JP2004167422A

JP2004167422A - Application method and application device

Info

Publication number: JP2004167422A
Application number: JP2002338068A
Authority: JP
Inventors: Chiyoaki Iijima; 千代明飯島; Hayato Kurasawa; 隼人倉澤
Original assignee: Seiko Epson Corp
Current assignee: Seiko Epson Corp
Priority date: 2002-11-21
Filing date: 2002-11-21
Publication date: 2004-06-17

Abstract

<P>PROBLEM TO BE SOLVED: To provide an application method and an application device which are suited for a curved surface member and is capable of forming a coating film having thin and uniform thickness in the plane by using the convenient method and device. <P>SOLUTION: The application device 1 is a device for forming the coating film for the curved surface member 10 containing a curved surface 11 constituted of a specified curvature. The application device 1 is provided with an applying fixture 2 which comprises a curved surface 5 having almost the same curvature with the specified curvature of the curved surface member 10, a nozzle 6 for injecting coating material M between the curved surface 11 of the curved surface member 10 and the curved surface 5 of the applying fixture 2 and a rotation arm 3 which allows the curved surface 11 of the curved surface member 10 and the curved surface 5 of the applying fixture 2 to face each other and has the rotation shaft 4 as a movement mechanism for relatively moving the curved surface member 10 and the applying fixture 2 while keeping the distance between the curved surfaces constant. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、有機材料膜等の塗膜を形成する塗布方法及び塗布装置に関し、特に曲面部材に対して膜厚の均一な塗膜を形成する技術に関するものである。
【０００２】
【従来の技術】
従来、曲面部材に対する塗膜形成方法としては、例えば特許文献１に記載されたようなディップコーティング法、あるいはスタンプ法等が知られている。
【０００３】
【特許文献１】
特開平１０−３４０６６号公報
【０００４】
【発明が解決しようとする課題】
このようなディップコーティング法、あるいはスタンプ法では、薄膜形成が困難であるとともに、膜厚が面内で不均一となり易い問題があった。
一方、液晶表示装置のように透過する偏光軸の変換に基づき表示のスイッチングを可能とする表示装置では、直線偏光を透過偏光軸可変手段たる液晶層に導入するために、該液晶層の外面側に偏光板を成膜した構成のものが知られている。ここで、例えば液晶表示装置を曲面に構成しようとする場合、平面状基板に偏光板を成膜した後に基板を変形させる方法、若しくは曲面状基板に対し上記ディップコーティング法、あるいはスタンプ法等により成膜する方法等が考えられる。前者の場合は、ガラス等で構成される基板を変形させる際に該基板に亀裂等が入る惧れがあり、また後者の場合は、基板を曲面状に成形した後に、偏光板を成膜するため、基板への亀裂発生等の問題は生じないが、上述の通り、薄膜形成が困難であるととともに、膜厚が不均一となり易い問題がある。
【０００５】
本発明は上記問題に鑑みてなされたものであって、曲面部材への塗布方法及び塗布装置に関し、簡便な方法及び装置により、薄膜で、しかも面内において膜厚の均一な塗膜を形成可能な塗布方法及び塗布装置を提供することを目的とする。
【０００６】
【課題を解決するための手段】
上記課題を解決するために、本発明の塗布方法は、一定の曲率にて構成される曲面を含む曲面部材に対して塗膜を形成する塗布方法であって、前記曲面部材の前記一定曲率と略同じ曲率の曲面を含む治具を用い、前記曲面部材の曲面と前記治具の曲面とを対向させ、各曲面の間に塗布材料を介在させつつ、前記曲面部材と前記治具とをその曲面間距離を一定に保ちながら相対移動させることにより、前記曲面部材の曲面に対して塗布材料を成膜することを特徴とする。
【０００７】
このような塗布方法によると、一定の曲率にて構成される曲面に対して膜厚均一な薄膜を形成することが可能となる。すなわち、曲面部材と治具の各曲面間に塗布材料を介在させつつ、曲面部材と治具とを曲面間距離を一定に保ちながら相対移動させることにより、曲面部材の曲面上に膜厚均一な曲面状の塗膜を形成することが可能となるとともに、該塗膜を曲面間距離に対応した薄膜とすることが可能となる。なお、本発明の塗布方法においては、曲面部材は治具よりも塗布材料に対して接着性の高い材料にて構成することが好ましく、また、例えば曲面部材について塗布材料との接着性を高めるために、治具表面に離型剤等を付しておくことが好ましい。
また、特に本発明の塗布方法によると、各部材を相対移動させながら塗膜を形成するため、成膜と同時に塗膜に対して剪断応力が発生し、例えば応力方向に応じて偏光ないし配向を発現する膜、具体的にはリオトロピック液晶色素膜等の塗布方法として好適となる。すなわち、本発明では、膜厚均一で薄膜の曲面状塗膜の形成と同時に、材料によっては、該曲面状塗膜に対して偏光性ないし配向性を付与することが可能となるのである。
【０００８】
また、上記課題を解決するために、本発明の塗布方法は、その異なる態様として、一定の曲率にて構成される曲面を含む曲面部材に対して塗膜を形成する塗布方法であって、前記曲面部材の前記一定曲率と略同じ曲率の曲面を含む治具を用い、前記曲面部材の曲面と前記治具の曲面とを対向させ、各曲面の間に塗布材料を介在させつつ、前記治具の曲面をその曲面の曲率半径に対応した回転半径にて回転移動させることにより、前記曲面部材の曲面に対して塗布材料を成膜することを特徴とする。
【０００９】
このような塗布方法によると、一定の曲率にて構成される曲面に対して膜厚均一な薄膜を形成することが可能となる。すなわち、曲面部材と治具の各曲面間に塗布材料を介在させつつ、治具の曲面をその曲面の曲率半径に対応した回転半径にて回転移動させることにより、曲面部材と治具とを曲面間距離を一定に保ちながら相対移動させることが可能となるため、曲面部材の曲面上に膜厚均一な曲面状の塗膜を形成することが可能となるとともに、この曲面間距離に対応した薄膜とすることが可能となる。なお、本発明の塗布方法においては、曲面部材は治具よりも塗布材料に対して接着性の高い材料にて構成することが好ましく、また、例えば曲面部材について塗布材料との接着性を高めるために、治具表面に離型剤等を付しておくことが好ましい。
また、特に本発明の塗布方法によると、治具の曲面をその曲面の曲率半径に対応した回転半径にて回転移動させながら塗膜を形成するため、成膜と同時に塗膜に対して剪断応力が発生し、例えば応力方向に応じて偏光ないし配向を発現する膜、具体的にはリオトロピック液晶色素膜等の塗布方法として好適となる。すなわち、本発明では、均一で薄膜の曲面状塗膜の形成と同時に、材料によっては、該曲面状塗膜に対して偏光性ないし配向性を付与することが可能となるのである。
【００１０】
前記治具は、前記曲面部材の前記一定曲率と略同じ曲率の曲面を含む曲面部と、該曲面部をその曲率半径に対応した回転半径にて回転移動させるための回転軸を有する回転アームとを備えることを特徴とする。このような構成の治具により、曲面部材との間で、曲面間距離を一定とした相対移動（例えば曲面部の曲率半径と同じ回転半径の回転移動）を確実に行うことが可能となる。
【００１１】
また、上記課題を解決するために、本発明の塗布方法は、さらに異なる態様として、一定の曲率にて構成される曲面を含む曲面部材に対して塗膜を形成する塗布方法であって、前記曲面部材の前記一定曲率と略同じ曲率の曲面を含む治具を用い、前記曲面部材の曲面と前記治具の曲面とを対向させ、各曲面の間に塗布材料を介在させつつ、前記曲面部材の曲面をその曲面の曲率半径に対応した回転半径にて回転移動させることにより、該曲面部材の曲面に対して塗布材料を成膜することを特徴とする。
【００１２】
このような塗布方法によると、一定の曲率にて構成される曲面に対して膜厚均一な薄膜を形成することが可能となる。すなわち、曲面部材と治具の各曲面間に塗布材料を介在させつつ、曲面部材の曲面をその曲面の曲率半径に対応した回転半径にて回転移動させることにより、曲面部材と治具とを曲面間距離を一定に保ちながら相対移動させることが可能となるため、曲面部材の曲面上に膜厚均一な曲面状の塗膜を形成することが可能となるとともに、該塗膜を曲面間距離に対応した薄膜に形成することが可能となる。なお、本発明の塗布方法においては、曲面部材は治具よりも塗布材料に対して接着性の高い材料にて構成することが好ましく、また、例えば曲面部材について塗布材料との接着性を高めるために、治具表面に離型剤等を付しておくことが好ましい。
特に本発明の塗布方法によると、曲面部材の曲面をその曲面の曲率半径に対応した回転半径にて回転移動させながら塗膜を形成するため、成膜と同時に塗膜に対して剪断応力が発生し、例えば応力方向に応じて偏光ないし配向を発現する膜、具体的にはリオトロピック液晶色素膜等の塗布方法として好適となる。すなわち、本発明では、均一で薄膜の曲面状塗膜の形成と同時に、材料によっては、該曲面状塗膜に対して偏光性ないし配向性を付与することが可能となるのである。
【００１３】
前記曲面部材は、該曲面部材の曲面をその曲率半径に対応した回転半径にて回転移動させるための回転軸を有する回転アームに支持されているものとすることができる。このような構成の曲面部材により、治具との間で、曲面間距離を一定とした相対移動（例えば曲面部の曲率半径と同じ回転半径の回転移動）を確実に行うことが可能となる。
【００１４】
本発明の塗布方法においては、前記曲面部材の曲面が凹状の場合には、凸状の曲面を備えた治具を用い、一方、前記曲面部材の曲面が凸状の場合には、凹状の曲面を備えた治具を用いるものとすることができる。このように曲面部材と治具の凹凸形状を対応させることにより、各曲面間距離を一定として、曲面部材と治具とを相対移動させることが可能となり、本発明の効果を一層確実に実現することが可能となる。
【００１５】
また、上記課題を解決するために、本発明の塗布方法は、その異なる態様として、一定の曲率にて構成される凹状曲面を含む曲面部材に対して塗膜を形成する塗布方法であって、前記曲面部材の前記一定曲率と略同じ曲率の凸状曲面を含む治具を用い、前記曲面部材の曲面と前記治具の曲面とを対向させ、各曲面の間に塗布材料を介在させつつ、前記曲面部材の凹状曲面に対して前記治具の凸状曲面を当接させながら両者を相対移動させることにより、前記曲面部材の曲面に対して塗布材料を成膜することを特徴とする。
【００１６】
このような塗布方法によると、一定の曲率にて構成される曲面に対して膜厚均一な薄膜を形成することが可能となる。すなわち、曲面部材と治具の各曲面間に塗布材料を介在させつつ、曲面部材の凹状曲面に対して治具の凸状曲面を当接させながら両者を相対移動させることで、曲面部材と治具との曲面間距離を一定に保ちながらの相対移動が可能となり、曲面部材の曲面上に膜厚均一な曲面状の塗膜を形成することが可能となるとともに、該塗膜を曲面間距離に対応した薄膜に形成することが可能となる。なお、本発明の塗布方法においては、曲面部材は治具よりも塗布材料に対して接着性の高い材料にて構成することが好ましく、また、例えば曲面部材について塗布材料との接着性を高めるために、治具表面に離型剤等を付しておくことが好ましい。
特に本発明の塗布方法によると、治具の凸状曲面を曲面部材の凹状曲面に当接させながら（すなわち所定量の圧力を加えながら）塗膜を形成するため、成膜と同時に塗膜に対して剪断応力が発生し、例えば応力方向に応じて偏光ないし配向を発現する膜、具体的にはリオトロピック液晶色素膜等の塗布方法として好適となる。すなわち、本発明では、均一で薄膜の曲面状塗膜の形成と同時に、材料によっては、該曲面状塗膜に対して偏光性ないし配向性を付与することが可能となるのである。
【００１７】
ここで、上記曲面部材を、内部に前記凹状曲面を備え、厚みの一定な球の一部を切り欠いた形状にて構成され、該凹状曲面に対応した曲面を備える載置台上にて、該曲面部材の凹状曲面に対して前記治具の凸状曲面を当接させ、該曲面部材の方向を一定に保ちながら、前記治具を平行移動させることにより、前記曲面部材に対して塗布材料を成膜するものとすることができる。このような方法を採用することにより、半球形状の曲面部材に対して極めて簡便に曲面塗膜を形成することができるようになる。すなわち、半球形状の曲面部材を載置台上に載置し、その凹状曲面に治具の凸状曲面を当接させつつ、曲面部材の方向を一定に保ちながら治具を平行移動させることにより、特別な装置を必要とせずとも簡便に曲面部材の凹状曲面上に塗膜を形成することが可能となるのである。
【００１８】
上述したように、本発明では塗布材料を偏光板の構成材料とし、具体的には剪断応力方向に偏光選択性を発現する材料を塗布材料とするのが好ましく、この場合、曲面部材と治具との相対移動方向に偏光軸が形成されることとなる。
【００１９】
以上のような塗布方法は、以下の塗布装置を用いることで好適に実施することができる。すなわち、本発明の塗布装置は、一定の曲率にて構成される曲面を含む曲面部材に対して塗膜を形成する塗布装置であって、前記曲面部材の前記一定曲率と略同じ曲率の曲面を含む治具と、前記曲面部材の曲面と前記治具の曲面との間に塗布材料を注入する注入機構と、前記曲面部材の曲面と前記治具の曲面とを対向させ、前記曲面部材と前記治具とをその曲面間距離を一定に保ちながら相対移動させる移動機構とを備えることを特徴とする。
【００２０】
このような塗布装置によると、注入機構により曲面部材と治具との間に塗布材料を介在させ、移動機構により曲面部材と治具とをその曲面間距離を一定に保ちながら相対移動させることで、曲面部材の曲面上に膜厚均一な曲面状の塗膜を形成することが可能となるとともに、該塗膜を曲面間距離に対応した薄膜とすることが可能となる。
また、特に本発明の塗布装置によると、各部材を相対移動させながら塗膜を形成するため、成膜と同時に塗膜に対して剪断応力が発生し、例えば応力方向に応じて偏光ないし配向を発現する膜、具体的にはリオトロピック液晶色素膜等の塗布装置として好適となる。すなわち、本発明では、膜厚均一で薄膜の曲面状塗膜の形成と同時に、材料によっては、該曲面状塗膜に対して偏光性ないし配向性を付与することが可能となるのである。
【００２１】
次に、本発明の塗布装置は、その異なる態様として、一定の曲率にて構成される曲面を含む曲面部材に対して塗膜を形成する塗布装置であって、前記曲面部材の前記一定曲率と略同じ曲率の曲面を含む治具と、前記曲面部材の曲面と前記治具の曲面との間に塗布材料を注入する注入機構と、前記曲面部材の曲面と前記治具の曲面とを対向させ、前記治具の曲面をその曲面の曲率半径に対応した回転半径にて回転移動させる回転移動機構とを備えることを特徴とする。
【００２２】
このような塗布装置によると、注入機構により曲面部材と治具との間に塗布材料を介在させ、回転移動機構により治具の曲面をその曲面の曲率半径に対応した回転半径にて回転移動させることで、曲面部材と治具とを曲面間距離を一定に保ちながら相対移動させることが可能となるため、曲面部材の曲面上に膜厚均一な曲面状の塗膜を形成することが可能となるとともに、該塗膜を曲面間距離に対応した薄膜とすることが可能となる。
また、特に本発明の塗布装置によると、治具の曲面をその曲面の曲率半径に対応した回転半径にて回転移動させながら塗膜を形成するため、成膜と同時に塗膜に対して剪断応力が発生し、例えば応力方向に応じて偏光ないし配向を発現する膜、具体的にはリオトロピック液晶色素膜等の塗布装置として好適となる。すなわち、本発明では、均一で薄膜の曲面状塗膜の形成と同時に、材料によっては、該曲面状塗膜に対して偏光性ないし配向性を付与することが可能となるのである。
【００２３】
前記注入機構として、注入量制御手段を備えた注入ノズルを、治具に設けることができる。すなわち、塗布材料の各曲面間への注入は、治具側から行うことができ、上記のように注入量制御手段を備えた注入ノズルを治具に設けることで、曲面間に好適な注入量で塗布材料を注入することが可能となり、形成する塗膜の膜厚を一層均一なものとすることができるようになる。
【００２４】
前記治具は、前記曲面部材の曲率と同じ曲率にて構成された曲面を含む曲面部と、該曲面部をその曲率半径に対応した回転半径にて回転移動させるための回転軸を有する回転アームとを備えるものとすることができる。このような構成の治具により、曲面部材との間で、曲面間距離を一定とした相対移動（例えば曲面部の曲率半径と同じ回転半径の回転移動）を確実に行うことが可能となる。
【００２５】
また、本発明の塗布装置は、その異なる態様として、一定の曲率にて構成される曲面を含む曲面部材に対して塗膜を形成する塗布装置であって、前記曲面部材の前記一定曲率と略同じ曲率の曲面を含む治具と、前記曲面部材の曲面と前記治具の曲面とを対向させ、前記曲面部材の曲面をその曲面の曲率半径に対応した回転半径にて回転移動させる回転移動機構とを備えることを特徴とする。
【００２６】
このような塗布装置によると、注入機構により曲面部材と治具との間に塗布材料を介在させ、回転移動機構により曲面部材の曲面をその曲面の曲率半径に対応した回転半径にて回転移動させることで、曲面部材と治具とを曲面間距離を一定に保ちながら相対移動させることが可能となるため、曲面部材の曲面上に膜厚均一な曲面状の塗膜を形成することが可能となるとともに、該塗膜を曲面間距離に対応した薄膜とすることが可能となる。
