CN110394278B - Coating apparatus and method for producing coating film - Google Patents
Coating apparatus and method for producing coating film Download PDFInfo
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- CN110394278B CN110394278B CN201910319181.7A CN201910319181A CN110394278B CN 110394278 B CN110394278 B CN 110394278B CN 201910319181 A CN201910319181 A CN 201910319181A CN 110394278 B CN110394278 B CN 110394278B
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- coating
- manifold
- coating liquid
- width direction
- slit
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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
- 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
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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
- 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
- B05C5/0258—Coating heads with slot-shaped outlet flow controlled, e.g. by a valve
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- 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
Abstract
The invention provides a coating device and the like, which can efficiently form a coating film with the thickness change in the width direction being sufficiently restrained. In the coating apparatus, the die head is configured such that the shape and size of a cross section of the manifold viewed in the width direction are the same over the entire width direction, and the edge of the side edge of the slit of the manifold is formed in a shape described by a quadratic curve defined by a specific equation.
Description
Technical Field
The present invention relates to a coating apparatus and a method for producing a coating film.
Background
Conventionally, for example, a die coater is known as one of coating apparatuses. The die coater is a coating apparatus: the coating liquid is discharged from a die onto a coating object such as a substrate moving relatively, thereby forming a coating film on the coating object. In the coating apparatus, the die has: a manifold having an inflow port and capable of feeding the coating liquid flowing in from the inflow port to at least one end portion of the manifold in a width direction of the coating object; and a slot communicating with the manifold and opening at a top edge of the die.
In this type of coating apparatus, the manifold is formed over the entire width direction of the coating object, and if the distance between the tip edge of the slit and the slit-side edge of the manifold (the length of the slit) is the same over the entire width direction of the coating object, the pressure loss of the coating liquid in the manifold and the pressure loss in the slit become larger as the coating liquid flows from the inflow port of the manifold to the above-described end portion. As a result, the flow rate of the coating liquid discharged from the slit becomes smaller and smaller as the coating liquid goes from the inlet toward the end, and the thickness of the coating film to be formed becomes thinner and thinner.
For this reason, for example, a technique is known in which a manifold having an inlet at one end in the width direction and capable of feeding a coating liquid from the inlet to the other end can be designed into a specific shape. Specifically, a technique has been proposed in which the slit-side edge of the manifold is formed so that the length of the slit decreases in a quadratic curve from one end portion of the manifold in the width direction toward the other end portion, whereby the flow rate of the coating liquid discharged from the slit can be made nearly uniform over the range from the one end portion to the other end portion (see patent document 1).
Documents of the prior art
Patent document
Patent document 1: japanese laid-open patent publication No. 2002-72409
Disclosure of Invention
Problems to be solved by the invention
However, in the coating apparatus as described above, it may take much labor and time to determine an appropriate shape of the slot-side end edge of the manifold, and even it may be impossible to determine an appropriate shape. This is because the variation in the thickness of the coating liquid in the width direction cannot be sufficiently suppressed.
In view of the above circumstances, an object of the present invention is to provide a coating apparatus and a method for producing a coating film, by which a coating film having a thickness sufficiently suppressed in the width direction can be efficiently formed.
Means for solving the problems
The present inventors have made intensive studies to solve the above problems and have made the following findings.
Specifically, it is assumed that the coating liquid flowing into the manifold advances along each of imaginary paths that are paths through which the coating liquid moves in the manifold and flows out from each predetermined position to the slit, and that are imaginary paths through which the coating liquid passes at the shortest distance through the slit and is discharged from each position at the opening of the slit. Further, it is assumed that the coating liquid discharged from the slit is a collection of coating liquids which advance along the respective virtual paths and are discharged from the openings of the slit. Also, assume that the values of the streams at the openings of the slots in the imaginary paths are the same across the width (e.g., such asIn FIG. 6, S0＝S1＝S2···＝SM)。
According to the general knowledge of physics, the total pressure loss of the coating liquid that proceeds along each imaginary path and is ejected from the opening of the slit is equal between the imaginary paths.
Therefore, if the total pressure loss in each virtual path can be calculated based on the assumption regarding the flow bundle using the distance between the outflow position and the discharge position (the distance between the end edge on the slit side of the manifold and the opening of the slit, that is, the slit length) and known parameters, the slit length at each position can be calculated such that the total pressure loss in each virtual path has the same value between each virtual path.
Then, a graph is prepared by plotting the calculated slot lengths for each ejection position, and a quadratic approximation curve is calculated from the graph. The slit-side end edge (end edge on the slit side) of the manifold is formed so as to have a shape along the calculated quadratic approximation curve, and the manifold is formed so that the shape and size of the cross section of the manifold viewed in the width direction are the same in the entire width direction. This makes it possible to make the flow streams of the coating liquid discharged from the slots close to the same value in all the slots (in the entire width direction of the coating object).
As described above, assuming that the streams have the same value in each virtual path and the shape and size of the cross section of the manifold are the same in the entire width direction, an equation is calculated based on the above assumption, and each slot length is determined so that the total pressure loss in each virtual path is constant by using the equation. The manifold and the slot are formed so as to have a shape along a quadratic approximation curve obtained from the determined length of each slot, and a die in which the manifold and the slot are formed is used. It was found that a coating film having a small variation in thickness in the width direction can be formed thereby, and the present invention has been completed.
