CN115397568A - Method for producing coating film - Google Patents

Method for producing coating film Download PDF

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Publication number
CN115397568A
CN115397568A CN202180027275.2A CN202180027275A CN115397568A CN 115397568 A CN115397568 A CN 115397568A CN 202180027275 A CN202180027275 A CN 202180027275A CN 115397568 A CN115397568 A CN 115397568A
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China
Prior art keywords
coating liquid
film
coating
liquid film
support
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CN202180027275.2A
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CN115397568B (en
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内海京久
国安谕司
落合昭纪
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Fujifilm Corp
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Fujifilm Corp
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/02Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber
    • B05D7/04Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber to surfaces of films or sheets
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D201/00Coating compositions based on unspecified macromolecular compounds
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/02Emulsion paints including aerosols
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40Additives
    • C09D7/60Additives non-macromolecular
    • C09D7/61Additives non-macromolecular inorganic
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2252/00Sheets
    • B05D2252/02Sheets of indefinite length

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  • Chemical & Material Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Dispersion Chemistry (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

The present invention provides a method for producing a coating film, which includes: a step A of continuously conveying a long support body and applying a water-based coating liquid to the continuously conveyed support body; and a step (B) for drying the coating liquid film obtained in the step (A) on a continuously conveyed support, wherein in the constant-speed drying step of the coating liquid film in the step (B), the curl of the coating liquid film is restricted so that the coating liquid film starts to be in non-contact with a laminate comprising the support and the coating liquid film, while the solid content concentration of the coating liquid film is 70 to 95 mass%.

Description

Method for producing coating film
Technical Field
The present invention relates to a method for producing a coating film.
Background
A method of producing a target coating film on a support in a continuous process in a roll-to-roll system is known.
As a method for producing a coating film, for example, there is a method in which a coating liquid for obtaining a target coating film is applied to a support and the obtained coating liquid film is dried. In this method, a curl regulating mechanism is sometimes used in order to suppress the curl (also referred to as warp) of the coating film.
As an example of a method of applying the curl regulating mechanism to the drying step, patent document 1 discloses a method of using a film developing apparatus including: a developing processing part for developing the undeveloped film; and a drying processing unit that performs a drying process of the film roll that is subjected to the developing process in the developing processing unit, wherein the drying processing unit includes: a hot air blowing mechanism for blowing hot air to the developed film to dry the film; a conveying mechanism for conveying the film while drying the film; and a curl regulating mechanism for regulating the curl in the film width direction caused by the drying process of the film, wherein the curl regulating mechanism uses a film developing device arranged at the downstream side of the conveying direction than the position of the film in the deceleration drying state.
Further, patent documents 2 to 5 disclose various curl regulating mechanisms.
Prior art documents
Patent literature
Patent document 1: japanese patent laid-open publication No. 2006-154375
Patent document 2: japanese patent laid-open No. 2014-166900
Patent document 3: japanese patent laid-open publication No. 2014-005085
Patent document 4: japanese laid-open patent publication No. 2012-125973
Patent document 5: japanese patent laid-open publication No. 10-337848
Disclosure of Invention
Technical problem to be solved by the invention
For example, in a method for producing a coating film on a continuously conveyed support, such as a continuous process in a roll-to-roll system, in which a step of applying an aqueous coating liquid to the support to form a coating liquid film and a step of drying the formed coating liquid film are performed, cracks and curls may occur in the obtained coating film.
Accordingly, an object to be solved by an embodiment of the present invention is to provide a method for producing a coating film in which cracks and curling are suppressed in a method for producing a coating film on a continuously conveyed support (for example, a method using a continuous process in a roll-to-roll system).
Means for solving the technical problems
The means for solving the above problems include the following embodiments.
< 1 > a method for producing a coating film, which comprises: step A, continuously conveying a long support body, and coating a water-based coating liquid on the continuously conveyed support body; and
a step B of drying the coating liquid film obtained in the step A on a continuously conveyed support,
in the constant-rate drying stage of the coating liquid film in the step B, the curl at which the coating liquid film starts to come into non-contact with respect to the laminate composed of the support and the coating liquid film is restricted while the solid content concentration of the coating liquid film is 70 to 95 mass%.
< 2 > the method of producing a coated film according to < 1 >, wherein the solid content concentration of the coating liquid in the step A is 30 to 60% by mass.
< 3 > the method for producing a coating film according to < 1 > or < 2 >, wherein the aqueous coating liquid is a coating liquid containing particles.
< 4 > the method for producing a coating film according to any one of < 1 > to < 3 >, wherein the non-contact curl regulation is performed by a method of ejecting a gas to one surface or both surfaces of the laminate and continuously conveying the laminate while bending the laminate in the thickness direction by the wind pressure of the gas.
< 5 > the method for producing a coating film according to any one of < 1 > to < 4 >, wherein the support is a metal support.
< 6 > the method for producing a coating film according to any one of < 1 > to < 5 >, wherein the support has a thickness of 10 μm to 30 μm.
Effects of the invention
According to an embodiment of the present invention, there is provided a method for producing a coating film in which cracks and curls are suppressed in a method for producing a coating film on a continuously-conveyed support.
