synchronism with the cam and link mechanism for positioning the light shielding member 54. As a result, the light shielding member positioning mechanism 170, the light shielding member attracting mechanism 174, the guide support mechanism 176, the light shielding member pressing mechanism 178, and the light shielding sheet strip applying mechanism 172 of the light shielding member assembling apparatus 126 can be operated in synchronism with rod feeding operation of the rod feed mechanism 124 (see FIG. 7).

In the light shielding member assembling apparatus 126, as shown in FIGS. 9 through 13A - 13C, the corners of the end 18 of a case body 14 which has been fed along the feeding direction on the case body assembling line 120 (see FIGS. 6 and 7) is positioned by the positioning member 148. When a light shielding member 54 is supplied from the light shielding member supply line 102, the positioning members

180a, 180c grip the longer side portions of the displacement member 58 and the positioning members 180b, 18Od grip the

shorter side portions of the displacement member 58, thereby positioning the light shielding member 54 (see FIG. 10).

The positioned light shielding member 54 is fed to a position over the slit 38 of the case body 14 when the suction block 182 is moved by the light shielding member attracting mechanism 174 while the upper surface of the light shielding sheet strip 60 is being attracted by the suction block 182 of the light shielding member attracting mechanism 174 (see FIGS. 9, 10, and HA) . When the light shielding member 54 is thus fed, the lower surface of the displacement member 58 is supported by the clamp 214 that has been inserted through the slit 38. As a consequence, the light shielding member 54 is vertically gripped by the clamp 214 and the suction block 182 (FIG. HB). While the light shielding member 54 is being vertically gripped, a portion of the light shielding sheet strip 60 is pressed downwardly by the presser 220, and the presser 220, the suction block 182, and the clamp 214 are lowered, so that the clamp 214 guides and places the light shielding member 54 onto the bottom 36 of the case body 14 (FIGS. HC and HD).

Since the light shielding member 54 thus placed is pressed against the bottom 36 of the case body 14 by the presser 220, the suction block 182 and the clamp 214 can be separated from the light shielding member 54 (FIG. HE). While the light shielding member 54 being pressed by the presser 220, the case body 14 is fed by the rod feed

mechanism 124 (see FIG. 7 ) to a next station disposed in the light shielding sheet strip applying mechanism 172 (see FIGS. 10 and 12) .

Then, the light shielding sheet strip applying mechanism 172 is lowered to a position near the light shielding sheet strip 60 in the case body 14 that has been fed. When the light shielding sheet strip applying mechanism 172 is further lowered, the distal end portion 258 of the presser 256 is brought into engagement with the light shielding sheet strip 60, pressing the light shielding sheet strip 60 downwardly toward the bottom 36 (see FIG. 13B).

When the distal end portion 258 of the presser 256 presses the light shielding sheet strip 60, the presser 220 is separated from the light shielding sheet strip 60 and returns to the upstream station (see FIGS. 10 and 13C). The cylinder rod 268 is displaced toward the other end 26 of the case body 14 to displace the heater 254 toward the other end 26 into abutment against the shorter side portion 66. The heater 254 then heats the region of the other end 26 which is covered with the shorter side portion 66 for a predetermined period of time (see FIGS. 10 and 13C). As a result, the substantially U-shaped applied seal 67 is formed on the covered region of the other end 26 (see FIG. 4). After the heater 254 has heated the shorter side portion 66 of the light shielding sheet strip 60 for a predetermined period of time, the actuator 266 is operated to retract the cylinder rod 268 to separate the heater 254

from the shorter side portion 66. Then, the slide table 270 is elevated to separate the heater 254 and the presser 256 upwardly from the light shielding member 54. In FIG. 10, the sequence of operation of the presser 220 during the assembly of the light shielding member 54 into the case body 14 is represented by arrows.

As shown in FIG. 6, the presser sheet supply apparatus 104 feeds a presser sheet ribbon 278 by a predetermined length. The presser sheet ribbon 278 thus fed is cut by a cutting mechanism 280 to predetermined dimensions, thereby forming a substantially rectangular presser sheet 56. The presser sheet 56 is supplied to the presser sheet assembling apparatus 128.

The cutting mechanism 280 operates as follows: The presser sheet ribbon 278 is gripped by a suction block, not shown, similar to the suction block 182 (see FIG. 9) and a cutter, not shown. Then, the presser sheet ribbon 278 is cut by the cutter, which is disposed obliquely to the presser sheet ribbon 278, thereby producing the presser sheet 56 which is substantially in the shape of a parallelogram. From the time when the presser sheet ribbon 278 is cut to the presser sheet 56 to the time when the presser sheet 56 is supplied to the presser sheet assembling apparatus 128, the presser sheet 56 can reliably be fed to the presser sheet assembling apparatus 128 without any cutter having a suction means in the path from the cutting mechanism 280 to the presser sheet assembling apparatus 128.

The presser sheet ribbon 278 may be severed by the cutter at the same time that it is gripped by the suction block.

As shown in FIGS. 14 and 15A - 15C, the presser sheet assembling apparatus 128 has a downwardly tapered presser sheet applying block 282 having a distal end 284 with a plurality of suction ports 286 defined therein for attracting a presser sheet 56. The suction ports 286 are arrayed in the longitudinal direction of the presser sheet 56. The suction ports 286 are connected to a suction passage 290 defined in the presser sheet applying block 282 and coupled to a suction pump, not shown, through a plurality of suction passages 288 that are defined in the presser sheet applying block 282. The distal end 284 also has a land (presser sheet applicator) 292 extending along the suction ports 286 and projecting downwardly. The land

292 has a plurality of protruding pins 294 arrayed along the suction ports 286.

The suction ports 286 are formed by counterboring so as to extend away from the land 292. Specifically, the suction ports 286 have respective central axes offset from the respective axes of the suction passages 288 in a direction away from the land 292. Therefore, when the suction ports 286 attract the presser sheet 56 to the distal end 284 due to a vacuum developed through the suction passages 288, 290 by the suction pump (not shown), the presser sheet applying block 282 provides a relatively large area for attracting the presser sheet 56 through the suction ports 286.

Accordingly, the presser sheet applying block 282 can attract the presser sheet 56 reliably.

When the distal end 284 attracts the presser sheet 56 through the suction ports 286, the land 292 generates ultrasonic vibrations and applies the ultrasonic vibrations to the contacting area of the presser sheet 56. At the same time, the protruding pins 294 bite into the presser sheet 56, enabling the presser sheet applying block 282 to attract and hold the presser sheet 56 more securely, and transmit the ultrasonic vibrations reliably to the presser sheet 56.

The suction ports 286 and the suction passages 288, 290 are basically symmetrical in shape with respect to the longitudinal direction (vertical direction in FIG. 14) and the transverse direction of the presser sheet applying block 282. The symmetrical configuration of the suction ports 286 and the suction passages 288, 290 is effective to avoid any adverse effects on the transmission of the ultrasonic vibrations from an ultrasonic transducer, not shown, to the land 292. In the presser sheet assembling apparatus 128, the presser sheet applying block 282 is vertically displaced by a mechanism which is essentially similar to the light shielding member attracting mechanism 174 and the light shielding member pressing mechanism 178 (see FIG. 9). Therefore, details of such a mechanism will not be described below.

In the presser sheet assembling apparatus 128, the

upper surface of a presser sheet 56 supplied from the presser sheet supply apparatus 104 is attracted and held by the distal end 284 of the presser sheet applying block 282, and the presser sheet 56 thus attracted and held is displaced to a position near the light shielding member 54 mounted in the case body 14 (see FIG. 15A).

The portion of the presser sheet 56 that confronts the light shielding member 54 is attracted and held by the suction ports 286, and the portion of the presser sheet 56 that confronts the land 46 (see FIGS. 3 and 4) is curved along the land 292 and engaged by the protruding pins 294 which bite thereinto. Then, the presser sheet applying block 282 is lowered toward the bottom 36 of the case body 14, pressing the presser sheet 56 against the land 46 and causing the land 292 to generate ultrasonic vibrations for a predetermined period of time. The generated ultrasonic vibrations are transmitted to the presser sheet 56, which is fused and fixed to the land 46 (see FIG. 15B).

When the presser sheet 56 is mounted in the case body 14 by the fused portion thereof, the presser sheet applying block 282 stops attracting the presser sheet 56 and also stops generating ultrasonic vibrations from the land 292, and then is displaced upwardly away from the presser sheet 56 (see FIG. 15C) . The above process of assembling the presser sheet 56 is performed in synchronism with rod feeding operation of the rod feed mechanism 124 (see FIG. 7), as with the light

- 6 A -

shielding member assembling apparatus 126.

As shown in FIG. 6, an image checking apparatus 299 for checking the position and shape of a presser sheet 56 that is applied to the case body 14 is disposed downstream of the presser sheet assembling apparatus 128, and a light shielding member checking apparatus 300 for checking the applied height of a light shielding member 54 (see FIG. 4) is disposed downstream of the image checking apparatus 299. In the light shielding member checking apparatus 300, after the case body 14 is positioned downwardly by the positioning member 148 (see FIG. 7), a length measuring sensor (not shown) inspects the applied height of the light shielding member 54 with respect to the case body 14 with a laser beam that is applied upwardly through an opening, not shown, defined in the plate 158. In addition, the light shielding member checking apparatus 300 may also have a movable sensor head which is moved to determine whether the light shielding member 54 is present or not and whether the light shielding member 54 is applied to a predetermined position or not. An image checking apparatus 302 for checking the applied position in which the light shielding member 54 is applied to the case body 14 is disposed downstream of the light shielding member checking apparatus 300. In the image checking apparatus 302, after the case body 14 is positioned downwardly by the positioning member 148 (see FIG. 7), the lower surface of the displacement member 58 is imaged by a camera, not shown, through an opening, not shown, defined in

the plate 158, and the applied position of the displacement member 58 with respect to the case body 14 is checked based on the image captured by the camera. A prism, not shown, may be disposed below the light shielding member 54 and the displacement member 58 may be imaged through the prism by the camera that is oriented horizontally.

Downstream of the image checking apparatus 302, there is disposed a foil applying apparatus 304 across the case body assembling line 120 and the lid assembling line 122, for applying a foil 90 (see FIG. 1) to the lid 16. The foil applying apparatus 304 has a heating metal plate, not shown, which presses a foil tape 306 with heat against the upper surface of the lid 16 (see FIG. 1) for a predetermined period of time. The heated and pressed portion of the foil tape 306 is transferred as the foil 90 to the lid 16.

The foil applying apparatus 304 has tension rollers, not shown, disposed on both sides of the case body assembling line 120 and the lid assembling line 122. The tension rollers apply a predetermined amount of tension to the foil tape 306 to keep the foil tape 306 under given tension when the foil tape 306 is peeled off from the lid 16 to which the foil 90 has been transferred.

Since the foil tape 306 extends across the case body assembling line 120 and the lid assembling line 122, small severed fragments from the foil 90 are attached to the foil tape 306 from which the foil 90 has been separated. A foil fragment receiver, not shown, for holding small severed

fragments from the foil 90 is disposed downstream of the foil tape 306 to prevent those small severed fragments from dropping onto the case body 14 and the lid 16.

An image checking apparatus 307 for checking the transferred quality of the foil 90 is disposed downstream of the foil applying apparatus 304 along the lid assembling line 122.

Downstream of the image checking apparatus 307, there is also disposed an image checking apparatus 308 along the case body assembling line 120 for inspecting a folded state of the first longer side segment 72 with respect to the second longer side segment 74 of the light shielding sheet strip 60 (see FIGS. 3 through 5). In the image checking apparatus 308, the first longer side segment 72 and the second longer side segment 74 are imaged by a camera, not shown, and it is inspected based on the captured image whether the portion of the first longer side segment 72 which is close to the incision 70 is positioned inwardly of the portion of the second longer side segment 74 which is close to the incision 70 or not.

A lid inverting apparatus 310 for turning the lower surface of a lid 16 upwardly in synchronism with rod feeding operation of the rod feed mechanism 124 is disposed downstream of the image checking apparatus 308 along the lid assembling line 122.

As shown in FIG. 6, the light shielding sheet supply apparatus 106 feeds a light shielding sheet ribbon 320 by a

predetermined length, as with the presser sheet supply apparatus 104. The light shielding sheet ribbon 320 thus fed is cut by a cutting mechanism 322 to predetermined dimensions, thereby forming a substantially rectangular light shielding sheet 22. The light shielding sheet 22 is supplied to the light shielding sheet assembling apparatus 130.

FIG. 16 shows in block form major components of a feed interval control mechanism 324 for feeding the light shielding sheet ribbon 320 by a predetermined length before a light shielding sheet 22 is cut off from the light shielding sheet ribbon 320 by the cutting mechanism 322. FIG. 17 shows an image of the light shielding sheet ribbon 320 which is captured by a camera 326. The feed interval control mechanism 324 comprises a servomotor 330 for rotating a roller 328 to feed the light shielding sheet ribbon 320, a camera 326 for capturing an image of the light shielding sheet ribbon 320 thus fed and outputting the captured image of the light shielding sheet ribbon 320, an image checker (feed interval calculator) 332 for calculating a present position required to feed the light shielding sheet ribbon 320 by the predetermined length based on the captured image from the camera 326, a PLC (programmable controller) 334 for calculating a feed interval from the detected present position and generating a control signal for the servomotor 330 based on the calculated feed interval, and a motor controller 336 for

controlling the servomotor 330 through a servoamplifier 338 based on the control signal from the PLC 334.

The light shielding sheet ribbon 320 has a plurality of substantially rectangular hot-melt seal members 321 each capable of bonding a light shielding sheet 22 to the end 18 of a case body 14 (see FIGS. 1 through 4). The substantially rectangular hot-melt seal members 321 are disposed at predetermined spaced intervals along the feed direction in which the light shielding sheet ribbon 320 is fed by the roller 328. The camera 326 captures an image of the light shielding sheet ribbon 320 including a seal member 321, and outputs the captured image to the image checker 332. Based on the supplied image, the image checker 332 calculates the difference between the present position of the seal member 321 and a reference position of the light shielding sheet ribbon 320, and outputs the calculated difference as the feed interval to the PLC 334.

Specifically, a substantially U-shaped, application reference piece 340 indicative of a reference position is placed in the vicinity of the light shielding sheet ribbon 320 that is fed by the rotating roller 328 so as to be included in the field of vision of the camera 326. The camera 326 captures an image of the light shielding sheet ribbon 320 including the seal member 321 and the application reference piece 340, and outputs the captured image to the image checker 332. The image checker 332 calculates, from the supplied image, the relative position of the seal member

321 with respect to a lower protrusion of the application reference piece 340 and the relative position of an upper protrusion of the application reference piece 340, calculates the deviation of the seal member 321 by the known dimensions of the application reference piece 340, and outputs the calculated deviation as the present position to the PLC 334. The PLC 334 calculates a feed interval from the supplied present position, generates a control signal based on the feed interval, and outputs the generated control signal to the motor controller 336. The motor controller 336 controls the servomotor 330 through the servoamplifier 338, rotating the roller 328 rotatably coupled to the servomotor 330 by an angular interval corresponding to the feed interval. The light shielding sheet ribbon 320 that is fed a predetermined length by the feed interval control mechanism 324 is attracted by a suction block, not shown, of the cutting mechanism 322 (see FIG. 6 ) at a predetermined cutting position and then cut off by a cutter disposed at suction ports of the suction block. The cut-off light shielding sheet ribbon 320 is supplied as a light shielding sheet 22 (see FIGS. 1, 2, and 4) to the light shielding sheet assembling apparatus 130. The suction block has a suction structure which is basically similar to those suction structures of the suction block 182 (see FIG. 9) and the presser sheet applying block 282 (see FIG. 14), and will not be described in detail below.