That is, the coating apparatus of the present invention has a die capable of applying a coating liquid to a coating object which moves relatively,
the coating device is composed of a coating device,
the die head has:
a manifold having an inflow port into which the coating liquid can flow, and capable of conveying the coating liquid flowing in from the inflow port in a width direction of the coating object; and
a slot in communication with the manifold and having an opening at a top end edge of the die,
the shape and size of the cross section of the manifold as viewed from the width direction are the same throughout the width direction,
the opening of the slot extends in the width direction,
setting an end or a center in the width direction in a region where the coating liquid is ejected from the slit at the opening as an origin, setting a direction from the origin along the opening and in which the coating liquid is conveyed as an x-axis, and setting a direction perpendicular to the x-axis from the origin as a y-axis, in this case,
the slot-side end edge of the manifold is formed in a shape plotted by a quadratic curve represented by the following equation (1),
assuming that the coating liquid flowing into the manifold from the inflow port advances along imaginary paths that flow out from the slit-side end edges toward the slit at a plurality of outflow positions arranged in the width direction, that pass through the inside of the slit in a direction parallel to the y-axis, and that are then discharged from a plurality of discharge positions of the opening,
for the m (m is an integer of 0 or more) virtual paths from the origin, the distance from the origin to the ejection position is represented as xm[m]The total pressure loss of the coating liquid from the inflow port to the opening is represented by Δ Pm[Pa]And a distance between the outflow position and the ejection position is represented as Lm[m]The amount of the solvent, in this case,
the following equations (2) and (2) can be used(3) To represent said Δ PmAnd said LmIn the context of (a) or (b),
so as to satisfy the equations (2) and (3) and make each delta P in each virtual pathmCalculating each L so that the values of the L are the same between the virtual pathsmFor each calculated LmAnd each LmThe corresponding xmThe relationship (c) is plotted to form a graph, and the quadratic curve is determined using a quadratic approximation curve of the graph.
y＝Ax2+Bx+C···(1)
A. B, C: coefficient [ - ]
When m is 0
m is greater than or equal to 1
W: coating width [ m ]
Q1: flow rate [ m ] of coating liquid flowing into manifold3/s]
Q2: flow rate [ m ] of coating liquid flowing out from manifold to portion other than slit3/s]
S: stream of coating liquid discharged from the slit (S ═ Q)1-Q2)/W)[m2/s]
h: height of slot [ m ]
R: radius of manifold [ m ]
nc: first viscosity parameter [ -]
ηc: second viscosity parameter of coating fluid in manifold [ -]
ns: first viscosity parameter [ -]
ηs: second viscosity parameter of coating liquid in slot [ -]
The above structure is explained in detail. Assuming that the shape and size of the cross section of the manifold viewed from the width direction are the same in the entire width direction and the streams of the coating liquid discharged from the openings of the slots have the same value between the virtual paths, the above equations (2) and (3) are derived based on the above assumptions, and the equations (2) and (3) are used. This makes it possible to use the known parameters and the unknown distance (slot length) L between the outflow position and the ejection position (i.e., opening)mTo represent each Δ PmSo that each of the Δ PmCalculating each L so that the values of L are the same between the virtual pathsm. Can be based on each calculated LmAnd determining a quadratic approximation curve. The slot-side end edges of the manifold are formed in a manner along the quadratic approximation curve. And, in matching with the slit side end edge, the manifold is formed in such a manner that the shape and size of the cross section viewed from the width direction are the same over the entire width direction.
By forming the manifold in the above manner, the flow rate of the coating liquid discharged from the opening of the slit can be made close to the same value in the entire width direction of the coating object. Therefore, the thickness variation of the formed coating film can be suppressed in the entire width direction.
Furthermore, the quadratic approximation curve can be determined from known parameters, which is efficient.
Therefore, a coating film in which the variation in thickness in the width direction is sufficiently suppressed can be efficiently formed.
The method for producing a coating film of the present invention comprises the steps of: the coating apparatus is used to discharge a coating liquid onto a relatively moving coating object, thereby forming a coating film.
With this configuration, since the coating apparatus is used, a coating film in which the variation in thickness in the width direction is sufficiently suppressed can be efficiently formed.
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 plan view showing an example of a manifold and a slot in a die provided in the coating apparatus according to the present embodiment, and shows the flow of the coating liquid from the manifold to the slot together.
Fig. 3 is a schematic side view showing the die of the present embodiment.
Fig. 4 is a schematic plan view schematically showing each virtual path of the coating liquid in the manifold and the slot in fig. 2 and a pressure loss in each virtual path.
Fig. 5 is a graph showing an example of a viscosity curve of a coating liquid.
Fig. 6 is a schematic plan view schematically showing each stream from the opening of the slot in each imaginary path of the coating liquid in fig. 4.
Fig. 7 is a schematic plan view schematically showing the slit length in each imaginary path of the coating liquid in fig. 4.
Fig. 8 is a graph showing an example of the relationship between the distance from the origin in the x-axis direction and the slot length in each virtual path.
Fig. 9 is a schematic diagram showing an example of the sectional shape and the sectional radius of the manifold.
Fig. 10 is a schematic plan view schematically showing each virtual path of the coating liquid in the manifold and the slot in the die head provided in another coating apparatus of the present embodiment and each flow bundle from the opening of the slot in each virtual path.
Fig. 11 is a schematic plan view schematically showing each virtual path of the coating liquid in the manifold and the slot in the die head provided in another coating apparatus of the present embodiment and each flow bundle from the opening of the slot in each virtual path.
Fig. 12 is a schematic plan view schematically showing the slit length in each virtual path of the coating liquid in fig. 11.
Fig. 13 is a schematic plan view showing an example of a manifold and a slot in a die head of another coating apparatus according to the present embodiment, and shows a flow of a coating liquid from the manifold to the slot together.
Fig. 14 is a schematic plan view schematically showing each virtual path of the coating liquid in the manifold and the slot in fig. 13 and each stream from the opening of the slot in each virtual path.
Fig. 15 is a schematic plan view schematically showing the slit length in each virtual path of the coating liquid in fig. 13.
FIG. 16 is a graph showing the viscosity profile of the coating liquid used in example 1.
Fig. 17 is a graph showing an example of the relationship between the distance from the origin in the x-axis direction and the slot length in each virtual path in example 1.
Fig. 18 is a graph showing the relationship between the thickness of a coating film formed by a coating apparatus having a die head provided with a manifold of example 1 and the distance from the origin in the x-axis direction.