また、特に本発明の塗布装置によると、曲面部材の曲面をその曲面の曲率半径に対応した回転半径にて回転移動させながら塗膜を形成するため、成膜と同時に塗膜に対して剪断応力が発生し、例えば応力方向に応じて偏光ないし配向を発現する膜、具体的にはリオトロピック液晶色素膜等の塗布装置として好適となる。すなわち、本発明では、均一で薄膜の曲面状塗膜の形成と同時に、材料によっては、該曲面状塗膜に対して偏光性ないし配向性を付与することが可能となるのである。
【００２７】
前記曲面部材は、該曲面部材の曲面をその曲率半径に対応した回転半径にて回転移動させるための回転軸を有する回転アームに支持されているものとすることができる。このような構成の曲面部材により、治具との間で、曲面間距離を一定とした相対移動（例えば曲面部の曲率半径と同じ回転半径の回転移動）を確実に行うことが可能となる。
【００２８】
なお、上述の通り、本発明では塗布材料を偏光板の構成材料とし、具体的には剪断応力方向に偏光選択性を発現する材料を塗布材料とするのが好ましく、この場合、曲面部材と治具との相対移動方向に偏光軸が形成されることとなる。なお、本発明の塗布装置においては、曲面部材は治具よりも塗布材料に対して接着性の高い材料にて構成することが好ましく、また、例えば曲面部材について塗布材料との接着性を高めるために、治具表面に離型剤等を付しておくことが好ましい。
【００２９】
【発明の実施の形態】
以下、本発明の実施の形態について、図面を参照して説明する。なお、本実施の形態においては、各図において各部材を図面上で認識可能な程度の大きさとするため、各部材毎に縮尺を異ならしめてある。
【００３０】
（第１の実施の形態）
図１は、本発明の塗布装置の第１の実施形態として、塗布装置１の概略構成をその作動状態とともに示す部分断面模式図である。塗布装置１は、曲面部材１０に対して塗膜を形成する装置であって、特に一定の曲率にて構成された凹状の曲面部１１に対して凹状塗膜を塗布するのに適した塗布装置である。
【００３１】
塗布装置１は、塗布治具２と、該塗布治具２を回転移動、好ましくは振り子移動させるための回転軸４と、該回転軸４と塗布治具２とを連結する回転アーム３とを備えており、この場合、回転アーム３と回転軸４とが塗布治具２を振り子移動させるための移動機構として機能している。塗布治具２には、塗布材料Ｍを塗布治具２の表面（曲面）５側に注入するためのノズル６が形成されており、ノズル６は回転アーム３内部を連通して図４に示した塗布材料貯留部２０に連結されている。このようなノズル６及び塗布材料貯留部２０を備えてなる注入機構により、塗布治具２の曲面５と、位置固定された曲面部材１０の曲面部１１との間に塗布材料Ｍが注入され、その塗布材料Ｍを両曲面の間に介在させつつ塗布治具２を振り子移動させることで、曲面部材１０の曲面部１１に凹状の塗膜が形成されるものとなっている。
【００３２】
図２は塗布治具２の構成を模式的に示す斜視図で、図３は塗布治具２の構成を模式的に示す平面図（ａ）、底面図（ｂ）、側面図（ｃ）である。このように塗布治具２は、塗布対象である曲面部材１０の曲面部１１の曲率と略同一の曲率にて構成された凸状の曲面５を有し、その曲面５に開口してなる開口部７に連通するノズル６を備えて構成されている。ここで、曲面５は、曲面部材１０の曲面部１１と対向配置されて、曲面部１１との間で薄膜を形成すべく微細間隔を保ちながら、曲面部１１と互いに相対移動をなすものとされている。具体的に、塗布治具２の曲面５と、曲面部材１０の曲面部１１との間の間隔は、５０μｍ〜２００μｍ（例えば１００μｍ）程度とするのが良く、この場合、形成される塗膜は、数μｍ〜数十μｍ（例えば１μｍ）程度となる。
【００３３】
なお、塗布治具２は詳しくは曲面部１１と対向する表面が曲面状に構成され、特に図１に示すように振り子移動方向と交わる方向に曲面が延びて構成されており、その交わる方向に延びた曲面が、例えば曲面部材１０の曲面部１１の円弧と略同一の大きさの円弧を備えた曲面となるように構成されている。これにより、一方向への振り子移動のみで曲面部１１上に薄膜を形成することが可能となり、また、膜に対する応力方向が一定方向に定められ、膜に対して偏光性或いは配向性等の異方性を付与することが可能となる。さらに、曲面部材１０側に面する曲面５に開口した開口部７は、振り子移動方向と交わる方向に延びて開口してなり、曲面５の略全面に亙って塗布材料が注入され易い構成となっている。
【００３４】
ここで、塗布治具２は曲面部材１０よりも塗布材料Ｍに対する接着性が小さい材料にて構成されている。これにより、確実に曲面部材１０の曲面部１１表面に塗膜が形成されることとなる。なお、塗布治具２の表面（曲面）５に対して、離型剤を塗布することで曲面部材１０への塗膜形成能を高めることもできる。
【００３５】
次に、回転アーム３は回転軸４に軸支され、塗布治具２の振り子移動を実現している。この回転アーム３は、塗布治具２を、その曲面５の曲率半径に対応した回転半径にて振り子移動させるべく、該曲率半径に対応した長さにて構成されている。これにより、塗布治具２の振り子移動中は、塗布治具２の曲面５と曲面部材１０の曲面部１１との間の曲面間距離は略一定に保たれることとなる。なお、塗布治具２と回転アーム３とは異なる部材を連結した構成としても良く、また、同一部材にて軸状の回転アーム３と塗布治具２とをそれぞれ成形するものとしてもよい。
【００３６】
図４は、塗布材料Ｍの供給機構を示す説明図である。上述したように、塗布治具２のノズル６は回転アーム３内部を挿通し、該回転アーム３の側面から供給管２１を介して外部の塗布材料貯留部２０に連結されている。塗布材料貯留部２０は、図示しない昇降機構により、貯留された塗布材料の液面が、開口部７に対して一定の高さとなるように昇降自在に構成されている。これにより、ノズル６から供給される塗布材料の供給量（時間当りの供給量）が、一定に保たれるようになり、一層均一な膜厚の塗膜を形成することが可能となる。
【００３７】
以上のような構成を備えた塗布装置１によると、曲面部材１０の曲面部１１と塗布治具２の曲面５とを対向させ、各曲面の間に塗布材料Ｍを介在させつつ、塗布治具２をその曲面５の曲率半径に対応した回転半径にて振り子移動させることにより、曲面部材１０と塗布治具２とをその曲面間距離を一定に保ちながら相対移動させることができるため、曲面部材１０の曲面部１１上に膜厚均一な曲面状の塗膜を形成することが可能となるとともに、該曲面状塗膜を上記曲面間距離に対応した薄膜に構成することが可能となる。
【００３８】
また、特に曲面部材１０と塗布治具２とを相対移動させながら塗膜を形成するため、成膜と同時に塗膜に対して剪断応力が発生し、例えば応力方向に応じて偏光ないし配向を発現する膜、具体的にはリオトロピック液晶色素膜等の塗布方法として好適となる。すなわち、本実施形態の塗布装置１では、膜厚均一で薄膜の曲面状塗膜の形成と同時に、材料によっては、該曲面状塗膜に対して偏光性ないし配向性を付与することが可能となる。具体的に、上記リオトロピック液晶色素膜を塗布材料として用いた場合には、剪断応力方向、すなわち振り子方向に偏光軸を備えた偏光板を形成することが可能となる。
【００３９】
（第２の実施の形態）
図５は、本発明の塗布装置の第２の実施形態として、塗布装置１０１の概略構成をその作動状態とともに示す部分断面模式図である。塗布装置１０１は、曲面部材１１０に対して塗膜を形成する装置であって、特に一定の曲率にて構成された凸状の曲面部（凸状曲面）１１１に対して凸状塗膜を塗布するのに適した塗布装置である。なお、当該第２の実施形態において、上述した第１の実施形態の塗布装置１と同様の構成のものについては同じ符号を付し、説明を省略する。
【００４０】
第２の実施の形態の塗布装置１０１は、塗布対象である曲面部材１１０を回転移動、好ましくは振り子移動させるための回転軸４と、該回転軸４と曲面部材１１０とを連結する回転アーム３とを備えており、この場合、回転アーム３と回転軸４とが曲面部材１１０を振り子移動させるための移動機構として機能している。一方、塗布装置１０１は、曲面部材１１０と対向して配置され、凹状曲面１０５を備える塗布治具１０２を有し、当該塗布治具１０２は位置固定されている。
【００４１】
塗布治具１０２には、塗布材料Ｍを塗布治具１０２の凹状曲面１０５側に注入するためのノズル１０６が形成されており、ノズル１０６は図４に示したものと同様の塗布材料貯留部に連結されている。このようなノズル１０６及び塗布材料貯留部からなる注入機構により、塗布治具１０２の凹状曲面１０５と、曲面部材１１０の凸状曲面１１１との間に塗布材料Ｍが注入され、その塗布材料Ｍを両曲面の間に介在させつつ曲面部材１１０を振り子移動させることで、曲面部材１１０の凸状曲面１１１に塗膜が形成されるものとなっている。
【００４２】
すなわち、本実施の形態においては、塗布治具１０２は、塗布対象である曲面部材１１０の凸状曲面１１１の曲率と略同一の曲率にて構成された凹状の曲面１０５を有し、その凹状曲面１０５の底部に形成された開口部１０７に連通するノズル１０６を備えて構成されている。一方、塗布対象である曲面部材１１０の凸状曲面１１１は、塗布治具１０２の凹状曲面１０５と対向配置されて、該凹状曲面１０５との間で薄膜を形成すべく微細間隔を保ちながら振り子移動し、凹状曲面１０５に対して相対移動するものとされている。
【００４３】
なお、塗布治具１０２は詳しくは凸状曲面１１１と対向する表面が曲面状に構成され、特に図５に示すように振り子移動方向と交わる方向に曲面が延びて構成されており、その交わる方向に延びた曲面が、例えば曲面部材１１０の凸状曲面１１１の円弧と略同一の大きさの円弧を備えた曲面となるように構成されている。これにより、振り子移動のみで凸状曲面１１１上に凸状の薄膜を形成することが可能となり、また、膜に対する応力方向が一定方向に定められるため、膜に対して偏光性或いは配向性等の異方性を付与することが可能となる。さらに、曲面部材１１０側に面する凹状曲面１０５に開口した開口部１０７は、振り子移動方向と交わる方向に延びて開口してなり、凹状曲面１０５の略全面に亙って塗布材料が注入され易い構成となっている。
【００４４】
ここで、塗布治具１０２は曲面部材１１０よりも塗布材料Ｍに対する接着性が小さい材料にて構成されている。これにより、確実に曲面部材１１０の凸状曲面部１１１表面に塗膜が形成されることとなる。なお、塗布治具１０２の凹状曲面１０５に対して、離型剤を塗布することで曲面部材１１０への塗膜形成能を高めることもできる。
【００４５】
以上のような構成を備えた塗布装置１０１によると、曲面部材１１０の凸状曲面１１１と塗布治具１０２の凹状曲面１０５とを対向させ、各曲面の間に塗布材料Ｍを介在させつつ、曲面部材１１０をその曲面１１１の曲率半径に対応した回転半径にて振り子移動させることにより、曲面部材１１０と塗布治具１０２とをその曲面間距離を一定に保ちながら相対移動させることができるため、曲面部材１１０の凸状曲面１１１上に膜厚均一な曲面状の塗膜を形成することが可能となるとともに、該曲面状塗膜を上記曲面間距離に対応した薄膜に構成することが可能となる。
【００４６】
また、特に曲面部材１１０と塗布治具１０２とを相対移動させながら塗膜を形成するため、成膜と同時に塗膜に対して剪断応力が発生し、例えば応力方向に応じて偏光ないし配向を発現する膜、具体的にはリオトロピック液晶色素膜等の塗布方法として好適となる。すなわち、本実施形態の塗布装置１０１では、膜厚均一で薄膜の曲面状塗膜の形成と同時に、材料によっては、該曲面状塗膜に対して偏光性ないし配向性を付与することが可能となる。具体的に、上記リオトロピック液晶色素膜を塗布材料として用いた場合には、剪断応力方向、すなわち振り子方向に偏光軸を備えた偏光板を形成することが可能となる。
【００４７】
（第３の実施の形態）
図６は、本発明の塗布装置の第３の実施形態として、塗布装置２０１の概略構成をその作動状態とともに示す部分断面模式図である。塗布装置２０１は、塗布対象である曲面部材２１０に対して塗膜を形成する装置であって、特にレンズのような球面を切り取ったような形状の球状内面に凹状塗膜を塗布するのに適した塗布装置である。
【００４８】
本実施形態の塗布装置２０１は、曲面部材２１０を載置するための載置台２０９を備え、載置台２０９の表面すなわち載置面２０８は、曲面部材２１０の外形状に合わせて曲面状に構成され、該曲面がレール状に長手方向に延びた構成をなし、すなわち円筒内面を部分的に切り欠いた形状を有している。また、載置台２０９には、塗布施行時の曲面部材２１０の初期状態（この場合、傾き状態）の設定を容易化するための真空孔２１５が形成され、曲面部材を一時的に固定する手段として機能している。
【００４９】
このような載置台２０９上に、図６に示すように曲面部材２１０を設置し、図７に示すように塗布治具２０２の凸状曲面２０５を当接させ、曲面部材２１０の方向を一定に保ちながら塗布治具２０２を平行移動させることにより、曲面部材２１０が外形に沿って傾きながら移動するため、凹状曲面２１１の内面全面に薄膜を形成することが可能となる。なお、この場合も塗布材料は、図４に示したものと同様の塗布材料貯留部から、塗布治具２０２に設けられたノズル（図示略）を介して注入される。このように、塗布治具２０２を載置台２０９のレール状に構成された載置面２０８に沿って平行移動させることで、曲面部材２１０がレール状載置面２０８に沿って傾きを連続的に変化させながら、該載置面２０８上を転がるため、凹状曲面２１１に当接させた塗布治具２０２の凸状曲面２０５が、塗布材料を薄膜且つ均一に凹状曲面２１１内部に塗布するものとなっている。
【００５０】
なお、このような塗布装置２０１を用いた塗布方法によると、塗布治具２０２の凸状曲面２０５を、曲面部材２１０の凹状曲面２１１に当接させながら塗膜を形成するため、成膜と同時に塗膜に対して剪断応力が発生し、例えば応力方向に応じて偏光ないし配向を発現する膜、具体的にはリオトロピック液晶色素膜等の塗布方法として好適となる。すなわち、本実施形態の塗布装置２０１では、膜厚均一で薄膜の曲面状塗膜の形成と同時に、材料によっては、該曲面状塗膜に対して偏光性ないし配向性を付与することが可能となる。具体的に、上記リオトロピック液晶色素膜を塗布材料として用いた場合には、剪断応力方向、すなわち振り子方向に偏光軸を備えた偏光板を形成することが可能となる。
【００５１】
また、本実施形態の塗布装置２０１においても、曲面部材２１０は塗布治具２０２よりも塗布材料に対して接着性の高い材料にて構成することが好ましく、また、例えば曲面部材２１０について塗布材料との接着性を高めるために、塗布治具２０２の表面に離型剤等を付しておくことが好ましい。さらに、塗布治具２０２として、塗布材料を注入可能なノズルを備えてなるものを用いたが、ノズル等の注入機構は必ずしも必要ではなく、例えば凹状曲面２１１内に所定量の塗布材料を注入しておき、注入した塗布材料を塗布治具にて引き延ばす方法によっても塗膜を形成することが可能である。
【００５２】
なお、本実施形態に示した塗布装置を用いた塗布方法は、例えば偏光膜をサングラスに対して塗布する際に好適であり、また、曲面の表示部を備えた液晶表示装置への偏光膜塗布に際しても好適である。
【図面の簡単な説明】
【図１】第１実施形態の塗布装置の概略構成をその作動状態とともに示す部分断面模式図。
【図２】図１の塗布装置の要部を示す斜視図。
【図３】図１の塗布装置の要部を示す平面図、底面図、側面図。
【図４】図１の塗布装置の塗布材料貯留部について示す説明図。
【図５】第２実施形態の塗布装置の概略構成をその作動状態とともに示す部分断面模式図。
【図６】第３実施形態の塗布装置の概略構成を示す斜視図。
【図７】図６の塗布装置を用いた場合の作用を示す説明図。
【符号の説明】
１，１０１，２０１塗布装置、２，１０２，２０２塗布治具、３回転アーム、４回転軸、６ノズル、１０，１１０，２１０曲面部材[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a coating method and a coating apparatus for forming a coating film such as an organic material film, and more particularly to a technique for forming a coating film having a uniform thickness on a curved member.
[0002]
[Prior art]
Conventionally, as a method of forming a coating film on a curved surface member, for example, a dip coating method or a stamp method as described in Patent Document 1 is known.
[0003]
[Patent Document 1]
JP-A-10-34066
[0004]
[Problems to be solved by the invention]
In such a dip coating method or a stamp method, it is difficult to form a thin film, and there is a problem that the film thickness tends to be non-uniform in a plane.
On the other hand, in a display device such as a liquid crystal display device which enables switching of display based on conversion of a transmitted polarization axis, a linearly polarized light is introduced into a liquid crystal layer serving as a transmission polarization axis changing unit. Is known in which a polarizing plate is formed as a film. Here, for example, when the liquid crystal display device is to be formed into a curved surface, a method of forming a polarizing plate on a flat substrate and then deforming the substrate, or the above dip coating method or a stamp method on a curved substrate is used. A method of forming a film or the like can be considered. In the former case, there is a risk that the substrate may be cracked when the substrate made of glass or the like is deformed, and in the latter case, the polarizing plate is formed after forming the substrate into a curved surface. Therefore, there is no problem such as generation of cracks in the substrate, but as described above, there is a problem that it is difficult to form a thin film and the thickness tends to be uneven.