In the feed interval control mechanism 324, after the light shielding sheet ribbon 320 is fed a predetermined length, an image of the seal member 321 may be captured by the camera 326, and the feed interval calculated by the image checker 332 and the actual feed interval by which the light shielding sheet ribbon 320 is actually fed based on the feed interval may be compared with each other to check and compensate for a feed error that the seal member 321 may be suffering. If light is applied to the light shielding sheet ribbon

320, the light shielding sheet ribbon 320 which is black in color and the seal member 321 which is white in color reflect different amounts of light, and the boundary between the light shielding sheet ribbon 320 and the seal member 321 represents a position where the amount of reflected light changes abruptly. The feed interval control mechanism 324 may therefore employ an optical sensor, not shown, instead of the camera 326 and the image checker 332. Specifically, the optical sensor detects a position where the amount of reflected light changes sharply, i.e., the boundary between the light shielding sheet ribbon 320 and the seal member

321, and the light shielding sheet ribbon 320 is fed by a predetermined length from the position where the amount of reflected light changes sharply. As shown in FIG. 6, the light shielding sheet assembling apparatus 130 has a light shielding sheet preassembling mechanism 341 disposed along the case body

assembling line 120, for temporarily attaching a light shielding sheet 22 (see FIGS. 1, 2, and 4) supplied from the light shielding sheet supply apparatus 106 to the end 18 of a case body 14, a light shielding sheet assembling mechanism 342 disposed downstream of the light shielding sheet preassembling mechanism 341, for attaching the preassembled light shielding sheet 22 to the surface 19a of the end 18 of the case body 14, and a case body pressing mechanism 343 disposed along the lid assembling line 122 in confronting relation to the light shielding sheet assembling mechanism 342, for pressing the other surface 19b of the end 18 when the light shielding sheet 22 is attached.

The light shielding sheet preassembling mechanism 341 has a spot heater, not shown. While the light shielding sheet 22 is being attracted by the suction block of the cutting mechanism 322 and pressed over the recess 28 of the case body 14, the spot heater is pressed against the upper surface of the light shielding sheet 22. The spot heater is energized to fuse and fix a portion of the seal member 321 to an edge of the recess 28, thereby temporarily attaching the light shielding sheet 22 to the case body 14.

FIG. 18 shows in side elevation, partly in cross section, the light shielding sheet assembling mechanism 342 and the case body pressing mechanism 343. FIG. 19 shows in cross section pressers 360a through 360c of the case body pressing mechanism 343.

The light shielding sheet assembling mechanism 342 has

a light shielding sheet assembler (light shielding sheet applicator) 344 supported on a slide block 346. The slide block 346 is movable toward and away from the end 18 of a case body 14 along a guide rail 352 mounted on a stage 350 which is placed on a table 348. The slide block 346 is coupled to an end of a substantially V-shaped link 354, whose other end is coupled to a link 356. A spring 345 is interposed between the light shielding sheet assembler 344 and the slide block 346 for normally urging the light shielding sheet assembler 344 to be pressed against the end 18 of the case body 14 under the resiliency of the spring 345.

When the link 356 is vertically moved by a cam mechanism, not shown, the link 354 is angularly moved about a bent corner thereof that is pivotally supported on the table 348, moving the slide block 346 and the light shielding sheet assembler 344 toward and away from the end 18 of the case body 14 while the slide block 346 is being guided by the guide rail 352. A heater 347 is mounted on the tip end of the light shielding sheet assembler 344. When the light shielding sheet assembler 344 is displaced toward the case body 14 and the upper portion of the light shielding sheet 22 (see FIGS. 1, 2, and 4) is pressed by the surface of the heater 347 as it is heated, the portion of the seal member 321 which corresponds to the heater surface shape of the heater 347 is fused and fixed to the edge of the recess 28. The light

shielding sheet 22 is then attached to the case body 14 through the applied seal 32 having the heater surface shape.

As with the light shielding sheet strip applying mechanism 172 (see FIG. 12), the light shielding sheet assembling mechanism 342 monitors the heated temperature of the heater 347. If the light shielding sheet 22 is applied to the edge of the recess 28 of the case body 14 at a temperature out of a predetermined temperature range, then the light shielding sheet assembling mechanism 342 can reject the case body 14 as a defective component or can shut down the film case manufacturing system 100 in its entirety.

As shown in FIGS. 18 and 19, the case body pressing mechanism 343 has three substantially L-shaped pressers (sheet applying pressers) 360a, 360b, 360c for pressing the other surface 19b of the end 18 of the case body 14. The pressers 360a through 360c is supported on a substantially L-shaped presser mounting block 372 by a slide block 359. The presser mounting block 372 is supported on a substantially L-shaped support member 364 by a support rod 362. A spring 363 is coaxially disposed around the support rod 362 between the presser mounting block 372 and the support member 364.

The support member 364 and another support member 380 are disposed on a table 384. A guide rail 382 is mounted on the side surface of the table 384 which faces the presser mounting block 372. The presser mounting block 372 is vertically movably guided by the guide rail 382.

A slide block 366 is vertically movably mounted on a lower portion of the guide rail 382 and is coupled to a link 388 by an angularly movable lever 386 that is pivotally supported on a support 385 mounted on the table 384. The slide block 366 has a protrusion 369 on an upper surface thereof, and the presser mounting block 372 has a pin 365 in vertical alignment with the protrusion 369. The side surface of the slide block 366 which faces the presser mounting block 372 comprises an upper straight surface and a lower tapered surface.

A plunger 370 is coupled to an upper portion of the presser mounting block 372 by a pivot shaft 367. A cam follower 361 is mounted on a vertically central portion of the plunger 370 and held in rolling contact with the side surface of the slide block 366. The plunger 370 has a lower portion supporting the pressers 360a through 360c through respective screws 368a, 368b, 368c toward the link 388, i.e., to the left in FIG. 18.

Springs (resilient members) 374a, 374b, 374c are disposed coaxially around the respective screws 368a, 368b, 368c between the presser mounting block 372 and the pressers 360a through 360c. A spring 371 is interposed between the plunger 370 and the presser mounting block 372.

When the link 388 is vertically moved by a cam mechanism, not shown, the angularly movable lever 386 is turned about its central portion that is pivotally supported on the support 385, vertically moving the slide block 366

along the guide rail 382.

When the slide block 366 is moved downwardly along the guide rail 382, the presser mounting block 372 is moved downwardly under the resiliency of the spring 363. The support rod 362, the plunger 370, the screws 368a through 368c, and the pressers 360a through 360c which are coupled to the presser mounting block 372 are also moved downwardly to a position that is as high as they can be supported by the support rod 362. When the slide block 366 is thus moved downwardly, the cam follower 361 coupled to the plunger 370 is relatively displaced onto the straight surface portion of the side surface of the slide block 366. The plunger 370 is displaced toward the light shielding sheet assembling mechanism 342, i.e., to the right in FIG. 18, releasing the screws 368a through 368c that have been supported by the plunger 370. The pressers 360a through 360c are moved to the end 18 of the case body 14 and press the other surface 19b thereof under the bias of the springs 374a through 374c. Then, the light shielding sheet assembler 344 is displaced toward the case body 14 to attach the light shielding sheet 22 to the case body 14.

The area of the presser 360b which is pressed against the end 18 of the case body 14 is greater than the area of each of the pressers 360a, 360c which is pressed against the end 18 of the case body 14. However, the pressing forces with which the pressers 360a through 360c are pressed

against the end 18 can be equalized by making the resilient force applied to the presser 360b by the spring 374b greater than the resilient force applied to each of the pressers 360a, 360c by the springs 374a, 374c. Before the light shielding sheet 22 is attached to the case body 14, the sides of the end 18 are positioned by the positioning members 390a, 390b and the side walls 42, 82 are positioned respectively by the positioning members 392a, 392b. Therefore, the light shielding sheet 22 can accurately be attached to the case body 14.

When the slide block 366 is moved upwardly along the guide rail 382, the cam follower 361 is relatively displaced from the straight surface portion onto the tapered surface portion of the side surface of the slide block 366. The lower portion of the plunger 370 is displaced around the pivot shaft 367 toward the link 388, i.e., to the left in FIG. 18, supporting the screws 368a through 368c. The pressers 360a through 360c are then released from being pressed by the springs 374a through 374c and are spaced away from the end 18 of the case body 14.

When the slide block 366 is further moved upwardly, the protrusion 369 abuts the pin 365. The presser mounting block 372 is now moved upwardly against the bias of the spring 363. The support rod 362, the plunger 370, the screws 368a through 368c, and the pressers 360a through 360c which are coupled to the presser mounting block 372 are also moved upwardly.

FIG. 2OA shows in plan the shape of a heater 402 of a light shielding sheet assembler 400 in a conventional film case manufacturing system, FIG. 2OB shows in plan the shape of an applied seal 404 formed by the heater 402 shown in FIG. 2OA, and FIG. 2OC shows in fragmentary cross section how a light shielding sheet 22 attached to the case body 14 by the applied seal 404 shown in FIG. 2OB shields light.

FIG. 21A shows in plan the shape of another heater 406 of a light shielding sheet assembler 400 in a conventional film case manufacturing system, FIG. 21B shows in plan the shape of an applied seal 408 formed by the heater 406 shown in FIG. 21A, and FIG. 21C shows in fragmentary cross section how a light shielding sheet 22 attached to the case body 14 by the applied seal 408 shown in FIG. 21B shields light. FIG. 22A shows in plan the shape of the heater 347 of the light shielding sheet assembler 344 in the film case manufacturing system 100 according to the embodiment of the present invention, FIG. 22B shows in plan the shape of an applied seal 32 formed by the heater 347 shown in FIG. 22A, and FIG. 22C shows in fragmentary cross section how a light shielding sheet 22 attached to the case body 14 by the applied seal 32 shown in FIG. 22B shields light.

As shown in FIG. 2OA, the heater 402 comprises a substantially rectangular base end portion 402a and two fingers 402b extending downwardly from respective opposite ends of the base end portion 402a. When the upper portion of the light shielding sheet 22 that has been temporarily

attached to the case body 14 is pressed from outside and heated by the heater 402, the portion of the seal member 321 (see FIG. 16) which faces the heater 402 is fused and fixed to the edge of the recess 28 in the end 18. As a result, the light shielding sheet 22 is applied to the case body 14 through the applied seal 404 which has the surface shape of the heater 402 (see FIG. 20B).

With the above shape of the applied seal 404, however, the light shielding sheet 22 tends to have large wrinkles 410 from the base end portion 404a of the applied seal 404 toward the lower end of the light shielding sheet 22, tending to cause the lower portion of the light shielding sheet 22 to lift from the bottom 24 of the end 18 of the case body 14. Accordingly, external light enters from the film discharge slot 20 into the case body 14, and the light shielding sheet 22 fails to keep the film discharge slot 20 and the interior of the case body 14 shielded against entry of light (see FIG. 20C).

As shown in FIG. 21A, the heater 406 comprises a substantially rectangular base end portion 406a, two fingers 406b extending downwardly from respective opposite ends of the base end portion 406a, and a plurality of teeth 406c extending downwardly from the base end portion 406a at spaced intervals between the fingers 406b. The teeth 406c are shorter than the fingers 406b. When the upper portion of the light shielding sheet 22 that has been temporarily attached to the case body 14 is pressed from outside and

heated by the heater 406, the portion of the seal member 321 (see FIG. 16) which faces the heater 406 is fused and fixed to the edge of the recess 28 in the end 18. As a result, the light shielding sheet 22 is applied to the case body 14 through the applied seal 408 which has the surface shape of the heater 406 (see FIG. 21B).

With the applied seal 408, as compared with the applied seal 404, the light shielding sheet 22 is caused by the teeth 406c to positively form smaller wrinkles 412 than the wrinkles 410 shown in FIG. 2OB, so that the lower portion of the light shielding sheet 22 is prevented from being lifted off the bottom 24. However, the light shielding sheet 22 tends to produce large wrinkles 414 in its central region. The large wrinkles 414 cause the light shielding sheet 22 to be lifted locally off the bottom 24. As a result, external light enters from the film discharge slot 20 into the case body 14, and the light shielding sheet 22 fails to keep the film discharge slot 20 and the interior of the case body 14 shielded against entry of light (see FIG. 21C). With the film case manufacturing system 100 according to the present embodiment, as shown in FIG. 22A, the heater 347 comprises a substantially rectangular base end portion 347a, two fingers 347b extending downwardly from respective opposite ends of the base end portion 347a, a tooth 347d extending downwardly from a central area of the base end portion 347a, and a plurality of teeth 347c extending downwardly from the base end portion 347a at spaced

intervals between the fingers 347b and the tooth 347d. The teeth 347c are shorter than the fingers 347b and the tooth 347d.

When the upper portion of the light shielding sheet 22 that has been temporarily attached to the case body 14 is pressed from outside and heated by the heater 347, the portion of the seal member 321 (see FIG. 16) which faces the heater 347 is fused and fixed to the edge of the recess 28 in the end 18. As a result, the light shielding sheet 22 is applied to the case body 14 through the applied seal 32 which has the surface shape of the heater 347 (see FIG. 22B) .

With the above applied seal 32, unlike the applied seals 404, 408 (see FIGS. 20B and 21B), since the tooth 347d is formed centrally on the base end portion 347a, the light shielding sheet 22 is caused to positively form smaller wrinkles 412, at given intervals, than the wrinkles 410 shown in FIG. 2OB, so that the lower portion of the light shielding sheet 22 is prevented from being lifted off the bottom 24. Because the lower portion of the light shielding sheet 22 abuts the bottom 24 and covers the film discharge slot 20, the light shielding sheet 22 keeps the film discharge slot 20 and the interior of the case body 14 shielded against entry of light (see FIG. 22C). In the light shielding sheet assembling apparatus 130 (see FIG. 6), each of the cam mechanisms for actuating the links 356, 388 is operated in synchronism with the cam and

link mechanism (not shown) for actuating the rod feed mechanism 124 (see FIG. 7), and the light shielding sheet preassembling mechanism 341 is also operated in synchronism with the same cam and link mechanism. As a consequence, the light shielding sheet preassembling mechanism 341, the light shielding sheet assembling mechanism 342, and the case body pressing mechanism 343 of the light shielding sheet assembling apparatus 130 are operable in synchronism with rod feeding operation of the rod feed mechanism 124. FIGS. 23A, 23B, and 23C show in fragmentary cross section a light shielding sheet assembling apparatus according to a first modification of the light shielding sheet assembling apparatus 130 (see FIG. 6). FIG. 24 shows in fragmentary cross section a light shielding sheet assembling apparatus according to a second modification.

FIG. 25 shows in fragmentary cross section a light shielding sheet assembling apparatus according to a third modification .

According to the first modification shown in FIGS. 23A, 23B, and 23C, light shielding sheet assemblers 420a, 420b, 420c are disposed respectively in three stations (first through third stations) disposed along the case body assembling line 120 (see FIGS. 6 and 7). In each of the stations, the light shielding sheet 22 is assembled on the case body 14.