Fig. 19 is a schematic plan view showing the shape of a manifold in the die of comparative example 1.
Fig. 20 is a graph showing an example of the relationship between the distance from the origin in the x-axis direction and the slot length in each virtual path of comparative example 1.
Fig. 21 is a graph showing the relationship between the thickness of a coating film formed by a coating apparatus having a die head provided with a manifold of comparative example 1 and the distance from the origin in the x-axis direction.
Fig. 22 is a schematic plan view showing the shape of a manifold in the die of comparative example 2.
Fig. 23 is a graph showing the relationship between the thickness of a coating film formed by a coating apparatus having a die head provided with a manifold of comparative example 2 and the distance from the origin in the x-axis direction.
Description of the reference numerals
1. A coating device; 5. a die head; 8. a slot; 8a, an opening; 9. a manifold; 9a, a first end portion; 9b, a second end; 9c, 9d, end edges; 10. an inflow port; 12. an outlet port; 15. a support portion; 17. a curing section; 31. a coating object; 33. coating liquid; 35. 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, 2, and 3, the coating apparatus 1 of the present embodiment includes a die 5, and the die 5 is capable of applying a coating liquid 33 to a coating object 31 that is relatively moving. The coating apparatus 1 having such a die is called a die coater.
The die 5 has:
a manifold 9 having an inflow port 10 into which the coating liquid 33 can flow, the manifold 9 being capable of feeding the coating liquid 33 flowing in from the inflow port 10 to at least one of an end portion 9a and an end portion 9b of the manifold in the width direction of the coating object 31;
a slot 8 communicating with the manifold 9 and having an opening 8a at the top end edge 5a of the die 5; and a supply unit 11 constituting a path for feeding the coating liquid 33 from the outside to the inlet 10.
In the present embodiment, the coating apparatus 1 (the die 5) is configured such that the inflow port 10 is formed at one end portion (first end portion) 9a of the manifold 9, and the coating liquid 33 flowing in from the inflow port 10 can be sent to the other end portion (second end portion) 9 b.
The coating apparatus 1 further includes a curing section 17, and the curing section 17 can solidify the coating liquid 33 applied from the die 5 to form each coating film 35. The coating apparatus 1 may not have the curing section 17.
The coating apparatus 1 further includes a support portion 15, the support portion 15 being capable of supporting the coating object 31 by its surface, and the support portion 15 being capable of moving the coating object 31 relative to the die 5 in the longitudinal direction. The coating apparatus 1 may not have the support portion 15.
The coating object 31 is not particularly limited, and examples thereof include a sheet-like member in a band shape.
As the sheet-like member, for example, a resin film can be cited. Examples of the resin film include lumiror (ルミラー) (registered trademark) manufactured by dongli corporation of imperial レ.
The support portion 15 supports the coating object 31 movable in the longitudinal direction from the side opposite to the side where the die 5 is arranged. The coating liquid 33 is applied to the coating object 31 supported by the support portion 15 and moving relative to the die 5.
The support portion 15 may be a roller.
In the present embodiment, the support portion 15 is configured to be disposed at a position facing the slit 8 of the die head 5, and to be capable of moving the application object 31 from one direction (downward in fig. 1) to the other direction (upward in fig. 1) with respect to the slit 8.
The curing section 17 is configured to be able to solidify the coating liquid 33 and form a coating film 35. The cured portion 17 can form a coating film 35 in a solidified state. The curing section 17 is not particularly limited as long as it can solidify the coating liquid 33. The curing section 17 can be set appropriately according to the type of the coating liquid 33 and the like.
The die 5 is configured to be able to discharge the coating liquid 33 from the slit 8 and to be able to apply a coating film 35 to the coating object 31 that is moving relatively.
The die 5 is configured to be able to discharge the coating liquid 33 to the coating object 31 moving in the vertical direction with respect to the slit 8 by disposing the slit 8 facing the side. The coating apparatus 1 is configured to be able to supply the coating liquid 33 from a storage section (not shown) for the coating liquid 33 to the die 5 via a pipe (not shown) and a pump (not shown). The slit 8 of the die 5 may be disposed so as to face downward or upward.
Specifically, the die 5 has: a first die block 6 located on the upstream side; and a second die block 7 located on the downstream side and disposed opposite to the first die block 6. The die 5 is formed by mating a first die block 6 and a second die block 7. By aligning the first die block 6 and the second die block 7 in this manner, it is possible to form: a manifold 9 capable of storing a coating liquid 33 supplied from a pump (not shown); a slot 8 extending from the manifold 9 towards the top end edge; and a supply section 11. Further, a gap between the tip edge of the first block 6 and the tip edge of the second block 7 constitutes an opening 8a (ejection port) of the slit 8. The opening 8a extends along the width direction of the coating object 31.
In fig. 1, the die 5 is shown without shims, and the die 5 is shown in a form in which the first die block 6 and the second die block 7 are aligned. In addition, the die 5 may be configured such that the first die block 6 and the second die block 7 are opposed to each other with the spacer interposed therebetween.
The tip end edge of the first block 6 and the tip end edge of the second block 7 are arranged so as to be located on a plane perpendicular to the radial direction of the support portion 15. The slit 8 is arranged in a direction parallel to the normal direction of the support portion 15.
The manifold 9 is formed such that the shape and size of the cross section thereof viewed from the width direction of the coating object 31 are the same throughout the width direction.
The shape of the cross section of the manifold 9 is not particularly limited, and may be, for example, a circular shape, a semicircular shape, a water droplet shape, or the like as shown in fig. 9 described later. The size of the cross section of the manifold 9 is also not particularly limited.
The radius of the cross section of the manifold 9 will be described later.
