Method and apparatus for manufacturing photographic film and photographic film cassette

A photographic film cassette manufacturing apparatus, has a perforator for providing a long film with perforations and a cutter for cutting the long film into individual filmstrips to be contained in the film cassette driven synchronously with transport of the long film. A magnetic recording head for recording data on a magnetic recording layer of the long film is driven in synchronism with the perforator and the cutter. The long film is transported in a first direction before being cut into the individual filmstrips. In cooperation with the cutting, a trailing end of the individual filmstrip in the first direction is moved in a direction which is reverse to the first direction to secure the trailing end to the spool. A cassette shell consisting of a pair of shell halves is temporarily assembled by mating the shell halves together while containing a spool inside the shell halves, and thereafter opened to an extent that confining elements still confine the position of flanges of the spool. The trailing end of the filmstrip is inserted into the opened cassette shell and secured to the spool.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates to a method of, and an apparatus for, 
manufacturing photographic film and photographic film cassettes. More 
particularly, the present invention relates to a method of, and an 
apparatus for, manufacturing a photographic filmstrip having a 
predetermined length and perforations, and data magnetically recorded 
thereon. The present invention also relates to a method of, and an 
apparatus for, cutting and winding the photographic filmstrip. The present 
disclosure is based on the disclosures of Japanese Patent Appln. Nos. 
4-206653, 4-272987 and 4-326982 filed August 3, October 12 and December 7, 
respectively, which disclosures are incorporated herein by reference. 
2. Description of the Related Art 
A photographic film cassette is constituted of a cassette shell, and a roll 
of photographic film accommodated in the cassette shell in light-tight 
fashion. 35 mm (135 type) film cassettes or cartridges are well known. 
Generally, a photographic filmstrip to be loaded in a cassette shell is 
manufactured by the following process. First, a sheet of film having a 
photosensitive emulsion layer applied on one surface thereon is slit to a 
predetermined width, and a consequent long strip of photographic film is 
wound about a rotary shaft, which is driven by a motor, into a roll. The 
long film is drawn from the roll and transported at a constant speed along 
a manufactured line. In the manufacturing line, a perforator forms 
perforations in the film at regular intervals. The long film having the 
perforations formed therethrough is then cut to predetermined lengths to 
form individual filmstrips. 
An automatic film cutting and winding apparatus which sequentially performs 
the process of drawing the long film by a predetermined length from the 
roll, cutting the long film at the predetermined length from the roll into 
individual filmstrips, transferring the individual filmstrip from the 
cutting position to a securing position, securing the filmstrip to a 
spool, and winding the filmstrip on the spool, is well known. 
Such an automatic film cutting and winding apparatus is disclosed, for 
example, in Japanese Patent Publication 63-4036, JPA 2-222946 and JPA 
3-182451. In the apparatus disclosed in Japanese Patent Publication 
63-4036, there is a film feeding and measuring section, a cutting section, 
an intermediate holder for storing a length of the long film that is 
approximately equal to the predetermined length of the individual 
filmstrip, a feed roller section for feeding the filmstrip out of the 
intermediate holder, and a film securing section, sequentially disposed in 
that order along a film transport path for feeding the long film from the 
roll toward the spool. The transient stock in the intermediate holder 
contributes to shortening a stand-by period in each of the above sections. 
In the apparatus disclosed in JPA 2-222946, a film feeding and measuring 
section, a cutting section, a feed roller section and a film securing 
section are sequentially disposed on the film transport path in order from 
the roll, to feed a filmstrip cut from the long film to a spool and secure 
the filmstrip to the spool. Thereafter, the feed roller section releases 
the remaining portion of the filmstrip therefrom, and the filmstrip is 
wound onto the spool. 
The most popular 135 type photographic film cassette has a cassette shell 
constructed of cylindrical barrel made of sheet metal and a pair of caps 
attached to opposite ends of the barrel. A spool with a photographic film 
wound thereon is loaded in the cassette shell. According to a method as 
known from Japanese Patent Publication 2-691, the photographic film is 
wound on the spool, and then subsequently wrapped with the barrel and the 
caps in a darkroom. Also a method for assembling such a conventional film 
cassette is known from Japanese Patent Publication 60-48748 wherein a 
temporary assembled cassette shell is partly disassembled in a film 
loading section disposed in a darkroom, to insert the spool with a film 
wound thereon into the cassette shell. Thereafter, the cassette shell is 
reassembled. 
Furthermore, a photographic film cassette of a leader advancing type is 
disclosed, for example, in U.S. Pat. Nos. 4,834,306 and 4,846,418, and JPA 
3-37645, wherein a cassette shell is constructed of resin molded products 
and a leading end of a filmstrip wound on a spool can be advanced to the 
outside of the cassette shell by rotating the spool in an unwinding 
direction. Because the leading end of the filmstrip is located inside the 
cassette shell not only after exposure but also before loading of this 
type of film cassette, light-shielding of the contained filmstrip is 
improved, and handling of the film cassette, during the loading and the 
removal thereof is easier as compared with conventional 135 type film 
cassettes. 
Recently, a photographic film has been disclosed in U.S. Pat. Nos. 
4,860,037 and 4,864,332, on which film data specific to the photographic 
film is magnetically recorded. The film data represents, for example, an 
ID code, a lot number and a film speed of the film, as well as the number 
of available frames in the film. The data is read by an appropriate device 
incorporated in a camera when the photographic film is loaded in the 
camera. Based on the data, a suitable photography mode of the camera is 
automatically selected, for example, to facilitate taking a high quality 
photograph. 
When finishing the photographic film in a photo-lab, it is necessary to 
always correlate the respective photographic films with the customers 
throughout the photo-finishing process. Therefore, data usable for such a 
correlation is also recorded on the photographic film. Japanese Patent 
Publication 3-2905 discloses a photographic filmstrip having 
discrimination data recorded in the vicinity of a perforation in 
associated with an exposure position in which an image frame is to be 
exposed. The discrimination data is binary data representing numerical 
values specific to each individual filmstrip, such as slit data, a 
supplementary number, etc. . . . And the discrimination data is 
magnetically recorded and/or photographically recorded as a latent bar 
code image or the like. 
In order to record such magnetic data on the photographic filmstrip, a 
magnetic recording layer is provided in a predetermined position on the 
long film, on a side thereof which is opposite from the photosensitive 
emulsion layer, before the long film is wound in a roll. 
However, when recording data on the magnetic recording layer, it has been 
very difficult to precisely position the data in correspondence with each 
image frame exposure position on the film, because the long film is 
transported at a very high speed during the film manufacturing, for 
example, at a speed of several tens of the ordinary film advancing speed 
in cameras, to increase production efficiency. Besides, it is impossible 
to exactly read the magnetic data from the photographic film unless each 
recording position has a definite positional relation to the image frame 
exposure position which is designated by a perforation or the like. Data 
reading is necessary during manufacturing, for checking if the data has 
been properly recorded on the magnetic recording layer. 
