CN102601906B - The manufacture method of curtain coating mould, die head and the manufacture method of film - Google Patents

The manufacture method of curtain coating mould, die head and the manufacture method of film Download PDF

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Publication number
CN102601906B
CN102601906B CN201110449486.3A CN201110449486A CN102601906B CN 102601906 B CN102601906 B CN 102601906B CN 201110449486 A CN201110449486 A CN 201110449486A CN 102601906 B CN102601906 B CN 102601906B
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Prior art keywords
die
die head
pair
side plate
film
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CN201110449486.3A
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CN102601906A (en
Inventor
上田忠
池邉贤治
樋口次郎
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Fujifilm Corp
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Fujifilm Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/34—Component parts, details or accessories; Auxiliary operations
    • B29C41/38—Moulds, cores or other substrates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/24—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length
    • B29C41/26—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length by depositing flowable material on a rotating drum
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/0605—Carbon
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
    • C23C16/26—Deposition of carbon only
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2905/00—Use of metals, their alloys or their compounds, as mould material
    • B29K2905/08—Transition metals
    • B29K2905/12—Iron
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2007/00—Flat articles, e.g. films or sheets

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Moulding By Coating Moulds (AREA)
  • Manufacture Of Macromolecular Shaped Articles (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Coating Apparatus (AREA)

Abstract

The invention provides a kind of curtain coating mould, the manufacture method of die head and the manufacture method of film, flow channel entry point is being provided with the upper opening of curtain coating mould of runner of dope circulation.Runner exit is at the lower front end portion opening of curtain coating mould.Casting mold has 1 pair of side plate and 1 pair of die lip plate.Runner is surrounded by 1 pair of side plate and 1 pair of die lip plate and forms.Die lip plate is made up of the component parts of the entrance of runner and the component parts of die lip plate main body and outlet and die head.Die head by bolt and die lip plate main body fastening.Die head comprises wedge-shaped die head main body and is arranged at the DLC film on whole surface of die body.DLC film is arranged at die body by ion vapour deposition method.

Description

The manufacture method of curtain coating mould, die head and the manufacture method of film
Technical field
The present invention relates to a kind of curtain coating mould (castingdie), the manufacture method of die head and the manufacture method of film.
Background technology
Owing to comprising polymer film (hereinafter referred to as the film) lightweight of light transmission and easily shaping, therefore extensively utilize as blooming.Wherein, utilize the cellulose esters film of cellulose acylate etc. except being used as picture photosensitive film, be also used as the blooming of liquid crystal indicator.The blooming of liquid crystal indicator refers to such as polarization board protective film or phase retardation film etc.
Main manufacture methods as film there will be a known solution film-forming method.In solution film-forming method, carry out casting films formation process, casting films drying process, stripping process and moistening film drying process successively.In casting films formation process, utilize curtain coating mould to flow out the polymer solution (hereinafter referred to as dope) comprising polymer and solvent from curtain coating mould, the supporter of movement forms casting films.In casting films drying process, enable solvent from casting films evaporation until casting films independently transmits.In stripping process, peel casting films through casting films drying process to be made moistening film from supporter.In moistening film drying process, solvent is made to make film forming from moistening film evaporation.
Casting mold has 1 pair of die lip plate, 1 pair of side plate and runner.1 pair of die lip plate is arranged to the moving direction near supporter and arranges.1 pair of side plate is arranged to extend from the die lip plate of a side across the die lip plate of the opposing party.Runner is surrounded by 1 pair of die lip plate and 1 pair of side plate and forms.On the face orthogonal with the flow direction of dope, runner be formed as moving direction from minor face to supporter extend and long limit to supporter move road width extend rectangle.The stainless steel (such as SUS316L etc.) that this die lip plate and side plate are little and lower relative to solvent solubility by coefficient of thermal expansion is formed.
Curtain coating mould flows out dope from runner exit towards the supporter of movement.Its result, forms liquid pearl between the leading section of the die lip plate of a side and supporter.In casting films formation process, if liquid pearl becomes unstable, then can cause casting films generation uneven thickness.Therefore, the stabilisation by making the leading section sharpening of the respective mode labial lamina becoming the starting point that liquid pearl is formed seek liquid pearl.Inequality refers to uneven state or uneven.
But the Vickers hardness due to SUS316L is that about Hv180 is soft, be therefore difficult to make leading section sharpening by machining.Therefore, have after the leading section of die lip plate arranges the layer (hereinafter referred to as hard layer) than SUS316L more hard, implement the method for predetermined machining.Thereby, it is possible to make the leading section sharpening of die lip plate.As this hard layer, there will be a known the carbide layers such as recorded in Japanese Patent Publication 2003-200097 publication.
Further, the preferable shape of the leading section of die lip plate changes according to the manufacturing condition of film.Therefore, die lip plate is divided into the die lip plate main body forming flow channel entry point and the leading section (hereinafter referred to as die head) forming runner exit, in the dismounting of die lip plate main body, die head is set freely.By utilizing such die head, easily can switch at 1 production line and manufacturing multiple film.