In the coating apparatus 1 of the present embodiment, the inflow port 10 is formed at the first end 9a of the manifold 9 on one side in the width direction. The coating liquid 33 can be sent from the first end 9a to the second end 9 b. Further, with respect to the flat surface on the side where the manifold 9 is formed in the die block 6 (here, referred to as the first die block), when viewed from the direction perpendicular to the flat surface, the end in the width direction of the region (coating region F) where the coating liquid 33 at the opening 8a of the slit 8 is ejected from the slit 8 is set as the origin O. The direction from the origin O along the opening 8a toward the second end 9b, which is the moving destination of the coating liquid 33, is set as the x-axis. The direction perpendicular to the x axis from the origin is set as the y axis (see fig. 4, 6, and 7).
In addition, the end portion in the width direction of the coating region F is the end portion in the width direction of the coating object 31 in the coating region F. The end set as the origin O is the end closer to the inflow port 10 in the application region F.
Further, it is assumed that the coating liquid 33 flowing from the inlet 10 into the manifold 9 follows the followingEach of these virtual paths K (here, K is referred to as0～KMWhere M is an integer of 1 or more), that is, as shown in fig. 4, 6, and 7, the coating liquid flows from a plurality of outflow positions of the edge 9c aligned in the width direction described above toward the slit groove 8, passes through the inside of the slit groove 8 in a direction parallel to the y-axis, and is then ejected from a plurality of ejection positions at the opening 8 a. For the m-th (m is an integer of 0 or more) virtual path K from the origin OmThe distance from the origin O to the ejection position is represented by xm[m]The total pressure loss from the inflow port 10 to the opening 8a is expressed as Δ Pm[Pa]The distance between the outflow position and the ejection position (slot length) is represented by Lm[m]。
In this case, Δ P can be expressed by the following equations (2) and (3)mAnd LmSo as to satisfy the expressions (2) and (3) and make each virtual path KmEach of Δ P in (1)mOn the imaginary path KmEach L is calculated so as to have the same valuemFor each calculated LmAnd x in each virtual path KmThe relationship between the two curves is plotted to form a graph, and a quadratic curve in the following equation (1) is determined using a quadratic approximation curve of the graph.
y＝Ax2+Bx+C···(1)
A. B, C: coefficient [ - ]
When m is 0
m is greater than or equal to 1
W: coating width [ m ]
Q1: flow rate [ m ] of coating liquid flowing into manifold3/s]
Q2: flow rate [ m ] of coating liquid flowing out from manifold to portion other than slit3/s]
S: stream of coating liquid discharged from the slit (S ═ Q)1－Q2)/W)[m2/s]
h: height of slot [ m ]
R: radius of manifold [ m ]
nc: first viscosity parameter [ -]
ηc: second viscosity parameter of coating fluid in manifold [ -]
ns: first viscosity parameter [ -]
ηs: second viscosity parameter of coating liquid in slot [ -]
The following describes the above equations (1), (2) and (3).
The quadratic curve shown in equation (1) is used to plot the shape of the end edge 9c on the slot side of the manifold 9.
How to derive the quadratic curve, i.e., how to determine the coefficient a, the coefficient B, and the coefficient C, will be described later.
Equations (2) and (3) are calculated based on the following assumptions.
Specifically, it is assumed that the coating liquid 33 flowing into the manifold 9 advances along each virtual path K such that the coating liquid flows out from a plurality of outflow positions arranged in the width direction at the end edge 9c toward the slit 8, passes through the inside of the slit 8 in a direction parallel to the y-axis, and is discharged from a plurality of discharge positions at the opening 8 a.
For the mth virtual path K from the origin OmThe distance from the origin O to the ejection position is represented as xm[m]The total pressure loss from the inflow port 10 to the opening 8a is expressed as Δ Pm[Pa]The distance between the outflow position and the ejection position (slot length) is represented as Lm[m]In this case, the expressions (2) and (3) represent the Δ PmAnd LmIn relation to (2)The formula (c). In equations (2) and (3), the slot height refers to the interval of the opening 8a of the slot 8 in the direction perpendicular to the width direction.
In addition, from the origin O (x)0[m]) The 0 th ejection position is the origin itself, and the first ejection position is spaced from the origin O by x1[m]The second ejection position is spaced from the origin O by x2[m]X is spaced from the origin O at the m-th ejection positionm[m]. The ejection positions may be spaced at equal intervals or at different intervals. Similarly, the outflow positions may be spaced at equal intervals or at different intervals.
In the present embodiment, the virtual paths K for the respective outflow positions and the respective discharge positionsmΔ P in (1)mSo as to satisfy the formulas (2) and (3) and make each delta PmOn each virtual path KmIn the same value as each other, each L is calculatedm。
Then, each of the calculated L's is combinedmAnd each x corresponding theretomThe relationship between them is plotted to form a graph.
Then, a quadratic curve for drawing the shape of the edge 9c of the manifold 9 is determined using the quadratic approximation curve of the created graph.
How to derive equations (2) and (3) will be described.
As shown in fig. 4, according to the common knowledge of physical laws, when the coating liquid 33 is discharged from the slit 8 of the die 5, the total pressure loss of the coating liquid 33 from the inlet 10 to the opening 8a of the slit 8 is assumed to be equal in each virtual path regardless of the discharge position in the width direction of the slit 8, and if it is assumed, the following expression (3) is satisfied for any mth path.
(Total pressure loss Δ Pm)＝
(pressure loss Δ P in the manifold)cm) + (pressure loss in Slot Δ Psm)···(3)
Based on the assumption that the total pressure loss is equal at any position in the width direction of the slit 8, the total pressure loss Δ P of the coating liquid 33 flowing from the inlet 10 and discharged from the slit 8 can be expressed by the following expressions (4) and (5), and specifically, can be expressed by the following expression (6). Further, the pressure loss in the y-axis direction in the manifold 9 is 0. And i is an integer of 1 to m inclusive.
