CN113492087B - Extrusion process - Google Patents
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- CN113492087B CN113492087B CN202110184506.2A CN202110184506A CN113492087B CN 113492087 B CN113492087 B CN 113492087B CN 202110184506 A CN202110184506 A CN 202110184506A CN 113492087 B CN113492087 B CN 113492087B
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- 238000001125 extrusion Methods 0.000 title claims abstract description 26
- 238000000034 method Methods 0.000 title description 20
- 239000000463 material Substances 0.000 claims abstract description 24
- 239000012530 fluid Substances 0.000 claims abstract description 5
- 239000007921 spray Substances 0.000 claims description 2
- 238000000576 coating method Methods 0.000 description 76
- 239000011248 coating agent Substances 0.000 description 73
- 239000010408 film Substances 0.000 description 58
- 239000007788 liquid Substances 0.000 description 20
- 238000005259 measurement Methods 0.000 description 11
- 230000000052 comparative effect Effects 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 5
- 239000011347 resin Substances 0.000 description 4
- 229920005989 resin Polymers 0.000 description 4
- 125000006850 spacer group Chemical group 0.000 description 3
- 229910001220 stainless steel Inorganic materials 0.000 description 3
- 239000010935 stainless steel Substances 0.000 description 3
- 230000003247 decreasing effect Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000011295 pitch Substances 0.000 description 2
- 229920000058 polyacrylate Polymers 0.000 description 2
- 229910001369 Brass Inorganic materials 0.000 description 1
- 239000010951 brass Substances 0.000 description 1
- 230000001143 conditioned effect Effects 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 229920006255 plastic film Polymers 0.000 description 1
- -1 polyethylene terephthalate Polymers 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
Classifications
-
- 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
- B05D1/26—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
- B05D1/265—Extrusion coatings
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/07—Flat, e.g. panels
- B29C48/08—Flat, e.g. panels flexible, e.g. films
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/30—Extrusion nozzles or dies
- B29C48/305—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2007/00—Flat articles, e.g. films or sheets
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
- Coating Apparatus (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
Abstract
The present invention provides an extrusion method using a die head having a slit for ejecting a fluid, wherein the extrusion method includes an adjustment step of adjusting the height of the slit in order to adjust the thickness of the ejected material ejected from the slit, the adjustment step including: calculating the thickness d at a position N among arbitrary positions 1 to N in a direction orthogonal to the flow direction of the ejected material by a predetermined formula (1) 2n So that the calculated thickness d is calculated by the prescribed formula (2) 2 ＝{d 21 ...d 2N Target value d of } and thickness ref ＝{d ref1 ...d refN Difference e= { e } between 1 ...e N The height of the gap is determined in such a way that it becomes smaller.
Description
Technical Field
The present invention relates to an extrusion process.
Background
Conventionally, a die having a slit for ejecting a fluid is used for manufacturing various products. For example, a coating device called a coater equipped with the die is used to form a coating film on the surface of a film or the like. In addition, a die called a T-die is used for producing a film in order to extrude a molten resin in a film form.
The manufacturing method using the die comprises a step for adjusting the thickness of the ejected material ejected from the slit to a desired value. For example, patent document 1 discloses a manufacturing method including an adjustment step of adjusting the height of the slit so as to adjust the thickness of the ejection material ejected from the slit.
Prior art literature
Patent literature
Patent document 1: japanese patent laid-open No. 2006-346649
Disclosure of Invention
Problems to be solved by the invention
However, in the past, the adjustment of the thickness of the ejection material was based on the intuition of the operator, and there was a problem that it was difficult to adjust the ejection material to a desired thickness. Specifically, there is a problem that, when the height of the slit at a position corresponding to the thickness of the ejection object is adjusted so as to change the thickness of a part of the ejection object to a desired value, the thickness is also changed at another position of the slit. That is, there is a problem that even if the thickness of a part of the ejected material is adjusted to a desired thickness, the thickness of another part that does not need to be changed changes.
In the extrusion method using the die, the thickness of the jet may be locally changed in addition to the uniformity of the thickness of the jet, and thus, the problem of thickness adjustment may similarly occur.
In view of the above, an object of the present invention is to provide an extrusion method capable of adjusting the thickness of an ejected material relatively easily and with high accuracy.
Solution for solving the problem
As a result of intensive studies, the present inventors have found that the amount of change in the height of the slit and the amount of change in the thickness of the discharge are in a proportional relationship before and after the height of the slit is adjusted, and have completed the present invention.
