CN117654825A - Gravure coating device, method for producing laminate, method for producing optical film, method for producing image display device, and coating unit - Google Patents
Gravure coating device, method for producing laminate, method for producing optical film, method for producing image display device, and coating unit Download PDFInfo
- Publication number
- CN117654825A CN117654825A CN202311141176.4A CN202311141176A CN117654825A CN 117654825 A CN117654825 A CN 117654825A CN 202311141176 A CN202311141176 A CN 202311141176A CN 117654825 A CN117654825 A CN 117654825A
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- Prior art keywords
- coating liquid
- coating
- producing
- laminate
- layer
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Classifications
-
- 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
- B05C1/00—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
- B05C1/04—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length
- B05C1/08—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line
- B05C1/12—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line the work being fed round the roller
-
- 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
- B05C1/00—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
- B05C1/003—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating incorporating means for heating or cooling the liquid or other fluent material
-
- 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
- B05C1/00—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
- B05C1/04—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length
- B05C1/08—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line
- B05C1/0817—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line characterised by means for removing partially liquid or other fluent material from the roller, e.g. scrapers
-
- 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
- B05C1/00—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
- B05C1/04—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length
- B05C1/08—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line
- B05C1/086—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line a pool of coating material being formed between a roller, e.g. a dosing roller and an element cooperating therewith
- B05C1/0865—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line a pool of coating material being formed between a roller, e.g. a dosing roller and an element cooperating therewith the cooperating element being a roller, e.g. a coating roller
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C11/00—Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00
- B05C11/02—Apparatus for spreading or distributing liquids or other fluent materials already applied to a surface ; Controlling means therefor; Control of the thickness of a coating by spreading or distributing liquids or other fluent materials already applied to the coated surface
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C13/00—Means for manipulating or holding work, e.g. for separate articles
- B05C13/02—Means for manipulating or holding work, e.g. for separate articles for particular articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41F—PRINTING MACHINES OR PRESSES
- B41F31/00—Inking arrangements or devices
- B41F31/02—Ducts, containers, supply or metering devices
- B41F31/06—Troughs or like reservoirs with immersed or partly immersed, rollers or cylinders
- B41F31/07—Troughs or like reservoirs with immersed or partly immersed, rollers or cylinders for rotogravure
Landscapes
- Application Of Or Painting With Fluid Materials (AREA)
- Coating Apparatus (AREA)
Abstract
The invention aims to provide a gravure coating device capable of inhibiting occurrence of defects, a manufacturing method of a laminated body, a manufacturing method of an optical film, a manufacturing method of an image display device and a coating unit. The gravure coating device of the present invention is characterized by comprising: a coating section for coating a coating liquid on at least one surface of a substrate; and a drying section for drying the applied coating liquid to form a resin layer, wherein the coating section includes a gravure roll capable of filling cells on the surface of the gravure roll with the coating liquid stored in the coating liquid storage section, and a coating liquid storage section in which the coating liquid is transferred onto the substrate in the cells, and the supply and discharge of the maximum amount of the coating liquid storable in the coating liquid storage section is performed every 150 seconds or less.
Description
Technical Field
The present invention relates to a gravure coating apparatus, a method for manufacturing a laminate, a method for manufacturing an optical film, a method for manufacturing an image display apparatus, and a coating unit.
Background
There are several manufacturing apparatuses capable of manufacturing a laminate from roll to roll, and a gravure coating apparatus is a representative example (patent document 1).
Prior art literature
Patent literature
Patent document 1: japanese patent laid-open No. 2008-100181
Disclosure of Invention
Problems to be solved by the invention
The gravure coating apparatus includes a reservoir tank (hereinafter, also referred to as "coating liquid reservoir") for storing coating liquid in a coating portion, as described in patent document 1, for example. At this time, for example, if the foreign matter is mixed in the coating liquid reservoir, the mixed foreign matter is applied to the substrate to be coated together with the coating liquid, and there is a possibility that defects in appearance may occur.
Accordingly, an object of the present invention is to provide a gravure coating device, a method for producing a laminate, a method for producing an optical film, a method for producing an image display device, and a coating unit, which can suppress the occurrence of defects in appearance.
Means for solving the problems
In order to achieve the above object, the gravure coating device of the present invention is characterized by comprising: a coating section for coating a coating liquid on at least one surface of a substrate; and a drying section for drying the applied coating liquid to form a resin layer, wherein the coating section includes a gravure roll capable of filling cells on the surface of the gravure roll with the coating liquid stored in the coating liquid storage section, and a coating liquid storage section in which the coating liquid is transferred onto the substrate in the cells, and the supply and discharge of the maximum amount of the coating liquid storable in the coating liquid storage section is performed every 150 seconds or less.
In order to achieve the above object, a method for producing a laminate according to the present invention comprises: a coating step of coating a coating liquid on at least one surface of a substrate; and a drying step of drying the applied coating liquid to form a resin layer, wherein the coating step includes: and a step of filling the cells on the surface of the gravure roll with the coating liquid stored in the coating liquid storage unit, and transferring the coating liquid in the cells to the substrate to perform coating, wherein the coating liquid storage unit is configured so that the supply and discharge of the maximum amount of coating liquid that can be stored in the coating liquid storage unit is performed every 150 seconds or less.