When securing a first end of the filmstrip, it is necessary to guide the 
first end into an engaging portion of the spool with accuracy, and protect 
the filmstrip from being scratched or blushed during the guiding. Such 
scratching or blushing may result in lowering the quality of the filmstrip 
to a certain degree. 
In spite of this fact, conventional automatic film cutting and winding 
apparatus guide the filmstrip through a relatively long distance toward 
the spool. That is, the filmstrip is transported in the same direction as 
in the measuring and cutting process toward the spool. Therefore, the 
first end to be secured to the spool is the forward end in the 
transporting direction, and the securing position, where the first end is 
secured to the spool, is spaced apart from the cutting position of the 
long film, by at least a distance corresponding to the length of the 
individual filmstrip. 
As a result, the first end cannot always be accurately positioned, because 
of shrinkage or curling of the filmstrip, variance in the transport amount 
of the filmstrip, and also fluctuation of curvature of the filmstrip 
during the slitting operation. Therefore, it has been very difficult to 
quickly and precisely guide and secure the first end of the filmstrip to 
the spool without scratching and blushing thereof. This hinders rapid 
manufacturing of the film cassette. This problem is especially serious 
because photographic films are being manufacture thinner and thinner in 
the interest of minimizing materials and lightening cameras. 
In the above-described leader advance type photographic film cassette, it 
is necessary, for permitting the film advancing operation, to prevent 
loosening of the roll of the photographic film wound on the spool when the 
spool is rotated in the unwinding direction. For this purpose, a 
photographic film cassette wherein flanges, which confine the opposite 
sides of the film roll on the spool, are formed from relatively soft 
material and/or formed separately from the spool core is known. When the 
spool is mounted in the cassette shell, the flanges are pressed against 
the opposite sides of the film roll by confining members formed integrally 
inside the cassette shell. Thereby, the film roll is tightly held by the 
flanges at opposite sides thereof and thus is prevented from loosening. 
When manufacturing such a film cassette, if the photographic film is first 
wound on the spool having the soft or separate flanges thereon, and 
thereafter the spool is mounted in the cassette shell, the flanges can be 
deformed or damaged by the confining members during the mounting of the 
spool in the cassette shell or during closing of the cassette shell. This 
is because the position of the flanges is unstable when not pressed by the 
confining members. For the same reason, the flanges are frequently not 
properly positioned inside the confining member in conventional 
manufacturing processes. 
The present invention is directed to solving the above-described problems 
and thus an object of the present invention is to provide a method of, and 
an apparatus for, manufacturing a photographic film having a magnetic 
recording layer, wherein data can be magnetically recorded exactly in 
proper position relative to each image frame exposure position and/or 
relative to either end of each individual filmstrip. 
Another object of the present invention is to provide a method of, and an 
apparatus for, manufacturing a photographic film cassette, wherein the 
positioning of the photographic filmstrip can be performed with accuracy 
when securing the filmstrip to the spool. 
A further object of the present invention is to provide a method of, and an 
apparatus for, manufacturing a photographic film cassette, which makes it 
possible to reliably wind the filmstrip into the cassette shell in the 
manufacturing process even when the spool has soft flanges or when the 
cassette shell and/or the flanges are separate parts from the spool core. 
SUMMARY OF THE INVENTION 
To achieve the above and other objects, according to the present invention, 
a perforator is driven synchronously with transport of a long film, and a 
magnetic recording head is driven in synchronism with the perforator. 
Thereby, magnetic data is positioned precisely in association with each 
image frame exposure position or area. 
When recording data magnetically on at least one end of an individual 
filmstrip, a cutter for cutting the long film into the individual 
filmstrips is driven synchronously with transport of the long film, and a 
magnetic recording head is driven in synchronism with the cutter. 
The present invention transports the long film in a first direction during 
the measuring process for measuring a predetermined length of an 
individual filmstrip, holds a trailing end of the individual filmstrip in 
relation to the first direction immediately before or after cutting the 
filmstrip from the long film, and moves the filmstrip by a predetermined 
distance in a second direction, which is reverse to the first direction, 
while holding the trailing end to secure the trailing end to a spool. 
Accordingly, the filmstrip can be guided through a relatively short path 
to the spool with accuracy while avoiding scratching or blushing of the 
filmstrip. 
When manufacturing a photographic film cassette that includes a spool 
having soft or elastic flanges formed separately from a spool core and 
fitted to the spool core, the cassette shell is temporarily assembled by 
mating shell halves together while containing the spool fitted with the 
flanges inside the shell halves. The cassette shell is then opened to an 
extent that confining elements still contact the flanges and confine the 
position of the flanges. One end of the filmstrip is then inserted into 
the opened cassette shell to be secured to the spool, and thereafter, the 
shell halves are mated together again to close the cassette shell. Then, 
the spool is rotated to wind the filmstrip into the cassette shell. 
Accordingly, the confining elements can not interfere with the flanges, so 
that the flanges are not damaged by the confining elements and are 
positioned properly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
An example of a photographic film cassette manufactured according to a 
preferred embodiment of the present invention is shown in FIG. 1. The 
cassette 2 is composed of a cassette shell 3, a spool 4 rotatably mounted 
in the cassette shell 3 and a photographic filmstrip 5 having a 
predetermined length. A pair of shell halves 3a and 3b constitute the 
cassette shell 3. The spool 4 includes a cylindrical spool core or hub 4a 
and a pair of flanges 4b disposed on opposite ends of the spool core 4a. 
In an initial state, the entire length of the photographic filmstrip 5, 
hereinafter referred to as simply a filmstrip, is tightly wound about the 
spool core 4a and located inside the cassette shell 3 with the lateral 
sides thereof confined by the flanges 4b. The outermost convolution of the 
roll of the filmstrip 5 is confined by ridges 6 formed integrally on the 
inside surface of the shell halves 3a and 3b. Therefore, the roll of the 
filmstrip 5 will not come unwound in the initial state. 
The opposite ends of the spool core 4a are exposed to the outside of the 
cassette shell 3, but not protrude beyond the lateral end faces of the 
cassette shell 3. The upper and lower shell halves 3a and 3b have 
respective port portions 8 and 9 which define a film passageway 11 of the 
filmstrip 5 when the shell halves 3a and 3b are joined together. 
Light-trapping members 10 are cemented on the opposing inner walls of the 
port portions 8 and 9. A separating claw 12 is formed at an inner portion 
of the port portion 9 of the lower shell half 3b. 
When the spool 4 is rotated in a clockwise direction in FIG. 1, by coupling 
a rotating device to one end of the spool core 4a, the roll of filmstrip 5 
is rotated along with the spool 4 in the cassette shell 3. At that time, a 
leading end 5a of the filmstrip 5 is pealed off the next inward 
convolution of the roll, by the separator claw 12, and guided to the 
outside of the cassette shell 3 through the film passage mouth 11. This 
function is referred to as a film advance function. 