Drawings
Fig. 1 is a schematic view showing each step of a method for producing a coating film according to an embodiment.
Fig. 2 is a schematic side view for explaining an example of the curl regulating mechanism in step B.
Fig. 3 is a schematic side view for explaining another example of the curl regulating mechanism in the step B.
Fig. 4 is a schematic diagram illustrating a method of measuring the curl amount.
Detailed Description
Hereinafter, an embodiment of the method for producing a coating film will be described. However, the present invention is not limited to the following embodiments, and can be implemented by applying modifications as appropriate within the scope of the object of the present invention.
In the present invention, the numerical range represented by the term "to" refers to a range in which the numerical values before and after the term "to" are included as the minimum value and the maximum value, respectively.
In the numerical ranges recited in the present invention in stages, the upper limit or the lower limit recited in one numerical range may be replaced with the upper limit or the lower limit recited in other numerical ranges recited in stages. In the numerical ranges described in the present invention, the upper limit value or the lower limit value described in a certain numerical range may be replaced with the values shown in the examples.
The elements shown in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention and there may be areas where emphasis is placed upon.
In the drawings, the same reference numerals are used for components having the same functions, and redundant description is omitted.
In the present invention, the "width direction" refers to a direction perpendicular to the longitudinal direction of the long support, the coating liquid film, and the coating film.
In the present invention, a combination of 2 or more preferred forms or modes is a more preferred form or mode.
Method for producing coating film
As described above, in the method for producing a coating film on a continuously conveyed support, the step of applying an aqueous coating liquid to the support to form a coating liquid film and the step of drying the formed coating liquid film are performed, and in the method for producing a coating film, cracks and curls may occur in the obtained coating film.
The occurrence of cracks and curling in the coating film is a remarkable phenomenon that occurs when an aqueous coating liquid in which the solvent or dispersion medium is actually water is used as the coating liquid.
The present inventors have studied the above-described method for producing a coating film, and as a result, have found that a coating film in which cracks and curling are suppressed can be produced by restricting curling in a non-contact manner from a coating liquid film at a certain timing in a constant-speed drying stage, and have completed the present invention.
The method for producing a coating film according to the present embodiment includes: step A, continuously conveying a long support body, and coating a water-based coating liquid on the continuously conveyed support body; and a step (B) of drying the coating liquid film obtained in the step (A) on a continuously conveyed support, wherein in the constant-speed drying step of the coating liquid film in the step (B), the coating liquid film is restrained from curling by bringing the coating liquid film into non-contact with a laminate comprising the support and the coating liquid film while the solid content concentration of the coating liquid film is 70 to 95 mass%.
According to the method for producing a coating film of the present embodiment, a coating film in which cracks and curling are suppressed is obtained.
On the other hand, in any of patent documents 1 to 5, no description is given of the limitation of curling in the drying step of the coating liquid film. That is, in any of patent documents 1 to 5, there is no description about the relationship between the solid content concentration of the coating liquid film and the timing of starting curl regulation.
Hereinafter, each step of the method for producing a coating film of the present embodiment will be described.
First, an example of a method for producing a coating film will be described with reference to fig. 1.
As shown in fig. 1, when the wound long support 10 is fed out at the leading end thereof and starts to be continuously conveyed, the aqueous coating liquid is applied by the coating mechanism 20 (step a). In the step a, a coating liquid film is formed from the aqueous coating liquid on the long support.
Next, the laminate 12 of the coating liquid film formed in step a and the support 10 is continuously conveyed to the drying mechanism 30, and the coating liquid film is dried on the support 10 (step B). In the step B, the coating liquid film on the long support is dried to form a coating film.
(Process A)
In the step a, a long support is continuously conveyed, and a water-based coating liquid is applied to the continuously conveyed support.
Here, the aqueous coating liquid refers to a coating liquid in which a solvent (or a dispersion medium) contained in the coating liquid is substantially water. The phrase "the solvent (or the dispersion medium) is actually water" means that a solvent other than water introduced when the solid component is used is allowed to be contained, and means that the proportion of water in the total solvent (or the total dispersion medium) is 90% by mass or more, preferably the proportion of water in the total solvent (or the total dispersion medium) is 95% by mass or more, and particularly preferably the total solvent (or the total dispersion medium) is water.
The solid component means a component other than the solvent (or dispersion medium).
Support body
The long support used in the present step is not particularly limited as long as it is a long support that can be applied to roll-to-roll.
On the other hand, a support having high thermal conductivity such as a metal support is likely to cause cracks and curls in the coating film. In the method for producing a coating film according to the present embodiment, a coating film in which cracks and curling are suppressed can be obtained even when a support having high thermal conductivity is used.
Examples of the support having high thermal conductivity include supports having a thermal conductivity of 200W/(m · K) or more. In the case where the support used in the present step has a multilayer structure including, for example, a metal foil and a resin film, the support has a thermal conductivity of 200W/(m · K) or more as long as the thermal conductivity of the entire support is 200W/(m · K) or more.
The upper limit of the thermal conductivity of the support is not particularly limited, and is, for example, 500W/(m · K).
