CN110280449B - Coating apparatus and method for producing coating film - Google Patents

Coating apparatus and method for producing coating film Download PDF

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Publication number
CN110280449B
CN110280449B CN201910203847.2A CN201910203847A CN110280449B CN 110280449 B CN110280449 B CN 110280449B CN 201910203847 A CN201910203847 A CN 201910203847A CN 110280449 B CN110280449 B CN 110280449B
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coating
coating liquid
liquid layer
layer
layers
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CN110280449A (en
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道平创
三宅雅士
那须徹雄
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Nitto Denko Corp
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Nitto Denko Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C11/00—Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00
    • B05C11/10—Storage, supply or control of liquid or other fluent material; Recovery of excess liquid or other fluent material
    • B05C11/1002—Means for controlling supply, i.e. flow or pressure, of liquid or other fluent material to the applying apparatus, e.g. valves
    • B05C11/1015—Means for controlling supply, i.e. flow or pressure, of liquid or other fluent material to the applying apparatus, e.g. valves responsive to a conditions of ambient medium or target, e.g. humidity, temperature ; responsive to position or movement of the coating head relative to the target
    • B05C11/1023—Means for controlling supply, i.e. flow or pressure, of liquid or other fluent material to the applying apparatus, e.g. valves responsive to a conditions of ambient medium or target, e.g. humidity, temperature ; responsive to position or movement of the coating head relative to the target responsive to velocity of target, e.g. to web advancement rate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C13/00—Means for manipulating or holding work, e.g. for separate articles
    • B05C13/02—Means for manipulating or holding work, e.g. for separate articles for particular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C5/00—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work
    • B05C5/02—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work the liquid or other fluent material being discharged through an outlet orifice by pressure, e.g. from an outlet device in contact or almost in contact, with the work
    • B05C5/0254—Coating heads with slot-shaped outlet
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C5/00—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work
    • B05C5/02—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work the liquid or other fluent material being discharged through an outlet orifice by pressure, e.g. from an outlet device in contact or almost in contact, with the work
    • B05C5/027—Coating heads with several outlets, e.g. aligned transversally to the moving direction of a web to be coated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C9/00—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important
    • B05C9/06—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important for applying two different liquids or other fluent materials, or the same liquid or other fluent material twice, to the same side of the work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/26—Processes for applying liquids or other fluent materials performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/36—Successively applying liquids or other fluent materials, e.g. without intermediate treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/007—After-treatment

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  • Application Of Or Painting With Fluid Materials (AREA)
  • Coating Apparatus (AREA)

Abstract

The invention provides a coating apparatus and a method for producing a coating film. The coating device includes a coating unit that coats one or more 1 st coating liquid layers that are coated on a coating object first and move together with the coating object with a subsequent 2 nd coating liquid layer, and is configured to cure the 1 st and 2 nd coating liquid layers to form a coating film, and is configured to: a dimensionless speed of a moving speed of an interface between the 1 st coating liquid layer and the 2 nd coating liquid layer with respect to a moving speed of the coating object and a length of a downstream lip of the coating section satisfy a specific equation.

Description

Coating apparatus and method for producing coating film
Technical Field
The present invention relates to a coating apparatus and a method for producing a coating film.
Background
Conventionally, as one type of coating apparatus, for example, a die coater has been used which sequentially discharges coating liquids from a plurality of coating units onto a coating object such as a substrate which is relatively moving, thereby continuously forming a plurality of coating liquid layers in a layered manner.
The die coater has a plurality of die heads as coating sections for ejecting a coating liquid and coating it on a coating object along a moving direction of the coating object. The die coating mechanism comprises: after a coating liquid layer is applied to a relatively moving coating object by an upstream-most coating section, a next coating liquid layer is applied before the previously applied coating liquid layer is cured in order from a next coating section to a downstream-most coating section, and then each coating liquid layer is cured to form a coating film (a laminate of each coating film layer) (see patent document 1).
Documents of the prior art
Patent document
Patent document 1: japanese patent laid-open No. 2000-185254
Disclosure of Invention
Problems to be solved by the invention
However, in the above-described coating apparatus, when a next coating liquid layer is applied on a previously applied coating liquid layer, the previously applied coating liquid layer may be deformed by the next coating liquid being discharged. Also, as the previously applied coating liquid layer is deformed, the next coating liquid layer may be deformed. As described above, if a problem occurs that the next coating liquid layer cannot be applied properly on the previously applied coating liquid layer, a coating film of desired quality cannot be obtained.
Therefore, it is desirable to appropriately coat the next coating liquid layer on the previously coated coating liquid layer.
On the other hand, in order to perform appropriate coating, it is necessary to set the production conditions to appropriate conditions, but from the viewpoint of work efficiency, it is preferable that the production conditions be in a wide range.
In view of the above, an object of the present invention is to provide an application apparatus and a method for producing a coating film, which can perform application in which the spreading of a previously applied coating liquid layer is suppressed when the next coating liquid layer is applied to the coating liquid layer under a wide range of production conditions.
Means for solving the problems
The coating device of the present invention comprises a coating section which coats a 2 nd coating liquid layer by discharging the next 2 nd coating liquid layer onto one or more 1 st coating liquid layers which are formed by discharging one or more 1 st coating liquids onto a coating object and are not cured and move relatively with the movement of the coating object,
the coating apparatus is configured to form a coating film by curing the 1 st coating liquid layer and the 2 nd coating liquid layer,
the coating section has an upstream lip and a downstream lip which are arranged so as to form a slit with a distance therebetween in a moving direction of the coating object, and is configured to discharge the 2 nd coating liquid onto the 1 st coating liquid layer from the slit,
the coating device comprises: the moving speed of the coating object is set as uw(m/s) and u represents the moving speed of the interface between the 1 st coating liquid layer and the 2 nd coating liquid layerc(m/s) ofcAnd uwThe ratio is a dimensionless velocity (-) expressed by the following formula (1), and the downstream side is set to beWhen the length of the lip in the moving direction is X (mm) and the dimensionless speed is Y, the X and Y satisfy the following formula (2).
[ number 1 ]
Figure BDA0001998328750000021
μpre: the smallest viscosity (Pa s) among the viscosities of the one or more coating solutions 1
μc: viscosity (Pa. s) of the coating solution 2
hG: a distance (m) between the interface and the downstream lip
hpre: total thickness (m) of the one or more 1 st coating liquid layers
ρpre: the maximum density (kg/m) among the densities of the one or more first coating liquids 13)
g: acceleration of gravity (m/s)2)
Number 2
Y≥0.0179×2+0.0638×+0.2···(2)
In the coating apparatus having the above-described configuration, it is also possible,
x is 0.1 to 4 inclusive.
The method for producing a coating film of the present invention is a method for producing a coating film using the coating apparatus, wherein,
the method for producing the coating film comprises the following steps:
applying a 2 nd coating liquid layer by discharging a subsequent 2 nd coating liquid onto one or more 1 st coating liquid layers that are formed by discharging one or more 1 st coating liquids onto a coating object first and are uncured and move relatively with the movement of the coating object; and
and curing the 1 st and 2 nd coating liquid layers to obtain a coating film.
Drawings
Fig. 1 is a schematic side view showing a coating apparatus according to an embodiment of the present invention.
Fig. 2 is a schematic side view schematically showing an example of the 1 st and 2 nd liquid coating layers applied by the application device of the present embodiment.
Fig. 3 is a schematic side view schematically showing an example of the 1 st and 2 nd liquid coating layers applied by the application device of the present embodiment.
Fig. 4 is a schematic side view schematically showing an example of the 1 st and 2 nd liquid coating layers applied by the application device of the present embodiment.
Fig. 5 is a schematic side view schematically showing the periphery of the 2 nd coating section of the coating apparatus in fig. 1 together with the movement speed of the 1 st coating liquid layer.
Fig. 6 is a schematic side view showing an enlarged area S in fig. 5.
Fig. 7 is a schematic side view schematically showing the force applied to the 1 st coating liquid layer in fig. 5.
Fig. 8 is a schematic side view schematically showing the periphery of the 2 nd coating section arranged to discharge the 2 nd coating liquid downward in the vertical direction together with the gravity acting on the 1 st coating liquid layer.
Fig. 9 is a schematic side view schematically showing the periphery of the 2 nd coating section when the 2 nd coating liquid layer is coated on the plurality of 1 st coating liquid layers, together with the moving speed of the 1 st coating liquid layer.
Fig. 10 is a schematic side view schematically showing the entire plurality of the 1 st coating liquid layer in fig. 9 as one coating liquid layer.