As shown in FIG. 2, the photographic filmstrip 5 has perforations 13a 
formed therethrough in association with a leading margin and a trailing 
margin of each image frame exposure area 5c. The perforations 13a are used 
for positioning the image frame exposure area 5c. Also, perforations 13b 
are formed in the leading end 5a on opposite lateral sides thereof for 
facilitating catching of the leading end 5a by a feed mechanism. A 
magnetic recording track 14a is formed on each lateral side of the image 
frame exposure area 5c between adjacent perforations 13a which indicate 
the leading and trailing margins of the same image frame exposure area 5c. 
These magnetic recording tracks 14a have film data, such as an 
identification code, recorded thereon. The magnetic recording tracks 14b 
are also provided in the vicinity of the leading end 5a and/or a trailing 
end 5e of the filmstrip 5 along the lateral sides thereof. 
The perforations 13a and 13b and the magnetic recording tracks 14a are 
formed in a long strip of photographic film (hereinafter referred to as a 
long film) 15. A magnetic recording layer is previously provided on one 
surface of the long film 15 opposite to the photosensitive emulsion 
surface thereof, in the form of a pair of continuous zones extending along 
the opposite lateral sides of the long film 15. After forming the 
perforations 13a and 13b and recording the film data on the magnetic 
recording tracks 14a and 14b, the long film 15 is cut into the individual 
filmstrips 5 in a manner as shown in FIG. 3, wherein a hatched area 15a 
shows a cut-out portion. 
FIG. 4 illustrates a cassette manufacturing apparatus for performing a 
preferred embodiment of a method of the present invention. The long film 
15, on which the photosensitive emulsion layer and magnetic recording 
layer are formed, is wound in a roll and fitted on a rotary shaft in a 
film manufacturing section 16 of the cassette manufacturing apparatus. The 
rotary shaft is driven by a motor (not shown) to feed the long film 15 
longitudinally to a transporting system including a pair of feed rollers 
18a and 18b. The feed rollers 18a and 18b transport the long film 15 at a 
predetermined speed, e.g., about 1 to 5 m/second. 
First, the perforations 13a and 13b are formed by a perforator 17 which is 
driven synchronously with the film transport. Next, a magnetic recording 
head 19 records data on the magnetic recording track 14a in synchronism 
with the perforator 17. The length of the long film 15 extending between 
the perforator 17 and the recording head 19 is maintained constant. Just 
downstream of the recording head 19, a magnetic reading head 20 is 
disposed to read and check the data having been recorded by the recording 
head 19. The data recorded by the recording head 19 may include the frame 
number, the film speed, the name of film manufacturer, and the like. 
The long film 15 having the perforations 13a and 13b formed therein and as 
the film data recorded thereon, is transported to a cutter 21. The cutter 
21 is also driven synchronously with the film transport, to cut the long 
film 15 in the way shown in FIG. 3, to provide the individual filmstrip 5. 
The filmstrip 5 is transported by another pair of feed rollers 22a and 22b 
toward a cassette assembling section 30. 
A second magnetic recording head 23 is disposed downstream of the cutter 
21, to record film data in the vicinity of the leading end 5a and/or the 
trailing end 5e of the filmstrip 5 along the magnetic recording track 14b. 
The second magnetic recording head 23 is driven synchronously with the 
cutter 21. Also the length of the filmstrip 5 extending between the cutter 
21 and the second recording head 23 is disposed just downstream from the 
second recording head 23 to read and check data having been recorded by 
the second recording head 23. The data recorded by the second recording 
head 23 may include the total available number of frames, the film speed, 
the name of film manufacturer, a lot number, data relating to manufacture, 
and the like. The film data may be appropriately located in the magnetic 
recording tracks 14a and 14b. 
The cassette assembling section 30 is constituted of a spool receiving 
station 30a where the spool 4, formed in another process, is received in 
the cassette assembling section 30, a film winding station 30b where the 
filmstrip 5 is wound on the spool 4, and a shell assembling station 30c 
where the spool 4 having the filmstrip 5 wound thereon is mounted in the 
cassette shell 3. 
The shell assembling station 30c is provided with an upper holder 31 and a 
lower holder 32 which are movable up and down to move toward or away from 
each other. The upper holder 31 holds the upper shell half 3a by suction 
force and transports the same downward to cover the upper half portion of 
the film roll 5 wound on the spool 4, whereas the lower holder 32 supports 
the lower shell half 3b and transports the same upward to cover the lower 
half portion of the film roll 5. After the shell halves 3a and 3b are thus 
mated together, the upper and lower holders 31 and 32 are retracted to 
allow transfer of the cassette shell 3 containing the spool 4 and the 
filmstrip 5 therein onto a carrier 33 by a transport device (not 
illustrated). Then, an ultrasonic horn 34 secures the shell halves 3a and 
3b to each other by ultrasonic welding. 
The operation of the above-described cassette manufacturing apparatus is 
described below. 
The photosensitive emulsion layer is provided on one surface of the long 
film 15 and the magnetic recording layer is provided on the opposite 
surface outside the image frame exposure areas 5c. Thereafter, the long 
film 15 is wound in a roll and loaded in the cassette manufacturing 
apparatus. 
The feed rollers 18a and 18b are driven by a step motor (not shown) to 
intermittently stop transporting the filmstrip 15 at predetermined 
intervals. The perforator 17 forms the perforations 13a and 13b in the 
long film 15 when the filmstrip 5 is intermittently stopped. Thereafter, 
the recording head 19 writes the film data on the magnetic recording track 
14a while the long film 15 is transported by the feed rollers 18a and 18b. 
Because the length of the long film 15 between the perforator 17 and the 
recording head 19 is maintained constant, the location of the magnetic 
recording tracks 14a relative to the perforations 13a is also maintained 
unchanged, so that the film data is recorded in a predetermined location 
in relation to each image frame exposure area 5c. The recording head 19 is 
brought into contact with the long film 15 during the recording only, and 
is retracted therefrom at other times to avoid damage the surface of the 
film 15. 
The reading head 20 reads the data recorded by the recording head 19 while 
the filmstrip 15 is transported. Because the reading head 20 is disposed 
just downstream of the recording head 19, the data can be reproduced at 
the substantially same time as the recording thereof. Therefore, specific 
synchronization of the reproduced data with the recording position during 
the reproduction is unnecessary. This contributes to simplifying the 
process of data checking. 
The long film 15 is further transported to the cutter 21 to be cut into the 
individual filmstrip 5 to be contained in the film cassette 2. The second 
pair of feed rollers 22a and 22b are also driven by a step motor to 
intermittently stop transporting the long film 15 at predetermined 
intervals. The cutter 21 cuts the long film 15 when the transporting is 
intermittently stopped. Thereafter, while the individual filmstrip 5 is 
transported by the feed rollers 22a and 22b, the second recording head 23 
records the film data on the magnetic recording track 14b of the leading 
end 5a and/or that of the trailing end 5e. Because the length of the 
filmstrip 5 between the cutter 21 and the second recording head 23 is 
maintained constant, the location of the magnetic recording track 14b is 
maintained unchanged. 