When m is 0
ΔPm＝ΔPs0···(4)
m is greater than or equal to 1
ΔP0＝ΔPs0
ΔP1＝ΔPc1+ΔPs1
ΔP2＝ΔPc1+ΔPc2+ΔPs2
ΔP3＝ΔPc1+ΔPc2+ΔPc3+ΔPs3
…
ΔPm-1＝ΔPc1+ΔPc2+ΔPc3+...+ΔPc(m-1)+ΔPs(m-1)
ΔPm＝ΔPc1+ΔPc2+ΔPc3+...+ΔPc(m-1)+ΔPcm+ΔPsm
···(6)
In general, the relationship between the shear rate and the viscosity of a liquid can be expressed by the following equation (7) using two viscosity parameters.
μ: viscosity of liquid
Eta: first viscosity parameter of liquid
n: second viscosity parameter of the liquid
When the relationship between the shear rate and the viscosity of the coating liquid 33 is obtained, a graph as shown in fig. 5 can be obtained.
Here, a region of the graph corresponding to the shear rate of the coating liquid passing through the portion of the manifold 9 and a region of the graph corresponding to the shear rate of the coating liquid passing through the portion of the slit 8 are examined in advance, and the two regions are shown in the graph of fig. 5, for example. That is, the relationship between the shear rate and the viscosity shown in the above equation (7) can be established for both of the two regions.
Therefore, the relationship between the shear rate and the viscosity of the coating liquid 33 when it passes through the manifold 9 can be expressed by the following equation (8). The relationship between the shear rate and the viscosity of the coating liquid 33 when it passes through the slit 8 can be expressed by the following equation (9).
μ: viscosity of coating liquid
ηc: first viscosity parameter of coating liquid in manifold
nc: second viscosity parameter of coating liquid in manifold
μ: viscosity of coating liquid 33
ηs: a first viscosity parameter of the coating liquid in the slot
ns: second viscosity parameter of coating liquid in slot
Further, it is assumed that the shape and size of the cross section of the manifold 9 viewed from the width direction are the same in the entire width direction, and the flow streams of the coating liquid ejected from the openings 8a of the slots 8 are the same in the entire width direction (i.e., S)0～SMAll of which are the same value), based on the above assumption, the above viscosity parameter as a known parameter and the unknown slit length (distance between the end edge 9c and the opening 8a) L are used in accordance with equation (6)mBy dividing each virtual path KmTotal pressure loss Δ P in (1)mThe above equations (2) and (3) can be obtained by converting the expression into an expression.
In fig. 4, for each virtual path K from 0 th to M thm(K0、K1、···KM) The pressure loss Δ P in the slot 8 in equations (2) and (3) is shownsmPressure loss Δ P in the manifold 9cmAnd total pressure loss Δ Pm(pressure loss Δ P in the slit 8smAnd pressure loss Δ P in the manifold 9cmSum, P in FIG. 4IN-Poutm＝ΔPm. ). FIG. 6 shows a flow stream S of the coating liquid 33 discharged from the opening 8am. The slot length L is shown in FIG. 7m。
Also, assume total pressure loss Δ PmOn each virtual path KmThe same value is obtained, and the virtual paths K are calculated according to the above assumptionmTotal pressure loss Δ P in (1)mOn each virtual path KmThe slot lengths L are equal to each otherm. For example canThis calculation can be performed using a solver in a plug-in of conventionally known table calculation software (for example, "MICROSOFT EXCEL (registered trademark)" manufactured by MICROSOFT corporation). Here, the meaning of the values being identical to each other is that the values can be minimized by an error function indicating the degree of difference (error) between the values.
Fig. 4, 6, and 7 show a mode in which L is calculated using equations (2) and (3)mThe shape of the edge 9c set first before is set to a shape linearly extending in the width direction (x-axis direction) of the application object 31. However, the shape of the first set end edge 9c is not particularly limited, and may be linear or quadratic curve.
The number of the outflow positions and the ejection positions through which the virtual path K passes (i.e., the value of m), and the interval between the outflow positions and the interval between the ejection positions (Δ x) are not particularly limited and can be set as appropriate.
For example, the larger the value of the number m of the outflow positions and the ejection positions (the number of virtual paths), the more uniform the flow rate of the coating liquid 33 ejected from the slit 8 in the entire width direction of the coating object 31 can be made, but the calculation tends to become complicated.
Thus, for example, after this aspect is taken into consideration, the number and intervals of the above-described outflow positions and ejection positions can be appropriately set.
Preferably, the interval between the outflow positions and the interval between the discharge positions are equal intervals.
When each slot length L to be obtained by the above-described mannermWith respect to each distance xmWhen the drawing is performed and the drawing is performed, for example, a graph shown in fig. 8 can be obtained.
When this graph is fitted with a quadratic function, a quadratic approximation curve as shown in fig. 8 can be obtained.
By using the coefficients in the obtained quadratic approximation curve for the coefficient a, the coefficient B, and the coefficient C in the above equation (1), a specific equation (1) can be specified.
Then, the edge 9c is formed in accordance with the determined equation (1). The manifold 9 is formed so that the shape and size of the cross section viewed from the width direction are the same in the entire width direction in conformity with the end edge 9 c.
In addition, when the coating liquid 33 is a newtonian fluid, a is close to 0 in equation (1), and therefore the approximate curve approximates to a straight line having a slope. Further, in the case where the coating liquid 33 is a newtonian fluid and the viscosity of the coating liquid is relatively low, and the flow rate of the coating liquid 33 ejected from the opening 8a of the slit 8 is relatively small, since both a and B are close to 0, the coating liquid 33 is approximated to a straight line parallel to the x-axis.
As described above, it is understood from expressions (2) and (3) that the shape and size of the cross section of the manifold 9 are the same in the entire width direction (i.e., x-axis direction), and therefore the radius R of the cross section of the manifold 9 is the same in the entire width direction (i.e., x-axis direction).