Examples of the support exhibiting the thermal conductivity include a metal support. More specifically, examples of the support exhibiting the thermal conductivity include metal supports made of copper, aluminum, silver, gold, and alloys thereof.
The metal support may be made of stainless steel, nickel, titanium, or invar alloy.
Among them, a copper support and an aluminum support are preferably used in view of shape stability and practical performance as the support.
The thermal conductivity of the support was measured by a laser flash method.
Specifically, the following method is used for measurement, for example.
First, the support was cut at 3 points in the width direction (specifically, positions 5mm apart from both sides in the width direction and the width direction center portion) by 5mm to 10mm in phi to obtain 3 measurement samples. The thermal conductivity of the obtained 3 measurement samples was measured by a thermophysical property measuring apparatus (KYOTO electrical measurement and measurement co., ltd., model LFA-502) to which a laser flash method was applied. The arithmetic mean of the 3 measurements was taken as the thermal conductivity of the support.
The thickness of the support body can be appropriately set from the viewpoint of application to the roll-to-roll system.
The thickness of the support is, for example, preferably 3 μm to 50 μm, and more preferably 10 μm to 30 μm.
The width and length of the support are appropriately set in consideration of the width and length of the target coating film, which is suitable for the roll-to-roll system.
The thickness of the support was measured as follows.
That is, with respect to the thickness of the support body, at 3 points in the width direction (specifically, positions 5mm apart from both side portions in the width direction and a width direction center portion), measurement was performed with a contact type thickness measuring machine such as S-2270 by Fujiwork co. The arithmetic mean of the 3 measurements was taken as the thickness of the support.
Aqueous coating liquid
The aqueous coating liquid used in the present step is not particularly limited as long as it is a liquid containing water and a solid component as a solvent (or a dispersion medium), as described above.
The solid components contained in the aqueous coating liquid include components for improving coating adaptability, in addition to components for a target coating film.
Examples of the water contained in the aqueous coating liquid include natural water, purified water, ion-exchanged water, purified water, and ultrapure water (e.g., milli-Q water). Further, milli-Q water is ultrapure water obtained by a Milli-Q water production apparatus of Merck Millipore Corporation.
The content of water in the aqueous coating liquid is not particularly limited, and is, for example, preferably 40% by mass or more, and more preferably 50% by mass or more, relative to the total mass of the aqueous coating liquid.
The upper limit of the water content may be less than 100 mass%, and for example, from the viewpoint of coating suitability, the upper limit is 80 mass% with respect to the total mass of the aqueous coating liquid.
The aqueous coating liquid may contain particles as one of the solid components. That is, the aqueous coating liquid may be a coating liquid containing particles.
When an aqueous coating solution containing particles is used, the particles are more aggregated in the constant-rate drying stage, and therefore, cracks and curling tend to be more likely to occur. However, by applying the method for producing a coating film according to the present embodiment, even when an aqueous coating liquid containing particles is used, the generation of cracks and curling in the coating film can be suppressed.
The particles are not particularly limited as long as they are granular, and may be inorganic particles, organic particles, or composite particles of an inorganic substance and an organic substance.
As the inorganic particles, known inorganic particles that can be applied to a target coating film can be used.
Examples of the inorganic particles include metal (alkali metal, alkaline earth metal, transition metal, etc., and alloys of these metals) particles, semimetal (silicon, etc.) particles, metal or semimetal compound (oxide, hydroxide, nitride, etc.) particles, and pigment particles containing carbon black, etc.
The inorganic particles include mineral particles such as mica, inorganic pigment particles, and polycrystalline diamond.
As the organic particles, known organic particles that can be applied to a target coating film can be used.
The organic particles are not particularly limited as long as they are represented by resin particles and organic pigment particles and solid organic particles.
Examples of the composite particles of an inorganic substance and an organic substance include composite particles in which inorganic particles are dispersed in a matrix composed of an organic substance, composite particles in which the periphery of organic particles is coated with an inorganic substance, composite particles in which the periphery of inorganic particles is coated with an organic substance, and the like.
The particles may be subjected to a surface treatment for the purpose of imparting dispersibility or the like.
Further, the composite particles can be obtained by performing surface treatment.
The particle diameter, specific gravity, use mode (for example, if not used in combination), and the like of the particles are not particularly limited, and can be appropriately selected depending on the target coating film or depending on conditions suitable for producing the coating film.
The content of the particles in the aqueous coating liquid is not particularly limited, and may be appropriately determined depending on the target coating film, conditions suitable for producing the coating film, or the purpose of adding the particles.
The solid component contained in the aqueous coating liquid is not particularly limited, and various components used for obtaining a desired coating film may be mentioned.
Specific examples of the solid component contained in the aqueous coating liquid include, in addition to the particles, a binder component, a component contributing to dispersibility of the particles, a polymerizable compound, a reactive component such as a polymerization initiator, a component for improving coating performance such as a surfactant, and other additives.
The solid content concentration of the aqueous coating liquid used in the present step is not particularly limited, but is preferably less than 70% by mass, and more preferably 30% by mass to 60% by mass.
Thickness of the coating liquid film-
The thickness of the coating liquid film formed in the present step is not particularly limited, and may be appropriately determined depending on the target coating film.