The filmstrip 5, cut to the predetermined length and having the film data 
recorded thereon, is transported by the feed rollers 22a and 22b to the 
film winding station 30b of the cassette assembling section 30, wherein 
the trailing end 5e is secured to the spool 4 previously received in the 
spool receiving station 30a. Thereafter, the entire length of the 
filmstrip 5 is wound on the spool 4 by a winding device (not illustrated). 
The spool 4, with the filmstrip 5 wound thereon, is transported to the 
shell assembling station 30c, wherein the upper and lower shell halves 3a 
and 3b are mated together to rotatably mount the spool 4 between the shell 
halves 3a and 3b. Thereafter, the ultrasonic horn 34 applies ultrasonic 
vibration to the cassette shell 3 to join the shell halves 3a and 3b 
together into one body. 
The photographic film cassette 2 thus manufactured is subjected to 
inspection for inspecting the construction and function of the film 
cassette 2. Only those film cassettes 2 which have passed the inspection 
are packed and shipped for sale. 
Instead of checking the data recorded by the recording head 23 directly 
after the recording, it is possible to check the data recorded on the 
magnetic recording track 14b of the leading end 5a simultaneously with 
inspecting the film-advance-function of the finished photographic film 
cassette 2. In this embodiment, a magnetic reading head 25 for reading the 
data recorded on the magnetic recording track 14b of the leading end 5a is 
disposed outside of the film passage mouth 11 of the photographic film 
cassette 2 which is positioned in a film-advance-function inspecting 
section, wherein the spool 4 is rotated by a rotating device 26 to advance 
the leading end 5a of the filmstrip 5 to the outside through the film 
passage mouth 11. Thereafter, the filmstrip 5 is rewound into the cassette 
shell 3. 
In the above-described embodiments, the transport of the long film 15 stops 
when the perforations 13a and 13b are formed by the perforator 17, and is 
resumed while the film data is recorded by the recording head 19. In order 
to reliably maintain the length of the long film 15 between the perforator 
17 and recording head 19 at a constant value, it is preferable to provide 
a buffer portion 35 for reserving a certain amount of a loop of the long 
film 15 between the perforator 17 and the recording head 19, as is shown 
in FIG. 5. In this embodiment, a loop sensor 36 is provided at a bottom 
portion of the loop to measure and control the amount of the loop 
contained in the buffer portion 35. 
For example, the length of the long film 15 extending between the 
perforator 17 and the recording head 19 is M times longer than the 
interval of the image frame exposure areas 5c (M is an integer), such that 
one of the perforation 13a is located right in front of the recording head 
19 at the moment when the long film 15 stops and the perforator 17 forms 
the perforation 13a. The recording head 19 starts recording a short time 
after the resume of transport of the filmstrip 15. As a result, the film 
data is recorded on the magnetic recording track 14a in association with 
each image frame exposure area 5c as shown in FIG. 2. 
Also, a second buffer portion 37 can be provided between the cutter 21 and 
the second recording head 23, to store a loop of a predetermined amount of 
the individual filmstrip 5. For example, the length of the filmstrip 5 
between the cutter 21 and the second recording head 23 is set to equal the 
predetermined total length of the filmstrip 5. Thereby, the trailing end 
5e of the filmstrip 5 is located right in front of the second recording 
head 23 when the cutter 21 starts cutting of the leading end 5a of the 
same filmstrip 5 and the trailing end 5e of the following filmstrip 5 as 
well. Therefore, the magnetic recording track 13b is reliably recorded in 
the trailing end 5e, as illustrated in FIG. 3. Other portions of this 
embodiment can be similar to the embodiment shown in FIG. 4, and the 
filmstrip 5 thus manufactured may be assembled into the film cassette 2 in 
the cassette assembling section 30 as shown in FIG. 4. Therefore, a 
detailed description of these portions is omitted. 
FIG. 6 illustrates another embodiment of the present invention. In this 
embodiment, the long film 15 is transported to an oscillating perforator 
38. The oscillating perforator 38 is driven synchronously with the film 
transport, and the magnetic recording head 19 is driven in synchronism 
with the oscillating perforator 38. The oscillating perforator 38 makes it 
unnecessary to stop transporting the long film 15 during forming the 
perforations 13a and 13b. Therefore, the oscillating perforator 38 can 
form the perforations 13a and 13b while the recording head 19 records the 
film data. However, in order to record the film data at regular intervals 
in predetermined positions, it is necessary to maintain the distance 
between the start perforating position of the oscillating perforator 38 
and the recording head 19 in relation to the long film 15. 
That is, the oscillating perforator 38 forms the perforations 13a and 13b 
while moving a constant distance back and forth in the film transporting 
direction, but the perforator 38 always starts perforating at the same 
position in the moving range thereof. Therefore, the distance between the 
start perforating positions of the oscillating perforator 38 and the 
recording head 19 is set, for example, M times longer than the interval of 
the image frame exposure areas 5c (M is an integer), such that one of the 
perforation 13a is located right in front of the recording head 19 at the 
moment when the oscillating perforator 38 starts perforating. The 
recording head 19 starts recording a short time later. As a result, the 
film data is recorded on the magnetic recording track 14a in association 
with each image frame exposure area 5c as shown in FIG. 2. 
Also an oscillating cutter 39 is provided for cutting the long film 15 into 
the individual filmstrip 5 without the need for stopping the transport of 
the long film 15. The distance between the oscillating cutter 39 and the 
second recording head 23 should be maintained constant, to make the length 
of the filmstrip 5 constant. For example, the distance between the 
oscillating cutter 39 and the second recording head 23 is set to equal the 
predetermined length of the filmstrip 5. Thereby, the trailing end 5e of 
the filmstrip 5 is located right in front of the second recording head 23 
when the oscillating cutter 39 starts cutting the leading end 5a of the 
same filmstrip 5 and the trailing end 5e of the following filmstrip 5. 
Therefore, the film data is recorded on the magnetic recording track 14b 
of the trailing end 5e, as shown in FIG. 3. Other portions of this 
embodiment can be similar to the embodiment shown in FIG. 4, and the 
filmstrip 5 thus manufactured may be assembled into the film cassette 2 in 
the cassette assembling section 30 as shown in FIG. 4. Therefore, further 
detailed description is omitted. 
Although the magnetic recording layer is provided along both lateral sides 
of the long film 15 on the surface opposite to the photosensitive emulsion 
surface in the above described embodiment, it is possible to provide the 
magnetic recording layer along one lateral side or on the whole surface of 
the long film 15 opposite to the photosensitive emulsion surface. It is 
also possible to dispose a photo-sensor or the like in an upstream portion 
of each of the recording heads 19 and 23 to more precisely determine the 
recording position. 