The present invention provides an extrusion method using a die head having a slit for ejecting a fluid, wherein the extrusion method includes an adjustment step of adjusting the height of the slit in order to adjust the thickness of the ejected material ejected from the slit, the adjustment step including: the thickness d at the position N among the arbitrary positions 1 to N in the direction orthogonal to the flow direction of the ejected material is calculated by the following formula (1) 2n So that the calculated thickness d is calculated by the following formula (2) 2 ＝{d 21 ...d 2N Target of } and thicknessValue d ref ＝{d ref1 ...d refN Difference e= { e } between 1 ...e N The height of the gap is determined in such a way that it becomes smaller.
[ math 1]
d 2n : the calculated thickness d of the spray after adjustment 2 ＝{d 21 ...d 2N Value at position n in }
d 2ave ：d 2 ＝{d 21 ...d 2N Mean value of }
K n : proportional constant k= { K 1 ...K N Value at position n in }
h 2n : imaginary height h of the gap after adjustment 2 ＝{h 21 ...h 2N Value at position n in }
h 2ave ：h 2 ＝{h 21 ...h 2N Mean value of }
h 0n : height h of the gap before adjustment 0 ＝{h 01 ...h 0N Value at position n in }
h 0ave ：h 0 ＝{h 01 ...h 0N Mean value of }
d 0n : thickness d of the jet before adjustment 0 ＝{d 01 ...d 0N Value at position n in }
d 0ave ：d 0 ＝{d 01 ...d 0N Mean value of }
[ formula 2]
e n ＝(d refn -d 2n )…(2)
e n : the difference e= { e 1 ...e N Value at position n in }
d refn : a target value d of the thickness of the ejected material ref ＝{d ref1 ...d refN Position in }The value at n
With this structure, if the height h of the gap before adjustment is found 0 Thickness d of the ejection material before adjustment 0 And the value of the proportionality constant K, the calculated thickness d calculated by the formula (1) can be based on 2 And a target value d of thickness ref The difference e between the two can determine the height of the gap, so that the thickness of the ejected material can be adjusted relatively easily and accurately.
In the extrusion method of the present invention, it is preferable that the difference e= { e expressed by the following formula (3) is obtained 1 ...e N H with minimum sum of squares 2 ＝{h 21 ...h 2N According to h }, according to 2 To determine the height of the gap.
[ formula 3]
With this configuration, the sum of squares of the differences e expressed by the formula (3) is determined by h which minimizes the sum of squares 2 The height of the gap is determined, so that the thickness of the ejected material can be adjusted with higher accuracy.
ADVANTAGEOUS EFFECTS OF INVENTION
As described above, according to the present invention, it is possible to provide an extrusion method capable of adjusting the thickness of an ejected material relatively easily and with high accuracy.
Drawings
Fig. 1 is a schematic perspective view of a die for an extrusion process of one embodiment.
Fig. 2 is an exploded perspective view of the die of fig. 1.
Fig. 3 is a schematic cross-sectional view of the die of fig. 1 taken along line III-III.
Fig. 4 is a graph for comparing the height of the gap before and after adjustment of example 1 with the variation of the thickness of the coating film.
Fig. 5 is a graph for comparing the height of the gap before and after adjustment of example 2 with the variation of the thickness of the coating film.
Fig. 6 is a graph for comparing the change in thickness of the coating film before and after adjustment of comparative example 1.
Fig. 7 is a graph for comparing the height of the gap before and after adjustment of example 3 with the variation of the thickness of the coating film.
Description of the reference numerals
1. A coater; 10. a die head; 11. a slit; 110. an opening; 13. a discharge section; 20. 1 st module; 21. a passage; 22. a chamber; 30. a 2 nd module; 40. a spacer member; 42. an opening; 50. an adjusting mechanism; 51. a slit; 52. an adjusting screw; 521. an outer screw; 522. an inner screw.
Detailed Description
Hereinafter, an extrusion method according to an embodiment of the present invention will be described with reference to the drawings.
The extrusion method according to the present embodiment is as follows: a coating solution as a fluid is applied to the surface of an object to be coated such as a film F using a coating apparatus called a coater 1 as shown in fig. 1 to 3, to form a coating film as an ejected material, and the coating film is formed on the surface of the film F.