In order to achieve the above object, the method for producing an optical film comprising the laminate of the present invention is characterized by comprising a step of producing the laminate by the method for producing a laminate of the present invention.
In order to achieve the above object, the method for manufacturing an image display device including the laminate of the present invention includes a step of manufacturing the laminate by the method for manufacturing a laminate of the present invention.
In order to achieve the above object, a coating unit used in a gravure coating device according to the present invention includes the gravure roll and the coating liquid storage unit, wherein the coating liquid is stored in the coating liquid storage unit, and the supply and discharge of the maximum amount of coating liquid that can be stored in the coating liquid storage unit is performed every 150 seconds or less.
Effects of the invention
According to the present invention, it is possible to provide a gravure coating device, a method for producing a laminate, a method for producing an optical film, a method for producing an image display device, and a coating unit, which can suppress the occurrence of defects in appearance.
Drawings
Fig. 1 is a cross-sectional view illustrating the constitution of a gravure coating device of the present invention.
Fig. 2 (a) and (b) are sectional views illustrating a coating section (coating unit) of the gravure coating device of the present invention.
Detailed Description
The invention will be described in more detail below by way of examples. However, the present invention is not limited to the following description.
In the present invention, "mass%" and "weight%" may be replaced with each other, and "part by mass" and "part by weight" may be replaced with each other, unless otherwise specified.
In the present invention, "on" or "on the surface" may be in direct contact with the surface or the upper surface, or may be in a state of being sandwiched by other layers or the like.
In the gravure coating device of the present invention, for example, the coating section further includes a pump connected to the coating liquid reservoir section through at least one of the first flow path for supplying the coating liquid to the coating liquid reservoir section, and a second flow path for discharging the coating liquid stored in the coating liquid reservoir section, and the pump may circulate the coating liquid by performing at least one of the supply and the discharge.
The gravure coating device of the present invention may further include a crosslinking unit that crosslinks the resin layer, for example.
In the method for producing a laminate of the present invention, for example, the circulation and discharge of the coating liquid may be performed by circulation of a pump.
In the method for producing a laminate of the present invention, for example, the step of crosslinking the resin layer may be further included after the step of drying.
In the method for producing a laminate of the present invention, for example, the substrate is a transparent substrate.
In the method for producing a laminate of the present invention, the resin layer may be any of a hard coat layer, an antiglare layer, a pressure-sensitive adhesive layer, an easy-to-adhere layer, an anti-blocking layer, an index matching layer, and an antifouling layer, for example.
In the method for producing a laminate of the present invention, for example, the ratio (a/B) of the storage volume (a) of the coating liquid storage portion to the volume (B) of the impregnated portion when the gravure roll is immersed in the coating liquid in the coating step may be 6.0 or less.
An example of a gravure coating apparatus, a method of producing a laminate, and a coating unit according to the present invention will be described below with reference to fig. 1 and 2. In addition, fig. 1 and 2 are both sectional views, but hatching is omitted for the sake of easy observation.
Fig. 1 schematically shows an example of the present invention. In fig. 1, a gravure coating apparatus 1 (hereinafter, also simply referred to as "the present apparatus 1") includes a coating section (coating unit) 20 for applying a coating liquid 203 on at least one surface of a substrate 101. In fig. 1, the number of coating portions 20 is one, but for example, two or more coating portions 20 may be provided, the coating liquid 203 may be applied to both surfaces of the substrate 101, or the coating liquid 203 may be applied to at least one surface of the substrate 101 a plurality of times.
The substrate 101 is, for example, a substrate that can be transported in a web by roll-to-roll processing, and examples thereof include a resin substrate and a metal foil. Examples of the resin base material include polyester polymers such as polyethylene terephthalate and polyethylene naphthalate; cellulose polymers such as diacetyl cellulose and triacetyl cellulose; a polycarbonate-based polymer; and acrylic polymers such as polymethyl methacrylate. Further, as a material for forming the resin base material, for example, a styrene polymer such as polystyrene or acrylonitrile-styrene copolymer; olefin polymers such as polyethylene, polypropylene, polyolefin having a cyclic or norbornene structure, and ethylene-propylene copolymer; vinyl chloride-based polymers; amide polymers such as nylon and aromatic polyamide. Examples of the material for forming the resin base material include imide-based polymers, sulfone-based polymers, polyether ether ketone-based polymers, polyphenylene sulfide-based polymers, vinyl alcohol-based polymers, vinylidene chloride-based polymers, vinyl butyral-based polymers, acrylic ester-based polymers, polyoxymethylene-based polymers, epoxy-based polymers, and blends of the above polymers. The resin substrate may be, for example, a transparent substrate. Examples of the metal foil include aluminum (Al), copper (Cu), and stainless steel (SUS). The substrate may have a roll width of 300 to 2000mm, 500 to 1800mm, or 800 to 1500mm, for example. The roll length of the substrate may be, for example, 1000 to 10000m, 2000 to 9000m, or 3000 to 8000m.