Although the filmstrip 5 is wound on the spool 4 and thereafter the spool 4 
with the filmstrip 5 is loaded in the cassette shell 3 in the above 
described embodiment, it is of course possible to mount the spool 4 in the 
cassette shell 3 and thereafter secure the filmstrip 5 to the spool 4 and 
wind it into the cassette shell 3. 
FIG. 7 illustrates a film cutting and winding section of a cassette 
manufacturing apparatus according to another embodiment of the present 
invention. A long film 15 is drawn from a roll and transported 
longitudinally along a film transport path. A puncher 42, for punching a 
pair of holes 5f in the long film 15, as shown in FIG. 8, at regular 
intervals corresponding to the length of an individual filmstrip 5 to be 
wound about a spool 4, a measuring feeder 43, a cutter 44, and a shooter 
45 are disposed along the transport path in order. 
The pair of holes 5f are arranged side by side in the lateral direction of 
the long film 15. Thereafter, the cutter 44 cuts out a portion 15a from 
the long film 15 to form a trailing end 5e of the filmstrip 5 and a 
leading end 5a of the next filmstrip 5 in a manner as shown by 
chain-dotted lines in FIG. 8, in relation to the transporting direction A. 
The measuring feeder 43 includes a pair of feed rollers 43a and 43b and 
stepwise transports the long film 15 by a given amount in the direction A, 
to insert a forward portion of the long film 15, that is, the portion 
corresponding to an unfinished one of the filmstrip 5, into the shooter 
45. Thereby, a rearward portion of the long film 15 that is to be cut out 
as the portion 15a is positioned in the cutter 44. Upon determining the 
given amount of transport of the long film 15, the measuring feeder 43 
stops the long film 15 for a short period of time and the cutter 44 cuts 
the long film 15. 
The shooter 45 is constituted of upper and lower guide plates 48 and 49 
disposed above and below the film transport path. The upper guide plate 48 
is stationary and provided with rollers 50a, 51a and 52a. The lower guide 
plate 49 is provided with rollers 50b, 51b and 52b disposed in opposition 
to the rollers 50a, 51a and 52a, respectively. The lower guide plate 49 is 
movable between a closed position for nipping the long film 15 by the 
rollers 50a, 50b, 51a, 51b, 52a and 52b, and an open position for 
displacing the filmstrip 5 cut from the long film 15 downward from the 
film transport path. The rollers 50a, 50b, 51a, 51b and 52a, 52b are 
driven to rotate in the same way at the same speed as the feed rollers 43a 
and 43b to move the film in the direction A. If the filmstrip 5 nipped by 
the shooter 45 has any defects, the filmstrip 5 is ejected from the 
shooter 45 in a direction shown by an arrow B in FIG. 7 by means of the 
rollers 50a, 50b, 51a, 51b, 52a and 52b, and a pair of rollers 53a and 53b 
disposed downstream of the shooter 45. 
An inserter 46 is disposed in the vicinity of the cutter 44. The inserter 
46 moves the filmstrip 5 cut from the long film 15 in a direction C, which 
is opposite to the direction A, and inserts the trailing end 5e of the 
filmstrip 5 into a slit 4c formed through a spool core 4a of the spool 4 
between flanges 4b, as shown in FIG. 9, to secure the trailing end 5e to 
the spool 4 through engagement between the holes 5f and claws 4d formed in 
the slit 4c. As shown in detail in FIG. 11, a rib 4e is also formed in the 
slit 4c to press the trailing end 5e at the portion between the holes 5f 
to prevent the claws 4d from slipping out of the holes 5f. After the 
trailing end 5e is secured to the spool 4, the spool 4 is rotated to wind 
the filmstrip 5 thereon by a drive mechanism of a winding unit 47, which 
is coupled to one end of the spool core 4a, as will be described in detail 
later. 
It is to be noted that the long film 15 is subjected to a perforating 
process and other necessary processes, prior to the cutting and winding 
process shown in FIG. 7. 
FIG. 10 illustrates the cutter 44. A cam 59 makes one revolution to 
reciprocate a base plate 60 once in a vertical direction, that is, the 
direction perpendicular to the film transport path, to make one cutting 
stroke. The base plate 60 has cutting edges 61 and 62 spaced a 
predetermined distance apart from each other, and an ejection mechanism 63 
disposed between these cutting edges 61 and 62 to hold and discard the cut 
portion 15a by vacuum suction force. A stationary cutting edge 64 is 
disposed in the opposite side of the film transport path from the cutting 
edges 61 and 62, in opposition to the space defined between these cutting 
edges 61 and 62. 
The base plate 60 also has a transfer 65 mounted thereto. The transfer 65 
is vertically movable relative to the base plate 60 between a position 
near the cutter 44 and a position near the inserter 46 placed in a 
stand-by position (see chain-dotted line). The transfer 65 has a vacuum 
suction mechanism incorporated therein for holding the top side of the 
long film 15 or the filmstrip 5. The transfer 65 also has a couple of pins 
65a protruding downward to engage in the holes 5f and fix the position of 
the long film 15 during the cutting. 
The inserter 46 is movable between the stand-by position shown in FIG. 10 
and a securing position shown in FIG. 12. The moving direction C from the 
stand-by position to the securing position is reverse to the direction A. 
The inserter 46 is constituted of a base portion 67, a table 68, and a 
spring 69. The table 68 is slidable on the base portion 67 parallel to the 
direction A between a position protruding from the base portion in the 
direction C as shown in FIG. 11, and a retracted position shown in FIG. 
12. The spring 69 urges the table 68 toward the protruding position. A 
hole 68a is formed in the table 68 for receiving the tip of the pin 65a 
when the transfer 65 moves down to the inserter 46. The base portion 67 
and the table 68 contains vacuum suction mechanisms 70, 71a and 71b for 
holding the bottom side of the filmstrip 5. The power of the vacuum 
suction mechanism 71a and 71b of the table 68 is adjustable independently 
of the vacuum suction mechanism 70 of the base portion 67. 
As the inserter 46 is moving into the securing position, the table 68 
strikes against a stopper 73 of the winding unit 47, as shown in FIG. 11, 
and is thus pushed by the stopper 73 back to the retracted position as the 
inserter 46 moves further into the securing position, as shown in FIG. 12. 
While the table 68 is being pushed back, the power of the vacuum suction 
mechanism 71a and 71b is lowered, so that the trailing end 5e, having been 
held by the table 68, slips off the table 68 into the slit 4c of the spool 
4 placed in the winding unit 47. The spool 4 is previously prepared and 
seriatim placed in the winding unit 47 by a spool feeder 74. 