The coater 1 includes a die 10 having a slit 11 for ejecting a coating liquid. The die 10 is configured to apply the coating liquid discharged from the slit 11 to an object to be coated such as a film F, which is supported by a roll member or the like and travels so as to be close to the opening 110 of the slit 11, to form a coating film on the surface of the film F. The die 10 is formed such that the discharge portion 13 of the opening 110 in which the slit 11 is formed protrudes toward the object to be coated such as the film F. In the present embodiment, the die 10 has a 1 st die block 20 (lower die block in the drawing) and a 2 nd die block 30 (upper die block in the drawing), and a slit 11 is formed between the respective die blocks. Hereinafter, the direction in which the film F or the coating film flows may be referred to as MD, and the direction perpendicular to the MD may be referred to as TD. The height of the opening 110 of the slit 11 is referred to as the height h of the slit 11.
The die 10 of the present embodiment further includes an adjusting mechanism 50 for adjusting the height h of the slit 11 on the side of the 2 nd die block 30. In the present embodiment, the adjustment mechanism 50 includes: a slit 51 arranged in the 2 nd module 30 along the width direction of the slit 11; and a plurality of adjusting screws 52 which adjust the interval of the slits 51 to adjust the height h of the slit 11. The plurality of adjustment screws 52 are arranged along the extending direction of the slit 51 (in other words, along the width direction of the slit 11). By rotating the adjustment screws 52 to advance or retract, the interval between the slits 51 is increased or decreased, and the height h of the slit 11 is increased or decreased.
As the adjustment screw 52, for example, a differential screw 52 can be preferably used. This facilitates fine adjustment of the height h of the slit 11. The differential screw 52 has an outer screw 521 formed to be hollow and an inner screw 522 formed to be screwed with the inner side of the outer screw 521. In addition, the outer screw 521 and the inner screw 522 are formed to have respective pitches different in size. Thus, when the outer screw 521 is rotated by 1 revolution, the slit 51 expands or reduces the pitch difference between the outer screw 521 and the inner screw 522 by an amount.
As shown in fig. 2, in the present embodiment, the die 10 has a plate-shaped shim member 40, and the shim member 40 is arranged so as to be sandwiched between the 1 st die block 20 and the 2 nd die block 30. The spacer member 40 is formed in a C-shape so as to open toward the opening 110 of the slit 11. By adjusting the width of the opening 42 of the shim member 40 of the die 10, the width of the coating film can be adjusted.
The height h of the slit 11 can be adjusted to be generally 0.01mm to 5mm. The width of the slit 11 is usually set to 200mm to 5000mm.
The number of the adjusting screws 52 is generally 3 to 90. The distance between the centers of the rotation axes of the respective adjustment screws 52 is generally set to 10mm to 400mm. The distances between the centers of the rotation axes are preferably equal distances each, but may be different distances from each other. In the present embodiment, the adjustment mechanism 50 has N adjustment screws 52. Hereinafter, the positions of the slits 11 and the positions of the coating films corresponding to 1 to N adjustment screws 52 are set as positions 1 to N.
As shown in fig. 3, the 1 st module 20 has a chamber 22 for temporarily storing the coating liquid supplied from a storage portion (not shown) for storing the coating liquid through the passage 21. The chamber 22 is formed in a concave shape. In addition, the chamber 22 is connected to the slit 11.
At least the 2 nd module 30 of the 1 st module 20 and the 2 nd module 30 may be made of a material capable of being elastically deformed by the pressing force of the adjusting screw 52 or the like. Typically, the 1 st module 20 and the 2 nd module 30 are made of metal such as stainless steel. In addition, the spacer member 40 is typically made of a metal foil such as stainless steel or brass or a plastic film such as polyethylene terephthalate.
Examples of the coating liquid include a polymer solution. The viscosity of the coating liquid is usually set to 0.0005pa·s to 200pa·s, preferably 0.001pa·s to 100pa·s. In addition, the viscosity was measured by a rheometer (manufactured by HAAKE company). The measurement conditions were that the shear rate was 1[1/s and the temperature was 20 ℃.
Next, the extrusion method according to the present embodiment will be described in detail.
The extrusion method of the present embodiment is a coating method using the coater 1 for forming a coating film on the surface of an object to be coated such as a film F. In order to adjust the thickness d of the coating film formed on the surface of the film F by ejecting the coating liquid from the slit 11, the coating method includes an adjustment step P of adjusting the height h of the slit 11 and an extrusion step of extruding the coating liquid after the adjustment step P. In the present embodiment, the flow rate of the coating liquid supplied from the housing portion of the coater 1 is set to be constant.
In the present embodiment, the flow rate of the coating liquid preferably means a mass flow rate. The flow rate of the coating liquid is not limited to the following cases: in the steady operation, the value calculated as [ maximum flow rate-minimum flow rate ]/average flow rate is 0.2 or less, preferably 0.1 or less.
