CN109789614B - Solution film-making method - Google Patents

Solution film-making method Download PDF

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Publication number
CN109789614B
CN109789614B CN201780060539.8A CN201780060539A CN109789614B CN 109789614 B CN109789614 B CN 109789614B CN 201780060539 A CN201780060539 A CN 201780060539A CN 109789614 B CN109789614 B CN 109789614B
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China
Prior art keywords
casting
film
wind
porous member
casting support
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CN201780060539.8A
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CN109789614A (en
Inventor
池田仁
吉田俊一
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Fujifilm Corp
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Fujifilm Corp
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Priority claimed from JP2017161940A external-priority patent/JP2018058345A/en
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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
    • B29C41/24—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
    • B29C41/28—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 an endless belt
    • 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
    • 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
    • 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
    • B29C41/46—Heating or cooling

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

The invention provides a solution film-forming method for manufacturing an optical film with further improved smoothness. The solution film-making apparatus makes a film from the dope. A casting film is formed by continuously casting a dope in which a polymer is dissolved in a solvent on a traveling conveyor belt, and the casting film is dried. The film is formed by peeling the casting film from the casting support. A web is provided so as to face a casting surface of the belt on which the dope is cast. The web is set in a state of being separated from the casting surface. The diameter of the through-going holes of the net is at most 7 mm.

Description

Solution film-making method
Technical Field
The present invention relates to a solution film-forming method.
Background
As a method for producing an optical film, there is a solution film-forming method. The solution film-forming method is one of the following methods: the casting film is formed by casting a dope in which a polymer is dissolved in a solvent onto a running casting support, the film is formed by peeling the casting film from the casting support, and the formed film is dried. The casting film is solidified on the casting support in a state in which the film formed by peeling can be conveyed. As a method of curing the casting film on the casting support, there is a method of drying the casting film.
Since the smoothness of the film surface of the cast film affects the state of the film surface of the obtained film, a method of improving the smoothness of the film surface of the cast film has been proposed. For example, in the method described in Japanese patent laid-open No. 2006-297903, the casting film is dried by the first drying step 1 and the second drying step 2. The first drying step 1 is to send air having a temperature of approximately constant within a range of 50 to 160 ℃ to a cast film which is just formed, from a first air outlet which has a longitudinal direction in the width direction of the cast support, while adjusting a static pressure to be constant within a range of 50 to 200 Pa. The 2 nd drying step is to send wind approximately parallel to the traveling direction of the casting support to the casting film from a 2 nd air blowing port facing the traveling direction of the casting support according to the amount of the solvent contained in the casting film after the 1 st drying step.
On the other hand, considering that uneven drying of the casting film is easily caused by the blowing wind, for example, in japanese patent laid-open No. 2003-103543, the casting film which has just been cast is dried by a condensing plate provided to face the casting support.
Disclosure of Invention
Technical problem to be solved by the invention
Glass used for an image display surface of a mobile terminal is easily broken by, for example, impact. Therefore, a film made of resin (polymer) for covering the glass surface and/or a film made of resin (polymer) for replacing glass are required. In this regard, optical films produced by conventional solution film-forming methods such as jp 2006-297903 a and jp 2003-103543 a have sufficient smoothness for applications such as protective films for polarizing plates. However, the smoothness is inferior to that of the above glass having a glossy feeling, and further improvement in smoothness is required for use as a protective film for the image display surface as described above, for example.
Accordingly, an object of the present invention is to provide a solution film-forming method for producing an optical film having further improved smoothness.
Means for solving the technical problem
In order to solve the above problems, a solution film-forming method of the present invention includes a cast film-forming step, a cast film-drying step, and a peeling step. The casting film forming process forms a casting film by continuously casting a dope in which a polymer is dissolved in a solvent on a running casting support. The casting film drying process dries the casting film. The peeling step peels the casting film subjected to the casting film drying step from the casting support to form a film. A porous member having a through hole with a diameter of at most 7mm is provided to face a casting surface of a casting support in a separated state.
The porous member is preferably a mesh or a porous plate.
The aperture ratio of the member surface having an opening formed by the through-hole is preferably in the range of 35% to 70%.
The distance between the casting support and the porous member is preferably in the range of 5mm or more and 50mm or less.
The casting film drying step preferably dries the casting film by a drying device disposed in a state of facing the casting surface of the casting support. The porous member is preferably disposed between a casting position of the dope casting and the drying device.
The porous member is preferably provided in a region where the wind speed is in a range of more than 0m/s and 1m/s or less in a state where the running of the casting support is stopped.
Preferably, the wind flowing between the casting support and the porous member is blocked by a wind blocking member disposed in a state of facing the edge of the porous member and protruding toward the casting support side than the porous member.
The wind shielding member is a wind shielding plate extending in a width direction orthogonal to a traveling direction of the casting support, and the wind shielding plate is preferably disposed in a state of being separated from the casting support on a downstream side of the porous member in the traveling direction of the casting support. The distance between the wind deflector and the casting support is preferably in the range of 1mm or more and 50mm or less.
The wind shielding members are wind shielding walls extending in the traveling direction of the casting support, and the wind shielding walls are preferably provided on both sides of the porous member in the width direction orthogonal to the traveling direction of the casting support in a state of being separated from the casting support. The distance between the wind shielding wall and the casting support is preferably in the range of 1mm or more and 50mm or less.
The wind blocking member is preferably disposed in a state of being in contact with the porous member.
Effects of the invention
According to the present invention, an optical film having further improved smoothness can be produced.
Drawings
Fig. 1 is a schematic view of a solution film forming apparatus.
Fig. 2 is a schematic view of a net.
Fig. 3 is an explanatory view of the aperture ratio.
FIG. 4 is a schematic view of a casting apparatus in which a casting support is a drum.
FIG. 5 is a schematic view of a casting apparatus provided with a wind shielding member.
Fig. 6 is a partial sectional view taken along the line (VI) - (VI) of fig. 5.
FIG. 7 is a schematic view of a casting apparatus provided with a wind shielding member.
Fig. 8 is a partial sectional view taken along the line (VIII) - (VIII) of fig. 7.
Fig. 9A is a schematic view of a casting apparatus provided with an auxiliary wind deflector, (a) is a schematic plan view of the wind deflector, the wind deflector wall, and the auxiliary wind deflector, and (B) is a schematic side view of the casting apparatus.
FIG. 9B is a schematic side view of a casting apparatus provided with an auxiliary wind shielding plate.
FIG. 10 is a schematic view of a casting apparatus provided with an auxiliary wind shielding wall, wherein (A) is a schematic view of a side surface of the casting apparatus, and (B) is a schematic plan view showing positions in a width direction Y of the wind shielding wall and the auxiliary wind shielding wall.
FIG. 11 is a schematic view of a casting apparatus provided with an auxiliary wind shielding wall, wherein (A) is a schematic view of a side surface of the casting apparatus, and (B) is a schematic plan view showing positions in a width direction Y of the wind shielding wall and the auxiliary wind shielding wall.
Fig. 12 is an explanatory diagram of a smoothness evaluation method.
Detailed Description
[ embodiment 1]
A solution film-forming apparatus 10 shown in fig. 1 embodying the present invention is used for manufacturing an optical film (hereinafter, simply referred to as "film") 11. The film 11 constitutes an image display surface of the mobile terminal, i.e., functions as a protective film on the outermost surface of a touch panel disposed in the image display section. The film 11 can be used as a substitute instead of conventional glass, or can be used in a state of being attached to the surface of glass. The thickness of the film 11 to be produced is in the range of 10 μm to 300 μm, preferably 100 μm to 300 μm, and more preferably 150 μm to 250 μm. In the present embodiment, the thickness is set to 200 μm.
The solution film-forming apparatus 10 includes a casting device 13, a tenter 14, a roll drying device 15, a slitter 16, and a winding device 17 in this order from the upstream side. In the present specification, the solvent content (unit;%) is a value based on the drying amount, and specifically, a percentage obtained by { MS/(MF-MS) } × 100 is given when the mass of the solvent is MS and the mass of the film 11 or the casting film 29 to be measured is MF.
The casting device 13 is a device for forming the film 11 from the dope 21. The cement 21 is a polymer solution in which a polymer is dissolved in a solvent. In the present embodiment, cellulose triacetate (hereinafter, referred to as TAC) is used as the polymer, but other cellulose acylate than TAC may be used. The cellulose acylate may have only 1 kind of acyl group, or may have 2 or more kinds of acyl groups. When the acyl group is 2 or more, one of them is preferably an acetyl group. The ratio of esterification of the hydroxyl groups of cellulose with carboxylic acid, that is, the degree of substitution of acyl groups preferably satisfies all of the following formulae (I) to (III). In the following formulas (I) to (III), A and B represent the degree of substitution with acyl groups, A represents the degree of substitution with acetyl groups, and B represents the degree of substitution with acyl groups having 3 to 22 carbon atoms.