The coating liquid 203 is, for example, a coating liquid commonly used in roll-to-roll processing, and examples thereof include a resin composition. Examples of the resin composition include a hard coat agent, an antiglare agent, a pressure sensitive adhesive, an ink, and an antifouling agent. The coating liquid 203 may contain a solvent, for example, a general organic solvent used as a diluting solvent for the coating liquid, and examples thereof include alcohols such as methanol, ethanol, isopropyl alcohol (IPA), butanol, t-butanol (TBA), and 2-methoxyethanol; ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclopentanone, and the like; esters such as methyl acetate, ethyl acetate, and butyl acetate; ethers such as diisopropyl ether and propylene glycol monomethyl ether; glycols such as ethylene glycol and propylene glycol; cellosolves such as ethyl cellosolve and butyl cellosolve; aliphatic hydrocarbons such as hexane, heptane, octane, etc.; aromatic hydrocarbons such as benzene, toluene and xylene. In addition, for example, the solvent may contain a hydrocarbon solvent and a ketone solvent. The hydrocarbon solvent may be, for example, an aromatic hydrocarbon. The aromatic hydrocarbon may be at least one selected from the group consisting of toluene, o-xylene, m-xylene, p-xylene, ethylbenzene, and benzene, for example. The ketone solvent may be, for example, at least one selected from the group consisting of cyclopentanone, acetone, methyl ethyl ketone, methyl isobutyl ketone, diethyl ketone, cyclohexanone, isophorone, and acetophenone. The viscosity of the coating liquid 203 may be, for example, 0.5 to 55 mPas, 0.8 to 50 mPas, or 1.0 to 45 mPas.
Examples of the method of applying the coating liquid 203 include a direct gravure method, a reverse gravure method, and a doctor blade type (doctor blade) method.
Fig. 2 (a) schematically shows an example of the application section (application unit) 20. The coating section 20a includes a gravure roll 201 and a coating liquid reservoir 202. Gravure roll 201 may be, for example, a large diameter gravure roll or a small diameter gravure roll. The diameter of the large-diameter gravure roll may be, for example, 50 to 200mm or 80 to 170mm. The diameter of the small-diameter gravure roll may be, for example, 20 to 50mm or 30 to 40mm. Cells (not shown) are formed on the surface of gravure roll 201. The cell volume of gravure roll 201 may be, for example, 2.0～100.0cm 3 /m 3 、5.0～80.0cm 3 /m 3 Or 10.0 to 70.0cm 3 /m 3 . The cell shape of gravure roll 201 may be, for example, lattice, tortoiseshell, diagonal, or pyramid. The number of threads of gravure roll 201 can be, for example, 50 to 1500 threads/inch, 60 to 1000 threads/inch, or 70 to 500 threads/inch. In addition, "line/inch" also refers to the number of dots per 1 inch (25.4 mm), and may also be expressed as "line" or "L/25.4mm". The depth of gravure roll 201 may be, for example, 3 to 200 μ, 5 to 150 μ, or 10 to 100 μ.
The coating portion 20a may further include a doctor blade (doctor knife) 204, for example. The material of the doctor blade 204 may be steel, ceramic, plastic, or zirconia, for example.
As shown in fig. 2 (a), the coating liquid reservoir 202 stores a coating liquid 203. The amount of the coating liquid 203 stored in the coating liquid storage portion 202 may be, for example, 0.2L or more, 0.5L or more, or 1.0L or more, for example, 10.0L or less, 9.0L or less, or 8.0L or less, for example, 0.2 to 10.0L, 0.5 to 9.0L, or 1.0 to 8.0L. The storage volume (a) is preferably 1.0 to 6.5L, for example, from the viewpoint of suppressing occurrence of defects by promoting discharge of the coating liquid.
As shown in fig. 2 (a), a part of the gravure roll 201 is immersed in the coating liquid 203. When the volume of the coating liquid reservoir 202 itself is set to (a) (hereinafter, referred to as "reservoir volume (a)") and the volume of the impregnated portion of the gravure roll 201 when immersed in the coating liquid 203 is set to (B) (hereinafter, referred to as "volume of the impregnated portion (B)"), the ratio (a/B) of the reservoir volume (a) to the volume of the impregnated portion (B) may be, for example, 6.0 or less, 5.9 or less, 4.0 or less, or 1.9 or less, may be, for example, 1.1 or more, 1.2 or 1.3 or more, and may be, for example, 1.1 to 6.0, 1.2 to 4.0, or 1.3 to 1.9. From the viewpoint of suppressing occurrence of defects, it is preferably 1.9 or less, for example.
In the coating liquid storage portion 202, the supply and discharge of the maximum amount of coating liquid that the coating liquid storage portion 202 can store is performed every 150 seconds or less. The coating liquid 203 may be supplied and discharged from an opening above the coating liquid reservoir 202, or a hole (not shown) may be provided in the coating liquid reservoir 202 and the coating liquid may be discharged from the hole. The time for supplying and discharging the coating liquid 203 may be, for example, once every 140 seconds or less, once every 120 seconds or less, once every 110 seconds or once every 60 seconds or less, and may be, for example, once every 6 seconds or more or once every 12 seconds or more. From the viewpoint of suppressing occurrence of defects by promoting discharge of the coating liquid, it is preferable that the coating liquid is discharged once every 60 seconds or less, for example.