The adjustment step P includes: a data acquisition step P1 in which the height h of the slit 11 at the positions 1 to N before adjustment is measured in the data acquisition step P1 0 ＝{h 01 ...h 0N And thickness d of the coating film at positions 1 to N before adjustment 0 ＝{d 01 ...d 0N And the height h of the gap 11 at any adjusted position 1 to position N 1 ＝{h 11 ...h 1N And optionally regulatedThickness d of coating film at positions 1 to N 1 ＝{d 11 ...d 1N Measurement is performed; a constant calculation step P2 of calculating a proportionality constant K that correlates the amount of change in the height h of the slit 11 and the amount of change in the thickness d of the coating film on the basis of the data obtained in the data acquisition step P1; and a height determination step P3 in which the thickness d of the coating film at the position N among the positions 1 to N is calculated by the following formula (1) 2n So that the calculated thickness d is calculated by the following formula (2) 2 ＝{d 21 ...d 2N Target value d of } and thickness ref ＝{d ref1 ...d refN Difference e= { e } between 1 ...e N The height h of the slit 11 is determined in such a way that it becomes smaller.
[ math figure 4 ]
[ formula 5 ]
e n ＝(d refn -d 2n )…(2)
[ data acquisition Process P1]
In the data acquisition step P1, the flow rate of the coating liquid supplied from the housing portion of the coater 1 is set to be constant, and the thickness d of the coating film before and after the height h of the slit 11 is arbitrarily adjusted is measured. Namely, the height h of the slit 11 at the positions 1 to N before any adjustment 0 ＝{h 01 ...h 0N And the thickness d of the coating film at positions 1 to N before arbitrary adjustment 0 ＝{d 01 ...d 0N And the height h of the gap 11 at any adjusted position 1 to position N 1 ＝{h 11 ...h 1N And thickness d at positions 1 to N after arbitrary adjustment 1 ＝{d 11 ...d 1N Measurements were made.
As the measurement value of the height h of the slit 11 at the positions 1 to N, a measurement value of the height of a portion corresponding to the adjusting screw 52 can be adopted. That is, the height h of the slit 11 at the same position in the TD direction as the adjustment screw 52 is used as the measurement value.
As the measurement value of the thickness d of the coating film at the positions 1 to N, the thickness d of the coating film at the same position in the TD direction as the adjustment screw 52 can be adopted. The thickness d of the coating film is measured, for example, by a linear gauge (manufactured by kawasaki fabrication).
In the data acquisition step P1, the data is acquired for h 0 ＝{h 01 ...h 0N Mean value h of } 0ave And d 0 ＝{d 01 ...d 0N Average value d of } 0ave And h 1 ＝{h 11 ...h 1N Mean value h of } 1ave And d 1 ＝{d 11 ...d 1N Average value d of } 1ave And (5) performing calculation. In the present embodiment, since the flow rate of the coating liquid is constant, d can be regarded as 0ave ＝d 1ave In this case, only d is calculated 0ave And d 1ave Any one of them may be used.
[ constant calculation step P2]
In the constant calculating step P2, the proportionality constant K is calculated by the following equation (4) which shows the data acquired in the data acquiring step P1 and the proportional relationship between the amount of change in the height h of the slit 11 at the position n and the amount of change in the thickness d of the coating film. More specifically, the calculated thickness d of the coating film at positions 1 to N is calculated using the following formula (4) 1cal ＝{d 1cal1 ...d 1calN [ such that d is calculated by the following formula (5) 1cal ＝{d 1cal1 ...d 1calN And d 1 ＝{d 11 ...d 1N Difference e between } 1 ＝{e 11 ...e 1N Calculating the proportionality constant K= { K at the positions 1 to N in a manner that the ratio becomes smaller 1 ...K N }. The proportionality constant K is a constant used in the following equation (1) substituted in the height determining step P3.