But if long-time continuous carries out casting films formation process, then the carbide layers be arranged on die head can be corroded.The corrosion of carbide layers is caused by the wash-out of binder metal (cobalt atom etc.).If use curtain coating mould with the state of carbide layers corrosion, then can cause film surface that the fault of striped occurs because of peeling off of carbide layers.Therefore, have to after often carrying out the casting films formation process of certain hour stop casting films formation process and the die head that more renews, the production efficiency of film can be caused like this to decline.Consider preferably the life-span to be longer than carbide layers and stable DLC (DiamondLikeCarbon, DLC) film is formed at die head from such background.DLC film preferably utilizes thermal chemical vapor evaporation (ChemicalVaporDeposition, CVD) to be formed at die head.But, if utilize hot CVD to form DLC film at die head, then can cause die head generation warpage.The die head that warpage occurs is difficult to be installed on die lip plate main body.
In recent years, along with the maximization of liquid crystal indicator, manufacture the new problem that the wide blooming of width becomes blooming supplier.The interval of 1 pair of side plate must be set as large than ever to manufacture width wide blooming, and lengthen die lip plate main body or die head.But because of the extended length of die head, the amount of warpage of the die head occurred when forming DLC film also increases.Therefore, the curtain coating mould manufacturing corresponding film wide cut is difficult to.
Summary of the invention
The present invention solves such problem, its object is to, and provides a kind of curtain coating mould of corresponding wide cut and the manufacture method of manufacture method and film thereof.
Curtain coating mould of the present invention is provided with the runner of the dope comprising polymer and solvent, flows out described dope, and includes 1 pair of side plate, 1 pair of die lip plate and DLC film.1 pair of side plate is separated and mutual subtend.The 1 pair of die lip plate is arranged from the described side plate of a side towards the described side plate of the opposing party and subtend mutually.Described runner is surrounded by described 1 pair of side plate and described 1 pair of die lip plate and forms.Described die lip plate has die lip plate main body and die head, and described die lip plate main body forms described flow channel entry point.Described die head is installed on described die lip plate main body and forms described runner exit.Described die head is stainless steel.The cross section of described die head is wedge shape.The length of the described die head in the orientation of described 1 pair of side plate is more than 50 divided by the value of the length of the described die head on the direction orthogonal with described orientation.DLC film is arranged at the front end of described die head, and is formed under the treatment temperature of less than 200 DEG C more than 130 DEG C.
The length of the described die head preferably in described orientation is more than 1500mm.
Preferred described die head comprises the die body and carbide layers that are made up of stainless steel.Described carbide layers is arranged at the front end that cross section is the described die body of wedge shape.
The thickness of preferred described DLC film is less than 2 μm.
The manufacture method of film of the present invention comprises casting films forming step, casting films drying steps, strip step, moistening film drying steps.Casting films forming step flows out dope from curtain coating mould and forms the casting films be made up of described dope at supporter.Described dope comprises polymer and solvent.Described casting mold has 1 pair of side plate and 1 pair of die lip plate.Described 1 pair of side plate is separated and mutual subtend.Described 1 pair of die lip plate is arranged from the described side plate of a side towards the described side plate of the opposing party and subtend mutually.The runner of described dope is surrounded by described 1 pair of side plate and described 1 pair of die lip plate and forms.Described die lip plate has die lip plate main body and die head.Described die lip plate main body forms described flow channel entry point.Described die head is installed on described die lip plate main body and forms described runner exit.Described die head is stainless steel.The cross section of described die head is wedge shape.The length of the described die head in the orientation of described 1 pair of side plate is more than 50 divided by the value of the length of the described die head on the direction orthogonal with described orientation.The DLC film formed under the front end of described die head is provided with the treatment temperature of less than 200 DEG C more than 130 DEG C.Casting films drying steps enables described solvent from described casting films evaporation until described casting films independently transmits.Strip step peels off described casting films to be made moistening film from described supporter.Moistening film drying steps makes described solvent make film forming from described moistening film evaporation.
The manufacture method of die head of the present invention is form the manufacture method being formed at the die head of the runner exit of the described dope of curtain coating mould.Described dope comprises polymer and solvent.Described runner is surrounded by 1 pair of side plate and 1 pair of die lip plate and forms.Described 1 pair of side plate is separated and mutual subtend.Described 1 pair of die lip plate is arranged from the described side plate of a side towards the described side plate of the opposing party and subtend mutually.Described die lip plate has the die lip plate main body and the surperficial described die head being provided with the stainless steel of DLC film that form described flow channel entry point.The manufacture method of this die head comprises preparation process (step A) and cured film forming step (step B).Step A prepares the die body of stainless steel.Step B arranges described DLC film by vapor coating method on the surface of described die body and obtains described die head.The length of the described die head in the orientation of described 1 pair of side plate is more than 50 divided by the value of the length of the described die head on the direction orthogonal with described orientation.The treatment temperature of described vapor coating method is more than 130 DEG C less than 200 DEG C.
Either method in described vapor coating method preferred ion evaporation, ion plating and plasma CVD.
In described step B, by implementing the fixture fixed target electrode of fluorine coating and described die body, utilize die body described in bolted and described fixture.
Preferably in the step B, the fastening position that the orientation of described 1 pair of side plate is set up in parallel is tightened by the bolt described die body and described support component.Along with the central portion of the orientation from described 1 pair of side plate becomes more and more less towards the torque of tightening of bolt described in both end sides.
According to the present invention, in the DLC film that die head initiation life is long while the warpage of die head can be suppressed.The wide film of width can be effectively manufactured by utilizing the curtain coating mould comprising this die head.
Those skilled in the art, can easy understand above-mentioned purpose and advantage by reference to accompanying drawing and the detailed description of preferred embodiments when read.