Fig. 2 (b) schematically shows another example of the application portion 20. The application section 20b further includes a pump 205, a first flow path 206a, and a second flow path 206b according to fig. 2 (a). The first channel 206a is a channel for supplying the coating liquid 203 to the coating liquid reservoir 202. The second channel 206b is a channel for discharging the coating liquid 203 stored in the coating liquid storage portion 202. In fig. 2 (b), the pump 205 is connected to the coating liquid reservoir 202 through the first channel 206a, but may be connected to the second channel 206b, or may be connected to both the first channel 206a and the second channel 206b, for example. The flow path may be made of metal or resin, for example, and may be a pipe or a hose.
Examples of the pump 205 include a diaphragm pump, a rotary pump, a centrifugal pump, a mornode pump, and an air pump. The discharge amount (liquid supply amount) of the pump 205 may be, for example, 0.5 to 20L/min, 1.0 to 18L/min, or 1.5 to 15L/min. From the viewpoint of suppressing the number of defects, it is preferably 1.8 to 12L/min, for example.
In fig. 2 (b), the pump 205 circulates the coating liquid 203 by performing at least one of the supply and the discharge, and the stored coating liquid 203 is supplied and discharged once every 150 seconds or less by the circulation. For example, when the pump 205 is connected only through the first channel 206a, only the supply is performed, and when the pump 205 is connected only through the second channel 206b, only the discharge is performed, and when the pump 205 is connected through both the first channel 206a and the second channel 206b, both the supply and the discharge may be performed. In the discharging, for example, a liquid collecting tank 207 of the discharged liquid shown in fig. 2 (b) may be provided, or the circulation of the coating liquid 203 may be performed without providing the liquid collecting tank. The time for replacement of the coating liquid 203 may be, for example, the same as that described in fig. 2 (a).
In fig. 1, the present apparatus 1 includes a drying section 30, and the drying section 30 dries the applied coating liquid 203 (resin layer 102 ") to form a resin layer 102'. The drying method may use, for example, the heating mechanism 301. The heating means 301 includes, for example, a heater, a heating roller, and a far infrared heater. The drying temperature is, for example, 50 to 250 ℃, 60 to 150 ℃, 70 to 130 ℃, and the drying time is, for example, 0.1 to 30 minutes, 0.2 to 10 minutes, 0.3 to 3 minutes.
The resin layer may be, for example, a hard coat layer, an antiglare layer, a pressure-sensitive adhesive layer, an ink layer (printing layer), an antiblocking layer, an index matching layer, an easy-to-adhere layer, or an antifouling layer.
The present apparatus 1 may further include, for example, a first winding-out section 10, a crosslinking section 40, a second winding-out section 50, a winding-up section 60, and the like. The crosslinking unit 40, for example, crosslinks the resin layer 102' to form the resin layer 102. The crosslinking may be performed using, for example, a crosslinking mechanism 401. The crosslinking mechanism 401 may be, for example, a lamp that emits light (ultraviolet rays or the like), an EB device that irradiates an electron beam, or the like. In the case where the crosslinking is performed by ultraviolet rays, the wavelength of the ultraviolet rays may be, for example, 200 to 380nm, 280 to 380nm, or 315 to 380nm. The irradiation time of the ultraviolet ray may be, for example, 0.1 to 5 minutes, 0.2 to 3 minutes, or 0.3 to 1 minute. The irradiation intensity of the ultraviolet ray may be, for example, 5.0 to 100mW/cm 2 、8.0～90mW/cm 2 Or 10.0-80 mW/cm 2 . The cumulative exposure amount of the energy ray source at 365nm, for example, may be 50 to 500mJ/cm 2 、100～450mJ/cm 2 Or 150 to 400mJ/cm 2 . The irradiation amount is 50mJ/cm 2 As described above, the curing is easily and sufficiently performed, and the hardness of the formed resin layer is easily increased. In addition, if it is 500mJ/cm 2 Hereinafter, coloring of the resin layer to be formed can be prevented. In the case where the crosslinking step is electron beam curing, the dose is, for example, 5 to 50kGy, preferably 5 to 40kGy, so as not to deteriorate the resin base material or to cause coloring. The acceleration voltage of the electron beam is 100 to 3000kV, preferably 150 to 300kV.
An example of a method for producing a laminate of the present invention will be described in further detail with reference to fig. 1 and 2.
First, the substrate 101 is drawn out from the first roll-out section 10 and conveyed to the coating section 20. In the coating section 20, a coating step (1) of coating the coating liquid 203 on at least one surface of the substrate 101 is performed. In the coating step (1), the coating liquid 203 stored in the coating liquid storage unit 202 is filled in a small chamber on the surface of the gravure roll 201, and the coating liquid 203 in the small chamber is transferred onto the substrate 101 to form the resin layer 102 "before drying". At this time, the coating liquid storage unit 202 supplies and discharges the maximum amount of coating liquid that the coating liquid storage unit 202 can store once every 150 seconds or less. The details of the coating section 20 in the coating step (1) are as described above with reference to fig. 2 (a) and (b). After the coating step (1), the resin layer 102″ is dried by the drying mechanism 301 in the drying step (2), thereby forming a resin layer 102'. After the drying step (2), a crosslinking step (3) may be further provided. In the crosslinking step (3), the resin layer 102' is crosslinked by the crosslinking mechanism 401, thereby forming the resin layer 102. After the drying step (2) or the crosslinking step (3), the base material 101 (laminate) on which the resin layer 102' or the resin layer 102 is formed is wound up by the winding unit 60 to form a roll. In the case where the resin layer is a pressure-sensitive adhesive layer or an adhesive layer, or in the case where a protective film is attached to the surface of the resin layer, for example, an attaching step (4) may be provided in which a release liner or protective film having undergone a release treatment on the base material is extracted from the second roll-out unit 50 and attached to the resin layer.