[ formula 6 ]
[ formula 7 ]
e 1n ＝(d 1n -d 1caln )…(5)
d 1caln Represents the calculated thickness d of the coating film after arbitrary adjustment 1cal ＝{d 1cal1 ...d 1calN A value at position n in.
d 1calave Representation d 1caln ＝{d 1cal1 ...d 1calN Average value of }. In the present embodiment, since the flow rate of the coating liquid is constant, d can be regarded as 1calave ＝d 0ave 。
K n Represents the proportionality constant k= { K 1 ...K N A value at position n in.
h 1n The height h of the gap 11 after any adjustment measured in the data acquisition step P1 1 ＝{h 11 ...h 1N A value at position n in.
h 0n The height h of the slit 11 before any adjustment measured in the data acquisition step P1 is shown 0 ＝{h 01 ...h 0N A value at position n in.
d 0n The thickness d of the coating film before any adjustment measured in the data acquisition step P1 0 ＝{d 01 ...d 0N A value at position n in.
e 1n Representing the difference e 1 ＝{e 11 ...e 1N A value at position n in.
d 1n Represents the thickness d of the coating film after any adjustment measured in the data acquisition step P1 1 ＝{d 11 ...d 1N A value at position n in.
For k= { K 1 ...K N Preferably by the least square method to make the difference e represented by the following formula (6) 1 ＝{e 11 ...e 1N The sum of squares of the squares is calculated so as to be minimum.
[ math figure 8 ]
The proportionality constant K may be considered to be constant (K 1 ＝K 2 ＝...＝K N ) The proportionality constant K is calculated by the least square method using the above formulas (4) to (6).
For example, K can be calculated by using a solver of EXCEL (registered trademark) by giving an arbitrary initial value.
[ height determination Process P3]
In the height determining step P3, the thickness d at the position N among the positions 1 to N is calculated by the following formula (1) 2n So that the calculated thickness d is calculated by the following formula (2) 2 ＝{d 21 ...d 2N Target value d of } and thickness ref ＝{d ref1 ...d refN Difference e= { e } between 1 ...e N The height h of the virtual adjusted gap at positions 1 to N is calculated in such a way that the gap becomes smaller 2 ＝{h 21 ...h 2N }。
[ formula 9 ]
[ math.10 ]
e n ＝(d refn -d 2n )…(2)
d 2n Representing the calculated thickness d of the conditioned coating film 2 ＝{d 21 ...d 2N A value at position n in.
d 2ave Representation d 2 ＝{d 21 ...d 2N Average value of }. In the present embodiment, since the flow rate of the coating liquid is constant, d can be regarded as 2ave ＝d 0ave 。
K n Represents the proportionality constant k= { K 1 ...K N A value at position n in. For K n Each K calculated in the constant calculation step P2 may be substituted or substituted inConsider K calculated under certain conditions.
h 2n Indicating the imaginary height h of the adjusted gap 11 2 ＝{h 21 ...h 2N A value at position n in.
h 2ave Represents h 2 ＝{h 21 ...h 2N Average value of }.
e n Representing the difference e= { e 1 ...e N A value at position n in.
d refn A target value d indicating the thickness of the ejected material ref ＝{d ref1 ...d refN A value at position n in.
In the present embodiment, for h 2 ＝{h 21 ...h 2N By least square method to make the difference e= { e expressed by the following formula (3) 1 ...e N The sum of squares of the squares is calculated so as to be minimum. For example, h 2 ＝{h 21 ...h 2N The } can be calculated by assigning an arbitrary initial value and using a solver of EXCEL (registered trademark). And based on the h 2 ＝{h 21 ...h 2N The value of } determines the height h of the adjusted gap 11 3 ＝{h 31 ...h 3N }. Height h of gap 11 after adjustment 3 ＝{h 31 ...h 3N "can directly use h 2 ＝{h 21 ...h 2N The value of } may also be used as h 2 ＝{h 21 ...h 2N The value of } is a value obtained by performing fine adjustment with reference to the value.
[ formula 11 ]
As described above, in the extrusion method according to the present embodiment, the height h of the slit 11 before adjustment is found 0 ＝{h 01 ...h 0N Thickness d of coating liquid before adjusting 0 ＝{d 01 ...d 0N Values of the } and the proportionality constant K, the calculated thickness can be calculated based on the formula (1)d 2 ＝{d 21 ...d 2N Target value d of } and thickness ref ＝{d ref1 ...d refN Difference e= { e } between 1 ...e N Determines the height h of the slit 11 2 ＝{h 21 ...h 2N Based on h } 2 ＝{h 21 ...h 2N The value of } determines the height h of the adjusted gap 11 3 ＝{h 31 ...h 3N Therefore, the thickness of the coating liquid can be adjusted relatively easily and with good accuracy. The extrusion method according to the present embodiment is excellent not only in adjusting the thickness d of the coating liquid to a target uniform thickness, but also in adjusting the thickness d of the coating liquid to a target non-uniform thickness.
The extrusion method of the present invention is not limited to the above embodiment. The extrusion method of the present invention is not limited to the above-described effects. The extrusion method of the present invention can be variously modified within a range not departing from the gist of the present invention.