The thickness of the coating liquid film may be, for example, 10 to 200 μm, or 20 to 100 μm, from the viewpoint of easy occurrence of cracks and curling.
The thickness of the coating liquid film was measured as follows.
That is, the coating liquid film was measured at 3 points in the width direction (specifically, at positions 5mm apart from both sides in the width direction and at the center in the width direction) by an optical interference type thickness measuring instrument, for example, an infrared spectroscopic interference type film thickness meter SI-T80 of KEYENCE CORPORATION. The arithmetic mean of the measured values at 3 points was obtained as the thickness of the coating liquid film.
Coating width-
The coating width (i.e., the width of the coating liquid film) in this step is not particularly limited, but may be selected from 100mm or more and 1000mm or more from the viewpoint of easy occurrence of curling.
The upper limit of the coating width is the width of the support.
The coating width was measured as follows.
The width of the coating liquid film was measured from the upper surface of the film surface of the coating liquid film by FALCIO-APEX776 of MITUTOYO CORPORATION, and this was taken as the coating width.
Coating-
The coating of the coating liquid in this step is performed by a known coating mechanism.
Specific examples of the coating mechanism (for example, the coating mechanism 20 in fig. 1) include coating apparatuses using a curtain coating method, a dip coating method, a spin coating method, a printing coating method, a spray coating method, a slit coating method, a roll coating method, a slide coating method, a blade coating method, a gravure coating method, a wire bar method, and the like.
[ Process B ]
In the step B, the coating liquid film obtained in the step a is dried on a continuously conveyed support.
Then, in the constant-speed drying stage of the coating liquid film in the step B, the curl at which the coating liquid film starts to come into non-contact with respect to the laminate composed of the support and the coating liquid film is restricted while the solid content concentration of the coating liquid film is 70 to 95 mass%.
The drying in this step means that the coating liquid film formed in step a is passed through a constant-speed drying step and a deceleration drying step until the target solid content concentration is reached.
Here, "constant-rate drying" is a drying manner in which the content of the solvent (or dispersion medium) in the coating liquid film decreases with time.
Generally, the coating liquid film is dried at a constant rate from immediately after formation until a predetermined time elapses, and then is dried at a reduced speed. The time for constant-rate drying is described, for example, in the chemical engineering review (pages 707 to 712, MARUZEN GROUP hair style, showa 55 (1980) 10 months and 25 days).
In the present invention, the change with time of the film surface temperature at the center portion in the width direction of the formed coating liquid film is measured, and a period during which the film surface temperature shows a predetermined value (specifically, a period during which the temperature change of the film surface temperature is kept within ± 5 ℃) in the measurement of the film surface temperature from immediately after the coating (immediately after the formation of the coating liquid film) is regarded as a "constant-speed drying stage".
Then, the period after the film surface temperature shows the predetermined value and the period after the film surface temperature rises is regarded as the "deceleration drying stage".
Further, the film surface temperature was measured with a non-contact radiation thermometer.
In the step B, the drying temperature may be changed stepwise or continuously in the direction of the conveyance of the coating liquid film. In this case, it is considered that the film surface temperature of the coating liquid film is also influenced and changed. Therefore, in the step B, a period in which the film surface temperature of the coating liquid film changes to the same extent as the amount of change in the drying temperature is included in the "period in which the film surface temperature shows a predetermined value".
That is, the constant-speed drying stage is considered until the film surface temperature of the coating liquid film rises to the amount of change in the drying temperature or more.
The constant-speed drying stage in the case where the drying temperature in step B is constant will be described in detail.
First, with respect to the coating liquid film formed on the support, the change with time of the film surface temperature in the central portion in the width direction is measured, and the relationship between the measured film surface temperature and the elapsed time is graphed, for example, with the film surface temperature being taken as the vertical axis and the elapsed time being taken as the horizontal axis.
In the obtained graph, a period during which the film surface temperature shows a predetermined value (specifically, a period during which the temperature change of the film surface temperature is kept within ± 5 ℃) in the measurement of the film surface temperature immediately after the coating (immediately after the coating liquid film is formed) is regarded as the constant-rate drying stage.
The point of change in the film surface temperature at which the film surface temperature changes when the film surface temperature increases is defined as the end point of the constant-speed drying stage. The change point is determined by the intersection of a straight line extending from the film surface temperature to the elapsed time side in the predetermined period and a tangent line drawn at the point where the gradient of the film surface temperature is maximum.
-crimp limitation-
In the step, in the constant-speed drying stage of the coating liquid film, the coating liquid film is restrained from curling in a non-contact manner with respect to a laminate composed of the support and the coating liquid film while the solid content concentration of the coating liquid film is 70 to 95 mass%.
That is, in this step, in the constant-rate drying step (i.e., during the period in which the film surface temperature shows a predetermined value), the solid content concentration of the coating liquid film increases from 70 mass% to 95 mass%, and the non-contact curl restriction of the coating liquid film is started with respect to the laminate composed of the support and the coating liquid film.