[0005]
The present invention has been made in view of the above problems, and relates to a coating method and a coating apparatus for a curved surface member, which can form a thin film and a coating film having a uniform thickness in a plane by a simple method and apparatus. It is an object of the present invention to provide a simple coating method and a coating apparatus.
[0006]
[Means for Solving the Problems]
In order to solve the above problem, a coating method of the present invention is a coating method for forming a coating film on a curved member including a curved surface configured with a constant curvature, wherein the constant curvature of the curved member and Using a jig including a curved surface with substantially the same curvature, the curved surface of the curved member and the curved surface of the jig are opposed to each other, and while the coating material is interposed between the curved surfaces, the curved surface member and the jig are formed. The coating material is formed on the curved surface of the curved member by relatively moving the curved surface while keeping the distance between the curved surfaces constant.
[0007]
According to such a coating method, it is possible to form a thin film having a uniform thickness on a curved surface having a constant curvature. In other words, the coating material is interposed between the curved surfaces of the curved member and the jig, and the curved member and the jig are relatively moved while keeping the distance between the curved surfaces constant, so that the film thickness is uniform on the curved surface of the curved member. A curved coating film can be formed, and the coating film can be formed into a thin film corresponding to the distance between the curved surfaces. In the coating method of the present invention, the curved member is preferably made of a material having higher adhesiveness to the coating material than the jig, and, for example, to enhance the adhesiveness of the curved member with the coating material. Preferably, a release agent or the like is attached to the jig surface.
In addition, in particular, according to the coating method of the present invention, since a coating film is formed while relatively moving each member, a shear stress is generated in the coating film at the same time as the film formation. It is suitable as a coating method for a film that expresses, specifically, a lyotropic liquid crystal dye film. That is, in the present invention, it is possible to impart a polarization property or an orientation property to the curved coating film depending on the material at the same time as the formation of the thin film curved coating film having a uniform thickness.
[0008]
Further, in order to solve the above problems, the coating method of the present invention is, as a different aspect thereof, a coating method for forming a coating film on a curved member including a curved surface having a constant curvature, Using a jig including a curved surface having substantially the same curvature as the constant curvature of the curved member, the curved surface of the curved member and the curved surface of the jig are opposed to each other, and the jig is interposed between the curved surfaces while a coating material is interposed therebetween. The coating material is deposited on the curved surface of the curved member by rotating the curved surface at a radius of rotation corresponding to the radius of curvature of the curved surface.
[0009]
According to such a coating method, it is possible to form a thin film having a uniform thickness on a curved surface having a constant curvature. That is, while the coating material is interposed between the curved surface member and the curved surface of the jig, the curved surface of the jig is rotated at a radius of rotation corresponding to the radius of curvature of the curved surface, whereby the curved surface member and the jig are curved. Since the relative movement can be performed while maintaining a constant distance, a curved coating film having a uniform thickness can be formed on the curved surface of the curved member, and a thin film corresponding to the distance between the curved surfaces can be formed. It becomes possible. In the coating method of the present invention, the curved member is preferably made of a material having higher adhesiveness to the coating material than the jig, and, for example, to enhance the adhesiveness of the curved member with the coating material. Preferably, a release agent or the like is attached to the jig surface.
In addition, in particular, according to the coating method of the present invention, since the coating film is formed while rotating the curved surface of the jig with a rotation radius corresponding to the radius of curvature of the curved surface, shear stress is applied to the coating film simultaneously with the film formation. This is suitable as a method for applying a film that develops polarization or orientation according to the stress direction, for example, a lyotropic liquid crystal dye film. That is, in the present invention, it is possible to impart a polarization property or an orientation property to the curved coating film, depending on the material, simultaneously with the formation of the uniform thin film curved coating film.
[0010]
The jig has a curved surface portion including a curved surface having substantially the same curvature as the constant curvature of the curved surface member, and a rotating arm having a rotating shaft for rotating the curved surface portion with a rotation radius corresponding to the radius of curvature. It is characterized by having. With the jig having such a configuration, it is possible to reliably perform relative movement (for example, rotational movement having the same radius of curvature as the radius of curvature of the curved surface portion) with the curved surface member at a constant distance between the curved surfaces.
[0011]
Further, in order to solve the above problems, the coating method of the present invention, as a further different aspect, a coating method for forming a coating film on a curved member including a curved surface having a constant curvature, Using a jig including a curved surface having substantially the same curvature as the constant curvature of the curved member, the curved surface of the curved member and the curved surface of the jig are opposed to each other, and the coating material is interposed between the curved surfaces. The coating material is formed on the curved surface of the curved member by rotating the curved surface at a rotation radius corresponding to the radius of curvature of the curved surface.
[0012]
According to such a coating method, it is possible to form a thin film having a uniform thickness on a curved surface having a constant curvature. That is, by rotating the curved surface of the curved member at a radius of rotation corresponding to the radius of curvature of the curved surface while interposing the coating material between the curved surfaces of the curved member and the jig, the curved surface member and the jig are curved. Since the relative movement can be performed while keeping the distance constant, it is possible to form a curved coating film having a uniform thickness on the curved surface of the curved member, and to reduce the coating film to the distance between the curved surfaces. It is possible to form a corresponding thin film. In the coating method of the present invention, the curved member is preferably made of a material having higher adhesiveness to the coating material than the jig, and, for example, to enhance the adhesiveness of the curved member with the coating material. Preferably, a release agent or the like is attached to the jig surface.