As shown in fig. 9, the radius of the manifold 9 (the radius of the cross section) can be set by using the shape factor D and using the equation of R ═ D × R according to the shape of the cross section of the manifold 9 viewed in the moving direction of the coating liquid 33. For example, when the cross-sectional shape is circular, the radius of the manifold 9 can be used as the radius r of the circle.
On the other hand, when the cross section has a semicircular or fan-like shape, the radius of the cross section can be set using the shape factor D as shown in fig. 9.
Further, as shown in fig. 2, an end edge 9d of the manifold 9 on the side opposite to the side where the slit 8 is located is formed in the same shape as the end edge 9c in such a manner that the interval with the end edge 9c is the same in the entire width direction.
As described above, the coating apparatus 1 of the present embodiment is configured such that the shape and size of the cross section of the manifold 9 viewed from the width direction are the same in the entire width direction, and the end edge 9c of the manifold 9 on the side of the narrow groove 8 is formed in a shape described by a quadratic curve represented by the following equation (1), Δ PmAnd LmThe relationship (c) is expressed by the following equations (2) and (3) such that the respective Δ P at the respective outflow positions and the ejection positions satisfy the equations (2) and (3)mOn each virtual path KmEach L is calculated so as to have the same valuemFor each calculated LmAnd each LmCorresponding xmThe relationship between the two curves is plotted to form a graph, and the quadratic curve is determined by using the quadratic approximation curve of the graph.
This structure will be explained. Assuming that the shape and size of the cross section of the manifold 9 viewed from the width direction are the same in the entire width direction, and the stream S of the coating liquid 33 ejected from the opening 8a of the slot 8mAt each virtual path KmThe same applies to the above, and based on the above assumption, the above expressions (2) and (3) are derived and used as the expressions (2) and (3). Then, the unknown distance (slot length) L between the outflow position (the end edge 9c of the manifold 9 on the slot 8 side) and the discharge position (i.e., the opening 8a) is used with the known parametersmTo represent Δ PmSo that the Δ P ismOn each virtual path KmEach L is calculated so as to have the same valuem. Based on the calculated LmAnd determining a quadratic approximation curve. Then, the end edge 9c of the manifold 9 on the side of the slit groove 8 is formed so as to follow the quadratic approximation curve. The manifold 9 is formed so that the shape and size of the cross section viewed from the width direction are the same in the entire width direction in conformity with the end edge 9 c.
By forming the manifold 9 in the above manner, the flow rate of the coating liquid 33 discharged from the opening 8a of the slit 8 can be made to be close to the same value in the entire width direction of the coating object 31. This can suppress the thickness variation of the formed coating film 35 in the entire width direction.
Furthermore, the quadratic approximation curve can be determined from known parameters, which is efficient.
Thus, the coating film 35 whose thickness variation in the width direction is sufficiently suppressed can be efficiently formed.
Next, a method for producing the coating film 35 of the present embodiment will be described.
The method for producing a coating film of the present embodiment includes the steps of: the coating apparatus 1 is used to discharge the coating liquid 33 onto the coating object 31 which is relatively moving, thereby forming a coating film 35.
With the above-described manufacturing method, since the coating apparatus 1 is used, the coating film 35 whose thickness variation in the width direction is sufficiently suppressed can be efficiently formed.
As described above, the present invention can provide a coating apparatus and a method for producing a coating film, by which a coating film having a thickness sufficiently suppressed in a width direction can be efficiently formed.
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.
In the above embodiment, the coating liquid 33 flowing in from the inlet 10 is entirely discharged to the slit 8 (for example, in fig. 6, Q)20). However, the present invention may adopt the following forms: for example, as shown in fig. 10, the manifold 9 has a discharge port 12, the discharge port 12 is capable of discharging the coating liquid 33 from the inside of the manifold 9 to a portion other than the slit 8, the die 5 has a discharge portion 13, the discharge portion 13 forms a path for sending the coating liquid 33 to the outside from the discharge port 12, a part of the coating liquid 33 flowing in from the inflow port 10 flows out to the slit 8, and the remaining part is discharged from the discharge port 12 through the discharge portion 13.
As shown in fig. 2, the embodiment described above shows a mode in which the end of the coating region F is positioned in alignment with the inflow port 10. However, the present invention may adopt the following forms: for example, as shown in fig. 11 and 12, the end of the coating region F is located inside the inflow port 10. In the embodiment shown in fig. 11, the regulating portions 21 for regulating the discharge of the coating liquid 33 are disposed at both ends in the width direction of the opening 8a of the slit 8. The width of the application region F (application width W) is reduced by an amount corresponding to the arrangement of the regulating portion 21.
As shown in fig. 2, the above embodiment shows an embodiment in which the inlet 10 is formed in the first end 9a of the manifold 9, and the coating liquid 33 flowing in from the inlet 10 is sent from the first end 9a to the second end 9 b. However, in the present invention, for example, as shown in fig. 13 to 15, the position of the manifold 9 where the inflow port 10 is formed may be a position corresponding to the center of the application region F.
In this case, as shown in fig. 13 and 14, the inflow port 10 is formed in the center portion in the width direction of the coating object 31 in the manifold 9, the center of the inflow port is formed so as to be aligned with the center of the coating region F, and the coating liquid 33 flowing in from the inflow port 10 can be sent to both the first end portion 9a and the second end portion 9b (i.e., both end portions).
In this case, the flow of the coating liquid 33 is assumed to be line-symmetric about a virtual straight line (not shown) passing through the center of the coating region F and parallel to the y-axis as a central axis. Then, as shown in fig. 15, assuming that the center of the application region F is the origin O, each L is determined in the same manner as described above for the application liquid 33 sent from the origin O to the second end 9b located on the downstream sidemThen, each L can be determined in the same manner for the coating liquid 33 sent from the origin O to the first end 9a located on the other sidem. The center of the coating region F is a position that bisects the coating region F in the width direction (i.e., the moving direction of the coating liquid) (1/2), and the center of the inlet 10 is a position that bisects the inlet 10 in the width direction (1/2).