Accompanying drawing explanation
Fig. 1 is the key diagram of the summary representing solution film-forming equipment.
Fig. 2 is the key diagram of the summary representing the curtain coating mould that is configured at curtain coating indoor etc.
Fig. 3 is the partial section of the summary of the fore-end representing curtain coating mould.
Fig. 4 is the stereogram of the summary representing die main body.
Fig. 5 is the exploded perspective view of the summary representing die main body.
Fig. 6 is the stereogram of the summary representing the runner being arranged at curtain coating mould.
Fig. 7 is the sectional view of the summary representing slit conduit.
Fig. 8 is the stereogram of the summary representing the die lip plate with die lip plate main body and die head.
Fig. 9 is the exploded perspective view of the summary representing the die lip plate with die lip plate main body and die head.
Figure 10 is the sectional view of the summary representing die head.
Figure 11 is the sectional view of the summary representing die body.
Figure 12 is the sectional view of the summary of the fore-end representing the die lip plate forming outlet.
Figure 13 is the sectional view of the summary representing DLC film forming apparatus.
Figure 14 is the stereogram of the summary representing the die head being installed on fixture.
Figure 15 is the stereogram of the summary of the die head representing fixture and be installed on fixture.
Detailed description of the invention
(solution film-forming equipment)
As shown in Figure 1, solution film-forming equipment 10 has curtain coating room 12, pin stenter 13, hothouse 15, cooling chamber 16 and batches room 17.As shown in Figures 1 and 2, curtain coating mould 21, casting drum 22, pressure-reducing chamber 23 and stripper roll 24 are set in curtain coating room 12.
The driving shaft 22a that casting drum 22 is arranged by level and axle (fixing) and are formed in the cylinder body 22b of driving shaft 22a.Driving shaft 22a is connected with drive unit (not shown).The preferred stainless steel of casting drum 22, from having sufficient corrosion resistance and intensity this point more preferably SUS316L system.
As shown in Figures 2 and 3, the curtain coating mould 21 with the runner 29 that dope 28 circulates has the sharp-pointed die main body in front end 30.Curtain coating mould 21 is installed on curtain coating room 12 so that die main body 30 is towards predetermined direction by bracket (not shown).The outlet 29o of runner 29 is at the lower front end outs open of die main body 30.Die main body 30 is arranged to outlet 29o near side face 22bx.Describe curtain coating mould 21 later in detail.
Near outlet 29o, the side face 22bx of casting drum 22 is moved to constant direction at a predetermined velocity by the driving of driving shaft 22a.Below the moving direction of side face 22bx is called Z1 direction.Curtain coating mould 21 flows out dope 28 (with reference to figure 1) from outlet 29o.To flow out and the dope 28 arrived before side face 22bx forms liquid pearl 33 (with reference to figure 3) from outlet 29o.The result that the dope 28 of arrival side face 22bx is extended to Z1 direction on side face 22bx forms banded casting films 34.Like this, in curtain coating room 12, the casting films formation process being formed the casting films 34 be made up of dope 28 by curtain coating mould 21 and casting drum 22 on side face 22bx is carried out.In addition, in casting drum 22, carry out the casting films drying process that solvent is evaporated from casting films 34.
Pressure-reducing chamber 23 is configured at than curtain coating mould 21 more by the upstream in Z1 direction.Under the control of control part (not shown), pressure-reducing chamber 23 attracts the gas of the Z1 direction upstream side by liquid pearl 33.By the state of pressure lower than the pressure in the downstream of liquid pearl 33 attracting this gas to form the upstream side of liquid pearl 33.Can attract to occur along with the movement of side face 22bx by pressure-reducing chamber 23 and near side face 22bx, flow to Z1 direction carry wind.Therefore, it is possible to suppress by with the vibration of the liquid pearl 33 caused of conflicting of carrying wind.In addition, the length of liquid pearl 33 can be shortened, therefore, it is possible to suppress the vibration of liquid pearl 33.The upstream side of preferred liquid pearl 33 and the pressure differential Δ P in downstream are more than 10Pa below 2000Pa.
Register 32 is connected with at casting drum 22.Register 32 is built-in with the temperature regulation section of the temperature regulating heat transfer medium.The heat transfer medium that register 32 makes to be adjusted to desired temperature is in temperature regulation section and be arranged in casting drum 22 between runner to circulate.The temperature of the side face 22bx of casting drum 22 can be held in desired temperature by the circulation of this heat transfer medium.And, by to arrange in the atmosphere in condensation curtain coating room 12 condensing unit (not shown) of contained solvent and reclaim the retracting device (not shown) of solvent of condensation, the concentration of solvent contained in the atmosphere in curtain coating room 12 can be remained in constant scope.
Stripper roll 24 is disposed in than curtain coating mould 21 more by the downstream in Z1 direction.Stripper roll 24 is carried out peeling off and is formed in casting films 34 on side face 22bx to be made the stripping process of moistening film 35.Moistening film 35 guides to the downstream of curtain coating room 12.
Be disposed with pin stenter 13, hothouse 15, cooling chamber 16 in the downstream of curtain coating room 12 from upstream side and batch room 17.Transfering department 40 between curtain coating room 12 and pin stenter 13 is arranged with the backing roll 41 of the moistening film 35 of multiple supporting.Backing roll 41 is rotated centered by axle by not shown motor.Backing roll 41 supports the moistening film 35 sent from curtain coating room 12 and guides to pin stenter 13.In Fig. 1, represent the situation being arranged with 2 backing rolls 41 at transfering department 40.But, the present invention is not limited thereto, the backing roll 41 of more than 3 can be arranged at transfering department 40.In addition, backing roll 41 also can be free roll.