In particular, according to the coating method of the present invention, since the coating film is formed while rotating the curved surface of the curved member at a rotation radius corresponding to the radius of curvature of the curved surface, shear stress is generated on the coating film simultaneously with the film formation. However, for example, it is suitable as a coating method for a film that develops polarization or alignment according to the stress direction, specifically, a lyotropic liquid crystal dye film. That is, in the present invention, it is possible to impart a polarization property or an orientation property to the curved coating film, depending on the material, simultaneously with the formation of the uniform thin film curved coating film.
[0013]
The curved member may be supported by a rotating arm having a rotating shaft for rotating a curved surface of the curved member at a rotation radius corresponding to the radius of curvature. With the curved member having such a configuration, it is possible to reliably perform relative movement (for example, rotational movement having a rotation radius equal to the radius of curvature of the curved surface portion) with a constant distance between curved surfaces between the jig and the jig.
[0014]
In the coating method of the present invention, when the curved surface of the curved member is concave, a jig provided with a convex curved surface is used. On the other hand, when the curved surface of the curved member is convex, a concave curved surface is used. A jig provided with By associating the curved surface member and the jig with the uneven shape in this way, it becomes possible to relatively move the curved surface member and the jig while keeping the distance between the respective curved surfaces constant, thereby more reliably realizing the effects of the present invention. It becomes possible.
[0015]
Further, in order to solve the above problems, the coating method of the present invention is, as a different aspect thereof, a coating method for forming a coating film on a curved member including a concave curved surface configured with a constant curvature, Using a jig including a convex curved surface having substantially the same curvature as the constant curvature of the curved member, the curved surface of the curved member and the curved surface of the jig are opposed to each other, and a coating material is interposed between the curved surfaces. A coating material is deposited on the curved surface of the curved member by moving the jig relative to the concave curved surface of the jig while bringing the convex curved surface of the jig into contact with the concave curved surface of the jig.
[0016]
According to such a coating method, it is possible to form a thin film having a uniform thickness on a curved surface having a constant curvature. That is, the coating material is interposed between the curved surface member and the jig and the convex curved surface of the jig is abutted against the concave curved surface of the curved surface member to move the two relative to each other. Relative movement is possible while keeping the distance between the curved surfaces with the tool constant, and it becomes possible to form a curved coating film having a uniform thickness on the curved surface of the curved member, and to move the coating film between the curved surfaces. It can be formed into a thin film corresponding to. In the coating method of the present invention, the curved member is preferably made of a material having higher adhesiveness to the coating material than the jig, and, for example, to enhance the adhesiveness of the curved member with the coating material. Preferably, a release agent or the like is attached to the jig surface.
In particular, according to the coating method of the present invention, the coating film is formed while the convex curved surface of the jig is in contact with the concave curved surface of the curved member (that is, while applying a predetermined amount of pressure). On the other hand, it is suitable as a method for applying a film in which a shear stress is generated and, for example, a polarization or orientation is developed according to the stress direction, specifically a lyotropic liquid crystal dye film. That is, in the present invention, it is possible to impart a polarization property or an orientation property to the curved coating film, depending on the material, simultaneously with the formation of the uniform thin film curved coating film.
[0017]
Here, the curved surface member is provided with the concave curved surface therein, is formed in a shape in which a part of a sphere having a constant thickness is cut out, and on a mounting table having a curved surface corresponding to the concave curved surface, The convex curved surface of the jig is brought into contact with the concave curved surface of the curved member, and while the direction of the curved member is kept constant, the jig is moved in parallel to apply the coating material to the curved member. A film can be formed. By employing such a method, it is possible to extremely easily form a curved coating film on a hemispherical curved member. That is, a hemispherical curved member is placed on a mounting table, and while the convex curved surface of the jig is in contact with the concave curved surface, the jig is translated while maintaining the direction of the curved member constant. This makes it possible to easily form a coating film on the concave curved surface of the curved member without requiring any special device.
[0018]
As described above, in the present invention, the coating material is preferably used as a constituent material of the polarizing plate, and specifically, a material that exhibits polarization selectivity in the shear stress direction is preferably used. In this case, the curved surface member and the jig are used. A polarization axis is formed in the direction of relative movement with respect to.
[0019]
The coating method as described above can be suitably implemented by using the following coating device. That is, the coating device of the present invention is a coating device that forms a coating film on a curved member including a curved surface having a constant curvature, and forms a curved surface having substantially the same curvature as the constant curvature of the curved member. A jig that includes the curved surface member and an injection mechanism that injects a coating material between the curved surface of the jig and the curved surface of the jig and the curved surface of the curved member and the curved surface of the jig. A moving mechanism for relatively moving the jig while keeping the distance between the curved surfaces constant.
[0020]
According to such a coating apparatus, the coating material is interposed between the curved member and the jig by the injection mechanism, and the moving member relatively moves the curved member and the jig while keeping the distance between the curved surfaces constant. In addition, it is possible to form a coating film having a uniform thickness on the curved surface of the curved member, and to form the coating film into a thin film corresponding to the distance between the curved surfaces.
In addition, in particular, according to the coating apparatus of the present invention, since a coating film is formed while each member is relatively moved, shear stress is generated on the coating film at the same time as film formation, and for example, polarization or orientation is changed according to the stress direction. It is suitable as a coating device for a film that develops, specifically a lyotropic liquid crystal dye film. That is, in the present invention, it is possible to impart a polarization property or an orientation property to the curved coating film depending on the material at the same time as the formation of the thin film curved coating film having a uniform thickness.
[0021]
Next, the coating device of the present invention is, as a different aspect, a coating device that forms a coating film on a curved surface member including a curved surface configured with a constant curvature, wherein the constant curvature of the curved surface member A jig including a curved surface having substantially the same curvature, an injection mechanism for injecting a coating material between the curved surface of the curved member and the curved surface of the jig, and causing the curved surface of the curved member and the curved surface of the jig to face each other. A rotating mechanism for rotating the curved surface of the jig with a rotating radius corresponding to the radius of curvature of the curved surface.