Fig. 11 is a schematic side view schematically showing a state in which the 1 st coating liquid layer and the 2 nd coating liquid layer are deformed.
Fig. 12 is a graph showing the relationship between the length (X) of the downstream lip portion of the second coating section 2, the dimensionless speed (Y), and the coating state for each of the X value and the Y value in test example 1.
Fig. 13 is a graph obtained by adding the approximation formula and the approximation line calculated from the graph in fig. 12 to the graph in fig. 12.
Fig. 14 is a graph in which approximate expressions and approximate lines are extracted from the graph of fig. 13 and shown.
Fig. 15 is a graph showing the relationship between the distance (gap) between the 2 nd interface and the downstream lip of the 1 st coating liquid layer, the length of the downstream lip, and the droplet pressure applied to the 1 st coating liquid layer (japanese: ビード pressure) in test example 2.
Description of the reference numerals
1. A coating device; 5. 1 st coating part; 7a, a downstream lip; 8. a slot; 15. a 2 nd coating section; 17a, a downstream lip; 18. a slot; 27. a curing section; 31. a coating object; 33. 1, coating liquid; 35. 1, coating liquid layer; 37. 1, coating a film layer; 43. the 2 nd coating liquid; 45. a 2 nd coating liquid layer; 47. 2, coating a film layer; 50. and (6) coating.
Detailed Description
First, a coating apparatus according to an embodiment of the present invention will be described with reference to the drawings.
As shown in fig. 1, 5 and 6, the coating apparatus 1 of the present embodiment includes a coating section 15, the coating section 15 coating a 2 nd coating liquid layer 45 by discharging a subsequent 2 nd coating liquid 43 onto one or more 1 st coating liquid layers 35 which are formed by discharging one or more 1 st coating liquids 33 onto a coating object 31 and are applied without curing and which relatively move with the movement of the coating object 31,
the coating apparatus 1 is configured to cure the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 to form a coating film 50,
the coating section 15 has an upstream lip 16a and a downstream lip 17a, the upstream lip 16a and the downstream lip 17a are arranged so as to form a slit 18 with a distance therebetween in the moving direction M of the coating object 31, the coating section 15 is configured to discharge the 2 nd coating liquid 43 from the slit 18 onto the 1 st coating liquid layer 35,
the coating device 1 is configured to: the moving speed of the coating object 31 is set as uw(m/s) and u is the moving speed of the interface 35b between the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45c(m/s) of ucAnd uwWhen the ratio of the downstream lip 17a to the downstream lip 17a is a dimensionless velocity (-) expressed by the following equation (1), the length of the downstream lip in the moving direction is X (mm), and the dimensionless velocity is Y, X and Y satisfy the following equation (2).
[ number 3 ]
Figure BDA0001998328750000051
μpre: the smallest viscosity (Pa. s) among the viscosities of the one or more coating liquids 33 of the 1 st coating liquid
μc: viscosity (Pa. s) of the coating solution 43 of the 2 nd part
hG: a distance (m) between the 2 nd boundary 35b and the downstream lip 17a
hpre: total thickness (m) of the one or more 1 st coating liquid layers 35
ρpre: the maximum density (kg/m) among the densities of the one or more coating liquids 33 of the 1 st coating liquid3)
g: acceleration of gravity (m/s)2)
[ number 4 ]
Y≥0.0179×2+0.0638×+0.2···(2)
Fig. 1 illustrates a mode in which the 2 nd coating liquid layer 45 is coated on one 1 st coating liquid layer 35 coated on the coating object 31 in advance, but the number of the 1 st coating liquid layers 35 coated in advance is not particularly limited as will be described later.
The coating apparatus 1 of the present embodiment further includes a coating section 5, the coating section 5 being located on an upstream side of the coating section 15 in the moving direction M of the coating object 31 and having an upstream lip 6a and a downstream lip 7a, the upstream lip 6a and the downstream lip 7a being arranged so as to form a slit 8 by being spaced apart from each other in the moving direction M of the coating object 31, and the coating section 5 being configured to discharge the coating liquid 33 of the 1 st order from the slit 8 onto the coating object 31 prior to the coating section 15.
In the coating apparatus of the present invention, the coating section 5 is not limited to the configuration capable of performing slot die coating in this manner. For example, the coating section 5 may be configured to be capable of gravure coating.
Hereinafter, the application section 5 to which the 1 st coating liquid layer 35 is applied first is referred to as a 1 st application section 5, and the application section 15 to which the 2 nd coating liquid layer 45 is applied later is referred to as a 2 nd application section 15.
The coating apparatus 1 further includes a curing unit 27, and the curing unit 27 is configured to cure the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 applied by the 1 st coating unit 5 and the 2 nd coating unit 15, respectively, to form the coating film layers 37 and 47.
The coating apparatus 1 further includes a support portion 25, and the support portion 25 supports the coating object 31 with a surface and moves relatively to the 1 st coating portion 5 and the 2 nd coating portion 15 in a longitudinal direction of the coating object 31.
The coating object 31 is not particularly limited, and may be, for example, a band-shaped sheet member.
The sheet member may be, for example, a resin film. Further, as the resin film, for example, lumiror (registered trademark) manufactured by dongli corporation and the like can be cited.
The support portion 25 supports the application object 31 moving in the longitudinal direction from the side opposite to the 1 st application portion 5 and the 2 nd application portion 15. The 1 st coating section 5 and the 2 nd coating section 15 sequentially apply the coating object 31 supported by the support section 25 and relatively moving with respect to the 1 st coating section 5 and the 2 nd coating section 15.
The support portion 25 may be a roller.
In the present embodiment, the support portion 25 moves the application target 31 from one side (left side in fig. 1) to the other side (right side in fig. 1) with respect to the slit 8 of the 1 st application portion 5 at a position facing the slit 8.
The support portion 25 moves the application object 31 from below (below in fig. 1) to above (above in fig. 1) together with the 1 st coating liquid layer 35 at a position facing the slit 18 of the 2 nd coating portion 15.
The curing unit 27 is configured to cure the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 to form the coating film layers 37 and 47. The cured portion 27 is cured to form a coating film 50 which is a laminate of the coating film layer 37 and the coating film layer 47. The curing section 27 is not particularly limited as long as the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 can be cured. The curing section 27 can be set as appropriate according to the type of the 1 st coating liquid 33 and the 2 nd coating liquid 43, and the like.
In the present embodiment, dies having slits 8 and 18 are used as the 1 st coating section 5 and the 2 nd coating section 15. The coating apparatus 1 including the die as such is called a die coater.
The 1 st coating section 5 ejects the previous 1 st coating liquid 33 from the slit 8 before the 2 nd coating liquid layer 45 is applied, and sequentially applies the 1 st coating liquid layer 35 on the coating object 31 which is relatively moving.
The 1 st coating section 5 is disposed so that the slit 8 faces upward, and discharges the 1 st coating liquid 33 toward the coating object 31 moving in the left-right direction with respect to the slit 8. The 1 st coating liquid 33 is supplied from a storage section (not shown) for the 1 st coating liquid 33 to the 1 st coating section 5 via a pipe (not shown) and a pump (not shown).
Specifically, the 1 st coating section 5 includes an upstream side die block 6 and a downstream side die block 7 disposed opposite to the upstream side die block 6. The 1 st coating section 5 is formed by aligning an upstream die block 6 and a downstream die block 7. By thus pairing the two die blocks 6 and 7, a manifold 9 for storing the 1 st coating liquid 33 supplied by a pump (not shown) and a slit 8 arranged from the manifold 9 toward the distal edge are formed therebetween. Further, a gap between an upstream lip 6a as a tip edge of the upstream die block 6 and a downstream lip 7a as a tip edge of the downstream die block 7 becomes an ejection port of the slit 8.
The upstream side lip 6a and the downstream side lip 7a are arranged so as to be located on a plane perpendicular to the radial direction of the support portion 25. The slot 8 is arranged parallel to the radial direction of the support portion 25.
The 2 nd coating section 15 discharges the subsequent 2 nd coating liquid 43 from the slit 18 subsequent to the coating of the 1 st coating liquid layer 35, and sequentially coats the 2 nd coating liquid layer 45 on the 1 st coating liquid layer 35 on the coating object 31 which is relatively moving.
The 2 nd coating section 15 is disposed so that the slit groove 18 faces sideways, and discharges the 2 nd coating liquid 43 onto the 1 st coating liquid layer 35 moving in the up-down direction with respect to the slit groove 18. The 2 nd coating liquid 43 is supplied from a storage section (not shown) for the 2 nd coating liquid 43 to the 2 nd coating section 15 via a pipe (not shown) and a pump (not shown).