The light shielding sheet assembler 420a which is disposed in an upstream station, i.e., the first station

shown in FIG. 23A, along the case body assembling line 120 has a heater 422a for applying a portion of the light shielding sheet 22 near the side wall 42. The light shielding sheet assembler 420b which is disposed in a middle station, i.e., the second station shown in FIG. 23B, along the case body assembling line 120 has a heater 422b applying a central portion of the light shielding sheet 22. The light shielding sheet assembler 420c which is disposed in a downstream station, i.e., the third station shown in FIG. 23C, along the case body assembling line 120 has a heater

422c for applying a portion of the light shielding sheet 22 near the side wall 82.

The heater 422a has a heating range (applying range) for the light shielding sheet 22, which partially overlaps the heating range of the heater 422b for the light shielding sheet 22, and the heating range of the heater 422b for the light shielding sheet 22 partially overlaps the heating range of the heater 422c for the light shielding sheet 22. As a result, these heaters 422a through 422c are jointly capable of applying the light shielding sheet 22 reliably to the case body 14.

According to the second modification shown in FIG. 24, a light shielding sheet assembler 430 is supported on an actuator 434 by a cylinder rod 432. The actuator 434 is coupled to a slide block 438 by a support member 436. The slide block 438 is movable along a guide rail 440 in the feeding direction in which the case body 14 is fed.

When the slide block 438 is moved along the guide rail 440 in the feeding direction by a cam and link mechanism, not shown, while the cylinder rod 432 is being moved toward and away from the case body 14 by the actuator 434, the light shielding sheet 22 can be applied to the case body 14 while light shielding sheet assembler 430 is being moved in the feeding direction in one station.

According to the third modification shown in FIG. 25, a heat-resistant rubber member 450 is mounted on the heater surface of the heater 347, and heat-resistant rubber members 452a, 452b, 452c are mounted on the respective pressing surfaces of the pressers 360a, 360b, 360c which are to be pressed against the end 18. When the pressers 360a through 360c press the end 18 through the rubber members 452a through 452c, since the rubber members 452a through 452c are held in close contact with the inner surface of the end 18, i.e., the other surface 19b thereof, the end 18 is uniformly pressed by the pressers 360a through 360c. When the heater 347 heats the light shielding sheet 22 through the rubber member 450, as the rubber member 450 is held in close contact with the light shielding sheet 22, the light shielding sheet 22 is more reliably heated by the heater 347.

As shown in FIG. 6, an image checking apparatus 460 for checking the applied state and shape of a light shielding sheet 22 on a case body 14 is disposed downstream of the light shielding sheet assembling apparatus 130 along the lid

assembling line 122. The portion of the side wall 160c (see FIG. 7) which confronts the image checking apparatus 460 is of a reduced wall thickness for ensuring a field of vision for the image checking apparatus 460 to check an image. When external light is applied to the thinner portion of the side wall 160c, the image checking apparatus 460 is capable of checking the applied state and shape of the light shielding sheet 22 through the side wall 160c. Since the grained surfaces of the recess 28 (see FIG. 1) have a different surface roughness from the other surfaces thereof, they provide an image to be checked which has a higher contrast than the light shielding sheet 22. The image checking apparatus 460 checks the image to ascertain whether the four corners of the light shielding sheet 22 are in their respective predetermined positions with respect to the case body 14 or not.

As with the presser sheet supply apparatus 104 and the light shielding sheet supply apparatus 106, the first discharge prevention sheet supply apparatus 108 feeds a discharge prevention sheet ribbon 470 by a predetermined length. The discharge prevention sheet ribbon 470 thus fed is cut by a cutting mechanism 472 to predetermined dimensions, thereby forming a substantially rectangular first discharge prevention sheet 34a (see FIG. 3). The formed first discharge prevention sheet 34a is supplied to the first discharge prevention sheet preassembling apparatus 132.

The cutting mechanism 472 operates as with the cutting mechanism 280 (see FIG. 6). The discharge prevention sheet ribbon 470 is gripped by a suction block, not shown, similar to the suction block 182 (see FIG. 9) and a cutter, not shown. Then, the discharge prevention sheet ribbon 470 is cut to predetermined dimensions by the cutter (not shown), producing the substantially rectangular first discharge prevention sheet 34a. From the time when the discharge prevention sheet ribbon 470 is cut to the first discharge prevention sheet 34a to the time when the first discharge prevention sheet 34a is supplied to the first discharge prevention sheet preassembling apparatus 132, the first discharge prevention sheet 34a can reliably be fed to the first discharge prevention sheet preassembling apparatus 132 without any cutter having a suction means in the path from the cutting mechanism 472 to the first discharge prevention sheet preassembling apparatus 132.

After the first discharge prevention sheet 34a is placed in position on the bottom 36 of the case body 14, the first discharge prevention sheet preassembling apparatus 132 applies a spot heater, not shown, to the upper surface of the first discharge prevention sheet 34a. Then, the spot heater is energized to fuse and fix a portion of a seal member on the first discharge prevention sheet 34a to the bottom 36, thereby temporarily attaching the first discharge prevention sheet 34a to the case body 14.

A checking apparatus 474 for checking whether the first

discharge prevention sheet 34a is present on the case body 14 or not is disposed downstream of the first discharge prevention sheet preassembling apparatus 132.

A film presser assembling apparatus 133 is disposed downstream of the checking apparatus 474 along the lid assembling line 122. In the film presser assembling apparatus 133, the holes 94a, 94b of a film presser 92 supplied from the film presser supply line 112 are fitted over positioning pins on a positioning table, not shown. After the film presser 92 is accurately positioned, a lid 16 that has been fed with its bottom up is positioned by the positioning member 148 (see FIG. 7). The positioned film presser 92 is then fed and assembled onto the lid 16.

At this time, the crimp pins 88a, 88b (see FIG. 3) of the lid 16 are inserted respectively through the holes 94a, 94b of the film presser 92, and the support foot 86 is inserted through the hole 96. Thereafter, the crimp pins 88a, 88b are pressed downwardly and heated by a heater block, not shown, to have their tip ends crimped, thereby assembling the film presser 92 on the lid 16. The film presser assembling apparatus 133 has a checking apparatus 476 for checking the height of the tip ends of the crimped crimp pins 88a, 88b.

The second discharge prevention sheet supply apparatus 110 is similar in structure to the first discharge prevention sheet supply apparatus 108. The second discharge prevention sheet supply apparatus 110 feeds a discharge

prevention sheet ribbon 480 by a predetermined length. The discharge prevention sheet ribbon 480 thus fed is cut by a cutting mechanism 482 to predetermined dimensions, thereby forming a substantially rectangular second discharge prevention sheet 34b (see FIG. 3). The formed second discharge prevention sheet 34b is supplied to the second discharge prevention sheet preassembling apparatus 134. After the second discharge prevention sheet 34b is placed in position on the bottom 36 of the case body 14, the second discharge prevention sheet preassembling apparatus 134 applies a spot heater, not shown, to the upper surface of the second discharge prevention sheet 34b. Then, the spot heater is energized to fuse and fix a portion of a seal member on the second discharge prevention sheet 34b to the bottom 36, thereby temporarily attaching the second discharge prevention sheet 34b to the case body 14.

A checking apparatus 484 for checking whether the second discharge prevention sheet 34b is present on the case body 14 or not is disposed downstream of the second discharge prevention sheet preassembling apparatus 134.

A discharge prevention sheet assembling apparatus 490 for applying the first and second discharge prevention sheets 34a, 34b is disposed downstream of the checking apparatus 484. In the discharge prevention sheet assembling apparatus 490, after the case body 14 is positioned by the positioning member 148 (see FIG. 7), the temporarily applied regions of

the first and second discharge prevention sheets 34a, 34b are pressed and heated by heater blocks, not shown, fusing the seal members of the first and second discharge prevention sheets 34a, 34b to the bottom 36 of the case body 14. The first and second discharge prevention sheets 34a, 34b are now finally applied to the case body 14.

As with the light shielding sheet strip applying mechanism 172 (see FIG. 12) and the light shielding sheet assembling mechanism 342 (see FIG. 18), the discharge prevention sheet assembling apparatus 490 monitors the heated temperature of the heater block. If the first and second discharge prevention sheets 34a, 34b are applied to the bottom 36 of the case body 14 at a temperature outside of a predetermined temperature range , then the discharge prevention sheet assembling apparatus 490 can reject the case body 14 as a defective component or can shut down the film case manufacturing system 100 in its entirety.

An image checking apparatus 492 for checking the applied state and shape of first and second discharge prevention sheets 34a, 34b on a case body 14 is disposed downstream of the discharge prevention sheet assembling apparatus 490.

A dedusting apparatus 494 for electrically neutralizing and dedusting a case body 14 and a lid 16 by applying a stream of ionic wind thereto is disposed downstream of the image checking apparatus 492. In the dedusting apparatus 494, two dust collecting cups, not shown, which are

complementary in shape to the case body 14 and the lid 16, are lowered into intimate contact with the case body 14 and the lid 16, respectively. Then, spaces covered with the respective dust collecting cups are evacuated and made air- tight by a vacuum pump. Thereafter, a stream of ionic wind is applied to the case body 14 and the lid 16 that are placed in the spaces . Since the dust collecting cups are held in intimate contact with the case body 14 and the lid 16, respectively, the case body 14 and the lid 16 are prevented from being positionally displaced under the pressure of the stream of ionic wind.

A lid turning apparatus 496 for turning the upper surface of the lid 16 upwardly in synchronism with rod feeding operation of the rod feed mechanism 124 (see FIG. 7) is disposed downstream of the dedusting apparatus 494 along the lid assembling line 122. The lid turning apparatus 496 turns the lid 16 in timed relation to the rod feeding operation of the rod feed mechanism 124 while the lid 16 is being fed a distance corresponding to one pitch by the rod feed mechanism 124, the lid 16 is prevented from being positionally displaced with respect to the case body 14 when the lid 16 is turned.

Downstream of the lid turning apparatus 496 along the case body assembling line 120, there is disposed a transfer apparatus 498 for transferring a lid 16 onto a case body 14 and combining the case body 14 and the lid 16 with each other in synchronism with rod feeding operation of the rod

feed mechanism 124 (see FIG. 7) ¹ .

A checking apparatus 500 is disposed downstream of the transfer apparatus 498 for checking- whether the film presser 92 is present or not and also checking an assembled state thereof, with a photoelectric sensor, and also for checking whether the lid 16 is present or not and also checking the height of the lid 16, with a laser sensor.

FIG. 26 shows in fragmentary perspective a sample pickup line 502 disposed downstream of the checking apparatus 500 (see FIG. 6).

As shown in FIG. 26, a case body 14 and a lid 16 which have been combined with each other by the transfer apparatus 498 (see FIG. 6) are discharged as a sample film case 10 along the sample pickup line 502. The transfer apparatus 504 that is disposed downstream of the checking apparatus

500 has an arm 506 for gripping the sides of a case body 14 that is fed on the case body assembling line 120 and then transferring the case body 14 and the lid 16 combined therewith onto the sample pickup line 502 in synchronism with rod feeding operation of the rod feed mechanism 124 (see FIG. 7) .

The sample pickup line 502 has a sample pickup chute 508 on which previously transferred sample film cases 10 have been placed. Therefore, the arm 506 transfers the case body 14 and the lid 16 onto the sample pickup line 502 while pushing the previously transferred sample film cases 10 with the gripped case body 14 in a discharging direction (pushing

direction) on the sample pickup chute 508.

The sample pickup chute 508 has a succession of recesses 510 defined therein at predetermined spaced intervals. The recesses 510 are deep enough to hold therein the bottoms 24 of the ends 18 of corresponding case bodies 14. The recesses 510 are shaped such that their depth is progressively smaller in the pushing direction. Therefore, when a sample film case 10 placed on the sample pickup chute 508 is pressed by the case body 14 gripped by the arm 506, the sample film case 10 can easily be discharged in the pushing direction along the sample pickup chute 508.

The arm 506 operates at all times in synchronism with rod feeding operation of the rod feed mechanism 124 (see FIG. 7). Consequently, even if no sample film case 10 is transferred onto the sample pickup chute 508, the arm 506 acts to push already transferred sample film cases 10 downstream on the sample pickup chute 508.

In FIG. 6, a transfer apparatus 504 transfers only those case bodies 14 and lids 16 that have been accepted by the upstream checking apparatus 156, 300, 302, 307, 308, 460, 474, 476, 484, 492, 500, onto a downstream feed line 512. The transferred case bodies 14 and lids 16 are fed as completed film cases 10 down the feed line 512 and discharged out of the film case manufacturing system 100. Those case bodies 14 and lids 16 that have been rejected by the checking apparatus and the image checking apparatus are transferred by the transfer apparatus 504 onto a defective

product discharge line 514 extending parallel to the feed line 512. The transferred case bodies 14 and lids 16 are fed as defective film cases 10 down the defective product discharge line 514 and discharged out of the film case manufacturing system 100.

The checking apparatus 156, 300, 302, 307, 308, 460, 474, 476, 484, 492, 500 are electrically connected on line to a facility controller, not shown. The facility controller reads detected signals transmitted from the checking apparatus 156, 300, 302, 307, 308, 460, 474, 476, 484, 492, 500, as shift information in synchronous with the transferring operation of the case body 14 and the lid 16, and updates the previously read shift information each time it reads the detected signals. The facility controller uses the shift information as operating conditions for the applying apparatus and assembling apparatus which are disposed downstream of the checking apparatus 156, 300, 302, 307, 308, 460, 474, 476, 484, 492, 500 along the assembling line 118. Specifically, if the facility controller receives a checked result indicating that a case body 14, a lid 16, or a film case 10 is defective and updates the received checked result as shift information, then the facility controller sends a control signal indicating that the case body 14, the lid 16, or the film case 10 is defective to the apparatus that are disposed downstream of the checking apparatus 156, 300, 302, 307, 308, 460, 474, 476, 484, 492, 500. In

response to the supplied control signal, the apparatus stop supplying or assembling parts to the case body 14, the lid 16, or the film case 10 that is indicated as defective, or stops checking the case body 14, the lid 16, or the film case 10 that is indicated as defective, or discharge the film case 10. For example, the transfer apparatus 504 transfers the film case 10 judged as defective onto the defective product discharge line 514 after it has received the control signal. The light shielding member supply line 102 has a displacement member supply mechanism 530 for supplying displacement members 58 (see FIGS. 3 through 5), a displacement member check line 532 for checking the shapes and orientations of the supplied displacement members 58, a light shielding sheet strip supply mechanism 534 for supplying light shielding sheet strips 60, and a light shielding member assembling line 536 for applying supplied light shielding sheet strips 60 to inspected displacement members 58 to form light shielding members 54. The displacement member supply mechanism 530 has a hopper (reservoir) 540 for holding displacement members 58, a ball feeder 542 and a linear feeder 544 (feeder unit) for feeding displacement members 58 supplied from the hopper 540 as an array of displacement members 58 that are oriented in a predetermined direction, and a separator 546 for holding and separating, one by one, displacement members 58 fed from the linear feeder 544 and delivering the separated

displacement members 58 to the displacement member check line 532.

The hopper 540 is disposed above the ball feeder 542. The hopper 540 supplies a displacement member 58 to the ball feeder 542 each time a displacement member 58 is fed from the ball feeder 542 to the linear feeder 544.