(I)2.0≤A+B≤3.0
(II)1.0≤A≤3.0
(III)0≤B≤2.0
The degree of total substitution a + B of the acyl group is more preferably 2.20 or more and 2.90 or less, and particularly preferably 2.40 or more and 2.88 or less. The degree of substitution B of an acyl group having 3 to 22 carbon atoms is more preferably 0.30 or more, and particularly preferably 0.5 or more.
Also, the polymer of the dope 21 is not limited to the cellulose acylate. For example, acrylic resins and cyclic olefin resins (for example, ARTON (registered trademark) manufactured by JSR Corporation) may be used.
As a solid component to be the film 11, the dope 21 may contain a component other than the polymer. Examples of the solid component other than the polymer include a plasticizer, an ultraviolet absorber, a retardation controller, and fine particles. The fine particles are a so-called matting agent used for the purpose of imparting lubricity and/or scratch resistance to the film 11, suppressing blocking when the film 11 is stacked, and the like.
As the solvent of the dope 21, a mixture of dichloromethane and methanol is used in the present embodiment. The solvent is not limited to the examples of the present embodiment, and for example, butanol, ethanol, propanol, or the like is used, and 2 or more kinds thereof may be used in combination as a mixture.
The casting device 13 includes a belt 23 as a continuous casting support formed in an endless shape, and a 1 st roller 26 and a 2 nd roller 27 rotating in a circumferential direction. The belt 23 is wound around the circumferential surfaces of the 1 st roller 26 and the 2 nd roller 27. At least one of the 1 st roller 26 and the 2 nd roller 27 may be a driving roller having a driving mechanism. The drive roller rotates in the circumferential direction, and the belt 23 in contact with the circumferential surface continuously travels in the longitudinal direction and circulates. In fig. 1, arrows marked with X indicate the traveling direction of the conveyor belt 23 and the conveying direction of the film 11. In addition, the casting support is not limited to the belt 23, and a drum (refer to fig. 4, 5) may be used.
A casting die (hereinafter, referred to as a die) 28 is provided above the belt 23. The die 28 widens the supplied paste 21 into a film shape spreading in the depth direction of the drawing sheet of fig. 1, and then continuously flows out from an outflow port (not shown). Thereby, the casting film 29 is formed on the traveling belt 23. In addition, a position where the dope 21 is cast on the traveling path of the belt 23, that is, a position where the dope 21 starts to contact the belt 23 is hereinafter referred to as a casting position, and denoted by a symbol PC.
In the present embodiment, the die 28 is disposed above the belt 23 on the 1 st roll 26, and the casting position PC is disposed on the 1 st roll 26. However, the position of the die 28 is not limited thereto. For example, it may be disposed above the belt 23 from the 1 st roll 26 toward the 2 nd roll 27, whereby the dope 21 may be cast on the belt 23 from the 1 st roll 26 toward the 2 nd roll 27. In this case, it is preferable that the roller 31 is disposed below the belt 23 from the 1 st roller 26 toward the 2 nd roller 27, and the die 28 is disposed above the belt 23 supported by the roller 31.
The 1 st roller 26 and the 2 nd roller 27 are each provided with a temperature controller (not shown) for controlling the temperature of the circumferential surface. The circumferential surface of the 1 st roller 26 is cooled to a temperature within a predetermined range, and the conveyor belt 23 is cooled once per one travel. Thereby suppressing the foaming of the casting film 29. The circumferential surface of the 2 nd roller 27 is heated to a temperature in a prescribed range, thereby drying the casting film 29 more efficiently.
The circumferential surface temperature of the 1 st roll 26 is preferably in the range of 0 ℃ to 40 ℃, and the circumferential surface temperature of the 2 nd roll 27 is preferably in the range of 15 ℃ to 80 ℃.
The slurry 21 reaching the conveyor belt 23 from the die 28 may be provided with a decompression chamber (not shown) upstream in the traveling direction of the conveyor belt 23 as a so-called runner. The decompression chamber decompresses the upstream side region of the flow passage by sucking the ambient gas of the region.
After the casting film 29 is dried to an extent capable of being conveyed to the tenter 14, it is peeled from the conveyor belt 23 in a state of containing the solvent, thereby forming the film 11. The stripping is preferably performed after the solvent content becomes 100% or less, and more preferably in the range of 25% to 70%.
At the time of peeling, the film 11 is supported by a roller (hereinafter, referred to as a peeling roller) 33 as a peeling section, and the peeling position PP at which the casting film 29 is peeled from the belt 23 is held fixed. The peeling roller 33 may be a drive roller provided with a drive mechanism and rotating in the circumferential direction. Further, the peeling is performed by the belt 23 on the 1 st roller 26. The belt 23 circulates to return from the peeling position PP to the casting position PC, and a new dope 21 is cast again at the casting position PC.
The casting device 13 is provided with an air supply drying unit 41 and a web 42 as a porous member. The air supply drying unit 41 is a casting film drying device that dries the casting film 29 to such an extent that the transfer after peeling from the transfer belt 23 can be performed. The air supply drying unit 41 is provided downstream of the die 28 in the traveling direction of the conveyor 23, and includes the 1 st to 3 rd air supply units 45 to 47, the 1 st and 2 nd air discharge units 48 and 49. These are arranged on the casting surface 23a side of the casting film 29 forming the belt 23, and the 1 st air supply portion 45, the 1 st air discharge portion 48, the 2 nd air supply portion 46, the 2 nd air discharge portion 49, and the 3 rd air supply portion 47 are arranged in this order from the upstream side in the traveling direction of the belt 23.
In this example, the 1 st air supply part 45 is disposed in the vicinity of the traveling path of the conveyor belt 23 on the 1 st roller 26, the 1 st air discharge part 48 and the 2 nd air supply part 46 are disposed in the vicinity of the traveling path of the conveyor belt 23 from the 1 st roller 26 toward the 2 nd roller 27, the 2 nd air discharge part 49 is disposed in the vicinity of the traveling path of the conveyor belt 23 in contact with the 2 nd roller 27, and the 3 rd air supply part 47 is disposed in the vicinity of the traveling path of the conveyor belt 23 in the vicinity of the position where contact with the 1 st roller 26 is started. The positions where the 1 st to 3 rd air supply portions 45 to 47 and the 1 st and 2 nd air discharge portions 48 and 49 are arranged are not limited to these, and may be in the vicinity of the traveling path of the belt 23 from the casting position PC to the peeling position PP. The number of the air supply portion and the air discharge portion is not limited to this, and may be set to a number corresponding to the length of the conveyor belt 23 or the like.
The 1 st to 3 rd gas supply parts 45 to 47 discharge the heated dry gas, and the 1 st and 2 nd gas discharge parts 48 and 49 suck and discharge the gas. Here, the conveyor belt 23, the mold 28, the 1 st to 3 rd gas supply portions 45 to 47, the 1 st gas discharge portion 48, the 2 nd gas discharge portion 49, and the like are housed inside a chamber 51 blocked from an external space, and the 1 st gas discharge portion 48 and the 2 nd gas discharge portion 49 discharge the sucked gas to the outside of the chamber 51. The supply air drying unit 41 includes an air supply controller 52 outside the chamber 51. The air blowing controller 52 includes a fan (not shown) and a control unit (not shown) that sends, for example, air as dry gas to the 1 st air supply unit 45 to the 3 rd air supply unit 47 via the fan, and adjusts the temperature and humidity of the gas separately from the flow rates from the 1 st air supply unit 45 to the 3 rd air supply unit 47 and the gas suction forces of the 1 st air discharge unit 48 and the 2 nd air discharge unit 49.
In the present embodiment, the dry gas from the 1 st to 3 rd gas supply portions 45 to 47 is heated to about 90 ℃. The thus-heated drying gas is made to flow as warm air on the casting film 29, thereby heating the casting film 29 and promoting drying. The temperature of the drying gas is preferably in the range of 40 ℃ to 140 ℃.