Pin stenter 13 has holding member (not shown), belt wheel (not shown) and dry wind supplying machine (not shown).Holding member is set to ring-type, and multiple pins (not shown) of keeping are carried out at the two ends with the width running through moistening film 35.Belt wheel makes holding member circulation travel.Dry wind is supplied to the moistening film 35 kept by pin by dry wind supplying machine.The entrance of pin stenter 13 is provided with and makes the engaging-in hairbrush in pin in the two ends of the width of moistening film 35 (not shown).Pin runs through the two ends of the width of moistening film 35 by the pressing of hairbrush.Further, keep the moistening film 35 at two ends to be travelled by the circulation of holding member by pin and transmitted.Solvent is evaporated from moistening film 35 by the contact with dry wind, and result can obtain film 45 from moistening film 35.Like this, carry out from transfering department 40 to pin stenter 13 making solvent make the moistening film drying process of film forming 45 from moistening film 35 evaporation.
Trimming device 47 is provided with between pin stenter 13 and hothouse 15.The two ends sending the width of the film 45 to trimming device 47 be formed formed by pin run through trace.Trimming device 47 cuts has this two end portions running through trace.This part be cut open is delivered to successively blocked blower fan (not shown) and disintegrating machine (not shown) by air-supply, more carefully is cut and raw material as dope etc. recycles.
Be provided with multiple roller 49 in hothouse 15, film 45 twists on these rollers and is transmitted.The temperature of the atmosphere in hothouse 15 or humidity etc. are regulated by not shown air conditioner.The drying process of film 45 is carried out in hothouse 15.Absorbing recovery device 52 is connected with at hothouse 15.Absorbing recovery device 52 reclaims the solvent evaporated from film 45 by absorption.
Cooling chamber 16 pairs of films 45 cool until the temperature of film 45 becomes roughly room temperature.At cooling chamber 16 and batch between room 17, set gradually except torch 54, annular knurl give roller 55 and trimming device 56 from upstream side.Except torch 54 carry out to send from cooling chamber 16 and charged film 45 carry out except electricity except electric treatment.Annular knurl is given roller 55 and is given to the width two ends of film 45 and batch and use annular knurl.Trimming device 56 cuts the width two ends of film 45 in the mode that annular knurl is left at the width two ends of film 45 after dicing.
Batch in room 17 coiling machine 63 being provided with and there is pressure roller 61 and core 62.Be sent to while the film 45 batching room 17 is pressed by pressure roller 61 and batch in core 62 in roll.
As shown in Figures 4 and 5, die main body 30 has 1 pair of side plate 71 and 1 pair of die lip plate 72 of stainless steel (SUS316 or SUS316L etc.).1 pair of die lip plate 72 is extended across the other end from one end of side face 22bx.Posture spaced apart on Z1 direction that 1 pair of die lip plate 72 is erect with relative side face 22bx.1 pair of side plate 71 is extended across the die lip plate 72 of the opposing party from the die lip plate 72 of a side.Posture spaced apart in the axis (hereinafter referred to as Z2 direction) of cylinder body 22b that 1 pair of side plate 71 is erect with relative side face 22bx.Like this, the runner forming surface 72a vis-a-vis of 1 pair of die lip plate 72, and the runner forming surface 71a vis-a-vis of 1 pair of side plate 71.Further, the interval of 1 couple of runner forming surface 71a is greater than the interval of 1 couple of runner forming surface 72a.
As shown in Figures 5 and 6, runner 29 is surrounded by 1 couple of runner forming surface 71a and 1 couple runner forming surface 72a and forms.As shown in Figure 6, on runner 29, be disposed with entrance channel 29a, manifold 29b and slit conduit 29c from the entrance 29i of the upper opening at die main body 30 towards outlet 29o.The dope 28 flowed into from entrance 29i is delivered to manifold 29b by entrance channel 29a.Manifold 29b makes dope 28, after the distortion of delaying polymer molecule contained in light dope 28 while Z2 Directional Extension, dope 28 be delivered to slit conduit 29c.Dope 28 is delivered to outlet 29o by slit conduit 29c.
As shown in Figure 7, slit conduit 29c is formed as rectangle on the face orthogonal with the flow direction Z3 of the dope 28 in runner 29.On the face orthogonal with direction Z3, the long limit of 1 couple of the cross sectional shape of slit conduit 29c is made up of runner forming surface 72a, and minor face is made up of runner forming surface 71a.
As can be seen from figures 8 and 9, die lip plate 72 may be partitioned into die lip plate main body 81 and die head 82.Die lip plate main body 81 is stainless steel (SUS316 or SUS316L etc.), is the component parts of entrance 29i.The cross section of die head 82 is wedge shape, for exporting the component parts of 29o.Die head 82 loads and unloads freely in die lip plate main body 81.The midway of split position slit conduit 29c in runner forming portion 72a of die lip plate 72.
(die head)
As shown in FIG. 9 and 10, die head 82 comprises die body 85 and is arranged at the DLC film 86 of die body 85.As shown in Figure 10, Figure 11, the die body 85 of wedge shape comprises the formation outlet leading section 90 of 29o and the installation portion 91 for installing in die lip plate main body 81.Leading section 90 is formed shrilly towards Z3 direction.As shown in figure 11, leading section 90 is made up of the exposed surface 90b meeting liquid level 90a and expose in outside of the part as runner forming surface 72a (with reference to figure 7).Die body 85 is stainless steel (SUS316 or SUS316L etc.), and is formed as approximate wedge shape.