Examples
The present invention will be described in more detail by referring to test examples, but the present invention is not limited thereto.
Example 1
(materials used)
The coating object: PET (polyethylene terephthalate) film (trade name: Diafil (Japanese: ダイヤホイル), manufactured by Mitsubishi chemical Strand corporation (Japanese: Mitsubishi ケミカル Co., Ltd.))
Coating liquid: acrylic Polymer (trade name: SK-Dyne, manufactured by Soken chemical Co., Ltd.)
The viscosity of the coating liquid was measured for each shear rate and patterned as follows. According to the obtained graph, the first and second viscosity parameters of the coating liquid in the manifold, the first and second viscosity parameters of the coating liquid in the slot, and the like are measured. The results are shown in table 1.
(method of measuring viscosity)
The viscosity of the coating liquid was measured at a temperature of 23 ℃ and a humidity of 50% RH using a variable instrument (model RS1, manufactured by HAAKE) having a jig (a tapered plate having a taper diameter of 25mm to 50mm and a taper angle of 0.5 to 2 ℃). On this premise, the shear rate was changed and the viscosities after the change of the shear rate were measured.
The results are shown in FIG. 16. Then, based on the result, the first and second viscosity parameters in the manifold and the first and second viscosity parameters in the slot are calculated, respectively.
Specifically, by preliminary experiments, the range of shear speeds equivalent to the flow of the coating liquid in the manifold and the range of shear speeds equivalent to the flow of the coating liquid in the slot in the shear speed-viscosity curve shown in fig. 16 were determined.
By fitting the shear rate-viscosity curves in the ranges of the determined shear rates using the above equations (8) and (9), the first viscosity parameter (n) of the coating liquid in the manifold can be obtainedc) And a second viscosity parameter (. eta.)c) And a first viscosity parameter (n) of the coating liquid in the slots) And a second viscosity parameter (. eta.)s)。
(calculation of stream S)
The stream S is calculated by the following equation:
s is (coating thickness (wet state) of the coating liquid set) x (moving speed of the coating object).
(determination and formation of manifold shape)
Based on a die having a manifold which is semicircular in cross section as viewed from one side in the width direction as shown in fig. 3 and extends in the width direction as shown in fig. 4, and the shape and size of the cross section of which are constant over the entire width direction. In the die, an inflow port is formed at a first end of the manifold, while a discharge port is not formed. The shape of the manifold is determined in the following manner.
As shown in table 1, the width of the coating liquid to be applied to the coating object, the moving speed (line speed) at which the support portion moves the coating object, the flow rate of the coating liquid when flowing into the manifold, the manifold radius, the slit height, and the like were set. The total pressure loss Δ P was calculated by using equations (2) and (3)mOn each virtual path KmCalculating virtual paths K passing through the outflow positions and the discharge positions to have the same valuemLength L of slot (c)m. In the calculation, the values shown in Table 1 were used as each of Δ LmInitial value (L) of0)。
Then, for the discharge position on the x-axis and the slot length LmThe relationship between the two is plotted, and a quadratic function is used for fitting the two to obtain a quadratic approximation curve. The results are shown in FIG. 17.
The shape plotted by the obtained quadratic approximation curve was determined as the shape of the slit-side end edge of the manifold. The manifold is formed in such a manner that the shape and size of the cross section of the manifold at the origin O are made the same as those of the cross section of the manifold in the entire width direction, that is, in such a manner that the shape and size of the cross section of the manifold are constant in the width direction. In this manner, a manifold as shown in fig. 2 is formed.
The coating object was coated under the conditions in table 1 using a die having the formed manifold. The coating liquid applied to the coating object is dried to form a coating film. The thickness of the resulting coating film in the entire width direction was measured using a linear gauge. The results are shown in fig. 18.
As shown in fig. 18, a coating film in which variation in thickness in the entire width direction was suppressed was obtained.
TABLE 1
Comparative example 1
The manifold was made as shown in fig. 19. In detail, the manifold is made in the following manner: the slot-side end edge of the manifold was linear (i.e., parallel to the x-axis direction) along the top end edge of the die (the opening of the slot), and the shape and size of the cross section as viewed from the width direction were the same as those of the manifold of example 1 in the entire width direction. The length (L) of the slots of this manifold was 40mm, and as shown in fig. 20, the length of the slots was the same across the width.
Coating was performed in the same manner as in example 1 using a die having a manifold fabricated under the conditions in table 2. The thickness of the resulting coating film was measured over the entire width direction.
The results are shown in FIG. 21.
As shown in fig. 21, the thickness of the obtained coating film greatly varied in the width direction.
TABLE 2
Comparative example 2
As shown in fig. 22, only the slit-side end edge of the manifold of comparative example 1 was additionally processed so that the slit-side end edge had the same shape (the same slit length) as the slit-side end edge of example 1. In other words, the end edge of the manifold of example 1 on the side opposite to the side where the slits were formed was additionally processed to have the same shape as the corresponding end edge of comparative example 1 (see fig. 19). The shape of the cross section of the manifold viewed from the width direction is semicircular and constant over the width direction. The size of the cross section becomes larger toward the downstream side in the moving direction of the coating liquid.
Coating was performed in the same manner as in example 1 using a die having a manifold fabricated. The thickness of the resulting coating film was measured over the entire width direction.
The results are shown in fig. 23.
As shown in fig. 23, the change in the thickness of the obtained coating film in the width direction was suppressed as compared with comparative example 1, but the change in the thickness was still large as compared with example 1.
Further, in comparative example 2, streaks appeared on the coating film. The reason is considered that, in comparative example 2, since the size of the cross section of the manifold is different in the width direction, the change in the velocity of the coating liquid in the manifold is different in the width direction (not monotonous change), and as a result, the coating liquid is largely disturbed when flowing in the manifold.