When the solid content concentration of the coating liquid film reaches 70 mass%, the solid content concentration is sufficiently high, and therefore, even if stress is applied to the coating liquid film due to curl limitation (for example, even if a gas is blown), the occurrence of cracks can be suppressed.
On the other hand, in the constant-rate drying stage, the curl limitation is performed until the solid content concentration of the coating liquid film reaches 95 mass%, whereby the curl limitation effect can be improved as compared with the case where the curl limitation is performed after the deceleration drying stage is reached.
In addition, since the curl control performed in this step is not in contact with the coating liquid film, it does not come into contact with the surface of the coating liquid film having the remaining fluidity in the constant-speed drying stage. As a result, the curl limitation can suppress the influence on the surface morphology, properties, and the like of the surface of the coating liquid film.
Therefore, by restricting the curling at the above timing, a coating film is formed in which the cracks and curling are suppressed.
The measurement of the solid content concentration of the coating liquid film can be obtained by measuring the non-contact thickness from the time when the aqueous coating liquid is applied to the support until the aqueous coating liquid becomes a dry film, using an infrared spectroscopic interference type film thickness meter SI-T80 of KEYENCE CORPORATION.
Specifically, first, the non-contact thickness was measured from the time when the aqueous coating solution was applied to the support until the aqueous coating solution became a dry film.
Then, the thickness of the dried film (dry film) was measured by a contact thickness meter. The thickness of the measured dry film is subtracted from the non-contact thickness measured previously to calculate the thickness of the solvent (or dispersion medium) in the coating liquid film at each measurement point.
The solid content concentration value is obtained by multiplying the thickness of the obtained dry film and the thickness of the solvent (or dispersion medium) by the respective densities (density of the dry film and density of the solvent), and converting the resultant into the dry film weight per unit area of the coating liquid film and the solvent weight at the measurement point.
The non-contact curl restriction used in the present step is not particularly limited as long as it is a mechanism that does not contact the coating liquid film and can restrict the widthwise end portion of the laminate of the coating liquid film and the support from curling (i.e., warping) on the coating liquid film side.
From the viewpoint of excellent curl regulating ability, it is preferable that the non-contact curl regulation is performed by a mechanism (hereinafter, also referred to as a curl regulating mechanism) that discharges a gas to one surface or both surfaces of the laminate and continuously conveys the laminate while bending the laminate in the thickness direction by the wind pressure of the gas.
The curl regulating mechanism also functions as a part of the drying mechanism because it promotes drying (i.e., increases the solid content concentration) by ejecting gas to the stacked body.
Crimp limiting mechanism
The curl regulating mechanism will be described with reference to fig. 2 and 3. Fig. 2 and 3 are schematic side views for explaining the curl regulating mechanism in step B.
In fig. 2 and 3, 32 denotes a before-curl-restriction region, and 34 denotes a curl-restriction region.
In the drying mechanism 30A shown in fig. 2, a curl regulating mechanism is used in the curl regulating region 34, which discharges a gas to one surface of the laminate 12 (i.e., the surface on which the coating liquid film is formed) and continuously conveys the laminate while bending the laminate in the thickness direction by the wind pressure of the gas.
In the drying mechanism 30B shown in fig. 3, a curl regulating mechanism is used in which gas is ejected from both surfaces of the laminate 12 (i.e., the surface on which the coating liquid film is formed and the exposed surface of the support) and the laminate is continuously conveyed while being bent in the thickness direction by the wind pressure of the gas in the curl regulating region 34.
As shown in the schematic side views of fig. 2 and 3, according to this curl regulating mechanism, the stacked body 12 can be conveyed while undulating in a wave shape. As described above, by conveying the laminated body 12 while undulating in a wave shape, the curl restriction can be effectively found, and the curl suppression effect can be improved.
Further, the drying speed of the coating liquid film can be controlled by adjusting the type of gas discharged from the curl regulating mechanism, the wind pressure, the temperature, the humidity, and the like.
The curl regulating mechanisms shown in fig. 2 and 3 have the same curl regulating ability.
The drying mechanism 30A shown in fig. 2 will be explained.
As shown in fig. 2, the laminate 12 of the coating liquid film and the support is transferred to the drying mechanism 30A, and the coating liquid film is dried.
In fig. 2, the solid content concentration of the coating liquid film in the laminate 12 is increased in the pre-curl-restriction region 32, and curl restriction is started in the curl-restriction region 34 while the solid content concentration of the coating liquid film on the support 12 is 70 mass% to 95 mass%.
In the pre-curl regulation region 32 in fig. 2, the solid content concentration of the coating liquid film in the laminate 12 is increased by using a drying mechanism (for example, a fan heater) as described later.
In the curl limiting region 34 in fig. 2, a plurality of carrying rollers 36 are provided in parallel on the same plane on the side of the support body, and a plurality of ejecting portions 38 for ejecting gas are provided in parallel on the same plane between the positions where the carrying rollers 36 are provided on the side of the coating liquid film.
A gas (for example, air at 40 ℃) is ejected toward the laminated body 12 from the ejection section 38, and the conveying roller 36 is rotated, whereby the laminated body 12 is conveyed while being bent in its thickness direction by the wind pressure of the gas.
The drying mechanism 30B shown in fig. 3 will be explained.