[0022]
According to such a coating apparatus, the coating material is interposed between the curved surface member and the jig by the injection mechanism, and the curved surface of the jig is rotationally moved by the rotation moving mechanism at a rotation radius corresponding to the radius of curvature of the curved surface. This makes it possible to relatively move the curved member and the jig while keeping the distance between the curved surfaces constant, so that it is possible to form a curved coating film having a uniform thickness on the curved surface of the curved member. In addition, the coating film can be formed into a thin film corresponding to the distance between the curved surfaces.
In addition, in particular, according to the coating apparatus of the present invention, since the coating film is formed while rotating the curved surface of the jig with a rotation radius corresponding to the radius of curvature of the curved surface, shear stress is applied to the coating film simultaneously with the film formation. Is generated, and is suitable as a coating device for, for example, a film that develops polarization or orientation in accordance with a stress direction, specifically, a lyotropic liquid crystal dye film. That is, in the present invention, it is possible to impart a polarization property or an orientation property to the curved coating film, depending on the material, simultaneously with the formation of the uniform thin film curved coating film.
[0023]
As the injection mechanism, an injection nozzle provided with an injection amount control means can be provided in the jig. That is, the injection of the coating material between the curved surfaces can be performed from the jig side, and by providing the injection nozzle having the injection amount control means in the jig as described above, a suitable injection amount between the curved surfaces can be obtained. Thus, the coating material can be injected, and the thickness of the coating film to be formed can be made more uniform.
[0024]
The jig is a rotary arm having a curved surface portion including a curved surface configured with the same curvature as the curvature of the curved surface member, and a rotating shaft for rotating the curved surface portion with a rotation radius corresponding to the radius of curvature. May be provided. With the jig having such a configuration, it is possible to reliably perform relative movement (for example, rotational movement having the same radius of curvature as the radius of curvature of the curved surface portion) with the curved surface member at a constant distance between the curved surfaces.
[0025]
Further, as a different aspect, the coating apparatus of the present invention is a coating apparatus that forms a coating film on a curved surface member including a curved surface having a constant curvature, and is substantially equal to the constant curvature of the curved surface member. A jig including a curved surface having the same curvature, a curved surface of the curved member facing the curved surface of the jig, and a rotational movement mechanism for rotationally moving the curved surface of the curved member at a rotational radius corresponding to a radius of curvature of the curved surface. And characterized in that:
[0026]
According to such a coating device, the coating material is interposed between the curved member and the jig by the injection mechanism, and the curved surface of the curved member is rotationally moved by the rotation moving mechanism at a rotation radius corresponding to the radius of curvature of the curved surface. This makes it possible to relatively move the curved member and the jig while keeping the distance between the curved surfaces constant, so that it is possible to form a curved coating film having a uniform thickness on the curved surface of the curved member. In addition, the coating film can be formed into a thin film corresponding to the distance between the curved surfaces.
In addition, in particular, according to the coating apparatus of the present invention, since the coating film is formed while rotating the curved surface of the curved member at a rotation radius corresponding to the radius of curvature of the curved surface, shear stress is applied to the coating film simultaneously with the film formation. Is generated, and is suitable as a coating device for, for example, a film that develops polarization or orientation in accordance with a stress direction, specifically, a lyotropic liquid crystal dye film. That is, in the present invention, it is possible to impart a polarization property or an orientation property to the curved coating film, depending on the material, simultaneously with the formation of the uniform thin film curved coating film.
[0027]
The curved member may be supported by a rotating arm having a rotating shaft for rotating a curved surface of the curved member at a rotation radius corresponding to the radius of curvature. With the curved member having such a configuration, it is possible to reliably perform relative movement (for example, rotational movement having a rotation radius equal to the radius of curvature of the curved surface portion) with a constant distance between curved surfaces between the jig and the jig.
[0028]
As described above, in the present invention, the coating material is preferably used as a constituent material of the polarizing plate, and more specifically, a material exhibiting polarization selectivity in the direction of shear stress is preferably used as the coating material. A polarization axis is formed in the direction of relative movement with the tool. In the coating apparatus of the present invention, the curved member is preferably made of a material having higher adhesiveness to the coating material than the jig, and, for example, to enhance the adhesiveness of the curved member with the coating material. Preferably, a release agent or the like is attached to the jig surface.
[0029]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the present embodiment, the scale of each member is different for each member so that each member has a size recognizable in the drawings.
[0030]
(First Embodiment)
FIG. 1 is a schematic partial cross-sectional view showing a schematic configuration of a coating apparatus 1 together with an operation state thereof as a first embodiment of the coating apparatus of the present invention. The coating device 1 is a device for forming a coating film on a curved surface member 10, and is particularly suitable for coating a concave coating film on a concave curved surface portion 11 having a constant curvature. It is.
[0031]
The coating apparatus 1 includes a coating jig 2, a rotating shaft 4 for rotating the coating jig 2, preferably a pendulum, and a rotating arm 3 for connecting the rotating shaft 4 and the coating jig 2. In this case, the rotating arm 3 and the rotating shaft 4 function as a moving mechanism for moving the coating jig 2 in a pendulum. The coating jig 2 is provided with a nozzle 6 for injecting the coating material M into the surface (curved surface) 5 of the coating jig 2. The nozzle 6 communicates with the inside of the rotary arm 3 and is shown in FIG. Connected to the applied material storage unit 20. By the injection mechanism including such a nozzle 6 and the coating material storage section 20, the coating material M is injected between the curved surface 5 of the coating jig 2 and the curved surface portion 11 of the curved member 10 whose position is fixed. The coating jig 2 is pendulum-moved while the coating material M is interposed between the two curved surfaces, whereby a concave coating film is formed on the curved surface portion 11 of the curved surface member 10.
[0032]