FIGS. 13 and 14 illustrate an example of the winding unit 47. The winding 
unit 47 includes a holder 75 constructed of a pair of disks 76 and 77 
which are spaced vertically from each other and rotated together by a 
holder motor, e.g., a step motor 78. A plurality of, for example six, 
chuck mechanisms 79 are mounted to the disks 76 and 77 and disposed at 
regular intervals around the rotational axis of the disks 76 and 77. A 
slip ring 78a is mounted on the rotary shaft of the step motor 78 to 
detect the rotational position of the holder 75. 
Each chuck mechanism 79 has a pair of rotatable axles 80 and 81 which 
protrude inward from the disks 76 and 77 and are axially movable toward 
each other in a direction parallel to the rotational axis of the disks 76 
and 77 to engage in the opposite ends of the spool core 4a. The spool 4 is 
thus rotatably chucked by the chuck mechanism 79. A pulley 82 is coupled 
to each axle 81 of the chuck mechanism 79. 
A servo motor 83 is coupled to a pulley 84 which is rotatably mounted on 
the rotary shaft of the step motor 78. A pulley 85 is fixedly coupled to 
the pulley 84. The holder 75 has a sleeve 78 fixedly mounted thereto and 
extending in coaxial with the rotational axis of the holder 75, and six 
clutch brakes 86 are mounted on the periphery of the sleeve 78 on the 
opposite side from the chuck mechanisms 79. A pulley 87 is fixedly coupled 
to an output shaft of each clutch brake 86, and a pulley 88 is fixedly 
coupled to an input shaft of each clutch brake 86. The six pulleys 88 are 
coupled to the pulley 85 through a timing belt 89 which is turned about 
the pulleys 85 and 88 in a manner as shown by solid line in FIG. 13, by 
way of five press roller 90. The press rollers 90 are secured to the 
sleeve 78. 
On the other hand, the six pulleys 87 on the input shafts of the clutch 
brakes 86 are each coupled to the pulleys 82 in one-to-one relation 
through a timing belt 91. In this way, the respective axles 81 of the 
chuck mechanisms 79 are driven by the single servo motor 83 while being 
individually rotated and stopped under the control of the associated 
clutch brakes 86. 
The holder 75 is rotated stepwise and pauses six times at regular intervals 
during one revolution. At the six stop positions of the chuck mechanisms 
79, chucking of the spool 4 and orientation of the spool 4 are 
sequentially performed. Therefore, the stop positions are referred to as 
work stations ST-1 to ST-6. At the work station ST-1, the spool 4, fed by 
the spool feeder 74, is chucked by one of the chuck mechanisms 79. At the 
work station ST-2, the slit 4c of the chucked spool 4 is oriented 
appropriately. At the work station ST-3, the filmstrip 5 is secured to the 
spool 4 by the inserter 46 in the above-described manner. Winding of the 
secured filmstrip 5 is performed at the work stations ST-4 and ST-5, and 
the spool 4 with the filmstrip 5 wound thereon is outputted from the 
winding unit 47 at the work station ST-6. Thereafter, the spool 4 with the 
filmstrip 5 is inserted inside a pair of shell halves constituting a 
cassette shell, and the shell halves are secured to each other, for 
example, by ultrasonic welding, thereby completing a photographic film 
cassette. 
The operation of the above-mentioned embodiment will now be described with 
reference to the timing charts of FIG. 15. 
The measuring feeder 43 stops transporting the long film 15 at time t1. 
Simultaneously, the cutter 14 cuts the long film 15 and, immediately 
before or after the cutting, the transfer 65 holds the trailing end 5e of 
the filmstrip 5 just cut from the long film 15. Thereafter, the lower 
guide plate 49 of the shooter 45 is moved into the open position, and the 
transfer 65 transfers the filmstrip 5 to the inserter 46 placed in the 
stand-by position. This transferring operation is completed at time t2. At 
the same time t2, the holder 75 stops rotating to position the spool 4 at 
the work station ST-3. Then, the inserter 46 holds the trailing end 5e of 
the filmstrip 5 by the vacuum suction force, whereas the transfer 65 
releases the filmstrip 5 from the vacuum suction force thereof. 
The inserter 46 moves the filmstrip 5 in the direction C, which is reverse 
to the transporting direction A of the measuring feeder 43. When the 
inserter 46 reaches the securing position, the trailing end 5e of the film 
5 is secured to the spool 4 placed in the work station ST-3. This securing 
operation is completed at time t3. At that time t3, the holder 75 is still 
stationary. 
The holder 75 starts rotating again from time t4, and stops again at time 
t5. At that time t5, the spool 4, having the filmstrip 5 secured thereto, 
arrives at the work station ST-4. Simultaneously with the start of 
rotation of the holder 75 at the time t4, one of the clutch brakes 86, 
that corresponds to the chuck mechanism 79 is positioned in the work 
station ST-3 from the time t2 to t4, is activated. As a result, the servo 
motor 83 is connected to the axle 81 of this chuck mechanism 79 to start 
winding of the filmstrip 5. The winding is conducted with one break or 
pause while the corresponding spool 4 is carried from the work station 
ST-3 to the work station ST-5. 
It is, of course, possible to start winding from the time t5 when the 
corresponding spool 4 arrives at the work station ST-4, and continue 
winding until the corresponding spool arrives at the work station ST-6. 
FIG. 16 shows another embodiment wherein the transfer 65 is omitted. 
Instead, an inserter 46 holds the trailing end 5e of the filmstrip 5 
immediately before or after the cutting thereof. Thereafter when a shooter 
45 moves in the open position, the inserter 46 displaces the filmstrip 5 
downward from the film transport path and then moves the filmstrip 5 in 
the direction C until the filmstrip 5 is secured to the spool 4. 
It is also possible to provide a cutting edge 95 on a table 68 of an 
inserter 46 as shown in FIG. 17. In this embodiment, a stationary cutting 
die 64 is spaced apart from the cutting edge 95 in correspondence with the 
cutout portion 15a of the long film 15 as shown in FIG. 8, when the 
inserter 46 is in the stand-by position. A movable cutting die 96 is 
mounted on a base plate 60 and opposed to the spacing between the cutting 
die 64 and the cutting edge 95, to cut out the portion 15a from the long 
film 15 by means of these cutting members 64, 95 and 96. 
Furthermore, in the embodiment shown in FIG. 17, in order to punch the 
holes 5f simultaneously with the cutting of the long film 15, a pair of 
punching pins 97 are mounted on the base plate 60, and corresponding holes 
having cutting edges 98 are formed in the table 68 of the inserter 46. 
Although the embodiments shown in FIGS. 7 to 17 have been described with 
respect to a cassette manufacturing method wherein a filmstrip is wound on 
a spool before the spool is loaded in a cassette shell, these embodiments 
are also applicable to such a cassette manufacturing method wherein a 
spool is previously mounted in a cassette shell, and thereafter a 
filmstrip is secured to the spool and wound into the cassette shell. 