In contrast, in example 1, no mottling occurred in the coating film. The reason is thought to be that, if the shape and size of the cross section of the manifold are the same across the entire width as in example 1, the moving speed of the coating liquid in the manifold changes monotonously, and therefore, the coating liquid is less likely to be disturbed when flowing in the manifold.
Claims (2)
1. A coating apparatus having a die capable of applying a coating liquid to a coating object which moves relatively, wherein,
the coating device is composed of a coating device,
the die head has:
a manifold having an inflow port into which the coating liquid can flow, and capable of conveying the coating liquid flowing in from the inflow port in a width direction of the coating object; and
a slot in communication with the manifold and having an opening at a top end edge of the die,
the shape and size of the cross section of the manifold as viewed from the width direction are the same throughout the width direction,
the opening of the slot extends in the width direction,
setting an end or a center in the width direction in a region where the coating liquid is ejected from the slit at the opening as an origin, setting a direction from the origin along the opening and in which the coating liquid is conveyed as an x-axis, and setting a direction perpendicular to the x-axis from the origin as a y-axis, in this case,
the slot-side end edge of the manifold is formed in a shape plotted by a quadratic curve represented by the following equation (1),
assuming that the coating liquid flowing into the manifold from the inflow port advances along imaginary paths that flow out from the slit-side end edges toward the slit at a plurality of outflow positions arranged in the width direction, that pass through the inside of the slit in a direction parallel to the y-axis, and that are then discharged from a plurality of discharge positions of the opening,
m is an integer of 0 or more for the mth virtual path from the origin, and a distance from the origin to the ejection position is represented by xm[m]The total pressure loss of the coating liquid from the inflow port to the opening is represented by Δ Pm[Pa]And a distance between the outflow position and the ejection position is represented as Lm[m]The amount of the solvent, in this case,
the Δ P can be expressed by the following equations (2) and (3)mAnd said LmIn the context of (a) or (b),
so as to satisfy the equations (2) and (3) and make each delta P in each virtual pathmCalculating each L so that the values of the L are the same between the virtual pathsmFor each calculated LmAnd each LmThe corresponding xmPlotting the relationship of (A) to obtain a graph, determining the quadratic curve by using the quadratic approximation curve of the graph,
algebraic expression 1
y＝Ax2+Bx+C…(1)
A. B, C: coefficient [ - ]
Algebraic expression 2
When m is 0
m is greater than or equal to 1
W: coating width [ m ]
Q1: flow rate [ m ] of coating liquid flowing into manifold3/s]
Q2: flow rate [ m ] of coating liquid flowing out from manifold to portion other than slit3/s]
S: stream of coating liquid discharged from the slit (S ═ Q)1-Q2)/W)[m2/s]
h: height of slot [ m ]
R: radius of manifold [ m ]
nc: first viscosity parameter [ -]
ηc: second viscosity parameter of coating fluid in manifold [ -]
ns: first viscosity parameter [ -]
ηs: second viscosity parameter of coating liquid in slot [ -]。
2. A method for producing a coating film, wherein,
the method for producing the coating film comprises the following steps: the coating apparatus according to claim 1, wherein the coating liquid is discharged onto the coating object which is relatively moved, thereby forming a coating film.
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| JP6722833B1 (en) * | 2020-03-19 | 2020-07-15 | 日東電工株式会社 | Extrusion method |
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| JPH10202159A (en) * | 1997-01-20 | 1998-08-04 | Hitachi Maxell Ltd | Extrusion type coating device |
| JP2003080148A (en) * | 2001-09-10 | 2003-03-18 | Dainippon Printing Co Ltd | Coating apparatus |
| JP2006095460A (en) * | 2004-09-30 | 2006-04-13 | Toppan Printing Co Ltd | Method for releasing air for die head, and die coater |
| CN105381925A (en) * | 2014-09-03 | 2016-03-09 | 日东电工株式会社 | Coating device and coating film manufacturing method |
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| JP2520751B2 (en) * | 1989-12-29 | 1996-07-31 | 富士写真フイルム株式会社 | Coating device |
| JP2001009342A (en) * | 1999-06-28 | 2001-01-16 | Dainippon Printing Co Ltd | Die head |
| JP2002072409A (en) | 2000-09-04 | 2002-03-12 | Fuji Photo Film Co Ltd | Coating application method and device for heat developable photosensitive material |
| JP4852808B2 (en) * | 2001-08-31 | 2012-01-11 | 大日本印刷株式会社 | Coating equipment |
| WO2006117999A1 (en) * | 2005-04-28 | 2006-11-09 | Konica Minolta Holdings, Inc. | Application device, application method, and band-like application object |
| JP5085046B2 (en) * | 2006-03-24 | 2012-11-28 | 日東電工株式会社 | Coating liquid coating method, coating apparatus used therefor, and design method thereof |
| JP4277034B2 (en) * | 2006-09-05 | 2009-06-10 | 信越化学工業株式会社 | Die coater coating method |
| JP2009202141A (en) * | 2008-02-29 | 2009-09-10 | Toray Eng Co Ltd | Slit die and slit die coater |
| JP5315453B1 (en) * | 2012-03-07 | 2013-10-16 | 日東電工株式会社 | Shim member, die coater and coating film manufacturing method |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH10202159A (en) * | 1997-01-20 | 1998-08-04 | Hitachi Maxell Ltd | Extrusion type coating device |
| JP2003080148A (en) * | 2001-09-10 | 2003-03-18 | Dainippon Printing Co Ltd | Coating apparatus |
| JP2006095460A (en) * | 2004-09-30 | 2006-04-13 | Toppan Printing Co Ltd | Method for releasing air for die head, and die coater |
| CN105381925A (en) * | 2014-09-03 | 2016-03-09 | 日东电工株式会社 | Coating device and coating film manufacturing method |
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| CN110394278A (en) | 2019-11-01 |
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