FIG. 2 is a perspective view schematically illustrating the configuration of the coating jig 2, and FIG. 3 is a plan view (a), a bottom view (b), and a side view (c) schematically illustrating the configuration of the coating jig 2. is there. As described above, the coating jig 2 has the convex curved surface 5 having substantially the same curvature as the curvature of the curved surface portion 11 of the curved member 10 to be coated, and an opening formed in the curved surface 5. It is provided with a nozzle 6 communicating with the section 7. Here, the curved surface 5 is disposed so as to face the curved surface portion 11 of the curved surface member 10, and relatively moves with the curved surface portion 11 while maintaining a fine interval to form a thin film with the curved surface portion 11. ing. Specifically, the interval between the curved surface 5 of the coating jig 2 and the curved surface portion 11 of the curved member 10 is preferably about 50 μm to 200 μm (for example, 100 μm). In this case, the coating film formed is , Several μm to several tens μm (for example, 1 μm).
[0033]
In addition, the coating jig 2 has a curved surface portion facing the curved surface portion 11 in detail, and particularly has a curved surface extending in a direction intersecting with the pendulum moving direction as shown in FIG. The extended curved surface is configured to be a curved surface having an arc having substantially the same size as the arc of the curved surface portion 11 of the curved surface member 10, for example. This makes it possible to form a thin film on the curved surface portion 11 only by moving the pendulum in one direction, and to determine the stress direction with respect to the film in a certain direction, and to make the film different in polarization or orientation. Anisotropy can be provided. Further, the opening 7 opened to the curved surface 5 facing the curved surface member 10 extends in a direction intersecting the pendulum movement direction and is opened, so that the coating material can be easily injected over substantially the entire surface of the curved surface 5. Has become.
[0034]
Here, the application jig 2 is made of a material having lower adhesiveness to the application material M than the curved surface member 10. Thereby, the coating film is surely formed on the surface of the curved portion 11 of the curved member 10. The ability to form a coating film on the curved member 10 can be enhanced by applying a release agent to the surface (curved surface) 5 of the application jig 2.
[0035]
Next, the rotating arm 3 is supported by the rotating shaft 4 to realize the pendulum movement of the coating jig 2. The rotating arm 3 is configured to have a length corresponding to the radius of curvature so that the application jig 2 is pendulum moved with a radius of rotation corresponding to the radius of curvature of the curved surface 5. As a result, during the movement of the pendulum of the coating jig 2, the distance between the curved surfaces between the curved surface 5 of the coating jig 2 and the curved surface portion 11 of the curved member 10 is kept substantially constant. The coating jig 2 and the rotating arm 3 may be connected to different members, or the shaft-shaped rotating arm 3 and the coating jig 2 may be formed by the same member.
[0036]
FIG. 4 is an explanatory diagram illustrating a supply mechanism of the coating material M. As described above, the nozzle 6 of the coating jig 2 penetrates the inside of the rotary arm 3, and is connected to the external coating material storage unit 20 via the supply pipe 21 from the side surface of the rotary arm 3. The coating material storage unit 20 is configured to be able to move up and down by a lifting mechanism (not shown) such that the liquid level of the stored coating material is at a constant height with respect to the opening 7. Accordingly, the supply amount (the supply amount per time) of the coating material supplied from the nozzle 6 is kept constant, and a coating film having a more uniform film thickness can be formed.
[0037]
According to the coating apparatus 1 having the above configuration, the curved portion 11 of the curved surface member 10 and the curved surface 5 of the coating jig 2 face each other, and the coating material M is interposed between the curved surfaces. By moving the pendulum 2 at a rotation radius corresponding to the radius of curvature of the curved surface 5, the curved surface member 10 and the coating jig 2 can be relatively moved while keeping the distance between the curved surfaces constant. A curved coating film having a uniform film thickness can be formed on the curved surface portion 11 and the thin curved film corresponding to the distance between the curved surfaces can be formed.
[0038]
Further, in particular, since the coating film is formed while the curved member 10 and the coating jig 2 are relatively moved, a shear stress is generated in the coating film at the same time as the film formation, and for example, polarization or orientation is developed according to the stress direction. This is suitable as a method for applying a film to be formed, specifically, a lyotropic liquid crystal dye film or the like. That is, in the coating apparatus 1 of the present embodiment, at the same time as forming a thin-film curved coating film having a uniform thickness, depending on the material, it is possible to impart polarization or orientation to the curved coating film. Become. Specifically, when the lyotropic liquid crystal dye film is used as a coating material, it becomes possible to form a polarizing plate having a polarizing axis in a shear stress direction, that is, a pendulum direction.
[0039]
(Second embodiment)
FIG. 5 is a schematic partial cross-sectional view showing a schematic configuration of a coating apparatus 101 together with an operation state thereof as a second embodiment of the coating apparatus of the present invention. The coating device 101 is a device for forming a coating film on a curved member 110, and particularly applies a convex coating film to a convex curved surface portion (convex curved surface) 111 having a constant curvature. It is a coating device suitable for performing. In the second embodiment, the same components as those of the coating device 1 of the first embodiment described above are denoted by the same reference numerals, and description thereof is omitted.
[0040]
The coating apparatus 101 according to the second embodiment includes a rotating shaft 4 for rotating and preferably moving a curved member 110 to be coated, and a rotating arm 3 for connecting the rotating shaft 4 and the curved member 110. In this case, the rotating arm 3 and the rotating shaft 4 function as a moving mechanism for pendulum moving the curved member 110. On the other hand, the coating apparatus 101 has a coating jig 102 that is disposed to face the curved surface member 110 and has a concave curved surface 105, and the coating jig 102 is fixed in position.
[0041]
The coating jig 102 is formed with a nozzle 106 for injecting the coating material M to the concave curved surface 105 side of the coating jig 102. The nozzle 106 is provided in a coating material storage section similar to that shown in FIG. Are linked. The coating material M is injected between the concave curved surface 105 of the coating jig 102 and the convex curved surface 111 of the curved member 110 by the injection mechanism including the nozzle 106 and the coating material storage unit. By moving the curved member 110 pendulum while interposing between the two curved surfaces, a coating film is formed on the convex curved surface 111 of the curved member 110.
[0042]
That is, in the present embodiment, the coating jig 102 has a concave curved surface 105 having substantially the same curvature as that of the convex curved surface 111 of the curved surface member 110 to be coated. The nozzle 105 is provided with a nozzle 106 communicating with an opening 107 formed at the bottom of the nozzle 105. On the other hand, the convex curved surface 111 of the curved surface member 110 to be coated is disposed to face the concave curved surface 105 of the coating jig 102, and the pendulum moves while maintaining a fine interval to form a thin film with the concave curved surface 105. It moves relative to the concave curved surface 105.
[0043]