The 1 st gas supply unit 45 and the 2 nd gas supply unit 46 are arranged in a state where an outlet (not shown) from which the dry gas flows out is directed in the traveling direction X of the belt 23, and thereby the dry gas is supplied to the casting film 29 being conveyed in the downwind direction. The dry gas becomes a fluid parallel to the film surface of the casting film 29. The 3 rd gas supply section 47 is disposed in a state in which an outlet port (not shown) from which the dry gas flows out is directed to the opposite side to the traveling direction X of the belt 23, and thereby the dry gas is supplied to the casting film 29 being conveyed in the counter wind direction. The dry gas also becomes a fluid parallel to the film surface of the casting film 29. The 1 st air discharging section 48 and the 2 nd air discharging section 49 are arranged in a state where a suction port (not shown) for sucking air is directed toward the casting film 29 through which the air passes. The 1 st air discharge portion 48 sucks air between the 1 st air supply portion 45 and the 2 nd air supply portion 46, and the 2 nd air discharge portion 49 sucks air between the 2 nd air supply portion 46 and the 3 rd air supply portion 47. Here, the orientation of the supplied dry gas is not limited to this, and may be an orientation perpendicular to the casting film 29. The outflow ports of the 1 st to 3 rd air supply portions 45 to 47 and the suction ports of the 1 st and 2 nd air discharge portions 48 and 49 are slit-shaped openings extending in the width direction of the conveyor belt 23 (the depth direction of the paper surface in fig. 1).
In the present embodiment, the air supply controller 52 controls the 1 st to 3 rd air supply units 45 to 47, the 1 st air discharge unit 48, and the 2 nd air discharge unit 49 independently of each other, but the present invention is not limited to this embodiment. For example, controllers (not shown) may be provided for the 1 st to 3 rd air supply units 45 to 47, the 1 st air discharge unit 48, and the 2 nd air discharge unit 49, respectively, and the 1 st to 3 rd air supply units 45 to 47, the 1 st air discharge unit 48, and the 2 nd air discharge unit 49 may be controlled by the respective controllers. The same applies to the case where the number of the air supply portions and the air discharge portions is changed.
The casting film drying device that dries the casting film 29 is not limited to the air supply drying unit 41, and a known drying device that dries the casting film may be used. For example, the air blower may be a box-shaped air supply box having a size covering the casting film 29, and a plurality of discharge nozzles provided on the opposite surface of the conveyor belt 23 of the air supply box to discharge the dry gas from the opening at the front end. And, for example, may be a condenser covering the size of the casting film 29. As the condenser, there is, for example, a condensing plate described in japanese patent application laid-open No. 2003-103543, which condenses the solvent evaporated from the casting film 29 into a gas by cooling, thereby promoting drying of the casting film 29.
However, as is known, there is a boundary layer on the casting film 29 generated by the solvent (referred to as solvent gas) evaporated from the casting film 29. The boundary layer is a region where the concentration of the solvent gas in the ambient gas further away from the casting film 29 is higher, and the higher the solvent content of the casting film 29 is, the thicker the thickness of the boundary layer is. Convection of the solvent gas occurs in the boundary layer, and this convection is considered as fluctuation of the concentration of the solvent gas in the boundary layer. The web 42 suppresses convection in this boundary layer and serves to promote drying of the casting film 29.
The mesh 42 is an example of a porous member having holes penetrating in the thickness direction, that is, through holes 70 (see fig. 2) formed therein. The web 42 is opposed to the casting surface 23a of the belt 23 and is set in a state of being separated from the casting surface 23 a. That is, the web 42 is set in a state of being separated from the casting surface 23a, and the conveyance path of the casting film 29 is set in a state of being covered with the web 42. The casting film 29 formed at the casting position PC passes through the conveyance path covered with the web 42. The diameter d70 (see fig. 3) of the through-hole 70 is 7mm at the most.
Here, the distance between the casting support and the web 42 is set to D. In this example, the casting support is the belt 23, and thus the distance D is the distance between the belt 23 and the web 42. The distance D is preferably in the range of 5mm to 50mm, more preferably 10mm to 30mm, and still more preferably 15mm to 25 mm. In addition, the distance D between the belt 23 and the web 42 is a distance between the casting surface 23a of the belt 23 and an opposed surface 42a (refer to fig. 2) of the web 42 opposed to the belt 23.
The web 42 is a member provided as a member of the casting film drying apparatus independently of drying the casting film 19. That is, in this example, the net 42 becomes a separate component from the air supply drying unit 41. When the above-described known drying device is used, which is different from the air supply drying unit 41, the net 42 is provided independently of the components of the drying device. For example, in the case of using the above-described gas supply box formed in a box shape having a size to cover the casting film 29, even if a porous member such as a mesh is provided at the tip of the delivery nozzle, the mesh 42 is provided as a member separate from the gas supply box having the porous member. Further, even when either the perforated plate or the net described in japanese patent application laid-open No. 2003-103543 is used as the above-described condensing device, the net 42 is provided as a member independent of these.
The web 42 is preferably disposed between the casting position PC and the air supply drying unit 41. In the air supply drying unit 41, the 1 st air supply part 45 is located on the nearest upstream side from the casting position PC in the traveling direction of the belt 23, and therefore, in this example, the web 42 is arranged along the traveling path of the belt 23 from the casting position PC to the 1 st air supply part 45.
The web 42 may be provided over the entire area from the casting position PC to the peeling position PP, and when the web 42 cannot be provided over the entire area, it is preferable to provide the web 42 on the conveyance path in an area where the wind speed is in a range of more than 0m/s and 1m/s or less in a state where the travel of the conveyor 23 is stopped. Specifically, the wind speed of the conveyance path of the casting film 29 is measured in a state where the web 42 is not provided, the travel of the conveyor belt 23 is stopped, and the air supply drying unit 41 is operated, and a breeze area where the wind speed is in a range of more than 0m/s and 1m/s or less is specified. In the breeze zone, the web 42 is set in a state of being separated from the casting surface 23a of the belt 23. In this example, the section from the casting position PC to the section between the 1 st air discharging unit 48 and the 2 nd air supplying unit 46 is defined as the breeze area, and therefore the mesh 42 is provided in this section.
The film 11 formed by peeling off from the conveyor belt 23 is guided to the tenter 14. An air blowing device (not shown) may be disposed on a transfer path between the casting device 13 and the tenter 14. The air blowing by the air blowing device promotes the drying of the film 11.
The tenter 14 is a 1 st film drying device that conveys the film 11 and promotes drying. The tenter 14 of the present embodiment also performs a stretching process of stretching the film 11 in the width direction by holding each end portion of the film 11 by clips 14a as holding members, conveying the film 11 in the longitudinal direction and applying tension in the width direction.
The tenter 14 has a duct 14b, and the duct 14b is disposed above the conveyance path of the film 11. The duct 14b has a plurality of slits (not shown) for sending out a dry gas (for example, dry air), and the dry gas is supplied by a blower (not shown). The blower sends the dry gas adjusted to a predetermined temperature and/or humidity to the duct 14 b. The duct 14b is disposed in a state where the slit faces the conveyance path of the film 11. Each slit is elongated in the width direction of the film 11, and a plurality of slits are formed at predetermined intervals from each other in the transport direction X. Further, the duct having the same structure may be provided below the conveyance path of the film 11, or may be provided both above and below the conveyance path of the film 11.
The roll drying device 15 is a 2 nd drying device for further drying the film 11. The temperature and/or humidity of the ambient air inside the roll drying device 15 are adjusted by an air conditioner (not shown). In the roll drying device 15, the film 11 is wound around a plurality of rolls 15a and conveyed.
The slitter 16 is a device for slitting both side portions of the film 11 to set the film 11 to a target width. In this cutting, both side portions of the film 11 including the holding trace by the jig 14a are cut. The slitting machine 16 may be disposed between the tenter 14 and the roller drying device 15. The winding device 17 is configured to be a roll by winding the film 11 around a winding core.
As shown in fig. 2, the net 42 is formed in a flat-woven fabric shape in which a plurality of 1 st umbilical members 71 extending in the 1 st direction and a plurality of 2 nd umbilical members 72 extending in the 2 nd direction orthogonal to the 1 st direction are knitted. The 1 st umbilical member 71 and the 2 nd umbilical member 72 are made of a material having resistance to the solvent component of the adhesive 21, and are made of metal in this example. The through-hole 70 surrounded by the 1 st umbilical member 71 and the 2 nd umbilical member 72 has openings formed in the facing surface 42a as the surface of the member facing the belt 23 of the mesh 42 and the opposing surface 42b as the surface of the member opposite to the facing surface 42 a.
As described above, the net 42 of this example is formed in a flat woven fabric, but the net is not limited to a flat woven fabric, and may be formed in another woven fabric such as a twill weave. The net is not limited to a woven shape, and may be a knitted fabric. As described above, the net 42 is an example of a porous member, and a porous member may be a porous plate (perforated plate).
