JP2003001163A - Device for forming single layer film of powder - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a device for forming a single layer film of powder suitable for forming a single layer film of powder which is uniform and dense in the face direction and in which a part of the powder is projected from a surface of a sticky layer on the surface of the sticky layer on a longlength sheet base body. SOLUTION: The device is provided with a container which vibrates at least in the thickness direction of the base body in a state that the position is kept parallel to the width direction of the longlength sheet base body, a medium which is filled inside the container, a supporting member which guides the base body in the medium while contacting with the base body and supports impact which is generated by vibration of the container. The uniform impact is applied to the width direction of the base body from the thickness direction of the base body via the medium.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a powder single-layer coating which is uniform and dense in the surface direction on the surface of an adhesive layer on a long sheet-like substrate and in which a part of the powder protrudes from the surface of the adhesive layer. The present invention relates to a powder single-layer film forming apparatus suitable for forming.

[0002]

2. Description of the Related Art As a method for forming a powder single layer coating,
(1) After forming an adhesive layer on a substrate, supply powder onto the adhesive layer, squeeze to make the surface uniform, and then press the powder with a press or pressure roll A method of embedding in a layer is disclosed in JP-A-9-318801 and JP-A-11-
No. 95004. Further, (2) a method is known in which powder is embedded in the surface layer of the adhesive layer by a vibrating device in which the container C is set on the vibrating mechanism V as shown in FIG. The container C is made of a hard material such as a hard synthetic resin or a metal, and is formed in a bowl shape having an opening c1 at the upper portion, and the opening c1 is bulged upward at the center of the bottom portion c2. A columnar part c3 is provided so as to reach the same height as the above. On the other hand, in the vibrating mechanism V, a diaphragm f3 is mounted on a machine base F via coil springs f1 and f2, and a vertical axis f extending upward at the center of the upper surface of the diaphragm f3.
4, a motor f5 is fixed to the center of the lower surface of the diaphragm f3, and a weight f7 is eccentrically attached to the output shaft f6 of the motor f5. The container C is set by placing the upper end of the columnar part c3 on the upper end of the vertical axis f4 while being placed on the vibration plate f3, and is excited when the motor f5 is driven and the weight f7 rotates. It is like this.

Powder and a pressure medium are put into a container C of this vibrating device, and while vibrating the container C, a substrate on which an adhesive layer is laminated and powder is adhered is passed through the pressure medium. .
Thereby, by the pressurized medium vibrated in the container C,
The powder on the adhesive layer is hit to embed the powder in the surface layer of the adhesive layer to form a powder single layer coating.

[0004]

[Problems to be Solved by the Invention] However, (1)
The coating method of can be applied to a long sheet-shaped substrate, but in the plane, there are a dense portion and a coarse portion where the packing density of the powder is dense, or the powder is lined up in the flow direction, There is also a problem that streak-like scratches are likely to occur. Also, with this method,
It was also difficult to embed the powder in the adhesive layer to a uniform depth over the entire surface of the substrate due to subtle variations in the pressure applied to the film from the press or pressure roller. further,
Regarding this pressure unevenness, the powder adheres to the exuding adhesive in the place where a large pressure is applied and the powder layer becomes a multi-layer, and the embedding is insufficient in the part where the pressure is small. There is a problem that defects are likely to occur due to the detachment of the powder when removing the excess powder in the process. Such a phenomenon was conspicuous when treating a substrate having a large area or when using a fine particle powder having an average particle diameter of 15 μm or less. In particular, in the case of powder having an average particle diameter of 15 μm or less, the specific surface area becomes large, which is greatly affected by the electrostatic force and van der Waals force due to triboelectrification, and the fluidity of the powder is remarkably reduced. It was difficult to uniformly and densely attach the powder to the surface. Further, even if there is no problem in fluidity, in such fine particle powder, the pressure of the pressure roll is dispersed, and the pressure applied to each powder is reduced, so that it has already adhered to the adhesive layer. It was difficult to embed other powders to a uniform depth in the gap between the powders.

Further, in the vibrating device of (2), since the vibration of the pressurizing medium in the container C is different between the central part and the peripheral part, it is uniform and uniform in the surface direction for a small substrate. It is possible to form a powder single-layer film in which powder is packed at a high density, but for a large area and highly flexible substrate such as a long sheet, the treatment in the container C is performed. However, even if the treatment can be performed, there is a problem that the embedding of the powder in the width direction of the substrate becomes uneven.