As shown in fig. 3, the laminate 12 of the coating liquid film and the support is transferred to the drying mechanism 30B, and the coating liquid film is dried.
In fig. 3, the solid content concentration of the coating liquid film in the laminate 12 is increased in the pre-curl-restriction region 32, and curl restriction is started in the curl restriction region 34 while the solid content concentration of the coating liquid film on the support 12 is 70 to 95 mass%.
In the pre-curl regulation region 32 in fig. 3, the solid content concentration of the coating liquid film in the laminate 12 is increased by using a drying mechanism (for example, a fan heater) as described later.
In the curl limiting region 34 in fig. 3, a plurality of ejection portions 38a for ejecting gas are provided in parallel on the same plane on the support side, and a plurality of ejection portions 38b for ejecting gas are provided in parallel on the same plane between the positions where the ejection portions 38a are provided on the coating liquid film side.
The gas (e.g., air at 40 ℃) is ejected toward the stacked body 12 from the ejection section 38a, and the gas (e.g., air at 40 ℃) is ejected toward the stacked body 12 from the ejection section 38b, whereby the stacked body 12 is conveyed while being bent in the thickness direction thereof by the wind pressure of the gas.
The curl regulating region 34 in fig. 2 and 3 may be provided at a position where the curl regulation starts while the solid content concentration of the coating liquid film of the conveyed laminate 12 is 70 to 95 mass%.
The change in the solid content concentration of the coating liquid film can be examined in advance, and the setting position of the curl regulating region 34 can be set based on the adjustment result.
Further, by determining the position where the curl limiting region 34 is provided and appropriately adjusting the transport speed of the laminate 12, the drying conditions of the pre-curl limiting region 32, and the like, the drying state of the coating liquid film can be controlled so that the solid content concentration of the coating liquid film reaches the curl limiting region 34 in the range of 70 mass% to 95 mass%.
The end point of the curl limiting region 34 is preferably, for example, a point between the exit of the drying means 30A or 30B. That is, the curl restricted area 34 preferably continues from the constant speed drying stage to the deceleration drying stage.
In the curl regulating region 34 in fig. 2 and 3, examples of the gas to be ejected toward the laminated body 12 include air.
The temperature of the gas to be ejected is, for example, preferably 25 to 200 ℃, and more preferably 30 to 150 ℃.
The velocity of the ejected gas is preferably, for example, 1.5 to 50 m/sec.
In addition, the amount of deformation of the laminated body 12 in the curl regulating region 34 can be adjusted.
As shown in fig. 2 and 3, when the laminate 12 is viewed from the side as the deformation amount of the laminate 12, there are a distance p between a mountain and an adjacent mountain in the laminate 12 having wavy undulations, and a height difference h between a mountain and a valley in the laminate 12. The distance p is equal to the distance between the conveying rollers 36 or the distance between the ejection portions 38b.
The distance p is, for example, preferably 100mm to 1500mm, and more preferably 200mm to 1000mm.
The height difference h is preferably 10mm to 500mm, and more preferably 20mm to 200mm.
The smaller the value of the distance p/height difference h, the higher the curl restriction force, and therefore, the smaller the value is, the smaller the curl restriction force is, the smaller the value is preferably 10 or less, and more preferably 5 or less. Since the number of components in the curl limiting region 34 increases or the size thereof increases when the value of the distance p/the height difference h is reduced, the lower limit value of the distance p/the height difference h is preferably set to an optimum value in consideration of the installation space of the device, the air intake capability, the cost, and the like. The lower limit of the distance p/height difference h is, for example, 2.
Temperature of membrane surface-
The temperature of the membrane surface in the constant-rate drying stage is not particularly limited, and may be, for example, 35 ℃ or higher.
Drying-
In this step, a known drying mechanism is applied to dry the coating liquid film.
As the drying means (for example, a part of the drying means 30 in fig. 1, and drying in the region before the curl restriction in fig. 2 and 3), specifically, an oven, a fan heater, an Infrared (IR) heater, and the like can be given.
As described above, the coating film is formed on the support through the step B.
The thickness of the coating film obtained through the step B is not particularly limited as long as it is a thickness according to the purpose, use, and the like.
In the method for producing a coating film according to the present embodiment, the thickness of the coating film is preferably 40 μm or more, more preferably 50 μm or more, and still more preferably 60 μm or more, from the viewpoint of easy occurrence of cracks and curling.
The upper limit value of the thickness of the coating film is not particularly limited as long as it is determined according to the use, and is, for example, 65 μm.
The measurement of the thickness of the coating film is the same as that of the coating liquid film.
[ other Processes ]
At least one of before the step a and after the step B may have another step, if necessary.
The other steps are not particularly limited, and include a pretreatment step performed before applying the coating liquid film, a post-treatment step performed on the formed coating film depending on the application of the coating film, and the like.
Specific examples of the other steps include a step of surface-treating the support, a step of hardening the coating film, a step of compressing the coating film, a step of cutting the coating film, and a step of peeling the support from the coating film.
The method for producing a coating film according to the present embodiment is a method for producing a coating film on a continuously conveyed support, and is therefore suitable for producing a coating film for applications requiring high productivity.