The coating jig 102 has a curved surface on the surface facing the convex curved surface 111, and particularly has a curved surface extending in a direction intersecting the pendulum moving direction as shown in FIG. The curved surface is formed so as to be a curved surface having an arc of substantially the same size as the arc of the convex curved surface 111 of the curved member 110, for example. This makes it possible to form a convex thin film on the convex curved surface 111 only by moving the pendulum, and since the stress direction with respect to the film is determined in a certain direction, the film has a polarization property or orientation property. Anisotropy can be imparted. Further, the opening 107 that opens to the concave curved surface 105 facing the curved surface member 110 extends in a direction intersecting with the pendulum movement direction and is opened, and the coating material is easily injected over substantially the entire surface of the concave curved surface 105. It has a configuration.
[0044]
Here, the application jig 102 is made of a material having lower adhesiveness to the application material M than the curved surface member 110. This ensures that a coating film is formed on the surface of the convex curved surface portion 111 of the curved member 110. The ability to form a coating film on the curved member 110 can be enhanced by applying a release agent to the concave curved surface 105 of the application jig 102.
[0045]
According to the coating apparatus 101 having the above-described configuration, the convex curved surface 111 of the curved surface member 110 and the concave curved surface 105 of the coating jig 102 face each other, and the coating material M is interposed between the curved surfaces. By moving the member 110 with a pendulum with a rotation radius corresponding to the radius of curvature of the curved surface 111, the curved surface member 110 and the application jig 102 can be relatively moved while keeping the distance between the curved surfaces constant, so that the curved surface A curved coating film having a uniform film thickness can be formed on the convex curved surface 111 of the member 110, and the curved coating film can be formed into a thin film corresponding to the distance between the curved surfaces. .
[0046]
Further, in particular, since the coating film is formed while the curved member 110 and the coating jig 102 are relatively moved, a shear stress is generated in the coating film at the same time as the film formation, and for example, polarization or orientation is generated according to the stress direction. This is suitable as a method for applying a film to be formed, specifically, a lyotropic liquid crystal dye film or the like. That is, in the coating apparatus 101 of the present embodiment, at the same time as the formation of a thin-film curved coating film having a uniform film thickness, depending on the material, it is possible to impart polarization or orientation to the curved coating film. Become. Specifically, when the lyotropic liquid crystal dye film is used as a coating material, it becomes possible to form a polarizing plate having a polarizing axis in a shear stress direction, that is, a pendulum direction.
[0047]
(Third embodiment)
FIG. 6 is a schematic partial cross-sectional view showing a schematic configuration of a coating apparatus 201 together with an operation state thereof as a third embodiment of the coating apparatus of the present invention. The coating device 201 is a device that forms a coating film on a curved surface member 210 to be coated, and is particularly suitable for coating a concave coating film on a spherical inner surface having a shape obtained by cutting a spherical surface such as a lens. Coating device.
[0048]
The coating apparatus 201 of the present embodiment includes a mounting table 209 for mounting the curved member 210, and the surface of the mounting table 209, that is, the mounting surface 208 is formed in a curved shape according to the outer shape of the curved member 210. The curved surface extends in the longitudinal direction like a rail, that is, the inner surface of the cylinder is partially cut away. Further, the mounting table 209 is formed with a vacuum hole 215 for facilitating the setting of the initial state (in this case, the inclined state) of the curved surface member 210 at the time of application, and serves as a means for temporarily fixing the curved surface member. It is functioning.
[0049]
On such a mounting table 209, the curved surface member 210 is installed as shown in FIG. 6, and the convex curved surface 205 of the application jig 202 is brought into contact as shown in FIG. 7, so that the direction of the curved surface member 210 is kept constant. By moving the coating jig 202 in parallel while keeping it, the curved surface member 210 moves while tilting along the outer shape, so that a thin film can be formed on the entire inner surface of the concave curved surface 211. In this case, the coating material is also injected from a coating material storage section similar to that shown in FIG. 4 via a nozzle (not shown) provided on the coating jig 202. In this way, by moving the coating jig 202 in parallel along the rail-shaped mounting surface 208 of the mounting table 209, the curved member 210 continuously tilts along the rail-shaped mounting surface 208. Since the roller 200 rolls on the mounting surface 208 while changing, the convex curved surface 205 of the application jig 202 abutting against the concave curved surface 211 applies the coating material to the inside of the concave curved surface 211 uniformly and thinly. ing.
[0050]
In addition, according to the coating method using the coating apparatus 201, since the convex curved surface 205 of the coating jig 202 is brought into contact with the concave curved surface 211 of the curved member 210 to form a coating film, This is suitable as a method for applying a film in which a shear stress is generated in the coating film and which exhibits, for example, polarized light or orientation in accordance with the stress direction, specifically, a lyotropic liquid crystal dye film. That is, in the coating apparatus 201 of the present embodiment, it is possible to impart a polarization property or an orientation property to the curved coating film depending on the material at the same time as the formation of the thin-film curved coating film having a uniform thickness. Become. Specifically, when the lyotropic liquid crystal dye film is used as a coating material, it becomes possible to form a polarizing plate having a polarizing axis in a shear stress direction, that is, a pendulum direction.
[0051]
Also, in the coating apparatus 201 of the present embodiment, it is preferable that the curved member 210 is made of a material having higher adhesiveness to the coating material than the coating jig 202. It is preferable to apply a release agent or the like to the surface of the coating jig 202 in order to increase the adhesiveness of the coating jig 202. Further, although a jig provided with a nozzle capable of injecting the coating material is used as the coating jig 202, an injection mechanism such as a nozzle is not always necessary. For example, a predetermined amount of the coating material is injected into the concave curved surface 211. In addition, a coating film can be formed by a method in which the injected coating material is stretched by a coating jig.
[0052]
The coating method using the coating apparatus described in the present embodiment is suitable, for example, when a polarizing film is applied to sunglasses, and is applied to a liquid crystal display device having a curved display portion. This is also preferable.
[Brief description of the drawings]
FIG. 1 is a schematic partial cross-sectional view showing a schematic configuration of a coating apparatus according to a first embodiment together with an operation state thereof.
FIG. 2 is a perspective view showing a main part of the coating apparatus of FIG.
FIG. 3 is a plan view, a bottom view, and a side view showing a main part of the coating apparatus of FIG. 1;
FIG. 4 is an explanatory view showing a coating material storage section of the coating apparatus of FIG. 1;
FIG. 5 is a schematic partial cross-sectional view showing a schematic configuration of a coating apparatus according to a second embodiment together with an operation state thereof.
FIG. 6 is a perspective view illustrating a schematic configuration of a coating apparatus according to a third embodiment.
FIG. 7 is an explanatory view showing an operation when the coating apparatus of FIG. 6 is used.
[Explanation of symbols]
1, 101, 201 coating device, 2, 102, 202 coating jig, 3 rotating arms, 4 rotating shafts, 6 nozzles, 10, 110, 210 curved surface members