For example, in the above embodiment, the coating method using the coater 1 has been described, but a method of forming a resin film using a T die or the like for extruding a molten resin may be used. In this case, the viscosity of the molten resin is preferably 1000pa·s to 5000pa·s.
In the above embodiment, the height h of the slit 11 is adjusted by the adjusting mechanism 50 having the slit 51 and the adjusting screw 52, but the present invention is not limited to this. As another adjusting mechanism 50, a hot bolt may be used instead of the adjusting screw 52. In addition to this, for example, the shim member 40 and the modules may be machined to adjust the height h of the slit. The data acquisition step P1 and the constant calculation step P2 may be performed using the coating machine 1 for trial production, and the coating machine 1 having the height h of the slit set in the height determination step P3 to obtain the desired thickness d of the coating film may be manufactured.
In the above embodiment, the least square method is shown as an approximation method, but in addition to this, for example, newton method may be used.
[ example ]
The invention is further illustrated below by means of examples.
In this example, a method of forming a coating film using a coater was studied.
[ coating device ]
The coater used in this example was made of stainless steel, and a 1300mm wide gap was formed between the 1 st and 2 nd modules. In addition, as a height adjusting mechanism of the slit, the coater has a slit provided in the 2 nd module and 26 (i.e., n=26, positions 1 to 26) adjusting screws (a distance between centers of rotation axes: 50mm and constant) arranged in the entire TD direction.
[ coating conditions ]
Under the coating conditions shown in table 1, an acrylic polymer dissolved in a solvent was applied as a coating liquid to the surface of a film as an object to be coated, thereby forming a coating film composed of the acrylic polymer as an ejection product.
[ Table 1]
Example 1
In example 1, the calculation of the proportionality constant k= { K at each of positions 1 to 26 is illustrated 1 ...K 26 And a method of adjusting the height of the slit in such a manner that the thickness of the coating film changes from an uneven state to a uniform state.
(data acquisition step P1)
Height h of gap at positions 1 to 26 before adjustment 0 ＝{h 01 ...h 0_26 And thickness d of the coating film at positions 1 to 26 before adjustment 0 ＝{d 01 ...d 0_26 Measurements were made. Next, the height of the slit is arbitrarily adjusted, and the height h of the slit at the arbitrarily adjusted positions 1 to 26 1 ＝{h 11 ...h 1_26 And optionally the thickness d at positions 1 to 26 1 ＝{d 11 ...d 1_26 Measurements were made. The measurement results are shown in table 2.
(constant calculating step P2)
From the above measurement values, the proportionality constant k= { K is calculated 1 ...K 26 }. Specifically, in the calculation of the proportionality constant K, d is calculated by using the least squares method of the above formulas (4) to (6) 1cal ＝{d 1cal1 ...d 1cal26 And d 1 ＝{d 11 ...d 1_26 Difference e between } 1 ＝{e 11 ...e 1_26 The sum of squares of the ratios k= { K) becomes the smallest proportionality constant k= { K 1 ...K 26 }. The results are shown in Table 2.
(height determination step P3)
The target value d of the thickness of the coating film shown in Table 2 was set ref ＝{d ref1 ...d ref26 Using the least squares method of the above formulas (1) to (3), the calculated thickness d for the positions 1 to 26 is calculated 2 ＝{d 21 ...d 2_26 Target value d of } and thickness ref ＝{d ref1 ...d ref26 Difference e= { e } between 1 ...e 26 The sum of squares of the squares becomes the minimum height h of the adjusted gap at positions 1 to 26 2 ＝{h 21 ...h 2_26 }. The results are shown in Table 2.
(extrusion step)
Height h as gap 3 ＝{h 31 ...h 3N Using h calculated above 2 ＝{h 21 ...h 2_26 The results of forming a coating film on the thin film and measuring the adjusted thickness are shown in table 2 and fig. 4.
As shown in table 2 and fig. 4, the thickness of the coating film before adjustment was in a state of being uneven in the vicinity of the width 225mm and the vicinity of the width 1075mm, and the thickness of the coating film after adjustment was adjusted to be substantially uniform in the entire width direction.