The 1 st umbilical member 71 and the 2 nd umbilical member 72 are independent of each other, but may be integrated by, for example, melting by heating. Also, the crossing angle of the 1 st umbilical member 71 and the 2 nd umbilical member 72 is not limited to 90 °. In this example, the distance between the adjacent 1 st umbilical members 71 is fixed, and the distance between the adjacent 2 nd umbilical members 72 is also fixed. Wherein at least one of the distance between the adjacent 1 st umbilical bodies 71 and the distance between the adjacent 2 nd umbilical bodies 72 may be unevenly disposed.
The diameter d70 of the through-hole 70 is the largest dimension. As shown in fig. 3, the through-hole 70 of this example is square, and therefore the length of the diagonal line is set to the diameter d70 of the through-hole 70. For example, when the through-hole 70 is elliptical in the opposing surface 42a and the opposing surface 42b, the length of the major axis is defined as the diameter d 70.
The aperture ratio of each of the opposed surface 42a and the opposed surface 42b is preferably in the range of 35% to 70%, more preferably 40% to 60%, and still more preferably 45% to 55%. The aperture ratio (unit is%) of the facing surface 42a is determined by the following method. When the facing surface 42a is viewed in the vertical direction, the area of the through-hole 70 in the facing surface 42a is S1 and the areas of the 1 st umbilical member 71 and the 2 nd umbilical member 72 are S2 per unit area. The area S1 of the through-hole 70 is the area of the cross-hatched portion in fig. 3. The area S2 is the area of the hatched portion indicated by oblique lines. The aperture ratio is obtained as { S1/(S1+ S2) } × 100. The aperture ratio in the opposing surface 42b is also determined in the same manner.
The operation of the above structure will be explained. The dope 21 continuously flows out from the die 28 to the traveling belt 23, thereby forming the casting film 29 on the belt 23 (casting film forming process). The casting film 29 is conveyed by the traveling belt 23 and guided to the air supply drying unit 41. The drying of the casting film 29 is promoted by the air supply from the 1 st air supply part 45 to the 3 rd air supply part 47 (casting film drying step). The 1 st air discharging portion 48 and the 2 nd air discharging portion 49 are disposed in a state where a suction port for sucking the gas is directed toward the casting film 29, so that the dry gas flowing out from the 1 st air supplying portion 45 to the 3 rd air supplying portion 47 flows on the casting film 29 more reliably. Therefore, the drying of the casting film 29 is promoted more effectively.
Since the web 42 is present on the transport path of the casting film 29 and the diameter d70 of the through-hole 70 is 7mm at the maximum, the convection of the boundary layer is suppressed and the boundary layer is stabilized. As a result, the film surface of the casting film 29 is conveyed in a very smooth state, and as a result, the film 11 with significantly improved smoothness can be obtained. If the diameter of the through-hole 70 is larger than 7mm, the smoothness of the obtained film 11 is worse than that in the case of a diameter of 7mm or less due to the influence of the air supply from the air supply drying unit 41 (the 1 st air supply part 45 in this example). Also, since the through-holes 70 are present, the function of drying the casting film 29 by the air supply from the air supply drying unit 41 (the 1 st air supply part 45 in this example) is maintained, thereby reliably promoting the drying of the casting film 29.
Since the respective opening ratios of the opposed surface 42a and the opposed surface 42b are 35% or more, the drying of the casting film 29 by the air supply from the air supply drying unit 41 (the 1 st air supply part 45 in this example) is more reliably promoted than the case of less than 35%. Since the aperture ratios of the opposed surface 42a and the opposed surface 42b are in the range of 70% or less, variation in the film surface of the casting film 29 due to the air supply from the air supply drying unit 41 (the 1 st air supply unit 45 in this example) is more reliably suppressed than in the case of being larger than 70%.
When the distance D between the belt 23 and the web 42 is 5mm or more, the contact with the traveling belt 23 is more reliably avoided and the variation of the film surface of the casting film 29 is more reliably suppressed, compared with the case of less than 5mm, and the film 11 with improved smoothness can be more reliably obtained. Further, when the distance D is 50mm or less, the variation of the film surface of the casting film 29 is more reliably suppressed than the case of being larger than 50 mm.
Since the section from the casting position PC to the air supply drying unit 41 is a section for transporting the casting film 29 immediately after formation, the transport path of the casting film 29 is the one in which the amount of the evaporated solvent is the largest. Therefore, this section is a section where the convection of the formed boundary layer is large. As described above, in the present example, the web 42 is provided between the casting position PC and the air supply drying unit 41, and therefore, the variation in the film surface of the casting film 29 due to the boundary layer is more reliably suppressed.
The above-described breeze region tends to cause a large convection of the boundary layer, and the web 42 is provided in the breeze region, so that the variation in the film surface of the casting film 29 due to the boundary layer is more reliably suppressed.
While the film 11 formed by peeling the casting film 29 from the belt 23 (peeling process) is conveyed by the tenter 14, the drying is promoted by the drying wind from the duct 14b, and is extended in the width direction by the clips 14 a. The film 11 is further dried by a roller drying device 15. In this manner, the film 11 is dried by the tenter 14 and the roller drying device 15 (film drying step). After the side portion is removed by the slitter 16, the sheet is wound into a roll by the winding device 17.
[ 2 nd embodiment ]
In embodiment 2, a drum is used as the casting support. Hereinafter, embodiment 2 will be described with reference to fig. 4. The embodiment 2 is the same as the embodiment 1 except that the drum 123 is used instead of the conveyor belt 23 and the air-supply drying unit 141 is used instead of the air-supply drying unit 41. In fig. 4, the same reference numerals as those in fig. 1 to 3 denote the same components and the like as those in embodiment 1, and therefore, the description thereof will be omitted.
The casting device 113 includes a die 28 for discharging the dope 21, and a drum 123 disposed below the die 28 for casting the dope 21 on a circumferential surface 123 a. A driving device (not shown) is connected to the drum 123, and a controller (not shown) is connected to the driving device. The drum 123 is rotationally driven around a rotation shaft 123b by a driving device controlled by a controller. Thereby, the circumferential surface 123a of the drum 123 rotates in a predetermined direction at a predetermined speed. The circumferential surface 123a functions as a casting surface. Therefore, in this example, the rotation direction of the circumferential surface 123a of the drum 123 is set to the traveling direction X of the casting support. A decompression chamber (not shown) may be provided upstream in the traveling direction X of the die 28.
The inside of the chamber 51 of the casting device 113 and the drum 123 are set to a temperature at which the casting film 29 is cooled and solidified (gelled). A flow path for the heat transfer medium is formed inside the drum 123, and the heat transfer medium at a predetermined temperature by a temperature controller (not shown) passes through the flow path. In this way, the temperature of the circumferential surface 123a is maintained at a predetermined value by the temperature controller. The heat transfer medium is more preferably a liquid than a gas from the viewpoint of easy handling and easy temperature control. The temperature of the peripheral surface 123a is appropriately set according to the kind of the solvent of the dope 21, the kind of the solid content, the concentration of the solid content in the dope 21, the time to the stripping position, and the like. The temperature of the peripheral surface 123a is preferably maintained at-10 ℃ or higher and 10 ℃ or lower. A temperature control device (not shown) is provided to maintain the temperature in the chamber 51 at a predetermined value. The temperature in the chamber 51 is appropriately set according to the temperature of the dope 21 during casting and the temperature of the peripheral surface 123 a.
The air supply drying unit 141 includes the 2 nd air supply unit 46, the 2 nd air discharge unit 49, and the 3 rd air supply unit 47. These are disposed in the vicinity of the circumferential surface 123a, and the 2 nd air supply portion 46, the 2 nd air discharge portion 49, and the 3 rd air supply portion 47 are arranged in this order from the upstream side in the traveling direction X.
In this example, the 2 nd air supply unit 46 is disposed in the vicinity of the downstream side of the end edge 42e (see fig. 5) of the net 42, the 3 rd air supply unit 47 is disposed in the vicinity of the upstream side of the peeling position PP, and the 2 nd air discharge unit 49 is disposed at a substantially intermediate position between the 2 nd air supply unit 46 and the 3 rd air supply unit 47. As shown in fig. 5, the edge 42e is a downstream edge of the web 42 in the traveling direction X. The positions where the 2 nd air supply part 46, the 3 rd air supply part 47, and the 2 nd air exhaust part 49 are arranged are not limited to these positions, and may be in the vicinity of the peripheral surface 123a from the casting position PC toward the peeling position PP. The number of the air supply portions and the air discharge portions is not limited to this, and may be set to a number corresponding to the length of the peripheral surface 123a or the like.