In the leading section 90 of die body 85, hard layer 92 is set in the mode exposed.The Vickers hardness Hv of hard layer 92 is greater than the Vickers hardness Hv of die body 85.Further, the Vickers hardness Hv of hard layer 92 is less than the Vickers hardness Hv of DLC film 86.The Vickers hardness Hv of preferred hard layer 92 is more than 1000 less than 2000.Further, the Vickers hardness Hv of preferred DLC film 86 is less than more than 1,200 2500.Vickers hardness Hv is the value converted with ISO14577 identation hardness (indentationhardness, Oliver & Pharr computational methods).
The formation material of hard layer 92 can enumerate tungsten carbide (TungstenCarbide, WC), Al 2o 3, TiN, Cr 2o 3deng, especially preferably WC.In addition, as WC, except being added with the WC-Co system as the cobalt of binder metal, also can enumerating WC-Ni system, WC-TiC system and WC-TaC system etc. and all can be used in the present invention.Hard layer 92 is such as formed by thermal spraying.The thickness of hard layer 92 is such as more than 50 μm less than 200 μm.
One example of the formation method of the die body 85 with hard layer 92 is shown.First, in the recessed hard layer forming region of the sharp parts of the die body 85 of wedge shape.Then, hard layer 92 is set in the hard layer forming region being arranged to concavity.Further, after forming hard layer 92, the mode being formed as the wedge shape that hard layer 92 exposes in leading section 90 with die body 85 carries out predetermined machining to whole die body 85.
As shown in figure 11, the length of the die head 82 on Z3 direction is being set to L z3and the length of die head 82 on the orthogonal direction in Z3 direction is set to L xtime, preferably (L x/ L z3) value be less than more than 50 400.And L xpreferably at more than 1500mm, more preferably at more than 2000mm.At this, the orthogonal direction in Z3 direction can be Z2 direction and also can be Z1 direction.Therefore, the length of the die head 82 on Z1 direction is being set to L z1and the length of die head 82 on Z2 direction is set to L z2time, (L x/ L z3) can (L be expressed as z2/ L z3) or (L z1/ L z3).
Installation portion 91 is set side by side with the through hole 95 running through die body 85 along Z2 direction.As shown in figure 12, screwed hole 96 is set in die lip plate main body 81.Like this, by through hole 95, fastening bolt 97 is fixed at screwed hole 96, thus fastening die lip plate main body 81 and die head 82.In addition, Tu12Zhong, complicated in order to avoid drawing, omits and represents DLC film 86.
(DLC film)
As shown in Figure 10, DLC film 86 is arranged on the whole surface of die body 85.Known vapor coating method can be utilized as the formation processing of DLC film 86.In order to reduce the amount of warpage of the die head after process 82, the temperature T1 of the die body 85 during preferred process is more than 130 DEG C less than 200 DEG C.Plasma CVD, ion plating, ionization vapour deposition method etc. are specifically had, wherein preferred ion vapour deposition method as vapor coating method.The thickness D of preferred DLC film 86 is such as more than 1 μm less than 2 μm.
As shown in figure 13, DLC film forming apparatus 99 has reflector 100, anode 101, negative electrode 102, target electrode 103 and gas introduction tube 104.Reflector 100 is for having the cylindrical shape of bottom.Anode 101 is arranged in reflector 100 with the state be electrically insulated with reflector 100.Negative electrode 102 and reflector 100 are arranged at than anode 101 more by the open end side of reflector 100 with being electrically insulated.Target electrode 103 is made up of stainless steel and is arranged at the front of the openend of reflector 100.Gas introduction tube 104 has openend in the inner space of reflector 100.By fixture 106, die body 85 is installed at target electrode 103.With the current potential of negative electrode 102 be reflector during benchmark 100, each current potential of anode 101 and target electrode 103 is respectively negative potential, and current potential is with anode 101, reflector 100, target electrode 103 order step-down.
As shown in Figure 14 and Figure 15, the fixture 106 of stainless steel comprises fixed head 110,2 pedal plates 111 and set bolt 112.Fixed head 110 is fastening with die body 85.2 pedal plates 111 are projecting from fixed head 110.The fastening die body 85 of set bolt 112 and fixed head 110.Fixed head 100 is set side by side with screwed hole 115 along Z2 direction.By through hole 95, set bolt 112 is fixed at screwed hole 115, thus fastening fastening members 106 and die body 85.
As shown in figure 13, reacting gas (C 6h 6deng) 117 be directed into the inner space of reflector 100 from gas introduction tube 104.Plasma is there is because of DC arc discharge between anode 101 and negative electrode 102.Carbonization hydrogen ion is generated from reacting gas 117 according to this plasma.The hydrocarbon ion generated is towards target electrode 103.Like this, hydrocarbon ion collision is installed on the die body 85 of target electrode 103, and result forms DLC film 86 in die body 85.Like this, the cured film formation process being obtained die head 82 by predetermined vapor coating method from die body 85 is carried out in DLC film forming apparatus 99.