The 1 st coating section 5 and the 2 nd coating section 15 may be slot dies including a chamber for pressure reduction.
Specifically, the 2 nd coating section 15 includes an upstream side die block 16 and a downstream side die block 17 disposed opposite to the upstream side die block 16. The 2 nd coating section 15 is formed by aligning an upstream die block 16 and a downstream die block 17. By aligning the two die blocks 16 and 17 in this manner, a manifold 19 for storing the 2 nd coating liquid 43 supplied by a pump (not shown) and a slit 18 disposed from the manifold 19 toward the distal edge are formed therebetween. Further, a gap between an upstream lip 16a, which is a tip edge of the upstream die block 16, and a downstream lip 17a, which is a tip edge of the downstream die block 17, serves as an ejection port of the slit 18.
The upstream side lip 16a and the downstream side lip 17a are arranged to be located on a plane perpendicular to the radial direction of the support portion 25. The slot 18 is arranged parallel to the radial direction of the support portion 25.
The smaller the length of the downstream lip 17a is, the larger the range of the gap between the 1 st and 2 nd coating liquid layers 35 and 45 can be, without the 1 st and 2 nd coating liquid layers 45 running. From this viewpoint, the length of the downstream lip 17a is preferably 0.1mm or more and 4mm or less.
In the present embodiment, for example, as shown in fig. 2, the 1 st coating unit 5 and the 2 nd coating unit 15 may be configured to apply one continuous 1 st coating liquid layer 35 and one continuous 2 nd coating liquid layer 45, respectively, in a direction (width direction, left-right direction in fig. 2) perpendicular to the moving direction M of the coating object 31.
For example, as shown in fig. 3, the 1 st application unit 5 may be configured to apply a plurality of 1 st application liquid layers 35 spaced apart from each other in the width direction (the left-right direction in fig. 3), and the 2 nd application unit 15 may be configured to apply a plurality of 2 nd application liquid layers 45 corresponding to the 1 st application liquid layers 35, respectively.
For example, as shown in fig. 4, the 1 st coating unit 5 may be configured to apply a single continuous 1 st coating liquid layer 35 in the width direction (the left-right direction in fig. 4), and the 2 nd coating unit 15 may be configured to apply a plurality of 2 nd coating liquid layers 45 spaced apart from each other on the 1 st coating liquid layer 35.
The coating apparatus 1 of the present embodiment is configured to: the moving speed of the coating object 31 is set as uw(m/s) and u represents the moving speed of the interface 35b between the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45c(m/s) ofcAnd uwWhen the ratio of the two is a dimensionless speed (-) expressed by the above formula (1), the length of the downstream lip 17a of the 2 nd coating portion 15 is X (mm), and the dimensionless speed is Y, X and Y satisfy the above formula (2).
The following describes the above equations (1) and (2).
First, as shown in fig. 1, 5, and 6, a description will be given of a mechanism of suppressing the running-out of the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 when one coating liquid layer 35 is applied on the application target 31 and the next coating liquid layer 45 is applied on the one coating liquid layer 35, and derivation of the mathematical formula (1).
In fig. 1, since the 1 st coating liquid layer 35 moves to follow the coating object 31 as a whole before the 2 nd coating liquid layer 45 is coated on the 1 st coating liquid layer 35 between the 1 st coating unit 5 and the 2 nd coating unit 15, the moving speed of the 1 st coating liquid layer 35 is the same as the moving speed of the coating object 31 in the entire thickness direction. That is, the moving speed of the previous coating liquid layer is the same as the moving speed of the coating object 31 at any portion in the thickness direction.
In this state, as shown in fig. 5, even if the 2 nd coating liquid layer 45 is applied on the 1 st coating liquid layer 35, an interface (hereinafter, may be referred to as a 1 st interface) 35a between the 1 st coating liquid layer 35 and the coating object 31 follows the movement of the coating object 31 in the same manner as before the 2 nd coating liquid layer 45 is applied. Therefore, the moving speed of the 1 st interface 35a of the 1 st coating liquid layer 35 is the same as the moving speed of the coating object 31.
In contrast, the interface (hereinafter, may be referred to as "2 nd interface") 35b between the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 is difficult to follow the movement of the coating object 31 when the 2 nd coating liquid layer 45 is applied, and is delayed from the movement of the coating object 31. Therefore, the movement speed of the 2 nd interface 35b of the 1 st coating liquid layer 35 becomes smaller than that before the 2 nd coating liquid layer 45 is applied, and the movement speed of each portion becomes smaller toward the 2 nd interface 35b from the 1 st interface 35a in the thickness direction of the 1 st coating liquid layer 35. If the moving speed of the 2 nd interface 35b becomes too small, the 1 st coating liquid layer 35 may be distorted as shown in fig. 11. Accompanying this, the 2 nd coating liquid layer 45 also generates a distortion. The moving speed of the 2 nd interface 35b of the 1 st coating liquid layer 35 is the same as the moving speed of the 2 nd coating liquid layer 45.
Therefore, the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 can be prevented from being distorted by making the moving speed of the 2 nd interface 35b of the 1 st coating liquid layer 35 close to the moving speed of the coating object 31.
As shown in fig. 7, the factors that affect the decrease in the moving speed of the 2 nd interface 35b of the 1 st coating liquid layer 35 include a pressure gradient applied to the 1 st coating liquid layer 35 by the droplet pressure of the 2 nd coating liquid 43, gravity applied to the 1 st coating liquid layer 35, and a shearing force applied to the 2 nd interface 35b of the 1 st coating liquid layer 35 by the 2 nd coating liquid layer 45.
Therefore, they are applied to the theoretical formula of fluid mechanics (navier-stokes equation) based on physics and mathematics. In application, it is assumed that the coating object 31 does not flow in a direction (width direction) perpendicular to the moving direction M. By this application, the moving speed u of the 2 nd interface 35b of the 1 st coating liquid layer 35cCan pass through the moving speed u of the coating object 31wUsing the pressure gradient in the 1 st coating liquid layer 35
Figure BDA0001998328750000101
The pressure gradient term, the gravity term and the shear force term of (3) are expressed as the following equation (3)And (4) showing. As shown in the following equation (3), the moving speed of the 2 nd interface 35b of the 1 st coating liquid layer 35 is the moving speed u from the coating object 31wAnd subtracting the pressure gradient term, the gravity term and the shearing force term.
As shown in the following numerical formula (3), the pressure gradient term includes the thickness h of the 1 st coating liquid layer 35preViscosity μ of coating liquid 33 No. 1preAnd pressure gradient in layer 1 of coating liquid 35
Figure BDA0001998328750000102
Such an element.
The pressure gradient
Figure BDA0001998328750000103
Is a gradient (i.e., pressure distribution) in the moving direction M of the coating object 31 of the pressure applied to the 1 st coating liquid layer 35 by the droplet pressure of the 2 nd coating liquid 43 discharged from the slit 18 of the 2 nd coating section 15.
The pressure applied to the 1 st coating liquid layer 35 at a position upstream of the 2 nd coating section 15 (i.e., before the 2 nd coating liquid 43 is discharged) is 0 and is equal to the atmospheric pressure. In addition, x is a coordinate in which the moving direction (advancing direction) of the coating object 31 is positive.
The gravity term includes a density ρ of the 1 st coating liquid layerpreGravity acceleration g, and thickness h of the 1 st coating liquid layer 35preAnd viscosity μ of coating solution 33 No. 1preAnd an angle θ formed by the moving direction of the application object 31 and the direction in which gravity acts.
The shear force term includes the thickness h of the 1 st coating liquid layer 35preViscosity μ of coating liquid 33 No. 1preViscosity μ of coating liquid 43 No. 2cAnd a moving speed u of the 2 nd interface 35b of the 1 st coating liquid layer 35cAnd a distance (gap) h between the 2 nd interface 35b of the 1 st coating liquid layer 35 and the downstream lip 17aGSuch an element.
[ number 5 ]
Figure BDA0001998328750000111
μpre: viscosity (Pa. s) of coating solution 33 No. 1
μc: viscosity (Pa. s) of the coating solution 43 of the 2 nd part
hG: a distance (m) between the 2 nd boundary 35b and the downstream lip 17a
hpre: thickness (m) of the 1 st coating liquid layer
ρpre: density (kg/m) of the 1 st coating liquid layer3)
g: acceleration of gravity (m/s)2)
θ: an angle (degree) formed by the moving direction M of the coating object 31 and the direction of gravity application
Then, if the obtained expression (3) is modified to show the moving speed u of the 2 nd interface 35b of the 1 st coating liquid layer 35cAnd the moving speed u of the coating object 31wRatio of (u)c/uw) The following formula (4) can be obtained.