The ball feeder 542 comprises a ball 548 and a vibration generator 550 for generating vibrations at the center of the ball 548. The vibration generator 550 applies vibrations to displacement members 58 supplied from the hopper 540 into the ball 548 for thereby feeding the displacement members 58 as an array to the linear feeder 544 oriented in a rotating direction. In the ball 548, an electrical neutralizer, not shown, applies a stream of ionic wind to the displacement members 58 to electrically neutralize the displacement members 58.

The linear feeder 544 supplies the supplied displacement members 58 to the separator 546.

As shown in FIGS. 27A and 27B, the separator 546 comprises a substantially rectangular block having two slots 552a, 552b that are open toward the linear feeder 544. After displacement members 58 are accommodated in the slots 552a, 552b, the separator 546 is moved and the displacement members 58 are separated. The separated displacement members 58 are then transferred to the displacement member check line 532 by a transfer apparatus 554 that is disposed alongside of the separator 546.

Specifically, when a displacement member 58 is inserted from the linear feeder 544 into the slot 552a, the separator 546 is moved along a substantially arc path perpendicular to the direction in which the displacement member 58 is inserted into the slot 552a, until the other slot 552b faces the linear feeder 544. As a result, a displacement member 58 can be inserted into the other slot 552b. During this time, the displacement member 58 accommodated in the slot 552a is moved and taken out of the slot 552a. While the displacement member 58 accommodated in the slot 552a is being moved, displacement members 58 are prevented from projecting from the linear feeder 544 toward the separator 546 by a stopper, not shown.

FIG. 27A shows the manner in which a displacement member 58 is fed with its beveled edge 71 facing the separator 546. FIG. 27B shows the manner in which a displacement member 58 is fed with its beveled edge 71 facing away from the separator 546, i.e., to the left in FIG. 27B. When the beveled edge 71 is disposed in either the position shown in FIG. 27A or the position shown in FIG. 27B, it is assumed that the displacement member 58 is fed with its upper surface facing upwardly. When the beveled edge 71 is disposed upstream as shown in FIG. 27B, it is assumed that the displacement member 58 is fed in a proper orientation.

As shown in FIG. 6, the displacement member check line 532 has an image checking apparatus 562 for checking the

orientation of a displacement member 58 (see FIGS. 3 through 5), a reversing apparatus 564 for turning around a displacement member 58, an image checking apparatus 566 for checking the shape of a displacement member 58, and a transfer apparatus 572 for transferring a displacement member 58 as a defective component into a defective component stacking case 568 or transferring a displacement member 58 as an acceptable component to a buffer conveyor 570. These apparatus 562, 564, 566, and 572 are successively disposed along a checking conveyor 560.

The checking conveyor 560 feeds a displacement member 58 transferred from the separator 546 by the transfer apparatus 554 to the right in FIG. 6 at a predetermined pitch. The image checking apparatus 562 checks (1) whether the fed displacement member 58 has its upper surface facing upwardly or not, and (2) whether the displacement member 58 is oriented opposite to the feeding direction or not.

The displacement member 58 has the beveled edge 71 at a corner thereof (see FIGS. 3, 5, 27A, and 27B). The image checking apparatus 562 checks whether the beveled edge 71 is in one of the positions shown in FIGS. 27A and 27B or not in the above checking process (1), and also checks whether the beveled edge 71 is upstream in the feeding direction or not in the above checking process (2). If a displacement member 58 has its beveled edge 71 positioned downstream as determined by the image checking apparatus 562 in the checking process (2), then the

reversing apparatus 564 positions the displacement member 58 with a positioning member that is similar to the positioning members 148 (see FIG. 7). Thereafter, the reversing apparatus 564 attracts the displacement member 58 with a suction block, not shown, away from the checking conveyor 560, then turns around the displacement member 58 by 180° , and transfers the reversed displacement member 58 to a station next to the checking conveyor 560.

The above sequence of reversing the displacement member 58 with the reversing apparatus 564 is carried out within a period of time corresponding to one pitch of movement of the checking conveyor 560, so that the displacement member 58 separated from the moving checking conveyor 560 can be returned to its original position in the next station. If a displacement member 58 has its beveled edge 71 positioned upstream as determined by the image checking apparatus 562 in the checking process (2), then the displacement member 58 is not turned around by the reversing apparatus 564.

The image checking apparatus 566 checks the shape of a displacement member 58.

The transfer apparatus 572 transfers a displacement member 58 that has been judged as defective (with the reverse side facing up) in the checking process (1) performed by the image checking apparatus 562 and a displacement member 58 that has been judged as defective (not having the desired shape) in the checking process performed by the image checking apparatus 566, as defective

components into the defective component stacking case 568, and also transfers displacement members 58 that have been judged as acceptable components in the checking process (1) performed by the image checking apparatus 562 and in the checking process performed by the image checking apparatus 566, to the buffer conveyor 570.

When some of the displacement members 58 that are successively fed on the checking conveyor 560 are judged as defective, if displacement members 58 that are judged as acceptable are directly transferred successively from the checking conveyor 560 to the buffer conveyor 570, then the string of displacement members 58 that are successively fed on the buffer conveyor 570 tends to lack some displacement members 58 because the defective displacement members 58 are removed. Thus, in the transfer apparatus 572, if a defective displacement member 58 is found on the checking conveyor 560, displacement members 58 that are found acceptable are transferred to changed positions on the buffer conveyor 570 for thereby preventing the string of displacement members 58 on the buffer conveyor 570 from lacking some displacement members 58.

On the displacement member check line 532, an electrical neutralizer, not shown, applies a stream of ionic wind to the displacement members 58 to electrically neutralizes the displacement members 58.

Downstream of the buffer conveyor 570, there are disposed a transfer apparatus 574, a positioning table 576,

and a transfer apparatus 578. A displacement member 58 (see FIGS. 3 through 5) that is fed downstream on the buffer conveyor 570 is transferred by the transfer apparatus 574 to the positioning table 576, positioned by a positioning member similar to the positioning member of the reversing apparatus 564, and thereafter transferred to the light shielding member assembling line 536 by the transfer apparatus 578.

The light shielding member assembling line 536 has a light shielding sheet strip preassembling mechanism 580 for temporarily applying a light shielding sheet strip 60 to the upper surface of a displacement member 58, a light shielding sheet strip presealing mechanism 582 for presealing the temporarily applied light shielding sheet strip 60, a light shielding sheet strip assembling mechanism 584 for finally applying the presealed light shielding sheet strip 60, an incision forming mechanism 586 for forming an incision 70 in the light shielding sheet strip 60, a longer side folding mechanism 588 for inwardly folding the longer side portion 68 of the light shielding sheet strip 60 with the incision 70 formed therein, toward the upper surface of the light shielding sheet strip 60, and a shorter side folding mechanism 590 for inwardly folding the shorter side portion 66 of the light shielding sheet strip 60 with the longer side portion 68 folded, toward the upper surface of the light shielding sheet strip 60. These mechanisms 580, 582, 584, 586, 588, and 590 are successively arranged in the

order named from an upstream side near the transfer apparatus 578 toward a downstream side near the main assembling line 114.

The light shielding member assembling line 536 also has a plurality of first suction mechanisms 592 disposed at given spaced intervals from the upstream side near the transfer apparatus 578 toward the downstream side near the main assembling line 114, for attracting bottoms of displacement members 58, a plurality of second suction mechanisms 594 (see FIG. 30) disposed at given spaced intervals downstream of the light shielding sheet strip presealing mechanism 582, for attracting the upper surfaces of light shielding sheet strips 60 presealed or applied to the displacement members 58, and a placement rail 596 extending from the light shielding sheet strip preassembling mechanism 580 to the light shielding sheet strip presealing mechanism 582, for placing displacement members 58 thereon.

The transfer apparatus 578 referred to above turns a displacement member 58 (see FIGS. 3 through 5, 27A, 27B) positioned on the positioning table 576 by 90° and transfers the displacement member 58 onto an upstream portion of the placement rail 596. At this time, the transfer apparatus 578 transfers the displacement member 58 such that the beveled edge 71 thereof is positioned downstream of the light shielding member assembling line 536 (near the main assembling line 114).

FIG. 28 shows in vertical cross section a displacement

member 58 placed on the placement rail 596 and each of the first suction mechanisms 592 for attracting the bottom of the displacement member 58. FIG. 29 shows in vertical cross section the manner in which displacement members 58 are fed by the first suction mechanisms 592. FIG. 30 shows in vertical cross section the manner in which displacement members 58 are fed by the second suction mechanisms 594.

The placement rail 596 comprises two parallel elongate plates 600a, 600b with a gap 602 defined between which is of a size to allow the rails 62, 64 of a displacement member 58 to be fitted therein.

Each of the first suction mechanisms 592 is basically similar in structure to the suction block 182 (see FIG. 9) of the light shielding member attracting mechanism 174 and the suction mechanism of the presser sheet applying block 282 (see FIGS. 14, 15A, 15B, 15C). Specifically, each of the first suction mechanisms 592 has a suction block 604 having a substantially T-shaped cross section. The suction block 604 has a plurality of first suction passages 606 defined therein which are open upwardly and a second suction passage 608 communicating with the first suction passages 606. The second suction passage 608 is connected to a vacuum pump, not shown, through a joint pipe 610 having a solenoid-operated valve 611. When a displacement member 58 is transferred onto the placement rail 596, the suction block 604 disposed directly below the gap 602 is elevated into contact with the bottom

of the displacement member 58. ^* Then, the vacuum pump connected to the joint pipe 610 is actuated and the solenoid-operated valve 611 is opened to develop a negative pressure in the first and second suction passages 606, 608 and the joint pipe 610. As a result, the displacement member 58 is attracted by the first suction mechanisms 592 and placed in position on the placement rail 596.

The first suction mechanisms 592 and the joint pipe 610 are vertically moved in unison with each other by a cam and link mechanism, not shown, and are moved a certain distance in the feeding direction (to the right in FIG. 29) for thereby feeding the attracted displacement member 58 at a predetermined pitch along the placement rail 596.

Preferably, the predetermined pitch should be equal to each of the spaced intervals between the first suction mechanisms 592, and the displacement member 58 should be fed in synchronism with rod feeding operation of the rod feed mechanism 124 (see FIG. 7) of the main assembling line 114. The first suction mechanisms 592 and the joint pipe 610 are moved in unison with each other only in the station where the placement rail 596 is positioned. In stations downstream of the light shielding sheet strip presealing mechanism 582 (see FIG. 6), the first suction mechanisms 592 and the joint pipe 610 are fixed in a given position, and the second suction mechanisms 594 are movable along the feeding direction of the light shielding member 54.

The joint pipe 610, which is movable in unison with the

first suction mechanisms 592, should preferably comprise a flexible pipe such as bellows or the like.

The second suction mechanisms 594 are similar in structure to the first suction mechanisms 592. The second suction mechanisms 594 feed a light shielding member 54 while attracting a light shielding sheet strip 60 from above in each of the stations positioned downstream of the light shielding sheet strip presealing mechanism 582 (see FIG. 6). Since the first suction mechanisms 592 are disposed at given spaced intervals as positioning mechanisms for attracting and holding the light shielding member 54 from the side of the displacement member 58, the second suction mechanisms 594 feed the light shielding member 54 between the first suction mechanisms 592. Specifically, when an upstream first suction mechanism 592 attracts and holds the displacement member 58 of a light shielding member 54, the second suction mechanism 594 is lowered to bring the tip end of the suction block 620 into contact with the upper surface of the light shielding sheet strip 60. Then, the solenoid-operated valve 611 is opened and the non-illustrated vacuum pump is activated to develop a negative pressure in the joint pipe 624, the second suction passage 626, and the first suction passage 628. At the same time, the first suction mechanism 592 is inactivated to release the displacement member 58. The second suction mechanism 594 now attracts the light shielding sheet strip 60. The second suction mechanism 594

and the joint pipe 624 are moved vertically in union with each other by the non-illustrated cam and link mechanism, and are also moved a certain distance in the feeding direction (to the right in FIG. 30). As a result, the attracted light shielding member 54 can be fed at a given pitch to a downstream first suction mechanism 592 and transferred thereto.

The given pitch referred to above is the same as the spaced intervals between the first suction mechanisms 592. When the second suction mechanism 594 feeds the light shielding member 54 to the downstream first suction mechanism 592 and the downstream first suction mechanism 592 attracts and holds the displacement member 58, the second suction mechanism 594 stops attracting the light shielding sheet strip 60. The second suction mechanism 594 is lifted and retracted in a direction perpendicular to the feeding direction, and thereafter moved back to a position near the upstream first suction mechanism 592 (see FIG. 30). The second suction mechanism 594 that has been moved back is advanced and lowered in a direction perpendicular to the feeding direction, toward a light shielding member 54 attracted and held by the upstream first suction mechanism 592. Thereafter, the second suction mechanism 594 repeats the above feeding operation. In FIG. 30, the second suction mechanism 594 has been described as being lifted and retracted, and then advanced and lowered in the direction perpendicular to the feeding

direction. However, the second suction mechanism 594 may be moved along a substantially arc path to the perpendicular direction.

The joint pipe 624, which is movable in unison with the second suction mechanisms 594, should preferably comprise a flexible pipe such as bellows or the like .

As shown in FIG. 6, the light shielding sheet strip supply mechanism 534 feeds a light shielding sheet ribbon 630 by a predetermined length, as with the presser sheet supply apparatus 104, the light shielding sheet supply apparatus 106, and the first and second discharge prevention sheet supply apparatus 108, 110. The light shielding sheet ribbon 630 thus fed is cut by a cutting mechanism 632 to predetermined dimensions, thereby forming a substantially rectangular light shielding sheet strip 60. The light shielding sheet strip 60 is supplied to the light shielding sheet strip preassembling mechanism 580.

The light shielding sheet strip preassembling mechanism 580 is of substantially the same structure as the first discharge prevention sheet preassembling apparatus 132, the light shielding sheet preassembling mechanism 341, and the second discharge prevention sheet preassembling apparatus 134. The light shielding sheet strip preassembling mechanism 580 temporarily applies a light shielding sheet strip 60 supplied from the light shielding sheet strip supply mechanism 534 to the upper surface of a displacement member 58 positioned on the placement rail 596.

The sides of the displacement member 58 that has been attracted and held by the first suction mechanism 592 on the placement rail 596 are positioned in the feeding direction and the direction perpendicular to the feeding direction by a positioning mechanism which is essentially similar to the light shielding member positioning mechanism 170 (see FIG. 10). When the light shielding sheet strip 60 is placed on the upper surface of the positioned displacement member 58 and a spot heater, not shown, is brought into contact with the upper portion of the light shielding sheet strip 60 which contacts the displacement member 58, a portion of the seal member on the lower surface of the light shielding sheet strip 60 is fused and fixed to the displacement member 58, thereby temporarily applying the light shielding sheet strip 60 to the displacement member 58.

The light shielding sheet strip presealing mechanism 582 is of substantially the same structure as the presser sheet assembling apparatus 128, the light shielding sheet assembling mechanism 342, and the discharge prevention sheet assembling apparatus 490. The light shielding sheet strip presealing mechanism 582 preseals the light shielding sheet strip 60 that has been temporarily applied to the upper surface of the displacement member 58.