The gravure coating device, the method for producing a laminate, and the coating unit of the present invention can be used for producing, for example, a hard coat film, an antiglare film, a pressure-sensitive adhesive film, an adhesive film, a printed film, an anti-blocking film, a film with an index matching layer, a film with an easy-to-adhere layer, an antifouling film, or a laminate obtained by combining these films. However, the gravure coating device, the method for producing a laminate, and the coating unit of the present invention are not limited thereto, and may be used for any application.
Examples
The following describes embodiments of the present invention. However, the present invention is not limited to the following examples.
In the following examples and comparative examples, a coating liquid reservoir tank having a reservoir volume (a) of 2.3L was used at a ratio (a/B) of 1.9, and the volume (B) of the dipping portion of the gravure roll was set to 1.2L. In addition, a coating liquid reservoir tank having a reservoir volume (a) of 7.4L was used under the condition that the ratio (a/B) was 5.9, and the volume (B) of the dipping portion of the gravure roll was set to 1.25L.
Example 1
A laminate (hard coat film) of this example was produced in the following manner.
(mixing of coating liquid for Forming hard coating)
As the resin contained in the hard coat layer, 3 parts by weight of a photopolymerization initiator (trade name "OMNIRAD907" manufactured by BASF corporation) and 0.01 part by weight of a leveling agent (trade name "PC4100" manufactured by DIC corporation, solid content 40 wt%) were mixed per 100 parts by weight of an ultraviolet curable acrylate resin (trade name "Luxydir17-806" manufactured by DIC corporation, solid content 80 wt%). The mixture was diluted with PGM/cyclopentanone mixed solvent (weight ratio 63/37) to give a solid content concentration of 36 wt%, to prepare a coating liquid for hard coat layer formation.
(production of hard coating film)
As the light-transmitting substrate, a transparent plastic film substrate (TAC, product name "KC4UA" manufactured by konikama america corporation) was prepared. The prepared coating liquid for forming a hard coat layer was supplied to the coating liquid reservoir at a liquid supply amount of 1.84L/min using an air pump on one surface of the transparent plastic film base material, and a coating film was formed using a micro gravure roll having a line number of 90 and a ratio (a/B) of 9. Then, the transparent plastic film base material on which the coating film is formed is conveyed to a drying step. In the drying step, the coating film is dried by heating at 80 ℃ for 1 minute. Then, the integrated light quantity was irradiated with a high-pressure mercury lamp at 220mJ/cm 2 The coating film was subjected to a curing treatment to form a hard coat layer having a thickness of 7.0 μm, to obtain a hard coat film of example 1.
Examples 2 to 3 and comparative example 1
A laminate (hard coat film) was produced under the same conditions as in example 1, except that the ratio (a/B), the liquid supply amount, and the supply and discharge times (replacement times) of the coating liquid were set as shown in table 1 below.
Example 4
The laminate (antiglare film) of this example was produced in the following manner.
(compounding of coating liquid for Forming antiglare layer)
As the resin contained in the antiglare layer, 5 parts by weight of a photopolymerization initiator (trade name "OMNIRAD184" manufactured by BASF corporation) and 2.5 parts by weight of a thickener (trade name "Sumecton SAN" obtained by diluting toluene to a solid content of 4% by weight) were mixed per 100 parts by weight of an ultraviolet curable acrylate resin (trade name "Luxydir17-806" manufactured by DIC corporation, the solid content of 80% by weight), 6.5 parts by weight of particles 1 (trade name "SYLOPHOBIC 200" manufactured by Fuji SYLYSIA chemical corporation), 6.5 parts by weight of particles 2 (trade name "SYLOPHOBIC 702" manufactured by Fuji SYSIA chemical corporation), and 0.7 part by weight of a leveling agent (DIC corporation, trade name "Megafac F-556", the solid content of 100% by weight) were mixed. The mixture was diluted with toluene to have a solid content of 44 wt%, and a coating liquid for forming an antiglare layer was prepared.
(production of antiglare film)
As the light-transmitting substrate, a transparent plastic film substrate (TAC, product name "KC4UA" manufactured by konikama america corporation) was prepared. The prepared coating liquid for forming an antiglare layer was supplied to the coating liquid reservoir at a liquid supply amount of 2.27L/min using a diaphragm pump on one surface of the transparent plastic film base material, and a coating film was formed using a micro gravure roll having a line number of 100 and a ratio (a/B) of 1.9. Then, the transparent plastic film base material on which the coating film is formed is conveyed to a drying step. In the drying step, the coating film is dried by heating at 80 ℃ for 20 seconds and at 110 ℃ for 40 seconds. Then, the integrated light quantity was irradiated with a high-pressure mercury lamp at 300mJ/cm 2 The antiglare film of example 4 was obtained by curing the coating film to form an antiglare layer having a thickness of 8.0 μm.