[ number 6 ]
Figure BDA0001998328750000112
Here, the pressure gradient in the 1 st coating liquid layer 35
Figure BDA0001998328750000113
Is affected by the length of the downstream lip 17a of the 2 nd coating part 15.
Thus, for pressure gradients
Figure BDA0001998328750000114
Instead of considering the length of the downstream lip 17a, the pressure gradient is set to 0 (zero) in the above equation (4)
Figure BDA0001998328750000115
Figure BDA0001998328750000116
This makes it possible to obtain the following expression (5).
[ number 7 ]
Figure BDA0001998328750000117
As described above, the moving speed u of the 2 nd interface 35b of the 1 st coating liquid layer 35cMoving speed u close to coating object 31wPreferably, therefore uc/uwIt is preferable to approach 1.
Here, cos θ is a value of-1 to 1 inclusive (-1. ltoreq. cos θ. ltoreq.1).
As shown in fig. 5, when cos θ is 180 °, when — ρ is set to "1 ═ 180 °pregcos θ max (- ρ)pregcosθ＝ρpreg) .1. the Therefore, if a value other than cos θ is constant, u of the above equation (5)c/uwAnd minimum.
On the other hand, when cos θ is 1 and θ is 0 °, in this case, - ρ ═ ppregcos θ minimum (- ρ)pregcosθ＝－ρpreg) In that respect Therefore, if a value other than cos θ is constant, u of the above formula (5) is constantc/uwMax (not shown).
And, in the case where 0 ° < θ < 180 °, uc/uwA value between a value when θ is 0 ° and a value when θ is 180 °.
For example, as shown in fig. 8, when the 2 nd coating unit 15 is disposed so that the slit 18 thereof faces downward and discharges the 2 nd coating liquid 43 onto the 1 st coating liquid layer 35 moving from one side (right side in fig. 8) to the other side (left side in the figure) with respect to the slit 18, θ is 90 ° and cos θ is 0. Thus, in this case, uc/uwA value between a value when θ is 180 ° and a value when θ is 0 °. When cos θ is 0, the mathematical formula (3) can be made independent of the gravity term (gravity term is 0). That is, the gravity applied to the 1 st coating liquid layer 35 is not applied in the direction of running the 1 st coating liquid layer 35.
Thus, it is possible to provideWhen θ is 180 °, u is defined asc/uwThe most unfavorable condition for approaching 1.
Therefore, when θ is 180 ° in the above formula (5), the formula (1) is derived as follows. In the following formula (1), the ratio (u) of the moving speeds is expressedc/uw) Referred to as dimensionless speed.
[ number 8 ]
Figure BDA0001998328750000121
In the above formula (1), when the 2 nd coating liquid layer 45 is applied on one 1 st coating liquid layer 35 coated on the coating object 31, μpre、μc、hG、hpre、ρpreAnd g is as follows.
μpre: viscosity (Pa. s) of coating solution 33 No. 1
μc: viscosity (Pa. s) of the coating solution 43 of the 2 nd part
hG: a distance (m) between the 2 nd boundary 35b and the downstream lip 17a
hpre: thickness (m) of the 1 st coating liquid layer 35
ρpre: the density (kg/m) of the coating solution 33 of the No. 13)
g: acceleration of gravity (m/s)2)
Next, as shown in fig. 9, a description will be given of a mechanism of suppressing the running-out of the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 when the plurality of 1 st coating liquid layers 35 are applied on the coating object 31 and the next 2 nd coating liquid layer 45 is applied on the plurality of 1 st coating liquid layers 35, and derivation of the formula (1).
As shown in fig. 9, for example, the coating apparatus 1 includes N-1 coating units (N is an integer of 3 or more) of the 1 st to N-1 st as going from the upstream side to the downstream side in the moving direction M of the coating object 31, wherein the 1 st to N-1 st coating liquid layers 35 are first coated on the coating object 31 by the 1 st to N-1 st coating units (1 st coating units) 5, and the next 2 nd coating liquid layer 45 (nth coating liquid layer) is coated by the nth coating unit (2 nd coating unit) 15.
In this case, when the 2 nd coating liquid layer 45 is coated on the 1 st coating liquid layer 35 on the outermost side (N-1 st), the moving speed of each 1 st coating liquid layer 35 gradually decreases from the 1 st coating liquid layer 35 on the innermost side (1 st) to the 1 st coating liquid layer 35 on the outermost side. The moving speed of each 1 st coating liquid layer 35 also gradually decreases from the coating object 31 side to the 2 nd coating liquid layer 45 side. The moving speed of the interface between the 1 st coating liquid layer 35 and the coating object 31 is the same as the moving speed of the coating object 31, and is uwOn the other hand, the moving speed of the interface between the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 in the (N-1) th is the same as the moving speed of the 2 nd coating liquid layer 45, and is uc。
As described above, the moving speed of the plurality of 1 st coating liquid layers 35 as a whole decreases from the interface between the 1 st coating liquid layer 35 and the coating object 31 toward the interface between the N-1 st coating liquid layer 35 and the 2 nd coating liquid layer 45.
Further, if the moving speed of the interface between the N-1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 becomes too small, the plurality of 1 st coating liquid layers 35 are deformed, and along with this, the 2 nd coating liquid layer 45 is also deformed.
Therefore, by making the moving speed of the N-1 st coating liquid layer 35 close to the moving speed of the coating object 31, it is possible to suppress the occurrence of the meandering of the plurality of 1 st coating liquid layers 35 and 2 nd coating liquid layers.
In this way, if the entire plurality of 1 st coating liquid layers 35 is understood as one 1 st coating liquid layer 35, the mechanism of suppressing the occurrence of the meandering of the entire one coating liquid layer 35 and the 2 nd coating liquid layer 45 is the same as the above-described case of coating the 2 nd coating liquid layer 45 on the one coating liquid layer 35 (see fig. 5).
As a factor affecting the decrease in the moving speed from the 1 st interface 35a toward the 2 nd interface 35b, the pressure gradient, gravity, and the shearing force are applied to the entire plurality of 1 st coating liquid layers 35 as described above (see fig. 7).
Therefore, even when the 2 nd coating liquid layer 45 is applied to the plurality of 1 st coating liquid layers 35, the above formula (1) can be applied by considering the entirety of the plurality of 1 st coating liquid layers 35 as one 1 st coating liquid layer 35.
That is, with respect to the above mathematical formula (1), not only in the case where the next 2 nd coating liquid layer 45 is applied on the one 1 st coating liquid layer 35 previously coated on the coating object 31 (two-layer coating), but also in the case where the next 2 nd coating liquid layer 45 is applied on the two or more 1 st coating liquid layers 35 previously coated on the coating object 31 (3 layers or more are applied), the mathematical formula (1) can be applied in the same manner as the above two-layer coating by considering the two or more 1 st coating liquid layers 35 previously coated as the one 1 st coating liquid layer 35 as a whole.
In this case, in the mathematical formula (1), the interface between the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 at the outermost (N-1 st) side and the moving speed thereof are the 2 nd interface 35b of the plurality of 1 st coating liquid layers 35 and the moving speed thereof.
The thickness of the 1 st coating liquid layer 35 was the total thickness of the 1 st to N-1 st coating liquid layers 35.
On the other hand, in the numerical formula (1), μpreThe smaller uc/uwSmaller, and therefore less favorable, conditions. Therefore, the smallest viscosity among the viscosities of the plurality of 1 st coating liquids 33 is used as the representative value.
In the mathematical formula (1), ρpreThe larger u isc/uwSmaller and therefore less favorable conditions. Therefore, the largest viscosity among the viscosities of the plurality of 1 st coating liquids 33 is used as the representative value.
Therefore, in the formula (1), when the 2 nd coating liquid layer 45 is coated on the plurality of 1 st coating liquid layers 35 coated on the coating object 31, μpre、μc、hG、hpre、ρpreAnd g is as follows.