The 2 nd gas supply part 46 and the 3 rd gas supply part 47 discharge the heated dry gas, and the 2 nd gas discharge part 49 sucks and discharges the gas. Here, the drum 123, the mold 28, the 2 nd air supply part 46, the 3 rd air supply part 47, the 2 nd air discharge part 49, and the like are accommodated inside the chamber 51 blocked from the external space, and the 2 nd air discharge part 49 discharges the sucked gas to the outside of the chamber 51. The supply air drying unit 141 includes an air blowing controller 52 outside the chamber 51.
The web 42 is preferably disposed between the casting position PC and the air supply drying unit 141. In the air supply drying unit 141, the 2 nd air supply part 46 is located on the upstream side closest to the casting position PC in the traveling direction X, and therefore, in this example, the web 42 is disposed in a state of facing the circumferential surface 123a from the casting position PC to the 2 nd air supply part 46. The net 42 has a curved shape along the circumferential surface 131a, and is provided in a state of being separated from the circumferential surface 131 a. The web 42 is larger than the width of the casting film 29 in the width direction (depth direction of the paper surface in fig. 4) of the circumferential surface 123a orthogonal to the traveling direction X. That is, the web 42 is provided so as to cover the entire width of the casting film 29 in the width direction. In addition, a width direction orthogonal to the traveling direction X is denoted by a symbol Y (see fig. 6).
In the present embodiment, the casting support is the drum 123, and the distance D is the distance between the drum 123 and the web 42. In this example, the distance D is preferably in the range of 5mm to 50mm, more preferably in the range of 10mm to 30mm, and still more preferably in the range of 15mm to 25 mm. The distance D between the roller 123 and the web 42 is a distance between the circumferential surface 123a and an opposing surface 42a (see fig. 2) opposing the roller 123 of the web 42.
The drying of the casting film 29 is promoted by the air supply or exhaust from the 2 nd air supply part 46, the 2 nd air exhaust part 49, and the 3 rd air supply part 47 of the air supply drying unit 141.
After the casting film 29 is solidified to such an extent that it can be transported to the tenter 14, the casting film 29 is peeled from the drum 123 while being supported by the peeling roller 33. The casting film 29 peeled from the drum 123 becomes the film 11, and is guided to the tenter 14 by, for example, a guide roller.
Instead of the tenter 14, a tenter (not shown) having a plurality of pin plates (not shown) as holding members may be used. Each needle plate includes a plurality of needles, and the needles penetrate into the side portion of the film 11 to hold the film 11, and travel in the held state to convey the film 11. In this case, the tenter 14 that conveys the film 11 with both side portions of the film 11 gripped by clips may be appropriately provided between the above-described tenter provided with the pin plates and the slitter 16.
The film 11 fed out from the tenter 14 is guided to a slitter 16, and both side portions thereof are continuously cut and removed. In the present embodiment, the so-called edge slitting step is performed between the tenter 14 and the roll drying device 15, but may be performed between the roll drying device 15 and the winding device 17 instead of or in addition to this.
The section between the casting position PC and the air supply drying unit 141 where the convection of the boundary layer formed is large in the absence of the web 42 is provided, but since the web 42 is provided between the casting position PC and the air supply drying unit 141, the convection of the boundary layer is suppressed similarly to the embodiment 1 even when the drum 123 is used as the casting support, and as a result, the variation of the film surface of the casting film 29 is more reliably suppressed.
[ embodiment 3 ]
Embodiment 3 will be described with reference to fig. 5 and 6. Embodiment 3 of the present invention is an embodiment in which a wind blocking member is provided in embodiment 2. Embodiment 3 is the same as embodiment 2 except that a wind blocking member is provided, and in fig. 5 and 6, the same reference numerals as those in fig. 1 to 4 are given as in embodiment 2, and therefore, the description thereof is omitted.
The wind shielding members are disposed so as to face the end edges 42c, 42d, 42e, and 42f of the net 42 and so as to protrude further toward the drum 123 than the net 42. As shown in fig. 6, the edge 42c and the edge 42d are side edges that are edges of the net 42 in the width direction Y. As shown in fig. 5, the edge 42f is an upstream edge of the web 42 in the traveling direction X. The wind blocking member is a member for blocking wind flowing into a gap (hereinafter referred to as a gap) 90 between the casting support (in this example, the drum 123) and the web 42. As shown in fig. 5 and 6, in the present embodiment, a wind shielding plate 81 extending in the width direction Y and wind shielding walls 82L and 82R extending in the traveling direction X are used as wind shielding members. As shown in fig. 6, the wind shielding wall 82L is a left wind shielding wall facing the traveling direction X, and the wind shielding wall 82R is a right wind shielding wall. The wind shielding plate 81 is provided in a substantially rectangular plate-like member extending in the width direction Y in an upright posture with respect to the peripheral surface 123a, and the wind shielding wall 82 is provided in a wall-like shape in a substantially rectangular plate-like member extending in the traveling direction X in an upright posture with respect to the peripheral surface 123 a.
The wind deflector 81 extends in the width direction Y and is disposed on the downstream side of the net 42 in the traveling direction X in a state of being separated from the drum 123. The wind deflector 81 is narrowed to seal an opening (hereinafter, referred to as a 1 st opening) on the downstream side in the traveling direction X of the gap 90, and is disposed in a state of facing the end edge 42e of the net 42 and protruding toward the drum 123 side than the net 42, thereby receiving the wind flowing into the gap 90. Similarly, the wind shielding wall 82L and the wind shielding wall 82R extend in the traveling direction X and are provided on both sides of the net 42 in the width direction Y in a state of being separated from the drum 123. In fig. 5, the wind shielding wall 82L is not shown in order to avoid complication of the drawing. The wind shielding walls 82L and 82R are arranged so as to face the end edges 42c and 42d of the net 42 and so as to protrude toward the drum 123 side from the net 42, respectively, so as to close the opening (hereinafter, referred to as the 2 nd opening) in the width direction Y of the gap 90, and thereby receive the wind flowing into the gap 90.
In fig. 6, the traveling direction X is the direction toward the front of the paper. Therefore, the net 42 is provided in the back side direction of the wind deflector 81. In fig. 6, the die 28 in the back side direction of the web 42 is not shown in order to avoid complication of the drawing. The wind-shielding plate 81 is disposed so as to face the downstream edge 42e of the net 42 and so as to protrude toward the drum 123 side from the net 42. This partially seals the 1 st opening, thereby blocking the wind flowing into the gap 90. In the present embodiment, the wind deflector 81 is shaped to protrude above the net 42 in the vertical direction with respect to the circumferential surface 123 a. However, since the wind deflector only needs to seal the gap 90 at the 1 st opening, it only needs to be disposed in a state of protruding further toward the drum 123 than the net 42, and is not limited to a protruding state upward in the vertical direction with respect to the circumferential surface 123 a.
The net 42 is in contact with the wind blocking wall 82L on the left side and the wind blocking wall 82R on the right side in the traveling direction X, of the end edges 42c and 42d on both sides in the width direction Y. In the following description, when wind blocking wall 82L and wind blocking wall 82R are not distinguished from each other, they will be referred to as wind blocking wall 82. The wind shielding wall 82 partially seals the gap 90 at the 2 nd opening, thereby shielding the wind flowing between the drum 123 and the mesh 42. In the present embodiment, the wind shielding wall 82 is formed to protrude upward in the vertical direction with respect to the circumferential surface 123a of the drum 123 than the net 42. However, the wind shielding wall only needs to seal the gap 90 at the 2 nd opening, and therefore, it only needs to be disposed in a state of protruding further toward the drum 123 than the net 42, and is not limited to a protruding state toward the upper portion in the vertical direction with respect to the circumferential surface 123 a.
Here, the distance between the wind deflector and the casting support is D2. In this example, the casting support is the drum 123, and thus the distance D2 is the distance between the lower end face 81a of the wind deflector 81 and the circumferential surface 123 a. The distance D2 is preferably in the range of 1mm to 50mm, more preferably 2mm to 30mm, and still more preferably 2mm to 10 mm. In this example, the distance D2 is, for example, 5 mm.
Further, a distance between the wind shielding wall and the casting support was D3. In this example, the casting support is the drum 123, and thus the distance D3 is a distance between the face 82a of the wind shielding wall 82L opposite to the end edge 42c of the web 42 and the face 123c of the drum 123 opposite to the wind shielding wall 82L, and a distance between the face 82a of the wind shielding wall 82R opposite to the end edge 42D of the web 42 and the face 123c of the drum 123 opposite to the wind shielding wall 82R. The distance D3 is preferably in the range of 1mm to 50mm, more preferably 2mm to 30mm, and still more preferably 2mm to 10 mm. If the distance D3 is within this range, the same distance may be used or different distances may be used.