Examples
The present invention will be described in more detail below with reference to examples. The materials, the amounts used, the ratios, the details of the respective steps, and the like shown in the following examples can be modified as appropriate without departing from the spirit of the present invention. Therefore, the scope of the present invention is not limited to the specific examples shown below.
In addition, "parts" are on a mass basis.
< preparation of support >
An aluminum support 1 (thermal conductivity: 230W/(m.K)) (abbreviated as AL 1) having a width of 220mm, a thickness of 10 μm and a length of 300m was prepared.
An aluminum support 2 (thermal conductivity: 230W/(m.K)) (abbreviated as AL 2) having a width of 220mm, a thickness of 30 μm and a length of 300m was prepared.
< preparation of aqueous coating liquid >
[ preparation of aqueous coating solutions A1 and A2 ]
The following components were mixed to prepare an aqueous coating liquid a. Then, the aqueous coating liquid a was diluted with pure water to prepare an aqueous coating liquid A1 having a solid content concentration of 60 mass% and an aqueous coating liquid A2 having a solid content concentration of 30 mass%, respectively.
Polyvinyl alcohol: 58 portions of
( CKS-50: degree of saponification 99 mol%, degree of polymerization 300, nippon Synthetic Chemical Industry Co., ltd. )
DKS co.ltd.cellrogenpr: 24 portions of
Surfactant NIHON emulosion co., ltd., EMALEX 710): 5 portions of
An aqueous dispersion of ART pearll J-7P prepared by the following method: 913 parts by weight
(Water dispersion of ART PEARL J-7P)
To 74 parts of pure water were added 3 parts of dissolved EMALEX 710NIHON emulosion Co., ltd., nonionic surfactant) and 3 parts of carboxymethyl cellulose (DKS co.ltd.). To the obtained aqueous solution, 20 parts of ART PEARL (registered trademark) J-7P (Negami Chemical Industrial co., ltd, silica composite crosslinked acrylic resin fine particles) was added, and dispersed at 10,000 rpm (solvents per minute; the same shall apply hereinafter) for 15 minutes by an ACE homogenizer (NIHONSEIKI KAISHA Ltd.) to obtain a water dispersion (particle concentration: 20 mass%) of ART PEARL J-7P.
The silica composite crosslinked acrylic resin fine particles in the obtained water dispersion had a true specific gravity of 1.20 and an average particle diameter of 6.5 μm.
[ preparation of aqueous coating liquid B1 ]
The following ingredients were mixed and stirred by a dissolver (2000 rpm, 30 minutes), to prepare an aqueous coating liquid B (dispersion a: dispersion B = 25. The viscosity of the aqueous coating liquid B was 20 mPas, and the average particle diameter of the particles was 0.108. Mu.m. Then, the aqueous coating solution B was diluted with ion-exchanged water (or pure water) to adjust the solid content concentration to 30% by mass, and the resultant was used as an aqueous coating solution B1.
Dispersion a prepared by the following method: 132.1 parts
Dispersion B prepared by the following process: 396.2 parts
Boric acid (crosslinker): 2.94 parts of
Polyvinyl alcohol (7.3 mass% aqueous solution): 230.7 portions
(KURARAAY CO., LTD., PVA 235, degree of saponification 88%, degree of polymerization 3500)
Diethylene glycol monobutyl ether: 2.7 parts of
(butisenol 20-P、KH Neochem Co.,Ltd.)
Ion-exchanged water: 93.5 parts
Polyoxyethylene lauryl ether (surfactant): 0.49 parts of
(EMULGEN 109P 10% aqueous solution, HLB 13.6, kao Corporation)
Ethanol: 41.4 parts of
(preparation of Dispersion A)
After mixing the following ingredients and ultrasonic dispersion, the dispersion was heated to 30 ℃ and held for 8 hours to prepare a dispersion a.
Fumed silica fine particles (inorganic fine particles): 299.6 parts of
(AEROSIL 300SF75、NIPPON AEROSIL CO.,LTD.)
Ion-exchanged water: 1400 parts of
Alpha 83 (40.0% aqueous solution): 300 portions of
(dispersant, TAIMEI CHEMICALS CO., LTD.)
(preparation of Dispersion B)
After mixing the following ingredients and ultrasonic dispersion, the dispersion was heated to 30 ℃ and held for 8 hours to prepare a dispersion B.
Fumed silica fine particles (inorganic fine particles): 225.2 portions
(AEROSIL 300SF75、NIPPON AEROSIL CO.,LTD.)
Ion-exchanged water: 1185 parts of
Cationic polymer a (25% aqueous solution) of the following structure: 90 portions of
[ chemical formula 1]
Figure BDA0003879768250000161
[ example 1]
With the apparatus configured as shown in fig. 1, an aqueous coating liquid A1 was applied to an aluminum support 1 (i.e., AL 1) to form a coating liquid film, and the formed coating liquid film was dried to obtain a coating film.
Specifically, an aqueous coating liquid A1 was applied to a continuously conveyed support AL1 with a coating width of 200mm (step a). The thickness of the coating liquid film formed was as described in table 1.