At this, die body 85 is heated to predetermined temperature by vapor coating method.Further, after carrying out vapor coating method, room temperature is cooled to.Warpage is produced in die body 85 in the process of this heating and cooling.Therefore, fluorine coating is implemented to the surface of fixed head 110, and frictional property is arranged at the surface of fixed head 110 lower than the fluorine film of the formation material (such as SUS316L) of die body 85.Carry out vapor coating method with the state of the fluorine film fixed die head main body 85 by low frictional properties, while the warpage of die body 85 can being suppressed thus, form DLC film 86 (with reference to Figure 10) in die body 85.Further, preferably along with from Z2 direction central portion towards both ends, Z2 direction, the torque of tightening of set bolt 112 (with reference to Figure 15) becomes more and more less.Such as, Z2 direction central portion central portion set bolt (being of a size of M6) to tighten torque be the torque of tightening of the end winding support bolt (being of a size of M6) of end, 10Nm, Z2 direction is 3Nm.Further, the torque of tightening of the set bolt (being of a size of M6) between central portion set bolt and end winding support bolt is 5Nm.Thereby, it is possible to form DLC film 86 (with reference to Figure 10) in die body 85 while suppressing the warpage of die body 85.
In above-mentioned embodiment, the scope forming DLC film 86 is set to the whole surface of die body 85, but is set to the leading section 90 of at least die body 85.
In above-mentioned embodiment, in order to casting films 34 be set to the state that can independently transmit and cool casting films 34, but the present invention is not limited thereto, solvent can be made to evaporate from casting films 34.
In above-mentioned embodiment, utilize casting drum 22 as supporter.But supporter is not limited to casting drum 22, the casting belt on the roller hanging and be around in and configure in the mode axially in level can be utilized.
When cast dope, the present invention can carry out following curtain coating, stacked curtain coating altogether while altogether curtain coating makes it stacked simultaneously by dope of more than two kinds, or by multiple dope successively curtain coating successively stacked curtain coating altogether of making it stacked altogether.In addition, two kinds capable of being combined are total to curtain coating.The while of carrying out during stacked curtain coating altogether, the curtain coating mould being provided with feed head can be utilized, also can utilize many fluted bodies curtain coating mould.
(polymer)
Cellulose acylate or cyclic polyolefin etc. can be utilized as polymer.
(cellulose acylate)
The acyl group used in cellulose acylate of the present invention can be only a kind or also can use acyl group of more than two kinds.When utilizing acyl group of more than two kinds, preferably wherein 1 be acetyl group.Preferably by the ratio of the cellulosic hydroxyl of carboxylic esterification, namely the substitution value of acyl group meets whole following formula (I) ~ (III).In addition, in following formula (I) ~ (III), A and B represents the substitution value of acyl group, and A is the substitution value of acetyl group and B is the substitution value of the acyl group of carbon number 3 ~ 22.In addition, preferably, more than the 90 quality % of Triafol T (cellulosetriacetate, TAC) are the particle of 0.1mm ~ 4mm.
(I)2.0≤A+B≤3.0
(II)1.0≤A≤3.0
(III)0≤B≤2.0
Total substitution value A+B of acyl group is more preferably less than more than 2.20 2.90, is especially preferably less than more than 2.40 2.88.Further, the substitution value B of the acyl group of carbon number 3 ~ 22 is more preferably more than 0.30, is especially preferably more than 0.5.
Cellulose as the raw material of cellulose acylate can be from any 1 cellulose obtained linter, slurry.
Carbon number as cellulose acylate of the present invention is the acyl group of more than 2, can be fatty group also can be aryl, without particular limitation of.These are such as cellulosic alkyl carbonyl ester, alkene carbonyl ester or aromatic carbonyl ester, aromatic series alkyl carbonyl ester etc., can have the group be substituted further respectively.As these preferred example, propionyl, butyryl, valeryl, hexanoyl, decoyl, caprinoyl, dodecanoyl, tridecanoyl, myristoyl, hexadecanoyl, stearyl, isobutyryl, tertiary butyryl, cyclohexane carbonyl, oleoyl, benzoyl, naphthalene carbonyl, cinnamoyl etc. can be enumerated.In the middle of these, more preferably propionyl, butyryl, dodecanoyl, stearyl, tertiary butyryl, oleoyl, benzoyl, naphthalene carbonyl, cinnamoyl etc., especially preferably propionyl, butyryl.
(solvent)
Aromatic hydrocarbon can be enumerated (such as the solvent preparing dope, benzene, toluene etc.), halogenated hydrocarbons (such as, carrene, chlorobenzene etc.), alcohol (such as, methyl alcohol, ethanol, normal propyl alcohol, n-butanol, diethylene glycol (DEG) etc.), ketone (such as, acetone, MEK etc.), ester (such as, methyl acetate, ethyl acetate, propyl acetate etc.) and ether (such as, oxolane, methyl cellosolve etc.) etc.In addition, in the present invention, dope refers to dissolution of polymer or the polymer solution being scattered in solvent and obtaining, dispersion liquid.
Preferably use carbon number to be the halogenated hydrocarbons of 1 ~ 7 in these, most preferably use carrene.From the viewpoint of the dissolubility of TAC, casting films from fissility, the physical property such as the mechanical strength of film and the optical characteristics of film of supporter, except carrene, preferably also mix a kind of and even several carbon numbers is the alcohol of 1 ~ 5.The content of alcohol is preferably 2 quality % ~ 25 quality % relative to whole solvent, is more preferably 5 quality % ~ 20 quality %.Concrete example as alcohol can enumerate methyl alcohol, ethanol, normal propyl alcohol, isopropyl alcohol, n-butanol etc., preferably uses methyl alcohol, ethanol, n-butanol or their mixture.