In the present embodiment, the net 42 and the wind shielding plate 81 are disposed in a state of contact, and the net 42 and the wind shielding wall 82 are disposed in a state of contact. This can block the wind flowing into the gap 90, and further suppress the fluctuation of the solvent in the boundary layer and promote the drying of the casting film 29 by the mesh 42 whose upper portion is open. As the wind shielding member, it is preferable to use (use) a wind shielding plate 81 and a wind shielding wall 82 in combination. Also, the net 42 and the wind blocking member may be integrally formed.
The operation of the above structure will be explained. The casting film 29 is conveyed through the drum 123 and thus conveyed along the circumferential surface 123a of the drum 123. Therefore, in terms of the shape of the drum 123, the dry gas supplied from the gas supply unit may become not only a fluid parallel to the casting film 29 but also a wind partially perpendicular to the film surface of the casting film 29 due to the influence of the exhaust from the 2 nd exhaust unit 49 and the travel of the drum 123. The air corresponding to the vertical direction or the like may generate a counter air against the casting film 29 during conveyance, that is, a back air. Sometimes a part of the blowback air blows into the gap 90 to disturb convection through the boundary layer on the casting film 29 of the web 42. Moreover, the concentration of the solvent gas is lower than that of the boundary layer. Therefore, when the counter blow is blown into a convection portion where the concentration of the solvent gas is relatively high, which is just cast and is not dried, the concentration of the solvent gas is different, which causes a large fluctuation in the concentration of the solvent gas. Further, the larger the fluctuation of the solvent gas concentration, the more serious the drying unevenness of the casting film 29 becomes. The drying unevenness is not preferable because it causes unevenness in thickness of the film 11 and deteriorates smoothness of the film 11.
On the conveyance path of the casting film 29, there is a mesh 42, and a wind blocking member that blocks the wind flowing into the gap 90 is provided. By combining the web 42 and the wind shielding member, it is possible to more reliably promote drying of the casting film 29 and suppress convection in the boundary layer on the casting film 29, and suppress fluctuation of the gas concentration.
The wind blocking member is a wind blocking plate 81 extending in the width direction Y, and is provided at the downstream end of the net 42 in a state of being separated from the drum 123. When the distance D2 between the wind-shielding plate 81 and the drum 123 is in the range of 1mm to 50mm, the wind-shielding plate 81 and the mesh 42 are used together while avoiding contact with the running drum 123 more reliably than in the case of less than 1mm, thereby more reliably suppressing variation in the film surface of the casting film 29 and more reliably obtaining the film 11 with improved smoothness. Further, the distance D2 is 50mm or less, and thus the variation of the film surface of the casting film 29 is more reliably suppressed by using together with the wind-shielding plate 81 and the mesh 42 than in the case of being larger than 50 mm.
The wind shielding walls 82 extending in the traveling direction X are provided in a state of being separated from the web 42 on both sides of the end edge 42c side and the end edge 42D side, and the distance D3 between the wind shielding walls 82 and the drum 123 is in the range of 1mm or more and 50mm or less, thereby more reliably suppressing the variation of the film surface of the casting film 29 and more reliably obtaining the film 11 with improved smoothness.
[ 4 th embodiment ]
Embodiment 4 of the present invention is an embodiment in which a wind blocking member is provided in embodiment 1. The 4 th embodiment is the same as the 1 st embodiment except that a wind shielding member is further provided, and in fig. 7 and 8, the same reference numerals as those in fig. 1 to 6 are given to the same portions, and therefore, the description thereof is omitted. In fig. 7, the wind shielding wall 82L and the end edge 42c are not shown in order to avoid complication of the drawing. In fig. 8, the 2 nd air supply part 46 is not shown in order to avoid complication of the drawing. In the present embodiment, since the net 42 is provided in the breeze area, the wind guard 81, the wind blocking wall 82L, and the wind blocking wall 82R are also provided in the breeze area. Wind deflector 81, wind shielding wall 82L, and wind shielding wall 82R are provided in a state of being in contact with mesh 42. The wind-shielding plate 81 is disposed in a state of facing the end edge 42e of the net 42, and the wind-shielding wall 82L and the wind-shielding wall 82R are disposed in a state of facing the end edge 42c and the end edge 42d of the net 42, respectively.
The wind shielding member is a member for shielding the wind flowing into the gap 90, suppressing convection in the boundary layer on the casting film 29, and suppressing fluctuation of the gas concentration, and is preferably provided as close as possible to the casting film 29. Therefore, in this example, the position where the wind shielding wall 82 is provided in the width direction Y is at a portion of the casting surface 23a but without the casting film 29, that is, above both end portions in the width direction Y of the casting surface 23 a.
In this example, the casting support is the belt 23, and thus the distance D2 is the distance between the lower end face 81a of the wind shielding plate and the casting face 23 a. Also, in this example, the casting support is the belt 23, so the distance D3 is a distance between the lower end face 82b of the wind shielding wall 82R and the casting face 23a or a distance between the lower end face 82b of the wind shielding wall 82L and the casting face 23 a.
The wind blocking member is a wind blocking plate 81 extending in the width direction Y, and is provided at the downstream end of the net 42 in a state of being separated from the conveyor belt 23. When the distance D2 between the wind shielding plate 81 and the belt 23 is in the range of 1mm to 50mm, the contact with the traveling belt 23 is more reliably avoided than in the case of less than 1mm, and the variation of the film surface of the casting film 29 is more reliably suppressed by using the web 42, and the film 11 with improved smoothness is more reliably obtained. Further, when the distance D2 is 50mm or less, the variation of the film surface of the casting film 29 is more reliably suppressed by using the mesh 42 than the case of being larger than 50 mm.
The wind shielding walls 82 extending in the traveling direction X are provided in a state of being separated from the belt 23 on both sides of the end edge 42c side and the end edge 42D side, and the distance D3 between the wind shielding walls 82 and the belt 23 is in the range of 1mm or more and 50mm or less, thereby more reliably suppressing the variation of the film surface of the casting film 29 and more reliably obtaining the film 11 with improved smoothness. Further, since the wind shielding wall 82 is provided at a position in the width direction Y on the casting surface 23a but not on the casting film 29, that is, above both ends in the width direction Y of the casting surface 23a of the casting film 29, it is possible to more reliably prevent the film surface of the casting film 29 from being affected by blowback air or the like.
[ 5 th embodiment ]
In embodiment 5 of the present invention, a wind shield plate 81b and an auxiliary wind shield member are further provided as wind shield members in embodiment 4. The 5 th embodiment shown in fig. 9A and 9B is the same as the 4 th embodiment except that a wind shield plate 81B and an auxiliary wind shield member are further provided, and in fig. 9A and 9B, the same reference numerals as those in fig. 1 to 8 are given to the same parts, and therefore, the description thereof is omitted. In fig. 9A and 9B, the wind shielding wall 82L is not shown in order to avoid complication of the drawings. In the present embodiment, a wind deflector 81b is provided on the upstream side of the net 42 in the traveling direction X, and auxiliary wind deflectors 83a, 83b, and 83c that contact the facing surface 42a (see fig. 2) of the net 42 and extend in the width direction Y are provided as auxiliary wind deflecting members. In the following description, the sub wind deflector 83a, 83b, 83c is referred to as the sub wind deflector 83 unless distinguished from each other. The number of the auxiliary wind deflectors 83 may be only 1, or may be plural, and in this example, 3 auxiliary wind deflectors 83a, 83b, and 83c are provided. In the embodiment shown in fig. 9B, the wind deflector 81B itself shown in fig. 9A is not provided, and the mold 28 functions as the wind deflector 81B as will be described later.
As shown in fig. 9A (a) and (B), the wind-shielding plate 81B is provided in a state of being separated from the conveyor belt 23 on the upstream side of the net 42 in the traveling direction X. The wind-shielding plate 81b is disposed so as to face the upstream end edge 42f of the net 42 and so as to protrude toward the conveyor belt 23 side from the net 42. Therefore, the die 28, the wind-shielding plate 81b, and the net 42 are arranged in this order from the upstream side to the downstream side in the traveling direction X. The wind-shielding plate 81b seals a part of an opening (hereinafter, referred to as a 3 rd opening) on the upstream side of the gap 90 in the traveling direction X. The wind-shielding plate 81b is only required to open the sealing gap 90 at the 3 rd opening, and therefore, is only required to be disposed in a state of protruding more toward the conveyor belt 23 than the web 42, and is not limited to a protruding state upward in the vertical direction with respect to the casting surface 23 a. The distance D21 (not shown) between the wind deflector 81b and the conveyor belt 23 is preferably in the range of 1mm to 50 mm. In this example, the distance D21 and the distance D2 between the wind deflector 81b and the conveyor belt 23 are the same. In this example, the wind-shielding plate 81b is disposed in contact with the net 42. Similarly, the wind-blocking plate 81 and the wind-blocking wall 82L, the wind-blocking plate 81 and the wind-blocking wall 82R, and the wind-blocking plate 81 and the mesh 42 are provided in a state of being in contact with each other.