At this time, a heater block, not shown, is locally pressed partly against the portion of the light shielding sheet strip 60 which is in contact with the displacement member 58 to fuse and fix a portion of the seal member to

the displacement member 58, thereby presealing the light shielding sheet strip 60 to the displacement member 58. As a result, the bonding strength between the presealed light shielding sheet strip 60 and the displacement member 58 becomes large enough for them to be attracted and fed by the second suction mechanism 594. The presealed light shielding sheet strip 60 and the displacement member 58 are now fed to the first suction mechanism 592 confronting the light shielding sheet strip assembling mechanism 584 by the second suction mechanism 594.

The light shielding sheet strip assembling mechanism 584 is of substantially the same structure as the presser sheet assembling apparatus 128, the light shielding sheet assembling mechanism 342, and the discharge prevention sheet assembling apparatus 490. The light shielding sheet strip assembling mechanism 584 finally applies the presealed light shielding sheet strip 60 to the upper surface of the displacement member 58.

The sides of the displacement member 58 that has been attracted and held by the first suction mechanism 592 are positioned in the feeding direction and the direction perpendicular to the feeding direction by a positioning mechanism (not shown) which is essentially similar to the positioning mechanism of the light shielding member positioning mechanism 170 (see FIG. 10) or the light shielding sheet strip preassembling mechanism 580. Then, the portion of the presealed light shielding sheet strip 60

which is in contact with the displacement member 58 is uniformly pressed by a heater block, not shown. As a result, the seal member is fused and fixed to the displacement member 58, finally applying the light shielding sheet strip 60 to the displacement member 58.

As with the light shielding sheet strip applying mechanism 172 (see FIG. 12), the light shielding sheet assembling mechanism 342 (see FIG. 18), and the discharge prevention sheet assembling apparatus 490 (see FIG. 6), the light shielding sheet strip assembling mechanism 584 monitors the heated temperature of the heater block. If the light shielding sheet strip 60 is applied to the displacement member 58 at a temperature outside of a predetermined temperature range, then the light shielding sheet strip assembling mechanism 584 can reject the light shielding member 54 where the light shielding sheet strip 60 is applied to the displacement member 58 as a defective component or can shut down the film case manufacturing system 100 in its entirety. FIG. 31 shows in perspective an image checking apparatus 640 disposed between the light shielding sheet strip assembling mechanism 584 (see FIG. 6) and the incision forming mechanism 586. FIG. 32 shows in perspective positioning members 660a, 660c of a positioning mechanism 642 of the image checking apparatus 640 and an actuating mechanism 644 for the positioning members 660a, 660c. FIG. 33 shows in perspective positioning members 660b, 660d of

the positioning mechanism 642 and an actuating mechanism 646 for the positioning members 660b, 66Od. FIGS. 34A and 34B show in plan the manner in which the position where a light shielding sheet strip 60 is applied to a displacement member 58 is checked.

The image checking apparatus 640 comprises a positioning mechanism 642 for positioning a light shielding member 54 which comprises a light shielding sheet strip 60 and a displacement member 58 that are finally applied to each other, actuating mechanisms 644, 646 for actuating the positioning mechanism 642, a camera 648 which is disposed above the positioned light shielding member 54, for capturing an image of the light shielding member 54 and an image processor 650. The positioning mechanism 642 comprises positioning members 660a, 660c for positioning shorter sides (upstream and downstream sides in FIGS. 31 through 33) of a displacement member 58, and positioning members 660b, 660d for positioning longer sides (sides in directions perpendicular to the feeding direction of the light shielding member 54) of the displacement member 58.

The positioning members 660a, 660c are substantially identical in shape to each other and are disposed along the feeding direction. The positioning members 660a, 660c have respective vertically extending, substantially inverted L- shaped proximal end portions (reference portions) 662a, 662c and respective substantially inverted L-shaped distal end

portions 664a, 664c projecting upwardly from upstream ends of the proximal end portions 662a, 662c. The distal end portions 664a, 664c have respective downstream and upstream sides which confront each other. When the upstream side of the proximal end portion 662a is pressed in the feeding direction under resilient forces of a spring 666a and the downstream side of the proximal end portion 662c is pressed in a direction opposite to the feeding direction under resilient forces of a spring 666c, the distal end portions 664a, 664c are moved toward each other for gripping the shorter sides of the displacement member 58.

The positioning members 660b, 660d are linearly symmetrical with respect to the feeding direction of the light shielding member 54. The positioning members 660b, 660d have respective substantially L-shaped proximal end portions (reference portions) 662b, 662d extending in the feeding direction and respective substantially inverted L- shaped distal end portions (positioning portions) 664b, 664d projecting upwardly from downstream ends of the proximal end portions 662b, 662d. The distal end portions 664b, 664d have respective distal end surfaces which confront each other. When the upstream sides of the proximal end portions 662b, 662d are pressed in directions perpendicular to the feeding direction under resilient forces of springs 666b, 666d, the distal end portions 664b, 664d are moved toward each other for gripping the longer sides of the displacement member 58.

- I l l -

The resilient forces of one of the springs 666a, 666c and one of the springs 666b, 666d are made larger than the resilient forces of the other springs for determining the position in which the displacement member 58 is held with respect to the positioning members pressed as reference positioning members by the ones of the springs and causing the other positioning members pressed by the others of the springs to press the sides of the displacement member 58 based on the reference positioning members. The actuating mechanism 644 shown in FIG. 32 and the actuating mechanism 646 shown in FIG. 33 are essentially identical in structure to each other, and their components will be denoted by identical reference characters.

The actuating mechanisms 644, 646 have respective upstanding tables 670 and support members 672, 674 extending parallel to each other from upper corners of the tables 670. Springs 666a through 666d have proximal ends fixed to the support members 672, 674. Rods 676, 678 are fastened by nuts 680, 682 perpendicularly to surfaces of the tables 670 below the support members 672, 674. Bearings 684, 686 are rotatably supported respectively on the distal ends of the rods 676, 678. Substantially I-shaped turn arms 688, 690 are attached to sides of the bearings 684, 686 for angular movement about the respective rods 676, 678 as central axes. The turn arms 688 have upper ends coupled to the proximal end portions 662a, 662b of the positioning members 660a, 660b by joints 692, and the turn arms 690 have upper

ends coupled to the proximal end portions 662c, 662d of the positioning members 660c, 660d by joints 693. Transmitting members 694 facing the tables 670 are mounted on other lower ends of the turn arms 688, and transmitting members 696 facing the tables 670 are mounted on other lower ends of the turn arms 690.

Guide rails 698 are vertically mounted on the surfaces of the tables 670 below the rods 676, 678, and slide blocks 702 connected to links 700 are slidably mounted on the guide rails 698. Substantially L-shaped transmitting members 706, 708 are fastened to the surfaces of the slide blocks 702 by screws 704. The transmitting members 706, 708 have upwardly spreading tapered surfaces 710, 712 disposed on upper portions thereof for contact with sides of the transmitting members 694, 696.

When the links 700 are vertically moved by cam mechanisms, not shown, the slide blocks 702 are vertically moved along the guide rails 698, vertically moving the transmitting members 706, 708 which are coupled to the slide blocks 702. The transmitting members 694, 696 are now moved toward or away from each other by being guided by the tapered surfaces 710, 712, with the result that the turn arms 688, 690 coupled to the transmitting members 694, 696 are angularly moved about the rods 676, 678. Therefore, the positioning members 660a through 66Od which are coupled to the turn arms 688, 690 by the joints 692, 693 are movable toward and away from the sides of the displacement member 58

by the angular movement of the turn arms 688, 690.

In FIGS. 31 through 34B, when the bottom of the displacement member 58 is attracted and held by the first suction mechanism 592 and the sides of the displacement member 58 are positioned by the positioning members 660a through 66Od, the light shielding member 54 is imaged from above by the camera 648. However, since the displacement member 58 is covered with the light shielding sheet strip 60, the image processor 650 is unable to recognize the position where the light shielding sheet strip 60 is applied to the displacement member 58 directly from the image of the displacement member 58.

When the light shielding member 54 is positioned by the positioning members 660a through 66Od, the image processor 650 calculates the position where the light shielding sheet strip 60 is applied to the displacement member 58 (the projecting lengths of the light shielding sheet strip 60) indirectly from distances da, dc between the surfaces of the distal end portions 664a, 664c which are in contact with the displacement member 58 and the shorter sides of the light shielding sheet strip 60.

In FIG. 34A, the projecting lengths (the distances da, dc) of the light shielding sheet strip 60 from the displacement member 58 in the feeding direction are calculated. If the applied position of the light shielding sheet strip 60 in the direction perpendicular to the feeding direction is to be calculated, then, as shown in FIG. 34B,

the widths of the distal end portions 664b, 664d along the feeding direction are made longer than the longer sides of the light shielding sheet strip 60, and the distances db, dd between the surfaces of the distal end portions 664b, 664d which are in contact with the displacement member 58 and the longer sides of the light shielding sheet strip 60 are detected. Then, the position where the light shielding sheet strip 60 is applied to the displacement member 58 can be calculated indirectly from the distances db, dd. With the image checking apparatus 640, the positions where the light shielding sheet strip 60 is applied to the two sides of the displacement member 58 are checked in one station. Alternatively, the image checking apparatus 640 may be divided into two stations, and the positions where the light shielding sheet strip 60 is applied to the two sides of the displacement member 58 along the feeding direction may be checked in the first station, whereas the positions where the light shielding sheet strip 60 is applied to the four sides of the displacement member 58 may be checked in the next station.

In the incision forming mechanism 586 shown in FIG. 6, while the bottom of the displacement member 58 is being attracted and held by the first suction mechanism 592 (see FIGS. 28 through 30) and the sides of the displacement member 58 are being positioned by positioning members which are similar to the above positioning members 660a through 660d (see FIGS. 31 through 34A, 34B), a cutter, not shown.

is applied to the light shielding sheet strip 60 to form an incision 70 (see FIGS. 3 and 5).

FIG. 35 shows in fragmentary perspective the manner in which a light shielding sheet strip 60 is folded by the longer side folding mechanism 588 and the shorter side folding mechanism 590. FIG. 36 shows in perspective major components of a folding actuating mechanism 728 for actuating the longer side folding mechanism 588 and the shorter side folding mechanism 590. As shown in FIG. 35, the longer side folding mechanism 588 has a substantially L-shaped longer side folding die 730 for inwardly folding the longer side portion 68 of a light shielding sheet strip 60 with an incision 70 defined therein (see FIGS. 3 through 5) toward the upper surface of the light shielding sheet strip 60, a substantially L-shaped holding die (first holding die) 732 for holding, from above, the other portion of the light shielding sheet strip 60, and a substantially L-shaped holding die 734 for holding, from below, the shorter side portion 66 of the light shielding sheet strip 60 and the other longer side of the light shielding sheet strip 60 in cooperation with the holding die 732.

The holding die 732 has a vertically slanted surface facing the longer side portion 68 of the light shielding sheet strip 60. A portion of the vertically slanted surface which extends from the incision 70 to a central area of the second longer side segment 74 comprises a tapered recess

736. The recess 736 is of such a shape that it is progressively deeper upstream in the feeding direction.

The portion of the light shielding sheet strip 60 which is applied to the displacement member 58 and the shorter side portion 66 of the light shielding sheet strip 60 are held by the holding die 732 from above, and the shorter side portion 66 and the longer side that is free of the incision are held by the holding die 734 from below. When the longer side folding die 730 that is disposed directly below the longer side portion 68 is elevated, a tip end 738 of the longer side folding die 730 is brought into contact with the longer side portion 68. As a result, the longer side portion 68 is inwardly folded toward the upper surface of the light shielding sheet strip 60 along the holding die 732 under the pushing forces of the longer side folding die 730.

At this time, the first longer side segment 72 and a downstream portion of the second longer side segment 74 are inwardly folded up to the slanted surface of the holding die 732, and the portion of the second longer side segment 74 which extends from the incision 70 to the central area of the second longer side segment 74 are folded slightly toward the upper surface of the light shielding sheet strip 60. Therefore, the recess 736 locally reduces the amount of folding of the second longer side segment 74. The shorter side folding mechanism 590 has a substantially L-shaped shorter side folding die 740 for inwardly folding the shorter side portion 66 of a light

shielding sheet strip 60 (see FIGS. 3 through 5) toward the upper surface of the light shielding sheet strip 60, and a substantially L-shaped holding die (second holding die) 742 for holding, from above, the portion of the light shielding sheet strip 60 which is applied to the displacement member 58.

The holding die 742 has a vertically slanted surface facing the shorter side portion 66 of the light shielding sheet strip 60. The side of the holding die 742 which faces the second longer side segment 74 has a projection 744 for pressing the central area of the second longer side segment 74.

When the portion of the light shielding sheet strip 60 which is applied to the displacement member 58 is held by the holding die 742 from above while the bottom of the displacement member 58 is being attracted and held by the first suction mechanism 592, the inwardly folded second longer side segment 74 is pressed downwardly by the projection 744. As a result, the amount of folding of the portion of the second longer side segment 74 which extends from the incision 70 to the central area thereof is locally reduced.

When the shorter side folding die 740 which is disposed directly below the shorter side portion 66 is elevated, a tip end 746 of the shorter side folding die 740 is brought into contact with the shorter side portion 66. As a result, the shorter side portion 66 is inwardly folded toward the

upper surface of the light shielding sheet strip 60 along the holding die 742 up to the slanted surface of the holding die 742 under the pushing forces of the shorter side folding die 740. The folding actuating mechanism 728 shown in FIG. 36 serves to actuate the longer side folding mechanism 588 and the shorter side folding mechanism 590 in synchronism with each other. The folding actuating mechanism 728 comprises an upstanding table 750 and two guide rails 752, 754 vertically mounted on the upstanding table 750. The guide rails 752, 754 extend in parallel to each other. Two slide tables 756, 758 are slidably mounted on the guide rails 752, 754 in spaced-apart relation to each other.

Two guide rails 760, 762 and two actuators 764, 766 are mounted on the slide table 756 in parallel spaced relation to each other. The actuators 764, 766 are coupled to respective supports 776, 778 which support the holding dies 732, 742, respectively, with flexible joints 768, 770. The supports 776, 778 have respective proximal ends 772, 774 coupled to the flexible joints 768, 770, respectively, and respective other ends supporting the proximal ends of the holding dies 732, 742.

On the slide table 758, there are mounted supports 780, 782 supporting the bottoms of the longer side folding die 730 and the shorter side folding die 740, respectively.

When the slide table 756 is vertically moved along the guide rails 752, 754 by a cam and link mechanism, not shown.

the holding dies 732, 742 are vertically moved by the guide rails 760, 762 and the supports 776, 778 in the same direction as the slide table 756.

When the flexible joints 768, 770 are vertically moved by the actuators 764, 766, the holding dies 732, 742 are vertically moved individually along the guide rails 760, 762 by the supports 776, 778.

When the slide table 758 is vertically moved along the guide rails 752, 754 by a cam and link mechanism, not shown, the longer side folding die 730 and the shorter side folding die 740 are vertically moved by the supports 780, 782 and the slide table 758.