μpre: the smallest viscosity among the viscosities of the plurality of coating liquids 33 of the 1 st level (b) ((b))Pa·s)
μc: viscosity (Pa. s) of the coating solution 2
hG: a distance (m) between the 2 nd boundary 35b and the downstream lip 17a
hpre: total thickness (m) of the plurality of 1 st coating liquid layers 35
ρpre: the maximum density (kg/m) among the densities of the plurality of coating liquids 33 No. 13)
g: acceleration of gravity (m/s)2)
Thereafter, the above case is unified with the case where there is one first coating liquid layer 35 as described above as follows.
μpre: the smallest viscosity (Pa. s) among the viscosities of the one or more coating liquids 33 of the 1 st coating liquid
μc: viscosity (Pa. s) of the coating solution 2
hG: a distance (m) between the 2 nd boundary 35b and the downstream lip 17a
hpre: total thickness (m) of the one or more 1 st coating liquid layers 35
ρpre: the maximum density (kg/m) among the densities of the one or more coating liquids 33 of the 1 st coating liquid3)
g: acceleration of gravity (m/s)2)
In this way, the above equation (1) is derived.
In the formula (1), the dimensionless speed is an index indicating a degree to which the movement of the 2 nd interface 35b of the 1 st coating liquid layer 35 follows the movement of the coating object 31. That is, the dimensionless speed is closer to 1 as the moving speed of the 2 nd interface 35b of the 1 st coating liquid layer 35 is closer to the moving speed of the coating object 31, and the dimensionless speed becomes 1 when they are matched. Further, the closer the dimensionless speed is to 1, the easier the 1 st and 2 nd coating liquid layers 35 and 45 are to be coated without generating the offset.
Conversely, the larger (smaller) the moving speed of the 2 nd interface 35b of the 1 st coating liquid layer 35 is from the moving speed of the coating object 31, the smaller the dimensionless speed becomes toward 0 as it becomes from 1, and the more likely the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 are to be deformed.
In addition, in the formula (1), the pressure gradient is divided by the pressure gradient among the elements included in the pressure gradient term, the gravity term, and the shear force term
Figure BDA0001998328750000151
The dimensionless speed can be changed by changing the other elements (the manufacturing conditions). Thus, the amplitude of the range of values that dimensionless speed can take with the divided pressure gradient
Figure BDA0001998328750000152
The range of numerical values that can be used for each element other, that is, the range of manufacturing conditions, corresponds to the range of values that can be used for each element other.
Next, the derivation of the above equation (2) will be described.
As described above, the pressure gradient in the 1 st coating liquid layer 35 when the 2 nd coating liquid layer 45 is applied
Figure BDA0001998328750000153
Is affected by the length of the downstream lip 17a of the 2 nd coating part 15.
Therefore, the length of the downstream lip 17a affects the running of the 1 st coating liquid layer 35 when the 2 nd coating liquid layer 45 is applied.
On the other hand, the dimensionless speed also affects the running of the 1 st coating liquid layer 35 when the 2 nd coating liquid layer 45 is applied.
In this way, the numerical range of the length of the downstream lip of the 2 nd application part that can be applied becomes large or small depending on the degree of the numerical value of the dimensionless speed. Conversely, the numerical range of the dimensionless speed that can be applied becomes larger or smaller depending on the extent of the length of the downstream lip 17 a.
However, as shown in the example described later, when the length X and the dimensionless speed Y of the downstream lip 17a satisfy the range shown in the following equation (2), the 2 nd coating liquid layer 45 can be applied without leaving the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 in a random manner, and both the numerical range of X and the numerical range of Y can be expanded. In the examples described below, the following describes whether the 2 nd coating liquid layer 45 can be applied without leaving the 1 st coating liquid layer 35 as it is, that is, whether the desired 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 can be obtained under each condition, by applying the 2 nd coating liquid layer 45 on the 1 st coating liquid layer 35 while variously changing the length of the downstream lip 17a and variously changing the dimensionless speed.
As shown in the example described later, each dimensionless speed is taken as the y-axis, the length of the downstream lip 17a is taken as the x-axis, each dimensionless speed and the downstream lip 17a corresponding to each dimensionless speed are marked together with whether the coating state is good or not, and in the obtained graph, the mark closest to the coating state failure and the mark with the good coating state are selected for each downstream lip 17a, and the selected mark group is approximated by a quadratic expression, thereby obtaining the mathematical expression (2) which is an approximate expression.
[ number 9 ]
Y≥0.0179×2+0.0638×+0.2···(2)
In this way, equation (2) is derived.
According to the above-described expressions (1) and (2), when the 2 nd coating liquid layer 45 is applied, the application conditions of the application apparatus 1 can be determined so as to satisfy the above-described expression (2) by utilizing the relationship with the 1 st coating liquid layer 35 applied first.
The thickness of each of the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 can be appropriately set so as to satisfy the above-described expressions (1) and (2). The thickness can be adjusted by adjusting at least one of the discharge amount of the 1 st coating liquid 33 and the 2 nd coating liquid 43 from the 1 st coating section 5 and the 2 nd coating section 15 and the moving speed of the coating object 31, for example, in accordance with the viscosity of each of the 1 st coating liquid 33 and the 2 nd coating liquid 43.
For example, if the thicknesses of the 1 st and 2 nd coating liquid layers 35 and 45 are too small, it is difficult to coat the entire desired area, and if the thicknesses of the 1 st and 2 nd coating liquid layers 35 and 45 are too large, they may droop due to their own weight, and thus it tends to be difficult to coat them.
Therefore, in view of this point, for example, the thickness of the 1 st coating liquid layer 35 is preferably 0.01 μm or more and 1000 μm or less, and more preferably 0.1 μm or more and 500 μm or less.
For example, the thickness of the 2 nd coating liquid layer 45 is preferably 0.01 μm or more and 1000 μm or less, and more preferably 0.1 μm or more and 500 μm or less.
Each 1 st coating liquid 33 contains a curing component, and is cured on the coating object 31 after being applied on the coating object 31.
The 2 nd coating liquid 43 contains a curing component, and is applied on the 1 st coating liquid layer 35 and then cured on the 1 st coating liquid layer 35.
The types of the 1 st coating liquid 33 and the 2 nd coating liquid 43 can be set as appropriate so as to satisfy the above-described numerical expressions (1) and (2).
Examples of the coating liquid 1, 33 and 43 include polymer solutions, and examples of the material used as the curing component include a thermosetting material, an ultraviolet-curable material, and an electron beam-curable material.
Examples of the 1 st coating liquid 33 include adhesives such as primers and ultraviolet-curable adhesives, and liquid crystals.
The use of them would have the advantage of: the adhesion between the 2 nd coating liquid layer 45 and the coating object 31 is improved.
The viscosity of the 1 st coating liquid 33 is preferably 0.0005Pa · s or more and 30Pa · s or less, and more preferably 0.001Pa · s or more and 20Pa · s or less. The viscosity is a value measured by a measurement method described in examples described later.
When the viscosity of the coating liquid 1, 33, is 0.0005Pa · s or more, there is an advantage that: can be easily applied by a conventionally known application method.
When the viscosity of the 1 st coating liquid 33 is 30Pa · s or less, there is an advantage in that: the liquid can be easily supplied to the application unit 5 by a conventionally known liquid supply unit such as a pump.
Density ρ of coating liquid 33 No. 1prePreferably 600kg/m3～1400kg/m3More preferably 700kg/m3～1300kg/m3. The density is a value measured by a measurement method described in examples described later.
The thickness of the 1 st coating liquid layer 35 (the thickness of each coating liquid layer 35 when the 1 st coating liquid layer 35 is plural) is preferably 0.1 to 1000 μm, and more preferably 1 to 500 μm. The thickness is a value measured by a measurement method described in examples described later.
Examples of the coating liquid 2 43 include adhesives such as ultraviolet-curable adhesives, pressure-sensitive adhesives, and liquid crystals.
The viscosity of the 2 nd coating liquid 43 is preferably 0.0005 to 30Pa · s, more preferably 0.001 to 20Pa · s. The viscosity is a value measured by a measurement method described in examples described later.
When the viscosity of the coating liquid 43 of the 2 nd coating liquid is 0.0005Pa · s or more, there is an advantage that: can be easily applied by a conventionally known application method.
When the viscosity of the coating liquid 43 of the 2 nd coating liquid is 30Pa · s or less, there is an advantage that: the liquid can be easily supplied to the application unit 15 by a conventionally known liquid supply unit such as a pump.
Density ρ of coating liquid 43 No. 2prePreferably 600kg/m3～1400kg/m3More preferably 700kg/m3～1300kg/m3. The density is a value measured by a measurement method described in examples described later.