As described above, fig. 9B is a diagram in which the surface (hereinafter, referred to as a side surface) 28a on the downstream side in the traveling direction X of the die 28 functions as the wind-shielding plate 81B of fig. 9A. The edge 42f of the net 42 is in contact with the side surface 28 a. The side surface 28a contacts the wind shielding wall 82L and the wind shielding wall 82R. As the wind deflector or the wind shielding wall, any one may be used as long as the opening of the gap 90 can be closed, and thus, as in this example, a mold or another device may be used.
As shown in fig. 9A (a) and 9B, the auxiliary wind deflectors 83a, 83B, and 83c are rod-shaped members that contact the facing surface 42a (see fig. 2) of the net 42 and extend in the width direction Y. The auxiliary wind guard 83 is disposed so as to face the casting surface 23a and so as to protrude toward the conveyor belt 23 side from the web 42. The distance D22 (not shown) between the auxiliary wind deflector 83 and the conveyor belt 23 is preferably in the range of 1mm to 50 mm. In this example, the distance D22 between the auxiliary wind deflector 83 and the conveyor belt 23 is the same as the distance D2 between the wind deflector 81 and the conveyor belt 23. In this example, the auxiliary wind deflectors 83a, 83b, and 83c are arranged in the order of the reference numerals 83c, 83b, and 83a from the upstream side to the downstream side in the traveling direction X in a state of being in contact with the net 42 at substantially equal intervals with respect to the length of the net 42 in the traveling direction X. The auxiliary wind deflectors 83a, 83b, and 83c are not necessarily arranged at equal intervals. The auxiliary wind-shielding plate 83 is a rod-like member having almost the same length in the width direction Y as the wind-shielding plate 81 or the wind-shielding plate 81b and arranged in contact with the wind-shielding wall 81R and the wind-shielding wall 81L, and is arranged in contact with the facing surface 42a of the net 42. In this example, all the auxiliary wind deflectors 83a, 83b, and 83c have almost the same length in the width direction Y as the wind deflector 81 and the wind deflector 81 b. One or both of the wind deflector 81b and the auxiliary wind deflector 83 may be used.
By providing the wind shielding plate 81b and/or the auxiliary wind shielding plate 83 in addition to the wind shielding plate 81 and/or the wind shielding wall 82, it is possible to effectively suppress generation of a large convection of gas in the boundary layer on the casting film 29 which is not dried immediately after flowing out from the die 28.
[ 6 th embodiment ]
Embodiment 6 of the present invention is an embodiment in which an auxiliary windshield member is further provided in embodiment 3. The 6 th embodiment shown in fig. 10 and 11 is the same as the 5 th embodiment except that an auxiliary wind shield member is further provided, and in fig. 10, the same reference numerals as those in fig. 5 and 6 are given to the same parts as those in fig. 3 or 2, and therefore, the description thereof is omitted. In the present embodiment, in addition to the wind blocking member, auxiliary wind blocking walls 84aR, 84aL, 84bR, and 84bL as wall-shaped members that come into contact with the facing surface 42a (see fig. 2) of the drum 123 of the net 42 and extend in the traveling direction X (the depth direction of the paper in fig. 10 and 11) are provided as auxiliary wind blocking members. In the following description, the auxiliary wind shielding walls 84aR, 84aL, 84bR, and 84bL will be referred to as the auxiliary wind shielding walls 84 unless otherwise specified. The auxiliary wind shielding walls 84 are provided on both right and left sides toward the traveling direction X. As the auxiliary wind shielding wall 84, one of an auxiliary wind shielding wall 84aR and an auxiliary wind shielding wall 84aL (hereinafter, referred to as "auxiliary wind shielding wall 84 a" when they are not distinguished) provided outside the casting film 29 as shown in fig. 10, and an auxiliary wind shielding wall 84bR and an auxiliary wind shielding wall 84bL (hereinafter, referred to as "auxiliary wind shielding wall 84 b" when they are not distinguished) provided on the casting film 29 as shown in fig. 11 is provided depending on the installation position in the width direction Y. The auxiliary wind shielding walls 84 are provided on both sides of the web 42 in the width direction Y in a state of being separated from the drum 123. The auxiliary wind shielding wall 84 is disposed in contact with the facing surface 42a of the net 42 and is disposed in a state of protruding toward the drum 123 side from the net 42. Therefore, the auxiliary wind shielding wall 84 is set in a state of being in contact with the opposed surface 42a of the mesh 42. The auxiliary wind shielding wall may be disposed in the gap 90 so as to protrude further toward the drum 123 than the net 42, and is not limited to a protruding state toward the upper portion in the vertical direction with respect to the circumferential surface 123 a.
As shown in fig. 10, the auxiliary wind shielding wall 84aR and the auxiliary wind shielding wall 84aL are disposed at positions in the width direction Y at the peripheral surface 123a of the drum 123 but at portions where the casting film 29 is absent, that is, both end portions 123aL, 123aR in the width direction Y of the peripheral surface 123 a. The auxiliary wind shielding wall 84aR and the auxiliary wind shielding wall 84aL are provided in a state of being in contact with the facing surface 42a of the net 42 above the both end portions 123aL, 123 aR. As shown in fig. 10(a), the auxiliary wind shielding wall 84a is set in a state of being separated from the drum 123. The distances D31 between the auxiliary wind shielding walls 84aL and 84aR and the drum 123 are preferably in the range of 1mm to 50mm, respectively.
As shown in fig. 11, the positions of the auxiliary wind shielding wall 84bR and the auxiliary wind shielding wall 84bL in the width direction Y are at portions not belonging to the product width (product region) 29P of the casting film 29, that is, both end portions 29SL, 29SR in the width direction Y of the casting film 29. The auxiliary wind shielding wall 84bR and the auxiliary wind shielding wall 84bL are provided in a state of being in contact with the opposed surface 42a of the net 42 above the both end portions 29SL and 29 SR. As shown in fig. 11(a), the auxiliary wind shielding wall 84b is provided in a state of being separated from the casting film 29, and the distances D32 between the auxiliary wind shielding wall 84bL and the auxiliary wind shielding wall 84bR and the drum 123 are preferably in the range of 1mm to 50mm, respectively. In this example, the auxiliary wind shielding walls 84bL, 84bR are set in a state of being in contact with the net 42.
By providing the auxiliary wind shielding wall 84a or the auxiliary wind shielding wall 84b in addition to the wind shielding plate 81 and/or the wind shielding wall 82, it is possible to effectively suppress generation of a large convection of gas in the boundary layer on the casting film 29 immediately after flowing out from the die 28 and without being dried.
Examples and comparative examples are given below. The details are described in examples, and only the conditions different from those in examples are described in comparative examples.
Examples
[ example 1] to [ example 20]
A film 11 was produced by a solution film-forming apparatus 10, and examples 1 to 20 were obtained. In table 1, when the metal mesh 42 is used as the porous member, the column of "kind of porous member" is described as "metal mesh", and when the porous plate is used, it is described as "porous plate". The thickness of the porous plate was 1mm, and the through-holes were arranged in a matrix at an angle of 60 °. In table 1, the "installation section" indicates an installation section of the porous member in the longitudinal direction of the conveyor belt 23. The "entire area" indicates a case of being provided in the entire area from the casting position PC to the peeling position PP, and the "before drying" indicates a case of being provided in a section from the casting position PC to the air supply drying unit 41, that is, a case of being provided between the casting position PC and the air supply drying unit 41. The "breeze area" indicates a case where the device is installed in the breeze area. In table 1, a column of "installation section" indicates "o" indicating the installation. Mucilage 21 was prepared by dissolving the solid components of mucilage 21 in a mixture of methylene chloride and methanol. The solid content of cement 21 is as follows. The conditions are shown in Table 1.
TAC 17.1 parts by mass
1 st plasticizer 1.7 parts by mass
0.7 part by mass of the No. 2 plasticizer
The sample sheet 62 (see fig. 12) obtained by sampling each film 11 obtained in a sheet form was evaluated for smoothness and wrinkling according to the following method and criteria. The evaluation results are shown in table 1.