But, recently being suppressed to for the purpose of Min. on the impact of environment, solvent composition when not using carrene is also studied, for this object, preferably use carbon number be 4 ~ 12 ether, the carbon number ketone that is 3 ~ 12, the carbon number ester that is 3 ~ 12, carbon number be the alcohol of 1 ~ 12.Sometimes suitably mix these to use.Such as, the mixed solvent of methyl acetate, acetone, ethanol, n-butanol can be enumerated.These ethers, ketone, ester and alcohol can have circulus.And any one the compound had in the functional group (that is ,-O-,-CO-,-COO-and-OH) of more than 2 ethers, ketone, ester and alcohol also can be used as solvent.
(additive)
Predetermined additive can be added to dope.Plasticizer, ultra-violet absorber etc. is had as the additive used in the present invention.Polycondensation ester is preferably used as plasticizer.
The thickness of film 45 preferably more than 20 μm less than 120 μm, more preferably more than 40 μm less than 100 μm.
The width of film 45 preferably at more than 700mm below 3000mm, more preferably more than 1000mm below 2800mm, especially preferably more than 1500mm below 2500mm.In addition, the width of film 45 also can be more than 2500mm.
(mist degree)
The mist degree of film 45 is preferably less than 0.20%, more preferably less than 0.15%, especially preferred less than 0.10%.Mist degree is set to less than 0.2%, contrast ratio when being assembled in liquid crystal indicator can be improved thus.Further, also have the transparency of film to become higher, be more easily used as the advantage of blooming and so on.
Further, postpone Re in the face of film 45 preferably at more than 20nm below 300nm, the thickness direction retardation Rth of film 45 is preferably at above below the 300nm of-100nm.
The assay method postponing Re in face is as follows.Postpone Re in face and to employ under temperature 25 DEG C, humidity 60%RH damping sample film 2 hours, and with the length of delay that automatic birefringence meter (prince KOBRA21DH measures (strain)) measures from the vertical direction of 632.8nm.In addition, Re is represented by following formula.
Re＝|n1-n2|×d
N1 represents the refractive index of slow axis, and n2 represents the refractive index of leading phase shaft 2, and d represents the thickness (thickness) of film.
The assay method of thickness direction retardation Rth is as follows.From damping sample film under temperature 25 DEG C, humidity 60%RH 2 hours, and the extrapolated value of the length of delay measured in the same manner while the value measured from vertical direction according to 632.8nm with ellipsometer (M150 Japan Spectroscopy Corporation system) and inclination face, according to following formulae discovery.
Rth＝{(n1+n2)/2-n3}×d
N3 represents the refractive index of thickness direction.
[embodiment]
(experiment 1)
In the DLC film forming apparatus 99 shown in Figure 13, form DLC film 86 by ionization vapour deposition method in die body 85 obtain die head 82 (with reference to Figure 10).It is SUS316L system that die body 85 make use of whole, and has the die body of WC-Co system hard layer 92 in leading section 90.The Vickers hardness Hv of hard layer 92 is 1300.About die body 85, length L z1for 2mm, length L z2for 2000mm, length L z3for 20mm.Utilize the surface of the fixed head 110 made at stainless steel (SUS316L) to be provided with the fixture 106 (with reference to Figure 14 and Figure 15) of fluorine film, die body 85 is fixed on target electrode 103.The temperature T1 of the die body 85 in cured film formation process is 150 DEG C ~ 200 DEG C.The thickness D of DLC film 86 is 1.6 μm.
(experiment 2 ~ 7)
In experiment 2 ~ 7, except the content shown in table 1, identical with experiment 1, form DLC film 86 in die body 85 and obtain die head 82.
[table 1]
The formation method of the DLC film in 1 ~ 7 is tested, humidity T1, basalis material, basalis hardness, length L shown in table 1 z2, the thickness D of DLC film 86 and the formation material on fixed head surface.Basalis material refers to the material of leading section 90, and basalis hardness refers to the Vickers hardness Hv of leading section 90.In addition, in experiment 2, make use of the fixture 106 (with reference to Figure 14 and Figure 15) of the fixed head 110 comprising stainless steel.In experiment 3,6, the formation method of DLC film forms DLC film 86 by ionization vapour deposition method instead of plasma CVD, and in experiment 7, the formation method of DLC film forms DLC film 86 by ionization vapour deposition method instead of hot CVD.In experiment 5, die body 85 is whole is SUS316L system, directly uses with the state not arranging hard layer 92 in leading section 90.The Vickers hardness Hv of die body 85 is 300.
(evaluation)
The die head 82 of 1 ~ 7 acquisition is by experiment evaluated as follows.
1. the warpage of die head
Die head 82 is carried out to the mensuration of amount of warpage W.First, die head 82 is disposed in base in the mode that sweep is downward.Gap maximum in gap between die head 82 and base is set to amount of warpage W.According to following benchmark, the amount of warpage W measured is judged.In addition, A, B are qualified grade, and C is defective grade.
A:W is less than 5 μm.
B:W is for being greater than 5 μm and less than 15 μm.
C:W is greater than 15 μm.