The thickness of the 2 nd coating liquid layer 45 is preferably 0.1 to 1000 μm, and more preferably 1 to 500 μm. The thickness is a value measured by a measurement method described in examples described later.
The 1 st coating liquid 33 and the 2 nd coating liquid 43 may be the same kind or different kinds.
When the 1 st coating liquid 33 and the 2 nd coating liquid 43 are different kinds, the viscosity of the 1 st coating liquid 33 is preferably higher than that of the 2 nd coating liquid 43.
The ejection amount of the 1 st coating liquid 33 from the slit 8 of the 1 st coating section 5 can be appropriately set so as to satisfy the expressions (1) and (2).
The discharge rate can be, for example, 0.01L/min to 50L/min.
The discharge amount of the 2 nd coating liquid 43 from the slit 18 of the 2 nd coating section 15 can be appropriately set so as to satisfy the expressions (1) and (2).
The discharge rate can be, for example, 0.01L/min to 50L/min.
The thickness of the object 31 to be coated is not particularly limited, but is preferably 20 μm to 100 μm, for example.
Fig. 1 shows a form in which the application object 31 is a long member having flexibility, but the application object 31 may be in a form of a single plate or a form having inflexibility.
The moving speed of the application object 31 can be adjusted by adjusting the rotation speed of the support portion 25, for example. The moving speed is preferably 1m/min to 300m/min, more preferably 5m/min to 50 m/min.
When the moving speed of the coating object 31 is 1m/min or more, the coating object can move more stably. For example, since the support portion 25 can be rotated more stably, the application object 31 can be moved more stably.
When the moving speed of the application object 31 is 300m/min or less, the wobbling and meandering of the application object 31 can be suppressed.
As described above, in the case of the coating apparatus 1 of the present embodiment, it is preferable that the 1 st coating liquid 33 has a viscosity of 0.0005Pa · s to 30Pa · s, the 2 nd coating liquid 43 has a viscosity of 0.0005Pa · s to 30Pa · s, and the moving speed of the coating object 31 is 1m/min to 300 m/min.
Next, a method for producing the coating film 50 of the present embodiment will be described.
The coating apparatus 1 is used in the method for producing the coating film 50 of the present embodiment.
The manufacturing method comprises the following steps:
a step of discharging a subsequent 2 nd coating liquid 43 from the 2 nd coating section 15 onto one or more 1 st coating liquid layers 35 which are formed by discharging and coating one or more 1 st coating liquids 33 onto the coating object 31 first, are uncured, and move relatively with the movement of the coating object 31, thereby coating a 2 nd coating liquid layer 45 (a subsequent coating step); and
the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 are cured to obtain a coating film 50.
In addition, the present embodiment further includes a step (previous coating step) of coating one or more 1 st coating liquid layers (one coating liquid layer in this case) 35 on the coating object 31 by one or more 1 st coating units 5 (one 1 st coating unit 5 in this case).
Specifically, in the method for producing the coating film 50 of the present embodiment, first, the length X and the dimensionless speed Y of the downstream lip 17a are set so as to satisfy the above equation (2).
In the setting of the dimensionless speed Y, the viscosity μ of the 1 st coating liquid 33 is set by adjusting the kinds and concentrations of the 1 st coating liquid 33 and the 2 nd coating liquid 43, the moving speed of the coating object 31, and the ejection amount from the 1 st coating section 5preViscosity μ of coating liquid 43 No. 2cAnd 1 st coating liquid layer 35, and a total thickness h pre1 density ρ of each coating liquid layerpre. The distance h between the 2 nd interface 35b of the 1 st coating liquid layer 35 and the downstream lip 17a is set by setting the arrangement of the 2 nd coating section 15G. Wherein the gravitational acceleration g is constant.
The length X of the downstream lip 17a of the 2 nd coating section 15 can be set when the die block 17 on the downstream side is manufactured.
Then, under the set conditions, the 1 st coating liquid 33 is discharged from the one or more 1 st coating units 5 onto the coating object 31 to coat the one or more 1 st coating liquid layers 35, and the 2 nd coating liquid 43 is discharged from the 2 nd coating unit 15 onto the 1 st coating liquid layer 35 to coat the 2 nd coating liquid layer 45. Next, the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 applied to the coating object 31 are cured by the curing section 27, and one or more 1 st coating film layers 37 and 2 nd coating film layers 47 (coating films 50 as a laminate thereof) are obtained.
When 3 or more coating liquid layers are to be applied to the coating object 31, the next coating liquid layer may be applied to the coating liquid layer previously applied so as to satisfy the above-described expressions (1) and (2) in the application of each of the 2 nd to nth coating liquid layers. Specifically, when a plurality of (N-1) th coating liquid layers 35 are to be applied to the application object 31, the 2 nd to N-1 st coating liquid layers 35 may be sequentially applied so as to satisfy the above expressions (1) and (2), and then, when the 2 nd coating liquid layer 45 is to be applied to the N-1 st coating liquid layer 35, the 2 nd coating liquid layer 45 may be applied so as to satisfy the above expressions (1) and (2).
With the above-described coating apparatus 1 and the method of producing the coating film 50 according to the present embodiment, the 2 nd coating liquid layer 45 is applied so that the relationship between the length X of the downstream lip 17a of the 2 nd coating section 15 and the dimensionless speed Y represented by the expression (1) satisfies the expression (2), and when the 2 nd coating liquid layer 45 is applied, the difference between the moving speed of the coating object 31 and the moving speed of the 2 nd interface 35b of the 1 st coating liquid layer 35 is reduced, so that the movement of the 2 nd interface 35b can sufficiently follow the movement of the coating object 31. Therefore, the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 can be coated with the 2 nd coating liquid layer 45 without unevenness.
Further, the range of the coating conditions under which coating can be performed without causing unevenness can be widened.
Therefore, when the next 2 nd coating liquid layer 45 is applied onto the 1 st coating liquid layer 35 applied previously, the application for suppressing the occurrence of the spreading of these coating liquid layers 35, 45 can be performed under a wide range of application conditions.
The coating apparatus 1 and the method for manufacturing the coating film 50 according to the present embodiment can be applied to, for example, a process material for forming a semiconductor chip.
In this case, the 1 st coating film layer 37 may be a die attach film, and the 2 nd coating film layer 47 may be a dicing tape. A laminate (coating film) 50 in which the 1 st coating film layer 37 and the 2 nd coating film layer 47 are laminated is laminated on a semiconductor chip such that the 1 st coating film layer 37 is positioned on the semiconductor wafer side, the semiconductor chip is cut so that a desired size and number of semiconductor chips can be obtained, and then the 2 nd coating film layer 47 is removed, and the exposed 1 st coating film layer 37 is laminated on another semiconductor chip.
The coating apparatus and the method for producing a coating film according to the present embodiment have the following advantages because they are configured as described above.
The present inventors have conducted extensive studies and found the following findings.
That is, when the next coating liquid layer is discharged onto the previously applied uncured coating liquid layer, the interface (1 st interface) between the previously applied coating liquid layer and the coating object follows the movement of the coating object, and therefore, the moving speed thereof is the same as the moving speed of the coating object. In contrast, the interface (2 nd interface) between the previously applied coating liquid layer and the next coating liquid layer is difficult to follow the movement of the application object due to the contact with the next coating liquid layer, and the movement speed thereof is lower than the movement speed of the application object. Further, if the moving speed of the 2 nd interface of the previously formed coating liquid layer is excessively lower than the moving speed of the coating object, the 2 nd interface becomes unable to follow the movement of the coating object. As a result, it was found that the coating liquid layer applied first was out-of-shape.
Further, in the case where the next coating liquid layer is applied to one coating liquid layer previously applied to the coating object (two coating layers) as described above, and in the case where the next coating liquid layer is applied to two or more coating liquid layers previously applied to the coating object (3 coating layers or more), the two or more coating liquid layers applied first can be understood as one coating liquid layer as a whole, and the occurrence of the coating liquid layer applied first can be found by the same mechanism as the two-layer coating.
Therefore, the present inventors have paid attention to the moving speed of the coating object and the moving speed of the interface (2 nd interface) between the 1 st coating liquid layer and the 2 nd coating liquid layer applied first, and have conducted earnest studies in order to apply the relationship between them to a theoretical formula of fluid mechanics (navier-stokes equation) based on physical and mathematical theories.
As a result, it was found that when the next 2 nd coating liquid layer is applied onto the one or more 1 st coating liquid layers applied previously, the moving speed of the 2 nd interface of the 1 st coating liquid layer can be expressed mathematically by the moving speed of the object to be coated, a pressure gradient term due to a pressure gradient generated in the 1 st coating liquid layer by the 2 nd coating liquid layer, a gravity term due to gravity applied to the 1 st coating liquid layer, and a shear stress term due to the moving speed of the 2 nd interface of the 1 st coating liquid layer.