[ Table 2]
Example 2
In example 2, the calculation of the proportionality constant k= { K considered to be constant at positions 1 to 26 is exemplified 1 ＝K 2 ＝...＝K 26 And a method of adjusting the height of the slit in such a manner that the thickness of the coating film becomes uniform. In example 2, h 0 、d 0 And d ref The value of (2) was set to the same value as in example 1. In addition, in the calculation of the proportionality constant K, d is calculated using the above formula (4) 1cal ＝{d 1cal1 ...d 1cal26 And d 1 ＝{d 11 ...d 1_26 Difference e between } 1 ＝{e 11 ...e 1_26 The sum of squares of the ratios k= { K) becomes the smallest proportionality constant k= { K 1 ＝K 2 ＝...＝K 26 Except for the above, the height of the slit was adjusted in the same manner as in example 1, and a coating film was formed on the film. The results are shown in Table 3 and FIG. 5.
As shown in table 3 and fig. 5, the thickness of the coating film after the adjustment was adjusted to be substantially uniform in the entire width direction as in example 1.
[ Table 3]
Comparative example 1
In comparative example 1, the result of the skilled operator adjusting the height of the slit without using the present method is illustrated. In comparative example 1, h 0 、d 0 And d ref The value of (2) was set to the same value as in example 1. In addition, based on h 0 And d 0 The height of the gap was adjusted 5 times using an adjusting screw. The results are shown in Table 4 and FIG. 6.
As shown in table 4 and fig. 6, the target value was deviated in the entire width direction. In particular, the thickness originally smaller than the target value becomes larger than the target value in the vicinity of the position 225mm of the adjusting screw, and the thickness originally larger than the target value becomes smaller than the target value in the vicinity of the position 625mm of the adjusting screw, and it is found that it is difficult to adjust by the experience of the operator.
[ Table 4 ]
In table 5 below, the accuracy of the thickness of the coating films before and after adjustment in examples 1 and 2 and comparative example 1 is summarized. Thickness accuracy was calculated by [ maximum thickness-minimum thickness ]/average thickness×100. As is clear from the results in table 5, the thickness of the coating film can be easily and precisely adjusted by the extrusion method of example 1, as compared with comparative example 1.
[ Table 5 ]
| Example 1 | Example 2 | Comparative example 1 | |
| Adjusting the number of times (times) of thread adjustment | 1 | 1 | 5 |
| Thickness accuracy before adjustment (%) | 9.46 | 9.46 | 9.46 |
| Thickness accuracy after adjustment (%) | 0.65 | 0.69 | 5.77 |
Example 3
In example 3, the determination of a proportionality constant k= { K considered to be constant at positions 1 to 26 is exemplified 1 ＝K 2 ＝...＝K 26 And a method of adjusting the height of the slit in such a manner that the thickness of the coating film changes from a uniform state to a non-uniform state. The coating conditions were as shown in table 6. The results are shown in Table 7 and FIG. 7.
[ Table 6 ]
As shown in table 7 and fig. 7, the thickness of the coating film after the adjustment was adjusted to be in a state of being substantially targeted unevenness in the entire width direction.
[ Table 7 ]
Claims (1)
1. An extrusion method using a die having a slit for ejecting a fluid at a constant flow rate, wherein,
the extrusion method includes an adjustment step of adjusting the height of the slit in order to adjust the thickness of the ejected material ejected from the slit,
the adjusting step includes the steps of: the thickness d at the position N among the arbitrary positions 1 to N in the direction orthogonal to the flow direction of the ejected material is calculated by the following formula (1) 2n ToThe calculated thickness d calculated by the following formula (2) 2 ＝{d 21 ...d 2N Target value d of } and thickness ref ＝{d ref1 ...d refN Difference e= { e } between 1 ...e N The height of the gap is determined in such a way that it becomes smaller,
the thickness d of the calculated ejection material at the positions 1 to N is calculated using the following formula (4) 1cal ＝{d 1cal1 …d 1calN [ such that d is calculated by the following formula (5) 1cal ＝{d 1cal1 …d 1calN And d 1 ＝{d 11 …d 1N Difference e between } 1 ＝{e 11 …e 1N Calculating the proportionality constant K= { K at the positions 1 to N in a manner that the ratio becomes smaller 1 …K N }，