Next, the laminate 12 of the coating liquid film and the support obtained in step a was transferred to the drying mechanism 30A shown in fig. 2, and the coating liquid film was dried using the curl regulating mechanism described in table 1 (step B).
In the curl regulating region 34 in the drying mechanism 30A shown in fig. 2, a gas was ejected to one surface of the laminate 12 (i.e., the surface on which the coating liquid film was formed), and the laminate was continuously conveyed while being bent in the thickness direction by the wind pressure of the gas (one surface floated in table 1). The conditions of the curl restriction in the curl restriction region 34 are as follows.
The kind of gas: air (W)
Temperature of the gas: 40 deg.C
Wind pressure of gas ejected to the surface on which the coating liquid film is formed: 1.3kPa
Air volume of gas ejected to the formation surface of the coating liquid film: 5m 3 /min
Deformation amount of laminate: distance p in fig. 2: 300mm, height difference h in fig. 2: 60mm, distance p/height difference h:5
The solid content concentration of the coating liquid film at the time of starting the curl restriction is 99 mass%, as shown in table 1, and the solid content concentration of the coating liquid film at the time of finishing the curl restriction is 99 mass%.
The support was conveyed at a speed of 3.0 m/min in the steps A and B.
The coating film was formed through the steps a and B as described above.
Examples 2 to 15 and comparative examples 1 to 10
A coating film was formed in the same manner as in example 1, except that the type of the support, the type and solid content concentration of the coating liquid, the thickness of the coating liquid film, and the solid content concentration of the coating liquid film at the time of starting the curl restriction were appropriately changed as shown in table 1.
[ evaluation of cracks in the coating film ]
With respect to the coating films obtained in the respective examples, the measurement samples were cut from the central portions in the width direction and the longitudinal direction. The size of the sheared measurement sample was a square of 50mm × 50 mm.
The surface of the test specimen was observed with a microscope at 50 magnifications to confirm the presence or absence of cracks having a diameter of 0.5mm to 2mm, and the cracks were evaluated according to the following criteria.
Evaluation index-
A: without crazing (i.e., without cracks)
B: cracking (i.e., cracks) of 1mm or less was observed
C: cracks exceeding 1mm were confirmed (i.e., cracks were present)
The results are shown in Table 1.
[ evaluation of curl of coating film ]
With respect to the coating films obtained in the respective examples, measurement samples including the widthwise sides of the coating film were cut from the central portion in the longitudinal direction. The sheared measurement sample had a rectangular shape of 3.5mm by 35mm in size.
As shown in fig. 4, the measurement sample (i.e., the laminate 14 of the coating film and the support) was left on a flat table 40, and the lifting at the portion corresponding to the side portion in the width direction of the coating film (i.e., the curl amount C) was measured at 3 points, and the arithmetic average value of the values at 3 points was obtained, and the curl was evaluated by the following index.
In addition, the measurement is carried out in an environment with the temperature of 23-25 ℃ and the relative humidity of 45-55%.
Evaluation index-
A: floating up to 1mm or less
B: floating over 1mm to 2mm or less
C: floating to over 2mm
[ Table 1]
Figure BDA0003879768250000181
As is clear from table 1, according to the method for producing a coating film of the example, a coating film having no cracks and little curling was formed.
The entire disclosure of japanese patent application No. 2020-073689, filed on 16/4/2020, is hereby incorporated by reference into this specification. All documents, patent applications, and technical standards cited in the present specification are incorporated by reference into the present specification to the same extent as if each document, patent application, and technical standard was specifically and individually indicated to be incorporated by reference.
Description of the symbols
10-support, 12-laminate of coating liquid film and support, 14-laminate of coating film and support, 20-coating means, 30A, 30B-drying means, 32-before-crimp-restriction region, 34-crimp-restriction region, 36-transport roller, 38a, 38B-ejection section, 40-stage, C-crimp amount, h-height difference between mountain and valley (height difference of corrugation), distance between p-mountain and adjacent mountain (interval of corrugation).

Claims (6)

1. A method for producing a coating film, comprising:
a step A of continuously conveying a long support body and applying a water-based coating liquid to the continuously conveyed support body; and
a step B of drying the coating liquid film obtained in the step A on a continuously conveyed support,
in the constant-speed drying stage of the coating liquid film in the step B, the curl of the coating liquid film, which starts to be in non-contact with the laminate composed of the support and the coating liquid film, is restricted while the solid content concentration of the coating liquid film is 70 to 95 mass%.
2. The method for producing a coated film according to claim 1,
the solid content concentration of the coating liquid in the step a is 30 to 60% by mass.
3. The method for producing a coating film according to claim 1 or 2, wherein,
the aqueous coating liquid is a coating liquid containing particles.
4. The method for producing a coated film according to any one of claims 1 to 3,
the non-contact curl limitation is performed by the following means:
the laminate is continuously conveyed while being bent in the thickness direction by the wind pressure of the gas while the gas is ejected to one surface or both surfaces of the laminate.
5. The method for producing a coated film according to any one of claims 1 to 4,
the support body is a metal support body.
6. The method for producing a coated film according to any one of claims 1 to 5,
the thickness of the support is 10-30 μm.
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