FIG. 18 shows a photographic film cassette 100 having the substantially 
same construction as the photographic film cassette 2 shown in FIG. 1, 
except a spool 101 has elastic flanges 103 made separately of resin 
material and fitted to the opposite ends of the spool core 102. The axial 
position of the flanges 103 on the spool core 102 is confined by a pair of 
ridges 109 formed on the inner periphery of a cassette shell 3 when the 
spool 101 is mounted in the cassette shell 3. The ridges 109 press the 
flanges 103 at circumferential portions thereof against lateral sides of a 
roll of filmstrip 5 wound on the spool core 102. 
Each flange 103 has a rim 103a curved to protrude inwardly in the axial 
direction of the cassette 100 when fitted on the spool core 102, to 
contact an outermost convolution of the film roll 5 at a lateral portion 
thereof and radially confine the outermost convolution. Thereby, loosening 
of the film roll 5 is prevented, and the film roll 5 is rotated together 
with the spool 101 when the spool 101 is rotated in an unwinding 
direction, that is, a clockwise direction in FIG. 18. As a result, when 
the spool 101 is rotated, a leading end of the filmstrip 5 is pealed off 
the next inward convolution by a separating claw 12 and thus advanced to 
the outside of the cassette shell 3 through a film passage mouth 11 which 
is formed between port portions 8 and 9 of upper and lower shell halves 3a 
and 3b constituting the cassette shell 3. Light-trapping members 10 are 
cemented to the inner wall of the port portions 8 and 9. 
The spool core 102 has annular shoulders 102a formed on opposite end 
portions thereof to stop the flanges 103 from moving too far inwardly on 
the spool core 102. A slit 105 for receiving a trailing end of the 
filmstrip 5 is formed in the spool core 102, and a pair of claws 106 and a 
pressing rib 107 are formed in the slit 102 to secure the trailing end to 
the spool 101 through engagement between the claws 106 and holes formed in 
the trailing end, in the same way as the above-described embodiments. 
Because the flanges 103 are elastic and separate parts, the position of the 
flanges 103 on the spool core 102 is unstable unless the flanges are 
properly pressed by the ridges 109. Therefore, when manufacturing such a 
photographic film cassette as shown in FIG. 18, it is desirable to 
properly mount a spool with flanges in a cassette shell and thereafter 
wind a filmstrip into the cassette shell be securing the filmstrip to the 
spool and then rotating the spool in a winding direction. FIGS. 19 to 22 
illustrate a cassette manufacturing apparatus according to an embodiment 
of the present invention for manufacturing the film cassette 100 shown in 
FIG. 18. 
Referring to FIG. 19 illustrating a film winding section of the cassette 
manufacturing apparatus, a rotational disk or table 120 has a plurality 
of, for example, six nests 122 each holding a cassette shell 3 containing 
the spool 101 therein. The nests 122 are disposed at regular intervals 
around the rotational axis of the table 120, and sequentially stopped at 
six work stations ST-1 to ST-6 disposed around the table 120 at intervals 
corresponding to the nests 122. 
A feeding conveyer 124 and a robot arm 125 are disposed in the work station 
ST-1. The feeding conveyer 124 successively feeds the cassette shells 3 
containing the spool 101 to the work station ST-1, and the robot arm 125 
seriatim transfers the cassette shell 3 from the conveyer 124 to the nest 
122 stopping at the work station ST-1. A pair of insert rollers 126 and a 
film guide 127 are movably disposed in the work station ST-3, as shown in 
detail in FIG. 21, wherein the cassette shell 3 is opened by the nest 122, 
and the film guide 127 is inserted into the opened cassette shell 3 so as 
to insert the trailing end 5e of the filmstrip 5 into the slit 105 of the 
spool 101 contained in the cassette shell 3. 
Thereafter, the spool 101 is rotated to wind the filmstrip 5 entirely into 
the cassette shell 3. An output conveyer 128 and a robot arm 129 are 
disposed in the work station ST-6 wherein the robot arm 129 grasps and 
transfers the cassette shell 3 containing the filmstrip 5 therein onto the 
output conveyer 128. Then, the output conveyer 128 sends the cassette 
shell 3 to the following process wherein the shell halves 3a and 3b are 
secured to each other by welding. 
Each nest 122 is comprised of a pair of holders 131 and 132 which are 
shaped to conform to the outer curves of the upper and lower shell halves 
3a and 3b, respectively, as shown in FIGS. 20 and 22. The first holder 
131, for holding the upper shell half 3a, is fixedly mounted on the top of 
the table 120, and a clamp 133 is attached to the first holder 131 through 
a shaft 133a to be movable up and down relative to the first holder 131. 
The shaft 133a extends vertically through the first holder 131 to project 
under the table 120. A spring 135 is mounted between a lower end 133b of 
the shaft 133a and the bottom surface of the table 120, so as to urge the 
clamp 133 to move downward to the table 120. Thereby, the upper shell half 
3a is clamped axially between the clamp 133 and a base surface 131a of the 
first holder 131. 
The second holder 132 is mounted to the table 120 through a hollow shaft 
132a to be pivotally and axially movable about the hollow shaft 132a 
relative to the table 120. The hollow shaft 132a is coupled to a not-shown 
control mechanism for controlling the pivotal and axial movement of the 
second holder 132 through a lever 137 secured to the hollow shaft 132a. 
Top and bottom clamps 138 and 139 for axially clamping the lower shell 
half 3b are attached to the second holder 132 through shafts 138a, 138b 
and 139a to be movable up and down relative to each other as well as to 
the second holder 132. 
The first shaft 138a of the top clamp 138 and the shaft 139a of the bottom 
clamp 139 have rack gears 141 and 142 formed thereon, respectively. The 
rack gears 141 and 142 are coupled to each other through a pinion 143, 
such that the clamps 138 and 139 are moved in cooperation with each other 
in the opposite vertical directions to each other. The second shaft 138b 
of the top clamp 138 extends coaxially through the hollow shaft 132a of 
the second holder 132, and the lower end 138c of the second shaft 138b 
projects under the table 120 beyond the lower end of the hollow shaft 
132a. A spring 146 is mounted between the lower end 138b of the second 
shaft 138a and the lower end of the hollow shaft 132a so as to urge the 
top clamp 138 to move downward to the table 120. 
Furthermore, a fork shaft 148 is rotatably mounted to the table 120 in a 
center position between the first and second holders 131 and 132. The fork 
shaft 148 is also movable in an axial direction so as to engage into one 
end of the spool core 102 of the spool 101 mounted between the shell 
halves 3a and 3b. A gear 149 is fixedly mounted on the lower end of the 
fork shaft 148. The fork shaft 148 is rotated by a not-shown drive 
mechanism through the gear 149. 