Examples 5 to 6 and comparative example 2
A laminate (antiglare film) was produced under the same conditions as in example 4, except that the ratio (a/B), the liquid supply amount, and the liquid replacement time were set as shown in table 2 below.
Example 7
A laminate (film with an easy-to-adhere layer) of this example was produced in the following manner.
(mixing of coating liquid for Forming an adhesive layer)
The transparent conductive resin (trade name "Denatron P-521AC", manufactured by Nagaschemtex Co., ltd., solid content: 4% by weight) was diluted with a pure water/ethanol mixed solvent (weight ratio: 10/45) as the resin contained in the easy-to-adhere layer so that the solid content concentration was 0.6% by weight, to prepare a coating liquid for forming an easy-to-adhere layer.
(production of film with easy-to-bond layer)
As the light-transmitting substrate, a transparent plastic film substrate (PET, trade name "cerameel MDA" manufactured by eastern corporation) was prepared. The prepared coating liquid for forming an easy-to-adhere layer was supplied to the coating liquid reservoir at a liquid supply amount of 5.0L/min using an air pump on one surface of the transparent plastic film base material, and a coating film was formed using a micro gravure roll having a line number of 190 at a ratio (a/B) of 1.9. Then, the transparent plastic film base material on which the coating film is formed is conveyed to a drying step. In the drying step, the coating film was dried by heating at 155℃for 1 minute to form an easy-to-adhere layer having a thickness of 0.04. Mu.m, to obtain a film with an easy-to-adhere layer of example 7.
Example 8, comparative example 3
A laminate (film with an easy-to-adhere layer) was produced under the same conditions as in example 7, except that the ratio (a/B), the liquid supply amount, and the supply and discharge times (replacement times) of the coating liquid were set as shown in table 3 below.
In the above examples and comparative examples, the number of defects (hereinafter, sometimes referred to as "point-like defects") was measured by the following method. In the hard coat films of examples 1 to 3 and comparative example 1, the number of the uneven patterns was measured as the number of defects. In the antiglare films shown in examples 4 to 6 and comparative example 2, the number of white spot patterns was measured as the number of defects. In the films with the easy-to-adhere layers shown in examples 7 to 8 and comparative example 3, the number of aggregates was measured as the number of defects. The aggregate is formed by agglomerating the coating liquid.
[ confirmation of defect-free ]
The films (optical films) of the above examples and comparative examples were cut (slit) into 1330mm×1000mm squares as test samples. For these test samples, the presence or absence of a point defect was confirmed by the following methods of Z-ray reflection inspection and point light source transmission inspection. The number of defects confirmed by the Z-ray reflection inspection and the point light source transmission inspection was added together as the number of defects per m (in/m). In addition, the same defect confirmed in both the Z-light reflection inspection and the point light source transmission inspection was measured so as to avoid repetition of counting.
< defect confirmation method: z light reflection inspection ]
Z light (model "Z-208" manufactured by mountain land Motor Co.) was irradiated from a position that was 400mm apart at an angle of 45 degrees with respect to the coated surface of the test specimen. The number of defects was measured by visually checking the coated surface from a position 300mm from the center of the coated surface at an angle of 45 degrees (90 degrees with respect to the light source) with respect to the test sample.
< defect confirmation method: point light Transmission inspection-
A point light source (model "L8425-01", manufactured by Photonics Corp. Of Toku., ltd.) was irradiated from a position 560mm from the center of the coated surface at an angle of 45 degrees with respect to the coated surface of the test specimen. The transmitted light after passing through the test sample is projected onto a whiteboard disposed at a position of 1050mm from the point light source. That is, the test sample is irradiated with light while the test sample is sandwiched between the point light source and the whiteboard (between the point light source and the whiteboard), and the transmitted light is projected onto the whiteboard. In case a defect is contained in the test sample, the defect is projected onto the whiteboard. Defects projected on the whiteboard were visually checked, and the number of defects was measured.
The number of defects in the examples, which were applied under the conditions that the ratio (a/B) was 6.0 or less and the liquid supply amount was small, was compared with the number of defects in the comparative examples (comparative examples 1 to 3) in each laminate, and was calculated as the defect number ratio. The appearance improvement effect was judged to be exhibited under the condition that the defect number ratio was 50% or less.
The supply and discharge times of the coating liquid are calculated by the following calculation formula.