2.DLC film strength
Fretting wear is carried out to DLC film and test visually observes the DLC film after carrying out friction-wear test, and according to the intensity of following benchmark evaluation DLC film.The program of friction-wear test is as follows.The friction gauge (Tribometer) (ball disc type) utilizing CSM instrument (CSMInstruments) company to manufacture carries out friction-wear test (JISR1613-1993).First, fix die head 82 on a spinstand, and turntable is rotated with predetermined rotating speed.Then, from the position of the DLC film 86 of pivot 3.0mm in the fore-end of die head 82, the Al of spherical (diameter is for 6.35mm) is pushed with predetermined load (5.0N) 2o 3test film processed.The speed of the DLC film 86 on thrusting position is 0.1m/ second.Die head 82 is made to rotate 20000 times with the state pushing test film.In addition, A, B are qualified grade, and C is defective grade.
A: breaking or coming off to DLC film unconfirmed.
B: confirm breaking or coming off of DLC film.Further, the life-span of the front end of die head 82 is longer compared with die head (die body 85) in the past.
C: confirm breaking or coming off of DLC film.Further, the life-span of the front end of die head 82 is identical with it or below it compared with die head (die body 85) in the past.
Evaluation result about above-mentioned assessment item is shown in table 1.In Table 1, the sequence number shown in assessment item represents sequence number additional in above-mentioned assessment item.

Claims (9)

1. a curtain coating mould, it is provided with the runner of the dope comprising polymer and solvent, flows out described dope, it is characterized in that comprising:
Be separated and 1 pair of side plate of mutual subtend;
1 pair of die lip plate, arrange from the described side plate of a side towards the described side plate of the opposing party and subtend mutually, wherein, described runner is surrounded by described 1 pair of side plate and described 1 pair of die lip plate and forms, described die lip plate has die lip plate main body and die head, described die lip plate main body forms described flow channel entry point, described die head is installed on described die lip plate main body and forms described runner exit, described die head is stainless steel, the cross section of described die head is wedge shape, the length of the described die head in the orientation of described 1 pair of side plate is more than 50 divided by the value of the length of the described die head on the direction orthogonal with described orientation, and
DLC film, is arranged at the front end of described die head, and is formed under the treatment temperature of less than 200 DEG C more than 130 DEG C.
2. curtain coating mould as claimed in claim 1, is characterized in that,
The length of the described die head in described orientation is more than 1500mm.
3. curtain coating mould as claimed in claim 1, is characterized in that,
Described die head comprises the die body and carbide layers that are made up of stainless steel, and described carbide layers is arranged at the front end that cross section is the described die body of wedge shape.
4. curtain coating mould as claimed in claim 1, is characterized in that,
The thickness of described DLC film is less than 2 μm.
5. a manufacture method for film, is characterized in that comprising following steps:
Flow out dope from curtain coating mould and form the casting films be made up of described dope at supporter, wherein, described dope comprises polymer and solvent, described casting mold has 1 pair of side plate and 1 pair of die lip plate, described 1 pair of side plate is separated and mutual subtend, described 1 pair of die lip plate is arranged from the described side plate of a side towards the described side plate of the opposing party and subtend mutually, the runner of described dope is surrounded by described 1 pair of side plate and described 1 pair of die lip plate and forms, described die lip plate has die lip plate main body and die head, described die lip plate main body forms described flow channel entry point, described die head is installed on described die lip plate main body and forms described runner exit, described die head is stainless steel, the cross section of described die head is wedge shape, the length of the described die head in the orientation of described 1 pair of side plate is more than 50 divided by the value of the length of the described die head on the direction orthogonal with described orientation, the DLC film formed under the front end of described die head being provided with the treatment temperature of less than 200 DEG C more than 130 DEG C,
Enable described solvent from described casting films evaporation until described casting films independently transmits;
Described casting films is peeled off to be made moistening film from described supporter; And
Described solvent is made to make film forming from described moistening film evaporation.
6. the manufacture method of a die head, it is formed at the manufacture method of the die head of the runner exit of the dope of curtain coating mould for forming, described dope comprises polymer and solvent, described runner is surrounded by 1 pair of side plate and 1 pair of die lip plate and forms, described 1 pair of side plate is separated and mutual subtend, described 1 pair of die lip plate is arranged from the described side plate of a side towards the described side plate of the opposing party and subtend mutually, described die lip plate has the die lip plate main body and the surperficial described die head being provided with the stainless steel of DLC film that form described flow channel entry point, it is characterized in that, the manufacture method of described die head comprises following steps:
(A) die body of stainless steel is prepared; And
(B) by vapor coating method, described DLC film is set on the surface of described die body and obtains described die head, wherein, the length of the described die head in the orientation of described 1 pair of side plate is more than 50 divided by the value of the length of the described die head on the direction orthogonal with described orientation, and the treatment temperature of described vapor coating method is more than 130 DEG C less than 200 DEG C.
7. the manufacture method of die head as claimed in claim 6, is characterized in that,
Described vapor coating method is the either method in ionization evaporation, ion plating and plasma CVD.
8. the manufacture method of die head as claimed in claim 6, is characterized in that,
In described step B, by implementing the fixture fixed target electrode of fluorine coating and described die body, utilize die body described in bolted and described fixture.
9. the manufacture method of die head as claimed in claim 8, is characterized in that,
In described step B, the fastening position that the orientation of described 1 pair of side plate is set up in parallel is tightened by the bolt described die body and support component, along with the central portion of the orientation from described 1 pair of side plate becomes more and more less towards the torque of tightening of bolt described in both end sides.
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