Therefore, the present invention forms a powder single-layer coating on the surface of an adhesive layer on a long sheet-like substrate, which is uniform and dense in the surface direction and in which a part of the powder protrudes from the surface of the adhesive layer. It is an object of the present invention to provide a powder single layer film forming apparatus suitable for this. The "powder single layer" in the present invention refers to a state in which the powders are spread in a plane so that they do not overlap each other in the thickness direction but are densely and almost at the same height as they contact each other. It is a point. Examples of this application include general coatings for improving the durability and strength of the surface as well as providing aesthetics, polishing applications, anti-slip or improving slipperiness, light reflection or light reflection prevention, electrical insulation or conductivity. , A flat lens for condensing and diffusing light, a transmissive screen, and the like.

[0007]

Therefore, the powder single-layer film forming apparatus of the present invention vibrates at least in the thickness direction of the substrate while maintaining the posture parallel to the width direction of the long sheet substrate. A container, a medium filled in the container, and a support member that guides the substrate into the medium while contacting the substrate and supports the impact force generated by the vibration of the container are provided. An impact force is applied to the substrate from the thickness direction of the substrate through the medium.

According to the powder single-layer film forming apparatus of the present invention,
Even on a long sheet-shaped substrate, the powder adhered to the surface of the adhesive layer can be embedded in a uniform and dense single layer in the surface direction with a part of the powder protruding. Furthermore, according to the present invention, it is possible to continuously form a powder single-layer coating by using a means for attaching powder to the adhesive layer, a means for removing excess powder, and the like. The "adhesive layer" in the present invention means a layer having an adhesive property at least from the step of adhering the powder to the step of embedding the powder.

[0009]

1 is a sectional view showing an embodiment of a powder single layer film forming apparatus of the present invention. As shown in FIG. 1, the powder single-layer film forming apparatus of the present invention comprises a container 2 arranged parallel to the width direction of a long sheet-shaped substrate 1 and a container 2 which comes into contact with the substrate 1 and is attached to the substrate 1. 2 and a supporting member 3 arranged on the opposite side. The container 2 can vibrate in the thickness direction of the substrate 1, but the support member 3 is fixed so as not to be affected by the vibration of the container 2. A medium 4 is filled in the container 2, and in the present embodiment, a guide member 5 that guides the base 1 to the support 3 is provided. Hereinafter, constituent members and operation examples of the powder single-layer film forming apparatus of the present invention will be described in detail.

A. Components 1. Container The container according to the present invention has a mechanism for vibrating at least in the thickness direction of the substrate while keeping the posture parallel to the width direction of the long sheet substrate. This makes it possible to vibrate the medium filled in the container and hit the powder adhered to the adhesive layer on the base material from the thickness direction of the base material.
Further, the vibration direction of the container may be either the vertical direction or the front-back direction with respect to the apparatus as long as it is the thickness direction of the base material, and the vibration of the container may be circular vibration or elliptical vibration.

As a means for vibrating the container, a known vibrating device such as a vibrating motor, an air vibrator, an electromagnetic vibrating device, or a mechanical vibrating device using a cam can be used. These vibrating devices are used in a wide range of fields such as feeders, hoppers, conveyors, sieves, part feeders, part aligners, vibrating tables, barrel polishing, etc. In consideration of the size and weight of the container, the structure of the device including them, and the like, an appropriate one can be selected from these. Further, in any of the devices, in order to embed the powder in the adhesive layer at a high filling rate and at a uniform depth, the vibration mode, the excitation force, The amplitude needs to be adjusted.

Regarding the frequency, 200 to 4000 cp
m is preferable, and more preferably 1000 to 3000 cp.
m. When the frequency is lower than 200 cpm, the medium has a weak force for embedding the powder in the adhesive layer, and the processing takes time, which is not preferable. On the other hand, when it exceeds 4000 cpm, the impact force is too large and the powder is easily detached from the adhesive layer, or the medium jumps out from the container, which is not preferable in production.

In selecting these models and determining the conditions, in order to stably embed the powder in the adhesive layer for a long time while moving the long sheet-shaped substrate provided with the adhesive layer, It is necessary that the media does not scatter out of the container, separate in the container, or lean toward one side. Furthermore, it is preferable that the powder and the medium flow slowly so that the portions in contact with the adhesive layer are replaced.