Time (min) for changing the coating liquid= (amount (L) of coating liquid stored in the coating liquid storage portion) -volume (L) of the immersed portion of the gravure roll)/liquid supply amount (L/min)
TABLE 1
| Example 1 | Example 2 | Example 3 | Comparative example 1 | |
| Ratio (A/B) | 1.9 | 5.9 | 1.9 | 5.9 |
| Liquid supply (L/min) | 1.84 | 4.89 | 4.89 | 1.84 |
| Time (seconds) for supplying and discharging the coating liquid | 36 | 75 | 14 | 200 |
| Number of concave-convex patterns (number/m) | 0.64 | 1.28 | 0.58 | 3.41 |
| Ratio of number of defects | 18.8％ | 37.5％ | 17.0％ | - |
TABLE 2
| Example 4 | Example 5 | Example 6 | Comparative example 2 | |
| Ratio (A/B) | 1.9 | 5.9 | 1.9 | 5.9 |
| Liquid supply (L/min) | 2.27 | 3.34 | 3.34 | 2.27 |
| Time (seconds) for supplying and discharging the coating liquid | 29 | 110 | 20 | 162 |
| White spot pattern number (number/m) | 0.29 | 3.42 | 0.23 | 9.93 |
| Ratio of number of defects | 2.9％ | 34.4％ | 2.3％ | - |
TABLE 3 Table 3
| Example 7 | Example 8 | Comparative example 9 | |
| Ratio (A/B) | 1.9 | 1.9 | 1.9 |
| Liquid supply (L/min) | 5 | 12 | 5 |
| Time (seconds) for supplying and discharging the coating liquid | 58 | 32 | 176 |
| Number of aggregates (number/m) | 0.96 | 0.34 | 2.84 |
| Ratio of number of defects | 33.8％ | 12.0％ | - |
As shown in tables 1 to 3, the coating liquid was replaced every 150 seconds, and the defect number ratio was 50% or less in any of examples 1 to 8. In addition, all defects are reduced regardless of the pattern of defects. The defect number ratio of examples 1, 3, 4, and 6 to 8, in which the ratio (A/B) was set to 1.9 times or less, was further reduced. Examples 1, 3, 4, 6 and 8 in which the liquid replacement time was set to be one time per 60 seconds or less, the defect number ratio was further reduced.
< additional notes >
Some or all of the above embodiments and examples may be described as the following additional descriptions, but are not limited to the following additional descriptions.
(additionally, 1)
An intaglio coating device, characterized in that it comprises: a coating section for coating a coating liquid on at least one surface of a substrate; and a drying section for drying the applied coating liquid to form a resin layer,
the coating part comprises a gravure roll and a coating liquid storage part,
the gravure roll can fill the coating liquid stored in the coating liquid storage part into a small chamber on the surface of the gravure roll,
the coating is performed by transferring the coating liquid in the cell onto the substrate,
in the coating liquid storage unit, the supply and discharge of the maximum amount of coating liquid that can be stored in the coating liquid storage unit is performed every 150 seconds or less.
(additionally remembered 2)
The gravure coating device according to appendix 1, wherein the coating section further comprises a pump, a first flow path and a second flow path,
the pump is connected to the coating liquid reservoir through at least one of the first flow path and the second flow path,
the first flow path is a flow path for supplying the coating liquid to the coating liquid reservoir,
the second flow path is a flow path for discharging the coating liquid stored in the coating liquid storage portion,
the pump circulates the coating liquid by performing at least one of the supply and the discharge.
(additionally, the recording 3)
The gravure coating device according to appendix 1 or 2, further comprising a crosslinking section that crosslinks the resin layer.
(additionally remembered 4)
A method for producing a laminate, comprising: a coating step of coating a coating liquid on at least one surface of a substrate; and a drying step of drying the applied coating liquid to form a resin layer,
the coating process comprises the following steps: a step of filling a cell on the surface of the gravure roll with the coating liquid stored in the coating liquid storage unit, transferring the coating liquid in the cell to the substrate, and applying the coating liquid,
in the coating liquid storage unit, the supply and discharge of the maximum amount of coating liquid that can be stored in the coating liquid storage unit is performed every 150 seconds or less.
(additionally noted 5)
The method for producing a laminate according to supplementary note 4, wherein the replacement is performed by a cycle of a pump.
(additionally described 6)
The method for producing a laminate according to any one of supplementary notes 4 and 5, wherein the step of drying is followed by a step of crosslinking the resin layer.
(additionally noted 7)
The method for producing a laminate according to any one of supplementary notes 4 to 6, wherein the substrate is a transparent substrate.
(additionally noted 8)
The method for producing a laminate according to any one of supplementary notes 4 to 7, wherein the resin layer is any one of a hard coat layer, an antiglare layer, a pressure-sensitive adhesive layer, an easy-to-adhere layer, an antiblocking layer, an index matching layer, or an antifouling layer.
(additionally, the mark 9)
The method for producing a laminate according to any one of supplementary notes 4 to 8, wherein a ratio (a/B) of a storage volume (a) of the coating liquid storage portion to a volume (B) of an impregnated portion when the gravure roll is immersed in the coating liquid in the coating step is 6.0 or less.
(additionally noted 10)
A method for producing an optical film comprising the laminate, characterized by comprising a step of producing the laminate by the method for producing a laminate according to any one of the appended notes 4 to 9.
(additionally noted 11)
A method for manufacturing an image display device including the laminate, characterized by comprising a step of manufacturing the laminate by the method for manufacturing a laminate according to any one of supplementary notes 4 to 9.
(additional recording 12)
A coating unit used in the gravure coating device according to any one of supplementary notes 1 to 3,
the coating unit includes the gravure roll and the coating liquid reservoir,
the coating liquid storage unit stores the coating liquid, and the supply and discharge of the maximum amount of coating liquid that can be stored in the coating liquid storage unit is performed every 150 seconds or less.
The present invention has been described above with reference to the embodiments, but the present invention is not limited to the above embodiments. Various modifications, which can be understood by those skilled in the art, may be made within the scope of the present invention with respect to the constitution and details of the present invention. Further, each embodiment can be appropriately combined with other embodiments.