As shown in FIG. 6, the shorter side folding mechanism 590 is followed downstream successively by a checking apparatus 790 for checking a folded position of the shorter side portion 66, and a transfer apparatus 794 for transferring a light shielding member 54 that has been judged as defective in the checking processes performed by the image checking apparatus 640 and the checking apparatus 790 as a defective component into a defective component stacking case 792 or transferring a light shielding member 54 that has been judged as acceptable by those checking apparatus as an acceptable component to the positioning mechanism 170 (see FIG. 10) of the main assembling line 114. As shown in FIG. 6, the film presser supply line 112 comprises a roller conveyor 800 for supplying film pressers 92 collected in a container 801, a belt conveyor 802

disposed between the roller conveyor 800 and the main assembling line 114, a transfer apparatus 804 for transferring a plurality of film pressers 92 fed from the container 801 to the belt conveyor 802, a checking apparatus 806 for checking the film pressers 92 on the belt conveyor 802 for their overlapping states and orientations, and a transfer apparatus 810 for transferring film pressers 92 that have been judged as defective in the checking process performed by the checking apparatus 806 as defective components into a defective component stacking case 808.

The container 801 is divided by partitions, not shown, into a plurality of bins arranged in four rows and three columns. A plurality of film pressers 92 are housed as a vertical stack in each of the bins . The housed film pressers 92 have sides held by side walls of the container

801 and protrusions, not shown, projecting inwardly from the partitions into the bins. Holes, not shown, are defined in the bottoms of the respective bins .

The container 801 has a recess defined in a corner thereof for indicating the orientation of the container 801. On the film presser supply line 112, when the container 801 is fed over the roller conveyor 800 to a predetermined position and stopped, an orientation sensor, not shown, detects the position of the recess, i.e., the orientation of the container 801. Based on the detected orientation, the transfer apparatus 804 successively transfers the film pressers 92 stored in the bins onto the belt conveyor 802.

After the stopped container 801 is positioned on the roller conveyor 800, the transfer apparatus 804 inserts a guide member, not shown, into one of the bins to position the four corners of film pressers 92, and elevates a lifter, not shown, through one of the holes in the container 801 from below to lift the film pressers 92 to a vertical position where they can be removed from the container 801. The vertical position to which the film pressers 92 are lifted is monitored by a sensor, not shown, which supplies a detected signal through a feedback loop to control the lifter so that the film pressers 92 will be lifted to the same vertical position at all times.

The transfer apparatus 804 also has a robot hand, not shown, for lifting a plurality of stacked film pressers 92. The transfer apparatus 804 applies a stream of ionic wind to the film pressers 92 lifted by the robot hand to electrically neutralize the film pressers 92. The applied stream of ionic wind is also effective to loosen the film pressers 92 for thereby separating lower film pressers 92 from the uppermost film presser 92.

The checking apparatus 806 has a positioning member, not shown, for positioning the opposite ends of a film presser 92 and a test piece, not shown, for contacting a surface of the film presser 92 to check the height of the film presser 92. The checking apparatus 806 also has a photoelectric sensor, not shown, for detecting the position of the cutout 92a (see FIG. 3) of the film presser 92 to

determine the orientation of the film presser 92. A film presser 92 that has been judged as acceptable by the checking apparatus 806 is transferred from a downstream portion of the belt conveyor 802 to the film presser assembling apparatus 133 by a transfer mechanism, not shown, of the film presser assembling apparatus 133.

The various apparatus of the film presser supply line 112 have their operational speeds variable. Therefore, if a film presser 92 is judged as defective and the string of film pressers 92 supplied to the lid assembling line 122 lacks a film presser 92, then the apparatus are operated in two cycles during one cycle of operation of the film presser supply line 112 to prevent the lacking film presser 92 from adversely affecting the lid assembling line 122, or in other words, to keep the string of film pressers 92 free of a lacking film presser 92.

The film case manufacturing system 100 according to the present embodiment is constructed as described above. Operation of the film case manufacturing system 100 will be described below with reference to FIGS. 1 through 36 and flowcharts shown in FIGS. 37 through 48.

The case body/lid supplying apparatus supplies case bodies 14 with lids 16 placed thereon to the assembling preparation line 116 (see FIG. 6) in step Sl shown in FIG. 37. Specifically, each case body 14 has its end 18 positioned upstream in the feeding direction (see FIG. 8) and the other end 26 positioned downstream when the case

body 14 is transferred from the* supply conveyor 138 of the case body/lid supplying apparatus to the reception conveyor 136 of the assembling preparation line 116.

Then, a plurality of sets of case bodies 14 and lids 16 fed on the reception conveyor 136 are separated one by one by a separator, not shown, in step S2.

Then, the checking apparatus 146 (see FIG. 6) checks a case body 14 and a lid 16 which have been separated. At this time, corners of the case body 14 are positioned by a tapered positioning member 148 (see FIG. 7) in step S3. The checking apparatus 146 checks whether the case body 14 has the lid 16 or not, checks the direction of the lid 16 with respect to the case body 14 in step S4 , and checks the lifting (height) of the lid 16 with respect to the case body 14 in step S5

On the defective piece discharge line 150 (see FIG. 6), it is determined whether the case body 14 and the lid 16 checked in steps S4, S5 are acceptable or not in step S6. If the case body 14 and the lid 16 are judged as defective, then they are discharged as defective components from the defective piece discharge line 150 in step S7. If the case body 14 and the lid 16 are judged as acceptable, then they are transferred to the case body assembling line 120 (see FIGS. 6 and 7) by the transfer apparatus 152 in step S8. After the case body 14 and the lid 16 are transferred to the case body assembling line 120 in step S9 shown in FIG. 38, the transfer apparatus 154 transfers only the lid

16 to the lid assembling line 122 in step SlO.

On the case body assembling line 120 on which the case body 14 is fed, a light shielding member 54, a presser sheet 56, a light shielding sheet 22, a first discharge prevention sheet 34a, and a second discharge prevention sheet 34b are assembled on the case body 14 in step SIl (see FIGS. 1 to 4). On the lid assembling line 122 on which the lid 16 is fed, the film presser 92 is assembled on the lid 16 in step S12. Then, the lid 16 with the film presser 92 assembled thereon is placed by the transfer apparatus 498 (see FIG. 6) onto the case body 14 in which the light shielding member 54, the presser sheet 56, the light shielding sheet 22, the first discharge prevention sheet 34a, and the second discharge prevention sheet 34b have been assembled, in step S13.

Then, the checking apparatus 500 checks whether the film presser 92 is present or not on the case body 14 and the lid 16 which are assembled together and also checks an assembled state of the film presser 92 in step S14. The checking apparatus 500 further checks whether the lid 16 is present or not and also checks the height of the lid 16 with respect to the case body 14 in step S15.

The transfer apparatus 504 transfers the case body 14 and the lid 16 which are fed on the case body assembling line 120 as a sample film case 10 to the sample pickup line 502 (see FIGS. 6 and 26) in step S16. The film case 10

transferred to the sample pickup line 502 is pushed in the pushing direction down the sample pickup chute 508 and discharged out of the film case manufacturing system 100 in step S17. Then, the transfer apparatus 504 (see FIG. 6) determines whether case bodies 14 and lids 16 are found acceptable in the checking processes performed by the checking apparatus 156, 300, 302, 307, 308, 460, 474, 476, 484, 492, 500 arranged on the assembling line 118 in step S18. The transfer apparatus 504 transfers a defective case body 14 and a defective lid 16 to the defective product discharge line 514, which discharges them as a defective film case 10 out of the film case manufacturing system 100 in step S19. The transfer apparatus 504 transfers an acceptable case body 14 and an acceptable lid 16 which are found acceptable in step S18 to the feed line 512. The feed line 512 discharges the case body 14 and the lid 16 as a completed film case 10 to an external film case storage machine or the like in step S20. FIG. 39 is a flowchart showing in detail the assembling sequence on the case body 14 in step SIl.

In step S21 shown in FIG. 39, the separation of the case body 14 and the lid 16 from each other is confirmed by the checking apparatus 156 (see FIG. 6). Then, the light shielding member 54 supplied from the light shielding member supply line 102 is applied to the case body 14 by the light shielding member assembling

apparatus 126 in step S22, and the presser sheet 56 for pressing the upper surface of the light shielding member 54 is applied to the case body 14 by the presser sheet assembling apparatus 128 in step S23. Then, the image checking apparatus 299 (see FIG. 6) checks the position and shape of the presser sheet 56 that is applied to the case body 14 in step S24. The light shielding member checking apparatus 300 checks the height of the light shielding member 54 applied to the case body 14 in step S25. Thereafter, the position of the light shielding member 54 (the displacement member 58) which is applied to the case body 14 is checked by the image checking apparatus 302 in step S26.

Then, the image checking apparatus 308 (see FIG. 6) checks a folded state of the first longer side segment 72 with respect to the second longer side segment 74 of the light shielding sheet strip 60 (see FIGS. 3 through 5) in step S27.

Then, the light shielding sheet 22 supplied from the light shielding sheet supply apparatus 106 is applied to the end 18 of the case body 14 by the light shielding sheet assembling apparatus 130 in step S28. The image checking apparatus 460 checks the applied state and shape of the light shielding sheet 22 on the case body 14 in step S29. Then, the first and second discharge prevention sheets 34a, 34b supplied from the first and second discharge prevention sheet supply apparatus 108, 110 are supplied to

the first and second discharge prevention sheet preassembling apparatus 132, 134, which temporarily apply the first and second discharge prevention sheets 34a, 34b to the case body 14. The first and second discharge prevention sheets 34a, 34b are thereafter finally applied to the case body 14 by the discharge prevention sheet assembling apparatus 490 in step S30. Thereafter, the image checking apparatus 492 checks the applied state and shape of the first and second discharge prevention sheets 34a, 34b on the case body 14 in step S31.

FIG. 40 is a flowchart showing in detail the sequence of assembling the light shielding member 54 into the case body 14 in step S22 shown in FIG. 39.

In step S32 shown in FIG. 40, the light shielding member 54 is assembled on the light shielding member supply line 102. Then, the assembled light shielding member 54 is supplied to the light shielding member assembling apparatus 126 in step S33. In the light shielding member positioning mechanism 170 (see FIG. 10) of the light shielding member assembling apparatus 126, the positioning members 180a, 180c grip the longer side edges of the displacement member 58, t and the positioning members 180b, 18Od grip the shorter side edges of the displacement member 58, thereby positioning the light shielding member 54 in step S34. Then, while the light shielding sheet strip 60 of the light shielding member 54 thus positioned is being attracted by the suction block 182 (see FIGS. 9 and 10) of the light

shielding member attracting mechanism 174, the suction block 182 is fed to a position above the slit 38 of the case body 14 (see FIG. HA) . Then, the bottom of the displacement member 58 is supported by the clamp 214 inserted through the slit 38, so that the light shielding member 54 is vertically sandwiched by the clamp 214 and the suction block 182 (see FIG. HB ). Then, with the light shielding member 54 being thus sandwiched, a portion of the light shielding sheet strip 60 is pressed downwardly by the presser 220, and the presser 220, the suction block 182, and the clamp 214 are lowered. The clamp 214 guides the light shielding member 54 to the bottom 36 of the case body 14, and places the light shielding member 54 on the bottom 36 (see FIGS. HC and HD) . Then, the suction block 182 and the clamp 214 are released from the light shielding member 54 thus placed (see FIG. HE), and the light shielding member 54 is positioned and held on the case body 14 only by the presser 220 in step S35.

Then, while the presser 220 is pressing the light shielding member 54, the rod feed mechanism 124 (see FIG. 7) feeds the case body 14 to the next station where the light shielding sheet strip applying mechanism 172 is disposed in step S36 (see FIGS. 10 and 12).

Then, the light shielding sheet strip applying mechanism 172 is lowered to a position near the light shielding sheet strip 60 in the case body 14 thus fed, and the distal end portion 258 of the presser 256 is abuts

against the light shielding sheet strip 60 and presses the light shielding sheet strip 60 toward the bottom 36 of the case body 14 (see FIG. 13B). After the distal end portion 258 presses the light shielding sheet strip 60, the presser 220 that has pressed the light shielding member 54 is separated from the light shielding member 54 and returns to the upstream station (see FIG. 10). At the same time, the cylinder rod 268 is displaced toward the other end 26 of the case body 14 to displace the heater 254 toward the other end 26 into abutment against the shorter side portion 66. The heater 254 heats the region of the other end 26 which is covered with the shorter side portion 66 for a predetermined period of time (see FIGS. 10 and 13C), applying the shorter side portion 66 to the covered region of the other end 26 in step S37. As a result, the U-shaped applied seal 51 is formed on the covered region of the other end 26 (see FIG. 4), and the shorter side portion 66 of the light shielding sheet strip 60 is applied to the covered region of the other end 26 through the U-shaped applied seal 51. After having heated the shorter side portion 66 of the light shielding sheet strip 60 for the predetermined period of time, the actuator 266 retracts the cylinder rod 268 to release the heater 254 from the shorter side portion 66. The table 272 is lifted to move the heater 254 and the presser 256 upwardly from the light shielding member 54.

FIGS. 41 and 42 are a flowchart of the sequence of assembling the light shielding member 54 in step S32 shown

in FIG . 40 .

In step S38 shown in FIG. 41, the hopper 540 (see FIG. 6) supplies displacement members 58 (see FIGS. 3 through 5) to the ball feeder 542, which arranges the displacement members 58 in a predetermined direction and delivers an array of displacement members 58 through the linear feeder 544 to the separator 546 (see FIG. 27). The separator 546 separates the displacement members 58 one by one from the array of displacement members 58 in step S39. A separated displacement member 58 is transferred to the displacement member check line 532 by the transfer apparatus 554 in step S40.

On the displacement member check line 532, the image checking apparatus 562 (see FIG. 6) checks the orientation of the displacement member 58 (see FIGS. 3 through 5) in step S41. If the displacement member 58 is judged as being oriented opposite to the feeding direction, i.e., as being oriented not normal, in step S42, then the reversing apparatus 564 corrects the orientation of the displacement member 58 by turning around the displacement member 58 through 180° in step S43. If the displacement member 58 is judged as being oriented normal in step S42, then the reversing apparatus 564 does not correct the orientation of the displacement member 58. Then, the image checking apparatus 566 checks whether the displacement member 58 is of a predetermined shape or not in step S44. If the displacement member 58 is judged as

defective (with the reverse side facing up) by the image checking apparatus 562 or if the displacement member 58 is judged as defective (not having a predetermined shape) by the image checking apparatus 566 in step S45, the transfer apparatus 572 transfers the displacement member 58 as a defective component into the defective component stacking case 568 in step S46. If the displacement member 58 is judged as acceptable by the image checking apparatus 562 and the image checking apparatus 566, then the transfer apparatus 572 transfers the displacement member 58 as an acceptable component to the buffer conveyor 570 in step S47. The displacement member 58 that has been transferred to the buffer conveyor 570 in step S48 shown in FIG. 42 is transferred from the buffer conveyor 570 onto the positioning table 576 by the transfer apparatus 574. After being positioned on the positioning table 576, the displacement member 58 is transferred onto the placement rail 596 of the light shielding member assembling line 536 by the transfer apparatus 578 in step S49. On the light shielding member assembling line 536, the light shielding sheet strip 60 is applied to the displacement member 58 in step S50. Then, the position where the light shielding sheet strip 60 is applied to the displacement member 58 is checked by the image checking apparatus 640 (see FIGS. 6, 31 through 34A, 34B) in step S51.

Since the displacement member 58 is covered with the

light shielding sheet strip 60,* the image processor 650 is unable to recognize the position where the light shielding sheet strip 60 is applied to the displacement member 58 directly from the image of the displacement member 58. Therefore, with the bottom of the displacement member 58 being attracted and held by the first suction mechanism 592, the light shielding member 54 is positioned by the positioning members 660a through 66Od, and the image processor 650 calculates the position where the light shielding sheet strip 60 is applied to the displacement member 58 indirectly from the distances da, dc between the surfaces of the distal end portions 664a, 664c which are in contact with the displacement member 58 and the shorter sides of the light shielding sheet strip 60 (and/or the distances db, dd) .