The difference e= { e expressed by the following equation (3) is obtained 1 ...e N H with minimum sum of squares 2 ＝{h 21 ...h 2N According to h }, according to 2 To determine the height of the gap,
d 2n : the calculated thickness d of the spray after adjustment 2 ＝{d 21 ...d 2N Value at position n in }
d 2ave ：d 2 ＝{d 21 ...d 2N Mean value of }
K n : proportional constant k= { K 1 ...K N Value at position n in }
h 2n : imaginary height h of the gap after adjustment 2 ＝{h 21 ...h 2N Value at position n in }
h 2ave ：h 2 ＝{h 21 ...h 2N Mean value of }
h 0n : height h of the gap before adjustment 0 ＝{h 01 ...h 0N Value at position n in }
h 0ave ：h 0 ＝{h 01 ...h 0N Mean value of }
d 0n : thickness d of the jet before adjustment 0 ＝{d 01 ...d 0N Value at position n in }
d 0ave ：d 0 ＝{d 01 ...d 0N Mean value of }
e n ＝(d refn -d 2n )···(2)
e n : the difference e= { e 1 ...e N Value at position n in }
d refn : a target value d of the thickness of the ejected material ref ＝{d ref1 ...d refN Value at position n in }
d 1caln : calculated thickness d of the ejection material after arbitrary adjustment 1cal ＝{d 1cal1 ...d 1calN Value at position n in }
d 1calave ：d 1caln ＝{d 1cal1 ...d 1calN Mean value of }
h 1n : height h of the gap after arbitrary adjustment 1 ＝{h 11 ...h 1N Value at position n in }
h 1ave ：h 1 ＝{h 11 ...h 1N Mean value of }
e 1n ＝(d 1n -d 1caln )···(5)
e 1n : difference e 1 ＝{e 11 ...e 1N Value at position n in }
d 1n : the thickness d1= { d of the ejection material after arbitrary adjustment 11 ...d 1N Position n in }Is a value of (2).
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| JP2020049547A JP6722833B1 (en) | 2020-03-19 | 2020-03-19 | Extrusion method |
| JP2020-049547 | 2020-03-19 |
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| JP2004148252A (en) * | 2002-10-31 | 2004-05-27 | Ricoh Co Ltd | Die nozzle and die nozzle designing method |
| 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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| JPS5672934A (en) * | 1979-11-16 | 1981-06-17 | Ishikawajima Harima Heavy Ind Co Ltd | Method and device for controlling thickness of plastic article by blow molding |
| JP3212648B2 (en) * | 1991-11-19 | 2001-09-25 | 東芝機械株式会社 | Adjusting the gap between the base of automatic T-die with deckle |
| JPH07204561A (en) * | 1994-01-19 | 1995-08-08 | Mitsubishi Heavy Ind Ltd | Coating device for slit nozzle |
| JPH09131561A (en) * | 1995-11-09 | 1997-05-20 | Toray Ind Inc | Coating device, coating method, producing device for color filter and its production |
| JP2000334359A (en) * | 1999-05-26 | 2000-12-05 | Sony Corp | Coating method and apparatus therefor |
| JP3870619B2 (en) * | 1999-09-01 | 2007-01-24 | コニカミノルタホールディングス株式会社 | Coating device |
| JP2002096370A (en) * | 2000-09-26 | 2002-04-02 | Toray Ind Inc | Mouthpiece, sheet, and apparatus and method for manufacturing the sheet |
| JP4304958B2 (en) * | 2002-10-31 | 2009-07-29 | 凸版印刷株式会社 | Coating apparatus and die slit thickness control method |
| CN1195588C (en) * | 2002-11-07 | 2005-04-06 | 上海耀华皮尔金顿玻璃股份有限公司 | Equipment for adjusting transverse flux evenness of lacquer curtain of lacquer showering |
| JP4389607B2 (en) * | 2003-03-03 | 2009-12-24 | 東レ株式会社 | Slit die, and method and apparatus for producing substrate having coating film |
| JP4436281B2 (en) | 2005-06-20 | 2010-03-24 | 東レエンジニアリング株式会社 | Coating equipment |
| JP2008194588A (en) * | 2007-02-09 | 2008-08-28 | Chugai Ro Co Ltd | Coating machine and coating liquid applying method |
| JP4798256B2 (en) * | 2009-05-27 | 2011-10-19 | トヨタ自動車株式会社 | Nozzle unit for applying damping material and damping material application device |
| BR112013031333B1 (en) * | 2011-06-07 | 2020-12-01 | 3M Innovative Properties Company | system for adjusting the position of slotted die |
| CN105921370B (en) * | 2016-06-21 | 2017-05-17 | 华中科技大学 | Film thickness control method for extrusion-coating machine |
| JP6397598B1 (en) * | 2018-04-25 | 2018-09-26 | 日東電工株式会社 | Coating apparatus and coating film manufacturing method |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2004148252A (en) * | 2002-10-31 | 2004-05-27 | Ricoh Co Ltd | Die nozzle and die nozzle designing method |
| 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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| CN113492087A (en) | 2021-10-12 |
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