1. Smoothness of the surface
The smoothness evaluation method is explained with reference to fig. 12. First, as a sample evaluation plate, a smooth glass plate 61 was prepared. A laminate 64 in which the glass plate 61, the sample sheet 62, and the black PET film 63 were laminated was prepared by attaching the sample sheet 62 to one surface of the glass plate 61 and attaching the black PET (polyethylene terephthalate) film 63 to the other surface. An optical transparent adhesive sheet (not shown) is used for the attachment. In the smoothness evaluation system provided with the fluorescent lamp 67, the laminate 64 was placed so that the sample sheet 62 faced upward. In the smoothness evaluation system, an observation point PW is set, and an image of the fluorescent lamp 67 reflected on the sample sheet 62 is observed from the observation point PW. As the fluorescent lamp 67, a 40W straight tube type fluorescent lamp having a tube diameter of 32.5mm was used.
The place where the stacked body 64 is placed is set to be horizontal, whereby the upper surface of the sample piece 62 is set to be horizontal. Further, the fluorescent lamp 67 extending in one direction is also arranged horizontally in the longitudinal direction, and the fluorescent lamp 67 and the upper surface of the sample piece 62 are parallel to each other. The fluorescent lamp 67 and the observation point PW were set to the same height, and the place where the stacked body 64 was placed was positioned so that the incident angle of light from the fluorescent lamp 67 to the sample sheet 62 became 60 ° and observation was possible at the reflection angle (i.e., 60 °), and an image of the fluorescent lamp 67 was observed from the observation point PW at the center 62c of the upper surface of the sample sheet 62. The distance between the fluorescent lamp 67 and the center 62c of the upper surface of the sample piece 62 and the distance between the observation point PW and the center 62c are both set to 2m, and denoted by reference symbol L1 in fig. 12. In fig. 12, the incident angle and the reflection angle are denoted by a symbol θ 1, and an outer contour line Li of the image of the fluorescent lamp 67 in a state where the light of the fluorescent lamp 67 is irradiated is drawn by a two-dot chain line. The outer contour line Li is observed as a straight line when the smoothness of the sample sheet 62 is extremely good, but is observed as a line having a larger wave pattern as the smoothness is worse.
When the laminate 64 is rotated with the center 62c as the rotation center in a state where the light of the fluorescent lamp 67 is irradiated, the image of the fluorescent lamp 67 reflected on the sample sheet 62 is observed at the observation point PW, and the rotation of the laminate 64 is stopped at a position where the amplitude of the outer contour line Li of the image is maximum, and the posture thereof is determined as the posture to be evaluated. The maximum value among the amplitudes of the outer contour line Li was set to V1, the width of the image corresponding to the width (diameter) of the fluorescent lamp was set to V2, and the value obtained by the calculation formula of V1/V2 was evaluated according to the following criteria, and this was used as the evaluation of smoothness. A is passed, B and C are failed. When there is an amplitude in the outer contour line Li, the dimension from the center of the amplitude of one outer contour line Li to the center of the amplitude of the other outer contour line Li is V2.
A: less than 1/10
B: 1/10 above and below 1/5
C: 1/5 or more
2. Crinkling
Depending on the drying conditions of the casting film 29, the solvent content ratio of the peeling position PP becomes high, and wrinkles are generated in the film 11 on the peeling roller 33, and wrinkles are also confirmed on the sample sheet 62. Therefore, the sample sheet 62 was visually observed, and the evaluation of wrinkling was performed according to the criteria described below. A is qualified, B is unqualified.
A: no wrinkles were confirmed in the sample sheet.
B: wrinkles were confirmed in the sample sheet.
After example 1 in which wrinkling was evaluated as B was performed, the traveling speed of the conveyor belt 23 was slightly decreased (specifically, in example 1, the traveling distance per 1 minute was decreased by 10%), and the film 11 was produced again under the same conditions as in example 1, except that the conditions were not changed. The film 11 thus obtained was evaluated for smoothness and wrinkles, and smoothness and wrinkles were evaluated for a in the same manner as in example 1, and wrinkles were improved in comparison with example 1, and evaluated for a.
After example 17 in which wrinkling was evaluated as B was performed, the traveling speed of the conveyor belt 23 was slightly decreased (specifically, in example 17, the traveling distance per 1 minute was decreased by 10%), and the film 11 was produced again under the same conditions as in example 17, except that the conditions were unchanged. The film 11 thus obtained was evaluated for smoothness and wrinkles, and smoothness and wrinkles were evaluated for a in the same manner as in example 17, and wrinkles were improved in comparison with example 17, and evaluation for a was obtained.
Comparative examples 1 to 5
Films were produced according to the conditions shown in table 1. Other conditions were the same as in the examples.
Smoothness and wrinkles were evaluated in the same manner and in the same criteria as in examples. The evaluation results are shown in table 1.
[ Table 1]
Figure BDA0002011530180000231
[ example 21] to [ example 30]
The film 11 was produced as examples 21 to 30 by replacing the casting device 13 of the solution film-forming apparatus 10 of fig. 1 with a solution film-forming apparatus (not shown) of the casting device 113 shown in fig. 5 and 6. The conditions are shown in Table 2. Similarly to example 15, the web 42 was provided in the "before-drying" zone, i.e., the zone from the casting position PC to the air supply drying unit 141, and in the breeze zone. The wind shielding plate 81 and the wind shielding walls 82L and 82R are disposed in close contact with the net 42 to close the gap 90 between the drum 123 and the net 42. In table 2, as described above, the "wind deflector installation distance" is the distance D2 between the wind deflector 81 and the drum 123, and the "wind deflector installation distance" is the distance D3 between the drum 123 and the wind deflector 82, and is the distance from the circumferential surface 123 c. The rest is the same as in example 15.
The sample sheet 62 (see fig. 12) obtained by sampling each film 11 obtained in a sheet shape was evaluated for smoothness and wrinkling in the same manner as in the example. The smoothness evaluation criteria are as follows. The evaluation results are shown in table 2.
AAA: no judgment (no amplitude of the outer contour line Li, i.e. V1 ═ 0)
AA: greater than 0 and less than 1/20
A: 1/20 above and below 1/10
B: 1/10 above and below 1/5
C: 1/5 or more
[ Table 2]
Figure BDA0002011530180000251

Claims (12)

1. A solution film-forming method comprising the steps of:
a casting film forming step of continuously casting a dope in which a polymer is dissolved in a solvent on a running casting support to form a casting film;
a cast film drying step of drying the cast film; and
a peeling step of peeling the casting film having passed through the casting film drying step from the casting support to form a film,
a porous member having a through hole with a diameter of at most 7mm formed therein is provided to face a casting surface of the casting support in a separated state,
the porous member is provided in a region in a range where a wind speed is greater than 0m/s and 1m/s or less in a state where travel of the casting support is stopped,
the wind flowing between the casting support and the porous member is blocked by a wind blocking member,
the wind shielding component is composed of a wind shielding plate and a wind shielding wall,
the wind shield extends in a width direction orthogonal to a traveling direction of the casting support, is provided on a downstream side of the porous member in the traveling direction of the casting support in a state of being separated from the casting support, is disposed in a state of facing an end edge on the downstream side of the porous member, and protrudes further toward the casting support than the porous member,
the wind shielding walls extend in a traveling direction of the casting support, are provided on both sides of the porous member in a width direction orthogonal to the traveling direction of the casting support in a state of being separated from the casting support, are arranged in a state of facing end edges of both sides of the porous member in the width direction, and protrude further toward the casting support than the porous member,
the wind deflector and the wind deflector wall are disposed in a state of contact with the porous member.
2. The solution film-forming method according to claim 1,
the porous member is a mesh or a porous plate.
3. The solution film-forming method according to claim 1,
the opening ratio of the member surface having the opening formed by the through hole is in a range of 35% to 70%.
4. The solution film-forming method according to claim 2,
the opening ratio of the member surface having the opening formed by the through hole is in a range of 35% to 70%.
5. The solution film-forming method according to claim 1,
the distance between the casting support and the porous member is in a range of 5mm or more and 50mm or less.
6. The solution film-forming method according to claim 2,
the distance between the casting support and the porous member is in a range of 5mm or more and 50mm or less.
7. The solution film-forming method according to claim 3,
the distance between the casting support and the porous member is in a range of 5mm or more and 50mm or less.
8. The solution film-forming method according to claim 4,
the distance between the casting support and the porous member is in a range of 5mm or more and 50mm or less.
9. The solution film-making method according to any one of claims 1 to 8,
the cast film drying step is to dry the cast film by a drying device disposed in a state of facing the casting surface of the casting support.
10. The solution film-forming method according to claim 9,
the porous member is disposed between a casting position where the dope is cast and the drying device.
11. The solution film-forming method according to claim 1,
the distance between the wind deflector and the casting support is in the range of 1mm to 50 mm.
12. The solution film-forming method according to claim 1,
the distance between the wind shielding wall and the casting support is in the range of 1mm to 50 mm.
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