Then, while the bottom of the displacement member 58 is being attracted and held by the first suction mechanism 592 and the sides of the displacement member 58 are being positioned by the positioning member, the incision forming mechanism 586 (see FIG. 6) forms the incision 70 (see FIGS. 3 through 5) in the light shielding sheet strip 60 in step S52.

Then, the longer side folding mechanism 588 (see FIGS. 35 and 36) inwardly folds the longer side portion 68 (see FIGS. 3 through 5) of the light shielding sheet strip 60 with the incision 70 formed therein, toward the upper surface of the light shielding sheet strip 60, using the

longer side folding die 730 in step S53.

The portion of the light shielding sheet strip 60 which is applied to the displacement member 58 and the shorter side portion 66 of the light shielding sheet strip 60 are held by the holding die 732 from above, and the shorter side portion 66 and the longer side that is free of the incision are held by the holding die 734 from below. When the longer side folding die 730 that is disposed directly below the longer side portion 68 is elevated by the folding actuating mechanism 728, the tip end 738 of the longer side folding die 730 is brought into contact with the longer side portion 68. As a result, the longer side portion 68 is inwardly folded toward the upper surface of the light shielding sheet strip 60 along the holding die 732 under the pushing forces of the longer side folding die 730.

At this time, the first longer side segment 72 and a downstream portion of the second longer side segment 74 are inwardly folded up to the slanted surface of the holding die 732, and the portion of the second longer side segment 74 which extends from the incision 70 to the central area of the second longer side segment 74 are folded slightly toward the upper surface of the light shielding sheet strip 60. Therefore, the recess 736 locally reduces the amount of folding of the second longer side segment 74. Then, using the shorter side folding die 740 of the shorter side folding mechanism 590, the shorter side portion 66 (see FIGS. 3 through 5) is inwardly folded toward the

upper surface of the light shielding sheet strip 60 in step S54.

When the portion of the light shielding sheet strip 60 which is applied to the displacement member 58 is held from above by the holding die 742 while the first suction mechanism 592 is attracting and holding the bottom of the displacement member 58, the inwardly folded second longer side segment 74 is pressed downwardly by the projection 744. As a result , the amount of folding of the portion of the second longer side segment 74 which extends from the incision 70 to the central area thereof is locally reduced.

When the shorter side folding die 740 which is disposed directly below the shorter side portion 66 is elevated by the folding actuating mechanism 728, the tip end 746 of the shorter side folding die 740 is brought into contact with the shorter side portion 66. The shorter side portion 66 is inwardly folded toward the upper surface of the light shielding sheet strip 60 along the holding die 742 up to the slanted surface of the holding die 742 under the pushing forces of the shorter side folding die 740.

Then, the checking apparatus 790 checks a folded position of the shorter side portion 66 in step S55.' The transfer apparatus 794 transfers a light shielding member 54 which has been judged as defective in the checking processes performed by the image checking apparatus 640 and the checking apparatus 790 in step S56, as a defective component into the defective component stacking case 792 in step S57.

A light shielding member 54 which has been judged as acceptable is transferred as an acceptable component to the positioning mechanism 170 (see FIG. 10) of the main assembling line 114 by the transfer apparatus 794 in step S58.

FIG. 43 is a flowchart of the sequence of applying the light shielding sheet strip 60 to the displacement member 58 in step S50 shown in FIG. 42.

The light shielding sheet strip supply mechanism 534 (see FIG. 6) cuts the light shielding sheet ribbon 630 into a light shielding sheet strip 60 in step S59, and supplies the light shielding sheet strip 60 to the light shielding sheet strip preassembling mechanism 580 in step S60.

In the light shielding sheet strip preassembling mechanism 580, the sides of the displacement member 58 that has been attracted and held by the first suction mechanism 592 (see FIGS. 28 and 29) on the placement rail 596 are positioned in the feeding direction and the direction perpendicular to the feeding direction by the non- illustrated positioning mechanism in step S61. The light shielding sheet strip 60 is placed on the upper surface of the positioned displacement member 58 and temporarily applied to the displacement member 58 in step S62.

Then, the light shielding sheet strip presealing mechanism 582 preseals the light shielding sheet strip 60 that has been temporarily applied to the upper surface of the displacement member 58 in step S63. The light shielding

sheet strip assembling mechanism 584 finally applies the presealed light shielding sheet strip 60 to the upper surface of the displacement member 58 in step S64.

FIG. 44 is a flowchart of the sequence of applying the presser sheet 56 to the case body 14 in step S23 shown in FIG. 39.

The presser sheet supply apparatus 104 (see FIG. 6) cuts the presser sheet ribbon 278 into a presser sheet 56 in step S65, and supplies the presser sheet 56 to the presser sheet assembling apparatus 128 in step S66. In the presser sheet assembling apparatus 128, the distal end 284 of the presser sheet applying block 282 attracts the upper surface of the supplied presser sheet 56 in step S67, and moves the attracted presser sheet 56 to a position near the light shielding member 54 mounted on the case body 14 (see FIG. 15A) .

Specifically, the portion of the presser sheet 56 which faces the light shielding member 54 is attracted by the suction ports 286. The protruding pins 294 bite into the portion of the presser sheet 56 which confronts the land 46 and which is curved along the land 292. The presser sheet 56 is pressed against the light shielding sheet strip 60 of the light shielding member 54 and the land 46, and the land 292 generates ultraviolet vibrations and applies the ultrasonic vibrations to the presser sheet 56 for a predetermined period of time. The presser sheet 56 is now fused and fixed to the land 46 in step S68.

FIG. 45 is a flowchart of the sequence of applying the light shielding sheet 22 to the case body 14 in step S28 shown in FIG. 39.

The light shielding sheet supply apparatus 106 (see FIG. 6) cuts the light shielding sheet ribbon 320 into a light shielding sheet 22 in step S69, and supplies the light shielding sheet 22 to the light shielding sheet assembling apparatus 130 in step S70. At this time, the feed interval control mechanism 324 feeds the light shielding sheet ribbon 320 by a predetermined length to produce the light shielding sheet 22 to accurate dimensions.

Then, in the light shielding sheet assembling apparatus 130, the positioning member 148 positions the case body 14 in step S71. Thereafter, the light shielding sheet 22 (see FIGS. 1, 2, and 4) supplied from the light shielding sheet supply apparatus 106 is temporarily applied to the end 18 of the case body 14 by the light shielding sheet preassembling mechanism 341 in step S72.

Then, the temporarily applied light shielding sheet 22 is finally applied to the surface 19a of the end 18 of the case body 14 by the light shielding sheet assembling mechanism 342 in step S73. At this time, while the other surface 19b of the end 18 of the case body 14 is being uniformly pressed by the three pressers 360a through 360c, the heater 347 is pressed against the surface 19a of the end 18 of the case body 14, so that the light shielding sheet 22 is reliably applied to the end 18 of the case body 14

through the applied seal 32.

FIG. 46 is a flow chart of the sequence of applying the discharge prevention sheets 34a, 34b to the case body 14 in step S30 shown in FIG. 39. The first discharge prevention sheet supply apparatus 108 cuts the discharge prevention sheet ribbon 470 into a first discharge prevention sheet 34a (see FIG. 3) in step S74, and supplies the first discharge prevention sheet 34a to the first discharge prevention sheet preassembling apparatus 132 in step S75.

Then, in the first discharge prevention sheet preassembling apparatus 132, the positioning member 148 positions the case body 14 in step S76. Thereafter, the first discharge prevention sheet 34a is temporarily applied to the bottom 36 of the case body 14 at a predetermined position thereon in step S77. Then, the checking apparatus 474 checks whether the first discharge prevention sheet 34a is present on the case body 14 or not in step S78.

As with the first discharge prevention sheet supply apparatus 108, the second discharge prevention sheet supply apparatus 110 cuts the discharge prevention sheet ribbon 480 into a second discharge prevention sheet 34b (see FIG. 3) in step S79, and supplies the second discharge prevention sheet 34b to the second discharge prevention sheet preassembling apparatus 134 in step S80.

Then, in the second discharge prevention sheet preassembling apparatus 134, the positioning member 148

positions the case body 14 in step S81. Thereafter, the second discharge prevention sheet 34b is temporarily applied to the bottom 36 of the case body 14 at a predetermined position thereon in step S82. Then, the checking apparatus 484 checks whether the second discharge prevention sheet 34b is present on the case body 14 or not in step S83.

Then, after the positioning member 148 (see FIG. 7) has positioned the case body 14 in step S84, the discharge prevention sheet assembling apparatus 490 finally applies the first and second discharge prevention sheets 34a, 34b in step S85.

FIG. 47 is a flowchart of the assembling sequence on the lid 16 in step S12 shown in FIG. 38.

The foil applying apparatus 304 applies the foil 90 (see FIG. 1) to the lid 16 in step S86, and the image checking apparatus 307 checks the applied quality of the foil 90 in step S87.

Then, the lid inverting apparatus 310 turns the lower surface of the lid 16 upwardly in step S88, and the film presser 92 supplied from the film presser supply line 112 is placed on the turned lid 16 in step S89. Thereafter, the film presser assembling apparatus 133 assembles the film presser 92 onto the lid 16 by crimping in step S90. Then, the lid turning apparatus 496 turns the upper surface of the lid 16 with the film presser 92 mounted thereon upwardly in step S91. The turned lid 16 is transferred onto the case body 14 placed on the case body assembling line 120 by the

transfer apparatus 498, whereupon the case body 14 and the lid 16 are assembled together in step S92.

FIG. 48 is a flowchart of the assembling sequence on the lid 16 in step S89 shown in FIG. 47. The film presser supply line 112 (see FIG. 6) supplies the container 801 containing film pressers 92 to the roller conveyor 800 in step S93. Then, a plurality of film pressers 92 supplied from the container 801 are transferred to the belt conveyor 802 by the transfer apparatus 804 in step S94. The transferred film pressers 92 are fed on the belt conveyor 802 in step S95. The checking apparatus 806 checks the film pressers 92 on the belt conveyor 802 for their overlapping states and orientations in step S96. A film presser 92 which has been judged as defective in step S97 is transferred as a defective component into the defective component stacking case 808 by the transfer apparatus 810 in step S98.

A film presser 92 which has been judged as acceptable in step S97 is positioned by the non-illustrated positioning member in step S99, and transferred from the downstream portion of the belt conveyor 802 to the film presser assembling apparatus 133 by the non-illustrated transfer mechanism of the film presser assembling apparatus 133 in step SlOO. On the lid assembling line 122, the lid 16 with the bottom facing upwardly is positioned by the positioning member 148 (see FIG. 7) in step SlOl. The film presser 92

supplied from the film presser supply line 112 is placed onto the positioned lid 16 in step S102.

With the film case manufacturing system 100 and a manufacturing method performed thereby according to the present embodiment, as described above, the main assembling line 114 is supplied with a light shielding member 54, a presser sheet 56, a light shielding sheet 22, first and second discharge prevention sheets 34a, 34b, and a film presser 92. The main assembling line 114 assembles the light shielding member 54, the presser sheet 56, the light shielding sheet 22, and the first and second discharge prevention sheets 34a, 34b into a case body 14, and also assembles the film presser 92 onto a lid 16. Since film cases 10 can automatically be manufactured without manual intervention, film cases 10 of accurate dimensions and same quality can be mass-produced highly efficiently.

Since case bodies 14 and lids 16 are checked in advance on the assembling preparation line 116, the assembling line 118 (the case body assembling line 120 and the lid assembling line 122) is supplied with only those case bodies 14 and lids 16 which have been judged as acceptable. As a result, the accuracy and yield of film cases 10 are ' increased.

At a location for receiving case bodies 14 and lids 16 between the case body/lid supplying apparatus and the assembling preparation line 116, the reception conveyor 136 is disposed between the two conveyors 140a, 140b of the

supply conveyor 138. Therefore, when the reception conveyor 136 receives a case body 14 and a lid 16, the central area of the case body 14 is supported by the reception conveyor 136, and the opposite sides of the case body 14 are supported by the two conveyors 140a, 140b. As a result, the case body 14 and the lid 16 are prevented from being positionally displaced at the receiving location, and can be fed to the assembling line 118 without being positionally corrected. Furthermore, since the assembling line 118 is constructed of the case body assembling line 120 and the lid assembling line 122, the components (the light shielding member 54, the presser sheet 56, the light shielding sheet 22, the first and second discharge prevention sheets 34a, 34b, and the film presser 92) can be assembled on the case body 14 and the lid 16 independently of each other. Therefore, the components can be assembled highly efficiently. Furthermore, the rod feed mechanism 124 is used to successively feed case bodies 14 and lids 16 at the same speed on the assembling line 118. As a consequence, the components can be assembled into the case bodies 14 and onto lids 16 with higher efficiency in synchronism with the operation of the rod feed mechanism 124.

Because one station has only one assembling apparatus, no physical interference occurs between the assembling apparatus installed in the respective stations. As a space required for maintenance is provided for each of the

apparatus , each of the apparatus can easily be serviced for maintenance .

Since the presser sheet 56 is applied (fused) to the case body 14 while the presser sheet 56 is being attracted, the light shielding member 54 as it is pressed from above by the presser sheet 56 is placed onto the bottom 36 of the case body 14. Accordingly, the slit 38 remains covered with the light shielding member 54 to shield the interior of the case body 14 against entry of light. In the presser sheet assembling apparatus 128, while the presser sheet 56 is being attracted through the suction ports 286 and the suction passages 288, 290 of the presser sheet applying block 282, the presser sheet 56 is applied (fused) to the case body 14 by ultrasonic vibrations generated by the land 292, so that the light shielding member 54 is reliably pressed from above by the presser sheet 56 and held on the bottom 36 of the case body 14. Therefore, the slit 38 reliably remains covered with the light shielding member 54. The suction ports 286 extend away from the land 292 so as to provide a large suction area for the presser sheet 56. The presser sheet 56 is thus applied while it is being reliably attracted through the suction ports 286.

When the presser sheet 56 is attracted under suction through the suction ports 286, the protruding pins 294 bite into the presser sheet 56. Therefore, the presser sheet 56 is applied while it is being reliably attracted through the

suction ports 286.

The checking apparatus (discharge prevention sheet checking apparatus) 474, 484 and the image checking apparatus (discharge prevention sheet checking mechanism) 492 check the discharge prevention sheets 34a, 34b for their shapes and applied positions. Accordingly, film cases 10 can be manufactured highly accurately.

The feed interval control mechanism 324 controls a feed interval for the light shielding sheet ribbon 320 based on an image of the light shielding sheet ribbon 320.

Therefore, light shielding sheets 22 of a predetermined length can be supplied all the time to the main assembling line 114.

The feed interval control mechanism 324 controls a feed interval for the light shielding sheet ribbon 320 based on an image of the light shielding sheet ribbon 320 including the seal members 321. Therefore, light shielding sheets 22 can be supplied highly accurately to the main assembling line 114. The feed interval control mechanism 324 controls a feed interval for the light shielding sheet ribbon 320 based on an image of the light shielding sheet ribbon 320 including the seal members 321 and the application reference piece 340. Accordingly, highly accurate light shielding sheets 22 can be supplied to the main assembling line 114.