Industrial applicability
As described above, according to the present invention, it is possible to provide a gravure coating device, a method for producing a laminate, and a coating unit, which can suppress occurrence of defects. The application of the present invention is not particularly limited, and the present invention can be applied to the production of all laminates.
The present application claims priority based on japanese application publication No. 2022-141766 filed on 9/6 of 2022, the entire disclosure of which is incorporated herein.
Symbol description
1. Gravure coating device (present device)
10. A first winding-out part
20. 20a, 20b coating section (coating unit)
30. Drying section
40. Crosslinking part
50. A second reel-out part
60. Winding part
101. Substrate material
102. 102', 102' resin layer
201. Gravure roll
202. Coating liquid storage part
203. Coating liquid
204. Scraper (sector knife)
205. Pump with a pump body
206a first flow path
206b second flow path
207. A liquid collecting tank.
Claims (12)
1. An intaglio coating device, characterized in that it comprises: a coating section for coating a coating liquid on at least one surface of a substrate; and a drying section for drying the applied coating liquid to form a resin layer,
the coating part comprises a gravure roll and a coating liquid storage part,
the gravure roll can fill the coating liquid stored in the coating liquid storage part into a small chamber on the surface of the gravure roll,
the coating is performed by transferring the coating liquid in the cell onto the substrate,
in the coating liquid storage unit, the supply and discharge of the maximum amount of coating liquid that can be stored in the coating liquid storage unit is performed every 150 seconds or less.
2. The gravure coating device according to claim 1, wherein the coating section further comprises a pump, a first flow path, and a second flow path,
the pump is connected to the coating liquid reservoir through at least one of the first flow path and the second flow path,
the first flow path is a flow path for supplying the coating liquid to the coating liquid reservoir,
the second flow path is a flow path for discharging the coating liquid stored in the coating liquid storage portion,
the pump circulates the coating liquid by performing at least one of the supply and the discharge.
3. The gravure coating device according to claim 1 or 2, further comprising a crosslinking section that crosslinks the resin layer.
4. A method for producing a laminate, comprising: a coating step of coating a coating liquid on at least one surface of a substrate; and a drying step of drying the applied coating liquid to form a resin layer,
the coating process comprises the following steps: a step of filling a cell on the surface of the gravure roll with the coating liquid stored in the coating liquid storage unit, transferring the coating liquid in the cell to the substrate, and applying the coating liquid,
in the coating liquid storage unit, the supply and discharge of the maximum amount of coating liquid that can be stored in the coating liquid storage unit is performed every 150 seconds or less.
5. The method for producing a laminate according to claim 4, wherein the supply and discharge of the coating liquid are performed by circulation of a pump.
6. The method for producing a laminate according to claim 4 or 5, wherein the step of crosslinking the resin layer is included after the step of drying.
7. The method for producing a laminate according to claim 4 or 5, wherein the substrate is a transparent substrate.
8. The method for producing a laminate according to claim 4 or 5, wherein the resin layer is any one of a hard coat layer, an antiglare layer, a pressure-sensitive adhesive layer, an easy-to-adhere layer, an anti-blocking layer, an index matching layer, and an antifouling layer.
9. The method for producing a laminate according to claim 4 or 5, wherein a ratio (a/B) of a storage volume (a) of the coating liquid storage portion to a volume (B) of an impregnated portion when the gravure roll is immersed in the coating liquid in the coating step is 6.0 or less.
10. A method for producing an optical film comprising the laminate, characterized by comprising a step of producing the laminate by the method for producing a laminate according to claim 4 or 5.
11. A method for manufacturing an image display device including the laminate, characterized by comprising a step of manufacturing the laminate by the method for manufacturing a laminate according to claim 4 or 5.
12. A coating unit, characterized in that it is a coating unit used in the gravure coating device according to claim 1 or 2,
the coating unit includes the gravure roll and the coating liquid reservoir,
the coating liquid storage unit stores the coating liquid, and the supply and discharge of the maximum amount of coating liquid that can be stored in the coating liquid storage unit is performed every 150 seconds or less.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2022141766A JP2024037101A (en) | 2022-09-06 | 2022-09-06 | Gravure coating equipment, laminate manufacturing method, optical film manufacturing method, image display device manufacturing method, coating unit |
| JP2022-141766 | 2022-09-06 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN117654825A true CN117654825A (en) | 2024-03-08 |
Family
ID=90062996
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202311141176.4A Pending CN117654825A (en) | 2022-09-06 | 2023-09-06 | Gravure coating device, method for producing laminate, method for producing optical film, method for producing image display device, and coating unit |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JP2024037101A (en) |
| KR (1) | KR20240034120A (en) |
| CN (1) | CN117654825A (en) |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP4782654B2 (en) | 2006-10-19 | 2011-09-28 | 株式会社ヒラノテクシード | Gravure coating equipment |
-
2022
- 2022-09-06 JP JP2022141766A patent/JP2024037101A/en active Pending
-
2023
- 2023-08-29 KR KR1020230113296A patent/KR20240034120A/en unknown
- 2023-09-06 CN CN202311141176.4A patent/CN117654825A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| KR20240034120A (en) | 2024-03-13 |
| JP2024037101A (en) | 2024-03-18 |
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