As shown An FIG. 21, at the work station ST-3, the second holder 132 pivots 
to rotate at an angle .theta. about the shaft 132a to separate the lower 
shell half 3b from the upper shell half 3a to widen the film passage mouth 
11. At that time, the flanges 103 are in contact with the ridges 109 of 
the lower shell half 3b by an amount L (see also FIG. 23). If the amount L 
is too small, the flanges 103 can be damaged by the ridges 109 or can be 
wrongly located relative to the ridge 109 when the lower shell half 3b is 
reset to the initial position to be mated with the upper shell half 3a. 
The suitable amount L varies depending upon the conditions of the ridges 
109 and the flanges 103, such as the curve of rounded edges, stiffness, 
smoothness of the surface, and so forth. 
According to the present embodiment, the amount L is experimentally 
determined to be not less than 0.3 mm under the following conditions: the 
external diameter a of the flanges 103 is 21.2 mm, the internal diameter b 
of the cassette shell 3 is 22 mm, the radial distance c from the 
rotational axis of the spool 101 to the inner end of the ridges 109 is 8 
mm, the radial distance d from the pivotal center of the shaft 132a to the 
axial center of the spool 101 is 14 mm, and the radius of curvature R of 
the rim 103a of the flanges 103 (see FIG. 23) is 0.2 mm. 
An experiment was performed by opening and closing the cassette shell while 
varying the amount L from 0.1 mm to 0.6 mm by an increment of 0.1 mm. The 
cassette shell 3 was opened and closed 20 times for each increment. The 
results of the experiment is shown in Table 1. 
TABLE 1 
______________________________________ 
L (mm 0.1 0.2 0.3 0.4 0.5 0.6 
______________________________________ 
TROUBLE C B A A A A 
______________________________________ 
In Table 1, "A" means no problems occurred, "B" means problems occurred 
less than four times per the 20 times open-and close operations, and "C" 
means problems occurred 4 times or more. Therefore, it is clear that the 
amount L should be 0.3 mm or more for the cassette as defined above in 
order to achieve desirable operation. 
The operation of the embodiment shown in FIGS. 19 to 23 will now be 
described. 
First, the light-trapping members 10 are cemented to the inner walls of the 
port portions 8 and 9 of the upper and lower shell halves 3a and 3b, for 
example, by means of heat-melting adhesive. Thereafter, the shell halves 
3a and 3b are sent to a temporary assembling process (not-shown) wherein 
the shell halves 3a and 3b are mated together after insertion of the spool 
101 therebetween. The above process can be performed in a lighted 
environment. Therefore, the elastic flanges 103 can be unfailingly and 
easily positioned inside the ridges 109 in the cassette shell 3. 
Next, the cassette shell 3, containing the spool 101 therein, is conveyed 
by the feed conveyer 124 to the work station ST-1 of the table 120 which 
is disposed in a dark room. At the work station ST-1, the second holder 
132 of the nest 122 is in an open position displaced pivotally away from 
the first holder 131. The clamps 138 and 139 are in a release position 
removed away from each other, and the clamp 133 of the first holder 131 is 
pushed upward, for example, by an oil hydraulic cylinder to provide a 
sufficient space enough to receive the cassette shell 3. Therefore, the 
robot arm 125 sets the cassette shell 3 between the holders 131 and 132 
from the top side of the nest 122. Thereafter, the second holder 132 is 
moved in a close position shown in FIG. 20, and clamps 133, 138 and 139 
are moved to clamp the cassette shell 3. 
The table 120 rotates to move the clamped cassette shell 3 from the work 
station ST-1 to the work station ST-2. At the work station ST-2, the fork 
48 engages into the spool core 102 and rotates the spool 101 to direct an 
inlet of the slit 105, that is, the left hand side of the slit 105 in FIG. 
21, to the outside of the table 120. While the table 120 is rotating to 
move the cassette shell 3 from the work station ST-2 to the work station 
ST-3, the second holder 132 pivots at the angle .theta. to separate the 
shell halves 3a and 3b from each other to such an extent that the 
insertion of the film guide 127 into the cassette shell 3 is permitted 
while the ridges 109 of the lower shell half 3b are still in contact with 
the flanges 103 by the amount L. Needless to say, the ridges 109 formed in 
the upper shell half 3a stay in contact with the flanges 103. 
At the work station ST-3, the insertion rollers 126 and the film guide 127 
are moved together to a film loading position shown in FIG. 21, wherein a 
forward end of the film guide 127 is inserted between the port portions 8 
and 9, that is, the widened film passage mouth 11 into a position close to 
and opposing to the inlet of the slit 105. Thereafter, the insertion 
rollers 26 are rotated, so that the filmstrip 5, which is previously 
provided with perforations and cut into a predetermined length, is 
transported toward the slit 105 through the film guide 127. When the 
trailing end 5e of the filmstrip 5 is thus inserted into the slit 105, the 
claws 106 and the pressing rib 107 secures the filmstrip 5 to the spool 
101. Then, the rollers 126 and the film guide 127 are moved back to a 
retracted position to avoid interference with the rotation of the table 
120. 
While the table 120 is rotating to move the cassette shell 3 from the work 
station ST-3 to the work station ST-4, the second holder 132 pivots back 
to the closed position to mate the shell halves 3a and 3b together again. 
By virtue of the continued contact of the ridges 109 with the flanges 103, 
the flanges 103 are smoothly and properly positioned inside the ridges 
109. 
When the cassette shell 3 arrives at the work station ST-4, the fork 148 is 
driven to rotate the spool 101 to wind the filmstrip 5 about the spool 
101. Thereby, the filmstrip 5 is drawn into the cassette shell 3 through 
the film passage mouth 11 until the filmstrip 5 has been entirely located 
inside the cassette shell 3. For example, the drive of the fork 148 may be 
stopped upon a sensor detecting a predetermined tension level of the 
filmstrip 5. 
The table 120 further rotates to move the cassette shell 3 containing the 
filmstrip 5 from the work station ST-4 to the work station ST-6. In this 
embodiment, the work station ST-5 is merely a stop position wherein no 
process is executed. At the work station ST-6, the robot arm 129 transfers 
the cassette shell 3 from the nest 122 to the output conveyer 128 to 
convey the cassette shell 3 to the next welding process. The emptied nest 
122 is moved to the work station ST-1 and supplied with another cassette 
shell 3 having no film therein. Thus, the process above is repeated. 
Although the above described embodiments relate to methods and apparatuses 
for manufacturing photographic film cassettes of leader advancing type, it 
is also possible to apply the invention to manufacturing of other types of 
photographic film cassettes. Also the spool may have a single claw in the 
slit, or may have another film securing mechanism. 
Control and timing of the invention can be accomplished with known devices. 
For example, a microprocessor based controller can be appropriately 
programmed and coupled to known sensors and drive devices such as motors 
and solenoids. Of course, hard-wired control systems can also utilized. 
While the present invention has been described in detail above with 
reference to a preferred embodiments shown in the drawings, it will be 
apparent to those skilled in the art that various changes and 
modifications of the present invention are possible without departing from 
the scope of the invention as defined by the appended claims.