If the above feed interval control based on the image checking is replaced with the detection with a sensor of a

change in the reflected amount of light based on different component concentrations in the light shielding sheet ribbon 320 and the seal members 321, then the feed interval can be controlled more accurately for supplying highly accurate light shielding sheets 22 to the main assembling line 114.

The light shielding sheet strip 60 and the displacement member 58 are applied to each other independently of the process of assembling the case body 14 and the lid 16, on the light shielding member supply line 102 separate from the main assembling line 114. Consequently, the light shielding member 54 is assembled and the case body 14 is assembled highly accurately.

Each time a displacement member 58 is inserted into one slot in the separator 546 by the linear feeder 544, the separator 546 is moved to bring another slot in the separator 546 into confronting relation to the linear feeder 544. Accordingly, many displacement members 58 can be separated within a short period of time, and hence the separator 546 operates highly efficiently. Since the separator 546 is moved along a substantially arc path perpendicular to the direction in which the displacement member 58 is inserted, even if the displacement member 58 projects from the linear feeder 544 while the separator 546 is in motion, the projecting displacement member 58 does not interfere with the separator 546. Therefore, the yield of displacement members 58 is high.

As the displacement member check line 532 checks

displacement members 58 in advance, the light shielding member assembling line 536 is supplied with only displacement members 58 that have been judged as acceptable in the checking process. Therefore, the accuracy and yield of the light shielding members 54 is high.

A light shielding sheet strip 60 is temporarily applied to the upper surface of a displacement member 58 such that the light shielding sheet strip 60 partly projects from the displacement member 58. Then, the temporarily applied light shielding sheet strip 60 is temporarily sealed and finally applied. When the displacement member 58 is placed over the slit 38, the projecting portion of the light shielding sheet strip 60 covers the boundary between the displacement member 58 and the slit 38, thus shielding the interior of the case body 14 more securely against entry of light.

The slit 38 is covered with the light shielding member 54 where the light shielding sheet strip 60 is partly folded by folding the longer side portion 68 on the incision 70 side and the shorter side portion 66. The shorter side portion 66 covers the portion of the slit 38 which is defined in the other end 26 of the case body 14, and the longer side portion 68 on the incision 70 side covers the portion of the slit 38 which is defined in the bottom 36 of the case body 14. As a result, the interior of the case body 14 is shielded more securely against entry of light when it is not in use. The incision 70 allows the position to be folded of the shorter side portion 66 to be easily

identified and hence allow the shorter side portion 66 to be easily folded. Accordingly, the process of folding the light shielding sheet strip 60 is made highly efficient.

When the slit 38 is covered with the light shielding member 54, the first longer side segment 72 of the longer side portion 68, which is joined to the shorter side portion 66 and extending from the incision 70, is positioned more inwardly of the case body 14 than the second longer side segment 74. The portion of the slit 38 which is close to the other end 26 of the case body 14 is high.

The longer side portion 68 is inwardly folded by the longer side folding die 730, and the portion of the light shielding sheet strip 60 which is applied to the displacement member 58 and the shorter side portion 66 are held by the holding die 732. The longer side portion 68 can thus be folded reliably.

Since the holding die 732 has the recess 736, when the shorter side portion 66 is folded, the first longer side segment 72 joined to the shorter side portion 66 is inwardly folded more toward the light shielding sheet strip 60 than the second longer side segment 74. When the slit 38 is covered with the light shielding member 54 having the inwardly folded light shielding sheet strip 60, because the first longer side segment 72 is disposed more inwardly of the case body 14 than the second longer side segment 74, the portion of the slit 38 which is defined in the other end 26 of the case body 14 is shielded securely against entry of

light .

The shorter side folding mechanism 590 has the shorter side folding die 740 for folding the shorter side portion 66 and the holding die 742 for holding the portion of the light shielding sheet strip 60 which is applied to the displacement member 58. Therefore, the shorter side folding mechanism 590 can reliably fold the shorter side portion 66. Furthermore, the projection 744 is effective to locally reduce the amount of folding of the second longer side segment 74. Therefore, when the light shielding member 54 covers the slit 38, the first longer side segment 72 joined to the shorter side portion 66 can be folded more inwardly of the case body 14 than the second longer side segment 74. Therefore, the portion of the slit 38 which is defined in the other end 26 of the case body 14 is shielded securely against entry of light.

The light shielding sheet strip 60 or the displacement member 58 is fed while the upper surface of the light shielding sheet strip 60 is being attracted by first suction mechanism 592 or the lower surface of the displacement member 58 is being attracted by the second suction mechanism 594. Consequently, when the light shielding member 54 or the displacement member 58 is to be processed, it can easily be positioned in the feeding direction and the direction perpendicular to the feeding direction. As a result, the light shielding member 54 or the displacement member 58 can be processed highly efficiently. As light shielding sheet

strips 60 and displacement members 58 are successively fed, the light shielding members 54 can efficiently be assembled by operating the apparatus disposed along the light shielding member supply line 102 in synchronism with the feeding timing.

The sample pickup line 502 for picking up case bodies 14 and lids 16 which are integrally assembled together as sample film cases 10 from the main assembling line 114 is disposed downstream of the main assembling line 114. Therefore, the sample film cases 10 can efficiently be picked up from the main assembling line 114.

The sample pickup chute 508 of the sample pickup line 502 has the recesses 510 for housing therein the bottoms 24 of the ends 18 of case bodies 14. Therefore, the sample film cases 10 can reliably be picked up from the main assembling line 114 through the sample pickup chute 508.

The recesses 510 are deepest at their ends closer to the main assembling line 114. Therefore, the sample film cases 10 placed on the sample pickup chute 508 are prevented from being delivered back toward the main assembling line

114. The depth of each of the recesses 510 is progressively smaller along the feeding direction. Consequently, when a sample film case 10 is transferred from the main assembling line 114 onto the sample pickup chute 508, those sample film cases 10 which have already been placed on the sample pickup chute 508 are pushed along the feeding direction. As a result, the sample film cases 10 can be picked up while the

sample pickup chute 508 is being held at rest.

Moreover, when a case body 14 and a lid 16 are to be assembled and checked on the main assembling line 114, the case body 14 and the lid 16 have their sides positioned by the positioning members 148. Since the case body 14 and the lid 16 are highly accurately positioned by the positioning members 148, the case body 14 and the lid 16 can be assembled and checked with high accuracy. As a result, the yield of film cases 10 is high. With the film case manufacturing system 100 and the manufacturing method performed thereby according to the present embodiment, even if the end 18 of the case body 14 has local thickness and shape variations, the light shielding sheet 22 is applied to the surface 19a of the end 18 while the other surface 19b thereof is uniformly pressed by the pressers 360a through 360c. The light shielding sheet 22 can thus uniformly be applied to the end 18 of the case body 14. As a consequence, the light shielding sheet 22 is reliably applied to the case body 14 for shielding the film discharge slot 20 reliably against entry of light with the light shielding sheet 22. As the light shielding sheet 22 can uniformly be applied to the case body 14 even if the end 18 of the case body 14 suffers thickness and shape variations, it is not necessary to adjust the conditions for molding the case body 14 or to adjust the position where the heater 347 and the pressers 360a through 360c are pressed against the end 18 of the case body 14 for the purpose of

uniformly applying the light shielding sheet 22. As a result, film cases 10 of the same quality can efficiently be mass-produced .

The end 18 of the case body 14 is pressed highly reliably because the pressers 360a through 360c are pressed against the end 18 under the resilient forces from the springs 374a through 374c.

As the pressers 360a through 360c are pressed against the end 18 of the case body 14 through the rubber members 452a through 452c, the rubber members 452a through 452c are held in close contact with the other surface 19b, with the result that the end 18 of the case body 14 is pressed highly uniformly. Since the light shielding sheet 22 is applied through the rubber member 450 by the heater 347, the rubber member 450 is held in close contact with the surface 19a. As a result, the light shielding sheet 22 is highly uniformly applied to the end 18 of the case body 14.

The light shielding sheet assemblers 420a through 420c are disposed along the feeding direction of the main assembling line 114 so as to have locally overlapping applying ranges of the light shielding sheet assemblers 420a through 420c for the light shielding sheet 22. Therefore, the light shielding sheet 22 is highly uniformly applied to the end 18 of the case body 14. The light shielding sheet assembler 430 is smaller in width than the light shielding sheet 22, and is movable in the feeding direction of the main assembling line 114 and

the direction perpendicular to the feeding direction. Consequently, the light shielding sheet 22 is highly uniformly applied to the end 18 of the case body 14.

With the film case manufacturing system 100 and the manufacturing method performed thereby according to the present embodiment, furthermore, after the case body 14 is positioned by the positioning member 148 and the light shielding member 54 is positioned by the light shielding member positioning mechanism 170, the light shielding member 54 is moved to a position above the slit 38 while the light shielding sheet strip 60 of the light shielding member 54 is being attracted by the suction block 182 of the light shielding member attracting mechanism 174. After the displacement member 58 of the light shielding member 54 which has moved to the position above the slit 38 is supported by the clamp 214 of the guide support mechanism 176, the light shielding member 54 is moved to the slit 38 while being guided by the clamp 214.

At this time, since the light shielding sheet strip 60 of the light shielding member 54 positioned by the light shielding member positioning mechanism 170 is attracted by the suction block 182, the light shielding member 54 attracted by the suction block 182 is positioned. On the other hand, since the light shielding member 54 assembled in the case body 14 is positioned by the clamp 214 extending through the slit 38, and the displacement member 58 of the positioned light shielding member 54 is supported, the light

shielding member 54 is positioned with respect to the slit 38 by the clamp 214. As a result, when the light shielding member 54 is moved over the slit 38 by being guided by the clamp 214, the light shielding member 54 is placed to cover the slit 38 highly accurately, shielding the interior of the case body 14 securely against entry of light. Therefore, the film case 10 is highly reliable, and highly accurate film cases 10 of the same quality can efficiently be mass- produced. As the light shielding sheet strip 60 of the light shielding member 54 is pressed by the presser 220 of the light shielding member pressing mechanism 178, the case body 14 can be fed to a next process while the slit 38 is being accurately covered with the light shielding member 54. When the suction block 182 is moved to a position near the slit 38 while being guided by the clamp 214, since the displacement member 58 and the light shielding sheet strip 60 accurately covers the slit 38, the interior of the case body 14 is highly shielded against entry of light by the displacement member 58 and the light shielding sheet strip 60.

With the slit 38 being fully covered with the portion of the light shielding sheet strip 60 which projects from the displacement member 58, the projecting portion, i.e., the shorter side portion 66, is applied to the case body 14. Therefore, the interior of the case body 14 is highly shielded against entry of light.

Inasmuch as the portion of the slit 38 which is defined in the bottom 36 is covered with the displacement member 58, the slit 38 is covered with the shorter side portion 66 of the light shielding sheet strip 60, and the shorter side portion 66 is partly applied to the other end 26 of the case body 14, the interior of the case body 14 is highly reliably shielded against entry of light.

Furthermore, since the portion of the slit 38 which is defined in the other end 26 is covered with the shorter side portion 66 of the light shielding sheet strip 60, when the heater 254 is held against the shorter side portion 66, the light shielding sheet strip 60 is reliably applied to the case body 14.

With the light shielding sheet strip 60 being pressed by the presser 256, any gaps are prevented from being created between the light shielding sheet strip 60 and the case body 14, and the light shielding sheet strip 60 is reliably applied to the case body 14. As a consequence, the interior of the case body 14 is highly reliably shielded against entry of light.

Because the light shielding member assembling apparatus 126 operates in synchronism with the feeding of case bodies 14 on the main assembling line 114, light shielding members 54 are assembled highly efficiently in the case bodies 14. With the film case manufacturing system 100 and the manufacturing method performed thereby according to the present embodiment, moreover, since the heater 347 has

fingers and teeth extending toward the film discharge slot 20, when the light shielding sheet 22 is applied in a cantilevered fashion to the end 18 of the case body 14 by the heater 347, the light shielding sheet 22 produces a number of small wrinkles 412 due to the fingers and teeth of the heater 347. These wrinkles are smaller than curls and shrinking portions of the light shielding sheet 22 and undulations of the light shielding sheet 22 which are produced by local thickness and shape variations of the end 18 of the case body 14. Therefore, those undulations can be reduced by forcibly producing those wrinkles 412. Consequently, even in the presence of curls and shrinking portions of the light shielding sheet 22 or local thickness and shape variations of the end 18 of the case body 14, the light shielding capability of the film discharge slot 20 is achieved by positively producing the wrinkles 412, and highly accurate film cases 10 of the same quality can efficiently be mass-produced.

The fingers 347b of the heater 347 which project toward the film discharge slot 20 are longer than the teeth 347c.

The fingers 347b thus shaped are effective to further reduce undulations of the light shielding sheet 22 in a region from the fingers 347b to the film discharge slot 20. Therefore, the light shielding capability of the film discharge slot 20 is high.

The tooth 347d is disposed centrally on the base end portion 347a, and the teeth 347c are disposed at certain

spaced intervals between the fingers 347b and the tooth 347d. This arrangement makes it possible to reduce undulations of the light shielding sheet 22 at its opposite sides and central area. Therefore, the light shielding capability of the film discharge slot 20 is high.

With the film case manufacturing system 100 and the manufacturing method performed thereby according to the present embodiment, moreover, after the light shielding sheet strip 60 is applied to the displacement member 58 and forming the light shielding member 54, the position where the light shielding sheet strip 60 is applied to the displacement member 58 is checked by the image checking apparatus 640. Consequently, only those light shielding members 54 which have been judged as acceptable in the checking process are supplied from the light shielding member supply line 102 to the main assembling line 114. Therefore, the light shielding capability in the case body 14 is high, and highly accurate film cases 10 of the same quality can efficiently be mass-produced. The image processor 650 detects, in an image from the camera 648, the distance between the surfaces of the positioning members 660a through 660d which abut against the displacement member 58 at the time the positioning members 660a through 660d grip the displacement member 58 and the sides of the light shielding sheet strip 60 near the abutting surfaces, as the length of the portion of the light shielding member 54 which projects from the displacement

member 58. Therefore, even though the position where the light shielding sheet strip 60 is applied to the upper surface of the displacement member 58 cannot directly be recognized from the image, it is possible to indirectly check whether the light shielding sheet strip 60 is applied at a predetermined position to the displacement member 58 or not .

Since the displacement member 58 is positioned in four directions by the positioning members 660a through 660d, the light shielding member 54 is prevented from being positionally displaced when it is checked. The positioning members 660a through 66Od are pressed against the displacement member 58 by the springs 666a through 666d for positioning the light shielding member 54 accurately. The displacement member 58 is also accurately positioned if it is attracted by the first suction mechanism 592.

Although certain preferred embodiments of the present invention have been described above, it should be understood that various changes and modifications may be made therein without departing the scope of the attached claims.

Industrial Applicability

With the film case manufacturing system and the film case manufacturing method according to the present invention, a main assembling line is supplied with a light shielding member, a presser sheet, a light shielding sheet, a discharge prevention sheet, and a presser. The main

assembling line assembles the light shielding member, the presser sheet, the light shielding sheet, and the discharge prevention sheet into a case body, and also assembles the presser onto a lid. Since a film case can automatically be manufactured without manual intervention, highly accurate film cases of the same quality can efficiently be mass- produced.