The container of the present invention preferably has a uniform cross-sectional shape corresponding to the width direction of the substrate. According to this shape, the medium can be vibrated uniformly in the width direction of the substrate, and the powder on the adhesive layer can be uniformly embedded.

The medium in the present invention is for impacting the powder with an impact force caused by vibrating the medium to embed the powder in the adhesive layer, and in particular, the powder initially attached to the adhesive layer. And push other powder into the gap between
It is extremely important because it has the ability to make the packing density of the powder bed higher and more uniform. This media has a diameter of 0.1
It is a 3.0 mm granular material, preferably a spherical material, and in order to embed the powder in the adhesive layer at a high filling rate and at a uniform depth, it is preferable that its shape is close to a true sphere, and It is preferable that the particle distribution is as narrow as possible.

In the case of a medium having a diameter of less than 0.1 mm, the powder adheres to the adhesive layer together with the powder, the ability to embed the powder in the adhesive layer is insufficient, and it is too small to handle. There is also a problem. on the other hand,
A medium having a size of 3.0 mm or more has a sufficiently large impact force, but on the contrary, it is difficult to embed the powder in the adhesive layer at a high filling rate and at a uniform depth, which is not preferable.

Specific examples of media include iron, carbon steel,
Alloy steel, copper and copper alloys, aluminum and aluminum alloys, other various metals, those made of alloys, or those made of ceramics such as alumina, silica, titania, zirconia, silicon carbide, further glass,
Quartz, hard plastic, hard rubber, etc. may be mentioned. With respect to hard plastics and hard rubbers, those containing fine particles of the above-mentioned various metals, alloys, ceramics, glass and the like can also be used.

The medium used in the present invention may be selected optimally depending on the thickness and adhesive strength of the adhesive layer, the particle diameter and specific gravity of the powder, the depth of embedding the powder, and the like. If the particle size of the medium is large, the impact force is large, but since there are few opportunities to transmit the force to the adhesive layer, the uniformity is poor, and the powder tends to be easily detached. On the contrary, when the particle size is small, the uniformity is high, but the impact force is small, so the embedding force is weak. Also, the degree of embedding of powder is closely related to the specific gravity of the media. If a material with a high specific gravity is used, the impact force will be large even with the same particle size, and if the material has a low specific gravity, the impact force will be small and the powder will be embedded. Power will be inferior. Therefore, it is generally preferable to use a medium having a relatively small particle size and a high specific gravity.

Further, in the present invention, the filling density of the powder layer is adjusted by compensating for the shortage of the powder amount and pushing another powder into the gap between the powder first adhered to the adhesive layer and the powder. 0.5 to 100 parts by weight of media for higher uniformity
It is preferable to use a medium in which about 2.0 parts by weight of powder is mixed in advance. In this case, it is preferable that the medium and the powder are vibrated in a container so that the medium and the powder are sufficiently mixed and the powder is attached to the surface of the medium. At this time, the adhesion state of the powder on the media surface is
Although it may be a single layer or a multi-layer, a combination in which both are separated even when vibrated is not preferable, and therefore it is necessary to confirm in advance the specific gravity and surface adhesion of both.

2. Support Member The support member in the present invention is arranged on the side of the substrate opposite to the above container so as to contact the surface of the substrate on which the adhesive layer is not provided. Further, this supporting member has a surface extending parallel to the elongated base body, and along this surface, the base body is guided into the medium filled in the container and adheres to the vibrating medium. An arrangement is formed that contacts the powder on the layer. Further, the contact surface of the support member with the base body supports the impact force when the medium strikes the powder on the adhesive layer by the vibration of the container.

As such a supporting member, a member having a uniform cross-sectional shape corresponding to the width direction of the base material and at least a lower portion of this cross section having an arc shape, specifically, FIG. As shown, the cross-sectional shape is circle, ellipse, water drop,
Bullet-like members are preferred. With these cross-sectional shapes, the arcuate region serves as a contact surface with the base body, and the long base body can be smoothly guided into the container along the contact surface. Further, when the supporting member is a cylindrical roller, the roller can be rotated as the substrate advances, but in the case of other shapes, the substrate can be slid along a plane parallel to the substrate. Make progress. Therefore, the material of the supporting member is preferably such that the friction with the base is small.