If this equation is modified, it can be expressed as an equation of the ratio of the moving speed of the 2 nd interface of the 1 st coating liquid layer to the moving speed of the coating object.
Here, the present inventors have further conducted extensive studies and found that the pressure gradient generated in the above-described first coating liquid layer 1 is affected by the length of the downstream lip of the coating section (the length in the moving direction of the coating object) from which the second coating liquid layer 2 is discharged.
Therefore, the pressure gradient may be considered separately from the length of the downstream lip, and instead, the pressure gradient may be set to 0 (zero) in the expression indicating the ratio of the moving speeds, thereby completing the expression. In this formula, the ratio of the moving speeds is referred to as a dimensionless speed.
In this equation, the dimensionless speed is an index indicating the degree to which the 2 nd interface of the 1 st coating liquid layer follows the movement of the coating object.
In this formula, the width of the numerical range that can be used for the dimensionless speed corresponds to the width of the numerical range that can be used for each element (each manufacturing condition) other than the pressure gradient, and therefore corresponds to the width of the manufacturing condition that can be applied.
On the other hand, in consideration of the length of the downstream lip of the coating section as described above, the present inventors variously changed the length and the dimensionless speed, and further, applied the 2 nd coating liquid layer on the 1 st coating liquid layer, and earnestly studied whether or not desired 1 st and 2 nd coating liquid layers can be obtained without generating the bleeding of the 1 st coating liquid layer under each condition.
As a result, it was found that the ranges of the length of the downstream lip and the dimensionless speed, which can obtain the desired 1 st and 2 nd coating liquid layers, can be expressed by a specific relational expression, and the manufacturing conditions for coating can be widened by setting the respective manufacturing conditions so as to satisfy the relational expression, thereby completing the present embodiment.
That is, the coating apparatus 1 of the present embodiment includes the coating section 15, the coating section 15 discharges the next 2 nd coating liquid 43 onto the one or more 1 st coating liquid layers 35 which are formed by discharging and coating the one or more 1 st coating liquids 33 onto the coating object 31 first, are uncured, and move relatively with the movement of the coating object 31, to coat the 2 nd coating liquid layer 45,
the coating apparatus 1 is configured to cure the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 to form a coating film 50,
the coating section 15 has an upstream lip 16a and a downstream lip 17a, the upstream lip 16a and the downstream lip 17a are arranged so as to form a slit 18 with a distance therebetween in the moving direction M of the coating object 31, the coating section 15 is configured to discharge the 2 nd coating liquid 43 from the slit 18 onto the 1 st coating liquid layer 35,
the coating device 1 is configured to: the moving speed of the coating object 31 is set as uw(m/s) and u is the moving speed of the interface 35b between the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45c(m/s) ofcAnd uwWhen the ratio of the downstream lip 17a to the downstream lip 17a is a dimensionless velocity (-) expressed by the following equation (1), the length of the downstream lip in the moving direction is X (mm), and the dimensionless velocity is Y, X and Y satisfy the following equation (2).
[ number 10 ]
Figure BDA0001998328750000241
μpre: the smallest viscosity (Pa. s) among the viscosities of the one or more coating liquids 33 of the 1 st coating liquid
μc: viscosity (Pa. s) of the coating solution 43 of the 2 nd part
hG: a distance (m) between the boundary surface 35b and the downstream lip 17a
hpre: total thickness (m) of the one or more 1 st coating liquid layers 35
ρpre: the maximum density (kg/m) among the densities of the one or more coating liquids 33 of the 1 st coating liquid3)
g: acceleration of gravity (m/s)2)
[ number 11 ]
Y≥0.0179×2+0.0638×+0.2···(2)
With this configuration, by applying the 2 nd coating liquid layer 45 so that the relationship between the length X of the downstream lip 17a of the application section 15 and the dimensionless speed Y represented by the above equation (1) falls within a range that satisfies the above equation (2), the difference between the moving speed of the application object 31 when applying the 2 nd coating liquid layer 45 and the moving speed of the interface 35b between the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 is reduced, and therefore the movement of the interface 35b can sufficiently follow the movement of the application object 31. Therefore, the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 can be coated with the 2 nd coating liquid layer 45 without unevenness.
Further, the range of manufacturing conditions under which coating can be performed without causing any unevenness can be widened.
Therefore, the application in which the spreading of the coating liquid layers is suppressed when the next 2 nd coating liquid layer 45 is applied to the previously applied 1 st coating liquid layer 35 can be performed under a wide range of production conditions.
In the coating apparatus 1 configured as described above, the X may be 0.1 or more and 4 or less.
With this configuration, the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 can be more reliably applied without leaving a gap between the 2 nd coating liquid layer 45 and the 1 st coating liquid layer 35.
The method for producing a coating film of the present invention is a method for producing a coating film using the coating apparatus 1, wherein,
the method for producing the coating film comprises the following steps:
applying a 2 nd coating liquid layer 45 by discharging a subsequent 2 nd coating liquid 43 onto one or more 1 st coating liquid layers 35 which are formed by discharging and applying one or more 1 st coating liquids 33 onto the coating object 31, are uncured, and move relatively with the movement of the coating object 31; and
the 1 st coating liquid layer 35 and the 2 nd coating liquid layer 45 are cured to obtain a coating film 50.
In this configuration, since the 2 nd coating liquid layer 45 can be applied to the 1 st coating liquid layer 35 by the coating device 1, it is possible to perform coating in which the spreading of the coating liquid layers is suppressed when the next 2 nd coating liquid layer 45 is applied to the previously applied 1 st coating liquid layer 35 under a wide range of production conditions as described above.
As described above, according to the present embodiment, it is possible to provide an application apparatus and a method for producing a coating film, which can perform application in which the spreading of the coating liquid layer is suppressed when the next coating liquid layer is applied to the previously applied coating liquid layer under a wide range of production conditions.
The coating apparatus and the method for producing a coating film according to the present embodiment are as described above, but the present invention is not limited to the above embodiments, and can be appropriately designed and modified within the intended scope of the present invention.
[ examples ] A method for producing a compound
The present invention will be described in more detail with reference to test examples, but the present invention is not limited thereto.
Test example 1
(materials used)
The coating object: PET (polyethylene terephthalate) film (trade name: DIAFOIL, manufactured by Mitsubishi chemical corporation)
1 coating liquid: acrylic Polymer (trade name: Paracron, manufactured by Genseiko industries Co., Ltd.)
Density and viscosity: as shown in Table 1
Coating liquid 2: acrylic Polymer (trade name: ART CURE, manufactured by Geneva industries Co., Ltd.)
Density and viscosity: as shown in Table 1
The density and viscosity were measured by the following measurement methods.
(method of measuring Density)
The densities of the 1 st coating liquid and the 2 nd coating liquid were measured by placing a predetermined weight of the 1 st coating liquid and the 2 nd coating liquid in a measuring cylinder and measuring the volumes of the liquids.
(method of measuring viscosity)
The viscosities of the 1 st coating liquid and the 2 nd coating liquid were measured at a temperature of 21 to 25 ℃ and a shear rate of 100(1/s) using a rheometer (model No. RS1, manufactured by HAAKE) including a jig (a conical plate having a cone diameter of 25 to 50mm and a cone angle of 0.5 to 2 °).
(application of the No. 1 coating liquid layer and the No. 2 coating liquid layer)
The application of the 1 st coating liquid layer and the application of the 2 nd coating liquid layer were performed under the conditions shown in table 1 using an application apparatus such as that shown in fig. 1, and the application states of the 1 st coating liquid layer and the 2 nd coating liquid layer were evaluated.
The thicknesses of the 1 st and 2 nd coating liquid layers and the distance between the 2 nd interface of the 1 st coating liquid layer and the downstream lip of the 2 nd coating section were measured by the following methods.
The coating state was evaluated by the following method. The expression (2) is derived as follows.
The results are shown in table 1 and fig. 12 to 14. In fig. 12, the length X of the downstream lip of the 2 nd coating section is represented by X-axis, the dimensionless speed Y is represented by Y-axis, and the coating state at each length X and dimensionless speed Y is represented by a graph. Fig. 13 is a graph in which the approximate lines indicating the range of the group of marks closest to the coating failure and coated well (i.e., the boundary between the coating-good range and the coating failure) calculated in fig. 12 are collectively shown in the graph of fig. 12. Fig. 14 is a graph obtained by extracting only the approximate line from fig. 13.