Claims

A coating method for forming a coating film on a curved member including a curved surface configured with a constant curvature,
Using a jig including a curved surface having substantially the same curvature as the constant curvature of the curved member, the curved surface of the curved member and the curved surface of the jig are opposed to each other, and the curved surface is formed while an application material is interposed between the curved surfaces. A coating method, wherein a coating material is formed on the curved surface of the curved member by relatively moving the member and the jig while keeping the distance between the curved surfaces constant.

A coating method for forming a coating film on a curved member including a curved surface configured with a constant curvature,
Using a jig including a curved surface having substantially the same curvature as the fixed curvature of the curved member, the curved surface of the curved member and the curved surface of the jig are opposed to each other, and the coating material is interposed between the curved surfaces. A coating material formed on the curved surface of the curved member by rotating a curved surface of the tool with a rotation radius corresponding to a radius of curvature of the curved surface.

The jig has a curved surface portion including a curved surface having substantially the same curvature as the constant curvature of the curved surface member, and a rotating arm having a rotating shaft for rotating the curved surface portion with a rotation radius corresponding to the radius of curvature. The coating method according to claim 1, further comprising:

A coating method for forming a coating film on a curved member including a curved surface configured with a constant curvature,
Using a jig including a curved surface having substantially the same curvature as the constant curvature of the curved member, the curved surface of the curved member is opposed to the curved surface of the jig, and the coating material is interposed between the curved surfaces. A coating method, wherein a coating material is formed on the curved surface of the member by rotating the curved surface of the member at a rotation radius corresponding to the radius of curvature of the curved surface.

5. The curved surface member according to claim 1, wherein the curved surface member is supported by a rotating arm having a rotation axis for rotating and moving a curved surface of the curved surface member at a rotation radius corresponding to the radius of curvature. Coating method.

When the curved surface of the curved member is concave, a jig provided with a convex curved surface is used. On the other hand, when the curved surface of the curved member is convex, a jig provided with a concave curved surface is used. The coating method according to any one of claims 1 to 5, characterized in that:

A coating method for forming a coating film on a curved surface member including a concave curved surface configured with a constant curvature,
Using a jig including a convex curved surface having substantially the same curvature as the constant curvature of the curved member, the curved surface of the curved member and the curved surface of the jig are opposed to each other, and a coating material is interposed between the curved surfaces. Forming a coating material on the curved surface of the curved member by causing the jig to move relatively while the convex curved surface of the jig is in contact with the concave curved surface of the curved member. .

The curved surface member includes the concave curved surface inside, is configured in a shape in which a part of a sphere having a constant thickness is cut out, on a mounting table having a curved surface corresponding to the concave curved surface, The convex curved surface of the jig is brought into contact with the concave curved surface, and while the direction of the curved surface member is kept constant, the jig is moved in parallel to form a coating material on the curved surface member. The coating method according to claim 7, wherein:

The said application material is a constituent material of a polarizing plate, and a polarization axis is formed in the relative movement direction of the said curved surface member and the said jig, The Claim 1 characterized by the above-mentioned. Application method.

A coating apparatus for forming a coating film on a curved surface member including a curved surface configured with a constant curvature,
A jig including a curved surface having substantially the same curvature as the constant curvature of the curved member, an injection mechanism for injecting a coating material between the curved surface of the curved member and the curved surface of the jig, and a curved surface of the curved member; A coating apparatus, comprising: a moving mechanism that opposes a curved surface of a jig and relatively moves the curved surface member and the jig while keeping a constant distance between the curved surfaces.

A coating apparatus for forming a coating film on a curved surface member including a curved surface configured with a constant curvature,
A jig including a curved surface having substantially the same curvature as the constant curvature of the curved member, an injection mechanism for injecting a coating material between the curved surface of the curved member and the curved surface of the jig, and a curved surface of the curved member; A coating apparatus, comprising: a rotating mechanism configured to face a curved surface of a jig and to rotationally move the curved surface of the jig with a rotation radius corresponding to a radius of curvature of the curved surface.

The coating apparatus according to claim 10, wherein a nozzle serving as the injection mechanism is provided in the jig.

The jig is a rotary arm having a curved surface portion including a curved surface configured with the same curvature as the curvature of the curved surface member, and a rotating shaft for rotating the curved surface portion with a rotation radius corresponding to the radius of curvature. The coating device according to any one of claims 10 to 12, comprising:

A coating apparatus for forming a coating film on a curved surface member including a curved surface configured with a constant curvature,
A jig including a curved surface having substantially the same curvature as the constant curvature of the curved member, an injection mechanism for injecting a coating material between the curved surface of the curved member and the curved surface of the jig, and a curved surface of the curved member; A coating device, comprising: a rotation moving mechanism that faces a curved surface of a jig and that rotates a curved surface of the curved surface member at a rotation radius corresponding to a radius of curvature of the curved surface.

The said curved member is supported by the rotating arm which has a rotating shaft for rotating the curved surface of this curved member by the rotation radius corresponding to the curvature radius, The rotation arm of Claim 10 or 14 characterized by the above-mentioned. Coating device.

The said application | coating material is a constituent material of a polarizing plate, and a polarization axis is formed in the relative movement direction of the said curved surface member and the said jig, The Claim 1 characterized by the above-mentioned. Coating equipment.