Further, the supporting member according to the present invention includes the supporting member shown in FIG.
As shown in, it is preferable to provide a guide member 5 for guiding the base body 1 so that the base body 1 approaches the contact surface with the base body. The guide member 5 can reduce the gap between the support member 3 and the base body 1 and prevent the medium 4 from entering the gap. If the media gets between the support member and the base, when the media in the container hits the powder on the base, the media that has entered may be pushed into the base, causing deformation or damage to the base. is there.

Further, the sectional shape of the supporting member is circular, elliptical,
When the width of the upper end is tapered such as water drops, as shown in FIG. 1, the distance between the guide members 5 is made smaller than the maximum width of the cross section of the support member, so that the above medium is formed. Can be more reliably prevented from entering.

3. Removing Means In the powder single-layer film forming apparatus of the present invention, a means for preventing the medium from entering between the supporting member and the substrate as described above is provided, but a gap between the supporting member and the substrate is further provided. Removal means may be provided for removing the media entering the. The method of removing the medium by this removing means may be any method such as sucking, blowing, scraping, wiping, etc. It is preferable to remove the medium immediately before the substrate comes into contact with the supporting member.

B. Operation of Powder Single Layer Coating Forming Apparatus The operation of the powder single layer coating forming apparatus of the present invention will be described with reference to the configuration shown in FIG. The long sheet-shaped substrate to be treated by the present powder single-layer film forming apparatus is a resin film, paper, resin-impregnated paper, metal film, or the like on which an adhesive layer is laminated, and a metal or A powder such as resin is attached. First, guide the base body 1 so that the surface of the base body 1 on which the powder adheres faces one of the guide members 5, and guide the surface on the opposite side to contact the support member 3,
The base body 1 is advanced along the support member 3, and the base body 1 is guided so that the powder adhesion surface faces the other guide member 5, and the base body 1 is moved in the lateral direction of the drawing (for example, from left to right). send. As a result, the lower half of the support member 3 is in contact with the base body 1. Next, the medium 4 is put into the container 2 to a depth of about one third of the diameter of the support member 3, and the powder on the substrate 1 and the medium 4 are brought into contact with each other.

Next, the container 2 is vibrated in the thickness direction of the substrate 1 (for example, the vertical direction in the drawing), and the substrate 1 is moved in the lateral direction in the drawing (for example, from left to right). At this time, the support member 3 and the guide member 5 serve as a mechanism that is driven to rotate as the base body 1 advances. As a result, the medium 4 is vibrated by the vibration of the container 2, and the medium 4 strikes the powder on the base body 1, whereby a uniform impact force is continuously applied in the width direction of the base body 1, and the powder is It is embedded in the adhesive layer with a uniform embedding depth to form a single-layer powder coating that is uniform and dense in the surface direction and in which a part of the powder protrudes from the surface of the adhesive layer.

[0027]

As described above, according to the present invention,
Even on a long sheet-shaped substrate, it is possible to form a powder monolayer film which is uniform and dense in the surface direction and in which a part of the powder projects from the surface of the adhesive layer. Further, by using the powder single-layer film forming apparatus of the present invention together with the means for adhering the powder to the adhesive layer and the means for removing the surplus powder, a product provided with the powder single-layer film is continuously manufactured. It is also possible.

[Brief description of drawings]

FIG. 1 is a sectional view showing an embodiment of a powder single-layer film forming apparatus of the present invention.

FIG. 2 is a perspective view showing an example of a supporting member in the powder single-layer film forming apparatus of the present invention.

FIG. 3 is a cross-sectional view showing an example of a conventional powder single-layer film forming apparatus.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Long-sheet base | substrate, 2 ... Container, 3 ... Support member, 4 ...
Media, 5 ... Guide member.

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Claims (4)

[Claims] 1. A container that vibrates at least in the thickness direction of the base body while maintaining a posture parallel to the width direction of the long sheet base body, a medium filled in the container, and while contacting the base body. A guide member for guiding the substrate into the medium and supporting an impact force generated by the vibration of the container, and applying an impact force in the width direction of the substrate from the thickness direction of the substrate through the medium. A powder single layer film forming apparatus characterized in that 2. The powder single-layer film forming apparatus according to claim 1, wherein the container has a uniform cross-section in the width direction of the substrate. 3. The powder single-layer film forming apparatus according to claim 1, further comprising a guide member for guiding the base body near the supporting member. 4. The powder single-layer film forming apparatus according to claim 1, further comprising a removing unit that removes the medium that is entering the gap between the supporting member and the base.