(method of measuring thickness of No. 1 coating film layer and No. 2 coating film layer)
The 1 st and 2 nd coating liquid layers are applied and dried so that the width of the 1 st coating liquid layer (the length in the direction perpendicular to the moving direction of the coating object, the same applies hereinafter) is wider than the width of the 2 nd coating liquid layer, and thereby the 1 st and 2 nd coating film layers are formed. The thickness of only the 1 st coating film layer formed was measured by a linear meter (D-10 HS, manufactured by Kawasaki corporation). On the other hand, the thickness of the region where the 1 st coating layer and the 2 nd coating layer overlap each other is measured by the linear meter, and the thickness of the 1 st coating layer is subtracted from the measured thickness to calculate the thickness of the 2 nd coating layer. Thus, the thicknesses of the 1 st coating layer and the 2 nd coating layer were measured.
(method of measuring distance (gap) between No. 2 interface of No. 1 coating liquid layer and downstream lip)
The distance (gap) between the coating object 31 and the downstream lip is measured by measuring the distance using a taper gauge, and subtracting the thickness of the 1 st coating liquid layer from the measured distance. The thickness of the 1 st coating liquid layer was calculated from the measured value of the 1 st coating liquid layer and the volume concentration of the 1 st coating liquid.
(evaluation method of coating State)
The coating state was evaluated as follows.
The application state of the 1 st and 2 nd coating liquid layers was evaluated.
When the 1 st and 2 nd coating liquid layers that had been applied were obtained and the 1 st and 2 nd coating liquid layers that were obtained were visually observed, the case where no defect in appearance and the desired 1 st and 2 nd coating liquid layers were obtained was marked with "o", indicating that the coating was very good.
The 1 st and 2 nd coating liquid layers that have been applied were obtained, and when the 1 st and 2 nd coating liquid layers that were obtained were visually observed, the case where streaks were observed and the 1 st and 2 nd coating liquid layers that were substantially desirable were obtained was marked with "Δ", indicating that the coating was substantially good.
As shown in fig. 12, the 1 st coating liquid layer was out-of-shape due to the discharge of the 2 nd coating liquid layer, and the 2 nd coating liquid layer was out-of-shape along with this, and a case where the desired 1 st coating liquid layer and 2 nd coating liquid layer could not be obtained was marked as "x", indicating a defect.
(derivation method of the numerical expression (2))
The results in table 1 were substituted into the above equation (1), and each dimensionless speed was calculated.
The obtained dimensionless speeds are set as the y-axis, the lengths of the downstream lips are set as the x-axis, the respective dimensionless speeds and the lengths of the downstream lips corresponding to the respective dimensionless speeds are marked, and the result of the coating state is shown by the kind of the mark, thereby obtaining the graph of fig. 12.
In fig. 12, a mark closest to a mark indicating a poor coating condition ("x" mark) and indicating a good coating condition ("thick line o") is selected for each downstream lip, and the selected mark group is approximated by a quadratic expression, whereby a mathematical expression (2) as an approximate expression is obtained as shown in fig. 13 and 14.
[ TABLE 1 ]
Figure BDA0001998328750000281
As is clear from the graphs shown in fig. 12 to 14, the coating is performed so that X and Y satisfying the formula (2) are ranges where Y is equal to or greater than the approximate formula, and the coating state is good.
In addition, even when a plurality of 1 st coating liquid layers are applied first, the coating is performed such that X and Y satisfy the formula (2), and the coating state of the 1 st coating liquid layer and the 2 nd coating liquid layer is good.
Test example 2
The influence of the length of the downstream lip of the coating section on the liquid droplet pressure was examined by coating the coating object with a layer of the coating liquid.
(materials used)
The coating object: PET (polyethylene terephthalate) film (trade name: DIAFOIL, manufactured by Mitsubishi chemical corporation)
Coating liquid: acrylic Polymer (trade name: ART CURE, manufactured by Geneva industries Co., Ltd.)
Weight concentration: 50 wt.%
Density: 960kg/m3
Viscosity: 1.22 pas
Wherein the density and viscosity are measured using the above-described measurement methods.
(application of a coating liquid layer)
With the coating apparatus as shown in fig. 1, the coating object is directly coated only by the 2 nd coating section. Specifically, under the following conditions, the distance (gap) between the coating object and the downstream lip of the 2 nd coating unit was variously changed to 50 μm to 250 μm for each of the cases where the length of the downstream lip of the 2 nd coating unit was 0.2mm and 3mm, and the coating liquid layer was coated on the coating object in a single layer, and the droplet pressure of the coating liquid at the time of coating was measured and the coating state of the coating liquid layer was evaluated.
Moving speed of coating object: 10m/min
Thickness of coating liquid layer: the thickness of the film is 70 mu m,
the droplet pressure of the coating liquid was measured by the following method. The coating state was evaluated by the above-described method.
The results are shown in FIG. 15.
(method of measuring droplet pressure)
The gap is made sufficiently large so that the coating liquid discharged from the 2 nd coating section does not reach the coating object, and in this state, the coating liquid is discharged from the 2 nd coating section (the coating liquid drops without reaching the coating object), and the pressure P of the coating liquid supplied to the 2 nd coating section at this time is measured0. On the other hand, in a state where the gap is adjusted as described above, the coating liquid is discharged from the 2 nd coating section toward the coating object (the coating liquid reaches the coating object and is coated on the coating object), and the pressure P of the coating liquid supplied to the 2 nd coating section at this time is measured1. Thereafter, by slave pressure P1Minus the pressure P0And the droplet pressure (P) of the coating liquid is measured1－P0)。
As shown in fig. 15, the smaller the length of the downstream lip of the 2 nd coating section is, the larger the range of the gap that can be coated becomes.
Therefore, it is understood that the smaller the length of the downstream lip of the 2 nd coating section is, the larger the range of coating conditions that can be applied is.
As described above, the embodiments and examples of the present invention have been described, but it is also planned to appropriately combine the features of the respective embodiments and examples from the beginning. It should be understood that the embodiments and examples disclosed herein are illustrative only and are not intended to limit the present invention. The scope of the present invention is defined by the claims rather than the embodiments and examples described above, and includes all modifications equivalent in meaning and scope to the claims.

Claims (3)

1. An application device includes an application section that applies a 2 nd coating liquid layer by discharging a subsequent 2 nd coating liquid onto one or more 1 st coating liquid layers that are uncured and that move relatively with the movement of an application object, the one or more 1 st coating liquid layers being formed by discharging one or more 1 st coating liquids onto the application object first to apply,
the coating apparatus is configured to form a coating film by curing the 1 st coating liquid layer and the 2 nd coating liquid layer,
the coating section has an upstream lip and a downstream lip which are arranged so as to form a slit with a distance therebetween in a moving direction of the coating object, and is configured to discharge the 2 nd coating liquid onto the 1 st coating liquid layer from the slit,
the coating device comprises: the moving speed of the coating object is set as uwAnd the moving speed of the interface between the 1 st coating liquid layer and the 2 nd coating liquid layer is ucWill ucAnd uwWhen the ratio of the downstream lip to the downstream lip is a dimensionless speed represented by the following formula (1), and the length of the downstream lip in the moving direction is X and the dimensionless speed is Y, the X and the Y satisfy the following formula (2),said u iswHas the unit of m/s, the unit of ucIn m/s, said X in mm,
Figure FDA0003513329510000011
μpre: the minimum viscosity of the 1 st coating liquid has a unit of pas
μc: the viscosity of the 2 nd coating liquid has a unit of Pa.s
hG: the distance between the interface and the downstream lip in m
hpre: the total thickness of the one or more 1 st coating liquid layers is m
ρpre: the maximum density among the densities of the one or more coating liquids 1 is expressed in kg/m3
g: acceleration of gravity in m/s2
Y≥0.0179X2+0.0638X+0.2…(2)。
2. The coating apparatus according to claim 1,
x is 0.1 to 4 inclusive.
3. A method for producing a coating film by using the coating apparatus according to claim 1 or 2, wherein,
the method for producing the coating film comprises the following steps:
applying a 2 nd coating liquid layer by discharging a subsequent 2 nd coating liquid onto one or more 1 st coating liquid layers that are formed by discharging one or more 1 st coating liquids onto a coating object first and are uncured and move relatively with the movement of the coating object; and
and curing the 1 st and 2 nd coating liquid layers to obtain a coating film.
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